2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
Dry Ice Cleaning to Improvise Dielectric Features of
High Voltage Windings in Turbine Generators
P.G.S.Kumar
AGM(retd.)BHEL
Director(Technical), MRTG Power Diagnostic Tests Pvt. Ltd.
Hyderabad, India
pgsk51@yahoo.com
Abstract- Surface electrical discharges and tracking in
service are attributed to contamination of end windings in
high voltage turbine generators. Unnoticed over a period of
time, it deteriorates winding dielectric, results in low
insulation resistance(IR), smaller polarization index(PI)
number and higher tan . Dirty windings block the
ventilation, increases power loss and reduce efficiency.
Eventually, machine stalls with sudden earth fault. This
paper discusses the novel purification method viz. Dry Ice
Cleaning (DIC) to clean the stator end windings of turbine
generator in a power plant. Effect of contamination on
dielectric parameters of windings is emphasized. Traditional
practices and cleaning agents to remove debris on overhangs
are presented. New process of solid CO 2 cleaning for dirt
removal during overhaul is described. Techno-economic
aspects in usage of this cryogenic material and technology
are highlighted. Experience on 120MW, 11 KV turbine
generator to enhance the life through DIC cleaning is
presented. Condition assessment dielectric test results before
and after DIC are depicted and compared.
Recommendations are given to asset managers of power
plants for eco friendly cleaning technology to protect the
environment and enhance life of the machine.
Key words- dry ice cleaning (DIC); eco friendly; dielectric
absorption (DA); dielectric insulation system (DIS); tracking;
turbine generator (TG)
I. INTRODUCTION
Turbine generators are work horses of power
generation in hostile environment at various power plants.
Air cooled machines of open ventilation system are more
prone to heavy dust collection. Pollutants viz. bearing oil,
carbon dust, mist, chemicals ingress into machine and
accumulate on end windings and core in service.
It blocks ventilation paths and rises the operating
temperature. Contaminated surface of end windings are
conductive zones for leakage currents during high voltage
generation. Electrical sparking between phases and grounded
core lead to permanent damage of insulation due to
accelerated thermal degradation.
Reconditioning of generator windings for
decontamination of oil, dirt, grease etc. is labor oriented task
in overhaul works. Various cleaning methods and solvents
are in vogue, time consuming and enhance green house
effect. This paper focused on new de-adulteration process
978-1-4799-0083-1/13/$31.00 2013 IEEE
viz. Dry Ice Cleaning (DIC), a rapid action to revitalize the
windings and core effectively. Frozen carbon dioxide at
regulated high speed impinges on test surface, sublimates
and leaves dry and clean media with no waste byproduct for
disposal. Condition assessment diagnosis such as IR, PI and
tan results ascertain dielectric deterioration due to
contamination on end windings. A brief overview of effect
of contamination on dielectric properties of windings is
summarized. New clean process of cleaning the windings
viz. dry ice blasting using solid CO 2 pellets is described.
Advantages of cryogenic cleaning over conventional
methods are highlighted. This work has been
accomplished on 120MW,11KV air cooled turbine
generator stator windings during maintenance shut down.
Improvement in test results of dielectric insulation
properties after the revolutionary cleaning method is
demonstrated. Recommendations to power plant asset
managers to make use of state-of-art cleaning technology
for environment protection and safety reasons are
highlighted.
II. DIELECTRIC PROPERTIES OF WINDINGS
High voltage winding with solid insulation is
embedded in magnetic core and held in position by
restraining support mechanism in overhangs. Dielectric
insulation system (DIS) is Achilles heel in machine system.
Largely, open ventilated air cooled turbine generators(TG) of
coal power plants in industries accumulate dust, oil, grease,
moisture and chemicals on surface of end windings in
operation. These foreign conductive particles play a
dominant role on degradation of insulation. In addition,
improper air sealing and oil leakages forcibly allow external
materials to deposit on end winding network.
Healthiness of insulation system is determined by various
dielectric examinations as listed below.
D.C. Insulation resistance(IR)
polarization index(PI)
dielectric absorption(DA)
capacitance and dielectric power loss(Tan )
partial discharge(PD) pattern
Polarization Depolarization Current
Analysis(PDCA)
IR vs. Voltage characteristic
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 2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
DIS of high voltage windings of TG comprises of Trending of winding temperature by embedded resistance
slot fill thermometers will give sufficient data on blocked ventilation
stress grading coats at slot exit paths. A gradual rise in temperature of particular slots over
overhang solid insulation time is an indication of poor ventilation and dust collection
in machine.
restraining support and bracing structure as shown
in fig.1.

Fig.1 Dielectric insulation system of TG windings

Fig.3 Carbon dust accumulation on overhangs of TG windings
Electrical representation of winding insulation system is
shown in Fig.2.

Fig.2 Electrical equivalent of DIS of winding Fig.4. Blocked ventilation with oil soaked carbon contaminants in core

Good insulation measures to high resistance in Conductive contamination propagates surface leakage
hundreds to thousands of mega ohms at virgin stage. In currents at high voltages. Tracking disintegrates organic
operation, machine is subjected to Thermal, Electrical, chemicals of insulation and provides permanent paths to
Ambient and Mechanical (TEAM) forces and environment earth and other potential phases as shown in fig.5. Though a
abuses which deteriorate insulation. Dielectric properties slow process, if continues for years in service, a major
show a decreasing trend of IR, PI and a raise of power loss sudden breakdown of machine may occur.
factor and PD activity.
Total current through insulation comprises of
Charging current due to machine capacitance
absorption current
constant conduction current
surface leakage current due to contamination
III. IMPACT OF CONTAMINATION ON DIELECTRIC
INSULATION
Environment pollution accelerates thermal, electrical and
mechanical stresses on insulation degradation. Dust
accumulates on end windings (fig.3), in ventilation ducts as
in fig. 4 and obstructs free flow of coolant. Sufficient air
may not reach restricted zones and looses thermal Fig.5. Tracking due to contamination
equilibrium. Hot spots will be created and properties of
insulation decreases. Dielectric life reduces to half for every Oil and grease soaked tyings of restraining system of end
10 deg C rise above the design parameter. winding is prone for loosening and disintegrate the structure.
It facilitates bar movement and fading of conductive coats in

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 2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
slots. Increased over hang vibrations and knife cuts on
dielectric insulation will occur. PD, surface discharges in
slots and surface tracking on overhangs occur. End result is
sudden failure of machine due to earth faults.
IV. CLEANING PRACTICE
Contaminated windings shall be freed of hazardous
foreign deposits in a systematic fashion to provide a new
lease of powerful life to the machine. Methods in vogue are
Vacuum cleaning and dry compressed air blowing
Mopping with cotton cloth
Caution:
Trichloro ethylene (C2HC13),
perchloroethylene (C2C14) and trichloroethan
(C2HC13) - products of chlorine are prohibited
solvents for cleaning the windings and core.
Spraying liquid solvent into inaccessible zones
shall be avoided.
Cleaning agents:
Volatile solvents such as benzene, ciclohexaire,
gasoline and toluene to some extent shall be
used.
A clean procedure to wipe the dirt of machine begins
from core centre. High velocity hot air is impinged into the
ventilation canals of the core from inside to outside radially
and core outwards axially. This is to ensure that dust clouds
leave the core and slots and exit from the ends of
electromagnet stack. Dry carbon and ash deposits on end
windings and stator core can be sucked through nozzles by
vacuum cleaners. Dry cloth and bristle brush are used by
hand to clean the dirt surface.
cleaning which utilizes dry carbon dioxide at high velocity
to impinge on surface of windings and core. It attained
popularity in western world owing to its benefits listed as
Plenty availability of atmospheric non toxic CO2
gas
No usage of toxic solvents
No damage to equipment
No waste creation and disposal
Less time of operation and high productivity
Thorough cleaning over traditional methods
No drying required
Safety to personnel and environment
Machine downtime and cost reduction
Power plant customers in India are tending to choose this
innovative method as an alternative clean fuel wash up of
soiled windings to traditional time consuming, labor
oriented and waste disposal process.
VI. DRY ICE PELLETS
Cleaning fuel in DIC process is solid carbon dioxide
granules. Dry ice pellets are of 1 to 3 mm in lengths of 10
to 15 mm as shown in the fig.6

A squeezed solvent cloth is used to wipe oil and grease

surface of the insulated end windings. Care shall be taken to
clean the bars in vent gaps in core with dry cloth only.
Solvents usage may endanger the stress grade graphite coats
in slot zones and semi carbide varnish layers at slot ends.
Vacuum suckers are used to collect flying debris out of the
machine not to pollute the environment. Drying by space
heaters and current loading followed the cleaning process to Fig.6 Solid CO 2 pellets
improve IR and PI value.
Properties of C0 2 snow are
V. DRY ICE CLEANING
White opaque solid C0 2
Dry Ice Cleaning(DIC) is a new clean cleaning Water free and dry
technology to remove rubbish from overhangs of windings
Non flammable, non poisonous and non toxic
in a cost effective manner and in less time. It is being used
Non conductive and dielectric constant=3.1KV/mm
in a very limited way for surface cleaning. 3
In the present power scenario, time to maintenance shut Density= 1.98 kg/m (Heavier than air density)
downs have cramped to less number of days due to power 0
Deposition temperature= -78.5 C
scarcity. Meticulous planning to bring back the machine to Sublimation pressure= 1 atm
bus is in forefront. All the efforts are considered to lessen Fast sublimation rate
the time of rotor dismantle, diagnosis tests, spares execution
and cleaning activities. VII. DRY ICE CLEANING PROCESS
The most efficient and high speed cleaning way of windings
Here is a creative technique viz. dry ice is by solid snow blasting. Principle of it is forcible injection
cleaning(DIC)/dry ice blasting/CO2 cleaning/cryogenic

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 2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
of particulate on to the dirty surface of winding to eject speed through compressed air nozzle. The cryogenic
safely the dirt. Ingredients such as frozen C0 2 and dry particles collide with clinged dust particles on surface of end
windings and core with a high momentum. The softness and
compressed air are used through dry ice blasting device to less dense of dry ice suits for insulation surface cleaning with
accomplish this job as shown in fig.7 no dents or damage to substrate as shown in the fig.9.

Fig.7: Dry ice cleaning equipment

Fig.9: Dry ice cleaning technique
Specification of DIC equipment is
The moving fluid exerts drag force on surface
Pellet hopper =9Kgs contamination particles. The separation force i.e.
Blasting pressure=0-7 bar (adjustable) aerodynamic drag of the forced air is
Dry ice consumption= 20-40 kg/hr. 2
Power consumption= 500 Watts Fd = Cd Ap
2
Supply voltage= 240 Volts,50/60 Hz,1 Phase
Connection= BSP Inside Where Cd = drag coefficient; Ap =projected area of the
Weight= 47 Kgs particle; = fluid density and = flow velocity
Dimensions (LXWXH)= 550X500X750mm The impact force of dry ice media on the dust particle is
2 3 1 6
Process is as follows FC = 1.12k12 5 m 5 D 5v 5

making of dry ice pellets/pre made snow blocks

acceleration of pellets to 200 to 300m/s through
nozzle by compressed air Where k12 is elastic characteristic of materials; m =
directing the pellets on to work piece as shown in reduced mass; D = reduced particle diameter and v =
fig.8
AD p
impact velocity. Vander Waals force Fv = where
12h 2
D p = particle diameter; distance h = separation to flat
plate; A = Hamkar constant
2
2 Dp
Electrostatic force is Fe = where = surface
4 r o
charge density; r = relative permittivity and o = vacuum
2
permittivity and liquid bridge force is F1 = 2 D p where
Fig.8 Dry ice cleaning process
as = surface tension.
Peeling of contamination from winding surface is If Fd + Fc > Fv + Fe + F1 , the dust particles adhered to
attributed to four scientific actions viz.,
the surface will be released.
Thermal effect
VIII. CASE STUDY
Kinetic effect
Sublimation effect A shut down for overhaul works and condition
Embrittlement assessment had been taken by the customer on 120MW,
11KV TG after 40000 hrs of operation. Dielectric
Pre made dry ice pellets, an abrasive material at a examination such as IR, DA, PI, tan and PD were
0 performed on DIS of the windings. Physically, the machine
temperature of -78.5 C are propelled out at supersonic

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 2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
was scanned of the overhangs and magnetic core for
abnormalities and contamination.
Accumulated dust with carbon in paste from had been found
on the exposed surface of the winding insulation as shown
in the fig.10.

(b)

Fig.10 Contaminated winding of Turbine generator

Customer preferred dry ice cleaning of windings to

minimize time schedule, protect environment from cleaning
liquid waste and for effective cleaning of inaccessible zones.
Machine windings were meticulously washed with solid ice
at line of sight to nozzle. Air pressure was adjusted to detach
only debris from insulation surface. It was noticed no peeling
off of varnish coats from winding insulation periphery. Job
had been finished in one shift time (8hrs.) with single
operating person to handle the dry ice equipment. Fig .11
depicts clean surface of end windings after DIC.

Fig.11. Dry ice cleaned winding of Turbine generator

Fig.12. (a) IR measurements before and after Dry ice cleaning (b) PI value
Dielectric tests such as IR, PI, DA and tan were before and after Dry ice cleaning (c) tan vs Voltage before and after Dry
ice cleaning
repeated on the windings. Results are plotted as shown in
fig.12a, b, and c. Results were analyzed to assess the healthiness of the
insulation system.
IX. INTERPRETATION OF RESULTS
Substantial improvement in IR values are noticed after
dry ice cleaning and maximized to 800 M from 250 M.
Conduction leakage current through moist and polluted
insulation media has substantially reduced and increase in
IR is perceived after cryogenic cleaning. A ratio had been
obtained by dividing IR at 10 minutes and IR at 1minute
and commonly termed as polarization index (PI).
IR10 min
P.I =
(a) IR1 min

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 2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
Index of 1.2,1.4 and 1.6 for three phase windings
indicate polluted windings. PI number rose to 4.5 from 1.2 in
one shift time of operation with new cleaning technology.
Conductive paths of humid and seal oil contamination had
been disintegrated effectively on end winding surface.
Dielectric absorption (DA) test was conducted on
insulation system of windings with a constant high voltage
level of 2.5KV megger. Duration of time is 10 minutes. IR
reading was noted at every 10 seconds for a period of 1
minute and after the remaining period; IR value for every 1
minute was recorded. No change in IR values over time
indicated moist and dusty deposits external to winding
periphery. After dry ice cleaning, uptrend in IR values over
a period of time was noticed as shown in fig.13. It is an
indicator of clean winding without contamination.
After clean
Before clean
Fig.13. IR values vs. time
X. DRAWBACKS
Loud noise of >90 DB is produced during DIC process
and requires earphones for protection.
Trained person to handle DIC equipment is necessary.
Line of sight from the nozzle is required for effective
removal of debris.
Ventilation to let out huge volume of released CO2 gas
is to be taken care off.
Safety hand gloves to be worn not to hurt the hands and
0 [2]
skin burn due to -78.5 C cold solid material handling.
Operator should wear breathing mask not to inhale flying
dust.
Nozzle to and fro movement is to be maintained to avoid
insulation damage and peeling of anti track paint on
winding surface.
XI. BENEFITS
Dry ice cleaning reduced the time over 50% of
conventional cleaning method. 8 hrs time had been utilized
to complete the dry ice cleaning task with one trained person.
In case of non dry ice cleaning method, 4 days time is
required to finish the wiping by employing 2 non technical
28
persons. Further, electrical drying job, a technical process
needs rolling of the machine and electrical connections with
proper ventilation.
Dry ice is non conductive and moisture less. Hence,
drying is not practiced.
Dry ice cleaning is purely green process. Secondary
waste cleaning and disposal time is saved.
Technically, dielectric properties such as IR, PI, DA and
tan parameters are improved in less time and cost as
shown in case study.
It is a sure method of moisture elimination and dust
removal. Machine can be brought to operation in less than
half of the time of conventional cleaning mechanism.
XII. CONCLUSION
Dry ice clean confirms to IS0:14000 standard and eco
friendly. It generates no secondary waste and adds nothing to
green house effect unlike solvent cleaning. By adopting DIC
process, we release no CO 2 to atmosphere. We help to
protect environment. Demonstration on 120MW, 11KV TG
windings improved dielectric characteristics of insulation
system and life enhancement. Tangible and intangible gains
are favoring the customers to incline for environmental
friendly dry ice clean method. Additional cost for
hazardous waste disposal and personnel employment for
clean up the surroundings is nil. Dry ice equipment can be
hired and skilled person will perform the cleaning in 8 hrs.
time.
Let us use and spread advanced technology of solid CO 2
cleaning method to provide clean environment for future
generation.
REFERENCES
[1] Joe Kapler, How to ensure stator and rotor winding contamination
does not cause a future generator failure Issue 1,May-2012,Iris
Power Ontario-Canada-L4V1T2
I.M.Culbert(MIEEE), Rotating Machines Engineer, IRIS Power LP ,
Review of cleaning methods for motor windings
[3] Mayadhar Swain, Insulation resistance and polarization index test of
generator& motor Electrical India,Vol.47,No.1,January 2007
[4] Siswanto, Motor externally by spraying water IHS Global spec
CR4, Mar2008, Indonesia
[5] Doble engineering Case study: Power factor tresting on high voltage
rotating machines September 2011
[6] Alex Lembreg, Oil ingress in medium GE generators
GER4618(07/12)
[7] Liu,Yi-Hung, Analysis of production process of fine dry ice particles
and application for surface cleaning Thesis or Dissertation Issue
2012-03026 Kyoto University.
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