DESIGN OF INSULATION

SYSTEM BY VACUUM
PRESSURE IMPREGNATION
PROCESS FOR TURBO
GENERATOR
PROJECT GUIDE: K. RAVI KUMAR
PRESENTED BY:
K. R. DHARANI DHARAN
(07N71A0212)
CH.V.S.S.PAVAN KUMAR
(07N71A0206)

OBJECTIVE:

In large scale industries manufacturing generators,

QUALITY plays a vital role. If the quality of the
generator manufactured is not maintained properly, then
it may lead to heavy losses. The losses may be either in
terms of economy or in terms of the power generation.
To manufacture a quality generator, an industry requires
sophisticated technology and the proper insulation for
the generator, since insulation is the heart of the
generator. So, the latest technology for insulation
adopted by BHEL (HYD) unit is VACUUM PRESSURE
IMPREGNATION which is of resin poor thermosetting
type.
This type is preferred as it is highly reliable and
processes good mechanical, thermal properties and
dielectric strength. As the quantity of the resin used is
less, the over all cost of insulation is reduced.

INTRODUCTION:
Maximum

percentage of total power generation is

obtained by conventional power plant. Of these
steam, diesel & gas turbine power plant are high
speed systems & here always three phase alternator
are only used.

In

such alternators, insulation plays a vital role of

these insulation types, resin poor thermosetting
types of (VPI) insulation is preferred as its life
period is above 500 years & as its posses good
mechanical , thermal properties & dielectric strength
as the quantity of resin (the insulating material )
used here is less , so the overall cost of insulation

 MAIN PARTS IN A SYNCHRONOUS-GENERATOR:

STATOR,
ROTOR,
EXCITATION SYSTEM,
COOLING SYSTEM,
INSULATION SYSTEM,
BEARINGS.

WHAT IS
INSULATION?
Insulation

is the heart for electrical

machines.
Insulation is the property which has
enormous resistance to the conductivity .
PROPERTIES:

1. ELECTRICAL PROPERTIES
2. MECHANICAL PROPERTIES
3. THERMAL PROPERTIES
4. CHEMICAL PROPERTIES

VACCUM PRESSURE
IMPREGNATION:
Dr.

MEYER
brought the
VPI system
with the
collaboration of
WESTING
HOUSE In the
year 1956.

CHARACTERISTICS:
Low

dielectric loss resulting in increased life of

insulation and so the machine.

High

resistance against the effect of moisture.

Reduction

Better

of time cycle of insulation.

penetration into minute air gaps in

between laminations .

RESIN MANAGEMENT:
The

resin tank contains the mixture of resin +

Hardener + catalyst for good insulation system.

The

chemical name of resin is BISPHENOL-A . it

is also called as Diphenol propane.

Hardner

is used to solidify the resin. Hardner

used in chemical Compositions is ANHYDRIDE
is nothing but removal of water molecule (H2o)
from a compound.

Catalyst

is used to accelerate the rate of

chemical reaction among resin and hardener.
The Catalyst used in the process is ZINC
NAPTHENE.

QUALITY CHECKS ON RESIN MIXTURE IN

RESIN POOR PROCESS:
The resin mixture is tested for viscosity at 60c and limiting
value of viscosity is 50m poise above which the resin is
rejected.

The resin is again tested for the increase in its viscosity at 60c
after 20 hours heating at 100c; the maximum value at this
point is 9m poise.

The

resin is then heated for its saponification number whose

specified value is 331.3 mg/koh/gram.
After

this test for the ester number which is the between

saponification number and total acid number. Its maximum limiting
value is 10. In case it exceeds 10 necessary addition resin or
hardener is done. According to saponification number the resin
mixture is released after each test for use.

RESIN POOR Vs RESIN RICH:

The insulation tape used in resin poor system has

8% of resin, where as resin rich system has 40%
resin.

Here time cycle is reduced compared to resin rich.

Further addition of resin is required from outside

VACCUM PRESSURE
IMPREGNATION INSULATION
PROCESS:
STEPS

INVOLVED IN VPI PROCESS:

PREHEATING
VACUUM CYCLE
DROP TEST
HEATING THE RESIN
ADMISSION OF RESIN IN TO TANK
PRESSURE CYCLE
POST CURING
COATING THE JOB
PERFORMANCE TESTS.

PREHEATING THE JOB:

PREHEATING
CHAMBER

The
completed
stator is
placed in
impregnatio
n vessel
and kept in
an oven for
a period of
12 hours at
a
temperature
of 60c.

Hydraulic lift

The preheated
job next will be
placed in the
impregnation
chamber by a
hydraulic

VACCUM CYCLE:
Vacuum is created so that the dust and the moisture
are removed from the job if any. The total stator is
subjected for vacuum cycle. After obtaining 0.2
millibar, the total stator is subjected for 9 hours, then
vacuum drop test is conducted.

DROP TEST:
In this test all the vacuum pumps are stopped and the
vacuum drop is checked.
Drop should not be greater than 0.06mbar.

 RESIN HEATING--RESIN INLET:

PRESSURISATION OF JOB:
RESIN PUMPING BACK TO THE RESIN TANK:
POST CURING:

 IMPREGNATION PLANT:
Horizontal Chamber dimensions:

Vertical Dimensions:

Inner diameter : 4000mm

Length
: 9000mm

Inner diameter : 1600mm

Length
: 3080mm

IMPREGNATION MEDIUM:
Epoxy resin
Hardener
Operating Pressure
Temperature
Resin storage capacity
Charge Weight

: solvent tree class F/Araldite MY-790

: BD 1102
: 6Bars Nitrogen
: 90c
: 5x 9000 Liters.
: 120T.

Curing Oven:
Temperature
Heating Medium
Max weight

: 140 to 170c
: Circulating hot air
: 120T.

TESTING PERFORMANCE OF
RESIN POOR SYSTEM:
BEFORE IMPREGNATION FOLLOWING TESTS ARE
CARRIED OUT:
1. BOTTOM LAYER TEST
2. TOP LAYER TEST
3. INTER CONNECTION CHECKING
4. A.C HIGH VOLTAGE TEST
5. MECHANICAL RUN TEST

AFTER IMPREGNATION FOLLOWING TESTS ARE CARRIED

OUT:
1.TAN TEST.
2. HIGH VOLTAGE Tests.

ADVANTAGES OF RESIN POOR INSULATION:

It has got better dielectric strength.
Heat transfer coefficient is much better.
Maintenance free.
The cost is less and it is the latest technology.
Reduction in time cycle and consumption MW is also less and it
gives high quality & good life for insulation.

DISADVANTAGES OF RESIN POOR

INSULATION:
Dependability for basic insulation materials on foreign countries.
If any short circuit is noticed, the repairing process is difficult.

APPLICATIONS:
All very high rating generators, with
rugged usage, i.e., generally in power
plants.(100MW-150MW)
Equipment exposed to frequent surges,
like terminal equipments.
Harsh or moist environment.

CONCLUSION:
Considering the manifold advantages of VPI System of
insulation the leading manufacturers of World are going
to adopt this system for generators up to 400 MW with
.
hydrogen gas cooling.
It has better thermal, electrical,
mechanical and chemical properties and its life time is
about 54o years.
In view of the above, in the coming decades the Indian
grids will use more of such generators. In the scenario
of World market which demands generators with less
cost at the best possible time with better reliability VPI
system of insulation will provide most viable solution.

View of a VPI ,
125 MW Generator

THANK-YOU