MANUFACTURING AND

DESIGN OF
INSULATION SYSTEM FOR
AIR COOLED TURBO
GENERATOR
BY : P.VINAY KUMAR
 preface
• Power is the basic necessity for
economic development of a country.
• production of electrical energy its
per capital consumption deemed as
an index of standard of living.
• An AC generator works on the
principle of ‘Electro Magnetic
Induction’.
• Turbo generators are machines
which can generate high voltages
and capable of delivering KA of
currents
• the designer should be cautious in
designing the winding insulation.
• insulation design plays a major role
on the life of the Turbo Generator
Introduction

• First half we discuss about

manufacture of a stator
• The latter half we stress more on
insulation design by V.P.I process
• Defination of insulation
manufacture of
generator
• generator manufacturing can be
broadly divided into three main
parts:
• 1. Stator manufacture
• 2. Rotor manufacture
• 3. Exciter manufacture
fLowchart of various stages I a generator
manufacture
STATOR MANUFACTURE
PROCESS:
 Stator core construction and
 Coil construction and their assembly.

single form wound coil being inserted into two slots

 Stator core construction

• 1.PREPARATION OF STATOR
LAMINATIONS
• a RECEPTION OF SILICON STEEL ROLLS
b SHEARING
•c BLANKING AND NOTCHING:
• i) Compound notching
• ii) Individual notching
• D. DEBURRING OPERATION
• E. VARNISHING: sheets are dried at a
temperature of around 260 – 350 oC

)
 STATOR CORE ASSEMBLY
• A. TRAIL PACKET ASSEMBLY
• B. NORMAL CORE ASSEMBLY
• 1) Stepped packed assembly
• 2) normal packet assembly
• a) In process pressings:
• b) Fitting of clamping bolts:
STATOR WINDING INSULATION
SYSTEM FEATURES
• Strand Insulation
• Turn Insulation
• Ground wall Insulation

• CLASSIFICATION OF
INSULATING MATERIAL:
Picture of above shit
 Stator Winding
• The most prime part of a winding is
insulation

Photographs of end windings and slots of random wound stator (Courtesy TECO Westing house
MANUFACTURE OF STATOR
COILS:

A) For resin poor process

• Reception of copper conductors:
• Transposition
• Putty operation:
• Stack consolidation:
• Bending:
• Final taping:
• FOR RESIN RICH PROCESS
• The coil manufacture is same as in
case of resin poor but differ in a few
stages
• Putty work:
• Final taping
• Final baking:
• 10.1 ADVANTAGES OF RESIN POOR SYSTEM OF
INSULATION:

• It has better dielectric strength

• Heat transfer coefficient is much better
• It gives better capacitance resulting in less dielectric losses
due to which the insulation life will be more
• The cost will be less and it is latest technology
• Reduction in time cycle and consumption for MW also less
and it gives high quality

• DISADVANTAGES OF RESIN POOR SYSTEM OF

INSULATION:

• If any short circuit is noticed, the repairing process is

difficult and need of excess resin from outside.
• Dependability for basic insulating material on foreign supply
• Assembly of stator:
• Reception of stator core:
• Winding holder’s assembly
– STIFFNER ASSEMBLY
• Eye formation
• Connecting rings assembly:
• Phase connectors:
 – ADVANTAGES OF RESIN RICH SYSTEM OF INSULATION:
• Better quality and reliability is obtained
• In case of any fault (phase - ground/ phase – phase short)
carrying the repair process is very easy.
• Addition of excess resin will be avoided because of using
resin rich mica tape

– DISADVANTAGES OF RESIN RICH SYSTEM OF

INSULATION:
• It is a very long procedure
• Due to fully manual oriented process, the cost is more
• It is possible to process stator bars only.
• Even though the advantages and disadvantages of both
the process are explained above, resin poor process is
the best of all, as the resin content used is almost only
35% compared to resin poor process and also show good
insulation properties justified in the later sections.
THE VPI PROCESS

• INTRODUCTION TO VACUUM
PRESSURE IMPREGNATION
SYSTEM (VPI )
• Drawback of earlier VPI SYSTEM
Vacuum Pressure Impregnation
of resin poor insulated jobs
• 1. Preheating
• 2. Lifting and shifting
• 3. Vacuum cycle
• 4. Vacuum drop test
• 5. Heating the resin
• 6. Resin admission.
• 7. Resin settling
• 8. Pressure cycle
• 9. Aeration
• 10. Post curing cycle
• 11. Cleaning