522-2004 (IEEE Guide For Testing Turn Insulation of Form-Wound Stator Coils For Alternating-Current Electric Machines)
522-2004 (IEEE Guide For Testing Turn Insulation of Form-Wound Stator Coils For Alternating-Current Electric Machines)
522-2004 (IEEE Guide For Testing Turn Insulation of Form-Wound Stator Coils For Alternating-Current Electric Machines)
IEEE Standards
(Revision of
IEEE Std 522-1992)
522
TM
9 August 2004
3 Park Avenue, New York, NY 10016-5997, USA
Print: SH95212
PDF: SS95212
Recognized as an
American National Standard (ANSI)
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Introduction
(This introduction is not part of IEEE Std 522-2004, IEEE Guide for Testing Turn Insulation of Form-Wound Stator
Coils for Alternating-Current Electric Machines.)
Many alternating-current, rotating electric machines are designed to have multiturn form-wound stator coils.
In these cases, the winding has two separate but interrelated insulating barriers:
Failure of either of these barriers will prematurely terminate the service life of the machine. A test level for
the ground insulation of twice-rated voltage plus 1 kV has been in existence for many years. This guide suggests methods and test levels for the turn insulation.
Experience has shown that turn insulation failures can be precipitated by abnormal steep-front surges caused
by factors such as lightning strokes, faulty breaker closures, or the malfunction of various types of switching
devices. However, turn insulation failures can also be caused by surges during normal breaker operations
when the circuit conditions are such that the rise time of the surge at the machine terminals is less than a few
microseconds. A measure of protection from such surges may be provided by installation of devices such as
surge capacitors at the machine terminals and surge arrestors, or by designing the coils with suitable turn
insulation capability. When used for this purpose, capacitor ratings are usually chosen to extend the rise time
of voltage surges to 5 s or longer.
The bibliography (Annex C) contains references that discuss the general surge environment and surge
strength of electric machines.
Notice to users
Errata
Errata, if any, for this and all other standards can be accessed at the following URL: http://
standards.ieee.org/reading/ieee/updates/errata/index.html. Users are encouraged to check this URL for
errata periodically.
Interpretations
Current interpretations can be accessed at the following URL: http://standards.ieee.org/reading/ieee/interp/
index.html.
Patents
Attention is called to the possibility that implementation of this standard may require use of subject matter
covered by patent rights. By publication of this standard, no position is taken with respect to the existence or
validity of any patent rights in connection therewith. The IEEE shall not be responsible for identifying
patents or patent applications for which a license may be required to implement an IEEE standard or for
conducting inquiries into the legal validity or scope of those patents that are brought to its attention.
iii
Participants
At the time this standard was completed, the working group had the following membership:
Chuck Wilson, Chair
Darrell Howell, Secretary
Dana Arndt
Saber Azizi
Ray Bartnikas
Kevin Becker
Stefano Bomben
Sudhakar Cherukupalli
Douglas Conley
Jim Dymond
Mark Fenger
Shawn Filliben
Paul Gaberson
George Gao
Nirmal Ghai
Bal Gupta
Guy Halldorson
Gary Heuston
Jeff Hudson
Patricia Irwin
Aleksandra Jeremic
Tom Kluk*
Lou Little
Bill McDermid
Hal Miller
Glenn Mottershead
Beant Nindra
Jim Oliver
Lori Rux
Howard Sedding
Greg Stone
Meredith Stranges
James Timperley
Ernesto Wiedenbrug
Joe Williams
John Wilson
Karim Younsi
*We all wish to express our sorrow that Tom Kluk passed away before this standard was published. His
input to this document was very valuable and much appreciated by everyone on the working group.
The following members of the individual balloting committee voted on this standard. Balloters may have
voted for approval, disapproval, or abstention.
Karl Berger
Thomas Bishop
Weijen Chen
Tommy Cooper
Guru Dutt Dhingra
Roger Daugherty
Byron Davenport
Gary Donner
James Dymond
Amir El-Sheikh
Gary Engmann
Jorge Fernandez-Daher
iv
Trilok Garg
Nirmal Ghai
Brian Gott
Randall Groves
Bal Gupta
Paul Hamer
Edward Horgan Jr.
David Jackson
Kevin Loving
Jesus Martinez
Walter Martiny
Thomas McCaffrey
William McDermid
Donald McLaren
Nigel McQuin
James Michalec
Krste Najdenkoski
Nils Nilsson
Alvaro Portillo
Johannes Rickmann
Manoj Shah
Gregory Stone
Meredith Stranges
Ernesto Wiedenbrug
Chuck Wilson
When the IEEE-SA Standards Board approved this standard on 9 February 2004, it had the following
membership:
Don Wright, Chair
Mark S. Halpin
Raymond Hapeman
Richard J. Holleman
Richard H. Hulett
Lowell G. Johnson
Joseph L. Koepfinger*
Hermann Koch
Thomas J. McGean
Daleep C. Mohla
Chuck Adams
H. Stephen Berger
Mark D. Bowman
Joseph A. Bruder
Bob Davis
Roberto de Boisson
Julian Forster*
Judith Gorman
Arnold M. Greenspan
Paul Nikolich
T. W. Olsen
Ronald C. Petersen
Gary S. Robinson
Frank Stone
Malcolm V. Thaden
Doug Topping
Joe D. Watson
*Member Emeritus
Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Satish K. Aggarwal, NRC Representative
Richard DeBlasio, DOE Representative
Alan Cookson, NIST Representative
Don Messina
IEEE Standards Project Editor
Contents
1.
Overview.............................................................................................................................................. 1
1.1 Scope............................................................................................................................................ 1
1.2 Purpose......................................................................................................................................... 1
2.
References............................................................................................................................................ 1
3.
Service conditions................................................................................................................................ 2
3.1 Operating stress............................................................................................................................ 2
3.2 Transient stress............................................................................................................................. 2
3.3 Withstand requirements ............................................................................................................... 2
4.
5.
Test procedure...................................................................................................................................... 3
5.1 Test sequences ............................................................................................................................. 3
5.2 Test conditions ............................................................................................................................. 4
5.3 Voltage levels............................................................................................................................... 4
6.
7.
General......................................................................................................................................... 4
Standard (3.5 p.u.) withstand envelope........................................................................................ 5
Alternate withstand envelope....................................................................................................... 6
Definition of surge envelopes ...................................................................................................... 6
Abnormal surges .......................................................................................................................... 6
Precautions................................................................................................................................... 6
Reduction in test levels for uncured coils .................................................................................... 7
vi
b)
c)
d)
Windings of machines in service to determine their suitability for further service (preventivemaintenance testing).
1.2 Purpose
The purpose of this guide is to
a)
b)
c)
Recommend devices suitable for measuring surges, with precautions to avoid erroneous results.
d)
e)
Present suggested surge test levels for various types of electric machines.
2. References
ASTM D1711-02, Standard Terminology Relating to Electrical Insulation.1
1ASTM
publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959, USA (http://www.astm.org/).
IEEE
Std 522-2004
ASTM D3426-97 (2004), Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength
of Solid Electrical Insulating Materials Using Impulse Waves.
IEEE Std 4-1995, IEEE Standard Techniques for High-Voltage Testing.2, 3
IEEE Std 43-2000, IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery.
IEEE Std 56-1977 (Reaff 1991), IEEE Guide for Insulation Maintenance of Large Alternating-Current
Rotating Machinery 10 000 kVA and Larger.
IEEE P62.2/-D23, Draft Guide for Diagnostic Field Testing of Electric Power ApparatusElectrical
Machinery.4
IEEE Std 432-1992 (Reaff 1998), IEEE Guide for Insulation Maintenance for Rotating Electric Machinery
(5 hp to Less Than 10 000 hp).
IEEE Std 434-1973 (Reaff 1991), IEEE Guide for Functional Evaluation of Insulation Systems for Large
High-Voltage Machines.
IEEE Std 492-1999, IEEE Guide for Operation and Maintenance of Hydro-Generators.
IEEE Std 510-1983 (Reaff 1992), IEEE Recommended Practice for Safety in High-Voltage and HighPower Testing.
3. Service conditions
3.1 Operating stress
The maximum operating (line frequency) voltage difference between turns in a coil depends upon the voltage between coil terminals and on the internal construction of the coil.
IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc.
3IEEE publications are available from the Institute of Electrical and Electronics Engineers, Inc., 445 Hoes Lane, Piscataway, NJ 08854,
USA (http://standards.ieee.org/).
IEEE standards project was not approved by the IEEE-SA Standards Board at the time this publication went to press. For information about obtaining a draft, contact the IEEE.
4This
IEEE
Std 522-2004
5. Test procedure
5.1 Test sequences
Coils may be tested at one or more of the following steps of manufacture:
a)
5Notes
Prior to insertion into the stator core. This is appropriate when the coils are to be installed at a location remote from the coil manufacturing plant. If the impedance of the coils in air is too low, they
may be assembled into a simulated core for testing purposes. Each coil in the winding should be
tested.
in text, tables, and figures are given for information only and do not contain requirements needed to implement the standard.
IEEE
Std 522-2004
b)
After coil installation, wedging and bracing, but before any connections are made. Each coil in the
winding should be tested.
c)
After series connections are made, but before insulating them and before making the connections
between phase groups. Each coil in the winding should be tested.
d)
After connecting into phase groups, but before connecting phase groups to one another (before or
after insulating the series connections). This test compares phase groups, not individual coils.
e)
After all connections are made and insulated. All maintenance tests are normally made under such
conditions.
If the test voltage is applied at the machine terminals, the electrical impulse voltage level should be
carefully selected in order to avoid overstressing ground insulation. In this case, the test may disclose only existing short circuits and not incipient weaknesses of the turn insulation.
Caution is advised in testing a complete phase winding from the machine terminals. A complete
phase winding consists of several series coils. Hence, the change in the voltage impulse shape
caused by the failure of the insulation between a turn-pair in a single coil in the complete phase
winding is often very small. Consequently, the failure of the turn insulation during the impulse test
of a complete winding may go undetected.
Otherwise, the test voltage can be induced into the stator coils by means of a surge-inducing coil
(Annex A). The test method given in Annex A will stress incipient weaknesses and may cause these
areas to fail.
Extra fully processed or uncured coils (if specified in the agreement between the manufacturer and the user)
that are not used in winding the machine may be tested to destruction to determine the turn-to-turn breakdown capability of the electrical insulation system design.
IEEE
Std 522-2004
machine design parameters such as size and weight of coil, length of turn, arrangement of turns within the
coil, operating volts per turn or per coil, system voltage, interturn and turn-to-ground capacitance, and others
to determine turn-voltage test levels for their products. These procedures have not been described explicitly
in the literature, and it is not feasible to describe them here. Agreement should be reached between the manufacturer and the user as to what testing technique and level should be applied to coils and at what stage(s)
of manufacture the tests should be performed.
T r = 0.0 s
(1)
T r = 0.1 s
(2)
V 3 = 5V 1 = 5 p.u.
T r 1.2 s
(3)
where
Vn (n = 1, 2, 3) is the momentary surge withstand capability across the coil,
VL
Tr
p.u.
is per unit, where the initial test voltage is multiplied by the given coefficient.
IEEE
Std 522-2004
6.6 Precautions
It should be noted that unimpregnated or uncured coilsi.e., those tested on the bench or that have been
wound in a stator but not VPId (vacuum pressure impregnation) or bakeddo not have fully cured insulation, and therefore will have a significantly lower surge withstand capability than fully cured coils. Also,
when one coil is tested in a stator with the core and frame grounded, the ground insulation of the remaining
coils in the winding will experience a reduced-level surge with similar frequency in sympathy with the coil
under test (see Stranges, et al. [B54]). The effective voltage of this sympathetic surge condition varies
with every coil tested.
6
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Std 522-2004
IEEE
Std 522-2004
Annex A
(informative)
A.1.2 Formulas
The test circuit (Figure A.2) used consists principally of lumped inductance (L) (the surge-inducing coil) and
capacitance (C), with minimum resistance (R). The frequency of oscillation of the surge voltage can, therefore be calculated from the formula:
2
1 1
R
f = ------ ------- --------2-
2 LC 4L
(A.1)
Which, when the second term under the radical is small compared to the first, reduces to:
1
f 0 = -----------------2 LC
(A.2)
For example:
a)
A 200 hp motor tested with a two-turn surge-inducing coil of 20 H inductance and a 16 F capacitor will have an oscillation frequency of 8900 Hz.
b)
A 69 500 kVA hydrogenerator tested with a two-turn surge-inducing coil of 130 H inductance and
a 2 F capacitor will have an oscillation frequency of 9800 Hz.
Copyright 2004 IEEE. All rights reserved.
IEEE
Std 522-2004
IEEE
Std 522-2004
line up with the slots of the stator coil selected for calibration. The laminated-iron sections should be insulated from the core of the machine being tested with a thin insulating material, such as 0.010 in (0.25 mm)
thick adhesive tape, and should be tightly fitted against the machine core. Connect the voltage-divider leads
to the stator coil being used for calibration. Apply a small voltage (1000 V) to the surge-inducing coil and
observe the voltage wave induced in a stator coil (this should be approximately 75% of the volts-per-turn
applied to the surge-inducing coil). When a suitable waveform is established (refer to Figure A.3 for the
expected pattern of the voltage wave), increase the applied voltage to obtain first-peak-amplitude equivalent
to the voltage desired for the test. This should be based on a minimum of 350 volts-per-turn peak with maximum voltage of 75% of the coil test voltage specified in Clause 6.
To determine the effect of a short-circuited turn, apply a deliberate short circuit across the exposed leads of
the stator coil and apply the same voltage level used to obtain the desired volts-per-turn stress. This will
establish the criteria for the test of the remaining coils in the winding and the waveforms of the short-circuited and normal coils should be generally proportional to those shown in Figure A.3. Proceed to test the
winding by moving the laminated-iron sections sequentially so they are positioned over each of the coils in
the machine. Record the oscilloscope settings, the voltage level applied to the surge-inducing coil, and the
amplitude of the first full peak of the voltage wave observed on the oscilloscope, identifying the top-slot
number of each coil as it is tested. Since the waveform observed on an oscilloscope screen for any set of
conditions can generally be determined more accurately by repetitive sweeps, perform at least three capacitor discharges to establish the form. The accuracy of this test in determining the location of a short-circuited
coil can be ascertained by exposing the leads of a stator coil found to be short-circuited, and retesting it with
a deliberate short circuit applied across the leads. There should be no significant change from the waveform
obtained during the previous test.
10
IEEE
Std 522-2004
A.3 Suggested test procedure for coils during winding (if surge comparison
equipment is not available)
The turn-to-turn test can be applied to each coil of a set of new coils, completely assembled in the slots and
with slot wedges in place, by applying the surge directly to the stator coil before insulating the connections.
In this arrangement, the voltage-divider leads are connected in parallel with the surge-generator leads to the
stator coil. The effect of a short-circuited turn under this test condition will be as indicated in Figure A.4.
Calibration of the voltage waveform is performed as previously described and the peak voltage is recorded
by top-coil-slot number with the voltages applied in steps of 0.2, 0.4, 0.6, 0.8, and 1.0 of the peak test voltage (reduced per the suggestions in paragraph 6.5 for unimpregnated or uncured coils). For a single shot
surge generator, five impulses should be applied at each level. (The number 5 is suggested to harmonize 522
with IEC 60034-15 [B21]). With the directly applied test technique, a short-circuited stator coil will provide
a flat response (Figure A.4) to the applied voltage and, therefore, the step voltages are of value in approximating the voltage level where a short circuit may develop in the stator coil. Be aware that when applying a
turn-to-turn surge test to a single coil in a stator core, all the coils in the core will receive some level of surge
voltage to the ground insulation because of the mutual inductance in the slots and the cross linkage on the
end windings. The magnitude of this induced surge to the ground insulation will vary as a function of the relative position of the floating coils to the coil under test and has been found to vary from 50% of the applied
surge to almost zero. This induced surge in the ground insulation can have detrimental effects as the induced
surges may overstress the ground insulation especially at the corners. This stress may initiate a future failure
site if the surge voltage level is too high when the coils are tested in the unimpregnated or uncured state
Stranges, et al. [B54].
11
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Std 522-2004
Circuit parameters are for guidance only. Other appropriate values may be used to produce the required
impulse shape.
12
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Std 522-2004
Annex B
(informative)
10 min __________
P.I. _______
Coil
Impedance/
Resistance
Impulse test
Coil
Passed
Failed
Impedance/
Resistance
Impulse test
Coil
Passed
Failed
Impedance/
Resistance
Impulse test
Passed
Failed
13
IEEE
Std 522-2004
14
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Std 522-2004
Annex C
(informative)
Bibliography
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[B13] EPRI Project RP 2307-1, Turn insulation capability of large ac motors, Final Report, EPRI EL5862, vol. 1 and 2, July 1988.
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Std 522-2004
[B14] Foust, C. M. and Rohats, N., Insulation testing of electrical windings, Transactions of the AIEE,
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[B15] Greenwood, A. and Glinkowski, M., Voltage escalation in vacuum switching operations, IEEE
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[B30] Koutsoukos, A. and Hadad, S. Z., Vacuum circuit breaker and motor insulation surge withstand,
Presented at American Power Conference, April 2426, 1984.
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[B31] Krankel, D. and Schuler, R. A., Method for checking the turn insulation of form-wound coil windings for high-voltage rotating machines, Brown Boveri Review, vol. 57, no. 4, pp. 191196, 1970.
[B32] Laforte, J. T., McCoy, R. M. and Sharma, D. K., Impulse voltage capability of rotating machine
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IEEE
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