Experience in Off-line insulation testing and

diagnosis of high voltage rotating machines

A.Shkolnik, I.Litvin

1. Introduction further be determined by the Polarization index test. This test

The high voltage rotating machine (motors and generators) is a gives the ratio of the insulation resistance at 10 minutes to the
major component in a power system and its proper functioning is value at 1 minute. Should the ratio be 2 or higher, then this should
vital to system operations. During its entire operational time, the be taken as a sign that service is required.
high voltage rotating machine has to withstand numerous stresses Moisture and contamination of the winding and sometimes also
such as thermal, electrical and mechanical. This generally results thermal aging are indicated by the PI test. Very low and very high
in degradation of the rotating machines insulation system. Rotating values are cause for concern and indicate an insulation system
machine failures are sometimes catastrophic and almost always that requires further investigation. Depending on what type of
include irreversible internal damage. Therefore, it is necessary to insulation has been used, Low PI values might point to the need
closely monitor their insulation condition. for drying out or cleaning of the machine, whereas windings near
This paper describes experience Central Electrical Laboratory the end of their useful lives may give very high values. In order to
(CEL) of Israel Electric Corporation has in off-line stator insulation identify possible problem areas, PI values between phases should
testing of high voltage rotating machines. The implementation of a be compared.
tool for the diagnosis of faults is based on analysis of test results.
Diagnosis of the condition of HV insulation is based of the 2.3. Dielectric Dissipation Factor (DDF)
following tests [1]: The dissipation factor test measures the insulation condition using
• insulation resistance (R) and polarization index (PI) alternating current techniques [2] by application of test voltages
measurement; less than or equal to the rated voltage of the test object. The test
• dielectric dissipation factor (DDF) and capacitance (C) is useful in determining overall machine integrity when used in
measurement; conjunction with other inspection activities. In order to measure
• partial discharge (PD) measurement and corona detection ; phase-to-phase insulation, the phases of the machine should be
• applied high voltage testing disconnected and each phase of the winding tested separately.
The recorded results are used for estimation of the insulation
condition of electrical machines and for operation and 2.4. Capacitance
maintenance recommendations. Surface contamination of the winding insulation, increased
humidity and temperature are factors which may cause
KEYWORDS capacitance to ground values to increase with time. The
Rotating Machines, Dielectric Dissipation Factor, Partial accumulation of moisture, dirt and conductive contaminants on
Discharge, High Potential Test. the stator insulation will also cause changes in winding insulation
capacitance, resulting in higher capacitance values. Degradation
2. Types of tests of the layers of corona protection may also cause a decrease in
capacitance. Testing is used to build up a basis for comparison and
2.1. Insulation resistance (IR) for constructing trends.
The insulation resistance of a machine winding depends on the
type of insulating material and on the condition of that material. As 2.5. Partial discharge (PD)
a rule, insulation resistance is proportional to insulation thickness Wherever internal de-lamination, surface or slot discharge in
and inversely proportional to the surface area of the conductor. electrical winding insulation occurs, PD activity may take place
Resistance values are affected by contamination, humidity, resulting in significant deterioration of insulation over time.
temperature, and other factors. Low values may point to moisture PD measurements are used for assessment of the condition of
ingress, dirt or damaged insulation. In order to measure phase-to- complete windings as well as of individual form wound coils and
phase insulation, the phases of the machine should be disconnected bars – particularly useful in machines rated above 3kV, where PD
and each phase of the winding tested separately. can also give an indication of deterioration of external slot or end
By periodic checking and recording of values, a good basis for arm surfaces.
judging condition of the insulation can be built. Even if readings
are higher than minimum suggested safe values for that machine, a 2.6. DC high potential
constantly downward trend should be treated as a warning of need The DC high potential test is a pass/fail test with respect to
of maintenance. Results close to suggested minimum values may integrity of insulation but is also a trending test, which detects
be considered satisfactory, provided that these values are constant moisture and contamination issues and is conducted by applying
over a number of periodic checks. Care should still be taken with a DC voltage to the winding relative to the frame. In order to
machines with insulation readings nearing their minimum. measure phase-to-phase insulation, the phases of the machine
should be disconnected, untested phases grounded and each phase
2.2. Polarization index (PI) of the winding tested separately. Examining the results of leakage
The state of insulation between the conductor and ground can current versus voltage will yield information on relative winding

65 2012 ‫ מאי‬,40 ‫גליון‬

 detector ICM system ( Power Diagnostix System GmbH). A resonance reactor
is used in parallel for compensation of high capacitance in large rotating
machines.
The software allows the test engineer to simultaneously perform both
measurement and record all necessary parameters.

Example 2

Motor data: 11500V 20000 HP. It has been periodically tested since 2000.
The picture below shows the trend of PD activity with time. It is clear to see
the increase in PD activity (Fig.1).

condition.
The leakage current depends on ambient moisture and surface 30000
contamination; therefore, this test detects moisture or dirt on the
windings. If a DC test is used, the test voltages should be those 25000
values recommended for AC testing multiplied by a factor of 1.7.
20000
2.7. AC high potential

Q,pC
The AC high potential test is a pass/fail test used to evaluate the L1 15000
condition of insulation and it should be noted that each time the L2
L3
AC high potential test is performed; the potential consequence is 10000
a winding failure.
New and rewound machines should have an AC high potential 5000
test of twice-rated terminal voltage plus 1 kV applied to them.
When the machine is repaired and the winding is not involved, 0
a reduced AC over voltage test may be performed prior to the 2012 2010 2008 2006 2004 2002 2000
commencement of works and again after completion of works. Years
In the case of failed windings, where insulation is replaced or a
partial rewind is performed, a reduced voltage final test may be
used. Fig.
Fig.11PD
PDactivity
activity trend
trendwith
with time
time

3. Test methods and test results The picture below also shows the trend with time of DDF f (U) (Fig.2).
The picture below also shows the trend with time of DDF f (U)
3.1. Insulation resistance and polarization index (Fig.2).
measurement.
For Insulation resistance and polarization index measurement,
CEL uses the Megger S1-5010 Insulation Tester. For rotating 2.4
L1, 2000
machines with a rated voltage of 3.3 kV, the applied test voltage
L2, 2000 2.2
is 2500 V. For rotating machines with rated voltages above 6.6 kV
the applied test voltage is 5000V. L3, 2000
2.0
Resistance and PI tests are performed simultaneously in an L1, 2006
automatic mode. L2, 2006
1.8

DDF, %
L3, 2006
Example 1 L1, 2006 1.6
Motor data: 6600V 1250 HP. The motor was put into operation L2, 2009
in 2000. 1.4
L2, 2009
During periodic testing, very low values ​​of insulation resistance
and high value of DDF were obtained. It should be noted that L1, 2011 1.2
the motors are located near the sea and the heating elements of L2, 2011
the motors worked properly. After heating the motors from an L3, 2011 1.0
external source, the value of insulation resistance increased, but 7 5 3 1
U, kV
immediately after turning off the heating for a short time dropped
to a low value. Based on this data, impregnation of insulation was Fig. 2 DDF f (U) trend with time
Fig. 2 DDF f (U) trend with time
recommended. The one motor was removed for repair. During
inspection in a repair shop, it was discovered that there was in
fact weak impregnation of the winding insulation. ImpregnationThere is There is a direct correlation between PD activity and DDF.
a direct correlation between PD activity and DDF.
was carried out and additional heating elements were installedFor PDFor PD localization,
localization, CEL uses CELtheuses the ultrasonic
ultrasonic sensorsensor
UE 200 UE(UE200system)
(UE and
on the motor. There was a significant improvement in insulationthe UV detectorand
system) the UV
Daycor detector
(OFIL Daycor
Ltd). This (OFIL
test was Ltd). This
performed test was
on open stator.
test values and the problem was solved. A similar repair was performed on open stator.
performed on the remaining motors of this type. Example 3
Example 3
3.2. Generator
Dissipation factor and partial discharge measurement. Generator data: 22500
data: 22500 KVA, 11000
KVA, 11000 V V
For DDF and PD measurements, CEL uses the Mobile InsulationDuringDuring periodicperiodic
testing, testing, highoflevels
high levels partial​​of partial were
discharge discharge werein one
recorded
Diagnosis & Analyzing System MIDAS 2881 ( Haefely Testof the recorded phases. An in additional
one of the PDphases.
test was Anrecommended
additional PD withtest
an was
ultrasonic
AG ), and the partial discharge detector ICM system ( Powersensor.recommended witha an
During this test ultrasonic
strong sensor.
discharge Duringwinding
between this testand
a strong
stator core
Diagnostix System GmbH). A resonance reactor is used in parallelwas discovered. The reason
discharge between for and
winding the stator
problem corewas
wasthe destruction
discovered. Theof the
for compensation of high capacitance in large rotating machines. semiconductor
reason forlayer (coronawas
the problem protection).
the destructionRewinding of the stator was
of the semiconductor
The software allows the test engineer to simultaneously performrecommended. At the pictures
layer (corona below shows
protection). PD pattern
Rewinding of the(Fig.stator
3). was
both measurement and record all necessary parameters. recommended. At the pictures below shows PD pattern (Fig. 3).

Example 2
Motor data: 11500V 20000 HP. It has been periodically tested
since 2000.
The picture below shows the trend of PD activity with time. It is
clear to see the increase in PD activity (Fig.1).

L1 L2 L3

Fig. 3 PD pattern

The picture below, taken by a burrowscope, shows destruction of the corona

protection layer of the stator coil (Fig. 4). 2012 ‫ מאי‬,40 ‫גליון‬ 64
 Generator data: 22500 KVA, 11000 V
During periodic testing, high levels of partial discharge were recorded in one
of the phases. An additional PD test was recommended with an ultrasonic
sensor. During this test a strong discharge between winding and stator core
was discovered. The reason for the problem was the destruction of the
semiconductor layer (corona protection). Rewinding of the stator was
recommended. At the pictures below shows PD pattern (Fig. 3).

L1 L2 L3
Fig. 3 PD pattern
Fig. 3 PD pattern
Fig. 5 Corona detection by UV camera
The picture below, taken by a burrowscope, shows destruction of 3.3. Applied high voltage testing
The picture
the corona protection layer ofbelow,
the statortaken
coil (Fig.by
4). a burrowscope, shows destruction of the corona
protection layer of the stator coil (Fig. 4). Mainly in CEL,high
3.3. Applied allvoltage
HV testing
testingis performed at AC up to 50 KV,
by using an HV compensation trans-reactor, which allows the use
Mainly in CEL, all HV testing is performed at AC up to 50 KV, by using an HV
of a low consumption power supply. The test circuit includes:
compensation trans-reactor, which allows the use of a low consumption power
regulating
supply. The testtransformer (1), regulating
circuit includes: trans-reactor (2), (1),
transformer testtrans-reactor
object (3),(2),
voltmeter
test (4),
object (3), ampere-meter
voltmeter (5) (Fig.6).
(4), ampere-meter (5) (Fig.6).

Fig. 4 Destruction of corona protection

Fig.6 AC High potential test scheme

Example 5 Fig. 4 Destruction of corona protection Fig.6 AC High potential test scheme

InInthe
thecase
caseofofspecial
specialrequirements fromfrom
the client, it is possible to perform
Generator data: 5 Fig. KVA,
133750
Example 4 Destruction
11500 Vof corona protection requirements the client,
DC high voltage testing for leakage current measurement. For this propose
it is possible to
Generator
In the course data: 133750
of periodic KVA,Corona
testing, 11500 V tests were carried out toCEL perform
locate DC high voltage testing for leakage
uses the DC Dielectric Test Set 70 kV (Biddle).
current measurement.
In the course of periodicwindings
testing, Corona tests were carried During
out For this propose CEL uses the DC Dielectric Test Set 70 kV
corona discharge on generator at nominal voltage. Corona
Example 5to locate corona discharge on generator windings atwas
nominal (Biddle).
3.4. Special test
testing, points of discharge were found. The generator repaired by the
voltage. During Corona testing, points of discharge were found.
manufacturer.
The
Isolation
generator
was
was
strengthened
repaired
with resin impregnated glass
byVthe manufacturer. Isolation was
The tape.
3.4. Partial Special
Dischargetesttest, in a traditional sense, performed at the phase
Generator
Corona data:
discharge 133750 KVA,
disappeared 11500
after repairing. The Corona
pictures voltage, does not allow testing of the insulation between phases in full, as the
below shows PD
In theup strengthened
course of of with
periodic resin impregnated
testing,(Fig.
Corona glass tape. discharge The
were carried out toapplied Partial
voltageDischarge
is 1.7 timestest,less
in a than
traditional
the truesense,
voltage.performed at theline
By applying
picked with aid
disappeared aafter
UV repairing.
camera 5). tests
The pictures below shows PD picked
locate
phase voltage,
voltage, does not
phase to ground allowistesting
insulation of to
subjected theadditional
insulation between
stress, because
corona discharge on generator windings at nominal voltage. During Corona
the applied
up with aid of a UV camera (Fig. 5). phases in voltage
full, asisthe
1.7applied
times larger than is
voltage the1.7
truetimes
voltagelessand thatthe
than increases
true
testing, points of discharge were found. The generator was repaired the by the
risk
voltage.
of insulation breakdown.
By applying line voltage, phase to ground insulation is
manufacturer. Isolation was strengthened with resin impregnated glass Therefore,
tape.for to our laboratory has developed and implemented a three-phase
subjected
scheme additional
measuring stress,
partial becausewhich
discharge, the applied
approximatesvoltagetheistesting
1.7
Corona discharge disappeared after repairing. The pictures below shows times PDlarger
conditions to bethan the true
as close voltagetoand
as possible realthat increases
working the risk
conditions. This ofKIT
picked up with aid of a UV camera (Fig. 5). includes
insulationa three phase regulating transformer and 3 HV trans-reactors with an
breakdown.
adjustable core gap, to regulate the inductance. This scheme allows the
Therefore,
application of our laboratory
three has developed
phase voltage andmachine
to the rotating implemented a three-
with compensation
phase
for scheme of
the capacity forthe
measuring partial
test object. discharge,
This scheme alsowhich
allowsapproximates
the testing of 3-
Phases simultaneously,
the testing conditions thus
toshortening
be as close the overall testingto
as possible time.
real working
The test circuit includes: regulating transformer (1), trans-reactor (2), test
conditions. This
object (3) (Fig.7).
KIT includes a three phase regulating transformer
and 3 HV trans-reactors with an adjustable core gap, to regulate
the inductance. This scheme allows the application of three phase
voltage to the rotating machine with compensation for the capacity
of the test object. This scheme also allows the testing of 3-Phases
simultaneously, thus shortening the overall testing time.
The test circuit includes: regulating transformer (1), trans-reactor
(2), test object (3) (Fig.7).

Fig. 5 Corona detection by UV camera

63 2012 ‫ מאי‬,40 ‫גליון‬

Fig. 5 Corona detection by UV camera

 [2] IEEE Std 286-2000 (R2006). IEEE Recommended Practice
for Measurement of Power Factor Tip-Up of Electric Machinery
Stator Coil Insulation.

Anatoly Shkolnik was born in Ukraine

on 1950. He received his M. Sc. degree
in electronic engineering (dielectrics and
semiconductors) from the Kiev Polytechnic
University (Ukraine) in 1973 and Ph.D. in
electrical engineering (electrical stations,
electrical machines) from Electric Power
Research Institute (Moscow, Russia) in 1990.
Fig. 7 Three-phase scheme for PD measurement He has experience in production, repair, testing and diagnosis
Fig. 7 Three-phase scheme for PD measurement of the HV equipment. Now he is senior specialist of the Central
4. Conclusion Electrical Laboratory in the Israel Electric; regular member of
4. Conclusion CIGRE SC D1- “Materials and Emerging Test Techniques”
4.1. Comprehensive testing of insulation condition yields more
information, so as to be better informed and make the right
4.1. Comprehensive testing of insulation condition yields more
decision. Igor Litvin was born in Ukraine on 1967.
information, so as to be better informed and make the right He received his M. Sc. degree in electronic
4.2. Timely periodic checks can identify problems and prevent the
decision.
breakdown engineering (industrial electronics) from the
4.2. Timelyof periodic
the insulation.
checks can identify problems and prevent the
4.3. The use of additional
breakdown diagnostic tools, such as US sensor and
of the insulation.
Donbas State Technical University, Alchevsk,
UV camera,
4.3. The use reduces repair diagnostic
of additional costs and costs
tools, of unplanned
such outages
as US sensor and UV Ukraine in 1991. He has experience in
relatedcamera, reduces
to equipment repair costs and costs of unplanned outages
failure. development, testing, repairing and adjustment
related to equipment failure. of power electrical equipment, electrical
BIBLIOGRAPHY drives, automatically industrial lines, testing
BIBLIOGRAPHY and diagnosis of the HV equipment. Now he is
[1] IEEE Std 1415-2006 electrical engineer of the Central Electrical Laboratory in the
[1] IEEE Std 1415-2006 IEEE IEEE
Guide Guide to Induction
to Induction Machinery
Machinery Maintenance Israel Electric.
Maintenance
Testing Testing
and Failure and Failure Analysis.
Analysis.
[2] IEEE Std 286-2000 (R2006). IEEE Recommended Practice for
Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil
Insulation.

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2012 ‫ מאי‬,40 ‫גליון‬ 62