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The Impact of High Potential (Hipot) Testing on Globally VPI’ed Stator Winding William Chen R&D Center TECO-Westinghouse Motor Company Round Rock, Texas, USA chenwill@tecowestinghouse.com Abstract—High potential (Hipot) tests have long been used by many on machine stator windings to assess the integrity of electrical insulation system in question. Most industrial standards limit those recommended test values on completed new machines ready for service or existing machines under service/maintenance conditions. There is only limited information available in the literature regarding tests done on globally VPI’ed windings at pre-VPI green coil and/or green winding stages, and its impact on insulation life. We are aware that a limited few users do specify green coil test requirements, with some of those criteria significantly different than our in-house test standard that has been used for many years with proven effectiveness. This study is to compare these two different test philosophies, to see the advantages and disadvantages between them, and to check whether those different test approaches would affect the ultimate goal: the long term insulation reliability of machines in service. Keywords— High potential (Hipot) test; stator; winding; insulation; VPI; green coil. I. INTRODUCTION High potential (Hipot) test is one of the most commonly used tools by OEM’s (Original Equipment Manufacturers), service shops, and end users alike to assess the insulation integrity of machines during both manufacturing processes or in service. Currently, there are three different types of voltage sources commonly used: Alternating current (AC) at power frequency (either 50 or 60 Hz, depending on the country where you are), direct current (DC), and very low frequency (VLF) at 0.1 Hz. Several industrial standards (such as NEMA, IEEE, IEC, etc.) have publications on various test methods, and some with recommended test values [1-3]. The use of AC Hipot test at power frequency is almost universal for new machines because of the similarity of its test stress to that encountered in service, the belief that AC tests are better in detecting defects, and the readily availability of AC supply [4]. For maintenance purpose, both AC & DC Hipot tests are used, with DC testing somewhat preferred. This is mainly due to the availability of cheap & small DC power supply (than similarly rated AC power source), possibility of aborting test on warning before a damage failure, and diagnostic information obtained in controlled tests [4]. On the other hand, there seems to be less & less VLF testing used on rotating machines in recent years. To our knowledge, that technique is now mainly used for cables testing. An EPRI 2007 survey did ask the question regarding testing on green coils used for globally VPI’ed machines [5]. A great majority of respondents (86%) in that survey left it to the vendors (mainly OEM or service shops) to decide or gave no response. This is quite understandable because every insulation system is different, especially at green coil stage. Each vendor should understand their insulation system the best. Besides, those (green coil) tests are generally considered to be their in- house/internal tests. Therefore, it is preferable for the vendors to have their own flexibilities and decide their own testing philosophy (such as whether testing at higher voltage but for a shorter duration, at lower voltage but a longer duration, and/or their acceptable risk level.) However, a limited few specifications do exist with these green coil test criteria specified [6-7], with one of them even put a hard limit such that “The (1-minute) DC hipot test voltage shall not exceed 100% of line-to-line voltage for global VPI windings” [7]. This approach is contradictory to our own long standing in-house practice of testing green coil winding at a higher voltage level but for a shorter period. A private conversation with a highly respected rotating machine expert also suggests a second OEM uses similar test level as ours but with an even longer test period. This confirms that we are not alone in using this (higher but shorter) testing philosophy. Therefore, this project is to find out whether such test limits as specified in those few specifications are really warranted and whether that could affect the ultimate insulation service life. II. SAMPLE COIL PREPARATION & TEST SET-UP A. Test (Green) Coil Preparations. Extra production coils were used for this study here. These coil design was 8-poles and rated at 13,200 V, with the coil straight section of 50”. They were divided into 3 groups, with 6-8 coils per group: • Group A green coils were tested per our current in- house standard (i.e., higher voltage level than those customer specs but with a shorter duration), followed up with that same test criteria per [7] (i.e., DC Hipot test at 13,200 V DC for 1 minute). 978-1-4799-8903-4/15/$31.00 ©2015 IEEE ISBN: 978-1-4799-8903-4 2015 IEEE 11th International Conference on the Properties and Applications of Dielectric Materials (ICPADM) 987 • Group B were tested with that same limiting test criteria per [7] only. • Group C were tested per our current in-house standard only. After those tests were done, all coils were fitted with pre- determined side plates to simulate how coils encounter in actual stator slots. All coil leads were also connected & fully insulated the exact same way as they are in the stator windings. See Fig. 1. Fig. 1. A group of green test coils with side plates installed. B. Coil VPI Processing & Testing. All these test coils were then processed through our standard VPI cycles. After VPI & bakes, side plates were removed and the following tests performed to compare their insulation performance among different coil groups: • Water immersion test. • Power factor (Dissipation factor) tip-up test. • Partial discharge test. • Surge withstand capability test on inter-turn insulation. • Short term AC dielectric breakdown test. • Long term voltage endurance test. III. RESULTS & DISCUSSION A. Water Immersion Tests These water immersion tests were performed per NEMA MG 1, part 20.18.1 [1]. Because of the large size of these test coils, a large outdoor water tank was used for this purpose instead of our smaller indoor tank. See Fig. 2 for the test set-up & coil. All coils passed the required 10 minutes insulation resistance measurements at 500 V DC, and then 1 minute AC Hipot tests at 1.15 *Un (i.e., 15,200 V AC). (a) (b) Fig. 2. Water immersion test on coils. (a) water tank, (b) coil immersed completely in the water while being energized. B. Power Factor (PF) Tip-up Tests PF tip-up test is to measure the difference in dielectric power factor of insulation between 2 different voltages. Several different test values are commonly used for tip-up calculations. Please see reference standards IEEE 286 [8] & IEC 60894 [9]. Fig. 3 is the comparison of normalized PF tip-up values between these 3 different coil groups when calculated between 60% & 20% of the line-to-line voltage (i.e., 0.6*Un - 0.2*Un). It is clear that there were some variations even in the same coil group. However, they were all within the normal range of our internal statistical database & did not show much difference between groups (e.g., the largest difference of standard deviation between groups was A & B, at only 0.08%). Fig. 3. Normalized PF tip-up comparison between different coil groups. C. Partial Discharge (PD) Tests PD could come from different sources/sites, such as coil’s micro-voids, defects, aging, etc., and could happen either internally or externally. In principle, PD can be considered a general indication of coil quality and is another commonly used test by many for coil insulation evaluation. However, ISBN: 978-1-4799-8903-4 2015 IEEE 11th International Conferenceon the Properties and Applications of Dielectric Materials (ICPADM) 988 because of the intrinsic differences in insulation systems, as well as different PD equipment used for testing, there are no absolute criteria suggested by the industry. See IEEE 1434 [10] or IEC 60270 [11] for additional references. In our evaluation here, coils were PD tested at both the rated line-to-ground (Un/√3) and line-to-line (Un) voltages. Fig. 4 shows the comparison of normalized PD results at line- to-ground voltage. The standard deviation of Group A seems to be a little larger than the other 2 groups. However, it is not clear to us whether that was the direct result from the extra Hipot tests applied on the green coil testing since all these PD values were still within our normal in-house statistical data range. Fig. 4. Comparison of normailized PD (Qm) readings between different coil groups when tested at line-to-ground voltage. D. Surge Withstand Capability Test on Inter-Turn Insulation The coils’ inter-turn insulation were evaluated using fast- rise-time impulses (about 0.1 - 0.2 μsecond) at 3.5 PU peak per IEEE 522 standard [12]. Afterward, test voltages were gradually increased up to our test set limit (of about 50-55 kV peak). See Fig. 5 for the test set-up. All coils passed the maximum test voltages without failure. E. Short Term AC Dielectric Breakdown Test on Groundwall Insulation The coils’ short-term groundwall dielectric strengths were tested per IEC 60034-15 method [13] using a 60 Hz AC Hipot test set. All coils first withstood the required AC voltage of (2* Un + 1 kV) for 60 seconds. After that, the voltage was slowly increased to 2* (2* Un + 1 kV) momentarily at the rate of 1kV/second, before immediately reduced back to zero. No coil failed under this test, either. Fig. 5. Coil surge test on its inter-turn insulation. F. Long Term Voltage Endurance (VE) Test The final test performed was the long-term voltage endurance test per IEEE 1043 standard [14] to see whether coils meet their expect service life requirements. This standard does allow tests to be proceeded at either room temperature or elevated temperature, although it is a general belief that testing at room temperature is actually harsher. Our internal practice is usually to have these tests done at room temperature. Fig. 6 shows one of our VE test cages with several coils being tested simultaneously under room temperature condition. Fig. 7 is the normalized VE life comparison of these 3 groups tested at 30 kV, following the recommended test voltage per Schedule A of IEEE 1553 standard for this voltage rating [15]. As we have expected, only limited difference exists between these 3 different coil groups, suggesting the different (Hipot test) voltage stress applied to these groups during green coil processing stage have very limited impact on their final insulation lives. Fig. 6. An example of long-term coil VE test set-up. ISBN: 978-1-4799-8903-4 2015 IEEE 11th International Conference on the Properties and Applications of Dielectric Materials (ICPADM) 989 Fig. 7. Normalized long-term VE life comparison. IV. CONCLUSION Based on these results above, the following conclusion can be drawn: • Our internal test method (i.e., at a higher test voltage level but for a shorter duration) does not negatively impact the ultimate service life of coil/stator winding insulation. • The limiting test criteria on green coils as suggested per specs [6-7] are not really warranted. It might, to the opposite, reduce the effectiveness of green coil testing on finding potential winding defects that might occur during stator winding process. • Because of each OEM’s own manufacturing experience, different insulation characteristics, and testing philosophy, it seems the best to leave those internal test limits (on the green coil/winding) to each individual OEM. ACKNOWLEDGMENT The author would like to thank Mr. Ut Pham & several others at TECO-Westinghouse Motor Company, who helped with sample coil preparations & test measurements. REFERENCES [1] NEMA MG-1, Motors & Generators, 2011. [2] IEEE Std 95-2002, IEEE Recommended Practice for Insulation Testing of AC Electrical Machinery (2300 V and Above) With High Direct Voltage. [3] IEEE Std 433-2009, IEEE Recommended Practice for Insulation Testing of AC Electrical Machinery with High Voltage at Very Low Frequency. [4] B.K. Gupta, G.C. Stone, J. Stein, “Stator Winding Hipot (High Potential) Testing”, IEEE Electrical Insulation Conference, pp. 409-413, Montreal, Canada, May 31-June 3, 2009. [5] J. Stein, EPRI Report 1014908, “Guide for TRotating Machine Stator Winding Hipot Testing”, March 2008. [6] EPRI Report 1011892, “Guideline for the Specification of Replacement and Spare AC Squirrel-Cage Induction Motors having Voltage Rating of 2,300V to 13,200V”, December 2005. [7] Tennessee Valley Authority Generation Engineering, Electrical Procurement Specification GE-SS-E9.2.1, “AC Squirrel-Cage Induction Motors Voltage Rating of 2300V to 13200V, 2012. [8] IEEE Std 286-2000, IEEE Recommended Practice for Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation [9] IEC 60894:1987, Guide for Test Procedure for the Measurement of Loss Tangent of Coils and Bars for Machine Windings. [10] IEEE Std 1434-2014, IEEE Guide for the Measurement of Partial Discharges in AC Electric Machinery. [11] IEC 60270:2000, High Voltage Test Techniques-Partial Discharge Measurements. [12] IEEE Std 522-2004, IEEE Guide for Testing Turn-to-Turn Insulation on Form-Wound Stator Coils for Alternating-Current Rotating Electric Machines. [13] IEC 60034-15:2009, Rotating Electrical Machines-Part 15: Impulse Voltage Withstand Levels of Form-Wound Stator Coils for Rotating AC Machines. [14] IEEE Std 1043-1996, IEEE Recommended Practice for Voltage- Endurance Testing of Form-Wound Bars and Coils. [15] IEEE Std 1553-2002, IEEE Standard for Voltage-Endurance Testing of Form-Wound Bars and Coils for Hdrogenerators. 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