Wind Turbin Insulation

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Insulating Systems for Wind Turbine Generators

We Enable Energy

As one of the oldest industrial companies in Switzerland, founded in

1803, we focus on products for power generation, rotating machines

and mechanical engineering. Von Roll is the global market leader and

the only company to offer the complete range of insulation products,

equipment, composites and services for electrical machines such as

wind turbine generators.

For more than 100 years, we have been making outstanding

contributions to this market, developing a number of highly

innovative products that have enabled both steady increases in power

output and more compact machines.

Customers enjoy the following advantages:

? One single source for all insulating materials

? Proven compatibility for system components

? Testing at Von Roll of both materials and systems

? Manufacturing technology and equipment

? Consulting in application engineering

? Training in insulation materials and systems

The insulation system of a wind turbine generator is a critical com-

ponent for reliable and long-lasting operation. The insulating system

and materials used for these machines are basically the same as for

conventional generators and must be carefully selected in order to

meet very high specific requirements.

The voltage output of generators in wind turbines ranges from 440 V to

6 kV. A variety of insulation systems are available and can be classified

according to two different types:

? Low Voltage insulation – typically up to a voltage output of 900 V, these

systems are based on a random wound or form wound coil design

? High Voltage insulation – for voltage output up to 6 kV, these systems

are based on a form wound coil design both in vacuum pressure

impregnation (VPI) and resin-rich (RR) technology

Our Products for Wind Turbine Generators

Von Roll offers full system solutions for every market shown in this

application tree. Please contact us or visit our website https://www.wendangku.net/doc/1d9465604.html, for further information.

Enameled Round Wires

Enameled Flat Wires

Covered Flat and

Round Wires

Testing

Consulting and Training

Mica

Machined Parts

Liquids

Flexible Laminates

Machine and Equipment

Conductive / Semi Conductive Tapes

Auxiliary Tapes Composites

Large Generators

HV Rotating Machines

Traction Motors

LV Rotating Automotive

LV Rotating Consumer

Transformers and Switchgear

Repair

Wind Turbine Generators

LV Rotating Industrial

Insulating Systems for Wind Turbine Generators

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Low Voltage Insulating Systems

The insulation systems for low-voltage wind turbine generators are composed of the following materials and services:? Winding wires ? Slot insulation ? Impregnation resin ? End-winding tape ? Wedges and closures ? Finishing varnishes ? UL testing

Most of these low-voltage products are listed in UL under different thermal classes.

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Winding Wires

Von Roll’s winding wires are at the leading edge of technology.

We offer a wide range of high-quality winding wires for wind turbine generators both in round

and rectangular forms. The following are the products we recommend for this application:

End Winding Tapes

Von Roll offers a wide range of high-quality adhesive tapes for a variety of applications.

As an end-winding tape for low-voltage wind turbine generators we recommend:

Slot Insulation, Wedges and Closures

Von Roll is a world leader in laminated flexible insulations and coated materials. Our materials for slot liners, phase insulation, barrier applications and closures for

low-voltage wind turbine generators are outstanding. We supply them in a wide variety of thicknesses to fit perfectly in your application. The following products represent the best choices in this category:

For wedges we recommend composite materials such as Vetronit ? G-11 or Delmat ? Epoxy 68660 that can be delivered either as sheets or machined parts. U and L profiles with bounded Nomex layers are also part of the slot insulation program on request.

Insulating Systems for Wind Turbine Generators 5

Impregnation Resins for Low Voltage Machines

Impregnation resins are among the most important components in any low-voltage machine. We offer a wide range of impregnation resins for low-voltage wind turbo generators with particular importance for class H systems.The most suitable materials are listed below:

The Damisol ? blue line includes materials that have no or very little VOC emission and were engineered to be environmentally friendly. Our resins are described in detail in a

separate brochure titled ?Impregnating Resins and Varnishes?.

Conductors

For conductors of high-voltage coils, we offer a complete range of high-quality products:? Covered wires with impregnated glass yarn (Silix ?)

? C overed wires with mixed glass/polyester yarn (Daglas ?), with or without coating ? Samicafilm ? tape-covered wires

? Flat rolled litz wires with bare or enameled s ingle conductors, covered with Samicafilm ? tape

Samicafilm ? tape covering on bare or enam-eled wires is the preferred conductor insulation for stator and rotor coils due to its substantial advantages:

? Better corona resistance ? Reduced insulation thickness ? Softer copper enabling easier workability ? Greater manufacturing flexibility

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Insulating Systems for Wind Turbine Generators

High Voltage Insulation Systems

Many different materials are used in constructing high-voltage coils for wind turbo generators:? Winding wire (A)? Conductor insulation (B)? Stack consolidation (C)

? Main wall insulation:

- For VPI mica tape (D) + resin (H) - RR Mica tapes (D)

? Conductive paint or tape (F) (typically for machines with voltages higher than 5 kV)? Finishing or sealing tapes (E)? Bracing materials (G)? Slot wedging materials (I)

Von Roll has developed a VPI insulation system under the name of Samicabond? with the follow-ing advantages:

? Resins with high tank stability at room temperature ? Impervious to moisture ? Low viscosity

? Fast curing with non-accelerated mica tapes ? Excellent electrical properties ? Class H

? Very high price/quality ratio

In this document the main products associated with this system will be exposed.

G

I

D E

A C

H

F

F

Insulating Systems for Wind Turbine Generators 7 Samicafilm? products are based on Von Roll Samica? mica paper impregnated with

modified epoxy resin, reinforced with one or two polyester film backings and with or

without adhesive coating.

Samicafilm? tapes are applied butt-lapped or overlapped to the conductor. We supply both

tape and taped conductors to our customers.

Samicafilm? tapes are thin but show outstanding corona resistance.

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Insulating Systems for Wind Turbine Generators

Coil Production

Stack Consolidation

We offer complete systems and are involved in every aspect of high-voltage technology, including process equipment. For wind turbine generators Von Roll has come up with a line of coil-producing machines that use flat-coil technology. This line of equipment increases our customers’ efficiency and includes the following units:? Wire dispensing and preparation ? Loop winding ? Taping ? Coil forming

Employing Samicafilm ? with hot-melt adhesive or glass-lapped wires at B stage enables rapid consolidation of conductor stacks without the need for additional consolidation products.

When using Samicafilm ? without hot-melt adhesive or non-B-stage wires, traditional hot-press consolidation is preferred. This system can be achieved by overlapping the stack with Thermopreg ? 251.78.

Von Roll standard materials for stack consolidation:

Coil-forming machine.

Insulating Systems for Wind Turbine Generators 9

Main Wall Insulation for the VPI System

Von Roll is highly committed to mica. Our added value is evident throughout the

entire manufacturing chain. It starts with mining, preparing the mica scrap and mica

paper pulp, producing mica paper and finally manufacturing mica tapes to the

highest standards for use in main wall insulations.

We have exactly the solutions you need to improve the quality and cost-effectiveness of

high-voltage insulation in your applications.

With Samicapor?, Von Roll has designed a range of outstanding VPI mica tapes that

fulfill the requirements of main wall and end-winding insulation, namely:

? High dielectric strength

? Corona discharge resistance

? Fast and easy impregnation

? Resin retention without draining

? Smooth application without creasing

? Both manual and fast-running machine application

? Full compatibility with predefined resin systems

Von Roll’s commitment to mica starts with mining and ends with the production of mica-taped wires.

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Taping Machines

Optimal quality application of Samicapor ? and Samicatherm ? tapes can be achieved with high-speed taping machines.

Overhang tapes for conventional hot pressing:

Main Wall Tapes for the RR System

Assuring optimum quality of main wall insulation requires careful selection of the micaceous tape and detailed attention to the way the tape is applied and processed. With these demands in mind, we have created a complete range of RR main wall insulation tapes under the name of Samicatherm ? that are used for wind turbine

generators:

Insulating Systems for Wind Turbine Generators 11

Pressing in the RR Process

RR processed coils need to be heated and pressed in order to achieve the proper final dimensions, while allowing flow of the resin, filling of possible voids and finally curing of the total insulation. State-of-the-art presses are the ideal solution.

The mica tapes used in main wall and overhang insulation contain materials that can easily be damaged and need to be protected against:? Moisture ? Mechanical load ? Damage

? Atmospheric pollutants

With Epoflex ? Von Roll found the appropriate solution that fulfills these requirements:

Finishing Tapes

Mica tapes for VPI applications.

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Glass or glass polyester cords.

The simplicity of the winding process for machines with ?dry? coils is a recognized

benefit of VPI technology. Substantial advantages obtain during the end-winding bracing and support process. Von Roll has developed a range of ropes, cords and sleeves for ?surge ring? intercoil lacing and tying applications.The main advantages of these products are:? Class C (glass) and F (polyester) applications ? Compressibility and resilience ? Glass or polyester yarn on the outside ? Wide range of dimensions

? Nonimpregnated for use with VPI; no further processing ? Impregnated polyester shrink cord for use with RR technologies

Machine Winding and Bracing

Composite Materials for Wind Turbine Generators

Von Roll offers a variety of high-quality composite materials that can be delivered as wedges, sheets, machined parts or special components for use in different sections of a high-voltage rotating machine. The following are just a selection. Please ask our

specialists about additional products.

Insulating Systems for Wind Turbine Generators 13

VPI Resins

Several families of resins have excellent electrical characteristics when cured. The

factors that influence the final choice of resin used are much more complex. Important considerations relate to features of the design of the machines and the choice of insulating system, taping and VPI processes.

Von Roll offers a variety of high-performance resins that are compatible with all the other

insulation materials within the system. For wind turbine generators we propose:

Machined parts tailored to customer specifications.

Different materials used for rotor and stator components and their application:

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The Damicoat ? range of finishing and overcoat varnishes includes air-drying and

oven-curing solutions. All are single-component for easy processing by spray, brush and even dipping and dip rolling.

Finishing Coating

The principles of air drying, controlled rate impregnation, pressuring and curing of resin are well understood by VPI process users and potential users.

Von Roll offers VPI systems tailored to meet the needs of all sectors of the rotating machine industry.

For new equipment or upgrading existing plants, we ensure state-of-the-art VPI technology to increase our customers’ efficiency.

Instrumentation for measuring capacitance, essential for in-line quality control of impregnation, is built into the systems.

Drying and Impregnation

Large Vacuum Pressure Impregnation (VPI) unit.

Insulating Systems for Wind Turbine Generators 15

Ensuring the requested specifications concerning mechanical, electrical and thermal characteristics means testing materials and systems.

Von Roll HV and LV laboratories can test their customers’ materials and systems according to IEC, UL and other specifications. Our low- and medium-voltage laboratory in the US is certified by Underwriters Laboratories ? Inc., performing system qualifications up to 6.9 kV.

? Thermal, electrical and mechanical aging tests ? Tan e measurements at different temperatures

? Partial discharge measurements with different voltage ranges

For a number of years we have been offering a unique program of high-voltage insulation training within our Von Roll Corporate University. The objectives of this program are:? B etter understanding of high-voltage insulation technology for rotating machines and up-to-date knowledge on insulating materials and systems ? P ractical experience in the application of electrical insulating materials

Testing

Training

Testing in the Von Roll laboratory.

Our training courses are attended by customers and partners from around the globe.

Von Roll is the sole full range supplier of materials and systems for the insulation of electrical machines as well as high-performance products for various high-tech industries.

A l l i n f o r m a t i o n i n t h i s d o c u m e n t s u b j e c t t o t h e p r o d u c t l i a b i l i t y c l a u s e a s p u b l i s h e d i n t h e W e b s i t e w w w .v o n r o l l.c o m u n d e r l e g a l i n f o r m a t i o n .C o n c e p t /D e s i g n : w w w .i d f x .c h , 06 2008

Mica

All materials related to high-voltage insulation. Von Roll’s commitment to mica starts with mining and ends with finished tapes.Wires

Insulated round, flat and Litz wires for high-voltage, low-voltage and electronic applica-tions.

Cables

Mica tapes for fire-resistant cables. Von Roll provides a wide range of products that are ideally suited to all commonly used standards. Liquids

Impregnation resins for high and low voltage, potting resins, casting resins, as well as en-capsulating and conformal coatings.Flexibles

Insulating flexible materials for low-voltage applications such as flexible laminates and adhesive tapes.

Composites

Engineered materials made from a resin and a support structure with distinct physical,

thermal and electrical properties. They can be molded, machined or semi-finished. Machines

Processing machines for high-voltage appli-cations. Von Roll supplies a wide range of machinery from coil and bar taping up to VPI (Vacuum Pressure Impregnation) equipment. Testing

Von Roll provides electrical, thermal and mechanical testing of individual materials as well as complete insulating systems. We are UL-certified.

Training

Von Roll Corporate University provides a training program in high- and low-voltage insulation to its customers.

We Enable Energy

About Von Roll

As one of Switzerland’s longest-established industrial companies, founded in 1803, Von Roll focuses on products and systems for power generation, motors in the high- and low-voltage sectors, compos-ites and other specialty products for the mechanical engineering. Von Roll is the global market leader in insulation products, systems, process equipment and services and is represented in 18 countries with around 3,100 employees at 32 sites.

Please contact us or visit our website https://www.wendangku.net/doc/1d9465604.html, for further information:

Europe, Middle East, Africa Von Roll Holding AG Steinacherstrasse 1018804 Au ZH Switzerland

P +41 44 204 3500F +41 44 204 3010

Asia/Pacific

Von Roll Asia Pte Ltd.

Blk 6 Serangoon North Avenue 5Singapore 554910Singapore

P +65 6251 7528 F +65 6251 7548

Americas

Von Roll USA, Inc.

8480 East Orchard Road Suite 1000

Greenwood Village, CO 80111USA

P +1 303-689-8441 F +1 303-689-8458