Responding to Customer Needs
Customers have demanded, and will continue to demand, improvements in performance and quality of products. This is seen in the extensive amount of testing our customers require of their motor and generator suppliers before equipment ships. Hyundai Ideal Electric Co. has responded to that demand by utilizing a state-of-the-art test floor. Our test floor allows for the complete testing of synchronous motors and generators, with full load testing of induction motors up to 8000 HP, at voltages from 400 V to 15 kV, and at 60 Hz and 50 Hz.
Each Unit Assembled and Tested
Each unit is completely assembled in our factory. The unit is then moved to the test floor, aligned and coupled to a driver. Electrical connections are made to all auxiliary items which will be monitored during the tests. The unit is then brought up to speed and all electrical and mechanical data is recorded on our state of the art collection system.
Customer requirements such as balance and overspeed are conducted and completed before the unit is released for shipment.
Hyundai Ideal Electric Co. invites all of our customers to attend these tests, and has provided a customer’s viewing lounge overlooking the test bedplates.
Our test facility includes capabilities such as:
- Test of induction and synchronous motors up to 22,000 HP
- Full load test of generators up to 6MW.
- Performance, temperature and efficiency testing per IEEE 115 and 112, IEC 34 and others
- Test voltages from 240 V to 13.8 kV
- 60 and 50 Hertz test frequencies
- Horizontal and vertical test configurations
- State-of-the-art Data Acquisition System
- Bently-Navada Adre Vibration Monitoring System
- Complete control from the master control room overlooking the test floor area
Massive Test Beds Result in Very Low System Natural Frequencies
The test floor consists of two vertical test pits and two test bedplates for horizontal machines. Each test bedplate has a weight in excess of one million pounds, insuring our capability to meet or exceed the stringent industry vibration criteria for massive, rigid mounting per API (0.02 ips maximum). Housing and shaft probe (if supplied) vibration readings are consistently less than all industry requirements.
Meeting Third-Party Requirements
Testing to meet all third-party requirements, such as API, DNV, ABS, Lloyds, CSA, CENELEC, and others. Click to view the ISO 9001:2008 certificate.
Vacuum Pressure Impregnation (VPI) System
The Hyundai Ideal Electric Company (HIEC) insulation system is a proven insulation system based on a global Vacuum Pressure Impregnation (VPI) method using mica tapes combined with epoxy resin. Global VPI is a widely used insulation method in the electric machine manufacturing industry. HIEC uses epoxy resins in the VPI process as they have been shown to be superior to the other VPI resin types. This insulation system is employed over the full range of form wound machines produced by HIEC.
HIEC Insulation System Features
- Class F (155°C) Temperature Rating
- Voltages up to 15 kV
- Mica Insulation combined with Epoxy Resin VPI
- Excellent Chemical, Oil, and Moisture Resistance
- High Dielectric Strength with Low Dielectric Losses
- High Mechanical Strength
- High Thermal Conductivity for Improved Heat Transfer
- Withstands Starting and Short Circuit Stresses, Voltage Surges, and Thermal Cycling.
The coils are manufactured from insulated copper conductor wire. Various combinations of conductor and turn insulation are used most employing mica turn tape to ensure high turn to turn impulse voltage withstand capability. Ground insulation consisting of multiple layers of fiberglass backed mica tape is applied to the entire coil to a thickness based on machine voltage. A conductive tape is applied over the mica as a final layer on the slot portion of the coil to suppress corona discharge. At higher voltages, a semi-conductive stress grading tape is applied to the coil from the end of the slot and extending up the coil end turn.
The coils are installed in the stator slots and retained with segmented slot wedges covering the full length of the core. Absorbent polyester felt spacer blocks are installed between the coil end turns. In addition, the coils are individually tied to heavy fiberglass rope rings to form a completely arch bound system with exceptional radial support yet allowing for axial movement due to thermal expansion. This end turn support structure is thoroughly saturated with epoxy resin during the VPI process and when cured forms a rigid support ring for the coils. The coil and stator lead connections are insulated with the same mica tape used for coil insulation.
The fully insulated stator is preheated in an oven to drive off any moisture or volatile components. The stator is moved to the vacuum pressure impregnation tank where a vacuum is drawn removing nearly all the air from the insulation. Epoxy resin is admitted to the tank while still under vacuum to fully cover the stator. The vacuum is released and pressure applied over the resin covered stator to force the resin completely into the insulation materials. Winding capacitance is monitored during the VPI process to assure complete resin penetration of the insulation materials. After removing the stator from the VPI tank, the stator is placed in an oven and baked to cure the resin and fully develop the properties of the insulation system.
- Checks on stator coils to assure dimensional uniformity and proper fit of coils in stator slots.
- High potential tests of coils during coil installation and prior to VPI.
- Turn to turn insulation tests of coils prior to VPI.
- Periodic tests of epoxy resin system.
- Periodic tests of power factor tip-up per IEEE Standard 286 to monitor insulation system performance.
- Final high potential test of completed winding after VPI at twice rated voltage plus 1000 volts.