FACILITIES INSTRUCTIONS, STANDARDS,

AND TECHNIQUES

Volume 3-1

TESTING SOLID INSULATION OF

ELECTRICAL EQUIPMENT

Internet Version of This Manual Created

September 2000

FACILITIES ENGINEERING BRANCH

DENVER OFFICE
DENVER, COLORADO

The Appearance of the Internet Version of This Manual

May Differ From the Original, but the Contents Do Not

UNITED STATES DEPARTMENT OF THE INTERIOR

BUREAU OF RECLAMATION

DECEMBER 1991
 CONTENTS

Par. Page

1. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Insulation life and deterioration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Causes of insulation failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Insulation test methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Insulation Resistance and Dielectric Absorption Tests

5. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6. Theory of insulation resistance and dielectric

absorption measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7. Skill required in making insulation resistance

and dielectric absorption measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8. Effect of previous charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9. Effect of temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10. Effect of moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11. Effect of age and curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12. Polarization index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

13. Test procedures and records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

14. Temperature correction factors for insulation resistance . . . . . . . . . . . . . . . . . . . . . 6

Insulation Resistance Meter Tests

15. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

16. Description of test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

17. Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

18. Dielectric absorption curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

19. Minimum values of machine insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

20. Transformer insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

21. Cable insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

High-Voltage DC Tests - Rotating Machines

22. Application - rotating machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

23. Correlation between dc and ac tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(FIST 3-1 12/91) i

 CONTENTS - Continued

Par. No. Page

High-Voltage DC Tests - Stepped Voltage Method

24. Description of test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

25. Current versus voltage curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

26. Resistance versus voltage curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

27. Log-log plots and discharge curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

28. Data sheet and voltage/time schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

29. Test technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

30. Polarization index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

31. Reason for voltage/time schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

32. Applicability of test schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

33. Maximum voltage for test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

34. Importance of regulated power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

35. Discharge of winding after test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

36. Minimum period of grounding after test before

returning to service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

37. Effects of temperature and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

38. Interpretation of curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

39. Progressive condition of insulation and

frequency of tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

High-Voltage DC Tests - Ramped Voltage Method

40. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

41. Description of test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

42. Ramped dc test schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

43. Ramped voltage test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

44. Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

45. Discharging the winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(FIST 3-1 12/91) ii

 CONTENTS-Continued

Par. Page
High-Voltage DC Tests - Cables

46. Cable testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

47. Advantages of dc high-potential test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

48. Test technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

49. Interpretation of test curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power-Factor Tests

50. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

51. Theory of power-factor measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

52. Significance of dielectric losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

53. Generator windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

54. Transformer windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

55. Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

56. Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Ionization Tests

57. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

58. Test methods for slot discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

High-Potential AC Proof Tests

59. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

60. Induced-potential and impulse tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

61. Voltage values for ac tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

High-Potential DC Proof Tests

62. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

63. Voltages for high-potential dc tests on machines . . . . . . . . . . . . . . . . . . . . . . . . 21

64. Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

iii (FIST 3-1 12/91)

 CONTENTS-Continued
Par Page

Turn-to-Turn Testing

65. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

TABLES
Table Page

I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

A Maximum dc test voltages for machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B High-voltage dc insulation test record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

C Voltage/time schedules for high-voltage dc

tests of stator insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

D Cable dc test voltage guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

E Temperature correction factors for the power

factor of power transfer windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

F ANSI standard test voltages for 60-hertz,

1-minute, high potential tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

FIGURES
Figure Page
....

I Continuous operating temperature vs. insulation life . . . . . . . . . . . . . . . . . . . . . . . . 53

2 Dielectric absorption curves before and after initial dry out

for Grand Coulee unit L-6 108,000 kV, 120-r/min, 13.8 kV,

60-Hz generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3 Insulation resistance and temperature correction

factor vs. temperature for figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Temperature correction factors for insulation resistance . . . . . . . . . . . . . . . . . . . . 56

5 One- and ten-minute resistance values during dry out of

37,500 kV.A, 13.8-kV hydrogenerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6 DC ramped-voltage test with unit buswork connected -

Yellowtail unit 2, 0A, February 26, 1979 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

(FIST 3-1 12/91) iv

 CONTENTS-Continued
Figure Page

7 DC ramped-voltage test with unit buswork not connected -

Yellowtail unit 2, 0A, March 13, 1979 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8 Arrangement for plotting insulation test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9 Log-log plots of dielectric absorption curves and discharge curves . . . . . . . . . . 60

10 Template analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

11 Comparison of test curves between 30- and 10-minute schedules,

OB, Grand Coulee, L-8, June 28, 1960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

12 Comparison of tests to show progress of deterioration

of winding insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

13 Characteristics of very dry winding before and after varnishing . . . . . . . . . . . . . 63

14 Typical stator insulation ramped-voltage test results -

new epoxy-mica insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

15 Typical stator insulation ramped-voltage test results -

new asphalt-mica insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

16 Typical stator insulation ramped-voltage test results -

asphalt-mica insulation with a localized weak spot . . . . . . . . . . . . . . . . . . . . . . . 65

17 Typical stator insulation ramped voltage test results -

very old asphalt-mica insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

18 High-voltage, dc test on a 1,500-kcmil varnished cambric,

250-mil (6.34-mm), lead-sheathed cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

19 Approximate charging kilovolt amperes of generator stators for

determining capacity of ac high- potential set required . . . . . . . . . . . . . . . . . . . 67

v (FIST 3-1 12/91)

1. Purpose.- The purpose of this volume is to becomes a void, subject to localized interior
briefly cover the methods available for deter- corona deterioration and resultant failure.
mining the insulating value of the insulation on This type of deterioration is more
generators, motors, transformer windings, ca- predominant in the phase terminal end of the
bles, circuit breakers, and high-voltage winding where the voltages to ground are
bushings. This volume is based on operating high enough to produce corona discharges.
experience of Reclamation and on a number of Evidence of asphalt compound migration
articles listed in the bibliography, which should would be bulges in coil tape, usually at the
be studied for more detailed information. lowest point in the coil. It has been known for
coils to remain in service, without failure, for
2. Insulation Life and Deterioration.-The years even if all the asphalt com-pound had
useful life of a thermoplastic e.g., (asphalt- migrated. This is not a healthy condition, but
mica) insulation system is practically ended the only remedy is reduced load or rewinding
when the insulation has become brittle enough the generator.
to develop cracks under the mechanical
stresses to which it is subjected. A direct The useful life of thermosetting e.g.,
cause of embrittlement is from operation at high (polyester-mica or epoxy-mica) insulation
temperatures over a period of time; cracking systems has not yet been determined as
results from mechanical stresses imposed upon they have not been in service long enough to
conductors having brittle insulation. The determine the eventual effects of aging. To
mechanical stresses are caused by (a) short- date, the main cause of failure of
circuit currents, (b) thermal expansion and thermosetting insulation systems has been
contraction of the conductors, and (c) vibration. vibration due to looseness in the slots.
The dielectric strength of insulation is not Newer epoxy-mica insulation systems have
significantly reduced by brittleness alone; proven to be especially prone to developing
however, electrical breakdown will quickly loose wedges and slot discharge because
follow the development of ensuing cracks. For the "hard" nature of the insulation system
this reason, close inspection for cracked does not mold itself to fit the slot as the old
insulation should be made at frequent intervals, asphalt-mica system did. Therefore, slot
and repairs made as necessary. discharge tests and visual inspection of the
installation for loose wedges and indication
The age and service history of the insulation of vibration are very important for
will provide some indication of its probable thermosetting insulation systems and should
condition. For example, a generator with class be performed more frequently than
B insulation that has been fully loaded 24 hours previously done for thermoplastic systems.
every day for 15 years at a temperature of 110
EC (as measured by resistance-temperature 3. Causes of Insulation Failures. - Many
detectors), probably has brittle insulation. failures of insulation are caused by the
Figure 1 shows the years of expected entrance of moisture. Organic insulating
insulation life versus continuous operating materials used on generator and transformer
temperature. windings have a high affinity for moisture
from the surrounding atmosphere or oil.
FIST Volumes 1-4 and 1-5 are guides to Therefore, it is of primary importance that
permissible overloading of generators and close periodic inspections be made of the
transformers, respectively, without undue equipment to make sure no water comes in
acceleration of insulation embrittlement. contact with the insulation through loose
joints, poor gaskets, leaky cooling coils, or
Another cause of failure in asphalt-mica wind- moisture-contaminated oil. Contamination of
ings is the migration of the asphalt compound exposed insulation by dirt and oil also
when the coil operating temperature reaches weakens the insulation and may cause
the flow point of the asphalt. As the compound failure. Another cause of ground insulation
migrates, the space occupied by the compound

1 (FIST 3-1 12/91)

failure in rotating machines is turn-to-turn Methods e. and f. are used primarily in factory
failures occurring and progressing into ground- tests and after initial erection of the equipment
wall breakdowns. in the field. Practically all routine field tests are
made using nondestructive methods a., b., c.,
4. Insulation Test Methods.- The principal and d. Neither the insulation resistance nor
methods used today for testing insulation are: power-factor test methods can accurately predict
the breakdown voltage of insulation. The
a. Insulation resistance and dielectric ab- results must be compared with values when the
sorption by high-voltage dc insulation test. insulation was new and of known voltage with-
stand. Therefore, power-factor or insulation re-
b. Insulation resistance and dielectric ab- sistance measurements must be made
sorption by high-voltage, dc (direct-current) periodically, beginning when the equipment is
test. new and in good condition, and the trend noted
of the test results. The great amount of data
c. Insulation current by dc, high-voltage, collected from insulation tests reveals that no
ramped test. single test method can be relied upon for indicating
all conditions of weakened insulation.
d. Power factor There are cases on record where transformer
insulation resistance tests gave no indication of
e. AC (alternating-current) voltage with- moisture, but power-factor tests on the windings
stand. definitely showed moisture. There are other
cases where the reverse was found. Therefore,
f. DC (voltage withstand) to minimize chance of deterioration escaping
notice, it is recommended that the periodic tests
on equipment be made by more than one of the
following tests:

Preferred test method

Equipment (Numbers show order of preference)

Motor and generator stator and (1) Insulation current by dc high-voltage ramped test
field windings or
(1) Insulation resistance and dielectric absorption

Power transformer (1) Power factor and (2) Insulation resistance and
dielectric absorption
or
(1) AC voltage withstand of oil and (2) Power factor

High-voltage cables (1) Insulation current by dc high-voltage ramped test

and (2) Power factor
or
(1) Insulation resistance and dielectric absorption
and (2) Power factor

High-voltage bushings (1) Power factor and capacitance and 2) Insulation

resistance and dielectric absorption

Circuit breakers (1) Power factor and (2) Insulation resistance and
dielectric absorption

(FIST 3-1 12/91) 2

 INSULATION RESISTANCE AND DIELECTRIC ABSORPTION

TESTS

5. Definitions.- The insulation resistance insulation resistance and time) is known as a

of an insulation is defined as the resistance dielectric absorption curve.
(in megohms) offered by the insulation to an
impressed direct voltage. The resulting 7. Skill Required in Making Insulation
current is called insulation current and Resistance and Dielectric Absorption
consists of two main components. Measurements.- Unless made with a high
degree of skill, insulation resistance and
a. The current which flows within the dielectric absorption measurements will show
volume of the insulation, and is major fluctuations due to variations of the
composed of: several factors discussed in the following
paragraphs, and will consequently be of little
(1) Capacitance current value. Each factor causes large errors in the
measurement of the insulation resistance and
(2) Dielectric absorption current these errors may not be chargeable to
inaccuracy of the measuring instrument. This
(3) Irreversible conduction current discussion applies primarily to generator
stator winding insulation, but also applies
b. The current which flows in the leakage generally to the insulation of all rotating
paths over the surface of the insulation, electrical machinery, cables, transformers,
and is termed leakage current. and other equipment except porcelain in-
sulators, lightning arresters, and bushings, on
6. Theory of Insulation Resistance and which a favorable insulation resistance
Dielectric Absorption Measurement.- reading cannot be accepted as indicating
When a dc voltage from a high-voltage, good condition. The condition of bushings is
dc insulation test instrument is suddenly best determined by the power- factor method.
applied to insulation, the insulation current
will start at a high value, gradually de- Field windings and other Iow-voltage
crease with time, and finally level off to a insulation should preferably be tested with a
stable value. The low initial insulation voltage source not higher than 500 volts, to
resistance is partly caused by the high initial avoid damage to the insulation. Before rotor
capacitance charging current. This fields are tested, the brushes should be
capacitance current rapidly decreases to a raised and the slip-ring insulation carefully
negligible value (usually within 15 sec.) as cleaned with a good solvent. The rotor field
the insulation becomes charged. The low insulation resistance is as important as the
initial insulation resistance is also partly stator insulation resistance.
caused by the high initial dielectric absoption
current. This current also decreased with 8. Effect of Previous Charge.- One
time, but more gradually, requiring from 10 factor affecting insulation and dielectric
minutes to several hours to decay to a neg- absorption measurements is the presence of
ligible value. However, for the pupose of a previous charge on the insulation. The
insulation resistance meter tests, the change charge may come from normal operation of a
in dielectric absorpiton current after 10 generator with an ungrounded neutral, or from
minutes can be disregarded. The leakage a previous measurement of insulation
current does not change with time of voltage resistance. Time may be saved if the
application, and this current is the primary generator winding is kept grounded until the
factor on which insulation quality may be test on the winding is made.
judged. Insulation resistance varies directly
as the thickness and inversely as the area of 9. Effect of Temperature.- Insulation re-
the insulation being tested. A curve plotted sistance varies inversely with temperature for
between insulation current and time (or most insulting materials. To properly compare

3 (FIST 3-1 12/910

periodic measurements of insulation resis- time lapse should not exceed 1 hour. For
tance, it is necessary either to take each transformers, a delay of about 1 hour after
measurement at the same temperature, or shutdown is recommended to reduce the
to convert each measurement to the same temperature gradient. Any type of forced
base temperature. A correction curve for cooling should be shut off at the same time
conversion of each measurement can be load is removed.
made by taking two successive dielectric
absorption curves, such as "C" and "D" in 10. Effect of Moisture.- Moisture, which
figure 2 , at two well-separated can enter the insulation of a generator or
temperatures by the standard procedure motor winding from damp air or which can
outlined in paragraph 12. The first or "hot" enter the winding of a transformer from wet
dielectric absorption curve "C” should be oil, will make a surprisingly large difference
obtained from a test made soon after in the insulation resistance. This is clearly
shutdown from a stable, full-load shown by the curves of figure 2 for a Grand
temperature condition. The second or Coulee generator. Curve "A" was taken
"cold" curve should be obtained after the shortly after the generator was placed in
equipment has cooled to a considerably service, at a temperature of 36 EC. Curve
lower temperature. Using only the two 10- "C" was taken after a dry-out run of 168
minute points of the two curves, plot a hours on the generator. The generator
straight line on semilog paper as in figure 3. winding was, therefore, more thoroughly
Extend the straight lines through a dried out in curve “C” than in curve "A,"
temperature range of 20 to 75 EC. As although evaporation of the volatile content
recommended by IEEE, 40 EC should be of the insulation or other curing or aging
used as the base temperature to which all effect may have had an appreciable effect.
measurements are corrected. Once this Low insulation resistance resulting from
conversion curve for the dry winding is exposure to moisture does not mean that the
established for a machine, the curve can insulation is unsuitable for operation,
be used as long as no rewinding or major particularly if the insulation resistance value
repair work is done. By means of this is comparable to that obtained from recent
curve, insulation resistance measurements periodic tests. Dry out of thermosetting
taken at any temperature can be converted insulation is not as big a factor, and is
directly to any other temperature within the sometimes not done, except to cure field
range of the curve. If this temperature applied insulation.
conversion curve is not available,
approximate conversion factors can be ob- 11. Effect of Age and Curing.- Insulation
tained from figure 4 which corrects to a with semisolid binder, such as asphalt-mica,
base temperature of 40 EC. Careful undergoes a curing process with time. This
measurement of temperature is important in curing process increases the dielectric ab-
making insulation resistance sorption current taken by the insulation, and
measurements. For generators with thus insulation resistance meter or high-
resistance temperature detectors, the voltage, dc test measurements show a
average of the readings from all detectors decrease in insulation resistance with
should be used. Otherwise, the average increasing age. The more noticeable effect
reading of several strategically placed of age on the leakage current is mainly the
thermometers should be used. The elapsed development of cracks and contamination.
time during removal of load, disconnection
of associated equipment, and preparation Solid insulations, such as porcelain, do not
for test will help to minimize the undergo a curing process and thus age, in
temperature gradient between insulation itself, does not change their dielectric
and temperature measuring device, but the absorption or leakage current components

(FIST 3-1 12/91) 4

12. Polarization Index.- The steepness 13. Test Procedures and Records. The
of the dielectric absorption curve taken at a test procedure for making dielectric ab-
given sorption tests is:
temperature indicates the relative dryness of
the insulation. This steepness may be ex- a. Hot resistance test - following
pressed as "polarization index" and is defined shutdown from full-load operation of at
as follows: least 4 hours, or until temperature is
stabilized:
Polarization index = R10/R1 = I1/I10
(if the voltage is constant) (1) Disconnect the equipment to be
tested from other equipment by opening
breakers, opening disconnecting
where: switches, or unbolting connections. Dis-
connect any potential transformers or
R10 = megohms insulation resistance other devices connected between
at 10 minutes phases and ground, or neutral and
R1 = megohms insulation resistance ground. Any external circuits which
at 1 minute cannot be readily disconnected should
I1 = insulation current at 1 minute be recorded in the test record.
I10 = insulation current at 10 minutes
(2) For at least 10 minutes, ground the
Table I shows the polarization index for the winding to be tested to drain off any
four curves of figure 2. As these data charge.
indicate, the difference in polarization index
between dry and moist insulation is more (3) Remove the ground connection,
pronounced at higher temperatures and connect the insulation resistance
therefore, the hot test is more sensitive. The tester, and begin taking dielectric
increase in polarization index with dryness of absorption readings. Take read-
insulation is also illustrated by the diverging 1- ings at 1 - minute intervals for 10
and 10-minute curves in figure 5. minutes. Make tests between entire

Table I

Curve Condition of Temperature Polarization

figure 2 insulation degrees Celsius Index, R10/R1
A Moist 36 1.88

B Moist 75 2.50

C Dry 75 3.11

D Dry 36 2.16

IEEE Standard No. 43 indicates the recommended minimum values of polarization index for a-c
(alternating current machines) are:

For class A insulation - 1.5

For class B insulation - 2.0
For class F insulation - 2.0

5 (FIST 3-1 12/91)

 stator winding and ground, and between humidity.

field winding and ground.
14. Temperature correction factors
(4) Record the temperature of equipment for insulation resistance. - The following
being tested. Use average of all resis- method may be used to correct the insulation
tance temperature detector indications, if resistance at any temperature to the
available, or use average reading of sev- insulation resistance at any chosen base
eral thermometers placed so as to obtain temperature if it is not possible to conduct the
best average of insulation temperature. insulation resistance tests at two widely
The temperature measurements will be different temperatures, as suggested in
more representative of average insulation paragraph 9. The method is only approximate,
temperature if the test is delayed 0.5 to 1 because the temperature coefficient of
hour after removal of load, to allow tem- insulation resistance varies widely with
perature gradient to level off. Generally, different materials and conditions and is not
this period will be required to complete always consistent for the same material. The
preparations for test. insulation resistance value at the 10-minute
point of the dielectric absorption curve should
(5) Ground the winding again for at least be used. The formula for determining
10 minutes. insulation resistance (Rb) at some desired
base temperature (Tb) when the known or
b. Cold resistance test. tested value of resistance (Ra) at temperature
(Ta) is:
(1) Four to eight hours after the hot resis-
tance test or when equipment has cooled Rb = f x Ra
to approximately ambient temperature,
make another test using same procedure where:
as outlined for the hot resistance test.
f = Temperature correction factor
c. Record all data on the "Oil and Insulation (from curve fig. 4)
Test Report," form PO&M 109. Plot the di- = 10A(Tb - Ta); A = Temperature coefficient
electric absorption and temperature correction of insulation resistance from table II.
curves. Calculate polarization index. Data
should include ambient temperature and

TABLE II

Apparatus Average value of temperature

or coefficient of
material insulation resistance A

Transformers with oil, class A insulation 0.030

Transformer oil 0.0173

A-C armature winding, class A insulation 0.033

A-C armature winding, class B insulation 0.0168

D-C armature winding 0.024

(FIST 3-1 12/91) 6

 INSULATION RESISTANCE METER TESTS

15. General.- The insulation resistance resistor in the 100-megohm range be

meter test method for determining the attached to the inside of the instrument
condition of electrical insulation has been cover for use as checking standard. It is
widely used for many years as a general recommended that the same test instrument
nondestructive test method. A serious be used for each periodic test on a certain
limitation of this test is that its operating piece of equipment, as differences in
voltage of 500 to 1,000 volts will not always instrument output characteristics may affect
detect insulation punctures, whereas the the shape of the dielectric absorption
higher voltages used by the high-voltage, dc curves, especially at the lower end.
testers will detect these punctures.
18. Dielectric Absorption Curve.-
The insulation resistance meter test will Insulation resistance is not a definite
show (a) the relative amount of moisture in measure of the voltage an insulation will
the insulation, (b) the leakage current over withstand, but when properly interpreted
dirty or moist surfaces of the insulation, and affords a useful indication of the suitability of
(c) winding deterioration or faults by means the winding for continued service. It should
of insulation resistance versus time curves. be remembered that values of insulation
resistance, even on identical machines and
16. Description of Test.- A dc voltage of for identical conditions, may vary over a
500 or 1,000 volts is applied to the insulation wide range. Changes occurring in insulation
and readings are taken to the insulation resistance are more significant than certain
resistance versus time. Data should be absolute magnitudes. This is shown by the
recorded at the 1-and 10-minute intervals slope of the curve plotted between
and at several other intermediate times. resistance readings and time, as further
discussed under paragraph 10, "Effect of
17. Test Equipment.- The hand-cranked moisture." This curve is called the curve of
insulation resistance meter has been the dielectric absorption. The test voltage should
standard instrument for many years for be applied for a standard period of 10
checking insulation resistance. The hand- minutes, with readings taken at intervals of 1
cranked instrument is satisfactory for "spot minute or less. Any such curve which
checks" but is not recommended for routine reaches a constant and lower than normal
dielectric absorption tests, because very few value in about 3 minutes or less, indicates
men can continue cranking for 10 minutes high leakage current (due to the leakage
without tiring and slowing up the cranking current being large in proportion to the
speed toward the end of the period. Motor absorption current), and the winding should
driven or electronic insulation resistance be thoroughly cleaned and retested or
testers operating from a 115-volt, ac source further investigated. Such cleaning should
or a self-contained battery are available and preferably precede all insulation resistance
should be used for this purpose. Because tests. In case of very damp insulation, the
the value of insulation resistance varies with dielectric absorption curve may start upward
applied voltage, it is important that the test and then droop to a value lower than at the
instrument have sufficient capacity to start of the test.
maintain its rated output voltage for the
largest winding being tested, and the output 19. Minimum Values of Machine In-
voltage be constant over the 10-minute test sulation Resistance.-"Recommended
period. For this reason, some of the smaller Practice for Testing Insulation Resistance of
test instruments may not be suitable for Rotating Machinery," IEEE Standard No. 43,
tests on large generators or transformers November 1974, indicates the
which draw a large dielectric absorption recommended minimum insulation
current. For occasional checks on the resistance Rm for armature and field
calibration and proper function of insulation windings of ac and dc machines can be
test instruments, it is recommended that a determined by the equation:

7 (FIST 3-1 12/91)

 Rm = Vt + 1 specifically to generator and motor windings, they

where: also apply, in general, to transformers, except
that no insulation values have been established
Rm = recommended minimum insulation for transformers. Also, the technique of
resistance in megohms at 40 °C measuring transformer insulation resistance is
of the entire machine winding not well known or standardized. If the transformer
windings are not immersed in oil, the insulation
Vt = rated machine terminal to terminal resistance will behave much like generator
potential, in rms kilovolts insulation resistance. The insulation resistance
will be less after adding the oil, because the
The winding insulation resistance obtained by insulation resistance of the oil is in parallel with
applying direct potential to the entire winding part of the solid insulation. Therefore, insulation
for 1 minute must be corrected to 40 °C to be resistance readings alone cannot be used to
used for comparison with the recommended indicate the progress of dry out of the winding
minimum value Rm. The insulation resistance of because the winding and the oil resistances
one phase of a three-phase armature winding cannot be separated. Tests should run on oil
with the other two phases grounded is samples as specified in Facilities Instructions,
approximately twice that of the entire winding. Standards, & Techniques Volume 3-5 at the
Therefore, the resistance of each phase, when same time as the test of the transformer winding,
the phases are tested separately, should be and the oil then filtered, if necessary, to remove
divided by two to obtain a value which, after the moisture. The change of insulation resistance
correction for temperature, may be compared with temperature when the transformer windings
with Rm. If guard circuits are used on the two are oil-immersed is similar to that in generators,
phases not under test when each phase is and curves similar to those of figure 3 are useful
tested separately, the observed resistance of for temperature standard-izing. Whether the
each phase should be divided by three to slope of these temperature correction curves is
obtain a value which, after correction for affected by moisture content in the oil is not fully
temperature, may be compared with Rm. For known. At the present state of the art, it is
insulation in good condition, insulation believed that the power factor test gives a better
resistance readings of 10 to 100 times the indication of transformer insulation condition than
value of Rm are not uncommon. It should be the insulation resistance test. Tests should be
remembered, however, that decreasing values made between each winding, between each
of insulation resistance obtained from periodic winding and ground with the other windings
tests are more indicative of deterioration of the grounded, and between each winding and ground
insulation than low values. Machines rated at with the guard circuit connected to the other
10,000 kV-A or less should have either the windings but not grounded.
polarization index or the insulation resistance
(at 40 °C) at least as large as the minimum
recommended values to be considered in 21. Cable Insulation Resistance.-The most
suitable condition for operating or for frequently used test on high-voltage cables is
overpotential tests. Machines rated above insulation resistance measured by means of an
10,000 kVCA should have both the polarization insulation resistance meter. The most
index and the insulation resis-tance above the informative test for high-voltage cables is the dc,
minimum recommended values. high-voltage test modified to combine a modest
voltage withstand with insulation current/voltage
When the end turns of a machine are treated measurement as described in paragraph 46.
with a semiconducting material for corona
elimination purposes, the insulation resistance Insulation resistance testing of cable differs from
may be somewhat lower than without such the testing of apparatus windings mainly
treatment. because of the high capacitance, if the cable is
long, which takes a longer time to charge, and in
20. Transformer Insulation Resistance.- the difficulty of obtaining a satisfactory
Although the foregoing paragraphs apply more

(FIST 3-1 12/91) 8

temperature measurement, insulation temperature of the various lengths, and a
resistance measurements are of value for weighted average computed. Tests should be
comparison rather than for conformance to made between each conductor, between each
stated minimums. The temperature of the conductor and ground with other conductors
cable is important and should be recorded grounded, and between each conductor and
with the insulation resistance. This will be ground with other conductors connected to
difficult if the cable is partly indoors and partly the guard circuit but not grounded.
outdoors, partly underground, partly above
ground, partly exposed, and partly in
conduits. It may be necessary to estimate the

HIGH-VOLTAGE, DC TESTS - ROTATING MACHINES

22. Application - Rotating Machines.- The f. The insulation resistance characteristics

high-voltage, dc test method is regarded as the up through the normal operating voltage
best test presently available for machine range appear to afford more information on
insulation, through it must be recognized that the winding insulation than any other practical
test also has some limitations. This test may test known.
also be carried to the point of being a high-
voltage, dc withstand test. Limitations

An understanding of the value of the test is a. The potential stress in some cases, such
aided by considering its advantages and as at the generator winding end turns, is not
disadvantages: entirely representative of that produced in
normal service.
Advantages
b. Longer time required to complete the dc
a. Very little supply power is required to test as compared to an ac test.
operate the test set.
c. Care necessary to distinguish change of
b. The test set is portable enough to be true leakage current from change of absorp-
readily useful. (Although larger than an tion current.
insulation resistance meter, it is far
smaller than an ac, high-voltage tester.) In order to obtain valid data on the condition of the
machine winding using high-voltage, dc tests, it is
c. The high-voltage, dc test is less destruc- necessary to disconnect the buswork from the
tive than other available high-potential unit. Unit buswork will quite often break down at a
tests. lower voltage than the winding. Figures 6 and 7
illustrate the difference in the results that can be
d. The small leakage current is not masked obtained with the buswork connected and
by ac charging current and therefore affords disconnected.
a quantitative measure of insulation quality.
23. Correlation Between DC and AC
e. Much less damage is done if breakdown Tests.- The dc puncture voltage may range from
should occur, because the capacity of the 1.41 times the rms ac puncture voltage for a
test set is small. cracked and abraded winding, where the puncture
path is essentially an air gap, to 2.5 times the

9 (FIST 3-1 12/91)

rms ac puncture voltage for well-compacted ac test. Consequently, on any but new
and impregnated mica insulation. IEEE windings, if the dc test indicates weakness,
Standard No. 95 mentions the factor 1.7 as ac overpotential test should not be applied.
appropriate for used insulation. Cases have Deteriorated coils should be located by
indicated that on winding insulation with some testing groups of individual coils by the dc
deterioration, the application of ac method or by use of a clip-on ammeter.
overpotential tests may cause further Ionization and power-factor tip-up tests may
deterioration, even though the insulation may be useful supplements in important repair
not puncture in the 1 -minute duration of the work.

HIGH-VOLTAGE, DC TESTS - STEPPED-VOLTAGE METHOD

24. Description of Test.- The stepped- curve is being plotted, the insulation
voltage technique of high-voltage, dc testing resistance (in megohms) can be calculated
of insulation consists of measuring the at the end of each voltage step. A resistance
insulation current at scheduled times for a versus voltage curve should be plotted, as
series of voltage steps up to an indicated shown on figure 8B. After the final reading at
insulation weakness or to well above the the first voltage step, the megohm scale for
the curve should be chosen so the first
normal operating ac peak voltage ( 2 x V
plotted point will be above the zero axis
rms). The insulation is then discharged about equal to the distance from zero along
through a microammeter and measurements the horizontal scale to the maximum test
are taken of current versus time. The data voltage. This will yield an approximately
are interpreted to determine insulation "square" plot for test of any size specimen,
quality. For interpretation, it is convenient to permitting comparison of curve shapes on a
graphically plot the insulation current against more uniform basis.
test voltage and to calculate and plot the
resistance versus test voltage.
27. Log-log Plots and Discharge
Curves.- In addition to the current versus
25. Current Versus Voltage Curve. -
voltage and resistance versus voltage
As the data are recorded on the data sheet,
curves, the following curves should be
a graph should be plotted of the insulation
plotted on three-by-three cycle, log-log paper
current (at the end of each voltage step)
(K&E No. 359120): (1) current versus time
versus the test voltage, see figure 6A. This
for the first voltage step, and (2) the
form of plotting has the advantage of
discharge current versus time after the last
employing readings taken directly from the
voltage step, see figure 9. The latter curve
test instrument. An incorrect reading or an
permits determination of the absorption
incorrectly plotted point is promptly apparent
exponent "n" and the proper template to be
and may be checked immediately. As long as
used for determination of the true leakage
the insulation current is not excessive (see
and absorption components of current from
paragraph 19 for standard insulation
the current versus time curve (1). Ordinarily,
resistance values) and continues in a
the template analysis will be performed later,
straight line with increasing test voltages,
see figure 10.
the test may be continued up to the
recommended maximum shown in table A.
28. Data Sheet and Voltage/Time
Schedules.- Form PO&M-155 should be
26. Resistance Versus Voltage used for recording data as shown by
example in table B. Table C gives voltage
Curve.- While the current versus voltage

(FIST 3-1 12/91) 10

time schedules for various insulation 31. Reason for Voltage/Time Sched-
ratings The data recorded should include ules.- The absorption current will seldom
the following: subside to a stable value within any practical
allowable time. Besides leakage current,
Date of test
some absorption current will be present in the
Time
final readings. This will not confuse results,
Test voltage (kV)
however, if sufficient time is allowed at each
Test current (FA)
voltage for the absorption current to subside
Resistance (MO)
to a proportional value. This requires a
Temperature of winding(EC)
schedule of progressively shorter absorption
Identification of apparatus under test,
times at successive steps of voltage,
and test instruments because at the beginning of each voltage
Parts of winding, bus, or equipment step after the first, part of the absorption has
included in test already been satisfied by the preceding
Relative humidity steps. Consequently, the proportional
absorption is reached in less time. Test
29. Test Technique.- The machine schedules with steps chosen to be conve-
winding should be grounded for at least 1 nient for insulation of various voltage ratings
hour immediately preceding the test, thus are shown in table C for stator windings.
ensuring that any absorbed charge is
drained off. The phases should be 32. Applicability of Test Schedules.--
separated and tested individually. Lightning The test schedules are arranged to include a
arresters and capacitors must be discon- minimum of three points up to and including
nected. Cables and/or buswork should be approximately normal peak operating voltage.
disconnected if it is convenient to do so. If Smaller voltage steps at the higher voltages
the separation of phases is unusually are chosen as this affords indication of any
difficult, the separation may be made once weakness with less danger of unexpected
for the benchmark tests, and thereafter the puncture. The additional points occasioned by
phases may be tested together until the smaller voltage steps add very little to the
deviation from normal is detected. Similarly, total time of the test. Therefore, the same
a winding and its cable or bus lead should schedules are practical for routine tests.
be separated and tested individually. If Departures from the schedules for finer steps
separation is difficult and the leakage of the when weakness is detected will seldom be
cable and of the winding are of the same necessary. The voltage steps are sufficiently
order (one not more than twice the other), conservative that the gradual raising of
they may be tested together thereafter until voltage in the former 30 minute test schedule
deviation from normal is detected. is no longer necessary. The schedules of
table C allow for raising the voltage
30. Polarization Index.- The voltage rapidly. To protect the microammeter during
should be raised abruptly to the first the rapid voltage change, it should be
voltage level with the start of timing for the switched to the next higher range.
test. Readings should be recorded of
insulation current at 1 minute, at 10 Schedules employing only 10 minutes on the
minutes, and at other 2- or 3-minute first voltage step, as shown in table C, are in-
intervals to the final reading The ratio of the tended to supersede the former schedules
1-minute to the l0-minute reading of which employed 20 to 30 minutes on the first
insulation current will afford useful step. The advantages of the change are:
indication of polarization index. This gives shorter overall time for testing, adequate
the test engineer an idea of insulation indication of weaknesses, the resistance
dryness early in the test. (Even though results for all steps will be on 10-minute basis
500 volts has been the standard for comparable to 10-minute insulation
determination of polarization index, the val- resistance meter readings for which
ues yielded at the first voltage steps of the there is much background, and the
respective schedules are very close to exponent of -0.8 on which the schedule is
those at standard voltage.) calculated is more representative of the

11 (FIST3-1 12/91)
average machine insulation. See figure 11 the test set. If random variations still persist,
for a comparison of test curves between the the currents may be averaged graphically. If
10- and 30-minute schedules for the same absorption currents are plotted against time
machine. on log-log paper, the mean will be a smooth
curve and almost a straight line from which
33. Maximum Voltage for Test.-If the the mean reading of the appropriate time
insulation microampere versus voltage plots may be selected. For this plotting, the time is
are straight lines, the test may be continued reckoned from zero when voltage is raised
to the maximum test voltages shown in table from the preceding step.
A. If curvature appears, the test should be
stopped when the resistance has dropped to 35. Discharge of Winding After Test.-
approximately one-third the maximum value Upon completion of the dc, high- voltage
unless it is desired to locate the weakness test, the winding should be discharged
by puncture so that it can be repaired. through the special discharge resistor
Cases of abrupt breakdown before the ordinarily provided with the test set. The
resistance curve approached zero have discharge resistor consisting of several
occurred in insulation where mechanical kilohms is for the purpose of retarding the
abrasion, cracking, or acute mica migration discharge current so no destructive surge is
existed. Hence, as a general practice, but produced. The winding may be solidly
particularly where mechanical defects are grounded when the voltage has dropped to
known to exist, tests should only be zero or after a few minutes of discharge
performed when time could be taken for have occurred.
bypassing a coil or other maintenance if a
weak point should be punctured. This allows 36. Minimum Period of Grounding
taking best advantage of the "proof" feature After Test Before Returning to Ser-
of the test. For the most conservative, vice.- A winding should remain solidly
nondestructive use of the test, a very abrupt grounded long enough after test for the ab­
increase in insulation current (excluding the sorbed charge to be completely drained off
random variations of absorption current before restoring the machine to service.
often found) is also warning that the test Windings vary greatly in the length of time
should be stopped. An abrupt rise in an absorbed charge will remain, but in
insulation resistance (drop in leakage absence of actual checks, it is
current) is rarely found, but when it occurs recommended the winding be grounded for
above the peak operating voltage for the at least 1 hour. If the dc, high-voltage test
winding, it has usually preceded breakdown precedes a maintenance ac overpotential
of the insulation. The increase of resistance test, it is advisable to double the minimum
is thought to be caused by vaporization of ground time to assure that absorbed charge
the moisture trails in the insulation, which does not contribute to puncture. Also, the
would immediately precede puncture. time spent in making a discharge test can be
credited to the total grounding time.
34. Importance of Regulated Power
Supply. - It is important that voltage 37. Effects of Temperature and Hu-
variations in the power supply to the test set midity.- The influence of temperature upon
be avoided. Because of the capacitance of leakage current of winding insulation under
the winding under test, even minor dc, high-voltage test is similar to the
fluctuations in supply voltage to the test set influence of temperature on insulation
will cause wide fluctuations of the resistance meter readings. However, the
microammeter and contribute to a random most significant factor of the dc, high voltage
scattering of test points. A voltage stabilizer test, the position of the curvature, is not
or electronic regulator in the power supply is appreciably affected by temperature; con­
recommended. Magnetic voltage stabilizers sequently, correction of individual test points
usually perform better when working into a to the standard temperature of 40 °C is not
resistance load than when driving a rectifier necessary. Because the dc, high-voltage
only. A 500-volt ampere regulator is usually test does require appreciable time, it is
sufficient so that about 200 volt amperes of desirable that the insulation be near ambient
resistance load can be used in addition to

(FIST 3-1 12/92) 12

temperature during testing to minimize of deterioration is shown by a shift of the

temperature change between test points. bend to a lower voltage over a period of
Experience indicates that tests at the lower time and by a lowering of the overall
temperature yield more sensitive warnings insulation resistance. A sharp bend is most
of weakness. Consequently, there is less indicative of a single area of weakness,
danger of unexpected puncture during while a gradual bend is most often
test at ambient temperature than at associated with numerous areas of
elevated temperature. Slight weakness. While the breakdown voltage
humidification of the winding, similarly, has occasionally has been predicted by a
been found to improve sensitivity of the projection of the resistance curve to zero,
test. This is believed to be caused by more this prediction is rather inaccurate and is
rapid absorption of moisture into any not the useful purpose of the test.
weakened or porous areas of insulation
than into good intact insulation. 39. Progressive Condition of Insula-
tion.- The dc, high-voltage test is believed to
38. Interpretation of Curves.-The give a practical indication of the electrical
quality of the insulation may be judged by quality of the insulation at the time of the test.
the position of any curvature or knee in the Although a rough estimate of the puncture
plot of insulation current versus test strength of the winding at the time of test may
voltage. If the plot is a straight line, the be made, of more concern is an estimate of
knee may be assumed to be above the the years of service remaining in a winding.
maximum test voltage. The higher the test Such an estimate is aided by comparing the
voltage at which the knee appears in the insulation tests over a period of time, as
curve, the better the insulation quality is. If shown in figure 12. Once satisfactory
the knee appears below the maximum peak benchmark data on a machine have been
ac voltage which could be applied to the established, the interval between tests may
winding in service, the insulation may be in be extended to from 3 to 5 years unless an
danger of an in-service failure. If the abnormality is indicated or suspected. Often
leakage current increases to the extent that when the insulation quality drops, it can be
its plotted curve becomes almost vertical, restored by cleaning and varnishing the
the winding is approaching failure on test winding. A drop in quality, which cannot be
and the test should be discontinued. This recovered, may be caused by deterioration
point is the most difficult to judge with this within the slots and must be regarded as per-
type of graph. Considerable experience is manent. Replacement of one or more coils
necessary to judge the maximum safe test may then be necessary. It is not unusual that
voltage from plotted insulation current. the revarnishing of winding end turns
produces a drop in insulation resistance at
Another approximate, though useful, the low and intermediate voltages. This may
indication of insulation quality is given by occur when a winding has become very dry.
the position of a major downward bend of The insulation quality at the higher voltages is
the resistance versus voltage curve (see more important; and, if this is improved, the
fig. 8B). Any major downward bend should overall quality is considered improved. This is
occur at a voltage above the peak illustrated in figure 13.
operating voltage ( 2 x V rms). Progress

13 (FIST 3-1 12/91)

 HIGH-VOLTAGE, DC TESTS - RAMPED VOLTAGE METHOD

40. General.- The ramped voltage test (17 volts per second) is less apt to damage
technique automatically linearizes the insulation than the step-method voltage
dielectric absorption component of insulation increments (approx. 1 kV/s).
current eliminating many of the problems
encountered in dc, stepped-voltage testing Typical ramped-voltage test responses are
methods. Automatic compensation of shown in figures 14 through 17. These
absorption current eliminates the need for curves are a composite of the capacitive
extensive absorption current calculations charging, absorption, and leakage currents.
and complex volt/time testing schedules.
Further improvements have been made For a full description of the operation and
through utilization of state-of-the-art au- theory of the ramped-voltage method, refer
tomatic testing equipment which has to Bureau of Reclamation Report REC-
removed the uncertainty of the human factor ERC-78-7, "A Programmable D-C High-
in adjusting test voltages and in recording Voltage Ramped Test System for Electrical
data. DC testing controllability, sensitivity, Insulation."
and repeatability are significantly improved
through the use of this test method. 42. Ramped DC Test Schedule. - A
ramp rate of 1 kV/min is normally used to
41. Description of Test.- The ramped test stator winding insulation. This rate
technique of insulation testing uses a produces a current response similar to the
programmable dc, high-voltage test set and stepped test and is somewhat of a
automatically ramps the high voltage at a compromise between maximum sensitivity
preselected rate (usually 1 kV/min). and minimum test duration.
Insulation current versus applied voltage is
plotted on an x-y recorder providing The maximum voltage limit is the same as in
continuous observation and analysis of the stepped test. However, the increased
insulation current response as the test pro- sensitivity and continuous-current
gresses. To evaluate an insulation, it is no monitoring features of the ramped test
longer necessary to hand plot insulation provides more information even when the
current and resistance versus applied test is terminated at approximately 85
voltage. Insulation quality can be evaluated percent of the maximum voltage limit. A
directly from the automatically recorded reduced voltage test can be used to
insulation current curves, because the evaluate very old, weak, or problem
observed insulation current nonlinearities insulation characterized by extensive
are directly proportional to leakage current corona damage, excessive abrasion, loose
variations. blocking, etc. Under no circumstances
should a reduced voltage test be used for
The test technique was designed so acceptance testing. Regardless of the
automated test results are similar in nature insulation quality, a reduced voltage limit is
to previous data obtained using USBR's dc, not recommended when the dc test is also
step testing schedules. to serve as a withstand or proof test. In any
event, to avoid an insulation failure, testing
The principal advantages of the ramp test should be terminated whenever leakage
over the conventional step method are that current starts to become excessive.
it requires only one person to perform the
test and provides that person with better The ramp test should be terminated when a
control and sufficient foresight of impending 1- to 2-FA, or larger, sharp increase in
failure to avoid damage to the insulation. The insulation current is observed. If the
elimination of the human factor from the time, increase is only a fraction of a
voltage, and current parameters yields microampere, testing can continue.
overall test results which are much more However, if the current is unstable or there
accurate and repeatable. In addition, the are more stepped type of increases directly
slow and continuous increase in applied following, testing should be halted.
voltage

(FIST 3-1 12/91) 14

An insulation having a gradually increasing will continue to increase in a nonlinear

leakage current response can tolerate much manner. Breakdown will occur as the
higher leakage current than an insulation current asymptotically approaches the
having abrupt current increases in the V-I vertical. Testing should be halted well before
response curve, A test on an insulation this point is reached.
having a slowly increasing leakage current
response should be stopped when the total 44. Grounding.- The powerplant ground
insulation current becomes three to six times mat is part of the high-voltage circuit. To mini-
larger than the capacitative charging mize induced alternating-current voltages in
component of current. this circuit, the test set grounds should be
connected to plant ground as close to the
43. Ramped-Voltage Test Results.- stator core as possible. The discharge
Figures 14 through 17 are typical stator resistor and grounding stick should be tied to
insulation ramped voltage test results. Actual the ground mat in the same area where the
record size is 25 x 38 cm (10 x 17 in). test set grounds are attached. Do not ground
these sticks at the test set ground terminals.
The curve shown in figure 14 is the response
of new epoxy mica insulation when ramp dc Due to the nature of the insulation absorption
tested. Above 5 kV, the curve is very linear, current, the winding must remain grounded for
indicating excellent insulation quality. 1.5 to 2 hours, or the voltage will recover by
itself to a fraction of the original dc test
The curve in figure 15 is typical of new voltage. An ac voltage should not be applied
asphalt mica insulation. This curve is also until the winding has been thoroughly
linear above 4 or 5 kV, indicating high- discharged (grounded for 1.5 to 2 hours).
quality insulation. Failure to properly discharge the winding
constitutes a safety hazard and could also
Figure 16 shows a very sharp increase in result in failure of the insulation upon
leakage current suggesting the insulation of application of an ac voltage.
one coil or portion of a coil is very
questionable. The test was terminated early 45. Discharging the Winding.- The
to avoid the possibility of damaging the highly capacitive and inductive properties of
insulation. stator windings make it essential that they be
discharged slowly. When the capacitively
The nonlinear response shown in figure 17 is stored energy in the winding is suddenly dis-
due to many minute discontinuities similar to charged through the winding inductance, dan-
the one shown in figure 16. The curve shows gerously high-voltage transients are
a very gradual increase in leakage current generated across the insulation. The voltage
and implies that a general deterioration of the should be reduced to a value below 5 kV with
insulation has taken place. As the test voltage a discharge resistor before applying the
increases, the slope of the leakage current grounds.

15 (FIST 3-1 12/91)

 HIGH-VOLTAGE, DC TESTS - CABLES

46. Cable Testing.- When the cables can current drawn can be readily measured and
be isolated from other equipment, they may tendencies to increase and decrease noted;
be tested to much higher limits than rotating (3) much less damage is done if a
machine insulation. Accordingly, a table of breakdown occurs because the capacity of
cable test voltages allowable for the equipment is small; and (4) the test
maintenance tests is included (see table D). equipment is relatively small and light
The recommended limits for maintenance because it needs to be only large enough to
tests of cables are much higher than for supply the insulation leakage current. A
rotating machine insulation because: (1) special precaution to be observed with the
cable insulation is less subject to cracking, dc method is the long time required to drain
ionization, and erosion than rotating machine off the charge after a test is made.
insulation; (2) a higher voltage is likely to be
necessary to show up the defects; and (3) a 48. Test Technique.- In maintenance test-
higher voltage is allowable in manner of a lng of cables, it is practical to combine the
proof test as there is less investment at more searching ability of the step-voltage
stake and the cost in time and expense of method with test to reasonable proof level
repairing a cable failure from test is (see table D). For most cable, insulation
comparatively small. The deterioration of absorption is not so prominent as to require
sheathed cables in service is most likely to a voltage/time schedule as extensive as for
occur at the potheads or the joints due to generator insulation. Five to seven equal
loss of impregnating oil or pothead voltage steps up to the desired test level,
compound, entrance of air, moisture, and co- allowing 2 minutes at each step, are usually
rona action in the air voids. sufficient. If the insulation is type with much
absorption, a generator insulation test
schedule may be used. The ramped-voltage
WARNING test technique may be used for cable testing
if the test set has a high enough voltage
High voltage cables should be tested with rating to reach a reasonable proof level for
negative voltage dc applied to the test the cable.
specimen. Never apply positive voltage
dc. Experiences by other utilities indicate 49. Interpretation of Test Curve.
that positive voltage dc greatly accelerates Warning of approaching breakdown on test
deterioration. is usually given by upward bend of the V-I
curve. However, with cables when weakness
is indicated, it is less important that the test
be terminated than with generators for the
47. Advantages of DC High-Potential reasons previously pointed out.
Test.- AC high-potential tests on long high-
Upward bend of the V-I curve is most often
voltage cables would be impractical because
an indication of trouble in the pothead such
of the high-charging kilovolt amperes
as voids, moisture, or imperfect makeup.
required and nonuniform voltage distribution
See figure 18.
over the length of the cable. The DC, high-
potential test method has the following
If resealing of potheads is required, it is
advantages over the ac method: (1) direct-
advised that another recheck be made a
potential testing causes no deterioration of
year later. Otherwise, routine tests of cables
the insulation up to within a few percent of
need to be conducted only at intervals of
the breakdown point; (2) the small leakage
about 5 years.

(FIST 3-1 12/91) 16

 POWER-FACTOR TESTS

50. Application.- The power factor of an temperature, and may be as much as 10

insulation is a measure of its dielectric power times as high at 80 EC as at 20 EC.
loss, and is not a measure of its dielectric Therefore, temperature corrections to a
voltage strength. The power-factor method is base temperature must be made, usually to
used primarily for testing the insulation 20 EC for a meaningful comparison between
condition of high-voltage bushings, cables, values taken at different temperatures. See
transformer windings, and transformer oil. table E for Temperature Correction Factors
of Power Transformers.
51. Theory of Power-Factor Mea-
surement.- Unless otherwise stated, the 53. Generator Windings. - The power-
terms "power factor" and dissipation factor" factor-voltage characteristic (power- factor
are used interchangeably in this discussion. tip-up) is used primarily as a quality-control
Insulation power factor is the cosine of the criterion in manufacturing. It is sometimes
angle between the applied voltage and used as an acceptance test on individual
current, and is obtained from measurement of coils. Power-factor tip-up has been used as
watts, volts, and amperes, usually with a a maintenance test because a change in the
specialized power-factor test set. Dissipation tip-up value over a period of time is an
factor is the cotangent of the angle between indication of change of condition of the coil
the applied voltage and current, and is usually insulation. The sensitivity of the power-factor
obtained from a direct reading of a dial on a tip-up test decreases with the length of coil
capacitance bridge. The values of power included in the measurement. Therefore, one
factor and dissipation factor are within 1 coil, or coil side, is the preferred test unit,
percent of being equal between 0 and 8 although coils are sometimes tested in
percent power factor, which covers most test groups of two or three to expedite testing.
values, but diverge as the values increase. Refer to IEEE Standard No. 286, July 1975,
Thus, both have equal significance as a "IEEE Recommended Practice for
measure of insulation value. It should be Measurement of Power-Factor Tip-Up of
remembered that power factor or dissipation Rotating Machinery Stator Coil Insulation,"
factor is a measure of insulation dielectric for a description of the power-factor tip-up
power loss, and is not a direct measure of test.
dielectric strength. Conditions which cause
abnormal power loss usually also cause 54. Transformer windings.- The power-
reduction of dielectric strength. The power- factor method is particularly recommended
factor values are independent of insulation for detecting moisture and other loss-
area or thickness, and increase only with an producing contaminants in transformer
increase of contamination by moisture, other windings. Experience has shown that the
foreign matter, or ionization, and therefore, power-factor test is more revealing than the
are easier to interpret than insulation insulation-resistance test when there is a
resistance values, which additionally depend high-loss dielectric in series (as in a
on insulation area and thickness. transformer winding surrounded by oil), and
is less influenced by surface leakage
52. Significance of Dielectric Losses.- components. Users have found many cases
An increase in dielectric loss may accelerate where high-power-factor readings indicated
insulation deterioration because of the moisture in the windings, although the oil
increased heating, but more commonly an dielectric tests were up to standard. The
increase of dielectric loss is evidence of power factor was brought back to normal by
other deterioration which also affects a dry-out run. Time-saving techniques have
dielectric strength. As in insulation resistance been developed whereby the losses in
tests, the change in periodic test readings is transformer bushings or windings can be
more indicative of insulation deterioration segregated without disconnecting the
than is absolute magnitude of readings. windings from the bushings.
Insulation power factor increases directly with

17 (FIST 3-1 12/91)

All windings not at test potential should be and Canada has been by means of
grounded. Each winding should be measured equipment supplied by the Doble Engineering
to all other windings and to ground, and also Co. The Doble test sets consist of a
all of the windings measured together to completely shielded, high-voltage, 60-Hz
ground. All possible winding combinations power supply which applies up to 10 kV to
should be tried. Refer to IEEE Standard No. the equipment being tested. Readings are
262, 1973, for more information concerning taken of volts, milliamperes, and watts, from
this test technique. which power factor is determined. The
equipment is suitable for use near high-
55. Cables.- The power-factor test on ca- voltage circuits without interference from
bles is usually an insensitive indication of induced voltages. The capacitance-test
deterioration except on very short lengths. bridge, a much simpler and less expensive
Cables often require more charging current tester, is available on some Bureau projects.
than the power-factor test set can supply. It applies about 80 volts to the equipment
However, "hot-collar" power-factor tests on being tested. Capacitance and dissipation
cable potheads are useful, sensitive factor are read directly on dials when the
indications of moisture and voids or other bridge is balanced. This equipment is not
substandard conditions in the potheads. sufficiently shielded against induced voltages
Abnormally high values of current and power to be suitable for use near high-voltage
indicate the presence of moisture and circuits, thus limiting its usefulness for field
abnormally low values indicate a void or the maintenance work. Although shields of sheet
absence of filling compound or oil. Hot-collar metal or screen can be used to enclose the
tests do not require a high-capacity test set. equipment bushings during tests, this method
is not desirable because of the danger in
56. Test Equipment.- Most of the power- handling these large metal parts near
factor testing done in the United States energized equipment.

IONIZATION TESTS

57. Application.- The ionization test is of the conductors where the insulation has
used primarily for detecting ionization been softened by the other effects.
(corona discharge) and slot discharge in
generator windings. Both ionization and slot Slot discharge is a capacitance discharge
discharge may cause deterioration of and occurs across poor contact points
insulation. Ionization generally occurs in between the coil surface shielding and the
voids inside the insulation within the ground stator iron. Deterioration is from the
shield section of the coil. destructive effect of this relatively
concentrated discharge. Coils which fit
Some internal ionization is present in most loosely in the slots may be subjected to this
higher voltage stator insulation. If it is trouble.
intense enough, it produces destruction of
the binder and other organic components by Test apparatus for corona detection requires
the chemical effects of the ozone and oxides much higher sensitivity than detection of slot
of nitrogen generated by the discharge (plus discharge. It is still of specialized category
moisture) and eventually by direct electronic and beyond the scope of this chapter.
bombardment. Destruction is often
aggravated finally by mechanical vibration

(FIST 3-1 12/91) 18

58. Test Methods for Slot Discharge.- discharge occurs at particular parts of the
A method used for detecting slot discharge in voltage cycle. Because the detector cannot
ac generator windings consists of energizing distinguish between hash originating in the
the winding from a high-potential ac test set winding and that originating in the power
at voltages of approximately 50 to 125 source, it is essential that the stator winding
percent of normal rated machine voltage or be energized from a good high-potential test
running the unit self excited and isolated from set or a transformer operated well below its
the system and observing on an oscilloscope rated voltage. Voltage of about 50 percent,
the resulting induced potentials from slot dis- normal or below which no corona occurs, is
charges. The detecting apparatus is first applied as a calibration point or base.
essentially a band pass filter passing a band The voltage is gradually raised until there is
of frequencies between 1,000 and 2,000 Hz distinct change in the hash on the
to an oscilloscope. The detecting apparatus oscilloscope screen. This is the point where
is coupled through a condenser to the slot discharge is considered to begin. A
terminal of the winding being tested or to a winding properly protected from slot
probe which is placed ill contact with the discharge should not produce hash at
stator coil shielding. With the oscilloscope voltages below approximately 125 percent of
sweep set for one-half the applied frequency, normal. Experience and special calibration
the characteristic hash indication appears at apparatus are necessary in order to properly
two or four places along the sweep since the interpret the results.

HIGH-POTENTIAL, AC PROOF TESTS

59. Application.- High-potential, ac tests If the ac proof test is to follow a high-voltage,

to determine the condition of insulation are dc test, the precaution of allowing adequate
used primarily on new equipment at the time, about 2 hours, for the absorption
factory, after erection in the field, or after charge to dissipate before application of the
rewinding in the field. The only positive ac over-potential test must be observed.
means of determining what voltage an
insulation will withstand is to apply voltage The procedure to be used on all ac proof
across it until failure occurs. However, this tests of stator windings is as follows:
test may be destructive and the full test
voltage is not recommended for application a. Break the 'Y" connection at the
to equipment that has been in service. In generator neutral, separating the three
deteriorated areas, the deterioration may be phases from each other and the
advanced by such tests even though failure powerhouse ground.
may not occur during the test. Thus, an
unknown part of the useful life may be spent. b. Disconnect all potential transformers
Reduced levels are sometimes permissible and surge-protection equipment, such as
as "suitability for service" tests. lightning arrestors, capacitors, etc., from
the generator terminal leads.
In any situation where a contract is involved,
have the contractor's representative present c. Ground both ends of the two phases
for the tests or obtain written permission which are not to be tested.
from the contractor for the Government to
perform the tests. d. Connect both ends of the phase to be
tested together with insulated wire and

19 (FIST3-1 12/91)

 bring the insulated wire to the vicinity voltage should then be lowered smoothly
of, but not connected to, the test set. to zero in approximately 1 minute.

e. If the test set being used does not k. Repeat steps 3, 4, 9, and 10 for the
have a built-in potential transformer for other phases to be tested.
high-side metering, a separate potential
transformer should be used to provide 60. Induced-Potential and Impulse
high-side metering. Tests.- Factory tests on new transformers or
regulators may include (a) 120- to 400-Hz
f. Check accuracy of test set indicating induced-potential test and (b) reduced full-
voltmeter by comparing it to a calibrated wave, chopped-wave, or full-wave impulse
voltmeter connected to the high-side tests. These tests require special equipment
potential transformer. and are not performed in the field, and will not
be covered in this bulletin. The standard 60-
g. Adjust spherical gap oil test set to Hz high-potential test, however, are simple to
flash over at the specified test voltage, perform and require only a transformer of
as calculated from charts. Then suitable voltage and capacity, with current
energize the test set without connecting limiting equipment and means for controlling
it to the stator-winding phase to be and measuring the output voltage.
tested. Raise voltage until gap flashes
over, noting reading of test-set 61. Voltage Values for AC Tests.-High-
voltmeter to verify reasonable potential, ac tests, if used in the field, should
agreement and that voltmeter scale and be performed in accordance with Standard
potential-trans-former ratio are correct. Techniques for High- Voltage Testing, IEEE
Some tests sets are not equipped with Standard No. 4, 1978, or its latest revision.
a spherical gap, so a separate The test voltage values to use are shown in
spherical-gap voltmeter should be used table F. All values in the table apply to 1 -
in conjunction with these sets. minute application of 60-Hz test voltage
applied between winding and ground, for
h. With the test set deenergized, adjust clean, dry windings at a temperature not
the spherical gap to flash over slightly below room temperature and preferably not
above the required test voltage. This will above 40 EC. The data given in table F under
provide protection in the event of a test "Periodic field tests on equipment in service"
set malfunction resulting in higher are manufacturers' recommendations, as no
voltage. ANSI standards have been adopted for this
purpose. The high-potential test voltage
i. Connect the test set to both ends of values for use on power cable vary with a
the stator winding phase to be tested. number of conditions and should be obtained
from the current cable standards. The
j. Energize the test set and raise the capacity of the high-potential test set (in
voltage smoothly until the mark on the kilovolt amperes required to test generator
test set indicating voltmeter is reached. stators of various ratings) is shown in figure
The rate of rise should be such that the 19.
test voltage is achieved within 1 minute.
Care should be exercised so as not to
overshoot the test voltage. This voltage
should be held for 60 seconds. The

(FIST 3-1 12/91) 20

 HIGH-POTENTIAL, DC PROOF TESTS

62. General.- High-potential, dc proof tests machinery windings rated 6,000 volts and
are ordinarily limited to 1- minute duration un- above, and when agreed upon by the man-
less otherwise specified. It is a pass or fail ufacturer and the user, the test voltage may
type of test and no particular significance is be a direct voltage of 1.7 times the ac, rms,
placed upon current values. The principal test voltage. IEEE No. 95 (1977)
advantage over the more common ac proof recommends that a ratio of 1.7 be used for
test is the smaller, simpler test apparatus. maintenance overvoltage tests.

63. Voltages for High-Potential DC 64. Cables.- High-potential, dc proof tests

Tests on Machines.- High-potential, dc are preferred by manufacturers for tests of
proof tests for generators, if used in the field, cables. Duration of the test is less critical
should be performed in accordance with than with ac proof tests. For certain tests, a
Standard Techniques for High-Voltage duration of 5 to 15 minutes is recognized by
Testing, IEEE Standard No. 4, 1978, or its the IPCEA (Insulated Power Cable Engineers
latest revision. The test voltage values Association). For maintenance tests of
should be approximately 1.7 times the ac, cables, it will ordinarily be advantageous to
rms, voltage values given in table F. ANSI use the test technique described in
C50.10 (1977) provides that for ac paragraphs 46 to 49, inclusive.

TURN-TO-TURN TESTING

65. General.- A turn-to-turn fault in a a. To establish the quality of the windings

rotating machine generally results in localized in new machines for warranty purposes;
overheating due to the very high current and
developed within the shorted turn. Eventually
the ground insulation is destroyed by the b. To establish the quality of an old
melting of the copper and a phase-to-phase winding for reliability purposes.
or phase-to-ground fault occurs. Testing for
turn-to-turn faults is generally not performed For more information on turn-to-turn fault
as a routine maintenance test but is used: testing, refer to IEEE Standard No. 522,
1977, "IEEE Guide for Testing Turn-to-turn
Insulation on Form-wound Stator Coils for
Alternating-current Rotating Electric
Machines-For Trial Use."

21 (FIST 3-1 12/91)

 BIBLIOGRAPHY

IEEE Recommended Practice for Testing Recommended Guide for Making Dielectric
Insulation Resistance of Rotating Machinery, Measurements in the Field, IEEE Standard No.
IEEE Standard No. 43, November 1974 62, April 1958

Temperature-resistance Characteristics of Test Code for Distribution, Power, and Regulating

Electrical Insulation, Technical Publication 21T4, Transformers, IEEE Standard No. 262, 1973
James G. Biddle Co., 1961
Maintenance Testing of Oil Circuit Reclosure
Field Testing of Generator Insulation, AlEE Insulation with High Voltage Direct Current, AlEE
Transactions, vol. 60, p. 1003, 1941 Transactions, vol. ill, pp. 1462-1465. 1054

Use of Dielectric-Absorption Tests in Dry-out of Evaluation of Generator Windings Based on In-

Large Generators, AlEE Transactions, vol. 64, pp. Stator Single Coil Power Factor Measurement,
56-60, 1945 AlEE Transactions, Brearly, Findlay, Louttit,
June 1961
Bushing and Associated Insulation Testing by the
Power Factor Method, AlEE Transactions, vol. 60, Insulation Testing by D-C Methods, Technical
p. 308, 1941 Publication 22T1, James G. Biddie Company,
1958
The A-C Dielectric Loss and Power Factor
Method for Field Investigation of Electrical Insu- IEEE Recommended Practice for Measurement of
lation, AlEE Transactions, vol. 60, p. 934, 1941 Power-factor Tip-up of Rotating Machinery Stator
Coil Insulation, IEEE Standard No. 286, July 1875
Insulation Testing as Applied to Power
Transformers, Electric Light and Power, February IEEE Guide for Testing Turn-to-turn Insulation on
1945 Form-wound stator Coils for Alternating-current
Rotating Electric Machines-For Trial Use, IEEE
Insulation Testing as Applied to Apparatus Standard No. 522, 1977
Bushings, Electric Light and Power, August 1945.
ANSI Standard No. C50.10, 1977
Slot Discharge Detection between Coil Surfaces
and Core of High Voltage Stator Windings, AlEE Cameron, A.W.W., Diagnosis of A-C Generator
Transactions, vol. 70, 1951 Insulation Condition by Nondestructive Tests,
AlEE Transactions, vol. 71, part III, p. 263, 1952
Detection of Slot Discharges in High Voltage
Stator Windings During Operation, AlEE Johnson, J. S., Checkups for Generators,
Transaction, vol. 70, 1951 Westinghouse Engineer, March 1951

IEEE Standard Test Code for Resistance Marcroft H. C., Field Studies of Generator
Measurement, IEEE Standard No. 118, 1978 Windings, AlEE Transactions, vol. 71, part III, p.
822, 1952
IEEE Guide for Insulation Maintenance of Large
Alternating-Current Rotating Machinery (10,000 Sidway, C. L., and B. R. Loxley, Techniques and
kVCA and Larger), IEEE Standard No. 56, March Examples of High Voltage D-C Testing of Rotating
1977 Machine Windings, AlEE Transactions, vol. 72,
part III, p. 1121, 1953

(FIST 3-1 12/91) 22

Hill, G. Leslie, Testing Electrical Insulation of Johnson, J. S., and A. W. Zwiener, D-C Testing
Rotating Machinery with High Voltage Direct Experience in Rotating Machine Insulation, AlEE
Current, AlEE Transactions, vol, 72, part III, Transactions, vol. 76, part III, pp. 416-420, 1957
p.159, 1953
Schleif, F R., and L. R. Engvall, Experience in
D-C High Voltage Testing, National Coil’s COIL Analysis of D-C Insulation Tests for Maintenance
TANK, October 1952 Programming, AlEE Power Apparatus and
Systems, pp. 156-161, June 1959
Cameron, AW.W., and A. M. Sinclair, Experience
and Development in Non-Destructive DC Testing Duke, Smith, Roberts, Cameron, Investigation of
for Maintenance of High-Voltage Stators, AlEE Maintenance Tests for Generator Insulation,
Transactions, vol. 75, part III, pp. 201-210, 1956 Power Apparatus and Systems, No. 55, pp. 471-
478, August 1961
Schleif, E R., Corrections for Dielectric
Absorption High Voltage D-C Insulation Test, Milano, U., A Programmable D-C High-volt-age
AlEE Transactions, pp. 513-517, August 1956 Ramped Test System for Electrical Insulation,
Report REC-ERC-78-7, Bureau of Reclamation,
Schurch, E. C., Experience with High Voltage October 1978
D-C Insulation Testing for Generator Stator
Windings, AlEE Transactions, vol. 75,part pp.
1082-1088,1956

23 (FIST 3-1 12/91)

TABLES

 Table A

MAXIMUM D-C TEST VOLTAGES FOR MACHINES

A-c voltage rating Old insulation New insulation*

of winding over 5 years old less than 5 years old
(kilovolts) (kilovolts) (kilovolts)
1/
100% 85%

2.3 - 2.5 5 4.25 6

4.16 10 8.5 12

6.9 - 7.2 15 12.75 20

11 - 13.8 20 - 25 17 - 21.25 30

1/
Normal limit for ramp testing. See paragraph 42 for more information on maximum test voltages for
machines.

* Any winding showing visible signs of deterioration should be considered old insulation for test
purposes regardless of age.

27 (FIST 3-1 12/91)

28

29

 Table C

VOLTAGE/TIME SCHEDULE FOR HIGH VOLTAGE D-C

TESTS OF STATOR INSULATION
Absorption exponent -0.8

All voltage changes with no time delay. Time tabulated are time form start of test to final reading for
respective voltage steps. Voltage is then raised to next step. The times scheduled under column A
are normally used. To save time, the first step may be increased as shown in Columns B, C, and D.

Dashed line indicates usual test limit for old insulation (5 years or more).

13.8-kV Insulation 6.9-kV Insulation

Minutes from start of test Minutes from start of test
kV A B C D kV A B C D
5 10 - - - 3 10 - - -
9 16-1/2 10 - - 5 16-1/4 10 - -
13 21-3/4 10 - – 7 21-1/4 15-1/4 10 -
15 25 18-3/4 13-1/2 10 9 25-1/4 19-1/2 14-1/2 10
17 28 21-3/4 16-1/2 13-1/4 10 28-1/4 22-1/4 17-1/4 13
19 30-1/2 24-1/4 19-1/4 16 11 30-3/4 24-3/4 19-3/4 15-1/2
21 33 26-3/4 21-3/4 18-1/2 12 33 27 22 18
22 34-1/2 28-1/4 23-1/4 20-1/4 12-1/2 34-1/2 28-1/8 23-1/2 19-1/2
23 36 29-3/4 24-3/4 21-3/4 13 35-3/4 29-3/4 24-3/4 20-3/4
24 37-1/4 31 26 23-1/4 13-1/2 37 31 26 22
25 38-1/2 32-1/4 27-1/4 24-1/2 14 38-1/4 32-1/4 27-1/4 23-1/4
14-1/2 30-1/2 33-1/2 28-1/2 24-1/2
26 39-3/4 33-1/2 28-1/2 25-3/4 15 40-1/2 34-1/2 29-1/2 25-3/4
27 41 34-3/4 29-3/4 27
28 42-1/4 36 31 28-1/4
29 43-1/4 37 32-1/4 29-1/2
30 44-1/2 38-1/4 33-1/4 30-1/2

4.16-kV Insulation 2.3-kV Insulation

Minutes from start of test Minutes from start of test
kV A B C kV A B C
2 10 - - 1 10 - -
4 47 10 - 2 17 10 -
6 22-1/2 15-3/4 10 3 22-1/2 15-3/4 10
7 26 19-1/4 13-3/4 3-1/2 26 19-1/4 13-3/4
8 29 22-1/4 16-3/4 4 29 22-1/4 16-3/4
8-1/2 30-3/4 24-1/4 18-3/4 4-1/4 20-3/4 24-1/4 18-3/4
9 32-1/2 26 20-1/2 4-1/2 32-1/2 26 20-1/2
9-1/2 34-1/4 27-1/2 20-1/2 4-3/4 34-1/4 27-1/2 22-1/4
10 35-3/4 29 23-3/4 5 35-3/4 29 23-3/4

10-1/2 37-1/4 30-1/2 25-1/4 5-1/4 37-1/4 30-1/2 25-1/4

11 38-3/4 32 26-3/4 5-1/2 38-3/4 32 26-3/4
11-1/2 40 33-1/4 28 5-3/4 40 33-1/4 28
12 41-1/4 34-1/4 29-1/4 6 41-1/4 34-1/2 29-1/4

30

 Table D. - Cable d-c test voltage guide

Part 1

Rubber and rubber-like insulated cable up to 28 kV

IPCEA Std. S-19-81, Fifth Edition, June 1976

Insulation grade

Other than
Maximum ozone-resisting Ozone-resisting
rated Conductor Conductor d-c/a-c ratio = 3.0 d-c/a-c ratio = 3.0
circuit size insulation
voltage (AWG or - thickness Mils Maximum conductor to ground d-c test
(kV) kcmil) mm values in kV*

Grounded Ungrounded Grounded Grounded

neutral neutral neutral neutral
service service service service

0.6 18-16 30 0.76 - - - -

14-9 45 1.14 5.4 5.4 8.1 8.1
8-2 60 1.52 6.3 6.3 10.8 10.8
1-4/0 80 2.03 7.2 7.2 13.5 13.5
225-500 95 2.41 9.0 9.0 15.3 15.3
525-1000 110 2.79 10.8 10.8 18.0 18.0
1000+ 125 3.18 12.6 12.6 20.7 20.7
1.0 14-8 60 1.52 9.0 9.0 10.8 10.8
7-2 80 2.03 10.8 10.8 13.5 13.5
1-4/0 95 2.41 13.5 13.5 15.3 15.3
225-500 110 2.79 16.2 16.2 18.0 18.0
525-1000 125 3.18 18.0 18.0 20.7 20.7
1000+ 140 3.56 19.8 19.8 20.7 20.7
2.0 14-8 80 2.03 10.8 10.8 13.5 13.5
7-2 95 2.41 13.5 13.5 15.3 15.3
1-4/0 110 2.79 16.2 16.2 18.0 18.0
225-500 125 3.18 18.0 18.0 20.7 20.7
500+ 140 3.56 18.0 18.0 20.7 20.7
5.0 8-4/0 155 3.94 21.0** 21.0** 21.0** 21.0**
225-1000 170 4.32 21.0** 21.0** 21.0** 21.0**
1000+ 190 4.83 21.0** 21.0** 21.0** 21.0**
8.0 6 and over 190 4.83 - - 27.0 -
6 and over 250 6.35 - - - 27.0
15.0 2 and over 295 7.49 - - 42.0 -
1 and over 420 10.67 - - - 48.0
25.0 1 and over 455 11.56 - - 60.0 -
28.0 1 and over 500 12.70 - - 63.0 -

* All test values rounded off to 1 decimal place, and voltages are 60 percent
of factory test.
** Not applicable to shielded cables, armored cables are 80 percent test
value and metallic sheathed cables are 90 percent test value.

31

 Table D (Continued)

RECOMMENDED THICKNESS OF VARNISHED CLOTH INSULATED CABLES

NEMA WC 4-1976, IPCEA STD S-65-375

Key for Part 2

Single and shielded Unshielded multiple

Maximum Conductor conductor conductor
rated size insulation thickness insulation thickness
circuit (AWG not including belt
voltage (kV) or
MCM) Grounded Ungrounded Grounded Ungrounded
neutral neutral neutral neutral
mils mm mils mm mils mm mils mm

0.6 14-8 45 1.14 45 1.14 45 1.14 45 1.14

7-2 60 1.52 60 1.52 60 1.52 60 1.52
1-4/0 80 2.03 80 2.03 80 2.03 80 2.03
213-500 95 2.41 95 2.41 95 2.41 95 2.41
501-1000 110 2.79 110 2.79 95 2.41 95 2.41
1000+ 125 3.18 125 3.18 110 2.79 110 2.79
1.0 14-2 60 1.52 60 1.52 60 1.52 60 1.52
1-4/0 80 2.03 80 2.03 80 2.03 80 2.03
213-500 95 2.41 95 2.41 95 2.41 95 2.41
501-1000 110 2.79 110 2.79 95 2.41 95 2.41
1000+ 125 3.18 125 3.18 110 2.79 110 2.79
3.0 10-2 — ---- — ---- 80 2.03 80 2.03
10-4/0 95 2.41 95 2.41 — — — —
1-500 — --- — --- 95 2.41 95 2.41
213-1000 110 2.79 110 2.79 — — — —
501-1000 — --- — --- 95 2.41 95 2.41
1000+ 125 3.18 125 3.18 110 2.79 110 2.79
5.0 8-4/0 140 3.56 140 3.56 95 2.41 95 2.41
213+ 155 3.94 155 3.94 110 2.79 110 2.79
8.0 6+ 170 4.32 190 4.83 110 2.79 110 2.79
10.0 6+ 190 4.83 235 5.97
12.0 6+ 220 5.59 250 6.35
15.0 6+ 250 6.35 330 8.38
21.0 2+ 345 8.76 455 11.56
23.0 2+ 375 9.53
28.0 1+ 455 11.56

32

 Table D. - Cable d-c test voltage guide (continued)

Part 2

Varnished Cloth Insulated Cable

NEMA WC 4-1976, IPCEA Std. S-65-375

d-c/a-c ratio = 2

Type of cable

Conductor Conductor Single conductor,

size insulation shielded multiple VC belted multiple
(AWG or thickness conductor and conductor cable, VC belted multiple
kcmil) mils mm nonbelted**, rated 5 kV and conductor cable,
nonshielded below rated above 5 kV
multiple 2 x 0.58 = 1.16 2 x 0.80 = 1.6
conductor

Maximum conductor to sheath or ground d-c test

values in kV*

Grounded and Grounded Ungrounded

ungrounded neutral neutral service
neutral service service

14-8 45 1.14 3.0 3.5

14-7 60 1.52 4.2 4.9
6-5 60 1.52 4.8 5.6
4-2 60 1.52 6.0 7.0
10-7 80 2.03 5.4 6.3
6-5 80 2.03 6.0 7.0
4-2 80 2.03 6.6 7.7
1-4/0 95 2.41 7.2 8.4
10-9 95 2.41 7.8 9.0
8 95 2.41 7.8 9.0 12.5
7 95 2.41 8.4 9.7 13.4
6-5 95 2.41 9.0 10.4 14.4
4-2 95 2.41 9.6 11.1 15.4
1-4/0 95 2.41 10.2 11.8 16.3
213-1000 110 2.79 10.8 12.5
8 110 2.79 10.8 12.5
7 110 2.79 11.4 13.2
6-5 110 2.79 12.0 13.9 19.2
4-2 110 2.79 12.6 14.6 20.2
1-4/0 110 2.79 13.2 15.3 21.1
213+ 110 2.79 13.8 16.0 22.1

*All test values rounded off to 1 decimal place, and voltages are 60 percent of
factory test.
**Nonbelted or belted with material other than varnished cloth.

33
 Table D.- Cable d-c test voltage guide (continued)
Part 2

Varnished Cloth Insulated Cable

NEMA WC 4-1976, IPCEA Std. S-65-375

d-c/a-c ratio = 2

Type of cable
Single conductor, shielded multiple
Conductor Conductor conductor and non-belted**,
size insulation nonshielded multiple conductor
(AWG or thickness Maximum conductor to sheath or
kcmil) mils mm groung d-c test values in kV*
Grounded and ungrounded neutral service
8 125 3.18 13.2
7 125 3.18 13.8
6-5 125 3.18 14.4
4-2 125 3.18 15.0
1-4/0 125 3.18 16.2
213+ 125 3.18 16.8
8 140 3.56 16.2
7 140 3.56 16.8
6-5 140 3.56 17.4
4-2 140 3.56 18.0
1-4/0 140 3.56 18.6
213+ 140 3.56 19.2
8 155 3.94 18.6
7 155 3.94 19.2
6-5 155 3.94 19.8
4-2 155 3.94 20.4
1-4/0 155 3.94 21.6
213+ 155 3.94 22.2
6-5 170 4.32 22.2
4-2 170 4.32 22.8
1-4/0 170 4.32 23.4
213+ 170 4.32 24.0
6-5 190 4.83 24.0
4-2 190 4.83 24.6
1-4/0 190 4.83 25.2
213+ 190 4.83 26.4
6-5 205 5.21 26.4
4-2 205 5.21 27.0
1-4/0 205 5.21 27.6
213-500 205 5.21 28.2
501+ 205 5.21 28.8
6-5 220 5.59 28.2
4-2 220 5.59 28.8
1-4/0 220 5.59 29.4
213+500 220 5.59 30.6
501+ 31.2

*All test values rounded off to 1 decimal place, and voltages are

60 percent of factory test.

**Nonbelted or belted with material other than varnished cloth.

34
 Table D. - Cable d-c test voltage guide (continued)
Part 2

Varnished Cloth Insulated Cable

NEMA WC 4-1976, IPCEA Std. S-65-375

d-c/a-c ratio = 2

Type of cable

Conductor Conductor Single conductor, shielded multiple

size insulation conductor and non-belted**,
(AWG or thickness nonshielded multiple conductor
kcmil) mils mm
Maximum conductor to sheath or
groung d-c test values in kV*

Grounded and ungrounded neutral service

6-5 235 5.97 30.0

4-2 235 5.97 31.2
1-4/0 235 5.97 31.8
213-500 235 5.97 32.4
501+ 235 5.97 33.0
6-5 250 6.35 32.4
4-2 250 6.35 33.0
1-4/0 250 6.35 33.6
213-500 250 6.35 34.8
501+ 250 6.35 35.4
6-5 330 8.38 45.0
4-2 330 8.38 45.6
1-4/0 330 8.38 46.2
213-500 330 8.38 46.8
501+ 330 8.38 47.4
4-2 345 8.76 48.6
1-4/0 345 8.76 49.2
213-500 345 8.76 49.8
501+ 345 8.76 50.4
2 375 9.53 54.0
1-4/0 375 9.53 54.6
213-500 375 9.53 55.2
501+ 375 9.53 55.8
2 455 11.56 64.2
1-4/0 455 11.56 64.8
213-500 455 11.56 66.0
501* 455 11.56 66.6

*All test values rounded off to 1 decimal place, and voltages are

60 percent of factory test.

**Nonbelted or belted with material other than varnished cloth.

35
 NOTE: CONCERNING PAPER INSULATED CABLE

Table D. - Parts 3 to 7

Use multiplying factors (F) for cables with small

conductors as follows:

Conductor size, AWG number

1 2 3 4 5 6

Factor F, stranded conductor

1.00 0.97 0.94 0.91 0.88 0.85

Table D. - Cable d-c test voltage guide - (continued)

Part 3

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968
d-c/a-c ratio = 2.4 at 25 EC

Rated kV Conductor Conductor

phase size insulation
to phase (AWG or thickness Single conductor shielded
Gr. Ung. kcmil) mils mm and nonshielded*

1 1 6-1000 60 1.52 12.1F

1001-2500 75 1.91 17.3
2501-4000 90 2.29 22.4
2 2 6-1000 65 1.65 13.8
1001-2500 80 2.03 19.0
2501-4000 95 2.41 24.2
3 3 6-1000 75 1.91 17.3F
1001-2500 90 2.29 22.4
2501-4000 100 2.54 25.9
4 4 6-1000 85 2.16 20.8F
1001-2500 95 2.41 24.2
2501-4000 105 2.67 27.7
5 5 6-1000 90 2.29 22.4F
1001-2500 100 2.54 25.9
2501-4000 105 2.67 27.7
6 - 6-1000 100 2.54 25.9F
1001-4000 105 2.67 27.7
7 - 6-4000 105 2.67 27.7F

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

36
 Table D. -Cable d-c test voltage guide (continued)

Part 3

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC 10th Edition, April 1968

d-c/a-c ratio = 2.4 at 25 EC

Rated kV Conductor Conductor

phase size insulation Single conductor shielded
to phase (AWG or thickness and nonshielded*
Gr. Ung. kcmil ) mils mm

8 6 6-4 125 3.18 29.4F

3-4000 110 2.79 29.4F
9 7 6-4 135 3.43 32.8F
3-4000 120 3.05 32.8F
10 - 6-4 140 3.56 34.6F
3-4000 125 3.18 34.6F
11 8 6-4 150 3.81 38.0F
3-4000 135 3.43 38.0F
12 9 6-4 155 3.94 39.7F
3-4000 140 3.56 39.7F
13 - 4-2 165 4.19 43.2F
1-4000 150 3.81 43.2
14 10 4-2 170 4.32 44.9F
1-4000 155 3.94 44.9
15 11 4-2 180 4.57 48.4F
1-4000 165 4.19 48.4
16 12 4-2 185 4.70 50.1F
1-4000 170 4.32 50.1
17 - 4-2 195 4.95 53.6F
1-4000 180 4.57 53.6
18 13 2-1 200 5.08 55.3F
1/0-4000 185 4.70 55.3
19 14 2-1 210 5.33 58.8F
1/0-4000 195 4.95 58.8
20 15 2-1 215 5.46 60.5F
1/0-4000 200 5.08 60.5
21 - 2-1/0 225 5.72 63.9F
2/0-4000 210 5.33 63.9
22 16 2-1/0 230 5.84 65.7
2/0-4000 215 5.46 65.7
23 17 2-1/0 240 6.10 69.1F
2/0-4000 225 5.72 69.1
24 18 2-2/0 245 6.22 70.8F
3/0-4000 230 5.84 70.8

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

37
 Table D. - Cable d-c test voltage guide (continued)

Part 3

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968
d-c/a-c ratio = 2.4 at 25 EC

Rated kV Conductor Conductor

phase size insulation Single conductor shielded
to phase (AWG or thickness and nonshielded*
Gr. Ung kcmil) mils mm

25 - 1-2/0 255 6.48 74.3

26 3/0-4000 240 6.10 74.3
19 1-2/0 260 6.60 76.0
27 3/0-4000 245 6.22 76.0
20 1-3/0 270 6.86 79.5
28 4/0-4000 255 6.48 79.5
21 1/0-3/0 280 7.11 82.9
29 4/0-4000 265 6.73 82.9
- 1/0-3/0 285 7.24 86.4
30 4/0-4000 275 6.99 86.4
22 1/0-3/0 285 7.24 88.1
4/0-4000 280 7.11 88.1
31 23 1/0-4000 290 7.37 91.6
32 24 1/0-4000 300 7.62 95.0
33 - 2/0-4000 310 7.75 98.5
34 25 2/0-4000 320 8.13 102.0

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

38

 Table D. - Cable d-c test voltage guide (continued)

Part 4

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968

d-c/a-c ratio = 2.4 at 25 EC

Rated Conductor
kV size Conductor
phase (AWG or insulation Multiple
to kcmil) thickness conductor
phase Round and mils mm shielded*
Gr. Ung. sector

8 - 6-4 R 125 3.18 29.4F

3-1000R 110 2.79 29.4F
2/0-1000S 110 2.79 29.4
9 - 6-4 R 135 3.43 32.8F
3-1000R 120 3.05 32.8F
2/0-1000S 120 3.05 32.8
10 - 6-4 R 140 3.56 34.6F
3-1000R 125 3.18 34.6F
2/0-1000S 125 3.18 34.6
11 8 6-4 R 150 3.81 38.0F
3-1000R 135 3.43 38.0F
2/0-1000S 135 3.43 38.0
12 9 6-4 R 155 3.94 39.7F
3-1000R 140 3.56 39.7F
2/0-1000S 140 3.56 39.7
13 - 4-2 R 165 4.19 43.2F
1-1000R 150 3.81 43.2
2/0-1000S 150 3.81 43.2
14 10 4-2 R 170 4.32 44.9F
1-1000R 155 3.94 44.9
2/0-1000S 155 3.94 44.9
15 11 4-2 R 180 4.57 48.4F
6-2 S 180 4.57 48.4
1-1000R 165 4.19 48.4
2/0-1000S 165 4.19 48.4
16 12 4-2 R 185 4.70 50.1F
6-2 S 185 4.70 50.1
1-1000R 170 4.32 50.1
2/0-1000S 170 4.32 50.1
17 - 4-2 R 195 4.95 53.6F
1-1000R 180 4.57 53.6
2/0-1000S 180 4.47 53.6

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

39
 Table D. - Cable d-c test voltage guide (continued)

Part 4

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968

d-c/a-c ratio = 2.4 at 25 EC

Rated Conductor
kV size Conductor
phase (AWG or insulation Multiple
to kcmil) thickness conductor
phase Round and mils mm shielded*
Gr. Ung. sector

18 13 2-1 R 200 5.08 55.3F

1/0-1000R 185 4.70 55.3
2/0-1000S 185 4.70 55.3
19 14 2-1 R 210 5.33 58.8F
1/0-1000R 195 4.95 58.8
2/0-l000S 195 4.95 58.8
20 15 2-1 R 215 5.46 60.5F
1/0-1000R 200 5.08 60.5
2/0-1000S 200 5.08 60.5
21 - 2-1 R 225 5.72 63.9F
2/0-1000R 210 5.33 63.9
2/0-1000S 210 5.33 63.9
22 16 2-1/0 R 230 5.84 65.7F
2/0-1000R 215 5.46 65.7
2/0-1000S 215 5.46 65.7
23 17 2-1/0 R 240 6.10 69.1F
2/0-1000R 225 5.72 69.1
2/0-1000S 225 5.72 69.1
24 18 2-2/0 R 245 6.22 70.8F
2/0 245 6.22 70.8
3/0-1000R 230 5.84 70.8
3/0-1000S 230 5.84 70.8
25 - 1-2/0 R 255 6.48 74.3
2/0 S 255 6.48 74.3
3/0-1000R 240 6.10 74.3
3/0-1000S 240 6.10 74.3
17 19 1-2/0 R 260 6.60 76.0
2/0 S 260 6.60 76.0
3/0-1000R 245 6.22 76.0
3/0-1000S 245 6.22 76.0

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

40
 Table D. - Cable d-c test voltage guide (continued)

Part 4

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968

d-c/a-c ratio = 2.4 at 25 EC

Rated Conductor
kV size Conductor
phase (AWG or insulation Multiple
to kcmil) thickness conductor
phase Round and mils mm shielded*
Gr. Ung. sector

27 20 1-3/0 R 270 6.86 79.5

2/0-3/0 S 270 6.85 79.5
4/0-1000R 255 5.48 79.5
4/0-1000S 255 6.48 79.5
28 21 1/0-3/0 R 280 7.11 82.9
3/0 S 280 7.11 82.9
4/0-1000R 265 6.73 82.9
4/0-1000S 265 6.73 82.9
29 - 1/0-3/0 R 285 7.24 86.4
3/0 S 285 7.24 86.4
4/0-1000R 275 6.99 86.4
4/0-1000S 275 6.99 86.4
30 22 1/0-3/0 R 285 7.24 88.1
3/0 S 285 7.24 88.1
4/0-1000R 280 7.11 88.1
4/0-1000S 280 7.11 88.1
31 23 1/0-1000R 290 7.37 91.6
3/0-1000S 290 7.37 91.6
32 24 1/0-1000R 300 7.62 95.0
250-1000S 300 7.62 95.0
33 - 2/0-l000R 310 7.75 98.5
250-1000S 310 7.75 98.5
34 25 2/0-IO00R 320 8.13 102.0
250-1000R 320 8.13 102.0

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

41

 Table D. - Cable d-c test voltage guide (continued)

Part 5

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC loth Edition, April 1968

d-c/a-c ratio = 2.4 at 25 EC

Conductor Conductor
Rated size insulation Multiple conductor
kV (AWG or thickness belted
phase kcmil) grounded and
to Round and ungrounded
mils mm
phase sector neutral service*

1 6-500 R 55x35 1.40x0.89 10.4F

2/0-500 S 55x35 1.40x0.89 10.4
501-750 65x40 1.65x1.02 14.5
751-1000 75x45 1.91x1.14 18.7
2 6-500 R 65x35 1.65x0.89 14.5F
2/0-500 S 65x35 1.65x0.89 14.5
501-750 70x40 1.78x1.02 16.6
751-1000 75x45 1.91x1.14 18.7
3 6-500 R 70x40 1.78x1.02 16.6F
2/0-500 S 70x40 1.78x1.02 16.6
501-750 75x40 1.91x1.02 18.7
751-1000 80x45 2.03x1.14 20.7
4 6-750 R 80x40 2.03x1.02 20.7F
2/0-750 S 80x40 2.03x1.02 20.7
751-1000 80x45 2.03x1.14 20.7
5 6-1000R 85x45 2.16x1.14 22.9F
2/0-1000S 85x45 2.16x1.14 22.9

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

42

 Table D. - Cable d-c test voltage guide (continued)

Part 6

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC l0th Edition, April 1968

d-c/a-c ratio =2.4 at 25 EC

Conductor Conductor
Rated size insulation Multiple conductor
kV (AWG or thickness belted
phase kcmil) grounded and
to Round and ungrounded
mils mm
phase sector neutral service*

6 6-1000R 90x50 2.29xl.27 24.9F

2/0-1000S 90x50 2.29xl.27 24.9
7 6-1000R 100x50 2.54xl.27 29.1F
2/0-1000S 100x50 2.54xl.27 29.1
8 6-1000R 105x55 2.67xl.40 31.3F
2/0-1000S 105x55 2.67xl.40 31.3
9 6-1 R 130x55 3.30xl.40 35.3F
1/0-1000R 115x55 2.92xl.40 35.3
2/0-1000S 115x55 2.92xl.40 35.3
10 4-1 R 135x60 3.43xl.52 37.4F
1/0-1000R 120x60 3.05xl.52 37.4
3/0-1000S 120x60 3.05xl.52 37.4
11 4-1 R 140x65 3.56xl.65 39.5F
1/0-1000R 125x65 3.18xl.65 39.5
3/0-1000S 125×65 3.18xl.65 39.5
12 4-1 R 150x65 3.81xl.65 43.6F
1/0-1000R 135x65 3.43x!.65 43.6
3/0-1000S 135x65 3.43xl.65 43.6
13 4-1 R 155x70 3.94xl.78 45 .SF
1/0-1000R 140x70 3.56xl.78 45.8
4/0-1000S 140x70 3.56xl.78 45.8
14 4-1 R 165x70 4.19xl.78 49.SF
1/0-1000R 150x70 3.81xl.78 49.8
4/0-1000S 150x70 3.81xl.78 49.8
15 4-1 R 170x75 4.32xl.91 52.0F
1/0-1000R 155x75 3.94xl.91 52.0
4/0-1000S 155x75 3.94xl.91 52.0

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

43
 Table D. - Cable d-c test voltage guide (continued)

Part 7

Solid-type Impregnated-paper Insulated Lead Covered

Cable Specifications
AEIC l0th Edition, April 1968

d-c/a-c ratio =2.4 at 25 EC

Conductor Conductor
Rated size insulation Multiple conductor
kV (AWG or thickness belted
phase kcmil) grounded and
to Round and ungrounded
mils mm
phase sector neutral service*

6 6-1000R 90x100 2.29x2.54 34.6F

2/0-1000S 90x100 2.29x2.54 34.6
7 6-1000R 100x100 2.54x2.54 40.3F
2/0-1000S 100x100 2.54x2.54 40.3
8 6-1000R 105x110 2.67x2.79 43.2F
2/0-1000S 105x110 2.67x2.79 43.2
9 6-1 R 130x110 3.30x2.79 49.0F
1/0-1000R 115x110 2.92x2.79 49.0
2/0-1000S 115x110 2.92x2.79 49.0
10 4-1 R 135x120 3.43x3.05 51.8F
1/0-1000R 120x120 3.05x3.05 51.8
3/0-1000S 120x120 3.05x3.05 51.8
11 4-1 R 140x130 3.56x3.30 54.7F
1/0-1000R 125x130 3.18x3.30 54.7
3/0-1000S 125x130 3.18x3.30 54.7
12 4-1 R 150x130 3.81x3.30 60.5F
1/0-1000R 135x130 3.43x3.30 60.5
3/0-1000S 135x130 3.43x3.30 60.5
13 4-1 R 155x140 3.94x3.56 63.3F
1/0-1000R 140x140 3.56x3.56 63.3
4/0-1000S 140x140 3.56x3.56 63.3
14 4-1 R 165x140 4.19x3.56 69.1F
1/0-1000R 150x140 3.81x3.56 69.1
4/0-1000S 150x140 3.81x3.56 69.1
15 4-1 R 170x150 4.32x3.81 72.0F
1/0-1000R 155x150 3.94x3.81 72.0
4/0-1000S 155x150 3.94x3.81 72.0

*All test values rounded off to 1 decimal place, and voltages are
60 percent of factory test.

44
 Table E. - Temperature correction factors for the
power factor of power transformer windings*

FP20 = FPT
K

where:

FP20 = power factor corrected to 20 EC

FPT = power factor measured at T EC

T = test temperature

K = correction factor from table

Test temperature T
O
C Correction factor K

10 0.80
15 0.90
20 1.00
25 1.12
30 1.25
35 1.40
40 1.55
45 1.75
5O 1.95
55 2.18
60 2.42
65 2.70
70 3.00

* From IEEE Standard No. 262, 1973.

45
46

47

48

49

FIGURES

Figure 1. - Continuous operating temperature vs. insulation life.

53

Figure 2. - Dielectric absorption curves before and after initial dryout for Grand
Coulee unit L-6 108,000-kVA, 120-r/min, 13.8-kV, 60-Hz generator.

54

Figure 3. - Insulation resistance and temperature correction factor vs.

temperature for figure 2.

55

Figure 4. - Temperature correction factors for insulation resistance.

56

Figure 5. - One- and ten-minute resistance values during dry out of 37 500-kVCA,
13.8-kV hydrogenerator.

57

Figure 6. - D-c ramped-voltage test with unit buswork connected-Yellowtail unit 2,

k A, February 26, 1979.

Figure 7. - D-c ramped-voltage test with unit buswork not connected-Yellowtail unit
2, k A, March 13, 1979.

58

Figure 8. - Arrangement for plotting insulation test data.

59

Figure 9. - Log-log plots of dielectric absorption curves and discharge curves.

60

Figure 10. - Template analysis.

61

Figure 11. - Comparison of text curves between 30- and 10-minute schedules, kB,
Grand Coulee, L-8 June 28, 1960.

62

 Figure 12. - Comparison of test to show progress of deterioration of wining

insulation.

Figure 13. - Characteristics of very dry winding before and after varnishing. (Note
that the insulation resistance meter reading may be lower but indicated
puncture strength higher after varnishing.)

63

Figure 14. - Typical stator insulation ramped-voltage test results-new epoxy-mica

insulation.

Figure 15. - Typical stator insulation ramped-voltage test results-new asphalt-mica

insulation.

64

Figure 16. - Typical stator insulation ramped-voltage test results-asphalt-mica

insulation with a localized weak spot.

Figure 17. - Typical stator insulation ramped-voltage test results-very old

asphalt-mica insulation.

65

Figure 18. - High-voltage, d-c test on a 1500-kcmil varnished cambric, 250-mil

(6.34-mm), lead-sheathed cable.

66

Figure 19. - Approximate charging kilovolt amperes of generator stators for

determining capacity of a-c high-potential set required.

67 *U.S. GOVERNMENT PRINTING OFFICE 1992-836.050