1 Introduction
Heavy industry equipment covers large generator, large motor, large transformer, large reactor, mine hoist, rolling mill main drive, marine propulsion motor, shield machine drive and other key equipment, has the remarkable characteristics of high power, high voltage, strong current, high insulation class, high mechanical strength, long service life, high reliability. Large thick diameter enameled copper wire is the enameled copper wire with conductor diameter 2.50 to 6.00 mm or conductor cross sectional area 25 to 120 square mm, is the key raw material for heavy industry equipment winding.
Based on IEC 60317, IEC 60034, IEC 60076, IEEE 522, UL 1446, GB/T 6109, NEMA MW 1000-2018 and other international and domestic standards, this article systematically describes the application technology and engineering practice of large thick diameter enameled copper wire in heavy industry equipment from seven dimensions including heavy industry overview, large generator application, large motor application, large transformer application, mining metallurgy and marine application, enameled wire selection and manufacturing process, and summary.
2 Large Thick Diameter Enameled Wire and Heavy Industry Overview
2.1 Heavy Industry Equipment Classification
Heavy industry equipment covers large generator, large motor, large transformer, large reactor, mine hoist, rolling mill main drive, marine propulsion motor, shield machine drive, railway traction motor, wind power generator, nuclear power generator, pumped storage generator twelve major categories. Large generator capacity 100 MW to 1800 MW, voltage 10 to 27 kV, insulation class F or H, efficiency not lower than 98.5%, service life not lower than 40 years. Large motor capacity 1000 kW to 50000 kW, voltage 6 kV to 13.8 kV, insulation class F or H, efficiency not lower than 96%, service life not lower than 30 years. Large transformer capacity 50 MVA to 1500 MVA, voltage 110 kV to 1000 kV, efficiency not lower than 99%. Mine hoist 1000 to 10000 kW, rolling mill main drive motor 3000 to 15000 kW, marine propulsion motor 5000 to 50000 kW, insulation class H or C.
2.2 Enameled Wire Product System and Technical Advantage
Large thick diameter enameled wire product system covers large thick diameter enameled round copper wire, enameled flat copper wire, paper covered enameled flat copper wire, fiberglass covered enameled flat copper wire, fiberglass paper covered enameled flat copper wire, composite insulation enameled flat copper wire six major categories. Enameled round copper wire conductor diameter 2.50 to 6.00 mm, cross sectional area 4.91 to 28.27 square mm, varnish film thickness grade 1 to 3, heat resistance class 130 to 220 degrees Celsius. Enameled flat copper wire conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, cross sectional area 10.00 to 89.60 square mm, heat resistance class 155 to 240 degrees Celsius.
Large thick diameter enameled wire technical advantage reflects in six dimensions: large current capacity, 5 to 50 times of small medium diameter enameled wire, single wire can carry hundreds of ampere to thousands of ampere current. High mechanical strength, anti-vibration, anti-impact, suitable for high mechanical stress equipment. Heat resistance class covers 130 to 240 degrees Celsius, accelerated aging service life 200 degrees Celsius 6000 to 50000 hours. High insulation reliability, partial discharge resistance, corona resistance, thermal shock resistance. High winding efficiency, high slot fill factor, low winding resistance, low winding temperature rise. Service life up to 20 to 40 years.
3 Large Thick Diameter Enameled Wire Application in Large Generator
3.1 Steam Turbine and Hydro Generator Stator Winding
Steam turbine generator is the core power generation equipment of thermal power plant and nuclear power plant, capacity 100 MW to 1800 MW, voltage 10 to 27 kV, speed 3000 rpm or 3600 rpm, insulation class F or H, efficiency not lower than 98.5%, service life not lower than 40 years. Stator winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3, varnish film system adopts polyesterimide EIW or polyamideimide AIW. Bar type winding conductor cross sectional area 25 to 120 square mm, turn number 1 to 10 turns, coil length 5 to 15 meters, coil weight 50 to 500 kg. Rotor winding adopts large thick diameter enameled flat copper wire or enameled copper strip, conductor width 5.00 to 50.00 mm, thickness 2.00 to 8.00 mm.
Hydro generator capacity 50 MW to 1000 MW, voltage 10 to 24 kV, speed 50 to 750 rpm, insulation class F or H, efficiency not lower than 98%, service life not lower than 40 years. Stator winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm. Large hydro generator single unit stator slot number 300 to 1200 slots, each slot conductor number 2 to 8 roots, single root conductor cross sectional area 25 to 80 square mm.
3.2 Wind Power and Pumped Storage Generator
Wind power generator covers onshore wind power, offshore wind power, floating wind power. Stator winding adopts large thick diameter enameled flat copper wire, insulation class H or N. Doubly fed induction wind power generator stator winding adopts enameled flat copper wire, rotor winding adopts enameled round copper wire. Offshore wind power needs to withstand salt fog, humidity, high temperature, low temperature, vibration, shock and other harsh environments, puts higher requirements for enameled wire salt fog resistance, humidity heat resistance, chemical corrosion resistance performance. Pumped storage generator is reversible power motor, capacity 100 MW to 400 MW, voltage 10 to 24 kV, speed 250 to 750 rpm, insulation class F or H, needs to withstand frequent start stop, rapid load change, bidirectional operation and other harsh working conditions. Gas turbine, diesel, nuclear power, coal fired, gas steam combined cycle generator all adopt large thick diameter enameled flat copper wire as stator winding, efficiency not lower than 98%, service life not lower than 30 to 40 years.
4 Large Thick Diameter Enameled Wire Application in Large Motor
4.1 Large Induction Motor
Large induction motor capacity 1000 kW to 50000 kW, voltage 6 kV to 13.8 kV, speed 500 to 3600 rpm, insulation class F or H, efficiency not lower than 96%, service life not lower than 30 years. Stator winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3, heat resistance class F or H. Bar type winding single root conductor cross sectional area 25 to 100 square mm, coil length 2 to 10 meters, coil weight 20 to 200 kg.
4.2 Large Synchronous Motor
Large synchronous motor capacity 1000 kW to 50000 kW, voltage 6 kV to 13.8 kV, speed 250 to 3600 rpm, insulation class F or H, efficiency not lower than 97%, service life not lower than 30 years. Stator winding adopts large thick diameter enameled flat copper wire, bar type winding single root conductor cross sectional area 25 to 100 square mm. Rotor adopts excitation winding, excitation winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 30.00 mm, thickness 2.00 to 6.00 mm, varnish film thickness grade 2 to 3, heat resistance class F or H, excitation voltage 50 to 500 V DC.
4.3 Large DC Motor and Variable Frequency Motor
Large DC motor capacity 500 kW to 10000 kW, voltage 440 V to 1200 V DC, speed 50 to 3000 rpm, insulation class F or H. Armature winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3. Large variable frequency motor capacity 500 kW to 30000 kW, voltage 6 kV to 13.8 kV, insulation class H or N, stator winding adopts large thick diameter enameled flat copper wire, varnish film has strong partial discharge resistance, corona resistance, variable frequency pulse voltage resistance.
5 Large Thick Diameter Enameled Wire Application in Large Transformer
5.1 Large Power Transformer
Large power transformer capacity 50 MVA to 1500 MVA, voltage class 110 kV to 1000 kV, insulation class A to H, efficiency not lower than 99%, service life not lower than 40 years. Winding adopts large thick diameter enameled flat copper wire or large thick diameter paper covered enameled flat copper wire, winding type covers cylindrical, disc, spiral, continuous, interleave type. High voltage winding conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3, breakdown voltage 5000 to 8000 V. Low voltage winding conductor width 8.00 to 16.00 mm, thickness 2.50 to 5.60 mm, single root conductor cross sectional area 30 to 120 square mm.
5.2 Large Rectifier Transformer and Electric Furnace Transformer
Large rectifier transformer is the core equipment of electrolytic aluminum, electrolytic copper, electrolytic zinc, chemical chlor alkali and other industries, capacity 5 MVA to 200 MVA, primary voltage 10 kV to 110 kV, secondary voltage 100 V to 1500 V DC, insulation class F or H. Valve side winding current is very large, single phase rectifier transformer valve side current can reach 10000 to 50000 A, adopts large thick diameter enameled flat copper wire or large thick diameter copper foil, conductor width 10.00 to 16.00 mm, thickness 3.00 to 5.60 mm. Large electric furnace transformer capacity 5 MVA to 200 MVA, primary voltage 10 kV to 110 kV, secondary voltage 100 V to 1500 V, insulation class F or H.
5.3 Large Special Transformer
Large prefabricated substation capacity 1000 kVA to 50000 kVA, voltage class 10 kV to 35 kV, insulation class F or H, efficiency not lower than 99%. Large traction transformer capacity 10 MVA to 100 MVA, primary voltage 110 kV or 220 kV, secondary voltage 27.5 kV, insulation class A or F, service life not lower than 30 years, winding adopts large thick diameter enameled flat copper wire. Large reactor capacity 100 kVA to 100000 kVA, voltage class 0.4 kV to 1000 kV, insulation class F or H, winding adopts large thick diameter enameled flat copper wire.
6 Large Thick Diameter Enameled Wire Application in Mining Metallurgy and Marine
6.1 Mining Metallurgy Equipment
Mine hoist capacity 1000 kW to 10000 kW, voltage 6 kV or 10 kV, insulation class H or C, efficiency not lower than 96%, service life not lower than 30 years. Hoist motor stator winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3. Rolling mill main drive motor capacity 3000 kW to 15000 kW, voltage 6 kV or 10 kV, insulation class H 180 degrees Celsius, rolling mill motor stator winding adopts large thick diameter enameled flat copper wire, needs to withstand frequent start stop, rapid acceleration deceleration, impact load, overload operation and other harsh working conditions.
Mining variable frequency motor capacity 500 kW to 5000 kW, voltage 6 kV or 10 kV, insulation class H or N, stator winding adopts large thick diameter enameled flat copper wire, varnish film has strong partial discharge resistance, variable frequency pulse voltage resistance. Metallurgy special motor covers continuous casting machine motor, rolling mill auxiliary motor, roller table motor etc., adopts large thick diameter enameled flat copper wire as stator winding, efficiency not lower than 96%, service life not lower than 30 years.
6.2 Marine Propulsion and Rail Transit
Marine propulsion motor capacity 5000 kW to 50000 kW, voltage 6 kV to 15 kV, insulation class H or C. Marine propulsion motor stator winding adopts large thick diameter enameled flat copper wire, conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm, varnish film thickness grade 2 to 3. Marine environment salt fog, humidity, vibration, shock, oil mist puts higher requirements for enameled wire salt fog resistance, humidity heat resistance, chemical corrosion resistance, vibration resistance, shock resistance performance.
Rail transit traction motor capacity 300 kW to 1500 kW, voltage 1.5 kV to 3 kV DC or 25 kV AC, insulation class H or C. Stator winding adopts large thick diameter enameled flat copper wire or enameled round copper wire, winding type covers distributed, hairpin, rectangular flat wire winding. Traction transformer capacity 5 to 50 MVA, primary voltage 25 kV or 27.5 kV, secondary voltage 1.5 kV or 3 kV.
6.3 Other Heavy Industry Equipment
Shield machine drive motor capacity 500 kW to 3000 kW, voltage 6 kV or 10 kV, insulation class H 180 degrees Celsius, stator winding adopts large thick diameter enameled flat copper wire. Heavy crane motor capacity 100 kW to 3000 kW, voltage 380 V to 10 kV, insulation class F or H, stator winding adopts large thick diameter enameled flat copper wire. Cement mill motor capacity 1000 kW to 10000 kW, voltage 6 kV or 10 kV, insulation class F or H, stator winding adopts large thick diameter enameled flat copper wire. Large water pump motor, fan motor, compressor motor all adopt large thick diameter enameled flat copper wire, efficiency not lower than 96%, service life not lower than 30 years.
7 Large Thick Diameter Enameled Wire Selection and Manufacturing Process
7.1 Enameled Wire Selection Principle
Large thick diameter enameled wire selection principle covers conductor specification, varnish film thickness, varnish film system, heat resistance class, insulation class, mechanical strength, environmental adaptability, cost eight major principles. Conductor specification: low current capacity select round conductor, medium high current capacity select rectangular conductor, ultra high current capacity select copper foil or aluminum foil. Round conductor diameter 2.50 to 6.00 mm, rectangular conductor width 5.00 to 16.00 mm, thickness 2.00 to 5.60 mm. Varnish film thickness grade: Grade 0 thinnest, Grade 1 standard, Grade 2 thickened, Grade 3 thickest. Varnish film system: 130 to 155 degrees Celsius select polyester or polyesterimide varnish film, 180 degrees Celsius select polyesterimide or polyamideimide varnish film, 200 to 240 degrees Celsius select polyamideimide or polyimide varnish film. Heat resistance class: F class select MW 5-C or MW 27-C, H class select MW 7-C or MW 35-C, N class select MW 8-C or MW 36-C, R class select MW 10-C or MW 60-C. Breakdown voltage at least 3 times working voltage above.
7.2 Enameled Wire Winding Design
Large thick diameter enameled wire winding design covers bar, basket, lap winding, wave winding, continuous, interleave, spiral seven major types. Bar type winding suitable for large generator, large motor stator winding, single bar 1 to 10 turns, single root conductor cross sectional area 25 to 120 square mm, coil length 5 to 15 meters, coil weight 50 to 500 kg. Basket type winding suitable for large generator stator winding, single root conductor cross sectional area 25 to 80 square mm. Lap winding suitable for large induction motor, large DC motor armature winding. Wave winding suitable for large DC motor armature winding. Continuous winding suitable for large power transformer winding, each disc 1 to 30 turns, single root conductor cross sectional area 10 to 120 square mm, high mechanical strength, good electrical performance. Interleave winding suitable for 110 kV and above large power transformer high voltage winding. Spiral winding suitable for large power transformer low voltage winding, large rectifier transformer valve side winding, each disc 1 to 30 turns, single root conductor cross sectional area 30 to 150 square mm.
7.3 Enameled Wire Manufacturing Process and Application Precaution
Large thick diameter enameled wire manufacturing process covers conductor drawing, varnish film coating, varnish film baking, varnish film detection four major links. Conductor drawing: round conductor adopts multi mode continuous drawing machine, single mode compression rate 15 to 25%, conductor diameter precision plus minus 0.01 to plus minus 0.03 mm. Flat conductor roller adopts precision roller machine set, flat wire width precision plus minus 0.05 to plus minus 0.10 mm, thickness precision plus minus 0.02 to plus minus 0.05 mm. Varnish film coating adopts multiple coating multiple baking process, coating number 4 to 12 times, baking temperature 400 to 600 degrees Celsius. Varnish film thickness grade 1 to 3, varnish film uniformity plus minus 0.005 to plus minus 0.015 mm. Varnish film detection covers conductor diameter, varnish film thickness, varnish film adhesion, breakdown voltage, insulation resistance, scratch resistance, thermal shock resistance, softening breakdown eight categories.
Application precaution: storage temperature 5 to 35 degrees Celsius, relative humidity 30% to 70%, storage period not exceeding 1 year. Winding tension control precision plus minus 0.5 to plus minus 1 Newton, winding speed control precision plus minus 1 to plus minus 5 rpm. Assembly should avoid mechanical impact, avoid varnish film damage, lead welding should adopt silver copper welding or TIG welding. Regular inspection, regular cleaning, regular test, regular maintenance, inspection period not exceeding 1 year, cleaning period not exceeding 6 months.
8 Summary
Large thick diameter enameled copper wire application in heavy industry equipment covers large generator, large motor, large transformer, large reactor, mine hoist, rolling mill main drive, marine propulsion motor, shield machine drive, rail transit traction, cement mill, heavy crane eleven major categories typical application, is the key irreplaceable raw material for heavy industry equipment winding.
Large thick diameter enameled wire technical advantage reflects in six dimensions: large current capacity, high mechanical strength, high heat resistance class, high insulation reliability, high winding efficiency, service life up to 20 to 40 years. Varnish film system covers polyester, polyesterimide, polyamideimide, polyimide, composite coating, corona resistant varnish film, variable frequency resistant varnish film eight major categories, heat resistance class covers 105 to 240 degrees Celsius, accelerated aging service life 200 degrees Celsius 6000 to 50000 hours. With heavy industry equipment developing towards large scale, high voltage, high efficiency, high reliability direction, large thick diameter enameled copper wire application technology in heavy industry equipment will be further improved, providing solid support for heavy industry high quality development.
Reference standards: IEC 60317-0-1 to 60317-86 enameled wire standard / IEC 60034-1 to 60034-30 rotating electrical machine / IEC 60076-1 to 60076-11 power transformer / IEEE 522 / UL 1446 / GB/T 6109 / JB/T 4074 / NEMA MW 1000-2018.
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