“The rotary machine sector is having to adapt to the EU's new chemical restrictions”
Regulatory context and need to redesign insulation systems
Changes to European regulations on chemical substances mean that mica-epoxy insulation systems in the windings of electrical machines need to be redesigned. TECNALIA is making its testing facilities available to validate the reliability of new dielectric materials.
The rotating electrical machine industry faces a major challenge
The rotating electrical machine industry (high-power motors and generators) faces a critical challenge as far as materials are concerned. Mica-epoxy insulation systems, which are the industry standard due to their high thermal and dielectric strength, are under scrutiny as a result of European chemical safety directives, particularly under the REACH Regulation.
Impact of the REACH Regulation on materials
The European Union’s goal is to phase out the use of hazardous chemical substances in industrial processes. In the case of winding insulation, the impact mainly concerns the components of epoxy resins and hardening agents, some of which are being restricted or classified as substances of very high concern (SVHC).
Implications for manufacturers
The REACH Regulation requires manufacturers of rotating machines to:
- Replace the chemical formulations of epoxy resins with alternatives that do not contain restricted substances.
- Redesign the impregnation and curing processes to ensure that the new materials continue to provide the adhesive and mechanical strength required.
- Ensure that the new compounds do not compromise the service life of windings when subjected to electrical and thermal stress.
Any changes to the chemical composition of mica-epoxy insulation could drastically affect the equipment’s ability to withstand partial discharges, thermal stress and mechanical vibration. A fault in the new formulation of insulation could lead to internal short circuits and the complete failure of the machine.
Therefore, the validation of these new developments is not optional, but a critical safety requirement.
We guarantee reliability in the transition between materials
Against this backdrop, TECNALIA has positioned itself as a key technology partner to help manufacturers of electrical machines transition to materials that comply with European regulations without compromising the quality of these products.
We have made our state-of-the-art testing facilities available to the industry to validate new insulation systems:
- Dielectric Strength and Partial Discharge Tests: to verify that the new resin has retained its insulating properties and has no critical ionisation points.
- Accelerated Thermal Ageing Tests: to ensure that the replacement of chemical components will not reduce the service life of windings under real operating conditions.
- Mechanical and Adhesion Tests: to verify that the mica and new epoxy matrix can withstand the mechanical stresses and vibrations typical of rotating machines.
These capabilities enable the electrical industry to meet the European Union’s environmental and health requirements, ensuring that innovation in materials translates into safe, efficient, fully certified equipment that is ready for the market.