Electrical machine coil insulation system and method

An electrical machine formed coil insulation system, comprising:

• turn insulation comprising at least one layer of a mica-containing tape disposed over each successive turn of substantially the entire formed coil;
• multi-layer of mica ground wall insulation comprising at least one layer of a mica-containing tape disposed over multiple turns of substantially the entire coil, wherein the multi-layer comprises a mica-containing overlap of a mica-containing tape;
• slot corona suppression insulation disposed over the ground wall insulation of at least slot cell cavity sections of the coil and extending beyond ends of a core of the machine;
• voltage grading insulation disposed over at least a portion of the slot corona suppression insulation and extending beyond the slot corona suppression insulation at ends of the coil;
• and
• armor insulation disposed over ends of the coil and at least a portion of coil leads, wherein the turn insulation and the multi-layer of mica ground wall insulation extend over the slot cell sections of the coil, and wherein the slot cell sections of the coil are configured to be disposed in a slot cell of the electrical machine, wherein the mica ground wall insulation comprises at least 160 gm/m2 of mica, and wherein the mica-containing tape is wound in ½ lap width overlap at a tension of between 16 to 18 ft-lbs wherein the coil comprises conductors having a gauge sized for operating at between approximately 6,900 and 16,000 volts.