Insulation Systems of Power Transformers

Conference on Electrical Power Equipment Diagnostics Bali, Indonesia Thomas Prevost

Figure 1.10 - Gaulard and Gibbs secondary generator, forefunner to the transformer. The original British patent is dated 1882. (courtesy of the Smithsonian Institution).

Early insulation materials were composed of cotton rags dipped in varnish.

Figure 1.12 - Stanley and his original converter, now known as a shelltype transformer. (Courtesy of General Electric Co., Men and Volts).

Large Power Transformer Materials

(reference 250 MVA Transformer)

Material Core Steel Sheet Steel Copper Wire Transformer Oil Kraft Pressboard Paper Total
Ref. ABB

Weight (kg) 67165 45573 24228 48000 5294 1479 200,000

% 34 22 12 24 2.65 .74

Transformer Oil
Provide Sufficient Dielectric Strength. Provide Sufficient Cooling/Heat Transfer. Minimize the contact of oxygen with cellulose and other materials susceptible to oxidation. * Information Carrier*
DGA, Oil Quality Tests

Transformer Oil
Types: Mineral Oil Naphthenic Paraffinic High Molecular Weight (R-Temp) Ester Synthetic Natural Silicon

Transformer Oil
Key properties: Low viscosity Low pour point High flash point Chemical stability High electrical strength

Typical Properties of Dielectric Fluids

Conventional Transformer Oil Viscosity, D445, cSt. @ 100 C: Density @ 20 C., kg/dm : Appearance: Pour Point, D97, C.: Dielectric Breakdown, D1816 (.08), kV: Dissipation Factor 100 c, D924: Dielectric Constant, D924 @ 20 C: Neutralization Number, D974, mg KOH/g: Fire Point, ASTM D92, C.: Biodegradability (per BOD tests): 3.0 0.86 yellow -40 56 0.007 2.2 0.02 165 some Silicone Fluid 16.0 0.91 clear -55 60 0.001 2.7 0.01 320 no (RTemp) High Molecular Weight Petroleum 14.5 0.86 yellow -21 56 0.001 2.3 0.01 308 yes Natural Ester 15 0.83 clear -10 52 4.0 3.0 0.06 300 yes

Solid Insulation
Function: Dielectric - Control Applied Voltage Mechanical - Support the Winding Thermal - Create Cooling Ducts

Solid Insulation
Primary insulation material used today continues to be cellulose, typically processed using the Kraft method. Paper Conductor Insulation Pressboard Winding forms Conductor Spacer Material Barriers Clamping

Cellulose Insulation Is a Renewable Resource

Solid Insulation

Barriers, Spacers, Clamps

Winding Insulation

ref. Weidmann Insulation Model

Conductor Insulation
Type Non-Creped Calendared Crepe % Elongation 2-4 8-12 Use Winding Cu Winding Cu CTC Leads

Crepe

50-200

Insulation Life
The thermal limit of transformer windings is the insulation on the conductor at the winding hot spot. The average winding rise is calculated as follows: IEEE C57.12.00 Ambient Average Wndg Rise Hot Spot Differential Hot Spot Temperature 55 C Rise 30 55 10 95 65 C Rise 30 65 15 110 *

* Only attainable with thermally upgraded insulation.

Thermal Upgrading Process:

Addition of chemicals to protect the cellulose from oxidation: this is primarily achieved with nitrous compounds such as urea, melamine, dicyandiamide, and polyacrylamide.

Cellulose Molecule

Single Glucose Ring

Amine Addition - Dicyandiamide Chemical Additive to paper. Consumes water as it is produced. Neutralizes acids as they are produced.
(ref Lundgaard)

Suppresses the self-catalyzing character of aging process by chemical reaction. During this process the stabilizing agent is consumed.

Aging Curves
Thermally upgraded paper Regular Kraft paper

Aging Curves

(Paper severely aged below this line)

Source: Westinghouse/ABB Brochure on Insuldur

Degree of Polymerization
Measurement of intrinsic viscosity after dissolving the cellulose in a specific solvent. Gives an average measurement of the number of glucose units per molecular chain. DP of Insulation Components prior to processing DP of Insulation Components following processing DP level considered as over-processed ~800 DP level considered end of life ~200 ~1200 ~1000

Degree of polymerization = measurement of n.

Paper Insulation Aging in Mineral Oil

DP 1000

DP 733

DP 549

DP 405

DP 309

DP 181

Progressive aging with time

End of mech str.

Brittle & dark

Effects of aging: - darkening of color - loss of electrical and mechanical strength; trans. failure - shortening of cellulose chains DP lowered - paper becomes wetter, and acidic IEEE Transformer Committee Panel Session October 25, 2005 - by-products contaminate the oil Source ABB Power Technologies, Inc.

Transformerboard Mechanical Role

Support Windings During Short Circuits Maintain Dielectric Clearances Support High Voltage Leads Support Auxiliary Equipment - LTC, DETC, Bus Bar etc.

Transformers Forces

Core

Outer Winding

Inner Winding

Radial Forces

Axial Forces

F Clamping Pressure = f(moisture,temperature,age)

F

pressboard presspaper copper

transformer winding coil

F
rigid clamping distance

Cellulose Insulation - Dielectric

Excellent Dielectric Insulator - H2 O < 0.5% by weight Low Dissipation Factor High Volume Resistivity Low Dielectric Constant

Insulation Strength Configurations For Distances a and b

Insulation Strength
Turn to Turn (impulse and 60 cy)
60 Hz.RMS & Impulse Design Voltage (KV)

1000 t = 0.2 sec 100 t = 1.0 sec FW 1.2 x 50 sec 60 cy

10

1 0 1 2 3 4 Turn to Turn Insulation Thickness (b)

t measured at 75% of crest

Insulation Strength
Coil-Coil (Impulse and 60 cy)
1000 t = 0.2 sec

Breakdown Voltage (kV)

t = 1.0 sec t = 3.0 sec FW 1.2 x 50 sec 60 Cycle

100

10 0 5 10 15 20 Coil-Coil Spacing "a" (mm)

t measured at 75% of crest

Electrical Strength of Transformer Oil

Partial Discharge - Inception Field Strength (kV/mm)

100

10

1 0.1 1 10
Oil Duct Width (mm)

100

1000

Degassed Oil, Non-Insulated Electrode Degassed Oil, Insulated Electrode

Creep Stress Analysis

Typical Creep Stress Areas

Creep Strength of Transformerboard

100

Gradient (kV/mm) - RMS-60 Hz.

10

Creep Strength

1 0.1 1 10 100 1000 Creep Path Length (mm)

High Moisture Content in Insulation Can Cause:

Accelerated Aging of the Cellulose Significant Reduction in Dielectric Strength Bubble Formation and Dielectric Failure Partial discharges in the Insulation Dry = Cellulose < 0.5% by weight & Oil < 10 ppm H2O

Other Insulation Materials

Aramid papers and pressboards
Advantage: High temperature rating (220 C) Good dielectric strength Excellent mechanical strength Low moisture content Disadvantage: Higher relative cost

Hybrid Insulation System with NomexTM

10%-50% Increase in MVA

 IEEE Std. 1276-1997 Guide for the Application of High-Temperature Insulation Material in Liquid Immersed Transformers recommends:
A max. copper rise of 950 C A max. hot spot temp. of 1700 C A max. top oil temp. of 1050 C

What parts are Nomex ?

Conductor Wrap Key spacers and sticks Tap and Lead shields FOA barriers (zig-zags) Crepe tape on leads, etc.

What other High Temperature Issues ?

Bushing capacity Tap changer capacity Oil Expansion Cable capacity Stray flux heating High temperature adhesives Gaskets, Gauges and Relays

Thank You for Your Attention