The Use of Low Frequency Heating Techniques in

the Insulation Drying Process for Liquid Filled

Small Power Transformers
By: John Bosiger, Manufacturing Support Manager
ABB Power T& D Company Inc.
Effectively removing the moisture from the cellulose

drying process equipment, has developed a new LFH process

insulation is a key process in the production of power

for

transformers and to ensuring the trouble-free operation of the

manufactured in South Boston, Virginia. This process was

power transformer for years of service. The quality of the

developed to meet South Bostons very stringent drying

drying of the insulating material is critical in meeting

requirements for small power transformer core and coil

dielectric requirements and assuring trouble free service for

assemblies that are processed in their own tanks with the

users. Through the many years of operation the oil/paper

transformer tank serving as a vacuum chamber.

ABB

Liquid

Filled

Small

Power

Transformers

dielectric system suffers a certain amount of aging depending

on the amount of moisture left in the cellulose insulation after

The concept of using AC current for drying transformer

manufacture. For example cellulose paper with 4 % moisture

insulation materials is not new.

content ages at 20 times that of cellulose paper with 0.5 %

engineers in the Sharon, Pennsylvania plant developed a

moisture. The generated aging products, such as acids, water,

proposal that was described as a new process for drying

decomposition gasses, etc., exercise a negative effect on the

cellulose insulation in oil filled distribution transformers by

insulation and depending on the degree of aging and moisture

employing internal heat and vacuum.

content can reduce the originally dielectric, thermal and

using such a system on large power transformers were made

mechanical properties of the oil/paper insulation system.

in the intervening years but were not successful due to

Various techniques have been utilized over the years,

problems associated with temperature supervision and long

including hot air circulation ovens and vacuum chambers for

heating cycles, particularly where heavy and thick insulation

distribution and small power transformers and solvent vapor

pieces were involved. The same problems do not arise, or if

phase for large power transformers. While this method of

ever only to a minimized extent because small power

drying using ovens and vacuum for distribution and small

transformers incorporate thin insulation systems compared to

power transformer has proven satisfactory, new technology

large power transformers. In 1982 engineers at EB National

developments have provided a much improved process of

Industri in Norway developed the predecessor of the system

removing water from the transformers cellulose insulation

currently installed in South Boston using a 20 & 50 hertz

and improving the quality of the transformer.

Micafil

supply. In 1988 Micafil took over the entire Low Frequency

Vakuumtechnik AG of Zurich, Switzerland, a pioneer in the

Heating technology from ABB National Industri. (In 1988

development and manufacture of a Low Frequency Heating

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In 1963 Westinghouse

Other attempts at

both EB National Industry and Micafil were ABB

companies.)

The low frequency converter used is a variable frequency

constant voltage output supply designed to heat for 20

The question is always asked why use low frequency (1

periods with each period equal to 1 cycle of the frequency

hertz) instead of 50/60 hertz current. To understand why low

converter (1 hertz). Since the low frequency supply is a

frequency current is used, we need to review the equivalent

constant voltage supply (16 fixed steps from 10 volts 800

electrical circuit of the transformer when connected for low

volts) the current decreases as the resistance heats so it is

frequency heating. The secondary winding is shorted

necessary to vary the effective heating current without

circuited and low frequency current is applied to the primary

changing voltage taps. This is accomplished by controlling

terminals of the transformer. The attachment THE

the low frequency converters number of firing periods to be

WORKING PRINCIPLE of low frequency heating drying

less than 20; therefore the effective heating current for

shows the electrical characteristics of the transformer. At low

heating the transformer windings is calculated as:

frequencies the resistance component of the transformer is

Effective heating current = Sq. Rt. (heating periods

almost equal to the impedance because the reactive

used/20) x Current for 1 period.

component is negligible .The required voltage to circulate

This way the current can be varied to achieve the desired heat

rated current through the windings is equal to 1/60 of the

rate of 1 degree/minute.

impedance voltage and the required wattage to heat the

Attached is a START UP TRANSFORMER DATA

windings is also reduced. The voltage needed to circulate

control screen that shows the transformer parameters that are

rated current or a percentage of rated current with the

used in determining the time requirements of the LFH

converter is:

processs different phases. When the transformer is ready for

Required Voltage = Rated Voltage x (%R/100) x

LFH drying, the transformer parameters are retrieved from

the design data across the facility computer network. These

(CF1/100) x 1.414
%R - % Resistance calculated from transformer

are the parameters needed for the LFH drying of this

transformer. The time of each of the LFH phases is set by

losses.
CF1 - % of rated current needed to heat the

such parameters as: 1) The pounds of cellulose insulation in

the transformer 2) Voltage rating of the primary winding 3)

transformer.

Current Densities of each winding and 4) Type of material of

1.414 Converter gain.

More importantly by using a low frequency supply the

each winding. Each individual transformers LFH process

voltage can be maintained low enough so that during the fine

cycle time is controlled by these parameters so that the proper

vacuum the windings can be heated with low frequency

drying is accomplished with the minimum amount of time.

current at the same time as pulling a vacuum on the

During the LFH drying process all of the key measured

transformer tank and avoid flash over in the insulation. In

process parameters such as: 1) Winding temperatures 2)

order to effectively remove moisture from inside the

Vacuum levels 3) Voltage 4) Current and 5) Moisture

windings you must have a high temperature (120 degree

extraction rate are trended on a time based trending chart as a

centigrade) and a low vacuum (.2 millibars). As the moisture

record of the process and also for future reference.

is removed the temperature drops so with the low frequency

heating current applied during the fine vacuum phase the

The Low Frequency Heating process consists of a multi-

temperature in the windings can be maintained at 120 degree

step circulating hot air heat, electric heating at 1 hertz and

centigrade.

vacuum as can be seen in the attached LFH PROCESS

chart. The LFH PLANT LAYOUT shows a layout of the

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components that make up the processing plant. The

average

transformer is completely sealed, helium leak tested and

resistance), the temperature stabilization time is to

connected for LFH processing (See attached pictures of the

allow the windings temperature time to equalize

transformer connected to the LFH process system.). The

throughout all of the winding and the insulation

following connections are performed prior to starting the

parts not in contact with the windings time to come

process:

to temperature.
1) The 1 hertz electrical supply leads are
connected to the HV terminals.

winding

temperature

measured

by

The speed of heat up must be limited to 1

degree/minute because of the high moisture content

2) The LV terminals are shorted with a copper

in the insulation so as to limit the depolymerization

short of sufficient size to safely carry the short

of the cellulose insulation and to ensure that the non-

circuit current.

coil insulation parts are properly heated.

3) The tank is grounded to the 1 hertz supply.

4) The vacuum and hot air pipes are connected to

Step 3: IPL 1 PHASE.

After the stabilization time has expired and the

the transformer cover.

5) The fluid level gauge used to indicate when the

transformer windings have been reheated to 100

degree centigrade, a hard vacuum is pulled on the

tank is full is connected.

6) The fluid fill line is connected to the

transformer tank. During this process a high

percentage (75%) of the total moisture is removed

transformer drain valve.

from the insulation. The voltage class and the

pounds of cellulose insulation in the transformer set
LOW FREQUENCY HEATING PROCESS: See the LFH

the IPL vacuum phase length. The purpose of this

PROCESS chart.

vacuum phase is to remove the evaporating moisture

driven from the cellulose insulation by the heat so

Step 1:

MEASUREMENT/LEAK TEST PHASE.

the moisture with not condense on the transformer

A vacuum leak test is performed on the

core.

transformer tank and the initial cold resistance of the

HV and LV windings is measured and stored along

Step 4: HEAT UP /STABILISATION PHASE 2.

The vacuum is released and the transformer tank

with the ambient temperature.

is raised to atmospheric pressure with the aeration

valve.

Step 2: HEAT UP /STABILISATION PHASE 1.

Low frequency electrical

current and

With the transformer tank at atmospheric pressure

circulating hot air heat the transformer windings to a

with the aeration valve open, the transformer

temperature of T11 (110 degree centigrade average

windings are heated by the low frequency current

winding temperature measured by resistance). The

circulating

windings.

primary and secondary winding temperature are

Simultaneously, dry hot air (125 degree centigrade)

determined by measuring the winding resistance. If

is circulated through the tank to preclude a

the primary winding temperature is less than 110

condensation build up in the tank and to heat up the

degree centigrade, the primary winding is heated

non-coil insulation parts. After reaching the average

with a D.C. current from the converter until the

winding temperature T1 (100 degree centigrade

primary winding is heated to 110 degree centigrade.

in

the

transformer

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It is important to heat the primary winding to 110

expired and the final vacuum has been maintained at

degree centigrade because it has the highest voltage

.2 millibars for the desired time. At this point the

class and contains the thickest insulation. After

low frequency current is removed and the water

reaching the average winding temperature of 110

extraction rate meter takes vacuum samples until the

degree centigrade, there is another temperature

water extraction rate meter determines the desired

stabilization time to allow the windings temperature

level of dryness of the insulation is obtained.

time to equalize throughout all of the windings and

FLUID FILLING PHASE

the insulation parts not in contact with the windings

Step 7:

time to come to temperature.

with heated insulating fluid under vacuum until the

After this phase the circulating air will not be used

fluid level gauge determines the tank is full.

and if the vacuum level needs to be adjusted it is

AERATION PHASE

done with dry nitrogen so that there is no chance that

Step 8:

moisture can enter the tank

During this phase the transformer tank is filled

After the fluid filling process is complete, dry

nitrogen is introduced into the tank to pressurize the

unit to 2 PSI.

Step 5: IPL 2 PHASE

After the stabilization time has expired and the
transformer windings have been reheated to 110
degree centigrade, a second hard vacuum is pulled
on the transformer tank. At this stage of the LFH
process, the majority of the moisture has been
removed from the insulation. The IPL 2 phase is

A key to the success of any operation is the

ability to monitor and control the process. The new
automatic Low Frequency Heating equipment
functions are computer controlled throughout the
drying process. The input voltage and current of the
Low Frequency Heating equipment is controlled to

equal in time to IPL 1 phase.

affirm that proper loading is being applied to the

coils. The high voltage and low voltage winding

Step 6: EV PHASE
The vacuum is pulled to 30 millibars and then the
winding temperature is heated to T25 (120 degree
centigrade average winding temperature). The
primary and secondary winding temperatures are
determined by measuring the winding resistance. If
the primary winding temperature is less than 120
degree centigrade, the primary winding is heated
with D.C. current from the converter until the
primary winding is heated to 120 degree centigrade.
Step 7: FINE VACUUM PHASE

temperatures and the vacuum level are continuously

monitored to insure that the process is optimized.
The continuous temperature measurements also
prevent the overheating of the insulation and will
automatically stop the process if any winding
exceeds its maximum allowed temperature. A water
extraction meter, that is place in the vacuum exhaust
line, is the final determination that the insulation is
dry.
The advantages of

The average winding temperature is maintained at

120 degree centigrade with the low frequency

Frequency Heating insulation drying process used in

South Boston are:

current while the vacuum on the tank is continued to

be pulled until the fine vacuum process time is

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the new automatic Low

691
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1.

State-of-the-art

computer

controlled

process

until the desired temperature heat up rate of rise is

monitoring and measuring equipment is used to

achieved or the maximum allowed current is

continuously monitor the currents, voltages and

reached.

resistances with automatic shut off if a deviation

occurs. The advanced control and measuring system
performs

extremely

accurate

6.

The lowest possible voltage to avoid flash over in

temperature

the insulation is possible using the low frequency

determination in the HV and LV windings and

converter. This allows the heat up of the windings

automatic verifies the correctness of the input

with low frequency current while simultaneously

transformer

being exposed to a strong vacuum.

data by comparing measured

to

calculated values. The monitoring system allows the

ability to trend all of the process parameters as a

7.

quality assurance record or for future reference.

2.

Vast improvement in the quality of the transformer

The most efficient use of energy to dry the

transformers insulation.

8.

The low frequency heating process insures a low

insulation is achieved by using the low frequency

depolymerisation of the cellulose insulation by

heating process to dry the cellulose insulation as

removing the majority of the moisture in the HEAT

compared to the conventional transformer insulation

UP 1 and IPL 1 while the winding temperature is

drying systems. The insulation is dried in its own

100 degree centigrade so that the cellulose insulation

tank and is never exposed to the atmosphere after it

is almost dry before been exposed to the higher

is dried. After most of the moisture is removed,

drying temperatures.

nitrogen is used to adjust the vacuum levels. After

the transformer is filled with its fluid, nitrogen is
used to pressurize the tank.

CONCLUSION:
The low frequency transformer insulation drying

3.

The windings are heated uniformly throughout the

process that has been in use at ABB Power T&D

drying process, assuring that the insulation deep in

Co.s Small Power Liquid Filled Transformer plant

the windings achieve a temperature that promotes

since 1996 has proven to be very successfully in the

moisture removal during the vacuum cycle.

removal of the moisture from the cellulose

insulation and insuring that the insulation power

4.

The continuous monitoring of the moisture of the air

factor is consistently under 0.5 %.

in the vacuum exhaust during the fine vacuum phase

assures that the insulation is dry upon the
completion of the process.

Attachments:

5.

The drying process cycle time is reduced by up to

THE WORKING PRINCIPLE OF LOW FREQUENCY

HEATING.

60% compared with the conventional oven and

START UP TRANSFORMER DATA

vacuum method. The automatic computer control

PICTURES OF CONNECTED TRANSFORMERS

system optimized the LFH process by having the

LFH PROCESS

controls automatically change the heating current

LFH PLANT LAYOUT

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