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350 M. Argin and G.G. Karady: Characterization of Polyurethane Foam Dielectric Strength
ABSTRACT
Internal flashovers in hollow insulation systems can produce serious damage.
Frequently, SF6 or N2 is used to eliminate this problem, but possible gas leakage may
endanger the insulation. This paper proposes the use of polyurethane foams to fill the
hollow spaces in insulation systems. Thus far, few publications deal with the dielectric
properties of foams. This paper demonstrates the dielectric strength of three different
foams which are investigated using ac and lightning impulse voltages under different
humidity and temperature conditions. The results show that polyurethane foams have
2-3 times better dielectric strength than air. The breakdown strength decreases with
the thickness of the foam; temperature and humidity have negligible effects on the
breakdown voltage. The major parameter is the size of the voids in the foam. Reducing
the size of the voids increases the breakdown strength. This can be achieved by
improving the manufacturing technology.
Index Terms — Breakdown strength, impulse voltage, insulation, polyurethane
foam.
4 TEST METHODS
Room temperature 24 °C Room RH 30-36%
The performance of the polyurethane foam has been 36% RH 45% RH 80% RH 24 ºC 40 ºC 60 ºC
investigated through the ac and lightning impulse breakdown Foam
15 15 16 15 15 17
1
tests. Foam
16 26 17 16 15 13
2
The ac breakdown test was conducted according to the IEEE Foam
11 NA 14 11 10 NA
Standard 4-1995 [8]. The test was performed with 60 Hz AC 3
voltages on a flat foam sample using a metal sheet as the
bottom electrode and a standard cylindrical electrode at the
top. The top cylindrical electrode dimensions were 51 mm in 5 TEST RESULTS
diameter and 25 mm in height with the edges rounded to a 6.4
mm radius. The high voltage tests were performed to determine the
A low voltage was applied to the foam sample and raised dielectric strength of polyurethane foam insulation exposed to
slowly with 0.8 kV/sec speed until breakdown. The different humidity and temperature conditions. The AC and
breakdown usually occurred at the edge of the electrode. The lightning impulse tests were conducted with samples that were
breakdown voltage was recorded. exposed to 36% RH, 45% RH, 85% RH and (24 °C), 40 °C,
and 60 °C. Table 4 illustrates the number of tests conducted
The dielectric strength of rigid pour polyurethane foam was with each foam type under different conditions.
also studied with standard positive polarity 1.2/50 lightning
impulses. The breakdown voltage was determined by a The test results are given in Table 4 and Table 5. The Tables
stepwise increase of the impulse voltage, thus applying five exhibit the values for breakdown strength. The strength is the
impulses per step with a 10 seconds time interval between two division of breakdown voltage to the thickness of the sample.
impulses until breakdown.
In general, the breakdown strength of solid insulation
The partial discharge was measured using a Haefely made materials tends to decrease with increasing temperatures and
partial discharge detector. In order to prevent surface humidity [10]; however, that is not true for polyurethane foam
discharges, the foam samples were tested in a vessel filled insulation.
IEEE Transactions on Dielectrics and Electrical Insulation Vol. 15, No. 2; April 2008 353
Table 4. Comparison of ac breakdown test results. The average AC breakdown strength is calculated as 49.7±9.8
kV/cm. The breakdown stress of air insulation, measured with
ac breakdown strength (kV/cm) the same arrangement, is 15 kV/cm. Hence, this foam
Room temperature 24 °C Room RH 30-36 % breakdown stress is about 3 times higher than that of air. The
36% RH 45% RH 80% RH 24 ºC 40 ºC 60 ºC figure shows that the breakdown strength is practically
Foam 36.5 6 53.2 2 55.9 7 37.0 1 54.6 6 44.6 6 independent from the thickness of Foam 1, which possesses
1 the thickness range of 0.7-1.6 cm.
Foam 39.2 7 45.5 3 35.3 6 39.2 7 40.3 8 40.3 5
2 120
Foam NA 44.2 5 40 4.2 44.2 5 51.2 2 NA
3
100
Breakdown Strength(kV/cm)
80
Foam 40
161.2 2 147.7 3 187.8 4 162.1 8 177.5 3 155.3 3
1
Foam
139.6 1 148.5 2 117.6 1 141 1 169.5 2 168.4 2 20
2
Foam
157.3 9 NA 131.9 1 162.3 8 146.9 2 NA
3 0
0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.81.85
Thickness(cm)
The test results reveal that in some cases the strength Figure 5. The ac breakdown strength versus thickness of Foam 2.
decreases, while in other cases it increases. In addition, the
standard deviation of the breakdown voltage is substantial. The breakdown strength decreases due to increasing
The study of void distribution presented before suggests that thickness as shown in Figure 5. All data points are within the
the voids have a major effect on the breakdown voltage [7]. 95% confidence interval except one. The average ac
breakdown strength is calculated as 39±7.0 kV/cm. This foam
During the tests, the partial discharge was measured as the breakdown stress is about 2.6 times higher than that of air.
voltage increased. The samples were immersed in oil, which
eliminated the surface discharge. The significant finding is
120
that partial discharge was not observed during the increase of
voltage.
100
80
TEST RESULTS
The test results show that the effect of humidity and 60
temperature on the breakdown strength of polyurethane foam
is small compared to the internal voids produced in variation 40
of the breakdown voltage.
20
120
0
100 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
Thickness(cm)
80
280 300
260 280
260
240
240
Breakdown Strength(kV/cm)
Breakdown Strength(kV/cm)
220
220
200
200
180
180
160
160
140 140
120 120
100 100
80 80
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6
Thickness(cm) Thickness(cm)
Figure 7. Lightning impulse breakdown strength versus thickness of Foam 1. Figure 9. The lightning impulse breakdown strength versus thickness of Foam
3.
There are no outliers. The average lightning impulse 7 DISCUSSION OF THE RESULTS
breakdown strength is calculated as 166.2±37.3 kV/cm. The
breakdown stress of air insulation, measured with the same 7.1 EFFECT OF TEMPERATURE
arrangement, is 55 kV/cm. This foam breakdown stress is It is believed that temperature does not affect the breakdown
about 3 times higher than that of air. stress of gases in the 20 – 100 °C range. However, an increase
in temperature may decrease the breakdown stress of the solid
part of the foam. ESEM investigation revealed that voids
300
composed of gases occupy 50%, 90%, and 70% of Foam 1,
Foam 2, and Foam 3, respectively. If a breakdown initiates in
250
the voids and the temperature does not affect the breakdown
stress of gases there, then the temperature effects on the foam
Breakdown Strength(kV/cm)
Figure 8 shows that the lightning impulse breakdown EFFECT OF FOAM DENSITY AND VOIDS
strength of Foam 2 decreases with thickness. All data points Foam 1 has the highest breakdown strength. It also has the
are within the 95 % confidence interval except for one highest density and smallest average void diameter. In
outlier. The average breakdown strength is 147.9±28.8 addition, voids only occupy 50% of the foam.
kV/cm. This foam breakdown stress is about 2.7 times
higher than that of air. Foam 2 has the lowest breakdown strength along with the
lowest density and a significantly greater average void
In Figure 9, the lightning impulse breakdown strength of diameter. In addition, voids occupy 90% of the foam.
Foam 3 decreases rapidly with increasing thickness. All
points are within the 95% confidence interval. The average Foam 3’s breakdown strength is in between that of Foam 1
lightning impulse breakdown strength is calculated as and Foam 2. Foam 3 has the second lowest density with voids
144.2±20.7 kV/cm. This foam breakdown stress is about 2.6 occupying 70% of the foam.
times higher than that of air. The standard deviation is much
less than that of found for Foam 1 or Foam 2, as in the ac These findings show the relationship between the
test. breakdown voltage and foam density as well as void size and
IEEE Transactions on Dielectrics and Electrical Insulation Vol. 15, No. 2; April 2008 355
void distribution. Foam with a higher density, smaller voids, The high density foams, with smaller void diameters,
and less void distribution is expected to have larger electric have higher breakdown stress.
breakdown strength. Therefore, high density foams should be The test indicated that isocyanic acid foam is better
used for electric insulation. than polymeric diisocyanate foam.
The foam breakdown stress is about 3 times higher
DIELECTRIC BREAKDOWN HYPOTHESIS than that of air under similar conditions.
The temperature and humidity effects are negligible
The breakdown behavior of porous dielectrics and solid
in the 0-100% RH and 20-60 °C range.
insulation materials has been studied by many authors [11,
12]. Partial discharges, one of the main factors that have
The overall average ac breakdown strength is calculated as
major impact on the breakdown mechanism of solid insulation
49.7±9.8 kV/cm, 39±7.0 kV/cm, and 44.7±6.3 kV/cm for
materials, has also been studied [13-15]. The influence of the
Foam 1, Foam 2, and Foam 3, respectively.
void parameters upon the induced charges due to partial
The overall average lightning impulse breakdown strength is
discharges for spheroidal voids was discussed. It was noted
calculated as 166.2±37.3 kV/cm, 147.9±28.8 kV/cm and
that the void orientation with reference to the applied field has
144.2±20.7 kV/cm for Foam 1, Foam 2, and Foam 3,
most important effect on induced charges in addition to void
respectively.
location, geometry and dimension, void gas pressure and
composition [13, 14]. In another study, decay of charge
accumulated by partial discharges deposited on the wall of a 9 ACKNOWLEDGEMENT
gaseous void due to surface currents at the void wall was We gratefully acknowledge the use of facilities within the
studied [15]. The paper concludes that the decay rate is Center for Solid State Science at Arizona State University.
significantly reduced by an increase in the permittivity of the
bulk medium.
10 REFERENCES
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breakdown mechanisms in porous dielectrics and solid Boca Raton, FL, USA, 1999.
[2] D. Koenig, H.J. Heller, B. Bayer and P. Westbrock, “PUR-Hard
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Hard-foam Insulation under Short-Time HV Stress”, IEEE Trans.
the voids than in the solid part of the foam. The increase Electr. Insul., Vol. 24, pp. 239-248, 1989.
in voltage generates discharge in the voids, which is then [4] D.Koenig and H.J. Heller, “Breakdown Performance of PUR-Foam
filled with conducting ions. This causes short-circuiting Insulation under AC-Voltage Stress”, Intern. Conf. Properties and
of the voids. The short circuit increases the voltage across Applications of Dielectric Materials, pp. 97-100, 1985.
[5] G.G.Karady, M.Argin, B.Shi, F.Rahmatian and A.H. Rose,
the solid particles. In addition, higher voltages increase “Electrical properties of rigid pour polyurethane foam applied for high
the electric field, which causes secondary short circuits in voltage insulation”, Proc. IEEE Power Eng. Soc. Transmission and
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Foam application for high voltage application” IEEE Conf. Electr.
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Insul. Dielectr. Phenomena (CEIDP), pp. 526-529, 2004.
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[8] IEEE Std 4-1995: “IEEE Standard Techniques for High-Voltage
voids independent of the void location and size. Because Testing” , 1995.
of the more-or-less uniform distribution of the electric [9]ASTM Standard Practice for Maintaining Constant Relative
field in the voids, we assume that the discharge starts Humidity by Means of Aqueous Solutions, ASTM Standard 104-02,
simultaneously in all voids; this suddenly increases the 2002.
[10] A. Schwaiger, “Theory of Dielectrics”, John Wiley & Suns, 1932.
electric field and produces an avalanche breakdown. [11] M.G. Danikas, “Discharge studies in solid insulation voids”, IEEE
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8 CONCLUSIONS [13] G.C. Crichton, P.W. Karlsson and A.Pedersen, “Partial discharges
in ellipsoidal and spheroidal voids”, IEEE Trans. Electr. Insul., Vol. 24,
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[15] I.W. McAllister, “Decay of charge deposited on the wall of a
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356 M. Argin and G.G. Karady: Characterization of Polyurethane Foam Dielectric Strength
Mehmet Argin was born in Germany. He received the George G. Karady (SM’70, F’78) received the BSEE
B.Tech degree from Istanbul Technical University and D.Eng. degrees in electrical engineering from the
(ITU), Turkey, in 1997 and the M.S. degree from Technical University of Budapest. Dr. Karady is the
Yildiz Technical University (YTU), Turkey, in 2000. Salt River Project Chair Professor at Arizona State
Between 1998 and 2001, he worked for YTU as a University, where he teaches electrical power and
Research/Teaching Assistant. He is currently pursuing performs research in power electronics, high voltage
his Ph.D. degree in electrical engineering at Arizona techniques, and electric power systems. Previously,
State University. he was with EBASCO Services, where he served as
Chief Consulting Electrical Engineer, Manager of
Electrical Systems, and Chief Engineer of Computer
Technology. Prior to that, he was Electrical Task supervisor for the Tokomak
Fusion Test reactor project at Princeton. He has worked for the Hydro Quebec
Institute of Research as a Program Manager. Dr Karady started his career at
the Technology University of Budapest, where he progressed from a Post
Doctoral Student to Deputy Department Head. Dr. Karady is a registered
professional engineer in New York, New Jersey, and Quebec. He is the author
of more than 200 technical papers. Dr. Karady is active in IEEE, and he was
chairman of the Chapter/Membership’s Award Committee, the Education
committee’s Award Subcommittee, and WG on Non-ceramic insulators of the
IEEE Power Engineering Society. Dr. Karady also served in the US National
Committee of CIGRE as Vice President and Secretary Treasurer.