e-ARWtr2016 transformers

Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

Environmental Protection for Larger Onshore and Offshore Wind Turbine

Transformers

Lorena CEBRIÁN, Rafael MURILLO, Miguel CUESTO

Technology Center for Transformers, ABB
Ctra. de Madrid km 314, 50012 Zaragoza, Spain
e-mail: lorena.cebrian@es.abb.com

Abstract — It is well known that windmill technology for both onshore and offshore applications is under continual
development, leading the size and power rating of each turbine to higher values [1]. Because of this increase, the
ratings of the transformers located either inside or outside the turbine’s nacelle are also increasing. Considering the
technical complexity and the high cost of each square meter built on the windmill, having optimized solutions is
very important for transformer selection.

A key driver for transformer design is the level of environmental protection that is dependent on the geographical
location of the windmills themselves. The degree of the ambient corrosivity will determine the amount of
environmental protection from humidity, salt and pollution when considering life expectancy and maintenance
activities. Solving this problem from a technical and economical viewpoint is a major challenge due to the location
of most of today’s wind farms.

Based on these previous reasons, achieving a robust and at the same time efficient environmental protection of
transformers is a key technical challenge for design. This is especially the case for higher voltage rated wind
transformers (36 kV) where the combination of reduced ambient dielectric withstand and high electrical stresses
need to be very well evaluated.

This paper will start presenting the state of the art regarding environmental protection of dry-type transformers
and describing the main technical challenges together with the innovative solutions developed to design, using the
adequate state-of-the-art tools, 36 kV dry-type transformers robust enough for different corrosive environmental
conditions. The paper will continue describing the manufacturing of several 36 kV and testing prototypes
performed at world-class laboratories. Results of the tests will also be presented. The document will end explaining
the conclusions of the development and proposing some recommendations that may be considered of interest;
taking into account that the IEC standard of transformers for windmill turbine applications [2] is currently under
revision.
Keywords — Wind transformer, dry-type power transformer, environmental protection, onshore, offshore,
windmill

I. INTRODUCTION
There is a continued interest in developing transformer solutions which aim at ensuring their robustness against
harsh environments, so as to make them suitable for all types of onshore and offshore applications in the
Windmill industry.

In addition to this and considering the importance of the space occupied within the turbine’s nacelle, the
robustness should be achieved in the most efficient way.

With this two motivations, a project was started to deal with this particular topic.

II. STATE OF THE ART REGARDING ENVIRONMENTAL PROTECTION OF DRY-TYPE

TRANSFORMERS
The first task to be performed in order to properly approach the project consisted on evaluating the current
design intended for windmill applications regarding its environmental withstanding, according to the
classification established by the IEC60076-11 standard for dry-type power transformers.

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 e-ARWtr2016 transformers
Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

In clause 13.2 of the mentioned standard, the different environmental classes in which a transformer can be
classified are described. In short, the range varies from E0 (no condensation or pollution expected over the
transformer) to E2 (frequent condensation/pollution expected). Current windmill transformers are typically
designed for E2 environmental class, which guarantees that the transformer can withstand the severe
environmental conditions of the validation test, which include a relative humidity of above 93% with a water
conductivity between 0.5 and 1.5 S/m. Therefore, the first step was to verify this point. In order to do this, the
standard describes in its clause 26 the procedure of the test to be performed to the desired design.

The performance of an environmental test is as follows:

• The transformer is placed in a test chamber with controlled temperature and humidity, achieved by
periodically atomizing water in the chamber.
• The transformer is kept in the chamber for not less than 6 hours without being energized.
• Within 5 minutes after this period, and while the transformer is still in the testing chamber, it is
submitted to a test with induced voltage. There are two types of tests depending on the type of system
they are intended for:
1. Transformers with windings intended for connection to a system which are solidly earthed or
earthed through a low impedance shall be energized at a voltage of 1.1 times the rated voltage for
a period of 15 min.
2. Transformers with windings intended for connection to systems which are isolated or earthed
through a considerable impedance shall be submitted to a test with induced voltage for 3
successive periods of 5 min. During the test, each high voltage terminal in turns shall be
connected to earth and a voltage of 1.1 times the rated voltage shall be applied between the other
terminals and earth.
• The test is considered as passed when no flashovers occur during the voltage application and no
serious tracking marks are shown in a subsequent visual inspection.

As it was verified on several previous occasions, the second type of test described is much more demanding
than the first one. Also, it is important to note that most windfarms have the second type of grounding system
for transformers, and therefore our aim became in all cases to validate our designs for this more demanding
second type of test.

A 2500 kVA 30/0.582 kV transformer for windmill was manufactured in order to be E2 tested according to the
described standard and validate the current solution. The values of the transformer were selected as similar as
possible to the ones required by the windmill market, in order to perform a realistic validation. The main
characteristics of this type of transformers, which are intended for an optimal behavior for windmill
applications are:

• Modified distance from main terminals to ends of coil

• Reduced HV-LV air gap, by using an improved insulation
• Supporting blocks manufactured with improved material
• Special design for the structural clamps

The described transformer was therefore tested at an independent high-voltage laboratory in the Netherlands,
where the complete E2 test sequence for the more demanding type of test was successfully passed and an
official certificate was issued.

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 e-ARWtr2016 transformers
Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

III. PROJECT DESCRIPTION AND TECHNICAL CHALLENGES

The second part of the project and also its main motivation was to implement a design which cannot only be
suitable for E2 environmental conditions, but also for the more restrictive E3 conditions described in the new
standard IEC60076-16. This standard, currently under revision, is specific for power transformers intended for
wind turbine applications, which is our main target for this project. It includes one more stage on the
environmental class classification of transformers, taking into account the harsh environments in which
windmill transformers have to operate on many occasions. On its clause 7.4.5, the standard describes the more
demanding environmental characteristics of the test to be carried out on transformers intended for an E3
validation. These include a relative humidity of above 95% and an increased salinity of the vaporized water in
the range of 3.6 to 4 S/m.

Table I. Environmental Conditions for Tests E2 and E3

These more demanding test conditions present a challenge in transformer design. The first task performed was
to internally carry out a prototype (not official) test equivalent to the E3 test described by the standard, to the
current solution for windmill transformer design intended for E2 in order to evaluate the results obtained and
find out the principal weak points towards which the design enhancement should be directed.

The selected transformer was again a 2500 kVA 30/0.582 kV design, in order to facilitate comparison between
results already obtained and future tests. The transformer did not pass the test, but several very interesting
conclusions were reached.

When the defined test voltage was applied, several flashovers were observed on the transformer between some
of its components. After a while, the continuous discharges stopped but some sparkling continued around
various parts of the transformer, which were identified in order to improve their behaviour in the future design.

Figure 1. Flashovers observed during first tests.

After the test, the transformer was inspected to analyse the consequences of the test over it. The main issue
were various tracking marks, which are not accepted at an E3 test evaluation. The tracking marks were found in
several components, made from different materials.

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Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

Figure 2. Traces of the flashovers observed during inspection.

Once this test was performed, the main weak points of the transformer´s design were identified, and a series of
internal tests were defined where different changes would be introduced to evaluate whether or not they solved
and/or improved the performance of the transformer on the E3 test. For every test, one of the phases of the
transformer was left unchanged so as to use as reference in relation to the design changes made. The design
changes involved concepts such as materials, distances and addition of new components.

A total of six internal tests were carried out in which several design changes were applied. Here below, the
different modification areas, their motivation and the results obtained are summarized:

Supporting block material

It was decided to perform a first test using supporting blocks manufactured with two different materials and
shapes. After the test, the type-1 blocks presented permanent burning marks all over their surface, whereas the
type-2 blocks showed no marks, performing completely different.

Therefore, it was validated that it is mandatory for the supporting blocks to be manufactured with an improved
material suitable for severe environmental conditions.

Figure 3. Type-1 supporting block Figure 4. Type-2 supporting block after E3 test
with burning marks after E3 test. presents no burning marks.

Antitracking coating
The first new concept tested was to include the usage of an antitracking coating for the surfaces which
presented some problems during the test, and had been marked or burned by the tracking occurring over them.
This type of coating will expectedly allow the varnished surfaces to withstand tracking without burning, along
with providing them with hydrophobic properties.

Several antitracking coating brands were tried, as well as different combinations of varnished/non varnished
surfaces on the transformer, keeping the target of an efficient use of this coating.

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Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

Figure 5. HV-LV barrier with Figure 6. Coating supporting blocks Figure 7. Transformer with coated
antitracking coating. and silicones. HV dome areas in two of its phases.

Unalike results were obtained with the usage of antitracking coatings, concluding that they enhance
performance when applied over some surfaces but can also worsen it on others. Moreover, it was observed that
this kind of coatings do not adhere optimally to all surfaces of the transformer, so extra care has to be taken
when deciding upon their application in order to obtain the desired results.

Block silicone pad material

The original silicone pads could show in some cases some tracking marks after the tests. Therefore, an intense
search of different types of silicones was carried out to find a suitable material that would not result burnt by
the tracking but will still maintain the same required mechanical characteristics as the current solution.

HV design
One of the main problems observed during the test were the flashovers taking place between the HV coils and
some grounded components, due to the high conductivity of the water present over the transformer surfaces
during the test. Therefore, in order to comply with it, there was a need of somehow increasing the tracking
distance, the surface behavior, or both. So several different solutions intended to improve, and at the same time
avoiding to overdimension in order to make the solution efficient, were tested to validate them and find one that
enhanced the dielectric performance and avoided the occurrence of flashovers during the test.

Magnetic core columns

Many of the flashovers happening during the previous tests were directed from the HV to the section of the
magnetic core columns which is left exposed between the coils and the clamps. Therefore, focus was also
directed to solving this problem by means of testing several solutions until the dielectric behavior was
improved.

IV. TEST RESULTS

After the described internal tests were performed and all the information was gathered, a final prototype was
prepared including all the validated improvements that had proved to enhance the dielectric behavior of the
transformer when exposed to severe environmental conditions. This transformer was officially tested at the
same independent high-voltage laboratory in the Netherlands, where an E3 test condensation test according to
IEC60076-16 standard, in its more demanding version (intended for connection to systems which are isolated
or earthed through a considerable impedance), was performed. The results were successful and the prototype
passed the test without any issues, validating the proposed design solution for these very restrictive
environmental conditions and therefore making it suitable for the windmill market in all aspects.

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 e-ARWtr2016 transformers
Advanced Research Workshop on Transformers (2)3 -5 October 2016. La Toja Island– Spain

Figure 8. Transformer ready to be tested after 6 hours condensation period.

V. CONCLUSIONS
There is a real need of an in-depth analysis and redesign of transformer characteristics to make them suitable
for the very demanding test conditions that the new standard for transformers intended for wind turbine
applications defines for environmental withstanding.

During the course of this project it was verified that the standard solution for E2 does not comply with E3
requirements, and by means of a set of experimental tests and design enhancements, the changes required to
obtain this validation were identified, defined considering an efficient use and finally applied in a prototype that
successfully complied with the test, therefore obtaining a dry-type transformer design solution for voltages up
to 36kV suitable for the most demanding windmill applications, that ABB can offer to the market.

The next steps of this project would be to increase the power rating and voltage of this kind of dry-type
transformers, going over 36kV, i.e. 72 kV insulation level. In order to achieve this, the challenge of their
dimensions will need to be re-addressed, since their larger size would once again become the main problem for
these dry-type designs to be used for windmill applications. ABB is already working on this new challenge with
a project to make it feasible.

REFERENCES
[1] Andrew Ho, Ariola Mbisrtrova and Giorgio Corbetta, The European offshore wind industry - key trends
and statistics 2015, EWEA (European Wind Energy Association) report, Feb. 2016.

[2] IEC 60076-11, Dry-type transformers. First edition 2004 – 05.

[3] IEC 60076-16, Transformers for wind turbine applications. Edition 1.0 2011-008 (currently under
revision).

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