INSULATION IN TRANSFORMERS

13TH MAY 2016

ELECTRICAL TECHNOLOGY
WEIDMANN ELECTRICAL TECHNOLOGY, INC.
A Member of the WICOR Group
Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 WHO IS WICOR

WEIDMANN ELECTRICAL TECHNOLOGY

WEIDMANN is a leading specialist for high voltage insulation and

world-wide technology partner for manufacturers and users of
transformers.

We develop and produce insulation materials, components and

systems and advise our customers in all aspects of transformer
design and operation.

Internet Siemens

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 WHO IS WICOR

WICOR
WEIDMANN INTERNATIONAL CORPORATION

•Founded in 1877

•Employees 4000

•Worldwide supplier for engineered products in

ELECTRICAL TECHNOLOGY and PLASTICS
TECHNOLOGY

•Privately held

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INSULATION IN TRANSFORMERS / 13 May 2016 / JM & JB
Locations

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 WHAT IS IN A TRANSFORMER

Modern Power Transformer

Insulation Systems
• Transformerboard
• Insulating Paper
• Laminated PB
• Laminated Wood
• Enamel – Wire
• Epoxy Coatings
• Paper Phenolic
• Dielectric Fluid

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 COST & INFLUENCE

Cellulose insulation in transformers

• Cellulose insulation in transformers comprise just a small percentage
of total transformer costs, yet have tremendous leverage over design,
size & weight.
• It is the weakest link in the transformers and has the most influence
during the ageing process

Insulation Other
Conductor
Oil 2% 5%
32%
14%

Core Steel
47%

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 COST AND BREAKDOWN

Large Power Transformer Materials

(reference 250 MVA Transformer)

Material Weight (kg) %

Core Steel 67165 34
Sheet Steel 45573 22
Copper Wire 24228 12
Transformer Oil 48000 24
Kraft - Cellulose
Pressboard 5294 3.0
Paper 1479 1.0
Total 200,000 100%

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Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 LIQUID INSULATION

Purpose of the Dielectric Fluid

•Provide Sufficient Dielectric Strength

•Provide Sufficient Cooling/Heat Transfer

•Preserve the Core and Coil Assembly

(By filling the insulating material voids)

•Minimize the contact of oxygen with cellulose and other

materials susceptible to oxidation

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 LIQUID INSULATION

Insulation Fluids

• Mineral Oil
• Naphthenic
• Paraffinic
• High Molecular Weight

• Silicone Fluid

• Synthetic hydrocarbons
- E.g. Polyalphaolefins

• Polyol Esters

• Natural Esters (seed oils)

-BioTemp®, FR3®

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Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 SOLID INSULATION

Role of Transformberboard in the Transformer‘s Insulation

Subsytem

• Only Two Components

• Water
• Cellulose

• Mechanical

• Dielectric

• Thermal Cellulose determines life and loading

• Class “A” Insulation - 105ºC class

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 CELLULOSE INSULATION

Cellulose

Northern Softwood Conifer: long, thin fiber (3-6mm)

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 CELLULOSE INSULATION

Electrical-Grade (kraft process) Paper and Pressboard

• Most electrical-grade pressboard and papers used in oil-filled

apparatus are made from wood cellulose refined using the “kraft”
process. (“kraft” = German word for “strong”.)
• The usual pulp furnish for electrical grade papers is unbleached,
kraft-process pulp made from spruce, fir, and pine tree species
from northern latitudes. Why? cold climate = slower tree
growth long fiber length = higher strength.

Cellulose Macromolecule

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 CELLULOSE INSULATION

Transformerboard Production
Cellulose

20X 200X

800X
Cellulose Enlargements

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 PURPOSE OF INSULATION

Purpose of Solid Insulation in Transformers

Mechanical
• Winding tool
• Support the windings during short
circuit
• Deal with axial and radial forces
• Maintain sufficient tensile,
elongation, tear and compression
strength during ageing of
insulation
• Maintain dielectric clearances
• Support leads and auxiliary
equipment

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 PURPOSE OF INSULATION

Purpose of Solid Insulation in Transformers

Dielectric
• Insulation should be able to deal
with various dielectric stresses

• Oil gap stresses

• Creep Stresses

• Stress in solid insulation

INSULATION IN TRANSFORMERS / 13 May 2016 / JM & JB 18

Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 PAPER MAKING

Paper Production
Pulp – Paper Flow

•Multiple wire-mesh assemblies allows for thicker material

•Paper is continually processed whereas Transformerboard is made one sheet

at a time

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 CREPE PAPER

Paper
Creped Material

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 CREPE PAPER

Paper
Creped Paper

• Provides extensibility (stretch) to the product

• Allows the paper to fit tightly over curved surfaces without wrinkles or gaps
• Resists tearing during coil winding
• Low Tensile Energy Absorption (toughness)

• Can be calendared
• Control thickness of creped material
• Adds some TEA

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 COATED PAPER

Paper
Adhesives

• Single or double sided

application

•B-stage epoxy creates a rigid

structure after heat treatment

• Diamond pattern creates a

small oil duct to allow for
impregnation

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 TUK

Paper
Thermal Upgrading
• All insulations degrade, changing chemical composition and properties over time.
Dielectric, Mechanical, and Chemical strength dissipates.

• This process is greatly accelerated by heat.

• If we increase the paper’s maximum “normal operating ” temperature to a higher level,

we can:

• Run the transformer at a higher temperature, without degradation, and thus raise
its capacity and productivity.
• Run the transformer at the prior normal temperature, and extend its life.

• Normal paper is designed for a 55º “rise” (40º ambient + 55º rise = 95º total.)

• Thermally Upgraded paper can operate at a 65º “rise” (40º ambient + 65º rise = 105º
total.)

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 WINDING TECHNOLOGIES

HV Layer Type Windings

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 WINDING TECHNOLOGIES

LV Layer Type Windings

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Other Insulation Products
Fixation Elements such as
clamps and blocks Transformerboard

Various paper products:

DPP, Kraft paper, Crepe
paper…

Copper conductor
Duct Strips insulated by crepe paper
for oil flow tubes
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 ELECTRICAL TECHNOLOGY

SMART INSULATION™ – DIRECT MONITORING APPROACH

Insulation System
with Embedded Sensors

SmartSpacer® T
Winding Cylinder Temperature

SmartSpacer® M
Conductor Moisture in Paper
(in development)

SmartSpacer® F
Clamping Force
(in development)
Sensors are integrated with
eNameplate software.

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Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

INSULATION IN TRANSFORMERS / 13 May 2016 / JM & JB 29

 BOARD MAKING

Transformerboard Production
Pulp - Transformerboard Flow

Kraft Pulp
Water
Mixing
Cleaners Chests
Stock Chests Refiners
Machine
Chest
De-flakers
Forming Roll
Cutter
Dryer Sheet Forming
Cutting Table

White
Water
Hot Press
(Machine diagram for production of Transformerboard precompressed.)
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 BOARD MAKING

Transformerboard Production
BM#1 – Low Density

BM#2 – High Density

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 PRESSBOARD

Transformerboard Production
Types of Transformerboard

*Difference is due to final drying process

Pre-compressed – High Density

• Dried Under Pressure and Temperature
• Restrained between screened platens – PEEK wires

Calendared – Low Density, Formable

• Dried Unrestrained – no pressure
• Circulating Air Over ~ 100m long
• Calendared – roll press to obtain final density

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 BOARD COMPONENTS

Function
Components and their use

Angle Ring
Cap Ring
Washer Block Asmb
Keyspacers
Crossover Patch

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 BOARD COMPONENTS

Function
Components and their use

Keyspacers
CTC Ramp
Dovetail Sticks
Rectangular Sticks
Cylinder

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 BOARD COMPONENTS

How is Pressboard used?

Clamping Ring (TX2) Angle Ring (FormVal) Radial Spacers (T4) Axial Spacers (T4)

Conductor Wrap
Winding Cylinder (T4) Static Ring (TX2 & Creped Paper)
(Paper)
HiLo Barriers (HiVal) Washers (T4)

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 ELECTRICAL TECHNOLOGY

WEIDMANN InsuLogix® Vault - the next step in SMART INSULATION™

Bushing
Monitors
Transformer
Thermal
Oil Level,
Devices
DGA

Pressure Load Tap

Devices Changer

Cooling
Metrology
Control
Switchgear
 VAULT

Control Panel components that can be replaced with the VAULT

Annunciator

Tap counter

Monitor

Relays

Monitor
Modules

INSULATION IN TRANSFORMERS / 13 May 2016 / JM & JB

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Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 AGING

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:

55 C Rise 65 C Rise 75 C Rise

Ambient (max ave.) 30 30 30
Average Winding Rise 55 65 75
Hot Spot Differential 10 15 15
Hot Spot Temperature 95 110 * 120 **

*Only attainable with thermally upgraded insulation.

** Only attainable with specialty cellulose insulation.

+10º C ≈ 12% Increase in Transformer MVA

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 AGING

Insulation Life
Aging Curves
Aging Curves
Thermally upgraded paper TUK
Regular Kraft paper

(Paper severely aged below this line)

Source: Westinghouse/ABB Brochure on Insuldur®

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 AGING

Insulation Life
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 = Average fiber length
• DP Incoming Kraft Pulp ~1400
• DP of Insulation Components prior to processing ~1200
• DP of Insulation Components following processing ~1000
• DP level considered as “over-processed” ~800
• DP level considered end of life ~200

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 AGING

Insulation Life
Degree of Polymerization

Degree of Polymerization = measurement of “n”

Quantity of uninterrupted molecules is indicative of structural stability

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 AGING

Insulation Life
Degree of Polymerization
Paper Insulation Aging in Mineral Oil

DP DP DP DP DP DP
181
1000 733 549 405 309

End of Brittle & dark

Progressive aging with time mech str.
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
• by-products contaminate the oil
Source ABB Power Technologies, Inc.
INSULATION IN TRANSFORMERS / 13 May 2016 / JM & JB 43
Agenda

1. Introduction
2. Insulation
1. Liquid Insulation
2. Solid Insulation (Cellulose)
1. Paper
2. Board
3. Insulation Life
3. Dielectric Stress/Design

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 DESIGN

FAILURE!

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 DESIGN

Dielectric Stress
Theoretical Failure Model

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 DESIGN

Dielectric Stress
Predicting Failures
Finite Element Analysis (FEA)
allows us to predict where
areas of high dielectric stress
could occur. We can then
arrange Transformerboard in a
manner that reduces the
likelihood of discharges
propagating.

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 DESIGN

Dielectric Stress
Predicting Failures – Local Stress
New FEA tools allow us to
simulate designs and stresses
much quicker

Stress Profile Between 4th & 5th Top HV

Sections = 10.9 kV/mm.

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 DESIGN

Dielectric Stress
WEIDMANN Reference Curves - Oil
100
Partial Discharge - Inception
Field Strength (kV/mm)

10

1
0.1 1 10 100 1000
Oil Duct Width (mm)

Degassed Oil, Non-Insulated Electrode

Degassed Oil, Insulated Electrode

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 DESIGN

Dielectric Stress
Predicting Failures – Oil Gaps

Using the WRCs we’re able to

determine a “safety margin” for the oil
based on a Weibull distribution

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 ELECTRICAL TECHNOLOGY

INSULATION SPECIFICATION GUIDE

WHY DID WE CREATE IT?

• Overall lack of concern in transformer specifications related to insulation

requirements
• If insulation is specified, typically the verbiage is very general or outdated
• WEIDMANN Guide provides support/data for specifying insulation materials
• Ultimately provides an important barrier to potential offshore suppliers
• Bring awareness about differences in insulation materials currently available on the
market and its effect on transformer performance, reliability and longevity

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 ELECTRICAL TECHNOLOGY

INSULATION SPECIFICATION GUIDE

WHY TRANSFORMER OWNERS SHOULD SPECIFY INSULATION MATERIALS

Transformer Manufacturer Transformer Owner / End User

Negligible % of Cost of Substation or Generating

Insulation Cost 2-8% of Transformer Selling Price
Plant where the transformer is located

Test Floor or In-Service Failure

Risk within Warranty
In Service Failure & Resulting Cost

Partial or total loss of Substation or Generation

Capital at Risk Cost of rework or replacement
plant 7 – 10 X Transformer Cost

Transformer Production and

Transformer operational life
Warranty Period
Duration of Risk
1 – 5 years 20 – 30 years

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 ELECTRICAL TECHNOLOGY

INSULATION SPECIFICATION GUIDE

WHAT IS IT?
Example 1: Solid Insulation Transformerboard

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THANK YOU!

Jinesh Malde Jason Beaudoin

Distribution Transformer Engineer Technical Services Engineer
WEIDMANN Electrical Technology Inc. WEIDMANN Electrical Technology Inc.
1 Gordon Mills Way 1 Gordon Mills Way
Saint Johnsbury, Vermont 05819 USA Saint Johnsbury, Vermont 05819 USA
Phone: +1 802 751 3381 Phone: +1 802 751 3327
E-mail: [email protected] E-mail: [email protected]
Web: www.wicor.com Web: www.wicor.com

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