CUGRE 2103 Presentation A - Portillo

AC Insulation Design of Power Transformers Fundamentals
Eng. lvaro PORTILLO LAURINO Transformer Consultant

Brenda 5920, Montevideo, CP11400, Uruguay Phone: (+598) 26007982 e-mail: acport@adinet.com.uy
CUGRE - 29th October 2013 Salto - Uruguay International Power Transformers Workshop - Challenges and Solutions 1
In this work we will try to give an overview of the insulation design process of high voltage "core-type" power transformers operated in AC networks for engineers involved in design review tasks All presented values and formulas are only orientations and can vary widely between manufacturers Emphasize the concepts
Summary
To probe his ability to work for many years in service, with permanent and transient voltage conditions, the transformers are subjected to factory acceptance dielectric tests This tests trying to represent the different conditions that the power system can impose to the transformer
The power transformers in electric networks are subjected: - permanently to continuously operating voltages - sometimes to transient overvoltages caused by faults, switching operations or lightning strikes
Introduction
The challenge for the transformer designer is define an insulation structure which comply with the dielectric tests
CUGRE - 29th October 2013 Salto - Uruguay International Power Transformers Workshop - Challenges and Solutions
This tests are the result of more than 100 years of experience and is generally accepted that if a transformer successfully passes these tests they have a very high probability of work for many decades in service without dielectric problems
The purpose of transformer insulation is to isolate parts or electrodes at different potentials from one another but the design of an insulation structure is not only define this distances inside the transformer Previous to this is necessary to define completely: - the geometry and number of insulation barriers between windings and between windings and ground - the insulation material type best suited for each part of the transformer - the thickness of the conductor insulation - if is necessary or not the use of static end rings in the windings - the type of winding (interleaved or not) These definitions have a big influence in the voltage distribution inside the transformer and in the electric fields that appears during the dielectric tests
Introduction
Once the material types and geometry is completely defined voltage distributions outside and inside the windings according to the test voltages and to the corresponding winding connection during test are calculated For AC voltages (50 to 200 Hz) the voltage distribution follows linearly the number of turns and can be calculated very precisely The calculation of impulse voltage distribution requires the simulation of the transformer by means of an equivalent circuit consisting of lumped R, L and C elements Then with this voltage distribution using simple analytical formulae or numerical methods (like Finite Elements Method) is possible to calculate the electric field or electrical stress in each point inside the transformer
Introduction
Introduction kV kV/mm
Density Plot: |E|, V/m
1.503e+007 : >1.582e+007 1.424e+007 : 1.503e+007 1.345e+007 : 1.424e+007 1.266e+007 : 1.345e+007 1.187e+007 : 1.266e+007 1.107e+007 : 1.187e+007 1.028e+007 : 1.107e+007 9.492e+006 : 1.028e+007 8.701e+006 : 9.492e+006 7.910e+006 : 8.701e+006 7.119e+006 : 7.910e+006 6.328e+006 : 7.119e+006 5.537e+006 : 6.328e+006 4.746e+006 : 5.537e+006 3.955e+006 : 4.746e+006 3.164e+006 : 3.955e+006 2.373e+006 : 3.164e+006 1.582e+006 : 2.373e+006 7.910e+005 : 1.582e+006 <0.000e+000 : 7.910e+005
Density Plot: |E|, V/m
1.503e+007 : >1.582e+007 1.424e+007 : 1.503e+007 1.345e+007 : 1.424e+007 1.266e+007 : 1.345e+007 1.187e+007 : 1.266e+007 1.107e+007 : 1.187e+007 1.028e+007 : 1.107e+007 9.492e+006 : 1.028e+007 8.701e+006 : 9.492e+006 7.910e+006 : 8.701e+006 7.119e+006 : 7.910e+006 6.328e+006 : 7.119e+006 5.537e+006 : 6.328e+006 4.746e+006 : 5.537e+006 3.955e+006 : 4.746e+006 3.164e+006 : 3.955e+006 2.373e+006 : 3.164e+006 1.582e+006 : 2.373e+006 7.910e+005 : 1.582e+006 <0.000e+000 : 7.910e+005
ITAIP Autotransformer 470/470/157 MVA 525/241.5/13.8 kV

The calculated electrical stress (kV/mm) in each point P must be less than the admissible dielectric strength (kV/mm) of the insulating material used in this point P for this test condition If not, the insulation design is modified and verified again, and this procedure iteratively must leads to an optimised solution Normally the design is defined in a way that the test stress does not exceed the PD inception values of the insulating materials Finally the success of the dielectric design depends on select high quality insulating materials with narrow dimension tolerances and shape stability and applying adequate stabilization, drying and impregnation processes to the insulation materials
Introduction
The transformer insulations are usually classified in: external or major insulations internal or minor insulations External or major insulations include principally insulations outer the windings:
Transformer Insulations
winding to winding (gaps between windings) phase to phase windings to ground (to core legs, to core yokes and to tank) winding leads (connections between windings, connections from windings to bushings, connections from windings to OLTC , etc.)
International Power Transformers Workshop - Challenges and Solutions 8
CUGRE - 29th October 2013 Salto - Uruguay
Phase to Phase Insulation
International Power Transformers Workshop - Challenges and Solutions
Winding to Ground Insulation
10
HV Winding Lead Insulation
11
Connections from Windings to OLTC
12
Internal or minor insulations include principally insulations inside the windings: conductor to conductor turn to turn section to section (axially along windings) layer to layer
13
Turn to Turn Insulation
14
Section to Section Insulation
15
16
Other essential elements in order to achieve a good dielectric design: Angle caps Angle rings Static end rings Internal surge arresters
17
Angle Caps
18
Angle Rings
19
Static End Rings
20
Internal Surge Arresters
21
Internal Surge Arresters
22
The transformers during operation are subject continuously to operating voltages and occasionally to overvoltages The overvoltages occurring in the power systems can be divided into:
Power System Overvoltages
lightning overvoltages aperiodic voltage waves with duration of one to tens of microseconds switching overvoltages damped oscillatory voltage waves with duration up to thousands of microseconds temporary overvoltages voltage waves at or close to the power frequency lasting for few minutes
The Applied Voltage Test at industrial frequency (50 or 60 Hz) With the applied voltage test the withstand strength of the external insulations (winding to winding and windings to earth) to service and temporary overvoltages is verified In this test there is not turn-to-turn voltage
Tests intended to verify the insulation withstand to operational voltage and to transient overvoltages
Dielectric Tests
The Induced Voltage Test (short and long duration) at industrial frequency (between 100 to 200 Hz) With the induced voltage test we verified principally the internal insulations (turn to turn, section to section) and also external insulations (phase to phase, winding to winding and windings to earth) to service and temporary overvoltages The long duration induced voltage test with PD measurement is intended to verify that the transformer will be free of harmful partial discharges under normal operating conditions
The Switching Impulse Test is intended to verify the capability of insulation to withstand slow rise time (greater than 100 s) transient voltages typically associated with switching operations in service With this test the internal and external insulations are verified to switching transients The fundamental test wave frequency is in the order of 2.5 kHz The voltage impulse shall have a time to peak of at least 100 s, a time above 90 % of the specified amplitude of at least 200 s, and a time to zero of a minimum of 1000 s.
Dielectric Tests
This impulse wave shape is purposely different from the standard waveshape of 250/2500 s recommended in IEC 60060-1, since IEC 60060-1 is intended for equipment without a saturable magnetic circuit. The time to peak is chosen to be long enough to give an essentially linear voltage distribution along the windings
25
The Lightning Impulse Test (full wave and chopped wave) is intended to verify the insulation withstand to fast rise time (around 1 s) transients overvoltages occurring in the power system as a result of lightning strikes With this test the internal and external insulations are verified to lightning transients The fundamental test wave frequency is in the order of 250 kHz The chopped wave test voltage impulse has a higher peak value and contains higher frequency components than the full wave impulse
Dielectric Tests
26
Dielectric Tests - Connections
27
The distribution of voltage to ground along the coils (Fig.a), for the different tests, is illustrated in the following figures:
Voltage Distribution in Windings
Fig.b shows the distribution of voltage in the applied voltage test (not turnto-turn voltage) Fig.c shows the distribution of voltage in the induced voltage test (voltage inductively distributed, proportional to the number of turns, through all windings) Fig.d shows the distribution of voltage in the atmospheric impulse test (oscillating voltages that produces non-uniform stresses in winding under test).
In the atmospheric impulse test the voltage distribution depends of the capacitances and inductances (self and mutual) of the windings The initial voltage distribution inside the windings is capacitive and at the end of the transient this voltage distribution is inductive During the transient the voltage in each point of the winding is oscillatory with frequencies equal to the natural frequencies of the transformer and with a damping depending of the transformer losses In the case of switching impulse test the voltage distribution is almost linear, similar to that experience during an induced voltage withstand test, and when specifying switching impulse test is not performed short-duration induced voltage test (Table 1 of IEC 60076-3:2013)
Voltage Distribution in Windings
In a paper-oil insulation system, stressed with AC voltage: the maximum admissible field stress of pressboard is higher than 20 kVrms/mm for an oil gap of around 5 mm values less than 12 kVrms/mm are admissible This difference is augmented by the fact that the permittivities of the two materials differ by a factor 2, resulting in field values twice as high in oil that in the adjacent board Furthermore, the relative strength of oil for an increasing gap width decreases: Therefore, in a paper-oil insulation system the solid material is used only to subdivide oil gaps and to insulate electrodes. The design of such systems concentrates in general on the electric strength of the oil gaps and of solid-liquid interfaces
External Insulation Design
External Insulation Design Weidmann Curves
These curves express the maximum admissible design value as a value of uniform electric field of low probability of partial discharge inception for 1 min AC test voltage (less than 1%)

Partial discharges should be excluded even during dielectric tests of insulations structures This design concept is extremely important Localization of partial discharges during transformer testing is unsafe and should be avoided to the greatest possible extent
32
Another type of breakdown that can occur in insulation structures consisting of solids and fluids is creep breakdown This occurs along a solid surface that is in contact with a liquid or gas These potential breakdown surfaces are nearly unavoidable in insulation design. In the end insulation area the pressboard must be used in such a manner that creep stress are practically precluded To achieve this the pressboard-oil boundary surfaces must run, as far as possible, parallel to the equipotential surfaces.

For the solid-liquid interfaces the maximum admissible creep tangential stress EC-AC along clean pressboard surfaces in degassed oil, in terms of the creep distance dC (in mm) along the surface, can be calculated using the following formula:
EC-AC in kVrms/mm, 1% probability of PD inception
34
Several parameters influence the breakdown behaviour of transformer oil and in consequence to this the oil-design curves The most evident parameter is the duration of voltage application on an insulation configuration Breakdown test has shown that oil-paper insulation exhibits an exponential decrease of strength when the duration of the voltage application is increased This volt-time breakdown characteristic can be represented with a equation of the type:
35
Design curves must reflect this dependence; therefore these curves are defined for a reference duration of 1 minute, AC, power frequency A multiplication factor is introduced to adapt the design curves for different time duration, e.g. lightning impulse (BIL), switching impulse (SIL), 1 hour induced voltage, etc. This factor is called Design Insulation Level (DIL) and it increases (reduces) the respective design curve value if the voltage application time is shorter (longer) than 1 minute:
External Insulation Design - DIL
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External Insulation Design - DIL
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The evaluation of extenal paper-oil insulation systems consist of calculation of stress and the subsequent comparison of stress values with admissible design values The calculation of stress is divide into three parts: Calculation of Voltage distributions within windings according to the specific test voltages and to the corresponding windings connections during the tests These voltages are converted to the equivalent voltage at 1 minute power frequency voltage The maximum of these equivalents in each insulation clearance will define the insulation design in this insulation clearance Finally, usually using the Finite Elements Method (FEM) or analytical formulas for simple geometries, the electric field within the insulation clearances is determined for the maximum equivalent voltage.

Winding to Winding Insulation
HV Radial Spacers Key spacers
HV Winding LV Winding
Angle End Rings collars
LV
Sticks Pressboard barriers
Pressboard barriers
39
From the point of view of the electric field calculation this configuration is very simple. Disregarding curvature effects, the electric field is uniform along all the height of the windings and can be calculated using the elementary formulas of a plane capacitor:
Where U is the applied voltage between the windings, dOil is the total oil width, dPsb is the total pressboard width and ( = 2.2) and ( = 4.4) are the permittivities of oil and pressboard respectively.
To simplify we suppose that all cylinders have the same width and all the oil ducts have the same width (this is not usual in practical cases): In this case, for AC test (1 min, 50 Hz), with degassed oil and insulated electrodes, applying equation for oil and equation for pressboard the design conditions will be:
41
Like an example, consider the design of a 245 kVrms main gap The voltages to be applied in the tests are: Um 245/ SI 850/ LI 1050/ LIC 1155/ AC 460 kV According to DIL factor approach the main gap will be designed for:
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Both Winding to Winding Insulations (LV-HV gaps) are equivalents from the point of view of the dielectric design
43
Phase to phase insulation
Winding to core return legs insulation
Winding to tank insulation Disregarding curvature effects these insulations are designed in the same way of winding to winding insulation
Winding to core return legs insulation

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Non-uniform electric fields End winding insulation Winding to core yokes insulations Winding leads insulations
45
For non-uniform electrical fields a very conservative approach would be to limit local maximum stresses to values given by the oil design curves for the full length gap In this case the larger part of the gap is not stressed at the limit of its dielectric strength This is not satisfactory as it leads to excessive dimensions and high costs On the other hand it would be risky to compare the average electric field stress with the design curves In highly non-uniform fields average values can be low compared with the maximum value in the gap These highly stressed gap parts intervals might be overstressed
The method for determining the electric strength in the case of non-uniform fields was developed and verified by experiment [Weidmann] Suppose a oil gap d with highly non-uniform electric field profile Beginning in the high field region, average stresses are calculated for gap intervals which are sucessively increasing from up to the total length: These average stresses are compared with the oil design curves values for a gap interval z The dielectric strength must be higher than the average stress for all the gap intervals z from z = 0 to z = d

Design curves for non-uniform electric fields
This method is widely used to define maximum permissible voltages in insulating structures with highly non-uniformed electrical fields and breakdown tests showed that these voltages are equivalent to a breakdown probability of 2%.
External Insulation Design - Example
Case 1
Case 2
Case3
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External Insulation Design Example
q( r ) Minimum Oil Gap 1 Oil Gap 2 Oil Gap 3 Case 1 1.19 @ r =125 mm Case 2 1.18 @ r =110.5 mm 2.30 @ r =177.5 mm 3.39 @ r =245 mm Case 3 1.62 @ r =54 mm 1.64 @ r =73.5 mm 1.64 @ r =245 mm
For the design of internal insulations the same rules explained in external insulations can be applied with the exception of DIL factor DIL must not be applied for internal design of the windings insulation These insulations shall be designed for each type of stress (service, AC tests, impulse tests, etc.) The internal insulation design is strongly dependent of the type of winding and of the measures taken by the designer to improve the lightning impulse voltage distribution by means of winding series capacitance increase (interleaved disk windings and intershield disk windings)
Internal Insulation Design
Turn to Turn Insulation - Kraft Paper - Admissible Field Stress
n = 0.22 for impulse tests n = 0.33 for AC tests


A oil duct is generally provided between sections of the disctype and helical-type windings to ensure the required dissipation of heat Due to the creepage distance formed by the pressboard spacers placed between the sections, the admissible voltage stress in these ducts is much lower than that tolerable for an oil gap of equal thickness Some manufacturers use curves defining the admissible section to section strength in function of the thickness of conductor insulation, parametric in the distance between the sections.

A more direct approach is to use directly an equation for the admissible creepage stress in uniform fields for AC (50 Hz, 1 min) and lightning impulse voltages: Other values that are verified are the oil electric field at the internal and external edges of the conductors of each section The limits for these stresses are around 11 kV/mm for AC (50 Hz, 1 min) and 29 kV/mm for lightning impulse voltages. All these values and formulas are only orientations and can vary widely between manufacturers
Thank you very much for your attention
55

CUGRE 2103 Presentation A - Portillo

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AC Insulation Design of Power Transformers Fundamentals

Eng. lvaro PORTILLO LAURINO Transformer Consultant

Density Plot: |E|, V/m

Density Plot: |E|, V/m

ITAIP Autotransformer 470/470/157 MVA 525/241.5/13.8 kV

CUGRE - 29th October 2013 Salto - Uruguay

Phase to Phase Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Winding to Ground Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

HV Winding Lead Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Connections from Windings to OLTC

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Turn to Turn Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Section to Section Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Section to Section Insulation

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Static End Rings

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Internal Surge Arresters

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Internal Surge Arresters

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Power System Overvoltages

CUGRE - 29th October 2013 Salto - Uruguay

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Dielectric Tests - Connections

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions

Voltage Distribution in Windings

CUGRE - 29th October 2013 Salto - Uruguay

Voltage Distribution in Windings

External Insulation Design

External Insulation Design Weidmann Curves

CUGRE - 29th October 2013 Salto - Uruguay

External Insulation Design

CUGRE - 29th October 2013 Salto - Uruguay

International Power Transformers Workshop - Challenges and Solutions