Industry System Testing for Liquid-

Filled Transformers An Update

Weidmann-ACTI Technical Conference
St. Petersburg, FL
November 14, 2007
Roger Wicks
DuPont
804-383-3300
Industry System Testing for Liquid-
Filled Transformers An Update
Background
Kraft-Mineral Oil Update
Extending this work to other insulation
systems
Background
DuPont and Weidmannhave been conducting
test using a dual-temperature aging model to
thermally age papers with different degrees of
upgrading (nitrogen content).
At last years conference two papers were
presented related to this study.
This presentation provides an update of the
testing from this study with a brief review of
information from those two papers.
Transformer Systems IEEE/IEC
IEEE C57.100 - Standard Test Procedure for
Thermal Evaluation of Liquid-Immersed Distribution
and Power Transformers.
IEC 62332 - IEC Technical Specification Electrical
Insulation Systems (EIS) Thermal Evaluation of
Combined Liquid and Solid Components. Part 1
General Requirements.
Existing C57.100 Methods
Distribution Transformers The LockieTest was
developed to evaluate insulation systems for
distribution transformers by aging complete
transformers.
Failure in the test is a dielectric failure after thermal
degredation. Several OEMs have facilities to do this
testing, specific to their internal insulation systems.
Recent testing has been conducted to develop life
data for combinations involving new fluid types.
LockieTest Facility
Picture courtesy of Cooper Industries
Existing C57.100 Methods
Power Transformer - Sealed Tube Method (Annex)
method is the basis for the historical life curves from
C57.92.
Very easy to do this type of test - limited equipment
required. A lot of historical data developed using this
method, and still broadly used to screen materials for
liquid-filled transformers.
Not very representative of the actual thermal profile
within a power transformer.
Sealed Tubes
Same materials as in Dual temperature cells, at the
size, due to reduced amount of oil in the cell to allow
for expansion due to the high temperatures of the oil.
Insulation pictured is just the conductor loop.
Dual-Temperature Model Aging
Sealed Tube designed to allow independent
control of conductor temperature and fluid
temperature.
Simulates hot spots within transformer
windings, with allowable top-oil temperatures.
For Cellulose-Mineral Oil aging have used
hot spot temperatures ranging from 140C to
200C, and top oil temperatures of 115C.
Dual Temperature Aging Cell
Insulation System - Breakdown
Test Cells
Dual temperature cells independent control of
conductor temperature and oil temperature
Dual-Temperature Aging Model Test
Purpose Utilize the IEC 62332 methodology to
evaluate thermally upgraded kraft comparing
results to historical data presented in C57.100.
Products to test: Range of kraft papers from 0%
nitrogen (non-upgraded paper) to 3.17% nitrogen
content (Insuldur) [0, 1.13, 1.72, 2.74 and 3.17%
nitrogen]
Evaluate materials (solid and liquid) under
conditions specific to their use within the
insulation system
Testing Protocol
Conductor insulation: Mechanical testing
(tensile strength), DP, nitrogen content,
moisture content.
Hot spacer material: Compressibility, DP,
moisture content.
Bulk cool insulation: Mechanical testing
(tensile strength), DP, moisture content.
Mineral oil: DGA, moisture, acid number,
furans.
Arrhenius Life Plot
End of Life 50% Tensile Retention
y =9354.244x - 17.797
y =8084.559x - 15.567
0
1
2
3
4
5
6
0.00205 0.0021 0.00215 0.0022 0.00225 0.0023 0.00235 0.0024 0.00245
1/T
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3.2%N2 Non-Upgraded Linear (3.2%N2) Linear (Non-Upgraded)
Arrhenius Life Plot of 50% Tensile Retention
Nov. 2006 Aging Plot
Arrhenius Life Plot
End of Life DP = 200
y =7836.8x - 14.361
R
2
=0.9638
y =7815.9x - 14.908
R
2
=0.8776
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0.00205 0.0021 0.00215 0.0022 0.00225 0.0023 0.00235 0.0024 0.00245
1/T
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3.2%N2 Non-Upgraded
Nov. 2006 Aging Plot
DP vs. Tensile Strength Retention
y =0.002x
3
- 0.1914x
2
+11.425x - 68.248
R
2
=0.96
0.00
200.00
400.00
600.00
800.00
1000.00
1200.00
1400.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00
Tensi l e Strength (% Retenti on)
D
P
Non-upgraded 3.2% N2 Poly. (Non-upgraded)
DP vs. Tensile - Paper
Dual-Temperature Method
compared to Sealed Tube Test
Conducting sealed tube tests with the same cell configuration (in an
oven) all materials at 148C. Historical expectation would be for
264 hours life. Historical aging, however likely involved sealed
with air and/or moisture content. Predicted life for the sealedtube
is 888 hours with our test set up and oil processing.
Non-upgraded Kraft Aging
y =-9.156479E-10x
3
+1.135695E-05x
2
- 4.050719E-02x +1.000000E+02
0.00
20.00
40.00
60.00
80.00
100.00
0 1000 2000 3000 4000 5000 6000 7000 8000
Hours at 148C
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Model Testing Sealed Tube Testing
Kraft-Mineral Oil Study - Update
Completion of initial aging, including 4
paper types
Start the study of the affect of moisture
Comparison of the data to industry life
curves
4 Paper Arrhenius
y =8357.4x - 16.176
y =9630.5x - 18.395
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0.00205 0.00210 0.00215 0.00220 0.00225 0.00230 0.00235 0.00240 0.00245
1/T
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3.18%N2 0%N2 1.72%N2 1.13%N2
200C 180C 160C 140C
4 Different Nitrogen content papers
100,000 hours
Middle two paper types
Percent Nitrogen vs. Aging
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0.00205 0.00210 0.00215 0.00220 0.00225 0.00230 0.00235
I/T
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1.72%N2 1.13%N2
200C 184C 160C
Sealed Tube Testing Upgraded paper
Sealed Tube Testing
0
20
40
60
80
100
0 500 1000 1500 2000
Hours at 148C
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0% Nitrogen 3.18% Nitrogen
All samples dry when put into ovens. 50% tensile life for non-upgraded paper
= 888 hours, for 3.18% Nitrogen papers = 1282 hours. C57.92 (sealed tube)
predicted life for non-upgraded papers (with 0.25 to 0.50% moisture) = 267
hours, for upgraded paper = 1479 hours.
Comparison to Industry Curves
Aging Curves - Non-Upgraded Kraft
y = 8357.4x - 16.176
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0.00215 0.00220 0.00225 0.00230 0.00235 0.00240 0.00245
1/T
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New Aging Cells -Dry Lockie Test Sealed Tubes
180C 164C 140C
Life better than predicted by industry curves
Effect of Moisture
One data point (green triangle) from second aging program at 1.2% moisture
Effect of Moisture on Kraft
y =-2.118653E-07x
3
+4.027244E-04x
2
- 2.681548E-01x +1.000000E+02
y =-2.523494E-05x
3
+1.130767E-02x
2
- 1.604166E+00x +1.000000E+02
0
20
40
60
80
100
0 200 400 600 800 1000
Hours at 172C
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Dry Insulation 1.8% Moisture 1.2% Moisture
Effect of moisture at temperature
Effect of Moisture on Kraft
y =-1.869676E-06x
3
+1.928611E-03x
2
- 6.170323E-01x +1.000000E+02
0
20
40
60
80
100
120
0 100 200 300 400 500 600
Hours at 180C
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Dry Insulation 1.2% Moisture
Effect of Moisture on Kraft
y =-6.668867E-08x
3
+1.841667E-04x
2
- 1.637252E-01x +1.000000E+02
0
20
40
60
80
100
120
0 500 1000 1500 2000
Hours at 164C
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Dry Insulation 1.2% Moisture
Effect of Moisture on Kraft
0
20
40
60
80
100
120
0 1000 2000 3000 4000 5000
Hours at 156C
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Dry Insulation 1.2% Moisture
These three sets of tests, along
with the point from the
previous slide at 172C, can
then used to develop a life
curve.
Aging Curves - Non-Upgraded Kraft
y = 7461.2x - 15.052
y = 8357.4x - 16.176
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0.00215 0.00220 0.00225 0.00230 0.00235 0.00240 0.00245
1/T
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New Aging Cells -Dry Lockie Test Sealed Tubes New Aging Cells - Wet
180C 164C 140C
Comparative Curves
Data estimated based on VERY limited data for the wet aging in
most cases only one cell. Also combined data for both 1.2 and 1.8%
Moisture.
Need to get data for 0.5% Moisture should fall close to C57.91 data.
Data from 0.5% moisture samples
Testing conducted on materials already wrapped (1.72% nitrogen papers).
50% point lower when wet (307 hours vs. 423 hours).
Data falls between expected life from historical C57.91 for upgraded and non-
upgraded papers: non-upgraded 133 hours, upgraded 664 hours. Not sure if
this is because the paper used falls somewhere in between .
176C Aging - Moisture - 1.72% nitrogen paper
0
20
40
60
80
100
0 500 1000 1500 2000 2500
Hours at 176C
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Dry Paper 0.5% Moisture Added
Further work
Re-evaluate non-upgraded and upgraded papers with
0.5% moisture content.
Evaluate effect of higher moisture contents.
Look at the effect of oil temperature.
- Single data point from related study at 150C
hot spot/130C oil 20% remaining tensile
strength for an upgraded kraft paper after 2000
hours.
- By comparison in our kraft study, non-
upgraded paper @156C has 50% tensile
strength at over 3000 hours.
Extending this work to other
insulation systems
Aging of NOMEX

paper in mineral oil

Comparison of sealed tube testing to dual-
temperature model testing.
Learningsto date from both kraft study and
high-temperature aging with NOMEX

paper.
IEC 60076-Part 14 provides options using a
variety of new materials.
IEEE 1276 Predicted Life
IEEE 1276 - IEEE Guide for the
Application of High-Temperature Insulation
Materials in Liquid-Immersed Power
Transformers
Based on Study by GE for ESEERCO
published in 1987.
Used data points from aging which did not
reach end of life
Samples were based on sealed tube testing
in mineral oil sealed with air.
Material Life Curves IEEE 1276
Comparison Aging
Predicted Life Dry Aging Sealed Tube Initial Model Test
240C 36,000 2,100 ~7,950
270C 3,860 365 ~1,280
NOMEX

Aging Results
y =9009.5390x - 13.0005
y =7059.0231x - 10.4366
0
1
2
3
4
5
6
0.0016 0.0017 0.0018 0.0019 0.002 0.0021
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(
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)
ESEERCO Dry Aging Model Test
320 265 250 220
100,000 hours
Issues Encountered in Model Aging
Long, high-temperature operation causes
leaks from sampling ports
Original concept of multiple oil sampling
from individual cells caused issues
Temperatures above 240C require a new
cell design
Aged conductor wrap acquires shape of
coil
Modified cross section for
future tests
Modified cross section has
helped reduce the thermal
input at hotspot temperatures
have scouted operation at
320C hotspot. Still may
need additional external
cooling (heat sink) to gain
control at 115C oil
temperature.
Paper shape after aging
Wire wrap acquires
shape of the conductor
leading to high
variability in tensile
testing
Solution is to use pre-slit
tensile strips as the test
papers for the aging.
IEC TS60076-14 Proposes Four
High-Temperature Insulation Systems
Homogeneous
High-temperature materials for all solid insulation
High-temperature insulating liquid
Hybrid
High-temperature solid insulation only when contacting conductor
Conventional insulating liquid
Semi-Hybrid
High temperature solid insulation on conductor only
Conventional insulating liquid
Mixed
High-temperature insulation only at localized hot regions
Conventional insulating liquid
Temperature Limits For Insulation
Systemswith Mineral Oil
130 90 110 N/A
High Temperature insulation
hot spot temperature rise
(K)
78
Conventional insulation
hot spot temperature rise
(K)
95 75 65 65
Average winding
temperature rise
(K)
100
Top oil
temperature
(C)
60
Top oil
temperature rise
(K)
Hybrid
Semi-
hybrid
Mixed Conventional
Temperature Limits For High-Temperature
Homogeneous Insulation Systems
180 150
Winding hot spot
temperature rise
(K)
130 115
Average winding
temperature rise
(K)
155 130
Top liquid
temperature
(C)
115 90
Top liquid
temperature rise
(K)
Silicone liquid
or
equivalent
Ester liquid
or
equivalent
Typical Applications for the Four
High-Temperature Insulation Systems
Homogeneous
Wind turbine step-up
Compact pole-type distribution
Hybrid
High power density mobile substation
High overload / high reliability applications
Semi-Hybrid
Generator step-up
High ambient applications
Mixed
Large power rectifier
Furnace application
Summary
Significant progress has been made in validating
the dual-temperature model test by evaluating the
life of kraft papers in mineral oil.
Current work involves the addition of moisture to
match existing life curves that serve as the basis
for the IEEE loading guides.
Testing of higher temperature materials, as
described in IEC 60076 Part 14, will allow a wide
variety of insulation options for manufacturers and
users of liquid filled transformers.