21, rue dArtois, F-75008 PARIS http : //www.cigre.

org

A2-104

CIGRE 2008

Developments of gas insulated transformer and low-viscosity silicone immersed transformer with the fire safety considered environment aspect

T. Kawamura, Tokyo University

T. Kobayashi, Tokyo Electric Power Company

Y. Shirasaka Japan AE Power Systems Corporation

H. Murakami, Mitsubishi Electric Corporation

Y. Ebisawa Toshiba Corporation

Japan

SUMMARY
The number of urban substations is rapidly increased with the big demand of electrical power. It is required that transformers should have fire-resistant performance and reduce environmental burdens, because the transformer is installed in metropolitan areas. There are considerable restrictions such as limitation of ground space, safety for concentrated population and so on to build substations in Japanese metropolitan area. Then, the underground substation and the substation in the building are increasing rapidly now, in which transformers need the performance of the non-flammable or the lessflammable with the consideration of fire-prevention and environmental friendliness. We are developing and delivering the low-viscosity silicone immesed transformer and the gas insulated transformer to the urban substations including the underground substations and the substations in the building. The low-viscosity silicone immesed transformer are less-flammable and the gas insulated transformer are non-flammable with the high reliability, and these transformers are installed on lots of urban substations in the Japan. This paper describes the development of these transformers using the new insulation systems with the new materials and these transformer applications in service.

KEYWORDS
Transformer, new insulating system, environment, fire-resistant, less-flammable, non-flammable, silicone liquid, low-viscosity silicone immersed transformer, SF6Gas insulated transformer

shirasaka-yukiyasu@mb.jaeps.com

1. Introduction The number of urban substations is rapidly increased with the big demand of electrical power. It is required that transformers should have fire-resistant performance and reduce environmental burdens, because the transformer is installed in metropolitan areas in which transformers need the nonflammable or the less-flammable. This paper describes the development of the low-viscosity silicone immersed transformer and the gas insulated transformers using the new insulation systems with the new materials and these transformer applications in service. 2. Silicone immersed transformers (SITs) We are developing low-viscosity silicone liquid immersed transformers(SITs) as disaster prevention and environmental friendly type corresponding to recent large demand of electric power, especially in metropolitan area. Main features are such that using silicone liquid widely using to traction transformers with rich experience as insulation liquid, new silicone liquid is made to be lower viscosity in order to achieve equivalent cooling capability as mineral oil. Moreover, low-viscosity silicone liquid with high flash point higher than 250 is used. Operation and maintenance are equivalent to existing mineral-oil immersed transformers(OITs) and voltage class up to 66/77kV has already been developed[1][2]. One example of operating view is shown in the Fig 1.

Fig 1. 66kV 5MVA SIT (Installed in buiding)

2.1 Characteristics of Silicone liquid CH3 CH3 CH3 Low-viscosity silicone liquid is one kind of Polydimethylsiloxane whose construction is shown in Fig 2. CH3 Si O Si O Si CH3 Typical characteristics of each insulation liquid are shown in Table 1. On Table 1, flash points of silicone CH3 CH3 n CH3 liquids, ester oils, etc. are higher than 250 . Fig 2. Structural Formula of Silicone liquid Furthermore, 20cSt silicone liquid (hereinafter called (Poly dimethylsiloxane) low-viscosity silicone liquid) has the lowest kinematic viscosity among high flash point liquids and it is similar value with mineral oil in comparison with other insulation liquid. So comparatively evaluating, Low-viscosity silicone liquid is most superior during all the insulation liquid shown in Table 1. Table 1. Typical of insulation liquids. Liquids Properties Density (at 15 C) Pour point (C) Flash point (C) Kinematic viscosity mm2/s (at 40 C) Silicone liquid 20cSt 50cSt silicone silicone liquid liquid 0.95 < -60 > 260 16.0 0.96 < -50 > 310 38.0 Vegetable oil Natural ester oil 0.92 < -21 > 330 33 Rapeseed oil 0.92 < -27.5 > 334 36 Synthetic ester oil 0.97 < -50 > 274 30 Mineral oil 0.87 < -32.5 145 8

2.2 Insulation performance In order to evaluate insulation performance for composite insulating systems constructed from insulation liquid and conductor covered with kraft paper inside the transformer winding, insulation test was performed by using inter-coil models shown in Fig 3. Partial discharge inception electric field strength for AC voltage and for lightning impulse voltage are shown in Fig 4. It is verified that insulation design can be equivalent in SIT compared with OIT because ratio between the permittivity

of silicone liquid(=2.7) and the silicone liquid immersed papers(=3.7) is lower than that between the mineral oil(=2.2) and the mineral oil immersed paper(=3.5). This helps to create a much more balanced electric field strength between the liquid and the solid with in certain insulation structures, such that for a given voltage, the voltage stress in the fluid is less for the silicone liquid than for mineral oil.
Partial discharge inception electric field strength (p.u.) 1.5

110 mm

190 mm A

L.Imp. 1.0 L.Imp.

A Conductor covered with kraft papar 0.39 mm thickness) Pressboard spacer Insulation support A - A section

4.5 mm

0.5

AC

AC 0

Fig 3. Configuration of inter-coil model.

0.39mm 0.44mm 0.88mm 20cSt silicone liquid Mineral oil

2.3 Thermal capability Proto-type of 66kV, 6MVA natural cooling SIT was used to compare the temperature rise of lowviscosity silicone liquid with that of mineral oil between Low-viscosity silicone liquid and Mineral oil shown in Fig 5. The measurement results are shown in Table 2. Maximum liquid temperature rise and average winding temperature rise of 20cSt silicone liquid are almost equal to those of mineral oil. Table 2. Comparison of cooling performances of 20cSt silicone liquid and Mineral oil (measurement) Item Temperature rise (p.u.: mineral oil base) Primary Secondary Cooling Liquid winding winding (Max.) medium (mean) (mean) 20cSt 1.0 1.1 1.1 silicone liquid Mineral oil 1 1 1

Fig 4. Comparison of partial discharge Inception electric field strength

Fig 5. Proto-type of 66kV 6MVA SIT 2.4 Diagnostic technology

We develop diagnostic technology to diagnose aging or abnormal operating conditions, including thermal aging conditions of insulating paper and Low-viscosity silicone liquid, and abnormal discharge with dissolved gases produced under partial discharge conditions by using winding models or needle-plane models[3]. This technology assumes the use of kraft or aramid paper for conductor insulations, and it is effective for preventive maintenance. (1) Thermal aging characteristics[3] As for kraft paper-pressed board insulation system, aging of insulation paper can be evaluated amount of CO2+CO in low viscosity silicone liquid, shown in Fig 6.1. This method is the same one used to diagnose OIT. As for aramid paper-aramid board system, low viscosity silicone liquid would age rather than aramid paper and the aging can be evaluated by measuring dissolved cyclic siloxanes concentration(D3+D4+D5) in low, because . heat resistance is higher in aramid paper than silicone liquid [3]. (2) Discharging abnormal conditions As a result of developments, in all cases of kraft paper and in cases where total partial discharge energy is larger for aramid paper model and needle-plane

model, diagnostic by dissolved gas pattern be H2 leading type. Also in case of mineral oil, it seems that abnormality caused by partial discharge or arcing is frequency observed as H2 leading type, and gas patter used to diagnose OIT can be applied to SIT, However, the case that total partial discharge energy is small for aramid paper models and needle-plane models are methane (CH4) leading type. The pattern is similar to that of the overheating caused by poor contacts and leakage current in mineral oil.
Percent Tensile Strength Retained 100 80 60 40 20 0 0 50000 (CO 2 +CO)Gases (ppm) 100000
Loss of Mass() 0.6 0.5 0.4 0.3 0.2 0.1 0 1 10 100 1000 10000 Cyclic Siloxanes (D3+D4+D5)(ppm)

Fig 6.1. Relationship between dissolved (CO2+CO) gases concentration and tensile strength of aged kraft papers.

Fig 6.2. The relationship between dissolved Cyclic siloxanes concentration (D3+D4+D5)
and loss of mass of silicone liquid.

Inverse Square Root of Ignition Time[sec^-1/2]

2.5 Evaluation for fire-resistant (1)Sample liquidsTest samples used included mineral oil, as well as 20cSt and 50cSt siliconeliquids, natural estel oil, synthetic ester oil, and polyol ester oils, all of which are compliant with the high flash point insulation liquid specified in IEC-TS-60076-14. (2)Fire-resistant test methodFire resistant characteristics were verified for insulation liquids by Cone calorimeter method according to IEC60695-8-3 TS Ed.2.0 (IEC proposed method ) and glass tape method according to JIS C 2101 (current method). (3) Test resultFire-resistant test results for each insulation liquid are shown on Fig 7.1- 4[4][5]. Ignition time characteristics natural ester oil, synthetic ester oil, and silicone liquids are all equally lower than mineral oil. (As shown in Fig. 7.1.) Heat release rate characteristics The peak heat release rate of silicone oil is extremely low, followed by synthetic ester oil and natural estel oil, and mineral oil is outstandingly higher. (As shown in Fig. 7.2) Smoke production characteristicsSilicone liquid has the lowest peak smoke production rate followed by synthetic ester oil and natural estel oil, while that of mineral oil is markedly higher. (As shown in Fig. 7.3)
0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00 0 10 20 30 40 50 Radiant Heat Flux[kW/m2] 60
Mineral Oil Polyol Ester Oil Synthetic Ester Oil 20cSt Silicone Liquid 50cSt Silicone Liquid Natural Ester Oil

1500

1200 Heat Release Rate [kW/m2]

Mineral Oil Natural Ester Oil Synthetic Ester Oil Polyol Ester Oil 20cSt Silicone Liquid 50cSt Silicone Liquid

900

600

300

0 0 200 400 600 800 1000 1200

Fig 7.1. Correlation between inverse square root of ignition time and radiant heat flux to the sample's surface.

Time[sec]

Fig 7.2. Time histories of the heat release rate of burning insulation fluids

Fire transfer capability characteristicsNatural ester oil, synthetic ester oil, and silicone liquids posses a lower flame propagation velocity than mineral oil, which is considerably higher. (As shown in Fig. 7.4) As a result, silicone-liquids are most superior on all of fire-resistant tests within the sample liquids.
3.5 3.0
Smoke Production Rate [m2/s] Mineral Oil Natural Ester Oil Synthetic Ester Oil Polyol Ester Oil
0.020 0.018 0.016

Thermal ineteria 1/{C(Tig-To)2}^-1/2

2.5 2.0 1.5 1.0 0.5 0.0 0 200 400

0.014 0.012 0.010 0.008 0.006 0.004 0.002 0.000

Mineral Oil

20cSt Silicone Liquid 50cSt Silicone Liquid

20cSt Silicone Liquid Polyol Ester Oil Synthetic Ester Oil Natural Ester Oil

600
Time[sec]

800

1000

1200

10

Radiant Heat Flux[kW/m2]

Fig 7.3. Time histories of the smoke production Fig 7.4. Correlation between inverse square root rate of burning insulation fluids of ignition time and radiant heat flux to the sample's surface 3. Gas Insulated Transformers (GITs) Over the last few years, much attention has been paid to evaluating the risk of a transformer-related fire or explosion[6]. Such a risk must be avoided obviously, especially in densely populated cities and nature conservation areas where a fire or explosion could directly and gravely impact humans and the natural environment. Where the risk is unacceptable, the solution is to use gas insulated transformers using the inert gas sulfur hexafluoride (SF6), as a cooling and insulating medium which has excellent non-flammable and non-explosive characteristics. In addition to avoiding the risk, GITs permit substantial space saving at substations when they are used in combination with gas insulated switchgear[7] . 3.1 Two types of GIT There are two types of GIT[8] categorized by the charged pressure of the SF6 gas: low-pressure types (0.12 ~ 0.14 MPa-g at 20 C); and high-pressure types (0.4 ~ 0.43 MPa-g at 20 C). The latter type has a higher charged pressure, in order to boost the insulating and cooling performance of the SF6 gas. Fig 8 and 9 show typical low-pressure and high-pressure GIT, respectively. Figure 10 indicates conditions under which each type is used.

The largest capacity GIT in the world at present

Fig 8.110kV-50MVA GIT Fig 9. 275kV-300MVA GIT

(Low Pressure Type) (High Pressure Type)

Fig 10 GIT Application

3.2 Non-explosive characteristic of the GIT Safety is the most significant advantage provided by a GIT: the transformer tank will not rupture in the event of a power arc within the transformer, and the transformer cooling and insulating medium itself

is non-flammable, so the transformer will not cause a fire. Even if dissolved gas is generated as a result of a power arc, the pressure of the gas would not rise much as a whole because the gas is generated in the SF6 gas.The pressure rise characteristics of GIT is very different from that of an oilimmersed transformer when dissolved gas is generated in the insulating oil medium, which is a liquid. This is why the GIT can be said to be nonexp lo siv e. Fig 11 shows th e p ressu re rise characteristic of an 275 kV-class oil- immersed transformer (OIT) and a GIT in case of internal arcing failure involving a 40kA short-circuit current at the line terminal. The figure compares the internal pressure rise rate that would be observed in the tank of an OIT with that of a GIT. The figure Fig 11. Pressure Rise for Internal Failure clearly indicates that internal pressure rises much

less in the GIT than in the OIT.

< GIT > Gas pressure rise was basically obtained according to CIGRE WG23-03 report[9]. Gas pressure rise: P = Varcarctank Where : Constant , Arc voltage: arc = 400V, Arc current: arc = 40kA, Tank volume: Vtank = 43m3 The overall gas pressure rise was obtained by simply adding the gas pressure rise to the normal gas pressure during operation. Calculations were made only for a single-phase tank, and pressure propagation to other phase tanks was not considered. The pressure rise calculated by simplified formula leads to higher pressure rise than the actual pressure rise. < OIT > The tanks internal pressure can be balanced at the point where distension of the transformer tank compensates for the difference between the amount of gas generated by the arc and the amount of insulation oil transferred from the tank to another part. The way of thinking was used as the basis for calculating the internal gas pressure rise using a fluid motion equation[10], Where Arc voltage: ar c = 5000V, Arc current: arc = 40kA Amount of gas generated: 0.50.9arcIarc /sec Transformer tank configuration: Special 3 phase tank (3 single-phase tanks + 1 OLTC tank + conservator) Tank coefficient of expansion: 150L/Kg/cm2 OLTC tank coefficient of expansion: 25L/Kg/cm2 Conservator coefficient of expansion: 50L/Kg/cm2 The conservators rubber bag contraction amount was considered to be 2000L. (Cross sections of pipes connected to the conservator is large enough) Calculations took into consideration on conduit length and cross sections of the connecting pipes among other phase tanks. 3.3 Environmental considerations No suitable gas has yet been found as an alternative to SF6 gas. The non-flammable and non-explosive characteristics of SF6 gas would, in the event of an accident, greatly reduce the risk of loss of life in a large urban center or damage to the environment in a nature conservation area. Thus, the GIT should be used in such locations under suitable management conditions. 3.3.1 Management of SF6 gas in a GIT To prevent SF6 gas from being emitted into the atmosphere, much care is taken at every stage of the GIT life cycle, factory manufacture, testing, delivery to on-site installation, operation, maintenance

and final disposal at the end of its useful life. Fig 12 shows a scene during factory assembly, when tests was conducted to detect gas leakage by using the accumulate method with plastic sheeting. The concentration of any SF6 gas inside the sheeting is measured at the first stage of the test. Measurements are taken again 12 to 24 hours later, to determine the amount of any leaked gas by measuring the difference in gas concentration levels considering the volume inside the sheeting, the temperature, and the elapsed time. If any leaked gas is detected, further tests are performed by wrapping individual parts in plastic sheeting and performing gas leakage tests again using the partial accumulate method (see Fig 13). After factory tests are completed satisfactorily, GIT is disassembled for shipping. At this time, a special gas recovery device is used to recover all SF6 gas until the gas pressure is less than1.33 10-4 MPa (1 Torr). Once the unit is installed on site, only parts that were disassembled after the factory test are tested for gas leakage, by using the same testing method shown in Fig 13. Leakage measurement requirements are currently not more than 1% of the entire volume of the SF6 gas in the GIT, in accordance with JEC-2350 recommendations (Japan Electrotechnical Committee Standards for GIS). The permissible JEC-2350 leakage rate is being revised from 1% to 0.5% in conformity with IEC62271 requirements. The revision will take effect before the end of 2007. It is possible to reuse the SF6 gas from a scrapped GIT. SF6 gas is a valuable resource worth recovering and recycling.

Fig 12. Gas leakage test

Fig 13. Gas leakage test on individual parts

3.3.2 Statistical survey of SF6 gas leakage Fig 14 shows the results of gas leakage tests performed in the field on 40 dead tank type GCB units in commercial operation[11]. Gas seals in 300 locations were examined. Gas leakage rates, which were processed statistically by seal location lengths, were found to be 0.1% per year, indicating excellent gas seal performance. As GIT gas seal technology uses the same or similar method as that for the GCB unit, the results of the above-mentioned tests demonstrates the GITs high gas sealing performance.

Fig 14. Results of testing on a dead tank type GCB in the field 3.3.3 Protection of the natural environment Some GIT have been installed to replace older OITs, to eliminate any risk of oil leaking into a river in a national park in Japan. Thus in case it is installed outdoors / indoors, the GIT, which does not use an insulating oil medium, completely prevents the risk of leaking oil or a transformer fire that would

damage the natural environment. The risk is prevented at every stage, from installation to commercial operation. 4. Conclusion Summary of results in development of Disaster Prevention and Environmental Friendliness type SIT as are as follows. (1) Insulation capability of SITs can be designed in equivalent dielectric strength with OIT. (2) Cooling capability can be designed equivalent with OIT based on the similar value of Kinematic viscosity and temperature test results by proto-type transformer. (3) Diagnosis technology was developed for evaluation of aging and abnormal conditions. (4) As the results of fire resistant test for Low-viscosity Silicone liquid and other sample liquids, totally Low-viscosity silicone-liquid is most superior of all of fire-resistant tests including ignition time, heat release rate, smoke production rate and fire transfer capability characteristics tested by Cone calorimeter and others. Low-viscosity Silicone immersed transformers have high fire resistant capability and high cooling capability with environmental friendlly, so it is fitting to use in urban substations, and many unit are already operating in metropolitan areas. GITs are the solution for substations where the risk to fire, explosion and oil leakage are unacceptable, because GITs are non-flammable and non-explosive. GITs have already been installed in many urban areas where population densities are high, as well as in a nature conservation area, and their reliability has been proven. We intend to work even harder to promote their potential as eco-friendly transformers. GITs are far safer than OITs and protect the global environment. We developed SIT and GIT using the new insulation systems with the new materials. These transformers will be operating in many urban substations in the future too.

BIBLIOGRAPHY
[1] T.Kawamura,Development of environment-considerate disaster-prevention type low-viscosity silicone -immersed transformers and gas insulated transformers(CIGRE SCA2 & D1 ColloquiumBruges 2007, PS1-08) [2] A.Yamagishi,Fundamental study on Development of Transformer with Low-viscosity Silicone Liquid (IEEJ Trans PE,Vol.126, No.2, 2002) [3] A.Yamagishi,et al, Degradation Characteristic of Transformer with Low-viscosity Silicone Liquid, (IEEJ SA-05-105, 2005) [4] O.Sugawa,Study on Evaluation of Combustion Behavior of Insulation Fluids for Environmental Disaster-Preventive Transformers(ISH T8-156, 2007) [5] K.Suzuki, Experimental Study on Ignition and Combustion Behaviors of Insulation Fluid for Transformer using Cone Calorimeter(IEEJ Trans PE, Vol.127, No.7, 2007) [6] D. Allen, Fire Avoidance in Transformer Substations (CIGRE ELECTRA No. 231, April 2007) [7] Y. Fushimi, Solution for Environmental Features of Underground Substation By Gas Insulated Equipment (CIGRE Session 2002, 23-101) [8] N. Amano, Design Concept for Urban Substations: State-of-the-art Gas Insulated Transformers (CIGRE ELECTRA No. 215, August 2004, pages 8-14) [9] Testing of Metal Enclosed HV Substation (CIGRE ELECTRA No. 42) [10] Disaster Prevention Measures for Substation Electric Technology Research Association in Japan (Vol. 40-5, 1985) [11] Y. Fushimi, Activities for Huge SF6 Emission Reduction in Japan (CIGRE Session 2004, B3213)