2012 IEEE 10th International Conference on the Properties and Applications ofDielectric Materials

July 24-28, 2012, Bangalore, India

Novel Insulation system in power transformer

2
3
Aruna. M 1*, N. Vasudev , Ravi .K.N ,

V. V. Pattanshetti

1 Acharya Institute of Technology, Bangalore, India

2 Central Power Research Institute, Bangalore, India
3. Sapthagiri College of Engineering, Bangalore, India

*E-mail: arunamks@yahoo.co.in

Abstract: The service life of a power transformer is

governed by the condition of the insulating material.
Due to deterioration of the transformer insulating
material, the dielectric strength decreases and reduces
the ability of the transformer to withstand Voltages.
Novel hybrid insulation can be used in order to
improve the mechanical strength apart from the
dielectric property. The cellulose insulation is presently
used in the power transformer which deteriorates over
time and also affects the characteristics of the
transformers. By improving the mechanical properties
of insulation, the short circuit withstand strength of
the power transformers can be improved. The high
reliability and the long life of novel hybrid-insulation
may result in cost savings
Keywords: Kraft paper, Aramid paper,
Polymer, Moisture, tan 0, Resistivity, Tensile

G-Paek

Introduction: Cellulose
Paper is hygroscopic.
Moisture may p enetrate to the interior of the
insulation and will be affecting the electrical properties
and causing further degradation. Since the process of
cellulose degradation is not reversible, results in a
limited life span of the transformer with the life span of
the cellulose. Ageing of cellulose is due to pyrolysis,
oxidation and hydrolysis causing a reduction in
mechanical strength [1], [2]. Dielectric properties have
to improve in an insulation system and hence
development of novel polymer insulation technology for
power transformers is necessary [4]. The current
situation in the power industry together with worldwide
economic and environmental situation, have led to a
renewed interest in insulation technology. Novel
polymer insulation technology is growing and expanding.
Polymers are widely used for a variety of electrical
applications and finding increasing applications in
power sector. The electrical properties of such polymers
are strongly influenced to the environmental induced
degradation mechanisms.

978-1-4673-2851-7/12/$31.00 2012 IEEE

The effects on the polymeric insulators were studied to

determine its ageing property.
The final goal is solid insulation should have longer life,
better reliability, lower cost and reduced losses are the
incentive with less material requirement related to low
weight. Less material results in limited size of the
transformer and are most economical.
The goal of the study is to examine the thermal behavior
of G-Paek (Garda-Poly Aryl ether ketone) polymer
insulation at high temperatures under overloading
condition. Firstly, because of the temperature dependent
characteristics of polymer materials and for a better
understanding of the mechanical behavior, it is necessary
to investigate the thermal and mechanical characteristics
of this novel polymer at high temperatures [3]. Particular
attention is given to the thermal effect in polymer with
regards to the compatibility of the components and the
different thermal coefficients of expansion. This polymer
has outstanding high-temperature constancy. It has a high
incessant service temperature with the advantages of easy
processing by injection molding and other techniques
common to thermoplastic polymers. The paper presents
the details of the experiments on G-Paek polymer for its
thermal and other characteristics with the results.
G-Paek compounds:

Novel Hybrid insulation, G arda-poly aryl ether

ketone (G-Paek) is formed from a special heat driven
plastics manufacturing process, long polymer chains as
shown in figure 1. Extreme high Performance of
thermoplastic (Poly Aryl Ether Ketone) material is
vrrgm,
semi crystalline granules appropriate for
injection molding, easy movement, and Light brown in
color.
co

Figure
Structure of
ketone of Paek

o--t-

Poly Aryl ether

G-Paek compounds are a tough aromatic thermoplastic

polymer with properties for use as a high-distinction
thermoplastic. G-Paek has a molecular structure of semi
crystalline polymer with a crystalline melting point
around 643 K (370C) and a glass transition is around
426 K (153C). G-Paek polymer delivers extended high
temperature performance; also other advantages are
toughness, strength and chemical resistance over other
solid insulations. G-Paek was developed to offer design
engineers a high-performance alternative to other
polymer at an affordable price. In conclusion high
performance meets affordability.
A critical factor in the reduced life of the electrical
equipment is heat. The transformer experiences the
operating temperature depends on the type of insulation
used in the winding of the transformer. Regular insulation
lifetime decreases rapidly with increases in transformer
internal operating temperatures. Insulation classes are
classified based on thermal endurance of the system for
maximum temperature rating purposes. Generally
insulation classes are A, B, F or H. These codes designate
the maximum temperature of the insulation can withstand
without failure. The classes of higher insulation can avoid
the reductions in transformer life and tripping of the
transformer overload device.
Thermoplastic novel polymer G-Paek compounds, also
found wider applications in the power industry due to
their reversible property besides being easy to process.
During this research an attempt has been made to develop
novel polymer insulation with considering their
advantages in the background. The thermoplastic G-Paek
compounds considered for the research are discussed
below along with their properties. Under overload
conditions, it is necessary to inspect the thermal and
mechanical characteristics of this novel polymer at high
temperatures. Particular attention is given to the thermal
effect in polymer with regards to the compatibility of the
components and the different thermal coefficients of
expansion.
High overloads can generate excessive temperature in the
winding and insulation. To avoid this temperature rise,
transformers can be designed for rated power close to the
value of overload.
Specimen preparation:

Injection Molding is used for producing test samples in

which the polymeric materials are usually molded.
Material, generally preheated in the oven up to a specific
temperature and then the material is poured into the
hopper of the injection molding machine.

The injection molding machines consist of three major

sections, viz Hydraulic unit, heating unit and mold unit.
The hydraulic unit consists of hydraulic motor for rotary
and reciprocating movement of the screw, heating unit
contains 4 zones of barrel heating to melt the polymeric
material and [mally mold unit includes impression mold
assembly and mold locking system. The inlet to material
or hopper comes in between first two units.
The processing temperature is set at 300C, 340C,
360C, & 3 70C for heating zone one, two, three and
four respectively as the barrel temperature. The mold
temperature is maintained at 110C. Using a specially
designed press and punch dies cutter mold, standard test
specimen sheet of 2 rum thickness is prepared.

Figure. 2 G-Paek samples of shapes of dog

bones, circular and square
They were cut into standard dog bone, circular,
rectangular and square shaped specimens as shown in
figure 2.
Thermal Properties:

G-Paek polymers are used to form the structural

components that experience or continuously operate in
high temperature environments. Figure 3 shows the
graph, key thermal property and demonstrate that G
Paek polymers have higher thermal properties than other
solid cellulosic insulations. Kraft has operating
temperature of 110C, Nomex, Aramid have 180C.
Nomex starts shrinking, results in degradation above
their operating temperature. In case of G-Paek, shrinkage
does not occur until temperatures above 260C (500F).
Thermal stability in G-Paek have strong chemical link ,
this in order narrates to the chemical stability .AII
electrical equipment in power system including power
transformer should operate as normal as well as the
contingency conditions. It mainly affects the life of the
insulation system.

The exact insulation system is limited according to the

load capability. G-Paek has glass transition temperature tg
at 153C, is the most efficient thermal strength with
respect to solid insulation at high service temperature, as
shown in figure 3. Hence novel insulation in comparison
with existing cellulose solid insulations is having better
thermal properties.
G-PAEK

In case of Aramid paper with transformer oil, at the 400

Hours of ageing can retain 70% of tensile strength and at
the lOOO H ours of ageing can retain lO% of tensile
strength.
In case of G-Paek, it retains 90% its tensile strength at the
300 Hours of ageing, 50-60 % its tensile strength at the
1200 Hours of ageing.

Table 1: Tensile strength of G-Paek at different

Temperature

500U
Temperature 23
loOo 150
200
G-Paek Mpa

110

88

50

45

26

Moisture resistance:

Figure 3 Key Thermal Properties

Mechanical Properties:

In the selection of a polymer for an exact usage, a strong

understanding of mechanical properties is indispensable
to obtain for the best performance. Many test methods
are available to predict the mechanical performance of a
polymer under certain conditions. These include tension
tests, flexural tests.
G-Paek polymers reveal outstanding mechanical
properties over a wide range of temperatures. As shown
from the table 1, G-Paek has superior tensile strength
over a wide choice of temperatures when compared to
other polymer. It has 50% of in tensile strength even at
250C when compared to other solid insulation (Kraft
and Aramid). It suggests a beneficial increase in other
mechanical properties that will allow the flexibility
needed to create the best performing and lowest cost
applications. G-Paek has high thermal conductivity,
long-term thermal resistance, and low thermal expansion
when compared to other solid insulation. The G - Paek
composite has a higher conductivity than the other
polymer material due to its higher crystallinity. It has
high temperature flexibility and excellent insulating
characteristics.
In case of Kraft paper, tensile strength decreases in the
early stages itself. Degradation of Kraft paper with
transformer oil starts at the 400 Hours of ageing and
decreases its strength after lOOO Hours. At 400 Hours of
ageing, retains 40% of tensile strength and at the lOOO
Hours of ageing, retains 5% of tensile strength.

Moisture absorption is a key factor in dimensional

stability and also results in a reduction in certain
mechanical properties. The resulting swell makes it more
difficult to hold tight dimensional tolerances. G-Paek has
high resistance to moisture absorption. Moisture usually
contains free water, suspended water, dissolved water and
chemically bound water. Karl Fischer titration is used to
examine the moisture content in all solid insulation
samples aged in oil at 400 Hours, 800 H ours and 1200
Hours. A failure of solid insulation due to moisture leads
to a t ransformer failure and extended period of outage.
Frequently, moisture is a source of the explosion for a
service-aged insulation system of power transformer.
In case of Kraft cellulose insulation, moisture content
increases significantly. In case of Aramid cellulose
insulation starts degrading for ageing in oil at 800Hours,
by testing identified that it contains 10.55 ppm of
moisture content. As cellulose insulation age increases,
moisture content also increases. G-Paek has low moisture
absorption. Moisture content in ppm in all solid
insulations as ages explained in figure 4.
Moisture content
l'
12

Figure 4 Moisture content ( ppm)

measured at 0.5 grams of aging oil

Electrical properties:

Even at 1200Hours of ageing, the least moisture content

of 0.96 ppm found in G-Paek. Henceforth G-Paek is
efficient solid insulation can be used in the power
transformers.
Flammability: G-Paek has ability to sustain a flame
upon ignition in a mixture of oxygen and nitrogen. The
flammability rating of G-Paek allows designing parts
thinner in the coating on the winding of the power
transformer and more cost effective.
SEM Analysis: Scanning Electron Microscopy study
was carried out in order to estimate the extent of
degradation in aged solid insulations test samples under
accelerated thermal and electrical stress. All test samples
were inspected for 500X magnifications in SEM
technology. An SEM analysis study was conducted by
using JEOL, Model JSM S40A (Japan) at IISC,
Bangalore. Coated test samples with gold for scanning
under SEM. Result of SEM for test sample G-Paek
indicates thoroughly crammed polymer molecules and
less number of pin holes as shown in figure 5. It clearly
indicates magnification micrograph when compared with
G-Paek, the fibers loosely linked of about 55% in
Aramid and 22% in Kraft cellulose paper insulation.
This is a distinctive identity of nature of the solid
insulations when aged due to the result of thermal
electrical and chemical degradation process. The SEM
micrographs images indicate that more pin holes are
present on the surface matrix composite causes more
wear and damage of the insulation system. G-Paek
micrographs have less pin holes when compared to Kraft
and Aramid micrographs. Hence G-Paek has more
tensile strength.

The most dangerous defects in insulation are caused by

electrical degradation. Electrical degradation will affect
the insulation both local and haphazardly. The defect
leads to [mal breakdown. The electric stress which is able
to endure may be due to charge transport, thermal or
mechanical properties and a co mpletely comprehensive
can only be gained by considering all of these. The
earliest breakdown theories treated breakdown events as
arising from thermal instabilities. Such uncertainties
could be in the steady-state power balance is in between
electrical heating and cooling or they could exist
essentially as a p ositive response process between
temperature and conductivity of insulations. Electrical,
thermal, mechanical or environmental stresses whose
action in an insulating material cause ageing. Electrical
properties like Loss Tangent, Dielectric constant,
Breakdown strength and Electrical Resistivity is as shown
in tables 2,3,4,5 and figures 6,7,S in Kraft, Aramid and G
Paek respectively.
Table 2 : Loss Tangent of Kraft, Aramid and GPaek
Polymer
Ageing
Kraft
Aramid
G-Paek
in Hrs
400
3.56 X1O-4
4.34 X1O-4
7.31 X104
SOO

12.26 X10-4

S.S9 X1O-4

6. 93 X1O-4

1200

IS.15 X1O-4

14.56 X10-4

10.34 XO-4

Loss

tangent

Ageingin Hrs

20

15

x
c

10

.'3
0

Kraft

Ararnid

LSOlid .--;;;ulat:ions l

G-Paek

Figure 6 Loss tangent of Kraft, Aramid and G-Paek

polymer
Aramid

G-Paek

Figure.5 SEM micrograph images (500X)

The SEM analysis reveals that novel polymer G-Paek

insulators have negligible surface roughness. .
Hydrophobicity or water repellent is an expression of the
fundamental chemical characteristics of the polymer
skeleton.

The loss angle of G=Paek have less as compared to other

cellulose insulation. G-Paek has a range of 10.34 X 10-4 at
1200Hours of ageing and IS.15 X 10-4 in Kraft and 14.56
X 10-4 in Aramid . So G-Paek can withstand more thermal
capacity.

Breakdown strength

Table 3 : Dielectric constant of Kraft, Aramid and

G-Paek polymer
Ageing in Kraft
Aramid
G-Paek
TT.

400
800

3.7
3.1

4.8
4.3

9.8
8.6

1200

2.4

3.9

7.8

10

Aramid

Aramid

G-Paek

Solid In,ulations

r-----

Kraft

Kraft

Afleingin Hr

Dielectric Constant

G-Paek

Solid Insul.tions

Figure 7 Dielectric constant of Kraft, Aramid

and G-Paek polymer

G-Paek has dielectric constant values of 7.8 at 1200

Hours, 2.4 in Kraft and 3.9 in Aramid. Above
designated values show that G-Paek have excellent
dielectric strength.

Figure 8 Breakdown strength of Kraft, Aramid

and G-Paek (Kvrnm-I)

In case of Kraft cellulose insulation BDV value was

reduced from 65.0 KV (new oil) to 45.7KV (end of
aging). In case of Aramid paper insulation BDV value
was reduced from 72.0 KV (new oil) to 58.98KV (end of
aging). In case of G-Paek insulation BDV value was
reduced from 78.00 KV (new oil) to 62.35KV (end of
aging). G-Paek shows enhanced improvement in
reversible degradation than cellulose insulation.
Table 5 : Electrical Resistivity of Kraft, Aramid and
G-Paek polymer
Ageing in
Kraft
Aramid
G-Paek
400

1.2X101L

I.4XlOI4

1.7X101O

800

2.4X1011
1.6X10II

3.2XlOu

2.65XlOl

2.6XlO13

1.97XlOl6

1200
Table 4: Breakdown strength of Kraft, Aramid and
G-Paek (Kvmm-I)
Ageing in
Hrs

Kraft

Aramid

G-Paek

400

65.0

72.00

78.00

800

55.67

68.32

70.23

1200

45.7

58.98

62.35

Hence all these withstanding strengths shows the

application as excellent solid insulation can applied to
the power transformer. G-Paek resistivity at even
1000Hours of ageing has in the range of 1016 Q-cm when
compared with cellulose of 1011 Q-cm and 1013 Q-cm. It
proves that G-Paek have more resist for thermal and
mechanical stresses.
Advantages of G-Paek Polymer: G-Paek
suitable for high temperature application like higher
strength & stiffness in application of load bearing,
excellent wear resistance, chemical resistant to aggressive
environments. Also mechanical strength at advanced
temperatures is excellent and better electrical
performance.

It has enhanced compressive strength, meaningfully

improved hydrolysis resistance, Exceptional radiation
resistance and chemical resistance at high temperatures,
Ultra-Low Outgassing and very high purity, Delivers
more wear resistance. G-Paek polymers are suitable for a
wide range of applications where outstanding
performance in mechanical, thermal and chemical like
Aerospace, Automotive, Coatings, Electronics , Food
Contact, Industrial, Nuclear, Oil and Gas, Shapes,
Semiconductor , Wire and Cable.
CONCLUSION:

G-Paek polymer was developed with a combination of

high-performance properties at an affordable price.
Particularly promising are insulation that offers greater
resistance against electrical compared with resistance of
other polymer. High thermal properties of power
transformer with G-Paek polymer allow us to increase
the rated transformer power.
By using thermal
upgraded novel G-Paek polymer insulation system
negligible risks, decreases losses in insulation system,
improve fIre safety, grain overload-ability and reduces
temperature problems. Hence transformers at higher
operating temperatures with novel insulation material
results in reduced weight and size of the transformer.
Owing to the reduced cooling system, this results in less
Insulating fluid. By using of novel G-Paek insulation
system in the power transformer, reduces material use
without increasing the losses, leads to reduce in the
cost.

Acknowledgement: I would like to acknowledge

Dielectric materials division and HV Division CPR!,

Bangalore for the support given for the project work.

References:

[1] H. Z. Ding Z. D. Wang "On the egradation

evolution equations of cellulose" Cellulose ( 2008)
15:205-224 DOl 1O.1007/s10570-007-9166-4.
[2] Hiroyuki Sugimoto, Tsunehisa Miki , Kozo
Kanayama , Misato Norimoto, "Dielectric relaxation
of water adsorbed on cellulose" Journal of Non
Crystalline Solids 354 (2008) 3220--3224.
[3] v. Sokolov, Z. Berler, V. Rashkes "Effective
methods of assessment of insulation system in power
transformers: A view based on practical experience"
[4] Petru V. NOTINGHER, Laurentiu BADICU,
DUMITRAN1,
Marius
Gabriel
Laurentiu
TANASESCU and Dorin paPA," "Dielectric losses in
international
insulations"
7th
cellulose-based
conference on electromechanical and power systems
October 8-9, 2009 - iai, Romania.
[5] A John Wiley & sons, inc., Publication "plastics
materials and processes a concise encyclopedia".