ISSUE 11

APRIL 2021 transformer-technology.com ISSN 2642-2689

Impact of the
Next Generation
of Design

Interview with Luiz Cheim, Senior Principal R&D Engineer at Hitachi ABB Power Grids
Design for the Future. Design for Success. Design for Safety.
Interview with Khayakazi Dioka, Corporate Specialist – Transformers and Reactors, Eskom Holdings SOC
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4 EDITORS &
IMPRESSUM

Impressum Editors

Editor in Chief Editor in Chief

Alan M. Ross, CRL, CMRP Alan M. Ross CRL, CMRP
Transformer maintenance
Associate Editor in Chief and reliability
Corné Dames 26 years industry
Independent transformer consultant experience

Contributing Editors
Diego Robalino, PhD, PMP
IEEE Senior Member Associate Editor in Chief
Jon Trout, PE and Chair of the Technical
Electric utility Advisory Board
Alan Sbravati, ME, MBA Corné Dames
Transformer insulating materials Independent transformer
Marco Tozzi, PhD consultant
Diagnostics and asset monitoring Transformer oils
Curtus Duff 20+ years industry
Power transformer design experience

Chair of the Technical Advisory Board

Corné Dames
Independent transformer consultant
Contributing Editor
Diego Robalino PhD, PMP
Technical Advisory Board Member
Edward Casserly, PhD
IEEE Senior Member
Senior Scientist, Transformer oils Transformer condition
Maria Lamorey assessment and
Industrial OEM manufacturing diagnostics
20+ years industry
Graphic design experience
Bekoncept Communication Boutique

Photo Cover
Shutterstock

Sales & Marketing Technical Advisory

Kevan Sears Board Member
[email protected] Edward Casserly, PhD
Senior Scientist,
Sales & Marketing Americas Transformer oils
Maria Salamanca 35 years industry
[email protected] experience

Sales & Marketing Mexico

Fernando Campos
[email protected]

Sales & Marketing Brazil Technical Advisory

Marcelo Braga Board Member
[email protected] Maria Lamorey
Industrial OEM
Marketing Global manufacturing
Marin Dugandzic 35 years industry
[email protected] experience
Transformer Technology April 2021 5

Issue 11

The Power
to Deliver
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utilities, Ergon’s HyVolt dielectric fluids are known for consistent quality, low
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6 EDITORS &
IMPRESSUM

ISSN 2642-2689 (Print)

ISSN 2642-2697 (Online)
Contributing Editor
DIGITAL Membership Jon Trout PE
Free Electric utility
14 years of experience
Transformer Technology magazine is a quarterly
magazine published by APC MEDIA LLC, 11210
West Rd, Roswell, GA 30075, USA. Published
content does not represent official position of APC
MEDIA LLC. Responsibility for the content rests
upon the authors of the articles and advertisers,
and not on APC MEDIA LLC. APC MEDIA LLC Contributing Editor
maintains the right to keep the textual and Alan Sbravati ME, MBA
graphical documents submitted for publication. Transformer insulating
materials
Copyright and reprint permission 18 years of experience
Abstracting is permitted with credit to the source.
Libraries are permitted to photocopy isolated
pages for private use of their patrons.
For other copying, reprint or republication
permission requests should be addressed to
[email protected]

Publisher: Contributing Editor

APC MEDIA LLC Marco Tozzi ME, MBA
1317 Winding River Trail Diagnostics and asset
Woodstock GA 30075, USA monitoring
15+ years of experience
transformer-technology.com

Contributing Editor
Curtus Duff
Power transformer design
4 years of experience
 Transformer Technology April 2021 7

Issue 11

Keep Your
Transformers
Working Reliably
in Extreme Conditions

Designed for Durability

The B100 Electronic Temperature Monitor enclosure is
designed to be rugged and durable to protect against
harsh environments created by water, dirt, dust and
temperature extremes. No calibration is required to
maintain accuracy.

Now with Optional H2 Monitoring!

RESPONSIVE To learn more about the B100 Monitor
visit: www.dynamicratings.com/b100
8 TABLE OF
CONTENTS

Index Contents

Table of
Editors & Impressum_04

Table of Contents_08

Editor’s Letter_14

Interview with Luiz Cheim, Senior

Principal R&D Engineer at Hitachi

18
Interview with Luiz Cheim,
ABB Power Grids_18 Senior Principal R&D Engineer
Technology Insights by Corné at Hitachi ABB Power Grids
Dames_28

New Options for Insulation Systems

in Power Transformers_36

Interview with Khayakazi

Dioka, Corporate Specialist –

Transformers and Reactors, Eskom

Holdings SOC_46
Transformer Technology April 2021 9

Issue 11

28
TECHNOLOGY INSIGHTS
by Corné Dames
In her new article, Corné Dames focuses
on environmental concerns, fire safety,
physio-chemical properties, and thermal and
dielectric performance of natural esters.

36
New Options for
Insulation Systems in
Power Transformers 46
Insulation systems for liquid filled power Interview with Khayakazi
transformers are a combination of Dioka, Corporate Specialist
materials that are aimed to provide the
required electrical, mechanical, thermal
Transformers and Reactors,
properties together with a full chemical Eskom Holdings SOC
compatibility for successful operation
of the transformer for several decades
under defined operation conditions.
10 TABLE OF
CONTENTS

Index Contents

Table of
21 Advantages of using Micafluid

technology in 2021_54

Insulating Oil Field Fill: Challenges

and Remedies_58

Why Do Some Bushings Fail?_62

Design for the Future. Design for

Success. Design for Safety._66

The Sen Transformer_74

Coming in May_81

54
21 Advantages of using
MICAFLUID technology
in 2021
Transformer Technology April 2021 11

Issue 11

58 66
Insulating Design for the Future.
Oil Field Fill: Design for Success.
Challenges Design for Safety.
and Remedies The reliability of electrical power creation and
Following the precipitous drop in large power transformer distribution must be continually safeguarded
(LPT) demand in the U.S. that started in the mid-1970s, and improved. This does not happen by chance
and then an explosion of new LPT installations that or through reactionary-maintenance tasks. This
has been ongoing since the early 2000s, what are the must be focused on from the early design stages
challenges facing the specialty refiners in the insulating oil and continued through the life of the assets
field fill market? Chris Kenney shares his expert opinion. tasked with these functions.

74
62 The Sen Transformer
Why Sometimes, a technical advance comes along that
is both simple, elegant and effective. This article
Do Some brings us the Sen Transformer, a solution that
Bushings offers a plethora of power flow control features
Fail? all in one unit and uses time-tested components
proven to be reliable, cost effective and portable to
meet today’s needs for a smart grid.
 TRANSFORMER
INSULATION SOLUTIONS
 TRANSFORMER
Transformer Technology April 2021 13

Issue 11

INSULATION SOLUTIONS
RESINS AND VARNISHES COMPOSITES
PRODUCT CHEMISTRY APPLICATION / FEATURES OIL FILLED DRY/CAST TRACTION PRODUCT STANDARD

Dolphon Epoxy 1k Impregnation resin, excellent X X Durapol F200 UP GM 203

CC-1180 mechanical and chemical GPO-3
resistance, VOC free, EN45545-2
approved Durapol M600 UP GM 205
Dolphon Epoxy 1k Impregnation mainly for traction X X Vetronit G11 EP GC 203
CC-1118 transformers, excellent G-11
mechanical and chemical resis-
tance, VOC free, thixotrop, Vetronit G11 T EP GC 22
EN45545-2 approved G-11
Treillis 64330
Hi Therm Polyester Impregnation and coating, hot X
BC- curing
346A, BB-
346A,
BR-346A NEW CONDUCTIVE POLY GLAS®
Dolphon Polyurethane Low temperature curing, flexible X C155 – TWO JOBS AT ONCE
BC-359, impregnation and coating
BB-359 At high voltage, the lamination stack need
to be electrically shielded to avoid local
Dolphon Polyester in Flexibilized impregnation resin, X increases of the electrical field at sharp
CC-1305 DAP low VOC
edges.
Permafil Polyester Special non-greening polyester X
724CT resin, low weight loss during By using a conductive banding tape, the
heat aging
usage of a metallic core shield in ad-
Permafil Polyester Unique semi-rigid solventless X dition to a mechanical fixation tape is
709T polyester with excellent tank obsolete. The quality is improved and the
stability process simplified, as the same process
Dolphon Polyester in Industry standard, high reactivity, X X applied for standard banding tapes can
CC-1105 DAP low viscosity, low VOC be applied. Material usage and cost can
be optimized because of the high me-
Dolphon Polyester For high thermal properties, 100% X chanical strength of the Poly Glas® C155
XL-3102 label free impregnation compared to other conductive materials
resin, high reactivity, low viscosity like cloth based prepregs.
Synthite Polyurethane Coating varnish, air drying X
AC 41
PROPERTY VALUE
Synthite Polyester Coating varnish, air drying X
AC 43
Thermal class F (155 °C)
Dolphon Epoxy 2k Coating varnish, best protection X
CW-1081 Thickness 0.33 mm

Base weight 550 g/m2

Resin Content 26%

BANDING
Curing conditions 3h @ 150 °C or
5h @ 135 °C or
PRODUCT DIMENSIONS APPLICATION / FEATURES OIL FILLED DRY/CAST TRACTION 14h @ 120 °C
Poly Glas® up to 1“ width Core leg support, Bandage, X (X) X Tensile strength 2500 N/cm per layer
76830 300, 750‘ standard duty material after curing,
length at 20 °C
Poly Glas® up to 1“ width Core leg support, Bandage, X (X) X Tensile strength 1800 N/cm per layer
76843 300, 750‘ moisture resistant formulation after curing,
length at 155 °C
Poly Glas® up to 2” width Core leg support, Bandage, X (X) X Specific surface 5 - 25 kΩcm/cm
76870 300’, 750’, moisture resistant formulation resistance after
1500’ length curing
Poly Glas® 50 mm (2“) Electrical shielding and X Specific volume 20 - 500 kΩcm
C155 width mechanical banding of core resistance
100, 200 m columns
length

FLEXIBLE LAMINATES CONTACT

Von Roll offers a broad range of standard and custom flexible laminates, combining different materials. With our Von Roll USA, Inc.
unique production capabilities we can offer widths up to 72” wide as well as special constructions designed for 200 Von Roll Drive
specific applications for our customers including a wide range of coated products.
Schenectady, NY 12306
USA
PRODUCT DIMENSIONS APPLICATION / FEATURES OIL FILLED DRY/CAST TRACTION

KMK up to 36“ wide Kraft paper / Polyester film X X

DMD up to 72“ wide Polyester mat / Polyester film X X P+1518-344-7100

F+1518-344-7288
NMN up to 72“ wide Aramid paper / Polyester film X
[email protected]
NKN up to 36“ wide Aramid paper / Polyester film X X

Special up to 36“ wide Pre-insulated copper or aluminum X

laminates foil laminate for strip winding

Coated up to 72“ wide Epoxy coated for layer insulation X X www.vonroll.com

Nomex
14 LETTER FROM
THE EDITOR

Dear Readers,

As a reliability professional, I see things from a I mentioned that I tend to view things through the
unique engineering perspective. Reliability is de- lens of reliability, which starts with a high-level
fined as the ability of an asset – and I would in- view of asset reliability:
clude a system – to perform its designed function
for its useful life. We could also safely add: If de- Design for reliability
signed properly and with proper maintenance This means avoiding unplanned outages and oper-
and operations, the lifecycle of that asset or as- ating in a way that is the normal operation of the
sets in a system can extend the life of the asset or asset in a system. For instance, we know that GSUs
the system. But that would be for another theme need to run at over-rating during highly demand-
and another time. For this issue, we are focusing ing times.
on the impact of current technology on the design
of transformers. Operational parameters
Same as above. Also, we know the abuse a furnace
When you consider the impact of the next gener- transformer takes in any industry like metals, glass,
ation of design, then when considering the design paper and food products and more.
of assets like transformers you quickly realize that
they are also greatly impacted by the design of Maintenance protocols
the components that make up the asset. As com- This might be one of the areas where changes
ponents change to meet the needs of the asset, to need to be made. How do you maintain a trans-
meet the needs of the system, you can see how the former when it has already exceeded its planned
next generation of design can actually take on a life by decades? As I presented at the most recent
life much greater than originally anticipated. IEEE-ESW event, preventive maintenance is often
the cause of unplanned or lengthy shutdowns, as
When we originally came up with the idea for this is predictive.
issue of Transformer Technology, we did not an-
ticipate how the unlimited ability for component Lifecycle planning
design could impact overall transformer design. It’s not just transformers that have aged well be-
What we did find was that the component designs yond their planned life. Cable systems, bus-work,
have to be considered, especially when those de- generators and so many more electrical system as-
signs actually increase the reliability of either the sets have lasted far longer than expected. Given
component or the component within the asset that studies indicate that only 11% of failures are
structure. I know! Only a reliability geek would due to age, this means we have a lot of life left in
think this way, right? billions of dollars of assets.

Let's look for instance at the design of bushings

and what's happening with the next generation of
bushing design. Resin-impregnated bushings and
new fluids within oil-filled bushings, and in gen-
eral the whole idea of the design of bushings, is
allowing for a more reliable transformer, which
means that we have to decide how those chang-
es in bushings will impact the overall reliability of
the system. This also impacts the lifecycle of the
transformer.

One of the things we did not expect was to be able

to look at the design of fluids and the impact that
that design has. For instance, Corné Dames in her
article on natural esters highlights the changes
that are taking place in the oils and fluids design
as part of transformer reliability.

Further down the line, in our September/October

issue we will delve even more deeply into oils and
fluids, and then in the November/December is-
sue we will look at bushings and other component
parts. But for this issue we just wanted to focus on
the plethora of component design changes that
are changing transformer design.
Transformer Technology April 2021 15

Issue 11

Coming in June is something

Alan M Ross
all of us at APC Media are
tremendously excited about, so
expect our announcement soon.
Not only is it the theme for a
June issue – it is the basis for a
New Community we will
be starting and supporting.

So, enjoy this issue and once you enjoyed it, share
the entire issue or just one article or interview with
someone you know can benefit from it. A thou-
sand do every month and for that we are grateful.

Coming up next for May is the theme: From Speci-

fication to Commissioning: Better Practices for
Better Outcomes. We already have a great issue
lined up but because it is a two-month issue, we
might be able to squeeze in another article or an
interview. If you have an idea, then connect with
me at [email protected].
I’d love to hear from you.

Finally, coming in June is something all of us at

APC Media are tremendously excited about, so ex-
pect our announcement soon. Not only is it the
theme for a June issue – it is the basis for a new
Community we will be starting and supporting.
Curator of the Community
Transformer Technology
Alan M Ross
Editor in Chief

President of EPRA
CRL, CMRP
16 TECH
TALKS

YOUR PASSION
AND KNOWLEDGE
ARE IMPORTANT
TO US

JOIN OUR
#COLLABORATIVE COMMUNITY

Are you passionate and knowledgeable

about your area of business or expertise?

Now You can contribute to knowledge

sharing in the transformer industry by

sharing your field experiences, case

studies, research results, or simply your

knowledgeable opinion on a topic of

interest to the industry.

Contact us at
[email protected]

to find out how you can

become part of the
Transformer Technology
community.
Tech Talks

To watch and listen visit

www.transformer-technology.com/
community-hub/tech-talks
 18

Senior Principal R&D Engineer at

Interview with Luiz Cheim Hitachi ABB Power Grids

Luiz Cheim
FEATURE
INTERVIEW
 Transformer Technology April 2021 19

Issue 11

I think research is in

The story behind the submersible

my DNA, as it is for

transformer inspection robot

Hitachi ABB Power
Grids. We are never
satisfied with the
world as we see it and
are always thinking
of better ways to
do things based
on innovation and
technology.
Photo: Hitachi ABB Power Grids
20 FEATURE
INTERVIEW

Alan Ross, the Editor in Chief of Transformer Technology magazine, spoke

with Luiz Cheim of Hitachi ABB Power Grids about TXploreTM, a service that
utilizes a submersible inspection robot to inspect and detect problems
inside fluid filled power transformers. Luiz was Alan’s guest on a recent
Tech Talk, and this interview is an edited excerpt from that.
Alan Ross: I first saw a demonstration of the I then moved to England where I worked at
submersible robot service for transformers - the Electrical Engineering Department of
TXploreTM, at the Doble Conference in 2018 Nottingham University for a number of years,
by the now retired ABB engineer, Craig and obtained my PhD, before I decided to go
Stiegemeier. Before we get into the TXploreTM, back to Brazil, where I worked with the same
Luiz, could you tell us a little about your research institution for another seven years.
background and career? I then worked for Siemens for eight years,
Photo: Hitachi ABB Power Grids

before I moved to Canada to join ABB and

Luiz Cheim: I am originally from Brazil and finally to the US, where I now work with Hitachi
my career has been a long journey. I received ABB Power Grids. I have also been heavily
my electrical engineering degree in Rio de involved with CIGRE, serving as the head of the
Janeiro in the 1980s and a master’s degree CIGRE Transformer Committee in Brazil from
while working at a research institute in Brazil. 2000 to 2006.
Transformer Technology April 2021 21

Issue 11

Professionally, I have always liked research. I Eric came out sweating from the transformer.
think research is in my DNA, as it is for Hitachi As I stood there, he would go back in and come
ABB Power Grids. We are never satisfied with out in intervals of 15 minutes. And I thought to
the world as we see it and are always thinking myself, there should be better ways to do this.
of better ways to do things, based on innovation
and technology. This wasn’t the first time I had seen that. I had
seen inspections before and even took part in
I have contributed to multiple patents in the a couple of them with my previous employer.
US and globally. The plaques you can see But for some reason that day, because of the
behind me at my office are gifts from Hitachi circumstances and the hot conditions, I went
ABB, in commemoration of those patents. The back to the office and thought, we have to do
submersible robot will add fifteen more to the this differently.
collection, hopefully.

As for the robot, robots have been used for

many years, but they have never really been
applied to transformers – so that was my
thinking as well.

AR Let’s talk about the robot. I presume

you were doing your research and
saw a problem relating to transformers. What
was the problem that you saw and decided you
were going to solve?

LC This is quite interesting. At that time

there was no product development
on robotic submersibles. There was nothing of
that kind. So, I was not looking for a solution to
a problem. I actually witnessed a situation on
site where I thought to myself: There must be a
better way of doing this.

I was invited to a customer meeting that took

place in a very large substation. I met the
customer and the group of engineers, and they
thought I might be interested to know there
were my colleagues at the site doing transformer
inspection. I didn’t know that because I was not
involved in that activity at that time.

They invited me to meet my colleagues and

see what was going on. We walked around the
substation to see an internal inspection of a
power transformer on a very hot day. The oil
had already been drained from the transformer
and I saw my colleague Eric standing there
ready to start the inspection.

Internal inspections of transformers are And this is how the idea was born. I started
difficult tasks in confined spaces, you need well searching online asking myself: Is there a
trained people and complete compliance with rulebook on how to solve this problem? Is there
required procedures to manage certain HSE a camera that we can send into transformers?
(Health and Safety) risks. I started digging, looking at pictures. The first
thing I found was a submersible 360-degree
Internal inspection of a transformer takes place camera, and I thought, maybe we can use this.
in a confined space where you enter through a
manhole, there is not much room inside and it I started brainstorming, and this is one of the
is dark, with an oily smell and oily surfaces and reasons why Hitachi ABB Power Grids is first
with the oxygen content being monitored to class. The company has what is called The
make sure the atmosphere inside is breathable, Innovation Database. So, I started sketching the
with dry air typically pumped in. idea of innovation because I knew we had to do
22 FEATURE
INTERVIEW

this differently. We need to send a machine, not

a human, inside the transformer. What would
be the advantages of that? Obviously, we don't
The robot can dive and go risk the health of an employee. Maybe, if we
do it successfully, we could save time so the
deep into places a human customer would benefit from having a much
lower downtime.
cannot reach and send a
I then took the idea of a submersible camera
very good image of what it to a few very experienced colleagues, and
they thought that customers and transformer
sees. The spectrum of views owners would never allow a foreign object to be
inserted into their five-million-dollar asset. You
can be observed and jointly should forget about it, some said.

What was needed was a change of paradigm

analyzed by the designers of because there was no idea like it before. But one
colleague from Switzerland had a vision and he
that very same transformer, as said, Luiz, I think we have something here that is
a paradigm changer!
the inspection is happening,
anywhere in the world.

Photo: Hitachi ABB Power Grids

Transformer Technology April 2021 23

Issue 11

He started discussing it internally and asked and Services (TCS). Craig Stiegemeier, for
me how I was planning to do this. I said I had no example, was in that group and he was very
idea; I am just a transformer guy! I am heavily supportive all the way, as was the robotics team.
involved with R&D working with algorithms and
machine learning, but I don't know how we are Obviously, we needed the material support, but
going to do this. We then planned to bring the without the robotics team, this would just be a
expertise we had in-house from our robotics good idea stuffed in some drawer somewhere.
team, who had nothing to do with transformers, They embraced the idea and put a lot of energy,
but they were looking for internal projects they people and money into it. Our two groups
could apply their know-how to. worked together for the first time ever. We
created a steering committee that included a
We brought them to the St. Louis factory in few people from the robotics team and a few
the US, presented my proposal and they said, from our team, myself and Craig Stiegemeier
Wonderful, let's do this together! included.

At this point I have to say, yes, I was the The steering committee was there to make
generator of the idea, but I had a huge support sure that the resources allocated to the project
from our entire organization bringing together were properly distributed and that we had the
the transformer knowledge from the TRES right people for it, as we were on a journey to
group – now called Transformer Components develop a technology. Yes, robot technology
was available, but not for transformers. There
was no robot that could navigate inside mineral
oil and clearly see things that are designed by
electrical and mechanical engineers.

It took us four years from the day I saw Eric at

that substation to develop the first prototype
that we started to test on real transformers.

AR The fact that ABB at the time allowed

the persistence and spending of time,
money, and human resources for four years to
get there speaks volumes about the company’s
commitment to a new future.

If I were a customer with a five-million-dollar

transformer that I was planning to shut down and
open up, and spend thousands or even hundreds
of thousands of dollars, bringing
in all these people, what
would you tell me
after your four-
year journey?

Don't do what you've been

doing for a hundred years
just because that is the way
you have always done it.
24 FEATURE
INTERVIEW

In the next decade I do

not expect to see a single
transformer being inspected
Obviously, the expert also needs to understand
in a conventional way because the transformer, the design, and what we
are looking for. You also might need to get a
permission from the planners or operators to
I believe that this technology disconnect the transformer. Then you have to
count on a downtime of three to six days.
is here to help people and
The number of variables and the costs can be
companies to reduce and huge. If you can do all this in a matter of hours
instead of days, that makes good sense, doesn’t it?
minimize risks and costs, and
In the next decade I do not expect to see
to optimize downtime. one single transformer being inspected in
conventional ways because I do believe that this
technology is here to help people and companies
to reduce and minimize risks and costs, and to
optimize downtime. You can do it properly and

LC Don't do what you've been doing for

a hundred years just because that is
the way you have always done it. Always ask
the robot can get to places that no human can.

The robot can dive and go deep into places a

yourself: What is a better solution? This is almost human cannot reach and send a very good image
academic. You don’t need to send people to such of what it sees. The spectrum of views can be
an inhospitable environment for 15 minutes at a observed and jointly analyzed by the designers
time. During the inspection, the expert also has to of that very same transformer, as the inspection
Photo: Hitachi ABB Power Grids

take nice pictures. He has to go in with a camera is happening, anywhere in the world. The robot is
and take a good shot even if the lighting is poor. able to communicate all the images – which was
And these shots have to be of high quality so that one of the 15 patents of this project. The processing
people like you and me can clearly see if there is a of images and the speed of communication
problem or not. It takes a very skilled person to do between the robot and the outside were one of
that, which is what Eric was. the difficulties we had to overcome.
Transformer Technology April 2021 25

Issue 11

dark with age, so the

robot needs special
vision and special
There were so many factors lighting.

that we had to specifically There were so

many factors
develop for this robot, that that we had to
specifically search
we ended up with 15 patents. for or develop
for this robot, that
we ended up with 15
patents. Everything we
designed for navigation
in mineral oil had to be new,
created from scratch. One new idea
generated many other ideas, which made the
entire process particularly interesting.

AR Nowadays OEMs are trying to reduce

the size of transformers, making it
harder for operators to get inside for inspections.
Once the robot was born, how did you get it to the
market?

AR What were other problems the team

had to overcome?
LC After the robot was developed it was
down to our marketing people, the
sales force and the strategic minds behind the
organization to decide how to use it. The robot is

LC There were a number of technical

problems that took us a while to solve.
We know that oil and gas companies around the
used as a service offered by Hitachi ABB Power
Grids, TXpertTM Services, part of the TXpertTM
Ecosystem; it is not sold as a product. Several
world use robots for inspection and repair, but of our Transformer Service Centers now offer
the transformer robot is going into mineral oil, not this Service across the world. We already have
water. So, the material used to build the robot had successful cases reported in Australia and other
to be compatible with oil to avoid any interaction parts of the world.
with the oil that would create a chemical reaction.
We had to search for ideal materials to utilize.

Another very important issue is that if anything

AR Tell me a little bit about how it was
used, what the problem was, and how
using the TXploreTM solved that problem.
happens to the robot, you need to be able to
recover it. If, for example, there is a part of
the robot that comes off, it will stay hidden
somewhere inside the transformer. This part has
LC There are many cases, but this particular
case in Australia was interesting because
the transformer owner suspected that the load
to be easily recoverable, so the robot needs to be tap changer (LTC) had an issue due to the DGA
able to capture and contain its own parts if they (Dissolved Gas Analyzer) data, so they decided
become loose and fall off. to do an inspection. We used the TXploreTM and
it took some four to five hours to complete the
Another problem was navigation through the entire process.
oil, which has to be highly controlled to avoid
creating any bubbles in the transformer. The The robot found nothing and was able to provide
propellers on the robot cannot generate bubbles very good pictures of all the accessible parts of
of any kind. the LTC. Since nothing was detected, the client
just placed the transformer back in service.
And, finally, high-quality vision. This was one of So, this was a positive case, where there was no
the most difficult issues as the oil can get really need for further inspection.
26 FEATURE
INTERVIEW

AR An LTC inspection can be expensive.

Also, we know that often when you try
to do maintenance or inspections on something
Once the prototype was completed, I was no
longer involved in the product development,
which was a very important phase as well. The
that doesn't have a problem, many times we robotics team completed the job of designing
create a problem. So, it is brilliant to be able to and manufacturing the product. They needed
say, the unit is not broken, put it back into service. drawings, components, spare parts, whatever
electronics was needed and a place for the robot

LC When our two teams, the transformer

services group and the robotics team,
decided to work together, our service team
to be built. So, the robotics team turned it into
a real product which they supplied to us.

operated as the customer who needed a solution.

We gave them the constraints because we
understood transformers, and they knew robotics.
AR I was impressed with the ability of the
light and camera function, regardless of
the color of the oil. I applaud whoever figured out
how to do that.
For example, we told them that when the robot
moves around, it can cause damage. If it touches
the solid insulation, we don't want it to scratch
the paper. So, ideally, the robot would be a sphere.
LC It's a special camera, yes. The quality of
the images is impressive. Whoever has
seen the robot in action, as you have seen it, they
And the first model actually was a ball. But then, must admit it is impressive. I learned a lot from
if the robot is too big, it might not be able to the robotics team, and they learned a lot from
navigate properly. So there were several steps in our business as well, in the process of working
the development of the ideal prototype. together for the first time.

This is why I am so grateful for a company like

Hitachi ABB, because where else can you find
this? You can have a brilliant idea, but if you don't
have the resources, or you don't have the people,
You can have a brilliant idea, or the support; or even if you do, it is not so easy
to make everyone work together if they are
but if you don't have the totally independent and different businesses as
we were and still are.
resources, the people, or the
support; or even if you do, it is AR Luiz, over your career you have made
a commitment to the advancement
of knowledge through IEEE, CIGRE and to the
not so easy to make everyone next generation, so on behalf of all of us at
Transformer Technology, thank you. You have
work together. This is why I been a great guest. Thank you so much.

To find out more about TXploreTM, visit the official webpage.

am so grateful for a company
like Hitachi ABB Power Grids,
because where else can you
find this?
Photo: Hitachi ABB Power Grids
Transformer Technology April 2021 27

Issue 11

BODY
OF
KNOWLEDGE
Transformer Technology
has launched a keyword

B ecause we are
searchable library of the
best information and
knowledge exchanged
through our publication
and platforms that is
committed to our
made available to all our
Members to use, learn
Mission – to help the
from and guide them in
their practice or work. next generation by
capturing the legacy
knowledge of the
current generation.

Start your search now:

transformer-technology.com/bok
28 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

A Critical Evaluation
of Natural Esters
for Application in Transformers
Due to the depletion of the mineral oil source and environmental impacts, the transformer industry
has shifted its focus from petroleum-based mineral oil to natural and synthetic esters. Ester fluids have
been present on the scene for quite some time now, and the environmental advantages and availability
have the industry moving towards this avenue more strongly as time passes. The gradual move to the
use of natural and synthetic esters is additionally supported by more data that is forthcoming from
industry-based studies that are focused on using these fluids in electrical equipment.

This article will focus on environmental concerns, fire safety, physio-chemical properties, and thermal
and dielectric performance of natural esters.

Finally, we will discuss the fundamental properties of natural esters and material compatibility
related to electrical design.

Photo: Shutterstock
Transformer Technology April 2021 29

Issue 11

Due to the depletion of the mineral

oil source and environmental
impacts, the transformer industry
has shifted its focus from
petroleum-based mineral oil to
natural esters and esters.

Corné Dames is the Managing Director of

Independent Transformer Consultants, al-
ways striving to keep on top of new devel-
opments and research. She has expertise
as Laboratory Manager in the analysis of
transformer oils and as diagnostician identi-
fying problem areas in transformers, as well
as profiling of transformers according to
available results thus empowering the cus-
tomer to take preventative steps in mainte-
nance. Corné has vast practical and theo-
retical knowledge on reliability maintenance
programs. Coming from a strong chemical
background she has insight in all the chemi-
cal processes that are part of the transform-
er system. Coupled with technical insight,
her knowledge and experience help custom-
ers optimize their reliability maintenance and
electrical asset lifetime.
30 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Introduction One of the significant concerns

related to the use of mineral oil is
In a transformer, the liquid-cellulose its flammability. A dramatic esca-
system forms the main component lation of power demand over the
of insulation. This system has past few years has led to overloaded
a trifold role as the dielectric electrical grids, resulting in failures,
barrier, mechanical support and fires, and consequent oil spills, for
heat dissipation route. The insu- which government regulatory agents
lating liquid is the backbone of are imposing stiff penalties due to
the entire system, as this part will their environmental impact. Mineral
have a tremendous impact on the oils may have a toxic effect on the
transformer's achieved lifetime [1]. environment that will impact that area
The insulating fluid in a transformer for many years to come. Having poor
has three functions — to electrically biodegradable properties, serious
insulate the active parts, to transfer mineral oil spills can contaminate the
heat from the conductors to the soil and our waterways. Additionally,
radiators, and to provide a diagnostic fire hazards are a real threat when
medium which enables engineers using mineral oils, especially in
to assess the equipment's health densely populated areas.
through regular monitoring and
analytical means. Additionally, As petroleum sources are depleting,
the insulating liquid is used for the threat of shortages is becoming a
arc quenching (in tap changers, reality. To ensure that ester fluids are
for instance) and as an acoustic used continuously and across many
Photo: Shutterstock

dampener. Both arc quenching and applications, we need to guarantee

acoustic dampening are essential the reliability and safety of electrical
for lifetime optimization. equipment.
Transformer Technology April 2021 31

Issue 11

Chemistry and the Emergence of

Properties Standard Mineral Oil Natural Ester
Insulating Fluids
Natural esters are extracted from crops Crops, sunflower,
Material used - Petroleum crude oil
like soybean, sunflower, rapeseed soyabean, etc.
(canola), flax, olive, poppy, etc.
Principle Complex mixture of Plant based natural
-
components hydrocarbons ester
International Standards
O
There is an increase in the use of
CH2 O C R 1
natural esters in the transformer O
Chemical
industry. They are currently used composition
- CH O C R 2
primarily in distribution and medium O
power transformers, in new units, CH2 O C R 3

and for retro-fill units. The first

Visual examination ASTM D 1524 Clear and light Clear and light
large power transformer of 420 kV
voltage class was filled with natural Color ASTM D 1500 Pale Yellow Pale Green
ester fluid back in 2013, in the
south of Germany, nearby Stuttgart. Color IEEE 0.5 </=1
Currently, there are around 30-40
units in this voltage class that are
already energized or in the process
Appearance of
of production, including projects in
liquid
Spain and Italy.

Table 1. Basic properties of insulating liquids: mineral oil and natural ester [2-6]
32 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Physio-chemical Properties Up to date, no cases of transformer

Acidity accelerates the oxidation fires have been reported involving
process in mineral oil and in cellulose natural ester liquid.
systems. In the presence of moisture,
the acid can cause rust on the iron Environmental Impacts
components in the transformer. The threat of depletion of crude oil
The acids in mineral oil are mostly sources is an ever-increasing reality.
short-chain carboxylic acids that Exhaustion of mineral oil would lead
are formed during the degradation to severe problems in many areas
process of mineral oil. These acids of the petroleum industry. That
are more aggressive, having an said, petroleum products are poorly
essential impact on paper lifetime. biodegradable, and they pollute the
soil and waterways when spills occur.
Natural esters have a higher inherent In densely populated areas, mineral
acid content, but they are long- oil filled transformers pose a risk
chain free fatty acids that are very due to the fire hazard and potential
mild for other materials and soluble environmental issues.
in the natural ester. For instance,
the formed acids include the well- Water Saturation
known “omega-3”, which is used as Water has a detrimental effect on
a medicine for reducing cholesterol the transformer's overall life and
levels. on the electrical properties of the
insulating liquid which needs to act
The interfacial tension (IFT) of a liquid as a barrier to ensure there is no
is defined as the measure of the force electrical flashover. A high moisture
required to break through an interface concentration in mineral oil leads to
between water and oil, thus related visible effects as the oil will seem to
to the molecular attraction/repulsion be "murky", not clear.
forces between them. Interfacial
tension is a significant indicator of Because natural esters
polar contaminants and oil decay are more hygroscopic
products in mineral oil. New mineral than mineral oils, having
oils generally have a relatively higher a saturation point
interfacial tension than new natural 10-15 times higher than
ester fluids. The lower variation of the
IFT in natural esters does not affect
the fluid performance, but it limits
the use of IFT as an indicator of fluid
degradation.

Fire Point and Flashpoint

The fire point and flashpoint are the
measures of the resistance of the
liquid to catching fire.

The flashpoint is defined as the

lowest temperature at which the
vapor pressure is sufficient to form
an ignitable mixture with air near that The gradual move to the use
liquid's surface.

The fire point is the lowest

of natural and synthetic esters is
temperature at which a liquid in an
open container will attain a vapor
additionally supported by more data
pressure sufficient to continue to
burn once ignited.
that is forthcoming from industry-
Mineral oil has a much lower based studies that are focused
flashpoint and fire point than ester
Photo: Shutterstock

fluids. A fire point of more than 300°C on using these fluids in electrical
is required to classify a liquid as
“less flammable”. equipment.
Transformer Technology April 2021 33

Issue 11

Mineral Oil Natural Ester

Oxidation Stability
An insulating liquid is prone to
IEC 60296 - Edition 4 -2012-02, IEC 62770 - Edition 1.0 - 2013-11, oxidation due to the presence of
Fluids for Electrotechnical Fluids for Electrotechnical carbon-carbon double bonds. In
Applications – Unused Mineral Applications – Unused Natural natural esters, there is a higher
Insulating Oils for Transformers Esters for Transformers and
concentration of carbon-carbon
and Switchgear Similar Electrical Equipment
double bonds in each molecule.
ASTM D3487-09 – Standard ASTM D6871-17, Standard
Therefore, natural esters are more
Specification for Mineral Specification for Natural prone to oxidation than mineral
Insulating Oil Used in Electrical (Vegetable Oil) Ester Fluids Used oils. This oxidation process is
Apparatus in Electrical Apparatus irreversible but inhibited by the
use of antioxidants in the product
IEEE STD C57.106-2006, IEEE IEEE STD C57.147-2008, IEEE
Guide for Acceptance and Guide for the Acceptance and
formulation. In this process, oxygen
Maintenance of Insulating Oil in Maintenance of Natural Ester will be consumed and incorporated
Equipment Fluids in Transformers into the product of the chemical
reaction. When natural esters are
Table 2. List of available international continually exposed to oxygen,
standards on different insulating oils complex molecules will be formed,
[4, 5, 7, 8, 9, 10]
increasing their viscosity. This
can also lead to oxygen formation
that of mineral oil, we containing byproducts such as
cannot apply the same alcohols, aldehydes, ketones and
moisture content limits. acids. Therefore, it is vitally important
Even with significant to minimize oxygen exposure during
amounts of moisture, the the manufacturing process and while
ester fluid can still retain the liquid is used in a transformer.
its dielectric properties. It Using sealed units will prevent
should be noted that the exposure to oxygen. A diaphragm
effect of water content barrier is required for large
on dielectric strength as transformers with conservators
a function of percent of between the internal and external
saturation is the same venting or a nitrogen headspace
for mineral oil and natural barrier.
ester fluids [11, 12].
Density
The relative density is stipulated
as the ratio of the weights of equal
volumes of liquid and water at 15°C.
Mineral oil (<0.91 g/ml at 15°C) has
a lower relative density than natural
esters (<0.92 g/ml at 25°C) as per the
IEEE standard method.

Pour Point
The pour point of standard mineral oil
is typically lower than -40°C, while the
pour point of natural esters is in the
range of -15°C to -25°C.

Dissolved Gas Analysis (DGA) and

Stray Gassing
Stray gassing is defined as the
formation of gases when insulating
oils are heated at relatively low
temperatures (90-200°C) [13].
A substantial quantity of stray gasses,
like hydrogen and ethane, is observed
in natural ester for some time after
energizing a transformer, which can
last for months. The susceptibility to
stray gassing can differ from batch
to batch [14].
34 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Natural esters have a lower gas References

generation in partial discharge phe- [1] D.P. Stockton, J.R. Bland, [10] ASTM D6871-17, Standard
nomena (hydrogen and methane T. McClanahan, J. Wilson, Specification for Natural
formation with traces of acetylene) than D.L. Harris and P. McShane, (Vegetable Oil) Ester Fluids Used
mineral oil at the same voltage level. “Natural Ester Transformers in Electrical Apparatus
Fluids, Safety, Reliability, and [11] T.A. Prevost, “Dielectric Properties
Effect of Concentrated Heat Flux Environmental Performance,” IEEE of Natural Esters and Their
The insulating fluid is heated to Petroleum and Chem. Industry Influence on Transformer
ensure an increased impregnation Technical Conf (PCIC) pp 1-7, 2007 Insulation System Design and
rate of the cellulose insulation. The [2] CIGRE Working group A2.35, “New Performance – An Update,”
insulating liquid is prepared in the experience in service with new IEEE PES Transmission and
heat exchanger chamber of the insulating liquids,” Brochure Distribution Conf. Exhibition,
filtration unit. Excessive heat flux No 436, ISBN 978-85873-I24-4, pp 30-34, 2006
harms the dielectric dissipation factor. 2010 [12] S. Zabeschek, “Design of Oil
Natural ester has a higher thermal [3] R. Marin, “Esters – Their structure Processing Units for Mineral Oils
limit than mineral oil to initiate phase and Their Properties,” CPRI and Natural Ester Fluids (FR3),”
change. Due to their higher viscosity, National Conf. on Environmentally Weidmann Transformer and
ester fluids will remain in contact Friendly Insulating Liquids Technology Seminar, Switzerland,
with the heating element for a more (EFIL-2013), New Delhi, pp 1-16, 2014
extended period than mineral oil. This 2013 [13] Cargill Reference Data R2070
means that the maximum allowable [4] IEEE STD C57.147-2006 – – EnvirotempTM FR3TM Fluid –
watt density for exposure is lower IEEE Guide for Acceptance and Dissolved Gas Guide, 2006
for natural esters. A solution to this Maintenance of Insulating Oil in [14] D. Marin, N. Lelekakis and
would be to limit the maximum watt Equipment V. Davydov, “Preliminary Results
density or heat flux density, or to avoid [5] IEEE STD C57.147-2008 – for Dissolved Gas Levels in
immersion heaters instead of turning IEEE Guide for Acceptance and a Vegetable Oil-filled Power
to plate-to-plate heat exchangers Maintenance of Natural Ester Fluids Transformer,” IEEE Electrical
to increase the heating surface and in Transformers Insululation Magazine, Vol 26,
reduce the concentrated heat flux. [6] Cooper Power Systems, Bulletin No 5, pp 41-48, 2010
00092 – Product information [15] Louis Blom, Wilec, Natural ester
Change in Fluid Properties – EnvirotempTM FR3TM Fluid – oil application in liquid-filled
The application of natural ester fluids Description, 2001 transformers, EE publisher
is monitored in a wide application [7] IEC 60296 – Edition 4 – 2012-02,
range in order to track the changes Fluids for Electrotechnical
in the fluid properties under actual Applications – Unused Mineral
service conditions. These results Insulating Oils for Transformers
compare well with those found in the and Switchgear
accelerated aging experiments done [8] IEC 62770 – Edition 1.0 – 2013-11,
under laboratory conditions. Natural Fluids for Electrotechnical
ester exhibits changes during the Applications – Unused Natural
aging process similar to those seen Esters for Transformers and Similar
in mineral oil. Electrical Equipment
[9] ASTM D3487-09 – Standard
As the natural ester ages, the dissipa- Specification for Mineral Insulating
tion factor as well as the acid value will Oil Used in Electrical Apparatus
increase, while the interfacial tension
and resistivity will decrease [15].

Conclusion

Natural ester has been available for

decades. In the transformer industry,
it has been established that natural
ester is safely applied in distribution
transformers and other transformer
applications. More than 10,000 distri-
bution transformers using vegetable
Photo: Shutterstock

ester fluids ranging from 10 kVA to

10 MVA are currently in service. As
we gain more practical data and case
studies from the industry, this fluid
application will be used more widely.
Transformer Technology April 2021 35

Issue 11

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transformers.
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Vibrant
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always on, whatever the demand. Count on FR3® fluid by Cargill®

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© 2021 Cargill, Incorporated. All rights reserved.

36 ADVERTORIAL

NEW
OPTIONS FOR
INSULATION SYSTEMS IN
POWER TRANSFORMERS

by Radoslaw Szewczyk
and Jean-Claude Duart

Radoslaw Szewczyk received his master’s

degree in Electrical Engineering at Lodz
University of Technology, Poland, in 1998.
He works for DuPont™ Nomex® Electrical In-
frastructure business as a Technical Service
& Development Expert for EMEA region. With
his background of transformer design engi-
neer, he supports transformer developments
with application of Nomex® insulation materi-
als. He is a member of IEC, IEEE and CIGRE
working groups.

Dr. Jean-Claude Duart has been employed at

DuPont de Nemours in Switzerland since 1995.
He currently works as Business Development
Leader for the Nomex® Electrical Infrastruc-
ture segment, in charge of technical devel-
opment in the area of power and distribution
transformers. Dr. Duart received his PhD in
Electrical Engineering from the University of
Toulouse in France while working as R&D En-
gineer for Jeumont Schneider Transformers
from 1990 until 1994. Dr Duart has published
several international papers in both electrical
insulation field as well as electrical arc ash
protection. He is part of IEC TC112 and TC10.
 Transformer Technology April 2021 37

Issue 11

Introduction Insulation systems for liquid

The development of new insulation materials has been critical in the evolu-
tion of the design of power transformers. Insulation systems for liquid filled
filled power transformers are
power transformers are a combination of materials that are aimed to pro- a combination of materials
vide the required electrical, mechanical, thermal properties together with a that are aimed to provide
full chemical compatibility for successful operation of the transformer for the required electrical, me-
several decades under defined operation conditions.
chanical, thermal properties
Materials enabling innovative power transformer solutions together with a full chemical
The offering of solid materials like papers or pressboards as well as dielectric compatibility for successful
fluids has been in constant evolution in the 20th century as the use of transform-
operation of the transformer
ers was expanding through the development of electrical networks around the
world. As the timeline in Figure 1 shows, several materials have played import- for several decades under
ant role in the design of the transformers over the past century. defined operation conditions.
Photo: Shutterstock
38 ADVERTORIAL

While the first half of the 20th century has seen the development and com-
bination of cellulose based materials for the solid insulation [1] and mineral oil
for the fluid, the second half of the century has seen the arrival of new materials
based on synthetic polymers.

Figure 1.
Timeline of main insulation materials for liquid filled power transformers

1920 1930 1940 1960 1970 1980 1990 2010

Kraft paper Pressed PCB TUK Silicone Synthetic Natural TUK paper
board fluid fluid ester fluid with Nomex ®
paper ester fluid
Mineral oil Nomex ® Nomex ®
paper pressboard

The options offered by the With the introduction of high-quality cellulose pulp, the production of cellu-
lose paper with improved performance has seen tremendous progress initiated
combination of various in the late 1920s making it the main choice of insulation combined with mineral
insulation materials oil. Another step was the introduction of thermally upgraded Kraft (TUK) papers
allow more flexibility for in the 1960s. Already at that time the aim was to improve the thermal stabili-
the designers to develop ty of the paper insulation, a limiting element when transformers have to over-
come challenging load profiles or need to meet more stringent size and weight
transformers that will constraints.
be able to operate in
environments where new About the same time, and in line with the interest of the chemical industry for
developing products that featured advance characteristics, a 100% synthetic
constraints have been paper was developed based on the known polyamide polymer, most known un-
evolving, whether they are der the name of nylon. Here again, in order to overcome the thermal limitation of
related to space and weight the nylon, the polymer was modified to integrate aromatic rings that would pro-
vide improved thermal performance (Figure 2). The DuPont™ Nomex® paper, an
restriction, loading profiles aromatic polyamide, also called aramid, was born. With its thermal class of 220
or ambient temperatures. in the air it was initially used in insulation systems for dry type transformers and
rotating machines. It took less than 10 years for the electrical industry produc-
ing oil filled transformers to consider it as an insulation for the conductors. An
Photo: Shutterstock

advantage was taken of its significant thermal capabilities combined with ex-
cellent electrical and mechanical characteristics, although applicable tempera-
tures had to be reduced due to limited thermal capability of dielectric liquids.
Transformer Technology April 2021 39

Issue 11

In the area of insulating papers, no other comparable technical steps were

achieved in the 20th century and it was only in the beginning of the 21st century
when another paper combining the benefits of thermally upgraded cellulose in-
gredients and aramid was developed. A new generation of thermally upgraded
paper was introduced, taking advantage of DuPont™ Nomex® to reach an im-
proved thermal stability compared to regular thermally upgraded Kraft paper
(Figure 3).

Figure 2. Figure 3.
DuPont™ Nomex® meta-aramid, poly(meta-phenyleneisophthalamide) DuPont™ Nomex® 910 structure

CONH Cellulose + Nomex®

CO NH
CO NH Cellulose

Cellulose + Nomex®
CONH

In parallel to the paper evolution the insulating fluids have also seen ma- While these materials development
jor developments in the 20th century. First, fluids like PolyChlorinated Biphenyl’s may not describe the only changes
(known as PCB) introduced in the 1940s as dielectric coolant and then replaced than occurred over the last 100 years
by silicon oil in the 1970s as they were found harmful to people’s health. Then, in insulation materials for liquid filled
the upraise of ester fluids, synthetic in the 1980s and then natural in the mid- transformers, they indicate important
1990s. It has been a constant search for solutions that could provide addition- categories that are used in transform-
al benefits like fire resistance or, more recently, biodegradability. However, still ers today to meet the evolving con-
today mineral oils remain the main insulating fluid for liquid immersed power straints to which transformers are ex-
transformers. posed.

It is also important to indicate that another major material was critical to

the development of advanced insulation systems, particularly with the increase
of operating voltages that power grids have seen. Almost 100 years ago Kraft
pressboard was invented allowing for development of insulating components
that would become critical in high and extra high voltage transformers. About
50 years later another pressboard type important for the development of ad-
vanced insulation system for power transformer was invented: the aramid
pressboard. The DuPont™ Nomex® pressboard followed a similar principle as
Kraft pressboard, i.e. combining specific known ingredients dedicated to elec-
trical applications and a manufacturing process involving press capabilities that
still remain unique today. This aramid pressboard also offers improved thermal
capabilities as compared to the Kraft pressboard.
40 ADVERTORIAL

Developments in insulation systems

In recent years it could be seen that transformer designs have evolved to
not only reduce the size and weight of units, but also improve their operat-
ing flexibility. Many modern design techniques or available state-of-the-art
technical solutions drive designs to be smaller and more optimal. However, the
use of aramid-based materials allows a step change in the ability to make
designs significantly more compact, when compared to “conventional” de-
signs that are based on cellulose insulation and mineral oil. These trans-
formers may also benefit from longer lifetime as the new insulation systems
are more thermally robust. They also offer more resistance to overload con-
ditions that may result from planned maintenance periods or unplanned de-
mands due to summer heat waves or other operational circumstances.

Industry standards, both IEC and IEEE, define such insulation systems
available for use in power transformers. The standards define typical con-
structions and provide guidance on how the “high temperature insulation
materials” shall be used. For example, Tables 1 and 2 present the tempera-
ture limits according to IEC 60076-14 [2]. Similar guidance can be found in
IEEE Std. C57.154 [3].

Table 1.
Hybrid insulation windings – thermal limits as per IEC 60076-14 [2]

Hybrid insulation systems

Conventional Semi-hybrid Mixed hybrid

insulation insulation insulation Full hybrid
system winding winding insulation winding

Minimum required solid high-temperature

105 120 130 130 140 155
insulation thermal class

Top liquid temperature rise (K) 60 60 60 60 60 60

Average winding temperature rise (K) 65 75 65 85 95 105

Hot-spot temperature rise for solid

78 90 100 100 110 125
insulation (K)

Table 2.
High-temperature insulation windings with ester liquids – thermal limits as per IEC 60076-14 [2]

Minimum required high-temperature

130 140 155 180
solid insulation thermal class

Top liquid temperature rise (K) 90 90 90 90

Average winding temperature rise (K) 85 95 105 125

Hot-spot temperature rise (K) 100 110 125 150

 Transformer Technology April 2021 41

Issue 11

Materials remain one of An example illustration of insulation systems is shown in Figure 4. While
few decades ago the Kraft insulation in mineral oil system was vastly used in
the critical elements to liquid immersed power transformers (Figure 4a), we have seen over the last
allow for the transformer five decades the arrival of different insulation systems. One recently devel-
designs to continue their oped system consists of the thermally upgraded Kraft paper enhanced with
evolution to meet end-user Nomex® on the conductors (referred to as Nomex® 910 paper) combined with
cellulose pressboard components and mineral oil (Figure 4b). This system
requirements. gives the benefit of longer insulation system lifetime when used at conven-
tional operating temperature but also help mitigating a load increase that can
be due to planned demand or due to climatic events, generally unplanned.

Another system that has recently emerged is a hybrid system where ar-
amid materials are used for conductor insulation, spacers and strips, while
other materials remain in cellulose pressboard. Recently, these systems are
combined with ester fluids (Figure 4c). This system is a response to increas-
Photo: Shutterstock

ing fire and environmental constraints that power utilities can see, e.g. in
large cities [4]. Historically the solid materials of this system have been asso-
ciated to mineral oil since the 1980s in applications for mobile transformers.
42 ADVERTORIAL

Core (top yoke) Core (top yoke)

Core (column)

Core (column)
HV HV
LV LV

a Core (bottom yoke) Core (bottom yoke) b

Core (top yoke) Core (top yoke)

Core (column)

Core (column)

HV HV
LV LV

c Core (bottom yoke) Core (bottom yoke) d

Figure 4.
Example illustration of various insulation systems for power transformers:
a - Kraft with mineral oil (conventional)
b - semi-hybrid with Nomex® 910 conductor insulation
c - hybrid system with ester fluid
d - high temperature system with ester fluid

Recently, an increasing number of developments focus on the use of ester

liquids, due to their fire safety and environmental advantages. The thermal ca-
pability of ester liquids would allow using them at higher temperatures (al-
though the test methods for more precise evaluation of thermal capabilities of
ester liquids are only under development). Then, transformer designs can shift
from hybrid systems (Table 1) towards more advanced high temperature insu-
lation systems (Table 2). These systems will require more extensive use of high
temperature materials in the transformer construction as illustrated in Figure 4d.
The combination of aramid insulation and ester liquids has already been used
for many years in smaller transformers, e.g. on-board traction units for rolling
stock and compact wind turbine step-up transformers. Nevertheless, the re-
search is continuing for better characterization of these systems and proving
their high performance.

New aramid-based insulation parts

Plans for more extensive use of aramid insulation in power transformer high
voltage insulation systems drives new developments for innovative insulation
Photo: Shutterstock

parts. One example is the development of formed 3-dimensional end insula-

tion components, such as angle rings, lead exit snouts, and edge protectors. For
some of these components there is a need to use a wet formable aramid board.
Transformer Technology April 2021 43

Issue 11

The development focused first on identifying the grade of wet aramid mate-
rial most suitable for forming the required 3D shapes of typical insulation parts.
Then, the materials were evaluated for the two typical processes of forming:

• machine forming for more regular angle ring sectors (caps and collars),
• hand molding for more complex combined shapes, e.g. winding exit snouts.

Process optimization led to development of parts that matched the benchmark

mechanical and dielectric performance of conventional cellulose based components.

The development of new insulation components also included laminated ar-

amid board for producing thick insulation blocks, e.g. for clamping rings and as-
sociated structures. Steps have been made for producing larger sheets of high-
density aramid pressboard. Comprehensive studies were performed for adequate
glue selection and the process for laminating such boards, and proper charac-
terization of critical properties. The testing included mechanical, dielectric and
thermal properties. The dielectric test confirmed the partial discharge inception
in the laminated board not happening below the required threshold of 9 kV/mm
(Figure 5). This included tests on the laminated board samples aged in synthetic
ester at the temperatures up to 155°C. Another test program analyzed dielectric
strength and the partial discharge behavior of the laminated board when dielec-
trically tested at elevated temperatures up to 120°C.

Figure 5.
Test arrangement for partial discharge measurement on laminated aramid
board after aging in synthetic ester (photo: DuPont/Siemens Energy)
44 ADVERTORIAL

Figure 6.
Example of insulation kit with winding cylinder shaped from high-density
aramid pressboard Nomex® 994 PSB (Photo: DuPont™)

Aging in hot synthetic ester liquid was part of the research to ensure the ap-
propriate long-term performance of the laminated material in service. Compati-
bility with the selected synthetic ester liquid was confirmed.

Additionally, the development was made for large winding cylinders. For pro-
ducing them, two aramid pressboard options have been evaluated:

• high-density aramid pressboard - in large sheets like those used for the
laminated board, or
• lower density aramid pressboard - available in even larger sheets and more
flexible but requiring more attention in the processing due to the air humidity
impact on dimensional stability.
Photo: Shutterstock

Figure 6 shows assembly of various insulation components mentioned previ-

ously in an innovative insulation kit for advanced power transformers.
Transformer Technology April 2021 45

Issue 11

Summary References
The options offered by the combination of various insulation materials allow [1] Prevost, T. A., Oommen, T. V.
more flexibility for the designers to develop transformers that will be able to op- “Cellulose insulation in oil-filled
erate in environments where new constraints have been evolving, whether they power transformers: Part I - history
are related to space and weight restriction, loading profiles or ambient tempera- and development,” IEEE Electrical
tures. Materials remain one of the critical elements to allow for the transformer Insulation Magazine, Vol. 22(No 1),
designs to continue their evolution to meet end-user requirements. Jan/Feb 2006, pp. 28–35
[2] IEC 60076-14:2013, Power
transformers – Part 14: Liquid-
immersed power transformers
using high-temperature insulation
materials
[3] IEEE Std C57.154TM-2012, IEEE
Standard for the Design, Testing,
and Application of Liquid-
Immersed Distribution, Power, and
Regulating Transformers Using
High-Temperature Insulation
Systems and Operating at Elevated
Temperatures
[4] Szewczyk, R., et al., “Replacement
of area substation transformers
with flexible units of reduced
footprint and increased overload-
ability,” e-CIGRE session 2020
DuPont™ and Nomex® are trademarks owned by affiliates of DuPont de Nemours, Inc.
46 FEATURE
INTERVIEW

Khayakazi
Corporate Specialist – Transformers
and Reactors at Eskom Holdings SOC

In our fleet,
we have over
600 transmission
transformers,
more than
Interview with Khayakazi Dioka

5,000 distribution
transformers and
over 400,000 units
of pole-mounted
transformers.
 Transformer Technology April 2021 47

Issue 11

Dioka
Photo: Eskom
48 FEATURE
INTERVIEW

Transformer Technology hosted Khayakazi Dioka, Corporate Specialist –

Transformers and Reactors at South Africa’s electricity utility Eskom
Holdings SOC, on a recent TechTalk anchored by Alan Ross, Editor in Chief.
This interview is an edited excerpt from that.

Alan Ross: My guest, Khayakazi Dioki, is with

Eskom, a company in charge of the transformer
fleet for the national transmission and
AR People need to know that when
you and I first met, the teddy
bears were behind you and I couldn't let go
distribution grid in South Africa. As Eskom’s without asking about that. While you are a
Corporate Specialist – Transformers and smart professional female engineer who has
Reactors, she is responsible for more tremendous responsibility for transformers,
transformers than any woman that I know. and are heavily involved in CIGRE, the teddy
bears are also part of another role that you
Congratulations on that Khaya and welcome! play as the mother of two daughters. Tell us a
It’s great to have you. little bit about your daughters.
Photo: Eskom

Khayakazi Dioka: Thank you so much, Alan. It's

a pleasure and honor to be interviewed by you. KD Thank you, Alan. I have two daughters
and I think they are very brilliant
Transformer Technology April 2021 49

Issue 11

young ladies. They take after the mother; the has failed and we are involved in failure
father agrees. investigations, which requires a different
approach. If the incident requires severe
One is almost twelve now and the other turned investigation and a specialist, this is when we
eight. They want to do a lot of things, but get involved. It is this kind of feedback that we
engineering is not one of them. I took them use to monitor the transformer throughout its
to work one time when we were doing design lifecycle. We can take that information and
reviews and one of my colleagues gave them feed it back into the revision of the specification
a calculation to do. We wanted to calculate the if there is a need for that.
stress between the windings. My daughter got
the distance correct, and then she said, “I want This is one of the advantages that we have, we
to be a transformer!” I think she was five. get to see the whole lifespan of the transformer,
i.e what causes the transformer to fail, if

AR When I told my two sons when I first

got involved with transformers some
twenty years ago, the youngest one said, “Dad,
that is in any way linked to the design, how
it was specified some 10 or 15 years ago. This
then helps in making improvements in the
I love transformers. I mean, Optimus Prime and specification and ensures the reliability of the
all that!” When he learnt it wasn’t that kind of transformers procured going forward.
transformers, he lost interest and became a Sometimes this involves the introduction of
movie producer. new technologies.

Let's talk a little bit about your role at both In our transmission network fleet, we have over
Eskom and CIGRE. At Eskom, you have an 600 power transformers and over 100 reactors.
enormous number of transformers that are Over and above that, we have over 5,000 power
your responsibility, both power and distribution transformers in the distribution network,
transformers. Obviously, you have a team of ranging from 1.25 MVA all the way to 160 MVA.
people that support you, but how do you go We also have pole-mounted and ground-
about managing such an incredibly large fleet mounted transformers, which are known as
of transformers? distribution transformers. That fleet alone is
over 400,000 units.

KD It's quite an interesting task. It is one

of the things that make me stay in
this field because I am not doing the same thing
We are responsible for the specification of those
transformers as well, selecting the suppliers
every day. I'm in the engineering environment, and ensuring that the designs are in accordance
so we own the technology. We look after all with our requirements. We conduct design
these transformers, from specification to reviews and perform all factory acceptance
finding the transformer, ensuring that whatever tests. But the actual asset management and the
we purchase as the organization is according to maintenance of the operation belongs to the
the need of our network. So, the specification is field staff and their management.
where it all begins.

We also specify according to the climate and

the South African need – not just the need of
AR The scope of what you do is as broad
as anything here in North America.
You mentioned the difference between the
the network, but also the environment that we things you would do to monitor and do the
are in as these transformers could be procured diagnostics on an 800 MVA unit as opposed
from anywhere in the country and they are of to what you would do on a 4.5 MVA unit.
different sizes. We have power transformers Obviously, there is a growth of monitoring and
ranging from 10 MVA, or even 2.5 MVA, to as high that's something that is happening in South
as 800 MVA. You can really appreciate the fleet Africa and the Eskom network. But you will not
size and the ranges that we have. use a monitor that costs $10,000 or $20,000 on
a pole-mounted transformer, which, if it fails,
This also makes the fleet lifecycle management it fails. So, from a reliability perspective, it is
a little bit different because the specification about an asset operating as it was designed to
needs to define what we need for all ranges, from operate for as long as it was designed for, which
the small power transformers to large power means lifecycle costeffectiveness is critical.
transformers. An example are the requirements for
condition monitoring, where the implementation Most transformers in North America are way
of some condition monitoring devices would not beyond their expected reliable life. I imagine
be cost-effective for smaller transformers. that you have some over 50 year old
transformers and some brand new ones
Another interesting aspect of this role is in your fleet as well. How do you go about
that one minute there is a transformer that deciding a monitoring program, a program
50 FEATURE
INTERVIEW

as opposed to monitoring, for an individual transformers or how we prioritize replacement.

transformer? Does age matter? What We do not replace according to age; we
conditions do you take into account when replace according to condition, because then
you start looking at getting data from a the condition will determine whether the
transformer? transformer needs replacement or not.

KD Monitoring for us is more related

to the size of the transformer.
What we use is what we call the Asset Health
AR This is brilliant because there are
too many places where we see
transformers being replaced because of age.
Appraisal (AHA). In the AHA, we know the They are actually replacing transformers that
condition of each and every transformer, and are good, but just old, and they are not replacing
this is updated every two to three years. The much newer ones that are not as good.
input from the report gives us an indication
of which transformers are healthy and which It must also be an enormous task to continu-
need attention. That attention could mean ously get the data and update it. For example,
replacement, immediate maintenance or any DGA can happen instantaneously, it does not
repair work that needs to be done. happen over two to three years unless the unit
is overheating. You must have a very robust
Based on the AHA report, we have recom- asset health program. Is that something that
mendations for replacement and critical you have developed at Eskom or you use
transformers are put on a replacement project. outside vendors? How do you manage that vast
Our projects department then starts the amount of data that is coming in?
procurement process for the transformers set
for replacement. The rest of the transformers
are categorized according to the maintenance
that is required. For instance, for a transformer
KD Within Eskom we have a database
for our maintenance activities.

that is in a bad condition, but that condition When it comes to DGA, there are two ways we
resulted from gassing of the transformer, we deal with that. Some of our transformers are
know that this indicates that the unit has a fitted with online gas monitors and as soon as
developing fault. And from there, that can be the gas value goes up, a message is sent to the
rectified. We investigate the developing fault, asset owner indicating that there is something
rectify it, and the transformer is back in service. going on with the transformer, so an immediate
This is generally how we categorize the action can be taken. But historically, we have
Photo: Eskom
Transformer Technology April 2021 51

Issue 11
52 TECHNOLOGY
FEATURE
INSIGHTS
INTERVIEWBY
CORNÉ DAMES

been doing manual oil sampling for all our a critical unit that is awaiting replacement. We
larger transmission transformers every six don't switch it out. If there is any work that needs
months. This information is then stored in our to be done on that transformer, you don't want to
database, at our research laboratory. switch it on and off and drain oil from it because
you might not be able to get that insulation back.
All of that data, for each transformer that has So, you handle the unit with care while it is in
been sampled, is readily available and I can service. In most cases when there is no human
access it from my computer. The data is then intervention those transformers can still stay in
recorded in our AHA program that I mentioned, service for a little longer.
where we feed all extracted data, and this
information gives us the trending data. We then look at major components such as
bushing and tap changers. We then need to zoom
I think this is key to DGA – trending the data to see into the condition of these components to ensure
whether a failure is developing on a given unit. that their condition is also good. An example
of an unfortunate case is when a very healthy
Also, every two years we do life assessment for transformer suddenly fails due to a bushing
each transformer, looking at paper insulation. failure. Unfortunately, the old technology of
This is all recorded in the same database where bushings, oil-impregnated bushings, has resulted
we have records on every transformer at Eskom. in many transformers catching fire. This is very
So, by monitoring insulation, we can calculate heartbreaking, to see a transformer that is
the asset health, check the status, and determine healthy suddenly fail due to a component that
whether it is in good or bad condition. The could have been replaced cost-effectively.
insulation, which is what the life expectancy
of your transformer depends on, carries more
weight than the rest of the data. AR Khaya, it has been a delight talking to
you. You are a wealth of knowledge,
and that knowledge is something that we
When we detect a transformer has a DP (degree want to share with our community and our
of polarization) value of around 200, for example, marketplace, so thank you very much.
meaning it is nearing the end of its life, do we
replace it immediately? No! If everything else is Khayakazi Dioka: Thank you very much for
fine with that transformer, it basically becomes having me.
Photo: Eskom
Transformer Technology April 2021 53

Issue 11
54 ADVERTORIAL

21
ADVANTAGES
OF USING
MICAFLUID
TECHNOLOGY
IN 2021
Photos: Micafluid AG

Driven by Swiss
technology since
1913 to give a longer Headquartered in Switzerland and with operation centres
and better life to in the EU, MICAFLUID is the sole beneficiary of a century-
old heritage of extensive knowledge and experience in the
transformers.
power industry, making it a world leader in the engineering
and development of insulating oil treatment, regeneration
and integrated systems.
Transformer Technology April 2021 55

Issue 11

Electricity is one of the most crucial discoveries in human history, providing com-
fort, encouraging inventions and having a huge importance fuelling our everyday
life. The most important enabler of all these possibilities are transformers, locat-
ed on all branches of the powerline. Yet, a great number of transformers in use
are already at, or close to, the end of their lifecycle. The ongoing integration of re-
newable energy-systems are causing fluctuations to occur more strongly and
more frequently, endangering the stability of the system [1].

Essential to the life expectancy of any transformer is the state of its insulating oil.
Not only is it an integral part of the oil and paper insulation system, but it also
serves to provide cooling and health indicators through oil analysis.

However, over time, the aging rate of transformer oils beside temperature is
accelerated by water, oxygen and gas content as well as acids derived from oil
degradation. These along with other contaminants adversely affect the dielectric
strength of the oil resulting in a lower Breakdown Voltage (BDV), propagating
CRP regeneration into a series of operational issues which shorten the service life of the asset.
plant inlet and outlet
oil colour change

Insulation oil types and how to

treat them
It is well known that the main oil types
in use today for insulations fall within
the following categories:

• Naphthenic based mineral oil

• Paraffinic based mineral oil
• Synthetic ester oil
• Natural ester oil
• Silicone oil

Each fluid has a different set of charac-

teristics which make them better suit-
ed to certain applications, conditions,
and cost.

Mineral oil is the most widely used

insulation oil despite having some
Natural esters are vegetable based fluids which appear to satisfy the growing
disadvantages due to its limited biode-
trend towards “greener” more biodegradable fluids while presenting high flash and
gradability and low fire point. It is im-
fire points. Its higher viscosity also calls for a higher vacuum capacity and more
portant to avoid light fractions in
specific treatment parameters.
vacuum and thermal cracking during
treatment.
Silicone is a synthetic fluid which has self-extinguishing characteristics with good
thermal stability. It also requires increased heat and vacuum for treatment due to
Synthetic ester is chemically derived
its extremely high viscosity. Furthermore, due to its non-compatibility with other
and optimized to have a higher fire
fluids, treatment systems have to be dedicated to silicone oil treatment only, to
point as well as better water solubility
avoid contamination of other oils.
and higher viscosity in comparison to
mineral oil. Treatment therefore re-
MICAFLUID VOP treatment systems are prepared to treat all types of oils and we
quires a higher process temperature, in-
are committed to deliver high quality oil purification systems which keep up with
creased vacuum capacity and specific
the latest developments in the world of insulation oils.
process cycles to avoid poor treatment
results.
Furthermore, due to an array of technical features which guarantee effective vac-
uum tight treatment without the risk of microbubbles or contamination, MICAFLU-
ID systems ensure process integrity without any compromises to the asset wheth-
er in a production line or substation.
56 ADVERTORIAL

21 Advantages of using
MICAFLUID technology in 2021
1. Efficient degassing with single stage vacuum
MICAFLUID plants require only the smallest suction capacity from the vacuum
pumps as the operating pressure for effective degassing is between 1-9 mbar.

2. Optimized electric heating system with horizontal configuration

The oil is indirectly heated and automatically regulated to within 1°C of the setpoint
while ensuring a thermal flux of <1 W/cm2 which prevents hot spot cracking of the oil
and guarantees its integrity.

3. Complete system is vacuum tight

The entire system is vacuum leak tested with a guaranteed leakage rate of
<0.025 mbar•l/s thus eliminating any entry of air into the process. No inlet feeding
pump is therefore required for normal oil treatment.
CFD VOP baffle
heating system [2]
4. Variable flow-through
Due to a oil level control system especially developed by MICAFLUID, the oil flow is
automatically adjusted to the flow-throughput set point without the risk of flooding.
MICAFLUID systems are designed to ensure laminar flow on the outlet which prevent
the creation of microbubbles usually caused by turbulence.

5. Thin film degassing

The patented oil distribution system for maintenance free thin film degassing over
the Raschig rings packed columns is known to be the most efficient method of
dehydrating and degassing insulating oil. This had been proven in a study performed
at the ETH Zurich.

6. Automatic froth control

All VOP plants are equipped with an Anti-Froth Control System. In case of unexpected A competent
foaming, the system detects and automatically reduces suction and flow through in the
degasser without breaking vacuum. This aids the treatment of high viscosity oils. and
7. Filtration with clog detection and automatic control experienced
Three options for fine filters are used in MICAFLUID systems, namely Nylon, Polypropylene
and Fiberglass with varying characteristics depending on the final application: partner to
• Beta X from β1000 to β5000
• Nominal fineness from 0.35 μm to 5 μm
the Electrical
• Temperature range up to 120°C
Furthermore, clog detection allows for early warning of a required filter change which
Industry!
can then be performed safely during treatment without stoppages or the introduction of
air into the system and process.
9. In-line Tan Delta measurement
8. In-line gas
and water content
measurement
Micafluid AG
Photo: Shutterstock

VZ212A applied VZ220A applied

on a VOP plant to on a VOP plant
measure water and to measure Tan
Photos:

total gas content Delta

Transformer Technology April 2021 57

Issue 11

10. In-line breakdown 11. Process supervision

voltage measurement with All MICAFLUID plants are controlled by
MicaSonic™ PLC which automatically control and
supervise each operating step and provide
process trend data and alarm history.
12. Alarming
Essential to process supervision is diagnosis and alarming. MICAFLUID systems
generate information alarm dialogues both on the HMI and via SMS for immediate
operator notification and action.

MicaSonic™ applied on a VOP plant to 13. Safety functions

measure
- Breakdown voltage [kV] Adhering to safety standards such as ISO/DIS 13849-1, MICAFLUID takes the safety of
- Moisture content [ppm] the operators, process and system very seriously and therefore have standard features
(@ 20°C and actual temperature as per IEC) such as over pressure and temperature protection for the entire installation. Further
features such as leak or flood detection, dry run protection and phase sequence control
ensures continuous fail safe operation.

14. Operator friendly 15. Industry 4.0 18. Low maintenance

With an intuitive touch screen interface, With the use of smart communication The robust plant design requires minimum
operation of any MICAFLUID system is protocols and sensors, MICAFLUID intervention, limited to vacuum pump oil
child’s play, reducing the time needed for systems are prepared for full client-side and filter change. Furthermore, since
operator training. integration embracing the Fourth MICAFLUID units are vacuum tight long
Industrial Revolution. term storage even in high humidity
corrosive environments.
16. Online treatment process on
energized transformer 19. Spare parts guarantee
MICAFLUID plants are prepared Micafluid offers an outstanding spare
to perform on onload treatment of parts and after sales service during the
transformers using the adaptable onload lifecycle of the plants.
kit which ensures a completely vacuum
tight process from start to end.
20. Retrofittable accessories
Retrofit of all supplements or optional
17. IEC compliant & energy efficient accessories, offered by MICAFLUID, can be
All units are IEC compliant thereby installed by the customer without
achieving the required performance with additional mechanical works on the plants.
efficient energy consumption.
21. Cost and travel reduction with
MVA Support Platform
By subscribing to Micafluid’s Machine
MICAFLUID is committed to Virtual Assistance (MVA) Support
Platform, users have instant access to
delivering highest quality oil
remotely control and supervise their
purification systems and our team machine as well as direct Micafluid
is fully dedicated and continually technical support and online diagnosis via
innovating a wide range of products, Secure Sockets Layer (SSL).
instruments and services focusing MVA quickly enables companies to
on the customer’s requirements. remotely view and act on the oil treatment
operation, reducing downtime, as well as
Our range includes: travel and operator costs.
VOP - Variable Oil Purification MVA Support Furthermore, having the possibility to
CRP - Conventional Regeneration Platform perform site or factory acceptance tests
VPU - Vacuum Systems and as well as training remotely,
OFP - Oil Filtration MICAFLUID is able to drastically reduce its
HOS - Hot Oil Spray carbon footprint.
ODS - Oil Distribution Systems
References
Headquarters Operations [1] M. Wrobel, Acoustic Hybrid Sensor for BDV
Micafluid AG, SA Monitoring in Insulating Oil
Micafluid AG
Portugal
Gaswerkstrasse 6 [2] S. S. Alfarawi, Evaluation of Hydro-Thermal
CH-8952 Schlieren Shell-Side Performance in a Shell-and-
+41 44 739 44 66
Switzerland Tube Heat Exchanger: CFD Approach
[email protected]
www.micafluid.com
58 EXPERT OPINION:
EXPERIENCE FROM
THE FIELD

Insulating Oil Field Fill:

Challenges and Remedies

by Chris Kenney President

Clover Oil and Chemical Company LLC
[email protected]

Chris Kenney spent the majority of his time

in the refining industry in the sales and mar-
keting of specialty hydrocarbon fluids, more
specifically in transformer oil sales. Chris
has worked in sales and sales management
with Ergon Refining, Cross Oil, Petro Canada
and most recently, Calumet Specialty Prod-
ucts. In all these assignments, he was at the
forefront in business development roles dedi-
cated to developing net new transformer oil
market share. Chris is an expert in the tech-
nical aspects of both naphthenic and par-
affinic transformer oils and has established
worldwide contacts in the power transformer
industry and US utility industry. Chris holds a
Bachelor of Arts from St. Joseph’s University,
and currently resides in Acworth, GA with his
wife Karen. Chris is available for either full, or
part-time consultation arrangements regard-
ing the sale and marketing of transformer oils.

Starting in the mid-1970s, yearly installment of large,

Photo: Shutterstock

extra high voltage power transformers in the

U.S. began to drop precipitously.
Transformer Technology April 2021 59

Issue 11

Since the early 2000s there has been LPTs as “large liquid dielectric power Transmission Transformers: the
an explosion of LPT (large power transformers having a top power low voltage side is rated 100 kV or
transformer) and EHV (extra high handling capacity greater than higher and the maximum nameplate
voltage) transformer installations or equal to 60,000 kVA (60 MVA), rating is 100 MVA or higher.
across the whole of the North whether assembled or unassembled,
American landscape. A 2011 report complete or incomplete” [1]. Generation Step-up Transformers:
from an antidumping investigation The 2011 NERC Spare Equipment The high voltage side is 100 kV or
by the United States International Data Task Force defines LPTs as higher and the maximum nameplate
Trade Commission (USITC) defined follows [2]: rating is 75 MVA or higher.

In 2002, the same demand for large power transformers

which seemed to evaporate starting in the
mid-1970s, robustly returned.
60 EXPERT OPINION:
EXPERIENCE FROM
THE FIELD

In the United States, starting in the We are now in one of the highest- What are the challenges facing the
mid-1970s, yearly installment of LPTs demand LPT markets in recent specialty refiners who attempt to
and EHV transformers began to drop memory. All of this could be loosely fill this market demand? There are
precipitously. This continued into the categorized as “the modernization many. Insulating oil field fill may be
late 1990s with a record low point of the grid,” also an article for one of the most difficult markets
in 1994. This decrease in demand another day. to satisfy on a consistent basis
led to a decline in the domestic compared to other specialty oil
LPT manufacturing base in the U.S. What does all this have to do with delivery requirements. This is due
and Canada. There were simply not insulating oil field fill? The latest figures to the very nature of the product
enough orders to keep plants in North I could gather up as to current demand application. I can think of no other
America busy making large power for mineral oil-based field fill would be specialty oil, when delivered, that
transformers. based on a 2014 U.S. DOE Homeland undergoes the scrutiny insulating
Security study [4] which looked at oils must pass. There are a number
As I discussed in my most recent the U.S. based LPT manufacturing of tests that are performed right off
article in Transformer Technology [3], base coupled to the modernization the truck, namely dielectric, moisture
the same sort of winnowing out of the of the U.S. electrical grid. In 2015, and sometimes power factor testing.
refiners who produced transformer over 500 large power transformers
insulating oils was occurring among were imported into the U.S. market An oil must pass these tests before
domestic LPT manufacturers. The from overseas manufacturers. This the truck is accepted for delivery.
transformer oil marketplace, as it had number included only the units Often these tests are performed in
been in years past, seemed to have imported into the market, not the challenging environments that neither
disappeared. Consequently, many entire U.S. macro market for LPTs. the operator nor the refiner has much
of the refiners who had previously Needless to say, the insulating oil control over. Some customers want
supplied the mineral oil marketplace field fill market is a serious market the truck to be sampled; have the
were shutting down these lines of considering the insulating oil volume sample sent to an independent lab,
business. and distribution requirements. and wait for the results while the

The subject relating to the globalization

of the LPT manufacturing base with
its resulting dislocations is a subject
for another article. In 2002, the same We are now in one of the highest
demand for large power transformers, demand large power transformer
which seemed to evaporate starting in
the mid-1970s, robustly returned. markets in recent history.
 Transformer Technology April 2021 61

Issue 11

truck and driver sit. In an era of a refused, called home or deferred time, and heightens the possibility
tight supply of line haul equipment to a later date. They all cause of late shipments – and off-spec
and drivers, this is never a welcome frustration and cost money on both product. Many of these issues are
request. Often, a 25-50 gallon dump sides of the transaction. Some are communication issues that can be
from the truck tank manifold will the fault of the OEM; some are the solved by a quality customer service
disappear as an “off spec” oil, usually fault of the refiner marketer, and department, preferably one with
with regards to dielectic. Often a truck some are the fault of the truck dedicated insulating oil customer
will return to the refinery having been carrier. By far the most irritating is service representatives.
declared “off spec” and will test “on when the OEM customer’s customer
spec” by the refinery lab. inserts what I call “rouge” specs on Refiners must also ensure they are
the oil delivery. This often manifests aligned with trucking companies that
Some large LPT OEMs are chronic itself in asking for PPM water have at least some trailers dedicated
in their placing an order and content far below the standard to only carrying transformer oils.
then calling the truck back after ASTM 3487 industry standard for Construction site crews must
the truck has left the terminal or moisture in product. provide trained oil test operators,
refinery. Others place orders which testing to ASTM standards on both
necessitate the procuring of a truck Lastly, in order to lessen delivery method and containers. In short,
and trailer and then abruptly cancel risks, proper logistical support everyone must do their job, take
because of technical issues with the must be provided by a remote quality seriously and commit at
transformer setup at the site. terminal infrastructure. Shipping every level to follow best practices
these products over long distances when handling the product.
These are just a few in a long list is expensive, ties up trucks for
of reasons that lead to loads being an unacceptably long periods of To oil suppliers who understand
the risks and rewards of engaging
in this particular piece of the
insulating oil supply chain to the LPT
market, there will be an adequate
Insulating oil field fill may be one financial return, ratable business,
of the most difficult markets to and growing revenue. To the OEM
manufacturer and utility, there will be
satisfy on a consistent basis due timely deliveries, lower construction
to the very nature of the product setup costs, and a quality product
with which to energize their new
application. transformer.

References
[1] U.S. International Trade
Commission (USITC), “Large
Power Transformers from Korea,”
Preliminary Investigation No.
731-TA-1189, September 2011,
available at http://www.usitc.gov/
publications/701_731/Pub4256.pdf
[2] The North American Electric
Reliability Corporation, “Special
Report: Spare Equipment Database
System,” October 2011, available at
https://drosheim.files.wordpress.
com/2012/10/sedtf_special_report_
october_2011.pdf
[3] Chris Kenney, “Transformer Oils
Supply Chain in North America:
Short and Long Term,” Transformer
Technology, Issue 9, Nov/Dec 2020,
pp 64-67
[4] U.S. Department of Energy, “Large
Power Transformers and the
U.S. Electric Grid,” April 2014,
Photo: Shutterstock

available at https://www.energy.
gov/sites/prod/files/2014/04/f15/
LPTStudyUpdate-040914.pdf
62 ADVERTORIAL

WHY DO
SOME
BUSHINGS
FAIL?

T
ransformer bushings are components of critical importance in
the operation of a transformer. Their failure is one of the major
causes of transformer failures, which sometimes can lead to fatal
consequences, such as explosions, fires and oil spills.

A failed transformer bushing can thus cause a lot of trouble in the field.
Not only is there a significant cost to replacing the bushing, but also the
resulting transformer failure can incur additional costs, much higher than
the cost of the failed bushing, and lead to downtime resulting in more
costs to the operator.

A
dditionally, there is the question of the
reputation of the transformer supplier,
as well as a possibility to be subjected to
penalties for power interruptions and failure
to deliver electricity to customers.
 Transformer Technology April 2021 63

Issue 11

Let’s look at the most common causes of bushing failures, specifically in regard
Part design to polymer transformer bushings.

is regulated Part Design

by standards Part design is regulated by standards such as those set by NEMA and IEEE. In
addition to meeting these standards, part design is also closely related to and
dependent on the properties of the polymer that is used to manufacture bushings.
such as those Fulfilling requirements such as creep distances, mounting, shed design and con-
figuring cable connections is influenced, to some degree, by optimized polymer
set by NEMA properties.
Things to look for in this area include the following:
and IEEE Optimizing thermal cycling ability – A good polymer must be able to withstand
extreme temperature changes. If overloading/overheating occurs due to a poor
contact, the bushing material may degrade. Therefore, it is important to know
the glass transition temperature of the polymer. According to IEEE C57.19,
Polymer the glass transition temperature must be higher than the allowed hot-spot
In bushing manufacturing, choosing the temperature.
correct polymer, which is typically an Cantilever strength requirements – To ensure higher cantilever strength of the
epoxy system (resin/hardener combi- material, it is important that all welded joints are free of pores. A porous weld
nation) is critical. The epoxy must be will cause hot-spots and lower the cantilever strength.
carefully selected so that the combination
of cured properties will accommodate Maximizing creep and strike distances – Maximizing the creepage and strike
the changing conditions encountered in distances of the insulator is essential in avoiding flash overs. To achieve this, all
service. This applies to both mechani- sharp edges should be rounded with radius. It is also important to have a good
cal strength and electrical insulation polymer in order to avoid dirt which, over time, may lead to flash over.
properties. In general, careful consider-
Maximizing heat dissipation – In or-
ation must be given to the following
der to maximize heat dissipation, it is
specific properties:
important to ensure that the adhesion
• Dielectric strength between the polymer and the conduc-
• Heat deflection temperature tor is not compromised, as this
• Heat aging adhesion will prevent any leakages
• Moisture absorption during operation.
• Tensile strength
• % Elongation
• Material type (for indoor or outdoor
service) Most Common Failures
These properties can be verified by The most common failures in the ma-
standard test procedures. terial include:
• Cracking
• Leaking bushings
• Direct short to transformer tank
(catastrophic failure)
• Loss of dielectric properties over
time (aging)
Photo: Shutterstock, CrossLink Technology Inc.

• Reduction in tracking resistance

over time
 64 ADVERTORIAL
Photo: CrossLink Technology Inc.

Manufacturing
In bushing manufacturing different production methods are
used. While some of these methods work quite well, others do
not. The difficulty is that the customers buying the bushings
have no way of confirming the quality of the product unless they
do full testing on every bushing, which is not feasible.
In order to overcome this issue, it is essential to ensure which-
ever method is employed to manufacture the parts, it must be
accurate and repeatable. For example, being off ratio in the resin/hardener mix
is not readily detectable by the end user, but chances are that the bushing will
fail in operation.
So, there is no room for error in the manufacturing process. Some of the most
Most Common Failures
common causes of failure that occur as a result of improper processing are: The most common failures that develop
as a result of improper processing
Insufficient conductor preparation – To avoid this, electrical grade copper must
include:
be used with proper brazing between the joints to ensure good contact. Other-
wise, poor contact will be the source of hot spots. Bushing leaks developing over time in
operation – Most commonly, bushing
Insufficient air removal from the mix – As a result of this, air voids may be
leaks are caused by ageing or by im-
trapped causing partial discharge (PD) and flash over.
proper gaskets, as well as the weak
Improperly dispersed fillers within the epoxy mix – This weakens the integrity adhesion between the epoxy and the
of the epoxy. conductor.
Incorrect processing temperatures (epoxy, mould and conductor) – Applying Excessive partial discharge – If the
incorrect temperatures may lead to void formation and cause the epoxy to be material is not de-aired properly, this
brittle, have poor adhesion and shorter service life. may result in excessive partial dis-
Off ratio epoxy mix – Off ratio epoxy mix will compromise the integrity of the charge.
material, so that the epoxy will not have its full physical or electrical properties Cracking during mounting or under
to meet the requirements for its application. maximum cable load – Cracking can
Less than completely cured epoxy – This compromises the integrity of the be caused by using improper epoxy. To
epoxy. avoid this problem, the epoxy should be
customized to different temperatures.
Inadvertent thermal cycling of components which are not fully cured – This
may cause premature failure in the field and compromises the full potential of Tearing when conductor temperature
the epoxy. rises due to high current – In order to
avoid this issue, it is important to know
the coefficient of thermal expansion of
the conductor and the epoxy, as well
as the glass transition temperature.

8 7 6 5 4 3

5.000 24.63

.625 1.250
1.000
25
B

5.000

B
1.200 15.63 7.75
 Transformer Technology April 2021 65

Issue 11

Selecting Your Supplier

Considering the gravity of the consequences of a bushing failure, it is important
to carefully select the supplier that is consistent and dependable.
An ISO quality system is a great place to start because consistency is an abso-
lute must. This is important because the end user cannot detect all things in a
bushing that can cause problems down the road, usually without warning.

Our Epoxy It also helps to work with suppliers who are not only experienced in manufactu­
ring the bushings, but are also engaged in developing, formulating and
manufacturing the epoxy resins that are used to make the bushings.
Transformer Some of the issues discussed above can be eliminated through “type testing”
Bushings are different parts because those properties will remain consistent as long as the
supplier’s process is repeatable. On the other hand, issues related to the man-
ufacturing process are particularly important because they are truly dependent
manufactured on consistency, while at the same time are difficult to detect by the user and will
likely lead to field failures over time.
to the highest At Crosslink Technology, we are vertically integrated, developing, formulating
and manufacturing our own epoxy resins, but also designing and manufacturing
quality the bushings. Our Epoxy Transformer Bushings are manufactured to the highest
quality standards and are available for both indoor and outdoor, and low to
standards medium voltage use. Crosslink has 40 years of experience with no field failures.
Our epoxy bushings are non-tracking and weathering resistant, so they offer
outstanding performance in all types of environments, even highly contaminat-
ed areas. Far lighter (60% lighter) and sturdier (10 times the tensile strength)
than porcelain, epoxy bushings will not crack due to thermal shock.
Epoxy bushings also have:
• A low partial discharge
• Superior Compression strength
• Flexural strength of cycloaliphatic that is up to 15 times greater than porcelain
• Resistance to high-power arcs (great dry arcing distance)
Through a dedicated research and development approach, Crosslink Technolo-
gy Inc. is constantly working to create innovative epoxy and polyurethane
formulations, and reliable high-quality cast components. Call or email us today
to discuss your needs for reliable transformer bushings.
Photo: CrossLink Technology Inc.

The Crosslink Cast Components Division manufactures Epoxy cast

transformer bushings and standoff insulators. The Crosslink Liquids
Division manufactures both Epoxy and Polyurethane custom
formulations.
2 1
Our mandate is simple: be innovative, provide the highest quality
components, and offer exceptional service to our customers.

From our North American plant, we have supported our global

customers for 40 years with low and medium voltage resin bushings
and insulators. With our in-house design capability, we assist our
.625-11-2b THREAD
D customers with their concepts. We formulate our own world class
resins to meet most electromechanical challenges you may face.
With our high-volume capacity and stocking programs, we are able
to service most lead time demands.

.750 We look forward to partnering with your team.

5.000

Crosslink Technology Inc.

www.crosslinktech.com
2.45
+1-905-673-0510
[email protected]

1.200 SECTION B-B

C
66 DESIGN FOR
SAFETY AND
SUCCESS

Design for the Future.

Design for Success.
Design for Safety.
by Martin Robinson

Martin Robinson is the founder, owner, and

CEO of IRISS Inc., a leading manufacturer of
infrared inspection windows. Robinson focus-
es on innovation and is a pioneer of Electrical
Maintenance Safety Devices (EMSDs) that
help protect technicians from harm while pro-
tecting their companies’ bottom line. He holds
several patents for condition-based mainte-
nance devices and has designed multiple
maintenance programs that include infrared,
ultrasound, partial discharge testing, non-
destructive testing (NDT) and energy man-
agement strategies. He holds a NEBOSH cer-
tificate in Occupational Safety and Health,
an IAM Certificate in Asset Management, is a
certified Level III Thermographer, a Certified
Maintenance and Reliability Professional
(CMRP) and a Certified Reliability Leader (CRL).
He is a member of IEEE, NFPA and is a stand-
ing member on the technical committee CSA
Z463 guidelines on maintenance of electrical
systems.
Photo: IRISS
Transformer Technology April 2021 67

Issue 11

The critical importance

of electrical power to
every aspect of our world
cannot be exaggerated.
Electricity must be
generated and distributed
effectively to end-users,
and any disruption in that
process means loss of
operations, money, and
in extreme cases, life.
Therefore, the reliability of
electrical power creation
and distribution must be
continually safeguarded
and improved. This does
not happen by chance
or through reactionary-
maintenance tasks. This
must be focused on from
the early design stages
and continued through the
life of the assets tasked
with these functions.

THE RELIABILITY OF ELECTRICAL

POWER CREATION AND DISTRIBUTION
MUST BE CONTINUALLY SAFEGUARDED
AND IMPROVED, WHICH DOES NOT
HAPPEN BY CHANCE OR THROUGH
REACTIONARY-MAINTENANCE TASKS.
68 DESIGN FOR
SAFETY AND
SUCCESS

Adopting a "Monitor, Inspect & As stated earlier, if we, as

Manage" approach is a proactive practitioners, connect reliability
way to avoid the concerns at and safety, we will gain much more
hand by maximizing the value of momentum, access more resources
workforce time and skill. Scalability and create an environment where we
is no longer an issue when, instead can make sure our transformers are
of going through the time and reliable, which also leads to increased
cost of expanding their workforce, safety. And safety continues to play
they can apply condition-based a more prominent role in relation to
reliability technologies to maximize electrical systems.
their available workforce skills
and availability. These reliability
technologies can be specified with Inspect
the specification engineer and original
equipment manufacturer at the initial Once the wireless monitoring system
design/build stage or retrofitted into notifies technicians of a possible issue
existing equipment through a simple with a transformer or other piece of
and inexpensive process. electrical equipment, the use of pre-
installed inspection windows on the
Additionally, by taking the Reliability asset allows a safe, efficient method
Engineering by Design (RED) of inspecting and assessing any
approach espoused by the Electric possible issue during an energized
Power Reliability Alliance (EPRA), condition. Once solely designed for
coupled with the Monitor, Inspect thermographic inspections using
and Manage approach as detailed in infrared cameras, advancements
this article, we will create a practical in manufacturing have led to the
system approach to asset reliability. inclusion of ports that allow for
ultrasound and partial discharge
Monitor technologies to be incorporated into
the inspection. Visual, infrared, and
With the use of a monitoring system ultrasound inspections can be done
on transformers and throughout simultaneously by a single employee.
substation electrical equipment,
asset conditions can be continually
collected, trended, and assessed.
Monitors feed data through a gateway
to software and applications, allowing
the information to be continuously
accessed from workstations and
mobile devices.

When the new equipment arrives from

the manufacturer with these monitors
built in, customized parameters can
be set for the specific operating and
environmental conditions the asset
is exposed to, which keep it within a
"safe zone" to maximize functional
reliability. When the asset condition
data exceeds the custom parameters,
alarms can notify electrical
technicians of a possible issue that
may require inspection. Keeping
human interaction with equipment to
only instances where confirmation
inspections of potential faults are
deemed necessary minimizes risk to
workers and eliminates the human-
error threat to asset functionality.
 Transformer Technology April 2021 69

Issue 11

Additionally, this design protects

inspectors from arc flash/electrocution
risk, removes the need for bulky IF WE, AS PRACTITIONERS, CONNECT
and expensive PPE, and allows the RELIABILITY AND SAFETY, WE WILL
inspection to be accomplished more
efficiently. Not only does this represent GAIN MUCH MORE MOMENTUM,
a significant process improvement ACCESS MORE RESOURCES AND
driven by original design, but it also
falls in line with the most recent NFPA CREATE AN ENVIRONMENT WHERE WE
70E updates and continues to protect CAN MAKE SURE OUR TRANSFORMERS
critical assets from human interaction/
mistakes that may cause failure. ARE RELIABLE.

Manage

The data collected during inspection

can be stored through intelligent
asset management tags attached to
the pre-installed inspection windows.
From the asset location, information
can be transmitted into a dashboard
system accessible from workstations
and mobile devices.

Customizable routes can be

established before, and condition
reports generated after data analysis
to further increase efficiency. These
designed aspects allow managers to
assess operations and decide how
best to increase Mean Time Between
Failure (MTBF).
Photo: IRISS
70 DESIGN FOR
SAFETY AND
SUCCESS

Proper Training for a larger workforce, the problem should drive the overall process
is multiplied. The only way to toward continuous improvements,
One major issue facing the industry succeed is to capitalize on reliability the proper tools are only as useful as
is a coming wave of retirements technologies designed into the the hands wielding them. Hardware
from the workforce, with fewer new system that allows the industry to and software designed/specified
workers entering the industry than do more with less. by the engineer and constructed by
the pending need created by this the OEM are ineffective if the people
exodus. As the electrical industry While designing for safety and responsible for their oversight are not
expands worldwide, creating the need reliability from the equipment-side adequately trained.
 Transformer Technology April 2021 71

Issue 11

Shifting to an engineered focused staff can be used for actual of education and certification to
reliability system for the electrical necessary maintenance/repair on-the-job training programs. These
maintenance team means training activities. online systems offer on-demand
new and veteran staff alike. With educational and training resources
"Monitor, Inspect & Manage" the Another Covid-era issue with that teach the use of these specific
use of technology allows single learning is that most educational reliability technologies. The workflow
individuals to accomplish inspection institutions have transitioned to is streamlined meaning that the
tasks with minimal training. online models. The electrical world skill-set requirements can be
Specialized skill sets of electrical- can benefit from adding this type minimized to particular tasks.

ALL POSSIBLE MEASURES TO ENSURE

ASSET RELIABILITY SHOULD BE
SPECIFIED AND IMPLEMENTED FROM
THE INCEPTION OF EQUIPMENT DESIGN
AND MANUFACTURE.
Photo: IRISS
72 DESIGN FOR
SAFETY AND
SUCCESS

Conclusions

As the old saying goes, "if you fail to

plan, then you should plan to fail." From
the inception of equipment design and
manufacture, all possible measures
to ensure asset reliability should be
specified and implemented. These
measures should prove themselves to
be learnable, repeatable, and continued
throughout any workforce changes
to cement the successful practices
into the very culture of the role
requirements.

Transformers and other critical

electrical power assets being monitored
remotely cut down on technicians'
routine tasks focused on engineering
and electrical operations by providing
around-the-clock coverage. When an
alarm notification is received, correctly
designed and installed inspection
windows allow an individual technician
to easily do visual, infrared, ultrasound
and partial discharge assessments
of the energized equipment. The data
collected on the asset can then be
stored, trended and analyzed through
the management software. This
process increases the Mean Time
Between Failure (MTBF) by allowing for
planned shutdown and maintenance
only when it is necessary.

Staffing issues brought about by the

combination of an expanding market
and a shrinking labor pool can be
overcome by streamlining operations
through technology. Both hardware
and software involved can be easily
integrated at minimal expense, while
the employees responsible for their use
can be trained through a combination
of online and on-the-job training.

STAFFING ISSUES BROUGHT ABOUT

BY THE COMBINATION OF AN
EXPANDING MARKET AND A SHRINKING
LABOR POOL CAN BE OVERCOME BY
STREAMLINING OPERATIONS THROUGH
TECHNOLOGY.
Photo: IRISS
Transformer Technology April 2021 73

Issue 11

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& DISTRIBUTION

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BACKUP POWER

SMART SOLUTIONS

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www.middleeast-energy.com | [email protected]
74 THE SEN
TRANSFORMER

The Sen Transformer

by Roy W. Alexander

Photo: Shutterstock
Transformer Technology April 2021 75

Issue 11

◼◼◼ We are all familiar with power transformers – the

◼ workhorses that make transmission and distribution
◼◼ transformers,
◼◼◼◼ of AC electric power possible. When we think of

◼◼◼◼ With the addition of a load tap changer (LTC) under

◼◼◼◼◼◼◼ to 120/240 V household utilization voltage.
we normally think of units that change

◼◼◼◼◼◼ load, transformers can easily regulate voltage.

voltages from for example 12 kV distribution voltage

Roy W. Alexander received a BSEE summa

cum laude in 1972 from the University of
Pennsylvania, Philadelphia. From 1972 to
2010 he was an engineer at PPL Electric Utili-
ties; from 1995 a Sr. Staff Engineer/Scientist.
He Received the “Young Engineer of the Year”
award in 1985 from the Pennsylvania Society
of Professional Engineers. He and his wife own
a power engineering consulting firm RWA
Engineering LLC in Cranberry Township, PA.
He is a distinguished member of CIGRE, hav-
ing served as USA delegate to Study Commit-
tee A3 Electrical Equipment from 2002 – 2008.
He was Chair of the PES Switchgear Com-
mittee 2001 – 2002 and served as working
group chair on numerous Standards Devel-
opment working groups. He is also a mem-
ber of the PES Capacitor Subcommittee,
the Insulated Conductors Committee, and
the IEEE Power Electronics Society.

Special transformers can also with the line, as shown in the single- components are independently variable.
regulate phase angle. But imagine a line diagram in Figure 1, to act The ratio of the compensating voltage
transformer which can independently as a series-connected emulated (Vs’s ) and the prevailing line current (I)
regulate voltage and phase angle. impedance of all kinds – inductive, through the line reactance (X) results
Imagine a transformer that injects a capacitive, resistive, or negative in a virtual four-quadrant emulated
compensating voltage (Vs’s) in series resistive while these real and reactive impedance.
 ◼ Imagine a transformer that injects a compensating voltage
◼◼◼ (Vemulated
76 THE SEN
TRANSFORMER

◼◼◼
◼◼◼◼◼
) in series with the line, to act as a series-connected

◼◼◼◼◼◼◼◼◼ components are independently variable.

s’s
impedance of all kinds – inductive, capacitive,
resistive, or negative resistive while these real and reactive

Figure 1. Single-line diagram of the Sen

Transformer The Sen Transformer uses a Shunt
Unit, referred to as Exciter Unit,
and a Series Unit, referred to as
Compensating-Voltage Unit (Figure
Pr , Q r 1 and Figure 2). The Compensating-
Shunt Series
Unit Unit
V s's I Voltage Unit creates a series-
connected compensating voltage
(Vs’s) that is variable in magnitude
Vs X and phase angle to modify the
Vs' Vr
sending-end voltage (Vs) to the
modified sending-end voltage (Vs’)
with desired magnitude and phase
angle, needed for desired active and
Pexch
reactive power flows (Pr and Qr)
Q exch
at the receiving end of the line with
Sen Transformer voltage (Vr). The compensating
voltage (Vs’s) is also at any phase
angle with the prevailing line current.
Therefore, it exchanges active and
reactive powers (Pexch and Qexch)
with the line, which is equivalent
Figure 2. (a) Schematic winding development to emulating an inductor (L) or a
of the Sen Transformer; (b) Phasor diagram in capacitor (C) and a positive resistor
power flow control mode
(+R) or a negative resistor (–R) in
series with the line and, thereby,
Vs'sA acting as an Impedance Regulator.
IA
VsA
0
IB Vs'A
a1 1
2
VsB 3
3

b1
2
1

IC Vs'B
0

c1
4

VsC
3
2
1

Vs'C
Vs'sB
0
a1 1
2
Va1
A 3 Vs
'sA 𝜷
4
3

b1
2
1

Vs'A
c1
3
2

𝝍 Vb
1

V c1
0

VsA
Vs'sC Va3 Va2
V sC V B
Vs'B V s's
C B a1 1
sB 𝝍
Photo: Sen Engineering Solutions Inc.

2 𝝍 𝜷
3
4
V s'C V Vb
3

b1 V c3 𝜷
Vc2
2
1

b
0

3 2
c1 Vs'sC
3
2
1
0

Exciter Unit Compensating-Voltage Unit

(a) (b)
(a) (b)
Transformer Technology April 2021 77

Issue 11

Figure 3. (a) Westinghouse-made power

electronics inverter-based FACTS Controller at
AEP’s Inez substation; (b) Sen Transformer of
comparable rating

Big Sandy Line

Coolant System
Series Xfmer Heat Exchangers

Shunt & Series UPFC Building

Intermediate Xfmers (Inverters & Control)
Spare Shunt Xfmer

Main Shunt Xfmer

100'

(a)

As you can see from Figure 2(a),

the Sen Transformer is a three-
phase transformer with a shunt
wye primary winding that provides
the input energy to the transformer.
The series-connected secondary
windings induce the compensating
voltage, using LTCs. Physically,
consider a three-legged core. All four
red windings are on one leg, all four
blue windings on an adjacent leg, and
all four green windings are on the
third leg. Therefore, three windings,
one from each core leg, are placed
in series on each phase of the Series 10'
Unit of the Sen Transformer (see
Figure 2(a) Compensating-Voltage
Unit). Each core leg will have one
shunt winding, connected phase to
ground on the input side (Exciter
Unit) and three series windings to be
connected in series – one from each
leg on each phase of the output side
(Compensating-Voltage Unit). (b)
78 THE SEN
TRANSFORMER

To reiterate, in total there are three that is several orders of magnitude on Gallium Nitride (GaN) and Silicon
shunt windings, one per phase on (several seconds verses several Carbide (SiC) due to their inherent
each core leg of a three-leg core milliseconds) faster than the Sen advantages of high-speed operation,
transformer (Exciter Unit); and nine Transformer, but this superfast which results in lower losses, high-
secondary windings, three in series, response capability goes unused temperature operation, lower cooling
one from each core leg connected in most utility applications. The requirement and smaller gate drive
on each phase of the Series Unit Sen Transformer uses time-tested, and smaller snubber circuits.
(Compensating-Voltage Unit) of the readily available, highly reliable
Sen Transformer. There are nine power transformer components. It Therefore, FACTS controllers become
LTCs, so the nine series windings can is inherently more efficient because obsolete in a relatively few years
each be controlled separately. the mechanical switches in LTCs do so that one-for-one component
The Series Unit of the Sen not suffer from the high conduction replacement becomes impossible in
Transformer can be made to look loss from on-state voltage drop and less than 10 years. In the utility world
like an inductor or a capacitor, and where 40-year equipment life is the
a resistor or a negative resistor norm, this means the entire power
with respect to the phase under electronics inverter-based FACTS
consideration. With the series winding installation may need to be replaced
of a Sen transformer placed into a several times in that 40 years. Simple
network, the line which it is connected maintenance of the power electronics
with can have its real and reactive requires highly skilled personnel that
impedance controlled independently. are not readily available. The global
Thus, active and reactive power standard and interoperability do
flows can be varied independently not exist due to a limited number of
as desired. The switches for the tap manufacturers. The inverter-based
changer are preferably mechanical power electronics FACTS Solution
vacuum or oil switches. These can is a highly expensive proposition,
respond in seconds, which is usually perhaps two orders of magnitude
fast enough for utility power flow more expensive than a long-lived and
control needs. easily-maintained Sen Transformer.

If faster response is needed, the The Sen Transformer is an obvious

switches can be based on power winner for power flow control needs
electronics thyristors which, once for the utilities worldwide.
turned on, commutate naturally.
This will move response time from
seconds to 50 ms, a 100-fold
increase in response speed.
This would increase cost and
decrease reliability significantly. References
Almost never is such a faster [1] K. K. Sen and M. L. Sen,
response time needed. Introduction to FACTS
Controllers, Theory, Modeling, and
The response time can even be Applications, Wiley & Sons and
reduced further to a few milliseconds IEEE Press, 2009
if a power electronics inverter-based [2] M. L. Sen and K. K. Sen,
FACTS controller is used, as shown “Introducing the SMART Power
in Figure 3(a). These inverters use Flow Controller - An Integral Part
force-commuted switches such as even higher switching loss from of Smart Grid,” 2012 Electrical
gate-turn-off (GTO) thyristors. transitioning on-to-off and off-to-on Power and Energy Conference,
several thousand times every second. October, 2012, London, Ontario
The Sen Transformer can provide These two losses the semiconductor [3] K. K. Sen and M. L. Sen,
the same power flow control switches cannot avoid. “Comparison of the Sen
functionality as the more expensive, transformer with the unified power
high maintenance, and non-mobile Another drawback of power flow controller,” IEEE Trans. Power
power electronics inverter-based electronics inverter-based solutions Delivery, vol. 18, no. 3, pp. 1523-
Photo: Sen Engineering Solutions Inc.

FACTS controllers does. Compare is that the semiconductor devices, 1533, Oct. 2003
the sizes and footprints of the such as GTO thyristors, used in the [4] N. G. Hingorani and L. Gyugyi,
two similarly capable power flow first-generation FACTS controllers, “Understanding FACTS: Concepts
controllers in Figure 3. are not available. The industry moved and Technology of Flexible AC
on to using Insulated Gate Bipolar Transmission Systems,” New York:
The power electronics inverter-based Transistors (IGBTs). IEEE Press, 2000
solution offers a response time The upcoming switches are based
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Transformer Technology COMING April 2021 81

Issue 11 IN MAY

From Specification
to Commissioning:
Better Practices
for Better Outcomes
specifications, design, transportation, commissioning

As a reliability subject matter expert, I am convinced

that all reliability starts at the design stage, and the de-
sign stage is more than just how a transformer is en-
gineered, configured and designed, but also how the
specifications are created and how it is transported and
commissioned. There are so many considerations that
will lead to either a reliable asset or one that could fail
unexpectedly or even catastrophically.
The roles of design engineering, operations, procure-
ment and purchasing are all impacted by and have an
important hand in the design phase of creating a reli-
able asset, as part of a reliable system. With great
contributions from Jon Trout of First Energy, Diego
Robalino of Megger, Dan Smith of LCRA, Jason Varnell
of Doble and Randy Williams of NASS, this will prove to
be an important addition to the Transformer Technology
Body of Knowledge.
Finally, there is still room for a few articles or inter-
views from our Community Members so please drop
me a line and let me know what compels you to add to
this topic; what you believe will be a contribution that
will have long-lasting value to the members of the TT
Community. We’d love to hear from you.

Alan Ross,
Community Moderator and Editor in Chief
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