Transformer Technology for the 21st Century

Richard L. Provost
Global Technology Development Manager - DuPont Co.

Introduction
A new technology for the transformer industry involves the use of high temperature
materials to provide a variety of economic, environmental and safety benefits to the user,
including: lighter weight, smaller size, reduction in fluids, improved safety, less
flammable, more capacity and lower energy losses.
This technology was developed jointly in the United States and Europe during the 1980's
and has gained popular usage throughout the developing world, including recently in
Korea, China, Argentina, Paraguay, South Africa, Taiwan and Australia.
A new IEEE Standard has been published to provide guidance to manufacturers and
users regarding the production and application of these transformers. Customers have
included users in the Power Utility, Industrial and Railway markets. The use of these
new transformers will change the electrical industry in the next century.
The high temperature materials, mainly Nomex aramid papers and boards can be used
with conventional fluids in an economic way for power and distribution transformers for
increased capacity and improved reliability. They can also be used with less flammable
or higher temperature fluids for dramatic reduction in size and weight, with greater safety
and environmental reliability.

Background
Developments by Westinghouse and General Electric Co. in the United States during the
late 1960's and early 1970's resulted in the use of Nomex aramid papers for improved
mechanical performance in the winding structure of liquid transformers. Maintenance
records of these transformers indicated that lower gas evolution was evidenced in these
units due to the removal of cellulose papers in the hottest portions of the transformer
winding. Even though these units were not thermally upgraded from the 65 K average
winding rise, the peak loading of these units which results in accelerated thermal
degradation of cellulose insulation, and release of water, CO and CO2, has been
improved.
During the 1980's, the development of thick aramid board structures allowed the
replacement of all the cellulose materials in the hot winding areas. This, in turn, allowed
manufacturers and users to take advantage of the thermal properties of Nomex and
upgrade the thermal performance of the transformers to average winding rises of 95 K to
115 K. The lack of gas evolution from the aramid polymer has shown much lower
concentrations of dissolved gases in these units, even at high peak loads. The data of
figure 1. show this comparison with the standard levels considered by IEEE and CIGRE
to be the first warning to users. Design uprates on the order of 25% to 50% increased
capacity in the same size package have been realized.

Figure 1.

Comparison of Dissolved Gas Analysis of Transformers

Insulated with Nomex

4000
CO
TDCG
CO2

Concentration (ppm)

3000

2000

1000

0
Nomex* Conduct or
Only
(65 K Rise)

Hybr id Insulat ion

(85-95 K Rise)

IEEE Limit - Nor mal

(65 K Rise)

CIG RE Limit
(65 K Rise)

In addition, the use of aramid materials with higher temperature fluids, such as Midel,
R-Temp, and silicone, have allowed reduction of size and weight of up to 30% by using
the full thermal advantages of both the solid and liquid components. As an added
advantage, these units are typically safer and more environmentally friendly than units
built with conventional mineral oil. This has found significant advantage in traction
transformers, with pole and pad distribution units placed in crowded city areas, and other
applications where the use around large densities of people is required.
Technical Improvements Lead to Maintenance Reduction
Thermal aging studies by General Electric Co. have been summarized in a technical
report to ESEERCO, a group of power utility companies in the northeastern United
States. In addition, recent studies by DuPont, in conjunction with Doble Engineering
Group, have verified reduced evolution of gases and much longer life expectancies with
the use of "hybrid" insulation systems, which use Nomex paper and board in the hot
winding area and cellulose materials in the cooler, bulk insulation areas of power
transformers. These systems also eliminate the furan compounds, which evolve from
the degradation of cellulose in the hot windings. Figure 2. Shows the results of tests on
aging of insulation packages in specially designed aging cells developed by DuPont.
The testing was carried out by Doble.
The cells were designed to duplicate the material ratios of a 25 MVA transformer,
including hot winding insulation, cool bulk insulation, copper and core steel. The hybrid
systems include Nomex on the conductor and spacers of the winding, with cellulose
board in the cooler sections of the cells. The hybrid and all-Nomex cells were aged at
240C on the conductor and 130C top oil temperature. The conventional cellulose cells
were aged at 160C on the conductor and 110C top oil.

Figure 2. Furan Generation

(2-Furaldehyde - ppb)

System

Conventional

Hybrid

All Nomex

160

240

240

500

127

1500

1390

5000

17199

300

12

Aging Temp. (C)

Aging Hours

These achievements necessitate a change from the focus of routine measurements of

fluids to track the aging and life of transformers. Dissolved gas measurements can still
be monitored to track such things as arcing and through faults within the units, but may
no longer give an indication of the long term aging effects of the winding insulation.
However, with the dramatic increase in life of the winding insulation using Nomex, the
thermal limit now shifts to the fluid. Therefore, monitoring of the fluid properties may be
the most reliable tracking point.
Studies of the aging data developed in the DuPont study show that monitoring properties
such as neutralization number and power factor could be used for such tracking. This is
not only more reliable testing but is simpler and easier to track. Removal of samples of
solid insulation would no longer be necessary. In addition, the time between monitoring
tests may be increased. Due to the small numbers of these types of transformers
relative to the total population, users have not yet employed these practices. However,
as the use of this technology becomes more common, it is expected that routine
maintenance and monitoring can be reduced, saving users expenses and resources.

Figure 3. shows the effect of aging on mineral oil power factor obtained from the DuPont
cells. The hybrid system shows lower impact at 130C oil aging than the cellulose
control system with 115C aging. Similar data for neutralization number of the oil are
presented in figure 4. Although the data are improved with the systems involving
Nomex, they can still provide an indicator for tracking the quality of the oil and provide
some early warning for the transformer user. The acid evolution from the cellulose
products is the major reason for the increased neutralization number. The hybrid system
contained bulk cellulose in the high temperature (130C) oil which was used for
accelerated aging time, and is worse than would be expected at top oil limits of 65 K to
70 K rise in real transformers.

Figure 3. Power Factor of Mineral oil after 5000 hours in aging cells

1.0
Cellulose
Hybrid
Nomex

0.8

Power
Factor
(%)

0.6

0.4

0.2

0.0
1000

2000

3000

4000

5000

6000

Aging Time (Hours)

Figure 4. Neutralization Number of Mineral oil after 5000 hours in aging cells

0.3

Cellulose
Hybrid
Nomex
0.2

Neutralization Number
(mg KOH / gm)
0.1

0.0
0

1000

2000

3000

4000

5000

6000

Aging Time (Hours)

The increasing use of on-line continuous monitoring will also make much of the testing
redundant. However, with fewer key properties to monitor, and elimination of on-site
sampling of solid materials, the on-line techniques may become even more reliable. In
addition, the reduced contamination of the fluids will result in much lower maintenance
costs for potential cleaning and refurbishing of the fluids.
One final improvement results from the greatly improved compression resistance of
Nomex aramid spacer board. Studies have indicated that these materials have no loss
in thickness at temperatures up to 150C. This compares to a loss of 4% per year in the
thickness of high-density cellulose spacer boards aged at 135C. Even greater loss in
thickness is experienced for cellulose at 150C, which can be developed at peak
overloads of 25% in conventional transformers. This loss can result in reduced short
circuit resistance and weakened winding strength. Routine maintenance to correct this
by tightening of the windings is necessary. With the new hybrid insulation systems using
Nomex, this is no longer necessary, eliminating another maintenance step, while
preserving the integrity of the windings.
The data of figure 5. were developed using 100 mm stacks of spacerboard, which were
dried and impregnated with mineral oil and initial compression over the first 4 days. The
test was terminated after 250 days with no change in thickness of the Nomex stack.

Figure 5.

Static Compression of Board at 10 MPa

100

Thickness reduction (%)

98

96

94

Aramid pressboard @ 135C

Aramid pressboard @ 150C
Cellulose pressboard @ 135C
Cellulose pressboard @ 150C

92

90

88
0

50

100

150

200

250

Aging time (days)

Application of Hybrid Technology

The development of hybrid technology, which uses Nomex aramid papers and boards
in the high temperature sections of the winding and cellulose in the remaining cooler
areas of the transformer, has lead to greatly increased performance while improving
transformer reliability and reduced maintenance. The first applications of this new
technology were in lightweight mobile transformers in the United States in the mid1980's and with upgraded rebuilt power transformers in the late 1980's. Since then,
these applications have been expanded around the world.
In the Asia Pacific region, Mobile transformers with hybrid insulation systems have been
developed in Korea and Australia. New studies are underway in Taiwan, Indonesia and
Taiwan. Chilectra, a major power utility in Chile, is now specifying hybrid mobiles for
their network, and is considering Korean-made units for their system. Most mobiles
purchased in the United States over the past 10 years utilize the hybrid concept for 50%
to 80% increase in power per unit size and weight. Many utilities, which own older
mobile units, have had them rebuilt and uprated to take advantage of this technology.
Many older transformers are failing at increased rates in developed countries in North
America and Europe because their networks were last expanded during the economic
expansion of the late 1960's and early 1970's. Initially these networks were greatly
overbuilt and the transformers were only lightly loaded. Load factors of 40% to 50%
were commonplace. In the past decade, these systems were not only becoming older,
but the load factors on transformers were steadily increased to 80% or more. This had
resulted in higher failure rates, and the need for increased capacity. Just repairing the
failed units was no longer an option.
The perfect solution to this dilemma was the development of re-engineered transformers
using the hybrid technology. By placing Nomex in the hot winding areas and reducing
oil duct space, more copper could be placed in the fixed core window. This results in an
average reduction of losses of 20% at the original rated capacity and / or a significant
uprate in the capacity of the original unit. With an average capacity increase of 50%,
some units were uprated as much as 100%. Power utilities have the added flexibility to
run the units with lower losses when loads are down and at higher capacity when loads
are at peak. The additional bonus of increased reliability and lower maintenance make
these choices economically very attractive. If that were not enough, the utility can now
add capacity to their network in a third of the time required to order a new transformer.
Uprated rebuilt transformers are now being specified around the world.
Table 1. Countries where Uprated Transformers have been specified & built
United States
Canada
Argentina
Chile
Paraguay

England
Belgium
Spain
Germany
Brazil

India
Australia
South Africa

The temperature limitation of conventional transformers is based on the cellulose in the

winding areas. Typically, the oil temperatures are quite low and this potential extra
capacity cannot be realized due to the cellulose limit. By replacing the cellulose parts in
the hottest areas of the transformer, the limitation of the winding is removed, and the
new limitation is shifted to the oil. A comparison of a transformer which was re-designed
and rebuilt with a hybrid system is presented in figure 6. One can note that the capacity
has increased by 50%, and the limit is now on the top oil, not in the winding. In fact, the
average winding temperatures are quite low for Nomex, which has a thermal index of
220C.
Figure 6. Temperature Rise Comparison

Original Unit

Re- desi gned Uni t

ONAN

ONAF

ONAN

ONAF

MVA

12

20

18

30

Av. Oi l r i se / Amb.
(K)

38

28

5 5 .7

4 5 .4

Av. Wi nd. r i se / Amb.

(K)

50

55

7 1 .5

8 1 .1

Top Oi l r i se / Amb.
(K)

44

37

6 4 .5

60

Cool i ng Mode

Expansion of Hybrid Technology

The success of the hybrid technology in mobiles and rebuilt transformers has expanded
to other new applications that can take advantage of the value of this concept. A good
example is rectifier transformers. These units typically undergo vast swings in their load
cycles, requiring the nameplate capacity to carry the highest loads in the cycle. This
results in the units being underutilized much of the time, which means increased cost of
no-load losses and higher initial investment than is needed.
An example of this approach was developed for the rail system of Yunnan Province in
China. Each trackside station requires two 10 MVA rectifiers for the rail, but the average
load is only about 5 MVA. During very short peaks, loads up to 15 MVA per unit are
required. The peak periods are less than two minutes and occur 6 to 12 times per day.
Initially, two units were replaced with two 7.5 MVA hybrid insulated units. After
successful results, the second phase of the project was to replace the two 10 MVA units
with one 13.5 MVA hybrid rectifier. After two years of application on the provincial

railway, the manufacturer, Yunnan Transformer Factory, will expand the application with
the Chinese National Railway Ministry.
The usage of hybrid rectifiers not only saves the cost of losses and investment, but also
has the benefit of improved reliability of the network, reducing the number of outages
and inconvenience to passengers. An almost identical project is underway in Spain
today, and consideration is being given to small local networks in Europe.
Another development under consideration in the United States, which has similar
implications, is for "peaking" transformers. These are substation units in vacation areas
(beaches, ski slopes) where there is heavy loading during several months per year, but
much lower loads during the majority of the year. The hybrid technology allows for a
transformer that is sized closer to the average load than the peak load, but can
withstand the high overloading when needed, without impacting the life expectancy.
Many other new applications are under development globally as word of this technology
for power transformers is spreading.
KEPCO has modified their specifications for 60 MVA substation units to allow production
of lighter 3 phase units for the saving of transportation, installation, maintenance, and
reduction of oil by one third. This is in addition to lower core losses compared to three
single-phase units. Other ideas under consideration globally include underground
vaults, furnace and mining units, and industrial plant power supplies.
An Economic Analysis
One of the key factors in the development of the hybrid technology was to establish new
performance capabilities of power transformers at a cost that users could afford. By
placing Nomex in the areas most needed for thermal benefit, and leaving the bulk of
the insulation system with traditional cellulose materials, the increase in cost is very
minimal and the benefits outstanding. With increased capacities of 50% and more, the
typical cost per kVA can actually be reduced by 30% to 50%.
Table 2. compares the total evaluated cost, including the cost of losses, of an uprated
rebuilt transformer to the purchase of a new unit of the same capacity. The user can
realize a substantial saving and put the unit back on line quickly.
Table 2. Added Value of Uprate Capacity
Hybrid Rewind Cost (20 30 MVA)
Cost of Losses
NL (18 kW @ $6000/kW)
LL (170 kW @ $2000/kW)
Total Evaluated Cost

$ 155,000
$ 108,000
$ 340,000
$ 603,000

Value of a New Transformer @ 30 MVA

Cost of Losses
NL (24 kW @ $6000/kW)
LL (120 kW @ $2000/kW)
Total Evaluated Cost

$ 400,000
$ 144,000
$ 240,000
$ 784,000

Net Savings

$ 181,000

High Temperature Insulation Systems

The hybrid insulation technology was developed for power transformers where the driver
is economic solutions considering the large volumes of solid insulation and liquid
coolants, and the high cost of losses. But for smaller transformers, such as traction and
pole and pad distribution, the driver is for safety, low environmental impact, and size and
weight reduction. The technology best suited for these applications is the use of the use
of high temperature solid and liquid components, to maximize the value of both.
Nomex aramid insulation has been used with ester based fluids, such as Midel,
silicone based fluids, such as DC 561, and modified hydrocarbons, such as R-Temp.
Once the low temperature materials are removed from the system, typical winding
temperature rises of 115C to 125C are possible. This can result in significant weight
and size reduction, on the order of 30% to 50%. The lower volumes of fluid reduce risks
for environmental problems in case of a leak. Since most of these fluids are less
flammable than mineral oil, they can provide safer networks.
Traction transformers for high speed rail networks adopted this technology in the mid
1980s in Europe. Today, all major manufacturers of these transformers use an
insulation system based on Nomex and high temperature fluids. The major benefits to
the users are: lower weight per kW, overload capacity, noise reduction, cleaner oil for
improved reliability and reduced maintenance, safer systems for use in tunnels and for
on-board passengers, and lower volume per kW for improved environmental impact.

Table 3. Traction Transformer OEMs using High Temperature Systems

ABB (Italy, Sweden, Switzerland, Germany)
Alstom (France, USA)
Siemens (Germany, Portugal)
Pauwels (Belgium)
Elin
Ganz-Ansaldo
Hyundai
Mitsubishi
Fuji Electric
General Electric

Another segment of the industry where the major drivers are the similar are for pole and
pad mounted distribution transformers. A project in France during the 1980s led to
the development of pole mounted transformers with silicone and Nomex. These units
were adopted by EDF for use in critical areas of people exposure, such as ski slopes
and in large cities around passageways. The key driver was for safety.
One of the most recent developments has occurred in Korea. Dong Bang Electric Co.
has developed a silicone & Nomex system to produce a lightweight pole mounted unit
of 150 kVA that has the same weight as a conventional 100 kVA unit. In addition to

reduction of size and weight, and lower fluid volume, the unit is safer and more reliable.
Prototype units are under testing in KEPCOs distribution network.
In addition, Dong Bang has developed new pad mounted prototype units of 300 kVA and
500 kVA capacity. These units are built with an outside cabinet, making the cabinet safe
to human touch, even with higher operating temperatures. An extension of this
technology includes development of a smaller low-loss transformer for critical parts of
the network. After evaluation of these prototype units by KEPCO, adoption of larger
volumes for routine production are expected in late 1999.
Figure 7. Dong Bang Electric Co. Pole Distribution Transformers

Cellulose &
Mineral Oil

Nomex &
Silicone

Another development involves the use of Nomex and R-Temp fluid for "Duplex"
transformers in Taiwan. Taiwan Power proposed the concept to stack a single phase
and a three phase distribution unit to save space in the inner city locations where both
residential and industrial customers are located side by side. The design creates top oil
and winding temperatures that exceed the normal limits of conventional units. The
average winding rise was raised from 65 K to 85 K. These units will save space and
have the additional benefits of lower total cost, safer, and improved reliability. Prototype
units have been built and are under evaluation.

Safer Power Transformers

During the 1960s, Westinghouse and General Electric Co. in the U.S. developed power
substation transformers that were safer than mineral oil filled units using SF6 gas
technology. This market never developed in the U.S., where there is plenty of space
and most substation units are placed in remote areas away from populated sections.

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These units were mostly for use in the 69 kV class. Both these manufacturers later sold
their technology to Japan (Mitsubishi & Toshiba).
During the late 1970s and early 1980s, several Japanese manufacturers refined this
technology to meet the demands for power stations inside the cities, where land is
scarce, and safety is a premium. The technology was improved to expand the usage
into the 230 kV class, and prototype developments today extend into 345 kV. The
major uses are for commercial buildings, high rises, subway power stations and
underground substations. The drivers for this technology are primarily safety and
compact size, but they additionally result in lower noise and lower losses.
Meanwhile, several European manufacturers began developments with SF6 technology
during the 1980s. AEG Schorch Co. in Germany began offering small, medium voltage
units to the marketplace in the late 1980s. All developments in Europe were put on hold
in the mid 1990s when the market prices for SF6 began to shoot upward 5 fold in one
year, and it was announced that SF6 was a major "greenhouse" gas. At the same time,
demand for these transformers were reduced in Japan due to the environmental
concerns and the long recession plaguing the country.
In the past few years, renewed interest has developed in Asian countries, such as
Taiwan, Korea and Hong Kong, where similar conditions exist as in the Japan market.
The need for high voltage and high power in areas within close proximity to large
populations require a safer technology than available with conventional liquid units.
There are two basic technologies for these kinds of transformers that evolve from the
low thermal conductivity of the SF6 gas. The thermal conductivity of SF6 gas is three
times greater than air, but 20 times lower than mineral oil. In one technology, the
transformers are designed to have high temperature operation and H class insulation
systems, with low pressure and forced circulation. The second technology involves use
of a pressurized tank, improving the thermal conductivity under high pressure, and use
of lower temperature class insulation systems (class B or F).
Although both technologies are used, the pressurized systems are more common in
Japan. With the discovery of SF6 as the worst "greenhouse" gas known, there have
been new environmental measures taken in many countries. Monitoring of pressurized
vessels has become a priority and a very expensive undertaking, due to the very low
levels of the gas that must be detected.
Nomex Technology in Gas Filled Transformers
With the environmental problems in mind, the preferred technology for the future should
evolve towards the low pressure systems to minimize the potential for leaks and to
conform to the new environmental regulations. Some additional advantages of the low
pressure systems with forced gas circulation are lower production costs and easier
maintenance of the transformers once in service. These systems utilize Nomex papers
and boards as the primary insulation in the windings, cylinders, spacers, end rings, and
angle rings.

11

DuPont has developed several special new products for this application. To take full
advantage of the dielectric strength of the gas and reduce the volumes needed, the
spacing must be minimized in the winding and insulation areas
Due to the high stress distribution in the gas spaces, the surfaces of the insulation must
be smooth and free of any protrusions or fiber fluff. Therefore, a new smooth surface
thin paper for wire insulation was developed, Type N-774. This material has increased
dielectric strength and very smooth surface, free of any fibers. Likewise, for use of thick
cylinders in the high stress gaps, our T-998 pressboard has a similar smooth surface
characteristic.
Aging tests with Nomex in SF6 gas indicate that it has an even longer life at 300C
than it does in air. This makes Nomex very suitable for these applications, even at
high overload temperatures.

Table 4. Retention of Nomex Properties after Aging in SF6

% Retention after 16 days

Aging at 300C
Property

Initial Value

Aged in Air

Aged in SF6

Tensile Strength
(lbs/inch)

197

46

92

Dielectric Strength
(kV/mm)

19.8

69

85

Summary
There are many opportunities today to take advantage of new technologies in
transformer design, construction and performance. The use of Nomex aramid
materials can provide enhanced performance whether used with traditional mineral oil
systems, newer high temperature fluids, or with high dielectric gases. In addition to
lower size and weight, increased overload capability, and improved reliability, these
transformers are well suited to the demands of the next century because they have little
or no environmental impact and are safer than conventional systems.
Developments on every continent are expanding the use of these new technologies and
creating new applications never before possible. In truth, an industry that has been
stagnant for many decades is now alive with ideas and opportunities. Mobile, substation
and rebuilt power transformers are providing users with much needed flexibility and
improved performance for their systems, with additional value in reduced maintenance
and added reliability. Lightweight traction and pole & pad distribution transformers are
being re-defined, with growing applications globally.

12

Specialty transformers like trackside rectifiers and underground vaults are establishing
new benchmarks for future capabilities. The advances for the 21st century are available
today, using the proven reliability of Nomex aramid insulation technology.

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