Degradation of Cellulose Insulation

in
Liquid-Filled Power Transformers
presented by:

Thomas A. Prevost
EHV-Weidmann Industries, Inc.

W-ACTI
2005 Fourth Annual Technical Conference
New Diagnostic Concepts for Better Asset Management
November 15, 2005
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Title:
Degradation of Cellulose Insulation in Liquid-Filled Power Transformers
Thomas A. Prevost
EHV Weidmann Industries, Inc.
Abstract: The life of a transformer is limited to the life of its solid insulation. Many
diagnostic techniques are used to assess the condition of the solid insulation. This
presentation will give a review of cellulose insulation, both paper and pressboard,
used in liquid filled power transformers. The manufacture of paper and pressboard
will be reviewed with an emphasis on those critical properties that determine
functional life. The degradation process of paper and pressboard will be reviewed
including those byproducts of aging that are used in diagnostic analysis. Techniques
to prolong the life of the solid insulation will be presented as well.

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The life of a transformer is limited to the life of the solid

insulation.
Much of the diagnostics performed on power
transformers is an attempt to determine the health of the
insulation system.
In order to understand the proper diagnostics to perform
and interpret the results of these tests a fundamental
understanding of the solid insulation materials is
essential.
Cellulose paper and pressboard is the most commonly
used solid insulation in oil-filled power transformers.
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What is the Life of an Transformer?

IEEE C57.91-1995 Guide for Loading Mineral-OilImmersed Transformers
Definitions:

3.5 transformer insulation life: For a given temperature of

the transformer insulation, the total time between the initial
state for which the insulation is considered new and the final
state for which dielectric stress, short circuit stress, or
mechanical movement, which could occur in normal service,
and would cause an electrical failure.
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What is the Life of an Transformer?

IEEE C57.91-1995 Guide for Loading Mineral-OilImmersed Transformers
Table 2Normal insulation life of a well-dried, oxygen-free 65 C average winding
temperature rise insulation system at the reference temperature of 110 C
Basis
Normal insulation life
Hours
Years
50% retained tensile strength of insulation
(former IEEE Std C57.92-1981 criterion)
65 000
7.42
25% retained tensile strength of insulation

135 000

15.41

200 retained degree of polymerization in

insulation

150 000

17.12

Interpretation of distribution Transformer

functional life test data
(former IEEE Std C57.91-1981 criterion)

180 000

20.55

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Materials Critical to Functional Life of a Transformer

Conductor Insulation
Thermally Upgraded Paper
Duct Spacers
High Density Pressboard
Lead Insulation
Crepe Paper

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Critical Properties of Paper and Pressboard that

Determine Functional Life
Chemical Purity
Mechanical Strength
Dielectric Strength
Thermal Stability

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Cellulose Basics:
Part I) Fiber Source
Boreal Forest
White Spruce
Black Spruce
Balsam Fir
Hemlock

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Chemistry of Wood
Wood contains four major substances:
Cellulose
Hemicellulose
Lignin
Extractives
For making paper and paper products, it is desirable to retain as
much of the cellulose and hemicellulose as possible.
Lignin is the chemical glue that holds the fiber together.
Most extractives are removed during pulping.

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Kraft Pulp
Cellulose materials used for electrical papers and
pressboard are usually manufactured from
coniferous trees pulped by the Kraft process.
Kraft Process
Cook the wood chips using heat,
pressure, and chemicals (pulping liquors)
Wash the pulp to remove the pulping
liquor

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Kappa Number
The Kappa number measures the amount of lignin present in a
pulp.

Kappa Number x 0.15 = % lignin in pulp

Conventional kraft cooking removes 92-96% of the lignin from

softwoods. Softwood is generally cooked to a kappa number of
32 which corresponds to a lignin content of 4.8%

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Handbook for Pulp and Paper Technologists

Figure 13-8. Photomicrographs of kraft softwood pulp before and after refining (Courtesy of
Institute of Paper Science and Technology).
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BM2 Wet End

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View from Wet End of 1.4 metre machine, BM2

This is a cylinder machine affording a multi-ply construction of the paper.
The machine also features a CLUPAK facility, twin head MEASUREX computer
control, float drying, size press, and on-line calendering.
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Board Machine
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Pulp - Transformerboard Flow

Sulfate Pulp
Water
Mixing
Chests
Storage Chests
Stock Chests

Refiners
Machine
Chest

Deflakers
Forming Roll
Cutter
Dryer

Sheet Forming
Cutting Table

White
Water
Hot Press
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Fig. 23 (Machine diagram for production of Transformerboard precompressed.)

Group

Transformerboard Mechanical Role

Support Windings During Short Circuits

Maintain Dielectric Clearances

Support High Voltage Leads

Support Auxiliary Equipment

-

LTC, DETC, Bus Bar etc.

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Transformers Forces

Core

Outer Winding

Inner Winding

Radial Forces

Axial Forces
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F Clamping Pressure = f(moisture,temperature,age)

F

transformer
winding
coil

pressboard
presspaper
copper

F
rigid clamping distance
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>(,
'0$11

6.


>3


Schematic of 550 kV BIL core and coil layout.

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Types of Transformerboard
* Difference is due to type of final drying

Calendered - Low Density Formable

-

Dried Unrestrained

Precompressed - High Density

-

Dried Under Pressure and Restrained

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Characteristics of Transformerboard
Physical and Mechanical
25

Hi-Val
T-IV

20
15
%
10
5
0
Oil Absorption

Compression
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Compression of Radial Spacers

Effect of Screen Pattern
Material = .059 Inch Thick T-IV
6
5

5.57
4 .3 1

W ith
S c re e n
P a tte rn

3
2 .0 5
2
1
1

W ith o u t
S c re e n
P a tte rn

0
C o m p r e s s io n

C o m p r e s s io n S e t

Note: Tested in accordance with ASTM D-3394 Bedding Pressure 150 PSI, Compacting 3000 PSI
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Aging of Pressboard Under Compression

Spacer Stack Height (mm)

102
100
98
96

135 Deg. C

94

150 Deg. C

92
90
88
0

50

100

150

200

250

300

Aging Tim e (Days)

Effect of aging on the thickness of a stack of Transformerboard.

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Shrinkage versus DP
Shrinkage after 250 Days of Aging
Aged at 135 C Aged at 150 C
4.8%
11.0%
Degree of Polymerization after 250 Days of Aging
Inititial Values Aged at 135 C Aged at 150 C
1190
164
152
Large difference in shrinkage versus Aging Temp.
Slight difference in DP versus Aging Temp.
While DP appears to have leveled off at a DP value
that would indicate end of life, the thickness of
the spacer material continues to decline.
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Thermal Upgrading of Insulation

In the late 1950s transformer manufacturers developed
Thermally Upgraded Papers (TUK).
In 1962 NEMA officially recognized TUK in standard TR-11962 by establishing another temperature rise limit of 65 C for
oil-immersed transformers using TUK.
Today 65 C rise transformers are the norm in N. America.

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The thermal limit of transformer windings is the insulation on the

conductor at the winding hot spot. The average winding rise is
calculated as follows:

Ambient
Average Wndg Rise
Hot Spot Differential
Hot Spot Temperature

55 C Rise
30
55
10
95

65 C Rise
30
65
15
110 *

* Only attainable with thermally upgraded insulation.

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Two types of Thermal Upgrading processes:

Modification of the cellulose chains specifically at
OH groups by cyanoethylation and acetylation.
Addition of chemicals to protect the cellulose
from oxidation: this is primarily achieved with
nitrous compounds such as urea, melamine,
dicyandiamide, and polyacrylamide.

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Cellulose Molecule

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Single Glucose Ring

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Cyanoethylation
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Ref. General Electric Company

Amine Addition - Dicyandiamide

Chemical Additive to paper.
Consumes water as it is produced.
Neutralizes acids as they are produced.
(ref Lundgaard)

Suppresses the self-catalyzing character of aging

process by chemical reaction.
During this process the stabilizing agent is
consumed.

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Aging Curves

Aging Curves
Thermally upgraded paper
Regular Kraft paper

(Paper severely aged below this line)

Source: Westinghouse/ABB Brochure on Insuldur

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Nitrogen
All of the various thermal upgrading processes
contain nitrogen.
Nitrogen is not found in cellulose
Nitrogen quantity is used to determine the amount of
thermal upgrading agent added to paper.
Different thermal upgrade processes will have
different nitrogen content levels to assure sufficient
upgrading.
ASTM D-982/ TAPPI T-418 Organic Nitrogen in
Paper and Paperboard
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Verification of 65 C Rise Insulation

Presently there is no clause in the standards which
state that the transformer manufacturer must verify
that Thermally Upgraded Paper is used.
Presently no acceptance test will indicate if thermally
upgraded paper is not used.
Currently being considered for IEEE C57.12.00
The transformer purchaser needs to specify!
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Degradation of Cellulose Insulation

Causes:
Moisture
Oxygen
Temperature
Effects:
Breakdown of the Cellulose Polymer
Reduced Mechanical Strength
Shrinkage (Under compression)
Byproducts:
Moisture
Gas
Carbon Monoxide/ Carbon Dioxide
Acids
Furans
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High Moisture Content in Insulation

Can Cause:
Accelerated Aging of the Cellulose
Significant Reduction in Dielectric Strength
Bubble Formation and Dielectric Failure
Partial discharges in the Insulation
Dry = Cellulose < 0.5% by weight
& Oil < 10 ppm H 2O
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Paper and Water in Transformers

KVA
Rating
3,000
10,000
16,000
20,000
30,000
40,000

Ref. S.D. Meyers

KV
13.2
115
115
132
154
230

Weight of
Paper (kg)
453.6
1,605.7
1837
2612.7
3637.8
4808.1

kg/KVA
0.15
0.16
0.11
0.13
0.12
0.12

5% Initial Moisture
Kilograms
Liters
22.7
23.1
80.3
81.8
91.6
93.1
130.6
132.9
181.9
185.1
240.4
244.5

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Moisture Accelerates Ageing Process

Ageing acceleration factor

25

20

15

10

0
0

10

12

Moisture content in paper (% W/W)

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Effect of moisture on Dielectric strength of

Insulation
60

Voltage U(kV)

50
x=
x=
x=
x=
x=

40
30
20

1%
4%
6%
8%
10%

10
0
30

40

50

60

70

80

90

100

Temperature (C )

Power factor tan (%)

30
25
x=
x=
x=
x=
x=

20
15
10

1%
4%
6%
8%
10%

High-voltage insulation systems

of Transformerboard must be
properly dried and impregnated
with oil. The insulation has to
be dried because moisture
increases the dielectric power
factor and increases the risk of
thermal breakdown.

5
0
30

40

50

60

70

80

90

Temperature (C )

100

110
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Moisture Promotes Bubble Evolution

Residual moisture in winding insulation can lead to
generation of gas bubbles at high temperature
This is the dominant concern in the selection of a
limiting hot spot temperature for safe operation
Determinant factors for bubble generation have been
identified :
Moisture content in insulation
Hydrostatic pressure
Duration of the high temperature

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Generation of gas bubbles at high temperature

T.V. Oommen et al, Atlanta, 2001

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Critical temperature for bubble evolution

190

Kobayashi rapid heating

Kobayashi slow heating

170

Temperature

150

Davydov

130
Oommen gas free

110
Oommen gas saturated

90
70
50
0

10

WCP % w/w

Ref. Sparling, Brian; GE Energy, Tutorial Transformer Insulation Condition Monitoring

RVP-AI Mexico, 2005

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Diagnostics techniques for assessing the condition

of insulation
Moisture of Oil
Dissolved Gas Analysis (DGA)
Degree of Polymerization (DP)
Furans
Power Factor
Polarization Index
Return Voltage
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Equilibrium Conditions
Water in Oil & Paper
20C

30C

50C

40C

60C

Water in Paper (%)

6
70C

5
4

80C

90C

100C

1
0
0

10

20

30

40

50

60

70

80

90

100

Water in Oil (ppm)

Ref. Norris

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Diffusion Time Constant on Insulation Material

140

Davydov et al. (winding model)

Davydov et al. (pressboard)

Temperature (C)

120

Griffin (insulated conductor)

Sokolov andVanin (full size transformer)

100

Oommen (distribution transformer)

80

Du et al. (theoretical)
Von Guggenberg (theoretical)

60

Sokolov et al. (theoretical)

40

FARADAY Model approximation

20
0
1

10

100

1000

10000

Diffusion time constant (hours)

Ref. Sparling, Brian; GE Energy, Tutorial Transformer Insulation Condition Monitoring
RVP-AI Mexico, 2005

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Dissolved Gas Analysis

The causes of fault gasses are classified into three categories:
1. Partial discharge
2. Thermal Heating
3. Arcing
When the insulation system is thermally overstressed, gasses
are produced and they will dissolve in the oil.
Hydrogen from the Oil
CO and CO2 from the insulation
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Degree of Polymerization
Measurement of intrinsic viscosity after dissolving the cellulose
in a specific solvent.
Gives an average measurement of the number of glucose units
per molecular chain.

DP of Insulation Components prior to processing

~1200

DP of Insulation Components following processing

~1000

DP level considered as over-processed

~800

DP level considered end of life

~200

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Effects of aging:
- darkening of color
- loss of electrical and mechanical strength; trans. failure
- shortening of cellulose chains DP lowered
- paper becomes wetter, and acidic
- by-products contaminate the oil
IEEE Transformer Committee Panel Session October 25, 2005
Source ABB Power Technologies, Inc.

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Aging process : Cellulose depolymerization

CH2OH
O
OH

OH

OH

CH2OH

OH
OH

OH
O

OH

CH2OH
O
OH

OH

OH

CH2OH
O
OH

CH2OH

CH2OH
O
OH
OH
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Cellulose Degradation

CH2OH
H
O

H
OH H

O
H

OH

Glucose Unit

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Degradation of Cellulose

CO

HOH

CH2OH

CARBON
MONOXIDE

H O O
H H
C OH H

WATER

CHO

HH

OH

FURAN

HOH

HOH
WATER
WATER
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Furans
Most labs determine the concentration of five furanic
compounds:
1.
2.
3.
4.
5.

2-furaldehyde
5-methyl-2-furaldehyde
5-hydroxylmethyl-2-furaldehyde
2-acetyl furan
2-furfuryl alcohol

(2FAL)
(5M2F)
(5H2F)
(2ACF)
(2FOL)

Note: 2FAL is stable for years while all other furanic

compounds are less stable. They tend to form and then degrade
to 2FAL over a time period of months.
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Furans
Causes of Specific Furan Compounds:
Compound

Cause

2-furaldehyde (2FAL)
5-methyl-2-furaldehyde (5M2F)
5-hydroxylmethyl-2-furaldehyde (5H2F)
2-acetyl furan (2ACF)
2-furfuryl alcohol (2FOL)

General overheating, Normal ageing

High temperatures
Oxidation
Rare, Causes not fully defined
High Moisture

Ref: Stebbins, R.D., Myers, D.S., Shkolnik, A.B., Furanic Compounds in Dielectric Liquid Samples: Review and Update of Diagnostic Interpretation and Estimation
of Insulation Ageing, Proceedings of the 7th International Conference on Properties and Applications of Dielectric Materials, 2003. Volume 3, 1-5 June 2003
Page(s):921 - 926 vol.3

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Relationship between 2FAL concentration and DP

Source:1999 data from S.D. Myers on 13 units [4]

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2- Furfural vs. DP Correlation Plots

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CORRELATION BETWEEN 2-FAL and DPV

2-FURALDEHYDE (ppb, microg/L)

0%

25%

50%

75%

100%

Residual Life

10000
VIT ST2

PAL T3
ALK 1-2B
ALK 7-8A

1000

ALK 5-6B

ALK 3-4B

KLY 2RX2
PAL T2

ASH T-1

KLY SP5RX

RYL SPT1

100

RLY SPT3

10

MCA TX

200

300

400

500

600

700

800

900

1000

1100

1200

DEGREE OF POLYMERISATION
Ref. GE Energy RVP-AI 2005
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Techniques to Mitigate the Ageing Process

It is not possible (today) to reverse the ageing of the cellulose insulation
Control (slow down) the ageing process
Remove the catalysts
Moisture
Acids
Oxygen
Process the oil
Removes moisture, acids, particles, gasses
Resets the Furan levels
Dry the transformer
Removes moisture from solid insulation
Reduces the clamping pressure on windings

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Techniques to Mitigate the Ageing Process

Control (slow down) the ageing process
Reduce oxygen
Maintain/Upgrade the Oil preservation system
Membrane in oil conservator
Reduce the temperature
Increase cooling
Control load

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Summary and Conclusion

Degradation of Cellulose Insulation in Liquid-Filled Power

Transformers
Selection of proper raw materials will prolong insulation life
Pure/Clean cellulose processed with the Kraft process.
Measured by Kappa number= low lignin content
High mechanical strength
High Density Pressboard Spacers with Surfaces Milled
Improved compression characteristics= Short Circuit Withstand
Thermally Upgraded Paper
Determined by level of Nitrogen.

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Summary and Conclusion

Degradation of Cellulose Insulation in Liquid-Filled Power

Transformers
The rate of Insulation degradation is related to the presence of
moisture, oxygen and temperature.
The byproducts of insulation ageing are:
Moisture
Gas
Carbon Monoxide/ Carbon Dioxide
Acids
Furans
These by-products are also catalysts for the ageing process.
Removal of these by-products will slow down the ageing process
Measurement of these by products can also be used to assess
insulation life.
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Summary and Conclusion

Degradation of Cellulose Insulation in Liquid-Filled Power

Transformers
Future Work
Further development of moisture models.
Diffusion
Equilibrium
Continue to verify Furan vs DP
Need to measure retired/failed insulation.
Include TUK vs Non-TUK

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Thank you for your attention

Questions??

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