Chau Hon Ho, E2, Insulation & Polymer Technologies Group, 15.05.

14

Solid insulation and electrical components

Overview

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June 17, 2014 | Slide 1
The electrical grid today

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June 17, 2014 | Slide 2
Examples of electric power equipment

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June 17, 2014 | Slide 3
Introduction

§ An electric insulator shows very low response in electric

field and high resistance to flow of electric charge.

§ Insulation systems for each electric power apparatus has

today led to very specific insulation systems that meets the
special requirements for every apparatus.

§ Properties of electrical insulation systems is far from being

related to the electrical properties of the insulation
materials only.

§ Manufacturing process may have a strong impact on the

final behaviour of the insulation system.

© ABB Group
June 17, 2014 | Slide 4
History

Before 1800 • Insulating properties known for various materials

1800-1920 • Investigation and application of insulating materials
• Natural occurring products such as wood, glass, asphalt, rubber, cotton,
silk, mica / paper laminate, fabric (cotton coated with natural resin or wax)
• First application: insulation of wires for magnet coils and overhead lines in
telegraph and telephone industry
• Natural rubber for cables (up to 1 kV)
• Paper / oil underground cable (sheathed with lead) for up to 14 kV
Since 1920 • 1920’s: Use of phenolic resins (Bakelite, discovered 1905)
• 1925: Use of alkyd resins (saturated polyester)
• 1930’s: First synthetic insulating materials polyvinylchloride introduced
to replace natural rubber in underground cable and house wiring
• 1940’s: Introduction of epoxy resins (Ciba)
• 1950’s: Use of commodities PE and PP (industrialized with Ziegler-Natta
catalyst, but PE already discovered in 1898)
• Late 1960’s: EPR / ATH as non-ceramic outdoor insulators
• Late 1970’s: Silicone composites for outdoor insulators
© ABB Group
June 17, 2014 | Slide 5 K. N. Mathes, in Electrical Electronics Insulation Conference, Boston, 1991, pp. 147-150.
Telegraph wire insulators – starting 1840’s

Glass
blocks

Rubber coated Ramshorn

encased in glass, wood
or asbestos compound

© ABB Group
June 17, 2014 | Slide 6
Insulation materials used in electrical equipment

Gases Liquids Solids - inorganic Solids - organic

Thermosets, e.g.
Air Mineral oils Porcelain
epoxy resin, PU

Elastomers, e.g.
Nitrogen Vegetable oils Silica / Alumina
silicone, EPDM

Chlor- / fluorinated Thermoplastics,

SF6 Mica
hydrocarbons e.g. PA, PE, PP

Noble gases Silicone oils Glass Cellulose

Synthetic Other ceramics

Gas mixtures Polymer fibers
hydrocarbons (oxides)

Vacuum Mixtures / Composites

§7
The ideal dielectric (insulation) material

§ Low losses and independent from temperature and frequency

§ High breakdown strength
§ Low dielectric constant
§ Low electrical conductivity
§ High thermal conductivity
§ High resistance to heat and arcs (shape and chemical nature)
§ Low flammability
§ High moisture resistance
§ High resistance to all chemicals
§ Easy to process and shape
§ Others, e.g. fulfilling mechanical requirements and compatible with
other materials (adhesion and thermal expansion)

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June 17, 2014 | Slide 8
Choice for appropriate insulation material

Design

Costs

Properties Processing

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June 17, 2014 | Slide 9
Influence of complexity of design and consequence of
failure of insulation on continuous electric stress

Capacitor High voltage AC cable Machine insulation Power transformer

E ~ 60-100 kV/mm E ~ 5-20 kV/mm E ~ 3 kV/mm E ~1.5 kV/mm

Increasing complexity of insulation system and consequence of failure

Paper & Oil

§ Advantages
§ Cheap
§ Paper/oil insulation shows good
dielectric performances
§ Cooling by convection (à “free” oil)

§ Drawbacks
§ Paper drying
§ Flammability
§ Thermal stability of paper/pressboard

§ Applications
§ Power & distribution transformers
§ HV bushings
§ Cables
© ABB Group
June 17, 2014 | Slide 11
Requirements for insulating liquid

In general:
§ High electric breakdown strength
Electrical § High volume resistivity
§ Good arc quenching properties
§ High specific heat and thermal conductivity
Stability
§ Excellent chemical stability and gas absorbing properties
Physical § Low density, low viscosity and good (low-temperature) flow properties
§ Low volatility
§ High flash point
Safety § Non-flammable
§ Non-toxic
§ Biodegradable

Particularly for transformers:

§ Fluid at all temperatures (low pour point)
§ Stable against oxidation
§ No generation of corrosive substances (à iron tank and core)
§ No generation of sludge (oxidation)
§12
Transformers: Flammability issue

§13
Porcelain

§ Advantages
§ Low cost
§ Good resistance to erosion
§ Inert
§ Mechanical support

§ Drawbacks
§ Brittle
§ High density / heavy
§ Manufacturing requires high
energy consumption

§ Applications
§ MV & HV housing (surge arresters,
instrument transformers, bushings, etc…)
© ABB Group
June 17, 2014 | Slide 14
Manufacturing of porcelain insulators

§ Main production steps

§ Preparation of a slurry (clay + water)

§ Filter pressing
§ Extrusion
§ Shaping
§ Drying
§ Firing
§ Assembly

§15
Polymeric materials

Thermosets Thermoplastics Rubbers

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June 17, 2014 | Slide 16
Thermosets – Thermoplastics

Thermosets (cross-linked)
§ Delivered as monomer
§ Polymerization during processing à casting
§ No melting and insoluble (shape irreversible)

Thermoplastics (non-cross-linked)
§ Delivered as polymer
§ Melting during processing à extrusion
§ Melting and soluble in solvents (shape
reversible)

… and entanglements

© ABB Group
June 17, 2014 | Slide 17
Thermosets – Thermoplastics
Thermosets Thermoplastics
• Temperature stability § Toughness
§ Creep resistance § Automated processes
§ Long term stability § Well adapted for high series (> 10000)
Advantages

§ Chemical resistance § Recyclability

§ Good processibility of filled bulk parts § High number of suppliers
§ High versatility § Usually lower material costs
§ Excellent adhesion § Large range of material properties (variety
of chemical structures)
§ High tracking resistance
§ Well adapted for low series (< 10000)
§ Brittleness § Low creep resistance
Drawbacks

§ Toxicity during processing § Low adhesion (need of primer)

§ Recyclability § Low tracking resistance
§ Limited number of suppliers
© ABB Group
June 17, 2014 | Slide 18
Polymers in electrotechnology

§ 5 % of crude oil used for

manufacturing polymers
§ 270 mio t / year polymer
production 2006
§ 65 % Thermoplastics
§ 10 % Thermosets
§ 10 % Fibers
§ 8 % Rubbers
§ 7 % Others (e.g. dispersions)
§ In comparison: 200 bn t / year
biopolymers in nature

§19
Filled thermosets

§ Advantages
§ Dry technology (no flammable liquid)
§ Good mechanical properties
§ Long term stability

§ Drawbacks
§ Brittleness
§ Environmental & health impact

§ Applications
§ Dry distribution transformers & bushings
§ Instrument transformers
§ GIS spacers

© ABB Group
June 17, 2014 | Slide 20
Mixing of resins for casting

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June 17, 2014 | Slide 21
Vacuum casting

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June 17, 2014 | Slide 22
Vacuum casting: GIS spacers

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June 17, 2014 | Slide 23
Vacuum casting: Dry bushings

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June 17, 2014 | Slide 24
Epoxy HV components

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June 17, 2014 | Slide 25
Epoxy HV components

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June 17, 2014 | Slide 26
Automatic pressure gelation

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June 17, 2014 | Slide 27
Imgregnation: Electrical machines (winding types)
Random wound Form wound coil Cable wound Ring motor /
coil motor motor motor generator

Winding Enamel wires Form wound coils MV cables Roebel bars

Insulation Enamel Mica tape / resin XLPE Mica tape / resin

(+ impregnation) (Global VPI) (VPI or RR)
Pros • Flexible winding • Benchmark today • Insulation already • High torque
• Fast assembly of • Optimized design applied on winding possible
winding possible • High output power / • No VPI needed • HV possible
• High automation volume ratio • Max. 70 kV
• Low-cost • HV ≤ 15 kV possible

Cons • Limited to 1 kV • Many production • Low fill factor • Many production

• Insulation limited in steps (costs ↑) • Production time steps (costs ↑)
performance • Wet chemistry • Cooling of stator • Wet chemistry
• Still impregnation • No differentiation to core required • More connections
competitors • Low thermal class needed compared
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of XLPE to form wound
Random wound coil

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Random wound coil

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Form wound coils for HV machines

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June 17, 2014 | Slide 31
Insulating materials used in high voltage slot windings

Binder Mica Conductive

(resin) flakes coating

Main wall insulation

Inner conductor
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June 17, 2014 | Slide 32
Coil manufacture

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June 17, 2014 | Slide 33
Coil manufacture

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June 17, 2014 | Slide 34
Mica tapes

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Slide 35
Vacuum pressure impregnation
1. Pre-dried machine transferred 3. Pressure phase: Insulation
to vessel and vacuum pulled impregnated with resin

2. Vessel flooded with resin 4. Resin transferred back to

storage tank

Machine removed from

© ABB Group
June 17, 2014 | Slide 36
vessel to oven and cured
VPI equipment

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June 17, 2014 | Slide 37
VPI resins

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June 17, 2014 | Slide 38
Thermoplastics

§ Advantages
§ Adapted for high series
§ High toughness
§ Recyclability

§ Drawbacks
§ Low creep resistance
§ Low resistance to tracking
§ Low adhesion

§ Applications
§ Low voltage circuit breakers
§ Embedded poles
§ HV cables
© ABB Group
June 17, 2014 | Slide 39
Processability of thermoplastics: injection molding

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June 17, 2014 | Slide 40
Injection molding: application for insulation

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June 17, 2014 | Slide 41
Processability of thermoplastics: extrusion / kneading

Mixing: Multi-screw

Conveying / Profile manufacturing: Single-screw

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June 17, 2014 | Slide 42
Extrusion: application for insulation

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June 17, 2014 | Slide 43
HV cable

1. Power cable
2. Conductive core (aluminium or copper)
3. Semiconductive screen
4. Insulation material
5. Semiconductive screen
6. Metal protective screen (e.g. lead)
7. Outer protective screen (PP yarn and
bitumen)

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June 17, 2014 | Slide 44
Manufacturing steps

Triple extrusion

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June 17, 2014 | Slide 45
Vertical cable line

Source: Maillefer brochure

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June 17, 2014 | Slide 46
ABB cable factory in Karlskrona

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June 17, 2014 | Slide 47
ABB submarine power cables

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June 17, 2014 | Slide 48
Elastomers (silicones)

§ Advantages
§ High elongation
§ Hydrophobicity (silicones)
§ Low flammability

§ Drawbacks
§ Cost
§ Environmental & health impact in
case of solvents

§ Applications
§ Cable joints & terminations
§ Housing (Bushings, surge arresters,
capacitors, etc.)
§ Vacuum interrupters
© ABB Group
June 17, 2014 | Slide 49
Injection molding of LSR housing

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June 17, 2014 | Slide 50
800 kV HVDC: The largest power transmission system
Silicone rubber outdoor insulation needed for compact design

Will provide 31 million people in Shanghai

with electrical power (6400 MW)

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June 17, 2014 | Slide 51
Helical extrusion of silicone rubber

Helical extrusion process for manufacturing of composite hollow core insulators

(silicone extruded onto tube and cured in ovens)

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June 17, 2014 | Slide 52
Fiber reinforced composites

§ Advantages
§ High stiffness & toughness
§ Light weight
§ Long term stability

§ Drawbacks
§ Cost
§ Environmental & health impact
Materials:
§ Applications
§ Glass, aramid or basalt fibres
§ Dry distribution transformers
§ Resin matrix (e.g. epoxy or
§ Hollow core insulators polyester)
§ GIS & GCB shafts

© ABB Group
June 17, 2014 | Slide 53
Filament winding process

© ABB Group
June 17, 2014 | Slide 54
Products made of fiber reinforced composites

Fuse cut-outs rods

Transformer
components
Dry distribution
transformers

HV surge
Composite shafts arresters
(GIS, GCB)

Hollow core insulators

(inside)
© ABB Group
June 17, 2014 | Slide 55
Conclusion

Insulation systems for each electric power apparatus has

today led to very specific insulation systems that meets the
special requirements for every apparatus.

© ABB Group
June 17, 2014 | Slide 56
© ABB Group
June 17, 2014 | Slide 57