Frequent Questions & Answers For

Global Energy Solutions
Frequent Questions &

Answers for
DuPontTM ReliatraN®
Version1 dated
June,2003
1
NOMEX ® is a Registered Trademark of E.I. DuPont de Nemours & Co. PERFORM WHEN THE HEAT’S ON
 Contents
 What is ReliatraN® page 5 ~ 6
 ReliatraN® Criteria page 7
 What is NOMEX®? page 8 ~ 15
What are the major advantages of page 16
ReliatraN ® Brand Transformers ?
 What are the benefits to the users of page 17
ReliatraN ® Brand Transformers ?
 How does DuPont maintain the high quality page 18 ~ 20
and reliability of ReliatraN® transformers?
 How does ReliatraN® perform under moisture? page 21 ~ 27
2
 Contents
How does ReliatraN® perform under dirty condition? page 28 ~ 29
 What’s the meaning of load loss by various insulation class? page 30 ~ 33
 How is dielectric withstand of ReliatraN® ? page 34 ~ 35
 How well does ReliatraN® perform during overloading? page 36 ~ 37
 How well does ReliatraN® withstand short circuit ? page 38
 What is the fire behavior of ReliatraN® ? page 39 ~ 45
3
 Contents
 How is ReliatraN® environmentally friendly ? page 46 ~ 48
 What does partial discharge mean to dry type transformer ? page 49
 What is VPI process ? page 50 ~ 51
 What is the maximum rating of ReliatraN® transformers? page 52
 Index page 53
4
 What is ReliatraN® ?
 ReliatraN® is poised to be the chosen brand for value-added
transformer solutions that apply to various distribution
transformer applications.
Microsoft
PowerPoint 프레젠테이션
5
Providing Global Energy Solutions
to the Electrical Industry
DuPontTM ReliatraN® Brand Transformers are
manufactured with UL® Certified Insulation
Materials , by a global network of ISO 9001
Certified Manufacturers, meeting the highest of
International Standards for Quality, Design,
Construction and Performance
DuPontTM ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 6
 DuPontTM ReliatraN® Criteria

The ReliatraN® standards are continuously reviewed to
incorporate new experience, materials, test procedures, etc
or to adapt new requirements
Microsoft Word
문서
7
 What is NOMEX® ?
The superior electrical properties of NOMEX®
paper and pressboard provide unique capabilities
for electrical equipment, resulting in new
classes and ratings. This includes:
 High Level of Safety

 Increased Load Capability
 Reduced Size and Weight
 Long Term Reliability
8
 NOMEX® Electrical Insulation has been used

in the most critical applications in all types
of electrical equipment.
Resin Cast Transformers

Ventilated Dry Transformers
Generators
Reactors
AC/DC Motors
Gas Filled Transformers
Liquid Immersed Transformers Hermetic Motors
9
The Advantages of NOMEX®
The unique capabilities of materials made

from Nomex® aramid polymer are a result
of it’s superior
Thermal,
Chemical,
Mechanical and
Electrical properties
10

THERMAL
THERMAL

Long Term Stability up to 220°C
 Short term exposures up to 350°C is possible
 Stable properties over a wide range of
temperature and humidity conditions
 Will not Melt, Flow or Support Combustion
below 250°C, with no toxic or corrosive
Off-Gases below 750°C
NOMEX ® is a Registered Trademark of E.I. DuPont de Nemours & Co. 11

PERFORM WHEN THE HEAT’S ON
O O
CHEMICAL
CHEMICAL N N C C
H H n
 No weak C-H bonds creates a strong resistance

to chemical attack by acids and alkalis
 Compatible with all oils, resins, varnishes,

fluorocarbons, refrigerants
12

MECHANICAL
MECHANICAL
 High tensile strength and tear resistance

prevent manufacturing problems
 High abrasion and cut resistance prevent
production and operational failures
 Good compression resistance provides a
stable and rigid structure during short
circuit or other mechanical stresses
13

ELECTRICAL
ELECTRICAL
 The low Dielectric Constant enables better

distribution of stresses between the
insulation and the cooling medium
 The low Dissipation Factor, even at high
temperatures, reduces dielectric loss
 High Resistivity at high temperatures up to
250°C in use
 Excellent Dielectric Strength under 50/60Hz
and under impulse conditions
14
The Advantages of Nomex®
Temperature Effect On
Dissipation Factor
0.30
0.25
Nomex®
Epoxy Resin
0.20
Dissipation Factor (60 Hz)
0.15
0.10
0.05
0.00
0 20 40 60 80 100 120 140 160 180 200 220 240
Temperature (°C)
15
Nomex® is a DuPont Registered Trademark
 What are the major advantages of DuPontTM
ReliatraN® Brand Transformers ?
 These State-of-the-Art ventilated dry type transformers

provide the best solution in reliable and versatile equipment
• Safe equipment which can be placed close to the load
• Flexibility in variable load situations
• Increased overload emergency capability
• Reduced Size and Weight for better space utilization
• Economical solutions for the distribution of power
ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 16

 What are the benefits to the users of DuPontTM ReliatraN®
Brand Transformers ?
 Highest Quality Standards
• DuPont standards for design and manufacture exceed the
local and global standards to ensure high quality and
reliability / long life
 Longest Warranty
• DuPont’s network of qualified manufacturers of
ReliatraN® transformers offer unprecedented five (5) years
warranty
 Cost Savings
• Lowest total owning cost from purchase to disposal over the
lifetime of the equipment

 How does DuPont maintain the high quality and
reliability of DuPontTM ReliatraN® transformers?
 DuPont provides the most updated technology on
design,manufacturing and testing to partners and
continuously monitors and audits all aspects of
production to deliver quality without any failure.
 Simple processing enables OEMs to produce

constant quality and reliability. All processes are visible
to detect any potential defect of transformer.

Coil Manufacturing Process
Cast coil VDT
Assemble mold -
Preheat resin -
Sophisticated process/
Weigh resin -
Simple
many parameters to
process/
quality impact
Mix resin - less
parameters
to quality
pouring Impregnation(VPI)
impact
curing drying
-
Disassemble
mold 19
 One of the special requirements for the transformer
installed at Nuclear Power Plant is longer life
( 40 years).
VDT had been used in many Nuclear Power Plants in US
due to reliable long life
 Failure rate of VDT at field is less than half of that of

other dry transformers in US.

 How does DuPontTM ReliatraN® perform under moisture?
 NOMEX® itself has high resistance under high humidity.
 VPI processing assure that windings are well protected against

harsh environment such as moisture and dust.
 Many tests and historical cases at operation sites have proved

that VDTs were safe to operate without outage at high humid
conditions.

 If a dry type transformer is energized after long storage period under
high humidity,it is recommended either to wipe dirt and moisture or
to energize without loading before placing a load on transformer.
 We do not recommend starting or operating a transformer with free

moisture on the coils as there may be surface deposits that are
conductive when wet.

Relative Volume Resistivity
of Materials (ohm - cm)
}
1020
{
50°C
Nomex® 1016 Insulators
220°C
1012
108
} Semiconductors
100
} Conductors
10-6
} Superconductors
10-10 23
Relative Volume Resistivity
of Materials (ohm - cm)
}
1020
{
50°C
1016 Insulators
Epoxy 100°C
Resin 1012
}
150°C
108 Semiconductors
100 } Conductors
10-6 } Superconductors
24
10 -10
Superior Humidity Resistance *
Relative Dielectric Dissipation Volume

Humidity Constant Factor Resistivity
(%) (60 Hz) (60 Hz) (ohm- cm)
_____________________________________________________
Dry 2.5 0.006 1016
50 2.7 0.006 1016
95 3.2 0.011 1014
* Properties for Nomex®10 mil (0.25 mm) T-410
25
Moisture resistance of VDT insulated with NOMEX®
A 1000KVA ventilated dry type transformer with NOMEX® insulation was
used in a special moisture demonstration by exciting the transformer
at full voltage immediately after being in a thunderstorm.
Transformer description
It is 1000KVA rated 13800 volts primary and 480Y volts secondary.
The temperature rating is 150C rise at a max. ambient of 40C. The BIL rating of the high
voltage is 95KV. The prior history of the transformer includes a short circuit test and impulse
test following the short circuit test.
The transformer was then subjected to higher impulses and subsequently flashed over at 138
KV. The partial discharge inception voltage when tested as individual coils was 1.9 times rated
voltage at 400 Hertz excitation.
The Demonstration
The transformer was placed outdoors during an extremely severe thunderstorm. The
thunderstorm lasted about one hour and 1.5 inches of rain fell. Immediately there after, the
transformer was brought to the testing area and excitation was applied.
The transformer withstood its full operating voltage with no sign of imminent flashover.
26
Moisture resistance of VDT insulated with NOMEX®
Conclusion
The NOMEX® insulated ventilated dry type transformer with VPI treatment exhibits superior
moisture resistance and can be used in outdoor locations in a properly designed outdoor
enclosure.
The thunderstorm demonstration was performed to show the superior moisture resistance of
coil construction.
Case study by Southern Transformer Co.

Alexander D.Kline,President
27
 How does DuPontTM ReliatraN® perform under dirty
condition?
 Coil structure is well constructed to separate each disk, which
will not allow cumulative dust collection between disks.
 Enough cooling space in LV, gap between LV/HV and HV
ensure effective cooling even at harsh environment such as
cement plants and mines
 One ASEAN power utility has operated several VDTs for
more than 15 years without any maintenance at all, though a
thick layer of dust covered windings.

29
 What’s the meaning of load loss by various
insulation class?
 The higher insulation class makes it possible to build

smaller size of coils, eventually leading to smaller
transformer size.
 The one of the advantages of H class dry type
transformer is compactness and lower no load loss with
more load loss compared with other transformers below
H class.

 Most of transformers operate at significantly below the full rated
load(average 60%) which benefits lower no load loss in terms of
economic view.
 Therefore, higher temperature designs more fully utilize

the raw materials and optimize losses, which is the
growing trend in the West.
 Reliatran® can be built for specific load loss, lower than

standard class H transformer by request.

Loss Evaluation Comparison
NLL 5:1 LL
1.20
Ratio of Cost of Losses
1.10
1.00
Class H vs. F
0.90 Class H vs. B
0.80
0.70
0.94
0.60
0.20 0.40 0.60 0.80 1.00 1.20
Load Factor
32
 Higher winding temperatures allow smaller coils
and smaller magnetic cores, saving cost, space and
weight.
Temp. Coil Size Comparison

Class (% of Class H)
Class B 130
Class F 115
Class H 100
Class C 90
33
 How is dielectric withstand of DuPontTM ReliatraN® ?
 Due to lower dielectric constant of NOMEX® than other
insulation materials, It has better distribution of stresses
throughout transformer
 There is no thick layer of Epoxy resin which means “No
cracking” on coils. One of the common problems with cast coil
is cracking to cause failure.
 Disk winding structure distributes the voltage stress evenly and
efficiently to meet BIL requirement of all standards.

NOMEX® Brand Paper & Pressboard
The Dielectric Constant of NOMEX® sheet insulation

is very low compared to most insulating materials.
Nomex® 1.5-2.5 Air 1.0

Inorganics 3.0-5.0 Mineral Oil 2.2
Glass 5.0-6.0 Silicone 2.7
Epoxy 4.0-6.0 Cellulose 4.5
The closer to the cooling medium(air), the better the

distribution of stresses throughout the transformer.
35
 How well does DuPontTM ReliatraN® perform during
overloading?
 Based on GB standard, the average winding rise is 125C and
max. hottest temperature is 180C.
 In this case there is temperature margin which is 40C
differential between thermal capability of Nomex(220C) and
max. hottest temperature(180C). This contributes to higher
overloading capability.
 For certain cases, one can put dual ratings on the name plate for
flexible operation either with lower load loss or higher capacity.

• Steady State Loading on the Basis of test temperature rise
(Quoted from ANSI C59.96-IEEE Guide for Loading Dry type distribution and power transformer)
Rated average winding For each degree C below

temperature rise the rated temperature rise,
increase rated load by
80C 0.57%
115C 0.43%
150C 0.35%
If a 1000KVA is 100C average winding temperature rise, the additional rating for over loading
can be calculated. (115C - 100C) x 0.43% + (150C - 115C) x 0.35% = 18.7%
===> 1000KVA x 1.187 = 1187KVA
* Note: In general, ReliatraN® provides about 30% additional capability for overloading based
on practical design.
 How well does DuPontTM ReliatraN® withstand short
circuit ?
 Design principles utilized for these transformers minimize
axial and radial mechanical forces in case of short circuit
accident.
 Transformers using this design have passed short circuit tests
mechanically and thermally for more than 30 years (in the US).
 VPI process with varnish enhances mechanical strength of
coils to prevent failure by short circuit accident.
 In addition, the disk structure in HV coil can hold winding
robustly.

 What is the fire behavior of DuPontTM ReliatraN® ?
 Aramids do not melt (hence it will not help the fire to
spread) and generate little or no smoke and emit no toxic
gas.
 Epoxy resin may emit some toxic gases when decomposed by
fire such as SO2, hydrogen sulfides and halides [Ref.1]
 Specialty tests like CENELEC HD-464 indicate
that VDT had less smoke, less weight loss, quicker self
extinguishment , less support to combustion than cast coil
 Nomex does not support combustion and can only be burned
with difficulty - even at elevated temperature (LOI >> 21%)

Quoted from “Development of Insulating Systems in Distribution
Transformers - Improvement of Fire Resistant Characteristic” by G.LE ROY
and F.SANDOZ
 “Full size testing of distribution transformer behavior under fire has been possible
thanks to the building by the French Coal Board Research Center (CERCHAR) of
a “fire gallery” guaranteeing against all environment pollution risks”
“Class H VDT: only slight effects occurred after some times - pyrolysis of the
superficial varnishes and metal frame paints ---.
Let us note that this good behavior is a consequence of the choice of materials done
on this equipment, on the basis of systematic fire test on samples(oxygen index at
various temperatures, combustion gas analysis).
Class B cast coil: Contrary to class H VDT, this equipment behavior was rather
disappointing and even, in some way, surprising.
About 3 minutes after being exposed to fire, whilest temperature reached only
about 150C , the transformer went into flames. In spite of the radiating panels
being switched off, combustion self supported itself until insulating matters
complete destruction.
 Conclusion: “ Especially the class H VDT, the only one having shown a completely
satisfactory behavior during the full size fire test.” 40

Quoted from “Development of Insulating Systems in Distribution
Transformers - Improvement of Fire Resistant Characteristic” by G.LE ROY
and F.SANDOZ
Transformer type VDT Cast coil Silicon Ugilec T
Class H(Aramid) Class B
Rating(KVA): 630 400 250 250 Liquid
mass tank/vessel (kg): - - 190/40 338/60
First fire occurrence (min): 30 3 30 20

Fire end (min): 40 70 110 55
Total energy measured at 12 m from the

fire (MJ after 40/60 min): 225/225 600/640 700/4900 400/500
Energy emitted by radiating panels (MJ): 336 143 ** 336 336
Transformer part in total energy (%): <1 80 95 55
Combustible destruction part (%) 20 100 100 20
100 300 75
Released carbon dioxide 10
mass(kg): - - - 25
Released HC1 mass(kg): 0.15 0.5 180 1.5
Released soot And dust mass (kg): 41
** Panels shut off owing to fire evolution
Flammability of insulation materials in
transformer
Limiting Oxygen Index

vs. Temperature
Limiting Oxygen Index (%)
40
0.13 mmNomex
0.13 mm PET Film
6 mm Epoxy/Filler
30
20
10
0 100 200 300 400
Temperature (°C) 42
CENELEC Norm HD-464 Testing for the
European Community
1. Severe Environments [ E ]
• Humidity Saturation at 50°C / 95% RH / 72 Hrs

- Must Successfully pass lightning impulse,
power frequency withstand voltage, and
measurement of partial discharge
• Saline Condensation at 93% RH / Saline Haze

of NaCl / 144 hrs / Running with water
- Must successfully pass overvoltage and power
frequency withstand voltage
43
CENELEC Norm HD-464 Testing for the
European Community
2. Thermic Impulse Test [ C ]

• Thermic Impulse test from -25°C to + 100°C
within 40 minutes
- Must pass impulse and partial discharge tests
3. Fire Testing [ F ]
• Winding subjected to pilot flame with heat source
of 800°C for 40 minutes
- During test, measure toxic off-gasses and smoke
emission
- After flame removal, measure time to extinction,
and weight loss
44
NOMEX® Insulated Transformer Coil
Subjected to CENELEC HD-464 Fire Test
500 100
450 Temperature rise OTF 90

Maximum Standard Temperature Rise
400 80
350 70
300 60
[K] 250 50 [%]

K %
200 40
150 30
100 20
Minimum Standard OTF
50 10
Alcohol + heating pannel Heating pannel only
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
Time (min.)
Fire Test Behavior According to HD 464

Temperature Rise and Optical Transmission Factor [OTF]
45
 How is DuPontTM ReliatraN® environmentally friendly ?
 When disposing NOMEX® by burning or burying, it does
not emit toxicity to contaminate soil and air.
Therefore NOMEX® can be recycled for fuel as energy
source, which was certified by European Cement plant
 Burying waste of epoxy resin is costly. Incineraton of epoxy

is not recommended due to potential hazardous off-gases
 NOMEX® can be incinerated at common furnace operating

temperatures.

 There is no waste of varnish after impregnation process while cast
coil should over-prepare epoxy resin to fill cast mold with
redundancy against shrinkage/leakage.
The waste at mixer and cast mold should be disposed carefully
not to impact environment.
 Cast coils leave particlulates with Epoxy resin and glass materials
when disposed. These materials are not present in VDT coils.
 When cast coil is ground for removing sharp edges, the dust
which is mixture of glass and Epoxy resin may impact
comfortable environment.

 There are no materials in VDT coils causing allergy and itch to
human body
 The quantity of materials requiring disposal is significantly less
than with cast resin coils (> 4 times)
 Compact size with lighter weight require less active
parts,which contributes for energy saving and green
environment.
(Production of silicon steel/copper wire entails fossil fuel
consumption resulting in air/water pollution.)

 What does partial discharge mean to dry type
transformer ?
 Reliatran® has a thinner layer of varnish without any
possible air bubble inside and is designed to have low voltage
stress far below corona inception voltage.
 Cast coil transformers assume the epoxy resin fill the gaps
and therefore design for epoxy dielectric, assuming no air -
if any air bubbles appear, there will be high stress on the air
and partial discharge will develop. It may cause insulation
breakdown resulting in transformer failure .

 What is VPI process ?
 This is the most evolved technology to produce high

quality coils with advanced equipment and material.
 Impregnation is done inside tank under

vacuum/pressure condition and there are no varnish
drops outside tank.

 During curing , there is some evaporation of
solventless varnish due to cross linking process
between monomers and resin. The vapor is not toxic
and is exhausted out by oven chimney. Varnish does
not cause skin irritation or allergic reaction to
people.
 Excess varnish can be returned to storage the tank

after impregnation process without any waste.

 What is the maximum rating of DuPontTM ReliatraN®
transformers?
 VDT transformers have been produced up to 15MVA and

35KV voltage class. Most popular range of product is up
to 3000KVA.
In general, Power Utilities limit electricity supply to users
below 10 MVA as max. due to distribution reliability and
economic reasons.
DuPontTM ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 52

 Index
 1.”Safety Aspects of Using Aramid and Paper and Pressboard in Dry Type
Transformer”
Dr.J.W.Rothuizen/ Switzerand
 2.”Development of Insulating Systems in Distribution Transformers - Improvement of
Fire Resistant Characteristics”
G.LE Roy/ F.Sandoz/France
 3. “Moisture Resistance of Nomex - Insulated “Glazed Coils””
Alexander D.Kline/USA
 4.ANSI C59.96 - IEEE Guide for Loading Dry Type Distribution and Power
Transformer
 5. CENELEC Norm HD 464 - Specialty test for Severe Environments,Thermic Impulse
and Fire

PAPER AND PRESSBOARD UL RECOGNIZED
DuPontTM ReliatraN ® is a Trademark of E. I. DuPont de Nemours and Co. 54


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Global Energy Solutions

Frequent Questions &

 What’s the meaning of load loss by various insulation class? page 30 ~ 33

 How is dielectric withstand of ReliatraN® ? page 34 ~ 35

 How well does ReliatraN® perform during overloading? page 36 ~ 37

 How well does ReliatraN® withstand short circuit ? page 38

 What is the fire behavior of ReliatraN® ? page 39 ~ 45

 What does partial discharge mean to dry type transformer ? page 49

 What is VPI process ? page 50 ~ 51

 What is the maximum rating of ReliatraN® transformers? page 52

 DuPontTM ReliatraN® Criteria

 High Level of Safety

 NOMEX® Electrical Insulation has been used

Resin Cast Transformers

Liquid Immersed Transformers Hermetic Motors

The Advantages of NOMEX®

The unique capabilities of materials made

The Advantages of NOMEX®

NOMEX ® is a Registered Trademark of E.I. DuPont de Nemours & Co. 11

The Advantages of NOMEX®

 No weak C-H bonds creates a strong resistance

 Compatible with all oils, resins, varnishes,

The Advantages of NOMEX®

 High tensile strength and tear resistance

The Advantages of NOMEX®

 The low Dielectric Constant enables better

 These State-of-the-Art ventilated dry type transformers

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 16

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 17

 Simple processing enables OEMs to produce

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 18

 Failure rate of VDT at field is less than half of that of

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 20

 VPI processing assure that windings are well protected against

 Many tests and historical cases at operation sites have proved

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 21

 We do not recommend starting or operating a transformer with free

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 22

Relative Dielectric Dissipation Volume

Dry 2.5 0.006 1016

50 2.7 0.006 1016

95 3.2 0.011 1014

* Properties for Nomex®10 mil (0.25 mm) T-410

Case study by Southern Transformer Co.

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 28

 The higher insulation class makes it possible to build

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 30

 Therefore, higher temperature designs more fully utilize

 Reliatran® can be built for specific load loss, lower than

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 31

Temp. Coil Size Comparison

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 34

The Dielectric Constant of NOMEX® sheet insulation

Nomex® 1.5-2.5 Air 1.0

The closer to the cooling medium(air), the better the

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 36

Rated average winding For each degree C below

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 38

ReliatraN® is a Trademark of E. I. DuPont de Nemours and Co. 39

satisfactory behavior during the full size fire test.” 40

First fire occurrence (min): 30 3 30 20

Total energy measured at 12 m from the

Limiting Oxygen Index