EVALUATION OF (Bio-)SLIM TRANSFORMERS VERSUS DRY-TYPE TRANSFORMERS

The following comparison is typical for the transformer product range of 1 to 6MVA and up to 36kV. Outside this scope transformer specifications need to be studied case-by-case and customising of the design becomes imperative, in general in favour of the liquid-filled type power transformers. Next to conventional liquid-filled transformers of Thermal Class A in which the insulation system consists of cellulose solid insulation combined with mineral oil, silicone fluid or ester, PAUWELS TRAFO developed a line of high-temperature liquid-filled transformers. These transformers have a homogeneous high-temperature insulation system as per IEC 60076-14 and IEEE 1276. They combine NOMEX paper and board with either silicone fluid (the SLIM transformer) or with the synthetic ester named MIDEL7131 (the Bio-SLIM transformer). The liquid is operated at a maximum temperature of 125C (which is only 25K higher than in Class A transformers, allowing the use of standard bushings, gaskets, paints) while the windings go as high as 165C (NOMEX is Class 220C). These (Bio-)SLIM transformers were especially developed for specific applications with severe operating conditions and restricted installation. They combine advantages regarding reliability, compactness, fire-safety, environmental friendliness, overloadability, life expectancy, overvoltage withstand. Typical applications are found in wind industry (nacelle installation or fitting the small tower door), traction, replacement of pcb-filled transformers, power upgrade of existing installations, public buildings,

PAUWELS, TRANSFERRING YOUR NEEDS INTO SOLUTIONS, OFFERS THE OPTIMAL TRANSFORMER FOR EACH APPLICATION THE RIGHT TRANSFORMER ON THE RIGHT PLACE

Van Schevensteen R

7/18/06

p1/7

PERFORMANCE Liquid-filled transformers generally have a 30% to 50% lower no-load loss level compared to dry-type transformers. No-load losses are present while the transformer is energized, usually 8760 hours per year. These losses therefore represent a considerable cost during its life. Example: a 2.5MVA/20kV liquid-filled will have 2.5kW no-load losses and a cast resin 5kW. At 0.05 Euro/kWh, this represents an annual saving of 1095 EUR. Liquid-filled transformers generally have a 5 to 8dB(A) lower noise level compared to dry-type transformers. The lower the noise, the lower the audible disturbance, but also the lower the risk for reflections, reverberations, resonance, vibrations of nearby panels or walls which may add to the overall sound level. Liquid-filled transformers can either be filled with a mineral oil, an ester (synthetic or vegetal) or silicone liquid. The selection depends on the specific applications of the transformer. Both silicone and esters will generate a price premium compared to the cheaper mineral oil filled unit. But they offer important advantages regarding environmental friendliness and fire behaviour. People who appreciate these added values will see a justification for the higher purchase price that will be partly compensated by reduced cost of the fire protection and liquid-retaining aspects of the installation. Dry-type transformers can either be open dry-type such as Securamid or Reliatran, or encapsulated in resin. The design of cast resin transformer can also vary. The LV-winding can be cast or insulated with prepreg material (cheaper), the HV-winding can be cast or wrapped with resin covered glassfilament (ABB patent). Here also each design will have its price consequences and typical pros and cons. The manufacturing process of cast resin transformers is more critical. The correct vacuum during casting must be respected; else partial discharges may appear which deteriorate the insulation. The ideal mix of the resin, hardener and fillers must be respected, else the difference in thermal expansion of conductors and resin may lead to mechanical stresses in the resin resulting in micro-cracks which can be penetrated by moisture and lead to transformer failure. In liquidfilled transformers, these parameters are of a less severe impact. That is why the measurement of partial discharges is a routine test for cast resin transformers and why climatic and atmospheric tests (including cold start) are defined for cast resin transformers only. Dry-type transformers are more sensitive to cooling efficiency, since the surrounding air is the only cooling medium. If the ventilation of the installation reduces, dry-types will heat faster than liquid-filled units which have the liquid as buffer. This phenomenon has an inverse effect when using forced cooling: ventilators on cast resin transformers can upgrade the rating to 140% while for liquid-filled this generally is limited to 125%. (Bio-)SLIM transformers have an additional thermal reserve compared to conventional liquid-filled units thanks to the NOMEX 220C class. Therefore they will not suffer from overloads or increased ambient temperatures. They are very well suited for installation in small substations or in applications with variable loads such as traction and wind turbines.

Van Schevensteen R

7/18/06

p2/7

While the typical design and physical and electrical characteristics of dry-type transformers, especially cast resin transformers, will limit their use to medium voltage applications (<36kV), liquid-filled transformers can also be built for HV and UHV systems. The Bio-SLIM line offers designs up to 66kV. Compared to dry-type transformers, (Bio-)SLIM transformers are the better alternative for installations at high altitudes and in severe atmospheres. SLIM transformers have been installed in the mountains near Mont Blanc. They hardly suffer from thin air or high humidity as dry-type transformers in which the air is both cooling and insulating medium. Condensation on the tank surface will not create creepage paths that may lead to flashover, as is the case when the cast coil surface becomes wet.

RELIABILITY Liquid-filled transformers have a mixed insulation system of a liquid plus impregnation cellulose or NOMEX, while cast resin transformers have a system of solid encapsulating resin and air. The glassy condition of the solid resin makes it very hard and brittle. This gives several disadvantages regarding electrical, mechanical, thermal and chemical stresses of which some are elaborated in the next points. In liquid-filled transformers, the MV-windings are generally wound directly onto the LV-winding creating one solid block. This set of windings is then solidly anchored onto the core legs. All this improves the ability to withstand shortcircuits, vibrations, shocks and earthquakes. In cast resin transformers the windings are generally separated from the core and from each other, by rubber support blocks. The large liquid volume with its high thermal time-constant is a good buffer for heat generated by the windings under overload conditions and thermal shocks. Liquid-filled transformers with continuous layer windings on the MV-side have an inherent better withstand against voltage surges (such as switching impulses, lightning and fast transients) than cast resin transformers with disc windings. Layer windings allow a more linear voltage distribution along the winding, giving lower electrical gradients and smaller voltage stresses. Properly liquidimpregnated inter-layerinsulation is a far better insulating system than vacuum resin casting. A liquid has the inherent feature of re-generation. If a small discharge occurs, or gas is formed on a critical path, the moving liquid is able to take that away before it can lead to a real failure. If the DGA monitoring would show too high concentrations of gasses, it is possible to streamline and re-use the liquid on-site. If the analysis of the gasses would reveal possible internal discharges, aging or arcing, the liquid-filled transformer can be more easily repaired than a cast resin transformer. In such transformers, it is all-or-nothing, the resin mould does not allow repair. The NOMEX and silicone/ester insulating system, as used in the (Bio-)SLIM, will hardly age, seen the design operating conditions leave sufficient safety margins. This increased life expectance, together with the low no-load loss level, results in an optimal TOC-evaluation, compared to dry-type transformers.

Van Schevensteen R

7/18/06

p3/7

The NOMEX used in the (Bio-)SLIM transformers is thermally, chemically, electrically and mechanical superior to any cellulose-based material (paper, cardboard, transformerwood, ). This means that these transformers will not only have a thermal reserve, but also have an inherent strength resulting in improved overvoltage and short-circuit withstand. All these strong points of (Bio-)SLIM transformers make them the ideal alternative in cases where the transformer is one of the critical components of which an extremely high reliability is required (near zero-defect performance). The lessons learned at the offshore windfarms of Middelgrnden and Horns Rev, where cast resin transformers proved to be a weak link, made Pauwels decide in general not to offer cast resin transformers for wind turbine generator transformer applications. This decision was supported by many wind turbine manufacturers and contracting companies, who decided to change from dry-type to the (Bio-)SLIM solution. In 5 years time close to 2400 (Bio-)SLIM transformers have taken a considerable part of the wind market segment for transformers, where up to then mainly cast resin ruled.

INSTALLATION Overall dimensions of a liquid-filled transformer will be generally smaller than that of a dry-type transformer, especially when the enclosure of the dry-type unit is included. This difference will be bigger with increasing voltage level. If compactness is an important requirement, the state-of-the-art option is offered by the SLIM-design, while the Bio-SLIM will offer the nec-plus-ultra in compactness and environmental safety. Thanks to the finned tank and the possibility to use round, oval-shaped (typical for Pauwels Trafo) or rectangular cores, designers have a great flexibility in customizing the dimensions of the liquid-filled transformers to any restrictions in size of the installation. Cast resin transformers do not offer any of these designflexibilities. Liquid-filled transformers are more appropriate for replacement purposes, especially for other liquid-filled transformers since one can respect the existing overall concept of connections, dimensions, protection, For replacement of PCB-units, the liquid-filled alternative is with silicone fluid or esters. Liquid-filled transformers can be designed for all kinds of environments in degrees of protection up to IP55. Indoor, outdoor, seaside, off-shore, Ex and ATEX explosion zones, industrial sites, chemical plants, and so on. Dry-type transformers generally are for indoor installations only (IP00-IP20), unless very expensive enclosures are included (up to IP33). Cast resin transformers were initially installed in buildings, hospitals and factories. Later they were also used in other applications such as underground (mines and tunnels), inside wind turbines and on offshore installations (drilling platforms and ships); but not with great success seen their higher failure rate. For underground installation preference is now often given to open dry-type transformers such as Reliatran and Securamid.

Van Schevensteen R

7/18/06

p4/7

For each of these applications a specifically designed liquid-filled transformer and appropriate installation and protection can offer an alternative with additional features, such as low no-load losses, low noise (buildings, hospitals and inside factory), low EMF (buildings and hospitals), withstand to vibrations (wind turbine nacelles and offshore), improved fire behaviour (silicone fluid and esters), higher compatibility to aggressive environments (industry, off-shore, underground, very cold locations, ). The argument that cast resin transformers can be assembled or repaired on site is only partly true. It is correct that a cast resin transformer is some sort of meccano which makes it often possible to assemble it, or to replace a failed winding, while the transformer stays installed. But as per good practice, the unit should receive electrical testing after assembly to prove it is okay. That is difficult to do in on-site situations. It is always better to bring the transformer back to a repair shop and have the job properly done. The superior thermal performance and compactness of (Bio-)SLIM transformers makes it possible to build ratings in KNAN-design where conventional transformers would already need forced cooling using ventilators. No ventilators means less inspection and maintenance, no energy used to drive the fans, higher reliability in case fans would malfunction, less noise, less space taken. While silicone fluid is biologically inert, MIDEL7131 is completely biodegradable. The advantages for use in wind turbine applications installed in nature and on sea are obvious. (Bio-)SLIM transformers can be designed to any required loss-level. The higher operating temperature doesnt necessarily mean that the transformer will generate more losses. We can customize the design to the heat dissipation capacity of the existing room. The design of the thermal profile of (Bio-)SLIM transformers makes sure that the transformer surface is not that much warmer than in conventional transformers. This allows to use conventional bushings, gaskets and paints. It is a misunderstanding to assume that the tank of a high-temperature transformer will be hot. The difference to conventional liquid-filled transformers is lower than +20K, but still cooler than the surface of a cast coil. It is mainly the heart of the transformers, i.e. the windings, that will reach high temperatures (max hotspot = 185C). This also means that no special thermal attention must be given for nearby switchgear, LV-panels, cable-trays, and so on. Common rules for proper workmanship can be used.

ELECTRICAL SAFETY The compatibility of liquid-filled transformers with Electro-Magnetic Fields (EMF) is much better than that of dry-type transformers. The earthed tank operates as a shielding making the active part immune to outside EMF and reducing the outwards radiated EMF. Liquid-filled transformers can therefore be installed closer to people and equipment that is sensitive to EMF (such as computers, electronics, medical apparatus, ). Dry-type transformers need an enclosure or special shielding.

Van Schevensteen R

7/18/06

p5/7

Liquid-filled transformers have an inherent safety against electrocution thanks to the earthed tank. This degree of safety can easily be extended to the connections by using plug-in type MV-bushings and rather simple LV-cable boxes. Dry-type transformers need an enclosure or have to be installed in a restricted area.

FIRE SAFETY When a liquid-filled transformer is victim to an external fire, it will take much longer before the transformer will start to participate in the fire. The flammable liquid is sealed inside the tank and will not be exposed to the flames until the tank bursts. Finned tanks are very flexible and can withstand considerable internal pressures. Windings of dry-type transformers are open to the flames and will more rapidly start to burn too. However, the amount of burnable material is limited and the risk for spreading of the fire small. This excellent fire behaviour of silicone filled transformers is confirmed by comparative fire test done by Pauwels Trafo at the laboratories of INERIS on a SLIM and a cast resin transformer. According to standard CENELEC HD464, quality cast resin transformers are typically classified as F1/C2/E2: o F1 = self-extinguishing and emitting a minimum of fumes in the event of fire o C2 = reliable under conditions of high thermal shock o E2 = performing well in damp, dusty, salty and polluted environments. As mentioned above, liquid-filled transformers can easily compete with the C2 and E2 classification and even surpass these requirements by far. However, in order to compete with the F1 fire classification, the liquid used must be of Class K3 as per IEC 61100. This is the case for silicone fluid or MIDEL7131. For fire safety, mineral oil transformers of class O1 are not to be considered an option. The best performance in liquid-filled transformers is given by Class K3 liquids having following advantages over mineral oil in the unlikely event of tank rupture: o Class K3 liquids (silicone and MIDEL) will delay any tank rupture due to internal failure during several tens of milliseconds compared to mineral oil; o Class K3 liquids (silicone and MIDEL) will be much more difficult to ignite and start a fire; o Class K3 liquids (silicone and MIDEL) once on fire, will have a selfextinguishing feature by creating a film on the surface, sealing the liquid from the air; o spreading of the fire and random damage will therefore be more limited; o spills of silicone liquid are less contaminating for the environment, while MIDEL7131 is completely bio-degradable. It is very important to note that international standard IEC 60695-1-40 Fire Hazard testing Guidance for assessing the fire hazard of electrotechnical products insulating liquids states that fires resulting from class K3 liquid-filled transformers are zero, while since the late 70s already some 150000 such transformers are in service.

Van Schevensteen R

7/18/06

p6/7

MAINTENANCE / MONITORING Liquid-filled transformers need almost no maintenance, especially when these are of the hermetically sealed type. The surface of the outer MV-winding of a cast resin transformer will often carry static electricity which attracts dust and metal particles. Together with moisture condensation this may lead to conductive paths and creepage flashover. Depending on the atmospheric conditions of the installation, regular maintenance by cleaning the MV-windings will be essential. One has the possibility to monitor the quality status and integrity of a liquid-filled transformer by doing (regular) oil sampling and Dissolved Gas Analysis. Using IEC/IEEE standards it is possible to get an idea of possible internal problems and to take preventive actions before failure. As mentioned above, cast resin transformers dont offer the feature. Apart from thermal monitoring, the quality status cant be checked; breakdown can not be predicted, they usually fail suddenly. Properly tested, installed and protected state-of-the-art liquid-filled transformers will rarely leak. EN 60076 presents some guidance to this matter. Overpressure valves and relays, surge arresters, oil-level sensors, thermometers, Pt100s and DGPTs are available. Definition of the level of protection and selection of the protective accessories is to be based on the criticality of the transformer, its installation and local safety regulations. The thermal monitoring of liquid-filled transformers offers more options and a higher accuracy than that of dry-type transformers. In liquid-filled transformers the thermal sensor is placed in a thermometer-pocket on the cover and it records top oil temperature. Using winding temperature indicators (WTI) it is possible to monitor the average winding temperatures too. In cast resin transformers the Pt100 or PTC-resistors can only be mounted in the resin insulation or in a cooling duct. This means that the temperature they register will be somewhere between hot spot and ambient air, depending on their actual location. The recycling at the end-of-life is much more economic for liquid-filled transformers. The conducting copper or aluminium of the windings is more easily recuperated since it is not cast into resin. Liquid-filled transformers allow a 95% material recycling, while cast resin only 65%. As mentioned above, (Bio-)SLIM transformers can offer KNAN designs where conventional transformers already need the assistance of fans to provide the required cooling efficiency. Ventilators are known to need frequent monitoring and maintenance. The fact that we could offer a 5.5MVA in SLIM design without ventilators still complying to the limited dimensions of the room, made RATP (the company that runs the Paris subway) decide to grant Pauwels a 4year contract for the supply of over 80 SLIM traction transformers.

Van Schevensteen R

7/18/06

p7/7