USING HIGH-TEMPERATURE INSULATION TO REDUCE KEY

TRANSFORMER MATERIALS
Jean-Claude DUART, DuPont, (Switzerland), jean-claude.duart@che.dupont.com
Thomas LIM, DuPont, (Singapore), thomas.lim@sgp.dupont.com
Richard P. MAREK, DuPont, (USA), richard.p.marek@usa.dupont.com
Radoslaw SZEWCZYK, DuPont, (Poland), radoslaw.szewczyk@pol.dupont.com

ABSTRACT
Over the last several years, key transformer material
shortages have occurred more and more frequently.
Coincidentally, the costs have risen dramatically as well and
are likely to continue in this upward spiral for some time.
One of the most effective tools capable of forcing significant
reduction in amount of materials used is implementation of
high-temperature insulation in the design of transformers.
This paper explores the influence of the high-temperature
insulation on materials used in transformer design.
Applicable standards and typical insulation systems are
discussed. Solutions for raw materials reduction are
presented and key parameters of several design examples
are analysed.
KEYWORDS
High-temperature insulation, Aramid fibre, Hybrid insulation
system, Semi-helical winding
INTRODUCTION
The size of a particular transformer and amount of materials
used are driven by lots of factors, like dielectric clearances
required to ensure proper insulation level, appropriate
conductor size to meet limits for losses, or necessity of
providing sufficient cooling for the windings. Improvement in
any of these areas could bring benefits in form of reduction
of size and weight of the equipment. There is not much
progress observed in dielectric withstand of the commonly
used solid or liquid insulation materials, so there is little
chance to reduce dielectric clearances in designed
transformers. Similarly, the copper and aluminum are still
the only materials good for use as current leading
conductors. However, some developments were made in
terms of the thermal characteristics of insulation materials
used in transformer industry.

The first step was made some 50 years ago, when thermally
upgraded cellulose was developed for transformer
insulation. During last 40 years materials with even higher
temperature capability have been developed. For solid
insulation the aramid fiber has been introduced as well as
high-temperature resistant enamels. Among insulating fluids,
silicones and ester fluids have become more and more
popular.

Traditional design of liquid-filled transformers has been
based for many years on cellulose solid insulation combined
with mineral oil and most of the accumulated world
experience in transformer design is based on these
materials. However, high-temperature insulation systems
based on solids and fluids that can withstand higher
operating temperatures are getting popular.

Sometimes, high ambient temperatures, space or weight
limitations force designers to look for new solutions. Then,
designs with higher temperature rises can be proposed as
an alternative for conventional designs. For example, aramid
fiber with thermal class of 220C allows operating of the
equipment at higher temperature rise for windings without
any negative impact on the insulation life. There has been
many transformer for different special applications built
during last years including traction and rectifier transformers,
transformers for mobile substations, or more recently,
transformers for wind farm applications. High-temperature
materials have been also used for upgrading of retrofitted
transformers.

Over the last several years, key transformer material
shortages have occurred more and more frequently.
Coincidentally, the costs have risen dramatically as well, and
are likely to continue in this upward spiral for some time.
Prudence and good ecological conscience would therefore
dictate conservation of these materials. At the same time,
more efficient designs are being driven by various governing
bodies in most industrialized countries and, more recently, in
many emerging countries, too.

Use of high-temperature insulation in the design of
transformers can be one of the most effective tools capable
of forcing significant change is the use of key transformer
materials. The traditional approach generally results in
higher losses as a consequence of the high temperature and
intended reduced material content. Recently, more
moderate approaches have been introduced to the market.
In some cases the losses of a conventional unit can be
matched or even reduced by re-engineering the design to
take advantage of the thermal capability of the high-
temperature material.
STANDARDS DEVELOPMENT
An IEC Technical Specification was published in late 2004
as Part 14 of IEC 60076 [1], in response to a growing
interest in transformers with higher operating temperatures.
It was developed to meet the international need for
additional guidance in the specification and design of liquid-
immersed power transformers, using either high-temperature
insulation or combinations of high-temperature and
conventional insulation. Four insulation systems are defined
in this document, both to provide design guidance and to
improve communication between the manufacturer and the
user [2]. Each system is described below.


Homogenous insulation system
A homogenous insulation system is a uniform composite of
solid and liquid insulations that have the same thermal
capability. The typical liquid-immersed transformer, for
example, is composed of cellulose solid insulation and
mineral oil liquid insulation. Both components have
approximately the same thermal capability. For conventional
transformers, this temperature is defined by the maximum
hot spot temperature of 98C, corresponding to the 105 (A)
thermal class.

Since the overwhelming history and expertise of the
transformer industry relates to this type of transformer, the
IEC 60076-14 document defines this insulation system as
the standard reference. This standard system is labeled the
conventional insulation system and consists of mineral oil
as the liquid insulation and non-thermally upgraded
insulation as the solid insulation. By reference then, all other
insulations capable of continuous operation at temperatures
above that of either mineral oil or non-thermally upgraded
cellulose (105C), are considered high-temperature
insulations. An insulation system composed of high-
temperature liquid and high-temperature solid insulation or
conventional liquid and high-temperature solid insulation is
considered to be a high-temperature insulation system.

This approach was also a practical necessity, since there is
no generally accepted test method for determining the
thermal capability of an insulating liquid. In fact, the stated
capabilities of the fluids listed in the document are
specifically noted as generally accepted values and the
table heading is Estimated maximum operating temperature
(C). Accordingly, the liquids were divided into three basic
categories that also define the maximum recognized
thermal capability. Given the lack of definition in the
standards, the categories and limits were based on
application history as a starting point. Table 1 compares the
maximum temperature limits for these three basic
combinations. The average winding temperature rise is
clearly defined as a maximum value. Lower temperature
rises than these maximums are reasonable and expected
due to the wide range of application and design flexibility.
Average winding temperature rise values in increments of 5
degrees are typical.

The remaining three defined insulation systems are related
in that they all use mineral oil or the equivalent as the
dielectric coolant and all use a combination of high-
temperature and conventional solid insulation. The
differences lie in the degree of usage for the high-
temperature insulation. Table 2 compares the maximum
temperature limits for insulation systems using conventional
fluid. Table 2 also emphasizes that there are two distinctly
different maximum hot spot temperature limits that must be
addressed and mapped in the thermal analysis.
Mixed insulation system
The mixed insulation system uses high-temperature solid
insulation adjacent to the winding conductors, which are
located in the hotter regions of the winding. This includes
conductor insulation and, if necessary, spacers, strips and
cylinders in direct contact with these conductors. Cellulose
material is then used in the rest of the winding and other
lower temperature areas, where thermal class 105 (A) limits
are met. The mixed insulation system uses the least amount
of high-temperature insulation and is essentially used to
augment the capability of the conventional insulation system.
The technique is used when normal average winding
temperature rises are needed, but it is desirable to exceed
the normal hot spot temperatures.

As an example, with many rectifier transformer designs, it is
necessary to reduce the average winding temperature due
to excessive hot spot temperatures. This reduces the
average winding temperature rise and also increases the
size of the unit. By using a mixed insulation system, it is
possible to operate closer to a normal average winding
temperature rise and then merely protect the hot spot
locations with higher temperature insulation.


Table 1: Maximum temperature limits of homogenous insulation systems

Insulation Type Limit Description Mineral Oil Ester Silicone
Maximum Top [C] 100 130 155 Liquid
Maximum Top Rise [K] 60 90 115
Maximum Hot Spot [C] 118 190 220
Maximum Aging Hot Spot [C] 98 170 200
Solid
Average Winding Rise [K] 65 115 130

Table 2: Maximum temperature limits of mineral oil insulation systems compared to conventional

Insulation Type Limit Description Conventional Mixed Semi-Hybrid Hybrid
Maximum Top [C] 100 Liquid
Maximum Top Rise [K] 60
Maximum Hot Spot [C] 118 Conventional Solid
Maximum Aging Hot Spot [C] 98
Maximum Hot Spot [C] N/A 150 130 170
Maximum Aging Hot Spot [C] N/A 130 110 150
High-Temperature Solid
Average Winding Rise [K] 65 65 75 95



Semi-hybrid insulation system
An application where high-temperature materials are used
only for conductor insulation is defined as a semi-hybrid
insulation system. When applied to all windings, the goal is
usually longer life and better reliability. In some cases, lower
cost or reduced losses are the incentive, where high-
temperature insulation may be used on only one winding.
Generator step-up transformers, furnace transformers and
other high load factor applications are all good candidates
for a semi-hybrid design. Another suitable application
applies to transformers designed for use in high ambient
temperature conditions.
Hybrid insulation system
The hybrid insulation system uses high-temperature solid
insulation adjacent to all winding conductors, including all
conductor insulation, spacers, strips and cylinders in direct
contact with the winding, and cellulose materials in lower
temperature areas where thermal class 105(A) limits are
met. The hybrid insulation system uses the largest
percentage of high-temperature insulation from the three
mineral oil systems. Table 2 also indicates that this system
has the highest thermal limits of the three, which fits well
with high overloading, small size and high power density.

Historically, medium power mobile transformers used as
emergency substation replacements were some of the first
applications to take advantage of the hybrid insulation
system. This technique was an excellent match for the high
power densities needed for this type of unit. The hybrid
insulation system has also been used in the repair industry
for many years. This approach often provides additional
capacity and quick delivery at an attractive price. More
recently, new units have been specified to provide improved
reliability, higher overload capacity, or to supply more
capacity in the same available space. These applications
must be designed to specifically take advantage of the
insulation thermal capability.
APPLICATION EXAMPLES
As stated before, the use of high temperature materials can
reduce key transformer materials in the transformers. With
the high prices of raw materials it may have a positive
impact on the price of the equipment. However, it was not
the economics which made it attractive to use high
temperature insulation systems. Reduction of materials
needed to build the transformer is necessary to meet strict
requirements related to low weight or limited size of the
transformer in some applications.

The typical case for reduced weight of raw materials are
transformers for mobile substations, where equipment of
specific power rating must be placed on the road platform.
High temperature insulation of windings allow to operate the
equipment at the temperature higher than conventional
transformers. This means that much more heat can be
generated in windings. Cross section area of conductors
may be reduced, which then reduces the size of entire active
part and the tank, too. It must be emphasized that high
temperature materials allow reduction of cross sections of
conductors to much more extend than conventional
materials and pushing the current densities to real extremes,
sometimes to 7-8 A/mm
2
, which in consequence gives great
results in weight reduction. Tables 3 and 4 show
characteristics of one example of a mobile transformer in
comparison to conventional designs having the same power
rating or having the same weight [3].

Table 3: Comparison of hybrid mobile transformer
and conventional design of the same power rating
hybrid
conventional
(same power)
Rated power [MVA] 45 45
Weight [kg] 44 100 57 500
No-load loss [kW] 11.9 10.0
Load loss [kW] 752 225
Avg winding rise [K] 95 65

Table 4: Comparison of hybrid mobile transformer
and conventional design of the same weight
hybrid
conventional
(same weight)
Rated power [MVA] 45 31.5
Weight [kg] 44 100 44 100
No-load loss [kW] 11.9 8.0
Load loss [kW] 752 110
Avg winding rise [K] 95 65

Another case where weight of the transformer matters is a
pole type transformer. Power rating of the equipment is
limited in this case by the weight of the unit which could be
installed on the pole. Properties of high temperature
materials offer potential increase of rated power up to 30%
with the size and weight kept at the given level, or if the
same power rating is maintained, the weight can be reduced
up to 30%. More detailed analysis of reduction in different
materials is presented on the case of 300 kVA transformer
used in Korean grid. Table 5 shows comparison of this
transformer as a conventional design and as a high
temperature execution.

Table 5: Summary of material savings in high
temperature design vs. conventional design of
300 kVA, 22.9 kV transformer installed in Korean grid
conventional high temp.
Avg wdg rise [K] 65 95
Top oil rise [K] 65 65
No-load loss [W] 692 650
Load loss [W] 4 186 5 472
Core steel [kg] 380 372 (-2%)
HV conductor [kg] 91 80 (-12%)
LV conductor [kg] 68 59 (-13%)
Liquid [l] 555 500 (-10%)
Insulation [kg] 14.2 11.7 (-18%)

In case of wind turbine application, where transformer is
located inside the tower, weight is not as critical as the
dimensions. However, transformer specification not always
allows to increase the losses of the equipment. An important
aspect here is also poor cooling of transformer located on
the bottom of the tower. An example of the design with


dimensions reduced significantly and losses reduced at the
same time is shown in table 6 [4]. In this design winding
temperature rise is increased to 110 K but top oil
temperature is still kept at the reasonably low level of 70 K.
Amount of oil in this transformer is reduced by 31%
comparing to conventional design. This is especially
important in this case, as the more expensive silicone fluid is
used here.

Table 6: Comparison of conventional design and high
temperature design of Bio-SLIM transformer
(2.3 MVA, 20 kV)
conventional Bio-SLIM
Avg wdg rise [K] 55 110
Top oil rise [K] 50 70
No-load loss [W] 2 350 2 350
Load loss @ 75C [W] 18 000 16 000
Length [mm] 2 085 2 160
Width [mm] 1 150 760
Height [mm] 2 150 2 125
Liquid weight [kg] 1 210 840
Total weight [kg] 6 000 5 040

HIGHLY OVERLOADED TRANSFORMERS
Another specific application of high temperature insulation
technology and material savings offered by it are
transformers exposed to high short term overloads. High
overloads can generate excessive temperature in windings
even if their duration is short. This can lead to significant
loss of insulation life and endanger reliability of insulation
system. To avoid excessive temperature rises in the
conventional way, transformers can be designed for rated
power close to the value of overload. As a result, the
transformer can be quite much oversized relative to its
normal continuous loading.


Figure 1: Example of daily loading of rectifier
transformer in railway network

Analysis made for rectifier transformers working in Polish
railway network showed that actual continuous loading of
some transformers might be only 26% of the rated power of
the transformer [5]. This results from highly variable loading
of transformer showed on the Fig. 1. The transformer is fully
loaded only when the train passes section of the system
supplied by this particular transformer.
In such a case transformer must be significantly oversized. It
uses its rated power only by a short time within the day and
after this it consumes relatively high no-load losses resulting
from big dimensions of the core. The solution can be
designing of transformer equivalent to lower rated power but
with higher overload capability. Lower rating of transformer
means less materials and smaller equipment to be installed
on site. Together with reduced no-load losses it makes such
a solution worth consideration. Higher overload capability
can be achieved by implementation of high temperature
insulating materials, e.g. solid insulation based on aramid
fiber in windings area. When hybrid insulation system is
chosen, the rated average winding rise can be raised up to
95 K, and aramid paper allows significant overheating of the
insulation without extended loss of life being a concern.
Table 7 presents a comparison of conventional transformer
being used and high temperature design proposed as a
replacement (normal loading during the day is 1,74 MVA).

Table 7: Comparison of conventional and hybrid
design for rectifier transformer exposed to high short
term overloads
conventional hybrid
Avg wdg rise [K] 55 95
No-load loss [W] 5 466 4 688
Full load loss [W] 40 993 61 496
Total loss @ 26%
load [W]
8 315 8 960
Core weight [kg] 4 676 4 003
Cu weight [kg] 3 114 2 464
Oil quantity [l] 3 449 2 847
Total weight [kg] 12 367 10 367

Similar study performed for 160 MVA autotransformers
installed in Polish National Grid (PSE) also proved potential
for material savings. Re-engineering of this autotransformer
to the cellulose-aramid hybrid could give together with some
other modifications up to 25% reduction in raw materials
needed and reduce total owning cost of the transformer,
although the load losses would be higher that in original
design [6].
TRANSFORMER WINDING DESIGN
The use of high temperature solid and liquid insulating
materials in homogenous insulation systems may bring
benefits in terms of material savings when entire transformer
is designed to operate at the temperature higher than
conventional. Then, cooling system may be reduced
significantly, which results in less steel used for the
transformer tank and less insulating fluid contained in it.
However, for insulation systems using mineral oil, the liquid
temperature must be kept at the standard level and only
winding design and full utilization of higher thermal capacity
of solid insulation gives potential for material savings.

The most natural material saving method is reducing the
cross section area of conductors. Higher temperature
gradients of windings can be taken by insulation of better
temperature class, and the same rated power can be
packed in smaller volume of active part. It may happen that
conductor cross section area may be reduced to the extend


a) b)
where the mechanical withstand of the winding for the short
circuit forces is the limit. This approach, however, leads
straight to the higher losses in windings. For general use
substation transformers it can be justified economically when
total owning cost of the equipment is considered, which
includes purchase price, evaluated losses cost and
installation costs. Then, higher losses cost can be
compensated by lower original equipment price (less
materials) and lower cost of installation, as the space
required for transformer may be significantly.

In many cases, however, the losses of the transformer are
fixed and reduced cross section of conductors is not an
option. Then, savings may be achieved by reduction of
cooling ducts within the windings. Windings insulated with
high temperature solid insulation material do not require as
much cooling as conventional ones. In some designs cooling
ducts may be eliminated partially or even completely from
specific windings.
Semi-helical winding
An example of the technique based on closing cooling ducts
within the transformer winding is a semi-helical winding
design. It is an alternative for traditional helical disc winding
used commonly for low voltage windings of power
transformers, and it is a case of semi-hybrid insulation
system.

The idea is based on the number of horizontal cooling
surfaces really needed for cooling of the winding. Normally,
each disc is cooled by two surfaces (top and bottom), where
oil flow is enabled by the radial spacer separating adjacent
discs (Fig. 2a). The radial duct spacer height may vary
depending on radial build of the winding, and may reach up
to 5 mm. For low voltage winding consisting of 80 discs this
gives 400 mm of axial space filled with spacer material. The
dielectric stress is no concern in case of low voltage discs.
Hence, the only reason for disc-to-disc spacing is cooling.
However, if cooling could be reduced due to high
temperature insulation materials used on the conductor,
some of the cooling ducts could be closed. In semi-helical
concept every second cooling duct is collapsed and regular
spacing is replaced with just a thin separator, e.g. 1 mm
pressboard, preventing turn insulation from mechanical
damages (Fig. 2b).


Figure 2: Concept of semi-helical winding
a) helix, b) semi-helix

Replacing regular spacers with thin separators improves
significantly windings filling factor. Saved space can be
used either for reducing the radial build of the coil or filled
with additional conductor copper. In the first case the
winding gets more compact. Consequently, the diameter of
outside windings gets reduced, too, and entire active part
dimensions get smaller. This leads to savings in materials
used and reduces losses. In case where increase of
conductor area is chosen, the saving on materials is not
observed but losses can be reduced.

An example of transformer design where semi-helical
winding is implemented is presented in table 8. The load
losses got reduced by 2.5%. It must be emphasized that this
loss reduction did not result in any increase of transformer
cost. Cost of more expensive insulation materials was
compensated by savings on components like core steel or
transformer oil.

Table 8: Comparison of helical and semi-helical LV
winding design in 30 MVA transformer
helix semi-helix
Avg wdg rise [K] 65 75
Conductor insulation cellulose aramid fiber
Winding height [mm] 1 676 1 676
Copper strand width
[mm]
5.44 6.38
Radial build [mm] 51.3 45.4
Core loss [W] 18 858 18 766 (-0,5%)
Load loss [W] 130 900 127 585 (-2.5%)
Core weight [kg] 10 954 10 900 (-0.5%)
Copper weight [kg] 6 817 6 827 (+0.1%)
Oil weight [kg] 13 928 13 619 (-2,2%)
Total weight [kg] 40 005 39 554 (-1,1%)
Material cost [$] 132 485 132 423 (0.0%)

It must be remembered, that efficiency of using semi-helical
winding may vary from design to design. It can be more
suitable for windings relatively cold before re-engineering or
for windings supported by wide radial spacers, where
eliminating of cooling ducts affects cooling surface to less
extent.
No-duct winding concept
Semi-helical winding can be used in low voltage disc type
windings of power transformers. Similar approach can be
found also in design of distribution transformers, where axial
cooling ducts can be eliminated. This increases
temperatures of windings to limits which can be withstand by
high performance insulation materials. Eliminating the axial
ducts from windings not only saves space but also increases
mechanical strength of windings, as the structure is more
solid. This could even eliminate necessity of epoxy bonding
of winding layers.

Windings with reduced number of axial cooling ducts or with
ducts completely eliminated have smaller diameters, which
reduces size of entire active part and the tank, too. Less raw
materials is needed in such a case and the transformer is
relatively smaller and lighter.
LEAD CABLE DESIGN
While generally accepted for the winding insulation, the use
of high temperature insulation has been recently considered


for another transformer component which are the lead
cables connecting windings to bushings or tap changers.
Currently the kraft paper is commonly used for that
application. The interest in applying high temperature
materials is based on the same principles as in the windings.
The potential benefits include allowing higher operating
temperature for peak load demands and reducing the
amount of copper for cost reduction and making the cable
more flexible and easier to install.

Thermal and electrical insulation properties of cellulose
based paper and aramid crepe paper Nomex 7T411 have
been characterized in publication [7]. Because these results
show that the aramid insulation has better thermal
performance, a concept of lead cable design was developed.
The aramid insulated cables could be sized to run at higher
temperature without any reduction in reliability or impact on
the thermal aging of the cable insulation.

Table 9: Example of cable selection depending on
insulation material and temperature gradient allowed
across the insulation

Example 1
20 MVA, 6 kV
1925 A
Example 2
50 MVA, 20 kV
1443 A
Number of
cables
2 2
Size of cable
[mm
2
]
253 177
Current per
cable [A]
1009 785
Kraft

20 K
Total current
allowed [A]
2018 1570
Number of
cables
2 1
Size of cable
[mm
2
]
152 253
Current per
cable [A]
999 1441
Total current
allowed [A]
1998 1441
Aramid

50 K
Copper savings
vs. kraft
40% 28%
Number of
cables
2 1
Size of cable
[mm
2
]
127 253
Current per
cable [A]
963 1562
Total current
allowed [A]
1926 1562
Aramid

60 K
Copper savings
vs. kraft
50% 28%

Two examples of insulation substitution are presented in
table 9. The kraft insulated cables sized for 20 K
temperature gradient across the insulation thickness have
been replaced with aramid insulated cables sized for 50 K or
60 K gradient. Example 1 shows reduction in cross section
area of cables used (253 mm
2
down to 152 mm
2
or
127 mm
2
) while example 2 shows reduction in the number of
cables (2 down to 1). The degree of material cost saving will
depend on the specific substitution. For example, the
aramid insulated cable of 253 mm
2
with 3.2 mm insulation
build could be loaded with 55% more current at 60 K
gradient comparing to kraft at 20 K gradient.

The total cost of insulated cable required is lower for the
aramid insulated cable. The cost of the 253 mm
2
, 3.2 mm
build, aramid insulated cable is approximately 2% higher
than the comparable kraft insulated cable but number of
cables could be reduced due to the additional capacity per
cable gained. Additional cost savings can be achieved due
to reduced space in the transformer required for the cables,
reduced complexity of supporting structure and finally
reduced labor associated with installation of smaller cables
or fewer cables.
CONCLUSIONS
Operating of transformers at the temperatures higher than
conventional gives a chance to make designs with reduced
weight and size. This can be a valuable approach in some
applications even though the losses generated by such
designs may be higher. There are also techniques which
allow to reduce materials use without increasing the losses,
which not only results in saving the space or weight of the
equipment but also gives an economical advantage.

Bio-SLIM is registered trademark of Pauwels International
N.V., Belgium
Nomex is registered trademark of E.I. du Pont de Nemours
& Co., USA

REFERENCES

[1] IEC/TS 60076-14:2004, Design and application of
liquid-immersed power transformers using high-
temperature insulation materials
[2] R.P. Marek, 2006, Discussions on a New IEC
Document for Liquid-Filled Transformers, 10
th
Insucon
International Conference, Birmingham, 75-81
[3] Pauwels International N.V., leaflet on mobile
transformers
[4] Pauwels International N.V., leaflet on BIO-Slim
transformers
[5] R. Malewski, A. Rojek, J.C. Duart, 2001,
Zastosowanie izolacji Nomex-celuloza do
transformatorw prostownikowych zasilajcych sie
trakcyjn, VIII Sympozjum: Problemy Eksploatacji
Ukadw Izolacyjnych Wysokiego Napicia EUI01,
Zakopane, 305-313
[6] A. Zbudniewek, R. Malewski, 2003, Zastpienie
wyeksploatowanych autotransformatorw 160 MVA,
220/115 kV przecialnymi jednostkami o zmniejszonej
mocy znamionowej, Elektroenergetyka Nr 3/2003 (46),
16-21
[7] R. Szewczyk, J.C. Duart, L.C. Bates, 2007, High
Temperature Operating Lead Cables for Power
Transformers, CWIEME Inductica conference, Berlin