Cellulose based insulation materials for oil immersed transformers

Dipl. Ing. (FH) Frank Kbler

KREMPEL GmbH

TRANSFORM Partner

Introduction

Name :

Frank Kbler

Education:

Electrical Engineer
Fachhochschule Esslingen - University of Applied Sciences

Position:

Head of Technical Service at KREMPEL GROUP

Member of IEC TC 15: Solid electrical insulation materials
since 2009.

Frank Kbler, KREMPEL GmbH

06.06.2013

Page 2

Content

From wood to paper the paper manufacturing process

Introduction of cellulose based materials:

- Insulating (Kraft) paper
- Presspaper
- Pressboard
- Laminated pressboard

Introduction of IEC standards

Applications

Characteristics of cellulose based materials

Frank Kbler, KREMPEL GmbH

06.06.2013

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Paper manufacturing

From wood to cellulose

Composition of wood:
45% Cellulose
15% Hemicellulose
35% Lignin, Resin
5 % Minerals

Pine wood

Only the pure cellulose fibres can

be used for manufacturing of high
grade insulation papers.
In a special process known as
Kraft- or sulphate process the
cellulose fibres are extracted
from the wood.

Frank Kbler, KREMPEL GmbH

06.06.2013

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Paper manufacturing

Chemical structure of the cellulose fibres

Cellulose is a polymer made of repeating

glucose molecules

Degree of polymerisation (DP):

Length of the molecule chains
DP value of new presspaper: approx. 1200

End of life is reached at a DP value of 200

Test standard: IEC 60450
In cellulose fibres many polymers are
connected by hydrogen bonding

Frank Kbler, KREMPEL GmbH

06.06.2013

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Paper manufacturing

Schematic paper manufacturing process

Pulper
(cellulose loosening)

Continous crusher
(grinding)

Vats
(interim storage)

Finishing
Reel cutter
(Edge cutting)

Calender

Mixer vat
(additives)

Machine vat
(suspension)

Cleaner

Paper machine
PM dryer
or
Hot press

PM wet part
(sheet forming)

Further processing
Reel cutter
(narrow reel)
Transverse cutter
(format products)

Frank Kbler, KREMPEL GmbH

06.06.2013

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Insulating paper

Manufacturing of insulating paper

Principle of a Fourdrinier paper machine:

Drying

Flow box

Production of a single paper layer

Typical density of the papers: 0.8 1.1 g/cm

Special type: crepe paper

Frank Kbler, KREMPEL GmbH

06.06.2013

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Insulating paper
Insulating paper material standards
IEC Standard

Title

IEC 60554-1

Specification for cellulosic papers for electrical purposes - Part 1:

Definitions and general requirements

IEC 60554-2

Cellulosic papers for electrical purposes

Part 2: Methods of test

IEC 606554-3-1

Specification for cellulosic papers for electrical purposes - Part 3:

Sheet 1: General purpose electrical paper

IEC 606554-3-2

Specification for cellulosic papers for electrical purposes - Part 3:

Sheet 2: Capacitor paper

IEC 606554-3-3

Specification for cellulosic papers for electrical purposes - Part 3:

Sheet 3: Crepe paper

IEC 606554-3-4

Specification for cellulosic papers for electrical purposes - Part 3:

Sheet 4: Electrolytic capacity paper

IEC 606554-3-5
Frank Kbler, KREMPEL GmbH

Specification for cellulosic papers for electrical purpose - Part 3:

Sheet 5: Special papers
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Insulating paper

Typical application for insulating paper in transformers:

Conductor insulation for the so called CTC

(Continuously Transposed Cable)

Layer insulation

Insulation of internal wiring made with crepe

paper tubes

Other application:
- capacitors
- measurement transformers
- transformer bushings

Frank Kbler, KREMPEL GmbH

Picture: Essex Germany GmbH

06.06.2013

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Presspaper

Manufacturing of presspaper
Principle of a presspaper machine:
Wet felt
Drying

Cylindrical sieves

Production of multilayer (3 7) paper

Typical density of the papers:

0.95 1.3 g/cm

Produced thicknesses: 0.04mm 0.5mm

Frank Kbler, KREMPEL GmbH

06.06.2013

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Presspaper

Presspaper types produced by KREMPEL

Designation

Krempel
Type

IEC Type

Colour

Transformer presspaper

RPT 3055

P.2.1 B IEC 60641-3-2

natural

Low density transformer

presspaper

RPT 3055
SL

P.4.1 A IEC 60641-3-2

natural

RPT 3055-2

P.2.1 B IEC 60641-3-2

natural

Maschine presspaper

RPG 3020

P.6.1 A IEC 60641-3-2

orangebrown

High grade presspaper

EPR 3040

P.6.1 B IEC 60641-3-2

grey-black

DPP

natural; red
resin

2-layer transformer presspaper

Krempel DPP

Frank Kbler, KREMPEL GmbH

06.06.2013

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Presspaper
Presspaper material standards

IEC Standard

Title

IEC 60641-1

Specification for pressboard and presspaper for

electrical purposes
Part 1: Definitions and general requirements

IEC 60641-2

Pressboard and presspaper for electrical purposes Part 2: Methods of test

IEC 60641-3-2

Pressboard and presspaper for electrical purposes Part 3:

Sheet 2: Requirements for presspaper, types P.2.1, P.4.1, P.4.2,
P.4.3 and P.6.1

Frank Kbler, KREMPEL GmbH

06.06.2013

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Presspaper

KREMPEL-DPP

Manufactured from presspaper with a diamond-pattern resin

coating. The epoxy resin is still in the reactive B-stage.
After application of heat and pressure for a certain time, the
partial resin coating of KREMPEL-DPP leads to bonding of
the electrical conductors with the layer insulation and mutual
bonding of the insulation material layers. The large axial and
radial mechanical forces arising in the case of a short circuit
are safely tolerated by this internal strengthening of the coil.
At the same time the partial coating leaves empty spaces
between the insulation and the electrical conductors:
- Air and moisture can be removed more easily.
- Faster oil impregnation.

Frank Kbler, KREMPEL GmbH

06.06.2013

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Presspaper
Application in oil filled distribution transformers

Layer insulation
Diamond dotted paper
Presspaper

Cooling channels
Corrugated pressboard
Ladder ducts and ladder grids

Strips

Internal wiring:
Crepe paper tubes

HV coil

Frank Kbler, KREMPEL GmbH

LV coil

06.06.2013

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Pressboard

Manufacuring of pressboard:

Principle of a pressboard machine:

Drying

Cylindrical sieves

Production of multi layer pressboard:

Typical density of the board:

0.95 1.3 g/cm

Produced thicknesses: 1.0 mm 8.0 mm

Frank Kbler, KREMPEL GmbH

06.06.2013

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Pressboard

Pressboard types produced by KREMPEL

Designation

IEC Type

Colour

Hot pressed pressboard POWERBOARD AK

B.3.1 A

Natural

Calendered pressboard

PSP 3050

B.2.1 B

Natural

Mouldable pressboard

PSP 3051

B.4.1

Natural

Machine pressboard

PSP 3010

B.6.1 A

OrangeBrown

POWERBOARD AK

LB.3.1 A.1
LB.3.1 A.2

Natural

Laminated pressboard

Frank Kbler, KREMPEL GmbH

Krempel Type

06.06.2013

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Pressboard

Pressboard Material standards

IEC Standard

Title

IEC 60641-1

Specification for pressboard and presspaper for electrical

purposes
Part 1: Definitions and general requirements

IEC 60641-2

Pressboard and presspaper for electrical

purposes Part 2: Methods of test

IEC 60641-3-1

Pressboard and presspaper for electrical purposes Part 3:

Sheet 1: Requirements for pressboard, types B.0.1, B.0.3,
B.2.1, B.2.3, B.3.1, B.3.3, B.4.1, B.4.3, B.5.1, B.5.3 and B.6.1

Frank Kbler, KREMPEL GmbH

06.06.2013

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Pressboard

POWERBOARD AK

Precompressed pressboard type B.3.1A according to

IEC 60641-3-1

Produced in our factory in Zwnitz / Germany

Natural coloured, made from

100 % unbleached cellulose

POWERBOARD AK offers:
- high purity
- very good mechanical strength
- low shrinkage
- high oil absorption capacity

Thicknesses: 1 - 8mm

Master sheet size: 4.2m x 2.2m

Frank Kbler, KREMPEL GmbH

06.06.2013

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Pressboard
Major production steps of POWERBOARD AK:

Frank Kbler, KREMPEL GmbH

06.06.2013

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Laminated Pressboard

Laminated Board
Laminated board is produced by bonding several layers of KREMPEL
POWERBOARD AK with different type of bonding agents.

Our laminated board is produced according to the IEC 60673-3-1

3 types of Laminated Board are available:

POWERBOARD AK-CG
Glued with an aqueous casein glue according
to type LB.3.1A.1
POWERBOARD AK-PG
Glued with a polyester resin according to type LB.3.1A.2
POWERBOARD AK-PHG
Glued with a phenolic resin similar to type LB.3.1A.2

Frank Kbler, KREMPEL GmbH

06.06.2013

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Laminated Pressboard
Laminated pressboard material standards

IEC Standard

Title

IEC 60763-1

Laminated pressboard for electrical purposes

Part 1: Definitions, classification and general requirements

IEC 60763-2

Specification for laminated pressboard

Part 2: Methods of test

IEC 60763-3-1

Frank Kbler, KREMPEL GmbH

Laminated pressboard for electrical purposes Part 3:

Sheet 1: Requirements for laminated precompressed
pressboard, Types LB 3.1A.1 and LB 3.1A.2

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Pressboard
Application of pressboard

Frank Kbler, KREMPEL GmbH

06.06.2013

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Fibre Structure

Fibre structure of presspaper and pressboard:

All fibres are oriented either in machine direction
or in cross machine direction.
Due to the production process the amount of
fibres oriented in machine direction is higher
than the amount in cross direction.

1 mm

Thickness

Different behaviour in the three major directions:

- Tensile strength, elongation
- Shrinkage

CMD
Frank Kbler, KREMPEL GmbH

06.06.2013

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Drying and Shrinkage

Shrinkage MD and CMD of POWERBOARD AK

Almost a linear relation

between moisture
content and shrinkage of
pressboard

Higher shrinkage in
cross direction due to
fibre orientation.

Dimensional change [%]

0,80
0,70
0,60

Machine Direction (3mm)

Cross Machine Direction (3mm)

0,50
0,40
0,30

0,20
0,10
0,00
0,00

Frank Kbler, KREMPEL GmbH

1,00

2,00
3,00
4,00
Moisture content [%]

5,00

06.06.2013

6,00

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Drying and Shrinkage

Shrinkage MD and CMD of POWERBOARD AK

Almost a linear relation

between moisture
content and shrinkage of
pressboard

Higher shrinkage in
cross direction due to
fibre orientation.

Dimensional change [%]

0,80
0,70
0,60

Machine Direction (3mm)

Cross Machine Direction (3mm)

0,50
0,40
0,30

0,20
0,10
0,00
0,00

Frank Kbler, KREMPEL GmbH

1,00

2,00
3,00
4,00
Moisture content [%]

5,00

06.06.2013

6,00

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Drying Time

Drying of POWERBOARD AK

30

Drying time depends mostly

on thickness of pressboard
Measuring parameter:
- Temperature: 105 C
- Sample size:
300 mm x 50 mm
- Moisture content before
drying: approx. 5%

Drying time [h]

25
20

15
10
5
0
1 mm

3 mm

5 mm

8 mm

Thickness of Pressboard

Frank Kbler, KREMPEL GmbH

06.06.2013

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Drying and water absorption

Storage parameter:
- Temperature:
23 C / 50 % r.h.
- Sample size:
300 mm x 50 mm

6,0

5,0

Change in weight [%]

Drying parameter:
- Hot air drying at:
105C
- Sample size:
300 mm x 50 mm

4,0

3,0
Drying (1mm)
Storage at 23C/50% r.h. (1mm)
Drying (3mm)
Storage at 23C / 50% r.h. (3mm)

2,0

1,0

0,0
0

10

15

20

25

30

35

40

45

50

Storage time[h]

Frank Kbler, KREMPEL GmbH

06.06.2013

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Influence of moisture
Influence of moisture to an oil / paper insulation
regarding PD and breakdown voltage*

Moisture in pressboard insulation means:

Reduced dielectric strength

Lower PD inception voltage

Accelerated degradation of the cellulose

fibres
Influence of moisture and temperature to aging of
oil / paper insulation*

Moisture content

*Reference:
Kahle, M.: Elektrische Isoliertechnik. Berlin, Heidelberg,
New York, London, Paris, Tokyo: Springer-Verlag 1989.

Frank Kbler, KREMPEL GmbH

06.06.2013

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Conclusion

The different production methods of cellulose based insulating materials

cause different properties and make them suitable for various applications.

Due to the fibre orientation presspaper and pressboard are anisotropic materials
which have different properties in machine direction and cross direction.

Due to the highly hygroscopic behaviour of cellulose based materials it is

recommended to protect dried parts from picking up moisture again.

An optimized drying process for all pressboard insulation parts used in a

transformer is essential to ensure a long life in service.

Frank Kbler, KREMPEL GmbH

06.06.2013

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