PERFORMANCE ANALYSIS OF VPI TRANSFORMER
Kacey.C.Lee and Sun Cheol Gweon
DuPont (Korea) Inc, New Korea Electric Co., Ltd
ABSTRACT
The ventilated dry type transformer(VDT) technology
has been evolving since the early 1960’s due to
technology development in design, processing equipment
and improvement of insulation materials such as
impregnating resins and insulation materials that have
higher thermal capability. In light of this technology
development, the most state of the art technology is so
called Vacuum Pressure Impregnated (VPI) transformers.
This paper explains the differentiated performance of
VPI transformers with analysis of tests done based on
IEC 60076-11. Technical information on application and
benefit of VPI transformers in this paper will be a guide
for users to select the best suitable transformer under
their specific operation condition.
INTRODUCTION
There are more global trends in electrical equipment
related to safety, environmental concerns, reliability,
energy losses, load growth (overload), space utilization,
international standards. Given these circumstances,
transformer OEMs have struggled to meet the various
demands from end users.
The VPI transformer introduced in this paper is insulated
with aramid papers and high temperature insulation
materials which insulation system is developed to be
rated with a thermal index of 220℃ for continuous
hottest spot operation based on ANSI C57.12.56. This
transformer has differentiated advantages versus other
distribution transformers such as liquid transformers, cast
resin transformers and gas insulated transformers.
Followings are some of advantages of VPI transformers.
-easy to repair (open coils),greater flexibility of coil sizes
and shapes, no cracking(no blocks of solid resin),
reduced size and weight per kVA, designed to be free of
partial discharge, high level of safety, increased overload
capability, improved reliability, reduced environmental
footprint.
It can also benefit end users with tailored design because
there is no steel tank containing insulation oil and no cast
mold holding epoxy resin and coils, which limit freedom
of flexible design to optimize use of active parts and
insulation materials.
Design principle
The design principle adopted in this paper focused on
IEC requirement with round core and coil construction.
The winding conductors are wrapped with aramid papers
(0.05 mm thick) by single half lap or double half lap
determined by primarily basic impulse insulation
level(BIL). The most critical parameter influencing cost,
size and reliability is clearances that are affected with
test conditions, continuous operation and correction
factors(altitude and temperature). There are two types of
clearance- jump in air and creep over surface. These
clearances become more critical for HV to LV coil,
HV/LV coil to core/ground, phase to phase, because most
failures occur at these locations as well as influence to
characteristic of transformers. The VPI transformer has
an optimized clearance that has been evolved with
various design experience and tests from transformer
OEMs, testing institutes and research labs. A typical
winding structure is based on a disk winding with comb
spacers. This structure is most effective to have high
electrical and mechanical strength, even voltage
distribution on HV windings, efficient cooling and less
hottest spot temperature. Slots in a comb spacer hold
conductors tightly and limit maximum voltage stress
below CEV(Corona Extinction Voltage), which improve
short circuit resistance and ensure partial discharge free
operation.
In addition, the structure of comb spacers exposes
conductor surface widely enough to cool the winding
temperature rise down, which contributes to reduced
thermal degradation of insulation materials. These design
features contribute to highly reliable VPI transformers.
Production process
VPI(Vacuum Pressure Impregnation) is the most
improved technology to produce high quality coils with
advanced equipment and materials. There are many
similar processes between VPI transformers and cast coil
transformers except processes of applying resin to
windings. Table I shows a process comparison of these
transformers.
Table I a process comparison between VPI transformers
and cast coil transformers
process VPI Cast Resin
Cast mold assembly - O
Pre-heating of coils O O
Resin heating - O
Resin weighing - O
Resin mixing - O ~35 kv - - O O
Resin casting O O
Curing O O
Cast mold disassembly - O

.Legend Figure I windings of VPI transformers

“-“: not applicable, “O”: apply a process

The simple processes in VPI transformers make it easier

to inspect all critical quality points of processes visually
and reduce the chance to have quality defects in
processing because of less variables that interact to
impact quality of coils.
.
The VPI equipment consists of two separate tanks
connected to each other through pipelines with valves (a)top view of random (b) front view of random
that controls degree of vacuum, pressure and level of winding winding
resin during impregnating process. A resin storage tank
has a function to control temperature inside tank so that
the shelf life of resin can be prolonged. Impregnation is
done inside an impregnating tank under vacuum and
pressure.
Typical VPI processing steps are pre-heat, dry vacuum,
wet vacuum, pressure cycle, removal, drain and bake.
The dry and the wet vacuum processes ensure that
residual moisture and volatile materials in coils disappear
(c)top view of disk (d)front view of disk
from insulation materials. Then the coils are fully
winding winding
encapsulated with high temperature varnish that
penetrates internally within the windings. The high
OEMs wind HV coils over LV coils normally to have
pressure process (about 600 kPa) enables no air bubble in
more integrated mechanical strength as well as save
resin encapsulation and full resin penetration into
labor cost in winding. One distinctive winding method in
windings. During curing, some evaporation of
HV coils is to use so called comb spacers for disk and
solventless resin results due to cross linking process
random windings. The insulation material to make comb
between monomers and resin. The vapor is not toxic and
spacers are glass sheet reinforced with resin which have
is exhausted out by the oven chimney. The resin used
various insulation class available up to 220℃.
in Class H VPI transformers is high temperature
insulation material that is normally effective even to OEMs sometimes use axial and radial spacers which
materials are ceramic or aramid papers/press boards
220℃ insulation system. There is no skin irritation or
other than comb spacers.
allergic reaction with resin to human body.
Application
There are several winding methods to wind high
The major application is for power and distribution
voltage(HV) and low voltage(LV) coils. A disc winding
transformers which kVA and voltage are available up to
is a standard method to wind HV coils for 10 KV or
30MVA and 35 kV. There is growing demand from
above. The winding method depends on kVA, rated
onboard ship and marine power due to compactness and
voltage, testing voltage, winding equipment. Table II
high reliability in transformers. Other common
outlines winding methods that most OEMs adopt for applications are furnace, mining/underground, nuclear
commercial production.
power plant, rectifier and inverter. For zig-zag
transformers, phase shift transformers and other
Table II Winding method for VPI transformer
transformers requiring many leads extracted from inside
Voltage Layer Section Disc Random windings, VPI transformers are most suitable because it
winding winding winding winding requires no special cast mold to make multiple bushings
for external connection and it has no concern on short
~ O - - - circuit among leads inside windings cast with epoxy
1000v resin or has no possible crack on epoxy coil surface
~ 5 kv O O O - around bushings that hold leads. It is also suitable for
both indoor and outdoor service when installed in an
~15 kv - O O - appropriate NEMA 3R enclosure.

~25 kv - - O O Attribution

1)Safety
The VPI transformer has no flammable liquid or any
other liquid insulation materials, so that there is no
pollution from leaks. High temperature insulation
materials and aramid paper that have high LOI(Limiting
Oxygen Index) meaning less flammable are adopted as a
primary insulation material in windings. It has least solid
insulation materials among dry type transformers in core
and coil assembly, which result in less smoke and flame.
A fire behavior test(F1) with a VPI transformer shows
safety aspect in case of fire in terms of low temperature
of smoke, low smoke level and minimum burn time after
removal of flame during a fire behavior test based on
IEC 60076-11.
Followings are a summary of test result.
.the sample spec: 3phase, 1600 kVA, 10kV/430-233 V
.Low levels of smoke (54.3% OTF vs. 20% limit)
.Low temperature of off gasses (maximum 290℃
vs.420K limit)
.immediate fire extinction after removal of flame
.Lost weight 3.6 kg out of 618 kg after the test
Note) OTF(Optical Transmission factor) represents
volume of smoke during a fire behavior test. The higher
OTF means more light transmission and less smoke.
2)Reliability
The thermal classification of transformers represents the
highest temperature the electrical winding can accept
while operating at the highest load condition (hot spot)
and should have insulating materials which at least
match this rating.
Highest temperature = average winding rise(K) + max.
ambient + hot spot allowance
This means that the insulation system must be rated to
match the hottest temperature of the winding, not just the
average winding temperature.
Table III Temperature class of insulation system based on
IEC60076-11
Temp. Avg.wind. Max. Hot spot Hottest
class rise amb.al allowance temp.
F 100 40 15 155
H 125 40 15 180
220 150 40 30 220
But some studies in the United States indicate that the
hottest spot differential may be higher than projected in
the standard, depending on coil design and shape.
Potentially it is as much as 10 to 20 k higher than hot
spot allowance stipulated by a standard. Harmonic
loading also results in increased temperature of the
windings/hottest spot. These facts together require down-
rating of the temperature class or up-rating of the
insulation materials. Otherwise, transformers may have a
premature failure due to insulation degradation in
windings caused by excessive temperature rise above
hottest temperatures shown in Table III. Transformer
OEMs use aramid papers which thermal index is 220℃
and other insulation materials also have higher thermal
index than required in 180℃ insulation system.
Therefore actual insulation system can tolerate higher
hottest temperature, which result in higher reliability of
transformers. In addition, this transformer can provide
additional capacity without shortening life span when
peak load exceeds a rated capacity of transformer.
Transformer engineers should take into consideration
that insulation materials must be capable of withstanding
the hottest temperature within the winding.
With respect to the life expectancy of transformers,
VDTs have been installed at nuclear power plants for
class1E application (application related to the direct
control of the nuclear reactors) that requires 40 years of
life span and capabilities such as surviving steam line
breaks over the transformers, radiation exposure and
seismic events.
3)Environmental impact
The materials, processes, energy in transformer
production have some impacts on the environment. This
fact forces users to consider integrating environmental
impact in selection, operation and disposal of trans -
formers when they evaluate and purchase them among
several types of transformers . If we look at the VPI
transformer in light of environmental footprint, firstly it
consumes less silicon steel and copper or aluminum
conductor due to it’s compact size and light weight,
which contributes for energy saving and green
environment. Production of steel, copper and aluminum
entails expensive fossil fuel consumption resulting in air
and water pollution. Secondly, all materials and
processes to build up VPI transformers have minimal
impact to environment and the human body. Thirdly it
doesn’t require replacement of insulation oil to maintain
transformers, which may cause environmental impact.
Lastly, when it comes to dispose transformers, salvage of
active materials in VPI transformers is a lot easier than
other transformers because there is no insulation fluid
and no thick and bulky resin layer around coils. It has
low volumes of insulation materials that eliminate the
burden of disposal of large amount of resin and
insulation fluid. Major insulation material of aramid
papers in VPI transformers can be disposed by burning
or burying. It does not emit toxicity to contaminate soil
and air (inert to the environment). Therefore aramid
papers can be recycled for fuel as an energy source,
which was certified by European cement plant operators.
4)Climatic and environmental behavior
VPI transformers have operated without any troubles
under harsh environment, which was also proved by
numerous tests. Recently VPI transformer tests
conducted by CESI with IEC 60076-11 produced the
following results.
1.Climatic test(C2)
The transformer was placed in a test chamber in which
the ambient temperature was gradually decreased to –
25℃ in 8 hours and this temperature was maintained for
12 hours. After the 12 hours have elapsed, a DC current
equal to 2 times the rated current was circulated in the
high voltage coils until they reached the thermal steady
state (165℃ which is ambient temperature plus 125℃
/winding temperature rise of class H transformer). After
this test, coils should not have crack and pass dielectric
routine tests and partial discharge test. The summary of
test result is as follows.
-passed a separate source AC withstand voltage test at
0.8 time of standard value for 60 seconds
-passed an induced voltage test at 0.8 times of standard
value at 150HZ for 40 seconds
-passed a partial discharge test at 1.3 times rated voltage
(<1.5 PC vs. 50PC limit)
-passed verification of the energizing at 1.1 times rated
voltage at 50HZ for 5 min (during the voltage application,
no flashover occurred, visual inspection did not show
any serious tracking)
If any air bubbles develop within windings, there will be
high stress on the air and partial discharge will develop.
It may cause insulation breakdown resulting in
transformer failure. The test result of partial discharge
proved that there was no air bubble inside a resin layer in
the VPI transformer.
In fact, VPI transformers have no concern with crack on
high voltage or low voltage coils since resin layer on
windings is very thin (less than 0.5mm thick). This
feature enable VPI transformers to fit the demand from
customers who install transformers at places with highly
fluctuating temperature. Even on assumption that it crack,
it does not cause a failure of winding due to reliable
insulation on conductors. This fact illustrates that VPI
transformers are superior to the transformers that rely on
thick epoxy resin layer for dielectric strength which may
crack by temperature variation.
2)Environmental test(E2)
The transformer was placed in a test chamber in which
temperature and humidity are kept under control. The
transformer was kept in air having a relative humidity
above 93% for not less than 6 hours without being
energized, which ensure condensation on transformer.
After condensation, the transformer was in the climatic
chamber for 144 hours. The temperature of the climatic
chamber shall be held at (50±3)℃ and relative
humidity held at (90±5)%. The summary of test result
with the VPI transformer is as follows.
-passed a separate source voltage withstand test at 0.8
time of standard value for 60 seconds
-passed an induced voltage test at 0.8 times of standard
value at 150HZ for 40 seconds
(during the voltage application, no flashover occurred,
visual inspection did not show any serious tracking)
This test had proved that windings were well protected
against harsh environments such as moisture and dust by
VPI processing. 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 including a VPI or cast resin
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.
Under dust and dirt conditions(high pollution) rather than
high humidity condition, VPI transformers have also
demonstrated it’s high performance, because the coil
structure is well constructed to separate each disk, which
will not allow cumulative dust collection between disks.
Properly designed coils have also enough cooling space
in LV, gap between LV /HV and HV, to ensure effective
cooling even at harsh environments such as cement
plants and mines. One ASEAN power utility has
operated several VDTs for more than 18 years without
any maintenance at all, though a thick layer of dust
covered the windings.
5)Short circuit withstand
Design principles utilized for VPI transformers minimize
axial and radial mechanical forces in case of short circuit
accident. In addition, VPI process with resin enhances
mechanical strength of coils with the disk structure in
HV coils that hold windings robustly. One recent short
circuit test with a VPI transformer conducted at KERI
(Korea Electrotechnology Research Institute) showed
extraordinary test results. The transformer could
withstand 4 seconds duration of short circuit current.
This was first trial to apply a short circuit current beyond
2 seconds which had applied to transformers mostly
based on IEC standard. The variation of % impedance
after short circuit test was about + 0.2% vs. 7.5%
tolerance. This result proved that there was no
deformation at all in HV/LV coils.
6)Overload capacity
Based on IEC 60076-11, the average winding rise is
125℃ and highest permissible hot spot temperature is
220℃ for class H. In this case, there is temperature
margin which is 30℃ differential between the highest
hot spot temperature(220℃) of class H transformer and
the highest hot spot temperature(250℃) of class 220
insulation class that typical class H VPI transformers
adopt.
Table IV Highest permissible hotspot temperature of IEC
60905
Insulation Rated Highest Average Ambient
class hot spot permissible winding temp. for
temp.℃ hot spot temp.℃ insulation
temp.℃ life
155(F) 145 190 100 20
180(H) 175 220 125 20
220 210 250 150 20
Note) Ambient temperature for insulation life calculation
is 20℃.
This contributes to higher overloading capability or
additional capacity over the rated capacity. For certain
cases, one can put dual ratings on the name plate for
flexible operation either with lower load loss or higher
capacity. When we refer to ANSI standard that provides a
guidance of steady state loading on the basis of test
temperature rise, users can calculate the additional
capacity of dry type transformers without compromising
life span. For instance, if one 1000KVA VPI transformer
has 100℃ test temperature rise, the additional rating can
be calculated with Table V.
Ex) - (115℃ - 100℃) x 0.43% + (150℃ -115℃)
x 0.35% = 18.7%
-1000 KVA x 1.187 = 1187 KVA
(increased rated capacity)
Users can still overload the VPI transformer over this
increased rated capacity.
Table V ANSI C57.96-IEEE guide for loading dry type
distribution and power transformer
Rated average winding For each degree ℃ temperature
rise below the temp. rise,
increase rated load by
80℃ 0.57%
115℃ 0.43%
150℃ 0.35%
7)Total owning cost
By definition, total owning cost (TOC) means all costs
involved from purchasing, installing, operating,
maintaining to disposing of transformers. Many utilities in
North America adopted this concept to purchase
transformers that help them save cost not only by
transformer price but including all costs up to disposal.
The price difference of dry type transformers are simply
represented by insulation class. As a rule of thumb, the
higher insulation class means the lower price because
higher insulation system contributes to compact size of
transformers. Generally speaking, class H VDT
transformers have price competitiveness vs. class F cast
coil transformers. With regard to operating cost,
transformer users evaluate the cost of energy losses for
transformers with loss evaluation criteria. To determine
this, they use complicated formulas based on loading
conditions and analysis of the load cycles for the
particular transformers being loaded, ultimately
developing the load factor for transformers. Normally two
types of losses are calculated for evaluation – no load
losses and load losses. The loss evaluation ratio is the ratio
of the cost of no load losses ($/KW) to the cost of the load
losses ($/KW) evaluated over the predicted lifetime of the
transformer. Normal evaluation ratio throughout the world
range between 3:1 up to 8:1, with the most common range
being between 4:1 to 6:1 in developed countries. Figure II
shows one example of loss evaluation comparison.
Figure II Loss evaluation comparison among dry type
transformers
This figure indicates that class H transformers saves
energy cost more than either class B or F transformers up
to 0.94 load factor which the loss ratio is 5:1.
From environmental standpoint, disposal of transformers
may have increasing cost in the near future due to more
regulation legislated by governments and international
standard bodies.
As described, the VDT transformers cost less at disposal
due to less materials and easiness for disposal.
In summary, the TOC of the class H VDT transformer
can attract users to evaluate the cost advantages with
other benefits that they can take from it.
Conclusion
More recently, the demands from various societies
connected to environment, high technology industries,
safety, energy have driven the transformer industry to
research and develop transformers that suit specific
requirements for different applications. This trend
benefits transformer users who seek diverse transformers
other than the transformers being used so far..
From this perspective, the VPI transformer can provide
users another option with a differentiated value
compared with few selected transformers existed for
several decades. It may outperform other transformers in
safety, reliability and environmental friendliness. This
paper guides transformer users to understand a
characteristic of the VPI transformers and help them
identify a transformer that best fits their application.
Reference
1.”Power transformers-part 11 Dry Type Transformer”;
IEC 60076-11-2004
2.”IEEE guide for loading dry type distribution and power
transformer”, ANSI C59.96, 1999
3.CESI, Test report for E2,C2 and F1 test, 2005
4.Tommy Nunn “A comparison of liquid filled and dry
type transformer technologies”, IEEE technical papers,
105-112, 2000
5.P.K.sen “Application guidelines for dry type
distribution power transformers”, IEEE technical papers,
105-110, 2003
6.”Standard test procedure for thermal evaluation of
insulation systems for ventilated dry type power and
distribution transformer”, IEEE C57.12.56, 1986
7.Linden W. Pierce “An investigation of the temperature
distribution in cast resin transformer windings”, IEEE
Tansactions on power delivery, Vol 7, No. 2, Apr. 1992