Insulation Design Using FEM Analysis

S V Kulkarni (svk@ee.iitb.ac.in)
Professor, Department of Electrical Engineering

Indian Institute of Technology Bombay, INDIA

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Need for Field Computation

Computation of fields is required in all low frequency and high frequency devices for:
Evaluation and improvement of performance parameters at the design stage Reliability enhancement Investigative analysis

Field computation provides a non-destructive technique for testing and evaluation In order to optimise material costs, in the present-day highly global market, an accurate analysis of the field distribution is essential

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

IIT Bombay

Methods for Computation of Fields

Analytical Methods:
Separation of Variables Method of Images Conformal Mapping Schwartz-Christoffel Transformation

Analog Methods:
Conducting Paper and Electrolytic Tank Analysis

Disadvantages:

These methods cannot be applied for:

Complex Geometries Non-uniformities, anisotropy and non-linearity in material properties
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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Numerical Methods
Tremendous advances in the computational domain and improvements in algorithmic techniques have contributed to the success of numerical techniques

Analytical

Numerical

Closed form solutions are possible If solutions are available, they are exact Dependence of the field on various factors can be easily determined Applicable to 1-D and some 2-D problems

Any complex geometry can be handled Can be applied to even 3-D problems Non-uniformities, material discontinuities and material anisotropies can be taken into account Applicable for a wide range of problems The solutions are reasonably accurate for engineering purposes
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Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Numerical Techniques
Difference methods: Finite difference method (FDM) Finite-difference time-domain method (FDTD) Variational / Weighted residual approach: Finite element method (FEM) Integral methods: Method of moments (MoM) Boundary element method (BEM) Charge simulation method (CSM) Other methods: Reluctance network or magnetic equivalent circuit method (MEC)

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

IIT Bombay

Numerical Methods
Boundary element method (BEM), charge simulation method (CSM) and method of moments (MoM):
The operator, in these cases, is an integral one These methods are mathematically more intensive and lead to a fully populated system matrix However, in many cases, there is a reduction in the order of magnitude of the problem
For example, in BEM, solution in a 3-D domain reduces to solving on 2-D boundaries. Similarly, a 2-D problem reduces to solution on a 1D domain.

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Illustration of BEM and CSM

BEM: Reduction of Order from 2-D to 1-D

CSM: 11 Charges inside the conductor; 6 Potential points on the conductor and 5 on the ground plane
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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Finite Element Method

The method of finite element analysis has emerged as the forerunner among all the numerical techniques Advantages:
The solution formulation is independent of the problems geometrical complexity Anisotropic, non-uniform and non-linear media can be incorporated into the solution scheme Availability of several commercial softwares makes applicability to real-life problems easier Finite element method can also be used in solving problems involving coupling of electromagnetic fields with circuits and/or other physical fields

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

IIT Bombay

Classification of FEM Problems

On the basis of application
Static problems Example: Insulation design, inductance computation in electrical machines Time-harmonic problems Example: Computation of eddy current losses in conducting regions of electrical machines Transient problems Example: Analysis of dynamic behavior of machines under transient conditions

On the basis of material property

Linear problems Non-linear problems Insulation design in most of the cases can be classified as quasi-static linear problem
Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Steps in FEM
1. Creation of geometry 2. Solution approximation (choice of type of finite element) 3. Meshing, definition of materials 4. Calculation of element coefficient matrices 5. Formation of global coefficient matrix 6. Imposition of boundary conditions 7. Solution of linear system of equations 8. Post-processing (getting desired performance parameters from the obtained field solution) Steps 4 & 5 are done internally by commercial FEM softwares
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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Steps in FEM
For a typical 2-D insulation design problem, the governing partial differential equation is:

2u 2u + 2 = x 2 y
FEM discretization leads to the matrix equation:

[K ]{U} = {b}
where, K is the global coefficient matrix and contains the geometry and material information, b is the force vector, which incorporates the boundary information / charge distribution, and U is the vector of unknown potentials The solution obtained corresponds to minimum energy of the system
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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IIT Bombay

Steps in FEM
The linear system of equations obtained is solved by direct or iterative methods

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Steps in FEM: An Illustration

Post-Processing: Finally, the results obtained from the solution of the problem can be used for computing various useful quantities of interest in the electrical apparatus, such as,
o o o o o

Voltage stress (electric field intensity) Eddy current losses Temperature rise Forces or torques Deformations

In insulation design application, we can calculate maximum stress, creep stress, stressed oil volume, cumulative stress values, etc.

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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IIT Bombay

Insulation Design in Transformers

As voltage rating increases, insulation design becomes the most important aspect of transformer design Comprehensive design verification is essential for reliability and optimization Pressure on designers to reduce material content of which insulation is a major component Margins between withstand levels and working stress levels are reducing It is important to accurately estimate stress levels for various critical electrode configurations inside the transformer
Prof. S.V. Kulkarni, EE Dept, IIT Bombay

IIT Bombay

Factors Affecting Insulation Strength

Moisture and impurities Temperature Time and frequency parameters of high voltage surge Thickness of insulation Quality of insulation components Quality of insulation processing / drying

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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High Voltage Phenomena

Jump / bulk-oil breakdown Creepage breakdown Partial discharge Corona

Withstand Theories
Stressed area / stressed volume theory Cumulative stress computation

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Major insulation: - Insulation between windings - Insulation between winding and core (limb/yoke) - Insulation between outer winding and tank - Insulation between high voltage leads and earthed parts Minor insulation : - Insulation between turns / discs Four types of tests : - Lightning impulse test - Switching impulse test - Short duration power frequency test - Long duration power frequency test with PD measurement
Prof. S.V. Kulkarni, EE Dept, IIT Bombay

IIT Bombay

Conversion of test levels to one equivalent test level: generally taken as short duration one-minute power frequency test
Test type Lightning impulse level Switching impulse level Long duration power frequency level
References: 1. 2. Dahinden, V., Schultz, K., and Kuchler, A. Function of solid insulation in transformers, TRANSFORM 98, April 1998, Germany, pp. 41-54. V. K. Lakhiani and S. V. Kulkarni, Insulation design of EHV transformers a review, International Insulation Conference, INSUCON 2002, Berlin, Germany, 18-20 June, 2002, pp. 283-287.

Multiplication factor

~ 0.44 ~ 0.55
~ 1.25

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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FEM Analysis of Hi-Lo Gap

LV HV

Accurate representation of conductor with its paper covering is essential Mostly 2-D FEM analysis is done Winding diameter effect should be accounted separately if x-y system is used

Sub-division of oil ducts increases kV/mm withstand stress Propagation of discharge streamer in oil is countered Electric stress is inversely proportional to permittivity - Barriers should be as thin as mechanically possible, otherwise there will be more stress in oil First duct should be as small as possible with due considerations to adequate cooling requirements

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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It is important to know contribution and significance of various factors affecting stress levels

It is essential to do a detailed FEM analysis while doing optimization

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Optimization through Design of Experiments + FEM approach

(Reference: D. A. Koppikar, S. V. Kulkarni, A. K. Dubey, "Optimization of EHV Transformer Insulation by Statistical Analysis", ISH'97, International Symposium on High Voltage Engineering, Montreal, 25 - 29 August 1997, Vol. 6, pp. 289-292)

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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End insulation Design

Oil ducts should be designed so that margin in each of the resulting oil ducts is approximately same Use of contoured angle rings along equipotential lines is required to minimize creep stress (refer page 357, Fig. 8.18 of the book: S.V. Kulkarni and S.A. Khaparde - Transformer engineering: design and practice Marcel Dekker, New York, May 2004)

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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IIT Bombay

Select a contour as shown in the earlier figure Find cumulative stress values in each oil duct and compare them with the reference withstand equation:

Eoil = 75d10.38
References: 1. 2.

kV/cm

Nelson, J. K. An assessment of physical basis for the application of design criteria for dielectric structures, IEEE Transactions on Electrical Insulation, Vol. 24, No. 5, October 1989, pp. 835-847) Kulkarni, S. V. and Khaparde, S. A. - Transformer engineering: design and practice - Marcel Dekker, Taylor and Francis Group, New York, May 2004

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Higher end insulation

Optimized end insulation - Angle ring in first duct - Angle ring with higher corner radius Reduced end insulation with same margin

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Cumulative creep stress calculation

(Reference: Nelson, J. K. Some steps toward automation of the design of composite dielectric structures, IEEE Transactions on Dielectrics and Electrical Insulation, Vol. 1, No. 4, August 1994, pp. 663-671)

(i) Note down the voltage values along the pressboard at the different points (e.g., at every 1 or 2 mm steps). (ii) Note down the highest stress point, i.e., the point along the pressboard at which the stress is highest. (iii) Determine on which side of the highest stress point the field is higher and extend the path by one spatial step in that direction. (iv) Find out the cumulative stress when the path is extended in either direction and choose a path extension in the direction yielding the higher cumulative stress. (v) Repeat the above step number (iv) until the complete creepage path along the angle ring is encompassed. (vi) Withstand for each of these creepage distances is calculated by,
kV/mm Reference: Derler, F., Kirch, H. J., Krause, C., and Schneider, E. Development of a design method for insulating structures exposed to electric stress in long oil gaps and along oil / transformerboard surfaces, International Symposium on High Voltage Engineering, ISH'91, Dresden, Germany, August 1991
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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Ecr = 15 d 2

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High voltage lead clearances

- Oil and paper stresses can be calculated by analytical formulae or FEM analysis - Stressed oil volume (between max. stress and 90% of max. stress) is calculated by approximate formula

SOV

r
18

(Kawaguchi, Y., Murata, H., and Ikeda, M. Breakdown of transformer oil, IEEE Transactions on Power Apparatus and Systems, Vol. PAS-91, January-February 1972, pp. 09-19)

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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-The 50 % power frequency breakdown probability stress is determined by

E 50 = 11 . 5 (SOV where SOV is in cm3

9 .5

+ 2 .5

kV/mm

Reference: Ikeda, M., Teranishi, T., Honda, M., and Yanari, T. Breakdown characteristics of moving transformer oil, IEEE Transaction on Power Apparatus and Systems, Vol. PAS-100, No. 2, February 1981, pp. 921-928.

- The safe withstand value is considerably lower than E50 value

- Different manufacturers will generally have different safety margins - Barriers are generally put between lead and earth, close to lead. Extra advantage due to barrier should not be considered if they are not along equipotential lines; in such cases, in fact, barriers could be counterproductive - When there are rows of tap leads, due to wall effect, stress is lower as compared to isolated lead
Prof. S.V. Kulkarni, EE Dept, IIT Bombay
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Conclusions
Insulation design for EHV/UHV transformers is a very challenging task FEM technique is now widely accepted as a standard tool for insulation design Techniques such as Design of Experiments can be used in conjunction of FEM analysis for optimization Cumulative stress / SOV concepts are used to find withstand Breakdown phenomenon is a statistical process and a proper value of factor of safety needs to be determined and used Integral numerical methods are also being used for finding field distribution 3-D analysis is essential for some electrode configurations

Prof. S.V. Kulkarni, EE Dept, IIT Bombay

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Thank You !