Conductor Insulation Tests in
Oil Aramid vs. Kraft
Thomas Prevost and Michael Franchek, E W - Weidmann Industries, Inc.
Background
he transformer is now over 100 years old. In its
T 100-year-pluslife, the transformer has undergone
many changes and improvements: Voltage levels
have increased from a few hundred volts to 765,000 V
and beyond, and the size has also grown from a few ki-
lovoltamperes to over 1,000 MVA in the largest trans-
formers. [ 11
Changes have also been made that have improved ef-
ficiency and reliability. Thinner laminations and laser-
etched core steels have reduced no-load losses dramati-
cally. Amorphous metals promise to reduce iron losses
even further. New winding and conductor configura-
tions have improved load-loss efficiency. Losses today
are only a fraction of what they were 20 years ago. [2]
Despite all these improvements, very little change
has occurred in the materials used to insulate oil-filled
transformers. Transformer insulation contains two basic
components: cellulose-based paper and mineral oil. Al-
though improved analytical techniques and manufactur-
ing practices allow more optimum use of these materi-
als in today's transformer insulation systems, the basic
components are virtually unchanged. [ 31
Aramid transformerboard is a recent development
that has led to a change in the solid material used in
some oil-filled transformer insulation structures. Its pre-
decessor, aramid paper, has been employed for 20
years or more as a dielectric insulation material in air.
It is still used extensively in open-ventilated transform-
ers and motors because of its high dielectric strength in
air and its high-temperature stability.
Aramid paper was used in oil-filled transformers as a
means to solve special problems on specific transform-
ers. Applications included insulating conductors whose
hot-spot temperatures exceeded the capability of cellu-
lose paper and insulating mobile transformers whose
average winding temperature rise was much higher
than in typical transformers and, in some cases, ex-
ceeded the capability of cellulose insulation.
Widespread use of aramid insulation in oil-filled
transformers was limited, however, because aramid in-
sulation was available only in paper form. This format
made it very difficult to obtain insulation components
normally made from pressboard or pressboard lami-
nates. The introduction of aramid transformerboard
solved this problem, and aramid insulation is starting to
0883-7554/89/0007-001OSO1.00 0 1989 IEEE
10 IEEE Electrical Insulation Magazine
Thinner laminations and laser etched core
steels have reduced no-load losses
dramatically.
find its way into more and more oil-filled transformers
around the world.
The higher temperature stability of aramid insulation,
up to 220°C, allows a higher temperature rise of the
winding without damage to the insulation structure.
The higher temperature rise capability permits either
an increase in megavoltampere rating with the same
amount of active material, or a dramatic decrease in
weight for a given megavoltampere rating. To date the
most common application of aramid-insulated oil-filled
transformers has been mobile, portable, railroad, and in-
dustrial transformers. The same winding temperature
rise increase can be applied to substation transformers
to improve overload capabilities and/or reduce size.
This increased use of aramid insulation in oil-filled
transformers led to the need for the conductor insula-
tion tests described in this article. It is commonly
known that aramid pressboard and paper are superior
to kraft insulation in thermal aging characteristics, me-
chanical strength, and dielectric strength in air. How-
ever, there was very little information on the dielectric
strength of an aramid/oil insulation system. The pur-
pose of this test series was to gather data on the dielec-
tric strength of aramid paper in oil used as turn-to-turn
insulation. A vast amount of data and design experience
exists for kraft paper conductor insulation. Therefore,
high-density, thermally upgraded kraft paper insulation
was tested as a control. The information gathered in
this test series should be helpful in the design of ara-
mid-insulated oil-filled transformers. [41
Setup
Some information on the dielectric strength of aramid
conductor insulation was given in an IEEE paper written
in 1971, by L. E. Feather and P. Voytik. The tests were
done with square sheets of stacked aramid or kraft paper
between disk electrodes. In contrast, the test setup used
JUIV/AUQUSt 1989-Vol. 5,NO. 4
in this test series more closely approximated the configu-
ration and type of electrical stress that occur in an actual
transformer. Two separate test series were conducted.
The first was a turn-to-turntest with the insulated conduc-
tors in direct contact. Next was a coil-to-coil (disk-
to-disk) test with the conductors separated by insulating
spacers. The coil-to-coil test series simulated the disk-
to-disk space in a transformer winding. The spacers
simulated radial spacers separating the individual disks
from each other.
Turn-to-Turn Test Series
The sample configuration was very important. Samples
were constructed to conform to a shape determined by
the Rogowski equation. The shape reduces the dielectric
stress at the ends of the sample and places the stress in the
12-in. contact area so that the failures occur in this area.
This contact area simulates the turn-to-turn contact area
in a transformer winding. The primary difference is that a
transformer has hundreds of feet of conductor in contact,
whereas our laboratory simulation test has only 1 ft.
The wire samples were made from rectangular copper
wire 0.102 in. wide, 0.410 in. high, and 23 in. long, with a
0.032-in. edge radius. The wire was machine-wrapped
with conductor paper insulation to the required thick-
ness. The individual conductor paper insulation thickness
was 0.002 in. The needed turn-to-turn thickness was
obtained by building up layers of the 0.002-in. wrap.
Individual layers were butted together, with the next
layer of insulation lapped halfway over the first. For
example, a 0.016-in. turn-to-turn insulation thickness
would have four layers of 0.002-in.paper, for a total build
of 0.008 in. per side, to give a 0.016-in. total turn-to-turn
insulation thickness. One end of each sample had the
conductor insulation removed to make the electrical
connection to the test voltage or to ground (see Fig. 1).
The samples were cut to size and then formed on a press
fitted with tools machined in a shape conforming to the
Rogowski equation. A range of total insulation thickness
was chosen in the turn-to-turn test to develop design
information across the spectrum of thicknesses used in
Fig. 1. Turn-to-turn sample.
E
I EE Electrical Insulation Magazine
oil-filled transformers. The four turn-to-turn thicknesses
used in this test series were 0.016,0.032,0.064,and 0.108
in. The base materials for the tests were Nomex T-410
aramid paper and Manning kraft.
The test fvrture was made of insulating material and
designed to accommodate the electrical connections to
the samples while holding the test samples in place. The
samples were held in position by three insulating push
rods that extended over the length of the flat contact area.
The push rods were smaller than the conductor’s 0.410-
in. height and were located on the back side of the sample.
This minimized their affect on the electrical field distribu-
tion around the sample. One wire electrode was then
attached to the high-voltage lead and the other was
connected to the ground. The sample was totally sus-
pended in oil except for the electrical connections and
the push-rod supports.
Sample Preparation
All the tests were performed in Exxon UnivoltB 60
transformer oil. It was important that the oil be of
sufficient quality to simulate oil used in high-voltage
transformers. The oil quality was tested routinely
throughout the test series and was required to meet the
following minimum standards: [ 51
Dielectric strength: 30 kV minimum at 1-mm gap
(ASTM D1816-79)
Moisture content: less than 10 ppm (ASTM D1533-
79 1
Gas content: less than 0.5 percent
Power factor: less than 0.005 percent (ASTM D924-
79 )
Interfacial tension: greater than 38 dyneskm (ASTM
D971-50)
Wire and spacer (coil-to-coil) test samples were pro-
cessed and oil-impregnated before being tested. The
processing procedure used for the samples was designed
to produce a moisture content in the insulation equiva-
lent to an operating oil-filledtransformer. The processing
cycle consisted of the following: [ 31
1. Samples were air dried for 48 hr at 105°C.
2. Samples were vacuum dried at 105°C until a steady-
state vacuum of less than 100 p was maintained for
24 hr.
3. Samples were vacuum oil-impregnated.A vacuum of
500 p. or less was maintained during the oil-impreg-
nation process.
4. Samples remained under impregnation oil for at least
24 hr before electrical testing.
5. Samples were transferred to the test tank without
atmospheric contact.
Test Method
The number of samples to be tested to achieve statisti-
cally acceptable results was determined by a preliminary
July/August 1969-Vol. 5, No. 4 11
 FULL WAVE IMPULSE 1 . 60 Hz-I-Min Withstand Test (ASTM 0149)
-Starting voltage was 70 percent of anticipated
failure voltage and held for 1 min.
-Voltage was stepped up 10 percent of the initial
voltage with a maximum step of 5 kV and held for
1 min.
-Steps were continued until the sample failed.
-Sample failure voltage value and time into the step
were recorded.

2 . Full-Wave Impulse--(1.2 X 50)-psec Wave (ASTM

03426)
-Impulse wave reached peak value in approxi-
mately 1.2 psec and decayed to 50 percent of
peak value in 50 psec after the start of the wave
(see Fig. 2 ) .
0 1 2 3 4 5 6 7 B 9 I0 -Negative-impulse voltage was used.
TIME ("SEC) -Start-up voltage was 70 percent of the anticipated
Fig. 2. Full-waveimpulse. failure voltage.
-Three shots were applied at each level with a
1-minhold between shots.
test series. As a result of this series, the following sample
-Voltage was stepped up from 5 to 10 percent of
sizes were established.
initial voltage with a maximum step of 16 kV.
Turn-to-turn: -Steps were continued until the sample failed.
Daft control-9 samples per thickness per test type, 144 -Sample failure voltage and the level at which the
samples total sample failed were recorded.
Aramid-18 samples per thickness per test type, 288
samples total 3. 3-psec Chopped-WaveImpulse
-Impulse wave resembled a 1.2 X 50 full wave
Coil- to -coil:
except that it was chopped by an external spark
ki-aft control-10 samples per distance per test type, 250
gap 3 psec after it had reached 75 percent of the
samples total
Aramid-25 samples per distance per test type, 625 peak value on the rise (see Fig. 3).
samples total -Procedure was the same as the full-waveimpulse.

The samples were tested to simulate the tests and
dielectric stress that the insulated conductors would
experience in a transformer on a manufacturer's test floor.
These tests conformed to ASTM methods. The following
tests were performed: [ 51
4. I -psec Chopped-WaveImpulse
-Impulse wave resembled a 1.2 X 50 full wave
except that it was chopped 1 psec after it reached
75 percent of peak value on the rise (see Fig. 4).
-Procedure was the same as the full-wave impulse.

3 uSEC IMPULSE 1 uSEC IMPULSE

E l 2 3 4 5 6 7 E Q 10 E l 2 3 4 5 6 7 E Q 10
TIUE (uSEC) TIUE (SED
Fig. 3. 3-psec impulse. Fig. 4. 1-psecimpulse.

12 IEEE Electrical Insulation Magazine JUly/AUgUSt 1989-Vol. 5, NO. 4

 regression equation to get an average failure line. The
aramid and kraft results for the same thickness are shown
on each figure to make comparisons easier.

Coil-to-Coil Tests
Coil-to-coil distances varied over a wide range of
spacing. The coil-to-coil distances tested ranged from
0.204 to 0.641 in. The test series contained five coil-
to-coil distances: 0.204,0.266,0.391,0.516,and 0.641 in.
The oil gap was established by placing three blocks in line
with the push rods of the test furture (see Fig. 8). For the

Fig. 5. Turn-to-turntest: 60 Hz.

FAILURE VOLTAGE (KV)

f 000

I00
-

I
-i L--
10 - I

0 01 Fig. 8. Coil-to-coilsample.
TURN-TO-TURN DISTAN
__-_ __I-

* KRAFT +*
I

Fig. 6. Turn-to-turntest: full-waveimpulse.

Fig. 9. Coil-to-coiltest: 60 Hz.

Fig. 7. Turn-to-turntest: 1-psecchopped wave.

The turn-to-turn test sequence was done alternating

between kraft and aramid samples.

Turn-to-Turn Results
Figures 5-7 represent, on a log-log scale, the results of
the turn-to-turn 60-Hz and impulse tests. The lines were
obtained by averaging the data for each turn-to-turn
thickness and then applying those averages to a linear Fig. 10. Coil-to-coiltest: full-waveimpulse.

IEEE Electrical Insulation Magazine JUly/AUgUSt 1989-Vol. 5, NO. 4 13

aramid-wrapped conductor, the spacer blocks were made
from high-density NomexB transformerboard (T-994).
For the kraft-insulatedconductor, spacer blocks produced
from precompressed kraft transformerboard (T-IV) were
used.
Each block was 1 in. long and in. wide, with thick-
nesses that varied to give the appropriate coil-to-coil
distance. The spacers simulate the radial spacers used in
disk transformer windings. The spacers were predried and
oil-impregnated according to the procedure discussed
previously.
Test Methods
The tests that were performed were identical to the
tests on the turn-to-turnsamples.
Coil-to-CoilTest Results
Figures 9-12 represent the results of the coil-to-coil
60-Hz and impulse tests. The kraft and aramid results for a
gwen coil-to-coil space are presented on each figure to
make comparisons easier.
Conclusions
This extensive test series shows that turn to turn, the
aramid paper is stronger dielectrically than the kraft
paper. The aramid was 25 percent stronger using a
full-wave impulse and 20 percent stronger using a l-psec
chopped wave.
There is little or no difference in the dielectric coil-
to-coil strength between the aramid and kraft papers. This
is true for all the coil-to-coil tests done: 60 Hz, full-wave
impulse, 3-psec chopped wave, and 1-Fsec chopped
wave. The 60-Hz turn-to-turn tests also show no signifi-
cant differences between the dielectric strength of aramid
and kraft. In these tests, the insulating fluid was probably
the intiator of the dielectric breakdown.
Based on the preceding results, it is possible to improve
the turn-to-turn impulse strength of liquid-filled power
transformers by using aramid paper in place of kraft paper.
The aramid also has improved mechanical strength and
I L U R E VOLTAGE (KV)
1000
- - ---I
I00 I
01
CO1L-TO-CO1L DISTAN
Fig. 11. Coil-to-coil test: 3-psec chopped wave.
14 IEEE Electrical Insulation Magazine
FAILUIZL VOLTAGE (KV)
i 000
ai
,
i 00 -. -
01
COIL-TO-COIL DISTANCE (IN)
-
Fig. 12. Coil-to-coiltest: 1-psec chopped wave.
thermal agmg characteristics. The use of aramid paper
does not reduce the 60-Hz turn-to-turn or the coil-to-coil
strength of the transformer winding.
The better dielectric and mechanical strength coupled
with its high-temperature stability make aramid an attrac-
tive choice when improved overload capacity or reduced
size and weight are important transformer characteristics.
References
[ l ] S. D. Myers, J. J. Kelly, and R. H. Parrish, A Guide to
Transformer Maintenance, Akron, Ohio: S.D. Meyers Inc.,
1981
[2] R. L. Bean, N. Chacken, H. R. Moore, and E. C. Wentz,
Transformersfor the Electric Power Industry, New York:
McGraw-Hill, 1959.
[3] H. P. Moser, V. Dahinden, H. Friederich, H. Hunast, K.
Lennarz, and 0. Potocnik, Transformerboard, Basel, Swit-
zerland, Gesamtherstellung: Birkhauser AG, 1979
[4] L. E. Feather and P. Voytik, “Application of Polyamide Pa-
per in Liquid-Cooled Transformers,” Proceedings of the
IEEE 10th Electrical Insulation Conference, pp 24-27,
1971
[5] IEEE Standard Techniques for High Voltage Testing, IEEE
Standard 4-1978, 6th Ed., IEEE, 1978.
Thomas A. Prevost graduated from Virginia Polytech with a
B.S.E.E. degree. He worked for three years for Tampa Electric
Company in Tampa, Florida.
He is currently employed as a Technical Service Engineer at
EHV-Weidmann Industries, where his responsibilities include
electrostatic analysis of insulation systems and supervision of
high-voltage testing.
Michael A. Franchek graduated from The Ohio State Univer-
sity with a B.S.E.E. and an M.S.E.E. He worked for five years for
the Westinghouse Large Power Transformer Division in Muncie,
Indiana. As a Senior Design Engineer, he was responsible for the
design and development of transformer insulation systems.
He is currently employed by EHV-Weidmann Industries as
Manager of Technical Services. He is responsible for the design
of customers’ insulation systems.
July/August 1989-Vol. 5, No. 4