International Conference on Electrical, Electronics, and Optimization Techniques (ICEEOT) - 2016
Design and Optimization of Inter-coil Insulation
system of a Cast Resin Transformer using FEM
1 2
Roopali Patil
PG student, M.E.(Power system)
Department of Electrical Emgineering
K.K.W.I.E.E&R, Nashik
Abstract—In this paper, a 400kVA, 11/0.433kV Cast resin
transformer (CRT) insulation system is considered for optimization. Due
to its numerous advantages, the design and manufacturing technology for
CRT is demanding, which can only be fulfilled if the design and
manufacturing is free from any defects. The reliability and life of the
CRT is defined by the life of its insulation system which is again a
function of thermal and electrical stresses. To meet the allowable criteria
for temperature rise is relatively an easy task for design engineers. Thus,
within a window of 30 years, the reliability and life of CRT remains the
function of electrical stresses only.
Any activity of partial discharge (PD) in solid insulation leads to
degradation of the solid insulation and premature failure. In the event of
PD, time to failure depends on PD energy, PD resistivity of the materials
and dielectric gap. Optimization of electric field and ensuring a void-free
insulation system is must to avoid the premature failure of CRT. The
electric field in CRT; more specifically, in high voltage winding depends
on the electrical stresses in inter-layer insulation and end insulation.
Insulation between two layers of high voltage winding is termed as layer
insulation, whereas insulation between coils of high voltage wingdings
and insulation to earth is termed as end insulation. At microscopic level,
turns per layer (differential turns), insulation thickness between layers,
and conductor radius decides the electrical stresses. Whereas for end
insulation, the spacing between coils and coil-to-earth potential is
deciding factor for electrical stresses.
This paper addresses the design and analysis of inter-coil
insulation system with finite element method (FEM) using 2D-ElecNet
software by Infolytica Corporation. This software can be used for all
types of electrostatic and electromagnetic analysis.
Keywords- Inter-coil Insulation, FEM, Electric field stresses.
I. INTRODUCTION
The objective of design optimization of the insulation
system is to minimize the transformer manufacturing cost at
maximum efficiency subject to constraints imposed by
international standards and transformer user specification.
Wherever distribution transformers have to assure the utmost
safety in areas frequented by people, Cast Resin
Transformers(CRT) are the ideal solution where the
limitations of liquid-filled transformers are avoided, but the
proven characteristics such as operating safety and service life
are retained. CRT not only have an advantage over oil
transformers but also Cast resin transformers incorporating
established alternative designs. Both the high voltage (HV)
and low voltage (LV) windings are made from copper
conductors. One of the characteristics of Cast resin
transformers is that the conductors of the HV and LV winding
are completely encapsulated in a cast resin body. This can
only be carried out in molded formers under vacuum. The
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Dr. B.E.Kushare
Head & Professor,
Department of Electrical Emgineering
K.K.W.I.E.E&R, Nashik
insulation level class of this type of system can only be
considered as class F, when considering the insulation system
as a whole.
When an insulation system is being investigated, its
breakdown voltage determines its application range. However,
the utilization factor (ratio of peak stress to average stress )
decided the effective ness of any insulation design. Therefore
the estimation and optimization of electrical field to avoid any
breakdown discharge, are important aid in the assessment of
insulating materials and insulation systems.
The aim of CRT design and optimization should be
carried out based on the specification given, using available
materials economically in order to achieve low cost, low
weight, small size and good operating performance. The
design should be satisfactory with respect to dielectric strength
and mechanical endurance, and windings must withstand
dynamic and thermal stresses in the event of short-circuit. In
order to meet the above requirements, transformer
manufacturers’ use cost optimization techniques during the
design phase to minimize material costs and satisfy the
utility’s loss evaluation requirement. The difficulty in
achieving the optimum balance between the transformer cost
and performance is a complicated task, and the techniques
that are employed for its solution must be able to deal with the
design considerations, so as to provide a design optimum,
while remaining cost-effective and flexible.
Finite element modelling (FEM) is a useful and commonly
used tool in the solution of electromagnetic problems that arise
in the design of distribution transformers. With approximately
30% of all transformer failures being due to insulation
breakdown (due to excessive electrostatic stress), electrostatic
FEM techniques are providing engineers with a valuable
means of more accurately quantifying the electric stress in
their designs.
II. PROBLEM DEFINITION
Cast resin transformers (CRT) are a preferred solution for
safety and reliability. It is always observed that during the
manufacturing process of a CRT, each transformer should be
measured for Partial Discharge (PD) Test before leaving the
manufacturing plant. This measurement gives information
about voids and defects in the insulation during
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manufacturing. The allowable PD level usually varies between
5 pC to 20 pC.
During operation, the transformer insulation can be
influenced by different parameters such as electrical, thermal
and mechanical stresses. As a result of stresses on the surface,
between the winding and the insulation; cracks and voids can
develop. In these voids and cracks PD can occur, which causes
a weakness of the insulation and reduces the reliability of the
transformer.
A. Problem Description
Design optimization of electrical insulation system by
evaluation of electrical field stresses for inter-coil insulation.
Analysis of the electrostatic field stresses results into
optimised spacing between the two coils of HV winding.
Therefore, the end insulation system can be designed with
better economy and performance.
Fig.1 Inter-coil Insulation
A 400kVA, 11/0.433kV, 50Hz, Single phase core type
Cast resin transformer has been considered for Optimization.
This has been done using Finite Element method by 2D-
ElecNet software. ElecNet provides powerful electric field
simulations for both static and current flow related problems.
The electrical stresses are evaluated for routine test, type tests
and continuous working voltage levels
A. One minute power frequency test voltage (induced over
voltage test)
B. Lightning impulse test voltage
C. Operating / terminal voltage during service
Since, the reliability and life of CRT is mostly the function
of electrical stresses. Here, this paper addresses to the design
and optimization of solid Insulation system in inter-coil
insulation of HV winding.
As any activity of partial discharge (PD) in solid insulation
leads to degradation of the solid insulation. The electric field
in CRT; more specifically, in high voltage winding depends
on the electrical stresses in inter-layer insulation and end
insulation.
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At microscopic level, turns per layer (differential turns),
insulation thickness between layers, and conductor radius
decides the electrical stresses. Whereas for end insulation, the
spacing between coils and coil-to-earth potential is deciding
factor for electrical stresses.
B. Boundary Conditions
To calculate the electric field stress value at different field
configurations;
a. Problem Domain - Electrostatic Domain is
enclosed in a Boundary
b. Geometry - 2D in RZ plane
c. Medium - Heterogeneous (‫ڙ‬0=1 and ‫ڙ‬r=4)
medium
d. Type of Problem - Electrostatic Problem
e. Governing Equation - Laplace equation (ǻ2V=0)
f. Boundary condition - Dirichlet boundary
condition
g. Peak voltage application to the HV winding.
C. HV winding arrangement
Fig.2 Design of HV winding
III. MODEL FOR ANALYSIS
Model : Analysis of Electric field stresses at Intercoil
Insulation of HV winding
The model considered in Fig. 3 can be analysed for electric
field stresses in inter-coil insulation depending upon the
thickness or gap for the insulation. The electric field stresses
are analysed for three different inter-coil spacing i.e. 30mm,
60mm and 90mm for solid insulation on the application of
peak voltage. As per Fig.3, the boundary conditions are
imposed on the model. The peak voltage distribution is
calculated and applied on the conductors as the boundary
condition.
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 Each conductor is modelled as per the voltage per turn
value calculated and the medium is defined by the respective
permittivity of the dielectric material.

Fig.5. Electric field stress at Top-coil section

Fig.3. Model for analysis of Inter-coil Insulation

On application of boundary conditions, the electric field

stresses are observed by Fig.4, which clearly defines the
highest stress point at the bottom section of the top coil near
the end conductor surface. This electric field stresses can be
uniformly distributed by optimizing the spacing between the
two HV coils such that the standard value of tolerable stress
become easily attainable. This results into reduction in the
failure of insulation system and thus increase in the lifespan of
transformer.

Fig.6. Electric field stress at the End conductor surface

Fig.7. Electric field stress for HV Coil spacing: 30mm

Fig.4 Electric field stresses in Inter-coil Insulation
The electric field distribution at the top (upper) coil section
is clearly shown in Fig. 5 and the field stress at the end
conductor surface is observed in Fig.6.
The electric field stresses are observed for the three
variations of HV coil spacing to optimize the end insulation of
the transformer.

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 Fig.8. Electric field stress for HV Coil spacing: 60mm
Fig.10 Results & Comparison of Analysis
Fig. 7, Fig. 8 and Fig. 9 shows the results of the field stress
analysis at HV coil spacing of 30mm, 60mm and 90mm
At 60mm insulation thickness, the highest stress point is
respectively.
noted exactly as 1.2kV/mm during peak voltage while the
electric field stresses are well below this value under normal
operating conditions.

References
[1] Minimum Weight Ei Core And Pot Core Inductor And
Transformer Designs, C.J.Wu,F.C.Lee , IEEE TRANSACTIONS
ON MAGNETICS, VOL. MAG-16, NO. 5, SEPTEMBER 1980.

[2] 3D Finite Element Analysis Of A Three Phase Power Transformer

Dorinel Constantin, Petre-Marian Nicolae, Cristina-Maria Nitu,
Eurocon 2013 • 1-4 July 2013 • Zagreb, Croatia.

[3] Electric Field Calculations On Dry-Type Medium Voltage Current

Transformers By Sandeep Kumar Lakshmichand Jain, A Thesis
The Degree Of Master Of Science Approved June 2012 By The
Fig.9. Electric field stress for HV Coil spacing: 90mm Graduate Supervisory Committee: ARIZONA STATE
UNIVERSITY August 2012.

IV. RESULTS FOR ANALYSIS [4] Recommended Design Voltage In Dry Type Transformer
Applications, Technical Data Sheet, Nomex

Analysis of the Electric field stresses for 03 variants
of Inter-coil insulation thickness has been performed using
FEM by ElecNet software. Comparing the results of analysis
with the Standard value of electric field stress w.r.t the
dielectric strength of Insulation i.e.1.2kV/mm[4] i.e.
1.69kVrms/mm in Fig.10, the optimised value of Inter-coil
spacing or the insulation thickness is concluded as 60mm
considering the factor of safety.
[5] Transformer Design By Finite Element Method With DOE
Algorithm, D. Phaengkieo Et.Al., 2013 International Conference
On Electrical Machines And Systems, Oct. 26-29, 2013, Busan,
Korea.
[6] William M. Flanagan, Handbook Of Transformer Design &
Applications—2nd Edition, Mcgraw-Hill Book Co., New York,
1986.
[7] Indrajit Dasgupta, Design Of Transformers, Tata Mcgraw- Hill
Publishing Co. Ltd., New Delhi, 2002.

[8] S. V. Kulkarni, S. A. Khaparde, Transformer Engineering Design

& Practice, Marcel Dekker, Inc., New York, 2004.

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