Transformer-dry-type-handbook1

Relentlessly Responsive DRY TYPE TRANSFORMER INSULATION HANDBOOK ISO 9001: 2008 CERTIFIED FABRICATOR OF THERMAL INSULATION MATERIALS THE GUND COMPANY 2121 WALTON ROAD ST LOUIS, MO 63114 TEL (314) 423-5200 FAX (314) 423-9009 WWW.THEGUNDCOMPANY.COM Table of Contents I Introduction to the Gund Company Preface Our Locations .5 Primary Customer Segments Transformer Insulation Components Overview 7-8 II Transformer Coil Insulation Components Coil Insulation Overview Winding Bobbins Insulating Core Tubes Conductor Insulation Layer Insulation Layer Insulation Tape Intra-Coil Phase Barriers Inter-Coil Phase Barriers Winding Combs Coil Shims Air Duct (Axial) Spacer Sticks 10 11 12 13 14 15 16 17 18 19 20 III.Coil Support & Superstructure Components Coil Supports 22 Insulating Nuts & Bolts 23-27 Phase Barriers 28 Insulating Angles & Channels 29 Stand-off Insulators 30 IV.Tap Changer Components Tap Changer Components 32 V Material Data Sheets Laminate Sheet, Rod, & Tubing Glass Epoxy Laminate Sheet & Tubes (NEMA Grades G-10/FR4 & G-11) 34-35 Glass Polyester Molded Insulation Materials www.thegundcompany.com Dry Type Transformer Insulation Handbook Tel (314) 423-5200 Fax (314) 423-9009 Glass Polyester Molded Sheets (NEMA Grades GPO-1, GPO-2, GPO-3) 36-39 Glass Polyester Molded Sheet, NEMA Grade N180 40 Glass Polyester Molded Sheet, DuraNohl™ N220 41 Glass Polyester Laminate Sheet, 220°C Grade SG-200 42 Glass Polyester Laminate Sheet, 220°C Grade HST-II 43 Glass Polyester Pultruded Angles & Channels 44-45 Glass Polyester Molded Stand-off Insulators 46-49 Glass Polyester Pultruded Shapes (Rods, Dogbones, & Squares) 50 Table of Contents Nomex™ Insulating Materials NomexTM Aramid Paper 51-53 NomexTM Paper Products 54 Other Flexible Transformer Insulation Materials Quin-T Family of Products 55-60 PolyPro FR™, Flame Retardant Polypropylene 61 Other Transformer Insulation Materials Glass Epoxy Filament Wound Tubing 62 VI Appendix Dry Type Transformer Kitting Checklist 64-68 Winding Comb Order Sheet 69 Application Engineering 70 Contacting The Gund Company 71 Tel (314) 423-5200 Fax (314) 423-9009 www.thegundcompany.com Dry Type Transformer Insulation Handbook www.thegundcompany.com Dry Type Transformer Insulation Handbook Tel (314) 423-5200 Fax (314) 423-9009 Section I Introduction to The Gund Company Preface The Gund Company has been in the electrical insulation manufacturing, fabrication, and distribution business for over fifty years We have introduced the Dry Type Transformer Insulation Handbook to better serve our customers in the manufacturing and repair of dry type transformer equipment Section I of this handbook offers some background information on The Gund Company and the segments of the electrical industry that we serve Sections II, III, and IV of this book contain transformer insulation application information Section V contains the technical data sheets for transformer insulation materials and Section VI, the final section, discusses Application Engineering and contact information for The Gund Company This handbook is intended for manufacturing engineers, repair specialists, field service technicians, purchasing agents, shop foremen, and everyone who may be involved in the specification, selection, and use of electrical insulating materials for transformer equipment The reader should be advised that this handbook does not represent a complete account of The Gund Company’s products and services nor a complete record of all insulation materials utilized in the many and varied transformer designs Instead, it is meant to be a collection of technical information pertaining to the most commonly encountered insulation materials and their application in transformers If a desired product or component cannot be found, please contact us and we can discuss potential options Please keep in mind that all information and data contained in this handbook is believed to be reliable, but all recommendations or suggestions are made without guarantee Furthermore, suggestions for use of material supplied shall not be construed as a recommendation or inducement to violate any law or infringe on any patent We hope that the product and application information along with the sample component drawings help involved individuals to make informed decisions The Gund Company welcomes any comments, suggestions, or applications questions We sincerely appreciate the opportunity to assist you in meeting your electrical insulation requirements Tel (314) 423-5200 Fax (314) 423-9009 www.thegundcompany.com Dry Type Transformer Insulation Handbook Our Locations Cedar Lake, Indiana (Chicago) • 30,000 Sq Foot Fabrication Facility Milwaukee, Wisconson • 50,000 Sq Foot Fabrication Facility • 20,000 Sq Foot Molding Facility Fergus, Ontario (Toronto) • 55,000 Sq Foot Fabrication Facility Milwaukee, WI Cedar Lake, IN (Chicago) St Louis, MO Mexico City, Mexico Mexico City, Mexico • 11,000 Sq Foot Fabrication Facility St Louis, Missouri • Corporate Headquarters • 62,500 Sq Foot Fabrication Facility www.thegundcompany.com Dry Type Transformer Insulation Handbook Fax (314) 423-9009 San Bernardino, CA Tel (314) 423-5200 San Bernardino, California • 20,000 Sq Foot Fabrication Facility Fergus, ON (Toronto) Primary Customer Segments By focusing on understanding our customer’s specific application requirements, TGC has delivered solutions to customers around the world TGC exports to more than 32 countries including Japan, Korea, China, Austria, United Kingdom, and Saudi Arabia Power Supply A natural extension of both the switchgear and transformer insulation business From Dry Type Transformer Components to Chassis Liners and every insulator in between, TGC can provide kitting solutions Switchgear Insulation Transformer Insulation Tel (314) 423-5200 Winding kits including coil spacer sticks, coil wedges, step blocks, terminal strips, phase barriers, cable clamps, and bus supports Layer insulation options and PSA layer tapes TGC is an integrated manufacturer of glass polyester laminates (GPO-3) with complete fabrication capability for phase barriers, terminal supports, bus bar supports, and cable clamps Fax (314) 423-9009 www.thegundcompany.com Dry Type Transformer Insulation Handbook Transformer Insulation Components Overview The Gund Company manufactures insulating components for many types of electrical transformers including: • • • • • Large Power Transformers Oil Filled Distribution Transformers Dry Type Distribution Transformers Dry Type Power Supply Transformers Electronic Transformers Though transformers perform a similar role in the power distribution system regardless of design, the various transformer insulation design parameters can be quite different For example, an oil filled transformer used for outdoor power distribution applications requires insulating components compatible with the dielectric fluid used in the transformer On the other hand, a dry type transformer used for power distribution inside a building requires a higher temperature insulation system typically rated for 180°C to 220°C While the design or function of an insulating component may be similar in both oil filled and dry type transformers, the material selection criteria can be completely different The Gund Company has put together the Dry Type Transformer Insulation Handbook to help serve as a reference tool for our customers involved in the manufacturing and repair of transformer equipment We have attempted to gather information on the most common insulation component applications as well as the most common insulating material alternatives If we have not included a particular material or application of interest to you, please contact us for a specific review of your requirements The Gund Company has also produced an Oil Filled Transformer Insulation Handbook which may be requested by contacting The Gund Company Whatever your transformer insulation requirement may be, The Gund Company has the material knowledge and technical capability to assist you in developing potential engineering solutions www.thegundcompany.com Dry Type Transformer Insulation Handbook Tel (314) 423-5200 Fax (314) 423-9009 Over the years, The Gund Company has served as a partner for many of our customers interested in lowering the cost structure of their design By partnering with our customers, we can review current insulation system designs in order to help identify areas for potential cost reductions Many of our customers participate in our “Cost Reduction Initiative Program” wherein we request design information, assembly drawings, and related information so that we can make a proposal that may lower the cost of production Common Insulation Components by Type of Transformer Type of Transformer Dry Type Transformer Electronic, Power Supply or Distribution Applications Oil Filled Transformer Medium & Large Power Applications Additional informatin found in TGC’s Oil Filled Transformer Insulation Handbook Oil Filled Transformer Distribution Applications Additional informatin found in TGC’s Oil Filled Transformer Insulation Handbook Insulating Component Common Materials Conductor Insulation Layer Insulation Layer Insulation Tape Winding Comb Coil Wedges Air Duct (Axial) Spacer Sticks Phase Barrier Coil Clamps Bus Bar Supports Winding Bobbins Insulating Nuts & Bolts Insulating Angles & Channels Stand-off Insulators Slit Nomex Aramid Paper Coils Nomex™ Aramid Paper, Quin-T Glass Cloth Tape, TESA 4617 Glass Polyester Laminate, SG-200, N220 Glass Polyester Laminate, GPO-3 Glass Polyester Dogbone Rod Glass Polyester Laminate, GPO-3 Glass Polyester Laminate, GPO-3 Glass Polyester Laminate, GPO-3 Glass Epoxy Laminate, G10 / G11 Glass Epoxy Laminate Glass Polyester Pultrusions Molded Glass Polyester Conductor Insulation Layer Insulation Layer Insulation Tape Crossover Pad Insulation Core Insulation Core Spacers Core Fastener Insulation Axial and Radial Spacers Punched Spacers Clamping Plates & Rings Lead Termination Insulation Lead & Cable Clamps Coil Supports – Step Blocks Insulating Nuts & Bolts Tap Changer Insulating Boards Lead & Cable Tubing Tie Plate Bolt Insulation Nomex™ & Creped Kraft Paper Diamond Epoxy Coated Kraft Glass Reinforced Polyester Tape Rag Paper Insulation – COPACO Glass Polyester Laminate, GPO-1 Glass Polyester Laminate, GPO-1 Glass Epoxy Laminate, G-10 Fabricated Pressboard Material Fabricated Pressboard Material Fabricated Pressboard Material, Laminated Wood Paper Phenolic Laminate, XXX Paper Phenolic Laminate, XXX Fabricated Pressboard Material, Laminated Wood Glass Epoxy Laminate, G-10 Low Power Factor Paper Phenolic Paper Phenolic Laminate, XXX Glass Epoxy & Steel Assembly Layer Insulation Layer Insulation Tape Crossover Pad Insulation Phase Barriers Insulating Angles & Channels Fuse & Terminal Boards Insulating Tubing Diamond Coated Kraft Paper Glass Reinforced Polyester Tape Rag Paper Insulation – COPACO Glass Polyester Laminate, GPO-1 Glass Polyester Pultrusion, GPO-3 Glass Polyester Laminate, GPO-1, NEMA XXX Paper Phenolic Tubing, XXX Tel (314) 423-5200 Fax (314) 423-9009 www.thegundcompany.com Dry Type Transformer Insulation Handbook www.thegundcompany.com Dry Type Transformer Insulation Handbook Tel (314) 423-5200 Fax (314) 423-9009 Section II Transformer Coil Insulation Components The Gund Company, Inc MANUFACTURERS OF ELECTRICAL INSULATION MATERIALS St Louis, Missouri – USA TEL - 314.423.5200 FAX - 314.423.9009 INSULATING COMPONENTS FOR POWER SYSTEMS EQUIPMENT MATERIAL DATA SHEET CeQuin with Glass & Film Item: CeQuin IF Key Characteristics Test Method By Thickness, Inches (mm) Units - English (SI) 0.007 (0.18) 0.012 (0.3) 0.018 (0.46) Tensile Strength ASTM D-528 lb./1 in (Kn/m) - (7) 10 - (7) 15 - (24.5) Grammage ASTM D-646 lb./yard2 (kg/m2) 0.22 (40) 0.32 (40) 0.43 (140) V/mil (Kv) 8.3 (0.4) 8.8 (0.6) 3.0 (0.8) Dielectric Breakdown ASTM D-149 CeQuin VF Key Characteristics Test Method By Thickness, Inches (mm) Units - English (SI) 0.007 (0.18) 0.012 (0.3) 0.036 (0.91) Tensile Strength ASTM D-528 lb./1 in (Kn/m) - (7) 10 - (7) - 30 - (53) Grammage ASTM D-646 lb./yard2 (kg/m2) 0.22 (40) 0.32 (40) 1.0 (300) V/mil (Kv) 8.3 (0.4) 8.8 (0.6) 4.5 (1.9) Dielectric Breakdown ASTM D-149 CeQuin IR Key Characteristics Test Method By Thickness, Inches (mm) Units - English (SI) 0.006 (0.15) 0.01 (0.25) 0.013 (0.33) Tensile Strength ASTM D-528 lb./1 in (Kn/m) - (12) - (12) 10 - (12) Grammage ASTM D-646 lb./yard2 (kg/m2) 0.11 (68) 0.27 (68) 0.36 (68) V/mil (Kv) 0.6 (0.2) 1.4 (0.5) 2.0 (0.6) Dielectric Breakdown ASTM D-149 CeQuin VG Key Characteristics Test Method Units - English (SI) Tensile Strength ASTM D-528 lb./1 in (Kn/m) Grammage ASTM D-646 Dielectric Breakdown ASTM D-149 CeQuin IGI By Thickness, Inches (mm) 0.01 (0.25) 0.013 (0.33) 0.017 (0.43) 0.23 (0.58) - (24.5) 10 - (24.5) - - (24.5) 10 - -10 (24.5) lb./yard (kg/m ) 0.27 (140) 0.38 (140) 0.54 (140) 0.65 (140) V/mil (Kv) 1.4 (0.5) 2.0 (0.7) 2.8 (1.0) 4.0 (1.2) 2 CeQuin IFI CeQuin VGV By Thickness, Inches (mm) Tel (314) 423-5200 Key Characteristics Test Method Units - English (SI) Tensile Strength ASTM D-528 lb./1 in (Kn/m) - (10.5) - -5 (24.5) Grammage ASTM D-646 lb./yard2 (kg/m2) 0.27 (60) 0.38 (140) V/mil (Kv) 10 (0.5) 4.0 (4.0) Dielectric Breakdown ASTM D-149 0.09 (0.23) 0.13 (0.33) Fax (314) 423-9009 All of the information, suggestions, and recommendations pertaining to the properties and uses of the products herein are based upon tests and data believed to be accurate; however, the final determination regarding the suitability of any material described herein for the use contemplated, the manner of such use, and whether the use infringes any patents is the sole responsibility of the user There is no warranty, expressed or implied, including, without limitation warranty of merchantability or fitness for a particular purpose Under no circumstances shall we be liable for incidental or consequential loss or damage 58 www.thegundcompany.com Dry Type Transformer Insulation Handbook The Gund Company, Inc MANUFACTURERS OF ELECTRICAL INSULATION MATERIALS St Louis, Missouri – USA TEL - 314.423.5200 FAX - 314.423.9009 INSULATING COMPONENTS FOR POWER SYSTEMS EQUIPMENT MATERIAL DATA SHEET Item: CeQuin I, II, III, V, & GESAT Description: The CeQuin products described herein are generically an aluminum silicate, unfired ceramic-like material which have had a combination of synthetic fibers and high-temperature binders engineered into their structures This results in a family of products that have excellent electrical and physical characteristics for use in high-temperature electrical insulation applications They are cost-effective materials that will outperform competitive organic materials that cost substantially more Availability: Fabricated Parts: The Gund Company custom fabricates insulation materials to the exact specifications and drawings of our customers CeQuin I Key Characteristics Units - English (SI) Tensile Strength, MD lb./yard (kg/m ) Elongation, MD % Grammage lb./yard (kg/m ) By Thickness, Mil (mm) (0.076) (0.125) 10 (0.254) 15 (0.38) 30 (0.76) 4.5 (0.8) 5.7 (1.0) 15 (2.7) 19 (3.4) 25 (4.4)