APPLICATION OF

INSULATING MATERIALS
HIGH VOLTAGE ENGINEERING

FIKA TRISNAWATI, M.T.

INTRODUCTION

• All electrical systems require some

form of insulation to prevent short
circuits and leakage currents.
• Insulators are available in three
forms: solid, liquid, and gas.
• The performance of these
insulators depends on temperature,
and they are classified according to
their temperature rating.
Temperature Classification for
Insulating Materials
• Insulating materials are designed to • Applications of Insulating
withstand electrical stress, in Materials in Electrical
addition to enduring other types of Equipment:
stress during manufacturing, 1. In power transformers
storage, and operation. 2. Rotating machines
• The performance of these materials 3. Circuit breakers
depends heavily on their operating 4. Power capacitors
temperature. Higher temperatures
5. High-voltage bushings
accelerate chemical degradation.
6. Small machines
 Temperature Classification for
Insulating Materials
• The classification of insulation materials based on temperature limits.
These classes indicate the maximum temperatures the materials can
withstand without degrading, which is essential for applications in
electrical and thermal insulation.

Impregnation: allowing a solid material to absorb certain liquids, which can

improve its durability, thermal resistance, or other properties in insulation
applications.
Temperature Classification for
Insulating Materials
• Base on IEC (International Electrotechnical Commission)
 Power Transformer Applications

• There are four main areas where insulation

must be used:
1.Insulation between different windings
2.Insulation between low-voltage windings
and ground
3.Insulation between high-voltage and low-
voltage windings
4.Insulation between high-voltage windings
and ground
Transformer Insulation Types
Transformer insulation is divided into • c) Insulation of Low- and High-
the following categories: Voltage Windings to Ground
• a) Conductor or Layer-to-Layer Typically consists of solid tubes combined
Insulation with fluid- or gas-filled spaces. The fluid or
gas in these spaces helps dissipate heat
− Uses direct organic enamel on the
from the core and coil structure and also
conductor for lower ratings.
enhances insulation strength.
− Uses paper or glass-type wrapping on
• d) Low-Voltage to Low-Voltage
rectangular conductors.
Winding Insulation
• b) Winding-to-Winding Insulation
Generally, in oil-filled transformers, this
− Kraft paper is used in smaller insulation system consists of oil-
transformers. impregnated pressboard.
− Pressboard, glass cloth, or porcelain is
used in higher-rated transformers.
Transformer Winding Insulation

• The winding insulation is typically made of

paper.
• Cellulose board is also used as internal
insulation in fluid-filled transformers.
• Cellulose insulation is impregnated with
transformer fluid to enhance its properties.
• Conductor insulation usually consists of
paper, in the form of pressboard.
• Pressboard is made from wood or a mixture
of wood and cotton.
• Strong resins are also used as an insulation
system for lower voltage ratings.
• Higher-temperature systems employ
synthetic fluids.
• Gas-insulated power transformers use
aluminum conductor sheets for windings and
polymer film for inter-winding insulation.
Transformer Oil
• Provides the necessary dielectric strength and insulation.
• Cools the transformer by self-circulating through the core and coil structure.
• Must remain in a liquid state within the operating temperature range of -40°C to
+50°C.
• Oxidizes when exposed to oxygen at high temperatures.
1. Forms peroxides, water, organic acids, and sludge, which can chemically degrade
the insulating paper and metal parts of the transformer.
2. Sludge is heavy and reduces the oil’s heat transfer capability, forming an
insulating layer on the coil structure and tank walls.
3. Oxidation effects are minimized by limiting oxygen exposure.
4. Transformer seals.
5. Often filled with nitrogen gas.
6. Uses activated clay or alumina to absorb oxygen.
7. Internal arcing discharges can break down the oil and cause explosions .
Dry-Type Transformer
• Insulation in dry-type transformers
uses composite materials (fiber
compositions with epoxy are becoming
common).
• Manufacturing involves fire-resistant
materials such as fiberglass, Nomex,
and aramid paper.
• This provides good dielectric strength
in the windings, simplifies the
manufacturing process, and reduces
the cost of vacuum impregnation for
low-voltage windings.
Applications in Rotating Machines
• There are two types of rotating machines:
1. Low-Voltage Machines: Up to 6,600 V,
using Class E or F insulation.
2. High-Voltage Machines: Above 6,600 V,
using Class F insulation. Machines above
22 kV are only built for special cases.

• The primary insulation material used in

these machines is mica, which is available
in very thin layers. The correct material
selection depends on power rating and
operating conditions. Polyester film, with
or without impregnation, is used for slot
insulation.
• In rotating machines, rotor and stator
insulation are particularly important. The
main stator insulation is always based on
mica. Additionally, for inter-bar insulation
Applications in Circuit Breakers
• A circuit breaker is a switch that automatically
opens the circuit when critical voltage or current ratings
are exceeded. AC current is generally considered easier
to interrupt than DC current.
• AC Current Interruption Sequence:
1) At the metallic arc segment of the circuit.
2) Deionization occurs as the current approaches zero,
preventing the arc from re-forming.
• Categories of Circuit Breakers:
1) Low-Voltage Type
2) High-Voltage Type
 Categories of Circuit Breakers
• Low-Voltage Circuit Breakers, including: • High-voltage circuit breakers include air
1. Use synthetic resin molds to encase the circuit breakers and oil circuit breakers.
metallic parts. Several insulating fluids are suitable for
2. For higher temperatures, ceramic parts are extinguishing arcs. The selection depends
used. on the rating and type of circuit breaker.
3. If an arc comes into contact with molded parts, • Commonly used insulating fluids
melamine or specific alkyl types are used due include:
to their high arc resistance.
- Atmospheric air
• Bushings in Low-Voltage Circuit Breakers
Contain solid porcelain cylinders and protectors, - Compressed air
or resin treated with paper wrapping on - High vacuum
electrodes that carry current.
- SF6 (sulfur hexafluoride)
• High-Voltage Bushings (66 kV and above)
- Are filled with oil to manage high-voltage - Oil (such as transformer oil and arc
demands. interruption oil)
- The construction details are extensive to ensure - Askarel, which produces toxic substances
reliability at high voltages. and corrosion
Insulating Materials for High-Voltage
Switchgear
Materials Details

Epoxy Resin Low-Pressure Castings: Used for bushings, switchgear,

busbars, and measurement transformers.
Bound Epoxy Resin Utilized in components such as arc control devices, circuit
breakers, and fiberglass applications.
Polyester Resin Insulation Components: Employed for circuit breakers (CB)
and phase barrier supports on switchboards.
Porcelain Insulators and Bushings: Commonly used in power
transformer insulators and bushings due to its excellent
dielectric properties.
Synthetic Resin Applications: Used in bushings, arc chambers, and
insulation papers, providing reliable electrical insulation.
Nylon Injection Molded Paper: Utilized for arc control devices in
circuit breakers, offering good mechanical strength and
insulation.
Silicone Rubber Filling Material: Used for joint boxes molded in SF6-
APPLICATIONS IN CABLES
• Synthetic rubber and plastic are used as
cable insulation. The insulation should
possess the following qualities:
1) Good elongation, tensile strength, and
toughness to withstand handling during
installation and service.
2) Low dielectric constant and low power • High-voltage cables also generate
factor. ozone, which can degrade the
3) High dielectric strength and high insulation, especially near the
insulation resistance. conductor.
4) Strong resistance to aging at high • For underwater applications, insulation
temperatures. materials must have very low water
5) Durability against prolonged exposure absorption.
to sunlight and various chemicals. • At low temperatures, insulation should
remain flexible and avoid becoming stiff
and brittle. Partial discharge within
APPLICATIONS IN CABLES
• The main types of insulation used in the
cable industry include paper, rubber, plastic,
and pressurized gas. Paper-insulated, lead-
sheathed cables are still in use due to their
reliability, high dielectric strength, low
dielectric loss, and long lifespan.
• For low and medium voltages (up to 3.3 kV),
polyvinyl chloride (PVC), polyethylene (PE),
and cross-linked polyethylene (XLPE) are the
most commonly used materials. PVC is
unsuitable for high voltages due to its high
dielectric constant and high losses.
Polyethylene offers a low dielectric constant
and low loss with high dielectric strength.
• For high-voltage and high-temperature
applications, Teflon (PTFE) is the best
material, withstanding temperatures up to
250°C.
 Applications Of Power Capacitors
• Power capacitors are used for voltage regulation
in power transmission systems, power factor
improvement in power distribution networks,
and power factor correction in high-frequency
applications such as induction heating.
• Additionally, they are used in DC applications,
including:
- Impulse Voltage Generators: For generating
high-voltage impulses in testing and research.
- Energy Storage: To store and discharge large
amounts of energy quickly when needed.
- Welding: For providing stable and controlled
energy in welding equipment.
- Flash Photography and High-Intensity X-Ray
Tubes: For delivering intense, short bursts of
energy in lighting and medical imaging.
• POWER CAPACITOR
CONSTRUCTION: • Properties Required for
1. Power capacitors are made from Insulating Paper:
multiple layers of thin insulating 1. High dielectric strength
paper and aluminum foil, with the
foil typically around 6 microns thick, 2. Low dielectric loss
acting as electrode layers within the
winding. Individual units are 3. High dielectric constant
connected in parallel to increase
capacity.
4. Uniform thickness
2. The capacitor assembly is placed in • Compared to paper,
a sealed, fully dried container and polypropylene film has higher
impregnated with insulating oil, such dielectric losses but a higher
as: operating voltage.
The Dielectric Concept in Paper
- Mineral Oil: High-cost but highly • Insulating paper remains widely and All-Paper Film in
effective for insulation. Capacitors
used, as once impregnated, it
- Diphenyl Chloride Oil: Lower-cost, provides many essential
non-flammable, and preferred for its properties for high-voltage
safety features applications and is also cost-
 Applications In High-voltage Bushings
• The primary insulating materials used in high-voltage
bushings include resin-bonded paper (RBP), oil-
impregnated paper (OIP), and resin-impregnated
paper (RIP). The paper is wound around a central
tube, with layers of conductor inserted to form a
series of concentric capacitors between the tube and
the mounting flange.
• Since the 1960s, resin materials have been widely
adopted for all types of bushings up to the highest
voltages. Resin insulation offers higher dielectric
strength than paper and requires less voltage control
at levels below 25 kV.
• However, partial discharge failures may occur due to
challenges in removing microvoids in the resin
surrounding the screens during the casting process.
The need to eliminate voids in the resin becomes
increasingly critical at higher voltages, often
necessitating a return to resin-impregnated, wound
Applications In Horse-power Motors
Small Generators:
• The insulation system must ensure reliability,
combining good processability, mechanical
strength, and tolerance to severe short-term
thermal stress during operation.
• The following materials have been found to have
excellent insulation properties: pressed paper
windings, multilayer NMN (made from Nomex
and polyester film), and saturated DMD (made
from non-woven polyester and polyester film).
Small Motors:
• The primary insulation material for small motors
is pressboard, as it does not melt.
• Multilayer materials made from pressboard and
polyester film (used in electrical equipment) can
withstand short-term thermal stress.
• Various types of polymers have been developed
and are widely used as insulating materials in
small motors.
Thankyou
Supported by:
Dr. Ir. Dina Maizana, M.T.