Röchling Engineering Plastics KG

Solid insulation materials in a transformer by
Röchling Engineering Plastics KG
Dipl.-Ing. (FH) Dennis Hoppmann
Röchling Engineering Plastics KG
TRANSFORM Partner
Speaker
Dipl.-Ing. (FH) Dennis Hoppmann
dennis.hoppmann@roechling-plastics.com
Age: 35
Studies
Electrical engineering with the focus on
energy supply and high voltage technology at
University Of Applied Science Osnabrück/Germany
2007 diploma in electrical engineering
Siemens AG
Electrical design of air cooled generators
Röchling Engineering Plastics KG
Application Engineer Composites
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 2
The range: Insulation materials by Röchling
Lignostone® Transformerwood®
(laminated densified wood)
Trafoboard®
(laminated pressboard)
Durostone®
(fibre reinforced plastics)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 3
Insulation materials by Röchling
Lignostone® Transformerwood®
(laminated densified wood)
 Well-proven insulation material for oil-filled power
transformers
 Invented by Röchling in 1915
 Premium quality supplier for the transformer industry
since 1950
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 4
Insulation materials by Röchling
Raw material red beech veneers
(Fagus sylvatica)
Covers about 30 % of the whole
forest area in Central Europe
Tree dimensions
Height:
45
Diameter: 0,7
Age:
80
meters
meters
years
Red beech: geographical distribution
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 5
Insulation materials by Röchling
Lignostone® Transformerwood® (laminated densified wood)
Red Beech veneers
glued with a phenolic resin
under heat and pressure
Properties
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann

Long fibres lend the material its
high mechanical strength

The capillary structure allows
fast drying process
and the absorption of oil
17.06.2013
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Insulation materials by Röchling
Lignostone® Transformerwood® methods of lamination
Crosswise lamination
Applications
Ø < 2,000 mm
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 7
Insulation materials by Röchling
Lignostone® Transformerwood® methods of lamination
Parallel lamination
Applications
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 8
Insulation materials by Röchling
Lignostone® Transformerwood® methods of lamination
Tangential lamination
Ø < 3.400 mm
Applications
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 9
Insulation materials by Röchling
Lignostone® Transformerwood® methods of lamination
crosswise
parallel
tangential
Density: L (0,95 g/cm3) or M (1,25 g/cm3)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 10
Insulation materials by Röchling
Lignostone® Transformerwood® density range
E-Modulus [MPa]
crosswise laminated
L 0,95 g/cm3
M 1,25 g/cm3
Density [g/cm3]
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 11
Insulation materials by Röchling
Lignostone® Transformerwood® Hybrid
Objective
Improving mechanical strength of
insulating parts without changing the
density and volume
Lignostone® Hybrid
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann

red beech veneers

phenolic resin

glass fibre reinforcements
17.06.2013
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The range: Insulation materials by Röchling
Lignostone® Transformerwood®
(laminated densified wood)
Trafoboard®
(laminated pressboard)
Durostone®
(fibre reinforced plastics)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 13
Insulation materials by Röchling
®
Trafoboard
Laminated pressboard per IEC 60763
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 14
Insulation materials by Röchling
Trafoboard® laminated pressboard
Raw material
 natural coloured hot pressed pressboard
 100% unbleached sulphate cellulose (type 3.1 according to IEC 60641-3-1)
thickness: 3 - 4 mm
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 15
Insulation materials by Röchling
Trafoboard® laminated pressboard
HD-PG
HD-PH
Polyester resin
Phenolic resin
Sheets:
Sheets:
standard sizes:
2.050 x 1.050 mm
2.125 x 1.350 mm
max. size: 4.150 x 2.150 mm
Rings:
up to Ø 3.150 mm
Cost advantages
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 16
Insulation materials by Röchling
HD-PG (polyester) HD-PH (phenolic)
Density
Flexural strength
MD
CMD
Modulus of elasticity
in flexural
MD
CMD
Shrinkage
MD
CMD
Thickness
Compressibility
C
Crev
Moisture Content
Oil absorption
pH of aqueous
extract
Conductivity of
aqueous extract
Electric strength II
(50 x 10 x 10mm)
Röchling Engineering Plastics KG
IEC 60763
Unit
Test method
g/cm3
ISO 763
min. 110
min. 90
MPa
ISO 178
13,0
10,5
-----
GPa
ISO 178
0,15
0,25
1,50
0,20
0,30
1,50
max. 0,40
max. 0,60
max. 4,00
%
IEC 60763-2
2,5
87
<5
2,6
93
<5
max. 3,0
min. 70
max. 5
%
IEC 60763-2
%
IEC 60763-2
8
10
min. 5
%
IEC 60763-2
6,0
6,5
5-8
pH
IEC 60763-2
6,1
7,0
max. 10
mS/m
IEC 60763-2
>8
>9
min. 8
kV/mm
IEC 243-1
LB 3.1A.2
1,25
LB 3.1A.2
1,25
Type LB 3.1A.2
1,15 – 1,35
130
115
120
110
14,0
11,0
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 17
Insulation materials by Röchling
Trafoboard® laminated pressboard
University of Applied Sciences Osnabrück
Science to Business GmbH
Electrical Power Systems
and High Voltage Technology
Scientific team
Prof. Dr.-Ing. E. Buckow
Dipl.-Ing. M. Havekost
Dipl.-Ing. M. Kröger
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 18
Insulation materials by Röchling
Trafoboard® HD-PG (polyester)
Test setup:
Shell Diala D
Test direction:
parallel to the lamination
Voltage increase: step by step
The measuring sensitivity for all measurements of partial discharge is <1,0 pC
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 19
Insulation materials by Röchling
Trafoboard® HD-PG (polyester)
PD = onset of partial discharge, DV = breakdown of test set-up
result: 9,1 kV/mm (Average)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 20
Insulation materials by Röchling
Trafoboard® HD-PH (phenolic)
Test setup:
Shell Diala D
Test direction:
parallel to the lamination
Voltage increase: step by step
The measuring sensitivity for all measurements of partial discharge is <1,0 pC
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 21
Insulating materials by Röchling
Trafoboard® HD-PH (phenolic)
PD = onset of partial discharge, DV = breakdown of test set-up
UG = sliding discharge on the smooth side of sample
UR = sliding discharge on the rough side of sample
result: 10,0 kV/mm (Average)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 22
Insulation materials by Röchling
Trafoboard® machining
saw
CNC machining 5 axis
metal detection
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 23
The range: Insulation materials by Röchling
Lignostone® Transformerwood®
(laminated densified wood)
Trafoboard®
(laminated pressboard)
Durostone®
(fibre reinforced plastics)
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 24
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Compression moulding for sheets
 Standard grades: GPO3, G-11…
 Special grades and dimensions
 Insulating class F and H
 Wet press/SMC technology
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 25
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Durostone® UPM S2
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 26
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Durostone® UPR S19
threaded rods
Durostone® UPM S2
step block
Durostone® UPM S2
core support
Durostone® UPM S2
beam
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 27
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
EAF Transformer
Durostone® EPC 205
Lead-through board
Features:
• Modulus of elasticity 30 GPa
• CTI 500
• Current > 200 kA
Single board: 4,035 x 3,270 x 70 mm
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
• Flatness/ no oil leakage
17.06.2013
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Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Pultrusion
 Max. width 1000 mm
 No limit in length!
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 29
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Pultrusion: high voltage applications
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 30
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Filament winding
 max.  4000 mm
 max. width 1.6m
 up to 4t
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 31
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Durostone® EPX-M
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 32
Insulation materials by Röchling
Durostone® (fibre reinforced plastics)
Durostone® EPX-M
lead ring
Durostone® EPX-M
shield ring
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 33
Röchling history
From coal to plastics
1822 – 1881
Röchling = Coal
• „Nucleus“ was a
coal business
in the Saarland
• Mid-nineteenth century
start of coal production
Röchling Engineering Plastics KG
1881 - 1978
Röchling = Steel
• Acquisition of the
Völklingen ironworks
in 1881
• Move into
plastics processing
in 1920
Dipl. Ing. Dennis Hoppmann
1978 - 2005
Diversified int.
industrial group
• Diversification after moving
away from coal and steel
industry in the course of the
international steel crisis
• From 1982 onwards
expansion of successful
plastics processing division
since 2006
Röchling = Plastics
• Change of strategy
from a conglomerate
to a plastics group
• Successful conclusion
of restructuring program
in 2005
17.06.2013
Page 34
Röchling Group
58 locations in 20 countries worldwide
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 35
Röchling today
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 36
Insulation materials by Röchling
Thanks for your attention!
Any questions?
www.roechling.com
Röchling Engineering Plastics KG
Business Unit Composites
Röchlingstr. 1
49733 Haren/Germany
Röchling Engineering Plastics KG
Dipl. Ing. Dennis Hoppmann
17.06.2013
Page 37