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electrical future

1. VISVESVARAYA TECHNOLOGICAL UNIVERSITY Belagavi- 590018 ADICHUNCHANAGIRI INSTITUTE OF TECHNOLOGY (Affiliated to VTU, Belagavi and Approved by AICTE, New Delhi) DEPARTMENT OF ELECRICAL AND ELECTRONICS ENGINEERING TECHNICAL SEMINAR ( 21EE 81 ) ON “ Manufacturing and Testing High Voltage Filter Capacitors ” Submitted by: SHARATH S B (4AI21EE022) Under the Guidance of: Mrs. K M KAVITHA B.E, M.Tech [Ph.D] Asst. Professor Dept. of E EE, A IT, Chikkamagaluru Co-Ordinator Mr s. RUMANA ALI B .E, M.Tech Asst. Professor Dept. of E E E, AIT, Chikkamagaluru

2. Manufacturing and Testing High Voltage Filter Capacitors

3. A Historical Overview The journey of capacitor development began in the 18th century with the invention of the Leyden Jar. Over the centuries, continuous innovation in materials and manufacturing has led to capacitors with superior electrical properties, enhanced efficiency, and greater durability. These advancements have made high-voltage capacitors indispensable in numerous electrical and electronic applications. 1 Early Innovations The Leyden Jar marked the start of energy storage technology. 2 Material Advancements Transition from paper to polymer dielectrics improved performance. 3 Modern Applications Capacitors now support diverse high-voltage systems.

4. Introduction High voltage capacitors are used to store and regulate electrical energy in high-voltage applications Voltage stabilization Signal filtering Energy storage

5. Literature Review Title / Year Author Name Description Manufacturing and Testing High Voltage Filter Capacitors,2024 Istók Róbert, Gál Tibor, Jasztrab Péter János, Petru Gabriel Puiu and Szén István This paper discusses the manufacturing and testing of 30kV, 33nF high-voltage filter capacitors , emphasizing manual production processes without compromising quality. It highlights three critical tests— voltage strength, partial discharge, and capacitance-dissipation factor —to ensure capacitor reliability and insulation performance. Review of Technologies and Materials Used in High-Voltage Film Capacitors, 202 1 Gnonhoue , O.G . This paper reviewed advancements in polypropylene film capacitors , emphasizing their low dissipation factor, high dielectric strength, and improved thermal stability . These findings support Istók Róbert et al.'s study, which highlights the role of polymer-based dielectrics in modern capacitor manufacturing.

6. Title / Year Author Name Description Partial Discharge Testing in High-Voltage Capacitors, 2010 Boggs, S.A. This paper analyzed partial discharge measurement techniques based on IEC 60270 standards , demonstrating how early detection of insulation defects can prevent catastrophic failures. The research aligns with Istók Róbert et al.'s findings, which emphasize partial discharge testing as a crucial step in capacitor quality assessment . Capacitor Fundamentals Sarjeant, W.J., 1989 This study provided a detailed analysis of capacitor behavior under high-voltage stress , focusing on dielectric strength, insulation resistance, and failure mechanisms . The research reinforced the necessity of strict quality control measures , a concept also emphasized in Istók Róbert et al.'s study on capacitor testing.

7. HV Capacitor Manufacturing Process Material Selection Choose polypropylene film, impregnated paper, or ceramic for insulation, and aluminum or metallized polymer films for electrodes . Electrode Preparation and Layering Cut electrodes precisely; layer dielectric material. Wind for efficiency or stack for higher energy densities. Vacuum Impregnation Introduce liquid dielectric under vacuum to eliminate air pockets, improving breakdown voltage and lifespan. Encapsulation and Sealing Protect core with epoxy resin or metal casing. Employ hermetic sealing to prevent moisture ingress.

8. Quality Control and Industry Standards Insulation Resistance Ensures minimal leakage and long-term reliability by measuring the resistance to current flow through the dielectric material. Partial Discharge Analysis Detects insulation defects or voids that could lead to premature failure using sensitive detection equipment. Voltage Withstand Testing Verifies the capacitor's ability to endure high-voltage conditions without breakdown, ensuring safety and performance.

9. Partial Discharge Testing 1 High AC Voltage Application Apply a high AC voltage across capacitor terminals, monitoring for discharge activity. 2 Sensor Detection Use ultrasonic sensors, high-frequency current transformers, and optical emission detectors. 3 Threshold Evaluation Assess discharge magnitude against acceptable thresholds for insulation defects. 4 Compliance and Reliability Ensure compliance with IEC 60270 for high insulation quality and operational reliability.

10. Capacitance and Dissipation Factor Tests Capacitance Measurement Use an LCR meter to measure how much charge the capacitor can hold. 1 Frequency Assessment Conduct tests at standard frequencies (50 Hz or 60 Hz) to simulate real-world conditions. 2 Dissipation Factor Measurement Analyze energy losses using an AC signal to detect dielectric inefficiencies. 3

11. Measured dissipation factor at different voltages The highest dissipation factor is measured in the case of 6kV and it is 2.84 x 10−4.

12. Advantages and Disadvantages of HV Capacitors Advantages High Dielectric Strength Low Dissipation Factor Excellent Insulation Resistance Efficient Filtering Capabilities High Energy Density Disadvantages Susceptibility to Partial Discharge Temperature Sensitivity High Manufacturing Cost Strict Handling Requirements Higher Energy Storage Risks

13. Applications Power Transmission Power factor correction and harmonic filtering for efficient energy transmission. Renewable Energy Smoothing power output in solar and wind energy converters. Electric Vehicles Voltage regulation in EVs, transportation, and charging stations.

14. Conclusion: The Future of High-Voltage Capacitors High-voltage capacitors have transformed electrical engineering. Continuous material and manufacturing innovation have improved their performance. They are essential for sustainable, efficient power transmission and industrial applications. The future will bring more advanced technologies, reinforcing the importance of high-voltage capacitors in evolving power networks. Advancements in Materials Polymer films, ceramics, and composites are key. Improved Reliability Self-healing properties ensure continuous operation. Expanded Applications Critical in renewable energy and smart grids.

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