WindingTemperatureSimulationSystem

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WindingTemperatureSimulationSystem
September2011
ByMikeMiller
Oneitemoftenoverlookedduringthetesting&commissioningofatransformeristheverificationoftheoilwindingtemperaturegradientwithinthewindingtemperaturesimulation
system.
Unlessthetransformercamewithsometypeoffiberoptictemperatureprobesmounteddirectlytothewindingsyouregoingtohavetorelyonasystemdesignedtosimulatethe
actualtemperatureofthewindingsandnotjustthetemperatureoftheinsulatingoilthatsurroundsandcoolsthosewindings.
Beforeconductingthesimulation,youwillneedtolocateand/orverifythefollowing:

1. Topoiltemperatureindicationforareferenceorstartingpoint
2. Sometypeoftransformerloadreference
3. Adevicetofinetunethatloadreference
4. Awayofapplyingatemperaturebiasbasedonthetransformersload
5. Theactualgradientvaluewhichcomesfromthemanufacturersheatrunortemperaturerisetestataknownloadpoint.
1.Topoiltemperature
Usinganotheroiltemperatureindicator,havethefaceplatereadHV,LVorTVWindingTemperature.ThesearenormallyreferredtointheANSI/IEEEstandarddeviceclassification
asa26device.Inthiscasewereusingitasatransformerthermalrelaysoitstruedesignationwillbea49deviceasdescribedbyIEEEstandardsbelow:
IEEEStdC37.22008IEEEStandardforElectricalPowerSystemDeviceFunctionNumbers,Acronyms,andContactDesignationsareasfollows:
3.1.26Devicenumber26apparatusthermaldeviceAdevicethatfunctionswhenthetemperatureoftheprotectedapparatus(otherthantheloadcarryingwindingsofmachines
andtransformersascoveredbydevicefunctionnumber49),orthatofaliquidorothermedium,exceedsapredeterminedvalueorwhenthetemperatureoftheprotectedapparatus
orthatofaliquidorothermedium,exceedsapredeterminedvalueordecreasesbelowapredeterminedvalue.
3.1.49Devicenumber49machineortransformerthermalrelayAdevicethatfunctionswhenthetemperatureofamachinearmaturewindingorotherloadcarryingwindingor
elementofamachineorpowertransformerexceedsapredeterminedvalue.
2.LoadReference
Loadreferenceisdonebytheuseofacurrenttransformer(CT).This(HotSpot)CTwillbeasingleratioCTandthatratioisspecifiedbythetransformermanufacturertosomewhat
matchthecurrentofthephaseorlegitsmonitoring.
3.Deviceforfinetuningtheloadreference
TheloadreferencewillbeintheformofthesecondarycurrentfromtheaboveCT.Thoughthissecondarycurrentwillremainproportionaltotheloadingofthetransformeritsnotof
muchuseatthispoint.Youwillneedtoadjustthesecondarycurrenttogivetheexacttemperaturebiasneededbyusingsometypeofcalibrationuniteitheranadjustableresistoror
asmallmultitapautotransformer.Thisdevicewillserveasthecalibratingmechanismforthewholesystem.

4.Applyingthetemperaturebias
Theeasiestwaytoaffectthereadingofatemperatureprobeistoheatit,usingtheheatercoilinsidethewellsofthermalplatesonthetransformertankwallsortankcover.
Youcantellthiswellisforthewindingtemperatureifithassomeformofconduitrunningtoit.InsidetheconduitaretheconductorsthatwillcarrythenowcalibratedCTsecondary
currenttotheheatercoil.
InthecaseoftheQualitrolthermalplates,thewindingtemperatureprobewellsaremarkedwitha(WT)forwindingtemperatureandan(LT)forliquidtemperature.Becertainnotto
confusethemwhencheckingthecalibrationoftheindicators,themselves.

5.ActualTemp
Thetemperaturegradientisfoundinthefactorytestreportsandshouldalreadybeappliedbythesettingofthecalibrationunit.
Thetablebelowisfromatemperaturerisetestofa55MVAtransformerduringtheFAT(factoryacceptancetests).
a.TerminalsX2X0telluswhichnumberstoreference.
b.Averagewindingtempatshutdown,subtractedby,Averageoiltemperatureatshutdown,plusthefactories3CconstantequalsaGradientof14.85CThisissayingthatthis
windingisrunning14.85Chotterthanthetopoiltemperaturewhenthetransformerisatfullload.Thisunitisa55MVA/15MVA,19.1kV/4.16kV,Dyn1Auxunit.

Nowyouarereadytocheckthesystemandmakesureeverythingisworkingproperly.
YouwillneedawayofsimulatingthesecondarycurrentofanenergizedCT.Therearemanychoicesincludingatopoftheline,DobleF2253allthewaydowntoapoorman's
special(lightbulbs,clamponampmeterandadimmerswitch).

Regardlessofwhatcurrentsourceyouuse,youllneedtoknowthecorrectamountofcurrenttoapplytothewindingsimulationsystemanditsheatsource.
Tofindthisout,youneedtoknowafewthingsaboutthetransformer:

1. TheHotSpotCTslocation(Figure5)
2. TheHotSpotCTsratio(Figure5)
3. ThecurrentataknownloadonthatCT(Figure6)

NowwellcalculatetheactualsecondarycurrentthattheHotSpotCTwillproducetakingtheseitemsintoconsideration.

1. CurrentonLV(X)at15MVAisshowntobe2,081.8amps
2. HotSpotCTratiois2090:5amps
Hereishowyoucalculatethesecondarycurrent:

TaketheknowncurrentmultipliedbyCTsecondary(2081.8*5)
ThendividetheproductbytheCTprimary(10,409/2090)
Theanswer=4.98amps
Now,youknowthatwhentheLV(X)isat15MVA,thesecondarycurrentoftheHotSpotCTwillbe4.98amps.Yourcurrentsourcehastobeabletosupplythe4.98ampstothe
terminalswheretheHotSpotCTsS1&S2leadsland.Youalsoknowthataccordingtothemanufacturer'stemperaturerisetest,thetemperaturegradientontheLVwindingis14.85
C.
Nowitistimetocalculatehowmuchcurrentyouwillneedtoactuallyapplytothewindingtemperaturesimulationssystemsheatsourcebyadjustingthecalibrationunit.
First,lookatthedevicesshowninfigure1andfigure2andhowtheyreadjustedtogetthecurrentweneed.
Fortheadjustableresistor:youwillusetheformula:
R=(4.9*Ih)/(IctIh)

R=Resistancevaluetosettheadjustableresistor.
4.9=Constant.
Ict=HotSpotCTsecondarycurrentatknownload.
Ih=Heatercurrentrequired
Nowfillintheformulawithourknownvalues:

R=(4.9*0.730)/(4.980.730)
R=(3.577)/(4.25)
R=0.841
Theadjustableresistorshouldsettoaresistancevalueof0.841Ohms.
Forthemultitapautotransformer:
Theconnectiondiagramwithinputandoutputratioswillhelpyouunderstandthemultitapautotransformer.
CurrentfromtheHotSpotCTisinjectedintotheX1andX2terminals(normally)andtheadjustedcurrentispickeduponanytwotapcombinationsbasedontheoutputcurrent
needed.
Example:
X1(tap1)toX2(tap5)have75.5turns.
Tap2totap7hasatotalof(14+13+31.5+3+3=)64.5turns.
Thatsaratioof1.171:1
4.98ampsfeedingintoX1&X2=4.252ampsontaps2&7.
4.98ampsfeedingintoX1&X2=4.45ampsontaps2&8.
(Caution,besureyourinjectingcurrentintothecorrectsideofthetransformer.)

Hereswhy:
4.98ampsintotaps4&5=13.36ampsontaps1&8!

NowthatNowthatyouknowhowtoadjustyourcurrentoutputupordown,youwillneedtofindthecorrectcurrenttoapplytotheheatercoil.First,youwillneedtolookattheheater
coilandseewhichheateryouhaveandwhatitsresistanceis.EachoftheQualitrolheaterswillhavetheirowncharacteristiccurve.

OnceyoumatchupyourheatertooneofthethreechartsbelowyoullthenneedtofindthetemperatureriseorgradientintheYaxisofthechartandtraceitacrosstothesolid
curvedlineandthentracestraightdowntothebottomorXaxisforthedesiredcurrenttobeinjectedintotheheater.
Keepingwithyourcurrentgradientof14.85CInthetransformeryouseea6091heaterelement.Referingtofigure10,followthe14.85Cacross,thentracedownyouwillseea
heatercoilcurrentof4.4amps.Thedashedlinesshowthepossibleerrorordeviationfromthechart.Therewillbesometrialanderrorwhensettingthisforthefirsttime.

Basedonthisinformation,ifyouareinjecting4.8ampsintotaps1and5,youwillget4.45ampsoutoftaps2and8.Usingthisinformation,youcanadjustthecurrentupordown
dependingonwhatthegaugereads.
Note:Foroilbulbtypetemperatureindicators,youwillneedtoletitcookforatleast30minutestogetagoodgradientreading.Qualitrolrecommendsafullthreehourstoallowthe
gaugetosettleout.Inthefirsthalfhouryouwillknowifyouareclose.Figure13belowillustratesatimeconstantcurveshowinghowfastthegaugewillrespondtotheheatgenerated
bytheheatercoil.

Insummary
Foranalogtypetemperaturegauges:Series104

1. Checkyourtransformertoseewhatdevicesitisusingforitswindingtemperaturesimulationsystem.
2. CalculatethesecondarycurrentofthehotspotCT.
3. Locateorcalculateyourtransformerstemperaturegradient.
4. Verifythesettingstothematchingunit,resistorortransformer.
5. Withthetransformerdeenergized,liftthehotspotCTsecondarywiresandrelatedgroundwiresandshortingscrews.
6. Landyourcurrentsourcewiresintheirplace.
7. Recordyourtopoilandwindingtemperaturebeforeinjectingcurrent.
8. Injectthecalculatedhotspotsecondarycurrent.

9. In30minutescheckyourwindingtemperature.Ifitsclose,proceed.Ifnot,killthepowerandreadjustthematchingunit.Givethebulbtimetocooloffbeforestartingthetest
again.
10. Onceyouhavereadjustedthematchingunitandthebulbhascooledbackdown,injectthesamecurrentagainintothesimulationsystem.
11. Atthe30minutemark,ifitsclose,keepgoingandinthreehoursrecordyourheatedwindingtemperature.
12. Nowsubtractyourunheatedtemperaturefromyourheatedtemperatureandthiswillbeyourmeasuredgradient.
Lookingatthetestunitagain:
Theunheatedwindingtemperatureindicatorread23C.
Thesamegaugeheatedforthreehoursnowreads38C.

38C23C=15C
Thegradientwas14.85C
Thatisadeviationof0.15C.Generallyadeviationof+/2.5Cisacceptable.
Fortheelectronictemperaturemonitors:
509,TTC1000,WeschlerAdvantage,etc.

1. Refertosteps2,3and5above.
2. Verifythegradient,hotspotCTratioandtransformerloadcurrentarecorrectlyenteredintothecontrollerssoftware.
3. Injectcurrentasdescribedabove,butyouwillpasscurrentthroughthewindowofthesplitcoreCToftheelectronictemperaturemonitor(ETM).AwireisusuallyloopedfromS1
toS2forthis.
4. Theelectronicmonitorsdonotneedthe3hourcooktime.Inthesoftwareyoucanchangethetimeconstanttozero(0)fortestingbutchangeitbackwhenyouaredone.
5. Thegradientisdisplayedinstantly.
DANGER/HAZARDOUSVOLTAGE:Alwaysuseextremecautionwhenworkingwithelectricityorelectricalequipment.Alwaysproperlydeenergizeandgroundthe
equipmentbeforemaintenance.Maintenanceworkshouldonlybeperformedbyqualifiedandproperlytrainedpersonnel.Theuseofunauthorizedpartsintherepair
ormaintenanceoftheequipmentortamperingbyunqualifiedpersonnelwillresultindangerousconditionswhichcouldresultindeath,severeinjuryorequipment
damage.
Theinformationcontainedhereinisgeneralinnatureandtheinstructionscontainedhereindonotpurporttocoveralldetailsorvariationsinequipment.The
instructionsarenotintendedtoprovideeverypossiblecontingencywhichmaybeencounteredduringinstallation,operationormaintenance.Usersshouldalways
usesoundpracticesinapplication,installation,operationandmaintenanceoftheequipment.Shouldfurtherinformationbedesiredorshouldparticularproblems
arisethatarenotcoveredsufficientlyfortheuser'spurposes,additionalinformationshouldberequestedfromyourlocalSiemensrepresentative.Siemensreserves
therighttomakechangesintheinformationshownhereinortomakeimprovementsatanytimewithoutnoticeorobligations.

09/01/2011
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