Académique Documents
Professionnel Documents
Culture Documents
VOLUME 2
Power nansformers
Authors A. W Goldman and C. G. Pebler
Written by
Stone & Webster Engineering Corporation
245 Summer Street
Boston. Massachusetts 02107
D. K. Sharma
Ordering Information
Requests for copies of this series should be directed
to Research Reports Center (RRC), P.O. Box 50490,
Palo Alto, CA 94303, (415) 965-4081.
For further information on EPRI's technical programs contact the EPRI Thchnical Information Division at (415) 855-2411, or write directly to EPRI's
Thchnical Information Center at P.O. Box 10412, Palo
Alto, CA 94303.
EL-5036, Volume 2
Project 2334
ISBN 0-8033-5001-5 volume
ISBN 0-8033-5015-5 series
Topics: Power transformers
'Ii"ansformer ratings
Taps and connections
Station auxiliary systems
Installation and maintenance
Voltage regulation
Notice
This series was prepared by Stone &. Webster Engineering
Corporation as an account of work sponsored by the Electric Power Research Institute, Inc. (EPRI). Neither EPRI,
members of EPRI, Stone &, Webster Engineering Corporation, nor any person acting on behalf of any of them:
(a) makes any warranty, express or implied, with respect to
the use of any information, apparatus, method, or process
disclosed in this series or that such use may not infringe
privately owned rights, or (b) assumes any liabilities with
respect to the use of, or for damages resulting from the
use of, any information, apparatus, method, or process disclosed in this series.
FOREWORD
In the past, several electrical equipment manufacturers published reference books dealing with
specific technical areas. Many utilities have stated
that these reference books have been very useful
to them in dealing with plant emergencies and in
making decisions on design, system planning, and
preventive maintenance.
Unfortunately, manufacturers today seldom
publish or update reference books on electric
power apparatus, mainly because of tighter budget constraints. Until now, utilities have had no upto-date industrywide practical reference manual
covering the various electric power apparatus and
electrical phenomena commonly encountered in
power plants. The Power Plant Electrical Reference Series was planned to fill this need.
EPRI believes that the series will save utilities
time and money. It will aid plant engineers in
Prevention of forced outages through proper
installation, application, and protection of
station auxiliary equipment
Recognition of potential problems and their
prevention
Selection of appropriate methods of maintenance to ensure trouble-free equipment
operation
Reduction of equipment installation time and
expense
Proper specification of equipment being
ordered
Better coordination and integration of system
components
This volume deals with power transformers. A
power transformer connects the generator to the
high-voltage transmission system. Another power
transformer connects the generator to the plant
medium-voltage auxiliary power system. 'Iransformer impedance is the major factor in the voltage regulation of the auxiliary power system, as
well as in the short-circuit duty of the switchgear.
Selection of transformers for use in power stations
requires knowledge of the power system and various parameters.
A wealth of information about transformers is
available in the transactions of the IEEE and in the
ABSTRACT
The unit transformer in a generating station connects the electric power output of the generating
unit to the high-voltage electric transmission gridi
the unit auxiliaries transformer, station service
transformer, and secondary-unit substation transformers supply the electric auxiliaries required for
operation of the power plant. In the lower range
of sizes, power transformers may be of standard
design types, but many of the transformers used
in power plants and all of the larger ones are
custom-designed-similar, but seldom identical, to
others built previously. This volume covers the
practical aspects of the selection, specification, installation, operation, testing, and maintenance of
these power transformers.
lransformer designs of particular interest to
power plant operators include liquid-immersed,
dry-type, and vapor-cooled transformers ranging
in size from 500 kVA to 1200 MVA. The function
and application of each design are described in
detail, from load considerations to noise criteria.
Photographs show the various types of oilpreservation systems, transformer connections,
and bushings. A variety of gages, monitors, and
indicators may be provided for liquid-immersed
transformersi these accessories are also discussed.
ACKNOWLEDGMENTS
&. Power
J. A. Maxwell, Georgia Power Company
W. L. Nail, Jr., Mississippi Power&. Light Company
D. G. Owen, Duke Power Company
Oklahoma
J. E. Stoner, Jr., Duke Power Company
CONTENTS
SECTION
PAGE
SECTION
2.10
2.11
2.12
............... 2-3
2.13
2.7
Application
Considerations ............. 2--22Maximum Sustained Load ....... 2--2-2Altitude ...................... 2-25
Ambient Thmperature .......... 2--25
Number of Windings ........... 2-2-5
Voltage Ratings and
Overexcitation ............... 2--25
'Iransient Overvoltage .......... 226
Load Current Waveform ........ 2-26
Harmonic Current Derating ..... 2-27
Impedance Voltage and
Regulation .................. 2-28
Impedance and Through-Faults .. 2-29
Phasing Out Three-Phase
Circuits .................... 2-29
Loss Evaluation ............... 2-30
Noise Criteria ................. 2-30
Acronyms &
Abbreviations ............... 2-xvii
2.1
PAGE
2.14
2-x
CONTENTS
SECTION
2.15
PAGE
2.16
2.17
2.18
2.19
FIGURES
FIGURE
PAGE
FIGURE
PAGE
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-6
2-7
2-25
2-26
. 2-8
2-9
2-10
2-11
2-12
2-13
2-3
2-4
2-5
2-15
2-16
TABLES
PAGE
TABLE
EXECUTIVE SUMMARY
Power transformers are used in generating stations to connect the main generator to the highvoltage transmission system and to connect
sources of electric power to distribution subsystems for operation of plant auxiliary electrical
equipment at medium- and low-voltage levels. The
proper selection of transformers for each application requires a knowledge of the types available
and their range of applicability. It also requires a
knowledge of terms, conventions, tolerances, and
factory tests as established in industry standards.
Background
Power plant electrical equipment operating at ac
voltages of 120, 460, 575, 4000, 6600, or 13,200 V
receives its power from higher-voltage sources: the
main generator and the switchyard. 'fransformers,
which are located near the load (where possible),
interconnect the voltage levels. Although the
smaller sizes of power transformers may be of
standard design types, the larger ones are customdesigned and similar, but seldom identical, to
others. This book provides practical guidance in
the selection of this equipment.
Objectives
This volume will provide power station engineers
with a background of transformer knowledge that
will enable them to apply transformers correctly,
assist in understanding existing standards and the
various options required for power transformer selection, and provide guidance to power plant personnel in planning inspection and testing programs.
Approach
A national survey of utility requirements yielded
pertinent information, and a search of available
literature on power transformers identified specific information pertaining to power plant
applications. The EPRI Review Committee, with
members from 11 utilities throughout the United
States, and other industry experts reviewed the
material for accuracy and completeness. The
resulting information was the basis for this volume
of the Power Plant Electrical Reference Series.
Results
The information in this volume will help in the
selection of power transformers in sizes from
500 kVA to 1200 MVA for power plant use. Specific application information will aid the engineering and operations departments of generating
facilities in selecting new and replacement
equipment.
ACRONYMS
&
ABBREVIATIONS
AA
transformer cooling method: ventilated
ac
alternating current
ANSI American National Standards Institute
BIL
Btu
CI
em
dB
dBA
de
decibe!(s)
adjusted decibel(s)
direct current
EHV
f
FA
FOA
FOB
FOW
gram(s)
hp
h
HV
HVAC
horsepower
hour(s)
high voltage
heating, ventilating, and air conditioning
hertz
Hz
I
IEEE
IROR
k
kV
kVA
kW
LTC
LV
meter(s)
m
milligram(s)
mg
MVA megavolt-ampere(s)
MVAR megavolt-ampere(s)-reactive
N
N1
newton(s)
number of years between the price year
and the year of tiTSt commercial operation
(Eq. A-1)
N2
OA
rms
resistance
transformer regulation
radio influence voltage
root-mean-square
SCR
SST
short-circuit ratio
station service transformer
UAT
UT
volt(s)
REG
RIV
VOLUME 2
POWER TRANSFORMERS
A. W. Goldman and C. G. Pebler
2.1 INTRODUCTION
Power-transformers are used in power plants to
connect the main generator to the high-voltage
(HV) transmission system and to connect sources
of auxiliary power to distribution subsystems for
plant auxiliary electrical equipment at lower voltage levels. Since they are basically static devices,
they require less maintenance than most of the
other apparatus. It is important, however, (1) that
each transformer be selected properly for the intended application; (2) that it be protected from
voltage surges, external short circuits, and
prolonged overload; and (3) that it be inspected,
maintained, and tested on a routine basis.
The power transformers of particular interest
to the designers and operators of power plants
range in size from 500 kVA to 1200 MVA in threephase designs and from 500 kVA to 550 MVA in
single-phase designs. 'fransformers installed inside
a building may be dry-type, resin encapsulated,
or liquid immersed in high-fire point or low-heat
release insulating fluids. 'fransformers installed
outdoors are generally mineral oil immersed.
In the lower size range the transformers may
be of repetitive design, but many of the transformers used in power plants and all of the larger ones
are custom designed-similar, but seldom identical, to others built previously.
'fransformer power and energy losses, though
relatively small, are of interest to the user for two
reasons: They cause increased fuel consumption,
and they result in heat release. The fuel consumed
in generating the loss of energy is an important
item in operating cost. The heat must be removed
and dissipated by some combination of conduction, convection, and radiation. "Self-cooled" transformers do not require any power-driven cooling
auxiliaries. Forced-cooled transformers employ
forced-water or forced-air cooling and may also
use pumps to circulate the insulating fluid. The
addition of rotating machinery to an otherwise
static device reduces the physical size and initial
cost of the transformer for a specific output
rating, but it may also reduce reliability and increase maintenance cost and losses.
Oil-immersed transformers require oil preservation systems to exclude oxygen and water vapor;
this retards sludging and deterioration of dielectric properties. Gas formation under oil may indicate local hot spots or decomposition of solid
insulating materials. For this reason gas monitors
are often installed to detect and collect generated
gases for laboratory analysis. 'fransformer oil
should be sampled and tested at regular intervals.
The analysis of both the collected gas and the oil
samples provides warning of abnormal conditions.
Power transformers are factory tested to ensure
quality of design and manufacture and to demonstrate their ability to meet performance requirements. Data obtained during such tests may also
provide benchmarks for later field tests.
A large transformer may be damaged by improper handling during loading, shipment, on-site
storage, testing, or installation. These operations
warrant meticulous attention.
The application of the above material to unit
transformers (U'Th), unit auxiliaries transformers
(UA'Th), station service transformers (SS'Th), and
secondary unit substation transformers is covered
under appropriate headings in this volume.
2-2
+
(Eq. 2-1)
harmonic factor
(for current)
-+-P"
7 _+___
I1
Hot spot temperature The highest temperature inside the transformer winding. It is greater than the average temperature (measured using the resistance change
method) of the coil conductors.
Hysteresis loss The energy loss in magnetic material
that results from an alternating magnetic field as the
elementary magnets within the material seek to align
themselves with the reversing magnetic field.
Impedance voltage The voltage required to circulate
rated current through one of two specified windings
of a transformer when the other winding is shortcircuited, with the windings connected as for rated voltage operation. It is usually expressed in per unit, or percent, of the rated voltage of the winding in which the
voltage is measured.
Insulation level An insulated strength expressed in
terms of a withstand voltage.
Insulation power factor The ratio of the power dissipated in the insulation, in watts, to the product of
effective voltage and current, in voltamperes, when
tested under a sinusoidal voltage and prescribed
conditions.
Lightning impulse insulation level An insulation
level, expressed in kilovolts, of the crest value of a lightning impulse withstand voltage.
Liquid-immersed transformer A transformer in
which the core and coils are immersed in an insulating
liquid.
Load tap changer (LTC) A selector switch device,
which may include current-interrupting contactors,
used to change transformer taps with the transformer
energized and carrying full load.
No-load tap changer A selector switch device used
to change transformer taps with the transformer
deenergized.
POWER TRANSFORMERS
Temperature rise The difference between the temperature of the part under consideration (commonly the
"average winding rise'' or the "hottest spot winding rise'')
and the ambient temperature.
'Iransient overvoltage The peak voltage during the
transient conditions resulting from the operation of a
switching device.
Unit auxiliaries transformer (UAT) A transformer
intended primarily to supply all or a portion of the unit
auxiliaries.
Unit transformer (UT) A power system supply transformer that transforms all or a portion of the unit power
from the unit to the power system.
Withstand voltage The voltage that electrical equipment is capable of withstanding without failure or disruptive discharge when tested under specified
conditions.
LIQUID-IMMERSED TRANSFORMERS
A liquid-immersed transformer consists of a magnetic core-and-coils assembly, either single-phase
or polyphase, immersed in fluid having good heat
transfer and insulating properties. The liquidimmersed transformer permits compact design,
and at this time transformers with ratings above
10,000 kVA or 34.5 kV are always liquid immersed.
Initially, the fluid was always a highly refined
mineral oil. Since such oils are flammable, liquidimmersed transformers located within buildings
were installed in fireproof vaults. Later, nonflammable fluids were developed for this application,
the most common being an askarel, polychlorinated biphenyl (PCB). These fluids have high
specific inductive capacitance (also called relative
dielectric constant or relative capacity) and good
heat transfer properties but are more expensive
and have lower dielectric strength than mineral
oil. The Toxic Substances Control Act of 1976 (1)
and the Code of Federal Regulations (2) now prohibit the manufacture of PCBs and limit the use
of PCB-bearing equipment. The federal regulation
specifies rigid rules and requirements for marking
PCB-bearing equipment in service and for disposing of PCB-bearing equipment and contaminated
materials resulting _from liquid spills (3).
2-3
DRY-TYPE TRANSFORMERS
Dry-type transformers are generally more expensive than oil-immersed transformers and depend
on solid insulation-film coatings, paper tape, or
a combination of the two-for most of their dielectric strength. Single-phase and polyphase drytype transformers are available in ventilated
designs, totally enclosed nonventilated designs,
sealed-tank designs, and gas-filled designs, the
ventilated type being least expensive. Their ability to withstand lightning and switching surge
impulse voltages is less than that of liquidimmersed designs. It may therefore be prudent to
protect their HV terminals with surge arresters,
even when the external leads to these terminals
are not directly exposed to lightning.
Ventilated dry-type transformers are suitable for
most applications inside buildings. In atmospheres
heavily loaded with dust or fibers, however, they
must be cleaned at regular intervals to keep their
ventilation passages clear. This type may be
equipped with fans to increase their kilovoltampere rating by 33%%. They have the lowest initial
cost of any in the family of dry-type transformers.
2-4
Totally enclosed, nonventilated dry-type transformers are suitable for use in moderately contaminated industrial environments. Because they
are nonventilated, they are designed to have low
heat losses-that is, very high efficiencies.
Sealed-tank transformers have the ability to
function in the severest environments. They have
their own sealed atmosphere and can function in
misty, oil-laden, dusty, highly contaminated areas.
Tnese transformers also have high efficiencies because of the necessity of having low heat losses.
Dry-type transformers are currently available in
self-cooled ratings up to 10,000 kVA and at voltages
up to 34.5 kV.
A variant of the dry-type transformer that is resin
encapsulated has been introduced recently. In one
form of this design, "cast-coil;' the coil is placed
in a mold and the resin coating is cast around it.
These transformers are available in sizes up to
5,000 kVA and voltages up to 34.5 kV. In another
form the coils are dipped in resin. The resinencapsulated design may be used in harsh environments where ventilated dry-types may not be
suitable. Although their initial cost is higher than
other dry-types, they may nevertheless be economical in high-load factor applications because of
their lower load losses (Volume 7, Au;te.iliary Electrical Equipment).
Some of the resins used in earlier resinencapsulated transformers gave off vapors at high
temperatures that were found to be flammable,
toxic, or both. In more recent designs these concerns have been resolved by tests and analysis of
the vapors showing them not to be harmful (4).
The application of a ventilated dry-type versus
a nonventilated dry-type or a sealed, gas-filled drytype transformer involves economic and environmental considerations (clean, dust-laden, wet, or
highly contaminated atmosphere). The gas-filled
transformer has the highest initial cost.
The application of a ventilated dry-type versus
a ventilated, encapsulated dry-type transformer
also involves these considerations.
Volume 7, Section 7.5 gives a comparison of the
relative equipment costs of the various dry-type
transformers.
POWER TRANSFORMERS
temperature and with suitable allowance for hottest spot difference, is within the long-time withstand capability of the insulating materials. For
liquid-immersed transformers, that rise is 65C
(15C hot spot allowance). Liquid-immersed transformers are now rated for 65C rise. Many transformers having 55/65C-rise ratings, however, are
still in service. Both designs are suitable for continuous operation at their 65C-rise ratings. The
difference between them is that the performance
characteristics, full-load losses, and impedance
voltage drop for the 55/65C-rise transformer are
based on 55C-rise loading. Where a transformer
must operate in a higher-than-usual ambient temperature, it is customary to specify a reduced temperature rise. The result is a larger transformer
that under "usual operating conditions;' carries
more load. For example, if the temperature rise
of a liquid-immersed transformer is specified as
55C, the permissible load increase under 30C
conditions that permit a 65C rise will be 12%.
The average temperature winding rise for drytype transformers, depending on the insulation
system, may be 80C, l15C, or 150C (all with
30C hot spot allowance) (6).
2-5
LIQUID-IMMERSED TRANSFORMERS
Liquid-immersed transformers larger than 500 kVA
may have both a self-cooled rating and one or two
additional forced-cooled ratings. The rating increase
produced by forced cooling varies with transformer
size, as shown in 'Th.ble 2-1 (8). At 20,000 kVA and
above transformers may have a single forcedcooled rating and no self-cooled rating.
2-6
Table 2.1
Type of
Cooling
OA!FA
Self-cooled kVA
Single
Phase
Three
Phase
P-ercent of Self-cooled
kVA Wrth Auxiliary
Cooling
First Stage
Second Stage
501-2499
2500-9999
10,000 and up
501-2499
2500-11 ,999
12,000 and up
115
125
133%
1000 and up
133%
12,000 and up
133%
AA/FA
OA/FA/FA
- OA/FA!FOA
Forced-cooled Ratings
10,000 and up
166'%
The standard method of indicating these multiple ratings is to list the rating(s), followed by the
corresponding cooling method(s). For example:
2000/2300 kVA, OAIFA indicates a transformer with a self-cooled (OA) rating of
2000 kVA and a forced-air-cooled (FA) rating
of 2300 kVA.
12,000/16,000/20,000 kVA indicates a transformer with a self-cooled rating and two
stages of forced cooling. Such transformers
have large radiators to produce thermosiphon circulation of the oil in the self-cooled
mode. They have two banks of fans and oil
pumps. These transformers are indicated as
follows:
o OAIFAIFA indicates that both the first stage
and the second stage of forced cooling use
forced air. The first stage uses half of the
available fans (one bank); the second stage
uses all available fans (both banks).
o OAIFAJFOA indicates that the first stage of
forced cooling uses forced air and the second stage uses forced oil and forced air.
o OA!FOAJFOA indicates that both the first
stage and the second stage of forced cooling use forced oil and forced air. The first
stage uses half of the available fans and oil
pumps (one bank); the second stage uses
all available fans and pumps (both banks).
25,000 kVA, FOA indicates a transformer
with no self-cooled rating. It has compact
coolers in place of radiators and cannot remain energized, even at no load, without its
fans and pumps in operation. Nevertheless,
most UTh and many UATh are of the FOA
POWER TRANSFORMERS
WATER-COOLED TRANSFORMERS
Forced-water-cooled (FOW) transformers are
often used instead of FOA types at hydroelectric
plants because of the ready availability of cooling
water. They are also often used at underground
hydro or pumped storage plants, where the transformers must be underground to be near the
equipment they serve. Large power transformers
have also been enclosed in masonry vaults for
noise control purposes. In such cases water cooling may be the only feasible method of heat dissipation. Because of concern for water leakage into
the oil, however, such transformers have specially
designed heat exchangers with double tube sheets
and concentric tubes to provide two metal barriers between the two fluids. In this design the
neutral space between the metal barriers can be
monitored and an alarm actuated if either barrier
begins to leak.
DRY-TYPE TRANSFORMERS
All dry-type power transformers have self-cooled
ratings. Those commonly used indoors in power
plants are ventilated (rated AA). Some are
equipped with fans to give them a dual rating
(AA!FA). A common size for LV secondary unit substation transformers is 1000/1333 kVA, AAIFA. Note
that the forced-cooled rating is one-third larger
than the self-cooled rating.
2.7 LOSSES
'Iransformers are very efficient. Large liquidimmersed transformers may have efficiencies
higher than 99%. Nevertheless, it may be worthwhile to pay an initial price premium for loss
reduction, which will result in still higher efficiency.
'Iransformer losses can be divided into three
general categories: no-load losses, load losses, and,
for forced-cooled transformers, cooling-system
losses. The no-load losses are mainly core hysteresis
and eddy-current losses, which are incurred as
long as the transformer is energized. They remain
essentially constant. The load losses are due to the
heating of winding conductors by the passage of
current and by other stray losses in conductors
and tank walls, which are load related. These losses
increase as the square of load current. The cooling
2-7
system losses are power used to drive the mechanical cooling auxiliaries-fans and oil pumpswhere these auxiliaries are present.
In medium and large power transformers the
load losses are much greater than the no-load
losses. The ratio of load losses to no-load losses
will be influenced by the loss evaluation figures
in the purchaser's bidding documents. 1b simplify
a generalization of available data, one can compare values on the basis of core-and-coils rating.
On this basis a 20-MVA FOA transformer, a
12/16-MVA OAIFA transformer, and a 12/16/2Q-MVA
OAIFOAIFOA transformer are directly comparable.
At 12 MVA such a transformer would have a
ratio of load losses to no-load losses on the order
of 3.5:1. At 16 MVA this ratio would be greater by
a factor of 1. 777; and at 20 MVA (if permissible)
the factor would be 2.779.
Very large pbwer transformers, nearly always
FOA, have loss ratios on the order of 7:1. Lower
ratios might be economical in many cases, but
such ratios may not be achievable within shipping
limitations.
EVALUATION METHOD
Loss evaluation is the process of estimating the
amount of initial outlay justified to avoid future
costs. Specifically, it answers the questions: "What
price premium are we justified in paying to reduce
transformer no-load loss by 1 kW? What premium
for 1 kW of load loss?" When the initial cost premium (a single payment amount) is compared with
the future costs avoided thereby (a nonuniform
series of annual amounts), it is convenient to use
life-cycle cost methods, which convert all cash
flows to present worth. It is, for example, not
justifiable to spend $100 today to avoid a $100 expense ten years from today; a far smaller amount
invested in some other aspect of the company's
business would grow to $100 in ten years. It is the
smaller amount that is the present value of the
future cost.
Loss evaluation seeks to determine how much
the purchaser would be justified in paying for the
transformers to reduce no-load loss by 1 kW and
how much per kilowatt for a similar reduction in
load loss. Since the premium would be a single
payment on delivery and the savings that justify
it are a nonuniform series of future costs, their
equivalence must be found by present-worth
methods. These methods, which involve the capital structure of the company, the estimated loading schedule for the transformer, and the present
2-8
Three-phase,
650C MVA Rating
Up to 138
161 to 230
Above 230
Up to 67.2 OA
or 112 FOA
sealed-tank
inert gas
modified
conservator
Above 67.2 OA
or 112 FOA
modified
conservator
modified
conservator
modified
conservator
SEALED-TANK SYSTEM
In the sealed-tank system the interior of the tank
is sealed from the atmosphere. The gas-plus-oil vol-
POWER TRANSFORMERS
2-9
Figure 21
210
..
.f
- - - - - .>
.......----
Pa.
POWER TRANSFORMERS
2-11
Figure 2-3
A VAT, also called a normal station service transformer, is one (usually fed from the main generator leads) that supplies power to the unit
auxiliaries.
An SST, also called a reserve station service
transformer or startup transformer, is one that
supplies power from a station HV bus to the plant
auxiliaries.
The phasing relationship between primary and
secondary windings of a three-phase transformer
is expressed in terms of terminal designations, for
which the standard convention is as follows: If one
is facing the LV side of the transformer, the HV
terminals are Hl, H2, and H3 from left to right and
the LV terminals are Xl, X2, and X3 from left to
right, as shown in Figure 2-4. More extensive information may be obtained from Reference 9.
'Iransformer winding phase relationships are
shown on the transformer nameplate.
2-12
H1
X1
X3<J
X2
A
A
H2
H3
H1
X1
X2
X3
X1
X3<J
H2
H3
H1
H3<J
X2
H2
a
a
X1 XZ X3
XO X1 X2 X3
X1 XZ X3
Figure 2-4 Transformer Terminal Designation in Accordance With ANSI Standard C57.12.7D-1978
wye-zigzag transformer, unless otherwise specified, the secondary voltages at terminals Hl, H2,
and H3 lead the primary voltages at terminals Xl,
X2, and X3, respectively, by 30 electrical degrees
(Figure 2-5).
The grounded wye connection of the HV winding permits grading its insulation from specified
BIT. at the terminals to a lower BIT. at the grounded
neutral. The delta connection of the LV windings
provides a low-impedance path for zero-sequence
and third-harmonic currents, thereby facilitating
selective relay tripping for single phase-to-ground
faults on the HV system and improving secondary
voltage waveform. The UT primary is usually impedance grounded at the generator neutral. For
other types of transformer neutral grounding see
Volume 8, Station Protection.
UATs
UA'IS are most frequently connected in delta on
the primary side and in wye on the secondary side
but with Hl, H2, and H3 voltages lagging Xl, X2,
and X3 voltages by 30 electrical degrees. The wyeconnected LV windings permit some form of neutral grounding to facilitate selective relay tripping
for single phase-to-ground faults on the mediumvoltage auxiliary power system. The lagging phase
SSTs
SS'Th are usually connected in grounded wye on
the HV side to permit the use of graded insulation. The LV windings may also be wye connected
to provide for a three-phase, four-wire system or
for neutral grounding. If the source of the SST is
the same HV bus as the one receiving the generator output, the phasing shown in Figure 2-5c may
be used. This connection results in a secondary
voltage in phase with the output of a UAT phased
as shown in Figure 2-5b.
A wye-wye transformer in this application does
not necessarily require a delta tertiary to provide
a low-impedance path for zero-sequence currents.
A three-legged core design, most frequently
offered in this size range, provides a virtual tertiary sufficiently well coupled to the other windings to present a low impedance as compared with
the neutral grounding resistor usually applied on
the secondary side.
If the HV source is different from the one to
which the UT is connected, it may be necessary
to use a delta-connected secondary for correct
POWER TRANSFORMERS
213
X1
H1
H1
H3<J
X2
Secondary
Primary
Secondary
Primary
H2
H2
H3
xo
a. Unit transformer
X1
H1
X1
H1
xo
X3
H2
H3
H2
Primary
Secondary
Primary
Secondary
X1
X1
H1
xo
Primary
X3
Primary
Secondary
H3
H2
Secondary
H2
X2
X1
X1
H1
H3
H2
X2
Primary
Secondary
Figure 2-5
phasing, in which case a separate grounding transformer is required to derive a neutral. Alternatively,
a zigzag-connected secondary can provide the
same phasing as a delta and would provide the neutral, but it may be the more expensive alternative
2-14
GROUNDING TRANSFORMERS
A zigzag-connected autotransformer may be used
on a three-wire system to derive a neutral for
grounding. The T connection is sometimes preferred when there are no phase-to-neutral loads,
because it permits the use of a two-legged core
with a single winding on each core leg, resulting
in a less expensive design. The neutral connection
is made to a tap on the stem of the T (Figure 2-5h).
2.10 TAPS
A power transformer may have taps in either primary or secondary windings so that its effective
turns ratio may be changed. In power plants such
changes are not usually required to establish a
new output voltage; instead they are needed to
reestablish the desired output voltage after a
departure due to a change in source voltage or
in load-related impedance voltage drop. If tap
changing must be done while the transformer is
loaded, special switching equipment is required
to transfer load current from one tap to another
without an interruption of service. This is called
tap changing under load.
Thp
Volts
Ame_eres
R16
R8
N
L8
L16
4576
4368
4160
3952
3744
1514
1586
1665
1753
1850
POWER TRANSFORMERS
2-15
2.11 BUSHINGS
Bushings are used on liquid-immersed transformers to carry the winding terminal connections
through the grounded metal cover or sidewall of
the tank. A porcelain rain shield over the external portion is skirted to provide a long surface
creepage path from terminal to ground flange.
The internal portion below the ground flange is
generally immersed in the transformer insulating
fluid. This portion may also be encased in
porcelain.
HV bushings are of the condenser type, insulated with layers of oil-impregnated kraft paper.
Copper or aluminum foil layers of graded axial
length in the paper insulation structure distribute electrical stresses and control voltage gradients. The shell is filled with oil to keep the paper
saturated, and the outer terminal is fitted with an
oil level gage or sight glass. A cushion of dry nitrogen above the oil allows for thermal expansion and
contraction of the oil. This cushion is sealed at a
pressure above atmospheric pressure to exclude
air and moisture. Bushings of this type must be
shipped and stored in a nearly upright position
to prevent dryout of any of the layers of paper.
In bushings rated 115 kV and higher one of the
foil layers is made available as a bushing potential
tap through an insulated conductor just above the
ground flange. This tap must be impedance
grounded through an external potential device or
solidly grounded by a grounding cap whenever the
bushing is energized. Condenser-type bushings
(Figure 2-7) rated below 115 kV, down to and
including 15 kV, have a power factor tap. The
power factor tap connects to the ground layer of
the capacitor core. An aluminum cap covers the
insulated power factor tap assembly and grounds
the tap connection when it is not in use.
Bushings are of two types, depending on their
provision for connection to the transformer windings. In a fixed-conductor type the central tube or
rod conducts current from the top terminal to the
bottom terminal. The winding lead is connected
to the bottom terminal. In a draw-lead type the
winding lead is drawn upward through the central tube and connected to the top terminal. Figure 2-7 shows a bushing with a threaded copper
tube that can be used with a fixed-conductor or
2-16
a draw-lead type connection. Figure 2-8 is an extrahigh voltage (EHV) bushing of the draw-lead type.
HV bushings are generally selected to have the
same BIL as that of the transformer HV winding.
For situations in which the atmosphere is highly
contaminated with particulate matter or for highaltitude installations it may be desirable to use
bushings having a longer porcelain rain shield. If
this aim is achieved by using bushings with a
higher BIL than that of the winding, the lower portion of the bushing will also be longer, requiring
a taller tank, which may exceed shipping limitations. The alternative is an extra-creep design, in
which the rain shield is taller but the portion inside the tank is not extended.
Lower-voltage high-current bushings, which are
used on the primary terminals of UTh, are generally
fixed-conductor, bulk type, again with porcelain
rain shields and oil impregnated (Figure 2-9). Such
bushings are not usually equipped with oil level
gages, but oil leakage has occasionally been a problem. There could also be a heat dissipation problem
if bushings with a lower temperature rating are
connected to isolated phase bus conductors operating at 105C. 'll'ansformer specifications should
state terminal conditions.
Secondary bushings on UATh and SSTh are of the
porcelain type, at least 110 kV BIL, and are sometimes mounted in the sidewalls of the tank below
transformer oil level. Faulty seals in such bushings
have caused fires in a few cases when transformer
oil leaked through a bushing seal into a cooler control cabinet.
Bushings are manufactured in accordance with
the requirements of ANSI/IEEE Standard 24-1984
(11) and tested in accordance with requirements
and test procedures of ANSI/IEEE Standard
21-1976 (12).
See Section 2.22 for bushing maintenance.
Figure 2-6
POWER TRANSFORMERS
Gaskets
Clear/view
oil reservoir
housing
Nameplate
Bushing
potential tap
Mounting
flange/ground
sleeve assembly
POC design
Figure 2-7
2-17
2-18
2.12 ACCESSORIES
The accessories described individually in the following subsections are available for large liquidimmersed transformers. Few of them are applicable to dry-type transformers.
The typical liquid level indicator is a sealed instrument body. Inside, an indicating needle sweeping
a calibrated scale is magnetically coupled to an external pivoted float arm, with the float at the top
surface of the insulating fluid. The scale is marked
to indicate high, low, and 25C levels. The indicator includes alarm switches.
For a transformer with an inert gas oil preservation system, the indicator is mounted at the top
of the transformer tank wall. For a transformer
with a conservator or constant oil pressure system, the indicator is mounted on the conservator
or oil reservoir.
TEMPERATURE INDICATORS
POWER TRANSFORMERS
Silver-plated blades
1...1 - - - - t o accommodate
line conductor
Porcelain-to-core
washer gasket
One piece
wet-process
porcelain shell
Clamping ring
Porcelain-to-bottom
washer gasket
Bottom
washer-to-springgasket
Spring assembly
Blade terminal
I " " ' - - - - - t o accommodate
transformer connector
Figure 2-9
2-19
220
;1111
(!
:' l
:..
a. Top oil
Indicating
pointer
Switch-setting
tabs
Capillary
tubing
Maximumreading
pointer
Credl
Reset-shaft
cap and gasket
Temperature
detector
Union connector
b. Hot-spot winding
a. Courtesy of Westinghouse Electric Corp., Pittsburgh, Pa.; b. Courtesy
of General Electric Co., Bridgeport, Conn.
FLOW INDICATOR
'Ii'ansformers employing forced-oil cooling may be
equipped with a flow indicator, including alarm
switches, for each pump. 'JYpically, the indicator
is a vane-operated instrument mounted on the
pump discharge pipe. The scale is not calibrated;
it merely shows whether there is oil flow from the
pump.
Where remote indication, recording, or data logging of top oil or winding hot spot temperature
is desired, the local temperature indicators can be
supplemented or replaced by 10-0 copper resistance temperature detectors. In general it is not
feasible to embed such detectors in the transformer windings. They should be located in the
wells just below minimum oil level (13).
POWER TRANSFORMERS
2-21
Figure 211
Figure 2-12
222
.....
....._
Figure 2-13
LIGHTNING ARRESTERS
Lightning arresters are most effective in protecting transformer insulation from surge voltages if
they are installed very close to the winding terminals. For this reason it is common practice to
POWER TRANSFORMERS
Semaphore
(normal position)
223
Semaphore
(tripped position)
Protective cover
Figure 2-14
224
and future, to be served by the transformer. However, it is less than the sum of the individual equipment ratings for several reasons. Motors are
available in discrete sizes. If a pump, for example,
requires 112 hp during normal operation, the driving motor is likely to have a rating of 125 hp.
However, that motor will seldom, if ever, operate
at 125 hp. In addition, many of the loads, such as
motor-operated valves, are intermittent. The
transformer may supply power to devices that will
not operate at the same time. Certain items may
be standby or spare, intended to operate only
when a similar item, possibly fed from the same
transformer, is unavailable for service. A single
transformer may also serve mutually exclusive
loads, such as an air conditioning compressor and
one or more duct heaters; when one is in operation, the other is not required.
1Wo factors often used in other contexts are relevant to this discussion. They are diversity factor
and demand factor. Diversity factor (greater than
1.0) is the ratio of the sum of the individual maximum demands of the items served to the maximum demand (usually integrated over a 15- to
30-min period) of the whole system. Demand factor (less than 1.0) is the ratio of the maximum
demand of the whole system to the total connected
load. Connected in this sense means "served;'
whether operating or not.
Of these two the diversity factor concept is the
more useful. Note that the aggregate demand is
divided by the diversity factor to find coincident
demand. However, diversity factors applicable to
power plant auxiliary loads cannot be found in tables. Each subsystem constituting the entire load
on a single transformer secondary winding must
be analyzed separately. In nearly all cases the analysis must be based on printed data (for example,
nameplate ratings, performance curves, manufacturers' literature), since the subsystem is not available for measurements.
Short-time overloads, such as those produced by
motor starting, are common in transformer applications. The resultant voltage drops may require
analysis, but these types of overloads, unless they
repeat at brief intervals, can be ignored in selecting transformer kilovoltamperes. Motor-operated
valves are usually omitted from the demand calculation for that reason. A motor-driven air compressor with automatic start/stop or automatic
unloader control, on the other hand, should be
included, especially if the driving motor is large
in relation to the size of the transformer. Such
loads usually are included at their average demand
POWER TRANSFORMERS
likely to be that associated with the LV unit substations fed from such medium-voltage subsystems, but the sum of such loads is generally a
small fraction of the medium-voltage load.
ALTITUDE
2-25
2-26
140
135
iC 130
1\
5125
...
120
0
X
LlJ
115
"
l'o..
I'- r::....
r-- ....
110
105
0.1 0.2 0.4 0.71
710
20
40 70 100
Time (min)
Figure 2-15
General Guide for Permissible Short-Time Overexcitation of Power Transformers (Rated Volts
per Hertz = 100% Excitation)
When the load current of a transformer has substantial waveform distortion, the distortion components will increase transformer losses and
temperature rise.
ANSI Standard C57.12.00-1980 (5) states that, for
"usual service conditions;' load current shall be
approximately sinusoidal and the harmonic factor
shall not exceed 0.05 per unit. Harmonic factor
POWER TRANSFORMERS
is the ratio of the effective value of all the harmonics to the effective value of the fundamental. The
effective value of all the harmonics is the square
root of the sum of the squares of the effective
values of the individual harmonics.
If the load to be served by a transformer includes large rectifiers or large solid-state variablespeed drives, an analysis should be made to
determine whether the harmonic factor of load
current under transformer full-load conditions is
likely to exceed 0.05. If so, that "unusual" service
condition should be explained in the transformer
procurement specification.
HARMONIC CURRENT DERATING
Example
The transformer rating is 16 MVA. Full-load secondary current is 2221 A. Of the total load loss, 25.9%
is stray losses. Stated another way, the total load loss
is 1.35 times the J2R loss [1/(1.0 - 0.259) = 1.35].
For the drive package, total fundamental (power
frequency) current is 1162 A and harmonics are
as follows: eleventh-8%; thirteenth-6.5%;
seventeenth-S%; nineteenth-4%; twenty-
2-27
load on a transformer secondary, transformer derating for harmonics will be negligible. In fossil
fuel plants, however, variable-speed drives are
sometimes used for boiler feedpumps and for
forced-draft and induced-draft fans. These are the
largest electric drives in the plant. Their harmonic
currents and reactive power requirements cannot
be safely ignored. A method of calculating derating
is explained below.
The first step in calculating the harmonic (derating) factor for current is to obtain from the supplier of the variable-speed drive package the
magnitude at full load of the fundamental and of
all harmonics of current drawn from the system
up to the twenty-fifth harmonic. The magnitude of
each harmonic is usually expressed in percent of
fundamental current. Frequently, the drive package filters out the lower harmonics, third through
ninth, so that these components do not flow
through the windings of the supply transformer.
The second step is to determine the root-meansquare (rms) value of the total load current, which
is the square root of the sum of the squares of fundamental and all harmonics, as noted in
Alternating-Current Circuits by Kerchner and Corcoran (19).
I = .../ I?j_ +
+ ... +
(Eq. 2-2)
+ (0.04) 2 + (0.025) 2
+ (0.02) 2 ] = 21,266
(Eq. 2-3)
2-28
[(1162)2 +
(Eq. 2-4)
+ (0.04
19)2 + (0.025
+ (0.02
23) 2
(Eq. 2-5)
Impedance voltage is the voltage drop in the windings due to their ac resistance and leakage reactance when the transformer is delivering full-load
current. In the case of dual- or triple-rated transformers with forced cooling, full-load current, for
the purpose of this definition only, corresponds
to the self-cooled rating. In the case of transformers with taps on the secondary winding, full-load
current is the current rating of the tap. Note that
at secondary voltages below tap voltage rating, the
transformer is not capable of delivering rated
kilovoltamperes continuously, despite being specified as having "full-kVA" taps. Under the LV conditions the tap current rating governs.
'fransformer regulation is defined as the rise in
secondary voltage when full load is removed. It
is expressed in percent of secondary voltage rating. Regulation increases with increasirig impedance and with decreasing load power factor.
X (1
"" (2221)2
1.35
(Eq. 2-6)
21,266 + 1,592,211
1.35
_ 1162
(Eq. 2-7)
= 771 A/phase
.J (PF)2
1)
(Eq. 2-8)
Where:
% REG "" transformer regulation, in percent
PF"" load power factor, per unit
POWER TRANSFORMERS
Table
Load
z.z
Percent lmpedancea
PF
0.90
0.88
0.86
0.84
0.82
0.80
2.28
2.47
2.64
2.80
2.94
3.08
2.76
2.99
3.19
3.38
3.55
3.71
3.24
3.51
3.75
3.96
4.16
4.35
3.74
4.04
4.31
4.56
4.78
5.00
9
4.24
4.58
4.88
. 5.16
5.41
5.65
10
4.75
5.12
5.45
5.76
6.04
6.30
significantly by secondary leads impedance voltage drop and will be additive to variations in transformer primary source voltage.
Low impedance is advantageous for voltage control but cannot be specified indiscriminately without consideration of its effect on short-circuit
currents (Volume 3, All}(iliary System Planning).
229
2-30
LOSS EVALUATION
POWER TRANSFORMERS
15
-.
10
Cl
31:
c:
"ii
-5
.s::
:I
,; -10
-g:I
+3o-
-15
Median
-20
;:;
It:
-3o-
-25
-30
L---..1...--..l--...l--...l--....L...-....L...--
120
Figure 2-16
231
2-32
showed considerable promise under closely controlled conditions but has not proved practical.
transformer during its entire travel, from the factory to the job site, in order to be able to report
on any incidents of rail humping.
UTs
The UT is the largest transformer in the plant. It
is generally located outdoors and is mineral oil immersed. In the United States such transformers
rarely have LTCs. Because they have to be kept
small enough to be shipped by rail, most UTh are
class FOA or class FOW. (Class FOW transformers
are commonly used at hydroelectric plants.) The
fact that a transformer of either design has no selfcooled rating usually is not a disadvantage, because in this application it will usually operate well
loaded whenever it is energized. It is important,
however, that the mechanical cooling auxiliaries
be placed in operation whenever the transformer
is energized. As compared with a triple-rated design (class OAIFA/FOA or class OA/FOAIFOA), FOA
or FOW transformers cost slightly less and require
less space.
The triple-rated design may be preferred, however, if switching equipment is added in the generator leads to the UT. That addition permits the
carrying of auxiliary power load by backfeeding
from the switchyard through the UT and the UATh
while the unit is shut down. The triple-rated transformer can operate in this mode without forced
cooling.
The UT differs from most other transformers
on the system. in that its HV winding is the secondary. Its LV winding most often is connected to
the generator through the isolated-phase bus. The
tank cover must be fitted with nonmagnetic
flanges around each LV bushing to support the individual phase enclosures for that bus. If the LV
bushings are cover mounted, as is frequently the
case, the strike distance from HV bushing terminals to bus enclosures must be adequate for the
voltage class. And, since large stray currents may
be present near the isolated-phase bus, the bus
enclosures must be insulated from the tank cover.
The arrangement of grounding conductors for the
bus enclosures and the transformer tank requires
special consideration. It is also necessary to ensure that the transformer LV bushings have temperature ratings suitable for connection to the bus
POWER TRANSFORMERS
voltage ratings for the UT is different from similar procedures for a substation transformer. These
characteristics must be selected with care to ensure that the full capability of the turbine generator will be available to the power system. Being
. far less expensive in dollars per kilovoltampere
than the generator, the transformer must not be
the bottleneck under any possible operating condition. The trade-offs must be explained to all interested parties-the power station engineers, the
operating personnel, the system planning engi
neers, and the substation and transmission
engineers-to arrive at prudent decisions. To this
end it may be necessary to analyze several alternatives and to prepare graphic presentations of
performance limitations, as demonstrated below.
TUrbine Generator The UT is the link between
2-33
matched to the turbine generator real power output with turbine inlet valves wide open and some
set of steam (or hydraulic) conditions for which
performance is guaranteed. That megawatt value
is not necessarily equal to the maximum continuous
real power output under winter (or maximum
head) conditions. Greater power than the above
megawatt value will reduce the allowable reactive
power flow to the system but will increase the UT
loading, as will be shown. Where a heat balance
(or hydraulic study) has demonstrated a greater
power output, it may be prudent to use that value
and the intersections of the corresponding vertical
locus line with the reactive capability curve as inputs to the transformer calculations.
Figure 2-17 is marked to indicate the generator
reactive capability limits, lag and lead, at the real
power output corresponding to generator
megavolt-amperes and rated power factor. These
values, 854.9 MW, 530 MVAR, and -346 MVAR,
are used in the transformer calculations for the
base case.
It is not possible to make the entire range of
generator full-power reactive capability available
to the power system under all system voltage conditions. 'll'ansformer real and reactive power
losses will absorb part of the generator output
under most conditions. Certain system voltage conditions may cause the generator to operate outside its allowable voltage range. These conditions,
in turn, may cause the transformer to operate outside its allowable range of voltage or current.
'll'ade-offs must be made when transformer
parameters are selected to ensure that the portions of the megavolt-ampere-reactive range that
are sacrificed under LV or HV conditions are those
least needed. Also, the transformer should not be
made unreasonably large; cost and space must be
considered.
Unit Auxiliary Load In the usual power plant
design one or more UATh will be connected to the
generator leads to provide a normal source for the
unit auxiliaries power system. When these transformers are in use, the unit auxiliaries load, as
seen from the primary terminals of the UAT,
drains off a portion of generator output before it
reaches the primary terminals of the UT. Since this
drain is a normal condition, the usual practice is
to recognize it and select the UT for net output.
In certain cases, however, transformers are sized
to accept the gross output of the generator in order to allow full-load operation of the unit while
2-34
---
800
vvv v
0.60 PF
0.70 PF
0.80 PF
600
Overexcited
limit 530 MV AR
""'
...J
vv vv
0::
200
>
V"
::E
r---. r--
'\
400
!'\.
200
I
400
0.95 PF
I
-
0.98 PF
r- r-.
r-. 0.95
r--....
PF
'to.....
0.90 PF
0.70 PF
I
0
r-....
---1--
.......
0.60 PF
600
854.9 MW
0.90 PF
r:
-- r-'
"0
".,
...J
r-
F::::::::
. ' I".."
v
vv
v
200
0.85 PF
vv
vv v
/
400
<(
0.80 PF
I
600
800
1000
1200
MW
Figure 2-17
POWER TRANSFORMERS
Megavolt-ampere rating
Impedance voltage
Secondary voltage rating
Primary voltage rating
The ratings selected will determine the relationships among these variables. There is some latitude in the selection of each rating. For that reason
it is useful to present the results of a set of selections in graphic form.
The generator reactive capability curve is a plot
of generator megavolt-amperes-reactive versus
generator megawatts, often in a family of curves,
one curve for each cardinal value of generator
hydrogen pressure. Separate curve sheets may be
presented, one for each value of generator voltage.
System
-Generator voltage 105.0x
600
E
Q)
.,
.,>-
0
1-
500
Transformer ii mit
400
300
200
Generator voltage 102.5X
100
-100
-200
-300
-.,
E
Q)
.,
-400
>-
.E
0
u...
2-35
Transformer limit
-600
-700
-800
-900
-1000
330
362
Bus CkVl
Figure 2-18
Base Case
2-36
Generator
24.9 kV
Rating
zr
UAT
24 kV
Auxiliary
bus
,.
1
Bose 24 kV
1107.65>: VI
103.75>:
I ..
I
I
VI
98.34>:
854.9
UA T load
Load losses
812.48 MW
499.29 MVAR
418.71 MVAR
Figure 2-19
POWER TRANSFORMERS
2-37
System
600
500
E
CP
( /)
400
>.
(/)
.....
200
Generator voltage 102.5"
100
a::
<(
>
::l:
-100
Generator voltage 100.0"
-200
-300
E
II)
.,
-400
>.
(/)
...0
-600
LL.
-700
Generator voltage 95.0"
-800
-900
-1000
330
362
Bus (kVl
Figure 2-20
2-38
System
600
..
500
...,
"'>.
"'0
300
1-
200
100
-200
et::
<
>
::::<
-300
..
-400
"'>.
"'E
-500
...,
.....
u..
-600
-700
Generator voltage 95.0"
-800
-900
-1000
330
362
Bus (kVl
Figure 2-21
POWER TRANSFORMERS
2-39
600
500
....rn
Q)
>.
rn
300
0
f-
200
100
0::
<
>
::::0
-200
-300
...."'
-400
Ill
>.
Ill
...0
-600
u..
362
Bus (kVl
Figure 2-22
below 345 kV, despite the fact that this is a "fullkVN tap. ANSI Standard C57.12.00-1980 (5) requires that tap to deliver rated kilovoltamperes at
rated tap voltage but not at lower voltages, where
the tap current rating intervenes.
At 330 kV, the generator and the transformer
both reach their thermal limits at a reactive power
flow to the system of approximately 410 MVAR,
with generator voltage at approximately 97% of
nameplate value. A higher generator voltage
would produce output beyond the thermal limits
unless it also produced an increase in switchyard
bus voltage.
The generator cannot quite reach its capability
limit, overexcited, when bus voltage is 362 kV. That
comer of the chart would require generator voltage greater than 105%. Similarly, the generator
cannot reach its reactive capability limit, underexcited, when bus voltage is less than 354 kV, because that condition would require generator
voltage below 95%. It is highly unlikely that operation in either of these portions of the domain
would ever be desired. However, in the vicinity of
system voltage-in this case 356 kV-the full range
of generator reactive capability can be used to
maintain the desired bus voltage without violating generator full-power voltage limits. The ex-
pected result is that generator voltage will remain
close to 100% most of the time.
Changes described below for succeeding figures
are from the base case; they are not cumulative.
Greater Real Power Output For Figure 2-20
generator maximum real power output was
2-40
600
500
...
....CD
>.
300
t-
200
100
-200
0::
<
>
::::0
-300
....
.,>.
E
...0
u..
-400
-600
-700
Generator voltage 95.0lll
-800
-900
-1000
330
362
Bus lkVl
Figure 223
Oversize Transformer
POWER TRANSFORMERS
2-41
600
500
...
Q)
>.
"'
"'0
300
1-
200
100
0:::
<
>
::::;:
-100
-200
Generator voltage 97 .5x
-300
voltage 95.0,;
-400
"'
-500
...
Q)
E
u...
-600
-700
-800
-900
-1000
330
362
Bus (kY)
Figure 2-24
Increased Impedance For Figure 2-24 the transformer impedance was increased from 9.17 to
16%. The higher impedance may be required to
High Impedance
2-42
1200
1000
E
Q)
+'
"'"'"'
0
I-
400
200
-200
-400
underexcited limit
-600
Generator voltage 95.0x
E
Q)
+'
"'"'"'
E
....0
-1000
-1200
LL.
-1400
-1600
-1800
-2000
330
362
Bus (kVl
POWER TRANSFORMERS
2-43
current.
Ie is the magnetizing component of exciting
current.
N IL is the load current per phase in the primary
secondary winding.
R is equivalent resistance per phase of trans-
2-44
1:N
I,
I UAT
N. IL
Io
IG
I.
Station
service
load
V'/N
Generator
I
T
V2
V'
System
load
Top
D
a. Equivalent circuit
v '1
b. Phosor diagram
divisor to correct the preliminary assigned primary voltage rating. Although this is not a precise
correction, it will be accurate enough for practical purposes. In case of doubt the corrected rating
can be put through a second iteration. Selection
of the primary voltage rating does not affect the
other ratings selected previously.
Performance Calculations Performance calculations are done by an iterative process to derive
initially unknown transformer output, which cor
responds to a selected point within the generator
reactive capability curve and a selected secondary
POWER TRANSFORMERS
2-45
UATs
In most large generating units the normal source
of power for the unit auxiliaries is the main generator leads, to which one or more UATh are connected
directly. This configuration has several advantages
over a transmission system source. Feeding power
for local use from that point reduces the power
flow through the UT and thereby reduces the load
losses in that transformer. It also reduces the magnitude of the voltage dips on the auxiliary power
system during close-in faults on the transmission
system, because the generator voltage is less affected by such faults than is switchyard bus voltage, being cushioned by the intervening
impedance of the UT. The available short-circuit
megavolt-amperage of this source, however, is often
greater than that of the switchyard bus, subjecting
the UAT to very large and often prolonged stresses
in the event of a fault on its secondary circuit. The
stresses will be prolonged if the fault is at the secondary terminals or at any point on the secondary
leads up to the secondary breaker. This occurs because, although the unit must be tripped rapidly
by protective relays (there being no other way to
isolate the fault), the generator will continue to
feed the fault during the period of generator airgap flux decay.
Because of the potential for large, prolonged
through-faults, potential transient overvoltages
(Section 2.13), and the usual requirement that the
primary terminals be configured to accept isolated
phase bus connections, transformers designed for
this service command a premium price.
Rating basis and temperature rise are explained
in Section 2.4.
For those users who prefer not to use forcedoil cooling systems the OAIFAIFA option is available
2-46
POWER TRANSFORMERS
Z-47
third)
AUXILIARY TRANSFORMERS
The term au}(iliary transformer is used here to denote a transformer feeding a 4.16-kV subsystem
from a 6.9- or 13.8-kV auxiliary bus. Since cable
voltage drops are far less important on a 4.16-kV
system than on an LV system, it is often feasible
to install the transformer outside the plant building and to use a mineral oil-filled design. Since
most such transformers have kilovoltampere
ratings of 10,000 or less, low impedance will not
lead to secondary fault current beyond the ratings
of the switchgear. In addition impedance voltages
on the order of 6% or less will be advantageous
in improving voltage regtilation.
GROUNDING TRANSFORMERS
It occasionally becomes necessary to derive a
2-48
SHOP TESTING
All of the tests except the short-circuit capability
test on a large transformer can be made in the
factory or in a well-equipped transformer repair
facility. Those marked "(F)" can also be made in
the field without unreasonable difficulty. Because
of the magnitude of short-circuit current required,
it is impractical to make through-fault tests on
transformers larger than 20,000 kVA.
The purpose of the tests is to demonstrate the
quality of the design and workmanship and to verify that performance guarantees have been met.
In certain cases the test results provide benchmarks with which future field tests results can be
compared. One test, winding resistance, calibrates
the windings at a known temperature to serve as
resistance temperature detectors during temperature rise tests.
Certain design tests may be specified by the purchaser for quality assurance purposes, even
though similar test results may be available for an
essentially duplicate transformer. In general the
tests in the category other will affect price.
Switching surge tests are only made, when
specified, on windings of 450-kV BIL and higher,
because, for windings of lower BIL, switching
surges in service are not expected to produce significant transient overvoltages.
Front-of-wave impulse tests are specified by certain purchasers who install rod gaps for bushing
protection.
Radio influence voltage tests were initially developed as a result of utility customer complaints
of interference with radio reception. Experience
convinced both manufacturers and purchasers
that these tests were sensitive indicators of insulation quality and that high levels of radio noise
often indicated a defect in design or factory workmanship likely to lead to premature failure. The
magnitude of the radio noise signal measured at
POWER TRANSFORMERS
Table 2.3
2-49
Transformer Tests
Routine
Design
Other
Notes3
D, F
D. F
D, F
D
Temperature rise
Applied voltage
Induced voltage
Lightning impulse
Front-of-wave impulse
Switching impulse
D
D
D
D
D, F
Insulation resistance
Audible sound level
Short-circuit capability
D. F
D
D
Leak
Oil analysis
3D
the bushing tap has been found to decrease considerably when the initiating partial discharge is
electrically remote from the bushing. Because of
that and also because of European practices other
methods of measurement are under study in the
industry. The two promising alternatives are wideband partial discharge (picocoulomb) measurements and ultrasonic measurements at the outside
surface of the transformer tank This second type
of measurement may be feasible in the field and
with the transformer in service. Neither method
is likely to be recognized in the standards until a
substantial data base has been established to replace the existing radio noise (microvolt) data base
(26).
The purpose of the dielectric tests is to demonstrate the capability of the transformer insulation
to withstand the test levels defined in ANSI standards. There are three dielectric withstand tests
that can be performed on a transformer: the
applied-potential test, the induced-potential test,
and the impulse test.
The applied-potential (low-frequency) test is
made to check the adequacy of the phase-to-phase
and phase-to-ground insulation and the insulation
between primary and secondary windings. In the
case of wye-connected windings with graded insulation the applied-potential test voltage must be
limited to the value appropriate for the BIL level
FIELD TESTING
Field testing is desirable when there is visible evidence of damage in shipment or following significant system disturbances, indications of excessive
temperature rise, or operation of a gas detector relay. Some tests are desirable on a routine basis. The
aim is to check the condition of the transformer
2-50
POWER TRANSFORMERS
2.17 FOUNDATIONS
Single-block foundations for large power transformers have been found less expensive than multiple piers. The block should extend at least 6 in.
beyond the transformer base and should, where
possible, include the jacking pads. Where the foundation is soil bearing and more area is required
than that of the block as determined by transformer base dimensions, the block may be placed
on a mat of suitable size.
2-51
2-52
2.21 INSTALLATION
The installation procedure begins when the transformer arrives on site. Before it is removed from
the rail car or other vehicle that carries it, it should
be examined for visible damage to the main
assembly, to any of the component parts that were
removed, or to any bracing added for shipment.
The carrier should be advised immediately of any
visible damage and should be given the opportu
nity to have a representative view the evidence.
Color photographs should be taken if appropriate.
If the car or vehicle is fitted with an impact
recorder, the chart should be examined by the
party who might make a claim against the carrier:
the shipper, in the case of sale FOB job site, or the
purchaser, in the case of sale FOB factory, whether
or not it was "freight allowed" or prepaid.
LIQUID-IMMERSED TRANSFORMERS
Any transformer with a sealed tank, shipped with
oil or gas, will have been shipped under positive
pressure, in most cases monitored by a pressure
gage. The reading on that gage and the corresponding tank temperature should be recorded.
An apparent loss of pressure may not be significant if the temperature at destination is far below
25C (77F). For example, a tank pressurized to
10 psig at 25C would show 6.45 psig if it had
cooled to 0F (-17.78C), even though there had
been no leakage. Alternatively, the transformer
may have been shipped with gas bottles and pressure regulator connected. In that case the bottle
pressures should be noted.
Detached components should be protected in
storage pending final assembly. They should be
inventoried to ensure that missing parts will not
interrupt assembly. Oil-f"illed bushings should be
stored in a nearly upright position, which may require building special racks.
A large transformer should be moved by an experienced rigger. Where a crane lift is feasible,
attachment should be made only to the lifting eyes,
with appropriate slings and spreaders. Where a
crane lift is not feasible, jacks may be applied (only
under the jack bosses) to permit placement of
rollers or greased timbers under the base. Timber cribbing or ramps may be required alongside
the carrying vehicle to facilitate sliding or rolling
the transformer to ground level.
An interior inspection should be made of any
sealed transformer as soon as weather permits
POWER TRANSFORMERS
DRY-TYPE TRANSFORMERS
Installation of dry-type transformers does not in
general require special procedures beyond those
appropriate to the installation of other electrical
apparatus. Prior to placement in service, however,
special care should be taken to keep the transformer dry. Thmporary space heaters may be
required. The transformer should not be energized at full voltage until insulation resistance or
power factor tests have confirmed that the insulation is dry. Thereafter, the no-load losses will
maintain core-and-coil temperatures above the
dew point.
2.22 MAINTENANCE
A correctly installed transformer operated within
its ratings and properly maintained should have
a life expectancy of 20 to 40 years. Maintenance,
in most cases, is neither costly nor time consuming. Some of it can be done while the transformer
is in service. It should, however, be done on a regular schedule, and careful records should be kept.
The first step in any maintenance program
should be to read the manufacturer's maintenance
instructions. These may differ from those of other
manufacturers or even from previous instructions
from the same manufacturer.
2-53
VISUAL INSPECTION
Every transformer should be inspected visually at
regular intervals. The length of those intervals
varies from company to company, depending on
prior experience, severity of service, and harshness of environment.
On most dry-type transformers there is little to
inspect, but on ventilated dry-types the grounding, terminal, and tap connections are visible, and
any buildup of lint or dust that might impede the
flow of cooling air can be seen. However, even on.
dry-types, abnormal ambient temperature or noise
may not be detected during visual inspection.
The gages of liquid-immersed transformers
should be read and their readings recorded. Following is a list of suggested observations and readings for a large, forced-cooled, liquid-immersed
transformer:
Observations
Th.nk pressure
Th.nk liquid level
Thp liquid temperature
Winding (hot spot) temperature
liquid flow at each pump
lightning arrester discharge counters
Nitrogen bottle pressures (inert gas system)
Fault gas monitors
In addition to the visual inspections some transformer testing can be done in the field (Section 2.16).
254
Periodically taken oil samples are expected to withstand approximately 30 kV in the standard test
cup. Breakdown below 26 kV is generally regarded
as unsatisfactory. Water, sludge, and other forms
of contamination can often be removed, even with
the transformer in service, by circulating heated
oil through a transportable oil-conditioning system
while testing repeatedly to monitor the improvement. Such a system may include heaters, Fuller's
earth beds, and a vacuum dehydrator.
through the windings at low voltage. This procedure must be carried out with care to avoid the
formation of hot spots that may degrade the insulation. The heating must be combined with vacuum
or other methods to remove the moist vapor. Each
manufacturer can furnish detailed procedures for
such operations.
CLEANING BUSHINGS
Outdoor apparatus bushings have skirted, glazedporcelain rain shields to provide a long surfaceleakage path from terminal to flange. In areas
where the air is contaminated with particulate matter, the porcelain may collect a heavy coating of
dust, which will become conductive when wet and
can lead to bushing flashover. The porcelain should
be cleaned as often as necessary with a nontoxic
solvent. Some users have found that a coating of
silicone grease will break up the conductive leakage path and thus prolong the interval between
washings.
GASING
absorbed a significant amount of water (a condition that may be diagnosed by insulation power factor or even Megger testing), it may be necessary
to employ a combination of methods, including
heating, to dry it out. In general dryout can be accomplished without untanking. The most common
method of heating is circulating alternating current
APPENDIX A
LOSS EVALUATION
In both indoor and outdoor applications transformer losses incur significant future cost beyond
that attributable to heat removal. That cost has two
components: a demand cost and an energy cost.
The demand cost is based on the amount of
capacity that the losses make ungross
available to the power system for meeting its peak
customer demand. The aggregate level of such
power losses will ultimately require that a new
generating unit be added to the system one year
earlier than would otherwise be necessary. Thus,
the demand penalty to be invoked for losses is
based on their magnitude under peak system load
conditions and on the dollars-per-kilowatt cost of
new generating capacity.
The energy cost of losses is based on the delivered cost of extra fuel burned to generate the loss
energy. All other components of generating cost,
such as fixed charges, maintenance, and operating costs other than fuel, are essentially unaffected
by the incremental kilowatthour production.
Fuel use on the system is not directly proportional to electrical load. Each generating unit is
more efficient near full load than at light load. At
no load a turbine requires input energy to overcome losses from several sources: friction and
windage losses incurred in running the turbine
generator and many of its auxiliaries at full speed;
throttling losses in partially open inlet steam
valves; pump and piping losses in the circulatingwater system incurred in maintaining condenser
and heat losses incurred in maintaining
masses of metal at high operating temperatures.
The result is that lightly loaded generating units
are inefficient. Their average fuel cost in cents per
kilowatthour is high. Near full load inlet steam
throttling losses are reduced because the valves
are nearly wide open. On some turbines, however,
a new form of loss appears near full load: a discharge loss caused by "choking" in the exhaust
annulus at high steam fiow. Nevertheless, the aggregate of all losses at full load becomes a small
fraction of the total input, most of which then
produces useful output. The result is that heavily
loaded generating units are more efficient than
lightly loaded units. Their average fuel cost in
cents per kilowatthour is lower.
256
Where:
CI = present worth of the outlay in the year of
N2
IROR IROR, expressed as a percentage, is a function of capitalization structure, cost of money, and
statutory tax rate. The proper worth to use in loss
evaluation should be obtained from a financial
officer of the company owning the plant. IROR
cannot be calculated from fixed charge rate.
Fuel Cost Attributable to Transformer Loss
Energy It is customary to predict the future
Period in
Years
1
2-5
6-10
11-15
16-30
100%
75%
50%
250Al
Load
-30
Load
Load
40
10
20
25
6
10
15
15
20
20
-Load
0
60
50
40
20
0
0
0
22
0%
Load
20
15
15
15
32
POWER TRANSFORMERS
fuel cost. Thus, the hours at 25% load will be multiplied by 0.0625, those at 50% by 0.25, and those at
75% by 0.5625 to find the kilowatthours for that year.
Each product must then be multiplied by the
applicable incremental fuel cost. Except for
hydroelectric plants and nuclear plants, it is
assumed that a generating unit will operate at 50%
load when its incremental fuel cost at that load
matches the system incremental fuel cost for that
system load condition. The incremental fuel cost
for the unit can be calculated from the net station incremental heat rate at that load and the
applicable fuel cost per British thermal unit.
For example, assume that the incremental heat
rates for the unit at 100, 75, 50, and 25% load are
12,000, 10,000, 9180, and 8770 Btu/kWh, respectively, and the fuel cost is $2.50 (price year per
million Btu). Then, if the unit (and its UT) are at
50% load, it is because the system incremental fuel
cost is $2.50 times 0.00918, or $0.0295/kWh. The
extra fuel cost incurred in the thirtieth year by
1 kW of (full-load) loss during the 20% of time in
which the unit is at 50% load will be:
0.20
8760
0.25
0.0295 = $10.05
2-57
2-58
Table A-1
Year of commercial operation
Fuel cost, cents per million Btu
Fuel price year
Fuel cost escalation rate, percentage
System average incremental fuel cost.
cents per kilowatthour
Internal rate of return, percentage
1990
250
1984
6.00
2.70
12.50
Year
1
2
3
4
5
6
25%
Load
Copper
0%
Load
Calculated Results
per kilowatt of Full-Load Loss
Iron
Present
Cost
Value
Cost
Present
Value
60
60
60
50
40
10
10
10
10
20
10
15
15
15
15
15
0
0
0
0
0
0
20
15
15
15
15
15
189.22
201.04
201.04
201.04
201.04
201.04
252.90
253.18
238.55
224.77
211.78
199.55
133.14
177.54
177.54
177.54
177.54
163.58
177.95
223.58
210.66
198.49
187.02
162.36
7
8
9
10
11
12
50
50
50
50
40
40
20
20
20
20
25
25
15
.15
15
15
20
20
0
0
0
0
0
0
15
15
15
15
15
15
201.04
201.04
201.04
201.04
201.04
201.04
188.02
177.15
166.92
157.27
148.19
139.62
163.58
163.59
163.58
163.58
145.97
145.97
152.98
144.14
135.81
127.96
107.59
101.38
13
14
15
16
17
18
40
40
40
20
20
20
25
25
25
6
6
6
20
20
20
20
20
20
0
0
0
22
22
22
15
15
15
32
32
32
201.04
201.04
201.04
160.83
160.83
160.83
131.56
123.96
116.79
88.04
82.95
78.16
145.97
145.97
145.97
72.64
72.64
72.64
95.52
90.00
84.80
39.76
37.47
35.30
19
20
21
22
23
24
20
20
20
20
20
20
6
6
6
6
6
6
20
20
20
20
20
20
22
22
22
22
22
22
32
32
32
32
32
32
160.83
160.83
160.83
160.83
160.83
160.83
73.64
69.39
65.38
61.60
58.04
54.69
72.64
72.64
72.64
72.64
72.64
72.64
33.26
31.34
29.53
27.82
26.22
24.70
25
26
27
28
29
30
20
20
20
20
20
20
6
6
6
6
6
6
20
20
20
20
20
20
22
22
22
22
22
22
32
32
32
32
32
32
160.83
160.83
160.83
160.83
160.83
160.83
51.53
48.55
45.75
43.10
40.61
38.27
72.64
72.64
72.64
72.64
72.64
72.64
23.27
21.93
20.66
19.47
18.34
17.28
60
REFERENCES
19. R. M. Kerchner and G. F. Corcoran. AlternatingCurrent Circuits. New York: John Wiley and Sons,
1960.
21. W. J. McNutt and M. R. Patel. "The Combined Effects of Thermal Aging and Short-Circuit Stress on
'Iransformer Life:' In IEEE Tl"ansactions on Power Apparatus and Systems, val. PAS-95, no. 4, July/August
1976, pp. 1275-83.
and Power Tl"ansformers. New York: American National Standards Institute, 1978. ANSI Std.
C57.12.70-1978.
10. Requirements for Load-Tap-Changing Tl"a.nsformers
:?-30,000 Volts and Below, 3750/4687 Through
60,000180,0001100,000 kVA Three-Phase. New York:
American National Standards Institute, 1977. ANSI
Std. C57.12.30-1977.
11. Standard Electrical, Dimensional and Related Requirements for Outdoor Apparatus Bushings. New York:
Institute of Electrical and Electronics Engineers,
1984. IEEE Std. 24-1984.
12. General Requirements and Test Procedures for Outdoor Apparatus Bushings. New York: American National Standards Institute and Institute of Electrical
and Electronics Engineers, 1976. ANSI/IEEE Std.
21-1976.
13. Basic Tl"ansformer Life Characteristics. Vol. 2, Evaluation of a Fluoroptic Thermometer as a Hot Spot
Sensor for Power Transformers. Palo Alto, Calif.:
2-60
REFERENCES
BIBLIOGRAPHY
El-Hawary, M. E. Electric lbwer Systems Design and Analysis. Reston, Va.: Reston Publishing Co., 1983, sect. 3.8,
fig. 3-24.
Evaluation of Alternative Insulating Oils for Use in 11-a.nsformers and Other Electrical Apparatus. Palo Alto, Calif.:
Electric Power Research Institute, February 1980.
EL-809-SY.
Fire Codes. Vol. 15, chaps. 7 and 8. Quincy, Mass.: National Fire Protection Association, 1983.
Frantz, T. P., and D. M. Korinek. "Low-Impedance Generator Step-Up ll:ansforrners: Improvements in System
Performance:' The Line, Summer 1975.
GasNapor- and Fire-Resistant Transformers. Palo Alto,
Calif.: Electric Power Research Institute, June 1980.
EL-1430.
General Electric Co. 1tansformer Connections. Schenectady, N.Y.: General Electric Co., June 1960. GET-2G.
Goldman, A. W. "Selection of Generator Step-Up ll:ansformer Ratings:' In IEEE 'llansactions on lbwer Apparatus and Systems, vol. PAS-100, no. 7, July 1981,
pp. 3425-31.
Guide for Application of 1tansformer Connections in
Three-Phase Distribution Systems. New York: American National Standards Institute, 1978. ANSI Std.
C57.105-1978.
2-62
BIBLIOGRAPHY
Heinrichs, F. W., Jr. "Theoretical and Statistical Dependence of the 'Iransformer Thst Regime on the StressLife Characteristics of Insulation Systems: In IEEE
'Iransactions on Power Apparatus and Systems, vol.
PAS-95, no. 4, July 1976, pp. 1159-64.
High-Ampacity Potheads. Palo Alto, Calif.: Electric Power
Research Institute, October 1975. Report EL-7817.
Horne, I. J. "Writing Specifications for Generator StepUp 'Iransformers:' The Line, Winter 1977.
Ignitability of High-Fire Point Liquid Spills. Palo Alto, Calif.:
Electric Power Research Institute, March 1981. NP-1731.
Installation, Application, Operation, and Maintenance of
Dry-'J}pe General-Purpose Power and Distribution 'Iransformers. New York: American National Standards Institute, 1982. ANSI Std. C57.94-1982.
Standard 'lest for Dielectric Breakdown Voltage of Insula.ting Liquids Using Disk Electrodes. Philadelphia, Pa.:
BIBLIOGRAPHY
'lest for Power Factor and Dielectric Constant of Electrical Insulating Liquids. Philadelphia, Pa.: American Society of Thsting Materials, 1982. ASTM Std. 0924-1982.
Tl"a.nsformer Noise Abatement Using 'II.med Sound Enclosures. Palo Alto, Calif.: Electric Power Research Institute, October 1977. EL-529.
2-63
INDEX
AA!FA, 27
Abnormal conditions, 2-1, 2-53
Alarm switches, 2-18, 2-20
Altitudes, 2-4, 222, 225
Ambient temperature, 23, 2-4,
25, 2-8, 222, 2-25, 2-53
Arrester ratings, 2-22
Arrester voltage ratings, 2-5
Arrhenius curve, 2-22
Askarel, 2-3
Autotransformer, 2-14
Cast-coil, 2-4
Combustible gas monitor, 2-21
Condenser-type bushings, 2-15
Connections for transformers,
2-46
Conservator, 2-8, 2-9, 2-10, 2-18
Conservator system, 2-8, 2-9, 2-10
Cooling auxiliaries, 2-1, 2-6, 2-7,
232, 2-46
Cooling fans, 23
Creepage path, 2-15
Current transformers, 218, 2-20,
221
Delta connection, 2-12
Demand factor, 2-1
Design center, 2-36, 2-40, 2-41,
2-43
Design tests, 2-48
Dielectric constant, 2-3
Dielectric strength, 22, 2-3, 2-8,
29, 2-25
Dielectric stress, 2-9
Dielectric tests, 2-49
Diversity factor, 2-1
Doble test, 2-50
2-66
INDEX
INDEX
Z-67