Z Tema 6 Transformer

Electrical Engineering Electrical Engineering Electrical Engineering
2017 2017 2017

Introduction and history
TRANSFORMERS
Alex David Valenzuela Santillán
Universidad Politécnica Salesiana
avalenzuela@ups.edu.ec
The first transformer - GANZ - 1886
SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

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FIRST
e/' : ,'7--~;.;(j "t. s) ·e,i,1.~·1'1.t&. "\ t> __ , KNOWN TO MIE 8&N
1 BY A GEC CO. IN 1889
~ 4~( ~~~ J;,-tff;;;:::_ SOOOV/SEC AT
0.8AMPS
& 500V PRI
ORIGINAL
COST
OF MANUFACTURE- t.22
......
.c
... CJ}
[o @I
~
l
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Three-phase core-type transformer

Three-phase shell-type transformer

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TRANSFORMER ON NO-LOAD: IDEAL
TRANSFORMER
Basic transformer equations:
2000 MVA
1000 Voltage across a winding is given by
MVA
1
1150kV E = 4.44 x f x xn
100 1000kV
MVA
where f is frequency, is total flux
10
100kV n is number off turns
MVA
25kV Simplified transformer circuit
1 E/n = 4.44 x f x
MVA 10kV
150kVA = 4.44 x f x B x A
100
1kV
kVA where B is flux density
1880 1900 1920 1940 1960 1980 2000
A is core area
Rate of development of transformers

2017 2017 2017
Basic transformer equations:
Voltage ratio = V1/V2 =n1/n2
Current ratio = I1/I2 = n2/n1
Impedance ratio = Z 1/Z2 = (n1/n2)2

Equivalent circuit of a transformer
Simplified equivalent circuit

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POWER LOSSES IN TRANSFORMERS AND COST OF OWNERSHIP HISTERESIS LOOP

EFFICIENCY FOR POWER TRANSFORMERS
LOSS EVALUATION
Evaluated cost of ownership = first cost + cost of losses

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TRANSFORMER TYPES
FOUCALT CURRENTS WINDING LOSSES AND STRAY LOSSES
OPERATING COSTS
Core losses - Choice of coresteel

Winding losses - Winding design
Stray losses - Control of leakage flux
SUBSTATION DESIGN SUBSTATION DESIGN

A typical small power distribution transformer SUBSTATION DESIGN

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Typical distribution
substation used in
mainland Europe
A locomotive mounted traction transformer

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1000 MVA, 400/1342 kV POWER TRANSFORMER 800 MVA bank of 400 kV generator transformers at Drax 1500 MVA bank, 525/330 kV autotransformers

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300 MVA, 762 kV single-phase autotransformers 1500 MVA bank of 800 kV transformers 2000 MVA, 400 kV quadrature booster at Stocksbridge

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Epoxy Cast Resin Transformer
An underwater transformer for installation at the base

of an oil-drilling platform in the North Sea special applications

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STANDARDS
IEC STANDARDS FOR POWER TRANSFORMERS (2)
IEC STANDARDS FOR POWER TRANSFORMERS (1) IEC 60076-6 : reactors
IEC 60076 Power transformers IEC 60076-7 : loading guide oil filled transformers
IEC 60076-1 : general IEC 60076-8 : application guide
IEC 60076-2 : temperature rise IEC 60076-9 : terminals and tapping markings
IEC 60076-3 : dielectric tests IEC 60076-10: determination of sound levels
IEC 60076-4 : guide for lightning impulse testing IEC 60076-11: dry-type power transformers
IEC 60076-5 : ability to withstand short circuit IEC 60076-12: loading guide dry-type transformers
Oil-filled transformers

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CORE STEEL
IEC STANDARDS FOR POWER TRANSFORMERS (3) Soft Iron Wire
4w/kg
IEC 60076-13: Self-protected liquid-filled transformers
IEC 60076-14: Design and application of liquid- 3w/kg
3 /k Iron Sheets
immersed power transformers using high temperature Hot Rolled Steel
insulation materials 2w/kg
Cold Rolled Steel
IEC 60076-15: Gas-filled type power transformers Domain
1w/kg Hi-B
C t l
Control
1880 1900 1920 1940 1960 1980 2000
Power loss characteristics of transformer steels

Development
D l t off low-loss
l steels

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Manufacture of
amorphous
strip
i on a
cooled wheel
using rapid-
cooling
technology
t h l
Construction of single phase transformer with
Three-phase transformer constructed from
amorphous metal strip- wound core amorphous metal strip-wound core
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3-phase amorphous transformer

Mandrel of Georg cut-to-length line A Georg cut-to-length line with slit-to-width steel coils
with laminated strip

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Types of construction of
transformer cores
D W Y
Main parameters of core Cruciform core section

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Core building berth for distribution transformers Core building berth for small distribution transformers Three limb core for small power distribution transformer

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Three limbed
core of small
power distribution
transformer
Core building for 3-phase distribution transformer

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Core building for a single phase transformer

Core building: a 9-leg treble tripler

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Yoke Yoke
Leg Leg
Core corner configurations

Step-lapped core joint at top of leg Mitred core with step-lapped joint

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Typical three-phase core-type transformer

Core on building berth ready to be lifted upright
of medium power range

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Core for 132 kV, 40 MVA transformer 4-leg core for a single-phase generator transformer 5-leg core for a three-phase generator transformer

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Windings
Copper-foil winding

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Foil windings for distribution transformers Bore horizontal winding machine

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Horizontal winding machine Horizontal winding machine for layer windings

Disc winding on horizontal machine

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Bore vertical winding machine

Layer winding on horizontal machine Layer winding machine
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Winding connections
STAR (Y) connection of windings
Isostatic-clamping of windings during drying

2017 2017 2017
Advantages of Star (Y) connection : Advantages of Delta (D) connection :
More economical for high-voltage windings

More economical for high-current,
Neutral point available low-voltage windings
Permits earthing directly or through an impedance In combination with a star winding it
Permits reduced insulation level at neutral
reduces the zero-phase sequence
Permits winding taps and tapchanger at neutral impedance of the transformer
Permits single phase loading with neutral current
DELTA (D) winding connection

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I0
Advantages of a zig-zag (Z) connection:
I0
Permits neutral current loading with inherently
low zero-sequence impedance I0
Reduces voltage unbalance in systems where I0
load is not evenly distributed between phases

Permits creation of an artificial neutral for 3I0
ZIG-ZAG (Z) winding connection the system
Zero-sequence fault currents induced in a Delta winding

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AUTOTRANSFORMER
Series winding
I2
Common winding (I 1-I2)
Neutral point
Example of clock-hour designation of 3-phase connections

Connection of windings for an autotransformer
Core and windings of a 40 MVA system transformer

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Advantages of an autotransformer connection:

Reduction in physical size
Reduction in impedance
Disadvantages of an autotransformer connection:

Low impedance permits high short circuit forces
Sensitive to lightning impulse surges
NT AH C
Tank-mounted separate compartment tapchanger with Diverter resistors to limit circulating current in separate-
double-compartment for selector and diverter switches RE PGA
compartment tapchanger during tap changing operations

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Cover-mounted transformer with in-tank tapchanger In-tank tapchanger connected to winding tappings
Cover-mounted transformer with in-tank OLTC

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TRANSFORMER CONSTRUCTION
Three limb cores ready for coil mounting Assembling winding onto core of distribution transformer
Active parts of single-phase 300 MVA, 762 kV autotransformer

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Mounting windings on a core Foil LV windings assembled on the core Assembly of small power distribution transformers

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HV and LV windings assembled onto three limb cores Windings with foil LVs mounted on a core Inserting top yoke of core after winding assembly

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A typical three-phase
distribution transformer
with enamel covered
Internal view round wire on HV winding
of 2000kVA and foil wound LV windings
distribution
transformer
Tank cover mounted small distribution transformer

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Step-lapped core joint at top of leg Nesting windings before mounting on to core
Assembly of windings on a core

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5-leg autotransformer: 1000 MVA at 400 kV

3-leg generator transformer 3-leg autotransformer: 1000 MVA at 400 kV
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5-leg generator transformer: 600 MVA at 400 kV 736 MVA generator transformer with in-tank LTC 5-leg generator transformer: 716 MVA at 525 kV

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TRANSPORTATION
Lowering a treble-tripler transformer in to the tank type car for transportation by railroad
Moving a 1000 MVA autotransformer by road

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Tank mounted radiators

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PARALLEL OPERATIONS OF TRANSFORMERS
Transformers connected in parallel must have:

Performance in Service similar power ratings Clock-face designation
of phase relationships
same voltage ratings (and ratios)
same phase angle relationship (clock hour number)
same percentage impedance (with some tolerance)

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Another transformer fire
ACCIDENTS AND
ST NE VE E R ULI AF
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Burnt out carcase 24 hours after fire

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For a fire or explosion to An arc can be caused by:

occur there must be: inter
inter-turn failure - low energy
inter-section failure Increasing
energy
an arc or strong spark in the presence of inter-winding failure release
inter-phase failure
oxygen or a combustible
b tibl gas
line to tank failure - high energy

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Mitigating actions to reduce risk of fire:
immerse transformer in inert atmosphere

rapid evacuation of oil from transformer
replace oil by higher fire-point fluid
replace oil by gas air or SF6
A three-phase cast-resin transformer with forced-air cooling

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Cast resin transformer in a protective enclosure

cooled by forced air or with a
High power cast resin transformer 8 000 kVA, 34.5 kV cast resin transformer with OLTC circulating water cooling system

2017 2017 2017
Average annual failure rate of all

Typical life of a generator
transformers in service is 2% transformer is 18-24 years
M
Mean ti
time to f il
t failure is
i 50 years Typical life of a transmission
Half of all transformers fail within
transformer is 40-60 years
50 years
Failure of layer-winding due to circulating currents

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35 30
30 25 Failure modes of transformers:
25 20
20 15
%
15 % natural ageing and deterioration
10
10
5 strategic end-of-life
5
0
0 Windings Core Terminals OLTC Other economic end-of-life
Design Manufacture Material Operations
technical end-of-life
Assigned causes of transformer failures (CIGRE) Assigned components causing transformer failure (CIGRE)

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Failure modes - natural ageing: Failure modes - strategic end-of-life:

new strategies for network operation
Failure modes - economic end-of-life:
gradual deterioration of monitored data changes in operating requirements
increase in maintenance costs reduced
d d loss
l with
ith new materials
t i l
new legal requirements
increase in lower maintenance costs
i i the
th number
b off disturbances
di t b application of new technologies
high cost of replacing obsolete parts
failure of similar equipment of a similar end of support from a supplier
age on the system - for old technologies

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Failure modes - technical end-of-life: Power transformers - indicators of

Failure of power transformers:
natural ageing and deterioration:
equipment damaged beyond repair mainly due to technical end-of-life
repair
i costs high
t hi h compared
d decrease in oil quality
rarely due to economic end-of-life
increase in dielectric loss angle
with replacement costs rarely due to strategic end -of-life recurring OLTC problems
security compromised after repair oil leakage from tank
natural ageing is a major risk which can be
corrosion of tank and radiators
accelerated by high water contamination damage to Buchholz, relays, cables etc.

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Reasons for transformer failure: Design deficiencies:

Poor specifications,
specifications design or manufacturing L k
Leakage flflux and i l i
d circulating currents
Inappropriate specifications:
weaknesses, material defects Inadequate shielding for electrostatic or
System disturbances, operational factors, Do not describe loading regime electromagnetic conditions
interactions with system Do not disclose switching operations mplify
Do not reveal environmental conditions the design
Maintenance, repairs, refurbishment that
have or have not been undertaken

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Local requirements
Material defects:
Company specifications Change in material or process
Inadequate quality control
International standards
Hierarchy of needs in design phase

Core melting due to circulating currents between
laminations (inadequate insulation coating)

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Operational conditions (2):

Operational conditions (1): Overloading (worse with moisture)
Part winding
inding resonance ind
duced
ced b
by
Through faults (short circuit currents) Interaction with power systems:
impulse or switching surge transients
Out-of-phase synchron isation M
Magnetising
i i inrush
i h currents
Fast front transients introduced by
Ferroresonance Harmonic currents from furnaces or trains
operation of disconnect switches or
vacuum switches

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Maintenance and repair operations: External factors:

Maintenance of on-load tapchangers Geomagnetic disturbances
Loose connections Seismic faults
Tools left in tank Fires
Fi
Water ingress during maintenance
Water corrosion in a conservator

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Transformer failure modes:
IInsulation
l ti PD/streamers/tracking
ElectricalOpen/short circuit, poor contacts,
earthing
thi connections
ti
Thermal Overheating, hotspot heating
Chemical
Ch i l Contamination
Mechanical Bending, fracture, vibration,
l
loose jjoints
i t
Bushing porcelain fractured during a seismic
Earthquake damage in New Zealand disturbance in Mexico
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Electrical protection:
Protection systems :
Excess current in secondary circuit Transformer protection devices:
Protect the transformer from faults in the
Excess current in primary circuit
network
Protect the network from internal faults in Difference between primary and Buchholz relay
the transformer secondary currents (transformer
ratio applied) Oil pressure/surge relay
Limit damage in the transformer to allow Low oil level
repair Earth fault currents
Underexcitation

Z Tema 6 Transformer

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Electrical Engineering Electrical Engineering Electrical Engineering

2017 2017 2017

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Three-phase core-type transformer

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Rate of development of transformers

Basic transformer equations:

Voltage ratio = V1/V2 =n1/n2

Current ratio = I1/I2 = n2/n1

Impedance ratio = Z 1/Z2 = (n1/n2)2

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

POWER LOSSES IN TRANSFORMERS AND COST OF OWNERSHIP HISTERESIS LOOP

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Core losses - Choice of coresteel

SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

A locomotive mounted traction transformer

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Epoxy Cast Resin Transformer

An underwater transformer for installation at the base

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

1880 1900 1920 1940 1960 1980 2000

Power loss characteristics of transformer steels

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

3-phase amorphous transformer

Electrical Engineering Electrical Engineering Electrical Engineering

Main parameters of core Cruciform core section

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Core building for 3-phase distribution transformer

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Core building for a single phase transformer

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Core corner configurations

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Typical three-phase core-type transformer

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Foil windings for distribution transformers Bore horizontal winding machine

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Horizontal winding machine Horizontal winding machine for layer windings

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Bore vertical winding machine

STAR (Y) connection of windings

Isostatic-clamping of windings during drying

SUBSTATION DESIGN SUBSTATION DESIGN SUBSTATION DESIGN

Electrical Engineering Electrical Engineering Electrical Engineering

Advantages of Star (Y) connection : Advantages of Delta (D) connection :