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PT UNINDO – AREVA
Contents 1. Introduction
2. Transformer core
3. Inrush Current
4. Transformer Winding
5. Insulation and Cooling Medium
6. Transformer Losses
7. Insulation Structure & Dielectric Withstand
8. Transformer Thermal Aspect
9. Short Circuit Analysis
10. Engineering
11. Manufacturing Process
12. Accessories, Protection & control
13. Final Acceptance Test
14. Technology Application
Faraday’s law
The electromotive force (e.m.f) is proportional to
the rate of linked flux changes
E = - N x dΦ/dt
X E = Electro motive force
X N = Number of turn
X dΦ/dt = Change the flux against time
Lenz’s law
The e.m.f is such any current produced acts to
opposite the linked flux.
Current Flux Current Counter Flux
E2
N1 N2
7 > Title of presentation - Date - References 7
ON LOAD Condition
V1
I1.X1
I2 R2 X2
I0 + I1 R1 X1 I1.R1
E1 I1 + I0
E2 V2
V1 E1
I1
Ip
I0
Φ
N1 N2
I2 Im
Θ
E1 : N1 = E2 : N2
V2
I1 x N1 = I2 x N2
I 2 R2
Bushing
Core
Transformer Tank
Winding
Control Cubicle
ΔV = V2 – V1
I2 R2 X2
I1 R1 X1
E2 V2
V1 E1
N1 N2
Reduced Power
Constant Power from tap n
S
V V S
I
I
Tap 1 n p Tap 1 n p
Seri Winding I2 = Is
Ns = N2 – N1
Tap Changer
I1
V2
V1 Ic = I1 – I2
N1 = Nc
Common Winding
Coil Clamping
Block
Cross Brace
Top Platform
Tie Rod
Bottom
Platform
Flux Packet
Coil Support
Blocks
Oil Diaphragm
Tank Base
18 > Title of presentation - Date - References 18
2. Transformer Core
145
140
135
Percent Excitation
130
125
120
115
110
105
0.1 1 10 100
Time - Minutes
S2.U
Ipeak = Z . Sin(ωt – y) – e-(t-t0)/τ.SinQ). K
t
Where;
K = Constanta value referring to the transformer connection
(Grounded STAR, DELTA) and other circumstantial.
U = Applied voltage (rms)
Zt = Transformer + network impedance.
y = Energization angle.
τ = Transformer time constant.
t = Core saturation time referring to maximum, remnant &
saturation induction behaviour.
Q = Angle function of core induction.
30 > Title of presentation - Date - References 30
Some Aspect Effecting Inrush Current
X Transformer number of phases and primary winding
connections;
Single phase transformer and/or shell type has higher inrush
current than three phase transformer and/or core type.
DELTA connection of primary winding three phase transformer
has lower inrush current than grounded STAR.
X Transformer capacity;
Higher transformer MVA rating has lower ratio between inrush
current and primary nominal current, but longer decay time.
X Transformer core steel, core design and nominal induction;
HiB core steel has lower inrush current than CRGO material.
But lap joint has lower inrush current than Step lap joint.
Lower impedance transformer normally has lower air core
reactance and then higher inrush current.
Φrem
time H
Flux nominal
Inrush current
Excitation
time
current
Type of winding;
Layer winding;
Single layer.
Multilayer.
Helical winding.
Disc winding.
Plain/continuous disc
Intershielded disc.
Interleaved disc.
Multistart winding.
XForm of conductor;
Round wire.( for small distribution
transformer)
Rectangular wire.
Twin/Tripple/Quadrople conductor.
CTC (Continuous Transposed Cable).
Netting-CTC/Paper less CTC
Axial/Radial
Packing for
transposition
Directed Oil
Flow washers
External DOF
washer
Internal DOF
washer
Transposition
set
Segment
Spacer
PROTECTION FOR
SCISSOR EFFECT
To Design With EDT&PD Team; To Build And To Test A Full Size 800 kV
UHVDC ISDW Prototype
X Class K;
Silicon oil
Synthetic ester
Hi-Temp natural liquid (seeds).
60
50
40
30
10
0
0 100 200 300 400 500 600
Achievement
X Environmentally friendly transformers and reactors
filled with vegetable oil
Vegetable oil totally biodegradable , with higher fire point
than mineral oil (envirotempFR3 oil from COOPER)
transformers and reactors up to 245kV, and rated power up
to 100 MVA (existing new references)
Application for Higher ratings to be evaluated if potential
for joint development with customers
Hpeak [A/m]
Pe = ke.f2.t2.Bmax2
ke = Constant depends on the core grade, typical values = 200 to 1000
t = core plate thickness [m]
B
Temperature
K 235 225
reference
Conductor
Flux line
AC current line
62 > Title of presentation - Date - References 62
Eddy loss distribution
1 2
1 2
63 > Title of presentation - Date - References 63
Stray losses of inside metallic parts & tank
Highest voltage Power frequency Full wave impulse Minimum air clearance
(kV peak) (mm)
(kV r.m.s) (kV r.m.s)
7.2 20 60 90
12 28 75 110
17.5 38 95 170
24 50 125 210
36 70 170 280
Standard Block
Stress Ring Profile thickness
²
10
1
0 5 10 15 20 25 30 35 40 45 50
path [mm]
Electrical
Creep = Y
HV Line Lead
T&D
Tap lead
connections
PTR
82 Quality > Title of presentation - Date - References 82
Bus Bar Connection For High Current Lead Exit
83 > Title of presentation - Date - References 83
Tap Changer Connection
84 > Title of presentation - Date - References 84
Inside CT Connection Lead Exit = Ground Level
Electrical
Clearance
checks
- FLASH
X
x = FLASH
DISTANCE
86 > Title of presentation - Date - References 86
PARTIAL DISCHARGES > 1000 nano Coulomb
A track path can display a “tree” shaped pattern
Creep from
HV to tank
wall along
the support
Creep from
board
HV wdg to
LV leads
during
Impulse
tests
»Convection
»Conduction
»Fan
1.3 x gradient
core
cooler
gradient
winding
Hot spot
Bottom oil
Mean oil
Top oil
Average winding
97 > Title of presentation - Date - References 97
Temperature Rise and Driven Factors
X Temperature Rise for Class A (IEC / ANSI C57);
Top oil rise ; = 60K / 55 K or 65 K.
Average oil rise ; = 65 K / 55 K or 65 K (By resistance method)
Hot spot rise ; = 78 K / 65K or 80K.
X Site elevation height;
The standard elevation height is 1000 m above sea level.
X Climatic temperature behaviors;
Yearly average ambient temperature (IEC std = 20oC)
transformer life time.
Hot monthly average ambient temperature (IEC std = 30oC)
Maximum ambient temperature (IEC std = 40oC) transformer
loading capability
Insulation class A E B F H
Bottom Oil
Annulus
(Ring)
Directed Oil
Flow entry point
CALENDERED
KRAFT BOARD Angle Rings
and Caps
CALENDERED
KRAFT BOARD Support Washers
r
x r
U Icc
Θo = Initial temperature in oC
Θ1 = Average winding temperature at certain time in oC
J = RMS short circuit current density in A/m2
t = Clearance time in second, max. 10 seconds
116 > Title of presentation - Date - References 116
Short Circuit - Dynamic Withstand
q V
r r r
F = qV ∧ B B
F
AXIAL FORCES I I
Fax Fax
dl
α
p σS σS
Leakage/ flux Rav α X
e
e
2B I
B F
Y
Rav
⎛ J −1 ni Ii 12 nJ I J ⎞
B = μ0 μr ⎜⎜ ∑ + ⎟⎟
⎝ i Hi HJ ⎠
B W1 W2 Wn
R1 R2
B2
r r r
p=I ∧B
R2
PJ .RJ
σ=
eJ
Hooke’s law ⇒ σ = E.I = E.
pJ PJ
E= Young modulus of material
Δ(2.Π.RJ ) ΔRJ
i= =
as 2.Π.RJ RJ
Internal counterpressure ΔR J
RJ PJ = eJ .E. 2
RJ
ΔRJ
FtJ = ( pJ RJ − FnJ )
dbs
Ft
2RJ
d bs
+ or
RJ
dMf
0 - x FtJ = −
dx
-Ft
and Hook law : EIy’’=-Mf
E : Young modulus
I : inertia
Mf : bending torque
e1 e2 en
Swidth
127 > Title of presentation - Date - References 127
Shearing Stress on CTC
F
τ
with epoxy
without epoxy
F2,0
F1,1 = F1,0 F1,n = F1,n-1
+ F2,0
F1,0
F2,n F2,n
F1,n F1,n
F1,n F1,n F1,n
kV
1200
H-Range
220
N-Range
110
E-Range
25 75 2500 MVA
TOP BEAM
TOP END
WEDGE
X E RANGE
TIE-ROD
Maximum Voltage ≤
170 kV
CRADLE
UPPER
CLAMPRINGS
LOWER
CLAMPRINGS
TOP BEAM
X N RANGE
FLITCH PLATE
Maximum Voltage ≤ 275
kV
UPPER
CLAMPRINGS
Weight of core steel
sheet, max 40 Ton
LOWER
CLAMPRINGS Weight of Part active max
80 Ton
Center-center distance
max 1600 mm
YOKE
SUPPORT
X Verification tools :
Overload capability of overloaded
Invodat capacitance network and voltage distribution
Corecalc Core losses and temp
Annuli Force oil entry evaluation
ASC Detailed core Design Program
Choc Transient impulse voltage Analysis
Clearstress Voltage Stress Evaluation
DOF Direct Oil Flow Evaluation
Fluxshunt Dimensional analysis for flux within tank shunt
Gradcalc Winding Gradient Evaluation
Radinsulation Lead clearances, thermal performances
RothFEM Forces, stresses, impedances and flux ploting
TRANSFORMER LEAKAGE
FLUX (GRID-FLUX LINES)
Breaking time
100%
Full wave
50%
30%
Active part
assembly
Drying
Repack
Assembly
Testing
A. PROTECTION DEVICE
- Protective Relay (Bucholz)
Function : to trip out the trafo if there is a
release of gas arising from the
decomposition of the solid and liquid
insulating material due to the action of
heat or electric arcing.
Principal Of Operation
- During normal operation, the relay is
completely filled with oil.
- When gas forms inside the trans-
former, it tends to flow towards the
conservator
- it accumulated progressively inside the
relay there by LOWERING the oil level.
- If gas continues to form, the oil level will A. Upper Float
affect the lower float B and relative B. Lower Flat
switch which is connected to the circuit
and causes disconnection of the
transformer power supply.
Function :
to measure the winding
temperature
Principal Of Operation:
measure the winding
temperature by means of a
special bulb surrounded by
heating resistance through
which passes a current
proportional to the current
passing through the
9. Microsw. Setting
transformer winding subject to 1. Case Pointer
a given load and immersed in 2. Locking Glass 10. Junction Box
Ring
insulating oil at temperature 11.Glass or
3. Fixing Rear polycarbo-nate
Flange window
4. Air Hole 12. Potentiometer for
5. Capillary Output heating resistance
adjustment
6. Dial
7.Microsw. Setting
Dial
8. Max. indicating
pointer
Function :
an equipment to relieve large volumes of gas or
insulating fluid rapidly when the pressure inside a
transformer reaches a pre-determined limit.
B. ACCESSORIES
- Oil Sampling Valve - Butterfly Valve
F=close position
O=open position
Power Input
Universal AC/DC
Self Diagnostics
Applications
Small to Large Power Transformers
RS 232 Port
Options for RS 485 and Protocol Converter
V2
Rx
DC power
V1
supply
Rx = Rstd x V1/V2
169 > Title of presentation - Date - References 169
Load loss & impedance measurement
This test will measure the load loss and impedance referring
to the rated current at some of tap changer positions.
The AC 3 phases supply is normally injected on the HV side
of the transformer. The power supply voltage is increased
until the nominal current is reached. The voltage giving
the rated current is the impedance voltage. This is
normally expressed as percentage of the rated voltage at
particular tap changer position.
If the rated current can not be reached due to testing
limitation or other reasons, the following correction factor
will be used. The minimum test current is 50% rated
current
Pextrapolation = Ptest x (Irated : Itest)2
During test, the transformer oil has to measured to correct
the copper temperature as ambient temperature reference.
The measured resistance has to be extrapolated to 75oC
(85oC for ANSI/IEEE with 65oC rise).
U’ - U
P 0 = Pm x ( 1 + )
U’
P0 = Corrected no load loss
Pm = Measured no load loss
U’ = Mean Voltage
U = RMS voltage
VHVN
rated frequency
Time (seconds) = x 120 , but no less than 15 seconds
test frequency
U1
tinduced
U2
ACLD
175 > Title of presentation - Date - References 175
Partial Discharge Measurement
Partial Discharge Measurement is measuring the small discharge
activity inside as well as outside around the transformer prior to
flash over occurrence. This measurement is a good tool to ensure
the transformer quality.
• Corona discharges occurs due to the sharp edge electrode.
• Surface discharges (creepage) occurs due to overstress component
parallel to the dielectric medium surface.
• Internal discharges occurs due to the non-homogenous dielectric
medium.
• Electric trees due to the particle or cavity in the solid insulation.
• Floating discharging occurs due to badly grounded component.
• Contact noise occur in case bad contact terminal.
HV = WYE
non-uniform
U1
2/3 UInduced
LV = DELTA
UInduced
v2 = 1/2u2 N
Usupply u2
1/3 UInduced
1 phase w2 = 1/2u2
V1 & W1
U1
LV = DELTA
u2
UInduced :S3 ced
n du
U I
w2 v2 N
Usupply
3 phase
W1 V1
Iinjected
Vinjected = Vrated x Z(%) x
Irated
x
(Pload loss + Pno load)
DAOT = ½ x (Ttop rad + Tbot rad) – Tamb) x
Pload loss
y
R2 Irated
GRCU = x (234.5 + T1) – (234.5 + T2) – DAOT x
R1 Iinject
y
R2 Irated
GRAL = x (228.1 + T1) – (228.1 + T2) – DAOT x
R1 Iinject
50%
50% impulse
100% impulse
SLN LE-NICKEL
3 x 1 PHASE 33.3 MVA
50 Hz, 63 Kv / 300 ~ 1800 Volt
OLTC ± 16 x 750 Volt
ODWF