Transformer Testing Station

Determining Sensitivity of a Relay to Inter-turn Faults on an Energized Power Transformer

Sponsored by:

Schweitzer Engineering Laboratories, Inc.

Transformer Testing Station

Team
Jacob Pomeranz Jared Mraz Eevi Maki
Mentor: Normann Fischer (SEL) Advisor: Dr. Joe Law

Transformer Testing Station

Catastrophic Transformer Failure!

Transformer Testing Station

Background
Inter-turn faults can destroy large power transformers Large transformers can cost millions of dollars New transformers can take up to 3 years for delivery Existing protection methods are not effective

Transformer Testing Station

Current Protection Methods

Buchholz relays
Operated by gas accumulation Can issue alarm signals for non-fault conditions

Transformer Testing Station

Current Protection Methods

Transfer Function Method
Effective for detecting faults Transformer must be de-energized

Transformer Testing Station

Needs
Determine the sensitivity of a microprocessor-based relay to inter-turn faults on an energized power transformer. Develop a protection scheme for detecting inter-turn faults

Transformer Testing Station

Specifications
Determine how sensitively protection can be set to detect inter-turn faults Specify and order a 3-phase transformer 55kVA transformer with taps being over as few turns as possible

Transformer Testing Station

Transformer Specifications
55kVA 240/240/25 Volts 3-phase Thermocouples to measure temperature Search coils to measure flux

Transformer Testing Station

Transformer Specifications
Taps at 1,2,3, and 5 turns on primary winding Windings rated for three times nominal current

Transformer Testing Station

Safety Concerns
Transformer must not be damaged or destroyed. Laboratory personnel and surrounding environment must remain safe during all testing.

Transformer Testing Station

Accomplishments
Transformer has been ordered Low-voltage fault tests have been conducted on an existing transformer Preliminary design for shorting circuit is operational

Transformer Testing Station

Goals
Explore detection of inter-turn faults on an energized power transformer To write a technical paper for presentation at WPRC Prevent damage to equipment and team members

Transformer Testing Station

Existing Test Circuit

Constructed to develop testing methods Shorting circuit is low capacity 15 kVA transformer Variac used to limit voltage and fault currents

Transformer Testing Station

Final Test Circuit Design

Shorting circuit will be high capacity Leads for test circuit as short as possible to reduce inductance 55kVA Transformer and shorting mechanism enclosed for safety Fusing must clear fault quickly to prevent damage

Transformer Testing Station

Existing Test Circuit

Transformer Testing Station

Existing Test Circuit

Transformer Testing Station

Existing Test Circuit

Transformer Testing Station

Test Circuit
Existing transformer
15kVA Coils rated 36A Shortable windings

Transformer Testing Station

Test Circuit
SEL-421Relay
Event recorder

Measures currents
Event reports exported to PC for analysis

Setup will be similar for final test circuit

Transformer Testing Station

Short Circuit
Contactor rated 600A Fuses used to clear fault High ampacity cable and bus bar for final design

Transformer Testing Station

Initial Test Results-Test 1

IA (A ) IB (A ) IC (A ) V A (kV ) V B (k V ) V C (k V )

IA ( A ) IB ( A ) IC ( A )

10

-1 0 0 .0 1 0 0 .0 0 5 -0 .0 0 0 -0 .0 0 5 -0 .0 1 0 2 .5 5 .0 7 .5 C y c le s 1 0 .0 1 2 .5 1 5 .0

V A (k V ) V B (k V ) V C (k V )

Transformer Testing Station

Initial Test Results-Test 2

) ) IB (A ) IC (A ) A V( A V A ( k V ) V B ( k V ) V C (I k
IA (A ) 10 5 0 -5 -1 0 0 .0 1 0 0 .0 0 5 -0 .0 0 0 -0 .0 0 5 -0 .0 1 0
50P1

IB (A )

IC (A )

V A (k V )

V B (k V )

V C (k V )

D ig it a ls

0 .0

2 .5

5 .0

7 .5 C y c le s

1 0 .0

1 2 .5

1 5 .0

Transformer Testing Station

Initial Test Results

Figure 3. Current flowing in shorting mechanism Vs. Phase Voltage

y = 4.5136x - 1.609
30

25

20

Current (Amps)

15

10

0 0 1 2 3 4 5 6 7 8 9 10

-5 Voltage (Volts)

Transformer Testing Station

Budget
Initial Budget
Motor Contactor Current Transformers Misc. Equipment

$12,376 -$ 585 -$ 678 -$ 100 -$ 9,376 $ 1,637

Transformer Remaining Budget

Transformer Testing Station

Plan
Additional work with 15kVA transformer
Gather data relating fault currents to phase voltage Determine relation between fault and load currents Obtain fuse elements capable of protecting transformer

Transformer Testing Station

Plan
Final design for shorting mechanism completed before transformer arrival
Additional detailed fault current modeling Thermal analysis for conductor sizing Size fuses to clear fault within 2-3 cycles Safe enclosure designed for fuse bank

Transformer Testing Station

Plan
Test bench design
Need to obtain dimensions from transformer manufacturer Bench must be functional and aesthetically pleasing

Transformer Testing Station

Plan
Final testing with 55kVA transformer
Fault signature not as apparent in phase quantities Filtering with MathCAD relay model necessary to determine fault signature Results used to design special differential protection scheme

Transformer Testing Station

Any Questions?
http://seniordesign.engr.uidaho.edu/2006_2007/teamprotection/