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Transformer Design
Review
By
Ir. Thum Peng Chew
B.E.(Hons), M.Eng.Sc.,FIEM, P.Eng
2 October 2012
Parameters in Transformer
Design
2 October 2012
Core
Core Clamp
Windings
2 October 2012
HV Bushings
Oil Gauge
Bushing CT
Chamber
Buchholz relay
OLTC
LV Bushings
Neutral Bushing
Valves
2 October 2012
Transformer Accessories
Dial-type thermometer gauges for oil and winding
temperature.
Oil gauge
Filter and drain valves
Nameplate
Handholds on cover or tank
Lifting eyes and lugs
Jack pad, ladder, ski-base
2 October 2012
Failure, %
Design Defects
Manufacturing Problems
Material Defects
Other Causes
Poor Maintenance
Lightning Surges
Short-circuits
35%
29%
13%
11%
6%
4%
2%
2 October 2012
Transformer Basics
2 October 2012
Winding Voltage
Rating, V volts.
Winding Current
Rating, I amperes
Star
Vr /3
Ir
Delta
Vr
Ir /3
2 October 2012
10
11
Magnetising Current
e
Induced sinusoidal
voltage
i exc
Non-sinusoidal
exciting current
i( t)
t +
i( t + )
Sinusoidal flux
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12
2 October 2012
13
Impedance Definitions
Definition based on rms values:
Impedance Voltage, Vz = {VR2 + Vx2}
Percentage Impedance, %Z = 100Vz/V obtained by
measuring exciting voltage, Vz to force rated
current flow with the winding shorted.
Derived from Losses PL and rated winding capacity,
S
%R = 100PL/S
%X = {%Z2 - %R2}
2 October 2012
14
Loss Components
No-Load Loss, PNL = Iron Loss + Losses at joints,
bolts and burrs + (also core vibrations and noise)
Load Loss, PLL = I2R Loss + Winding Eddy Current
Loss + Stray Losses
Copper Loss, Pcu = I2R Loss + Winding Eddy
Current Loss
Thus, Load Loss, PLL = Copper Loss + Stray Losses
2 October 2012
15
Components of Losses
Losses
No-Load
Loss
Iron
Loss
Joint
Loss
Load
Loss
Vibration
Noise
Copper
Loss
I2R
Loss
2 October 2012
Stray
Loss
Eddy Current
Loss
16
Iron Loss
Iron loss depends on the quality of steel
Expressed as
Specific Iron Loss in terms of watts per kg mass.
For a typical design Bm, the specific loss is around
1.1 W/kg.
Amorphous Steel Low Loss
2 October 2012
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2 October 2012
18
19
20
21
Winding
with N turns
Core
Cross-sectional
area per turn, a
Duct space
2 October 2012
22
23
2 October 2012
24
25
SUMMARY OF LOSSES
No-Load Loss Hysterisis Loss proportional to frequency and peak
magnetic flux density to the power of 1.6 to 2.5.
Loss at joints, bolts and burrs.
Stray Loss at end-edges
Load Loss
Copper loss (I2R)
Eddy Current Loss from circulating current induced by
magnetic leakage flux and proportional to square of
frequency, peak magnetic flux and lamination thickness.
Stray Loss by magnetic leakage to clamps and tank walls,
etc.
2 October 2012
26
27
Frame Size
The Frame Size in MVA, S = 3S MVA = VI x 106 is
related to the physical size defined by physical
dimensions, Afe and ACu .
S = 2.222f(BmAFe)(JACu) per phase
where f = operating frequency, Hz (50)
Bm = Peak Flux Density, T(1.6 1.8)
J = winding current density, A/mm2(3.0 3.5)
AFe = nett magnetic core leg cross-sectional area,
m2 , m=BmAFe
ACu = total copper cross-sectional area, m2
2 October 2012
28
2 October 2012
29
bLH
bLV
sm = 2 rm
bL0
bHV
rLV
hH0
Core
rm
2 October 2012
rHV
bm = bLV + bHV
Am = sm bm
= (sLVbLV +sHVbHV)
hL0
Mean turn Radius
bH0
hw
sHV = 2 rHV
LV Winding
HV Winding
30
Reactance
The percentage reactance, %X
= 0.79SfN2cw/V2h
Where h = winding axial length, mm
c = all windings mean turn length (sLV + sHV), mm
w = the reactive window width through which the
total leakage flux passes, determined from bLH +
(bLV + bHV).
h = length of leakage flux.
%X = 0.79Sfw/{(V/N)2h/c}
2 October 2012
31
Impedance Variation
For a given core, capacity and voltage
transformation ratio, a lower reactance requires a
larger magnetic core cross-section reflected in
the windings mean turn length.
As the reactance is increased, the core crosssection decreases and the iron loss also
decreases but the copper loss increases.
The ratio of Cu/Fe losses increases.
2 October 2012
32
33
Temperature Rise
Losses give rise to Temperature Rise
- Heating up the Windings
- Heating up the Insulation particularly the Oil
Thus, there are allowable maximum temperatures
of windings and insulation (oil).
If the ambient design temperature for oil is 30C,
then the oil maximum temperature rise is 75C.
2 October 2012
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35
2 October 2012
36
2 October 2012
37
2 October 2012
38
Cooling
With losses heating up the insulation and oil, a
transformer has to dissipate the heat to the
outside environment so that its maximum
temperature rise is not exceeded.
It is done by natural cooling of the tank surface.
At larger capacities, additional cooling surfaces
has to be added with radiators which are
detachable from the tank.
Assisted cooling can be achieved by adding fans
to blow air across the radiators.
2 October 2012
39
First Letter
(Cooling medium)
Second Letter
(Cooling mechanism)
Code Letter
O
K
L
N
F
D
External
Third letter
(Cooling medium)
Fourth letter
(Cooling medium)
Internal External
A
W
N
F
Description
Liquid with flash point less than or equal to 300C
Liquid with flash point greater than 300C
Liquid with no measurable flash point
Natural convection through cooling equipment and
windings
Forced circulation through cooling equipment, natural
convection in windings
Forced circulation through cooling equipment, directed flow
in man windings
Air
Water
Natural convection
Forced circulation
Table 2.1.2 lists the code letters that are used to make up the four-letter designation.
This system
of identification
has comeCopyright
about through
standardization
between different
2 October
2012
40 international
2012 TPC
Solutions
standards organizations and represents a change from what has traditionally been used in the U.S. Where
OA classified a transformer as liquid-immersed self-cooled in the past, it is now designated by the new
Tank Vibrations
The vibrations transmitted to the tank are altered
by the tanks vibration modes before they are
emitted as audible noise. Thus, no rigid
connections between core and tank.
The tank design/manufacture has to take into
account of resonance modes and reflection
patterns around the tank.
Panel mass-to-stiffness ratio changes the
resonance frequency, vibration patterns and
noise amplitude - stiffeners.
2 October 2012
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Noise Measurement
2 October 2012
42
TRANSFORMER CORE
2 October 2012
43
44
2 October 2012
45
Core Materials
Core loss W17/50 (W/kg)
www.leonardo-energy.org
0.
3
5
CG
2.0
O0
.30
1.0
CGO 0.23
HiB 0.23
0.30
1955 1960 1965 1970 1975 1980 1985 1990 1995 2000
Year
46
1. Around 1900, hot-rolled steel became the basic material for the core, made up of
individual sheets separated by insulating layers to reduce no-load losses. Cold-rolled
Grade
0.23
M3
0.90
0.27
M4
1.12
0.30
M5
1.30
0.35
M6
1.45
0.23
23ZDKH85
0.85
0.27
27ZDKH90
0.90
0.23
23M-OH
1.00
0.23
TCH-0
0.90
0.27
TCH-1
1.00
2 October 2012
47
Yoke
End Limb
Centre Limb
Magnetic Flux flow
Mitred Joints
Flux changes
direction at joint
Vanished
Yoke Laminations
2 October 2012
48
49
Clamp
Circular Core
To be
Surrounded by
Concentric
Windings
2 October 2012
Core Diameter, d
50
2 October 2012
51
52
Direction of Roll
2 October 2012
53
Core Building
Lamination are laid down flat on a building jig to
avoid deformation.
l Identical laminations are laid on top of one another
before changing to the complementary lamination for
interleaving.
l The smaller the number, the lower the loss but
longer time required to build.
l Add laminations until given stack dimension is
reached.
Stacking factor > 0.97
l Jig is turned for core to stand vertically.
l
2 October 2012
54
Interleaved
Mitred Joints
2 October 2012
55
Laminated Stack
Space Factor ~ 1.0
2 October 2012
56
57
Core Joints
Usually interleave/ overlapping mitred joints between
limbs and yokes to alternating disposition of different
lengths of lamination to reduce magnetic reluctance,
vibrations and improve mechanical strength.
Minimise the gaps between the abutting plates to
reduce transfer of flux and hence extra eddy current
loss in the steel.
Hence, limit the number of identical plates before
stacking the overlapping plates.
2 October 2012
58
Identical Plates
Stacking
Lamination
Abutting
2 October 2012
Interleave
59
60
27.03
53.06
21.86
43.02
osses, calculated as
osses at normal tap
.
edge stack on the stray loss was studied and the estimated
results are reported in Table XIII below.
Mode
Max. Tap
Nor. Tap
Min. Tap
TABLE XIII
COMPARISON OF LOSS IN EDGE STACK
Reduction in
Edge Stack stray loss, kW
loss (%)
Standard design
Modified design
4.90
2.18
55.51
5.40
2.57
52.42
4.38
2.09
52.27
SS RESULTS
timated by software
is shown in Table XI
LOSSES
ray losses, kW
Nor. Tap
Min. Tap
49.95
46.93
53.06
43.02
6.22 %
8.33 %
LOSSES
2 October 2012
Total
stray losses in transformer after 61
modification
Copyright 2012 C.
TPC
Solutions
The total stray losses estimated in the transformer with
modified shunt and divided edge stack are presented in
Precise estim
may not be pr
computation of
the economic
modern high s
deep insight
asymmetric tra
to exploit these
designs, explor
areas like shun
wise wall shun
The authors a
granting permi
[1] Ramaswamy
non-magnetic
International
September 20
Limbs
2 October 2012
62
2 October 2012
63
2 October 2012
64
65
Frames, also called yoke beams, are made of mild steel sides of transformer at extreme tap positions. The loss in the
scale, taking care
material and are used for clamping of yokes and supporting frames calculated from magnetic field values is as shown in
FEM technique.
the windings. The frames are modeled as epures coinciding Table VI below.
in such structura
with their physical locations for magnetic field plotting and
TABLE VI
magnetic field o
estimation of losses.
STRAY LOSS IN FRAMES
area leading to
Stray loss, kW
Fig. 5 & 6 below show the plots of the modulus of flux
Mode
shows the vector
Top Frame
Bottom Frame
Total
density components (Bx, By, Bz) in top & bottom frames
temperature rise
Max. Tap
0.98
1.74
2.72
along the height of the frame (from bottom to top) on the
Nor. Tap
0.82
1.43
2.25
value differentiat
HV side of the transformer at normal tap position. For
Min. Tap
0.58
1.24
1.82
being the highest
estimation of loss in the frames, it is essential to obtain the
The loss in the bottom frame, which is higher as compared
maximum and minimumFifteenth
values National
of flux densities
occurring
to the
top frame,
is commensurate
with the higher flux
Power Systems
Conference
(NPSC),
IIT Bombay,
December 2008
along the height of the frames, which is represented by Fig.
concentration
invariation
the bottom
5. Flux density
alongframe.
the height of the Top Frame
notations
B1
&
B2
in
Fig.
5
&
6.
The stray loss values in shunts, estimated based on above typically at normal tap position, obtained for top and bottom
D. Estimation of Stray Loss in Flitch Plates
magnetic field values, are indicated in Table IV below.
frame are as under. See Table V.
Flitch plates, made of MS
andV with slots at top and
TABLE IV
TABLE
STRAY LOSSES IN SHUNTS
bottom positions
are used
inONCENTRATION
the presentINcase.
The flitch
FIELD C
FRAMES
MAGNETIC
Stray loss, kW
Magnetic
(B), T to the
plates are 200 mm wide and 12mm
thickfield
modeled
Mode
Bottom
Frame
has
higher
loss
HV Side
LV Side
Side Shunt
Total
Top
Frame
Bottom
scale, taking care of the slots and analysis carriedFrame
out using
Flux
density
Max. Tap
0.78
2.51
0.54 from
3.83
Maximum value (B1)
0.00744
0.02022
FEM
technique.
It
is
important
to
note
that
the
stray
Nor. Tap
1.38
2.54
0.36 effect.
4.28
Minimum value (B2)
0.00032
0.00139 losses
proximity
Min. Tap
0.76
1.47
0.25
2.48
in such
elements are
quite
low but
the isincident
The structural
field concentration
in the
bottom
frame
over 2.7
Loss
is
proportional
field
on
them
can
be
quite
high
for
the
exposed
It is observed that the stray loss values in HV side shunts magnetic
times of that in top frame. This is attributed to lesser
leadingbetween
to unacceptable
local
hot spots.
Fig.the
7 bottom
& 8
are lower than those on LV sidetodue
to their
smaller height area
flux
density.
distance
the winding
bottom
edge and
2
shows
the
vector
plot
of
eddy
current
density
J
(A/m
)
and
and larger distance from the outer most winding.
frame.
temperature
risetheprofile
(K) from
minimum field
to maximum
Similarly,
maximum
and minimum
values are
C. Estimation of Stray Loss in Frames
value
differentiated
by
a
colour
band
from
blue
to
red,
obtained
for
top
and
bottom
frames
both
for
HV
andredLV Fig. 7. Vector plo
Power Systems Conference (NPSC), IIT Bombay, December 2008
Frames, also called yoke beams, are made of mild steel being
theofhighest.
sides
transformer at extreme tap positions. The loss in the
material and are used for clamping of yokes and supporting frames calculated from magnetic field values is as shown in
mated based on above typically at normal tap position, obtained for top and bottom
The magnetic
the windings. The frames are modeled as epures coinciding Table VI below.
Table IV below.
frame are as under. See Table V.
eddy
currents. T
their
physical
locations
for magnetic
field
plotting and
Fig.with
5. Flux
density
variation
along the
height
of
the
Top
Frame
TABLE
VI
TABLE V
Fig. 6. Flux density variation along the height of the Bottom Frame
solid and slotted
estimation ofMlosses.
STRAY LOSS IN FRAMES
TS
AGNETIC FIELD CONCENTRATION IN FRAMES
flux density bein
Stray loss, kW
Fig. 5 & 6 below show the plots
of the
of flux
kW
Magnetic
fieldmodulus
(B), T
Mode that owing to the proximity effect, the
It
is
observed
edges, it results
Top Frame
Bottom Frame
Total
ide Shunt
Total
Frame
Frame frames
density components (Bx, By,Top
Bz)
in topBottom
& bottom
regions of the flit
Max. Tap
0.98
2.72of top
maximum flux
density occurs
in the 1.74
bottom part
0.54
3.83
(B1)frame0.00744
along theMaximum
height value
of the
(from bottom0.02022
to top) on the
Nor.
Tap
0.82
1.43
2.25
the slots are pro
0.36
4.28
Minimum value (B2)
0.00032
0.00139
frame and the top part of bottom frame.
HV side of the transformer at normal tap position. For
Min. Tap
0.58
1.24
1.82
0.25
2.48
The field concentration in the bottom frame is over 2.7 The maximum and minimum values of flux densities, bottom locations.
of loss in the frames, it is essential to obtain the
The loss in the bottom frame, which is higher as compared
es in HV side shunts estimation
times of that in top frame. This is attributed to lesser
maximum
and
minimum
values
of
flux
densities
occurring
to
the top frame, is commensurate with the higher flux
o their smaller height distance between the winding bottom edge and the bottom
along the height of the frames, which is represented by concentration in the bottom frame.
500
winding.
frame.2 October 2012
66
Copyright 2012 TPC Solutions
notations
B1 & B2 in Fig. 5 & 6.
Similarly, the maximum and minimum field values are
D. Estimation of Stray Loss in Flitch Plates
s
obtained for top and bottom frames both for HV and LV
Flitch plates, made of MS and with slots at top and
e made of mild steel sides of transformer at extreme tap positions. The loss in the
bottom positions are used in the present case. The flitch
Loss in Frames
Core Clamping
Bands
Steel Support
Steel Beam
2 October 2012
67
Core Clamping
Bands
Steel Beam
Wood Laminations
2 October 2012
68
69
2 October 2012
70
71
Core Insulation
2 October 2012
72
TRANSFORMER WINDINGS
2 October 2012
73
WINDING CONDUCTORS
Copper in oil-type
Aluminum in dry-type
For economy, in the form of:
Wires low current (< 10A) but poor space factor.
Strips (> 10A, J = 3.5 A/mm2)
Foils and Sheets (current limited by thickness of foil or
sheet) and have high space factor and good cooling
ability.
2 October 2012
74
transposing operation.
Stray losses can be a constraint on high-reactance designs. Losses can be controlled by using a
combination of magnetic shunts and/or conducting shields to channel the flow of leakage flux external
to the windings into low-loss paths.
Continuously Transposed
Conductor (CTC)
Forces exist between current-carrying conductors when they are in an alternating-current field. These
forces are determined using Equation 1.15:
F = B I sin
where
F = force on conductor
B = local leakage flux density
= angle between the leakage flux and the load current. In transformers,
sin2.1.6is Schematic
almost of single-phase shell-form construction.
FIGURE
always equal to 1
2 October 2012
75
WINDING INSULATIONS
Those within a winding to prevent electrical inter-turn
breakdown by having appropriate insulation, cooling
by circulation using paper board-type spacers of high
dielectric strength.
Major insulation between windings and between a
winding and earth requiring good mechanical
strength and electrical properties (puncture
strength) .
2 October 2012
76
Insulation Types
For wires, Synthetic Enamel for low voltage
withstand.
For Strips, Paper for higher voltage.
For two or more strips in parallel and
transposed, synthetic insulation on
individual and paper for overall wrapping.
2 October 2012
77
Overall Insulation
Oil or SF6 gas
OIL QUALITY
Max. Viscosity = 40 mm2s-1 at 20C
Max. Acidity = neutralised by 0.03 mg KOG per gram.
Breakdown Voltage = 40 kV at 2 kV/s between 13 mm
dia. Spheres at 25mm apart.
Same permitivity of other insulants
Maintenance:
Keep out Moisture oil conservator, silica gel and
breather, drycol
2 October 2012
78
2 October 2012
79
Winding Temperature
The Thermal Image Method
Thermometer immersed in top oil and
connected to a dial-type instrument.
Transformer load current injects heat through a
current transformer.
The temperature indicated = top oil
temperature, 0 + k c the temperature
difference across the coil insulation.
k =1.1 1.5
2 October 2012
80
2 October 2012
81
x2
Fadorlevds
x3
x4
HV Winding
Regulating Winding
Iron Core
Radial Flux
Tank Shunt
Slotted Flitch Plate
and laminated tank
shunt reduce losses
Authorized licensed use limited to: INDIAN INSTITUTE OF TECHNOLOGY BOMBAY. Downloaded on October 25, 2008 at 01:26 from IEEE Xplore. Restrictions apply.
Fig. 2.3
2 October 2012
As mentioned in the previous section, the stray flux has the effect of creating eddy
82
Stray Losses
The Total Stray Loss =
20% 25% of Total Load Loss
But can be reduced to
8% 10% of Total Load Loss
By flux control methods magnetic shunts
2 October 2012
83
Min. Tap
4.38
Sr.
No.
1
2
3
4
5
6
TABLE X
TOTAL STRAY LOAD LOSSES IN TRANSFORMER
Component
Stray losses, kW
Max. Tap
Nor. Tap Min. Tap
Tank
13.60
13.48
11.95
Shunts
3.83
4.28
2.48
Frames
2.72
2.25
1.82
Flitch Plates
0.65
0.62
0.52
Edge Stack
4.90
5.40
4.38
Winding eddy losses
27.67
27.03
21.86
Total Stray + Eddy losses
53.37
53.06
43.02
84
COMPARISON OF
Mode
St
Max. Tap
Nor. Tap
Min. Tap
It is observed
reduction in the t
have the effect of
marginal and hen
losses with modifi
B. Modification
In large transfor
considerable eddy
abnormal local h
bubbling of oil in
edge stack on the
results are reported
COM
Mode
Max. Tap
Nor. Tap
Min. Tap
Stand
The temperature
2 October 2012
85
Item
No.
Source of Loss
Loss Reduction
Tank
Edge Stack
Flitch Plate
Frames
2 October 2012
86
permeability at the entry point reduces making it less effective as compared to the
edge-wise shunt. The flux distribution at the entry point is quite complicated. The
presence of inter-laminar non-magnetic gap reduces the average permeability in
the direction normal to the laminations to a low value, hence the flux tends to stay
within a particular lamination until it saturates. The flux finds its way through the
next lamination when the earlier lamination saturates and so on. Thus, it can be
seen that the effectiveness of the width-wise shunt is less as compared to the edgewise shunt.
The manufacturing process of edge-wise shunts is quite elaborate. In one of the
forms, a set of laminations are epoxy moulded (like that of laminated flitch
plates). In another design, it can be made into a wound form. The loss advantage
with the edge-wise shunts has to be assessed vis--vis their higher cost and
manufacturing time as compared to the width-wise shunts. The performances of
these two types of shunts are compared in [64] by finding their effective
anisotropic permeability. A substantial reduction in tank stray losses is reported in
[26] by the use of edge-wise shunts. It is preferable to experimentally check the
quantum of stray loss reduction before standardizing the use of edge-wise shunts.
Magnetic Shunts
Stray Losses in Structural Components
Figure
5.28 Width-wise shunt
Width-wise
Shunt
209
Edge-wise Shunt
(5.34)
Solutions
87
213
88
paper [34] 1999 IEEE. Reprinted, with permission, from IEEE Transactions on
TheDelivery,
directionVol.
of eddy
currents
indicates
the9961001.
predominance
of radial field
at the
Power
14, No.
3, July
1999, pp.
The dependence
of flitch
crossloss
section,
mm
fromofthe
surface.
There gap,
are no
eddy to
current
loops in
plate
on the0.5
axial
length
windings,
core-LV
winding
yoke clearance
thickness
ofgap
the is
plate
(see figure
These
are the
reasons
for the
effectiveness
and
LV-HV
observed
to be5.14).
high. The
flitch
plate
loss varies
almost
linearly
of slots
in thegap.
SS plate.
The eddy
current
loops by
aremultiple
parallel to
the surface
(on which
with
LV-HV
A quadratic
surface
derived
regression
analysis
can
theused
fluxby
in designers
incident) indicating
the eddy lossestimation
in the SS plate
predominantly
be
for a quickthat
but approximate
of theisflitch
plate loss.
due loss
to the
radial
field. can
Hence,
the to
slots
in the
SS(with
plateslots/without
are more effective
as
The
value
obtained
be used
decide
type
slots) and
compared
to the MS
plate.
This means that
the loss
should
reduce
material
(magnetic
mild
steel/non-magnetic
stainless
steel)
of the
flitch approximately
plate to control
byloss
a factor
of (n+1).
FromThe
theeffectiveness
first two results
givenand
in table
we see
that the
its
and avoid
hot spots.
of number
length5.2,
of slots
in reducing
reduction
in the
loss is more
(12 times)
than
expected
(8 times).
may
be due
losses
can be
ascertained
accurately
by 3-D
field
calculations.
In theThis
paper,
in-depth
to fact that
each slot
is 5 paths
mm wide
causing
a further
reduction
in steel
the loss
to the
analysis
of eddy
current
has been
reported
for slotted
mild
anddue
stainless
reduced
of conduction.
steel
flitcharea
plates,
having dimensions of 1535 mm200 mm12 mm, used in a singleDue33toMVA,
higher220/132/11
resistivity of
the losses in the SS plate are lower than the MS
phase
kVSS,
autotransformer.
plate.
results
from tables
and(MS)
5.2 are
compared
for the
no slots
it can6
ForIfthis
analysis,
a mild5.1
steel
flitch
plate with
r=1000
andcase,
= 410
be seen has
thatbeen
the SS
plate loss
not significantly
themm
MSatplate
lossThe
for
mho/m
studied.
The iscorresponding
skinlower
depththan
is 1.1
50 Hz.
12 mmobtained
thickness.areFor
a higher thickness,
the loss
thevalues
SS plate
mayare
exceed
the
results
summarized
in table 5.1.
The in
loss
shown
for one
loss in of
thethe
MS
plate, which
fourth
complete
plate.is in line with the graphs in figure 5.5. It shows that in
order to get lower losses with SS material, its thickness should be as small as
possible with due considerations to mechanical design requirements. With the SS
Table
Loss in effect
MS flitch
plate
Mildalthough
Steel losses
Flitch
Plate
plate, 5.1
shielding
is not
available. Hence,
in the
flitch plate are
reduced
with
SS
material,
the
stray
loss
in
the
first
step
of
the
core
Case number
Description
Loss inmay
wattsincrease
substantially
if
it
is
not
split.
Therefore,
thicker
flitch
plates
with
a
low
incident
1
No slots
120
flux density should be of MS material.
2
1 slot throughout
92
A laminated flitch plate (consisting of M4 grade CRGO laminations) has also
3
3 slots throughout
45
been analyzed through 3-D FEM analysis by taking anisotropy into account. The
7 slots
throughout
direction 4along the flitch plate
length
is defined as soft direction32
and other two
5
1
slot
of
400mm
100
directions are defined as hard directions. Thelength
loss value obtained for
the laminated
6 is just 2.5 watts,
3 slots
of 400mm
flitch plate
which
is quitelength
lower than the SS52
plate. Hence,
7 slots
of 400mm
length
laminated7 flitch plates are
generally
used
for large power 45
transformers,
particularly generator transformers, where the incident flux density is quite high.
187
Table
Losses
in Dekker,
SS flitch
Copyright5.2
2004
by Marcel
Inc. plate
Case Number
1
2
3
4
Description
No slots
7 slots throughout
7 slots 400 mm long
3 slots 400 mm long
Loss in watts
98
8
11
17
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89
5.8 Evaluation
of Stray Loss
Due to High Current Lead
High Current
Bushing
Mounting
In furnace transformers and large generator transformers, the stray loss
Plate induced eddy currents in structural components in the vicinity of high c
2 October 2012
90
Stray Loss due to HV leads tends to be lower than that from LV leads
because of the proximity of LV leads to tank wall.
Control tank loss with shunts.
2 October 2012
91
given in figure 5.4 (c), an explanation similar to that for Case 1 can be given. The
application of Amperes circuital law gives double the value of current (i.e.,
2HL=I) as compared to Case 1. Hence, as the thickness (2b) decreases, the current
has to pass through a smaller cross section of the plate and thus through a higher
resistance causing more loss.
In the previous three cases, it is assumed that the incident magnetic field
intensity is tangential to the surface of a structural component (e.g., bushing
mounting plate). If the field is incident radially, the behavior of stray loss is
different. Based on a number of 2-D FEM simulations involving a configuration in
which the leakage field from the windings is radially incident on a structural
component (e.g., tank or flitch plate), the typical curves are presented in figure
5.5. The figure gives the variation of loss in a structural component as the
thickness is increased, for three different types of material: magnetic steel, nonmagnetic steel and aluminum. The curves are similar to those given in [4] wherein
a general formulation is given for the estimation of losses in a structural
component for any kind of spatial distribution of the incident magnetic field.
Let us now analyse the graphs of three different types of materials given in
figure 5.5.
2 October 2012
92
ACK
The authors are grate
granting permission to p
Reduction
in inStray
Losses
C. Total stray losses
transformer after
modification
Sr.
No
1
2
3
4
5
6
TABLE IXV
TOTAL STRAY LOAD LOSSES WITH MODIFIED SHUNT
AND DIVIDED EDGE STACK
Stray losses, kW
Component
Max. Tap Nor. Tap Min. Tap
Tank
12.13
11.68
10.59
Shunts
3.83
4.36
1.35
Frames
2.72
2.25
1.82
Flitch Plate
0.65
0.54
0.62
Edge Stack
2.18
2.57
2.09
Winding eddy losses
27.67
27.03
21.86
Total Stray + Eddy losses
49.18
48.43
38.33
Sr
TABLE
XVTPC Solutions
Copyright
2012
93
WINDING TYPES
Selection dependent on current and voltage ratings.
Helical
l Multi-layer
l Disk Coil
l
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94
HELICAL TYPE
A turn-by-turn formation of helix of constant diameter
for low voltage and heavy current.
Capacitance to earth, C and is large.
With wire type, applicable to the high voltage windings
of small capacity distribution transformers.
With strip type, applicable to the low voltage winding of
distribution transformers.
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99
Helical Multi-Layer
For a wide range of currents, a helical coil can be
wound over another layer.
Multi-layer helical windings can be formed by
connecting each helical layer in series. This
found in 132 kV windings.
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DISK TYPE
Continuous disk coils consisting of a number disks
wound alternatively inside-to-outside and outside-toinside for higher voltage and low current and great
short-circuit strength.
Relatively low series capacitance to high capacitance to
earth.
Tendency is large but as the transformer gets larger
reduces
Applicable to high voltage windings.
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101
Turn No.
"#$%&' !!()
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102
Chapter 4
Turn 1
Outside Crossover
8-Parallel, 3-turn
Continuous disc Winding
Turn 2
Turn 3
Inside Crossover
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103
Rating
(MVA)
High-Voltage Winding
Low-Voltage Winding
kV
Type
kV
Type
<1
11, 33
Foil,
Crossover
or multilayer
0.43
Helix
System
1 - 30
33, 66
Disc
11
Disc, Helix
or Disc-helix
Transmission
> 30
132 - 500
Disc, Multilayer
11, 33, 66
Disc or
Disc-helix
Generator
> 30
132 - 500
Disc, Multilayer
11 - 22
Disc-helix
Distribution
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105
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106
With larger units, a dedicated tap winding may be necessary to avoid the ampere-turn voids that occur
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107
Drum Rotation
Ducts
108
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109
Transposing Coil
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111
112
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114
Preparing Transition to
Outside-in Coil Layer
Temporary transition
115
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Assembled Windings
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119
Tapping Leads
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Terminal Bushings
and Surge Arresters
121
TRANSFORMER TANK
2 October 2012
122
Tank
Stiffeners
Drain Valve
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123
Tank
Lifting Point
Hot-oil Gasket
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124
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125
Tank Design
Achieve mechanically strong vessel for supporting
the mass of core, windings and oil during
transportation and lifting. Optimised to hold
minimum oil to a safe and reliable amount.
Provide rigidity with stiffeners yet reduce vibration
to limit panel size whose length is proportional to
the wavelength of vibrations in air.
Stiffeners are for lifting holds, jacking pads,
supports and draw holes.
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126
Tank Cover
Tank cover can be bolted or arc-welded. Gasket
material is protected from excessive
compression by limit stops.
All plates, sections, lifting points are welded.
OLTC may be attached to tank cover.
Tank is tested for leakage and able to withstand at
least 25% excess internal pressure.
Space at bottom for collection of sediments.
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127
Magnetic Screening
To reduce stray loss
Some magnetic flux flow from the core to outside
the winding and to the tank.
A magnetic screen converges the magnetic flux to
itself by forming a low-reluctance path.
The screen surrounds the windings or are mounted
as core-plates on the internal tank walls.
They carry a lower flux density (0.4 T) at normal
current.
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Tank Tests
Type Test
Low-Oil Pressure test at 6.6 kN/m-2
Oil-Pressure Test at twice normal; oil pressure or
normal oil pressure plus 35kN/m-2
Plates do not deflect above specified value.
Routine Test
Oil-leakage test at 35 kN/m-2
Above normal pressure for 24 hours.
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Oil Preservation
Oil is used for Electrical Insulation and for
Transformer Cooling
Oil Preservation serves to maintain the quality and
properties of oil for the long-term so as not to
affect the winding paper insulation.
Do not allow the oil temperature to exceed a
maximum value and to prevent the ingress of
moisture.
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Transformer Temperature
Chapter 2 Transformer Losses and Temperature Rise
Hg
Top of winding
Average oil
Bottom of winding
Top oil
Hot-spot
Average winding
Bottom oil
Temperature rise
October
Copyright
2 The
hot 2012
spot temperature rise
at the 2012
top ofTPC
theSolutions
winding
132
2 October 2012
133
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134
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135
Radiators
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136
Installed Radiator
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137
138
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139
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140
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141
Synthetic Diaphragm
Place inside the conservator to compensate for oil
volume variations due to temperature changes.
Prevent condensation of moisture in the
conservator and keeps the oil dry.
Inside the diaphragm is air at say, 0.1 bar and
outside is oil.
Made up of high elastomeric nitrile-coated fabric
that can resist oil and oil contamination.
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Oil Conservators
OLTC Conservator
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143
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144
Transformer Accessories
Dial-type thermometers for oil and winding
temperature.
Oil gauge
Pressure Relief device
Filter and drain valves
Nameplate
Handholds on cover or tank
Lifting eyes and lugs
Jack pad, ladder, ski-base
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145
Temperature Gauges
Oil Temperature
Gauge
2 October 2012
Winding Temperature
Gauge
146
OLTC Panel
2 October 2012
147
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148
Breathers
2 types:
Most common Silica Gel Cobalt Chloride
The other Freezer Dehydrator or Automatic
Insulation Drier - Drycol.
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149
150
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151
Gas-actuated Protection of
Transformer
This requires that the main tank is full-filled with oil
and gas produced within has to be released
quickly and directly to the air via a pressure
relief-device attached to the top of the main tank.
Thus, the conservator is connected by an oil-filled
pipe from the main tank and has only one space
for atmospheric contact via the breather.
Hence, the Buchholz Relay.
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153
Buchholz Relay
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154
Buchholz Relay
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155
156
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Earth bar
Site Connection to Earth
2 October 2012
158
Terminal Bushings
Surge
Arresters
Bushings
2 October 2012
159
Surge Arrester
HV Bushing
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160
Transformer Bushings
Two re-entrant types:
Synthetic-resin-bonded paper bushing
Oil-impregnated paper bushing for EHV.
Both of which layers of electric screens to grade
the stress of the insulant enclosed in porcelain
The requirement is to ensure thermal stability of
the insulation hence, lower dielectric dissipation
factor and permittivity and high thermal
conductivity.
The bushing can accommodate a current
transformer.
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Lead Connections
The winding is connected with a flexible pullthrough lead which is connected internally to the
top-end helmet of the bushing. The whole space
is filled with oil.
The lead is fitted with a gas-bubble deflector to
prevent gas released from getting trapped in the
space.
Externally, arcing gap prevent damage to the
porcelain by power arc.
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162
Bushing Tests
Type Tests:
Thermal stability, Wet voltage withstand, surgevoltage, visible corona, temperature rise, oilimmersed voltage withstand, power factor and
internal discharge.
Routine Tests:
Oil leakage, voltage withstand, internal discharge,
surge-voltage, power factor.
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Cable Gland
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Lifting Lug
Frame Earth
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165