1-Design Concepts and Specification - Betancourt

Powering reliable solutions for you
Design Concepts and Specification

Enrique Betancourt R.
Transformers Technology and Diagnostics Seminar

Prolec GE - WEIDMANN
May 2013 Monterrey, NL
Copyright Prolec GE Internacional Powering reliable solutions for you
Proprietary information
Contents
1. 2. 3. 4. 5. 6. Fundamentals Construction Basic Requirements Types of Transformers Components and Performance Parameters Key Design Stages
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Copyright Prolec GE Internacional
1. Fundamentals
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Definition and Principle of Operation

ELECTRICAL TRANSFORMER: DEVICE WITH NO CONTINUOUSLY-MOVING PARTS, THAT BY MEANS OF ELECTROMAGNETIC INDUCTION, TRANSFERS ELECTRICAL ENERGY BETWEEN TWO CIRCUITS AT, GENERALLY, DIFFERENT VOLTAGE BETWEEN TERMINALS.
a
Magnetic Field (Flux) Electric Current
i1
V
Flux
i2
E
2
(NxI)
N1 N2 N 1
Winding No. 1
Winding No. 2
Ferromagnetic Core
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The Role of Transformers in the Grid
20 kV
3-phase generator step-up
500 kV
220-127 V
115 kV
1-phase pad-mount
Network Autotransformer
1-phase pole-mount
220-127 V
13.2 kV
600-127 V
3-phase primary substation xfmr
3-phase pad-mount (CPAD)
network
secondary substation transformer (SST) - liquid - vent dry - cast coil
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2. Construction
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Basic Construction of a Power Transformer (Core type, >7.5MVA)
- Silicon steel laminations - Stepped to fit round section - Vertical Legs, horizontal Yokes - Size impacts tank height and length
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Core Insulation
- Clamp and isolate the core - Core grounded at a single point - Cooling ducts to avoid hot spots
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Winding Packages
- Each phase-package has primary and secondary windings - Cylindrical shape provides high mechanical strength - Inner LV Wdg. outer HV Wdg. - Oil enters cool at bottom and leaves hot at top
- High strength rings axially clamp the windings
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Frames and Tank Attachments
- Tie together the core laminations - Provide support for coil clamping and lead structures - Large size units require insulated clamps - Must withstand handling, shipping and short circuit forces
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Lead Structures
- Provide safe dielectric clearances for winding leads - Must withstand shipping and short circuit forces
- Provide support for NLTC and other components
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Leads
- Rated for maximum operation and test currents - Insulation according to test voltage and clearances
- Hot spot below winding hot spot

- Brazed or crimped joints - For high currents, magnetic clearances important
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Bushings
- Allow pass of HV leads through grounded tank cover or walls - Most from procelain, some polymeric - LV solid, HV condenser type - Connector area according to maximum current
- Normally mounted in turrets with current transformers

- Most oil-air type
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Tank Bottom
- Robust for lifting and transportation - Flat or with stiffeners - Attachment points for seismic forces - Inner attachments for core and coils
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Tank (w/o cover)
- Structural, low carbon steel (mainly) - Keeps core and coils oil immersed, clean and free from moisture - Welds and gaskets must be leak proof - It withstands vacuum processing, handling, shipping, operating pressure and seismic forces - Reacts with magnetic leakage flux to produce stray losses
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Transformer Assembly
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Tank Cover
- Welded to the walls - Non-magnetic steel inserts - Holds main and auxiliary bushings, CTs and pressure relays - For conservator type, conveys bubbles quickly to gas relay
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Tank Radiators
- Attached with valves and flanges to the walls - Heat exchangers made of soft steel panels
- Fans improve heat transfer rate

- Single or common headers convey oil out of (top) and back in (bottom) the tank
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Conservator Tank
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Bushings and Arresters
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3. Basic Requirements
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Technical Requirements
Normal Spec
Type (conventional 2W, 3W, Auto, GSU)

Load Rating (base and extended), MVA Rated Voltages (HV, LV, TV), kV
Winding Connection (Y, Delta, Z)

Temperature Rise (65oC, 55oC) Impedance (voltage drop) Ambient Temperature (30oC Avg., 40oC mx) Core overexcitation 110% no load, 105% at full load
Tolerances according to ANSI-IEEE
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Special Requriements
Core overexcitation Overloads with/without loss of life
Impedances for more than two windings

Impedance swing within taps range Extreme ambient temperatures (55oC-50oC)
Short circuit with overvoltage

Corrosive operating ambient Frequent short circuits, switching or lightning Reduced tolerances (impedance, losses, ratio)
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Criticals to Quality (CTQs)
Total owning cost (initial cost + losses) Cost of transportation and erection on site Performance as specified Service reliability On time delivery on site
Cycle time for delivery of drawings
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Design Challenges
Balanced cost of losses (no-load and Load) vs. materials cost Cooling (Normal and Emergency Load) Exact estimation of hot spot temperatures Limit thermal degradation of cellulose and oil Limit thermal surface load (mW/mm2) Avoid excessive gas generation Overvoltage Endurance (Impulse, Switching) Limit electrical stress in oil Exact calculation of voltage distribution Mechanical Withstand (Short Circuit, Vacuum, Shipping) Exact calculation of forces and stresses Estimation of impact strength of materials
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4. Types of Transformers
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Transformer Classifications
Number of Phases
Three Phase Single Phase
b/2 b 1
Type of Core
Core type Shell type

b/2
2 3
Main Cooling Medium

Oil (air/water) Air (air/water) Synthetic Fluid
Application in the Power System

Substation step down Generator step-up Autotransformador (inter tie) Regulator Distribution Industrials
3
b/2 1 b/2 b
Number of Main Windings

Two winding Multiwinding (usually three)
Transformation Ratio
Off circuit Taps (10% Range) On Load Tap Changer (20% Range) No taps
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( Source: Dietrich, Transformatoren )
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Three-Phase Winding Connections

H1 X1 X2 X3 Xo H2 H3
Wye Connection
Delta Connection
Higher voltages Neutral can be grounded
Higher currents Capacitively referred to ground
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Autotransformer Connection
IH Throughput power: VH * IH = VX * IX
NS
IX
Converted power:
VX * IC
VH
IC NC
Converted / Throughput:
VX = 1 VX / VH = NS / (NS + NC)
Lower cost than equivalent transformer Same grounding H and L sides (galvanic coupling) Y-Y Connection Low impedance, high short circuit forces Lower benefits as VX << VH
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Variable Turns Ratio

I I
N/2
90% turns
V
N/2
V
10% turns
De-energized Tap Changer (DETC)

Small range (+/- 5%) Few steps Low cost Low maintenance Normally on HV side
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On Load Tap Changer (LTC)

Larger range (+/- 10%) Tens of steps High cost Intensive maintenance
Can be HV or LV side Copyright Prolec GE Internacional
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Transformer Application
Generator Step Up:
Takes power at generator low voltage-high current, and scales up voltage for efficient, long distance transmission LV normally Delta connected (12-23kV), HV (69-760 kV) is Wye connected Tie two transmission systems of different voltages together Both high and low voltage are Wye connected LV winding common to primary and secondary sides A delta tertiary winding is commonly used for harmonic suppression and neutral stabilization. Affords cost savings over two winding transformers Usually applied for voltages of 69kV and above
Step down transmission voltage from lines to suitable levels for bulk distribution Most common connection for US application is Delta-Wye LTCs are commonly used on the LV, to regulate load voltage Takes power from the generator or the HV transmission system and steps down to serve station loads
Autotransformers:
Substation Step Down:
Station Auxiliary:
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Three Phase Transformer
Single Phase Transformer in a 3-Phase Bank
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5. Components and Performance Parameters
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Fundamental Design Equation

AC voltage excitation of a ferromagnetic core
Zi Zi i N i R
N d dt
V(t) = Vmax* sin(t) = Z*i(t) + N d(t)/dt If Z*i(t)<<N d/dt
y N (d(t)/dt)
Then
(t) = (1/N)* f[Vmax*sin( t)] = (-1/N*) Vmax*cos (t)
max = Vmax / (N*2pf)= e2 Veff / (N*2pf) Veff = 4.44 f *N* max = 4.44 f *N * Area *Bmax
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Turns Ratio
The ferromagnetic core builds a magnetic circuit The flux is the same in every section of a single loop
Open circuit voltages:
N N
1 2
2

2
V1 4.44 f N1
V2 4.44 f N 2
V3 4.44 f N 3
3
3
N
3
V1 V2 V3 N1 N 2 N3
Three winding transformer
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Exciting Current of Power Transformers
Exciting Current
im e i
e Induced Voltage Magnetic Flux i Exciting Current im Magnetization Current ic Exciting Loss Current
ic
Non sinusoidal waveshape

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Harmonics in Exciting Current
Main harmonics in Exciting Current I1m Fundamental frequency component (50/60 Hz). Im3 3rd harmonic component Im5 5th harmonic component
Phase shift between harmonics in a three phase system
3rd harmonic is dominant, and cancels in 3 phase systems.
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Core and Shell Types
Core Type (3P)
Shop assembly of a shell type core (1P)*

* Courtesy: Tramosa, Monterrey Repair Shop
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Types of Cores
20 12 30 32
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Core lamination cuts:

Cycle? Stock? Losses? Noise? Scrap? Hot spots? Width?
FM COMPOUND FM SPLIT 20 12 30 32 FM SOLID SM SOLID
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Core Joints
a) Low flux density 5 0,5 mm
Upper Yoke
b) Higher flux density

Lower Yoke
Flux concentration in the gaps at joints
Step lapped joints
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Excitation losses (NLL, Core loss)

W / Kg
1.8
VA / Kg
18
P
1.6 1.4 1.2 1 0.8 P 1.5= 0..87 W / kg 0.6 0.4 0.2 S 1.5= 1..17 VA/kg 0 1.5 0.6 0.8 1 1.2 1.4
16 14 12
10
8
6 4 2
Magnetic flux distribution in a three limb core
1.7 1.6 1.8 T 2
Core Loss
Magnetic flux concentration, driving hot spot at the T joint
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Components of Core Loss

: Hysteresis Loss B B5 Br W = H dB [ w/m ]
3
W /cycle = f H dB ~ Area within hysteresis loop
Hc
H Area = f (Bmax) Hysteresis Loss : PH = Volume * f *c * Bmax e e = 1.5 . . . 2.0 Experimental c, e material constants
Cancellation of circulating currents in a laminated core.
Core Eddy-Current : Loss
In each loop :
d eind ~ dt
Concentric loops icirc. ~
eind length
0 sin wt Solid Core
0 sin wt Lam inated Core
eind 2 Peddy ~ ength l
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The laminated core exhibits strongly reduced eddy current losses, because each path ha s low induced voltage and high electrical resistance . Copyright Prolec GE
Internacional
44
Core material losses

Material 110 Losses
100
Material Losses W/kg

Standard
2.0
1.0 0.5 0.3 0.2 0.1
%
90 80
Hi-B 70 60
Laser Future
0.05 0.02 0.03
50
0.35
0.3
0.27
0.23
0.2
Thickness
mm
50
0.01 0.6
0.8
1.0
1.2
1.4
1.6
1.8 T 2.0
Flux Density
Trend in core loss for cold laminated steels.
Comparison Hi-B vs. Amorphous Metal

1.- Hi-B silicon steel 2.- Amorphous metal
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Excitation VA
1.8
W/kg
1.6
Conventional
Other key variables for the Core:
1.4
1.2
1
Mechanical strength and stability

Grounding Hi B Clamping pressure
0.8
0.6 0.4 0.2 0 1.5 0.6 0.8 1 1.2 1.4 1.6
Volts per turn

Gaps at the joints
1.7 1.8 2
Tesla
Comparison HiB vs. Conventional oriented grain steel

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Conductors and Windings

1) 1) 2) 3)
2)
3)
4)
5)
Types 1) 2) 3)
of Conductors Rectangular conductor with paper insulation. Twin conductor. Continuously Transposed Conductor (CTC).
Layer and Disk Windings 1) Layer Wdg. (double layer). 2) Continuous Disk Wdg. 3) Sequential Disk Wdg. 4) Pair of continuous disk sections. 5) Pair of interleaved disk sections.
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Types of Windings
Helical (single, doble, triple)
Layers
Tapping Winding Barrel with taps
Multistart
Disks Continuous Intershield Interleaved Layers Conventional Special arrangements
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Insulation Assemblies
( Source: Transformatoren, Dietrich )
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Field Plots for Insulation Design
Core
LV Wdg. A
HV Wdg. A
HV Wdg. B
( Source: EHV Weidmann )
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Finite Element Mesh
Core
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Equipotential Lines
Core
LV Wdg.
A
HV Wdg. A
HV Wdg. B
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Lead structures
DESIGN CONSIDERATIONS Materials Dielectric and magnetic clearances
Short circuit and transportation forces

Assembly process (factory and field) Temporary assembly elements
Operating temperature and heat run overloads

Magnetic balance Current share in parallel circuits
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Main Tank
DESIGN CONSIDERATIONS
Structural steel
Low temperature operation

Seismic withstand Shipping lugs
Welds for accessories

Location of accessories Non magnetic inserts Shipping detachable components Gas collecting pipework Gaskets
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Insulating materials
Main materials
Insulating Fluid Paper and pressboard Synthetic paper and pressboard Wood (natural and synthetic) High strength plastics Glue and adhesives Enamels
Requirements
Dielectric withstand Mechanical strength Temperature index Process resistance (VP, vacuum, oil) Long-term chemical stability
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Courtesy of Weidmann Electrical Technology
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6. Key Design Stages

Cooling Mechanical forces Dielectric stress
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Transformer Cooling Circuit

Natural circulation of oil through the windings:
Natural air cooling ONAN

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Forced Air Circulation ONAF

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Transformer cooling circuit

Forced oil circulation ODAF, OFAF
ODAF Forced flow through the windings
OFAF Forced flow into the tank, only
Radiators
Fans Pump
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Cooling of windings Cooling of Windings

Temp Barrier Barrier
Tamb
TOT HST
Oil Conductor
DOF Washer deflectores
Spacer
Axial Duct Radial duct Wdg. Depth Gradient Cu-Oil
Oil Flow
Conductors
Axial Cut View
Section (top) View
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Short circuit withstand
LV Fa LV HV
HV Fa
( Fuente: Dietrich, Transformatoren )
Magnetic Field and Resultant Forces

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SC forces in core type transformers

Lateral section view of phase package Top view of phase package
FA
Core
ISC
FR
Outer Winding
Inner Winding
Force vs. time

Center Line
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Axial effect of SC forces
Conductors
Spacers
Axial Forces
Spacers
Conductors
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Short circuit strength and reliability

Short circuit endurance is fundamental for reliable operation
SC currents in power systems grow with interconnection

Standardized tests guarantee SC endurance under controlled conditions, but, for how many more years? How many short circuit events?
Most insulating materials undergo degradation after long service

DGA and conventional testing do not guarantee timely detection of mechanical weakness, to avoid catastrophic failures good, proven design and manufacturing practice is a MUST New techniques, as on line mechanical vibration monitoring, and off-line SFRA promise better ability to detect incipient degradation
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Isostatic winding sizing
Hydraulic Jacks clamp the windings
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Impulse withstand
Interleaved Windings
c
1
c
1
c
1
c
1
C1 is high
Continuous Disk Winding
c
1
c
1
c
1
c
2
c
2
c
2
c
2
c
Types of Disk Windings
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c
1
c
1
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Non linear voltage distribution
Cg
Lightning Impulso de Impulse Tensin
Cs
V1
Cg
Cs
V2
t
Cg
Cs
V3
V1 > V2 > V3 . . . .
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Lightning impulse overvoltage

P.U. Impulse Voltage
1,0 0,8 0,6 b 0,4
1.0 P.U. Impulse Voltage
t
d
a
0,2 0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9 h/H
1,0
Relative winding length
H InitialVoltage Distribution in Disk Windings a.- Continuous disk winding. b.- Interleaved disk winding. c.- Partially interleaved winding. d.- Final voltage distribution. CORE WINDING h
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Reactance between windings
( Source: Karsei, Kereny, Kiss, Large Power Transformers )
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Winding arrangements
( Source: Karsai, Kereny, Kiss, Large Power Transformers )
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Equivalent Circuit
( Source: Karsai, Kereny, Kiss, Large Power Transformers )
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Powering reliable solutions for you

Design Concepts and Specification

Transformers Technology and Diagnostics Seminar

Copyright Prolec GE Internacional Powering reliable solutions for you

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Definition and Principle of Operation

Magnetic Field (Flux) Electric Current

Copyright Prolec GE Internacional

The Role of Transformers in the Grid

3-phase primary substation xfmr

3-phase pad-mount (CPAD)

secondary substation transformer (SST) - liquid - vent dry - cast coil

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Basic Construction of a Power Transformer (Core type, >7.5MVA)

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

- High strength rings axially clamp the windings

Copyright Prolec GE Internacional

Frames and Tank Attachments

Copyright Prolec GE Internacional

- Provide support for NLTC and other components

Copyright Prolec GE Internacional

- Hot spot below winding hot spot

Copyright Prolec GE Internacional

- Normally mounted in turrets with current transformers

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Tank (w/o cover)

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

- Fans improve heat transfer rate

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Bushings and Arresters

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Type (conventional 2W, 3W, Auto, GSU)

Winding Connection (Y, Delta, Z)

Tolerances according to ANSI-IEEE

Copyright Prolec GE Internacional

Impedances for more than two windings

Short circuit with overvoltage

Copyright Prolec GE Internacional

Criticals to Quality (CTQs)

Cycle time for delivery of drawings

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

Core type Shell type

Main Cooling Medium

Application in the Power System

Number of Main Windings

( Source: Dietrich, Transformatoren )

Copyright Prolec GE Internacional

Three-Phase Winding Connections

Higher voltages Neutral can be grounded

Higher currents Capacitively referred to ground

Copyright Prolec GE Internacional

Copyright Prolec GE Internacional

V(t) = Vmax* sin(t) = Zi(t) + N d(t)/dt If Zi(t)<<N d/dt

(t) = (1/N)* f[Vmaxsin( t)] = (-1/N) Vmax*cos (t)