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As per present day transformer design practice, the peak rated value of the flux density is kept about 1.7 to 1.8 Tesla, while the saturation flux density of CRGD steel sheet of core of transformer is of the order of 1.9 to 2 Tesla which corresponds to about 1.1 times the rated value. If during operation, an electrical power transformer is subjected to carry rather swallow more than above mentioned flux density as per its design limitations, the transformer is said to have faced over fluxing problem and consequent bad effects towards its operation and life. Depending upon the design and saturation flux densities and the thermal time constants of the heated component parts, a transformer has some over excitation capacity. I.S. specification for electrical power transformer does not stipulate the short time permissible over excitation, though in a round about way it does indicate that the maximum over fluxing in transformer shall not exceed 110%. The flux density in a transformer can be expressed by B = C V/f, where, C = A constant, V = Induced voltage, f = Frequency. The magnetic flux density is, therefore, proportional to the quotient of voltage and frequency (V/f). Over fluxing can, therefore, occur either due to increase in voltage or decrease in-frequency of both. The probability of over fluxing is relatively high in step-up transformers in Power stations compared to step - down transformers in Sub-Stations, where voltage and frequency usually remain constant. However, under very abnormal system condition, over-fluxing trouble can arise in step-down Sub-Station transformers as well.
The flux in a transformer, under normal conditions is confined to the core of transformer because of its high permeability compared to the surrounding volume. When the flux density in the increases beyond saturation point, a substantial amount of flux is diverted to steel structural parts and into the air. At saturation flux density the core steel will over heat. Structural steel parts which are nu-laminated and are not designed to carry magnetic flux will heat rapidly. Flux flowing in unplanned air paths may link conducing loops in the windings, loads, tank base at the bottom of the core and structural parts and the resulting circulating currents in these loops can cause dangerous temperature increase. Under conditions of excessive over fluxing the heating of the inner portion of the windings may be sufficiently extreme as the exciting current is rich in harmonies. It is obvious that the levels of loss which occur in the winding at high excitation cannot be tolerated for long if the damage is to be a voided. Physical evidences of damage due to over fluxing will very with the degree of over excitation, the time applied and the particular design of transformer. The Table given below summarizes such physical damage and probable consequences. Component Physical evidences involved Discoloration or metallic parts and adjacent insulation.Possible carbonized material in oil. Evolution of combustible gas.
SL
Consequences
Contamination of a oil and surfaces of insulation. Mechanical weakening of insulation Loosing of structure. Mechanical
structure Electrical and mechanical weakling of winding insulation Electrical and mechanical weakening of insulation, Mechanical Weakening of support.
2 Windings
Lead conductors.
Core lamination.
Discoloration of insulating material in contact with core. Discoloration and carbonization of organic/lamination insulation Evaluation of gas.
Electrical weakening of major insulation (winding to core) increased interlaminar eddy loss.
5 Tank
Blistering of paints
It may be seen that metallic support structures for core and coil, windings, lead conductors, core lamination, tank etc. may attain sufficient temperature with the evolution of combustible gas in each case due to over fluxing of transformer and the same gas may be collected in Buchholz Relay with consequent Alarm/Trip depending upon the
quantity of gas collected which again depends upon the duration of time the transformer is subjected to over fluxing. Due to over fluxing in transformer its core becomes saturated as such induced voltage in the primary circuit becomes more or less constant. If the supply voltage to the primary is increased to abnormal high value, there must be high magnetising current in the primary circuit. Under such magnetic state of condition of transformer core linear relations between primary and secondary quantities (viz. for voltage and currents) are lost. So there may not be sufficient and appropriate reflection of this high primary magnetising current to secondary circuit as such mismatching of primary currents and secondary currents is likely to occur, causing differential relay to operate as we do not have overfluxing protection for sub-Stn. transformers.
F = (V/f)/(Vn/fn)
1.1
1.2
1.25
1.3
1.4
continuous
0.5
From the table above it may be seen that when over fluxing due to system hazards reaches such that the factor F attains a values 1.4, the transformer shall be tripped out of service instantaneously otherwise there may be a permanent damage.
protection operates when the ratio of the terminal voltage to frequency exceeds a predetermined setting and resets when the ratio falls below 95 to 98% of the operating ratio. By adjustment of a potentiometer, the setting is calibrated from 1 to 1.25 times the ratio of rated volts to rated frequency. The output from the first auxiliary element, which operates after fixed time delay available between 20 to 120 secs. second output relay operates and performs the tripping function. It is already pointed out that high V/f occur in Generator Transformers and Unit-Auxiliary Transformers if full exaltation is applied to generator before full synchronous speed is reached. V/f relay is provided in the automatic voltage regulator of generator. This relay blocks and prevents increasing excitation current before full frequency is reached. When applying V/f relay to step down transformer it is preferable to connect it to the secondary (L.V. said of the transformer so that change in tap position on the H.V. is automatically taken care of Further the relay should initiate an Alarm and the corrective operation be done / got done by the operator. On extreme eventuality the transformer controlling breaker may be allowed to Trip.