Thermal management of transformer

ABSTRACT

Power transformers play a vital role across the electrical grid network. This element of the grid network is
commonly located in the outdoor environment. Unfortunately, there is no well defined environmental condition
to be used as a design guide line. Therefore, this leads to a lack of defining the solar load effect, the worst
maximum and minimum ambient temperature, the climbing ambient temperature variation per hour, the Pico
and micro climate effects, the maximum altitude, the worst maximum and minimum relative humidity and the
dew point temperature.

The environmental condition was selected based on 3 different cities in the northern hemisphere. These cities
are Riyadh, Saudi Arabia, Colorado spring, USA and Ottawa, Canada. These cities represent the different
environmental conditions which the power transformer can be subjected to it. The current investigation will
determine the temperature variation across the windings, insulators and the core. These temperature variations
can be eventually used to determine the potential thermal stresses which can lead to the major failure of the
transformer. It discusses a new approach to the design of thermal management for high-frequency high-power
transformers. It is based on heat removal by conduction. Advanced heat conducting elements like heat-pipes are
implemented. The heat is collected on dedicated surfaces called thermal surfaces where the heat exchange with
the environment occurs .which can be used in this type of which, in turns, can be used as a starting point for the
thermal community to develop a special standard for outdoor high powered equipment.

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CHAPTER 1
INTRODUCTION
Electrical power transformer is a static device which transforms electrical energy from one circuit to
another without any direct electrical connection and with the help of mutual induction between two
windings. It transforms power from one circuit to another without changing its frequency but may be
in different voltage level.

1.1 Working Principle of Transformer

The working principle of transformer is very simple. It depends upon Faraday's law of
electromagnetic induction. Actually, mutual induction between two or more winding is
responsible for transformation action in an electrical transformer.

According to Faraday's law of electromagnetic induction, there must be an EMF induced in

the second. If the circuit of the later winding is closed, there must be an current flowing
through it. This is the simplest form of electrical power transformer and this is the most basic
of working principle of transformer. Whenever we apply alternating current to an electric
coil, there will be an alternating flux surrounding that coil. Now if we bring another coil near
the first one, there will be an alternating flux linkage with that second coil. As the flux is
alternating, there will be obviously a rate of change in flux linkage with respect to time in the
second coil.

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1.3 Main Constructional Parts of Transformer

The three main parts of a transformer are,

Primary Winding of Transformer- which produces magnetic flux when it is connected to

electrical source.

Magnetic Core of Transformer- the magnetic flux produced by the primary winding, that
will pass through this low reluctance path linked with secondary winding and create a
closed magnetic circuit.

Secondary Winding of Transformer- the flux, produced by primary winding, passes

through the core, will link with the secondary winding. This winding also wounds on the
same core and gives the desired output of the transformer.

Fig.1 Transformer Construction (single-phase)

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1.2 How Does Temperature Affect the Life of a Transformer

Temperature is one of the prime factors that affect a transformer's life. In fact, increased temperature is
the major cause of reduced transformer life. Further, the cause of most transformer failures is a
breakdown of the insulation system, so anything that adversely affects the insulating properties inside
the transformer reduces transformer life. Such things as overloading the transformer.

Moisture in the transformer.

Poor quality oil.

Insulating paper.

Extreme temperatures affect the insulating properties of the transformer.

Most transformers are designed to operate for a minimum of 20-30 years at the nameplate load, if
properly sized, installed and maintained. Transformers loaded above the nameplate rating over an
extended period of time may have reduced life expectancy.

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2. WHAT AFFECTS THE THERMAL LOADING?

Most professionals in the power industry are very familiar with the fundamental principle of how a
transformer functions electrically. A transformer is a voltage changing device composed of a primary
and secondary winding interlinked by a magnetic core. A three phase power transformer used in
transmission and distribution systems shares the same principle.
However, its core is bigger to accommodate the three phase primary and secondary windings.
Additionally, insulation in the form of oil or paper is required to isolate the difference in potential
between phases. Three phase transformer losses will generate enough heat so that external cooling
systems must be added. A closer look at these characteristics is necessary to better understand the
thermal aspects of power transformers.

2.1 The Core and Windings

When one thinks of a transformer core, one usually visualizes it as a piece of solid metal. On the contrary, the
core is built up by horizontally or vertically stacking thin iron laminations or sheets, which eventually form the
cores leg and yoke, as seen in Fig.2. The primary function of the transformer core is to provide a low
reluctance path for the flux that links the primary and secondary windings. Ideally, we would like a zero
reluctance flux path between the two windings. However, due to the iron laminations that form the core, the
transformer core experiences losses that eventually produce heat. These core losses can be classified as
hysteresis and eddy current losses. See the section on transformer losses, below, for further details.

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Fig.2. Three Phase Transformer Core.

2.2 Insulation
Insulation is required whenever there is a difference in potential between two points . In an overhead three
phase transmission line with bare conductors, no insulation is necessary between the conductors since air
separation is used as an insulator, preventing the flow of current. However, in power transformers, distance
between phase conductors is not efficient way of separating the potential differences. As a result, paper is used
as an insulator, allowing closer proximity between phases and thus maximizing space. By far, paper is the best
insulating material used today because of its high dielectric strength properties. Paper insulation in a power
transformer is installed between windings of the same phase, windings to ground, and windings from different
phases. Other parts of the transformer also experience a difference in potential, such as the transformer tank
wall with the windings, which also requires some form of insulation. In order to minimize the transformers
footprint, this distance must be shortened as much as possible. Transformer manufacturers shorten the necessary
distance by using insulating oil, which not only insulates, but also serves as a coolant within the transformer.
Thus, transformer insulation is the heart of transformer design, and maximum transformer performance during
loading depends on the insulations Credibility. Transformer losses are one of the primary factor affecting this
credibility, which is the focus of the next section.

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2.3 Transformer Losses

Even though transformers are very efficient devices, converting from 95-99% of their input power, some
of its energy is lost during the voltage transformation. The losses in a power transformer can be
classified as no-load losses and load losses.

2.4 No-Load Losses

With no load in the secondary windings, an energized transformer behaves as a highly inductive
element, similar to a shunt reactor. In order to keep this transformer energized, the alternating excitation
current is drawn from the system, producing an alternating mutual flux in the primary winding. This
mutual flux is taken by the core at a rate that depends on the system frequency. The energy requirements
for this cyclic magnetization of the core results in two types of transformer losses: eddy and hysteresis
losses. Induced voltage in the laminations produced by the alternating flux results in undesirable
currents within the laminations. Such currents are called eddy currents, which do not contribute to power
output, and their energy is lost to heat. The alternating magnetization of the core will cause the
molecular composition of the iron core to align itself with the changing field. The energy lost from
successive reversal of magnetization in the core is called hysteresis loss.

2.5 Load Losses

The load losses in a power transformer are due to the electric resistance of windings and stray losses.
The resistive action of the winding conductor to the current flow will be lost in the form of heat and will
be dissipated in the surrounding area inside the transformer. The magnitude of that loss increases by the
square of the current. Stray losses occur due to the leakage field of winding and due to high currents
seen in internal structural parts such as bus bars. Stray losses can affect the overall rating of the
transformer because they can create hot spots when the current leads become excessive, affecting the
overall life of the transformer .

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3. MODERN TECHNIQUES TO INDICATE THE

TRANSFORMER TEMPERATURE

Many methods have been developed for measuring temperature. Most of these rely on measuring some
physical property of a working material that varies with temperature.

3.1 Types of temperature indicator

There are mainly two types of temperature indicators used in transformer. Principally both of the
instruments are the same but, one is used for oil temperature and the other is used for winding
temperature. There is another type of temperature indicator often used in power transformer, which is
little bit different principally and this is remote temperature indicator.viz

Oil temperature indicator (OTI)

Winding temperature indicator (WTI)
Remote temperature indicator (RTI)

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3.1.1 Oil Temperature Indicator (OTI)

This device is used to measure the top oil temperature. An oil temperature indicator or OTI is also used for
protection of transformer.

Operating Principle of Oil Temperature Indicator

This device measures top oil temperature with the help of sensing bulb immersed in the pocket by
using liquid expansion in the bulb through a capillary line to operating mechanism. A link and lever
mechanism amplifies this movement to the disc carrying pointer and mercury switches. When volume of
the liquid in operating mechanism changes, the bellow attached to end of capillary tube expands and
contracts. This movement of bellow is transmitted to the pointer in temperature indicator of transformer
through a lever linkage mechanism.

3.1.2 Winding Temperature Indicator or WTI

This device measures the LV and HV winding temperature. A winding temperature indicator or WTI is

is also used as the protection of the transformer.

Fig 3 Winding temperature indicator

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Construction Detail of Winding Temperature Indicator, WTI:

Winding temperature indicator consists of a sensor bulb placed in an oil filled pocket in the transformer tank
cover. The bulb is connected to the Instrument housing by means of two flexible capillary tubes. One capillary
is connected to the measuring bellow of the instrument and the other to a compensating below

Fig 5 Diagram representing the winding temperature indicator.

Working Principle Winding Temperature Indicator:

An indirect system is used to measure winding temperature, since it is dangerous to place a sensor close to
the winding due to the high voltage. The indirect measurement is done by means of a Thermal Image.
The measuring system is filled with a liquid which changes its volume with rising of temperature. Inside the
instrument is fitted a heating resistance which is fed by a current proportionate to the current flowing through
the transformer winding. To do this we connect the terminal of the heating resistance with the Bushing Current
Transformer so that reflection of change in load is reflected in the Winding Temperature Indicator, WTI. The
Winding Temperature Indicator, WTI is provided with a maximum temperature indicator. The heating resistance
is fed by a current transformer associated to the loaded winding of the transformer. The increase in the

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temperature of the resistance is proportionate to that of the winding. The sensor bulb of the instrument is located
in the hottest oil of the transformer, therefore, the winding temperature indicates a temperature of hottest oil
plus the winding temperature rise above hot oil Level the hotspot temperature.
Winding Temperature of Transformer may rise due to increased loading of Transformer or due to some
internal fault. Normally the Winding Temperature Indicator, WTI gives alarm at 85 C and Trip signal at 95 C
in India.

Fig.4 Transformer winding temperature indicator

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4. TEMPERATURE SENSORS

4.1 Temperature Sensor

A temperature sensor plays an important role in many applications. For example, maintaining a specific
temperature is essential for equipment More frequently, however, temperature detection is part of preventative
reliability. For example, while an appliance may not actually perform any high temperature activities, the
system itself may be at risk to overheating. This risk arises from specific external factors such as a harsh
operating environment or internal factors like self-heating of electronics. By detecting when overheating
occurs, the system can take preventative action. In these use cases, the temperature detection circuit must be
reliable over the expected operating temperature range for the application. Designing a robust temperature
detection circuit does not have to be expensive. Nor does a low cost detection circuit have to compromise on
responsiveness and accuracy. This article looks at the different types of temperature detection technologies
available and what each has to offer. It also explores the requirements of various applications and how
engineers can design a temperature detection circuit optimized for their specific needs.

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Fig 5. Temperature Sensor-Thermistor Probe

4.2 Temperature Sensor Types

4.2.1 Negative Temperature Coefficient (NTC) thermistor

A thermistor is a thermally sensitive resistor that exhibits a large, predictable, and precise change in
resistance correlated to variations in temperature. An NTC thermistor provides a very high resistance at low
temperatures. As temperature increases, the resistance drops quickly. Because an NTC thermistor experiences
such a large change in resistance per C, small changes in temperature are reflected very fast and with high
accuracy (0.05 to 1.5 C). Because of its exponential nature, the output of an NTC thermistor requires
linearization. The effective operating range is -50 to 250 C for gas encapsulated thermistors or 150C for
standard.

4.2.2 Resistance Temperature Detector (RTD)

An RTD, also known as a resistance thermometer, measures temperature by correlating the resistance of
the RTD element with temperature. An RTD consists of a film or, for greater accuracy, a wire wrapped around
a ceramic or glass core. The most accurate RTDs are made using platinum but lower cost RTDs can be made
from nickel or copper. However, nickle and copper are not as stable or repeatable. Platinum RTDs offer a fairly
linear output that is highly accurate (0.1 to 1 C) across -200 to 600 C. While providing the greatest accuracy,
RTDs also tend to be the most expensive ofz temperature sensors.

4.2.3Thermocouple

This temperature sensor type consists of two wires of different metals connected at two points. The
varying voltage between these two points reflects proportional changes in temperature. Thermocouples are non-
linear, requiring conversion when used for temperature control and compensation, typically accomplished using

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a lookup table. Accuracy is low, from 0.5 to 5 C. However, they operate across the widest temperature
range, from -200 to 1750 C.

4.2.4 Semiconductor-based sensors

A semiconductor-based temperature sensor is placed on integrated circuits (ICs). These

characteristics that can be used to monitor changes in temperature. They offer a linear response but have the
lowest accuracy of the basic sensor types at 1 to 5 C. They also have the slowest responsiveness (5 to 60 s)
across the narrowest temperature range (-70 to 150 C).

4.2.5 TPT-32 Temperature sensor for oil-fi lled transformers

With thousands of fi ber optic temperature sensors used and installed worldwide, FISOs heavy duty TPT-32 fi
ber optic temperature sensor, specifi - cally designed for permanent installation in oil-fi lled transformers,
clearly demonstrates FISOs experience and leading edge in transformer instrumentation for direct winding
temperature measurement.

The TPT-32 sensor possesses a resilient construction, resistance to chemicals and all dielectric resistant
materials featuring complete immunity to EMI and RFI environments. With a 3 mm outer diameter, a unique
double PTFE oil permeable sheathing with transversal slits (spiral wrap), the TPT-32 is designed to withstand
installation stresses, harsh testing conditions such as kerosene vapour, heat runs and induced vibration during
the overall lifetime of the transformer.

Key features
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Withstands temperatures up to 225C (437F) n

Double PTFE sheathing n

Proven semiconductor optical absorption principle n

EMI/RFI immune n

Resists dielectric oil n

Resists kerosene vapor n

High fl exibility and visibility n

Interchangeable n

No calibration n

Custom lengths from 1 to 15 meters K

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Specifications

Temperature range 40C to 225C (40F to 437F)

Resolution 0.1C

Accuracy 2C

Available sensor length 1 to 15 meters

Connector type ST connector

Fiber type 200 m silica fiber

Cable sheathing Double PTFE sheathing (spiral wrap)

with transversal slitting

0.9 mm PTFE cable* 3 mm

PTFE spiral wrap cable*

Sensor dimensions dimensions 1.5 mm O.D. (see figure below)

Sensor certification Dielectric and kerosene vapor tests approved

Part number TPT-32

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REFRENCES

1) K. Sheltami, G. Refai-Ahmed and M. H. Shwehdi, "Thermal management of high power transformer in

different outdoor environment conditions," The Ninth Intersociety Conference on Thermal and
Thermomechanical Phenomena In Electronic Systems (IEEE Cat. No.04CH37543), 2004, pp. 543-548
Vol.1

2) Swift GW, Molinski TS, Lehn W. A fundamental approach totransformer thermal modelling part I
theory and equivalentcircuit. IEEE Trans Power Deliv 2001;16(2):1715.

3) https://www.electrical4u.com/oil-winding-and-remotetemperature-indicator-of-transformer/

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CONCLUSION

Loading capability of power transformers is limited mainly by winding temperature. It

has been the practice to assess this temperature from a measurement of oil temperature at the top of the tank
with an added value calculated from load current and winding characteristics. With more frequent occurrence of
overloading, it has been found that this simplified approach is not suitable for several types of overload and
transformer design.

As determined in this paper, understanding the fundamental principles of thermal

loading for power transformers is a critical factor in comprehending overload limitations
for power transformers. The limitation on the loss of life of the insulation and the winding
hottest-spot temperature are the driving factors for overload limits. These limitations
allow us to create dynamic ratings and philosophies that give us guidelines for loading
transformers beyond nameplate ratings. In addition, an early warning system method
was introduced that alerts system operators in advance of possible temperature
violations

The increase in the transformer temperature would lose all of its life in half of its chosen normal life.

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