Power Transformer Load Loss Measurement

Gert Rietveld
Ernest Houtzager
Milos Acanski
Dennis Hoogenboom
Enrico Mohns
Henrik Badura
Ilija Pecelj

ELPOW workshop, 31 Aug 2016

 Outline

• Power transformers - losses

• Why loss measurements?
• Transformer loss measurement systems
• ELPOW: TLMS calibration systems
• Summary

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Power Transformers

Power transformers are used to

scale voltages in the grid

High Voltage low losses

3
 Power transformer losses

Loss mechanisms:
1. No load losses (Zb = ), caused by iron core, continuous
2. Load losses (Zb = 0 ), copper loss, depends on current
3. Stray losses depend on design

4
 Why loss measurements (1)

• Cost of losses in power transformers are comparable to the product

cost TCO (total cost ownership)
• Environmental impact is significant

Cost of (no-)load loss equals product costs

 Why loss measurements (2)

Consequence: regulations - EcoDesign Directive:

“improve environmental performance of energy-
related products through better design”

Saving potential in use phase through more efficient designs

estimated as 16 TWh/year ( 17 % of present losses)
3.7 Mt of CO2 emissions (50 % of total Danish electricity consumption)
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 Why loss measurements (3)

Consequence: more requirements in standards

IEC 60076-19 (uncertainty calculation), and upcoming IEC 60076-20:

99.9

99.8

99.7
Minimum PEI [%]

99.6

99.5

99.4
Liquid immersed - Tier 1
Tier 1: 1 July 2015
99.3
Liquid immersed - Tier 2
Dry-Type - Tier 1 Tier 2: 1 July 2021
99.2
Dry-Type - Tier 2
99.1
0 20 40 60 80 100 120
Rated Power [MVA] 7
 Why loss measurements (4)

Consequence: customers (utilities) put fines on losses in excess of

guaranteed maximum losses

Example calculation for a large transformer (100 MVA)

• Guaranteed maximum losses: Pgar = 500 kW (0.5 % loss)
• Fine for excess losses: 10.000 €/kW

3 % measurement uncertainty (150 ppm) corresponds to

500 kW · 3 % · 10.000 €/kW = 150.000 €

(manufacturer and customer have to decide who pays for uncertainty)

Reliable loss measurement with low uncertainty

gives confidence and less discussions 8
 Uncertainty matters! (compliance)

Ecodesign allows no tolerance: if measured loss is above the limit,

the transformer is not in conformity
Ecodesign limit

Actual loss
Probability

Accurate test
Test result
fails to detect
Inaccurate test
compliance
High accuracy =
low risk of incorrect
decisions
Loss
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 Transformer Loss Measurement

Power supply P = V · I · cos

TLMS typical measurement range: 0 – 100 kV, 0 – 2 kA

Uncertainty: 3 % - 5 % (IEEE C57.12.00, IEC 60076-19, Ecodesign)
Traceable to international measurement standards
 Measurement challenge

Power: P = U · I · cos with 90

P = U · I · cos (90 - ) = U · I · with = (90 - ) 0

U and I are large numbers 1 % uncertainty is very easy

is a very small number:
for PF=0.01, = 0.57 1 % uncertainty is a big challenge!
(6 m , 0.34 min, 100 µrad)
1 % losses

phase accuracy, not amplitude accuracy required!!

TLMS consists of high-quality components
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 TLMS calibrations

Only a calibrated TLMS system, traceable to national standards, gives

proven, reliable quality in load loss measurements

Two approaches in TLMS calibrations

• Component calibration (< 0.5 %; at PF=0.01 0.2 min, 3 m )
Easier to perform, larger overall system uncertainty
• System calibration (< 3 %; at PF=0.01 1 min, 17 m )
Difficult to perform, low uncertainty, all effects included

Increased measurement challenge: TUR = 3 – 10

Reference measurement accurate to < 0.15 min (50 µrad, 3 m )
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 ELPOW aim for TLMS calibration

Aim: system calibration of TLMS up to 100 kV and 2 kA, with an

uncertainty of better than 50 µW/VA

Two approaches:
• Simultaneous generation of voltage V and current I
• Phase lock current I to externally applied voltage V
• Realise feedback loop

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 LMS for testing power trafos

Generating part Measuring part

• “voltage and current up to 150 kV and at least 2 kA…”

• “uncertainties better than 50 ppm…”
 Generation: phantom power

30 kVA
2 channel source 0 V - 250 V
• 16 bit DACs
• 10 VPK
• phase lock
• external synchronization
or 15 Hz … 60 Hz intern DAC
or 50 Hz line

10 kVA
R1: 0 A – 50 A
R2: 0 A – 25 A

To do:
• Stability transconductance amplifier must be optimized
• Assessment of the phantom power source
 Measuring system

U = 150 kV

Voltage Transformer
Class 0.02 LabView Software

U, I, , P, Q, S

Power Comparator
Class 0.01
I = 2 kA
To do overview:
1. Optimization of the software
• timing to read the comparator
• automatic correction of the transformer error
Current Transformer 2. Uncertainty calculation
Class 0.002 3. Assessment of the system
 TLMS system calibration
Challenge: lock I to V
within 0.3 m (5 µrad)
V I

DSP is a key element

2nd reference CT + RD22 watt meter as check 17
 Actual VSL implementation

VT (CC-based capacitive divider)

Power reference (RD22 watt meter)

Control (DSP)

Power amplifier (G)

CTs Transformer /
(3-stage compensated) current generator

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 Components of VSL system

Generation:
• Rohrer wideband amplifier (20 A, 150 V) + step-up transformer

Measurement:
• VT: HV capacitor (100 pF, 100 kV) + CC-based LV divider
– Uncertainty: 15 – 25 ppm (phase / magnitude)
• CT: 3-stage wideband; errors < 1 ppm (uncertainty 5 ppm)
– Wideband 5 A shunt for conversion to voltage
• Power: two 24-bit ADCs (NI)
Expected overall phase uncertainty: < 25 ppm (25 µrad)

Verification: RD22 power meter (< 10 ppm) + CT + VT

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 Control loop

The control loop has 2 main parts:

I
ADC Z-n I [n-m]

V [n] DAC
90°
Phase
shifting Q

First part: high speed. Second part: high accuracy ( feedback)

(NRC analogue system needs accurate 90 reference signal)
Results:
• Extensive testing with different voltage signals; different phase
shifting blocks studied
• Low noise: 4 – 5 µrad; agreement with power meter < 10 µrad
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 First on-site trial

• Much more noise than in lab (30 µrad vs 5 µrad)

• Agreement VSL LL and RD22 reference: within 15 ppm
• Agreement with NRC better than 25 ppm
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 Conclusion

Power transformer losses are significant

– Economically: TCO and fines
– Environment: CO2 emissions
Requirements from EU regulations,
IEC / IEEE on both the actual losses
and measurement accuracy

Transformer Loss Measurement Systems need calibration

– Proven, validated accuracy < 3 % @ PF = 0.01
– ELPOW: System calibration < 0.5 % @ PF = 0.01
– simultaneous generation
– current phase locking
(promising first results < 0.3 %!)

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