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Charlotte, North Carolina, March 17, 2008 Presented by: Marcel Fortin (Consultant), Pierre Riffon (HydroQubec), Juergen Gerth (ABB) and Richard P. McLaughlin (Kema Powertest)
Introduction
Charlotte, North Carolina, March 17, 2008 Presented by: Marcel Fortin Eng Test specialist Consultant
Contributors
Marcel Fortin: test specialist retired from Hydro-Qubec High Power Laboratory Juergen Gerth: Technical Manager of ABB Inc. Power Transformer Division at Varennes, Quebec, Canada. Pierre Riffon: test specialist for the Hydro-Qubec Quality Control Department Richard P. McLaughlin: Test Engineer Supervisor, KEMA Powertest.
Marcel Fortin Eng, Charlotte, SC, March 17, 2008
Presentations
Standard Status M Fortin Designing Transformers to Withstand ShortCircuit Forces J Gerth Short-Circuit Withstand of Power Transformers, Utility Perspective P Riffon Short-Circuit Testing of Liquid Filled Transformers R McLaughlin Some Particular Cases M Fortin
Marcel Fortin Eng, Charlotte, SC, March 17, 2008
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Jrgen Gerth Technical Manager ABB Inc. Varennes, Quebec Canada Designing Transformers to withstand Short-Circuit Forces
- 1/14 -
In case of external short-circuits the first peak of the fault current over the transformer will increase to a multiple of the rated current. The fault current is governed by: Open-circuit voltage Source and transformer impedance Instant of fault onset
- 2/14 -
Displacement of current
Designing Transformers to withstand Short-Circuit Forces 2D Plot of the magnetic stray field lines of a two winding transformer.
Radial direction
Axial direction
The stray flux has components in axial and radial direction. There are field compoments outside the windings.
- 3/14 -
The direction of forces is always directed perpendicular to the magnetic field lines Forces usually are split into the two components Radial forces Axial forces
Electromagnetic forces tend to increase the main insulation duct and to increase existing un-symmetries.
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- 5/14 -
Conductor tilting
Bending of cables
- 6/14 -
Designing Transformers to withstand Short-Circuit Forces Steps to design transformers to survive short-circuits Step 1: Run fault current calculations, covering all external fault modes:
Three phase fault on HV, LV and Tertiary side Line to line fault on HV, LV and Tertiary side Line to ground fault on HV and LV side
Consider the network impedance in line with the Standard or the spec. Consider different tap changer positions Consider that impedances are subject of tolerances Consider that current limiting reactors may show saturation effects
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Designing Transformers to withstand Short-Circuit Forces Step 2: Calculate the forces and the stresses
Radial forces and copper stresses in all windings Spiralling forces on the exits Axial compression forces and:
Bending stresses in the cables Stresses on the paper of the winding conductors Critical tilting stresses of the winding conductors
Axial forces on the end supports and stresses in the mechanical support structure
The highest fault current will not always lead to the highest forces in a winding. Superimposed fields of other windings may create higher stresses
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Design the windings radially self supporting Select the cable dimensions, copper yield strength and epoxy bonding to meet the stresses Focus on axial ampere-turn balancing optimization of all windings, Require close manufacturing tolerances, Provide solid clamping of the windings, Provide safe fastening of the winding exits and connection leads.
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Designing Transformers to withstand Short-Circuit Forces Which simplifications are applied during design?
The forces alternate with the square of the current. During design only the peak force is calculated and considered as a static force. A dynamic factor may be used to consider the dynamic effects. Core and coils are a 3 D arrangement. The routine field calculations are ran with 2 D programs, Layer and helical windings have a pitch creating variable displacements. It depends on the manufacturers rules which displacement is considered, The calculation of the forces on the winding exits is based on a simplified model. The mechanical withstand limits of helical windings against spiralling forces are based on limited number of experiments.
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Designing Transformers to withstand Short-Circuit Forces Which improvements have been achieved over the last 20 years?
Computer programs run fault current and force calculations for all fault conditions and all winding connections automatically, 3 D magnetic tools have been applied for R&D work, Epoxy bonding of winding conductors has become available and the application became a standard practice, Hard and very hard drawn copper is applied more frequently, Pre-compressed pressboard is exclusively used, There is more focus on the short circuit strength during the design stage, More experience has been gained in the field and by testing.
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The rules did not fully cover the case, There are effects which have not been considered,
Due to shortcomings during manufacturing, Due to transportation issues or poor test preparations,
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Test results are an important feedback and a valuable source for improvements. Due to the high cost and the limited number of test facilities the number of tests will remain limited. Submitting a transformer to a short-circuit test is always connected to high expenses for the purchaser. In case of a failure the expenses become very high for purchaser and manufacturer. A short-circuit test therefore involves a risk for both parties.
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Designing Transformers to withstand Short-Circuit Forces Personal observations after 40 years in business
Designing for short-circuit strength was not high on the list 40 and 30 years ago, Radial buckling, axial winding collapse and broken press rings were a non-rare experience, In the meantime the design philosophy has changed, More experience has been gained, mainly after performing tests, There are better design rules, the calculation tools were improved, and there are better materials to strengthen windings and winding supports, I did not see a winding with buckling, collapsing, tilting indication for more than 10 years in a transformer designed during that period.
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6912 3255
10 6
1 3
0,145 0,184
0,015 0,092
11,15 9,20
1,15 4,60
A CIGRE TF with WG 12.19 made survey in 1997 (18 utilities in 11 countries). Time frame of the results: 1993 1997 (5 years)
Transformer impedances for units rated 25 to 200 MVA were in the range of 14,3% to 19,5%.
Pierre Riffon, Eng., Charlotte, SC, March 17, 2008
Is a short-circuit test to be considered? A composite evaluation of all aspects (technical and economical) shall be done. Costs of performing a short-circuit test series shall then be compared with the costs, inconveniences and risk of having a failure in service.
No
Yes
How to be sure that a transformer subjected to a short-circuit test has no internal damages
By doing additional diagnostic tests such as FRA or FRSL; By adding a dissolved gas-in-oil analysis after tests; By doing a mandatory and detailed out-of-tank active part inspection;
How to be sure that a transformer subjected to a short-circuit test has no internal damages
By requesting a temperature rise test at maximum rating after the active part inspection; By requesting dielectric type tests to be performed after the active part inspection at 100% of the rated test levels; By requesting all other type and routine test at 100% of the various ratings.
Conclusions
Short-circuit failures represent only a few percentage of total transformer failures but do generally result in catastrophic failures. Test is the only method to guaranty the ability of a transformer to withstand a short-circuit. Tests are providing valuable inputs to designers and utilities for improving actual and future designs and service continuity.
Pierre Riffon, Eng., Charlotte, SC, March 17, 2008
Conclusions
Short-circuit tests are expensive and an extensive technical, economical and risk evaluation should be conducted before requiring a test. Adequate diagnostic methods, active part inspection and final type and routine tests at 100% of the rated levels are needed to insure that a short-circuit test did not damage the transformer.
Pierre Riffon, Eng., Charlotte, SC, March 17, 2008
PERFORMANCE OF SHORTCIRCUIT TESTING INITIAL IMPEDANCE MEASUREMENTS Measure on all necessary taps that the short-circuit tests are to be apllied to. Typically only takes a several minutes for each tap position.
Richard P. McLaughlin, Charlotte, SC, March 17, 2008
PERFORMANCE OF SHORTCIRCUIT TESTING SHORT-CIRCUIT CURRENT CALCULATIONS Calculate the required shortcircuit current values based on the limitations and equations in IEEE C57.12.00 and C57.12.90.
Richard P. McLaughlin, Charlotte, SC, March 17, 2008
CONCLUSIONS
The impedance variation larger than that specified in the test standard is the most common after the short-circuit tests.
CONCLUSIONS
KEMA (Arnhem) shows that in 11 years of testing (of 77) large transformers (25 - 440 MVA, 20 500 kV), 31% fails initially to pass the short-circuit test, mostly because an unacceptable increase in reactance. 1
1
KEMA'S TEST EXPERIENCES WITH SHORT-CIRCUI T WI THSTAND CAPABILI TY OF LARGE POWER TRANSFORMERS : R. P. P. Smeets, L. H. te Paske, P.P. Leufkens - KEMA T&D Testing Services, Arnhem, the Netherlands
CONCLUSIONS
Every tested transformer provides many levels of concern, all must be accounted for with every short-circuit test.
CONCLUSIONS
Each test facility shall make accommodations for the areas covered, and not covered, in this tutorial depending on their circumstances presented to them at the time of the test.
Richard P. McLaughlin, Charlotte, SC, March 17, 2008
Content
Low X/R transformers Multi winding autotransformers Non-circular coils Axial split transformers
Axial split
Axial-split transformers comprise transformers having 3 or more windings with 2 or more windings physically superimposed axially one the same magnetic leg. Each of the axial-split windings can be connected to different sources and/or loads by different sets of bushings.
H1 load 1 source
load 2
Axial split
Fault shall be applied to only 1 axial split winding To lower the magnetizing inrush the post-set method is preferred
Clause 12.2.3.1 of the draft and CIGRE paper 12-104
H1 load 1 source
load 2