The Polytransformer Concept:(*) A Multi-voltage Substation Power Transformer

Miguel OLIVA, Antonio MARIN, Lorenzo PRIETO ABB Power Technology S.A., Power Transformers, Escritor Conde Zamora s/n, 14004 Cordoba, Spain Phone: (+34) 957 469169, fax: (+34) 957 469190, e-mail: miguel.oliva@es.abb.com / antonio.marin@es.abb.com / lorenzo.prieto@es.abb.com
(*)

International Patent Pending.

Abstract The Polytransformer is a compact, multifunctional, customized power transformer that may be used in multiple substations at different voltages. This paper explains and provides information about the Polytransformer concept, a multi-voltage substation power transformer. Keywords Polytransformer, power transformer, spare transformer, multi-voltage transformer.

On the other hand, contingency planning has to be performed related to arrangements in case of a transformer failure that results in a prolonged outage. Such contingency planning to mitigate risks includes spare units and redundant transformers. The availability of spare transformers is valuable to minimize the risk in case of a problem or failure, especially in generating plants or important substations in the transmission system. Some utilities are optimising the number of spare transformers because they are sometimes questioning if the investment in a spare transformer is economically justified. In this context, transformer manufacturers have to provide the utilities not only high quality and reliable products but also flexible solutions to support the economic justification of an investment in transformer spares. Such justification can be strengthened and supported proposing a multifunctional, compact and customized power transformer, having minimum feasible transport dimensions, which may be used as spare for different transformers in multiple substations and additionally, because of its versatility, it has other alternative applications: Back up transformer during peaks of load, installation in new substations or leasing/renting to other utilities that could need and urgent transformer or replacement.

I.

INTRODUCTION:

THE NEED OF A SINGLE MULTIFUNCTIONAL

TRANSFORMER FOR DIFFERENT TRANSMISSION SYSTEMS

The change of the electric power industry to a fully competitive and deregulated market has focused the attention in asset management. Large power transformers represent a significant asset in the utility delivery system. They are one of the most important and costly components and the critical nodes in the electricity networks. In this competitive environment, the secure supply of electricity with strict cost control, reliability and quality is imperative. Utilities have to use their existing equipment more efficiently ensuring high reliability and an adequate level of quality in the service provided. As a consequence, there is a need of increased equipment utilization in parallel with a reduction in forced outages and failure rates. Large power transformers are a major concern to any electric utility when it comes to reliability because they are critical to the operation of the delivery system and their replacement involve a considerable amount of time and expense. In one side, scheduled and predictive maintenance operations are important to determine the actual condition of the transformers and can be used to minimize incidences and to optimise performance.

II. THE POLYTRANSFORMER CONCEPT: A MULTI-VOLTAGE SUBSTATION POWER

TRANSFORMER

A customized standardized transformer is not a new concept. Many utilities already have standardized power transformers in their systems or are progressively defining them, principally in their transmission and distribution networks. The main economical and technical advantages include reduced cost and delivery time, proved and optimised design, easier maintenance and availability of spare parts. Those advantages are more evident when related to spare or multi-functional transformers. The Polytransformer concept was born during a standardization process carried out by a utility in Spain. In

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addition, this particular company had the need of spare transformers to interconnect the 400kV, 230kV and 132kV systems, mainly as a contingency plan in case of emergency in some critical substations. The minimum requirements were to have a three-phase spare unit with the maximum power rating that could make possible an easy and quick transportation. That way, the spare transformer could be readily available for several substations. From that basic necessity, additional considerations were taken into account to provide extra features to have, not only a spare transformer, but also a unit with a broad scope and universal range of application. A shell form transformer design was considered because it had some intrinsic characteristics that fitted closely into the targeted purpose. The main features of the Polytransformer are: - Multiple voltage ratings at the high voltage and low voltage side. The Polytransformer is designed with internal taps providing different alternatives to allow connection between different transmission systems (for example, 400kV to 230kV, 400kV to 132kV, 400kV to 110kV, 230kV to 132kV and 230kV to 107kV). Depending on the connection, the power rating of the transformer varies. An onload tap changer regulation is also provided. The different voltage rating alternatives can be selected by changing connections internally when the unit is prepared for shipment to a different station. The winding arrangement flexibility and the facility to provide different tap connections inherent to a shell form transformer design allowed to achieve a simple and reliable design. - Multiple voltage ratings of the tertiary winding. The tertiary can be also designed with internal taps to provide several voltage levels to match different substations needs. - Maximum power rating meeting the existing transportation restrictions and the temperature rise limits specified by the standards. - Compact design to allow the Polytransformer to be shipped to many different substations. A shell form design helps to accomplish compact shipping dimensions providing additionally mechanical robustness to withstand transportation and hauling accelerations. This way, the Polytransformer can be easily shipped to many different substations. - Minimum installation dimensions to optimise the substation space requirements. Minimizing total dimensions allows replacement a wide range of existing transformers or installation in substations with limited space.

- Short circuit impedance of the Polytransformer is designed taking into consideration the impedances of existing transformers. Parallel connectivity with other units is achieved by adequately controlling the on-load tap changer. - Customized design: The Polytransformer can be designed to be electrically and dimensionally compatible with different transformers existing in a particular transmission system, meeting particular specifications and applicable standards. - Standardized external components to reduce the number of spare parts and to facilitate their availability.

III. ADVANTAGES AND APPLICATIONS OF THE POLYTRANSFORMER

Based upon the described features, the Polytransformer may be used for several applications: - Spare Transformer: The Polytransformer may replace a wide number of different transformers from several substations. The Polytransformer is a multi-voltage spare transformer that can be used as a universal spare unit, which means that has different voltage ratings to be used to connect different transmission systems and has compact dimensions to be shipped to any substation in a particular transmission system. All in one single product that optimises the required installation dimensions. - New substations: The standardized design allow the Polytransformer to be used in new substations. It can be installed permanently on-site or used as temporary replacement of other units. - Valuable asset: It also may cover the requirements of other utilities or industries. The Polytransformer can be rented, leased or lent to others in case of emergency or temporary need. - Peaks of Load: The Polytransformer can also be used to provide additional power in the network during seasonal or emergency consumption peak periods. This reduces the risk of black outs, and will prevent other installed units from being overloaded. - Reduction of inventory and maintenance cost: As the Polytransformer can take the place of different transformers, the total number of spare transformers in a system could be reduced, with the subsequent reduction of inventory, investments and maintenance costs.

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IV. A PRACTICAL EXAMPLE

As commented before in this document, the Polytransformer was a concept that was first developed for a Spanish utility. That particular Polytransformer is described briefly below: The Poltransformer schematic representation is showed in Figure 1: The insulation levels of the terminals are showed in Table III:
Table III Insulation levels (BIL, kV), 400kV Connection

Terminal High Voltage (400 kV) Low Voltage (230 kV) Low Voltage (138 kV) Low Voltage (110 kV) Neutral Tertiary (33 kV) Tertiary (26.4 and 24kV)

BIL (kV) 1425 950 650 450 170 170 125

- Connection to 230 kV systems on High Voltage Side: The autotransformer can be also connected to a 230kV system having the rated values indicated in Table IV:
Table IV Voltage Ratios, 230kV Connection

Voltage ratio (HV/LV) 230 / 132 kV 230 / 107 kV

Power rating 260 MVA 200 MVA

The tertiary can be selected to have a nominal voltage rating of 19kV, 15kV or 13.8kV as indicated in Table V:
Table V Tertiary Voltage Ratios, 230kV Connection

Tertiary Rated Voltage 19 kV 15 kV 13.8 kV

Power rating 34.5 MVA 34.5 MVA 34.5 MVA

The insulation levels of the terminals are showed in Table VI:

Figure 1. Transformer Schematic Representation Table VI Insulation levels (BIL, kV), 230kV Connection

The unit is a three-phase, shell form autotransformer, 50Hz, Ynad11 connection, OFAF cooling and on lad tap changer regulation at the neutral end (variable flux regulation).

- Connection to 400 kV systems on High Voltage Side: The different voltage ratios and power ratings when the autotransformer is connected to a 400kV system on high voltage side are showed in Table I:
Table I Voltage Ratios, 400kV Connection

Terminal High Voltage (230 kV) Low Voltage (132 kV) Low Voltage (107 kV) Neutral Tertiary (19 kV) Tertiary (15 and 13.8 kV)

BIL (kV) 1425 950 450 170 170 125

- Transformer shipping dimensions The shipping dimensions of the transformer are showed in Table VII:
Table VII Shipping Dimensions

Voltage ratio (HV/LV) 400 / 230 kV 400 / 138 kV 400 / 110 kV

Power rating 450 MVA 325 MVA 260 MVA

Shipping Dimensions (mm) Length 10950 Height 4270 Width 3200

The tertiary can be selected to have a nominal voltage rating of 33kV, 26.4kV or 24kV as indicated in Table II:
Table II Tertiary Voltage Ratios, 400kV Connection

The shipping weight is 203000 kg. An overview of the transformer arranged for shipment is showed in Figure 2.

Tertiary Rated Voltage 33 kV 26.4 kV 24 kV

Power rating 60 MVA 60 MVA 60 MVA

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Front View

Front View

Side View

Top View

Figure 2. Shipping arrangement

- Transformer assembled dimensions The total dimensions of the transformer completely assembled are showed in Table VIII:
Table VIII Installed Total Dimensions

Figure 3. Assembled Transformer

Installed Total Dimensions (mm) Length 13530 Width 6025 Height 9140

The main weights of the transformer are indicated in table IX:

Table IX Transformer Weights

Transformer Weights (kg) Active part 162000 Tank and accessories 65000 Oil 64000 Total 291000
Figure 4. 3D Transformer View

That particular Polytransformer was designed to be mechanically and electrically compatible with other three phase transformers installed in the 400kV transmission system (up to six existing different designs). The cooling equipment was designed with oil-air coolers to minimize the total space required for installation. All the accessories and fittings in that unit are standard, which means that are used in other transformers already installed in the network, mainly to help the maintenance operations and the availability of spare parts. An overview of the transformer completely assembled is shown in Figures 3 and 4.

- Paralleling with transformers having different OLTC regulating range The on load tap changer regulation of this autotransformer has been designed to have 21 positions. It has a variable flux regulation located at the neutral end. The regulation range varies depending on the selected connection. Table X shows the different ranges.

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Table X OLTC Regulation Ranges

Voltage ratio (HV/LV) 400 / 230 kV 400 / 138 kV 400 / 110 kV 230 / 132 kV 230 / 107 kV

OLTC Regulation 230 kV +3,5% -3,8% 138 kV +9% -9,8% 110 kV +12,7% -13,5% 132.3 kV +3,5% -3,8% 106,86 kV +5,4% -6%

to reach mutual objectives like quality and reliability. In addition, the resultant products are completely adapted to the real needs of the final user. The Polytransformer concept is already confirming its competence and performance. Four Polytransformers have been already manufactured and other three are in process. Two of the four existing units are been used to solve urgent transformation needs and have been rented by the owner to other utility, the first one is interconnecting systems from 400 to 230 kV and the second one from 400 to 132 kV.

In case that the autotransformer needs to parallel with other units having different regulating ranges, those have to be limited in the common part of the ranges. If the number of regulating positions is different, the transformer could be equipped with a programmable PLC. This PLC can be programmed to control the load tap changer in the spare transformer and to select the optimum position in every case. It receives indication of the tap position of the transformer to parallel, from that information decides what is the most suitable tap changer position of the controlled spare unit and gives the order to accordingly raise or lower the tap changer position. Figure 5 shows the physical arrangement of the PLC inside its control cabinet:

Figure 5 OLTC Control PLC

V. FINAL SUMMARY
The availability of spare transformers in key substations is important as a contingency plan in case of a problem or failure of an operating unit. The multi-voltage substation power transformer is a multivoltage transformer that provides multiple features in one single product. It is a compact, customized standard autotransformer with several voltage ratings that could be shipped and installed in diverse substations within a transmission system. The Polytransformer is a multifunctional product that has different possible applications. It can help to minimize the number of transformer spares available in a transmission system and to justify the investment in spare units. The active collaboration between the utilities and the transformer manufacturers is an optimum and proved way
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