Short Circuit Test Report Three Phase Circular Transformer 12/16.8 MVA Transformer ONANI/ONAF Cooling Class 55/65 Degree Celsius Rise Liquid Filled Circular Core & Coils ABBShort Circuit Test Report Three Phase Circular Transformer 12/16.8 MVA Transformer ONAN/ONAF Cooling Class 55/65 Degree Celsius Rise Liquid Filled Circular Core & Coils Introduetion ABB Inc, has added a circular design to their long list of successful short circuit tests for Liquid Filled ‘Small Power Transformers manufactured at South Boston, Virginia. This transformer was rated at 12 ‘MVA with a primary of 67 KV 350 kV BIL and secondary of 15 kV 110 kV BIL. ‘The transformer passed ANSI/IEEE C57.12.90 short circuit test with less than 1.0% change in impedance (allowed tolerance for circular design is 2.0% per this standard). This successful test proves the circular design transformers built by Liquid Filled Small Power Transformers of ABB Inc. (manufactured in South Boston, Virginia) have the strength to meet the toughest demands, ‘This successful test also allows Liquid Filled Small Power Transformers of ABB Inc. (manufactured in South Boston, Virginia) to provide customers with circular design transformers with proven short circuit strength in accordance with ANSI/IEEE standard 57.12.90, ‘The ratings of transformers available with circular construction are listed below. kVA <=20MVA High Voliage <= 725 KV <= 350 KV BIL. Low Voltage 34.5 kV <= 200 kV BIL, Cooling Class ONAN , ONAN/ONAF , ONAN/ONAF/ONAF Coil Construction Layer Type Construction Core Construction Cruciform Type Construction Step Lap, Stacked Load Tap Changer Optional ‘This report documents the proof of short circuit strength through information on the design and through results of the short circuit test regarding the 12 MVA circular transformer.Design Selection The transformer described below was selected to verify the design calculations and design construction for circular core and cols. The construction consists of layer wound sheet low voltage and layer wound strap high voltage. The design was chosen because it models typical circular design construction and short Circuit forces, thas allowing the verification of the design concept. Rating 12/168 MVA Circular Core & Coils 3 Phase 55/65 °C Rise ONAN/ONAF Cooling Class Oil Filled 60 He High Voltage: 67,000 Volts ‘Tap Position 1: 70,600 Volts ‘Tap Position 2: 68,800 Volts ‘Tap Position 3: 67,000 Volts: Tep Position 4: 65,200 Volts ‘Tap Position 5: 63,400 Volts 350KV BIL Delta Connected Aluminum Strap Conductor Layer Type Construction Low Voltage: 13,090 Volts, 10 kv BIL ‘Wye Comnected Aluminum Sheet Conductor Layer Type Construction Impedance: 8.40% (Design)Design ‘The transformer tested was a circular core and coil design with a three-legged stacked core and low-high coil design, Aluminum conductors were used in both the low voltage and high voltage windings. The low voltage was a two section, series connected (Part Coil) sheet winding. The high voltage winding was Durabil (epoxy) coated strap conductor winding. Both windings were layer wound construction. ‘The core parts consisted of bolted stec! construction to support the core and provide means of lifting the ‘core & coils assembly. The coils were designed and built (o withstand all horizontal short circuit forces ‘with no external supports or braves. ‘The stee! core parts and pressboard barriers provided mechanical restraints for vertical movement during short cixcuit forces, ‘The calculated horizontal short circuit forces for transformer are as follows: Horizontal force between LV to HV winding in each coil with Symmetrical short circuit current: +359,100 pounds. Horizontal force between LV to HV winding in each coil with Asymmetrical short cireuit current +949,000 pounds. ‘The calculated vertical short circuit forces for transformer are as follows: ‘Vertical force on LV and HV windings in each coil with Symmetrical short circuit current: LY: +255 pounds (downward) HV: — +327 pounds (downward) ‘Vertical force on LV and HV windings in each coil with Asymmetrical short circuit current: LY: +673 pounds (downward) HV: — +863 pounds (downward) Vertical force is minimized as a result of sheet conductor being used in the low voltage winding. This allows the electrical center ofthe low voltage windings to align with the electrical center of the strap wound high voltage winding. As a result ofthis, the vertical component of the fundamental force of repulsion between the windings is significently reduced.Based on the results of Calibration Test #1, the following calculations were made: Power Rating (MVArgaxsrornen): LRMVA Primary Voltage: 70.6 KV Delta (shorted) ‘Tap Position 1 Secondary Voltage: 13.09 KV Wye (connected to source) Category: m Rated Secondary Line Curzent (Iparen): 529.27 Amperes Rated Secondary Line-Line Voltage (Vparen): 13,090 Volts Applied Line-Line Voltage (Vaceasuren): 1,107.3 Volts Resulting line current (Iusasureo): 537.2 Amperes ‘Transformer Impedance (Zreansronscx) = (Vaceasunen / Veareo) X (Irate /Tnzastneo) 08334 PLU, ‘Test System Power (MVAsystex) = 1,898 MVA, Test System Impedance (Zsysreu) -0P.U. ‘Test System Impedance corrected to base of transformer (Zsvsrex.xrut ) Zovsrae* (MV Arpaxseonmn / MVAsystew ) = 0.00632 P.U. ‘Short Circuit Line Current (Isc) mp Short Cizcuit Winding Current (scsepa) Tgcune (for WYE connected) = 5,903 Amperes ‘Watts Measured (Wyeysinen) = 4,300 watts Resistance (R ) ‘Wozasunen / (3 * Ineasuea’) =0,05117 ohms Impedance (Z) ‘weasune | ueasenen * 8 ) 19006 ohms Reactance (X) =z -R?) 18896 ohms X/R =23.24 Asymmetric Current Factor (K.) et ANSVIEEE standards C57.12.00 = 2.6507 Peak Short Circuit Line Current (lpeax.un) * Iscume 5,646 Amperes Short Circuit Winding Current (Ig.yoa) =K *Tscwoa 5,646 Amperes‘Based on the results of Calibration Test #2, the following calculations were made: Power Rating (MVArmanseonuen): 12MVA Primary. Voltage: 63.4 KV Delta (shorted) ‘Tap Position 5 Secondary Voltage: 13,09 KV Wye (connected to source) Category: m Rated Secondary Line Current (Inna): 529.27 Amperes Rated Secondary Line-Line Voltage (Vaaren): 13,090 Volts Applied Line-Line Voltage (Vieeasvrso): 1,078.1 Volts ‘Resulting line current (Izasunso): 532.9 Amperes ‘Transformer Impedance (Zrransronven) (Vessunen ! Vaateo) x Upareo / Tyzasunen) = 0.08180 PU. ‘Test System Power (MVAsysrex) 898 MVA ‘Test System Impedance (Zaysrew) = 10P.U. ‘Test System Impedance corrected to base of transformer (Zsystewxewn) Zeustea * (MV Azzansrorver / MVAsysren) = 0.00632 P.U, Short Circuit Line Current (Igcxve) Tnatep / Zreansronsen * Zsysrewaxra) = 6,006 Armperes ‘Short Circuit Winding Current (Igc-woo) = Isc.ung (for WYE connected) = 6,006 Amperes Watis Measured (W ysasunen) ~ 44,800 watts Resistance (R) Wrcasuncn! (3 * Iyeasunep’) 1.05259 ohms Impedance (Z) ‘veasunen / (Iyeasuren * V3) 16803 ohms Reactance ( X ) (ZR?) = 1.16684 ohms ‘Short Circuit Winding Current (Ise.woa) =K* Keewoa = 15,874 AmperesTest Location ‘The transformer was short circuit tested at the KEMA-Powertest Lab in Chalfont, PA on July 10, 2002. The testing was performed by 2 shorting device on the high voltage bushing terminals to apply the fault, and then applying power to the low voltage bushing terminals. A synchronous switch was used to control the closing timing to obtain the required asymmetrical current. The voltages were metered on the low voltage side and the currents were measured on the low voltage side of the transformer (See Figure 1). The tests were performed with the core and coil assembly in the tank and under oil. Transformer 4 ‘Test Sequence on Unit In summary, the test sequence was as follows: 1). Initial lectrical Tests 2). Calibration Tests (for short circuit tests) a) Initial Impedance Test #1 (HIV tap position 5) )_ Initia! Impedance Test #2 (HV tap position 1) 3). Short Circuit Tests 8) Calibration Test #1 at approximately 50% voltage (HV tap position 1) b) Short Circuit Test #1 (0.25 second duration) (HV tap position 1) ©) Demagnetization of Transformer 4) Short Cirouit Test #2 (0.25 second duration) (HV tap position 1) 2) Impedance Test #1 (HV tap position 1) 2) Calibration Test #2 at approximately 50% voltage (HIV tap position 1) 8) Short Circuit Test #3 (0.25 second duration) (ITV tap position 1) 1) Short Circuit Test #4 (0.25 second duration) (HV tap position 1) 4) Impedance Test #2 (HIV tap position 1) 4) Calibration Test #3 at approximately 50% voltage (HIV tap position 5) ) Short Circuit Test #5 (0.5 second duration) (HV tap position 5) 1) Short Circuit Test #6 (0.5 second duration) (HV tap position 1) 1m) Impedance Test #3 (HV tap position 1) 4). Final Blectricel Tests 5) Impulse Test ©) Visual InspectionBach phase was subjected to two asymmetric shots and four symmetrical shots as specified by ANSUIEEE €57.12.90 standard. See Table 1 for summary of short cizcuit tests. Test Phase Phase Phase Required Number A B c Duration Short Circuit #i_| Asymmetrical ‘Symmetrical ‘Symmetrical 10.25 seconds ‘Short Circuit #2 | Asymmetrical ‘Symmetrical ‘Symmetrical (0.25 seconds ‘Short Gireuit #3 | Symmetrical ‘Asymmetrical ‘Symmetrical (0.25 seconds Short Circuit #4} Symmetrical ‘Asymmetrical ‘Symmetrical (0.25 seconds Short Circuit #_| _ Symmetrical ‘Symmetrical “Asymmetrical 0.25 seconds Short Circuit #6_| Symmetrical ‘Symmetrical ‘Asymmetrical (0.50 seconds Table 1 Test Results A tabulation of the full short circuit tests are shown below. Short Cireuit Tests ‘Test Number Results Shoct Circuit #1 ‘Met or exceeded requirements of ANSIAEEE C37.12.90 Short Circuit #2 ‘Met or exceeded requirements of ANS/IEEE C57.12.90 Short Circuit #3 “Met or exceeded requirements of ANSVIEEE C57.12.90 Short Circuit #4 ‘Met or exceeded requirements of ANSVIEEE C57.12.90 Short Cireuit #5 ‘Met or exceeded requirements of ANSI/IEEE C57, 12.90 ‘Short Cixeuit #6 ‘Met or exceeded requirements of ANSIEEE C57.12.90 Table 2 Impedance Tests Test Number HV Tap Position | Value % Results Change Titial Impedance Test#_| TapPositionS | 2.0232. ohms | - = Initial Impedance Test #2 | Tap Position |__| 2.0614 obs | 5 ‘impedance Test #1 “Tap Position || 2.0572 ohms | 0.204% Met or exceeded requirements of ANSV/IEEE CS7.12.90 Timpedance Test #2 ‘TapPosition | 2061S ohms | 0.016% “Met or exceeded requirements of ANSVIEBE €57.12.90 Tmpedance Test Tap Position | | 2.0567 ohms | 0.229% “Met or exceeded requirements of ANSVIEEE C517.12.90 Table3Electrical Tests Test Initial Test | ‘Final Test % Change ‘Results Timpedance 8.19% 827% 0.977% Pass Core Loss 10,854 watts 10,758 watts 0.88% Pass Load Loss 42,935 watts 43,284 watts 0.813% Pass ‘Total Loss 53,789 watts 54,042 watts 0.470%. Pass Exciting Qurrent 0.1173 % 0.1197 % 2.086% Pass HV Applied Potential | Passed at I40EV | Passed at 140 KV ~ Pass 60 seconds 60 seconds LV Applied Potential | Passed at 34 kV Passed at 34 kV - Pass 60 seconds 60 seconds Induced Potential | Passed at 200% volts | Passed at 200% volis - Pass 180 Hz, 7200 cycles_|_180 Hz, 7200 cycles HV Resistance 3.7196 ohms. 5.6584 ohms 070% Pass LV Resistance 0.04544 ohms 0.04491 ohms 1.166% Pass. Table 4 ‘The transformer also passed insulation resistance, power factor, ratio, and polarity tests at both intial and final electrical tests. ‘The transformer also passed impulse test performed per ANSVTEEE C37.12.90 requirements, The impulse test was conducted after conclusion of final electrical tests. Visual Examination ‘The core and coil assembly was removed from the tenk and given a visual inspection afterall electrical tests were completed, Photographs were also taken of the core and col assembly. The coils were then ‘emoved from the assembly and each was visually inspected. Photographs were also ‘taken ofthe coils. The core framing, core and coi assembly, cols, and core were in excellent condition. One ofthe coils was ‘unwound to visually inspect the conductors and bonding between conductors and layer insulation. Photographs were also taken during the unwinding ofthe coil. The coil and all of its components were in excellent condition. The transformer maintained its functional integrity after short circuit testing, Conclusions ‘The short circuit tests on this unit are fully documented with test data and oscillogram records of the voltage and current and test data, Visual examination was thoroughly conducted on transformer, core & coil assembly, and coils after the conclusion of all tests. Photos were also taken during all visual inspections to document the inspections, ‘The short circuit testing conducted per the latest short circuit test standard (ANSIIEEE C57.12.90) prove the mechanical and electrical integrity of the circular design concepts used in core and coil construction for ‘Liquid Filled Small Power Transformers of ABB Inc. (manufactured at South Boston, Virginia). Tests Witnessed by: Report Prepared by: ‘Kevin Knouse — Mechanical Design Manager David Elzey ~ Senior Design Engineer Ray Nicholas — Engineering Manager Kevin Knouse ~ Mechanical Design ManagerShort Circuit Test Measurements Current Voltage |__ Measurements Impedance Measurements oy. ‘sym Measured | %Change | Between | C.C.v. [Tria Test (kv)_| Phase (kA) (%) () Phases | (kV) 1 [initialimpedance |= 1,100] A 0.531 8.244 = AtoB | 1.084 [Test #1 B 0.530 8.180 - Btoc | 1.072 fo tap poston 5 c 0.837 a7 : Ctoa | 1.079 AVG 0.533 8.180 : AVG | 1.078 2 |initiatimpedance | 1,100] A 0.535 8.398 AtoB | 1.112 [Test #2 B 0.534 8.336 - Bioc | 1.102 HV tap position 1) c 0.542 8272 S CtoA | 1.109 AVG 0.537 8335 : ave_| 1.107, Voltage Current Measurements Time | _Moasurements ocv. Total] Sym | Peak] Sym@ | Sym@ | Duration | Between Trial] Test (kV)_| Phase | (kA) | (kA) | (kA) |25 ms (kA)| End (kA) |(seconds)| Phases 3 [Calibration Test#1 | 6000 [ A | 430 | 285] 7.95| 294 292 | 0264 [ AtoB |(HV tap position 1) B | 283 | 283} 408] 283 260 | 0268 | Btoc c | 443 | 205] 751] 277 271 | 0268 | Coa ave | 325 | 284 | - 2.85 274 - AVG |Short Circuit Test 4 fe 12,700] a |1260| 7.55 |>20.90| 7.91 ote | 0264 | AtoB HV tap position 1) B | 660 | 6.43 | 10.50) 6.35 548 | 0268 | Btoc c | 1240] 7.63 |>20.70| 7.50 621 | 0268 | Ctoa ave |1060| 7.22 | - | 7.25 5.96 - AVG 5 [Demagnetization | 13,040 hort Circuit Test 6 2 12,700] A |11.90| 728 | 19.90] 7.39 603 | 0266 | AtoB | 11.600 (HV tap position 1) B | 693} 635 |1190) 629 557 | 0270 | Btoc | 11.650 c | 1040] 7.13 }17.50| 6.93 605 | 0270 | Ctoa | 11.490 ave | 975 |es2| - | 687 5.89 : AVG _| 11.610 Current Voltage Measurements Impedance Measurements. ocy. ‘sym Measured | %Change | Between | C.CV. Irriat Tost (kv)_[ Phase (kay (%) 2) Phases | (kV) 7 |impedance Test#1 |= 1,100] A 0.682 8.384 “0.466 AtoB | 1.103 (HV tap position 1) B 0.530 8317 0.202 Btoc | 1.090 c 0.536 8.253 0223 | cto | 1.095 AVG. 0.533 8318 0.204 Ave | 1.096 Table 5Short Circuit Test Measurements (continued) Voltage Current Measurements Time |_Measurements O.cy. Total] Sym | Peak] Sym@ | Sym@ | Duration | Between [Trial Test (kV)_| Phase | (kA) | (kA) | (kA) |25 ms (kA)| End (kA) |(seconds)| Phases 8 [Calibration Test #2] 6000] A [3.74 | 277 | 637 | 277 271 0259 | AtoB {HV tap position 1) B | 448] 279) 751] 289 269 | 0263 | Btoc c | 305 | 280} 523] 283 269 | 0263 | CloA ave | 375 | 2.79 | - 2.83 270 = AVG | 5.569 ort Ciroult Test 9 12,500] A | 831 | 663 |1420] 652 592 | 0251 | atop | 11.470 (HV tap position 1) B | 1130] 6.65 | 18.60] 635 560 | 0255 | Btoc | 11.510 c | 744 | 598 |1310] 6.12 566 | 0255 | Ctoa | 11.470 ave | 9.00 | 642} - 633 573 = ave _| 11.483 [Short Ciroult Test 10 fea 12400] A | 667 | 5.82 [1140] 5.77 554 | 0262 | AtoB | 11.430 {HV tap position 1) B | 1060| 638 |17.80] 6.12 548 | 0265 | BtoC | 11.300 c | 863 | 668 | 1520] 6.64 595 | 0266 | Ctoa | 11.310 ave | 865 | 629] - 6.18 5.66 - ave_| 11.347 Current Voltage Measurements Impedance Measurements ocy. ‘sym Measured | %Change | Between] C.C.V. Trial Test (kv)_| Phaso (kA) (%) (h) Phases | (kv) 11 |impedance Test #2 |= 1,100[ A 0.529) 8.403 0.062, Atos | 1.099 |HV tap position 1) B 0.527 8.335 0.005 Btoc | 1.086 c 0.534 8271 0.011 CtoA | 1.091 AVG 0.530 8.337. 0.016 AVG _} 1.092 Voltage Current Measurements Time | _Measurements Total] Sym | Peak sym@ | Sym@ | Duration | Between | C.CV. Trial] Test (kV)_| Phase | (kA) | (kA) | (kA) |25 ms (kA)| End (kA) |(seconds)| Phases | (kV) 12 [Calibration Test#3 | 6.000 A [290] 283] 457] 283 27 | 0252 | AtoB | 5.584 (HV tap position 5) B | 382] 280/653] 277 268 | 0257 | Btoc | 5.561 c | 440 | 288 | 751] 294 297 | 0287 | Ctoa | 5.543 AVG | 370 | 283 | - 2.85 2.78 - AVG | 5.563 iShort Crouit Test 13 pS 12,700] A | 10.10| 7.48 |17.60) 7.62 624 | 0262 | atop | 11.620 {HV tap position 4) B | 872 | 7.08 [1500] 681 595 | 0262 | Btoc | 11.470 c | 1330] 7.75 |22.20] 7.39 641 | 0268 | Ctoa | 11.370 ave [10.70] 7.44 | - 727 6.20 : ave _| 11.490 Table 5 (continued)Short Circuit Test Measurements (continued) Voltage Current Measurements Time |_Measurements ‘Sym Sym ocy. Total | Sym | Peak |x 10" |@ 25 ms| @ End| Duration | Between | C.c.v. [Trial Test (kv) | Phase | (ka) | (ca) | (kA) |(A%s)|" (kA) | (kA) [(seconds)| Phases | (KV) \Short Circuit Test, 14 12,500] A | 7.65 | 587 | 13.40} 1.89] 6.00 | 5.77 | 0526 | AtoB | 11.650 IV tap position 1) B | 639 | 5.71 [1080] 1.73| 56s | 577 | 0522 | Btoc | 11.580 c | 994} 6.40 | 1670] 210] 589 | 583 | 0526 | ctoa | 11.570 ave |793|589| - |101] 585 | 579 | Avs _| 11.600 Current Voltage Measurements Impedance Measurements. ocv. ‘sym Measured | %Change | Between | 6.C.V. [Trial Test (kv)_| Phase (kA) (%) 2) Phases |_ (kV) 45 impedance Test #3 [=1,100[ A 0.529 8381 0.202 AtoB | 1.097 (HV tap position 1) B 0.527 8.313 0.263 Bioc | 1.084 c 0.534 8.253 0.222 CtoA | 1.089 AVG 0.530 8.316 0.229 ave | 1.090 Table 5 (continued)Short Circuit Test History Year | KVA [Phase | Primary | Secondary | Timpedance ‘Comments 1954 [S00 3 [13,8000 2I6V | __4.00% Single-phase tests i959 | 333 | 1 | 13,800V | __216V| 5.00% ‘Single-phase tests 1960 |2,500 | 3 | 13.200V 480 7.00% ‘Single-phase tests 1964 [500 [3 | 12.470 240V[ 5.60% 1964 [~ 500} 3 | 27,000 2I6V | _4.10% ‘Single-phase tests 1965 [2,500 | 3] 12,000 27rIv {530% ‘Single-phase tests 1965 | 2,500 [3 | 12,000 277 | 5.80% ‘Single-phase tests 1965 | 8003 | 11,200] _4160V | 5.60% 100 tests 1965 | 833 11,400 V * 3.80% 1966 [833 12,000 V = [5.50% ‘Single-phase tests 1966 | 833 12,000 V = [5.50% ‘Single-phase tests 1966 | 833 12,000. =P 550% ‘Single-phase tests 1967 [7,667 [1 | 34,400V Fe] F2.70% ‘Equivalent to 5 MVA 3 Phase 197i | 1,667 [1 | 34,400 | 7200V' | _*6.10% ig71 [2,500 [3 | 24,900 V| 13,200-v | *#2.50% ‘Auto Transformer 197i | 2,500 3 | 24,900°V- [13,200 V | ##2.50% ‘Auto Transformer 1971 | 2500[ 3 | 24900V | _12.470V |_="*2.60% ‘Auto Transformer 1976 | 5,000 | 3 | 67,000 | 12470 |__7.20% | Tested per ANSVIEEE CS7.19,00a - 1974 1976 | 70,000 | 3 | 26400 | 8320] 5.80%. 197 | 10,000 |~3 | 26400] 8320 | 5.80% 1979 | 2,500, 3 | 13,200V a0V | 5.75% ‘Vapor-Gas design. ‘Tested per ANSU/IEEE C57.12.90a - 1978 179 | 5000 3 | 34a00v [ago | 7.00% 1981 | 10,000 [3 | 43,800] 22.800. | __7.50% | Tested per ANS/IEEE C57.12.90a - 1980 1982 [11,200] 3 | 22,860 | 13,200V | 5.30% ‘Auto Transformer 1999 [11,2003 | 68,000 [13,200 | 8.00% 0.5% change in impedance 2000 | 15,000} 3 | 67,000V | 12,470] 7.30% LTC on LV side. <1.0% change in impedance 2001 | 15,00 {3 | m8e0V| 13.2000] "7.10% ‘Auto Transformer. ‘2002 | 12,000 | 3 | 67,000 | _13,000V | 8.40% | Cireular Design. <0.5 % change in impedance Notes: * One L.V. coil at 2.4 KV and one L.V. coil at 277 V. ** One L.V. coil at 2.4 KV and one L.V. coil at 7.56 KV. *** Short-circuit current limited to 25 times normal (4% impedance). **** Actual test performed assuming customer’s system impedance in addition to transformer impedance per specifications of customer. Table 6ABB Inc. ‘Small Power Transformers Liquid Filled P.O. Box 920, 2135 Philpott Road South Boston, VA 24592 Phone: 800-333-6757 Rev. 00 Oct. 22, 2002