Siemens Energy optimises power transformers with the aid of 3D EM Simulation

2014 CST AG - http://www.cst.com Page 1 of 6

Siemens Energy optimises power transformers with
the aid of 3D EM Simulation
Finding customised solutions for any applications and specifications of transformers this is the task of Siemens Energy T TR
PN. It is difficult to obtain off-the-shelf solutions for furnace and converter transformers as well as transformers for High
Voltage Direct Current for ratings greater than 200 MVA. 3D EM Simulation with CST EM STUDIO (CST EMS) is a vital tool
in the optimisation process of transformer installations.
Figure 1: Typical 40 MVA Siemens Transformer
The challenge of transformer design
The demands on power transformer design are diverse they must conform to national and international standards and fulfill
the specifications of the electricity utilities and their contractors. These conditions are to a large extent determined by the
network to which they are connected and specific factors at the installation site. The dimensioning of the power transformer
must adhere to the necessary specifications. In this process, mechanical, electromagnetic and thermal characteristics must be
taken into account. For every manufactured transformer, a works test is carried out to ensure correct operation and safety
under operating conditions spanning several years.
Insulation Design
The development of insulation systems and components is one of the design goals in transformer design. This involves
knowledge of the electrical insulation between windings and the insulation between energised windings, conductors and
grounded components. The conception, design, construction and material of a given insulation arrangement are determined by
the specification requirements. In power transformers, mineral oil and impregnated fibrous material, also known as
transformer board, are generally used. The system consisting of pressboard and oil channels is referred to as an insulation
system.
Siemens Energy optimises power transformers with the aid of 3D EM Simulation
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Effective modeling of Complex Geometries
The User-Interface of CST STUDIO SUITE is very easy to use and enables the fast construction of models. This model is
then meshed and solution matrices set-up for use in the numerical solvers. CST EMS allows the user to lower simulation times
by defining symmetry conditions which reduce the simulation domain and required memory. Figure 2 shows a model of the
active part of a five-leg power transformer with three wound legs which was constructed entirely in CST EMS. For complex
geometries, CST EMS allows the import and modification of a wide range of 3D formats.
Figure 2: Simplified model of the active part of a transformer
Insulation arrangements can still, even with some simplification, pose a difficult challenge for numerical simulations since the
dimensions of these structures can be of the order of several meters while the thickness of the individual components, such as
transformer board barriers, is in the range of a few millimeters.
Since the barrier strength and oil channel width are decisive factors in the dimensioning of the insulation system, a powerful
and robust mesher is important. As well as a tetrahedral-based mesh generator CST EMS also offers a hexahedral-based
mesh scheme ensuring that the user can apply the best method for the problem. In addition to global mesh settings, the user
also has the opportunity to refine the mesh locally on a component or material level. As an example of a typical simulation,
Figure 3 shows an equipotential plot from an electrostatic simulation of the outlet section of a winding arrangement (active
part). For this simulation, the original 5 leg active part was reduced to a single leg.
Siemens Energy optimises power transformers with the aid of 3D EM Simulation
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Figure 3: Electric potential around a single-leg winding arrangement
CST EM STUDIO establishes operational stability
A virtual operational stability test involves the 3D simulation, analysis and further development of insulation systems between
various electrode arrangements. Electrostatic simulations are used to provide momentary values of the electric stress which
typically arise in the testing of a transformer. The tetrahedral-based electrostatic solver in CST EMS is particularly suited to this
simulation since it allows an accurate surface and efficient volume discretisation. This helps to determine the potential
distribution around electrodes and on insulating surfaces which is critical for establishing the effectiveness and strength of the
insulation systems. Figure 4 shows an equipotential plot in an oil-transformer board insulation system.
Figure 4: Equipotential Plot of the Electric Field Stress
Siemens Energy optimises power transformers with the aid of 3D EM Simulation
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The right solver for the job
CST EMS offers a wide range of numerical solvers for various types of problems. For the calculation of induced
electromagnetic losses in the individual elements of the transformer, the magneto-quasi-static solver is used. The sources for
such simulations include the windings of the active part and the winding connecting leads.
The active part, which consists of the iron core and the leg sections with concentric windings and their insulation, forms the
heart of the transformer. Stray fields lead to electromagnetic losses in the surrounding metallic construction elements.
Simulation of this situation would aid in the reduction of the losses by appropriate shielding measures or changes to conductor
placement. Analysis of the magnetic field in the core, shown in Figure 5, assists the investigation of the shielding effectiveness
of the shielding walls.
Figure 5: Analysis of shielding wall effectiveness : Magnetic energy density
No new transformer development without CST EM STUDIO
The importance of simulation in the high voltage design, construction and dimensioning process as well as the calculation of
electromagnetic losses in the active part is continually increasing. For this simulation the CST EMS Low Frequency time
harmonic solver was used. In Figure 6, the electromagnetic losses in the pressboard are shown where the skin effect can be
clearly seen. To support accurate modeling of the skin depth, 2nd order elements were used. Alternative techniques such as
surface impedance modeling are also available, which can significantly increase the performance of simulations.
Siemens Energy optimises power transformers with the aid of 3D EM Simulation
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Figure 6: Loss Density in the press frame
Thermal considerations also play a role in the design process. The loss distribution from the low frequency simulation can be
used as a thermal source in the CST MPHYSICS STUDIO (CST MPS) thermal solver. This transfer of the losses from the
electromagnetic solver to the thermal solver is carried out seamlessly within the same model and opens up a range of analysis
possibilities.
Siemens Energy Sector
Siemens Energy Sector is the worlds leading supplier of a wide range of products, solutions and services for power generation,
transmission and distribution as well as for the production, conversion and transport of the primary fuels oil and gas. We are
the only supplier worldwide with comprehensive knowhow encompassing the entire energy conversion chain and, in particular,
plant-to-grid connections and other types of interfaces. We focus primarily on the requirements of energy utilities and industrial
companies particularly those in the oil and gas industry.
Our Energy Sector has some 85,000 employees worldwide. In fiscal 2009, it generated external revenue of 25.4 billion and
profit of 3.3 billion.
Author
Ronny Fritsche,
Siemens AG Sector Energy T TR PN
Katzwanger Str. 150, 90461 Nrnberg
mail: ronny.fritsche@siemens.com
Siemens Energy optimises power transformers with the aid of 3D EM Simulation
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Tel: 0911 434 2432, Fax: 0911 434 2315