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DOI 10.1007/s00202-006-0008-4
O R I G I NA L PA P E R
Received: 17 September 2005 / Accepted: 16 January 2006 / Published online: 11 April 2006
Springer-Verlag 2006
Abstract Non-flammable characteristic of dry-type castresin transformers make them suitable for residential and hospital usages. However, because of resins property, thermal
behavior of these transformers is undesirable, so it is important to analyze their thermal behavior. Temperature distribution of cast-resin transformers is mathematically modeled in
this paper. The solution of the model was carried out successfully by finite difference method. In order to validate the
model, the simulation results were compared with the experimental data measured from an 800 kVA transformer. Finally,
the influences of some construction parameters and environmental conditions on temperature distribution of cast-resin
transformers were discussed.
Keywords Thermal modeling Dry-type transformer
Cast-resin Finite difference
1 Introduction
The transformer is a key component in the transmission and
distribution system of electrical energy. In some cases, as
in hospitals and residential areas, transformers must be protected against flame and explosion. Therefore, specialists
and designers tend towards new kinds of transformers. Thus,
non-flammable transformers have been built [1]. These transformers employ non-flammable insulations in their structure.
One of such insulations is askarel, which includes polychlorinated biphenyls (PCBs). However, in the mid-1970s, it was
determined that PCBs were not environmentally acceptable.
E. Rahimpour (B)
Electrical Engineering Department, Faculty of Engineering,
University of Zanjan,
Daneshgah road (Tabriz road km 5),
P. O. Box 45195-313, Zanjan, Iran
E-mail: ebrahim.rahimpour@web.de
Tel.: +98-241-5152678
D. Azizian
Iran Transformer Research Institute (ITRI),
Zanjan, Iran
302
where,
qro : local radiation heat, transferred in height z in outer
surface (W),
:
qro
local radiation heat flux in height z in outer surface
(W/m2 ),
h ro : local heat transfer coefficient for radiation from outer
surface [W/(m2 K)],
:
emissivity coefficient of surface,
Ts :
local temperature of surface (K),
Tair : ambient temperature (K),
A:
the surface on which radiation occurs (m2 ), and
:
Stephan Boltzmans coefficient (5.67 108 W/
(m2 K4 )).
Fig. 1 Schematic view of cast-resin transformer
T:
ku :
Gr =
Nuz kair
Z
4 Pr 2 Gr
36 + 45 Pr
gq co Z 4
kair 2
(5)
1/5
(6)
(7)
where,
qco :
local convection heat, transferred in height z in outer
surface (W),
:
qco
local convection heat flux at location z in outer surface (W/m2 ),
q co : average heat flux in outer surface (W/m2 ),
h co :
local heat transfer coefficient for convection from
outer surface [W/(m2 K)],
kair :
thermal conductivity of air [W/(m K)],
Gr : Grashoff number for uniform heat flux,
Nuz : Nusselt number,
Pr:
Prandtl number,
:
volumetric expansion of air (1/K),
:
kinematical viscosity of air (m2 /sec),
g:
acceleration of gravity (m/sec2 ), and
Z:
vertical distance (m).
The aforementioned equations are valid over the Grashoffs range (105 Gr 1010 ) [9]. Note that , , and kair
are dependent on unknown temperatures [10,11].
2.3 Part 3: air ducts
In this part, the radiation and conduction heat transfers are
negligible in comparison to the convection.
303
,
+
Nu Z = C2 (1 + R)
Z 1 + R
70
2
for Z 60
wherein,
(b/Z )Gr Pr
Z =
1/2
(b/L)Gr Pr
(11)
(12)
Gr =
gq Dh4
kair 2
(13)
Dh = 2
(14)
Finite difference method, in which the so called resistive elements are employed, is used to solve the Eq. (1). This method
applies the energy conversion law to state the Eq. (1) in the
numerical form. The energy conversion law in the steadystate expresses:
(A) ro
ri
(B)
m ,n+1
R+n
zu
zd
qi
m,n
b
z = zu /2+ zd /2
r = ri /2+ ro /2
qo
Fig. 3 Schematic view of a duct (including four dog bones) from top
of the transformer
m-1,n
Rm-
m+1,n
R+m
Rnm,n-1
Fig. 4 a Units in radial and vertical directions (2 nodes in radial direction and 13 nodes in axial direction are shown in this division). b
Schematic view of a unit, which is represented by a node named m, n
304
otherwise
otherwise
otherwise
otherwise
2r m 2
|I |
hw
(19)
where , rm , and I represent electrical resistivity, mean radius, and current of conductor, respectively. Now assume that
the nodes in the radial direction are selected in the middle of
insulation (Fig. 6), so that the related unit contains fourth part
of four conductors beside insulation. In this case, losses of
each unit (qm,n ) can be calculated as shown in Fig. 6, as the
summation of the losses in its conducting parts.
Note that, winding losses depend on temperature, as it
can be seen in the following equation.
K eddy
Ptotalnew = Pdc K E +
(20)
KE
with,
KE =
(18)
Tnew + Tk
Tbase + Tk
(21)
and
Tk :
48 K for Aluminum and 38.5 K for Copper,
Pdc :
dc losses calculated in the temperature Tbase , and
Ptotalnew : total losses in the new temperature Tnew .
305
Fig. 6 Losses of one unit (qm,n ) as the summation of the losses in its
conducting parts
(22)
wherein,
[G]: coefficients matrix,
[T ]: temperatures matrix, and
[Pc ]: heat matrix.
[G] and [Pc ] are dependent on matrix [T], so an iterative
process is necessary to solve the Eq. (22). For thermal
modeling of cast-resin dry-type transformer, 58 nodes are
selected in the radial direction and 55 nodes in the vertical
direction and temperatures are calculated by solving (22).
4 Verification of model
To evaluate the validity and accuracy of the discussed thermal model, a cast-resin dry-type transformer is chosen as a
306
400 V
HV terminal voltage
20 kV
667.54 watt/m2
LV line current
1154.7 A
HV line current
23.09 A
Power
800 kVA
LV connection
HV connection
Frequency
50 Hz
LV turns
18
HV turns
1,559
120
120
(B)
110
110
Temperature ( C)
Temperature ( C)
(A)
100
=60C
=120C
=240C
=300C
90
80
70
100
90
80
70
60
200
400
600
Vertical Distances (mm)
Measured
Calculated
800
200
400
600
Vertical Distances (mm)
800
Fig. 8 Comparison of modeling and experimental results. a Measured temperature distribution in different angles. b Comparison between
measured and simulated results
Table 3 The average and the hottest spot temperature rises of the test object
Modeling
Experience
IEC std [4]
Reference [9]
HS/AV
LV
HV
LV
HV
LV
HV
88
85
100
95.8
93
100
103
Not measured
115
119.3
Not measured
115
1.17
1.24
1.15
1.26
1.15
1.26
1. Experimental errors
1. Some laboratory environmental conditions such as air
displacements, which cannot be determined precisely
and create inaccuracy.
2. Body of the infrared periscope may be warmed subject
to magnetic fields. This can cause an error in temperature reading [15].
2. Modeling errors
1. Errors caused by numerical calculations due to some
computational operations such as rounding and estimation.
2. Errors due to limited number of nodes, increased number of nodes in radial and vertical directions can
improve the precision, but the time for running the
program outweigh the precision.
With the help of verified model, the influences of some parameters on temperature distribution are evaluated. These parameters and results of their analysis are given as follows:
1. Air ducts
There are three air ducts in the test object. The behavior
of all of them is similar. The influence of the air duct
between LV and HV windings (air duct 3 in Fig. 7) on
200
1.5
(A)
180
307
(B)
LV
HV
LV
HV
1.4
160
HS/AV
Average Temperature ( C)
140
120
100
1.3
1.2
1.1
80
0
20
40
60
80
Air duct's width (mm)
100
20
40
60
80
Air duct's width (mm)
100
Fig. 9 Effect of air ducts width on temperature distribution of windings. a Average temperature. b Ratio of HS/AV
95
90
85
80
120
110
(A)
Temperature( C)
Temperature( C)
100
160
180
(B)
105
100
95
210
230
240
250
Radius(mm)
Radius(mm)
Fig. 10 Effect of eddy losses on temperature distribution in LV winding (a) and HV winding (b), in the middle of windings
6 Conclusion
Cast-resin dry-type transformer is modeled in this paper in order to calculate temperature distribution in its windings. The
validity and accuracy of the modeling results is shown with
308
100
130
95
90
=0.8
=0.9
=0.95
85
120
140
160
Temperature( C)
Temperature( C)
(A)
(B)
120
110
=0.8
=0.9
=0.95
100
90
180
220
Radius(mm)
230
240
250
Radius (mm)
Temperature( C)
Fig. 11 Effect of radiation of outer surface on temperature distribution in LV winding. (a) and HV winding (b), in the middle of windings
( denotes emissivity coefficient of outer surface)
150
100
Air ducts
Edge bands
Eddy losses
Radiation from outer surface
Heat transfer from top surface
Heat transfer from bottom surface
Dog bones
50
b=0.0 , t=0.0
b=0.8 , t=0.0
b=0.0 , t=0.8
0
200
400
600
800
1000
HV winding
Strong
Insignificant
Considerable
Insignificant
Weak
Insignificant
Considerable
Strong
Insignificant
Insignificant
Considerable
Weak
Insignificant
Insignificant
(B) 1.175
90
89
HS/AV
Average
Temperature( C)
(A)
LV winding
88
87
1.17
1.165
86
85
5
10
Nomber of dog bones
1.16
5
10
Nomber of dog bones
Fig. 13 Effect of dog bones on temperature distribution of LV winding. a Average temperature b Ratio of HS/AVb
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