Investigation of Transformer Electromagnetic Forces Caused by External Faults Using FEM Ana C, de Azevedo, Ivan Rezende, Antonio C. Delaiba, José C. de Oliveira, Bismarck C. Carvalho, and Herivelto de $. Bronzeado, Member, IEEE Absiraet—This paper is focused on the investigation of trans- formers internal electromagnetic forees caused by external faut ‘The simulations are based on the finite elements method (FEM) {to model a three—phase transformer and also to calculate the forces via traditional mechanical and electrial equations. Normal rmmetrical fault conditions are used for the estimation of internal radial and axial forces. This work, which leads to specific transformer performances, allows to verify the ‘of the method usc! and also the physical consistence ional simulations, The results shown in this p fare flux distribution, losses and other information regarding the equipment operation. The FEM approach has shown to be ‘4 powerful tool on the estimation of mechanical stress within transformers and it can be quite useful at the design stage of ‘such deviees. Index Terms~ electromagnetic force; finite element method; short-cireuit currents; transformer modeling. 1 INtRopucrion LURING normal lifetime, transformers are submitted to a variety of stresses. One of the most critical ones are extemal shortcireuits. Under these circumstances, high currents circulate in the transformer windings and, therefore, high internal forces are produced, which can damage the transformer. Reference [1] describes all aspects of this phenomenon and its relationship with the transformer performance. Techniques to mitigate the impacts of these frees are also considered in this reference. However, solutions to overcome electromagnetic forces occurring on the transformer windings during short eireuit conditions depend on the material selection and careful structural design [2] This paper is concentrated on the use of Finite Element Methods (FEM) t9 model transformers. This method provides ‘ comprehensive view of the overall transformer magnetic and electrical behavior under normal and disturbance conditions. In addition, it provides a significant degree of accuracy [3], Which is very useful fo analyze eletromagnetc forces. ‘A.C. de Azevedo is PAD sen in he Faculty of lectricl Engineer of «he Feral University of Ube, Bra (mai acazevedoel ib) Resende ie MSc sudent in te Faculy of Hectical Engines ofthe Fodetal Univesity of Ubendia, Bra e-mail ivanfunel@yaboacom ‘A.C. Delibe (emai: delsibeufitnn) and J.C. de Oliveira (emai sivir@ufit) are withthe Focaltyof Electrical Engines ofthe Federal] University of Ubelindia, Brazil emai dolib(aatih). B.C. Canalho i wih the Deparment of Hletical Engineer of the Federal University of Mato Grosso, Brazil e-mail boas. HL de S. Broazeado is with the Companhia Hidro Elérica do Sto Francisco ~ CHESF, Bri (e-mail: bebron ees pov.h) 1-4244-0288-3/06/$20.00 ©2006 IEEE, Using 15kVA three-phase transformer parameters, computational investigations were carried out to test the method application. The results are compared to analytical values using the traditional and well-accepted methods. IL, ELECTROMAGNETIC FORCES IN TRANSFORMERS. Fig, | shows the main fluxes distribution within a shell-type transformer with concentric windings. The currents in the ‘windings and other classical transformer operational variables are also shown. The mechanical forces produced are indicated to provide a first interpretation of the phenomenon here considered. Coneeming this figure, the magneto motive force (mmf) in the outer winding is slightly greater than the mmf of the inner winding. This implies in the forces direction shown in the figure, Jakes] Oun Fig. 1, Flux distribution, fields and axial and radial Fores in concentric windings. ‘The fluxes in the transformer may be divided in: (@) lux Broo related to the center leg; (b) fluxes Jy and gx, respectively, at air space between the ‘windings (leakage flux) and between the inner winding and the core; (€) fluxes gras and yas in the outer legs and; (@) lux yin the air space outside the windings and core,It is well known that the electromagnetic forces that act at the transformer windings are generated by the interaction between currents density and leakage field density. These forces can be calculated using (1) [4]. PHIXB a is the force density vector, J isthe current density where: vector and B is the leakage flux density vector. When the transformer operates under normal conditions, the electromagnetic forces on the windings are small as. the ‘currents and leakage magnetic fluxes are relatively small However, during external fault situations, the currents in the swindings increase and consequently the leakage flux. This yields to new and higher electromagnetic forces at the windings. Under these circumstances, the radial and axial ‘components of the leakage ficld and electromagnetic forces ‘must be fully considered, In a transformer with concentric windings, the axial ‘component of the leakage flux density (B,), which is normally higher than the radial component (B;), interacts with the ccurent in the windings, producing a radial force (F,). This is responsible for the mutual repulsion between the inner and outer windings. The radial component of the flux density has its lowest value half way the winding length, At this point, the ‘lux is practically axial. The highest vatuc of the radial flux ‘occurs at the top and bottom ends of the windings where the path of the magnetic flux is curved, This radial flux component imteracts with the current, producis fonoe (F) which acts to compress oF to expand the windings [2) It is important to note that any asymmetry between ‘windings can produce large axial forces and to cteate a serious tisk for the transformer integrity. This effet can be illustrated through a displacement between windings as shown in Fig. 2 (5. Fig. 2(a) shows a situation where the inner and outer ‘windings are symmetrical and balanced built up. In this case, the leakage flux is symmetrically distributed, generating ‘opposite axial forees at the ends of the winding and, thus, producing a null resultant force. On the other hand, Fig. 2(b) shows a high physical displacement between the inner and outer windings. This ccauses different values for the axial forees in each half ‘winding, This situation makes the full balancing of the winding. very difficult and produces a dangerous resultant force on the windings. ee YS S| Y Sve SINE @ » Fig. 2. Axil fines om the windings: (a) windings magnetically balanced (symmetrical (6) windings dspace axial. ITIL, CALCULATION OF THE ELECTROMAGNETIC FORCES: During normal operation, the magnetic field within 2 transformer is basically confined to its ferromagnetic core ‘Therefore, the leakage flux is relatively small Under short circuit conditions, the leakage flux. greatly increases, hence, the forces occurring on the windings. AS the leakage flux can be expressed as @ function of the eurtent in the windings, the resultant force, as given in (1), will be proportional to the squared current, independently ofthe type of arangement of the transformer windings. Sine the maximum electromagnetic forees are produced by three-phase short circuits, itis usual to design transformers to Withstand the maximum peak of this short eicuit current. This condition takes into account the transformer connected to an infinite busbar [3]. In this context, the equation to determine the worst condition of short circuit current (F,) for a three- phase transformer is (6) 1 bABestrt10 fara Where: Ky/2 is the factor of asymmetry; MVA isthe transformer rating power [MVA]; V is the transformer rated voltage [VJ Z.is the per unit impedance ofthe transformer Q ‘The following sections present analytical expressions to calculate the axial and radial forces and the leakage magnetic fields A. Radial Electromagnetic Forces for Concentric Windings Template ‘The radial force components in a transformer with concentric windings are calculated easily and accurately as shown bellow [6] Fig, 3 illustrates a eross section for a transformer with two ‘concentric windings. The resultant forces inthe inner and outcr ‘windings are also shown.The axial field density (B,) has its maximum (constant value) in the region between the windings (Leakage flux) and it is null in the internal and external surfaces of the inner and outer windings, respectively. Thus, the foree, in per unit of length, throughout the length of the coils remains practically constant and canbe accurately calculated. Distrib of sal “ —s & g t Fig 3. Cross section of transformer with concsntic windings, showing the ssa eld density (8, andthe ada are (>) Neglecting the flux spreading out at the ends of the windings, the radial force (F,) due fo the interaction between the instantancous ampere-turns in cach winding (ni) and the leakage field density (B,) (3), is given in (4, 4x(ni) T | 5 or 7] ° = Eta 197] @ i Where: i is the currents in transformer winding, n is the ‘number of turns, fis the length of the winding and Dj is the ‘mean diameter of the winding, B. Axial Electromagnetic Forces for Concentric Windings Fig, 4 shows the distribution ofthe radial field and the axial forces in an arrangement with asymmetrical windings. It can bbe noted the height of the outer winding is shorter than that of the inner winding. This asymmetry causes a great density of radial flux in the region where the imbalanced of ampere-tums occurs [7]. 3 The analytical calculation of the radial leakage field (and therefore, the axial force) mentioned is not as simple as the axial field calculations, ‘A welkaccepted approach for the above calculation is the Residual Ampere-turms Method. This is based on the principle that any arrangement of concentric windings can be split into two groups having balanced ampere-turn. One produces the axial field andthe other the radial field (6) To calculate the axial compression force by the mentioned rthod, it is necessary to known the following parameters: (@) the effective length of path ofthe radial flu, hay (Fig. 4). I differs for each arrangement of tapings; (©) the average radial flux density (B,), considering the average diameter ofthe transformer, according with (5); (©) the average value of ampere-tums which is equal to (U2ja(ni), where ais the length of tap section (or group of short-circuited tums), expressed as a fraction of the total length ofthe winding. 6) To determine the axial force (F,) for a transformer with tap section in one end of the external winding is used (6): 2na(ni)’ oe) 6 It is important to say that, for configuration showed at Fig, 4, the value of fg is 0,222h, Reference [6] shows the expressions to calculate electromagnetic forces for other specific tap arrangements. IV. COMPUTATIONAL INVESTIGATION This section describes the computational results for a ISKVA three-phase transformer with concentric windings. Table T shows the geometric, electric and magnetie main characteristics for the transformer considered. TABLEL “Transeomuen CHARACTERISTICS Tekage impedance Carlos Frequency [Oster winding | Taner winding — Volga TV Case dnsiy 258 ani? Windings toms 66. ‘Winding ss 190 W ‘Winding resistance oowa ‘Exeral winding diameter Isbx10"m Tossi0 Inceroal winding diameter 1B: S7<10%m WE se Adah ce Basu |S AD6«1O7 we wid 80810" m ‘6310 m Fig 4. Cross seton ofa transformer, radial fied density and axial force ‘Magnetic fx density) 1551638 Lat edsFig. 5 shows the magnetization curve of the steet-siticon used for the transformer core. This saturation curve was implemented in the finite element software, ‘The studies selected to be presented in this paper comprise four transformer operating situations. These distinct conditions are fully described bellow. Induction (7) Regge. Magratizing force (Alm) ig 5. Magnetization euve of the transformer. Case A - Transformer Normal Operation Fig, 6 illustrates the magnetic field density distribution (B) during the normal operation of the transformer (steady state) ‘To camry out the computational studies a set of balanced three- phase currents was used, with the central phase as reference. ‘The current peak value used is $5,664. Fig. 6. Magnetic fx density during normal operation of the transform. As can be noticed in Fig. 6, under the normal condition, the magnetic flux stays predominantly in the ferromagnetic ‘material. In this situation, the leakage magnetic field is very small, so are the forces on the windings. Case B- Transformer Feeding a Short Cireuit In this case, the short circuit current level was determined in, accordance with (2). Fig. 7 shows the fluxes atthe transformer under this new condition, Comparatively 10 the previous case (normal operation), severe fluxes modifications can be noticed. A larger amount of flux is diverted to the air outside the ferromagnetic core. Thus, the leakage fluxes and the forces are largely increased. Fig. 7. Magnetic fx density fora shat iru operation of transform, Case C- New Tap Arrangement under Normal Operation This situation corresponds to a similar condition of Case A, ion of one tap section to the external winding. In tended to investigate the influence of this new configuration upon the clectromagnetic forces in the device. Fig. 8 gives the magnetic field density distribution in the transformer for this new situation, Fig. 8. Magnetic Mux density for normal operation with Asymmesrica ‘Windings (tp inthe mide It can be noticed that, the insertion of the tap section, originated a changing of flux distribution in the core, in regarding to the Case A. The most noticeable difference is associated to the increase of the leakage flux, mainly in the radial direction. This will produce a higher mechanical strength and the new radial field component is larger Case D- New Tap Arrangement with Short-Circuit Fig, 9 shows the transformer operation under the same short cireuit condition of Case B, with the inclusion of one tap section to the external winding.In addition to the effect pointed out for Case B, inthis case, it can be noticed that the magnetic flux distribution suffers a laxger change when the new tap section was inserted. This, in its tum, produces higher mechanical strength as the new radial field component is larger. Fig. 9. Magne fax dons fr shor cick operation with Asynmsicl ‘Wining (pinche mile) The results ofthe analytical calculations for axial and radial forces in all cases investigated are summarized in Table Il. It can be noted that, when the transformer are under short circuit (case B), the radial force is 3000 times higher than the value found in the normal operation (ease 4). On the other hand, the increase ofthe axial force is almost negligible. TABLE FORCES AND CURRENTS BT TRANSFORMER WINDINGS a Cased Goren [OW | $5.66 | 2657 | 3326 | 3026 tal [aw [see | 2nn7 | 25n7__| 2587 Rated [ow | sas | viseo | 22 | 2009 Force i [| 327 [to | asses | 330 viol [ow | ots [oes | 103s | 1035 Force om [* [om [om | om | om ‘+ OW= Oner windings TN nner winding A comparison between the results of cases B and D (both with tap insertion) shows that the radial force in the case D increased 1.5 and 1.35 times for the outer and inner winding, respectively. On the other hand, the axial forces increase 2500 and 280 times, respectively, in the outer and the inner windings \V. ComPARISON BETWEEN FEM AND ANALYTICAL RESULTS, Table IIL synthesizes the analytical and numerical (FEM) results for the transformer normal operation (nominal current) and under short circuit conditions, without the tap section. The results derived from both methods are in close agreement, This may be used as a first validation step towards the use of the FEM technique to estimate internal transformer forces under short-cireuts conditions, s It is important to emphasize that the only radial forces results are shown in Table III due to the difficultics in obtaining the necessary data for calculating the axial forces (51 ‘TABLE ANALYTICAL AND NUMERICAL (FEM) CALCULATIONS INTHE NORMAL (CASE 'A) AND SHORI-CLCUTT (CSE A} CONDITIONS cen [Gee | maa | mea a Pe L an roa? Toa [Gown | thas Saal fatty comb | S oo a, | me os mt | r [a a ™ Case B 20x10 4x10 | 14.56x10° | 10x10" VI. Concwusions This paper has presented a computational approach using Finite Element Method to obtain clectromagnctc forees on the transformer concentric windings under external short circuit conditions The FEM mapping of the fux distribution within the transformer for several situations was considered. The investigations carried out so far allow the following conclusions: + Regarding the quantitative aspects, it was observed a good agreement between the computational (FEM) and. the analytical results for all conditions. studied, showing the validation of the numerical method used in this work; ‘With respect to the qualitative aspects, the simulations carried out have shown that the use of tap sections may produce large changes on the magnetic flux distribution within the transformer, resulting in significant increase inthe radial magnetic field density and, therefore, on the axial force. This force is often responsible for damaging transformer’s physical structures supporting the windings; # The FEM mapping of the magnetic field density has shown thatthe high currents caused by extemal short-citcuits that circulate in the concentric windings produce a large effect upon the fux path. This causes significant increase on the axial leakage field and, consequently, on the radial forces + Tho insertion of tap sections in the external windings may be seen asa short-circuit between tums, which producesasymmetries between windings. This tends to cause an increase of both radial and axial forces, with the later being. responsible for 8 great number of damages in transformers. VIL. REFERENCES 1} Kothari S. Vi, Kbapends, $. A, “Transfmer Engineering ~ Design and Pracice, Marcel Der, Is, New York, 2004 [D] IEEE Guide fee Faure Investigation, Documentation and Analysis for Power Transformers and Shust Reactors, IEEE: Standard C57.125, 1991 [3] Wang, 1, Butler, KL, “Fst Elemonts Analysis of Intral Windiags aul in Disubution “Transformers, IEEE. Transecdon on Maguetc vol 26, No3, July 2001 (4) Yun-Oia, T, JineQin, Q, Zong, X. “Numerical Cleuaton of ‘Shor: Cireuit Becvomagnsic Foret on the Transformer Winding" IEEE Transaction on Magnetis vol 26, No2, March 199, [5] Heathcote, J. Mats, “UEP Transformer Book", 120 ed, Oxted, Elsevier Science Ld, 199%. [6] Water, M, “The Shor-Cicait Stengih of Power Transformer”, MeDonsla & Co, Ld, Loon, 1966 [7] The Shor Circuit Perfomance of Power Transformers, Brochure CIGRE WG 12.19, 200, VILL. BiocRaies ‘Ana Claudia de Azevedo ws bor in SS0 Gonso do Absets, Brazil, in 1972. She received her BSe ‘om the Foderal Univesity of Maro Groso, Braz J 1999, and ber MSc dogiee ftom sho Fedorl University of Uberandia ~ Brazil, in 2002. She is curently working towards er PAD depres. Her { i ressarch intrest areas ae: Blotemechaniel Siess Mm fn Power Transformer. Tyan Rezende was borin Tes Corps, Baal in TBI. Ske rsceived. his BSe form the Feder Universiy of $0 Joto Del Re, Brazil in 2008, He is cuemly working towards his MSe degre. His research interest ares are: Electomechanial Stes in Power Transformers. Autinio Carlos Delaiba was born in Botucatu, Bra in 1984 He gradato rm Fedral University (of Bares, Braal in 1979. He rocsivod his MSe Segre fom of University of Sto Paulo, Brazil in 1987 and his PAD degree from te Federal University ‘of Uberizndis, Brozil in 1997, He is camenly & professor and a recarcher atthe Facly of Hectrcal Engineering, Federal University of Ubetiiadia. His ‘saeh interest areas are Power Quality, ‘Transmission, and Distribution of Energy. José Carlos de Oliveira wos bom in ajube-MG, [Bra He rcuived his BSe and MSe degrees fom the Feral University of lajubs-Brazi, and bis PRD degre from the Univesity of Manchester = Insite of Science Technology ~ Manchestr-UK. Hei curently ' professor and a researcher atthe Faculty of Electrical Tnginering, Federal Universiy of Ubeandia ~ Brazil He bas taught and published in a vaney of subjects relied to Electra! Power Systems and Power Quali fmarck Castillo Carvalto was bors ia Roboré — ‘Senta Cr, Bolivia, in 1987. He roceved his BSe frm ‘he Feleal University of Mato Gros, Brail in 1981, snd his MSc dogre ftom the Feder Univesity of ‘Uerlndia~ Braz, in 2002. He is euremly working towards his PRD depres His esearch intrest arcas ar: lectreal Power Syiem, Power Quality and Renewable Energy eoncemed to Wind Power eriveto de Souza Bronzeado (M97) was bors in Remigio, Pari, Brazil on April 2, 1953. He vwos grated ty the Universidade Feder] do Para, Braz, ip July 1975, and since thea ho ‘works for the Compasiia Hideo Hlézea do So Francisco ~ CHESF, being responsible for Power (Qualy and RAD Projets He received his MSC degree in Power System Engineering, in 1993, thom the University of Aberdevn, Sealand (UK). He iS abo the. chaiperson of the Sudy Commitee C4 of Cixé-rasl and the IEEE Joint, Caper PESIASIPELS, Norhest 1, Section Bahia, Bra, His rewarch interes inchude transformer modeling fer ansen staies and Power Quality problems