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ABB PTSS 2005 A childs perception
ABB PTSS 2005 The public perception
ABB PTSS 2005 The public perception
ABB PTSS 2005 The public perception
ABB PTSS 2005 The reality transport
Key Learning points to ensure lifetime
Agenda
History
Design Principles
Construction
Tapchangers
Testing
Operation
ABB PTSS 2005
Introduction - Transformer History
ABB PTSS 2005 Transformers in the past
1891 1971
Power and Distribution transformers today
System
Main Distribution
Local Distribution
ABB PTSS 2005
Introduction Transformer Types
16000 amps Transmission Transformer
400 kV
600 400 / 132kV
amp Transmission
s
substation
Generator Transformer
15/400kV
s
mp
0a
100
s
a mp 132 kV
0
33/66 kV 150
Main substation
System Transformer
33 / 132kV
400/230V
Secondary
substation
Distribution
11/22 kV substation
ABB PTSS 2005
50 amps
Primary
substation Local distribution Transformer
33 / 11kV
Introduction Transformer Types
G Generation (Power Station)
16000 amps
23kV
400kV, 600 MVA
920 amps
350 amps
NGC
400kV, 240 MVA
132kV
1050 amps RECs
400 amps
52 amps
132kV 11kV
33kV 33kV
1575 amps
90 MVA 15 MVA 11kV
260 amps
415V G
1 MVA
ABB PTSS 2005
Introduction
Introduction Ideal transformer
Learning Point
ABB PTSS 2005 Introduction - Transformer Construction
Introduction Specification.
Learning Point
Design Principles - Capitalisation
Electrical loss allocated / kW for no-load and load losses. Used
with selling price to evaluate transformer ownership cost
Selling Price + loss evaluation = Capitalised price.
Evaluationof Transformer
650
600
550
500
350
300
250
200
150
1 2 3 4 5 6 7 8 9 10
Design No.
Drycol
Gas/oil relay
Bushings HV / LV
Coolers
Tertiary
Pressure relief
Oil pipes
ABB PTSS 2005
Main tank
Transformer Construction - Core
Learning point
Transformer Construction Core - Quality
ABB PTSS 2005 Transformer Construction 3 Limb Core
Design Principles Construction sequence.
HV Disc or Layer
LV Spiral or Foil
Number of turns =N
Number of turns = n Current = kVA(ph)/kV(ph)
Current = =I
kVA(ph)/kV(ph)
Ampturns = N*I
=i
Ampturns must balance,
Ampturns = n*i
N*I = n*i
Core
LV HV Taps
Taps Multistart
Tap turns add or
subtract to adjust
turns ratio
Volts*Amps(HV)
=
ABB PTSS 2005
volts*amps(LV)
Transformer Construction - Core Types
Single phase
2 limb wound
3 limb, 1 wound and 2 unwound
4 limb, 2 wound and 2 unwound
Three phase
3 limb all wound
5 limb, 3 wound with 50/50 or 60/40 ratio
Stepped lapped
ABB PTSS 2005
ABB PTSS 2005 Transformer Construction
Stepped Step Lapped Core
Lap Core Construction
Transformer Construction
Stepped Step Lapped Core
Lap Core Construction
Air gap
3mm
15mm
ABB PTSS 2005
Transformer Construction - Windings
Transformer Construction - Windings
Low voltage
Helical
Layer
High voltage
Layer
Disc
Interleaved
Intershielded
Design considerations
Thermal
Impulse withstand
Short-circuit withstand
ABB PTSS 2005
Transformer Construction Windings - LV
Finish
ABB PTSS 2005
Helix Layer
Transformer Construction Windings - LV
Helical Layer
+ +
High current easy to wind
Mechanically strong good short-circuit resistance
- -
Transpositions Lower current
Difficult to wind Mechanically weaker
Helix can raise short-circuit
problems
ABB PTSS 2005
Transformer Construction Windings - HV
Disc Layer
+ +
High current easy to wind
Mechanically strong harder to impulse protect
Good impulse withstand
- -
Transpositions Lower current
Difficult to wind Mechanically weaker
Labour intensive
ABB PTSS 2005
Transformer Construction Windings - HV
ABB PTSS 2005 Transformer Testing Lightning protection
Transformer Construction Windings
Transformer Construction - Windings
Transformer Construction - Windings
Lightning Withstand Protection - Methods used
Cs Cg
V
Cs
432 1 Cs d
Cs
567 8 Cs V/d in kV/mm
Cs
432 1 Cs
Cs
Cs
567 8
Cs small
Disc
ABB PTSS 2005
Transformer Construction - Windings
Lightning Withstand Protection Winding voltages
120
100
Rate of change of Voltage
80 Disc
Interdisc
60
Intershield
40 Ideal
20
0
0 10 20 30 40 50 60 70 80 90 100
ABB PTSS 2005
Transformer Construction - Windings
Lightning Withstand Protection Voltage Overswing
120
100
Rate of change of Voltage
80
Interdisc
60 Overswing
Ideal
40
20 Overswing
0
0 10 20 30 40 50 60 70 80 90 100
ABB PTSS 2005
Transformer Construction - Insulation
Solid
provides insulation and mechanical support capability
Liquid
provides insulation and cooling capability
ABB PTSS 2005
Transformer Construction - Solid Insulation
Solid
pressboard
highly refined cellulose made by paper techniques
high electrical strength
only when clean, dry and impregnated with oil
paper
as pressboard
used as conductor covering, wraps etc.
essential that it is kept clean and mechanically sound
ABB PTSS 2005
Transformer Construction - Liquid Insulation
Liquid
Transformer oil, Nynas 10GBNP
Naptheninic
gas absorbing
Transformer Construction Active part HV taps
ABB PTSS 2005
ABB PTSS 2005 Transformer Construction Active part LV
Transformer Construction Active part tapchanger
ABB PTSS 2005
ABB PTSS 2005 Transformer Construction Cast Resin
Design Principles Voltage regulation
Tapchangers
ABB PTSS 2005
Design Principles Tapchanger
Design Principles - Tapchanger
Two operating conditions
On-Load
Off-circuit
On-Load predominant in Power transformers
Off-circuit predominant in Distribution Transformers
Two physical tapchanger positions
In-tank, diverter in own sealed chamber
Bolt-on, separate from main oil
Both with either single compartment - selector in the same oil as
diverter.
or Double compartment - diverter in its own segregated oil volume.
ABB PTSS 2005
Learning Point
Design Principles -Tapchanger types
Divertor
Selector
Design Principles -Tapchanger types
Divertor
Selector
ABB PTSS 2005
In-Tank UC
Design Principles Tapchanger diverter
To Tap
To Tap Selector
Selector
Transition
Transition
Resistor
Resistor
ABB PTSS 2005
Design Principles - In-tank or Bolt-on
Double compartment Tapchanger in main tank, diverter in own tank, selector in transformers oil
ABB PTSS 2005
Single compartment Tapchanger in own tank, selector and diverter in own oil
Design Principles - Double compartment
Design Principles - Barrier Boards
Tapchanger in main tank, selector in transformers oil
ABB PTSS 2005
Tapchanger in seperate tank, selector in own oil
Design Principles - Tapchangers
Design Principles - Tapchanging
Main winding
Coarse
Tap winding
Selector Taps
3
Changeover Switch
3
Fine
3
Diverter
ABB PTSS 2005
Design Principles - Tap positions
Transformer Construction - Accessories
Terminals
Air , Oil or GIS bushings
Safety / Protection
Surge arresters
Pressure relief device
Bucholz Relay
WTI / OTI
Maintenance
Conservator
Silica Gel Breather / Drycol refrigerated breather
ABB PTSS 2005
Learning Point
Transformer Construction Accessories - WTI
End
Transformer Construction Accessories - PRV
<1 metre
ABB PTSS 2005
End
Transformer Construction Accessories - Bucholz
Bucholz Relay
To conservator
End
Transformer Construction - Accessories
End
ABB PTSS 2005 Transformer Testing
Transformer Failure Fire and Explosion
Transformer Failure.mpeg
ABB PTSS 2005
Transformer Testing
Routine tests
Ratio, resistances, load and no-load losses
Impedances
High voltage
Applied and induced at power frequency
Impulse
ABB PTSS 2005
Learning Point
Transformer Testing
Type
Temperature rise, ONAN, OFAF etc.
High voltage
Surge, impulse, chop and switching.
Noise level
Zero-phase impedance
Special
Short - circuit.
ABB PTSS 2005
Transformer Testing - Routine
Ratio
turns ratio between sets of windings, measured by ratiometer,
checks for correct turns
Polarity
checks the correct electrical direction of each winding
Vector group
checks the correct phase relationship of each winding
Resistances
d.c. resistance of each winding at each tapping position at a
known temperature, checks for poor connections and incorrect
winding.
ABB PTSS 2005
Transformer Testing - Routine
Transformer Testing - Routine
Dielectric tests
Applied voltage
Whole of one winding raised in voltage, others earthed. Tests
winding to winding and to earth insulation.
Overpotential
Two times volts per turn or more induced
Supply LV winding
Checks volts per turn and line lead to earth
Partial discharge at > 132kV
caused by voids, corona etc. during the overpotential test
checks insulation in winding, between windings etc.
ABB PTSS 2005
Transformer Testing - Routine / Type Testing
Impulse
simulates a lightning strike
Waveshape and neutral current measured and compared
between reduced and full value waves throughout the series
Series normally 1 RW, 3 FW, 1RW
Checks windings ability to withstand a lightning strike.
ABB PTSS 2005
ABB PTSS 2005 Transformer Testing Impulse testing
ABB PTSS 2005 Transformer Testing Impulse Turn/Turn
ABB PTSS 2005 Transformer Testing to Earth
Transformer Testing - Type Testing
Impulse
as routine with the addition of 2 chopped waves to simulate a
flash to ground.
RSO
Low voltage recurrent surge oscillograph which safely simulates
the impulse test. Useful design info tool
Switching surge
creates almost magnetic v/t distribution
lower voltage than impulse but over longer time
ABB PTSS 2005
Transformer Testing - Type Testing
Noise
Measured under no-load energisation ( core source)
IEC 551 spec, measured at 0.3m from tank
different rules for different sizes and for OFAF coolers
ABB PTSS 2005
Transformer Testing - Type Testing
Temperature rise
all cooling options checked ONAN, OFAF etc
transformer energised from HV with LV shorted
full losses circulated ( No-load plus load) until top oil
temperature stable to give top oil temperature rise. < 60C
reduced to full load current
shutdown measurement of d.c resistance
compared to cold resistance to give winding average
temperature
mean winding rise = average temperature - ambient < 65C
ABB PTSS 2005
Transformer Testing - Type Temperature Rise
Resistance ohms
0 1 2 3 4 5 6 7 8 9 mins
ABB PTSS 2005
Transformer Testing - Type Testing
Transformer Testing - Special Testing
Short circuit
Pre faulted
LV shorted and HV closed onto supply
Normally 3 shots per phase, each phase different tap
Current calculated from impedance and system
First peak gives dynamic forces, r.m.s. gives thermal effect
Routine tests before and after S/C test
Visual inspection
variation in impedance should be less than 0.5%
ABB PTSS 2005
ABB PTSS 2005 Transformer Testing - Short-circuit test set up
Thermal - Definitions
Top Oil rise
Temperature of the oil at the tank top or cooler top above the ambient
temperature.
Mean Winding rise
Average temperature of the winding above ambient temperature.
Limits set by specification ( IEC, BS, BEBS-T2) at:-
Top oil rise - 60 K
Mean Winding rise - 65K or 70K for directed oil systems
In addition
Hot spot temperature
limits vary 98, 105, 125 C and are ambient dependant
calculated from MWR * k + TOR +Ambient
k=1.3 for large transformers
ABB PTSS 2005
Thermal - Windings
Winding gradient
Surface heat dissipation
Insulation thickness
Boundary layer for natural / forced cooling
Mean oil temperature
Average of top exit and bottom entrance temperatures
Mean oil + winding gradient = mean winding rise < 65 C
Ambient + top oil + 1.3* winding gradient= Hot spot temp <98C
ABB PTSS 2005 Thermal - winding cooling
ON OF OD
Thermal External cooling
ONAN
OFAN
OFAF
ONAF
Pump
Learning Point
Thermal Load Cycling - IEC 60076-7
g
Winding Grad
Average Oil Temp
Winding bottom
ABB PTSS 2005
Temperature rise
Thermal Load Cycling - IEC 60076-7
Thermal Load Cycling - IEC 60076-7
Thermal Load Cycling - IEC 60076-7
Thermal Hot Spot by hour
120
ONAN OFAN OFAF ONAN
100
80
MVA
Degrees C and MVA
Wdg Grad
Top Oil Rise
60 Ambient
WTI
HSR
HS Temp
40
20
0
0 5 10 15 20
ABB PTSS 2005
Hours
Thermal Load Cycling - IEC 60076-7
Hot Spot Temperature v MVA at 15 C constant Ambient
120.0
100.0
98 C Limit
Minor load profile changes
80.0 Lead to significant ageing effects
Degrees C and MVA
40.0
20.0
0.0
120.0
0.0 4.0 8.0 12.0 16.0 20.0 24.0
Hours in day
100.0
80.0
MVA / Degrees C
40.0
ABB PTSS 2005
0.0
0.0 4.0 8.0 12.0
Hours
16.0 20.0
24.0
Thermal Load Cycling - IEC 60076-7
Figure 3 - Time to achieve Overload before ageing occurs
500
450
400
350
Time before ageing
300
Time to Hot Spot Limit @ 10C
250 Time to Hot Spot Limit @ 20C
Time to Hot Spot Limit @ 30C
200
150
100
50
0
0 10 20 30 40 50 60 70 80 90
ABB PTSS 2005
MVA pre-load
90
80
70
60
Pre-Fault MVA
50
Pre fault MVA 20 C Amb.
40
30
20
10
0
100 120 140 160 180 200 220 240 260 280
ABB PTSS 2005
Minutes
Time to design limit for different Pre-fault and post fault loading
Thermal Load Cycling - IEC 60076-7
Figure 2 - BSP Tx Life reduction v MVA v Ambient
130
120
60
50
0 5 10 15 20 25 30 35 40
Ambient C
ABB PTSS 2005
Loss of life factors for different ambients and long term loading
Thermal Load Cycling ABB TEC system
ABB PTSS 2005 Thermal ABB TEC system
ABB PTSS 2005 Thermal Load Cycling ABB TEC system
http://tec1.vbelnat.se/tecwebb/
Dry type transformers
Vacuum Cast Coils
From 25 kVA up to 30MVA.
Standard Overload 40%.
HV up to 36 kV.
LV up to 36 kV.
Frequency 50Hz, 60Hz, 50/60Hz, 16.667Hz.
Cooling AN/ANAN/ANAF
Insulation 155C (Class F).
Ambient design 40C.
ABB PTSS 2005
Dry type transformers
Advantages
Safe windings design.
Strong strength against short circuits
Partial discharges free
The lowest noise and losses level
Higher impulse voltage withstand test
Broad experience on 36kV Um
Low dielectric ageing.
ABB PTSS 2005
Dry type transformers
Resibloc
From 25kVA up to 30MVA.
Std. Overload 40% (2.5MVA), 33% (2.5-5MVA), 25% (+5MVA).
HV up to 41.4 kV (From +630kVA).
LV up to 36 kV.
Frequency 50Hz, 60Hz, 50/60Hz, 16.667Hz.
Cooling AN/ANAN/ANAF/AFWF.
Insulation 155C (Class F).
Ambient design 40C.
ABB PTSS 2005
Key Learning points to ensure lifetime
ABB PTSS 2005