Oltc Fundamental

OLTC Fundamentals
By Mats Carlsson
On-Load Tap-Changers
EETC Alexandria Zone November 2006
ABB - 1
Outline
ABB Components introduction Tap-changers Bushings Life cycle support
ABB Power Technologies - 2 Components 2003-05-12
Power Transformer Components
Bushings
TapChangers
The High Voltage Valley in Ludvika, Sweden
High Power Laboratory Transformer Tap-changers
Swedish Transmission Research Institute
HV Circuit Breakers
HV Instrument Transformers HV Surge Arresters
High Voltage Laboratory
High Power Capacitors
Transformer Bushings
HV Thyristor Converters
HV Shunt Reactors
Power Transformers
Components Ludvika, Sweden

KEY FIGURES 2005
Revenue
MUSD
~100
External ABB sales ~50% Employees No of Bushings >10000 ~300
No of Tap Changers >2000
Export share 95%
R&D expenditure
~10%
Tap-changer historical overview (2)

1910 First tap-changer produced (type HM)

1927 HA 1953 HF 1963 UCB (in-tank) 1964 UZB (on-tank)
1965 UCC
1978 UCG 1978 UZE
1983 UCL
1987 UZF 1991 UBB
ABB is the largest manufacturer of bushings

Resin impregnated (RIP) with composite or porcelain insulators 36 - 550 kV Oil impregnated (OIP) with porcelain insulators 36 - 800 kV
Conformance: IEC, IEEE & Regional Standard Variants
Transformer components in challenging applications!
HVDC transformers
Phase-shifters e.g. 1630 MVA & 400 kV
Subjects

Tap-changer types Principles of operation Transition resistor Switching time Contact life Maintenance News! Tie-in resistor Tests Development
On-load tap-changers
ABB (ASEA) has manufactured tap-changers since 1910. More than 45 000 units of the modern design are today in operation worldwide.
Design philosophy:
Highest reliability
Easy maintenance
Longest lifetime
Longest lifetime by using first class materials and by thorough tests. Typical contact life is 350 000 through 500 000 operations.

Highest reliability by using few parts and making simple designs Easiest maintenance by same reasons as above
ABB Tap-Changer Reliability

Reported unscheduled service interruptions due to the tap-changer
0,06%
0,05%
0,04%
Amount
0,03%
0,02%
0,01%
0,00% 1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
Year
An average of 5000 years between these stops!
Failures of Tap Changers from 1996-2005

Failures during service.
Year failure was reported Failures during service, as % of tap changers in service
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
0,04 % 0,03 % 0,04 % 0,01 % 0,03 % 0,01% 0,02% 0,01% 0,03% 0,02%
The figures include all failures, independent of age and types of tap-changers, which have led to a service interruption of the transformer, caused by fault in the tap-changer.
WHAT IS AN ON-LOAD TAP-CHANGER?
A device for changing the tapping connection of a winding while the transformer is on load
Current is interrupted Must not happen!
One loop of the regulating winding is short-circuited Must not happen!
Transition Resistors
Transition Resistors

Resistor type Reactance type
Electronic types
Others
Reactance type is mainly used in ANSI-standard countries, most often to regulate on the LV side of the transformer.
Electronic types belongs to the future
Resistor types most common today.
Can be diverter switch type or selector switch type.

Diverter switch type consists of separate diverter switch and tap selector
Selector switch type consists of a combined diverter switch and tap selector unit
Types of Switching
A.
Linear Switching

Selector Switch Coarse Winding
Not very common (~20%) Simple design trafo & oltc Smallest regulating range Smallest losses
B.
K 9
Plus/Minus Switching
K 10
9
Most common (~70%) Additive (+) & subtractive (-) Change Over Selector
Regulating Winding
C.
Selector Switch
Coarse/Fine Switching

Least common (~10%) Coarse winding insertion Change Over Selector Small losses
Principle Circuits of OLTC Transformers (1)

For two-winding power transformers, the most popular arrangments is the regulation at the neutral end of the winding. This solution provides the most economical tap winding arrangement with generally graded insulation combined with a compact three-phase neutral point OLTC.
OLTC in Y or Star Connected Windings
Principle Circuits of OLTC Transformers (2)
3-Pole Line-End Arrangment
2-Pole + 1-Pole Line-End Arrangment
3-Pole Mid-Winding Arrangment
OLTC in Delta-Connected Windings
MVA Transformer Ratings
> 80
80
80
50
60
150
150
300
HVDC
1000
-----------------------------------------------------------------------------------------------------------------
1
USB 200
UZF 650
UZE 650
L (m)
UB 2 B35 UCG.N/C 0 3 UCG.N/C 1050 UCL.N/III UCD.N/III 1050 Short 1050 UCG.N/III 1050 4 1050
UCC.N 1050
All are of Jansen type, i.e. spring operated switches and of resistive type.
Tap-changers, diverter switch type

Diverter
Tap selector 7
6 5
4
Transformer regulating winding
Italy, Terna

400 kV, 1630 MVA Weight 820,000 kg Footprint 13x15x10 m
Two-phase UC-type Tap-Changer mounted on special transformer
Top section with mounting flange Shielding rings Diverter switch Connectors between diverter switch ant tap selector Tap selector with preselector
Switching sequence for Diverter-Switch type Tap-Changer
5 6
5 6
5 6
5 6
5 6
5 6
5 6
5 6
Animation Switching sequence for Diverter-Switch type Tap-Changer

Features for the UC tap-changer

Extensive
More
service experience
service record
than 9000 units in service
Excellent
Quick
and easy maintenance

outside diverter switch housing design, no special tools needed
Shaft Open
Reliable
Few
parts and robust design
Simple No
on-line filtration needed
UC tap-changers

Completely clean cover Bevel gear for shaft system outside cover Lift our diverter switch without removing shafts! Operate motor-drive and tap selector when diverter switch is removed Operate diverter switch as desired!
UC tap-changers
Diverter switch electrically connected and mechanically coupled without screws Kept on place by springs on top, pressed by the cover
UC tap-changers

Easiest possible maintenance
No dismantling of diverter switch needed for inspection & cleaning
UC tap-changers
No need to bring diverter switch down from transformer for maintenance Transformer outage less than one day for maintenance
ABB tap-changers in furnace transformers
UCG top section with shaft, bevelgear &
motor-drive
mechanism
The cover has been
removed.
(Six minutes passed)
Note that the shaft system is not
dismantled
Tube for draining, guiding and oil sampling Springs for fixing diverter switch Mounting information
Hook to lift...
Lift...
Continue to lift...
Dvierter switch
lifted out. (Ten minutes passed)
Drive disc with

slot for drive pin
UC Tap-changer Maintenance (overhaul)

Bottom in tap selector cylinder
Notch for driving pin
Driving pin
Operate the
diverter switch from one side...
...to the other without caring about the position...
No harm if you
operate the motordrive.
You dont have to
note the tap position

number.
Put the spare or overhauled diverter switch back...
Fork for guiding
Switch not yet in proper position
Before operated to correct position
Operate the hand crank till you see and hear that...
that it falls down to its proper position. Everything is

now mechanically
and electrically
connected.
When the tapchanger is operated to correct position you can put the cover on.
(Less than 20 minutes passed)
UC tap-changers
Simple, open design with very few parts offers highest reliability and easiest maintenance!
Diverter Switch
Upgrade your old transformer

Plug & play concept

Interchangeability in old transformers For all UCGs since 1978
Tap-changer with vacuum interrupter technology

Proven experience
Vacuum bottles, based on 25 years of ABB experience and millions of successfully delivered units provide for an extremely reliable product
Vacuum more complex Monoploy
Humidity oil samples

Normally maintence after 5-7-15 years Failures often happens after maintenance
Modular motor drive

Improved service friendliness and flexibility
Adding / changing of functionality in the field Self diagnostic and event handling Reduced number of parts Transmission gear made from maintenance free elements Shortened delivery time and increased flexibility in order process

Modular motor drive
On-load tap-changers Summary
Extremely high reliability
Excellent service records

Easiest maintenance Models for all applications available New technology to be introduced during 2007
GSA bushing VVAH cooler UZF tap-changer

Active part of transformer prepared for UZE type tap changer. Transformer tank with integrated tap-changer tank.
Benefits of using the on-tank UZ

No oil filter is needed Less cleats and leads (conductors), which can easily be made in parallel No drive-shafts or bevel gears The UZ is needed later in the production process Short delivery time
Three-phase fully insulated phases or neutral point design Tap-changer, motordrive and shaft system integrated
Extremely simple excellent maintenance properties

UZF tapchanger
Three phase boards

Integrated motor-drive mechanism

BIL 650kV / 600A fully insulated Up to 100 MVA transformers
No drive-shafts or bevel gears

The UZ require a smaller tfo

less oil less sheet metal less beams less welding less work
The UZ require a smaller transformer tank

less oil less sheet metal less beams less welding less work
In-tank On-tank

Smaller oil conservator The UZ does not determine the height of the transformer
Mobile transformer by Porter, USA, equipped with UZE type tap-changer
Tap-changers, selector switch type
1 I
1 I
1 I
1 I
1 I
1 I
1 I
1 I
On-Load Tap-Changer Type UB
UBB type tap-changer
Selector switch type

Introduced in 1992 More than 5000 units in service Uses the contact system from UZtype tap-changer

Fibreglass cylinder Fixed contacts mounted through cylinder wall with excellent tightening system Fixed and moving contacts replaceable from inside the tap-changer
Pre-selector switch Three fully insulated phases Moving contacts Current collectors
Central shaft
Shield
Current collectors
Neutral connection between phases
Moving contact system consisting of:

Transition
resistor contacts
Main
arcing contacts contacts
Current
Main arcing contacts by copperwolfram alloy

Current carrying contacts by silverplated brass Contact tips by solid silver
Pre-selector contacts with four contact fingers
TIE-IN RESISTOR
Only for plus/minus and coarse/fine connections. Used when the recovery voltage over the change-over selector exceed the max. value (between 25-40kV dependent on OLTC)
TIE-IN RESISTOR
Main Winding
Change-Over Selector
Tap Winding
Switch (only connected during change-over operations)
TIE-IN RESISTOR
Main Winding
Tap Winding
TIE-IN RESISTOR
Main Winding
Tap Winding
TIE-IN RESISTOR
Main Winding
Tap Winding
TIE-IN RESISTOR CONNECTION
Main Winding
Tie-in Resistor
Tap Winding
Main Winding
Tie-in Resistor
Tap Winding
Main Winding
Tie-in Resistor
Tap Winding
Switch (only connected during change-over operations) Switch (only connected during change-over operations)
Calculation of Tie-In Resistor

Needed to calculate the Tie-In Resistor value are:
Capacitance from the regulating winding to adjacent windings or earth. (Included influence from leads) Voltage on the adjacent windings and the voltage over the regulating winding. Transformer connection data and frequency.
H1
Tank
HV C1
RW C2
Recommendation Letter

Oltc Fundamental

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OLTC Fundamentals

ABB Components introduction Tap-changers Bushings Life cycle support

ABB Power Technologies - 2 Components 2003-05-12

Power Transformer Components

The High Voltage Valley in Ludvika, Sweden

High Power Laboratory Transformer Tap-changers

Swedish Transmission Research Institute

HV Instrument Transformers HV Surge Arresters

High Voltage Laboratory

High Power Capacitors

ABB Power Technologies - 4 Components 2003-05-12

Components Ludvika, Sweden

External ABB sales ~50% Employees No of Bushings >10000 ~300

ABB Power Technologies - 5 Components 2003-05-12

No of Tap Changers >2000

Export share 95%

Tap-changer historical overview (2)

1910 First tap-changer produced (type HM)

ABB is the largest manufacturer of bushings

ABB Power Technologies - 7 Components 2003-05-12

Conformance: IEC, IEEE & Regional Standard Variants

Transformer components in challenging applications!

ABB Power Technologies - 8 Components 2003-05-12

Phase-shifters e.g. 1630 MVA & 400 kV

ABB Power Technologies - 10 Components 2003-05-12

ABB Power Technologies - 11 Components 2003-05-12

ABB Power Technologies - 13 Components 2003-05-12

ABB Tap-Changer Reliability

An average of 5000 years between these stops!

Failures of Tap Changers from 1996-2005

ABB Power Technologies - 15 Components 2003-05-12

ABB Power Technologies - 16 Components 2003-05-12

WHAT IS AN ON-LOAD TAP-CHANGER?

ABB Power Technologies - 17 Components 2003-05-12

ABB Power Technologies - 18 Components 2003-05-12

ABB Power Technologies - 19 Components 2003-05-12

ABB Power Technologies - 20 Components 2003-05-12

Current is interrupted Must not happen!

ABB Power Technologies - 21 Components 2003-05-12

One loop of the regulating winding is short-circuited Must not happen!

ABB Power Technologies - 22 Components 2003-05-12

ABB Power Technologies - 23 Components 2003-05-12

ABB Power Technologies - 24 Components 2003-05-12

Resistor type Reactance type

ABB Power Technologies - 25 Components 2003-05-12

ABB Power Technologies - 26 Components 2003-05-12

Electronic types belongs to the future

ABB Power Technologies - 27 Components 2003-05-12

Resistor types most common today.

Can be diverter switch type or selector switch type.

ABB Power Technologies - 28 Components 2003-05-12

ABB Power Technologies - 29 Components 2003-05-12

Selector Switch Coarse Winding

ABB Power Technologies - 30 Components 2003-05-12

Principle Circuits of OLTC Transformers (1)

OLTC in Y or Star Connected Windings

Principle Circuits of OLTC Transformers (2)

3-Pole Line-End Arrangment

2-Pole + 1-Pole Line-End Arrangment

3-Pole Mid-Winding Arrangment

ABB Power Technologies - 32 Components 2003-05-12

OLTC in Delta-Connected Windings

ABB Power Technologies - 34 Components 2003-05-12