Finite Element Analysis of Transformer Clamping Structure to Study

Effect of Copper Shield on Structural Losses and Winding Eddy Losses

Ram Krishna Mishra1, Saravanan Selvaraj2
Bhaskara, R&D Building No1, Crompton Greaves Ltd, Kanjur Marg E,Mumbai-400042, MH
E-mail: [email protected] Mob: +919819479353

Abstract- The losses due to transformer leakage field comprise a small percentage of the
power in a transformer. Yet these losses produce localized heating which can compromise its
operation. The stray field strength increases rapidly with growing rating. The stray flux
intruding into the structural parts gives rise to eddy currents in them. The resulting eddy
current losses may be considerable, thereby increasing the load loss of transformer [1, 5].
The objective of this work is to calculate stray losses in magnetic structures of 400 MVA
Single Phase, 500 kV-230 KV Auto Transformer and study the effect of Copper shield on
structural losses and winding eddy losses, using commercial software package Magnet
(Infolytica Corp.) based on Finite element Method (FEM). Due to presence of non linear
magnetic materials, the sinusoidal source with 60 Hz frequency induces non-sinusoidally
varying magnetic fields. A transient solution (which calculates time varying magnetic field) is
required for calculating fields in non-linear materials. However, this requires more
computational resources. Therefore Time harmonic solution (which calculates field at 60 Hz
frequency) with linear magnetic materials is used for this analyses. Further, 3D time
harmonic analysis has been done to analyze the effect of varying Cu shield thickness on loss
density and finally its effect on winding eddy losses has been investigated.

Keywords- Eddy Current; Cu Shield; Time Harmonic;

I. INTRODUCTION
of power transformers hence it is important to
The paper investigates effects of Cu shield on the calculate transformer performance as accurately as
stray losses occurring in core clamping structure of possible. Accurate calculations of stray losses of a
the core and how it affects leakage field pattern power transformer based on numerical model may
which in turn changes eddy losses occurring in also improve transformer structure in terms of
winding of power transformer. The 3D geometric reduced losses and increased overall efficiency [4].
model of power transformer was made and solved The stray losses in the power transformer are
with finite element method. The time harmonic composed of additional losses in windings and of
analysis is used to investigate the discussed losses which are originated in transformer's
problem. On this basis, we calculated the leakage structural parts (Fig. 1). The losses in the windings
magnetic field around the coils at nominal current are the subject to a power and voltage level of the
loadings. Further, radial and axial field values are power transformer. The additional losses in the
calculated inside each conductor and eddy losses in windings and in the construction, due to leakage
common winding are calculated with and without magnetic field can not be separately measured.
Cu shield.
The additional losses in the windings can be
II. LOSSES IN TRANSFORMER accurately calculated using two-dimensional axi-
symmetric finite element model of the transformer
Transformer is the most efficient machine in power but for an accurate calculation of stray losses in the
system with efficiency more than 99%. However, construction parts and to study effect of Cu shield
manufacturers want to attain even higher efficiency on winding eddy loss, the 3D finite element model
and in turn become more competitive in the market of the power transformer must be used.
 n × E = Z n n × (n × H ) (1)
Where n is the outwardly directed unit vector
normal to the surface and Zs is the standard surface
impedance. Eq. (1) represents the standard Rytov–
Leontovich impedance boundary condition. For a
good conductor, of conductivity σ and permeability
µ, the surface impedance Zs in Eq. (1) is taken to be
Z s = Rs (1 + j ) (2)
Where j = − 1 and Rs is the surface resistance.
1
Rs = (3)
σδ
With δ denoting the skin depth
2
δ= (4)
ωµσ
And ω is angular frequency. Eq. (1) is applicable at
Fig. 1: Quarter Model of transformer core with upper the points on the conductor surface, where δ is
Frame, Cu Shield and Windings. much smaller than the local radii of curvature. In
surface impedance boundary condition (SIBC)
III. METHODOLOGY method, the mesh of the conducting region is not
used and therefore no field is calculated inside it,
A. Surface Impedance Boundary Condition which is numerically more efficient. Ahuja et al [6]
The 3D model of power transformer is used for time used this method to calculate eddy losses in the tank
harmonic solver based on finite element method. plates due to leakage flux.
The transformer dimensions are measured in meters
and for detailed electromagnetic analysis a very B. Winding Eddy Losses
large number of finite elements would be needed. Eddy loss per unit surface area of a conductor is
This would be especially true if the electrically given by [2]
conductive parts, such as tank walls and yoke
clamps are treated as volumes. It is necessary to H 2  eξ − e −ξ − 2 sin ξ 
Pe = 0  ξ
σδ  e + e −ξ + 2 cosξ 
(5)
realize that they should be described by very dense
finite element mesh, due to small depth of magnetic Where ξ = 2b/δ.
field penetration in to conducting parts [2, 3]. When dimension (thickness) of the conductor is
Dimensions of each finite element in tank walls and quite small as compared to its depth of penetration
clamps should be in the size class below millimeter. for 2b << δ i.e., ξ << 1
So the number of finite element would increase
H 2 ξ 3 H 02 8b 3
above software computational possibilities. For this Pe = 0 =
purpose, so-called surface impedance is introduced σδ 6 σδ 6δ 3
[7, 8]. This will significantly reduce the number of H 2 8b 3ω 2 µ 2σ 2
finite elements and allow the calculation of losses in ⇒ Pe = 0 (6)
σ 24
the tank walls and other transformer's construction
1
parts. Leontovich [9] presented a simple form of the ⇒ Pe = ( µH 0 ) 2 σω 2 b 3
boundary condition for highly conducting bodies, 3
which relates the electric field intensity (E) and the Now, if the thickness of the winding conductor is t,
magnetic field intensity (H) at each point on the then substituting b=t/2
conductor surface as
 1
3
2 2 3
 t  ω B0 t σ stiffeners. Non-Magnetic materials (insulating
Pe = B02σω 2   = (7) materials) are not considered. To reduce
3 2 24
complexity, HV side and LV side are analyzed
separately and windings are modeled as copper
cylindrical shell with ampere turns. Laminated core
is modeled as solid block.

The transformer is not symmetrically built-up. The

side of transformer with high voltage terminals is
longer in comparison with the low voltage side so
HV side and LV side are analyzed separately. The
clamping plate magnetic steel was modeled with
relative permeability µr = 200, and conductivity ρ =
1.05e-7 ohms.m

The main disadvantage of used method for eddy

current losses calculation is that all electromagnetic
quantities harmonically fluctuate by first harmonic.
Fig. 2: Winding Conductor in a Leakage Field. This is not the case when we deal with non-linear
characteristic of iron. Because of this magnetic non-
It is more convenient to find an expression for the linearity the magnetic field in the material has non-
mean eddy loss per unit volume (since the volume sinusoidal form. Nevertheless, the losses are
of the conductor in the winding is usually known). calculated relatively accurate.
Hence, dividing by t and finally substituting
resistivity (ρ) in place of conductivity, we get the V. RESULTS
expression for the eddy loss in the winding
conductor per unit volume due to axial (By) and Eddy current losses occurring in clamping
radial (Bx) components of leakage field (Fig. 2) are structure and winding eddy losses are calculated for
two different cases viz with and without Cu shields
ω 2 B y2t 2 and results are recapitulated in Table I. The plot for
(Pe )axial = (8) total loss for the case when Cu shield is not being
24 ρ
used is shown in Fig. 3.
ω 2 B x2 w 2
(Pe )radial = (9)
24 ρ

IV. 3-D MODEL OF TRANSFORMER

The 3D finite element model is made based on

dimensions of a 400 MVA Single Phase, 500 kV-
230 kV Auto Transformer. All the numerical
calculations of magnetic fields and eddy current
losses were done by commercial software package
MagNet (FEM).

The electric connections between the coils and the Fig. 3: Loss Density Distribution in HV Side Frame
tank wall insulator as well as limb clamps were not (without Cu Shield).
taken into account. Tank plates are modeled without
It is evident from Fig. 3 that middle part of upper VI. CONCLUSIONS
and lower frame is subjected to high stray field and Eddy current losses occurring in different
need protection. The losses occurring in lower structural part of transformer have been predicted.
frame are higher than the upper frame (Table I) Inaccuracy of calculations can be mainly ascribed to
because of its closer proximity to windings. mathematical simplifications and to material’s
nonlinear magnetic properties description. The
The plot for total loss for the case when Cu shield is results show the difference in eddy current losses
used is shown in Fig. 4. It is clearly visible from occurring in top frame, bottom frame, tie rods and
Fig. 4 that a Cu shield considerably reduces the Cu shields and it can be deduced that the eddy
effect of stray field and losses occurring in frame current losses in transformer frame and tie rods can
and tie rods are significantly reduced [10]. be reduced drastically with the use of shielding
techniques. However metallic shielding has adverse
effect on winding eddy losses and overall cost of
material so it should be chosen judiciously keeping
rating of the transformer in mind.

About the Authors

Ram Krishna Mishra1 got his B. Tech.

Degree in Electrical Engineering from
Rohilkhand University Bareilly in 2003
and M.Tech. Degree in Electrical
Engineering with specialization in
Power System from VJTI, Mumbai in 2008. He
joined Global R&D Centre, Crompton Greaves
Ltd., Mumbai, India in 2008.
Fig. 4: Loss Density Distribution in HV Side Frame (with He is engaged in Electromagnetic Analysis and
Cu Shield). Coupled Field Analysis of Transformers and
Motors. Ram Krishna Mishra can be contacted at:
The Winding eddy losses are calculated for both [email protected], 022-67559029
with and without Cu shield for CV winding. In the
case when Cu shield is being used, losses occurring Saravanan Selvaraj2 received his
in CV winding are 33.3 kW whereas in the case B.E. Degree in Electrical Engineering
without Cu shield the losses came equal to 32.5 kW from Madras University, Tamilnadu in
so there is an increase of 0.8 kW. 2002 and M. E. Degree in High Voltage
Engineering from Anna University,
Table I TamilNadu in 2005. He joined Global R&D Centre,
Comparison of losses occurring in top frame, bottom
frame, tie rods and Cu shields Crompton Greaves Ltd., India in 2005.
He is engaged in High Voltage insulation design,
Electromagnetic Analysis and Coupled Field
Analysis of Transformers and Switchgears.
Saravanan Selvaraj can be contacted at:
[email protected], 022-67559041
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(NPSC), IIT Bombay, December 2008. Trafotech 2006.
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