Calculation of Losses in The Core Clamps of A Transformer Using 3-D Finite-Element Method
Calculation of Losses in The Core Clamps of A Transformer Using 3-D Finite-Element Method
Abstract: The calculation of losses in the core clamps of a finite-element method while induced eddy currents have
40 MVA distribution transformer which occur due to winding been modeled by means of surface impedance boundary
stray field is presented. A principle of surface impedance has condition [3].
been used in a 3-D finite-element model of the transformer to
calculate the losses. The influence of variations of the clamp
dimensions and the material on the losses has also been II. TRANFORMER DATA
analyzed. The transformer main data are: rated power 40 MVA,
voltage 110/23/6.3 kV ± 8×2 % with on-load tapping,
Keywords: transformer, stray field losses, 3-D finite-element cooling ONAN/ONAF. Fig. 1 shows the manufactured
method, surface impedance
distribution transformer of the same power rating.
I. INTRODUCTION
The competition among manufacturers of small and
medium power distribution transformers on the world
market is quite fierce. In such conditions even the smallest
difference in the efficiency of the transformer between
different manufacturers for the same power rating can make
a difference and determine which company gets a
commission. It often happens that small manufacturers
which are not competitive in terms of price and short-term
delivery have to terminate their production.
For these reasons the losses in the clamps [1] and the
tank [2] of power transformers which are relatively small
compared to the losses in the core and the windings become
important. The knowledge of these losses in the design
stage can lead to a proper decision on how to size these
auxiliary constructive elements of the transformer and Figure 1: 40 MVA distribution transformer
which materials to choose in order to reduce the losses and
prevent the local heating. These losses are caused by the III. FINITE-ELEMENT MODEL
stray fields of the windings.
The ability to predict these types of losses in the Fig. 2 shows the detail of the transformer where the
transformer is especially important if they occur in no-load clamps are visible while Fig. 3 shows the corresponding 3-
operation, i.e. as soon as the transformer is connected to the D finite-element model. Only one quarter of the transformer
grid, and are not dependent on the load current. is modeled while the rest is replaced with Dirichlet and
In our case the 40 MVA, 110/23 kV distribution Neumann boundary conditions. Both core and winding
transformer has been analyzed for which the losses in the clamps are modeled to make the transformer model as
core and winding clamps have been calculated using 3-D realistic as possible.
Figure 2: Core clamps of the 40 MVA, 110/23 kV distribution transformer
(a) (b)
Figure 3: 3-D finite-element model of the transformer. (a) solid model, (b) meshed model
(b)
Figure 4: Distribution of losses on the surface of the core clamps (a) front side, (b) back side
1 2
The skin depth at 50 Hz varies form 1.2 mm to 1.83 mm P= Re( Z s ) H . (4)
for the permeabilities listed in Table I. The thickness of the 2
core clamps, winding clamps and the tie rods is not less
TABLE I: CLAMP LOSSES AS A FUNCTION OF IRON PERMEABILITY AND
than 20 mm. In that case the use of surface impedance is CONDUCTIVITY
justified. Moreover, it significantly reduces the
computational time since it is not necessary to generate very Material properties Ploss (W)
dense FE mesh in the surface layers of the clamp parts. The μr = 300, σ = 5⋅106 S/m 3233.2
surface impedance is defined as [4] μr = 500, σ = 5⋅106 S/m 3232.8
μr = 700, σ = 5⋅106 S/m 3198.8
E ωμ μr = 300, σ = 6⋅106 S/m 3218.8
Zs = = (1 + j ) (1)
H 2σ μr = 500, σ = 6⋅106 S/m 3239.6
μr = 700, σ = 6⋅106 S/m 3220.4
where E and H are phasors of the electric and magnetic
μr = 700, σ = 8⋅106 S/m 3238.8
field strength respectively, ω is the supply frequency in
rad/s, μ is the permeability, and σ is the conductivity of the
material. The losses in the clamps can be reduced by using
The power transmitted through unit surface area of the different materials and by changing the clamp dimensions.
clamp can be calculated using the expression for Poynting Fig. 5 shows an example of using a narrower clamp whose
vector in the complex domain [5] width has been reduced so that its edge coincides with the
narrowest core lamination step.
1 *
N= E×H (2)
2
*
where H is the complex conjugate of the magnetic field
strength phasor. Both E and H are tangential to the clamp
surface and perpendicular to each other, while N is
perpendicular to the clamp surface pointing in the direction
of the flow of energy. From (1) and (2) it follows that
1 * 1 2
N= Z s H × H = Z s H = P + jQ . (3)
2 2
The losses per unit area of the clamp are then equal to the Figure 5: Cross section of the transformer core and core clamp
real part of the Poynting vector, i.e. with reduced width
The winding clamps which are heavily exposed to the The losses calculated for the cases of narrower core
winding stray fields can be made of chrome alloy which has clamps, shorter winding clamps made of iron and regular
lower conductivity und thus lower losses than iron. The size winding clamps made of chrome alloy are given in
chrome alloy has a relative permeability equal to 1 and its Table II.
conductivity is equal to 1.4⋅106 S/m. In that case the skin From the table it follows that if the core clamp is made
depth is equal to narrower by 38 %, the total core and winding clamp losses
are reduced by 35 %. In the case when winding clamps are
2 2 made twice shorter the total clamp losses are reduced by
δ= = = 60.2 mm (5)
ωμκ 2π 50 ⋅ 4π 10−7 ⋅1.4 ⋅106 22.9 %. Finally, when instead of iron a chrome alloy is used
for regular size winding clamps the total clamp losses are
Since the thickness of the clamp is 20 mm, it is apparent reduced by 42.8 %.
that the surface impedance in this case can no longer be
used. Therefore, the simulation has been carried out using
surface impedance for the core clamp and regular mesh for V. CONCLUSION
the winding clamps. For providing valid results it was
necessary to use denser mesh for the winding clamps as This paper presents the results of numerical analysis of
shown in Fig. 6. losses in the core and winding clamps of the 40 MVA
distribution transformer. The losses are calculated by means
of 3-D finite-element method using surface impedance
approximation for the conducting parts of the clamps. It is
difficult to confirm these results by measurement since in
the standard tests performed on the transformer it is
impossible to distinguish clamp losses from the tank losses
and additional losses in the windings due to skin-effect.
ACKNOWLEDGMENT
We thank the manufacturer KONČAR Distribution and
Special Transformers Inc. for providing us the valuable
design data for the 40 MVA distribution transformer
analyzed in this paper.
All 3-D finite-element calculations were performed using
Infolytica MagNet software.
REFERENCES
[1] L. Šušnjić, Z. Haznadar, Z. Valković, “Electromagnetic
Analysis Applied to the Prediction of Stray Losses in Power
Figure 6: Finite-element mesh for the case of winding clamps Transformer,” ICEM 2004, Cracow-Poland, 5-8 Sept. 2004.
made of chrome alloy [2] C. Guérin, G. Tanneau, G. Meunier, “3D Eddy Current Losses
Calculation in Transformer Tanks Using the Finite Element
Method,” IEEE Trans. Magn., Vol. 29, No. 2, pp. 1419-1422,
TABLE II: LOSSES IN THE CLAMPS WITH MODIFIED DIMENSIONS AND March 1993.
MATERIAL PROPERTIES [3] S.A. Holland, G.P. O’Connell, L. Haydock, “Calculating Stray
Material Ploss Losses in Power Transformers Using Surface Impedance With
properties (W) Finite Elements,” IEEE Trans. Magn., Vol. 28, No.2, pp.
1355-1358, March 1992.
Core clamps with reduced width μr=500, [4] E. Schmidt, J. Schöberl, P. Hamberger, “Influence of the
2101.6
of the plate by 38 % σ=5⋅106 S/m Effective Core Permeability on Eddy Current Losses in Power
μr=500, Transformers,” ICEM 2004, Cracow-Poland, 5-8 Sept. 2004.
Twice shorter winding clamps 2492.8
σ=5⋅106 S/m [5] Z. Haznadar, Ž. Štih, Elektromagnetizam. Zagreb: Školska
knjiga, 1997, vol. I (in Croatian).
Core μr=500,
Iron core clamps 1762.8
clamp σ=5⋅106 S/m
with regular size
μr=1,
winding clamps Winding
made of chrome σ=1.4⋅106 86.8
clamp
alloy S/m
Σ 1849.6