POWER TRANSFORMER

SOLUTION

AKLI, 4 April 2013

GRID
ALSTOM Technology
Center

2
 ALSTOM Global Power Transformer Manufacturers

TST AGM ATT

UK Germany Turkey
MMC
Canada


AST
Technical Int.Center China
France

UTR
Indonesia

TFR
TCT Australia
Brazil
PTI
India
Group Highlight experience :
Power transformer : 2250 MVA, 1200 kVAC, 1000 kVDC
Reactors : 125 MVAR , 765 kV
Furnace transformer : 200 MVA, 260 kAmp
Presentation title - 01/01/2010 - P 3
 Type of Transformers
AUTOTRANSFORMATEUR TRANSFORMATEUR
D’ INTERCONNECTION POUR LINE cc
T.H.T.

CENTRALE
CENTRALE
TRANSFORMATEUR
ELEVATEUR BOBINE
BOBINE D’INDUCTANCE
D’INDUCTANCE
H.T. DE LISSAGE
SHUNT

TRANSFORMATEUR
ABAISSEUR
TRANSFORMATEUR
TRANSFORMATEUR
D’ INTERCONNECTION
ALIMENTATION DE FOUR

H.T.

TRANSFORMATEUR
ABAISSEUR
TRANSFORMATEUR
SOUS-STATION M.T.
TRACTION
TRANSFORMATEUR
ALIMENTATION DE B.T.
REDRESSEURS

B.T. TRANSFORMATEUR TRANSFORMATEUR

DISTRIBUTION CABINE DISTRIBUTION SUR
TRANSFORMATEUR DE POTEAU
LOCOMOTIVE
TRANSFORMATEUR SEC

Presentation title - 01/01/2010 - P 4

 1100 MVA 525 kV in Germany

Presentation title - 01/01/2010 - P 5

 Shunt Reactor 100 MVAR 765 kV

Presentation title - 01/01/2010 - P 6

Transformer Core
Transformer Core
 Core Determination Factors
No Load Loss (and No Load Current) ;
− No load loss is independent with the loading of the transformer, but it is dependent with
the applied voltage per turn of the winding.
− It has more significant economical component cost in capitalization than other losses
due to it’s appearance independency with the cyclic loading.
− IEC standard tolerance for no load loss = +15%, no load current = +30%.
Over excitation capability ;
− For generator application, the transformer shall be designed for over excitation up to
140% in 5 second during load rejection.
− For distribution application (and general purpose), the transformer has to be designed
by considering
• Over voltage up to 110% continuous at no load condition.
• Over voltage up to 105% continuous at full load condition.
• Core temperature limit at required maximum ambient temperature
(Design limit < 140oC at center, < 105oC at surface to avoid gassing).
Sound power / sound pressure level.
− The local regulation for sound pressure/sound power limit.
− Installation location ; populated area, remote area.
 Type of CORE steel

Purpose : the path for the flux lines with low

magnetic reluctance
Core material in power transformer ;
Cold Rolled Grain Oriented Silicon Steel.
Available thickness = 0.23 mm, 0.27 mm, 0.30 mm
Lamination insulation = CARLITE 0.012 mm
Grade ;
− Conventional Grain Oriented = High losses.
− Hi-B Grain Oriented = Medium losses.
− Laser/plasma refinement GO = Low losses.
 Refined Domain – Extremely low Losses Core Steel

Presentation title - 01/01/2010 - P 11

Core-Joint - Mitred Joints

But Lap Joint

Step Lap Joint

Bended Core type – NO Core Bolts
(In order to avoid hot spot due to magnetic discontinuity)
Transformer Windings
Transformer Winding
Type Of winding Conductor

Material :
− Aluminum (not common usage, for special purpose only)
− Electrolytic copper (E-CU 58 F 20 acc. to DIN 40500)

Type of winding conductor :

− Foil conductor (for distribution transformer).
− Round wire (for distribution transformer).
− Insulated magnet wire with kraft paper, enamel (PVA, PE-
AIW), thermally up graded, nomex T410.
− Twin/Triple/Quadruple conductors.
− CTC (Continuous Transposed Cable)
− Netting CTC / Perforated CTC.
 Continuous Transposed Cable

Presentation title - 01/01/2010 - P 17

 Helical Heavy Current - Netting CTC

Presentation title - 01/01/2010 - P 18

Winding – ALSTOM terminology

Axial/Radial
Packing for
transposition

Directed Oil
Flow washers

External DOF
washer

Internal DOF
washer

Transposition set

Segment Spacer
Mechanical & Industrial
Standardization

20
Transformer Tank & Metal Supports
Organization - Standardization
PTR R&D PTR Industrial

Standardization Director
Design, Quality & Cost

Product Center

N H S R
Manager Manager Manager Manager

Electrical Electrical Electrical Electrical

Design Design Design Design

Mechanical Mechanical Mechanical Mechanical

Design Design Design Design

Industrial Industrial Industrial Industrial

Rules Rules Rules Rules

Roll out of rules & tools

(range specific)

Unit 1 ... Unit N

22
 H –Design = ROBUST up to 5G

CORE STEEL BANDAGES

TOP PIN & CUP ANCHORING

BOTTOM ACTIVE PART’S PIN & CUP ANCHORING

23
 H Range – Concept (experienced up to 1100 MVA)

ALSTOM - UK practice

24
 SEISMIC ANALYSIS UP TO 5G
Cooperation with ITB, oldest technical institute in Indonesia.
Contact person ; Prof. Dr. Komang Bagiasna
Analysis ; Static & Dynamic
Experiences;
− 2008 ; CHILEAN LNG – (50 MVA)
− 2009 ; QAFCO – Middle East (50 MVA – 82 MVA ONAN = 13 units)

25
SEISMIC PROOF transformer

26
Cooling

27
Transformer Cooling
Oil Flow - Directed Cooling

The winding
is starved of
oil

Coil
support
block

Oil seal Base

(diaphragm) Trough

END VIEW
29
ODAF Technology

• Oil Viscosity Factors:

It can be seen from manufacturers data that the viscosity of the oil differs between oil types. This
will have an impact upon the performance of the coolants performance and should be borne in
mind when evaluating the calculations.
Typical values are given below:
VISCOSITE DES HUILES MINERALES EN FONCTION DE LA TEMPERATURE
1600

ShelL DIALA F

1400
Esso UNIVOLT 52

Shell DIALA S
1200
Nynas 10 GBN
Viscosité (cSt)

1000

800

600

400

200

0
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40

Température (°C) 30
Real Hot Spot Fiber Optic Measurement
INFRA RED to monitor the surface hot spot

Maximum < 125oC

32
ODAF COOLING

33
ODAF with AIR COOLER

34
Tap Changer

35
Tap Changer
 Off Circuit Tap Changer

Presentation title - 01/01/2010 - P 37

 OLTC (On Load Tap Changer)

Diverter Switches
(current breaking – change
over)

Change Over Switches

(no current breaking)
Tap Selector
(tap changing without current
Presentation title - 01/01/2010 - P 38 breaking)
Vacuum Interrupter -
OLTC

Free – maintenance for 300000 operation

Transformer Bushings

40
Bushings
RIP bushings

• PNR - transformer bushings – oil-to-air

• PTFR – transformer bushings – oil-to-air high current

• PCTR – transformer bushings – oil-to-oil

• PNHR – transformer bushing 800 kV HVDC

RIP oil to air bushing

Top terminals passed

a high cycle fatigue
test (<1000 x)

• Voltage range: 52 kV up to 245 kV,

acc. IEC 60137 & IEEE Composite insulators
typetested twice.
Pre-assembled
single piece.
• Current range: 800 A up to 2.000 A
Top Terminal
analysed and
optimized with FEM

• Status: range completed up to 245 kV,

420 kV in progress
Measuring Tap
passed Vibration
test (3g)

• Type test: passed up to 245 kV, 1.250

A, certified by CESI
 High current bushing

• Customized bushings can be designed and manufactured

• A similar product according to ANSI/IEEE std is available

• Voltage range: PTFR 24 and 36 kV, acc. IEC 60137 & IEEE

• Current range: 7,5 kA up to 24 kA

• Type test: passed, certified by KEMA

 Oil to oil bushings

Thermical, electrical,
mechanical performance
calculated and validated.
Picture: top shield calculation

New Top Terminal design

adapted to easy and robust
shield mounting in any direction
• Reference : IEC 60137 & IEEE

• Current range: 800 A up to 2.000 A

• Status: design complete finished,

prototyping done (300kV, 1.250A), New Measuring Tap developped.
500 kV to be developed soon All tests passed successfully

• Type test: passed up to (300kV, 1.250A)

 HVDC converter transformer bushing PHI 820 kV

RPV - Milano
Technical University of Graz

Successfully AC/DC type tested in GRAZ

and thermally (5000 A) in ALSTOM RPV
Moisture Evacuation and Stabilization

48
Moisture in Cellulose Material

The active part as heart of transformer is containing

approximate 25% cellulose insulation material.

This cellulose material will drive the insulation

structure of the transformer to strengthen the
voltage withstand up to 100 times the air
insulation voltage strength.

Moisture in cellulose of winding conductor

insulation is detected thru the water content in oil.

49
 Oil Moisture Content vs. Dielectric Strength

100
Electric strength %

80
60
40
20
0
0 20 40 60
Water in oil, ppm
 Dryness of paper vs voltage withstand

100
Electric strength, ppm

80

60

40

20

0
0 1 2 3 4 5 6 7 8 9 10
Water in paper %
 Partial Discharge Inception vs Moisture in Paper

100

80
Discharge inception
voltage %

60

40

20

0
0.01 0.1 1 10
Water in paper %

Presentation title - 01/01/2010 - P 52

 Paper Water Content Equilibrium
T2 air temperature (°C) T1 oil temperature (°C)
 rel. humidity (%) 20° 30° T1

40°

10 T2 10° 20° 10° 30° 20° 30°

 50 50 100 50 100 100
water content of paper [%]

50°

5 60°

70°
80°
90°
100°

0
0 20 40 60 80

water content of oil [ppm]

 ISO-Static pressure while the winding in the oven

Presentation title - 01/01/2010 - P 54

Automatic Vacuum Vapor Phase Oven
9.5 x 5.5 x 5 m (L x W x H)

300 kW heating, 125 oC, 0.025 mBar

Automatic process under programmable computer
Dew point control (final ; less than -45oC)
Water extraction (final ; less than 0.01 g/ton.h)55
 Vacuum Vapour Phase Oven Automatic Control

Presentation title - 01/01/2010 - P 56

Manufacturing and Industrial

57
58
Safety Harness Attachment Points

59
ERGONOMIC Design

Elevated Oil level Indicator

60
CHERRY PICKER
Safety high installation
Movable Equipment

61
AIR Cushion Movable Platform (SAFETY compliance)

62
TESTING LABORATORY
1600 kVp Full Wave Impulse, 1300 kV Switching
Zero Flux Losses measurement
Sound proof wall & Faraday cage – Magnetic Shield

63
Technology VISION & TRENDS

64
Technology VISION & TREND
ECO – design (CO2 reduction);
− Low noise & Low partial discharge
− Environmental Friendly
− SAFETY Precaution
SMART grid ;
− EWS (Early Warning System)
− CBM (Conditioned Based Maintenance)
− Aging & Failure prevention
− Intranet Information Technology
• On Line Partial Discharge (UHF or Ultra-sonic method)
• On Line Gas Monitoring.
• On Line Hot Spot Temperature Monitoring.
• Tap Changer Behaviour Monitoring

65
 Green Transformer : Free Maintenance Transformer

Presentation title - 01/01/2010 - P 66

 MS 3000 – System Architecture

Architecture of Remote IED Solution (on request)

Intranet / Internet
Office FAX
ALARM

TCP/IP (Ethernet)

Substation Telephone Protection & Control

Protocols, e. g.
(Modem)
IEC 60870-5-101/104,
DNP3.0, Modbus,
IEC 61850
TCP/IP or
RS232 Point to Point, e. g.
Notebook Remote IED and 0/4 .. 20 mA, Dig.
Webserver Module

Transformers
Field Bus
or more

Monitoring
Modules

MS 3000 Online Condition Monitoring & Expert System for Power Transformers – Didik Widianto May 2012
 Measuring & Analyse Quantities - Flexible Design
Active Part
 Apparent / active /reactive power Bushings
 Power factor (cosφ)  Operating voltages on HV, MV, LV and TW
 Phase angle side
 Load factor  Over voltages on HV, MV, LV and TW side
 Actual losses  Number of over voltages
 Top oil temperature, acc. to thermal model  Last over voltage
 Hot spot temperature  Change of capacitances
 Thermal model  On-line capacitances on HV, MV, LV side
 Direct fibre optic winding temperature  Capacitive displacement currents
 Bottom oil temperature  Power loss factor (tanδ)
 Ageing rate (actual, average last 30 days)  Leakage currents
 Lifetime consumption  Load currents on HV, MV, LV and TW side
 Gas in oil content/ gradients  Over currents and short-circuit currents
 Relative moisture in oil (water activity) [%]  Number of over- and short-circuit currents
 Moisture of insulation paper  Last over current or short-circuit current
 Bubbling temperature and safety margin  Etc.
 Breakdown voltage of insulation oil
 Overload capacity (maximum overload)
 Emergency overloading time when overloading
OLTC
  OLTC position (last and actual)
Emergency overloading time when cooling failed
  Last OLTC operation
Etc.
 Number of switching operations of OLTC
 Sum of switched load current of OLTC
Cooling unit  Diverter switch current during switching
 Ambient temperature Conservator operation
 Operating state/times of pumps or group of pumps  Oil level  Number of OLTC operations until service
 Operating state /times of fans or group of fans  Humidity of air in conservator  Sum of switched load current until service
 Oil in- and outlet temperatures/ temperature differences  Gas quantity in Buchholz relay  Power consumption of motor drive
 Water in- and outlet temperatures/ temperature  Gas gradient in Buchholz relay  Time of inrush current
differences  Switching time
 Cooling efficiency (thermal resistance)  Index of switched energy
 Cooling power  Contact erosion of main/ auxiliary contacts
 Intelligent cooling control, dependent on load/  Etc.
temperature
 Etc.
MS 3000 Online Condition Monitoring & Expert System for Power Transformers – Didik Widianto May 2012
 On-Line Dissolved Gas Analysis

MS 3000 Online Condition Monitoring & Expert System for Power Transformers – Didik Widianto May 2012
 On-Line Dissolved Gas Analysis

MS 3000 Online Condition Monitoring & Expert System for Power Transformers – Didik Widianto May 2012
 Free Maintenance Concept

1. No contact between transformer oil and outside

air. No maintenance to replace silica gel breather.
2. No maintenance on the OLTC’s compartment’s
oil. The maintenance is required after approx.
150000 operation replace the OLTC’s contacts.
3. Transformer behavior at real time data can be
monitored by GSM or internet.
4. The loading and investment can be planned much
in advance.

Presentation title - 01/01/2010 - P 71

 CANADA : ARCTIC remote area transformer

Special tank & support steel suitable for -50oC temperature

Presentation title - 01/01/2010 - P 73
CANADA : Stainless steel radiator for arctic + high
corrosive

74
POSO ENERGY 80 MVA & 90 MVA 275
kV

75
Export to Phillipines 100 MVA 230kV

76
PHILIPINES : 2 x Interbus Transformer 100 MVA
230/115kV

Equipped with on line monitoring – EARLY WARNING system

77
MS3000
 Mobile Transformer

Presentation title - 01/01/2010 - P 78

THANKS

79
www.alstom.com