Alessandro Magris, Technical Service Manager

Training KAHRAMAA ph 11
32/40MVA 66/11kV Transformer

© ABB
Month DD, YYYY | Slide 1
 What is a transformer?
© ABB
Month 04, 2015 | Slide 2
Power Transformers
Definitions

a static piece of apparatus with two or more windings

which, by electromagnetic induction, transforms a
system of alternating voltage and current into another
system of voltage and current usually of different
values and at the same frequency for the purpose of
transmitting electrical power (IEC 60076-1 ed.3:2011)

A transformer is generally a four – terminal device

that is capable of transforming an alternating
current (AC) input voltage into a relatively higher or
lover AC output voltage. (Wikipedia)

A couple of coils of wire in close proximity

and an a.c. source suffice for the transfer of
electrical energy via mutual induction. (I.
Gottlieb – Practical Transformer Handbook)

© ABB
Month DD, YYYY | Slide 3
Power Transformers
Definitions

The function of the transformer is to change electric power

from a voltage to another. (J.B. Gibbs - Transformer Principle and
Practice 2ed – McGraw Hill – 1950)
losses

power power

I1 I2
V1 V2

power power

losses

• Transparent for the power

• bidirectional

© ABB
Month DD, YYYY | Slide 4
Power Transformers
History

1831 – 1832: discovery of induction

1831- Michael Faraday (UK)

1832- Joseph Henry (USA)

Faraday Law: The induced electromotive force in any

closed circuit is equal to the negative of the time rate of
change of the magnetic flux through the circuit.

© ABB
Month DD, YYYY | Slide 5
Power Transformers
History

1836: Rev. Nicholas Callan (Ireland)

invented the induction coil

Induction coil is a transformer used to produce high voltage

AC current from a low voltage DC source. It was the first type
of electrical transformer.

© ABB
Month DD, YYYY | Slide 6
Power Transformers
History

1851: Heinrich Daniel Ruhmkorff (Germany)

patents the Ruhmkorff coil, an improved version of
induction coil of Rev. Callan

© ABB
Month DD, YYYY | Slide 7
Power Transformers
History

1876: Pavel Nikolayevich Yablochkov invents a

lightning system based on induction coil.
Paris, avenue de l’Opera
illuminated by Yablochkov
candles - 1878

1882: Gaulard – Gibbs (UK): patent of new current

distribution system by inductors (based on the
concept of induction coil)

© ABB
Month DD, YYYY | Slide 8
Power Transformers
History

1885: Karoly Zipernowsky, Otto

Blathy and Miksa Deri (GANZ -
Hungary) - patent of ZBD
transformers

Two types of designs with closed magnetic circuits:

• Copper windings wound around iron wire ring core
• Copper windings surrounded by iron wire core

© ABB
Month DD, YYYY | Slide 9
Power Transformers
History

1885 - 1886: George Westinghouse and William

Stanley (USA) create a transformer that is practical
to produce

(easy to machine and wind in a square shape, making a core

of E shaped plates)
1889: Mikhail Dobrovolsky developed the first
three – phase transformer in Germany at AEG

© ABB
Month DD, YYYY | Slide 10
Power Transformers
Basic Fundamentals

Faraday Law: The induced electromotive force in any closed

circuit is equal to the negative of the time rate of change of
the magnetic flux through the circuit.

© ABB
Month DD, YYYY | Slide 11
Power Transformers
Basic Fundamentals

Typical for step – down transformers

Easier to manufacture

Typical design for large GSU

units
More complex design
Short – circuit proof

© ABB
Month DD, YYYY | Slide 12
Power Transformers
Basic Fundamentals

Three-phase transformer: 3 legs core

3 single phase transformers

© ABB
Month DD, YYYY | Slide 13
Power Transformers
Connection groups

Delta connection Star connection

Zig –zag
connection

© ABB
Month DD, YYYY | Slide 14
Power Transformers
Connection groups
b)
I II III
12
Connection and phase
I
displacement symbols for
III
II three-phase transformers
a)
I II III 12 12
I II III
I I

III
Symbols:
III II
II
HV -> capital letter: Y, D, Z
11 I II III
I II III
I
III
LV -> small letter: y, d, z
II
II
III I Neutral: N , n
5
Dyn11 YNyn0d5

c)
12
I II III I Example: Dyn11 (left)
II
III Clock number: phase shifting
11 between HV and LV:
I
II «1» corresponds to 30°
III

YNad11
«5» corresponds to 150°
Figure 4.4 a, b, c - Examples of clock number notation IEC 60076-1 [1] «11» corresponds to 330°
© ABB
Month DD, YYYY | Slide 15
Power Transformers
Summary of part 1

The function of the transformer

is to change electric power from
a voltage to another
Invented and developed at
end of 1800 – beginning of
1900
Two main designs: core
type and shell type
Different connections types –
Capital letter: higher voltage
Small letter: lower voltage

© ABB
Month DD, YYYY | Slide 16
 Why do we need transformers?
© ABB
Month DD, YYYY | Slide 17
Why do we need transformers?
Key elements of energy networks

© ABB
Month DD, YYYY | Slide 18
Why do we need transformers?
Why a transformer in a network? – Minimize Losses

Main characteristics of an electrical network:

Power delivered ∝
Network Losses ∝ ,

To minimize network losses (and maximize the efficiency) it

is necessary to decrease current through the network
increasing its voltage.
© ABB
Month DD, YYYY | Slide 19
Why do we need transformers?
Why transformers in a newtork? – Minimize Losses

Power Step – up Transmission Step – down

producer transformer / distribution Customers
transformer
grid
6.3kV – 24kV to
11.5kV 66/132/220/4 400V
00kV

© ABB
Month DD, YYYY | Slide 20
Why do we need transformers?
Why transformers in a newtork? – Voltage regulation

V1
V1_L V2_L
V2

Due to the impedances of generator, distribution network and

transformers, in case of a load increase, voltages will decrease.

A way to mitigate the effect of the load on the voltages is the

change of number of turns, in order to compensate the voltage
drop at customer side and to maintain this voltage at a constant
level (CFVV).

© ABB
Month DD, YYYY | Slide 21
Why we need transformers?
Wrap up

Transformers are key element

of an electrical network

They are used in order to

minimize losses of an electrical
system and to permit an
efficient transmission and
distribution of power over long
distances

They permit voltage regulation

© ABB
Month DD, YYYY | Slide 22
 How to define a transformer?
© ABB
Month DD, YYYY | Slide 23
How to define a transformer?
International Standards

Definition of a Standard
document specifying nationally or internationally agreed
properties of manufactured goods, principles for
procedure, etc.

Main standard followed for transformers:

 IEC 60076 European influence

 ANSI C57.12.XX American Influence

 BS

© ABB
Month DD, YYYY | Slide 24
How to define a transformer?
IEC Standards

Issued by International Electrotechnical Commission.

IEC 60076 – IEC standards regarding transformers
 IEC 60076-1: General
 IEC60076-2: Temperature rise
 IEC 60076-3: Insulation levels, dielectric tests
 IEC 60076-4: Guide to lightning impulse test
 IEC 60076-5: Ability to withstand short – circuit
 IEC 60076-7: Loading guide for power transformers
 IEC 60076-10: Determination of sound level

© ABB
Month DD, YYYY | Slide 25
Power Transformers
IEC 60076-1 - Definitions

I1 I2
V1 V2

 Power
 Voltages V1, V2
 Insulation class
 Connection group
 Losses
 Short circuit impedance (or voltage)
 Site Temperature
 Cooling system
 Type of tap changer and regulation range
© ABB
Month DD, YYYY | Slide 26
How to define a transformer?
Rated Power

Rated power
A conventional value of apparent power assigned to a
winding which, together with the rated voltage of the winding,
determines its rated current.

3 three phase transformers

© ABB
Month DD, YYYY | Slide 27
How to define a transformer?
Voltages

Rated voltage
the voltage assigned to be applied, or developed at no-load,
between the terminals of an untapped winding, or of a
tapped winding connected on the principal tapping
for a three-phase winding it is the voltage between line
terminals
Insulation class
rated withstand voltages which characterise the dielectric
strength of the insulation
LI AC

LI: lightning impulse withstand voltage level

AC: highest rated AC withstand voltage level to earth
© ABB
Month DD, YYYY | Slide 28
How to define a transformer?
Losses

No load loss
the active power absorbed when a rated voltage (tapping
voltage) at a rated frequency is applied to the terminals of
one of the windings, the other winding or windings being
open circuited

Load loss
the absorbed active power at a rated frequency and
reference temperature associated with a pair of windings
when rated current (tapping current) is flowing through the
line terminals of one of the windings, and the terminals of the
other winding are short circuited.
Further windings, if existing, are open-circuited

© ABB
Month DD, YYYY | Slide 29
How to define a transformer?
Short Circuit Voltage

Short circuit voltage: parameter related to magnetic

coupling of windings.
It is the voltage (expressed in %Vnominal) that applied to the
HV winding determines the circulation of nominal current in
LV in short-circuit.
Short circuit impedance: impedance measured by one
winding while the other is closed on short – circuit.

Zcc e Vcc expressed in percentage value have the same

values

© ABB
Month DD, YYYY | Slide 30
How to define a transformer?
Definitions

power

V1 V2

Zcc

No load losses Load losses

(independent (dependent
from the load) from the load)

© ABB
Month DD, YYYY | Slide 31
How to define a transformer?
Site Temperature

Site temperature
The temperature of cooling air at the inlet to the cooling
equipment not exceeding:
 40°C at any time Impact on
cooling system
 30°C monthly average of the hottest month and transformer
life
 20°C yearly average
And not below
 -25°C in the case of outdoor transformers
Impact
 -5°C in the case of transformers where both the on
materials
transformer and cooler are intended for installation indoors

© ABB
Month DD, YYYY | Slide 32
How to define a transformer?
Cooling

Liquid immersed transformers cooling identification is expressed by a four –

letter code:
1. letter Internal cooling medium

O Mineral oil or synthetic insulating liquid with fire point ≤300°C

K Insulating liquid with fire point >300°C
L Insulating liquid with no measurable fire point
2. letter Circulation mechanism for internal cooling medium

N Natural thermo-siphon flow through cooling equipment and in windings

F Forced circulation through cooling equipment, thermo-siphon flow in windings

Forced circulation through cooling equipment, directed from the cooling into at least the
D main windings
3. letter External cooling medium

A Air

W Water

4. letter Circulation mechanism for external cooling medium

N Natural convection

F Forced circulation (fans, pumps)

© ABB
Month DD, YYYY | Slide 33
 Transformer Cooling System

External circuit Internal circuit

Heat outlet

The heat
Heat generation
Core and windings
Oil pump
(eventually) generated by
losses should be
Fan
pulled out
(eventually) Tank with oil

© ABB

© ABB Group
| Slide 34

S b 23 2016 |
 Transformer Cooling System

The oil
circulation can
be natural or
directed
across the
windings

© ABB
| Slide 35
 Transformer Cooling System
ONAN and ONAF

RG Type

RR Type

Radiator (ONAN) Fan (ONAF)

It increases the thermic exchange of
Radiant element that increases the oil-air radiator forcing air through the fins
thermic exchange

© ABB
| Slide 36
How to define a transformer?
Cooling - ONAN

Advantages Disadvantages

- No needs of auxiliary - Big dimensions and high

supply for cooling weight
© ABB
Month DD, YYYY | Slide 37
How to define a transformer?
Cooling – ONAN/ONAF

Advantages Disadvantages
- Radiators are calculated for - Increase of auxiliary
60% – 70% of the rated power.
Reduction of total weight and
losses
dimensions
- Increase of noise

© ABB
Month DD, YYYY | Slide 38
How to define a transformer?
Cooling OFAF

Advantages:
 Solution more compact,
suitable for transformers
with high losses

Disadvantages:
 The fans and the pump will
increase the electrical
consumption of the
transformer

 The fans and the pump will

increase the noise of the
transformer

 In case of failure of the

cooler, the transformer will
be cooled only by the tank
(about 5% - 10% of the
nominal power of the
transformer).

© ABB
Month DD, YYYY | Slide 39
How to define a transformer?
Cooling OFWF

Advantages:
 Solution more compact, suitable
for transformers with high losses

Disadvantages:
 The customer has to provide a
water supply with defined values
of water flow and pressure

 The pump will increase the

electrical consumption of the
transformer

 The pump will increase the noise

of the transformer

 In case of failure of the cooler, the

transformer will be cooled only by
the tank (5% - 10% of the
nominal power of the
transformer).

© ABB
Month DD, YYYY | Slide 40
How to define a transformer?
Wrap up

International standard: common

language between customers
and manufacturers
Transformers are defined by
several parameters: Power,
voltages, short circuit
impedance, site temperatures
Dielectric test are performed in
order to prove the goodness of
insulation system
Several cooling systems

© ABB
Month DD, YYYY | Slide 41
 Power transformer, how it looks like?
© ABB
Month DD, YYYY | Slide 42
 Power Transformer Training
Part 4: Manufacturing
 Dry type transformers

 Oil type transformers

 Windings (type of windings, type of materials,

winding area.

 Magnetic core (type of designs, type of materials,

type of joints)

 Assembly area

 Tanking

 Treatment

 Final assembly
© ABB
| Slide 43
 Transformers:
Dry type

Dry

Open wound Cast Resiblock

© ABB
| Slide 44
 Transformers:
Oil insulated

Oil

Substation Transformer Mobile Substation Transformer

© ABB
| Slide 45
 Transformers:
Cast vs. Oil

Cast vs. oil

Advantages Disadvantages
• Low environmental impact • Insulation
• Not explosive • Big dimensions/high weight
• Fire resistance • Cost
• Simple maintenance • Outdoor installation
• Installation cost
• Short-circuit withstanding
© ABB
| Slide 46
 Transformers:
Oil vs. cast

Oil vs. cast

Advantages Disadvantages

• Outdoor installation • Fire/explosion risk

• Reduced weights and • Environmental pollution
dimensions
• Installation cost
• High insulation
• Reduced cost

© ABB
| Slide 47
Power Transformers
How they look like?

© ABB
Month DD, YYYY | Slide 48
Power Transfomers: How they look like?
Core

Core: an unbroken path for magnetic flux

 Magnetic Core is needed to confine magnetic flux and to
realize and efficient magnetic link between input and output
windings
 It gives rigidity to the mechanical structure of the active part

© ABB
Month DD, YYYY | Slide 49
Power Transfomers: How they look like?
Core Materials

Grain oriented electrical steel

 Grain oriented: superior magnetic performances (low loss,
higher flux density) in direction of rolling
 Electrical steel: silicon steel (3% Si) in order to increase
resistivity (and reduce eddy losses)

© ABB
Month DD, YYYY | Slide 50
Power Transfomers: How they look like?
Core manufacturing procedure

• Magnetic sheets are cut

according the design. E –
part is built together while
the upper yoke is
manufactured not closed
on the lower part

 Core clamps are placed on the lower joke and the E – part is
turned in vertical position
 After the installation of windings and insulations, upper yoke
is closed and core clamps are placed and closed
 Clamping system will be tight after hot treatment, immediately
before final tanking

© ABB
Month DD, YYYY | Slide 51
Power Transfomers: How they look like?
Core Joints

Conventional
joint

Step - lap

Oblique joint: 45°C

Step lap: reduction of air gaps and improvement of magnetic
contact

© ABB
Month DD, YYYY | Slide 52
Power Transfomers: How they look like?
Performances influenced by magnetic core

 No load losses
 No load current
 Noise level
 Inrush current

© ABB
Month DD, YYYY | Slide 53
Power Transfomers: How they look like?
Windings

© ABB
Month DD, YYYY | Slide 54
Power Transfomers: How they look like?
Windings

Windings are necessary to get the required number of turns

and to carry on the nominal current.

Materials used for windings constructions are:

Copper (Cu)
Aluminum (Al)

CTC – continuous
Flat wires – paper covered transposed cable – paper
covered or netting type
© ABB
Month DD, YYYY | Slide 55
Power Transfomers: How they look like?
Type of windings

Foil windings

Layers or Multilayer windings

Disc or Helical Windings

© ABB
Month DD, YYYY | Slide 56
Power Transfomers: How they look like?
Foil Winding

Typical LV winding
 Turns are made by Foil
windings having
thickness 0.4 – 1.5mm
 0.22mm DDP insulation
between turns

Advantages:
 Fast and easy to manufacture
Disadvantages:
 Not useful for high power (> 20 – 25MVA)

© ABB
Month DD, YYYY | Slide 57
Power Transfomers: How they look like?
Layer/Multilayer windings

Multilayer windings: set of layers (flat

wire)
Useful for transformers up to 25MVA
and 72.5kV and currents up to 400A
 Fast and easy to manufacture

L4: 4 layers CTC

 Useful for LV windings with high
current

Regulation windings

© ABB
Month DD, YYYY | Slide 58
Power Transfomers: How they look like?
Helical windings

Used for LV winding

Advantages:
 Useful for high current
Disadvantages
 It requires long
manufacturing time
 Helical – flat wire winding is
not indicated in HCC

© ABB
Month DD, YYYY | Slide 59
Power Transfomers: How they look like?
Disc Winding

Used for LV and HV windings

Advantages:
 Useful for managing of
high currents and high
number of turns
 Very good control of LI
voltage distribution
Disadvantages
 It requires long time for manufacturing

© ABB
Month DD, YYYY | Slide 60
Power Transfomers: How they look like?
Performances influenced by windings

 Load losses
 Load noise
 Short circuit withstand capability

How to minimize load losses?

Load losses depends from two factors

 Current density Minimize current density

 Conductor thickness (eddy losses) Reduce thickness

© ABB
Month DD, YYYY | Slide 61
Power Transfomers: How they look like?
Active part Assembly

© ABB
Month DD, YYYY | Slide 62
Power Transfomers: How they look like?
Active Part Assembly

 Placement of windings on the core

 Closing of the upper yoke and placement of upper core
clamps and tie – rods
 Installation of cover and bushings
 Installation of tap changer (if any)
 Manufacturing of HV and LV connections and cleats &
leads
 Ratio test

© ABB
Month DD, YYYY | Slide 63
Power Transfomers: How they look like?
Active Part Treatment

Why do we need treatment?

Water is dangerous for transformers:

 Reduction of dielectric strength of oil (risk of
breakdown)

 Negative impact on characteristics of insulation

(reduction of expected lifetime)

Hot treatment is necessary to remove moisture from

insulation materials.

© ABB
Month DD, YYYY | Slide 64
Power Transfomers: How they look like?
Active Part Treatment

Two methods of treatment:

 Low Frequency Heating
Active part is placed on its tank under vacuum. Heating is
generated by low frequency currents imposed through
transformer windings. The process is stopped when there is
no more moisture to remove

 Vapour Phase
Active part heating is done in a oven under a kerosene
atmosphere (pressure 0.3bar). The process is stopped when
there is no more moisture to remove

© ABB
Month DD, YYYY | Slide 65
Power Transfomers: How they look like?
Active Part Treatment

What happens after the treatment?

 Clamping system is retightened. All connection and joint

are checked
 Active part is placed into the tank. Cover is closed (last
time active part is accessible)
 Oil filling

© ABB
Month DD, YYYY | Slide 66
Power Transfomers: How they look like?
Final Assembly

 Oil filling
 Installation of conservator
 Installation of wiring system
 Installation of radiators and fans (if heat run test is
required)
 Installation of auxiliary accessories

Transformer is ready for test

© ABB
Month DD, YYYY | Slide 67
Transformer Manufacturing
Transformer and accessories

© ABB
Month DD, YYYY | Slide 68
 Power Transformer Training
Part 5: Accessories
 Bushings

 Tap changers

 Oil thermometer and winding temperature indicator

 Buchholz

 Oil level

 Pressure relief valve

 Dehydrating breathers

 Current transformers

 Cooling system

 Air cell / conservator

© ABB
| Slide 69
 Transformers Accessories
Bushing
INTERFACE:
•Oil to Air
•Oil to Oil
•Oil to SF6

CONSTRUCTION TYPE
•CONDENSER TYPE
•Oil impregnated paper
•Resin impregnated
paper (RIP)
•NOT CONDENSER TYPE

EXTERNAL COVER:
•Porcelain
•Sylicon

© ABB
| Slide 70
 Transformers Accessories
What is a Bushing

© ABB
| Slide 71
 Transformers Accessories
Voltage distribution

© ABB
| Slide 72
 Transformers Accessories
Condenser fundamentals

© ABB
| Slide 73
 Transformers Accessories
Condenser construction

© ABB
| Slide 74
 Transformers Accessories
Condenser capacitance plate

© ABB
| Slide 75
 Transformers Accessories
Condenser effectiveness

© ABB
| Slide 76
 Transformers Accessories
Electric field distribution

© ABB
| Slide 77
 Transformers Accessories
Bushing Electrical Stresses

© ABB
| Slide 78
 Transformers Accessories
Test vs Operating voltages

© ABB
| Slide 79
 Transformers Accessories
Lighting Impulse Voltage-Test wave forms

© ABB
| Slide 80
 Transformers Accessories
Bushing Mechanical stresses

© ABB
| Slide 81
 Transformers Accessories
Bushing Dialectical losses

© ABB
| Slide 82
 Transformers Accessories
Bushing Dialectical losses

© ABB
| Slide 83
 Transformers Accessories
Bushing Capacitance & Test Cap

© ABB
| Slide 84
 Transformers Accessories
Bushing Capacitance & Test Cap

© ABB
| Slide 85
 Transformers Accessories
How to select a Bushing

© ABB
| Slide 86
 Transformers Accessories
Bushing technologies
 OIP- technology was used until the 1980‘s
 RBP- technology was used starting about in the 1940‘s.
 In the 1960’s when PD- measurement became more and more
established, the RBP- technology was replaced again by OIP-
bushings and this also was the beginning of developing another dry
technology the RIP- bushings
 In the 1970‘s RBP was superseded by RIP bushings
 In the 1980‘s RIP had it‘s break through and became more and more
required by our clients
 In 2011, RIS (Resin Impregnated Synthetics) as a brand new
technology is introduced where a 3D plastic mesh replaces the paper
in RIP bushings
 Another major step in technology was made 1992, when the first
bushings with composite insulators were delivered

© ABB
| Slide 87
Transformer Accessories
OIP (Oil Impregnated Paper)

Construction: Even paper is wrapped onto the conductor and capacitive grading
layers are inserted at defined positions (same as for RIP). The flange
and the insulator will be assembled and evacuated. Followed by
oil filling under vacuum and the entire assembly is hermetically sealed.
Advantages: - Low cost and fast production (no curing of resin etc)
- Because of the porcelain on the oil side, the bushing is not
adsorbing moisture

Disadvantages: - Fire hazard and danger of oil contamination in case of damage

- Oil expansion vessel necessary
- In case of horizontal assembly, elevated oil expansion vessel or
self- maintaining pressure system necessary
- Core must be in oil at all times, even during transportation
(transportation angle <15°)
- Extensive construction due to massive volume of oil

© ABB
| Slide 88
RIP (Resin Impregnated Paper)

Construction: Creep paper is wrapped onto the conductor. Capacitive layers are insert at defined
locations. Following, the core is dried and epoxy resin is cast under vacuum.
The core remains in the vacuum vessel until the resin is completely cured.
Ultimately, the core will be machined to its final shape.
Advantages: - PD free => long life time!!
- Oil– and gas- tight in all directions
- Completely dry bushings are possible
- Condenser core is mechanically solid
- „state-of-the-art technology“

Disadvantages: - The condenser core tends to adsorb moisture due to the paper contents
Therefore long term storage precautions are necessary
- Compared to OIP higher costs and longer production time

© ABB
| Slide 89
Dry Bushings
Advantages

 PD – free up to double
phase to earth voltage
 Low dielectrically losses
 100% dry bushing, no oil
leakages possible
 Minimal risk of explosion
 No maintenance and no
constant monitoring needed
 Transportation and storage
in any position

©ABB
© ABB Group
September 23, 2016 ||Slide
Slide 90
90
 Transformers Accessories
Bushing
 Bushings

GOB

GSA

Ceramic Bushing
COMEM

© ABB
| Slide 91
Accessories
Tap Changers

Tap changer: equipment which permits to change number of

turns of a winding.
Types of tap changer
 Able to operate when transformer is energized (on – load)
 Can be operated only when transformer is not energized
(off – load or off – circuit)
Purpose:
 compensate voltage fluctuations of a side in order to
maintain constant the other side (CFVV)
 Change voltage of a side while the other side is constant
(VFVV)

© ABB
Month DD, YYYY | Slide 92
 Transformers Accessories
Tap changer
On-load tap changer
it modifies the ratio (V1:V2) with the
transformer energized OLTC UBB Type

No-load tap-changer
it modifies the ratio (V1:V2) with
transformer de-energized (out of service)

© ABB
| Slide 93
 Transformers Accessories
Tap changer

On load Tap
Switch
Changer

Selector

Motor
drive

© ABB
| Slide 94
Transformers Accessories
Tap changer
Diverter

Tap selector

7
6
5
4

Transformer
© ABB
| Slide 95 regulating winding
 Transformers Accessories
Protection Equipment

Thermometers WTI
Thermometer
It shows the max temperature of oil
© ABB
| Slide 96
(under cover area)
 Transformers Accessories
Protection Equipment
Oil Temperature Pt100
Pt 100 sensors need not to be calibrated T (oC) Pt 100 (ohm)
-40 84,3
-30 88,2
-20 92,2
-10 96,1
0 100,0
10 103,9
20 107,8
30 111,7
40 115,5
50 119,4
60 123,2
70 127,1
80 130,9
90 134,7
100 138,5
110 142,3
120 146,0
130 149,8
140 153,5
150 157,2
Top and bottom oil temperature sensor Pt100. 160,9
160
© ABB
Also used for tap-changer temperature
| Slide 97
 Transformers Accessories
Protection Equipment

Buchholz

Buchholz EMB

Relay Buchholz
It shows the formation of gas in the oil
(alarm and trip)

© ABB
| Slide 98
 Transformers Accessories
Protection Equipment

Level
Visual indication and electric signals of oil
level in the conservator Level Gauges

© ABB
| Slide 99
 Transformers Accessories
Protection Equipment

Pressure Relief
Valve

Pressure Relief Valve

It works in case of overpressure

© ABB
| Slide 100
 Transformer Accessories
Dehydrating Breathers

Filter MAIER
Salts for drying process of air filled in the
conservator

© ABB
| Slide 101
 Transformer Accessories
Current transformers

CT (current transformers)
Toroidal type

© ABB
| Slide 102
 Thermal model
© ABB
Month DD, YYYY | Slide 103
Power Transformers
IEC 60076 – 2: temperature rise

IEC temperature limits:

 Yearly average: 20°C
 Hottest month average temperature: 30°C
 Hottest temperature: 40°C

Maximum design temperature rises:

Maximum
 Maximum top oil temperature rise: +60K temperature
rises
 Maximum windings temperature rise: +65K
depends by
 Maximum hot spot windings temperature rise: +78K the design
In case that one of the limits is exceeded, maximum design temperature rises
shall be decreased of the same amount

Rate of Loss of life of transformers is considered normal

when yearly average winding hot spot temperature is equal
to 98°C

© ABB
Month DD, YYYY | Slide 104
 Temperature rise

DEFINITION ACCORDING TO IEC 60076-2

Normal ambient temperature limits is: -25°C and +40°C

Considering θa=40°C:
- Top oil rise: 60 K
- Average winding rise (by resistance measurement)
for transformers identified as ON.. or OF.. 65 K
- Hot spot rise : ∆θhr = H × gr =78 K

The effect of altitude

If the installation site is more than 1000m above sea-level but the factory is not, then the
allowable temperature rise during the test in the factory shall be reduced as follows:
For a naturally cooled transformer (..AN) the limit of average temperature rise shall be
reduced by 1 K for every interval of 400 m by which the installation altitude exceeds 1000
m.
For a forced cooled transformer (..AF) the reduced shall be 1 K for every 250m.

© ABB
| Slide 105
Power Transformers
IEC 60076 – 2 – Temperature rise

Thermal model of a transformer (according IEC)

Wdg
Amb temp Oil temperature rise
Hot spot

60K
65K
78K
+40°C +100°C +105°C +118°C

© ABB
Month DD, YYYY | Slide 106
 Temperature rise
Specific case with θa equal to 50°C

- Top oil rise: 50 K

- Average winding rise (by resistance measurement)
for transformers identified as ON.. or OF.. 55 K

- Hot spot rise : ∆θhr = H × gr =68 K

© ABB
| Slide 107
Power Transformers
IEC 60076 - 2: temperature rise

Top oil H x gr
Relative position

Winding hot spot

gr
Av winding

temperature

© ABB
Month DD, YYYY | Slide 108
 Thermal Diagram

Hot spot rise:

∆θhr = H × gr

H=1.3 for power transformer

© ABB
| Slide 109
Power Transformers
IEC 60076 – 2 – Temperature Rise

Why temperatures and hot spot are so important?

 The knowledge of transformer temperatures permit an

exact calculation of maximum power
 Transformer life depends by the health of insulation parts
 the higher the temperature, the more the mechanical
characteristics of insulation parts degrade

According IEC Hot Spot temperature is the parameter to use

the for calculation of loss of life and for the estimation of the
remaining life

© ABB
Month DD, YYYY | Slide 110
 Relative ageing rate
Aging of the insulating system in the transformer
IEC 60076-7

© ABB
| Slide 111
 Relative ageing rate

For non-thermally upgrade paper

(105 98 )
Es:   105C
h -> V 2 6
 2.24

For thermally upgrade paper

where θh is hot-spot temperature in °C

© ABB
| Slide 112
 Loss-of-life calculation

Where:
Vn is the relative ageing rate during interval n
tn is the nth time interval
n is the number of each time interval
N is the total number of intervals during the period considered

© ABB
| Slide 113
 International Standard
60076-3

© ABB
| Slide 114
 International Standard
Definitions
 Electrical characteristics
 Highest voltage for equipment
Definition according to IEC 60076-3

Highest voltage for equipment (Um)

applicable to a transformer winding is the highest r.m.s phase-to-
phase voltage in a three-phase system for which a transformer
winding is designed in respect of its insulation.
Standardized values of Um are given in the Standard.
The value to be used for a transformer winding is the one equal to,
or nearest above, the rated value of the winding

© ABB
| Slide 115
 Transformers Fundamentals
Requirements and tests for different windings

100
LI
100
SI
50 50
1000-2000 s
© ABB
0 0
| Slide 116

1,2 50 t s 100-200 s t s
 International Standard
Rated withstand voltage

© ABB
| Slide 117
 International Standard
Recommended clearances

© ABB
| Slide 118
 International Standard
Temperature classes

Insulation system
Part Max over temperature
temperature [°C]

105 (A) 60
Windings (over 120 (E) 75
temperature 130 (B) 80
measured by 155 (F) 100
resistance variation 180 (H) 125
method) 200 135
220 150

The temperature never

Core, metallic parts has to reach values that
can damage the core
© ABB
| Slide 119
 Transformers: Testing
© ABB
Month DD, YYYY | Slide 120
 Power Transformer Training
Part 3: Testing

 Routine/Type Tests

 Special Tests

 Oil dielectric strenght

 Advanced diagnostic testing

(Advanced oil analysis, thermography, SFRA, DFR)

© ABB
| Slide 121
 Transformer Test
Test Room Area

Transformer in testing room

© ABB
| Slide 122
 Transformer Test
Routine/Type Tests

Routine Tests: Type Test:

- Measurement of winding -Temperature-Rise test (60076-
resistance (60076-1 10.2) 2)
- Measurement of voltage ratio - Dielectric type test (60076-3)
and check of phase
displacement (60076-1 10.3)
- Measurement of short-circuit
impedance and load losses
(60076-1 10.4)
- Measurement of no-load losses
and current (60076-1 10.5)
- Dielectric routine test (60076-3)
- Tests on on-load tap-changers
(60076-1 10.8)

© ABB
| Slide 123
 Transformer Test
Special Tests

Special tests:
- Dielectric special tests (60076-3)
- Determination of capacitances windings-to-earth and between windings (60076-1 10.1.3 b)
- Determination of transient voltage transfer characteristic (60076 10.1.3 c)
- Measurement of zero-sequence impedance (s) on three-phase transformers (60076-1 10.7)
- Short-circuit withstand level (60076-5)
- Determination of sound level (60551)
- Measurement of the harmonics of the no-load current (60076-1 10.6)
- Measurement of the power taken by the fan and oil pump motors (60076-1 10.1.3 h)
- Measurement of insulation resistance to earth of the windings and/or measurement of
dissipation factor of the insulation system capacitances (60076-1 10.1.3 i)

© ABB
| Slide 124
© ABB Group
September 23, 2016 | Slide 124
 Transformer oil test
Oil dielectric strength
Sphere dimensions
D=25 mm d=2,5 mm

IEC 422 fixes recommended values for the

dielectric strength according to the insulation
class:
> 50 kV V <170kV
> 30 kV V <72,5kV

Other oil test:

- water content(< 30-40 ppm)
- gas-chromatographic analysis

© ABB
| Slide 125
 Transformer Test
Advanced Diagnostic Testing
 Routine tests
 Electrical measurements
 Insulation resistance of the windings
 Insulation resistance between core/core clamps/tank
 Voltage ratio
 Short circuit inductance
 Ohmic resistance of the windings
 Capacitance and dissipation factor of Windings and Bushings

 Oil analysis
 DGA
 Dilelectric stenght
 Humidity
 Neutralisation number
 Color and aspect
 Tang delta
 Interface tension
 PCB content
© ABB

© ABB Group | Slide 126

S b 23 2016 |
 Transformer Test
Advanced Diagnostic Testing – Advanced Oil Analysis
 Oil
 Metal in Oil Testing
 Particle count
 Oxidation Inhibitor Testing
 Furanic Analysis
 Corrosive Sulfide

 Paper
 Degree of Polymerization Testing

© ABB
| Slide 127
 Transformer Test
Advanced Diagnostic Testing
 Infrared Thermography

 Field Induced Testing (with mobile laboratory)

 Applied Voltage Test (with mobile laboratory)
 Partial discharges measurement (with mobile laboratory)
 Impulse Test (with mobile laboratory)
 Sweep frequency response analisys (SFRA)
 Frequency Dielectric Spectroscopy (DFR)
© ABB
| Slide 128
 Transformer Test
Advanced Diagnostic Testing - SFRA
 Sweep Frequency
Response Analysis
(SFRA)

© ABB
| Slide 129
 Transformer Test
Advanced Diagnostic Testing - SFRA
Typical results: FRA frequency ranges

Core influence

Winding influence

Leads, grounding influence

© ABB
| Slide 130
 Transformer Test
Advanced Diagnostic Testing - DFR

 Dielectric Frequency Response (DFR)

Purpose of measurement
 Diagnostic test of
insulation system
 Moisture content
 Oil Conductivity Uncertain area
Big Errors at Low
Temperatures

© ABB
| Slide 131
 Transformer Test
Advanced Diagnostic Testing - DFR
 Dielectric Frequency Response (DFR)

 Extension of the standard power frequency C-Tan() measurements

 Measurement of capacitance and loss as a function of frequency
 Typically from milli Hz to kilo Hz.
 Used to assess the insulation status.

Real part = Capacitance Tan() =Imag./Real part

Imaginary part = Loss

50 Hz 50 Hz
© ABB
| Slide 132
© ABB Group
September 23, 2016 | Slide 132
 On-line Monitoring

 Increase of uptime of the transformers

 Early detection of hidden defects
 Keep “sick” unit in service until repair / replace
 Optimize maintenance
 Plan maintenance actions
 Priorities for maintenance actions
 Optimized loading
 Overload under controlled conditions
 Ageing rate, moisture, temperature
 Plan for investments
 Repair
 Replacement
© ABB
| Slide 133
 On line monitoring - TEC
 TEC: Transformer with Electronic Control

 Enhanced cooling control

 Data recording
 The transformer is prepared for future demands

The transformer can also be more loaded as:

 Remote connection
 Overload forecasts
 Calculates overloaded capacity
 economical aspect of the overloading due to
the extra ageing of the insulation
 The enhanced cooling control can starts coolers
earlier

© ABB
| Slide 134
On line monitoring TEC - Main screen
Easy overview of transformer status

© ABB
| Slide 135
 On line monitoring - TEC - Communication

© ABB
| Slide 136
© ABB Group
September 23, 2016 | Slide 136
On line monitoring – TEC - Transformer Sensors
Air (ambient) Temperature
TAir Two thermometers, placement:
•One in the sun
•One in the shadow not to close to the tank

Traditional Top Oil Temperature

Should be used as a back-up for
the cooling control

TEC Top Oil Temperature

Placed as the traditional top
oil thermometer

CT Cooler Group Feedback

T Top Oil One signal from each cooler
group needed
Current Transducer
Placed on the lead from TEC Bottom Oil Temperature
the current transformer. Cabinet The thermometer must be
(Normally placed in the placed to represent the oil
transformer cabinet.) T Bottom Oil temperature entering the
winding

Moisture Detector Hydrogen Detector

Placed according to the Placed according to the
manufacturer. manufacturer
(Vaisala HMP228 with
© ABB
| Slide 137 moisture content in ppm)
On-line Monitoring
Advanced Monitoring Sensors Moisture sensors

4-20mA outlet for

moisture content and
temperature in oil.
Moisture content in
ppm.

Sensor part

AQUAOIL 300 from GE

Valve

Connection to be
welded in adapter

HMP 228 from Vaisala

© ABB
| Slide 138
MMT 318 from Vaisala
Advanced Monitoring Sensors
Sensors – Dissolved gases
Hydran from GE Hydrogen sensor

Installation in cooling system Installation on main tank

© ABB
| Slide 139
On-line Monitoring
Hydran Gas Detection
• Monitors the gas dissolved in the transformer oil
• Sensor consists of a permeation cell, dissolved gas diffuse into a gas
collection space.
• The total amount of gases in collection space gives Hydran reading

H201Ti
Gases Detected Penetrating Sensor
to collection space
H2 100 %
CO 15 %
C2H2 6%
C2H4 1.8 %

Hydran reading = H2 + 0.15 . CO + 0.06 . C2H2 + 0.018 . C2H4

© ABB
| Slide 140
 On-line Monitoring
Combined Hydrogen detectors ABB

HydroTEC 1001+
Composite Dissolved Gas
and Moisture Sensor

Combined Hydrogen detectors GE

Hydran M2 With moisture measurement
Gases Detected Penetrating Sensor
to collection space

H2 100 %
CO 18 %
C2H2 8%
C2H4 1.5 %

Hydran reading = H2 + 0.18 . CO + 0.08 . C2H2 + 0.015 . C2H4

© ABB
| Slide 141
On-line Monitoring

Sensors – ex. bushing monitoring (C, pf/tan)

© ABB
| Slide 142
On-line Monitoring
General Electric IDD (Intelligent Diagnostic Device)
for bushings monitoring

© ABB
| Slide 143
 On-line monitoring system of the oil

© ABB
| Slide 144
 On-line monitoring system of the oil
 On site monitoring of the oil: Energy Support ON LINE DGA

© ABB
| Slide 145
 On-line monitoring system of the oil
 On site monitoring of the oil: ON LINE DGA
On-line monitoring of 11 gas
 Hydrogen H2
 Methane CH4
 Ethane C2H6
 Ethylene C2H4
 Acetylene C2H2
 Propane C3H8
 Propene C3H6
 Carbon dioxide CO2
 Carbon monoxide CO
 Oxygen O2
Maximum 4 transformers at the same
 Nitrogen N2 time

© ABB
| Slide 146
 On-line monitoring system of the oil
 on line DGA with SERVERON Model TM3

On-line monitoring of 3 gases

 Methane CH4
 Ethylene C2H4
 Acetylene C2H2

Monitoring also of
 Moisture in oil
 Oil temperature
 Ambient temperature
 Ambient temperature in function of the load

Correlates 3 fault gases, moisture in oil, oil temperature and ambient temperature to
transformer load.
The combination of on-line DGA data automatically populating the Duval Triangle
provides insight into fault diagnosis

© ABB
| Slide 147
 On-line monitoring system of the oil
 on line DGA with SERVERON Model TM8
On line monitoring of 8 gases
 Hydrogen H2
 Oxygen O2
 Methane CH4
 Carbon monoxide CO
 Carbon dioxide CO2
 Ethylene C2H4
 Ethane C2H6
 Acetylene C2H2
 Nitrogen N2

Monitoring also of
 Moisture in oil
 Oil temperature
 Ambient temperature
 Ambient temperature in function of the load

Correlates all 8 fault gases, moisture in oil, oil temperature and ambient temperature to transformer
load
The model TM8 data supports all IEEE and IEC diagnostic tools for rapid warning and diagnosis of
developing faults
© ABB
| Slide 148
 On-line monitoring system of the oil
 on line DGA with Transfix
On line monitoring of 9
gases
 Oxigen O2
 Nitrogen N2
 Hydrogen H2
 Methane CH4
 Carbon monoxide CO
 Carbon dioxide CO2
 Ethylene C2H4
 Ethane C2H6
 Acetylene C2H2

Monitoring also of
 Moisture in oil

© ABB
| Slide 149
 On-line monitoring system of the oil
 on line DGA with TransportX
On line monitoring of 8
gases
 Hydrogen H2
 Methane CH4
 Carbon monoxide CO
 Carbon dioxide CO2
 Ethylene C2H4
 Ethane C2H6
 Acetylene C2H2

Monitoring also of
 Moisture in oil

© ABB
| Slide 150
 On-line monitoring system of the oil
 on line DGA with Morgan Shaffer Calisto

Calisto Calisto2 Calisto5 Calisto9

Hydrogen (H2) X X X X
Carbon monoxide (CO) X X X
Methane (CH4) X X
Acetylene (C2H2) X X
Ethylene (C2H4) X X
Ethane (C2H6) X
Carbon dioxide (CO2) X
Oxygen (O2) X
Nitrogen (N2) X
Moisture X X X X

© ABB
| Slide 151
 On-line monitoring system of the oil
 on line DGA with MTE Hydrocal
Hydrocal 1001 Hydrocal 1002 Hydrocal 1003 Hydrocal 1005

Hydrocal 1008
1001 1002 1003 1005 1008
Hydrogen (H2) X X X X X
Carbon monoxide (CO) X X X X
Methane (CH4) X
Acetylene (C2H2) X X
Ethylene (C2H4) X X
Ethane (C2H6) X
Carbon dioxide (CO2) X
Oxygen (O2)
Nitrogen (N2)
Moisture X X X

© ABB
| Slide 152
On-line Monitoring
Fiber optic measurement
(most common FISO and NEOPTIX):
For measurement of
• Winding temperature
• Oil temperature
• Core temperature
• Ambient temperature
• Oil and water (for OFWF) temperature

© ABB
| Slide 153
Local Business Unit Transformers Italy

Power Transformer Training

VARIOUS
 Power Transformer Training
Part 6: Various
 Packing-Shipping-Site Assembly

 Transformer energisation

 Start-up procedure

 Maintenance: general rules

 Maintenance: accessories and insulating oil

 Insulation material: type and properties

 Parallel operation

 Efficiency

 Inrush current

 Short circuit currents

 Transformer overvoltages

 Noise level of transformers

© ABB
| Slide 155
 Packing – Shipping – Site Assembly

SEE « ERECTION INSTRUCTIONS MANUAL

© ABB
| Slide 156
 Transformer Energization

• examination of correct execution assembly and connections

• examination of efficiency accessories and protection circuits
• control tap-changer functionality
• eventual repetition test
• oil dielectric rigidity
• voltage ratio/ phase displacement
• insulation resistance
• no-load supply( secondary open)
• on-load operating

© ABB
| Slide 157
 Start Up Procedure

© ABB
| Slide 158
 Maintenance
General rules

Depending on the power and the work load of the

transformers, inspection periods can be daily or
weekly.

The purpose of periodical inspections is to verify that

nothing abnormal has arisen with regards to:

• noise
• leakage
• level and temperature of dielectric
• operation of the cooling

© ABB
| Slide 159
 Maintenance
General rules

During the first month of activity, frequent checks must

be made in order to establish a program of systematic
inspection according to the particular conditions of
operation.

An example of preventive maintenance program

should be (under average operating conditions):

Type of check / Insulating Stars of Cleaning of Operation of Dielectric

Frequency of check Liquid level Air drier bushings Buchholz relay strength

every week X X
every month X
every quarter X
every year X

© ABB
| Slide 160
 Maintenance
Accessories and insulating oil

Accessories Every two years, the electrical equipment fitted on the transformer (Buchholz relay,
level gauges, temperature indicators, etc.) and the electrical equipment fitted inside
the control cabinet, have to be inspected and checked by skilled technicians.

If the transformer works on continuous service, every two years it is suitable to take
Insulating off a sample of oil from the top at the bottom of the tank and carry out a dielectric test.
Oil In case of an insufficient result ---> re-check and filter the oil

Every eight-ten years it is necessary to make a more complete chemical test to

establish:
-the percentage of deposit which shall not exceed 0,1%
-the sulphur content which shall not exceed 0,25%
-the absence of inorganic acids and alkalis
-the absence of asphalt and resins
-the percentage of organic acid, expressed as a normality, which shall not exceed 1.
In case of an insufficient result ---> replace the oil

© ABB
| Slide 161
 Insulation Material
Properties

A good insulation material must have the following properties:

1. High dielectric strength

2. Good mechanical properties
3. Long lifetime at operating temperature
4. Easily workable

The insulation system is an aggregate of paper,

pressboard (cellulose) and mineral oil

© ABB
| Slide 162
 Insulation Material
Solid type

Cellulose materials
Cellulose insulation is made of
slow growing types of wood,
having long fibres.
Long fibres give long life-time,
and high density gives high
dielectric strength.

The cellulose fiber is built up from a

large number of ring-shaped
molecules.
In order to utilize the dielectric
insulating characteristic of cellulose
materials, it must be impregnated with
transformer oil.

© ABB
| Slide 163
 Insulation Material
Solid type

Other important insulation materials are:

- Wood:
often used for support
- Porcelain:
mainly used for bushings in oil-immersed
transformers
- Solid synthetic insulation materials:
in oil transformers can be used as insulation
barriers, spacers and duct sticks

© ABB
| Slide 164
 Insulation Material
Fluid type

The most important functions of fluid insulation are:

 Insulation
 Cooling
Another function is to carry information about the condition of the active part inside
the transformer

Types of fluid insulation materials:

• Mineral oil: is the main insulation medium
• Dimethyl Silicone • These fluids are reserved for special applications
• Synthetic Ester • They are more expensive than mineral oil
• Synthetic Hydrocarbon • They are used mainly for improve fire safety and
• Agricoltural Ester environmental impact

© ABB
| Slide 165
 Transformer Oil
Types and features

Mineral Silicon Ester

origin hydrocarbures silicon sintetic

Norms IEC296 IEC836
density 0.8-0.9 1 1 kg/dm3
fire 145 350 350 °C
dielect. Strength 70 50 50 kV (2.5mm)
Biodegradability no no 80%
Cost 100% 600% 1000%
Miscibility with mineral no no

© ABB
| Slide 166
 Transformer Oil
Other features

© ABB
| Slide 167
 Transformer Operation
Parallel Operation

• Only transformers having the same phase displacement between primary and secondary
voltage can be operate in parallel.

• Poles with the same polarity on HV and LV side shall be connected in parallel

• Transformers should have approximately the same voltage ratio

• The short-circuit impedance voltage should be the same (within ±10%)

• The power rating of the transformers should not deviate more than 1:3

• Tap changers should have tap position giving voltage ratios as close as possible

More details are in IEC 60076-8

© ABB
| Slide 168
 Transformers Fundamentals
Efficiency

output power output power

η 
input power output power  losses

Where:

• P0 is the no load losses (kW) at rated voltage

• PL is the load losses (kW) at rated current
• P2 is the active power (kW) supplied to the load
• n is the relative degree of loading.
At rated current n=1.

© ABB
| Slide 169
 Transformer Over-currents
Inrush current

Flux wave

Typical inrush current waveform Case of maximum inrush current

© ABB
| Slide 170
 Transformer Over-currents
Short circuit currents

The electromagnetic strenghts try

to increase the volume of the
magnetic flux.
•The internal winding try to
reduce its radius
•The external winding try to
increase its radius
•Heights tend to decrease

© ABB
| Slide 171
 Transformer Over-currents
Short circuit currents

t0
R L
v(t) ~ i(t)
v(t )  Vm sin( t   )

2 V   t   L
R
i cc ( t )   sin (  t     )  sin (   ) e  tan  
L
;
Z cc   R

i
R
2V  t

icc(t)
corrente unidirezionale sin (   ) e L
Z cc

© ABB
| Slide 172
 Short circuit currents
Limit cases

2 V   t   L
R
i cc ( t )   sin (  t     )  sin (    ) e L
 ; tan  
Z cc   R

-φ= 0

-φ=π/2

© ABB

© ABB Group
| Slide 173

S b 23 2016 |
 Short Circuite Forces
Basic concepts

F= L* I x B where: B is leakage flux density vector

I is current vector
L is winding length

Fleming’s rule: It’s useful for individualize easily the direction of the force

I
B
I medio

B
indice

F
F
pollice
pollice

© ABB
| Slide 174
 Short Circuit Forces
Calculation of force components

 Radial forces: RINN

Fext
Finn Hw

Wext
Winn
The average hoop stress in the winding is:

where At is cross sectional area of turn

 Buckling phenomena

© ABB
| Slide 175
 Short Circuit Forces
Calculation of force components

Axial forces: Rated power per limb in kVA

(uniform ampere-turn distribution Fa Fa

in winding with equal heights)

Hw

Wext

Winnn

Fa Fa

Axial force distribution

The IEC 60076-5 describe short-circuit testing procedure

© ABB
| Slide 176
 Transformer Over-voltages
Classification

Internal Over-voltages  Within the power system

Origin
External Over-voltages Atmospheric phenomena

Temporary over-voltages (TOV)

Duration  from less than one second up to several hours

Transient over-voltages
 from nanosecond up to a few milliseconds

© ABB
| Slide 177
 Transformer Over-voltages
Limitations of Over-voltages

Temporary Over-voltages:
- TOV due Earth-Fault
- Load rejection over-voltages
- TOV due to Ferro-resonance

Transient Over-voltages:
The ability of a transformer to withstand transient over-voltages is characterized by its Basic Impulse Level
(BIL) (that corresponds to the peak value of the standard test voltage impulse).

Devices to limit the transient over-voltages:

- non-linear resistor-type surge arresters with series gaps
- metal-oxide surge arresters without gaps
- sparks gaps, that is an open air gap between two terminals

© ABB
| Slide 178
 Noise level of transformer

Core  magnetive and magnetostrictive forces

Main sources of noise Windings  electromagnetic forces
Cooling equipment

where:

Sound pressure level: p0 is reference level =20μPa =0dB;

p is the sound pressure measured by a
microphone

where:

Sound power level: S0 is reference area 1m2;

S is area of measurement surface

© ABB
| Slide 179
 Transformers: ABB approach
© ABB
Month DD, YYYY | Slide 180
ABB Transformers
A long pioneering story

The combined experience of 700

years of transformers
manufacturing

 ASEA
 BBC
 GE (USA)
 Westinghouse
 Ansaldo/ItalTrafo/IEL/OEL/
OTE
 National Industries
 Strömberg

 and more ....

© ABB
Month DD, Year | Slide 181
ABB Transformers
Technology
Rated voltage
Power Transformers

171 kV Small Power Transformers

72.5 kV Dry Type

CORE TYPE

Liquid filled
distribution
36 kV

SHELL TYPE

10 MVA 40 MVA 63 MVA Rated power

Four common technology platforms guaranteeing highest quality

© ABB
Month DD, Year | Slide 182
ABB Transformers – Global Capacity
55 Transformer Factories Locations

© ABB
© ABB

Group |
Month DD, Year | Slide 183
ABB Transformers – PG SPT
Where we are

Finland – Vaasa

Switzerland - Geneva

Turkey –
USA – South Boston China – Zhongshan
Istanbul
& Datong
USA – Crystal Springs Italy – Monselice
Vietnam - Hanoi
Colombia - Pereira
Vadodara– India
Thailand -
Bangkok

© ABB
Month DD, Year | Slide 184

|
ABB Small Power Transformers
Concepts

PRODUCT EXCELLENCE PROCESS EXCELLENCE

means: means:
 Reliability  Modular design
 Proven technology  Standardized design tools
 Demonstrated short  High throughput production
Circuit strength lines
 Latest production technologies

UNIQUENESS ON THE MARKET means:

 Dedicated technology & production lines, unlike some competitors
that often scale from power transformers down to distribution (→
heavy concept & design) or scale from distribution transformers to
power (→ reliability & testing problems)
 )

ABB requires a common design and manufacturing system,

called Global Product Platform, to cover this range of products
© ABB
Month DD, Year | Slide 185
SPT Global Product Platform
Design and Optimization

Transformers design and optimization result from:

Customer specifications

$
Transformer design
TOC
minimu Losses
m Trafo Eva
cost l.
TOC
k
W
Costs

Optimizing the transformers is a complex task

© ABB
Month DD, Year | Slide 186
SPT Global Product Platform
Engineering Tools: COMMON DESIGN SYSTEM

 Single software platform for electrical and mechanical design

 3D design system

Input
parameters

Parameter
Parameter

list
Mapping

Drawing
BOM

Verification tools INPUT

DXF DRAWING FILES
WinTran UCM C.A.M. ERP interface
FOR S.A.W.M.
TrACE, ACE

© ABB
Month DD, Year | Slide 187

|
SPT Global Product Platform
Engineering Tools: CDSe Design Tool

Input
Power and Voltage
parameters
Design
Core, windings,
conductors, insulation

Calculate
No Load Losses
Load Losses
SC Impedance
Winding Temperatures
Radial SC forces
Tank Dimensions and
weights

© ABB
Month DD, Year | Slide 188
SPT Global Product Platform
Engineering Tools: Verification

Computer modelling
Transient analysis (wintran):
- Voltage distribution
- Dielectric stress calculation
Short circuit:
- Flux distribution
- Axial/radial short circuit
forces and stresses
Noise level
Load losses

© ABB
Month DD, Year | Slide 189
SPT Global Product Platform
Engineering Tools: Mechanical Design

CDSm is a is a design system based on Pro-E 3D CAD and a

proprietary command interpreter called Rule Engine

It manages BOM, drawings, and information contained in other

files (mainly Excel)

It manages passing information to the ERP system (to be locally

adapted)

Parameter
Mapping
cds.XML FILE

© ABB
Month DD, Year | Slide 190

|
SPT Global Product Platform
Engineering Tools: Mechanical Design

Core and Active Part

Windings

Tank
Externals

Cover

© ABB
Month DD, Year | Slide 191
SPT Global Product Platform
Engineering Tools: Simulations

Simulations make possible an accurate

knowledge of the final overall transformer
performances about electromagnetic
mechanical and thermal phenomena

Skilled specialists, through computer aided

engineering and simulation-optimization
techniques, support engineering
product development

ABB has proprietary and commercial

2D/3D simulation tools for particular
ABB
designs and optimized custom Simulation
Toolbox
solutions

© ABB
Month DD, Year | Slide 192
SPT Global Product Platform
Engineering Tools: Simulations

 All phenomena in a transformer can be analyzed through simulations

 The transformer final performance can be accurately determined during
design stage
MECHANICS
DIELECTRICS

THERMAL
MAGNETICS

THERMO-
FLUIDODYNAMICS

© ABB
Month DD, Year | Slide 193

|
SPT Global Product Platform
Test Failure management

Test failures are stored in a global database

 For each test failure a local investigation is performed. If
needed BU experts are involved
 Every three months test failures are discussed between all
technical managers, PG global technology managers and
other BU experts

Goal of this meetings is to avoid the repeteability of

dangerous situation and to share knowledge between
factories

© ABB
Month DD, Year | Slide 194
Power Transformer Production
ABB Monselice – process execution

Preliminary
Tender is PM check all
planning of
included in the documents
most probable
resources and PO and shedules
KOM OA
production
order list KO meeting
scheduling

Development of
Customer
electrical design Electrical Active Part Customer
Active Part drawings
Design development
Design drawings
development design
Order of critical Review Review
Accessories review

Production
Windings
drawings Production
Submission of development production
Customer Drawings
drawings to Materials orders
customer Approval design
Order of active
part components review Core production

Oil filling and Dismantling and

Active part Active part Active part
manufacturing treatment tanking
preparation for FAT preparation for
FAT shipment

© ABB
Month DD, YYYY | Slide 196
Power Transformer Production
Simplified Process execution

© ABB
Month DD, YYYY | Slide 197
Power Transformers
LI and AC

© ABB
Month DD, YYYY | Slide 198