Guide Transformer Spec Issues
Guide Transformer Spec Issues
Guide Transformer Spec Issues
Specification Issues
www.epecentre.ac.nz
Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
DISCLAIMER
This document was prepared by the Electric Power Engineering Centre (EPECentre) at the University of Canterbury
in Christchurch, New Zealand. The content included in this document is based on a power transformer specification
workshop held in July 2007. The EPECentre takes no responsibility for damages or other liability whatsoever from the
use of this document. This includes any consequential damages resulting from interpretation of material.
Reviewed & edited by: Wade G. Enright BE(Hons), PhD, MIPENZ, MCIGRE
Produced & co-edited by: Joseph D. Lawrence BE, MEM, PMP, MPMINZ, MNZIM
Acknowledgements: Sponsors and participants of the EPECentre Power Transformer Conference 2007, Workshop:
Guide to Transformer Technical Specification, 3 July 2007, University of Canterbury, Christchurch, New Zealand
www.epecentre.ac.nz
© 2008 Electric Power Engineering Centre, University of Canterbury, Christchurch, New Zealand. All rights reserved,
no part of this publication may be reproduced or circulated without written permission from the Publisher.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
CONTENTS
FOREWORD ...................................................................................................................................3
INTRODUCTION .............................................................................................................................4
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
FOREWORD
Wade Enright
Dr. Wade G. Enright
August 2007
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
INTRODUCTION
During 2006 and 2007 to date, an unusually high number of requests have arrived for Technical Specification
reviews, both in New Zealand and Australia.
More than six power transformer Technical Specifications for machines over 200MVA in New Zealand alone.
The challenges of a significantly loaded electrical network reliant on service aged equipment: refurbish and/or
replace.
The challenges of increasing load and “new” generation types e.g. wind turbines.
The commodity price issues (copper, electrical steel, structural steel and oil).
The changes from well established European factories to new South East Asian manufacturing sites.
The need for form relationships with new people (new manufacturer personnel, new employers/clients).
It may be that power transformer Technical Specifications has become cumbersome, out of focus and needs a
“spring clean”.
Published Documents
Published documents that contain guidelines specific to power transformer Technical Specification:
CIGRE Working Group 12.15., “Guide for Customers Specifications for Transformers 100MVA and 123kV and
above”, Technical Brochure 156, April 2000.
Heathcote, M.J., “The J&P Transformer Book”, Twelfth Edition, Newnes, 1998, ISBN 07506 1158 8.
ABB, “Testing of Power Transformers, Routine Tests, Type Tests and Special Tests”, 1st Edition, ABB Business
Area Power Transformers, 2003, ISBN 3 00 010400 3.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
To formally and fairly communicate exactly what you want the Contractor to deliver.
To be able to accurately offer services and products which provide a satisfactory solution
(technical/commercial) to an Employer (Client); while remaining a long-term profitable
business.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
AS60076.4 – 2006 “Power Transformers – Guide to What is the plan if the Partial Discharge fails?
the lightning impulse and switching impulse testing –
power transformers and reactors.” The Partial Discharge test initially failed but has now
passed, how does this make you feel?
AS2374.5 - 1982 “Power Transformers – Ability to
withstand short-circuit.”
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
e) Indoor substation
Buchholz relay.
Pressure relief.
Vented cable box.
Generator Circuit Breaker.
Bushing monitoring.
Conservator tank isolation.
Choice of oil.
Temperature indicators.
Fire protection (foam).
General Notes:
All scenarios require risk assessment.
Consider use of polymer bushing i.e. GSA, etc.
All scenarios depend on transformer size and blast
wall requirements.
Oil containment bunding with fire-traps/ drainage.
Situational considerations – not one answer for all
remote transformers or all hydro, etc.
All situations consider:
NFPA850 Guidelines – but these are only
guidelines, but you must go through and specify.
Blast walls for specified separation.
Bunding w/ drainage to suffocate fire.
Shutter valves on conservators.
Differential Protection.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
Provide alternatives.
Assurance that the design will work and meet
PART 2.THE DETAILED DESIGN specifications.
REVIEW Provides assurance that the employer is getting
what we want.
Facilitates forum for improvements in design that
may impact on overall cost and performance.
When the Detailed Design Review process is
Gain understanding of the design so we can gain
specified: understanding of test results.
Find any steps in design/manufacture that you
want to witness to help with maintenance.
a) Employers (Clients), what Detailed Design
Review (DDR) outputs do you require and why?
b) Contractors (suppliers), what are the key matters
Using knowledge of supplier to tailor client
requirements. that will influence the power transformer detailed
Adding value to project. design that you need the Employer (Client) to
clarify?
Specifically reviewing: component mounting,
footprints, weights, shape, oil volumes etc. Ensuring spec following best practice.
Reconfirmation of 'no surprises' / confirmation Possible provision of future on-line monitoring
that supplier has the ability to deliver. equipment.
Compatibility with existing spares / stock, inter- What is important to client i.e. on time, cost, etc?
compatibility with existing network.
Confirmation of spec / deviations.
Key scope requirements.
QA (Quality Assurance) requirements.
Fit for purpose.
Drawing, documentation, manuals, maintenance
Delivery. procedures.
Inspection process. Required specs.
Transport / shipping to site. Seismic requirements.
Site constraints. Weight - gross, transport.
Performance criteria. Dimensions - centre of gravity.
Cooling plus interlock systems. Terminations.
Material listing. Specification does not cover all details. Need
DDR these details, Allows agreement on these
Acceptance tests.
details.
Type tests / compliance. No DDR for standard transformers only one
off/New Designs.
Special tests.
Also discussed customer acceptance
Material quality. Clarification of:
Out of date standards included in spec.
Review of mechanical design.
Standard Designs i.e. 6MVA spec but a
Review of loss calculations. 7.5MVA standard – cheaper, faster, and
easier.
Scope of DDR and timing of review at supplier. Component specification – e.g. bushings,
Compare DDR outputs to specification clauses. colour, tap changer type – This may effect
delivery and cost.
Special transformers need proper DDR. Transport issues.
Report on basis of IEC and CIGRE DDR guide Paint colour.
documents. Factors relating to delivery and cost.
Result is confidence in the transformer design.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
General Notes:
Should a detailed spec be required? How about the
customer saying we need a transformer to fill this
space, these are the connections, go to it. However,
still a lot of things need to be known. Different
tolerances are not always required, overbuilding, etc.
It’s about relationship/confidence in supplier. QA
systems, review, etc. should be done before
specifications i.e. due diligence.
Standardisation of one set of designs does not
always work, as component costs may change
meaning the set design is no longer the most
economical.
Where is the innovation coming from? Suppliers or
Clients? Probably a combination of both. Clients
drive adoption of certain items e.g. condition
monitoring. Suppliers drive changes in winding types,
materials, etc.
In general, this is a very important process that is
important for both parties. It aids clarification and
understanding of how to proceed with design
(contractor) and provides a certain level of
optimisation for the employer (client) i.e. relationship
building.
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
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Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
c) Why are on-load tap changers being fitted to e) When transformers over 150MVA are specified,
generator step-up transformers and what are the how should they be livened if the high voltage
implications of increasing tapping ranges and network must be used? What are some
decreasing step sizes? experiences with such livening?
Insurance policy. Point on wave switching.
Guarantees and flexibility? 480MVA back livening, audible complaint from
other transformer for 10– 15 minutes.
Transformer design.
Pre-Insertion resistors.
Old school, conservative.
Asset owner compliance.
More voltage regulation required. f) What are the key acceptance criteria that will
Near load centres. allow an Employer (Client) and Contractor
Increase tap range: extreme ends of tap settings (Supplier) to close-out a project?
are not used. Setting of maintenance procedures.
Totally useless offload sufficient. Drawings.
More leads and more introduced points of
potential failure. Documentation.
EGR (Electricity Governance Rules) Defects.
requirements impact on generators ability to
support/import reactive power is severe. Warranty, commercial bonds, etc.
Tap changers are not needed on generator
Successful livening.
transformers with an AVR (Automatic Voltage
Regulator). Handover of drawings, manuals, test certificates,
etc.
d) Is single-point earthing of core, frames, and tanks Clear communication and well defined procedure
needed.
a good approach? What happens when the single
Define in contract.
point earthing fails? Pass site acceptance test.
Good idea! Cost trade-off on insulation maybe.
Agreed acceptance testing completed.
General Notes:
In service for specified period and handed over.
Single point earthing lives! Need better construction
On site install / commissioning completed and to withstand transport failures, lamination failures etc,
documentation complete. not necessarily insulation failure. Need better access
for repair, replacement.
Fence sitting: cost of coping with circulating
current vs. single point. On-Load Tap Changer (OLTC) - AVR might be all
Want device that is reliable regardless of design good, but if it has a problem, the OLTC provides
Choice of single point earthing or not is a trade good backup. But it may still not be needed as it
off between equipment costs and losses. The won't be in operation if AVR is out.
“best” will vary with circumstances.
May need OLTC to allow for future system
expansion/change. Lowers system reliability but
increases system flexibility. System planners should
consider this more. OLTC alters voltage seen by
generator, but AVR can withstand plus minus 5%
typically anyway (sometimes!).
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Electric Power Engineering Centre – Guide to Transformer Technical Specification Edition 1, August 2007
APPENDIX A
Page 13 of 94
Refurbishment & Repair of Power Transformers-
A review of current practices in New Zealand
Specific aspects
What could be done during refurbishment
Review of specifications
Repair of Power Transformers
- What could be done – An overview from the contractor
500 60 to 66%
300 30%
200 0%
2.000
The purchase price of transformers 1.800
has doubled in the last three years 1.600
Cost of repair likely to be 20-25% of 1.400
P r ic e In d e x
the cost of new transformer. 1.200 Pq/Po
Lead times for new transformers 1.000
exceeds 12 months 0.800
0.000
At least the complete winding of the Jan-04 Aug-04 Feb-05 Sep-05 Mar-06 Oct-06 Apr-07 Nov-07 Jun-08
faulted phase Month-Year
Minimises risk
APPENDIX B
Page 30 of 94
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
(θh-98)/6
V=2 92oC 0.5
98oC 1.0
104oC 2.0
110oC 4.0
yearly average hot spot 98oC
134oC 64
Temperature class;
Insulation class A E B F H
Operating temperature 105oC 120oC 125oC 145oC 220oC
Tuesday, August 21, 2007 Introduction Power Transformer 9
Temperature Identification
Hf x gradient
core
cooler
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
gradient
winding
Bottom oil
Mean oil
Average winding
Top oil
Hot spot
Hot spot factor is normally presented between
1.1 to 1.5 depending on winding design.
Tuesday, August 21, 2007 Introduction Power Transformer 10
Cooling Medium
INTERNAL COOLING MEDIUM
Besides the thermal absorption, the internal cooling medium
also functions as the insulation medium.
Class A;
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
Pump
Tuesday, August 21, 2007 Introduction Power Transformer 14
Class A Standard Temperature Limits
Pumped - Fully Directed oil flow cooling is the most effective solution
to fulfill those conservative temperature limit requirements for medium
& large power transformer.
The 50/100% for ONAN/ODAF cooling is the optimum combination
in the case of pumped, finned radiator & fan combination (external
cooling).
Directed cooling;
For pumped unit (OD), the Fully Directed windings with oil
Directed to the windings and through the windings is the most
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
overloading conditions.
The value of the gradient is that as the current increases, the
gradient rises by the power of 1.6 for Non-Directed cooling,
1.2 for natural flow Directed cooling and 2.0 for Fully
Directed pumped oil flow.
The gradient of a competitive unit of Non Directed cooling is
typically almost double the Fully Directed (OD) unit and ,if
one overloads, the gradient temperature increase can be quite
dramatic and limits overload capacity.
Tuesday, August 21, 2007 Introduction Power Transformer 19
Recommended Cooling Method
Directed cooling;
4. Fully Directed flow units can be made electrically stronger
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
than Non Directed flow units as the duct size on either side
of the winding can be significantly reduced (increased
strength per mm). In naturally cooled units ie ONAN and
ONAF, the duct normally need to be increased for cooling
considerations due to very low thermosyphonic oil flow.
5. It is the fact that the pumped – fully Directed flow unit will
eliminate the local overheated oil around the hot spot area.
This system is suitable for Hybrid design technology in
mobile transformer application or other compact transformer.
Tuesday, August 21, 2007 Introduction Power Transformer 20
Recommended Cooling Method
Directed cooling;
6. Due to it’s high cooling effectiveness, the Fully Directed flow
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
ON Cooling
1. Determined by thermosyphonic principle of Buoyancy effect.
2. Driven by winding heat due to losses (I2R + eddy losses) and
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
OD Cooling
1. Determined by thermo-hydrodynamic calculation at
equilibrium hydraulic pressure.
2. Driven by winding heat due to losses (I2R + eddy losses),
designed oil speed, pump capacity and cooling medium
properties (mass density, viscosity, specific heat capacity).
270 mm/s
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
180 mm/s
110 mm/s
OD design
Oil Directed
Twin Boosters
Insulation
weakening Gassing
Fully directed cooling with pump is the most suitable for medium & large
transformer. The directed cooling with no pump can be used for cost
effectivenes consideration on small/medium transformer.
Conductor paper ;
The cellulose paper should have Degree Polymerization min. 950.
Low partial discharge product shall be performanced at factory test;
=> 40 pC up to 120% Voltage for 30 minutes.
=> 75 pC up to 150% Voltage for 30 minutes.
=> to monitor the partial discharge at induced level, 1min.
FUTURE
FUTURE SOLUTIONS
SOLUTIONS ??
CALENDERED
KRAFT BOARD Angle Rings
and Caps
CALENDERED
KRAFT BOARD Support Washers
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
Gas Symbol
Before After unit in ppm/hour Typical
Hydrogen H2 < 0.8 10.13 ppm 1.27 <2
Oxygen O2 0.96 0.77 % -
Nitrogen N2 2.15 1.61 % -
Carbon monoxide CO 7.17 9.40 ppm 0.27 <2
Carbon dioxide CO2 122.32 205.78 ppm 10.43 < 11
Methane CH4 1.75 2.01 ppm 0.03 < 0.25
Acetylene C2H2 0.08 0.11 ppm - < 0.25
Ethylene C2H4 0.11 0.10 ppm - < 0.25
Ethane C2H6 0.12 0.11 ppm - < 0.25
Tuesday, August 21, 2007 Introduction Power Transformer 53
Future – Environmental Friendly Liquid
• Environmental liquid = Enviro-Temp FR3 by COOPER
• Inhibited oil = Nitro 10XT by NYNAS
Property – typical values Inhibited oil FR3
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
60
Water Absorption of Dielectric Fluids
Exposed to Ambient Air (1 of 2)
600
40
500
400
0
0 500 1000 1500 2000 2500 3000 3500 300
100
0
0 500 1000 1500 2000 2500 3000 3500
100% Saturation =
Exposure Time (hrs)
FR3, 1200 ppm
Mineral Oil, 80 ppm
70
D 1816 Dielectric Breakdown (kV)
60
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
50
40
30
10
0
0 100 200 300 400 500 600
APPENDIX C
Page 92 of 94
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