Siemens Energy Optimises Power Transformers With The Aid of 3D EM Simulation

CST SUCCESS STORY
Siemens Energy Optimises Power Transformers

with the Aid of 3D EM Simulation
Ronny Fritsche, Siemens AG Sector Energy T TR PN
Active Part Figure 1 Typical 40 MVA

High Voltage Bushing Siemens Transformer.
Low Voltage Bushing
Tap Charger
Tank
Conservator
Actuation of Tap Charger
Radiator
Finding customised solutions for any applications and specifications of transformers –

this is the task of Siemens Energy T TR PN. It is difficult to obtain off-the-shelf solutions
for furnace and converter transformers as well as transformers for High Voltage Direct
Current for ratings greater than 200 MVA. 3D EM Simulation with CST EM STUDIO®
(CST EMS) is a vital tool in the optimisation process of transformer installations.
Siemens Energy Sector is the world’s leading supplier of a wide faces. We focus primarily on the requirements of energy utili-
range of products, solutions and services for power generation, ties and industrial companies – particularly those in the oil and
transmission and distribution as well as for the production, gas industry.
conversion and transport of the primary fuels oil and gas. We
are the only supplier worldwide with comprehensive know- Our Energy Sector has some 85,000 employees worldwide. In
how encompassing the entire energy conversion chain and, in fiscal 2009, it generated external revenue of € 25.4 billion and
particular, plant-to-grid connections and other types of inter- profit of € 3.3 billion.
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1
CST SUCCESS STORY
The Challenge of Transformer Design
The demands on power transformer design are diverse – they

must conform to national and international standards and fulfill
the specifications of the electricity utilities and their contractors.
These conditions are to a large extent determined by the network
to which they are connected and specific factors at the installation
site. The dimensioning of the power transformer must adhere to
the necessary specifications. In this process, mechanical, electro-
magnetic and thermal characteristics must be taken into account.
For every manufactured transformer, a works test is carried out
to ensure correct operation and safety under operating conditions
spanning several years.
Insulation Design
The development of insulation systems and components is one of

the design goals in transformer design. This involves knowledge
of the electrical insulation between windings and the insulation
between energised windings, conductors and grounded compo-
nents. The conception, design, construction and material of a gi-
ven insulation arrangement are determined by the specification
requirements. In power transformers, mineral oil and impregna- Figure 2 Simplified model of the active part of a transformer.
ted fibrous material, also known as transformer board, are gene-
rally used. The system consisting of pressboard and oil channels is
referred to as an insulation system.
Effective Modeling of Complex Geometries
The User-Interface of CST STUDIO SUITE® is very easy to use and

enables the fast construction of models. This model is then mes-
hed and solution matrices set-up for use in the numerical solvers.
CST EMS allows the user to lower simulation times by defining
symmetry conditions which reduce the simulation domain and
required memory. Figure 2 shows a model of the active part of
a five-leg power transformer with three wound legs which was
constructed entirely in CST EMS. For complex geometries, CST EMS
allows the import and modification of a wide range of 3D formats.
Insulation arrangements can still, even with some simplification,

pose a difficult challenge for numerical simulations since the di-
mensions of these structures can be of the order of several meters
while the thickness of the individual components, such as trans-
former board barriers, is in the range of a few millimeters.
Figure 3 Electric potential around a single-leg winding arrangement.
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2
CST SUCCESS STORY
Since the barrier strength and oil channel width are decisive fac-
tors in the dimensioning of the insulation system, a powerful and
robust mesher is important. As well as a tetrahedral-based mesh
generator CST EMS also offers a hexahedral-based mesh scheme
ensuring that the user can apply the best method for the problem.
In addition to global mesh settings, the user also has the oppor-
tunity to refine the mesh locally on a component or material level.
As an example of a typical simulation, Figure 3 shows an equipo-
tential plot from an electrostatic simulation of the outlet section
of a winding arrangement (active part). For this simulation, the
original 5 leg active part was reduced to a single leg.
CST EM STUDIO Establishes Operational Stability
A virtual operational stability test involves the 3D simulation, analy-

sis and further development of insulation systems between various
electrode arrangements. Electrostatic simulations are used to pro-
vide momentary values of the electric stress which typically arise
in the testing of a transformer. The tetrahedral-based electrostatic
solver in CST EMS is particularly suited to this simulation since it
allows an accurate surface and efficient volume discretisation. This
helps to determine the potential distribution around electrodes
and on insulating surfaces which is critical for establishing the ef-
fectiveness and strength of the insulation systems. Figure 4 shows
an equipotential plot in an oil-transformer board insulation system.
The Right Solver for the Job

Figure 4 Equipotential Plot of the Electric Field Stress.
CST EMS offers a wide range of numerical solvers for various types
of problems. For the calculation of induced electromagnetic losses
in the individual elements of the transformer, the magneto-quasi-
static solver is used. The sources for such simulations include the
windings of the active part and the winding connecting leads.
The active part, which consists of the iron core and the leg sections
with concentric windings and their insulation, forms the heart of
the transformer. Stray fields lead to electromagnetic losses in the
surrounding metallic construction elements. Simulation of this
situation would aid in the reduction of the losses by appropriate
shielding measures or changes to conductor placement. Analysis of
the magnetic field in the core, shown in Figure 5, assists the investi-
gation of the shielding effectiveness of the shielding walls.
Figure 5 Analysis of shielding wall effectiveness : Magnetic energy density.
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CST SUCCESS STORY
No New Transformer Development Without „CST EMS is now an integral part of the develop
CST EM STUDIO
ment process of various power transformer
The importance of simulation in the high voltage design, construc-
tion and dimensioning process as well as the calculation of electro- components at Siemens (Energy). This is especially
magnetic losses in the active part is continually increasing. For this
simulation the CST EMS Low Frequency time harmonic solver was a consequence of the intuitive user-interface and
used. In Figure 6, the electromagnetic losses in the pressboard are
shown where the skin effect can be clearly seen. To support accurate the variety of available solvers. Thanks to the close
modeling of the skin depth, 2nd order elements were used. Alternati-
ve techniques such as surface impedance modeling are also available, co-operation with the CST EMS development team,
which can significantly increase the performance of simulations.
requests, suggestions and ideas have been openly
Thermal considerations also play a role in the design process. The
loss distribution from the low frequency simulation can be used embraced and rapidly implemented. This forms
as a thermal source in the CST MPHYSICS® STUDIO (CST MPS)
thermal solver. This transfer of the losses from the electromagne- the basis for our decision to further increase our
tic solver to the thermal solver is carried out seamlessly within the
same model and opens up a range of analysis possibilities. usage of CST‘s solutions“
Figure 6 Loss Density in the press frame.
Author
Ronny Fritsche
Siemens AG Sector Energy T TR PN
Katzwanger Str. 150, 90461 Nürnberg
Germany
mail: ronny.fritsche@siemens.com
Tel: +49 911 434 2432, Fax: +49 911 434 2315
www.cst.com
4

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CST SUCCESS STORY

Siemens Energy Optimises Power Transformers

Active Part Figure 1 Typical 40 MVA

Finding customised solutions for any applications and specifications of transformers –

The Challenge of Transformer Design

The demands on power transformer design are diverse – they

The development of insulation systems and components is one of

Effective Modeling of Complex Geometries

The User-Interface of CST STUDIO SUITE® is very easy to use and

Insulation arrangements can still, even with some simplification,

CST EM STUDIO Establishes Operational Stability

A virtual operational stability test involves the 3D simulation, analy-

The Right Solver for the Job

Figure 5 Analysis of shielding wall effectiveness : Magnetic energy density.

Figure 6 Loss Density in the press frame.

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