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HV-Power-Transformer-Design-and-Mfg-Oct-8-9.pdf
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transformer
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1
Power Transformer Fundamentals:
Design and Manufacturing
Waldemar Ziomek, Engineering Manager
CG Power Systems Canada Inc
IEEE Training, Houston, Texas,
Oct.8-9, 2013
Overview
• Transformer Design
– Transformer Types
– Construction and Parts
• Core & Coils
– Electrical design
• Losses & Impedance
• Thermal, Dielectric & Short Circuit
• Cooling & Sound Level
– Mechanical design
• Tank
• Oil Preservation
• Transformer Manufacturing Process
2
Power Transmission & Distribution
3
The traditional power supply chain - from the
central power generator to the consumer:
GENERATION TRANSMISSION SUB-TRANSMISSION DISTRIBUTION DISTRIBUTED POWER
Generator Step-Up Auto-Transformer Step-Down Pads
Transformer Transformer
115/10 or 20 kV 500/230 230/13.8
132 345/161 161
161 230/115 132
230 230/132 115
345 69
500 34
With and without LTC
Specification vs. Design
• SPECIFICATION GIVES BASIC
PARAMETERS:
– Voltages (kV, BIL) ,
– power rating ( MVA),
– impedance (IZ), …
• DESIGNER/PRODUCER GIVES:
– Dielectric system
– Magnetic system
– Thermal system
– Mechanical system
– Oil flow ‘system’
– Sound ‘system’
4
Standards
USA
(ANSI) IEEE Std C57.12.00-1993, standard general requirements for liquid-
immersed distribution, power and regulation transformers ~ 50 Pages
ANSI C57.12.10-1988, safety requirements 230 kV and below 833/958 through
8,333/10,417 KVA, single-phase, and 750/862 through 60,000/80,000/100,000
KVA, three-phase without load tap changing; and 3,750/4,687 through
60,000/80,000/100,000 KVA with load tap changing ~ 30+ Pages
(ANSI) IEEE C57.12.90-1993, standard test code for liquid-immersed
distribution, power and regulating transformers and guide for short-circuit
testing of distribution and power transformers ~ 107 Pages
NEMA standards publication no. TR1-1993; transformers, regulators and
reactors ~ 2 Pages
• CSA
• IEC
5
Simple Transformer
• Left coil - input
(primary coil)
– AC Source is connected
to
– Magnetizing current flows
and establishes the flux
in core
• Right coil - output (secondary
coil)
– Load
• Magnetic circuit (core)
• Problems ? Stray flux, transients,
heating, vibrations, noise, losses,
regulation, saturation, human errors,
dielectrics (high voltage insulation),
non-linear magnetics, fluid
dynamics, material defects,
contamination, etc.etc.
6
Real single phase transformer
7
Wound leg
LV winding
HV winding
Return core leg
In order to better control the stray flux distribution, both windings
are wound on same core leg
Equivalent Circuit
8
Rp+jXp Rs+jXs
X m
R m
Load
Rp+Rs ’ Xp+Xs’
X m R m
Load
9
Transformer Design Basis
Thermal
Dielectric
Short Circuit
Quality
Reliability
Consistent performance
Long Service life
Design Procedure
•
Select Core Diameter & Area (A)
•
Select Maximum Flux Density (Bm)
•
Find Volts/Turn = 4.44 x Freq x Bm x A
•
Find LV Turns = LV volts per Phase/ (V/T)
•
Find HV Turns = HV volts per Phase/ (V/T)
•
Select current densities LV & HV
•
Select Conductor Area = Current / Density
•
Select type of Winding:
–
Helical,Disc,Center-fed,end-fed
•
Finalize HV Axial & Radial
•
Finalize LV Axial & Radial
10
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