ELECTRA N215 - Aot 2004 8

1. Introduction
Recently, electric power demand
has been constantly increasing, espe-
cially in urban areas. With this increase
of power demand, substations tend to
be constructed near urban and resi-
dential areas in order to reduce the loss
in the power distribution and improve
the reliability of the power supply.
The primary purpose of substations
is to supply customers with stable
power safely. Moreover, in recent years,
public requirement for harmonization
with the environment has become more
compelling.
Especially, devices installed in indoor
or underground substations are required
to be of disaster-preventive type to
ensure safety as one measure for har-
monization with the environment. Under
such situations, installations employing
non-flammable gas insulated trans-
formers, instead of conventional oil
immersed transformers are increasing.
In the underground substation, a
275 kV gas insulated transformer and a
gas insulated switchgear are used in com-
bination. In an oil-less extra-high voltage
underground disaster-resistant substa-
tion, a gas insulated transformer plays a
key role.
To meet such requirements, gas
insulated transformers of 22 kV to
330 kV classes are now in practical
use not only in Japan, but also in
Southeast Asia, Australia and other
regions. In areas where further
increase and concentration of electric
power demand from urban areas are
expected, construction of indoor and
underground substations of disaster
preventive type used in combination
with gas insulated transformers will
increase in future.
Basic design concept of the gas insu-
lated transformer is almost the same as
the oil immersed transformer. Therefore,
international standards (IEC or ANSI) are
mostly able to apply for gas insulated
transformers. Service condition, insula-
tion level, measurement method etc. can
be determined by international stan-
dards. But there are some difference
caused by difference in characteristics
between oil and gas. For example, in the
consideration of the over loading capa-
bility of gas-filled-type transformers, gen-
eral concept and calculation method of
IEC 60076-7 can be applicable, but IEC
60076-7 cannot be applied directly to gas
insulated transformers.
This paper will introduce SF6 gas
insulated transformers that have been
developed taking advantage of their
excellent characteristics. [1]
2. History of
Non-flammable Trans-
formers
Studies on fire-retarding or non-
flammable transformers started in the
U.S.A. from 1930s and the application
of SF6 gas, which was proved to have
excellent insulating and arc suppress-
ing performance to transformers was
investigated.
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DESIGN CONCEPT OF URBAN
SUBSTATIONS
State-of-the-art Gas Insulated
Transformers
By Naoki AMANO*, Noboru HOSOKAWA and Motoyasu
ICHIKAWA (Japan)
*Email Address: amano-naski@nb.jaeps.com
0407-013Mep-ok 4/01/07 18:35 Page 8
9
INVITED PAPERS
ELECTRA is the journal
of CIGRE Members.
Nevertheless, a number of
columns under the section
Invited Papers are now
open to all contributors.
This we hope will enhance
exchanges between
all players in the area
of electrical power.
If in your country you have
information about signifi-
cant events or innovation in
the area of electricity,
please share this with us.
Your contribution
(2 500 words maximum)
should be sent directly to
the Central Office or to your
National Committee.
It will then be forwarded to
the Editing Committee.
We rely on your collabora-
tion, for which we thank you
in advance.
No. 215 - August 2004 ELECTRA
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The first gas insulated transformers
were commercialized around 1956.
They were General Electrics 69 kV,
2000 kVA of an all SF6 gas design, and
Westinghouses 69 kV, 7500 kVA using
PFC liquid as the cooling media.
On the other hand in Europe,
actual production of such transfor-
mers has been reported from France,
Germany and Russia.
In Japan, a product of 66 kV,
3000 kVA was commercialized in 1967.
In the background of the dramatic
development of gas circuit breakers
and gas insulated switchgears, deve-
lopment of gas insulated transformers
accelerated thereafter. Gas insulated
transformers of 154 kV class were
developed in the first half of 1980s and
275 kV class in the second half of
1980s. In order to cope with the
demand for raised voltage and
increased capacity of the 275 kV class,
etc., products with high gas pressure
for improving cooling and insulating
performance were commercialized.
Meanwhile, compound type gas insu-
lated transformers, in which PFC liquid
with excellent cooling properties is
used in combination with the SF6 gas
as the insulating media were also com-
mercialized. Currently, various types of
gas insulated transformers, up to the
500 kV class, have been developed.
The operation results of the SF6 gas
insulated transformers manufactured by
Japanese manufacturers are graphed
below. The cumulative total number of
units is 3258 of those, 2853 units are
being operated in Japan, 254 units in
Hong Kong, 82 units in China and 47
units in Singapore. In addition, they are
also being delivered to Taiwan, Aus-
tralia, Egypt, Thailand, Korea, etc.
Their cumulative capacity is 33.3 GVA
of which 24.7 GVA is being operated in
Japan as shown in Fig. 2. [2]
Fig. 2 Delivery results of SF6 gas insulated transformers manufactured in Japan
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ELECTRA N215 - August 2004 10
3. Examples of
applications to
underground
substations
Because of the following application
effects compared with oil immersed
transformers, gas insulated transfor-
mers have been delivered to many
indoor and underground substations
installed in urban and residential areas:
Because the gas insulated trans-
formers are of the non-flammable type,
fire extinguishing and disaster preven-
tion facilities can be simplified.
Need for the sump tank and pres-
sure discharging tube is eliminated and
the conservator is also made unneces-
sary because of little changes in the
internal pressure due to temperature
fluctuation, enabling reduced height of
the transformer room.
By directly connecting to the gas
insulated switchgear, the installation
area can be reduced.
By taking these advantages, total
economic effects can be considered,
including reduction of construction
expenses enabled by reducing the total
space required and rationalizing the
disaster prevention facilities. Here,
examples of substations using gas insu-
lated transformers are given.
An example of an extra-high volt-
age substation, is a 275 kV, 300 MVA all
gas type substation. This transformer
was designed in pursuit of compactness
because it was installed in an under-
ground substation constructed in the
central location of Tokyo. The rated gas
pressure was raised to 0.43 MPa-g to
improve SF6 gas insulating and cooling
performance. The tank for this high-
pressure gas has a circular cross-sec-
tion. In addition, the transformer is of
a specific 3-phase structure, consider-
ing transportation. Heat exhausted
from the transformer is cooled with a
water-cooled heat exchanger and emit-
ted to the air from the cooling tower
on the top of the building. Through
application of this gas insulated trans-
former, 50% reduction of installation
space was achieved, compared with an
oil immersed transformer.
Another example of application is a
substation installed in the underground
space of a commercial building in Syd-
ney, Australia. A gas insulated trans-
former of all gas type with the worlds
largest capacity has been delivered.
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Fig. 1 330kV, 400MVA Gas Insulated Transformer
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C O N T I N U E D
INVITED PAPERS
ELECTRA is the journal
of CIGRE Members.
Nevertheless, a number of
columns under the section
Invited Papers are now
open to all contributors.
This we hope will enhance
exchanges between
all players in the area
of electrical power.
If in your country you have
information about signifi-
cant events or innovation in
the area of electricity,
please share this with us.
Your contribution
(2 500 words maximum)
should be sent directly to
the Central Office or to your
National Committee.
It will then be forwarded to
the Editing Committee.
We rely on your collabora-
tion, for which we thank you
in advance.
This 330 kV, 400 MVA gas insulated
transformer is an autotransformer, and
is designed for compactness of the sub-
station and reduction of loss, with 0.43
MPa-g gas pressure, 3-phase structure
etc. as shown in Fig.1.
Many gas insulated transformers of
66 kV or less have been delivered to
indoor and underground substations.
Standard products of this rating or less
have low gas pressure (0.11 to 0.14 MPa-
g) and are of the gas natural-cooling type.
Fig.2 and Table 1 show 64.5kV,
30MVA gas insulated transformer and
a comparison table between gas insu-
lated transformer and oil-immersed
transformer.
4. Feature of Gas
Insulated Transformer
Structures
Many technologies are required to
realize SF6 gas insulated transformers.
(1) Cooling design
(2) Insulation design: Gas insulation
and solid insulation
(3) Tank design
(4) Accessories
This section describes the concepts
of these outstanding technologies with
respect to gas insulated transformers.
[3] [4]
4-1. Cooling design
SF6 gas has lower cooling perfor-
mance than that of insulating oil. The
thermal capacity of the same volume dif-
fers by 177 times and the heat transfer
coefficient for the same flow velocity dif-
fers by 7.3 times (SF6 gas with gas pres-
sure 0.12 MPa-g, at 20C). To overcome
these differences in physical properties,
the following measures are taken :
(1) Reducing the generated loss
(2) Raising the design temperature
allowance using high heat resistant
materials.
4-1-1 Natural-cooling (GN)
type Gas insulated trans-
former
For a natural-cooling (GN) type gas
insulated transformer, the gas flow path
is designed to minimize its pressure loss
so that the gas flow circulated by free
convection can be increased. For exam-
ple, a large intake opening and
Fig.2 64.5kV, 30MVA Gas Insulated Transformer
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ELECTRA N215 - August 2004 12
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wide vertical duct are used to ease
cooling gas flow into the coil. Never-
theless, as the loss increases according
to the capacity increase, the size of gas
insulated transformer becomes large
because of the low cooling perfor-
mance. Therefore, the practical capa-
city of the Natural-cooling (GN) type is
limited to approximately 30 MVA. For
larger capacities, the Directed-cool-
ing (GD) type is employed, in which gas
is forcibly circulated with gas blowers.
4-1-2 Directed-cooling (GD)
type Gas insulated trans-
former
It is necessary to circulate large vo-
lume of gas in order to give the equi-
valent cooling performance as the oil
immersed transformers. In case of SF6
gas, large volume of gas flow has no
such an adverse effect as flow electri-
fication phenomenon on the insulation.
The cooling structure of the GD
type gas insulated transformer is cha-
racterized by its partition plate, which
separates the tank into upper and
lower section. The partition plate also
plays an important role in letting the
gas flow evenly to the iron core and coil
(see Figure 3). Gas cooled by the cooler
is led to the lower section of the tank.
Because flow of the gas is blocked by
the partition plate, the pressure in the
lower section becomes higher than that
in the upper section. The pressure dif-
ference is applied evenly to all cool-
ing ducts mounted on the iron core and
coils, letting the gas flow dependent
on the flowing resistance of each duct.
Flowing gas takes the heat generated
from the iron core and coils and the
heated gas is transferred from the
upper gas space to the cooler. The par-
tition plate distributes the gas flow to
all cooling ducts. The necessary gas
flow can be ensured by controlled flow-
ing resistance of the cooling ducts.
Computer-aided flow analysis is used
in the cooling design to ensure the ne-
cessary gas flow.
4-2. Insulation design
The insulation is characterized by
raised gas pressure to strengthen SF6
gas insulation performance and by
insulation structure composed of gas
(SF6 gas) and solid (plastic film, etc.).
It is necessary to understand both of
these features and design the insula-
tion, realizing good coordination
between them.
Fig. 3 Structure of SF6 gas insulated transformer
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4-2-1 Gas (SF6 gas)
insulation
Gas insulation involves gas gaps
such as the main gap and those
between coils (sections). Especially, the
electric field design of the wedge-type
gap (triple junction portion) formed
around high-voltage parts such as a coil
is the most important.
(1) The dielectric strength of SF6
gas depends on gas pressure and has
an impulse ratio smaller than that of
insulating oil. Investigation on the
dielectric strength (lightning impulse
test voltage) in a short-time region is
important for the insulation design.
(2) The ratio of the dielectric constant
between solid and cooling media in the
gas insulated transformer is approxi-
mately 3 and that in the oil immersed
transformer is approximately 2. This
means that the gas insulated trans-
former has a larger electric field shared
for the wedge type gas gap with the sur-
rounding solid insulator, approximately
1.5 times that of the oil immersed trans-
former. Investigation on dielectric
strength in this area is important.
4-2-2 Solid insulation
Use of the appropriate insulation
material leads to obtaining high insulat-
ing ability (for example, turn insulation).
Polyethylene terephthalate (PET) and
polyphenylene sulfide (PPS) are mate-
rials with high air-tightness, thermal resis-
tance and dielectric strength and are
used as coating materials for element
wires. The turn insulation using PET film
with high air-tightness has a higher
breakdown voltage. The insulating mate-
rials around the coil are selected, taking
into consideration the solid insulation
performance as well as the thermal resis-
tance based on the cooling design.
4-3. Tank design
For gas insulated transformers, the
gas pressure is set higher than the
atmospheric pressure in order to obtain
the necessary cooling and insulating
performance. There are two types of
gas pressure given below.
(1) Low gas pressure (0.11 to 0.14
MPa-g at 20 deg.): For medium- and
small-capacity transformers.
(2) High gas pressure (0.35 to
0.43MPa-g at 20 deg.): For large-capac-
ity transformers.
The higher the gas pressure, the more
round shape of tank, cylindrical or spher-
ical, is required for relaxation of stress
caused by the internal pressure.
Because SF6 gas has a high global
warming potential, the tank must have
a structure that prevents SF6 gas from
being emitted into the air during its life
cycle, from installation to removal. For
example, as the on-load tap changer
requires periodic maintenance, the
diverter switch of the on-load tap
changer is placed in a separate
INVITED PAPERS
ELECTRA is the journal
of CIGRE Members.
Nevertheless, a number of
columns under the section
Invited Papers are now
open to all contributors.
This we hope will enhance
exchanges between
all players in the area
of electrical power.
If in your country you have
information about signifi-
cant events or innovation in
the area of electricity,
please share this with us.
Your contribution
(2 500 words maximum)
should be sent directly to
the Central Office or to your
National Committee.
It will then be forwarded to
the Editing Committee.
We rely on your collabora-
tion, for which we thank you
in advance.
TABLE.1 Comparison between Gas Insulated Transformer
and Oil immersed transformer
0407-013Mep-ok 4/01/07 18:35 Page 13
ELECTRA N215 - August 2004 14
gas section. Cooling systems also
require periodic maintenance and but-
terfly valves are mounted between the
main unit tank and cooling system to
provide different gas sections. Thus the
volume of gas treated can be mini-
mized during maintenance.
4-4. Accessories
Accessories applicable to gas
insulated transformers have been
developed.
4-4-1 On Load Tap Changer
The on-load tap changer for gas insu-
lated transformers consists of a diverter
switch and tap selector, likewise those for
oil immersed transformers. The diverter
switch is equipped with a vacuum valve
for turning the current ON/OFF, pre-
venting the arc current generation in SF6
gas. This eliminates the need for devices
such as an on-line oil purifier used for oil
immersed transformers. Since the tap
selector is placed in the gas, unlike the
one for oil immersed transformers, lubri-
cation of the contactor by surrounding
insulating oil cannot be expected. There-
fore, a roller contact is used.
4-4-2 Cooler
Likewise for oil immersed trans-
formers, radiators (for low gas pressure
only), and unit coolers and water-cooled
coolers can be used for cooling. In
order to raise the cooling performance,
the circulated gas flow must be
increased. This is achieved by using
thick piping and large-capacity gas
blowers. The rated flow of the gas
blower is 20 to 40 m3/min and usually
two to six gas blowers are mounted for
each gas insulated transformer.
Because SF6 gas has less specific
gravity than that of insulating oil, it pro-
vides a higher degree of freedom in the
arrangement of radiators. For example,
a radiator can be mounted at a position
higher than the transformer main unit.
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4-4-3 Protective devices
Likewise for oil immersed trans-
formers, protective devices are mounted
on gas insulated transformers. To deter-
mine whether the equipment operation
can be continued or not, protective
devices related to gas pressure and tem-
perature, etc. are applied. Gas insulated
transformers require less devices than
oil immersed transformers, realizing sim-
plified protection system.
5. Future Trends in Gas
Insulated Transformers
Accompanied by the increase of
applications, progress has also been
made in the standardization of gas insu-
lated transformers. JEC2200 (1995)
Transformer in Japan describes a gas
insulated transformer and IEC is also
studying the standardization of gas
insulated transformers.
Basic technologies for gas insulated
transformers have been already estab-
lished. The promotion of technology
development to take further advantage
of gas insulated transformers, such as
development of more compact structures
by applying new materials, etc. is
expected. In the future, operating guide-
lines will be arranged concerning overload
operation performance and maintenance
and management criteria, etc. to enable
appropriate operation and maintenance.
References
[1] S.Tsukao et al. Application of Gas
Insulated Transformers to Underground
Substations in Japan, IEEE 2002.P517
[2] N.Amano et al. Compact Sub-
station Technologies State-of-the Art
and Future Trends, CIGRE ELECTRA
2002.August
[3] K.Toda et al. Structural Features
of Gas Insulated Transformers, IEEE
2002.P508
[4] S.Yamada et al. The Largest
Capacity Gas Insulated Transformer, IEE
Japan 2003. March II
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