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Cigr 2009
6th Southern Africa
Regional Conference
R.P.P. SMEETS
KEMA
(The Netherlands)
L.H. TE PASKE
KEMA
(The Netherlands)
P.P. LEUFKENS
KEMA
(The Netherlands)
T. FOGELBERG
ABB
(Sweden)
SUMMARY
The ability to withstand a short circuit is recognised more and more as an essential characteristic of
power transformers. IEC and IEEE Standards, as well as other national standards specify short-circuit
testing and how to check the withstand capability. Unfortunately, however, there is extensive evidence
that the matter is not as simple as the standards make it sound.
Failures caused by short circuits are still a major cause of transformer outages, though failure rates
vary widely in different countries and systems, depending on various circumstances, network
characteristics and the equipment installed.
Experience is reported of short-circuit testing of large power transformers during the past 13 years by
KEMA. In total, 102 transformers >= 25 MVA participated in the survey. Test statistics show that at
first access to standard IEC 60076-5 short-circuit tests, 28% failed initially. Failures were observed
throughout the complete range of voltage (20 - 500 kV) and power (25 - 440 MVA) tested.
KEYWORDS
Power transformer, short-circuit, testing, standardization
* : e-mail:
rene.smeets@kema.com, KEMA T&D Testing Services, the Netherlands
**: e-mail: thomas.fogelberg@se.abb.com, ABB Transformers, Sweden
Therefore, these must be the basics for a short circuit safe design. The short circuit force gives rise to
mechanical forces in milliseconds to hundred of tons.
The current peak value and the correspondent forces depend on many factors. In HV systems, the most
probable type of short circuit is a single-line-to-earth fault, normally due to environment conditions
such as a stroke of lightning on the line, equipment failure at the the station, pollution of insulation
strings, etc. Sometimes, short circuit faults develop into other more extensive faults, such as a singlephase-to-earth fault developing into a double-phase-to-earth and eventually a three-phase fault. The
relative severity of the different types of fault depends on the characteristics of the system. On the
other hand there are factors as arc resistances and earth network impedances which will have
compensatory effects.
Electromagnetic forces tend to minimize the magnetic energy density in the volume. It means that
inner windings will tend to reduce its radius and the outer windings the contrary, increase their radius.
In axial directions the windings are trying to reduce their heights.
Forces and related withstand criteria can be splitted into 2 components:
1. Radial forces.
The failure modes for radial forces include:
- buckling of inner windings (see fig.1) ;
- diameter increase of outer winding;
- spiralling of end turns in helical windings (see fig. 2).
An important feature of proper short circuit management is that inner windings are subject to free
buckling. It means they are self-supporting. There are no radial supports from core to windings and
from winding to winding. It means that the strength is determined by Cu hardness (yield point) and
conductor geometry. Spiralling is avoided by tough criteria or non-helical windings are used. Also the
dynamic response from the winding is considered
2. Axial forces.
The failure mode for axial forces includes:
- mechanical collapse of yoke insulation, press rings, press plates and core clamps;
- conductor tilting;
- conductor axial bending between spacers;
- possible initial dielectric failures inside windings, followed by mechanical collapse.
The axial forces are calculated with FEM programs where axial displacement due to workshop
tolerances are fully considered; even so axial displacement due to winding pitch. Windings are dimensioned for maximum compression forces, where dynamic effects are embedded.
Ampere turn balancing between the windings is a
Which transformer units are worth being
prerequisite to avoid axial forces on the windings.
considered for short-circuit testing?
Therefore strict manufacturing tolerances for
windings are needed. As windings are springs
- Key generator step-up transformers and auxiliwith about 20% cellulose, the correct compacting
ary units in power plants
during known moisture and temperatures are the
- Key feeding transformers at power plant subkey to get the right spring constant for long time
stations or huge load centers
- Strategic intertie transformers, three-winding
service. Here well-defined processes in the
system transformers (tertiary), auto-transformwinding shop and active part assembly are a must.
ers
The final pressure setting after the vapour phase
Transformers with axially split winding conprocess shall then bring the windings under
nections
pressure during its life time.
Still the most important criteria are that all
windings need their pressure to avoid any
displacement between the windings.
Designing power transformers is an iterative and interactive process to find an optimal solution from
the point of view of:
- masses and losses
- sound level
- short circuit strength
- winding temperature, hot spots and cooling equipment
- dielectric strength between windings and inside windings
"Countries like China and India, where we today hear alot about problems with short-circuit failures have not given any
contribution to the survey" (quote from [1]).
number of transformers
40
initially not OK
32
initially OK
24
16
8
0
25-50
50-100
100-200
>200
MVA (rated)
number of transformers
28
initially not OK
24
initially OK
20
16
12
8
4
0
20-100
100-200
200-300
300-400
>400
kV (rated)
duct spacers; dielectric flashover across HV-winding or to the tank; displacement of pressboard
insulation; tank current due to damaged conductor insulation; damage to tapchanger;
- Bushings: broken or cracked LV-bushings.
number of transformers
In the cases (the majority) that the reactance change is within the tolerances set by the standards, it is the
observation that (visual) inspection and routine testing in a few cases (approx. 7% of the cases) still leads
to rejection.
Visual inspection is necessary, because
14
initially not OK
deformations and displacements in
12
initially OK
supporting structures, clamping syst10
ems, insulation materials, winding exit
8
leads, external connections from the
6
coils to the tapchanger and within the
4
on-load tapchanger can not be detected
2
by the reactance measurements only.
0
96
97
98
99
00
01
02 03
year
04
05
06
07
08
Fig.5: Initial failure rate during the past 13 years 1996 - 2008
In fig. 5, the testing volumes and failure rates are indicated of tests at KEMA (>= 25 MVA). As can be
seen, there is a significant increase in testing need in recent years. The overall tendency of failure rate is
slowly decreasing in time, insofar the small population allows such a conclusion.
Experience with the short-circuit reactance measurements is that for power transformers a variation of
more than 1.0% indicates a large deformation in one or more coils. Also a gradually increasing variation
during the short-circuit tests, although in total not more than 0.5% to 1.0%, indicates a progressive
movement of winding conductors. Variations of the reactance values between the short-circuit tests in a
strange way form an indication of large flexibility of the windings.
One could wonder on what causes the high failure rate, observed by short-circuit test laboratories world
wide compared to the much lower failure in service. The main reason must be the severity of the tests,
compared to actual service conditions. From a recent enquiry of CIGRE WG13.08 it can be concluded
that on a statistical basis, large power transformers have to face several full and many small short-circuits
during their life, more precisely: the 90 percentile was estimated to be 4 full short-circuits in 25 years.
Thus, it must be assumed that this actual (full) short-circuit current in service is normally (much) smaller
than the rated short-circuit current for which the transformer is designed.
Because of the expected future increase in short-circuit power, especially in developing countries, this
situation may change, and the fact must be faced that during the life of the ageing transformer, its
withstand against short-circuits will be brought to the limits.
IV. CONCLUSIONS
It is concluded that short-circuit testing is a vital part of the design process, and a crucial verification
tool at the end of it [1, 12, 13]. The high failure rate at testing (around 28 %) is the best demonstration
that calculation tools alone are not sufficient to design a transformer capable to withstand the worst
case of short-circuit current.
V. REFERENCES
1. G. Bertagnolli: "Short-circuit Duty of Power Transformers", Book printed by ABB Trasformatori
Legano(Milano), ISBN Italy, 1996.
2. IEC 60076-5 Annex A, "Theoretical Evaluation of the Ability to Withstand the Dynamic Effects of
Short Circuit", 2006
3. CIGRE WG12.05: "An International Survey on Failures in Large Power Transformers in Service",
Electra 88, pp.21-37, 1983.
4. G. Bastos et al., "An Analysis of the Increase on Failure Rate Phenomenon and Measures taken to
improve Transformer Reliability", paper A2.01, CIGRE Conference 2006
5. G. Bertagnolli: "Results of short-circuit performance of transformers", CIGRE Transformer
Colloquium, Budapest, Short-circuit performance; Tests and Failures, report 2, CIGRE TC 12, 1999.
6. IEEE Transformer Comm. meeting, Presentation Hydro Quebec, 2008
7. G. Macor et al., " The Short-Circuit Resistance of Transformers: The Feedback in France Based on
Tests, Service and Calculation Approaches". CIGRE Conference, paper 12-102, 2000.
8. N.V.C. Sastry, H. Gupta, "Short-Circuit Test on EHV Transformers", 9th Int. Conf. on Short-Circuit
Currents in Power Systems, Cracow 2000
9. H. Gupta, N.N. Misra, "Concerns about Short-Circuit Tests", TrafoTech 2002, pp. 121-25, Mumbai,
India, January 2002
10. M. Wang, "1995-1999 Fault Statistics & Analysis All Transformer Type in China", Electrical
Equipment 2(1), 2001
11. Y. He, M. Wang, "The Transformer Short-Circuit Test and the High-Power Laboratory in China the Past, Present and Future", IEEE Electrical Insulation Magazine, Jan/Feb. 2004, vol.20 no.1, pp
15 - 19.
12. A.L.J. Janssen, L.H. te Paske, "Short-circuit Testing Experience With Large Power Transformers,
CIGRE conference, paper 12-105, 2000
13. T. Fogelberg, "Surviving a short-circuit", ABB Review 1/2008
14. A. Wiesbeck, "High Reliability of Power Transformers - Short Circuit Reliability", CEPSI
Conference, Macau, 2008