Transformer Technology 变压器原理-莫小袁 or 沈耀明

Transformer Technology
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Outline
1. Basic knowledge of transformer

1.1 Basic principle of transformer
1.2 Function of transformer
1.3 Category of transformer
1.4 Development History of transformer
1.5 Representing method of product model of power transformer
2. Key technology of transformer manufacturing
3. Intelligent technology of transformer
4. Development & prospect at home and abroad
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Transformer is a kind of static equipment with two or multiple winding (coil) for
power transmission. By applying electromagnetic induction principle, the equipment
transforms voltage and current in one system into voltage and current in another
system under the same frequency. Generally the voltages and currents are of different
values and the same frequency.
Circuit (coil)
Magnetic circuit
(core)
Schematic diagram of Faraday's

experiment device
(August 29, 1831)
3/127
Structure:
Primary winding, or first-time winding,
is called primary or first-time for short.
The number 1 is marked on the Power supply
bottom, e.g. u1.

Secondary winding, or second-time
winding, is called secondary or second-
time for short. The number 2 is
marked on the bottom, e.g. u2.
i1
d A

Primary electrodynamic e1 N1 u1 e1 N1
force dt i2
X a
d
e N
secondary
electrodynamic force 2 2 u2 ZL
dt e2 N2
e1 N1 x
e2 N2
By properly changing number of turns of windings, the ratio of electrodynamic force between
primary and secondary winding can be changed to adjust voltage. This is the basic operation
principle of transformer.
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Definition of non-load
With single-phase as example:
I. Analysis of electromagnetic process
5/127
Deduction of relation formula between magnetic flux, electric potential and voltage
Order:
In the formula: E1m=N1m (Max. value)

E1m is max. value of electric potential
Among which m is max. value of magnetic flux.
Effective value E1=E1m/1.414=2fN1m/1.414 = 4.44fN1m
N1=original number of turns of windings, f=varying frequency of magnetic flux
6/127
1.2 Function of transformer
By applying power transformer, highly efficient transmission of electric in long distance,
proper power distribution and safe power use can be achieved in electric power system.
Power
plant
Important power
transmission
equipment, voltage Family,
increase or decrease school
Primary substation
High voltage 220kV / 110kV
power
transmission
line
Super uhv
substation
1000kV/750kV/ Distribution
500kV / 220kV Secondary substation transformer
110kV / 35kV / 10kV 10kV / 400V
7/127
1By purpose:
Power transformer (step-up transformer, step-down transformer, distribution transformer )
Special transformer (electric furnace transformer, rectifier transformer, traction transformer, mining
transformer, electric welding transformer, etc.)
Instrument transformer (voltage transformer and current transformer) and testing high voltage transformer
2By phase number:
Single-phase transformer
Auto transformer: for common transformer, there is only
Three-phase transformer
magnetic contact, but no electric contact between primary and
Multi-phase transformer secondary winding. The feature of auto transformer is that there
3By winding number are both magnetic coupling contact and electric contact between
primary and secondary winding. Compared with common
Dual-winding transformer
transformer, auto transformer can save material, reduce cost,
Three -winding transformer reduce volume and weight of transformer, which facilitating
Multi-winding transformer transport and installation of large-scale transformer.
Auto transformer
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4By voltage regulating method
Non-magnetization voltage
Non-magnetization (non-load) voltage regulating
transformer : the transformer whose secondary winding is non-
regulating transformer loaded, and voltage of primary winding is separately regulated
On-load voltage regulating from grid (when there is no power supply for magnetization)
transformer On-load voltage regulating transformer: the transformer
5By cooling method whose voltage is regulated on-load. It cannot practice voltage
Oil-immersed transformer regulation when there is short circuit failure in load or line, as
there is short circuit current flowing in transformer.
Inflatable transformer
Dry-type transformer
6By core structure
Core form transformer
Shell form transformer
7By capacity
small-size transformer
Medium-size transformer
Large-size transformer Epoxy cast dry-type
SF6 gas insulation
Extra large-size transformer Oil-immersed transformer
transformer
transformer
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1.4 Development history of transformer
China 1922, 1953, 1957, 1970, 1979, 2004, 2008, 2009,

(voltage class) 2.2kV 110kV 220kV 330kV 500kV 750kV 1000kV 800kV
World
Faraday 1450MVA-500kV
discovered law TR 250.2MVA-800kV
of magnetic HVDC
induction 4MVA-50kV 100MVA-330kV 268.5MVA-765kV
TR TR TR (single phase)
Worlds 1st
transformer
(Hungary
GANZ) 1000MVA-1000kV
UHV (single phase)
80MVA-220kV 600MVA-500kV 3000kVA-66kV 1000MVA-1050kV 400MVA-330kV

TR (single phase) GIT
TR TR (single phase) GIT(2 002) /127
10
What does OSFPSZ9-250000/220 mean?
JB/T3837-2010 Identification Method of Transformer Product Model,

composing form of product model of power transformer:
Special using environment code (usually not marked,

TH- damp &heat, TA dry & heat)
Nominal system voltage (kV)
Rated capacity (kVA)
Special purpose or special structure code (do not mark if

the product has no special purpose or structure )
Energy loss level code (9, 10, 1, 12, 13, 15)
Letter of product model
11/127
Alphabetical order of product model & meaning
No. Category Meaning Representing letter
Independent
1 Winding coupling method
Auto coupling O
Single phase D
2 Phase number
Three phase S
Transformer oil
Air (Dry-type) G
Gas Q
Winding external insulating
3 Pouring type C
medium Forming solid
Wrapping type CR
High burning point oil R
Vegetable oil W
A class

E class E
B class B
Oil-immersed F class F
H
H class
D
Insulation & heat The temperature of insulation system is C
4 The temperature of insulation system is
resistance class note 1
E class E
B class B
F class
Dry-type
H class H
The temperature of insulation system is D
The temperature of insulation system is C 12/127

Natural circulation cooling device
Category of cooling
5 Air cooler F
device
Water cooler S
Natural circulation
6 Method of oil circulation
Forced oil circulation P
Double winding
7 Number of winding Three winding S
Split winding F
Non-magnetization voltage regulating
8 Voltage regulating mode
On-load voltage regulating Z
Copper Copper
foil Aluminium B
Aluminium foil L
9 Material of coil wire note 2
Copper-aluminium compositenote3 LB
Cable TL
DL
Electrical steel sheet
10 Material of iron core
Amorphous alloy H
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sealing type note 5 M
For switch-on Q
For anti-lightning protection B
For capacity regulation For T
cable outlet L
For isolation G
For capacitance compensation RB
For oil field power illumination Y
For power plant and power substation CY
Special purpose or special Complete insulation note 6 J
11
structure note 4 For synchronous motor magnetization LC
For underground use D
For wind power generation F
Three-phase combined type note 7 H
Disintegrated transport JT
Common structure R
Rolling (winding) core
Three-dimensional
RL
structure
e.g. OSFPSZ9-250000/220 means

Auto coupling three-phase forced oil circulation and air cooling three-winding copper wire on-load
voltage regulating Type 9 transformer
Capacity 250MVA, high voltage 220kV
In JB/T3837-2010, convertor transformer is listed in the category of convertor transformer, its model
begins with the letter ZZ. 14/127
Protection code (usually not marked, TH- damp &heat,
TA dry & heat)
High voltage winding rated voltage class (kV)
Rated capacity (kVA)
Design S/N (1, 2, 3 b for half copper half aluminium)

Voltage regulating method (non-magnetization voltage regulation
is not marked, Z-on-load voltage regulation)
Wire material (copper wire is not marked, L-aluminium wire)
Winding number (dual-winding is not marked, S: three-winding,
F: dual split winding)
Circulation method: natural circulation is not marked, P-forced
circulation)
Cooling method (J-oil-immersed self-cooling, not necessary
to be marked; G-dry air self-cooling, C-dry-type cast
insulation; F-oil-immersed air cooling, S-oil-immersed
water cooling)
Phase number (Dsingle phaseSthree phase)
Winding coupling method (usually not marked, O auto

coupling)
e.g. OSFPSZ9-250000/220 means

Auto-coupling three-phase forced oil circulation and air cooling three-
winding copper wire on-load voltage-regulation Type 9 transformer
Capacity 250MVA, high voltage 220kV 15/127
Outline

2.1 Key technology of transformer
2.2 Introduction to structure, material & accessories of transformer
2.3 Manufacturing process & key control point of transformer
2.4 Test of transformer
2.5 Operation & maintenance of transformer
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2.1.1 Insulation technology of transformer
2.1.1.1 Introduction & category
The insulation class of transformer shall be in accordance with GB311 Insulation Coordination of High-voltage
Power Transmission and Transformation Equipment.
Insulation system is an important component of transformer. The electric insulation strength of transformer
determines its reliable operation in power grid. Transformer insulation includes internal insulation and external
insulation.
Windings of the same phase
Windings of different phases
Major insulation Winding to oil tank
Winding to core beam, winding to core side beam
Winding
Winding end to yoke
Between winding wire turns
Minor insulation Between winding wire pies
Internal insulation Between winding layers
Lead wire to ground
Major insulation
Lead wire Lead wire to different-phase winding
Minor insulation Between lead wire of 1 winding
Switch to ground
Major insulation Between lead wire contact of different-phase
Switch winding on switch
Minor insulation Between lead wire contact of same phase winding
Bushing connecting parts
External insulation Bushing
Between bushings 17/ 127
2.1.1.2 External insulation
It refers to electric insulation strength of transformer gas, mainly including
bushing insulation.
The charged part of bushing

gas determines gas spacing
to ground. Gas insulator of bushing
determines distance of gas
discharge part. Please choose
proper bushing according to
Voltage class voltage class of transformer. But
of bushing parameter should be modified in
determines special areas, including high
inter-phase altitude, severe pollution areas.
spacing. Standard includes GB4109,
IEC60815, etc.
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2.1.1.3 Internal insulation
It refers to electric insulation strength inside transformer.
Because of structural reason, there are many non-uniform electric fields inside transformer,
exerting great impact on insulation strength.
Major and minor insulation structure of winding, insulation structure of lead wire, etc. are
important.
Major insulation structure of winding:

divide large bushing spacing into small ones.
Proper configuration of small oil passage in
thin paper tube-like structure is applied.
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1-9
2.1Keytechnologyoftransformer
2.1.1.4 VFTO
VFTO: Very Fast Transient Overvoltage
TR DS CB
Generation mechanism: it is generated by
re-arcing when breaking weak charging

current. Power Load side
side
Circuit Circuit Circuit Circuit Circuit Circuit A1L
C1L C1L B1L B1L A1L
Voltage on power side
Re-arcing shock wave

voltage Voltage on load
GIS side
Inter-pole voltage
Transformer
Cut-off
Voltage on Voltage on load side
power side
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2.1.1.5 General features of convertor transformer insulation
AC electric field determinant: dielectric coefficient
A/C potential distribution ( oil/ paper = 2.2/3.2)
DC electric field determinant: resistivity

Coil voltage wave form of convertor transformer
800
D/C side coil terminal
600
400
V
Voltage to ground (kV)
k
200
D/C potential distribution ( oil/ paper = 1/50)
0
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 Convertor transformer insulation should also consider:
200
Overlapping of AC/DC
A/C side coil
400 terminal
Overlapping of D/C and lightning surge
Reversal of polarity
-600
-
21/127
-
Oil
2.1.2 Energy loss of transformer tank
Constitution of energy loss of transformer:
(1) Non-load energy loss: magnetic hysteresis loss + eddy loss
Clamp
Related to silicon steel sheet material, core type, magnetic flux
density, core processing technology.
(2) On-load energy loss: resistance loss + additional loss
Resistance loss is mainly determined by size of load current
Core
and winding resistance.
Coil
(3) Energy loss of auxiliary machinery: power consumed by
draught fan and oil pump.
Leakage flux distribution

inside oil tank
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2.1.3 Temperature rise of transformer
2.1.3.1 Maximum value of temperature rise
Internal coil and core of transformer generates energy loss, and the heat should be dissipated by
medium such as transformer oil. Oil temperature and winding of transformer, as well as control of
metal structure temperature directly determine service life of transformer.
GB1094.2 regulates maximum temperature rise of various parts of transformer. According to
general regulation: top oil temperature 55K; winding average 65K; winding hot spot 78K.
Schematic diagram of coil cooling Schematic diagram of cooling

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2.1.3.2 Cooling of transformer
Cooling method of transformer generally includes the following categories:
(1) Natural cooling (ONAN), cooling device is gilled radiator
(2) Natural oil-circulated air-cooling (ONAN/ONAF), cooling device is gilled radiator + fan
(3) Forced oil-circulated air-cooling (ONAN/ONAF/ODAF), cooling device is gilled radiator + fan +
oil pump or cooler + oil pump.
ODAFPlease choose proper cooling method according to capacity and heating value of transformer.
Common 20kV transformer used by substation applies ONAN; 500kV transformer applies
ONAN/ONAF, main transformer used by power plant applies ODAF.
Gilled radiator Cooler

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2.1.3.3 Oil flow charge
PB oil
Hydroxy
group O - H+
+
Polar group on
paper surface (PB) Aldehyde
group C - H+
+
O
Polarizing ability:
COOH > CHO > OH Carboxyl
group C - O - H+
+
O
The technology preventing oil flow
High electronegativity of oxygen attracts
Absorb anion in oil charge:
hydrogen, causes polarization of
hydrogen on the surface Limit on flow speed
Dispersion of oil outlet
Oil flow charge: Smooth flow path shape
It is a phenomenon occurred inside the transformer applying forced Limit on use of insulating
oil circulation. The electrostatic effect generated by friction material category
between oil flow and insulation parts surface electrifies solid Management of charging degree
insulation parts surface and insulation oil. of insulation oil 25/127
Failure feature:
2.1.3.4 Sulfuration of oil Majority: inter-turn insulation breakdown, higher
voltage coil (upper part)
Feature of transformer oil sulfuration:
Transformer put into operation for 5-7 years
1. Corrosive sulphur reacts with metal to form metal sulfide (copper sulfide, silver
Machine under high temperature operation
sulfide)
(electric reactor, etc.)
2. Copper sulfide, silver sulfide (good conductor of electric) falls from metal surface
Generally there is no sign for indication (gas in
3. Copper sulfide separates out from insulation paper of coil conductor, and
oil, etc.)
causes turn-to-turn insulation breakdown
Put grinded metal plate into insulation oil and heat for a Insulation paper
period of time, tell corrosion degree by colour change and copper wire
attached to copper
sulfide
ASTM D 1275 sample copper strip 19Hr@ 140
Strategy:
1. Remove sulphur compound

(maintain oxidation stability level)
2. Change oil (replace with non corrosive new oil)
3. Oil dilution (diluted by non corrosive oil)
4. Add Passivators (recommended by NYNAS)

(not approved in ASTM D )
26/127
2.1.4 Short circuit mechanical force of transformer
Under impact of short circuit current, various parts of transformer in operation will generate
huge electrodynamic force, and winding temperature will increase rapidly. It will pose serious
challenge to dynamic and thermal stability of transformer.
Applicable standards: GB1094.5, IEC60076-5
1Correct and reasonable mechanical force design
2Application of manufacturing technology and proper material
a) Winding applies hard copper wire;
b) Guarantee constant pressure drying of winding, and pre-

compacting treatment of cushion block;
c) Use perfectly round pressing plate, guarantee strength and

rigidity of pressing plate, guarantee the winding is fully
compressed
d) Improve structure of low voltage winding, and improve

mechanical strength of low voltage winding head.
e) Strictly control height difference between windings, reduce axial

force of winding.
27/127
2.1.5 Noise of transformer
An increasing use of large-scale transformer in residence and public place has raised higher
demand for noise control of transformer. As a main noise source of power substation, it is
especially important to control noise of transformer.
Noise reduction measures:

(1) Non-load noise:
Reduce magnetic flow density of iron core
Application of magnetic grain-oriented
54.4dBA silicon steel sheet with high conductivity
61.9dBA 61.0dBA Reasonable structure of iron core
(2) On-load noise:
Control compression state of coil
Improvement of processing & manufacturing
technology of structural components
(3) Noise of cooling device
Application of low-noise fan and cooler
(4) Application of sound insulation device
6 lapping iron core

28/127
2.1.6 D/C magnetic biasing
Causes:
1. Dynamic change of solar plasma wind interacts with geomagnetic field to create geomagnetic storm,
whose change induces electric potential gradient on earth surface. When this low-frequency electric filed
with certain duration acting on power transformer of neutral point grounding, it will induce geomagnetic
induced current in winding, with frequency between 0.01Hz~1Hz.
2. When D/C power transmission line is in mono-pole operation, there is strong D/C current flowing
underground, making D/C current flows through A/C neutral point direct grounding transformer winding
close to line .
Impact:
1. Increase non-load loss of transformer
2. Increase transformer vibration and noise
3. Temperature rise of metal parts near core
Solution:
1. Take impact of D/C magnetic biasing into consideration
during transformer design & manufacturing stage
2. Specific method to eliminate D/C current flowing into
transformer mainly includes: small resistance current-
limiting method, capacitance isolation D/C method, Plant test of D/C
reverse current injection compensation method, electric magnetic biasing
potential compensation method, etc.
29/127
2.2 Introduction to structure, material and accessories of transformer
Comparison between core form and
shell form transformer
Core form Shell form
Core
Round/epoxy tape binding Quadrangle/compressed by wedge

Easy to be evenly compressed Difficult to be evenly compressed
Feature Easy to be effectively cooled Difficult to be effectively cooled
Coil
Simple structure Complicated insulation structure

Easy processing Low mechanical strength (square
Feature High mechanical strength coil & square conductor) Difficult to
Easy to control oil cooling speed control oil cooling speed
30/127
Composition of transformer
1. Inside
Core
Coil
Insulating parts
Oil
Voltage regulating switch
2. Outside Oil storage tank

High voltage
Low voltage
Cooling device bushing
bushing
Bushing
Protective device for oil
Protecting and measuring
device
Cooling
Oil Transformer device
pump 31/127
Core
Core forms an enclosed magnetic path inside

transformer, and also serves as framework for coil
installation. It is a very important component to
electromagnetic property and mechanical strength
of transformer.
Basic structure of core

Upper yoke Main leg
Main leg: coil winding part Core leg Side leg

bandage
Side leg: the part forming magnetic
flux circuit
Yoke: the part forms upper and lower
Core leg
of magnetic flux loop bandage Lower yoke Pulling
plate
32/127
Common core type
Core stacking method
Common cross stacking

Common cross stacking
Ladder stacking
STEPLAP stacking
33/127
Core material
1 Silicon steel sheet
Hot-rolling silicon steel sheet
Cold-rolling non-oriented silicon steel
sheet
Cold-rolling oriented silicon steel sheet
Cold-rolling oriented high-conductivity
magnetic silicon steel sheet
Cold-rolling oriented magnetic
domain-refined high-conductivity
magnetic silicon steel sheet
2 Amorphous alloy
Feature of amorphous alloy:

Advantage: high magnetic permeance,
low energy loss
Disadvantage: low saturation magnetic
flux density, thin, difficult to be
processed, high material price
Can only be applied to some
distribution substation 34/127
Coil
Coil is a basic component for transformer to End
Head insulation
convert voltage. Coil consists of different turns,
Oil passage
and the voltage for each turn is the same. With
coils of different turns, different level of voltage is
generated.
In order to meet the requirements in insulating
Insulating cylinder
strength, mechanical strength, heat dissipation, etc.,
transformer coil is generally divided into 2 types:
Layer type
Cylinder type and foil type (mainly applied to
epoxy cast dry-type transformer)
Pie type
continuous type, internal panel continuous type, Cylinder type Spiral type
entangled type, spiral type, etc.
Continuous type Internal panel continuous type Entangled type 35/127

Coil category
Advantage Disadvantage Applicable scope

Easy
Low voltage, small
Cylinder enwinding, Low stability, poor
capacity coil, voltage
coil Good impact heat dissipation
regulating (TAP) coil
performance
Good heat Complex structure and Low voltage, high

Spiral coil
dissipation enwinding current coil
Most wide application

Easy structure,
Continuous Poor impact (capacity 80MVA and
easy above, voltage 3
coil performance
manufacturing
110kV)
Internal
Relatively High voltage, large
panel Complex structure and
good impact capacity coil
continuous enwinding
performance (220kV~500kV)
coil
High voltage, large Cylinder coil Spiral coil Continuous coil Entangled coil
Entangled Good impact Complex structure and
capacity coil
coil performance enwinding
(750kV and above
36/127
Coil wire material
R
Divided into copper wire, aluminium wire, copper foil angle
and aluminium foil
At present aluminium wire is not used
At present oxygen-free copper is used for copper wire Round wire Rectangular wire
By wire cross section area: round and rectangular wire
Wire insulation
Paint: polyester paint, polyurethane paint,

acetal paint, etc.
Insulating paper: cable paper, Dennison
paper, crepe paper, etc.
PET thin film: applied to copper wire of
gas transformer
Mesh-packed copper wire
37/127
Common rectangular copper wire
Flat type copper wire

Assemble line
Transposed conductor
Flat type Assemble Transposed
copper line conductor
wire
Transposed conductor
Consist of a certain number of
enamel-cover flat type wire
Each wire should be regularly
transposed in turn
Effectively reduce eddy current loss
38 /127
Internal insulation structure of coil External insulation structure of coil
Insulation
Supporting
cylinder
Pressing ring Internal oil strip
End ring ferrule baffle
assembly
Angle ring
Electrostatic
End ring ring
External oil
Cushion block
baffle
Angle ring
Divide oil clearance from oil end to upper
yoke into several small clearances to
increase electric strength Stay Cushion block Internal oil baffle
Electrostatic ring
Enlarge end radius, applied to mitigate Filler strip for transposition
electric field concentration in the end 39/127
Insulating material
Insulating cardboard
Forming insulating parts Cardboard
Electrostatic ring core End ring
Compression ring End ring

40/127
Insulation structure of coil outlet line
EHV
transformer
outlet structure
UHV
transformer
outlet structure
41/127
Transformer oil
Transformer oil plays a dual role of insulation

and heat transfer
Transformer oil is prepared by refinement of

and adding of a proper amount of into a distillate
in petroleum refining process of natural oil
Main ingredients of transformer oil are

naphthene, alkanes and aromatic hydrocarbons.
Category of transformer oil: by carbon

structure (structural group composition)
Base oil %Cp=42-50 naphthenic base oil

Base oil %Cp=50-56 intermediate base oil
Base oil %Cp=56-65 paraffinic base oil

Note % Cp: percentage of carbon atoms on alkyl side chain accounting for 42/127
total carbon number of molecule
Transformer oil physical properties
Parameters Description
Viscosity reduces as temperature rises
Motion viscosity Viscosity index of naphthenic base oil is lower than paraffinic base oil, making it easier
to cool transformer
Pour point: the min. temperature for oil to flow
Condensation point: the max. temperature when oil is unable to flow
Pour point
An important index
(condensation point)
More important to areas with cold climate, as it should be guaranteed that circulation
can still be carried out in such kind of climatic condition
Flash point refers to the min. temperature of steam created by heated oil mixes with air
Flash point and burns when exposed to open fire;
It indicates evaporativity of oil, the lower the flash point, the higher the evaporativity
2040 , proportion not exceed 895kg/m3
Density Proportion of oil should be as low as possible, impurity and water in oil easy to be
precipitated
No impact on operation performance of oil, can be applied to judge if oil processing
Interfacial tension
procedure is contaminated and oil aging degree after a period of time
The most direct index to check oil refinement
Chroma
The oil deteriorates if chroma rises in period of use
Moisture content Moisture content greatly affect breakdown voltage of oil
PCB (polychlorinated As toxic compounds, PCB is generally not allowed to be added
biphenyl) content
Total furan (furfural) By testing this index in transformer operation, aging degree of transformer fiber insulation
content can be identified 43/127
Transformer oil chemical properties Transformer oil electrical properties
Parameters Description Parameters Description
One of the important index to identify Breakdown voltage value of oil under
Acid value oil oxidation stability power frequency voltage
(neutralized A main index to indicate early
Breakdown It indicates the stress tolerance ability of
value degradation stage of oil, also an operation
voltage oil
performance index
Corrosive Affected by impurity and temperature of
Corrosive to oil, the lower the better oil
sulfur Pulse Peak voltage of oil when breakdown
A main index to judge quality of breakdown occurs under impulse voltage
transformer oil voltage
It refers to anti insulation aging ability; Its value is sensitive to determining
Oxidation Dielectric
the value is indicated by oil acid value and degradation and contamination of
loss factor
stability transformer oil
precipitate contents after artificial
oxidation. The lower the two indexes, the
higher the oil stability.
44/127
Voltage regulating method
Common mode of non-load independent transformer Common mode of auto transformer
Neutral point voltage Center voltage

regulation regulation
Common mode of on-load independent Voltage regulation at high-voltage side
transformer
Linear Positive and Thickness Voltage regulation at Voltage regulation at neutral point45/127
regulation negative regulation medium-voltage side
Voltage regulating switch
In order to supply stable voltage to grid, control power flow and regulate load current, voltage
regulation should be provided to transformer. Voltage regulating switch is the component
used to regulate voltage.
Category: on-load switch and non-load switch

Non-load voltage regulating switch
Non-load switch can only be

used to change transformer voltage
by changing tapping position of
transformer when transformer is
not magnetized
Common types of non-load
switch:
Drum type
Cage type
Strip type 46/127
On-load tap Conventional OILTAP design Vacuum VACUTAP design
On-load voltage regulating switch switch
Rated Max. to 1200 A (three-phase) Max. to 1300 A (three-phase)
current
Tungsten/copper arcing contact Vacuum cutout
(The photo is MIII600)
Arc Mineral transformer oil Vacuum
quenching
medium
Maintenance At least 50,000 times operation Maintenance free within 30,000
cycle (varied according to different times operation
models of on-load tap switch), (not require regular maintenance)
or 7 years after operated in star
connection, 2-4 years after Greatly reduce cycle cost of
operated in angle connection or transformer service life
other line terminal connection
(Choose the first fulfilled
condition)
Service life 220,000 to 500,000 times 600,000 times operation
of contact operation
(according to different models
of on-load tap switch)
Service life Tap operation 800,000 times Tap operation 1,200,000 times
of change-
over switch
core
Vacuum type Structural Mineral oil as lubrication, Mineral oil (or insulation liquid
Oil-immersed comparison insulation, cooling and arc as replacement) as lubrication,
quenching medium insulation, cooling medium
Switch electric arc generated in Switch electric arc quenched in
oil vacuum cutout
Carbon particles formed in oil No switch electric arc in oil
On-load tap switch oil Carbon particles not formed
contaminated On-load tap switch oil not
contaminated
Oil filter Must be installed in many Installation not required

application situations 47/127
Cooling device
Water cooler
Air cooler
Radiator
48/127
Bushing
Transformer uses bushings to connect windings of

different voltage classes to circuit, and uses bushings By insulation type:
of different voltage classes for insulation of oil tank.
According to use condition, bushing should meet
Pure porcelain
various requirements including insulation used Oil impregnated
(internal & external insulation), load current (rated & paper capacitance
overload), mechanical strength (stable & earthquake), Epoxy resin
etc.
Silicone rubber
By purpose:
Oil-air
Oil-oil
Oil-SF6
49/127
Bushing
Pure porcelain bushing
Widely applied to voltage <40.5kV, current <10000A
Mainly consisting of wiring board, insulator,
conductive rod, cast aluminium alloy flange, etc.
Inner bushing is filled with insulation oil in operation,
air inside bushing can be released by opening air relief
cock on upper bushing
Bushing can be vertically or horizontally placed
Oil impregnated paper capacitance bushing

Mainly consisting of wiring terminal, oil conservator,
insulator, flange, conductive rod (conductive tube),
capacitor core, etc.
There is oil level gauge on oil conservator of bushing
head to indicate oil level change
There is flange for installation connection on the
middle of bushing. There is air relief cock to release air
in upper transformer during oil-filling process, as well
as measuring bushing tg and lead wire device for
measurement of partial discharge 50/127
Bushing
Epoxy resin impregnated-paper capacitance bushing

Manufacturing method: it is a concentric conical series capacitor manufactured by winding
insulation paper and section aluminium foil on conductive tube, which is used to keep
electric field uniform. It is manufactured by vacuum drying, epoxy resin impregnation and
solidification.
Oil-air bushing Oil-SF6 bushing
51 /127
Oil protection device
Free breathing system & open oil
storage tank
Capsule or diaphragm-type oil
storage tank
Corrugated oil storage tank
External Internal
oil type oil type
52/127
Protecting & measuring device
53/127
Protecting & measuring device
Gas relay
When internal failure of transformer causing oil decomposition
to create gas, or causing oil flow impulse, relay contact will act
to connect designated control circuit and timely send signal, or
automatically cut transformer.
Pressure relief valve
Accident occurs inside oil tank, causes rise of tank pressure to
reach opening pressure of relief valve. Relief valve will swiftly
open within 2ms to quickly reduce pressure inside oil tank.
Burst pressure relay (large capacity transformer)
When accident occurring inside oil tank, burst pressure relay
measures increase of dynamic pressure inside tank. The higher
the increase rate of oil pressure, the quicker the relay movement.
Oil flow meter (with oil pump)
It is used to monitor oil pump operation, and also monitor
whether oil pump is reversed, valve is open, pipeline is
blocked, etc. When oil flow amount is reduced to a certain
amount, the meter will send alarm signal.
Current transformer
Thermometer 54/127
2.3.1 Manufacturing process of transformer

Core External assembly
Core cutting Standing Coil Connecting Drying
stacking winding
Coil
winding
Disassembly Base On-site assembly Put into

Test
for delivery operation
55 /127
2.3.2 Key control point
1Core process
Silicon steel sheet entry inspection and core plate dimension error control;
Laminated clearance;
Core assembly;
Core inspection.
2Coil process
Environment tidiness and humidity & temperature control of coil winding,
strictly prevent mixing of impurities;
Application of new manufacturing tools with high precision;
Proper use of auxiliary material (use control of recording pen);
Use control of cohesive material;
56/127
2.3.2 Key control point

3Body assembly & connecting process
Environment tidiness and humidity & temperature control, strictly prevent
mixing of impurities ;
Application of integrated assembly process;
Apply cold crimping and other connecting technology to connect lead wire;
4Application of kerosene gaseous phase drying equipment
5External assembly process
Application of welding and welding joint leakage detection (dye flaw detection,
etc.) technology reduces oil tank leakage;
Application of pre-treatment of steel plate integrated shot blasting of oil
tankpaint spraypaint film drying process guarantees paint quality of transformer;
Application of vacuum spray absolute oil technology further improves processing
capacity of transformer oil;
Welding structure of oil tank before transformer test prevent leaking on
transformer edge
6Application of shock recorder in transport
57/127
2.3.4 On-site assembly
Management of sealed air pressure in transport

Prevent damp of Management of exposure time of insulation parts
insulation parts
Humidity management of exposed insulation parts by dry air
Prevent impurities from Dustproof management when replacing transport cover plate
entering oil tank or operating inside oil tank
Remove moisture in Vacuum pumping, moisture content in insulation parts should

insulation parts be managed under 1%
Management of
Oil filter, remove impurities, water and air in insulation oil
insulation oil
Control of particle and residual bubble in Degassing filter circulation placing time management
body oil
Installation test Accessory inspection test oil test partial discharge test
Prevent falling when operating in high place

Prevent accident in Prevent oxygen deficit when operating inside oil tank
installation process
Prevent falling when lifting heavy material
Large scale leakage of insulation oil
58/127
2.4 Transformer test
Non-destructive test
(inspection test or special test)
2.4.1 Test purpose
Measuring insulation resistance
1To carry out product quality management and (absorption ratio), leak current,
improve product quality; dielectric loss, partial discharge, etc.
2To evaluate finished product quality one by one;
Destructive test (voltage withstand test)
3To examine structure of new product;
4To provide data to improve structure for new Power frequency voltage withstand, induction
product development voltage withstand, D/C voltage withstand,
lightning and operation impact performance.
2.4.2 Test category
Special test
Routine test (delivery test) Test method and technical requirement should be
Type test
All transformer should accept the test. negotiated and decided by manufacturer and user
a. Measuring winding D/C resistance; Test conducted on a together. Limit value is not provided to certain
b. Voltage ratio measuring & transformer with item standard.
connecting group mark number check; representing feature. It a. Insulation special test;
c. Measuring short circuit impedance is to prove that the b. Capacitance measuring of winding to ground
and load loss; transformers being and between windings;
d. Measuring non-load current and represented also c. Measuring transient voltage transmitting
non-load loss; conform to regulation property;
e. Measuring winding insulation requirement. d. Measuring 0 sequence impedance of three-
resistance and insulation dielectric loss phase transformer;
a . Temperature rise
factor (tan); e. Measuring short circuit withstand capacity;
f. Insulation routine test; test; f. Measuring sound level;
g. On-load tap switch test; b . Insulation test. g. Measuring non-load current harmonic wave;
h. Insulation oil test h. Measuring suction power of fan and oil pump .
59/127
2.4.3 Main test items of transformer
1Power frequency voltage withstand test:
To examine main insulation strength of winding to ground and between windings.
Test schematic
diagram
Capacitance equivalence line of three-winding transformer

H-high voltage winding, M-medium voltage winding, L-low
voltage winding, C1-capacitance of high voltage winding to
ground, C2-capacitance of medium voltage winding to ground,
C3-capacitance of low voltage winding to ground, C12-
capacitance between high & medium voltage windings, C23-
capacitance between low & medium voltage windings
Transformer under power frequency voltage withstand test /127

60
2Lightning impulse test:
In operation, transformer is often under attack from overvoltage of atmospheric lightning.
This test is conducted to test whether transformer insulation has sufficient impulse
insulation strength under simulated lightning overvoltage.
Definition of standard wave

Wave form parameter:
Wave head 1.230%s
Wave tail 50 20%s
Typical impulse test circuit

61 /127
To decide whether the transformer passes lightning impulse test:
Main criterion: impulse voltage incoming wave form and neutral point flaw detection current wave
form. Take record of wave form under 50% (reduce voltage) and 100% voltage, and decide
whether the transformer passes test or not by directly comparing wave forms.
Use transfer function of data recorder, calculate transfer function.
Analysis & comparison of Analysis & comparison of frequency domain

time domain
62/127
3Short-time induction voltage withstand (ACSD):
To verify withstand voltage strength between transformer winding phases and minor insulation of
windings (among turns, levels and sections).
Voltage to
ground
Test potential distribution diagram of

classified insulation transformer Distribution mark diagram of 750kV transformer under
potentials between windings induction voltage withstand test
Induction test of three-phase dual-winding transformer

Induction high-voltage test circuit diagram of all insulated transformer
B-transformer under test HL-current transformer HY-voltage transformer
Typical test circuit /127
63
Test method of partial
discharge
Commonly used impulse
Chemical
detection
detection
detection
detection
detection
Optical
Electric
Sound
current detection method of
Other
partial discharge
electric detection method
Typical partial
discharge map
Single air gap Multiple air gaps

internal discharge Surface discharge Corona discharge
internal discharge
Discharge interruption waveform:
Poor Controllable silicon Harmonic waveform created Modulated or non-modulated Interruption caused
contact component interruption by magnetic saturation interrupting waveform by fluorescent lamp
64/127
4Temperature rise test:
To verify that under nominal operation state of transformer, whether the loss generated by main
body and heat balance temperature of heat dissipating device are in conformity with stipulation of
related standards, and to verify whether the product structure is reasonable, to find whether the
product has partial overheating.
Core High-voltage Low-voltage Oil tank

winding winding wall Wall temperature
of oil tank
Oil temperature
Oil
Core temperature
Winding
temperature
Air
temperature
Temperature rise distribution of oil- Temperature-height distribution

immersed transformer parts diagram of oil-immersed transformer
Formulation of temperature rise test standard is directly related to insulation material used by
transformer products. Temperature rise level is also determined by insulation material with the
lowest heat resistance level which is used by product.
65/127
(5)Gas analysis:
Under thermal stress and electric stress, oil/paper insulation material will age, split and decompose in
transformer operation, producing CO2, CO and a small amount of varied low molecular hydrocarbon gas. If
the equipment suffers from early stage overheating or discharge failure, the generating amount of varied
gases, especially hydrocarbon gases, will increase, most of which will be dissolved in oil. As the failure
deteriorates, when there is more generated gas than dissolved gas, part of the gases will be released in the
form of free gas.
Gas components generated by different failure types

Failure type Primary gas Secondary gas
content content
Oil overheating CH4C2H4 H2C2H6
CH4C2H4CO
Separated gas volume

Oil & paper H2C2H6
overheating CO2
partial discharge in oil H2CH4CO C2H6CO2
& paper
Spark discharge in oil C2H2H2
Electric arc in oil C2H2H2 CH4C2H4C2H6
Temperature of
insulation oil
Electric arc in oil & C2H2H2CO CH4C2H4C2H6
Transformer oil-heat decomposition
paper CO2
& gas separation during oil paper
Damp or oil bubble H2 insulation heat failure
66/127
2.4.4 New technology/method for test
(1)RVM(Recovery Voltage Measurement
As a new non-destructive diagnosis method for humidity and aging state of solid insulation material
of oil-paper insulation transformer, the method measures recovery voltage of transformer insulation
medium, analyzes insulation state of transformer according to polarized frequency spectrum and
evaluates insulation service life.
RVM polarized spectrum of transformers with

different moisture content
After 25 years operation 36/20kv New transformer 76.5/40kv
After 15 years operation 120/20kv
Main time constant

Typical RVM polarized spectrum
Usually, the larger the main time constant, the lower

the initial slope ratio, the better the insulation state. RVM polarized spectrum of transformers with
different operation years /127
67
(2) Ultra High Frequency partial discharge detection
UHF detection method has wide and high detection frequency band (300M1500MHz), thus
featuring high sensitivity and strong interference immunity capacity. By detecting existence of UHF
signal inside power transformer, it can identify whether there is partial discharge inside power
transformer.
Monitored Oil Sealing &

equipment valve fastening
unit
Oil valve
sensor
Detection diagram
Mode
identification
Partial discharge
UHF sensor
UHF signal
Electromagnetic
wave Result
display
Antenna Filter Amplifier Wave A/D
detector transfer
Failure
location
Technical realization principle of UHF partial discharge monitoring system
68/127
2.5.1 Overhaul, operation & maintenance regulation of oil-immersed transformer
GB/T6451-1999 Technical Parameters & Requirement of Three-phase Oil-immersed Power Transformer
GB/T7252-2001 Analysis & Identification Guide of Gas Dissolved in Transformer Oil
GBJ148-1990 Construction & Acceptance Regulation of Power Transformer, Oil-immersed Reactor, and Mutual Inductor of
Electric Device Installation
GB2536-1990 Transformer Oil
GB50150-1991 Electric Equipment Commissioning Test Standard of Electric Device Installation Project
GB 261-1983 Measuring Method of Flash Point of Petroleum Products
GB 264-1983 Measuring Method of Acid Value of Petroleum Products
GB/T 507-1986 Measuring Method of Dielectric Strength of Insulation Oil
GB 5654-1985 Measuring of Power Frequency Relative Dielectric Constant, Dielectric Loss Factor & Volume Resistivity of
Liquid Insulation Material
GB/T 7599-1987 Measuring Method of Transformer Oil & Steam Turbine Oil Acid (BTB Method)
GB 7600-1987 Measuring Method of Water Content in Transformer Oil under Operation (Coulometry)
GB 7601-1987 Measuring Method of Water Content in Transformer Oil under Operation (Gas Chromatography)
DL/T 421-1991 Measuring Method of Volume Resistivity in Insulation Oil
DL/T 423-1991 Measuring Method of Air Content in Insulation Oil by Vacuum Pressure Difference Method
DL/T 429.9-1991 Oil Quality Test Method in Electric Power System Measuring Method of Dielectric Strength of Insulation Oil
DL/T 450-1991 Measuring Method of Air Content in Insulation Oil (CO2 Elution Method)
DL/T572-1995 Operation Procedures of Power Transformer
DL/T573-1995 Overhaul Guidelines of Power Transformer
DL/T574-1995 Operation & Maintenance Guidelines of On-load Tap Switch
DL/T596-1996 Preventive Test Procedures of Electric Equipment
State Grid Corporation of China Management Regulation of Power Substation
State Grid Corporation of China Technical Standard of 110 (66) kV500kV Transformer (Reactor)
State Grid Corporation of China Operation Specification of 110 (66) kV500kV Transformer (Reactor)
State Grid Corporation of China Technical Supervision Specification of 110 (66) kV500kV Transformer (Reactor)
State Grid Corporation of China Accident Prevention Measures for 110 (66) kV500kV Transformer (Reactor)
69/12 7
2.5.2 Operation & maintenance duties
Good transformer demands good maintenance. 3 duties of operation & maintenance:
In order to timely
detecting problems,
Observe Record Report please equip with
necessary instrument
and device, e.g.
binoculars, infrared
thermometer &
(By eyes) see infrared imager, etc.
(By nose) smell
(By ears) listen Comprehensive On time
Key point and
different point
1Far infrared temperature monitoring for bushing, joint and other parts, temperature rise of all parts should
conform to related regulations.
2Enhance patrolling and insulation oil performance detection in early operation stage of transformer.
3 For transformer in operation, use core to connect external earthing bushing to detect core earthing current
when necessary. 70/127
2.5.3 Operation, maintenance & inspection standard
Routine Maintenance Regular

inspection inspection
23 years
General overall
Replacement of
consumables
10 years
Overhaul cycle can be properly extended according to status overhaul condition.
71/127
2.5.4 Routine inspection of transformer
1Transformer: temperature, oil level, oil leakage, noise & vibration;

2Cooling device: noise & vibration, oil leakage, operation, dirt;
3Bushing: oil leaking, oil level of bushing, whether there is crack, damage or dirt
on porcelain petticoat;
4Moisture absorber : dryness, colour change;
5Pressure relief valve: oil leakage;
6Others: timely arrange related personnel to carry out inspection in case of special
weather such as gale, mist, rainstorm, heavy snow, etc.
72/127
2.5.5 Regular inspection of transformer
Inspection part Inspection item Cycle
Insulation resistance Insulation resistance (including

2~3 years
bushing)
Voltage withstand
2~3 years
Acid value measurement
Dielectric loss measurement

Insulation oil Immediately after put into operation;
Analysis of gas dissolved in oil After 3 months;
After 6 months;
Air content
Measured annually afterwards.
Moisture content
Oil pump, fan 1 year

Cooler
Cooling tube, support, etc. 1~3 years
Connecting overhead line
Bushing 2~3 years
Appearance
Note: see instructions for detailed explanation of inspection items of other parts.
73/127
2.5.6 Other accessories
Control circuit 2 or 3 years 1. Measure terminal-to-ground insulation resistance with 500 megger;
(annual for control 2. Check junction box: for rain soaking or terminal rusting or loosening
break-brake circuit)
2 or 3 years 1. Oil leakage; 2. Gas amount in gas relay;
Gas relay (annual for control 3. Check motion of relay contact by test button;
break-brake circuit)
Oil 2 or 3 years 1. Calibrate temperature indicator;
thermometer 2. Moisture inside thermometer or not
Winding
thermometer
Thermocouple 2 or 3 years 1. Calibrate temperature indicator;
Oil level 2 or 3 years 1. Motion of floating ball and indicator; motion of contact
2. Moisture inside oil level gauge or not
Oil flow relay 2 or 3 years 1. Motion performance check
2. Moisture on oil flow meter or not
74/127
2.5.7 Replacement of transformer consumables in overhaul
Parts Replacement cycle

Oil-pump bearing If a bearing with more than 10 years service life makes
(ball bearing) abnormal noise, replace all bearings when transformer is shut
down.
Cooling fan bearing If a cooling fan bearing with more than 10 years service life
(non-lubricating) makes abnormal noise, replace all bearings when transformer is
shut down.
Oil-tight sealing With more than 15 years service life, replace all sealing
ring elements according to specific condition.
On-load tap Replace according to requirements on user instruction of on-
changer load tap changer and electric power operation unit.
75/127
2.5.8 Common accident prevention of transformer
Carry out transformer failure prevention test according to Preventive Test

Procedures of Electric Power Equipment DL/T596-1996.
Prevention of transformer insulation breakdown

accident:
Prevent water and air from entering transformer;
Prevent mal-operation and failure operation of
protective device
Suggestion: after transformer is put into operation, set

up transformer files to take record of routine
operation data, failure of each time, and
problems. We will analyze and handle
problems together with you when necessary.
76 /127
Outline

3.1 Concept & specification of intelligent transformer
3.2 Intelligent online monitoring project of transformer
3.3 Standard for each test item
3.4 Intelligentization
77/127
3.1.1 Concept of intelligent transformer
Intelligent transformer consists of transformer and intelligent electronic device;

transformer includes various kinds of sensors, controllers, electronic current & voltage
mutual inductor for monitoring of health status of transformer; intelligent device include
monitoring function group (consisting of main IED and other monitoring IEDs) and
merging unit.
What is intelligent electronic device?
Intelligent Electronic Device (IED) is a kind of processor-equipped electronic device
with all or part of the following functions:
1Collect or process data;
2Receive or send data;
3Receive or send control command;
4Execute control command.
<#>
78/127
3.1.2 Technical features of intelligent transformer
Status
visualization
Network Integrated
control function
Technical
Digitalized features of Information
measuring intelligent interaction
transformer
79/127
3.1.3 Design specification
QGDW 383-2009 Technical Guidelines of Intelligent Power Substation

QGDW 410-2010 Technical Guideline of Intellectualization of High-voltage Equipment
Q/GDW 394 2009 Design Specification of 110(66)kV220kV of Intelligent Power Substation
Q/GDW 394 2009 Design Specification of 330kV750kV of Intelligent Power Substation
QGDW 428-2010 Technical Specification of Intelligent Terminal of Intelligent Power Substation
QGDW 424-2010 Technical Specification of Electronic Current Mutual Inductor
QGDW 425-2010 Technical Specification of Electronic Voltage Mutual Inductor
QGDW 426-2010 Technical Specification of Merging Unit of Intelligent Power Substation
Q GDW 429-2010 Technical Specification of Ethernet LAN Switch of Intelligent Power
Substation
QGDW 430-2010 Technical Specification of Intelligent Control Cabinet of Intelligent Power
Substation
QGDW 431-2010 Site Debugging Guidelines of Automatic System of Intelligent Power
Substation
<#>
80/127

3.1.4 Schematic diagram of intelligent components of transformer
81/127
82/127
Intelligent online monitoring project of transformer
Oil temperature & environment

temperature monitoring
Monitoring & control of cooler
Partial discharge monitoring
Core grounding &
current monitoring
Bushing insulation monitoring
Winding hotspot
temperature monitoring
Oil chromatography &
micro water monitoring
3.2.1 Structure & layout method of cabinet casing
of intelligent components
83/127
3.2.2 Monitoring of gas dissolving in oil
Gas chromatography:
Chromatography applying gas as mobile phase (carrier gas) is called gas
chromatography (GC). When analyzing specimen by gas chromatography,
the specimen is gasified under heating condition, and taken into
chromatographic column by carrier gas. As the function of constituents is
different in stationary phase and in carrier gas, their movement speed in
chromatographic column is varied. After a period of time, the specimen is
separated, and is taken into detector by carrier gas in turn. Concentration
and mass of each constituent is transformed into electrical signal changes,
and recorded in the form of chromatogram. Quantification is conducted
according to peak height or peak area of chromatogram.
84/127
Gas category under

online monitoring Hydrogen
H2 Temperatureofheatsource
Partialdischargeornot
Damp
CO
Carbon monoxide Whetherthereisthermolysisof
CO2 solidinsulationmaterial
Agingofsolidinsulationmaterial
In accordance with GB/T 7252- Carbon dioxide
2001 Guide to Analysis and CH4 Whether average temperature is too high
Identification of Gas Dissolved

in Transformer Oil Methane C 2H6
Ethane C 2H4 Featuretemperatureof
overheatingfailure
C 2H2
Ethylene
Electricdischargephenomenonornot
Acetylene Ultra high overheating failure point
temperature
Online monitoring of constituents including
02, micro water, etc. can be customized.
85/127
System composition & operation principle
Monitoring instrument consists of host machine, gas cylinder and oil tube. After
site installation of oil inlet and outlet circuit to transformer, the product can be put
into operation by connecting to communication cable and power supply.
Oil-immersed
transformer
Communication
Oil-gas separation
Separation test of mixed gas method

Oil circulation
Oil
extraction Monitoring
Concentration value of
valve system
gases (PPM)
Oil return
valve
86/127
3.2.3 Monitoring of optical fiber winding temperature
When large-scale transformer is operated, the distribution of coil temperature is

not uniform. High coil temperature will affect safe operation and service life of
transformer. Monitoring of temperature change of transformer coil is a main
content of online monitoring of transformer. When practicing optical fiber
temperature measuring, optical fiber probe should be buried in place with the
highest temperature to provide basis of service life evaluation of the transformer.
87/127
Monitoring of winding temperature by optical fiber
Safe & reliable design:

Solid LED light source prevents bulb
failure
Impulse protection: 3000V
3rd generation enhanced probe, with
the lowest probe damage rate during
transformer installation
200m quartz optical fiber
Double-layer Teflon sheath, Kevlar
cable.
88/127
Product configuration
Host machine
Optical fiber probe
Through machine of oil tank wall
Multi-layer plate of oil tank wall
External extension optical fiber
Optional protective cover of oil tank wall
Carbon steel ring

Assembly of through machine & multi-
Oil tank
layer plate of oil tank wall (including
passageway machine)
ST connector
Viton O-type rubber cushion
External extension
External extension
optical fiber Optical fiber probe
optical fiber
Welding
To instrument
Outside transformer Inside transformer

89/127
System composition
Through
device
External
Optical optical
fiber fiber
probe RS485
Transformer Wall of Data collector

coil oil tank
90/127
Installation of optical- 4
fiber probe 3
2
1
91/127
3.2.4 Insulation monitoring of bushing
Bushing failure accounts for a large proportion in transformer failure. At present,

the mature technology is to extract bushing tap grounding, and install online
monitoring device on tap.
92/127
Bushing insulation monitor is to diagnosis their condition by measuring sum of vector quantity of
leakage current of bushing end shield. Rectangle component change of sum of vector quantity of
three-phase current (red component) is used for calculating change of capacitance C, while same-
phase component change in blue component is used for calculating change of power factor. Angle
between vector quantity of three-phase current and reference current is used for judging parameter of
which bushing changed.
Sum current
PD sensor
Null meter Power factor

B balance unit Summation unit Capacitance change
change
93/127
3.2.5 Iron core earth current monitor
During normal functioning of transformer,

current to earth formed by suspended
potential of iron core is at milliampere.
Earth bar of iron core
Where iron core has multi-point earth or
short circuit, the current to earth increases,
which leads to heating fault. Therefore,
Current sensor
current sensor is connected on earth line of Data collection
iron core to measure the current to earth, the Data processing
signal is processed by data collector and
updated to upper computer for data analysis. Data transmission
94/127
Sensor for monitor of current to earth of iron core
The sensor is a ring-shaped CT wound for iron core mounted in a overlap

form to effectively measure the amplitude of current.
Current to earth of iron core

Specifically designed
sensor
High-precision
measurement
Simple installation
Free of maintenance
95/127
3.2.6 Partial discharge monitor
HV
side oftransformer
LVside
oftransformer

In respect of instantaneous fault

Iron core
earthing
Iron coreearthing

and sudden fault, partial discharge
monitor is faster and more sensitive
1 2
than oil gas monitor. Compared with
PD sensor WCT
WCT PD sensor

oil gas monitor, partial discharge
monitor can rapidly and timely give
early warning to abnormal condition
of transformer insulation and
RS485
discharge fault, provide necessary
IED
PD monitor IED
guide data for its normal functioning
Network port
and improve its reliability, safety and
effectiveness.
MaIED
in IED
96/127
Partial discharge monitor probe Transformer box

wall
PD sensor
Installation
Transformer
oil tank wall
UHF
coupler
Real
photo
97/127
3.2.7 Cooler control
The cooler controller acquires related information (oil surface temperature, winding
temperature, load current, etc), assess hot point temperature of winding, control the cooler and
feedback functioning condition information of cooler to cooler controller.
98/127
3.2.8 Routine signal monitor
Target: oil temperature, ambient temperature, oil level, oil pressure, current,
light and heavy gas, etc.
99/127
3.3.1 Standard of gas dissolved in the oil
Name Item Min value Measuring extent

H2 10L/ L 02000L/L
C2H2 0.5L/L 0100L/L
CH4 2L/L 01000L/L
Monitor IED of
gas dissolved in C2H4 2L/L 01000L/L
the oil C2H6 2L/L 01000L/L
(chromatography)
CO 50L/L 02000L/L
CO2 50L/L 010000L/L
H2O 2% RH 2%100%RH
Monitor IED of H2 10L/L 02000L/L
gas dissolved in
C2H2 3L/L 3100L/L
the oil
(electrochemistry) H2O 2% RH 2%100%RH
100/127
3.3.2 Standard for current to earth of iron core, partial discharge

and optical fiber winding temperature
Name Item Standard parameter value
Measuring extent 10mA~10A

Current to earth of iron 2.5mA
Measurement Less than 100mA
core
precision 100mA 2.5%
Min detectable discharge signal 300pC

Partial discharge
Max detectable discharge signal 10000pC
Measuring extent 0
-200
Optical fiber winding
temperature Uncertainty 2
101/127
3.3.3 Standard for cooler control
Standard
Name Item
parameter value
Start of cooling system Zero error
Activate one group of cooler Zero error
Deactivate one group of cooler Zero error
Control
Activate all the coolers Zero error
Deactivate all the coolers Zero error
Stop cooling system Zero error
Success or failure of cooling system start Zero error
One group of cooler activated Zero error
One group of cooler deactivated Zero error
State of oil pump (normal, fault) Zero error
State State of each group of cooler (functioning, fault, Zero error
stop)
State of power supply of cooler (normal, fault, loss Zero error
of phase, power failure)
State of cooler (manual, auto) Zero error
State of oil flow Zero error 102/127
3.3.4 Standard for routine signal monitor
Standard parameter
Name Item
value
1) Oil level port 1cm
2) Continuous monitor of oil level 1cm

3) Analog value of gas accumulating quantity 15%
4) Top oil temperature 1

Routine signal
monitor 5) Bottom oil temperature 1
6) Analog thermometer for winding Class 1.5 or 2.5
7) Ambient temperature
8) Voltage and current of incoming and outgoing 0.5%
line
103/127
3.4.1 Intelligent management system of transformer
Intelligent management system of transformer enables

real-time online monitor of transformers functioning state,
early diagnosis of latent fault, early fault and sudden fault,
so that safe and reliable functioning is ensured. It also
provides functions of state information management, state
assessment, diagnosis and control.
It is mounted in main IED of intelligent components. The
interface can display functioning parameters and state
parameters of transformer and functioning state of system.
The system can display measured parameters either in the
form of curve or report, and it also enables state
assessment.
104/127
3.4.2 Block diagram for diagnosis for integrated faults of transformer
105/127
3.4.3 Information transmission of intelligent
components
Intelligent substation can be divided into control

layer, intermediate layer and process layer according
to network structure.
The model is based on IEC-61850 protocol and is
distributed in the form of frame network. All the
equipments on the intermediate layer and process
layer are modeled according to IEC-61850 protocol
to enable inter-operability.
106/127
TOSHIBA
Transf01mer Intelligent components cabinet Substation
Motor
Cable
..
<Xlllb'Ol
.. ..
II!C613l0 . ..
., 1 2C61Il0
l
,.., Cable I I!C618lO Ndol\n cabl
1 2C618l0
.
'"!nage.
Top ci.ltaq>, bottom oil Ca II!C613l0 Ndol\ :abl

temp., oron core earth 1 2C611l0
cturm, llXlbieJJl temp. mea<uremont device
Optical fi er I I!C618l0 a
Opilcil fiber probe ,_.emp. 1 2C618l0 12C6 I 3l0 Optical fiber
To exchanger of subslatian cootrollayer
II!C613l0 :abl
I Maio IDDIIitor lED 1 2C611l0
r
Piping I I!C613l0
Oil & gosport micn: water ;tor .
Cable II!C613lO NdxmD :abl
Partial disc:bargesensor itm- er
Ex hanger
Cable I I!C613l0 I2C6 I 3l0 Optical fiber Combinedunit or exchanger of proclO!s
n !aye<(colJed input, oulpUI Olll'elll and
mooitnr sensor IDCIIi!nr volt!ge of IJ3DS!imuer)
Optical b II!C613l0 :abl
Elec:b'OoDt ow!uailnducer C<mbiDed unit 1a C613H Optical fiber
To exchmger of process layer
Pressure release,, Cable D cabl

I I!C613lO
liquid le\-.l,r relay, 12C6 I 3l0 Optical fiber
Ulllt To exchmger ofprocess layer
SWitdl gJS,
- -
107/127
3.4.4 Network structure of intelligent substation
108/127
Outline

4.1 Application of advanced analysis tools
4.2 Direction of large volume and high voltage
4.3 Direction of environmental protection and high reliability
4.4 Direction of overload capacity, long service life and
intelligence
109/127
4.1 Advanced analysis tools: introduction of CAE theory
CAE (Computer Aided Engineering), means that computer is used to assist solution
and analysis of complex engineering, and structural and mechanical performance of
product, and optimization of structural performance, etc.,
The core concept of CAE system is discretization of structure, i.e.: to discretize actual
structure to combination of regular units of limited number, physical performance of
actual structure can be analyzed via discretized unit, so that approximate result that
meets engineering precision requirement is derived to substitute for analysis of actual
structure, in this way, many complex problems that shall be solved in actual
engineering but can not be solved by theoretical analysis are solved.
We can use CAE software to analyze static structure and dynamic state; research
linear and non-linear problem; analyze structure (solid), fluid, electromagnet,
temperature, noise, etc.
Common CAE software: ANSYSABAQUSADINAALGORCosmos, etc;

Hereinto: ANSYS, as large-scale multi-physical field simulation software, now has
widest application scope and highest maturity degree in China.
110/127
4.1 Advanced analysis tools: multi-physical field
calculationoftransformer
Transformer oil is not only insulating medium but also cooling medium;
Transformer simulation
Transformer is very complex in structure, and it consists of hundreds of

conductors, structural parts and irregular oil piping;
Transformer is relatively large in size and structure, but very small in
conductor penetration depth. Eddy loss in the conductor caused by skin
effect and proximity effect will differ at different positions;
Power transformer simulation is a very complex coupled problem for
multi-fields: electromagnetic field fluid temperature field;
Electr
Calculation result f omag Calculation result of
netic
electromagnetic loss field electromagnetic force
as load of fluid field as noise calculation
load
Transformer
Fluid (multi- Noise
field physical
field) Inner structure of
Inner structure of transformer decides
transformer decides noise spread
distribution of inner direction and
flow field of Struct strength
ure
insulating oil 111/127
4.1 Advanced analysis tools: Structural strength analysis application of
transformer
For transformer producer, CAE software can
solve
Static analysis Dynamic analysis

Eg: Strength analysis of oil tank; Eg: Analysis of vibration resistance
Strength analysis of inner structural of transformer and bushing;
parts, etc; Vibration analysis of iron core, etc;
Strength analysis of oil Strength analysis of inner

tank of transformer structural parts of transformer 112/127
4.1 Advanced analysis tools: electromagnetic field analysis
applicationoftransformer
solve
Electric field analysis Magnetic field analysis

Eg: Inner and outer insulation of Eg: Loss caused by magnetic field
transformer, etc; distribution and leakage magnetic
field of transformer, and current
Calculation
of electric desity, etc; Calculation of flux
field at density of iron core and
winding end winding of transformer;
of
transformer;
Calculation of Distribution of axial

insulating electric magnetic field of coil
field of outgoing line winding
of transformer; Distribution of crosswise
magnetic field of coil
winding
113/127
4.1 Advanced analysis tools: fluid temperature field analysis
applicationoftransformer
solve
Fluid field analysis Temperature field analysis
Eg: Calculation of fluid field Eg: Calculation of temperature

and flow speed of insulating rise of transformer;
oil in the transformer;
Calculation of temperature field of

iron core coil of transformer;
Distribution of fluid field of insulating oil Calculation of temperature field

in the transformer; of iron core coil of transformer;
(section view)
114/127
4.1 Advanced analysis tools: noise analysis application of transformer
For transformer producer, CAE software can solve
Inner noise of transformer Noise analysis of substation
Analysis
result after
simplifying
model
Noise
frequency
spectrum at
each part of
transformer
115/127
4.1 Advanced analysis tools: also used for introduction of power
systemanalysisprogram
Software name Developer Function and features Typical applications
1. Electromagnetic transient state analysis for power
Electromagnetic
system;
US Bonneville transient state
EMTP 2. Resonance overvoltage calculation for power
Power Bureau calculation program for
system;
power system;
3. Mechanical & electrical transient state calculation;
High-performance
Mainly applied in digital simulation of control link of
MATLAB US Mathworks general scientific
power system, etc;
calculation software
1. Law that reference changes from time when power
Canada
DC electromagnetic system is interfered or parameter changes;
PSCAD/ Manitoba
transient state 2. Applied in FACTS control system design of HV DC
EMTDC Hydropower
calculation software; transmission, harmonic wave analysis of power
Bureau
system;
Complete original Besides general stable state and transient state
models of program; simulation for power system, it also simulates:
Germany Simulated frequency 1. Transient overvoltage during closing impact of
NETOMAC
Siemens band width; transformer;
Satisfy large-scale 2. Transient unload process of saturated/non-saturated
calculation demand; transformer, etc;
116/127
4.2Directionoflargevolumeandhighvoltage
With development of new materials, process and transport approach, volume of
single column keeps increasing, it is an avoidable trend to use ultra-large volume
and ultra-high voltage power transformer to transmit power:
Voltage:
AC class: develop from 220kV, 330kV, 500kV and 750kV to 1000kV.
DC class: develop from 500kV to 800kV and 1100kV.
Volume:
Single-phase transformer:
(500kV class): develop from 250MVA and 334MVA to 500MVA and above
(1000kV class): develop from 1000MVA to 1500MVA
Three-phase transformer: develop from 240MVA and 750MVA to 1000MVA
and 1500MVA
450 ton open web 380 ton

girder wagon schnabel car117/127
4.2 Direction of large volume and high voltage
For AC1000kV For DC800kV For large volume
118/127
4.3Directionofenvironmentalprotectionandhighreliability
Behavior of environmentally-friendly and highly reliable transformer:
1. Low loss
a) Development and application of superconducting transformer
b) Application of new material and new structure
2. Low pollution
a) Development and application of low-noise transformer technology
b) Substitution for mineral transformer oil: application of gas
transformer, dry transformer, vegetable oil, silicone oil, etc
c) Avoidance of corona and radio interference
3. Compact structure, high safety
4. Strong overload capacity, long service life
5. Intelligent application
119/127
Low loss: superconducting transformer
Only utilize properties of zero resistance among features of zero resistance, diamagnetism
and quantum tunneling effect of superconducting material. Compared with currently normal
transformer, the loss is only at percentage level.
Critical
Family name General chemical formula
temperature
Rare earth family
R,Ba2CuO4-x, 36K
214
Rare earth family
123 (yttrium RBa2Cu3O7-x 90K
family)
Bi
superconducting Bi2Sr2Can-1CunO2n+4,n=2,3 110K
family
TI
Tl2Ba2Can-1CunO2n+4
superconducting 45K95K and 120K
n=1,2,3
family
Hg
630kVA/10.5kV-0.4kV superconducting
HgBa2Can-1CunO2n+2+x, 85K120K and
n=1,2,3 133K
Normal family
Superconducting
Item transformer(G Currently, manufacture process problem for Bi
transformer
B/T6451)
family I and yttrium family II is solved and they
No-load loss 1090 W 1200 W reach commercialized level, but manufacture cost
Load loss 110 W 6200 W and operation cost are high.
Impedance 2.7% 4.5% Properties of superconducting transformer need to
Winding be further researched.
Bi-2223/Ag Cu
material
120/127
Low pollution: substitute for mineral transformer oil, vegetable insulating oil
1. Good natural decomposition, small influence to environment

Rapeseed oil mainly consists of five esters of fatty acid and has simpler composition than mineral oil
and it is free of sulfur.
2. Good electrical performance

Compared with mineral oil, its dielectric constant (about 1.3 times higher than that of mineral oil) is
near to that of insulating paper, insulating breakdown voltage can rise by about 15%
3. Better thermal transmission

For its low viscosity which is 0.7 times as much as that of mineral oil, the thermal transmission effect
of coil is improved, its efficiency is 1.2 times higher than that of mineral oil, while cooling efficiency
is improved greatly.
4. High safety
Burning point above 200
5. Extensive sources
It has not been widely applied for the reason of manufacture cost, oxidation resistance, etc.
121/127
Compact structure, high safety
1. Full use of land resources, transport of
1. Ceaseless development of urbanization energy sources from mountain zone,
construction Demand for underground demand for smaller footprint of power
substation, high-rise substation station to conquer transport limit
Demand to substitute large-volume
2. Offshore wind power output, construction three-phase transformer for 3 sets of
demand for offshore substation platform single-phase transformer
Application of large-volume disassembled-

Application of dry transformer, gas transport transformer
insulating transformer
3 sets of 1 set of three-

single phase phase
Footprint reduces by: 60
Transport weight reduces by 70
Develop to three-phase 1500MVA
122/127
Large-volume disassembled-transport transformer (ASA)
123/127
Compact structure, high safety
Dry transformer: applied below 72.5kV 30MVA
Gas transformer: Max volume 330kV 400MVA (insulating medium: SF6 gas)
Advantage: compact structure, safety (inflammable, explosion proof), simple
installation, easy maintenance and overhaul
Low gas pressure Example of distribution of 275kV
for voltage below 300MVA substation
220kV
150MVA-275kV
gas insulating
reactor
High gas pressure

for voltage 220kV
and above
300MVA-275kV GIS
Gas insulating transformer
Footprint when GIS is fitted reduces by 40%
compared with oil-immersed transformer
124/127
Gas insulating transformer
Explosion proof Simple installation and maintenance
Oil tank Oil-immersed transformer Gas insulating transformer
100
strength 1 Oil level meter Gas density switch
Pressure rise (%)
80
2 Coil thermometer Coil thermometer
60 Oil-immersed 3 Oil conservator
transformer
40 4 Oil conservator capsule
Gas insulating 5 Moisture absorbing aspirator
20
transformer
6 Gas detection relay
0
7 Oil thermometer Gas thermometer
0 0.2 0.4 0.6 0.8 1 1.2
Accident duration (s) 8 Gas relay
9 Sudden pressure relay Impact gas relay
Simple switch maintenance 10 Pressure release valve

11 Online oil filter
Simple gas chromatograph

analysis
125/127
4.4Directionofstrongoverloadcapacityandlongservicelife
Advanced design methods strong overload
Application of FEM, FAM, SIM methods
Technical support of modern measurement
capacity and
long service
life
Flow velocity
vector diagram Warranty of modern
manufacture process
Application of new
material Intelligent Reasonable functioning
Service life depends on field way
Adjust according to integrated
Mainly on non- state of the system
replaceable insulating
paper and insulating part Online monitor of transformer
Degree of polymerization performance and state during
may reflect aging extent functioning
of cellulose CO2+CO, furfural, acetone Online
Chemical formula of monitor and analysis of gas Accurate
cellulose measurement of temperature
Load record
Temperature rise
diagram of oil in
the coil
Glucose ring 126/127
Thank you!
127/127

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Transformer Technology

1. Basic knowledge of transformer

2. Key technology of transformer manufacturing

3. Intelligent technology of transformer

4. Development & prospect at home and abroad

Schematic diagram of Faraday's

bottom, e.g. u1.

In the formula: E1m=N1m (Max. value)

China 1922, 1953, 1957, 1970, 1979, 2004, 2008, 2009,

80MVA-220kV 600MVA-500kV 3000kVA-66kV 1000MVA-1050kV 400MVA-330kV

What does OSFPSZ9-250000/220 mean?

JB/T3837-2010 Identification Method of Transformer Product Model,

Special using environment code (usually not marked,

Special purpose or special structure code (do not mark if

Letter of product model

No. Category Meaning Representing letter

e.g. OSFPSZ9-250000/220 means

Design S/N (1, 2, 3 b for half copper half aluminium)

Winding coupling method (usually not marked, O auto

e.g. OSFPSZ9-250000/220 means

1. Basic knowledge of transformer

2. Key technology of transformer manufacturing

3. Intelligent technology of transformer

4. Development & prospect at home and abroad

The charged part of bushing

Major insulation structure of winding:

Voltage on power side

Re-arcing shock wave

AC electric field determinant: dielectric coefficient

A/C potential distribution ( oil/ paper = 2.2/3.2)

DC electric field determinant: resistivity

Leakage flux distribution

Schematic diagram of coil cooling Schematic diagram of cooling

Gilled radiator Cooler

1. Remove sulphur compound

2. Change oil (replace with non corrosive new oil)

3. Oil dilution (diluted by non corrosive oil)

4. Add Passivators (recommended by NYNAS)

1Correct and reasonable mechanical force design

2Application of manufacturing technology and proper material

a) Winding applies hard copper wire;

b) Guarantee constant pressure drying of winding, and pre-

c) Use perfectly round pressing plate, guarantee strength and

d) Improve structure of low voltage winding, and improve

e) Strictly control height difference between windings, reduce axial

Noise reduction measures:

6 lapping iron core

Round/epoxy tape binding Quadrangle/compressed by wedge

Simple structure Complicated insulation structure

2. Outside Oil storage tank

Core forms an enclosed magnetic path inside

Basic structure of core

Main leg: coil winding part Core leg Side leg

Core stacking method

Common cross stacking

Feature of amorphous alloy:

Continuous type Internal panel continuous type Entangled type 35/127

Advantage Disadvantage Applicable scope

Good heat Complex structure and Low voltage, high

Most wide application

Paint: polyester paint, polyurethane paint,

Flat type copper wire

Forming insulating parts Cardboard

Electrostatic ring core End ring