CBIP Plant

6th International Conference on Large Power Transformers – Modern Trends in
Application, Installation, Operation & Maintenance
DESIGN, MANUFACTURING, TESTING,

INSTALLATION AND COMMISSIONING OF
LARGE RECTIFIER TRANSFORMERS
FEEDING 3.4 MW RECTIFIER UNITS FOR
NUCLEAR RESEARCH APPLICATIONS
by
DR.R.D.KULKARNI
BHABHA ATOMIC RESEARCH CENTRE
rdk@barc.gov.in
February 22nd - 23rd , 2017, Scope Complex, Lodhi Road, New Delhi, India 1
Outline of Presentation
• Working of Typical Nuclear Power Plant
• Simulation of Safety Related R&D Studies in Experimental Facilities
• Specifications of High Power Rectifier Units
• Single Line Diagram of Electrical Power System feeding Rectifier Units
• Schematic Block Diagram of 3.4 MW Rectifier Unit
• Approach for Design of High Power Rectifier Transformer
• Simulation of 12 Pulse, 3.4 MW Rectifier Unit
• Factors considered for the Design of High Power Rectifier Transformer
• Parametric values of rectifier transformer and mineral oil
• Testing methodology of Rectifier Transformer
• Testing, site installation and commissioning of rectifier transformer
• Conclusions
Working of Typical Nuclear Power Plant
Simulation of Safety Related Studies in Experimental Facilities
3-D view of ITL Phase-II

Simulation of Safety Related Studies in Experimental Facilities
Old FRCS
New FRCS
Specifications of High Power Rectifier Units
• Input: 33±10% kV, 3 Phase, 50±3% Hz, AC
• Output: Maximum 10,000 kA at 340 Volts DC
• Output Power: 3,400 kW
• Current/power stability: ± 0.25% of set value
• Response time: < 100 milli second from 10% to 100% of set value
• Type of control: Secondary control incorporating phase angle control
method using SCR as a control element in a closed loop manner
• Mode of control: CC/CP adjustable from 10% to 100% of rated value
• Type of load: Resistive (Direct heating of Inconel tubes of Fuel Rod Cluster
Simulator (FRCS) of NPP)
• Cooling: Step down Power Rectifier Transformer is ONAN, Inter Phase
Transformer is forced air cooled & SCR assemblies are DM water cooled
• Circuit configuration: Twelve pulse, fully controlled bridge rectifier system
• DC current sensor: Clamp-on type DCCT to sense, monitor, control current
• Power monitor: Incorporation of isolated, true RMS power transducers
Single Line Diagram of Electrical Power System feeding Rectifier Units
Schematic Block Diagram of 3.4 MW Rectifier Unit
Approach for Design of High Power Rectifier Transformer
• Rectifier transformer supply DC load currents.
• Secondary windings of rectifier transformers interfaced with rectifier circuits
based on semiconductor devices and thus, generate harmonic currents.
Secondary current is highly discontinuous and flows part of the cycle.
• Transformer primary current is continuous, however, THD exceed the limit
mentioned in IEEE: 519 guidelines and hence need attention.
• Harmonic currents causes overheating, induce voltage stresses, core
saturation and offer serious problems if they are not evaluated properly.
• Design of magnetic circuit parameters- operating flux density.
• Calculation of true RMS magnitude of voltage & current
• Sizing of copper conductor of windings
• Modeling/software simulation of the transformer and rectifier together to
extract the harmonic spectrum of the current.
• Designer use this approach for optimal design of rectifier transformer.
• IEEE standard No. C57.18..10.1998 verifies usefulness of this methodology.
Simulation of 12 pulse, 3.4 MW Rectifier Unit
0
Simulation Result of DC Output Current Waveform
1
Simulated Result of Secondary Current Waveform
2
FFT Analysis of Secondary Current Harmonic Content in Secondary Current
Harmonic Order Frequency Magnitude
(Hz) (% of Fundamental)
Fundamental 50 100
3rd 150 0.39
5th 250 19.85
7th 350 13.39
11th 550 8.27
13th 650 6.34
17th 850 4.54
19th 950 3.50
23rd 1150 2.58
25th 1250 1.92
29th 1450 1.35
31st 1550 0.94
35th 1750 0.56
37th 1850 0.32
47th 2050 0.25
49th 2150 0.25
3
Simulated Results of Primary Current Waveform
4
FFT Analysis of Primary Current Harmonic Content of Primary Current
Harmonic Order Frequency
(Hz)
Magnitude
(% of Fundamental)
Fundamental 50 100
3rd 150 0.35
5th 250 0.33
7th 350 0.34
9th 450 0.31
11th 550 8.06
13th 650 6.47
15th 750 0.28
17th 850 0.27
19th 950 0.29
21st 1050 0.21
23rd 1150 2.45
25th 1250 0.2
27th 1350 0.15
29th 1450 0.14
31st 1550 0.1
35th 1750 0.52
37th 1850 0.34
47th 2350 0.22
49th 2450 0.27
5
Problems caused due to harmonics
 Generally, transformers are designed to operate at rated frequency.
 The effects of harmonics on transformers are commonly unnoticed
and disregarded until over heating & pre-mature failure happens.
 Transformers that have operated adequately for long periods have
failed in a comparatively short time.
 Main causes are:
 Overheating of windings
 Over - stressing of the insulation of the windings
 Core deformation and extra vibration
 Skin effect
 Nuisance tripping of circuit breaker
 Triple-n harmonics currents circulate in delta windings
6
Effect of harmonics on losses
7
February 22nd - 23rd , 2017, Scope Complex, Lodhi Road, New Delhi, India
Derating of transformer due to presence of harmonics
• To estimate by how much a standard rectifier transformer should be
de-rated so that the total loss on harmonic load does not exceed the
fundamental design loss. The De-rating Factor can be given by
where:
e – the eddy current loss at the fundamental frequency divided by the loss due to a DC current equal
to the RMS value of the sinusoidal current, both at reference temperature.
n – the harmonic order
I –the RMS value of the sinusoidal current including all harmonics given by RMS value of the sinusoidal
current formula
In – the magnitude of the nth harmonic
I1 – the magnitude of the fundamental current
q – exponential constant that is dependent on the type of winding and frequency typically 1.5 to 1.7.
9
Life of rectifier transformer handling harmonic currents
• To estimate life reduction of transformer, the deterioration rate of its insulation materials has to be
considered, too. About fifty per cent of life reduction of transformer is caused by thermal stresses
created by non-linear load
• The most important factor in life reduction of transformer is hotspot. The temperature of the
winding is calculated from the following equation-
• Where θHS = Hot spot temperature

• θA = Ambient temperature
• θTO = Top oil rise Over ambient temperature under non-linear load current
• θTO-R = Top oil rise under rated condition
• θg = Hot spot rise over top oil temperature under non linear load current
• θg-R = Hot spot temperature rise over top oil rise under rated condition
• PLL = Load loss under Non linear condition
• PLL-R = Load loss under rated condition
• PNL = no load loss
0
Life of rectifier transformer handling harmonic currents
• The maximum allowed current for decreasing rated power and capacity
of transformers with harmonic load can be determined that this action
be called de-rating for estimate reduced transformer life, degradation
rate of insulation material must considered. 50% reduction of
transformer life is due by thermal stress is caused by harmonic currents.
Most important factor in reducing the life of transformers is θHS point
temperature. Reduction of life and real life of a transformer can be
calculated from the following relations.
• Real life = Life (pu) × normal insulation life
1
Factors considered for design of rectifier transformer
• Current density
• Operating flux density
• Sizing of core cross section
• De-rating capacity of the transformer
• Transformer utilization factor
• Provision of electrostatic shield between primary & secondary
windings
• Limit on temperature rise of winding
• Adequate fixing/bolting of core to take care of vibrations, etc.
• Individual ratings of primary & secondary windings
• Calculation of losses and efficiency
• Use of appropriate insulation materials
• Consideration of skin effect at harmonic frequency
• Estimation of life of the transformer
2
Parametric values of rectifier transformer
Parameter Description Value
Number of phases 03 nos.
Rated voltage of high voltage winding (Primary winding) 33 kV ± 10%
Rated voltage of low voltage winding (Secondary winding) LV1 310.2 V
Rated voltage of low voltage winding (Secondary winding) LV2 313.83 V
Rated frequency of both primary and secondary side 50 Hz ± 5%
Rated capacity of high voltage winding (Primary winding): Delta connected 4235 kVA
Rated capacity of low voltage winding (Secondary winding) LV2: Star connected 2192 kVA
Rated current of high voltage winding (Primary winding) 74.09 A
Rated current of low voltage windings (Secondary windings) LV1 and LV2 4080 A
Insulation Class ‘A’
Short Circuit Impedance (Z) 7.49%
Vector Group Dd0y1
Ambient Temperature 450 C
Relative Humidity 95% Non-condensing max.
Guaranteed Maximum Temperature Rise of Oil and Windings 350 C & 450 C
Cooling method ONAN
Max. No Load Losses 5.2 kW
Max. Copper Losses 32.5 kW
Total Load Losses in Rectifier Operation 45 kW
Weight of Core & Winding (Un-tanking Weight) 8450 Kgs.
Transformer (Mineral) Oil (As per IS: 335-2005) with Quantity 4900 Liters (4350 Kgs.)
Total Weight of Transformer 19100 Kgs.
List of applicable codes, standards and specifications IEC 60076, IS 2026
Dimensions 3750 (W)×3570 (D)×3825(H)
List of Accessories As per GA drawing
Parametric Values of Mineral (Transformer) Oil of Rectifier Tranformer
Sr. No. Parameter Test Value as per IS: 1866-2000 Test Method
(Test Description) Required Actual
1 Appearance -- ---- Clear Visual
2 Density at Room Temperature g/cc 0.89 Max. 0.8150 IS 1448 (P16) - 2007
3 Kinematic Viscosity at 27 C0 cSt 27 Max. 11.28 IS 1448 (P25) - 2007
4 Flash Point (PMCC) 0C 140 Min. 147.5 IS 1448 (P21) - 2007
5 Pour Point 0 C -6 Max. -27 IS 1448 (P10) - 2007
6 Total Acid Number mg KOH/g 0.03 0.03 IS 1448 (P1 Sec 1) - 2007
7 Inorganic Acidity mg KOH/g ---- Nil IS 1448 (P2) - 2007
8 Water Content ppm 20 Max. 13.5 ASTM D 6304 - 04
9 Corrosive Sulphur % by Wt ---- Non corrosive ASTM D 1275
10 Total Sediments % by Wt 0.1 Max. Nil Centrifuge Method
11 Break Down Voltage kV 40 Min. 60.7 ASTM D 877
12 0
Interfacial Tension at 27 C mN/m 35 Min. 45 IS 6104 - 1971
13 Dielectric Dissipation Factor (Tan δ) at 900 C -- 0.015 Max. 0.0081 IS 6262 - 1971
14 Specific Resistance at 270 C Ω-cm ---- 1678.05 × 1012 IS 6103 - 1971
15 Specific Resistance at 900 C Ω-cm ---- 62.15 × 1012 IS 6103 - 1971
16 Dissolved Gas Analysis (DGA) Obtained Value (ppm)
a) Hydrogen (H2) Nil IS 10593 - 2006
b) Oxygen (O2) 5934 &
c) Nitrogen (N2) 16748 IS 9434 - 1992
d) Methane (CH4) Traces (<1)
e) Ethylene (C2H4) Nil
f) Ethane (C2H6) Nil
g) Acetylene (C2H2) Nil
h) Propylene + Propane (C3H6 + (C3H8) Nil
i) Carbon Dioxide (CO2) 107
j) Carbon Monoxide (CO) 2
4
Testing Methodology of Rectifier Transformer
• Type tests of transformer:
 Transformer winding resistance measurement
 Transformer ratio test
 Transformer vector group test
 Measurement of impedance voltage/short circuit impedance and load loss
(Short circuit test)
 Measurement of no load loss and current (Open circuit test)
 Measurement of insulation resistance
 Dielectric tests of transformer
 Temperature rise test of transformer
 Tests on on-load tap-changer
 Vacuum tests on tank and radiators
5
• Routine tests of transformer:
 Transformer winding resistance measurement
 Transformer ratio test
 Transformer vector group test
 Measurement of impedance voltage/short circuit impedance and load loss
(Short circuit test)
 Measurement of no load loss and current (Open circuit test)
 Measurement of insulation resistance
 Dielectric tests of transformer
 Tests on on-load tap-changer
 Oil pressure test on transformer to check against leakages and gaskets
6
• Special tests of transformer:
 Dielectric tests
 Measurement of zero-sequence impedance of three-phase transformers
 Short-circuit test
 Measurement of acoustic noise level
 Measurement of the harmonics of the no-load current
 Measurement of the power taken by the fans and oil pumps
 Tests on bought out components/accessories such as buchhloz relay,
temperature indicators, pressure relief devices, oil preservation system, etc.
7
• Tests to be done at user site:
 Pre-commissioning tests: The transformer also goes through some other
tests, performed on it, before actual commissioning of the transformer at
site. The transformer testing performed before commissioning the
transformer at site is called pre-commissioning test of transformer. These
tests are done to assess the condition of transformer after installation and
compare the test results of all the low voltage tests with the factory test
reports.
 Periodic/condition monitoring tests: These tests include the periodical
checking the health of the transformer and monitoring the signatures of
various parameters of the transformer.
 Emergency tests: There are especially carried out during the breakdown
of the transformer as well as during the observance of some of the
abnormality in the parametric value of the transformer.
8
Tests performed on Rectifier Transformer at factory
• Routine Tests:
 Visual Inspection for quality of workmanship, finish, dimensional checks, etc.
 Transformer oil testing as per IS: 1866 and IS: 335
 Winding Temperature Indicator / Oil Temperature Indicator Electrical and Calibration Tests
 Gas Operated Relay and Pressure Relief Valve Electrical Tests
 Insulation Resistance Tests and Measurement of Polarization Index
 Measurement of Winding Resistance (As per IS: 2026 - Part 1, Clause 16.2)
 Turns Ratio Test (As per IS: 2026 - Part 1, Clause 16.3)
 Magnetic Balance Test
 Capacitance and Tan Delta Measurement
 Induced Over Voltage Withstand Test (As per IS: 2026 - Part 3, Clause 11.1 and 11.2)
 Vector Group Test for Dd0y1 Transformer
 Dielectric Test (As per IS: 2026 (Part 1- Clause 16.7 and 16.6)
 Separate Source Voltage Withstand Test (As per IS:2026(Part3-Clause 10.1,10.2,10.3,10.4&10.5)
 Measurement of No Load Losses and Current (As per IS: 2026 - Part 1, Clause 16.5)
 Measurement of Voltage & Current Harmonics at No Load (as per IS:2026-Part1,Clause 16.13)
 Measurement of Acoustic Noise Level (As per IS: 2026 - Part 1, Clause 16.12)
 Measurement of Impedance Voltage/Short Circuit Impedance & Load Losses (As per IEEE
C57.18.10-1998 and IS: 2026- Part 1, Clause 16.3)
 96 hours No Load Test
 Oil Leakage Test as per CBIP Standards
9
Testing performed on Rectifier Transformer at factory
• Type Tests:
 Heat Run (Temperature Rise) Test (As per IS: 2026- Part 2): The heat
run test has been carried out on the rectifier transformer by
simulation of copper loss for minimum period of 2 hours after the
stabilization of temperature (variation within ± 10 C in one hour) at all
measuring locations including hot spots. The locations for the
temperature measurement have been mutually decided between the
supplier and the user. The temperature at any location has not
exceeded the design value.
 Impulse Voltage Withstand Test
0
Assembled view of rectifier transformer without oil tank
1
Assembled view of rectifier transformer with oil tank
2
Installation, on site testing and commissioning of Rectifier Transformer
• Following low voltage routine tests have been performed on site as
part of commissioning processes.
 Polarity, phase angle displacement and phase sequence
 Voltage ratio
 Winding resistance
 Windings and core insulation resistance measurements (Megger test)
 No-load losses and excitation current at 90%, 100% and 110% of rated voltage (AC
separate source)
 Load losses with reduced current (separate AC source)
 Short-circuit impedances
• The following HV tests have been performed on site:
 AC applied voltage
 Longtime induced voltage (one hour) with electrical and acoustic monitoring and
measurement of Partial Discharges and voltage level up to 150% of rated voltage
feed by a separate controllable source
 No-load energization with rated voltage during 24 hours with electrical and acoustic
monitoring and measurement of Partial Discharges and voltage level up to 115% of
rated voltage feed by a separate controllable source.
3
Conclusions
 Rectifier transformer has been designed carefully determining various design
parameters by performing combined simulation.
 Due to presence of harmonics, the parameters like current density, magnetic
flux density, selection of transformer core, sizing, etc. have been worked out.
 Overcoming satisfactorily the issues of overheating, over fluxing, core
saturation, voltage stresses, losses & efficiency, etc.
 Manufacturing of rectifier transformer referring design data sheet derived from
the specifications.
 Factory tested to evaluate the performance which was found satisfactory.
 Rectifier transformer has been installed at the R&D site considering standard
guidelines and safety practices.
 On-site testing carried out to confirm the technical specifications.
 First charging of rectifier transformer at no load was carried out successfully
at site following the check list.
 Full load commissioning is performed gradually step by step manner up to the
rated capacity and the performance has been found satisfactory.
4
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Sinusoidal Sources and (Non) Linear Loads", IEEE Paper No. 0-7803-5812-0/00, 2000.
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for nuclear research application", Proc. of IEEE first Int. Conf. on Power Electronics, Intelligent Control & Energy Systems (ICPEICES 2016)
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5

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6th International Conference on Large Power Transformers – Modern Trends in

Application, Installation, Operation & Maintenance

DESIGN, MANUFACTURING, TESTING,

Working of Typical Nuclear Power Plant

3-D view of ITL Phase-II

Schematic Block Diagram of 3.4 MW Rectifier Unit

Simulation of 12 pulse, 3.4 MW Rectifier Unit

Simulation Result of DC Output Current Waveform

Simulated Result of Secondary Current Waveform

Simulated Results of Primary Current Waveform

• Where θHS = Hot spot temperature

• Real life = Life (pu) × normal insulation life

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