Iiee Tagum 2012 On-Load Tap Changer

Basic Information
High Speed Resistance Type

On-Load Tap-Changers
for Power Transformers
On-Load Tap Changers in the
Energy Delivery Chain
VOLTAGE REGULATION
Add turns to primary or secondary winding
Subtract turns to primary or secondary winding
UP nP nS nP
= US = ∗UP UP = ∗US
US nS nP nS
Lower
Voltage Transformer
Regulation Turns Ratio
Raise
Theory of Operations
No-Load Tap Changers
No-Load Tap Changers

• NLTC: No Load Tap Changer
• DETC: De-energized Load Tap Changer
• Off-Load Tap Changer
SHUT-DOWN THE TRANSFORMER

On-Load Tap Changers
On-Load Tap Changers
• OLTC – On Load Tap Changer
• TCUL – Tap Changer Under Load
• Load Tap Changer
IF TRANSFORMER IS ENERGIZED – ARC WILL OCCUR

TRANSITION RESISTORS = LIMIT ARCING EFFECTS DURING BRIDGING
HIGH SPEED TAP CHANGING SPRING LOADED MECHANISM (in mS)
Typical Arrangements of OLTC
PARAMETERS: Us = Step Voltage
• VARYING INCOMING VOLTAGE 0.5%-1.4% OF NOMINAL
• STEADY OUTGOING VOLTAGE VOLTAGE
Us = 860 Volts
1.25% of Nominal
TWO WINDING
DELTA-WYE POWER TWO WINDING
TRANSFORMER WYE-DELTA POWER
TRANSFORMER
Typical Arrangements of OLTC
PARAMETERS:
• VARYING INCOMING VOLTAGE
• STEADY OUTGOING VOLTAGE
Us = 1380 Volts
1.00% of Nominal
WYE-WYE
AUTOTRANSFORMER
POWER TRANSFORMER
Common OLTC Arrangements
Moderate regulating ranges up to With a reversing change-over selector

a maximum of 20 %. the tap winding is added to or
subtracted from the main winding so
The tapped turns are added in
that the regulating range can be
series with the main winding and
doubled or the number of taps be
changes the transformer ratio. The
reduced
rated position can be any one of
the tap positions. Ex. Linear arrangement = 17 taps
positions / Reversing Switch = 33 taps
REVERSING CHANGE-OVER
LINEAR
SELECTOR ARRANGEMENT
ARRANGEMENT
Tap Changer Data
Common OLTC Installations
BOLT-ON TYPE IN-TANK TYPE

ON-LOAD TAP CHANGER ON-LOAD TAP CHANGER
Tap Changer Data
Design Principle: Resistance Type OLTC Installations
BOLT-ON TYPE IN-TANK TYPE

ON-LOAD TAP CHANGER ON-LOAD TAP CHANGER
BOLT-ON TYPE
SELECTOR IN-TANK IN-TANK
SWITCH (ARCING SELECTOR DIVERTER SWITCH
TAP SWITCH) SWITCH (ARCING (ARCING SWITCH)
TAP SWITCH) WITH PRE-TAP
SELECTOR
Tap Changer Data
Oil Insulation System
Two Oil Systems BOLT-ON TYPE

SELECTOR
SWITCH (ARCING
1 – On-load tap changer 4 TAP SWITCH)
2 – Motor drive unit
3 – Protective relay
4 – Oil conservator
3
1
2
Oil Function:
– Insulation Medium
– Arc Quenching Medium
– Cooling Medium
Tap Changer Data
Two Oil Systems

IN-TANK
SELECTOR SWITCH (ARCING TAP SWITCH) 5
4
1 – On-load tap changer head 1
2 – Selector Switch
5 – Oil conservator 2
Oil Function:
– Insulation Medium 3
– Cooling Medium
Tap Changer Data
Two Oil Systems

IN-TANK DIVERTER SWITCH (ARCING SWITCH)
WITH PRE-TAP SELECTOR
1 – On-load tap changer

2 – Diverter switch
3 – Tap selector
6 – Oil conservator
Oil Function:
– Cooling Medium
Tap Changer Switching Principle
SELECTOR SWITCH (ARCING TAP SWITCH)
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
MAIN CONTACT
Transition Contacts
Oil Function:
– Cooling Medium
Switching
Tap sequence
Changer rinciplePrinciple
Switching
IN-TANK DIVERTER SWITCH (ARCING SWITCH) WITH PRE-TAP SELECTOR
DHKa SKa WKa WKb SKb DHKb
DHKa
Oil Function: SKa
– Insulation Medium WKa
– Arc Quenching Medium WKb
– Cooling Medium SKb
DHKb
0 10 20 30 40 50 ms
REINHAUSEN ASIA PACIFIC Date: 1/31/2003

Tap Changer Switching Principle ® M
Switching
IN-TANK sequence
DIVERTER typeSWITCH)
SWITCH (ARCING OILTAPWITH PRE-TAP SELECTOR
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching
IN-TANK sequence
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching
IN-TANK sequence
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching
IN-TANK sequence
Ic
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching
IN-TANK sequence
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching sequence type OILTAP® M
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching sequence type OILTAP® M
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Switching
IN-TANK sequence
DHKa
Oil Function: SKa
DHKb
0 10 20 30 40 50 ms

Basic Information
Modern On-Load Tap-Changers

for Power Transformers
Modern
VACUTAPOLTC Design:
VV and VR VACUUM SWITCHING
Selector Switch
® (Arcing Tap Switch) Vacuum Selector Switch Design Principles
VACUTAP VV – Switching Sequences
from tap position n to n+1
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL Ic
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern
VACUTAPOLTC Design:
Selector Switch
operation finished
tap n tap n+1
MTS TTS
R
IL
MTS
MSV MSV TTV
TTS
TTV
ca. 150 ms STC
Oil Function:
Modern OLTC Design: VACUUM SWITCHING
DIVERTER SWITCH (ARCING SWITCH) WITH PRE-TAP SELECTOR

tap n tap n+1
MC
MSV TTF
MTF
TTV
IL
TTF
n n n+1 n+1
MC MC MC
MSV MTF
TTV
MTF
MSV
TTV
R
TTF
n n+1
approx. 100 ms Oil Function:

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC
IL
MC MC
MSV MTF
TTV
MTF
MSV
TTV
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC
IL
MC MC
MSV MTF
TTV
MTF
MSV
TTV
R
TTF
n n+1
Michael Mieling

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV Ic
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV
R
TTF
n n+1

tap n tap n+1
MC
MSV TTF
MTF
TTV
TTF
n n n+1 n+1
MC MC MC
IL MTF
MSV
TTV
MTF
MSV
TTV
R
TTF
n n+1
approx. 100 ms
operation finished
tap n tap n+1
MC
MSV TTF
MTF
TTV
IL
TTF
n n n+1 n+1
MC MC MC
MSV MTF
TTV
MTF
MSV
TTV
R
TTF
n n+1
Design Criteria for OLTCs:
Preparations of Specifications
CUSTOMER / END-USER TRANSFORMER OEM

• MVA-rating Specify the overall profile of the OLTC OEM:
• Tap winding (for wye or delta) • Quality
• Rated voltage and regulating range • Reliability
• Number of service tap positions • Economy
• Insulation level to ground • OLTC lifespan
• Lightning impulse • Range of ratings
• Insulation power frequency • After Sales Services
TRANSFORMER OEM OLTC OEM

• Rated through-current: Iu • Breaking capacity
• Rated step voltage: Ui • Overload capability
• Rated step capacity: Pst = Ui x Iu • Short-circuit current
• MVA-rating • Contact life
• Tap winding (for wye or delta) • Potential Connection of Tap Winding
• Rated voltage and regulating range during Change-Over Operation
• Number of service tap positions • Effects of the Leakage Impedance of Tap
• Insulation level to ground Winding during the Operation of the
• Lightning impulse Diverter Switch when passing the Mid-
• Insulation power frequency Position of the Resistor-Type OLTC
Why Maintenance?
Resistor Type On-Load Tap

Changer
Why Maintenance?
Properly operating OLTC must:

• Maintain clock-work precision
• Maintain high speed operating
mechanism
• Sufficiency of electrical contacts
• Switching endurance
Table 1
Transformers Failure Statistics
1955-1965 1975-1982 1983-1988

FAULTS
No. of % of No. of % of No. of % of
Unit s Unit s Unit s Unit s Unit s Unit s
Winding 134 51 615 55 144 37
Tap Changers 49 19 231 21 85 22
Bushings 41 15 114 10 42 11
Terminal Boards 19 7 71 6 13 3
Core 7 3 24 2 4 1
Miscellaneous 12 5 72 6 101 26
Tot al 262 100 1127 100 389 100
Reference:
IEEE St d. C37.91-200
Survey of Large US Utilit ies wit h > 100 Transformers
Why Maintenance?
Maintenance strategies
Preventive Maintenance on LTCs
Why Maintenance?
FAQ 1: Maintenance Drivers
What is OLTC Maintenance and its drivers?
OLTC Maintenance is the

combination of all technical, Load transformer for maximum
economical efficiency
administrative and managerial
actions during the lifecycle of
an OLTC intended to retain it Detect first sign of failure
into a state which it can perform condition
its required function
continuously
Manage and extend transformer life
– Perform cost effective
maintenance
Reduce unscheduled outages &

equipment failures
Why Maintenance?
FAQ 2: Fixed Position
Why should we implement routine maintenance on OLTCs even if we

operate it at Fixed Position?
Causes for OLTC at Fixed position
(a.) Problems with the transformer or OLTC
(b.) System requirements of the network or
(c.) Misconception of ‘preserving’ the life of the OLTC
Unwanted Effects:
X Weather all abnormal electrical phenomena
X Accumulation of moisture (intrusion) without “mixing”
X Contact temperature (during faults and resistance build-up)
X Time in-service will affect the electrical contact life,
X No abrasive wiping action
X Corrosion on the contact surface
X Lead to likely result as an OLTC thermal runaway.
Why Maintenance?
FAQ 2: Fixed Position
I2R = Conducting
LONG TERM I2R = HEAT
POSITION – path recovery
THERMAL STORMS /
FAULTS
CONTACT PITTING
I2R I2R I2R
I2R I2R
I2R OXIDATION FILM
I2R I2R
R R R R
LOCALIZED
COKING = HEATING
ANNEALING EFFECT
= LESS HEAT
DISSIPATION I2R = HEAT
= ∆T
>>DT = Oil DIELECTRIC

Dissociation PROPERTIES
BREAKDOWN
Why Maintenance?
FAQ 3: Maintenance Strategies
What are the strategies for OLTC Maintenance?

1. Risk and event-based maintenance
• Run-to-Failure
• Highest cost – consequential damage
2. Time – based
• Fixed time of operations cycle
3. Operations-based
• Fixed number of operations
Time in Service or Number of Operations
Sample Criteria: First Inspection 2 years Every 70,000 Ops (w/o Filter)
Every 5 years thereafter Every 100,000 Ops (w/ Filter)
Implementation: WHICHEVER COMES FIRST !

Why Maintenance?
FAQ 4: End-User Maintenance
Is it enough to annually change the oil for OLTC? NO !!!

• Achieve what? Is the oil and outage costs justifiable?
• Internal inspection must be conducted
• Only trained personnel must do the inspection
• Maximum permissible contact wear must be determined
• Replacement of mechanically stressed parts
• Clean-out accumulated oil carbon deposits on all parts
(prevent coking and annealing effects)
• Check the protective relay
• Check transition resistors
• Align and inspect motor drive linkages and components
• Check end-position and braking
Energy accumulator
springs
Contacts Contact leads

Why Maintenance?
FAQ 5: Maintenance Application
How do I apply proper maintenance for the OLTC?

• Check your OLTC regularly
• Follow the recommended SERVICE INTERVAL
• Choose the correct SERVICE PROVIDER (Insured for
Service)
• Buy only ORIGINAL and GENUINE parts
• Keep maintenance record of your OLTC
• Employ a cost-effective & practical approach – use
PROFESSIONAL SERVICES from the OLTC OEM only
• Check that your OLTC is updated to the latest Maintenance
Bulletin
• REMEMBER – to always keep your OLTC at the highest
possible level of operational reliability – YOU MAY NEED IT
• REMEMBER – disregarding of the OLTC OEM maintenance
intervals puts at RISK the entire transformer itself
SUMMARY:
Key to Successful OLTC Asset Management
END-USER: OLTC MANUFACTURER
• User’s operating • Manufacturer’s

experience knowledge and
experience
• Transformer and
OLTC • Technical solutions
applications for
condition based
• Targets of Asset maintenance and
Management equipment
preservation
Cooperation and partnership
Optimum solution for transformer population, considering individual transformer
and OLTC application
Including consideration of related managerial activities (performance of
maintenance work, in- or outsourcing of maintenance work, etc.)
Thank you for your attention.
All Information in this Presentation are copyrighted by
Maschinenfabrik Reinhausen unless otherwise noted. Prior
approval from Reinhausen Asia Pacific Sdn Bhd and/or its
authorized Philippine Distributor is required for any citations
or re-publication.

Iiee Tagum 2012 On-Load Tap Changer

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Iiee Tagum 2012 On-Load Tap Changer

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Basic Information

High Speed Resistance Type

No-Load Tap Changers

SHUT-DOWN THE TRANSFORMER

IF TRANSFORMER IS ENERGIZED – ARC WILL OCCUR

Moderate regulating ranges up to With a reversing change-over selector

BOLT-ON TYPE IN-TANK TYPE

BOLT-ON TYPE IN-TANK TYPE

Two Oil Systems BOLT-ON TYPE

Two Oil Systems

Two Oil Systems

1 – On-load tap changer

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

DHKa SKa WKa WKb SKb DHKb

REINHAUSEN ASIA PACIFIC Date: 1/31/2003

Modern On-Load Tap-Changers

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

from tap position n to n+1

tap n tap n+1

tap n tap n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

from tap position n to n+1

CUSTOMER / END-USER TRANSFORMER OEM

TRANSFORMER OEM OLTC OEM

Resistor Type On-Load Tap

Properly operating OLTC must:

1955-1965 1975-1982 1983-1988

What is OLTC Maintenance and its drivers?