Design, Function and Operation of On-Load Tap-Changers

Uwe Seltsam

Maschinenfabrik Reinhausen GmbH

TRANSFORM Partner
About the Author

Uwe Seltsam

Maschinenfabrik Reinhausen GmbH, Regensburg / Germany

– Manager Technical Specialists –

Scientific Background

Dipl.-Ing. (FH) Electrical Engineering

Professional Background

10 years at Maschinenfabrik Reinhausen GmbH

Technical Service / Troubleshooting

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 2

Agenda

1. On-load tap-changer in regulating transformer

2. On-load tap-changer – Design types
3. Switching sequence of tap selector and diverter switch insert
4. Maintenance
Intervals for OILTAP® and VACUTAP®
Parameter contact wear
Parameter replacement of parts
Parameter oil carbonization
Checks after maintenance
Checks between maintenances
5. Oil change criteria
6. Influence of humidity on dielectric strength
7. Avoiding carbon deposits or their effects
8. On-load tap-changer – Protective devices
9. Diagnostics

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 1. On-load tap-changer in regulating transformer

On-load tap-changers (OLTCs) are used for changing the transmission ratio under load
U1 Transformer: 40 MVA, 110 kV 16 %
/ 21 kV
110 kV 17.6 kV
Mwg = Main winding
Cwg = Coarse winding OLTC: M III 350 Y – 123/C – 10 19 1G
Mwg Rwg = Regulating winding Step voltage: 17.6 kV : 9 steps ≙ 1.955 kV/step ≙ 1.78 %
LU = Diverter switch insert
555 wdgs
U2
Cwg - 21 kV
120 wdgs + 129 wdgs

k
Rwg 9 LU
108 wdgs 2
12 wdgs/step 1 U1 = N1
U2 N2

Nominal: U2 = 21 kV = constant
Example 1: U1 = 110 kV
N1 = 110 kV • 129 wdgs / 21 kV = 675 wdgs
U2 = 110 kV • 129 wdgs / 675 wdgs = 21.02 kV
Example 2: U1 = 116 kV
N1 = 116 kV • 129 wdgs / 21 kV = 711 wdgs
U2 = 116 kV • 129 wdgs / 711 wdgs = 21.05 kV

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 4

2. On-load tap-changer – Design types
Tap-change operation Vectorial diagram Contact movement

A,B

OILTAP® Main contacts

(only for V III 350 Y/Δ,
V III 500 Y / Δ,
Type M since 1972 V I 350, V I 700)

a,b
Main switching
e. g. M III 600 9 steps contacts

3-pole a1, b1
Transition contacts
Star connection Ra, Rb
Insulation to ground Transition resistors

Um = 123 kV Ua, Ub
Voltages of tappings

Ust
Step voltage

U, I
Voltage, current of tap-
changer terminals

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 5

2. On-load tap-changer – Design types
Operation Vectorial diagram Contact movement

A,B

OILTAP® Main contacts

(only V III 350 Y/Δ,
V III 500 Y/ Δ,
Type V since 1979 V I 350, V I 700)

a,b
Main switching
e. g. V III 200 10 steps conttacts

3-pole a1, b1
Transition contacts
Star connection R
Insulation to ground Transition resistor

Um = 76 kV Ua, Ub
Voltages of tappings

Ust
Step voltage

U, I
Voltage, current of
tap-changer terminals

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 6

2. On-load tap-changer – Design types

VACUTAP®
Type VR® since 2004

e. g. VRF III 1300 10 steps

3-pole
Star connection
Insulation to ground
Um = 76 kV

Switching sequence

Switching direction n  n+1

MSV Main switching contact
(vacuum interrupter), main path

MTF Transfer contact, main path

TTV Main switching contact (vacuum

interrupter), transition path

TTF Transfer contact, transition path

MCA Main contact side A

MCB Main contact side B

ZnO ZNO varistor

R Transition resistor

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2. On-load tap-changer – Design types

VACUTAP®
Type VV since 2000

e. g. VV III 400 10 steps

MTS Tap-selector contact, main path

MSV Main switching contact (vacuum interrupter), main path
TTS Tap-selector contact, transition path
TTV Transition contact (vacuum interrupter), transition path
STC Sliding take-off contact
R Transition resistor
IC Circulating current

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3. Switching sequence of tap selector and diverter switch

IB

Tap pre-selection without current Diverter switch insert operation type M

Switching principle of diverter switch insert: Flag switching cycle

Operation switching time approx. 40 – 50 ms
Load period of transition resistors approx. 30 ms
IB = Operating through-current
IK = Circulating current
Link to movie
R = Transition resistor

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 4.1 Maintenance – Intervals for OILTAP® and
VACUTAP®

OILTAP® - Regular maintenance, depending on

time of service or no. of operations
(whichever comes first)

Neutral-point application
after every 5 – 7 years
after every 50,000 – 150,000 operations

Delta application
after every 2 – 4 years
after every 20,000 – 100,000 operations
Maintenance of tap selector
after every 1 to 1.2 million operations

Diverter switch insert type M

Service life 800,000 operations
For OLTC-specific maintenance intervals, refer to the respective
operating instructions or the label on the motor-drive unit.

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 4.1 Maintenance – Intervals for OILTAP® and
VACUTAP®

VACUTAP® - Regular maintenance, only depending on

the number of operations

Neutral-point or phase application

after every 300,000 operations
Tap selector maintenance
after every 1.2 million operations

Reason for time-independent maintenance:

No oil carbonization since arcs do not occur in insulating oil

For network applications, the VACUTAP® is more or less

maintenance-free. Diverter switch insert type VR®
Example: Service life 1.2 million operations
Switching frequency 5,000 operations per year
 maintenance after 60 years.

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 11

 4.1 Maintenance – Intervals for OILTAP® and
VACUTAP®

Monitoring – TM100, Tapguard® 260

Maintenance depending on condition
Maintenance criterion Calculation

Parts subject to wear No. of ops. specification for parts change

Oil change and cleaning Calculation algorithm for oil carbonization
Contact wear Calculation algorithm for single and difference wear

Maintenance time
Visual presentation
Present condition 0 ... 100 %
Prediction for 100 % moment
Semaphore function green/yellow/red

Red signal prevents additional operations

by the motor-drive unit, but it is not
integrated into the tripping circuit for the
circuit breaker.
Front panel Tapguard® 260

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 4.2 Maintenance – Parameter contact wear
MSCB TCB TCA MCA

Criteria for OILTAP®:

Single wear and MCB MCA

Difference in wear between switching

and transition contact
MSCA MSCB
Parameters for contact wear: TCA TCB
Number of operations: variable value
Contact system of diverter switch type M
Arcing current: variable value
Medium arc duration: approx. 6 ms
Arc voltage: 25 – 30 V Step voltage

Contact material: Cu or CuW sintered material Ust

Wear on main switching contact: SG

proportional to operating through-current

MCA MSCA TCA TCB SCB MCB
Wear on resistor contact:
independent of operating current, but proportional to MC = Main contact
circulating current Ic (Ic = Ust / Rres) MSC = Main switching contact
TC = Transition contact
Exceeding the wear differences influences the switching R = Transition resistor
sequence – a short circuit between taps may occur. SG = Spark gap
Max. permissible single wear = 4 mm
Max. permissible difference in wear = 2.5 mm

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 13

 4.3 Maintenance – Parameter replacement of parts

Depending on no. of ops.

Springs, leads, etc.
Depending on wear
Arc contacts, etc.
Preventively
Cover gasket, etc.
E.g. Energy accumulator spring for type
Up-dating M: 400,000 – 500,000 ops.
Measure for increasing operating reliability
Adjustment to current state of manufacture
Diverter switch insert:
Replacement after 800,000 operations (OILTAP®)
Replacement after 1.2 million ops. (VACUTAP®)
Tap selector:
Maintenance after every 1.0 to 1.2 million operations,
E.g. Braided lead for type M:
depending on OLTC type 250,000 operations
MR original parts are the basis for safe operation.

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 14

 4.4 Maintenance – Parameters oil carbonization

Criterion:
Heat removal from the transition resistors must
not be restricted by oil carbonization.
Determining factors for degree of carbonization:
Number of operations
Arc energy
Type of oil: Little difference between naphthenic-base
or paraffin-base oil

Drying of a sooted tap-changer leads to baking of

carbon deposits on the surfaces and to a reduction of
the dielectric strength.

Use only transformer oil for cleaning. Electrical cleaners

evaporate on the surface of the insulating material and
lead to humidity.
Diverter switch type insert T Diverter switch type insert T
before cleaning after cleaning

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 15

4.5 Maintenance – Checks after maintenance

The following checks have to be performed:

Identical indication of positions between on-load tap-changer and motor-drive unit
Functional check of final positions
If protective relay is in position “OFF“, it must not be possible to put the circuit breaker in
the circuit
Transformer ratio test during major modification work on the on-load tap-changer (e. g.,
replacement of motor-drive unit, or after connecting or disconnecting tap-selector leads)

1) Diverter switch with oil compartment

2) Motor-drive unit
3) Protective relay
4) Drive shafts

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 4.6 Maintenance – Checks between maintenances

Motor-drive unit Visual check

Heater in operation
Door closed

Protective relay Functional check

together with transformer
protection test

Drying agent OLTC Reliability (effectiveness)

oil conservator together with transformer test

Oil monitoring Oil exchange criteria, see section 5

Disconnected OLTC maintenance before re-commissioning of transformer if

operating time and downtime exceed maintenance interval of
transformer
on-load tap-changer (OILTAP®)

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 17

5. Oil change criteria

OLTC application of OILTAP® Dielectric strength* Water content

Neutral-point application Minimum 30 kV / 2.5 mm Maximum 40 ppm

Use in auto-transformer or Minimum 40 kV / 2.5 mm Maximum 30 ppm

regulation in delta winding

OLTC application of VACUTAP®

All Minimum 30 kV / 2.5 mm Maximum 30 ppm

*Dielectric strength, measured in accordance with IEC 60156

The temperature of the oil sample must be measured at the time when the oil was taken.
The values specified for dielectric strength apply to oil temperatures of 20 ± 5 °C at the time of
evaluating the oil sample.

Recommendation:
Dielectric strength of > 50 kV / 2.5 mm for new insulating oil that must be filled in after maintenance.

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 18

 5. Oil change criteria

Time of oil sample test:

It is up to the user of the transformer to check the insulating oil, and the test should be
done at the same time when an oil sample of the transformer is taken
Class 1 in accordance with IEC 60214-1: after every 5 years (use in neutral-point)
Class 2 in accordance with IEC 60214-1: after every 2 years (use in auto-transformer,…)
Whenever it is suspected that humidity is absorbed (drying agent ineffective etc.)

Ask the OLTC manufacturer if other insulating liquids (ester liquids, etc.) are used.

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6. Influence of humidity on dielectric strength

Facts:
Diverter switch oil of OILTAP® is a mixture of oil,
carbon deposits and humidity
Water absorption of carbon deposits is several times
as high as water absorption of oil
Carbonized oil with inadmissibly high water content puts
insulation distances at risk which are exposed to voltage
stress

Effects:
Electrical-field distortion with local discharges
Thermal decomposition of surface of insulating material
Creepage paths
Breakdown of insulating distance with flashover

Switching shaft
Example of creepage paths

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 7. Avoiding carbon deposits or their effects

Vacuum technology in the VACUTAP®

No carbon deposits since arcs do not occur in insulating oil

Vacuum interrupter

Oil filter unit, filter cartridge

with paper filter: absorbs carbon particles (6 – 9 microns);
in use for annual number of > 15,000 operations / year
with paper filter and drying agent (4 kg granulate):
absorbs carbon particles and water (approx. 420 g)

The effectiveness of the drying agent of the filter cartridge must be

determined by oil sample and water content analysis.

Oil filter unit – OF100

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 21
 8. On-load tap-changer – Protective devices

Protective relay = flow-controlled relay type RS2001

(standard equipment)
Response value, e. g. for M III 600: 1.2 m/sec ± 20% bei 20°C
Pressure relief (burst membrane) in OLTC cover
Static response pressure about 4 – 5 bar
RS2001
Pressure relief valve type MPreC® (instead of burst membrane)
Response value about 1.3 – 1.8 bar, depending on OLTC type
Monitoring of drive shafts, e. g., for multiple-column OLTC design

The above-mentioned protective devices must be integrated in the

tripping circuit of the circuit breaker of the transformer.

End position limiting device in OLTC and/or motor-drive unit Burst membrane

Find out the cause after a protective device has responded!

MPreC®

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 9. Diagnostics

Increased tap selector contact resistance

if contacts are not silver-plated:
Signs of impurity layer
Resistance measurement in accordance with
CIGRE report 12-205/1994 rounds off
gas-in-oil analysis;

Extract from CIGRE report

Tap-selector contacts colored to “black-grey“:

Signs of silver-sulfide (impurity layer)
Check for corrosive sulfur (oil, etc.)

Separated silver-sulfide layer may lead to flashovers.

Tap selector contact with silver-sulfide

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 9. Diagnostics

Gas-in-oil analysis for diverter switch insert oil in OILTAP®:

No informative value with respect to arcing on main switching contacts
and transition contacts.

Oil
No. of ops. temp. H2 CH4 C2H6 C2H4 C2H2 CO CO2 O2 N2
[°C]
0 16 127 31 3 70 359 10 344 17500 39400
29000 50 17796 12205 3642 36170 102172 330 3032 10800 48100
50000 22 13553 13000 4200 50000 103000 317 7733 4900 25300
Example for OLTC type M

Gas-in-oil analysis for diverter switch insert oil in VACUTAP®:

An evaluation pattern is currently being developed.

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 24

9. Diagnostics

Torque measurement:
Integral part of monitoring TM100 and
TG260®, including assessment (semaphore
function). Online procedure.
Torque measurement directly on OLTC head
with mobile measuring device.

Example of torque progress

Tap-change operation sequence assessment:

Indirect assessment of tap-change operation
sequence of diverter switch by measuring the
contact wear (OILTAP®).
Measurement of tap changes of diverter switch
insert operation using direct current.

Diverter switch insert type G

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 25
Summary

• On-load tap-changers are available in/with different

switching principles: high-speed resistor and reactor principle
types: non-vacuum and vacuum

• On-load tap-changers are available for different applications

power transformers for transmission and distribution
transformer for industrial use (e.g. arc-furnace or ladle furnace transformers)
HVDC transformers
phase-shifting-transformers
transformers for operation at explosion-prone sites (e.g. offshore platform)

• Maintenance
maintenance intervals of the respective on-load tap-changer shall be observed at any time to
ensure trouble-free operation of the transformer. Original spare parts and trained service staff
have also be seen as mandatory.

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 26

About MR

Maschinenfabrik Reinhausen GmbH

 Founded in 1868
 Family ownership since 1891
 Brand name since1901
 World market leader in transformer switching
 2,850 employees in 7 business areas
 30 locations – world-wide
 Doing business in 190 countries
 Company sales: 630 million EUR

 www.reinhausen.com

Uwe Seltsam, Maschinenfabrik Reinhausen GmbH 07.06.2013 Page 27