Fig.

Tap Changer

WORKING OF

ON LOAD TAP CHANGER (OFF CIRCUIT)

(1) AN INTRODUCTION TO ON LOAD TAP CHANGER

A tap changer is a connection point selection mechanism along a power transformer winding
that allows a variable number of turns to be selected in discrete steps. A transformer with a
variable turn ratio is produced, enabling stepped voltage regulation of the output. The tap
selection may be made via an automatic or manual tap changer mechanism.

VOLTAGE CONSIDERATION
If only one tap changer is required, manually operated tap points are usually made on the high
voltage (primary) or lower current winding of the transformer to minimize the current handling
requirements of the contacts. However, a transformer may include a tap changer on each
winding if there are advantages to do so. For example, in power distribution networks, a large
step-down transformer may have an off-load tap changer on the primary winding and an on-
load automatic tap changer on the secondary winding or windings. The high voltage tap is set
to match long term system profile on the high voltage network (typically supply voltage
averages) and is rarely changed. The low voltage tap may be requested to change positions
multiple times each day, without interrupting the power delivery, to follow loading conditio ns
on the low-voltage (secondary winding) network.
To minimize the number of winding taps and thus reduce the physical size of a tap changing
transformer, a 'reversing' tap changer winding may be used, which is a portion of the main
winding able to be connected in its opposite direction (buck) and thus oppose the voltage.

CLASSIFICATION OF TAP CHANGING

OFF-CIRCUIT DESIGNS (NLTC OR DETC):

Also called No-Load Tap Changer (NLTC), off-circuit tap changer, or De-Energized Tap
Changer (DETC).
In low power, low voltage transformers, the tap point can take the form of a connection
terminal, requiring a power lead to be disconnected by hand and connected to the new termina l.
Alternatively, the process may be assisted by means of a rotary or slider switch.
Since the different tap points are at different voltages, the two connections cannot be made
simultaneously, as this would short circuit a number of turns in the winding and produce
excessive circulating current. Consequently, the power to the device must be interrupted during
the switchover event. Off-circuit or de-energized tap changing (DETC) is sometimes employed
in high voltage transformer designs, although for regular use, it is only applicable to
installations in which the loss of supply can be tolerated. In power distribution networks,
transformers commonly include an off-circuit tap changer on the primary winding to
accommodate system variations within a narrow band around the nominal rating. The tap
changer will often be set just once, at the time -of installation, although it may be changed later
during a scheduled outage to accommodate a long-term change in the system voltage profile.
ON-LOAD DESIGNS (OLTC):

Also called on circuit tap changer or On Load Tap Changer (OLTC).

For many power transformer applications, a supply interruption during a tap change is
unacceptable, and the transformer is often fitted with a more expensive and complex on-load tap-
changing (OLTC, sometimes LTC) mechanism. On-load tap changers may be generally classified
as either mechanical, electronically assisted, or fully electronic.

Fig. On Load Tap Changer

 (2) ON-LOAD TAP-CHANGERS FOR POWER TRANSFORMERS
Power transformers equipped with on-load tap- changers (OLTCs) have been the main
components of electrical networks and industrial applications for nearly 90 years. OLTCs
enable voltage regulation and/or phase shifting by varying the transformer ratio under load
without interruption.

From the start of tap-changer development, two switching principles have been used for load
transfer operation – the high-speed resistor-type OLTCs and the reactor-type OLTCs.

Over the decades both principles have been developed into reliable transformer components
which are available in a broad range of current and voltage applications. These components
cover the needs of today’s network and industrial process transformers and ensure optimal
system and process control.

The majority of resistor-type OLTCs are installed in- side the transformer tank (in-tank
OLTCs) whereas the reactor-type OLTCs are in a separate compartment which is normally
welded to the transformer tank.

This paper mainly refers to OLTCs immersed in trans- former mineral oil. The use of other
insulating fluids or gas insulation requires the approval of the OLTC manufacturer and may
lead to a different OLTC de- sign, as shown in chapter.

SWITCHING PRINCIPLE

The OLTC changes the ratio of a transformer by adding or subtracting to and turns from either
the primary or the secondary winding. The transformer is therefore equipped with a regulat ing
or tap winding which is connected to the OLTC.

The principle winding arrangement of a 3-phase regulating transformer, with the OLTC located
at the wye-delta-connection in the high volt- age winding. Simple changing of taps during an
energized status is unacceptable due to momentary loss of system load during the switching
operation. The “make (2) before break (1) contact concept”, shown in Figure 4, is therefore the
basic design for all OLTCs. The transition impedance in the form of a resistor or reactor
consists of one or more units that bridge adjacent taps for the purpose of transferring load from
one tap to the other without interruption or appreciable change in the load current. At the same
time they limit the circulating current (IC) for the period when both taps are used. Normally,
reactor-type OLTCs use the bridging position as a service position and the re- actor is therefore
designed for continuous loading. The voltage between the taps mentioned above is the step
voltage, which normally lies between 0.8 % and 2.5 % of the rated voltage of the transformer
 Fig switching sequence of OLTC
With a reversing change-over selector the tap winding is added to or subtracted from the main
winding so that the regulating range can be doubled or the number of taps reduced. During this
operation, the tap winding is disconnected from the main winding. The greatest copper losses
occur, however, in the position with the minimum number of effective turns. This reversing
operation is realized using a change-over selector which is part of the tap selector or of the
selector switch (arcing tap switch). The rated position is normally the mid position or neutral
position.

Fig. Switching sequence of tap selector – diverter switch (arcing switch)

The double reversing change-over selector avoids the disconnection of tap winding during the
change-over operation. In phase-shifting transformers this apparatus called the advance-retard
switch.

Which of these basic winding arrangements is used in each individual case depends on the
system and operating requirements. These arrangements are applicable to two winding
transformers as well as to autotransformers and to phase-shifting transformers where the tap
winding and therefore the OLTC is inserted in the windings (high-voltage or low- voltage side)
depends on the transformer design and customer specifications. For regulated
autotransformers, fig. 8 shows various circuits. The most appropriate scheme is chosen with
regard to regulating range, system conditions and/or requirements, as well as weight and size
restrictions during transportation. Autotransformers are always wye-connected.

a) Three pole line-end arrangement

b) One and two pole line-end arrangement

c) Three pole mid-winding arrangement

I neutral end regulation (fig. 8 a) may be applied with a ratio above 1 : 2 and a moderate
regulating range up to 15 %. This operates with variable flux. a scheme shown in fig. 8 c is
used for regulating high voltage for low voltage U2 regulation, the circuits fig. 8 b, 8 d, 8 e and
8 f are applicable. The arrangements fig. 8 e and 8 f are two core solutions. Circuit fig. 8 f
operates with variable flux in the series transformer, but it has the advantage that a neutral end
OLTC can be used. In the case of arrangement according to fig. 8 e, the main and regulat ing
transformers are often placed in separate tanks to reduce transport weight. At the same time,
this solution allows some degree of phase shifting by changing the excitation connections
within the intermediate circuit. Over the last few years, the importance of phase- shift ing
transformers used to control the power flow on transmission lines in meshed networks has been
steadily increasing .The fact that IEEE provides a “guide for the Application, specification and
Testing of Phase-shifting Transformers“ proves the demand for These transformers often
require regulating ranges which exceed those normally used. To achieve such regulat ing
ranges, special circuit arrangements are necessary. Two examples are given shows a circuit
with direct line-end regulation, fig. 10 an intermediate circuit arrangement illustrates very
clearly how the phase-angle between the voltages of the source and load systems can be varied
by the OLTC position. Various other circuit arrangements have been implemented.
 (3) DESIGN CONCEPT OF ON LAOD TAP CHANGER

Apart from tap selection, the most important task of an OLTC is the break function or current
(load) transferring action. After transferring the current, the contact which “breaks” must be
capable of withstanding the recovery voltage. The required switching capacity (the product of
switched current and recovery voltage) for a specific contact in an OLTC is based on the
relevant step voltage and cur- rent but is also determined by the design and circuit of the OLTC.
The switching capacity itself is primarily a function of the contact design, contact speed and arc-
quenching agent.

Historically, most power transformers use mineral oil as a cooling and insulation medium. The
development of OLTCs toward the present “state of the art” de- signs also focused on
transformer oil. Apart from the insulation properties of the transformer oil, the arc- quenching
behavior of the switching contacts deter- mined the design and size of “oil-type” OLTCs.

In an oil-type OLTC, the OLTC is immersed in trans- former oil and switching contacts make
and break current under oil. This conventional OLTC technology has reached a very high level
and is capable of meeting most of the transformer manufacturers’ requirements. This applies
for all the voltage and power fields today, which will probably remain unchanged in the
foreseeable future.

Along with the increase in demand for electrical energy in metropolitan areas, the necessity for
installing transformers in buildings creates a need for regulating transformers with reduced fire
hazards. In addition to this and with respect to the prevention of water pollution, regulat ing
transformers that do not require conventional mineral oil as an insulating or switching medium
are preferable.

Apart from gas-immersed transformers, which are mainly used in Japan, dry-type transformers
and trans- formers with alternative insulating fluids meet these requirements, which are
increasingly being requested.

Conventional tap-changers are not really suitable for this kind of regulating transformers,
because the use of mineral oil as a switching medium is – for the rea- sons mentioned above –
not desirable and would also require technically complex and expensive overall solutions.

In addition, worldwide deregulation in the electric industry is still a concern. As part of this
market, mechanisms have been encouraged to price transmission services and encourage both
generation and trans- mission investment.
OIL-TYPE OLTCS – OILTAP

The OLTC design that is normally used for higher ratings and higher voltages comprises a
diverter switch (arcing switch) and a tap selector. For lower ratings, OLTC designs in which
the functions of the diverter switch (arcing switch) and the tap selector are combined in a
selector switch (arcing tap switch) are used.

With an OLTC comprising a diverter switch (arcing switch) and a tap selector, the tap-change
operation takes place in two steps. The next tap is first preselected by the tap selector at no
load. The diverter switch then transfers the load current from the tap in operation to the
preselected tap. The OLTC is operated by means of a drive mechanism. The tap selector is
operated by a gearing directly from the drive mechanism. At the same time, a spring energy
accumulator is tensioned, which operates the diverter switch – after release at a very short time
interval – independently of the motion of the drive mechanism. The gearing ensures that this
diverter switch operation always takes place after the tap preselection operation has finis hed.
The switching time of a diverter switch is between 40 and 60 Ms with today’s designs. During
diverter switch operation, transition resistors are inserted which are loaded for 20–30 Ms, i.e.
the resistors can be designed for short-term loading. The amount of resistor material required
is therefore relatively small. The total operation time of an OLTC is between 3 and 10 seconds,
depending on the respective design.

A selector switch (arcing tap switch) as shown in carries out the tap-change in one step from
the tap in service to the adjacent tap. The spring energy accumulator, wound up by the drive
mechanism actuates the selector switch sharply after releasing.

Fig. oil type OLTC

 (4) DESCRIPTION OF EQUIPMENTS
TAP CHANGER TYPE M

The OILTAP® M on-load tap-changer is used to vary the ratio of oil-immersed

transformers under load. In general it is designed for network transformer as well as industrial
transformer applications. The tap-changers comprise a diverter switch and a tap selector
in a single column design and represent the most recent state of technology. The tap-
changers offer both transformer manufacturer and user a great number of essential
advantages.

Fig. OLTC type M

VERSATILITY:

– three-pole design for neutral application at 350 A, 500 A and 600 A ratings for
three-phase wye-connected windings
– single-pole designs at 350 A, 500 A, 600 A, 800 A, 1200 A and 1500 A
ratings for auto connected windings or single-phase transformers
– available with ±9, ±11, ±13, ±15, ±17 steps – insulation to ground and tap
selector size can be selected independently of one another
 – convenient for bell-type tank installation – additional devices for potential tie-
in of tap winding during change-over operation of the change-over selector (tie-
in resistors, potential contact)

COMPACTNESS:

– high speed transition resistor type diverter switch with arc extinction at the
first current zero
– diverter switch uses snap-action mechanics by energy accumulator mounted
directly on the diverter switch
– minimum possible tap selector dimensions because four available sizes ensure
matched impulse voltage with stand ability
– radial dimensions of the tap selector are reduced by special shaping of all parts
on high potential, distances between tap selector bars determined by actual
voltage stress – optimised integration of the change-over selector into the fine
selector contact circle

ROBUSTNESS– LONG LIFE:

– rapid tap change operation, low thermal stress on the transition resistors
– diverter switch arcing contacts made of tungsten-copper alloy at 500 A and
above
– –simple tap selector design, effective contact cooling, high short-circuit with
stand ability
– tap selector gear with steady torque during the tap changer operation

EASY TO INSTALL – COST SAVING:

– oil-immersed installation of the entire tap-changer in the transformer main tank

– simple to connect
– drive shaft and pipe connections easy to orientate
– straight forward coupling to motor drive unit

REDUCED MAINTENANCE:

– long contact life

– quick and easy to disassemble diverter switch insert
– simple to adjust and control
– oil suction pipe built-in
– diverter switch contacts easy to replace
MOTOR DRIVE UNIT

An on-load tap-changer is normally used in power transformers in an electric grid, where its
function primarily is to keep a constant voltage out from the transformer. Some on-load tap-
chargers are used in transformers where their function is to control the power of the transformer
by regulating the voltage. The on-load tap-changer can be described as a mechanical switching
device that will change the turn ratio in the transformer without interrupting the load current.
This makes it possible to keep a constant voltage out from the transformer and to compensate
for variations in the load.

A common on-load tap-changer generally consists of a motor drive unit, an axis system, a
diverter switch with a housing, and a selector mounted under the diverter switch. Such an on-
load tap-changer is named a diverter switch type. Another on-load tap-changer, wherein the
selector and the diverter switch are merged into the same unit is named a selector switch type.

The main objective of an electric motor drive unit is to drive the connected on-load tap-changer
to a higher or a lower tap of a transformer. Electric motor drive units for tap changers are rather
complex and the cost for their production and assembly- is considerable. Further, electric motor
drive units are to a large extent order designed, with a customer requirement as basis, which
further increases cost for their production and assembly.

Fig. Motor assembly for OLTC

BENEFITS OF MOTOR DRIVE UNIT:

An object of the present invention is to provide an electric motor drive unit for tap-changers
which is adaptable to different customer requirements.

The invention is based on the realization that by providing an on-load tap-changer with an
electric motor drive unit at a minimum the following advantages are achieved:

• Reduced lead time in production

• Flexibility for late order changes

• Service friendly design

• Reduced tap-changer motor drive cost

PROTECTIVE RELAYS:

A relay is automatic device which senses an abnormal condition of electrical circuit and
closes its contacts. These contacts in turns close and complete the circuit breaker trip coil
circuit hence make the circuit breaker tripped for disconnecting the faulty portion of the
electrical circuit from rest of the healthy circuit. The protective relay is designed to protect
the on-load tap-changer and the transformer during a malfunction within the on-load tap-
changer or the selector switch oil compartment. It trips when the specified oil flow speed
between the on-load tap-changer head and the oil conservator is exceeded. The protective
relay must be connected so that the transformer is immediately isolated from the power when
the protective relay trips.

Fig Protective Relay

MOUNTING OF DRIVE SHAFT AND BEBEL GEAR UNIT

Due to the special arrangement of the tap-changer phases in three columns, the horizontal drive
shaft must be mounted between the three tap-changer heads above the tank cover. Since a
swivelling of the upper gear unit will initiate a switching action, make sure that the adjustment
position of the diverter switch is re- gained after the alignment of the gear units.

Fig Drive Shaft and Bebel Gear

FOR THIS PURPOSE PROCEED AS FOLLOWS:

 Check that the operating positions of all columns are identical (tap-changer head,
inspection window). Each one of the one-phase OLTCs must be in the adjustment
position.
 Turn the upper gear unit of the tap-changer heads into the desired installation position
and fix them there (tighten thrust collars and tab-lock the screws).
 Take note of the arrow on the drive shaft flange below the punched serial number. The
direction of the arrow indicates the rotation sense when crank- ing the motor drive
clockwise and must be identical on all gear units.
 Operate the tap-changer poles separately by one step by rotating the trunnions counter-
clockwise until the diverter switch operates once. Check coincidence of operating
positions of all tap-changer heads.
 Mount the horizontal drive shaft between the tap- changer heads.
 Return the OLTC set that is all tap-changer poles together, into the adjustment position.
The adjustment position is reached by turning the drive shaft in clockwise direction.
 Check simultaneous operation of all diverter switches. Check coincidence
of position of all tap- changer heads and the motor drive unit.
 Mount the vertical drive shaft.

Make sure that bevel gear serial number and on-load tap-changer serial number are
identica l. The horizontal drive shaft must be in proper alignment with the trunnion
in the tap-changer head. After loosening the thrust collar (6 bolts M8, was. 13) the
upper gear unit can be swivelled (fig. 39). After adjusting the upper gear unit, the
thrust collar must be re-tightened (max. torque 15 Nm). Tab-lock the screws. In
case of bevel gears in special design and intermediate bearings of the vertical or
horizontal drive shaft above instructions apply analogously.

Square shafts, coupling brackets, coupling bolts, screws, nuts and lock tabs are made
of corrosion-proof steel. We recommend, however, to apply the same outside
coating here as to the transformer tank. The square shafts and the guard plate for the
footstep protection for the horizontal drive shaft at the trans- former cover are
supplied in oversize (various standard lengths). These parts must be cut to the
required size before mounting. Finally equalize the rotation lag between on-load
tap- changer and motor drive unit will be completed.