RECENT DEVELOPMENTS IN POWER TRANSFORMERS FOR ABROAD 1 FORWORD We have exported several hundreds of power trans- formers to the countries shown in Fig. / and listed in Table J. These units are playing an important role in power sta- tions and industrial plants, and are highly evaluated by users for their excellent characteristics and high reliabilities. This is because they have been manufactured by paying careful attention to customer standards, versatile specifica- tions, climatic conditions at site, transportation and instal- lation, ete. in addition to the superior know-how accumu lated over many years of manufacturing trensformers for domestic electric power companies. This article is to give an outline of exported power transformers of extra high voltage and large capacity, aside from such export transformers for industrial use as electric furnace transformers and rectifier-transformers which are also favorably received worldwide. Up-to-date technologies applied to those exported transformers will be introduced, including construction, features and supply record. Ml, TECHNICAL REQUIREMENTS AND MEASURES OF POWER TRANSFORMERS FOR ABROAD We ate promoting a wide range of research and de- velopment activity, from basic research to computer-aided 32 upc 621.3142 Yoshiaki tkeda Kimio Hondo Kazunori Hashiba analysis in the field of transformers, We have also accumu- lated abundant experiences and technologies, for example, through the trial manufacture and reliability test of the extra high voltage and ultra high voltage transformers, in ‘order to supply the high reliable transformers to the domes- tic electric power companies. These accumulated technolo- gies are, of course, fully utilized in manufacturing the power transformers for abraod, However, the technical re quirements of the export transformers somewhat differ from those of the domestic use transformers as shown in Table 2, and therefore it is essential to elaborate on the design of matching them as well as possible. IIL, FEATURES OF FUJI POWER TRANSFORMERS 1. Construction and features 1) Core and frame The core is made of high quality oriented silicon steel laminations without holes for clamping bolts. The legs and yokes are jointed by lapping at an angle of 45° on the ‘comer of the core. The core legs of the large capacity transformer are tightened by the reinforced glass band at a certain intervals as shown in Fig. 2, and the core legs of the medium capaci- ‘ty transformer are tightened by the insulation tube. In either case, the magnetic flux flows uniformly in the Fig. 1 Countries where Fuji power transformers wore exportedTable 1 List of power transformers for abroad {more than 100 MVA) T | a [Sumber] Rated capacity ] Rated vottax> | F1® looting gatam],T2P_ [Quant Delivery No ene or pase &) uency OAUMEYSEM hanger) ty | time Senvsios Biestrioos dt 500 220 | See ee eat Sme/7ens2 so | so | onar/orar|outc| 12 | 1980 1 | Argentina a a ‘Comision Tecnica Mixta | 3 | 300/300/100 | $00/231/13.8 | ONAN/OFAF[OLTC[ 1 | 1979 | deSatoGrnde [3 [asorisofs | sooji3e/ia.8__ | 50 | ONAN/OFAF|ouTC| 2 [1978 3 [1asjiaso | 230/67.5/22.5 | S0 | ONANIOFAF[oLTC) 1 _| 1977 State Electricity 3_[12s/zs/a0_|230/67.5/22.5 | 80 | ONAN/OFAN/OLTC | ~2_| 1980 Commission of Vietoia [3 [s0/iso/3 | 220/66/11 50 | ONAN/OFAN OLTC| 1 | 1981 2 | Australia 3 fresnissi | 230/66/22 50 | ONANJOFAN OLTE 1 | 1982 carcty Trost of 3 [Ro 775/66 30 | ONAF/OFAF|OLTe| 2 | 1966 South Australia 3__[180 275/66 50 ONAF/OFAF|oLtc| 1 | 1980 51252, ‘ONANION- 126 | 60 nvic] 6 | 1978 British Columbia ve 3" AFIOFAF 3 |canada | Hydro and Power S125 243, ONANION- | vae Authority Pare | oo |QNeMee |wvic) 3 | 1978 B36 60 | ONANTOFAF|NVTC|3_| 1979 RD rT Indonesia Asshan 262.5/38 30 [orar onrc| 2 | 1980 Aluminum EE 262.583 30 [OFAF out) 2) 1981 "Korea Electric Company 3.8/ 60 | OFWF, ove] 2 | 1978 5 |Kores [Pohang Iron & Ste isa Roaneion Sie 75 Taassien |asarzani | ao forar fotxe| 2 | 197 Ministry of Fsoticty Ff ONAN/ON- r 6 Joman | Mistry 0 3 ns 139/33 so /ONANON gure] 2 | 1979 3 [so0js00is0 | 20/nns/a.8 ONANIOFAF|NVIC) 2 _| 1978 7 | rapines_| Ns Power 37 | toojoo740 | 200)65/138 | 60 | oNANIONAr|oLTe | 1 [1999 3 _[1oojroo720[220/115/13.8 | 60 | ONANJONAF otc) 2 | 1978 8 [Qatar DAG 3/150 ‘azi6s (30 | onawiorar|orre| 2 _| 1976 9 | awa Arabi) Q24E9 Oversens 3 | 138/230 60 | onanjonar|otre| 3 | 1977 z T. ‘i 1B) 17 00)s0090 | 345,164, ee 1 SA Biss 60 jorar — forte} 5 | 1996 10 Taiwan | Talwar Power ShsTs vals | i | 1300 pany Here | [a [izonaomo fisveonr | 6o jorar forse] 2 [BSS | 3 [2007200150 | 220/69/11 50_| ONANJONAF oLTe| 1 | 1976 tectrcity Generating = 11] matana | Hestrety Generating [3 Ta9q/200/80 | 230/115/22 50 |OFAF ouTe) 1 | 1981 3 [680 [papas 30 [OFAF |Nvic[ 1 1982 12 Turkey | Devlet Su Isler 3 [isonsors | 380/154/30 50_[OFAF_ovte| 1 _| 1977 Bonneville Power 1 (20000788 60 jorar — foute! 3 | 1968, 13[usa. | Administration : 4 3 [250 20/115 [60 OrAF [oLte) 3 | 1968 | Novands Aiuminam | 3 [130 161/345 | 60 OFAF——NVIC| 1 1975 CA de Administration : 14 |voneeuen | C48e Atminctration | 5 | so9 malas 60 |orwe —[wvre) 2 | 1979 (Other countries where transformers more than 30 MVA have been supplied ‘Costa Rica” Malaysia UAE (Abu Dhabi) Inga Mexico Viet Nam aq Nepal Singapore Jordan Silanka ‘Peru Recen! Developments in Foner Tarsermers lor Abrood 33Table 2. Technical point of power transformers for abroad Description © Many’ are lie side on-load tap-chaning auto-transformers ‘© Some are transformers with 8 -connected superhigh voltage winding. © Thete are various trends in impedance. TEC, ANSI, BS, CSA, AS, NEMA and other foreign standards are often required to comply with, and therefore the difference between these applicable standards and Japanese standards of JIS and JEC has to be clatfied As to the mass-produced parts, we recommend those products in accord ance with Japanese standard, ‘Since partial discharge test, front of wave text, and sviiching impulse test are frequently required, — these tests are implemented so that the standards are satisfied. ‘Since the generated Iosses ate ovaluated economically, the relationship between the guarantee values of copper loss and iron loss, and the quantity of materi is optimized the most eco- nomically i Because the special specification are equired for the bushing, cable head, winding temperature indicator, pressure relief device, pressure relay et., measures are taken so that they can be easly supplied. fe In case of transformers for oll producing Counteies and counties in the gid region where special insulation oil is needed, local availability of insulation oil i always investigated, And also itis always checked by sample tests whether the insulation oil meets the spplicable standard and whether it tem Winding type and arrangement are constantly + being optimized, high voltage tap-changee i being 1) Variety of specifications doveloped, to cope with these problems. 2) Standards 3) Insulation test, 4) Loss evaluation 5) Accessories 6) Insulation oil ince the transformers are transported a long way on sea and land under fairly severe conditions, impact recorders are provided to confirm whether or not the abnormal shock has been given during transportation, Construction of transformer tank is designed so as to suit inland transport ation tothe sit, | Thore are various installation 7) Transporting conditions jon sites, such as Tigi regions, op fabrication method, and paint are selected according to these conditions. Special p are used against sunlight in tropical regions “oolng system is frequently of triple rating (ONANJONAT/OPAF), Cooling system is designed so that it will be easily operated and it will be provided with high cooling capacity at cach rating, Tegions, ete, The material, and color 8) Installation site conditions 9) Operation (©) Cylindrical layer winding {) Dise winding Fig. 3 Dise winding and cylindrical layer winding Fit.2 Core voltage and large current windings. Not only flat square conductors, but also common in- sulted conductors and transposed conductors are used as the winding conductor to reduce the eddy current loss in inding of the large capacity transformers Thermally upgraded insulation paper is used as the con- ductor insulation, as required. All the windings are contin ously wound with minimum blazing connections to im- prove the reliability. Such specifications of transformers for abroad as rated voltage, capacity, winding connection, voltage regulation rolling direction of the silicon steel sheet, thus the no load loss is minimized. No load loss may also be reduced by using the highest silicon quality steel Hi-B and decreasing ‘the magnetic flux density. The frame tightening the wind- the ing is of a simple beam construction, The upper and lower frames are interconnected by connecting plates provided along the core legs. 2). Windings Windings are arranged concentrically as. standard, Dise windings or cylindrical layer windings are applied principaly for the extrahigh and super-high voltage wind- ings and helical windings are applied principaly for the low 34 system, impedance, etc. vary widely, especially in the cease of auto-transformers. We can easily decide which type FUJI ELECTRIC REVIEWFig. 4 ise winding (@) Calculation result by computer (b) Measured result by model Fig, 5 Electrical potential distribution of winding, disc winding or cylindrical layer winding shown in Fig, 3, shall be more suitable for a specification com- paring the advantages of two winding methods, since we have the manufacturing facilities and capability of both windings and since we have many experiences of having supplied both windings. That gives us an ample flexibility for design of windings, including tap winding arrangements. In other words, we can meet easily for various requirements of each customer. The cylinderical layer winding is frequently used in auto-transformers, becaused it is easy to analize potential vibrations and it is also easy to design insulation of wind- ings. Recently, however, the use of the high series capaci- tance winding of disc coil shown in Fig. 4 is steadily i creasing, because the complex potential vibrations of the disc coil as shown in Fig, 5, electric field around the coils, insulation strength between coils, etc. caused by the im- Fig. 6 Magnetic fold pulse voltage can be exactly anatized by detailed computer analysis and from many experiments on various coils of trial manufacture. In case of large capacity transformers, itis essentially important to anilize the details of leakage magnetic field produced by ampere-tums of winding so as to minimize stray-load loss and local heating and to maximize short circuit strength. This problem of leakage magnetic field has been constantly studied through the detailed leakage magnetic field map plotted by computer as shown in Fig. 6. Thus, the quality and dimensions of the structural material and distance from the winding, thickness of the ‘magnetic shield, etc. are suitably selected. 3) Insulation ‘The interwinding insulation is arranged so that the oil gap is divided by multilayer insulation barrier of press board. End of high voltage winding is provided with round electrode insulation, the exterior of which is further insulat- ed by pre-fabricated type pulp moulded insulation barriers. The press-segment and press-table for the windings are ‘made of laminated wood and the lead supports are made of laminated press-board. This laminated wood and laminated press-board are easy to work, have excellent oil-impregnat- ing, and are electrically stable and mechanically strong. The long oil gap around the high-voltage lead, etc. is divided by pre-fabricated type pulp moulded insulation barriers to re- duce the insulation distance to ground, to make the trans- former compact, and to save oil. 4) On-load tap-changer Our on-load tap-changer is of resistor type and has a satisfactory record of long year operation. As pointed be- fore, export transformers have to meet various technical re- quirements for such transformers as single-phase transform- cers with large capacity and autoctransformers with tap changer on secondary line side, In order to cope with these variety of requirements, we have recently developed a new series of tap-changer under the technical licence from Trafo Union, West Germany. An outline of new onload tap- changer, called BM series, is shown in Fig, 7. This ondoad 35f Aa ae tena daar || | ay Gaara ——S series omtood Tensei 1 Tewacon | [rose w tapehanger wat inet te tne 204 ey ros 8 tos 8 fee 8 fon OB tapchanger is @ combination of a tap selector and a diverter switch according to voltage, through-current and number of taps, as listed in Fig. 8. Many parts are appropriately de- signed for common use in order to increase reliability. This new series can be applied to the rated phase current of 200 ‘A.up to 300A. In addition to the existing types that break the arc in oil, an on-load tap-changer using a vacuum valve in diverter switch section (VS-LTC) has been practicalized to meet the demands for high frequency switching and longlife as shown in Fig. 9. 2, Manufacturing facilities We strictly conduct various quality control programs to increase reliability in the course of manufacturing process, including control of workmanship, inspection of products and technical training and management of workers. The work environment is also improved and the latest manufac- turing facilities are used to keep stable quality of products and to improve production efficiency. 1) Dustproof air conditioned work shop Such works are performed in the dustproof aircondi- tioned work shops as insulations work, winding, pre- tightening of winding, assembling of core and winding, final tightening of winding after drying, assembling of tap- changer, ete. These work shops ate partitioned at each manufacturing process and are provided with the ceiling that can be opened and closed by electric motors. Air that is cleaned and dehumidified by a filter is constantly cir culated in these workshops and the humidity is maintained constant through the year to provide a good work environ- ment. 2) Vapor phase drying fumace ‘The core and coils of the transformer is dryed by the vapor phase drying method. This is a method to blow kerosene vapor on assembled core and coils in the furnace, and to evaporate moisture in the insulation by the con- densation latent heat which is discharged from kerosene vapor during its liquefaction The winding is uniformly 36 Fig. @ Combination system of BWsaries on-load tap-changor Fig. 9 Diverter switeh of vacuum switch ondoad tap-changer wstte} heated up to the inner parts without the intervention of oxygen and at the same time cleaned by liquefied kerosene. This method has an advantage in obtaining a stable quality of the insulation in a short drying time 3). Air easters Air casters, as well as cranes, are used to carry heavy objects in the factory. The complete assembled transform- ers ate disassembled for the shipment after shop test and are carried to the factory wharf by air casters. There, it is loaded a ship by gin pole crane and shipped directly to its final destination IV. TYPICAL MANUFACTURING EXAMPLES 1, 625//TKV 900/3 MVA autotransformer for BPA, USA We have delivered 3 units of 525/V3KV 900/3 MVA single-phase auto-transformers to Bonneville Power Admini stration, USA, as early asin 1968. These auto-ransformers are designed for 112% continuous load and are provided with on-load tap-changer of a step voltage of 6.25//3 kV Vol. 26 No.2 1989 FUJI ELECTRIC REVIEW‘on 241.5 KV line side. Please note that these advanced tech- nologies were developed as early as in 1968. On these auto- transformers, an AC long-term dielectric test was carried cout for the first time at 1.SE=475 kV for 2 hours, com- bined with partial discharge test, according to the request of BPA. They have been successfully operated since then 2, 512.5//3KV auto-transformer for BCH, Canada Recently we delivered six $12.5//3kV 1200/3 MVA and three 672/3MVA single-phase autoctransformers to Canada, The British Columbia Hydro and Power Authority is known throughout the world for its precise specificat and high quality requirements. We feel that the successful delivery of these auto-transformers is a reflection of the fact that our technical level and quality level are appreciat- ed worldwide. Outlines of this 1200/3 MVA auto-trans- Formerss are as follows: Fig. 10 5125/3 kV 1200/3 MVA auto-transtormer for BCH, Canada 1) Specifications ‘The rough specifications of this unit are shown in Table 3, Followings are main features of the specifications. (2) Extra-high voltage and large capacity auto-transformer (2) Ambient temperature of ~30 °C is specified. 3) No-voltage tap-changer is provided on secondary (242 KY) ine side. (4) Taree stage cooling is specified (5) AC long-term dielectric testis specified. Fig, 10 is an exterior view of this auto-transformer and Fig. 11 is an outline drawing. 2) Interior construction A two-leg core construction is applied. The legs and yokes were tightened by the reinforced glass bands. The core was devided into blocks by cooling ducts. However, the grounding leads were accessible at the outside of the tank so that the insulation resistance of each block could be measured at shipment and at the site. ‘The windings were wound in parallel on two legs and the tap winding, series, parallel winding, and tertiary wind- ing were arranged concentrically in the above order from the outside to the core side, Fig. J2 shows the core and coils of this auto-transformer. The conductors were in sulated with thermally upgraded insulation paper. An inter- nal current limiting reactor was connected to the tertiary ‘winding to make its impedance large. Pre-fabricated type pulp moulded insulation barriers are provided for the insulation near the windings. The shape and arrangement of the pulp moulded insulation barriers were scrutinized and dicided by the electric field map mentioned before. Leads of 512.5 kV side are enveloped by insulation paper and it is provided with pre-fabricated insulation bar- Fig, 17 Outline of 812.5//3 kV 1200/3 MVA auto-transformer for BCH, Canada fecent Developments In Power Translormets for Abrood 37ae 861 2-0N 96104 maiagy 91u9313 11nd Table 3. Specifications of main poner transformers for brosd 7 Datvery time [968 [ ipre-iseo [97 wre [ae | iss 179 we | bso | Bonnevite | Taiwan Power | Devlet Su | Ba Cotum-| Same asat | Comision Tee-| Sameasat | CA de Admint| Servicios Elec- | Power Admini} Company "| es Tukey | bi Hydro & | I j newt) i Strationy | teosdel Gran Customer stration (BPA), | Power Author-| Salto Grande | Fomento Elee-) Buenos Aites | usa. ] | ity (BCH), | c™, trio | sa. @EGBA), Canada ‘renting | (CADAFE), | Avzentina [EeeeeEEEdd4 [EEE Es dd BEEP EPEC) Std EEE | EEE end Wool | PEE [3 a | a 6 [2 1 2 2 "Standars [ ASACS7.I2 | ANSICST.I2 | JECI63 | CSACHS | SACRE | _16C6 1C-76 1EC76 7 Outdoor auto- | Outdoor auto- | Outdoor auto- | Outdoor auto- | Outdoor auto- | Outdoor Outdoor | Outdoor ail transformer | transformer | transformer | transformer | transformer | transformer | transformer | transformer | transformer Number of phates 1 3 3 Frequency (i) | 60 30 0 | Capacity (MVA) 30 | 672,672 150 ' en 12)872180 ysoyrsoyes | s00/300/100 | 500 Vottase&&¥) 5125 242 Y 300,220 5125 202)19.6 25/282 19.6) soojissiiaa | sooaaiise | 24/432 228139 wisrt) Ve al a Val te ee Mena Inpetince lags PSST) | joera | iayra90 | vanisojias | a7jioa/i2a (rier49zi64a| vapiaisa | 12/34/46 4 napa? Erma covey § ee eee ee rete tatae te) tment fl wave { | \ Test voltage oe ce ov) Leahiing imps | 640750130 taiojs/ao |1s079soa00 | 17807950130 1780/980130 | vasrsonie | somes |isopsorio >is - — cn |" Switching impulse | 1180/540)/— a =| ta807- 7 Taso asi _| = i300) [xe Gaorrsyi0 | 07325770 | s7o;2/70 | Sae/a~pai | Saefaw/ar | aoraBO/ee | eaonasfae | _TO}690 | 740/295/200 Connection IA ALA | AA | AIA ALE AIALE li ALA AIA I AMAIA Tapeh | Ontos | T ontost [ Novortge | Nositage | —Onlosd | Onoad | Novolage | Ondond apechangst | tap-changer_| tap-chenger | tapchanger | tap-sharaer | tapechanger | tapshanger | tap-hanger SE Ee Pe Ee EE Pe eee seme ial ee [Eten tienen ersten eb erase Centingmstod rar | orar | orar [PMGIRIAYTONSYRSANoxwnorar owaworar | orwr | oxatons ee [eee pee Pe ae eee | Peco PE OPA orar fe eee ee Special single t fee hase ype | For fii region For iid rson| |Special phase | (cosining of ors0°e | of SO" ‘ype as | |Fig. 12 Core and coils 70 in O10 2030 40 50 G07 BT Fig. 13 Partial discharge tex sequence riers which are concentric cylindrically arranged, so that the dielectric strength is improved. It is fixed firmly by steel- ring which is ground potential. Adequate insulation strength of the important lead clamps and bushing tail, was also confirmed by electric field mapping. Since the tap- changer is provided at 242 kV line side, 2 high voltage was constantly applied on tap-changer. Therefore, the contact supports are made of corona free voidless material and shield rings are provided at the top and bottom of the con- tacts to reduce the electric field strength. 3) Tank and external fittings The tank is of so called bell type. The tank flange is provided at the bottom. The core and coils can be inspected by lifting the tank up with a small crane. The tank is made of special steel to meet the —50°C frigid region specification. All weldings are of notchless. ‘The tank is constructed so that a soundproof enclosure could be mounted if required in future The cooler is a separate type with panel radiators and had triple rating of ONAN/ONAF/OFAF. The two groups of radiators are connected by series pipe and oil pumps are provided midway between two groups so as to prevent mis: ‘operation of the pressure relay at the time of pump start or pump stop. Low-noise cooling fans are provided considering pos sible future modification of transformers into low-noise ty- econ! Developments ia Fower Transformers for Abroad Taiwan) Fig, 15.500 kV 150 MVA transformer for CTW, Argentina pe. ‘The bushings are oil impregnated paper condenser type in accordance with CEMA Standards. The center conductor of the $12.5 kV bushing is a draw-rod type. According to the specification of accessories, auto- matic reset type pressure relief device of M/S Qualitrol and pressure relay of M/S CGE are supplied. Such diaphragm of conservator, gaskets, contact of relay and insulation oil are supplied as suitable for the climatic conditions of frigid region. 4) Test ‘The AC dielectric tests were performed in the sequence shown in Fig. 13 by combining a longterm dielectric test and partial discharge test and good results were obtained. Heat run test was also performed under the three stage of cooler rated conditions ONAN/ONAF/OFAF respectively aid the specifications were satisfied, 3. Other typical examples Table 3 shows other extra-high voltage transformers we have supplied so far, Brief description of those transformers are given below. (1) 345/V3 kV 500/3MVA auto-transformer for TPC, Taiwan, 39Q) @) @) ©) 40 ‘These are auto-transformers with on-load tap-changer provided on the secondary line side. Due to the weight limit of 45 tons for inland transportation, the main bodies of these auto-transformers were disassembled into two section on-shipment and re-assembled at the site. (See Fig. 14.) 380 kV 150 MVA autotransformer for Turkey. This is a 3-phase auto-transformer with on-load tap- changer provided on the neutral point, 500 kV 300MVA auto-transformer and 500 kV 150 MVA transformer for CTM, Argentine. Both transformers are of 3-phase type with ONAN/ OFAF cooling. The 300MVA auto-transformer was disassembled into each phase on shipment due to the weight limit of 70 tons for transportation. 432 KV SOOMVA transformer for CADAFE, Vene- zuela. These are generator transformers with OFWF cooler for power station and are specified of $50 MVA con- tinuous operation conditions. The core is a 3-eg core and transposed conductor is used as the winding con- ductor. Primary windings are led out through 3 bushings (rated current 15000 A) and connected to each phase segreg ated isolated buses. S00/V3 kV 855/3MVA_ transformer for SEGBA, Argentina. These are separate winding transformers of high im- pedance with ondoad tap-changer for 2100 A provided ‘on the neutral point of secondary winding. Other transformers with onload tap-changer on high voltage windings of delta connection. ‘These transformers have been delivered to Costa Rica, Taiwan and other countries. Our standard method to provide on-load tap-changer for transformers with high voltage winding of delta connection is to provide 2 units of connecting single-phase on-load tap-changer on line side. 6) V. CONCLUSION Before finishing this article of introducing an outline of | our transformers for abroad, we would like to add a few ‘words on future trend of electric power world wide Supported by increasing demands for electricity all over the world, electric power system no doubt expand, with its voltage and capacity becoming higher and larger continuously. Consequently it is essentially important for us to provide power transformers with high reliability and high efficiency. We shall proceed further with our research and development program in order to cope with recent tend and requirements. We shall be very happy if we can contribute to the development of electric power system through our technology and capability of supplying reliable power transformers which meet various requirements from various countries Vol. 26 No, 2 1980 FUJI ELECTRIC REVIEW