Power Systems

Over-Voltage Requirements
Panel Session &
IEEE Standards meeting Their Impact
Pittsburgh, Pa. 10 06 03 On transformer design
© ABB Power Technology Products - 1 -

Sponsored by The
Performance Characteristics
Subcommittee
3/26/2004
Background
Background, cont.
 Background,cont.

„ Calculated Core Excitation can reach 115 %

which limits the 100 % design core induction

„ To avoid core saturation

„ To avoid H2 / CH4 gas generation due to mild heating of thin

oil-film between laminations of transformer cores at full load

 Topics to be presented
„ Influence of system conditions on transformer core excitation
( G. preininger )

„ Influence of core excitation on core design ( R. Girgis )

„ Over-voltage requirements and system operating parameters for

GSUs and Autos ( B. Patel and D. Chu )

„ Experience with Utilities specifications, system operations, and

impact on core over-excitation / Recommendations ( H. Moore )
 Influence of
Panel Session
IEEE Standards meeting
core excitation
Pittsburgh, Pa. 10 06 03 on core design
© ABB Power Technology Products - 6 -

Ramsis Girgis
St. Louis, Mo
3/26/2004
 Topics to be presented
„ Core Saturation

„ Electrical steel BH curve

„ Maximum core excitation / Design Example

„ H2 / CH4 Generation from thin oil-film between core laminations

„ Maximum core excitation at full load / Design Example

„ Core Noise

„ Items to be considered for new revisions of ANSI standards

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 B-H Curves

2.0
1.9 D
H
1.8
R
1.7
Induction B (T)

1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
1 10 100 1000 10000
Magnetizing Force H (A/m)
 B-H Curves
2.0
1.9
1.8
1.7
1.6
Induction B (T)

D
1.5 H
1.4 R
1.3
1.2
1.1
1.0
0.9
0.8
0 1000 2000 3000 4000 5000
Magnetizing Force H (A/m)
 Maximum Core Excitation
„ Maximum Core excitation < Core pre-Saturation level

„ < 1.92 – 1.95 T for RGO core steel

„ < 1.95 – 1.98 T for HI-B & DR core steel

„ 100% excitation = Core pre-saturation level / p.u. over-excitation

„ Design Example:

„ Over-excitation = 1.05 100% excitation = 1.92 / 1.05 = 1.83 T

„ Over-excitation = 1.15 100% excitation = 1.92 / 1.15 = 1.67 T

„ Significant difference in transformer cost if no other limits

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Core Hot-Spot Location (3 phase, 3 limb core)

Location of core hot-spot

Measured Core Temperature Rises

Yo ke Cro s s S e c tio n T-J o in t Cro s s S e c tio n

63.0 68.0

75.9
71.1

75.9 81.8 64.1

67.0 73.8 62.3

 Maximum Core Excitation
„ Core excitation under full load < level causing unacceptable levels of H2

rate of generation

„ Core hot spot < 125 / 130 C under maximum levels of core excitation, full

load, and maximum ambient temperatures

„ A high core over-excitation at full load, typically requires lower 100% flux

density / larger number of core cooling ducts / lower loss core material

„ Design Example:

„ Large core, 5 cooling ducts, 11 mil RGO material

„ Core over-excitation = 1.05 at F.L.: Design is ok

„ Core over-excitation = 1.15 at F.L.: RGO would need to be replaced by DR

„ Significant difference in transformer cost

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 Maximum Core Excitation
„ Noise level of transformer at maximum Core over-excitation

could produce unacceptable noise levels

„ < 1.92 – 1.95 T for RGO core steel

„ < 1.95 – 1.98 T for HI-B & DR core steel

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 Attainable values of Over-excitation
„ ANSI Standards:
„ Transformer must deliver rated MVA at > = 0.8 power factor at 105%
continuous secondary voltage

„ Primary voltage:
„ 105% + regulation (can reach 115% voltage)

„ For GSUs, shouldn't the primary voltage be limited by the maximum voltage
the generator can deliver at full load?

„ For Autos, shouldn’t the primary voltage be limited by the maximum allowed
system voltage variation (+/- 5 %)?
 Core Hot Spot Temperature Limit
„ ANSI does not presently have a core hot spot temperature limit

„ ANSI states that a metallic part not in contact with current carrying

conductor insulation, should not attain excessive temperatures under

maximum loads

„ Some recent customer specifications include a limit of 125 – 130 C

limit for core hot spot temperature for the worst case of core over-
excitation, load, and ambient temperature

„ There is a need for IEEE Transformers Committee to introduce a core

hot spot temperature limit
 DGA Guide – C57.104

„ Guide does not presently address the mechanism of H2/CH4

gas generation due to core overheating
„ Recommended Addition
„ Add wording about the mechanism where H2 and CH4 is produced
at low ppm per day with a 6-8 ratio
„ Is caused by moderate core overheating
„ Not harmful to the unit
© ABB Power Technology Products - 22 -

T
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 Consolidated Edison Company
of
New York
© ABB Power Technology Products - 23 -

Donald Chu
 System Description
„ Electric Sales: 53,000,000 MW-Hours
„ Peak Load: 12,200 MW
„ Underground: 91,000 cable miles (T&D)
„ Overhead: 36,000 wire miles (T&D)
„ Transmission Transformers: 116
„ Area Station Transformers: 240
© ABB Power Technology Products - 24 -
 Transmission System Voltage Requirements
Voltage Voltage Limits (kV) Duration

Class (kV) Range Lower (minutes)

Over 160 - 0

138 153-160 - 10

146-152 124 30

130-145 130 Continuous

© ABB Power Technology Products - 25 -

Over 400 - 0

345 381-400 - 10

363-380 311 30

328-362 328 Continuous

 Typical Area Station Bus Voltage Schedule
Total 13.8 kV Bus Load (MW) 13.8 kV Bus Voltage (kV)

0 - 40 13.4

41 - 80 13.5

81 - 120 13.6
© ABB Power Technology Products - 26 -

121 - 160 13.7

161 – 200 13.8

Above 200 13.9

 Typical Area Station Configuration
„ Four 132-13.8 kV, 65.3 MVA transformers with +/- 12 % LTC and
LV output paralleled
„ 132-13.8 kV, 65.3 MVA transformer with +/- 12 % LTC spare (HV
energized)
„ 13.8 kV double synchronizing bus
„ 2-3 13.8 capacitor banks
„ Double contingency, lose 2 transformers (meet load
© ABB Power Technology Products - 27 -

requirement with 3 transformers)

 Area Station
Double Synchronizing Bus Design
Syn Bus

Syn Bus Breakers

Transformer Circuit
Transformer
Switcher
© ABB Power Technology Products - 28 -

Breakers

To Network Load

Syn Bus
 Typical Area Station Normal Operating
Condition

„ 140-145 kV HV bus voltage

„ Non-summer loading: Four transformers loaded to
approximately 30 % of nameplate rating (65.3 MVA)
„ Summer loading: Four transformers loaded to
approximately 80 - 90 % of nameplate rating (65.3 MVA)
„ NLTC: 125.4 kV position
© ABB Power Technology Products - 29 -

„ LTC: 12L position (12.558 kV position)

„ Power factor: 0.93
 Typical Area Station Contingency Operating
Condition

„ 138-140 kV HV bus voltage

„ Summer loading: Three transformers loaded to
approximately 143 % of nameplate rating (65.3 MVA): 93.8
MVA for 8-hours
„ NLTC: 125.4 kV position
„ LTC: 16R position (15.468 kV position)
„ Power factor: 0.93
© ABB Power Technology Products - 30 -
 NY City M1R Noise Performance Requirement
(Sound Pressure Level)

Manufacturing Zone Maximum Average Sound Level (db)

Octave Band Freq. (Hz)

20 - 75 79

75 - 150 74

150 - 300 66
© ABB Power Technology Products - 31 -

300 - 600 59

600 - 1,200 53

1,200 – 2,400 47

2,400 – 4,800 41

Above 4,800 39
© ABB Power Technology Products - 32 -

TEAMWORK
 TRANSFORMER CORE EXCITATION

presented by: Harold Moore

Harold Moore & Associates
© ABB Power Technology Products - 33 -

October 6, 2003
 TRANSFORMER CORE EXCITATION

CHANGE IS NEEDED.
REALISTIC CHANGE WITH SIMPLE RULES MAY
NOT BE POSSIBLE.
USER: NEEDS ASSURANCE THAT DESIGNS WILL
NOT APPROACH SATURATION.
USER: MUST PROVIDE CHARACTERISTICS OF
© ABB Power Technology Products - 34 -

SYSTEM AND OPERATION.

DESIGNER: MUST HAVE SYSTEM AND OPERATING
CONDITIONS.
DESIGNER: AWARE OF ASPECTS THAT CAN
CREATE OVER EXCITATION.
 EXPERIENCES

GENERAL
USERS DO NOT HAVE AN ADEQUATE DEFINITION
OF SYSTEM VOLTAGES OR CONTINGENCIES.
SOME PLANNERS SPECIFY “SUPER SAFE”
VOLTAGE VARIATIONS.
DESIGNERS NOT TRAINED TO RECOGNIZE
© ABB Power Technology Products - 35 -

POSSIBLE OVER EXCITATION CONDITIONS.

 EXPERIENCES
GENERAL
USERS DO NOT HAVE AN ADEQUATE DEFINITION
OF SYSTEM VOLTAGES OR CONTINGENCIES.
“ I DESIGN BY THE SPECIFICATION.”
MANY TRANSFORMERS ARE OVER EXCITED AT
PRESENT.
© ABB Power Technology Products - 36 -

HIGHER SYSTEM VOLTAGES.

DETC IS NOT CHANGED
CONFUSION: NAMEPLATE IS FOR RATED
VOLTAGES AND AT NO LOAD.
 GENERATOR STEP UP
SPECIFICATIONS
TAP POSITION FOR CONTINGENCY
UPGRADE OF MACHINES
INCREASE GENERATOR EXCITATION FOR VAR
CONTROL
© ABB Power Technology Products - 37 -

LACK OF DEFINITION WHEN GENERATOR

VOLTAGE WAS LIMITED.
 TRANSMISSION AUTOS
STEP UP OR STEP DOWN OR BOTH?
LOCATION OF TAPS
USER SPECIFIED WRONG LOCATION
DESIGNER DID NOT QUESTION
INCREASE OF SYSTEM VOLTAGES
© ABB Power Technology Products - 38 -
 STEP DOWN AUTOS
STEP UP AND STEP DOWN?
LOCATION OF TAP CHANGER
VARIATION OF TRANSMISSION VOLTAGES NOT
DEFINED
SYSTEM VOLTAGES INCREASED
© ABB Power Technology Products - 39 -
 DISTRIBUTION STEP DOWN
USER SPECIFIED ANSI/IEEE WITH HIGH
IMPEDANCE
EXPECTATIONS THAT RATED VOLTAGE COULD BE
MAINTAINED AT FULL LOAD WITH REDUCED HIGH
SIDE VOLTAGE.
TAP CHANGER LOCATION AS RELATED TO HIGH
© ABB Power Technology Products - 40 -

SIDE VOLTAGE.
 RECOMMENDATIONS FOR CHANGE
1. DEFINE SYSTEM VOLTAGE VARIATIONS
2. DEFINE SPECIAL OPERATING CONDITIONS.
CONTINGENCIES.
3. SPECIFY WHAT IS TO BE ACCOMPLISHED BY TAPS- NOT
WHERE THEY ARE LOCATED.
4. DEFINE MINIMUM POWER FACTOR OF LOAD.
5. NOW THE DIFFICULT PART…
© ABB Power Technology Products - 41 -

MAINTAIN REQUIREMENT FOR 110 % AT NO LOAD.

LIMIT INDUCTION AT 110 % OR DEFINED SYSTEM AND
OPERATING CONDITIONS.
1.93 TESLA FOR STEP LAP JOINTS.
1.9 TESLA FOR NON-STEP LAP JOINTS.
 RECOMMENDATIONS FOR CHANGE – cont.
5. NOW THE DIFFICULT PART…
MAINTAIN REQUIREMENT FOR 110 % AT NO LOAD.
LIMIT INDUCTION AT 110 % OR DEFINED SYSTEM AND
OPERATING CONDITIONS.
Š 1.93 TESLA FOR STEP LAP JOINTS.
Š 1.9 TESLA FOR NON-STEP LAP JOINTS.
© ABB Power Technology Products - 42 -

DESIGNING ABOVE LIMITS RESULTS IN NO MARGIN FOR

ABNORMAL CONDITIONS.
LIMIT HOT SPOT AT DEFINED CONDITIONS TO 125 C.
Š IEEE MUST DEFINE ACCEPTABLE CALCULATIONS.
Š WILL WE SHARE DATA TO OBTAIN ACCEPTABLE
CALCULATIONS?
 THE IEEE STANDARD
MUST HAVE WELL WRITTEN AND EASY TO UNDERSTAND
TUTORIAL. MAINTAIN REQUIREMENT FOR 110 % AT NO
LOAD.
THE REQUIRED SYSTEM CONDITIONS DEFINITIONS MUST BE
SIMPLE AND CLEAR.
© ABB Power Technology Products - 43 -
 Gustav Preininger
Consultant Operating of Transformers
20.08.2002

Power System Over-voltage Requirements

and

Their Impact on Transformer Design

© ABB Power Technology Products - 44 -

Introduction

pittrop01
 Operating of Transformers
Standards

ANSI/IEEE C57.12.00 - 4.1.6.1 Capability

Transformers shall be capable of:

a) Operating continuously above rated voltage or below rated
frequency, at maximum rated kVA for any tap, without exceeding
the limits of observable temperature rise in accordance with 5.11.1
when all of the following conditions prevail:
1) Secondary voltage and volts per hertz do not exceed 105% of
rated values
2) Load power factor is 80% or higher
© ABB Power Technology Products - 45 -

3) Frequency is at least 95% of rated value.

b) Operating continuously above rated voltage or below rated
frequency, on any tap at no load, without exceeding the limits of
observable temperature rise in accordance with 5.11.1, when
neither the voltage nor the volts per hertz exceed 110% of the
rated values.
pittrop02
 Operating of Transformers
Transformer Diagram (1)

∆V = I2 * jz
0.0ind
0.8ind

V1 ϕ
1.0 V2

0.8cap
0.0cap

1.0
0.8cap 0.8ind I2~I1
© ABB Power Technology Products - 46 -

0.0cap 0.0ind
pittrop03
 Operating of Transformers
Core-type: Innermost winding Supplied

++
© ABB Power Technology Products - 47 -

pittrop04
 Operating of Transformers
Core-type - Outermost Winding Supplied

++
~

pittrop05
 Operating of Transformers
Shell-type - Outside Winding Supplied

++
+
© ABB Power Technology Products - 49 -

~ ++

pittrop07
 Operating of Transformers
Shell-type - Central Winding Supplied

+ +
+ ++
© ABB Power Technology Products - 50 -

~
~
+ +

pittrop08
 Operating of Transformers
Overexcitation

O.25 T

S S
Core

Core

Core
© ABB Power Technology Products - 51 -

0T
BC ~ 2.0 T BC ~ 1.75 T BC ~ 2.0 T
pittrop09
 Operating of Transformers
Transformer Diagram (2)

V1 = √ V22 + 2*V2*∆V*sinϕ + ∆V2

Parameters influencing the result:
V1 ∆V
ϕ
Secondary voltage V2 v2 = V2/V2rated V2
Frequency F f = F/Frated
I
Load P2 p2 = P2/P2rated
Load power factor cosϕ sinϕ = √1-cos2ϕ
ϕ
Impedanz z

Primary Excitation
v1/f = V1/V1rated *1/f = √(v2/f)2 + 2*p2*z/f*sinϕ + p2/v2*z)2
and with f = 1
v1 = V1/V1rated = √v22 + 2*p2*z*sinϕ + (p2/v2*z)2
pittrop10
 Operating of Transformers
v1 = v1(cosϕ, z, v2)

1.20 f=1
v1 v2 = 1.05 p2 = 1
v2 = 1.0
1.15

z = 0.2
1.10

z = 0.15
© ABB Power Technology Products - 53 -

1.05
z = 0.1

0
0.80 0.85 0.90 0.95 1
cosϕ
pittrop11
 Operating of Transformers
v1 = v1(p2, z)

f=1
1.30 cosϕ = 0.8
v1
1.25

z = 0.15
1.20
V2 = 1.05
1.15
z = 0.10
V2 = 1.00
© ABB Power Technology Products - 54 -

1.10
V2 = 0.95

1.05

1.00
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
p2
pittrop12
 GSU/AUTO
OPERATING VOLTAGES
113kV 115kV-117kV 119kV

Average Operating Range

225kV 233kV – 239kV 242kV

Average Operating Range

510kV 513kV - 525kV 535kV

© ABB Power Technology Products - 55 -

Average Operating Range

 GSU/AUTO
POWER FACTOR
0.85 (LAG) 0.9 (LAG) – 0.95 (LAG) UNITY

Average Operating Range

© ABB Power Technology Products - 56 -
 DON’T FORGET
Large carries larger load of…..
Loading near maximum rating

Short-circuit concerns and consequences

Out of phase synchronization

Unit – connected operation

© ABB Power Technology Products - 57 -

Full-load rejection

Lower than generator voltage rating

FOA design – Loss of cooling concern

Special Duty – Pump storage application, etc.