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fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPWRD.2016.2579165, IEEE
Transactions on Power Delivery
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proposed. These methodologies can be based on the use of where k 3 / 7 is a parameter obtained from the stress vs.
mechanical failure criteria. strain curve; y 0.1% corresponds to the strain; and
Currently, mechanical failure criteria are typically used to
y 70 MPa is the yield stress of copper.
determine the failure proximity of windings when a short
circuit occurs. However, most of these criteria use the By determining the Von Mises stress through (1), the Von
asymmetric peak of the short circuit current and consider Mises criterion can thus be applied to the transformer
failure to happen only when the value of the MS is higher than windings. The Von Mises criterion can be represented as
the critical stress of the winding. However, a failure may also shown in Fig. 1, where it is seen that the Von Mises stresses
happen when values of the MS are lower than the critical stress that are located on the inside of an elliptical cylinder do not
of the winding. lead to plastic failure of the transformer windings.
It is known that short circuit currents through transformer
windings have a dynamic behavior; consequently, the MS
caused by these currents also have dynamic characteristics.
The mechanical failure criterion that uses the dynamic
characteristics of the MS to evaluate failure proximity and
allows failure to occur for values of MS lower than the critical
stress of the winding is called the fatigue criterion [13].
In this paper, a methodology for failure proximity
evaluation in transformer windings is proposed. The
methodology is based on computer simulations and on two
different failure criteria: Von Mises and fatigue.
II. THEORETICAL FRAMEWORK
In this section, the theoretical framework regarding the two
failure criteria: Von Mises and fatigue.
A. Von Mises Criterion Fig. 1. Elliptical cylinder representing the safety region of the Von Mises
Depending on the value of the MS, generated by EF, the criterion.
windings may withstand plastic failure. The Von Mises B. Fatigue Criterion
criterion is one of the most employed criteria to investigate
plastic failure in ductile materials [14], such as the copper in Fatigue is a phenomenon in which a progressive
the transformer windings. According to this criterion, if the deterioration of a metal occurs when subjected to dynamic
value of the MS, which is the Von Mises stress, is larger than a loads [14].
critical value, the winding is expected to present plastic failure. Fatigue failures are characterized by material rupture. In
This can be seen in (1). these cases, the MS value that occurs is lower than the critical
1 material stress value. Thus, the fatigue criterion can be
2 2 2 3 2 3 1 2 2
v m 1 crit , (1) employed in order to evaluate the MS values that do not cause
2 plastic failure, but may still cause fatigue failure.
where vm is the Von Mises stress; 1 , 2 and 3 are the The tools used in the fatigue criterion to evaluate fatigue
are the S-N curves, or Wöhler diagrams. The S-N curves relate
principal stresses; crit is the critical stress of the winding,
the number of cycles left until fatigue failure with the
which is calculated by (2) through the Newton-Raphson mechanical stress. The S-N curves can be expressed by (4).
method. In this expression, it can be verified that the critical
S a Nb , (4)
stress is dependent on the constructive characteristics of the
windings [15], [16], [17]. wherein S is the mechanical stress; N is the number of cycles;
2 a and b are parameters of the S-N curve.
m 1 0m m h
crit crit 0 E 0 0 , (2) From (4), it can be said that the S-N curves can be used to
4 R perform studies of lifespan in components that are subjected to
where m = 11.6 and 5.4 are parameters obtained from the mechanical stresses, such as the transformer windings.
mechanical stress vs. strain curve of copper; E0 = 110 GPa is The S-N basic curve of copper presented in Fig. 2 is based
the elastic modulus; h is the radial build of the winding; R is on the references [14] and [18]. This curve intersects two basic
the mean radius of the winding and 0 [16] is a parameter that points, the first being the mechanical stress at 103 cycles,
which corresponds to 90% of the tensile strength of copper;
can be obtained through (3).
and the second is the mechanical stress at 106 cycles, which is
1
k m 1 m
called the fatigue limit. With these two points, the S-N fatigue
0 y m , (3) curve can be estimated and the lifespan of the winding can be
E0 y
studied.
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Transactions on Power Delivery
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160
III. METHODOLOGY
140
The main input data required for the simulation are the
120
transformer parameters. In this paper, a 3D model of a
100 100 MVA power transformer is used, and its main
80 characteristics are presented in Table I, where LV represents
60 3 low voltage, and HV stands for high voltage.
4 5 6
10 10 10 10
Number of cycles TABLE I
Fig. 2. S-N basic fatigue curve for copper, where a = 509.1 and b = -0.1367. 100 MVA power transformer characteristics.
The S-N fatigue curves can be modified so that the security Parameter Value
margin against the occurrence of fatigue failure is increased. Power (MVA) 100
Number of winding turns LV/HV 394/796
This increase in lifespan is achieved by reducing the value of
Mean diameter of winding LV/HV (mm/mm) 903/1201
the fatigue limit, defined in the previous paragraph. Frequency (Hz) 60
The fatigue limit can be reduced due to the characteristics Impedance (%) 9.32
of the material (composition, basis of failure, variability), Voltage LV/HV (kV/kV) 138/230
manufacturing (method, heat treatment, surface condition),
environment (corrosion, temperature) and design (size, shape). The results are obtained using Comsol Multiphysics®,
Thus, the reduced fatigue limit can be calculated by (5). which is a FEM-based software. A 3D model of the 100 MVA
power transformer is shown in Fig. 3.
1
f k s k t k f kT f 0 ,
n
(5)
where f is the reduced fatigue limit; ks, kt, kf and kT are the
fatigue limit modifying factors; f 0 is the fatigue limit of the
S-N basic curve and n is a safety factor. The S-N curve with
the reduced fatigue limit is called the S-N admissible curve.
Additionally, when a short circuit occurs on the transformer
windings, the damage caused is cumulative and, in time, leads
to reduction of the winding’s lifespan. Thus, to quantify the
cumulative fatigue damage, the Palmgren–Miner cycle-ratio
summation rule, also called Miner’s rule, can be used. Miner’s
rule is presented in (6).
ni
D, (6)
Fig. 3. 3D model of the 100 MVA power transformer.
Ni The proposed methodology is based on the following steps:
where ni is the number of cycles of the stress level i ; Ni is Developing a 3D model transformer, with
characteristics presented in Table I, to be
the number of cycles necessary to lead to fatigue failure, for
introduced as input data in Comsol Multiphysics®;
the stress level i ; D is the accumulated damage. When
Performing the computational simulation uniting the
D = 1, failure occurs. electromagnetic and mechanical physics under a
The calculation of the cumulative damage, according to transient short circuit condition;
Miner’s rule, evidences that a group of mechanical stresses Determining the failure proximity of the winding by
occurring, for example, in the transformer winding, contributes using the Von Mises and fatigue criteria;
to the reduction of the area below the S-N fatigue curve and Estimating and evaluating the number of short
thus to the reduction of the lifespan of the winding. This group circuits that cause the reduction of lifespan to a
of stresses is characterized by mechanical stress amplitudes, predetermined level.
i , that last ni cycles. In order to evaluate the failure proximity in transformer
The accumulated damage thus leads to a percentage of life windings via computer simulations, Comsol Multiphysics® is
reduction of the winding, which can be determined by the employed. The software input data is the 3D transformer
expression (7). model displayed in Fig. 3. This 3D modeling is used in order
n fr to obtain a more accurate representation of the transformer
R% 1 100 (7) windings. Moreover, the determination of the mechanical
n fad
stresses is dependent on the winding geometry, which is not
where R% is the percentage of reduction of life, nfr is the accurately represented in 2D.
number of fatigue limit cycles obtained after a short circuit and Once the transformer model is inserted in Comsol
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Multiphysics®, the computational simulations can be increased in order to locate, when necessary, the critical
performed. In order to do so, it is necessary to use short circuit asymmetry factor of the winding.
equations as input data in the software. According to Fig. 4 and to the Von Mises criterion, the low
Simulations of the short circuit currents circulating through voltage winding fails, plastically, with an asymmetry factor of
the terminals of the windings are performed for different 2.18 (which corresponds to a current peak of 13.8 kA). On the
asymmetry factors. These currents are input data of the other hand, Fig. 5 indicates plastic failure of the high voltage
electromagnetic physics, in which the output data is the EF. winding with an asymmetry factor of 1.8 (current peak of
These EF are the input data of the mechanical physics, which 6.8 kA).
produces the Von Mises stresses as output. As a result, it is
possible to correlate the maximum Von Mises stress with the 80
stresses, i.e., that does not cause plastic failure in the windings. Von Mises Stress
40
In order to employ the fatigue criterion in the windings, the Critical Stress
0
IV. RESULTS
The failure proximity is presented in Figs. 4 and 5 for the -5
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The transient short circuit current according to [19] and In order to employ the fatigue criterion, the admissible S-N
[20] is shown in Fig. 6. During such an event, the dynamic curve is determined, considering that the fatigue limit
behavior of the radial and axial EF on the high voltage modifying factors, presented in expression (10), are ks = 1,
winding can be determined using the procedure presented in kt = 0.75, kf = 0.62, kT = 1 and n = 3 [22]. With these
the references [21], [22] and [23]. The EF are presented in parameters, the S-N admissible curve is obtained, as presented
Figs. 7 and 8. in Fig. 10.
25
Radial Electromagnetic Force (MN)
200
S-N admissible curve
20 S-N basic curve
100
10
5 50
0
0 0.05 0.1 0.15 0.2 0.25 0 3 4 5 6
Time (s) 10 10 10 10
Number of cycles
Fig. 7. Dynamic radial electromagnetic force on the high voltage winding
under a short circuit current with an asymmetry factor of 1.4. Fig. 10. S-N admissible fatigue curve in the high voltage winding, where
a = 3894.4 and b = -0.4313.
2
The lifespan of the winding is determined using Miner’s
Axial Electromagnetic Force (MN)
20 %
Fig. 8. Dynamic axial electromagnetic force on the high voltage winding 150 30 %
40 %
under a short circuit current with an asymmetry factor of 1.4. 50 %
60 %
100
70 %
In Figs. 7 and 8, the dynamic behavior of the 80 %
90 %
electromagnetic forces on the windings in the radial and axial 50 100 %
direction is presented. Since these forces are proportional to
the current squared, they are pulsating. Electromagnetic forces 0 3 4 5 6
also generate MS with dynamic behavior, which can be 10 10 Number of Cycles 10 10
observed in terms of Von Mises stresses, shown in Fig. 9. Fig. 11. Reduction of lifespan of high voltage winding due to the occurrence
of cumulative short circuit currents.
70
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With that in mind, it is clear that, for a fixed mechanical lead to a certain reduction in lifespan. Notice how the vertical
stress, the increase in the percentual reduction of lifespan range in Fig. 13 is clearly higher than that in Fig. 12, although
causes a decrease of the number of supported cycles to fatigue both surfaces have roughly the same shape.
failure. Besides, for a fixed number of cycles, the increase in
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPWRD.2016.2579165, IEEE
Transactions on Power Delivery
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VIII. BIOGRAPHIES
Jalberth Araujo was born in 1988 in Campina
Grande, Paraíba, Brazil. He obtained the B.Sc.,
M.Sc. and D. Sc. Degrees, all in Electrical
Engineering, in 2012, 2013 and 2016, respectively,
at the Federal University of Campina Grande
(UFCG). In addition, Jalberth is a professor of
engineering courses at the Faculty Maurice of
Nassau (Unit Campina Grande). His research
interests include high voltage equipments, harmonics, frequency response and
computer simulation of transformers.
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