Recent Power Transformer Technology

Kenji Ookubo
Masaaki Kousaka
Kenji Ikeda

1. Introduction sheets, coating-processed sheets, or high magnetic flux

density (B8), corresponding to the requirements for low
Power transformers are essential components of no-load loss or low sound level.
substation equipment for the efficient and stable To reduce the man-hours required for assembly
operation of electric power systems. There is demand and work lead-time, we have standardized the types of
for transformers with lower price and higher reliabili- materials and components used in the core. The
ty. In addition, depending upon the onsite conditions, manufacturing process automates a series of opera-
such as narrow roads, mountainous areas or highly tions; the automatic press line cooperates with the Fuji
congested urban areas, harmony with the surrounding Electric’s original automatic core stacking facility to
environment is required throughout shipping, installa- make the cutting of silicon steel sheets and stacking
tion and operation. Contribution to the global environ- work of the lower yoke and legs in a sequence. The
ment throughout the transformer life cycle is also facility stacks the cut core sheets on the core erection
required. equipment and stands them upright as a core. Glass-
As topics of recent interest, we have been promot- fiber bands are commonly used to bind the core into a
ing the application of the technology of UHV level single unit. This process helps stabilize the perfor-
equipment to general power transformers, and focus- mance quality of the core.
sing on the Hanshin-Awaji great earthquake disaster, For three-phase large power transformers, if it is
the reinvestigation of disaster prevention and safety. desirable to reduce the weight of the upper yoke for a
In response to diverse requirements, Fuji Electric transformer with rated power of 600MVA or more, or if
has always developed and applied new and reliable there is a limitation in height for transportation, we
technology. This paper describes recent features of utilize a five-legged core instead of a three-legged
power transformer technology. construction.
2.1.2 The winding
2. Oil-Immersed Large Power Transformers Fuji Electric has aggressively expanded the use of
transposed conductors for windings. Transposed con-
2.1 Structuring technology for the core and windings ductors make the continuous winding work reasonably
The core and windings are important components easy and shorten the required man-hours and work
determining basic performance and reliability that lead-time, they are also useful to decrease the eddy
should always be maintained and improved. However, current losses in the winding.
the core and windings are also a source of energy loss, (1) Interleaved disc winding using the transposed
causing problems in the energy environment. To conductors
conserve resources, it is necessary to downsize these Conventional high voltage windings use from two
components and lighten the materials used. Moreover, to ten or more flat conductors with normal or common
these components occupy a large percentage of the insulation paper to construct the interleaved disc
cost. It is also necessary to develop fast- and easy-to- winding. In this case, a high series capacitance can be
make structures because Japanese labor, at present, is obtained from the capacitance between conductors that
among the most expensive in the world. Fuji Electric are repeatedly wound in the radial direction of the coil.
has been promoting technological development with Interleaved disc winding using transposed conduc-
total evaluation and measures to overcome these tors is introduced to increase series capacitance by
contradictory problems, and the coordinated and har- creating a disc coil with one or two transposed
monized marketing of products. conductors in such a way that the conductor of the first
2.1.1 The core coil extends over to the third coil and then returns
We have utilized high-grade grain-oriented silicon- back to the second coil. In this manner, a high series
steel sheets in the core, selecting material with thin capacitance can be obtained from the capacitance

Recent Power Transformer Technology 89

Fig.1 Coil configuration of interleaved disc winding Fig.2 Actual-scale model of interleaved disc winding using
transposed conductors
U

Flat conductor Transposed

conductor
(a) Conventional interleaved (b) Interleaved disc winding using
disc winding transposed conductors

between coils that are axially arranged. Figure 1

compares coil compositions and conductor connections
of the interleaved windings.
The conventional continuous disc winding has been
widely utilized in transformers, including extra-high- Fig.3 Three-dimensional electric field analysis for terminal
voltage class transformers, to increase the efficiency of lead outlet
winding manufacturing and decrease the eddy current
losses in the winding. In addition, the aforementioned
interleaved disc winding demonstrates excellent light-
ning impulse voltage withstand characteristics, and Relative value
Frame
contributes to reduced equipment size when applied to Enlarged

the extra-high-voltage class. The winding work and

Curved portion
insulation performance was verified using the actual- of lead
Core
scale winding model shown in Fig. 2.
(2) Self-bonded transposed conductors
Press segment
Short-circuit current flows into the winding when
the system connected with the transformer is short- Primary winding
circuited, and then an electromechanical force is
Secondary winding
generated in the winding. Conductor strength must be
improved so that the transformer can withstand this
electromechanical force that increases with transform-
er rated power. The use of stiff material such as semi-
hard copper increases the lead-time for winding work
on the winding form. upon the shape of the conductor and its coating
The self-bonded transposed conductor consists of insulation, the oil may be separated into multiple
element wires enameled with heat-stiffened resin. layers by molded barriers.
After forming the winding, the element wires are Depending upon the insulation structure, analysis
heated to dry, and during this time they are integrated is performed using the finite element method (FEMT),
en bloc. This improves the strength of the conductors finite difference method (FDMT) or the surface charge
and the winding. After the winding is completed, method, and work is performed to simplify and make
direct current is supplied and the conductor is heated efficient the structure while maintaining the reliability
to securely integrate the element wires into a single of the insulation.
unit and stiffen the winding itself. Figure 3 shows an example of three-dimensional
analysis by the surface charge method. This example
2.2 Insulation technology analyzes the electric field distribution around the high-
2.2.1 Review of insulation structure voltage lead conductor extracted from the upper part of
The insulation of the oil-immersed transformer is a winding. The computational accuracy of convention-
basically a composite insulation structure consisting of al two dimensional electric field analysis is limited
insulation oil and oil-impregnated paper. Depending because the curved portion of the lead and the shape of

90 Vol. 45 No. 3 FUJI ELECTRIC REVIEW

Fig.4 ZnO surge absorber Fig.5 Three-dimensional current distribution analysis of the
connection box

1U ZnO surge absorber

A10
A1

2U

A9

(a) Connection to tap winding

2.3 Technology for reducing eddy-current and stray load

(b) External view
losses
On the load losses of the transformer, it is possible
AM183541
to exactly calculate the resistance and eddy-current
losses in the winding. However, the source of stray
load loss cannot be determined since only the differ-
grounded peripheral parts are influenced by the elec- ence of measured load losses and the aforementioned
tric field. However, it is possible to understand the calculated losses are obtained as collective values. At
electric field distribution in detail with such three- Fuji Electric, stray load loss is being closely studied to
dimensional analyses and to find a reasonable insula- locate the source of the stray load loss, and to decrease
tion structure. the amount of loss.
Moreover, to improve the reliability of the insula- 2.3.1 Three-dimensional magnetic field analysis
tion structure, we have carefully observed the detailed Because the amount of magnetic flux that over-
mechanism at the start of partial discharge. We flows from the winding or is generated around the
implement precise measures to control the withstand large current lead increases with the transformer
voltage tolerance, utilize insulating materials with low rated power, the study of magnetic flux is indispens-
dielectric constants, and arrange the shield on the able in the evaluation of eddy currents, stray load loss
grounded side. of adjacent structures, and in the implementation of
2.2.2 ZnO surge absorber measures against local overheating.
In an extra-high-voltage transformer, when the To implement a reasonable design specific to the
lightening impulse voltage impinges on the winding structures and the materials, Fuji Electric performs
terminal, a voltage oscillation occurs within the wind- three-dimensional magnetic field analysis and precise-
ing and across the tap coils. This voltage oscillation ly computes the current distribution in the structural
occasionally becomes a problem depending upon the paths, the eddy current distribution and the associated
winding arrangement, connecting conditions, and the losses. In addition to the losses, we also evaluate the
tap positions of the winding, and therefore, requires temperature distribution in the structures based on
enlargement of the insulation distance or reinforce- the above calculation results.
ment of the insulation structure. To avoid this Figure 5 shows an analysis of the current distribu-
potential problem, we use a ZnO surge absorber with a tion in the connection box, where large currents flow
nonlinear voltage characteristic connected to the corre- from the transformer primary side to phase-isolated
sponding winding part and to suppress excessive buses connected with the generator in a power plant.
oscillatory voltage. Installing these elements in the This example shows that it is possible to construct a
transformer tank simplifies the associated insulation common connection box for all three phases instead of
structure and makes the entire equipment more com- independent connection boxes for each phase as has
pact. Figure 4 shows the external view and the been done in the past. This figure shows neither an
application example of the ZnO absorber. A long-term abnormal current concentration nor cause for local
excessive voltage test has verified the reliability of the overheating, as seen from the currents displayed as
ZnO absorber with no deterioration. line bunch flows on the box.

Recent Power Transformer Technology 91

Fig.6 Analysis and measurement of unbalanced currents Fig.7 Oil-flow velocity distribution inside and outside the
between conductors with the helical coil windings windings

1 2 3 4 5 6 7 8 9 10 11 12
24 23 22 21 20 19 18 17 16 15 14 13

24 1 2 3 4 5 6 7 8 9 10 11
23 22 21 20 19 18 17 16 15 14 13 12

23 24 1 2 3 4 5 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
(a) Arrangement and transposition of helical coils

130
(c) Imbalance rate (%)

120
Cylinder Disc winding
110 winding
Measured value
100
(a) Distribution of flow velocity vectors
90
Calculated value 15 Measured value
80
Cylinder winding
70 Cylinder winding
1 6 11 16 21 Disc winding
Conductor number Disc winding
Flow velocity (cm/s)
(b) Current distribution of helical coil conductors Disc winding
10
Calculated value
Solid line;
cylinder winding
Dotted line;
disc winding
2.3.2 Measures against eddy-current and stray load 5

losses in the winding

In windings that carry extremely large currents,
we use many conductors connected parallel. The
0
linkage of each conductor with the leakage flux slightly 0.25 0.5 0.75 1
differs, and therefore, causes an imbalance in the Flow quantity (p.u.)
(b) Flow velocity distribution at the outlet of the windings
currents among the parallel conductors and increases
the load loss. This load loss adds to the eddy current
loss that is usually calculated on the assumption of
balanced currents. We can decrease the imbalance of and momentum. The software performs a steady state
these currents by selecting the optimal way of transpo- analysis using a turbulent flow model.
sition of each conductor. Figure 7 shows an example of the analysis and the
Fuji Electric has developed simulation software for measurement of the oil-flow velocity distribution for
these unbalanced currents to choose the best transpo- the actual-scale model. The agreement of these results
sition method. Figure 6 shows an example of the is comparatively good.
current imbalance rate between conductors in helical Because this technique can confirm whether the
windings. oil-flow velocity distribution meets the design objec-
tive, we can accumulate data and then apply it to
2.4 Cooling technology practical designs.
2.4.1 Oil-flow velocity distribution inside and outside the 2.4.2 Zigzag oil-flow
winding In directed oil-flow type transformers, we mainly
To optimize the cooling structure inside and out- use the zigzag oil-flow method instead of the conven-
side the winding, it is necessary to understand the oil- tional duct flow method. The zigzag oil-flow method
flow distribution in detail. improves heat transfer from the winding to oil, makes
For this purpose, we used a three-dimensional a balanced distribution of the winding temperature
supersonic wave Doppler flow velocity meter. This rise, and decreases the highest temperature of the
meter is capable of detecting echoes of supersonic wave transformer. As results, this method decreases the
pulses that are reflected from a tracer particle moving size of the cooling equipment and improves the reliabil-
in oil, and measures the three-dimensional instanta- ity. Comparison of the modeled analysis and actual
neous flow velocity. A gas bubble was inserted into the measurements using an actual-scale model has verified
oil as the target tracer. On the other hand, we used good agreement of the temperature distribution, and
general-purpose heated fluid analysis software (finite made it feasible to choose the best oil-passage struc-
volume method) to obtain the oil-flow velocity. The ture, including the method of arranging the curving
principal equation is the law of conservation of mass plates.

92 Vol. 45 No. 3 FUJI ELECTRIC REVIEW

Fig.8 Shipping of the transformer with the steel plate dampers 2.5.3 Sound emission analysis
mounted The boundary element method is applied to sound
emission analysis in which the given vibration distri-
bution of the transformer surface is used to compute
the sound level distribution on a plane separated some
distance from the transformer. By selecting a bound-
ary surface through which the sound propagates, this
method solves the wave propagation equations for this
surface in terms of a boundary integration formula.
We used laser light to measure the vibration distribu-
tion on the surface of a three-phase model core, and
calculated the sound level distribution [dB(A)] in a
plane 30cm from the core. Figure 9 compares example
data for typical high harmonics of the vibration and
noise.

3. SF6 Gas-Immersed Transformer

As nonflammable substation equipment, SF6 gas-

immersed transformers attracted attention when the
manufacture of transformers containing PCB (poly
chloro biphenyl) synthetic oil was prohibited due to
environmental pollution problems. Since the latter
half of the 1980’s, SF6 gas-immersed transformers
2.5 Noise reduction technology have been widely used to improve disaster prevention,
The sound level of a transformer, i.e. the noise, is safety, and the environmental harmony of electric
now a regulatory problem closely related to the city life equipment. Recently, this trend has been accelerated
environment in urban areas and the home life environ- especially in Japan and China, including Taiwan and
ment in residential areas. Low noise specifications for Hong Kong. In Japan, the scope of application
power transformers are universally spread throughout currently ranges from small distribution transformers
the domestic marketplace. of the 6kV class to extra-high-voltage large power
To decrease the transformer noise, it is important transformers.
to use core sheets with small magnetostriction, to SF6 gas-immersed transformers are best suited for
improve the corner jointing of core sheets, and to the various performance requirements of urban substa-
optimize the soundproofing equipment, including that tions. Because a conservator is unnecessary, the
of the coolers. With consideration of the noise specifi- ceiling height can be reduced in rooms where this
cations, Fuji Electric always tries to apply optimal transformer is installed. This contributes to reduced
anti-noise measures. We also try to devise an optimal building construction costs.
shipping form as well as to simplify onsite construction
work as much as possible. 3.1 Details of development
On the other hand, to clearly find the relation Fuji Electric has extended the product series of the
between vibration and transformer noise, we are SF6 gas-immersed transformers as follows.
investigating with basic numerical analysis. (1) For the 6kV class, products from 50 to 2,000kVA
2.5.1 Step-lap jointing of the core corner have been standardized as a series.
Changing the jointing method of the core corner (2) For the 22 to 77kV class, products from 3,000 to
sheets from the conventional bat-lap joint to the step- 15,000kVA, for which most demand is expected,
lap joint decreases the transformer noise approximate- have evolved into a new series, the ALFOS Σ, with
ly 4 to 6 dB(A). The exciting current and no-load loss a new structure that uses windings of aluminum
can also be decreased. Fuji Electric utilizes the step- foil sheets.
lap joint as a standard for low noise specifications. (3) For high-voltage and the large power rated class,
2.5.2 Steel sheet dampers Fuji Electric has already delivered 3-phase 154kV/
Steel sheet dampers sandwich the resin between 25MVA and 3-phase 110kV/40MVA units.
two thin steel plates and attenuate the vibration
effected by the shear deformation of the resin. Steel 3.2 Prototype transformer for 66kV/60MVA
sheet dampers have been used since the 1970’s and Advancing toward the production and marketing of
Fuji Electric recently attained a sound level of 60 large power rated 3-phase 66kV/60MVA gas-immersed
dB(A) for a three-phase 450MVA transformer. Figure 8 transformers with SF6 gas-directed forced-water cool-
shows an application example for the transformer. ing for intermediate substations, a prototype for one

Recent Power Transformer Technology 93

Fig.9 Analysis and measurement of vibration and noise distribution for the three-phase core model
Typical high-harmonic components

300
Hz

400
Hz

(a) Distribution of maximal vibration (b) Calculated noise distribution dB(A) (c) Measured noise distribution dB(A)
displacement (µm)

Fig.10 SF6 gas-immersed prototype transformer being tested Table 1 Specifications of the 66kV 60MVA SF6 gas-immersed
for reliability (Single-phase, 60/3MVA) transformer prototype
Standard JEC-2200-1995
Cooling method Gas-directed and forced-water (GDWF)
Insulation system E
Maximum winding
49K
temperature rise
Number of phases Single
Frequency 50Hz
Rated power 60/3MVA
Primary : 66/ 3 ±6/ 3 kV (17 taps)
Rated voltage
Secondary : 22/ 3 kV
Rating Continuous
Short-circuit
16%
impedance
Primary : LI 350kV AC 140kV
Withstand test voltage
Secondary : LI 150kV AC 50kV
SF6 gas pressure 0.13MPa (gauge pressure at 20°C)

AM183483
forces.
The insulation system of the transformer is class
phase of this transformer was manufactured for trial E. However, the primary winding uses Nomex-
and verification purposes. insulated electric wires (class H) to provide sufficient
Figure 10 shows the transformer being tested, and tolerance for the short-time overload capacity. The
Table 1 lists the specifications of the prototype trans- primary winding uses a mixed interleaved disc wind-
former. ing for improved insulation reliability against lighten-
Before designing the prototype, Fuji Electric stud- ing impulse voltage. The secondary winding uses heat-
ied the component technology as part of the develop- resistant self-bonded transposed conductors for im-
mental work for this transformer, confirmed its perfor- proved mechanical strength. Consequently, a unit
mance using three-dimensional electric field analysis, could be assembled with smaller size and lighter
gas flow analysis, model experiments, etc., and estab- weight than before.
lished insulation and cooling design technology as well This prototype equipment passed all the tests
as measures against short-circuit electromechanical prescribed in the JEC Transformer Standard and

94 Vol. 45 No. 3 FUJI ELECTRIC REVIEW

Fig.11 Vacuum switch type on-load tap-changer tap-changers can now be used with SF6 gas-immersed
transformers.
Advantages of this on-load tap-changer are listed
below.
(1) The current is switched with vacuum switches,
which are installed in a SF6 gas-immersed cham-
ber separate from the transformer tank.
(2) The switching mechanism of a two-resistor and
four-vacuum-switch system assures high reliability.
The vacuum switches are secured by a cassette
structure that facilitates the inspection work.
(3) Since the roller contacts are used to connect the
tap selector with the winding taps in the trans-
former tank, harmful metallic wear powders do
not peel off.
(4) The operating mechanism has achieved high per-
formance with electronic and digital control. This
(a) Tap-changer (b) Operating mechanism contactless method assures improved reliability
and maintainability.
AM167807 / AM152856

4. Conclusion
demonstrated sufficient quality to enter production.
The high degree of correspondence between the compo- Fuji Electric will continue to aggressively intro-
nent technology and the performance of the prototype duce new materials, to develop components and pro-
equipment confirmed that larger equipment could be cessing methods to promote resource conservation and
manufactured without problems. recycling, to further develop advanced technology in
response to the requirements of society, and to imple-
3.3 Vacuum switch type on-load tap-changer ment useful proposals for reducing the total life-cycle
The aforementioned SF6 gas-immersed transform- cost, that is, to help optimize the investment of the
er is equipped with a 600A on-load tap-changer system customer side. In addition, we will also continue
consisting of two resistors and four vacuum switches development of transformer peripherals, for example,
with an electronically controlled operating mechanism active noise control.
shown in Fig. 11. The two models of 400A and 600A

Recent Power Transformer Technology 95

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