TRANSFORMER TECHNOLOGY GPT

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1 Core-Form TRANSFORMER TECHNOLOGY GlobalPT Corporation

2 performs research and engineering developments and co-ordination of works of technical partners in the field of technological progress and commercial products. In 2010 was reorganized with new more powerful design team for the Ultra-high-voltage transformers and shunt reactors. Transformer and Shunt Reactor design Step up transformers: up to 800 kv Autotransformers: up to 500 kv Phase shifting transformers: up to 220 kv HVDC transformers: up to ±500 kv Scott-connection transformers: up to 220kV The volume of information transferred to the customer: 1. Detailed manufacturing drawings (up to 500 pieces) of magnetic core, insulation, active part, leads, tank, cooling system, outline drawing. 2. Manufacturing technology of some transformer parts. 3. Reports of all calculations carried out during transformer design, such as: Electromagnetic calculation report; Mechanical calculation report; Insulation calculation report; Thermal calculation report; Hydraulic calculation report. 2

3 Work Procedure in Design Center Transformer Specification Confirmation Specialists Technical Council Tech. Council Electric Basic Design Fundamental Transformer Data Bidding Specification Tender Team Layout Design Electric Detail Design Magnetic System Design Core Configuration Core Lamination Core Duct Installation Upper Yoke-Beam Design Lower Yoke-Beam Design General View, Units and Parts Specification and Instruction Core Team Winding Detail Design Electric Circuit Review Winding Specification Winding Details (Each Leg) Static Ring Design Space and Angle Specification and Instruction Winding Team 3

4 Work Procedure in Design Center (Cont d) Electric Detail Design Insulation Detail Design Main Insulation Layout Insulation Detail of each Leg Leveling Insulation Specification and Instruction Lead Detail Lead for each terminal OLTC Tap Lead Spec. and Instruction Insulation Team Active Part Design General View, Units and Parts Earthing Design and Diagram Specification and Instruction OLTC Arrangement OLTC Tap Lead OLTC Installation Spec. and Instruction Tank Shunt Tank Layout Shunt Mounting System Technical Projection Specification and Instruction Wall Frame Beam Bottom Pipe Lifting-Lug Support Cover Box Housing Specification and Instruction Tank & Metal Construction Team Assembly & Installation General View, Units, Parts Weight Table Hoisting Information Expander & Bushing Installation Specification and Instruction 4

5 Technologies and Specialized Area Providing Total Design Data for Core-Form Transformer Unit - Basic electrical design data - Detail Calculation reports for analysis and manufacturing - Manufacturing specification and drawings - Providing Design Review - Assistance to manufacturing process and factory test Other Technical Consulting Areas Transformer Technical Consulting for Technology Development & Improvement - General Transformer and Special Transformer in all of the Range) Transformer Problem Solving Project - Design/Manufacturing Process Transformer Patented Technologies Development and Share Transformer Technology Seminar/Training Transformer Bidding & Detail Design Works Transformer Design Guidance Transformer Computing Software for Deign Calculation and Analysis The other Technical Assistants for Transformer Development and Design 5

6 1 Magnetic System Design Glass-Fibre Core Bandage Core Cooling Duct Sound Level Reduction 4 Leg & 5 Leg Core Construction Oleocel Cylinder (Electrostatic Barrier) 6

7 2 Clamping System(Yoke-Beam) Design Core Clamping/Core Bandage Wooden Road in each step edge Pressure Plate Design Yoke Beam Construction Concept - Effective load distribution for Active part lifting - Bottom Support for Active part - Outer leg clamping Metallic Band for Yoke-beam Upper/Bottom Yoke Beam and Pressure Plate Jointing Structure Support Between Yoke-Beam Plate and Last Core Step Yoke-Beam Structure Material Mechanical Strength Magnetic Flux Control and Yoke-beam structure Earthing Policy 7

8 2 Clamping System(Yoke-Beam) Design 8

9 2 Clamping System(Yoke-Beam) Design Upper Beam Structure Upper Beam Structure Front Steel Band 9

10 3 Winding Design Conductors Conventional Rectangular wire CTC, Continuously transposed conductor 10

11 3 Winding Design Winding Type - Layer - Helical - Continuous with & without Contra Shield - Interleaved 11

12 4 UHV Insulation Design 1. Main Insulation Coil-Coil, Coil-Ground Insulation by FEM(Field-Element-Method) Calculation Program Insulation Barrier Layout Angular Ring(Matched to equipotential line) Electrostatic Shield Ring to control field configuration 12

13 4 UHV Insulation Design 2. Winding Insulation Turn-to-Turn, Disk-to-Disk Insulation By Impulse Voltage Distribution and Voltage Oscillation Calculation Program Turn Insulation Duct Size 13

14 4 UHV Insulation Design 3. Winding Protection Zn-O varistor to reduce electric stress in winding Voltage oscillation reduced 14

15 4 UHV Insulation Design Active Part 15

16 5 UHV Lead Design UHV Lead Terminal Construction Large diameter copper tube cover thick insulation papers to control electric stress concentration Multi-concentric molded transformer board barriers to improve insulation reliability Bushing Terminal and Lead Connection Construction 16

17 5 UHV Lead Design 17

18 6 Short-Circuit Strength Under any fault condition, withstandable without thermal and mechanical breakdown in specified time period 3Ø Phase SC, 1Ø Line-to-Line SC, Double Line-to-Ground, Line-to Line SC Short-Circuit Current Calculation Mechanical Stress Calculation Electromechanical Forces (Radial and Axial) 18

19 7 Leakage Flux Control Non-magnetic Material in high intensity area Slitted Pressure(Side) Plate Last Core Step Slitted Shunt on Tank wall 19

20 8 Cooling Design Oil-Natural Air-Natural Forced Cooling 20

21 9 Tank Design 21

22 10 Transportation 22

23 List of Tasks List of Tasks, which were worked out and could be developed by 1 Power transformers and autotransformers of general purpose with 150~765 kv and up to 1200kV and power of 1000 MVA in single and three-phase execution. Autotransformers with voltage of 765 kv and power of 333 MVA and more with voltage regulation in the neutral. According to customer requirement regulation can be longitudinal (without phase shift between HV and LV) and longitudinal- crosscut (with phase shift between HV and LV). Crosscut regulation can be built-in or as a separate transformer regulation. Autotransformers with voltage of kv with low power trial winding (2-10%) without outer reactor for short circuit current limitation. (there are a lot of experience work АТ 125MVA /220 kv by help of trial winding) Transformers with small transposition factor which is close to 1 (500/400 or 330/400). Know-how was developed for this transformers, which allow to solve short circuit problem in one unit Generated transformers with kv voltage and power of MVA in single or three phase execution for outer and inner delivery. Transformer characteristics are in the world level. There are additional know-how, which allow to improve reached characteristics. There are variants of transformer designing depending on transportation conditions. 23

24 List of Tasks 2 Phase regulated transformers are aimed for power flux regulation in multi outline electric systems. There are new development of phase regulated transformers in single phase execution with ±60 ~15 regulation and throughput power 160~640MVA, which is aimed for distant Siberia, i. Sakhalin area, which can work in the mode of power flux regulation in the closed power line and in the mode of glaze-clear ice in the power line. Further we have specified list of works which were made by our specialists according to FRT problem: FRT series is developed in 220/220 kv single phase execution, 640 MVA 15, 320 MVA 30, 160 MVA 60. group power. Phase regulating scheme allows to increase voltage and power at the same time (in the limit of OLTC existing abilities). Active material expenses in FRT single phase execution according to the new scheme does not exceed expenses in three- phase execution. Transportation and installation of single phase FRT does not differ from general power transformers 63 MVA, 110/110 kv FRT is developed with 60 regulating range for experimental installation, aimed for glazeclear ice soldering mode ravelling courses (South of Ukraine) phase shift regulating scheme is developed in power converter transformers 24

25 List of Tasks 3 Converter transformers with power from 1 to 1000 MVA, aimed for electric furnace and electrolysis manufacturing. There are new development of converter unit (regulated transformer, phase regulating device, converter transformer, saturable reactors in general tank), aimed for aluminum plants. One transformer unit works in 12-phase straightening mode. Regulation of straightening mode range 0~Un Value of regulating step 1.5~2% Planned regulation by the help of saturable reactors 2-3 steps equivalent multi-impulse impact on mains supply at parallel work 2, 3, 4, 5, 6 units is equal accordingly 24, 36, 48, 60, 72. necessary phase shift between units is ensured at transformer operation all transformer units are interchangeable. There are new development, which deal with transformer units cost decreasing on %. 25

26 List of Tasks 4 Furnace transformer, which involve wide power range, voltage range and function. 4260kVA 10000/105.5V 8500kVA 10000/204V 26

27 List of Tasks 5 Scott transformers with power 60MVA and voltage 154/55 kv and two legs construction (instead of existing four legs), which ensure decreasing of laboriousness and manufacturing. Benefits from innovated Scott design changes Less Labor Intensiveness in Manufacturing : 1.5~2 Times Lower - Windings : 6 windings instead of 12 windings - Less Insulation and Simple Lead connection - Simple Assembly Works Less Material Cost : 30% Lower - Windings wire copper : Much less than Original one - Not exceed to Original Core Steel New Technical Solutions Developed - Many Design contain unique know-how, it may patented. 27

28 Scott Transformer Outline 28

29 Scott Transformer Special Winding Design- Block WDG. 29

30 List of Tasks 6 Development of principally new multi-phase converter transformers with power until MVA, aimed for power straightening substations (U=100V, I Σ = 200~300kA). New scheme at positive calculation results will ensure decreasing of active material expenses on 10-15%. Additional finance is required for this job. 30

31 Pictorial Overview Parameter Values Single phase autotransformer Prototype Rated Capacity, MVA 210 Phase 1 Rated Frequency, Hz 50 HV - Rated Voltage, kv 1150/ 3 31

32 Pictorial Overview Parameter Values Single phase autotransformer Prototype Rated Capacity, MVA 417 Phase 1 Rated Frequency, Hz 50 HV - Rated Voltage, kv 1150/ 3 32

33 Pictorial Overview HV Lead Exit Installation Practice 33

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