Load Tap Changers for Power Transformers
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1 Load Tap Changers for Power Transformers Dr. Dieter Dohnal / Maschinenfabrik Reinhausen GmbH Dipl. Ing. Bernhard Kurth / Reinhausen Manufacturing Inc.
2 Load Tap Changers for Power Transformers Content Basic Principle of the Load Tap Changer (LTC) / General LTC Arrangements Commonly Used Winding Connections Basic Arrangements of Regulating (Tap) Windings Basic Switching Principles of LTCs Design Principles of Oil Type LTCs Design Principles of Vacuum Type LTCs Today s Expectations from LTCs The Vacuum Switching Technology of Today Summary of Advantages of the Vacuum Switching Technology Life-Cycle Cost Considerations 11/24/2003 Page 2
3 Basic Principle of LTCs LTCs allow to change the ratio of a transformer by adding turns to or subtracting turns from either the primary or the secondary winding For this purpose, the transformer is equipped with a regulating or tap winding, which is connected to the LTC terminals LTC Principle winding arrangement of a regulating transformer in Y-connection 11/24/2003 Page 3
4 General LTC Arrangements LTCs divided in 2 groups: 11/24/2003 Page 4
5 Commonly Used Winding Connections LTC Application at the Neutral End of Y-Connected Transformer Windings Three-phase star point LTC (LTC operating voltage in general only 10% of the line voltage) 11/24/2003 Page 5
6 Commonly Used Winding Connections LTC Application in Delta-Connected Transformer Windings 11/24/2003 Page 6
7 Commonly Used Winding Connections LTC Application in Autotransformers Examples for basic arrangements of the tap winding for regulation of U 2 11/24/2003 Page 7
8 Commonly Used Winding Connections LTC Application in Autotransformers Examples for basic arrangements of the tap winding for regulation of U 1 11/24/2003 Page 8
9 Commonly Used Winding Connections LTC Application in Autotransformers with a Series Transformer Examples for basic arrangements of the tap winding for regulation of the U 2 11/24/2003 Page 9
10 Commonly Used Winding Connections LTC Application in Phase-Shifting Transformers Example for single core design / direct circuit arrangement 11/24/2003 Page 10
11 Commonly Used Winding Connections LTC Application in Phase-Shifting Transformers Example for dual core design / symmetrical circuit series unit exciting unit connection diagram phasor diagram 11/24/2003 Page 11
12 Basic Arrangements of Regulating (Tap) Windings 11/24/2003 Page 12
13 Basic Switching Principle of LTCs Transfer of Load Current I C I: through current I reactor principle impedance = reactor (pa) (pa=preventive auto transformer) arcing I I C I resistor principle impedance = resistor Single Contact Switching Not applicable due to the loss of the system load / short circuit Make Before Break Switching Applicable but requires an impedance to limit the circulating current that appears in the bridging or transition positions 11/24/2003 Page 13
14 Design Principles of Oil Type LTCs Resistor Oil Type LTCs Arcing Switch (Diverter Switch) and Tap Selector (Reinhausen: M, MS, R) Arcing Tap Switch (Selector Switch) WES/ABB: UZD, UZE, Reinhausen: V; combine selecting and switching functions into one device Reactor Oil Type LTCs Arcing Switch (Transfer Switch) and Tap Selector (*) Arcing Tap Switch (Selector Switch) (*) (Combines selecting and switching functions into one device) (*) discontinued 11/24/2003 Page 14
15 Design Principles of Resistor Oil Type LTCs Diverter Switch (Arcing Switch) with Tap Selector Design diverter switch tap selector switching principle design 11/24/2003 Page 15
16 Design Principles of Resistor Oil Type LTCs Selector Switch (Arcing Tap Switch) Design switching principle example for in-tank design 11/24/2003 Page 16
17 Design Principles of Vacuum Type LTCs Resistor Vacuum Type LTCs Vacuum Diverter Switch and Tap Selector Reinhausen plans start of series production for 1 st Quarter 2004 Tap Selector with integrated Vacuum Interrupters Type V V introduced by Reinhausen in 2000 Reactor Vacuum Type LTCs Vacuum Interrupter Mechanism and Tap Selector (LRT200) By-pass Switch, Vacuum Interrupter Mechanism and Tap Selector Reinhausen RMV, Westinghouse UVT 11/24/2003 Page 17
18 Design Principles of Reactor Vacuum Type LTCs Tap selector, By-pass and Vacuum Interrupter (VI) Design tap selector by-pass reactor V I Switching principle RMV-II 11/24/2003 Page 18
19 Today's Performance Expectations from LTCs Low failure rate Long-term uninterrupted availability of the regulating transformer Extension of the maintenance intervals Reduction of the maintenance work Main target Reduced operating costs The Available Tool The Vacuum Interrupter 11/24/2003 Page 19
20 The Vacuum Switching Technology in LTCs One Solution for the next Generation of LTCs Historically: Rapidly wearing tungsten-copper arcing contacts in mineral transformer oil Today and Tomorrow: Primarily Vacuum Interrupters replaced by 11/24/2003 Page 20
21 The Vacuum Switching Technology in LTCs Highlights The vacuum interrupter is a hermetically sealed system arc has no interaction with the surrounding medium the switching characteristics do not depend on the surrounding medium The arc (drop) voltage in vacuum (5-10V) is considerably lower than in oil (25-30V) or SF 6 low energy consumption (~ I x U arc x t) reduced contact wear 11/24/2003 Page 21
22 The Vacuum Switching Technology in LTCs Highlights Elimination of the insulating medium as the arc quenching agent elimination of by-products e.g. carbon when using transformer oil Eliminates need of an on-line filtration system easy disposal of used insulating medium 11/24/2003 Page 22
23 The Vacuum Switching Technology in LTCs Highlights No aging of the quenching medium constant switching characteristics throughout the entire lifespan of the vacuum interrupters getter effect of metal-vapor plasma with absorption of free gas molecules No interaction/oxidation during switching high rate of re-condensation of metal-vapor on contacts significantly extends contact life consistently low contact resistance 11/24/2003 Page 23
24 The Vacuum Switching Technology in LTCs Highlights Extraordinarily fast dielectric recovery of the quenching distance of up to 10 kv/µs Ensures short arcing times (less than one half-cycle) even in the case of large phase angles between current and voltage or high voltage steepness du/dt after the current zero e.g. converter transformers 11/24/2003 Page 24
25 Reinhausen Vacuum Interrupters for LTCs Key Design Parameters Mechanical lifespan in transformer oil any other given insulating medium operating temperature range expected lifespan of the LTC Switching performance (current, step voltage) Contact lifespan Physical dimension 11/24/2003 Page 25
26 Reinhausen Vacuum Interrupters for LTCs Permanent Improvement in Research and Development Example for Application in Reactor Type LTCs 180 mm Vacuum interrupter for 2500A, introduced in the early 70 s (VACUTAP LTC type UVT) Vacuum interrupter for 2500A, introduced in 1993 (VACUTAP LTC type RMV-II) Vacuum interrupter for 1320A, introduced in 2000 (VACUTAP LTC type RMV-A) 11/24/2003 Page 26
27 Reinhausen Vacuum Interrupters for LTCs Comparison of Contact Wear Vacuum interrupter: Low arc drop voltage and re-condensation of metalvapor plasma The contact wear rate for LTC vacuum interrupters is at least 10 times less than for copper-tungsten contacts Example for 1000 A shows only 3% of wear found in copper-tungsten contacts Message Vacuum interrupters specifically designed for LTCs easily reach 500,000 switching operations 11/24/2003 Page 27
28 Reinhausen Experience with the Vacuum Switching Technology in LTCs Application in reactor type tap-changers (UVT, RMV-I, RMV-II and RMV-A) since the mid-eighties approx. 4,000 LTCs built with 12,000 vacuum interrupters more than 51,000 years of trouble-free field operation Reactor VACUTAP LTC type RMV-II for 1,500A, 2,000A and 2,500A Reactor VACUTAP LTC type RMV-A for 600A and 1,320A 11/24/2003 Page 28
29 Reinhausen Experience with the Vacuum Switching Technology in LTCs Application in resistor type tap changers for external mounting for the regulation of dry type transformers 9 since 1995 approx. 640 LTCs built with 2,100 vacuum interrupters Resistor VACUTAP LTC type VT for 500A Resistor VACUTAP LTC type AVT for 150A 11/24/2003 Page 29
30 Reinhausen Experience with the Vacuum Switching Technology in LTCs Application in resistor type tap-changers for in-tank installation for the regulation of oil-filled power transformers since 2000 approx. 800 LTCs built with 4,800 vacuum interrupters Resistor VACUTAP LTC type VV for 250A, 400A and 600A 11/24/2003 Page 30
31 Reinhausen Vacuum Switching Technology Latest Development: Resistor VACUTAP LTC Type VR Resistor type In-tank design Max. rated through current 3-phase/2-phase: 1,300 A 1-phase: 3,000 A Max. rated step voltage: 4,000 V Max. BIL level to ground: 1,175 kv Switching principle 11/24/2003 Page 31
32 Reinhausen Vacuum Switching Technology The Next Step Introduction of the vacuum switching technology in all resistor type diverter switches in Reinhausen s main product segments Vacuum type LTCs to replace Oil type LTCs in the range of 600A to 3,000 A Vacuum type LTCs as an alternative to Oil type LTCs in the range up to 600A Series production and delivery start: beginning of /24/2003 Page 32
33 Reinhausen Vacuum Switching Technology Development of Market Share Vacuum Type LTCs versus Oil Type LTCs in percentage of units < 1 % Vacuum Type 17 % Vacuum Type 50 % Vacuum Type 75 % Vacuum Type Oil Type Oil Type Oil Type Oil Type /24/2003 Page 33
34 Advantages of the RMV Vacuum Type LTC Summary Vacuum Interrupter is a hermetically sealed system Arc does not interact with the surrounding medium Carbon by-product eliminated when working in insulating oil Reduction of mechanical wear of mechanism Eliminates need for on-line filtration equipment Allows use of alternative insulating fluids Vacuum Interrupter has a fast dielectric recovery of the quenching medium Short arc time Reduced contact wear (<10% of wear found in oil) No aging of the quenching medium Constant or improving switching characteristics (gas molecules absorption by getter effect = the more it switches the better the vacuum interrupter becomes!!) 11/24/2003 Page 34
35 Advantages of the RMV Vacuum Type LTC Summary (Cont.) Substantial Reduction of Operating Costs Elimination of on-line filter (acquisition, operating and maintenance costs) Fewer oil replacements (oil can be re-used several times), easier oil disposal Contact replacements basically eliminated for network applications Easier contact wear evaluation and maintenance procedures Note: UZ type LTCs have only 30,000 operations contact life per stationary contact. There are 17 stationary contacts per phase (51 total) that need to be evaluated for contact wear, together with 18 moving contacts. 500,000 operations can only be achieved if the customer uses entire operating range uniformly, 16L N 16R N 16L N 16R RMV-II: 1,000,000 operations vacuum interrupter life RMV-A: 750,000 operations vacuum interrupter life Reduction of maintenance costs (contacts, oil, labor) 11/24/2003 Page 35
36 Advantages of the RMV Vacuum Type LTC Summary (Cont.) Substantial Reduction of Operating Costs (Cont.) Reduction of transformer down-time for maintenance Extension of maintenance interval Reinhausen Vacuum LTCs: the 1 st LTCs without time-based maintenance intervals!!! Type V V: maintenance free through 150,000 operations Type V R: maintenance free through 150,000 operations RMVs with with new VIM Model B : Type RMV-II: maintenance free through 500,000 operations Type RMV-A: maintenance free through 250,000 operations Vacuum Interrupter Monitoring System (VIM System) model A supplied standard with every RMV 11/24/2003 Page 36
37 Vacuum Switching Technology in Reinhausen LTCs Life-Cycle-Cost Considerations Maintenance-free through 150,000 operations with type V V and V R LTCs Maintenance-free through 250,000/500,000 operations with type RMV LTCs Benefits Significant savings in maintenance costs Considerably reduced operating costs no time-based maintenance Oil Type Delta application 10 x maintenance Example: lifespan of 40 years < 150,000 operations Oil Type longer availability of the transformer simplified maintenance logistics protection of environment and natural resources due to reduction of oil changes Star-point application 6-7 x maintenance Vacuum Type Maintenance FREE Maintenance requirements during LTC lifespan for a typical network application 11/24/2003 Page 37
38 Vacuum Switching Technology in LTCs Conclusions At the present time and for the foreseeable future the Vacuum Switching Technology in LTCs presents the best formula to achieve the highest standards of Quality Reliability Economy towards a maintenance-free LTC design 11/24/2003 Page 38
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