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Miguel OLIVA, Antonio MARIN, Lorenzo PRIETO ABB Power Technology S.A., Power Transformers, Escritor Conde Zamora s/n, 14004 Cordoba, Spain Phone: (+34) 957 469169, fax: (+34) 957 469190, e-mail: miguel.oliva@es.abb.com / antonio.marin@es.abb.com / lorenzo.prieto@es.abb.com
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Abstract The Polytransformer is a compact, multifunctional, customized power transformer that may be used in multiple substations at different voltages. This paper explains and provides information about the Polytransformer concept, a multi-voltage substation power transformer. Keywords Polytransformer, power transformer, spare transformer, multi-voltage transformer.
On the other hand, contingency planning has to be performed related to arrangements in case of a transformer failure that results in a prolonged outage. Such contingency planning to mitigate risks includes spare units and redundant transformers. The availability of spare transformers is valuable to minimize the risk in case of a problem or failure, especially in generating plants or important substations in the transmission system. Some utilities are optimising the number of spare transformers because they are sometimes questioning if the investment in a spare transformer is economically justified. In this context, transformer manufacturers have to provide the utilities not only high quality and reliable products but also flexible solutions to support the economic justification of an investment in transformer spares. Such justification can be strengthened and supported proposing a multifunctional, compact and customized power transformer, having minimum feasible transport dimensions, which may be used as spare for different transformers in multiple substations and additionally, because of its versatility, it has other alternative applications: Back up transformer during peaks of load, installation in new substations or leasing/renting to other utilities that could need and urgent transformer or replacement.
I.
INTRODUCTION:
The change of the electric power industry to a fully competitive and deregulated market has focused the attention in asset management. Large power transformers represent a significant asset in the utility delivery system. They are one of the most important and costly components and the critical nodes in the electricity networks. In this competitive environment, the secure supply of electricity with strict cost control, reliability and quality is imperative. Utilities have to use their existing equipment more efficiently ensuring high reliability and an adequate level of quality in the service provided. As a consequence, there is a need of increased equipment utilization in parallel with a reduction in forced outages and failure rates. Large power transformers are a major concern to any electric utility when it comes to reliability because they are critical to the operation of the delivery system and their replacement involve a considerable amount of time and expense. In one side, scheduled and predictive maintenance operations are important to determine the actual condition of the transformers and can be used to minimize incidences and to optimise performance.
A customized standardized transformer is not a new concept. Many utilities already have standardized power transformers in their systems or are progressively defining them, principally in their transmission and distribution networks. The main economical and technical advantages include reduced cost and delivery time, proved and optimised design, easier maintenance and availability of spare parts. Those advantages are more evident when related to spare or multi-functional transformers. The Polytransformer concept was born during a standardization process carried out by a utility in Spain. In
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addition, this particular company had the need of spare transformers to interconnect the 400kV, 230kV and 132kV systems, mainly as a contingency plan in case of emergency in some critical substations. The minimum requirements were to have a three-phase spare unit with the maximum power rating that could make possible an easy and quick transportation. That way, the spare transformer could be readily available for several substations. From that basic necessity, additional considerations were taken into account to provide extra features to have, not only a spare transformer, but also a unit with a broad scope and universal range of application. A shell form transformer design was considered because it had some intrinsic characteristics that fitted closely into the targeted purpose. The main features of the Polytransformer are: - Multiple voltage ratings at the high voltage and low voltage side. The Polytransformer is designed with internal taps providing different alternatives to allow connection between different transmission systems (for example, 400kV to 230kV, 400kV to 132kV, 400kV to 110kV, 230kV to 132kV and 230kV to 107kV). Depending on the connection, the power rating of the transformer varies. An onload tap changer regulation is also provided. The different voltage rating alternatives can be selected by changing connections internally when the unit is prepared for shipment to a different station. The winding arrangement flexibility and the facility to provide different tap connections inherent to a shell form transformer design allowed to achieve a simple and reliable design. - Multiple voltage ratings of the tertiary winding. The tertiary can be also designed with internal taps to provide several voltage levels to match different substations needs. - Maximum power rating meeting the existing transportation restrictions and the temperature rise limits specified by the standards. - Compact design to allow the Polytransformer to be shipped to many different substations. A shell form design helps to accomplish compact shipping dimensions providing additionally mechanical robustness to withstand transportation and hauling accelerations. This way, the Polytransformer can be easily shipped to many different substations. - Minimum installation dimensions to optimise the substation space requirements. Minimizing total dimensions allows replacement a wide range of existing transformers or installation in substations with limited space.
- Short circuit impedance of the Polytransformer is designed taking into consideration the impedances of existing transformers. Parallel connectivity with other units is achieved by adequately controlling the on-load tap changer. - Customized design: The Polytransformer can be designed to be electrically and dimensionally compatible with different transformers existing in a particular transmission system, meeting particular specifications and applicable standards. - Standardized external components to reduce the number of spare parts and to facilitate their availability.
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Terminal High Voltage (400 kV) Low Voltage (230 kV) Low Voltage (138 kV) Low Voltage (110 kV) Neutral Tertiary (33 kV) Tertiary (26.4 and 24kV)
- Connection to 230 kV systems on High Voltage Side: The autotransformer can be also connected to a 230kV system having the rated values indicated in Table IV:
Table IV Voltage Ratios, 230kV Connection
The tertiary can be selected to have a nominal voltage rating of 19kV, 15kV or 13.8kV as indicated in Table V:
Table V Tertiary Voltage Ratios, 230kV Connection
The unit is a three-phase, shell form autotransformer, 50Hz, Ynad11 connection, OFAF cooling and on lad tap changer regulation at the neutral end (variable flux regulation).
- Connection to 400 kV systems on High Voltage Side: The different voltage ratios and power ratings when the autotransformer is connected to a 400kV system on high voltage side are showed in Table I:
Table I Voltage Ratios, 400kV Connection
Terminal High Voltage (230 kV) Low Voltage (132 kV) Low Voltage (107 kV) Neutral Tertiary (19 kV) Tertiary (15 and 13.8 kV)
- Transformer shipping dimensions The shipping dimensions of the transformer are showed in Table VII:
Table VII Shipping Dimensions
The tertiary can be selected to have a nominal voltage rating of 33kV, 26.4kV or 24kV as indicated in Table II:
Table II Tertiary Voltage Ratios, 400kV Connection
The shipping weight is 203000 kg. An overview of the transformer arranged for shipment is showed in Figure 2.
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Front View
Front View
Side View
Top View
- Transformer assembled dimensions The total dimensions of the transformer completely assembled are showed in Table VIII:
Table VIII Installed Total Dimensions
Installed Total Dimensions (mm) Length 13530 Width 6025 Height 9140
Transformer Weights (kg) Active part 162000 Tank and accessories 65000 Oil 64000 Total 291000
Figure 4. 3D Transformer View
That particular Polytransformer was designed to be mechanically and electrically compatible with other three phase transformers installed in the 400kV transmission system (up to six existing different designs). The cooling equipment was designed with oil-air coolers to minimize the total space required for installation. All the accessories and fittings in that unit are standard, which means that are used in other transformers already installed in the network, mainly to help the maintenance operations and the availability of spare parts. An overview of the transformer completely assembled is shown in Figures 3 and 4.
- Paralleling with transformers having different OLTC regulating range The on load tap changer regulation of this autotransformer has been designed to have 21 positions. It has a variable flux regulation located at the neutral end. The regulation range varies depending on the selected connection. Table X shows the different ranges.
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Voltage ratio (HV/LV) 400 / 230 kV 400 / 138 kV 400 / 110 kV 230 / 132 kV 230 / 107 kV
OLTC Regulation 230 kV +3,5% -3,8% 138 kV +9% -9,8% 110 kV +12,7% -13,5% 132.3 kV +3,5% -3,8% 106,86 kV +5,4% -6%
to reach mutual objectives like quality and reliability. In addition, the resultant products are completely adapted to the real needs of the final user. The Polytransformer concept is already confirming its competence and performance. Four Polytransformers have been already manufactured and other three are in process. Two of the four existing units are been used to solve urgent transformation needs and have been rented by the owner to other utility, the first one is interconnecting systems from 400 to 230 kV and the second one from 400 to 132 kV.
In case that the autotransformer needs to parallel with other units having different regulating ranges, those have to be limited in the common part of the ranges. If the number of regulating positions is different, the transformer could be equipped with a programmable PLC. This PLC can be programmed to control the load tap changer in the spare transformer and to select the optimum position in every case. It receives indication of the tap position of the transformer to parallel, from that information decides what is the most suitable tap changer position of the controlled spare unit and gives the order to accordingly raise or lower the tap changer position. Figure 5 shows the physical arrangement of the PLC inside its control cabinet:
V. FINAL SUMMARY
The availability of spare transformers in key substations is important as a contingency plan in case of a problem or failure of an operating unit. The multi-voltage substation power transformer is a multivoltage transformer that provides multiple features in one single product. It is a compact, customized standard autotransformer with several voltage ratings that could be shipped and installed in diverse substations within a transmission system. The Polytransformer is a multifunctional product that has different possible applications. It can help to minimize the number of transformer spares available in a transmission system and to justify the investment in spare units. The active collaboration between the utilities and the transformer manufacturers is an optimum and proved way
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