H. Heydari* S.M.

Pedramrazi Regular paper Impact of Mechanical Forces in a 25kA Current Injection Transformer
Since Current Injection transformer (CIT) systems are within the major group of the standard type test equipments in electrical industry, their performances are very important. When designing a high current devices, there are many factors to be considered from which, unharmful effects of mechanical forces due to high current (25kA) passing through secondary winding of a CIT must be ensured. Since the electromagnetic forces is proportional to the square of current, up to the present time, as far as the authors are aware no report on impact of mechanical forces considerations for current injection devices has been made. This paper attempts to fill this void in our knowledge by considering various issues related to the mechanical forces in a 25kA CIT, using 2D electromagnetic fields (EMFs) simulation tools (Ansys 8.1) to calculate stray reactance fields and the mechanical forces in a single turn secondary winding of the CIT. Keywords Current Injection Transformer (CIT), Mechanical Forces, Leakage Flux, Finite

Element Method (FEM). 1. INTRODUCTION Electrical equipment such as circuit breakers, protective relays, and meters are routinely tested to verify proper operation of current sensing elements. This testing is performed using high-current, low-voltage test equipment that provides a means of adjusting the value of current and also of measuring the operating time of the device under test. When designing a high current devices, there are many factors to be considered from which, unharmful effects of mechanical forces due to high current (25kA) passing through secondary winding of a CIT must be ensured. As the current densities rise the electromagnetic forces acting on the turns of the coil become very significant. CIT systems are within the major group of the standard type test equipments in electrical industry and their overall performances are very crucial. Secondary voltage of CIT is usually low, (less than 10 volts) whereas, the output current is very high (1kA-100kA). The CITs use for testing equipments such as circuit breakers, that must carry short-circuit current. Testing can assure that your product meets or exceeds performance standards. During CITs operation, the mechanical vibration of windings and thermal expansion of wires take place simultaneously. However, as the current densities rise the transformer windings are exposed to excessive electromagnetic forces [1, 2]. Under this condition, the winding will undergo substantial geometry changes in the coil shape leading to coil/insulation damage and consequently impedance change. The relative displacements between wire insulation and other component parts of the winding may injure the insulation, leading to turn faults [3-5]. In this condition the behavior of transformer windings must be grasped precisely and reflected in their strength design for better reliability [6]. The vibration is influenced by force, inertia, material property, friction, etc [7]. When the winding of transformer carry current, a leakage flux field is produced
*Center of Excellence for Power System of Automation & Operation, Electrical Engineering Department, Iran University of Science and Technology heydari@iust.ac.ir, m_pedram_razi@yahoo.com Copyright JES 2007 on-line : http://journal.esrgroups.org/jes/

between the concentric windings (i.e. high voltage and low voltage windings). The principal component of the leakage flux is axial. The current carried by the winding conductors (circumferential direction) interact with the leakage flux and produces forces as shown in Fig.1.

Fig. 1. Direction of Forces generated due to interaction of Flux and Current The nature of the leakage flux is such that it is mostly in the axial direction (except in the ends of the windings) and hence the maximum radial force occurs around the mid-height of the coils. Radial forces act outward on the outer winding and inward on the inner winding (see Fig.2).

Fig. 2 Leakage flux pattern and direction of forces acting on high current and low current sides. Near the ends of the windings, a large part of the leakage flux bends towards the core leg and thereby causes a radial component of the flux. The interaction of this radial component of flux with the winding current produces axial forces that tend to compress the winding conductors along the vertical axis. However, there are both radial forces and axial forces generated in a transformer winding. During the short circuit condition, large amount of currents flow through the windings. The forces generated in a transformer subject to short circuit conditions are magnified many times more compared to those under normal

operating conditions. For example, a transformer with 6 percent of leakage impedance will carry 16 times the rated current during short circuit and this will result in forces more than 250 times those under normal operating conditions. Also, the peak forces are much higher than the RMS forces. The axial vibration of a transformer winding was studied by massspring system and the effect of magnetic center misalignment was taken into account [7]. A nonlinear dynamic model for the axial vibration of the transformer winding was established. In this model, the electromagnetic forces not only vary with time, but also with the displacement of windings [6]. The simulation of copper and core losses of the CIT from which temperature rise of secondary windings together with thermal limitation were calculated [8]. Numerical calculation of short circuit electromagnetic forces on the transformer winding in a 17MVA transformer is investigated in [9]. The estimation of the force magnitudes and directions was carried out and compared with those from short circuit condition [10]. The skin and proximity effects were also considered and their effects on the force diffusivity were studied [11,12,13]. Up to the present time, as far as the authors are aware no report on impact of mechanical forces considerations for current injection devices has been made. This paper attempts to fill this void in our knowledge by considering various issues related to the mechanical forces in a 25kA CIT, using 2D electromagnetic fields (EMFs) simulation tools (Ansys 8.1) to calculate stray reactance fields and the mechanical forces in a single turn secondary winding of the CIT.

2. FEM MATHEMATICAL ANALYSIS The simulations are based on the edge element method and mainly magnetic vector potential method [14-15]. The former method constitutes the theoretical foundation of low frequency EMF element The vector potential method is applicable for both 2-D and 3-D EMFs. Considering static and dynamic fields and neglecting displacement currents (quasi-stationary limit), the following subset of Maxwells equations apply: {H } = {J }, (1)

{E } = {

B }, t .{B } = 0.

(2) (3)

The basic equation to be solved is in the form of: (4) The terms of this equation are defined below; the edge field formulation matrices are obtained from these terms follow with boundary conditions. -Degree of freedom:

[C ]{u}+[K ]{u} = {J i }.

{Ae } {u} = , {ve }

(5)

where {Ae } and {ve } are magnetic vector potentials and time integrated electric scalar potential respectively. Coefficient matrices:

[K AA ] [0] , [K ]= vA [K ] [0]

(6)

[K AA ]=[K L ]+[K N ]+[K G ],

[K ]=
L Vol

(7)
T

([N

] ) [v ]([N A ] [N A ][ ] ({v}[N A ] ))d (vol ),

T T T

(8) (9) (10) (11) (12) (13) (14) (15)

[K G ]=

Vol

([N

]T )T [v ]([N A ]T )d (vol ),

[K N ]= 2

dvh T T T T T 2 ({B } ([N A ] )) ({B } ([N A ] )) d (vol ), d (B ) vol

[K VA ]= ([N ]T )T [ ]{v}[N A ]T d (vol ),

[C AA ] [C Av ] , [C ]= Av T [C vv ] [C ] AA [C ]= [N A ][ ] [N A ]T d (vol ),
vol

[C Av ]= [N A ][ ] {N }T d (vol ),
vol

[C vv ]= ({N }T )T [ ]{N }T d (vol ),

vol

-Applied loads:

{J A } {J i } = t , {I } {J A } = {J S } +{J pm },
{J } = {J s }[N A ] d (vol ),
S T vol

(16) (17) (18) (19) (20)

{J pm } = ([N A ]T )T {Hc} d (vol ),

vol

{I t } = {J t }[N A ]T d (vol ),
vol

where [N A ] , {N } , {J s } , {J t } , vol , {H c } , vo , [v ] ,

dvh , [ ] , and {v} are d (B )2 matrix of element shape function for {A} , vector of element shape function for { } , V

source current density vector, total current density vector, volume of the element, coercive force vector, reluctivity of free space, partially orthotropic reluctivity matrix, derivative of reluctivity with respect to the magnitude of magnetic field squared, orthotropic conductivity, and velocity vector respectively. The magnetic field density is the first derived result. It is defined as the curl of the magnetic vector potential. This evaluation is performed at the integration points using the element shape function:

{B} =[N A ]T {Ae },

(21)

where, {B} , and {Ae } are magnetic field density, and nodal magnetic vector potential respectively.

3 CIT DESIGN PRINCIPLE According to Faraday's law,

dB (22) dt where, N is the number of turns and Ai is the effective cross sectional area of the magnetic core. In the case of laminated and tap-wound cores, this is less than the physical area AC due to interlamination space and insulation. The form factor K is defined as the ratio of the rms value of the applied voltage waveform to V V (23) K = rms . V Combining (22) and (23) yields Vrms = KfNBm Ai (24) eind = NAi where, f is the frequency of eind and T is the period of eind . Equation (24) is the classic equation for voltage in a transformer where, K for sinusoidal waveform is K=4.44. Parameters of case study CIT transformer as below: Secondary voltage of the CIT, V2 =5 (V ) and output current is, I 2 =25 (kA) Q2 =125 (kVA) . The volts per turn ratio, V/T for a conventional transformer is determined by using (25), where R is 0.7 for single phase and 0.55 for three phase. In (40), P is the rated power in kVA, %IZ means the per unit impedance in percentage, f is the frequency and Q is unity for single phase.
2 0.376 P f V = R Q (v ) 1 T (% IZ / 5) 2 60
1

(25)

If voltage per turn to be as: Et =5 (V / T ) Maximum flux density obtains as: Et 5 m = = = 22.5( mwb) 4.44 f 4.44 50 For flux density Bmax = 1.3 (T ) we have [17]:
22.5 103 = 0.0173(m 2 ), K f = 0.9 1.3 0.0173 = 192.2 (cm ) A = c 0.9 A = 13.84 13.84 (cm ) c Since the magnetic flux flow through the outer limbs is half of that of the central limb, so that their cross sectional area is also half of that of the central leg, that is: b = 2a a = 6.92(cm) Ai =
2

If the current densities of the primary and secondary windings are 1 = 2.25 106 ( A

m2

2 = 100 106 ( A

m2

) respectively, then the window area, Aw obtained as (26):

Q = 4.44 f Bm K w

1 2 Ai Aw 1 + 2

(26)

125 103 = 4.44 50 1.3 0.328

100 2.25 2 106 0.0173 Aw Aw = 345 (cm ) 100 + 2.25

The cross section area of primary winding is:

I 2 AP = P = 138.8mm , 1

and the cross section area of secondary winding is:

I 2 AS = S = 250 mm . 2

The main design parameters of the CIT are shown in Table 1. Table 1. Design parameters of the CIT 125kVA Capacity 400/5V Voltage 312.5/25000A Current 50Hz Frequency Single-phase Phase Materials 30M5 Nominal Bmax 1.6T Effective Cross Sectional Area 14100mm2 Copper Material 3.2mm22mm Cross Section 2.25A/mm2 Jc 5.0V V/N

Ratings

Core

Windings

4 THE LEAKAGE FLUX AND MECHANICAL FORCES ON THE CIT WINDINGS

Generally, the flow of flux density in a medium is three dimensions, r, z and . The flux density resultant BR (t) is given by:
2 2 BR (t) = Br (t) + B 2 (t) + B (t) (27) z Where: r, z and denote the directions of the flux. The A vector potential is needed to

calculate magnetic flux and Because of symmetric of transformer [9],

A =0

(28)

So,

B = 0

(29)

In this study we only use 2-D simulation and the dimension is assumed to be constant. A computer aided method that is based on magnetic vector potential and finite element

equations [6] was used to obtain the leakage magnetic field distribution around the coil winding of 25kA CIT.

A z A A Bz = + r r Br =

(30) (31)

The section in which the magnetic field is to be calculated is divided up into small triangular elements. Within one element, the vector potential A is considered to vary linearly and is constant coefficient. A = 1 + 2r + 3 z (32) This is equivalent to a constant radial component of flux density within the element.

Br =
Bz =

A = 3 z

(33)

However, the axial component varies with the location.

A A A + = + 2 r r r

(34)

But in the numerical solution, the triangles are made small enough, so that the axial component Bz at the centroid can be taken as representative for the triangle as a whole.

Bz =

Ac + 2 rc 1 A + Am + An 3 l

(35)

Because of the linear variation within the element, the vector potential Ac at the centroid is the average of the values at the three vertices.

Ac =
Total stray flux density:

(36)

BT = B 2 + B 2 r z
From (30), (32) and (34):

(37)
2

A 2 2 2 BT = 2 + 3 + 2 A c + c rc rc

(38)

Equation (32) written for each of the three vertices produces three equations, which are solved with respect to the two coefficients 2 and 3 ( 1 is not needed).

2 =

1 [ A l (z m z n ) + A m (z n z l ) + A n (z l z m )] D

(39) (40)

3 =
where

1 [ A (rn rm ) + A m (rl rn ) + A n (rm rl )] D l

D = (rm z n rn z m ) + (rn z l rl z n ) + (rl z m rm z l )

(41)

If l, m and n are assigned in a counter clockwise direction, D is positive, and equal to twice the area of the triangle.

3.

FINITE ELEMENT METHOD

The FEM of the CIT is performed in order to verify the effectiveness of the theoretical equations used in the design process and validate the design parameters. The FEM in the CIT involves two stages, magnetic flux distribution within the CIT core, and mechanical forces being imposed by the stray flux upon the windings of the CIT.

4.1 Simulation Results of the Flux Distribution within the Core and Windings

In this section, the simulation results obtained using Ansys software are discussed. The color plotting of the magnetic flux density within the core and windings obtained as a result of simulation process are explained. The color plot of the magnetic flux density obtained as a result of 2D magneto static simulation is shown in Fig.3. The flux density at any point of the CIT is found from this color plot. It is seen from the plot pattern that the main flux paths are not confined within magnetic core, but they detour through the windings some of which cross the windows and the rest return back to the core. These flux leakages will impose mechanical forces upon the windings which could have harm effects on them.

Fig.3. Axial and Radial stray field in primary winding

Fig.4 shows the stray flux density plots passing through the windings. It shows that the most of the stray fields in top and bottom of the primary and secondary windings are diverted opposite to each other, into the left and right yoke of the core. This is due to the fact that, the current flowing into primary and secondary windings is 180o out of phase

with each other. However, it can also be seen that the rest of these fields are crossing the windows and join the fluxes in the outer limbs of the core.

Fig. 4. Stray field vector in top of primary and secondary Windings

Fig.5 and Fig.6 show the variations along vertical and horizontal axes, of radial stray field along the primary winding approaching the gap between the two windings. The radial components of the magnetic field alternate between the maximum positive (top of the windings) and maximum negative (bottom of the windings), while in the midway of top and bottom, the stay fields are reduced to nearly to zero. The maximum values of the stray fields alternated at the top and bottom of the winding are about 9mT. Fig.6 shows the axial stray field variations along the gap between two windings. Unlike the radial fields, the axial stray fields are minimal (5.2mT) at both vertical ends of windings, while they are increased (9.7mT) around their centre. Figures. 5 and 6 show that at the position where the radial field component attains maximum, but the axial component is minimal, and vice versa. 4. MECHANICAL FORCES

In case of high current injection transformers, the main coupling between the mechanical and magnetic field results from the interaction between the magnetic stray field of currentcarrying coil conductors and the electric current in conductive parts of the vibration winding structure Generally Electromagnetic forces are calculated as flux density times current times length. F = BLI (42) As there are stray radial and axial field components within the windings, so the corresponding forces are divided into two radial and axial components. The radial force due to axial flux tends to separate the two windings, whereas the axial force due to radial flux tends to compress the windings. The total radial forces give rise to tensile stresses in the outer winding, but compressive and bending stresses in the inner winding.

Fig.5. Radial stray field variation along the primary winding

Fig.6. Axial stray field variation along the primary winding However, bending stresses can be reduced by increasing the number of axial spacers between the core leg and the winding. The maximum axial force per unit volume occurs at the winding end. It tends to bend individual disks axially between radial spacers. Axial forces build up down through the winding. The mechanical force due to 25kA in the CIT is presented in this section. As the result shows the axial force imposed upon the coils is negligible because the coils are symmetrical, so this proves the validity of the model. Since the axial stray field almost covers the whole area of the windings the radial force component also is also applied throughout the windings. Fig.7 shows the electromagnetic force vectors on windings area. It can be seen that the whole area of the windings are under the radial forces, while axial forces pressurize only the top and bottom areas of the windings. These phenomena are shown in Figures 8 and 9, where in Fig.8, the axial forces are only applied to two ends of windings and it is negligible in the other area. While Fig.9 shows that the radial forces are distributed throughout the

winding area, whereas they are at two ends of the windings become weaker. At the position where the radial field component attains maximum, the axial component is minimal, and vice versa.

Fig.7. Electromagnetic force vectors on windings area

The Table.2 shows the axial and radial components values of primary and secondary windings. Table.2: Electromagnetic forces values on windings Winding Radial component Axial component Primary 33N 0.0003N Secondary 1624N -5.8N The calculated values of the pressure from the forces and winding areas are shown in Table.3. Table.3: Pressure value on copper conductor Winding Stress Primary 0.075MPa Secondary 0.0232MPa It can be seen from the Table 3 that the stress value is smaller than allowable stress so the windings are impervious versus the radial forces. Skin effect and proximity effect may be significant as far as the force distribution is concerned but the have no significant effect on the total force [11].

Figure.8. Axial force distribution in windings area

Fig. 9. Radial force distribution in windings area

5 CONCLUSIONS

This paper presented a 25kA CIT design model based on finite elements accounting for dominant effects of "magnetic field distributions" on the mechanical stresses. The turns of windings are effective parameter on electromagnetic forces. It was found that in the CIT despite 25kA current in secondary winding the mechanical force is not harmful to the winding, since the value of the ampere/turn is not noticeable. For a good design, the number of high current winding turn and its limitation is a key factor. Because, applied stresses on the winding cross section are proportional to forces, so in this study the forces were low and were not harmful to the windings of the 25kA CIT. The present approach has been described with reference to exemplary embodiments. However, it will be readily apparent to those skilled in the art that it is possible to embody

the phenomena in specific electromagnetic systems other than that described above without departing from the spirit of the concept.

ACKNOWLEDGMENTS

The authors would like to thank Prof. Mohsseni from University of Tehran for his critical and extensive comments led to a transparent and a useful representation of this work. The financial support of the Tehran Regional Electric Company; Energy Ministry of Iran is gratefully acknowledged. The authors would also like to express their sincere gratitude to the editorial board and the referees for their constructive comments which enhanced the quality of the paper.

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