Current Transformer: (Design, Manufacturing and Quality Checks/Tests)

Current Transformer
(Design, Manufacturing and Quality Checks/Tests)
Name : Shailesh Mahajan Division : S1 Category : General 1

Design of current transformer
Function of Current Transformer
• Transformation of Current – For e.g. 2000A to 1A.

• Provide Insulation against High Voltage

Design of current transformer
CT Design
• Electromagnetic Design • Insulation Design

CT Electro-magnetic Design
4
Electro-magnetic design
Basic Principle :
Primary Ampere turns = Secondary Ampere Turns
Np X Ip Flux induced in the cores Is corresponding to Ns

Electromagnetic Design :
Volt = 4.44 X f X Bm X Core area X Turns
Volt X Amp = 4.44 X f X Bm X Core area X Amp. X Turns
VA proportional to secondary Ampere Turns
VA = (Resistance of CT + Lead Resistance + Instrument Burden)

Errors in the CT output :
Np X Ip = (Ns X Is) + ( Ie X Ns)

Ie = Excitation current of core
(Ie X Ns) = Error component
Ratio error :
Sec. AT not exactly equal to Primary AT
Phase error :
Sec. AT not in exact phase opposition to Primary AT

CT Flux density Operation for different cores :
Metering, Protection & Special Protection
Core Material : CRGO laminations toroidally wound
Bm
16 Flux Density at ALFTimesCurrent
14.2 Flux Density at kPV
4.5 Flux Density for Metering at Rated Current Usually Less than
4.5kG.

1) Metering Cores :
• Stringent accuracy class (0.2s/40VA) operating

Bm less & increased core cross section.
• Realistic burden values to be specified to avoid

Bulky cores and hence increase in CT Cost.
• As ratio decreases (75/1 , 50/1) meeting stringent

accuracy becomes difficult.

1) Metering Cores :
• ISF achieved choosing operating Bm 4 to 4.5 kG

at rated current, saturation Bm = 20 kG
• Stringent Accuracy with ISF met using Auxiliary core.

2) Protection Cores :
• Accuracy over wide range of Primary current

(20 to 30 times rated current).
• P class cores are normally operated at 17kG at

ALF times rated current.

3) Special Protection Cores :
• For PS class
Vk = Fault factor X (Rct + Rlead + Rb)
• Bm at Vk is 14.2 kG
• Core size is decided by Bm & Turns thus core losses

are defined & thus Iexe is also defined – Hence
specifying very low Iexe is unrealistic.

3) Special Protection Cores :
• As the ratio increases turns increases the kPV

available also increases & Iexe reduces with increase
in turns – Higher CT ratios are preferable.
• Higher secondary current (5A) lesser turns and hence

high Iexe. Currents.

CT Insulation Design
14
Insulation design
• Type of Construction : Live Tank
secondary
• Core & secondary on Top
primary • Insulation on secondary
• Short length primary
Secondary leads

Insulation design
• Type of Construction : Dead Tank
1) Eye Bolt Type
•Core& Sec. at Bottom
•Insulation on Primary
•Long length primary econdary

Insulation design
• Type of Construction : Dead Tank
2) Hair Pin Type
•Core& Sec. at Bottom
•Insulation on Primary
•Long length primary

Insulation design
• Type of Insulation : “ OIP “
High Quality Insulation Materials

- Kraft paper
- Aluminium Foils
- Napthene based high performance
mineral oil

Insulation design
INSULATED SHELL
Shell side
Insulation
P1 P2
(Tank)
SECONDARY WINDING
Bushing side
Insulation (Porcelain)
CONDENSOR BUSHING

Insulation design
• Voltage Gradation By Two methods –
1) Condenser Grading:-
- Inserting Aluminium foils
- Uniform voltage stress across capacitor
formed
Ro INSULATION
BUSHING PIPE
Ri
Bushing

Insulation design
• Condenser Grading –
95%
100% 90%
80%
70%
60%
Condenser Grading of CT 50%

Insulation in Porcelain
Portion
40%
Cx = Capacitance &
TanD Measuring Lead
30%
20%
10%
5%
Cx 0%

Insulation design
• Voltage Gradation By Two methods
2) Appropriate Shaping of Electrodes :-

- Well contoured Electrodes for
High Voltage & Earth
Ro Ri
INSULATION
SHELL
Shell cross section
cores
Insulation thickness
Sectional view of Shell Insulation

Insulation design
CT Processing – Drying & Impregnation
• Well defined Autoclave Cycles –kV Range wise
• Elaborate Drying cycle
• Fixed Rough & Fine Vacuum Time cycles
• Defined rate of Oil Impregnation –Volume wise

Insulation design
Features :-
-Uniform Stress control
-High Dielectric Strength
-Insulation build up as per well defined steps
- Minimum Human interface

• 60% of total insulation machine wound
• 2/3 rd of hand taped is premade
- Fault current effectively carried to ground

• well contoured rigid Al. cast shell
-Lower temperature coefficient of tandelta.

• Effective drying & impregnation Cycle

Features of Live Tank CT Design
25
Current Transformers - Constructional designs
Live Tank Dead tank
Primary conductor
Paper-oil insulation
Secondary cores
And windings

Features of Live Tank Design Current Transformers
1. No thermal aging of insulation

INSULATED SHELL
• Insulation is on secondary
P1 P2
windings.
• Insulation is practically at
SECONDARY WINDING ambient temperature.
• Thermal stability attained in
8-12 hours.
• Long duration stability and
CONDENSOR BUSHING
reliable long service life.
420 kV CT : Ratio – 2000-1000-500/1 No. of cores – 5 Max. heat – 50 W

2. Excellent Short circuit performance
• Short length primary

• No effect of electro-dynamic
forces due to absence of
long length return conductor
• Negligible transient errors at
system fault current due to
negligible self inductance.
3. No localized saturation of cores due to absence

of return conductor.
4. Suitability for high frequency transients

5. Ease of handling at site
• Weight is at the top.

• Majority weight is close to
crane hook
• No possibility of swinging
while making horizontal to
vertical.

CT Manufacturing Process
30
Secondary winding over core

Core testing

Porcelain insulator assembly

Tests before autoclave processing

Vacuum drying and oil impregnation

CT Stage Inspection Program
& Quality Checks
36
Routine tests
• Resistance measurement at ambient and calculate at R75.

• Inter-turn over voltage test
• Power frequency withstand voltage test on secondary
windings and their sections at 3/5 kV rms.
• Determination of ISF for metering cores.
• Determination of composite error for protection core

Equipment for OVIT test

EHV Laboratory-
(Electro-magnetically shielded - Faraday Cage)

AC HV test source 750 kV,1 amp – ASEA sweden make

AC HV test source 750 kV,1 amp – ASEA sweden make
PD Meter Control Panel of HV Test System

Final HV Insulation tests
• Capacitance and tangent
delta measurement at 10
kV and rated voltage
before PFWV.
• One minute power
frequency voltage
withstand test on primary
winding.
• Partial discharge
measurement at HSV and
1.2*HSV/root3 while
reducing voltage.
• Capacitance and tangent
delta measurement at 10
kV and rated voltage after
PFWV.

CT Quality Checks (on site)
43
On site checks – Instruction Manual
Pre-Commissioning Checks
Commissioning
Periodic Maintenance

Periodic check- Bellow level monitoring
CT - Bellow Assembly
Oil Communicating Type
Bellow Construction.
Ambient Temperature Increases;
Bellow V(oil) Increases.
V(Bellow) Increases.
Ambient Temperature Decreases;
V(oil) Decreases.
V(Bellow) Decreases.
Pressure Remains almost Same.
In case of Pressure Generation in

one CT in the substation (due to PD)
, the bellow level of that CT will
increase.
In case the Bellow level in one of the
CT in the substation doesnot vary with
CT Assembly temperature , oil leakage must be
present in the CT.

Bellow
Product
Bellow Level Low & Doesnot Vary with Ambient Temperature.

Thus Product is Leaking & Hermatic Sealing is disturbed.

Bellow
Product
Bellow Level is High.

Thus Pressure in Product.
Pressure due to Gas Generation.
Gas Due to PD at Rated Voltage.

Periodic maintenance
• Tandelta of CT
• DGA of CT

Capacitor Voltage Transformer
(Design, Manufacturing and Quality
Checks/Tests)

Principle of Operation

CVT - Design Aspects
51
CVT Basic Design & Schematic Diagram
CC Unit HV Terminal.
System
Phase
Voltage, V1
( kV ) C1 EMU Unit
Int.V.T.
Tap Sec.
L
Voltage , V2 Voltage , V3
( kV) C2 ( Volt)
Zd V
NHF
Aux.Sec.Wdg.
Earth Screen Between

HV & LV

Equivalent Capacitance (CHF) :
Between HV& NHF
(1/CHF) = (1/C1) + (1/C2)
CC Unit
HV Terminal. MV Tap Voltage : 10kV to 16kV.
C1 EMU Unit If Voltage Between HV & NHF = V,

Int.V.T. Then Divider Ratio
L u = ( V / MV Tap ) =[ (C1+C2) / C1 ]
C2 and C1 = [ u / (u-1) ] x CHF
Zd V C2 = u * CHF
NHF Resonance Frequency (f)
Aux.Sec.Wdg. f = 1/[ 2 *3.141*Sqrt.( Lmag*(C1+C2))]
Where
Earth Screen Between ‘Lmag’ is magnetising
HV & LV
inductance of VT

Zd = Damping Device
CC Unit It consist of ( Resistor / Resistor +
HV Terminal. L-C Circuit ) and mounted
inside EMU.
V = Varistor
C1 EMU Unit (1 or 2 in series or 4 in series
Int.V.T. depending on kV Class & CHF
) and mounted in Secondary
L Terminal Box.
C2
Zd V Earth Screen Between HV & LV :
NHF Prevents Surge / Impulse Voltage
Aux.Sec.Wdg. Transfer from HV to LV.
Earth Screen Between

HV & LV

Electromagnetic Unit (EMU)
Compensating
Intermediate Compensating
Reactor
Voltage Reactor
Transformer
Zd (Damping
Resistor)

(EMU)-Secondary Terminal Box
Drain coil Fuses /

MCBs
Varistor
Surge
Arrester

CVT – Equivalent Circuit
Aux. wdg
Compensatin
g
Reactor wdg 2
Secondary
Inductor Pri. wdg Secondary wdg 1
kV

CVT – Ferro resonance – Pre-cautions
Fuse Burden
Avoid using Inductive Burden (e.g. Isolation Transformer)

If Unavoidable - Ensure that the Operating Flux Density is Less than
6kG
In the event of Uncontrolled Ferro resonance the Over voltage can be
2.5 p.u
It is necessary to ensure that the actual Burden doesn't exceed rated value.
In the event of Fuse Blowing / MCB Tripping , Investigate in detail to
remove cause.

CVT – Ferro resonance – Pre-cautions
Fuse Burden
Avoid Switching of Burden in Live Condition.

Check Physical Condition of Varistor in Terminal Box periodically.
Watch for Bulging / Burning / Overheating.
In such cases the causes could be Over voltages due to "Continues &
Uncontrolled Ferro resonance" or Persistent Over voltages.

CVT – Transient response
Primary Zero
Primary Voltage
Secondary Voltage
The sub-harmonic oscillations are caused by active ( energy storing ) elements

in the circuit ….
Present Day Relays suppress the sub-harmonics & only pickup 50Hz Voltage
signal - Hence Transient Response is not critical during operation, when
compared with Ferro-resonance.

CVT – Transient response

Manufacturing Process
& Quality Checks
for Capacitor Divider Unit
62
Capacitor Elements
Capacitor Element Winding Capacitor Element
Check no.of turns

Stack Making
Dry Stack Pressing Dry Stack
• Check no.of elements & capacitance

• D.C voltage testing @ 1.8 kV

Stack processing and pressing
Drying & Impregnation

in autoclave Wet Stack Press
Monitoring temp.&vacuum

Capacitor assembly and flooding
Under vacuum flooding
-Nitrogen filling in bellow

-Leak test in oven at 700C
-Capacitor Unit Ready for Test

Manufacturing Process
& Quality Checks
for Electro-magnetic Unit
67
Voltage Transformer winding and assembly
Low Voltage Winding Intermediate VT assembly
Turns Ratio Test

Core Coil Current @ 4 kV

EMU components assembly and processing
Intermediate VT assembly
Drying & Impregnation
Inductor assembly
Current at 200 V

EMU components tanking and terminal box assembly
Secondary terminal box assembly EMU Tanking
Polarity Check

EMU under vacuum oil flooding
EMU oil flooding Oil flooded EMU
EMU Ready for

Testing

CG CVT Features
72
Features
• Both CC unit and EMU are hermetically sealed individually.

• Use of stainless steel bellow to take care of volumetric variation
in oil due to variation in ambient temperature.

Features
• Capacitor elements are manufactured from capacitor tissue

paper and BOPP film in class 10,000 room.
• Autoclave processed stacks are assembled in porcelain
insulator with corrosion resistant aluminium alloy end fittings.
• Filled with dried and de-gassed insulating oil under vacuum.

Features
• EMU consists of a
medium voltage
transformer,
compensating reactor,
damping element and
surge protection device.
• EMU tank cover is made
of high strength, anti
corrosion aluminium
alloy.

Features
• Use of gap less high

energy metal oxide varistor
across separate auxillary
winding to limit over-
voltages.

Limitations for higher simultaneous burden
77
Ferroresonance Phenomenon
Ferro-resonance Phenomenon
Varistor Operating Voltage
Damping of Oscillations
Duration Of Secondary Short

Std.- 100mSec
Fuse / MCB Tripping - 2-3 mSec.
• Where ever there is series connection of C and non-linear L, ferro-resonance is
but natural.
• CVT consists of capacitors in CC unit and inductor, inductive voltage transformer
in EMU causing ferro-resonance.
• Exchange of energy between C&L results into overvoltages during ferro-
resonance

Ferro-resonance is caused by either of the following conditions.
• Cable fault on the secondary side of the CVT.

• Saturation of inductive burdens connected on secondary side of
CVT
• Sudden change of burden when CVT is energised.
Hence CG recommends following actions
• Avoid using inductive burden (e.g. isolation transformer), if

unavoidable ensure that its flux density is < 0.633 tesla (6
kilogauss)
• Ensure that actual burden does not exceeds rated values.
• In the event of fuse blowing / MCB tripping, investigate in detail.

Well damped ferro-resonance
Un-damped ferro-resonance

CVT-Routine tests
81
Routine tests as per IS / IEC standards
Reference.Standards.
• IS 3156(1992) & IS 9348 (1998)
• IEC 186(1987) ( old std ) & IEC 358(1990)
• IEC 60044-5(2004)
• IEC 61869-5(2011) Latest

Routine Tests - CVTs
1. Capacitance and tangent delta measurement at 10 kV and at rated

voltage on CC unit before PFVW test.
2. One minute power frequency withstand voltage test on CC unit.
3. Partial discharge measurement at Highest System Voltage (HSV) and
1.2 x HSV/3 while reducing voltage from one minute level.
4. Capacitance and tangent delta measurement at 10 kV and at rated
voltage on CC unit after PFVW test.
5. One minute power frequency voltage withstand test on neutral terminal
of CC unit at 4 kV.
6. Verification of terminal markings of secondary windings in EMU
7. Induced high voltage test on EMU at 150 Hz for 40 sec.
8. One minute power frequency voltage withstand test on secondary
windings, its sections and neutral end of intermediate voltage
transformer at 3 kV on EMU.

Routine Tests - CVTs
9.Accuracy check on complete CVT –

Metering Winding - Ratio error and phase angle error measurement are
carried out at 25% and 100% of rated burden and also at the
simultaneous burden if specified; at 100% of the rated voltage as per
IEC 60044-5(2004)
Protection Winding – Ratio error and phase angle error measurement
are carried out at 25% and 100% of rated burden at 5%, 150% of
rated voltage as per IEC 60044-5(2004)
10.Ferro-resonance check is performed by short circuiting secondary
terminal 3 times at 80% of rated voltage and 3 times at 150% of rated
voltage as per IEC 60044-5(2004).

CVT- Pre-commissioning tests and
monitoring during operation
85
Pre-commissioning checks
Low Voltage Ratio check

Continuity of Connections ( Inductance & Intermediate VT Compensating
Winding Terminal Connections after Accuracy Setting) & Earthing of Neutral
Leads
Continuity of Connection in Capacitor Unit.
Absence of Oil Leakage from Capacitor Unit.
NHF Terminal is either Earthed or Connected to Drain Coil , Surge Arrestor /

PLCC Unit.
"N" Neutral of Intermediate voltage transformer should be connected to

earth.

Checks during operation at site
Capacitor Unit
High Stress Zone
Risk in the Event of Oil Leakage
Do not Take Oil Sample
Do not Open / Repair at Site
Check for oil leakages / oil indicator
EMU Unit
Medium Voltage Compartment

Oil Condition Monitoring
Monitor the Temperature of Tank Body
Check for oil leakages / oil indicator

Simultaneous monitoring of CVTs in three phases
V1
V2
V3
Capacitor Divider Ratio ( V1/V2 )= [ (C1 + C2) / C1 ]
C1 = { C per Element } / Number of C1 elements.

C2 = { C per Element } / Number of C2 Elements.

Simultaneous monitoring of CVTs in three phases
Constraints in Cap. Measurement on CVT.
CC Unit
- Capacitor Divider Unit needs to be
EMU
Unit dis-assembled from EMU
- If Only "N" is disconnected ,
Capacitance Measurements
are inaccurate , due to "Cs"
Stray Capacitances.
Cs
Measurement Precision
should be Less Than
Cs +/- 10pF. ( One element
N failure causes a change of
around 17 to 35 pF ).
Cs - Stray Capacitance to Ground / Hence it is not
Earth. recommended as a regular
test.
Best alternate is to ;
- Use of Zero Sequence Relay.
- Periodically measure Voltage output of all 3 Phases simultaneously.

Thank you
90

Current Transformer: (Design, Manufacturing and Quality Checks/Tests)

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Current Transformer: (Design, Manufacturing and Quality Checks/Tests)

Hochgeladen von

Copyright:

Verfügbare Formate

Current Transformer

(Design, Manufacturing and Quality Checks/Tests)

Name : Shailesh Mahajan Division : S1 Category : General 1

Function of Current Transformer

• Transformation of Current – For e.g. 2000A to 1A.

Name : Shailesh Mahajan Division : S1 Category : General 2

• Electromagnetic Design • Insulation Design

Name : Shailesh Mahajan Division : S1 Category : General 3

Np X Ip Flux induced in the cores Is corresponding to Ns

Name : Shailesh Mahajan Division : S1 Category : General 5

Volt = 4.44 X f X Bm X Core area X Turns

Volt X Amp = 4.44 X f X Bm X Core area X Amp. X Turns

VA proportional to secondary Ampere Turns

VA = (Resistance of CT + Lead Resistance + Instrument Burden)

Name : Shailesh Mahajan Division : S1 Category : General 6

Errors in the CT output :

Np X Ip = (Ns X Is) + ( Ie X Ns)

Name : Shailesh Mahajan Division : S1 Category : General 7

Name : Shailesh Mahajan Division : S1 Category : General 8

• Stringent accuracy class (0.2s/40VA) operating

• Realistic burden values to be specified to avoid

• As ratio decreases (75/1 , 50/1) meeting stringent

Name : Shailesh Mahajan Division : S1 Category : General 9

• ISF achieved choosing operating Bm 4 to 4.5 kG

• Stringent Accuracy with ISF met using Auxiliary core.

Name : Shailesh Mahajan Division : S1 Category : General 10

• Accuracy over wide range of Primary current

• P class cores are normally operated at 17kG at

Name : Shailesh Mahajan Division : S1 Category : General 11

3) Special Protection Cores :

• Core size is decided by Bm & Turns thus core losses

Name : Shailesh Mahajan Division : S1 Category : General 12

3) Special Protection Cores :

• As the ratio increases turns increases the kPV

• Higher secondary current (5A) lesser turns and hence

Name : Shailesh Mahajan Division : S1 Category : General 13

• Core & secondary on Top

primary • Insulation on secondary

• Short length primary

Name : Shailesh Mahajan Division : S1 Category : General 15

• Type of Construction : Dead Tank

1) Eye Bolt Type

•Core& Sec. at Bottom

•Long length primary econdary

Name : Shailesh Mahajan Division : S1 Category : General 16

•Core& Sec. at Bottom

•Long length primary

Name : Shailesh Mahajan Division : S1 Category : General 17

• Type of Insulation : “ OIP “

High Quality Insulation Materials

Name : Shailesh Mahajan Division : S1 Category : General 18

Name : Shailesh Mahajan Division : S1 Category : General 19

• Voltage Gradation By Two methods –

Name : Shailesh Mahajan Division : S1 Category : General 20

Condenser Grading of CT 50%

Name : Shailesh Mahajan Division : S1 Category : General 21

2) Appropriate Shaping of Electrodes :-

Shell cross section

Sectional view of Shell Insulation

Name : Shailesh Mahajan Division : S1 Category : General 22

CT Processing – Drying & Impregnation

• Well defined Autoclave Cycles –kV Range wise

• Elaborate Drying cycle