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Converting wind energy to electrical power is the fastest growing segment of the US energy sector.
Today, wind energy represents less than 5% of the US electrical generation and is targeted to reach 20%
in the foreseeable future. For this to happen, new sites need to be developed in spite of a down turning
economy.
Bolstered by available federal stimulus dollars, we are seeing a virtual modern day 'land-rush'. In the
words of one industry leader, 'if there is a site that has a viable wind profile, access to network
connections, and access for delivery of materials, and we don't develop it, some one else will.'
This head long rush to install more and more wind turbines has outstripped the usual developmental
learning curve, where new technologies mature by a process of trial and error, resulting in defining
equipment suited for the job at hand.
The added economic pressure of today's market has made an already competitive market even more
demanding. This has, in the view of many industry insiders, resulted in purchasing decisions for
equipment based largely on the lowest initial cost solutions and not solutions that will provide the best
choice in terms of total cost of ownership, network stability, less down time and lost revenue from high
maintenance issues. This is nowhere as apparent as in the case of Wind Turbine Generator (WTG)
transformers.
Historically this WTG transformer function has been handled by conventional, 'off the shelf' distribution
transformers, but the relatively large numbers of recent failures would strongly suggest that WTG
transformer designs need to be made substantially more robust. The practice of using conventional 'off
the shelf' distribution transformers as a low cost solution is folly. In some cases site operators are
maintaining a quantity of spare transformers to combat the frequent outages caused by standard
distribution transformers being used where they are not suitable.
The role of the Wind Turbine Generator (WTG) transformer in this process is critical and, as such, its
design needs to be carefully and thoughtfully analyzed and reevaluated.
Transformer Loading:
Wind turbine output voltages range from 480 volts to 690 volts. The turbine output is transformed, by the
WTG transformer, to a collector voltage of 13,800 to 46,000 volts. The turbines are highly dependant
upon local climatic conditions; and this can result in yearly average load factors as low as 35%. The
relatively light loading of WTG transformer has a favorable effect on insulation life but introduces two
unique and functionally significant problems.
The first problem is when lightly loaded or idle, the core losses become a more significant economic
factor while the coil or winding losses become less significant. Typically used price evaluation formula
do not apply to this scenario. NEMA TP1 and DOE efficiencies are not modeled for the operational
scenario where average loading is near 30-35% and, consequently, should be cautiously applied when
calculating the total cost of ownership for WTG transformers.
The second problem is that the WTG transformer is subjected to frequent thermal cycling as a function of
varying turbine loads. This causes repeated thermal stress on the winding, clamping structure, seals and
gaskets. Repeated thermal cycling causes nitrogen gas to be absorbed into the hot oil and then released
as the oil cools, forming bubbles within the oil which can migrate into the insulation and windings to create
hot spots and partial discharges which can damage insulation. The thermal cycling can also cause
accelerated aging of internal and external electrical connections.
2
Harmonics and Non-Sinusoidal loads:
WTG transformers are switched with solid state controls to limit the inrush currents. While potentially
aiding in the initial energization, these same electronic controls contribute damaging harmonic voltages
that, when coupled with the non-sinusoidal wave forms from the turbines, cannot be ignored from a
heating point of view. When a rectifier/chopper system is used, the WTG transformer must be designed
for harmonics similar to rectifier transformers, taking the additional loading into consideration as well as
providing electrostatic shields to prevent the transfer of harmonic frequencies between the primary and
secondary windings.
Conclusions:
The role of WTG transformers in today's wind generation scheme is unique; it's design must be equally
unique and robust. Don't trade long term reliability and lower total cost of ownership for low initial cost