Maintaining Short Circuit

Strength in Transformers
Second Annual
Weidmann-ACTI Conference
November 12, 2003

Thomas A. Prevost
EHV Weidmann Industries Inc.

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Group

Short Circuit Withstand Capability

A key factor throughout transformer life is the ability to
withstand short circuits.
Severe radial and axial forces can damage the insulation
integrity and deform windings.
Windings are pre-loaded to a pressure at least as high as the
maximum calculated axial short circuit force.
Tight windings mitigate short circuit damage due to
movement of the conductors.

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Group

F Clamping Pressure = f(moisture,temperature,age)

F

transformer
winding
coil

pressboard
presspaper
copper

F
rigid clamping distance
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Group

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Group

copper 12 x 3, R 1 mm
Kraft paper insulation 1 mm
pressboard spacer 2 mm

40

25

25

Spacers (2 mm thick) interspersed with paper insulated

copper conductor disk segments. Apparent pressed area: 625 mm2.
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Test-devices, with model-1 (left) and model-2 (right). The

models are processed under a constant pressure of 5 N/mm2
prior to assembly in the device.
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Variation of Spacer Thickness During Processing

112
110

<-- 7 Days-->

Spacer Stack Height (m m )

108
106
104
102
100
98
96
94
As-Is ( 6% m/c, 1 N/mm^2)

Compressed ( 6 % m/c, 10
N/mm^2)

Vacuum Dried (10 N/mm^2)

Oil Impregnated (10 N/mm^2)

Effect of coil processing on the thickness of a 100 mm stack of

Transformerboard spacer material. Material was vacuum dried for 7
days at 0.5mbar under a load of 10 N/mm2.
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Effect of Temperature
At the moment the test temperature increases to 60C (450 hours), a
sudden increase in pre-load pressure was observed resulting from
dimensional expansion of the components of the test-devices, due to the
different material expansion coefficients.
Pressboard: pb 4510-6/K
Steel:
st = 1010-6/K
Copper:
cu = 1710-6/K
When cellulose replaced by a 30 mm high stack of silicate glass, the
clamping force decreased from 1.58 to 1.04 kN at a temperature
increase from 23 to 60C.

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9.0

Pressure (N/mm) and temperatu

8.5

8.0

Air temperature

7.5

Board temperature
Pressure
7.0

6.5

6.0

5.5

5.0
0

10

Time (minutes)
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Group

9.0

Pressure (N/mm) and temperature (C/10

Air temperature
Board temperature
8.5

Oil temperature
Pressure

8.0

7.5

7.0

6.5

6.0
0

Time (minutes)

8
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10
Group

Model Deg. C

Oil Deg. C

Pressure

25

25

No Change

80

25

Decrease

25

80

Increase

80

80

No Change

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p re s s u re
(N /m m )

fo rc e (k N )
m o is tu r e (% )

7
6
5

4
3

4
3
2

2
1

1
0

0
0

10

20

m o d e l- 1 ( s p a c e r s )

30

40
tim e (h )

50

60

70

m o d e l- 2 ( s p a c e r s a n d c o n d u c t o r s e g m e n t s )
m o is tu r e

Clamping force and moisture content versus time for the non-oiled
models.
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WEIDMANN

SK21600WP1

Schematic of 550 kV BIL core and coil layout.

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Clamping Pressure vs Temperature

6
5.5
5
Pressure (N/mm^2)

4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
-20

20

40

60

80

100

Tem perature (Deg. C)

Variation in static clamping pressure

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Effects of Aging
Over the life of a transformer the cellulose insulation will be
subjected to thermal cycles which cause aging of the cellulose
material.
We have found in recent tests that the aging of cellulose material
has an even more pronounced effect on the thickness of material
under pressure.
Pronounced dual effect of material decomposition from
degradation of the cellulose polymer (de-polymerization) and
from the settling of the material due to pressure.

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Aging of Pressboard Under Compression

Spacer Stack Height (mm)

102
100
98
96

135 Deg. C

94

150 Deg. C

92
90
88
0

50

100

150

200

250

300

Aging Tim e (Days)

Effect of aging on the thickness of a stack of Transformerboard.

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Initial Value
DP

1190

135 C

150 C

164

152

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11

100C

10

Pressure (N/mm) and temperature (C/10)

Air temperature
7

Board temperature

60C

Pre ssure

20C

design pressure 2.5 N/mm2

0
0

10

Time (days)

Model was pre-dried under constant pressure of 5 N/mm^2

The daily load cycling shoes an oscillation of the clamping pressure from 2 to 4 N/mm^2
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Group

11

100C

10

Pressure (N/mm) and temperature (C/10)

Air temperature

Board tempe rature

6

60C

Press ure

design pressure 2.5 N/mm2

20C

0
0

10

Time (days)

Model was Pre-dried with no pressure.

The loss of pressure during the first load cycle is significant.
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Group

Conclusion
Units in Manufacture
Power transformers must be clamped to a pressure at least as
great as the maximum anticipated short circuit force.
Spacer material should be of pure high density cellulose with
the surfaces milled to avoid excessive compression set.
Winding spacer material should be pre-stabilized by drying
under pressure.
It is critical that the insulation structure is thoroughly dried
and oil impregnated prior to applying final pre-load pressure.
The effect of oil impregnation on the decease in pre-load
pressure has been found to be caused by thermal contraction.
It is best to pre-load the transformer at 30C to 50C to
assure the windings have a proper pre-load force over the
operating range of the transformer.
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What Does this Mean to My Transformers in Service?

Effects of Moisture
Moisture is a by-product of aging of cellulose insulation.
An increase in moisture will result in an increase in clamping
pressure.
An increase in moisture degrades the insulation strength of the
insulation system.
Dryout of the insulation will lower the clamping pressure.

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Group

What Does this Mean to My Transformers in Service?

Effects of Temperature
Cellulose has a TEK three times greater than copper or steel.
An increase in temperature will result in an increase in
clamping pressure.
Daily load cycles will result in oscillations in the clamping
pressure.
A transformer will have a better chance to withstand a short
circuit when heavily loaded.

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What Does this Mean to My Transformers in Service?

Effects of Aging
Many utilities now operate above nameplate at the peak of the
load cycle and keep insulation loss-of-life below a daily limit of
0.05%.
As the transformer insulation material ages the clamping
pressure decreases.
Moisture is a by-product of insulation aging.

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 Field Processing of Transformers

On units with high moisture, the moisture tends to hide the
loose winding problem, until such time as the unit is
reprocessed.
Due to todays higher transformer loading practice and in
order to prolong transformer life, more frequent monitoring
and oil processing in the field is now required.
Removal of moisture improves the overall dielectric system
and extends insulation life. Unfortunately, it can have a
detrimental effect on the remaining pre-load pressure of the
transformer windings.

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 Field Processing of Transformers

To assure sufficient clamping pressure inspection and

tightening in the field may be required.
Processing prior to inspection assures that the pressure
remaining on the windings is representative of the operating
conditions.
If tightening is found to be necessary, pressure should be
applied uniformly over the windings, and tightened as
quickly as possible after reprocessing to avoid uptake of
moisture.

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