CONSTRUCTION OF P OWER TRANSFORMER TANK AGAINST HIGH

SEISMIC REQUIRED RESPONSE SPECTRUM

ASEP DHARMANTO1, M SHOKEH2

ASEP.DHARMANTO@CGGLOBAL.COM, MSHOKEH@YAHOO.COM

ABSTRACT

The vulnerability of transformer construction to damage in future earthquakes, as well as an available

standards and technologies to protect against earthquake damage are reviewed. Requirement actions due to
earthquake loading high performance level seismic and refer to IEEE 693-2005 have been undertaken to check
the strength of transformer assembly. The 3D models transformer tank construction seismic analyze with Finite
Element Analysis (FEA) of dynamic response spectrum analysis using SAP2000. Result and design check the
structural strength have been undertaken to demonstrate that specified earthquake loading does not produce
unacceptable stresses in the transformer construction.

Keywords: transformer construction, high performance level of seismic, IEEE 693-2005, Finite Element
Analysis, response spectrum analysis.

1. INTRODUCTION

The Haywards electrical substation is one of national grid operator Transpower's largest substations and is a key
part of New Zealand's national electricity network. 220 kV to 110 kV interconnecting transformers at Haywards
supply the regional 110 kV network that serves much of the Wellington Region. Supply transformers at
Haywards step down voltage to 33 kV and 11 kV and provide a connection to the Wellington Electricity
subtransmission and distribution network serving the central-north Hutt Valley.

The 110/11kV transformer and the associated equipment will be installed in the threestory building and areas
subject to earthquakes, and shall be designed to withstand, in working order and without excessive
displacement, the stresses arising from the following load combinations. The existing three-story building
(Fig.2) required detailed assessment and strengthening for earthquakes up to a 2,500 year return period event.

Fig.1 Hayward Power Transformer

1) Mechanical Engineer, PT CG Power System Indonesia

2) Structural Engineer, PT Mitra Pratama Inovasi
The objective of the design of transformer resistant to earthquakes is mainly minimizing damages and preserve
electrical system, even for the most severe cases. It is desired that the structures will resist to high earthquakes
with no damage, bushing and internal connections must not be damaged to the point of failure in such an event.

2. IEEE AND HAYWARD SEISMIC QUALIFICATION

Seismic qualification tests are used to demonstrate through experimentation that a piece of equipment is able to
perform its intended function during and after an earthquake. In the U.S., electrical equipment is seismically
qualified using a standard developed by the IEEE. The IEEE standard entitled IEEE 693-2005 Recommended
Practices for Seismic Design of Substations details procedures for qualification of electrical substation
equipment for different seismic performance levels low, moderate, and high [1]. With regard above clause the
spectra shall be those defined in the consultant spectrum (Fig.3) and shall into account the critical damping of
the synchronous condenser building.

Based on client requirement seismic qualification by Finite Element Analysis (FEA) modeling is permissible for
transformers as they are too large to be tested by shake table test. Transformers shall be qualified using dynamic
response spectra FEA. The qualification response spectra shall be determined from the approved synchronous
condenser building analysis results derived from site specific spectra. The transformer model analysis shall
include all appendages and internal components [2].

Fig.2 Hayward Transformer on Three story building [3]

3. DYNAMIC MODAL RESPONSE SPECTRUM

3.1 Modals.

Modal analysis is study of the dynamic properties of structures under vibration excitation and s to seek modes of
shape of a structure and determine the natural frequency of each variety vibration of building structures by
ignoring damping. In other words the natural frequency is the frequency of the structure where the structure will
vibrate when there is outside interference.
Eigen problem

Mode superposition is dynamic response procedure that evaluates and superimposes linear vibration mode
shapes are free to characterize patterns of movement. Shape mode configuration describes natural structures
with lateral movement patterns. Structures with N degrees of freedom will have N corresponding mode shapes.
Each mode shape is independent and normalized patterns of movement that can be strengthened and excite the
resultant displacement pattern.

This procedure is used to determine the range of the vibrating structure. This method is very useful to determine
the behavior of the structure. This procedure can also be used as a base in the capital superposition time history
analysis and response spectrum. Magnitude discussed was the natural frequencies angle, mode shapes, and a
vibration period T. In the free vibration in structures having many degrees of freedom (MDOF), then the matrix
equation of motion difrensial

(1)

If the value of damping ratio is relatively small, it can be adopted in the structure of degree of freedoms with
value c = 0, then the equation

(2)

With harmonic function which { }i is eigenvector of a mass coordinate on the i-th mode,
then

(3)

(4)

Where,
[K] = stiffness matrix
[M] = diagonal mass matrix
= diagonal eigenvalue matrix
matrix of diverse vibrating direction (eigenvector) associated with eigenvalue.

each eigenvalues and eigenvectors explain mode of a vibration-free structure. Eigenvalue i-th associated
with the natural frequency i-th as follow

(5)

On the condition of movement of the foundation (ground acceleration) structures having n-degrees of freedom
will have the n-mode or pattern. Each mode will contribute to the horizontal deviation of each mass. On this
principle, the mass of the i-th deviation or Y-i can be obtained by summing the influence or contribution of each
mode. Contributions mode j of the horizontal deviation of the mass of all i is expressed as a product of ij (i th
equation and j th mode shape). The equation can be expressed in the following formula:

(6)

Where,
= vector of mass participation.

The above equation is called the participation of each mode or participation factor. Mass participation factor
providing a representation of how many parts that contributes to eigenmode, or in other terms, how much
vibration energy is dissipated through the eigenmode.
3.2 Response Spectrum

Response Spectrum is the maximum response of a structure consisting of displacement, velocity and maximum
acceleration with the natural frequency (natural period) or the amount of the desired function of a particular
burden for all possible systems single of freedom [4]. Abscissa of the spectrum is the natural frequency (or
period) of the system and the ordinate the maximum response. With the availability of spectrum response graph,
one can determine the structure of the inertia force caused by the movement of the foundation.

Fig.3 Hayward Response Spectrum

3.3 Shell and principle stress

The model of tank wall and transformer core built with shell models. A shell is a plane geometry with thickness
and combined behavior of the membrane bending plate. In a dynamic analysis, the mass of the structure is used
to compute inertial forces. The mass contributed by the Shell element is lumped at the element joints. No inertial
effects are considered within the element itself.

The total mass of the element is equal to the integral over the plane of the element of the mass density, m,
multiplied by the thickness, th. The total mass is apportioned to the joints in a manner that is proportional to the
diagonal terms of the consistent mass matrix.. The total mass is applied to each of the three translational degrees
of freedom: UX, UY, and UZ. No mass moments of inertia are computed for the rotational degrees of freedom
[5].

Fig.4 Principal Stress on Shell

4. MODELING AND ANALYSIS

The 110/11kV Hayward power transformer is composed of transformer tank, radiator, conservator, bushing,
cable box, core and coil, and mineral oil. Tank transformer sizes are 4850mm x 1750mm x 3800 mm with total
mass all parts 107 tons. Mineral oil in transformer is applied as pre stressed to the wall with two assumptions,
static condition and during vertical earthquake condition, since the transformer is filled completely with oil and
there is no sloshing effect under consideration.

Fig.5 Oil distributon pre streessed

The finite-element element package SAP2000 Version 14 is used for development of the finite-element model.
Prior to create model, it is determined property thickness of shell, area of frame and density of each part, and
then mass is calculated accordingly. All transformer parts are modeled with actual shape with shell and frame.
Wall of parts are modeled with shell 100mm x 100 mm. Core and coil are modeled with shell structures with
thickness 50 mm and it is simplified to box shape. Core-coil are supported by guider, top guider and pedestal are
modeled frame element and bottom guider are modeled with shell element. Radiator is modeled with shell
structures with thickness 10 mm and one mass radiator is 950 kg. Cross brace for supporting radiator, core and
coil and cable box use element model. Bushing and arrester use frame model.

Fig.6 Shell mesh and frame construction transformer

Transformer bushings and surge arresters are required seismic qualification method by time history shake-table
tests. Failure bushing and arrester were not encountered in this finite element method (FEM). In this FEM,
Bushing and arrester are modeled with frame and line pull load acting on the bushing and arrester is taken
2000N, however those both parts affect and experience of their supports cause of dynamic effect.

Anchoring transformer at its bottom skid plate, there are six group of anchor with six number of anchor. Anchor
defined as fix one of shell point, that it cannot be moved to three directions. Then the model that will be
simulated is a horizontal movement (Directions Directions X + Y) and vertical movements (Direction Z) of
Response Spectrum. Load combinations based on the IEEE 693-2005,

Comb 13: Dead + Impact Horizontal (Directions Directions X + Y) + Impact Vertical (Direction Z).

The value acceleration g for vertical movement is 80% from value horizontal Response Spectrum as stated in
IEEE 692-2005.

Fig.7 Flow chart of analysis Response Spectrum with FEM SAP2000

4.1 Discussion of Result.

Damping characteristics of a structure may change with the level of stress of the materials in the structure. All
levels of damping associated with this practice should be associated with levels of stresses below the allowable
material stresses mandated herein. A maximum damping value of 2% can be assumed on all equipment and
structures. Soil Site Qualification RRS-Hayward with 2% damping is used in finite element. Process of analysis
finite element are monitored namely output mass participation, period and frequency, maximumminimum shell
stress and axial force (stress) of frame. In this analysis mass participation percentage sumUX, sumUY and sum
UZ was reached above 90 percent at mode number 170.

a. Shell tank transformer.

Two type materials steel constructions are used St37 with allowable stress 144 MPa and St52 with allowable
stress 207 MPa. Based on limitation under allowable stress if there are high stress, the construction of tank
transformer to be modified with some supporting and gusset for strengthen. Then cycle process finite element
process to be repeated from the first. The output shell stresses are table S11, S22 and S12. Then the principal
stress can be gained through formula

(7)

(8)
Based on Fig.4, where,
S11 = Direct stress acting on the positive and negative 1 faces in the X-axis direction.
S22 = Direct stress acting on the positive and negative 1 faces in the Y-axis direction
S12 = Shear stress acting on the positive and negative
 Table 1 Ouput SAP2000-Critical Shell Stress

The output table S11, S22 and S12 was modified with Excell sheet to get Principal Stress. Common
constructions tank transformer use mild steel construction with Yield Stress 240 MPa. If there are stress between
144 MPa to 207 MPa, plates are used ST52 steel construction. And if stress higher than 207 MPa, the thickened
plate is needed, followed by finite element process again. Tank wall thickness is modified from 12 mm to 16
mm. Conservator support is added with support channel H beam from cover as Fig.8.

Fig.8 Shell tank analysis model and application construction

b. Frame Cross brace.

Radiator position is to be made stiff and applied with channel L beam cross brace in every top and bottom
radiator. The core coil assembly is supported by six H beam support to HV and LV wall. These cross braces and
supports should able against axial force. The output of frame in SAP2000 is axial force, it can be compressive
force or tensile force. The axial compressive force (P) could make the cross brace slenderness or buckling. The
ratio (R) shall be larger than 1. R is comparison between allowable stress (Fa) and compressive force (P) divide
section area(A). The equation R is follow:

(9)

(10)
 (11)

(12)
Where,
E = Modulus of elasticity
Fy = Yield Strength
L = Length of beam
K = Effective length factor
r = radius of gyration
Cc = Column buckling / Slenderness ratio
Fa = Allowable stress
A = Section area of column beam
P = Compressive Force from SAP2000 output.

Table 2 Slendeness Ration of frame cross brace

Fig.9 Frame cross brace analysis model and application construction

c. Joint Anchor bolt

According IEEE693 static calculation for anchor bolt based on Hayward horizontal (SA) 1g then multiple with
static factor 1.5 then value horizontal acceleration to be 1.5g. Vertical acceleration is 80 percent from horizontal
acceleration, so static vertical acceleration to be 1.2g.

On this analysis output finite element for natural frequency on the first mode is 16.37 Hz, if see Fig.3 the first
natural frequency of transformer already pass the maximum g max of Response Spectrum. Anyhow this
frequency 16.37, transformer still at above high position of 1g RS.

From result the output table joint reaction, we can check the appropriate anchor type based on their allowable
tensile and shear stress of anchor, by this following formula (13). At this analysis the result ratio between forces
and allowable forces of anchor bolts under value 1.
 (13)

Where,
F1 = Horizontal Force X direction from table Joint Reaction.
F2 = Horizontal Force Y direction from table Joint Reaction.
F3 = Vertical Force Z direction from table Joint Reaction.
Fv = Allowable Shear Force of Anchor Bolt.
Ft = Allowable Tensile Force of Anchor Bolt.

Table 3 Output SAP2000-Joint Reaction Forces and Moment

Table 4 Ratio Strength of Anchor Bolt

Fig.10 Joint analysis for anchor bolt

d. Bushing
Bushing is not analyze in Finite Element and to be tested in manufacturer site. Bushing material is composite
silicone insulator. The shake table test configuration of the Oil-outdoor bushing for transformers is given with
Fig.11. The bushing has been installed in the mounting position 20 from vertical. The mounting frame has
natural frequencies above the seismic frequencies and above all natural frequencies of the bushing. All force and
acceleration impacts were carried out at the flange of the bushing. According to the standard IEEE 693-2005 an
additional weight of 7 kg was installed at the upper air end. Qualified to High Seismic Performance level with
2g ZPA of the Required Response Spectrum (RSS). According to D.4.4 of IEEE 693-2005 this is four times of
A.1 (high RSS). The bushing passed the shake-table test without any modification. No physical damage from
testing could be found at the bushing by visual inspection after the test runs[9].
 Fig.11 Bushing shake table test
5 CONCLUSION

Finite Element with Response Spectrum Analysis can calculate natural frequency, mode of shape, normal and
shear stress of each shell, forces in joint and frame. The finite-element method is employed to perform an
analytical study to better quantify the construction of transformer. Furthermore the results of the finite-element
analyses and those of prior work are used to develop a proper model to investigate the appropriateness of
assembly tank transformer base on high seismic environment.

6. REFERENCES

[1] IEEE 695-2005 : IEEE Recommended Practice for Seismic Design of Substations.

[2] Transpower New Zealand Ltd, Seismic Policy, TP.GG 61.02, Issue 2, April 2009.

[3] K. Grinlinton, D. Wood, F. Ayan and P. Clayton, Seismic strengthening of the Synchronous Condenser
Transformer Building at Haywards, PCEE -2011.

[4] SR. Singiresu, Mechanical Vibration, Prentice Hall Fifth Edition, 2010.

[5] SAP2000 Version 14, Integrated Finite Element Analysis and Design Structures, Basic Analysis
References, 2009.

[6] Selahattin Ersoy, Seismic Response of Transformator Bushing Systems And Their Rehabilitation Using
Frictional Pendulum System, Civil Engineering, New Jersey Institute of Technology, January 2004.

[7]Reyolando MLRF, Dynamics of Civil Structures Under Seismic Excitation, Brazilian Conference on
Dynamics, June 2010

[8] C.G. Salmon and J.E. Johnson, Steel Structures, Design and Behavior, 1996.

[9] HSP Hochspannungsgerate Gmbh,Seismic Test Qualification Report-RIP Condenser Bushing, 2010.