See discussions, stats, and author profiles for this publication at: [Link]

net/publication/380518519

Design for Short Circuit Withstand Capability of a Transformer

Chapter · May 2024

CITATION READS
1 891

2 authors:

Geno Peter [Link] Alexander

109 PUBLICATIONS 937 CITATIONS

Vellore Institute of Technology University
241 PUBLICATIONS 2,264 CITATIONS
SEE PROFILE
SEE PROFILE

All content following this page was uploaded by Geno Peter on 12 May 2024.

The user has requested enhancement of the downloaded file.

Chapter

Design for Short Circuit Withstand Capability

of a Transformer

Dr. Geno Peter1, and Dr. Albert Alexander Stonier2

1CRISD, School of Engineering and Technology, University of Technology Sarawak,
Sarawak, Malaysia
2Department of Electrical and Electronics Engineering, Kongu Engineering College,

Tamil Nadu, India

Abstract

During their normal lifetime, transformers are subjected to a variety of

electrical, mechanical, and thermal stresses. One of the most critical
situations is that caused by external short circuits, which produce high
currents in the transformer windings and, hence, high internal forces in
the windings. The ability to withstand short circuits identifies the
requirements for transformers to sustain without damage the effects of
overcurrents originated by external short circuits. These forces are
potential sources of damage to transformers. In this paper, the different
parameters for the short circuit withstand capability of a transformer are
calculated considering a 1500KVA, 22KV/415V, Dyn11 Distribution
Transformer. The short circuit withstand test of a transformer cannot be
performed in the test laboratory of any manufacturer. There is a need for
high test field power, especially for large units with ratings of 100 MVA
and above. The tests can only be performed at a few powerful test
stations, such as those operated by KEMA (Netherlands), EDF (France),
CESI (Italy) or IREQ (Canada) [1]. Short-circuit tests are expensive. The
cost of the test itself is high. The cost also increases due to activities such
as transporting the transformer under test from the factory, local
installation at the test laboratory and again at the factory, untanking and
inspection, repetition of dielectric tests, etc. For this reason, the


Corresponding Author’s Email: genopeter@[Link].
2 Geno Peter and Albert Alexander Stonier

International Electrotechnical Commission (IEC) standards also permit

demonstration of the short-circuit ability using calculation and design
considerations.

Keywords: distribution transformer, windings, dielectric test, short circuit

test, thermal stress, mechanical stress, electrical stress

1. Introduction

The short circuit test is carried out to verify the integrity of short circuits
developed when short circuit current flows through the transformer. The tests
must be carried out on a new transformer before it is ready for service.
Protection accessories such as Buchholz relays and pressure relief devices
must be mounted. Routine tests must be conducted on the transformer prior to
the short-circuit test. If windings have tappings, the reactance and resistance
must be measured for the tapping positions at which the short circuit test will
be carried out [2]. There are numerous accepted methods for calculating power
transformer short-circuit withstand capability. But for distribution
transformers, for the combinations of the types of windings we are using (i.e.,
foil/enamelled wire, foil/rectangular copper, rectangular copper/rectangular
copper), there are no agreed standard methods. The most important aspect is
the strength imparted by the resin dotted paper, which is used as an inter-layer
insulation in these winding types. This insulation imparts additional strength
to the windings during processing, bonding the individual windings as a single
unit and presenting a composite structure to the short-circuit forces, rendering
the windings very capable against such forces. In the following calculations,
weight age has not been given to this aspect. Hence, the actual figures, if any,
will be much better and safer compared to the derived values. Even though the
high voltage winding is symmetrically placed with respect to the low voltage
winding, for calculations a certain asymmetry is assumed, which in reality is
not true. By the very nature of this assumed asymmetry, the calculated figures
are purely hypothetical, and since the stresses are lower even at this assumed
asymmetry, they will be much lower under practical conditions. The duration
of the symmetrical short-circuit current must be limited to avoid excessive
overheating. According to IEC 60076-5, the duration shall be 2 s, unless
otherwise agreed between the purchaser and the supplier. During this time, the
temperature in the windings must not exceed certain values specified in IEC
60076-5 when calculated using the standard’s formulas.
 Design for Short Circuit Withstand Capability of a Transformer 3

Table 1. Design Parameters

Measured Measured
Parameters Specifications
(HV Side) (LV Side)
6%
Short Circuit Impedance 6.222% ----
(Normal Tap)
Reactance --- 0.6% ----
Per unit Impedance --- 0.063 ----
Resistance per Phase at 2.49271 0.000214
---
75° Ω/Phase Ω/Phase
Winding height --- 52.8 cm 59 cm
No of Turns Per Limb --- 1221 14
Current Density of
--- 1.59 A/mm2 1.6077 A/mm2
winding
Mean Diameter of winding --- ---- 29.55cm
Copper Thickness --- ---- 0.22 cm

2. Rating of the Transformer

All electrical systems are susceptible to short circuits and the abnormal current
levels they create. These currents can produce considerable thermal and
mechanical stresses in electrical distribution equipment. Therefore, it’s
important to protect personnel and equipment by calculating short-circuit
currents during system upgrade and design. The rating of the transformer for
which the short circuit withstand capability is calculated is shown below.
Rated Power: 1500KVA
Rated Voltage (Primary/Secondary): 22KV/415V
Rated Current (Primary/secondary): 39.37/2086.81A
Short Circuit Impedance: 6%
Vector group: Dyn11

3. Calculations of the Short Circuit Parameters

3.1. Asymmetrical Short Circuit Current

Short circuit current normally takes on an asymmetrical characteristic during

the first few cycles of its duration [4]. The asymmetrical short circuit current
for the high voltage (HV) and low voltage (LV) windings is calculated.
4 Geno Peter and Albert Alexander Stonier

Isc = √2 × ( 1 + e(– π ×R⁄X) ) × ( Iph /Ez ) (1)

where,

Iph = Rated Phase Current

R = % Resistance
X = % Reactance
Ez = Per unit impedance
R/X = 0.6/6.222 = 0.0965

For HV Winding

Isc = √2 × ( 1 + e(−π×0.0965) ) × ( 22.73/0.0625)

Isc = 894.2 A

For LV Winding

Isc = √2 × ( 1 + e(−π×0.0965) ) × ( 2086.81/0.0625), where π = 3.141

Isc = 82089.5 A

3.2. Hoop Stress

The radial forces produced by the axial leakage field act outwards on the outer
winding, tending to stretch the winding conductor, producing a tensile stress
(also called a hoop stress) [5]. The hoop stress for the HV and the LV windings
are calculated.

2
σ𝑚𝑒𝑎𝑛 = K copper × (Iph × R dc ) / (Hw × Ez2 ) kg/cm2 (2)

where,

lph = Rated Phase Current

Rdc = Resistance per phase at 75°C
Hw = Winding Height
Ez = Per unit impedance
 Design for Short Circuit Withstand Capability of a Transformer 5

K copper = 0.031 × {( 1 + e(– π ×R⁄X) )/1.8}2 (3)

= 0.031 × {( 1 + e(−π×0.0965) )/1.8}2 = 0.029

For HV Winding

σ𝑚𝑒𝑎𝑛 = (0.029 × 22.732 × 2.49271)/(52.8 × 0.06252 )

= 181.1 kg/cm2 (Maximum Allowed 700 kg/cm2)

For LV Winding

σ𝑚𝑒𝑎𝑛 = (0.029 × 2086.812 × 0.000214024)/(59 × 0.06252 )

= 117.3 kg/cm2 (Maximum Allowed 700 kg/cm2)

3.3. Radial Bursting Force

In a transformer with concentric windings, the axial component of leakage

flux density interacts with the current in the windings, producing a radial force
(Fr). This is a well-known phenomenon responsible for the mutual axial
repulsion between the inner and outer windings. The radial flux component
interacts with the winding currents, producing an axial force which acts in
such a way to produce an axial compression or expansion of the winding coils
[2]. When the transformer operates under normal conditions, the forces are
small. However, during external fault situations, the currents and fluxes reach
high values, producing extreme radial forces. In general, transformers are
designed to withstand the maximum current peak of three-phase short circuits,
calculated as if the transformers were connected to an infinite busbar.

Fr = (2σ𝑚𝑒𝑎𝑛 π Iph N )/ (S × 100000) MT (4)

where,

N = No of Turns per Limb

S = Current Density of winding
6 Geno Peter and Albert Alexander Stonier

For HV Winding

Fr = (2 × 3.14 × 181.1 × 22.73 × 1221 )/ (1.59 × 100000)

Fr = 199 MT

For LV Winding

Fr = (2 × 3.14 × 117.3 × 2086.81 × 14 )/ (1.6077 × 100000)

Fr = 134 MT

3.4. Supports to Be Provided in and for LV Winding

The spacers are inserted to provide the necessary strength to the winding
against the radial forces. Every conductor has radial oil flow due to the use of
radial spacers for conductor support [6]. Spacer thickness can be changed to
allow improved cooling and decreased winding rise, or directed oil flow within
the winding can be applied to improve the effectiveness of the winding
conductor cooling [9].

N1 = (Dm / (T × N)) × √(12 σ𝑚𝑒𝑎𝑛 /E) Nos. (5)

where,

σ𝑚𝑒𝑎𝑛 = Hoops Stress in kg/cm2

Dm = Mean Diameter of winding in cm
T = Copper Thickness in cm
E = Young’s Modules for copper, which is 1.13 x 106 Pascal

N1 = (29.55/ (0.22 × 14)) × √(12 × 117.3 /1130000)

= 0.4 Nos

Here, no support is necessary. Actual support is provided in the form of a

Partinax cylinder, which is continuous. The LV cooling ducts are spaced at 19
mm (14 mm between the supports). There are 29 such stubs. Hence, support
for LV winding is more than adequate.
 Design for Short Circuit Withstand Capability of a Transformer 7

3.5. Internal Compressive Forces on Winding

The inner winding experiences radial forces acting inwards, tending to

collapse or crush it, producing a compressive stress. Due to the fringing of the
leakage field at the ends of the windings, the axial component of the field
reduces, resulting in smaller radial forces in these regions [7].

Fc = 0.034 × Sn × (Ez × Hw ) MT (6)

where,

Sn = Rated kVA
Ez = Per unit impedance in Ohms
Hw = Winding Height in cm

The internal compressive forces on the winding was found to be

Fc = 14.60 MT

Force in LV winding, Fc = 9.74 MT around (2/3) of the compressive forces

on the winding.
Force in HV winding, Fc = 4.87 MT around (1/3) of the compressive
forces on the winding.

3.6. External Axial Imbalance Force Due to Axial Asymmetry

Fa = 6.4 × (Isc × W)2 × (X/Hg ) × Lg × 10(−8/Lrg) (7)

where,

‘Isc’ is 894.2 and ‘W’ is 1221

X/Hg = Assumed asymmetry is 0.015 (1.5%)

Lg = Mean length of winding, i.e., 130.6 cm

Lrg = Hw/π + (radial depth HV + radial depth LV + H-L gap)/2 + Core to

LV clearance = 23.72 cm (Length of radial stray path)
8 Geno Peter and Albert Alexander Stonier

Fa = 6.30 MT

3.7. Tensile Stress in Tie Rod

In order to prevent deformation under short-circuit forces, windings are

compressed under the top and bottom clamping members with the help of tie
rods. The axial end thrust under fault conditions is minimised by the suitable
balance of the ampere-turns over the length of the windings. In the case of a
bigger transformer, the HV tapping leads are taken out of two positions to
balance the short-circuit forces in a much better way [6].

Pt = (Fa − 1/3Fc ) × 1000/ (Nt × At ) kg/cm2 (8)

where,

No of Tie Rods (Nt) = 4 nos

Diameter of Tie Rod (Dt) = 1.6 cm
Area of Tie Rod (At) = (𝜋/4)× Dt2 cm2
At = 2.02 cm2

Pt = (6.3 − 4.87) × 1000/ (4 × 2.02 )

Pt = 177.0 kg/cm2, Maximum Allowed 1100 kg/cm2

3.8. Bending Stress on Wooden Beam

The wooden beam is subjected to stresses while lifting the core-winding

assembly, during clamping of windings, or due to short-circuit end thrusts.
Typically, short-circuit stresses determine their dimensions. The stresses in the
wooden beam are determined from the calculated values of the short-circuit
forces acting on them.

σ𝑚𝑎𝑥 = (F × Lc )/(B × D2 /6)/n/Ncb (9)

where,

Total Axial Force (F) = (Fa − 1/3Fc) = 1430 Kg

 Design for Short Circuit Withstand Capability of a Transformer 9

Leg center or tie rod center (Lc) = 49 cm

Beam thickness (B) = 7 cm
Beam height (D) = 23 cm
No. of Jacking Points (n) = 4
No. of sections on wooden Beam (Ncb) = 4
σ max = 7.1 kg/cm2, Maximum Allowed 1100 kg/cm2

3.9. Capability of Withstanding Thermal Effects

The thermal effect of the short circuit currents on winding temperatures is

critical during a short circuit event. Fault winding currents are significantly
higher than for normal loads, and extremely high winding temperatures are
possible unless these conditions are also considered during the conductor
selection of the transformer [2]. During the short-circuit event, heat transfer
through the cooling arrangement is not considered since the thermal time
constants of the windings are much longer (usually several minutes) than the
fault duration. As a result, the winding temperatures during the fault must be
calculated.

θ1 = θ0 + 2(θ0 + 235)/A (10)

where,

A = {106000/ (J2 × t)} − 1 (11)

Normal Current Density (Jn)

Short circuit Current density (J) = Jn/Ez A/mm2
Duration of short circuit (t) = 2 Sec
Initial winding temperature (Ѳ0) = Winding Temperature + Ambient
Temperature Initial winding temperature = 65°C + 40°C = 105°C
For HV Winding

= 105+ 2 (105 + 235)/80.9

10 Geno Peter and Albert Alexander Stonier

= 113.4°C

where

A = {106000/(25.442 2)}-1

A = 80.9

This value is below the permissible 250°C as per the Standards, Hence the
cross sectional area of winding is sufficient as regards the short circuit [8].
For LV Winding

= 105+ 2 (105 + 235)/79.1

= 113.6°C

where

A = {106000/(25.72322 2)}-1

A = 79.1

This value is less than the standard limit of 250°C, indicating that the
cross-sectional area of the winding is sufficient to prevent a short circuit.

Conclusion

This design was tested on a distribution transformer rated at 1500KVA,

22KV/415V, and Dyn11. Current flows through the winding conductors,
which are situated in the magnetic leakage field. The conductors are then
subjected to mechanical forces. These forces are not static. They are pulsating.
Each time the current passes through zero, the forces are also zero. At normal
load current, the forces are small. They increase with the square of the current,
so during the high overcurrents that arise if a short-circuit in the system occurs,
 Design for Short Circuit Withstand Capability of a Transformer 11

the forces must be given attention when designing the transformer. The short
circuit current may amount to 10-20 times the rated current of the transformer,
which means that the forces in the windings may be 100-400 times larger at a
short circuit than in normal service. The forces cause large movements in the
windings. These movements are invisible to the human eye. A representative
transformer was sent to KEMA (Netherland) for the short circuit withstand
test. It is no wonder the transformer passed the test without any disturbances
created internally or externally by the transformer.

References

[1] IEC 60076-1, “Power Transformers,” Part 1: General, 2000.

[2] M. S. Naidu, V. Kamaraju: “High Voltage Engineering,” Third Edition, Tata
McGraw-Hill, 2007.
[3] IEC 60060-1, “High Voltage Test Techiques,” Part 1: General, 1989.
[4] IEEE/ANSI Standards C57. 12.00 “IEEE Standard General Requirements for Liquid
Immersed Distribution, Power, Regulating Transformers,” 2000.
[5] G. Bertagnolli, “Short - Circuit Duty of Power Transformers,” Italy, 1991.
[6] IEEE/ANSI Standards C57.123 “IEEE Guide for Transformer Loss Measurement,”
2002.
[7] ABB, “Testing of Power Transformers,” Zurich, 2003.
[8] E. Kuffel, W. S Zaengl, “High Voltage Engineering Fundamentals,” Frankfurt,
1984.
[9] Peter, Geno & Sherine, Anli & Iderus, Samat. (2020). Enhanced Z-source inverter-
based voltage frequency generator to conduct induced over voltage test on power
transformers. International Journal of Power Electronics. 12. 493. 10.1504/
IJPELEC.2020.110752.

View publication stats