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Comparative Study of Grain Oriented and Non - Oriented Electrical Steels in Magnetic Shunts of Power Transformers
Comparative Study of Grain Oriented and Non - Oriented Electrical Steels in Magnetic Shunts of Power Transformers
Comparative Study of Grain Oriented and Non - Oriented Electrical Steels in Magnetic Shunts of Power Transformers
Ixtapa, Mexico
Abstract—This paper presents a comparative study of the use magnetic devices depending on their magnetic and electrical
of grain oriented electrical steels (GOESs) and non–oriented properties. On the other hand, GOES laminations are mainly
electrical steels (NOESs) in magnetic shunts of power utilized to manufacture power transformer and distribution
transformers. The electrical steels are analyzed and compared in
magnetic shunts of a real 190 MVA three–phase, three–legged
transformers where low power losses and high magnetic flux
power transformer. 3–D finite element (FE) simulations are densities are required and desired [1]-[3]. GOESs present high
carried out to evaluate the stray loss and thermal impact of the permeability and low iron losses in rolling direction of the
GOES and NOES shunts in the power transformer. The shunts laminations and NGOESs present the same magnetic
are modeled utilizing their magnetization properties and the properties in any lamination direction. For example, some
structural elements of transformer are modeled utilizing surface GOESs present relative permeabilities between 50,000 and
impedance boundary conditions. To validate the simulation
results the load losses are measured and estimated without and
70,000 compared with some NOESs which present relative
with magnetic shunts and they are compared with FE simulation permeabilities between 4,000 and 10,000 in the same rolling
results. A difference of 9 % is calculated between measurements direction of laminations [4], [5]. Furthermore, the NOESs are
and simulations of stray losses in transformer with shunts. approximately 20–25 % cheaper than the GOESs and it can
Finally, a cost analysis is carried out to compare the material and lead to a significant saving of material costs in power
manufacturing costs of GOES and NOES shunts. The NOES transformers. Table I shows some common properties of
shunts produced 9 % more stray losses, 80 % more eddy current
losses, and they increased 2 % the weight of transformer
NOESs and GOESs: mass density ms, electrical conductivity
compared with GOES shunts. A maximum material cost σs, and lamination thickness tk [4], [5].
reduction of 26 % is obtained using NOES shunts. The
transformer did not present temperature problems with the use TABLE I. PROPERTIES OF GOESS AND NOESS
of NOES shunts. The results presented in this paper show that Electrical Steel σs (S/m) tk (mm) ms (kg/m3)
6
NOES shunts are as effective as conventional GOES shunts in M–3 (GOES) 1.96×10 0.23 7,650
reducing the stray losses, temperature, and costs in power M–4 (GOES) 1.96×106 0.27 7,650
transformers without putting in risk their operation. M–5 (GOES) 1.96×106 0.30 7,650
M–6 (GOES) 1.96×106 0.35 7,650
M–10 (NOES) 1.85×106 0.35 7,600
Keywords — power transformer; stray loss; non–oriented
M–15 (NOES) 2.00×106 0.35 7,650
electrical steel; grain oriented electrical steel; magnetic shunt; hot– M–22 (NOES) 2.00×106 0.47 7,650
spot M–36 (NOES) 2.32×106 0.47 7,770
M–47 (NOES) 2.70×106 0.64 7,750
I. INTRODUCTION
Non-oriented electrical steels (NOESs) and grain oriented Generally, the magnetic shunts utilized in power
electrical steels (GOESs) are employed to manufacture transformers are made of GOES laminations, which offer low
hundreds of electromagnetic and magnetic devices for reluctance paths to the stray flux produced by transformer [1],
different applications and industries around the world. NOES [2]. The magnetic shunts avoid the penetration of the stray
laminations are mainly utilized to build rotating electrical flux in steel structural elements of power transformers to
machines, small transformers, and other electromagnetic and prevent the induction of high eddy currents and the production
of high temperatures or hot–spots [1], [2]. Fig. 1 shows a with a shunt system made of alloy laminations. The material
photo of magnetic shunts used in tank walls of a 30 MVA cost of both systems was compared. The cost of the alloy
transformer. As we mentioned above, the GOESs offer high shunts is twenty four times more expensive than NOES shunts
permeability and low iron losses and for this reason, the [10]. Dobzhanskyi et al. proposed the use of NOES shunts in
transformer manufacturers prefer to use GOES shunts in transverse flux machines. Transverse machines with NOES
power transformers, but to the best of our knowledge, in the shunts demonstrated better performance than the machines
past some transformer manufacturers in United States of without magnetic shunts. Authors found that NOES shunts
America utilized NOES shunts in shell–type power reduce the cogging torque and improve the magnetic flux
transformers. Some manufacturers and designers remain distribution in the transverse machines [11]. Finally, authors
skeptical about the use of NOES shunts in power transformers. found that NOES shunts increase the weight of the transverse
For this reason, it’s important to evaluate and to compare machines and complicate the manufacturing process.
GOES and NOES shunts in power transformers to know their In this paper, GOES and NOES shunts are analyzed and
advantages and disadvantages. compared in a real 190 MVA three–phase, three–legged
power transformer utilizing 3–D finite element (FE)
simulations. The tank walls of power transformer are shielded
with GOES shunts [12], [13]. FE simulations are performed to
calculate stray losses in the structural elements of transformer
under an increment in the load of the transformer of 12 %
(overload condition = 228 MVA). The magnetization curves
in the rolling direction of the electrical steels are employed to
model the magnetic shunts. The stray loss and temperature
impact of the use of NOES and GOES shunts in tank walls of
power transformer is presented, evaluated, and compared.
Finally, a cost analysis is presented to compare the use of
GOESs and NOESs in shunts of power transformers.
The main novelty of this paper is to demonstrate the
effectiveness of the use of GOES and NOES shunts as
practical options to reduce stray losses and temperature
without putting in risk the integrity and operation of power
transformers.
The value of electrical conductivity of the low carbon steel transformer. Fig. 4 shows the stray loss density distribution in
depends on its operating temperature [19]. Temperatures the tank with shunts. In this figure, one can see a significant
between 80°C and 100°C are expected in the transformer for reduction of stray losses in the tank when magnetic shunts are
overload operation. An electrical conductivity σcs = 5.8×106 employed. A difference of 9.1 % is calculated between the
S/m is utilized in the clamps and tank for a maximum stray loss calculated in simulation and the stray loss measured
temperature of 100°C. in transformer (8.20 kW), see Table II.
The skin depth effect is defined as the depth below the
surface of the material at which the electromagnetic wave is
reduced to 1/e ≈ 0.37. In this case, the skin depth δcs for the
low carbon steel material is given by:
1
δ cs = (5)
π f σ cs μ rcs μ o
π f μ rcs μ o
Ps =
4σ cs S H t • H t*dS (6)
where Ht is the tangential magnetic field, H t* is its conjugate, Fig. 4. Stray loss density distribution (in W/m2) in tank with shunts.
and S are the surfaces of the structural elements of
transformer.
III. STRAY LOSS IMPACT OF GOES AND NOES SHUNTS
Some researchers have demonstrated the effectiveness of
surface impedance boundary conditions in the computation of Four GOESs and five NOESs are analyzed in the magnetic
losses in structural parts of transformers [20]-[22]. shunts of the power transformer. The magnetization curves in
rolling direction are utilized to model the different GOES and
E. Transformer without Magnetic Shunts NOES in the magnetic shunts of the transformer.
A total stray loss Ps = 79.173 kW is calculated in the Table III show the stray losses calculated in the
structural elements of transformer without shunts. A stray loss transformer utilizing GOES and NOES shunts in the
Ps = 71.268 kW is calculated in the tank of power transformer. transformer. This table includes the case for transformer
Fig. 3 shows the stray loss density distribution in the tank without shunts. From this table one can see that stray losses in
without shunts. A difference of 2.5 % is calculated between the core clamps do not change significantly with the use of
the stray loss calculated in FE simulation and the total stray NOES and GOES shunts in tank walls. In addition, one can
loss measured in transformer (81.20 kW), see Table II. see that eddy current losses increase five times in the NOES
shunts compared with the eddy current losses in GOES shunts.
F. Transformer with Magnetic Shunts
From this table, one can see that the stray losses in the tank
A total stray loss Ps = 7.447 kW is calculated for the power increase for NOES shunts compared with GOES shunts. The
transformer with M–5 shunts. A stray loss Ps = 3.933 kW is stray losses in the tank increase a maximum of 9 % with the
calculated in the tank and a total eddy current loss Peddy = use of NOES shunts. One can obtain a maximum stray loss
1.377 kW is calculated in the shunts. A stray loss reduction of reduction of 91.13 % using GOES shunts and using NOES
94.5 % is obtained utilizing shunts in the tank walls of shunts one can obtain a maximum stray loss reduction of
2018 IEEE International Autumn Meeting on Power, Electronics and Computing (ROPEC 2018). Ixtapa, Mexico
88.44 %. It indicates that GOES shunts are 2.7 % more necessary to compute the temperature in the tank for M–47
efficient than NOES shunts. shunts to verify a possible presence of hot–spots or high
Fig. 5 shows the eddy current loss distributions in M–3 temperatures in the tank (T > 140°C) under overload condition
shunts and in M–47 shunts. From this figure one can see that (228 MVA). Hot–spots degrade the transformer oil and
there is a higher concentration of eddy current losses for M–47 produce serious failures in power transformers [22].
shunts compared with the eddy current losses for M–3 shunts. 3–D FE thermal simulations are carried out to compute the
M–47 shunts presented 80 % more eddy current losses than temperature distribution in the tank walls of the power
M–3 shunts. transformer. The methodology proposed in [22] is utilized to
compute the temperature in the tank walls of the transformer
TABLE III. STRAY LOSSES CALCULATED FOR GOES AND NOES SHUNTS utilizing thermal convection boundaries. The stray losses
IN POWER TRANSFORMER
Stray loss
obtained in the FE electromagnetic analysis are utilized in the
Magnetic Clamps Tank Shunts Total
Shunts (W) (W) (W) (W) reduction FE thermal analysis like heat sources to compute the
71,268
temperature distribution. Convection boundaries are
No shunts 7,905 − 79,173 −
M–3 2,095 3,769 1,159 7,023 91.13 % collocated in the surfaces of tank walls [22]. These boundaries
M–4 2,070 3,742 1,282 7,094 91.04 % require a heat transfer coefficient and a top oil temperature
M–5 2,137 3,933 1,377 7,447 90.59 % [23]. A heat transfer coefficient is calculated using the theory
M–6 2,067 3,742 1,566 7,375 90.68 %
4,091 2,764 88.44 %
of a vertical plate immersed in an oil medium [23]. A top oil
M–10 2,300 9,155
M–15 2,303 4,066 3,205 9,574 87.91 % temperature of 100°C for transformer overload condition is
M–22 2,358 4,180 3,622 10,160 87.17 % assumed. The properties of transformer oil at 100°C are
M–36 2,304 4,046 4,056 10,406 86.86 % shown in Table IV [24], [25].
M–47 2,291 4,096 5,817 12,204 84.59 %
TABLE IV. TRANSFORMER OIL PROPERTIES AT 100°C
Property Value
Mass density (mcs) 835 kg/m3
Thermal conductivity, (kcs) 0.1253 W/m°C
Kinematic viscosity, (υ) 2.87×10–6 m2/s
Prandtl number, (Pr) 41.75
Coefficient of thermal cubic expansion, (β) 8×10–4 °C–1
Temperature difference between tank and oil, (ΔT) 10°C
Standard Gravity, (g) 9.81 m/s2
Height of tank walls, (l) 4.2 m
different lamination directions [26]. For rolling and transverse Table VI shows the cost reduction of the use of NOES
direction, electrical steels present a thermal conductivity of shunts instead GOES shunts. In this table one can see that the
21.0 W/(m·°C) and a thermal conductivity of 3.3 W/(m·°C) is use of NOES shunts reduces the material costs compared with
presented in normal direction (in the lamination stacking the use of GOES shunts in the power transformer. For
direction) [26]. Fig. 7 shows the temperature distribution in example, a maximum saving of 26.32 % can be obtained if
the M–47 shunts of power transformer. An average one utilizes M–47 shunts instead of M–3 shunts in the
temperature T = 102°C is calculated in the M–47 magnetic transformer.
shunts of the transformer. There is not presence of hot–spot or Furthermore, labor and energy costs do not change
high temperatures in the power transformer. significantly in the manufacturing process of GOES and
NOES shunts. During the lamination cutting process the labor
and energy costs are not affected, but during the lamination
stacking process the labor costs and manufacturing times can
be reduced between 5–10 % when workers stack NOES
laminations which have a greater thickness than the GOES
laminations.
Finally, the welding process costs of NOES and GOES
shunts are not increased.
TABLE VI.
PERCENTAGES OF TOTAL SHUNT COST REDUCTION
(COMPARISON OF THE USE OF NOESS INSTEAD GOESS IN SHUNTS)
M–3 M–4 M–5 M–6
Moreover, NOES shunts increased 9 % the stray losses in shielding: numerical analysis and experiments,” IEE Proceedings–
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