e-TRAFOTECH 2020 Conference

SPECIFICATION ENHANCEMENTS FOR RELIABILITY

AND ALIGNMENT WITH LATEST STANDARDS

Shashank Kulkarni
SIEMENS Ltd

e-TRAFOTECH 2020, New Delhi, INDIA

 Need for
Specification Enhancement
• Age old specifications, (e.g current & flux density limts)
• Revision in National / International standards
• Relaxed qualifying criteria, (e.g SC criteria)
• Differential evaluation criteria, (Different capitalization)
• Lack of transparency in data base of failures analysis
• Site quality inconsistency, (Leakages, short supply)
• Outdated design and manufacturing technology
• High failure rate (Test field enhancements)
• High capacity in transformer factories
• Low profitability for long term viability
• High import content,
• High cost reduction pressures
• Limited sub-vendors
e-TRAFOTECH 2020, New Delhi, INDIA
 1. Additional Specification
Requirement
• No capitalization, Instead maximum Load losses + I2R loss fixed
• Instead of generalized specification, specific numerical values shall be
mentioned wherever possible. e.g.
o limits of current density (≤3A/mm2) & flux density (≤1.73T).
o Nomenclature of CRGO as per IS 3024
o Densities of insulation material (pressboard min 1.15gm/cm3, min
paper 0.75gm/cm3 etc.)
o Thickness of DFT >155 µm
• Effect of global warming on temperature limits
o Max. Ambient temp in some parts of India reaches upto 55 °C
o Top oil Rise reduced from 50°C to 45°C
o Average winding rise reduced from 55°C to 50°C
o Hot Spot rise is reduced from 66°C to 61°C
o Tank hotspot limit 110 °C added to limit gassing in oil

e-TRAFOTECH 2020, New Delhi, INDIA

 2. Adherence to
Latest Standards
• Stringent Bushing Tan ɗ value (≤0.005) are specified over IEC 60137

• Dry power frequency withstand voltage of Transformer bushings shall be

approx. 10% higher than winding insulation level & that of other
bushings

• Switching impulse withstand voltage for 220kV class winding was not
mentioned in some of the utility specification

• Abnormal Operating conditions shall be included in specification

• IEC 60076-2 guideline shall be followed for number of Fiber Optic

Probes

e-TRAFOTECH 2020, New Delhi, INDIA

 3. QR for Short Circuit
Proof Design
• Similarity with reference transformer for SC proof design must be checked
as per IEC 60076-5 Annex B.
• However often there remains some ambiguity in interpretation of this
standard.
• We propose following categories to compare similarity.
o Cat A: change in some materials does not affect the short circuit
performance. E.g bushings, CRGO grade, external cooling & accessories
– No need for additional checks
o Cat B: change in these aspects may affect the short circuit performance.
E.g. MVA, impedance, losses, internal cooling (OD), Type of operation,
three limb to five limb core
– Additional calculations during Design review to be checked.
o Cat C: Changes in these parameters are not acceptable from SC point of
view. E.g. Change in manufacturing practices, single limb OR 2 limb
designs, All other categories not fitting in definition of similar transformer. –
Not acceptable from SC point of view
e-TRAFOTECH 2020, New Delhi, INDIA
 4. Manufacturing Facility &
Process
• Step Lap Core instead Mitered core is proposed
• Dust Free environment in winding area.
• Preferred to have facility to measure particle count in oil
o 1000 particle/100 ml; particle size ≥ 5 µm.
o 130 particle/100 ml; particle size ≥ 15 µm
• Due point mesurément after 24 hours of dry air filling is proposed.
o -38°C at 20°C ambient temperature
o -36°C at 30°C ambient temperature
o -30°C at 40°C ambient temperature

e-TRAFOTECH 2020, New Delhi, INDIA

 5. Test Lab Specification
• As per latest IEC 60076-3, IVPD is a routine test for Um>170kV

• background PD level should not exceed 50 pC

o measurement of PD at high frequency above 1MHz shall be avoided
o EHV lab for FAT must have valid NABL accreditation of IEC 17025:2005
o Low background PD are achievable with electrostatically shielded EHV lab.
o manufacturer shall have high voltage and high current filters to reduce
background PDs

• Measurement of accurate losses during (FAT)

o Winding resistance meter with accuracy of +/-0.05% for scale of 100 mΩ
o Power Analyzer calibrated at low power factors of Unity PF

e-TRAFOTECH 2020, New Delhi, INDIA

 6. Digitization & Cyber security
• Use of Industry 4.0 revolution for asset management using IoT, digital twin &
cloud-based computing
• It is recommended to have following minimum measuring facility:
o Oil level Indicator
o Oil Temperature: PT100
o Winding current with current transducer for 4-20mA output.
o GPS location
o Digital thermal image of transformer with Hotspot information
o Overload capability calculation
o Residual life of transformer
o Integrated DGA with H2+Moisture measurement
o Integrated bushing tan delta measurement
• There are various cyber security standards are suggested in the paper

e-TRAFOTECH 2020, New Delhi, INDIA

 Thank You

e-TRAFOTECH 2020, New Delhi, INDIA