NAME :

Dr. Karsten Viereck

COUNTRY :
Germany
REGISTRATION NUMBER : 1740

GROUP REF. :
PREF. SUBJECT :
QUESTION N :

A2
2
1

Vacuum switching technology

A part of an environmentally friendly transformer
I.

INTRODUCTION

Power grids for electrical energy supply are highly dynamic networks, utilising power
transformers to regulate and control the power flow. Regulated power transformers are
equipped with on-load tap-changers (OLTCs) to change their ratio and, subsequently, adapt
the transformer output voltage to the respective conditions. This enables the power supply
network to be kept stable under changing load conditions. Tap-changers are sophisticated
mechanical devices which also must adapt to high-voltage conditions. This combination
makes them unique components in energy supply technology.
The application of vacuum switching technology allows the enhancement of maintenance
intervals. In the same way DGA will become more importance in combination with intelligent
condition based monitoring to detect electrical problems.
In terms of life cycle assessment on-load tap-changer monitoring is an appropriate tool to
fulfill the requirements of the user (i.e., to use the operating equipment more efficiently).
Accordingly, the tap-changer monitoring system provides the basis for the following features:

diagnostics
life cycle assessment
early detection of faults
increased reliability of operating equipment
flexible use of monitoring equipment
reduction in maintenance costs

Also included is the use of monitoring systems for tap-changers in transformers to meet the
special requirements of the transformer environment.
The combination of the monitoring system with an integrated expert system provides the data
base for the new type of storage and indication media for modern substation control and
protection systems.
The transition to condition-related maintenance of tap-changers, increasingly important to the
cost-conscious user, and the introduction of a computer-supported control and protection
system requires that manufacturers of tap-changers develop a special monitoring system.
Intelligent data acquisition systems for tap-changers must be capable of chronologically
recording the tap-changer's operating history, describing its present operating condition, and
predicting future behavior.
In addition, transformer users are demanding increased tap-changer reliability and reduced
maintenance costs. In order to be able to use the data available and, at the same time, to adapt
it to the condition-related maintenance, it is essential that the operating condition of the tapchanger be constantly monitored, signaled, and recorded [1].

Insulating liquids used in transformers have to perform a multiple role as an electrical

insulating and heat transfer agent. They must have adequate dielectric strength to withstand
the electrical stresses imposed in service as well as a favourable combination of thermal
conductivity, specific heat and viscosity to ensure sufficient heat transfer for the particular
equipment.
The use of less-inflammable liquids, such as High Molecular Weight Hydrocarbons
(HMWH), synthetic and natural esters, which can be used in combination with vacuum type
diverter switches offer benefits in terms of high fire safety and environmental friendliness.
Increasing power consumption in metropolitan areas brings high-voltage levels right into
urban environment and power transformers have to be installed downtown. Demanding safety
standards require less- or non-inflammable liquids for equipment placed within or around
building structures to minimize the hazard of fire and explosion damage in the event of
electrical faults within the equipment. These fluids should also be biodegradable to minimize
environmental risks.
II. METHODOLOGY OF TAP-CHANGER MONITORING SYSTEMS
A.

The assessment of the torque characteristics

Owing to the diverse mechanical and electrical functions of a tap-changer, there are many
different procedures and principles used in developing an on-line monitoring system. These
tests show that when a malfunction occurred in the tap-changer, the malfunction diagrams
obtained by assessing the torque were considerably more significant than those obtained by
using acoustic or acceleration measuring methods which also require a more complex expert
system.
For this reason, a real time tap-changer monitoring system should be based on measuring and
assessing the torque of tap-changers.
B.

Required basic function modules of a monitoring system for tap-changers

The main features of the monitoring system are shown in fig. 1:

Figure 1: Modules of the basic monitoring system for LTC

Temperature measurement
In the basic set-up the monitoring system has temperature measurement channels which
measure the temperature in the diverter switch, the temperature of the transformer oil in the
main tank below the tap-changer head, and the outside temperature. The measured
temperatures of the diverter switch oil and transformer oil as well as the limit value
monitoring can be used to estimate the overload capacity of a tap-changer. The outside
temperature measurement, however, is used to correct parameters (e.g., with torque
measurement).
Torque measurement and switching supervision
The determination of the torque characteristics by measuring the active power of the motor, as
described in [1], provides the basis of the monitoring system.
By determining the absolute fine tap selector position during the switching operation by
means of a resolver, a calculation system can assign the thus determined torque measuring
values to the exact angular position of the tap selector. This system is designed for installation
in the motor drive and is developed specifically for this purpose. Monitoring of the torque
occurs during the switching operation in real time.
At the same time, the function of the diverter switch is monitored by the built-in switching
supervisory equipment. This ensures that all the mechanical components of the gearing unit
from the motor drive to the mechanical sub-assemblies of the tap-changer are monitored. In
the same way it is possible to generate an impulse which synchronizes the complete torque
data record. Anomalies in the torque characteristics are detected in the monitoring system by
separate assessment of all the individual functions of a switching operation.
For the exact torque assessment the diagram is split into eight sections, each provided with a
certain limit value.
Contact wear model and measurement of load current
A mathematical wear model is integrated into the software of the monitoring system. This
model was developed on the basis of wear tests carried out on diverter switch contacts by the
factory test department and from experience gained by our service department. It allows the
monitoring system to calculate the total wear on the diverter switch contacts and the
differences in wear, and then to issue a prognosis on when the next contact replacement is
required. As the contact wear in the diverter switch is to a large extent dependent on the
transformer load current to be switched, the information on the load current has to be
provided (e. g., by bushing-type current transformer).
If the tap-changer monitoring system can be coupled to a monitoring system for a transformer
by using optical fiber, the load current data can also be transmitted from there.
If the tap-changer monitoring system is running as logical node (SLTC) within an IEC 61850
substation control system, the value of the transformer load current can be obtained from the
main substation controller.
Determination of position
By using a resolver in the new motor drive, the monitoring system is able to determine the
exact position of the fine tap selector during a switching operation in real time. As opposed to
solutions used up to now, this makes it possible to directly correlate data on the position of the
fine tap selector with torque data.

In this manner, it is also possible to determine the position of the tap-changer after a
completed switching operation and to monitor the end position of the tap-changer.
DGA of tap-changer
The maintenance criteria for tap-changers used to date, certainly contribute to the high
operating reliability of the tap-changer
For sensor technology, suitable sensors with solid electronic will be available for the use on
transformers, thus ensuring that the range of options and functions is extended.
Online DGA sensors for vacuum type tap-changers will extend the range of supervision.
Trend analysis of gas content related to key gases is the first step into online DGA.
Hydrogen and Carbon Monoxide are the major key gases which important to detect electrical
and thermal problems.
III. REQUIREMENTS ON A SUITABLE LIQUID FOR TAP-CHANGERS
While the insulating liquid in a transformer has the main task of cooling and (in combination
with the fixed insulation) insulating windings and bushings with regard to high voltage, a
suitable liquid for tap-changers must also fulfill other requirements, as there are:
The arcs on the main switching contacts resulting from switching activity must be
cooled and quenched.
All mechanically moving parts (gears and selector contacts) must be sufficiently
lubricated in order to reach a high mechanical life which correlates to the lifespan of
the transformer (>30 years).
The spring-driven diverter switch must be able to continue functioning properly in
all occurring ambient conditions, i.e. within the entire permissible oil temperature
range (typically -25 to +125C), proper switching sequences of the contact system
must be ensured. Within this temperature range, the oil viscosity varies by several
orders of magnitude.
Finally, many different high-performance materials are used inside a tap-changer to
achieve high electrical and mechanical functionality and a long working life, all of
those must be compatible with the insulating liquid used.
Mineral insulating oil has always fulfilled all demands. However, it is clearly visible that the
tap-changer is the decisive component which determines the applicability of alternative
insulating liquids.
Good arc-quenching behavior of the oil is essential for the classic generation of arcbreaking-in-oil tap-changers. The high arcing stress which occurs during normal operation
leads to severe oil deterioration and formation of acids, soot and cracking products. When
alternative liquids are used, the arc-quenching behavior becomes unpredictable because it is
determined by numerous parameters, such as viscosity, thermal properties and molecular
composition of the liquid.
The actual switching technology uses vacuum interrupters which fully encapsulate the
switching arcs. With this, the arc-quenching behavior loses its major role. OLTCs using this
vacuum switching technology are highly suitable to be operated in alternative liquids,
showing the same switching performance as in mineral oil. An additional benefit is gained
from the reduced oil degradation which is limited to thermal oil ageing, thus increasing oil
replacement intervals and disposal. This comes along with enhanced maintenance intervals
which could be achieved for vacuum switching type OLTCs.
Therefore, our focus will be placed on tap-changers with vacuum switching technology.

IV.

LESS-INFLAMMABLE INSULATING LIQUIDS

Less-inflammable liquids are liquids which meet specific requirements on fire-safety, i.e. they
have a flash point of >300C (K-class liquids, according to IEC 61100). Various such
insulating liquids have become established on the market. Table 1 shows the four categories
Liquid

Brand Name (Manufacturer, Country)

High Molecular Weight

Hydrocarbons (HMWH)

BETA-Fluid (DSI, USA),

MICTRANS-G (Michang Oil, Korea)
R-TEMP Fluid (Cooper, USA)

Silicone Oils

Transformer Fluid 561 (Dow Corning, USA)

TR50 (Wacker-Chemie, Germany)
KF-96 (Shin Etsu Silicones, Japan)

Synthetic Esters

MIDEL 7131 (M&I, U.K.)

ENVIROTEMP200 (Cooper, USA)

Natural Esters

ENVIROTEMP FR3 (Cooper, USA)

BIOTEMP (ABB, USA)

Table 1: Categories and Brand Names for Alternative Liquids

which have been requested to be used with tap-changers.
Since HMWH and silicones are only limitedly applicable as tap-changer insulating liquids
due to the disadvantages cited above, ester liquids are the promising alternative, also with
regard to the environment. The combination of vacuum-type tap-changers and ester liquids
offers a perfect pair which is able to meet future application demands [3].
One indisputable advantage of natural esters in contrast to synthetic esters is their favourable
CO2 balance. Natural esters are CO2-neutral, meaning that carbon dioxide absorbed by plants
during up growth is rereleased into the atmosphere in the same amount during final disposal
of the oil. Thus, the employment of natural esters in technical applications contributes
positively to environmental protection.

REFERENCES
[1]

Karsten Viereck, Control and Supervisory System for the Life Management of Transformers, CEPSI,
2004, Shanghai [conference paper]

[2]

Dieter Dohnal, Investigation and Guidelines for the Application of Natural and Synthetic Ester Liquids
to Tap-Changers for Power Transformers, Siemens Transformer Conference; 2008 San Antonio, USA,
[presentation]

[3]

Rainer Frotscher, On-Load Tap-Changers with Vacuum Switching technology for increased fire safety,
reliability and environmental performance, ARWtr, 2010, Santiago de Compostela, Spain [conference
paper]