Cergre International Conference on Large High Voliage Electric Systems 1982 Session ~ 1-9 September 12-02 ‘THE MEASUREMENT OF TRANSFORMER, WINDING TEMPERATURE by BF, HAMPTON, M.E, WOOLLARD ©.C. STINTON DLR, MEDHURST, Hawker Siddeley Power Tronsformers ‘Transmission ‘A.J. ROGERS: and Technical Services Division, Central Electricity Research Laboratories Central Electcity Generating Board (United Kingdom) sunmary ‘Two methods of direct hot spot measurenent are given. One uses the vapour pressure of acstone contained in a capsule embedded inthe winding, the pressure being Eransuicted via an oil-filled pefe capillary tube te a pressure cransducer at earth potential. Jn the other, laser Light is polarised and trene~ mitted by optical fibres to a quarts block in the (Binding. Tee plane of polarization is rotated, and tho emerging 1ight analysed, In addition a revised method of cooling curve correction is proposed which gives improved accuracy in the vinding temperatures derived from temperature Keywords Tranaforner ~ Winding ~ Hotspot ~ Temperature + Introduction In is essential to know the maximum temperature reached by the vinding insulation if a transforser is to be loaded efficiently and its Life expectancy calculated, The thermal image vinding temperature indicator has given reasonable results over many years, but is known co be inaccurate, Because of Chis incertainty of measurement, the CEGD restrict the maximum indicated hoe spot temperature in their Gransformers to 125°C, although the loading guide [1] “aitoss 140°C to be reached. Clearly = better Khivledge of the true hotspot temperature would enable the transformer to he utilised nore fully. Knowing the temperature history of the winding would enable the Life expectancy of the transforner to be estinated more accurately, snd perhaps allow a worth= hile delay before the transformer was replaced oF Peintoreed. Although the thermal image temperature indicator has approximately the same thermal tine constant aa the Ginding, heating the bulk oil causee an additional olay if the traneformer is euddenly loaded fren cold, or subjected co an energency overlosd, In this Situation the windinge could be mvch hotter hat indicated and estinates of the maximin peru oad grossly in error. Better temperature measurements are also necded during teating. At present there is no accurate nneans of calculating the hotspot from temperature hneasurenents taken when che transforwer is on test, ‘and no way of knowing with certainty whether {et mects the manufacturer's guaranteed waximin Cenperature These Limitations could be overcone by measuring che winding temperature directly, and various ingenious Schemes have been reported; see for example, [2] ‘The problem is to produce a measuring unit ub{eh is ‘rugged and small enough to be enbedded in che vinding without causing too mich disturbance, and fo crane mile the temperature information eo a veceiver at earth potential. However the overriding requirement iis chat the device mist in no way weaken the electrical insulation of the ceansrormer, either lunder impulse or power Frequency voltages. ‘The two schemes reported here are thought co be promising, and one of then is being fitted into 32 kV Oistribution transformers for field trials. Improving the accuracy of hotspot determination from conventions! temperature rise tests ha also been considered. Tae 'Multiflov' priaeiple. for tren former rating [1] has been discussed for several yoars, but its Introduction has deen delayed by oubtt with rogard to gone of the reasoning and values used in the derived formulae, partieulerly in respect of tho vinding oil average temperature vise Moreover, thers are anomalies in TEC 76-2 [4]. Some of thase aspects are now discussed and modifications Suggested auch that additional eupport can be given to the Multifloy principle, particularly for trans~ formore with directed ofl flow. 2. The Vapotheem 2.1 Consteuction ‘The Vapotherm operates by measuring the vapour pressure of a volatile Liquid contained ina capsule buried in the winding, A‘sulcable liquie for102 measuring temeratures up to the required 150° is feetone, the vapour pressure of which is given by G) 1210598 9.26208 = E7668 106? where P = vapour pressure (W/m?) © = temperatura (°C) Vapour pressure thermometers in which the working flvid is sealed into a metallic capsule and capillary tube are found in a variety of applications. The difference with the Vapotherm is that the capsule and pressure transducer are connected by a small-bore ptfe tube, vhich {x filled with eilicone of] to ensure that a vapour busble cannot form in it and perhaps lead to breakdown Good electrical inaulation slong the tube is assured by the excellent dielectric properties of prfe, and because its permittivity (2.1) closely matches’ that of transformer ofl (2.2). Figure 1; The Vepetherm capsule ‘The acetone in the capsule is separated from the silicone of1 by # thin-walled metal sac, as shown in Figure 1. In vse, the sac expands to accommodate the expansion of oil in the tube as the transformer Temperature rises, However the pressure of the oil depends only on the temperature of the acetone in the capsule, and is independent of sna1l changes in the volume of the silicone ofl or ptfe tube. The See is nade from thin copper fol to winiuise the pressure drop serose it, but should the ptfe tube Decome danaged and the silicone oil escape, che Hides of the sac collapse together and prevent the loss of acetone, This ensures that the transformer cannot be put at risk by a bubble of vapour escaping into the vinding. The cuter case of the capsule Is nude of stainless steel and measures 8 x 2.5 * 50m. Te is an advantage if the pressure transducer needs only a spall change in ofl volume over its range of 0-1 mi/me, A convenient type Incorporates 2 strain Bauge on a stainless steel diaphragm, and has a Sealed vacuum reference so that absolute pressure messuronents are made. Since the ptfe comecting tube may be up to 2 n long, the transducer can be nounted at any convenient point on the earthed frame OF the Eransfomer and electrical connections made Eheough a terminal box on the tank 2.2 Performance and Testing, Since the vapour prassure/tenperature relationship of acetone is known accurately, individ calibration of Yapothern unite ie, in principle, Unnecessary. However although the pressure transducers used have very good Linearity, their sensitivity varies slightly from one unit to the ext and they need individual calibration. ‘This { achieved by adjustent of their excitation voltage. The practice adopted is to inmerse the capsule in an ofl bath at a known temperature, usually 110°C, and Adjust the excitation voltage until the indicated pressure corresponds to the theoretical value. Taking @ typleal capsule and varying the ofl bath temperature between 30°C and 150°C then gave the experinental points show, together with the theoretical curve, in Figure 2, The error in the Ieasurenent leq €0 the ingicated tempezature being Te tow at 150°C, and 2-3°C high at 30°C. The greatest source of error is the small agount of air Erapped in the Vapotherm while it is being Filled. The accuracies mentioned were obtained using a relatively sinple vac filling procedure, and are thought acceptable for winding temperature measure= ents, By using a more elaborate {I1ling technique, perhaps the errors could be reduced. They eight then become comparable with those caused by the small pressure crop across the copper sac. Samples of ptfe tube with joints made in them have been filled with silicone oil and subjected to pressure, temperature ané mechaniesl loading cycles ith eatistactory results. Complete Vapothern units lire now being Life-tested by igmersing the capsule alternately in oil baths at 30°C and 150°C, and over the few hundred cycles recorded so far have shown no change in their exlibration: ee oe ‘TEMPERATURE. “c Higure 2: Pressure moasured by the traneducer 2.3. Bigting the Vapotherm ia a Winding lie rely on the transformer designer to locate the hottest spot of the winding after calculating the oad and eddy losses of each turn or dise, and taking into account aay discontinuities sich as ping sections. In. disc winding che hottest ise may be the second or third from the top, and the Vapother capsule is wound midvay into that disc (Figure 3). It ie positioned between axial Spacers, and in the core window if the oil flow ia this arta is affected by adjacent windings or interphase barriers.CAPSULE PRESSBOARD FILLING PTFE TUBE Higure 3: Position of capsule in the winding The capsule ic in direct contact with the bared conductor, which is locally straightened. Wedges of pressboard are fitted at each end to avoid pressure ‘on the capeule during winding and under short-circuit condition. Use ie mode of alutinium foil and Loaded resin te provide electrostatic shielding and good thermal contact. Finally, the conductor insulation is reinstated and the ptfe tube brought out through tho winding end end ingvlation. ‘The radial space needed by the capsule depends on the dianeter of the winding, and may be 4-5 a This is accomodated either as a local bulge, or by renoving one or two terns from the disc, The brand ducer is mounted on the top end frane of the core, ‘and screened leads are brought from it to a cermital box on the tank cover. 2.4 Output Signal The transducer genevates a voltage proportional co the pressure, and so its output Increases non Linearly with teaperature. For conveniencs, the signal is Linearized. First the voltage is converted to a binary signal. ‘This {s channelled Co a "programmable read oaly menory’ (FROW), which has 2047 addresses capable of Storing 8 bits! Each address is programmed with the Cenperature, within the range 30-150%C, corresponding toa given pressure, The 8 bit output of the PROM is converted to analogue form, giving a current Linearly dependent on temperature. This is ampli tied to give a 0-10 eA de signal suitable for Feeding into the network tele-coatrol aysten, and also displayed locally ae a temperature on a digital meter, 3. The Optical Method 3.1 Principle The method relies upon the temperature dependence of tthe optical activity of exyatalline quarts. When Linearly polarized Light is passed into a quarts block so as to propagate along the erystal~ Optic axis, it vill energe linearly polarized but with its direction of polarization rotated by the batural optical activity of the quarce, The angle of rotation depends upon the length of optical path, the wavelength of the Tight and the temperature of ehe material. Ae » given wavelength there is a reo Linear dependence on path length and, also, & linear dependence on teaperature over a Linited temperature range. The temperature dependence of the rotation was seasured at the He-Ne Lager vavelength of 632.8 nm. The rotation at T°C vas found to be given by: Op * 18.7 + 1.34 « 107) deg mm =a ‘over the range 18°C to 180°C. Light from a 5 if He-Ne laser is Launched into a Single multimode fibre at the centre of a bundle of such fibres. This fibre conveys the light up to the optical transducer block. When the Light emerges from the fibre the emergent cone ie intercepted by lens which collimates it to pase it as 2 parallel beam firee through a polarising priem, then through 4 quartz block parallel to ite optic axis and Finally through 2 quarter-vave plate. The Light thon falls oa to a plane mirror vhich causes the Light to pass back through the elements in reverse order, to be launched inte the bundle of multimode fibres vaich surrounds the original input fibres Taie bundle takes the Light to a photodetector which provides an electrical current proportional to the received light pover. This signal is then fed to a divider which nornalises it to the level of the launched laser pover with the aid of a reference aignal from the laser The optical action of chis arrangement Is a¢ follows: the polarizing prism ensures that the Light which enters the quartz block is linearly polarized in ite Acceptance divection, vhich is defined as the reference direction OX. The optical activity of the quartz rotates the polarization direction of the Light so that it emerges from the block polarized at angle rp to Ox (ep is equal to pq2, 1 being the length of the block in wn). The quarter wave plate is set vich ics fast axis at angle 0 to OX. The double passage through the quarter wave plate (with the assistance of the plane mirror reflection) is equivalent to 2 single passage through a half~wave plate, also set at the angle ®. The effect of this is co'rotace the polarization dixection through an angle -2(rq ~ 6).” On passing back through the quarts block the original rotation is reversed leading to a further rotation of ~rp. Thus on arriving back at the polarizing prism the polarization direction lies st an angle: = 2g - = ey = 20, 8) to the direction OX, which ia, by definition, the acceptance direction of the prism. ‘The prism now acts as a polarizing analyzer and vill pase the Light power 2 y 7 cot” 2rq ~ 0) where P is the Light power incident on the analyzer. ‘Thue 2 7 PUL cos Or, = 00/2 Now in order that the variation of Pp be Lineae with ry around @ mean teuperature T, we require that ry - 0/8 -@) for this givesreo 7 2 be, seyse = where Sep and Srp represent small deviations trom mean values. The power variation éPp is conveyed via the optical fibre bundle to the photodetector. The power’ P will de proportional to the laser output Dover, Poy and this we may obtains direct indies Fion Of Sty by dividing the photodetector signal by f signal proportional £0 Po.” sry (= épp 4) is, of Course, related to temperature via equation (1), and thus we obcain a measurement of the eenperacure variation of the device. fn important feature of this arrangenent is that the output indication is Independent of both magnetic Sind clectsie Fields. A longitudinal magnetic Feld GL produce a rotation of the polarszation diree~ ion via the favaday magneto-optse effect. [b.) but the rotation is independent of the direction of propagation, Thus for a magnetically induced rot Hon ry we have, for the total rotation produced: 2p ty ee ty = Rey = 9), a before, Tore are two relevant electric field effects. The First, an clectrogyration effect [7] is sero for Lighe ‘propagating dovn ehe optic auf. The other, Pockel's electro-optic effect [8], ia negligibly small for linearly polarized enefgeat light. ‘A diagram illusteating the device construction fa shown in Figure 4, The positional stability of the Bt BE Crerasnme eben construction of the optical device Bigure 4 device conponents as the temperature varies is of critical importance. The components are housed in @ precision-bore Pyrex tube of Length $5 mm and dia~ eter 9 um. The optical fibre bundle is terminated fn a glase-reinforced epoxy-resin ferrule which is, held in a eight-fieting glass end-cap suitably moulded to ensure that the fibre ends lie at the focus of the soda-glass convex collimating lens. ‘The polarizing prism is a split calcite cube enclosed ina glass count. The two Sections of the prism are separated by an annular mica spacer. The quactz block is 19 am long and has a square cross-section of side 6 mm, this being a tight fie within the cube. ‘The miltiple order quartz quarter-wave plate and che aluminized plane mirror are held within a cight Sitting glare mount which is rotatable in order co control the angle, 8, which the wave-plate's fast axis makes with the acceptance angle of the polarizing prism, The front face of the wave-plate is protected by a glase spacer. ‘me optical fibre bundle consists of 60 fibres each Of 88 tm outer diameter surrounding a single 250 ym cuter diameter fibre which carries the input Light. ‘The nuuerieal aperture of all fibres is 0.48. The Fibre bundle {2 sheathed in Tefzel which allove operation up to 180°C and does uot degeade when in contact with transformer ofl at chis temperature, 4.3 Device Characterisi Light from a He-Ne Laser was Launched into the Central fibre for passage up Co the transducer which was placed in an oven vhose. temperature was ‘Sccurately controllable, Light’ from the back-end of the laser was used a6 the Light-power reference (Pp). ‘The quarter-wave plate was set to satisfy the con aiejon given by equation (2) at a tenperature of To0%; this places the pole of waximm linearity in the middle of the range 20°C to 180°C and thus ensures that the characteristic is maximally Linear over thie Tange, The Light returning from the device via the fibre bundle was received by a photo lode whose output was amplified and then fed to divider fer normalisation, The oven temperatuce was alloved to etabilise at each measurement point and fin ineegration tine of 10 s was used for each output reading. ‘Tho measured characteristic, showing normalised detector output at a function of temperature, is given in Pigure 5 and is seen to he substantially finear. The error hare inply an accuracy of £2°C In the tonperature meagurenent. Over the tenpers~ ture range 20°C co 180°C the corresponding total rotation of the polarization direction is 15". ourrur my. 020 406080 100 120 140 160 180 TEMPERATURE, °C Figure 5: Teuperature characteristic 4. An Tnproved Method of Cooling Gurve Correction 4. Temperature Correction for Cooling During Reeistance Curve Messurencits Tu 76, Fig. 2, states that resistance readings made after the transformer has been switched off must be Corrected for the charige in the average ofl temperature, The method is hardly practical because (a) of the need to read several thermometers and take resistance weasurenents at known tines, (b) the measuring devices have their own thermal tine constants, and (e) it is unlikely that in all cases the average ofl temperature is the top oflEomperature minus half the drop across the cooler, Tf the individual vinding average oi1 eenperature is determined from the asymptote of the resistance curve, how can corrections to the test points be applied using the average oil temperature? 4.2 Maintaining Yans and Vater Puspe Running TEC 76 specifies that Fane and vater pumps are to be Sstoppod at shut-down, but ofl pumps left running during resistance measurements, ‘Thie requirencit is illogical because the steady etate prior to shut~ dom is changed to a transient thermal condition, with drastically reduced cooling, when the power is awitehod off. The stored heat energy in the winding Flows into the ofl, raising the botton of] tenpere tute at shown in Figure 6 "for an ODWF transformers and hence the winding eemperatures, : 5 eI Figure 6: Rise in top and bottom oi temperatures ‘The duration of the transient condition depends on the tine constants involved, but ae those of the windings are typically 5-15 minutes sono offect on Che resistance mossurenente must be expected, Our principle ie to maintain unchanged the cooling chroughout the test and to correct for the appreciable cooling experienced when forced cixeu- Tation is used. This is achieved by first calew- ating the traneforser tine constant from the top bbulk oil tenperature ever the latter part of the heat vun, where the winding to ofl tenperature gradients are substantially constant. The [ndividue! winding tenperature rises deduced from the cooling curve are then corrected for the falling temperature of the complete transformer, 4.3, Measured Time Constant « = Tine (or suffix te indicate conditions at time ©. ‘Transformer tine constant. Oya = Finding average temperature. 4 = Bulk (Cop cooler) oil average temperature. 044 7 Winding of1 average temperature, 8, = O11 temperature at bottom of cooler or inlet to windings 8, 7 Gradient = (©, ~ 8,4) 0, = Ambient cemperature, A = Prefix to indicate teaperature rise. - reo Rye 7 Winding resistance measured at known temperature (ise, "cold resistance") Rup = Minding resistance meapured at tive ¢ from y= Power index to adjust geadient for ‘Tho final ofl teaperature and + can be derived from the heating curve whore the rated pover Loss has heen supplied continsously vith ao’ change to the cooling conditions. Referring to Figure Ty t) and tty are the tines corresponding 0 Q.6 and 0.95 of the final temperature, and t2 is aidvay between then, From these values che top bulk ofl average touperature rise at the tine of veducing current to vated value i = 20,2 20, 48, ~ 905! “mF mejT ty and ob” WO, + a0, = Bad, ‘Top bulk ofl temperature vise 4.4 Correction Applied to Hach Measured Resistance Ac ty the winding average temperature rise (iGyat) above ambient for each measured point corrected for falling transformer temperature ean be derived from12-02 i €o sh: (yg #225) ~ (+ | * [Re From these corrected values, the winding average temperature rise (0l,) spd the winding of] average Eenperature rise (Oly), both referred to shut-down, Can be found graphically or calculated using ropreseion analysis. 4.5 Repulte from Test Measurements Table 1 shove the vinding average and winding ofl average tenperature rises derived In accordance with Tee 76 methods (a) and (b) from the test results of two ODAP transformers (of different manufacture) when fane and pumps vere left operating. Tho gradients dg deduced from the values in Table 1 fand faferred to"80°C are shown in Table 2. %— ETRE | Te Tee pereata) | 327-200) “oo w7a,hon/ig2 w| Ser Cow] Ser] com| Ser] com eat 1 = 1008 com Tz method =| =| =| = feet fan Proposed method | 52,0] 5540 [43.6 [44.8 lasz6 | 41.8 Difference Py OL Pe feais | 0.7 ‘eat 2 = 80% om ec method =n |e | = feo |252 Proposes motnd | 42,7 [43.9 [36.9 [a6 [3629 [38.6 Dirterence a7 pen Pht Pie feats | -0t7 ‘ep 119 + 0% ee metho 17.3 30.9 fso.0 fos. | 31-7 Proposed method inca f3.3 pass 303 [3303 bisterence rola Weare [tara race | x6 ‘ap 19 WY ~ 206 “oc method si.8 |56.7 po-t |s8.5 [9-1 [39.1 Proposed method [5625 |58.0 faz lx.0 parz [41.0 Difference ita forts fare frase foca |eno ‘Table 1 Diggerences i Conperature rises oe wena Pie tint tia TeteaG.z2am | rt | 7.0 [zero] ate | 7.9 | nee] Reman” | | 35 fs | os | 13 | Sa ‘iaing reece TET om eae ge] ae | a3 | 2 Average winding to oii Cenperature ditference able 2: 4.6 Discussion ‘The values of b8yg determined by IEC 76 and the proposed method re in reasonable agreesent. However, the values of winding average oi] tenperature rise Mog differ. when used wich the basic Holtit_iow principle, the new values give the Cemperature of the oil leaving the top of the windings as 1,3 °C lover to’ 6.3 Chigher than that found using TEC 76. Tf the TEC 76 index 'y* values (deduced from che average oil temperature according to clause 3.7.2) are taken as a vhole, the four results give an arithmetic mean of 1.79. The three results from che Proposed mathod have a mean of 2,09; the expected Value is 2.00, However, the standaré deviations Sin = 1) foe the IEC 76 and the proposed method are 0,73 and 0.16 respectively. Hence the 9ST con- fidence level using ‘standard error of means" would give values for 'y! of 1.42 to 2.16 for the existing Tec 76 methods, and 2.00 to 2.17 for the proposed rnethod, This ie considered 4 vorthuhile improvenent. 5. Referenc [2] Moading Guide for Oft-imereed Transformers" (IBC Publication 354, 1972) [2] Nieson, S. "Passive Hocspot Detector! (EPRE Journal, March 1978, pp4i-i5) [2] carruthers, M.c. and Norris, Ba MMhermal Rating of Teanafornera' (Proc. TEE, Vol. 115, No. 9, 1969, pp 1564-1570) [i] "18 Power Teansformare' (IEC 76, Pare 2, 1976) [5] thange's Handbook of Chemistry’ (ei, JA, Dean, 12th edit, seceion 10, 928) [le] raraday, Me "Magnetic Rotation of Polarized Light” (Trans. Royal Society, Vol. 135, 46, pl) (7] Rogers, A.J. "The Glectrogyration #ffect in Crystalline Quarts’ (Proc. Royal Society, Series A, Vol, 353, 1977 ppi7-192) [et] Rogers, A.J. "A Method for Simtaneous Neasurenent of Current and Voltage on a HV Line Using Optical Techniques" (Proc, TEE, Vol. 23, No. 10, 1976, 9957-960) Acknowledgements Mr W.B.D, Grant of S®&M Ltd developed cechniques for anufacturing the Vapocherm, and the Linearization cireuit was produced by Mr G.E. Hanson of CERL. ‘This paper is published by permission of the Central Electricity Generating Board and Havker-siddeley Power Transformers Led. Ext de a Confrence Intemational der Grad Réseau Blecrquer Season de 1982