On-Load Tap-Changers OLTC Fundamentals: by Mats Carlsson

OLTC Fundamentals On-Load Tap-Changers
By
Mats Carlsson EETC Alexandria Zone
November 2006
© ABB - 1
Outline
 ABB Components introduction

 Tap-changers
 Bushings
 Life cycle support
© ABB Power Technologies - 2
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Power Transformer Components
Bushings
Tap-
Changers
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The High Voltage Valley in Ludvika, Sweden
Swedish Transmission HV Circuit

Research Institute HV Instrument
High Power Breakers Transformers
Laboratory
HV Surge
Transformer
Arresters
Tap-changers
Transformer
High Power Bushings
Capacitors
High Voltage
Laboratory HV Thyristor
Converters
Power
HV Shunt Transformers
Reactors
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Components Ludvika, Sweden
KEY FIGURES 2005

 Revenue ~100 MUSD
 External ABB sales ~50%
 Employees ~300
 No of Bushings >10000
 No of Tap Changers >2000
 Export share 95%
 R&D expenditure ~10%
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Tap-changer historical overview (2)
 1910 First tap-changer produced (type
HM)
 1927 HA
 1953 HF
 1963 UCB (in-tank)
 1964 UZB (on-tank)
 1965 UCC
 1978 UCG
 1978 UZE
 1983 UCL
 1987 UZF
 1991 UBB
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ABB is the largest manufacturer of bushings
Resin impregnated (RIP) Oil impregnated (OIP)
with composite or porcelain with porcelain insulators
insulators 36 - 550 kV 36 - 800 kV
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Conformance: IEC, IEEE & Regional Standard Variants

Transformer components – in challenging
applications!
HVDC Phase-shifters
transformers e.g. 1630 MVA & 400
kV
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Subjects
 Tap-changer types
 Principles of operation
 Transition resistor
 Switching time
 Contact life
 Maintenance
 News!
 Tie-in resistor
 Tests
 Development
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On-load tap-changers
ABB (ASEA) has

manufactured tap-changers
since 1910.
More than 45 000 units of
the modern design are
today in operation world-
wide.
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Design philosophy:
 Highest reliability
 Easy maintenance
 Longest lifetime
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 Longest lifetime
by using first class materials and by thorough tests.
Typical contact life is 350 000 through 500 000

operations.
 Highest reliability
by using few parts and making simple designs
 Easiest maintenance
by same reasons as above
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ABB Tap-Changer Reliability
Reported unscheduled service interruptions due to the tap-changer
0,06%
0,05%
0,04%
Amount
0,03%
0,02%
0,01%
0,00%
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
Year
An average of 5000 years between these stops!

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Failures of Tap Changers from 1996-2005
Failures during service.
Year failure was reported Failures during service, as %
of tap changers in service
1996 0,04 %
1997 0,03 %
1998 0,04 %
1999 0,01 %
2000 0,03 %
2001 0,01%
2002 0,02%
2003 0,01%
2004 0,03%
2005 0,02%
The figures include all failures, independent of age and types of tap-changers, which have led
to a service interruption of the transformer, caused by fault in the tap-changer.
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WHAT IS AN ON-LOAD TAP-CHANGER?

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A device for changing the tapping connection

of a winding while the transformer is on load
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Current is interrupted
Must not happen!
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One loop of the

regulating winding is
short-circuited
Must not happen!

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Transition Resistors
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Transition Resistors
 Resistor type
 Reactance type
 Electronic types
 Others
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 Reactance type
is mainly used in ANSI-standard countries, most often to
regulate on the LV side of the transformer.
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 Electronic types
belongs to the future
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 Resistor types
most common today.
Can be diverter switch type or selector switch type.
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 Diverter switch type

consists of separate diverter switch and tap selector
 Selector switch type
consists of a combined diverter switch and
tap selector unit
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Types of Switching
A. Linear Switching
 Not very common (~20%)
 Simple design trafo & oltc
 Smallest regulating range
 Smallest losses
Selector
Switch
Coarse
Winding
B. Plus/Minus Switching
 Most common (~70%)
10
K K  Additive (+) & subtractive (-)
9 9
 Change Over Selector
Regulating Winding
C. Coarse/Fine Switching
Selector
Switch  Least common (~10%)
 Coarse winding insertion

 Change Over Selector
 Small losses
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A B C
Principle Circuits of OLTC Transformers (1)
For two-winding power

transformers, the most popular
arrangments is the regulation at
the neutral end of the winding.
This solution provides the most
economical tap winding
arrangement with generally
graded insulation combined with a
compact three-phase neutral
point OLTC.
OLTC in Y or Star Connected Windings

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Principle Circuits of OLTC Transformers (2)
2-Pole + 1-Pole
3-Pole Line-End Arrangment 3-Pole Mid-Winding Arrangment
Line-End Arrangment
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OLTC in Delta-Connected Windings

MVA Transformer Ratings
> 80 80 80 50 60 150 150 300 HVDC 1000

-----------------------------------------------------------------------------------------------------------------
1
UZF UZE
650 UBB
USB 650 2 350
200 UCG.N/C
3 UCG.N/C 1050 UCL.N/III
UCD.N/III
Short 1050 1050 UCC.N
UCG.N/III 1050
L (m) 4 1050 1050
All are of Jansen type, i.e. spring operated switches and of resistive type.
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Tap-changers, diverter switch type
Diverter
Tap selector
7
6
5
4
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regulating winding
Italy, Terna
 400 kV, 1630 MVA
 Weight 820,000 kg
 Footprint 13x15x10 m
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Two-phase UC-type
Tap-Changer
mounted on special
transformer
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Top section with mounting

flange
Shielding rings
Diverter switch
Connectors between diverter

switch ant tap selector
Tap selector with pre-

selector
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Switching sequence
for Diverter-Switch
type Tap-Changer
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5
7
4
6
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5
7
4
6
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5
7
4
6
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5
7
4
6
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5
7
4
6
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5
7
4
6
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5
7
4
6
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5
7
4
6
Animation
Switching sequence
for Diverter-Switch
type Tap-Changer
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Features for the UC tap-changer
Extensive service experience

 More than 9000 units in service
 Excellent service record
Quick and easy maintenance
 Shaft outside diverter switch housing
 Open design, no special tools needed
Reliable
 Few parts
 Simple and robust design
 No on-line filtration needed

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UC tap-changers
 Completely clean cover

 Bevel gear for shaft system
outside cover
 Lift our diverter switch without
removing shafts!
 Operate motor-drive and tap
selector when diverter switch is
removed
 Operate diverter switch as
desired!
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UC tap-changers
 Diverter switch electrically

connected and mechanically
coupled without screws
 Kept on place by springs on top,
pressed by the cover
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UC tap-changers
 Easiest possible
maintenance
 No dismantling of
diverter switch needed
for inspection & cleaning
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UC tap-changers
 No need to bring diverter

switch down from
transformer for
maintenance
 Transformer outage less
than one day for
maintenance
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ABB tap-changers in furnace transformers
UCG top section

with shaft,
bevelgear &
motor-drive
mechanism
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The cover has been

removed.
(Six minutes passed)

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Note that the shaft

system is not
dismantled
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Tube for draining,

guiding and oil
sampling
Springs for fixing

diverter switch
Mounting
information
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Hook to lift...
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Lift...
Continue to lift...
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Dvierter switch
lifted out.
(Ten minutes passed)

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Drive disc with

slot for drive pin
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UC Tap-changer Maintenance (overhaul)
Bottom in tap selector cylinder
Notch for
driving pin
Driving pin
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Operate the
diverter switch
from one side...
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...to the other without

caring about the
position...
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 No harm if you
operate the motor-
drive.
 You don’t have to
note the tap position
number.
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Put the spare or

overhauled diverter
switch back...
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Fork for guiding

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Switch not
yet in proper
position
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Before operated
to correct
position
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Operate the hand crank

till you see and hear
that...
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… that it falls
down to it’s
proper position.
Everything is
now mechanically
and electrically
connected.
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When the tap-

changer is
operated to correct
position you can
put the cover on.
(Less than 20
minutes passed)
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UC tap-changers
 Simple, open design with

very few parts offers
highest reliability and
easiest maintenance!
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Diverter Switch
Upgrade your old transformer
Plug & play concept
 Interchangeability in old
transformers
 For all UCGs since 1978
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Tap-changer with vacuum interrupter technology
Proven experience
 Vacuum bottles, based on

25 years of ABB experience
and millions of successfully
delivered units provide for an
extremely reliable product
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 Vacuum more complex
 Monoploy
 Humidity – oil samples
 Normally maintence after 5-7-15 years
 Failures often happens after maintenance
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Modular motor drive
Improved service friendliness

and flexibility
 Adding / changing of
functionality in the field
 Self diagnostic and event
handling
 Reduced number of parts
 Transmission gear made from
maintenance free elements
 Shortened delivery time and
increased flexibility in order

process
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Modular motor drive
Summary
 Extremely high reliability
 Excellent service records
 Easiest maintenance
 Models for all applications available
 New technology to be introduced during 2007
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GSA bushing
VVAH cooler
UZF tap-changer
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 Active part of transformer

prepared for UZE type tap
changer.
 Transformer tank with
integrated tap-changer
tank.
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Benefits of using the on-tank UZ
 No oil filter is needed

 Less cleats and leads
(conductors), which
can easily be made in
parallel
 No drive-shafts or
bevel gears
 The UZ is needed
later in the
production process
 Short delivery time
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 Three-phase fully
insulated phases or
neutral point design
 Tap-changer, motor-drive
and shaft system
integrated
 Extremely simple -
excellent maintenance
properties
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 UZF tap-
changer
 Three phase
boards
 Integrated
motor-drive
mechanism
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 BIL 650kV / 600A fully insulated

 Up to 100 MVA transformers
 No drive-shafts or bevel gears
 The UZ require a smaller tfo
 less oil
 less sheet metal
 less beams
 less welding
 less work
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 The UZ require a smaller transformer tank

 less oil
On-tank
 less sheet metal
 less beams
 less welding
 less work
In-tank
 Smaller oil conservator

 The UZ does not determine the
height of the transformer
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Mobile transformer by Porter, USA, equipped with UZE type tap-changer
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I
Tap-changers, selector switch type
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1
2
3
4
5
6
7
I
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2
3
4
5
6
7
I
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2
3
4
5
6
7
I
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2
3
4
5
6
7
I
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2
3
4
5
6
7
I
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2
3
4
5
6
7
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2
3
4
5
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7
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2
3
4
5
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7
I
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On-Load Tap-Changer Type UB
 UBB type tap-changer

 Selector switch type
 Introduced in 1992
 More than 5000 units in service
 Uses the contact system from UZ-
type tap-changer
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 Fibreglass cylinder
 Fixed contacts mounted through cylinder
wall with excellent tightening system
 Fixed and moving contacts replaceable
from inside the tap-changer
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 Pre-selector switch
 Three fully insulated phases
 Moving contacts
 Current collectors
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 Central shaft
 Shield
 Current collectors
 Neutral connection between

phases
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Moving contact system consisting of:
Transition resistor contacts
Main arcing contacts
Current contacts
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 Main arcing contacts by copper-

wolfram alloy
 Current carrying contacts by silver-

plated brass
 Contact tips by solid silver

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 Pre-selector contacts with four

contact fingers
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TIE-IN RESISTOR
 Only for plus/minus and coarse/fine connections.
 Used when the recovery voltage over the change-over selector exceed
the max. value (between 25-40kV dependent on OLTC)
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TIE-IN RESISTOR
Main Winding Change-Over Selector
Tap Winding
Switch (only connected during change-over operations)

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TIE-IN RESISTOR
Tap Winding

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TIE-IN RESISTOR
Tap Winding

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TIE-IN RESISTOR
Tap Winding

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TIE-IN RESISTOR CONNECTION
Tie-in Resistor
Tap Winding

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Tie-in Resistor
Tap Winding
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Tie-in Resistor
Tap Winding
Switch
Switch(only(only
connected during change-over operations)
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connected during change-over operations)

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Calculation of Tie-In Resistor
Needed to calculate the Tie-In Resistor value are:
 Capacitance from the regulating winding to adjacent windings or earth. (Included
influence from leads)
 Voltage on the adjacent windings and the voltage over the regulating winding.
 Transformer connection data and frequency.
H1
Tank
HV U RW
C1 C2
+ -
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On-Load Tap-Changers OLTC Fundamentals: by Mats Carlsson

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OLTC Fundamentals On-Load Tap-Changers

 ABB Components introduction

Swedish Transmission HV Circuit

KEY FIGURES 2005

Conformance: IEC, IEEE & Regional Standard Variants

ABB (ASEA) has

Typical contact life is 350 000 through 500 000

An average of 5000 years between these stops!

WHAT IS AN ON-LOAD TAP-CHANGER?

A device for changing the tapping connection

One loop of the

Must not happen!

 Diverter switch type

 Coarse winding insertion

For two-winding power

OLTC in Y or Star Connected Windings

OLTC in Delta-Connected Windings

MVA Transformer Ratings

> 80 80 80 50 60 150 150 300 HVDC 1000

L (m) 4 1050 1050

Top section with mounting

Connectors between diverter

Tap selector with pre-

Extensive service experience

 No on-line filtration needed

 Completely clean cover

 Diverter switch electrically

 No need to bring diverter

UCG top section

The cover has been

(Six minutes passed)

Note that the shaft

Tube for draining,

Springs for fixing

(Ten minutes passed)

Drive disc with

Bottom in tap selector cylinder

...to the other without

Put the spare or

Fork for guiding

Operate the hand crank

When the tap-

 Simple, open design with

Plug & play concept

 Vacuum bottles, based on

Improved service friendliness

increased flexibility in order

 Active part of transformer

 No oil filter is needed

 BIL 650kV / 600A fully insulated

 The UZ require a smaller transformer tank

 Smaller oil conservator

 UBB type tap-changer

 Three fully insulated phases

 Neutral connection between

Moving contact system consisting of:

Transition resistor contacts

Main arcing contacts

 Main arcing contacts by copper-

 Current carrying contacts by silver-

 Contact tips by solid silver

 Pre-selector contacts with four