MODEL TO ACHIVE SC PROOF TRANSFORMERS WITHOUT INCREASING

THE NUMBER OF SC TESTS

Hassan SAYED and Margareta VARGA

HV Trafo Solutions S.R.L., Romania

ABSTRACT In short terms, what does SC proof transformer

The advanced calculation and simulation means today for the:
methods are essential but not enough for the - Utility/Client: Reliable network, stable profit.
purpose of increasing the SC reliability of the - Manufacturer: Extra man hour, extra material,
Power Transformers. This paper presents a new special precautions and extra cost.
method to update the conservative procedure of - Test laboratory: Only ONE tested transformer,
SC proof manufacturing, leading by this in long limited number of certification.
term to increase the number of SC proof
transformers in the networks, without increasing Current practice, how it is targeted to achieve SC
the number of performed SC tests. proof transformers by the:
- Utility/Client: Request for SC test of ONE unit
INTRODUCTION with similar characteristics of the supplied
Why all transformers should be SC proof? transformers.
The outage for the power transformers is caused - Manufacturer: Special design, special
by external SC of the power system in the manufacturing and quality procedure of that ONE
highest present, which is a clear indication for the special transformer which will be SC tested!
lack of SC proof transformers. Therefore to - Test laboratory: Executing SC test procedure
achieve a reliable network it is basic to ensure and certifying only ONE transformer, that special
that the most expensive and most sensitive design of the Manufacturer!
component of the power network (transformer) is This is the maximum what is possible in 2018?
SC proof. The answer is NO.

Why cannot be guaranteed a transformer 100% HYPOTHESIS

as SC proof? With the modern technology of designing and
If we look into the transformer manufacturing manufacturing, it is possible to achieve SC proof
procedure, from the design to the test we can transformers as standard units. With the latest
see it clearly that there are error factors/problem design tools it is possible to predict the behaviour
sources in the procedure of the transformer of the transformer under SC, this combined with
manufacturing. Even if the calculations are 100% the right production and quality process, can be
correct and confirmed by FEA from electrical and reached SC proof transformers.
mechanical design point, the chance to fail is still
50% as the manufacturing procedure has to OBJECTIVES
follow the precision of the design to achieve the Identifying current practice problems
closest possible transformer to the designed one. It’s costly, time consuming, hard procedure which
Even if the manufacturing procedure was perfect at the end not ensure the highest number of SC
and the manufactured transformer is 100% proof transformers on the network, as the focus
similar to designed one, there is still 20-30% was only on one special unit.
chance for failure as the built in material quality In fact, precise design calculations or paying
has to have the same properties considered extra attention and care for one special unit, will
during the design, by controlling the material never be enough to secure a series of "similar"
quality and production process this probability of transformers to be SC proof. Therefore every
failure can be reduced significantly. party involved in the chain of power transformer
industry should update it's methods.
Summary, if all the process steps are made with
highest preciseness there can exist at least 15- Finding solution to reliable transformer from SC
20% chance for failure. point
The answer will be upon you, how much per cent To make a network reliable not enough to make
your factory is achieving from this precision.

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only one transformer of the network SC proof, II. Repeated steps in each year for the
therefore the changes should start at the subject factory or up on request from the
specification requirements from the Utility/End customer:
user, where the in process inspection should be 1. Technical evaluation of production
mandatory, with knowable team in power methods for:
transformer design and manufacturing a. Winding manufacturing
procedure, who are able to review every stage b. Winding treatment(pressing, drying,
such as the winding, active part assembly and assembling, storing)
tank assembly process. c. Phase block assembling
To comply with the specification, the d. Clamping system fixation
Manufacturer should apply the available e. Internal connections
simulation and calculation methods and
techniques offered by the latest software and PC 2. Technical evaluations of the material
capabilities to ensure a SC proof design. quality check procedure.
Combining with a production procedure which
using the latest machineries for precise active The main question is, if the manufacturer is
part manufacturing and the available techniques capable of producing reliable SC transformer,
and equipment for material quality check would before starting any kind of SC calculations. As
result a much higher probability for SC proof one successfully SC tested unit is not proving
transformers than ever before. To update the that the production is qualified to produce
Manufacturer's procedure would bring lower cost continuously reliable SC proof transformers.
in 5 years terms as the number of replacements
of failed transformers during guarantee period Why is viable this method?
would drop down, as the transformers would be Basically, a similar method should be the normal
SC proof. procedure of every successfully qualified factory
Therefore the SC Test Lab. should be capable among the SC proof transformer manufacturers.
and open to extend the practical knowledge and We know this is not the case, and we are willing
design skills of their team to be fully aware of the to present by this method an opportunity to focus
power transformer designing and manufacturing more on improvement and spend less on costly
process in order to certify transformers based on test procedures. Although we agree, in case of a
the below method. new factory the shortest way to its customers, is
to perform a SC test on its designs. After all this
METHOD
could be changed by changing the mentality of
The base of our method is observational, through
the industry in the first place, to open for new
practical experience of the past 13 years, with
opportunities and techniques.
participation in the design/manufacturing and
testing of successfully SC tested transformers.
COMPLIANCE WITH STANDARDS
This method can be applied as general rule since
Our proposed method has simple strict steps
it is also supported by the IEC standards, where
which are divided into two categories:
in the 60076-5 the theoretical evaluation of the
I. Repeated steps for each design:
ability to withstand the dynamic effects of SC is
considered as equivalent with a SC test carried
1. Detailed design review, which includes out in a SC test lab.
the investigation of electrical and mechanical Also, it is clearly mentioned as a similarity
parts from the point of: condition, the reference unit and new unit has to
a. Calculation and theoretical correctness go through the same manufacturing process.
b. Practical and physical correctness
c. Minimum material quality description
d. Simulation of operation(multi-physics)
CONCLUSION
Every aspect of the transformer manufacturing
even such sensitive requirement as SC proof,
2. In process attendance and inspection
can be efficiently and economically ensured by
during manufacturing. updating the old-school procedures and
techniques with the possibilities of the new
simulation and calculations and techniques of the

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design, quality and manufacturing procedures.
Everything is only a matter of invested work and
effort at the start up and above all the true
intention behind the actions.

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