TRAFOTECH 2018-Tenth International Conference on Transformers

Calculating circulating currents in clamping structure and enhancing

Mr. Manan Pandya, SIEMENS Ltd., Mumbai

INTRODUCTION
For large power transformers with high current The firm arrows and dashed arrows show
leads, the magnetic field due to the current direction of main current (in leads) and circulating
flowing in winding exit conductors and currents (in clamping frame parts) respectively. It
connection leads can lead to circulating currents can be observed that they are in opposite
in clamping frame (steel structure supporting the direction.
core and pressing the windings) which, if not
adequately calculated and controlled during
design stage, can lead to hot-spots and
consequently into gassing problems. Proper
control of circulating currents can lead to
enhancement of reliability and contribute towards
trouble-free operation of transformer.

CONCEPT
In large transformers, the clamping frame
structure supports the core and is typically made
of steel. Magnetic field due to the current flowing Figure B
in winding exit conductors and connection leads
get ‘linked’ with the clamping frame components EFFECTS
like the tie-plates, top and bottom frames etc. The total magnitude of losses created due to
and induce voltage in them. If the frame circulating currents is generally not the most
components are electrically connected, they act critical aspect as losses are typically less than
as a “shorted” turn or a loop and hence allow few kW. Normally, it is the loss densities (which
current to flow in ‘loops’ of clamping frame. This can reach dangerously high levels in certain
current is referred here as circulating current in parts or joints between components) that create
clamping structure. The concept of circulating excessive heating and lead to gassing when >
current in case of single phase generator 140deg.C. Cases of frame parts reaching
transformer with single layer LV inner winding is temperatures > 800deg.C and melted steel parts
depicted in Figure A. It shows flux linkage with due to circulating currents are also known. Hot
top frame and tie-plates of main and return limbs spots can typically occur when the clamping
while Figure B depicts flux linkage with bottom structure is inadequate to carry the circulating
frame. currents. Either the components are themselves
inadequately dimensioned to carry the current or
they may be not cooled sufficiently. Another
major location of hot spots can be the
mechanical joints between the frame
components where currents are flowing from one
component to another. Improper quality of joints
can lead to hot spot and subsequently lead to
gassing. The circulating currents can also be
induced in core laminations and lead to ‘core
burning’ issues which can be observed especially
at the mitered joints of core. One of the root
causes for such issues is that the frame parts as
well as the joints between components are
designed primarily with mechanical
considerations and not designed suitable to carry
currents, which can go up to few hundred
Figure A amperes in certain cases. Designers designing
 TRAFOTECH 2018-Tenth International Conference on Transformers

the frames may not be fully familiar of magnitude the reality. Figure C shows a current density
of electromagnetically induced currents. arrow plot from 3D FEM calculation of the above-
Electromagnetic design review, necessary mentioned single phase generator transformer.
calculations as well as suitable design changes The direction of circulating currents can be
could be helpful in avoiding problems due to compared with Figures A & B.
circulating currents.
RISK OF HIGHER CIRCULATING CURRENTS
CHALLENGES Risk of induction of higher circulating currents is
Circulating currents are generated due to the more in following cases:-
inductive coupling between the connection leads ● Generator transformers with high current
(or winding exit conductors) and the clamping innermost winding having lead entry & exit at
frame components. Parameters like, magnitude top and bottom; mainly because of
of current, number of parallel leads, distance uncompensated magnetic fields from the high
from leads to clamping frame, relative distances current leads
of high permeability materials from frame and ● Transformers where number of tap leads (of
leads, influence of stray field from winding, regulating winding) is large and most of the
quality of joints between frame components, leads are carrying current in same direction
influence of tank and shielding types etc. affect ● Transformer having innermost multi-start
the generation of circulating current and its regulating winding with very large tap range
thermal effects hence it is quite challenging to ● Inadequate ‘magnetic’ distance from high
accurately estimate its effects. Analytical current leads or tap lead bundle towards
approaches using hand calculations or simpler frames or tie-plates
2D FEM simulations may not be accurate.
CASE STUDY OF CIRCULATING CURRENTS
CALCULATED BY INGENIOUS 3D FEM
METHOD
Commercial 3D FEM package was used to
simulate the electromagnetic situation for a large
single phase test transformer. The calculated
values were compared with actual current
measurements carried out on the frame
components. The simulations and test
measurements were carried out at 50% rated
current as they were done on active part in air.
Rogowski coil based current sensors were
installed on steel parts of interest. Adequate care
from thermal and safety aspects has to be taken
for testing in this condition.

Electromagnetic calculation:
● detailed 3D geometry was imported in FEM
tool
● 50% ampere-turns were assigned to the
windings
● properties based on material test reports were
assigned to all parts
● surface impedance boundary condition was
applied to mild steel parts eg. fames, tie-
Figure C plates, tank etc. as this leads to steel parts
being calculated as ‘hollow’ surfaces with
3-D electromagnetic field simulation is useful for losses concentrated only on outer ‘skin’ and
estimation of current to great extent. Over and not as volumes. As a result the
above specialized 3D FEM tools, necessary meshing/computational time and effort is
competence and broad experience is needed to reduced considerably. For ‘measuring’ the
determine how much close the results can be to currents through frame parts, an ingenious
approach was developed where current
 TRAFOTECH 2018-Tenth International Conference on Transformers

transformers (CT) were simulated over the

Figure E

RISK MITIGATION
After calculation of circulating currents, below
actions may be undertaken for avoiding the
heating and gassing problems:
1. design the parts and ensure their cooling by
Figure D taking the current into consideration eg. tie-
plates cooling can get critical in some cases
For the test transformer, calculated values vs. 2. ensure the quality of joints eg. surface finish,
measured values were compared at 13 data free of burrs, rust, paint etc.
points (locations). The error in 85% of data points 3. ensure adequate contact pressure at joints
was found to be < ±20%. Reasons for outliers under all conditions for life time eg. tie-plate to
was not clear but mostly they were for cases frame joints
where either the absolute magnitude of current 4. magnetic field compensation by routing leads
was relatively less or the part was physically of opposite current nearby eg. axial exit of
rather away from magnetic field source. two layer LV winding
Simulations at various current levels show that 5. higher distance from high current leads to
the induced currents can be linearly extrapolated frame parts
for higher main currents. Thus current values at 6. by-passing the joints with well-defined parallel
rated or overload conditions can be predicted. paths on frames; where control over currents
is better
EDDY Vs CIRCULATING CURRENTS
Conceptually, the circulating currents are
different than eddy currents. The eddies are CONCLUSION
generally created in conducting parts due to Circulating currents can lead to dangerous hot
magnetic field linkage but they are confined spots in certain transformers. This leads to gas
within the part and generally flowing in a smaller generation and eventually end users may be
circular paths. While circulating currents are forced to take a shutdown, jeopardizing the
induced in a network of connected conducting reliability and availability of critical asset like
parts and they flow from one part to another. transformer. The calculation and mitigation of
Resultant currents/losses are interaction of eddy circulating current is quite complex and requires
and circulating currents. Figure E shows current competence in advanced magnetic field
density arrow plot for tie-plate currents as well as calculations as well as detailed knowledge of
current in secondary CT coil. The eddy current in design and processes. With proper tools and
tie-plates (due to winding stray field) is adding to adequate knowledge this risk can be mitigated at
circulating current (due to LV leads) on left side the design stage itself.
of phase center leading to higher current density
(red color) while it is in opposite direction on right
side leading to lesser current density (blue color).