What is Transformer
Transformer is an electrical device which transfers electrical energy from one circuit to another using conductors or transformer coils. Transmission and Distribution of energy from generation point to distribution is vital. Generally, two most widely used transformers are Step-up and Step-down.
Benefits of Transformer
Change the voltage
The main advantage of transformers is that they can change the voltage. Since different loads require different voltages, the existence of transformers makes power transmission and use more flexible.
Improve the efficiency of power transmission
By increasing the voltage through transformers, the efficiency of power transmission can be improved. This is because as the voltage increases, the current decreases, thereby reducing the wire diameter and line loss required for the power line.
Save line materials
Since transformers can increase the voltage, the wire diameter required for the power line can be reduced, so line materials can be saved. This also makes the cost of power engineering lower.
Reduce power loss
Since the existence of transformers makes power transmission more efficient, it can reduce power loss. In long-distance power transmission, the use of transformers can significantly reduce energy losses in the power grid.
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Types of Transformer
Autotransformers
The primary and the secondary windings of standard transformers are oriented in opposite directions, but in autotransformer windings, the primary and secondary windings are physically and magnetically connected in series.
Air-core transformer
The main and secondary windings are both coiled on a non-magnetic strip, with the flux linkage between them being through the air. The mutual inductance of an air-core transformer is lower than that of an iron core transformer, implying that the reluctance supplied to the produced flux is higher in the air medium. In an air-core type transformer, however, hysteresis and eddy current losses are fully eliminated.
Iron core transformer
The main and secondary windings are both wound on several iron plate bunches, providing a great linkage path to the generated flux. Because of the conductive and magnetic properties of iron, it provides less reluctance to the linkage flux. These are common transformers with good efficiency when compared to air core transformers.
Distribution transformer
The main purpose of a distribution transformer is to lower the voltage for distribution to commercial and residential consumers.
Step-up transformer
The voltage level on the secondary side is increased by the step-up transformer. By increasing the number of turns in the secondary winding, the low primary voltage is increased. The primary winding to secondary winding ratio is less than 1. The schematic diagram of the step-up transformer is given below.
The Materials of Transformer
Core material
The core materials used in transformer mainly include iron sheet, low silicon sheet and high silicon sheet. Adding silicon into the steel sheet can reduce the conductivity of the steel sheet and increase the resistivity. It can reduce the eddy current and reduce the loss. We usually call the steel sheet added with silicon as silicon steel sheet. The quality of the silicon steel sheet used in the transformer is very high
The quality of silicon steel sheet is usually expressed by magnetic flux density B. generally, the b value of black iron sheet is 6000-8000, that of low silicon sheet is 9000-11000, and that of high silicon sheet is 12000-16000.
The materials commonly used for winding transformers
Enameled wire, sand wire, silk wire, the most commonly used enameled wire. The requirements for conductor are good conductivity, enough heat resistance of insulating paint and certain corrosion resistance. In general, it is best to use Q2 type high strength polyester enameled wire.
Insulating material
In winding transformer, insulation materials should be used for isolation between coil frame layers and winding resistance. General transformer frame materials can be made of phenolic paperboard, polyester film or telephone paper can be used for isolation between layers, and yellow cloth can be used for isolation between winding resistance.
Impregnating material
After winding the transformer, the last process is impregnating insulating paint, which can enhance the mechanical strength of the transformer, improve the insulation performance and prolong the service life. Generally, cresol varnish can be used as the impregnating material.
Power Distribution
Transformers are used extensively in electrical power distribution systems to step up voltage for long-distance transmission and step down voltage for distribution to homes and businesses.
Voltage Regulation
They are used to regulate voltage levels, ensuring that the voltage supplied to electrical devices remains within acceptable limits.
Electrical Isolation
Transformers provide electrical isolation between the input and output circuits, preventing direct current flow and protecting devices from electrical noise and faults.
Electronic Devices
They are used in electronic devices like chargers, adapters, and inverters to convert voltage levels for different components.
Industrial Applications
Transformers are used in various industrial applications, such as welding equipment, motor drives, and power supplies.
Renewable Energy
Transformers play a crucial role in connecting renewable energy sources like solar panels and wind turbines to the grid by converting the generated electricity to the appropriate voltage levels.
Audio Equipment
In audio systems, transformers are used for impedance matching, noise reduction, and ground loop isolation.
Instrumentation
Transformers are used in instrumentation applications to convert current and voltage signals to levels suitable for measurement and control.
Railway Systems
They are used in railway systems for traction purposes, to step up power for trains and step down power for signaling and lighting.
HVAC Systems
Transformers are used in heating, ventilation, and air conditioning (HVAC) systems to control the voltage supplied to various components.
How to Reduce the Partial Discharge of Transformers
Dust control
Among the factors that cause partial discharge, foreign matter and dust are very important factors. The test results show that metal particles with a diameter of ф1.5μm can produce a discharge much greater than 500pC under the action of an electric field. Whether metallic or non-metallic powder, a concentrated electric field is generated, which reduces the initial discharge voltage of the insulator and the breakdown voltage. For this reason, it is important to keep the environment and the body clean during the transformer manufacturing process, and dust must be strictly controlled. Strictly control the degree to which the product is affected by dust in the production process, and establish a sealed dust-proof workshop.
Centralized processing of insulating parts
It is very important that it contains metal dust because once the insulation sheet is attached to the metal dust, it is difficult to completely remove it. Therefore, it is necessary to centralize the treatment in the isolation workshop and set up an area that must be isolated from other dust-producing areas.
Strictly control the processing burr of silicon steel plate
Transformer core parts are formed by longitudinal and cross-cutting. These cut cuts have varying degrees of burrs. Burrs not only cause short circuits between chips, but also increase losses and increase the thickness of the core. What's more: when the iron core is inserted into the yoke or is subjected to vibration during operation, burrs can fall on the fuselage and discharge may occur. Even if the burrs fall to the bottom of the box, they can be arranged in an orderly manner under the influence of the electric field, causing a potential discharge to the ground. Therefore, the core burr should be as small as possible. The burr of the core part of the 110KV product should not be greater than 0.03mm.
Leads, cold-pressed terminals
The use of lead-pressed terminals is an effective measure to reduce the amount of partial discharge. When using phosphor copper welding, a large amount of spatter slag is formed, which is easy to diffuse to the body and insulator. In addition, the source boundary area must be separated by submerged asbestos wires so that water can enter the insulation. If the moisture is not completely removed after insulating the winding, the partial discharge of the transformer will increase.
Rounded component edge
The purpose of rounding the edges of the parts:
Improve the field power distribution and increase the discharge starting voltage. Therefore, metal structural parts such as clamps, pull plates, pads and bracket edges, pressure plates and outlet edges, the walls of the box riser and the magnetic shielding cover on the inside of the box wall in the iron core must be rounded.
Prevents friction from generating iron filings. For example, the contact part of the clip's hanging hole with the lanyard or hook should be round.
Product environment and body coating in the process of final assembly
After the hull is vacuum dried, the hull should be sorted before packaging. The larger the product, the more complex the structure and the longer the completion time. When the stem is compressed and fastened tightly, the stem is exposed to air, during which moisture absorption and dust dispersion occur. Therefore, the car body should be cleaned in dust-proof areas such as when finished (or exposed to air). time) more than 8 hours, must be dried again. After the completion of the hull, the stage of vacuuming and tank filling begins. Since stem insulation absorbs moisture during the stem trimming phase, it is necessary to dehumidify the stem. This is an important measure to ensure the dielectric strength of high-voltage products. The method used is to vacuum the product. Determine the vacuum time according to the body.
Vacuum lubrication
The purpose of vacuum oil injection is to inject transformer oil in a vacuum, eliminate dead spots in the insulation structure of the product by vacuuming the transformer, completely evacuate the air, and then completely absorb the transformer body. After oil injection, wait at least 72 hours before testing the transformer, because the degree of penetration of the insulation material is related to the thickness of the insulation material, the temperature of the insulation oil, and the immersion time. The higher the degree of penetration, the less likely it is to ejaculate, so make sure that you have passed enough absorption time.
Sealing of fuel tank and parts
The quality of the sealing structure is directly related to the leakage of the transformer. If there is a leakage point, moisture will inevitably enter the inside of the transformer, causing the transformer oil and other insulating parts to absorb moisture, which is one of the partial discharge factors. Therefore, it must meet reasonable sealing values.
Parts of a Transformer
Core
The core of the transformer is used to support the windings. It is made of soft iron to reduce eddy current loss and Hysteresis loss, and provides low reluctance path to the flow of magnetic flux. The diameter of a transformer' s core is directly proportional to copper loss and inversely proportional to iron loss.
Windings
Windings consist of several copper coil turns bundled together, each bundle connected to form a complete winding. Windings can be based either on the input-output supply or on the voltage range. Windings that are based on supply are classified into primary and secondary windings, meaning the windings to which the input and output voltage is applied respectively. On the other hand, windings based on voltage range can be classified into high voltage and low voltage windings.
Insulating materials
Insulating materials like papers and card boards are used to isolate primary and secondary windings from each other as well as the transformer core. These windings are made of copper due to high conductivity and ductility. High conductivity minimizes the amount of copper needed and minimizes losses. Moreover, high ductility results in easy bending of conductors into tight winding around the core that also minimizes the amount of copper and volume of winding.
Transformer oil
The transformer oil insulates as well as cools the core and coil assembly. The core and windings of the transformer must be completely immersed in the oil that normally contains hydrocarbon mineral oils.
Conservator
The conservator is an airtight metallic cylindrical drum fitted above the transformer that conserves the transformer oil. It is vented at the top and is filled only half with the oil to allow expansion and contraction during temperature variations. However the main tank of the transformer with which the conservator is connected is completely filled with the oil through a pipeline.
Breather
The breather is a cylindrical container filled with silica gel, which is used to keep the air that enters the tank moisture-free. This is because the insulating oil when reacts with moisture can affect the insulation and cause internal faults, which is why it is a must to keep the air free from moisture. In the breather, when the air passes through the silica gel, the moisture contents are absorbed by the silica crystals.
Tap changer
To balance voltage variations within the transformer, tap changers are used. There are two types of tap changers – on load and off load. In on load tap changers, tapping can be changed without isolating transformer from the supply, while in off load, the transformer needs to be disconnected from the supply.
Cooling tubes
As the name suggests, cooling tubes are used to cool the transformer oil. The circulation of oil within the transformer may be natural or forced. In the case of natural circulation, when the oil temperature rises, the hot oil naturally moves to the top and cold oil moves down, while in case of forced circulation, an eternal pump is used.
Buchholz Relay
Placed over the connecting pipe that runs from the main tank to conservator tank the Buchholz Relay senses the faults occurring within the transformer. It operates by the gases emitted due to decomposition of transformer oil during internal faults. Thus, this device is used to sense and in turn protect the transformer from internal faults.
Explosion vent
The boiling hot oil from the transformer is expelled during internal faults through the explosion vent to avoid explosion of the transformer. This is generally placed above the level of the conservatory tank.
Transformer Maintenance Methods
Clean the transformer housing and radiator regularly to prevent the accumulation of dust and impurities from affecting the heat exchange effect, while also reducing the temperature to ensure the normal operation of the transformer. Pay attention to safety when cleaning to avoid electric shock accidents.
Regularly check the transformer insulation system, including insulating oil, disconnector, insulator and grounding switch, to ensure that it is intact and can prevent leakage and short circuit faults. If there is a problem, it should be handled in time.
Regularly check the transformer oil level and oil quality to ensure that the oil level is appropriate and the oil quality is good. If the oil quality is poor or contaminated, replace the oil in time. At the same time, check the sealing of the oil tank regularly to avoid oil leakage.
Check the transformer cooling system, including oil pump, water pump, fan and radiator, to ensure its normal operation. If there is a fault, it should be handled in time to avoid overheating of the transformer and affecting the operation.
Regularly check the transformer electrical connections and terminals to ensure normal contact and fixation. If there are any problems, they should be dealt with in time to avoid electrical failures and safety accidents.
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