2-china triangle transformer development en
TRANSCRIPT
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7/29/2019 2-China Triangle Transformer Development En
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HAIHONG CO.,LTD
Technological Development andContribution to Energy Conservation of
3D Core Transformers in China
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HAIHONG CO.,LTD
Technical Characteristics of 3D Core
Transformer2
Amorphous Alloy 3D Core
Transformer3
3D Core Transformer's Contribution to
Energy Efficiency
4
Table of Content
Preface1
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China is a country of the fastest growth of energy consumption in the world and also acountry suffering energy scarcity; energy conservation is a basic state policy for China to
build a conservation-minded society. To honor the two commitments of Chinese
government, namely the proportion of non-fossil fuel in primary energy consumption
should be around 15% by 2020; and CO2 emission of per unit of GDP should be down by
40-45% over 2005, the task of energy conservation and emission reduction is daunting.
According to estimation, power loss during transmission and transformation accounts foraround 7% of the gross generation; while transformer is important equipment in power grid
and the total loss caused by transformers accounts for around 3% of the gross generation.
Every 1% reduction of power loss of transformers could save 10 billion KWH per year.
Given the policy background of ensuring power supply, conserving energy and reducing
emission, it is inevitable to promote high-efficiency and energy-saving transformers.
I Preface
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Energy-saving transformers reduce power loss through two ways: first, structureimprovement, representative product is 3D Core Transformer; second, the adoption of
conducting magnetic material of low magnetic saturation, representative product is
Amorphous Alloy 3D Core Transformer.
The R&D of 3D structure transformer started in 1960s; due the constraints of materials and
technologies, by the end of 1990s, some domestic manufacturers introduced core equipment
and gradually developed 3D Core transformers. After 2003, core transformers havegradually won users' recognition and been put into use. With the technology R&D of 3D
Core Transformer maturing and supporting equipment being developed, there are more and
more manufacturers of 3D Core transformers with certain production capacity and 3D Core
transformers are being widely used.
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Since 2005, over 100,000 sets of 3D Core transformers have been put into operation
in various fields and the products performing excellently in performance parameters,
performance-to-price ratio, noise, quality reliability etc.Currently, the capacity of a single set of in-grid 3D Core oil-immersed transformer
could reach 6300kVA, voltage class could reach 35kV. Currently, the capacity of a
single set of dry type 3D Core transformer could reach 5000kVA, voltage class could
reach 35kV;
Currently, over 200 manufacturers could produce S13 oil-immersed transformer in
China, and over 60% of them could produce 3D Core transformer. The industrial base
is wide;
Currently, 3D Core transformers using Amorphous Alloy have been developed,
signifying another great breakthrough of 3D Core transformers in the field of energy-
saving transformers.
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II Technical Characteristics of 3D Core Transformer
3D Core is a structure with 3 identical single frame continuously wound by several
trapezoid tape; three pillars of the core shape a equilateral triangle and the 3 phases are
symmetrical.
3-phase magnetic circuits of the core are completely balanced; the magnetization direction
is identical with the direction of rolling of silicon steel, magnetic flux distribution is even
with neither lap nor seam; there is neither obvious high resistance area nor distortion ofdensity of magnetic flux at the seams.
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3D Core transformer is an energy-savingtransformer with better structure and
performance. It has the following
outstanding benefits:
(1) reduced material;
(2) reduced energy;(3) 3-phase equilibrium;
(4) low no-load current;
(5) low noise;
(6) strong overload capacity;
(7)strong emergent short-circuit
protection;
(8) low strength of electromagnetic field.
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Material reduction rationale of 3D Core Transformer-No.1
3D Core is continuously wound by several
trapezoid tape; different sizes of trapezoid
tapes are cut by special line cutting machine,
and the material utilization rate is almost
100%.
The upper and lower yoke and pillar
of the stack core will unavoidably
punch off waste materials of thetriangle; according to estimation,
such waste materials account for
around 5% of the gross weight of the
core.
Diagram of 3D Core
Diagram of stack core processing process
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Material reduction rationale of 3D Core Transformer-No.2
HAIHONG CO.,LTD published a dissertation on the 05edition of the transformer magazine for 2012, titled Analysis
of Basic Characteristics of S13 3D Core Transformer. The
analysis and calculation of the weight difference of 3D and
stack cores under the condition of same diameter, profile,
window height and center distance show that S13 3D core
transformer could save around 20-25% of silicon steelcompared with S13 stack core transformer of the same
capacity.
3D Core under the same conditions
Stack Core under the same conditions
comparison of consumption of silicon steel
Stack core
3D core
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Material reduction rationale of 3D Core Transformer-No.3
The fill-factor within the circle of the profile of pillar of 3D core; with same effective
pillar area, the diameter of 3D Core pillar is small, thus reducing the length of winding
wire and saving winding wire. Therefore, 3D core transformer could save winding wire
compared with stack core transformer.
Profile of 3D Core pillar Profile of Stack Core pillar
Fill-factor 0.95-0.96 Fill-factor 0.89-0.925
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Energy reduction rationale of 3D Core Transformer
Unit metal loss of core PtProcessing factor K0Gross weight of core
G
Formula of no-load loss of transformerP0 =K0G Pt
P0is directly proportional to G, K0 , Pt
Gross weight of core G 3D Core saves core material compared with Stack Core;
Processing factor K0 3D Core processing factor: 1.05-1.1, Stack Core processing factor: 1.15-1.3;
Unit metal loss of core Pt It depends on the performance of silicon steel sheet; using high brand number (low
loss) sheet could reduce no-load loss effectively.
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3-phase equilibrium of 3D Core Transformer
Phase A Phase B Phase C
Magnetic circuit connectingphase A and B
Magnetic circuit connecting phase
A and C
Magnetic circuit connecting
phase B and C Analysis of stack core 3-phase magnetic
circuit:
Length of coupled magnetic circuit between
Phase A-C: Lac=(2*M0+H0)*2
Length of coupled magnetic circuit between
Phase A-B and Phase B-C:
Lab=Lbc=(M0+H0)*2
Conclusion: the magnetic circuit betweenPhase A-C is longer and the magnetic
resistance is bigger, leading to bigger no-load
current of Phase A and Phase C, thus
disequilibrium of the 3-Phase.
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Low no-load current of 3D Core Transformer
ModelNo-load current (A)
Phase a Phase b Phase c
S9-M-315/10
3.30 2.70 3.47
3.69 2.93 3.82
3.79 3.06 3.58
S13-MRL-315/10
0.47 0.46 0.46
0.48 0.46 0.47
0.50 0.52 0.48
See the following table for the comparison of value of testing of no-load current of oil-immersed3D core and stack core:
The table shows that: The 3 phases of no-load current of oil-immersed stack
core transformer is imbalanced, with phase b the
smallest;
The 3 phases of no-load current of 3D core immersed
oil transformer is balanced and low.
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Low noise of 3D Core Transformer
On-site testing value: 43.5dB(A)
low noise of on-site operation
3D core is tightly and continuously wound silicon steel tapes byspecial core winding machine with no seams; the magnetic
conduction direction of the silicon steel tape is identical with
direction of magnetic circuit of the core, thus addressed the noise
problem due to the incoherent magnetic circuit of stack core,
minimizing the noise.
Compared with S11 stack core oil-immersed transformer, S13 3D
core oil-immersed transformer of the same capacity could reducenoise by 10-20dB (A).
The testing result shows that the noise of SCB13 3D core dry-type
transformer could be reduced to below 45dB(A).
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Strong overload capacity of 3D core transformer
As shown in the right picture, 3-phase coils of 3D Core transformer arein a layout of "", temperature difference of upper and lower metal
yokes give rise to air convection; due to the chimney effect at the
triangular area of the core, cold air will replenish to the center tunnel
from bottom up, and heat radiates out from the inner slope of the upper
metal yoke; the natural circulation takes away heat generated by the
transformer rapidly.
Meanwhile, the metal yoke of 3D core is semicircular with a slope of
30 degree, a thickness of 0.75 time of the diameter of core pillar; the
area exposed at the end of the coil is enlarged and the colling
conditions of 3-phase is the same. Capitalizing on the chimney effect,
heat could not concentrate at the triangular area and the temperature
increase at the center triangular area is similar to the temperature
increase at the top layer.
Diagram of theory of cooling of 3D Core transformer
Plane view of circular coil of 3D core Temperature increase testing model
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Strong short-circuit protection capacity of 3D core transformer
To reduce the length of upper and lower metal yokes of the core so as to save silicon steel,
traditional stack core transformer has olive-shaped core profile and corresponding olive-
shaped coil structure. The stress of the long and short axises of the olive-shaped coil is
uneven, compromising the short-circuit protection capacity of the transformer.
3D core transformer has circular core profile and circular coil, therefore the anti-impactcapacity is strong under short-circuit power impact.
Diagram of 3D core circular coilDiagram of stack core olive-shaped coil
Analysis and comparison from coil structure:
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Strong short-circuit protection capacity of 3D core transformer
There is no oil track at the arc section at two sides of the short axis of the olive-shaped
coil, so temperature at the two points are the highest; long-term overheating leads to
insulation aging, thus leading to short-circuit and other failures.
While 3D core transformer uses circular coil with oil track around the circular, leading
to appropriate distribution of oil flow, thus generating the optimum cooling effect.
Analysis and comparison from coil heat stability:
Plane view of olive-shaped coil of stack coresection without
oil track Top view
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Strong short-circuit protection capacity of 3D core transformer
Fixture and padding of plane coil transformer are mainly arranged at the two sides of
core; Majority of end area of Phase B coil under the metal yoke could not be tightly
pressed, thus the stress situation is inferior to Phase A and C. While the frame pieces and
paddings of the 3D triangular core transformer are distributed around the transformer and
the paddings are pressed tightly by metal press in the center; the 3-Phase stress are
symmetric and identical; Fixture of 3D core transformer is a triangular frame structure, integratedly welded. due to
the stability of triangular, the overall strength is big and the 3-Phase stress is identical, so
the short-circuit protection capability is strong.
Analysis and comparison from motion stability of coil
Body of 3D core transformerBody of plane core transformer
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Low strength of electromagnetic fields of 3D core transformer
The tight and symetrical coil structure of 3D coil greatly reduces scattering magnetic filedsaround the transformer. Limited magnetic leakage reduces electromagnetic radiation.
Analog picture of 3D core magnetic fields
Top view of 3D Core magnetic fields
Top view of stack core magnetic fields
Front view of 3D Core magnetic fields
Front view of 3D Core magnetic fields
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III Amorphous alloy 3D core transformer
Amorphous alloy 3D core transformer
combines the dual advantages of amorphous
alloy material and 3D core structure.
This product makes breakthrough on the
plane core structure of amorphous alloy
transformer and adopts the perfectcombination of 3D core structure and low loss
feature of amorphous alloy material,
addressed the bottleneck of traditional
amorphous ally plan core transformers, such
as loud noise, weak short-circuit protection,
small capacity, large volume, high material
consumption and non-renewable use of core,showing bright prospect for development.
Amorphous alloy belts
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IV Contribution to energy conservation of 3D core transformer
According to estimation, if all newly installed transformers in China uses 3D core
transformer, it could save over 100,000 tons of silicon steel per year, greatly reduce rods
and materials, saves energy of 1.45 million tons of standard coal and saves 3.088 billion
yuan of electricity and cutting 29,000 tons of SO2 emission.
According to statistics, there are 1.1 million sets of S7 and below high loss transformers in
operation; if part of them could install S13 3D core transformer, the economic and social
benefits will be tremendous. Take products with a capacity of 500kVA as an example:
ProjectNumber
of sets
Electricity
saving per
year
(KWH)
Saving
electricity bill
per year
(yuan)
In (tons) of
standard
coal
Cutting
(tons) of
CO2
emission
indirectly
Cutting
(tons) of
SO2
emission
indirectly
Replacing S7
with
S13
1 21,300 15,500 7.23 18.80 0.15
1.1
million23.43 billion 17.05 billion
7.953
million
20.68
million165,000
Note: electricity bill calculated at 0.73 yuan/KWH, standard coal consumption for power generation calculated at
340g/kwh according to the figure in 2010.
CO2 emitted by the burning of 1 kg of standard coal calculated at 2.6kg, and for 20g for SO2.
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