BHEL make Instrument

Transformers
More than 30 years of Experience
 BHEL make Instrument
Transformers
• High reliability is demanded from application point
of view, which is adequately exhibited & proven by
successful operation of BHEL make Instrument
Transformers
• We are able to meet diverse demands of various
clients
• Our Instrument Transformers conform to the latest
provisions of Indian as well as International
standards
 Major Customers
• BHEL make Instrument Transformers are in
successful operation at various sub stations
of
NTPC, PowerGrid, MSEB, UPSEB, TNEB,
BBMB, KEB, KPCL, Neepco, MPEB etc.
 Instrument Transformers
• Instrument Transformers are subdivided as:
– Current Transformers, Outdoor type 110 to 400
kV
– Voltage Transformers ...........VT
• VTs are again of two types
– Magnetic Voltage Transformers (MVT)(Up to 220
kV are manufactured at BHEL Jhansi)
– Capacitor Voltage Transformers (CVT) (Up to 400
kV are manufactured at BHEL Bhopal)
 Current Transformers
• Highly reliable operation of current transformers
successfully proved by:
– Partial discharges within specified limits
– High short time current withstand tested for 40 kA for 3
Seconds
– Suitable to withstand abnormal stresses due to operation
of isolators, LAs, breakers
– Thermal stability proved by tests
– Low temperature coefficient of Tangent delta ensures
high stability of insulation even at elevated voltages
 Reliability

• BHEL make instrument transformers

have performed in EHV systems
exceptionally well
• Use of our instrument transformers
ensures long trouble free service, which
means availability of protection when
needed
 Manufacturing Process
• All stages of Manufacturing Process are according to BHEL
procedures & Quality assurance system which is certified to
ISO‑9001.
• The main insulation & assembly are done in a clean
surrounding in order to avoid contamination.
• Before filing with processed insulating transformer oil, the
transformers are dried under vacuum so as to reduce the
moisture content
• Effective sealing is provided to enable negligible moisture
level during service.
 General Description of Outdoor
Current Transformers

Outdoor CTs are basically of 3 types of

construction
1 Dead Tank with U (Hair Pin) shaped
primary
2 Dead Tank with Eye Bolt primary
3 Live Tank or Inverted primary CT
 Constructional Details of
BHEL make CTs

• We at BHEL manufacture Hair pin CTs

because of proven exceptionally high
reliability
• These CTs are Oil filled and
hermetically sealed with Nitrogen gas
cushion
 Constructional Details of
BHEL make CTs
• The primary is linked with independent
secondary ring cores having windings
connected to terminal box on the tank
side.
• The whole assembly forms a common
space for oil and is sealed from the
atmosphere, the top chamber serving
as an expansion chamber.
 Constructional Details of
BHEL make CTs

• The space above the oil is filled with

nitrogen which acts as a cushion for
changes in oil volume due to
temperature and load current variations.
 Application of Current
Transformers
• Current Transformers are further
classified from application point into
– Metering CTs
– Protective CTs
 Application of CTs
• The duty of the Metering CTs requires
higher accuracy over the normal
operating current range
• The duty of the Protective CTs requires
specified accuracy for correct
reproduction during the passage of the
abnormal current through primary due to
system fault conditions.
 Multi ratio CT & selection of
ratios (e.g. 150 ‑200 ‑300 / 1)

• A CT can be of multiple ratios.

• The desired ratio can be achieved in 3
ways
– Primary reconnection
– Secondary tap selection
– Primary & Secondary both
Simultaneously
Disadvantages of Primary reconnections

• Short circuit forces increases at higher

primary turns
• Useful only when ratios are in geometric
proportions (e.g. 150 -300 -600 / 1)
• Reconnection is possible only after
shutdown & opening of line connections
• In case of multi core CTs, independent
selection of ratio is not possible
 Advantages of Primary Reconnections

• Fixed secondary output

• Higher Amp. Turns even at lower ratio

leading to better accuracy & reduced core
size

• Simple secondary winding

 Some special features of
Instrument Transformers
• Proper drying of the paper insulation
used in Instrument Transformers is an
essential pre‑requisite for its long and
trouble free service
• We ensure that the paper insulation
used is in a state of perfect dryness by
continuous monitoring of the process
 Technical features of BHEL make
400 kV C Ts
• Hair pin design having porcelain with
metallic flanges which is extremely robust
and stable.
• Well adapted against Seismic forces
• High reliability proved in service
 Technical features of BHEL make
400 kV C Ts(Cont’d)
• Positive pressure of Nitrogen is provided over oil
for hermetical sealing, which controls
contamination of oil. Thus CT is practically
maintenance free
• High conductivity copper tube is used as primary
winding ensuring better thermal and mechanical
performance, during fault conditions
• Total independent selection of ratios through taps
on secondary windings provides operational
simplicity with individualistic ratio selection on any
secondary core
 Technical features of BHEL make
400 kV C Ts
• Metering core is carefully designed to provide
safety to the connected instruments from too
large a value of over current during fault
conditions.

• With the nearby High power short circuit

CPRI test station, all other Testing facilities
for complete routine and type tests for high
voltage are available
 Technical features of BHEL make
400 kV C Ts
• CTs have been demonstrated to be
exceptionally robust to withstand high
frequency FAST transient currents as
prescribed by CIGRE.
• Such transients are now known to have led
to catastrophic failures of CTs worldwide.
• The appearance of such transients is
explained under “Unusual Stresses”
 General Design Aspects – CTs
• Five main factors
– Rated Primary Current
– Rated Short time Current
– Insulation Level
– Pollution requirement
– Burden & Accuracy on different secondary
cores
 General Design Aspects - CTs
• Rated Primary Current
– The design is made according to the standards for
permitted temperature rise over the specified ambient
for the continuous Rated Primary Current. The
extended current rating if specified is to be taken care
of.
– The extended current rating may be from 120% to
200%.
– The extended current means that accuracy is
maintained up to that level and CT can continuously
carry the thermal current equal to the rated extended
current
 GeneralDesign
General Design Aspects
Aspects- -CTs
CTs
• Rated Short time Current
– This is the maximum thermal current Ith which must
be withstood by CT for a period of one second. The
maximum temperature permitted for oil insulated
CTs is 250 Deg. C.
– It is essential that CT can safely withstand the fault
current flowing through it at its position, else in the
eventuality of CT failure the entire associated
equipment is left unprotected as no signal will be
available to relay for decision making.
– The dynamic withstand is calculated by the first
current peak which can reach 2.5 times the Ith
 Short Time Current (Ith)

• If short time withstand current is not

specified, it can be estimated by
converting the Fault level in MVA to
short time current using the rated
voltage, or, the breaking capacity of the
associated breaker may be used
• For 400 kV CTs the Short time rated
current is given as 40 kA for one Second
 Short Time
Short Time Current
Current(Ith)
(Ith)
• The peak value of the dynamic current gives
rise to the electromagnetic forces between the
primary winding turns or arms of the hairpin.
• The force is proportional to the square of this
dynamic peak current
• It is essential that CT should withstand both
the thermal effects of short time current as well
as the forces due to the dynamic current
 Insulation Level
• The CTs or the Instrument Transformers must
withstand the continuous operational voltage and also
the over-voltages of the network. These include:
– AC one minute test voltage
– Lightning Impulse withstand voltage
– Switching Impulse withstand voltage as defined for
300 kV and above system voltages

– Highest System voltage Um

 Primary Winding P1 P2

• The primary winding insulation is

designed on the basis of equal
capacitance and uniform Axial
stresses principle.
• The insulation of 330 and 400 kV
CTs is formed from 19 equal
capacitive grading steps formed
from the insertion of Aluminium foils
between High quality Kraft paper
CO RE 1 CO RE 5
CO RE 2
CO RE 4
CO RE 3
 Pollution Condition
• The total creepage is specified
according to IEC: 44 for the pollution
condition as
– Light, Medium, Heavy and Very heavy
where the minimum creepage distance
of the porcelain weather casing shall be
16, 20, 25 and 31 mm/kV respectively.
 Burden and Accuracy
• The primary of CT is connected in series
with the transmission line & thus the
primary current is not affected by the
burden of CT secondary cores
• Neglecting exciting current of CT core,
from the principle of equal Ampere-Turns,
the primary and secondary Currents of CT
are related by:
Np Ip
Is 
Ns
 Burden and Accuracy
• The errors in the CT are introduced by the
exciting current as shown in the equivalent
circuit & its simplified version:
ip ie
Is
iw iwl BURDEN

ip ie Is
BURDEN
 Burden and Accuracy

• The error in the CT is introduced by

the exciting current Ie as can be
seen by the relation:
Ip = Ie + Is , or
I s = Ip - I e
 Errors
• The exciting current Ie introduces errors in
ratio and phase, which are defined by
standards as:
K n .I s  I p
Current ( Ratio) Error   100
Ip
Phase displacement:
This is the phase angle difference between
primary & Secondary Current Vectors & is
positive when Secondary current leads
primary current
 Burden and Accuracy

• For keeping the exciting current low

– Flux density in the CT core is kept low,
– The CT core diameter must be reduced
– The AMP TURNS are made as high as
possible.
 Accuracy
• The CT error is inversely proportional to the square of
Ampere Turns
• To get high accuracy with low value of instrument
security factor the core material is made of Nickel
Iron alloy
• Metering cores : To protect the meters and
instruments from the damaging effects of high fault
currents the core must be designed to saturate at say 5
to 10 times rated current.
• FS, Instrument Security Factor in general indicates
the over current expressed as a multiple of the rated
current. This is applicable only at the rated burden.
 Burden and Accuracy
• The accuracy class is maintained from 25%
to hundred per cent of the rated burden.
• Therefore if high VA burden is specified the
errors will increase at lower burdens due to
the invariable use of the TURNS correction.
• Since the minimum error is generally reached
between 50 - 75% of rated burden, the core
can be optimised by setting the rated burden
at about 1.5 times the real burden.
 Unusual Stresses in EHV CTs
• The understanding of high frequency stresses
in UHV systems and other considerations
such as thermal stability etc. makes it possible
to critically review designs and produce most
reliable Instrument Transformers
• The high frequency stresses in EHV CTs can
be represented on a zone of
amplitude‑frequency plane. For example in
400 kV CTs the amplitude is up to 1000 kV &
frequency from 100 kHz to 5-20 MHz
 Unusual Stresses(Cont’d)

• The traditional tests therefore did not cover

the stresses produced by disconnector,
breaker or LA operation in a station for a 400
kV system.
• The operation of the Isolator is the most
dangerous for the 400 kV CTs. Numerous
arcing discharges take place whenever it is
opened or closed to put the voltage on the
bus bar or to take away the energisation from
the busbar.
 Unusual Stresses(Cont’d)

• Let us consider the closing of the

disconnector.

• When the gap between the poles starts

to reduce during closing operation the
first discharge will take place between
poles at voltage maximum.
 Unusual Stresses(Cont’d)
• Because of sudden change of the voltage
from zero (Ignoring the charge in the busbar
due to the capacitive coupling) to the crest of
the system voltage, the high frequency current
will flow.
• This wave then spreads on the bus bar and
successive reflections of these waves leads to
high frequency oscillations. There are many
resonant frequencies due to the presence of
different inductances and capacitances.
 Unusual Stresses(Cont’d)
• The capacitance of the Instrument transformer and
Power transformer mainly supports this current.
The discharge ceases within a few microseconds.
• The jaws of the disconnector after some
milliseconds again shall have the disruptive
discharge but at a lesser voltage. This rate of
spark over increases as the poles get nearer.
• When the disconnector arms are nearer in a 400
kV network, as many as 40 restrikes can take
place across its slowly moving poles.
 Unusual Stresses(Cont’d)

• Due care in design is exercised to avoid

formation of large voltage drop patches
at high frequencies where there were
none at Power frequency of 50 Hz.
• This avoids failure of CT insulation due
to the operation of Disconnectors, LAs
and Breakers
 DO's for CTs

• Check for any transit damage

• Check the nitrogen pressure on the top
chamber before commissioning
• Check oil level in CT
• Attend leakages on bushings immediately
• Examine the porcelain for dirt deposits &
clean periodically
 DO's for CTs(Cont’d)
• Ensure that the terminals of unloaded
secondary are shorted
• Earth the power factor terminal by earthing
post
• Check that tank is earthed positively and
permanently.
• Use the lifting lugs provided on the bottom
tank for lifting the CT by slings
 DON'Ts for CTs

• Do not mix oil unless it conforms to IS 335

• Do not commission the CT, if the oil is not
seen in oil gauge
• Do not allow dirt and deposits on bushings.
Clean periodically
• Do not leave terminals of unloaded
secondary open
• Do not lift the CT by primary terminals or by
porcelain housing
 Some special features of
Instrument Transformers
• In order to ensure leak‑proofness of the
gasketted joints, Instrument
Transformers of BHEL make are
subjected to oil pressure test of 0.7 kg.
per sq. cm (10 psi)
• Any leak detected is rectified and
further application of pressure is
continued.
Capacitor Voltage Transformers
• 400 kV
Capacitor
Voltage
Transformer
 Evolution of CVT Concept
• Capacitor Divider
• Capacitor Divider with Transformer
• Capacitor Divider with Tuning
Reactor and Transformer
 CAPACITOR DIVIDER

C1 C1

IL IL

V1

C2 V2 V in C2 V2 Z
 CAPACITOR DIVIDER WITH
TRANSFORMER
C1
X L = XC 1 + C 2
C1 IL
IL
n
V1 C2 Z
Vin
C2 Vin V2

n :1
 CAPACITOR DIVIDER WITH
TUNING REACTOR AND
TRANSFORMER
C1
X L= X C 1 + C 2
C1 IL
n IL
V1 C2 Z
Vin
C2 Vin V2

n :1
 Schematic Diagram of CVT
C1
MVR
X1 X2
1 2 3 4 5 6 7 8 9 10

11
1a

C2 1a'
1n
Link 2
12
21
22 2a
31 2a'
32 2n
IVT 41 Link 2
42
51 3a
52
61
DAMPING DEVICE
3n
62 Link 2

LINK 3 LINK 1
 Capacitor Voltage Transformer
• The Capacitor Voltage Transformers (CVTs)
are used for supplying voltage signal to the
measuring instruments and protective relays
• Simultaneously the CVTs are used as
coupling capacitors for Power Line Carrier
Communication (PLCC).
• The CVT consists of the Capacitor Voltage
Divider(CVD) and Electromagnetic (EM) unit.
 Design features of BHEL make
CVTs
• Stepless Design
• Hermetically Sealed Unit
• Simple and Reliable Circuit
• PLCC Performance
– High frequency capacitance within 80% to 150% of the rated
value & HF resistance 40 Ohms at carrier frequencies.
– Stray capacitance / Stray conductance of LV(HF) terminal of
Capacitor divider of CVT less than 300+0.05*Cn pF and 50
micro Siemens respectively from 30 to 500 kHz
Design features of BHEL make CVTs
• Ferro-resonance Stability
– The CVT must be stable against Ferro-resonant
oscillations. This is assured by careful matching of high
impedance damping device with the CVT parameters.
The design provides stability in all respects such as ,
• Sudden energizing of the CVT when connecting in the
UHV line or the bus
• Single or three pole high speed auto reclosing
Removal of secondary short circuit, and
• Sudden changes of primary Voltage
 Design features of BHEL make
CVTs
• Elimination of spark gap
– The CVT is designed so that spark gap
or over voltage protection device
across intermediate capacitor is not
needed
– The improved damping and spark gap
elimination ensure excellent reliability of
CVT during operation
 Design features of BHEL
make CVTs
• Transient Response

– Meticulous design care, in particular

the high impedance ferro-resonance
damping device presenting minimum
burden has ensured better transient
response for CVTs as compared to
IS: 3156/IEC 186 stipulations
 Precommissioning Checks- CVTs
• Check ratio of the CVT at low voltage of about 230 to 2000
volts to confirm soundness. The CVT ratio will tally with the
marked value.
• If Zero secondary voltage is found. It indicates one of the
possibilities:
– Secondary shorting , or,
– Discontinuity in winding inside the transformer, or, Broken
connection inside the capacitor.
• The partial breakdown on the high voltage capacitor will
result in higher voltage on secondary
• Lower secondary voltage may be due to the partial failure in
the intermediate capacitor zone
 DO's for CVTs
• Check for any transit damage.
• Check the Nitrogen pressure and CVT ratio at low voltage
before commissioning.
• Check oil level in EM Unit.
• Attend leakages on CVT immediately
• Examine the capacitor porcelain for dirt deposits and clean
periodically on deenergised and safely earthed CVT.
• Check that the tank is earthed at two points and links 1,2 & 3
are kept in position.
• Check that the primary and secondary terminal box covers
are in position and sealed properly.
 DON'Ts for CVTs
• Do not connect Auxiliary VT/or inductive burden in CVT
secondary which saturates before three times the rated
voltage
• Do not short the CVT secondary terminals or primary
tapping coils
• Do not connect CVT secondary in closed delta
• Open delta connections should not be earthed at more
than one point.
• Do not roll, don’t keep upside down, and don’t leave the
capacitor housings in horizontal position which is
generally observed at site
 DON'Ts for CVTs

• Do not leave primary/secondary terminal

box cover open
• Do not energize CVT from secondary side
• Do not energize CVT, if earth links 1, 2 and
3 are not in proper position
Design features of BHEL make CVTs
Capacitor Voltage Divider
•Temperature compensated capacitor
dielectric system, results in low temperature
coefficient of capacitance.

•Shift in accuracy, due to steady as well as the

sudden temperature changes is minimum,
which leads to stable CVT accuracy.
We at BHEL wish to thank you,
for giving a patient hearing