10-Transformer Cooling - Radiator Analysis

BALIKESIR ELECTROMECHANICAL INDUSTRIAL PLANTS CO.
DEVELOPMENT OF A TEST ROOM IN ORDER TO EXAMINE

TRANSFORMER COOLING SYSTEMS
Gkhan KALKAN
R&D Manager
November 16, 2015
Introduction
Thermal performance of power transformers has a significant effect on service life.

Flow characteristics within the active part and cooling equipment as well as
dimensions effects the heat transfer rate.
To better understand oil flow in the windings based on design parameters (spacer
width, disc width, cooling duct width etc.) CFD simulation tools can be used.
With coupled heat and flow solver, heat transfer parameters between cooling medium
and heat generating sources can be determined.
Some software couples electromagnetic and CFD simulations in steady state and
transient conditions
Increased capabilities of simulation tools can be used to determine thermal and
hydrodynamic properties of power transformers and reactors
Difficulties with CFD Simulations

Power transformers dimensions are becoming larger as the power rating increases
Number of mesh and nodes increase as the dimensions become larger
Simplifications are necessary to run the simulations
Symmetries with respect to some axis do not bring sufficient simplifications to the
model
Radiator CFD Analysis

Radiator Model/ONAN
Radiator cross-sections are very thin

To capture the true behavior of the flow at oil-duct
boundaries, inflation needs to be implemented
This generates very high number of mesh even for single
radiator section
Oil duct

Radiator model/ONAN
Single section radiator can be modeled with quarter model utilizing the symmetry in
terms of both the dimensions and the flow
Even in this case, for large power transformers, 2,143,041 mesh elements are
needed without fans and pumps.
Great simplifications can be obtained by modeling radiators as porous model
Flow volume mesh

Flow volume model
Quarter flow volume model

CASE (Natural ester transformer oil)
Temperature distribution
at inlet
Temperature distribution
at outlet
Inlet-velocity
Outlet-velocity

Porous Model
Porous model needs Pressure Drop vs. Velocity graph of the radiator
Simulations need to be run on actual, symmetric, model of the transformer
Outlet temperature, Pressure Drop and Heat Flux can be obtained based on the given
boundary conditions.
Velocity
Outlet
Temperature
Pressure Drop
Heat Flux
m/s
Pa
W/m2
0.05
345.6837
190.7731
284.8672
0.04
344.1276
159.2608
280.0674
0.03
341.6559
127.4781
272.5842
0.02
337.0856
94.8802
258.6851

Porous Model Velocity vs. Pressure Drop Graph
Simulations can be carried out for different oil types
Whole cooling unit can be modeled using porous zone to save from computation time

Porous Model Validation with 3 Section Model
Simulations are also checked with three sections and collector pipe to validate single
section model
Oil Flow in Cooling
Duct
(Porous Model)
P/L
(Radiator)
Collector Oil
Entry Velocity
Radiator Oil
Entry Velocity
P
(Radiator)
(m/s)
(Pa)
(m/s)
(m/s)
(Pa)
0.0025
15.8004
0.00535
0.01
50.56128
0.005
30.2713
0.01069
0.02
96.86816
0.0074
41.6955
0.01604
0.03
133.4256
0.0099
53.6156
0.02139
0.04
171.56992
0.0124
64.8941
0.02673
0.05
207.66112
0.0149
76.1434
0.03208
0.06
243.65888
0.0173
86.9805
0.03743
0.07
278.3376

Comparision of Radiator Model and Porous Model
Same simulations are also carried out with porous model.
Viscous resistance coefficient for radiators are determined.
Great simplifications for whole transformer CFD analysis can be performed.
VELOCITY-PRESSURE DROP GRAPH
250
Pressure Drop (DeltaP)
200
150
100
50
Radiator Model
Porous Model
0
0.01
0.02
0.03
0.04
Velocity (m/sn)
0.05
0.06
Test Room
Why Test Room is Needed?
All these efforts and simulations need to be validated.
Convection coefficients on air side has to be determined for radiators with multiple
number of sections.
As the number of sections increase, heat dissipation characteristics of radiator
decrease.
Performance of different oil can be determined and compared.
Different radiator oil-duct geometries, fan and pump performances can be tested.
Test room can be used to determine thermal and hydrodynamic characteristics of
windings with some modifications in future.
Performance of cooling equipment at different temperatures can be tested.
Test Room
Test Room Capacity
Test room is designed so that temperature range between -20 C and +50 C can be
achieved within 2 C accuracy
Thermal Capacity of the test room is 60 kW ( 5 kW)
Maximum radiator length is 4 metres
Maximum number of radiator sections is 30
Cooling fans and pumps can be added
Natural and forced convection can be simulated and tested
Test Room
3D Model
Test room will be equipped with control room where the flow and temperature settings
for the room, chiller group and tanks are controlled.
All the readings from temperature and flow sensors will be recorded into a PC.
Test Room
Test Room Dimensions
Measurement Systems
Temperature, Pressure and Velocity Measurements
Fiber optic sensors will be used to determine the air side convection coefficients.
The readings will be obtained from the top, middle and the bottom of the radiator
section.
Readings will be provided for every radiator section for forced and natural flow.
The average values will be computed to calculate the average convection
coefficient.
Test room temperature will be measured from 20 points and will be used to control
the test room temperature.
6 PT100 temperature sensor will be used to measure the oil temperature.
Oil flow will be increased/decreased with variable speed pumps.

Pressure at the inlet and outlet of the radiator will be measured by pressure gauges.
Measurement Systems
Velocity Measurement in Natural Flow
A challenge is to measure the inlet and outlet velocity at natural flow conditions.
Velocities are extremely slow at natural flow, close to creep flow
First, pressure drop and temperatures along the radiators will be measured.
Inlet to radiators will be closed and a second valve will be opened.

This new valve will allow oil to flow into a container (Short Circuit the flow line).
By adjusting the valve, same pressure drop will be generated.

For a certain period of time, the oil will spill into the container.
Weight and temperature of the oil will be measured.
Inlet and outlet density can be found.
Using continuity equation both inlet and outlet velocities can be determined.
Measurement Systems
Velocity Measurement in Natural Flow
Pressure difference gauge
Valve 2
inlet
oil collector pipe (top)
Valve 1
Mass (Volume)
Short Circuit the Flow Line
outlet
oil collector pipe (top)

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BALIKESIR ELECTROMECHANICAL INDUSTRIAL PLANTS CO.

DEVELOPMENT OF A TEST ROOM IN ORDER TO EXAMINE

Thermal performance of power transformers has a significant effect on service life.

Difficulties with CFD Simulations

Radiator CFD Analysis

Radiator cross-sections are very thin

Radiator CFD Analysis

Great simplifications can be obtained by modeling radiators as porous model

Flow volume mesh

Quarter flow volume model

Radiator CFD Analysis

Radiator CFD Analysis

Radiator CFD Analysis

Radiator CFD Analysis

Radiator CFD Analysis

Pressure Drop (DeltaP)

Performance of cooling equipment at different temperatures can be tested.

Natural and forced convection can be simulated and tested

Oil flow will be increased/decreased with variable speed pumps.

Inlet to radiators will be closed and a second valve will be opened.

By adjusting the valve, same pressure drop will be generated.

oil collector pipe (top)

Short Circuit the Flow Line

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