Thermal-flow characteristics analysis of a novel resilient capacity ceramic insulated winding dry type transformer

With the increasing demand for the resilient capacity of transformers in high-proportion renewable energy grids, the overload capacity of transformers and the thermal conductivity of winding insulation materials have been put forward as important requirements. In response to these requirements, a novel ceramic high temperature tolerance insulation winding is proposed in this paper and is applied in a ceramic insulated winding transformer. A combination of simulation and experimentation is used to analyze the thermal-flow characteristics of this transformer. The temperature and flow field distribution characteristics of transformers with both winding insulation methods (ceramic and Nomex paper) are compared. The internal mechanism of reflux near the iron core and high voltage winding under forced air cooling is clarified. A superior outside cooling condition is obtained. A prototype ceramic insulated winding transformer is developed and tested to verify the accuracy of the simulation model. The results show that the hotspot temperature of the ceramic insulated winding transformer under natural cooling is 10.7% lower than that of the Nomex paper insulated winding transformer. With forced air cooling of 2, 3, 4, 5, and 6 m/s applied at the bottom, the hotspot temperature of the ceramic insulated winding transformer is 11.4%, 10.5%, 9.7%, 14.0%, and 17.8% lower than that of the Nomex paper insulation winding transformer, respectively. Under forced air cooling, a reflux phenomenon is observed in both transformers in the vicinity of the iron core and high voltage winding due to the formation of adverse pressure gradient region and wall viscous force blocking. The strength of the reflux is affected by the magnitude of the forced air cooling flow velocity and the construction of the transformer. The optimal range of the external cooling flow velocity for the ceramic insulated winding transformer is 3–4 m/s. The errors between the simulated temperature and the measured temperature at the nine monitoring points of the prototype are all less than 5%, which verifies the effectiveness of the simulation model. The experimental and theoretical basis for the design and application of resilient capacity dry type transformers is provided by this research.