Forced Air Cooled Transformer

Forced Air Cooled Transformer (Up to 15 MVA):
The air is circulated through the winding of transformer by

means of blower. This arrangement is housed in metal box
with proper insulation between windings. The blowers
will blow the air through the windings and hence hot air is
gained cooled by the outside natural conventional air.
Oil-Immersed forced air cooled Transformer
In this type the transformer is cooled by the oil which in
turn cooled by the forced air in radiator. A bank of coolers
or blowers is situated in the transformer radiator which
forces the air through the cooling fins. The hot oil enters in
these cooling fins by the natural convention and cooled oil
again flows through the windings. This cooling method is
used normally large transmission transformers situated
outdoors, in power plants and in power stations.
Oil-Immersed Self cooled Transformer:
In this type the transformer windings and core are cooled
by the mineral oil. The heated oil circulated through
radiator by national convention and hence cooled by the
surrounding air. This type is normally used for
distribution type transformer with low ratings.
Oil-Immersed water cooled Transformer
This type of cooling is used for very large transformers
with very high power rating above 500 MVA. In this the
Transformer is cooled by oil which then passes through
the oil-water heat exchangers. Two 100 % oil pumps are
placed to circulate the hot oil through the two heat
exchangers. The heat oil dissipates the heat to the water
and again flows through the windings and core. The
service water is used for cooling. We can operate the
transformer with one cooler but if two fails then we have to
trip the transformer.
Shell and tube type coolers
In the shell and tube design a tube bundle or stack is fitted into a
shell . The end plates are sealed at either end of the shell and
provision is made at one end for expansion. The tubes are sealed
into the tube plate at either end and provide a passageway for the
cooling liquid. Headers or water boxes surround the tube plates and
enclose the shell.
They are arranged for either a single pass or, as in Figure below, for
a double pass of cooling liquid. The tube bundle has baffles fitted
which serve to direct the liquid to be cooled up and down over the
tubes as it passes along the cooler. The joint arrangements at the
tube plate ends are different. At the fixed end, gaskets are fitted
between either side of the tube plate and the shell and end cover.
At the other end, the tube plate is free to move with seals fitted
either side of a safety expansion ring. Should either liquid leak past
the seal it will pass out of the cooler and be visible. There will be no
intermixing or contamination.
Plate type heat exchangers
The plate-type heat exchanger is made up of a number of pressed

plates surrounded by seals and held together in a frame . The inlet
and outlet branches for each liquid are attached to one end plate.
The arrangement of seals between the plates provides passageways
between adjacent plates for the cooling liquid and the hot liquid .
The plates have various designs of corrugations to aid heat transfer
and provide support for the large, flat surface. A double seal
arrangement is provided at each branch point with a drain hole to
detect leakage and prevent intermixing or contamination.
Fig:Shell and tube type heat exchanger
Operation
Temperature control of coolers is usually achieved by adjusting the

cooling liquid outlet valve. The inlet valve is left open and this
ensures a constant pressure within the cooler. This is particularly
important with sea water cooling where reducing pressure could
lead to aeration or the collecting of air within the cooler. Air
remaining in a cooler will considerably reduce the cooling effect.
Vents are provided in the highest points of coolers which should be
opened on first filling and occasionally afterwards. Vertical mounting
of single pass coolers will ensure automatic venting. Positioning the
inlet cooling water branch facing downwards and the outlet branch
upwards will achieve automatic venting with horizontally mounted
coolers. Drain plugs are also fitted at the lowest point in coolers.
Maintenance of coolers
Clean heat transfer surfaces are the main requirements for

satisfactory operation. With sea water cooling the main problem is
fouling of the surfaces, i.e. the presence of marine plant and animal
growth.
With shell and tube coolers the end covers are removed to give
access to the tubes for cleaning. Special tools are usually provided
by the cooler manufacturer for cleaning the tubes. The end covers
can also be cleaned.
Tube leakage can result from corrosion. This can be checked for, or
identified, by having the shell side of the cooler circulated while the
cooling water is shut off and the end covers removed. Any seepage
into the tubes will indicate the leak. It is also possible to introduce
fluorescent dyes into the shell-side liquid: any seepage will show
under an ultraviolet light as a bright green glow. Leaking tubes can
be temporarily plugged at each end or removed and replaced with a
new tube.
Plate-type coolers which develop leaks present a more difficult

problem. The plates must be visually examined to detect the faulty
point. The joints between the plates can present problems in
service, or on assembly of the cooler after maintenance.
Where coolers are out of use for a long period, such as during
surveys or major overhauls, they should be drained on the sea
water side, flushed through or washed with fresh water, and left to
dry until required for service.
Fig:Plate type heat exchanger - construction and operation
What is a heat exchanger ? – A device that transfers heat
through a conducting wall from one fluid to another. Heat
exchangers are used to transfer heat from a hotter fluid (liquid or
gas) to a colder fluid. This broad definition covers a wide range of
equipment, including boilers, condensers, distilling plants, and
ventilation cooling coils.
Shell-and-tube heat exchanger is fabricated from round tubes

that are settled in, and run parallel to a shell. Heat is transferred
between the fluids by passing through the walls of tubes. This type
of exchanger consists of six basic elements: the bonnet, tubsheet,
shell, tubes, baffles or support plates, and the tie rods.
Shell and tube heat exchangers for engine cooling water and
lubricating oil cooling (Figure 1) have traditionally been circulated
with sea water. The sea water is in contact with the inside of the
tubes, tube plates and water boxes.
A two-pass flow is shown in the diagram but straight flow is

common in small coolers. The oil or water being cooled is in contact
with the outside of the tubes and the shell of the cooler. Baffles
direct the liquid across the tubes as it flows through the cooler. The
baffles also support the tubes and form with them a structure which
is referred to as the tube stack.
Fig 1 :Conventional tube type cooler

The usual method of securing the tubes in the tube plates is to roll-
expand them. Tubes of aluminium brass (76% copper; 22% zinc;
2% aluminium) are commonly employed and the successful use of
this material has apparently depended on the presence of a
protective film of iron ions, formed along the tube length, by
corrosion of iron in the system.
Fig: SHELL-AND-TUBE HEAT EXCHANGER
Unprotected iron in water boxes and in parts of the pipe system,

while itself corroding, does assist in prolonging tube life. This factor
is well known (Cotton and Scholes, 1972) but has been made
apparent when iron and steel in pipe systems have been replaced
by non-ferrous metals or shielded by a protective coating.
The remedy in non-ferrous systems, has been to supply iron ions

from other sources. Thus, soft iron sacrificial anodes have been
fitted in water boxes, iron sections have been inserted in pipe
systems and iron has been introduced into the sea water, in the
form of ferrous sulphate.
The latter treatment consists of dosing the sea water to a strength

of 1 ppm for an hour per day for a few weeks and subsequently
dosing again before entering and after leaving port for a short
period. Electrical continuity in the sea-water circulating pipework is
important where sacrificial anodes are installed.
Metal connectors are fitted across flanges and cooler sections where
there are rubber joints and 'O' rings, which otherwise insulate the
various parts of the system. Premature tube failure can be the
result of pollution in coastal waters or extreme turbulence due to
excessive sea-water flow rates. To avoid the impingement attack,
care must be taken with the water velocity through tubes.
For aluminium-brass, the upper limit is about 2.5 m/s. Although it is

advisable to design to a lower velocity than this — to allow for poor
flow control - it is equally bad practice to have sea-water speeds of
less than 1 /sec.
A more than minimum flow is vital to produce moderate turbulence

which is essential to the heat exchange process and to reduce silting
and settlement in the tubes. Naval brass tube plates are used with
aluminium-brass tubes.
Fig :Details of Cooler expansion arrangement
The tube stacks are made up to have a fixed tube plate at one end
and a tube plate at the other end (Figure above ) which is free to
move when the tubes expand or contract. The tube stack is
constructed with baffles of the disc and ring, single or double
segmental types. The fixed end tube plate is sandwiched between
the shell and water box, with jointing material, Synthetic rubber 'O'
rings for the sliding tube plate permit free expansion.
The practice of removing the tube stack and replacing it after
rotation radially through 180 degrees, is facilitated by the type of
cooler described. This may prolong cooler life by reversing the flow
so that tube entrances, which are prone to impingement damage,
become outlets. Cooler end covers and water boxes are commonly
of cast iron or fabricated from mild steel.
Unprotected cast iron in contact with sea water, suffers from

graphitization, a form of corrosion in which the iron is removed and
only the soft black graphite remains. The shell is in contact with the
liquid being cooled which may be oil, distilled or fresh water with
corrosion inhibiting chemicals. It may be of cast iron or fabricated
from steel.
Manufacturers recommend that coolers be arranged vertically.

Where horizontal installation is necessary, the sea water should
enter at the bottom and leave at the top. Air in the cooler system
will encourage corrosion and air locks will reduce the cooling area
and cause overheating. Vent cocks should be fitted for purging air
and cocks or a plug are required at the bottom, for draining.
Clearance is required at the cooler fixed end for removal of the tube
stack,

Forced Air Cooled Transformer

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Forced Air Cooled Transformer (Up to 15 MVA):

The air is circulated through the winding of transformer by

Plate type heat exchangers

The plate-type heat exchanger is made up of a number of pressed

Temperature control of coolers is usually achieved by adjusting the

Clean heat transfer surfaces are the main requirements for

Plate-type coolers which develop leaks present a more difficult

Shell-and-tube heat exchanger is fabricated from round tubes

A two-pass flow is shown in the diagram but straight flow is

Fig 1 :Conventional tube type cooler

Fig: SHELL-AND-TUBE HEAT EXCHANGER

Unprotected iron in water boxes and in parts of the pipe system,

The remedy in non-ferrous systems, has been to supply iron ions

The latter treatment consists of dosing the sea water to a strength

For aluminium-brass, the upper limit is about 2.5 m/s. Although it is

A more than minimum flow is vital to produce moderate turbulence

Fig :Details of Cooler expansion arrangement

Unprotected cast iron in contact with sea water, suffers from

Manufacturers recommend that coolers be arranged vertically.

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