Countershielded Winding

Design Process and Shop Documents

Presentation for UNIPOWER, May 2009

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 1
 Design Process

1. Calculation chart
• Provide some extra bays : 10-20 turns
• In DESPT, use winding type “other disc”
2. First selection of shields is made with
Countershield_dhth_v5.xls
• Number of shields is defined per disc-pair

All tools mentioned in this presentation are available on :

\\Ptbdm1\pt_unipower\Current Plant Practices\Design\PTB Practices\Countershielded windings\Shield
Design for Countershielded Disc Windings

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 2
Optimisation of a Counter-Shielded Disc Winding (CGL procedure)

description : MP00110
configuration : LV-HV-FR
geometry : end fed geometry factor = 1
BIL = 550 [kVp] ground capacitance = 4096 [pF]
center distance between core legs = 1121 [mm] part Cg1 = 444 [pF]
core center to tank distance, HV side = 785.5 [mm] part Cg2 = 3651 [pF]
core center to tank distance, LV side = 725.5 [mm] ground capacitance per disc-pair = 107.78 [pF]
series capacitance (unshielded) = 1063 [pF]
outer diameter LV = 698 [mm] effective conductor height = 8.40 [mm]
total pressboard thickness in main gap = 10 [mm] turn-to-turn capacitance = 1025 [pF]
estimated max. radial stress at ID = 19.62 [kVp/mm]
inner diameter HV = 774 [mm] estimated axial stress at ID = 0.1092 [p.u.]
outer diameter HV = 991 [mm] Wagner's  -factor (unshielded) = 0.318 [-]
total winding height HV = 1018 [mm] number of shielded disc-pairs = 6
total number of discs in HV = 76 revised axial stress at ID = 0.1034 [p.u.]
number of turns per disc in HV = 18 min. required conductor insulation = 0.586 [mm]
conductor type in HV = rectangular total shield conductor length = 73.3 [m]
axial conductor height in HV = 8.40 [mm] estimated max. voltage to ground = 758.8 [kVp]
conductor insulation (paper) in HV = 0.70 [mm] max. axial stress (between shields) = 13.0 [kVp/mm]
average spacer thickness in HV = 4.50 [mm] = 56.6 [%]
spacer width in HV = 40 [mm] max. axial stress (between discs) = 10.9 [kVp/mm]
number of spacers per circle in HV = 20 = 91.1 [%]
max. radial stress in paper = 40.6 [kVp/mm]
inner diameter FR = 1051 [mm] = 72.8 [%]
total winding height FR = 801 [mm]
allowed total stress in oil = 23.00 [kVp/mm]
 paper = 3.03 [-] allowed axial stress in oil at ID = 12.00 [kVp/mm]
 pressboard = 4.36 [-] allowed stress in paper = 55.8 [kVp/mm]
 oil duct = 2.65 [-]
 oil = 2.18 [-] Ok !

Number of overrule Shield

Disc-pair Series cap for
34
(middle-to-top)
shield turns shield turns/divisions per
shielded pair  -factor
per disc-pair turns disc
1 S1 7.78 7.78 3 18/20 T/D 5051 0.146
2 S2 5.96 5.96 2 20/20 T/D 4117 0.162
3 S3 4.35 4.35 2 3/20 T/D 3291 0.181
4 S4 2.94 2.94 1 9/20 T/D 2572 0.205
5 S5 1.75 1.75 0 18/20 T/D 1961 0.234
6 S6 0.77 0.77 0 8/20 T/D 1458 0.272
1063 0.318

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 3
 Design Process
3. Based on experience with test-coil, the discs with
less than one turn of shield are not considered
• This automatically removes the need for overbuild
4. If it is specified to use “n turns + nbay/nbay”
divisions  reduce to “n turns + (nbay-1)/nbay”
5. Determine the number of turns to be removed
from shielded discs
• Shield = 1.5 mm + main conductor insulation
• Main conductor thickness = radial build / no of turns
6. Check the remaining number of bays that can be
dropped
• Must be sufficient to make the continuous disc winding
Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 4
 Design Process

Shield Round
Proposed Practical - # turns Packing
thickness packing
3 18/20 T/D 3 18/20 T/D 8.8 2 2.6 3
2 20/20 T/D 2 19/20 T/D 6.6 2 2.6 3
2 3/20 T/D 2 3/20 T/D 6.6 2 2.6 3
1 9/20 T/D 1 9/20 T/D 4.4 1 1.3 1
0 18/20 T/D
0 8/20 T/D

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 5
 Design Process
7. Make the PULSE model
• One segment per pair of discs
• Winding type : Countershielded disc

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 6
 Design Process
8. Evaluation of the PULSE results
--------------------------------------------------------------------------------------------------
NODE MAX.[kV] TIME[us] SEGM.[kV] TIME[us] TURN[kV] AXI.[kV] TIME[us]
--------------------------------------------------------------------------------------------------

145) 564.774 20.000 71.846 1.400 ~ 1.996 72.137 1.000

147) 548.947 19.800 75.921 1.000 ~ 2.109 64.812 1.200
149) 519.687 16.800 63.017 2.200 ~ 31.509 63.382 2.400
151) 512.024 16.800 55.722 3.800 ~ 27.861 60.586 4.400
153) 487.442 14.800 55.522 5.400 ~ 27.761 61.968 5.800
155) 511.686 2.000 51.014 7.600 ~ 25.507
156) 549.913 2.000
---------- ---------- ---------- ----------
max : 564.774 75.921 31.509 72.137

drop over voltage between voltage between

shielded shield and main shield-ends of
disc pairs conductor consecutive
disc-pairs
x 6/5 for v03.0-2g

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 7
 Design Process
9. Evaluation of the PULSE results (cont’d)
• Drop over shielded disc pairs
• < allowed voltage between discs
• Voltage between shield and main conductor
• < 70% of Karsai
• Voltage between shield-ends of consecutive disc-pairs
• < allowed voltage between discs
10. Modify design if necessary
• More or less shielding
• Increase distance between (double) discs locally
• If voltage between shield and conductor is to high,
insulation on shield conductor can be increased
  replace series capacitances in PULSE v03.0-2g
Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 8
 Design Process
11. In case insulation on shield differs from main
conductor insulation
• Not implemented in PULSE v03.0-2g
• Use “series capacitance calculation in case of shielded
disc_v1.xls”
• The CGL formula can be used

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 9
 Design Process
text version 1 DHTH CGL Del Vecchio
permitivities eps paper 3.2 3.03
eps pressboard 4.5 4.36
eps oil duct 2.65
eps oil 2.3 2.18
diameters inner diameter mm 779.6
outer diameter mm 991
bare conductor height h conductor mm 8.4
CTC (yes or no) n
end disc (yes or no) n
insulated conductor thickness d conductor mm 5.8

06.01.01/R02 ; this is not the last version of this

insulated shield thickness d shield mm 2.2
number of shields per disc ns 3.9

Attention : formulas DHTH are as per RD-

number of conductive turns per disc nt 15.8
number of discs in the winding ndisc 76
number of shielded disc pairs in the winding nsdp 8
paper insulation d conductor mm 0.7
d shield mm 0.7
key spacer thickness d spacer mm 4.5
width of key spacer w spacer mm 40
number of bays n bay 20
duct in the middle of the disc for zig-zag cooling n
10
1

document.
total distance between discs d total mm 5.2
coverage factor b 0.288
equivalent permitivity between discs eps equiv 2.930 2.993
capacitance between discs Cs pF 1465 1040
capacitance between turns of a disc Ct pF 993 1026
capacitance between turn and shield Cst pF 1115 1026
capacitance between two turns of two consecutive HV discs Cax pF 93
capacitance between two shield turns of two consecutive HV discs Cas pF 35
series capacitance unshielded disc pair Cser pF 992

series capacitance shielded disc pair Cser pF 5135 5043 5080

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 10
 Design Process
12. Magnaxi
• Model the shielded winding per part having discs with
equal number of turns
• Look for the best axial position LV-HV to minimize axial
forces
• For end-fed design with shielded part at one end, best is
to bring the center of ampère-turns of LV and HV at the
same height

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 11
 Winding Table
1. General principles to make the Winding Table

• According to “ST0709004 instructions winding table for

shielded disc_v1.doc”

• Prepare a winding table for the continuous disc winding,

considering that the shielded discs have less turns

• Drop bays : use the minimum number of drop bays in

the shielded part

• Overbuild : is easily avoided as < 1 turn shield/disc is

not used

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 12
 Winding Table
1. General principles for the Winding Table (cont’d)
• Packing :
• Remaining bays minus 1 of the last turn of shield are
packed between the turns. Packing starts at 50 mm from
the shield and ends in a wedge. The thickness of the
packing is made in one piece, typically 2 or 3 mm.

• All the discs with the same cumulated thickness of main

conductor have identical packing at the inner side of the
discs. This inner packing to be made in as less pieces as
possible.

• All the discs with the same cumulated thickness of main

conductor have an equal amount of shield plus packing
between turns.

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 13
 • Application of
principles
guarantees as
much as
possible
continuity for
the winding
process

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 14
 Winding Table
2. List of Disc Types on Winding Table

MAIN CONDUCTOR SHIELD PACKING

nr TYPE TR BAYS TR BAYS mm
30 A 17 18
18 B 17 12
12 C 17 13
4 D 16 18 1 9 1
4 E1 15 18 2 3 3
4 E2 15 18 2 19 3
4 E3 15 18 3 18 3

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 15
 Winding Table
3. Special information for the shielded ride-down discs
• Use “determination of shield length for a downward disc -
version 2.xls”
• shift : Instead of in bay #, the cross-over must be made “shift”
mm before (-) or after (+) bay #.
• uitv : mm of packing at inner side of disc
• knip .. sh : During upwards winding, cut shield in that bay
• shield-end is immediately finished !
• knip .. uitv : During upwards winding, cut packing in that bay
• eind .. sh : Final position of the end of the shield
• eind .. uitv : Final position of the end of the packing
4. Additional information for shielded ride-up discs
• uitv, eind .. sh, eind .. uitv
• braz : bay where shield crosses-over to ride-down disc
Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 16
 Winding Table
1 E3 15 18
uitv 3
knip 4 9 sh
knip 4 10 uitv
shift -674
eind 3 17 uitv
eind 3 16 sh
4.5mm
2 E3 31 16
uitv 3
eind 27 19 uitv
eind 28 0 sh
braz 31 18
4.5mm
Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 17
 Winding Table
Determination of knip...sh, knip...pack, shift Version 2

nbay 20 number of bays

Di
Do
775
981
mm
mm
inner diameter of the winding (not considering inner packing)
outer diameter
calculate
ds 2.1 mm thickness of shield
pack 2.6 mm inner packing
ns 3.9 number of turns of shield 3 +bays 18
ns+ 3.95 number of turns of shield+packing 3 +bays 19
n 15.9 number of turns of main conductor 15 +bays 18
ns* 4.545635 cut shield during upward winding --> knip...sh = 13 bays after end...sh
ns+* 4.599572 cut packing during upward winding --> knip...pack = 13 bays after end...pack
shift -674 mm shift of cross-over

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 18
 Calculation Chart
1. Add a column with relevant information of the
shield conductor
Wikkeling en Type en KITcode LS - lagen HS - gek + counter shield HS - counter shield FR - gek. lus gekopp.

Blanke draad [mm] CTC 33x(9.0x1.7) 3R x (7.8 x 1.4) 7.8 x 1.5 19 x 1.7
Geisol. draad/CTC [mm] 18.8 x 31.2 8.5 x 5.5 8.5 x 2.2 19.7 x 2.4
Isolatie dikte [mm] 0.1 lak / 0.6 papier 0.3 / 0.4 papier 0.7 papier 0.7 papier
# * draad mm² =  mm2 1 x ( 33 x 14.937 ) = 492.92 3 x 10.705 = 32.12 1 x 11.485 1 x 31.937 = 31.94

Vlak of kant vlak R=0.65 vlak R=0.5 vlak R=0.5 vlak R = 0.65
Stroomdichtheid [A/mm2] 3.394 4.246 4.270
Geleider lengte per poot [m] 184.8 3652.4 125.0 568.0
Weerstand per poot [ohm] 0.00787 2.38831 (bestellen 10% res) 0.37347

Wikkeltijd per Tfo [h] 48 175 75

Bl. Cu gewicht per Tfo [kg] 2432 3132 39 484

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 19
 Calculation Chart
2. Shield conductor length
• Is also output from “determination of shield length for a
downward disc - version 2.xls”

final position of shield inner diameter D1 919.4364

outer diameter D2 969.4145
length 11571.3

position of shield during upward winding inner diameter D3 780.2

outer diameter D4 840.3697
length 11571.3 -1.14E-08

• Take 10 % margin for order

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 20
 New Developments
1. Double zig-zag with shields
2. Double shields
• Almost doubles the series capacitance
• Learned from ex-competitor
• Between turns and ...
• Between parallel conductors
3. Internal shield
• 1 turn without bracing at inside between disc-pairs
• Learned from ex-competitor
• Reduces oscillations after impulse
• ≥ 362 kV

Sunday, April 10, 2022 ST0905004 Countershielded Winding, Design Process and Shop Documents 21