Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “power transformers”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Transformer power management controllers and transformer power management methods

Transformer power management controllers and transformer power management methods are described. According to one aspect, a transformer power management controller includes processing circuitry configured to monitor an electrical characteristic of electrical energy which is received from a secondary of a transformer of an electric power system, use the monitored electrical characteristic to determine transformer loading information which is indicative of an amount of power which is being supplied by the secondary of the transformer to a plurality of loads which are coupled with the secondary of the transformer, and use the transformer loading information to adjust an amount of the electrical energy which is supplied by the secondary of the transformer to at least one of the loads which is coupled with the secondary of the transformer.

Pratt, Richard M.↗
DOE OSTI2025

Intercell Power Transformer for Power Balancing of Polyphase Wireless Power Transfer Systems

Polyphase wireless power transfer (PWPT) systems experience receiver side imbalances in misaligned conditions. This paper proposes a method for power balancing in PWPT systems, specifically addressing the challenges caused by receivers coil unequal coupling. An intercell power transformer (IPT) is introduced at the receiver side to mitigate the effects of coil mismatch. Simulations of the PWPT system incorporating IPT demonstrate its effectiveness in enhancing power distribution. For voltage-fed rectifiers (VFR), the IPT increases the conduction angle, resulting in higher output power. In current- fed rectifiers (CFR), the IPT promotes uniform power sharing among rectifiers, thereby reducing electrical stress on semiconductor devices and passive components. Simulation results indicate that, under coil misalignment, the IPT improves output power by approximately 49% for VFRs and 44% for CFRs compared to conventional PWPT systems without IPT.

Wojda, Rafal [ORNL] (ORCID:0000000286609268)↗
DOE OSTI2022

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

As we know, power transformers are the most critical asset of the transmission network. Although highly reliable, they still can fail prematurely or ultimately retire at the end of their service life. In today’s design practices, transformers are tailored to their specific application and therefore cannot replace each other unless identical. Additionally, they provide minimal support to the grid operation and therefore limit the grid flexibility and resiliency when facing severe conditions. In this presentation, we will introduce the concept of flexible power transformer and demonstrate how one single unit can serve as a spare to multiple units in a given fleet, allow to control the power flow between transformers or lines operating in parallel and ultimately be used to limit subsequent faults in transmission lines. We will also introduce the world’s first prototype in operation, a 60MVA, 165kV flexible autotransformer.

flexible power transformer, autotransformer, varia↗
DOE OSTI2022

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

GE Research and its partner Prolec GE have designed, built and deployed in the field the world’s first flexible power transformer. The flexible power transformer is a transmission class 3-phase autotransformer configurable in impedance and in voltage which allows it to serve as a universal spare for multiple units in a given fleet. However, the key innovation in this new concept is the online adjustable leakage impedance which allows the transformer to change its impedance without interrupting the transmission line operation. The flexible power transformer can be designed with up to three low voltage transmission class ratings and up to 12 impedance values changeable both online and offline. This report provides an overview of the design, manufacturing, testing, and commissioning of the 165kV, 60MVA prototype built including the results of the field performance validation tests. The prototype was specified in collaboration with Cooperative Energy, the utility host. It was designed and tested in the factory according to IEEE standard C57.12.00 and followed all protocols for transportation, installation, and commissioning of a power transformer. In addition to the prototype, a flexible protection system capable of automatically adjusting its settings upon the transformer impedance was also developed and deployed in the for testing and validation. On September 3, 2021 the prototype was energized in Cooperative Energy’s substation in Columbia, Mississippi to become the world’s first flexible power transformer in operation. Its performances and impact on the grid operation were demonstrated through different field tests. Results obtained confirm that the impedance of the flexible transformer can be varied under load through its full range, from 4.3% to 9.3%, without adverse impacts on the line operation, the protection system, the transformer stability and health condition. Results also proved that the flexible transformer is very effective in controlling power transfer through the line or load sharing between units operating in parallel. Indeed, it was proven that higher impedances decrease the thruput power of the transformer while lower impedances increase it. Up to 26MW was controllable on a line loading of 45MVA. It was also possible to demonstrate that the variation of the transformer impedance has no effect on the circulating current between units in parallel, except a minor transient during the impedance change. It was also proven that the flexible protection relay can update its protection settings automatically when the impedance change was detected. The prototype has operated continuously for more than 12 months now with a peak load exceeding 50MVA corresponding to >80% of its ONAN power rating. No alarm, trip or sign of failure has been reported by the utility. In addition to the development and deployment of the flexible transformer prototype, investigations were carried out on new nanodielectric fluids to replace the mineral oil used in power transformers with the goal of reducing their footprint and weight. The key parameters that were targeted for improvement included the breakdown voltage to reduce clearances between windings and tank hence the footprint; viscosity and thermal conductivity to increase the cooling efficiency and therefore to reduce the winding material. Several nanodielectric mixtures with mineral oil including with alumina (Al2O3), titania (TiO2) and Borum Nitrate (BN) with different surfactants have been analyzed and tested. Unfortunately, despite encouraging results no nanofluid candidate has been found viable to replace mineral oil. With the formulations tested, breakdown voltages are generally similar to mineral oil at lower particle contents and worse at higher particle contents. Viscosity appreciably increased at particles concertation over 2 wt% and thermal conductivity increased slightly at 5wt% and appears to be 10-15% higher at 10 wt% particle content. It is recommended to continue investigations to find solutions that can help increase the power density of future flexible power transformers. Flexible power transformers can significantly help the future power grid by providing more flexibility and resiliency. Indeed, by providing voltage and impedance flexibility, flexible power transformers reduce the need for multiple spares, hence inventory costs for utilities. With their online controllable impedance, they can provide support to the grid and help manage short-circuit currents, power flow, line congestion, and grid stability which will become more important with higher penetrations of intermittent renewable resources. During the field validation tests, it was demonstrated that up to 26MW was controllable on a line loading of 45MVA when the transformer impedance was varied from its minimum to its maximum range. Also, with the impedance range, the short-circuit currents could be reduced by up to 38% at the load side of the transformer. With its controllable impedance, flexible transformers can be used in future strategies of grid resilience to help better prepare the grid to face forecasted severe events including storms, heat waves and contingencies. The flexible power transformers can also find role in other applications including high voltage transmission cables such as offshore wind farms where solutions for energizing the cables and managing the reactive power are of critical importance. The designed flexible power transformer is now fully validated and ready for commercialization. Further analysis on the benefits of flexible power transformers for grid stability and short-circuit management including current limiting capability, reclosure and line restoration, control of inrush current, sizing of flexible AC components (FACTS) would help its rapid adoption by the industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Fluid power circuit having switch-mode power transformer and methods

A fluid power circuit with a switch-mode power transformer used to transfer power while keeping the pressure of power source and reverse osmosis processes relatively decoupled. The switch-mode power transformer uses the inertia of a hydraulic motor driven electric generator and switching of a hydraulic motor inlet between high and low-pressure ends to decrease the pressure at which power is being transmitted to a reverse osmosis process.

Simmons, II, Jeremy W.↗
DOE OSTI2022

Modular Hybrid Solid State Transformer (H-SST) for Next Generation Flexible and Adaptable Large Power Transformer (LPT) (Final Technical Report)

A 500 kVA HSST, the world first of such system, has been successfully developed. The HSST has the capability to regulate the power flow of the transmission or distribution power lines, or provide voltage regulation. The HSST design is modular therefore it has the ability to be connected in series of parallel to form a large power transformer with smart controllability. The project has enabled a high TRL level prototype be demonstrated at University of Texas at Austin which can lead to additional commercialization and demonstration opportunities. A large number of students were trained under this program that will benefit the power grid industry. A number of publications are published at well known international conferences and journals, further accomplish the mission of knowledge development and dissemination.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Computational Analysis and Optimized Modeling of Geomagnetically Induced Currents in Power Transformers

In this project we aim to better understand the effect of geomagnetically induced currents (GIC) on power transformers. Expanding upon our previous work focused on producing a methodology for accuracy-enhanced computation of GIC signatures (i.e., time-domain current magnitude variation for the event duration) from a combination of physics-based and data-driven computational tools, we propose the use of these GIC signatures as inputs for a physically-detailed and optimized model of the power transformer to investigate how GIC determination and transformer modeling influence the evaluation of GIC effects on the transformer operation, as well as in its interaction with the power grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Seismic Resilience of Large Power Transformer Bushings & Non-SF6 Industrial Base Scan Review

Large (high voltage) power transformers (LPT), and more specifically, their bushings, are known to be susceptible to seismic failure. With bushing failure, a transformer will have to be replaced, which has a considerable lead time, adding to the power outage duration. Cost-efficient, proven solutions are not currently available to mitigate this risk, which can persist for the more than 30-year life of a particular transformer. This work will focus on developing and demonstrating a hardware solution to address seismic vulnerabilities and reduce outage risks from LPT failure. Sulfur Hexafluoride (SF6) is a specialty gas with excellent electrical insulation properties which has been used extensively in the power industry. This gas is unfortunately also one of the most potent greenhouse gases known to humanity. A 2014 report by the Intergovernmental Panel on Climate Change found that SF6 has a global warming potential (GWP) 23,000 times higher than Carbon Dioxide, and has the highest GWP of all gases assessed (Myhre 2013). SF6 is almost exclusively man-made and is produced for use as an insulator in high voltage electrical equipment. This makes the production and use of SF6 one of the leading sources of anthropogenic climate change. To fully eliminate the environmental impacts of SF6, alternative technology is needed. The ideal replacement would be a technology that can fulfil the same role as SF6, at the same cost or cheaper, but without adverse environmental effects. Currently, no technology fits this description, however several promising technologies have begun to enter the market. An industry scan was performed to assess the state of industry adoption and manufacturing capability for SF6-free alternative technologies for use at the high-voltage level, and the primary barriers to broader adoption.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Modeling the impact of high thermal conductivity paper on the performance and life of power transformers

Degradation of insulation paper is a key contributor to the failure of power transformers. Insulation degradation accelerates at elevated temperatures, which highlights the potential for better thermal management to prolong life. While several studies have analyzed the benefits of high thermal conductivity oil for reducing temperatures inside a transformer, this study is an initial assessment of the benefits of high thermal conductivity paper on transformer life. Blending particulates with cellulosic fibers offers a pathway for high thermal conductivity paper (with good dielectric properties), which can reduce internal temperatures. Presently, life extensions that can be achieved by the use of such thermally conducting papers were estimated, with the thermal conductivity of the paper being the key parameter under study. The analytical-numerical thermal model used in this study was validated against experimental measurements in a distribution transformer, adding confidence to the utility of the model. This model was then used to provide estimates of hot-spot temperature reduction resulting from the use of papers with higher thermal conductivity than baseline. Transformer life was predicted conventionally by tracking the degree of polymerization of paper over time, based on an Arrhenius model. Results indicate that increasing the thermal conductivity of paper from 0.2 W/mK (baseline) to 1W/mK reduces the hot spot temperature by 10°C. While degradation significantly depends on the moisture and oxygen content, the model shows that such a temperature reduction can increase life for all conditions, by as much as a factor of three.

42 ENGINEERING↗
DOE OSTI2026

Large Power Transformer Supply Chain Gap Analysis and Domestic Content Strategies for Hydropower Rehabilitation: Supplemental Report

Large Power Transformers (LPTs) are indispensable to U.S. hydropower operations, serving as generator step-up (GSU) units that interconnect hydro facilities to the transmission grid. Yet the LPT supply chain faces mounting stress from aging infrastructure, limited domestic production, and long lead times. Currently, more than 80% of LPT demand is met through imports, with primary suppliers including Mexico, South Korea, Brazil, Austria, and Canada. Domestic manufacturers supply only about 20% of units, constrained by bottlenecks in high-grade Grain-Oriented Electrical Steel (GOES), copper conductors, bushings, and on-load tap changers (OLTCs). Hydropower rehabilitation projects in particular face additional challenges due to custom design requirements, remote siting, and regulatory needs around domestic content. Regional cost disparities, driven by transportation logistics, labor markets, and import price volatility, further exacerbate project risks. To address these vulnerabilities, coordinated action is required: strengthening domestic capacity for GOES and secondary components, developing near-site assembly hubs, and leveraging IRS domestic content safe harbors to incentivize U.S. manufacturing. This addendum refines the 2024 NREL Hydropower Supply Chain Gap Analysis by focusing specifically on critical issues related to LPT domestic manufacturing capacity and key considerations for hydropower developers and asset owners.

13 HYDRO ENERGY↗
DOE OSTI2024

Geomagnetically Induced Current Field Test on Large Grid-Connected Power Transformers: Analysis, Model Development, and Simulations

Geomagnetic-induced current (GIC) flow in power grids can cause undesirable effects such as transformer overheating, harmonics, higher reactive power demand, etc. Many simulation models have been developed to study these effects, but real-world verification on modern transformer designs is rare. Here, this paper presents the first long-duration GIC field test in the U.S. performed on high-voltage, grid-connected transformers featuring winding clamps and tie rods instead of conventional tie bars. Field measurements were taken to evaluate GIC effects. These measurements also aided in developing and validating thermal and electromagnetic transient (EMT) models of the transformers. During the test, significant current and voltage distortions were observed along with considerable transformer reactive power losses. Analysis of the field measurements showed that the transformers’ hottest spot was at the inner windings, and their k-factors were close to factory test and software default values. Thermal simulations indicated that the transformers would not violate their thermal limits even for a GIC waveform that peaks at about 200 A/phase. EMT simulations revealed that increased transformer loading may reduce GIC-induced reactive power demand and harmonics in certain scenarios. The study also highlighted potential inaccuracies in using the k-factor method to calculate transformer reactive power losses.

EMTDC↗
DOE OSTI2022

DC compensation for power transformer through neutral DC injection

A power transmission system can include a transformer and compensator circuit(s), each coupled between a node of the transformer and a ground connection. The compensator circuit(s) can each be configured to counteract a DC signal component of an AC signal at the transformer. The compensator circuit(s) can include a converter circuit having an AC side and a DC side and configured to convert a DC voltage on the DC side to an AC signal at the AC side. The compensator circuit(s) can include a DC link coupled to the DC side of the converter circuit. The compensator circuit(s) can include a controller configured to measure a DC signal component between the load and the ground; to determine, based at least in part on the DC signal component, a compensating signal configured to counteract the DC signal component; and to inject, by the converter circuit, the compensating signal to counteract the DC signal component.

Burkes, Klaehn W.↗
DOE OSTI2022

Electric Grid Supply Chain Review: Large Power Transformers and High Voltage Direct Current Systems

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. The need to modernize and increase the capacity of the U.S. power grid is increasing due to growing population, aging infrastructure, grid resilience requirements, operational flexibility needs, and a growing portfolio of renewable energy. As part of the Paris Climate Agreement the United States has committed to reducing its net greenhouse gas emissions by 50 to 52 percent below 2005 levels in 2030 and has set a goal of 100 percent carbon pollution free electricity by 2035 (The United States of America Nationally Determined Contribution, 2021). Meeting these targets will require a significant expansion of the power system to integrate a large amount of new renewable resources (United States Department of State & United States Executive Office of the President, 2021). However, many critical components supporting the power grid have limited to no domestic manufacturing capacity and face complex challenges in supporting a rapid expansion of the grid to meet multiple objectives, including decarbonization goals. This report focuses on two key grid components: large power transformers (LPTs) and high-voltage direct current (HVDC) transmission.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Transformer-powered surrogates close the ICF simulation-experiment gap with extremely limited data

Abstract Recent advances in machine learning, specifically transformer architecture, have led to significant advancements in commercial domains. These powerful models have demonstrated superior capability to learn complex relationships and often generalize better to new data and problems. This paper presents a novel transformer-powered approach for enhancing prediction accuracy in multi-modal output scenarios, where sparse experimental data is supplemented with simulation data. The proposed approach integrates transformer-based architecture with a novel graph-based hyper-parameter optimization technique. The resulting system not only effectively reduces simulation bias, but also achieves superior prediction accuracy compared to the prior method. We demonstrate the efficacy of our approach on inertial confinement fusion experiments, where only 10 shots of real-world data are available, as well as synthetic versions of these experiments.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

SiC-Based Wireless Power Transformation for Data Centers & Medium Voltage Applications

Data centers have grown in physical size and their electrical power consumption has grown to levels of several 100kW and approaching 1 GW in large installations. The low voltage electrical distribution inside of Data Centers consists of several conversion stages and a lot of wiring to bring the power from medium voltage (MV) levels outside of the building to the low voltage levels that the servers and racks require. Energy losses during distribution and conversion and high incident arc flash energy levels at the point of use are significant. The electrical distribution system is complex and costly.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

FLEXIBLE POWER TRANSFORMERS TO IMPROVE RESILIENCY OF TRANSMISSION NETWORKS

For decades, transformer flexibility of operation has been limited to adjustable voltage ratio and, in some cases, several ratings with staged cooling. Transformers reconnectable to multiple voltage ratings have been primarily applied as emergency replacements. Other versions of “flexible transformers” were developed for continuous, long-term operation at specific sites, with application limited to large utilities. A new technology that supports today’s power systems adaptability requirements has been developed to provide not only voltage and power rating flexibility, but also an adjustable short-circuit impedance. This last, unique feature allows for a closer match to actual system operational requirements and could be used in the future to enhance resiliency and improve dynamic control of electrical grids. While the solution’s fundamentals have already been introduced in several technical forums, the intention of this article is to focus on the potential benefits of this new type of transformer and share the deployment experience of a full-scale prototype that has been in operation in a major U.S. utility since 2021

flexible transformer, resilient grid, variable lea↗
DOE OSTI2021

Beyond ethics: The transformational power of overlapping motivations in implementing strategic sustainability actions

Abstract We develop a methodology to identify patterns between sustainability motivations, actions and engagement. We apply this methodology to analyse a 3 1/2‐year intervention that yielded 151 sustainability actions undertaken by 46 outbound tour operators. We find three aspects that can be explained by the tour operators' motivations to act sustainably, namely, a connection between: (i) the actions taken in the context of the organisation's business model, (ii) the intensity of the approach, measured by the resources invested in it and the operator's commitment level and (iii) the evolution of the response. These patterns demonstrate how ethical motivations are common and a precondition to acting sustainably, but, in themselves, these motivations are not sufficient to integrate sustainability practices into the core business or to maintain commitment over time. It is the combination of a high ethical commitment with clear strategic intent, materialised in commercial and operational motivations, that increases the connectedness, and intensity, of sustainability actions amongst ethically committed firms.

Bonilla‐Priego, Maria Jesus↗