Inverted High Voltage Transformer Compartment Design
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Solution Overview
Problem
Traditional high voltage assemblies, such as oil-immersed power transformers and reactors, face inefficiencies due to the need for a conservator above the assembly, which increases costs and requires additional space and equipment for assembly and transportation, as well as potential oil leakage risks during overpressure events.
Innovation Solution
A high voltage assembly design featuring a first compartment with an active component and a second compartment connected via a return fluid connection, including a pumping means to deliver insulation fluid, allowing the second compartment to be placed below the nominal fluid level, reducing costs and space requirements, and incorporating a pressure relief valve to prevent oil leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conservator is placed above the high voltage assembly to receive expanding oil volume, then the insulation fluid level can be maintained, but the overall assembly height increases and additional support structures are required
Solution Approach 1:
The conservator is inverted and placed below the nominal insulation fluid level instead of above it. The open end of the conservator faces upward, allowing it to receive expanding oil volume while being positioned at the bottom of the assembly. This inversion resolves the contradiction by maintaining the fluid level control function while eliminating the need for additional height and support structures.
Solution Approach 2:
The conservator is positioned in the horizontal dimension at the bottom of the assembly rather than extending vertically above it. By placing the conservator in the lower compartment and using horizontal fluid connections, the design transitions from a vertical arrangement to a horizontal one, reducing assembly height while maintaining functionality.
2Reliability
If a traditional conservator arrangement is used, then the insulation fluid can be managed, but more space above the ceiling is occupied and manufacturing costs increase
Solution Approach 1:
The conservator is inverted and positioned at the bottom of the assembly with its open end facing upward. This allows the conservator to be placed in the lower compartment, freeing up the space above the ceiling for other components and reducing the overall footprint of the assembly while maintaining insulation fluid management capability.
3Reliability
If a separate conservator is used, then insulation fluid expansion can be accommodated, but manufacturing and assembly costs increase due to circumstantial assembly and heavy equipment requirements
Solution Approach 1:
The conservator is merged with the metal enclosure to form an integral, monolithic structure. The conservator and the main assembly share common walls and are manufactured as a single unit, eliminating the need for circumstantial assembly, heavy cranes, and complex reassembly operations. This integration directly reduces manufacturing and assembly costs while maintaining the function of accommodating insulation fluid expansion.
Solution Approach 2:
The metal enclosure serves dual functions: it acts as both the main structural housing and as the conservator for insulation fluid management. By making the conservator an integral part of the enclosure, the structure performs multiple functions simultaneously, reducing the need for separate components and simplifying manufacturing.
4Ease of manufacture
If the second compartment is placed below the nominal fluid level, then manufacturing costs are reduced, but the pumping means must actively manage fluid delivery
Solution Approach 1:
The system uses gravity to its advantage by positioning the conservator below the nominal fluid level. When insulation fluid expands, it naturally flows into the conservator. When fluid is needed, the pumping means actively delivers fluid from the conservator back to the first compartment. This self-service approach using gravity reduces the need for complex active control systems while maintaining cost-effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces manufacturing and transportation costs, minimizes the substation footprint, and enhances safety by preventing oil leakage during overpressure events, while maintaining operational fluid levels through controlled fluid management.
Implementation Method 1
the return fluid connection comprises a pumping means adapted to deliver insulation fluid from the second compartment to the first compartment
Implementation Method 2
the first compartment and the second compartment are connected via a pressure relief valve. In the event of an overpressure in the first compartment, the pressure relief valve transports the oil directly into the second compartment
Implementation Method 3
the second compartment comprises a breather. The breather allows a variable insulation fluid level inside the second compartment
Implementation Method 4
When the oil temperature drops, the oil flows back into the compartment by means of the gravitational force of the oil itself
Data Source
Figure 1
Figure 2
AI summary
A high voltage assembly (2) is provided, in particular, a high voltage transformer or a high voltage reactor, comprising a first compartment (12) containing an active component (4) and a second compartment (14). The first compartment (12) is connected to the second compartment (14) via a return fluid connection (40), wherein the return fluid connection (40) comprises a pumping means (42) adapted to deliver insulation fluid from the second compartment (14) to the first compartment (12).