ZX-BRY02 : Technical Overview and Power Industry Application

Abstract

This paper introduces the ZX-BRY02 Transformer Winding Deformation Tester, a specialized testing instrument for power transformers rated 6kV and above, as well as special-purpose transformers. It elaborates on the instrument’s testing principle compliant with China’s electric power industry standard DL/T911-2004, core technical features, key performance indicators, and its application value in ensuring the safe and stable operation of power systems. With high precision, strong intelligence, and efficient on-site testing capability, this instrument provides a reliable, non-destructive solution for early detection of transformer winding deformation faults.

Introduction

Power transformers are the core equipment of power transmission and distribution systems, and their operational reliability directly determines the safety and stability of the entire power grid. During long-term operation and transportation, power transformers are inevitably subjected to the impact of fault short-circuit currents and physical collisions. The strong electro-dynamic force generated by short-circuit events will cause the transformer windings to lose mechanical stability, resulting in permanent deformations such as local distortion, bulge, or dislocation. These hidden defects, if not detected and handled in a timely manner, will seriously deteriorate the transformer’s insulation performance, and even lead to catastrophic equipment failure and large-scale power outages.

According to DL/T911-2004, the frequency response analysis (FRA) method is the standardized and mainstream approach for transformer winding deformation detection. This method identifies potential deformation defects by detecting the amplitude-frequency response characteristics of each transformer winding, and conducting vertical (historical) or horizontal (inter-phase) comparative analysis of test results. Based on this standard, the ZX-BRY02 Transformer Winding Deformation Tester is developed to provide an efficient, high-precision, and intelligent solution for on-site and laboratory winding deformation testing.

Core Testing Principle

The ZX-BRY02 tester is designed based on the classic frequency response analysis method. It injects a sweep frequency signal into one end of the transformer winding, and collects the response signal at the other end. By measuring the amplitude-frequency characteristic curve of the winding in the frequency domain, the instrument can accurately reflect changes in the distributed capacitance and inductance parameters inside the winding.

Any mechanical deformation of the winding will cause corresponding changes in these parameters, which are presented as deviations in the frequency response curve. Through quantitative comparison and analysis of the curves, the type, location, and severity of winding deformation can be effectively judged, realizing non-destructive detection of hidden faults without disassembling the transformer body.

Key Technical Features and Performance Advantages

The ZX-BRY02 tester has outstanding advantages in testing convenience, intelligence, accuracy, and efficiency, which are mainly reflected in the following aspects:

Simplified On-site Testing Process: The instrument only requires the removal of the transformer connection bus during testing, without the need for transformer body disassembly or core lifting, which greatly reduces on-site testing workload and shortens the power outage time required for maintenance.

High-performance Sweep Frequency Capability: It supports two sweep modes: linear sweep (10Hz to 10MHz, 40000 sampling points) and section sweep (0.5kHz to 1MHz, 20000 sampling points). The scanning interval can be flexibly set to 0.25kHz, 0.5kHz, or 1kHz, meeting the multi-resolution analysis needs of different voltage levels and types of transformers.

High Intelligence and Automation: The instrument realizes fully automatic range adjustment and sampling frequency adjustment, eliminating manual parameter setting errors. After wiring is completed, the test can be run automatically; operators can view historical curves or stop the test at any time during the measurement process, greatly reducing the professional threshold for on-site operators.

Professional Data Analysis and Diagnosis: It is equipped with a built-in automatic analysis and diagnosis system, supporting historical curve comparison analysis, and can simultaneously observe up to 6 curves for horizontal and vertical comparison. The system automatically saves environmental parameters and test results, and supports color printing, facilitating the archiving and traceability of test data.

Ultra-high Testing Efficiency and Repeatability: The measurement time for each phase is less than 60 seconds, and the full winding test of the whole transformer can be completed within 10 minutes, significantly improving testing efficiency. The same-phase test reproducibility reaches 99.99%, ensuring the reliability and consistency of long-term repeated test results.

Strong System Compatibility: The instrument adopts a Windows platform software system, which is compatible with Win98, 2000, XP, Win7, Win8, and Win10 operating systems, with a humanized software design for easy operation.

Key Technical Indicators

The core performance indicators of the ZX-BRY02 fully meet and exceed the requirements of DL/T911-2004, with the main parameters as follows:

Application Value in the Power Industry

The ZX-BRY02 Transformer Winding Deformation Tester has a wide range of application scenarios in the power industry, covering the whole life cycle management of power transformers:

Factory Inspection: Used for type tests and factory tests of transformers in the manufacturing link, to ensure that the winding state of the transformer leaving the factory meets the design requirements.

Handover Test: Used for on-site handover tests after transformer installation and transportation, to detect whether the winding is deformed during transportation and hoisting.

Operation and Maintenance Inspection: Used for regular preventive tests of in-service transformers, to realize early detection and early warning of potential winding deformation defects, and avoid sudden equipment failure.

Post-fault Diagnosis: After a short-circuit fault occurs in the transformer, it can quickly and accurately evaluate the damage degree of the winding, and provide a reliable basis for maintenance strategy formulation.

By using this instrument, power operation and maintenance departments can effectively improve the lean management level of transformers, reduce the risk of major equipment accidents, and significantly reduce the economic losses caused by unplanned power outages.

Conclusion

The ZX-BRY02 Transformer Winding Deformation Tester, based on the standardized frequency response analysis method, has the characteristics of high precision, high intelligence, convenient operation, and excellent portability. It fully complies with the relevant provisions of DL/T911-2004, and can accurately and efficiently detect winding deformation defects of 6kV and above power transformers. As a reliable professional testing instrument, it plays an important role in ensuring the safe and stable operation of power transformers and improving the reliability of power systems, with broad application prospects in the power industry.

GDZX is a manufacturer of power detection equipment, offering a diverse range of products with comprehensive models and providing professional technical support. Contact us at +86-27-6552607 or +86-17396104357.Website: http://en.gdzxdl.com/