836 PARROTT: HIGH-VOLTAGE [5th Mar.

HIGH-VOLTAGE TESTING TRANSFORMERS

(100,000-750,000 VOLTS).

By R. G. PARROTT, Student.
(Abstract of paper read before the MANCHESTER STUDENTS' SECTION,
$th March, 1912.)

The object of this paper is to discuss certain theoretical and

practical features relating more especially to the design and construc-
tion of high-voltage testing transformers of a normal voltage above
100,000.
Electrical Characteristics. In considering the most important
electrical characteristics, the aim should be to use as large a sectional
area o iron, and as few turns in the winding as possible, together with
sufficient additional insulation between the end-turns of the high-
tension winding to enable it to withstand the high-frequency
oscillations which are invariably present during most switching
operations, short circuits, etc. Owing to the increased volts per turn,
brought about by the use of a larger sectional area of iron, the number
of turns will be reduced. The copper factor will therefore be higher, and
the windings will not only be easier to insulate and cheaper to wind, but
will be stronger mechanically with less chances of open circuits
occurring. Again, the reactance, which is proportional to the square of
the number of turns, will be reduceda desirable feature where
extreme accuracy of ratio is required. The value of the volts per turn
has, during the past ten years, risen from approximately 3-4 to 15-25.
Output.In the majority of cases where the transformer is only re-
quired for testing small samples of insulation, the output in kilovolt-
amperes will be very small, but with cables, transmission lines, large
electrical plant, etc., the necessary output, since each acts as a con-
denser, will be much greater on account of the larger magnetising
current taken by such apparatus. Since the output of the testing
transformer depends on the static capacity of apparatus to be tested, an
approximate idea of the necessary kilovolt-amperes required for any
particular apparatus may be obtained from the following formula,
which is based on the flow of current to a condenser where a sine
wave of E.M.F. is applied to its terminals.
2
K.V.A. = I E 10-3 = 2 . 7T . OO . C E X
where I = current in testing transformer r>o = frequency in cycles per second,
C = capacity of apparatus under test in microfarads, and E = test voltage.
FIG. I.750,000-volt Testing Transformer.
1912.] TESTING TRANSFORMERS. 837

It has therefore become general practice to provide a transformer having

sufficient output to allow of a practical type of construction being adopted,
and to be able to supply the chirging current and leakage current, as well as
the energy absorbed by dielectric hysteresis, and having also a minimum
impedance drop on short circuit. The size of the transformer, apart from the
kilovolt-amperes output, will be largely influenced by the over-potential and
flash tests guaranteed.
Temperature Rise.Owing to the fact that the mijority of testing
transformers are rarely used continuously, it is not necessary to rate them on
the basis of temperature rise after continuous full-load run, but it should be
sufficient to rate them on the basis of the maximum current the transformer
could deliver for short periods. The actual temperature of the insulation
should always be kept below 90 to 95 0 C, otherwise its properties will very
soon be destroyed. For this reason, and because of the comparatively large
quantity of insulation, it is advisable to rate the copper at a fairly low density,
approximate 800 amperes per square inch, and provide cooling ducts where
the insulation is likely to become bulky.
Design of Tanks.Since the watts per cubic foot of active material are
low, and the necessary clearances to prevent flashing over between the
windings and inside of tank are comparatively large, a plain tank gives
sufficient radiating surface to keep the temperature at a safe value. This is
demonstrated by the fact that more than 90 per cent, of the testing
transformers are immersed in plain boiler iron tanks with either welded or
riveted joints. A typical design is shown in Fig. 1, which illustrates a 500-
k.v.a. 75o,ooo-volt, 60-period testing trans-former built by the General
Electric Company, Schenectady, U.S.A. The dimensions are 8 ft. X 13 ft. X
15^ ft. high, and 28 ft. to the top of the terminal.
Relative Advantages and Disadvantages of the Shell and Core Type for
High Voltages.For comparatively low voltages there is little to choose
between the two types, but for the higher voltages it becomes per-fectly
obvious, after a little consideration, that the core type is the only practical
solution as regards both construction and cost.
The author is of the opinion that for voltages above 50,000 the core type
should be adopted, although some manufacturers can balance the cost at
approximately double this value. Considering the question first of all from
the manufacturer's point of view, with special reference to the mechanical
construction, one will see that the coils of the shell type, having a greater
mean turn, are much more likely to suffer damage from bending and twisting
due to their increased flexibility and difficulty in handling than the more
rigid circular core type coils of much smaller dimensions.

The actual quantity of insulating material is larger and more awkward

and expensive to handle than that required on the core type. The time
required for completely assembling a core type transformer is less than that
required for a shell type.
From the operating engineer's point of viewwith reference to
838 PARROTT : HIGH-VOLTAGE [5th Mar.,

breakdownsit is easy to see that a high-tension coil can be replaced in a

very much shorter time in the case of the core type than in the case of the
shell type, where all the iron has to be dismantled before the coils can be
separated.
Insulating Materials.The insulation of the windings is of course the
most important feature to be considered where high voltages are present. Far
better results are to be obtained by the proper selection and mechanical
disposition of the insulation than by simply relying on a sufficient quantity
of such material.
Parts to be insulated from each other should be designed to have
approximately uniform electrostatic capacities, so that the insulation may be
under uniform electric stress and free from high potential differences due to
condenser effect.
Fibrous materials alone should not be relied on except for mechanical
protection, since their dielectric properties are not good unless thoroughly
treated with compounds, gums, varnishes, etc., which are far more durable.
Mineral oil is one of the very best insulating materials, and is invariably used
to much advantage with all high-voltage transformers. In addition to its good
dielectric properties, it effectively protects the windings from moisture and
is a good cooling medium.

Arrangement and Construction of Winding.There seems to be no

standard practice with regard to the grounding of either the end or the middle
point of the high-tension winding. Some firms build all their testing
transformers with one side permanently grounded to the core. This seems
good practice since it meets practically all conditions of test. The effect of
grounding will be to reduce the dimensions and cost of the transformer. The
smaller the output and the higher the voltage, the greater will be this
reduction in cost.
There are many ways of connecting the high-tension coils, but the two
most commonly in use arefirstly, the connection of all coils in series,
starting at the top of one leg and finishing at the top of the nextthis gives
the maximum voltage difference between the top coil 6f each leg (see Fig. 2
which shows the windings of the 750,000-volt transformer shown in Fig. 1).
Secondly, the coils of both legs are cross-connected all the way up from the
bottom to the top of the legs. With this arrangement there is very little
voltage difference between coils on different legs in the same plane.

An extremely interesting and novel type of construction is illus-trated in

Fig. 3it shows the windings of a 5oo,ooo-volt testing transformer built by
the Westinghouse Company, Pittsburg Pa, U.S.A. The coils connected are as
follows : The bottom coil on the left-hand leg has one end grounded and the
other end connected to the bottom right-hand coil, which is again connected
to the top right-hand coil by a connection which passes through the
innermost micarta tube. This top coil is then cross-connected to the top left-
hand coil (not shown), which is connected through the inner micarta tube to
the second from the bottom on the same leg, and so on until finally the high-
voltage end
FIG. 2.Windings of 750,000-volt Testing Transformer.
1912.] TESTING TRANSFORMERS. 839

of the winding is brought out at the middle coil. The great saving in copper
factor and height by adopting this method is marked.
The main considerations in connection with the winding of coils are :

1. Sufficient and proper insulation between turns, between layers, and

between sections.
2. Mechanical strength, making it impossible for any turns to become
displaced.
By reference to Fig. 2, it will be noticed that the group of coils on each
leg rest on a metal ring, and that the top coils are also capped by a metal
ring. These rings are to prevent damage to the coils aris-ing from discharges
induced to ground, considering each leg as a condenser.

In connection with the arrangement and construction of the wind-ings the

chief points to be watched are :
1. Proper and most economical general arrangement.
2. Sufficient insulation per turn and per coil.
3. Sufficient puncture distance and creepage surface between all
points where there exists a high-potential difference.
4. Due consideration to the proper mechanical construction of both
the windings, the insulation, and their support.
Insulation on End-turns.It has been found from experience that to
obtain immunity from breakdown due to the accumulation of high voltages
on the end-turns of high-voltage windings, it is quite sufficient to grade the
insulation at each end of the winding to a depth of only about 4 to 6 per
cent., but the exact amount varies according to the standard practice of the
different manufacturers. External choke coils are sometimes used in place of
this special grading, as may be seen from Fig. 1.

It is not considered good practice to have either series parallel

connections or tappings on the high-tension winding unless absolutely
necessary, as it is desirable that the high-tension terminal gear should be as
simple as possible.
High-voltage Terminals.The main essentials which should be em-
bodied in the design of a high-voltage terminal are, first, sufficient creeping
surface to prevent a flash-over taking place between the live metal lead and
the tank through which it passes, and secondly, sufficient thickness of
insulation between the live lead and the tank to prevent a puncture taking
place.
Glass terminals are occasionally used for 100,000 volts, but not above.
Porcelain terminals have been made for use up to 500,000 volts. The "
condenser " type terminal and the " oil-filled " terminal are used up to the
highest voltages.
The most economical method of constructing the "condenser" type of
terminal (Fig. 4 c and d) is that in which the total thickness of in-sulation
between conductor and support is divided into a number of sections of equal
thickness, separated from each other by metal cylinders.
 840 PARROTT: HIGH-VOLTAGE [5th Mar.,

of such dimensions as to give a series of condensers of the same

electrostatic capacity. The voltage across any one of these condensers
will be inversely proportional to its capacity, according to the well-
known law of condensers in series, with the result that the potential

//////////////////////s//// / / / / / / / / / / / / / / / / / / / / / / ////////////////////////
'////////////////////////I-/.

(a)

(b)

(C)

u1 I
q r ; f'
i | =- | (f)
= & i

11
^ ^ FR m i
i ifTP ^
i

FIG. 4.High-voltage Terminals.

gradient throughout the dielectric will be constant, and the best con-
ditions against puncture provided for.
Since the thickness of insulation between each layer of tinfoil is the
same, and the capacities are all equal, the ends of the tinfoil will lie in a
logarithmic curve, so that the creepage volts per millimetre are not the
same all along the surface of the terminal. If, however, the ends of the
tinfoil are made to lie in a straight line, when the capacities of
 1912.] TESTING TRANSFORMERS. 841

the first and last condensers are equal, the exact distribution of stress may be
determined from the following formulafor the capacity of two parallel
cylinders :
The capacity = - *'' in microfarads,
ioMog I o . -
i

where k = specific inductive capacity, / = length in centimetres, rx = inner

radius in centimetres, and r2 = outer radius in centimetres.
The result of applying this formula shows that there will be an increase
in capacity of each condenser from both the inside and out-side towards the
centre of the terminal. This is partly compensated by leakage to ground, and
by the addition of a metal cap on the top of the terminal. The result,
therefore, of making the creepage potential gradient constant does not
seriously interfere with the best conditions of puncture.

Another form of construction is that in which the ends of the tin-foil are
made to lie in straight lines, while the thickness of insulation per layer is
varied to obtain approximately equal capacities.
The "oil-filled" terminal (shown in Fig. i) consists essentially of a built-
up shell of insulating material, generally of hard wood or red fibre, in the
form of short concentric cylinders, all fitting closely together and clamped
tightly by the live bolt passing through the middle. This shell is then filled
with a high-grade insulating liquid or compound, such as oil or asphaltum.
Between the different sections are placed concentric discs of pressboard with
the object of increasing the external creeping surface. In practically all cases
the conductor passing through the centre of the terminal is heavily insulated
from the surrounding shell by means of a number of concentric cylinders
properly spaced.
Fig. 4 (a to/) shows to scale a number of different makes of terminals, all
for a test voltage of 200,000 volts for 1 minute.
(a) Glass tube terminal.
(b) Porcelain " oil-filled " terminal.
(c) " Condenser " type terminalThe British Westinghouse Com-
pany.
(d) "Condenser" type terminalThe American Westinghouse
Company.
(e)^ " Bulk" type terminalThe American Westinghouse Company.
(/) " Oil-filled " terminalThe General Electric Company, U.S.A.

In conclusion, the author wishes to express his thanks to Messrs. The

A.E.G. Company, Brown, Boveri & Co., Ltd., Machinenfabrick Ocrlikon,
The British Westinghouse Company, Ltd., Siemens and Halske, and Siemens
Bros. & Co., The American Westinghouse Company, The General Electric
Company (U.S.A.), and The British Thomson-Houston Company, Ltd., for
photographs illustrating their designs of high-voltage transformers.