DISTRIBUTION TRANSFORMERS

The purpose of a distribution transformer is to reduce the primary voltage of the electric distribution system to the
utilization voltage serving the customer. A distribution transformer is a static device constructed with two or more
windings used to transfer alternating current electric power by electromagnetic induction from one circuit to another
at the same frequency but with different values of voltage and current.

In North America, 40 million distribution transformers are in service, and another one million are installed each year
(Alexander Publications, 2001). The transformer connection determines the customer’s voltages and grounding
configuration.

The most common overhead transformer is the 25-kVA unit; pad mounted transformers tend to be slightly larger
where the 50-kVA unit is the most common.

Distribution transformer impedances are rather low. Units under 50 Kva have impedances less than 2%. Three-phase
underground transformers in the range of 750 to 2500 kVA normally have a 5.75% impedance as specified in
(ANSI/IEEE C57.12.24-1988). Lower impedance transformers provide better voltage regulation and less voltage flicker
for motor starting or other fluctuating loads. But lower impedance transformers increase fault currents
on the secondary, and secondary faults impact the primary side more (deeper voltage sags and more fault current on
the primary).

Standards specify the insulation capabilities of distribution transformer windings. The low-frequency test is a power-
frequency (60 Hz) test applied for one minute. The basic lightning impulse insulation level (BIL) is a fast impulse
transient. The front-of-wave impulse levels are even shorter-duration impulses.

Distribution transformers are “self cooled”; they do not have extra cooling capability like power transformers. They
only have one kVA rating. Because they are small and because customer peak loadings are relatively short duration,
overhead and padmounted distribution transformers have significant overload capability. Utilities regularly size them
to have peak loads exceeding 150% of the nameplate rating.
3.1 IntroductionIn general, distribution transformers are used to reduce primary system voltages (2.4–34.5 kV) to
utilization voltages (120–600 V). Table 3.1 gives standard transformer capacity and voltage ratings according to ANSI
Standard C57.12.20-1964 for single-phase distribution transformers. Other voltages are also available, for example,
2400 × 7200, which is used on a 2400 V system that is to be changed later to 7200 V.

Table 3.1

Standard Transformer Kilovoltamperes and Voltages

3.2 Types of Distribution Transformers

Heat is a limiting factor in transformer loading. Removing the coil heat is an important task.
In liquid-filled types, the transformer coils are immersed in a smooth-surfaced, oil-filled
tank. Oil absorbs the coil heat and transfers it to the tank surface, which, in turn, delivers it to
the surrounding air. For transformers 25 kVA and larger, the size of the smooth tank surface
required to dissipate heat becomes larger than that required to enclose the coils. Therefore,
the transformer tank may be corrugated to add surface, or external tubes may be welded to
the tank. To further increase the heat-disposal capacity, air may be blown over the tube
surface. Such designs are known as forcedair-cooled, with respect to self-cooled types.
Presently, however, all distribution transformers are built to be self-cooled.

Therefore, the distribution transformers can be classified as (1) dry type and (2) liquid-filled
type. The dry-type distribution transformers are air-cooled and air-insulated. The liquid-
filled-type distribution transformers can further be classified as (1) oil filled and (2) inerteen
filled.

The distribution transformers employed in overhead distribution systems can be categorized

as

1. Conventional transformers
2. Completely self-protecting (CSP) transformers
3. Completely self-protecting for secondary banking (CSPB) transformers

The conventional transformers have no integral lightning, fault, or overload protective

devices provided as a part of the transformer. The CSP transformers are, as the name implies,
self-protecting from lightning or line surges, overloads, and short circuits. Lightning
arresters mounted directly on the transformer tank, as shown in Figure 3.1, protect the
primary winding against the lightning and line surges. The overload protection is provided
by circuit breakers inside the transformer tank. The transformer is protected against an
internal fault by internal protective links located between the primary winding and the
primary bushing. Single-phase CSP transformers (oil-immersed, polemounted, 65°C, 60 Hz,
10–500 kVA) are available for a range of primary voltages from 2,400 to 34,400 V. The
secondary voltages are 120/240 or 240/480/277 V. The CSPB distribution transformers are
designed for banked secondary service. They are built similar to the CSP transformers, but
they are provided with two sets of circuit breakers. The second set is used to sectionalize the
secondary when it is needed.

The distribution transformers employed in underground distribution systems can be

categorized as
 1. Subway transformers
2. Low-cost residential transformers
3. Network transformers

Subway transformers are used in underground vaults. They can be conventional type or
current-protected type. Low-cost residential transformers are similar to those conventional
transformers employed in overhead distribution. Network transformers are employed in
secondary networks. They have the primary disconnecting and grounding switch and the
network protector mounted integrally on the transformer. They can be either liquid filled,
ventilated dry type, or sealed dry type.

The ABB Corporation developed resibloc dry-type distribution transformers from 112.5
through 25,000 kVA, and from 2,300 through 34.5 kV primary voltage level and 120 V
through 15 kV secondary voltage level. Such transformers have windings that are
hermetically cast in epoxy without the use of mold. The epoxy insulation system is
reinforced by a special glass fiber roving technique that binds the coil together into virtual
winding block. As a result, they have unsurpassed mechanical strength with design
optimization through 25,000 kVA. Figure 3.2 shows such resibloc network
transformer. Figure 3.3 shows a dry-type pole-mounted resibloc transformer. Figure
3.4 shows a dry-type resibloc network transformer. Figure 3.5 shows an outdoor three-phase
dry-type resibloc transformer. Figure 3.6 shows a pad-mount-type single-phase resibloc
transformer. Figure 3.7shows a pad-mount three-phase resibloc transformer. Figure
3.8 shows an arch flash-resistant drytype three-phase resibloc transformer. Figure 3.9 shows
a TRIDRY dry-type resibloc transformer. Figure 3.10 shows a VPI dry resibloc
transformer. Figure 3.11 shows a pad-mount installation of three-phase resibloc transformer.

These resibloc transformers provide the ultimate withstand to thermal and mechanical
stresses from severe climates, cycling loads, and short circuit forces. The epoxy insulation
system is highly resistant to moisture, freezing, and chemicals, and is used in most
demanding applications. Such transformers are nonexplosive with resistance to flame and do
not require vaults, containment dikes, or expensive fire suppression systems. Primary basic
impulse insulation level (BIL) is up to 150 kV and secondary BIL is up to 75 kV.

They can withstand a temperature rise of 80°C. They have no danger of fire and explosion
and have no liquids to leak. Thus, they require minimal maintenance. They can be used
indoor and outdoor enclosures. The resibloc transformers will not ignite during an electrical
arc of nominal duration. If ignited with a direct flame, resibloc will self-extinguish when the
flame is removed.

Resibloc transformers are utilized in some of the harshest indoor and outdoor environments
imaginable. However, while core and coil technologies have been enhanced to combat
caustic and humid environments, resibloc transformers still require the protection of a
properly designed enclosure. An enclosure that flexes or bends under high wind loading can
compromise electrical clearances from the transformer to the enclosure, which can lead to
transformer failures as well as electrical safety hazards.

For example, an enclosure that allows excess water entry into it also poses unique risk. Such
enclosure designs have been used along coastal areas and frigid northern slopes where high
winds and driving rain are common. They can be also supplied with forced air cooling. The
temperature sensors are located in the LV windings and are connected to the three-phase
winding temperature monitor that controls the forced air cooling automatically.

Figure 3.12 shows various types of transformers. Figure 3.12a shows a typical secondary-
unit substation with the high voltage (HV) and the LV on opposite ends and full-length
flanges for close coupling to HV and LV switchgears. These units are normally made in sizes
from 75 to 2500 kVA, three-phase, to 35 kV class. A typical single-phase pole-type
transformer for a normal utility application is shown in Figure 3.12b. These are made from
10 to 500 kVA for delta and wye systems (one-bushing or two-bushing HV).