AREVA

Power Transformer Design Aspect
Didik Susilo Widianto

Technical Director
PT UNINDO – AREVA
Contents 1. Introduction
2. Transformer core
3. Inrush Current
4. Transformer Winding
5. Insulation and Cooling Medium
6. Transformer Losses
7. Insulation Structure & Dielectric Withstand
8. Transformer Thermal Aspect
9. Short Circuit Analysis
10. Engineering
11. Manufacturing Process
12. Accessories, Protection & control
13. Final Acceptance Test
14. Technology Application
3 > Title of presentation - Date - References 3

1. Introduction

Basic Theory
Faraday’s law
The electromotive force (e.m.f) is proportional to
the rate of linked flux changes
E = - N x dΦ/dt
E = Electro motive force
N = Number of turn
dΦ/dt = Change the flux against time
Lenz’s law
The e.m.f is such any current produced acts to
opposite the linked flux.
Current Flux Current Counter Flux

NO LOAD Condition
E = - N dΦ
Φ/dt = - N d(Φ
Φm Sin(ω
ωt))/ dt = - Nω
ω. ΦmSin(ω
ωt – π/2)
At f = 50 Hz, Φ = Β.Α E = 222.14 . Ν.Β.Α
At f = 60 Hz, E = 222.14 .N.B.A.(f/50) E1
E = e.m.f (electromotive force) in Volt
Φ = Flux in Weber I0
Ip
B = Peak Induction in Tesla
Φ
A = Core cross section in m2 Im
I0 = No load current in Amp. I0
Im = Magnetizing current in Amp.
Ip = Losses current in Amp. E1 E2
E2
N1 N2
ON LOAD Condition
V1 I1.X1
I2 R2 X2
I0 + I1 R1 X1 I1.R1
E1 I1 + I0
E2 V2
V1 E1
I1
Ip
I0
N1 N2
I2 Im Φ
Θ
E1 : N1 = E2 : N2
V2
I1 x N1 = I2 x N2
I2R2
Θ = the load power factor I2.X2

E2
Power Transformer Main Parts
Oil Preservation
Bushing
Core
Transformer Tank
Winding
Control Cubicle
Cooler Transformer Liquid

Transformer Power Rating
Transformer power rating is expressed by MVA as a product of

rating voltage and rating current.
The power rating [S] is a product of reactive power [Q] and
active power [P];
S [MVA] = S(Q2 [MVAR] + P2 [MW] )

Referring to IEC 60076 – 1;
S [MVA] = S3 x E2[kV] x I2[Amp] 10-3
Referring to ANSI/IEEE C57.12.00;
S [MVA] = S3 x V2[kV] x I2[Amp] 10-3
= S3 x (E2 + ∆V)[kV] x I2[Amp] 10-3
Hence, in ANSI/IEEE standard the power rating has considered
voltage drop at stated power factor

Voltage Drop/Rise
∆V = V2 – V1
I2 R2 X2
I1 R1 X1
E2 V2
V1 E1
N1 N2
∆V = K (VR.CosΘ Θ) + K2/200 x (VR.Sin Θ – VX.CosΘ

Θ + VX.SinΘ Θ)
VX VZ ∆V = Voltage drop/rise [%]

K = Loading factor
VR = Transformer resistance [%]
VX = Transformer reactance [%]
VZ = Transformer impedance [%]
Θ Θ = Load power factor
VR
Tap Regulation
Tap Regulation ; the required voltage ratio to control the

fluctuated voltage of network to deliver the expected
constant voltage.
Two type of tap regulator = Tap Changer ;
1.OLTC (On Load Tap Changer) = Tap regulation when the
transformer energized/under loading.
2.OCTC (Off Circuit Tap Changer) = Tap regulation when the
transformer de-energized (no transformer terminal is
connected to any network/generator)
Tap regulation is expressed by the number of step & the
percentage of nominal voltage for each step regulation.
Example = 150 kV + 7 x 1.5% / -10 x 1.5%

Flux Behavior Due To Tap Regulation
Two type of tap regulation ;

CFVV = Constant Flux Variable Voltage
The transformer volt/turn as well as the core flux will
constant along the tap regulated positions.
This is the most common tap regulation system.
VFVV = Variable Flux Variable Voltage
The transformer volt/turn as well as the core flux will
vary referring to the tap regulated positions.
This is used due to high current tap regulation at
furnace application or booster type regulation.

Position Of Tap Changer
Normally, the most optimum solution for tap changer

location is the neutral end of winding for STAR
connected winding.
For DELTA connected winding with insulation class of
72.5 kV and lower, the line end location of tap changer is
normally the most optimum solution.
For DELTA connected winding with insulation class
higher than 72.5 kV class, the middle electrical location
of tap changer will be the optimum.
The electrically as well as geometrically location of tap
changer will also determine the impedance & losses
behavior.

Tap Regulation vs Power Rating
There are two kinds of power rating;

CONSTANT Power Rating;
The power is constant for all tap regulation position.
REDUCED Power Rating;
The power is reduced with constant current rating from a
certain tap regulation position.
Reduced Power
Constant Power from tap n
S
V V S
I
I
Tap 1 n p Tap 1 n p

Autotransformer Concept
Seri Winding I2 = Is
Ns = N2 – N1
Tap Changer
I1
V2
V1 Ic = I1 – I2
N1 = Nc
Common Winding
I1, I2 = Current primary (1) & secondary (2)

V1, V2 = Voltage primary (1) & secondary (2)
Common Winding = N1 x (I1 – I2)
Seri Winding = (N2 – N1) x I2

On Load Tap Changer
ON TANK OLTC IN TANK OLTC

ACTIVE PART - Areva definitions
Frame Tank Location
Upper Yoke Top Frame
Insulation Cup
Coil Clamping
Block
Cross Brace
Top Platform
Tie Rod
Bottom
Platform
Flux Packet
Coil Support
Blocks
Oil Diaphragm
Tank Base
2. Transformer Core

CORE
Purpose : the path for the flux lines with low

magnetic reluctance
Core material in power transformer ;

Cold Rolled Grain Oriented Silicon Steel.
Available thickness = 0.23 mm, 0.27 mm, 0.30 mm
Lamination insulation = CARLITE 0.012 mm
Grade ;
Conventional Grain Oriented = High losses.
Hi-B Grain Oriented = Medium losses.
Laser/plasma refinement GO = Low losses.

Induction vs Core Loss

Core Stacking - Mitred Joints
But Lap Joint
Step Lap Joint

Core Cutting
Three Legs Core

½W
Five Legs Core (3 wounds + 2 return)

Bandaged Core

Core Determination Factors
No Load Loss (and No Load Current) ;
No load loss is independent with the loading of the transformer, but it is
dependent with the applied voltage per turn of the winding.
It has more significant economical component cost in capitalization than other
losses due to it’s appearance independency with the cyclic loading.
IEC standard tolerance for no load loss = +15%, no load current = +30%.
Over excitation capability ;
For generator application, the transformer shall be designed for over excitation
up to 140% in 5 second during load rejection.
For distribution application (and general purpose), the transformer has to be
designed by considering
Over voltage up to 110% continuous at no load condition.
Over voltage up to 105% continuous at full load condition.
Core temperature limit at required maximum ambient temperature
(Design limit < 140oC at center, < 105oC at surface to avoid gassing).
Sound power / sound pressure level.
The local regulation for sound pressure/sound power limit.
Installation location ; populated area, remote area.
Core Saturation Capability For Load Rejection
145
140
135
Percent Excitation
130
125
120
115
110
105
0.1 1 10 100
Time - Minutes

3. Inrush Current

Definition
Inrush Current is the excitation current that will occur due

to the existence of magnetic flux remnant when the
transformer is first switched into the service.
The inrush current can have the peak value up to 5 times

the nominal current. The most unfavorable inrush
current arises when switching in take place at a zero
voltage transition.
Due to the magnitude of the inrush current, the over

current relay may interpret this current as the failure
current to open the circuit breaker on the system.

Inrush Current Calculation
Maximum Inrush Current can be estimated with the some

empirical factors referring to the core stacking method, gap
between core and the first excited winding, primary winding
connection, network & transformer impedance and transformer
core behavior. This is an important information to determine the
over current and differential relays setting point.
The actual inrush current is difficult to be estimated as this will
be dependent to the existence of remanence flux due to
previous system cut out at certain voltage angle.
Maximum inrush current estimation method;
Empirical formula.
Electromagnetic transient computer software;
EMTP (Electro Magnetic Transient Program), CANADA.
SLIM – electromagnetic function, AREVA

Estimating Inrush Current
Empirical formula to calculate the peak of inrush

current is as followings;
S2.U
ωt – y) – e-(t-t0)/ττ.SinQ). K
Ipeak = Z . Sin(ω
t
Where;
K = Constanta value referring to the transformer connection
(Grounded STAR, DELTA) and other circumstantial.
U = Applied voltage (rms)
Zt = Transformer + network impedance.
y = Energization angle.
τ = Transformer time constant.
t = Core saturation time referring to maximum, remnant &
saturation induction behaviour.
Q = Angle function of core induction.
Some Aspect Effecting Inrush Current
Transformer number of phases and primary winding
connections;
Single phase transformer and/or shell type has higher inrush
current than three phase transformer and/or core type.
DELTA connection of primary winding three phase transformer
has lower inrush current than grounded STAR.
Transformer capacity;
Higher transformer MVA rating has lower ratio between inrush
current and primary nominal current, but longer decay time.
Transformer core steel, core design and nominal induction;
HiB core steel has lower inrush current than CRGO material.
But lap joint has lower inrush current than Step lap joint.
Lower impedance transformer normally has lower air core
reactance and then higher inrush current.

B
Flux nominal + remnant
Φrem
time H
Flux nominal
Inrush current
Excitation
current
time

4. Transformer Windings

Winding
Type of winding;
Layer winding;
Single layer.
Multilayer.
Helical winding.
Disc winding.
Plain/continuous disc
Intershielded disc.
Interleaved disc.
Multistart winding.
Winding Conductor
Type of material conductor;

Electrolytic copper.
Aluminum.
Form of conductor;
Round wire.( for small distribution
transformer)
Rectangular wire.
Twin/Tripple/Quadrople conductor.
CTC (Continuous Transposed Cable).
Netting-CTC/Paper less CTC

Winding – Areva terminology
Axial/Radial
Packing for
transposition
Directed Oil
Flow washers
External DOF
washer
Internal DOF
washer
Transposition
set
Segment
Spacer

Disc Winding
PROTECTION FOR
SCISSOR EFFECT
Extra paper = 2 layers

overlapped of Clupack

CTCs winding
Epoxy bonded
Try to use CTC with max. 55 strands per cable.

Epoxy bonded in low chip type is recommended for force capability.
Strand thickness 1.2 mm to 2.6 mm.
Strand width 5.0 mm to 12.5 mm.
Insulation increase of each strand = 0.10 PVA + 0.05 low chip epoxy.
Insulation increase of bundle, minimum 0.50 mm.
Minimum key spacer thickness for ZIG-ZAG cooling = 4.0 mm.

Soft Cross Over for CTC – DISC winding
Missing turn block = 1

cable thick
Inside cross over
protection
Cross over block =

thick pressboard

Heavy current helical winding

Intershielded Disc Winding
Provide the best controllable high

frequency dielectric voltage distribution

Intershield Disc Winding Technology Research
In 2007 : To Tests Models ISDW With Few Turns/Disc With Results To Be

Used As Input For The Design Of A Full Size 800 kV UHVDC ISDW Prototype
To Design With EDT&PD Team; To Build And To Test A Full Size 800 kV
UHVDC ISDW Prototype

Intershielded Disc Winding

5. Insulation and Cooling Medium

Cooling Medium
INTERNAL COOLING MEDIUM

Besides the thermal absorption, the internal cooling
medium also functions as the insulation medium.
Class A;
Mineral oil (Inhibited or Un-inhibited oil).
Class K;
Silicon oil
Synthetic ester
Hi-Temp natural liquid (seeds).

Oil Molecules

Oil Specification

Oil Finger Print

Oil’s Aromatic Check (Sulphur Content and other)

Future – Environmental Friendly Liquid
Environmental liquid = Enviro-Temp FR3 by COOPER
Inhibited oil = Nitro 10XT by NYNAS
Property – typical values Inhibited oil FR3
Antioxidant, phenols 0.08% per Wt n.a.
Oxidation stability by 120oC 500 hours continuous
Biodegradable in 21 days 25% 100%
Saturated moisture at 25oC 80 ppm 1200 ppm
Temp. rise for unity life time *) 60/65/78 K 80/110/130 K
Flash point 145oC 330oC
Pour point -57oC -18oC

Natural ester dielectric behavior
Dielectric Strength versus Water Content
80
70
D 1816 Dielectric Breakdown (kV)
60
50
40
30
Envirotemp FR3 fluid

20
conventional transformer oil
10
0
0 100 200 300 400 500 600
Water Content (ppm)

Eco-Design/vegetable oil transformer
History;
2005: order for joint development with customers of vegetable oil transformers
2006: oil characteristics review and prototype transformers design, manufacture and
test
2007 Q1: commissioning and monitoring of 90MVA 132kV transformer in UK
2007 : devel of PTR design rules book, oil specification , manufacturing and filling
process , maintenance rules and nominal parameters
2007 : commercial agreement with oil supplier Cooper for local vegetable oil
distribution.
Achievement
Environmentally friendly transformers and reactors
filled with vegetable oil
Vegetable oil totally biodegradable , with higher fire point
than mineral oil (envirotempFR3 oil from COOPER)
transformers and reactors up to 245kV, and rated power up
to 100 MVA (existing new references)
Application for Higher ratings to be evaluated if potential
for joint development with customers

6. Transformer Losses

Power Transformer Losses
Losses is the active energy component

to be absorbed by the transformer and
associated component such as fan,
pump, control circuit. Mainly this losses
will become the heat energy.
Losses contain;
Core loss = No load loss.
Load loss
Auxiliary loss

Core Loss
Core Loss = No Load Loss ; is the loss of the

energy when the transformer under no load
condition (the primary terminal is connected to
the power source, the secondary/tertiary etc are
open). This loss is expressed by Watt or kWatt.
Core loss contains;
Hysteresis loss; The magnetic power that inherently
absorbed due to the magnetic behavior of the
transformer core material. This energy is required to re-
align the magnetic domain for the flux at certain time.
Eddy-current loss; The loss of active power caused by
the circulating current as the result from the
perpendicular flux into the core plate with it’s resistive
component characteristic. Thinner plate will give lower
eddy-current loss of core material.

Hysteresis Core Loss
Bmax [T]
Ph = kh.f.Bmaxn
kh= Hysteresis constant depend on the
core material (3x10-3 to 20x10-3)
n = Exponent varies from 0.5 to 2.3 δB

dependent on the core material
Hpeak [A/m]

Eddy-Current core loss
Pe = ke.f2.t2.Bmax2
ke = Constant depends on the core grade, typical values = 200 to 1000
t = core plate thickness [m]
B

Load Loss
The current flowing through the windings

of a loaded transformer will create loss
energy in the form of heat.
The load loss is normally expressed at
75oC or 85oC.
85oC shall use thermally upgraded paper
This load loss is containing

DC losses = the dominant component loss is caused by
the product of current to the DC resistance of winding
conductor
Stray losses = the loss is caused by the leakage
magnetic impinging on the winding conductor and other
internal conductive material inside the transformer.

DC loss
1 2 3
DC losses = I12Rdc1 + I22 (Rdc2 + Rdc3)

Rdc = ρ . L/A
I1, I2 = current flowing in winding 1,2,3 [A]

Rdc = DC resistance of each winding. [Ω]
ρ = winding conductor resistivity. [Ω
Ωm]]
L = Length of winding conductor. [m]
A = Winding conductor cross section. [m2]
Winding Conductor Property
Propeties Unit Copper Aluminum
Conductivity % IACS 100 60.97
Resistivity@20oC ρ (Ω
Ω.m) 1.7241 x 10-8 2.8280 x 10-8
Temperature
K 235 225
reference
Specific mass Kg/m3 8890 2703

Conductivity vs temperature
For Copper at temperature T1 and T2

ρ2 = ρ1 x (235 + T2) / (235 + T1)
Resistivity at 75oC = 2.1 x 10-8 Ωm.
DC loss at 75oC in Watt = 2.36 x 10-12.τ2.M
τ = current density [A/m2]
M = conductor mass [kg]
For Aluminum at temperature T1 and T2
ρ2 = ρ1 x (225 + T2) / (225 + T1)
Resistivity at 75oC = 3.46 x 10-8 Ωm.
DC loss at 75oC in Watt = 12.8 x 10-12.τ2.M
τ = current density [A/m2]
M = conductor mass [kg]

Eddy Current Loss in AC system
When the winding is AC (Alternating Current) loaded, the
leakage flux impinges on the winding conductors and as a
consequence eddy currents are generated in these
conductors. This eddy current will push the distributed
current on the skin area of conductor. This phenomena is
known as SKIN EFFECT.
Conductor
Flux line
AC current line
Eddy loss distribution
The eddy loss distribution is not uniform

along the winding. Normally the eddy
losses at winding end is higher than at
winding middle.
It is important to control the eddy loss at
top end winding to avoid very high hot
spot gradient temperature.
Brad
B rad Brad
1 2
1 2
Stray losses of inside metallic parts & tank
Inside tank of a power transformer is containing a lot

number of leakage flux.
The higher transformer impedance will result the bigger
number of leakage flux.
Leakage flux impinging onto metallic structural parts and
tank wall + cover will contribute the additional load loss.
This loss is normally controlled between 5% to 15% of the
total load losses.
This additional loss due to leakage flux is controlled by
the following methods;
Magnetic shunt panel to collect the leakage flux.
Copper or aluminum flux rejecter.
A-magnetic metallic part.
Splitting the wide plate width.

Infra Red Thermal Investigation
Infra Red Thermal Check

To avoid local hot spot > 125oC

7. Insulation Structure & Dielectric Withstand

Dielectric Voltage Withstand Test
International standard reference;
SPLN
IEC 60076 part 3.
ANSI/IEEE C57.12.00 & C57.12.10
Continuous over voltage up to 110% no load, 105% full load
condition.
Applied voltage withstand = the over voltage withstand between
each winding to other part in the transformer for one minute.
Induced voltage withstand = the over voltage withstand between
each turn and/or disc of each winding and the winding to earth for
few seconds dependent on the testing frequency 120 x fnetwork/ftesting
[seconds]. This over voltage may have magnitude up to twice of
nominal voltage.
Transient over voltage withstand = the over voltage withstand due
to switching and /or lightning. The wave shape has duration up to
few microseconds with it’s instantaneous peak over voltage
withstand may have magnitude up to 3.5 times the nominal peak
voltage for

IEC Standard Insulation Level
Highest voltage Power frequency Full wave impulse Minimum air clearance
(kV peak) (mm)
(kV r.m.s) (kV r.m.s)
7.2 20 60 90
12 28 75 110
17.5 38 95 170
24 50 125 210
36 70 170 280
72.5 140 325 630
115 185 450 830
123 230 550 900
170 275 650 1250
325 750 1450
245 395 950 1900 2250
300 460 1050 2300 2650
362 510 1175 2700 3100

Voltage Withstand Criterium
No Flash over (puncture and creepage)

Partial Discharge under requirements;
Less than 100 pC at 110% voltage.
FREE PARTIAL DISCHARGE ;


INSULATION Coordination
»The Radial and Axial stresses between windings

and to Earth have to be managed by an insulation
structure which considers the combined individual
stresses.
»This structure has to consider both electrical
requirements and thermal requirements for oil flow
»Ithas to consider the effects of voltage transients
and the problems of manufacture and processing
»Ithas to be economic using minimum clearances
and minimum of expensive components.

Oil Strength Behavior

Water Content in Paper
»0.5% dryness PD inception voltage is 83% induced voltage.
»1.0% dryness PD inception voltage is 41% induced volatge.

Water Content Equilibrium

Dryness of insulation vs voltage withstand
Water Content in paper shall be less than 0.5% (from 17% originally).
Oil breakdown shall be greater than 60 kVrms/2.5 mm (IEC) from 30 kV/2.5 mm.

Transformer Active Part Insulation:
a. MINOR INSULATION : Insulation between individual

sections and pairs of discs in a winding or inter turn of
layer winding.
b. MAJOR INSULATION : Insulation between windings
c. END INSULATION : Insulation between windings and

the core.
d. LEAD INSULATION : Insulation on exit leads.
e. CLEAT BAR : Insulation on interconnecting leads

Top End Insulation
Optimised number of angle rings
Standard Block
Stress Ring Profile thickness
Standard Oil Ducts

Cleat bar clearances
A = Cylinder to Plane OR treat as

Tie Rod profile for analysis.
B = Cylinder to Plane.
C = Cylinder to plane.
D & E will affect calculation limits.
F = Point to Plane ?

FEM Models
High Voltage Stress Detection

Insulation Structures
Validation Criteria
Peak Stress in paper coverings

Peak Stress in Oil adjacent to covered electrodes
Peak and Average Stress in Oil ducts
Cumulative Stress in Oil
Bulk Oil Volume Stresses
Peak and Cumulative Creep Stress
Failure Probability of small oil volumes at peak
stress

608 series (4% grading):
Bulk oil stress critical path from HV winding to LV winding
100
|E|[kV/mm]
²
10
stress (absolute value)

cumulative stress
Strength gas saturated oil
Strength degassed oil
1
0 5 10 15 20 25 30 35 40 45 50
path [mm]
Stress in duct next to HV Stress Ring

ACTIVE PART - clearances
Creep is an electrical failure
using a solid object as a path
Electrical
Creep = Y

ACTIVE PART (coil erection cleat bar)
Tap changer
(or Tap switch)
HV Line Lead
T&D
Tap lead
connections
Tap lead Cable

connections Run/Channel
81
PTR Quality > Title of presentation - Date - References 81
Bus Bar Connection For High Current Lead Exit
Tap Changer Connection
Inside CT Connection Lead Exit = Ground Level

Flash Over To Sharp Edge Of Metal Steel
Flash is the distance between two objects, using Oil or
Gas as a path (sharp edges, corners e.t.c. are high
risk) Consider the closest point is not always the
RISK!
Electrical
Clearance
checks
- FLASH
X
x = FLASH
DISTANCE
PARTIAL DISCHARGES > 1000 nano Coulomb
A track path can display a “tree” shaped pattern

CREEPAGE - FAILURES
Creep from
HV to tank
wall along
the support
Creep from
board
HV wdg to
LV leads
during
Impulse
tests

FLASH OVER / BREAKDOWN - FAILURE

8. Transformer Thermal Aspect

Thermal Aspect To Control Ageing & Lifetime

Transformer Life Time
Transformer life time is mostly determined by the life time of

winding conductor insulation paper.
Cellulose insulation paper is built of several chain of glucose

molecules. The number of glucose molecule in the cellulose
paper is known as DEGREE POLIMERIZATION.
New insulation paper Degree polymerization > 850.
End life of insulation paper Degree polymerization < 200.
At DP < 200 paper will be brittle as it has the tensile strength
of HALF of new paper tensile strength.
THERMAL ASPECT has significantly contributed in the reducing

of glucose chains on paper.

Glucose Molecule Of Cellulose Insulation

HEAT Source
Total Active Losses in kiloWATT

»(A) I2R + Eddy losses (Max Loss > Minimum Tap)
»(B) Stray Losses (Steel Structure + Tank)
»(C) Core Losses
»(D) Sun Radiation
TOTAL Losses to be evacuated = A + B + C + D

COOLING MEDIUM
INTERNAL COOLING MEDIUM

The internal cooling medium has function also as internal
insulation medium.
Mineral oil (Inhibited or Un-inhibited oil)
Silicon oil
Synthetic ester
Hi-Temp natural liquid (seeds).
EXTERNAL COOLING MEDIUM

Air
Water

Directed Cooling
»Convection
»Conduction
»Fan

Temperature Identification
1.3 x gradient
core
cooler
gradient
winding
Bottom oil
Mean oil
Top oil
Average winding
Hot spot
Temperature Rise and Driven Factors
Temperature Rise for Class A (IEC / ANSI C57);
Top oil rise ; = 60K / 55 K or 65 K.
Average oil rise ; = 65 K / 55 K or 65 K (By resistance method)
Hot spot rise ; = 78 K / 65K or 80K.
Site elevation height;
The standard elevation height is 1000 m above sea level.
Climatic temperature behaviors;
Yearly average ambient temperature (IEC std = 20oC)
transformer life time.
Hot monthly average ambient temperature (IEC std = 30oC)
Maximum ambient temperature (IEC std = 40oC) transformer
loading capability
Insulation class A E B F H
Operating temperature 105oC 120oC 125oC 145oC 220oC

Class A Temperature Design Limits
*) suitable for Maximum temperature design limit [oC]

thermally up graded
paper insulation Oil Winding Metal part Consequences
Annual average 80 98 / 110 * 110 Life time
Cyclic load 105 120 / 130 * 130 Gas generation
Emergency 115 140 140 Gas generation
Short emergency 115 160 160 Gas generation
Thermal short circuit

Conductor
1.Copper 115 250 160
softening
2.Aluminum 115 200 160

Cooling Method – Oil Immersed
Oil circulation External cooling IEC 60076 ANSI C57 BS 171
Natural flow Air Natural flow ONAN OA ON
Natural flow Air Forced flow ONAF FA OB
Forced/Blasted Air Natural flow OFAN *) *)
Forced/Blasted Air Forced flow OFAF FOA OFB
Forced & Directed Air Forced flow ODAF FOA OFB
Forced & Directed Water Forced flow OF(D)WF FOW OFW
*) not specifically indicated

Rules Reference List
Material Properties
Thermal Conductivities of Solid Dielectric Materials
Material Thermal Conductivity (W/ m/ K)
Paper 0.17
Pressboard 0.21
Nomex 0.125
PVA Enamel 0.16
Thermal Conductivities of the Core

Direction Thermal Conductivity (W/ m/ K)
In the plane of the laminations 21
Perpendicular to the plane of the laminations 3.3
Thermodynamic Properties of Cooling Liquids

Property (units) Oil Ester Synthetic Silicone
Oil
Cubic Expansivity (/ K) 0.000795 0.000750 0.000700 0.001040
3
Density (kg/ m ) 849 931 810 912
Dynamic Viscosity (kg/ m/ s) 0.00399 0.009589 0.01500 0.02052
Specific Heat Capacity (J/ kg/ K) 2080 2216 2400 1525
Thermal Conductivity (W/ m/ K) 0.1272 0.1535 0.1000 0.1500

Directed Oil Flow
Examples of washer applications (External):
Duct maintained with sticks
Duct maintained with segments

PRE-ASSEMBLY - directed oil flow
Directed Oil Flow arrangements may not be present in TX designs, dependant upon
local Design influences
Bottom Oil
Annulus
(Ring)
Directed Oil
Flow entry point
Check that the Oil path is

clear & free from leaks

Future Material Insulation

Alternative Insulation - Hybrid Design
CALENDERED
KRAFT BOARD Angle Rings
and Caps
CALENDERED
KRAFT BOARD Support Washers
NOMEX® T-993 Static Rings

Creped NOMEX®
CALENDERED Cylinders
KRAFT BOARD
Conductor
NOMEX® T-410 Insulation
Axial & Radial

NOMEX® T-994 Spacers
PRECOMPRESSED Clamping Rings, Blocks

KRAFT BOARD

Transformer life Time

9. Short Circuit Analysis

Definition
Short circuit current is the current flowing thru the transformer
part at the condition that the secondary side of power flowing
from primary to secondary has been short circuited.
Since the power transformer is the reactive apparatus, the short
circuit current will be limited by this transformer impedance
inherently.
There are two kind of short circuit analysis;
Symmetrical short circuit analysis such as three phases short
circuit.
Asymmetrical short circuit such as single phase to ground or
two phases short circuit and/or to ground.
Symmetrical short circuit current will be the biggest short circuit
current for all loaded winding with all the winding terminals are
brought out.
For unloaded winding such as stabilizing winding, the single phase
short circuit as well as the two phases short circuit shall be
analyzed.

Short Circuit Withstand
A). Thermal capability.

The transformer conductor shall be designed to limit the
produced heat due to short circuit below the temperature
where the conductor material will start to loose it’s
designed tensile strength for certain period of time. This
clearance time will be used as the protection coordination
reference.
1. Thermal limit for Copper conductor 250 oC.
2. Thermal limit for Aluminum conductor 200 oC.
B). Dynamic capability.
Each part inside the power transformer has to be
supported and clamped sufficiently to anticipate the
forces happen due to the result of the peak of short
circuit current and the leakage induction.

IEC 60076 – 5 ; Minimum Short Circuit Impedances

Oscillogram Showing The SC Current and Forces

Short Circuit Current
Ipeak = S2 x Iccrms
  x Πr
−  arctan   + 
  r  2 x x
DC Offset K = 1 + e × sin arctan
r
x r
U Icc
Clearance time = 3 seconds

Short Circuit -Thermal Withstand
For Copper Conductor, Θ1 shall be less than 250oC

2 x ( Θ0 + 235)
Θ1 = Θ0 +
106000
-1
J2 x t
For Aluminum Conductor, Θ1 shall be less than 200oC

2 x ( Θ0 + 225)
Θ1 = Θ0 +
45700
-1
J2 xt
Θo = Initial temperature in oC
Θ1 = Average winding temperature at certain time in oC
J = RMS short circuit current density in A/m2
t = Clearance time in second, max. 10 seconds
Short Circuit - Dynamic Withstand
A moving charge q, at the speed V, in a magnetic field B,

is subject to a force F according to LAPLACE' s law
q V
r r r
F = qV ∧ B B
F

Axial & Radial Stresses
Axial Stresses come from radial component of the

leakage field. This axial stresses can be minimized by an
adequate balancing of the magneto motive forces on the
whole height of the winding.
The clamping device through flitch plate, tie rod,
clamping beam are pre-loaded with the bigger force than
axial short circuit force to anticipate any movement and
deformation due dynamic short circuit force.
Radial Stresses come from axial component of the
leakage field. This type of force can not be minimized as
this is directly dependent on the magneto motive force
of inner and outer side windings.
The concentrically winding shape is the best geometry
to resist the radial stresses.
The inherently conductor tensile/compressive strength
shall be higher than the available short circuit forces.
Sometime the reinforced material (e.g. CPR) is required.

B
RADIAL FORCES I I
Frad Frad
mmf
F = I dl x B
core
AXIAL FORCES I I
Fax Fax

Mean Hoop Stress
dl
α
p σS σS
Leakage/ flux Rav α X
e
e
2B I
B F
Y
Rav

Hoop Stresses Of Multilayers
leakage field in the middle of the layer
 J −1 ni Ii 12 nJ I J 
B = µ0 µr  ∑ + 
 i Hi HJ 
B W1 W2 Wn
Hi = electrical height of the layer k F F

F
F H
F
Electromagnetic pressure F
R1 R2
B2
r r r R2
p=I ∧B

Self Supporting / Counter Pressure
Layer type winding: self supporting reaction equivalent

counterpressure
with the thin cylinder hypothesis (RJ>>eJ)
PJ .RJ
σ=
eJ
Hooke’s law ⇒ σ = E.I = E.
pJ PJ
E= Young modulus of material
∆(2.Π.RJ ) ∆RJ
as
i= =
2.Π.RJ RJ
Internal counterpressure ∆R J
RJ PJ = eJ .E.
RJ2
∆RJ

Bending Stress Between Supports
Layer type winding : Bending stress ; reaction of support
dbs
Ft (
FtJ = pJ RJ − FnJ )
2RJ
d bs
+ or
RJ
dMf
0 - x FtJ = −
dx
-Ft
and Hook law : EIy’’=-Mf
E : Young modulus
I : inertia
Mf : bending torque

Buckling Stress

Axial Forces

Tilting Stress

Compressive Stress On Radial Spacer
e1 e2 en
Swidth
Shearing Stress on CTC
Epoxy cable : shearing stress on epoxy
F
τ
with epoxy
without epoxy
Epoxy avoid any relative movement from one strand to another

Clamping Forces
Clamping forces : reduction of number of elements
F4,0 F3,1 = F4,0

F2,n = F2,n-1
+ F3,n-1
F3,0 F2,1 = F3,0
F2,0
F1,1 = F1,0 F1,n = F1,n-1
+ F2,0
F1,0
initial step 1 step n

nb of elements : 4 nb of elements : 3 nb of elements : 2

Clamping Structure
Clamping structure reactions

if F2,n > F1,n if F1,n > F2,n
Rt= -F2,n Rt= 0 Rt= -(F1,n + F2,n ) Rt = 0 Rt= -(F1,n -F2,n )
F2,n F2,n F2,n
F2,n F2,n
F1,n F1,n
F1,n F1,n F1,n
Rb = -F1,n Rb = -(F1,n + F2,n ) Rb = 0 Rb= -(F2,n -F1,n ) Rb = 0
Clamping forces ≥ Σ of reactions on each layer

Axial Clamping System
Clamping the winding assembly with pre-compressed load >

the axial force per phase & active part weight/3

Maximum Allowed Forces And Stresses

10. Engineering

Mechanical Design
kV
1200
H-Range
220
N-Range
110
E-Range
25 75 2500 MVA
Mechanical Design standardize the best practice

Transformer Tank
TOP BEAM
TOP END
WEDGE
E RANGE
TIE-ROD
Maximum Voltage ≤
170 kV
CRADLE
Weight of core steel

sheet, max 20 Ton
Center-center distance
max 1350 mm
UPPER
CLAMPRINGS
LOWER
CLAMPRINGS

Transformer Tank
TOP BEAM
N RANGE
FLITCH PLATE
Maximum Voltage ≤ 275
kV
UPPER
CLAMPRINGS
Weight of core steel
sheet, max 40 Ton
LOWER
CLAMPRINGS Weight of Part active max
80 Ton
Center-center distance
max 1600 mm
YOKE
SUPPORT

Engineering Tools
Full integrated engineering program :

TARGET (Transformer Architecture Generating Tools)
As Main Program to design main variable of transformer part
active, optimation tools for choosing design vs Price level
Link (export/import) to verification tools

Vérification Tools
Verification tools :
Overload capability of overloaded
Invodat capacitance network and voltage distribution
Corecalc Core losses and temp
Annuli Force oil entry evaluation
ASC Detailed core Design Program
Choc Transient impulse voltage Analysis
Clearstress Voltage Stress Evaluation
DOF Direct Oil Flow Evaluation
Fluxshunt Dimensional analysis for flux within tank shunt
Gradcalc Winding Gradient Evaluation
Radinsulation Lead clearances, thermal performances
RothFEM Forces, stresses, impedances and flux ploting

Vérification Analyses
TRANSFORMER LEAKAGE
FLUX (GRID-FLUX LINES)
U Example of impulse wave 1.2µs /

50µs
50 µs
Breaking time
100%
Full wave
50%
Wave chopped on the tail

0%
times in µs
1.2 µs Falling time
Undershoot
Voltage
30%

11. Manufacturing Process

Manufacturing Process
Core cutting Core stacking Winding Insulation
Active part
assembly
Drying
Repack
Assembly
Testing

Core Stacking

Winding Manufacturing

Check Cross Over Of Winding

Connection & Insulation

Active Part Tanking After Repack

Single Phase Reactor: New Design

Single Phase Autotransformer
240 / 3 MVA 250 / 150 kV
Yoke Shield for reactor

12. Accessories, Protection & Control

Protection and Additional Accessories
A. PROTECTION DEVICE
- Protective Relay (Bucholz)
Function : to trip out the trafo if there is a
release of gas arising from the
decomposition of the solid and liquid
insulating material due to the action of
heat or electric arcing.
Principal Of Operation
- During normal operation, the relay is
completely filled with oil.
- When gas forms inside the trans-
former, it tends to flow towards the
conservator
- it accumulated progressively inside the
relay there by LOWERING the oil level.
- If gas continues to form, the oil level will A. Upper Float
affect the lower float B and relative B. Lower Flat
switch which is connected to the circuit
and causes disconnection of the
transformer power supply.

- Protective Relay (Bucholz)

- RS 2001 relay for OLTC

Function :
to protect tap changer and transformer from
1. Flap Valve
any damage if a defect arises in the tap
2. Permanent Magnet
changer . This relay operates to put the trafo
off circuit 3. Reed Switch
Principal Operation:
It responds only if oil flows occur from tap
changer head to the oil conservator

- Winding Temperature Indicator
Function :
to measure the winding
temperature
Principal Of Operation:
measure the winding
temperature by means of a
special bulb surrounded by
heating resistance through
which passes a current
proportional to the current
passing through the
9. Microsw. Setting
transformer winding subject to 1. Case Pointer
a given load and immersed in 2. Locking Glass 10. Junction Box
Ring
insulating oil at temperature 11.Glass or
3. Fixing Rear polycarbo-nate
Flange window
4. Air Hole 12. Potentiometer for
5. Capillary Output heating resistance
adjustment
6. Dial
7.Microsw. Setting
Dial
8. Max. indicating
pointer

- Oil Temperature Indicator
1. Case 8. Max. indicating pointer

2. Locking Glass Ring 9. Microsw. Setting
Function : Pointer
3. Fixing Rear Flange
to measure the oil temperature inside power 10. Junction Box
4. Air Hole
transformer tank 5. Capillary Output
11.Glass or polycarbo-
nate window
6. Dial
7.Microsw. Setting Dial

- Oil Level Indicator
Function :
to measure the level reached by the oil in a transformer
conservator
Principal Of Operation
- The changing oil level in the conservator is detected by
a float attached to a suitably – long rod which is
connected to the magnetic transmission axle
- A permanent magnet, whose flux passes through
attachment flange 2.0, is coupled to the pin turned by the
float-carrying arm. The aforementioned parts fitted to
flange 2.0 are placed inside the conservator through a
hole made in a suitable position which is perfectly
sealed by the flange it self.
- A second permanent magnet inside instrument gauge
1.0, dragged round by the first magnet, moves a second
shaft on which the optical level- indicator pointer and a
cam are fitted. The cam trips the microswitch (Es) which
electrically indicate that the oil has reached a certain
level.

- Pressure Relief Device
Function :
an equipment to relieve large volumes of gas or
insulating fluid rapidly when the pressure inside a
transformer reaches a pre-determined limit.

B. ACCESSORIES
- Oil Sampling Valve - Butterfly Valve
F=close position
O=open position

Automatic Voltage Regulator - KVGC

Fibre Optic Temperature monitor
1 - 8 Channels
Cooling/Alarms/Protection
-30°C to +200°C
Programmable relays
Analog output
0–1ma or 4–20ma
Ring Lug Terminals
Memory Retention
90 days at 1/minute – factory set
Power Input
Universal AC/DC
Self Diagnostics
Applications
Small to Large Power Transformers
RS 232 Port
Options for RS 485 and Protocol Converter

- Screw and Globe Type Valve

13. Final Acceptance Test

Definition
Final Acceptance Test is the crucial moment for a

transformer , verifying the manufactured transformer has
met the guaranteed performances and is ready to
function under specified circumstance.
Purpose of testing is to ensure that the transformer has
fulfilled the quality performance and to validate the
specific contractual requirements.
Validate the design
Validate the manufacturing process.
Compare the measurements with the technical data
specification.
Establish a finger print of the transformer, useful for
comparison with the future/on site measurement such as
SFRA, capacitance, insulation resistance etc.

Testing Procedures
The testing procedures are divided in three parts as

followings;
1. Routine Tests; These tests are subjected to be
performed on each individual transformer prior to
delivery.
2. Type Tests (IEC) / Design Tests (ANSI/IEEE);
These kind of tests are performed on one
transformer representing the other transformers
with the similar design.
3. Special Tests (IEC) / Other Tests (ANSI/IEEE);
These tests are non-mandatory tests and have to
be agreed between the manufacturer and the
purchaser.
Routine Tests
Routine Test is containing the following tests;

1. Insulation resistance measurement.
2. The electric strength of the transformer liquid.
3. Winding resistance measurement.
4. Voltage ratio & polarity/vector group checks.
5. Load loss & impedance measurement.
6. No load loss & no load current measurement.
7. Dielectric – routine tests (induced & applied tests)
8. Tap changer test (OLTC and/or DETC).
9. Functional tests on control devices, CT ratio checks.

Type/Design & Special/Other Tests
Type tests (IEC) /Design tests (ANSI/IEEE);

1. Temperature rise test.
2. Dielectric – type test (lightning impulse test)
Special tests (IEC) /Other tests (ANSI/IEEE);

1. Dielectric – special test (PD measurement)
2. Zero sequence impedance measurement.
3. Sound level measurement.
4. Capacitance and power factor.
5. Harmonic measurement of no load condition.
6. Fans and/or oil pump power consumption measurement.
7. SFRA (Swept Frequency Response Analysis).
8. DGA (Dissolved Gas Analysis) measurement.
9. Tank destructive test.
10. Transformer short circuit.

Insulation Resistance Measurement
This insulation is normally known as MEGGER insulation

test. This measures the DC insulation value containing the
oil or other transformer liquid, cellulose pressboard,
insulation paper and other insulation material between
windings and winding to core.
The power supply is DC voltage source 1000 VDC up to
5000 VDC. Due to capacitance of different insulation
medium, the insulation value of combined materials will
take some times prior to get the stabilized result.
The acceptance criterium ;
Interwinding insulation = minimum 500 Ohm.
Winding to core = minimum 200 Ohm.
The wet insulation material may result very low insulation
resistance.

Winding DC Resistance Measurement
Winding DC resistance is measured thru two bushings for

each winding. The measurement is performed with bridge
connection of VOLT – Ampere meters or high accuracy
digital multimeter.
Care shall be taken for the effect of self-inductance. Hence
the oil temperature shall be recorded.
Anomalous result can detect bad connection joint within
the winding, inter winding or winding to bottom terminal of
bushing.
Rstd
V2
Rx
DC power
V1
supply
Rx = Rstd x V1/V2
Load loss & impedance measurement
This test will measure the load loss and impedance referring
to the rated current at some of tap changer positions.
The AC 3 phases supply is normally injected on the HV side
of the transformer. The power supply voltage is increased
until the nominal current is reached. The voltage giving
the rated current is the impedance voltage. This is
normally expressed as percentage of the rated voltage at
particular tap changer position.
If the rated current can not be reached due to testing
limitation or other reasons, the following correction factor
will be used. The minimum test current is 50% rated
current
Pextrapolation = Ptest x (Irated : Itest)2
During test, the transformer oil has to measured to correct
the copper temperature as ambient temperature reference.
The measured resistance has to be extrapolated to 75oC
(85oC for ANSI/IEEE with 65oC rise).

Correction factor for load loss due to temperature
The load loss [Pcu/Pal] is containing I2Rdc + stray loss and

guaranteed at 75oC for IEC standard transformer and
ANSI/IEEE standard transformer with 55oC temperature rise.
For ANSI/IEEE standard transformer with 65oC temperature
rise, the temperature reference for load loss is 85oC.
The DC resistance & load loss are measured at testing
laboratory ambient temperature (Θ Θambient). For in case the oil
temperature during load loss measurement has exceeded
3oC different with the actual ambient temperature, this oil
temperature shall be used for measurement ambient
temperature.
[235 + 75 (or 85)] [225 + 75 (or 85)]

KCU = KAL =
[235 + Θambient] [225 + Θambient]
Pcu(al) 75oC (or 85oC) = I2Rdc x K + Stray loss / K

No Load loss and Current
The 3 phase, AC, power supply at 90%, 100%, 110% of

rated voltage is connected to the LV winding to induced
the nominal voltage on HV as well as the other winding.
The total (3 phases) losses & injected current to reach
the rated voltage are known as no load loss, no loda
current respectively.
Correction factor for no load losses;
U’ - U
P0 = Pm x ( 1 + )
U’
P0 = Corrected no load loss
Pm = Measured no load loss
U’ = Mean Voltage
U = RMS voltage

Applied Over Voltage Test
Purpose ; to check the voltage withstand between the tested

winding to other separated windings (not in series/parallel
connection), core, steel structure and tank.
The test is made of single phase AC voltage at rated frequency
for 60 seconds duration applied to one winding while other
windings & core are grounded.
The test is successful if no collapse of the test voltage occurs.
VHVN

Induced Over Voltage Withstand Test
Purpose; To ensure that the insulation between turns, between
discs, inter windings, winding to core/steel structure, cleat bars
withstand the over voltage switching referring to guaranteed
power frequency insulation class.
Two type of induced test;
Short duration Over Voltage Test (ACSD);
AC single phases power supply for STAR connection non-uniform
insulation. For ANSI/IEEE standard and some customer requirements
are requiring the three phases power supply for STAR connection
non-uniform insulation.
AC three phase power supply for WYE or DELTA connection of
uniform insulation.
rated frequency
Time (seconds) = x 120 , but no less than 15 seconds
test frequency
Long duration Over Voltage Test (ACLD); Over voltage up to 130%

or 150% Um for 30 minutes with partial discharge measurement.
Time Duration For ACSD & ACLD Induced Test
U1
tinduced
U2
1.1Um 5 min 5 min

5 min 5 min
ACSD U1 = induced voltage

U2 = 1.3 Um for < 300 pC
= 1.5 Um for < 500 pC
1.1Um < 100 pC
U1 For phase to earth Um : S3
tinduced
U2
1.1Um 5 min 30 min

5 min 5 min
ACLD
Partial Discharge Measurement
Partial Discharge Measurement is measuring the small discharge
activity inside as well as outside around the transformer prior to
flash over occurrence. This measurement is a good tool to ensure
the transformer quality.
• Corona discharges occurs due to the sharp edge electrode.
• Surface discharges (creepage) occurs due to overstress component
parallel to the dielectric medium surface.
• Internal discharges occurs due to the non-homogenous dielectric
medium.
• Electric trees due to the particle or cavity in the solid insulation.
• Floating discharging occurs due to badly grounded component.
• Contact noise occur in case bad contact terminal.

Single Phase Induced Voltage Vectorial
HV = WYE
non-uniform
U1
2/3 UInduced
LV = DELTA
UInduced
v2 = 1/2u2 N
Usupply u2
1/3 UInduced
1 phase w2 = 1/2u2
V1 & W1

Three Phases Induced Voltage Vectorial
HV = WYE
uniform
U1
LV = DELTA
u2
UInduced :S3 ed
u c
nd
UI
w2 v2 N
Usupply
3 phase
W1 V1

Temperature Rise Test
Purpose : to check the temperature rises (top oil, average

winding & hot spot) do not exceed the guaranteed temperature
rises.
The test can be performed by BACK TO BACK test or SHORT
CIRCUIT methods. The short circuit method is mostly used for
this temperature rise test.
In the short circuit method, all three phases low voltage
windings are short circuited to generated the total losses as
well as the current, Principally the test is performed by
supplying the current to provide the total losses (no load + load
losses) for oil temperature check and then to provide the rated
current for winding temperature check.
Since the oil time constant is very long (it can take several
hours) while the conductor time constant is practically only few
minutes, the injected current for total losses is performed first
to get stabilized oil temperature then followed by reduced
current to rated current to get winding temperature at rated
capacity one hour prior to shut down.

DC Resistance For Temperature Analysis
Oil temperature can be detected by direct measurement
referring to oil temperature indicator.
Winding temperature at rated capacity is calculated by
comparing the DC resistance value at cold condition
with known ambient temperature and the DC resistance
value at rated current just prior to shut down.
The transformer has to be cleared for any capacitive
charge before taking the hot DC resistance measurement
by using charging stick. The charging time has to be
kept as short as possible to keep measurement
accuracy, but this period may need several minutes.
The hot DC resistance is extrapolated from several
measured DC resistance values after shut down and
cleared charging.
If there is tap changer with several tap positions, the tap
position with highest load loss is taken as reference for
temperature analysis.

Some Of Equations For Temperature Rise Analysis
1. Power Supply is provided on HV tap pos. with highest load loss.
(Pload loss + Pno load)

Iinjected = Irated x Pload loss
Iinjected
Vinjected = Vrated x Z(%) x
Irated
2. Top Oil Rise and Average Oil Rise at Rated Capacity

x
DToil = (max. {Tcover, ,Ttop rad’} – Tamb) x
Pload loss
x
DAOT = ½ x (Ttop rad + Tbot rad) – Tamb) x
Pload loss

3. Winding Temperature Gradient at Rated Current.
y
R2 Irated
GRCU = x (234.5 + T1) – (234.5 + T2) – DAOT x
R1 Iinject
y
R2 Irated
GRAL = x (228.1 + T1) – (228.1 + T2) – DAOT x
R1 Iinject
4. Average Winding Temperature Rise and Hot Spot Rise.
DTCU = DAOT + GRCU DTAL = DAOT+ GRAL
HSCU = DToil + HSF x GRCU HSAL = DToil+ HSF x GRAL

Definitions;
1. Iinjected = Injected current [A]
2. Irated = Rated current at stated tap [A]
3. Vinjected = Testing Voltage [kV]
4. Pload loss = Maximum load loss [kW]
5. Pno load loss =Measured no load loss [kW]
6. T1, T2 = Ambient temperature at condition 1,2 respect.[oC]
7. Tcover = Oil temperature on top cover [oC]
8. Ttop rad = Oil temperature on top radiator [oC]
9. Tbot rad = Oil temperature on bottom radiator [oC]
10. DToil = Top oil temperature rise [K]
11. DAOT = Mean oil temperature rise [K]
12. DT = Average winding temperature rise [K]
13. GR = Winding gradient temperature [K]
14. x = Exponent for oil temperature due to losses.
0.8 for ON cooling of < 2500 kVA.
0.9 for ON cooling
1.0 for OF or OD cooling
15. Y = Exponent for winding gradient due to current.
1.6 for ON or OF cooling
2.0 for OD cooling

Lightning Impulse Tests
Purpose ; To check the transformer capability against

the fronted over voltage caused by atmospheric
discharge with time peak between 0.1 ms to 20 ms and
tail duration of less than 300 ms.
Considering the transformer as a complex network of
RLC component, the distribution of such very high
frequency over voltage such as lightning impulse will be
highly influenced by the capacitive component of
transformer.
The lightning impulse test is performed by comparing
the result of 100% impulse test against the 50% and/or
75% impulse test result. If there is failure, the voltage
wave form as well as the current wave form will have
different shape as the wave of reduced level.

Full Wave Impulse
100%
50%
front time tail time
Front time = 1.2 ms + 30%

Tail time = 20 ms + 20%
Peak value + 3%
Voltage Wave Current Wave
50% impulse
100% impulse

14. Technology Application

Single Phase Solution

Single Phase Reactor: Original Design

Less Maintenance

ATT expérience in Industrial Transformers
Electrolysis Industry => Rectifier Transformers
(Aluminium, Zinc, Copper, Chlorine)
Chemical, Oil&Gas Industry => Converter Transformers
Steel Industry => Electrical Arc Furnace

(EAF)Transformers

Furnace transformer on UTR
SLN LE-NICKEL
3 x 1 PHASE 33.3 MVA
50 Hz, 63 Kv / 300 ~ 1800 Volt
OLTC ± 16 x 750 Volt
ODWF


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Power Transformer Design Aspect

Didik Susilo Widianto

3 > Title of presentation - Date - References 3

4 > Title of presentation - Date - References 4

5 > Title of presentation - Date - References 5

Θ = the load power factor I2.X2

Cooler Transformer Liquid

8 > Title of presentation - Date - References 8

Transformer power rating is expressed by MVA as a product of

S [MVA] = S(Q2 [MVAR] + P2 [MW] )

9 > Title of presentation - Date - References 9

∆V = K (VR.CosΘ Θ) + K2/200 x (VR.Sin Θ – VX.CosΘ

VX VZ ∆V = Voltage drop/rise [%]

Tap Regulation ; the required voltage ratio to control the

11 > Title of presentation - Date - References 11

Two type of tap regulation ;

12 > Title of presentation - Date - References 12

Normally, the most optimum solution for tap changer

13 > Title of presentation - Date - References 13

There are two kinds of power rating;

14 > Title of presentation - Date - References 14

I1, I2 = Current primary (1) & secondary (2)

15 > Title of presentation - Date - References 15

ON TANK OLTC IN TANK OLTC

16 > Title of presentation - Date - References 16

18 > Title of presentation - Date - References 18

Purpose : the path for the flux lines with low

Core material in power transformer ;

19 > Title of presentation - Date - References 19

20 > Title of presentation - Date - References 20

But Lap Joint

Step Lap Joint

21 > Title of presentation - Date - References 21

Three Legs Core

Five Legs Core (3 wounds + 2 return)

23 > Title of presentation - Date - References 23

25 > Title of presentation - Date - References 25

26 > Title of presentation - Date - References 26

Inrush Current is the excitation current that will occur due

The inrush current can have the peak value up to 5 times

Due to the magnitude of the inrush current, the over

27 > Title of presentation - Date - References 27

Maximum Inrush Current can be estimated with the some

28 > Title of presentation - Date - References 28

Empirical formula to calculate the peak of inrush

30 > Title of presentation - Date - References 30

31 > Title of presentation - Date - References 31

32 > Title of presentation - Date - References 32

Type of material conductor;

34 > Title of presentation - Date - References 34

35 > Title of presentation - Date - References 35

Extra paper = 2 layers

36 > Title of presentation - Date - References 36

Try to use CTC with max. 55 strands per cable.

37 > Title of presentation - Date - References 37

Missing turn block = 1

Cross over block =

38 > Title of presentation - Date - References 38

39 > Title of presentation - Date - References 39

Provide the best controllable high

40 > Title of presentation - Date - References 40

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