POWER TRANSFORMER - STANDARDISATION MANUAL 261

Chapter - 7

Design Review

Working Group Members

Mr. M. Vijayakumaran – ALSTOM Ltd

Mr. S. K. Negi – GETCO

Mr. Y. V. Joshi – GETCO

262 POWER TRANSFORMER - STANDARDISATION MANUAL
 POWER TRANSFORMER - STANDARDISATION MANUAL 263

CHAPTER - 7

DESIGN REVIEW

1. INTRODUCTION

A design review is a planned exercise to ensure that both parties understand the application and the requirements
of the applicable standards and specification. It is the opportunity for both parties to scrutinize the proposed
design to ensure that the requirements will be met not only technical requirements but also those relating to
other aspects of the contract, like quality. The whole emphasis of a design review is directed at establishing
what is being provided is fit for purpose in all respects for the intended performance in service and that the
manufacturer uses proven materials, design tools, methodology and experience to assure the product will meet
this requirement, also in all respects.

Design reviews implies also to strengthen the relationship between the purchaser and manufacturer and a
good opportunity for the purchaser to better understand the technical capabilities of the manufacturer and for
the manufacturer to understand the need of their customers for the sake to have products adapted to their
needs. Hence the design review is a good opportunity to interchange experiences that can be used to propose
enhancements or betterments. For these reasons it is strongly advisable for the purchaser to have expert
transformer engineer(s) with them during the meeting.

A design review, initiated and chaired by the purchaser should be held for the purpose of conducting an in-
depth review of the ordered Power Transformer and to allow the purchaser to have a clear understanding of the
transformers design, manufacture and test including the likelihood of operating in service as intended.

The following are the pre-requisites for carrying out the design review:

1. It is desirable to have vendor assessment of the manufacturer before placement of order.

2. Design review should be part of the tender inquiry and it becomes obligatory on the part of the customer
and manufacturer to ensure compliances with the contract specifications.

3. It is to be ensured that all stake holders are involved in the design review. The designer both mechanical
and electrical, ultimate user, production head and if possible, sub vendor also could be invited for the design
review. Agenda is to be prepared by customer and sent to manufacturer well in advance.

4. Review may include certain informations which are of proprietary nature. It is, therefore, desirable to have
mutual agreement between the purchaser and the manufacturer for the confidentiality of information.

5. It is important for the success of design review that both the purchaser and manufacturer are clear on the
requirements and well prepared to have open and frank sharing of information.

2. OBJECTIVES OF DESIGN REVIEW

Both the purchaser and manufacturer must understand that following objectives are met during the design
review:

1. To ensure that there is a clear and mutual understanding of the transformer technical requirements accord-
ing to purchaser specification and applicable industry standards.

2. To understand the application and verify the system and project requirements and to indicate areas where
special attention may be required.
264 POWER TRANSFORMER - STANDARDISATION MANUAL

3. To verify that the design complies with the technical requirements.

4. To identify any prototype features and evaluate their reliability and risks.

5. To interchange experiences that can be used to identify eventual betterments in the design and / or im-
provements and changes in the specification.

6. To better understand the technical capabilities of the manufacturer.

7. To strengthen the technical relationship between purchaser and manufacturer and eventually to improve
and go deep in the transformers design knowledge by some participant on the purchasers side.

3. ELEMENTS OF DESIGN REVIEW

Having understood the purpose of design review and objectives, it is important to know the various elements
of design review which will clear all the doubts about the functionality (application), soundness of designs with
margins, selection of material and components and also specific operating requirements for its designed life.
They are broadly as follows:

S. No. Elements

1. System data

2. Environmental data

3. Transformer parameters

4. Transformer design

5. Transformer ancillaries and accessories.

6. Transformer oil

7. Fabrication

8. Testing

9. Name plate

10. Transportation

11. Site erection, testing & commissioning

12. Health and safety equipments

13. Contract documents and drawings

14. Document submission time scale

 POWER TRANSFORMER - STANDARDISATION MANUAL 265

Design review guidelines of Cigre WGA2.36 (Technical brochure 204) have elaborated above elements in detail
as under:

Sr. No. Elements of Check Points

design review

1. System data System Voltage Variations

Tap changers
System Frequency Variation
System Short Circuit Capacity
System Switching and Transformer Protection
High Frequency Transients (HFT)
Voltage Transients
Current Harmonics
Geomagnetic Induced Currents

2. Environmental Ambient temperature range, rate of change of temperature and effect on the overload
data capability
Lowest Cold Load Start-up (LCLS)
Solar radiation
Site altitude
Humidity
Pollution
Seismic zone and response spectra
Geomagnetic currents
Ultraviolet (UV) radiation
Isoceraunic level

3. Transformer Alternating Current Terminal Voltages

parameters Insulation Levels – line to line and line to ground
Winding Impedances
Cooling Provisions
Temperature Limits
Short Circuit Withstand Capability
Cable Connection Bushings and Isolated Phase Bus Bar Connections
Sound Levels
Losses – No load and load losses
Excitation
High Temperature Design

4. Transformer Core
design Windings
Thermal design
The short circuit capability
Core, Winding Assembly and Drying
Leads and Cleats
Insulation Design
Leakage Flux Control
Drying and Processing
Sound Level
Seismic

5. Transformer Bushings
ancillaries and Bushing and Internal Current Transformers
accessories. Tap Changers
Internal Surge Arresters
Control Cabinet and External Cabling
Online Monitoring Equipment

6. Transformer oil Review as per exclusive Chapter 6 of this Manual.

7. Fabrication General Construction

External Cooling Equipment
Conservators/Preservation Systems
Fabrication Drawings
Gas Collection System Design
Surface Preparation and Planning
266 POWER TRANSFORMER - STANDARDISATION MANUAL

Sr. No. Elements of Check Points

design review

8. Testing As per Annexure - 7.1

9. Rating Plate As per figure 7.1

10. Transportation Transportation Plan and Handling

Design for Transport
Transportation Shipping Profile
Transportation Routing
Transportation Shipping Impact Withstand
Fixtures on Transformer
Marking of Center of Gravity
Ship and Barge Issues
Rail Car Issues
Road Transport Issues
Transportation monitoring management of transformer
Transportation of transformer accessories, components removed from the transformer
Acceptance criteria for receiving transformer
Transformer Unloading to Foundation

11. Site erection, As per the exclusive Chapter 5 of this Manual.

testing &
commissioning

12. Health and safety As per guideline and policy of customer. Also refer Chapter - 5 on Erection, Testing and
commissioning of this Manual.

13. Contract As per Annexure - 7.2.

documents and
drawings

14. Document As agreed between purchaser and manufacturer.

submission time
scale

Design review does not absolve or substitute manufacturer’s ultimate responsibility for the adequacy of transformer
design and construction, including design limits and margins, quality, performance on test and in service.
 POWER TRANSFORMER - STANDARDISATION MANUAL 267

REFERENCES

The following list may be referred, but this is not a limitation on referring to other standards and codes as long as it
serves the purpose for effective design review.
IEC 60044: Current Transformers.
IEC 60050: International Electrotechnical Vocabulary – Chapter 421: Power Transformers and Reactors.
IEC 60060-1: General Definitions and Test Requirements.
IEC 60071-1: Insulation Coordination - Part 1: Definitions, Principles and Rules.
IEC 60071-2: Insulation Coordination - Part 2: Application Guide
IEC 60076-1: Power Transformers - Part 1: General.

IEC 60076-2: Power Transformers - Part 2: Temperature Rise.

IEC 60076-3: Power Transformers - Part 3: Insulation Levels and Dielectric Tests.
IEC 60076-5: Power Transformers - Part 5: Ability to withstand Short-Circuit.
IEC 60076-6: Power Transformers - Part 6: Reactors
IEC 60076-7: Power Transformers - Part 7: Loading guide for oil- immersed Power Transformers.
IEC 60076-8: Power Transformers - Part 8: Application Guide for Power Transformers.
IEC 60076-10: Power Transformers - Part 10: Determination of Transformer and Reactor Sound Levels.
IEC 60076-11: Power transformers - Part 11: Dry-type transformers
IEC 60076-18: Power transformers - Part 18: Measurement of frequency response
IEC 60076-16: Power transformers - Part 16: Transformers for wind turbine applications
IEC 60137: Bushings for Alternating Voltage Above 1000 V.
IEC 60214-1: Tap-Changers - Part 1: Performance requirements and Test Methods.
IEC 60214-2: Tap-Changers - Part 2: Application guide.
IEC 60270: High-voltage test techniques - Partial discharge measurements
IEC 60296: Fluids for Electro-technical applications - Unused mineral insulating oils for transformers and switchgear
IEC 60815-1: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 1:
Definitions, information and general principles
IEC 60815-2: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 2:
Ceramic and glass insulators for a.c. systems
IEC 62032: Guide for the Application, Specification and Testing of Phase-Shifting Transformers
Other documents of relevance are:
ISO 9001: Quality System – Model for Quality Assurance in Design/Development.
CIGRÉ TB 209: Short Circuit Performance of Power Transformers
CIGRÉ TB 528: Guide for Preparation of Specifications for Power Transformers
CIGRÉ TB 530: Guide for Conducting Factory Capability Assessment for Power Transformers.
268 POWER TRANSFORMER - STANDARDISATION MANUAL

A
400

10
10
1

1
XXX Transformer Pvt. Ltd.
315 MVA 400/220KV AUTO TRANSFORMER
REF. STANDARDS IS:2026
COOLING ONAN/ONAF/OFAF

RATING (HV-MV) MVA 189/252/315 FREQUENCY Hz 50

PHASES. 3/3
(LV) MVA 63/84/105

HV V 400000 IMPEDANCE TAP.NO.1 %

VOLTAGE.
RATED MV V 220000 TAP NO.9 %
HV-MV(315MVA BASE)
2

2
VOLTAGE
LV V 33000 TAP NO.17 %

VECTOR GROUP REF. YNa0d11

HV A 272.79/363.73/454.66
FULL LOAD CORE MASS kg.
MV A 495.99/661.32/826.66
CURRENT
HV kg.
LV A 1102.21/1469.61/1837.02
COPPER MASS (BARE) MV kg.
HV kV 1300/1050/630
REG kg.
BASIC INSU. MV kV 1050/-/460
LEVEL LI/SI/P.F. CORE & COIL MASS kg.
LV kV 250/-/ 95
TRANSPORTATION MASS kg.
Neutral kV 95/-/ 38
TANK & FITTINGS MASS kg.
3

3
50°C at ONAN
OIL °C 55°C at ONAF/OFAF
GTD. TEMP. RISE MASS OF TOTAL OIL kg.
55°C at ONAN (WITHOUT 10% EXTRA OIL)
WDG °C 60°C at ONAF/OFAF
10% EXTRA OIL kg.
MAKER'S SR. NO.
TOTAL MASS kg.
YEAR OF MANUFACTURE
QUANTITY OF OIL IN OLTC Ltrs.
WORK ORDER NO. TRANSFORMER OIL QUANTITY Ltrs.
(WITHOUT 10% EXTRA OIL)
CUSTOMER
PO . NO. & DATE PAINT SHADE CHOICE
1U OLTC PRE H.V.
TAP M.V. L.V
CONECTION SELE- CURRENT(A)
POSN. VOLTAGE
IN EACH CTOR
600

ONAN ONAF OFAF VOLTAGE CURRENT VOLTAGE CURRENT

NO. (V)
VECTOR GROUP 2U
PHASE POSI. 189 MVA 252 MVA 315 MVA (V) (A) (V) (A)
4

4
1 13 - 12 440000 247.99 330.66 413.33

YNa0d11 3U 2 13 - 11 435000 250.84 334.46 418.08

3 13 - 10 430000 253.76 338.35 422.94

N 3V
4 13 - 9 425000 256.75 342.33 427.91
2W 2V 5 13 - 8 420000 259.80 346.41 433.01
3-4
3W 6 13 - 7 415000 262.93 350.68 438.22

1W 1V 7 13 - 6 410000 266.14 354.85 443.57 ONAN

1102.21
8 13 - 5 405000 269.43 359.24 449.05
ONAN (@63MVA)
33000
2 2 2 9a 13 - 4 400000 272.79 363.73 454.66 220000 495.99 ONAF

MV 9b 13 - 3 400000 272.79 363.73 454.66

ONAF
661.32
1469.61
(@84MVA)
OFAF OFAF
9c 13 - 12 400000 272.79 363.73 454.66 826.66 1837.02
(@105MVA)
1 1 1 10 13 - 11 395000 276.25 368.33 460.41

11 13 - 10 390000 279.79 373.05 466.32

12 13 - 9 385000 283.42 377.90 472.37

13 13 - 8 3-12 380000 287.15 382.87 478.59

5

5
2U 2V 2W 14 13 - 7 375000 290.98 387.97 484.97
3W1S1
TV WTI

3W1S2 15 13 - 6 370000 294.91 393.22 491.52

3U
3V 16 13 - 5 365000 298.95 398.60 498.26
3W
1N TMS CT
2U3S1 2V3S1
17 13 - 4 360000 303.10 404.14 505.18
2U3S2 MV WTI
2V3S2

1U 1V 1W kpV > Imag MAX

CT CORE RATIO ACC. BURDEN at Vk/2 TERMINAL
(Volt) SEC.RES. Application
NO. AMP. CLASS (VA) >
(OHM) MARKING
@2000/1ATap (in mA) @2000/1ATap
N1S1 1U1S1 2U1S1 1V1S1 2V1S1 1W1S1 2W1S1
N1S2 1U1S2 2U1S2 1V1S2 2V1S2 1W1S2 2W1S2 1U1S1-1U1S2-1U1S3-1U1S4
N1S3 1U1S3
1U1S4
2U1S3
2U1S4
1V1S3 2V1S3 1W1S3 2W1S3 CT1U 1 500-1000-2000/1 PS - 2000 30 10 1V1S1-1V1S2-1V1S3-1V1S4 REF.
N1S4 1V1S4 2V1S4 1W1S4 2W1S4
CT1W

CT2W
CT1U

CT2U

CT1V

CT2V

CTN
N2S1 1U2S1 2U2S1 1V2S1 2V2S1 1W2S1 2W2S1 1W1S1-1W1S2-1W1S3-1W1S4
N2S2 1U2S2 2U2S2 1V2S2 2V2S2 1W2S2 2W2S2 CT1V
N2S3 1U2S3 2U2S3 1V2S3 2V2S3 1W2S3 2W2S3 1U2S1-1U2S2-1U2S3-1U2S4
1U2S4 2U2S4 1V2S4 2V2S4 1W2S4 2W2S4
N2S4
1W3S1
CT1W 2 500-1000-2000/1 PS - 2000 30 10 1V2S1-1V2S2-1V2S3-1V2S4 Differential
HV WTI 1W2S1-1W2S2-1W2S3-1W2S4
1W3S2
1 1 1 2U1S1-2U1S2-2U1S3-2U1S4
CT2U 1 500-1000-2000/1 PS - 2000 30 10 2V1S1-2V1S2-2V1S3-2V1S4 REF.
2W1S1-2W1S2-2W1S3-2W1S4
3 3 3 CT2V
4 4 2U2S1-2U2S2-2U2S3-2U2S4
4
5 5 5 CT2W 2 500-1000-2000/1 PS - 2000 30 10 2V2S1-2V2S2-2V2S3-2V2S4 Differential
TO OLTC

6 6 6 2W2S1-2W2S2-2W2S3-2W2S4
7 7 7
4 8 4 8 4 8 UN1S1-UN1S2-UN1S3-UN1S4
9 3 9 3 9 CTNBF
3 12 12 10 12 10 1 500-1000-2000/1 PS - 2000 30 10 VN1S1-VN1S2-VN1S3-VN1S4 REF.
10
11 11 11 BEFORE WN1S1-WN1S2-WN1S3-WN1S4
12 12 12
NEUTRAL UN2S1-UN2S2-UN2S3-UN2S4
13 13
6

13 FORMATION 2 500-1000-2000/1 PS - 2000 30 10 VN2S1-VN2S2-VN2S3-VN2S4 Differential

2 2 WN2S1-WN2S2-WN2S3-WN2S4
2
UN1S4 VN1S4 WN1S4
1 PS - 30 10 N1S1-N1S2-N1S3-N1S4 REF.
HV
UN1S3 VN1S3 WN1S3 500-1000-2000/1 2000
UN1S2 VN1S2 WN1S2 CTN
UN1S1 VN1S1 WN1S1
CTNBF
UN2S4
CTNBF
VN2S4
CTNBF
WN2S4 2 500-1000-2000/1 PS - 2000 30 10 N2S1-N2S2-N2S3-N2S4 REF.
UN2S3 VN2S3 WN2S3
UN2S2 VN2S2 WN2S2
UN2S1 VN2S1 WN2S1 HV WTI 1 506/2 5 15 - - - 1U3S1-1U3S2 MEASURING

MV WTI 1 827/2 5 15 - - - 2V3S1-2V3S2 MEASURING

TYPE OF OIL :
TV WTI 1 1837/2 5 15 - - - 3W1S1-3W1S2 MEASURING
VACUUM WITHSTAND CAPABILITY 760 Hg
OLTC RATING & MAKE: TMS CT 1 827/1 5 5 - - - 2U3S1-2U3S2 MEASURING

GTD.(KW) MEASURED (KW) NOISE LEVEL: ________dB

NO LOAD LOSS
TAN DELTA OF WINDING : ________%
LOAD LOSS
STRAY LOSS MOISTURE CONTENT IN ACTIVE PART : ________% of wt.
AUXILLIARY LOSS

PROPERTY OF CUSTOMER NAME

6-Ø6 Holes.
7

TYPICAL RATING PLATE FOR POWER TRANSFORMER

E

A
J

Fig. 7.1: Typical Rating Plate

 POWER TRANSFORMER - STANDARDISATION MANUAL 269

ANNEXURE 7.1
TESTING

Sr. no. Tests, measurements & checks

1 Dimensions, fittings and equipment

2 Turns ratio

3 Polarity & phase relationship

4 Insulation resistances

5 Winding resistances

6 Insulation power factor

7 Capacitances

8 Load loss & impedance voltage

9 Impedance characteristic across tap range

10 Zero-phase-sequence impedance

11 No-load loss & magnetizing current

12 Audible sound

13 Temperature rise

14 Gas in oil analyses

15 Lightning impulse voltage tests

16 Switching impulse voltage tests

17 Applied voltage tests

18 Induced voltage test & partial discharge

19 Single-phase magnetizing current test

20 Oil pressure

21 Control system, components, instruments

22 Ancillary equipment power losses

23 CT checks

24 RSO

25 Frequency Response Analysis (FRA)

26 Tap changer

27 Secondary wiring insulation resistances

28 Oil samples

29 Inventory

30 Contract documents

31 QA records
270 POWER TRANSFORMER - STANDARDISATION MANUAL

ANNEXURE 7.2
Contract Documents and Drawings for approval

Sr. No. Documents

1 Contract drawings
Certificates
a. ISO Quality Assurance
b. ISO Environmental
c. OHSAS

2 Product Source Schedule

3 Production Plan & Reporting Programme

4 Design Review Minutes

5 Quality System

6 Quality Plan

7 Test Plan

8 Factory Acceptance Test (FAT) Reports

9 Transport Plan

10 Transformer Site Commissioning Plan

11 Method Statements

12 Risk Assessments

13 Training

14 Site Works

15 Site Contractor(s) & Supervision.

16 Site Tests

17 Operation & Maintenance Manuals