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CRITICAL TECHNICAL ASPECTS DURING DESIGN, MANUFACTURING AND

TESTING OF INDIA'S FIRST 1200 kV UHVAC TRANSFORMER

R.K. Tiwari* S.K. Gupta R.K. Singh G.Lalwani J.S.Kuntia

Bharat Heavy Electricals Limited, Bhopal
INDIA

SUMMARY

Considering the power demand-supply equation of the next two decades in the Indian
subcontinent, 1200 kV UHVAC system has emerged as one of the most viable options for
bulk power transfer from power hubs to distant load centers. While higher transmission
efficiency is the prime motive of UHVAC system, reliability in commercial operation
remains the biggest challenge, more so, due to worldwide paucity of its experience. The
UHVAC transformer is probably one of its most important links and needs a critical approach
from all angles before putting into the field operation.

The paper aims at providing an insight into various technical aspects while developing India's
first 1200 kV transformer for its National Test station. The paper elucidates dielectric
considerations of a UHVAC Auto transformer, with regard to 1200 kV winding & lead exit
assembly. Apart from dielectric considerations, UHVAC transformer has unique design
features like significantly higher solid insulation content, higher axial and radial clearances of
windings as compared to EHV transformer. These unique features greatly influence the short
circuit behavior and cooling design of the transformer. The paper explains the specific
considerations to take care of short circuit integrity and cooling adequacy of an UHV AC
transformer.

The paper also throws light on special technological considerations like processing & other
manufacturing aspects to take care of specific features. It also shares the test methodology
adopted for generation and control of high voltage parameters for a 333 MVA, 1200 kV
transformer.

KEYWORDS

1200 kV, UHVAC, Auto Transformer, Winding, Lead Exit, Corona Shield, short circuit and
cooling adequacy

*rktiwari@bhelbpl.co.in
I. INTRODUCTION
For establishing 1200 kV UHVAC transmission system in India, its central transmission
utility POWERGRID Corporation of India, is setting up a 1200 kV experimental National
Test Station at Bina (MP) in association with CPRI and indigenous equipment manufacturers
for detailed system studies, field-testing and trials of 1200 kV equipments. Adequate field
trials are necessary before putting into commercial operation, for ensuring the integrity of the
UHVAC system/ associated equipments under onerous operating conditions.
Transformer being one of the most critical equipments of UHVAC system, its performance
has a great bearing on the success of an UHVAC system. The design, manufacturing and
testing of a reliable 1200 kV Transformer poses severe challenges to the designers. The
conventional design techniques of 400-765 kV Transformer can not be simply scaled up for
1200 kV Technology and they alone are not adequate to precisely design the transformer
owing to the awesome magnitude of various over voltages (arising out of abnormal fault
conditions, switching and lightning transients) and other specific considerations like VFTO,
PD levels under such applications. Higher voltage level coupled with unique design features
like insulation content, larger size of UHVAC Transformer etc. makes the task of design,
manufacturing and testing even more challenging.
Main insulation design of 1200 kV winding needs specific attention with regard to the discs
near line end and in vicinity of 1200 kV lead exit. The lead exit design is specifically
designed for 1200 kV applications with 3-D FEM to take care of large volume effect, larger
solid insulation content, geometry at the bending location of lead exit etc. Thermal stability
of the leads during full load operation and its mechanical stability during transport/ short
circuit need to be critically analysed. Testing of 1200 kV transformer needs a specially
designed corona shield to take care of large job size and its clearances from walls/ roof.
Transportation of UHVAC transformer needs special attention due to its higher transport
height and critical 1200 kV lead exit.

II. 1200 kV TRANSFORMER SPECIFICATION

The basic parameters and technical specification of the 1200 kV Transformer were finalized
after several round of discussions of joint working group which were based on detailed study
of specifications of UHVAC Transformers worldwide and the insulation coordination
requirements of future 1200 kV Transmission grids in India. Due to transport constraints,
UHV Transformers will essentially be single phase[1]. Voltage regulation of 1200 kV is not
specified in India, as voltage regulation is available on 400 kV side to cater to the voltage
fluctuation. Brief technical parameters of the 1200 kV Auto Transformer are given in table I.
TABLE I
Rated Power (MVA) HV/IV/LV 333/333/111
Rated no load voltage (kV) HV/IV/LV 1150/√3/400/√3/33
Rated Frequency & no. of phase 50 Hz, 1-Phase
% Impedance HV- IV 18%±10% tol.
HV- LV 40% (MIN.)
IV- LV 20% (MIN.)
Insulation Levels
i) Full wave Lightning impulse voltage (kVp) HV/IV/LV/Neutral 2250/1300/250/95
ii) Switching impulse voltage (kVp) HV 1800
iii) ACLD PD level <100 pC at 1.5Um/√3
Type of Cooling, Cooling Equipment OFAF or ODAF,
4x33.3% OFAF coolers
Temp. rises Top Oil/ Winding by resistance 0C 40/ 45

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III. DESIGN CONSIDERATIONS
The most critical issues in designing the UHVAC 1200 kV Transformers are -
1. Insulation design and technology - major and minor insulation design
2. 1200 kV lead exit
3. Short circuit withstand capability
4. Thermal performance
5. Transport limitations

Special design features of 1200 kV UHVAC Transformer

1. Significantly high solid insulation content

2. Very high fault level
3. Higher radial/ axial clearances in windings
4. Increased height and lateral dimension of windings
5. Higher force of stabilization
6. Very high air clearances

Transformer Insulation Structure Design

The most challenging task in design of UHVAC Transformer is the Dielectric integrity of
insulation system of the transformer. Some of the critical issues necessitating specific
attention for a 1200 kV transformer are:

a. Dielectric considerations:
The conventional design techniques/ FEM alone are not sufficient at such high levels of
voltages during normal operation/ abnormal fault conditions, switching and lightning
transients. The safety margins needs to be enhanced to take care of large oil volume effect
etc. Technical considerations like VFTO, PD control at 1200 kV level etc. needs to be
analysed in detail. The ducts and insulation near line end of 1200 kV winding are decided on
the basis of composite dielectric stress evaluation of windings as well as tube of 1200 kV lead
exit.

Fig.1 represents main insulation structure of the transformer. The dimensions and
arrangement of the major insulation i.e. LV winding to core, HV winding to tank, top and
bottom ends of windings to yoke are determined by electric field calculations and verified by
FEM analysis under all onerous conditions imposed during testing and field operation. The
insulation structure is designed to be Partial discharge Free at over-voltage of 1.5 PU. Minor
insulation in 1200 kV windings i.e. the insulation between turns, insulating strength between
discs and the impulse creep strength at winding ends is designed accordingly.

The design process of the insulation system can be divided into two steps-

1. Calculation of dielectric stress in all locations of windings/ lead exit

2. Analysis of the stress considering the corresponding strength of the insulation and
subsequent modification of the insulation arrangements.

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 Fig. 1, Structure of main insulation

A 1200 kV winding has to be essentially centre lead takeout, as 1200 kV at winding end is
not feasible (due to requirement of end clearances of the order of 800-1000 mm from
winding top). The transport limitations and end clearances of 400 kV ends of 1200/ 400 kV
winding windings limit the maximum height of each winding section of the order of 2.5 m
approx..Thus, only 1.25 m height is available for accommodating each group of 1200 kV
winding. Meeting the dielectric design duties of such voltages at such low height needs FEM
analysis of the composite winding assembly under all conditions of Lightning Impulse (LI) of
2250 kVp, Switching Impulse (SI) of 1800 kVp and Power Frequency Over-voltage with
Partial discharge (PD) measurement at 1.5 x 1200 kV. Safety margin of at least 1.1 (as
against 1.0 to 1.05 for transformers up to 765 kV) has been considered in all the above cases,
to take care of large volume effect of oil under high stress.

Most critically stressed areas of 1200 kV winding during Lightning Impulse (LI) are the first
few discs near line end and the discs at the junction point of interleaved/ordinary discs. To
withstand these high stresses, duct size of first few discs have to be kept of the order of 10-15
mm, interleaving has to be typically higher than 65-70 % and radial paper content has to be
kept around 50 % higher as compared to a 765 kV transformer. The shield ring at the winding
end is also highly stressed. The duct size and paper covering at these locations are worked out
after detailed FEM analysis. From ACPD perspective, turn-to-turn insulation, the vertical
spacer adjacent to 1200 kV winding and burrs on Copper surface needs special attention.
Figs. 2 to 5 shows typical electric field optimization analysis of 1200 kV winding insulation
structure.

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Fig. 2, Max. stressed field lines for Outer Fig. 3, Max. stressed field lines for Inner of SW
edge Bottom SER Ring under LI edge of SW top SER under PF over voltage

Fig. 4, Max. stressed field lines for Inner side Fig. 5, Max. stressed field lines for Outer side
of middle of SW under PF over voltage of middle of SW under LI voltage

SER = Static End Ring, SW = 1200 kV Series winding

b. Design of 1200 kV lead exit:

The electrode design (lead exit design) is one of the most critical areas of a 1200 kV
transformer and involves field calculations by complex 3D simulation in FEM. Up to 765 kV
class, lead assembly with insulated metal tube or with a barrier arrangement may be used.
However, for 1200 kV, the lead design has to be tailor- made with sub-divided barrier
arrangement having varying duct sizes as per FEM analysis and to optimize insulation
distance and obtain sufficient uniform voltage distribution and partial discharge free system.
Maintaining the geometry and optimum duct sizes in the lead assembly is of utmost
importance and any change in the duct size deteriorates the dielectric stress levels to quite a
great extent as compared to 765 or a 400 kV class transformer. Hence, composite and
prefabricated line lead assembly rather than preparing line lead assembly during
manufacturing of the transformer is used.
The requirement of very large air clearance, critical dielectric requirements of an UHVAC
transformer and transport requirements necessitates use of specially designed Chimney type
turret for lead exit as shown in Fig 6. The turret is designed to take care of stresses not only
during service, but also aims at minimum exposure to atmosphere during assembly at site.

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 Fig. 6, 1200 kV Lead Exit arrangement

c. Short circuit duty consideration:

Unique features derived from dielectric considerations like higher insulation content, higher
radial/ axial clearances pose additional challenges in mechanical/ short circuit design, which
needs to be considered by the designer.

Typical comparison of axial content of insulation is as below:

Typical Comparison of axial insulation content (mm) along vertical columns of HV winding
1200 kV auto transformer 765 kV auto Transformer 400 kV auto Transformer
Solid insulation 1500-1700 mm 1300- 1500mm 1100-1300 mm

Much higher content of axial and radial insulation as indicated above introduces higher
uncertainty in the axial structure. Design parameters like variation in height of different
columns due to tolerances, compressibility, and reverse compressibility of insulation structure
etc., influence SC performance to a greater extent. The solution lies in minimizing the effect
of high variations by adopting suitable compensating measures.

Due to higher end clearances, flux lines have a greater tendency to bend at winding ends
increasing the radial flux component at ends. The Ampere-turn balance is relatively poor due
to non uniformity caused by larger winding spacers near line lead. The fault level is also
much higher. Thus, from Short circuit perspective, UHVAC transformer needs higher design
margins to take care of uncertainties as described above.

Due to the aforesaid reasons, there is greater fringing of flux at ends causing higher winding
eddies on the end conductors. It is advisable to either use CTC at ends or if PICC is used then
its axial height at ends has to be typically below 12 mm. Duct size may be increased at these
locations to take care of hot spots.

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d. Cooling adequacy:

Due to much higher paper insulation on winding conductor ( typically 50 % higher than a
765 kV transformer), there is a reduction in heat dissipation from winding to oil. Suitable
correction factor is applied on the calculated temperature gradient of 1200 kV winding to take
care of this aspect. The correction factor is manufacturer specific and is decided after CFD
analysis backed by fibre optic measurement of the hot spots. Cooling through each channel
and axial/ radial duct is precisely ensured so that there are no hot spots.
Results of measurements on 1200 kV transformer: Actual hot spot temperature
measurements by 8 nos. Fibre optic temperature sensors during temperature rise test on
various sections of windings and core has been done. Hot spot temperature up to 91 deg C
(winding top end) was observed. Also Tank and cooling equipment surface temperatures
measurement performed by Infra-red Thermography to know any surface hot spot
temperatures. The maximum tank surface temperature observed was 79 deg C.

e. Corona Shield:
1200 kV shield has to be specially designed to take care of corona during ACPD test at 1.5
times 1200 kV. The problem is even more critical due to larger dimension of test object and
shield, resulting in lower clearances from earth electrode. Boundary element method has been
selected for calculation of stresses under various test conditions. 2-D contours of the 3-D
equipotential and equigradient contours has been considered in selected vertical planes. Fig. 7
shows the electric field stress plot of corona shield under test condition. Fig. 8 shows the
picture of developed 1200 kV corona shield.

Fig. 7, Electric field stress plot of corona shield Fig. 8, Corona Shield Picture

IV. MANUFACTURING OF TRANSFORMER

Apart from the design challenges, the manufacturing and testing of 1200 kV UHVAC
Transformer needs equal attention. The Transformer is completely manufactured in the state
of the art facility of newly built UHV Transformer block in the dust free and controlled
environments. The cleanliness and controlled manufacturing atmosphere is much more
important for an UHVAC Transformer and utmost care has been taken during the
manufacturing. Special winding moulds employed for making 1200 kV HV winding. Due to
extra- ordinary size of HV winding, maintaining dimension stability and verticality was the
biggest challenge during winding and same was achieved by strict quality control during
manufacturing. Achieving required dimensional accuracy and verticality of core was another
big challenge during manufacturing. All insulation items were procured from a single
supplier in a kit form and were pre-calibrated to ensure uniformity in axial insulation

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structure. Special tools and techniques in pressing of core-coil assembly is employed to
achieve required design pressure and to maintain the dimension stability of active part of the
transformer.

V. DRYING AND PROCESSING ASPECTS:

Typical insulation content per limb in a 1200 kV UHVAC transformer is approx 70% higher
than 765 kV Auto transformer (approx. 13 Tonne per limb in 333 MVA, 1-ph, 1200 kV auto
transformer as against 7.5 Tonnes in a 500 MVA, 765 kV Auto transformer). The radial
distance between the outermost and the innermost windings pressboard barriers is typically
35 % higher as compared to a 765 KV transformer. This means that masking effect of inner
insulation items during VPD processing is more predominant in a 1200 kV transformer and
needs special care to extract moisture from hygroscopic pressboard and paper insulations.
Thus the processing cycle is longer to ensure proper dryness of innermost insulation, it is
equally important to ensure that the outer and exposed insulation items are not over- dried.
Extended time transformer oil soaking, oil rinsing, particle reduction up to ≤10000 particles >
2 microns per litre and longer settling time have been adopted to ensure proper oil
impregnation in the innermost insulation items and to ensure removal of suspended particles
to the levels desired for a UHVAC transformer. All these aspects are of utmost importance
during manufacturing of the UHVAC transformer.

VI. TESTING OF TRANSFORMER

The successful testing of the 1200 kV Transformer was big challenge as it involves dielectric
testing at 2250 kVp Lightning Impulse, 1800 kVp Switching Impulse and Partial Discharge
(PD) test at 1.5 x 1200 kV. Due to larger size of the test object and effect of stray
capacitance, the front time is typically longer in impulse testing. Various combinations of
capacitances in impulse generator circuit were tried before applying full impulse test voltage
and with proper selection of test circuit and parameters, a front time of 1.8 microseconds in
lightning impulse waveform of 2250 kVp achieved against full standard lightning impulse
front time of 1.2 micro-seconds ± 30% [2].
PD measurement at 1.5 times the rated voltage of 1200 kV was toughest task during testing
as transformer was to be operated at 1.5 x 1200 kV for 1 hour and during the testing,
surrounding and laboratory is highly charged due to electrostatic field which are prone to
corona discharges at such levels. This requires specially designed corona shield, discharge
free connection and controlling the PD from surrounding ground electrodes.
Following routine and type tests were carried out successfully in NABL accredited Ultra
High Voltage (UHV) Lab at factory-

1. Measurement of insulation resistance and PI value of windings

2. Measurement of capacitance and tan delta of windings
3. Measurement of windings resistance
4. Measurement of load losses and impedances
5. Separate source voltage withstand test
6. Measurement of no load loss and current at 90%, 100% and 110% excitation
7. Switching impulse voltage withstand test on HV with transferred surge measurement on LV
8. Full wave lightning impulse withstand test with transferred surge measurement on LV
9. Induced over voltage test with PD measurement (ACLD)
10. Temperature rise test
11. Over load temperature rise test

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12. Measurement of harmonics in no load current
13. Measurement of acoustic noise level
14. Infra-red thermography during temperature rise test
15. Hot spot measurement by fibre optic sensors

The developed 333 MVA 1200 kV UHVAC Transformer tank shipping dimensions LxWxH is
6700x4550x4960 mm and shipping weight is 212 Tons. Complete picture of the developed 1200 kV
Transformer is shown in Fig. 9. In Fig. 10, transportation of transformer tank to site on hydraulic
road trailer is shown.

Fig. 9, 333 MVA 1200 kV Transformer Fig. 10, 1200 kV Transformer transportation

VII. CONCLUSION
1200 kV UHVAC system is being considered as a futuristic transmission system in India and
adequate field trials are planned shortly. In order to meet the stringent dielectric duties of the
transformer at such higher voltage levels, a critical dielectric analysis is essential to take care
of all aspects in different critical locations, specially with regard to proper selection of safety
factor, design of discs near line end and 1200 kV lead exit etc. Apart from dielectric
considerations, short circuit integrity and cooling design are to be analysed with regard to
unique design features of UHVAC transformer. Manufacturing under strict quality control in
a complete dust free and controlled atmosphere is a prerequisite for UHAVAC transformer.
Processing of UHVAC transformer needs to be specifically designed to extract moisture from
innermost part of insulation without over-drying the outer insulation. Design of Corona
shield for 1.5 X 1200 kV needs special considerations and complex FEM analysis. The
testing of UHVAC transformer needs specific considerations for generation and control of
surges of such magnitude. The size of UHVAC transformer poses another challenge during
testing of transformer.
The 333 MVA 1200 kV Transformer has been successfully designed, manufactured and
tested. This has been transported to site and erection/ commissioning has also been
completed, overcoming all the odds. The 1200 kV UHVAC Transformer will be backbone of
1200 kV Transmission system and therefore highest reliability in operation is mandatory.
Successful field operation of the developed 1200 kV transformer and associated 1200 kV
equipments and systems at 1200 kV National Test Station under onerous site conditions shall
establish a milestone for technology development in the country in the field of Ultra High

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Voltage and shall pave way for establishment of high capacity 1200 kV Transmission lines in
India.

VIII. ACKNOWLEDGEMENT

The authors are thankful to BHEL Management for permission to publish this paper.

BIBLIOGRAPHY

[1] LI Guang-fan et al, “Type selection and test technology of UHV transformers”,
(IEC/CIGRE UHV Symposium Beijing July 2007).
[2] IEC 60076-3 "Power Transformer"