2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

Research on Overload Capability of Oil-immersed

Distribution Transformer Based on Hot Spot
Temperature Model
Haifei Wang Manyu Xue Tingkang Wang
State Key Laboratory of Advanced State Key Laboratory of Advanced State Key Laboratory of Advanced
Electromagnetic Engineering and Electromagnetic Engineering and Electromagnetic Engineering and
Technology Technology Technology
Huazhong University of Science and Huazhong University of Science and Huazhong University of Science and
Technology Technology Technology
Wuhan, China Wuhan, China Wuhan, China
hfwang@hust.edu.cn xuemany@163.com tkwang@hust.edu.cn

Yuning Hou*(corresponding author) Jianchun Chen Jianming Sun

State Key Laboratory of Advanced State Key Laboratory of Advanced China Railway Fourth Survey and
Electromagnetic Engineering and Electromagnetic Engineering and Design Institute Group Company
Technology Technology Limited
Huazhong University of Science and Huazhong University of Science and Wuhan, China
Technology Technology
Wuhan, China Wuhan, China
619505294@qq.com m201771396@hust.edu.cn

Abstract—As the user load continues to increase, the safety
accidents caused by the overload of the transformer frequently
occur. In order to improve the safety and stability of the
transformer operation, this paper conducts an in-depth study on
the overload capability of the transformer based on the hot spot
temperature model. When the oil-immersed distribution
transformer is overloaded, the internal temperature of the
transformer rises, causing insulation aging and reducing the
service life. This paper first introduces the characteristics of
distribution transformers in different types of loads, and
analyzes the changes occurring inside the transformers during
overload operation, and then based on the hot water
temperature calculation model in GB/T 1094. 7-2008 standard,
from the perspective of operating temperature and heat aging,
The research and analysis of the overload capacity of the
distribution transformer is carried out, and the relationship
between the allowable overload time of the transformer and the
allowable overload multiple is obtained, and the theoretical
analysis of the life loss is made.
Keywords—the oil-immersed distribution transformer, the
allowable overload time, the allowable overload ratio, remaining
service life.
I. INTRODUCTION
According to the statistics of the Transformer Branch of
China Electrical Equipment Industry Association, the
domestic 10KV voltage class distribution transformer
accounts for about one-third of the transformer market.
Among them, the oil-immersed distribution transformer plays
a vital role in the operation of the power grid. When the
transformer is overloaded, the internal temperature of the
transformer will increase, the mechanical characteristics will
be reduced, and the insulation heat aging will occur. In severe
cases, the transformer will be damaged or even explode,
resulting in safety accidents and huge economic losses. In-
depth study of the overload capability of oil-immersed
distribution transformers is conducive to the safe and stable
National Natural Key Research and Development Program of China
2017YFB0903100, Fundamental Research Funds for the Central
Universities 2017KFYXJJ017, Graduates’ Innovation Fund, Huazhong
University of Science and Technology (NO.2019YGSCXCY073)
978-1-7281-3398-0/19/$31.00 ©2019 IEEE
operation of the transformer, and the reliability and economy
of the distribution network.
So far, domestic and foreign scholars have conducted
extensive research on transformer overload capability.
Reference [1] considers the temperature rise characteristics of
transformer heat generation and divergence, formulates
reasonable boundary conditions for transformer overload
capability, and verifies the overload capacity of transformers
by using the overload model. Based on the basic theory of heat
transfer and the hot spot temperature calculation model in
transformer load guide, literature [2] proposed a hot spot
temperature model suitable for FR3 insulating oil distribution
transformer, and compared its overload performance with
traditional mineral oil distribution transformer; Literature [3]
is based on the mixing Analysis of heat resistance grade and
temperature rise limit of oil-immersed transformers for
insulation systems and conventional insulation systems, using
hot spot temperature models to evaluate the overload
capability of transformers in different insulation systems, and
cost comparison and structural adjustment of hybrid insulation
system transformers; Based on the theoretical analysis of
transformer overload, the boundary conditions of
environmental temperature, initial load, overload multiple, oil
temperature and hot spot temperature are proposed in
literature [4], and the overload capability of the transformer is
verified according to the accounting model. Literature [5]
studied the overload operation state of oil-immersed
transformers, analyzed the long-term danger and short-term
danger caused by overload, and proposed the overload limit of
oil-immersed transformers; Literature [6] oil-immersed power
Based on the transformer load guide, the specific limit
conditions of overload and the overload check process are
determined. The prediction model of winding hot spot
temperature based on top oil channel oil temperature is
established from the perspective of energy conservation.
The above research lacks the corresponding quantitative
analysis of the overload capability of the transformer. In order
to understand the overload capability of the transformer, this

978-1-7281-3398-0/19/$31.00
Authorized licensed use limited to: Centro©2019 IEEE
Universitário Fei. Downloaded on August 27,2020 at 16:11:44 UTC from IEEE Xplore. Restrictions apply.
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)
paper discusses the impact of transformer overload operation.
Based on the hot spot temperature model, the quantitative
analysis of the relationship between transformer overload time
and overload multiple under different types of loads is carried
out. Combined with the life loss model, the transformer life
loss caused by overload is calculated, and the oil immersed
distribution transformer is analyzed in depth, which has
important guiding significance for the planning and design of
the distribution network as well as the safety and economic
operation.
II. THEORETICAL ANALYSIS OF TRANSFORMER
OVERLOAD
A. The Characteristics and Impact of the Load Type
There are many types of oil-immersed distribution
transformers. Different classification standards have different
classifications. In the oil-immersed transformer load guide,
the load is classified into normal periodic load, long-term first-
aid load, short-term first-aid load according to the magnitude
of the load overload and the action time.
The current and temperature limits are shown in Table I
for the above three different load modes.
TABLE I. CURRENT AND TEMPERATURE LIMITS FOR DIFFERENT
TYPES OF LOADS
Load types Index Limit
current/pu 1.5
hot spot
120
normal periodic load temperature/℃
Top oil
temperature/℃
105
current /pu 1.8
hot spot temperature
long-term first-aid
/℃
140
load Top oil temperature
115
/℃
current /pu 2.0
short-term first-aid hot spot temperature
— decreases.
/℃
load Top oil temperature
—
/℃
The characteristic of normal periodic load is that during a
certain period of a cycle, the load acting on the transformer
and the internal temperature is higher, and the relative heat
aging rate is greater than 1; However, in another period of time,
the applied load and temperature is lower, and the relative heat
aging rate is lower than 1; If the aging value of the period
when the relative heat aging rate is greater than 1 can be
compensated by that less than 1, it can be considered that the
load has the same effect on the transformer as the rated load,
and it is not necessary to evaluate the overload capability
under the normal periodic load.
The long-term emergency load is a type of load that occurs
due to the long-term exit of some equipment. This operation
may last for several weeks or months, which will accelerate
the aging of the transformer, but does not directly endanger
the insulation safety. It usually occurs when the transformer is
out of operation for a long time due to malfunction or overhaul,
the system mode is changed, and the load is increased, and the
new transformer cannot be put into operation in a short period
of time. Due to the overload mode, the internal temperature of
the transformer will reach a steady state, so the overload
capacity can only be evaluated from the allowable overload
multiple ratio.
Authorized licensed use limited to: Centro Universitário Fei. Downloaded on August 27,2020 at 16:11:44 UTC from IEEE Xplore. Restrictions apply.
Short-term emergency load is caused by a fault in the
power system, resulting in a serious change in load
distribution, causing severe overload in a short period of time.
This type of load can cause the internal temperature of the
transformer to reach a dangerous level, resulting in faster
aging of the transformer insulation. Therefore, in this load
mode, the transformer overload capability is comprehensively
evaluated from the allowable overload multiple and the
allowable overload time.
When the transformer is overloaded, various changes will
occur in the internal structure of the transformer, which will
accelerate the insulation aging of the transformer and reduce
the service life. The internal impact is as follows:
 The temperature of the windings, clamps, leads,
insulating oil and insulating parts will rise and reach an
unacceptable level.
 The leakage flux density outside the core will increase,
causing the metal component coupled to the leakage
flux to heat up due to eddy currents
 The main magnetic flux acts together with the
increased leakage flux, which limits the core over-
excitation capability.
 As the temperature changes, the moisture and gas
content in the solid insulation and oil will change.
 Sleeves, tap-changers, cable terminations and current
transformers will also be subject to high thermal
stresses, which will affect their structural and
operational safety margins.
When the hot spot temperature suddenly rises above the
critical temperature, bubbles may be generated in the
insulating paper. For transformers with normal water content,
this critical temperature is between 140 and 160 °C. As the
moisture content increases, the critical temperature also
B. Hot Spot Temperature Calculation Model and Life Loss
Model
The template is used to format your paper and style the
text. All margins, column widths, line spaces, and text fonts
are prescribed; please do not alter them. You may note
peculiarities. For example, the head margin in this template
measures proportionately more than is customary. This
measurement and others are deliberate, using specifications
that anticipate your paper as one part of the entire proceedings,
and not as an independent document. Please do not revise any
of the current designations.
The internal temperature of the transformer is the main
factor affecting its overload capacity. Therefore, the model
uses hot spot temperature as the main basis for evaluating
transformer overload capacity and life loss. The internal
temperature distribution of the transformer is shown in Figure
1.
In this model, the complex heat distribution inside the
transformer is simplified, assuming that the oil temperature of
the tank increases linearly from bottom to top. The hot spot
temperature can be obtained by adding the ambient
temperature, the top oil temperature rise, and the hot spot to
the top oil temperature difference.
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

Position The loss of transformer life over a certain period of time is

expressed as
Hot spot
N
temperature
Top oil temperature H  gr L   Vn tn (8)
rise n 1

Where n is ordinal number of each time interval in the

study phase, Vn is relative aging rate during the nth time
Average oil gr interval in the study phase, tn is the time in the nth time interval,
temperature rise N is the total number of time intervals during the study phase.
The recommended values are generally used for each
Bottom oil temperature parameter in the above hotspot temperature calculation model,
Temperature(K) and the recommended values of the thermal characteristic
parameters of the oil-immersed transformer in the ONAN
Fig. 1. Transformer internal temperature distribution cooling method are shown in Table II.

When the transformer load rises, the hot spot temperature TABLE II. IMERSED TRANSFORMER THERMAL CHARACTERISTIC
can be expressed as PARAMETER RECOMMENDED VALUE （ONAN）

  1  RK 2 
x
 Recommended
 h (t )   a   oi    or  Thermal Characteristic Parameter
   oi  Value
  1 R   (1)
oil index x 0.8
f1 (t )  H gi   H gr K y  H gi  f 2 (t ) winding index y 1.6
When the transformer load drops, the hot spot temperature oil time constant  0 180
can be expressed as
winding time constant  w 4
x
 1  RK 2  constant k11 1.0
 h (t )   a   or   
 1 R  constant k21 1.0
(2)
 constant k22 2.0
 1  RK 2  
x

  oi   or     f 3 (t )  H gr K
y
  1  R  
where  h (t ) is the hot spot temperature,  a is the ambient
temperature,  oi is top oil temperature rise in initial state,
Hgi is the hot spot to top oil temperature difference in initial
state,  or is total oil temperature rise under total loss, Hgr is
hot spot to top oil temperature difference at rated current, R is
the ratio of load loss to no-load loss, K is load factor, x is top
oil index, y is winding index, f1 (t ) is the time function
reflecting the rise in temperature of the top oil, f 2 (t ) is the
time function reflecting the hot spot on the change of the top
oil temperature difference, f 3 (t ) is time function reflecting
the decrease in top oil temperature rise. The time function
above can be expressed as
f1 (t )  1  e  t /( k11 0 ) (3)
f 2 (t )  k21 (1  e  t / ( k22 0 ) )  (k21  1)(1  e  t / ( 0 / k22 ) )
 t / ( k11 0 )
f 3 (t )  e (5)
The insulation capacity of the transformer determines the
service life of the transformer. There are many factors
affecting the insulation aging of the transformer, such as
temperature, water content, oxygen content and acid content.
The temperature plays a major role. For the convenience of
research, the life model in this paper is analyzed taking hot
spot temperature as the main factor. The relative aging rates
of non-heat modified paper and heat modified paper are
expressed as
V  2(h 98)/ 6
(
15000

15000
130  273  h  273
) of the transformer is 1.34.
V e
loss ratio R 5
hot spot coefficient H 1.1
total oil temperature rise  or 55
hot spot to top oil temperature difference
23
H gr
III. EVALUATION OF TRANSFORMER OVERLOAD
CAPABILITY
A. Evaluation of Overload Capacity under Long-term
Emergency Load
Based on the above hot spot temperature model, under the
action of long-term emergency load, the overload time is
longer and the value of t is larger. Therefore, the value of f1 (t )
and f 2 (t ) in the formulas (1) to (5) is 1, and the value of
f3 (t ) is 0. Substitute the above thermal characteristic
(4) parameters into the formula (1) and the relationship between
the temperature of the transformer hot spot and the overload
multiple can be obtained. According to the hot spot
temperature limit specified in the national standard, the
allowable overload ratio of the transformer under the long-
term emergency load can be obtained. The curve of the
transformer hot spot temperature with the overload ratio under
the long-term emergency load is shown in Fig. 2.
It can be seen from the curve that the temperature of the
hot spot increases with the increase of the overload rate under
the long-term emergency load. The standard specifies that the
temperature limit of the transformer hot spot is between 140℃
and 160℃, and When the hot spot temperature limit under
(6) long-term emergency load is 140 ℃, the overload ratio limit
(7)

Authorized licensed use limited to: Centro Universitário Fei. Downloaded on August 27,2020 at 16:11:44 UTC from IEEE Xplore. Restrictions apply.
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

generally less than 30 minutes, so the overload capacity of the

Fig. 2. Change of transformer hot spot temperature with overload ratio
under long-term emergency load
transformer cannot be evaluated only from the factor of
allowing the overload ratio and the length of the overload time
t should also be considered. Based on the above-mentioned
hot spot temperature. The trend of hot spot temperature with
overload ratio and overload time can be obtained. The graph
is shown in Fig. 3.
In the IEEC 57.91-1995 standard, the hot spot temperature
limit of the transformer under short-term emergency load is
160°C. Using this temperature limit, Based on the change
curve of hot spot temperature with the overload ratio and the
overload time in Fig. 3, the overload time of the transformer
under different overload ratio loads can be obtained, as shown
in Table 4.
K=1.1

250 K=1.2
Based on the hot spot temperature under different overload

Hot spot temperature(℃)

K=1.3
ratios of the transformer in Figure 2 and the life loss model 200 K=1.4
represented by equations (6) and (8), the aging rate and 160 K=1.5
lifetime loss of the transformer under different ratios can be 150
K=1.6
calculated, as shown in Table III. 100 K=1.7
K=1.8
TABLE III. HOT SPOT TEMPERATURE, AGING RATE AND LIFE LOSS OF 50 K=1.9
TRANSFORMER TRANSFORMER UNDER LONG-TERM EMERGENCY LOAD
K=2
0
Hot Spot 0 200 400 600 800 1000 1200 1400 1600 Limit
Actual life /
Overload Ratio Temperature Aging Rate
Ideal life Overload time(min)
(℃)
1 98 1 100% Fig. 3. The variation of hot spot temperature with overload time under
different overload ratios
1.1 109.3618 3.715702 26.91%
1.2 121.4037 14.93496 6.70% It can be seen from Fig. 3 that under the same overload
1.3 134.0981 64.7298 1.54% ratio load, the hot spot temperature of the transformer
increases continuously with the increase of the overload time.
1.34 140 128 0.78%
When the overload time reaches a certain value, the hot spot
1.4 147.4217 301.6963 0.33% temperature remains relatively stable and does not change
1.49 160 1290.2 0.08% with the overload time; When the same overload time is
applied, the hot spot temperature of the transformer increases
1.5 161.3538 1508.573 0.07%
with the increase of the overload factor. For each different
1.6 175.876 8075.503 0.01% overload ratio load, the long-term overload operation takes
It can be seen from Table 3 that under the long-term about 500 minutes, and the hot spot temperature reaches a
emergency load, with the increase of the overload ratio, the relatively stable level. In the lower load state, it can run for a
final stable value of the hot spot temperature is continuously long time.
increased, the relative thermal aging rate of the transformer is
TABLE IV. TRANSFORMER OVERLOAD RATIO AND OVERLOAD TIME
also rapidly increased, the insulation aging is accelerated, and UNDER SHORT-TERM EMERGENCY LOAD
the life loss is continuously increased. When the transformer
hot spot temperature limit is 140 °C, it can be seen from the Overload Ratio K Overload Time t/min
table that the overload ratio limit is 1.34 times. At this time,
the relative aging rate of the transformer is 128, and the ratio 1.1 
of the actual life to the ideal life is only 0.78%; When the hot 1.2 
spot temperature limit is 160 °C, the overload ratio limit is 1.3 
1.49 times, the relative aging rate of the transformer is 1290.2,
and the ratio of the actual life to the ideal life is only 0.08%. 1.4 
When the overload is 1.6 times longer, the hot spot 1.5 769.5731
temperature inside the transformer rises to 175.876 °C, and the 1.6 343.5902
aging rate reaches 8075.503. The ratio of the actual life to the
ideal life is only 0.01%. It can be seen that it has a huge impact 1.7 239.5655
on the insulation properties, mechanical properties and service 1.8 181.3817
life of the transformer when transformer works under the long-
1.9 142.4169
term high-overload.
2 113.9501
B. Evaluation of Overload Capability under Short-term
It can be seen from Fig. 3 and Table IV that if the hot spot
Emergency Load temperature limit is 160 °C, when the load overload ratio is in
Compared with the long-term emergency load, it has a the range of 1.1~1.49, after the transformer is overloaded for
shorter action time during the short-term emergency load, a long time, the hot spot temperature will not exceed the

Authorized licensed use limited to: Centro Universitário Fei. Downloaded on August 27,2020 at 16:11:44 UTC from IEEE Xplore. Restrictions apply.
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

temperature limit, so it is allowed to work for a long time in Based on the hot spot temperature calculation model in
overload state; When the overload ratio is greater than 1.49, GB/T 1094. 7-2008 standard, this paper quantitatively
the allowable overload time decreases continuously with the analyzes and evaluates the overload capability of the
increase of the overload ratio; If the overload ratio is 1.5, the transformer from the long-term emergency load and short-
hot spot temperature will reach the limit when the overload term emergency load. Under long-term emergency load, when
time lasts for 7769.371min; When the overload ratio is 2, the the hot spot temperature limit is 140 °C, the overload ratio of
temperature limit is reached at 113.9501 min of overload. The the transformer should not exceed 1.34. At this time, the
limiting relationship between the allowable overload ratio and relative aging rate of the transformer is 128, and the ratio of
the allowable overload time can be obtained when the the actual life to the ideal life is only 0.78%. Under the short-
transformer is overloaded. term emergency load, when the overload ratio is in the range
of 1.1~1.49, it is allowed to overload for a long time. When
When working with the short-term first-aid load in the overload ratio is 1.5, the allowable overload time is
different overload ratios, the temperature rise of each part of 7769.73min. When the overload ratio is 2, the allowable
the transformer is shown in Table 5. overload time is 113.9501min.
TABLE V. TRANSFORMER TEMPERATURE RISE UNDER SHORT-TERM The above research results can provide important technical
EMERGENCY LOAD
reference for power grid planning and design, transformer
Top Oil
capacity selection and its safety and economic operation.
Hot Spot Temperature
Overload Temperature Temperature ACKNOWLEDGMENT
Difference
Ratio  h /℃ Rise
H /K
This work was supported by National Natural Key
 0 / K Research and Development Program of China
2017YFB0903100, Fundamental Research Funds for the
1.0 97.9983 54.9983 23.0000
Central Universities 2017KFYXJJ017, the Graduates’
1.1 109.3609 62.5719 26.7890 Innovation Fund, Huazhong University of Science and
1.2 121.4027 70.6121 30.7906 Technology (NO.2019YGSCXCY073). Yuning Hou is the
corresponding author.
1.3 134.0970 79.0995 34.9975
1.4 147.4204 88.0171 39.4033 REFERENCES
1.5 161.3524 97.3502 44.0021 [1] C. Qing. “Research on improving the overload capacity of large
transformers,” Zhejiang University,2010
1.6 175.8744 107.0857 48.7888 [2] Z. Lihua, L. Yuchuan, W. Zhong. “Evaluation of overload capacity of
1.7 190.9700 117.2117 53.7584 FR3 insulating oil distribution transformer,” Hydropower Energy
Science, vol 36, no 3, pp. 201-204, 2018
1.8 206.6242 127.7176 58.9066 [3] Z. Lihua, L. Danhua, Z. Zongxi. “Analysis of overload capacity and
1.9 222.8232 138.5939 64.2294 structure optimization of oil-immersed distribution transformer in
hybrid insulation system,” Hydropower Energy Science, vol 35, no 10,
2.0 239.5546 149.8316 69.7230 pp. 180-183, 2017
It can be seen from Table V that under the short-term [4] C. Qing, W. Guozhong, S. Xiang. “Research on improving the overload
emergency load, as the overload ratio increases, the capability of 500kV large transformers,” Mechanical and Electrical
temperature rise of the top oil and the temperature difference Engineering, vol 27, no 12, pp. 94-97, 2010
between the hot spot and the top oil increase continuously. [5] A. Ming, Y. Weilong. “Analysis of overload limit of oil-immersed
power transformer,” Jilin Electric Power, vol 35, no 2, pp. 35-36, 2005
When the overload ratio is 1.5, the steady-state temperature of
[6] W. Zhengqi, L. Wenhua, D. Zhenbo. “Research on Calculation Method
the hot spot temperature is 161.3524°C, wherein the top oil of Overload Capability of Oil-Immersed Amorphous Alloy
temperature rises to 97.3502°C, and the hot spot to top oil Distribution Transformer,” High Voltage Electrical Appliance, vol 52,
temperature difference is 44.0021°C. no 11, pp. 102-106, 2016
[7] General Administration of Quality Supervision, Inspection and
IV. CONCLUTION Quarantine of the People's Republic of China. GB/T 1094.7-2008 “Oil-
immersed power transformer load guide”. Beijing: China Standard
When the oil-immersed distribution transformer is Press, 2008.
operating in overload state, the internal temperature will rise
sharply, the insulation aging will be accelerated, the service
life will be reduced, even the transformer will be damaged in
serious cases, which will affect the safe and stable operation
of the distribution network.

Authorized licensed use limited to: Centro Universitário Fei. Downloaded on August 27,2020 at 16:11:44 UTC from IEEE Xplore. Restrictions apply.