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

Research on Overload Capability of Dry

Distribution Transformer Based on Hot Spot
Temperature Model
Haifei Wang Tingkang Wang Manyu Xue
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 tkwang@hust.edu.cn xuemany@163.com

Jianming Sun Wei Xiong Yuning Hou*(corresponding author)

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

Abstract—When the dry distribution transformer is

overloaded, the internal temperature will rise abnormally,
resulting in aging of the transformer insulation and a decrease
in service life. Based on the hot temperature function
relationship in GB/T 1094. 12-2013 standard, under the
continuous load and transient load, the transformer overload
capability is studied and analyzed respectively. The theoretical
analysis of life loss and the relationship between the allowable
overload time of the transformer and the allowable overload
ratio is obtained.
Keywords—the dry distribution transformer, the allowable
overload time, the allowable overload ratio, remaining service
life
I. INTRODUCTION
According to the survey results of relevant departments,
since 2000, the development and application scale of dry-type
transformers has been increasing, and the output has increased
year by year. In 2005, the output has exceeded 40 million
KVA. Especially in distribution transformers, the proportion
of dry-type transformers continues to increase. In recent years,
dry-type transformers account for nearly half of the large and
medium-sized cities in China[1]. Although China has become
a major producer and seller of dry-type transformers in the
world today, research on the load capacity of dry-type
transformers is still insufficient. General dry transformer
manufacturers do not have their own dry transformer load
capacity curve.
Dry distribution transformers are used in many places in
the power grid. When overload operation occurs, insulation
aging, life reduction, and even damage will occur, which will
cause large economic losses and safety hazards to the power
grid[1]. This paper deeply studies the overload capacity of dry
distribution transformers, which has important guiding
significance for the planning and design of power grids as well
as safety and economic operation.
Scientific Research Project of China Railway Fourth Survey and
Design Institute Group Company Limited(2018K055).
According to the structural characteristics of resin-cast
dry-type transformers, a 10kV resin-cast dry-type transformer
was selected to analyze the temperature field distribution
under natural cooling and forced cooling[2]. Literature [3]
analyzes the superiority of epoxy resin dry-type transformers,
and discusses the advantages of epoxy resin dry-type
transformers in dealing with complex problems from the
aspects of environmental performance, overload handling
capability and safety issues. The finite element method is used
to analyze the flow-solid-thermal coupling of two-
dimensional symmetrical structure of dry-type transformer,
and the temperature distribution law of the core and winding
of dry-type transformer under different load conditions is
obtained[4]. Literature [5] introduced the overheating
condition of the dry-type transformer core and analyzed the
causes of the transformer core overheating. Based on the basic
principles of accelerated heat aging evaluation, combined with
the standard , literature [6] discussed the logic of dry-type
transformer thermal aging evaluation implementation,
proposed an operational method. The humidification
accelerated aging test of the transformer Nomex insulation
paper was carried out, and the influence of temperature and
moisture on the dielectric properties of Nomex insulation
paper was analyzed[7]. Literature [8] analyzed the distribution
characteristics of the temperature field, and carried out the
three-dimensional and two-dimensional calculation of the
temperature field to determine the highest temperature rise.
The thermal time constant calculation and influencing factors
of epoxy resin cast dry-type transformer windings were
analyzed, and the thermal time constant was tested and
calculated. The thermal time constants of different parts were
obtained[9].
This paper analyzes the overload theory of transformers in
detail. In the ANSYS software, the internal magnetic field of
the transformer is simulated when the transformer is
overloaded, and the internal magnetic lines and magnetic
induction density are compared under different overload ratios.

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 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)
Based on the simulation analysis, the transformer overload
capability is evaluated
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 in
different insulation system temperatures.
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.
TABLE I. MAXIMUM HOT SPOT TEMPERATURE AND CURRENT OF
DRY TRANSFORMER
Insulation System Maximum Winding Peak Hot Spot
Temperature(℃) Current Temperature (℃)
(p,u,)
105(A) 1.5 130
120(E) 1.5 145
130(B) 1.5 155
155(F) 1.5 180
180(H) 1.5 205
200 1.5 225
220 1.5 245
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.
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.
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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 under the short-term
emergency load is as follows:
 Under the short-term emergency load, the temperature
will rise sharply, and the internal components will see
a large mechanical stress, which will cause partial
cracking of the epoxy resin and severely reduce the
insulation capacity.
 The overload current under short-term emergency load
shows short-term and repeatability, which will cause
serious mechanical damage to the winding.
 When the temperature rises to a certain extent, the
mechanical properties will be degraded, resulting in a
greatly reduced insulation capability and short-circuit
resistance of the transformer.
The internal impact under the short-term emergency load
is as follows:
When the internal temperature of the transformer is higher,
the thermal aging of the mechanical and insulating properties
of the conductor will be accelerated, and the degree of aging
will be accumulated to a certain extent, which will reduce the
insulation life of the transformer, especially when the
electrical equipment is short-circuited
B. Hot spot temperature model theory and life loss analysis
of dry transformer
The relationship between the hot spot temperature function
under continuous stable overload can is as follow[10]:
 HS   a   HS (1)
When the cooling method of the transformer is natural-air-
cooled, the temperature rise of the hot spot under the given
load is as follow:
 HS = HS  r  I 
2m
(2)
When the cooling method of the transformer is forced-air-
cooled, the temperature rise of the hot spot under the given
load is as follow:
 HS   HS  r   I 2 CT 
X
(3)
TK   HS
CT  (4)
TK   HS  r
Where  HS is the hot spot temperature rise under a given
load,  HS  r is the hot spot temperature under the rated load,
I is the load rate, CT is the resistance temperature correction
coefficient, m is the empirical coefficient,  a is the ambient
temperature,  HS is the hot spot temperature at a given load
rate, TK is the temperature constant of the conductor, X is the
forcing Air cooling experience coefficient
The hot spot temperature function relationship under
transient overload is as follow:
 t

t   U  i  1  e    i (5)
 
 HS  t   a (6)
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

C ( HS  r   e )
=
Pt
Where i is the initial hot spot temperature rise at the
beginning of a load rate, t is the hot spot temperature rise
after the load change time, U is the final hot spot
temperature rise when the load rate I n does not change, t is
the time,  is the time constant of the winding under a given
load,  e is the influence of the iron core on the temperature
rise of the winding hot spot when it is no-load, C is the
effective capacity of the winding, Pt is the total loss of the
winding under rated load and rated temperature rise.
III. EVALUATION OF TRANSFORMER OVERLOAD
CAPABILITY
A. Simulation Analysis Of Magnetic Field In Dry
Transformer Overload
In this paper, the transient field of the dry type transformer
of type SCB10-50/10 is simulated the ANSYS finite element
analysis software, and the 2DMaxwell model is built. When
the transformer is overloaded, the internal magnetic lines and
magnetic flux changes are analyzed. The transformer model
and dimensional parameters are shown in the Fig.1 and table
II respectively.
(7)
Fig. 2. The magnetic flux and magnetic induction density distribution in
the quarter cycle (0.005 s)
It can be seen from the figure that at 0.05s, there is almost
no magnetic field line inside the B-phase iron core, and the
magnetic induction density is close to 0; The distribution of
magnetic field lines and the distribution of magnetic induction
density inside the A-phase and C-phase iron cores are
approximately symmetrically distributed; When the overload
current reaches 1.2 times, the minimum magnetic flux of A
and C phase cores is 0.0028115 Wb/m, the maximum
magnetic field line is 0.19979 Wb/m, the minimum magnetic
induction density of A and C phase cores is 0.13551 T, and
the maximum magnetic induction density is 2.0325 T.
When the overload current reaches 1.5 times, the internal
magnetic flux and magnetic induction density distribution of
the transformer in the one-half cycle (0.01s) are shown in Fig.
3.

Fig. 3. The magnetic flux and magnetic induction density distribution in

Fig. 1. Transformer 2Dmaxwell model structure diagram the quarter cycle (0.01 s)

TABLE II. DIMENSIONAL PARAMETERS OF THE TRANSFORMER It can be seen from the figure that at 0.01s, the internal
2DMAXWELL MODEL magnetic lines of the A-phase iron core are most closely
distributed, and the magnetic induction density is the largest;
Parameter Length (mm) The internal magnetic field lines of the C-phase iron core are
Core diameter 100
the most sparse, and the magnetic induction density is the
smallest; When the overload current reaches 1.5 times, the
Core height 640 maximum value of the A-phase magnetic line distribution is
Core length 540 0.19995 Wb/m, and the maximum magnetic induction density
is 2.0353T.
Core air gap height 440
Core air gap width 120 In order to more clearly analyze the distribution of internal
magnetic lines during transformer overload, the horizontal
Winding height 340 direction of the longitudinal middle of the A-phase core is
Low voltage winding width 3 selected as the research path, and the curve of magnetic flux
High voltage winding width 6
and magnetic induction density is plotted as shown in the Fig.
4 and Fig. 5.
Epoxy resin thickness 1
It can be seen from the figure 4 that the magnetic field
By applying different overload ratio current excitations, lines in the middle part of the A-phase iron core gradually
the changes of magnetic lines and magnetic induction density increase in the horizontal direction, showing a linear
inside the transformer under different overload ratios can be distribution characteristic, with a minimum value of 0.005
obtained. When the overload current reaches 1.2 times, the Wb/m at 0 mm and a maximum value of 0.199 Wb/m at 100
magnetic flux and magnetic induction density distribution mm.
inside the transformer in the quarter cycle (0.005 s) are shown
in Fig. 2. It can be seen from the figure 5 that the magnetic induction

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 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)
Fig. 4. The magnetic flux distribution of the A-phase core in the
horizontal direction
Fig. 5. The magnetic induction density distribution of the A-phase core in
the horizontal direction
density of the middle part of the A-phase core is almost
constant in the horizontal direction, with a minimum value of
1.96407T at 0mm and a maximum value of 1.96421T at
100mm.
B. Evaluation Of Transformer Overload Capability
Based on the internal magnetic field simulation analysis of
the transformer overload in the previous section, combined
with the hot spot temperature model in the second chapter, the
overload capacity of the dry transformer can be analyzed and
calculated, and the overload time allowed under different
overload multiples can be obtained. The ambient temperature
is an important factor affecting the overload capacity of the
transformer. This paper analyzes the overload capacity when
the ambient temperature is 20 °C and 40 °C respectively. In
the two cases, the relationship between the overload ratio and
the overload time of the dry transformer is shown in the Fig.
6 and Fig. 7.
Fig. 6. The overload capacity of transformer when the ambient
temperature is 20 °C
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It can be seen from the figure 6 that when the initial load
rate is the same, the overload ratio is inversely proportional to
the allowable overload time. The longer the overload time, the
smaller the overload ratio is allowed. As the initial load rate
increases, the overload capacity of the dry-type transformer
gradually decreases. Under the same overload ratio, the
allowable overload time gradually decreases with the increase
of the initial load rate. When the ambient temperature is 20 °
C and the initial load factor is 0.6, if the transformer overload
ratio is limited to 1.5, the allowable overload time is 1000 s,
and the transformer overload ratio is limited to 2, the
allowable overload time is 556 s.
Fig. 7. The overload capacity of transformer when the ambient
temperature is 40°C
Comparing the two figures, it can be seen that the ambient
temperature affects the overload capacity of the transformer,
mainly reflected in the impact of the initial load rate under
other identical conditions. When the ambient temperature is
40°C and the initial load ratio is 0.9, if the transformer
overload ratio is limited to 1.5, the allowable overload time is
500 s. When the transformer overload ratio is limited to 2, the
allowable overload time is 254s.
IV. CONCLUTION
When the dry distribution transformer is overloaded, the
internal temperature will rise sharply, the insulation aging will
be accelerated, the service life will be reduced, and the
transformer will be damaged in serious cases, which will
affect the safe and stable operation of the distribution network.
Based on the hot spot temperature calculation model in
GBT 1094.12-2013 standard, this paper analyzes the overload
theory of transformers in detail. In the ANSYS software, the
internal magnetic field of the transformer is simulated when
the transformer is overloaded, and the internal magnetic lines
and magnetic induction density are compared under different
overload multiples. Based on the simulation analysis, the
transformer overload capability is evaluated and the
conclusions are as follows: When the ambient temperature is
20 ° C and the initial load factor is 0.6, if the transformer
overload ratio is limited to 1.5, the allowable overload time is
1000 s, and the transformer overload ratio is limited to 2, the
allowable overload time is 556 s. When the ambient
temperature is 40°C and the initial load ratio is 0.9, if the
transformer overload ratio is limited to 1.5, the allowable
overload time is 500 s. When the transformer overload ratio is
limited to 2, the allowable overload time is 254s.
ACKNOWLEDGMENT
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

This work was supported by Scientific Research Project of [6] K. Guangzhao. “Analysis of Epoxy Resin Vacuum Pressure Casting
China Railway Fourth Survey and Design Institute Group Dry Type Transformer,” Equipment Management and Maintenance,
vol 19, no 23, pp. 151-152, 2018.
Company Limited(2018K055). Yuning Hou is the
[7] G. Yinjun, L. Yan, L. “Naisheng. Calculation of Temperature Rise of
corresponding author. Amorphous Alloy Dry-type Transformer,” Transformer, vol 55, no 6,
pp. 1-5, 2018
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