TRAFOTECH 2018: Tenth International Conference on Transformers
DESIGN CONSIDERATIONS FOR TRANSFORMERS IN UNUSUAL SERVICE
CONDITIONS
Prashant Kumar, Tarun Garg
ABB India Limited, Power Transformers, Vadodara
Abstract:
Transformers are one of the critical equipment
used in Electrical System. Planners may
sometimes need to install transformers under
unfavourable or unusual service conditions.
Specific design changes will be required in
transformers to meet the performance
requirements under such service conditions.
This paper lists out some unusual service
conditions for power transformers and discusses
the specific modifications required in design and
engineering to meet the unusual service
conditions.
Introduction
Transformer designer should take care of the
service condition in which the transformer is to be
installed so that overall reliability of the equipment
is ensured.
IEC 60076-1-2011, Cl.4.2 lists out the normal
service conditions for transformers. Some of them
are listed below:
a) Altitude-A height above sea-level not exceeding
1000 m.
b) The temperature of cooling air at the inlet to the
cooling equipment not exceeding:
40 °C at any time;
30 °C monthly average of the hottest month;
20 °C yearly average.
And not below:
–25 °C in the case of outdoor transformers;
–5 °C in the case of transformers where both
the transformer and cooler are intended for
installation indoors.
For water-cooled transformers, a temperature of
cooling water at the inlet not exceeding:
25 °C at any time; 20°C yearly average.
c) Installation environment
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An environment with a pollution rate (IEC 60137
& IEC 60815) that does not require any special
consideration regarding the external insulation
of transformer bushings or of the transformer
itself.
An environment not exposed to seismic
disturbances requiring special consideration in
the design. A ground acceleration level ag is
below 2ms-2 or approximately 0.2 g) is assumed
normal.
d) Environmental conditions within the following
definitions according to IEC 60721-3-4: 1995
are considered usual and mostly does not
require specific attention
● Climatic conditions 4K2 except that the
minimum external cooling medium
temperature is –25 ºC;
● Special climatic conditions 4Z2, 4Z4,4Z7;
● Biological conditions 4B1;
● Chemically active substances 4C2;
● Mechanically active substances 4S3;
● Mechanical conditions 4M4.
IEC 60076-1-2011, Clause.5.5 lists out various
unusual service conditions. This paper identifies
and describes some of these unusual service
conditions and measures to deal with them
A) Seismic disturbances > 0.2g (regions beyond
4M4).
B) Altitude more than 1000m above sea level.
C) Extremely cold climatic conditions (Places
with temperature below -25oC like Polar
Regions).
D) Excessive and abrasive dust, corrosive
components.
For better understanding of various conditions let us
first classify the environment in various categories.
Environment has been classified into various sub-
class as per IEC 60721-3-4-1995. Definition for each
 TRAFOTECH 2018: Tenth International Conference on Transformers

of above sub-class is given in the standard. Based IEEE Std. 344-2004 Recommended Practice for
on the below table, environmental condition of any seismic qualification of class 1 E equipment for
particular site can be defined Nuclear Power Stations
Cate Description of Sub-category Uniform Building Code 1994 (for US market)
gory parameters
IEC-TS-61463-2016 Bushings-Seismic Qualifications.
K Climatic 4K1, 4K2, 4K3 ,4K4 While procuring transformers customer specification
conditions 4K4H ,4K4L must clearly specify the seismic level for the site.
Transformers for seismic zones shall be
Z Special climatic 4Z1, 4Z2 ,4Z3 ,4Z4
designed for following aspects.
conditions 4Z5, 4Z6, 4Z7, 4Z8
4Z9, 4Z10 1) Strengthening of foundation bolting and active
B Biological 4B1, 4B2 part clamping.
conditions
There are two widespread practices of anchoring of
C Chemically 4C1 ,4C2, 4C3, 4C4 transformer to the foundation. Welding the
active base of transformer to the anchored plate on
substances foundation (popular in US) or use M24 or M36
Foundation bolts on longer sides of
S Mechanically 4S1 ,4S2, 4S3 ,4S4 transformer. Bolts are taken from the roller
active frames mounted on rails on foundation. (One
substances or two bolts from each frame).

M Mechanical 4M1, 4M2, 4M3, 2) Using bushing with higher cantilever strength.
conditions 4M4, 4M5 ,4M6,
4M7 ,4M8 3) Strengthening of core clamping frame and
active part anchoring to base and cover.

4) Accessories like Buchholz relay, Oil level

A) Seismic disturbances > 0.2 g ( regions
beyond 4M4)
Transformers installed at locations prone to frequent
earthquakes, or involving mechanical vibration
more than 4M4 (0.2g) requires special
consideration.
Seismic design of Transformers should meet the
requirements of following standards:
IS: 1893(Part 1) -2002 Criteria for earth quake
resistant structures –General
IS: 1893 (Part 4) -2005 Criteria for earth quake
resistant structures – Industrial Structures
IEEE Std. 693 -2005 Seismic Design
Substations- Appendix
gauge and temperature indicators shall be of
special type. Actuating contacts shall be of
micro-switch and should not mal operate at 4-
M-6 condition as per IEC 60721-3-4 and
EN50216-2.
5) All external structure attached to main tank of
transformer shall be strengthened to meet the
‘g’ forces arising from earthquake forces.
Measures should be taken to reduce the
sympathetic vibrations. Use of vibration
dampers, like elongated bellows, will help to
reduce the propagations of vibration from
coolers to tank.
of
B) Altitude more than 1000m above sea level

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 TRAFOTECH 2018: Tenth International Conference on Transformers
When transformers are installed at altitudes more than
1000 m above sea level, certain additional margins
in design shall be followed.
1) Correction in air clearances
With increase in altitude, the density of air
decreases. Consequently the dielectric property of
air decreases which reduces the breakdown
voltage. The external dielectric strength of
transformers depends wholly upon air. Hence to
get the same voltage breakdown withstand as at
normal altitudes, we need higher live clearances in
air.
Recommended minimum air clearances are given 4) Correction in Insulation levels of Bushing
in Table 4 of IEC 60076-1-2013 for altitude up to
1000m above sea level. The recommended
clearances shall be increased by 1 % for every
100 m by which the altitude exceeds 1 000 m.
2) Correction in Temperature rise
Recommended temperature rises for altitude ≤1000 is given in
IEC 60076-2 table 1. This is based on annual average
ambient temperature of 20oC and a correction
method is listed in table 2 for ambient
temperatures different from standard.
If the installation site is more than 1 000 m above sea-
level but the factory is not, then the designed
temperature rises shall be reduced from
guaranteed values as follows and tested:
- For a naturally cooled transformer (....AN), the
limit of top-liquid, average and hot-spot winding
temperature rises shall be reduced by 1 K for
every interval of 400 m by which the Installation’s
altitude exceeds 1 000 m;
- For a forced-cooled transformer (…. AF), the
reduction shall be 1 K for every 250 m exceeding
1 000 m.
A corresponding reverse correction may be
applied in cases where altitude of the factory is
above 1 000 m and the altitude of the installation
site is below 1 000 m.
3) Dry Type Transformers
In case of dry type transformers ( meeting IEC
60076-11 ed2.0-2018) temperature rises specified
in table 2 shall be reduced by 2.5 % (for natural
cooling) or 5 % (forced air cooling) for every 500
metres by which intended working altitude exceeds
1000 metres. A corresponding reverse correction
may be applied in cases where the altitude of the
test room is above 1000 metres and the altitude of
the installation of site is below 1000 metres. When
the installation altitude is between 1000-3000
metres above sea level, but tested at normal
altitude, the rated short duration separate source
AC withstand voltage shall be increased by 1 % for
each 100 metres above 1000 metres.
In order to ensure that the external withstand
voltages of the bushing are sufficient at an
altitudes exceeding 1000 m, the arcing distance
normally required shall be increased. Oil to air
bushings shall be selected with an increased
insulation level. Correction factor as defined in IEC
60137:2017 shall be applied to the rated level
ka = em ( H-1000)/8150
Where,
H= altitude (in meters), with a maximum of 4000
meters.
m = 1 for lightning impulse withstand voltage
m= 1 for power-frequency withstand voltage where
Um ≤ 245 kV. For higher Um altitude correction is
not applicable because bushings are tested with
switching impulse already corrected for altitude?
m= according to figure 1 for switching impulse
withstand voltage.
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 TRAFOTECH 2018: Tenth International Conference on Transformers

During operation and in service, the following

precautions are to be taken in transformers.
1) Energisation shall be always at no load and
shall be maintained for at least 2 hours before
putting on load. Load shall be increased
gradually say, in stages of 20% in every 30
minutes.
2) Avoid OLTC operations until the oil heats up.
Refer to the guidelines from the tap changer
manufacturer.

D) Transformers for highly polluted and

corrosive environment.
C) Extremely cold climatic conditions
ISO 9223:2012 classifies the environmental corrosivity.
When transformers are to be installed at very low Corrosivity category is a technical characteristic
o o
ambient temperatures (-30 C ~ -50 C) the which provides a basis for the selection of
following design aspects are to be considered. materials and protective measures in atmospheric
environments subject to the demands of the
1) Steel used for tank fabrication should have specific application, particularly with regard to
sufficient impact strength. Grade of steel, service life.
welding material and fasteners should be
suitable for the sub-zero ambient temperatures.Corrosivity of atmosphere is divided into six categories
2) Oil seals should be cold resistant Nitrile or Viton
rubbers to suit the specified ambient Corrosiv Corrosivity Typical environment
temperature. ity
3) All accessories and their actuating contacts category
shall be suitable for the specified low ambient C1 Very low Heated spaces, dry &
temperatures. Dry type RIP bushings are to be cold zone, very low
preferred over OIP Bushings. pollution, low humidity,
4) Design external parts to avoid snow e.g. certain types of
accumulation. Avoid long connecting pipelines desert
by mounting coolers on the tank.
5) Pour Point of the mineral oil used shall be at C2 Low Unheated spaces,
o
least 10 C lower than the lowest cold ambient Temperate Zone, Low
temperature. IEC 60294 ed4.0 2012 has pollution level, (SO2 5
specified 4 grades of oil with lowest cold start μg/m3),rural areas,
energising temperatures ( LCEST) of -5, -20, small towns
o 2
-30 & -40 C with viscosity of 1800 m /s at C3 Medium Temperate zone,
LCESTs. For temperatures below this levels, Medium; Pollution
external heating will be necessary during (SO2: 5 μg/m3 to 30
energization. Oil grade used shall be of low μg/m3), Urban areas,
density (naphthenic grades have this Coastal area with low
characteristics) so that any ice (density 0.88- chloride
0.92) formed from the moisture separated out of
oil will not float over oil and cause flashover C4 High Temperate Zone, high
across live parts. pollution (SO2: 30

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 TRAFOTECH 2018: Tenth International Conference on Transformers

μg/m3 to 90 μg/m3) - Select the optimum one, taking into account the
industrial area, surface preparation method that will be used.
Coastal area without - Consult the paint manufacturer in order to
salt spray. confirm the choice and to determine what
commercially available paint system(s)
C5 Very highTemperate and corresponds to the paint system.
subtropical zone, very
High pollution (SO2: Generally for transformers located in corrosive
90 μg/m3 to 250 environments, following measures maybe be taken
μg/m3), significant
effect of chloride. 1) Protection of the metallic surface with good
quality paint and procedure and paint thickness
CX Extreme Subtropical and as per ISO 12944-5-2017. PU paint is
tropical zone (very recommended.
high time 2) Selection of accessories like BR, PRV, and
MOLG etc. made up of less corrosive material
of wetness), very high like Aluminium wherever possible. Or else
SO2 pollution (higher should be having corrosive resistance painting
than like C5M.
3) Radiator can be hot dipped Galvanized and
250 μg/m3) painted.
4) Outdoor electrical panels shall be made of high
These environment classifications are based on grade Stainless steel like SS304, SS316.
experiments that have measured the rate of metal 5) High creepage distance like 25 mm/kV or
loss for uncoated steel. The classification of 31mm/kV for bushing shall be used. The profile
environments applies to structural steel exposed to shall be selected based on IEC60815-2008 for
ambient (less than 120°C [248°F]) conditions. insulators.

For specific environmental condition, like presence of a

For transformer which are subject to C4 & above corrosive
environment, it is necessary to select correct
material, a better surface treatment and painting
procedure. In this regards, ISO 12944-5-2017
suggests guidelines for selecting the appropriate
paint system.
- Determine the corrosivity category of the
environment (macroclimate) where the structure
will be located (see ISO 12944-2). In certain locations, high content of hydrogen sulphide
- Establish whether special conditions
(microclimate) exist which can result in a higher
corrosivity category (see ISO 12944-2).
- Look in Annex A for the relevant table. Tables
A.2 to A.5 give proposals for different generic
types of paint.
- System for corrosivity categories C2 to C5, while
Table A.1 gives an overview of the contents of
Tables A.2 to A.5.
- Identify in the table paint systems with the
required durability.
particular corrosive nature compound, chemistry
depended solution shall be adopted. Its interaction
with each and every component shall be assessed
in detail and solution shall be adopted for them.
Solution can be choosing in terms of material type,
electroplating for sacrificial corrosion protection,
painting, encapsulation etc.
(H2S) may be present in atmospheres eg:
geothermal power stations, certain chemical
factory etc. When hydrogen sulphide concentration
in air is 5-10 ppm concentration, its reacts with
copper & steel. Following special features were
incorporated by authors in the design of
transformers for a geothermal power project where
hydrogen sulphide content in atmosphere was
high.
1) Electroplating of bushing terminals, contacts of
LV switchgears, Contacts of BR, PRV, MOLG,
Other protection devices with Tin or nickel.

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 TRAFOTECH 2018: Tenth International Conference on Transformers

2) Sulphur free gasket material for tank and other 5) IEC 60079-10-1-2015: Explosive
parts. This is because sulphur reacts with the atmospheres-Classification of areas -
H2S and will cause brittleness of gaskets Explosive gas atmospheres.
leading to leakage. Corrosion inhibitors like 6) IEC 60721-3-4-1995: Classification of
Zerust Vapour capsules were placed inside the environmental conditions. Classification of
cubicles. groups of environmental parameters and
3) All the cabling work was done with tin plated their severities.
stranded cables instead of bare copper strands. 7) IEC 60137-2017 : Insulated bushings for
4) Control cubicles were fabricated from SS316L alternating voltages above 1 000 V
grade steel and designed for protection class IP 8) IEC 60815-2008: Selection and dimensioning
66.Outdoor cubicles were of cast aluminium of high-voltage insulators intended for use in
with painting for outdoors. polluted conditions.
5) All monitoring accessories were with casted 9) IEC60068-3-3-1991 Seismic Test methods.
aluminium cases with C5M type coating as per 10) IEC TS 61463-2016- Bushing Seismic
ISO 12944-5-2017. Qualifications
6) Stainless Steel Valve (SS304 class) were used. 11) C57.12.00-2010 IEEE for Power
7) Stainless steel cable glands were used with transformers
shrouds. 12) IEEE 693-2005 Recommended Practice for
seismic design of sub stations
Conclusion: 13) SS-EN ISO 9223:2012 (E): Corrosion of
metals and alloys – Corrosivity of
When transformers are to be installed in areas with atmospheres –Classification, determination
service conditions different from as stipulated in and estimation.
national standards, appropriate design changes 14) ISO 12944-5-2017 : Corrosion protection of
are to be incorporated to get performance steel structures by protective paint systems
requirements as per standard. 15) W.Lampe, Power transformers & Shunt
Customer specifications should clearly mention the Reactors for Arctic regions, IEEE
changes from standard service conditions as per transactions on Power Delivery, Vol PWRD-1
National standard and at design review stage get No1,1986
confirmation from manufacturer that appropriate
design features are incorporated to meet the
unusual service conditions at particular site.
Special design features required for transformers
to be installed in high seismic zones, high
altitudes, extremely cold climates or corrosive
atmospheres are covered in this paper so that
manufacturers and users can take care of them.

Bibliography

1) IEC 60076-1-2011, Power transformers -

General.
2) IEC 60076-2-2011, Power transformers -
Temperature rise for liquid-immersed
transformers
3) IEC 60076-3-2011, Power transformers -
Insulation levels, dielectric tests and external
clearances in air
4) IEC 60079-10-0-2011: Explosive
atmospheres-General requirements.

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