ENERGYCON 2014 • May 13-16, 2014 • Dubrovnik, Croatia

Open-core Power Voltage Transformer: Concept,

Properties, Application
Igor Žiger #1, Boris Bojaniü #2, Danijel Krajtner #3
#
Konþar - Instrument Transformers, Inc.,
J. Mokroviüa 10, 10090 Zagreb, Croatia
1
igor.ziger@koncar-mjt.hr
2
boris.bojanic@koncar-mjt.hr
3
danijel.krajtner@koncar-mjt.hr

Abstract—The Power Voltage Transformer, which is a single-
phase unit used for direct conversion of power from high to low
voltage, is becoming more and more relevant for substation
application. This is why this paper aims to present the properties
and advantages of the open-core design concept, which has been
functioning very well for a number of years in inductive voltage
and combined instrument transformers, enhancing the
transformer reliability and operational safety. Furthermore, the
intention is to list the known possible application options of these
transformers and finally to succinctly point out the guidelines for
future development, which would benefit both the manufacturer
and the user.
Keywords: Open-core, Power Voltage Transformer,
Power supply, internal arc resistance
ferroresonance immunity, inherent explosion safety and
decrease of inrush current. All these points will be addressed
in more detail in the later chapters of the paper.
Apart from singling out the benefits of the open-core
concept, the aim of the article is to point out the possible
applications of these transformers as well as to pinpoint the
future trends in development of these transformers and the
ways to make them as compact and cost-effective as possible.
II. TRANSFORMER CONCEPT AND COMPONENT OVERVIEW

I. INTRODUCTION AND DEFINITIONS

A Power Voltage Transformer is a single-phase unit used

for direct transformation of power from high, transmission
level voltage (up to 550 kV) to low voltage (under 1 kV).
Typical power ratings of open-core power voltage
transformers are in the range from 10 to 167,5 kVA.

The basic concept of these transformers is that they are

instrument transformers by design and power or distributive
transformers by purpose. This means that these transformers
are designed under the principles and according to standards
relevant for instrument transformers, retaining the same
insulation requirements, short-circuit withstand capability and
possibility of permanent operation at increased voltage
(usually 1,2 times the rated voltage) [1] - [3]. This approach
eliminates the necessity for rather complex and expensive
protection and monitoring systems and by default assumes a
long-term, maintenance-free operation. On the other hand, the
function of these transformers is inherited from power
transformers as they are used to supply power for various
applications, which will be mentioned later in the paper and 1. Primary terminal 5. Insulator 9. Secondary winding
which stem precisely from the way these transformers are 2. Bellows cover 6. Mineral oil 10. Open core
designed. In some cases, these transformers can serve a dual
3. Stainless steel bellows 7. Main insulation 11. Terminal boxes
function, incorporating both power transmission and
measurement or protection utilization in one enclosure. 4. Heat sink 8. Primary winding 12. Transformer base

Fig. 1. Transformer cross-section, with an outline of the main components

The open-core design, available only with paper-oil main
insulation, brings several extra benefits to the table when
viewed both form designer and user standpoints, such as:

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 ENERGYCON 2014 • May 13-16, 2014 • Dubrovnik, Croatia
First, it is necessary to briefly list and describe the main
transformer components. An example of the power voltage
transformer can be seen in Fig. 1.
The basis for the transformer design is thhe open core, which
is basically a pole in the center of the trannsformer, while the
main magnetic flux path is closed througgh the surrounding
non-magnetic material.
The design of all other components is diictated by the open
core. This is most apparent with the desiign of the primary
winding and the main insulation cylinder. More
M precisely, the
open core allows the primary winding to t be divided into
serially connected sections which are com mpletely exposed to
the natural oil flow, as well as the coonstruction of the
capacitively graded main insulation, whiich is essential in
order for transformers to comply with requiirements for higher
voltage levels. Furthermore, the capacitivee screens from the
main insulation are connected to the sectioons of the primary
winding, thus assuring a constant synergyy between the two,
leading to transformer insusceptibility towarrds overvoltages of
different character and origin [4]. Thiss also allows an
immediate and utter control of parameterss during the design
process.
Additionally, as the main insulation is geometrically
cylindrical, this also draws some technologgical benefits, such
as the ability to produce the main insulationn by machine, thus
greatly speeding up the production processs and reducing the
frequency of worker intervention. This ensuures uniformity and
high precision during in-factory production processes [5].
The active part of the transformer is placced into a porcelain
or composite insulator, essentially making the transformer its
own bushing, contributing to the slendder design of the
transformer and consequently decreasing the t overall weight,
and dimensions, while improving the weight w distribution
along the transformer. The tall, lean buiild also positively
influences the leakage reactance and the immpedance voltage of
these units [6]. The aforementioned conceept also eliminates
practically all metallic constructive componnents in the path of
the main or the leakage magnetic flux, whicch could potentially
lead to increased additional, stray losses [77]. The only metal
components in the path of the flux are thee insulator flanges,
whose losses are controlled during the electrical design
process [6]. The impedance voltage of o these units is
comparable to that of the closed corre power voltage
transformers of the same ratings.
III. OPEN-CORE DESIGN SPECIFIC FEATURES
The main advantages of the open-core concept,
c which will
be tackled one by one in this chapter, are:
• Ferroresonance immunity
• Inherent explosion safety
• Inrush current decrease
• Insusceptibility to overvoltages of varrious character
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A. Ferroresonance immunity
Ferroresonance can be defiined as a non-linear resonant
phenomenon which manifests inn oscillations between the non-
linear inductance of the transsformer and grid capacitance.
This phenomenon can lead to increased voltages or currents
appearing across the transformeer, possibly resulting in damage
to the transformer itself [8]. Thiis has been found to be an issue
with closed core inductive voltaage transformers in service.
The open magnetic core cann, for calculation purposes, be
substituted with a closed core with
w an equivalent air gap. The
width of the air gap can be dettermined using both analytical
and numerical approach [9]. Foor power voltage transformers
this value typically ranges from
m 10 to 30 mm, depending on
the core geometry.
This air gap influences thhe magnetizing curve of the
transformer, making it more linnear and smoothening the curve
knee-point. The comparison of typical magnetizing curves for
open and closed core transformeers can be seen in Fig. 2.
When the grid capacitance raange is added to the same chart
(Fig. 2), it is apparent that the probable range of intersection
between the magnetizing curvee and capacitance, which is a
prerequisite for ferroresonaance, is vastly smaller (non-
existent even) for open-core traansformers than for closed core
transformers. Although this chartc is based on instrument
transformers, the same logicc extends to power voltage
transformers as both types share the same common
denominator, to put things graphhically [6].
Fig. 2. Comparison of the open and corre magnetizing curves in respect to the
network capacitance
This fact has been recognizzed by the IEC, so the recent
technical report by IEC 618699-102 workgroup, which deals
with topics connected to ferrorresonance of inductive voltage
transformers, recommends incluusion of an air gap into the core
of any inductive transformer ass a measure to greatly decrease
or eliminate ferroresonance [10]].
Ferroresonance immunity of
o open-core transformers is
verified with multiple criiteria, including numerical
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simulations of most common situations for ferroresonance
inception in transmission networks, most importantly the
situation when the transformer is energized through a
capacitor for field grading optimization of the open circuit-
breaker [8]. However, the most important criterion is field
experience with open-core inductive voltage transformers,
where no fault was ever recorded that could be connected to
ferroresonance.
B. Inherent explosion safety
Protection from transformer explosions is usually
associated with SF6 insulated transformers, because of the
rupture disc incorporated into the design of their enclosure
[11]. This concept successfully mitigates the effect of the
internal fault.
The open-core concept introduces explosion safety to
paper-oil insulated power voltage transformers. The explosion
safety principle is different from their SF6 counterparts,
meaning that it eliminates the possibility of internal arc
inception under normal operating conditions, a property which
will be described in more detail in this chapter. This feature is
one of, if not the most important asset of open-core power
voltage transformers, which ensures a better operational
security and availability.
As it was mentioned in the second chapter of this paper, the
primary winding consists of multiple independent sections
(whose number is dictated by the voltage level and/or power
rating of the transformer). This fact causes the transformer to
be insusceptible to the inception of the internal arc.
If the fault originates from inside of the transformer, then it
is most probably located in the primary winding, either
between turns or layers of one section or between two
adjacent sections. In either of these cases, due to the sectioned
design, the fault remains localized to only one section and
does not spread through the entire winding. The grid voltage
is then distributed across all other sections, thus limiting the
fault current and preventing a direct short circuit connection
between high voltage and ground. Even if the fault is located
in the main insulation, due to the fact that screens from the
insulation cylinder are galvanically connected to the
corresponding primary winding sections, the fault again
remains localized to one section of the winding, while the rest
of the sections prevent a catastrophic breakdown of the
transformer.
This feature actually makes the power voltage transformers
comparable to capacitive voltage transformers, in regard that
their insulation also consists of many elements (capacitive)
connected in series and prevents a direct line to ground fault
in the same way.
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Essentially, this means that the internal fault is reduced
from a fast and disruptive occurrence to a slower, noticeable
phenomenon.
These hypotheses were confirmed by testing open-core
inductive voltage transformers, where a worst case scenario
was simulated. One winding section was intentionally short-
circuited. The transformer was then subjected to rated voltage
while electrical parameters and pressure inside the transformer
were monitored. While the transformer was connected to high
voltage, the primary current (mainly consisting of the
magnetizing current), was increased approximately two-fold
and remained well in the value range of milliamperes,
meaning that it did not venture in ranges associated with
network short-circuits (values in kA).
Furthermore, the increased thermal stress of the faulty
winding caused an increased release of gasses from
transformer oil, which led to an increase in volume and
consequently to a pressure rise inside of the transformer.
When the oil pressure exceeded the design value of the
intentional weak spot of the transformer (bellows and bellows
cover), a controlled release of pressure occurred in the
dilatation bellows, without any oil spill, resulting only in
detaching the bellows cover from the transformer. This
occurrence is illustrated in Fig. 3 and 4.
Conveniently, the connection towards the primary terminal
is established by means of the bellows cover, meaning that its
detachment also disconnects the transformer from the grid,
thus interrupting the supply to the fault location. This ensures
an automatic disconnection of the transformer under fault
conditions.
Another convenience is that the information about the
pressure rise inside the transformer can be obtained well
before the bellows cover detaches either by checking the
bellows position in the oil level indicator window or by
monitoring the pressure rise itself. The latter is actually the
basis for an efficient and reliable monitoring of power voltage
transformers. The most common solution is an overpressure
switch which can trip the monitoring or the protection system
when the oil pressure exceeds a certain predefined value,
indicating that the transformer needs to be inspected.
This ensures an unparalleled reliability of open-core
transformers and is more than sufficient for all power voltage
transformer monitoring needs, with very little to no additional
cost.
In the end, it is necessary to emphasize that the contents of
this paragraph apply to any internal fault under normal
operating conditions. If a transformer is succumbed to an
overvoltage which exceeds the rated insulation level, an inner
or outer arc can occur and cause damage to the transformer.
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In the above equation, Al is the

t core cross section, Aį is the
area enclosed by one turn of thee winding, i0 is the mean length
of the magnetic path, while B, Bs and Br are the rated flux
density, saturation flux densityy and remanent flux density,
respectively [13].

The inrush current magnituude is influenced by several

factors, ranging from the mooment of connection and the
voltage wave angle to the remmanent magnetism displayed in
the upper equation by Br variabble. Remanent magnetism is a
consequence of the hysteresis loop and the inability of the
magnetic core to demagnetize innstantly [14].

With closed core transformeers, the remanent flux density

can range from 50 to 90 % of rated flux density value,
depending on the core materrial and core assembly [13].
According to equation 1, thhe remanent flux density is
superposed to the rated flux dennsity, meaning that the core can
be deeply saturated, thus resullting in a high inrush current
Fig. 3. Inductive voltage transformer before the bellow
ws cover detached value.

The introduction of the air gaap into the magnetic circuit can
drastically decrease the remanent magnetism and,
consequently, the peak valuee of inrush current. This is
confirmed in relevant literaturee [13], [14]. Additionally, we
can draw a parallel to the cuurrent transformer cores with
transient response requirementss, such as TPY or TPZ classes,
which according to IEC 611869-2 standard require the
remanent magnetism (i.e. remannence factor Kr) to be less than
10 % of the rated flux. If the typical air-gap values of such
cores, which range from 4 - 12 mm are compared with typical
equivalent air gap value of the t open-core power voltage
transformers, listed in the abovee chapters, it can be concluded
that the open core practically eliminates the remanent flux
altogether [15].

Fig. 4. Inductive voltage transformer after the bellowss cover detached
This fact, coupled with the loow rated flux density of power
voltage transformers (due to the instrument transformers
design philosophy), guaranteees a lower inrush current
magnitude, thus decreasing the t probability of accidental
tripping of the protection systems and lowering the
mechanical strain to the transforrmer itself.

C. Inrush Current Decrease D. Insusceptibility to overvoltagges of various character

Inrush current is a current of transient character which is To understand this featuree, it necessary to show the
present when any transformer is switched on. It can achieve equivalent diagram of the openn-core transformer active part.
magnitudes which are 10 or more times higgher than the rated This is shown in Fig. 5 [16].
current of the transformer [12]. The peak value
v of the current
is defined by equation 1.

1 Al l 0
im = (2 B + Br − Bs ) (1)
μ 0 Aδ w

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Fig. 5. Equivalent diagram of the open-core power voltage transformer active
part
The main goal of a well-designed insulation system is an
equalized distribution of dielectric stresses along all areas of
the insulation, both internal (oil impregnated paper insulation,
between layers and sections of primary winding) and external
(insulator – air boundary). As it can be seen in Fig. 5,
transformer is actually a complex LC network (resistance
values, although present, do not influence the dielectric stress
distribution of the transformer), which means that the
dielectric stress distribution is hugely dependent on the
frequency of the overvoltage applied [16].
The number of nodes in this network corresponds to the
number of primary winding sections. As it was described
before, each section is directly connected to a capacitive
screen in the main insulation. The capacitance between two
adjacent screens is represented by C1 - Cn capacitances in the
equivalent diagram. The self-capacitance of the section is
small by comparison and can be disregarded [16]. Each screen
has a capacitance to ground designated with Co1 - Con. Each
section is represented by its self-inductance (L1 - Ln) and an
array of mutual inductances towards all other sections. These
two sets of parameters comprise the inductance matrix. The
inductance matrix is calculated using FEM Analysis, while the
capacitances can be calculated analytically, because of the
cylindrical geometry of the insulation [16][17].
Once all lumped parameters are determined, they can be
imported into EMTP solver, which can then calculate the
voltage distribution across the primary winding for various
operation scenarios, most notably the lightning impulse, the
switching impulse and the sinusoidal overvoltages of different
frequencies.
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Each of these parameters can be easily controlled by design;
the section inductance can be fine-tuned by changing the
number of turns of each section, and capacitances can be
optimized by changing the geometry of capacitive screens in
the main insulation.
An example for the calculation of lightning impulse voltage
distribution for 362 kV, 100 kVA Power Voltage Transformer
can be seen in Fig.6.
As it can be seen from the chart, the voltage distribution is
practically linear during the entire impulse voltage wave
duration.
Section number
Fig. 6. Lightning impulse voltage distribution for 362 kV Power Voltage
Transformer
This ability to withstand overvoltage of various origin and
character (waveform, amplitude, frequency) is well confirmed
by a range of tests and positive service experience of the
open-core inductive voltage transformers [16]. The feature
that separates Power Voltage Transformers from inductive
voltage transformers is their behavior under sinusoidal
voltages for different frequencies. This is because the power
voltage transformers have a lower primary winding
inductance (due to a smaller number of turns) than their
instrument transformer counterparts, which results in a very
stable voltage distribution over a typical range of lower
frequencies. While the voltage distribution for instrument
transformers is fine tuned for both the rated frequency and the
test frequency of the power-frequency withstand voltage test
(usually 100 - 150 Hz), experience has shown that for power
voltage transformers it is enough to adjust the distribution
only for the rated frequency, and a wide range of other
frequencies will exhibit the same distribution. This fact is
illustrated in Fig. 7 and Fig. 8, which show calculated and
measured voltage distributions for a 145 kV 50 kVA Power
Voltage Transformer unit. This behavior is inherent to all
transformers of this type.
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 ENERGYCON 2014 • May 13-16, 2014 • Dubrovnik, Croatia
Fig. 7. Voltage distribution for 145 kV Powerr Voltage Transformer
expressed in [p.u.]
Fig. 8. Percentage deviation from ideal voltage distribution
As it can be seen in the figures abbove, the voltage
distribution is highly linear in all cases. Fuurthermore, a strict
control of dielectric stress in the entiree active part also
controls the stress distribution on the insulaator surface. These
two combined cause the transformers to be able to achieve the
insulation requirements for the highesst voltage levels.
Additionally, the transformers are partial-ddischarge free (PD
less than 10 pC) even at power frequency withstand voltage.
This fact greatly enhances the lifetime of thhe transformer and
adds another layer to the preventionn of transformer
breakdowns due to insulation aging innfluenced by PD
inception. This was described in more detaiil in the referenced
study [18].
IV. APPLICATION
The most common application of these transformers is for
“in-house” supply of various substations, meaning
m the supply
of auxiliary equipment, protection and moniitoring systems.
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In this configuration, the Power Voltage Transformer
substitutes a distributive transformer or a diesel generator.
This solution is very conveniennt in remote substations which
have no access to the distrribution system, common in
countries which have large teerritories with low population
density, such as the USA, Canada or Australia. An example of
such transformers for this appliccation is shown in Fig 9.
The other conventional, albeeit less common application is
for the power supply of remotee industrial consumers, such as
communication towers or antennnae, mines, pump stations, etc.
In this case, by building a lighttweight station it is possible to
ensure an economical, robust annd reliable power supply.
Due to their modest weigght and convenient transport
possibilities, these transformerss can be used for a temporary
supply of local consume while thet substation is being built, or
as an emergency supply after faaults or environmental disasters.
Fig. 9. 362 kV transformers for auxiliarry supply of a substation in Estonia
The three possible applicaations mentioned above are
considered conventional. On the t other hand, the following
application adds a social factor to the mix and is more future-
oriented. The idea is to use thee Power Voltage Transformers
as a primary unit in a substationn to provide electrical energy to
remote communities and users. This way it is possible to reach
numerous rural communities orr mountainous areas where the
construction of the distribution grid is economically unviable
or even technically impossiblee, thus allowing the access to
stable electrical energy to those who do not have it.
To put things into perspecttive, according to a report by
International Energy Agency (IIEA) from 2011, there are 1,3
billion people in the world without
w the access to electrical
energy. Ninety-five per cent off these people populate remote
areas in Africa, India and Soutth-east Asia. These are regions
characterized by vast territoriies where the layout of the
distribution system is exxtremely demanding, both
economically and technically. According
A to the same report,
in order for the entire populatioon of the world to have access
to electrical energy, the necesssary yearly investment in that
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part of the energy sector should amount to 3% of total
investments in the entire energy sector [19]. Apart from
investing in renewables, which is a very present trend in
recent years, a significant portion of that should be invested in
the improvement of the grid infrastructure and the
construction process of new power lines and substations.
A substation based on the Power Voltage Transformer as
the main transformer can be very compact and straightforward,
resulting in savings in both the primary and secondary
equipment, protection and monitoring alike. As mentioned
before, the Power Voltage Transformer as a concept
eradicates the need for expensive and complex protection and
monitoring systems. A HV switchgear (which would most
probably exceed the transformer itself in sheer cost) can be
replaced by an HV fuse, no extensive monitoring is necessary
and maintenance is basically limited to periodic visual checks
and routine site measurements, the same as with instrument
transformers.
Some confirmation of this has already been reported, as
cost-benefit analyses of pilot projects have shown that this
type of substation can be approximately three times cheaper
than a regular substation [20].
V. FUTURE DEVELOPMENT
The first and the most obvious direction of development is
to further optimize the internal electrical and mechanical
design. This includes the improvement of materials and
components, the utilization of contemporary technologies and
an eventual reduction in transformer dimensions. This form of
development is a continuous process and is present in all types
of transformers, power and instrument alike. This also
includes improving computational techniques, algorithms and
methodology. This is a normal evolution of the product.
The second approach would be to increase the appeal of the
product by determining the outer contributing factors which
could lead to a better user experience or a more economically
viable product. Finally, the goal is also to make the entire
substation which revolves around the Power Voltage
Transformer as simple and compact as possible.
One example that positively affects the size and price of the
transformer itself is the use of a small distributive regulating
transformer on the secondary side (for instance 690 V to 120
V). This results in a smaller transformer with lower overall
losses [6]. Additionally, it allows a more advance voltage
regulation, as the power voltage transformer design only
allows voltage regulation in no-load conditions and in limited
range.
The perks of the open-core concept, thoroughly analyzed in
previous chapters, unlock the potential for an additional
simplification of Power Voltage Transformer based
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substations and/or add a new degree of protection. The ability
to auto-disconnect by detaching the bellows cover in case of
an internal fault, opens a possibility to eliminate the HV
circuit-breaker. This stems from the fact that even under the
worst possible internal fault, the fault current is in the ampere
range, which can be disconnected purely by means of a
disconnector.
It should be noted, however, that it is still necessary to
invest additional efforts in the development and the
verification of this solution with an aim to reduce the footprint
and complexity of a substation to a minimum.
VI. CONCLUSION
The main objective of the paper was to present an open-
core Power Voltage Transformer as a solution for an auxiliary
supply of substations or remote consumers, both communities
and industry.
The objective was also to list, explain and summarize the
advantages of the open-core based transformers. These
advantages support the “maintenance free” philosophy, but
also up the ante, meaning that, due to their explosion safety,
ferroresonance immunity and other traits, they can truly be
labelled as “install-and-forget” units which are proven to
operate reliably in all conditions, which is the premise of the
entire concept.
Furthermore, precisely because of these advantages, the
substation design can also be simplified and made more
financially attractive. Therein lies the potential for a more
widespread use of Power Voltage Transformers as primary
units for power supply and distribution to remote areas in the
vicinity of overhead power lines.
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[10] IEC/TR 61869-102 Ed.1.0 “Instrument Transformers - Ferroresonance

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