Power Transformer Design

Power Transformer Design
Transformer Design Concepts

Markham Technical Seminar
October 4 & 5, 2022
Prolec GE Waukesha / Proprietary and Confidential

© Prolec-GE Waukesha, Inc.
Suresh Babanna
Principal Design Engineer
suresh.babanna@prolec.energy
Suresh joined Prolec GE Waukesha in June 2020.
He has been in the transformer industry since 1990,
spending the majority of those years as a transformer
electrical design engineer. He also has experience as
a transformer test engineer and in transformer
manufacturing, sales and marketing.
Suresh has a Diploma in Electrical Engineering from

SJ Polytechnic, Bangalore; a bachelor’s degree in
Electrical Engineering from Bangalore University
(India) as well a master’s degree in High Voltage
Engineering from Indian Institute of Science,
Bangalore India.

Transformer Cutaway View
Prolec GE Waukesha / Proprietary and Confidential October 4, 2022 3

Design Parameters
Normal operation – MVA rating,
Application – GSU, Phase Shifting,
voltage ratio, connection
Multiple Windings,
LTC/DETC, % impedance, parallel
Zig-Zag, Series / Parallel, etc.
operation, sound levels
Loss evaluation, Existing

Transformer Controls &
Customer size and weight restrictions
online Monitoring shipping by rail/road
Specification
Short circuit, overloading, Dielectric Requirements

over fluxing, seismic BILs-LI, SI, induced
conditions, voltage, applied voltage
Unusual Service Conditions Type of cooling –
Temp rises, Top
oil, Average
winding, Hot spot -
winding and core.
DGA limits

Overall Bid and Design Process
Customer specifications and requirements
Bid Design
Review Bid Design /Requirements
Finalize design Parameters
Verification Design Sheets
Mech Design
Design Review
Approval Drawings Release to Shop

Final Design Steps
▪ Review bid design, customer requirements and specification

▪ Find a reference design, if available
▪ Good starting point or guide
▪ Finalize core diameter, winding turns, type of winding, gap between windings and
end clearances
▪ Select number of turns/disk, tap sections, conductor paper, type of conductor, duct
between sections/turns
▪ Check voltage ratio error, change number of turns, if required

Final Design Steps
▪ Balance ampere-turns in LV windings, in case of de-energized taps in the main HV winding

▪ Calculate % impedance, core loss, load loss and compare with guaranteed parameters
▪ Change conductor size and winding height, as required
▪ Calculate impulse voltage distribution in winding and between gaps
▪ Find max voltages and use PD curve calculations to ensure proper margin
▪ Finalize wound-in-shield requirement for HV winding

Final Design Steps
▪ Calculate % impedance at rated and tap extremes between windings and compute
fault currents
▪ If requested, calculate electrostatic field plots to ensure stress does not exceed limit
▪ Perform short-circuit withstand calculations, analyze stresses in windings, key-spacers,
end forces; based on results, change winding conductor if required and recalculate
the stresses

FEA field plots for leakage flux and SC Forces
INDICATES
FORCE
DIRECTION
LV HV
Mag field
“leaks” out
radially
whenever
Axial locations
there is an
of where HV
axial DETC taps are
spreading located
out of turns
in a coil. The
larger the
axial spread
of turns, the
more radial
the field
Note the force becomes
arrows are
acting in 3-D and
perpendicular to
the mag fields Finite Element Analysis of Leakage
Field Between Coils
Short circuit Forces
Axial Forces on Winding Conductors

(and other components)
Radial Forces on Winding Conductors
Combination of Axial/Radial Forces
Because of various directions of forces

(axial, radial….forces are thus acting in
3-D
Electrostatic Field Analysis
Stresses are limited in

design to 12kV/mm

Final Design Steps
▪ If changes were made to the design, re-calculate impulse withstand
▪ Perform leakage flux analysis, calculate tank losses, eddy losses, frame losses
▪ Calculate temperature rise of clamps and tank
▪ Increase end clearances and tank clearances, as required
▪ Calculate flitch plate and outer core temperature rise and split flitch plate/outer
core packet, if needed

Leakage Flux Analysis

Final Design Steps
▪ Perform temperature rise calculations and finalize number of radiators and fans to limit
the guaranteed top oil rise, average winding rise, hot spot temperature.
▪ Perform overload temperature rise calculations, if specified
▪ Prepare detailed design sheets which provide technical information for winding drawings,
internal layout, external layout, controls and approval/manufacturing drawings
▪ Prepare detailed test specification based on ANSI and customer requirements

Design Process
Finish
Start Cycle time varies depending on the design complexity
Approvals
Order Entry
Marketing Specification
& Questions
Engineering
Electrical Design
Initial Electrical Cooling Electrical
BOM Checks Design Design Group
Internal Tank Accessory

Outline
Mechanical Mechanical
Design Design Layout BOM Design Group
Controls
Controls
Controls Design Controls Drawings
BOM Design
Group
Submit
Nameplate Approval
Complete BOM
Drawings to
Customer
Substantial design work is complete with approval package submission.

Insulation Design

Insulation Design :
• Insulation Materials
• Design Margins
• Insulation Design Method
• Impulse Voltage Distribution

Insulation Materials
Major Insulation
PB RING
Insulation of windings to ground, core, other
windings within the phase and to other phases WA
PB BLOCKS
WA
WA
COLLAR
Materials SR
WA
SR WA
SR
• Pressboard (cellulose)
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
GAP
− High density (TIV) – cylinders
− Medium density (Hi-Val) – collars WDG
TV
WDG LV WDG HV
DISK DISK
− Layered TIV (TX2) – rings, washers HELIX
• Nomex – for higher temperatures

• Laminated Wood – rings
FRM CYL
FRM CYL
FRM CYL
GAP
GAP
CYL
CYL
CYL
CYL
CYL
CYL
CYL
CYL
CYL
CYL
CYL
GAP
CYL
• Kraft Paper (cellulose) – leads SR
SR
WA
• Copaco (cotton based paper) – leads WA
WA
WA
WA WA
• Resin/epoxy materials – PB BLOCKS
on metal parts PB RING

Minor Insulation Spinning Fill Conductor Lead
• Insulation between different parts of

one winding – between turns, stands
of conductors, discs or layers
Materials
• Kraft Paper – conductor insulation/spinning
• Nomex – spinning, spacers
• Formvar – conductor insulation

Spacer
• Epoxy (CTC) – conductor insulation
• Copaco (cotton based paper) – leads Inner
• Pressboard Xover
Outer
‒ High density (T4) – spacers Xover
‒ Medium density (Hi-Val) – collars, etc.
‒ Layered TIV (TX2) – structural parts

Insulating Fluids Other Materials
• Mineral Oil
Lead Insulation
• Natural Esters (FR3, eN 1215,
• Kraft Paper
eN1204)
• Copaco
Advantages of Natural Ester • Nomex
• Slows aging of cellulose • Pressboard
(equiv. to roughly 10 ˚C lower Lead Supports
winding rise) • Maple
• Higher Flashpoint (330˚C vs • Laminated Wood
140˚C) • TX2
• Environmental Bushings, Insulators
advantage/containment • Resin/epoxy materials
Drawbacks: • Porcelain
• Cost
• Higher viscosity
• Solidifies below -20˚C
Design Margins
Townsend
Mechanism
Avalanche
Breakdown
• This type of breakdown applies to gases and results in a breakdown

voltage which depends on distance
A similar mechanism operates in oil and breakdown voltage

versus gap thickness curves are used
Design Margins
An ionized streamer The oil gaps are generally

starting out will the weak link in the
propagate very fast, insulation system
breaking down the oil
at its tip.
4 mm Oil gap breaking down in 1 /1,000,000 of second

Design Margins
Dielectric Breakdown Types

Insulation Design Method
1) Establish Voltage between parts

Use Volts per turn for AC, transient calculations for impulse
type Voltages.
2) Localized Stress Check
Find stress through Finite Element methods, compare with
allowable limits. Use Stressed Oil Volume or test models to
arrive at design stress levels by using appropriate margin.
3) Oil duct stress limits
Check average stress in oil ducts vs size of duct, apply
appropriate margin.
4) Creep Stress Analysis
Compare creep stress path against Weidmann creep curve

Localized Stress (FEA analysis)
5 mm / 0.2” paper
covering
Oil Volume at
over 90% stress
= 10 cm3
Max Stress 7.5 kV/mm

-190 V/mil
Field (FEA) Plot of Cable with 89 mm/3.5” strike to Ground

Localized Stress
• 10 cubic cm of SOV
gives predicted AC
average breakdown of
10.3 kV/mm AC (260
V/mil)
• Use 60% of breakdown

level (cables have large
breakdown level scatter)
• Max stress allowed for

the cable example is
10.3 kV/mm * 0.6 =
6.2 kV/mm /157 V/mil
Applying Stressed Oil Volume

Localized Stress (FEA Analysis)
Controlling localized stress

Localized Stress Control
• Shielding of sharp points with corona

rings and cable shields

Localized Stress
4 kV/mm / 100 V/mil

10.5 kV/mm/268 V/mil
Too high for bare corner
HV
242 kV
5.5”(140 mm)
• Cable shield reduces local stress down to 38% of previous


Localized Stress
• Charge piles up on the sharp edges of
conductors.
• w/o static ring = 12.5 kV/mm (318 V/mil)
• Exceeds recommended Weidmann design
level of 12 kV/mm HV
HV
• To lower the stress, we shield the

conductor edge w/ static ring
7.7 kV/mm (196 V/mil)
Using static rings to control localized stress
Oil Duct Stress
• Weidmann’s Partial discharge inception curves for 1 minute
a.c. voltages - d in mm
Design for max 80% of P.D.I. (20% margin)
• Appropriate margin from PDI is lower than from breakdown
Obsolete
(pressboard)

Oil Duct Stress
• Use degassed oil non insulated for duct next
to winding (<0.5 mm ins.wall)
• Use insulated case for center ducts
Epb,ac = (kVrms/mm) = 17.5 * d-0.37
Equiv. oil gap = 59 (oil) + 7 (pb) * 2.2/4.4 = 62.5 mm 345 kV hipot test
(230 kV class unit)
Stress at 1st duct= 345 kV / 62.5 mm x
ave/min. gap radius = 6.0 kV/mm Dielectric constants
This is less than the 6.0 kV/mm design limit - OK Oil = 2.2, Pressboard=4.4
Applying oil duct stress in hi-lo gaps between windings.

Creep Stress
Local stress is 5.7 kV/mm (146 V/mil) – ok

Average creep stress is 0.85 x 416 kV / 140 mm
= 2.5 kV/mm
Allowable = 0.8 x 15 x 140 ^(- .37) = 1.92 kV/mm
Creep stress limit is exceeded!
TX spacer
Phase to phase 416 kV

enhanced test cable to cable
5.5” (140 mm separation)
Creep Stress along cable separator

Check for local stress, oil duct stress vs duct size and creep stress

Barriers and extended creep paths

Insulation Coordination
• Transformer oil / pressboard insulation can withstand
higher voltages for shorter periods of time
3 C B A
Relative
strength
2
1 10 102 103 104 105 106 107

time (s)
Oil or pressboard breakdown relative strength vs time - schematic

Volt/Time curve
Impulse: Short term, high Voltage
• Impulse breakdown strength is
• 2.1-4.0 times the 1 min 60Hz
strength
Types of Impulse Tests

• Full Wave Level = BIL
• Chopped Wave = 1.10 x BIL
• Switching Surge = 0.83 x BIL
a, b: lightning simulation
c: breaker simulation
Impulse Wave Shapes

• The voltages from line to ground can be said to be equivalent to a short term applied test.
Also called DIL (design insulation level)
• The voltages within the transformer will not be distributed the same way for each test
• Impulse voltage distribution is very non-linear and varies through the duration of the impulse
• The highest equivalent voltage between the parts of the transformer being analyzed must be
identified for each case – the full range of tests must be considered
• The voltage distribution between parts under impulse can be measured with low voltage impulse
method before the unit is tanked to verify the voltage between parts is as calculated
Converting to Equivalent AC (1 min) - DIL

Voltage Distribution – Capacitive Distribution

Impulse Distribution (Initial Voltage Distribution)
Improving initial impulse distribution with internal shields

Impulse Voltage Distribution – Building a Circuit Model
• The number of coil subdivisions is

arbitrary. Can make finer subdivisions
where voltages are critical.

Impulse Voltage Distribution
• Comparison with
Experiment Test of
an Autotransformer

Impulse Voltage Distribution
• 4 Disks Below the HV impulsed Terminal.

Calculated vs measured Voltages to ground.
• The Voltage distribution was measured before
tanking with a VD (RSO) test using recurring
<100 V impulse waves.

Thermal Design

Thermal Design
• Guaranteed Temperature Rise per IEEE Std C57.12.00
‒ Average Winding Temperature Rise = 65ºC
‒ Hot-spot Winding Temperature Rise = 80ºC
‒ Top Oil Rise = 65ºC
• Ambient Temperature per IEEE Std. C57.12.00

‒ Temperature of cooling air (ambient temperature) shall
not exceed 40°C, and the average temperature of the
cooling air for any 24 hour period shall not exceed 30°C

Thermal Design
• Transformer cooling design must be capable of
dissipating total loss at maximum MVA
‒ Total Loss = No load loss + load loss at maximum MVA
• Standard cooling configuration is ONAN/ONAF/ONAF

• Select number of radiators, type of fans based on
guaranteed sound level
• If an overload requirement is specified, perform overload
calculations to meet specified temperature rise limits and
loss of life limits during overload

Types of Oil Circulation
Natural Circulation
• Most commonly used for Power Transformers
• Due to losses in windings under load, thermosiphon action results in oil movement
in the windings
• With natural circulation, oil velocity is low, resulting in 20–30 degrees C
temperature difference between the bottom and the top radiator oil
• Most economical and lower maintenance; loss of one fan typically results in minor
loss of cooling capacity

Radiator and Fan Considerations

Radiator and Fan Considerations
• Radiators are the most common means used to increase the amount of
exposed oil surface area to the surrounding air
• Hot dip galvanized radiators offer several advantages over standard painted
radiators
• Location of radiators is based on customer preference, footprint and cooling
configuration
• Fans are a relatively inexpensive means to increase the rate of heat
dissipation from the radiators

Types of Oil Circulation
Forced Oil
• Pumps are used to circulate oil, resulting in higher oil velocity and 4–8°C
temperature difference between the bottom and top oil
• Used mostly for mobile transformers and large rating
GSU transformers
• If forced oil is not directed, the oil flow in the winding is natural due to gravitational
buoyancy, addition of the pump impacts cooler performance
• Higher maintenance, loss of one pump results in major loss of cooling capacity

Oil Forced Cooling
OFWF Cooling OFAF Cooling

Forced Oil Directed Cooling
In the forced oil directed arrangement, the cold oil is pumped
into the windings in a predetermined manner to ensure better heat transfer.

Oil Circulation Inside Transformer
Non-Guided Oil Flow Guided Oil Flow
Oil is free to Strategic washers
find its own are placed in the
path from the winding to direct
bottom of the the oil flow along
winding to the specific pathways
top of the
winding

Non-Guided & Guided Flow Washers in Winding
Internal OFW
External OFW

Thermal Software
• Models the entire transformer, including the windings, tank, and radiators; allows
for convection and radiation heat transfer from the tank and radiators with or
without fans
• Calculates the top, mean and bottom tank oil temperature rises
• Calculates each winding gradient
• Calculates steady state and transient overload temperatures
• Determines m and n components, the thermal time constant and loss of life
• Capable of modeling pumped flow capabilities for both steady state and transient
conditions

Thermal Performance

Temperature Rise Tests
• Performed at both self-cooled (ONAN) rating and

maximum forced air (ONAF) rating for all new
designs or as required by customer spec
• Overload temperature rise tests performed if
required by customer specification
• Temperature results from a thermal duplicate can be
supplied as an alternative to performing
temperature rise tests

Temperature Rise Calculations
• Measurements during Temperature Rise Test:
‒ Top oil temperature, Top and bottom radiator oil temperatures, 3 ambient temperatures and Hot winding
resistance at shut down
• Top oil Rise = Top oil temperature – average ambient
• Mean oil rise = average of top & bottom radiator oil
temperatures – average ambient
• Average winding temp = (Hot Resistance/Cold Resistance) * (234.5 + cold resistance ambient) –
234.5
• Winding Gradient = Average winding rise – mean oil rise
• Hot spot Rise = Top oil rise + Hot spot gradient
‒ Hot spot gradient = Average gradient (1 + k)
‒ k = hot-spot factor based on maximum eddies due to actual radial and axial leakage field

Temperature Distribution Model
TOP OF WINDING TOP OIL HOTSPOT
AVERAGE OIL AVG WINDING
PERMISSIBLE AVG WINDING
PERMISSBLE WINDING
HOTTEST SPOT RISE
AND TOP OIL RISE
BOTTOM OF WINDING BOTTOM OIL
65 ◦C 80 ◦C
TEMPERATURE RISE

Winding Gradient
• Average gradient is the difference between the average conductor temperature and the
average oil temperature
in the tank
• Higher the gradient the greater the amount of cooling required
• Gradient ~ current density, watts/square inch of winding surface area, inverse of oil velocity
• Hot spot gradient is higher than average gradient and depends on maximum eddy loss

Leakage flux at different tap position - Example

Hot Spot Temperature Calculation - Results
The inner winding and Winding 3 had to be redesigned to lower

the hot-spot temperature rise below 80°C

Insulation Life

Background
Insulating materials inside a transformer breaks down from
Insulation
Thermal Stresses
Overheating
Partial Discharges
Electrical Stresses
Arcing

Background
• Fault categories
• Localized overheating
• General overheating
• Partial Discharge/Corona
• Arcing
Hydrocarbon Hydrocarbon
Fault Energy
Molecules Gases
• These gases indicate

• Fault condition
• Materials involved in the fault
• Severity of the condition

DGA - Background
Gas Generation in oil verses temperature.

Gases of Interest
Enough useful information can be extracted from 9 gases:

Atmospheric
• Nitrogen (N2)
• Oxygen (O2)
Oxides of carbon
• Carbon Monoxide (CO)
• Carbon Dioxide (CO2)
Hydrocarbons
• Methane (CH4)
• Ethane (C2H6)
• Ethylene (C2H4)
• Acetylene (C2H2)

Gases of Interest (cont.)
Insulation Carbon Monoxide, Carbon Dioxide

Overheating
Thermal Fault
Oil Hydrogen, Methane, Ethane < 150 C
Overheating Hydrogen, Ethylene, Trace Acetylene >
500C
Hydrogen and Methane

Partial Small amounts of Ethane and Ethylene
Discharge
Electrical Fault
Arcing Hydrogen and Acetylene

Small amounts of Ethane and Ethylene

Insulation System
• Combination of highly refined hydrocarbon-based oil and cellulose paper insulation
of high purity makes up the insulation system of a typical oil-filled transformer
• Oil impregnation of the paper allows it to operate at a high voltage stress without
dielectric breakdown
• Insulation deteriorates from the effects of temperature, moisture and oxygen
• Moisture and oxygen content in transformer can be minimized by oil preservation
systems:
‒ Sealed tank design with nitrogen preservation system
‒ Conservator system with an air bladder
• This leaves insulation temperature as the controlling parameter of insulation
deterioration

Failure of Insulation System
General category of events contributing towards failure of
Insulation system:
• Deterioration/aging of insulation over a long

period of time due to exposure to
temperature, moisture and oxygen
• Operating incidents like overload, short-
circuit, and dielectric transients stress aged
insulation

Insulation Requirements
• Maintain dielectric strength for impulse/switching voltages
• Maintain mechanical strength against short circuit stresses
• Mechanical strength deteriorates long before dielectric strength becomes an issue
• Direct and Indirect tests to assess insulation condition
• Direct Tests
‒ Tensile Strength Test used as a measure of deterioration
• First used in the 1920s, criteria for an end of insulation life estimated to be at 50% retained
tensile strength
• Later, levels as low as 20% retained tensile strength were considered to be end of insulation life
• Requires a fairly large sample of insulation, which is difficult to get from
a transformer

Direct tests to assess insulation condition
Degree of Polymerization Test used as a measure of deterioration
• DP test refers to the average number of glucose rings in the molecule (1000–1200 for new
insulation, with an endpoint or minimum of 200
for aged insulation)
• Requires only a small sample of insulation
• DP value provides much better indication of cellulose insulation mechanical characteristics
than loss of tensile strength

Indirect tests to assess insulation condition
• Indirect Tests are performed on the byproducts of paper in the oil
• Most popular
• Oil samples can be taken when the transformer is operating
• Indirect tests
• Dissolved Gas Analysis
• Carbon Monoxide and Carbon Dioxide generated due to degradation of paper
• Furfuraldehyde Analysis by high performance liquid chromatography is a means of estimating
degradation of insulating paper.
• Furfural is one of degradation product of cellulose in oil
• Estimation of DP from Furfural content
• Type of oil preservation, oil degassing, mechanical filtration and electrical discharge affects the
furfural content

Insulation Life
• “Normal” Insulation Life for well-dried and oxygen-free insulation systems with the Hottest-
spot temperature maintained at 110°C (see table below)
• Many transformers last much longer than “normal” life since the hot-spot temperature does
not stay this high constantly due to load and ambient temperature variations
Normal Insulation Life

Criteria
Hours Years
50% retained tensile strength of insulation 65,000 7.42
(from C57.92 criteria)
25% retained tensile strength of insulation 135,000 15.41
200 retained DP in insulation 150,000 17.12
Distribution Transformer Functional Life Test 180,000 20.55
data (former C57.91 criteria)

Loading Beyond Nameplate Rating

Effects of Loading Beyond Nameplate Rating
• Increased loss of insulation life due to higher temperatures

• Generation of free gas at temperatures of ~ 140º C and beyond could result in a
dielectric failure
• Increased resistance in the contacts of tap changers due to build-up of oil
decomposition
• Oil expansion may be greater than capacity of transformer, causing pressure build-
up and pressure relief device operation
• Other risks are cited in IEEE C57.91

Free Gas Generation: Bubble Evolution
• Sources of Bubbles
‒ Gasses dissolved in oil
‒ Gasses generated from decomposition of
insulation
‒ Water vapor from paper insulation
in windings
• Sudden release of gas/vapor as bubbles is
possible under
overloading
• BUBBLE GENERATION FROM
OVERLOADING IS MOSTLY DUE TO
WATER VAPOR RELEASED FROM
PAPER INSULATION

The bubble evolution temperature may be estimated
by the following equation:
6996.7
Θbubble =
22.454 + 1.4495 InWWP - In Ppres
1.585
Vg
- ( EXP (0.473WWP)
) 30
-273
Where:
Ppres Total pressure, mm mercury (torr.)
Vg Gas content of oil, %(v/v)
WWP Per cent by weight of moisture in paper (dry
basis)
Θbubble Temperature for bubble evolution, °C

Bubble Generation
• Gas blanketed units and conservator
units show little difference in bubble evolution at
low moisture levels
• Increasing gas saturation in oil lowers bubble
evolution temperature only at
high moisture levels
• Bubble generation from overload is mostly due to
water vapor released
from paper insulation
• Accepting 140 °C as hot-spot temperature limit
appears to be valid
for moisture content above 1.5%

Temperature Limits for Overload
• Hottest-spot conductor temperature = 140º C for Long Time

and 180º C for short-time emergency loading
• Top oil temperature = 110º C
• Maximum loading = 200%
• IEEE standard temperature rise allows 24H average ambient
of 30º C, with maximum of 40º C
Actual ambient temperatures should be used to

compute the transformer’s loading capability.
Transformers surrounded by buildings/walls can
result in re-circulation of heated air and higher
ambient.

Calculation of Overload Temperatures
• Overload temperature rise must be calculated accurately with a method / software

which can predict m & n exponents and thermal time constant for different overload
conditions
• To limit temperature rise values high speed fans can be used during overload, if
higher sound level is acceptable
• IEEE C57.91 explains two methods for calculating oil and winding temperatures:
‒ Section 7 is a simplified non-iterative calculation that can be put into a spreadsheet
application
‒ Annex G is a computer program written in basic. Utilizes a convergence process to
determine the maximum loading capability. Allows for variation in ambient temperature.
Also provides an estimation of the loss of insulation life for the loading cycle

Industry Practice Transformer Loading
Theoretical Life – Aging Acceleration Factor
15000 15000
𝐹𝐴𝐴 = 𝑒𝑥𝑝 −
110 + 273 𝐻𝑆𝑇 + 273
HST = Hot Spot Temperature C
N
 FAAn tn
n =1
FEQA = N
 tn
n =1

Measurement of Overload Temperatures
• Conventional temperature monitors measure simulated
winding hot spot temperature (top
oil + incremental rise due to winding hot spot gradient
based on CT current) which may not respond quickly
under overload conditions
• If frequent variable overloading is required beyond 125%
nameplate rating then it may be beneficial to measure
winding temperature hot-spot with the help of Fiber optics
device to limit overload to a safe temperature limit; the
following need to be considered:
‒ Probes are difficult to position / locate
‒ Risk of damage during manufacturing of
core and coil assembly
‒ Expensive system ($30k+ with 4–8 probes)

Fiber Optic Installation

Effects of Oxygen and Moisture on Aging

Other factors affecting Transformer Aging
• Time of Overload
• Temperature
• Types of Paper ( thermally upgraded Kraft vs Kraft)

Dynamically Loaded Transformers
• Utilize the transformer Asset closer to actual operating limits without

compromising on Reliability and Life Expectancy
• Fully optimize the loading based on actual ambient conditions
• Forecast the loading and overloading capability of transformers for
emergency, short and long time loading.

Factors to be considered for Dynamic Loading
• Condition Appraisal of the Asset – age, vintage, overall condition, auxiliary

equipment
• Transformer Thermal model – established and verified
• Aging Criteria established
• Deploy Dynamic loading program
• On line monitoring : ex DGA or Fiber optic temperature measurement to
confirm the performance
• Input real time load and weather data (usually from SCADA)
• Monitor real time temperatures

Transformer Health Equipment

Dehydrating Breathers
• Ensure dry air is maintained inside
LTC, conservator, sealed tank or
control cabinet, improving reliability
• Air flows through silica gel to remove moisture
prior to entering air space
• Silica gel may be recharged by heating or
replaced with new gel
• Auto-Recharging Breathers
• Recharge automatically, eliminating the
need for manual regeneration or
replacement of silica gel
• Remote indication of recharging cycles and
equipment alarms is possible

LTC Oil Filtration Systems
• Typically used on non-vacuum LTCs
to remove carbon and metallic
particle contaminants (down to 3
microns) and free moisture in oil
• Maintain condition of LTC oil to
extend the life of equipment and
can extend the period between
maintenance intervals
• Retrofit to existing units in the field

Electronic Temperature Monitors
Examples
• Electronic temperature monitors are becoming more and more common
• Still fairly common to see both analog and electronic monitors for redundancy
• Consider whether or not you plan to do your own programming in the field
• Make sure your spec is clear if you want the transformer manufacturer to do the programming for you as
this can be costly
Its not uncommon for the programming to cost several times more than the device. Scheduling of the
programming with vendor can create delays in production.
Electronic Monitoring
• Monitoring and control are available in a variety of
packages and units, transformer requirement vary by
make and model
• Alarm conditions
• Transformer loading and calculations
• LTC condition and control
• Online DGA
• Online bushing power factor and capacitance
measurement
• Fiber optic temperature monitoring
• Useful on older equipment to monitor unit condition
• Less value on new equipment but does provide
baseline information for future condition assessment

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Transformer Design Concepts

Prolec GE Waukesha / Proprietary and Confidential

Suresh has a Diploma in Electrical Engineering from

Prolec GE Waukesha / Proprietary and Confidential

Prolec GE Waukesha / Proprietary and Confidential October 4, 2022 3

Loss evaluation, Existing

Short circuit, overloading, Dielectric Requirements

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Review Bid Design /Requirements

Finalize design Parameters

Verification Design Sheets

Approval Drawings Release to Shop

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▪ Review bid design, customer requirements and specification

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▪ Balance ampere-turns in LV windings, in case of de-energized taps in the main HV winding

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Axial Forces on Winding Conductors

Radial Forces on Winding Conductors

Combination of Axial/Radial Forces

Because of various directions of forces

Stresses are limited in

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Internal Tank Accessory

Substantial design work is complete with approval package submission.

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• Nomex – for higher temperatures

on metal parts PB RING

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• Insulation between different parts of

• Formvar – conductor insulation

• Copaco (cotton based paper) – leads Inner

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• This type of breakdown applies to gases and results in a breakdown

A similar mechanism operates in oil and breakdown voltage

An ionized streamer The oil gaps are generally

4 mm Oil gap breaking down in 1 /1,000,000 of second

Dielectric Breakdown Types

1) Establish Voltage between parts

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Max Stress 7.5 kV/mm

Field (FEA) Plot of Cable with 89 mm/3.5” strike to Ground

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• Use 60% of breakdown

• Max stress allowed for

Applying Stressed Oil Volume

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Controlling localized stress

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• Shielding of sharp points with corona

Controlling localized stress

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4 kV/mm / 100 V/mil

• Cable shield reduces local stress down to 38% of previous

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• To lower the stress, we shield the