Preparation of Transformer Specification

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 Important learning
 Understanding of transformer parameters and
system requirements
 Proper use of standards
 Awareness on how specification requirements
affect cost
 Increase interactions between users and
manufacturers for mutual benefits
 Importance of Tender Review and Design Reviews
 Obtain maximum benefits from Globalization
 Encourage innovations

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Purpose of Technical Specification
 For User: “To formally and clearly communicate exactly
what the contractor has to deliver”
 For Contractor: “ To be able to offer product and services
which provide a satisfactory solution to user”
 To avoid relationship mishaps associated with costly
variation in work
 To give an opportunity for manufacturer to apply improved
design, material, accessories and manufacturing methods
 To provide an opportunity for users and manufacturers to
work together for the benefit of industry
 To procure lowest life cycle cost transformer not lowest
project price meeting all the system need.

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 Standards
 IEEE C57.12.00, CSA-C88-M90 and IEC 60076 have different
requirements for many parameters. Some examples are:
• Normal or usual service condition
• Rated power
• Over voltage conditions
• Overload capacity at low ambient temperature
• Tolerances on impedance and losses
 Both user and manufacturer to be aware of latest revisions in
standards and also topics discussed in Transformer committee
meetings
 Standards do not by themselves form specifications
 Users to make sure that the standards satisfy their needs
 There is no industry standard or manufacturer standard
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 Ratings
 The transformer’s MV.A rating is usually determined
based on
• Expected load growth
• Available generation
• Expected rate of return on the investment
 Influence the transformer rating:
• Applications such as two windings, auto, step up or
down etc
• Load factor
 Limits the MV.A rating:
• Site location
• Transportation Limitation
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 Single phase vs Three phase
 Determining factors:
• Dimensional and weight limitations
• Transport restrictions
• Air clearances
• Reliability (Risk assessment)

 Specifications for replacement transformer:

• Neutral bushing current rating
• Tertiary bushings current rating
• Type of transformer core
• LTC (same run-through positions)
• Polarity (subtractive or additive)
• Voltage rating of tertiary delta

 If it is economical and feasible (existing foundations, space limitation, etc.), then

should replace the old single-phase transformers with a new three-phase transformer
rather than buying another single-phase transformer .

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 Wye:
Winding Connections
• Graded insulation, Neutral available, LTC is cheaper
• Winding and line currents same
 Delta:
• Fully insulated, Neutral not available, LTC expensive for higher kV
• Winding current is √3 times lower than the line current
 Zigzag:
• Design of windings/connections non standard
• Complex to provide taps, although there are ways to provide them in a
cost effective way
• Low zero sequence impedance and need for a grounding reactor
 If neutral required, then a wye or a zig-zag is economical
 If neutral required on a delta side, then a grounding transformer is
required.
 Suppression of third harmonics often leads to a choice to have one of the
main windings delta connected
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 Stabilizing Windings
 New clause 5.11.1.2 Thermal rating for stabilizing windings (buried tertiary), was added in
C57.12.00 - 2015
• Stabilizing windings shall be designed to withstand the transient and continuous thermal
duty as specified by the user and in accordance with the allowable temperature limits of
section 5.11.1
• In the event no continuous thermal duty for the stabilizing winding can be established
from the user’s specification, the manufacturer shall design the stabilizing winding
considering the circulating current in that winding resulting from a full single phase load
in the largest main secondary winding.
• The manufacturer shall determine the kVA rating for the stabilizing winding based upon
the transformer’s equivalent circuit for a single phase loading condition.
• The manufacturer shall calculate values of average and hottest-spot temperatures for the
stabilizing winding to verify compliance with allowable temperatures. Initial conditions for
these calculations shall be based on the transformer operating at its maximum continuous
rating, before switching to the loading conditions described above in the first or second
paragraph, whichever is applicable.

 Questions may rise:

• kVA rating for the stabilizing winding will vary from manufacturer to manufacturer
• How the thermal design of stabilizing winding be verified? Shut down on Tertiary or
accept the manufacturer’s calculation?

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 Vector Group
 Time angle expressed in degrees between voltages
 The same angle shift between HV and LV can be achieved
by various vector groups
 Vector group has to be carefully selected because
• transformer cost
• system operation
 Each vector group has a different zero sequence
impedance, resulting in different fault currents
 Relative costs of Yd, Dy, Yz and Dz vector groups depend on
voltage rating of each winding, current rating of each
winding and tap changer requirement.

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 Insulation Levels
 Insulation levels to be based on insulation coordination
 Insulation levels to be decided prior to quote process
 Insulation levels have a large impact on cost and losses
 Front-of-wave tests not necessary with present day
arresters
 Understand the risk if higher insulation level for bushings
 Specify details of system transients
 Test levels to be selected from standards

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 Terminals
 Indoor or outdoor, coastal/corrosive/dust etc.
 Highest system voltage , Insulation level of L & N bushings
 Type of terminal (oil-to-air, oil-to-oil, oil-to-SF6 etc.)
 Cover-mounted or horizontally-mounted on the side wall
 Standards to which to comply (IEEE/ANSI or IEC)
 Special details (Bus-duct or any other special requirements)
 Requirement of cap tap and/or potential tap
 Porcelain or composite bushings, Creepage length, External
clearances
 Interchangeability details
 Number of TV terminals

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 Accessories
 List all accessories
 State if certain type/make or model are acceptable
 Manufacturer to provide accessory details in Manual
 Check air-cell compatibility to inhibitor oil
 Specify if certification for revenue metering is required
 For valves specify the size, function and the type
 Details of packing and shipping
 Shipping list to include instructions for storage
 Training of users field personnel is recommended
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 Types of Cooling
 Specify 65°C rise per standards. Avoid specifying 55/65°C rise
 Specify ONAN, ONAF, ODAF as per standards. Avoid OA, FA etc
 ONAN/ODAF/ODAF cooling is beneficial for large ratings
 For units with pump, oil velocity in winding to be verified to
avoid electrostatic charges
 Even at base rating operating with fans/pumps is beneficial
 WTI time constant to be reviewed for different cooling types.
 If load factor is high, single ODAF cooling is more
advantageous.
 ODWF cooling is advantageous if cooling water is available.
For these coolers it is important to specify leak detector
coolers.

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 Sound Levels
 Sound levels stated in NEMA or CSA are higher compare to
what is required due to environmental restriction
 Low sound level has impact on cost
 Sound level on bridging position is important with reactor LTC
 Sound level of Series transformer can vary with tap position

 Sound levels with constant flux and variable flux taps

 Sound level reduction methods
 Sound level at load

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 Tap Range and Location
 Function of taps as defined in standards

 Tap range selection (Adequacy of LTC range to meet

regulation)
 Tap location selection
 LTC selection

 Suggestions to simplify requirements (ex eliminate DETC)

 Formation of oxide film on DETC tap changer contacts
 Working as a team is important

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 Taps in Auto-Transformer
 Avoid specifying taps in the LV line
 If possible avoid specifying DETC taps

 Do not specify both DETC and LTC taps

 Do not specify DTEC taps on the tertiary

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 Items to consider for Taps
 Reliability and cost of non-linear elements (Zno discs) across the taps verses
the designs without the non-linear elements.
 To specify tap changer make and type only when specifically needed.
 At tender review to check tie-in elements effect in service.

 Not to state that selector contacts must not be in main oil.

 RCBN and FCBN.
 Type of tap changer influence on buckling forces on tap winding.
 Current splitting.
 Step-up and step-down operations. Also how the taps are used.
 Vacuum verses non-vacuum tap changers

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 Tap Changer Application
 Constant flux taps (CFVV).
 Variable flux taps (VFVV).
 Mixed regulation taps (Cb.VV).
 Change in types of taps based on step-down operation, step-
up operation, used for input voltage fluctuations or used to
compensate for regulation.
 Types of taps and effect on the following:
• Impedance
• Short-circuit
• Sound level
• Losses
• TV voltage

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LTC location and core flux in two
winding transformers

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LTC location and core flux in autotransformers

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 Tap Changer Types
 LTC:
• Resistor type / Reactor type
• Tank mounted / In-tank
• Vacuum / Non-vacuum with filters
• Reversing / Coarse-fine / Linear
• Use of Series transformer
• Use of Non-linear devices
• Tie-in resistors/capacitors
• Extra continuous current rating, 1.5 p.u. or 2 p.u. etc.
• Taps in body of main winding or as a separate winding.
 DETC:
• Linear/Bridging
• Taps in body of main winding or as a separate winding
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 Impedance
 Definition
 Influence of impedance on system
 Influence of impedance on cost
 Impedance values recommended in standards
 Impedance variation at different tap position
 TV to LV and TV to HV impedances
 Impedance of Zig-Zag transformers
 Impedance values at extreme taps
 Impedance on auto transformers (CIGRE paper "Methods
and Means of Voltage Regulation of Large
Autotransformers“ is a good reference)

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 Loss Evaluation
 IEEE C57.120 is a good reference
 NL loss $/KW, Load loss $/KW at a reference MVA
 Specifying kW/h or loss limit itself may not give optimum
results
 Reference temperatures for loss is important
 Penalty values if loss exceed guarantee
 Encourage innovations to reduce the losses
 IEC recommends incentive for loss tested lower than
guarantee
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 Transformer Optimization

Loss Evaluation:
$3000/kW No Load
$1750/kW Load

Note: All Values Normalized to % Function of Optimal.

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 Over-Excitation
 High over excitation requirement has a bearing on
transformer cost and increases the load losses
 Duration of over excitation has a great bearing on the
selection of the flux density
 Specifying the linearity of the core makes transformer costly
 Specify the exact over excitation the core sees in service to
reduce the transformer cost

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 Short-Circuit Requirement
 Future characteristics of the system

 Sub-transient reactance of rotating machinery

 System and transformer grounding conditions
 Impedances of externally connected apparatus

 Pre-fault operating voltage

 Special requirements for Station auxiliary or GSU
 Terminal arrangement e.g. isolated phase bus etc.

 System impedance, Ratio Zero to Positive sequence impedance

 Short circuit test
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 Short-Circuit Withstand
 Hoop stress on outer windings
 Buckling stress on inner windings
 Axial bending stress on windings
 Stress on insulation axial and radial spacers
 Tilting strength of conductors
 Stress on clamping rings and clamping structure
 IEC standard gives very useful details

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 Special requirements
 Providing specific system/site conditions can help avoid
over-designing
• High and low ambient conditions
• System over voltage
• Pre-fault voltage
• System impedance
• LTC current rating
 Operating temperature, viscosity of the oil in the LTC and
the LTC cut-out temperature setting are to be properly
coordinated.

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 Special requirements
 Operating altitude when above 1000 meters
 Site conditions, High or low ambient, Site pollution levels
 Transport weights/profile restrictions
 Site accessibility/layout of fittings
 GIC, Special switching conditions, GSU back feed
 Types of load like Motors, SVC etc.
 Oil preservation system (Nitrogen pressurized/conservator)
 Special oils like FR3
 Fiber optics, On-line monitoring devices
 Painting, Wheels and similar requirements

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 Overloads
 Overload profile
 Number of occurrences in a year
 Information per clause 9.7 of C57.91
 Hot-spot, Top oil rise, Loss of insulation life
 Operation (step-down or step-up)
 Load on the tertiary (arithmetic, vector loading etc.)
 Ambient temperature at each load
 Requirement of overload test
 DGA levels during the overload test
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 Implications of Overloads
 Evaluation of free gas.
 Loss of insulation life.
 Overheated gaskets resulting in leakage.
 Reduced mechanical strength of the insulation.
 Permanent deformation of materials.
 Tap changer thermal runaway condition.
 Operation of relief devices.
 Excessive pressure built-up in bushings.
 Risk of damage of internal parts (CTs, current limiting devices,
tap changers etc.).
 Increase in regulation.

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 Parallel Operation
 When parallel operation with the existing transformers is required
following should be included in specifications:
• Rated MV.A.
• Exact turns ratio of the windings at all the taps.
• Impedance on rated and tap extremes.
• Diagram of connection and phasor relationship between
windings.
• Compatibility of controls to maintain the correct tap positions on
all transformers while minimizing the circulating current.
• Type of paralleling method preferred
 Impedances should be same at maximum rating for paralleling 2
units of different rating
 User should provide Name plate, LTC schematic and test report
details which would contain all the information for paralleling.
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 Parallel Operation
 Some paralleling methods are given below:
• Master / Follower
• Power factor
• Negative reactance
• Circulating current
• Circulating reactive current
 Paralleling information on the existing units is not proprietary.
 If the tolerances on impedances lesser than those in the standards
are required, then the required tolerances should be stated in the
specifications.
 Parallel operation is user responsibility. Manufacturer designs the
transformer to the specifications.
 IEEE standard C57.153 ‘Transformer Paralleling Guide’ is a good
references
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 Rating Plate/Name Plate
 Size of the letters and numerical defined in (C57.12.00-2010 4mm
minimum)
 MVA for each winding, cooling type including 3 winding, arithmetic or
vector
 Phase diagram, Terminal markings and polarity
 Winding connection, including TV terminal details
 Table for LTC, DTC tap positions, voltages and current
 Voltage transformers, potential devices, current transformers
 Nonlinear devices, capacitors, resistors or other internal devices
 Compliance standard, Year of manufacture
 Tested Impedances on rated and extreme taps
 Vacuum with stand capability, PCB levels
 Future uprating provision(where applicable)
 Limitations if any for reverse power flow (CV current, wind farm units)
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 Alternatives
 Users should consider alternate bids quoted by manufacturer

 Consult the manufacturers to determine the parameters rather asking

alternatives with different parameters (impedance, insulation levels,
winding connections etc.).
 Encouraging alternatives not only saves money to the user but also
helps towards innovation for overall benefit of the industry.
 Work as a team to decide on requirements than asking for many
options to quote
 Management of users and manufacturers should nourish the cost
saving and reliability ideas of their engineers.
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 Suggestion to remove Ambiguity
The clauses that are either ambiguous or will add considerable cost with
almost no benefit should not be included in the specifications. A few are
given below.
• Missing technical information per industry standard.
• Assembled in a manner best suited for the application.
• Best materials should be used.
• Adequate barriers shall be provided.
• No exceptions, no deviations and no alternatives will be accepted.
• Per manufacturer’s standard.
• Life of the transformer must be 40 years.
• Tank should have adequate stiffeners.
• Only bids from the manufacturers with a skilled labor force will be
considered.
• Core should be built with high grade laminations.

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 Suggestion to remove Ambiguity
• Oil should be of good quality.
• Calculations must be by computer programs only.
• Top oil limit of 105⁰C and hot-spot limit of 120⁰C for over loads also.
• Design of the taps should be as CFVV and also as VFVV.
• All components shall provide utmost reliability.
• No abnormal deterioration of insulation in service.
• Should conform to high standards of engineering, design and
workmanship.
• Impedance shall be stated in the order.
• Materials used shall be of established quality.

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 Avoid over specifying
 In tank LTC selector in separate compartment
 Continuous overload

 Arithmetic and vector load for three winding units

 Testing at 25% higher levels than standard

 Short circuit duration of 5 sec

 Infinite bus instead of finite system impedance

 Very high pre-fault voltage

 Many options to quote

 Too much data at quote stage

 Parameters in specification to be refilled in data sheet
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 Data Sheets
 Data sheets should ask only for information needed in quote evaluation

 Important parameters are

• No-load loss at 20°C.

• Load loss at 85°C at a specified MVA and on the rated tap.
• Loss of cooling equipment.
• Type and rating of DETC and LTC tap changers.
• Type and rating of bushings.
• Impedances at rated and extreme tap positions.
• Core or shell type and number of wound legs
 Data sheets are not a substitute to the Tender Review meeting.
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 Tests
 Tests are listed in CSA, IEEE and IEC standards
 Recommend specification ask tests as per standard (ex: Partial discharge in
pC and not micro-volts) unless the system conditions require to test
differently. (switching surge wave shape, single phase induced test etc.)
 Obtain test certificates of all accessories and components (DETC tap
changers, bushings, CTs, pressure relief devices, bolts used for lead
clamping structures, glue used on insulating items etc.)
 Understand testing methods and limitations(ex: Sound level under load)
 Tests before shipping, after receiving at the station, before energization
are very important.

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 Tender Review
 Quote Review meeting is very important and it is recommended to involve all
concerned including consultants.
 Suggest to discuss the following in quote review:
• Manufacturing and test capabilities.
• Quality program and inspections.
• Transportation and Delivery track record.
• Shop failures, investigation & corrections.
• Field problems and how rectified.
• Exceptions/comments in the tender.
• Design of core, coils, tank etc.
• Processing practices of core & coils and oil.
• Taps and suitability for system voltage variation
• Impedance and suitability for operation
• Philosophy of design and manufacture to withstand short-circuits forces and
how it meets system conditions.
• Thermal and overload calculations.
• After sales/warranty service capability

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 Design Review
 Design Reviews involves effort and cost and so the
specifications should state these requirements
 IEC/CIGRE publications provide very good reference
 Items to be discussed in Design Review:
 Magneic circuit
• Flux density in legs and yokes at maximum system voltage
(specially in 5 legged cores and split cores).
• Type of core (core or shell) and joints (step-lap etc.).
• Laminations surface insulation.
• Clamps design for short-circuit forces and for lifting.
• Cooling ducts and core maximum temperature.
• Core grounding.
• Undesirable hot-spots due to the leakage flux.
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Design Review

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Design Review

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 Windings
Design Review
• Design of coils and their construction.
• Types of conductors and their suitability.
• Impact of taps location on short-circuit forces and on insulation
design.
• Cooling design to avoid undesirable hot-spots.
• Stresses in oil and in solid insulation.
• Construction of static shields, stress rings etc.
• On pumped units velocities in different parts.
• Leads exists.
• Off-set, modeling etc. for calculations of forces.
• Design and construction of counter shields, interleaving,
transpositions etc..
• Review of purchasing specifications of winding conductors, all
components and materials.
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 Design Review
 External to the coils
• Design and construction of current limiting reactors, tap
changer reactor, series transformer etc.
• Design of core shunts, clamp shunts, tank shields etc.
• Leads layout, leads structures, clearances etc.
 Accessories
• Principle of operation, construction, mounting etc.
• Safety systems design and location (fall arrest systems,
pressure relief devices, emergency exits etc.).
• Gaskets material and design.
 Manufacturing and processing
• Machinery to cut laminations to avoid burrs.
• Air gaps during core assembly and binding of the core.
• Method of core lifting after the assembly.
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 Design Review
 Manufacturing and processing
• Maintaining tightness of the windings.
• Winding methods, removing from the lathe and sizing.
• Workmanship of installation of counter shields, making
interleaved joints, cross-overs, transpositions etc.
• Vapour-phase process, pre-tanking, moisture control etc.
• Painting specifications and painting process.
 Inspection and testing
• Quality standards and procedures.
• Inspection and tests of raw materials and accessories.
• Pre vapour-phase tests (ratio, vector group etc.).
• Oil tests before filling.
• Factory tests on completely assembled unit.
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 Design Review
 Shipping and installation

• Marking, packing and shipment of the parts.

• Preparation of the main unit for shipment.
• Transportation method and the route of shipment.

• Type and location of impact recorders.

• Pre-shipment tests (SFRA, core megger, power factor etc.).
• Inspection and tests at site before unloading.

• Erection steps and processing at site.

• Pre-commissioning tests.
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 Transportation
 Clearly state if there is any transportation or site restriction on
dimension and weight
 Clearly state the FOB point
 If shipped by rail car then provide nearest rail siding address
 Prefer to state the transformer should be filled with dry air or dry
nitrogen during transportation
 Prefer to state the number and type of impact recorder, mounting
location

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 Globalization
 Specifications are the first and the most important tool
 Use simple English with globally known terminology

 Due to stiff competition safety margins between stresses and strengths

are reduced by almost all the manufacturers
 After sales service capability is a very important factor
 Update the specifications from the good experiences in other
standards and countries
 Specifications should include user maintenance practices, safety
requirements and transport limitations
 Some countries give subsidies for export. This makes local
manufacturers bankrupt and the local knowledge to evaporate.
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 Conclusion
 Technical specification is most important document to procure
reliable and cost effective transformers
 Users to devote adequate resources and time for evolving the
specification
 Pre-bid meeting between user and manufacturer is important
 Standards are to complement the specifications and does not
form a specification themselves
 Users should not be averse to alternate technical solutions
 Manufacturers to understand system requirements and how
parameters affect operation of unit
 Manufacturers to understand the importance of
transportation, erection, commissioning and maintenance of
transformers
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 Conclusion
 Technical personnel of both teams to work without barriers
 Innovations are important for the industry and so
management of both sides to encourage this aspect
 We should work towards a global guide for transformer
specification
 There are lessons to learn from other countries where
standardization and cooperation efforts have resulted in Win-
Win situation
 User and manufacturer to work as a team to achieve overall
benefit to the industry

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Q&A?

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