The Making of a Power Transformer

Typical cooling arrangements

1 3 4 Discussion:
1. Standard ONAN cooling with fans for ONAF
2. Integral mounted radiator (ONAN,AF,OF)
3. Separately mounted radiator (ONAN,AF,OF)
4. Integral oil / water cooler (OFWF)
2 5 5. Integral oil / water cooler (ODAF)
• Different types of transformer oils and what are
PCB oils?
• Precautions to be taken while selecting transformer
cooling arrangement in areas suspended with fine
sand particles (desert area)
• How oil quantity is selected for optimising the
transformer MVA rating.
Assignment:
• Select the most optimum cooling type and corresponding rating for a station transformer (220kV/6.9kV,
31.5MVA).
• Select the number of / radiators and fans required as standby for the above transformer and justify the
selection based on capital cost and running cost considerations
Power Transformer…
1.0 GENERAL Discussion:
1.1 Application/ 1. Different applications of power transformers
Designation
2. The meaning of full load rating and the overload
1.2 Quantity capability of a power transformer
1.3 Installation 3. Restrictions of a three phase transformer design
1.4 Type 4. Use of different types of winding design
1.5 3 Phase / Single Phase Unit

1.6 Rating of each unit

1.7 Cooling -
1.8 ONAN / ONAF / OFAF rating
a) Pri , Sec,Teri

Assignment:
• What are the factors which decide if a large transformer is to be designed as single phase units or three
phase unit?
Power Transformer…
2.0 RATINGS Discussion:
2.1 No load voltage
1. Selection of MVA rating for each winding
2.1.1 Primary Winding
2. The ratio of rating corresponding to different
cooling methods
2.1.2 Secondary/ Tertiary Windings
3. What is vector group and its relevance
2.2 Frequency
2.3 Rating for each type of cooling
4. Percentage impedance and the tolerance limits
ONAN , ONAF, OFAF 5. Impact of percentage impedance on transformer
performance

2.4 Percentage impedance

a) Primary to Secondary
b) Primary to Tertiary
c) Secondary to Tertiary
Assignment:
• How is transformer regulation taken into account while
deciding on transformer no load ratio for a generator
transformer connected to 11kV and 220KV system.
• Can auto wound type of transformer be used for
stepping up generator voltage?

Assignment:
• How is the transformer primary rating calculated if a 3 winding transformer is used to step up two
generators.
• List out the different vector group combinations used in power plants
Power Transformer: Core and coil
3.0 CORE Discussion:
Whether overfluxing as per clause 4.6 1. What is overfluxing?
and 4.7 (b) & (c) of Section - D
required 2. Impact of overfluxing and design limitations
4.0 WINDING CONNECTIONS 3. Relevance of star, delta and unloaded delta
4.1 Winding Connection (Vector Group)
connection
4. What is power flow direction?
HV (primary)

HV ( secondary)

HV (Tertiary)

4.2 Application / Direction of Power Flow

Assignment:
• What is the specification for overfluxing limits for generator transformer application. Which are the
other transformers in a power plant which requires overfluxing withstand capability?
Power Transformer: System data
5.0 SYSTEM DATA Discussion:
5.1 System Voltage
1. Difference between Nominal and Highest voltage
HV - Nominal / Highest
2. Why system neutral is earthed?
MV - Nominal / Highest
LV - Nominal / Highest 3. How to ground a system without neutral?
(Delta connected system)
5.2 Fault Level
5.2.1 Primary
4. What is power flow direction?
5.2.2 Secondary
5.3.3 Teritiary
5.3 System Neutral Earthing :
a) Effectively
b) Resonant
c) Non-effectively
d) Isolated

Assignment:
• Does system neutral grounding effect the nominal and highest voltage?
Power Transformer: Insulation
6.0 WINDING INSULATION
Discussion:
a) Uniformly insulated 1. Do we need to specify the winding insulation?
b) Non-uniformly insulated
2. What is uniform and non uniform insulation
3. Advantages of non uniform insulation

Assignment:
• List out the transformer connections and voltage levels for which non uniform insulation design can be
adopted
Power Transformer: Insulation level
8.0 WINDING INSULATION TEST VOLTAGES
Discussion:
8.1 Impulse voltage withstand +ve/-ve (1.2 / 50s
Wave)
1. What is BIL and its relevance to winding
insulation
HV/ MV/ LV(primary/ secondary/ tertiary
2. Power frequency high voltage with stand level
HV Neutral/ MV Neutral (Effectively earthed)
3. Should system BIL and transformer BIL be same?
HV Neutral/ MV Neutral(Earthed through
resistance) 4. What is lightning impulse and switching impulse
8.2 Power frequency voltage withstand (Separate
source /
Induced voltage)
HV/ MV/ LV(primary/ secondary/ tertiary
HV Neutral/ MV Neutral (Effectively earthed)
HV Neutral/ MV Neutral ( Earthed through
resistance)

Assignment:
• List out the BIL and power frequency withstand level for : 33kV,66kV,110kV,220kV,400kV,765kV
systems
Power Transformer: Temperature rise
9.0 TEMPERATURE RISE Discussion:
9.1 Ambient temperature
1. Relevance of ambient temperature (mean,
maximum and minimum)
9.2 Temperature rise of top oil by 2. How does temperature effect the life of
thermometer transformer
3. What is hot spot temperature
9.3 Maximum temperature rise of
windings by resistance 4. Overload capability of transformer

Assignment:
• What is the limit for winding and oil temperature rise?.
• How is winding and oil temperature measured in a transformer?.
Power Transformer: Tapping
10.0 TAPPING
Discussion:
10.1 Tapping on windings 1. How to vary the voltage in a transformer
2. Difference between on load and off circuit taps
10.2 Whether on load / off-circuit
3. Selection of tapping range and step
10.3 Tapping range
4. Different types of voltage variation associated with
10.4 Tapping step tap changers (Constant voltage / constant flux)
10.5 Category of voltage variation (As 5. What is the relationship between transformer
per IEC : 60176) rating and tap capacity.
10.6 Voltage class of OLTC 6. Location of taps in the winding and the voltage
10.7 Capacity rating of OLTC
7. Difference between AVR for tap change provided
for step down transformer, step up transformer and
ICT

Assignment:
• Study the arrangement required to parallel transformers with on load tapchangers
• How is reactive power flow controlled using OLTC in generating station.
Power Transformer: Bushings
1. Rated Voltage class – kV Discussion:
1. Why do we require a bushing
2. Rated Current class – A
2. Different types of bushings
3. What is creepage distance
3. Minimum clearance in air - mm
4. Relevance of clearance in air and in oil
(ph-ph/ph-gnd)
5. How to protect a bushing from lightning impulse
4. Minimum creepage distance (Total) – 6. What is Bushing Current Transformer?
mm

5. Protected creepage distance (min) – mm

Assignment:
• How is creepage distance selected and what are the standard norms.
Power Transformer: Misc. aspects
1.0 Other optional accessories as per Section –
D, Clause No. 21.
Discussion:
1.1 WTI/OTI transducers
1. Remote indication of transformer oil and winding
temperature
1.2 Colour shade of final painting
1.3 Bolted joint near base of tank
2. Tank construction (bell type !)
1.4 Skids 3. What is a skid?
1.5 Wheel (Required only for all) 4. How to chose type of wheels
1.5.1 Plain / Flanged 5. What is anti earthquake clamping device
1.5.2 Unidirectional / Bi-directional
6. Why transformer tank and radiators should be
1.5.3 Additional wheels for stability required designed for withstanding vacuum.
1.6 Vacuum withstand capability 7. Transporting large transformers- precautions to be
1.6.1 Main tank with bushings, fittings and accessories taken
1.6.2 Radiators

1.7 Transformer to be transported:

a) Filled with oil
b) Without oil with inert gas, gas cylinder, reducer
connection, pressure gauge
Interconnecting Transformer (ICT)
Conservato
r

Oil level
Bushing switch
Conservato
r
Oil
Bushing sampling
pipe
LA
Bucholz
relay
Bushing
Turret

Tertiary
grounding

Radiator

Cooling fan Transforme Transforme Transforme

r rail r tank r Oil pit
Cast Resin- Dry Type Transformer

Transformer enclosure

3Phase core type