Transformer Types Ieeemvtrans 2011

IEEE SF / IAS Seminar
April 2011
Finn Schenck
Schneider Electric
Transformer Types
Liquid-Filled Unit Substation

Liquid-Filled Padmount
Schneider Electric - Projects and Services PEC MV Transformers - 2010
Transformer Types
VPI Dry Unit Substation

Cast Unit Substation
Dry Vs. Liquid Transformers

DRY
No fluid to spill or burn
Cost is higher than oil
Resistant to moisture
Minimum Maintenance
UL Listed
Liquid
Lowest Purchase Price
Sealed Tank
Lowest Losses per $
UL Listing
Loads of Options
Pad Mounted (TamperResistant)
Substation Flexible
Definitions (Buzzwords)
BIL (Basic Impulse Level)
The level of momentary over voltage that the transformers insulation can withstand
without damage/failure.
IMPEDANCE
The percentage of rated voltage required to circulate rated current in one winding with
the other winding short circuited.
EXAMPLE
A transformer with a 5.75% impedance and a 480 volt low voltage winding would require
(0.0575 x 480 volt) or 27.6 volts to circulate rated current.
IN SHORT Impedance is simply the opposition to the flow of current in the transformers
windings.
(Impedance has a resistive and an inductive component.)
REGULATION
The drop in secondary voltage that occurs as the load on the transformer is increased
and is expressed as a percentage of rated voltage.
EFFICIENCY
The ratio of power absorbed by the transformer to the total power drawn from the supply
line.
Rule of Thumb Cost Comparison

Mineral Oil
Hi Fire Point Seed Oil
VPI
VPE (Epoxy)
Cast Coil
Lower Temerature Rise
Copper
5 DB Noise Reduction (Dry)
Hinged Doors on Dry and Cast Enclosures
I.R. Viewing Windows on Dry and Cast Encl.
Insulated Bus on VPI and Cast Encl.
1.0
1.2
1.25 1.75
1.35 1.85
1.55 2.0
15 % to 40 % Add
35% - 35% Add
10%
A bargain
An Even Better Bargain
$2K 5K, but a good
idea just the same.
6
H.V. BIL Comparison

Voltage Class
Dry Type
Std
Opt
Liquid/Cast
Std
Opt
2.4 KV
5 KV
8.3 KV
15 KV
25 KV
35 KV
46 KV
20 KV 30 KV
30 KV 45 KV
45 KV 60 KV
60 KV 95 KV
110 KV 125 KV
150 KV --------------
45 KV
60 KV
75 KV
95 KV
125 KV
150 KV
250 KV
60 KV
75 KV
95 KV
110 KV
150 KV
200 KV
------
Impedance
IEEE Standard
5.75 Nominal for 750 kVA and Above
Manufacturers standard within the IEEE Standard range for 500 kVA and
below
Large units and higher voltages have different standards
Note
IEEE allows a +/- 7.5% Tolerance
Example for 5.75% Impedance Range would be 5.32% to 6.18%
Insulation Classes
TRANSFORMER
TYPE
INSULATION
CLASS
WINDING
RISE
MAXIMUM
AMBIENT
HOTSPOT
GRADIENT
HOT SPOT
TEMPERATURE
POWER-DRY
220 DEG. C
150 DEG. C
+ 40 DEG. C
+ 30 DEG. C
CAST COIL
185 DEG. C
115 DEG. C
+ 40 DEG. C
+ 30 DEG. C =
LIQUID-FILLED
120 DEG. C
65 DEG. C
+ 40 DEG. C
+ 15 DEG. C =
220 DEG. C
185 DEG. C
120 DEG. C
Temperature Rise
Dry
150 Degree C
115 Degree C
80 Degree C
Standard
Optional
Optional
Cast
115 Degree C
80 Degree C
Standard
Option
Liquid Filled
65 Degree C
55/65 Degree C
Standard
Optional
10
Altitude
STANDARD: Designed for operation at a maximum altitude of

3300 ft. (1000m) above sea level
If a non standard condition exists (i.e.. Altitude above 3300 ft ASL
then:
Transformer must be de-rated or
Transformer must be specifically designed for the special altitude
consideration.
11
OVERLOAD EXAMPLE
3000 kVA Dry Type Xfmr.
Temp. Rise
(Deg. C)
150
kVA Rating
(AA)
Fan Cool Rating

(FA)
Base kVA
(3000)
AA + 33%
(4000)
115/150
Base kVA + 15%,

(3450)
AA + 33%
(4600)
80/150
Base kVA + 35%

(4050)
AA + 33%
(5400)
12
NEMA Standard Sound Levels

kVA
51-150
225-300
301-500
501-1000
1001-1500
1501-2000
2001-2500
2501-3000
3001-4000
4001-5000
7500
10,000
LIQUID-FILLED
51
55
56
58
60
61
62
63
64
66
67
68
VPI
55
55
60
64
65
66
68
68
70
71
75
78
CAST
N/A
58
60
64
65
66
68
68
70
71
75
78
NOTE: ALL VALUES ARE IN DECIBELS (db) AND ARE FOR BASE kVA RATINGS (FAN PACKAGES WILL INCREASE
db LEVELS)
13
Energy Efficient (EE) MV Transformers

The Department of Energy (DOE) has determined that energy conservation
standards for MV Distribution Transformers will result in significant conservation
of energy so they have passed DOE 10 CFR Part 431 Energy Conservation
program for Commercial Equipment.
Starting January 1, 2010 all medium voltage distribution transformers with
ratings of 2500 kVA and below, 34.5 KV primary and below and 600V class
secondary voltages must meet minimum efficiency requirements.
Liquid Filled Padmounts, Liquid Filled Substations, Dry Type VPI and Power
Cast products MANUFACTURED after January 1, 2010 are all included.
EE Low Voltage transformers implemented in 2006, this law is extending
efficiencies to Medium Voltage.
14
DOE Energy Efficiency Applies to:

Medium Voltage Liquid
10-833 kVA 1 phase
15-2500 kVA 3 phase
2. Medium Voltage Dry

15-833 kVA 1 phase
15-2500 kVA 3 phase
15
Minimum Efficiency Tables

Liquid Filled
Table I.1 - Standard levels for Liquid Immersed Distribution Transformers,
tabular Form
Table I.1
kVA
10..
15..
25..
37.5
50
75
100.
167.
250.
333.
500.
667.
833.
Single Phase
Efficiency %
98.62
98.76
98.97
99.01
99.08
99.17
99.23
99.25
99.32
99.36
99.42
99.46
99.49
kVA
15
30..
45
75.
112.5.
150..
225.
300..
500..
750..
1000
1500
2000.
2500
Note: All efficiency values are at 50 percent of nameplate-rated load,
Appendix A, DOE Test procedure. 10 CFR Part 431, Subpart K
Three Phase
Efficiency %
98.36
98.62
98.76
98.91
99.01
99.08
99.17
99.23
99.25
99.32
99.36
99.42
99.46
99.49
determined according to the
16
Applies to all Transformers Sold in:

All 50 US States
Unincorporated Territories (Possessions): American Samoa, Guam,
Marshall Islands, Puerto Rico, US Virgin Islands
Freely-associated states: Federal States of Micronesia, Northern
Marianas, Palau
17
Does not Apply for Transformers

Exported to a country outside the US
Armed Forces bases located outside the US unless specified or to a US
territory
US Embassies unless specified
18
Transformers Affected:
Have an input voltage of 34.5 kilovolts or less;
Have an output voltage of 600 volts or less; and
Are rated for operation at a frequency of 60 Hertz
19
Excluded Transformers
A transformer with multiple voltage taps, the highest of which
equals at least 20 percent more than the lowest;
A transformer that is designed to be used in a special purpose
application and is unlikely to be used in general purpose
applications, or
Any transformer not listed in this definition that is excluded by the
Secretary by rule
20
Excluded Transformers
Autotransformers
Drive (isolation) transformers
Grounding transformers
Machine-tool (control) transformers
Nonventilated transformers
Rectifier transformers
Regulating transformers
Sealed transformers
Special-impedance transformers
Testing transformers
Transformer with tap range of 20 percent or more
Uninterruptible power supply transformers
Welding transformers
Step up Transformers
21
Seismic
22
Liquid Filled Transformers
Padmount
Unit Substation
23
Liquid Filled Padmount

Product Scope:
75-5000kVA
55, 65, 55/65 Temp. Rise
2.4 - 34.5kV Class Primary 150kV BIL Max
600V - 5kV Class Secondary 75kV BIL Max.
Self-Cooled Overload Only (12% with 55/65)
ONAN only - NO ONAN/ONAF (no fans)
No Fans means, NO FANS!
Weather Resistant high and low voltage compartments
Tamper-Resistant Design
(Available up to 20,000 kVA via special quotation)

24
Fluid Offerings
MINERAL OIL
Type II (Inhibited) Ergon Hyvolt II
Mainly Outdoor (Fire Point = 165 Deg. C)
Least Expensive of all Fluids
BIOTEMP
(ABB)
Renewable Natural Agricultural Product
Certified by UL as Less-Flammable Fluid
Fire Point = 360 Deg. C
Factory Mutual Approved
Biodegrades 97% in 21 days
No fusing restrictions
LESS FLAMMABLE SEED OIL
FR3 FLUID
(Cooper Industries)
Extends insulation life
25

Bay-o-net
Fuses
Temperature
Liquid Level
Tap Changer Gauge Pressure Relief Gauge
Upper Fill Plug
valve
Pressure
vacuum
Gauge
HV
Compartment
LV Compartment
HV Bushings
Drain
Valve
LV Bushing
Name Plate
26
Radial Feed vs Loop Feed

A.
Radial Feed
3 HV Bushings
B.
Loop Feed
6 HV Bushings
A transformer with loop feed construction can be used on 2 types of systems:

1. Dual Source Radial Feed
2. Loop Feed System
27
Live Front Construction

Contains exposed current carrying parts in HV
compartment (IEEE C57.12.34)
Components: Porcelain Bushings
Live Front bushings arranged in horizontal pattern,

Radial and Loop Feed
28
Live Front Transformer

Note: 5/8 eyebolt terminal-optional 2 or 4 hole pad is available by special quote
29
Dead Front Construction

No exposed current carrying parts HV compartment (IEEE
C57.12.34)
Components: Wells, Inserts, One Piece Bushings, Feed-thru inserts
Available In: 15, 25,35kV Classes
Available In: 200 Amp - Loadbreak
600 Amp - Non-Loadbreak
Note: Can not interchange different classes of components.
Radial Feed: Bushings in horizontal pattern.

Loop Feed: V Type Configuration
30
Dead Front-Radial Feed

Dead Front-Loop Feed

31
Dead Front Bushing Well

32
Bushing Insert
33
No Load Tap Changer
34
35
Switching
All transformers (radial and loop feed construction) are not equipped with
HV switches. Switching can be accomplished remotely.
Padmount can be equipped with:
1. Two Position (ON-OFF) Switch
(Can be used on radial and loop units.)
2. Three Position Switch
Line A Only, Line B Only, Off
(Dual source application.)
3. Four Position Switch - Permits Sectionalizing
(Loop feed transformers only.)
36
Arresters
Arresters
Silicone carbide or MOV (Metal-Oxide Varistor) most common.
Operation
MOV is a granular ceramic (semi-conductor)
Conducts during a High Amplitude Transient and diverts excess voltage to
ground
Provides a transient path to a common point earth ground.
37
Bayonet Type Fuse
38
39
40
41
42
Liquid Filled Unit Substation
43

225-10,000kVA
55, 65, 55/65 Temp. Rise
2.4 - 34.5kV Class Primary - 250 kV
BIL Max.
600V - 8.7kV Class Secondary - 75kV BIL Max.

ONAN/ONAF also known as AA/FA
Available up to 20,000 kVA - 69 kV primary, 5 kV up to 34.5 kV
secondary via special quotation with Square D Name Plate.
Now available up to 60 MVA base rating, 161 KV primary, 34.5
Secondary with ABB Name Plate
44

Standard efficiency (Energy Efficient per DOE2010)
K-Rated units
UL Listing
Factory Mutual
Evaluated loss designs
Oil, Silicone, and Less Flammable Seed Oil
45
Fluid Offerings
MINERAL OIL
Type II (Inhibited) Ergon Hyvolt II

Mainly Outdoor (Fire Point = 165 Deg. C)
Least Expensive of all Fluids
SILICONE
(Dow Corning 561)

Less Flammable Liquid (Fire Point = 343 Deg. C)
Indoor Use
Expensive Fluid
BIOTEMP
(ABB)
Renewable Natural Agricultural Product
FR3 FLUID
(Cooper Industries)
46
Unit Substation Transformers

Close coupled to HV or LV switchgear
Includes throats, flanges, etc.
Coordination through Unit Substation Coordination Group
Stand alone with full or partial height ATCs

Connection to HV Non-Seg Busway or LV I-Line Busway
Includes standard 12 Throat
Busway Plant will provide connection box to throat
Coordination through MV Transformer Group
Special retro-fit connections/dimensions available
47

Cooling Options
(ONAN)
Self-Cooled
(Oil Natural Air Natural)
(55/65 Deg. C Self-Cooled = 12% Overload)
(ONAN / FONFA) *
Self-Cooled With Provisions For Future

Addition Of Fans
(ONAN / ONFA) *
Self-Cooled With Fans To Provide Additional

Capacity
*NOTE: Controlled By: Top Of Oil or Winding Temperature Indicator

(Winding Temp Ind. is expensive option)
48
Liquid Filled Transformers
Fans Increase Capacity As Follows:

< 2000 kVA
Increase
15%
2500 Through 10000 kVA

Increase
25%
49
Arrester Classes
1. Distribution Class
Heavy Duty Type
2. Intermediate Class Higher Energy Handling Capability

3. Station Class
Note:
Provide Greatest Degree Of Protection,

Highest Level Of Energy Handling, Max
Capability = 80kA
Intermediate or Station Class Arresters require larger ATCs
50
51
52
End of Section
53
Dry Transformers
54
Dry Transformers
Advantages
Excellent for Indoor Use
Schools, Hospitals, Office Buildings
Locations where a liquid spill can not be tolerated
No containment pit required, providing for lower installation and
maintenance costs
Non-Flammable
220C Insulation Class
Will not support combustion
Approximately the same Price of a Seed Oil Unit

Most economical when compared to UniCast II or PowerCast II
55
Dry Transformers
Disadvantages
Lower BIL Levels than Liquid Filled
Standard for 15kV Class is 60kV BIL, Liquid Filled is 95kV BIL
Standard for 600V Class is 10kV BIL, Liquid Filled is 30kV BIL
Moisture Absorption
Must pre-dry unit before energizing to eliminate moisture from coils
More Susceptible to Airborne Contaminants

Ventilated enclosure, contaminants may accumulate on coils
56
Picture of VPI Process
57
Dry Transformer
COOLING OPTIONS
(AA)
(AA/FFA)*
(AA/FA)*
*
Self Cooled
Self Cooled with provisions for future forced air
Self cooled with forced air
Capacity will be increased by 33 1/3% with the addition of fans
For example:
1000kVA @ 150C = 1000/1333kVA
1000kVA @ 115/150C = 1000/1150/1533kVA
1000kVA @ 80/150C = 1000/1300/1733kVA
58
Selectable Product Scope

225 - 5000 kVA
150, 115, and 80 Degree C Rise
2.4 - 34.5 kV Class Primary
150kV Primary BIL
600V - 5kV Class Secondary
(Available up to 13,000 kVA via special quotation)
59
Cast Coil Transformers

Power Cast II and UniCast II
60
Cast Resin Transformers

(The Need)
Replacement for Askarel
(Non-Flammable)
Environmentally Safe
(By Products of Combustion)
BIL Equivalent to Liquid Filled

Primary Voltages Higher than Dry Type
Mechanical Short Circuit Strength
(Superior)
61

(The Coil)
HV/LV Coil
62
LV Coil w/Cooling Ducts
63
Core/Coil Assembly
64
Benefits
Cast Coil vs. Liquid
No Fluids to Leak, Contaminate, or Burn
Far Less Maintenance, No Yearly Fluid Testing
No Decommissioning Costs
Higher Short Circuit Strength
Non - Flammable
Longer Design Life when compared to Mineral Oil
Greater Fan Overload Capability
Lower Installation Costs
65
Benefits of Cast Coil vs.

Conventional VPI
Resistant to Moisture and Contaminants
Higher Standard BIL Levels
Lower Operating Costs
Lower Standard Temperature Rise - 80 vs 150
More Efficient
Less Maintenance
Longer Design Life

More Reliable
Greater Design Flexibility
Higher kVA Ratings
Higher Primary and Secondary Voltages
66
IMPEDANCE
DEFINITION
The percentage of rated voltage required to circulate rated current in one
winding with the other winding short circuited.
EXAMPLE
A transformer with a 5.75% impedance and a 480 volt low voltage winding
would require (0.0575 x 480 volt) or 27.6 volts to circulate rated current.
IN SHORT
Impedance is simply the opposition to the flow of current in the transformers
windings.
(Impedance has a resistive and an inductive component.)
67
IMPEDANCE
High or Low Impedance does not necessarily mean Low or High Efficiency.
Impedance consists of two components:
1) A Resistive Component
2) A Reactive Component
%IZ =
( % IR ) 2 + ( % IX ) 2
68
Efficiency
Definition:
The ratio of power absorbed by the transformer to the total power drawn from the supply
line.
Efficiency can be calculated using the following formula:
EFF = [1 - (Y + (L)2 (X))/(100L + Y + (L)2 x)] 100
Where X = % IR @ 100% Load
Cosine 0
Cosine 0 = Power Factor
Cosine 0 = Power Factor
% IR = Load Loss (KW) x 100

Rated kVA
% FE = No Load Loss (KW) x 100

Rated kVA
Y = % FE @ 100% Load
Cosine 0
L = Load Factor
(Per Unit Load)
= % Load
100
69
Example:
What is the efficiency at 100% load and 1.0 power factor of the 75kVA
transformer with:
No-Load Loss: 341 Watts
Load Loss: 1478 Watts
Impedance: 3.45 %
% IR = (1.478/75) x 100 = 1.97
PF
= 1.0
= % IR = 1.97 = 1.97
PF
1
% FE = .0341 x 100 = 0.454

75kVA
Y
= % FE = 0.454 = 0.454
PF
1
= % Load = 100 = 1
100
100
70
Heat Dissipation
Some consultants think that a transformer with a lower

temperature rise is better for vault and indoor applications. This
is not correct.
Transformers have losses.
Each watt of total loss = 3.413 BTU/Hr
Multiply the total loss by this value to determine the heat which
must be dissipated by air conditioning, ventilation, etc.
71
Tests
WINDING RESISTANCE
PURPOSE: The fundamental purpose of this test is to supply resistance data which
will be used to calculate I2R conductor losses and winding temperatures. It also
enables a check of coil continuity and hence, is often used in the field as an indicator
of possible damage to any internal coil connections.
RATIO, POLARITY, AND PHASE RELATION

PURPOSE: To verify that the transformer has the correct number of turns in each
winding (ratio and that the polarity and phase relationship of the windings are correct.
INSULATION POWER FACTOR

PURPOSE: To verify that the transformer has been properly dried and that its
moisture content is not excessive. Insulation power factor is defined as the ratio of
power dissipated in the transformer insulation (in watts) to the product of the effective
voltage and current (in volt-amperes) while being tested with a sine-wave voltage.
72
Tests
EXCITATION LOSS
PURPOSE: To verify that excitation losses, which consist primarily of winding losses
due to exciting current and losses in the transformers core, meet guaranteed values
promised to the customer.
EXCITATION CURRENT
PURPOSE: To verify core construction quality
LOAD LOSS
PURPOSE: To verify that the load losses meet the guarantees given to a customer.
IMPEDANCE
PURPOSE: To verify guarantees given to the customer.
73
Dielectric Tests
APPLIED POTENTIAL TEST
PURPOSE: To verify that the dielectric strength of the insulation from
winding to ground and winding to winding is adequate.
PROCEDURE: A voltage level defined by IEEE is applied to the winding
under test for a period of 60 seconds. (34KV for 15 KV, 95KV BIL Units)
INDUCED POTENTIAL TEST
PURPOSE: To verify the insulation between turns and layers of the same
winding, and phase to phase clearance is sufficient.
PROCEDURE: A special high frequency generator is used to prevent the
core from saturating due to the high voltage that is induced in the winding.
(120, 180, 240 or 400 Hz are commonly used). A voltage up to two times
the rating of the winding is applied for a period of 7200 cycles.
74
Impulse Test
PURPOSE
To verify that the transformer

insulation (BIL) can withstand the
transient over voltages.
TYPES OF IMPULSE TESTS
Half Wave
Full Wave
Chopped Wave: A more severe
test as it simulates a transient that is
chopped to ground by an arrester
QC impulse is done on all of our

products. This impulse test includes
full and half wave. The Chopped
Wave is included when ANSI
Impulse Test is included in the
specification.
75
Design Tests
TEMPERATURE RISE TEST
PURPOSE: To verify that the top oil and winding temperature rise does not
exceed the guaranteed levels under full load operation.
SOUND LEVEL TEST

PURPOSE: To verify that the sound level produced by the transformer is
within guaranteed values. The principle noise associated with transformers,
aside from that produced by any cooling fans, is an audible hum due to a
phenomenon called Magnetostriction. When core steel is excited by a
magnetic field it contracts slightly. This dimensional change which occurs
120 times per second for a 60 cycle system (once every half cycle) is
defined as Magnetostriction.
76

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IEEE SF / IAS Seminar

Liquid-Filled Unit Substation

Schneider Electric - Projects and Services PEC MV Transformers - 2010

VPI Dry Unit Substation

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Dry Vs. Liquid Transformers

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Rule of Thumb Cost Comparison

Schneider Electric - Projects and Services PEC MV Transformers - 2010

H.V. BIL Comparison

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

STANDARD: Designed for operation at a maximum altitude of

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Fan Cool Rating

Base kVA + 15%,

Base kVA + 35%

Schneider Electric - Projects and Services PEC MV Transformers - 2010

NEMA Standard Sound Levels

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Energy Efficient (EE) MV Transformers

Schneider Electric - Projects and Services PEC MV Transformers - 2010

DOE Energy Efficiency Applies to:

2. Medium Voltage Dry

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Minimum Efficiency Tables

Applies to all Transformers Sold in:

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Does not Apply for Transformers

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Liquid Filled Transformers

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Liquid Filled Padmount

(Available up to 20,000 kVA via special quotation)

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Liquid Filled Padmount

Upper Fill Plug

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Radial Feed vs Loop Feed

A transformer with loop feed construction can be used on 2 types of systems:

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Live Front Construction

Live Front bushings arranged in horizontal pattern,

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Liquid Filled Padmount

Live Front Transformer

Dead Front Construction

Radial Feed: Bushings in horizontal pattern.

Liquid Filled Padmount

Dead Front-Radial Feed

Dead Front-Loop Feed

Liquid Filled Padmount

Dead Front Bushing Well

Liquid Filled Padmount

Liquid Filled Padmount

No Load Tap Changer

Schneider Electric - Projects and Services PEC MV Transformers - 2010

Liquid Filled Padmount