IET Electric Power Applications

Research Article

ISSN 1751-8660
Application of grounded metallic enclosing Received on 7th October 2015
Revised on 4th December 2015
mesh for expanding rated voltage of Accepted on 26th December 2015
doi: 10.1049/iet-epa.2015.0449
dry-type transformer www.ietdl.org

Luiz F. de Oliveira 1, Sérgio H.L. Cabral 2 ✉

1
Departamento de Engenharia, WEG T&D, Blumenau, Brazil
2
Departamento de Engenharia Elétrica e Telecomunicações, Universidade de Blumenau, Blumenau, Brazil
✉ E-mail: scabral@furb.br

Abstract: Thanks to the awareness of safety, dry-type transformer has experienced a significant demand, lately. However,
a limiting condition for an even more significant increase in its demand is that its maximum rated voltage is about 36 kV, in
most of countries. Beyond this limit, dry-type transformer becomes definitely uneconomical in comparison to oil-filled
transformer because of the expressive increase in dielectric clearance distances and consequent drawbacks. Thus, the
aim of this work is to propose a way for overcoming this limit, based on shielding the electric field of the high-voltage
windings of the dry transformer with a grounded metallic mesh. The effectiveness of the proposition is shown whereas
most of the undesirable of its consequences are also evaluated. Namely, losses and temperature rise concerns as well
as items of standard dielectric tests, which are analysed through computer modelling and simulation. Due to its
outstanding importance, analysis of distribution of lightning impulse voltage along the high-voltage winding is also
experimentally performed. The result is a set of key hints given by the authors and to be observed by transformer
designers for making real the production of dry-type transformer with a rated voltage higher than 36 kV.

1 Introduction
Despite some drawbacks, the dry-type transformer has some
well-recognised and unquestionable advantages over the oil-filled
transformer [1, 2]. Ranging from the obvious impossibility of oil
leakage and a consequent environment pollution until the fact that
most of the types of resin practically do not propagate fire, dry
type is somehow famous for being safer than oil-filled transformer.
Yet, oil-filled transformer can even explode and spill off its hot oil
as well as exhale toxic gases, in case of fire due to a short circuit,
for example. Thus, dry-type transformer is not only preferred for
some applications in which people are around it but it is
sometimes strongly recommended, which may explain its
relatively high and increasingly demand. However, dry-type
transformer is not commercially available for the whole range of
rated voltages of the power system. Despite some few exceptions,
as in [3, 4], its maximum rated voltage has roughly been limited to
36 kV. Although dry-type transformer with a higher rated voltage
is technically feasible, the imperative reason for this limit is purely
economic. It lies in the facts that, by taking all the usual
procedures of transformer design, for any rated voltage higher than
36 kV some of the clearance distances should increase so much. In
consequence, the size as well as the weight and thus the price of
the dry-type transformer would become a drawback, in comparison
to an oil-filled transformer [2]. Other undesirable consequences
would be the significant increase in the value of the no-load losses
as well as the leakage impedance. Additional consequences are
discussed in [5]. Specifically, the need in increasing clearance
distances occurs because of the significant difference between the
values of the dielectric permittivity of its two unique insulating
materials, resin and air, as well as of the relatively low value of
dielectric withstand of the air, in comparison to that of the resin.
In consequence, when a high-voltage (HV) winding of a dry-type
transformer is energised a high value of electric field appears
along the air distance, exactly where the dielectric withstand is
lower. Nonetheless, overcoming suchlike barriers is a natural
challenge and need for all those who design transformers. Thus,
although [3, 4] can be taken as significant examples of succeeded
propositions, they do not present the main features for designing a
dry-type transformer with a rated voltage higher than 36 kV. Thus,
based on these concerns, this work brings a somehow new
proposition for the effective reduction of the dielectric distances in
the design of a dry-type transformer with rated voltage higher than
36 kV. This proposition is based on [6] and suggests the use of a
grounded metallic mesh for enclosing the HV winding and
confining its HV gradient for reducing its clearance radial distance
to the low-voltage (LV) winding. For better illustrating this
proposition, an analysis of the main features of the design of a real
1500 kVA, 13.8/0.38 kV, 60 Hz transformer is performed for
showing how the increase in its rated voltage may take place. On
the other hand, because this transformer has a very basic design, it
can play the role of a good reference for every transformer
designer. Thus, key issues of transformer design like losses,
temperature raise and dielectric tests are carefully analysed through
computer simulation. Still, because of its significant importance,
the analysis of the performance under lightning impulse test is also
made through experimental simulations. The result is a set of
hints, clues and analyses for all the well-known critical items of
the design of a dry-type transformer for allowing every designer to
be engaged in the production of dry-type transformer with a rated
voltage higher than 36 kV.
2 Concerns of insulating radial distance for
dry-type transformer
Today, for most of transformer manufacturers and under normal
conditions, the maximum rated voltage for a dry-type transformer
is about 36 kV. The key reason for defining this limit is that a
significant increase in the radial distance between the HV and the
LV windings is necessary for any rated voltage higher than 36 kV.
This is so because most of this radial distance is air filled since its
primary function is to allow heat exchanging for both windings
through the airflow between them. However, this air radial
distance also serves as a natural dielectric barrier between
windings. On the other hand, since the radial distance is composed

IET Electr. Power Appl., 2016, Vol. 10, Iss. 5, pp. 411–418
& The Institution of Engineering and Technology 2016 411
by air and resin, the dielectric permittivity of the atmospheric air is ɛo
and about 4.4ɛo for the resin that involves the windings, a
significantly HV gradient appears along the air radial distance
when an abnormal but predictable voltage is applied to its HV
winding, for example, during a dielectric test.
For illustrating this situation, Fig. 1 shows the values of the rms
electric field plotted along the radial distance of one phase of a
1500 kVA, 13.8/0.38 kV, 60 Hz, dry-type transformer under a test
voltage of 50 kV at industrial frequency to its HV winding. The
Fig. 1a corresponds to the actual condition of design, whereas the
Fig. 1b corresponds to a hypothetic condition, if no resin is
applied on any of the windings.
Consider this analysis as done in a radial distance far from the
edges of the concentric windings and therefore the electric field
may be considered as uniform. Also, consider that the radial
distance is zero at the outer radius of the LV winding and 50 mm
at the inner radius of the HV winding. In the case of the Fig. 1a,
the radial length of resin on the HV winding is about 6 mm.
Thus, in accordance with the radial profiles of voltage gradient of
Fig. 1 it is noticeable how the inherent use of the resin causes a
significant decrease in the voltage gradient along the distance
where it is applied, whereas it also causes an increase in the
voltage gradient along the remaining air radial distance. Therefore,
in the case of the presence of an even higher voltage across the
HV winding, the voltage gradient along the air radial distance can
reach its limit [Usually, 3 kV/mm for air and 20 kV/mm for resin
are values taken as references at room temperature . However, for
temperatures up to 140°C, as in the case of an operating power
transformer, both these limit become quite lower.] before voltage
gradient within the resin can reach its own limit. In Fig. 1b,
maximum value of electric field is 0.9 kVrms/mm that corresponds
to 1.27 kVpeak/mm.
Despite this is a very clear way to show how the resin causes the
transference of voltage gradient, the most critical region for defining
the radial distance is close to the edges of the windings. This is
because in this area distortion of the electric field makes the limit
of voltage gradient along the air radial distance to be quite lower
than 3 kV/mm.
In any case, it is clear that the air radial distance is the weaker and
thus the key element for the definition of distance between LV and
HV windings.
Thus, for dealing with this matter, the authors propose a method
for confining the electric field of the HV winding within its resin
domain without any transference to the air radial distance, which
Fig. 1 Profile of the amplitude of the rms voltage gradient (electric field) along radial distance
a Real condition, with cast resin
b Hypothetical condition, without cast resin on windings
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allows reducing it as well as considering higher rated voltage for
the HV winding and for the transformer, as a whole. In its
essence, the proposed method consists of enclosing the resin
external walls of the HV winding with a grounded metallic mesh.
Special attention must be paid to the shape of the enclosing mesh
for avoiding it to become a short-circuited coil and thus cause
transformer damages. Figs. 2a–c show some details of the design
of the proposed mesh.
From Fig. 2 it is noticeable that the proposed method is not that
same well-known electrostatic shielding, which consists of a
grounded solid metallic foil lying between the HV and the LV
windings for providing their capacitive decoupling. On the other
hand, the proposed mesh covers the HV winding almost
thoroughly with a layer of resin between them, whereas another
layer of resin covers the mesh, externally. One of the main reasons
for taking a mesh as metallic enclosing is exactly for its easier
application before the resin may be dry, along its production.
Fig. 3 shows the profile of gradient voltage along the radial
distance for the same 1500 kVA, 13.8/0.38 kV, 60 Hz dry-type
transformer, in a similar condition as of Fig. 1, when the metallic
mesh is included.
Comparison of results of Figs. 1 and 3 shows how effective the
proposed mesh is in mitigating the voltage gradient along the air
radial distance between windings of each phase. In consequence,
the level of voltage gradient within the resin layer increases
significantly. However, the obtained level is far to reach the
withstand limit of any usual type of resin, which means a more
efficient and rational use of the material.
However, it is suspectable that the addition of the proposed mesh
may disturb negatively the performance of the transformer in other
items than the distribution of the electric field along radial distance
of the windings, at industrial frequency. Especially, in regard to
losses, for both conditions of on-load and no-load, that are expected
to increase after addition of the proposed enclosing mesh and thus
the maximum working temperature of the transformer may exceed
acceptable limits. On the other hand, even about all the concerns of
the new distribution of the electric field along radial distances the
addition of the mesh is also supposed to compromise the
performance of the transformer. That is why standard tests of
dielectric withstand are also analysed. Ranging from the applied
voltage test to the induced voltage test, by including the lightning
impulse voltage test, the influence of this new and grounded
element must be carefully analysed. Thus, this is what is done in
the sequence, by exploring the most important tests.
IET Electr. Power Appl., 2016, Vol. 10, Iss. 5, pp. 411–418
& The Institution of Engineering and Technology 2016
Fig. 2 Profile of the amplitude of voltage gradient (electric field) along radial distance
a Basic view of the proposed mesh
b External view of a proposed mesh applied to a HV winding
c Cross-section view of a HV winding with proposed mesh in detail
Fig. 3 Profile of the amplitude of voltage gradient (electric field) along radial distance with proposed mesh applied to the HV winding
2.1 Temperature rise and loss measurement – no-load
and on-load conditions
Due to its concentric position in each HV winding of a three-phase
transformer, the proposed metallic mesh becomes naturally
submitted to the magnetic field leakage from the windings and it is
thus possible that some current may be induced in it and give
origin to significant additional eddy losses under both no-load and
on-load operating conditions of the transformer. If so, a consequent
undesirable increase in temperature may be expected and the
proposed method should be revaluated. However, the providentially
proposed geometry for the mesh allows cancellation of all the
internally induced currents and thus only a perimeter induced
current flows in it, as shown in Fig. 4. Thus, for limiting the
amplitude of this induced current it is recommended that a properly
low conductive metallic material may be used for composing the
mesh. In addition, some care must be taken for this choice not
affecting the requested mechanical flexibility of the metallic mesh
for the sake of its workability, which is not a very difficult task.
On the other hand, again because of its meshing design, the
enclosure does not disturb the heat exchange of the windings and
thus a very low or non-significant influence of the mesh on
transformer losses is to be expected. In fact, since it is metallic, it
may contribute for the temperature distribution to become uniform
along the winding height, which can be taken as an advantage.
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& The Institution of Engineering and Technology 2016
However, regarding voltage insulation, the presence of the grounded
mesh will imply in the need of an increase of the resin layer between it
and the HV winding, in comparison to the condition of not existing this
mesh. For its turn, because of its relatively low capability in conducting
heat, this increase of the layer of resin will make the heat exchange of
the HV winding difficult and thus measures for decreasing the heat
generation from the HV winding must be taken. Essentially, an
increase in the cross-section of the HV winding conductor is the very
first and natural measure.
Thus, this clearly seems as being a very important compromise to
take into consideration when analysing the addition of the grounded
enclosing mesh to the HV winding. In fact, the less is in the increase
in the resin layer, the less is the increase in the cross-section of the
HV winding conductor. Therefore, taking a resin with value of
dielectric strength as highest as possible is desirable because of the
less increase in resin layer and consequent lower increase of
cross-section of the HV winding conductor.
2.2 Applied voltage test
For an ordinary dry-type transformer, when the test of applied voltage
at industrial frequency is performed through its LV winding, there are
two regions where concerns with stressing electric field are
considerably high. Namely and in accordance with Fig. 5a, obtained
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Fig. 4 Process of cancellation of currents induced by the leakage magnetic field in the bulk of the mesh
from computer simulation with FEMM [7] of the same transformer
taken for obtaining Fig. 3, two of these regions are along the whole
radial distance of the volume between the LV winding and the core
leg (region I) and along the radial distances at the edges (upper and
lower) of the layers of the LV winding (region II).
On the other hand, two other regions present stressing electric
field if the same test is performed through its HV winding. These
regions are presented in Fig. 5b, also obtained from FEMM
simulation. One of them is along the whole radial distance
between the LV and the HV windings (region III), whereas the
other is at the edge of the upper and lower disks of the HV
winding (region IV). It is thus noticeable that except for the
change of the winding to be under applied voltage at industrial
frequency, the regions III and IV can be considered as equivalent
to the regions I and II, respectively.
Regarding the stressing electric field, it is important to mention
that since the electric field is not uniformly distributed, the limit
taken for the voltage gradient along any air distance is not 3 kV/mm,
anymore, but rather lower.
The region I is filled with air that has a lower dielectric strength
than the resin. On the other hand, since the voltage of the
energised winding is relatively low, the definition of this radial
distance is not so critical and it is usually based on the experience
of the designer. For its turn, the region II becomes stressed because
of the influence of the yoke of the core, which is grounded and it
thus gives origin to a significant axial component of the electric
field between the yoke and the edge of the layers of the LV winding.
On the other hand, the adoption of the proposed enclosing metallic
grounded mesh will cause some significant changes on the electric
field distribution during the test of applied voltage at industrial
frequency that will allow significant changes in clearance distances
of some of the previously analysed regions.
At first, for the applied voltage test through the LV winding,
electric field in the regions I and II will not suffer any significant
Fig. 5 Computer simulation of the distribution of electric potential with definition of the regions where the voltage gradient is critical during the applied voltage
test
a Regions I and II, around the LV winding
b Regions III and IV, around the HV winding
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influence of the mesh. However, for the applied voltage test to the
HV winding the use of the mesh will allow reducing significantly
the distance between LV and HV windings, since the HV winding
will have its electric field confined to the region of resin between
it and the mesh, as obtained by computer simulation and shown in
Fig. 6.
Therefore, the key region to where all the concerns converge
lies exactly on the HV winding disks. More exactly, between
the HV disks and the evolving grounded metallic mesh. Thus,
since this region is filled with resin, it is interesting to take the
advantage of using some with a value of dielectric strength as
highest as possible for this task, for the distance between the
HV winding and the mesh may be as shortest as possible.
Therefore, it will not jeopardise the heat exchange of the HV
winding, as pointed out in the previous section. However,
additional precautions like taking disks with cross-section with
round edges for avoiding highly stressing electric field are
mandatory.
At last, about the curing process of the resin, much more care than
is regularly required is necessary for avoiding the presence of any
minimum air bubble and consequent air void that might trigger the
process of insulating disruption.
2.3 Impulse voltage test
Due to the concerns with high frequencies associated to this kind of
solicitation, in which the impulsive voltage becomes non-uniformly
distributed along the length of the winding, this issue has been
intensively investigated as in [6, 8], for example. In fact, the
winding response to any applied impulsive voltage will strongly
depend on the wave shape of the voltage as well as on its
geometry, which implies in the value of its distributed parameters,
namely, inductances, capacitances and resistances.
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& The Institution of Engineering and Technology 2016
 Regarding the relevance of this item and as already mentioned, the Table 1 Resumed data of comparison between measured and
same 1500 kVA, 13.8/0.38 kV, 60 Hz, Dyn1, dry-type transformer simulated results shown in Fig. 7
was taken as a practical, well-known and thus a confident Item Measured Simulated Error
reference. This transformer has 13 turns foil windings in the LV
side, whereas in the HV side there are ten continuous disks, casted peak value of input voltage, V 94.1 94.1 –
in epoxy resin. Thus, one of its ten disks HV winding was time to peak value of the input voltage, 1.7 1.7 –
modelled through the most well-recognised finite-element µs
peak value of voltage to ground for the 70 65.5 −6.43%
techniques for obtaining its distributed parameters [8–10], whereas fifth disk, V
its LV winding was taken as grounded element, as it is usually resonant frequency of the response, kHz 58.8 49.5 −15.82%
done. On the other hand, one of its HV winding was submitted
to a practical application of a standard 1.2/50 μs low-amplitude
(94.1 V) lightning impulse voltage and measured results were
compared with its computer modelling simulation of this same allowing the simulation to be performed in a commonly available
condition, performed with PSPICE simulator [11], as in [6]. Due personal computer as well as the use freely available circuit
to the impossibility of access to most of the disks of the HV simulators.
winding but only to that connected to its regulating winding, disk Aside the indicated minor differences, the computer model of the
number 5, practical measurement results are only from it. HV winding that has been taken is validated and it is henceforth
Fig. 7 shows the comparison between both results, whereas supposed to represent confidently the HV winding of the actual
Table 1 indicates the resumed data of the comparison of its graphics. transformer.
Data of Table 1 allow considering that computer modelling results Thus, additional extrapolating results of computer simulation for
of the real transformer are satisfactory because of their relatively low the application of a 1.2/50 μs impulsive voltage are presented in
difference to practical results, namely, the peak value of the applied Figs. 8a and b that show the behaviour of voltage to ground for all
impulse voltage and its time, the peak value for the voltage to ground the disks and between every two adjacent disks, respectively.
for the fifth disk and the resonant frequency of the response. In While Fig. 8a shows some well-recognised and quite predictable
accordance with [8], all the differences related to time between the results for the behaviour of the voltage to ground of each disk,
two responses are due to modelling principles. Ideally, each turn Fig. 8b shows a very important result that is the existence of a
of the HV winding should be modelled by one circuit with RLC maximum value of voltage between two adjacent disks. It is
lumped parameters. However, the computational effort would between the tenth (to which the impulse voltage is applied
increase significantly and a more capable computer would be whereas the end of first disk is grounded) and the ninth disks. The
necessary for simulation. On the other hand, the authors have amplitude is about 20 V, or about 20% of the input voltage, which
preferred a simple approach with one circuit with RLC lumped suggests that some additional concerns with insulation between
parameters for modelling each disks of the HV winding in view of these two disk must be taken into account.

Fig. 6 Computer simulation of the distribution of the electric potential around the LV and the HV windings with the presence of the grounded metallic mesh

Fig. 7 Graphics of voltage to ground of disk 5. Computer simulated, experimental and input voltages

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Fig. 8 Computer simulation of the input impulsive voltage and the responses of all the ten disks of the HV winding of the real transformer
a Voltage of each disk to the ground
b Voltage to between two adjacent disks

3 Behaviour of HV winding under impulse voltage
with grounded metallic mesh
On the basis of the same transformer taken as reference for the
previous analysis, the addition of the grounded mesh was then
considered for the simulation of the application of the same
standard lightning impulse to the HV winding and this condition
was simulated with the validated computing model. Thus, Fig. 9
shows the graphics of the input voltage and the voltage to ground
for the fifth disk of the HV winding.

Fig. 9 Computer simulation results for the input impulsive voltage and the response of the fifth disk – the presence of the grounded metallic mesh is taken into
account

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416 & The Institution of Engineering and Technology 2016
Fig. 10 Computer simulation of the input impulsive voltage and the responses of all the ten disks – the presence of the grounded metallic mesh is taken into
account
a Voltage of each disk to the ground
b Voltage to between two adjacent disks
In this case, simulation shows that peak value of voltage to ground
for the fifth disk is significantly higher than in that case in which the
metallic mesh is not present, as shown in Fig. 9. Thus, that same
96.1 V input voltage of before gives origin to a 89.8 V of peak
value to ground as response of the fifth disk, whereas it had been
about 65.5 V for the condition without metallic mesh. For its turn,
this increase of stressing voltage may not be taken as significantly
worrying for harming the winding insulation because the distance
between HV and the grounded metallic mesh is filled with resin
that is adequate to withstand such an increase of voltage stress,
proportionally, without any significant need in increasing the resin
layer between them.
In addition, Fig. 10a shows the computer simulation of the voltage
to the ground for all the ten disks. Thus, it basically shows that
maximum peak of voltage to ground has the same level of about
90 V for all the disks. On the other hand, Fig. 10b shows the
computer simulation of the voltage between every two adjacent
disks. Thus, in a similar way that it has obtained for the HV disks
without the grounded mesh, shown in Fig. 8b, a maximum voltage
of about 60 V takes place between the initial disks, 10 and 9. In
this case, the peak voltage is about three times the value for the
same position when the grounded mesh was not present.
However, in the same way as done before, this result does not
mean any additional worry for the transformer designer if the
thickness of layer of cast resin between the HV disks and the
grounded mesh has dielectric withstand enough for not collapsing
during such a solicitation.
Therefore, none of the main aspects of the dielectric concerns of a
transformer design seems to represent a very significant barrier to
IET Electr. Power Appl., 2016, Vol. 10, Iss. 5, pp. 411–418
& The Institution of Engineering and Technology 2016
overcome the adoption of a rated voltage higher than the limit
of 36 kV.
4 Conclusions
In accordance with the analyses of results obtained from computer
and experimental simulations as well as on discussions about the
behaviour of losses, the proposal of the use of a grounded metallic
mesh presents itself as a feasible alternative for the desired
increase in the maximum rated voltage of the dry-type transformer.
While the presence of the grounded metallic mesh does implicate
in the increase in the voltage stress for most of the standard
dielectric tests, the intrinsically requested increase in the thickness
of layer of resin between the HV winding disks and the grounded
mesh properly allows the dielectric withstand. This is so because
the proposed mesh transfers the highest valued electric field from
the air to the resin radial distance of the HV winding, thanks to a
providential increase in the thickness of the layer of resin between
the HV winding and the mesh. On the other hand, unavoidable
and undesirable consequences of that increase in the thickness of
the layer of resin can be easily mitigated by two propositions,
given by the authors, namely, the increase in the cross-section of
the conductor of the HV winding and the use of a very
high-quality resin. Thus, based on what is available and feasible,
the transformer designer can decide the amount of each of the two
propositions to be taken.
At last, it is important to mention that besides allowing the
increase in the rated voltage beyond 36 kV, the presented
417
propositions can be also applied for reducing the size of any dry-type
transformer with rated voltage <36 kV.
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