SECTION -4

THERMAL DESIGN &

OVERLOADING CAPABILITY
OF TRANSFOREMRS
 LIFE OF TRANSFORMERS

Today, with the new global technologies, advanced software

programs and in-house R&D efforts (with earlier technical
collaboration base), the normal life of transformer has
extended up to about 30 – 35 years. However, among other
factors affecting ageing of the transformer, overloading
capability of transformer is the one vital factor.
 Major factors affecting performance
of transformers
• Frequent short circuits
• Over voltages
• Different ambient temperatures
• Overloading for long duration
(Short duration overloading is allowed as per IS:6600)
• Poor maintenance practices
 Thermal Design
• A transformer is designed to be operated continuously at
rated kVA at weighted ambient temperature of 320C and
hot spot temperature of 980C.
• Hot spot temperature is maximum temperature that any
part of the winding reaches under given load conditions
and ambient.
• Heat is generated from the winding due to
I2 x R, eddies and stray losses. It is also generated from
the core. This heat is transferred to the oil. Temperature
difference between winding surface and the oil flowing
over it depends upon heat emitted from the winding
surface, location of the cooling ducts and in radial and
axial direction of the windings, size of cooling ducts and
viscosity of the oil. Oil passing over to winding carries
heat produced from its surface. This heat is dissipated to
the oil through convection.
 Thermal Design

Hot oil moves to the top due to difference in density of hot

and cold oil. This hot oil goes to radiators provided in
cooling circuit. The radiators dissipate heat and the cool oil
returns to the winding via bottom end of the tank. Thus a
continuous flow of oil is set up in a closed loop during
transformer operation.
 Overloading capability of
Transformers
• There is no deterioration of insulation life up to a
hot spot temp. of 980C
• Transformer gains life when the hot spot
temperature is below 980C and it loses life when
temperature goes beyond 980C
• Condition of insulation deteriorates more rapidly
in temperature zone extending up to 1400C.
• The rate of deterioration of insulation doubles
with every temp. rise of 60C. Under no
circumstances the hot spot temp in the windings
should exceed 1400C.
 Cyclic Loading
• i) Normal Cyclic Loading:
A higher ambient temp. or higher than a rated load current is
applied during part of the cycle, but from the point of view of
thermal ageing this loading is equivalent to the rated load at
normal ambient temp.
ii) Long-time Emergency Cyclic Loading:
Loading resulting from the prolonged outage of some system
elements that will not be reconnected before a steady state temp.
rise is reached in the transformer. This is not a normal operating
condition and its occurrence is expected to be rare, but it may
persist for weeks or even months and can lead to considerable
ageing.
 Short-time emergency loading

• Unusually heavy loading due to the occurrence of one of more

unlikely events which seriously disturb normal system loading,
causing the conductor hot spots to reach dangerous levels and,
possibly, a temporary reduction in the dielectric strength. This
type of loading is expected to occur rarely & it must be rapidly
reduced or transformer disconnected within a short time (half
an hour) to avoid its failure.
 Short-term risks
a) The main risk for short time failures is the reduction in
dielectric strength due to presence of gas bubbles in a
region of high electrical stress in paper insulation & at
the surfaces of heavy metallic parts. Bare metal parts
which are in contact with oil, may rapidly rise to high
temp. It should therefore not exceed 1800C.

b) Temporary deterioration of the mechanical properties at

higher temp. could reduce the short-circuit strength.

c) Due to oil leakage, pressure built-up in the bushings may

result in failure, even gassing in bushing may occur if
temp. of the insulation exceeds 1400C
 Long-term risks
a) Cumulative thermal deterioration of the mechanical properties
of the conductor insulation will accelerate at higher temp. If
the deterioration proceeds far enough, it may reduce the
effective life of transformer, particularly if the latter is
subjected to system short circuits.
b) Other insulation materials, structural parts and the conductors
could also suffer ageing at higher temp.
c) The contact-resistance of the tap-changers could increase at
elevated currents and temp. and in severe cases, thermal
runaway could take place.
d) The gasket materials in the transformer may become brittle at
elevated temp.
 Short-term risks

d) The expansion of the oil could cause

overflow in the conservator.

e) Breaking of excessively high currents in

the tap-changer could be hazardous.
 Relative rate of using life
Winding hot spot temperature RRUL (P. U.)
Degree C
80 0.125
86 0.25
92 0.5
98 1.0
104 2.0
110 4.0
116 8.0
122 16.0
128 32.0
134 64.0
140 128
Hot spot temperature vs useful life in hours per day

Winding Hot spot Useful Life (Hrs. per day)0

Temperature (Degrees C)
98 24
101.5 16
104 12
107.5 8
110 6
113.5 4
116 3
No. of hrs., for any given wdg hot spot temp, that will
cause one day’s ageing
Cont’d..
Hrs. per day Degrees C

2 119.5
1.5 122
1 125.5
0.75 128
0.5 131.5
0.375 134
0.25 137.5
0.188 140
 Current & Temp. limits applicable to loading
beyond nameplate rating
Types of Distrn Medium Large
Loading Trs. Power Power
Trs Trs.
Normal Cyclic loading:
Current 1.5 1.5 1.3
(p.u.)
Hot spot temp in metallic 140 140 120
parts in contact with
insulating material (0C)

Top oil 105 105 105

Temp. (0C)
 Current & Temp. limits applicable to loading
beyond nameplate rating
Types of Distrn Medium Large
Loading Trs. Power Power
Trs Trs.
Long-time emergency Cyclic loading:
Current 1.8 1.5 1.3
(p.u.)
Hot spot temp & metallic 150 140 130
parts in contact with
insulating material (0C)
Top oil 115 115 115
Temp. (0C)
 Current & Temp. limits applicable to loading
beyond nameplate rating Cont.d..
Types of Distribution Medium Large
Loading Transformer Power Power
Transfor Tran.
mer
Short-time emergency loading:
Current(p.u.) 2.0 1.8 1.5
Hot spot temp & metallic No limit Set 160 160
parts in contact with But Above 140
insulating material (0C) to 160 will
Jeopardize
dielectric
Top oil 115 115
Strength
Temp. (0C)
 Precautions to be taken for
overloading
• The current should not exceed 1.5 times the rated value as
per IS:6600.

• To check components (tap changer, bushings) capability of

carrying higher load.

• To check thermal capability of associated equipments such

as cables, switchgear & current transformer.
 Precautions to be taken for overloading

• In summer (hot season) overloading should be avoided as

far as possible. Whereas, during winter overloading can be
done to the extent of 150% provided hot spot temp. does
not exceed 1400C.

• Overloading should not be for a longer time.

• Like other categories of ageing such as human beings,

other machineries, for giving a trouble-free service, as the
transformer goes older, overloading should be minimized