Transformer Design Comparisons

General description of core/coil types Analysis of short-circuit forces Specific analysis of coil types and strengths Overload capability Cost comparisons Weight / dimensional comparison

Sunbelt Transformer

Stacked Core Construction

Also known as core form Utilizes variety of lamination thickness and quality 5-100 MVA typical

Sunbelt Transformer

Stacked Core Construction

Sunbelt Transformer

Wound Core Construction

Also known as distributed gap Usually utilizes lowest cost core steel Below 5 MVA typical Below 1 MVA standard All pole-type transformers

Sunbelt Transformer

Cylindrical Coil Construction

Coils have cylindrical cross-section Concentrically wound with HV over LV (Lowest voltage nearest core) Requires stacked core

Sunbelt Transformer

Rectangular Coil Construction

Coils have rectangular cross-section HV over LV winding Core can be stacked (core form) or wound (shell form)

Sunbelt Transformer

Short-Circuit Strength
Winding Forces Repel
Force on conductor equal to current times magnetic field High short-circuit current translates into high forces

Horizontal Component
Present in ALL designs

Vertical Component
Varies with design

Sunbelt Transformer

Short-Circuit Strength
Horizontal Forces
Present in ALL designs Cylindrical coil movement limited by tensile strength Rectangular coils must be horizontally braced to restrict movement

Sunbelt Transformer

Short-Circuit Strength
Vertical Forces
Present in all wire-wire designs as current cannot redistribute from top to bottom of coil NO vertical forces in designs with full-height sheet winding (1 turn per layer)

Sunbelt Transformer

Short-Circuit Verification
Anderson Program
Most widely used finite element program addressing shortcircuit strength and temperatures Created by Odd W. Andersen

ANSI Short-Circuit Requirements

Pass Standard Dielectric Tests After SC Test No Mechanical Movement No Abrupt Changes in the Voltage or Current Wave Shape 2.0% Leakage Current Change (7.5% for non-circular coils) 5% Excitation Current Change After SC Test (stacked cores)

Sunbelt Transformer

Transformer Design Comparisons

Construction types to be compared:

Cylindrical, Disk Coils; Stacked Core Cylindrical, Layer Coils; Stacked Core Rectangular, Layer Coils; Stacked Core Rectangular, Layer Coils; Wound Core

Sunbelt Transformer

Cylindrical-Disk Coil Construction

No horizontal bracing
Only insulation separates phases Conductor tensile strength limits horizontal movement

Full-circumference vertical bracing

Known as pressure plates, these distribute forces across entire coil

Sunbelt Transformer

Cylindrical-Disk Coil Construction

Pressure plate functions
Support weight of coils on bottom Contain vertical forces during short circuit Distribute forces across entire horizontal surface of the winding Keep coils from expanding when not oilimmersed

Sunbelt Transformer

Cylindrical-Disk Coil Construction

Wound on keyed winding tube Pressed vertically to exact size Very little electrical stress disk-to-disk Good beyond 750 KV BIL

Sunbelt Transformer

Cylindrical Or Rectangular Layer Coils

Sheet LV Strap HV
Balanced Ampere Turns Centerlines No Vertical Forces - with only one turn-per-layer

Strap LV Strap HV
Unbalanced Ampere Turns Centerlines as taps changed Vertical Forces Present

Sunbelt Transformer

Layer Coil Construction

Simple winding tube Epoxy-coated paper as layer insulation If wound in singlesection can have high layer stress High amounts of paper require extra processing Limited to 350 KV BIL

Sunbelt Transformer

Rectangular Layer Construction

Solid endplates required for smaller KVA designs Engineered endplates such as box beams for higher KVA Extensive bracing leads to increased weight for rectangular-layer

Sunbelt Transformer

Disk Coil Heat Transfer

Best Heat Transfer
Open fluid flow with keyed-spacers separating disks 4 degree winding rise easy to obtain The only design that should be used with two stage cooling

Sunbelt Transformer

Layer Coil Heat Transfer

Poorest Heat Transfer
Oil only flows through ducts 10 degree winding rises are typical; makes two stage cooling almost impossible Number of ducts limited by short-circuit strength Demand a heat-run if two stage cooling is expected

Sunbelt Transformer

Transformer Design Comparisons

Description of core design differences Short-circuit strength Description of coil design differences Overload capability Cost comparisons Weight / dimensional comparison

Sunbelt Transformer

$ - The bottom line.

Evaluated by initial purchase price
Rectangular is lowest cost weakest short-circuit design Cylindrical-layer is 10-15% more eliminates horizontal bracing 5% additional for Cylindrical-disk buys vertical bracing and no need for horizontal support; strongest design possible

Evaluated by total ownership cost

No-Load losses less in cylindrical design and load losses equivalent A $5/NL Watt evaluation can pay for cylindrical design Layer designs have other problems such as gassing from high moisture content in improperly cured insulation

Sunbelt Transformer

Weight and dimensional comparisons

Space Utilization
Cylindrical will have smaller pad footprint, almost always taller and thinner than rectangular design Overall volume will always be smallest with rectangular design ideal network or vault application transformer

Weight
Short-circuit bracing requirements make the rectangular unit much heavier Cylindrical disk will have 20-30% more oil content/KVA
Standard 10/14 MVA cylindrical disk will weigh about 55000 lbs Standard 10/14 MVA rectangular layer will weigh 75000 lbs

Sunbelt Transformer