Transformer Manufacturing

Process

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Most common types of power transformers:
GSU’s (Generator Step-Up):
• 2 windings HV/LV
• 3 windings HV/LV1/LV2 + 5%
• with D.T.C. in HV, typically ± 2x2.5%
• normally no L.T.C. - 5%

• Connection Wye/Delta
• typical LV: 10, 20, 25 kV
• typical HV: 33, 69, 115, 138, 161, 230, 345, 500 kV
• Single-phase
• Three-phase
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Most common types of power transformers:
Auto-Transformers:
• 1 winding (series + common winding)
• 2 windings (series + common) + tertiary winding
• D.T.C. in HV
• L.T.C. in HV or LV
• Single-phase or three-phase
• Connection: always Wye/Wye
• purpose of tertiary winding
– suppression of harmonics
– can be buried (no bushings brought out)
– sometimes brought out for station service voltage
• Manufacturer shall determine the tertiary size (rating)
• Auto-transformer has smaller frame size
e.g. Rating = 300 MVA Frame size:
HV = 230 kV 230-115 x 300 = 150 MVA
LV = 115 kV 230

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Most common types of power transformers:
Step-down transformers:
• 2 winding HV/LV + D.T.C.
• 2 winding HV/LV + L.T.C. winding
• 3 winding HV1xHV2/LV + D.T.C.
HV1xHV2/LV + L.T.C. winding
HV/LV1xLV2 + D.T.C.
HV/LV1xLV2 + L.T.C. winding

D.T.C.  HV
L.T.C.  LV

D.T.C.  LV or HV
L.T.C.  HV or LV

• Connection: Delta - Wye (majority)

Wye - Delta
Wye - Wye
• Three-phase
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Manufacturing Process:

– Core Construction – Processing

– Insulation – Tanks
– Windings – Testing
– Core and Coil – Shipping

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Manufacturing Process:
Core Dimensions

Transformer Consulting Services Inc.

Manufacturing Process:
Core Dimensions
Circular core cross section:

Diameter of the core circle (DCC)

Stacking Height (SH)
Steps of 5 mm for DCC

Widest sheet width

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Manufacturing Process:
•
Core Cutting - Georg
Automatically stacks legs & yokes (Minimize Handling)
• Purchase uncut slit rolls of steel or pre-cut

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Manufacturing Process:
Core ‘Logs’ Stacked

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Manufacturing Process:
Core stacking methods
BUTT-LAP STACKING:
• Local concentration of flux
• higher excitation current & core loss.

STEP-LAP STACKING:
•Reduced Local flux concentration
•lower excitation current & core loss.

Core Material- Grain Oriented Silicon

M - NON-LS; H - LS H
ZDKH (laser scribed)
ZDMH (mechanically scribed)

Transformer Consulting Services Inc.

Manufacturing Process:
Core Material
• A cheap material that can be used when loss and/or noise
requirements are less important (e.g. normal CGO, 0.35 mm or
0.30 mm)
• A very low loss material that can be used when high loss or
capitalisation requirements are set (e.g. laser treated HiB, 0.23
mm)
• if necessary, an intermediate material with a good “cost to
performance ratio” (e.g. M2H, 0.30 mm for low noise
transformers)

*cold-rolled grain-oriented (CGO)

Transformer Consulting Services Inc.

Manufacturing Process:
Core Induction
The induction is one of the main transformer characteristics,
determining its size and cost to a great extent.

induction  = size  and cost 

But: • material limitations

• impedance limitations
• continuous overvoltage limitations
• time limited overvoltage limitations
• sound level restrictions

Transformer Consulting Services Inc.

Manufacturing Process:
Core Induction
Material limitations:
The material saturation induction is approx. 2.0 to 2.05 Tesla. Keep the flux within the
core, to avoid high losses and temperatures in other metallic parts!
The maximum allowed nominal induction then becomes:
• Bmax = 1.85 T for CGO material
• Bmax = 1.9 T for HiB material

Impedance limitations:
To avoid local saturation due to significant leakage field:

CGO material HiB material

Uk > 20% Bmax = 1.75 T Bmax = 1.8 T
Uk > 30% Bmax = 1.7 T Bmax = 1.75 T

Transformer Consulting Services Inc.

Manufacturing Process:
Core Induction

Continuous overvoltage limitations:

To avoid saturation, the induction must be reduced:

CGO material HiB material

105% Unom Bmax = 1.85 T Bmax = 1.90 T
110% Unom Bmax = 1.82 T Bmax = 1.82 T
115% Unom Bmax = 1.74 T Bmax = 1.74 T
120% Unom Bmax = 1.67 T Bmax = 1.67 T

Transformer Consulting Services Inc.

Manufacturing Process:
Core Induction
Time limited overvoltage limitations:
Example: A generator step-up transformer with nominal induction of 1.75 T can handle:

Transformer Consulting Services Inc.

Manufacturing Process:
Core Induction
Sound level restrictions:
A very low sound level can be reached by reducing the induction, but then the core
weight increases, limiting the gain!

Induction   core weight 

 
sound level  sound level 

net effect = sound level 

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Manufacturing Process:
Core Stacking
• Use of temporary bolt guides for stacking
• 2, 3, 4 & 5 leg cores manufactured for single & three phase units

Transformer Consulting Services Inc.

Manufacturing Process:
Core Stacking
• Oil ducts utilized to control temperature rise
• Temporary, Permanent or combination of banding

Transformer Consulting Services Inc.

Manufacturing Process:
Core Stacking

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Manufacturing Process:
Coil Winding Shop
• Winding room separate from other manufacturing areas
• Positive Pressure
• Horizontal/Vertical winding mandrels

Transformer Consulting Services Inc.

Manufacturing Process:
Coil Winding
• Windings are circular concentric type
• Conductor are either copper magnetic wire or continuously transposed conductor
• Conductor purchased pre-wrapped with thermally upgraded paper or Nomex
• High strength wire or epoxy bonded CTC used when high short circuit forces
• Winding type chosen according to voltage & application, Cont. Disc,
Interleaved Disc, Helical, etc.

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Manufacturing Process:
Continuously Transposed Conductor

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Manufacturing Process:
CTC – Thermally upgraded paper

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Manufacturing Process:
CTC - epoxy bonded, netting tape

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Manufacturing Process:
CTC - Perforated Nomex

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Manufacturing Process:
Magnet Wire, Paper Insulated

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Manufacturing Process:
Winding Types
2 main groups
helical windings disc windings

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Manufacturing Process:
Flat/Edge Wound

Wound on flat side Edge Wound

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Manufacturing Process:
Winding Types
2 main groups
helical windings disc windings
• Boomerang • Continuous disc
• Giron • Interleaved
• Equally transposed • Partial Interleaved
• Layer and multilayer • Axial Interleaved
• Multistart

Mainly LV, TV, CR and FR Mainly HV, LV, FR

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Manufacturing Process:
Helical Winding

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Manufacturing Process:
Helix – Boomerang MW

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Manufacturing Process:
Helix- Boomerang, Giron, Double Helix
equally Transposed
Use(Varies from Manufacturer to Manufacturer):
–1 or 2 layers
–Up to 325 kV BIL for single-layer windings
–Up to 200 kV BIL for two-layer windings
–Axial cooling ducts in the winding or with zigzag cooling depending on what kind
of helix
–Preferably with at least one turn between successive transpositions

Advantages:
–Cheap winding
–No radial overbuild at the transpositions depends on Boomerang type

Disadvantages:
–One brazing per transposition on Boomerang type
–Cannot be used for zigzag cooling without radial overbuilds on Giron and Double
helix type

Transformer Consulting Services Inc.

Manufacturing Process:
Tapped helix MW / CTC
• Regulating winding(for LV)
• Easy to wind, high Cu cross-section possible
• Eccentric duct necessary if used as inside winding

For outside windings

For inside windings

Transformer Consulting Services Inc.

Manufacturing Process:
Multistart MW / CTC
• With ZnO-discs : up to 1050 kV BIL, Without ZnO-discs : up to 450 kV BIL if impulsed
and up to 950 kV BIL if not impulsed
• Easy to wind, Uniform Amp-turns distribution, Robust winding, especially when MW
is used on the edge
• Medium to high paper insulation thickness needed, due to the voltage difference of
1 or 2 taps between adjacent wires. This can cause high thermal winding gradients.

Transformer Consulting Services Inc.

Manufacturing Process:
Continuous disc
• Many electrical turns, up to 550 kV BIL with key spacers, above 550 kV BIL with key
spacers in combination with interleaved part at impulse side
• Easy to wind, No brazing, High axial space factor and reduced manufacturing time for
version without key spacers
• Partial turns can cause extra sections, Decreased radial space factor for the version
without key spacers

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Manufacturing Process:
Continuous disc Transposition

Transposition at each cross over

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 Continuous disc Transposition

Transposition at each cross over

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Manufacturing Process:
Interleaved
• Many electrical turns, typically above 550 kV BIL, if necessary for impulse reasons
Adjacent is standard method for interleaving, Braided interleaving method if
necessary for lightning impulse
• High impulse withstand capability, due to improved voltage distribution
• Brazing necessary, and thus very time consuming with CTC, Total number of sections
must be even

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Manufacturing Process:
Interleaved Winding

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Manufacturing Process:
Shielded Winding

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Manufacturing Process:
Shielded Winding

Transformer Consulting Services Inc.

Manufacturing Process:

Winding Selection
Based on:
• winding voltages: (nominal, test, impulse, …)
– number of turns
– electrical clearances
– ZnO discs allowed?
• winding current:
– needed Copper cross-sectional area
– maximum allowed temperature (average and hottest spot)
• cooling type: axial cooling or zigzag cooling
• winding position in the core window

Transformer Consulting Services Inc.

Manufacturing Process:

Directed and non-directed oil flow

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Manufacturing Process:
Lead Connection
• Stress ring and pick tail connected with lead

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Manufacturing Process:
Upender

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Manufacturing Process:
Insulation Shop
• Insulation Shop separate from other areas
• Winding cylinders and spacers are made from high density pressboard

Transformer Consulting Services Inc.

Manufacturing Process:
Complete Winding Insulation Package

Transformer Consulting Services Inc.

Manufacturing Process:
Coil Sizing
• Coil sizing force applied to check and adjust (of stabilize) the winding height

Transformer Consulting Services Inc.

Manufacturing Process:
Coil Assembly
• Winding type

• Conductor Type

• Insulation components

Transformer Consulting Services Inc.

Manufacturing Process:
Coil Assembly

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Manufacturing Process:
Coil Assembly

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Manufacturing Process:
Coil Assembly

Transformer Consulting Services Inc.

Manufacturing Process:
Coil & Core Assembly
• Exposed edges of core are bonded with low viscosity, high strength epoxy resin which
penetrates and bonds laminations.
• Prefabricated coil to clamp insulation is placed on bottom clamps

Transformer Consulting Services Inc.

Manufacturing Process:
Coil & Core
Assembly

• Coils lowered over core

• Top coil to clamp
insulation
• Top clamps
• Top core inserted

Transformer Consulting Services Inc.

Manufacturing Process:
Lead Braising

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Manufacturing Process:
Lead Braising

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Manufacturing Process:
• LV Cu bus bar instead of cable for high current

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Manufacturing Process:
• HV Center Fed with snout and draw lead to bushing; reactor for RMV tap changer

Transformer Consulting Services Inc.

Manufacturing Process:
Coil & Core Assembly
• Windings are clamped using external or internal tie rods to provide additional
support for axial forces
• Leads and busbars are rigidly supported to withstand forces from shipping &
short circuits
• Assembly moved on air cushions

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Manufacturing Process:
LTC Lead Connection

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Manufacturing Process:
DTC Lead Connection

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Manufacturing Process:
DTC Lead Connection

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Manufacturing Process:
Link Board: Re-connectable LV

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Manufacturing Process:
ZnO
• Used for taps usually above 550kV impulse voltage

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Manufacturing Process:
Vapor Phase Unit
•Complete core and coil assembly is dried using a vapor phase cycle
method
• Power factor & water extraction are continually monitored
• Kerosene is vaporized & drawn by vacuum into autoclave

Transformer Consulting Services Inc.

Manufacturing Process:
Tank Shop
• Designed to withstand full vacuum filling
• Facilities for lifting, jacking, and pulling provided

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Manufacturing Process:
Tank Shop

• All tanks are grit-blasted cleaned

before priming and painting.
• Inside painted white for good
visibility during internal
inspections.
• Shunt Packs

Transformer Consulting Services Inc.

Manufacturing Process:
Tank Covers
• Raised flanges are provided to prevent water entry
• Cover is designed to prevent water collection
• High quality steel plate is cut by an automated waterbed plasma cutter

Transformer Consulting Services Inc.

Manufacturing Process:
Re-Pack & Tanking
• After vapor phase unit is re-packed and undergoes final hydraulic clamping
• Maximum exposure time to atmosphere is limited to under 16 hours

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Manufacturing Process:
LTC Lead Connection

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Manufacturing Process:
LTC Lead Connection

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Manufacturing Process:
Exciter and Series Transformer

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Manufacturing Process:
Final Assembly
• Installation of conservator, radiators, pumps, fans, etc.

Transformer Consulting Services Inc.

Manufacturing Process:
Final Assembly
• Fans bottom mounted

Transformer Consulting Services Inc.

Manufacturing Process:
Final Assembly
• The surge of one pump should die down before the next pump comes-on

Transformer Consulting Services Inc.

Manufacturing Process:
Testing
• All Industry standard tests :
 Routine Tests
 Loss Measurement and Temperature Rise tests
 Dielectric tests
 Zero-phase-sequence
 Audible Sound Level
 Short-circuit tests, if required (performed at the IREQ lab)

Transformer Consulting Services Inc.

Manufacturing Process:

Factory Pretest
Test Standard Section Engineering Instruction
Parallel Turns No EMT 200.011
Ratio,Polarity,Core meg. Std EMT 200.011
R.S.G. Yes EMT 200.011
Non Linear Resistors Std EMT 200.011
CT's & PT's Std EMT 200.011
LTC Reactor Std EMT 200.011
LTC Pretest prior to tank. Std EMT 200.011.1

Transformer Consulting Services Inc.

 Manufacturing Process:
Factory Tests
Ratio Std ANSI C57.12.90 7.3.3
Polarity Std 6.2.2
Resistance Std 5.3.1
Core Loss & Exciting Current Std 8.1
Load Loss & Impedance Std 9.1
Zero Sequence Impedance 9.5
Temperature OA 11
Rise Tests FA 11
Overload 11
Lightning HV 10.3 kV LIL
Impulse HVN kV LIL
LV kV LIL
LVN kV LIL
TV kV LIL
Switching HV 10.2 kV SIL
Impulse LV kV SIL
Applied HV 10.5 kV rms
Potential LV kV rms
TV kV rms
Induced Potential 10.7
Partial Discharge 10.8
Sound Level 13
110 % Voltage Run CAN/CSA-C88-M90 16.3.k
Core Loss after Dielectrics ANSI C57.12.90 8
CAN/CSA-C88-M90 16.3.k
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Manufacturing Process:
Factory tests cont.
Test Standard Section Engineering Instruction
Dissipation Std EMT200.012.6 & ANSI 10.9
Core Megger Std CSA & EMT 200.012.1
CT Resistance Std
CT Ratio & Polarity Std CSA & EMT 200.012.4
PT Ratio & Polarity Std CSA & EMT 200.012.4
Hi-Pot: Panels, Fans, Std CSA & MI 355.021
Pumps
Hi-Pot: PT's & CT's Std CSA & EMT 200.012.4
Hot Spot Calibration Std CSA & EMT 200.012.8
Top Oil Calibration Std CSA & EMT 200.012.8
GDR Alarm & Trip Std CSA & EMT 200.012.8
Panel Operation Std CSA & EMT 200.012.7
Line Drop Compensator Std CSA & MI 355.105
Fan, Pump Losses;Klixon Std CSA & EMT 200.012.7
Tapgear Operation Std CSA & EMT 200.012.7
Pressure Tests Std CSA & MI 358.012

Gas-in-Oil Samples

PCB Oil Sample

ADDITIONAL TESTS

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Manufacturing Process:
Unit in Test

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Manufacturing Process:
Paint Booth
• Epoxy base paint system, meets ANSI C57.12.28

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Manufacturing Process:
Shipping
• Dismantle the transformer by removing the parts that need to be removed for shipping
• Process the unit for shipment by filling with oil, dry air or nitrogen depending on the
specific work instructions
• Main unit shipping check points:
– Unit checked against shipping outline
– All wrapping done and all plugs tied in upright position
– All loose parts, wires, leads, chains, etc. are secured
– Ladder door bolted & door stop tied down
– Swing panel in control box secured
– Control box locked
– Instruction manual in control box
– Impact recorders installed & started with instructions attached
• Parts shipping check points:
– Fan motor drain holes plugged and tags attached
– All cable & straps tight and ends secured
– All parts numbered
– Bushings packaged to prevent damage

Transformer Consulting Services Inc.

Manufacturing Process:
Impact recorder
• Testing:
– Impact recorders should be allowed to run a minimum of twelve (12) hours
before being initialized for a trip
– Verify that the stylus locking has been removed
– Shake the recorder in all three directions and check for stylus motion
– Turn the impact recorder on and allow it to sit undisturbed to check its
clock operation

• Installation:
– On rail shipments, one impact recorder is to be mounted on the deck of
the rail car within 18” of the transformer and one impact recorder is to
be mounted on the transformer
– On truck shipments, two impact recorders shall be mounted on the
transformer. Two impact recorder supports, near the center of gravity, will
be provided on each transformer.
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Manufacturing Process:
Shipping Parts

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Manufacturing Process:
Shipping Transformer (Trailer)

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Manufacturing Process:
Shipping Transformer (Rail Car)

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Transformer Consulting Services Inc.
 Th End

Transformer Consulting Services Inc.