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Use and Maintenance of
Oil-immersed Distribution Transformers

Elvim range
Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 1
Elvim, Merlin Gerin and Telemecanique become Schneider Electric

Moving our brands under the flagship brand Schneider Electric is an ambitious project that will make things simpler for all our partners and customers. Selection becomes simpler, the guarantee of equipment compatibility is reinforced and the integration of recently acquired technologies is optimized. The products themselves remain the same. With a single brand, Schneider Electric confirms its presence as a global specialist in energy management. With a network close to you and fast-responding teams, we commit to help you make the most of your energy, improve your efficiency and ensure the sustainable development of your business.
New product marking
Gradually, all major product families will be marked Schneider Electric. Only the product marking visual design changes. All the other specifications will remain the same: Technical features, function, weight, quality, commercial reference, technical information, From the 2nd trimester 2009, oil-immersed distribution transformers will be branded Schneider Electric and the name Elvim will become a range name.
From now on you will see
Use and Maintenance of
Oil-immersed Distribution Transformers

Elvim range
The transformer is an electrical machine that allows the transmission and distribution of electric energy simply and inexpensively, since its efficiency is greater than 95%. Through the brief description of the use and maintenance of the oil-immersed distribution transformers, the present technical leaflet provides useful information for the engineers, who are involved in the selection, purchasing, installation, operation and maintenance of transformers.
Contents
Section A: Use of Transformers
A.1 Transformer Types A.1.1 Classification of transformers according to the use Classification of transformers according to the cooling method Classification of transformers according to the insulating medium Classification of transformers according to the construction of the magnetic circuit General characteristics Advantages of Elvim distribution transformers Magnetic circuit Windings Metallic parts Assembly Cooling medium Tank Cover Lifting lugs Rollers Draining and sampling oil valve Neutral earthing link High voltage bushings Low voltage bushings Low voltage connectors Tap changer Voltage selector Transformer thermometer Oil conservator Buchholz relay Air dehumidifier Filling valve Oil level indicator Rating plate Tank earthing point Accessories of sealed type transformers Type tests Routine tests Special tests Rated power Temperature rise Ambient temperature Altitude of installation Short-circuit impedance Vector group No-load losses page 4 page 5 page 5 page 6 page 7 page 7 page 8 page 8 page 9 page 9 page 9 page 10 page 10 page 10 page 10 page 10 page 10 page 11 page 11 page 11 page 11 page 11 page 11 page 12 page 12 page 12 page 12 page 12 page 13 page 13 page 13 page 14 page 14 page 15 page 16 page 16 page 16 page 16 page 16 page 16 page 17 A.1.2 A.1.3 A.1.4 A.2 A.3 Elvim Distribution Transformers Transformer Manufacturing Features A.2.1 A.2.2 A.3.1 A.3.2 A.3.3 A.3.4 A.3.5 A.4.1 A.4.2 A.4.3 A.4.4 A.4.5 A.4.6 A.4.7 A.4.8 A.4.9 A.4.10 A.4.11 A.4.12 A.4.13 A.4.14 A.4.15 A.4.16 A.4.17 A.4.18 A.4.19 A.4.20 A.5.1 A.5.2 A.5.3 A.6.1 A.6.2 A.6.3 A.6.4 A.6.5 A.6.6 A.6.7
A.4 Transformer Components
A.5 Transformer tests A.6 Transformer electrical characteristics
A.6
Transformer electrical characteristics
A.6.8 A.6.9 A.6.10 A.6.11 A.6.12 A.6.13 A.6.14
Load losses Rated voltage Frequency Noise Efficiency Short-circuit current No-load current
page 17 page 17 page 18 page 18 page 18 page 18 page 18 page 19 page 19 page 20 page 21 page 21 page 22 page 23 page 23 page 24 page 26 page 28 page 30 page 32 page 34 page 34 page 35 page 35
A.7 A.8 A.9
Transformer standards Tolerances Transformer operation A.9.1 A.9.2 A.9.3 Overloading Parallel operation Load distribution of transformers in parallel operation
A.10 Transformer order form A.11 A.12 Transformer selection A.11.1 A.11.2 Electrical utilities Industrial users Single-phase transformers, from 5 to 50 kVA, 20/0.231 kV Three-phase transformers, from 250 to 1600 kVA, 20/0.4 kV Three-phase transformers, from 250 to 1600 kVA, 20/0.4 kV, with low losses Three-phase transformers, from 250 to 1600 kVA, 20-15/0.4 kV Three-phase sealed type transformers, from 25 to 1600 kVA, 20/0.4 kV Calculation of transformer efficiency Calculation of voltage drop Parallel operation of transformers Transformer selection
Elvim A.12.1 transformers series A.12.2
A.12.3 A.12.4 A.12.5 A.13 Examples A.13.1 A.13.2 A.13.3 A.13.4
Section B: Transformer installation and maintenance

B.1 B.2 B.3 B.4 B.5 B.6 Dimensions of transformer installation area Instructions for transformer installation Instructions for transformer maintenance Instructions for thermometer connection Instructions for the connection of the Buchholz relay Instructions for the connection of the air dehumidifier page 36 page 37 page 37 page 38 page 39 page 40
Schneider Electric Services
page 41
Section A:
Use of Transformers
A.1 Transformer types
The transformers are classified into various categories, according to their: (a) use, (b) cooling method, (c) insulating medium, (d) core construction. These categories are presented in the following subsections.
A.1.1 Classification of transformers according to the use

According to their use, the transformers are classified into the following categories:
(a) Distribution transformers

They are used in the distribution networks in order to transmit energy from the medium voltage (MV) network to the low voltage (LV) network of the consumers. Their power is usually ranging from 50 to 2500 kVA.
(b) Power transformers

They are used in the high-power generating stations for voltage step up and in the transmission substations for voltage step up or step down. Usually their power is bigger than 2,5 MVA.
(c) Autotransformers
They are used for voltage transformation within relatively small limits, for connection of electric energy systems of various voltages, for starting of AC (alternative current) motors, etc.
(d) Test transformers

They are used for the execution of performance tests with high or ultra-high voltage.
(e) Special power transformers

They are used for special applications, e.g. in furnaces and in welding.
(f) Instrument transformers

They are used for the accurate measurement of voltage or current.
(g) Telecommunication transformers

They are used in telecommunication applications aiming at the reliable reproduction of the signal in a wide range of frequency and voltage.
A.1.2 Classification of transformers according to the cooling method

The identification of oil-immersed transformers according to the cooling method is expressed by a four-letter code. The first letter expresses the internal cooling medium in contact with the windings. The second letter identifies the circulation mechanism for internal cooling medium. The third letter expresses the external cooling medium. The fourth letter identifies the circulation mechanism for external cooling medium. For example, if the internal cooling medium is mineral oil, which is circulated with natural flow, and the external cooling medium is air, which is circulated with natural convection, then this cooling method is coded as ONAN (Oil Natural Air Natural). In power transformers, various cooling methods are used including oil circulation by pumps, or forced air circulation by fans, or both of the above. As a result, the following cooling methods exist: ONAF: Oil Natural Air Forced. OFAN: Oil Forced Air Natural. OFAF: Oil Forced Air Forced. OFWF: Oil Forced Water Forced. Combinations like ONAN/ONAF, ONAN/OFAN or ONAN/OFAF are also applicable.
A.1.3 Classification of transformers according to the insulating medium

According to their insulating medium, the transformers are classified into the following categories:
(a) Oil-immersed type transformers

The insulating medium is mineral oil or synthetic (silicon) oil.
(b) Dry type transformers

The cooling is implemented with natural air circulation and the windings are usually insulated with materials of H or F class. The materials of H class are designed in order to operate, in normal conditions, under temperatures up to 180C and the materials of F class under temperatures up to 155C.
(c) Resin type transformers

The resin type transformer is a dry type transformer insulated with epoxy resin cast under vacuum.
A.1.4 Classification of transformers according to the construction of the magnetic circuit
The construction of the magnetic circuit of the three-phase transformers can be done, alternatively, as follows:
(a) With three legs (vertical limbs)

The magnetic flux of one leg must close through the other two legs and the flux also flows through the windings of the other phases, namely the transformer has non free return of the flux.
(b) With five legs (vertical limbs)

Free return of the flux through the external legs.
There are two different technologies for stacking the sheets of the magnetic material of the core:
(a) Stack core

The layers of the sheets of the magnetic material are placed one over the other and the vertical and the horizontal layers are over lapped.
(b) Wound core

The magnetic circuit is of shell type and the sheets are wound.
Two different materials are used for core construction:
(a) Silicon steel sheet

The silicon steel sheet that is used for the core construction is an alloy consisting of 97% iron and 3% silicon. This material has crystallic structure. The silicon steel sheets have thickness from 0.18 up to 0.5 mm. There are also silicon steel sheets for operation in high magnetic induction (Hi-B).
(b) Amorphous metal sheet

The amorphous metal sheet that is used for the core construction is an alloy consisting of 92% iron, 5% silicon and 3% boron. This material has not crystallic structure. It has 70% lower no-load loss than the silicon steel. The thickness of the amorphous metal sheet is 0.025 mm, namely it is about 10 times thinner than the typical thickness of the silicon steel sheet.
A.2 Elvim Distribution Trasformers

A.2.1 General characteristics
At the industrial site of Schneider Electric Greece, Elvim distribution transformers are manufactured, with voltages up to 36 kV, having oil as cooling medium and the following technical characteristics: Single-phase transformers from 5 up to 500 kVA. Three-phase transformers from 25 up to 2500 kVA.
A.2.2 Advantages of Elvim distribution transformers

A potential transformer user has a lot of reasons to choose Elvim distribution transformers that are manufactured by the industrial site of Schneider Electric Greece. Some of the most important reasons are the following: More than 35 years of experience in transformer manufacturing (the manufacturing site is active since 1969). As a result, the best techniques and methods are used during transformer design and manufacturing. The application of the ISO 9001 quality assurance system in combination with the very careful monitoring of the whole industrial process lead in the manufacturing of high quality transformers. The application of the ISO 14001 environmental management system assures the protection of the environment and the reasonable use of natural resources during the transformer production. The application of the OHSAS 18001 Health & Safety system assures that each employee enjoys the maximum level of health and safety in the working environment. The use of the best materials for the transformer construction. The reliability of the suppliers of the transformer materials is systematically monitored and checked. The high automation of the industrial process has dramatically decreased the delivery time. For example, special transformers can be delivered within 3 weeks. All the transformer offers are treated very carefully in order to finally give an offer, which fully satisfies the needs of the transformer user. The offer is technically complete and represents the optimum technical and economical solution for the specific transformer application. The wound core technology that is followed has the following advantages, in comparison with the stack core technology: Lower magnetization current. As a result, the transformer has lower current harmonics (better quality), lower consumption of reactive power and lower magnetization current. Less noise.
A.3 Transformer Manufacturing Features

A.3.1 Magnetic circuit
The wound core technology is followed and magnetic materials with low losses are used. The magnetic circuit is of shell type and the cores are wound. The production procedure of the wound core is as follows: the magnetic material is slit into sheets of standard widths. Next, the sheets are cut to predetermined lengths. Next, the sheets are wound on a circular mandrel and a circular core is created. Annealing treatment follows in order to recover the cores physical and electrical properties. The quality control department checks the quality of the wound core. Figure 1 shows one wound core.
Figure 1: Wound core.
A.3.2 Windings
The type of coil is rectangular concentric winding. For the low voltage coil, copper sheet or copper rectangular wire is mainly used. The high voltage coil is constructed from copper wire or copper rectangular wire. The combination of copper sheet in low voltage with copper wire in high voltage plus coated press paper with epoxy resin as interlayer insulation, increases the coils ability to withstand short-circuit. Important points during the production procedure are the following: Coil heat treatment at 100C so that epoxy resin is polymerized giving an extremely compact product, All coils pass through quality control. Figure 2 shows the assembled active part (cores and coils) of one three-phase wound core type transformer.
COILS
Figure 2: Transformer active part.
CORES
A.3.3 Metallic parts

For the construction of transformer metallic parts, the following basic mechanical equipment is used: CNC machines for cutting, punching and bending of steel sheets. Different types of welding machines (i.e. MIG-MAG, TIG, and electrode) for the welding of the metallic parts. Machines for construction and welding of corrugated panels and tanks. Certified technicians and welders are the operators of these machines. Stud welding equipment for stud welding on the transformer cover so that secure insulator placement is achieved. Equipment for oil leak detection of the transformer tanks. Modern painting shop for the painting of the metallic parts. The usual painting procedure includes the following steps: sandblasting, decreasingphosphatizing Fe, painting with 4 coats (two primer coats and two final color coats) with total thickness of 160 m. This painting procedure results in a durable corrosion protection and therefore lengthy life expectancy.
A.3.4 Assembly
For the transformer assembly, the following basic equipment is used: various cranes from 1 to 35 tons, one drying chamber to dry the active parts in order to remove the moisture, which is absorbed by the transformer insulating materials during the production procedure, two vacuum chambers, in which the transformers are filled with oil, machines for the processing of transformer oil, so that the oil obtains the appropriate characteristics, according to the international standards.
A.3.5 Cooling medium

Transformer oil according to IEC 60296 specifications is used as cooling medium. The initial filling of transformer with oil is done under high vacuum in order to assure the high penetration of oil everywhere and to remove air bubbles or moisture that could cause dielectric failure of coil. Oil can also be filled later on without vacuum under the prerequisite that the oil level covers the active part and the oil has been filtered. In agreement with the customer, the oil can be supplied from Schneider Electric or another company provided that the oil is according to the given standard.
A.4 Transformer Components

A.4.1 Tank
The transformer tank consists of the bottom plate, frame, and the tank sides. The tank sides are made of corrugated panels in order to increase the total cooling area. The tank of sealed type transformers (without oil conservator) is filled with oil and is sealed. The corrugated panels do not allow the creation of significant increase of pressure internally, which is caused by the increase of oil temperature during transformers operation. The transformer tank has two earthing points. The rolling system or the base skid is welded to the tank bottom plate.
A.4.2 Cover
There are two lifting lugs on the tank cover, which are used for lifting and carrying the transformer. On request, the thermometer pocket and the thermometer with two electrical contacts are placed on the cover. Moreover, a neutral earthing link is also placed on the cover. A pressure relief device is usually placed on the cover of the sealed type transformers.
A.4.3 Lifting lugs

The lifting lugs are used for lifting and carrying the transformer.
A.4.4 Rollers
The transformers up to 160 kVA are usually manufactured as pole-mounted. The transformers above 160 kVA are equipped with bi-directional rollers.
A.4.5 Draining and sampling oil valve

In the lower part of the tank side there is a draining and sampling oil valve, which allows the oil sampling in order to test the oil dielectric strength.
A.4.6 Neutral earthing link

This link ensures the neutral earthing of the three-phase winding with the transformer tank.
A.4.7 High voltage bushings

For medium voltage of 6, 10, 20, 30 kV, porcelain bushings according to DIN 42531 are used. Alternatively, on request, plug-in bushings can be used.
A.4.8 Low voltage bushings

Low voltage bushings of 1 kV series, according to DIN 42530, are used in the low voltage.
A.4.9 Low voltage connectors

Low voltage connectors, according to DIN 43675, are used.
A.4.10 Tap changer

The applying medium voltage to the primary winding of transformer is not stable and depends upon the transformer position in the distribution network. Therefore, taken the primary voltage as granted, the tap changer is used in order to keep the secondary voltage of the transformer as stable as possible. The tap changer is placed into the transformer tank. The control interface of the tap changer is placed on the cover. The handling of the tap changer must be done when the transformer is out of voltage, as follows: initially, the handle of the tap changer is pulled upwards so that the pin is released and entered into the fixed annulus. Then we turn the handle right or left so that the pin is placed to the desirable tap position. If it is desirable to switch from one position (e.g. position 1) to another (e.g. position 5), then the handling is implemented step by step, through all intermediate positions (e.g. positions 2, 3, 4). The taps positions are inscribed on the rating plate of the transformer. For example, when the transformer is designed to operate in two voltage levels, e.g. 20 kV and 15 kV, then using a 5-position tap changer, the regulation of the primary voltage can be 2x2.5 % for medium voltage 20 kV (i.e. voltages 19.0, 19.5, 20.0, 20.5, and 21.0 kV) and 2x3.3 % for medium voltage 15 kV (i.e. voltages 14.0, 14.5, 15.0, 15.5, and 16.0 kV).
A.4.11 Voltage selector

The voltage selector (changeover switch) is used for the change of the transformer operating voltage from one voltage level to another (e.g. from 15 kV to 20 kV and vice-versa) in proportion with the voltage of the network that the transformer is connected. The handling of the voltage selector is the same with the handling of the tap changer, the only difference is that the annulus has two positions (e.g. 15 kV or 20 kV). For example, if we want a 20-15/.4 kV transformer to operate with primary voltage 19.5 kV, we set the voltage selector at the 20 kV position and the tap changer at the -2.5% position.
A.4.12 Transformer thermometer

The thermocouple of the thermometer is set at the higher oil layer, in order to measure the maximum oil temperature. The electrical contacts of the thermometer are regulated to the desirable temperatures and are connected to the protection circuit for alarm and tripping of the circuit, when the corresponding temperature limits are exceeded.
A.4.13 Oil conservator

During the transformer oil temperature variation, and consequently the oil volume variation, the oil conservator undergoes this oil volume fluctuation. The oil conservator is equipped with an oil level indicator with two marks: the first mark shows the oil level at -20C and the second the oil level at +20C. Transformers with oil conservator are usually equipped with an air dehumidifier and a Buchholz relay.
A.4.14 Buchholz relay

The protection of the oil-immersed transformers from internal faults, which cause the development of gases or strong oil leakage, is implemented with Buchholz relay, which is installed between the transformer tank and the oil conservator. In case of gases creation (as a result of internal fault) or lack of oil, the first float is moved downwards and the alarm contact is activated. If the gases are sufficient (i.e. the internal fault is significant), then the second float is moved downwards and the trip contact is activated. The trip contact is also activated in case of strong oil flux to the oil conservator after short-circuit or internal fault. Moreover, the Buchholz relay provides protection from oil leakage.
A.4.15 Air dehumidifier

The air dehumidifier is placed on the oil conservator. Because of contraction and expansion of oil volume, the air passes through the dehumidifier towards and from the oil conservator. The air dehumidifier contains SiO2 crystals (silica gel), which absorb the air moisture. The silica gel should have the following colors: Yellow (silica gel is fully dry). Soft blue-white (silica gel is full of moisture). The silica gel absorbs the moisture until its color is yellow. When it is full of moisture and it changes its color and becomes soft blue-white, it must be dried or it must be replaced. Drying is achieved by heating it at temperatures between 120C and 150C until its color becomes yellow again.
A.4.16 Filling valve

The transformers are equipped with a filling valve, in order to have the ability to fill the transformers with mineral oil.
A.4.17 Oil level indicator

For the sealed type transformers (without oil conservator), the oil level indicator is placed on the tank side or on the transformer cover. For the transformers with oil conservator, an oil level indicator of tube type (glass transparent tube) or magnetic type is placed on the oil conservator.
A.4.18 Rating plate

According to the international standards, all the transformer data are mentioned on the rating plate: type of transformer, power in kVA, phases, frequency, short-circuit impedance, vector group, type of cooling, windings material, serial number, year of manufacturing, core and windings weight, oil weight, total weight, maximum ambient temperature, winding temperature rise, oil temperature rise, rated voltage of the primary winding, rated voltage of the secondary winding, rated current of the primary winding, rated current of the secondary winding, no-load losses, load losses, positions of tap changer and positions of voltage selector (if one exists).
A.4.19 Tank earthing point

Two tank earthing points are placed near the bottom of the tank (one earthing point in diametric opposite direction with the other earthing point), in order to have the ability for tank earthing.
A.4.20 Accessories of sealed type transformers

The sealed type transformers are usually equipped with a pressure relief valve and thermometer or DGPT2 relay. The DGPT2 relay has an overpressure switch, thermometer with alarm and trip contacts and oil indicator with contact for the trip of the circuit.
Elvim Oil-immersed Distribution Transformer

Buchholz relay High voltage bushings Tap changer Low voltage bushings Lifting lug
Oil conservator Oil level indicator
Air dehumidifier
Thermometer
Rating plate
Tank
Rollers
A.5 Transformer tests

The transformer tests are classified, in accordance with the specification IEC 60076, as follows: Type tests. Routine tests. Special tests.
A.5.1 Type tests

The type tests, which are performed on one transformer from every transformer type, are the following:
(a) Temperature rise test

The procedure of the temperature rise test is performed according to IEC 60076-2. With this specific test, the following tasks are implemented: a) the determination of the temperature rise of the oil, and b) the determination of the average temperature rise of the windings.
(b) Lighting impulse test

The procedure of the lightning impulse test is performed according to IEC 60076-3. With this specific test, the transformers withstand against overvoltages is checked. These overvoltages are caused from: a) traveling waves (that are caused from thunders) of transmission lines, b) sudden on/off switching of breakers, c) short-circuits at the substation area.
A.5.2 Routine tests

The routine tests are performed on every transformer separately. The routine tests include:
(a) Measurement of winding resistance

The procedure of the measurement of windings resistance is performed according to IEC 60076-1. During this test the resistance of each winding is measured and the temperature is recorded. The test is performed with DC (direct current). The measurement of the resistance of the windings is performed using a resistance bridge.
(c) Measurement of short-circuit impedance

The measurement of short-circuit impedance is performed according to IEC 60076-1. The short-circuit impedance, which is expressed as a percentage of the rated voltage, represents the transformers impedance. The international standards require the short-circuit impedance to be calculated at the reference temperature of 75C.
(b) Measurement of the voltage ratio and check of phase displacement

The measurement of the voltage ratio is performed according to IEC 60076-1. The objective of the specific test is to compare the measured values of the transformer ratio with the respective guaranteed values. For the transformer, the turns ratio is equal to the voltage ratio of primary and secondary winding, namely:
(d) Measurement of load losses

The measurement of load losses is implemented with the secondary winding short-circuited and by increasing the voltage of the primary winding till the current of the primary winding reaches its nominal value. The load losses are calculated at the reference temperature of 75C.
(e) Measurement of no load current and no-load losses

The measurement is performed according to IEC 60076-1. The no load current represents the real value of current that is required to magnetize the magnetic core. The no-load losses represent the active power that is absorbed by the transformer core when it is applied rated voltage and rated frequency in the one winding (e.g. secondary) and the other winding (e.g. primary) is open-circuited.
U1 U2
N1 N2
A.5.2 Routine tests (continue)

(f) Dielectric routine tests
The dielectric routine tests are the following:
(b) LV windings
The MV windings are short-circuited and grounded with the transformer tank. Then, single-phase voltage is applied to the LV windings, this voltage is determined by the voltage of the LV system, in which the transformer is going to be connected.
Applied voltage dielectric test

The duration of the test, according to IEC 60076-3, is 1 min. With this specific test, the following are checked: a) the insulation between MV and LV windings, b) the insulation between the tested windings and the tank, and c) the insulation between the tested windings and the magnetic circuit. The procedure of the measurement is as follows.
Induced voltage dielectric test

Three-phase voltage, twice the rated voltage, is induced to the transformer for 1 min. However, due to the doubling of the voltage, the magnetic induction is also doubled, resulting in transformer saturation and, consequently, there is a danger for the transformer to be destroyed. In order to avoid saturation, the frequency is doubled, so that the magnetic induction remains constant. Finally, during this test, the volts per turn and therefore the volts per layer are doubled. With this test, the dielectric strength between turns and layers is verified.
(a) MV windings
The LV windings are short-circuited and grounded with the transformer tank. Then, single-phase voltage is applied to the MV windings, this voltage is determined by the voltage of the MV system, in which the transformer is going to be connected.
A.5.3 Special tests

The special tests are not included in the category of type or routine tests and are executed after agreement between customer and manufacturer. The special tests are the following:
(a) Dielectric special tests (b) Determination of capacitances of windings-to-earth and between windings (c) Short-circuit withstand test
According to this test, the transformer is subjected to successively short-circuits of 0.5 sec duration and the transformer must withstand these short-circuits. Since this test requires high power, it is executed in special test centers. For example, in Greece, the Tests Research and Standards Center of Public Power Corporation executes this test.
(e) Measurement of the harmonics of the no-load current ( f) Measurement of insulation resistance and/or measurement of dissipation factor (tan) of the insulation system capacitances (g) Radio interference voltage (h) Measurement of zero-sequence impedance
(d) Determination of sound levels

The transformer is energized at no-load and at rated voltage and rated frequency, so the noise peripherally to the transformer can be measured. The test is performed in accordance to specification NEMA TR - 1/1974.
A.6 Trasformer Electrical Characteristics

A.6.1 Rated Power
The rated power, Pn, of the three-phase transformer is calculated by the following formula: Pn= Un In 3 where Un is the rated voltage and In is the rated current of the transformer.
A.6.2 Temperature rise

The temperature rise is the maximum rise when the transformer operates at the primary rated voltage, secondary rated current and rated frequency.
Transformer typical characteristics:

The average temperature rise of the winding The top oil temperature rise is 60 K.
is 65 K.
A.6.3 Ambient Temperature

The rated power of the transformer is typically calculated for the following conditions: Maximum ambient temperature of 40C. Average daily ambient temperature of 30C. Average annual ambient temperature of 20C. On request, transformers operating under different ambient temperature conditions can be produced.
A.6.4 Altitude of installation

The rated power of the transformer is valid for installation altitude up to 1000 m. If the transformer is going to be installed in an altitude higher than 1000 m, this should be mentioned in the transformer specification.
A.6.5 Short-circuit impedance

The short-circuit impedance is the percentage of the primary rated voltage that has to be applied at the transformer primary winding, when the secondary winding is short-circuited, in order to have the rated current at the primary winding. The short-circuit impedance is very important, because it represents the transformers impedance. The higher the short-circuit impedance, the higher the voltage drop. The lower the short-circuit impedance, the higher the short-circuit current, in case of short-circuit. Based on the short-circuit impedance, the following are determined: the voltage drop due to the transformer loading, the distribution of loads in case of transformers parallel operation, and the short-circuit current.
A.6.6 Vector group

The vector group determines the phase displacement between the primary and the secondary winding. The three primary or secondary windings can be connected with different ways in order to have a threephase transformer. These connections are the following: D (d): delta connection for high voltage (low voltage) winding Y (y): star connection for high voltage (low voltage) winding Z (z): zigzag connection for high voltage (low voltage) winding N (n): the neutral exists in high voltage (low voltage) winding for connection outside the transformer.
A.6.7 No-load losses

The no-load losses include losses due to no-load current, hysteresis losses and eddy current losses in core laminations, stray eddy current losses in core clamps and bolts, and losses in the dielectric circuit. Table 1 presents the 5 lists (E0, D0, C0, B0, A0) of no-load losses for transformers from 50 to 2500 kVA, according to EN 50464-1:2007.
Rated power kVA P0 W
E0
LwA dB(A) P0 W
D0
LwA dB(A) P0 W
C0
LwA dB(A) P0 W
B0
LwA dB(A) P0 W
A0
LwA dB(A)
Short circuit impedance %
50 100 160 250 315 400 500 630 630 800 1000 1250 1600 2000 2500
NOTE:
190 320 460 650 770 930 1100 1300 1200 1400 1700 2100 2600 3100 3500
55 59 62 65 67 68 69 70 70 71 73 74 76 78 81
145 260 375 530 630 750 880 1030 940 1150 1400 1750 2200 2700 3200
50 54 57 60 61 63 64 65 65 66 68 69 71 73 76
125 210 300 425 520 610 720 860 800 930 1100 1350 1700 2100 2500
47 49 52 55 57 58 59 60 60 61 63 64 66 68 71
110 180 260 360 440 520 610 730 680 800 940 1150 1450 1800 2150
42 44 47 50 52 53 54 55 55 56 58 59 61 63 66
90 145 210 300 360 430 510 600 560 650 770 950 1200 1450 1750
39 41 44 47 49 50 51 52 52 53 55 56 58 60 63 6 4
P0 = no load losses
LwA = sound power level
Table 1: No load losses P0 (W) and sound power level (Lw(A)) for Um 24kV
A.6.8 Load losses

The load losses include losses due to load currents and eddy current losses in conductors due to leakage fields. Table 2 presents the 4 lists (Dk, Ck, Bk, Ak) of load losses for transformers from 50 to 2500 kVA, according to EN 50464-1:2007. For example, a transformer has a combination of losses of Dk-A0, if its load losses belong to list Dk, and its no-load losses belong to list A0.
Rated power kVA 50 100 160 250 315 400 500 630 630 800 1000 1250 1600 2000 2500 Dk W 1350 2150 3100 4200 5000 6000 7200 8400 8700 10500 13000 16000 20000 26000 32000 Ck W 1100 1750 2350 3250 3900 4600 5500 6500 6750 8400 10500 13500 17000 21000 26500 Bk W 875 1475 2000 2750 3250 3850 4600 5400 5600 7000 9000 11000 14000 18000 22000 Ak W 750 1250 1700 2350 2800 3250 3900 4600 4800 6000 7600 9500 12000 15000 18500 6 4 Short circuit impedance %
Table 2: Load losses Pk (W) at 75C for Um 24kV
A.6.9 Rated voltage

The rated primary voltage (input voltage) is the voltage at which the transformer is designed to operate. The rated primary voltage determines the basic insulation level (BIL) of the transformer, according to international standards (IEC 60076). The BIL is a basic transformer characteristic, since it indicates the transformer ability to withstand the overvoltages that can appear in the network. The calculation of the winding insulation is based on the basic insulation level. The rated secondary voltage (output voltage) is the voltage at the terminals of the secondary winding at noload, under rated primary voltage and rated frequency.
A.6.10 Frequency
The frequency at which the transformer is designed to operate is 50 Hz or 60 Hz in accordance with the network frequency.
A.6.11 Noise
The transformer noise is due to the magnetostriction of the sheets of the magnetic circuit. In general, a transformer operating at low magnetic induction has low noise level.
A.6.12 Efficiency
The distribution transformers are very efficient machines since their efficiency is greater than 95%. The power efficiency of any electrical machine is defined as the ratio of the useful power output to the total power input. The efficiency can be defined by simultaneously measuring the output and the input power. However, this measurement is expensive and difficult, especially for large machines. Moreover, in case of high efficiency machines (e.g. transformer), higher precision can be achieved, if the efficiency is expressed through the losses. Consequently, the transformer efficiency is calculated by the following formula: n= where S is the transformer load in VA, losses are the losses in W and cos is the power factor. The transformer efficiency is increased with the decrease of transformer losses. The transformer losses are divided into no-load losses and load losses. The no-load losses are constant, while the load losses are proportional to the transformer load. Consequently, the efficiency of the transformer is calculated by the following formula: n=
S cos S cos + NLL + LL(S/SB )2
S cos S cos + losses
where NLL are the no-load losses, LL are the load losses and SB is the rated power of the transformer in VA.
A.6.13 Short-circuit current

The short-circuit current is composed of the asymmetrical and the symmetrical short-circuit current. The amplitude of the first peak of the asymmetrical short-circuit current is equal to 2 times the value of the symmetrical short-circuit current. The factor 2 depends on the ratio of Ux /Ur, where Ux is the voltage drop in the reactive components of the transformer and Ur is the voltage drop in the resistance components of the transformer. Table 3 presents the values of the factor 2 versus the ratio Ux/Ur. The symmetrical short-circuit current, IK , is expressed as a function of the rated current In. If the secondary winding is short-circuited and the nominal current is applied at the primary winding, the following equation holds: The asymmetrical short-circuit current stresses mechanically the transformer, while the symmetrical short-circuit current stresses thermally the transformer. Elvim transformers are designed and tested to withstand short-circuit currents according to IEC 60076-5.
Ux / Ur 2
1 .5 1 2 3 4 5 6 8 10 15 25 50 1.51 1.63 1.75 1.95 2.09 2.19 2.28 2.38 2.46 2.56 2.66 2.77
IK In
100 UK
where UK is the short-circuit impedance.
Table 3: Values of the factor 2 versus the ratio Ux /Ur
A.6.14 No-load current

The no-load current represents the current that the transformer absorbs, when rated voltage is applied to the primary winding and the secondary winding is open-circuited. The no-load current is expressed as a percentage of the value of the rated current.
A.7 Transformer Standards

The transformer manufacturing is based on the international standards as well as on specific customer needs. From time to time, some of the standards may be modified and in that case they are republished. A list of transformer standards, according to IEC, is shown in Table 4.
Number Standard
1 2 3 4 5 6 7 8 IEC 60076-1 IEC 60076-2 IEC 60076-3 IEC 60076-5 IEC 60137 IEC 60354 IEC 60726 IEC 60905
Description
Power transformers: general Power transformers: temperature rise Power transformers: insulation levels and dielectric tests Power transformers: ability to withstand short circuit Bushings for alternating voltages above 1000 V Loading guide for oil-immersed power transformers Dry-type power transformers Loading guide for dry-type power transformers
Table 4: Transformer standards according to IEC.
The above standards are related with the electrical characteristics and the accessories of transformers. The IEC 60076 standard describes the electrical characteristics and the transformer tests that are related with the dynamic, thermal and electrical withstand of transformers. The DIN standard defines the transformer accessories and the EN 50464-1 standard defines the lists of transformer losses and short-circuit impedance.
A.8 Tolerances
Constructional reasons result in deviations between the measured parameters and the values that are defined by the specification of the transformer user (i.e. the guaranteed values). Table 5 presents the tolerances that are applied to certain items, according to IEC 60076-1.
tem
Voltage ratio Short-circuit impedance No-load losses Load losses Total losses (load and no-load) No-load current
Tolerance
The lower of the following values: a) 0.5% of guaranteed voltage ratio b) 1/10 of the measured short-circuit impedance on the principal tapping 10% of the guaranteed short-circuit impedance +15% of the guaranteed no-load losses +15% of the guaranteed load losses +10% of the guaranteed total losses (load and no-load) +30% of the guaranteed no-load current
Table 5: Tolerances on certain transformer items according to IEC 60076-1.
A.9 Transformer Operation

A.9.1 Overloading
The rated overloading of transformer depends on the transformers previous load or the corresponding oil temperature at the beginning of the overloading. Examples of the permissible duration and the respective levels of the acceptable overloadings are shown in Table 6. For example, if the transformer is loaded with 50% of its rated power continuously, then the transformer can be overloaded to150% of its rated power for 15 minutes or to 120% of its rated power for 90 minutes.
Previous continuous Oil temperature loading (C) (% of rated power)

50 75 90 55 68 78
Duration (min) of overloading for specific levels of overloading (% of rated power)

10% min 180 120 60 20% min 90 60 30 30% min 60 30 15 40% min 30 15 8 50% min 15 8 4
Table 6: Permissible duration and level of acceptable overloading.
Moreover, it should be noted that the oil temperature is not a safe measure for the winding temperature, since the time constant of the oil is 2 to 4 hours, while the time constant of the winding is 2 to 6 minutes. Therefore, the determination of the permissible duration of the
overloading must be done very carefully, since there is a danger for the winding temperature to exceed the critical temperature of 105C, without this being visible by the oil temperature.
A.9.2 Parallel operation

The parallel operation of two or more transformers is feasible, when the following requirements are met:
Their vector groups should be the same and the
The ratio of their rated power should be less Their voltage ratio should be the same
than 3:1. (the permitted tolerance is according to IEC 60076-1, Table 5, A.8). Their short-circuit impedance should be the same (the permitted tolerance is according to IEC 60076-1, Table 5, A.8).
connection should be implemented with the corresponding terminals U-u, V-v, W-w. In other words, the transformers must have the same inherent phase angle difference between primary and secondary terminals, the same polarity and the same phase sequence. It should be noted that, in case that the vector groups are not the same, the parallel operation of transformers of groups 5 and 11 is permitted, if the connection is implemented according to Table 7.
Transformer group for parallel operation

5
Group of existing transformer

5 11
Connection between phases High Voltage Low Voltage

R S T U V W U W V or W V U or V U W U V W U W V or W V U or V U W rst xyz wvu or v u w or u w v uvw zyx or y x z or x z y
11 11 5
Table 7: Parallel operation of transformers of groups 5 and 11.
A.9.3 Load distribution of transformers in parallel operation

If the parallel operated transformers have the same voltage ratio but different short-circuit impedance, then the load is distributed among them in such a way that each transformer accepts a specific level of load for which the short-circuit impedance becomes the same for all the parallel operated transformers. When none of the parallel operated transformers is permitted to be overloaded, the transformer with the minimum short-circuit impedance must operate maximum under its rated power. Consequently, the load distribution is given by the following equation: Pi = Pni where Pi is the load that is distributed to the i transformer, Pni is the rated power of the i transformer UKi is the rated short-circuit impedance of the i transformer and UK min is the minimum rated shortcircuit impedance of the n parallel operated transformers. Finally, the total power of the n parallel operated transformers is:
n
(P )
i=1
i
UK min UKi
<
P.
i=1
i
UK min UKi
An arithmetic example of the load distribution of transformers in parallel operation is given in A.13.3.
A.10 Transformer order form

The transformer order form includes the following data: Customer Sales engineer Transformer type Rated power (kVA) Rated primary/secondary voltage (kV) Frequency (Hz) Installation Altitude Cooling Transformer type Oil conservator Transformer dimensions (mm) Taps Short-circuit impedance (%) at 75C Vector group No-load losses (W) Load losses (W) tolerance acc. to IEC tolerance acc. to IEC other tolerance other tolerance 50 indoor 1000 m ONAN oil yes length 2x2.5% width 60 outdoor >1000 m other dry type no height others three-phase single-phase
Maximum temperature rise of winding Top oil temperature rise Maximum ambient temperature Painting type Accessories
65 K 60 K 40C RAL 7033
other other other other DGPT2 oil indicator thermometer
Buchholz relay air dehumidifier pressure relief valve
rollers Distance between rollers (mm)
Quantity (items) Unit price () Payment method Order date Delivery date Comments
A.11 Transformer selection

The selection of the most appropriate transformer starts with the definition of the proper and detailed specification. The special needs of each project specify the special characteristics or accessories that are needed. The evaluation of the alternative transformer offers depends on the transformer user. The economic evaluation method of the transformers by the electrical utilities and industrial users is presented below.
A.11.1 Electrical Utilities

The electrical utilities evaluate the transformers based on the criterion of the total owning cost, TOC (), which is calculated from the following equation: TOC = BP + A* NLL + B* LL, where BP () is the transformer sales price, A (/W) is the no-load losses factor, NLL (W) are the noload losses, B (/W) is the load losses factor, and LL (W) are the load losses. Among alternative transformer offers, the economical optimum is the one with the minimum total owning cost. The values of the parameters BP, NLL, and LL are determined by the transformer manufacturer. The values of the parameters A and B are determined by the electrical utilities.
A.11.2 Industrial Users

The procurement of transformers by the industrial users is based mainly on the transformer sales price and secondary on the transformer losses. An arithmetic example for the determination of the most economical transformer for an industrial user is presented in A.13.4.
A.12 Elvim Transformers Series

In this paragraph, five indicative Elvim transformers series are presented.
A.12.1 Single-phase transformers, from 5 to 50 kVA, 20/0.231 kV

General Description
Single-phase distribution transformers, 50 Hz. IEC 60076 standard is followed. The cooling is implemented with natural circulation (ONAN) of mineral oil according to IEC 60296. Sealed type transformers. Outdoor installation. Pole-mounted. Rated primary voltage 20 kV, rated secondary voltage 231 V at no-load. The top oil temperature rise is 60 K and the average temperature rise of the winding is 65 K. Tolerances of losses and short-circuit impedance according to IEC 60076. The transformer painting type is RAL 7033.
Basic Equipment
3-position tap changer with 5 % tappings at 20 kV. LV and HV bushings. Valves for filling, filtering and oil sampling. Pole-mounting elements. Rating plate.
Electrical Characteristics Rated Power (kVA)

No-load losses (W) (*) Load losses at 20 kV (W)(*) Voltage drop at full load (%) Load Load 75% cos =1 cos = 0.8 cos =1 cos =1 cos = 0.8
5
55 150 3.04 3.99 4 96.06 95.12 96.42 95.56
10
55 320 3.23 4.00 4 96.39 95.52 96.96 96.23
15
70 485 3.26 4.00 4 96.43 95.58 97.04 96.33
20
85 650 3.28 4.00 4 96.46 95.61 97.08 96.38
25
105 725 2.94 3.97 4 96.79 96.02 97.34 96.69
30
120 800 2.71 3.93 4 97.02 96.31 97.53 96.93
50
180 1350 2.74 3.93 4 97.03 96.32 97.56 96.96
Rated short-circuit impedance (%)(*) Efficiency (%) 100% cos =0.8
Order Details
Rated power Short-circuit impedance Rated voltages No-load losses Rated frequency Load losses Altitude of installation (if the altitude exceeds 1000 m) Primary tappings Special accessories Ambient temperature
(*)
Transformers with different losses and short-circuit impedance can be manufactured, on request.
General Arrangement of Single-phase Transformers, from 5 to 50 kVA, 20/0.231 kV
1. Filling plug DIN 42553 form "D" 2. Drain and sampling valve DIN 42551 NW22 3. Lifting lugs 4. H.V. bushings 5. L.V. bushings 6. Rating plate 7. Off-load tap changer 8. Transformer base 9. Pole mounted elements
Dimensions (mm)
Rated power (kVA) A (mm) B (mm) C (mm) Total weight (Kg) 5 620 540 930 115 10 620 540 1050 140 15 690 630 1020 155 20 690 630 1020 165 25 730 640 1020 210 30 730 640 1020 225 50 805 770 1035 295
Due to evolution of standards and materials, the present manual will bind us only after confirmation from our transformer design department.
A.12.2 Three-phase transformers, from 250 to 1600 kVA, 20/0.4 kV

General Description
Three-phase disrtibution transformers, 50 Hz. IEC 60076 standard is followed. Transformers with oil conservator. The cooling is implemented with natural circulation of mineral oil according to IEC 60296. Indoor or outdoor installation. Ground-mounted. Rated primary voltage 20 kV, rated secondary voltage 400 V at no-load. Vector group Dyn11. The top oil temperature rise is 60 K and the average temperature rise of the winding is 65 K. Tolerances of losses and short-circuit impedance according to IEC 60076. The transformer painting type is RAL 7033.
Basic Equipment
5-position tap changer with 2 x 2.5 % tappings at 20 kV. LV and HV bushings. Oil conservator with oil level indicator. Thermometer with oil level indicator and electrical contacts. Buchholz relay. Air dehumidifier. Valves for filling, filtering and oil sampling. Bi-directional rollers. Rating plate.
Electrical Characteristics Rated power (kVA)

No-load losses (W)(*) No-Load losses at 20 kV (W)(*) Voltage drop at full load (%) Load Efficiency (%)) Load cos=1 cos=0.8 cos=1 cos=1
250 610 4450 1.94 4.92 6 98.02 97.53 98.37 97.97 400 850 6450 1.78 4.82 6 98.21 97.77 98.53 98.17 500 1000 7800 1.73 4.79 6 98.27 97.85 98.58 98.24 630 1200 9300 1.65 4.74 6 98.36 97.96 98.66 98.33 800 1450 11000 1.55 4.68 6 98.47 98.09 98.74 98.43 1000 1750 1.52 4.66 6 1250 2100 1.48 4.64 6 1600 2550 19800 1.41 4.59 6 98.62 98.28 98.87 98.59
13500 16400
Rated short-circuit impedance (%)(*) 100% cos=0.8 75% cos=0.8
98.50 98.54 98.13 98.18 98.77 98.81 98.47 98.51
Order Details
Rated power Short-circuit impedance Rated voltages No-load losses Rated frequency Load losses Vector group Altitude of installation (if the altitude exceeds 1000 m) Primary tappings Special accessories Ambient temperature Details of cable boxes (on request)
(*)
General Arrangement of Three-phase Transformers, from 250 up to 1600 kVA, 20/0.4 kV
1. Transformer tank 2. Tank cover 3. Lifting lugs 4. Roller DIN 42561 5. Draining and sampling valve DIN 42551 6. Neutral earthing link 7. High voltage bushing DIN 42531 8. Low voltage bushing DIN 42530 9. Low voltage connector DIN 43675 10. Tap changer 11. Thermometer with two electrical contacts 12. Oil conservator 13. Buchholz relay 14. Air dehumidifier 15. Filling valve DIN 42553 16. Oil level indicator 17. Rating plate 18. Tank earthing point
Dimensions (mm)
Rated power (kVA) A (mm) B (mm) C (mm) D (mm) Total weight (Kg) 250 1475 905 1530 520 1100 400 1700 1005 1490 670 1380 500 1735 1005 1720 670 1700 630 1710 1050 1815 670 1940 800 1855 1195 1890 670 2380 1000 1960 1290 1895 820 2650 1250 1940 1270 2085 820 3200 1600 2155 1450 2095 820 3760
Due to the evolution of standards and materials, the present manual will bind us only after confirmation from our transformer design department.
A.12.3 Three-phase transformers, from 250 to 1600 kVA, 20/0.4 kV, with low losses
General Description
Three-phase distribution transformers, 50 Hz. Combination of losses Dk-A0, EN 50464-1:2007. IEC 60076 standard is followed. The cooling is implemented with natural circulation of mineral oil according to IEC 60296. Transformers with oil conservator. Indoor or outdoor installation. Ground-mounded. Rated primary voltage 20 kV, rated secondary voltage 400 V at no-load. Vector group Dyn11. The top oil temperature rise is 60 K and the average temperature rise of the winding is 65 K. Tolerances of losses and short-circuit impedance according to IEC 60076. The transformer painting type is RAL 7033.
Basic Equipment
5-position tap changer with 2 x 2.5 % tappings at 20 kV. LV and HV bushings. Oil conservator with oil level indicator. Thermometer with oil level indicator and contacts. Buchholz relay. Air dehumidifier. Valves for filling, filtering and oil sampling. Bi-directional rollers. Rating plate.
Electrical Characteristics Rated Power (kVA)

No-load losses (W)(*) Load losses at 20 kV (W)(*) Voltage drop at full load (%) Load Efficiency (%) Load cos=1 cos=0.8 cos=1 cos=1
250 425 3250 1.37 3.33 4 98.55 98.20 98.81 98.52 400 610 4600 1.22 3.25 4 98.71 98.40 98.95 98.69 500 750 5500 1.17 3.22 4 98.77 98.46 98.99 98.73 630 860 6500 1.11 3.17 4 98.85 98.56 99.05 98.82 800 940 8700 1.26 4.49 6 98.81 98.52 99.04 98.80 1000 1100 1.22 4.47 6 1250 1350 1.24 4.48 6 1600 1700 17000 1.24 4.48 6 98.84 98.56 99.07 98.84
10500 13300
Rated short-circuit impedance (%)(*) 100% cos=0.8 75% cos=0.8
98.85 98.84 98.57 98.56 99.07 99.07 98.85 98.84
Order Details
Rated power Short-circuit impedance Rated voltages No-load losses Rated frequency Load losses
(*)
Vector group Altitude of installation (if the altitude exceeds 1000 m) Primary tappings Special accessories Ambient temperature Details of cable boxes (on request)
General Arrangement of Three-phase Transformers, from 250 to 1600kVA, 20/0.4 kV, with low losses
1. Transformer tank 2. Tank cover 3. Lifting lugs 4. Roller DIN 42561 5. Draining and sampling valve DIN 42551 6. Neutral earthing link 7. High voltage bushing DIN 42531 8. Low voltage bushing DIN 42530 9. Low voltage connector DIN 43675 10. Tap changer 11. Thermometer with two electrical contacts 12. Oil conservator 13. Buchholz relay 14. Air dehumidifier 15. Filling valve DIN 42553 16. Oil level indicator 17. Rating plate 18. Tank earthing point
Dimensions (mm)
A.12.4 Three-phase transformers, from 250 to 1600 kVA, 20-15/0.4 kV

General Description
Three-phase distribution transformers, 50 Hz. IEC 60076 standard is followed. The cooling is implemented with natural circulation of mineral oil according to IEC 60296. Transformers with oil conservator. Indoor or outdoor installation. Ground-mounted. Rated primary voltage 20 and 15 kV, rated secondary 400 V at no-load. Vector group Dyn11. The top oil temperature rise is 60 K and the average temperature rise of the winding is 65 K. Tolerances of losses and short-circuit impedance according to IEC 60076. The transformer painting type is RAL 7033.
Basic Equipment
Voltage selector. 5-position tap changer with 2 x 2.5 % tappings at 20 kV and 2 x 3.33 % tappings at 15 kV. LV and HV bushings. Oil conservator with oil level indicator. Thermometer with level indicator and contacts. Buchholz relay. Air dehumidifier. Valves for filling, filtering and oil sampling. Bi-directional rollers. Rating plate.

No-load losses (W)(*) Load losses as 20 kV (W)(*) Voltage drop at full load (%) Load Efficiency (%) Load 75% cos=1 cos=0.8 cos=1 cos=1 cos=0.8
250 575 4000 1.77 4.82 6 98.20 97.76 98.52 98.15 400 810 6350 1.75 4.81 6 98.24 97.81 98.56 98.21 500 930 7500 1.67 4.76 6 98.34 97.94 98.65 98.31 630 1000 9300 1.65 4.74 6 98.39 98.00 98.70 98.38 800 1180 10800 1.52 4.66 6 98.52 98.16 98.81 98.51 1000 1360 1.45 4.62 6 1250 1720 1.25 4.49 6 1600 1950 17400 1.26 4.49 6 98.81 98.51 99.03 98.79
12800 13500
Rated short-circuit impedance (%)(*) 100% cos=0.8
98.60 98.80 98.26 98.50 98.87 99.02 98.59 98.77
Order Details
(*) Transformers with different losses and short-circuit impedance can be manufactured, on request.
General Arrangement of Tree-phase Transformers, from 250 to 1600 kVA, 20-15/0.4 kV
1. Transformer tank 2. Tank cover 3. Lifting lugs 4. Roller DIN 42561 5. Draining and sampling valve DIN 42551 6. Neutral earthing link 7. High voltage bushing DIN 42531 8. Low voltage bushing DIN 42530 9. Low voltage connector DIN 43675 10. Tap changer 11. Voltage selector 12. Thermometer with two electrical contacts 13. Oil conservator 14. Buchholz relay 15. Air dehumidifier 16. Filling valve DIN 42553 17. Oil level indicator 18. Rating plate 19. Tank earthing point
Dimensions (mm)
A.12.5 Three-phase sealed type transformers, from 25 to 1600 kVA, 20/0.4 kV

General Description
Three-phase distribution transformers, 50 Hz. IEC 60076 standard is followed. The cooling is implemented with natural circulation of mineral oil according to IEC 60296. Sealed type transformers (without oil conservator). Indoor or outdoor installation. Ground-mounted. Rated primary voltage 20 kV, rated secondary 400 V at no-load. Vector group Yzn5 (up to 160 kVA) and Dyn5 (from 250 kVA to 1600 kVA). The top oil temperature rise is 60 K and the average temperature rise of the winding is 65 K. Tolerances of losses and short-circuit impedance according to IEC 60076. The transformer painting type is RAL 7033.
Basic Equipmemt
5-position tap changer with 2 x 2.5 % tappings at 20 kV. LV and HV bushings. Valves for filling, filtering and oil sampling. Oil level indicator. Bi-directional rollers. Rating plate. Pressure relief device. Thermometer with two electrical contacts.

No-load losses (W)(*) Load losses at 20 kV (W)(*) Voltage drop at full load (%) Load Efficiency (%) Load 75% cos=1 cos=0.8
25
110 700 2.84 3.96 4
40
170
50
180
63 100
230 320
125 160
380 460
250
650
400 630
800 1000 1600
930 1270 1350 1700 2300
985 1100 1350 1750 2100 2350 3250 4600 6500 8600 10500 13600 2.51 2.26 2.20 1.81 3.87 3.77 3.75 3.57 4 4 4 4 1.75 1.54 3.54 3.43 4 4 1.47 4.63 6 1.32 1.21 4.53 4.46 6 6 1.25 1.22 1.03 4.48 4.47 4.33 6 6 6
Rated short-circuit impedance (%)(*)
cos=1 96.86 97.19 97.50 97.55 97.97 98.05 98.27 98.46 98.64 98.78 98.77 98.79 99.02 cos=1 97.38 97.64 97.91 97.95 98.29 98.36 98.54 98.70 98.84 98.97 98.98 99.00 99.18 cos=0.8 96.75 97.07 97.41 97.45 97.87 97.96 98.18 98.37 98.56 98.71 98.73 98.75 98.97
100% cos=0.8 96.11 96.52 96.90 96.96 97.48 97.58 97.85 98.09 98.30 98.48 98.47 98.50 98.77
Order Details
(*) Transformers with different losses and short-circuit impedance can be manufactured, on request.
General Arrangement of Three-phase Sealed Type Transformers, from 25 to 1600 kVA, 20/0.4 kV
Alternative position of rating plate
D B 1. Corrugated panels 2. Tank earthing point 3. Filling valve DIN 42553 4. Draining and sampling valve 5. Lifting lugs 6. High voltage bushings 7. Low voltage bushings DIN 42530 8. Rating plate 9. Thermometer with two electrical contacts 10. Tap changer 11. Pressure relief device 12. Rollers 13. Neutral earthing link 14. Oil level indicator
Dimensions (mm)
Rated power (kVA) A (mm) B (mm) C (mm) D (mm) Total weight (Kg)
25 850 680 1140 520 365 40 870 680 1140 520 435 50 900 680 1140 520 450 63 930 680 1200 520 500 100 950 680 1260 520 640 125 1000 680 1275 520 705 160 1130 770 1275 520 825 250 1370 855 1270 520 1050 400 1530 895 1350 670 1450 630 1820 1160 1350 670 1950 800 1870 1240 1460 670 2220 1000 1900 1220 1570 820 2600 1600 2260 1415 1600 820 2740
Due to the evolution of standards and materials, the present document will bind us only after confirmation from our transformer design department.
A.13 Examples
A.13.1 Calculation of Transformer Efficiency
Let us assume that a three-phase transformer, 630 kVA, 20/0.4 kV, has 1200 W no-load losses and 9300 W load losses. Determine the transformer efficiency at full load (case 1) and at 75% load (case 2) for power factor 1.0 and 0.8.
Case 1: full load

The efficiency at full load and for power factor equal to 1.0 (cos =1.0) is calculated as follows: 1 = = S cos = S cos + NLL + LL(S/SB)2 630000*1.0 = 0.9836 = 98.36 % 630000*1.0 + 1200 + 9300*(1.0)2
Case 2: load 75%

The efficiency at load 75% and cos =1.0 is: 3 = 472500*1.0 = 98.66 % 472500*1.0 + 1200 + 9300*(0.75)2
The efficiency at load 75% and cos =0.8 is: 4 = 472500*0.8 = 98.33 % 472500*0.8 + 1200 + 9300*(0.75)2
The efficiency at full load and cos =0.8 is: 2 = 630000*0.8 = 97.96 % 630000*0.8 + 1200 + 9300*(1)2
A.13.2 Calculation of Voltage Drop

Let us assume that a three-phase transformer, 630 kVA, 20/0.4 kV, has 9300 W load losses and 6% short-circuit impedance. Determine the voltage drop at full load (case 1) and at 75% load (case 2) for power factor 1.0 and 0.8. The voltage drop is given by the following equation: Udrop = S (er cos + ex sin ) + 1 1 ( S )2 (er sin - ex cos )2 , where 2 100 SB SB er = LL = 9300 = 0.014762 = 1.4762% and ex = 630000 SB U2k - e2r = 0.062 - 0.0147622 = 0.05816 = 5.816 %
Case 1: full load

For cos = 1 , sin =0. Udrop = S (er cos + ex sin ) + SB + 1 1 ( S )2 (er sin - ex cos )2 = 2 100 SB = 1.0*(1.4762*1 + 5.816*0) + + 1 1 (1.0)2 (1.4762*0 - 5.816*1)2 = 1.645 % 2 100
Case 2: load 75%

For cos = 1, the voltage drop is calculated as follows: Udrop = (0.75) * (1.4762 * 1 + 5.816 * 0) + + 1 1 (0.75)2 (1.4762 * 0 - 5.816 * 1)2 = 1.202 % 2 100
For cos = 0.8, the voltage drop is: Udrop = (0.75) * (1.4762 * 0.8 + 5.816 * 0.6) + + 1 1 (0.75)2 (1.4762 * 0.6 - 5.816 * 0.8)2 = 3.543 % 2 100
For cos = 0.8, sin =
1 - (cos )2 = 0.6.
Udrop = (1.0) * (1.4762 * 0.8 + 5.816 * 0.6) + + 1 1 (1.0)2 (1.4762 * 0.6 - 5.816 * 0.8)2 = 4.741 % 2 100
A.13.3 Parallel Operation of Transformers

Let us assume that three transformers operate in parallel. The first transformer has 800 kVA rated power and 4.4% short-circuit impedance. The rated power and the short-circuit impedance of the other two transformers is 500 kVA and 4.8%, and 315 kVA and 4.0%, respectively. Calculate the maximum total load of the three transformers. Among the three transformers, the third transformer has the minimum short-circuit impedance, i.e Uk, min = 4.0 %. The load of transformer 1 is: Uk, min Pn,1 = P1 U = 800 4 = 728 kVA. k,1 4.4 The load of transformer 2 is: Uk, min Pn,2 = P2 U = 500 4 = 417 kVA. k,2 4.8 The load of the transformer 3 is: Pn,3 = P3 Uk, min Uk,3 = 315 4 = 315 kVA. 4 The maximum total load of the three transformers is: Ptot = Pn,1 + Pn,2 + Pn,3 = 728 + 417 + 315 = 1460 kVA. The three transformers have total installed power: P = P1 + P2 + P3 = 800 + 500 + 315 = 1615 kVA. From the above, it is concluded that the maximum total load (1460 kVA) represents the 90.4% of the total installed power (1615 kVA). It should be noted that, in order the maximum total load to be equal to the total installed power, the transformers must have the same short-circuit impedance.
A.13.4 Transformer Selection

Let us assume that an industrial user wants to buy a 630 kVA transformer. The transformer will operate with 60% average loading, 8 hours per day, 200 working days per year. Two transformer manufacturers submit two different offers to the industrial user. The first manufacturer offers a transformer with 1200 W no-load losses and 8700 W load losses at a sales price of 5870 . The second manufacturer offers a transformer with 940 W no-load losses and 6750 W load losses at a sales price of 7045 . Considering that the depreciation of the transformer purchase investment is going to be done in 5 years and the energy charge is 0.075 /kWh, calculate the economical optimum offer. The comparison of the two offers will be based on the annual total owning cost, which is the sum of the annual buying cost and the annual usage cost. An approximation of the annual buying cost can be found by dividing the sales price with the years of depreciation. An approximation of the annual usage cost can be calculated based on the annual charge due to the transformer operation (annual charge for load losses and no-load losses).
Manufacturer A
The annual buying cost () is: OC1 = 5870 = 1174 5
Manufacturer B
The annual buying cost () is: OC2 = 7045 = 1409 5
The annual charge () for the no-load losses is: NLLC1 = 8,760 h * 1.2 kW * 0.075 = 788.4 kWh The annual charge () for the load losses is: LLC1 = (200 * 8 h) * 0,62 * 8.7 kW * 0.075 = 375.84 kWh The annual total owning cost () is: TOC1 = OC1 + NLLC1 + LLC1 = 2338.24
The annual charge () for the no-load losses is: NLLC2 = 8,760 h * 0.94 kW * 0.075 = 617.58 kWh The annual charge () for the load losses is: LLC2 = (200 * 8 h) * 0,62 * 6.75 kW * 0.075 = 291.6 kWh The annual total owning cost () is: TOC2 = OC2 + NLLC2 + LLC2 = 2318.18
As a result, although the transformer sales price of the second manufacturer is 20% more expensive (i.e. 1175 more expensive), the transformer of the second manufacturer is finally more economical, since its annual total owning cost is 0.9% less (i.e. 20.06 less). From the above, it is concluded that the cheapest transformer is not always the most economical. In particular, the difference at the annual total owning cost could be more than 0.9%. This will happen, if we consider more years for the depreciation (instead of the current assumption of 5 years), or if we use the transformer more (instead of the current assumption of 60% average loading, 8 hours per day, 200 working days per year).
Section B:
Transformer Installation and Maintenance

B.1 Dimensions of transformer installation area
When the transformer is going to be installed inside an electrical room (indoor installation), particular attention should be paid to the calculation of the dimensions of the installation area as well as to the ventilation of the installation room. The ventilation of the electrical room influences the cooling, and consequently, the transformers life. The distance between the walls of the room and the transformer end points must be from 50 to 60 cm.
Calculation of air resistance

For the calculation of the dimensions of the openings for the input and output of air in the electrical room, the calculation of the air resistance is required. For the air resistance, the symbol W is used in the sequel. The value of the air resistance depends on the existence or not of lattices, meshes and venetian blinds. If there are no lattices, meshes and venetian blinds in the input and output openings of the air, then the minimum air resistance is : Wmin = 4. For each lattice, the value WL=1 is added to the value of Wmin . For each mesh, the value WM =1.5 is added to the value of Wmin . For each adjustable venetian blind, the value of WV = 3 is added to the value of Wmin . For example, for a transformer installation room with two meshes (one in the input and one in the output of air), the minimum air resistance is: W = Wmin + 2 WM = 4 + 2 x 1.5 = 7. The lowest possible temperature in the transformer electrical room is achieved with the following ways: the opening for the output of the hot air is placed in the highest possible location, and the opening for the input of the cold air is placed in the lowest possible location.
Calculation of cross-section area of the input and output openings

The cross-section area of the opening for the input of air, F1 (m2), is calculated by the following formula: 104W , F1 = 4.25 . V . 100 H . t3 where V is the total transformer losses (kW), W is the air resistance, H is the height (m) of the opening for the output of air from the horizontal symmetry axis of transformer (Figure 3), and t is the temperature rise (C) of the transformer room. The cross-section area of the opening for the output of air, F2 (m2), should be 10% to 15% larger than the cross-section area of the opening for the input of air (F1).
Gravel Pit for oil Figure 3: Dimensions of transformer installation room.
B.2 Instructions for transformer installation

The transformer is delivered at the industrial site of Schneider Electric at Inofyta, Greece. The responsibility for the safe transportation, unloading, and connection to the network belongs to the transformer user. The substation must be constructed after study and design from a certified engineer and the relevant authorities (e.g. electrical utility, etc) must approve the substation design. Under the transformer, there should be an oil collection tank, which has on its upper part a metallic mesh and gravel. The oil collection tank must have the appropriate volume, so that in case of leakage all the quantity of the transformer oil can be collected within the oil collection tank. The whole substation has an isodynamic mesh. The resistance of the earthing must be less than 1 and generally the substation must be constructed in accordance with the existing instructions and regulations of the local authorities (e.g. construction authority, electrical utility). The unloading and transportation of the transformer should be done in such a way that the transformer does not deviate by more than 15 from its horizontal position. When the transformer is installed at its position, no deviation is allowed from its horizontal position. If the transformer is equipped with a Buchholz relay, the Buchholz connection instructions must be followed. Before the connection of the transformer to the network, the transformer must be optically checked, in order to ensure that it has no damage during its transportation or it has no oil leakage. In case of scratches in its painting, the transformer must be repainted immediately in order to avoid future rust.
B.3 Instructions for transformer Maintenance

The transformer is a very reliable electrical machine and it will practically need no maintenance during the many years of its operation. However, this presupposes that the transformer remains clean and it is not overloaded more than the permissible levels of duration and loading. Moreover, it also assumes that the network that the transformer serves is not affected by short-circuits, overvoltages, thunders, and the coupling apparatus of the high and low voltage as well as the transformers protective devices operate normally. In practice, it is not possible to guarantee all these conditions, thats why the following are recommended:
1. Optical inspection (every three months)

Check if the transformer is clean, especially on the surface of insulators (dust and moisture can cause flashover). Check for oil leakage. Check for damage in the transformer painting. In case of scratches, they should be repainted in order to prevent the tank oxidation. Check of the oil level of the oil indicator, when the transformer is out of operation. For example, if the ambient temperature is +20C and the reading of the oil indicator is below the reading of +20C, then oil filling is required. Check of the condition of the air dehumidifier. If the color of the silica gel becomes yellow, then it is in good condition, while if it has a soft blue-white color, then it must be dried or it must be replaced. Before each action it is necessary: to turn off the medium and low voltage switches, to ground the transformer in order to remove any capacity loads.
2. Oil check (every year)

Check of the oil dielectric strength. This is based on the sample that is taken, by opening the draining and sampling oil valve of the transformer. 10 lt of oil are initially taken out and next, a sample of 1 lt is taken. The cans, bottles and funnels that are going to be used for sampling, must be absolutely clean and dry. The bottle, which is going to be used for the shipment of the oil, must be hermetically sealed. If the check results in an oil dielectric strength less than 40 kV, then the oil must be replaced or must be reprocessed with a special cleaning apparatus. Check of the operation of the Buchholz relay, the thermometer and the condition of their contacts.
B.4 Instructions for thermometer connection

The transformer thermometer is used to follow the variations of the oil temperature. The thermometer has two normally open contacts, which change status when the transformer reaches the predetermined limits. The first contact (alarm contact) is used for warning and the second (trip-off contact) is used for tripping off the circuit breaker at the low voltage switchboard. The warning could be: Activation of alarm, Load rejection, Optical indication (warning lamp). The suggested activation adjustments of the transformer contacts are: 90C for warning (left movable pointer with red end), 100C for trip-off (right movable pointer with red end). A general arrangement of the transformer and Buchholz relay is shown in Figure 4. A typical wiring of thermometer and Buchholz connected to an alarm panel is shown in Figure 5.
Figure 4: General arrangment of thermometer and Buchholz.
Figure 5: Typical wiring of thermometer and Buchholz connected to an alarm panel.
B.5 Instructions for the connection of the Buchholz relay

If the transformer has a Buchholz relay, the following connection instructions are suggested: Initially, the protective cylindrical cover of the testing button of the Buchholz relay must be unscrewed, and then the cylindrical piece of wood (which blocks the floats during transportation) must be removed. Next, it is necessary to check (from the inspection door) if the Buchholz relay is full with oil. In case that it is not full, the hexagonal cover must be removed and the ventilation valve must be opened so that the Buchholz relay to be filled with oil. The filling and the free movement of the floats with the contacts are checked through the inspection door. As soon as the Buchholz relay is filled with oil, the ventilation valve must be closed again. A general arrangement of the Buchholz relay (and the transformer) is shown in Figure 4. A typical wiring of thermometer and Buchholz relay connected to an alarm panel is shown in Figure 5.
(Electrical contacts and check of the operation of the protection circuits, page 40)
Dry type contacts for signaling (alarm and trip)
B.5 Instructions for the connection of the Buchholz relay (continue)

Electrical contacts
The electrical contacts consist of two pairs of normally open contacts. The one pair of contacts is used for alarm and the other pair of contacts for tripping off the circuit breaker. The required voltage is 24-230V alternative or direct current.
Check of the operation of the protection circuits

The check of the operation of the protection circuits is implemented through the following steps: The cylindrical cover of the testing button is removed and the button is gradually pressed so that to get down the floats. Next, it is checked if the alarm contacts and the trip-off contacts are closed. As soon as the testing button is left free, the floats are moved to the normal position and the contacts open. The alarm contacts (3 and 4) are connected to an alarm horn, which will operate when gases are collected to the Buchholz relay or the oil level gets down. The trip-off contacts (1 and 2) act on the trip-off coil of the medium voltage circuit breaker and open the circuit breaker, when the oil level gets down or the oil pressure in the transformer tank increases suddenly.
B.6 Instruction for the connection of the air dehumidifier

If the transformer has an air dehumidifier, the following connection instructions are suggested: Waterproof packing is used for the transportation of the dehumidifier, in order to avoid the absorption of moisture by the silica gel. During the placement of the dehumidifier to the transformer, the oil glass (which is under the dehumidifier) is removed. Then the oil glass is filled with mineral oil until the end of the tube (which goes out of the dehumidifier) to be sink in the oil. In case of transformer transportation, the dehumidifier must be removed, its tap must be sealed and a cap must be put to the tube of the oil conservator. The air dehumidifier is shown in Figure 6.
VE.11/TV75 type
1. Top cover 2. Stainless tank 3. Transparent silica gel tank 4. Tube 5. Transparent oil tank 6. Oil indicator - air input 7. Base 8. Rating plate 9. Draining tube 11. Air input
Type VE.1
Oil H D F weight 1500 kg
silica gel Tank weight volume
250 mm 100 mm 1/2 GF 0,35 kg 0,465 dm3
Figure 6: Air dehumidifier
Schneider Electric Services

Schneider Electric Services offer:
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For questions please contact our Customer Care Center:
+30 800 11 62900 (toll free) or +30 210 62 95 325
Make the most of your energy
Inofyta Plant 55th km Athens-Lamia N.R., GR-32011 Inofyta, Greece Customer care center: +30 800 11 62900 (toll free)
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Use and Maintenance of

Oil-immersed Distribution Transformers

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 1

Elvim, Merlin Gerin and Telemecanique become Schneider Electric

New product marking

From now on you will see

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 2

Use and Maintenance of

Oil-immersed Distribution Transformers

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 1

A.4 Transformer Components

A.5 Transformer tests A.6 Transformer electrical characteristics

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 2

Transformer electrical characteristics

A.6.8 A.6.9 A.6.10 A.6.11 A.6.12 A.6.13 A.6.14

A.7 A.8 A.9

Elvim A.12.1 transformers series A.12.2

A.12.3 A.12.4 A.12.5 A.13 Examples A.13.1 A.13.2 A.13.3 A.13.4

Section B: Transformer installation and maintenance

Schneider Electric Services

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 3

A.1.1 Classification of transformers according to the use

(a) Distribution transformers

(b) Power transformers

(d) Test transformers

(e) Special power transformers

(f) Instrument transformers

(g) Telecommunication transformers

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 4

A.1.2 Classification of transformers according to the cooling method

A.1.3 Classification of transformers according to the insulating medium

(a) Oil-immersed type transformers

(b) Dry type transformers

(c) Resin type transformers

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 5

A.1.4 Classification of transformers according to the construction of the magnetic circuit

(a) With three legs (vertical limbs)

(b) With five legs (vertical limbs)

(a) Stack core

(b) Wound core

Two different materials are used for core construction:

(a) Silicon steel sheet

(b) Amorphous metal sheet

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 6

A.2 Elvim Distribution Trasformers

A.2.2 Advantages of Elvim distribution transformers

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 7

A.3 Transformer Manufacturing Features

Figure 1: Wound core.

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 8

A.3.3 Metallic parts

A.3.5 Cooling medium

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 9

A.4 Transformer Components

A.4.3 Lifting lugs

A.4.5 Draining and sampling oil valve

A.4.6 Neutral earthing link

Use and Maintenance of Oil-immersed Distribution Transformers - Elvim range / page 10

A.4.7 High voltage bushings

A.4.8 Low voltage bushings

A.4.9 Low voltage connectors

A.4.10 Tap changer