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A transformer is only as strong as its weakest link

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Electric arc furnace transformer Alstom

Transformer rating
Capacity (or rating) of a transformer is limited by the temperature that the insulation can tolerate. Ratings can be
increased by reducing core and copper losses, by increasing the rate of heat dissipation (better cooling), or by
improving transformer insulation so it will withstand higher temperatures.

A physically larger transformer can dissipate more heat, due to the increased area and increased
volume of oil.

A transformer is only as strong as its weakest link, and the weakest link is the paper insulation, which begins to
degrade around 100 C. This means that a transformer must be operated with the hottest spot cooler than this
degradation temperature, or service life is greatly reduced.

Presspahn A proven surface insulation material, resistant to high voltage and a high capacity for impregnation with transformer oil (by UKi
one of Europes largest suppliers of electrical insulation materials)

Reclamation typically orders transformers larger than required, which aids in heat removal and increases
transformer life.
Ratings of transformers are obtained by simply multiplying the current times the voltage. Small transformers are rated
in VA, volts times amperes.
As size increases, 1 kilovoltampere (kVA) means 1,000 voltamperes, 1 megavoltampere (MVA) means 1 million
voltamperes. Large generator step-up (GSUs) may be rated in hundreds of MVAs.

A GSU transformer can cost well over a million dollars and take 18 months to 2 years or longer to
obtain.

Each one is designed for a specific application. If one fails, this may mean a unit or whole plant could be down for as
long 2 years, costing multiple millions of dollars in lost generation, in addition to the replacement cost of the
transformer itself.
This is one reason that proper maintenance is critical.

This transformer used to be strong, but (on photo: Transformer paper insulation damaged due to poor maintenance; credit:
gcequipment.com)

Reference: Transformers: Basics, Maintenance, and Diagnostics U.S. Department of the Interior Bureau of
Reclamation

About Author //
Edvard Csanyi
Edvard - Electrical engineer, programmer and founder of EEP. Highly specialized for
design of LV high power busbar trunking (<6300A) in power substations, buildings and
industry fascilities. Designing of LV/MV switchgears. Professional in AutoCAD
programming and web-design. Present on

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2 Comments
1.
Hammed Abdulgafar
Jul 07, 2014
so intresting
(reply)

2.
Foluso Omolewa
May 29, 2014
I mistakenly unsubscribed so I want to subacribe again. You are doing a good job by helping
others. Thank you
(reply)
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