POWER TRANSFORMER - STANDARDISATION MANUAL

Chapter - 7
Design Review

Working Group Members

Mr. M. Vijayakumaran ALSTOM Ltd
Mr. S. K. Negi

GETCO

Mr. Y. V. Joshi

GETCO

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POWER TRANSFORMER - STANDARDISATION MANUAL

POWER TRANSFORMER - STANDARDISATION MANUAL

CHAPTER - 7

DESIGN REVIEW
1. INTRODUCTION

A design review is a planned exercise to ensure that both parties understand the application and the requirements
of the applicable standards and specification. It is the opportunity for both parties to scrutinize the proposed
design to ensure that the requirements will be met not only technical requirements but also those relating to
other aspects of the contract, like quality. The whole emphasis of a design review is directed at establishing
what is being provided is fit for purpose in all respects for the intended performance in service and that the
manufacturer uses proven materials, design tools, methodology and experience to assure the product will meet
this requirement, also in all respects.

Design reviews implies also to strengthen the relationship between the purchaser and manufacturer and a
good opportunity for the purchaser to better understand the technical capabilities of the manufacturer and for
the manufacturer to understand the need of their customers for the sake to have products adapted to their
needs. Hence the design review is a good opportunity to interchange experiences that can be used to propose
enhancements or betterments. For these reasons it is strongly advisable for the purchaser to have expert
transformer engineer(s) with them during the meeting.

A design review, initiated and chaired by the purchaser should be held for the purpose of conducting an indepth review of the ordered Power Transformer and to allow the purchaser to have a clear understanding of the
transformers design, manufacture and test including the likelihood of operating in service as intended.

The following are the pre-requisites for carrying out the design review:
1.

It is desirable to have vendor assessment of the manufacturer before placement of order.

2. Design review should be part of the tender inquiry and it becomes obligatory on the part of the customer
and manufacturer to ensure compliances with the contract specifications.
3. It is to be ensured that all stake holders are involved in the design review. The designer both mechanical
and electrical, ultimate user, production head and if possible, sub vendor also could be invited for the design
review. Agenda is to be prepared by customer and sent to manufacturer well in advance.
4. Review may include certain informations which are of proprietary nature. It is, therefore, desirable to have
mutual agreement between the purchaser and the manufacturer for the confidentiality of information.
5. It is important for the success of design review that both the purchaser and manufacturer are clear on the
requirements and well prepared to have open and frank sharing of information.
2.

OBJECTIVES OF DESIGN REVIEW

Both the purchaser and manufacturer must understand that following objectives are met during the design
review:
1.

To ensure that there is a clear and mutual understanding of the transformer technical requirements according to purchaser specification and applicable industry standards.

2. To understand the application and verify the system and project requirements and to indicate areas where
special attention may be required.

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POWER TRANSFORMER - STANDARDISATION MANUAL

3.

To verify that the design complies with the technical requirements.

4.

To identify any prototype features and evaluate their reliability and risks.

5. To interchange experiences that can be used to identify eventual betterments in the design and / or improvements and changes in the specification.
6.

To better understand the technical capabilities of the manufacturer.

7.

To strengthen the technical relationship between purchaser and manufacturer and eventually to improve
and go deep in the transformers design knowledge by some participant on the purchasers side.

3.

ELEMENTS OF DESIGN REVIEW

Having understood the purpose of design review and objectives, it is important to know the various elements
of design review which will clear all the doubts about the functionality (application), soundness of designs with
margins, selection of material and components and also specific operating requirements for its designed life.
They are broadly as follows:

S. No.

Elements

1.

System data

2.

Environmental data

3.

Transformer parameters

4.

Transformer design

5.

Transformer ancillaries and accessories.

6.

Transformer oil

7.

Fabrication

8.

Testing

9.

Name plate

10.

Transportation

11.

Site erection, testing & commissioning

12.

Health and safety equipments

13.

Contract documents and drawings

14.

Document submission time scale

POWER TRANSFORMER - STANDARDISATION MANUAL

Design review guidelines of Cigre WGA2.36 (Technical brochure 204) have elaborated above elements in detail
as under:
Sr. No.

Elements of
design review

Check Points

1.

System data

System Voltage Variations

Tap changers
System Frequency Variation
System Short Circuit Capacity
System Switching and Transformer Protection
High Frequency Transients (HFT)
Voltage Transients
Current Harmonics
Geomagnetic Induced Currents

2.

Environmental
data

Ambient temperature range, rate of change of temperature and effect on the overload
capability
Lowest Cold Load Start-up (LCLS)
Solar radiation
Site altitude
Humidity
Pollution
Seismic zone and response spectra
Geomagnetic currents
Ultraviolet (UV) radiation
Isoceraunic level

3.

Transformer
parameters

Alternating Current Terminal Voltages

Insulation Levels line to line and line to ground
Winding Impedances
Cooling Provisions
Temperature Limits
Short Circuit Withstand Capability
Cable Connection Bushings and Isolated Phase Bus Bar Connections
Sound Levels
Losses No load and load losses
Excitation
High Temperature Design

4.

Transformer
design

Core
Windings
Thermal design
The short circuit capability
Core, Winding Assembly and Drying
Leads and Cleats
Insulation Design
Leakage Flux Control
Drying and Processing
Sound Level
Seismic

5.

Transformer
ancillaries and
accessories.

Bushings
Bushing and Internal Current Transformers
Tap Changers
Internal Surge Arresters
Control Cabinet and External Cabling
Online Monitoring Equipment

6.

Transformer oil

Review as per exclusive Chapter 6 of this Manual.

7.

Fabrication

General Construction
External Cooling Equipment
Conservators/Preservation Systems
Fabrication Drawings
Gas Collection System Design
Surface Preparation and Planning

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POWER TRANSFORMER - STANDARDISATION MANUAL

Sr. No.

Elements of
design review

Check Points

8.

Testing

As per Annexure - 7.1

9.

Rating Plate

As per figure 7.1

10.

Transportation

Transportation Plan and Handling

Design for Transport
Transportation Shipping Profile
Transportation Routing
Transportation Shipping Impact Withstand
Fixtures on Transformer
Marking of Center of Gravity
Ship and Barge Issues
Rail Car Issues
Road Transport Issues
Transportation monitoring management of transformer
Transportation of transformer accessories, components removed from the transformer
Acceptance criteria for receiving transformer
Transformer Unloading to Foundation

11.

Site erection,
testing &
commissioning

As per the exclusive Chapter 5 of this Manual.

12.

Health and safety

As per guideline and policy of customer. Also refer Chapter - 5 on Erection, Testing and
commissioning of this Manual.

13.

Contract
documents and
drawings

As per Annexure - 7.2.

14.

Document
submission time
scale

As agreed between purchaser and manufacturer.

Design review does not absolve or substitute manufacturers ultimate responsibility for the adequacy of transformer
design and construction, including design limits and margins, quality, performance on test and in service.

POWER TRANSFORMER - STANDARDISATION MANUAL

REFERENCES
The following list may be referred, but this is not a limitation on referring to other standards and codes as long as it
serves the purpose for effective design review.
IEC 60044: Current Transformers.
IEC 60050: International Electrotechnical Vocabulary Chapter 421: Power Transformers and Reactors.
IEC 60060-1: General Definitions and Test Requirements.
IEC 60071-1: Insulation Coordination - Part 1: Definitions, Principles and Rules.
IEC 60071-2: Insulation Coordination - Part 2: Application Guide
IEC 60076-1: Power Transformers - Part 1: General.
IEC 60076-2: Power Transformers - Part 2: Temperature Rise.
IEC 60076-3: Power Transformers - Part 3: Insulation Levels and Dielectric Tests.
IEC 60076-5: Power Transformers - Part 5: Ability to withstand Short-Circuit.
IEC 60076-6: Power Transformers - Part 6: Reactors
IEC 60076-7: Power Transformers - Part 7: Loading guide for oil- immersed Power Transformers.
IEC 60076-8: Power Transformers - Part 8: Application Guide for Power Transformers.
IEC 60076-10: Power Transformers - Part 10: Determination of Transformer and Reactor Sound Levels.
IEC 60076-11: Power transformers - Part 11: Dry-type transformers
IEC 60076-18: Power transformers - Part 18: Measurement of frequency response
IEC 60076-16: Power transformers - Part 16: Transformers for wind turbine applications
IEC 60137: Bushings for Alternating Voltage Above 1000 V.
IEC 60214-1: Tap-Changers - Part 1: Performance requirements and Test Methods.
IEC 60214-2: Tap-Changers - Part 2: Application guide.
IEC 60270: High-voltage test techniques - Partial discharge measurements
IEC 60296: Fluids for Electro-technical applications - Unused mineral insulating oils for transformers and switchgear
IEC 60815-1: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 1:
Definitions, information and general principles
IEC 60815-2: Selection and dimensioning of high-voltage insulators intended for use in polluted conditions - Part 2:
Ceramic and glass insulators for a.c. systems
IEC 62032: Guide for the Application, Specification and Testing of Phase-Shifting Transformers
Other documents of relevance are:
ISO 9001: Quality System Model for Quality Assurance in Design/Development.
CIGR TB 209: Short Circuit Performance of Power Transformers
CIGR TB 528: Guide for Preparation of Specifications for Power Transformers
CIGR TB 530: Guide for Conducting Factory Capability Assessment for Power Transformers.

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POWER TRANSFORMER - STANDARDISATION MANUAL

10

400
10

XXX Transformer Pvt. Ltd.

315 MVA 400/220KV AUTO TRANSFORMER
REF. STANDARDS

ONAN/ONAF/OFAF

COOLING
RATING

(HV-MV)

MVA 189/252/315

FREQUENCY

(LV)

MVA 63/84/105

PHASES.

FULL LOAD
CURRENT

BASIC INSU.
LEVEL LI/SI/P.F.

HV

400000

MV

220000

IMPEDANCE
VOLTAGE.
HV-MV(315MVA BASE)

33000

HV

A 272.79/363.73/454.66

VECTOR GROUP REF.

MV

A 495.99/661.32/826.66

CORE MASS

LV

A 1102.21/1469.61/1837.02
kV 1300/1050/630

MV

kV 1050/-/460

LV

kV

250/-/ 95

Neutral

kV

95/-/ 38

OIL

50C at ONAN
55C at ONAF/OFAF

55C at ONAN
60C at ONAF/OFAF

VECTOR GROUP
YNa0d11

2U
3U
3V

1V

MV

2V
3W

1W

MV WTI

2V1S1
2V1S2
2V1S3
2V1S4
2V2S1
2V2S2
2V2S3
2V2S4

CT1W

1V1S1
1V1S2
1V1S3
1V1S4
1V2S1
1V2S2
1V2S3
1V2S4

3W1S2

1W

CT2V

CT1V

CT2U

CT1U

2U1S1
2U1S2
2U1S3
2U1S4
2U2S1
2U2S2
2U2S3
2U2S4

3W1S1

1W1S1
1W1S2
1W1S3
1W1S4
1W2S1
1W2S2
1W2S3
1W2S4

2W1S1
2W1S2
2W1S3
2W1S4
2W2S1
2W2S2
2W2S3
2W2S4

kg.

MASS OF TOTAL OIL

(WITHOUT 10% EXTRA OIL)

kg.

10% EXTRA OIL

kg.
kg.

QUANTITY OF OIL IN OLTC

Ltrs.

TRANSFORMER OIL QUANTITY

(WITHOUT 10% EXTRA OIL)

Ltrs.
CUSTOMER
CHOICE

3
4
5
6
7
8
9
10
11
12

12

3
4
5
6
7
8
9
10
11
12

4
3

12

CTNBF

VN1S4
VN1S3
VN1S2
VN1S1
VN2S4
VN2S3
VN2S2
VN2S1

OFAF
315 MVA

440000

330.66

413.33

13 - 11

435000

250.84

334.46

418.08

13 - 10

430000

253.76

338.35

422.94

13 - 9

425000

256.75

342.33

427.91

13 - 8

420000

259.80

346.41

433.01

13 - 7

415000

262.93

350.68

438.22

13 - 6

410000

266.14

354.85

443.57

13 - 5

405000

269.43

359.24

449.05

9a

13 - 4

400000

272.79

363.73

454.66

9b

13 - 3

400000

272.79

363.73

454.66

9c

13 - 12

400000

272.79

363.73

454.66

10

13 - 11

395000

276.25

368.33

460.41

11

13 - 10

390000

279.79

373.05

466.32

12

13 - 9

385000

283.42

377.90

472.37

13

13 - 8

380000

287.15

382.87

478.59

14

13 - 7

375000

290.98

387.97

484.97

15

13 - 6

370000

294.91

393.22

491.52

16

13 - 5

365000

298.95

398.60

17

13 - 4

360000

303.10

404.14

3-4

3-12

VOLTAGE

L.V

CURRENT VOLTAGE

(V)

220000

(A)

ONAN
495.99
ONAF
661.32
OFAF
826.66

(V)

33000

CURRENT

(A)

ONAN
1102.21
(@63MVA)
ONAF
1469.61
(@84MVA)
OFAF
1837.02
(@105MVA)

498.26

RATIO
AMP.

CORE
NO.

ACC.
CLASS

BURDEN
(VA)

505.18

kpV
(Volt)

Imag
at Vk/2

@2000/1ATap

(in mA)

>

MAX
SEC.RES.

(OHM)
@2000/1ATap

500-1000-2000/1

PS

2000

30

10

CT1W

500-1000-2000/1

PS

2000

30

10

CT2U

500-1000-2000/1

PS

2000

30

10

2000

30

10

CT2V

CTNBF

WN1S4
WN1S3
WN1S2
WN1S1
WN2S4
WN2S3
WN2S2
WN2S1

CT2W

500-1000-2000/1

PS

CTNBF
BEFORE
NEUTRAL
FORMATION

500-1000-2000/1

PS

2000

30

10

500-1000-2000/1

PS

2000

30

10

500-1000-2000/1

MEASURED (KW)

TERMINAL
MARKING
1U1S1-1U1S2-1U1S3-1U1S4
1V1S1-1V1S2-1V1S3-1V1S4
1W1S1-1W1S2-1W1S3-1W1S4
1U2S1-1U2S2-1U2S3-1U2S4
1V2S1-1V2S2-1V2S3-1V2S4
1W2S1-1W2S2-1W2S3-1W2S4
2U1S1-2U1S2-2U1S3-2U1S4
2V1S1-2V1S2-2V1S3-2V1S4
2W1S1-2W1S2-2W1S3-2W1S4
2U2S1-2U2S2-2U2S3-2U2S4
2V2S1-2V2S2-2V2S3-2V2S4
2W2S1-2W2S2-2W2S3-2W2S4
UN1S1-UN1S2-UN1S3-UN1S4
VN1S1-VN1S2-VN1S3-VN1S4
WN1S1-WN1S2-WN1S3-WN1S4
UN2S1-UN2S2-UN2S3-UN2S4
VN2S1-VN2S2-VN2S3-VN2S4
WN2S1-WN2S2-WN2S3-WN2S4

Application

REF.

Differential

REF.

Differential

REF.

Differential

PS

2000

30

10

500-1000-2000/1

PS

2000

30

10

HV WTI

506/2

15

1U3S1-1U3S2

MEASURING

MV WTI

827/2

15

2V3S1-2V3S2

MEASURING

TV WTI

1837/2

15

3W1S1-3W1S2

MEASURING

TMS CT

827/1

2U3S1-2U3S2

MEASURING

CTN

TYPE OF OIL :
VACUUM WITHSTAND CAPABILITY 760 Hg
OLTC RATING & MAKE:
GTD.(KW)

ONAF
252 MVA

247.99

N1S1-N1S2-N1S3-N1S4
N2S1-N2S2-N2S3-N2S4

UN1S4
UN1S3
UN1S2
UN1S1
UN2S4
UN2S3
UN2S2
UN2S1

ONAN
189 MVA

M.V.

(V)

CT1V

13

13

13

VOLTAGE

3
4
5
6
7
8
9
10
11
12

4
3

H.V.
CURRENT(A)

13 - 12

CT1U

TO OLTC

CTNBF

TANK & FITTINGS MASS

CT

1W3S1

kg.

2V3S2

1V

CT2W

2U3S2

1W3S2

HV

3U
3V
3W

2V3S1

1U

TV WTI

2W

2U3S1

12

kg.

TRANSPORTATION MASS

5
2V

2U

CORE & COIL MASS

PRE
OLTC
TAP
CONECTION SELEPOSN.
IN EACH
CTOR
NO.
POSI.
PHASE

2W

HV WTI

kg.

600

1U

CTN

kg.

MV

PAINT SHADE

PO . NO. & DATE

1U1S1
1U1S2
1U1S3
1U1S4
1U2S1
1U2S2
1U2S3
1U2S4

HV

WORK ORDER NO.

N1S1
N1S2
N1S3
N1S4
N2S1
N2S2
N2S3
N2S4

YNa0d11
kg.

TOTAL MASS

YEAR OF MANUFACTURE

TMS CT

REG kg.

MAKER'S SR. NO.

1N

COPPER MASS (BARE)

HV

WDG

TAP.NO.1
TAP NO.9

TAP NO.17 %

LV

GTD. TEMP. RISE

50
3/3

RATED
VOLTAGE

IS:2026

Hz

>

268

REF.
REF.

NOISE LEVEL: ________dB

NO LOAD LOSS
LOAD LOSS
STRAY LOSS
AUXILLIARY LOSS

TAN DELTA OF WINDING : ________%

MOISTURE CONTENT IN ACTIVE PART : ________% of wt.

PROPERTY OF CUSTOMER NAME

7

6-6 Holes.
TYPICAL RATING PLATE FOR POWER TRANSFORMER
A

E
J

Fig. 7.1: Typical Rating Plate

POWER TRANSFORMER - STANDARDISATION MANUAL

ANNEXURE 7.1
TESTING
Sr. no.

Tests, measurements & checks

Dimensions, fittings and equipment

Turns ratio

Polarity & phase relationship

Insulation resistances

Winding resistances

Insulation power factor

Capacitances

Load loss & impedance voltage

Impedance characteristic across tap range

10

Zero-phase-sequence impedance

11

No-load loss & magnetizing current

12

Audible sound

13

Temperature rise

14

Gas in oil analyses

15

Lightning impulse voltage tests

16

Switching impulse voltage tests

17

Applied voltage tests

18

Induced voltage test & partial discharge

19

Single-phase magnetizing current test

20

Oil pressure

21

Control system, components, instruments

22

Ancillary equipment power losses

23

CT checks

24

RSO

25

Frequency Response Analysis (FRA)

26

Tap changer

27

Secondary wiring insulation resistances

28

Oil samples

29

Inventory

30

Contract documents

31

QA records

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POWER TRANSFORMER - STANDARDISATION MANUAL

ANNEXURE 7.2
Contract Documents and Drawings for approval

Sr. No.

Documents

Contract drawings
Certificates
a. ISO Quality Assurance
b. ISO Environmental
c. OHSAS

Product Source Schedule

Production Plan & Reporting Programme

Design Review Minutes

Quality System

Quality Plan

Test Plan

Factory Acceptance Test (FAT) Reports

Transport Plan

10

Transformer Site Commissioning Plan

11

Method Statements

12

Risk Assessments

13

Training

14

Site Works

15

Site Contractor(s) & Supervision.

16

Site Tests

17

Operation & Maintenance Manuals