5 transformer constructions youre most likely to

see inside buildings

5 Transformer constructions you're most likely to see inside buildings (on photo: General
Electric ventilated dry type transformer - 30 KVA, 480 Volt Primary, 208/120 Volt Secondary)

Transformer constructions
Liquid filled, ventilated dry and gas filled dry types
There are several different types of transformer constructions you can see installed in
substations inside commercial and other buildings. This article is generally applicable only to
transformers of the liquid filled, ventilated dry, or gas filled dry types. Liquid insulated and gas
filled transformers have their windings brought out to bushings or to junction boxes on the ends
or the top of the transformers.
Ventilated dry type transformers usually have their windings terminated within the enclosure of
the transformer to either stand-off insulators or bus bar terminals.
Ok, these are the five transformer constructions you are most likely to meet in a substation
inside buildings:
1.
2.
3.
4.
5.

Liquid filled transformers

Ventilated dry type transformers
Sealed dry type transformers
Cast-coil dry type transformers
Totally enclosed, non-ventilated dry type transformers

1. Liquid filled transformers

Are constructed with the windings encased in a liquid-tight tank filled with insulating liquid.
The liquid provides insulation between the various sections of the windings and between the
windings and the tank, and serves as a cooling medium, absorbing heat from the windings and
transferring it to the outside of the tank.
Liquid filled transformers should be avoided inside commercial buildings unless nonflammable or less-flammable liquids are used or unless proper precautions are taken by building
a transformer vault that meets the requirements of the NEC. And of course, then only if all
applicable jurisdictional and insurance carrier requirements have been met.
To increase the transfer of heat to the air, tanks are provided with cooling fans (to increase the
area of the radiating surface) or with external cooling tubes or radiators. The hot liquid circulates
through the radiators, transferring the heat picked up in the transformer windings to the radiator
and then to the surrounding air.

Liquid filled transformer

Fans are sometimes installed to force air over the radiators in order to increase the full load
rating by approximately 15% on transformers rated 750-2000 kVA and 25% on transformers
rated 2500-10 000 kVA.
IMPORTANT NOTE! It is essential that the liquid in the transformer be maintained, clean,
and free from moisture! Moisture can enter the transformer through leaks in the tank covers or
when moisture-laden air is drawn into the transformer.
Transformers can draw air into the tanks through breathing action that results from changes in
the volume of liquid, and air in the tank that occurs with changes in temperature. Most modern
transformer constructions are tightly sealed and do not breathe if they are free from leaks.

Transformer oil tank

Insulating liquid, through the normal aging process, develops a small amount of acid that, if
allowed to increase above well-established limits, can cause damage to insulation in the
transformer.
Yearly testing to determine the dielectric breakdown voltage of the liquid (a low dielectric
test indicates the presence of water or other foreign material) and neutralization number (a high
neutralization number indicates the presence of acid in the liquid) by a competent testing
laboratory will greatly prolong the life of the transformer.
Liquid samples should be withdrawn under carefully controlled conditions as directed by the
group making the liquid test. In some areas, this service is available from the electric utility.
The classification and handling of existing liquid filled transformers with regard to
polychlorinated biphenyl (PCB) contamination is subject to strict control by environmental
agencies.
It is important that any existing liquid filled transformers that have not been evaluated tagged,
or otherwise classified be properly handled. Liquid filled transformers, which contain from 50
500 parts per million (ppm) of PCB, have successfully been brought into the 050 ppm range,
which is within the limits of non-PCB contamination.

2. Ventilated dry type transformers

Are constructed in much the same manner as liquid filled transformers, except that the
insulating liquid is replaced with air, and larger clearances and different insulating materials
are used to compensate for the lower dielectric strength of air.

Both ventilated dry type and sealed dry type transformer constructions use a UL component
recognized insulation system that is suitable for operation at an ultimate temperature of 220C.
The normal temperature rise of the windings is 150C by resistance.
If transformers are purchased with a 220C insulation system, but are rated for full load use at a
lower temperature (115C or 80C rise), then an improvement in efficiency, overload
capability, and life can be expected.
Consideration should also be given to nonlinear harmonic loads, such as SCRs, UPS, rectifiers,
and variable speed drive applications, since these higher harmonics can cause appreciably higher
eddy and stray loss heating in the windings as well as very high currents in the neutrals of these
transformers.

Ventilated dry type transformer

Very often special designs for nonlinear load applications are preferable to just oversizing the
unit because of the skin effect at the higher frequencies.

The ventilated dry type transformer is provided with a sheet metal enclosure that surrounds
the winding for mechanical protection of the windings and the safety of personnel. Ventilating
louvers are installed in the enclosure to permit thermal circulation of air directly over the
winding for cooling. Fans are sometimes installed to force air directly over the windings in order
to increase the full load rating by approximately 30-40%.
These types of transformers are normally installed indoors and require the periodic cleaning of
the complete core and coil assembly and an adequate supply of clean ventilating air.
These transformers are gaining acceptance in the 15 kV and 34.5 kV class, and can be built to
match the BIL of liquid immersed transformers and with special enclosures for use outdoors.
Meggering before energizing is recommended after a lengthy shutdown or lengthy periods when
the insulation has been subjected to moisture.

Ventilated dry transformer 45 kVA

3. Sealed dry type transformers

Sealed dry type transformers are constructed in essentially the same way as ventilated dry type
transformers. The enclosing tank is sealed and operated under positive pressures. It may be
filled with nitrogen or other dielectric gas. Heat is transferred from the winding to the gas within
the transformer housing and from there to the tank and to the surrounding air.
The sealed dry type (gas filled) transformer can be installed both outdoors and indoors and in
areas where a corrosive or dirty atmosphere would make it impossible to use a ventilated dry
type transformer.

ABBs sealed dry type transformer with complete absence of oil, entirely welded tank assembly,
N2 gas overpressure for tank deterioration monitoring, 2-position ground switch, 70 percent
overloading capability, similar footprint to liquid-filled units with cooling fans and power rating
up to 1,000 kVA and 15 kV primary voltages

4. Cast-coil, dry type transformers

Are constructed with primary and secondary windings encapsulated (cast) in reinforced epoxy
resin. Because of the cast-coil construction, they are ideal in applications where moisture or
airborne contaminants, or both, are a major concern. This type of construction is available with
primary voltage ratings through the 34.5 kV class and BIL ratings through 200 kV.
These transformers are ideal alternatives for liquid or gas filled units in indoor or rooftop
applications. They may be forced air cooled to increase their self-cooled ratings by 50%.

Cast-resin dry type transformer

5. Totally enclosed, non-ventilated dry type transformers

Are constructed in essentially the same way as ventilated dry type transformers. The enclosure,
while not sealed, contains air, so the units have the same BIL capabilities as ventilated dry type
transformers.
The totally enclosed, non-ventilated dry type transformer can be installed both indoors and
outdoors and in areas where a corrosive or dirty atmosphere would make it impossible to use a
ventilated dry type transformer.
These units are available with fan cooling for a minimum 25% increase in capacity.

Totally enclosed, non-ventilated dry type transformer (on photo: Square D 3-phase 150KVA dry
transformer)

All above described transformer constructions has various temperature measurement

equipment and controls for determining the winding temperature and for activating cooling,
tripping, or alarm devices. To make sure the ultimate temperature of the insulating system is not
exceeded, imbedded detectors should be wound in each low-voltage winding.
Reference // Recommended Practice for Electric Power Systems in Commercial Buildings
IEEE STD 241