TOSHIBA

POWER TRANSFORMERS

TOSHIBA POWER TRANSFORMERS

In 1894 Toshiba started producing transformers. Since then, we have successively completed the following
power transformers, each epoch-making when considering Japan's industrial level in those years.

1909

44kV, 4.5MVA Bank

Hodogaya Substation, Yokohama Electric Co., Japan

1917

110kV, 13.2MVA Bank

Inawashiro Hydroelectric Power Co., Japan

1926

154kV, 20MVA Bank

Gifu Substation, Nihon Electric Power Co., Japan

1939

220kV, 80MVA

Xu Chuna Jiang Power Station, Chang Jin Jiang Hydroelectric Power

Co.,China

1952

275kV, 117MVA

Shin-Aimoto Substation, Kansai Electric Power Co., Japan

1958

275kV, 200MVA

Chiba Thermal Power Station, Tokyo Electric Power Co., Japan

1960

275kV, 300MVA

Yokosuka Thermal Power Station, Tokyo Electric Power Co., Japan

1961

330kV, 300MVA Bank

Electricity Commission of New South Wales Substation, Australia

1963

275kV, 430MVA

Owase-Mita Thermal Power Station, Chubu Electric Power Co., Japan

1967

275kV, 680MVA

Anegasaki Thermal Power Station, Tokyo Electric Power Co., Japan

1967

512.5kV, 600MVA Bank

B.C. Hydro & Power Authority Power Station, Canada

1968

525kV, 1200MVA Bank

Bonneville Power Administration Substation, U.S.A.

1971

500kV, 1000MVA Bank

Shin-Koga Substation, Tokyo Electric Power Co., Japan

1973

275kV, 1100MVA

Kashima Thermal Power Station, Tokyo Electric Power Co., Japan

1974

275kV, 450MVA

Sunen Substation, Chubu Electric Power Co., Japan

1974

525kV, 1100MVA

Sodegaura Power Station, Tokyo Electric Power Co., Japan

1977

500kV, 1500MVA Bank

Shin-Koga Substation, Tokyo Electric Power Co., Japan

1977

500kV, 680MVA

Okuyoshino Pumped Storage Power Station, Kansai Electric Power Co.,

1977

525kV, 1200MVA

Fukushima 1st Nuclear Power Station, Tokyo Electric Power Co., Japan

1982

765kV, 805.5MVA Bank

EDELCA Guri Power Station, Venezuela

1985

515kV, 1260MVA

Tsuruga 2nd Nuclear Power Station, Japan Atomic Power Co., Japan

1988

765kV, 1650MVA Bank

Furnas Foz do Iguacu Substation, Brazil

Recently, with the sharp increase in

demands for electric power, power
transformers have grown in scale
while unit capacity has shown as
increasing tendency.
Especially, thermal/nuclear power
plant transformers have displayed a
notable tendency toward large
capacity. Toshiba has successively
renewed its records on unit capacity
such as 200MVA in 1958, 300MVA in
1960, 430MVA in 1963, 680MVA in
1967, 1100MVA in 1973, 1200MVA in
1977. In 1985 we manufactured a
world-record product of 60Hz, 515kV,
1260MVA delivered to Tsuruga 2nd
Nuclear Power Station, Japan Atomic
Power Co., Japan.
While substation transformers are
mostly equipped with on-load tap
changers, based on technical knowhow under license of Maschinenfabrik
Reinhausen GmbH, Germany,
Toshiba developed a resistance-type
on-load tap changer, which was
promptly standardized to ensure high
reliability. A large number of
transformers providing on-load tap
changers up to 800 VIVA are being
produced, and many auto-transformers up to 765 kV-1650 MVA bank
are being manufactured by

Toshiba.
Recently, transformers connected to
gas-insulated switchgear (GIS) are
being broadened in application.
As to all voltage classes no larger
than 500kV, Toshiba established a G
IS connection technique, resulting in
the successful manufacture and
delivery of 500kV, GIS direct-coupled
transformers. Transformers for
pumped-storage power stations and
underground substations are subject
to strict restrictions on transport
dimensions and weight. Through
adopting an innovative method of
dividing components to facilitate
transportation and assembly
technique, Toshiba manufactured and
delivered three-section type 275kV,
300MVA transformers to underground
substations, 345kV, 300MVA
transformer to pumped-storage power
station and a nine-section type 500kV,
680MVA transformer to an
underground power station, whose
equivalent cannot be seen in any part
of the world.
By initiating research on 500kV
transformers early in 1955, and
through exerting efforts subsequently
several times in related research and
development activities,

in 1967 Toshiba successfully

completed and delivered a 500kV
transformer to the B.C. Hydro &
Power Authority, Canada. This was
the first practical model ever built in
Japan for an ultra high-voltage power
transformer. Further, in 1971,
500/275kV-1000MVA autotransformer-banks were completed as
the first 500kV transformer product to
be delivered for domestic use. In
1977, Toshiba also delivered
1500MVA-bank autotransformers.
In 1988, 765/525kV1650MVA autotransformer-banks were delivered to
Brazil as the first 765kV
autotransformer product.
Supported by such technology,
Toshiba successively manufactured
and delivered the aforementioned
gigantic thermal, nuclear power
station transformers and hydroelectric
power station transformers which
requires the difficult transportation
with strict transport restrictions.
Regarding transformers of the 500kV
and above, Toshiba boasts one of the
world's largest supply record, having
exceeded 120,OOOMVA in total
capacity of supplied transformers (330
units).

Features

High Reliability
Core Structure Offers
Splendid Characteristics
Advanced Winding
Application
Perfect Drying Process
Sufficient Mechanical
Strength against
Short-circuiting

Highly Efficient Cooling

Perfect Measure against
Leakage Flux

Adequate Oil-leakage
Preventive Structure
Simplified Installation Work

The high reliability of Toshiba products is widely

recognized by users in Japan and abroad. It is backed
up by an accumulation of technology, which has been
carefully achieved by adding new technologies

to conventional technologies, the ability to design

capable transformers, an excellent working
environments and facilities, and thorough use of
inspection and testing system.

Adopting of a miter-joint core, in which the

characteristics of grain-oriented silicon steel are fully

utilized, displays with Toshiba transformers less no-load

loss and no-load current, as well as low noise.

Toshiba adopts the disk windings with optimum

insulation design based on the voltage oscillation
analysis by computer in high voltage winding.

The windings are manufactured by highly skilled

workers in a dust-proofed room.

Toshiba transformers are of the core type, in which the

core-and-coil assembly is independent of the tank, so
that the core-and-coil assembly can be completely dried
through our unique vapor phase drying method.

Toshiba transformers offer excellent insulation, and are

free from shrinkage caused by aging.

Efforts are now being exerted to ensure sufficient shortcircuit strength by maintaining a balance of ampereturns between windings, determining materials to be
used on the basis of mechanical force calculated by
computers, and exercising adequate care in the
pretreatment fastened by applying pressure with a

hydraulic jack on a thick annular insulating plate set on

the top thereof. Further more, a perfectly dried,
precompressed, pressboard is used, so that the winding
is provided with adequate strength to withstand shortcircuit mechanical force.

Forced-cooling is used on the winding and inside the

core, with oil kept circulating through its interior in order
to achieve a large cooling effect. Since the windings are
effective in voltage distribution, the

winding conductors are uniformly insulated, and no

reinforcement of insulation is necessary. Because of
this favorable voltage distribution, the rise of
temperature is uniform.

In a large-capacity, high-impedance transformer,

probable leakage flux is calculated by computers on
each part so that a magnetic shield, corresponding to
the result of each calculation, is provided on the inner
surface of the tank and the clamp surface opposite of
the coil, to prevent a large amount of leakage flux.

Slits are provided on core-leg clamping plates and so

on, in order to reduce stray loss as a prevention against
local overheating. Further more, nonmagnetic steel is
used as necessary in large-current bushing pockets and
parts, in the vicinity of large-current lead.

The tank is of all-welded construction in which there is

no possibility of oil leakage. Nitrile rubber gaskets,
excellent in oil resistance and weather resistance, are

used in such openings as manholes and accessory

mounting parts.

Since the transformer is transported with its core-andcoil assembly kept in the factory-assembled stage, high
reliability is maintained and installation in the field is
simplified. Further more, by utilizing its

advantage of being a built-in type, it is a standard

practice to transport the on-load tap changer as
assembled in the main tank.

Core
Three-phase transformers usually
employ three-leg core. Where
transformers to be transported by rail
are large capacity, five-leg core is
used to curtail them to within the
height limitation for transport.
Even among thermal/nuclear power
station transformers, which are
usually transported by ship and freed
from restrictions on in-land transport,
gigantic transformers of the
1000MVA class employ five-leg core
to prevent leakage flux, minimize
vibration, increase tank strength, and
effectively use space inside the tank.
Regarding single-phase
transformers, two-leg core is well
known. Practically, however, threeleg core is used; four-leg core and
five-leg core are used in largecapacity transformers. The sectional
areas of the yoke and side leg are
50% of that of the main leg; thus, the
core height can be reduced to a
large extent compared with the twoleg core.
For core material, high-grade, grainoriented silicon steel strip is used.

The steel strip surface is subjected

to inorganic insulation treatment.
All cores employ miter-joint core
construction. Yokes are jointed at
an angle of 45 to utilize the
magnetic flux directional
characteristic of steel strip.
A computer-controlled automatic
machine cuts grain-oriented silicon
steel strip with high accuracy and
free of burrs, so that magnetic
characteristics of the grain-oriented
silicon steel remains unimpaired.
(Fig. 6)
Silicon steel strips are stacked in a
circle-section. Each core leg is
fitted with tie plates on its front and
rear side, with resin-impregnated
glass tape wound around the outer
circumference. Sturdy clamps
applied to front and rear side of the
upper and lower yokes are bound
together with glass tape.
And then, the resin undergoes
heating for hardening to tighten the
band so that the core is evenly
clamped (Fig. 7).
Also, upper and lower clamps are

connected by a core leg tie plate;

fore and hind clamps by connecting
bars. As a result, the core is so
constructed that the actual silicon
strip is held in a sturdy frame
consisting of clamps and tie plates,
which resists both mechanical force
during hoisting the core-and-coil
assembly and short circuits, keeping
the silicon steel strip protected from
such force.
I n large-capacity transformers,
which are likely to invite increased
leakage flux, nonmagnetic steel is
used or slits are provided in steel
members to reduce the width for
preventing stray loss from increasing
on metal parts used to clamp the
core and for preventing local
overheat. The core interior is
provided with many cooling oil ducts
parallel to the lamination to which a
part of the oil flow forced by an oil
pump is introduced to achieve forced
cooling.
When erecting a core after
assembling, a special device shown
in Fig. 8 is used so that no strain due
to bending or slip is produced on the
silicon steel plate.

Fig.6 Computer-controlled Core Lamination Line

Fig.7 Bind-type Core

Fig.8 Core Erecting Cradle

Winding
Various windings are used as shown
below. According to the purpose of
use, the optimum winding is selected
so as to utilize their individual
features.

Hisercap Disk Winding

(Interleaved disk winding)
In hisercap disk winding,
electrically isolated turns are
brought in contact with each other
as shown in Fig. 9.
Thus, this type of winding is also
termed "interleaved disk winding."
Since conductors 1 - 4 and
conductors 9 - 12 assume a shape
similar to a wound capacitor, it is
known that these conductors have
very large capacitance.

This capacitance acts as series

capacitance of the winding to highly
improve the voltage distribution for
surge.
Unlike cylindrical windings,
hisercap disk winding requires no
shield on the winding outermost
side, resulting in smaller coil
outside diameter and thus reducing
transformer dimension.
Comparatively small in winding
width and large in space between
windings, the construction of this
type of winding is appropriate for
the winding, which faces to an
inner winding of relatively high
voltage. Thus, general EHV or UHV
substation transformers employ
hisercap disk winding to utilize its
features mentioned above.

Continuous Disk Winding

This is the most general type
applicable to windings of a wide
range of voltage and current
(Fig.10). This type is applied to
windings ranging from BI L of 350kV
to BI L of 1550kV.
Rectangular wire is used where
current is relatively small, while
transposed cable is applied to large
current. When voltage is relatively
low, a transformer of 100MVA or
more capacity handles a large

current exceeding 1000A. In this

case, the advantage of transposed
cable may be fully utilized.
Further, since the number of turns
is reduced, even conventional
continuous disk construction is
satisfactory in voltage distribution,
thereby ensuring adequate
dielectric characteristics. Also,
whenever necessary, potential
distribution is improved by
inserting a shield between turns.

Helical Coil
For windings of low voltage (20kV
or below) and large current, a
helical coil is used which consists of
a large number of parallel
conductors piled in the radial
direction and wound. Adequate
transposition is necessary to
equalize the share of current among
these parallel conductors.
Figure 12 illustrates the transposing
procedure for double helical coil.
Each conductor is transposed at
intervals of a fixed number of turns
in the order shown in the figure, and
as a result the location of each
conductor opposed to the high
voltage winding is equalized from
the view point of magnetic field
between the start and the end of
winding turn.

Insulation Structure
On parts where the electric field is
liable to be concentrated, such as
the winding ends of disk windings,
detailed electric field analysis by
computer determines the optimum
shield shape and the insulation
distance so that the surrounding oil
is kept free from excessive electric
stress (Fig. 13).
Further, spaces between windings
close to a uniform field employ a
barrier insulation structure in which
an oil gap is formed by pressboard
(Fig. 14), so that partial discharge
characteristics and dielectric
strength are improved through an
adequate barrier arrangement,
resulting in stabilized insulating
performance. The windings are
clamped according to the following
steps.
When the annular, thick insulating
plate placed on the coil top has
been clamped by a hydraulic jack,
insulator wedges and blocks are
inserted between the insulating plate
and the underside of the upper yoke
and clamp, so that each coil is
clamped uniformly and completely.
Regarding pressboard to be used
for spacers and duct pieces on the
coil, precompressed pressboard is
used. Coils maintaining adequate
short-circuit strength for many years
and free from shrinkage through
aging have been realized through
uniformly, completely clamped
construction and insulating materials
excellent in compressive
characteristics combined with
adequate drying.
Further, all insulating materials used
for clamping these coils are oil
impregnable and the optimum type
for applications under high electric
fields.
The connective parts of coil leads
are likely to invite electric field
concentration as a result of the
edges of terminals and clamping
bolts. To alleviate stress
concerntration, each connection is
wound with aluminum-foil-laminated
crepe paper into a streamlined
shape and completely covered with
insulating paper.

10

Prevention of Internal Partial Discharge

and Insulation Treatment
In the case of transformers specified
with several reduced-insulation
levels, such as EHV or UHV
transformers, the ratio between
testing voltage and operating voltage
is small. To ensure high reliability in
extended operation under high
voltage, thorough quality control must
be effected to prevent dangerous
partial discharge. Main causes of
partial discharge include:
Incompletely dried insulations
Voids in insulations
Electrically floating metals and
incomplete contact under electric
field of high intensity
Edged electrodes
Concentrated electric stress applied
to oil gap
Intermixed foreign matter or dust
To eliminate these causes, the
following measures are taken in the
process of design and manufacture;
to confirm reliability, a partial
discharge test is conducted at the
final stage.

without causing damage to the

insulations.
Upon completion of drying, the coil is
clamped in a low-humidity room
adjusted to 5% or below relative
humidity to prevent any reabsorption
of humidity (Fig. 17).
When a core-and-coil assembly has
been installed in a tank, the tank is
evacuated to a high vacuum state to
remove reabsorbed humidity on the
insulations surface and voids in
impregnated insulation; then
deaerated oil is filled under the high
vacuum.
Upon completion of a factory test, the
transformer is transported to the site
(with its accessories disassembled
and packed as required) for
installation and assembly. During
installation and assembly at site,
adequate care is taken to dehydration
and the prevention of water
absorption as in the case of factory

by computer to determine the

optimum electrode shape, insulation
construction, and insulation
dimensions to ensure careful control
of the electric field.

Dust Control
The penetration of all sorts of dust
and foreign matter, as well as metallic
particles, is unfavorable to
transformers; such matter incurs
partial discharge. To avoid this
penetration, the transformer coreand-coil is assembled in a dustcontrolled dust-proofed room; winding
operations are performed in a doubleceiling room -a dust-proofed room
provided with an additional ceiling
(Fig. 16).
Dust is further controlled by coating
metal structures of the core-and-coil
assembly and the tank interior with
white paint; should dust or foreign
matter penetrate from the exterior, it
can be readily detected.

Removing Voids
Voids in impregnated insulation such
as paper and pressboard can be
completely removed by oil filling
under a vacuum. Depending on the
glue material and the using method,
there is a possibility of creating voids
inside. Thus, oil-impregnable glue is
used and due care is exercised to
avoid using excessive glue.
Fig.16 Dust-proofed Workshop

Electric Field Control

Fig. 15 Wave Form of Partial Discharge

Drying/Oil Filling Treatment

I n the core-type transformer, the
core-and-coil assembly is
independent of the tank, so that the
assembly is allowed to completely
dry. When drying the core-and-coil
assembly, Toshiba's innovative vapor
phase drying method is used, in
which special oil vapor is sprayed on
the assembly to utilize latent heat
produced when the oil vapor
condenses.
Since heating is effected deep inside
evenly and quickly, the assembly can
be completely dried

Insulation between high- and low

voltage windings, between windings
and the tank/core, and between coil
layers depends mainly on the oil
impregnated paper and oil gaps.
Unless voids are created in layers of
insulation paper, partial discharge
occurs first on oil gaps. The electrode
shape and insulation dimensions
must be carefully selected to keep the
oil free from excessive stress.
The electric field tends to concentrate
on the small shaped lead wires from
coils and lead wire connections,
edges of terminals and clamping
bolts, and metal structures such as
cores, clamps, and the tank which are
facing these high-voltage electrodes.
As to parts liable to invite electric field
concentration, detailed electric field
analysis is conducted

Fig.17 Vapor-phase Drying Oven

Fig.18 Transformer Final Testing

11

Measures against Leakage Flux

With the increase in transformer capacity,
the leakage flux also rises, so that stray
loss is increased or local overheat is
caused. For large-capacity transformers, it
becomes very important from the
standpoint of improved reliability to
thoroughly comprehend leakage flux and
to take measures to minimize stray loss.
At Toshiba, careful measures against
leakage flux are taken on the basis of the
results of computer-aided analysis on
leakage flux distribution and eddy current
loss on each part of the transformer, fully
utilizing our rich experience in producing a
huge number of large-capacity
transformers.
As to eddy current loss in coil conductors,
the loss of each coil part is determined
from leakage flux distribution. Transposed
cable and various types of transposition
are applied in accordance with results of
the above-mentioned loss analysis to
prevent local overheat from being caused
by excessive loss.
Generally made of mild steel, tanks and
other structural members are high in
permeability and liable to invite leakage
flux concentration.
Thus, the tank inner surface is provided
with a shield made of conductor plate
such as aluminum or a laminated shield
made of silicon steel strips to prevent
leakage flux from penetrating the tank,
thus reducing a large eddy current loss
created on steel members.
As to other structural members, efforts are
exerted to prevent local overheat or
excessive deterioration of adjacent
insulation from being caused by eddy
current loss, while employing
nonmagnetic materials in accordance with
leakage flux on each part, providing slits
in steel members to narrow the width as
described in the section on "Core " and
adopting other measures appropriate for
respective parts.

Fig.19 Example of Leakage Flux Distribution Analysis by a Computer

12

Tank
The tank is manufactured by
forming and welding steel plate to
be used as a container for holding
the core and coil assembly together
with insulating oil. The Toshiba
transformer tank offers the
following features:
Subjected to automatic beam
welding machine (Fig. 20) and
other special facilities, the tank
possesses high quality and
strength.
Transformers to be transported by
ship are structured in a semioval
shape on both ends of the tank
and provided with reinforcement
members rationally arranged,
resulting in increased strength and
decreased weight.
The tank bottom is fitted with a skid
base by welding and provided with
pull lugs to facilitate rolling in the
longitudinal and transverse
directions.
Capable of withstanding a high
vacuum of 0.1 torr or below, the
tank can be filled with oil under a
vacuum; to thoroughly remove
gases and moisture from the
insulation.
The tank is of completely enclosed,
welded construction.
Oilproof nitrile rubber gaskets are
used on those parts which must be
removed from the standpoint of
assembly in the field or during
maintenance; flanges thereon are
provided with accurately machined
grooves or gasket retainers to
ensure proper tightening of
gaskets. Consequently, there is no
possibility of oil leakage over an
extended period (Fig. 21, 22).
The tank internal surface and the
metallic part of the core-and-coil
assembly are coated with white
paint to help observe dust
accumulation.

Fig.20 Automatic beam welding machine

13

Cooling System
Self-cooled Type
Panel type radiators are mounted on
the tank.
Since any cooling fans and oil
pumps are not used, this type is
widely applied owing to its facilitated
maintenance, Panel type radiators
have features of decreasing oil
volume and withstanding a vacuum
(Fig. 23).

Air-cooled-air-cooled
T
Cooling
fans are installed on the
radiators to increase the cooling
effect. Usually, the cooling fans will
be put into service when natural
cooling becomes inadequate to
maintain the oil and/or winding
temperature within the specified limit
under a heavy load (Fig. 24).

Forced-oil,
Forced-air-cooled Type

Forced-oil,
Water-cooled Type

This is a system in which unit

coolers, each consisting of a cooling
tube, fan, oil-submerged pump, and
oil flow indicator assembled as a
unit, are arranged around the tank in
the necessary amount. Steel pipe
fitted with fins and dipped in zinc,
with an excellent corrosionproof
characteristics, is adopted as
cooling pipe.
In the tank cooled oil is delivered to
the windings and ducts on the core,
so that each part is cooled uniformly
and effectively (Fig. 25).
In some cases, a cooling device
consisting of a combination of oilsubmerged pumps and radiators
with cooling fans is used as a
cooling device for multirating of a
forced-oil, forced-aircooled/forcedaircooled/self-cooled transformer
(Fig. 26).

In case that a large amount of

cooling air is unavailable such as
in underground substations, water
cooled type is applied. The oil
circulates through the casing
outside the water tubes, and the
water circulates through the water
to be.
Where the cooling water pressure
is maintained at a higher level
than oil pressure, a double-tubetype cooler is applied (Fig. 27).

Table 1 Standard design of cooling system

Cooling System
Self-cooling
(ONAN)

type

Capacity

Cooling equipment

30,000kVA or below

Panel-type radiators

Forced-air-cooled
type (ONAF)

30,000kVA~150.000kVA

Panel-type radiators and cooling fans

Forced-oil, forced-aircooled type (OFAF)

150,000kVA or more

Unit cooler or panel-type radiator, and

Installation of cooling fans and pumps

In addition to the above, a forced-oil, water-cooled type (OFWF) and forced-oil, self-cooled type
(OFAN) are available.

14

Fig.23 Self-cooled type Transformer

Fig.24 Forced-air-cooled type Transformer

Fig.25 Forced-oil, Forced-air-cooled type Construction

Fig.26 345kV-75MVA Forced-oil, Forced-air-cooled type Transformer

Fig.27 Forced-oil, Water-cooled type Construction

15

Accessories
Oil Preservation System
Oil conservator type, nitrogenenclosed type, and diaphragm type
(Type OH-D), are employed for the oil
preservation system.

Diaphragm-type Oil Preservation

System (Type OH-D)
The oil preservation system Type OH-D
is provided with a synthetic rubber air cell
stretched over the oil surface in the
conservator to completely isolate the
insulating oil from outside air. This is
most suitable for high-voltage, largecapacity transformers (Fig. 28).
Since air in the air cell is connected to the
open atmosphere through a dehydrating
breather, the air cell shape varies
according to expansion and contraction
of the oil, keeping pressure in the air cell
at the atmospheric pressure.
Diaphragm-type oil preservation system
Type OH-D offers the following features:
Oil can be filled into the transformer
tank without being exposed to the air.
Since insulating oil is completely
isolated from the atmosphere by an air
cell, there is no possibility of oxygen or
moisture penetrating the oil.
Pressure on the surface of the oil is
constantly maintained at the
atmospheric pressure, offering no
possibility of the oil becoming
supersaturated and forming bubbles;
thus, high dielectric strength can be
maintained.
No need to refill nitrogen gas or
measure the gas purity simplifies
maintenance.
No need of attachments to be
separately installed results in less floor
area.
The air cell is made of nitrile rubber
reinforced with nylon cloth, ensuring
splendid oil-proofing and high strength.

Fig.28 Construction of Oil Preservation System Type OH-D

Fig.29 Oil Preservation System Type OH-D

Dehydrating Breather (Types FG,

FP, FS)
Air in the air cell of conservator Type
OH-D is exposed to the open
atmosphere through a dehydrating
breather to prevent dew condensation.
Regarding moisture absorbent, a
granular type free from deliquescence
is used.
To display the extent of moisture
16

Fig.30 Dehydrating Breather

absorption of the moisture

absorbent, it is also mixed the kind
of moisture absorbent which is blue
color under a dry state and changes
to pink as moisture absorption

progresses. When no breathing is

conducted, the breather is isolated
from the open air by oil to prevent the
moisture absorbent from needlessly
absorbing moisture (Fig. 30).

Dial Oil Level Indicator

For indicating on the dial a change
of oil in the conservator, the
indicator is tilted downward to
permit easy supervision of the oil
level even if it is installed at a high
level. Any change in the oil level is
detected by a float, converted into
rotary motion by a gear, and
transmitted to the external pointer
through a magnet. The float side is
completely isolated from the pointer
side by a partition through which the
rotary shaft does not pass,
preventing oil leakage. The pointer
side is of airtight construction with
moisture absorbent contained
therein to prevent the glass inner
side from clouding (Fig. 31).
Fig.31 Construction of Dial Oil Level Indicator

Protective Relays
The following protective devices are
used so that, upon a fault
development inside a transformer,
an alarm is set off or the
transformer is disconnected from
the circuit. In the event of a fault, oil
or insulations decomposes by heat,
producing gas or developing an
impulse oil flow. To detect these
phenomena, a Buchholtz relay is
installed.

Buchholtz Relay
The Buchholtz relay is installed at
the middle of the connection pipe
between the transformer tank and
the conservator. There are a 1st
stage contact and a 2nd stage
contact as shown in Fig. 32.
The 1st stage contact is used to
detect minor faults. When gas
produced in the tank due to a minor
fault surfaces to accumulate in the
relay chamber within a certain
amount (0.3Q-0.35Q) or above, the
float lowers and closes the contact,
thereby actuating the alarm device.
The 2nd stage contact is used to
detect major faults. In the event of a
major fault, abrupt gas production
causes pressure in the tank to flow
oil into the conservator. In this case,
the float is lowered to close the
contact, thereby causing the circuit
breaker to trip or actuating the
alarm device.
Fig.32 Buchholtz Relay

17

Temperature Measuring Device

Liquid Temperature Indicator
Liquid temperature indicator (BM
SERIES) is used to measure oil
temperature as a standard
practice. With its temperature
detector installed on the tank cover
and with its indicating part installed
at any position easy to observe on
the front of the transformer, the dial
temperature detector is used to
measure maximum oil temperature.
Thanks to its double construction,
the indicator can be removed
regardless of oil in the transformer
tank. The indicating part, provided
with an alarm contact and a
maximum temperature pointer, is of
airtight construction with moisture
absorbent contained therein; thus,
there is no possibility of the glass
interior collecting moisture whereby
it would be difficult to observe the
indicator (Fig. 33).
Further, during remote
measurement and recording of the
oil temperatures, on request a
search coil can be installed which
is fine copper wire wound on a
bobbin used to measure
temperature through changes in its
resistance.

Winding Temperature Indicator Relay (BM SERIES)

The winding temperature indicator
relay is a conventional oil
temperature indicator supplemented
with an electrical heating element.
The relay measures the
temperature of the hottest part of
the transformer winding. If
specified, the relay can be fitted
with a precision potentiometer with
the same characteristics as the
search coil for remote indication.
The temperature sensing system is
filled with a liquid, which changes in
volume with varying temperature.
The sensing bulb placed in a
thermometer well in the
transformer tank cover senses the
maximum oil temperature. The
heating element with a
matching resistance is fed with

current from the transformer

associated with the loaded winding of
the transformer and compensate the
indicator so that a temperature
increase of the heating element is
thereby proportional to a temperature
increase of the winding-over-themaximum-oil temperature. Therefore,
the measuring bellows react to both
the temperature increase of the
winding-over-the-maximum-oil
temperature and maximum oil
temperature. In this way the
instrument indicates the temperature
in the hottest part of the transformer
winding.
The matching resistance of the
heating element is preset at the
factory.

Fig. 34 Construction of Winding Temperature Indicator Relay

Fig.33 Oil Temperature Indicator

18

Fig.35 Winding Temperature Indicator

Pressure Relief Device

When the gauge pressure in the tank
reaches abnormally to 0.35-0.7kg/c m2
the pressure relief device starts
automatically to discharge the oil.
When the pressure in the tank has
dropped beyond the limit through
discharging, the device is automatically
reset to prevent more oil than required
from being discharged.

Tap Changer

Off-circuit Tap Changer

Off-circuit tap changer is used for
regulating the voltage after the
transformer has been completely
de-energized.
At Toshiba, two standard types of offcircuit tap changers are available: a
wedge-type off-circuit tap changer and
a slide-type off-circuit tap changer.
The wedge-type is used when taps are
provided halfway on the winding; the
slide-type is used when taps are
provided on the end of the winding.
The wedge-type is shown in Fig. 37.
The spring, which applies a contact
pressure to the contact piece, is most
highly compressed at its regular
position. Thus, in conjunction with
wedge action of the contact piece, a
sufficiently high amount of contact
pressure can be obtained, negating
the possibility of incomplete contact.
To prevent oil leakage, an oil seal is
used on that part of the tank cover
through which the operating shaft
passes.

Fig.36 Pressure Relief Device

Fig.37 Construction of Wedge-type Off-circuit Tap Changer

19

On-load Tap Changer

Developed on the basis of technical
license from MR Co., Germany,
Toshiba On-load Tap Changer FK
Series boasts the following features:
The entire on-load tap changer
can be built in a tank to facilitate
assembly and transport of the
transformer.
By performing resistance-type
breaking, arcing time is short, and
both oil contamination and contact
wear can be considerably
reduced. Further, this tap changer
ensures high reliability and long
life.

The tap selector is provided with

contact pieces structured to permit

conducting large current; each
contact piece is provided with a
shield electrode on its upper and
lower sides for needs of insulation.
The mechanical parts are
provided with adequate strength to
meet torque as required, thus
ensuring high reliability during
extended operation.

The three-phase tap changer is

split into three segments,

becoming suitable for changing
the neutral-point tap on starconnection winding. This type of
tap changer can also be used as a
large-capacity, single-phase tap
changer with current shunted by
impedance of the transformer
windings.
The diverter switch can be lifted
from the tap changer, offering
maintenance ease.

Table 2 Standard Types of On-load Tap Changers

Type

Max, step voltage (V)

Max, load current (A)

FKT-M100J

3,300

550

FKT-T100M

4,000

1,120

Fig, 38 On-load Tap Changer Type FKT-T100M

20

Fig, 39 Section of On-load Tap Changer

Bushing
Having manufactured various types
of bushings ranging from 6kV-class
to 800kV-class, Toshiba has
accumulated many years of splendid
actual results in their operation.
Plain-type Bushing
Applicable to 24kV-class or below,
this type of bushing is available in a
standard series up to 25,OOOA
rated current. Consisting of a single
porcelain tube through which passes
a central conductor, this bushing is
of simplified construction and small
mounting dimensions; especially,
this type proves to be advantageous
when used as an opening of
equipment to be placed in a bus
duct (Fig. 40).

Oil-impregnated, Paper-insulated
Condenser Bushing
The oil-impregnated, paperinsulated condenser bushing, mainly
consisting of a condenser cone of
oil-impregnated insulating paper, is
used for high-voltage application
(Fig. 41, 42). This bushing, of
enclosed construction, offers the
following features:
High reliability and easy
maintenance.
Partial discharge free at test
voltage.
Provided with test tapping for
measuring electrostatic capacity
and tan .
Provided with voltage tapping for
connecting an instrument
transformer if required.

Fig.42 345kV Oil-impregnated Paper-insulated Condenser Bushing (SF6 Gas-Oil)

21

Low-noise Transformer
From the standpoint of protecting
the surrounding living environment,
the problem of noise is attached
much importance.
Thanks to a combination of
Toshiba's excellent core
construction and assembling
technique, our large-capacity
transformers are manufactured at
lower noise level than the standard
level for transformers specified in
NEMA-TR1.
However, when a transformer is
installed close to the boundary line
of a power station/substation, or
when several transformers are
installed at the same station, it may
be necessary to employ
transformers with even less noise.
According to the required decrease
of noise, large-capacity
transformers are decided the
combination of various noise
enclosed constructions and cooler.

22

Construction of Noise Enclosure

Curtain-type enclosure
The transformer tank side walls
are covered with steel plate panels
around their outer circumference.
The steel plate interiors are lined
with sound-absorbent material to
prevent noise from built-up.
Steel-panel noise enclosure
The transformer tank side walls
and covers are entirely covered
with steel plate panels. Welded
construction is used in all assembly
of steel plate panels to minimize
noise, resulting in a high
noiseproofing effect.

Fig.43 Construction of Low-noise Transformer

Concrete-panel noise enclosure

The transformer tank side walls
and covers are entirely covered
with a noise enclosure consisting of
concrete and steel plate combined.
Since mass of concrete-panel is
greater than that of steel plate, the
concrete-panel noise enclosure
achieves greater noise reduction
than the steel-panel noise
enclosure.
Concrete noise enclosure
The transformer tank side walls
and covers are entirely covered
with a reinforced concrete wall.
This construction achieves the
greatest noise-reducing effect.

Low-noise Combination of Transformer

Low-noise Cooler
Typical coolers applicable to lownoise transformers include the
followings:
Low-noise unit cooler with lowspeed cooling fan
Low-noise unit cooler with soundabsorbing duct on the front
of cooling fan
Independent radiator of selfcooled type or forced-oil,
self-cooled type
Water-cooled unit cooler

Large-capacity transformers of the

100-300MVA class adopt the
following various types of
combination in accordance with
noise level requirements:
Noise level: 70-80 dB
The transformer tank side walls
are covered with a curtain-type
enclosure; a low-noise unit
cooler with low-speed cooling
fan is installed.
Noise level: 60-70 dB
The transformer tank is covered
with a steel-panel noise
enclosure; a low-noise unit
cooler with low-speed cooling
fan or noise-absorbing duct is
installed.

Fig.44 Steel-panel Noise Enclosure

Noise level: 55-65 dB

The transformer tank is covered
with a concrete-panel noise
enclosure; a radiator bank or
low-noise unit cooler with noiseabsorbing duct is installed.
Noise level: 50- 60 dB
The transformer tank is placed
in a concrete noise-enclosure.
Generally, an forced-oil, selfcooled system is employed with
the radiator bank installed
outside the concrete noiseenclosure. If circumstances
require, a unit cooler of the
water-cooled type or super lownoise type is installed.

Fig.45 Concrete-panel Noise enclosure

23

Construction of Cable Connection

And GIS Connection
Cable Connection
In urban-district substations
connected with power cables and
thermal power stations suffered from
salt-pollution, cable direct-coupled
construction is used in which a
transformer is direct-coupled with the
power cable in an oil chamber.
Toshiba employs an indirect
connection system in which, with a
cable connecting chamber attached
to the transformer tank, a coil
terminal is connected to the cable
head through an oil-oil bushing in the
cable connection chamber.
Construction of the connection
chamber can be divided into
sections. Cable connections and oil
filling can be separately performed
upon completion of the tank
assembling.

24

Fig.46 Indirect Cable Connection

GIS (Gas Insulated

Switchgear) Connection
There is an increasing demand for
GIS in substations from the
standpoint of site-acquisition
difficulties and environmental
harmony. In keeping with this
tendency, G IS connection-type
transformers are ever-increasing in
their applications.
At Toshiba, the SF6 gas bus is
connected directly with the
transformer coil terminal through an
oil-gas bushing.
Toshiba's oil-gas bushing support is
composed of a transformer-side
flange and an SF6 gas bus-side
flange, permitting the oil side and the
gas side to be completely separated
from each other.

Fig.47 Direct GIS Connection

Transportation
It is important to transport a
transformer in the same condition
as it was completely assembled,
dried and tested at the factory. This
makes it possible to ensure high
reliability and to shorten the period
for on-site installation.
A Toshiba transformer is
transported in the same upright
position as it was in final
assembling so that on-site
installation becomes very simple,
requiring no special operations.
While a transformer is in
transportation, its main tank is filled
with dry air or dry nitrogen to
completely prevent the core and
coils from absorbing

moisture until final on-site oil filling.

When extreme transport
restrictions are imposed, as in the
case of power stations in
mountains or when roads are
subjected to weight restrictions or
when the entrance for underground
hoisting is narrow in the case of
installation with urban underground
substation, the following transport
procedure is employed: A threephase transformer is divided into
sections so that one-phase section
housed in a tank is carried into the
site at a time, and the three
sections are assembled

into the original three-phase

transformer at the site.
The transformer core and coils are
transported to the site in the same
condition as it was assembled and
tested at the factory, and they are
joined to each other using special
ducts and leads submerged in oil.
When further strict transport
restrictions are imposed, a singlephase unit may be divided into two
or three sections. Toshiba
delivered a 500kV, 680MVA threephase transformer in nine sections
- a record-breading product!

Fig.48 Loading a 50Hz, 420kV, 700MVA Transformer

25

Research and Development

For the research and development
of equipment coping with the
tendency toward high voltage and
large capacity, the cooperation of
engineers in every field is
necessary -such as electrical,
mechanical, chemical and metal
engineering, as well as statistics.
Toshiba Heavy Apparatus
Engineering Laboratory is exerting
efforts to cultivate basic techniques
covering various fields in close
cooperation with the manufacturing
department including the design,

production, and test/inspection

sections, thereby playing a major
role in new product development,
improved product performance,
and enhanced reliability. The
world-prominent, latest testing
facilities in this Laboratory are fully
utilized in the development of
ultrahigh-voltage insulation
structures represented by Toshiba
UHV transformers and 500kV
transformers, as well as in
fundamental research concerning
various types of discharge and

breakdown, including breakdown in

oil which supported development.
Further, all possible efforts are
exerted by the staff of this
Laboratory in basic to applied
research on extensive engineering
fields ranging from electromagnetic
phenomenon, structural strength,
heat transfer and cooling, noise,
vibration, and earthquake proofing
-including insulation and metallic
materials.

Fig.49 UHV Laboratory

26

Fig.50 2300kV AC Testing Facilities

Fig.51 6000kV Impulse Generator

Fig.52 Analysis with Computer

Fig.53 UHV Prototype Auto-transformer 500/3MVA-1200/3kV-50Hz

27

TOSHIBA
1-1, SHIBAURA 1-CHOME, MINATO-KU, TOKYO, 105-8011, JAPAN
TEL: 03(3457)3612 FAX: 03(5444)94196

Overseas Office:
London, Moscow, Vienna,
Beijing Shanghai, Guangzhou,
Hong Kong, New Delhi,
Bangkok, Taipei, Manila,
Jakarta, Colombia,
Rio de Janeiro, Buenos Aires

Toshiba International Corporation:

San Francisco, Houston,
Vancouver
Toshiba International Corporation
Pty. Ltd.: Sydney, Melbourne
Toshiba International Company
Limited: London

For further information, please contact your nearest Toshiba Liaison Representational or International Operations-Energy System.
The data given in this catalog are subject to change without notice.

6814-7

99-4 C1