The State of The Art in Engineering Methods For TR
The State of The Art in Engineering Methods For TR
1149 - 1158
The complexity of transformer design demands reliable and rigorous solution methods. Survey of current research reveals
the continued interest in application of advanced techniques for transformer design optimization. This paper summarizes
some of the most important developments in this research area. The main purpose is to provide a synthesis of the
published research in this field and stimulate further research interests and efforts in the respective topics.
Keywords: Survey, Transformers, Transformer Design, Transformer Design Optimization, Numerical Techniques,
Artificial Intelligence, Equivalent Circuit Models, Experimental Models
special purpose transformers such as converter structure of the survey overview presented in the next
transformers, test transformers, instrument transformers or Sections.
telecommunications transformers, which can be both in the
range of power transformers and in the range of
distribution transformers as far as rated power and rated
voltage are concerned.
As far as the cooling method is concerned,
transformers may be designed either as oil-immersed or
dry type transformers. In oil-immersed transformers, the
insulating medium is oil while in dry type transformers,
the cooling is implemented with natural air circulation.
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, four
cooling methods exist: ONAF (Oil Natural Air Forced),
OFAN (Oil Forced Air Natural) (OFAF Oil Forced Air
Forced) and OFWF (Oil Forced Water Forced).
Combinations like ONAN/ONAF, ONAN/OFAN or Fig. 1. Transformer survey structure.
ONAN/OFAF are also applicable [4].
Transformer magnetic circuit is constructed in either a
shell or a core structure. They are distinguished from each
other by the manner in which the primary and secondary 3. Research dedicated to specific transformer
coils are placed around the laminated steel core. The shell characteristics
type transformer is one where the windings are completely
surrounded by transformer steel in the plane of the coil. In The numerous computational methods and
core type, the windings surround the laminated iron core. engineering models proposed for transformer analysis and
There are two different technologies for stacking the the accurate prediction of their characteristics can be
sheets of the magnetic material of the core, providing a roughly categorized into four main groups:
further distinction to a) stack core transformers, where the 1. Numerical techniques that consist some of the most
layers of the sheets of the magnetic material are placed one widely used tools for transformer simulation. Among
over the other and the vertical and the horizontal layers are the proposed techniques of this group, the Finite
over lapped, and b) wound core transformers, where the Element Method (FEM) is the most prevalent one.
magnetic circuit is of shell type and the sheets are wound. 2. Stochastic methods including Artificial Intelligence
Multi-winding transformers, as well as poly-phase (AI) techniques, such as Genetic Algorithms (GAs),
transformers, can be made in either shell or core type which have seen increased usage in the transformer
designs, with a magnetic circuit that consists of five (in design area over the last few years.
shell-type transformers) or three legs (in core-type 3. Improved versions of the transformer equivalent
transformers), respectively. circuit, in order to include semi-empirical
descriptions of the core and winding characteristics
that affect the accuracy of calculations. Its use is still
2.2 Transformer design considerations common in the manufacturing industry, due to its
simplicity and its ability to provide reliable results,
Transformer design must take into account numerous especially in cases of standardized geometries.
performance parameters and technical constraints. The 4. Experimental methods, combining data provided by
research in the relevant literature may deal with each one measurements with analytical or other methods, in
of these parameters separately, or concern the overall order to provide efficient models for the accurate
transformer optimization. Fig. 1 presents the main representation of certain transformer characteristics.
categories of the literature survey, which define the
The state of the art in engineering methods for transformer design and optimization: a survey 1151
eddy and circulating current loss in windings, losses in order to simplify the time and complexity of the
flitch plate, core edge loss, loss due to high current field, calculations required in automated design process.
and frame and tank losses. Stochastic methods are also employed for solving
Moreover, a short methodological survey is carried problems of this category, as by Thilagar and Rao [67],
out by Krawczyk and Turowski [47], showing the need of who suggested an exact equivalent circuit model for the
eddy current analysis in electric devices. estimation of all impedance parameters of three winding
The FEM analysis is quite commonly used for the transformers, with the use of GA. The suggested method
eddy loss calculations [48,49]. Pern and Yeh [50] are also estimates geometrically a complex parameter, that is,
engaged in the formulation of an A-V finite element mutual leakage between secondary and tertiary windings.
method to simulate the electromagnetic field and current
distribution in the windings of power transformers with
non-negligible circulating current. In addition, the foil- 3.4 Inrush current
winding eddy loss is estimated by Ram [51]. Furthermore,
the eddy current field due to both windings and heavy Transformer inrush currents are high-magnitude,
current leads in large power transformers is analyzed in harmonic-rich currents generated when transformer cores
[52] by using the improved T-Ω method. are driven into saturation during energization. These
When a three-phase three-limb core type transformer currents have undesirable effects, including potential
is subjected to the load-loss measurement test, it is found damage or loss-of-life to the transformer, protective relay
that the losses and currents of the phases are asymmetrical misoperation, and reduced power quality on the system
(and unequal). Reference [53] attempts to give a [68]. Inrush current prediction is therefore another
comprehensive explanation for the asymmetry in the loss important issue during transformer design and various
values of the three phases during the load-loss test. A approaches to deal with it are present in the technical
three-phase transformer has been analyzed using a literature.
comprehensive 3-D time-harmonic FEM analysis. Numerical techniques are present in the above context
of inrush current prediction, as in [69], where 2D FEM is
applied to three-legged power transformers for the
3.3 Leakage field and short-circuit impedance evaluation of forces on the windings due to inrush current
and their comparison to the respective short-circuit forces.
The calculation of transformer leakage flux is a However, the majority of the methods used for inrush
prerequisite to the calculation of reactance, short-circuit current simulations are based on the derivation of
impedance, short-circuit forces and eddy current losses. appropriate equivalent circuits, taking into account the
The finite element method has been extensively core geometry [70] and structural characteristics [71], the
employed in transformer leakage field evaluation. The first core material nonlinear characteristics [72] or using real-
research attempts, presented over three decades ago, [54], time measurements [73]. Artificial neural networks have
focused on 2D modeling, due to the restricted performance also been employed for the computation of inrush current
abilities provided by the early development of personal and forces [74].
computers. 2D FEM remains an efficient tool for leakage
field and short-circuit impedance evaluation and more
recent developments in the prediction of these parameters 3.5 Stresses and dynamic behavior under short
are presented in the literature [55]. Although the 2D circuits
modeling is convenient and useful in some design
problems, it can be found insufficient for detailed analysis The short-circuit current in a transformer creates
and computation of the transformer magnetic field, and enormous forces on the turns of the windings. The short-
therefore the three-dimensional (3D) solution becomes circuit currents in a large transformer are typically 8 to 10
necessary [56-60]. The boundary-element method is times larger than rated and in a small transformer are 20 to
another numerical technique extensively used for 25 times larger than rated. The forces on the windings due
electromagnetic problems [61]. The main attraction of this to the short-circuit current vary as the square of the
method is the simplicity of the data required to solve these current, so whereas the forces at rated current may be only
problems, along with the high accuracy obtained with a few newtons, under short-circuit conditions these forces
boundary elements. Moreover, the combination of can be tens of thousands of newtons. These mechanical
boundary and finite elements is another widely used and thermal stresses on the windings must be taken into
numerical field analysis technique presenting significant consideration during the design of the transformer.
advantages in transformer leakage field modeling [62,63]. Transformer behavior under short-circuits is one of the
To overcome the main numerical techniques major concerns during their design, since the ability to
drawback, namely the complexity of the required mesh overcome the resulting stresses and currents for external or
size, especially in 3D configurations, alternative leakage internal faults of a certain time duration without significant
field evaluation models have been proposed, with the use consequences on their operation is a requirement often
of a 3D reluctance network method [64], falling into the present in the international technical standards. The
category of equivalent circuit representation. An accurate representation of this behavior is mainly realized
alternative method of transformer leakage field calculation through numerical techniques due to their prevalence in
is based on simplified analytical formulas [65,66], a the transformer detailed magnetic field calculation, [75-
method often employed by transformer manufacturers in 80]. Equivalent circuit approaches are also employed,
although their application is usually coupled to some
The state of the art in engineering methods for transformer design and optimization: a survey 1153
detailed calculation, often based to numerical method [81], temperature rise. The temperature rise in a transformer is
in order to ensure better representation of the phenomena intrinsic to that transformer at a fixed load. The design of
occurring during short-circuits. the cooling system is based on the hot-spot temperature
value, and different methods for its prediction are
3.6 Transformer noise proposed in the literature, along with the overall
temperature distribution prediction, according to the
Transformers located near a residential area should transformer cooling method.
have sound level as low as possible. The design and the The finite difference method is proposed by Pierce
manufacture of a transformer with low sound level require [94] for hot-spot temperature prediction in dry-type
in-depth analysis of noise sources. Core, windings and transformers. 2D FEM thermal calculation is proposed in
cooling equipment are three main factors of noise, with the [95] for the calculation of core hot-spot temperature in
first factor the paramount one. To determine a method for power and distribution transformers. Most recent trends in
the optimum design of the noise-reduction transformer, thermal modeling employ coupled electromagnetic-
noise attenuation of a simple structured prototype thermal finite element models [96,97].
transformer that utilizes C-cores is quantitatively discussed Appropriate equivalent circuits are developed in [98]
based on the equivalent circuit analysis [82,83]. Similar for the core rise temperature calculation and power
work is presented in [84]. Finally, a recently developed transformer thermal distribution [99-101]. In [102] and
calculation scheme for the computer modelling of the [103] the parameters of the proposed oil-immersed
load-controlled noise of oil-insulated three-phase power transformer thermal model derive with the use of genetic
transformers is presented in [85]. This modelling scheme algorithms. Dynamic thermal models are also proposed in
allows the precise and efficient computation of the coupled the literature [104-106], taking proper account of oil
electromagnetic, mechanical and acoustic fields. The viscosity changes and loss variation with temperature.
equations are solved using the FEM as well as the Particle swarm method and neural networks are also
boundary element method (BEM). encountered in the relevant research field [107,108].
Experimental investigation of thermal distribution of
3.7 Transformer insulation cast-resin and oil-filled transformers is carried out in [109]
and [110], respectively. Experimental data are used for the
The insulation of a transformer is linked to its ability improvement of analytical equations that predict thermal
to withstand surge phenomena and overvoltages likely to distribution of liquid filled transformers in [111].
occur during its operation. For this purpose, the related Last but not least, in order to improve power
work may deal with the analysis of such phenomena, so as transformer reliability, a special focus has been carried out
to design an adequate transformer insulation system. Other on insulating materials and especially on insulating oils.
factors that affect transformer insulation life are vibration The most commonly used liquid in power transformers is
or mechanical stress, repetitive expansion and contraction, mineral oil due to its low price and its good properties
exposure to moisture and other contaminants, and [112]. However, the performance of mineral oil starts to be
electrical and mechanical stress due to over-voltage and limited. Numerous activities have been initiated to try to
short-circuit currents. improve the properties of mineral oil or to find other
Numerical methods are more scarcely applied for the substitute liquids. Natural esters or vegetable oils have
simulation of the above phenomena, and are mainly used been used successfully as transformer dielectric coolants,
for the calculation of the transformer electric field [86]. On alternatively to conventional mineral oils [113-117]. Their
the other hand, the majority of research is based on application offers some advantages, such as safety against
equivalent circuit representation for transformer analysis a fire incident, environmental friendliness and improved
under overvoltages, respective to their geometrical transformer performance. Moreover, mixtures consisting
characteristics [87], their dynamic behavior [88], their of mineral oil and two other kinds of insulating liquids
frequency response characteristics [89] or the (namely silicon and synthetic ester oils) are investigated in
characteristics of the network where they are connected [118,119]. Finally, the “retrofilling” application, in this
[90]. Other attempts to model the insulation structure of case replacing mineral oil with natural esters, is also
transformers and the quantitative analysis of its dielectric presented in [120], as a method to extend the remaining
response are also encountered [91,92]. Finally, the thermal life of an aging transformer.
exploitation of measurements and the experience from the
impact of the operational characteristics on the insulation
life assessment is often one of the main methods to design 3.9 Transformer DC bias
an insulation system and predict its ability to withstand
any transient phenomena during the transformer life [93]. Direct Current (DC) can flow in Alternating Current
(AC) power lines if a DC potential difference exists
3.8 Transformer cooling between the various grounding points. Such a difference
can be caused by a geomagnetic storm or the injection of
Transformer cooling is one of the most important DC current by one of the ground electrodes of a DC link
parameters governing a transformer’s life expectancy. The [121]. Direct current flowing through the earthed neutrals
total temperature is the sum of the ambient and the of transformer windings causes a DC component in the
1154 Eleftherios I. Amoiralis, Marina A. Tsili, Pavlos S. Georgilakis
magnetising current. Owing to non-linearity, the waveform superconducting coil that simulated the inner secondary
of this current is strongly distorted. The prediction and winding of a high-superconducting traction transformer is
impact of this phenomenon has been studied with finite presented in [147,148]. Moreover, the magnetization
element method [122-124] and equivalent magnetic losses in HTS pancake windings according to the
circuits [125,126]. operating temperature, is discussed in [149].
There is a considerable progress in the technology of
gas immersed transformers in the last decade. Unlike the
3.10 Transformer monitoring and diagnostics oil-immersed transformers, they have SF6 gas for the
insulation and cooling purposes [150,151].
Despite the fact that monitoring and diagnostics are
not part of the transformer design process, they are
relevant to the main design considerations. For this 4. Transformer design optimization
purpose, an overview of some key works dealing with the
characteristics presented in the previous Sections is The difficulty in achieving the optimum balance
provided in the present Section. between the transformer cost and performance is a
AI techniques and stochastic methods are prevailing complicated task, and the techniques that are employed for
in the present category. Neural networks are encountered its solution must be able to deal with the design
in the majority of the research dealing with transformer considerations of Section 3, so as to provide a design
fault diagnosis [127-131]. They are also employed for oil- optimum, while remaining cost-effective and flexible. The
immersed distribution transformer monitoring in [132]. research associated with design optimization is therefore
Furthermore, Stochastic Petri Nets are used for the more restricted involving different mathematical
simulation of the fault diagnosis process of oil-immersed optimization methods.
transformers and the definition of the actions followed to Techniques that include mathematical models
repair the transformer [132]. Particle swarm method is employing analytical formulas, based on design constants
used for winding deformation identification in [133]. and approximations for the calculation of the transformer
Finally, fuzzy systems and expert systems are proposed in parameters are often the base of the design process
[135] and [136] for the gas analysis and insulation adopted by transformer manufacturers [152]. Artificial
monitoring, respectively. Intelligence techniques have been extensively used in
order to cope with the complex problem of transformer
design optimization, such as genetic algorithms (GAs) that
3.11 Recent trends in transformer technology have been used for transformer cost minimization [153],
performance optimization of cast-resin distribution
In the last decade, rapid changes and developments transformers with stack core technology [154] or toroidal
have been made in the field of the transformer design. core transformers [155]. Neural network techniques are
Continuous efforts are directed at developing also employed as a means of design optimization as in
improved electrical steels with lower iron losses for [156] and [157], where they are used for winding material
energy-efficient transformers. It is well known that low selection and prediction of transformer losses and
magnetic losses of amorphous material are attributable to reactance, respectively. Deterministic methods may also
the material's amorphous condition and small thickness of provide robust solutions to the transformer design
the ribbon [137,138]. The core losses can be limited by optimization problem. In this context, the deterministic
insulating coatings [139], and various types of coatings method of geometric programming has been proposed in
have been developed for application to both fully [158] in order to deal with the design optimization
processed and semiprocessed electrical steels. In addition, problem of both low frequency and high frequency
Matsuura et al. [140] presented long-term property transformer. The overall manufacturing cost minimization
reliability for iron-based amorphous alloy for use in oil- is scarcely addressed in the technical literature, and the
immersed transformer cores. main approaches deal with the cost minimization of
Advent of high-temperature superconducting (HTS) specific components such as the magnetic material [159]
materials has renewed interest in research and or certain performance parameters as the output power
development of superconducting transformers. The [160], the load loss minimization [161,162] or the no-load
principal advantages of HTS transformers are: much lower loss minimization [163].
winding material content and losses, higher overload Apart from the transformer manufacturing cost,
capacity and possibility of coreless design. Some another criterion used for transformer evaluation and
considerations from design point of view are discussed in optimization is the Total Owing Cost (TOC) taking into
[141,142], while in [143] new perspectives of HTS account the cost of purchase as well as the cost of energy
transformer design are introduced. The development of losses throughout the transformer lifetime [164]. An
technology based on liquid nitrogen at temperature up to important part of the transformer cost optimization
79oK has reduced the complexity and cost of the research is devoted to the TOC minimization, as follows.
superconducting transformers [144,145]. A development Distribution transformer TOC optimization is analysed in
of three-phase 100 kVA superconducting transformer with [165-168]. Since the load losses are directly linked to the
amorphous core has been reported in [146]. A high- type of the considered load and the specific details of the
The state of the art in engineering methods for transformer design and optimization: a survey 1155
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1156 Eleftherios I. Amoiralis, Marina A. Tsili, Pavlos S. Georgilakis