COMPEL - The international journal for computation and

mathematics in electrical and electronic engineering

THE PRACTICAL APPLICATION OF FEM TECHNIQUES IN TRANSFORMER DESIGN &
DEVELOPMENT
V Darley
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To cite this document:
V Darley, (1992),"THE PRACTICAL APPLICATION OF FEM TECHNIQUES IN TRANSFORMER
DESIGN & DEVELOPMENT", COMPEL - The international journal for computation and mathematics in
electrical and electronic engineering, Vol. 11 Iss 1 pp. 125 - 128
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 COMPEL - The International Journal for Computation and Mathematics in Electrical and Electronic Engineering
Vol 11, No 1, 125-128 (c) James & James Science Publishers Ltd

THE PRACTICAL APPLICATION OF FEM TECHNIQUES IN

TRANSFORMER DESIGN & DEVELOPMENT

V Darley
Design Engineer
GEC ALSTHOM Transformers Limited, Lichfield Road, Stafford ST17 4LN England

Introduction
Power 4 Distribution Transformers are complex assemblies of metallic and
insulating materials which generate equally complex electrostatic and
electromagnetic fields.
Since the first transformer was built, there has been an ongoing drive to
find methods of field analysis which would allow more accurate
calculation and therefore a better understanding of the effects of these
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fields.
Very ingenious 2D mathematical and analogue techniques of field analysis
have been devised all of which have been very useful but have had various
limitations in the representation of complex and often non-linear 3D
arrangements. 3D analogue modelling has always been extremely difficult,
time consuming, expensive and inaccurate, except in the special case
involving rotational symmetry.
However, FEM computer techniques and the rapid advances in computer power
and graphics have revolutionised transformer field analysis and now
provide a powerful tool to make more efficient use of materials whilst
preserving the integrity of the transformer.
Potential problem areas can now be more easily identified and therefore
solutions found at an early stage in the design process. Equally, any
problems that occur during test or service can be resolved much more
quickly than in the past.
This paper presents case studies to illustrate the way in which both 2D
and 3D FEM techniques are being used to develop knowledge of material
behaviour in electrostatic and electromagnetic fields and hence improve
design information.
GEC ALSTHOM Transformers Limited at Stafford use an FEM package (SLIM)
developed at the GEC ALSTHOM Research Centre at Stafford, and the
examples described in this paper have been solved using this software.
The software was originally devised for the solution of generator field
problems but has been successfully adapted for transformer applications.
Example of Electrostatic Studies
2D analogue and digital techniques have always been more easily applied
to transformer electrostatic rather than electromagnetic field problems,
although a complete analysis has rarely been possible. 3D FEM techniques
now permit the complete representation of insulation structures including
directional properties of materials.
Voltage Stress Amplification in Insulation Structures
The concentric configuration of HV power transformer windings is well
known and understood. Between HV and LV coils there are radial and
axial components of voltage which if uncontrolled, combine to give a
potentially high voltage stress at the oil to paper covered conductor
interface.
The gap between windings is a barriered insulation structure with axial
pressboard spacers equally spaced circumferentially to provide the oil
ducts between concentric pressboard barriers.
125
 126 V. Darley

If failure occurs in this region during high voltage power frequency or

impulse voltage proving tests, the failure usually involves one or more
of the axial spacers at the inside diameter of the HV winding. In
order to fully examine this phenomenon, a complete electrostatic
analysis of the region is required using a 3D solution.
The method of gaining design information in the past has been to carry
out a 2D analogue or FEH electrostatic field analysis of the region
without the axial spacers represented. Physical models have then been
tested to destruction which have had all of the insulation components
included. Thus design limits could be empirically set for the voltage
withstand of a specific insulation structure without knowing the true
breakdown voltage stresses.
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 Application of FEM Techniques in Transformer Design 127

The results of a 2D FEM study are shown in Figure 2a. (no spacers
represented), where the voltage stress in oil is shown in the region of
the most highly stressed conductor.
When the same situation is plotted using 3D FEM software, with all of the
FEM components represented, then the complete voltage stress conditions
can be seen in the region of the axial dovetail sticks. A slice is shown
in Figure 2b. beneath the dovetail stick in the region of the breakdown.
The voltage stress in oil at the oil to paper covered conductor interface
has been amplified because of the high relative permitivity of the radial
spacers.
The capability of calculating the voltage stress distribution in such a
complex 3D insulation structure increases our knowledge of transformer
material behaviour and work is continuing to understand and utilise the
information gained so far.
Example of Electromagnetic Studies
With the advent of 3D FEM techniques, the most significant advance in
transformer field analysis has been in the solution of electromagetic
problems.
Because of the non symmetric nature of the electromagnetic phenomena in
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transformer structures, a 3D analytical approach is required for accurate

solutions. The 3D electromagnetic programs now available allow the
calculation of eddy current losses and the representation of non-linear
and laminated steel characteristics.
Eddy Current Loss in Core Clamping Frames
Eddy current overheating of the steel structures in a transformer caused
by the stray magnetic fields of the windings can be controlled in a
number of ways. ' The material characteristics can be changed, e.g. by
using non-magnetic steel or non-ferrous materials, or systems can be used
which either collect or divert the magnetic stray flux and take it away
from the critical regions.
Flux collectors consisting of electrical core steel laminations placed
between the windings and the core clamping frames collect and redirect
the stray magnetic fields preventing these fields from reaching the steel
clamps.
Aluminium or copper shielding placed over and extending beyond the limits
of components at risk of eddy current heating, divert the stray magnetic
flux.
 128 V. Darley

An FEM analysis of a 3D eddy current problem is shown in the solid model

of Figure 3. This study was carried out to analyse the losses in the
core clamping frames and tank wall of a 3-phase transformer and the
subsequent reductions in loss afforded by the use of a laminated flux
collector which channels stray flux from one phase to the other two
phases.
The model makes use of lines of symmetry as can be seen in the
photograph.
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The distribution of loss in the core clamping frame with flux collectors
is shown in Figure 4a. and the subsequent increase in loss affected by
the removal of flux collectors is shown in Figure 4b. clearly showing the
advantages of the technique.
Discussion
Future Work
The translation of eddy current loss patterns into temperature patterns
is now an attainable goal and a FEM thermal solution program is in an
advanced state of development at the GEC ALSTHOM Stafford Research
Centre.
At the same time, work is being carried out to determine the accuracy of
eddy current solutions using carefully devised experimental models.
It is intended that this work together with other supportive work, can be
used as a basis for the accurate determination of temperature rise of
mild steel tanks and core clamping frames when subjected to known eddy
current losses or stray fields.
Design & Development Utilisation
FEM analysis now forms an integral part of the GEC ALSTHOM Transformers
power and distribution design and development effort at Stafford. The
range of study is extensive and even includes the study of d.c. behaviour
with polarity reversal for laminated (directional resistivity) materials
in converter transformers.
FEM techniques provide direct design support and are a valuable tool in
problem solving and understanding the behaviour and effect of materials
in electrostatic and electromagnetic fields.
The transformer designer now has the knowledge to make more efficient use
of insulating and magnetic materials leading to the most cost effective
and technically advanced designs.
 This article has been cited by:

1. References 507-524. [CrossRef]

2. Janusz TurowskiStray Losses, Screening, and Local Excessive Heating Hazard in Large Power
Transformers 45-94. [CrossRef]
3. M. Rizzo, A. Savini, J. Turowski. 2000. Influence of flux collectors on stray losses in transformers.
IEEE Transactions on Magnetics 36:4, 1915-1918. [CrossRef]
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