One program for the whole design of a large power transformer.
Electrical, dielectric, short-circuit, thermal and mechanical design of oil-immersed power transformers, from nameplate data to the clamping drawings, with FEM and transient modules in the same environment. Written and used by the engineers who design, test and analyse transformers at HVCC.
- Voltage class
- 400 kV
- Typical unit range
- 50 – 400 MVA
- Design · FEM · Transients
- 3 modules
- Desktop, runs offline
- Windows
A design model that every calculation reads.
Change the core diameter or the tap range and the impedance, the short-circuit forces, the losses and the temperature rises follow. Nothing is copied between spreadsheets.
Where the design lives
Nameplate, circuit, regulation, core, windings, insulation, impedance, losses, cooling and clamping in one project file. Each tab is a step of the design and reads the same model.
Field results, back into the model
Takes the geometry from the main interface and returns the leakage field, the additional losses conductor by conductor and a hot-spot temperature computed alongside the IEC method.
What the test floor will see
Short-circuit currents winding by winding and tap by tap, lightning impulse full and chopped, switching impulse and induced AC voltage, solved node by node along every coil.
Large manufacturers wrote their own. Everyone else uses spreadsheets.
The big groups have in-house design systems and do not sell them. Regional manufacturers design with Excel and the memory of one senior engineer. Power Transformers Design was written for the second group.
Regional transformer builders
Factories producing 50 to 400 MVA units that want one design method the whole office can use, check and hand on when the senior designer retires.
Factories being set up
New production lines that need a complete design toolchain before the first order, together with the process know-how HVCC supplies for plant layout and manufacturing.
Design, repair and review
Companies that design or verify transformers for others: repair and revamping shops, EPCs and consultants doing design review of third-party units.
From nameplate to workshop drawings in nine steps.
The tabs follow the order in which a transformer is actually designed. Every screen below is the program itself, on the same 225 MVA autotransformer. Click any image to enlarge it.
- Step 1 of 9
Nameplate and circuit
- You enter
- Three-phase unit or single-phase bank, autotransformer, cooling from ONAN to OFWF, vector group, frequency, altitude, tertiary winding, two primary or two secondary voltages, series-parallel secondary.
- You get
- Rated voltages and currents for every winding and cooling stage, star and delta connections, the single-phase electric circuit with series, common, regulating and tertiary windings, and the insulation levels Um, BIL, SI and AC for each winding and neutral.
Main tab: transformer type, cooling, options and nameplate data Power tab: ONAN and ONAF ratings per winding Rated voltages, connections and phase currents Rated insulation levels Um, BIL, SI, AC Single-phase electric circuit: SER, COM, REG, TER - Step 2 of 9
Regulation and tap changer
- You enter
- Regulation on any winding, reverse, linear or coarse-fine, number of steps and percentage, constant-current position.
- You get
- Voltage and current at every tap position, step voltage, fine and coarse winding voltages, and the on-load tap changer picked from the MR and ABB catalogues with its contacts, positions and location in the winding.
Reverse regulation on the secondary: nine steps, 11.39 % Tap changer selection from the MR catalogue - Step 3 of 9
Core
- You enter
- Number of limbs, step-lap, volts per turn, flux density, magnetic material with its specific loss and apparent power, cooling ducts, flitch plates.
- You get
- Circular limb section built stack by stack, net cross-section and fill factor, limb width, core weight and no-load losses, yoke geometry and the base cylinder diameter that the windings will sit on.
Limb design: 24 stacks, 899 mm diameter, 90.7 % fill factor Core parameters: volts per turn, induction, losses, flitch plates - Step 4 of 9
Windings and insulation
- You enter
- Disc, layer or multi-layer coils for the tertiary, common, regulating and series windings; conductor, number of discs, radial spacers, axial and radial insulation.
- You get
- Turns per coil, electrical and mechanical heights, copper fill factor, the radial spacer schedule disc by disc, and the end insulation of every coil drawn with washers, angle rings and pressboard elements.
Coil properties: disc winding with radial spacer schedule End insulation drawn for each of the four coils - Step 5 of 9
Impedance and losses
- You enter
- Winding pair, tap positions, external series reactor if any, reference temperature.
- You get
- Short-circuit impedance for every pair of windings at nominal and extreme taps, DC losses for each tap position with current density, and the additional eddy losses per radial conductor from the FEM DC solution.
Short-circuit impedance: 10.2 % primary to secondary, X/R 39.7 DC losses tap by tap for the secondary winding Eddy losses from the FEM DC solution, conductor by conductor - Step 6 of 9
Short circuit
- You enter
- Fault case, tap position, clamping type: flitch plates, tie rods, tube.
- You get
- Transient short-circuit currents winding by winding, radial stresses with buckling coefficient for self-supporting or insulation-supported coils, axial compression, bending and tilting, and the forces on beams, clamping rings, flitch plates and tie rods before and during the fault.
Radial stress and buckling for the four coils Short-circuit currents from the transients module Radial stress profile along the tertiary coil Axial stress: compression, insulation, bending, tilting Axial stress profile along the common coil Forces on beams, rings, flitch plates and tie rods - Step 7 of 9
Dielectric
- You enter
- Impulse type: lightning full or chopped, switching; impulsed winding and terminal; surge arrester; induced AC and partial-discharge test levels.
- You get
- Voltage at every node of every coil with oil and paper stress as a percentage of withstand or in kV/mm, the waveform at any node, and the same for the induced AC and partial-discharge test, using a magnetic model per winding.
Lightning impulse: node-by-node stress and waveforms Impulse calculation set-up with magnetic models per winding Induced AC and partial-discharge test set-up Induced voltage: stress per node and waveform - Step 8 of 9
Thermal
- You enter
- Radiators: units, elements, height, pitch, depth; fans: number, diameter, air flow; guaranteed temperature rises.
- You get
- Cooling capacity and top-oil and mean-oil rise in ONAN and ONAF, then for each coil the mean winding rise and the hot spot both by the IEC method and by FEM, checked against the guaranteed values.
Winding temperature rises: hot spot by IEC and by FEM Cooling system: radiators, fans, ONAN and ONAF rises - Step 9 of 9
Mechanical
- You enter
- Clamping arrangement, materials.
- You get
- The general drawing of the clamping structure and the dimensioned drawing of each of its 23 components, from beams and pressing plates to tie rods and jack brackets, with material and bolt callouts ready for the workshop.
Clamping structure: general drawing with 23 numbered parts Component drawings with dimensions and materials
Project P1087, as shown on this page.
All screens above come from one design file. This is the machine it describes, in the program's own figures.
- Type
- Three-phase autotransformer with tertiary, 50 Hz, 1000 m
- Rated power
- 225 MVA ONAF·168.8 MVA ONAN·tertiary 75 MVA
- Voltages
- 228 / 136.3 / 21.5 kV·YNad11
- Insulation, HV
- Um 245 kV·BIL 850 kV·SI 650 kV·AC 360 kV
- Regulation
- ±9 steps, reverse, on the secondary·±11.39 %
- Impedance
- 10.2 % primary – secondary, ONAF·X/R 39.7
- Core
- 899 mm limb·1.264 T·72.6 t·no-load losses 31.3 kW
- Windings
- TER, COM, REG, SER·disc and layer coils
- Hot spot, ONAF
- 52 – 68 K by IEC·52 – 63 K by FEM
Adapted to your factory, proven on your transformer.
A design program is only as good as the rules inside it. Delivery is an engineering job, not a download.
Adaptation
Material catalogues, design rules and manufacturing limits set to those of your plant, so the program designs what your workshop can build.
Validation project
One of your transformers designed together with HVCC and compared against its test report before the licence is handed over.
Training on site
Your designers learn the program on their own projects, with the HVCC engineer at the next desk.
Maintenance
Technical assistance, corrections and updates under a yearly maintenance agreement.
Licensed per seat. Additional seats on the same site at a reduced fee. Pricing on request.
- IEC insulation levels Um · BIL · SI · AC
- IEC hot spot + FEM check
- MR and ABB OLTC catalogues
- ONAN · ONAF · OFAF · ODAF · OFWF
- Three-phase units and single-phase banks
- Autotransformers
- Furnace and distribution options
Oil Analysis & Maintenance
A diagnostic database for a transformer fleet. The one shown holds 137 transformers and 1,798 oil analyses.
- Owners, transformers and analyses in one file, with the history of each unit
- Dissolved-gas diagnosis: Rogers, Doernenburg, key gas, Duval triangle, TDCG rate, furans and paper degradation
- Oil quality: breakdown voltage, water, tan δ, interfacial tension, acidity, gas saturation, with reconditioning or reclamation advice
- Included in HVCC condition-assessment and life-extension contracts
See it on one of your transformers.
Send a nameplate and a test report. We run the design in the program and compare the results with the measured values, then show you the screens on your own machine.
- Call
- +39 331 781 7077
- Brochure
- HVCC brochure, PDF