ISSUE 12

May 2021 transformer-technology.com ISSN 2642-2689

Better Practices
for Better Outcomes
From Specification
to Commissioning
Interview with Jon Trout, Manager of Transmission Operations Support, FirstEnergy
Interview with John Ulcar, Co-founder and Director, and Edson Fariello, CEO at Crosslink Technology
Interview with Patrick F. McAtarian, General Manager at Andax Industries
 COMING
IN JUNE

Women in
Power Systems
We are delighted to announce that the June issue of
Transformer Technology will not be about transform-
ers at all. It will be the launch of a new APC Media
Community - Women in Power Systems.

While we realize there are groups like Women in

Engineering in IEEE, Women in Power in Cigre, Women in
Reliability and Asset Management in Reliabilityweb.com
and likely many more we are not even aware of, Women
in Power Systems will be unique.

WPS as we call it, will not be commercially supported

but will be supported by a limited number of sponsors.
It will also rely heavily on interviews, presented as
video-casts or podcasts on WPS website and other
media channels; as well as profiles and impactful
stories that will then be curated and featured, starting
with our June issue.

WOMEN IN POWER SYSTEMS (WPS) is a community

that advocates for women in all Power Systems roles
by leading organizations to see and celebrate the
benefits of women leading in their current and future
positions.
Our Advisory Board, all women by the way, has deter-
mined the best approach and made it a point to include
many other professional women within power industry,
not just women engineers. Women in Procurement,
Management, HR, Business Development, Executive
Leadership, Marketing and a host of other professional
women make up Women in Power Systems.

We believe the June curations will set a new standard

for what a collaborative and informative community
can be. Weekly features will be curated into our follow-
ing 2021 issues as WPS Curations.

From that point forward, Transformer Technology will

continue to build on its community just as Women
in Power Systems does on its own community; both
adhering to the high-quality standards that APC Media
follows.
SEARCHING FOR
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LET THEM FIND YOU!

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NEW MARKETS?
WE WILL SHOW YOU HOW.

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and strengthen your presence
in the transformer market.

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4 EDITORS &
IMPRESSUM

Impressum Editors

Editor in Chief Editor in Chief

Alan M. Ross, CRL, CMRP Alan M. Ross CRL, CMRP
Transformer maintenance
Associate Editor in Chief and reliability
Corné Dames 26 years industry
Independent transformer consultant experience

Contributing Editors
Diego Robalino, PhD, PMP
IEEE Senior Member Associate Editor in Chief
Jon Trout, PE and Chair of the Technical
Electric utility Advisory Board
Alan Sbravati, ME, MBA Corné Dames
Transformer insulating materials Independent transformer
Marco Tozzi, PhD consultant
Diagnostics and asset monitoring Transformer oils
Curtus Duff 20+ years industry
Power transformer design experience

Chair of the Technical Advisory Board

Corné Dames
Independent transformer consultant
Contributing Editor
Diego Robalino PhD, PMP
Technical Advisory Board Member
Edward Casserly, PhD
IEEE Senior Member
Senior Scientist, Transformer oils Transformer condition
Maria Lamorey assessment and
Industrial OEM manufacturing diagnostics
20+ years industry
Graphic design experience
Bekoncept Communication Boutique

Photo Cover
Shutterstock

Sales & Marketing Technical Advisory

Kevan Sears Board Member
[email protected] Edward Casserly, PhD
Senior Scientist,
Sales & Marketing Americas Transformer oils
Maria Salamanca 35 years industry
[email protected] experience

Sales & Marketing Mexico

Fernando Campos
[email protected]

Sales & Marketing Brazil Technical Advisory

Marcelo Braga Board Member
[email protected] Maria Lamorey
Industrial OEM
Marketing Global manufacturing
Marin Dugandzic 35 years industry
[email protected] experience
Transformer Technology May 2021 5

Issue 12

ISSN 2642-2689 (Print)

ISSN 2642-2697 (Online)
Contributing Editor
DIGITAL Membership Jon Trout PE
Free Electric utility
14 years of experience
Transformer Technology magazine is a quarterly
magazine published by APC MEDIA LLC, 11210
West Rd, Roswell, GA 30075, USA. Published
content does not represent official position of APC
MEDIA LLC. Responsibility for the content rests
upon the authors of the articles and advertisers,
and not on APC MEDIA LLC. APC MEDIA LLC Contributing Editor
maintains the right to keep the textual and Alan Sbravati ME, MBA
graphical documents submitted for publication. Transformer insulating
materials
Copyright and reprint permission 18 years of experience
Abstracting is permitted with credit to the source.
Libraries are permitted to photocopy isolated
pages for private use of their patrons.
For other copying, reprint or republication
permission requests should be addressed to
[email protected]

Publisher: Contributing Editor

APC MEDIA LLC Marco Tozzi ME, MBA
1317 Winding River Trail Diagnostics and asset
Woodstock GA 30075, USA monitoring
15+ years of experience
transformer-technology.com

Contributing Editor
Curtus Duff
Power transformer design
4 years of experience
6 TABLE OF
CONTENTS

Index Contents

Table of
Coming in June_02

Editors & Impressum_04

Table of Contents_06

Editor’s Letter_10

Tips for Writing the Perfect

Specification_14
14
TOTUS – Total Transformer
Tips for Writing the
Monitoring_20 Perfect Specification
Interview with John Trout, Manager Writing a transformer specification for the
first time can be a daunting task. This article
of Transmission Operations should serve as a “getting started” guide on
creating the perfect specification, breaking
Support, FirstEnergy_22 down the details into an easier way to think
about writing a specification. It will touch
5 Questions on Transformer on structure, IEEE standards, performance
characteristics, core and coil design, external
Grounding_32 design and testing and commissioning.

Interview with John Ulcar, Co-

founder and Director, and

Edson Fariello, CEO at Crosslink 20

Technology_38 TOTUS – Total
Transformer Monitoring
Solving Movers for the Transformer

Industry_48
Transformer Technology May 2021 7

Issue 12

22 38
Interview with John Trout, Interview with John Ulcar,
Manager of Transmission Co-founder and Director, and
Operations Support, Edson Fariello, CEO at
FirstEnergy Crosslink Technology

32
5 Questions on
Transformer
Grounding
This short but very important article
answers five critical questions about
transformer grounding, which, when
done properly, can save lives.

48
Solving Movers for the
Transformer Industry
8 TABLE OF
CONTENTS

Index Contents

Table of
Temperature Rise Test Corrections

for Three-Winding Transformers

with Axial Split-Windings_52

GFRP insulation components allow

revisions to transformer design:

How Durostone® CR contributes

to compact design and resilient

transformers_60

Transformer Insulation (Quality)

Matters _64 52
Interview with Patrick F. McAtarian, Temperature Rise Test
General Manager at Andax Corrections for Three-
Industries_72
Winding Transformers
with Axial Split-Windings
Vibration and Noise Reduction of
The split-winding arrangement in core-form
Transformers: PTTX’s Artisan Spirit power transformers requires special thermal
design considerations. Presently, industry
of “Daring to Be the First”_80 standards do not provide significant detail
on the temperature rise test for these unique
Interview with John F. Darby, arrangements. This paper will demonstrate
how to supplement the industry standards for
President of Niagara Power this special transformer construction and some
common problems that arise in practice.
Transformer_86

Protection and Control

60
Commissioning: Two Steps
GFRP insulation components allow
Forward, One Step Back_94 revisions to transformer design:
How Durostone® CR contributes to
compact design and resilient
transformers
Transformer Technology May 2021 9

Issue 12

64 86
Transformer Insulation Interview with
(Quality) Matters John F. Darby,
Many do not recognize the importance of specifying President of
the insulation system and the vital role it plays in the Niagara Power
attainment of the specification’s objective. This article Transformer
makes a great case that investing a few more dollars of
cost by specifying a more robust and reliable insulation
system reduces the total cost of ownership by adding life
to the asset.

72 94
Interview with Protection
Patrick F. and Control
McAtarian, Commissioning:
General Manager Two Steps
at Andax Industries Forward, One
Step Back
The energy industry is moving
forward at warp speed on
technological and infrastructure
changes. A major gap has
emerged among the resources
that provide protection and
control commissioning services
on power systems, and it boils
down to lack of training and
system knowledge.

80
Vibration and Noise Reduction of Transformers:
PTTX’s Artisan Spirit of “Daring to Be the First”
10 LETTER FROM
THE EDITOR

Dear Readers,

There has been a significant change in the past Think about that! What other major asset can you
decade relating to specifications for transform- name that has 100-year-old critical equipment?
er purchases. The pendulum has swung from a Not many, if any. This is what an engineering focus
heavy reliance on engineering input to procure- on design and specification creates.
ment-driven specifications. What does this mean
for us engineers who used to be the final say on But as the advancement of procurement systems
what was specified and where we were allowed, and the advent of purchasing guidelines became
even encouraged, to work directly with potential more prevalent, cost cutting became the mantra of
bidders to develop the very best specifications? the day, and it still rules today. Try to meet with bid-
We had things our way for a long time. ders on large asset purchases in a more commod-
itized marketplace, like transformers have become,
However, that came with a cost, with less regard and it is likely you won’t be able to. I believe this cre-
for the actual cost of the asset and more focus on ates a huge gap in specifications. Transformers are
the application of the asset. In my world of reli- unique based on so many factors, such as footprint,
ability, that was great given that all reliability be- application, ratings, clearances and a myriad of other
gins in the design phase – I cannot emphasize that factors, and it is a shame that the process of creating
enough. That is true of the assets like transform- the specifications cannot take advantage of the tre-
ers, circuit breakers, cables etc., but it is also true mendous knowledge and experience of the better
for the entire system those assets make up. For OEMs. Low purchasing cost will not likely lead to the
substation reliability, every asset must meet a re- lowest Total Cost of Ownership (TCO), another major
quired specification that is compliant to the stan- reliability principle, or create systems that are able
dard for reliability you demand of the system. to withstand significant analogies – weather events,
When assets fail, the system fails. grid resilience events and more.

More than likely, we may have over-engineered or However, I see the shift coming back to a point of
overbuilt assets as a result. Robustness of trans- equilibrium, with the better procurement profes-
formers is legendary. Prior to becoming the Pres- sionals and systems addressing the need for more
ident of the Electric Power Reliability Alliance collaboration in the design and specifications pro-
(EPRA), I worked for SDMyers as the VP of Reli- cesses. That balance will allow engineering to have
ability and every year we celebrated the birthday a more important say in the process, without sac-
of all of the transformers that we tested the previ- rificing value over cost. Value is TCO. Cost is not
ous year with a life of over 100 years. value.
Transformer Technology May 2021 11

Issue 12

In transformer design, the

pendulum has swung from a
heavy reliance on engineering

Alan M Ross
input to procurement-
driven specifications. As the
advancement of procurement
systems and the advent of
purchasing guidelines became
more prevalent, cost cutting
became the mantra of the day,
and it still rules today.
While most of our articles and interviews in this
issue do not address this pendulum shift, they do
approach specification, transportation and com-
missioning in a very special way. I am very proud
of all of our authors and interviewees who are
passionate and committed to meeting the needs
of the practitioners, balancing the procurement
requirements and presenting great content to be
added to the Transformer Technology Body of
Knowledge (BoK).

I am sure that you will enjoy this.

Curator of the Community
Transformer Technology
Alan M Ross
Editor in Chief

President of EPRA
CRL, CMRP
12 TECH
TALKS

YOUR PASSION
AND KNOWLEDGE
ARE IMPORTANT
TO US

JOIN OUR
#COLLABORATIVE COMMUNITY

Are you passionate and knowledgeable

about your area of business or expertise?

Now You can contribute to knowledge

sharing in the transformer industry by

sharing your field experiences, case

studies, research results, or simply your

knowledgeable opinion on a topic of

interest to the industry.

Contact us at
[email protected]

to find out how you can

become part of the
Transformer Technology
community.
Tech Talks

To watch and listen visit

www.transformer-technology.com/
community-hub/tech-talks
14 SPECIFICATION
TIPS

Tips for Writing the

Perfect Specification
by Curtus Duff
and Charlie Bowman

Photo: SPX Transformer Solutions

Because no rules exist, one thing to remember is that the perfect

specification is the specification that results in the perfect
transformer for your requirements and operating conditions.
Transformer Technology May 2021 15

Issue 12

Do you need a transformer? If not today, then tomorrow.

As the world ages and populations grow, the need for
power—specifically, reliable power—grows with it.
As infrastructure comes due for replacement and
everything we own becomes electrified, this aging of
equipment and additional load demand means the need
for more transformers.
Charlie Bowman is a Lead Mechanical En-
gineer at SPX Transformer Solutions where
he manages the external design team. He re- Writing a transformer specification for the first time
ceived his Bachelor of Science in Mechanical
Engineering from Purdue University in 2018.
can be a daunting task. Transformers come in all
His first position out of school was with shapes, sizes and with a variety of features, and every
utility has different requirements. The specification is
SPX Transformer Solutions in the Engineering
Development Program, which led him to the
current role he has held for just under a year. the document that communicates those requirements
He enjoys golf and hiking with his wife in
Pewaukee, Wisconsin. to the transformer manufacturer. No rules exist for
what should be in the specification, but an unlimited
number of options do exist from which a utility
can choose.

Specifications can run into topics deeper than you

have time to read in this article. So, rather than trying
to answer every question, this article should serve
Curtus Duff is an Electrical Design Engineer at as a “getting started” guide on creating the perfect
SPX Transformer Solutions where he designs
medium and large power transformers. He
specification, breaking down the details into an easier
graduated from Purdue University in 2016 way to think about writing a specification. It will
with a Bachelor of Science in Electrical
Engineering. Upon graduation he started at
touch on structure, IEEE standards, performance
SPX Transformer Solutions in the Engineering characteristics, core and coil design, external design
Development Program with six-month rota-
tions each in Design, Testing, Manufacturing,
and testing and commissioning.
and Application Engineering. Upon completion
of the program in 2018, he joined the design
team. He and his wife reside in Waukesha,
Because no rules exist, one thing to remember is
Wisconsin where they enjoy finding small food that the perfect specification is the specification that
markets to try cooking new foods. On the
weekends he can be found mountain biking
results in the perfect transformer for your requirements
or skiing. and operating conditions.

Structure Transformer manufacturers receive

a lot of bid opportunities and are
This one might seem obvious, but usually under time constraints
a good transformer specification to bring a bid package your way.
needs structure. Any specification Having an organized specification
can have many parts, and a good is the best way to ensure that the
specification keeps those parts bid process goes smoothly and
organized. Break the specification the bid package offered by the
down into pieces and have a table manufacturer contains all of your
of contents in the beginning. requirements.
16 SPECIFICATION
TIPS

IEEE Standards worked together diligently to develop required. A good example of this
standards for all types of transformers is normal/usual service conditions
Conveniently for all of us, the trans- and continue this work revising versus actual service conditions.
former industry provides standards to relevant standards as the needs arise. IEEE C57.12.00-2015 Section
guide us. Employing these standards Referencing these standards for 4 states that normal conditions are
helps ensure a manufacturer designs your own knowledge is a must, but a low of -20°C, a high of 40°C and
and builds reliable infrastructure. referencing them in your specification an average of 30°C during any
Many standards organizations exist is recommended, as well. 24-hour period for ambient
globally, such as CSA, IEC and IEEE, temperatures [1]. In most cases,
and the applicable standards can In the United States, the two main these guidelines will be fine, but, if
vary depending on where you are standards to reference are IEEE not, that is a piece of information your
located. In the United States, the IEEE C57.12.00 [1] and C57.12.90 [2]. transformer manufacturer will need.
PES Transformers Committee is your For some utilities, just referencing
friend! Collective members throughout these standards might be enough. More than just service conditions,
its over 100-year history have For others, additional detail may be the standards touch on ratings,

Standards should be used as guidelines with variances

communicated when needed. This strategy is a solid way to ensure
you are acquiring a transformer that meets your exact needs.

Photo: SPX Transformer Solutions

Always consider the variety of items specified in the performance

characteristics section and think about how they might impact cost.
Transformer Technology May 2021 17

Issue 12

construction, short circuit, testing effective as a single three-phase Of course, that is not the only thing
and tolerances. While the standards transformer, it may be your only electrical designers do. They also
cannot write a specification for you, option. For another example, if the manage the kind of winding that
they are a great starting point and location in which the transformer is is optimum in a given space, the
should be referenced. If a particular to be located falls within the range of turns per disc, strands per turn,
part of the standard applies to your normal service conditions, consider tap changers, tapped windings, the
requirements, then quote it in your specifying the transformer as a 65°C strength of the windings for a short
specification. If you need a variance rise unit. IEEE C57.12.00-2015 [1] circuit fault, the dielectric clearances,
from standards, state how so without Section 5, Clause 11, explains this. the load and no-load losses, the
being ambiguous. For example, With the introduction of thermally impedance and much more. Many
IEEE C57.12.00-2015 Section 7 gives upgraded paper insulation, 65°C rise variables exist, and these variables
information on how to provide system is the new normal. Harking back should be considered levers of
characteristics for short circuit to transformers of old, without the optimization for the designer.
consideration [1]. If these system thermally upgraded paper insulation,
characteristics are not provided, the they were specified as 55°C rise for Freedom for an electrical designer to
standard gives guidance for assumed average oil and average winding rise make choices is what brings you an
system characteristics. If you need and a 65°C hot spot rise. Now these optimized transformer cost, and that
110% pre-fault voltage and the same transformers can be specified is why manufacturers often encourage
assumption of an infinite bus, this as 65°C and 80°C rise respectively. specification writers to consider
will not be captured by the standard, Notice that 65°C to 80°C is a change carefully the limiting parameters he/
and you will have to explicitly of 15°C. If you do decide to specify a she might include in a specification.
state this in your specification. 55°C rise unit, consider allowing 70°C While limiting parameters is
For a low impedance unit, cost for hot spot rise, as your unit is going unavoidable in some cases, such
could be impacted significantly, so to be built with thermally upgraded as when a transformer might need
understanding what you are asking paper insulation. This will help bring to fit through a tight place or, as a
for is important! down the cost of your transformer retrofit, need to be physically sized a
without sacrificing any loss of life. certain way, in other cases, “designer’s
In summary, standards should be choice” may be the best option.
used as guidelines with variances Always consider the variety of Specifying CTC only, a minimum
communicated when needed. This items specified in the performance radial dimension of a copper strand,
strategy is a solid way to ensure characteristics section and think exactly how taps must be arranged
you are acquiring a transformer that about how they might impact cost. or a minimum key spacer thickness
meets your exact needs. Ask yourself what is truly necessary can lead to higher cost and, often, no
for your particular situation. real benefit. These are items that take
Performance Characteristics Regardless of what you decide, away elements of a designer’s ability
communicate your choices clearly to to give you an optimized design at an
Performance characteristics are the manufacturer. optimized price.
likely the most important part of
the specification. This section is Core and Coil While you may have good reasons
usually found near the beginning of for including a variety of limiting
the spec and tells the manufacturer For an electrical designer, the core parameters in your specification,
exactly what kind of transformer and coil is the fun part! Like most understanding how these design
you are looking to purchase. Many engineering practices, designing parameters can impact cost is
decisions need to be made by the the core and coil is a lovely game important as you evaluate whether
purchaser when going through all of tradeoffs for optimization. In or not they are critical to the
of the items that will be contained particular, this is the part where the application. As these levers of
in the performance characteristics designer calculates the volts per optimization are taken away from
section. IEEE C57.12.00-2015 [1] turn. From the transformer equation the electrical designer, designers
Section 5 can help walk you through V/T = 4.44BAf, the designer can have to make changes accordingly.
these components: phases, voltages, vary the volts per turn by adding These changes can end up resulting
winding connections, MVAs, no load or subtracting turns from the high in a design that is not as optimized
and load loss evaluations, impedance, voltage and low voltage accordingly cost-wise as it could have been.
insulation levels, etc. while maintaining the correct ratio Regardless, if what you are asking is
for voltage transformation. What possible, then it can be done. Make
For example, if dimensional designers are controlling is the sure to clearly state your intentions
limitations exist for delivering a B – flux density (think no-load loss) so the designer understands
large three-phase transformer to a and then adjusting the A – area of the what you are looking to receive.
mountainous area, perhaps a bank core accordingly. This practice allows Depending on complexity, an open
of three single-phase transformers the design to hone in on an optimized line of communication with your
would be a better choice. While amount of copper and core steel, manufacturer may be necessary
a bank of three single-phase thereby offering you a transformer at as the company starts the design
transformers might not be as cost an optimal cost. process.
18 SPECIFICATION
TIPS

External Design (Tank, precise instructions on not only what With the introduction of new devices
Accessories and Controls) accessories are necessary, but any and monitoring systems, control
preferences on vendor, configuration cabinets are more complex than ever.
The tank design begins with any site and segment placement, are important To make sure the controls design
dimensional limitations, shipping to include in your specification. If no goes smoothly, include model-specific
restrictions and oil preservation preferences are indicated, the information for all preferred devices
system requirements. These factors manufacturer will select and place within the control box so proper wiring
influence the cooling layout, drive equipment per IEEE and its own internal diagrams can be acquired. Possible
equipment placement and overall standards. While this equipment will devices could include electronic
unit footprint. Including site drawings undoubtedly be effective, it might not temperature monitors, LTC controllers,
and photos ensures no details are fit your preferences exactly. Examples relays and terminal blocks. If any
overlooked, especially if the design is of accessories include bushings, devices have preferred mounting
a retrofit. arresters, valves, gages, sensors and locations within the control cabinet or
cooling fans. Any spare parts or future wiring requirements, such as terminal
Accessories play a key role in how the equipment provisions should also style, those should also be noted.
user interacts with the transformer, be included so they can be factored
and the possibilities for selection into the proposal and, subsequently, Site environmental conditions should
and placement are limitless! Explicit, the order. always be provided in detail as they

From core and coil to external design, the common thread is

effective communication. Be clear and concise about your
requirements and remember that good specifications are crafted
over years with multiple inputs and revisions, all in the pursuit of
acquiring the perfect transformer.
 Transformer Technology May 2021 19

Issue 12

Any spare parts or future equipment provisions should also be

included so they can be factored into the proposal and,
subsequently, the order.

drive external clearances, accessory When considering external transformer substation as possible is important
rating selection, control box enclosure design, writing an effective to ensure a successful installation.
design and equipment mounting. specification can be simple: focus Details could include an ideal route to
Examples include extreme altitudes, on your needs. The manufacturer the substation and layout drawings
temperatures, pollution exposure, cannot tell you exactly what you of the actual substation and/or pad
sound limitations or levels of seismic need, as a multitude of factors on which the transformer will sit. The
activity. Unless you are designing drive those decisions. What the more information you provide, the
a substation for the first Mars manufacturer needs is clear language more accurate a quote you will receive.
settlement, odds are the manufacturer describing all vital, non-negotiable Complete information will also allow
has seen your conditions before and requirements. Provide as much for a more comprehensive plan to get
can arrive at a solution that best fits information as possible up front, your transformer hooked up as fast as
your needs. free of contradictions. Disconnects possible with no delays.
between the specification and
customer requirements can often Conclusion
lead to questions, miscommunication
and additional costs for late changes An exorbitant amount of factors
in the design. If areas exist where need to be considered—and
you have no preferences, trust the documented—when writing a full
manufacturer’s expertise to fill in the transformer specification. While the
gaps between your needs to arrive aforementioned tips and tricks may
at an optimized external transformer be useful, they merely scratch the
design. surface of what it takes to finalize a
full specification. From core and coil to
Testing and Commissioning external design, the common thread is
effective communication. Be clear and
Testing and commissioning are concise about your requirements and
the final pieces to bringing that remember that good specifications are
new transformer to its pad in your crafted over years with multiple inputs
substation. Testing includes the final and revisions, all in the pursuit of
quality checks before the transformer acquiring the perfect transformer.
gets wired up and fired up after
commissioning. Once again, the IEEE As a final example as to why
makes testing easy in C57.12.00 and transformer specifications are
C57.12.90 [1], [2]. Reference C57.12.00, so important, note that it is not
Table 17, to see all standard tests for uncommon for transformers in rural
Class 1 and Class 2 transformers. areas to require additional external
Then reference C57.12.90 to get clearances on the cover for local
more information on each test. You wildlife. If you are one of those utilities
can use the IEEE standard list of needing to adjust for this, make sure
tests in your specification and then you tell the transformer manufacturer
make adjustments according to your whether you expect the critter landing
particular needs. on the cover to be a squirrel or a stork!

You might be looking for your

transformer manufacturer to handle
freight, rigging and installation as well, References
which means shipping the transformer [1] IEEE C57.12.00-2015 – IEEE
to you, placing the transformer on Standard for General Requirements
Photo: SPX Transformer Solutions

your pad and installing it according for Liquid-Immersed Distribution,

to the manufacturer’s—and your— Power, and Regulating
requirements. Installation typically Transformers
involves a set of field tests to verify [2] IEEE PC57.12.90 - IEEE Draft
the condition of the transformer post- Standard Test Code for Liquid-
shipping then placing the transformer Immersed Distribution, Power, and
on your pad. For these items, supplying Regulating Transformers
as much information about the
20 ADVERTORIAL

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TOTAL TRANSFORMER MONITORING

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The challenge for asset managers is little visibility on
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How Does TOTUS Total Transformer Monitoring

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detecting acetylene in the transformer, TOTUS delves
deeper into arcing activities, identifying the phase and
winding, as well as visibility on the number of arcing
events. TOTUS gives asset managers the ability to
correlate data to generate a deeper understanding of
changes in the transformer, driving accurate decision
making about asset health.
Transformer Technology May 2021 21

Issue 12

Data

1. Detect periodic step increase

of acetylene – Genuine internal

2. with PD Monitor – High

Energy Events detected at each
C2H2 increase

3. Locate arcing winding & phase

– PD Triangle shows HV winding
phase H3

4. Identify the defect failure – PD

Decision

Inspect transformer focusing immediately

www.camlingroup.com
 22

Manager of Transmission Operations

Interview with Jon Trout Support, FirstEnergy

Jon Trout
FEATURE
INTERVIEW

Photo: FirstEnergy
Transformer Technology May 2021 23

Issue 12

Jon Trout is Manager of Transmission Operations Support for FirstEnergy,

an electric utility headquartered in Akron, Ohio, and a contributing editor of
Specifications are
not static documents.
They are living and
they need to change

Transformer Technology.
periodically to keep
up with technology
changes and material
enhancements.
24 FEATURE
INTERVIEW

Jon Trout is Manager of Transmission Operations Support for FirstEnergy, an

electric utility headquartered in Akron, Ohio, and a contributing editor of
Transformer Technology. Jon previously worked with transformer manufac-
turers to supply FirstEnergy with reliable electric power system equipment
and has experienced many changes in the world of transformer technology
over the years. For this issue dedicated to speci ications, commissioning and
transportation, Jon shared some of his experiential knowledge in a Tech Talk
with our Editor in Chief, Alan Ross. This interview is an excerpt from that.

Alan Ross: I welcome my guest and a friend – Jon going to try to sell you a small economy vehicle.
Trout of FirstEnergy, and a contributing editor of They are going to sell you a truck, which is what
Transformer Technology. you need. So, you need to tell the manufacturer
what you need the transformer to do, so that it
Jon Trout: Thank you, Alan. meets your expectations.

AR Jon, experiential knowledge is

really something that Transformer
Technology promotes, and you certainly
The second thing is long term planning. When
you purchase a transformer, you intend to
keep it for quite a while. And that entails a
have had a tremendous amount of that. One lot of things including your capabilities, the
of the first things you did when you were warehousing, your spare parts inventory and
at FirstEnergy is develop specifications for everything that is required to maintain that
transformers. You had to look at the past, transformer over the next 25 to 50 years. Also,
the present, and the future. In your past you need to specify to the manufacturer the
experience when you were developing specs, type of equipment you need on a transformer
what were the most important aspects that because you may already have spares for some
you would look at? of the equipment you plan to have on your
transformer.

JT You mentioned a little bit of it – looking

back at the past to see what has worked
well, and then looking forward to the future.
Another important consideration is the kind
of maintenance you plan for the unit. For
I will break it down to two things. example, if you are planning to do routine full
inspections that require draining the oil out,
The first is, if you are creating a specification, the manufacturer needs to know how the oil
you want to set clear expectations. There are will be drained so that they can make sure you
many manufacturers out there that make can do your inspection. Do you want valves
transformers for many different applications. on your radiators in case one starts leaking, so
You need to be able to define what you need you can replace a single radiator as opposed
the transformer to do, how you are going to having to cut off the whole thing? These are
to apply it to your particular scenario, and the specifications you need to provide for your
what capabilities it needs to have, so that the manufacturer when you think long term and
manufacturer can understand your particular how you intend to maintain the transformer
need and provide you with the best fit for your over the course of its life.
application. This also includes considerations
like physical constraints: Do you have a limited
space for this particular unit? Is it next to a
building? Does it have to fit in a position where
AR Design, Operate, Maintain and
then Lifecycle planning – they
are the four stages of reliability and they
an old transformer came out? fit right in with what you are talking about.
The reliability of electrical systems starts at
Photo: Shutterstock

I use the following analogy: if you go to a car design, it all starts with specs.
dealer and tell them you need a vehicle, you
could end up with anything. But if you tell You and I have been involved in a lot of situ-
them that you work construction, they are not ations at different points in our careers, and
Transformer Technology May 2021 25

Issue 12

Looking back at the past to

see what has worked well,
and then looking forward
to the future are the two
most important aspects to
look at when developing
transformer specs.
26 FEATURE
INTERVIEW

sometimes, we would help somebody develop As he said, many times the supplier that is going
specs, only for them to go out and take them to bid on a transformer can look over your
to a marketplace and buy low bid. In the utility specifications and help you develop better
world, you are going to go out in a bid base. ones. Was there a time, or a relationship, where
you asked somebody to check if you were

JT Usually, there is a bid process that goes

along with purchasing transformers.
missing anything in the scope of your specs?
Photo: Hitachi ABB Power Grids

There is often an established vendor list, but

you are most likely always going to bid the
transformer purchase.
JT Yes, there are plenty of consultants who
can provide that support and help you
develop your specifications. I have done some
of that in the past for companies. Also, there

AR Chuck Baker, one of our authors and is feedback from manufacturers. They will ask
Photo: Shutterstock

contributors, was on a recent EPRA questions about your specs and say: We do this
Forum talking about services and maintenance. slightly differently. Here is how we may handle
He mentioned the same thing you did - that this particular area of what you are requesting.
you had to make sure you get the scope right. Is that OK?
Transformer Technology May 2021 27

Issue 12

Specifications are not static documents. They are chosen in your bid process. But once you get
living and they need to change periodically to into the manufacturing stage and you are doing
keep up with technology changes and material a plant inspection, you get to see the individual
enhancements. So, the feedback from the manufacturing processes – how they wind the
manufacturer will provide insight into what they coils, how they do tank manufacturing, how they
do and how they do it, and why they think it is an do installation, how they route the leads around
excellent way to do it. And then it is up to you as the transformer, etc.
the purchaser to validate whether you can accept
a deviation from your spec or not, which usually All of this is vital to understanding the real
doesn't happen during the bidding process. That is capacity of the manufacturer. And most
usually because you can establish the relationship manufacturers would love to tell you all about
with the manufacturer. their quality control processes. They enjoy talking
about their plant and this is also the opportunity
As a specification writer, you ought to be to build the relationship with the manufacturer.
reviewing your spec periodically to make sure So, when doing a plant inspection, ask them how
that it is still what you want it to be and to see they track material and different components as
if there are any changes you need to make to they come from different areas of the factory to
keep up with enhancements in technology or eventually come together into the transformer.
processes. They will love to tell you about that.

AR I want to go to another thing that I

know you are experienced in, and that
is plant inspections. You have finally made the
Another thing for you to think about is the layout
of the facility, as this also contributes to getting
quality products. Are messy, dirty manufacturing
specs, the bid is out, you got the bid. Now the processes separate from the clean processes?
manufacturer is starting to build the transformers For example, you would not want to have your
and you are doing the different stages of winding room and your tank manufacturing areas
inspection. Tell me a little bit about that from right next to each other. Tank manufacturing,
the perspective of purchasing people and the welding and cutting create a lot of debris, dust
procurement people – what should they do? What and dirt, and you want your windings as clean and
should they hold the manufacturer accountable crisp and pristine as possible. You will learn about
for? And what has been your experience with their capacities from how they dry their coils, how
plant inspections? they size them, etc.

JT Plant inspections are a great opportunity

to interact directly with the actual
manufacturing capabilities of whoever you have
Also, talk to the people in the factory and ask
them about their experience – ask them how
long they have been doing it, whether they love

Plant inspections are a great

opportunity to interact
directly with the actual
manufacturing capabilities
of whoever you have chosen
in your bid process and to
build the relationship with
the manufacturer.
28 FEATURE
INTERVIEW

what they do and find out about their level of

experience, specifically in three areas. First,
the engineering group – you want to know how
JT That is a good question. It is important
for the purchaser to understand what
tests are relevant for them and they want to be
experienced they are in the design. Second, you present for. Not all tests are equally important.
want to know about the winding area. What is For example, for the wiring tests, you may be
the experience level of the winders? This is really able to let the manufacturer handle them and
important as the winding area is one of the key just show you a test report of how they wired
areas of the transformer manufacturer. And the control panel. On the other hand, lightning
thirdly, you want to know about the testing team. impulse and partial discharge tests are really valid
How experienced are they? Do they know the and valuable to witness because that gives you
standards? Are they familiar with the standard an insight into how well the transformer is put
that you are requiring the testing to be done together.
to? Do they handle testing according to other
standards, like IEC versus IEEE? The key is to ask good questions about how the
manufacturer set the test up. Make sure they
Once you have a good understanding of that, it understand what the testing standard is, whether
will give you some confidence in the capabilities it is IEEE or IEC, or whatever standard you are
of the manufacturer, and help you grow that requiring. You want to make sure that they
relationship. understand that standard and know how to set up
the test. Also, you need to watch very carefully to

AR You have just talked about that plant

visit where you go out and do the
inspection. There is now acceptance testing
make sure that the data they are getting matches
the acceptance criteria in the standards that you
have laid out.
where you have to confirm that you accept the
Photo: Shutterstock

manufacturing process. The manufacturer has to This requires that you as the owner are familiar
transport the unit and you have to do commission with what those standards say and how the
testing before you install it. What goes on during results should come out. You have to be willing to
acceptance testing? push the manufacturer a little bit if things don't
Transformer Technology May 2021 29

Issue 12

or you ask the manufacturer to assume that

responsibility, they need to know if there are
any constraints. For example, if you are in a very
mountainous area, you may have a situation
where the only way to get to your location is
through a railroad tunnel. The manufacturer
needs to be informed of that because you would
hate to have the transformer come down the
railroad and hit the top of the tunnel – that is not
a good day for anybody.

I will tell you one story. We had a situation where

we bought a transformer, the manufacturer did
a route-study and everything looked good. But
there was a minor mistake in the route-study
– they checked bridge heights in the center-
lane, closest to the center of the highway. But
the bridge had an arch on it. So, the transformer
would have cleared in the center, but on the right
lane where the bridge is slightly lower, it didn't
clear, and it snapped a bushing off.

These are some of the concerns you need to be

careful about and make sure that your route is
well planned.

AR I would like to go into something that I

know you are heavily involved in, and
that is preparing the next generation.

You are now that bridge generation between my

generation and the next. It must be an enormous
challenge for you and an enormous amount of
fun for you to be able to make a difference in
look the way you expect, ask them to explain and generations. What are you doing in that sense
have them show you how the results fit in with right now?
your expectations.

AR The last thing I want to talk about is the

commissioning. What are some of the
challenges that you have seen at the stage when
the transformer comes in; when it is transported
and commissioned? If the unit doesn’t work or if
it fails within a year, somebody is going to look
at you as the final guy and ask what you did
wrong. Whether it happens in the design, in the
inspections, the testing, the transportation or the
commissioning, you are going to get blamed for
mistakes. In your experience, how did you address
it? What kind of problems have you seen?

JT It goes back to the specs again. Because

the transformer spends the vast
majority of its life not moving, the time that it
spends moving and is subject to damage is the
transportation process. That is why you want to
make sure that it is properly specified and is going
to handle the voyage from the manufacturing
facility to the designated site.

Depending on whether you as the owner take

on the responsibility for the transportation
30 FEATURE
INTERVIEW

JT It is a great opportunity, Alan, as we

look to the future. It is funny how
quickly time passes when you feel like you are
the people involved with maintaining the
utility industry to make sure that we are well
suited for whatever the next big change is
a brand-new engineer, and then all of a sudden, going to be.
you blink and you realize you are mid-career. I
see it as an opportunity to pass on knowledge
to the next generation, helping them grow into
whatever the next big revolution is going to be.
AR Jon that is excellent! This has been
an inside perspective from someone
who has done it; experience from someone who
has even made some of the mistakes that all of
We have some ideas and thoughts about us make, and grown from that. As the editor in
what that might be. But we want to prepare chief of Transformer Technology, I appreciate
the people that come after us to be able to the knowledge and insight that you bring us.
take on the challenges that they face, and the Thank you for sharing it with us.
Photo: Shutterstock

challenges that we face and help them learn

from that. One of the things that I very much
enjoy is trying to develop that next generation
of engineers, commissioning people and all
JT As always, it has been really nice talking
to you, Alan, and I appreciate it. Thank
you very much for your time.
Transformer Technology May 2021 31

Issue 12

One of the things that

I very much enjoy is
trying to develop the
next generation of

Photo courtesy of Delta Star Inc.

engineers, commissioning
people and all the
people involved with
maintaining the utility
industry to make sure
that we are well suited
for whatever the next big
change is going to be.
32 TRANSFORMER
GROUNDING

5 Questions on Transformer
by Howard Eaton Grounding

Photo: Shutterstock
Transformer Technology May 2021 33

Issue 12

As a veteran of the U.S. Navy and a gradu-

ate of the Naval Academy, it’s not a surprise
that Howard Eaton is a big proponent of the
Southwest Electric core value Take Action.
Howard’s day-to-day activities include over-
seeing the custom switchgear manufactur-
ing plant, as well as many of the substation
and switchgear field services. He also main-
tains the engineering services licensure in
several of the states the company serves.

Editor’s Note:

Years ago, I worked for a CEO who was one of the most
gracious people I had ever known. It was said of him that
there were only two reasons that people could get terminated
from the company. One was abusive behavior to other
employees, whether physical or verbal and the other was –
improper grounding. Seriously! It was that big of a thing to
him because it was all about safety.

“Work Safe, Home Safe” was the motto of my former

company. One of the most important aspects of this motto
was to make it something that was deeply rooted in our field
crews. These were the employees most at risk from improper
grounding of transformers they were going to be working on,
and if our crews did not ground properly in their work, then
other people and a lot more assets would be at risk. How did
we make sure that the proper grounding procedures were
followed? We made it a big deal when we communicated the
importance that our CEO placed on the proper grounding of
transformers; and we trained, retrained and practiced.

This short but very important article answers five critical

questions about transformer grounding. We have added this
to the Body of Knowledge on our website and I would suggest
that if you have any employees or peers who should know the
answers to these questions that you forward this article to
them. It could save lives. Enjoy, and apply.
34 TRANSFORMER
GROUNDING

We often focus on the importance

of regularly testing and maintaining
distribution transformers to preserve
and extend their useful life. However,
the life and safety of your electrical dis-
tribution system begins at installation.
You hired someone to install and 2.
ground your transformer. You When should I be concerned about
assumed they understood and proper grounding?
followed all appropriate codes and
considered the health and safety 1. Recently, our service teams
of your personnel and equipment. What is the purpose of grounding the responded to a customer concerned
But what happens when they do transformer? about abnormal heating of a newly
not? Are you aware of some of the installed, refurbished transformer.
dangers that could be lurking due Neutral transformer grounding serves Electrical testing replicated initial
to an error or omission from the as a permanent and continuous factory test results, but oil sampling
contractor? Our crews recently conductive path to “earth” with showed combustible gases, which
responded to an unfortunate example sufficient ampacity to carry any indicated overheating. Considering
of just this scenario, involving fault current and sufficiently low this transformer was lightly loaded
transformer grounding. impedance to limit the voltage rise and weather conditions during the
above ground, and facilitates the 5-week period it was energized
We often focus on the importance operation of the protective devices in did not include severe heat, this
of regularly testing and maintaining the circuit. These functions reduce is an unexpected result. It should
distribution transformers to shock hazards to personnel and also be noted that the crew
preserve and extend their useful life. limit damage to equipment. Failing identified significant variations in
However, the life and safety of your to properly connect and ground the phase voltages during their initial
electrical distribution system begins system neutral in 4-wire systems inspection. Our recommendations
at installation. One of the critical establishes what is often called a included monitoring the transformer
elements of establishing a safe “floating neutral”. In this condition, during subsequent operation and
and effective distribution system the neutral is not referenced to retesting in 3 months. The primary
consists of proper transformer ground allowing voltages to “float” to concern expressed in our report,
grounding and connection of the a maximum of phase RMS voltage however, was the connection of
system neutral in 4-wire systems. relative to ground. The amount of the system neutral. The picture
Those familiar with the National float depends largely on the load shown should be a red flag to
Electrical Code, NFPA 70, will balancing of the connected system anyone concerned with the health
recognize that there is significant and can be particularly damaging to and safety of their employees and
time devoted to proper grounds single-phase loads. More importantly, equipment. It clearly depicts the
Photo: Shutterstock

within the code. Many do not this condition creates an extremely failure of the contractor to complete
understand why, nor the significance dangerous touch potential hazard the installation necessary to protect
of these requirements. with the ability to injure or even kill. personnel and equipment.
Transformer Technology May 2021 35

Issue 12
36 TRANSFORMER
GROUNDING

4.
What are the dangers?

Why is this such a critical concern?

Primarily, this directly affects
the safety and well-being of the
operational staff, as well as the
downstream equipment. Without
establishing an effective ground-fault
current path, the ground-fault current
will not flow to expose the ground-
3. fault to protective devices. This 5.
Is the transformer properly grounded? results in failure of the overcurrent How do I avoid this happening to me?
protection device to operate
Our first and most urgent correctly to clear the fault condition. The best way to protect your people,
recommendation to this customer In addition, potential builds on facility, and infrastructure is to know
was to ensure the transformer and equipment enclosures and surfaces where to find answers. For further
distribution system were properly and the risk of electrical shock or research and future reference,
connected and grounded prior to re- electrocution becomes a significant consider the following significant
energization. Article 250 of the NEC and potentially deadly safety hazard domestic codes and standards:
Grounding and Bonding was not which is usually discovered too late,
adequately nor appropriately followed with tragic results. NFPA 70 – National Electrical Code
when this transformer was installed. (NEC)
A system bonding jumper was not Failing to connect the “grounding ANSI C2 – National Electric Safety
installed as required to create an electrode conductors” can also Code (NESC)
effective ground-fault current path. create a situation where secondary IEEE 142-2007 – IEEE Recommended
Additionally, the neutral conductors voltages are unstable during Practice for Grounding of Industrial
were not connected to the X0 operation. This was proved during and Commercial Power Systems
bushing. They were simply left taped the initial inspection when phase (The Green Book)
off in the enclosure. Combined, these voltages were observed to vary
actions defeat any fault protection significantly (nearly 20%). Without A thorough understanding of these
associated with the system a proper return path to the source, standards is critical to avoiding
protection and control scheme. Note phase voltages will often vary similar situations and identifying
that the system neutral should not be with respect to load balancing. In sources of risk to operations and
grounded at locations other than the addition to potentially damaging personnel.
service entrance, or, in this case, the single-phase loads, these voltage
supply transformer, as per applicable variations may be the likely source
codes. This could place earth in of the overheating indicated by the
Photo: Shutterstock

parallel with the system neutral presence of combustible gasses and

and create corresponding potential potentially dramatically reduce the
variations. service life of this transformer.
Transformer Technology May 2021 37

Issue 12

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FIELD SERVICES

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 38

Co-founder and Director

Interview with John Ulcar at Crosslink Technology
FEATURE
INTERVIEW

CEO at
and Edson Fariello
John Ulcar

Crosslink Technology
 Transformer Technology May 2021 39

Issue 12

Edson Fariello

Because we are
formulators, we
understand the
chemistry
intimately and
know how it
could be applied
to the bushing.
This is what
makes us unique.
Photo: Crosslink Technology
40 FEATURE
INTERVIEW

Founded in 1981, Crosslink Technology has been providing a wide range of

chemical engineering services and custom-cast electrical solutions, including
transformer bushings, for four decades. In a recent Transformer Technology
Tech Talk, we talked to the company co-founder and director John Ulcar
and the CEO Edson Fariello about Crosslink’s path to the road of excellence.

Alan Ross: In this interview I have the pleasure production. Then the sales bug got me, and I got
of talking to two of the leaders of Crosslink involved in sales and marketing for quite some
Technology – CEO Edson Fariello, the leader time.
taking it to the next generation, and John Ulcar,
the founder who is still heavily involved in the
organization. AR John, tell us a little bit about the
early stages of Crosslink and how
it started, why you started it. Why would you
John, when was it that you decided you needed start a company instead of getting a steady job
to have a different leader to move things somewhere and retiring at 55?
forward? Was it difficult to pass the reins on to
Edson?

John Ulcar: This was a part of our succession

JU I was always a formulator. The first job
I had when I graduated from university
was as formulator, particularly in urethanes
plan. We have a very aggressive growth plan, and urethane foams. My business partner at
and I knew that I wasn’t going to be around the time, Karl Egenberger, was an electrical
forever. So, for the continuity of the business engineer. He noticed there was a great demand
and for our customers, we wanted to make for customization for various products. The large
sure we had a proper succession plan going players in the market would provide standard
forward. Once we found assets, the passing of products like product cards, but there was very
the baton was very easy. Edson is very talented little innovation at the time with the existing
and skillful. He understands the industry, our suppliers.
customers’ needs and how we meet them.
We founded a company in 1981, starting as
Alan Ross: Edson, tell us a little bit about how formulators for the electrical and electronic
you first got involved with Crosslink. What did industry and for large companies like
you know at the time? Westinghouse, General Electric and Ferranti-
Packard. After about two years, we were
Edson Fariello: It started a few months before successful at casting their transformers,
I joined the company. I had little knowledge particularly the potential transformers (PTs) and
back then. It was an incredible surprise when current transformers (CTs). The engineers at that
I started talking not only to John, but also to time, particularly at Westinghouse, were asking
the board. John put together a board for the us to formulate products that they could keep
company to look into the future, and here we in service for 60+ years. That was an important
are, celebrating our 40th anniversary this year. part of their business model, to provide longevity
to the electrical grid. We accelerated testing to
I have been very blessed in joining such an provide the required properties, and we did it
incredible organization with such incredible quite successfully.
people.
One day, we had a meeting at Westinghouse

AR Edson, is your background

organizational or technical?
when a mechanical engineer came to us with
an idea. He worked in the bushings department,
where, due to the company size and red tape, it

EF It is both. I have a degree in chemical

engineering, but I also went to business
school. Before receiving my MBA, I worked
would take them between six and nine months
to produce either a prototype or samples. Since
we knew epoxies, he asked us to cast some
in process engineering, quality control and bushings for them.

In well over 30 years, we have not had a reported

leakage in the field.
 Transformer Technology May 2021 41

Issue 12

At that time, we had been supplying materials of the things I want to talk about – the idea that
for bushings, but we had never cast one. In about Westinghouse came along and said they wanted
three weeks, we had a mold, cast the bushings transformers that would last 60 years or more.
and completed the full thermal cycle testing, Many people in our industry do not realize
-40°C to +140°C. Within three weeks, we took the difficulty of finding bushings, of working
three samples to that mechanical engineer. with a company that knows about bushings
He was so impressed that he asked for twelve well enough and that understands that the
more, which became 100 more, which became next generation of bushings is going to change
1,000 more. everything.

We were selling material for both PT and One of the things that fascinate me the most
CT bushings to several other electrical about Crosslink is your ability to meet a
manufacturers, such as Ferranti-Packard, customer. How do you approach the customer
now Siemens, and we noticed a trend: these to provide that customized solution?
companies knew how to do casting, but they had
issues with casting bushings. The biggest issue
was being able to handle the cantilever load and
not have a leak. There is an interface between
EF One of the first things that John taught
me when I started with Crosslink
Technology was that sometimes you have a
the epoxy and the conductor. We came up with transformer worth half a million dollars waiting
a very proprietary method of castings bushings somewhere for a couple of bushings. The owners
and in well over 30 years, we have not had a cannot ship it and the transformer cannot, in
reported leakage in the field. According to some turn, serve their customers. One of the things
reports, other bushings manufacturers have that we at Crosslink try to do every day is to be
5-10% leakage, so our record is really good. really fast. We deal with very short lead times,
much shorter than what you would expect from

AR That is interesting. At a company

I worked for, every year we would
celebrate the birthday of 100-year-old
a cast component manufacturer. We are also
vertically integrated. On one side of our plant, we
make the liquid epoxy that will be used to cast
transformers in service. And the last year we the bushing in the other part of the plant, which
did it, we had seven that we tested. That is one helps a lot.
Photo: Crosslink Technology

One of the things that we at Crosslink try to do

every day is to be really fast.
42 FEATURE
INTERVIEW

AR That means that you innovate both

the epoxy end and the bushing
manufacturing. I would like to go into
JU They bring us in at the design stage. Let
me go back one step. It is interesting
that we can have several customers supplying
innovation on behalf of the original equipment the same end user, each with different
manufacturer (OEM). Does the OEM bring you in requirements for a certain type of bushings.
at an early stage when they are manufacturing Every single customer is unique despite the fact
for an investor-owned utility? When do they that we are all in the same industry. In some
bring you in? cases, it could be that the end properties are
similar, but the manufacturing and processing
requirements are different. Our customization
is to the specific customer, which meets the
requirements of the end user.
 Transformer Technology May 2021 43

Issue 12

At Crosslink, we have over 1,500 proprietary

formulations. Companies not only get us involved
in the design of the bushings, but also with the
challenges with the supply chain.

AR Where does innovation come when

you are meeting somebody else’s
specifications? Where do you teach that original
JU There are two components of that
process. What I think makes us
unique is that because we are formulators, we
specifier that they could make a better bushing, understand the chemistry intimately and we
safer and longer lasting? Give us a little bit of know how it could be applied to the bushing.
insight into how you use innovation.
The second part is our electrical engineering.
Photo: Crosslink Technology

We partner with the electrical engineers of the

customer companies, and quite often they are
dealing with space constraints. There is partial
discharge, and a number of other electrical
properties that have to be accounted for. In
 44
FEATURE
INTERVIEW

Photo: Andax Industries

Transformer Technology May 2021 45

Issue 12

some cases, the design can be done by both the There are three different things, and that is the
customer engineers and our engineers. reality of the customer market we live in. As the
market changes, it is going to impact everyone.
And then there is the chemical part of it. In some Where is Crosslink going to fit that niche, and
cases we design the epoxy to meet the processing what you are going to focus on as a company
requirements; in other, there are mechanical the most?
requirements. They have a high cantilever
requirement because of the cables that are
being attached to it, as well as extreme thermal
cycling or extreme temperatures. We balance
JU Right now, we are focusing on two
new developments within the
bushing industry. One is to decrease the partial
the mechanical properties and the chemical discharge in the electrical and increase some
properties of the epoxy with the design itself. of the electrical properties within the epoxies
That is where I think we marry the two together themselves.
very neatly.
We have a program in place to start developing

AR One of the things that we believe is a

foundational principle is the principle
of excellence. How have you built it in? If
products with improved properties that will
increase their longevity in the field.

you have been in business with a formulating A property we are focusing on the most is
division and a casting division for 40 years, you decreasing partial discharge. Our goal is to get
must have a reputation for excellence. to zero, that is the brass ring. We are making
significant improvements in that part of the

EF I think it is a daily endeavor, Alan. As

John was saying, and I myself have seen,
business. Secondly, we are looking at mimicking
porcelain from the point of view of self-cleaning

Our future efforts are focused on decreasing

partial discharge as well as developing a system
that will ensure the bushings have self-cleaning
properties, approaching those of porcelain.

we not only have companies getting us involved out in the field, especially in polluted areas.
in the design of the bushings, but also with the As is commonly known, porcelain is not the
challenges with the supply chain. We have over easiest product to work with. It is brittle, and it
1,500 proprietary formulations. It is very rarely has other issues, but it does have great outdoor
that we have to start from scratch on any resin, self-cleaning properties. With epoxy, we are
particularly the ones that we use for bushings. providing a product that is much more stable
We are making more investments this year on from a mechanical point of view. Even if some
the technology required to make bushings and hunters want to shoot at it as practice, it will
to improve our manufacture of the resins. This not be destroyed in the field. At the same time,
is an ongoing process that will continue over the we are developing a system that will ensure
next five to ten years. It is the way to go for every the bushings have self-cleaning properties,
company that wants to maintain the speed of approaching those of porcelain.
delivery and be able to customize the solutions
to their customers.
AR If you get even close, that is a big deal.
We know that weather is the biggest

AR The world today is agile. You have to

be flexible and be able to adjust. It
sounds like that agility is built into your DNA,
enemy of porcelain. If you can solve both of
the problems, that would be one of the next-
generation innovations that are coming.
which is a huge advantage.
I would like to congratulate Crosslink on
Here is a hard question. We have moved into a 40 years of excellence. Thank you for being
situation where purchasing always wants the that kind of a privately held company in this
cheapest price, engineering wants the product massive industry that is providing value and a
that meets specifications and works, and a lower, total cost of ownership, and passing on
CFO wants the lowest total cost of ownership. the legacy to the next generation.
46

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48 ADVERTORIAL

SOLVING
MOVERS FOR
THE TRANSFORMER
INDUSTRY

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For the transformer industry

Solving is one of the leading manufacturers of customised systems for handling
heavy loads. Based on over 40 years of experience we provide solutions both on
air bearings and wheels.
Air film technology is considered ideal for handling transformers weighing several
hundred tons quickly and smoothly through production and test facilities.
Solving provides a variety of transporters for handling transformers, windings,
cores and components ranging from simple manual Movers for smaller com-
ponents to remote controlled and automated systems for bulky windings and
transformers and for frequent operation.

Photo: Solving
Transformer Technology May 2021 49

Issue 12

Solving Movers for transformers weighing up to 700 tons

Several manufacturers of transformers have used Solving’s Air Film Movers a
long time to assemble windings, cores and active parts and to move them into
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Solving provides handling equipment for cores, windings and components
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steel pallets from one station to another An Air Film Mover consists of a rigid steel
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50 ADVERTORIAL

AN EXAMPLE OF AN AIR FILM BASED MOVER

HANDLING TRANSFORMERS WEIGHING SEVERAL
HUNDRED TONS

High voltage power transformers are amongst the largest and heaviest production
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clearances between the connections and the surrounding building structure.
When these connections, high voltage bushings, are assembled and cooling oil
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AN EXAMPLE OF AN AIR FILM BASED MOVER

HANDLING TRANSFORMERS WEIGHING SEVERAL
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transformers or combined as a used to control the movement of all assembly processes to
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required.
Photo: Solving
Transformer Technology May 2021 51

Issue 12

SOLVING WHEELED MOVERS

There are various kinds of Solving wheeled Movers, all of them being tailored to
suit specific customer requirements. One example is a wheeled Solving Mover for
smooth handling of transformer bushings in a narrow layout.

Solving has installed a customised, radio-guided and battery-powered Mover to

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WWW.AMERICANSOLVING.COM
52 SPECIAL TRANSFORMER
TEMPERATURE RISE
TESTING

Temperature Rise Test Corrections

for Three-Winding Transformers
with Axial Split-Windings
by Jason Varnell
 Transformer Technology May 2021 53

Issue 12

Introduction

Jason Varnell is a member of Doble Global In core-form transformers with a

Power Services, employed as a Principal Trans- concentric winding arrangement, two
former Engineer working on projects that in- or more separate winding sections
clude factory inspections, condition assess- may be situated one above the other
ment, design reviews, failure analysis and (axially). This unique arrangement
other general consulting projects. He has is commonly referred to as “axial
over 10 years of experience, having most split-windings” or “axially-stacked
recently served as Lead Design Engineer at windings”. The split-winding
SPX Transformer Solutions in Goldsboro, arrangement is most commonly used
NC where he managed an electrical design in three-winding rectifier transformers
group. He has extensive expertise in core- and three-winding unit auxiliary
form transformer design and construction transformers (UAT). Three-winding
having personally designed several hun- transformers with axial split-windings
dred power transformers. An active mem- are unique because the two axial
ber of IEEE Transformer Committee, Jason sections are normally associated with
has contributed to the revision or creation two different terminals. Therefore,
of a significant number of IEEE transformer unique combinations of varying
standards. Jason Varnell received a bachelor's voltage, impedance and active power
degree in Electrical Engineering (Honors) from can be present, which requires special
the North Carolina State University with an consideration.
emphasis in Power Systems and Power System
Protection. In addition to the various possible
terminal characteristics described
above; there exists a fundamental
difference in the temperature rise
distribution model when compared
to the traditional full-axial height
winding arrangement because the
relative top-oil, average-oil and
bottom-oil temperature rises are
not the same for all windings. It is
therefore necessary to understand
the differences in the two temperature
rise distribution models and then
be able to refine the relative oil
temperature rises for each winding in
order to appropriately determine the
average winding temperature rise and
winding hottest-spot temperature rise
for each winding.

Presently, industry standards do

not explain the modifications that
are needed to the temperature
rise test for these special winding
arrangements. This paper will
demonstrate how to supplement the
industry standards for this unique
Photo: Shutterstock

transformer construction and some

common problems that arise in
practice.
54 SPECIAL TRANSFORMER
TEMPERATURE RISE
TESTING

____________

An application for the axial

split-winding arrangement
may be to serve large unit
auxiliary loads within one
three-winding transformer
at a generation plant, as
opposed to using two
separate two-winding
transformers.
____________

Winding Arrangement

The traditional and most common

winding arrangement for core-
form transformers includes an
arrangement in which the windings
are approximately the same height
and are arranged concentrically
over one another (radially). Figure 1
depicts the traditional transformer
winding arrangement for a three-
winding transformer with the
primary (designated as “HV”)
placed concentrically in-between
two secondary windings, “XV”
and “YV”. The axial split-winding
arrangement includes two or more
separate winding sections that are
situated one above the other axially.
An application for the axial split-
winding arrangement may be to
serve large unit auxiliary loads within appreciably different between the two This assumption yields additional
one three-winding transformer at arrangements, and therefore greater assumptions such as the top-oil
a generation plant, as opposed to attention is required in determining temperature rise is adjacent to the
using two separate two-winding the oil temperatures. Namely, in the top of the windings and, similarly,
transformers. The application could axial split-winding arrangement, the the bottom-oil temperature rise
allow interconnection of two separate “YV” winding from Figure 2 should is adjacent to the bottom of the
auxiliary buses and possibly with not use the average-oil temperature windings. In other words, the
secondary voltages and active power rise of the tank oil, rather it is temperature rise of the oil inside the
ratings at different levels [1]. necessary to determine the average- windings is assumed to increase
Figure 2 depicts an axial split-winding oil temperature rise for the “YV” linearly with the height of the
arrangement with one set of winding separately from the tank windings. Additionally, the heat
secondary windings designated as average-oil rise. generated from the windings, in
“YV” placed axially above the other the form of losses, is assumed to
set of secondary “XV” windings. Transformer Temperature Rise transfer (on average) to the adjacent
Distribution oil in proportion to the corresponding
The importance in noting the winding height. In graphical form,
Photo: Doble Engineering Inc.

difference between the axial split- In the traditional transformer these assumptions result in two
winding arrangement and the temperature rise distribution model, parallel lines, with one representing
traditional concentric winding the winding heights are assumed the winding temperature rise relative
arrangement is that the transformer to be uniformly distributed within to height and the other representing
temperature rise distribution is the transformer core window. the oil temperature rise relative to
Transformer Technology May 2021 55

Issue 12

height. The difference

between the two parallel
lines is the temperature
drop between the winding
and the adjacent oil, which
is commonly referred to
as the average winding
gradient.

In the traditional
transformer temperature
rise distribution model, the
average-oil temperature
rise (Figure 3 – Point B)
is determined by the
arithmetic mean of the
top-oil temperature rise
(Figure 3 – Point A) and
bottom-oil temperature
rise (Figure 3 – Point C).
Also, in the traditional
model, the average
winding temperature rise
(Figure 3 – Point B’) is
the sum of the average-
oil temperature rise and
the average winding
gradient. Point K in
Figure 3 is the winding
hottest-spot (“hotspot”)
temperature rise and is
determined by the sum of
Figure 1. Traditional transformer winding Figure 2. Axial split-winding transformer winding
the top-oil temperature
arrangement arrangement
rise and hotspot gradient,
which is determined by
a hotspot factor and the
average winding gradient.
The hotspot factor is a
dimensionless quantity
greater than 1.0 and is
YV YV
individually assigned
to each winding based
on a combination of
XV HV YV YV HV XV HV HV mathematical analysis and
empirical test results from
direct measurement [2] .
XV XV
A figure similar to
Figure 3 can be found in
International Standard
IEC 60076-2[3]. The IEC
standard uses similar
56 SPECIAL TRANSFORMER
TEMPERATURE RISE
TESTING

Figure 3. Traditional transformer temperature rise

distribution model

A K

RELATIVE TANK HEIGHT

B B’

XV HV YV YV HV XV

OIL
WINDINGS

TEMPERATURE RISE (oC)

points to help illustrate the terms for rise distribution model. In the axial The “XV” winding in Figure 4 will
bottom-oil, average-oil, and top-oil split-winding transformer temperature require similar adjustments to the
temperature rise; however, it defines rise distribution model, one of the temperature rise distribution model.
the vertical axis of the chart as main differences is the oil temperature The “HV” winding in Figure 4
“Winding Height (%).” rise to be used to determine the uses the traditional temperature
Although the IEC standard associates average winding rise. It should not rise distribution model because the
the 0%, 50%, and 100% of the use the average-oil temperature rise windings are not stacked axially and
winding height with the location of (Figure 4 – Point B) of the tank oil, are full height.
the bottom-oil temperature rise, rather it is required to determine the
average-oil temperature rise, and average-oil temperature rise across Corrections to the
top-oil temperature rise of the tank the “YV” winding, which is Point D Temperature Rise Test
(respectively); the differentiation in in Figure 4. Point D is the arithmetic
the vertical axis is useful for the axial mean of the oil rises from points A The purpose of the temperature
split-winding transformer temperature and B of Figure 4. rise test is to establish the top-oil

Figure 4. Axial split-winding temperature rise

distribution model for YV winding

A K

D’
RELATIVE TANK HEIGHT

D
YV YV

B
HV HV

XV XV

OIL
YV WINDING

TEMPERATURE RISE (oC)

Transformer Technology May 2021 57

Issue 12

temperature rise, average winding One difficulty that can occur during of the total-losses for which the
temperature rises, and winding the total-loss injection for three- temperature correction equations
hottest-spot temperature rises. winding transformers, which may are valid. Due to the transformer
The temperature rise test is primarily also be prevalent during the rated impedance requirements or active
composed of four components. winding-current injection portion power ratings, it is possible that the
The first component is the cold- of the temperature rise test, is that required total-losses fall outside
resistance measurements of the differences in impedances and active of the minimum percentage as
windings. Next is the total loss power ratings can result in under- indicated in the industry standard.
injection for determination of oil loading or over-loading of certain Alternatively, it may be of interest
temperature rise. Special attention terminals under test. Figure 5 helps to the end user to meet and not
is given to each component of illustrate the equivalent three- deviate from the industry standards.
the temperature rise test for winding impedance network and Therefore, it may be recommended to
transformers with axial split- can be derived from Equations 1 have the transformer manufacturer
windings, but this paper will focus on through 3. Equation 4 and Equation design the transformer windings and
the cold-resistance measurements 5 can be used to solve for the load- ancillary equipment to withstand
and total loss injection because the current division if both the “XV” and any resulting over-loads, which
principles described can easily be “YV” terminals were shorted during result from maintaining at least the
applied to the other two remaining the short-circuit method of the minimum percentage of the total-
components. temperature rise test (i.e. a short losses as indicated in the industry
across point “X” and point “Y” in standards. It should be noted that the
Cold-Resistance Figure 5). industry standards also have upper
Measurements ranges for the percentage of total-
____________ losses and rated winding current for
The industry standards which oil temperature rise correction
have very definite criteria to calculations can be made; however,
minimize recording errors This stable reference the IEEE and IEC standards are not in
in the cold-resistance agreement in regard to the allowable
measurement [4]. One of
temperature for each axial ranges.
the major prerequisites is split-winding should follow
the determination of the There are additional considerations
cold winding temperature
the method for determining that may need to be considered in
since resistance varies the oil temperature rises determining the required total-loss for
proportionately with unique three-winding transformers
temperature. Cold resistance
according to the axial split- such as axial split-winding
measurements require the winding temperature rise transformers. The derivation of the
windings and oil temperature to load-current division from Equation
be stable. This stable reference
distribution model. 4 and Equation 5 and the use of the
temperature for each axial ____________ measured impedances and losses
split-winding should follow the for each two-winding combination
method for determining the oil can result in some inaccuracies
temperature rises according to the in large transformers where eddy
axial split-winding temperature rise This can present difficulties in losses in windings and stray flux
distribution model. achieving total-loss injection losses in structural components are
because the over-loading of one set considerable. Additional corrections
Total-Loss Injection of terminals may be significant and to determine the three-winding
result in exceeding recommended (combined) total-losses may be
The most common method for temperature rise limits or current useful and required [5].
temperature rise testing power ratings of ancillary equipment.
transformers is to utilize the short- Therefore, it is recommended that After the top-oil temperature rise
circuit method, whereby the load the details of the temperature rise has stabilized during the total-
is simulated by the effect of short- test for transformers that fall within loss injection, according to the
circuit current. In the case of total- this scenario be presented and requirements in industry standards,
loss injection, the primary goal is to agreed to during the tender stage. then the short-circuit current should
simulate and sustain total-losses on The transformer manufacturer may be reduced to the rated winding
the transformer that coincide with present recommendations to inject currents. The instant where the
previously measured no-load and less than 100% of the total-losses total-loss injection transitions to the
load losses for a given active power and then apply corrections to the oil rated winding-current injection is
rating for the purpose of determining temperature rises as outlined in the commonly referred to as “cutback.”
the steady-state oil temperature industry standards [3], [4]. It should The oil temperatures should be
rises. be noted that the industry standards recorded for the total-loss injection
typically have a minimum percentage
58 SPECIAL TRANSFORMER
TEMPERATURE RISE
TESTING

Figure 5. Equivalent three-winding impedance

network

ZX
𝑍𝑍𝐻𝐻𝐻𝐻 −𝑍𝑍𝑋𝑋𝑋𝑋 +𝑍𝑍𝐻𝐻𝐻𝐻
𝑍𝑍𝐻𝐻 = Equation 1
2
X
ZH 𝑍𝑍𝑋𝑋𝑋𝑋 −𝑍𝑍𝐻𝐻𝐻𝐻 +𝑍𝑍𝐻𝐻𝐻𝐻
𝑍𝑍𝑋𝑋 = Equation 2
2
𝑍𝑍𝐻𝐻𝐻𝐻 −𝑍𝑍𝐻𝐻𝐻𝐻 +𝑍𝑍𝑋𝑋𝑋𝑋
H 𝑍𝑍𝑌𝑌 = Equation 3
2
𝑍𝑍𝑌𝑌
𝑀𝑀𝑀𝑀𝑀𝑀𝑋𝑋 = 𝑀𝑀𝑀𝑀𝑀𝑀𝐻𝐻 Equation 4
𝑍𝑍𝑋𝑋 +𝑍𝑍𝑌𝑌
Y 𝑍𝑍𝑋𝑋
𝑀𝑀𝑀𝑀𝑀𝑀𝑌𝑌 = 𝑀𝑀𝑀𝑀𝑀𝑀𝐻𝐻 Equation 5
𝑍𝑍𝑋𝑋 +𝑍𝑍𝑌𝑌

ZY

immediately before the cutback. If direct measurement is used to

The recorded oil temperatures determine the winding hottest-
should be categorized according to spot temperature rise during the
the axial split-winding temperature temperature rise test, and there
rise distribution model for windings exists unequal loading of the axial
that are axially-stacked. These split-windings, then the direct
categorized oil temperature rises, measurement may not result in
from the moment of cutback,
will be used to determine
the final average winding ____________
temperature rises and winding
hottest-spot temperature rises
after rated winding-current Due to the transformer
injection and hot-resistance impedance requirements or
measurements are completed.
active power ratings, it is
Other Special Thermal possible that the required
Considerations
total-losses fall outside of
The axial split-winding example the minimum percentage
presented in this paper
illustrated two axially-stacked as indicated in the industry
sections divided into two equal standard.
height winding segments.
In practice, other winding
constructions are possible, such
____________
as two unequal height winding
segments due to differences in
voltage or impedance requirements. meaningful winding hottest-spot
Unequal height winding segments temperature rises at rated load for all
present additional challenges in of the windings. It should be noted
determining the bottom-oil, average- that this scenario exists due to the
oil, and top-oil temperature rises for short-circuit temperature rise test
each axially-stacked winding. method; however, it is not a limitation
that necessarily exists in operation.
It may also be advisable to install For reasons already explained in this
temporary or permanent temperature paper, it is possible that one of the
measurement probes at the winding axial split-windings will be under-
heights that coincide with the tank loaded while the other over-loaded
oil adjacent to the bottom, middle, during temperature rise testing, which
and/or top of the axial split-windings. means that a more refined calculation
Additionally, a different temperature may be necessary to determine the
Photo: Shutterstock

rise calculation method can be applied calculated winding hottest-spot

based on the proposed winding temperature rise from the direct
heights of each axial split-winding. temperature measurements.
Transformer Technology May 2021 59

Issue 12

Conclusion

Transformers with split axial-

windings present unique challenges
when performing temperature rise
testing. The industry standards
generally have enough provisions
to determine the oil and winding
temperature rises for split axial-
windings if some discretion is used
in applying various corrections as
presented in this paper. This paper
provided some considerations for
the temperature rise distribution
model and temperature rise test via
the short-circuit method. This paper
emphasizes the necessity to consider
transformers with axial split-windings
____________ as a unique design, which requires
special involvement between the
buyer and transformer manufacturer
It is possible that one of during the tender stage.

the axial split-windings will References

be under-loaded while the [1] IEEE Guide C57.116, IEEE Guide for
Transformers Directly Connected
other over-loaded during to Generators, IEEE, 3 Park Avenue,
temperature rise testing. New York, NY 10016, USA
[2] IEEE Standard 1538, IEEE Guide

____________ for Determination of Maximum

Winding Temperature Rise in
Liquid-Filled Transformers, IEEE,
3 Park Avenue, New York,
Due to the difficulty in obtaining a NY 10016, USA
correct measurement at full load and [3] IEC 60076-2, Power transformers
total-losses, it may not be advisable - Part 2: Temperature rise for
to use the direct measurement to liquid-immersed transformers,
guarantee the winding hottest-spot International Electrotechnical
temperature rise. Another option Commission, 3, rue de Varembé,
may be to determine the hotspot PO Box 131, CH-1211 Geneva 20,
factor from the direct temperature Switzerland
measurement [2] for each axial split- [4] IEEE Standard C57.12.90, IEEE
winding at the presumed loading Standard Test Code for Liquid-
based on the load-current division Immersed Distribution, Power, and
as determined from Equation 4 Regulating Transformers, IEEE,
and Equation 5. Once the hotspot 3 Park Avenue, New York,
factor is determined for the applied NY 10016, USA
test current then the temperature [5] IEC 60076-8, Power transformers
corrections based on the industry - Part 8: Application guide,
standards can be applied to the International Electrotechnical
oil temperature rises and winding Commission, 3, rue de Varembé,
temperature rises. The hotspot PO Box 131, CH-1211 Geneva 20,
factor can then be applied to the Switzerland
corrected winding gradient and then [6] Nordman, H. and Takala, O.,
added to the top-oil temperature rise “Transformer Loadability Based
for each axial split-winding. When on Directly Measured Hot-Spot
determining the hotspot factor, it may Temperature and Loss and Load
be necessary to review the variation Current Correction Exponents,”
in the hotspot factor at different CIGRE Report No. A2_307-2010
percentages of rated load [6].
60 ADVERTORIAL

INSULATION
GFRP

COMPONENTS
ALLOW REVISIONS
TO TRANSFORMER
DESIGN
How Durostone® CR contributes to compact design and resilient transformers

One of the megatrends is urbanization: Urban living is the

dominant lifestyle of the future. By 2050, two thirds of the
world population will live in cities. This leads to an increasing
demand for energy in the same space. Therefore, transformers
with the same or smaller dimensions, but with higher capacity,
are needed. Additionally, the need for mobile transformers is
increasing while aged transformers are replaced.
Both developments require transformers to be compact and
more resilient. This leads to higher requirements for the
construction insulation materials in the active part of the
transformer. The new Durostone® CR materials’ mechanical
properties provide the ability to revisit the overall design.
 Transformer Technology May 2021 61

Issue 12

Shield end ring made of Durostone® CR:

Close tolerances because of no shrinkage leading
to high dimensional stability

Glass fiber reinforced plastic (GFRP) is

a material that has so far only played
a subordinate role in the construction
of oil-filled transformers, but it has the
potential to boost the construction of
compact and high-performance designs.

The current construction elements Compared to steel, the electrical properties of GFRP provide advantages in terms
inside the transformer are steel and of stray losses and smaller transformer design.
wood-based materials like laminated
press-board (LP) and laminated de- Compared to wood-based materials, GFRP provides better mechanical proper-
nsified wood (LDW). But a material that ties. In addition, the operating temperature of GFRP is higher, since wood-based
has so far only played a subordinate materials are normally used at a maximum operating temperature of 105°C. On
role in the construction of oil-filled the contrary, the critical property for fiber-reinforced plastics are the electrical
transformers has the potential to boost properties in point of partial discharge. GFRP does not absorb any oil. Therefore,
the cons-truction of compact and high- the manufacturer must ensure that the material is free of air bubbles. A special
performance designs: glass fiber know-how is required in the production process and special resin systems to
reinforced plastic (GFRP). fully utilize the advantages of GFRP.

Durostone® CR was specifically developed

Photo: Röchling

for oil-filled power transformers with

the highest requirements.
62 ADVERTORIAL

Platform made of Durostone® CR:

improved mechanical properties and reduced
clamping ring thickness

Durostone® CR provides higher

performance, more compact design
with a higher capacity and higher
operating temperatures, thus supporting
a new design for modern transformers
performing at the highest requirements.

Röchling Industrial, a world-leading The difference to common composites is the high dielectric strength without on-
plastics and composites manufacturer, set of partial discharge, which is much lower for typical fiber-reinforced plastic
has more than 60 years of experience compared to laminated pressboard (LP) and laminated densified wood (LDW).
in the production of high-power insu- With Durostone® CR dielectrical properties of up to 10 kV/mm without onset of
lating materials. Röchling has been partial discharge are possible, which is on the same level with LP. Highest reliabil-
challenged to develop GFRP grades for ity for the electrical insulation properties is crucial for the construction elements
transformer construction. The new ma- in the active part of the transformer.
terials are combined in the Durostone®
CR (CR = Compact & Resilient) product For the development of Durostone® CR, Röchling made use of the broad experi-
family. Durostone® CR was specifically ence with LDW and LP. The Röchling brand Lignostone® Transfomerwood® has
developed for oil-filled power trans- been used in transformers for over 60 years. In 2009 Röchling expanded with
formers with the highest requirements. Trafoboard® HD-PH, a laminated pressboard with excellent dielectrical properties.

The electrical properties of Durostone® CR in point of onset of partial discharge

are approved from well-known institutes in the industry which have the highest
standard with a measuring sensitivity for partial discharge of <1 pC. The compat-
ibility with dielectric liquid has been tested by Doble with no negative influence.
Furthermore, Durostone® CR has the advantage of no shrinkage during the dry-
ing process because it is not hygroscopic. This provides closer tolerances and a
more stable design. Additionally, it can be advantageous for threaded rods since
there is no need for reassembling after the drying process.
 Transformer Technology May 2021 63

Issue 12

Durostone® fasteners:
No additional labor after vapor phase

Durostone® CR beam:
No stray losses lead to a higher efficiency

To summarize, the advantages of

Durostone® CR are:
• Higher mechanical properties
• High PD-inception field strength
• Dielectric liquid compatibility
• No shrinkage during drying
• Higher temperature class

These lead to new possibilities for the transformer designer. Since Durostone® CR
is available in large dimensions, it can be used as a clamping ring with a diame-
ter of up to three meters, for very high mechanical requirements. Beams and fas-
teners with a length of more than 5 meters are available. It can replace steel beams
due to its very high stiffness of up to 30 GPa, which reduce eddy currents in the
beam and gives more freedom in the HV-Design.
Photo: Röchling

All these factors support a new design for modern transformers performing at the
highest requirements. Durostone® CR provides higher performance, more com-
pact design with a higher capacity and higher operating temperatures.
64 INSULATION
QUALITY MATTERS

Transformer Insulation
(Quality) Matters
by Mark Suddarth

Mark Suddarth has more than 30 years of

experience in Business-to-Business industri-
al sales and product management at a glob-
al level, with the last 12 years at Weidmann
Electrical Technology. He has an MBA from
Webster University and a BS in Biomedical
Engineering from Vanderbilt University. Mark
has extensive knowledge of crepe and flat/
kraft insulating materials, with responsi-
bility for expanding Weidmann’s customer

re d riven base and developing the overall Americas re-

es a ave
gion business strategy for all crepe materials.

u t i l i t i
ctric eds and h res,
In addition to Mark’s passion for engineer-

e l e ing and all things paper, he is also quite the

o d a y’s r s ’ ne r failu l
linguist with fluency in English and French

T e f o
stom lerance very rea
along with knowledge of Spanish and Arabic.

by c u to
r y l o w o s t s ”a
y o f the
a ve g “risk-c e qualit de
n h i
maki eration. T used ins e
id m th
cons ion syste ritical to ost
at c
insul former is t matter m y,
s a it
a tran ments th er: reliabil
re n
requi asset ow ngevity.
e o
to th ncy, and l
e
effici
Photo: Weidmann Electrical Technology Inc.
Transformer Technology May 2021 65

Issue 12

Since each transformer can feed a bottom-line financial performance of incidents, especially with an aging
large number of customers, failure of the utility/asset owner. fleet of transformers
a single transformer and the resulting • Reduce maintenance cost and cost
loss of service means lost revenue, When utility engineers and managers of the overall operation
repair or replacement, and other were asked in a recent survey to rank • Reduce insurance costs
collateral costs to the asset owner and the importance of operation factors,
operator. Sudden, catastrophic failures they listed equipment reliability as the In normal power transformer
can be highly visible and negatively number one for the following reasons: operation, the condition of the
impact customer satisfaction and insulation system determines the
• Reduce unplanned outages life expectancy of the transformer.
• Minimize the risk of major A simple risk analysis shows
the different levels of risk for the
transformer manufacturer and the
owner/end user relating to insulation.

Many do no
t recognize
importance the
of specifyin
the insulatio g
n system
and the vita
l role it play
in the attain s
ment of the
specificatio
n’s objectiv
e.
66 INSULATION
QUALITY MATTERS

Transformer manufacturer Transformer owner / End user

Negligible percentage of cost of substation or generating

Insulation cost 2-8% of transformer selling price
plant where the transformer is located

Test floor or in-service failure within

Risk In service failure and resulting cost
warranty

Partial or total loss of substation or generation plant

Capital at risk Cost of rework or replacement
7-10 times transformer cost

Transformer production and warranty

Duration at risk Transformer operational life 20-30 years
period (1-5 years)

n g h ig h q u al it y in su la tion materials
Specifyi ve rall price,
lig ib ly im p ac t th e o
will only neg
t si g n ifi ca n tl y au g m en t the efficiency,
bu
d lo ng ev ity of th e as se t, lowering
reliability, an
of ownership.
the end user’s total cost
Simply stated, while important to Many transformer purchasers’
both the manufacturer and end user, specifications contain very specific
the risk for the end user is much requirements for items such as
greater than that of the transformer copper conductors, core materials,
manufacturer. Since the quality of fluids, cooling equipment, bushings
materials used inside a transformer gauges, instruments, paint and
is critical to the requirements that external components/hardware.
matter most to the asset owner – However, many do not recognize
reliability, efficiency and longevity, it the importance of specifying the
stands to reason that the purchaser insulation system and the vital
should have a greater say in the role it plays in the attainment of
selection and design of the insulation the specification’s objective. Given
system. that the total insulation system
cost makes up only 2-8% of the
Have you ever wondered why there total transformer price, you would
can be a significant difference in prices anticipate that all operators/end
offered by different manufacturers users would specify this in their
for the same quote request? How is tender documents, but this is not
this possible? A major reason has to the case. Specifying only the highest
do with the priorities and strategy of quality insulation materials available
the transformer manufacturer. The to be used inside the transformer will
first priority is for the unit to pass negligibly impact the price whereas
the factory test so it can be shipped significantly augment the efficiency,
and sold. The second priority is reliability, and longevity of the asset
to get the transformer through the and lower the end users, total cost of
warranty period, so they are no ownership.
Photo: Weidmann Electrical Technology Inc.

longer responsible. These priorities

sometimes lead the manufacturer to In the final analysis, it is the
use cheaper, lower quality insulation responsibility of the utility transformer
alternatives, but these types of specialist to specify the best
materials will not deliver the long term transformer designs and materials for
reliability needs of the end users who construction to maximize operational
rely on the transformer to operate reliability, while minimizing risk, as
efficiently and reliably for many years. a key part of their investment and
Transformer Technology May 2021 67

Issue 12

The condition
of the insulation
system determin
es
the life expectanc
y
of the transforme
r.
 68
INSULATION
QUALITY MATTERS

Photo: Weidmann Electrical Technology Inc.

Transformer Technology May 2021 69

Issue 12

insulation materials are used inside

their transformers is that today's
The power transformers are expected
use quality to operate well beyond the 20-30
d o
criti inside f mate
year life expectancy of their hefty
predecessors, while utilities now
c a r
that al to th transf ials
expect 50-60 years of reliable service
from their fleet. This is despite leaner
e o
ass matter requir rmer is designed transformers, increasingly
e m e
effic t owne ost to ments
severe weather events, increasing
electrical demands, increasing grid/
ienc r: t
y, an reliabil he
transmission voltages and grid-
resilience requirements, all of which
d lo it
nge y,
place operation stress on the most
vity. critical component to transformer
reliability and life expectancy – the
insulation material.

Such expansion in life expectancy of

power transformers is only possible
with a combination of:

performance improvement strategies. transformers are often smaller • Solid/reliable design which
With the insulation system of the in size and lighter in weight with manufacturers provide
power transformer making up only capabilities more closely aligned • Top-quality insulation materials
5% of the total cost and a fraction of with operating needs. • Operational excellence supported
the total investment of a generation by state-of-the-art monitoring
facility or substation, it makes These modern-day “efficiencies”
sense to specify the best insulation were not achieved by accident, but Significant advances in power
materials, designs, and systems to rather by optimization and pushing transformer fault/alarm monitoring
reduce overall risks and total cost of the edges of design parameters devices and systems is another
ownership. which have significantly decreased reason today’s power transformers –
the size of oil/flow/cooling new and old – are able to operate
Another important reason end users channels, resulting in increasing many years longer than previously
should be sure to specify top-quality demands and stresses on the thought possible. Technology
insulation materials are used inside critical magnet wire insulation. today provides power transformer
their transformers has to do with Significant cost savings in steel, asset owners the ability to monitor
transformer designs which have copper and oil have been achieved their most valuable assets in real
evolved from previous decades when at the burden of the single most time 24/7/365, allowing operators
transformers were over-engineered important component to reliability to quickly and precisely adjust
and over-built. Driven mainly by cost/ and longevity of a transformer – and balance loading, whereby
economic pressures to do more with the magnet wire insulation. protecting the critical insulation
less, modern-day power transformer system from life-shortening damage
designs deliver the same or higher Yet another important reason when overloaded and run too hot.
operating performance as their hefty why end users should be sure Additionally, combined with regular
predecessors, but today's power to specify that only top-quality oil testing, such monitoring systems
provide operators with actionable
mitigation recommendations to
faults/alarms, which enable them to
much better manage transformer
performance and mitigate issues
before problems grow to the point
where asset life is reduced or
critical damage occurs. Although
equipping power transformers with
sophisticated fault/alarm monitoring
systems obviously increases the
initial cost of the asset, these one-
time costs are easily outweighed by
the benefit of significant reduction of
the total cost of ownership over the
50-60 year life of the asset.
IT’S EASY
TO KEEP IN
THE LOOP!

WITH

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transformer-technology.com
Transformer Technology May 2021 71

Issue 12

TRANSMISSION
& DISTRIBUTION

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BACKUP POWER

SMART SOLUTIONS

RENEWABLE
ENERGY
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& MANAGEMENT

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 72

General Manager of
Interview with Patrick F. McAtarian Andax Industries
FEATURE
INTERVIEW

Photo: Andax Industries

Patrick F.
 Transformer Technology May 2021 73

Issue 12

. McAtarian

Andax Industries is celebrating over 40 years in business.

At Andax, we focus
our energies on the
electric utility and
industrial markets,
providing solutions
that customers will
not typically find
off the shelf.
74 FEATURE
INTERVIEW

Andax Industries is celebrating over 40 years in business. In a recent Tech

Talk, company co-owner and General Manager, Patrick F. McAtarian talked
to us about what it takes to base your success on custom solutions and keep
the family-owned business innovative and successful for decades to come.

Alan Ross: Patrick, your company boasts over

four decades in the leak-and-spill control,
secondary containment and emergency
PM That is one of the categories of
products we offer. We found that
our core customer base had many different
preparedness business. In my previous life, we needs, some of which could be fulfilled from
once had a major oil spill. When I first met you, a different perspective. An electric utility, for
I didn’t know that the remediation system we example, will have a need for testing equipment
used to contain that spill was manufactured by in order to test transformers for PCBs.
Andax Industries. Tell us a little bit about what To transport the samples needed for analysis
your company does. and diagnostics, they would typically use a
Pelican™ case, lined with anything from plastic
Patrick McAtarian: Thank you, Alan. Andax wrap to rolled up newspaper. We created a
Industries has been in business for over custom case with precut foam to fit the fragile
40 years. I co-own the company with my equipment. The foam ensures protection so that
brother, as General Manager and head bottle the equipment can be dropped off at UPS or
washer. At Andax, we focus our energies on FedEx and get to its destination safely.
the electric utility and industrial markets,
providing solutions that customers will not
typically find off the shelf. That often involves
custom applications that fit customers’
AR I would like to know more about the
heart and soul of your business. For
privately held companies, companies where
particular requirements. We fabricate products owners are involved, we find that vision is
and containment systems to meet their critically important to where they are going
particular needs. and how they present themselves to their
customers, suppliers and employees. What is

AR I understand that you produce

custom-designed foam packaging
your vision for Andax Industries?

for the shipping of electronic or laboratory

equipment and other fragile instruments. Is that
a special division of the Andax business?
PM In previous conversations that you
and I have had, Alan, I believe we both
recognized the fact that there is a transformation
 Transformer Technology May 2021 75

Issue 12

Our goal at Andax is to re-educate the customer base on the lessons

that have been learned from the past on how to solve a particular
issue, and to provide not only products, but also the methodology to
keep utilities and their employees safe.
Photo: Andax Industries
76 FEATURE
INTERVIEW

going on in the electric utility markets and other look at a problem and see how you can solve it
industries as well. Common knowledge is not as in a different way. Tell me a little bit about how
prevalent as it once was. We see that people are you handle innovation.
not thinking outside the box when trying to solve
a particular problem.

Our goal at Andax is to re-educate the customer

PM One thing that helps with innovation
is listening to the customer. We both
have a piece of the puzzle. They have the
base on the lessons that have been learned concern, and we potentially have the know-how
from the past on how to solve a particular issue, on the application of materials, structures and
for example, how to deal with the leaking pad engineering in order to address that concern
mounted or overhead transformer. We feel and solve it. That is our focus – listening to the
that we are going to be able to provide not only customer. They are the experts in their field and
products, but also the methodology to keep we can apply our knowledge to provide them
utilities and their employees safe and give them with a cost-effective solution. For example, there
the proper tools to do the job right the first time. is a lot of new technology coming out, but the
Our goal is to assist the electric utilities and help majority of transformers out there still have
the line crews do their job. oil in them. For the safety of the line crews, we
provide a containment solution that allows them

AR One of the things I love about your

approach is that instead of selling a
product, you are selling a solution which starts
to work safely and efficiently and assure OSHA
and DOT compliance.

with the problem. You design the solution

around the problem. AR Leak repair is a very big issue in some
of the older transformers. If oil
can get out, then moisture can get in, which
You have a lot of different solutions, from large deteriorates the transformer. I believe the
scale to smaller scale. All of that must have future is bright for Andax because carbon-
been created through innovation, the ability to based oils are still used to fill most transformers,
 Transformer Technology May 2021 77

Issue 12

especially in North America. What other areas to go out for remediation or disposal after being
within the electrical system do your products taken down. If they hadn’t been leaking already,
and services apply to? these bushings usually start to leak when laid
down. Our product allows the utility workers to

PM We have a wide range of products

that address concerns for electric
utilities – from overhead pole mounts, through
hermetically seal those insulated bushings and
ship them out for disposal or storage.

pad mounts, all the way up to substation units – We also have portable containment pools that
and that makes for some very large containment help contain fluid in case of an accident during
bags. transport. A utility truck typically carries over
100 gallons of diesel fuel, 30 to 50 gallons of
One of our claims to fame has been the hydraulic fluid on the vehicle itself plus a
development of an insulator bushing sac that radiator. If it gets into an accident, this may
is designed to allow utility workers to lay down create a contamination issue since it usually
an insulator bushing when they take it out of happens over a storm drain. We provide instant
service. They may be saving it because it is still portable systems that a line crew can put
in good condition and they want to store it for a underneath a leak in less than three seconds to
couple of years, or it may be damaged and needs contain up to 150 gallons.

We provide portable containment pools that help contain fluid in case

Photo: Andax Industries

of an accident during transport.

78 FEATURE
INTERVIEW

AR I believe that the development of

these solutions goes back to your
vision and what makes you unique. If I were a
This issue signaled a need in the industry for
a change in the way transformers were being
contained while lifted and moved. We at
customer with not just one problem, but with Andax Industries listened to our customer base,
potential problems – how would you engineer a found out what their primary concerns were
solution for me? and realized that they needed a product that
would allow them to contain the transformer

PM It goes back to experience which

resides in the company. We have had
decades of service in the electric utility market
while lifting it in a completely OSHA compliant
manner, in accordance with the manufacturer's
lifting lugs. Using alternative methods such as
and insight into their concerns. Also, listening FIBCs makes for an unstable load, which can
to the customer and getting what their main potentially cause a failure or a fatality.
priorities are is very important.
We engineered a product that allows the utilities
Here is an example of a solution we recently to have complete access to the lifting lugs of the
designed to help solve the issue of lifting and transformer while moving it. We integrated
transporting pole-mount transformers. a duffle cover system that allows closing
up the transformer when taking it back to
In order to make shortcuts to the work methods the yard, making it weatherproof so it can
for lifting and moving pole-mount transformers, be stored outside while they are waiting for
some utilities were using bags with straps and the transformer repair company or disposal
flexible intermediate bulk containers (FIBCs), company to come and pick it up, without having
claiming that the process would be DOT and to necessarily store it inside. Engineering that
OSHA compliant. DOT is very specific about what solution also involved development of new
you can put into an FIBC, and a transformer is materials that were not available at the time.
not one of them. FIBCs are designed and tested Using high tech materials, we developed some
for materials such as soils, gravel or seeds. unique welding processes

Photo: Andax Industries

 We engineered a product that would allow our customers to contain
the transformer while lifting it by the manufacturer's lifting lugs and in
compliance with OSHA regulations.

to be able to manufacture the product. In the end, we do at Andax every day. We value family, being
we provided the utility with a compact product able to go home at the end of the day. We want
that could fit into a storage compartment on to do our part to make sure that our customers
a truck, enabling OSHA compliant lifting and can do that as well.
containment of the transformer.

AR This means your solution also affects

safety, which should be the number
AR We at Transformer Technology
appreciate the companies that
transfer experience and knowledge from one
one concern of every utility. Is there anything generation to the next. There is a lot of
else that you would like to share about Andax? generational change underway in our industry
and a lot of talk about how to bring young

PM We are a family-owned company, now

led by the second generation. We have
been in business for well over 40 years and we
people into our niche business. It will be
interesting to follow Andax as you introduce
the next generation of engineered products.
plan on being around for another 40, God willing. Patrick, thank you very much.
You only get to do that by providing quality
products, answering your customers’ concerns
and standing behind your product. That is what PM Thank you, Alan. I appreciate the
opportunity.
80 ADVERTORIAL

PTTX’S ARTISAN
VIBRATION AND SPIRIT OF
NOISE REDUCTION OF “DARING TO BE
TRANSFORMERS THE FIRST”
Having conducted multiple experimental research
studies on the factors that cause core vibration,
and following our “artisan spirit”, PTTX has put
forward solutions and guidance for the transformer
core industry that address a technological issue of
vibration and noise reduction. This paper introduces
the contributions made by PTTX in the industry –
optimization of silicon steel sheets processing
performance and core assembly parameters.
 Transformer Technology May 2021 81

Issue 12

In recent years, with the continuous expansion of power networks and urban
development, it is becoming more and more common for small and medium-
sized transformers to be installed in residential and commercial areas or other
application scenarios. These transformers generate noise pollution, affecting
the lives of residents nearby. Therefore, vibration and noise reduction have
become a special concern in the transformer industry and other supporting
industrial chains.

According to research studies, transformer noise is mainly caused by the vibration

of the transformer and its cooling system, and its intensity is associated with the
transformer capacity, silicon steel sheet materials, core structure, magnetic flux
density, and vibration performance of the cooling unit.

In fact, the vibration of transformers is mainly caused by core vibration, which

is brought about by the following two factors:

1. The first is the core vibration due to the magnetostriction of the silicon steel sheet;
2. The second is the longitudinal traction force caused by the distortion of the
magnetic line of force at the joint of iron core and the side thrust caused by
an uneven magnetic flux distribution in the iron core between silicon steel
sheets.

In view of these two main factors of influence, PTTX has concentrated our
efforts on optimizing the processing performance of silicon steel sheet
material and the assembly process of iron core, thus providing guidance and
making explorations for the technological transformation and environmental
Photo: PTTX

protection production in the transformer core industry.

82 ADVERTORIAL

Internal stress and magnetostriction reduction of the silicon steel sheet by

automatic and serialized production

PTTX cores are made of high-quality cold rolled grain-oriented silicon steel
sheets insulated by mineral oxide. In the actual application of the silicon steel
sheet, a lot of care is paid to the influences of the magnetostriction and magnetic
conductivity on the finished core products. Therefore, special measures are
taken to mitigate the influence of processing on the silicon steel sheet in terms
of stress characteristics, end flatness and thickness uniformity.

Magnetostriction is the root cause of core noise. In this regard, PTTX has
invested over $46.3 million to build a smart core factory able to maintain
constant temperature and humidity, which has become our country’s leading
demonstration center in the transformer core industry. In the factory, smart
stereoscopic warehouse logistics devices are used to provide full process
automation from the storage of electrical steel raw materials to the stacking of
finished core products. During the process, soft-contact procedures are used
to handle all electrical steel materials – this means that we do not use a crane
to lift products and our personnel is not involved in direct production or touches
the electrical steel during the entire process. This helps reduce the generation
of silicon steel sheet stress, thus ensuring the flatness and thickness uniformity
of the end surface and reducing the joint by stacking steel sheets one by one, all
of which results in noise reduction.
 Transformer Technology May 2021 83

Issue 12

In addition, the serial production mode of “edge-yoke–edge–yoke–column” for

the cut-to-length line of fully assembled cores denies the “two-step” mode of the
traditional core sheet production (upper/lower yoke, left/right/center column),
thus minimizing the issue of thickness difference of five columns existing in the
traditional core sheet production mode. While ensuring the uniform thickness
of silicon steel sheets, the slitting machine set is equipped with on-line iron loss
and thickness detectors, intelligent stereoscopic warehouse logistics equipment
and fully automated packaging line for fixed-size silicon steel sheets, which
further reduces the influence of human factors on the performance of silicon
steel sheets and helps achieve vibration reduction.

Compared to the traditional process, PTTX uses lean, serial, and smart auto-
matic production devices that reduce all the process coefficients by 5% in silicon
Photo: PTTX

steel raw materials, iron core manufacturing and assembly, helping us meet our
customer needs and reach product performances.
84 ADVERTORIAL

Assembly parameters re-defined based on multiple research

PTTX technology R&D team carried out the analysis of the relationship between
core assembly parameters and clamping force between silicon steel sheets,
as well as the mechanical analysis of the cores under pre-tightening torque
assembly conditions and binding process conditions. The results led to the
conclusion that the clamping force between iron core pieces can be controlled
by assembly parameters.

PTTX also conducted research on the influence of pre-tightening torque and

binding process on core vibration. The results showed that the core assembly
parameter is associated with the core capacity in a qualitative way. With the
increase of core capacity, the pre-tightening force of core assembly, assembly
torque and the number of binding strips increase as well, while the spacing of
binding bands decreases.

Based on the above findings, PTTX performed analytical statistics on the structural
parameters and assembly parameters of different types of cores produced.
Taking the dry-type transformer core as an example, the bolt torque and binding
Photo: PTTX

parameters were determined for various types of cores with capacities from
100 kVA to 800 kVA, 800 kVA to 2,000 kVA, and 2,000 kVA and above.
Transformer Technology May 2021 85

Issue 12

Through tests PTTX established that in the actual production, considering the
Contact us:
on-site equipment and materials in the workshop, adopting different assembly
parameters on corresponding cores with different capacities can effectively Wuxi Putian Iron Core Co., Ltd.
control the vibration and noise of the transformer core, improve the qualified E-mail: [email protected]
rate of products and reduce economic losses caused by rework, which is of Web: en.pttx.com
Tel: +86 510 83798338
great significance for achieving lean production of transformer core assembly
Fax: +86 510 83798338
and improving the production efficiency. Address: No.19 Jingxiang Rd,
Xishan District, Wuxi, China
Cooperation between universities and industry is a practice PTTX has always
PTTX Global Offices:
followed since its establishment. The company established a long-term coope-
Headquarters: Wuxi, China
rative laboratory with Xi’an Jiaotong University. Since 2016, the company has European Office: Frankfurt, Germany
played an exemplary role in the Study on Vibration and Noise of Core Process Middle East Office: Dubai, UAE
Holes, Research on Influence of Pieces Stacking Method on Core Noise of
Dry-type Transformer, Experimental and Simulation Study on Influence of Bolt
Tightening Sequence on Transformer Core, Experimental Study on Influence
of Bolt Torque on Transformer Core and Research on Influence of Assembly
Parameters on Transformer Core Vibration. The technological advancement
steps that have been studied and demonstrated can serve as the guidance for
the development of the industry.
86 FEATURE
INTERVIEW

John F. Darby
President of Niagara
Power Transformer

Investing in
relationships is
the key to our
success today and
fundamental to
Interview with John F. Darby

the vision of how

we are going to be
successful in the
future.
 Transformer Technology May 2021 87

Issue 12
Photo: Niagara Power Transformer
88 FEATURE
INTERVIEW

Following the recent rebranding of Niagara Transformer to Niagara Power

Transformer, and the start-up of a new arm of the business that will take
on repairs, we talked to the third-generation CEO, John Darby, about the
company’s history spanning nearly 100 years, their unique value proposition
and the vision for the future and the next generation.

Alan Ross: John, I am fascinated by companies built up around the Great Lakes and Niagara
that have been in business as long as Niagara Falls. My great uncle opened a business in
Power Transformer has. The company is nearly 1924, primarily to do repair work on motors,
100 years old, would that be fair to say? electromagnets and switchgear transformers for
that heavy industrial base that surrounded the
John F. Darby: Correct, we are approaching our Great Lakes.
Photo: Niagara Power Transformer

100th anniversary in 2024. Our history goes back

to 1920 when my great uncle emigrated from In the late 1920s, our industrial customers began
Guelph, Ontario into the Buffalo Metropolitan asking us to consider making new transformers
Area. Those who know the history of the to fill a market void. A few years later, in 1933,
industrial Great Lakes know that this was a we began making new industrial transformers,
very vibrant area of the country. There was a followed with an expansion ten years later into
tremendous amount of industrial infrastructure the utility-grade transformer market.
Transformer Technology May 2021 89

Issue 12

This dichotomy between making heavily

engineered industrial transformers and
sophisticated utility transformers that we do
JD As implied by our long-term perspective
in relationship building with our
customers, we are not transactional in any way
today has lasted almost 100 years. and our value proposition really underscores
that. The way we compete and live our

AR That is amazing. I remember we

joked about this: I usually say that in
my opinion the best transformers were made
Relationships matter mantra is accentuated by
four attributes that we see as a four-legged stool.

by a company called Westinghouse back in Number one, we think we have the best people
the 1970s. And you said they were not; they in the industry. It starts with our technical
were made by Niagara Transformer and they ability and our deep engineering. We love taking
just put the Westinghouse label on them. So on tough engineering challenges. In today's
in fact, for the last 15 years I have been saying world where so many manufacturers are very
the best transformers were made by Niagara focused on a specific product type, we are
Transformer back in the 1970s, which would just the opposite. We are what you call high
indicate that you have a vision for the future. mix, low volume. We will take on engineering
challenges that others, even much larger and

JD As you approach the 100th anniversary

with three generations leading the
company, you focus to a certain extent on your
much more complex organizations, do not
have the engineering bench for. That is how
we did so much private labelling, not only with
history. But obviously, you also focus on what Westinghouse and GE, but also with Square D
the next 100 years are going to look like. We over the years, because even though they were
are in an interesting apex between history and competitors some days, they were also very
future. It gives us a good opportunity to go back good customers other days.
and think about what our vision for the future
is and how we are going to interpret that in a We lead with quality in everything that we
rapidly changing business climate. do. You can do unique and tough engineering
challenges, but if you don’t put quality first, then
What is old is new again encapsulates our the engineering doesn't really matter. And we do
vision. The first utility customer that we started all that in very competitive lead times.
doing business with in 1943 is still an active
customer today, more than 75 years later. You We are responsible for the specification of those
might ask yourself how we achieved that long- transformers as well, selecting the suppliers
term partnership. We did it by living two words: and ensuring that the designs are in accordance
Relationships matter. with our requirements. We conduct design
reviews and perform all factory acceptance

The first utility customer that we tests. But the actual asset management and the
maintenance of the operation belongs to the
started doing business with in field staff and their management.

1943 is still an active customer

today, more than 75 years later. Being able to rotate people,
You might ask yourself how we taking on tough engineering
achieved that. We did it by living challenges, executing with
two words: Relationships matter. incredible quality and meeting
customer-defined lead times
Even in the digital age of Zoom, we feel that long- – these are the four attributes
term relationships really matter in our business
and our industry. We like what we call long-term that we compete on and that
marriages with our partners and our employees, encapsulate our Relationships
and certainly with our customers. We think
that investing in relationships is the key to our matter mantra.
success today and fundamental to the vision of
how we are going to be successful in the future. Obviously, we are sensitive to a lot of the
continuous process industries that we deal

AR That is the hallmark of excellence.

Another thing the customers look
for is a unique value proposition. What is it
with on the industrial side, such as steel,
electrochemical and mining. We operate 24
hours a day, seven days a week, 365 days a year
that Niagara Power Transformer brings to the so we can meet their schedule. Being able to
marketplace? rotate people, taking on tough engineering
90 FEATURE
INTERVIEW

challenges, executing with incredible quality In order to do what you have been doing
and meeting customer-defined lead times – for three generations, there had to be next-
these are the four attributes that we compete generation knowledge passed on. It is the
on and that encapsulate us. knowledge that you have, the knowledge that
your engineers have, and that the workers
If any of your readers have an engineering have. We are all facing the same problem:
Photo: Niagara Power Transformer

challenge that nobody else will take on, we How do you prepare the next generation?
likely will. How do you recruit them? After that, how do
you prepare them to handle the problems

AR Excellent, we will make sure our

member companies know that when
they have a need for an engineered-by-design
that are changing all the time? What is it that
you at Niagara do to be able to approach
this need for next-generation transfer of
solution. knowledge?
Transformer Technology May 2021 91

Issue 12

JD In our particular case, it all starts with

the leadership team. Our company
is not only almost 100 years old, but it is also
We have had employees who have been with us
for 30, 40, 50 years. We even had an employee of
55 years. We have less than 0.5% turnover, which
approaching the fourth generation transitioning in today's marketplace is absolutely unheard of.
into the business. My son, who is finishing We tend to be very selective and make decisions
his studies at Cornell University, has already looking at both sides of the employment. We
begun to plug in and learn the business from do a lot of training and engagement. And the
my point of view. But I can tell you, he looks at results, I think, speak for themselves, at least in
human resources and many other things very our business where we have a lot of long-term
differently than I do. It is reassuring, because I and committed employees. If you choose not to
did the same thing with my dad and he in turn be a transactional company, then you cannot be
did the same thing with my great uncle, who transactional in engaging your workforce either.
started the firm. It is a balancing act. Having an
equal measure of interest and aptitude in the
business like ours, I think is essential. AR Let’s talk a bit about the future. One
of the things that impresses me about
Niagara Power Transformer is that you are a
At the same time, we want to be open to being company based in a tough state. To do business
innovative. We want to be open to applying those in New York is not the easiest. You are an
fundamental business and engineering skills in American manufacturer, American-made,
new ways in a rapidly changing environment, but you are also a global supplier to a
not only for suppliers and customers, but also for marketplace which is fast becoming even more
employees. As we all have lived through this last global because the need for uniquely designed
year of significant and almost unbelievably quick solutions.
changes and challenges, the last year has really
underscored that. Take yourself a decade or two out. What do you
think is happening in our industry and how are
Preparing the next generation starts with you connecting with it?
being open to new innovative ideas, while
having the family at the core. That provides
the underpinning of how we approach not only
recruiting technical engineers from all over the
JD There are some very exciting things
going on that I think we as a company
can take advantage of. You pointed out that we
world, but also our local and national people do our manufacturing in the United States, but
that supply our direct labor talent. we do have design offices in China and Canada.
We are very familiar with taking advantages
We are very selective about who we hire, even of the expertise and inventory in other parts
in today's very competitive marketplace for of the world. But we convert that into our own
our top labor, and we underscore that with execution here in the U.S. It is a very exciting
family approach. Again, using that term long- time to take those strengths and channel
term marriage, we want to make sure that it is a them inwards, because there are a number of
partnership not just for the company, but also good interesting things that are going on.
for the employee. And we spend a tremendous
amount of time in the selection process. The electric vehicle market is just in its infancy.
That is going to be a tremendous, sustained
When somebody comes on board, we invest market opportunity for those in our space. Here
a lot in giving them numerous ownership in New York State, we are pushing for 100%
opportunities, from the most junior person renewable generation. I think there is still a lot
on the production floor, all the way through of runway left for renewables, particularly solar
engineering. That way they have a sense and battery storage. I believe that presents
that the family has their back, and they us some great opportunities, a bipartisan US
have a sense of ownership. We don't want infrastructure bill that is being discussed in
transactional employees. We want people who the Congress and the Senate led by our new
are long-term committed to quality and to our president, Mr. Biden. That obviously would be
success. And that is also what we look for in very exciting in terms of making investments in
customers. energy efficiency, infrastructure, redundancy,
and continuing to replace aging infrastructure

If any of your readers have that is long overdue.

an engineering challenge that Finally, I think that there is a sense of uncertainty

nobody else will take on, we among our North American customers, and
to some degree our European customers, who
likely will. are concerned about stretched supply chains,
92 FEATURE
INTERVIEW
 Transformer Technology May 2021 93

Issue 12

particularly those that have pursued 100% Asian- market will enhance and sustain our business
oriented supply chains. They are concerned going forward.
about access to products, technical support, and
to a quick and nimble response in case there is a We are excited about reaching 100 years in
problem. I think that demographic shift is never business and the fourth generation taking
going to go back to what it was in the 1950s, nor over. I think we are well positioned as a
do I think we want it to. company. We are healthy. We have invested
$45 million in our plant and equipment
here in Buffalo. We have one of the world's
We are excited about reaching most state-of-the-art facilities to take on the
100 years in business and the opportunities that the macro environment
is going to rapidly present. I am very excited
fourth generation taking over. about our prospects, and I believe that we
will balance our old school value system
There is a movement back to really taking a against the opportunities that are rapidly
hard look at redundancy and supply chains. evolving and presenting themselves to our
Certainly, Asian competitors offer a lot of market.
Photo: Niagara Power Transformer

cost advantages, but they are not a one-stop

solution to all potential problems that our
more sophisticated customers are recognizing.
I do think that shortening up supply chains and
AR What is old is new again. Thank you
for these fantastic insights, John.

providing redundancy to supply chains that

our focused outside of the North American JD Thank you very much Alan, we
appreciate the opportunity.
94 PROTECTION
AND CONTROL
COMMISSIONING

Protection and Control Commissioning:

Two Steps Forward, One Step Back
by Kenneth L’Esperance
and Jeff Hardin

Ken L’Esperance, P.E., has 40 years of expe-

rience in the energy industry. He has held
many upper-level engineering positions and
owned his own engineering consulting com-
pany from 1987 to 2014. He is currently the
director of the engineering services division
of RMS Energy Co., LLC. Ken has his NETA
Level IV certification from the International
Electric Testing Association (IETA) and is
certified on 138 kV, 69 kV, 13.8 kV, 4.16 kV,
480 V, and 208Y/120-volt systems, including
designing, testing, commissioning, and trou-
bleshooting. He holds a Bachelor of Science
in Electrical Engineering from Michigan
Technological University.

Jeff Hardin, electrical engineer, is a dedicated

technical leader with nearly 20 years of ex-
perience in the energy industry. He is expe-
rienced in utility design and operations and
has extensive training on NERC standards,
NETA testing standards and NFPA 70E
standards. He has held many senior level
positions for consulting firms and a utility,
and currently serves as vice president of sales
and estimating for RMS Energy Co., LLC.
Jeff has a Bachelor of Science in Electrical
Engineering from the University of Kentucky.
 Transformer Technology May 2021 95

Issue 12

THE ENERGY INDUSTRY IS MOVING FORWARD AT WARP SPEED

ON TECHNOLOGICAL AND INFRASTRUCTURE CHANGES.
YET, THE PUSH FOR THESE ADVANCEMENTS HAS CREATED
A MAJOR GAP AMONG THE RESOURCES THAT PROVIDE
PROTECTION AND CONTROL COMMISSIONING SERVICES ON
POWER SYSTEMS, WHICH BOILS DOWN TO LACK OF TRAINING
AND SYSTEM KNOWLEDGE.
Photo: RMS Energy
96 PROTECTION
AND CONTROL
COMMISSIONING

During the past decade, the These protective relays work between The Reliability of
energy industry has undergone normal and expected operating Electromechanical Relays
major transformations in conditions and the inevitable system
infrastructure redevelopment faults that come with any power There are myriad faults that can
and the introduction of game- distribution system. The tried-and- be detected by electromechanical
changing advancements in true electromechanical relays detect relays. Over voltage, under voltage,
power systems technology. power system conditions and provide differential faults and distance
With these major leaps a measured and appropriate fault sensing for line protection are just
forward, the important process response with repeatability and a few that will generate the fault
of protection and control reliability during decades of in-service condition necessary for the relays
commissioning, which verifies, time. Electromechanical relays are still to take action. ANSI and IEEE have
documents and places into considered to be amazing technology, standardized relay function codes
service newly installed or and those who invented them are such as "50/51," which speak the
retrofitted electrical power responsible for the kind of reliability power engineers’ language for
equipment and systems, has and safety that our power systems instantaneous overcurrent (50) and
become increasingly critical. enjoy today. time overcurrent (51), signaling a

Yet, the push for these advancements

has created something of an
unfortunate and unforeseen gap in
the industry. Many qualified personnel
who truly understand protection and
control commissioning are becoming
harder to find due to retirement of the
aging workforce and a smaller number
of young professionals entering
to replace them. This reduction in
experience and knowledge in some
quarters occurred as the technology
vastly improved, while training and
certification programs for technicians
substantially lagged behind. In fact,
what used to take seven to 10 years of
intense education, mentoring and final
certification have been compressed
into just a few years as a way to catch
up. This has created a production line
of less qualified technicians who may
not possess the required knowledge or
comprehension of the commissioning
process and the very equipment that
needs inspection. Deep understanding
of protection and control standards,
NERC, new technologies, a
reconfigured power grid system and
the equipment itself, are requirements
among technicians necessary to
be proficient and accurate in their
commissioning work.

One simply needs to look at the new

processes and advances in relay
equipment to get a view of how things
have changed in commissioning
services. The baseline of protection
and control standards has always
revolved around electromechanical
relays, the true marvels of technology
that are as old and dependable as
those who invented or improved
upon them, like Tesla and Edison.
 Transformer Technology May 2021 97

Issue 12

command to trip a circuit breaker only one particular element. such as opening a circuit breaker
when line current becomes excessive, This limited functionality simply or tripping a lockout device when
avoiding severe overheating or even requires that far too many relays must needed.
fire. perform the fault functions needed to
ensure that today’s more advanced The bottom line is that power
This dependable relay technology and complex power distribution systems can run a long time without
hasn’t changed much, as it has systems continue operating at peak a fault ever occurring. But with power
been the foundational workhorse efficiency. systems, an industry axiom is that
for decades; that is, until the advent trouble is always brewing. When the
of solid state and micro-processor- Another drawback of electromechan- time comes for a failure, and it will
based relays. With all the change ical relays is that they require periodic come, a dependable relay or series
in the power industry, the major testing and calibration. These relays of relays are necessary in order to
downside of electromechanical relays depend upon mechanical motion, accurately detect the fault, act upon it,
has become the limitations of its so maintenance on the relays and perform the function needed that
inherent single-element functionality, themselves is required to produce avoids system damage and costly
which is designed to detect faults for accurate and reliable core operations, outages.

DEEP UNDERSTANDING OF PROTECTION AND CONTROL

STANDARDS, NERC, NEW TECHNOLOGIES, A RECONFIGURED
POWER GRID SYSTEM AND THE EQUIPMENT ITSELF, ARE
REQUIREMENTS AMONG TECHNICIANS NECESSARY TO BE
PROFICIENT AND ACCURATE IN THEIR COMMISSIONING
WORK.
Photo: RMS Energy
98 PROTECTION
AND CONTROL
COMMISSIONING

Solid State and Microprocessor basket.” Of course, with so many operating conditions, and selectivity
Relays functions embedded into a single needed to prioritize response between
relay, a rare failure of such equipment protective elements and upstream
The creation of solid-state relays, can produce wider scale and less and downstream devices. These
which don’t rely on mechanical contained damage compared to microprocessor relay protocols are
motion, was a step forward in electromechanical relays. major advantages within today’s
replacing the mechanical motion of its complex and more advanced power
predecessor. But the industry did not Microprocessor relays include a system solutions.
dwell too long on solid-state relays, flexible selection of parameters that
because they also required calibration make them an easier application in The complex digital algorithms needed
and maintenance. the power system, and the provision to realize these multi-functional
of more accurate data. There are benefits now require another level of
It was not until the microprocessor three important parameters available understanding for the technician to
became more affordable and in such relays, including response attain. These attributes, along with the
dependable that the industry characteristics, sensitivity, and programmable logic elements and the
witnessed bigger leaps forward in selectivity. complex communication technologies
protection and control. These digital within microprocessor relays, allow
marvels leave the analog world Response characteristics are now a for intricate networking and reporting
behind, with their ability to rely on family of curves allowing for a variety capabilities and demand a working
more accurate and sustainable of customized characteristics that knowledge in many technical realms.
digital technology that perform multi- can be monitored and measured.
function protection protocols, putting The selection of parameters can Integration of supervisory control and
the proverbial “many eggs into one provide sensitivity for a wide range of data acquisition (SCADA) also creates

OPERATING A TEST SET IS VERY DIFFERENT FROM THE

ESSENTIAL ASPECTS OF UNDERSTANDING WHAT THE TEST
SET IS ACTUALLY DOING WHILE PERFORMING A TEST ON A
PARTICULAR RELAY OR RELAY ELEMENT.
 Transformer Technology May 2021 99

Issue 12

a large pipeline of collected data. technicians must test not only the ensure the plan is both solid and valid.
Operators are no longer flying blind relays involved, but also the system This authentication of commissioning
when such integration provides critical in which they reside. This is often plans comes with comprehensive
data on operating currents, fault where industry resources lag, knowledge and deep understanding
oscillography, power factor, min/max because operating a test set is very of the relays and how they relate to
data and other critical parameters. different from the essential aspects complex power systems. Without this
of understanding what the test set is knowledge set, the accuracy of the test
Required in any successful actually doing while performing a test is relying on the test itself, with little to
commissioning effort is complex on a particular relay or relay element. no input from the technician to guide
and up-to-date testing equipment, the analysis toward a comprehensive
including multiple independently Technicians who are new to the field or and successful conclusion of the
controlled voltage and current have not had the proper indoctrination commissioning project.
channels; independent phase into the inner workings of a modern
relationship control of all channels; commissioning process will be Understanding Elements of Proper
and accurate reporting of results as challenged to create an accurate and Commissioning
the test is being conducted. positive outcome in even the most
basic commissioning projects. To conduct proper commissioning
Starting with a Good Plan For example, while a relay test system on any power system, a full
(RTS) can be run for an overcurrent understanding of the following
A good commissioning plan begins test, a complex power scheme that elements is essential for a positive
with the realization of the benefits of includes differential protection, energy and accurate outcome:
the power systems in play. To realize calculations, and other factors needs to
reliability and predicted response, clear through a comprehensive plan to Zones of Protection

Current Transformer Characteristics

a. Saturation curves
b. Accuracy class considerations
c. System burden considerations

Breaker response and timing

Redundancy for enhanced reliability

Functional testing – programmable

logic elements

Trip equations

SCADA systems
a. Communications capabilities
b. Fiber networks
c. Site DSC considerations

A solid commissioning plan will

include a physical checkout from
point to point. Testing of wiring and
its configurations is the first step in
any good plan, to ensure wiring is
properly installed. Today, utilities have
control houses prebuilt offsite and
subsequently dropped into place, a
major step in efficiency for both time
and money. However, this is where
assumptions get made – that wiring
is predestined for proper installation.
But nothing could be further from
the truth. Wiring is where things
go wrong both early and often, and
not checking every single point and
Photo: RMS Energy

connection upfront will substantially

hamper any proper commissioning
plan.
100 PROTECTION
AND CONTROL
COMMISSIONING

Conclusion

Any industry resource that conducts

thorough and accurate protection
and control commissioning and
adheres to proper protection and
control standards will employ
technicians and other experts who
have the proper years of experience
to accommodate for the more
complex power systems we have
today. Commissioning companies
must not only recruit the right people
and pay them appropriately, but
also invest in ongoing development
and training to ensure every
commissioning job takes on the best
and most accurate commissioning
approach.

Ensuring the proper outcome of a

commissioning project has various
aspects that include the right testing
equipment and plan, coupled with
technicians who have the experience
and knowledge to apply to ensure
protection and control standards are
ANY INDUSTRY RESOURCE THAT CONDUCTS THOROUGH AND achieved. It’s only a matter of time
when the industry catches up and
ACCURATE PROTECTION AND CONTROL COMMISSIONING starts to churn out more qualified
AND ADHERES TO PROPER PROTECTION AND CONTROL technical personnel; but until that
time, choosing a commissioning
STANDARDS WILL EMPLOY TECHNICIANS AND OTHER partner based on their technicians’
EXPERTS WHO HAVE THE PROPER YEARS OF EXPERIENCE TO expertise and knowledge base is a
Photo: RMS Energy

critical aspect to ensuring the safety

ACCOMMODATE FOR THE MORE COMPLEX POWER SYSTEMS and reliability of modern complex
WE HAVE TODAY. power systems.
Transformer Technology May 2021 101

Issue 12

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