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Session
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DEVELOPMENT OF INDIAS FIRST 1200 KV TRANSFORMER FOR

TESTING OF LARGE RATING 800 KV SHUNT REACTORS

R. K. Singh*

S. K. Gupta

J. S. Kuntia

R. K. Tiwari

Transformer Engineering Division,

Bharat Heavy Electricals Limited, Bhopal, India

1. Introduction
1200 kV UHVAC system is being envisaged as next
transmissionvoltagetomeetthefuturehighpowertransfer
requirement in India. Development of 1200 kV UHVAC
Transformers in India is taking into shape with BHEL first
to develop 1200 kV Transformer. BHEL is progressing
step by step in basic issues for development through
development and improvement of design analysis tools
and particularly insulation design technology required for
such ultra high voltage Transformers. The experience in
development of 1200 kV Transformer for testing purpose
is being further extended for development of 333 MVA,
1150/400/33 kV single phase Auto Transformer, which
is also under development at BHEL, for Indias first 1200
kV Experimental Test Station of Powergrid India at BINA
for field studies and trials.
800 KV AC transmission line has already been
commercially established in the country for bulk power
evacuation. 800 KV Transformers, Shunt Reactors
and Instrument Transformers have been developed.
Power Transformers, Shunt Reactors and Instrument
Transformers are vital equipments in the complex UHV
transmission system.
Testing of 800 KV Shunt Reactors necessitates higher
voltage rating testing Transformer.
Although for testing transformer the transient voltage
requirement similar to outdoor field transformer is
not envisaged , however in order to have the hands on
experience of manufacturing and testing of 1200 KV
transformer, impulse voltage calculation in the windings
of transformer has been introduced to ascertain the
withstand capability as per test requirement in the
specification. This leads to refinement and establishment
of design analysis software for transient voltage test
requirement for 1200 KV UHVAC Transformers. Other
design considerations viz. short circuit forces ability and
heat transfer characteristics are also evaluated. Extremely
high voltage level and large capacity of UHV Transformer
lead to more technical difficulty and innovative technology
in main insulation design, lead exit design, core clamp

plate and tank structure design, transportation etc.

needed. Presently very few manufacturer worldwide have
made power transformers for 1200 KV system voltage.
The major aspects considered and challenges faced
during design and engineering of 1200 KV Transformer
are discussed in this paper.

2. Transformers Parameter
This transformer will be installed in a limited space and
will be employed for testing of 800 KV 1- phase Shunt
Reactor. Hence it is a single-phase transformer. Due
to transport limitation and available technology, UHV
Transformers are generally single phase. The 1200 KV
class transformers in former Soviet Union, Italy, Japan
and China are all single phase. As only one voltage level
is desired, voltage regulation of 1200 kV is not required
hence no tapping has been specified.
Important specification parameter features are given in
table I.
TABLE I
Specification features of 1200 kV Transformer
Rated Power (MVA) HV/LV
Rated no load voltage (kV) HV/
LV
Rated Frequency & no. of phase
% Impedance HV-LV
Insulation Level

180/180
1200/3/138/3

i) Separate source power

frequency voltage withstand
HV/LV

70/275 kVrms

ii) Induced over voltage

withstand with PD meas. HV/LV
iii) PD level at 1040 kV
(1.5Um/3) for 60 sec.
iv) Full wave Lightning impulse
voltage HV/LV
v) Switching impulse voltage HV/
LV

50 Hz, 1
12%10% tol.

1040/275kVrms
<100 pC
2300/550 kVp
1675/ - kVp

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Session - II

Design - II

Type of Cooling, Cooling

Equipment
Top Oil/ Winding by resistance
Tempr. rises 0C

OFAF, 4x33%
OFAF coolers
50/ 55

3. Design
Challenges in the design of this 1200 kV ransformer
is mainly related to 1200 kV insulation technology.
The development of reliable 1200 KV Transformer
requires a well developed and proven design
concept. Reliable and proven design for extra high
voltage and high power rating require good basic
and theoretical understanding regarding physics of
transformer and extensive experience in transformer
design, manufacturing, testing and field trial.
The design concept used by us is based on technical
knowledge acquired over 40 years of experience in
transformer design and development ranging from
1 MVA to power transformers up to 500 MVA 800
KV class 1-phase auto transformer (forming a bank
of 1500 MVA), HVDC converter transformer, Shunt
Reactors up to 80 MVAR, 800 kV class 1-phase
(forming a bank of 240 MVAR) etc. Prototype
manufacturing of 800 kV equipments is under
progress.
Computer aided design tools are extensively
employed in the following areas:
i) Optimization of basic parameters like core
dimensions, magnetic flux in core, number of
turns in the windings, current density in windings,
cable dimensions in the windings etc.
ii) Study and analysis
electromagnetic fields.

of

electrostatic

and

iii) Simulation of windings to study voltage distribution

under transient over voltages like lightning and
switching over voltages.
iv) Evaluation of electro-dynamic forces in windings
and on various parts during external short circuit.
v) Thermal performance and analysis.
Transformer insulation is subjected to the
continuous influence of operating voltage and over
voltages. The over-voltages may consist of lightning
over-voltages (aperiodic surges-duration from ones
to tens of sec), switching over-voltages (oscillation
surges with considerable attenuation-duration up
to several thousand sec) and temporary overvoltages at or near power frequency (voltage rises
lasting up to several minutes). Dielectric strength
of transformer should be sufficient to withstand
dielectric stresses due to these over voltages.

During insulation design of transformer all such

over-voltages are converted into equivalent design
insulation level (DIL) for calculation of major
insulation distances. Clearances between windings
and other major insulation distances are calculated
based on our empirical formulae for worst DIL
condition.
The basic parameters of this 1200 KV Transformer
like core frame dimensions, magnetic flux in core,
number of turns in windings, current density
in windings, conductors dimensions, winding
dimensions etc. has been optimized with the state
of the art computer software.
Low voltage to high voltage winding insulation,
windings end insulations, disc to disc insulation
and between turns insulation are most critical and
complex part of transformer insulation arrangement.
Di-electric design calls for much more controlled
stress distribution. Sub-divided oil-barrier insulation
system is used between the windings and between
the winding ends and the yoke (major insulation).
This type of major insulation is reliable and has
proved effective during the long term operational
experience. In HV winding sufficient disc to disc
insulation and insulation paper covering on turns
has been kept to withstand operating voltages and
over voltage stresses as decided by DIL.
Sub-divided oil-barrier insulation structure is also
envisaged for the 1200 kV lead exit to optimise
insulation distance and obtain sufficient uniform
voltage distribution.
After optimization of design important technical
performance parameters like no load losses, load
losses, short circuit forces, winding temperature
gradients etc. has been calculated by the computer
software.
Verification of withstand capability of transformer
for following areas has been done at the design
stage

a) Electric strength of insulation of transformer

The calculation of electric fields and strength of
main insulation are performed for representative
areas such as top, middle and bottom areas of
windings and along the windings.

b) Short circuit withstand

Magnetic flux distribution in different parts of
windings and transformer parts and corresponding
mechanical forces and withstand capability of
windings, clamping structures etc.

Session - II

Paper 1

c) Thermal design
Thermal distribution in windings, core clamping
structures, tank wall etc. are obtained and windings
temperature gradients are calculated. The cooling
performance is made more effective by directed oil
flow washer and oil guiding rings in the windings.
The oil speed in the winding ducts kept within limits
so that it must not lead to any electrostatic charging
effects.

4. Investigation of Insulation Electrical

Strength
The insulation arrangement is determined by all
dielectric test requirements and voltage conditions
during operation. Tests by power frequency
voltages up to 1.5 Um and of one hour duration are
intended for checking partial discharge behaviour
of insulation under continuous working voltage over
a designed life and over voltage applications[1].
For the calculation of transient voltage stresses in
windings a special sophisticated computer software
has been used. For all specified voltage conditions
the stresses have been calculated at each and every
location of windings. The withstand capability has
been checked and main insulation configuration for
the transformer has been designed. The dielectric
strength of winding edge insulation is determined by
oil spacing between the rounded edge of the static
ring and barrier adjacent to the winding. Electrostatic
field distribution and stresses have been analyzed
by 2D field plots. High voltage connections (1200
KV line lead) outside the windings are also verified
by field plots to check electrical clearances. Fig.1
shows the schematic diagram of the transformer
windings. It can be seen that the HV winding is split
in two parts. The major part is with two group design
and minor portion with helical design placed close
to the core. The LV winding appears in between the
two portions of HV winding. In order to carry out
impulse voltage distribution in HV winding, which is
considered more critical compared to LV winding, an
appropriate number of sections have been chosen.
The inductances and capacitances associated with
these sections have been calculated and electric
network has been derived. The network is solved
using in-house developed programme to compute
voltage in any portion of the HV winding [2]. Fig.2
shows the impulse voltage distribution in the HV
winding of transformer at selected nodes.

Fig. 1: Schematic Diagram of 1200 kV Transformer

Fig. 2 : Impulse Voltage Distribution in HV Winding

Fig. 3: 1200 kV Transformer. Impulse Level=2300 kVp.

Maximum Stress close to HV Winding

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Session - II

Design - II

MVA 420 KV class single phase generator transformer

(forming a bank of 600 MVA). Experience of these tests
has given very good base for establishment of proven
calculation methodology for short circuit forces. Short
circuit withstand capability of 1200 KV transformer
is analyzed with the help of computer softwares. The
transformer is carefully designed and ampere-turn
balancing is done. Epoxy bonded CTC conductor
and proof stress copper conductors are used to have
mechanical strength, rigidity and stability.

6. Conclusion
UHVAC Transformers are critical part of transmission
and therefore needs high reliability. Successful design,
manufacturing, testing and installation of this 1200 KV
transformer shall establish a milestone for technology
development in India in the field of Ultra High Voltage
equipments for Ultra High Voltage transmission system
and future development of 1200 kV Transformers and
Shunt Reactors for commercial installation.

7. Acknowledgement
Fig. 4 : Power Frequency Field Distribution for 1178 kVrms
(Symmentrical Half Winding considered)

5. Short Circuit Electro Dynamic Forces

Strength
High fault currents during system short circuits with
consequent higher magnitudes of electrodynamic
forces in high power UHV transformer required an
adequate mechanical design. BHEL already performed
full scale short circuit tests on more than 20 nos. high
rating power transformers including two designs of 200

The authors are thankful to BHEL Management for

permission to publish this paper.
Reference
1) LI Guang-fan et al, Type selection and test technology of
UHV transformers, IEC/CIGRE UHV Symposium Beijing
July 2007.
2) Gupta, S. C. & Singh, B. P., Determination of impulse
voltage distribution in windings of large power
transformers, Electric Power Systems Research, pp. 183189, 1992.
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