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Figure 10: Practical core constructions using cold-rolled silicon steel and
mitre joints.

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Figure 11: Typical core loss values at 50Hz.

1 – conventional grade, 0.3mm

2 – HI-B grade, 0.23mm
3 – HI-B grade laser irradiated, 0.23mm
4 – amorphous metal compound, 0.13mm
[Ref. CIGRE Paper 12-09,1986]

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2.3 Winding Arrangements and Insulation

In most low voltage power transformers (including 11kV

windings in large transformers) the winding turns are wound
on a base cylinder over spacers to form one or more layers,
thus giving a helical winding coil configuration.

At higher voltages the conductors are transposed to form

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discs of perhaps ten turns each. These may be wound in pairs
and stacked at the assembly stage or wound as a continuous

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winding (see Figure 8(a), 12, 13 and 15). Conventionally
these operations are carried out with the mandrel horizontal
but modern techniques allow vertical winding, thus avoiding
the turning through 90o on completion.
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The Pancake Coils used in Shell Type windings are wound
separately and are of larger dimensions than the equivalent
Core-Type Discs. The Shell form is limited to a few
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manufacturers.

Possible winding configurations are given in Figures 12 and

13, including the insulation arrangements. The usual
configuration for delta windings, e.g. 33 and 66kV is
indicated in Figure 12 (a) (ii).

A major factor in the design of high voltage windings is to

ensure they will withstand lightning impulses as well as
power frequency over-voltages. The relevant test levels for
Um < 300kV are given in Figure 4. The design of windings to
withstand the electric stresses will be discussed with
reference to Figures 15 and 16.
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Figure 12: Layout of windings for core and shell types.

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Figure 13:
Insulating materials and typical locations as used
in power transformers

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Figure 14: Impulse voltage distributions.

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Figure 15a
Winding designs for improvement of voltage distributions

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