Transformer Engineering Case Studies
Operational challenges
solved with engineering precision
Explore how Weidmann’s engineering expertise solves complex transformer challenges. These case studies highlight real-world scenarios where data, simulation, and precision design come together to improve reliability, extend service life, and enhance performance across global transformer applications.
Our transformer engineering case studies
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Converter transformer load losses
Locally the LV-winding had very high losses, causing conductors to overheat with consequent turn to turn failure. Because of the small amount of cellulose being degraded, the Dissolved Gas Analyses (DGA) may not alert the end user about the imminent failure.
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GSU transformer upgrade – tank hot spot
Significant localized tank cover flange heating had been observed by infrared scan on a 185 MVA GSU transformer, compromising the aimed upgrading (by 23%) of the name plate MVA rating. The enhanced oil cooling could not cope with the localized tank hot spot.
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Forces under double inrush condition
Axial forces on HV winding under inrush condition need to be evaluated, taking into account residual core magnetization and the presence of a rectifier transformer connected to the MV. The regulating transformer has to face double inrush currents (its own and the one of the rectifier transformer).
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Top lead exit thermal analysis
Lead exits in copper with or without slits have been simulated in order to determine the best design from a thermal point of view.
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LV losses
Very high load losses in the LV winding have been observed. The LV winding was built following the “classical” design rules for the transposition of conductors in parallel. However, only simulations can verify the validity of the “classical solution” for each specific design.
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Tank temperature rise verification
The couples magnetic-thermal simulation of a rectifier transformer has been performed. The presence of a complex LV busbars system makes the localization of the hot spots not trivial.
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Dielectric measurement in a wind farm
After relatively little time being installed, a significant number of tower transformers have suffered failures. Initially these faults seemed to have no justification apart of a defect of production or design of the transformers, as for example, the current flow was almost always less than nominal.
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Enhanced thermal class insulation for increased transformer performance
As a leading transformer manufacturer in the Middle East, UTEC addresses the region’s specific demands, including wide temperature swings and variable loads, by improving insulation to reduce thermal, electrical, and mechanical stress.
