What is a medium-voltage transformer?

A medium-voltage distribution transformer or service transformer is a transformer type

that provides the final voltage transformation in the electric power distribution system,
stepping down the voltage used in the distribution lines to the level used by the
customer.

Practical levels of voltage are often referred to as medium voltage, meaning the
incoming voltage to the transformer is on the order of 5 kV to 35 kV. Some distribution
voltages may exceed 35 kV and would be considered high voltage, but most of the
distribution system is within the medium-voltage range. Modern distribution transformers
are manufactured in accordance with many standards, most notably by IEEE (Institute
of Electrical and Electronics Engineers) and IEC (International Electrotechnical
Commission).

In the United States, the features and functionality of most distribution transformers fall
under IEEE standard C57.12.00 (Standard General Requirements for Liquid-Immersed
Distribution Power and Regulating Transformers), however, there are a multitude of
standards that apply to specific types and applications of transformers including
substation type, compartmental padmount type, single-phase pole mounted
transformers, generator duty transformers, high-temperature transformers, and many
more.

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fundamentals: Types | Ratings | Arrangement | Protection | Monitoring | Production
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What are the types of medium-voltage distribution

transformers?
Substation transformer

The substation transformer is the heart of the electrical substation. This transformer
changes the relationship between the incoming voltage and current and the outgoing
voltage and current. Substation transformers are rated by their primary and secondary
voltage relationship and their power carrying capability. For example, a typical
substation transformer would be rated 15 kV, 25 kV, 35 kV or 46 kV on the primary at a
power rating of about 5-20 MVA. The secondary or low voltage can be 15 kV down to 5
kV or even less than 600 V. Substation-style transformer design and functionality is
dictated by IEEE standards C57.12.00 and C57.12.36. These type transformers consist
of a core and coils immersed in oil or dielectric fluid in a steel tank. The oil or fluid
serves both as an insulator and as a coolant to keep the core at reliable operating
temperatures. Substation units are easily identified by their exposed bushings, gauges,
panels or monitoring equipment and are typically located behind a fence or with a
restricted area.
Three-phase pad-mounted transformer

A three-phase pad-mounted transformer is a ground-mounted electric power distribution

transformer in a locked steel cabinet mounted on a concrete pad. These types of
transformers are generally smaller (45 – 5000 kVA) but can be produced at larger
station sizes as well (up to 10 MVA). These are installed in locations near or within
public areas. The compartmental, tamper-resistant pad-mounted transformer design
makes it ideal for applications where public safety is imperative. The overall design and
functionality is dictated by IEEE standard C57.12.34, while the tamper-resistant nature
of the pad-mount transformer is dictated by IEEE standard C57.12.28 or C57.12.29 for
coastal areas.

Single-phase pad-mounted transformer

Single-phase pad-mounted transformers are commonly installed in residential areas

and are intended for power distribution through underground systems. Features and
layout of single-phase pad-mounted transformers can be found in IEEE standard
C57.12.38. These transformers are typically rated 10-167 kVA (up to 250 kVA per
scope of IEEE standards) and up to 35 kV on the primary.
Single-phase pole-mounted transformer

Single-phase pole-mounted transformers are frequently installed in residential areas but

can also be common for small businesses requiring three-phase power from a bank.
These transformers can vary in size from as small as 5 kVA to as large as 500 kVA,
with voltages up to 35 kV line-to-line. Pole-mounted transformer banks allow three
single phase units to be connected to a three-phase system to distribute through
overhead lines. Winding connection styles, mounting standards, and overall layout and
functionality is held to IEEE standard C57.12.20.

Ventilated dry-type transformer

Ventilated dry-type transformers are voltage changing (step-up or step-down) or

isolation devices that are air-cooled rather than liquid-cooled. The transformer case is
ventilated to allow air to flow and cool the coil(s). For outdoor operations, a dry-type
transformer enclosure will usually have louvers for ventilation. Dry-type
transformers adhere to IEEE standards C57.12.01 and C57.12.91, with ratings from 15
kVA to 30 MVA, and primary voltages above 601 V.
What are the types of transformer ratings?
Ratings are the fundamental blueprint for describing the performance characteristics
and style of a transformer.

Standard ratings for types of distribution transformers are found in IEEE product
standards including the following:

• IEEE Std C57.12.20 (Overhead Type)

• IEEE Std C57.12.34 (Three-Phase Pad-Mounted Compartmental)
• IEEE Std C57.12.36 (Distribution Substation Transformers)
• IEEE Std C57.12.38 (Single-Phase Pad-Mounted)

Key ratings defined

kVA: Transformers are rated in kilo-volt-amperes (kVA). kVA is used to express a

transformer rating because not all transformer loads are purely resistive. The resistive
component consumes power that is measured in watts, whereas the reactive
component consumes power measured in VARs. The vector sum of these two loads is
the total load, VA or kVA
Voltage: The voltage designation defines both the way a transformer may be applied to
a system and the transformer design. IEEE Std C57.12.00 defines the designation of
voltage ratings of single and three-phase transformers.

Voltage designation examples:

Three-phase

• 12470Y/7200 V
• 12470GY/7200 V
• 7200 V Delta

Single-phase

• 7200/12470Y V
• 12470GY/7200 V
• 7200 V Delta

Temperature rise: A kVA rating is based on the current that the transformer can carry
without exceeding its temperature rise rating. The more heavily loaded a transformer
becomes, the higher its internal temperature gets. The maximum temperature rise that
the transformer can withstand without abnormal loss of life is governed by customer
specifications or by IEEE standards

Fluid: For over a century, transformers have utilized conventional mineral oil as a
dielectric coolant. It offers reasonable cost with proven, reliable, long-term
performance. Maintenance procedures are well established and used mineral oil can
usually be reconditioned for use by filtering and degassing. The fire point of mineral oil
is approx. 155 oC, while the fire point of a less-flammable fluid is above 300 oC. This
makes less flammable fluids, such as Envirotemp FR3, the better alternative for
installations indoors, on top of buildings or in high-pedestrian traffic areas. Use of less-
flammable fluids is recognized as a method of reducing fire hazard, indoors and
outdoors, by the National Electrical Cod (NFPA 70) and the National Electric Safety
Code

Key ratings
kilo-volt-amperes (kVA)
Primary voltage
Secondary voltage
Basic Insulation Level (BIL)
Impedance
Frequency
Cooling type
Temperature rise
Cooling: The heat that the core/coil assembly generates must be dissipated to the air
via the tank and cooling fins. The more surface area on the tank, the more heat that
may be dissipated. Adding cooling fins is an option for increasing surface area without a
significant increase in oil quantity, keeping costs lower than increasing the size of the
tank itself. Every liquid filled transformer is identified with a four-letter code describing
the transformer cooling method. IEEE C57.12.00 defines cooling methods, or the
cooling class, for distribution transformers.

• First letter: Internal cooling medium in contact with the windings

o O Insulating liquid with fire point ≤ 300 oC (see ASTM D92)12
o K Insulating liquid with fire point > 300 oC
o L Insulating liquid with no measurable fire point
• Second letter: Circulation mechanism for internal cooling medium
o N Natural convection flow through cooling equipment and in windings
o F Forced circulation through cooling equipment (i.e., coolant pumps),
natural convection flow in windings (also called non-directed flow)
 o D Forced circulation through cooling equipment, directed from the cooling
equipment into at least the main windings (also called directed flow)

• Third letter: External cooling medium

o A Air
o W Water
• Fourth letter: Circulation mechanism for external cooling medium
o N Natural convection
o F Forced circulation [fans (air cooling), pumps (water cooling)]
• Basic Insulation Level (BIL): The amount of insulation built into the unit to
withstand an impulse voltage
• Impedance: The vector sum of the inherent resistance and reactance of the
transformer. Transformer impedance determines how much available fault current
is present at the transformer secondary terminals
• Frequency: Typically, 50 or 60 Hertz. The transformer will be designed for the
system frequency

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What is involved in a transformer arrangement?

The arrangement of a transformer is defined by the type of components such as live-

front vs deadfront, location of components (loop vs radial feed system), indoors vs
outdoors, throat vs flange (substations). All of them are based on the application and
following IEEE standards such as C57.12.36 (substations), C57.12.34 (three-phase
compartmental type), C57.12.38 (single-phase padmount), and C57.12.20 (single-
phase overhead type). Many features of modern distribution transformers are centered
around the form and fit of the unit within a facility, specific area or region, or by
application. The design and layout of the transformer can link to particular feature sets
or requirements such as the tamper-resistant nature of a compartmental-type pad-
mount transformer.

Live-front vs dead-front primary bushings

There are two distinct choices for high-voltage connection of a transformers.

Live-front (Porcelain type): The voltage-carrying parts are exposed. Livefront

terminations have high voltage connectors, arresters, or fuses are exposed to the
operator after cabinet has been opened.

Dead-front (separable insulated connector type): Often referred to as deadfront

bushings. Safety is enhanced as there are no current-carrying parts exposed to the
operator.

Deadfront connectors fall into two main categories: loadbreak and deadbreak.

• Types of dead-front connectors

o IEEE 386 – Standard for separable insulated connector systems
o 200 A load-break
 15 and 25 kV
o 35 kV (2 standards)
 Large Interface
 Small Interface
o 600 A and 900 A dead-break
 15, 25 and 35 kV
• Connectors and configurations
o Configurations (bushing layout)

 Radial feed
 Loop feed
 Bushing layout options
 ANSI/IEEE C57.12.34 defines bushing spacing, bushing
height, termination compartment size
 Minimum
 Specific
System configurations

There are two basic types of distribution system configurations:

• Radial system
• Loop system

These system configurations can be used alone or in combination with one another on
different portions of the distribution system. Complex combinations are sometimes
referred to as networks consisting of radial and loop branches with multiple sources of
supply.

Radial system

A radial system employs one dedicated transformer to serve a customer or group of

customers. The drawback is the fact that if there is a failure in the distribution line all of
the customers downstream from the problem are without power. In the below example,
the transformers are shown with fuses, which would isolate them from the distribution
line in the event of an overload or transformer failure. Radial systems are mostly used in
rural or remote areas. Radial feed systems require transformers to have only one high-
voltage bushing per phase line being connected (one for grounded wye applications and
two for delta and wye applications), since no current is being looped through any
transformer.

Loop system

A loop system is fed by two different feeders – one connected to each end of the loop.
Theoretically, the entire loop of transformers could be fed by either source, or the
transformers can be split up between the two sources, depending on where an “open
point” is created. In the event of a failed underground cable, this open point is “moved”
(by using load-break switches or elbows), so that no customers are out of power while
the cable is repaired. In the below example, the transformers are shown with fuses,
which would isolate a failed transformer, limiting the outages to those customers fed by
the failed transformer. Loop feed transformers have two high-voltage bushings per
phase line being connected, so current can loop through the transformer, downstream
to the next one.
IEEE standard C57.12.28 – Enclosure integrity (Tamper resistance)

The purpose of this standard is to describe the requirements for enclosure integrity of
pad mounted equipment that provides long field life with minimum maintenance and
resist tampering.

Enclosure security

• Enclosure mounting: The enclosure must allow for flush mounting on a flat
mounting surface
• Water resistant: The enclosure must resist the entry of water into the enclosure
(except under flood conditions), so that it does not impair the operation of the unit
• Resistant to foreign objects: The enclosure must prevent the entry of objects
such as sticks, wires and rods
• Sharp corners: The enclosure shall minimize projections and sharp corners
• Corrosion resistance: The hinges, hinge pins and pentahead bolts shall be made
of type 304 stainless steel or a material of equivalent corrosion resistance
• Locking devices: The enclosure must contain a locking device that resists
breaking and bending, and must comply with the enclosure access test, the fire
resistance test, the pry test, the push tool test, the pull tool test and the probe
wire test

Segments on a substation transformer

The plan view shows the ANSI segments used to identify the location of both the high-
voltage and low-voltage bushings.

Segment 1 (front): Nameplate, gauges, valves, etc.

Segment 2: Standard for wall-mounted bushings (optional segment 4)

Segment 3: Standard for cover-mounted bushing

Segment 4: Standard for wall-mounted bushings (optional segment 2)

Cooling types

• Radiator panel style

o Welded
o Bolted (removable)
o With fan(s)
• Corrugate style
o Corrugate without fan(s)
o Corrugate with fan(s)

Top view

Bushing enclosure options on a substation transformer

• Throat: ≤ 24" inside height

• Flange: ≥ 24” inside height

What types of transformer protection are available?

There are many types of transformer protection available. They are specified to protect
the transformer itself, other equipment and even the safety of nearby people and
property. Many of these protections might be required by code.

Main types of protection

 • Over-current protection: Fuses, breakers, interrupters
• Over-voltage protection: Arresters

There are many variations of these items that are tailored to different types of
transformer arrangements. These transformer protective devices, when coordinated
with up- and down-stream protections, can protect from a full range of events and help
to minimize outages caused by those occurrences by localizing the disruption or
shutting down the system for higher severity.
Overcurrent protection

Overcurrent protection from fault conditions and overloading can be accomplished with
various types of fuses and breakers. Sometimes these will be used in combination
together and they often need to be coordinated together as a system to get a proper
protection and functionality.

• Fusing: One of the common types of overcurrent protection for transformers is

fusing. Transformers use several types of fuses and there are benefits and
disadvantages to each.
o Expulsion: Expulsion fuses are inexpensive protection and available in a
few different types. The most common for medium-voltage distribution
transformers is the Bay-O-Net style fuse. Once the fault condition is
repaired, the expulsion fuse is easily replaced from the outside of the
transformer tank. For proper protection, it needs to be used in-series with
an isolating link or with partial range current limiting fuses. Available up to
38 kV class
 o Cartridge: Cartridge fuses are similar to Bay-O-Net fuses, but they do not
have handles for external removal. They are completely inside the tank but
would be accessible from the access cover on top. The advantage of this
style is that there are slightly higher amperage ratings available than
currently offered in the Bay-O-Net fuses.
o Current limiting (full range vs partial): Current limiting fuses are another type
of protection. They can limit the amperage that occurs during a fault event
by forcing the current to go to zero. These are typically low-impedance
faults in which the windings of the transformers are faulted and there is
limited or no impedance for the fault current to flow through the transformer,
which can cause damage to other equipment in the system if there are no
current limiting fuses in place.
o Expulsion + partial range current limiting fuse in-series: One of the most
common types of protection for distribution transformers is a combination of
an expulsion fuse and a partial range current limiting. In this arrangement,
secondary faults and overload currents are cleared by the Bay-O-Net fuse,
and high-level faults are cleared by the current-limiting fuse. The two fuses
are connected in-series, and are coordinated so that the current-limiting
fuse operates only upon internal equipment failure

• Breakers: Breakers are a type of resettable overcurrent protection. They come in

a variety of amperage and voltage categories.
o High-voltage breakers are typically standalone devices and are found in an
open substation. Medium- and low-voltage breakers can be standalone
devices or can be grouped and assembled into a switchgear lineup or a
mounted panelboard.
• VFI (interrupters): A type of breaker that is unique to Eaton transformers is the
Vacuum Fault Interrupter (VFI). This device is taken directly from Eaton’s pad-
mounted switchgear equipment and integrated directly into the transformer as an
electronically tripped, resettable primary protection device. In addition to the
protection, this device can also be used as a loadbreak switch (on-off switch). The
electronic controls for this device can allow for external control schemes.
• Magnex: Eaton’s Cooper Power series Magnex interrupter is a resettable
overcurrent protection device that can be used to protect lower primary amperage
transformers from damaging overloads and faults. Like the VFI, it can be used as
a loadbreak device.

Overvoltage

• Arresters: Distribution, intermediate and station class

o Livefront
o Riser pole
o Deadfront
o Under-oil
o Low-voltage
What is transformer monitoring?
A transformer monitoring system is defined as a group of components built together to
sense and monitor the various parameters of a transformer that are vital to its
functionality. Distribution transformer monitoring sensors transmit timely, accurate
readings for voltage, energy, current and temperature. These fundamental data points
provide direct information on the condition of the transformer that can be used for
protective relaying, predictive diagnostics, or to provide relevant information to electric
utility operators. Additionally, these data points can be extrapolated to reveal enhanced
grid performance and asset health information.
• Switches: There are two main categories of transformer switches.
o Load-break (energized operation) switch: A load-break switch has the
capability to operate while the transformer has current flowing through it
and may be used for turning a unit on/off, changing incoming feeds or
sectionalizing the incoming loop.
 Break-Before-Make (BBM): This type of loadbreak switch is
constructed with conductive blades that are momentarily separated
between switching operations, briefly deenergizing the circuit while
switching.
 Make-Before-Break (MBB): This type of loadbreak switch has
conductive blades that are constructed such that the circuit is never
fully open, and energy continues to flow throughout the switching
operation.
o De-energized (non-load-break) switch: A de-energized switch cannot be
operated while a transformer is under load or has current flowing through it.
 Common de-energized switches include tap-changers, dual voltage
switches or delta-wye switches.

• Gauges: Transformers have a multitude of gauges that allow for easy monitoring
or status checks of condition. Some of the most common types include liquid or
winding temperature gauges, liquid level gauge and pressure/vacuum gauges.
Most gauges come in one of two styles.
o Analog, non-contact type gauge: Used for local monitoring only of a
transformer diagnostic
o Contact gauge, or gauge with contacts: Includes internal conductive
contacts capable of closing or opening when a given condition arises,
relaying an electrical signal to an annunciator or control room as an alarm
signal
• Transducers: For more sophisticated monitoring schemes, the use of transducers
can be applied. A transducer is a type of gauge that records a real-time signal and
outputs the data in the form of an analog signal, typically a 4mA to 20mA signal,
for recording and tracking real-time data. New smart transformers are using
transducers to monitor real-time diagnostic data to help better predict the longevity
of the transformer.
• Sampling valve: Sampling valves are most often incorporated into a transformer
drain valve. The sampling valve is a crucial component of a liquid-filled transformer
as it gives the operator the ability to pull a portion of the transformer fluid to run
dissolved gas analysis, or other fluid testing, that may help determine the overall
health of the unit. Eaton and other manufacturers now offer the fluid sample valve
externally for safe access while the transformer is still energized.

• Visible break: Visible break is a term referring to a switch that allows visible
isolation of a single-phase or three-phase circuit. The purpose of including the
visible break switch is to allow an operator to quickly and effectively determine if a
transformer or line is truly de-energized. Eaton transformers can be provided with
external visible break on padmount transformers to allow safe de-energization
without the need to enter the primary or secondary cabinets.
 • Relays/schemes: System protection is the art and science of detecting problems
with power system components and then isolating these components. Protective
relays, associated communication systems, voltage and current sensing devices,
station batteries and DC control circuitry make up the gambit of apparatuses in a
protection system. Ultimately these protective devices and sensors help keep
equipment such as transformers, reactors, generators, capacitors, buses and
transmission lines protected from the dangers of surges, faults and overcurrent
events.

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What types of manufacturer production tests are

performed on transformers?
Distribution transformer testing is performed in accordance with the routine testing set
forth by the IEEE standards committee, specifically outlined in IEEE standard C57.12.00
with procedures and methodology outlined in IEEE standard C57.12.90.

There are two types of test categories:

• Routine tests: Tests performed by a manufacturer on all production units. Units

that do not pass these tests do not meet IEEE standards
• Design tests: Tests that are performed only on new designs or prototypes

Routine tests

Ratio, polarity and phase-relation test

1. The purpose is to verify the correct high-voltage and low-voltage turns ratio (at all
tap positions and voltage settings)
2. This test verifies the unit is checked for open circuit conditions, short circuit (turn-
to-turn) conditions and proper polarity and phase relationship (start vs. finish
leads)
3. Test results are per IEEE standards C57.12.00 (+/-0.5% tolerance on test value
from design value). Results are reported as either pass or fail

Resistance test

1. The purpose is to verify coils resistance and wire size is as expected when
compared to design values, to obtain a resistance value to upgrade (correct)
winding losses and to perform heat run calculations
2. Procedure for substation units is to test on rated tap and tap extremes. Padmount
units are tested in nominal tap position only. In general, all readings are taken line-
to-line, and high-voltage and low-voltage windings are connected in-series
3. Test results for reporting are not required by IEEE standard C57.12.00 but are
available upon request. When used for heat run testing, the measurement is used
for calculating I2R values and separating stray losses from measured winding
losses

Insulation power factor test

1. The purpose is to determine the ratio of the power dissipated in the insulation in
watts to the product of the effective voltage and current. (Is the insulation dry
enough?)
2. The procedure for power factor testing is to short all high-voltage terminals
together, and likewise with the low-voltage terminals. A 60 Hz, 120 V signal is
applied to the unit by the measurement bridge. The first measurement is taken
high-voltage to ground, the second high-voltage to low-voltage, and the final low-
voltage to ground.
 3. Test results are pass or fail: Test results are compared to an empirically derived
curve of insulation factor power vs. temperature (typical pass value for a
distribution transformer would be 1.0% or less).

Quality Control (QC) impulse test

1. The purpose is to verify the insulation integrity and BIL rating of units
2. The procedure consists of applying one reduced wave (approximately 50% of
rated BIL) and one full wave (rated BIL) to each terminal. Non-impulsed terminals
are grounded. First an operator would monitor the voltage and current waves on a
DIMS 5 oscilloscope and then examine voltage and current waves for mismatch
between reduced and full waves.

Core loss (No Load Loss) and percent exciting current test

1. The purpose of the test is to check accuracy of design calculations, check

workmanship and materials and collect actual measured values for customer use
and total ownership calculations. The results are also used in heat run calculations
 2. The procedure consists of applying voltage to the low-voltage winding. Substations
are tested on rated tap at 100% and 110% of rated voltage, while padmount units
are tested at 100% only
3. The test results are compared to customer guarantees or design values for a pass
/ fail status

Induced potential (OX) test

1. Induced potential (also called low-frequency or overexcitation “OX” testing) is

performed on all units prior to winding loss and impedance testing
2. The purpose of this test is to check turn-to-turn and layer-to-layer insulation
3. The procedure consists of applying twice-rated voltage to the low-voltage side of
the unit, at 180 Hz for 40 seconds, or at 400 Hz for 18 seconds (the IEEE standard
dictates the unit must see 7200 cycles).
4. Test results are reported as performed and passed when customer request
certified test data, otherwise the test is considered a pass or fail

Winding loss (Load Loss) and percent impedance test

1. Winding loss (or load loss) testing is performed on all units during final testing
2. The purpose of the test is to check the test values against the design calculations,
check workmanship and materials and collect actual measured values for
customer use. Results may also be used in heat run calculations
3. The procedure for substation units is to test on rated tap and tap extremes.
Padmount units are tested at the nominal position only. The operator must short-
circuit the low-voltage winding and circulate rated current in the high-voltage
winding in order to measure the losses
4. Test results are compared to customer guarantees or design values for a pass /
fail status

Optional tests

IEEE Impulse Test (reduced wave, two chopped waves, full wave)

1. The IEEE impulse test is performed (60 kV BIL and above) upon request
2. This design test is performed because the application of two chopped waves
applies different stresses to the winding than the full wave and puts the unit under
similar stresses as a lightning strike or bushing flashover event. The test is meant
to simulate the violent surges a transformer may see throughout its lifetime
3. The procedure for this test is to apply in sequence one reduced wave, two
chopped waves and one full wave. The crest value of wave and time to chop is per
IEEE standard C57.12.00, Table 4, unless otherwise specified
4. Test results are examined, matching reduced wave, first full waves and second full
waves for variations in wave shape. Waveforms should overlay with minimal
deviations. Matching before and after traces will result in a pass for the test
Sound level test

1. Audible sound level testing is performed when purchased or for design verification
2. The purpose of this test is to determine the amount of audible noise generated by
the transformer
3. The specific procedure, including distance and sound sensor (microphone)
placement is dictated in IEEE standard C57.12.90. In order to conduct the test, the
unit to be tested is placed in a sound chamber and then energized at rated
voltage. Sound levels are measured at prescribed intervals around the perimeter
of the unit. The readings are then averaged to obtain the transformer sound level
4. Test results are reported and held per NEMA standards, specifically NEMA TR-1