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Engineering
 


Engineering - SPX Waukesha Quality Begins Here

For over 40 years, SPX Transformer Solutions has engineered power delivery solutions that provide consistent performance and long service life. Waukesha® transformers, whether engineered in Goldsboro, NC or Waukesha, WI, are synonymous with quality and reliability and are custom designed to meet specific customer requirements or applications needs.

  • Transformer Quality Inside
  • Engineering Design
  • eDrawings™
  • Performance Specification
  • Customer Communication

Transformers Quality Inside

Waukesha® power transformers have earned a reputation for quality and are custom designed to meet specific customer requirements. This process begins by accessing design data from one of the industry’s largest computer-based libraries. Hundreds of alternative core and coil configurations are reviewed for each proposal, allowing SPX Waukesha engineers in Wisconsin and North Carolina the opportunity to select the optimum electrical design that will satisfy a customer's individual needs. Other programs then plot the forces that a coil will experience during a short circuit, helping to optimize the mechanical design. Computer data also furnishes precise information on flux density, conductor size, cooling requirements, dielectric characteristics, power losses and more.

Combined with SPX Waukesha’s more than 40 years of transformer manufacturing and engineering history, these design tools help ensure every Waukesha® transformer provides consistent, dependable performance and long service life. The following drawing of a representative Waukesha® power transformer illustrates many of our quality design features built into every unit:

cutaway showing transformer quality 1. Core / No-load losses minimized by utilizing laser-scribed, super grain-oriented steel.

2. Lamination width customized to achieve a near perfect circle core cross section, resulting in the most efficient use of materials plus a lighter, more compact, high performance transformer.

3. Coil assembly rigidly braced in a high-strength frame that distributes clamping forces around the full circumference of the windings.

4. Submerged-arc welding process produces deep penetration welds, virtually eliminating leakage from welded tank joints.

5. Inside tank surfaces are painted white to facilitate internal inspections.

6. Exterior tank coated
to a minimum thickness of 3 mils; this coating has superior endurance characteristics and meets ANSI C57.12.28 standards.

7. Galvanized radiators provide excellent corrosion resistance and require minimal maintenance (fan guards and blades also galvanized).

8. Material-stabilized coils
are pressure-fit within the core frame.

9. Patented De-Energized Tap Changer (DETC)
features simple and compact in-line contact arrangement (Patent Number 5,744,764).

10. Load Tap Changer
per IEEE C57.131 and IEC 60214; Waukesha's UZD® is designed to withstand up to a half-million operations without need for contact replacement.

11. NEMA 3R Control Box
is an enclosure for customer interface with transformer monitoring equipment, LTC and transformer cooling controls. Anti-condensation heaters, covered document box, three-point door latch and padlockable door handle are standard as is stainless steel external hardware and a large, removable bottom plate for customer conduits and cabling.
Transformer cutaway image depicts typical medium power design.  

Whatever the market or customer need, when it comes to transformers, components or service support — SPX Waukesha will be there for you.

For more information, to discuss your specification requirements, or to receive a power transformer quotation, contact us, contact the SPX Waukesha Sales & Service Representative nearest you or utilize our on-line resource: General Inquiry Form.

Visit the SPX Waukesha Library for downloadable PDFs of our most popular literature.

transformer
The optimum Waukesha® transformer design is the one that meets and exceeds our customer’s needs.

Engineering Design Requirements

Your SPX Waukesha Engineering Team has experience with a wide range of transformer configurations and special requirements, including:
  • Station / Substation Transformers
  • Autotransformers (with or without a Tertiary Winding)
  • GSU (Single or Double Low Voltage Winding), UAT, SST
  • Voltage Regulators
  • Phase Shifting Transformers
  • Units with Load Tap Changers (LTC)
  • Multiple Windings (more than two Loaded Windings)
  • Dual-Voltage (Series/Multiple) HV or LV
  • Split Windings
  • Zigzag Connections
  • Units with Special Overloading Requirements
  • Unusual Service Conditions (listed in the IEEE/ANSI Standard C57.12.00-2006)

 

Design Optimization

The SPX Waukesha design process utilizes an optimization strategy with the goal of providing the lowest Total Owning Cost (Selling Price + Cost of Losses) and best transformer design for the customer’s application. To achieve this goal, an experienced team of Engineers most familiar with a customer’s specification is assigned to work on the project, which begins by accessing design data from one of the industry’s largest computerized libraries of power equipment configurations. To optimize materials, production scheduling and delivery, hundreds of alternative core and coil designs may be reviewed for each proposal, allowing SPX Waukesha engineers to select the optimum design based on the customer's individual needs.

An optimum transformer design results when a balance is achieved between the costs of:

  1. Variable commodities such as Steel, Copper and Oil
  2. Losses
  3. Manufacturing labor hours
  4. Plant capability constraints
  5. Shipping constraints

Our goal is to design and deliver a transformer with a Performance Specification that meets or exceeds our customer’s requirements.

 

Design Techniques & Tools

Waukesha® transformers are designed and manufactured in accordance with the latest standards of IEEE , NEMA, ANSI or IEC, as well as the quality standards of ISO 9001:2008. Advanced engineering tools and software are utilized, including:

Electrical Engineering SoftwareElectrical Engineering Software

  • Transformer Design Programs — to calculate impedances, losses, thermal performance, etc.
  • TA(Technical Advisory) — online design documentation containing the design rules for building a transformer. Revision is controlled under ISO 9001:2008 guidelines
  • Impulse Distribution Program — to analyze dielectric stresses on windings during transformer impulse tests
  • Short Circuit Programs — to analyze forces on windings and structures during a short circuit employing FEA (Finite Element Analysis) or boundary element methods
  • Cooling Design Programs — to calculate transformer cooling requirements and overload performance
  • Optimization Program — to determine the lowest Total Owning Cost design for the customer’s application

Mechanical Engineering Software

  • Mechanical Engineering SoftwarePro/ENGINEER® — True 3D Modeling program with fully parametric models. Design inputs from a SQL database with outputs directly to the MRP system and to manufacturing machine centers
  • Pro/MECHANICA® — Finite Element Analysis (FEA) application, used for new product development
    NOTE: Pro/ENGINEER® 3D CAD software and Pro/MECHANICA® FEA software are registered trademarks of PTC (Parametric Technology Corporation), Needham, MA, USA. For additional information, please visit www.ptc.com.
  • TA (Technical Advisory) — online design documentation containing the design rules for building a transformer. Revision is controlled under ISO 9001:2008 guidelines
  • Tank Sizing Program Customized tank sizing programs for Medium-Power and Large-Power designs. Automatically sets tank size and bushing locations for every design.

 

Design Changes

When changes are required in the design, the SPX Waukesha Engineering team works closely with our Manufacturing , and Quality departments to continually provide up-to-date computerized Engineering Change Orders (ECOs). To help achieve consistent quality, work process flows are governed by stringent ISO 9001:2008 guidelines. This teamwork helps provide components and assemblies that are manufactured to customer specifications with the most current engineering information.


Whatever the market or customer need, when it comes to transformers, components or service support — SPX Waukesha will be there for you.

For more information, to discuss your specification requirements, or to receive a power transformer quotation, contact us, contact the SPX Waukesha Sales & Service Representative nearest you or utilize our on-line resource: General Inquiry Form.

Visit the SPX Waukesha Library for downloadable PDFs of our most popular literature.


eDrawingseDrawings

Collaboration, Speed, Simplicity

In addition to 2D drawings, SPX Waukesha can now provide detailed 3D models that customers can manipulate on their own computers to better see their transformer designs using a simple and efficient tool called eDrawings. Our engineering department can quickly share these approval drawings and corresponding 3D models via e-mail to better facilitate the design approval process.

eDrawings has no licensing costs associated with it, and it requires no CAD experience to use. It provides useful mark-up and dimensioning tools, small file sizes and powerful collaboration tools to help communicate ideas and transformer design information between all involved parties faster than ever before.

eDrawings Viewer Installer

To get started, click here to download the eDrawings Viewer and User Guide.

Sample Application Screens

Sample eDrawings

 

 

Whatever the market or customer need, when it comes to transformers, components or service support — SPX Waukesha will be there for you.

For more information, to discuss your specification requirements, or to receive a power transformer quotation, contact us, contact the SPX Waukesha Sales & Service Representative nearest you or utilize our on-line resource: General Inquiry Form.

Visit the SPX Waukesha Library for downloadable PDFs of our most popular literature.

Sample Power Transformer Performance Specifications

For: Acme Power Company
Quotation No.: F 001, Item No.: 1A, Project Name: New Substation

TRANSFORMER RATINGS
Phase 3 Cooling HV Volts XV Volts YV Volts ZV(TV) Volts
Frequency 60 Class 115,500 D 26,180 Y

 

 

Temp Rise, ° C 65 OA 20.0 MVA 20.0 MVA MVA MVA
Insulating

 

FA 26.667 MVA 26.667 MVA MVA MVA
Liquid Oil FA 33.333 MVA 33.333 MVA MVA MVA

ADDITIONAL TAP VOLTAGES    
Terminal Style Taps or kV Capacity
HV DETC 118250-115500-112750-110000-107250 Full
XV   NONE  
YV      

PERCENT IMPEDANCE VOLTS   AUXILIARY LOSSES AND SOUND LEVEL  
% Windings At MVA   MVA Class Cooling Loss (Watts) Sound Level dB
8.50 H - X 20.000   20.0 OA 0.0 73
  H - Y     26.667 FA 1,000 75
  X - Y     33.333 FA 2,000 76
        The above values for cooling loss do not include ancillary equipment (heaters, control devices, etc.) losses of 500 Watts

INSULATION LEVELS (kV)   PERFORMANCE BASED ON A LOADING OF  
Terminal Winding Bushing   HV Winding 115,500 Volts @ 20.0 MVA
HV Line 450 550   XV Winding 26,180 Volts @ 20.0 MVA
HV Neutral       YV Winding   Volts @   MVA
XV Line 150 150   ZV(TV) Winding   Volts @   MVA
XV Neutral 150 150            
YV Line       EFFICIENCIES Base MVA (ONAN) = 100%
YV Neutral       Load 100% 75% 50% 25%
ZV(TV) Line       Percent 99.56 99.63 99.67 99.61
ZV(TV) Neutral                

REGULATION     PERFORMANCE DATA No Load Temp: 20 °C/Load Loss Temp: 85 °C
Power Factor Percent Regulation   Exciting Current (Percent) and Loss (Watts)    
1.0 .73   Excitation Exciting Current(%) No Load Loss Load Loss Total Loss
0.9 4.35   100% .500 14,900 73,400 88,300
0.8 5.66   105%        
      110%        

MECHANICAL DATA — Not for Construction Purposes. Dimensions are in inches & weights are in pounds (approx. values)
Outline Drawing Number: Shipping: Truck job site w/o oil supplied by Georgia

 

Base Assembled Shipping   Weight (lbs.)
Height (A) ---- 204   Core and Coils 40,500
Width (B) 116 140 140 Tank and Fittings 24,500
Depth (C) 52 152 88 Liquid (2,800 gallons) 21,000
Height over Cover (D) ---- 144 148 Total Weight 86,000
        Shipping Weight, heaviest piece 60,000

Whatever the market or customer need, when it comes to transformers, components or service support — SPX Waukesha will be there for you.

For more information, to discuss your specification requirements, or to receive a power transformer quotation, contact us, contact the SPX Waukesha Sales & Service Representative nearest you or utilize our on-line resource: General Inquiry Form.

Visit the SPX Waukesha Library for downloadable PDFs of our most popular literature.

Customer Communication

The SPX Waukesha design team interfaces regularly with the assigned Project Manager who maintains a close working relationship with each customer and/or channel partner. Many issues and questions are addressed before the design process is started, and the SPX Waukesha team maintains an ongoing dialog with each customer during the design phase to ensure that additional questions are answered. Depending on the transformer, a Design Review Meeting may be scheduled to go over electrical and mechanical details and drawings and modify any areas, as needed, or as agreed.


Other e-Enablement Communication Tools Available from SPX Waukesha

WebEx Drawing Reviews

Using WebEx technology, SPX Waukesha offers customers the ability to meet in cyberspace to facilitate on-demand collaboration, web and video conferencing worldwide. This technology facilitates electrical design and approval drawing reviews by focusing on the same items addressed when customers travel to our locations:

• Specifications
• Electrical designs
• Mechanical designs
• 3D Design models (using eDrawings)

Design and drawing information is shared in a virtual conference room setting, in real-time, via standard internet connection. This eliminates travel issues, offering considerable time-saving benefits to customers.

Virtual Witness Testing

With virtual witness testing, customers can view their transformer on SPX Waukesha’s test floors via a secure internet connection from a physical site of their choice, reducing travel time and costs while allowing them the flexibility to work on other projects at the same time.


Whatever the market or customer need, when it comes to transformers, components or service support — SPX Waukesha will be there for you.

For more information, to discuss your specification requirements, or to receive a power transformer quotation, contact us, contact the SPX Waukesha Sales & Service Representative nearest you or utilize our on-line resource: General Inquiry Form.

Visit the SPX Waukesha Library for downloadable PDFs of our most popular literature.

 

 

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