Power Transformer Engineering

For over 50 years, SPX Transformer Solutions has engineered power delivery solutions that provide exceptional performance and long service life. Waukesha® transformers, whether engineered in Goldsboro, North Carolina, or Waukesha, Wisconsin, are synonymous with quality and reliability and are custom designed to meet specific customer requirements and applications.

Additional Information
POWER TRANSFORMER ENGINEERING

HOW WE ENGINEER FOR YOU

​Customer Communication

Project manager maintains a close working relationship with each customer to address issues even before the design process starts and serves as main contact throughout the course of the order.

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Design

SPX Transformer Solutions' Engineering Team has experience with a wide range of transformer configurations and special requirements.

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Industry Standards

Helpful links for writing your transformer specifications to industry standards.

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​​TRANSFORMER QUALITY STARTS ON THE 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 Transformer Solutions’ 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 Transformer Solutions’ more than 50 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:

  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 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; the Waukesha® 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.

ENGINEERING DESIGN

Engineering Design Requirements

Your SPX Transformer Solutions’ 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
  • Transformers with load tap changers (LTC)

  • Multiple winding transformers (more than two loaded windings)
  • Dual-voltage (series/multiple) high voltage (HV) or low voltage (LV)
  • Split winding transformers
  • Transformers with zigzag connections
  • Transformers with special overloading requirements
  • Transformers for use in unusual service conditions (listed in the IEEE/ANSI Standard C57.12.00-2006)