2000 KVA Distribution Transformer-11/0.433 KV | Malaysia 2024

2000 kVA transformer for stable and efficient power in regenerated oil processing plant

01 General

1.1 Project Description

This distribution transformer is delivered to America in 2024 and designed according to the international standard IEC 60076-1:2011. It is a 2 MVA liquid-immersed transformer with a high/low voltage rating of 11 kV / 0.433 kV and a Dyn11 vector group, ensuring reliable industrial power distribution and proper phase shift alignment between high and low voltage sides.

This transformer is designed for a regenerated oil processing plant, handling waste oil. It provides a stable and reliable power supply for continuous industrial equipment such as pumps, heaters, and compressors. With 2 MVA capacity and NLTC ±2×2.5% voltage adjustment, it ensures steady output voltage even under fluctuating loads.

First, the power distribution transformer can supply both single-phase and three-phase equipment. The Dyn11 connection provides a three-phase four-wire output. Single-phase loads work without causing voltage imbalance. Three-phase machines get enough power efficiently.

Second, the plant setup demands high current capacity and flexible cable connections. Our design includes a high-voltage cable box capable of accommodating 16×1C 630 mm² XLPE/PVC copper cables and low-voltage copper busbars for branch connections, enabling straightforward installation and future expansion.

Finally, industrial operations require efficient cooling and low energy loss. The transformer’s ONAN cooling, copper windings, and liquid insulation ensure reliable operation within an ambient temperature range of -25°C to 40°C. With a no-load loss of 1.94 kW, load loss of 18.3 kW, and 5% impedance, the transformer achieves a balance of efficiency, safety, and thermal performance suitable for continuous industrial operation.

1.2 Technical Specification

2000 kVA distribution transformer specification and data sheet

1.3 Drawings

2000 kVA distribution transformer drawing and nameplate

02 Manufacturing

2.1 Core

The core laminations are carefully selected in thickness to balance performance and cost, with step-lap joints and mitered corners to reduce air gaps and magnetic reluctance. Grain-oriented steel aligns magnetic domains for low loss, while precise stacking ensures mechanical stability and minimal vibration. This core design supports reliable, efficient power transfer for medium and high-voltage transformers.

2.2 Winding

The distribution transformer features three-phase copper windings designed for reliable energy transfer and low electrical loss. The windings are precisely arranged and insulated to withstand thermal and mechanical stress, supporting continuous operation within an ambient temperature range of -25°C to 40°C. With insulation class A and a Dyn11 vector group, the coils ensure stable voltage, high efficiency, and long-term durability in industrial power distribution applications.

2.3 Tank

The bushings are on the top of the tank and covered with a cable box for protection. The box keeps the bushings and switches safe from damage and rain. The tank is sealed and filled with clean transformer oil. The oil gives insulation and removes heat. This design keeps the transformer safe, reliable, and long-lasting in industrial use.

2.4 Terminal Cabinet

The power distribution transformer features separate cable boxes for high and low voltage sides, with bushings extending from the tank to the cable boxes for easy cable connection. The high-voltage box accommodates up to 16 × 1C 630 mm² XLPE/PVC copper cables, while the low-voltage side includes 4 copper busbars for future branch connections. Both boxes ensure safe, organized, and reliable power distribution.

2.5 Final Assembly

1. Winding assembly: According to design requirements, windings of specified sizes are wound onto the transformer core, including both primary and secondary windings. Insulation layers are placed between the coils. 2. Insulation treatment: The windings are treated with insulating varnish and baked to ensure excellent insulation performance. 3. Installation of other components: Oil temperature indicator (OTI), pressure relief valve, Buchholz relay, oil level indicator, no load tap changer, cable boxes, earthing terminal, and others. 4. Oil filling: Fill the transformer tank with insulating oil until the internal space is fully filled and the oil level meets the required standard.

03 Testing

Testing Standard and Routine Test

1 Measurement of voltage ratio and check of phase displacement
2 Measurement of winding resistance
3 Check of core and frame insulation for liquid immersed transformers with core or frame insulation
4 Measurement of d.c insulation resistance between each winding to earth and between windings
5 Applied voltage test (av)
6 Measurement of no-load loss and current
7 Induced voltage withstand test (ivw)
8 Measurement of short-circuit impedance and load loss
9 Leak testing with pressure for liquid-immersed transformers (tightness test)

04 Packing and Shipping

4.1 Packing

After factory testing, drain most of the oil, dry the interior, and fill with dry air or nitrogen under slight positive pressure. Install a pressure gauge and relief valve to prevent overpressure. Remove radiators, oil conservator, gas relay, and oil pipes; pack separately. Seal all flanges with bolts to prevent leaks during transport. Add corner protectors (foam, plastic, or cardboard) and wrap the unit with protective film. Pack the transformer in a steel-frame wooden crate. Attach shock monitors if required, and mark the crate with forklift symbols and center-of-gravity indicators. Cover the crate top with a moisture-proof tarp.

4.2 Shipping

Check the transformer’s size and weight, and plan a route avoiding height, width, and weight limits. Use low-bed or specialized trucks with enough capacity. Align the center of gravity and secure the base with proper fasteners. Use slings or chains through designated holes, avoiding fragile parts. Lock internal components and seal all doors. During transport, keep speed ≤60 km/h and tilt ≤15°. Avoid sudden moves and vibrations. Assign escorts to monitor the load and stop in severe weather. When lifting, keep rope angles ≤60°, use spreader bars if needed, lift upright, and for units without top lugs, use bottom lifting rods.

05 Site and Summary

This 2 MVA oil-immersed transformer was delivered to America in 2024. It is used in a regenerated oil processing plant. It gives stable power to pumps, heaters, and other equipment. It has copper windings, ONAN cooling, and a Dyn11 connection. It works with low loss, high efficiency, and long life. It is made for safe and steady use in industrial work.