Course Details/Schedule

Day 1

• Introduction to transformers and IEEE standards
• History and evolution of transformers
• Classification of transformers (power, distribution, instrument)
• Functional overview and applications
• Key IEEE standards for transformer design and manufacturing
• Safety, performance, and testing compliance (IEEE C57 series)

Day 2

• Electromagnetic Theory and magnetic field fundamentals
• Basics of electromagnetism (Faraday’s Law, Lenz’s Law)
• Magnetic flux, reluctance, and core saturation
• Magnetic circuits and hysteresis
• Influence of magnetic field on transformer performance
• Application of field theory in design calculations

Day 3

• Core design and material selection
• Transformer core functions and types (shell vs. core type)
• Core materials: CRGO, amorphous steel
• Core construction: laminated vs. wound
• Core loss (hysteresis & eddy current) and minimization
• Optimization techniques for load and no-load losses
• Design based on IEEE C57.12.00 and C57.12.90

Day 4

• Transformer winding techniques
• Types of windings (cylindrical, helical, disc, interleaved)
• Conductors: copper vs. aluminum
• Selection of winding configuration for voltage/current rating
• Leakage reactance and short-circuit strength considerations
• Cooling implications on winding design

Day 5

• Insulation systems and dielectric design
• Types of insulation: solid, liquid, and gas
• Dielectric strength and thermal class
• Insulation coordination (IEEE C57.131)
• Breakdown mechanisms and aging
• Impulse and AC voltage insulation design

Day 6

• Thermal design and cooling methods
• Transformer heating sources and loss analysis
• Temperature rise and thermal modeling (IEEE C57.91)
• Cooling methods: ONAN, ONAF, OFAF, etc.
• Thermal performance testing
• Temperature sensors and thermal protection

Day 7

• Mechanical design and manufacturing process
• Mechanical stresses during operation and short circuits
• Structural design of windings, core, and tank
• Manufacturing process flow:
• Core stacking
• Winding and insulation
• Drying and assembly
• Vacuum oil filling and sealing techniques

Day 8

• Transformer design software tools
• Overview of commercial software
• Magnetic and thermal simulation modeling
• Finite element analysis (FEA) in transformer design
• IEEE guidelines on simulation validation

Day 9

• Testing, quality control, and IEEE compliance
• Routine, type, and special tests (IEEE C57.12.90)
• Partial discharge, impulse, and load loss testing
• Factory Acceptance Testing (FAT) and documentation
• Quality control in transformer manufacturing
• Failure modes and diagnostic testing 

Day 10

• Design checklist and IEEE conformity review
• Common design challenges and troubleshooting
• Sustainability and environmental considerations
• Use of biodegradable insulating oils
• Design for recyclability and low-loss operation