Power Transformer Division

Kuhlman power transformers are designed in accordance

with the highest engineering standards to provide reliable
and economical service for a wide variety of utility and
industrial applications. Designs take full advantage of
improved core, coil and insulation materials, new
manufacturing techniques and processes, and the latest
advances in power transformer technology.

Transformers 2500 through 10,000 kVA , three phase are

self-cooled with additional single stage forced-air cooling
available. Three phase transformers larger than 10,000 kVA
are available self-cooled, with up to 2 stages of forced air
cooling. Load tap changing designs

Primary voltages through 161 kV are offered, as well as a Modular Distribution Substation
full range of options in all ratings. All designs feature high
short circuit strength to withstand repeated through fault
conditions encountered in modern power systems. Kuhlman Kuhlman Electric provides Modular Distribution Substations
power transformers have a sturdy construction, are (MDSTM) by consolidating a high side circuit switcher and
compact, economical, and simple to operate and maintain. low side switchgear onto the transformer, reducing the overall
They have exceptionally good service records under all types substation costs as well as the space required for the
of applications and loading conditions. substation.

Designs have been optimized to incorporate the best The MDS TM combines Powell Electrical Manufacturing
materials, processing and design concepts for any given and S & C Electric to provide the complete modular
transformer rating and service requirement. substation. The switchgear is available in 5 through 15 kV,
1,200 through 4,000 amp ratings, and in 27 and 38 kV,
1,200 through 2,500 amp ratings.

Modular Distribution Substations offer many advantages:

•Lower total overall substation costs.
•Less installation time and expense.
•Dramatically reduced real estate requirements.

Conventional, no load tap changing MDS TM Design

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 Power
Transformers

Power Transformers
Power transformers with or without load tap changing through
37.5/50/62.5 MVA,161 kV

Cores
Kuhlman power transformers are designed with mitered,
step-lapped joints providing high mechanical strength and
optimum magnetic performance. Individual laminations are
accurately cut to size and mitered for each core design.
The combination of premium steel and optimum construction
provides Kuhlman power transformers with low core losses
and quiet operation.

Windings
All Kuhlman power transformer windings are cylindrical
construction for maximum short-circuit strength. High voltage
windings are continuous wound disk type. Low voltage
windings are generally multi-strand, disk or helical type. All
Tank
windings are designed to withstand repeated through fault
conditions.

Core and Coil Assembly

The assembled core and coils are locked together in a unified
structure. Heavy insulated steel or laminated pressure rings
at the top of the coils are held in place by heavy steel jack
bolts on the underside of the top core clamp. The locking
system for the complete core and coil assembly provides
symmetrical coil clamping force at the center line of each
core leg ensuring full axial compression under all conditions.

Tanks
Transformer tanks are all-welded steel construction and
provide a compact, rugged enclosure for the core and coils.
All tanks are designed for full vacuum processing and filling.
Lifting lugs near the top corners permit lifting of completely
assembled transformers. Horizontal tank braces have sloped
tops to shed water, repel dirt, and help minimize corrosion.

Three phase core and coil assembly

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 De-energized Tap Changer
Kuhlman self-aligning no load tap changers
assure good electrical connections at all times.
The de-energized tap changer handle is
mounted at a convenient operating height,
normally on the end of the tank. The operating
handle is simple to operate, snaps into
position, and has provisions for padlocking.

Load Tap Changer

Kuhlman three phase power transformers with
load tap changing (LTC) use vacuum,
reactive, or resistive mechanisms. The LTC
operates with a total of 33 positions. There
are sixteen (16) 5/8% steps above and below
normal voltage for a total tap range of 20%
of rated secondary voltage. Automatic voltage
controls are provided with additional manual No-load tap changer operating handle
override.

LoadTap Changing Equipment and Options:

• Local tap position indicator,

optional remote indicator

• Operations counter

• Raise and lower switches for

alternate manual control

• Motor and control circuits protected

by breakers

• Optional parallel operation with new

or existing LTC transformer

All load tap changing mechanisms are in

separately sealed oil compartments and can
be serviced independently of the main
transformer tank.

Load tap changing mechanism compartment

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 Power
Transformers

Control Cabinet Forced Air Cooled, Class OA/FA and

OA/FA/FA
The control cabinet is a separate weather-tight enclosure
mounted on the side of the transformer tank. The control
cabinet houses all terminal blocks for customer connections, Forced air cooling may be added to the radiators to increase
controls for cooling, and load tap changing equipment. the transformer capacity. Weatherproof motor driven fans
Control cabinets are heavy gauge steel with gasketed doors are mounted on the radiator to provide increased air flow.
and three point stainless steel latches. Cabinet interiors have Each fan is connected with a weatherproof cable and a
a high gloss white finish and are equipped with a door separable connector for ease of maintenance.
activated light and accessory outlet with ground fault
protection. Fan operation is controlled either manually or by automatic
controls that are activated by the winding temperature
indicator and/or top oil thermometer.

Control Cabinet

Self-Cooled, Class OA
All Kuhlman power
transformers have a self-
cooled rating. Flat panel
radiators are used as the
cooling surface in
addition to the main tank Motor driven Fan
surfaces. Radiators are
either bolted on with
individual shut-off valves
or welded directly to
the tank. Radiator
configuration is orderly,
compact and designed to
provide the best cooling
efficiency in the least
amount of space.

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 Sealed Tank Oil
Preservation
Sealed tank oil preservation systems
are standard on all Kuhlman power
transformers. The gas space over the
oil is sufficient to allow for oil
expansion over the entire range of
operating temperatures. A pressure
vacuum gauge is provided to monitor
the pressure inside the tank. A self-
sealing pressure relief device is
provided on the transformer cover to
vent excessive pressures that may
develop during abnormal or fault
Sealed Tank
conditions.

Inert Gas Oil

Preservation System
(option)
This system maintains a positive
pressure of nitrogen gas on the
transformer at all times. A regulating
valve on the high pressure nitrogen
cylinder controls the nitrogen supply
and a pressure relief device is
provided for relieving pressure
outside the normal operating range.

Air Bladder
Conservator Oil
Preservation System
(option)
The air bladder conservator oil
preservation system provides a
reservoir of oil above the main tank,
along with expansion space. This
system keeps the main tank
completely full of oil under all
operating conditions.
Inert Gas System

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 Power
Transformers

Standard Accessories Electrical Test ANSI, IEEE and NEMA

Standard Tests:
• De-energized tap changer for Testing and quality checks throughout
operation at ground level with the manufacturing process assure total • Resistance measurements
padlocking provisions quality in the final product. Testing of
the completed transformer is • Ratio
• Lifting lugs for lifting complete
transformer conducted in accordance with industry • Load loss and impedance
• Magnetic liquid level gauge standards. • Core loss and excitation current
with minimum, maximum, and • Polarity or phase displacement
25oC markings • Applied potential
• Dial type liquid temperature • Induced potential
gauge with maximum
temperature drag hand • RIV or partial discharge for class
• Nameplate mounted at eye level II power transformers
• Tank ground pads, two mounted • Impulse for class II power
on opposite diagonal bottom transformers
corners • Insulation power factor
• Skid base for moving in all
directions with corner jack pads
• Bottom drain and top fill valves
• Pressure relief device
• Sealed tank oil preservation Special or Design Test:
system with pressure/vacuum
gauge • Audible sound level
• Winding temperature indicator • Temperature rise
for forced cooled transformers • Impulse
at 10 MVA and above.
• Switching surge
• Partial discharge measurement
Optional Accessories • Frequency Responce Analysis
(Partial List) (Framit)
• Bushing current transformers • Steep Front Impulse
• Surge arresters and mounting
brackets
• High voltage or low voltage
terminal compartments
• Wye-delta and series-multiple
terminal connections
• Forced air cooling or provisions
for forced air cooling
• Inert gas or air bladder
conservator oil preservation
• Winding temperature indicator
(below 10 MVA)
• Electronic temperature indicator
• Fiber optic winding temperature
indicator
• Microprocessor LTC controls

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 Modular Distribution Substation TM
(MDS TM)
Kuhlman Electric provides Modular Distribution Substations The circuit switcher provides reliable, economical switching
by consolidating a high side circuit switcher and low side and protection. The circuit switcher's simple straightforward
switchgear onto the transformer, reducing the overall design means fewer parts, lower initial costs and lower
substation costs as well as the space required for the operating cost.
substation.
Modular Distribution Substations offer many advantages;
Kuhlman has partnered with Powell Electrical lower total overall substation costs, less installation time
Manufacturing and S & C Electric to provide the complete and expense, and dramatically reduced real estate
modular substation. The MDS is available up through 37.5 and space requirements.
MVA base rating, 138 kV, with or without load tap
changers.

The switchgear includes reliable, long-life interrupting circuit

breakers with draw-out configuration. The switchgear is
available in 5 through 15 kV, 1,200 through 4,000 Amp
ratings, and in 27 and 38 kV, 1,200 through 2,500 Amp
ratings.

Each circuit breaker cell assembly contains:

•A closed door racking mechanism provides the

ultimate in safety.

•The self-contained battery system is offered in either Powell metal-enclosed switchgear

48 or 125 VDC.

•The voltage transformer draw-out assembly is

designed to prevent mis- operation and increase
operator safety.

•The station service transformer draw-out assembly

is available in 15 or 25 kVA based upon your load
requirements.

•Generous panel space is provided for mounting

protective relays, meters and additional instruments.

S & C Electric, type 2010 Circuit Switcher

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 Power
Transformers

Field Engineering Services

“Turnkey Installations”
Kuhlman Electric offers the option of complete field
installation service for all your transformer needs, regardless Unloading
of the manufacturer of the transformer.

Transportation to site, unloading, inspection, installation and

testing are all provided under the direction and supervision
of field service technicians. This means that Kuhlman takes
full responsibility to insure that all of the details of the
installation are performed. Service begins at the factory and
follows the transformer through every step of packing,
shipping, arrival at the job site, installation and final Assembly
inspection. The transformer is inspected upon arrival,
supervised during unloading, and Kuhlman ensures the
installation is completed properly and on-time. Kuhlman’s
Field Engineering Services can save days of installation time
by using this closely coordinated work process.

The cost of the service is minimal compared to the value,

assurance and protection that Kuhlman provides. To
guarantee power transformers are installed properly and Oil-Filling
with the least amount of time and effort, have them installed
by Kuhlman .... the people who know transformers the
best.

Testing

Trained crews ensure the reliability of

every transformer installed.