Optimized gap positions for improved leakage impedance in dry-type transformer design

The power and distribution transformers must be properly designed to operate in a variety of conditions and manufactured following all applicable international standards to provide a reliable energy supply to consumers. The transformer can fail if it is improperly designed, and it cannot withstand the short-circuit condition if the short-circuit current is not calculated properly. Short-circuit current can be easily calculated by evaluating the leakage impedance. Customers can also demand the transformer companies to increase or decrease the leakage impedance. This paper evaluates the effect of the gap's position in the four different sections of the high voltage winding on the leakage impedance of the two-winding transformer and proposes effective design options for minimizing the leakage impedance. The accuracy of the finite element models was also investigated using an experimental laboratory transformer model specially designed for optimizing the leakage impedance. The experimental and finite element methods results show that the leakage impedance can be changed to the desired value and limits and easily assessed by the finite element analysis technique. The results indicate that even with the same use of the winding and core material, there was a considerable difference in the leakage impedance for each of the conditions. •Power transformers must adhere to international standards for reliability.•Accurate leakage impedance assessment is vital for short-circuit current calculation.•The position of axial gaps between windings is crucial for leakage impedance.•The study proposes effective design options to minimize leakage impedance.•Gap positions must be considered for optimal design.