Independent design and validation of transformer active parts and mechanical systems — focused on reducing technical risk, improving performance and ensuring manufacturability.
Active Part Design
End-to-End Active Part Engineering
We deliver complete core-type active part design for power transformers and shunt reactors up to 420 kV. From electromagnetic performance to mechanical integrity, every component is engineered and validated for real operating conditions.
Scope of Design
- Magnetic Core & Yoke: Main flux-carrying structure with optimized lamination geometry.
- Windings: LV, HV, and tertiary coil design for all winding configurations.
- Clamping Structures: Mechanical supports ensuring axial and radial stability under all load conditions.
- Insulation System: Full dielectric coordination for all operating and test voltage levels.
- Internal Leads: Connection systems designed to minimize stray losses and mechanical stress.
Core Configurations
Experience across a wide range of designs:
2/0 · 2/2 · 3/0 · 3/2
Engineering Approach
All designs are supported by comprehensive calculations, ensuring compliance with IEC / IEEE / GOST standards and reliable performance under real operating conditions:
- Electromagnetic Calculations: Load losses, no-load losses, short-circuit reactance and zero-sequence impedance.
- Mechanical Strength: Short-circuit force analysis and structural integrity verification.
- Thermal Analysis: Hot-spot prediction and cooling system performance under continuous and overload conditions.
- Dielectric Validation: Voltage stress and insulation safety factors verified across all test levels.
Proven Experience
- Short-Circuit Validated: Designs successfully tested under laboratory short-circuit conditions.
- Alternative Fluids: Experience with ester and biodegradable insulating oils.
- Voltage Range: Projects from medium voltage up to EHV class (420 kV).
Result for the Client
- Lower Risk: Design validated before entering production, eliminating late-stage surprises.
- Cost Optimization: Reduced material intensity through precise electromagnetic modeling.
- Operational Reliability: Verified performance under short-circuit, thermal, and dielectric stress conditions.
Mechanical Design & External Systems
Complete Transformer Mechanical Engineering
We provide full mechanical design of transformer tanks and external systems —
from concept to complete production documentation.
Scope of Services
From specification review to final documentation, we cover the full mechanical design lifecycle:
- Specification Analysis: Review of client requirements and applicable standards.
- Concept Development: Initial layout and equipment configuration definition.
- Approval Drawings: Preliminary documentation submitted for customer review and sign-off.
- Tank: Structural and pressure vessel design.
- Conservator: Oil expansion system and breather integration.
- Cooling Systems: Radiators, fans, pumps and cooling loop configuration.
- Piping & Auxiliaries: Valves, sensors, and auxiliary system routing.
- Structural Supports: Frames, lifting lugs, and transportation fixtures.
Engineering & Delivery
- Component Verification: Critical parts review and lead time assessment.
- BOM: Complete bill of materials with supplier specifications.
- Production Drawings: Detailed manufacturing and assembly documentation.
- Technical Documentation: Service manuals and complete technical files.
Advanced Applications
- Marine & Offshore: C5-M rated designs for coastal and offshore substations.
- Seismic Design: Structural analysis and optimization for high PGA environments.
- Special Structures: Custom solutions for non-standard site or transport requirements.
Validation
All solutions are supported by simulation-backed verification, ensuring compliance with project-specific requirements:
- Mechanical Calculations: Stress and deformation analysis for all structural components.
- Structural Simulations: FEA-based verification of tank and support integrity.
- FAT Validation: Design verified against factory acceptance test requirements.
Result for the Client
- Production-Ready: Complete, validated design package delivered for manufacturing.
- Fewer Delays: Upfront validation reduces costly late-stage design changes.
- Standards Compliance: Full conformance with IEC / IEEE / GOST and project-specific requirements.
Documentation & Deliverables
Engineering Documentation Ready for Production
Documentation Package
We provide complete and structured documentation packages, delivered as formal project documentation upon request:
- Calculation Reports: Documented engineering analysis covering all design disciplines.
- Design Drawings: Production-ready mechanical and electrical drawings.
- Technical Specifications: Formal description of design parameters and requirements.
- BOM & Supplier Data: Complete material list with specifications and sourcing information.
Our approach ensures that your design is validated before it reaches production — reducing technical risk, avoiding costly redesigns, and enabling you to get it right the first time.
