H‑Infinity

Transformer design is the foundation of reliable power delivery. Every transformer — from a 100 kVA pad-mounted unit to a 250 MVA autotransformer — must be engineered to handle its specific electrical, mechanical, and thermal duty throughout its 25- to 40-year service life. At H‑Infinity, we design transformers that meet exact customer specifications while exceeding applicable standards for safety, efficiency, and longevity.

01What We Design

Our transformer design services cover:

▸Distribution Transformers — Dry-type (CAST RESIN, OPEN DRY) and oil-immersed (pad-mounted, pole-top, substation) units from 25 kVA to 3 MVA, 15 kV to 35 kV.
▸Power Transformers — Three-phase and single-phase units from 5 MVA to 300+ MVA, 66 kV to 132 kV, including auto-transformers and phase-shifting transformers.
▸Special Purpose Transformers — Furnace transformers, rectifier transformers, traction transformers, and offshore/gas-turbine integrated units.
▸Retrofit & Up-Grade Design — Winding upgrades, core replacement, bushing upgrades, and tap-changer modifications for existing transformers.

02Why Transformer Design Matters

Poor transformer design leads to costly operational problems:

▸Efficiency Losses — A transformer with poor core design can have no-load losses 10–15% above rated values, costing hundreds of thousands in energy over its lifetime.
▸Thermal Degradation — Hot spots from inadequate winding design accelerate insulation aging, reducing transformer life by decades.
▸Mechanical Failure — Inadequate short-circuit strength leads to winding deformation or collapse during fault conditions.
▸Over-Specification Cost — Over-engineered transformers inflate capital cost unnecessarily; proper design balances performance and cost.

03Our Approach

We follow a structured design process from concept through manufacturing support:

1. Technical Specifications

Define voltage ratings, MVA capacity, impedance, tap range, connection group, cooling class, and environmental conditions (ambient temperature, altitude, pollution level).

2. Electromagnetic Design

Core sizing, winding configuration, flux density selection, and no-load/load loss optimization using finite element analysis (FEA).

3. Mechanical & Thermal Design

Short-circuit strength calculation, tank design, cooling system sizing, hot spot temperature analysis, and mechanical restraint design.

4. Manufacturer Review

Review manufacturer design calculations, material specifications, and test procedures. Validate designs before production begins.

04Scope of Transformer Design

Our transformer design services include:

▸Transformer Specifications — Comprehensive technical datasheets covering all design parameters, material requirements, and testing criteria.
▸Loss Optimization Studies — Life-cycle cost analysis (LCC) to optimize no-load and load losses against incremental transformer cost.
▸Technical Bid Evaluation — Review and compare manufacturer proposals for compliance with specifications, focusing on design margins and material quality.
▸Design Calculations Review — Verification of manufacturer's electromagnetic, thermal, and short-circuit calculations.

05Standards & Compliance

✓IEC 60076 Series — Power Transformers

✓IEEE C57.12 — Distribution Transformers

✓IEEE C57.12.00 — General Requirements

✓ANSI C57 — American National Standards

06Why H-Infinity

Our transformer design team includes senior electrical engineers with 15+ years of experience on transformer specifications for refineries, petrochemical complexes, power plants, and utility substations across the Middle East. We've reviewed designs for over 500 transformers ranging from 50 kVA to 300 MVA, and our specifications are known for technical rigour and clarity. We don't just follow templates — we understand the electromagnetic, thermal, and mechanical principles that make transformers perform.

Transformer Design