High Voltage 160kV Step-Up Power Transformer: Efficient 20MVA / 30MVA / 60MVA Solutions for Substations
The 160kV High Voltage Step-Up Power Transformer is designed to increase voltage levels efficiently for power generation plants and substation applications. Available in 20MVA, 30MVA, and 60MVA ratings, it supports stable energy transmission from generation sources to high-voltage networks. The transformer adopts a carefully optimized electromagnetic design that enhances voltage conversion efficiency while maintaining controlled thermal and electrical performance. Its oil-immersed insulation system ensures reliable cooling and long-term insulation stability under continuous operating conditions. The structural design emphasizes mechanical strength and operational safety, enabling dependable performance in outdoor substations and demanding grid environments. This step-up transformer is well suited for modern power systems that require efficient voltage elevation, reduced transmission losses, and consistent operational reliability.
- Primary Voltage Ratings 132kV, 138kV, 160kV or others
- Secondary Voltage Ratings 32.4/13.8/11/10.5/6.6/6.3kV or customized
- H.V. Tap Range ± 8×2.5% HV taps or others
- Type Oil-immersed power transformer
- BIL up to 350kV
- Standards IEEE, ANSI, IEC
- Application power generation plants, renewable energy facilities, transmission substations
- Power Rating 20MVA / 30MVA / 60MVA
- Certificate UL, CESI, ISO, KEMA
- Cooling Method ONAN/ ONAF
- Opeartion Step Down & Step Up
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
High Voltage 160kV Step-Up Power Transformer: Efficient 20MVA / 30MVA / 60MVA Solutions for Substations
Technical Specifications
Accessories
| Rated Power | 20MVA / 30MVA / 60MVA |
| Rating Primary Voltage | 132kV, 138kV, 160kV |
| Secondary Voltage |
32.4/13.8/11/10.5/6.6/6.3 kV Customized |
| Frequency | 50/60Hz |
| Vector Group | Dyn11, YD11, YNd11 |
| Winding Material | Aluminum/Copper |
| Efficiency | As IEEE, CAS Std or Customized |
| Impedance Voltage | As IEC |
| Altitude | ≤1,000m or Customized |
| Enclosure material | Mid Steel |
| HV Bushing |
| LV Bushing |
| OLTC/NLTC |
| Lifting hook for complete transformer |
| Name plate |
| Oil temperature |
| Winding temperature |
| Radiators |
| Oil level |
| Pressure relief valve |
| CT |
Customization Optional
High Voltage 160kV Step-Up Power Transformer: Efficient 20MVA / 30MVA / 60MVA Solutions for Substations
The 160kV Step-Up Power Transformer can be extensively customized to meet diverse generation and substation requirements. Electrical parameters such as rated capacity, primary and secondary voltage levels, frequency, and impedance can be engineered to match specific grid connection points. Customers may select optimized winding arrangements to enhance efficiency or short-circuit strength depending on operational priorities. Voltage regulation solutions can be configured through tailored tap changer designs, allowing accurate adjustment to accommodate generation variability and grid fluctuations. Insulation systems may be upgraded to support higher thermal margins, elevated altitudes, or severe environmental conditions. From a mechanical and operational perspective, the transformer design can be adapted to various installation environments and project constraints. Tank structures may be reinforced for seismic regions or designed with compact layouts for space-limited substations.
Enhanced surface protection systems are available for installations exposed to high humidity, industrial pollution, or strong ultraviolet radiation. Cooling configurations can be optimized to align with load cycles and ambient temperature ranges, ensuring stable thermal performance during peak operation. Optional accessories include advanced monitoring and protection devices such as temperature sensors, gas detection relays, pressure relief systems, oil level indicators, and digital monitoring interfaces compatible with modern substation automation systems. Additional options such as low-noise designs, alternative insulating fluids, customized paint finishes, and project-specific markings further support flexible deployment. All customized solutions undergo dedicated engineering verification to ensure performance reliability and standards compliance.
Packing and Shipping
High Voltage 160kV Step-Up Power Transformer: Efficient 20MVA / 30MVA / 60MVA Solutions for Substations
The packing and shipping process for the 160kV Step-Up Power Transformer is designed to ensure maximum protection throughout transportation and handling. Before packing, the transformer is subjected to final inspection, surface cleaning, and protective treatment. All openings and interfaces are securely sealed to prevent contamination. Detachable components such as bushings, cooling equipment, conservators, and control cabinets are removed when necessary and packed separately in reinforced crates with internal cushioning and moisture-resistant liners.
The transformer's main body is secured to a heavy-duty transport base engineered to support its weight and minimize mechanical stress. Shock-absorbing materials, reinforced bracing, and stabilizing supports are applied at critical points to reduce vibration and impact during transit. Moisture barriers, desiccants, and protective wrapping systems are used to preserve insulation integrity. For long-distance or overseas transport, additional preservation methods such as inert gas filling or controlled vacuum sealing may be applied.
Transportation arrangements are selected according to transformer size, weight, route conditions, and destination requirements. Shipment options include flat-rack containers, open-top containers, or break-bulk cargo for oversized units. All packing materials comply with international export standards, including ISPM-15 requirements for wooden packaging. Clear markings indicate lifting points, center of gravity, orientation restrictions, and safety instructions to ensure correct handling during loading and unloading.
Each shipment is accompanied by comprehensive documentation, including packing lists, inspection records, quality certificates, test reports, technical drawings, and operation manuals. Upon arrival at the installation site, customers receive detailed guidance for unloading, storage, and installation. Optional services such as on-site supervision, oil processing, accessory installation, and commissioning support can be provided to ensure smooth project execution.
The transformer's main body is secured to a heavy-duty transport base engineered to support its weight and minimize mechanical stress. Shock-absorbing materials, reinforced bracing, and stabilizing supports are applied at critical points to reduce vibration and impact during transit. Moisture barriers, desiccants, and protective wrapping systems are used to preserve insulation integrity. For long-distance or overseas transport, additional preservation methods such as inert gas filling or controlled vacuum sealing may be applied.
Transportation arrangements are selected according to transformer size, weight, route conditions, and destination requirements. Shipment options include flat-rack containers, open-top containers, or break-bulk cargo for oversized units. All packing materials comply with international export standards, including ISPM-15 requirements for wooden packaging. Clear markings indicate lifting points, center of gravity, orientation restrictions, and safety instructions to ensure correct handling during loading and unloading.
Each shipment is accompanied by comprehensive documentation, including packing lists, inspection records, quality certificates, test reports, technical drawings, and operation manuals. Upon arrival at the installation site, customers receive detailed guidance for unloading, storage, and installation. Optional services such as on-site supervision, oil processing, accessory installation, and commissioning support can be provided to ensure smooth project execution.
32
32 years of industry experience
Manufacturer Test
High Voltage 160kV Step-Up Power Transformer: Efficient 20MVA / 30MVA / 60MVA Solutions for Substations
Progress test
Progress testing for the 160kV Step-Up Power Transformer is conducted throughout the manufacturing process to maintain strict quality control. Incoming materials such as magnetic core steel, conductors, insulation components, and insulating oil are inspected to confirm compliance with approved specifications. During core assembly and winding fabrication, inspections focus on mechanical accuracy, insulation placement, and structural stability. The active assembly undergoes controlled drying and vacuum processing, with parameters monitored to ensure proper moisture removal.
Intermediate electrical checks include continuity verification, winding resistance measurement, and preliminary voltage ratio confirmation. Tank fabrication is inspected for welding quality, dimensional accuracy, and surface protection consistency. Pressure and sealing tests are performed prior to oil filling to confirm oil tightness. All progress test results are documented and reviewed to ensure traceability and early identification of potential deviations before final testing.
Design Tests
All transformers will be tested after finishing the production test items as follows:
♦ Leak testing with pressure for liquid-immersed transformers
♦ Test of transformer oil
♦ Measurement of voltage ratio and check of phase displacement
♦ Measurement of winding DC resistance
♦ Measurement of d. c. Insulation resistance between each winding to earth, and check of the core and frame insulation
♦ Capacitive bushing test
♦ Measurement of dissipation factor (tan δ) of the insulation system capacitances, and determination of capacitances windings-to-earth
♦ Measurement of no-load loss and current at 90%,100%,110% of rated voltage
♦ Operation test on on-load tap-changer
♦ Measurement of short-circuit impedance and load loss
♦ Lightning impulse test
♦ Induced-voltage test with partial discharge measurement
♦ Auxiliary wiring check
♦ Current transformer test
♦ Frequency response analysis test
Transformer Factory Acceptance Test
The Factory Acceptance Test (FAT) for the 160kV Step-Up Power Transformer is performed after final assembly to verify compliance with technical specifications and applicable standards. Routine electrical tests include winding resistance measurement, voltage ratio verification, vector group confirmation, polarity checks, and insulation resistance testing. Dielectric testing involves applied voltage and induced overvoltage withstand tests to validate insulation strength.
Performance testing evaluates no-load losses, load losses, impedance characteristics, and temperature rise to confirm efficiency and thermal stability. Partial discharge testing assesses insulation quality, while impulse testing verifies the transformer’s ability to withstand transient overvoltage events. Mechanical inspections cover tank pressure testing, oil leakage inspection, cooling system operation checks, and tap changer functionality verification. Oil samples are analyzed for dielectric strength and cleanliness. FAT results are compiled into a detailed report and approved prior to shipment.
Routine Test - Polarity 1-Ph
Purpose of Testing
The purpose of testing the polarity of a single-phase transformer is to ensure that the primary and secondary windings are correctly oriented, preventing issues like improper phase connection. It also verifies that the transformer operates safely and efficiently in the intended electrical system.
Testing Equipment
Test equipment: Polarity Tester (e.g. Megger, Hioki, etc.)
Voltage source: usually 500 V, 1000 V or customized as needed
Environmental monitoring: Temperature and humidity meter (records ambient temperature and humidity)
Voltage source: usually 500 V, 1000 V or customized as needed
Environmental monitoring: Temperature and humidity meter (records ambient temperature and humidity)
Pre-Test Preparation
Disconnect the device from the power supply and ensure that it is properly grounded and discharged.
Check the connection terminals and wiring to ensure that there is no looseness or contamination.
Test under suitable environmental conditions: relative humidity less than 75% and no rain (recommended temperature: 20-30°C).
Check the connection terminals and wiring to ensure that there is no looseness or contamination.
Test under suitable environmental conditions: relative humidity less than 75% and no rain (recommended temperature: 20-30°C).
Test Progress
Connect the Test Instrument:
Connect the test equipment to the bushing or terminal of the device under test and ensure proper grounding.
Apply Test Voltage:
Select the appropriate test voltage according to the rated voltage of the device. For single-phase systems, the applied voltage should comply with the equipment specifications (such as 220V or 380V, etc.).
Connect the test equipment to the bushing or terminal of the device under test and ensure proper grounding.
Apply Test Voltage:
Select the appropriate test voltage according to the rated voltage of the device. For single-phase systems, the applied voltage should comply with the equipment specifications (such as 220V or 380V, etc.).
Test Standard
IEC 60076 Oil-immersed power transformers
Measure and Record
Start the test and record the following parameters:
Phase sequence: Confirm whether the phase sequence of the power supply is correct.
Polarity: Check whether the wiring meets the predetermined polarity (positive and negative terminals are connected correctly).
Voltage: The actual voltage value during the test.
Phase sequence: Confirm whether the phase sequence of the power supply is correct.
Polarity: Check whether the wiring meets the predetermined polarity (positive and negative terminals are connected correctly).
Voltage: The actual voltage value during the test.
Temperature Correction
Measure different wiring points (such as input and output) for comparative analysis to ensure that the electrical polarity is consistent.
Repeat Testing (if necessary)
If necessary, correct the measured parameters to the reference temperature (usually 20°C) to ensure the accuracy of the test results.
Evaluation Criteria (Reference)
Correct polarity: The wiring meets the expected polarity requirements and meets the standard. Reverse polarity: If reverse polarity occurs, it should be corrected immediately and retested. Polarity uncertainty: If there is any uncertainty, further check the power supply and wiring configuration.
*These comprehensive tests ensure that each transformer meets performance standards and operates
reliably under various conditions.
Application
This transformer is widely used in power generation plants, renewable energy facilities, transmission substations, grid interconnection points, and industrial power systems requiring efficient voltage step-up and reliable high-voltage power transmission.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
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Do you have UL listed?Yes, our transformer has UL listed. We have exported to America many pad mounted transformer,substation transformer and HV.
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