Digital twin of cast resin transformers

This article presents the benefits and development process of transformer digital twin applications to manage the current and future challenges to the transformer industry. Computer aided engineering (CAE) tools such as the finite element method (FEM) simulations play a vital role in the development of transformer digital twins. HTT has developed DryTrafo, a digital twin application for cast resin transformers using multiphysics simulations. A three-phase rectifier transformer unit, 2000 kVA 10500/720 V is used to explain the development and working principle of the twin simulations under the portfolio of DryTrafo. These transformer digital twins can provide value in several stages, from planning and realization to field operations to help produce efficient designs, forecasting the transformer thermal behaviour under different load cycles, visualizing maximum permissible overload capabilities, and remaining useful life estimation