Power transformers play a vital role in adjusting voltage levels during transmission. This study focuses on optimizing the structural design of power transformer tanks, particularly high-voltage (HV) tank walls, to enhance their mechanical robustness, performance, and operational reliability. This research investigates various stiffener designs and their impact on stress distribution and deformation through finite element analysis (FEA). Ten different configurations of stiffeners, including thickness, width, type, and position variations, were evaluated to identify the optimal design that minimizes stress and deflection while considering weight constraints. The results indicate that specific configurations, particularly those incorporating 16 mm thick H beams, significantly enhance structural integrity. Experimental validation through pressure testing corroborated the simulation findings, ensuring the practical applicability of the optimized designs. This study’s findings have implications for enhancing the longevity and reliability of power transformers, ultimately contributing to more efficient and resilient power transmission systems.

While power transformer manufacturers are well versed in electrical aspects such as ampere-turns and amps per square inch, optimizing electrical efficiency, voltage regulation, and insulation, there is a potential oversight regarding the intricate mechanical challenges associated with electrical design. As transformers evolve in size and capacity, mechanical forces become increasingly significant, necessitating a closer examination of the mechanical aspects of electrical design. This study focuses on the design of power transformer tank walls. To address the challenge associated with larger tank wall deflection (for both the high-voltage and low-voltage sides) during pressure tests, different stiffeners such as flat stiffeners, changed flat stiffener dimensions, flat bar supports for stiffeners, and H-beams were added to the tank wall and modeled for finite element analysis. The tank wall design was optimized for higher mechanical strength, lower deflection, and lower mass by assessing the von Mises stress and deformation of different stiffeners. The findings of this study will contribute to a better understanding of how design adjustments affects mechanical strength, stress distribution, and overall reliability, providing valuable insights for the industry.