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In the distribution transformers design oval windings are used due to economic advantages. On the other hand, such windings are more susceptible to radial forces in a short circuit. A diamond dotted paper with an epoxy coating is used in order to increase the stiffness of the winding. Despite that, winding failure may occur during the short circuit, e.g. buckling of inner winding. Because of a very thin foil conductor (typically 0.5-2 mm), the most critical is inner low voltage foil winding which can collapse due to radial forces at stresses far below the elastic limit of conductor material. This paper shows an analytical approach to the calculation of critical stress in inner oval foil winding with epoxy coated insulation. Critical stress was calculated using the equation for free buckling of round winding. Equivalent Young's modulus of elasticity was obtained experimentally from the testing of the sample model loaded with bending force on a tensile test machine. A total of 12 test samples were formed from aluminium foil conductor and diamond dotted paper and cured at the temperature of 105°C. The results were successfully verified on distribution transformers subjected to short circuit withstand tests.

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In the paper design improvements of distribution transformers related to improved energy efficiency and environmental awareness are discussed. Eco design of transformers, amorphous transformers, voltage regulated transformers and transformers filled with ester liquids are analyzed. As a consequence of growing energy efficiency importance, European Commission has adopted new regulation which defines maximum permissible levels of load and no-load losses of transformers with rated power ≤ 3150 kVA, and minimum peak efficiency index for transformers with rated power > 3150 kVA up to 40 MVA. The impact of new regulation on the design and economy of transformer is presented. Amorphous transformers, with up to 70 % lower no-load losses in comparison to the conventional transformers, could be an alternative with respect to energy efficiency. Although their initial price is higher than the price of conventional transformers, some studies show that they might have economic advantages. The increasing penetration of distributed energy sources can cause an increase in voltage variations in low voltage networks. To keep the voltage within limits defined by EN50160, voltage regulated distribution transformers could be used. Although mineral oil has been used as a dielectric fluid in transformers for many years, there are some environmentally friendlier alternatives – natural and synthetic ester-based fluids.