TRAFOTECH 2018:Tenth International Conference on Transformers

TRANSFORMERS FOR FUTURE POWER NETWORKS

Mahesh V Nene
The Tata Power Co Ltd.
Mumbai

Transformer – is vital equipment in electrical shall be capable of handling such

power systems used in Generation, situations.
Transmission and Distribution and up to last b) The growing network and increasing
mile connectivity with customer. But for fault current levels and its impact on
many years Transformers have not changed transformer health is growing. The
from their basic concept of major elements. design of future transformer shall
have to cater to such condition.
c) Use of electronics at consumer end
Are today’s transformer having following and its impact on power system and
attributes: generation of harmonics is a
challenge. Future transformers shall
be ready for this challenge.
a. Lesser foot print - as space crunch is d) Stringent GRID Availability norms
increasing and growing customer requirement.
b. Environment friendly – cannot afford Future transformer shall be
any product having adverse impact maintenance free and shall have
on nature devices which can predict the
c. Zero Fire Hazard maintenance requirements.
d. Low on maintenance and cost
e. Having built with diagnostic devices
embedded in transformer, which can To have all these attributes, we will have to
trigger online alarms drastically think in replacing current set up
of material used and devices provided for
condition monitoring - in existing
The answer is not affirmative. In certain Transformer manufacturing and designing.
cases changes are taking place but not in
totality.
Existing mineral oil-based transformer are
fire prone, requires higher foot print,
Then what are all things apart from ones requires cost for maintenance and not easy
mentioned above that shall be there in to maintain and not environmentally friendly.
FUTURE transformers.

There are some of the options:

a) Distributed generation will slowly
pick up the pace and intermittency
brought by the distributed generation 1. Gas filled – SF6 Transformer – Will
will have impact on substation eliminate mineral oil and other
transformers. Sudden load increase problems but will have other
on Transformer will be common challenges.
thing, when wind or solar generation 2. Ester filled transformer – Very less
will drop. The future transformer fire prone and is having growing
demand.

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3. Dry type transformers – Does not Let us discuss about transformer of different
have any liquid or fluid insulating configuration in terms of insulating media
media but has PD issues. and understand merit and demerit for further
4. Amorphous transformers – though deliberation.
reduces no load loss, high initial cost
of procurement
5. Mineral oil-based transformers with GAS FILLED TRANSFORMER:
improved cooling capacity and
nitrogen fire blanketing systems
The experimentation on SF6 gas filled
transformer (Gas Insulated Transformers –
But are these options enough: We will also GIT) started quite a long back and GIT are
have to have transformers which can: already in service in many countries. In
India GIT are rare to find. The new advent
of using 0.5 MPa pressure GIT has got
1. Withstand high fault current many advantages. Following para discusses
2. Shows stability to high harmonics merit and demerit of GIT.
due to UPS and electronic circuitry

Merit:
Needless to say on-load tap-changer
are one of the weak portion of
transformer and has resulted into cause 1. Gas Insulated Transformers (GIT)
of Transformer failure. Going ahead a are environmentally friendly and can
standardization of Transformer design – be recycled easily.
utility specific standard design will have 2. Low on Foot Print and NO Fire risk
to be thought of, where TAPLESS – SF6 gas is non-flammable and
transformer can be designed for fire-fighting equipment in the
Transmission Utility. This type of tapless transformer room is unnecessary.
design though not in practice needs to Liquid or oil purifying processes are
be deliberated and researched more not used in GITs, so the substation
with utility and OEM participation. space is also minimized. No need of
Voltage management to be limited to Fire emulsifier system.
distribution area. 3. GIT can be integrated directly with
gas insulated switchgear (GIS) to
form a single, enclosed unit. This
Utility specific design can also consider allows space savings and integrated
standard foot print, specific MVA rating control over the gas system.
for a specific voltage level, having 4. Significant tank pressure increase
robust winding and core design to take does not occur during internal
heavy fault current. failures due to the gas characteristic,
and the risk of a tank explosion or
fire incident can be eliminated
We will have to discuss various options by completely.
putting merit to each attribute and 5. The height of the transformer room
performance of the different type of can be reduced since neither a
transformers available, in short a matrix conservator or pressure release
needs to be formed to understand, what device is required.
best options come out. 6. SF6 does not react with materials
commonly used in transformers,
especially insulating materials. GITs

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are operated at higher temperatures Octafluorocyclobutane (C4F8) is a possible

(Class E) than OITs (Class A), and a replacement for SF6. It’s molecule is
different class of insulation is made up of fluorine and carbon
therefore used. Use of the atoms, removing the risk of creating
appropriate insulation material like poisonous Sulphur-based gases
Polyethylene terephthalate (PET) during arcing. It is more dense than
and poly phenylene sulfide (PPS) SF6 and has a dielectric strength 3,6
leads to high insulating ability and times the breakdown voltage of air
are materials with high air-tightness, (as opposed to 3,0). It is also has a
thermal resistance and dielectric lower global warming potential
strength and are used as coating (GWP) of 10 300 (as opposed to 22
materials for element wires. 800 for SF6).

As on date GIT up to 400 MVA at 500 kV

Demerit: are available and further
development are happening. The
merit and demerit will have to be
1. Gas insulated transformers are weighed and utilities in India shall
more expensive but, this cost take a call on same.
difference may balance out over
the life of the transformer, as ESTER FILLED TRANSFORMER:
maintenance is cheaper. Ester filled (natural and synthetic)
transformer have been researched
for quite long and in use in India and
2. Environmental regulations on many other foreign countries.
greenhouse gasses require Though initial cost is slightly higher
SF6 to be handled carefully and due to cost of ester, has many
recycled where possible. This advantages over mineral oil filled
can create additional installation transformer. Following para
and repair costs, depending on discussed merit and de-merit of the
local laws. ester filled transformer.

Merit:
3. A GIT requires complex cooling 1. Low foot print
due to SF6‘s low thermal 2. No fire risk
conductivity, and  the cooling 3. Can be installed inside building
system (blowers, heat 4. No need of fire emulsifier system
exchangers etc.,) generally 5. Requires less maintenance
needs redundancy to ensure that 6. Higher cost of insulating oil gets
a small equipment failure or traded off against other merits.
maintenance does not reduce
the transformer rating
dramatically De-merit:

1. One major drawback of ester

Apart from the merit and demerit mentioned, filled transformer is thickening of
SF6 gas is GHG and hence ester oil, once it comes in
alternative gas is required which will contact with air (oxygen). This
have similar merit but will not have change the viscosity of the oil.
GHG disadvantage. Reduces the flow rate, affects

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cooling effect. Hence air ingress suppression, no fire rated walls,

into ester filled transformer has roofs, doors, etc.); shorter runs of
permanent detrimental effect, higher current cables (the
which cannot be reversed. transformer is closer or indoor
installation to buildings); and lower
building codes (easier project
management).
The Ester filled Transformer are already in 6. Less on-site assembly (for units with
service in many utilities in India, but up to no enclosure or with enclosure
lower MVA capacities. We need to explore shipped assembled) no filling of oil
the utilization for higher MVA capacity. In on site, no assembly of radiators,
the Distribution sector ester filled bushings or other parts.
transformer is gaining great momentum. 7. No pressurized components.
The real challenge remains more in 8. Lower maintenance required due to
Transmission sector. the absence of
protection/motorization accessories
for oil/gas.
DRY TYPE TRANSFORMER: 9. Reduced load losses at higher
loadings
Dry type transformer are also in use in
many low rating MVA applications. These De-Merit:
type of transformer are not new and have
been researched for quite long. Actually it
avoids all the problems of fluid based 1. Dry type transformer have failed due
transformer 9 Mineral oil, ester filled, gas to PD activity. The design and
filled transformers). Does not require need construction of these transformer in
for any radiator, cooling mechanism etc. controlled environment is a major
However is not in use at higher capacity challenge.
rating application.

Now a day’s Dry type transformer up to 145

Merit: kV, 60 MVA are available. The merit and
demerit will have to be weighed and utilities
in India shall take a call on the same.
1. A dry-type is non-explosive, self-
extinguishing and has very little
smoke produced during arcing AMORPHOUS TRANSFORMERS:
failure.
2. Suited for indoor and underground
installations. The magnetic core of this transformer is
3. Since it does not need bushings, made with a ferromagnetic amorphous
there are less potential failures metal. The typical material (Metglas) is an
4. Dry type transformers, windings are alloy of iron with boron, silicon,
epoxy encapsulated under vacuum, and phosphorus in the form of thin (e.g.
as a result, the transformer has a 25 µm) foils. These materials have
very strong short-circuit resistance high magnetic susceptibility, very
resulting in a low failure rate during a low coercivity and high electrical resistance.
system fault. The high resistance and thin foils lead to
5. Less code restrictions: lower civil low losses by eddy currents when subjected
works (no containment, no fire to alternating magnetic fields. On the

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downside amorphous alloys have a lower occurring for the lifetime despite
saturation induction and often a transformer load.
higher magneto- striction compared to
conventional crystalline iron-silicon electrical
steel. o Easy repair: its modular construction
makes repair easy and fast.

Distribution transformers constitute the

largest group of transformers in any o Better overload capacity: Overload
electrical network, and therefore losses in capacity is better as heat generation is
these transformers can constitute the less due to less loss and obviously less
highest losses in the network. Distribution effect on aging of insulation.
transformers carry a load which varies with
time during the day and are sized to cater
for the maximum load during the day, but o Better distribution efficiency:
often the average load is far below this and distributions efficiency increases due to
the minimum load can be far below the reduced no-load loss. This can save
maximum. monetary investments in generations
capacity concern.

Losses in a distribution transformer consist

of no-load losses, which are independent of o Environmental caretaker: Also
the load, and load dependent losses. A low contributes to the protection of the
load factor, or usage profile, means that no- environment as it lowers the emission
load losses can form a high percentage of of CO2 and SO2 as result of reduced
the total losses in the transformer, and the generation need
development of distribution transformers is
focused strongly on reducing these no-load
losses without compromising the Demerit:
performance of the transformer. The most
efficient distribution transformers, which are
in service continuously except for o The final product in the ribbon form is
maintenance and failure breaks, record a brittle and narrow continuous. To cut
loss of approximately 2 to 4% of the this into section is a tough job. Hence
electricity they conduct, and electric utilities preferred to be manufactured as a
and industries are constantly searching for hollow cylindrical wound core of single
methods and technologies to reduce continuous strip.
operating costs and energy losses.
Amorphous metal distribution transformers
(AMDT) offer the possibility of achieving this o The larger cross-section of the core is
goal required for same power and rating of
silicon steel lamination. This is due to
less useable peak magnetic field
Merit: intensity in the amorphous core. Also
causes added weight and size.

o Less no-load losses: No load losses

are 20 to 30% less as compared to a o With the large size of core longer,
conventional silicon steel winding conductors are obvious which
sheet transformer which keeps causes increased load losses.

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o AM cores have a lower stacking factor increased until a critical value of

than CRGO. As a result of its hardness concentration after which it starts
and thickness, the manufacturing decreasing. Due to the presence of these
surface of amorphous alloy is uneven, nanoparticles, higher breakdown
so the associated stacking factor is corresponds to longer time to breakdown.
only 0,85 while the stacking factor
silicon steel is 0.95.
(ii)The variation in space charge distribution
caused by suspension of nanoparticle
o Difference between amorphous core manifested that the presence of negatively
transformers and CRGO transformers charged particles changes the space
is the cross-sectional structure of the electric field distribution and
core. Because of the difficulty of decreases/increases the breakdown
producing amorphous strips, there are properties. The differences in the cause of
limited production sizes available polarization among dielectric nanoparticles
(typically 213 mm, 170 mm, and 140 and conductive nanoparticles result in
mm). Although conventional electrical different breakdown performance among
steel transformers can be oval or round different types of nano-fluids.
in cross-section, amorphous cores may
be square or rectangular in shape. This
is a disadvantage in terms of cost for (iii)The suspension of nanoparticles
amorphous core transformer. improves the breakdown performance of oil
until a critical value of nanoparticle
concentration after which the breakdown
MINERAL OIL FILLED TRANSFORMER – voltage tends to decrease. This decrease in
with improved Nanotechnology particles: breakdown voltages is mainly attributed to
agglomeration of nanoparticles at higher
volume concentration.
Use of nano - particles of various metal
oxides actually improves overall breakdown
strength of the transformer oil. The size and (iv) For negative impulse breakdown
concentration of the nano-particles affects voltages, the transformer oil showed higher
the impulse breakdown strength of the dielectric strength as compared to the nano-
transformer oil. In one of the experiments fluids with different concentrations.
conductive magnetic nanoparticles Fe3O4,
insulative nanoparticles Al2O3, and semi-
conductive nanoparticles TiO2, were used to Many development are taking place in nano
develop nano-fluids with different fluids which will be replacing mineral oil
concentrations. used in transformer and which will have
very good effect.

The impulse breakdown strength of

prepared nano-fluids was tested and RELIABILITY CENTERED MAINTENANCE
analyzed. The conclusions obtained from (RCM ) PRACTICES –
this study are as follows:
As the stringent regulatory norms will get
(i)The positive lightening impulse enforced, utilities are now moving towards
breakdown voltages of three nanofluids condition based monitoring and
modified by Al2O3, TiO2, and Fe3O4 showed maintenance practices and further towards
improvement as the concentration is reliability centered maintenance practices.

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The basic requirement of RCM is to have Every utility will have to then form its own
online and offline condition monitoring matrix based on their own requirement,
systems in place, which will give sufficient regulatory approvals and associated risk
data to formulate health index for the and cost. Decision will then be a well-
equipment and transformer in particular. informed decision.
This health index will be used to predict the
maintenance requirement. It will also be
able give prescriptive maintenance practice. At Tata Power, we are using ester filled
Run-Repair-Replace strategy can also be transformer in distribution network. We have
formed from the index and data retrieved also adopted gas filled instrument
from the condition monitoring. The RCM transformers. We are started using online
way will lead utilities to take a well informed DGA monitoring devices on pilot basis. We
decision. have adopted RCM way of maintenance
practice and going in the direction of
condition based monitoring and
So the transformer for future power maintenance practice.
networks must have online condition
monitoring devices installed and health
index created based on the same, indicating Going ahead we will be exploring other
its own health in real time basis. Online possibilities also, depending on the
DGA, Moisture PPM, Oil tan delta sets can requirement, cost implications and
be installed on transformer. Many other regulatory aspects. It is expectation from
devices like online PD are also being utilities that OEM will come out with new
created by various organization. A complete age transformers having following attributes
set of all these online condition monitoring discussed earlier:
devices will help create the data for health
index.
a. Lesser foot print
b. Environment friendly
SUMMARY : c. Zero Fire Hazard
d. Low on maintenance and cost
e. Having built with diagnostic devices
Though various technology are existing, the embedded in or on transformer
ultimate call for selection of the transformer f. Robust design of winding to take
and online condition monitoring devices, care of high fault current and
will depend on : harmonics
g. Design sufficiency to take care of
sudden load variation – considering
A. Cost of procurement and RE intermittency
maintenance
B. Cost of new technology , its
repeatability and scalability References:
C. Regulatory approvals
D. Real need of the technology
E. Ease of doing business – [1]    Hitachi: “Hitachi amorphous metal
vendor availability in India, core”, www.hitachi-
skilled manpower America.us/ice/transformer/products/amorp
F. Customer centricity – Real hous_core/#sthash.SpMfCjkk.8KP015Br.pdf
customer need [2]    R Hasegawa: “Energy Efficiency of
Amorphous Metal Based
Transformers”, www.leonardo-

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energy.org/sites/leonardo-energy/files/root- Property of Transformer Oil by Qi

files/PL-7.pdf Wang, Muhammad Rafiq, Yuzhen
[3]    BRG Energy: “Manufacturing of Lv, Chengrong Li, and Kai Yi
amorphous
metals”, www.brgenergy.com/process.html
[4]    C Hsu: “Systematic Study of Low Loss [8] HiDry: dry-type power transformers for
Amorphous Core Transformers: Design and sub-transmission – ABB
Testing”, Eighth WSEAS International
Conference on Instrumentation,
Measurement, Circuits and [9] T Holman: “Gas insulated transformers
Systems,  www.wseas.us/e- (GITs), study of the design and applications
library/conferences/2009/hangzhou/IMCAS/I of SF6 insulated power transformers”,
MCAS39.pdf University of Technology, Sydney, October
[5]    Katsutoshi Inagaki: “Amorphous 2013.
transformer contributing to global [10] N Amano, et al: “Design concept of
environmental protection”, Hitachi urban substations: state-of-the-art gas
Review, www.hitachi.com/rev/pdf/2011/r201 insulated transformers”, Cigre Electra 215,
1_05_113.pdf August 2004.
[11] Z Zhong: “Online insulation monitoring
system for gas insulated transformer”, Cigre
[6] www.polytechnichub.com/advantages- 20th International Symposium on High
disadvantages-amorphous-metal- Voltage Engineering, August 2017.
transformer [12] Dr N Kumarappan: “Recent trends and
technological developments in transformer
insulation”, Electrical India, November 2015.
[7] Research Article - Preparation of Three [13] “Kenya Power plans gas-insulated
Types of Transformer Oil-Based Nanofluids transformers to fend off vandals”, Business
and Comparative Study on the Effect of Daily Africa, 25 August 2016
Nanoparticle Concentrations on Insulating

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