Transformers

VOL 3 ISSUE 3 JULY 2016 MAGAZINE

Vapor phase INTERVIEWS:

COLUMNS: transformer H.E. MOHAMMED
TAP-CHANGER KNOW-HOW drying M. SALEH
MARKET REVIEW
WOLFGANG
SORGATZ
Transformer condition
assessment

NEW: ECOTAP VPD

THE COMPACT CLASS FOR DISTRIBUTION TRANSFORMERS Dynamic
ISSN 1849-7268 (Digital)

testing of OLTC
Superconducting
transformers Integration of
distributed grid
Transformers and power quality infeed

CENTRE OF EXCELLENCE FOR TRANSFORMERS TRANSFORMER SECURITY INSULOGIX VAULT

NATURAL ESTER-FILLED TRANSFORMER FIELD EXPERIENCES ECOTAP VPD THE COMPACT OLTC

50
INTERVIEW WITH H.E. MOHAMMED MOHAMMED SALEH,
DIRECTOR GENERAL AT FEWA
H.E. Mohammed Mohammed Saleh, Director General at
FEWA, talks about the companys vision for sustainable
growth while preserving the environment along with achieving
a balance between economic and social development. He also
talks about FEWAs transformer fleet, procurement policy
and specifications development.
20
42
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
CONTENT
66
INTERVIEW WITH WOLFGANG SORGATZ
TLM CONFERENCE
Wolfgang Sorgatz talks about the TLM Conference which is a
successful and neutral platform for all stakeholders in the
transformers industry, from manufacturers of transformers,
instruments and materials, to their industrial partners and
end customers, such as utilities, power plants and entire
municipalities.
COLUMN: TAP-CHANGER KNOW-HOW
INSULATING LIQUIDS PART II
Rainer FROTSCHER
In this issue, alternative insulating liquids
and their potential for being used with
tap-changers is discussed, based on
extensive research performed on various
alternative liquids over the past 20 years, with the objective
of qualifying selected tap-changer models to be used with
these liquids.
COLUMN: ESTIMATING CURRENT AND
FUTURE TRANSFORMERS MARKETS
Steve AUBERTIN
The globalisation of the power and
distribution transformers markets and
the increase of available market data
has presented manufacturers with a new
twist on an old problem. How to obtain
accurate information about the current and future markets?
This article explores some of the issues and reviews some of
the sources.
3
CONTENT

NEWS
10
CENTRE OF EXCELLENCE FOR TRANSFORMERS IN
28 ZAGREB
The Centre of Excellence for Transformers in Zagreb is involved
in three major areas: continuous research and development,
a specialist postgraduate study in transformers, and an
international colloquium on transformers. The Centre has
28 been founded by the KONAR Group in cooperation with its
member companies and partners - the affiliated company
KONAR - Power Transformers Ltd. and Zagreb University.

FIELD EXPERIENCES WITH THE WORLDS LARGEST

36 NATURAL ESTER-FILLED TRANSFORMER
Today, electric utilities have to secure electricity supply while
maximizing health and environmental safety, particularly in
areas of high population density. Monitoring results for the
worlds largest natural ester-filled transformer reveal that
in almost three years in service the transformer has been

36 operating perfectly, demonstrating the long term suitability

as an alternative for mineral oil transformers even at high
voltage ratings.

THE INSULOGIX VAULT

54 A SECURE SOLUTION FOR YOUR TRANSFORMERS
AGAINST THE THREAT OF CYBER ATTACK
Chris AMEND, Robert BEGIN
The InsuLogix VAULT is the first solution of its kind to bring
together transformer condition monitoring, controls, and
substation security in a cyber-secure platform that exceeds

54 North American Electric Reliability Corporation security

requirements, all in an integrated, interoperable, and
extensible hardware and software architecture.

VAPOR PHASE TRANSFORMER DRYING PART II

60 Gregory R. STEEVES
The dielectric strength and the life of the insulation are
very dependent on its moisture content. During the
manufacturing process, the materials absorb moisture
with incidental contact with the air and must be efficiently
and effectively dried before the transformer shipping and
60 commissioning. Vapor phase drying as part of transformer
manufacturing is discussed in this paper.

ECOTAP VPD
70 COMPACT ON-LOAD TAP CHANGER FOR
DISTRIBUTION TRANSFORMERS
Maschinenfabrik Reinhausen has recently presented the
worlds most compact on-load tap-changer for distribution
transformers - ECOTAP VPD, which achieves maximum cost-
effectiveness for the entire transformer/on-load tap-changer
system. The unit is perfectly tailored to the processes
70 of transformer manufacturers and is highly versatile in
application.

4 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 Abdulla Hakeem
Regional Application Specialist

Benefit from our experience in

comprehensive power transformer
diagnostics
All of the experiences that I have as an application specialist flow into
our transformer test systems. Designed by engineers for engineers,
our solutions are reliable, portable and robust for daily field use, with
individual wiring diagrams and an integrated assessment according
to various standards. Our wide range of transformer test sets covers
everything from conventional tests such as power factor up to modern
methods like dielectric frequency response and SFRA.

www.omicronenergy.com/transformer
CONTENT

COST-EFFECTIVE AND FAIL-SAFE INTEGRATION

76 OF DISTRIBUTED GRID INFEED
Saskia BAUMANN
Decentralised energy production is on the rise. However, its
integration in the existing grid infrastructure is a challenge
for distribution grid operators. Regulated distribution
transformers and voltage regulators assist the operators in
overcoming this challenge.
76
TRANSFORMERS AND POWER QUALITY PART I
82 Petar Milkov UZUNOV
This article investigates the generation of higher harmonics
in small transformers supplying power to household, office
and industrial equipment. The study is based on the results
of the analysis of the magnetic field of the transformers
with the Finite Element Method and measurements. Due
to the large number of small transformers, they pollute the
electrical network and are a factor in lowering the quality of
82 electrical power.

SUPERCONDUCTING TRANSFORMERS PART II

90 Mike STAINES, Mohinder PANNU, Neil GLASSON,
Nathan ALLPRESS
Transformers using High Temperature Superconductor (HTS)
wire instead of copper conductor, and liquid nitrogen instead of
dielectric oil, have been in development for almost two decades
now. This paper describes the testing procedure conducted as
part of a recently completed HTS transformer demonstration,
90 and some implications for the outlook for this technology.

ADVANCED TRANSFORMER CONDITION

96 ASSESSMENT PART I
Jon L. GIESECKE
Aging transformers are an issue that must be understood
and addressed. This article offers guidance in setting up
a complete Predictive Maintenance programme for the
condition assessment of critical oil-filled power transformers
and ancillary substation components.
96
DYNAMIC ANALYSIS AND TESTING OF ON-LOAD TAP
104 CHANGER
Cornelius PLATH, Markus PTTER
This article presents an overview of the main testing
methods for on-load-tap-changers of power transformers.
It discusses in detail the application and analysis of dynamic
resistance measurement, which has become increasingly
common in recent years.

104 110 EVENTS

6 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 16
20
E
GR

e
nc
gu nd C I

ra
Pa 3
,F
at
5
ris
st 3
n
go

Au St a

ELECTRIFYING
Er
it
Vis

6
-2
21

Ergon's HyVolt Insulating Oils have been helping you

keep the lights on for decades.

Consistent products with consistent results.

ergoninternational.com | + 32 2 351 23 75
ergonnsa.com | 601-933-3000 (+1 outside US)
 CONTACT US
Australasia:
Vince Hantos
hanti@optusnet.com.au
Tel: +61 40 768 03 31

France
Serge Motta
serge.motta@gmail.com
Tel: +33 6 95 11 61 20

Germany & Netherlands:

Tomas Arenius
tomas.arenius@transformers-magazine.com
Tel: +49 1717328152

Subscribe now! India:

Ashutosh Kumar Govil
govil48@gmail.com
Tel: +91 99 750 975 34

Subscribe to Transformers Magazine and Italy:

Dario Ferrigato
keep track of the latest news and trends in dario.ferrigato@faet.it
the power transformer industry. Tel: +39 0289231 215

Middle East:
M. Shakeel Sadique Shaikh
shakeel@skypowertech.com
Tel: +97 1508909031

Each USD 96 / one year/ 4 issues Nordic Countries:

Tomas Arenius
Discount 10% for more than 10 pcs. tomas.arenius@transformers-magazine.com
Tel: +49 1717328152

Republic of China:
Jason Song
jason.song@transformers-magazine.com
Tel: +86 137 0197 2706

Individual digital subscription: Russian Federation:

USD 54 Alexander Drobyshevski
drob@vei.ru
Tel: +79 03 618 33 42

Corporate digital subscription S: South Korea:

Jeffrey Chi
USD 190 (for companies up to 30 employees) artex21c@artex21c.com
Tel: +82 2 581 5444
Corporate digital subscription M: Southern Africa:
USD 320 (for companies with 30 to 100 employees) Peter Busch
peterhoekwil2@gmail.com
Tel: +27 82 559 9970
Corporate digital subscription L:
Turkey:
USD 590 (for companies over 100 employees) Sinan Ozcan
sinan.ozcan@consultra-tr.com
Tel: +90 554 482 0041

USA:
Barney Giacobello
barney.giacobello@transformers-magazine.com
Tel: +1 732 236 8153
Online full subscription:
USD 19 ASIA:
Ye Wang
wang.ye@transformers-magazine.com
Tel: +86 156 9022 8274
Online free subscription:
FREE EMEA:
Tomas Arenius
tomas.arenius@transformers-magazine.com
www.transformers-magazine.com Tel: +49 1717328152

ROW:
www.facebook.com/transformersmagazine Marin A. Dugandzic
www.twitter.com/TransformersMag marin.dugandzic@merit-media.com
www.linkedin.com/groups/Transformers-772397 Tel: +44 20 373 474 69
TRANSFORMERS MAGAZINE
ISSN 1849-3319 (Print) ISSN 1849-7268 (Digital)
EDITORIAL BOARD
Editor-in-Chief:
Mladen Banovic, PhD, Merit Media Int., Croatia
mladen.banovic@transformers-magazine.com
EXECUTIVE EDITORS
Michel Duval, PhD, Hydro Quebec, Canada
Jean Sanchez, PhD, Utility, France
Jin Sim, Jin Sim & Associates, Inc., USA
Juliano Montanha, SIEMENS, Brazil
Craig Adams, TRAFOIX, Australia
Arne Petersen, AP Consulting, Australia
Michael Krger, OMICRON electronics GmbH,
Austria
Zhao Yongzhi, Shandong Electrical Engineering
& Equipment Group Co., Ltd, China
Art Director: Momir Blazek
Photo: Shutterstock.com
Front page: Cover image by Maschinenfabrik
Reinhausen GmbH
Language Editor: Marina C. Williams
ADVERTISING AND SUBSCRIPTION
Marin A. Dugandzic
+44 20 373 474 69
marin.dugandzic@merit-media.com
TRANSFORMERS MAGAZINE
Transformers Magazine is published quarterly
by Merit Media Int. d.o.o., Setaliste 150. brigade
10, 10 090 Zagreb, Croatia. Published art
icles dont represent official position of Merit
Media Int. d.o.o. Merit Media Int. d.o.o. is not
responsible for the content. The responsibil
ity for articles rests upon the authors, and the
responsibility for ads rests upon advertisers.
Manuscripts, photos and other submitted
documents are not returned.
Subscription rates:
Print edition: $96 (1 year, 4 issues)
Digital edition: $54 (1 year, 4 issues)
Online edition - full access: $19 (1 year, 4 issues)
Online edition - free access: free of charge for
registered users
www.transformers-magazine.com
REPRINT
Libraries are permitted to photocopy for the
private use of patrons. Abstracting is permited
with credit to the source. A per-copy fee must
be paid to the Publisher, contact Subscription.
For other copying or republication permissions,
contact Subscription. All rights reserved.
Publisher: Merit Media Int. d.o.o.
Setaliste 150. brigade 10,
10 090 Zagreb, Croatia
Contact: +385 1 7899 507
Contact: +44 20 373 474 69 UK
VAT number: HR09122628912
www.transformers-magazine.com
Bank name: Zagrebacka banka
Bank identifier code: ZABAHR2X
Bank IBAN: HR8023600001102375121
Director: Ana Jelcic
This issue is printed with the support of Ministry
of Science, Education and Sports of the Republic
of Croatia
www.transformers-magazine.com
Dear Readers,
I
n the Editorial message for the April issue, I
wrote about a common interest in forecasting
the market and industry trends, and pointed to
grid investments of nearly USD750B in the first
quarter of this year, which were all announced
and covered in our breaking news, as one poten-
tial indicator of the future business. Since then we
have published announcements on additional
investments valued at more than USD1 trillion.
While these announcements do not offer a foun-
dation for accurate predictions, they inform our
readers on the geographical areas of large invest-
ments and enable them to timely prepare for ten-
ders. This is exactly what I hear, especially from
the sales people, readers like about Transformers
Magazine.
Our e-Bulletin is a very practical tool to keep up-
dated with all developments on the global scene.
This weekly publication will save you a lot of
time, making all publicly accessible information
available at a glance. Therefore, I would like to in-
vite all our readers who havent subscribed to the
e-Bulletin to do so as soon as possible, and en
courage their colleagues, too. The registration is
free and very quick to do all that is necessary
is to provide your name and email address at:
www.transformers-magazine.com/e-bulletin
For readers looking to gain a deeper insight into
the market, I recommend reading the market re-
view article.
Over the past three months, in the business sec-
tor we have seen a few acquisitions the largest
being the acquisition of Crompton Greaves T&D
business, and several new plants opened such as
the new GEs instrument transformer facility in
Florida. More new plants have been announced,
as well as some potentially big sales such as SGB,
Tata Steels UK business, etc.
Some new technology concepts have also been
announced, such as new transformer core tech-
nology and high efficiency shielded toroidal
transformers. The new transformer core tech-
nology uses a low-temperature FAST technique
(field-assisted sintering technique), which enables
direct creation of perfectly sized cores from raw
starting materials (iron nitride powders) which
dont require any machining, promising signifi-
cant savings.
But lets get back to technical issues. Transformers
EDITORIAL MESSAGE
Magazine has been receiving more and more
manuscripts for technical articles. While this
doesnt affect or slow down our review process,
it may mean that an article will not be due for
publication immediately after the review process
has finished, but in the next available issue. This
is important for authors who would like to have
their articles published in a specific issue, and who
are thus encouraged to check submission dead-
lines for their manuscripts with our editorial staff.
A lot of our recent communication with readers
and authors has regarded natural and synthetic
esters, voltage regulated distribution transformers
and grid resiliency, suggesting that there is a lot of
activity surrounding these topics.
The communication with organizers of confer
ences, seminars and other transformer related
events is also increasing, indicating that there is
a growing awareness of importance of network
ing and global visibility, both for business and
professional development. In this respect, using
the opportunities available through Transformers
Magazine and its channels (website, e-Bulletin,
breaking news, etc.), and combining them with
those provided by Transformers Forum, an ever-
growing community of 19,000 members world-
wide, will create a synergistic effect and enhance
your chances for networking and global visibility.
It is thus no wonder that more and more people
from the industry take advantage of these oppor-
tunities.
The combined audience of Transformers Magazine
and Transformers Forum spreads across nearly
190 countries, making them two truly global plat-
forms with all the associated benefits for readers
and users.
This issue of Transformers Magazine brings an
overview of most important news, and features
two interesting interviews, a profile of the Centre
of Excellence for Transformers, several technical
articles and a few advertorials. All pieces provide
a lot of technical and business-related content,
which I hope you will enjoy.
Have a pleasant reading!
Mladen Banovic, Editor-in-Chief
9
 GRID INVESTMENTS
BGE to invest $4B over
next five years in power
system upgrades
Baltimore Gas and Electric Company (BGE)
in Maryland, USA will invest $4 billion
during the next five years in the power
system upgrades and expansions in order
to ensure fewer power outages and faster
restoration of power when outages occur.
P reparing for summer heat and potentially severe
storms, the company has recently invested more
than $8 million in critical distribution projects and
new technologies as well as in the installation of a
new substation and feeder, the company said in a
statement.
This work is part of the approximately $500 million
invested each year in the companys systems.
Source: BGE
Telengana power
infrastructure to receive $500M loan approved
$6B funding for $1.45B electrification
Telengana state in India will receive funding
of $6 billion from the Union Government program in Sumatra
to develop the state power sector and
improve the efficiency of the electricity
distribution companies, Transco and
Power Generation Corporation.
T he $6 billion funding will be used for the develop-
ment of electrical infrastructure and the facilities
to ensure around-the-clock power supply in state vil-
lages.
According to the Union Minister Bandaru Dattatreya,
the central government has already provided $1.7 bil
lion for the state efforts to provide electricity to each
and every village in the country.
Source: Deccan Chronicle
10
Utility to procure $6B
worth of distribution
equipment
Indias state-run utility company Power
Grid Corporation will spend $6 billion
to procure distribution equipment from
domestic vendors on behalf of states,
required for implementation of the rural
electrification and network strengthen
ing programmes.
T hrough the online reverse auction conducted in
April and May, Power Grid sought supply of critical
equipment, including power transformers, distribution
About 110 domestic equipment manufacturers em-
panelled with Power Grid were participating in the
auction.
transformers, conductors and cables for all states. Source: The Economic Times
Vancouver Island to
power up with $2B a
year over next decade
BC Hydro is implementing a major
capital plan, and will be investing around
$2 billion a year over the next decade
in the improvement of the electricity
infrastructure on the Vancouver Island
in British Columbia, Canada.
A s part of this programme, BC Hydro has re-
cently completed a major $36 million expan-
sion of the George Tripp substation in Victoria,
Along with the upgrades nearing completion at
the Horsey substation, this represents a $73 mil-
lion investment to upgrade Victorias two major
BC, which involved adding a new step-up trans- substations.
former and switchgear breaker equipment, and Other capital projects currently under way in-
installing a new 230 kilovolt underground trans- clude multi-million substation projects in South
mission cable that connects to nearby Horsey Wellington, Buckley Bay and Campbell River.
substation. Source: BC Hydro
Indonesias state-run utility PLN will
receive a $500 million loan from the
World Bank aimed to support imple-
mentation of the electrification pro-
gram which will bring electricity to
parts of Sumatra which are yet to be
connected to the national grid.
T hehe program, which will complement existing
power generation investments in Sumatra, in-
volves addition of 28,300 transformers and 40,000
$1.45 billion but funding will not only come from
the bank.
In Indonesia, 39 million people still do not have
kilometres of power lines. proper access to electricity, 9 million of whom live
According to the World Bank, the total cost of im- in Sumatra.
proving access to electricity in Sumatra stands at Source: Jakarta Globe
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Transformers are required to operate in many harsh environments offshore, arctic, desert, tropical, etc.

PROTECT YOUR
TRANSFORMERS
SENSITIVE INTERIOR
IN ALL CONDITIONS.
MAKE IT
LIFELONG.

The leading European transformer

KONAR - Steel Structures Inc. tank manufacturer www.koncar-mk.hr
PROJECTS
US DOE approves
$2.5B transmission
project
The U.S. Department of Energy (DOE)
has approved the development of the
Clean Line Energys $2.5 billion Plains &
Eastern Line transmission project in an
effort to modernize the grid and accele-
rate the renewable energy deployment.
T he Clean Line project, designed to deliver up to
4,000 MW of wind power through a 1,135 km
direct current transmission line, also includes deve-
lopment of a 500 MW converter station in Arkansas,
including a power transformer and associated elec-
trical equipment. The project, which will meet the
electricity needs of more than 1.5 million homes in
the mid-South and Southeast US, is planned to com-
mence in 2017. Source: EBR
$1.5B sub-Atlantic
transmission project
with $100M substation
proposed
USA: With Pilgrim Nuclear Power Station
in Plymouth, Massachusetts shutting
down permanently in mid-2019, the
site is being considered by another
energy producer for the construction
of a new power substation to be built
as part of the $1.5 billion sub-Atlantic
transmission project.
G reen Line Devco LLC, a collaborative of Anbaric
Transmission and National Grid, are looking to
build a $100 million transmission substation in Ply-
mouth to convert the electricity source for that part
of the regions grid to onshore wind and hydropower
generated in Maine and Canada.
Source: Cape Cod Times
12
EIB to support $1.5B
transmission project with
$720M funding
$1.5 billion electricity transmission
project in Scotland, United Kingdom
will be supported by funding from the
European Investment Bank (EIB).
T he European Investment Bank (EIB) will provide
$719.70 million in financing to support the de-
velopment of a high-voltage direct current (HVDC)
power transmission link to connect the electricity grid
on either side of the Moray Firth in northern Scotland.
Source: EBR
$1.17B Central Asian
transmission project
launched
The $1.17 billion CASA-1000 power
transmission project has been
inaugurated by the officials from
Afghanistan, Pakistan, Tajikistan and
Kyrgyzstan, after the competent
ministries from the four countries
finalized the document and decision
on the implementation of the project.
T he CASA-1000 project will pave the way for the
transmission of electricity from Tajikistan and
Kyrgyzstan to Afghanistan and Pakistan through
1,250 km of high voltage transmission line.
Two converter stations with power transformers and
associated electrical equipment will be built for the
project, including a 1,300 MW AC-DC converter sta-
tion at Sangtuda, Tajikistan.
Another high-voltage transformer will be built in the
city of Pul-e-Khumri, Baghlan province to ensure
supply of 300 MW of electricity to Afghanistan.
Source: The Nation; Photo: RFERL
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
PEOPLE
ABB plans for
leadership succession;
new MDs appointed
As part of leadership succession plan-
ning, ABB has appointed Tauno Heinola
as Managing Director of ABB in Australia,
effective 1 October 2016.
H einola will succeed Axel Kuhr, who will be-
come Managing Director in Japan.
The appointments are part of a leadership suc-
cession at ABB: Kuhr replaces Tony Zeitoun,
who is currently Managing Director in Japan
and will retire from ABB at the end of the year,
while Pekka Tiitinen, currently President of the
Discrete Automation and Motion (DM) div
ision, will succeed Heinola as Managing Director
in Finland. Source: ABB
Alstom T&D India
appoints CFO
Alstom T&D India Ltd announced the com-
pany appointed Mr. Gaurav Manoher Negi
as Chief Financial Officer.
M r. Negi will assumed the position from 1 June
2016 taking over from Mr. S. M. Momaya, who
ceased to be a whole-time Director and Chief Finan-
cial Officer of the Company as of 31 May 31 2016.
Source: Equity Bulls
Malaysian transformer
maker appoints new
chairman
Malaysian transformer manufacturer Suc-
cess Transformer Corp Bhd has announced
the company appointed Datuk Chua Tia
Guan as its chairman.
T he appointment follows the resignation of
Chiam Tau Meng due to personal commitment
after heading the company for two years, reports the
Edge Market. Source: The Edge Markets
Winder Power
appoints new Group
Manufacturing Director
Winder Power, UKs manufacturer of power
and distribution transformers, announced
the appointment of Keith Robertshaw as the
Companys Group Manufacturing Director,
effective from 1 April 2016.
A n industry professional with extensive expert
ise, Keith transitioned from the role of General
Manager of the Newton Derby division within
Winder Power. Source: Winder Power
WORKS HERE.

S4
SHELL DIALA PROTECT YOUR TRANSFORMER,
OPTIMISE ITS PERFORMANCE, EXTEND ITS LIFETIME

Shell Diala S4 is a range of innovative transformer oils developed to meet the

challenging conditions faced by your transformers. Produced using Shells gas-to-
liquids technology, they deliver exceptional performance for extending the lifetime
of your transformer under conditions of increasing oil stress. The range includes
transformer oils that meet IEC 60296 and ASTM D3487 Type II specifications.

www.shell.com/lubricants
 BUSINESS
German transformer
maker approaches
potential buyers in Asia
Buyout group BC Partners is approach
ing potential buyers for its German
power transformer maker SGB-SMIT,
four years after a sale to Chinas State
Grid was halted by political interven
tion, according to three sources familiar
with the matter.
I nformation packages have been sent out to pros-
pective buyers mainly in Asia, the sources said, but
a formal auction, which may not be concluded until
2017, has not been launched yet.
Back in 2012, Chinas State Grid was in exclusive talks
to buy SGB, but it failed to receive political support for
a deal as Chinas National Development and Reform
Commission had considered the sector to be suf
fering from overcapacity.
SGB Starkstrom was originally part of Germanys
second-biggest utility, RWE. It was sold to private
equity group HCP Capital Group in 2004 and then to
BC Partners in 2008.
Source: Yahoo Finance; Photo: SGB-SMIT
Crompton Greaves
power business acquired
First Reserve International, a US private
equity fund, announced the signing of an
investment to acquire a subset of the in-
ternational power transmission and dis-
tribution division of Crompton Greaves
Ltd., which will be rebranded as Pauwels.
A share purchase agreement has been signed for
CG power businesses in Europe, North America
and Indonesia for an enterprise value of $126 million.
The acquired division, which is expected to be re-
branded as Pauwels, makes transformers and switch-
gears, and provides systems across the transmission
and distribution sectors.
Source: First Reserve; Reuters
14
G reybull Capital will bring in a package of $575
million provided by a combination of banks and
its shareholders, to fund working capital and future
investments in the business, reports Metal Miner.
The deal includes the sale of Scunthorpe steel plant,
mills in Teesside and northern France, an engineering
workshop in Workington, a design consultancy in York,
a bulk terminal, and associated distribution facilities.
Transformers Forum
marks a new milestone!
In May this year, Transformers Forum,
a dynamic community operated
through LinkedIn and supported
by Transformers Magazine, proudly
announced its new milestone
19,000 forum members!
T ransformers Forum is a busy transformer industry
hub offering a unique platform where members
can share and discuss their ideas, knowledge, experi-
ence and opinions within the industry.
This constantly growing community offers experts
and novices alike an opportunity to build competence
and broaden their technical horizons and experience
by taking part in the pool of technical knowledge and
H owever, with the United Kingdom voting to
leave the European Union in the recent referen-
dum, several bidders are close to abandoning talks
with their Indian owner as the outcome of the EU
referendum threatens to deepen the crisis enveloping
the UKs biggest steel producer.
Sky News has learnt that one of the shortlisted seven
bidders has signalled that exiting the EU would dimi-
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Tata Steel sells most
of its European assets
Following its earlier announcement
of the decision to sell its poorly
performing business in the U.K., Indias
Tata Steel has sold its long products
business assets in Europe to investment
firm Greybull Capital.
With this sale, the balance of Tata Steel U.K. business
comprises primarily all of its operations at Port Talbot,
which manufacture slabs, hot-rolled coil, cold-rolled
coil and galvanized coil.
After the sale of all U.K.-based assets, Tata Steel will
operate only the Ijmuiden (Netherlands) unit.
Source: Metal Miner
relevant experience, collected from the members from
all over the world.
We would like to invite you and your colleagues to join
the Forum and check out the advanced features that
this platform offers.
Connect and engage with your peers through this ac
tive community and stay in the loop!
Welcome!
Tata Steel bidders get
cold feet over Brexit
Tata Steel has shortlisted seven bidders
looking to buy its UK assets JSW
Steel, Chinas Hebei Iron & Steel, US
Nucor, Liberty House, Excalibur, PE
Players Greybull Cap & Leeds-based PE
company Endless.
nish the prospects of him pursuing a takeover, with
similar concerns expressed by a number of other
prospective buyers.
Sources said that Tata Steel had raised the
possibility of putting its British business into
some form of liquidation, but no decisions had
been taken.
Source: Money Control; Sky News
 WITH MIDEL
TRANSFORMER
FLUIDS

AND HERE

AND HERE

AND HERE

AND HERE

ITS
SAFER
HERE

When it comes to protecting what matters, there can be no compromises.

MIDEL ester transformer fluids are the first and only choice for unrivalled
risk mitigation. MIDEL also enables innovation in transformer design, so
manufacturers can make safer, more flexible transformers for tomorrows
transmission and distribution needs. Its time to go beyond mineral oil.
MIDEL is transforming asset performance, reducing risk and delivering cost
savings every day across the world. Call MIDEL lets make it safer together.

Search: MIDEL Safety Inside

midelsafetyinside.com or call +44 (0)161 864 5422
 PRODUCTS
A new transformer TRAX transformer
resilience concept for and substation testing
maximized grid stability solution
Siemens has launched a new transform
er resilience concept developed to
achieve maximum grid resilience.
T he concept Pretact for resilient grids comprises a
three-pillar-plan to enable customers to prevent
failures, protect their equipment and react in cases
of emergency.
This new concept addresses emergencies, retrofits
and new installations along the entire energy value
chain to increase network stability by modular fea-
ture/ solution architecture for power and distribu
tion transformers.
Source: Siemens
First dry-pluggable
bushing for voltages up
to 362 kV
HV-CONNEX Size 7-S is the first dry-
pluggable bushing specially designed
for mobile emergency transformers and
for high-voltage levels up to 362 kV.
C ONNEX bushing can be simply unplugged and
replaced with a new one without any laborious
oil preparation. Power transformers equipped in this
way are flexible in their use and easy to transport,
enabling them to be used as emergency transformers.
This means that damaged transformers can be re
placed within a very short time.
This product innovation encapsulates the extensive
know-how of PFISTERER, the worlds only manufac-
turer of pluggable bushings for the HV sector.
Source: Pfisterer
16
Megger has developed a complete
solution for transformer and substation
testing TRAX.
T he new solution features a software and an app-
based interface.
The finest power testing equipment with an added
functionality is packed into one box for easy transport
and application in the field. Source: Megger
ECOTAP VPD - The
new compact class for
distribution transformers
Maschinenfabrik Reinhausen (MR) launch
ed a new generation of on-load tap-chan-
gers for voltage regulation distribution
transformers with the world premiere held
at the CWIEME Fair in Berlin yesterday.
T he premiere of the new ECOTAP VPD was
opened by Dr. Nicolas Maier-Scheubeck, Managing
Director of MR, while the group of experts includ
ing Manuel Sojer from MR, Armin Vielhauer from
E.ON, Bernhard Schowe-von der Brelie from FGH
and Thomas Dederichs from BDEW presented the
technical chartacteristics of the product and its ap-
plication aspects in the power distribution network.
The new ECOTAP VPD is the worlds most compact
on-load tap-changer for distribution transformers
offering the largest range of services. It achieves ma-
ximum cost-effectiveness for the entire transformer/
on-load tap-changer system, is maintenance-free, al-
ready satisfies the requirements of the EU Ecodesign
Directive for 2021, and can be operated with syn
thetic and natural esters as insulating fluids.
Source: MR
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
NEW TECHNOLOGIES
PowerBridgeNY
helps making greener
transformers
PowerBridgeNY, a proof-of-concept cen-
ter (POCC) program which is advised by
the New York Academy of Sciences and
provides early-stage investments and
services to help inventors and scientists
turn their high-tech, clean-energy ideas
into a successful business, has helped
establishment of a new company which
has designed a new green transformer.
W ith the green technology developed
within the POCC program, a new high
efficiency shielded toroidal transformer has
been designed by two engineers-turned-entre-
preneurs as a cost-effective and clean-energy
alternative to traditional transformers.
Source: The New York Academy of Sciences
Iron nitride transform
ers could boost energy
storage options
A team led by Sandia National Labora
tories, U.S. Department of Energy
research and development national
laboratory, has developed a way to
make a magnetic material that could
lead to lighter and smaller, cheaper
and better-performing high-frequency
transformers.
T he new method uses a low-temperature FAST
technique (field-assisted sintering technique),
which enables the creation of transformer cores
from raw starting materials in minutes, without de-
composing the required iron nitrides, as could hap-
pen at the higher temperatures used in conventional
sintering, reports ECN Magazine.
Source: Sandia National Laboratories;
Photo: Randy Montoya
DiTAS TEST SYSTEM FOR
DISTRIBUTION TRANSFORMERS
New modular system for distribution transformers is optimized for high testing throughput without limitation in quality.

FAST. COMPACT. RELIABLE.

AUTOMATED.

APPLICATIONS
n Inducedvoltagetests
n Appliedvoltagetests
n No-loadlosstests
n Loadloss/short-circuittests
n Temperaturerisetests

TEChNICAL PARAMETERS
DiTAS 170-500/4.8
n Converterpower:170kVA170kW
n Compensationpower:500kvarcapacitive
n Frequencyrange:40200Hz
n Outputvoltage:4.8kV
n Testobjectsize:upto5MVA

DiTAS 80-250/4.9
n Converterpower:80kVA80kW
n Compensationpower:250kvarcapacitive
n Frequencyrange:40200Hz
n Outputvoltage:4.9kV
n Testobjectsize:upto2.5MVA
BENEFITS
n Fullyautomatictestproceduresandreporting
n Highestsafetyconditionsforoperatingstaffacc.toIEC62061(SIL3)
n Designwithstaticfrequencyconvertersasuniversalpowersource
n Modulardesignwithintegratedmeasuringunits
n Cost-effectivesystembasedonprovenHIGHVOLTdesign

Visit us at the CIGRE Session in Paris from 22 to 26 August 2016 at booth no. 230.

www.highvolt.de
MARKET OVERVIEW
Market overview
Recently published market research reports provide an insight into the global
and regional industry trends and perspectives. We bring you a summary of the
made forecasts and highlighted tendencies:
T the global power and distribution transformers
market is estimated to be worth $35 billion in
2016. On a global level, there is pressure on utility
companies to refurbish and replace the aging trans-
former population, and on transformer manufactu-
rers to provide efficient and alternative transformer
and material solutions. In this respect, progressing
into the next decade more competition is expected
to come from China, India and South Korea.
The global power transformer market is projected to
reach $29.9 billion by 2020 and exceed $34.6 billion
by 2022. This means the market will grow at 5.9 %
over the coming few years. However, unstable raw
material prices are likely to challenge the market
demand over the next six years. Large power trans-
former segment is projected to grow at the highest
CAGR of 7.8 % between 2014 and 2020. This market,
which had an estimated valuation of $18.35 billion
in 2013, is projected to rise to $31.05 billion by 2020.
The focus in the coming years will be on large power
transformers that run on alternative energy sources.
100 MVA to 500 MVA output power leads the glo-
bal power transformer market, which accounted for
about 68 % of the total industry share in 2015, with
gains estimated at 6.2 % over the next few years.
Medium transformers market accounted for over 40
% of the overall revenue share in 2014, and is expec-
ted to witness significant growth over the next few
years. Small transformers segment is estimated to
grow owing to high demand for stepping voltages
down within a distribution circuit of a building or to
supply power to equipment.
Smart grids holds a 98.56 % market share in the ove-
rall global solid state transformer market, and is ex-
18
pected to grow at a CAGR of 32.71 %. The solid state
transformer market in the Asia-Pacific region is in
its nascent stage, with a huge market potential in the
distribution network of power grids.
Growing demand for power and investments in
power transmission & distribution network for up-
gradation and expansion is expected to drive pad-
mounted transformer market at a rate of 5.21 %
from 2015 to 2020. Three phase pad-mounted trans-
former and dry-type pad mounted transformer are
the segments with highest growth in pad-mounted
transformer market.
The North American traction transformer market is
estimated to grow at a CAGR of 9.4 % from 2014 to
2019.
The global transformer monitoring solutions mar-
ket is expected to grow at a CAGR of 36 % during
the period 2016-2020. One trend that is expected to
boost market growth is the introduction of automa-
ted high-voltage transformer monitoring solutions.
While demand for electricity in emerging markets
is the key growth driver, one of the challenges that
could hamper market growth is the high price of
transformer monitoring systems.
The power sector offers a promising future to the
global packaged substation market with growing
demands for electricity, following increasing urbani-
zation and industrialization in the developed as well
as developing nations.
Finally, let us note that this year the first shell-type
765 kV transformer has been manufactured at a
factory in Memphis, Tennessee, making it the first
transformer of this rating to be manufactured locally
in the United States in 25 years.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
MARKET REGULATION
Steel world met in
Brussels to address
overcapacity
Representatives from around 30 coun-
tries including China, Japan, Germany,
India, the U.K. and the U.S. met with
World Trade Organization, World Steel
Association, and Organization for Eco-
nomic Cooperation and Development
(OECD) representatives in Brussels to
seek possible solutions to the huge over-
capacity that fuels the steel crisis.
T
he main objective of the meeting, which was orga-
nized by OECD, was to exchange views on the po-
licy actions that would help reduce steel excess capa-
city, and to strengthen efforts to increase transparency
through information sharing about measures taken
to address excess capacity and promote structural ad-
justment in the steel industry.
Source: OECD; Photo: OECD (Flickr)
Union urges immediate
government action on
U.S. steel crisis
As the United States Trade Represen-
tative called a hearing on the global
steel industry and its impact on the U.S.
steel industry and steel market, Uni-
ted Steelworkers (USW) International
President Leo W. Gerard urged the U.S.
Government to create an immediate ac-
tion plan on US steel crisis, reports Sys-
Con Media.
As the United States Trade Representative called a
hearing on the global steel industry and its impact
on the U.S. steel industry and steel market, United
Steelworkers (USW) International President Leo W.
Gerard urged the U.S. Government to create an im-
mediate action plan on US steel crisis, reports Sys-
Con Media. Source: Sys-Con Media
Authorized converter
Flexible insulation products
COLUMN
Tap-changer know-how
Insulating liquids Part II: Non-mineral insulating liquids
1. General
In the previous edition of Transformers
Magazine, the typical properties of min
eral insulating oils were illustrated. In this
issue, the column will discuss alternative
insulating liquids and their potential for
being used with tap-changers.
A short update on the Recycled mineral
oils chapter (see Insulating liquids Part I,
section 2.4., Transformers Magazine, Vol
3, Issue 2, April 2016) seems to be adequate
here. The IEC Standard Management
Board has given instruction that recycled
mineral oils shall be integrated into IEC
60296 (which, up to now, was dedicated
exclusively to unused mineral oils). To
execute this, IEC Working Group TC10/
MT38 has been established, which shall
immediately revise IEC 60296 and give
proper advice on how to recognize and
classify recycled mineral oils based on
their performance only and not on their
provenance. 28 participants have been
nominated for the working group by the
IEC National Committees, producers of
recycled oils among them.
20
O ver the past 20 years, extensive
research on various alternative liquids
has been performed with the objective of
qualifying selected tap-changer models
to be used with these liquids. The liquids
and eligible tap-changer models have
been chosen according to their market
share. Really laborious is the evaluation
of the arc-quenching behavior, which
includes the determination of arcing
times at high and low oil temperatures,
and the amount and composition of
deterioration products, such as carbon
(soot), acids and gases. Gases can be
toxic, and acids can attack solid insulating
materials [1]. For this reason, research
work has been focused on vacuum type
on-load tap-changer (OLTC) models,
so that the alternative liquid can be used
both inside the transformer tank and
tap-changer oil compartment. Non-
vacuum type models (oil switching
OLTCs) should only be used with
alternative liquids in the transformer
tank / tap selector compartment, while
the diverter switch compartment is filled
with mineral oil. De-energized tap-
changers (DETCs) may also be used with
alternative liquids.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
2. Non-mineral insulating
liquids
Certain non-mineral liquids have been
identified as suitable substitutes for min
eral insulating oil, providing benefits for
special applications. High-temperature or
downtown substation transformers need
liquids with low flammability (high flash
point); transformers in environmentally
sensitive areas should be filled with fully
biodegradable liquids, and for applica-
tions like traction transformers the liquid
should be chemically inert.
Eligible liquids show significant differ
ences to mineral insulating oils concern
ing their composition, properties and
performance; therefore, they dont comply
with the mineral oil standards discussed in
Insulating liquids - Part I. If such liquids
shall be used in tap-changers, each liquid
has to be tested and evaluated properly.
One apparent difference, for example, is
the higher viscosity of some alternative
liquids (see Fig. 1). Viscosity affects the
timing of the tap-changer switching oper
ation at (very) low oil temperatures, and

influences the oil flow which determines
the cooling of transformer windings, ter-
minals, contacts and transition resistors.
Furthermore, liquid viscosity also influen-
ces the arc-quenching behavior. Even for
vacuum type OLTCs, low-energy arcs or
sparks are produced at the change-over se-
Figure 1. Viscosity of different insulating liquids on a ln(ln()) scale, and temperature limits
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Over the past 15 years, extensive research on
various alternative liquids has been performed
with the objective of qualifying selected tap-
changer models to be used with these liquids
lector which reverses the regulating wind
ing or switches the coarse tap winding in
and out. Capacitive currents of up to 500
mA have to be broken, and recovery volt
ages up to 40 kV on the opening contacts
must be controlled. For liquids showing a
higher viscosity than mineral oil, the switch
ing capacity of the change-over selector is
reduced, because arcing-times are longer
than in mineral oil. This is probably due to
the effect that cold liquid is not delivered
fast enough into the hot arcing path to
cool and quench the switching arc within
the admissible time frame.
2.1. Ester liquids
Ester liquids can be divided in two fam
ilies: synthetic and natural esters. Syn
thetic esters (e.g. MIDEL 7131, M&I,
U.K.) have been invented in the late 70s
as an environmental friendly alternative
Rainer FROTSCHER
to the non-flammable, but highly
questionable polychlorinated biphenyls
(PCBs). Synthetically composed from
alcohols and sat urated fatty acids, all
molecules are nearly same size, which
gives them well-defined properties. They
show good oxidation stability, but are
rather expensive.
Natural esters, however, are prod
uced from seed oils, such as soya (e.g.
ENVIROTEMP FR3 by Cargill, U.S.),
rapeseed (e.g. SunOhm Eco by Kanden
Eng., Japan, or MIDEL eN by M&I, U.K.),
sunflower (BIOTEMP by ABB, with-
drawn from market) and others. They are
a blend of unsaturated and saturated fatty
acids in order to achieve a sensible balance
between oxidation stability and low-tem-
perature behavior. One exotic variant of
natural esters is palm oil (e.g. Pastell Neo,
Japan): despite exclusive use of saturated
21
 COLUMN
High-temperature or downtown substation
transformers need liquids with low flam-
mability; transformers in environmentally
sensitive areas should be filled with fully
biodegradable liquids, etc.
fatty acids, it has a low pour point of less
than -30 C, good oxidation stability, but a
flash point only slightly higher than min
eral oil. This palm oil cannot be regarded
as a less-flammable liquid. MIDEL eN
also shows a pour point lower than -30 C
but is less-flammable at the same time.
Here, pour-point depressant additives
help to improve the liquid flow at low oil
temperatures.
The higher the percentage of unsaturated
fatty acids, the more the liquid tends to
polymerize under permanent air expos
ure, leading to an increase in viscosity and
finally to a jelly-like appearance. As this is
not acceptable, it is highly recommended
to use natural esters only in sealed appli-
cations. Free-breathing application with
natural esters may work for distribution
transformers with limited breathing
(there is some long-term experience in the
U.S.), but not for highly optimized power
transformers and OLTCs.
Both synthetic and natural ester liquids
are biodegradable, show very low oral and
aquatic toxicity, and are classified as not
water endangering. This allows usage in
installations in sensitive environments
such as water catchment areas, off-shore
wind parks or downtown substations.
For the latter, a low fire hazard is essential.
Ester liquids show a much lower fire haz
ard than mineral oils, not only through
the significantly higher flash point, but
also through the lower calorific value
(Table 1). This means that the energy prod
Table 1. Classification of insulating liquids acc. to IEC61039 (Extract)
Fire point (ISO 2592)
Class O 300 C
Class K > 300 C
Class L Not quantifiable
Synthetic ester
Class K
Natural ester
Table 1: Classification of insulating liquids acc. to IEC61039 (Extract)
22
uced in a fire is significantly lower than
for mineral oils. By using a K-class less-
flammable liquid, clearances and fire pro-
tection measures can be reduced for both
indoor and outdoor transformers [2].
Ester liquids can hold huge amounts
of moisture, compared to mineral oil.
While a typical mineral oil gets saturated
with 50-60 ppm water at 20 C, natural
ester can hold up to 1000 ppm and syn-
thetic ester approximately 2200 ppm of
water at 20 C [3], [4]. This hygroscopic
behavior provokes two effects:
the water content in the cellulose insu-
lation of the transformer is lower than
with mineral oil; and
the dielectric strength of the liquid stays
high even with hundreds of ppm of wa-
ter (high moisture tolerance).
The reason why ester liquids can hold so
much water is simply due to their polar
structure: water (which is also polar) can
easily attach to the acid groups of the
ester molecules via hydrogen bonds; see
Fig. 2.
The permittivity of ester liquids is rough-
ly 1.5 times higher than that of mineral
oils. This leads to more uniform field
distributions in combination with solid
insulation materials. On first glance,
this seems to be an advantage, but it also
me ans that the absolute field strength
inside the solids is higher than with min
eral oils. Therefore, inadequate impreg-
nation or little cavities inside the solids
have a more distinct detrimental impact
Calorific value (ASTM D240)
Category 1
Category 2
Category 3
Synthetic ester
Natural ester
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
H
O
+ H
O -
R C
O R
Figure
Figure2.2:Polar
Polarmolecules
molecules and hydrogenbonds
and hydrogen bondsareareresponsible for
responsible for high water absorption capability of
ester liquids
on the dielectric strength of the solid
insulating material.
Another difference in electrical pro-
perties of ester liquids is their different
streamer propagation behavior, which
is visible on inhomogeneous electrode
configurations and long insulating dis
tances. Numerous investigations (e.g. [5],
[6]) have revealed that fast streamers in
ester liquids develop at lower voltages
and have a longer stopping length than
in mineral oil. This means that, for tap
selectors showing moderately inhomo-
geneous fields and insulating distances of
typically 5-10 cm, lower withstand volt
ages are achieved. This is true for lightning
impulse (LI) as well as for operating fre-
quency (AC) voltage waveforms, and has
been verified by numerous full-size tests
on different tap selector arrangements.
As a consequence, a bigger tap selector
size may be appropriate or, as a work
around, varistors can be added along
the regulating winding to limit the AC
and LI voltages which are applied during
42 MJ/kg
< 42 MJ/kg and 32 MJ/kg
< 32 MJ/kg
Category 3
Category 2
transformer testing or which can occur
as overvoltages in service.
On the other hand, homogeneous
field configurations do not show this
phenom e non, probably because the
starting point of a streamer discharge
which leads to a flashover is not proper-
ly defined it is statistically distributed.
So, for typical phase-to-phase or phase-
to-ground insulation arrangements with
optimized homogeneous field geometry,
the full withstand voltages as for mineral
oil can be applied.
It is highly likely that the streamer break-
down behavior also depends on the ab-
solute level of the applied voltage. It has
been found that OLTCs for distribution
transformers do not require the said re-
duction of withstand voltages in ester
liquids. With the grade of field inhomo-
geneity being comparable to bigger-sized
tap selectors, the comparatively low LI
and AC test voltage levels applied for
Um 36 kV or lower are probably not high
enough to reveal the differences between
ester liquids and mineral oil. Further in-
vestigation on this seems to be necessary.
For short distances (like in the IEC 60156
or ASTM D877 / D1816 standards De-
termination of the breakdown voltage
at power frequency), the differences in
stopping length are not influential be-
cause the insulating distance is just too
short. This is why ester liquids achieve
the same (or higher) breakdown voltages
(BDV) than mineral oil. So, by consider
ing the BDV only, one cannot judge
Figure 3. Semi-solid tufts of silicone oxide; left: after 3 weeks at 20 C, 2 kV/mm; right: after 6 hrs at 50 C, 5 kV/mm
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Both synthetic and natural ester liquids
are biodegradable, show very low oral and
aquatic toxicity, and are classified as not
water endangering
the dielectric quality of an ester liquid.
Because every brand behaves different-
ly, it would be good if one had an easy
method to quantify the streamer break-
down behavior of an unknown ester li-
quid in comparison to mineral oil under
realistic dielectric field conditions, with
out the need of running full-size tests on
tap-changers.
The lubricating behavior has been evalu-
ated as well, as it is an extremely import
ant parameter for tap-changers. Ester
liquids show a comparable (or slightly
better) lubricating behavior than mineral
oil, and so ensure low mechanical wear
and the same mechanical endurance
as for mineral oils for all mechanically
operating parts.
All ester liquids contain acids, which
may attack solid non-metal materials,
such as nitrile rubber gaskets, plastics
or paints. Natural esters are more gentle
to these materials than synthetic esters.
It has been observed that nitrile rubber
gaskets get brittle in synthetic ester but
swell in natural ester, with the grade of
degeneration depending on the individ
ual rubber composition. Sophisticated
thermoplasts or thermoset materials, as
commonly used in modern tap-chan-
gers, may lose some percentage of their
mechanical strength when stored in ester
liquids. This must be considered in the
design process.
On the other hand, at least natural esters
show an excellent compatibility with cel-
lulose (Kraft paper): cellulose ageing is
2.5 times slower than in mineral oil; it
seems as if the ester protects the cellu-
lose from ageing [7].
2.2. Silicones
Silicone liquids consist of chains of sili-
cone oxide, which have been saturated by
methyl groups (siloxane). A huge range
of products with different viscosities is
available; for electrical purposes, viscos
ities of 20 mm/s and 50 mm/s (at 25 C)
are used. Silicone liquids are usually used
in small high-temperature transformers
(e.g. traction transformers) or voltage
transformers, but very seldom in power
transformers. They have an extreme lon-
gevity, behave inert, but are not easily
biodegradable.
Already at moderate field stress, as it can
occur on tap-changer electrode configur
ations, silicone liquids produce clusters
(tufts) of semi-solid silicone oxide (Fig. 3).
23
COLUMN
Drawbacks of silicone liquids in combin
ation with tap-changers is the affinity to
build up jelly bridges between electrodes
and their insufficient lubrication behavior
In moving oil, these tufts may be washed
off the electrode, dissolve completely in
the liquid or attach again to other un-
coated electrodes as a thread, with un
known long-term effect on the dielectric
strength of the insulating gap. This affin
ity to build up jelly bridges between elec-
trodes is also the reason why the BDV of
silicone liquids is noticeably lower than
that of mineral oils or ester liquids. It also
hampers their use with higher system
voltages (e.g. Um >72.5 kV).
Another drawback of silicone liquids in
combination with tap-changers is their
insufficient lubrication behavior. Tests
have revealed that the mechanical wear
on sliding friction arrangements, which
are common for tap-changers, is multiple
times higher than in mineral oil. This
leads to a significantly reduced lifetime
Table 2. Possible combinations of MR tap-changers with alternative liquids
OLTC type HMWH
VACUTAP VV
VACUTAP VM
(except VM 300)
VACUTAP VRC/VRE
VACUTAP VRD/VRF 1)
VACUTAP RMV-II
VACUTAP iTAP, ECOTAP
OILTAP M/RM
Mineral oil inside OLTC oil compartment
OILTAP V
Mineral oil inside OLTC oil compartment
DEETAP DU 2)
: Approved
Table 2: Possible combinations of MR tap-changers with alternative liquids
CF3 O CF CF2
n m
CF3
Halogenated polyether (perfluorinated polyether)
Halogenated polyether (perfluorinated polyether)
24
of mechanically operated parts. It may be
acceptable for DETCs which are seldom
operated, but not for OLTCs. To over-
come this deficit, a trial has been set up
in which 10 % MIDEL 7131 was added
to KF-96AE, a 20 mm/s silicone liquid
from ShinEtsu Chemicals (Japan). This
in fact improved the lubricating capabil
ity significantly, but resulted in unwant
ed side effects: the switching arcs of the
change-over selector (low energy arcs)
caused some deterioration of both ester
and silicone liquid, which ended in an
awkward mixture of black soot deposits
(produced by MIDEL 7131) and said jel-
ly threads of silicone oxides. This mixture
was highly conductive and caused unpre-
dictable dielectric breakdowns. So, the
message is clear: The mixing of a silicone
liquid with an ester liquid is definitely
not recommendable if there is arcing!
Synthetic ester Natural ester
Approved non-silicone liquid
in OLTC oil compartment.
2) 2)
: Not approved 1) On request 2) Special case; please consult MR for individual approval
O CF2 O CF3
HMWH (high molecular weight hydrocarbon)
Overall, silicone liquids offer only a
very limited applicability for on-load
tap-changers. They may be used with
DETCs if field strength is kept low so
that a formation of semi-solid tufts can
be avoided and if the DETC is not oper
ated excessively. Up to 50,000 operations
over the whole lifetime of the transform
er is acceptable. This is also true for the
change-over selector of the VACUTAP
VV, which can be operated in silicone li-
quid without restrictions. This has been
verified by tests. Wherever possible,
bare electrodes (e.g. terminals, shielding
rings) should be coated or paper-wrap-
ped to minimize the detrimental effect of
said tufts. In any case, the OLTC oil com-
partment has to be filled with another
approved liquid (mineral oil, ester liquid
or HMWH).
2.3. High molecular weight
hydrocarbons
High Molecular Weight Hydrocarbons
(HMWHs, also called LFH, less-flam-
mable hydrocarbons) were invented in
the 1970s as the first substitute to PCBs.
The major brand was R-TEMP Fluid
(by Cooper Industries, USA), which was
manufactured until 2005. Former Cooper
scientist David Sundin (DSI) issued
Silicone oil an improved LFH called BETA-Fluid,
2) which is still available and is mainly used
for distribution transformers in the U.S.
In Korea, a local comparable product
called MICTRANS-G has been used for
less-flammable regulated power trans-
formers in underground downtown sub-
stations.
HMWHs are refined from paraffinic pet
roleum resources. Their long saturated
2) hydrocarbon chains care for low flamma-
bility, but are also responsible for a much
2) higher viscosity, which limits their use
in cold environments. Principally, these
H H H H
H C H H H H HH C H
C C C C
H C
H C C C C
H
H H H HH C H H H
H
H
HMWH (high molecular weight hydrocarbon)
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
liquids work well in all types of tap-chan-
gers, because their properties (except
Extensive tests on different tap-changer
viscosity) are similar to classic mineral types and model setups have been performed
insulating oils. The high viscosity causes
longer arcing times which lead to signifi
with various HMWHs, natural and synthetic
cantly reduced switching capa cities of esters and silicone oils, resulting in possible
the change-over selector. Because ester
liquids can fully replace HMWHs, an
combinations of MR tap-changers with
oncoming fading out of such liquids can alternative liquids
be predicted.

2.4. Halogenated polyether Even if this project has never been real natural and synthetic esters. Diverter
ized, one can state that halogenated switches have been stressed in the cold-
Halogenated polyethers (e.g. GALDEN, polyether can principally be used with climate chamber to find the lowest oper
by Solvay, France) are a liquid family vacuum-type OLTCs. ating temperature with permissible tim
mainly used as a cooling agent for heat- ing, and all non-metal materials used in
exchangers. They are non-flammable, 3. Approvals for tap-changers the respective tap-changer types were
but can be deteriorated by pyrolytic pro- with alternative liquids cooked for 180 days in 70-115 C hot
cesses, such as arcing. This causes Per- alternative liquids to ensure material
Fluorolso-Butylene (PFIB) and COF2, Extensive tests on different tap-changer compatibility. Several publications have
which is further deteriorated to, a very types as well as on model setups have been issued which give details on the test
aggressive, hydrofluoric acid (HF). been performed with various HMWHs, methods used and illustrate the behavior
natural and synthetic esters and silicone of tap-changers in these liquids [8], [9],
One variant of GALDEN, HT200, has liquids to determine the limits for use. [10].
been investigated for potential use in Complete tap-changers have been worn
transformers and OLTCs. In a project out in mechanical endurance tests per- As a summary, Table 2 gives an overview
for Italy, initial tests with an OILTAP M forming up to 1.5 million operations and on possible combinations of MR tap-
have been performed during 1995-1998. they were destroyed in high-voltage tests changers with alternative liquids. From
The goal was to develop regulated power to determine the true withstand voltages the test results, admissible operating con-
transformers, sized 25-40 MVA, for Um of all insulating distances in HMWHs, ditions have been derived; see Table 3.
170 kV, with GALDEN filling. The excel-
lent cooling properties and the high li-
quid density of HT200 should allow for a Table 3. Parameters and limit values for tap-changers in alternative liquids
very compact transformer design. A ser-
vice duty test was performed which, after
18,000 operations, revealed inadmissibly
prolonged arcing times of the switching
contacts. The liquid was analyzed and
showed the toxic deterioration products
mentioned above. A visible indication
for HF was the dull surface of the diverter
switch oil compartment (made of glass-
reinforced plast ic, GRP). Additional
160,000 mechanical operations on a tap
selector caused unremarkable mechani-
cal wear and so proved a sufficient lubri-
cating capability.

R1

R2 C R3
R1 C O
CH2 O C
O
O CH3 CH3 CH3
R3 O CH2 R2
R2
CH O C R1 C C O CH2 C CH2 O C C R1
CH3 Si O Si O Si CH3
O R2 CH2 O R3
R3 O CH3 CH3 CH3
CH2 O C O C n
O R3 C R2
Silicone oil (polydimethylsiloxane)
Natural ester Natural ester R1
(triglyceride fatty acid ester) Synthetic ester
Synthetic ester (pentaerythritol Silicone oil (polydimethylsiloxane)
(triglyceride fatty (pentaerythritol organic acid ester)
organic acid ester)
acid ester)
w w w . t ra n sfo r m e r s - m a g a z i n e . co m 25
COLUMN

It is possible to upgrade a mineral oil filled measures like rubber bags or nitrogen-
filled expansion tanks have to be applied
regulated power transformer with oil-switch to prevent the natural ester from persis-
ing type OLTC to a modern, less-flammable tent contact with oxygen from the ambi-
ent air.
and environmentally friendly transformer If sealing measures are applied, an ade-
with vacuum type OLTC quate protection concept for the tap-
changer has to be adopted, because the
standard oil flow relay may not work pro-
perly in combination with sealed expan-
Please note that the voltage values for Required operating temperature range sion tanks.
withstand voltage and recovery voltage of Material compatibility
the change-over selector are expressed as Breathing conditions When retrofilling a mineral oil-filled trans-
percentage levels of the standard values former with an ester liquid, it has to be
for mineral oil, the values varying with The tap-changer manufacturer will also considered that the residual mineral oil
the OLTC type. check the application for possible geomet remaining in the cellulose will reduce the
ric incompatibilities (e.g. insulating dis flash point and fire point of the liquid mix-
4. Retrofitting tances to tank walls etc.). ture. To maintain a fire point of more than
If one or more limit values defined in Table 300 C, it is recommended to keep the min
It is possible to upgrade a mineral oil 3 are violated, adequate measures must be eral oil contamination below 3-5 % [11].
filled regulated power transformer with taken:
oil-switching type OLTC to a modern, If the required withstand voltages do ex- 5. Outlook
less-flammable and environmentally ceed the permissible values which have
friendly transformer with vacuum been defined for the chosen ester liquid, Producing oil from natural gas is one way
type OLTC. Some considerations are the risk of a flashover must be estimated to face the fading resources for high-qual
necessary to ensure a safe and reliable and, if not tolerable, adequate measures ity crudes which are necessary to produce
operation with the new liquid (and tap- must be taken (like surge arresters or var a good transformer oil. But this process
changer). First, it must be determined if istors). In rare cases, a substitution of the needs a lot of energy. Much less energy is
the combination of the tap-changer and tap-changer with a bigger size can be ap- needed to generate synthetic esters, and
desired liquid according to Table 2 is propriate. they are fully biodegradable. Natural esters
approved. In case of an OILTAP M, the Tie-in measures may need adjustment. are presently the only insulating liquids
diverter switch can easily be replaced A temperature lockout must be installed which are really CO2 neutral. Their devel
by a VACUTAP VM model. Then, the to prevent the tap-changer from switch opment continues, improving oxidation
following parameters have to be checked: ing at liquid temperatures beyond the stability and pour point. Dupont has re-
Required withstand voltages for all rele- permissible temperature range. cently issued a new sustainable ester-based
vant insulation distances Unsuitable gaskets should be exchanged fluid which perfectly fits to the NOMEXTM
Required recovery voltage on change- to avoid leakage in the long-term. solid insulation product line, paving the
over selector If natural ester liquids are used, sealing way for high-temperature applications.
It looks as if natural ester liquids show the
best compromise between usability, price
and environmental friendliness of all al-
Author ternative liquids which are commercially
Dipl.-Ing. (TU) Rainer Frotscher was born in Bremen, Germany available. But they stay in competition with
on March 4, 1960. He received his Masters Degree in Electrical arable crop which is needed for food prod
Engineering from the Technical University of Munich where he uction. As in many other areas, finding
wrote his thesis in high-voltage engineering. a balance between different interests is a
Dipl.-Ing. Frotscher works for Maschinenfabrik Reinhausen question of social, environmental and eco-
(MR) in Regensburg, Germany as an expert for special tap- nomical responsibility. Breeding of oil seeds
changer applications. with higher output continues and can slow
He has been working on various projects concerning the down the increment of arable crop needed
technology of on-load tap-changers. His area of expertise is the applicability of al- for industrial vegetable oil products.
ternative liquids and DGA on tap-changers. As a member of CIGRE and DKE, he In this context, however, attempting the
has authored multiple publications and he contributes to several working groups in use of palm oil as insulating liquid appears
CIGRE, IEEE and DKE. questionable from the technical perspec-
tive and from the perspective of the accel
Phone : +49 (0) 941/4090-4136 erated tropical rain forest conversion into
Fax : +49 (0) 941/4090-4005 palm oil plantations.
Email : r.frotscher@reinhausen.com A promising alternative can be oil from
Address : Maschinenfabrik Reinhausen GmbH algae. Current projects investigate the culti-
Falkensteinstrae 8, 93059 Regensburg, Germany vation of super-efficient microalgae to prod
uce feedstock from which fuels and maybe

26 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

A promising alternative can be also oil from
algae, because super-efficient microalgae
might be cultivated to produce feedstock
from which fuels and maybe also an electric
al insulating liquid can be refined
also an electrical insulating liquid can be
refined. Algae consume carbon dioxide
from the atmosphere and so help solving
another apparent problem of mankind. But
the biggest benefit is that algae can be grown
anywhere, in direct vicinity of the markets
where the oil is needed. Not endangering
sensitive environments, short routes of
transportation - wouldnt that be great?
Bibliography
[1] W. Breuer, G. Hegemann, Behavior of
On-Load Tap-Changers in MIDEL 7131 A
PCB-Alternative for Transformers, CIGRE-
Symposium 05-1987, Vienna, Austria
[2] M. Lashbook, M. Kuhn, The use of ester
transformer fluids for increased fire safety
and reduced costs, paper A2-210, CIGRE
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
2012, Paris, France
[3] M&I Materials, Technical Data Sheets
on MIDEL 7131, http://static.mimate-
rials.com/midel/documents/technical/
MIDEL_7131_Technical_Information_
Pack_A4.pdf
[4] Cargill, Reference Data R2020 on
ENVIROTEMP FR3, http://www.cargill.
com/wcm/groups/public/@ccom/docu-
ments/document/na3076889.pdf
[5] C. T. Duy, O. Lesaint, A. Denat, and N.
Bonifaci, Streamer propagation and break-
down in natural ester at high voltage, IEEE
Transactions on Dielectrics and Electrical
Insulation, vol. 16, pp. 1582-1594, 2009.
[6] P. Jarman, G. Wilson, P. Dyer, F. Perrot,
Q. Liu, Z.D. Wang et.al., Electrical Perform
ance of Ester Insulating Liquids for Power
Transformers, CIGRE SC A2 & D1 Joint
Colloquium 2011, Paper PS2-O-5, Kyoto,
Japan
[7] P.McShane, K. Rapp, J. Corkran et.al.,
Aging of paper Insulation in Natural Ester
Dielectric Fluid, IEEE Transmission and
Distribution Conference, Atlanta, USA,
Nov 2001
[8] R. Frotscher, On-Load Tap-Changers
with Vacuum Switching technology for in-
creased fire safety, reliability and environ-
mental performance, Advanced Research
Workshop on Transformers, Santiago de
Compostela, Spain, 2010
[9] R. Frotscher, D. Vukovic, J. Harthun,
M. Schfer et.al., Behaviour of Ester Liquids
under Dielectric and Thermal Stress From
Laboratory Testing to Practical Use, paper
D1-105, CIGRE 2012, Paris, France
[10] R. Frotscher, Alternative Liquids
for Tap-changers, Technical Publication
F0310300, Maschinenfabrik Reinhausen
GmbH, Regensburg, Germany, 2014,
http://www.reinhausen.com/en/Xparo-
Download.ashx?raid=86521
[11] Cargill: Recommended Procedures for
Retrofilling Oil-Filled Transformers, Section
S900-20-2 Reference Document, 2006
27
EVENTS
PROFILE
The Centre of Excellence
for Transformers in Zagreb
involves companies which
cover the transformer
business from R&D to
decommissioning
Centre of Excellence for
Transformers in Zagreb
Introduction
The Centre of Excellence (CoE) for
Transformers in Zagreb was founded
following the decision by the Management
Board of KONAR - Electrical Industry
Inc. (pronounced Konchar) in 2005.
Playing a vital role in this enterprise,
KONAR - Electrica l Industry Inc.
involved all transformer manufacturing
companies from the KONAR Group
in the project, including KONAR -
Electrical Engineering Institute Inc., as
well as KONAR - Power Transformers
Ltd. (KPT), which is a joint venture of
SIEMENS and KONAR. Considering
that about 1.5 % of the world transformers
production is concentrated in Zagreb,
founding the CoE was a logical step
towards optimization of transformer
R&D, and also a scientific step forward.
28
Even more, it was a course of action
to address the education and training
problem that we face today in that
undergraduate studies simply do not
provide sufficient education in this area.
The CoE was devised to cover three
major areas: continuous research and
development, a specialist postgraduate
study in transformers, and an international
colloquium on transformers. The specialist
postgraduate study in transformers is an
international programme of study organ
ized in cooperation with the Faculty of
Electrical Engineering and Computing, and
the Faculty of Mechanical Engineering and
Naval Architecture at Zagreb University. The
international colloquium on Transformer
Research and Asset Management is a con
ference held every 2.5 years in one of the
picturesque towns of Croatia. This event
attracting great interest of researchers and
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
scientists from all over the world has been
sponsored by KONAR as the Gold Sponsor.
The core team of the CoE consists of
Miroslav Poljak, Ph.D., Member of the
Man a gement Board at KONAR -
Electrical Industry Inc.; Boris Potoki,
President of the Management Board at
KONAR - Power Transformers Ltd.; Ivan
Klapan, President of the Management
Board at KONAR - Distribution
and Special Transformers Inc.; Ante
Rogoznica, President of the Management
Board at KONAR Instrument Trans
formers Inc.; Rajko Gardijan, Member
of the Management Board at KONAR
- Electrical Engineering Institute Inc.;
and eljko tih, Ph.D., Full Professor
at the Faculty of Electrical Engineering
and Computing, Zagreb University. The
former members include Ivan Mili and
Vladimir Pleko.
 Considering that about 1.5 %
of the world transformers
production is concentrated in
Zagreb, founding the Centre
of Excellence was a logical
step towards optimization of
transformer R&D, and also a
scientific step forward

Foundation for the modern transformer

business
KONAR - Electrical Industry Inc. boasts
more than 90 years of experience in
manufacturing electric power products,
including all types of transformers. It all
began in 1921, when the production and
repair of rotating machines and trans-
formers was started at the site of todays
KONAR headquarters.
The company has had many milestones
over its long history. One of them was the
development of the first induction ma
chine with the winding made with an enamel
insulated wire, which was manufactured
here in 1930 following the idea by the en-
thusiastic engineer Anton Dolenc (later a
famous professor at Zagreb University).
The wire had to be varnished in the fac
tory because it had not been available on
the market. The machine was tested oper
ating under water for hours, and this rep
resented a world milestone.
Today, energy and transportation make
the core business of the KONAR
Group, which comprises 18 daughter
companies with 3,700 employees, and
one affiliated company employing nearly
580 people. Approximately 50 % of the
Groups production volume is exported
to foreign markets.
The Group companies manufacture
all types of transformers in Zagreb
from instrument transformers, through
distribution and special transformers,
to all types of power transformers, as
well as transform er components and
measurement and monitoring systems.
Large power transformers are manufac
tured by the affiliated company

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 29
 PROFILE
In the last ten years, KPT has exported
nearly 98 % of its production volume to
86 countries worldwide
Large power transformers
KONAR - Power Transformers Ltd.
(KPT), a joint venture founded with
SIEMENS. Over the past 10 years, the
factorys aver
age annual production has
reached over 16,000 MVA.
KPTs portfolio includes generator step-
up transformers, large transmission trans-
formers and autotransformers up to 1,000
MVA and 550 kV, as well as transformers
for industry purpose such as furnace and
rectifier transformers, transformers for
railways, and HVDC transformers. The
company also delivers transformers for
off-shore platforms, able to operate in very
harsh conditions.
318 MVA transformer transported by Antonov cargo plane to the Philippines in 2013
30
Since 1949 KPT has manufactured close
to 3,000 units with a total capacity of more
than 300,000 MVA. Thus far, 18 transform
ers of different ratings, voltages and designs
(including special transformers) have suc-
cessfully passed short circuit withstand
tests at international laboratories such as
KEMA and CESI, which is yet another tes-
timony to KPTs design and technology.
Placing its focus on quality and customer
satisfaction, the company invests a lot in
the continuous product improvement,
combining its own in-house R&D
capacity with that of KONAR - Electrical
Engineering Institute and SIEMENS.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
1,000 MVA autotransformer under test at KPT
Moreover, it is KPTs philosophy to stay
committed to the continuous improvement
of all processes, aiming to be technically and
financially competitive on the global mar-
ket. Staying true to this attitude, the com
pany was able to put the production and
non-conformity costs under control. Also,
they have established partner relationship
with material suppliers as well as their
customers worldwide and the results of all
these efforts and investments are clearly
visible in their market competitiveness.
Over the last ten years, the company has
exported nearly 98 % of the production vol
ume to 86 countries worldwide.
Transformer under short-circuit test at KEMA
Distribution and special transformers
KONAR - Distribution and Special der, the company rather focuses on the solid serve customers who look for advanced so-
Transformers Inc. (D&ST) is the com preparation of the tender documents and lutions for their grid.
pany manufacturing distribution and the risk review, knowing that there is no ten-
special transformers, as well as small and der that one can be sure of winning today. There are other special transformers that
medium power transformers. Currently D&ST manufactures, and among them is a
employing more than 500 people, D&ST The competitive and deregulated market recently developed traction transformer for
supplies the domestic market, which is drives the business and requires continu KONARs 160 km/h commuter train.
its main market, accounting for approxi ous investment in R&D. However, recent
mately 15 % of the production volume. changes in the raw materials price ratio Always looking ahead, the company is very
Companys largest international markets have also caused changes in product con- open to innovations and invests a lot in
are the neighbouring countries, followed cept. For example, the increase in the price R&D. While this has resulted in significant
by Europe as a whole, the Middle East of copper in relation to the price of alumin changes made in distribution transformers
and Africa. Their main export countries ium saw the round core technology for technology, with power transform ers
include Sweden, Finland, Germany, distribution transformers, a very well estab the focus remains on smaller and gradual
France, Switzerland, Austria, Italy, the lished technology which provided excel- steps, such as introducing new materials,
Czech Republic, Hungary, Saudi design optimization, etc. D&ST is one
Arabia, UAE, Qatar, Nigeria, Ghana, of the first OEMs to have tested new
Morocco, etc. KONAR D&ST is one of the solid and fluid materials as soon as
This is a market segment which is very
first OEMs able to deliver trans they appeared, which has created an
opportunity to produce transformers,
competitive. While positioning on the formers produced with virtu- particularly special units, with virtually
market takes a lot of time, losing this ally any materials available any materials available on the market to
position is very easy, and may happen meet almost any type of requirements.
to the company which is not able to ful- on the market to meet almost
fil some of the customer requirements. any type of requirements Closely monitoring all novelties and
Without a continuous development of developments on the market, the com-
products, sales and other operations pany is present at all major events and
within the company, without changing the lent results, being suddenly outperformed its experts participate in international
models and adequate prioritising, it is not by the square and oval core technology working groups for standards develop-
possible to achieve a long-term success. In with aluminium windings. This was a big ment. With the constant involvement in
its strive for excellence, D&ST has managed change that happened over a very short the latest trends and developments, the
to set the right targets and build the team period of time and those OEMs which company was ready in time for the new
that works together on all aspects of the failed to adopt this technology very soon EU EcoDesign Regulation for Transform
business, growing into the company which became uncompetitive. ers and now offers low-loss transformers
is a widely accepted and reputed supplier of which meet the Tier 1 requirements of the
transformers. D&ST is actively implementing new solu- regulation. Development of new solutions
tions for on-load voltage regulation in dis- for even stricter Tier 2 requirements to be
Although the price is a decisive criterion tribution transformers to be used in smart enforced in 2021 is already under way.
in this segment, it is not the main focus of grid. Although this technology makes dis-
D&ST operations. When applying to ten- tribution transformers much more com- The companys efforts also go into improv
plicated and therefore more expensive, ing quality control and information and
by developing its own solution D&ST has communication systems enabling man
demonstrated the ability and readiness to agement of a large amount of data.

Transformer test bay at KONAR D&ST with a distribution and a power transformer
PROFILE

Instrument transformers
KONAR - Instrument Transformers for some product types, KONAR has sold
Inc. has been manufacturing instrument licences to other manufacturers in China,
transformers since 1947, boasting a 70-year India and Iran.
experience in this business. Employ ing
more than 240 people, the company has Open core VT is a unique solution on
an annual production capacity of 4,000 todays market, which was first developed
high voltage transformers and 10,000 me- in 1966 by Academician Professor Vojislav
dium voltage transformers. KONARs in- Bego. He is the author of the voltage balance
strument transformers are sold globally in through which he discovered, in the 1980s,
more than 100 countries. that the definition of the voltage unit, Volt,
had an error of 8 ppm. Being verified later 800 kV current transformer AGU-765
The key milestones in the companys 70- by other research, in 1990 the definition of
year history include: Volt was adjusted by 8 ppm. machine-wound, which is very important.
1973: Production of first 420 kV On request transformers can be
transformers
1992: Production of combined Fulfilling the strictest accuracy re- equipped with a robust and simple
monitoring solution in order to
transformers quirements, KONARs combined prevent equipment damage.
2003: Production of first 500 kV transformers are the most compact
and 750 kV transformers Open core VTs are also practically
2006: Production begins at the and cost-effective solution in terms immune to ferroresonance, which
joint venture in China of their purchase price, transpor- can take place only in very few and
2010: Production of first 800 kV
transformers
tation, real estate, installation and very rare cases of enormously large
capacity. Actually, ferroresonance
2012: Production of power maintenance costs has never occurred in the grid with
voltage transformers (PVTs) KONARs open-core transformers.
The primary winding of the open core
KONARs instrument transformers are VT consists of several separate sections, KONARs combined transformers util
designed according to customer specifi- enabling compensation of the angle error ise an open core voltage transformer and
cations ensuring minimum material con- caused by magnetizing current. In case of a current transformer, which are fully
sumption and minimum weight in a PD- an internal fault between turns or layers of integrated. This solution, with the com-
free design for the power frequency voltage. the primary winding, the fault remains lo- mon main insulation, is unique on the
There has been a lot of experience with PD calised in one section, while the grid voltage market considering that other solutions
phenomena in the company as well as sci- is distributed among all other sections, thus are, in essence, two transformers in the
entific research, and now this knowledge limiting the fault current within a range same housing. Being the most compact,
has been applied in practice. of mA instead of kA. In this failure mode KONARs solution is also the most cost-
an internal arc cannot happen because the effective one in terms of the purchase
KONAR boasts unique products, such resulting process is slow and non-eruptive. price, as well as transportation, real estate,
as the voltage transformer (VT) with open Transformer will automatically be discon- installation and maintenance costs, mak
core, a combined instrument transformer nected without fracturing the insulator or ing it customers regular choice. More
and a power voltage transformer, which causing oil spill. With the increase of the over, with this solution KONAR is able
drive the companys success in the instru- transformer rated voltage, the influence of to fulfil the strictest accuracy require-
ment transformers market. What is more, a short circuit is reduced. This provides a ments. The only oil-filled combined trans-
huge advantage in terms of safety and ex- former at 420 kV level is KONARs!
plosion prevention. The entire insulation is
PVTs or service station voltage transform
ers provide power supply from a high volt
Power voltage transformer VPT-362, Estonia age grid, e.g. 550 kV, of capacity up to 333
kVA, at the time being. PVTs are used for
supplying substations when a low voltage
network is not available, or when transmis-
sion is entirely separated from distribution.
It is also very convenient for rural electrifi-
cation. All advantages enabled by open core
are utilised here, simplifying the protection
significantly while ensuring maximum
safety. When on-load regulation is required,
a distribution transformer is simply con-
nected to the secondary of the PVT.

32 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Transformer monitoring system hardware and software

R&D, testing, diagnosis and monitoring

KONAR - Electrical Engineering
Institute Inc. has been conducting
research on dielectric, electromagnetic
and thermal problems, as well as losses,
noise and other phenomena, and product
development for more than 60 years.
Over the last 25 years, the Institute has
been actively involved in the research of
dielectric problems and losses. The research
of harmonics in the medium voltage grid
and their influence on the measurement
accuracy of instrument transformers, which
the Institute has recently pioneered, is now
the required research to be conducted in
the transmission grid.
Following the introduction of ester fluids,
the Institute has conducted a very extensive
experimental and simulation research on
dielectric systems for power transformers,
which covered both the HVAC and HVDC
transformer insulation systems.
The Institute also supports KONAR
transformer plants in transformer design.
a vast 60-year experience in the field of phys
ical and chemical testing of materials used
in power engineering, as well as diagnostics
of the transformer insulation system con-
dition (oil-paper) for new and operating
transformers.
The Institute has pioneered the automation
of transformer factory testing, developing
a test system which provides test reports
immediately upon completion of the test.
Further, since 2003 the Institute has been
KONAR offers solutions for monitoring large,
medium and small power transformers, including
overvoltage transient recording and tan delta
and capacitance monitoring for bushings
Rendering of the HV lab to be built at KONAR - Electrical Engineering Institute
supplying a comprehensive transformer
monitoring systems (TMS), for which
they have developed their own hardware
and software platforms with an in-house
solution for communication with IEDs
and control centres. The solution is ac-
credited according to latest edition of
IEC 61850, making transformer ready
for the smart grid. By May 2016, these
monitoring systems have been delivered
to more than 30 countries, with the main
customers being SIEMENS, KONAR,
Hyundai, Hyosung, EPC companies, etc.

Another business area of the Institute

is on-site diagnostic testing. The
Institute boasts a database containing
measurement results of instrument and
power transformers dating back to 1963.
The oldest transformer recorded in the
database, which is still in operation, was
manufactured in 1965.

The research, product development and

on-site diagnostics conducted by the
Institute are supported by the Laboratory
for Physical and Chemical Testing, which
provides experimental laboratory data on
material characteristics. The Laboratory is
accredited according to IEC 17025, and has

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 33
PROFILE
In addition to TMS, the main monitoring
product for large power transformers,
TMS+ is a solution with an overvoltage
transient recorder which customers use as
a disturbance recorder. The portfolio also
includes TMS mini, a compact and cost-
effective solution for small and medium
power transformers in the range of 40 - 100
MVA.
Another product is a solution for tan delta
and capacitance monitoring for bushings,
utilising three different methods: the sum
of currents, referent voltage from VTs, and
a comparison between a pair of bushings.
The Institute operates a high voltage lab,
which is certified according to IEC 17025,
providing all types of thermal and dielectric
tests of bushings. With the growing testing
business, they are now expanding their fa-
cilities, building a new lab.
Institutes employees are academically ac-
tive, and eight of them are involved in the
specialist postgraduate study in transform
ers at the University of Zagreb.
Tanks, coolers and other power
transformer components
34
Transformer components
KONAR - Steel Structures Inc. manu
factures all types of tanks for transformers
above 100 MVA. The current annual output
of 5,000 tonnes, and the plan to increase
it to over 6,000 tonnes per year, positions
the company among the leading European
manufacturers in this market segment. The
customers may benefit from its geographical
location, which is almost in the centre
of gravity of transformer OEMs, and the
ability to support customers, particularly in
demanding cases.
The biggest transformer tank manufactured
by KONAR - Steel Structures Inc. was de-
livered in 2012. The tank measured 12.25 m
in length, 3.79 m in width, 4.63 m in height,
and weighed 56.2 tonnes. Along with the tank
cover, which was 11.69 m long, 3.385 m wide,
0.4 m high, and weighed 10.4 tonnes, the
whole unit weighed 109 tonnes.
In addition to transformer tanks, the com-
pany annually manufactures 1,500-2,000
tonnes of welded constructions for other
applications, such as ovens for drying
transformer windings.
Other products include flexible
winding mandrels for leading
transformer OEMs, as well as vari
ous tools and constructions for
transformer manufacturing plants.
The company is currently investing
in expanding their product portfolio
with new products for transform
ers, but this will be an-
nounced in due time.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
In addition, KONAR - Steel Structures
supplies tanks for off-shore plants with
strict requirements, such as those accord
ing to NORSOK M-501 standard for sur-
face preparation and protective coating.
Some of the company employees are certi-
fied with FROSIO and ACQPA certificates,
which enables them to reliably supervise
and perform all processes, as required for
such applications. The company is not only
able to produce welding of the required
quality and support transformer OEMs in
Transformer tanks, drying
ovens, flexible wind ing
mandrels and fans for
cooling power transformers
are among most recognized
KONAR products by
power transformer OEMs
designing transformer tanks that meet the
set requirements, but also to manufacture
constructions for such requirements with
mixed materials, e.g. steel and stainless
steel, which is very demanding. Their suc-
cess in such complicated systems includes
hot deep metallisation for hollow objects,
where zinc must not enter the object. This
is an extremely complicated process, and
KONAR - Steel Structures is among very
few companies able to metalize such large
objects. Transformer OEMs can rely on the
companys support when faced with such
requirements from their customers. In fact,
with all the support the company experts
can provide, the more complicated the pro-
ject, the more transformer OEMs can profit
from their cooperation with KONAR.
It is eventually the end customers who
profit from such support, which
is the ultimate goal of all par-
ticipants in the supply chain.
Even in cases when the
object will not be operating
in off-shore conditions,
customers today tend to
require that these standards
are met, as this will ensure
that they will get better
quality.
Fans for power transformers

KONAR - MES Inc., another company
within the Group, manufactures fans
for cooling power transformers. Their
big advantage is that they manufacture
all components themselves, including
the motors, which enables them to offer
short lead times, even when faced with
special requirements, such as particular
power supply voltage, corrosion and IP
protection, etc. Their fans are delivered
mainly to European transformer
OEMs, but also to OEMs in the Middle
East, Russia, India and Mexico, while
transformers using KONARs fans are
delivered all over the world.

KONAR companies have grown to become reputed market players, covering the entire transformer
business and all of its processes, from R&D to decommissioning. Together with the Centre of
Excellence for Transformers, they make Zagreb a recognized hub for transformers.

SUBSCRIBE TO TRANSFORMERS MAGAZINE eBULLETIN AND RECEIVE A DIGEST OF THE MOST

RELEVANT NEWS AND UPDATES FROM THE TRANSFORMERS BUSINESS, TECHNOLOGY AND JOB MARKET!

Why subscribe?
Regularly follow the latest project and business
opportunities
Keep up to date with the latest news on technology
and business developments in the industry eBulletin
Keep regularly informed on the specific and
global market trends
Find out about the latest products and services eBulletin
on the market
Follow global career opportunities

Sign up for free at www.transformers-magazine.com/e-bulletin

Sign up! and stay informed on the news that matters to you!

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 35
EVENTSINSULATION
LIQUID

ABSTRACT
Electric utilities have a duty to sup-
ply electricity securely whilst being
mindful of environmental needs and
fire safety, especially in urban areas.
Mineral oil in power transformers is
the most critical conventional ma-
terial used. Substituting mineral oil
with bio-degradable and renewable

Field experiences
liquid such as natural ester, provides
a much higher level of safety and sus-
tainability.

with the worlds

This article presents monitoring re-
sults for the worlds largest natural
ester-filled transformer of advanced
design. The results show that thus

largest natural
far, over nearly three years in service,
the transformer has been operating
perfectly, and that there are abso
lutely no concerns with the operation

ester-filled
of such transformers.

KEYWORDS
natural ester, Envirotemp FR3,
large power transformer, field results transformer
36
36 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Regulations require from electric utilities to
secure electricity supply while maximizing
health and environmental safety, particularly
in areas of high population density
Envirotemp FR3 fluid monitoring results
1. Introduction
Today many regulations are in place de-
manding from electric utility companies
to consider a lot more than just secur
ity of supply when expanding the grid.
While operators need to ensure technical
performance capability, concerns about
issues of personal safety and environ-
mental protection are of no less import
ance. To be able to respond to these
requirements, utilities need innovative
technologies to equip themselves for the
energy supply market of the future [1].
Sustainable, bio-degradable and renew
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
ADVERTORIAL
Photo courtesy of TransnetBW GmbH
2. Power transformers for
new requirements
able these concepts are the driving For power transformers, which are con-
force behind the power industry today, ventional pieces of electric equipment
with an impact not only on the method built according to the physics concepts
of energy generation, but also on the and with materials developed decades
components used. Sparing use of resour- ago, it is critical to implement new ma-
ces and employment of renewable raw terials based on renewable resources to
materials in place of fossil fuels wherever achieve sustainability, reliability, and
possible has become a must. safety.
Substituting mineral oil with bio-degradable
and renewable liquid such as natural ester,
provides a much higher level of safety and
sustainability
37
LIQUID INSULATION

Photo courtesy of SIEMENS Photo courtesy of TransnetBW GmbH

Figure 1. SIEMENS Envirotemp FR3-fluid-filled large power transformer at dispatch from the factory (left); being commissioned at the

Another concept gaining importance is

the development and installation of elec-
The worlds largest power transformer
trical equipment able to provide a high filled with natural ester Envirotemp FR3
level of health and environmental safety
and reliability, particularly in regions of
fluid, manufactured by SIEMENS, has been
great infrastructure density where reducing operating at the highest voltage level in the
the risk level has become a major goal. Germanys grid for almost three years
Insulating oil is the most critical con-
ventional material used in power trans-
formers. As a consequence, the need for 3. Natural ester boosts been limited up to 230 kV until re-
achieving a higher level of sustainability transformer performance cently.
and environmental safety has placed
focus on natural esters as a substitute Natural esters have been used in In April 2013, Siemens successfully test
for transformer oil. In relation to the in transformers for decades, predomin ed the worlds largest power transformer
creased biodegradability and sustain antly in distribution transformers, filled with natural ester EnvirotempFR3
ability requirements, natural ester based and small and medium power trans- fluid, developed and built at their power
fluids are among the most important and formers. However, their usage in large transformer factory in Nuremberg,
widely used alternative liquids. power high-voltage transformers has G ermany. This transformer is owned
and operated by TransnetBW, one of the
four transmission network operators in
Table I. Specific data of 420 kV natural ester transformer Germany.
Rated voltage 420 kV
Several articles have been published thus
Rated power 300 MVA far on the various aspects of the transform
er using FR3 fluid, comparing the pro-
Voltage ratio 405 11%/115/22 kV
perties of natural ester and mineral oil [1],
Cooling type KDAF/KNAN describing design aspects and first service
results [3], discussing advantages of using
Liquid Natural ester (Envirotemp FR3 fluid)
natural esters as insulating liquid in power
Insulation level 630 kV AC/1425 kV LI/1050 kV SI transformers [4], and presenting aspects
of electrical, thermal and mechanical de-
Liquid weight ~95 tons sign, as well as manufacturing, testing,

38 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 Photo courtesy of TransnetBW GmbH

substation (centre); and in operation (right)

Over the past two and a half years in service,
the transformer has undergone many tests
and measurements, including gas analysis,
water content, breakdown voltage and tan
delta analyses of natural ester samples,
and more
transportation and operation of the FR3-
filled transformer [5].
unit will have a longer expected life span
than a similar mineral oil unit.
Designed to operate at the highest volt
age level in Germanys power grid, the
transformers rated voltage was specified
to 380 kV, and its insulation levels meet
the standard IEC 60076-3.
The transformer also boasts a some-
what special mechanical design, using
sealing equipment materials based on
fluororubber, and components which
were all qualified for operating in natural
ester liquid. Specially designed bushings
for medium voltage and wye connection

3.1. New design

The worlds largest transformer filled

with Envirotemp FR3 fluid is rated at 420
kV, uses new design criteria, and is the
largest unit using a renewable resource li-
quid. The rated power of this transformer
is 300 MVA, with an overload condition
of up to 400 MVA [2].

Its cooling performance satisfies the

l
imits prescribed by the standard IEC
60076-2. In regard to the cooling type, the
transformer was designed to use forced
cooling for the inner and outer cooling
circuit, but also to operate up to 180 MVA
load with non-forced cooling. In this de-
sign, the esters are not supposed to experi-
ence limiting top oil temperatures, so this Figure 2. Concentrations of gases dissolved in natural ester

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 39
LIQUID INSULATION

The water content, dielectric strength and in operation. Notably, the presence of
ethane increased over the two and a
tan delta indicate this is a well prepared and half years in service. In comparison
perfectly normally operating transformer - to the transformers using mineral oil,
ethane is generated by different natural
the DGA results back that up decomposition processes taking place
inside the transformer with an insulation
system which is a combination of natural
ester and cellulose. These differences
between the two insulation systems are
based on the chemical structure of the
various liquids, and they are explained
in detail in the IEEE DGA guide [6].
Another distinction lies in a different
solubility of gases in mineral oil and
natural esters. Consequently, many, but
not all, normally operating transformers
filled with FR3 fluid have a higher
ethane content than their mineral oil
counterparts. Other hydrocarbon gases
remained low [7].

The analysis of the moisture in the trans-

former oil (Figure 3) was based on the oil
samples which were taken from the trans-
former at quarterly intervals in order to
Figure 3. Water content in natural ester samples
evaluate the transformer condition.

Breakdown voltage and tan delta of nat

were type tested in the Research and Over the past two and a half years in ural ester samples were also regularly
Testing Laboratory of the transformer service, the transformer has undergone measured and showed no significant
factory in Nuremberg. Cable joints with many tests and measurements. These in- changes with respect to the required
specially designed coupling capacitors cluded gas analysis, as well as water con- values (Figure 4).
were used for the low voltage connection. tent, breakdown voltage and tan delta
These capacitors were also type tested in analyses of natural ester samples, and Other parameters, such as the density of
the transformer factory in Nuremberg. more. natural ester sample (Figure 5) and oil
viscosity, were also measured to further
4. Experiences from the field Dissolved gas analysis (Figure 2) was check the condition of the transformer.
used to reveal the types of gas produced While some of these measurements are
At the time of the transformer manu- inside the transformer during its time done on every third sample, all of these
facture it was agreed that monitoring of
the ester-filled EHV transformer will be
jointly performed by the customer and
the manufacturer in the coming months
and years. Now, we realize that this moni
toring has yielded valuable results which
contribute to the knowledge of ester li-
quid behaviour.

4.1. Monitoring results

Although there have been other simi-

lar power transformers developed and
put into operation since the time of the
transformer manufacture, this is still the
worlds largest power transformer of its
kind. Using the monitoring data collect
ed over time, this article brings an over-
view of the behaviour of the transformer
during operation.
Figure 4. Breakdown voltage and tan delta of natural ester samples

40 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

All results collected from SIEMENS worlds
largest transformer filled with Envirotemp
FR3 fluid show that so far there have been
absolutely no concerns with the operation
of such transformer
parameters help us establish that the
transformer is in good condition and
that the condition of the natural ester its-
elf has no influence on its performance.
The performed measurements and their
results show that there have been no ab-
normalities in the operation of the trans-
former and that its performance has
been perfect and according to all stand
ard expectations.
4.2. Other measurements
PD measurements and offline insula
tion resistance measurements were per
formed before the transformer was put
in operation, while further tests and elec-
trical measurements will be conducted
in the upcoming months. As there has
been no outage of the transformer for a
longer period, and with all other meas
urements indicating a perfect condition
of the transformer, there was no need for
these tests before.
It is important to closely monitor the
behaviour of these transformers now to
help us understand their long-term be-
haviour and provide valuable references
Figure 5. Density of natural ester sample
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
and experience for the future, and our
findings contribute to this. At the mo-
ment, IEC is drafting a standard for in-
service natural esters, and this will pro
vide an additional relevant reference.
Conclusion
In the early days, there were certain con-
cerns about building a large power trans-
former with the use of natural ester fluids.
However, all of the findings collected
from monitoring data of the worlds lar-
gest transformer of this type demonstrate
that this is a transformer with a perfectly
normal behaviour, causing absolutely no
concern and operating according to all
expectations and standards prescribed
by the IEEE reference guide. Any differ
ences in the values are acceptable accord
ing to the IEEE guide.
The water content, dielectric strength
and tan delta results indicate that this is
a well prepared and a perfectly normally
operating transformer and the DGA
results support this.
All these findings suggest that this solu-
tion is the future for power transformers,
serving not only as an alternative to min
eral oil now, but also as its replacement
in the future. With this in view, apply-
ing these solutions now is becoming
increasingly important in order to gain
experience with the alternative liquids
that seem to be a perfectly suitable
replacement for mineral oil.
Bibliography:
[1] Ronny Fritsche, Transformers: Natural
Esters Replace Mineral Oil - Greener
than ever, Electrical Monitor, April 2015
[2] Ronny Fritsche, Uwe Rimmele, Frank
Trautmann, Michael Schfer, Prototype
420 kV Power Transformer Using Nat
ural Ester Dielectric Fluid
[3] Ronny Fritsche, Ivanka Atanasova-
Hhlein, Karsten Loppach, Frank Traut-
mann, Uwe Rimmele, Michael Schfer,
Gernot Adamietz, Large Power Trans-
formers using Natural Insulation Li-
quids aspects of design and first ser-
vice results
[4] Ronny Fritsche, Nachhaltige Elek-
trische Isolierung Dank Pflanzenlen,
Automatisierungs- & Elektrotechnik,
2015
[5] Ronny Fritsche, Grotransformato-
ren mit natrlichen Isoliermitteln, VDE
Diagnostik Tagung; November 2014
[6] C57.155-2014 - IEEE Guide for
Interpretation of Gases Generated in
Natural Ester and Synthetic Ester-Im-
mersed Transformers, IEEE; 2014
[7] R2070_FR3_Dissolved_Gas_Guide
v5 August 2006
Contact
Sabine Bowers
Business Development Manager
Envirotemp Dielectric Ester Fluids
Cargill - Germany
Email: sabine_bowers@cargill.com
Web: www.envirotempfluids.com
41
 COLUMN
Estimating current and future
transformers markets
W
ith the increasing global
isation of markets and
manufacturers keen to
explore the attractiveness
of less familiar markets, there has never
been a greater need for reliable and
accurate data and market intelligence to
assist in making important marketing
decisions. The development of the
internet has meant that there has never
been more information readily and
easily accessible, which has inevitably
resulted in a variety of sources of varying
42
degrees of reliability that should assist in
the decision making process.
As the volume has increased, so has
the need for a filtering or pre-digesting
process to interpret that huge volume
of information and turn it into action
able data. One way in which this filtering
process is delivered is in the form of pub
lished market research reports, and this
is particularly the case for transformer
markets which are the subject of a pleth
ora of published reports.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Published research vs
tailored research
Published market research is inevitably
a compromise between providing infor
mation that is of interest to a wide base of cus-
tomers and yet targeted enough to answer
specific questions of any purchaser. The
benefit is that its cost is much lower than
that of the tailored research by a factor
of 10 to 20 times while the drawback is
that it has to be used intelligently, or inter-
preted to ensure the best use of the infor-

mation provided in the report. A market
research project which is targeted on one
specific country can cost the purchaser
The globalisation of the transformers market
and the increase of available market data has
presented manufacturers with a new twist on an
old problem how to obtain accurate information
on current and future markets
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
as much as a published report covering
an entire region or even one with global
coverage. So, how does that trade-off
Steve AUBERTIN
between cost and depth of information
work in practice?
A tailored research project should be de-
signed to provide a large enough budget
for a researcher to develop a detailed spe-
cification and project plan that will en-
compass international travel to conduct
face-to-face interviews with the senior
decision makers who specify, purchase
and/or supply transformers. The results
of those interviews will be analysed and
collated into very detailed market size
43
COLUMN
The usefulness, reliability and value-for-
money that can be obtained from a pub-
lished report is dependent entirely on the
knowledge, skill and professionalism with
which it is produced
and market share tables showing sup-
pliers market position and competitive
intelligence for the market segment being
surveyed. A published report cannot
provide the same level of detail, but it can
provide sufficient data and competitive
information which is detailed enough
to provide reliable working data suitable
for most marketing needs. Some of the
indirect data sources that are available to
the authors of published reports are listed
below.
Sources of information on transformer
market size include:
Utility companies published capital and
operational expenditure plans
National development plans
Transmission company reliability assess-
ments
Industrial production statistics
Published trade statistics
National generating capacity statistics
44
Sources of information on market shares
include:
Suppliers published annual financial reports
Investor presentations
Detailed import data
Industry trade organisations
Anti-trust enquiry reports
The usefulness, reliability and value-for-
money that can be obtained from a pub-
lished report is dependent entirely on the
knowledge, skill and professionalism with
which it is produced. A professionally
produced market report will have taken
months of diligent research, analysis and
experience to produce and it will provide
reliable data which can save the purchaser
much wasted time and effort, measured
not only in terms of the effort required to
search through the huge volume of infor-
mation which is of variable quality, often
unsourced, may be contradictory and of
questionable reliability; but which may
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
additionally equate to thousands of man-
hours and dollars or euros in misguided
market initiatives.
An example of the data which can be ob-
tained from a published report which can
be interpreted to provide detailed infor-
mation is shown below, and it relates to
trade data.
Power and distribution transformers are
only produced in meaningful quantities
in some 50 countries, which means that
the market in the other 150 countries is
satisfied by imports. By analysis of the an-
nual import statistics of these countries,
the market size and market shares of the
suppliers can be assessed.
Table 1 illustrates the market share of im-
ports by country of origin into Qatar over
the period 2011 to 2013. These figures not
only show that the market is worth $97
million, but also clearly indicate the largest
supplier countries. By applying the know-
ledge of the manufacturing companies in
each of these countries, the market shares
by supplier company can be deduced.
Additionally, these aggregated figures can
easily be deconstructed by size of trans-
former, to illustrate which companies are
supplying which types of transformer to
Qatar.
 YOUR PARTNER FOR TRANSFORMER
MANUFACTURING

LAE Srl is the pioneer organizer

of TRAFOGRID ALLIANCE, a group
PARTNER OF
of companies with extensive
experience in the field of
transformers, producing machines
and equipment for all stages of ALLIANCE
transformer production.

TRAFOGRID ALLIANCE offers its

services for new turn-key plant
projects or where increased
production capacity or new
implementations are required.

www.lae-srl.com Tel. +39 0545 21 29 71

lae@lae-srl.com
www.trafogrid.com Via E. Fermi, 39
info@trafogrid.com 48022 Lugo (Ra) Italy
COLUMN
The market size calculation for the 50
or so countries that produce power and
distribution transformers is a little more
complicated. The formula is: production
+ imports - export = market size. As il-
lustrated in Table 1, trade statistics can be
analysed and a similar process will reveal
the production data. Most countries col-
late and publish manufacturing data, but
it is usually aggregated at too high a level
to be of use. Such data will usually show
the value of electrical engineering prod
ucts produced in a country, but will not
show the value of power or distribution
transformers produced. This has to be
extracted from within the broader hea-
ding. This process requires a large input of
market knowledge and experience, which
is too detailed for inclusion here, but a
knowledgeable and professional researcher
can deconstruct the data and provide
meaningful data.
Lies, damned lies
and statistics
One aspect of interpreting data can be
summarised by dont just take pub
lished facts as being set in stone, 100 %
accurate. GDP growth rates for a country
may be based on three-year-old estimates;
population figures for some countrie s
even UN figures can be based on a
census that was conducted 10 years ago.
46
Much of the data freely available claims to be cur-
rent or up-to-date, but even hard facts must be
viewed with caution and interpreted to ensure that
the appearance is not misleading
Table 1. Qatar transformer imports, 2011-2013
Qatar imports 2011 to 2013 averaged
Source country $ millions
Korea South 26.9
Croatia 22.9
Turkey 12.2
Italy 9.8
France 4.8
Germany 4.7
USA 3.1
Indonesia 3.0
Spain 2.9
Denmark 1.8
Brazil 1.5
Austria 1.2
Other 2.4
Total 97.1
Source: Data from UN Comtrade database
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
At first sight, a large geographical market may
appear to offer the best opportunities for a new
entrant, but appearances may be deceiving,
because the most open market and hence the
best potential may not be the largest
A web source shows that the global instal exporting countries statistics to the target
led generating capacity increased from country. Certainly there are often large
5,624 GW in 2013 to 5,699 GW in 2014, variations between what exporting coun-
which indicates that the global demand tries and the recipient importing coun-
for GSU transformers was 75 GVA in tries record. Table 1 illustrated the aver-
2014 (not including replacement for re- aged imports into Qatar as recorded by
tired plant). In reality, these transformers the countries exporting products to Qatar.
would have been ordered in 2011 for deli- For comparison, Table 2 shows imports as
very between 2012 - 2013, for commission recorded by Qatar.
ing in 2014, so depending on whether
you count the market as at the time of There are some large discrepancies be
order, time of delivery, time of payment, tween the two sets of figures. It is not un-
or time of commissioning, these 2014 fig usual, and perfectly understandable, for
ures may actually have been a part of the there to be variations from one year to
transformer market as far back as 2011. another. For example, a large order may
Just to further confuse the issue, the 2014 be supplied and recorded in the exporting
data quoted was accessed from the EIA country data in one year, but it may not
database in 2014, in which the latest year appear in the recipient country until the
for which hard data is listed is 2012, so the year after. It is for that reason that three-
basis of the analysis slips back six years in years figures have been averaged to iron
the past towards 2009 or 2010. out the effects of any single year; however,
$30 million versus $97 million probably
Many of the smaller countries do not illustrates systematic differences in record
produce reliable import statistics and a ing protocols between the two sets and
more reliable source is the sum total of a judgement has to be made as to which
Table 2. Recorded transformer imports into Qatar, 2011-2013
Qatar imports 2011 to 2013 averaged
Source country $ millions
Korea South 9.0
UAE 5.1
Germany 3.5
Italy 2.7
UK 1.2
USA 1.2
Turkey 1.1
Croatia 1.0
China 0.7
Saudi Arabia 0.6
Other 4.1
Total 30.4
Source: Data from UN Comtrade database
figures to rely on. This judgement requires
knowledge and industry experience.
Identifying opportunities
It can be misleading to assume that a large
market means plenty of opportunity for a
new entrant. It can be, and often is argued
when assessing a new market entry, that
even a small share of a large market is
worthwhile pursuing. This may well be
the case, but the more important and less
often asked question is how accessible that
market is. The Asian (including China)
market for transformers is worth a little
under US$17 billion annually, however
over 91 % of the market is satisfied by
goods used in the country of manufac-
ture. The total import market share of all
Asian countries is 8.65 % or US$1.5 bil
lion, of which 5.1 % are from other Asian
countries. Therefore, manufacturers from
every other country are fighting for a
share of the US$0.5 billion extra-regional
business. The same analysis for Western
Europe shows that a similar value (US$0.5
billion) is available to non-European sup-
pliers out of a total market of US$3.6 bil-
lion. The region with the largest available
free market is North America, where from
a total market of US$5.5 billion, 36 % or
US$2.0 billion is supplied by non-North
American countries.
Future forecasts
For many product areas researchers rely
on GDP growth forecast as the basis of
their view of the future; however, for in-
frastructure products such as transform
ers, a heavy reliance on such indicators
can be misleading. Transmission and dis-
tribution network development may be
the result of increased economic activity
in any country, but there are many other
factors that impact market development.
Electrical engineers do not wait until the
economists say that GDP has increased
by 2 percentage points and then write
out an order for a new power station or
several new substations. They are making
much more complicated calculations in-
volving load growth, changing load pat-
terns, population development, industry
investment, housing starts, maintenance
requirements and even climate change.
On top of this, they are balancing the de-
mands of capital expenditure versus oper
ational expenditure. Yes, a new transformer
will be more efficient and will pay for it
self inside 10 years, but without the capital

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 47
 COLUMN

Table 3. A global transformer market overview

Regional market Market size Domestic Import Intra region Extra region Extra region
$ million share share share share available $ million

Western Europe 3,596.0 36.72 % 63.28 % 83.64 % 16.36 % 588.2

Eastern Europe 913.8 69.29 % 30.71 % 78.55 % 21.45 % 196.0
FSU 2,192.9 58.42 % 41.58 % 80.62 % 19.38 % 424.9
Africa 2,158.5 45.64 % 54.36 % 48.28 % 51.72 % 1,116.4
Middle East 2,025.5 11.42 % 88.58 % 31.48 % 68.52 % 1,387.9
Indian Subcontinent 1,354.2 61.98 % 38.02 % 63.84 % 36.16 % 489.7
Asia 16,836.7 91.35 % 8.65 % 96.53 % 3.47 % 584.1
South & Central America 2,006.9 61.42 % 38.58 % 74.41 % 25.59 % 513.5
North America 5,501.1 55.29 % 44.71 % 63.85 % 36.15 % 1,988.6
Australasia 402.0 39.70 % 60.30 % 48.45 % 51.55 % 207.2
Source: UN Comtrade data & Goulden Reports Analysis

Greater insight is required when forecasting community continues to make sure that
the lights dont go out. Political inputs into
future markets for power and distribution infrastructure development decision mak
transformers than simply searching for the ing and all of the attendant delays that this
causes to flagship projects must be a major
economic forecast with the highest GDP annoyance to the constructors and the sup-
growth. Its not that easy. pliers of the transformers which hang on
those decisions. Nevertheless, overall this
represents only a small percentage of the
global market at any one time.
expenditure budget to make the replace- tribution transformer markets declined
ment, a 30-year-old unit may have to be instead of increasing. In conclusion, there is a great deal of infor-
left in place even if it is costing money in mation available to transformer manufac-
losses to do so. We have developed models Political decisions can also have a detri- turers and their strategic planners, some
to calculate these factors and to make mental effect on transformer markets, but of which is freely available, some of which
judgements of future growth rates, but it is worth noting that the global market is charged for. There are three categories:
these only assist; they do not provide for transformers was $40 billion in 2015.
a definitive answer. When utility com 18 % of that was generator transformers, That which is free which is probably
panies in some countries were preparing 29 % were transmission transformers too voluminous, may be contradictory,
for privatization in the 1990s, theoretically and 53 % were distribution transformers. is of doubtful reliability and will require
they should have been replacing and en- Politicians only generally interfere with pre-digesting or at least prioritising by
hancing their 40-year-old networks pro- large newsworthy projects usually a part experienced staff; otherwise, it will take
viding plenty of transformer orders. In of the generator and transmission trans- too long to assimilate.
practice, to conform with the needs of a former segments, a relatively small per- Published market research which is
beauty competition for investors, they centage of the total market. Meanwhile, charged for, but is not generally prohibi-
cut back all unnecessary expense and dis- the rest of the infrastructure engineering tively expensive; however, it will need to
be interpreted to meet individual needs
and used selectively.
Tailored specific research which is
Author highly targeted, but will need to be care
fully designed to avoid wasted expend
Steve Aubertin is the Managing Director of Goulden iture.
Reports and following a first career in electrical
engineering has spent the last 30 years researching and Some of the issues raised above will be
reporting on the global market for electrical products in explored in greater detail in future col
umns, and the intuitive and counter in-
both published and in the form of tailored research for tuitive problems of sizing, forecasting and
specific clients. predicting market conditions will be dis-
cussed in greater detail.

48 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 FLAT RATE
GRAPHIC DESIGN
Passion for transformers and design

Flat rate design offers a flat-rate pricing structure for all of your graphic design needs.
Under a frame agreement concluded at the outset of the project, we deliver all graphic
design solutions tailored to your needs at a flat monthly rate.
INTERVIEW
EVENTS

FEWAs vision is to provide

electricity and water
services aiming to improve
the standard of living and
achieve sustainable growth

50 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 The company employs more than 2,500 people,
and comprises four main directorates, four core
and five supporting departments, six main offices
and as many as 16 branch offices

Interview with
H.E. Mohammed
Mohammed Saleh,
Director General at
FEWA
FEWAs profile
Federal Electricity & Water Authority
(FEWA) was established as an independ
ent entity with an aim to
run its own projects, be efficient and
self-dependent, and improve peoples
lives by dealing with the demands of
the public. Established in 1999, FEWAs
main objective is to cater to the needs of
the population in the Northern areas. In
pursuing this main goal, FEWA has had
to create a balance between the cost of
production and the distribution price,
while at the same time considering
to unify the existing variable pricing
strategies, studying the consumption
behaviour and creating awareness
among the consumers on the efficient
use of electricity and water. The company
employs more than 2,500 people, and
comprises four main directorates, four
core and five supporting departments,
six main offices and as many as 16
branch offices. We supply more than
570,000 customers across four cities.
FEWAs vision is to provide electricity and
water services to improve the standard of
living and achieve sustainable growth by
2021. Seeking simultaneously to achieve
UAEs vision 2021, the company aims to
ensure sustainable development while
preserving the environment along with
achieving a balance between economic
and social development. Looking to im-
prove and provide the best for customers,
our goal is to reach a high level of cus
tomer satisfaction. At the same time, our
efforts towards achieving sustainability
and higher level of efficiency also include
continuous education and raising aware-
ness of the public on different techniques
of conserving both water and electricity
resources. Finally, we aim to ensure that

The main fleet operation challenges that the

utility faces in order to keep the system running
uninterruptedly include high temperatures, high
humidity level, and dust storms
w w w . t ra n sfo r m e r s - m a g a z i n e . co m 51
INTERVIEW
Among other advancements, we are plan-
ning to introduce a vacuum-type OLTC in
power transformers, and use a new type of
transformer oil to ensure better perform
ance and long life of the equipment
administrative services are provided in
accordance with standards of quality, ef-
ficiency and transparency.
It is our mission to develop electricity and
water facilities infrastructure in order to
meet the growing electricity and water
demand in the Emirates under FEWA jur
isdiction in a common goal to enhance
sustainable development.
FEWAs transformer fleet
In FEWAs transformer fleet there are
approximately 75 of ONAN/ONAF
power transformers with the capacity
level ranging from 50 to 90 MVA, and the
voltage level of 132/33 to 132/11 kV. In
addition, there are around 280 ONAN/
ONAF power transformers rated between
15 to 25 MVA, and the voltage level of
33/11 kV.
The number of distribution transformers
in our fleet, which range from 250 to 2,000
52
kVA in capacity and have the voltage level
of 11/0.433 kV, is approximately 15,000. It is
important to note that only five percent of
FEWAs power transformers, both medium
and low voltage, are more than 20 years old,
while the majority of the units are less than
20 years old. A type of failure in the power
transformers that we have noticed is cable
termination failure, which completely dam
ages the cable box. In distribution transfor-
mers we notice damage to bushings due to
high temperature and humidity.
The main fleet operation challenges
that the utility faces in order to keep
the system running without any
interruption include high temperatures,
high humidity level, and dust storms.
These conditions require high standards
of the system maintenance, fast fault
diagnosis and rectification to maintain
international standards.
In the transformer procurement proced
ure, FEWA gives preference to local sup-
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
pliers, but we are also open to global sup-
pliers through public tenders.
Looking into the future
FEWAs 132 kV transmission grid is
constantly expanding to accommodate
the current and future load growth
requirements and hence satisfy the N-1
criteria for reliability. Additionally, we are
continuously enhancing the distribution
network to cater for the load growth in each
of the regions. In regard to the equipment,
FEWA has recently hired a consultant to
review and update the specifications for
transformers and substations. We are also
planning to introduce a vacuum-type
OLTC in power transformers, and use
a new type of transformer oil to ensure
better performance and long life of the
equipment. FEWA is also working on
pilot projects in the field of Automatic
Metering System (AMI), and Distribution
Management Systems (DMS).
Biography:
H.E. Mohammed Mohammed
Saleh is the Director General of the
Federal Electricity & Water Authority
(FEWA) and has over 33 years of
experience in the utilities sector.
Think about the environment
while developing, manufacturing
and operating transformers.
EVENTS
MONITORING
The InsuLogix VAULT
ABSTRACT
As the modern world becomes
increasingly wired, more critical
systems and infrastructure are linked
via the internet. While that has given
rise to incredible new technology
efficiency and capability, it has
also meant that more countries are
vulnerable to hacking and cyber
attack. The InsuLogix VAULT is a
state-of-the-art transformer con
troller and monitoring integrator de
signed to meet the pending U.S. NERC
CIP cyber security requirements for
grid devices, providing a platform to
monitor a utilitys entire fleet.
54
The most advanced and secure solution for
your transformers against the threat of
cyber attack
A
s the modern world becomes in-
creasingly wired, more critical
systems and infrastructure are
linked via the internet. While
that has given rise to incredible new tech-
nology efficiency and capability, it has also
meant that more countries are vulnerable
to hacking and cyber attacks.
In a recent briefing to the U.S. House Per-
manent Select Committee on Intelligence,
NSA Director Navy Admiral Michael
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Rogers told the House that a number of
foreign governments had already man
aged to penetrate U.S. energy, water and
fuel distribution systems, which has po-
tential to damage essential services.
As recently as December 23, 2015
Uk rainian Power Companies experi
ence d unscheduled power outages
leaving 700,000 people without power.
Public reports indicate that the Black
Energ y (BE) malware was discovered

on the companys networks. A report by
Bloomberg News noted a cyber attack
which caused a British Petroleum owned
gas pipeline in Turkey to explode. At
the time, this pipeline running from
Baku-Tbilisi-Ceyhan was thought to be
one of the most secure in the world. In
December 2014, amid the much publi-
cized massive hack of Sony Pictures by
North Korea, the German government
released a report describing a successful
cyber attack that infiltrated the industrial
controls of a German steel mill. The report
said the attack caused massive damage
by making it impossible to shut off the
blast furnaces and at the same time over
working and sacrificing the life of the fur-
nace transformer that supports the mill.
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
InsuLogix VAULT Transformer Security
Make your transformer the most secure asset in your substation by complying
with NERC Critical Infrastructure Program Standards.
The InsuLogix VAULT is designed to meet CIP-002 thru CIP-011 (cyber) and CIP-
014 (physical) standards as well as IEEE 1686.
As Admiral Rogers stated: This is not
theoretical, this is something that is im-
pacting our nation and those of our allies
every day.
In todays world, reliability in our electric
al grid requires cyber security. A cyber
attack on devices that protect and control
equipment in the electrical grid could
result in significant outages and dam
age to equipment. This is especially true
for Substation Class Medium and Large
Power Transformer (LPT). LPTs are
custom-designed equipment that entail
significant capital expenditures and long
lead times due to intricate procurement
process. Pricing varies by size and manu-
facturer but such units can cost millions
of dollars and weigh between 100-400
tons. Procurement and manufacturing is
a complex process that could extend lead-
times to 20 months. Although the cost of
replacing transformers can be considered
substantial, it pales in comparison to an
actual outage in a large city when multiple
units are taken down.
Protecting transformers from cyber attack
should be a top priority for the owner of
these critical assets.
WEIDMANN ELECTRICAL TECHNOLOGY
INC. has teamed up with SYNEXXUS
Inc., a leading provider of integrated
systems for the U.S. military, to develop
and produce the most comprehensive
transformer health monitoring and se-
curity system solution in the market. The
WEIDMANN InsuLogix VAULT is the
first solution of its kind to bring together
transformer condition monitoring, con
trols, and substation security in a cyber-
secure platform that exceeds North
American Electric Reliability Corporation
(NERC) security requirements, all in an
integrated, interoperable, and extensible
hardware and software architecture. The
InsuLogix VAULT meets or exceeds U.S.
Department of Defense requirements for
Advertorial
development, sourcing and production of
technology driven products.
The InsuLogix VAULT promotes inter
operability through its ability to run both
WEIDMANN and third party developed
applications in a cyber-secure software
platform. It is designed to accept input
sources from the widest possible array of
third party devices, monitoring equip-
ment, and physical security tools, such as
cameras and access control systems.
Advanced cyber-secure software running
on the InsuLogix VAULT integrates in-
puts from WEIDMANN and other in-
telligent electronic devices used in moni
toring and controlling electrical assets
and yard security in electrical substations.
Key features include monitoring of a
transformers operating condition, con-
trol of cooling, alarms, recording of events
such as through-faults, AC metering and
power quality, local weather, and physical
security including live video and event
triggered video recording. The InsuLogix
VAULT controller is a compact, solid-
state device impervious to physical dam
age and electronic intrusion with proper
installation.
Bestselling investigative reporter, Ted
Koppel, speculates in his newly published
book, Lights Out, that a major cyber attack
It is the policy of the United States
to enhance the security and resili-
ence of the Nations critical infra-
structure and to maintain a cyber
environment that encourages ef-
ficiency, innovation, and economic
prosperity while promoting safety,
security, business confidentiality,
privacy, and civil liberties.
President Barack Obama
Executive Order 13636, February 2013
55
MONITORING
on Americas power grid is not only pos-
sible but likely, and paints a picture of a
U.S. utility infrastructure that is shockingly
unprepared. However, given the electric
utility industrys exceptional track record,
proactive efforts by NERC to advance
security measures, and the availability of
technology solutions like the InsuLogix
VAULT, the doomsday scenario imagined
by Koppel underestimates the resilience
of, and ongoing advancements for, our
nations electric grid.
The InsuLogix VAULT pro-
vides transformer security
now and into the future
The InsuLogix VAULT is designed to
support not only the security standards
levied on Bulk Electric System (BES)
transformers, but on transformers of all
sizes and applications, as standards and
grid reliability expectations are likely to
be placed on smaller systems over time.
In addition, to ensure compliance with
future regulations, the InsuLogix VAULT
has implemented security controls that
meet or exceed policies and standards for
a BES Medium Impact Cyber System per
CIP-002-5 Cyber Security, and BES Cyber
System Categorization. The InsuLogix
VAULT provides cyber-secure data stor
age, web-based front-end applications,
and associated analytic tools hosted on
cyber-secure systems that are compliant
with Criminal Justice Information System
Policy, CJISD-ITS-DOC-08140-5.4.
The InsuLogix VAULT also provides
physical security of your transformer and
substation through use of video and access
control. The InsuLogix VAULT provides
three video and access control packages
InsuLogix VAULT Flexibility
The InsuLogix VAULT can acquire, aggregate, record and make available
key data to SCADA, EMS, and DCS data from WEIDMANN or third party
monitors and sensors. Examples of sensors/monitors that can be
connected to the InsuLogix VAULT include:
Gas monitors
Moisture monitors
Fiber optic temperature monitors
Online bushing and lightening arrestor monitoring systems
Voltage and current sensors
Connections to cooling devices such as fans
56
Remote Command Telemetry Unit (RCTU)
Basic, Enhanced, and Pro offering cus-
tomers security capabilities at lower prices
than previously possible by leveraging the
InsuLogix VAULTs in-place processing
and communications architecture.
The InsuLogix VAULT features the abil
ity to optimize the transformers utiliza
tion rate by helping to find the acceptable
balance of insulation loss of life and risk.
The system uses WEIDMANN Optimum
Performance Monitor (OPM) and
eNamePlate software that can simulate
and help plan various dynamic loading
scenarios before a critical loading deci-
sion is made. The results of that decision
in terms of the actual loss of life are then
calculated and communicated to the
user. The InsuLogix VAULT can be op-
tionally configured with WEIDMANNs
SmartInsulation system of fiber optic
sensors embedded directly in the transformer
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
windings. These sensors can measure
Temperature (T), Moisture (M) directly
in the insulation, and winding clamping
Force (F), to generate critical transformer
health information.
Maximize your transformers
performance level with the
InsuLogix VAULT through
real-time and future load
planning
The OPM software embedded in the
InsuLogix VAULT is designed specifically
for Load Planning and for Asset Managers
to simulate and verify transformer per
formance over a broad range of operating
parameters. Typical output would include
real-time thermal margins, present and
accumulated insulation loss-of-life, pre-
dicted maximum normal and emergency
loading levels and insulation loss-of-life
at future loads all allowing the operator
to respond to emergency situations. Util
ization of the InsuLogix VAULT will
allow asset owners to increase peak MVA
load capacity, extend individual life of
transformers, and balance load across the
entire fleet. The InsuLogix VAULT can
simulate a variety of operating conditions
based on data obtained from the unit spe-
cific factory (heat run) test data, and when
combined with ambient temperature
forecast, perform a location based loading
assessment. The InsuLogix VAULT pro
vides the asset owner with transformer
digital or dynamic nameplate (as compared
to analog or static transformer nameplate)
for normal and emergency loading scen
arios. In addition, the InsuLogix VAULT
will fuse all of the health monitoring in-
formation under one platform by elim
inating the necessity of having multiple
loaner devices and multiple algorithms
to interpret data from each connected
transformer. Ultimately, this could lead to
a reduction in resource demands required
to monitor multiple devices installed on
transformers.
InsuLogix VAULT Enhanced Reliability
The InsuLogix VAULT utilizes Optimum Performance Monitoring (OPM)
software to establish a WEIDMANN Health Index for your transformer.
The OPM software provides true real-time health monitoring of your
transformer by utilizing key information directly from your transformer.
This information is consolidated to provide a WEIDMANN Health Index
that will assist Asset Managers to make ever more strategic decisions on
transformer loading.

The InsuLogix VAULT will

reduce overall costs by con-
solidating several individual
devices into one box

The InsuLogix VAULT enables simpli-

fication of a transformer control design
through the following functionalities:
loss of voltage or time delay relay, thermal
monitor, advanced power meter, annun-
ciator, transformer monitor, voltage regu
lation, touch screen control functions,
Ethernet Switch, cellular modem, access
control, video monitoring and security
alerts. The InsuLogix VAULT is a third
party-friendly platform that enables cus-
tomers to continue using industry-leading
sensors from other manufacturers. InsuLogix VAULT Monitor

The InsuLogix VAULT will simplify

hardware configuration during ordering
and installation. The InsuLogix VAULT
remote command telemetry unit (RCTU)
comes standard with redundant AC and
DC power supply inputs, 32 digital inputs,
16 relay outputs, 8 analog inputs, dedi
cated metrology inputs (3 phase voltage
and 4 current inputs), 8 resistance tem-
InsuLogix VAULT Optional Smart Display
perature detector (RTD) inputs, 4 serial
ports, an 8 port Ethernet switch, a cellular
modem. This flexibility allows you to re-
duce and simplify the total footprint of the
control box. The InsuLogix VAULT pro
vides a scalable platform that allows for most
functions found in a typical transformer
control system. Taking full advantage of
system capabilities reduces the number of
single purpose devices required while also
reducing the overall size and consequently
the cost of the control cabinet.
By enabling the user to conduct conveni-
ent, remote site inspections with cameras
in the substation, the InsuLogix VAULT
reduces asset physical inspection and
maintenance costs. Rather than dispatch
ing a team to collect data, remote operators
can access complete/synchronized trans-
former system information. Data can be
analyzed in fleet views and custom reports
through the remote interface to compare
performance of similar units. In addition,
transformer drawings, test reports and
instruction manuals can be downloaded
from the remote interface transformer ar-
chive drop box. The InsuLogix VAULT
utilizes a transformers wellness history,
sensory data and trending, and capitalizes
on the advanced analytics of the systems
OPM diagnostic engine in order to justify
a transition from calendar-based mainten
ance to condition-based maintenance.

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 57
MONITORING

The VAULT effectively becomes the

transformers brain, storing and
recalling every data point, every
event in the life of the transformer.
It can then analyze that data,
act and learn, protect itself, and
communicate by text or email.

K. Shane Smith
Manager of Delta Stars Customer
Solutions Group

The InsuLogix VAULT system inputs can

be utilized to trigger alerts to an individual
or group. The alerts can be in the form of
text messages or email messages such as
open door alerts, access control denial of
service, annunciation event, and motion
detection, to name a few. A good example
is false pressure relief and sudden pressure
alarms. The InsuLogix VAULT makes it
possible to configure the system to send an
email or text message so that maintenance
teams can be dispatched to the substation
when an alarm is raised. A camera can be
configured to pan-tilt-zoom (PTZ) to see
if the Pressure Relief Device (PRD) flag
is raised. With the addition of an analog
pressure sensor to the control scheme, it
is now possible to review current system
pressure and review recent history for
sudden changes.
As an early adopter of the InsuLogix
VAULT, Delta Star, Inc. has started de-
ploying the InsuLogix VAULT at scale
on specified transformers, including mo-
bile transformers and mobile substation
equipment. According to K. Shane
Smith, Manager of Delta Stars Customer
Solutions Group, the InsuLogix VAULT
is a key component of Delta Stars intel-
ligent, secure transformer. Todays trans-
former owners and operators are under
increasing pressure to deliver safe and
reliable energy more efficiently while
maintaining the security of the infra-
structure. Our industry is the best in the
world when it comes to dependable ser-
vice, so the bar is already set very high.
Delta Star has been custom designing
and manufacturing transformers and
transformer control systems for deca-
des; never has there been a comparable
platform that combines industry-leading
interoperability, defense-proven cyber
protection, video capability, and redun-
dancy in communications with advan-
ced analytics. The InsuLogix VAULT
RCTU and Display
e
ffectively becomes the transformers plifying the overall transformer control
brain it can store and recall every data scheme. If the response to the product
point, every event in the life of the trans- unveiling at the 2016 IEEE Transmission
former then analyze that data, act and and Distribution Conference in Dallas is
learn, protect itself, and communicate any indication, the industry is eager to
by text or email. All of this while sim embrace and realize the benefits.
Authors
Chris Amend attended the University of Cincinnati and received
his B.S. in Aerospace Engineering. He assumed his current role
of Director of Project Management at SYNEXXUS in 2014. Prior
to coming to SYNEXXUS, he spent 10 years working for the U.S.
Department of Defense. His work included the design, integration,
test and management of several satellite programs at the Naval
Research Laboratory Spacecraft Engineering Division. He also has
worked as a Senior Engineer as a member of the F-18 Fleet Support Team providing in
service sustainment support of aircraft sub-systems. He holds a Professional Engineering
license in the state of Virginia as well as a Program Management Professional certification.
Robert Begin attended Clarkson University and received his
B.S.E.E. in Electrical and Computer Engineering in 1991. After
graduating from Clarkson, he joined EHV-WEIDMANN
Industries as a Technical Service Engineer with focus on transformer
insulation system design. In 1996 he joined WEIDMANN Systems
International as a Sales Account Manager for the Power and
Distribution Transformer markets in North America. In 2004 he
accepted a position with WEIDMANN-ACTI Inc. as the Business Development Manager
for products and services related to transformers in the utility and industrial marketplace.
In 2007 he became the Sales Manager for the Power market in the U.S. and Canada and
continues to work in this capacity for WEIDMANN Electrical Technology.

58 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 JOIN US IN
NORTH AMERICA
CWIEME Chicago unites leading suppliers of machinery
and components with high profile manufacturers from
across the Americas.

THE HEART
OF YOUR INDUSTRY
Dont miss this opportunity to network, make new contacts
and keep up-to-date with your industry.
Register for your free ticket at:
www.coilwindingexpo.com/chicago/TM1
EVENTS TECHNOLOGY
DRYING

Vapor phase
ABSTRACT
Vapor phase drying is the most effect
ive method for drying transformer in-
sulation in a manufacturing setting.

transformer
The process does not lend itself well
to transformer drying in the field for a
variety of reasons, including the dif-
ficulty of removing residual kerosene
which can cause a potential change

drying Part II
in transformer oil flash point. Several
Photo courtesy of Konar D&ST, Zagreb, Croatia

techniques are available for transform

er insulation drying in both the field
and in manufacturing. Vapor phase
drying as part of transformer manu-
facturing is discussed in this paper.
Vapor phase drying as part
KEYWORDS
of transformer manufacturing
Vapor phase, transformer drying, vac
uum chamber, VPD process
60 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Typical vapor phase steps
Loading of coil(s): One or more coils
are loaded into the vapor phase vacuum
chamber (autoclave). Typically, a number
of thermocouples are installed at various
locations (depths & heights) in the coils
to monitor and record the load tempera-
ture throughout the process.
If isostatic pressing is part of the system,
press plates are set and hydraulics are
connected.
Leak test and preheat: After the coil is
inside the chamber with thermocouples
connected, the chamber door is closed.
Pressure is reduced by vacuum to a preset
level and leak-up rate is checked to verify
a tight door seal and vacuum integrity of
the chamber. Preheating of the system in
preparation for the next step begins.
Wet cycle: Vacuum pump(s) lower the
pressure in the chamber to the appropri
ate starting level. Solvent is then intro
duced into the chamber, heated and
circulated through a spray system. Hot
solvent being sprayed onto the load at
reduced pressure transfers heat. The
temperature and pressure of the system
provide an environment for rapid water
evapo ration. Sufficient heat is added
by the spray system to both replace lost
latent heat from water evaporation, and
also to raise the load temperature for
the dry cycle step. As the hot solvent
contacts the load and transfers heat, its
temperature drops so that it runs down
into the solvent pool for recirculation.
In some products, a higher end temp
erature is required to set epoxy impreg-
nated components. Precise temperature
control is required so as to heat rapidly
while minimizing overshoot of the upper
temperature limit of the insulation.
Water evaporating from the load leaves
the chamber through the vacuum system
and is condensed for collection ahead
Typically 90-95 % of the
total water content is
removed during the wet
cycle
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Sometimes it is advantageous to allow the
coil to sit under oil until the production
floor is ready to use the coil in the next
step of assembly
of the vacuum pumps. Relatively small
amounts of solvent that carry over with
the water are also condensed and collect
ed.
The length of the wet cycle is determined
by the load (coil: insulation & winding)
size. Typically 90-95 % of the total water
content is removed during the wet cy
cle. It is not possible to remove all of the
water content in this part of the cycle be-
cause dryness level is dependent on the
vacuum level. In this step the vacuum
level is controlled to optimize solvent use
efficiency in the chamber.
The end of the solvent cycle is deter
mined primarily by the temperature
of the load and/or the amount of water
collected from the load. The process is
instrument driven, but often minimum
times are set in the controls based on the
load size/mass and coil type.
Dry cycle: The solvent is pumped out of
the chamber while low vacuum is main-
tained. After the solvent drain is complete,
vacuum is no longer limited and the
vacuum system is allowed to lower the
pressure further causing the remaining
moisture to evaporate.
Because the load was raised to a specific
temperature during the wet cycle, there
is adequate residual heat in the coil ma-
terials for the remaining water to eva-
porate without significant temperature
drop. Platecoils or other chamber wall
heating methods may also be employed
to provide radiant heat for this part of
the process. Platecoils also serve to mi-
nimize heat loss through the insulated
chamber walls during high vacuum. This
consideration is especially important on
vapor phases for shell form transformers,
which have a relatively smaller heat sink
than core form (higher insulation to met
al parts ratio).
High vacuum continues until the balance
of the water is extracted. It is also during
Gregory R. STEEVES
this time that residual vapor phase sol-
vent will evaporate under high vacuum
and be removed with the final water
for collection. This results in all solvent
being removed from the system prior
to addition of transformer oil during
impregnation.
Impregnation: Dry, degasified transform
er oil is pumped into the chamber to
submerge the load under oil. Vacuum is
maintained until the load is under oil, at
which time dry air or nitrogen is used to
break vacuum back to atmospheric pres-
sure.
In the absence of air and water in the coil,
oil fills all voids in the assembly in a pro-
cess known as impregnation.
Oil drain and unload: Transformer oil
is pumped rapidly from the chamber so
that the coil can be unloaded. Sometimes
it is advantageous to allow the coil to sit
under oil until the production floor is
ready to use the coil in the next step of
assembly.
Figure 7 is taken from a typical vapor
phase cycle. The bright red line is the
vacuum level. Most of the other lines are
temperatures read from thermocouples
placed in various locations in the insu-
lation being dried. The wet cycle can be
seen between hours zero and 105 where
it remains relatively flat during the spray-
ing of Isopar to add heat. The tempera-
ture lines show how this raises the tem-
perature of the insulation rapidly so that
under low pressure, water is removed
continuously through this step.
After all thermocouples achieve a mi-
nimum value (in this case 110 C), and
extracted water measures the expected
quantity, Isopar is removed from the
vac
uum chamber and vacuum is no
longer limited. As the pressure drops,
the relatively small amount of remaining
water continues to evaporate. This pro-
cess continues until endpoint milestones
61
DRYING TECHNOLOGY

Several vacuum chamber configurations are
available depending on the factory layout and
the coil types to be processed
(final pressure, air dewpoint, etc.) are
achieved.
Vapor phase vacuum chambers
Several vacuum chamber configurations
are available depending on the factory
layout and the coil types to be processed.
With sufficient overhead lift capability, a
top loading configuration such as the one
in Figure 8 (shown with a hydraulically
opened clamshell cover) could be used.
Trolleys might accommodate single coils
or multiples. Isostatic presses, as shown
in Figure 10, may be integrated into the
trolley to maintain pressure on the coils
which will undergo shrinkage as water is
removed from the cellulose.
Dryness / endpoint
Several methods can be employed to pre-
dict completion of the drying process:
Vacuum level & coil temperature: Piper
charts like the one in Figure 11 provide a
good indication of the water content re-
maining in the coil based on its tempera-
ture and the final vacuum level achieved.
Often there is a hold time that must expire
after achieving the vacuum level target
with coil temperature maintained above a
minimum value to reach the desired dry
point as indicated by the chart.
Vacuum dew point: Dew point instru-
ments that provide continuous moisture
content in the vacuum stream leaving the
vapor phase chamber are a good indicator
of the dryness of the system. Most dew
point instruments come on scale early in
the high vacuum dry cycle. The dew point

End loading configurations such as the
one shown in Figure 9 are available with
either vertical or horizontal opening
doors. A trolley system is used to shuttle
the load in and out of the chamber.
There is a hold time that must expire after
achieving the vacuum level target with coil
temperature maintained above a minimum
value to reach the desired dry point

Figure 7. Sample vapor phase data curves with insulation temperature and vacuum levels vs time

62 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

drops continuously as the coil dries with
dropping pressure achieving dew point
values of -30 C or below.

Capture extracted water and measure:

The water and solvent condensed from
the vacuum stream during the wet (low
vacuum) cycle are easily condensed, coll-
ected and separated. Filter-separators
will strip much of the water and further
separation can be achieved by settling as
the mixture cools. The water (if desired)
can be measured. During the high vac
uum drying phase, the pressure is too low
to collect the water by condensing and it
must be frozen from the vacuum stream
using a cascade freeze trap. Collected ice is
thawed and added to the measured water
collected. If complete measurement of the
extracted water during the entire cycle is
desired, cascade cold traps can be utilized Figure 8: Top loading clamshell chamber
for this part of the cycle.

Solvent handling / recovery

VDU (Vacuum Distillation Unit)

Though the solvent can easily be filtered

and water removed, it will gradually ac-
cumulate transformer oil. Even after
complete draining of the oil after impreg-
nation there is a residual film of oil inside
the chamber that will be dissolved into
the solvent during the subsequent vapor
phase cycle. Since the oil will dissolve into
solution, it cannot be filtered out. On sys-
tems without an oil impregnation cycle,
residual oils within the active parts will
eventually cause the same issue.

However, as was presented in the vapor

pressure chart in Figure 5 in Part I of this
paper, the solvent and transformer oil (or
other residual oils) can be separated by vac
uum distillation in a small VDU (vacuum
distillation unit Figure 12) with the like-
new solvent returned to the source tank.

This continuous maintenance of the sol-

vent ensures that the boiling range re-

The water and solvent

condensed from the
vacuum stream during
the wet cycle are easi-
ly condensed, collected
and separated Figure 9: End loading chamber with trolley

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 63
DRYING TECHNOLOGY

The continuous main-

tenance of the solvent
ensures that the boil
ing range remains con-
stant so that results
are repeatable from
one vapor phase cycle
to the next
mains constant so that results are repeata-
ble from one vapor phase cycle to the next. Figure 10: Isostatic press for shell form coil integrated into the trolley

Transformer oil purification

equipment
Transformer oil purifiers of adequate
capacity to rapidly fill the vapor phase
chamber with highly purified oil are an
important part of the overall system.
Different approaches can be taken to suit
each situation.

Small purifier with vacuum storage:

If adequate vacuum storage is available,
oil can be dehydrated to low moisture and
degasified to low gas content (typically
<10 ppm water and 0.25 % dissolved gas)
and then stored under vacuum to main-
tain these levels. A high speed pump can
then be used to transfer oil to the vapor
phase when required so that the purifier
does not have to be as large to meet the
high flow rate demand of the vapor phase.

High flow rate purifier: Alternately,

a larger flow rate purifier can be used to
single pass the oil from storage and to pro-
cess it as it transfers into the vapor phase.

Multi-stage purifier: For classes of trans-

formers requiring lower water content
(1-3 ppm) and lower gas content levels
(<0.1 % total gas), multi-stage purifiers are
available (Figure 13) to process oil at levels
<100 microns (0.10 Torr).

Transformer oil puri-

fiers of adequate ca
pacity to rapidly fill the
vapor phase chamber Figure 11. Piper chart (moisture equilibrium diagram)
with highly purified oil By finding the intersection of the final pressure (vacuum) achieved during drying, and the
insulation temperature at the final pressure, the colored line at the intersection provides a
are an important part good estimate of the final percent of moisture (water) remaining in the insulation.
of the overall system 1,000 microns = 1 Torr (millimeter of mercury) = 1.33 mbar

64 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Conclusion
Vapor phase drying is the most efficient
and effective method for the drying of
transformer insulation in a manufactur
ing setting. It is advantageous over other
methods in terms of time, repeatability
and quality of end product.

Author
Greg Steeves is
the General Man
ager and principle
engineer of Baron
USA, LLC, provider
Figure 12. Vacuum Distillation Unit for solvent (VDU)
of transformer dry-
out and di electric
fluid processing systems for OEMs, utili-
ties and field service organizations world-
wide. Greg joined Baron USA as Engi-
neering Manager in 1987. He is currently
responsible for managing the daily ope-
rations and overseeing the application,
engineering design and manufacturing
of oil purification equipment, vacuum
chambers, vapor phase processing and
transformer dry-out equipment. He ear-
ned his degree in Mechanical Engineering
from Tennessee Technological University
and is licensed in the state of Tennessee.
Figure 13. Multi-stage oil purifier

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 65
EVENTS
INTERVIEW

Interview with
Wolfgang Sorgatz
TLM Conference
Introduction conference in Germany, we organized the open conference and this year, which also

T
first international TLM Conference in marks our tenth anniversary, for the first
ransformer Life Management Dubai, followed by Guangzhou in China. time we have an exclusive media partner
(TLM) Conference was first They were both very successful. At one of Transformers Magazine.
held ten years ago, following the the conferences in China, there were more
idea to create a comprehensive than 300 participants. Conference topics
platform where all industry stakeholders
transformer manufacturers, customers Conference values As the conference is growing and chang
and service companies could participate ing, so are the topics. Every year we
and have the opportunity to introduce TLM Conference is a neutral platform for detect key trends and developments, as
their products and services. The idea was all stakeholders in the transformers indus- well as issues and concerns in the indus-
to have all people dealing with transform try, from manufacturers of transformers, try that resound all over the transformers
ers and doing business in the transform transformer instruments and transformer world, and among them we try to decide
ers industry gathered together in one materials, to their industrial partners and on the best topics we want to address at
place. end customers, such as utilities, power the conference. In the past we dealt with
plants and entire municipalities, which is questions on the regulation of the
We started as a German conference, which why it is so successful. They can all meet electricity market and even
was organized by ENERGY Suppor t, in one place and discuss what can be done had guest speakers who
ABB and the Schering-Institute for to extend the lifetime of the transform talked about this issue.
High Voltage Engineering of the Leibniz ers, from all these various, but equally Today, there is an is-
University of Hannover. It all started with important perspectives. The participants sue of how to extend
these three partners wishing to contribute can thus access all technical information the lifetime of the
to the same goal and encourage advance- and get a rounded picture of the complete equipment. We are
ment of the industry by having all people management cycle, as well as the mainten faced with diffe-
from the transformer world converge at ance issues involved. So, the conference rent challenges
one conference. is streamlined to focus on the transform that we wish to
ers world, but within it, it offers a great combine in the
In time, as TLM Conference bore great mixture of topics and participants, which topics we dis-
success in the German market, we recog- many see as one of the greatest benefits of cuss. How-
nized there was the same demand in the participating. ever, each
international market to have a conference time the
which would focus on the transformers TLM partners focus
industry only. This is where we decided to of the
use the transformers conference manage- TLM Conference is supported by ABB, the
ment experience gained in Germany and Schering-Institute of the Hannover Uni-
go global. Three years after our maiden versity and ENERGY Support. This is an

The idea behind TLM was to create a com

pre
hensive platform where all industry
stakeholders could participate and have the
opportunity to introduce their products and
services
66 TRANSFORMERS MAGAZINE | Volume 3, Issue 3
 conferences is the reliability of the trans-
former operation and its maintenance.
These topics cover a lot of other topics and
issues, such as test methods, continuous
monitoring, interpretation of measure-
ment and monitoring results and asset
management.

The next TLM conference is taking place

in Knigswinter, Germany from 26th to 27th
September. We expect to have more than
200 participants and over 25 exhibitors as
well as around 20 presentations from sev
eral countries.

This years topics will be centred around key

changes in the energy supply in the areas
of monitoring and asset management, as
well as insulation liquids and condition
assessment. More specifically, the
conference will discuss voltage
regulators for distribution
networks, models for
data recognition
and asset man
agement,
DGA

TLM Conference is a neutral platform

for all stakeholders in the transformers
industry

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 67
 INTERVIEW
TLM Conference is supported by ABB, the
Schering-Institute of the Leibniz University
of Hannover and ENERGY Support, with
Transformers Magazine as an exclusive
media partner
techniques, UHF PD detection, FRA, in-
tegration of offline and online monitoring,
heat transfer in insulation fluids, recycled
naphthenic base oils, ester fluids, GtL trans-
former oil, X-wax inside transformers, spe-
cial hollow insulators for bushings, as well
as topics looking at the far future, such as
generation of energy using nuclear fusion
technology.
It will provide an overview of all the expe-
rience and research that we have, including
speeches and presentations by our univer-
sity researchers, a lot of university speakers,
as well as some key speakers from the in-
dustry, who will all discuss the current situ
TLM provides an overview of all the ex-
perience and research that we have, in-
cluding speeches and presentations by
our university researchers, as well as key
speakers from the industry
68
ation, but also talk about new effects and
technical methods in the market.
Naturally, research and development will
form a big and important part of the con-
ference.
Continuous growth
TLM is an annually-based conference
which is continually growing, and it is ex-
panding to the international market. Since
there are many international participants,
we provide translation into English, which
is the second language of the conference.
While the main language is German, a lot
TRANSFORMERS MAGAZINE | Volume 3,
of the presentations are actually given in
English.
A true international conference is the TLM
in Dubai, where the official language is
English. Regrettably, it will not be held this
year due to a political situation in the re
gion and the complications for some par-
ticipants from the region to travel to Dubai.
However, we are exploring other regions in
the world, such as the U.S., Vietnam, Thai-
land or Malaysia, and looking for oppor-
tunities to convey this successful platform
there, creating more opportunities for par-
ticipants from other regions in the world to
share the knowledge in the same way we
find it to be so fruitful and beneficial.
To be able to do so, we need a strong part-
ner in the region, preferably a strong-posi-
tioned company who is a leader in the area
and knows the key manufacturers and cus-
tomers.
Exhibition
Although we have regular exhibitors and
sponsors each year, we are open to new
sponsors and offer various sponsorship
packages. Gold Sponsorship package in-
cludes a complimentary exhibition booth
at the conference exhibition area, 3 com-
plimentary conference registrations for
2, Issue 3
4
We are exploring other regions in the world,
such as the U.S., Vietnam, Thailand or Ma-
laysia, and looking for opportunities to con-
vey this successful platform there, creating
more opportunities for participants from
other regions
company employees, and 5 complimen-
tary registrations for their customers. It
is of great value for the company to be
able to select which customers they want
to meet at such event and strengthen the
relationship with them without any add
itional costs! Silver Sponsorship benefits
also include a complimentary exhib
ition booth at the conference exhibition
area, and a free conference registration
for two of their employees. They can in
vite two of their customers to attend the
conference free of charge. Both Gold and
Silver Sponsors have an opportunity to
publish a full-page print advert in the
TLM documentation, such as the con-
ference programme and proceedings, as
well as in downloadable documents free
of charge. Bronze Sponsors are provided
with a complimentary exhibition booth,
a complimentary conference registration
for one employee, and a 50 % discount on
the second conference registration. The
options available to exhibitors, which
provide balanced opportunities for pre-
senting to the relevant audience, and
meeting key industry people and select
ed customers without additional costs,
make TLM a favourable and effective ex-
hibition hub.
Universities and industries
collaborate
The involvement and participation of
different universities, and the specialized
knowledge associated with it, gives TLM
Conferences an additional, educational
value, providing a platform where people
from the industry can have an immediate
access to most current research and de-
velopments. This collaboration between
universities, industries and customers is
what makes this conference unique.

Wolfgang Sorgatz holds a degree in marketing and engineering. He has a 14-year Wolfgang Sorgatz
experience in the products of ENERGY Support, where he is responsible for sales, Technical Director
service, training and product development. Wolfgang also has a vast experience and Sales
in marketing of capital goods in Europe. Before joining ENERGY Support he ENERGY Support
GmbH
introduced a new brand in the test and measurement business to the European Sperberweg 47
market. Starting from scratch, this brand has developed into one of the most well- 41468 Neuss /
known brands in the German market today. Germany

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 69
TRANSFORMER IN GRID

ECOTAP VPD - the worlds most compact on-load tap-changer for

distribution transformers achieves maximum cost-effectiveness for
the entire transformer/on-load tap-changer system

70 TRANSFORMERS MAGAZINE | Volume 3, Issue 3


ECOTAP VPD
Compact on-load tap changer for distribution transformers
I
n t h e t r a n s f o r m e r s i n d u s t r y,
Maschinenfabrik Reinhausen (MR) is
a synonym for voltage regulation. Ma-
jority of transformers today operating
around the globe are equipped with some
kind of a tap-changer from MR.
In the past, voltage regulation used to be
required only at higher voltage levels in the
transmission grid. However, nowadays,
due to several reasons, voltage regulation
is increasingly required in the distribution
grid at lower voltage levels.
The operating principle of the proven MR
vacuum technology with 500,000 main
tenance-free tap-change operations ensures
reliable operation for decades, without the
need to service the primary equipment
Figure 1. The ECOTAP VPD on-load tap-changer (right) and the associated controller (left)
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Having launched the worlds first tap-
changer solution for voltage regulation
distribution transformers (VRDTs) ready
for mass production in 2012, MR set new
standards in this area. In May 2016, at an
official launch event at the CWIEME fair in
Berlin, Germany, MR presented a new, more
advanced generation of tap changers for dis-
tribution transformers - ECOTAP VPD.
The new ECOTAP VPD combines the
know-how MR has accumulated over the
decades in vacuum on-load tap-changers
ADVERTORIAL
with the experience in VRDTs gained
through working with transformer manu
facturers and operators. The ECOTAP
VPD provides a superior vacuum technol
ogy at a price that makes use of VRDTs
even more attractive and further expands
the range of application.
Technologically superior
economically convincing
The compact dimensions of the ECOTAP
VPD on-load tap-changer permit instal-
lation in virtually any power-rating class
of distribution transformers without any
major changes to the footprint. What is
more, the electro-mechanical operating
principle of the proven MR vacuum tech-
nology with 500,000 maintenance-free
tap-change operations ensures stable
and reliable operation for decades, with
out the need to service the primary
equipment. The direct drive with up
71
TRANSFORMER IN GRID
Figure 2. Targeted use of voltage regulation distribution transformers
Voltage regulation distribution transformers
are used to maintain a constant voltage in
public, industrial, and private distribution
grids, but also to avoid expensive grid re
inforcement and to decouple networks
to 20 tap-change operations per minute
enables quick re-sponses to changing grid
conditions. Nine tap-changer positions,
with a mid-position which the operator
is free to choose, ensure a large regulating
range with fine steps between the tap
changes. Thanks to its IP54 degree of pro-
tection, the ECOTAP VPD can be used
outdoors and in selected synthetic and
natural esters. Operation in applications
with stringent environmental compatibil
ity and thermal demand requirements is
therefore also possible.
The compact controller, another new fea-
ture, certainly lives up to its name as it is
just 10 cm wide and 35 cm tall. Using an
adapter, it can be installed on the busbar to
the width of one single fuse panel to save
space. All parameters can be set with ease
on the controller, so no laptop is needed.
Wide range of possible
applications in public grids
VRDTs are real all-rounders they main-
tain a constant voltage in public, indus
trial, and private distribution grids by com-
pensating for fluctuations in the medium
72
avoided and grid equipment put to more
and, if necessary, high-voltage levels and
responding dynamically to changes in
the feed-in and demand. Selective use,
focusing on one specific task in the low-
voltage grid, is now a very common appli-
cation. Nowadays, VRDTs are also used to
optimize the cost-effectiveness of the grid
Figure 3. Feeder-based use of voltage regulation distribution transformers
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
topology and to decouple voltage at me
dium- and low-voltage levels.
Ensuring a stable voltage within a narrow
band regulated by standards is a huge
challenge for distribution grid operators
because they need to integrate a growing
amount of renewable energy (increase in
voltage) and more new types of demand
(decrease in voltage). As a result, the oper
ators are having to take expensive grid
reinforcement measures, even though the
thermal capacities of their equipment in
the grid are far from being fully exploited.
A VRDT with the new ECOTAP VPD
solves the crux of the problem compli-
ance with the voltage band through dy-
namic adaptation. The low voltage is de-
coupled from the medium and the voltage
band can be re-distributed and therefore
used more effectively. The grids ability to
absorb power can be increased by up to a
factor of 4.
In most cases, by using VRDTs expen
sive grid reinforcement can be completely
economical use. In this regard, reference
is generally made to selective use, where
individual secondary substations are
equipped with a VRDT, Figure 2.
When VRDTs are used on a feeder basis
or in all parts of the grid, the focus is on
the medium-voltage grid.
Feeder-based use, Figure 3, is always re-
commended if there is a risk of the volta-

Figure 4. Voltage regulation distribution transformers used in all parts of the grid
ge band limits being infringed in a larger
interconnected area at the medium-voltage
level starting at a certain distance from
the primary substation. This may be the
case at the end of feeders or due to large
fluctuating or constant feed-in and/or
consumers. Decoupling the underlying
low-voltage grids from the voltage of the
affected medium-voltage feeder or ring
permits much greater changes in voltage
band than would otherwise be possible.
This results in greater potential for feed-
in and demand to be integrated into the
medium-voltage grid and the underlying
low-voltage grids.
Voltage regulation dis-
tribution transformers
can spare operators
from building new sub-
stations, resulting in
savings for rent, main-
tenance and servicing
of the stations, as well
as for investments in
replacement or new
equipment
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
If VRDTs are used in all parts of the grid,
all secondary substations not located in
the direct vicinity of the primary substa-
tion are fitted with new technology.
This is a good idea if there is a risk of the
voltage band being infringed in the en-
tire medium-voltage grid. The desired
voltage value on the HV/MV trans-
former can also be reduced in order to
allow an even higher voltage rise in the
me-dium-voltage grid. In this way, the
VRDTs can prevent or postpone major
grid reinforcement measures in the me-
dium-voltage grid.
Figure 5. Voltage regulation distribution transformers help optimize the grid topology
By using voltage regula
tion distribution trans
formers the grids abil
ity to absorb power can
be increased by up to a
factor of 4
Optimization of the grid
topology
An efficient distribution grid has as little
equipment as possible. VRDTs with
ECOTAP VPD increase the efficiency of
grid sections and reduce the total number
of secondary substations, thereby cutting
investment and maintenance costs, Figure
5. The number of secondary substations
needed for a grid area is determined
firstly by the maximum possible distance
between the secondary substation and grid
connection points from a voltage standpoint
and, secondly, by the maximum demand to
be covered and/or the maximum feed-in to
be transported.
VRDTs dynamically adapt the voltage
and thereby permit a larger electrical
supply radius around each secondary
substation. In this way, even consumers
or feed-ins a long distance from the sec
ondary substation can be connected. The
grid operator can combine two second
ary substations or can be spared from hav
ing to build a new secondary substation.
73
 TRANSFORMER IN GRID
Figure 6. Voltage regulation distribution transformers help stabilize industrial
processes
This results in savings for rent, mainte-
nance and servicing of the stations, as
well as for investments in replacement
or new equipment. The only requirement
is that one transformer is configured so
that its performance is sufficient for the
enlarged grid area.
Stabilizing industrial
processes in volatile grids
Industrial processes are extremely de-
pendent on a stable voltage, which isnt
always provided. In grids with limited
generator power, long distances or volatile
consumers and producers, the supplying
medium voltage may be subjected to
large fluctuations in voltage. As a result,
production processes may be inter
rupted, motors may not start or control
systems may crash. This can cause serious
damage, especially in sensitive industrial
processes. In addition to direct impacts
on processes, frequent changes in voltage
may also have a negative impact on the
life of equipment.
A VRDT with ECOTAP VPD in the in-
dustrial distribution grid ensures that
consumers have a stable supply of voltage
regardless of the volatility of the medium
voltage, Figure 6. Due to the large regu
lating range, even large fluctuations in the
medium voltage can be reliably regulated
for many years and without any main
tenance. The compact dimensions help to
keep costs down because the VRDT can be
installed in place of the conventional one.
74
Energy costs can also be significantly
reduced by optimized voltage. Energy
consumption for conventional loads is
affected by factors such as the voltage
with which the equipment is supplied.
If equipment is supplied with a higher
voltage than needed, the equipment con
sumes more energy than needed.
Using a VRDT with ECOTAP VPD in
the industrial distribution grid allows
equipment to be supplied with a voltage
actively optimized for it. This reduces
energy consumption without limiting
the equipments function. The VRDTs
con-troller balances the voltage between
what is available and what is ideal for
consumption. Before the voltage falls to
a level where equipment operation is at
risk, the VRDT intervenes and restores
Figure 7. Voltage regulation transformers in a photovoltaic park
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
ECOTAP VPD in the in-
dustrial distribution
grid allows equipment
to be supplied with a
voltage actively opti-
mized for it, reducing
energy consumption
and costs without limit
ing the equipments
function
the voltage to a level which is ideal for
consumption. This enables energy costs
to be reduced by up to fifteen percent.
Dispersed generation
plants economically
complying with grid
connection conditions
For integration into the grid, dispersed
generation plants based on renewable
energies (photovoltaics, wind, biogas)
must meet the relevant requirements
of the grid operator in the form of grid
codes. The provision of reactive power,
which depends on grid voltage, is partic
ularly critical. In cases where the re
quirements placed on providing reactive
power are particularly demanding, mak
ing the required reactive power available
can often only be accomplished either by
oversizing the inverters or by requiring
the generation plant to operate such that
it reduces the amount of active power fed

Figure 8. Voltage regulation transformers in a wind park
into the grid to suit the situation. Neither
approach is particularly attractive; the for-
mer because it increases the system costs
of the generation plant and the latter be-
cause it restricts the systems output. The
operators profits suffer in both cases.
The voltage decoupling made possible
by the voltage regulation transformer
means there is no need to oversize the
inverters or reduce the amount of active
power fed to the grid, which ultimately
makes the generation plant more cost-
effective. Alternatively, the additional
space obtained by using the voltage regu-
lation transformer can be used to operate
an existing generation plant with a high-
er power rating. Voltage regulation trans-
formers can be integrated in all dispersed
generation plants. Typical examples in-
clude photovoltaic parks, Figure 7, and
wind parks, Figure 8.
In the case of wind turbines, voltage
regulation transformers can be com-
bined with all drive-train concepts, such
as asynchronous generators or full-scale
inverters. The voltage regulation trans-
former can either run on its own or be
integrated in the generation units regu
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
lation system. Given the very limited
amount of space available, particularly in
wind turbines, the compact dimensions
of the ECOTAP VPD are as important as
the large regulating range and the main-
tenance-free operation in alternative in-
sulating fluids.
Manufacturing voltage
regulation distribution
transformers
Distribution transformers are as simple
as they can be. Adding a new function
ality requires also certain changes in
transformer manufacturing plant, from
the design through manufacturing to
Contact
Dr. Sojer, Manuel
Head of Strategy and
Marketing Power
Quality
ECOTAP VPD is per-
fectly tailored to the
processes of trans
former manufacturers
and withstands all
usual treatment pro-
cesses in the plant such
as evacuation, drying,
testing, etc.
testing. When developing ECOTAP
VPD, MR has used all the knowledge
gained though decades of cooperation
with transformer OEMs, so that the final
product withstands all usual treatment
processes in the plant (evacuation,
drying, testing, etc.). Practically all re
nowned transformer OEMs have
developed and tested their VRDTs.
This means that distribution utilities in
most cases can source VRDTs from the
same vendors they use for traditional
distribution transformers.
ECOTAP VPD more power,
more value
The new ECOTAP VPD is the worlds
most compact on-load tap-changer
for distribution transformers offering
the largest range of services. It achieves
maximum cost-effectiveness for the en-
tire transformer/on-load tap-changer
system, is maintenance-free, already
satisfies the requirements of the EU
Ecodesign Directive for 2021, and can
be operated with synthetic and natural
esters as insulating fluids. The ECOTAP
VPD is perfectly tailored to the proces-
ses of transformer manufacturers and is
highly versatile be it in public distribu-
tion grids, industrial applications or dis-
persed generation units.
Phone +49 941 40 90-2430
Fax +49 941 40 90-902430
m.sojer@reinhausen.com
www.reinhausen.com
75
TRANSFORMER IN GRID
EVENTS

Cost-effective and
fail-safe integration of
distributed grid infeed
Highly efficient, controllable distribution transformers and voltage regulators
1. Introduction world with a small number of large power
ABSTRACT generation facilities and a large number of
Photovoltaics, biogas and wind turbines loads. While expansion of the grid would
Grid expansion represents a save resources and reduce CO2 emissions. cover this inherent system deficiency, it
technically obvious but also However, they also result in fluctuating would not correct it. Grid operators are
very expensive solution for the energy flow directions, as well as load currently faced with completely different
infeed of renew able energy
and voltage fluctuations. Traditional tasks, being obligated to provide for
sources. A more intelligent
distribution grids with their conventional the infeed of renewable power sources.
solution is the implementation
distribution stations and classic trans With no affordable intermediate storage
o f c o n t ro l l a b le d i s t r i b u t i o n
formers are not designed for these con devices currently available, they must
transformers whose ratio can
ditions. Capacity could certainly be also harmonize supply and demand of
be controlled under load, as
expanded, but this does not resolve the power, and smoothen peaks using power
well as voltage regulators used
core issue. The concept was developed for a generation and load management.
in the medium voltage grid.

KEYWORDS
Decentralised energy production is on the rise,
voltage regulation, renewables,
distribution grid, regulated distri- but its integration in the existing grid infrastruc
bution transformers ture is a challenge for distribution grid operators
76 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

With their variable voltage under load,
FITformer REG a regulated distribution
transformer and voltage regulators are
two of the available solutions providing a
supplement for grids with voltage range
issues. Both solutions offer a cost-effec-
tive alternative to traditional grid expan-
sion and are easily integrated in existing
structures.
2. Better voltage control
with distribution trans-
formers for the MV/LV grid
(e.g. 20 kV/0.4 kV)
There are currently different concepts
for regulated distribution transformers,
where the integration of a tap changer on
the high-voltage side of the distribution
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
With their variable voltage under load, regu
lated distribution transformers and voltage
regulators can be used as a supplement in grids
with voltage range issues
transformer appears to be the simplest
solution for many operators. These
units are essentially small versions of
controllable power transformers a
concept known from large transformers
and therefore easy to understand. The
advantage of this solution is precise
control enabled by the tap changer on the
high-voltage side. However, this requires
that the operator accepts somewhat
higher losses, caused by the tap changer
design. It includes additional reactors, as
well as the risk of feedback loops with the
medium-voltage transformer occurring
when the regulation of the distribution
transformer takes place in small steps
once a small voltage change from the MV
grid happens.
Designed with a different approach,
FITformer REG is a regulated distribution
transformer whose underlying philoso-
phy is not to regulate voltage exactly to
the volt, but rather to very flexibly keep
it within the allowed voltage range in
accordance with EN50160 [1], with ex
tremely low losses. In order to achieve
this, the regulated distribution trans-
formers has been supplemented with a
load controller on the low-voltage side
in addition to the load-free control range
on the high-voltage side. This regulated
distribution transformer enables voltage
adjustment under load in three stages
to ensure distributed infeed from micro
power plants. The operating characteristics
and dimensions of the distribution trans-
former remain virtually unchanged.
Figure 1 shows the results from the im-
plemented regulation algorithm in an
application case. As illustrated, frequent
switching caused by the medium power
transformer stepping is avoided (point 1)
because the limits are not reached. How
ever, when the voltage of the three phases in
the grid increases (as shown by the green
lines at point 2), the feed-in is negative
(see the blue line at point 3), and the volt
ages reach the upper limit of the configured
voltage level (point 4). The transformer
lowers the voltage at point 4 by stepping
from position 2 to position 1 shown on the
Saskia BAUMANN
right-hand axis, where the three steps of
the regulated distribution transformer are
indicated. After a while, the voltage reaches
the lowest limit (point 5) and the transform
er steps back from position 1 to position 2 on
the right axis to increase the voltage.
Losses always play a major role when rat
ing electrical machines and have a big
impact on the lifecycle costs, defining the
ecological footprint of the transformer.
Therefore, in the development of this
regulated distribution transformer both
the control technology and economic
factors were considered. In the available
ratings from 250 kVA to 630 kVA, the
transformer meets the loss requirements
according to the European standard, e.g. a
distribution transformer up to (not incl.)
1.25 MVA:
Pk = Ck+5 % and P0 = A0+20 %, [2]
where Pk defines the load losses and P0
defines the no load losses.
Transformers are divided into classes
where A is the class with the lowest and
C with the highest losses. For regulated
distribution transformers there are ad-
ditional losses allowed, which enables
replacement of transformers in existing
substations with regulated distribution
transformers, considering that losses have
a direct impact on the design as well as the
size of a transformer.
Depending on the product, utilities must
accept that regulated distribution trans-
formers not only cost more, but also imply
higher operating costs . This transformer
is designed with optimized losses, and
therefore reduces these costs. Its control
system causes only low additional los-
ses, which could be compensated by an
adapted design of the active section, so
that it exhibits the same low losses as the
standard distribution transformer. With
an additional focus on keeping acquisi
tion costs as low as possible, the develop-
ment of this transformer resulted in a con-
trollable distribution transformer with a
shorter amortization time.
77
EVENTS
TRANSFORMER IN GRID

Position
Stufe
240.0 600.0

480.0

360.0
235.0 3
240.0

120.0

230.0 0.0 2

-120.0

-240.0
225.0 1
-360.0

-480.0

00:00:00 06:00:00 12:00:00 18:00:00 00:00:00

16.03.2012 16.03.2012 16.03.2012 16.03.2012 17.03.2012

Figure 1. Measuring recording during operation of a regulated distribution transformer for 24 hours, starting point 00:00:00

Algorithm implemented in the regulated dis short-circuit indicators, current/voltage

sensors, motor-driven medium-voltage
tribution transformer ensures that frequent switching devices and a controllable dis-
switching caused by the medium power tribution transformer. The modular struc-
ture of the iSub also allows the operator
transformer stepping is avoided to install only individual components in
existing stations.

The actual distribution station is capable

2.1. Technological details
The regulated distribution transformer
presented in this paper is a special kind of
transformer where the windings are pro-
duced with three low-voltage taps which
are routed from the transformer through
the hermetically sealed corrugated wall
tank to the control unit. With its compact
design, it can also be used to replace for-
mer traditional distribution transformers
in commonly compact stations without
difficulty.
control has been developed. This permits
grid operators to gradually expand their
conventional distribution stations and
adapt them to the changing grid condi-
tions and requirements. In the complete
configuration (including all three stages),
the intelligent distribution stations (iSub)
are equipped with Remote Terminal Units
(telecontrol and regulating devices), smart
of directly controlling the locally installed
controllable distribution transformer, but
also to send commands to various other
grid components with the existing meas
ured values, such as to inverters in power
generation systems. This enables a very
rapid response to extreme high and low
load periods in combination with highly
fluctuating infeeds from wind and solar

Highly robust and reliable vacuum contac-

tors are used, which are characterized by
especially high reliability, operating safety
and compact design. Voltage regulation is
implemented in two stages. Voltage limits
for slow and fast switching, as well as the
desired rated voltage can be entered in the
form of parameters. The control system
can be individually adjusted to various grid
conditions by entering delay times.
2.2. Controllable transformers in the
distribution grid of the future
Future distribution grids need more than
just controllable transformers. There
fore, a modular 3-stage concept based Figure 2. Comparison of the two-winding transformer and the voltage regulator -
on monitoring, telecontrol and load flow autotransformer

78 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Figure 3. Medium voltage in phase control station
power. For the grid operator, this represents
an option to optimize future investments.
3. Integration of renewable
power sources using volt
age regulators in the MV grid
(e.g. voltage level 10 kV or
ficant changes in the operating voltage principle, an autotransformer (Figure 2). A
20 kV) at individual distribution stations. This special feature of autotransformers is that
In some applications, it may be expedi-
ent to combine intelligent power stations
or controllable distribution transformers
with voltage regulators. This is particu-
larly the case in areas where high levels of
power generation from wind and photo-
voltaic systems are paired with high power
consumption in industrial grids.
The current distribution grids in rural
areas are often characterized by long
transmission lines and low cross-sections
a reliable design for the drop in voltage
resulting from the relatively low loads.
However, multiples of the load peaks can
result in medium voltage systems to which
many distributed feeders are connected.
In this combination, fluctuating load and
infeed conditions can give rise to signi-
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
In areas where high power generation from al
ternative sources is paired with high industrial
loads, it is expedient to combine intelligent
power stations with voltage regulators
makes compliance with the voltage limits
of +/-10 % in the distribution grid levels
an ever-increasing challenge. Voltage ad-
justments in the medium-voltage grid are
currently frequently made only with tap
changers in the substation transformers.
As a result, voltage changes cannot be cor-
rected; instead, the voltage change affects
the entire medium-voltage grid, thus ne-
cessitating expansion of the grid.
The more intelligent option is using regu
lators to equilibrate the various load con-
ditions with fine-tuned control, main
taining a constant output voltage.
These voltage regulators are independent-
ly installed transformers which can sub
stitute an additional substation in the MV
grid. This particular voltage regulator is, in
the primary and secondary windings are
connected both magnetically and electric
ally. The step-up autotransformer can in-
crease the input voltage from 100 V to 110
V with a series connection of the secondary
winding to the upper end of the primary
winding. This procedure is reversed in the
step-down transformer to lower the voltage
to 90 V. The integrated mechanical switch
enables both functions to be combined,
achieving a control range of 20 % (+/-10 %).
These parts are mounted in one tank and
filled with oil for cooling and insulation
purposes. One voltage regulator is con-
nected to one phase of the grid. In the me-
dium voltage substation, there are three
voltage regulators installed. The voltage
regulator serving as medium voltage sub-
station will be installed in an existing grid.
79
EVENTS
TRANSFORMER IN GRID

An economically opti
m a l g r i d s o lu t i o n
should also account
for the existing voltage
control equipment

Figure 4 presents a comparison between
the voltage levels over a period of 24 hours
in a summer time with and without using
a medium voltage regulator. The graphs
clearly indicate that the range of the volt
age deviation will be minimized due to the
direct voltage adjustment in the medium
voltage grid.
only be switched when the transformer
is de-energized, and of course the pri-
mary substation with its medium power
transformer with the on-load tap chan-
ger, which can contribute significantly to
improving the voltage based on its large
control range. This makes it clear that not
only should independent voltage control
equipment be planned in the grid, but
also that the existing and future control
equipment requirements must be coord
inated.

4. Which solution for which

grid situation?
As both controllable distribution trans
formers and voltage regulators essentially
address the same grid planning issue, the
optimum solution for the grid operator
must be determined using a planning
process. The necessary workflow is
described in the next section.

The first step in the planning horizon is

to determine the critical points in the
grid where voltage issues can be antici
pated. This can be achieved with long-
term measurements for the current situ-
ation. However, future scenarios require
the performance of corresponding grid
calculations based on the load and utility
forecast.

An economically optimal solution should

also account for the existing voltage con-
trol equipment. This includes the cur-
rently existing distribution transformers Figure 4. Comparison of voltages for a 24-hour load cycle in summer, with and without
with their off-load tap changers that can the in-phase regulator

80 TRANSFORMERS MAGAZINE | Volume 3, Issue 3


Figure 5. Overview of the optimization environment
Not only should independent voltage control
equipment be planned in the grid, but also
the existing and future control equipment
requirements must be coordinated
The planning workflow consists of the fol-
lowing individual steps [3]:
- Load/generation forecast with determi-
nation of the resulting extreme operat
ing cases
- Determination of the requisite voltage
regulating elements
- Determination of installation locations
- Coordination of control settings with
existing grid elements
- Equipment configuration
The grid nodes to be monitored need not
generally be at the end of the supply line.
It is therefore especially important to de-
termine the required measuring points -
of course these can be determined in the
context of field testing for an existing grid.
Despite this, analytical support would be
helpful in simplifying field testing or even
rendering it superfluous.
Therefore, a corresponding procedure
has been developed to determine the
minimum required set of measured data
based on optimization calculations. The
grid calculation program PSS SINCAL
[3] is first used to generate a grid model
using all necessary information on the
grid topology as well as the load and gen
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
erating units. The starting point for the
optimization is then the case in which all
grid nodes are explicitly monitored with
voltage measurement. Next, the mixed-
integer optimization is used to determine
the subset of grid nodes to be explicitly
monitored, which is absolutely necessary
for complete observability regarding per-
missible voltage limits. The voltage condi-
tions are then implicitly observable for all
other grid nodes where the voltage meas
urement can be eliminated. A grid node is
implicitly observable if there is no load or
generation condition in which a voltage
range is violated at any node under consi-
deration of the explicit measuring points.
The results are calculated in a graphical
optimization environment with the net-
work editor, parameter configuration unit,
Author
Saskia Baumann holds a B.A. in mechanical engineering and
an MBA. She joined Siemens in 2011 and has been working
in various positions within the distribution transformers
segment of Siemens Transformers. Currently she is the
responsible product manager for regulated distribution
transformer products.
visualization of voltage bands and variant
analysis components (Figure 5). The cen-
tral area presents the voltage profile of the
network across all network nodes and dem
onstrates that the voltages are within the
permitted range in both extreme cases after
optimization (green colour). The black
lines indicate the resulting voltages at the
neutral positions of the regulating equip-
ment as the starting point of optimization.
Conclusion
Although the shift in energy policy (en
ergy turnaround) poses a significant
challenge for grid operators, solutions are
available. The use of intelligent technol
ogy enables the elimination of expensive
and comprehensive grid expansion. This
can be applied both to the low voltage grid
where regulated distribution transformers
can be used for the infeed of energy from
distributed producers, and in the medium
voltage grid where voltage regulators can
compensate for the fluctuating infeed and
load. However, the grid situation must first
be analyzed. The use of voltage regulators
and controllable distribution transformers
must be carefully configured if the most
cost-effective possible implementation of
new resources is to be achieved. The pre-
sented controllers and the corresponding
innovative planning solutions provide an
important contribution and support to
the grid operators when confronting the
technical and economic challenges posed
by the energy turnaround.
Bibliography
[1] DIN EN 50160, Merkmale der Span-
nung in ffentlichen Energieversorgungs-
netzen
[2] Eco directive 2009/125/EG
[3] Ohl, Betz, Wagner, Blug, Mladenovic,
Optimierte Koordination von Span-
nungsregeleinrichtungen. EW 12/2015
[4] Website PSSSINCAL:
http://www.siemens.de/pss-sincal
81
TRANSFORMER IN GRID
EVENTS

ABSTRACT
This article examines issues related
to power quality and generation of
higher harmonics in single-phase
transformers of low power supply,
supplying electricity to household,

Transformers
office and industrial equipment.
Generation of higher harmonics of
these transformers was simulated
on basis of the results of the Finite

and power
Element Method (FEM) analysis of the
magnetic field. Harmonic composition
of the current in the primary side was
determined using a Fourier transform
applied to the curve of the current

quality Part I
obtained through the FEM analysis.
The results were fully confirmed
by the experimental study of the
harmonic composition of the current
in the primary side of the investigated

Modelling and researching ge-

one-phase transformer.

The used approach is unique, and it

enables manufacturers to explore the
harmonic composition during the de- neration of higher harmonics in
sign stage, and take appropriate mea-
sures to reduce their magnitude. small single-phase transformers
KEYWORDS used by domestic and industrial
consumers
FEM, small transformers, harmonics,
power quality, electrical power systems

82 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 Petar Milkov UZUNOV

Due to the large number of small transformers,

they pollute the electrical network and are a fac-
tor in lowering the quality of electrical power

1. Introduction
Electricity is one of the most widely used
forms of energy in our time, which can be
attributed to the easy reception, transmis-
sion and conversion of this type of energy
to consumers. In terms of electricity con-
sumption, this is a type of product which
is characterized by a number of indicators
that determine its quality. Users requiring
high quality of supplied electricity will pay
the right price for it.
In the transmission of electricity from the
source to the consumer, there are various
undesirable factors that can be observed:
lightning strikes, frequency interference,
high harmonics and shock loads. These
fluctuations in power consumption and
switching to different loads affect others in
the network, thus reducing its basic para-
meters and quality, and adversely affecting
the end users, i.e. consumers.
There is a lot of scientific research and
literature discussing the effects of poor
power supply quality on consumers [1-3].
Consumers themselves can also aggravate
the quality of electricity [3]. However, the
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
issue of which consumers exactly affect
these quality indicators and how this works
(i.e. the very mechanism of the process)
has been less studied and requires more
theoretical and experimental research.
Transformers are static electromagnetic
devices which occupy an important place
in the process of transmission and con
sumption of electricity. When an AC
power source is connected to a transform
er, current flows in its primary circuit, even
when secondary circuit is open-circuited.
This current is the current required to
produce flux in the real ferromagnetic
core, and it consists of two components:
- the magnetization current, which is the
current required to produce the flux in
the transformer core, and
- the core-loss current, which is the cur-
rent required to make up for hysteresis
and eddy current losses in the core.
From the graphical representation of the
magnetization current in the classical
theory of electrical machines [4], one can
see that the magnetization current in the
transformer is not sinusoidal. The higher-
frequency components in the magneti-
zation current are due to magnetic satur
ation in the transformer core, and they
can be quite large compared to the funda-
mental component.
It should be noted here that contempor
ary designers design transformers so that
they operate with a magnetic flux density
close to saturation point for the maximum
use of the ferromagnetic core material. In
general, the more the transformer core is
saturated, the larger the harmonic compo-
nents will become.
Even a transformer supplied with sinusoidal
voltage has non-sinusoidal no-load current,
i.e. it generates high harmonics which pene-
trate into the grid and reduce the quality of
electricity
Consequently, even when supplied with
sinusoidal voltage, their no-load current
will have a pure non-sinusoidal shape,
i.e. transformers will generate high har-
monics which penetrate into the grid and
reduce the quality of electricity.
The objective of this article is to study
the mechanisms of generating higher
harmonics and the influence of small
single-phase transformers used in house
hold, office and industrial equipment,
which are the external loads, on the quality
of the power system. Specific studies were
conducted on a single-phase transformer,
shown in Figure 1a. Its technical data
is outlined in Table 1 and its electrical
scheme presented in Figure 1b.
Usually, electrical machine textbooks
graphically present and explain a
distortion of the shape of the current in the
primary side [4], while other references
[5, 6] describe various analytical models
of the generation of higher harmonics in
transformers.
The finite element method (FEM) offers
the most accurate way to determine
mechanisms of generating higher har
monics in transformers based on
modelling and analysis of their magnetic
field. FEM enables the analysis of the
magnetic fields recording the non-
linearity in the used magnetic materials,
which is difficult to obtain by the relevant
analytical models that are based on the
theory of electric and magnetic circuits.
The study of the generation of harmonics
makes it possible to take appropriate actions
to measure, control and improve the perform
ance of transformers in order to prevent
83
 TRANSFORMER IN GRID

them from polluting electricity supply and a) b)

impairing its quality. Also, it enables propo-
sition and implementation of relevant tech-
nical solutions to neutralize this harmful
effect and improve power quality.

2. Modelling of the electro-

magnetic field of the trans-
former based on Maxwells
equations in differential form
2.1. Equations of the magnetic field

The quasi-stationary magnetic field of

the transformer was modelled based on
the system of differential equations of
the electromagnetic field, recorded on Figure 1. Investigated transformer: a) main view; b) electrical scheme of the transformer

the magnetic vector potential A and the
potential of the electric field V.
A
From the equations (4) and (5) one can E = V
The first Maxwell equation reads as follows: + A, (9)
derive the following: t
H = J . (1)
B rot A where A represents moving of
Here, on the right hand side the compo- H = =
. (6) the field.
D
nent t is ignored due to the electric flux
density, and
only the conductivity current From the second Maxwells equation, Applying (9), (2) and (8) to (1), the fol-
density J is=taken
E into consideration: lowing result is obtained:
B
rot E = , (7)
J = E. (2) t
A

A
( ) + A = V . (10)
The equation for the continuity magnetic and the equation (6), the following is derived: t
field principle is:
B
E = + ( B) . (8) The magnetic vector potential A is cal
B = 0, (3) t culated by the
use of (10). Then, using (5),
From (8) follows (6) and (9), B and H are obtained.
where B is the magnetic flux density.
Equations (1) to (3), together with the
relationship between the magnetic field Table 1. Technical data of the investigated transformer
intensity and the magnetic flux density, Quantity Value
which corresponds to
Rated power [VA] 130

B = H, (4) Primary voltage [V] 220

allow usto define the magnetic vector po- Rated frequency [Hz] 50
tential A as Secondary no-load voltage 5 % [V]
U21 / U22 / U23 / U24 50 / 18 / 18 / 10
B = rot A . (5)
Rated secondary current [A]
I21 / I22 / I23 / I24 0.5 / 0.5 / 0.5 / 4.5

The study of the genera- Number of turns of the primary winding 760

tion of harmonics makes Number of turns of the secondary windings

w21 / w22 / w23 / w24 172 / 62 / 62 / 35
it possible to improve Diameter of the wire [mm]
the performance of primary winding 0.6
transformers and pre- secondary winding 0.6 / 0.6 / 0.6 / 1.4

vent pollution of elec- Material of the transformer core M530

tricity supply Class of insulation F

84 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 a) b) The non-linear model-
1
ling of the material core
6 was performed using
5 the basic curve of mag-
4 netization
3

2
Figure 2. FEM model: a) region in which equations of the magnetic field are solved: 1 - magnetic
core of the transformer; 2 - primary coil; 3,4,5,6 - secondary coils; b) discretized area
Part V in (9) is taken from the definition
of the source of electromotive force (e.m.f.).
2.2 Numerical modelling of the
single-phase transformer
The analysis of the transformers magnetic
field was conducted in two dimensions in
the region shown in Fig. 2a, divided into a
network of 4,014 nodes and 7,960 triangu-
lar finite elements of the first order (Fig. 2b).
The non-linear modelling of the material
core was performed using the basic curve
of magnetization shown in Fig. 3a.
The transformer was modelled by a combi-
nation of the circuit theory and the FEM,
which is the best way to simulate the op
eration of an electromagnetic device and to
test the electromagnetic processes therein.
The primary winding of the transformer
was powered by a voltage source V1 (Fig.
a)
3b). Therefore, the source supplying the
primary winding with a sinusoidal volta-
ge had a set voltage amplitude, frequency
and initial phase to model the network,
supplying transformer with a sinusoidal
voltage.
Series resistor R1 was connected to the
circuit of the primary winding. Its value
can be calculated from no-load losses, as
shown in the following equation:
U12
R1 = , (11)
PPhyst
hyst + P eddy
eddy
where
Physt is hysteresis losses in the transformer
core,
Peddy is eddy current losses in the trans
former core,
U1 is the effective value (RMS) of the pri-
mary voltage.
b)
The distribution of the magnetic field
(Figure 4a) was obtained after solving the
equation (10) for the time t = 0 to 120 ms
with the increment of 1 ms these were
the six periods of the supply voltage. This
number of periods was assigned in order
to attenuate the transient process from the
inclusion of the transformer and obtain
the actual shape of the established mag-
netizing current of the transformer. Har
monic analysis of this current waveform
was performed. Otherwise, if there is a
non-steady state process, this will cause
incorrect results of the Fast Fourier Trans-
form (FFT) analysis.
To prove that the distortion of the current
shape is due to the non-linearity of the
magnetic characteristics of the ferromag-
netic core material and its saturation, an
other analysis of the transformer magnetic
field was performed, substituting the fer-
romagnetic core material with a material
with a linear relation between the mag-
netic flux density and the magnetic field
intensity, that is, a material with constant
relative magnetic permeability 1000.
As a result, sinusoidal shape of the current
through the primary winding in no-load
mode was obtained i.e. the magnetizing
current had sinusoidal shape in this parti-
cular case (Fig. 5).
3. Experimental study of
the harmonic composition
of the transformer
magnetizing current

In order to verify the results of the har-

monic analysis of the current obtained by
FEM data post processing, an experiment
was performed in which the waveform of
the magnetizing current of the modelled
transformer in no-load mode was meas
ured using a digital oscilloscope. The pic-
ture of the experimental set-up is shown
in Fig. 6.
Figure 3. Modelling of the transformer: a) basic curve of magnetization of the magnetic steel
M530; b) circuit and parameters of the power supply, source of e.m.f.

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 85
 TRANSFORMER IN GRID

a) b)

Figure 4. Results from the analysis of the transformer magnetic field: a) distribution of magnetic flux density for the time t = 2 ms; b) the current
through the primary winding of the transformer

The tested single-phase transformer was current contains pronounced third and To prove that the dis-
powered by a laboratory autotransformer fifth harmonics, with RMS values I3 and I5
supplied with single-phase voltage of 220 respectively. tortion of the current
V RMS with a pure sinusoidal shape. Its shape was due to non-
secondary windings were not connected
to any load. The current waveform of the 4. Fouriers analysis of the linearity of the core,
transformer was taken from the voltage transformer current another analysis was
drop on the series resistor R.
Fig. 7 shows the distortion of the shape performed substituting
The current waveform displayed on the of the no-load current of transformer, the ferromagnetic with
digital oscilloscope is shown in Fig. 7. which is caused by higher harmonics
generated due to non-linearity of the linear core material
From Fig. 7 it is clearly visible that the cur-
rent contains high harmonics generated
only by non-linearity in the magnetic char
acteristics of the steel core and its satu
ration. The RMS value of the current was
measured with the multimeter, which is
a true RMS device which measured the
real RMS value of the current, although it
is non-sinusoidal. The measurement re-
sults are displayed in Table 2.

The digital oscilloscope has a built-in fea-

ture to help realize FFT. RMS values of
harmonics are also provided in Table 2. In
Fig. 8 the harmonic spectrum of the trans-
former current is shown. It was found
that, in practice, apart from the funda-
mental harmonic with RMS value I1, the
Figure 5. Waveform of the transformer magnetizing current when the core is made from
magnetic material with linear properties

Table 2. Results of the experimental study of the current harmonic composition

Magnitude Harmonic amplitudes RMS value
I 0 I 1 I 3 I 5 I
Unit mA mA mA mA mA
Experience 18 64 18 6 70

86 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 To verify the results of
2 the current harmonics
5 obtained by FEM data
4
post processing, the
magnetizing current of
the transformer was
measured using a digi-
1 tal oscilloscope with a
built-in FFT
3

I1m
2
I2
Figure 6. Experimental set-up: 1 investigated transformer; 2 laboratory autotrans I = I 02 + ++ km , (12)
former; 3 resistance; 4 digital oscilloscope; 5 multimeter 2 2

where Ikm is the amplitude of the higher

harmonics with number k = 2, n .

Using this equation and the results from

the harmonic analysis, the RMS value of
the current can be calculated. Table 3 pre-
sents a comparison of this RMS value, to-
gether with amplitudes of the harmonics,
with the amplitudes of the experimentally
measured higher harmonics. It was found
that they differ little within the margin of
the FEM calculation error, which indi-
cates the correctness of the constructed
Figure 7. Waveform of the transformer current
FEM model of the transformer, especially
the approach to modelling and the calcu-
magnetic characteristics of the steel the transformer current. lation of the harmonics generated by the
core, and saturation effects. transformer due to strong non-linearity in
It is obvious from the figure that the the magnetic properties of the core steel.
In order to obtain a harmonic com current of the transformer presents two
position of the current through the more pronounced higher harmonics
primary winding, FFT was used. A the third and fifth, which are caused by
mathematical programme provided non-linearity in the magnetic characte- The 3rd and 5th current
harmonic analysis of the current
waveform, as illustrated in Fig. 9. As a
ristics of the transformer core steel and
which distort the shape of the current
harmonics, which are
result, the harmonic spectrum of the waveform. caused by non-linearity
current was obtained, shown in Fig. 9.
From the theory of electrical engineer
in the magnetic charac
Fig. 9 shows a screen of a specially ing it is known that the RMS value teristics of the trans
developed application displaying the
shape of the curve of the current, and
of a non-sinusoidal magnitude, as
transformer current, can be calculated
former core steel, are
the results of the harmonic analysis of by the following equation: more pronounced
Table 3. Comparison of the results of the harmonic analysis of the transformer current with FEM and experience
Magnitude Harmonic amplitudes RMS value
I 0 I 1 I 3 I 5 I
Unit mA mA mA mA mA
Experience 18 64 18 6 70
FEM 8 6.43 19 11 68

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 87
TRANSFORMER IN GRID

Conclusion To remove this harmful effect and improve power

This article investigates the generation quality it is recommended to connect to the net-
of higher harmonics in small single- work passive and active filters designed to filter
phase transformers supplying power to
household, office and industrial equip- out the 3rd, 5th and 7th harmonics
ment. The results of the finite element ana-
lysis of the magnetic field have been used to
obtain the waveform of the current in the
primary side of the transformer operating
at no load. Its shape is different from sinu-
soidal wave, i.e. the current contains higher
harmonics, which occur due to non-linear
ity in the magnetic characteristics of the
magnetic materials used in transformers,
and due to saturation effect. To obtain
magnitudes of these harmonics, harmonic
analysis was performed by the FFT.

The results of the simulations with FEM

were fully confirmed by measurements
Figure 8. Harmonic analysis of the transformer current obtained by a digital oscilloscope
of the harmonic composition of the ma-
gnetizing current of the transformer with
a digital oscilloscope. Despite their low
power, the fact that there is a large number
of such transformers in the electrical grid
means that this is a serious pollutant and
is therefore a factor in the reduction of the
quality of electricity.

To remove this harmful effect and im

prove power quality, it is recommended
to connect passive and active filters to the
network, which are designed to filter out
the 3rd, 5th and 7th harmonics.

Bibliography
[1] C. Tsanev, C. Tsvetkova, Power quality,
Avangard Prima, Sofia, 2011(in Bulgarian).
[2] J. Arrillaga, D. A. Bradley, P. S. Bodger,
Power system harmonics, John Willey & Sons,
2010.
[3] J. Schlabbach, D. Blume, T. Stephanblome,
Voltage Quality in Electrical Power Systems,
IET Power and energy series 36, United
Kingdom, 2000.
[4] Stephen J., Chapman, Electric machinery
fundamentals, Mc Graw Hill, 5th edition, 2010.
[5] Krishna Vasudevan, Sridhara Rao,
Sasidhara Rao, Electrical Machines I, Indian
Institute of Technology, Madras, http://www.
nptel.ac.in/courses/IIT-MADRAS/Electrical_
Machines_I.
[6] Ismail Daut, Syafruddin Hasan, Soib Taib,
Magnetizing Current, Harmonic Content and
Power Factor as the Indicators of Transform
er Core Saturation, Journal of Clean Energy
Technologies, Vol. 1, No. 4, October 2013
Figure 9. Waveform of the transformer magnetizing current and the results of its harmo-
nic analysis (basic harmonic frequency 50 Hz)
Author
Petar Uzunov, Electricity System Operator, received his BSc
and MSc degrees in electrical engineering from the University
of Gabrovo, Bulgaria in 1988, and his PhD from the same
university in 1998. From 1988 to 2007 he was an Assistant
Professor, Chief Assistant Professor and Associate Professor
at the Basic Principles of Electrical Engineering and Power
Energetics Department at the Technical University of Gabrovo.
From 2008 to 2012 he headed the department. From 2012 to 2015 he worked at
Mechatronica SC, Gabrovo, Bulgaria as the Head of the R&D Department. He is
the author of 10 textbooks, more than 60 articles, and two inventions. His research
interests include optimal design of electrical machinery, simulations and research of
electromagnetic processes in electrical machines and apparatus based on the analysis
of electromagnetic field through Finite Element Method and hysteresis modelling.

88 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 Coiltech 2016
28-29 September Pordenone

What is Coiltech?

The exhibition
Launched in 2010, Coiltech is now the
fastest growing international exhibition
in the Coil & Winding industry specifically

that sets a new

designed to do business in a professional
yet friendly environment.

What the producers in the

standard in the
Transformers Industry will
find at the show
GO and NGO electrical steel

Transformers
Insulation materials, oils and resins
Magnet wire

marcogarofalo.net
Coil winding machines
Test equipment

industry
Accessories for Transformers

Meet over 300 International Companies

in the Coil & Winding Industry
Coiltech is a nice
exhibition, well organized
and where we got the chance
to meet suppliers that Find machinery Meet and greet old
and components for the and new suppliers in
we already knew and also development of your the Transformers
discover new ones. [] we products. Industry.
found at Coiltech what we
needed for our business.
Frank Breunig
Siemens Energy Sector Power
Transmission Div. - Germany
Be part of the World Magnetic Conference (WMC),
a strategic opportunity for the technicians of the
WMC Transformers industry. These are just a few examples
of the topics discussed at the Conference:
Current developments in air- New technological solutions for
core impulse transformer usage. resin encapsulated transformers.
Discover more topics on our website

Discover more about the WMC and Redeem your free

ticket for Coiltech 2016 online at: www.visitcoiltech.com

Venue - Coiltech Viale Treviso,1 - 33170 Pordenone - Italy

TECHNOLOGY
EVENTS

ABSTRACT
Superconducting transformers using
high current density High Tempe-
rature Superconductor (HTS) wire
cooled with liquid nitrogen can be
lighter and more efficient than con-
ventional powe r transformers. This
paper describes the 1MVA 11/0.415 kV
HTS transformer developed by a New
Zealand - Australian team, featuring
HTS Roebel cable in the 1.4 kA-rated
low voltage winding. Comparison of
HTS and conventional transformer
designs at 40 MVA rating shows low
er lifetime cost of losses makes HTS
base-load transformers cost-com-
petitive in higher energy cost mar-
kets. Power density - more MVA in a
restricted footprint - could be a deci
sive advantage in mobile applications.

KEYWORDS
superconductor, Roebel cable, cryo-
genic

90 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

 Mike STAINES, Mohinder PANNU, Neil GLASSON, Nathan ALLPRESS

Superconducting
transformers Part II
Liquid nitrogen, super-high current
density the future of the grid?
3.2 Testing Compared to conventional oil-immersed
The load loss of the transformer windings transformers, HTS transformers can be smal-
was measured for convenience in an air
core configuration with shorted output, as
ler, lighter, more efficient, and have overload
shown in Fig. 4. The extremely low elec- capability without reduction in lifetime
trical loss necessitates a custom measure-
ment setup with high phase accuracy, sub-
tracting the loss in the short and current
leads from the input power. The results are the superconductor, while the black line surement is that we can now confidently
striking (log-log plot, Fig. 5): the load loss includes the contribution of eddy current predict the load loss in larger transform
increases with current close to a power of loss in the copper terminals of the low ers, where the benefits of HTS relative
3.5 rather than the familiar quadratic de- voltage winding. The great significance to copper begin to outweigh the higher
pendence of resistive loss. The load loss of this agreement of modelling and mea- purchase price.
is hysteretic, proportional to frequency
rather than independent of frequency like
normal resistive loss. At 50 Hz the electric
al loss per phase at rated current is 120W,
only 0.036%. Because of the steep power
law dependence, the loss drops by about
a factor of 10 when the current is halved.
Assuming a cryocooler with cooling pen
alty of 13.5 W/W (watts input power per
watt cooling power), the electrical loss
translates to a load loss of 0.4 %, about half
the 10 kW load loss typical of a 1 MVA
transformer. Note that this comparison
indicates the potential energy savings on
load losses using the most efficient cryo-
coolers currently available. In practice our
system used stored liquid nitrogen and a
less efficient crycooler.

Prediction of load loss is a non-trivial

computation compared to the loss in
copper conductors, but calculations [6]
by our collaborator Enric Pardo accurately
reproduce our measurements. The blue
line in Fig. 5 shows the predicted loss in Figure 4. Setup for load loss measurement, windings in cryostat without core fitted

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 91
 EVENTS
TECHNOLOGY

The extremely low electrical loss necessi will then narrow and may reverse because
of the lower core losses of the lighter core
tates a custom measurement setup with high possible with HTS.
phase accuracy, subtracting the loss in the Short circuit fault current performance of
short and current leads from the input power the transformer was not tested, but model-
ling [7] tells us it would be a highly effective
fault current limiter, with the impedance
jumping rapidly from the normal reactive
impedance of 5 % to about 13 % at the onset
of a fault. It will then increase sharply as the
resistivity of the copper shunt layer increases
roughly seven-fold from 77 K to room
temperature, with fault impedance ulti-
mately approaching 100 %. However the
fault current hold time is limited with the
standard 0.1 mm thick REBCO conductor
by the time taken to heat to room tempera-
ture only about 0.15 sec. The recovery time,
isolated from the load, would be some tens
of seconds. If the fault is not isolated within
0.15 s the HTS wire would suffer irrevers
ible thermal damage.
We estimate the mean tensile stress in the
Figure 5. Load loss measurements and modelling for one phase of the 1 MVA HTS trans- HV winding at peak fault current to be 100
former as a function of current in the low voltage winding MPa, well below the maximum recom-

The results of factory electrical testing are

shown in Table 2. In testing, the transform
er performed as designed over a period of
months cooled to liquid nitrogen temper
ature, several weeks of this time drawing
current continuously. During insulation
testing, a flashover occurred at over 20
kV on HV bushings on two of the cryo
stats. The problem was traced to the filled
epoxy used in adapting the bushings for
cryogenic use. Commercial resin bushings
have been tested in cryostats up to 650 kV
Basic Impulse Insulation Level (BIL), so
this is not a fundamental problem.
The contribution of cryostat losses to the
no-load loss was not measured directly but,
Prediction of load loss
using a 13.5 W/W cooling penalty as above, in HTS is much more
we estimate it to be about 0.65 % of rated complex than in cop-
load, 3/4 of it due to the current leads. As
expected, this means the no-load losses of per conductors, but our
this HTS transformer are significantly high modelling is in a very
er than the conventional equivalent at 1
MVA rating. In transformers with higher
good agreement with
ratings, with LV volts of 11 kV or higher, measurement, enabling
the contribution of the cryostat and current us to confidently pre-
lead losses will become progressively less
significant. The disparity in the no-load los- dict the load loss in
ses of HTS and conventional transformers larger transformers

Table 2. Results of factory electrical testing

Item Design value Tested value

Transformer ratio 45.9 45.91

Connection Dyn11 Dyn11
No-load current 0.25 % Not tested
No-load loss (core losses only) 1.2 kW Not tested
Short circuit impedance 5 % min 5.95 %
Electrical load loss at rated current 0.034 % 0.036 %
Withstand voltage test 28 kV/60 sec/50 Hz Partial success
Lightning impulse test 75 kV/1.5/50 sec Partial success

Partial success = in testing of individual phases phase A complied with all tests. B & C failed at epoxy insulated extensions.

92 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

mended stress for the wire of 700 MPa. The
LV winding is not designed to be self-sup-
It is unlikely that HTS transformers with rat
porting under fault current stresses, and is ings of a few MVA or less will ever be com-
supported by a 10 mm thick GRE former,
with the cable restrained within a 2 mm
mercially competitive with conventional
deep helical recess machined in the former. transformers
4. Economics
It is unlikely that HTS transformers with
ratings of a few MVA or less will ever be
commercially competitive with conven
tional transformers. But how do the rela-
tive costs stack up at higher ratings? In a
recent study, making use of the validated
loss modelling method [5], we estimated
the Total Cost of Ownership (TCO) of
a 40 MVA 110/11 kV HTS transformer
design compared to a conventional trans-
former [8]. The purchase price of the HTS
transformer is estimated to be around
65% higher than the conventional design.
Major components of the cost are the su-
perconducting wire and the cryosystem,
each roughly a third of the total. A number Figure 6. Comparison of the total cost of ownership of HTS and optimised copper 40 MVA
of considerations influenced the choice of transformers as a function of no-load loss evaluation factor A
a 40 MVA rating: it represents a significant
step up from previous HTS transformers
into the range where commercial compet would be 0.09 %, compared with typical ers and omitted. We will need to accu
itiveness might be expected, not too large values of around 0.3 % for conventional mulate more experience with closed-cycle
for modelling validity or a design and build transformers of this rating. How much is transformer cooling systems before we can
project, and a sizeable market sector. We such low loss worth? This depends on the quantify any cost advantage to HTS from
make the assumption that 110 kV rated value ascribed to losses - the loss evalu eliminating oil maintenance costs.
high voltage windings are achievable with ation factor [10], dollars per kW of lifetime
HTS wire. Potential problems with partial losses. These numbers can vary substantially For transformers operating at 100 % load
discharge at the edges of the thin HTS tape in different markets [11] with no-load factor (solid lines), e.g. base-load gener
can be circumvented by laminating with loss evaluation factors in some European ator step-up transformers, the savings
metal stabiliser with radiused edges. Wind markets twice those in the United States, in lifetime cost of losses compared to a
ings of 138 kV insulation class have been for example. The loss evaluation factor for conventional transformer are enough to
successfully tested [9]. load loss, labelled B, is typically 30 % of make HTS competitive in markets with
the no-load loss factor A. Fig. 6 compares loss evaluation factors greater than about
40 MVA is not an upper limit for HTS TCO as function of no-load loss evaluation 7,000 US$/kW despite the higher initial
transformers. The present limit for con- factor for a 40 MVA 110/11 kV transform purchase price.
ductor critical current is around 90 A/mm er design. The copper designs have been
at 77 K, 180 A/mm at 65 K. Using wide optimised for minimum TCO as the loss In the case of transformers operating at
HTS conductor generally results in higher evaluation factors vary. Fire protection lower load factor, with the load loss evalu-
losses. Fully transposed high current wind costs estimated at 15 % of purchase price ation factor assumed to be 30 % of the no-
ings can be realised with Roebel cable, with have been included in the copper trans- load loss evaluation factor (dashed lines),
the limit perhaps around 300 MVA for a former purchase and installation costs. the HTS transformer will have higher cost
220/22 kV transformer, depending on the Apart from cryocooler maintenance costs, of ownership even at very high loss evalu-
strand count in the cable, before resorting maintenance costs have been assumed the ation factors.
to connecting strands in parallel without same for HTS and conventional transform
transposition. The majority of demonst-
ration HTS transformers have in fact used
parallel conductors with varying degrees of
transposition to achieve high current.
The loss modelling shows that at 40 MVA the
load losses (including cooling penalty) would
4.1 Reduced cost of losses be 0.09 % compared with typical values of
The loss modelling shows that at 40 MVA around 0.3 % for conventional transformers
the load losses (including cooling penalty) of this rating
w w w . t ra n sfo r m e r s - m a g a z i n e . co m 93
 EVENTS
TECHNOLOGY

The HTS design is almost 1/3 the weight ownership cost of large conventional
transformers. The value of reduced size
of a conventional transformer, which can and weight has not been included in the
be decisive in some applications, such as comparison of Fig. 6.

transformers in confined space, or mobile HTS transformers with inherent Fault

transformers
4.2 Eliminating negatives,
accentuating positives
To be competitive in a wider market the
purchase price of HTS transformers will
have to come down, and the HTS trans-
former will need to derive added value
from its other characteristics: smaller size
and weight, low fire and environmental
risk, and, perhaps, fault current limiting.
In the longer term, the purchase price of
an HTS transformer will certainly fall. For
this study we assumed an HTS conduc-
tor price of 50 US$/kAm, the price for a
length of wire for which the product of
critical current (measured at 77 K) and
length is equal to 1 kAm. This is a near
term price projection, but the long-term
price may be as low as 10 US$/kAm. At
that point HTS wire will be cheaper than
copper. Cryocoolers can also be expected
to fall in price as production volumes rise.
The comparison in Fig. 6 already includes
fire protection costs for the convention
al transformer, assumed to be 15 % of
purchase price. In some situations merely
mitigating the fire risk of oil-immersed
transformers with fire protection systems
is unacceptable. HTS transformers with
their liquid nitrogen dielectric could be
a cost-competitive alternative to SF6 gas-
insulated transformers in this niche.
The reduction in weight made possible
with HTS wire is illustrated by the com-
parison in Table 3. Two conventional
transformer designs are represented,
optimised for different loss evaluation
factors. The HTS design is not opti-
mised against loss evaluation factor but
is driven by the need to keep total los-
ses within the capacity of a single high-
capacity cryocooler to contain capital
cost. The HTS design is almost 1/3 the
weight of a conventional transformer,
less than 1/4 that of a high efficiency
transformer design optimised for higher
loss evaluation factor. In some situations
this weight reduction will be decisive.
Examples are transformers in confined
space, or mobile transformers, where the
ability to fit a transformer with a larger
rating in a given footprint may be a cru-
cial constraint. Transport costs from fac-
tory to site can be a significant fraction
of the purchase and installation costs,
as much as 30 %. The cost scales rapidly
with weight, adding significantly to the
Current Limiter (FCL) capability could
deliver much of the value of stand-
alone superconducting FCL in particular
network situations [12], for example
allowing new generation to be added
without the need for circuit breaker up-
grades. Resistive fault current limiting
capability is comparatively easy to incor-
porate in an HTS winding. The supercon-
ductor will enter a high resistance state as
its critical current is exceeded and the
fault current will then flow in the metal
stabiliser layer of the wire. If the metal
layer has sufficient resistive impedance,
it can augment the windings reactive
impedance and provide additional fault
current limiting. On the other hand, the
winding resistance must be low enough
so that the winding will cool down and
become superconducting again when
the fault is isolated. The resistance and
thermal mass of the HTS windings can
be adjusted by modifying the stabiliser
layer. However, it is challenging to com-
bine fault current limiting with a fault
withstand time much beyond 10 cycles
and to have the winding recover from a
fault current under load. The transform
er protection system plays a very impor-
tant role here. If faults can be isolated in
a fraction of a second rather than one
or two seconds, the design of conductor
and windings for low impedance cur-
rent limiting HTS transformers becomes
more achievable.

OLTCs are one significant aspect of conven On-Load Tap Changers (OLTC) are one si-
tional transformer technology requiring gnificant aspect of conventional transform
er technology requiring further develop-
further development for HTS service ment for HTS service. If OLTC can operate

Table 3. Weight comparison of HTS and conventional 40 MVA transformer designs. The conventional designs are optimised for the given loss
evaluation factors A and B

Comparison of optimised conventional and HTS transformer designs

A B Current density Peak flux density Total mass*

US$/kW US$/kW Tesla tonnes
Standard 4000 1200 3 A/mm2 1.68 72
High efficiency 8500 8500 1 A/mm2 1.53 110
HTS NA NA 60 A/mm 1.7 25

* Includes oil and radiators for conventional, liquid nitrogen and cryostat for HTS

94 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

immersed in liquid nitrogen, the heat load
of multiple leads connecting windings to
an external oil-immersed OLTC could be
avoided. In principle, tap changers with
vacuum interrupters should be adaptable
to operation in liquid nitrogen but this re-
mains to be demonstrated.
5. Conclusions
HTS transformers can be more efficient
and lighter than the oil-immersed copper
equivalent. Without mineral oil, fire and
environmental hazards are eliminated.
Resistive fault current limiting can be in-
corporated if the transformer protection
scheme allows the fault isolation time to
be short enough.
Our 1 MVA transformer project demon
strates that HTS Roebel cable can be used
in high current LV windings and that load
losses in HTS transformers can be confi-
dently predicted.
HTS transformers can be cost-competi-
tive with conventional transformers: at
larger ratings and high load factors on
the basis of reduced load losses; in mobile
transformer applications because more
power can be packed in a given weight
and space footprint.
In the longer run, as the cost of wire and
cooling falls with a maturing HTS tech-
nology and market, we can expect HTS
transformers to become serious compe-
tition to the incumbent oil-immersed
copper transformer technology in a pro-
gressively wider range of applications. For
a long time HTS technology had a champ
ion within the transformer industry in the
shape of Waukesha Electric Systems, who
had ambitious and clear-sighted goals [13].
With their withdrawal from HTS R&D
just a few years ago, there is a pressing need
for an industry-led effort to progress this
technology to commercial reality.
Bibliography
[6] Enric Pardo, Mike Staines, Zhenan Jiang and
Neil Glasson, AC loss modelling and measure
ment of superconducting transformers with
coated-conductor Roebel-cable in low-voltage
winding, Supercond. Sci. Technol., Volume 28,
114008, 2015
[7] Michael Staines et al, The development of a
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Roebel cable based 1 MVA HTS transformer, Su- [11] T. Fogelberg et al, Energy efficient transfor-
percond. Sci. Technol., Volume 25, 014002, 2012 mers and reactors - Some incentive models and
[8] Mike Staines, Enric Pardo, Liam Jolliffe, Mo- case studies to show the long term profitability of
hinder Pannu, and Neil Glasson, Prospects for such designs, CIGRE Session paper 2012, A2-204
HTS transformers in the grid: AC loss and eco- [12] Leonard Kovalsky et al, Applications of Su-
nomics, European Conference for Applied Su- perconducting Fault Current Limiters in Elec-
perconductivity, Poster paper 1A-LS-P-02.06, tric Power Transmission Systems, IEEE Trans.
2015, www.victoria.ac.nz/robinson/research/ Appl. Supercond. Vol 15, pp 2130-2133, 2005
publications/Staines_EUCAS2015.pdf
[13] E F Pleva, V Mehrotra and SW Schwenterly,
[9] Bill Schwenterly and Ed Pleva, HTS transform Conductor requirements for high-temperature
er development, Presentation for DOE peer superconducting utility power transformers,
review, 2010, www.htspeerreview.com/pdfs/ Supercond. Sci. Technol. Vol 23, 014025, 2010
presentations/day%202/applications/6_AP_
HTS_Transformer_Technology.pdf Acknowledgement
[10] Dudley L. Galloway and Dan Mulkey, Funding for the 1 MVA Transformer pro-
Chapter 2.2 Distribution Transformers, in Elec- ject was provided by the New Zealand
tric power transformer engineering, edited by Ministry of Science and Innovation under
James H. Harlow, ISBN 0-8493-1704-5, CRC HTS Accelerated Development contract
Press, 2004, Section 2.2.14.3 C08X0818.
Authors
Mike Staines is a Senior Scientist at Robinson Research Institute,
Victoria University of Wellington, with a PhD in Physics obtained in
1979. Mike has been engaged in HTS research since 1987, working
in superconducting materials synthesis, wire development, and mea
surement of electrical properties, particularly AC loss, of HTS wire
and windings. He was Science Leader for the 1 MVA HTS transform
er development. His current work focuses on extending the fault
current performance of HTS windings, reducing the cost and complexity of transformer
cooling systems, and quantifying the value proposition for HTS transformers.
Mohinder Pannu is Strategic Engineering & Projects Manager at
Wilson Transformer Co Pty Ltd, developing new product applica-
tions for the Power industry. He holds a B.Tech (Hons) in Electrical
Engineering from The Indian Institute of Technology and an MBA
from Monash Mt Eliza Business School. He has background experi-
ence in Power Transformer Design, Quality and Test. He is a mem-
ber of Cigre Australian Panels A2 and D1.
Neil Glasson is a Senior Research Engineer at Callaghan
Innovation, with a PhD in Mechanical Engineering obtained in
1993. Neil has been involved in this transformer project as the lead
Engineer since its beginning in 2009. Engineering challenges faced
in the project were dominated by the need to efficiently make things
really cold - without breaking them and keep them that way for a
long time. Neil came to this role from 10 years as Engineering Man
ager for a stainless steel fabricator, but had to quickly learn about advanced composite
fabrication for this project as many of the components had to not only be compatible
with cryogenic temperatures but also be non-conductive. Callaghan Innovation is the
government agency charged with accelerating the commercialisation of innovation with
New Zealand businesses.
Nathan Allpress is a Mechanical Engineer at Callaghan
Innovation, with a BE (Hons) obtained in 2009. Nathan joined the
HTS transformer project after working on aspects of HTS Roebel
cable manufacture and testing, making use of that experience in the
design of the low voltage winding. Other related research projects
he has worked on include the development of a small-scale nitro-
gen liquefaction plant.
95
RISK ASSESSMENT
EVENTS

Load growth coupled

with aging transformers
is a disaster waiting to
happen

96 TRANSFORMERS MAGAZINE | Volume 3, Issue 3


Advanced transformer
condition assessment
Transformer lifecycle and risk
assessment
1. Introduction
I write this article from pure experience,
having performed transformer mainte-
nance for many years at a major utility,
and then being part of an Electric Power
Research Institute (EPRI) team tasked
with developing a Predictive Maintenance
(PdM) process for transformers and sub-
station components. History and expe-
rience have proven that there is no magic
bullet for maintaining transformer health.
Doing annual or periodic inspections is
well worth the effort, but common sense
thinking leads me to believe that installing
full-time monitoring on critical tier 1 assets
is probably the best way to avoid an unex-
pected failure. But not all transformers me-
rit the same level of attention. Utilities and
refineries have many transformers with
varying complexity and purpose. I recom-
mend rating each one and assigning them
in one of the three following tiers.
Tier 1 transformers will get the highest
level treatment; some will be outfitted with
full-time Partial Discharge (PD) monitor
Determining the health of a transformer is a
process that can make the difference between
a transformers long life and an early death
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Part I
ing and Dissolved Gas Analysis (DGA).
Tier 2 and 3 transformers will rarely be
chosen for full-time monitoring. The in-
spection process for all three tiers must
be thoughtfully applied. As transformer
experts (substation teams), our job is to
maintain the highest level of operational
capability for our transformers and sub
stations. A coordinated program of online
and portable monitoring must be used to
make sure that we are doing our part. The
criticality of each transformer in your care
should be ranked and that ranking used
to provide guidance to your PdM team
on just what is the correct level of moni-
toring. The lack of a spare transformer
and the lead time to have a new one built
(typically 18 to 24 months), delivered on
site, and installed is a consideration in the
overall process.
The technology advances: Infrared Thermo
graphy, Ultrasonic Noise Analysis,
Partial Discharge Detection, Dissolved
Gas Analysis, and Vibration Analysis are
all very high tech and necessary to deter-
mine the health of our transformer fleet.
Jon L. GIESECKE
ABSTRACT
Infrared Thermography, Ultrasonic
Noise Analysis, Partial Discharge De-
tection, Dissolved Gas Analysis, Vi
bration Analysis all these techniques
are great stand-alone diagnostic
tools; however, when used properly,
combining the data obtained through
each technique, an incipient fault can
be identified long before it degrades
the insulation and creates a failure.
This paper will provide guidance in
setting up a complete Predictive Main-
tenance program to be able to provide
owners of oil-filled power transform
ers (4 kV and up), i.e. utilities, re-
fineries, military, mining, etc., with a
complete health report and condition
assessment of critical oil-filled power
transformers and ancillary substation
components. The testing described in
this paper is done on energized, fully
loaded transformers.
Authors vast experience with doing
Partial Discharge testing reveals that
nearly 80 % of all oil-filled power
transformers exhibit some PD. This
low level PD activity is not detrimental
to the health of the transformer. It is
usually a burr or sharp corner that is
producing the activity. I consider this
just nuisance PD and most times it
continues for the entire life of a trans-
former without a failure related to PD.
KEYWORDS
Partial Discharge, Transformer Con-
dition Assessment, Risk Analysis Tool
97
 EVENTS
RISK ASSESSMENT

In the past 20 years since switching from
reactive to predictive transformer main
tenance, the advancement of technology
has exploded
Each of the listed technologies is proven
very effective; however, combining the in-
formation from each technology will pro-
vide solid answers to those who ask: How
much life is left in my transformer? For
many years I have dedicated my career path
to the development and use of technology
to determine the on-line condition assess-
ment of power transformers and ancillary
support equipment. Along with determining
the remaining life is the issue of an action
plan: repair, replace or continue to trend.
In the past twenty-two years since switch
ing from reactive to predictive trans-
This article will provide knowledge about
the latest methods and guidance in setting
up a quality program. The goal is to be
able to give a complete health report and
condition assessment of critical oil-filled
power transformers while they remain
in service. Remember, the processes de
scribed in this paper are done on ener-
former maintenance, the advancement of gized, fully loaded transformers. No clear
technology has exploded. However, the ance or blocking is needed to accomplish
average utility is still doing transformer these tasks. All tests are completely non-
inspections as it did twenty-two years ago. intrusive.
Consider what information a transformer
is willing to give up: it will tell you what is
2. Analyzing data from
wrong with it if you are willing to listen.
history, coupled with field
A transformer makes noise in both the
survey information
sonic and the ultrasonic range;
A transformer gives off heat which Each transformer owner has information
must be removed during operation; and data from each transformer under
A transformer sends signals of their care. This data is stored in file cabi-
impending insulation failure while in nets and computer programs and is ready
operation. to go to work for you. Mining the data

Table 1. Risk analysis grading tool

Test year 2016 Nemx Nemx Xfmr2 Xfmr 2 Xfmr3 Xfmr3 Xfmr4 Xfmr4 Xfmr5 Xfmr5 Xfmr6 Xfmr6 Xfmr7
1164 1164
Criteria Value Factor Value Factor Value Factor Value Factor Value Factor Value Factor Value
Serial number
6536968 R270131A G859918P G859918G M153429 S1689-01 S1689

Leaks N 0 N 0 N 0 N 0 N 0 N 0 N

Control wiring condition good Y 0 Y 0 Y 0 Y 0 Y 0 Y 0 Y

Winding power factor 0.48 0 0.49 0 0.55 -5 0.45 0 0.71 -5 0.44 0 0.45

Oil power factor @ 25C 0.04 0 0.032 0 0.079 0 0.073 0 0.043 0 0.054 0 0.021

DGA condition code 3 -8 1 0 1 0 1 0 1 0 1 0 2

Full time DGA monitoring Y 0 N -5 N -5 N -5 N -5 N -5 N

Current gas generation - arcing Y -10 N 0 N 0 N 0 N 0 N 0 N

Current gas generation - thermal

N 0 N 0 N 0 N 0 N 0 N 0 N

Oil acidity 0.02 0 0.02 0 0.02 0 0.02 0 0.02 0 0.01 0 0.01

Oil IFT 38.9 0 40.3 0 33.5 0 38 0 36.5 0 40.5 0 40.7

Oil dielectric (D877) 36 0 39 0 44 0 34 0 38 0 38 0 44

Water in oil (% Saturation) 3 0 65 -10 11.3 0 64.1 -10 5.4 0 8.4 0 5.9

PD burst interval in waveform 9 0 8 0 9 0 9 0 9 0 9 0 8

Arcing/sparking in waveform N 0 N 0 N 0 N 0 N 0 N 0 N

Lightning arrester test at full voltage

N -5 Y 0 Y 0 Y 0 Y 0 Y 0 Y

Full time PD monitoring N -5 N -5 N -5 Y 0 Y 0 Y 0 Y

Manufacture date 1961 2008 1970 2012 1985 2005 2005

Age in years 55 -28.125 8 1.25 46 -22.5 4 3.75 31 -13.125 11 -0.625 11

Winding temperature (diff. from 55)

26 9 29 9 15 9 17 9 24 9 25 9 26

Highest top oil temp past year 45 0 42 0 38 0 40 0 35 0 45 0 40

Past thermal problems in DGA N 0 N 0 N 0 N 0 N 0 N 0 N

98 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

that already exists, then combining it
with current conditions allows us to pro-
vide a grade for each transformer. This
aids in determining the risk analysis and
apply the correct surveillance for each
transformer. Once the data is entered
into the Excel spreadsheet (Table 1) from
your available data source, maintaining
the spreadsheet is simple. Data gathered
while doing inspections is entered and
any changes to the DGA is also entered.
The age is changed on all transformers by
one click of the mouse. There is no limit
to the number of transformers that can
be watched simultaneously. Grades are
presented numerically as well as a letter,
and a secondary grade is also given to in-
dicate the highest possible score achiev
able when all deficiencies are corrected.
The Excel spreadsheet contains formulas
built into each cell that do the calcula-
tions on the risk of each condition and
how it affects the health and life expect
ancy of each transformer entered on the
spreadsheet.
The crucial nature, age, long lead time, and
the interconnection of the grids electrical
system demand that the best maintenance
approaches possible are applied to help en-
sure reliability
I have just inspected a critical 500 kV Examine what you are doing now!
transformer that is sitting next to a failed
transformer that is still smoldering. The A typical inspection program includes
operating transformer has partial dis the following:
charge and arcing confirmed by DGA
and by a specialized tool for doing on- Visual inspection
line partial discharge measurements. It Dissolved gas analysis
also captures arcing from the component Infrared outside control
under test. Using hind-sight, these trans- Offline electrical testing
formers should have been outfitted with
Note: Most utilities are doing this inspec-
on-line monitoring which would have tion process, which has not changed in the
seen the catastrophic fault prior to the past twenty years, or more.
failure. This is a very serious condition
which could result in the loss of electric An enhanced program could include
power to a major portion of a small city. these additional components:

3. Do you think that waiting time for major components, and the in-
until a disaster strikes is the terconnection of the grids electrical sys- Vibration analysis (determine core
time to react? tem demand that the best maintenance
The aging of the electrical infrastructure
worldwide is a critical problem that each
of you face. There is no way to get around
that fact. As aging transformers continue
to fail, a new level of awareness of the ma-
gnitude of the situation becomes very clear.
Load growth coupled with aging transform
ers is a disaster waiting to happen.
Many transformers fail unnecessarily.
Accurate condition assessment and pro-
per care of these valuable assets is needed
now more than ever. With the transform
er fleets average age over 40 years and the
new transformer fleet having a high
er-than-expected failure rate, a proac-
tive approach to PdM is needed. Large
power transformers are not off-the-shelf
items and must be ordered one to two
years in advance. The repair and replace
ment schedule is critical in most cases.
Certain random failures can occur any time,
but as a transformer ages, there will be
measurable warning signs that somehow
foretell the cause(s) of degradation or im-
pending failure
The crucial nature, fragility, age, long lead
lysis (portable and on-line)
and coil assembly tightness)
approaches possible are applied to help
ensure reliability.
4. Transformer life
cycle management / risk
management
Determining the condition, health and
risk assessment of a transformer is a pro-
cess that can be the difference between a
transformers long life and an early death.
Certain random failures can occur any
time and with little or no warning, but as a
transformer ages, there will be measurable
warning signs that somehow foretell the
cause(s) of degradation or impending
failure. The insurance industry states that
insulation failure is the number one cause
of transformer failure. So how do we de-
termine the insulation quality while these
transformers remain in service?
Partial discharge monitoring and ana-
Sound level measurements (precursor
to looseness)
Grading method (transformer assess-
ment and ranking tool)
Template building (tier assignment
done here)
Note: Adding these to your existing pro-
gram could greatly reduce the unexpected
failure rate.
Template building is a process where
each transformer gets its own criterion
sheet. A team of substation engineers
gathers information on each transformer
and decides what type of diagnostic data
should be collected based on the critical
ity of each transformer. Tier assignment is
done at this time. Tier one transformers
are considered critical and should get the
most attention. Tier two transformers
are important but have redundancy and
spares. Tier three transformers are least
important and could run to failure with
out major upset of the grid.
Combining data from several
techniques will provide information
Very rarely will a failure occur without
first revealing some small change that
is detectable utilizing one or more tech-

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 99
EVENTS
RISK ASSESSMENT

If the source of the fault is located in an area
where its sound reaches the tank wall, acous
tic sensors could triangulate the exact spot
of the fault
niques. Having stated this, information
provided in this paper will direct and
assist the reader starting an inspection
process or expanding your existing PdM
program.
This paper is designed to show the bene
fits of doing a complete Transformer
Condition Assessment (TCA). Com-
bining the data from various techniques
will provide insight and understanding
of often subtle, pre-failure signs. In ad-
dition, a complete TCA will provide
an as-accurate-as-possible gauge of the
health of the transformers subsystems,
including: pumps/cooling system, Load
Tap Changer (LTC), De-energized Tap
Changer (DETC) and lightning/surge
arresters.
Partial Discharge (PD) is unwanted
electrical activity. PD is similar to cor
ona and occurs at high voltage sine wave
peaks. Most low-level PD activity is
load-dependent. As the load increases,
the voltage decreases. When the voltage
decreases, the PD will decrease or disap-
pear completely, and then return when
the voltage returns to full value.
My experience with doing PD testing
reveals that nearly 80 % of all oil-filled
power transformers exhibit some PD.
This low level PD activity is not detri-
mental to the health of the transformer.
It is usually a burr or sharp corner that
is producing the activity. I consider this
just nuisance PD and most times it con-
tinues for the entire life of a transformer
without a failure related to PD. How
ever, when true insulation breakdown
occurs, both indicated and worsened
by the PD, and reaches a point that it
threatens the life of a transformer, a
decision must be made to remove the
transformer from service.
action. In a quest to determine unwanted
activity, data can be gathered at a mo-
ment in time, like taking a snapshot, or
continuously over 24 hours or more, like
making a movie. Movies generally tell a
more complete story.
By adding the enhancing technologies to
your TCA process, major failures will be
averted. Major money will be saved, and
a major safety feature will be built into
every visit to the high-voltage transform
er yard.
Detecting acoustic and electrical
problems on energized equipment
The following PD test described is used
to determine the severity of an electrical
fault using the burst interval of the PD
pattern captured by the High Frequency
Current Transducer (HFCT). Then, if
the source of the fault is located in an
Asset managers need to know what to do and
when to do it to be able to extend transform
er life or avoid impending failure
area where its sound reaches the tank
wall, acoustic sensors could triangulate
the exact spot of the fault. Fault sound
reaches the tank wall about 90 percent
of time. The remaining 10 percent of
faults are too deep within the core and
coil assembly, and the sound cannot be
detected externally. In these cases, at
least the severity of the fault and the fact
that the transformer will require some
work deep within the windings is deter-
mined.
Acoustic tests have been used for many
years to detect and locate partial dis
charges in power transformers, but the
addition of the HFCT installed on the
case ground of the subject transformer
makes the process complete. It is more
difficult to determine if a problem in
an oil-filled transformer is related to
mechanical or electrical malfunction
utilizing acoustic sensors alone. Partial
discharge testing using both acoustic
sensors and an HFCT makes the deter-
mination easy and increases the pro-
tection factor for these utility industry
assets.
Figure 1 shows acoustic and electrical
PD activity obtained simultaneously. The

Because PD is present in so many trans-

formers, knowing the present condition
of each transformer under your care is
critical. Without systematic TCA, there is
insufficient information available to con- Figure 1. Data showing classic partial discharge: the top screen shows Acoustic Emis
fidently decide when to take appropriate sion (AE); the bottom screen shows Electromagnetic Interference (EMI)

100 TRANSFORMERS MAGAZINE | Volume 3, Issue 3


Figure 2. The wave data indicating PD with a burst interval of 2.3 ms
Figure 3. Pulse Phase Graph showing no PD activity
Figure 4. Pulse Phase Graph showing small PD activity
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
top portion of the screen shows recorded
acoustic sensor data, and the bottom
shows data from the HFCT. In the ex-
ample presented by this figure, the spac
ing of both the Acoustic Emission (AE)
and HFCT sensors is 16 milliseconds,
which is one full sinewave. The test
equipment used for this data collection is
the TP500A from PowerPD. The TP500
software has built-in bandpass filters
which enable the user to filter out noise
and pinpoint the PD, arcing or sparking.
Source location of the fault is done using
the acoustic sensors.
Severity criteria
Asset managers need to know what to
do and when to do it to be able to extend
transformer life or avoid impending fail
ure. The ability to trend the deterioration
process aids the asset manager in de
ciding when to take action.
Figure 2 shows acoustic and PD data
measured for amplitude and duration.
This is easily trended by comparing
subsequent test results under similar
conditions. The top window in this fig
ure shows the AE bursts with sensor #2
(red) being closest to the source. The
bottom window shows the PD burst
captured from the case ground lead
using the HFCT.
The signature captured by the HFCT, in
the bottom portion, indicates a severe
case of PD. The spacing between the end
of one burst and the beginning of the
next burst, called burst interval, is get-
ting dangerously close to 2 milliseconds,
clearly indicating a failure is imminent.
Burst interval is critical information in
determining the severity of PD.
Going deeper into the burst interval
(60 Hz/milliseconds)
A review of test results for acceptance is
performed using the following criteria
based on burst interval:
8-7 milliseconds: satisfactory (many
times 7 to 8 millisecond burst is found
and is a non-damaging PD)
6-5 milliseconds: engineering review
and evaluation needed
5-4 milliseconds: consider removal
from service in near future
3-2 milliseconds: unsatisfactory, make
plans to remove and repair now;
101
EVENTS
RISK ASSESSMENT

There are times when

the DGA is indicating
PD, but it is not possible
to get any PD to be ac-
tive until 110 % voltage
is reached. Once the PD
begins, it will drop off
when we back down to
the rated voltage

experience shows that 2 milliseconds

is the critical point for catastrophic Figure 5. Pulse Phase Graph showing increasing PD activity requiring caution
failure
<2 milliseconds: removal from ser-
vice, danger of catastrophic failure

Testing at repair facilities allows you to

select the voltage you wish to use, any-
where from 50 % to 150 %. There are
times when the DGA is indicating PD
but it is not possible to get any PD to
be active until 110 % voltage is reached.
Then the PD will begin, but it will drop
off when we back down to 100 %. When
the PD begins to deteriorate the insula-
tion, the activity will increase at a lower
voltage. If there is a small insignificant
nuisance PD, it will have a burst interval
of about 8 milliseconds. As the insula
tion deteriorates the PD begins at a lower
voltage and stops at a lower voltage.
PD is a voltage related event. The Pulse
Figure 6. Pulse Phase Graph showing dangerous PD activity
Phase Graphs, shown in Figures 3 to 6,
indicate varying severity of PD based
on burst interval and not amplitude. As
the PD occurs closer to the zero voltage Author
crossing, the risk of failure increases. My Jon L. Giesecke is an expert in combining technologies
experience has been that 2 milliseconds used in in-service inspection of high voltage oil-filled
is the critical cut-off point prior to a cata power transformers and substation diagnostics, with over
strophic failure. The charts in Figures 3 20 years of experience in transformer/substation predictive
to 6 are hand-drawn to show examples of maintenance and over 25 years in substation electrical
burst interval. maintenance. Prior to forming JLG Associates LLC in 2006,
he was employed by EPRI Solutions as a senior project
The wave data in Figure 2 indicates a PD manager in the Substation Predictive Maintenance business area. Mr. Giesecke
with a burst interval of 2.3 milliseconds is also an ITC level III thermographer and has instructed at the FLIR ITC
(ms). It was recommended to remove training center. He served on the board of directors of the International Society
this unit from service. of Professional Thermographers, Inc. (ISPoT), and chaired the ethics committee.
He was also responsible for PdM template development for fossil and nuclear
applications. His career in electrical maintenance spans over 30 years with
Exelon, formerly Philadelphia Electric Company. During his career with PECO,
Part II of this paper will discuss light- he held many positions, from helper to foreman, including 4 years of Doble
ning/surge arrester testing and vibration testing, 2 years in outage planning, 2 years as training coordinator for the nuclear
and sound level analysis, presenting the group, and 2 years as turbine/generator foreman.
case studies and final conclusions.

102 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

MOBIL GC

Portable Gas
Chromatograph
The MOBIL GCs unique characteristic is its ability to
function both under on-site conditions and also in
the laboratory.

The Dissolved Gas Analysis allows early recognition of

transformer defects and possible failures.

By observing the manufacturers established service

intervals and through use of the MOBIL GC unneces-
sary and substantial breakdown costs are minimized
dramatically.

State of the art technology High Sensitivity through Vacuum Degassing

portable Gas Chromatograph
Ideal for on-site measurements and also for
Laboratories
Available in different versions, with most
sensitive detection up to 11 gases
Fully automatic measurement procedure
fully compliant to ASTM D3612 and IEC 60567
Automatic sample injection
Measuring Total Gas Content
High Selectivity through Gas Chromatography
Suitable for Acceptance- Service- and Routine
tests - Direct analysis of Buchholz gases
Easy Calibration with Peakmastergas, suitable
for all Transformeroils
Expert system for quick and easy conclusions
Evaluation according to: IEC 60599, Roger
Ratios, Duval etc.
Rugged case- waterproof for extreme
environmental conditions

With this in mind, we organise our TLM Conference. To achieve a stable integrated electricity network, generation,
transmission and distribution companies must employ best practice performance methodologies to achieve
optimal resilience and a future-proof grid.

Interested in learning more and share your knowledge at Transformer Life Management Conference?

www.energy-support.de
Energy Support GmbH . Sperberweg 47 . D-41468 Neuss
T +49 (0)2131 40 39 60 7 . F +49 (0)2131 40 39 60 8 . info@energy-support.de
EVENTS
DIAGNOSIS

ABSTRACT
The dynamic resistance measurement Dynamic analysis
and testing of
was developed as a supplementary
measurement in order to analyse the
switching process of the on-load tap
changer. The article considers the im-
portance of on-load tap changers and

on-load tap changer

their main testing methods with the
focus on dynamic resistance meas
urement.

KEYWORDS Dynamic resistance

measurement
power transformer, on-load tap
changer, OLTC, dynamic resistance
measurement, DRM

104 TRANSFORMERS MAGAZINE | Volume 3, Issue 3


Introduction
Power transformers represent the most
expensive link between generation and
utilization of electric power. One very im-
portant component of a power transform
er is the on-load tap changer (OLTC). As
its name suggests, an OLTC permits tap
changing, and hence regulating voltage
without interrupting the load current.
This can be accomplished in various ways,
resulting in considerably diversified tap
changer designs. The two most common
ones are the so-called inductive and resist
ive type tap changers.
Studies, as shown in Figure 1, show that
about 30 % of reported failures of sub
station power transformers are related to the
aging effects on OLTCs. Due to this high
failure rate, it is very important to monitor
the condition of the power transformers
OLTC closely. Unlike other more static
components in a transformer, the OLTC
consists of numerous moving parts. Manu
facturers typically recommend a main
tenance cycle that mostly depends on the
total number of switching operations.
1. Types of OLTCs
To analyse and assess the dynamic resist
ance measurement (DRM) in a proper
manner, it is important to know the type
and the construction of the OLTC. There
are two common OLTC technologies in
the market. The inductive ones, which
are typically used in the North America
on the low-voltage side, and the resistive
OLTCs, which are often used in the rest of
the world on the high-voltage side.
This article focuses on resistive type tap
changers. In general, there are two dif-
ferent types of resistive tap changers: di-
verter switch and selector switch type, as
shown in Figures 2 and 3.
The diverter switch types have two parts: a
tap selector at the top to select the next tap
within the main transformer tank, and a
To analyse and assess
the DRM measurement
in a proper manner, it
is important to know
the type and the con
struction of the OLTC
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Cornelius PLATH, Markus PTTER
The dynamic resistance measurement was
developed in order to analyse the dynamic
switching process of on-load tap changers
diverter switch at the bottom to switch the
load current with its own oil volume. With
this OLTC type, the tap selector is switched
before the diverter switch, and the type is
mostly used in higher power ratings.
The selector switch type combines the
function of the diverter switch and the
tap selector, within its own oil volume,
separated from the oil of the main trans-
former tank.
2. Common methods for
OLTC testing
Power transformer OLTCs need close
monitoring of their condition due to their
high failure rate. As a basis for the ana
lysis, the following diagnostic methods
can be used:
Static winding resistance
measurement of the individual
taps (offline)
The static winding resistance measure-
ment is a very important diagnostic meas
urement tool and the most commonly
used testing method. A conventional
s
tatic resistance measurement can be
used to check the winding as well as all of
the internal connections, such as the con-
nection from the bushings and the tap
changer mobile contacts to the winding,
the contacts of the tap selector and the
main contacts of the diverter switch. An
assessment can be made by comparing
the results with the factory report or by
Figure 1. Failure location of substation transformers based on 536 failures [1]
calculating the deviation from the aver
age of the three phases.
Vibro-acoustic measurements
by using acceleration sensors
(offline/online)
The vibro-acoustic method is used to
detect acoustical signals caused by mech
anical movement. The recorded profiles,
which range up to 10 seconds and bet-
ween 10 Hz 100 kHz in time and fre-
quency domain are compared with exist
ing reference profiles to identify certain
failure modes [3].
Position and torque measurement
on the drive axis (offline/online)
The OLTCs drive mechanism, compris
ing of a motor, drive shaft and gear, oper
ates the selector switch while charging a
spring to actuate the diverter or selector
switch, respectively. The position and
torque measurement uses motor supply
parameters (current and voltage) to de-
tect mechanical problems and aging of
the drive mechanism. The results can be
compared with a reference profile or bet-
ween the taps.
Dissolved Gas Analysis (DGA)
of the oil in the tap changer
compartment (offline/online)
The DGA in the OLTC compartment
has become more common. During the
switching process of an OLTC, discharge
and heating occurs which generally leads
to a higher concentration of gasses in the
105
 DIAGNOSIS

Figure 2. Diverter switch with two resistance contacts [2] Figure 3. Selector switch with two resistance contacts [2]

tap changer compartment compared to
the main tank during normal operation.
Thus the interpretation of gas levels sig
nificantly varies from the interpretation
of gas levels obtained from the main tank
of the power transformer [4].
Each measurement method is important
to analyse the condition of OLTCs.
3. Dynamic Resistance
Measurement (DRM)
Typical switching times of the diverter
or selector switch between 40 and 60 ms
make it difficult to detect any effects dur
ing the switching process using a con-
ventional static winding resistance meas
urement, which might take a few minutes.
Therefore, the principal of the DRM was
developed as a supplementary diagnostic
method for this specific use.
Using the same setup (Figure 4a), the dy-
namic resistance measurement measures
the fast switching process of the diverter
The DGA in the OLTC
compartment has be-
come more common
switch. DRM can detect arcing contacts,
switching times of the diverter switch,
switching interruptions, due to broken
commutating resistors or broken leads for
example, and the complete wear of con-
tacts. Therefore, it provides a deeper in-
sight into the OLTCs dynamic condition.
By analysing the recordings, it is possible
to draw a number of conclusions related
to the condition of the OLTC. There are
three different ways to display the dynam
ic behaviour of the diverter switch:
(1) Current curve
(2) Voltage curve
(3) Resistance curve
In further contemplation we will refer
only to the current curve.
Current curve
The current curve, as seen in Figure 4b, is
the most common way to interpret DRM
measurements, as it is widely used for
static resistance measurement and gives
the possibility to detect current interrup-
tions.
By applying a short circuit to the opposite
side of the transformer, the current signal
becomes more sensitive, as the current
drop (ripple) increases as shown in Fig
ures 7 and 8. This is a result of a lower time
constant due to the shorted main induct
ance. A direct comparison of the current
signal is difficult when measuring with
different test equipment, as the ripple is
dependent on the dynamic properties of
the current source. But the principle and
the different stages of the switching pro-
cess are always visible, regardless of the
source parameters.
Voltage curve
Alternative to the current signal, the dy
namic behaviour can also be assessed

Table 1. Common methods for OLTC testing [5]

Measurement method Application/ purpose Problems
Static winding resistance Check the windings as well Contacts alignment, contact wear
as the internal connections
Vibro-acoustic Detect acoustical signals Linkage/gears, Timing/Sequence,
caused by mechanical movement contacts alignment, arcing,
overheating/coking, contact wear, transition
Position and torque Detect mechanical problems and Linkage/gears, control/relays, motor,
aging of the drive mechanism brake, lubrication, contacts alignment
Dissolved gas analysis Detect higher concentration of gasses Arcing, overheating/coking
in the tap changer compartment
Dynamic resistance Measure the fast switching process Timing/sequence, contact wear, transition
of the diverter switch

106 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

Figure 4a. Typical measurement setup of DRM
current curve

using the voltage or resistance curve. By

injecting a DC current, as shown in Fig
ure 5, the recorded voltage signal seen in
Figure 6A can be obtained. When using
the voltage curve, however, it is crucial Figure 4b. Typical dynamic behaviour of the diverter switch in operation current curve
to make sure that the voltage signal does
not get cut off due to a voltage limiter of
the source, which would make it difficult decrease the time constant of the system. To compensate for this effect, a method to
to analyse the signal. In addition to the In addition, a high stray inductance may determine the inductive part of the voltage
cut-off voltage, transients as shown in the cause a significant inductive voltage, which by simultaneously measuring the voltage
example of Figure 6A between stage 1 and cannot be separated from the resistive volt on the opposite winding was introduced
2 would not be seen as clearly if the voltage age part using the setup shown in Figure 5. several years ago [6].
limit was reached. Analog to the current
curve, a direct comparison of the meas
ured curves is not possible when meas
The current curve is the most common way to
uring with different test instruments. interpret DRM measurements, as it is widely used
Resistance curve for static resistance measurement and gives the
The resistance curve, as seen in Figure 6B possibility to detect current interruptions
cannot be measured directly, but is a calcu-
lation derived from the measured voltage
and current based on the setup shown in
Figure 5. A short circuit on the opposite
transformer terminals can be applied to

Figure 5. Typical measurement setup of DRM Figure 6. Typical dynamic behaviour of the diverter switch in operation voltage and resistance
voltage and resistance curve curve

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 107
 DIAGNOSIS

Figure 7. Difference in the DRM when switching up and down1 Figure 8. Difference in the DRM when switching the diverter switch in
alternating directions1
1
Measured on MR Type DIII-200-14 27 3 GF, 1966

Test currents in the range of 3-5 A were, in
most cases, sufficient to achieve a stable
measurement of the switching process
The resistive curve has a big advantage
of being independent from the current
source used. Another advantage is that
the values of the commutating resistors
can be determined directly. As the in
duced voltage on the secondary side could
be very high, it requires special protection
mechanisms for the testing device.
As the current curve is currently the most
commonly used way to perform DRM
measurements, the following sections
will focus on this method in more detail.
4. Analysis of measurement
results
Based on this non-invasive testing method,
failures can be detected without opening
the OLTC compartment. The type and the
construction of the OLTC must be known
to be able to analyse and assess the DRM
measurement in a proper manner. A refe-
rence fingerprint measurement, which
is taken after commissioning or when the
diverter switch is known to be in a good
condition, allows efficient analysis.
vary during the switching process. In ad-
dition, contact resistance, contact move-
ment, interruptions, winding inductance,
arcing and bouncing of the contacts may
influence the amplitude.
Timing:
Differences in timing may indicate mech
anical problems, excessive wear of con-
tacts and/or contact bouncing. A certain
difference may be acceptable and will
greatly depend on the design and model
of the OLTC.
5. Variation in the dynamic
resistance results
5.1 Choosing the correct test current
When measuring the static resistance,
lower test currents in the range of sev
eral amperes are preferred, especially for
HV windings [7]. Although testing of
low impedance LV windings may require
test currents in the range of 10-20 A, it is
recommended that currents should not
exceed 15 % of the rated current of the
winding. Larger currents may heat up the
windings. As the resistance measurement
is temperature-dependent, this could lead
to inaccuracies in the measured resistance
[8]. In general, these considerations also
apply to DRM measurements including
the following:
Test currents below 3 A or 1 A have
shown to be more sensitive to contact
bouncing, which can lead to false inter-
pretation of the results. A common effect
which can be observed is that a residual
oil coating on the contacts causes the
current to interrupt several times during
the test. These oil residues are usually not
considered problematic when the OLTC
operates under normal load conditions.
In turn, test currents in this range may be
able to indicate long-term aging effects
such as coking at an earlier stage, but
these advantages still have to be investi-
gated further by conducting additional
case studies.
Higher test currents in the range of
3-5 A were, in most cases, sufficient to
achieve a stable measurement of the
switching process. In these cases, minor
discontinuities, for example due to oil
coating on the contacts, did not affect
the results. Field tests did not reveal any
differences when further increasing the
current to 10 A or 15 A.

In general, two types of information can

be interpreted when looking at the cur-
rent profile: DRM is a non-invasive testing method whereby
Amplitude: failures can be detected without opening the
Transition resistors cause the current to OLTC compartment
108 TRANSFORMERS MAGAZINE | Volume 3, Issue 3
DRM has proved to be beneficial for analysing
the switching process and mobile contacts
of OLTCs on power transformers
5.2 Secondary short circuit
Shorting the secondary side of the trans-
former can have two positive effects. First,
if the current is interrupted during switch
ing, the energy stored in the magnetic core
may not be released, and the fast change
in the current will not generate such a
high voltage on the opposite winding.
The other positive effect is that the cur-
rent drop (ripple) while switching was in
most cases observed to be twice as high,
because the main inductance was short
ed. This makes the DRM a more sensitive
method, but also has an impact on the
curves, making them more significant.
5.3 Switching process from tap to tap
When analysing and comparing different
taps, it needs to be considered whether the
curves differ in case of the OLTC switching
up or down. This is important because in
the former case some windings are added
to the circuit, while in the latter, case wind
ings are subtracted based on the trans-
former tap winding and OLTC winding,
so the wiring diagram could be different
for different transformers. If windings are
added, the additional inductance needs to
be loaded with energy, and if they are sub-
tracted, the loaded energy in the induct
ance is released. This effect is much more
likely if the secondary side is not shorted,
as seen in Figure 7.
The measured curves also differ when
switching from an odd to an even tap pos
ition, as the diverter switch is rotating in
alternating directions (Figure 8). This
can usually be seen as different switching
times of the individual stages. In addition,
bouncing of contacts can sometimes only
be seen in one direction.
An example of software which allows
analysis and comparison of static and dy
namic resistance measurements is Prima-
ry Test Manager (PTM). PTM shows the
switching process of the individual taps in
a single diagram, so that they can be com-
pared amongst each other easily. As the
current signatures of many OLTC designs
may vary by their phase and switching di-
rection, the PTM software offers unique
filtering options to compare up and down
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Bibliography
[1] Cigr Working Group A2.3, 2015, TB 642 -
Transformer Reliability Survey
[2] Rudolf Klaus, 50 Jahre VDE Bezirksverein
operations for even and odd positions and Nordbayern, Die Entwicklung von Stufen-
all three phases. This enables the user to schaltern fr Hochspannungstransformatoren
analyse measurement results for a com-
[3] K. Viereck, A. Saveliev, Acoustic Tap-Chan-
prehensive failure diagnosis. ger Monitoring using Wavelet Analyses, ISH
2015, Pilsen, 2015
Conclusion [4] IEEE Guide for Dissolved Gas Analysis
in Transformer Load Tap Changers, IEEE
A conventional static resistance measure C57.139-2010
ment can be used to test the winding as [5] Jur Erbrink, Edward Gulski, Johan Smit,
well as all of the fixed internal connec- Rory Leich, 20th International Conference on
tions. In some cases, however, it is not Electricity Distribution, Experimental Model
possible to detect defects using the stand for diagnosing on-load tap changer contact
ard winding resistance measurement [9]. aging with dynamic resistance measure-
Therefore, the DRM as a supplementary ments, 2009
measurement has proved to be benefi-
cial for analysing the switching process [6] E. Woschnagg und H. Koglek, Zum Prob-
and mobile contacts of OLTCs on power lem der Widerstandsmessung von niederoh-
transformers. By using the same test setup migen Transformatorwicklungen, 1977
as for static resistance, the DRM function [7] OMICRON, Standard electrical tests for
enables insight into the fast switching power transformers, www.omicron.at
process of the diverter switch to detect
mechanical wear-and-tear of the contacts, [8] IEEE Standard Test Code for Liquid-Im-
leads and commutating resistors without mersed Distribution, Power and Regulating
additional wiring effort. As a result, the Transformers and IEEE Guide for Short-Circuit
reliability of the OLTC assessment can be Testing of Distribution and Power Transfor-
mers, IEEE C57.12.90 2006
improved; maintenance costs can be re-
duced; and most importantly, unexpected [9] Raka Levi, Budo Milovic, TechCon 2011,
and expensive outages can be avoided. OLTC Dynamic testing
Authors
Cornelius Plath graduated with a Masters degree in Electrical
Power Engineering and Business Administration from the RWTH
Aachen University in Germany. During his studies he was involved
with several industry funded research projects on the condition
assessment of electrical power apparatuses at the Institute of High
Voltage Technology. He joined OMICRON in 2010 as an Applica-
tion Engineer, and currently holds a Product Manager position. He
has extensive international application experience, specializing in the electrical diag-
nostics of circuit breakers and power transformers.
Markus Ptter studied electrical Engineering at the University
of Paderborn and graduated in 1997. From 1999 he worked for
OMICRON electronics, first as an electrical engineer in the field of
transformer diagnostics, and from 2008 onwards as product man
ager for testing and diagnostic solutions for primary assets. In his
role as product manager, he focused on developing innovative solu-
tions for power transformer testing. Markus Ptter was a member
of the IEC TC14 transformer committee and the Cigre Working Group A1.39. He was
also actively involved in an AM Forum working group focusing on Dynamic Resistance
Measurement on on-load tap changers (DRM on OLTCs). Markus passed away in June
2015 following a tragic accident.
109
EVENTS
Understanding the complexities
of transformers with the Life of a
TransformerTM Seminar
Doble transformer seminar comes to Dublin this October
O
wners and operators of transform
ers make tough choices each day
when considering what is best for
short term individual transformer reliabil
ity and long term transformer population
management. Doble Engineering Com-
pany helps engineers and managers in
the electric power industry find solutions
to these complex transformer ownership
issues through its unique Life of a Trans-
formerTM Seminar, which will be held in
Dublin, Ireland on 25-28 October 2016.
This seminar guides participants through
transformer design all the way to failure
analysis, equipping attendees with valu
able knowledge needed to make more
informed decisions about these critical
110
assets, whether its regarding on-site test
ing and analysis or long-term replacement
strategies. Attendees are presented with
practical information, which can result
in making an immediate, measurable
impact on transformer performance and
reliability.
You need to have a thorough understand
ing of the complexities of transformers so
you can make informed decisions about
transformer maintenance and manage-
ment, said Don Angell, vice president of
global strategy and solutions at Doble.
Part of our commitment to the power
industry includes the sharing of critical,
practical knowledge. We bring together
experts from across the industry to make
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Photo courtesy of J. Michael Worthington, Jr.
sure our seminar attendees are getting the
information they need to excel at their
jobs and support the needs of their orga-
nizations.
In 14 years of hosting this educational
event across Europe, the Middle East and
the United States, Dobles Life of a Trans-
former Seminars have trained more than
7,500 electric power professionals from
over 50 countries. Throughout each sem
inar, industry leaders responsible for
power transformer engineering, manu-
facturing, maintenance, production and
management offer big picture perspec
tives regarding efficient transformer ma-
nagement with emphasis on the dynamics
of that particular region.
Agenda topics include everything from
specification writing to supplier selec-
tion, discussions on various types and
components of transformers, overviews
of diagnostic testing and monitoring ap-
proaches, and transformer population
management. Advanced training sessions
enable participants to delve more deeply
into areas such as calculation methods,
short-circuit withstand, thermal design
and noise mitigation.
An optional half-day laboratory diag-
nostics seminar is also available for attend
ees. This course is ideal for those who re-
view oil analysis data to assess transformer
condition. Dobles laboratory experts
detail how to identify and assess rapidly
emerging transformer conditions with oil
quality analysis, dissolved gas analysis and
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
other diagnostic tools, combining theor
etical instruction with hands-on examples,
practical experience and case studies to il-
lustrate common issues found in the field.
The industry expo will include com
panies such as Celtic Recycling, EKOFluid,
Electrical Oil Services, GE Grid Solutions,
Mistras Group, Shell UK, Transerv Europe
and Unifin International.
The Life of a Transformer Seminar will
directly follow EuroDoble 2016, a peer-
to-peer knowledge sharing forum for ex-
changing best practices in maintenance,
protection and asset management of
power utility assets.
More details can be found at:
www.doble.com/loateurope.
111
 EVENTS

CWIEME Chicago
now a three-day event
After three years of steady growth, North Americas leading electrical
manufacturing tradeshow is moving from two days to three allowing
more time for attendees and exhibitors to connect, as well as to offer a
professionally-accredited training course and workshop

T
his October CWIEME Chicago
will return to the Donald E. Stevens
Convention Center in Rosemont,
Illinois for not just two but three days of
buying, selling, networking and know-
ledge sharing within the electric motor,
generator and transformer manufacturing
communities.
The move is in response to both attendee
and exhibitor demand, backed by a steady
increase in participation figures over the last
few years. In 2015, the show saw a 10 per
cent rise in total attendance with a 24 per
cent increase in OEM representation. This
growth shows no sign of slowing in 2016.
The level of interaction was astounding
last year between both the exhibitors and
customers, said Hank Pennington, pre-
sident of Essex Brownell, supplier of wire,
cable, insulation and other components
to the motor repair, OEM and electronics
markets. Weve seen CWIEME Chicago
grow over the years and are very excited
about the momentum this year. We plan to
get a bigger booth to keep this momentum
going!
Exclusive CEU-accredited
workshops
As well as allowing more time for cus
tomers and suppliers to make new contacts
and cement existing relationships, the
move to three days also enables the inclu-
sion of a new CEU-accredited 1 day work-
shop, alongside the regular CWIEME
Chicago technical programme. The trai-
ning programme, will tackle specific de-
sign and technical challenges and course
participants will benefit from teaching
and interaction with expert instructors
from the industry and academia.
The training programme will be run by
Dan M. Ionel, Professor of Electrical En-
gineering, and L. Stanley Pigman, chair in
Power at the University of Kentucky, and
Dr Dave Staton, Founder and President,
Motor Design Ltd, on the afternoon of day
two and the morning of day three, Octo-
ber 5 and 6 respectively. Tickets will be
available to purchase on a first-come, first-
served basis. Further details, along with
workshop schedules and content over-
views, will be published on the CWIEME
Chicago website in due course.
We are thrilled to announce the addition
of Professor Ionels workshops to CWIEME
Chicago 2016, said Haf Cennydd,
portfolio director at i2i Events Group.
The tailored expert advice he and his
colleagues can provide will help to fill
important knowledge gaps for electrical
engineers at all levels and support their
ongoing professional development. The
initiative is a clear example of our com-
mitment at i2i Events Group to adding
value for our show participants.
Learning opportunities for all
The regular CWIEME Chicago technical
programme, meanwhile, will be available
free of charge to all attendees and exhibit
ors at the show. The full schedule for

112 TRANSFORMERS MAGAZINE | Volume 3, Issue 3

2016 is also yet to be published but last
years speakers give a strong idea of the
caliber of programming. They included
K onstantinos Laskaris, principal motor
designer at Tesla Motors; Timothy Gill,
deputy chief economist at the National
Electrical Manufacturers Association
(NEMA); Ashley Armstrong from the
Appliance Standards Program at the US
Department of Energy; James Bell, princi-
pal consultant at MagnetoDynamics; and
Mark Raymond, senior staff engineering
associate at Underwriters Laboratories (UL).
New Exhibitor Zone
Another addition in 2016 is the New
Exhibitor Zone. By grouping all new
exhibitors together, making it quicker
and easier for attendees to discover new
products and initiate new partnerships.
This years new exhibitors supply every
thing from electrical steels, permanent
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
magnets, laminations, and insulating oils,
to wires, cables, winding machines, and
welding equipment. We also see the return
of the dedicated Machinery Demo Zone,
where attendees can witness all the latest
technology and equipment in action.
We might not be in a golden age of
American manufacturing anymore, but
were seeing a definite tendency towards
re-shoring in the United States which
bodes well for the future of the CWIEME
community, Cennydd said. Many of our Venue:
attendees and exhibitors at CWIEME
Chicago are finding that for mid-to-low
volume, higher complexity products, it
makes sense to manufacture in the United
States. With its long-standing heritage
in the industrial heart of America and
strong brand values, CWIEME Chicago
is committed to spreading the knowledge
and facilitating the connections that will
help bring American manufacturing back
home.
CWIEME Chicago North
Americas most comprehen
sive showcase for the coil
winding and electro-magnet
ic industry
Dates and opening times:
Tuesday October 4, 2016 10am to 5pm
Wednesday October 5, 2016 10am to 5pm
Thursday October 6, 2016 10am to 3pm
Donald E. Stephens Convention Center,
Rosemont, Illinois
Admission: Free until Friday September
30, after which an onsite registration fee
of $40 will apply for those who have not
already registered online.
For more information and to register for
the event, please visit:
www.coilwindingexpo.com/chicago
113
 EVENTS CALENDAR
Transformer Technology Symposium
9 10 August 2016, Bangalore, India
This Symposium is organized by an interdisciplinary
team with expertise in multi-physics simulations in
conceptual design and design calculations, finite element (FEM),
multi-body dynamics (MBD), computational fluid dynamics (CFD),
electro-magnetic simulations (EMAG), fatigue damage durability,
manufacturing process simulation (including casting, metal forming,
powder forming), and multi-disciplinary optimisation (including shape
& topology optimisation and parametric optimisation).
International Council on Large Electric Systems
21 26 August 2016, Paris, France
The CIGRE Session 2016 provides an opportunity to listen
to contributions from international senior executives as
well as experts and specialists through official presentations,
panel discussions, technical meetings and poster sessions. In parallel
of the Session, a Technical Exhibition is held in the same location.
The exhibition offers the opportunity to all visitors, including CIGRE
delegates, to discover new services, tools, equipment and materials as well
as the most advanced technologies in the field of power systems.
East African Power Industry Convention 2016
21 22 September 2016, Nairobi, Kenya
The 2016 EAPIC conference and exhibition will bring
together leaders from the regional and international
power and energy community to discuss the status of critical projects,
spot lucrative opportunities and share best practice. The event includes
a strategic conference and a large trade exhibition which provides a
platform for public and private stakeholders to engage in discussions
around the future of East African energy utilities, giving stakeholders
the opportunity to benchmark their operations, achievements and
challenges against their peers and seek suppliers who are looking to gain
access to projects across the region.
The International Conference on Condition
Monitoring and Diagnosis 2016
25 28 September 2016, Xi`an, China
The technical program will include papers presented
in regular, poster and plenary sessions covering a
broad range of topics, such as evaluation of failure and degradation of
power equipment based on CMD, advanced sensors and diagnosis
techniques for Smart Grid, strategy planning and asset management
for power equipment, fusion of large data and smart grid control with
CMD techniques for power equipment, insulation structure design and
lifetime assessment for HVDC system, and degradation and lifetime
assessment of new energy devices for power generation and storage.
Transformers Magazine official media partner
Transformer Life Management Conference
26 27 September 2016, Knigswinter, Germany
The main goal of the TLM conference is to find ways
for prolonging the residual lifetime of transformers
and to reduce unplanned outages. This year the TLM
symposium will focus on the question of how to ensure transformer
safety and operation in the network in the face of increasing loading
and age. The symposium and associated technical exhibition is directed
at engineers, physicists, chemists, technicians and consultants involved
in the manufacturing, design, operation, assessment and maintenance
of transformers, as well as universities and research institutes with an
interest in the reliable operation of electrical networks.
114
Power Nigeria Exhibition and Conference
27 29 September 2016, Lagos, Nigeria
Over the next decade, Nigeria is set to become
one of the fastest developing nations for power
generation, transmission and distribution with all sectors of the power
industry in need of drastic development. This event spread over 3 days will
provide insight into the efforts and operations of the Nigerian national
electricity distributors and the government, present financial issues and
challenges, and feature a workshop on gas to power value chain.
Transformers Magazine media partner
Coiltech International Coil Winding Expo and
Conference
28 29 September 2016, Pordenone, Italy
The seventh edition of one of the fastest growing
international exhibitions for the coil & winding
industry will bring together leaders in the electro
mechanical industry who will share information on the market
development, new technologies, materials and procedures. The event
includes both a conference with speakers from academic institutions and
the industry, and an exhibition which traditionally covers all materials
and machinery used in the production of electric motors, generators,
transformers and winding systems.
Transformers Magazine media partner
CWIEME Chicago
4 6 October 2016, Chicago, USA
This year, CWIEME Chicago boasts two changes
it is now a three-day event and it features a new
exhibitor zone. Showcasing expert minds and the latest
technologies, CWIEME Chicago 2016 is the meeting place for the coil
winding, electric motor and transformer manufacturing industries
across the Americas. A visit will help you to find the solutions your
business needs, meet leading suppliers, network, forge new partnerships
and strengthen existing ones.
WEIDMANN Transformer & Technology
Seminar 2016
11 13 October 2016, Istanbul, Turkey
This newly offered 3-day transformer seminar includes
an array of industry experts and companies presenting
and discussing topics such as materials and components used in
transformers, design of distribution and power transformers, factory
testing, operation of transformers and on-site testing. The seminar
was developed to give the participants both an introduction and a
comprehensive overview about transformer technology.
Transformers Magazine media partner
2016 EuroDoble Colloquium and Workshop
24 26 October 2016, Dublin, Ireland
EuroDoble Colloquium and Workshop is a forum
for sharing best practices on managing primary and
secondary assets in our ageing power networks, power
stations and industrial sites. As the power industry today faces a long
list of challenges and concerns, this event brings together peers in the
power industry to discuss the pressing topics that impact your job
all to ensure the reliable flow of power. Now in its 22nd year, the 2016
EuroDoble Colloquium and Workshop will focus on three important
focus topics: the impact of new technologies, managing safety, and
secondary systems.
TRANSFORMERS MAGAZINE | Volume 3, Issue 3
Combined readership from nearly 190 countries

The most recognized global publication

for the transformers industry.
We give you the most effective tools to

Communicate and Grow!

www.transformers-magazine.com info@merit-media.com +44 203 734 7469
3UHWDFW
5HDFWLQDGYDQFH
6LHPHQV7UDQVIRUPHUVKDVGHYHORSHGDFRPSUHKHQVLYHDQGPRGX
ODUVWUDWHJ\IRUJULGUHVLOLHQFH7KHFRQFHSWQDPHG3UHWDFWLV
PDGHXSRIWKHWKUHHSLOODUV35(9(173527(&75($&7HDFK
FRQWDLQLQJGLIIHUHQWPRGXOHV:LWKLQWKLVFRQFHSW6LHPHQV7UDQV
IRUPHUVDOVRRIIHUVSURGXFWVWKDWDUHPXOWLIXQFWLRQDOSRFNHW
NQLYHVLQHPHUJHQF\FDVHV0RELOHUHVLOLHQFHXQLWVZLWKSOXJDQG
SOD\EXVKLQJVDUHYHUVDWLOHLQLQVWDOODWLRQDQGFDQEHWUDQVSRUWHG
DQGLQVWDOOHGUDSLGO\7KLVUHGXFHVUHFRYHU\WLPHWRDIHZKRXUV
UDWKHUWKDQZHHNV
)RU6LHPHQV7UDQVIRUPHUVJULGUHVLOLHQFHLVDVWDWHRIPLQG

VLHPHQVFRPWUDQVIRUPHUUHVLOLHQFH