Adoption of K Class Fluids for Distribution Transformers

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 Changing Requirements
‡ With scarcity of space in metropolitan cities , Vertical
growth is on the rise .
‡ Buildings with 100 + floors are being planned.
‡ The requirement for location of substations at multi-
levels for high-rise is becoming a necessity.
‡ Presently only Dry Type Transformers are allowed
to be located at intermediate levels.
‡ K Class filled transformers can be an suitable
alternative for overcoming the limitations of Dry
Type transformers.

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 Considerations

‡ K Class Fluids can be used in all mineral oil

distribution transformers WITHOUT
MODIFICATIONS

‡ K Class Fluids -Synthetic ester can be used in

FREE BREATHING transformers without any
additional seals etc.

‡ Synthetic ester is fully miscible with mineral oil.

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 Environmental Benefits

100

90

80 Synthetic Esters

70

60

50

40

Biodegradation (%)
30

20
Mineral Oil
10
Silicone Liquid
0
0 5 10 15 20 25 30
Time (Days)

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 Moisture Tolerance-
Breakdown voltage vs. moisture content at 20ƒC

90

80

70

60

50

40
Synthetic Ester
30

Breakdown Voltage (kV)

Mineral Oil
20
Silicone Liquid
10

0
0 100 200 300 400 500 600 700 800 900 1000
Moisture Content (ppm)

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Comparison of Transformers filled with K-class fluids
v/s Dry Type Transformers.

The comparison is being made for Transformers up to

5 MVA and 33kV on the following parameters-
- Performance
- Reliability
- Installation
- Fire safety
- Maintenance & Monitoring

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Comparison of Transformers filled with K-class fluids v/s DryType
Transformers- Performance Analysis -1
‡ Loss levels :K class fluids have 30% to 50% loss level as
compared to Dry type transformers.

‡ Noise level: K-class fluids have @ 8 db lower noise level

as compared to dry type transformers.

‡ Environment: K-class fluids are environment friendly.

‡ Manufacturing process: Dry type transformers have to

be manufactured under highly controlled conditions so
as to ensure that the mix of resins,hardners and fillers do
not have a different thermal expansion as compared to
that of the conductor.

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 Comparison of Transformers filled with K-class fluids v/s
Dry Type Transformers- Performance Analysis -2

‡ Ventilation system: dry type transformers are highly

sensitive to the functioning of the external cooling
system. Failure of the external cooling system leads to
thermal runaway
‡ Atmospheric conditions: Dry type transformers are
affected by high humidity.

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 Comparison of Transformers filled with K-class fluids v/s Dry Type
Transformers- Reliability Analysis-1

‡ Short circuit withstand capacity: Dry type

transformers are very susceptible to shocks related
to short circuits.The windings are seperated from
each other and the core by rubber blocks.
The Transformers filled with K-Class fluids can
withstand overload conditions and thermal shocks.
‡ Regeneration of insulation levels:K-class fluids have
the ability to regenerate their insulation levels on
account of the theory of convection in fluids.The flow
of fluids take away the gas formed before it can lead
to a real failure.

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 Comparison of Transformers filled with K-class fluids v/s Dry
Type Transformers-Installation Analysis -1

-Dimensional Details: The dimensional details of Dry type

transformers are much higher than those of transformers filled
with K-Class filled fluids.

This factor makes it extremely difficult to install Dry type

transformers in areas which have space constraints.
-(indicate the % volumetric difference in terms of a table
wrt rating and voltage class)

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 Comparison of Transformers filled with K-class fluids v/s Dry
Type Transformers- Installation Analysis -2

‡Onsite repairs: Dry type transformers cannot be repaired at site.

‡Thermal performance: The superior thermal performance of

Transformers with K-Class fluids make it suitable for KNAN design.
This in turn means that the allied accessories such as ventilation
systems, filters etc are not needed.

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Comparison of Transformers filled with K-class fluids v/s Dry
Type Transformers- Fire Safety -1
‡Effect of external fire : it will take much longer for a transformer filled
with K-class fluids to participate in the fire. The fluid is contained inside
the Transformer tank and will not be exposed to the flames unless the
tank bursts. The design of the tank is such that it can withstand internal
pressure.
Dry type transformers are more susceptible to external fire.

‡Internal fire: The flash point for K-class fluids is 275degC and the fire
point is 320 deg C. K-ĐůĂƐƐĨůƵŝĚƐŚĂǀĞďĞĞŶƉƌŽǀĞŶƚŽ͞ƐĞůĨĞdžƚŝŶŐƵŝƐŚ͘͟
This ensures that it does not contribute in any way to spreading of the
fire.
-Data indicates that there are no fires with K class fluids.

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Comparison of Transformers filled with K-class fluids v/s Dry
Type Transformers- Maintenance and Monitoring -1

‡Maintenance: Dry type transformers have a tendency to

attract dust ( due to static electricity on the surface of the
transformer).This coupled with the moisture
condensation leads to conductive paths and creepage
flashover.
‡Monitoring: the conventional methods of monitoring a
mineral oil filled transformer can be extended to
Transformers filled with K-class fluids.
-Based on field experience failure rate of the temperature
sensors for dry type transformers are very high.

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 Comparison among Dielectric media among c
media
¾Environmentally benign (biodegradable)
¾Higher fire point in comparison to mineral oil
¾Good thermal characteristics: Low thermal expansion coefficient, thermal
conductivity comparable with mineral oil
¾Can be mixed with mineral oil
¾Excellent dielectric properties: high disruptive strength, low dependence of
dielectric characteristics on moisture content
¾High oxidation stability
¾Strongly hygroscopic, can absorb large quantities of moisture while retaining
its insulating properties
¾Cellulose insulation impregnated with K-Class Fluid ages far less than with
mineral oil
¾Materials customarily used in transformer construction are compatible with
Quicker environmental approval procedure due to biodegradability

14
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 WƌŽŽĨƐ͙͘͘>ŽƐƐ>ĞǀĞůĚĂƚĂ

Slim Siltrim Silfo Cast

(Pauwels) (Areva T&D) (Siemens) Resin IP00
(ABB)
2MVA 2MVA 2 MVA
20/24kV 20/24kV 20/24kV 2MVA,
20/24kV

No Load 2.1 2.4 2.6 4.2

Loss kW

Load 19 18 14.5 19.5

Loss kW
(@125°
C)

Reference: The Line,

May 2000, Pauwells

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Retrofilling Mineral Oil Filled Transformers with K Class Synthetic Esters

Draining of Mineral Oil ʹMineral Oil was pumped out of the transformer into a
container, the oil was completely drained and care was taken to remove as much
oil as possible. The core assembly was taken out and oil was allowed to drip. The
conservator tank and main tank were also cleaned properly. The core coil
assembly was rinsed with Synthetic ester and left for two hours to allow oil to be
released from the windings.

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Retrofilling Mineral Oil Filled Transformers with K Class Synthetic Esters

Rinsing-The core coil assembly was once again rinsed, the conservator
tank was flushed with the Synthetic Ester. The tank and radiator were
rinsed with warm oil thoroughly.
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Retrofilling Mineral Oil Filled Transformers with K Class Synthetic Esters

Preparing for refilling-All the gaskets, oil seals, bushings and silica gel
breather were replaced with new ones.

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Retrofilling Mineral Oil Filled Transformers with K Class Synthetic Esters

Filling with Synthetic Ester -The core assembly was placed inside the tank.
The transformer was filled with the Synthetic ester based oil through drain
valve in the bottom of the tank with a dedicated pump. The LV bushing
connections were done and the main tank covert was closed.

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 Thermal Profile of DTs
Equipment: DTs K Class OIL Equipment: DTs K Class OIL
Ambient Temperature: 30°C Ambient Temperature: 29°C
Location: 630 KVA DT 1 Load: R126A, Y183A, B111A, N60A Location: 630 KVA DT 1 Load: R28A, Y35A, B13A, N22A

Max. Temperature rise above Ambient 9.5϶ΛϮϮйůŽĂĚŝŶŐ Max. Temperature rise above Ambient 4.4϶ΛϰйůŽĂĚŝŶŐ
Thermal profile on DT tank & Radiator observed ʹ Normal Thermal profile on DT tank & Radiator observed ʹ Normal

Thermal Imaging of the retrofilled transformer-After energising the transformer

on load ,IR images of the DT were taken to ensure that there was no abnormality
with the DT.

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