Transformers

VOL 8 ISSUE 2 APRIL 2021 MAGAZINE

COLUMNS: INTERVIEWS: TECHNICAL ARTICLES:

Through-faults and slow Tilo Else Return on DGA investments
breakers Ricardo Suarez Transformer management
Standards – Part V system
Monica Manara
Books on power Apsorption index – Part II
transforments – German III Ismail Güner
Eurelectric report
commentary

Innovation in traction
ISSN 1849-7268 (Digital)

transformers from
Hitachi ABB Power Grids
Traction transformers ▪ Industrial transformers ▪ Megger IDAX 322
100 years of excellence ▪ Leak repair ▪ Transport monitoring ▪ Sustainable transmission
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 CONTENTS

INTERVIEW:
TILO ELSE
Siemens Energy’s Vice President for Distribution Transformers
Tilo Else is Siemens Energy’s Vice President for Distribution
Transformers, responsible for the company’s global dry-type and
fluid-immersed distribution transformer and traction transformer
businesses. In the interview, he talks about the energy market
10 transition, associated challenges, and how Siemens Energy is dealing
with those challenges.

INTERVIEW:
RICARDO SUAREZ
CEO of Prolec
Prolec GE manufacture transformers for all power generation, trans-
mission and distribution applications, from applications in conventio-
nal and renewable energy generating plants, to primary and secondary
substations. All their transformers are designed and manufactured to
36 the highest standards, combined with high quality materials and com-
ponents, providing superior performance for our customers.

INTERVIEW:
COVEME - innovating insulation materials
MONICA MANARA, Chief Commercial Officer
Coveme is a manufacturer of insulation materials for different
applications, including dry-type and oil-filled transformers. With 60
years of know-how in converting films, the company employs nearly
300 people and generates more than €100 million p.a. The part of
58 business relating to transformers and motors insulation makes up 20
% of their operations, and their plan is to double that percentage.

INTERVIEW:
ISMAIL GÜNER
The author of TM Best article 2020
Interview with Ismail Güner, the author of Best article 2020 entitled
“The power of sharing knowledge”, published in Transformers
Magazine. Ismail Güner is an experienced power transformer engineer
currently working at Hydro-Québec. In the interview, he talks about
76 the importance of knowledge and experience sharing as well as the
challenges and trends the transformer industry is facing today.

The next Coil Winding events of 2021

see you at
Coiltech Coiltech
Webinar Italia
High Voltage Talks
21 April 2021 Manufacturing International Coil&Winding
of Distribution Transformers Exhibition
05 May 2021 Quality Control 22-23 September Pordenone
of Power Transformers www.visitcoiltech.com
Further topics and dates: www.quickfairs.net

www . t ra n sfo r m e r s - m a g a z i n e . co m
pdc210502 TM 198x66 23 03 2021 bozza 3.indd 15 24/03/21 15:33 3
Scrivi un messaggio
CONTENTS

COLUMN: ARE THROUGH-FAULTS AND SLOW

BREAKERS DAMAGING YOUR TRANSFORMER?
Brian SPARLING
Through-faults are often transient in nature, resulting in the
fault being cleared in a few milliseconds by the power system
protection. They can cause short overloads that result in
excessive mechanical and thermal stresses on the core and coil
30 assembly, which affect the transformer aging. In addition, the
fault on the breaker can be fatal to the transformer.

COLUMN: STANDARDS RELEVANT TO TRANSFORMERS – PART V

P. RAMACHANDRAN
The article brings a list of the currently active IEC, IEEE,
EN standards together with CIGRE technical brochures.
Those standards and brochures are of great importance for

50
transformer design, maintenance and exploitation. One can
say that they shape today’s modern transformer technology.

COLUMN: BOOKS ON POWER TRANSFORMERS IN

GERMAN – PART III
Compiled by Vitaly GURIN and P. RAMACHANDRAN
German literature on power transformers is covered from 1888 (the
first book on transformers published anywhere, just three years af-
ter the transformer patenting), up to the most recent publications
issued in 2019. The purpose of this compilation of published books
70 on power transformers is to give a historical summary on the topic,
which may also be useful to other specialists in their research.

INNOVATIVE SOLUTIONS FOR ROLLING STOCK

16 TRACTION TRANSFORMERS
Valter PORCELLATO, Paolo CASTANGIA, Hitachi ABB Power Grids
Hitachi ABB Power Grids has more than 30,000 traction transformers
currently in operation across the world in more than half of the world’s
trains, pioneering this technology for over 100 years. The article details
16 the latest innovative solutions of the Hitachi ABB Power Grids’ traction
transformers portfolio.

TRANSFORMER APPLICATIONS FOR THE INDUSTRY:

24 AN OVERVIEW
Ilario SCIAN, Suhel PATEL, Hitachi ABB Power Grids
The article provides an overview of different transformer applications for
the industry, starting from the industrial transformers for energy-inten-
sive industries that use electrical energy as a major resource for produc-
24 tion, like electric arc furnaces and high-current rectifiers, but also con-
verter transformers or transformers feeding motor drives or industrial
processes with a few examples in practice to illustrate the application.

THE MEGGER IDAX 322 - ACHIEVING DFR SUCCESS

44 FOR ALL APPLICATIONS
Olle BENZLER
To meet an ever-demanding market for reliable insulation condition
analysers, Megger is proud to present the latest Dielectric Frequen-
cy Response test instrument in the IDAX family: IDAX 322 - designed
44 with the assessment guidance informed by international standards
and over 25 years of field experience with DFR technology.

KONČAR GROUP - 100 YEARS OF EXCELLENCE

62 WITHOUT COMPROMISE
Končar Group - a Croatian company, a regional leader in
manufacturing and supplying electrical equipment for the energy,
transportation and industrial sector, this year marks its centenary.
Starting from a small workshop through a century of excellence, the
62 KONČAR Group has developed its portfolio with many innovations,
novelties and thousands of successful projects.

4 TRANSFORMERS MAGAZINE | Volume 7, Issue 4 | 2020

 Christoph Engelen
Product Manager

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With just one setup for multiple tests, TESTRANO 600 significantly reduces
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ensure a new level of accuracy and the multi-touch color display enables
smart and comfortable operation.

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CONTENTS

TRANSFORMER LEAK REPAIR STORY FROM

80 POLYWATER®
The fast and effective repair of power transformer oil or SF6 leaks is an
important part of a consistent power supply that minimise economic
losses for both power utilities and their customers. Leaking gaskets
can be repaired using the Polywater® PowerPatch® Leak Repair system.
80 This solution requires less time and is more economical compared to
standard solutions.

INVESTIGATING RETURN ON ONLINE DGA INVESTMENTS

86 FOR SERVICE AGED POWER TRANSFORMER
Bhaba P. DAS
DGA is a widespread method for diagnostics of the transformers. A ma-
jor benefit of online DGA monitoring is its ability to detect failures that
are evolving faster than the usual yearly sampling interval. Besides, the
86 return on investment in online DGA is often justified due to savings as-
sociated with a lower risk of failure, as showed in the case study.

CONSISTENT TRANSFORMER TRANSPORT

98 MONITORING – DETECT DAMAGE EARLY AND ACT
SMT ELEKTRONIK GmbH developed a MONILOG® - a portfolio of
products for monitoring the transportation of the goods, a practical
solution that also can be used to monitor the transport of the
transformers. MONILOG® measures, logs, and transmits signals in
98 real-time such as mechanical shocks, GPS, pressure, and many more.

TRANSFORMER MANAGEMENT SYSTEM - TRAFOGRADE

106 Marek SZROT, Janusz PŁOWUCHA, Paweł MOLENDA
The article presents TrafoGrade – a transformer management
system based on a multi-parameter evaluation of the technical
condition. This method is highly useful in the decision-making
process for transformer population management.

106 116
SHAPING THE ENERGY TRANSITION WITH SUSTAINABLE
POWER TRANSMISSION
Siemens Energy recognises trends in energy transition with sustaina-
ble power transmission, thus started developing technologies that
are actively shaping the path to a climate-friendly future. The article
brings the latest information on the various Siemens Energy's products
that are designed in a sustainable and climate, and eco-friendly way.

ABSORPTION INDEX OF INSULATION AT END OF

124
116 SERVICE LIFE – PART II
Vitaly GURIN
The goal of the article is to describe the absorption index as the criteri-
on for evaluation of insulation condition assessment, to give simple and
practical recommendations for maintenance staff dealing with the old-
aged transformers based on the test results. The article summarises
author's experience on the numerous measurements of the insulation
resistance conducted at the transformer sites in multiple countries.

124 132 ESTER TRANSFORMER FLUIDS AND THEIR

POTENTIAL ROLE IN EUROPE’S IMMINENT
RECKONING WITH ITS AGEING GRID INFRASTRUCTURE
Tim MARTIN
The single biggest investment driver is the modernisation of ageing inf-
rastructure. European distribution grids will need investments of €375-
425 billion until 2030. Retrofilling transformers with natural or synthetic
ester fluid to replace mineral oil is a perfect example of a solution that
extend asset life and optimise loading performance at the same time.

132 136 EVENTS

6 TRANSFORMERS MAGAZINE | Volume 7, Issue 4 | 2020

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 EDITORIAL MESSAGE
TRANSFORMERS MAGAZINE
ISSN 1849-3319 (Print) ISSN 1849-7268 (Digital)
EDITORIAL BOARD
Editor-in-Chief:
Mladen Banovic, PhD, Merit Services Int., Croatia
mladen.banovic@transformers-magazine.com
EXECUTIVE EDITORS
Michel Duval, PhD, Hydro Quebec, Canada
Jean Sanchez, PhD, EDF, France
Michael Krüger, PhD, OMICRON electronics, Austria
Jin Sim, Jin Sim & Associates, Inc., USA
Juliano Montanha, SIEMENS, Brazil
Craig Adams, TRAFOIX, Australia
Dear Readers,
Arne Petersen, Consulting engineer, Australia
Zhao Yongzhi, Shandong Electrical Engineering
& Equipment Group Co., Ltd, China I strongly believe that it is this unbridled
optimism and the zeal that could not have
Barry M. Mirzaei, LargePowerTransformers Inc.,
Canada
EDITORS
Daosheng Liu, Jiangxi University of Science and
gone unnoticed while we were preparing
Technology, China
Mislav Trbusic, University of Maribor, Slovenia
the materials for this issue of Transformers
Dr. Mohammad Yazdani-Asrami, University of Magazine that have marked this edition
Strathclyde, United Kingdom
Dr. Shuhong Wang, Xi’an Jiaotong University,

China
ASSISTANT EDITOR
Pedro Henrique Aquino Barra, MSc,
EESC/USP – University of São Paulo, Brazil
Art Director: Momir Blazek
Photo: Shutterstock.com
Front page image: Hitachi ABB Power Grids
Language Editor: Lidija Kasik
ADVERTISING AND SUBSCRIPTION
Ante Prlic
+44 20 373 474 69
ante.prlic@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 art­i­
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ity for articles rests upon the authors, and the
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Man­uscripts, photos and other submitted
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Subscription rates:
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Digital edition: $60 (1 year, 4 issues)
Online edition - full access: $20 (1 year, 4 issues)
Online edition - free access: free of charge for
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REPRINT
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Director: Mladen Banovic, PhD
T
he April issue of the magazine
is in front of you. While
thinking about whether there
is something that makes this issue
unique in relation to the previous
issues, endless conversations I had
with our authors and collaborators
when preparing the materials for
publication in recent weeks and
months came to my mind. These
working conversations about articles
would often take a turn to a completely
private sphere and, as I thought about
them later on, I realised that many
of us work in circumstances that are
often very challenging on a personal
level. I find it useful that, nowadays, we
can do lots of things online, but these
conversations have led me to conclude
that everything has its limits. It is
understandable that it is not at all easy
to dwell exclusively in your home for
a long period of time. However, while
one would expect widespread apathy
among people on such occasions,
I got the impression that there has
never been more optimism among us.
I strongly believe that it is exactly this
unbridled optimism, which has sprung
in the midst of these challenging
circumstances, and the zeal that could
not have gone unnoticed while we were
preparing the materials for this issue
of Transformers Magazine, that have
marked this edition. This optimism
is exactly what I would like to convey
to all our loyal readers through these
written words.
It is nice to hear that, even in
such challenging circumstances,
Transformers Magazine globally
connects us and further empowers
not only our readers who give
meaning and purpose to the
magazine, but also all of us who
actively participate in the making
of the magazine: our authors,
reviewers, editors, collaborators
and the entire editorial board.
While the Transformers Academy
is an additional piece in the opulent
mosaic that brings to you another
dimension of interactivity, and
the Transformers Forum provides
simplicity, directness and speed of
communication, we now also offer
books which, some might say, capture
the very essence of knowledge.
Our latest book release, the OLTC
Dynamic Testing Guide authored
by Dr. Raka Levi, has already been
well received by our readers, just as
our other publications, and we hope
that we will continue to meet your
expectations in the future.
I hope you will find this issue a useful
and pleasurable read.
Dr. Mladen Banovic, Editor-in-Chief

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 9
INTERVIEW

10 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

Tilo Else is Siemens Energy’s Vice President for Distribution Transform-
ers, responsible for the company’s global dry-type and fluid-immersed
distribution transformer and traction transformer businesses
TILO ELSE
Siemens Energy’s Vice President for
Distribution Transformers
The energy market is rapidly
evolving with the energy
transition as one of the most
fundamental changes: What
challenges does this rapidly
changing energy landscape
pose for customers?
The energy transition poses big challenges
to all of us – the authorities and govern-
ments, our customers, and also the manu-
facturers of energy equipment. Transmis-
sion and Distribution System Operators
(TSOs and DSOs), as well as our industry
and infrastructure customers, are faced
with rising global demand for energy and
three radical changes at the same time:
1. Decarbonization: worldwide increas-
ing focus on the environment (strong
increase in renewable energy genera­
tion, sustainable power distribution
with lower losses, a stronger focus on
electrical transportation);
2. Decentralization: embraced system
complexity by decentralized energy
sources and prosumers;
3. Digitalization: adopting digital solu-
tions to improve asset performance
and grid management.
Our GEAFOL® dry-type transformers show
excellent electrical, mechanical, and ther-
mal characteristics, and with epoxy resin
insulation, they are especially eco-friendly
and fire-resistant
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Consequently, our customers are facing
the challenge of keeping the grid con-
nection resilient and reliable during the
energy transition while also focusing on
increasing sustainability and exploiting
opportunities of new technologies and
digitalization. In addition, there is an in-
creasing focus on localization, especially
in the wind industry.
How do you address these
challenges and customer
needs at Siemens Energy
distribution transformers?
At Siemens Energy, we support our cus-
tomers from renewables business, in-
dustry business, power distribution and
transportation not only with the latest
innovations, we also provide expertise in
how to implement the new technologies
and which products and solutions would
be most favorable for a specific challenge.
With our global production network, we
are able to serve our customers global-
ly with the same highest standards and
quality.
We offer a complete portfolio of stan-
dardized and customized low-loss
dry-type distribution transformers and
fluid-immersed distribution transform-
ers. Both technologies have their specific
strengths and application fields. Our
GEAFOL® dry-type transformers show
excellent electrical, mechanical, and
thermal characteristics, and with epoxy
resin insulation, they are especially
eco-friendly and fire-resistant. They are
mainly used in onshore wind turbines,
industrial applications close to the load
centers, data centers, modern buildings,
and ships.
Tilo Else is Siemens Energy’s Vice
President for Distribution Transform-
ers, responsible for the company’s
global dry-type and fluid-immersed
distribution transformer and traction
transformer businesses. He earned
his diploma for Business Administra-
tion at the University of Leipzig, Ger-
many, and spend some time in Sili-
con Valley. He started his career at
Siemens as a Strategy Consultant in
2000. For more than 15 years, he has
been working for the Energy business
at Siemens, mainly Transformers and
Medium Voltage Products & Systems.
During this time, he has built up an
impressive track record in running
and improving operational business
for more than a decade on the fac-
tory and business segment level. He
also headed several central func-
tions such as Group Strategy, Central
Transformer Sales commercially, and
Transformer License Department.
11
INTERVIEW
With our new 66 kV low-loss fluid-immersed
transformer, we set a new standard for effi-
ciency and also for sustainability with a bio-
degradable ester insulation
Our fluid-immersed distribution trans-
formers FITformer®, with their compact
design and high efficiency, are used very
broadly. We offer very environmentally
friendly cooling and insulation systems
using biodegradable fluids such as syn-
thetic ester or natural ester. Our low-loss
designs using amorphous cores and other
high-tech core materials are supporting
the decarbonization demand further-
more. With a voltage range of up to 66 kV,
they are the perfect choice for new wind
12
offshore applications. Specifically, for our
rail operators and train manufacturers
worldwide, we also provide reliable and
flexible traction transformers which in-
crease train efficiency and performance
and handle the highest ratings in a mini-
mum of available space. Both GEAFOL®
and FITformer® distribution transformers
are nearly maintenance-free, have proven
the highest reliability and of course, they
come as Sensformer® with the latest digi-
talization features.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
For every application area, we can of-
fer our customers a perfect distribution
transformer with a special focus on sus-
tainability and the highest performance
supported by digitalization. All our trans-
formers do already comply with Tier II of
the European EcoDesign Directive for in-
creased energy efficiency that needs to be
applied from 1 July 2021 onward.
What role does co-creation
play in this context?
A lot of our products, especially for DSOs,
are highly standardized and are produced
in large quantities. Other distribution
transformers, for example, for data cen-
ters, are built according to customer speci­
fications. For both transformer types,
co-creation does not play an important
role. But this is very different for indus-
try customers, wind applications, and
traction transformers, where co-creation
plays a very important role. For industry,
the distribution transformers need to be
specifically designed to fit customer re-
quirements – frequently in co-creation
with the customer. The same is true for
wind applications where the transformers
need to perfectly match the turbine me-
chanical and technical requirements.
We see wind energy tech­
nologies developing extremely
fast with ever-larger turbines
under development and 66 kV
as a new standard for offshore
wind farm array – How do you
see Siemens Energy’s wind
distribution transformers
in this evolving market?
How do you make sure your
transformers stay relevant to
next-generation wind farms?
We are currently a leading transformer
supplier for the offshore wind industry,
and we intend to keep this position. We
know this is only possible with state-of-
the-art technologies and very close co-
operation with the leading wind offshore
turbine OEMs. With our new 66 kV low-
loss fluid-immersed transformer, we set
a new standard – for efficiency (already
in line with the new EcoDesign Tier II
directive that does not even have to be
applied to wind offshore applications),
and also for sustainability with the bio-
degradable ester insulation. But we are
far from resting and are already working
with the next customer to develop the
most efficient, reliable, and sustainable
distribution transformer for his specific
wind offshore turbine.

To pool all our ideas and efforts for prod-

uct and process innovations, we set up
specific innovation laboratories that drive
innovations for distribution transformers
– in terms of increasing customer value,
experimenting with digitalization, and in
terms of improving our production pro-
cesses. However, our twelve factories play
a very important role in staying close to
our customers and implementing innova-
tions and local requirements.

How has digitalization shifted

the focus of the distribution
transformer market?

Digitalization is widely talked about in

the Energy Sector nowadays. Until we
launched Sensformer® in 2018, there was
no transformer available with digital fea-
tures – we were the frontrunner, and we
are shaping the market also today with
our digital innovations. But the focus
of our customers still is on the physical
product and its performance. Howev-
er, the digital features of transformers
start to play a role in the selling process.
Our customers want to understand how
digitalization can help to improve asset
performance and manage the increas-
ing complexity of the power grids. In
this respect, our customers count on
our experience and value our consul-
tancy services. We offer our customers
a complete digitalization package from
sensors through secured cloud connec-
tion to apps or even integration of the
operational data and analytics into the
customer’s IT environment.
What is the value-add for
customers of digitized
distribution transformers?
First of all, the digitalization of transform-
ers adds transparency to the current oper-
ation status. Per default, all Sensformers
are equipped with direct measurement
of oil level, top oil temperature, low volt-
age winding current, and GPS location.
Near real-time data are available anytime
and anywhere. Smart data analytics create
great customer value, e.g.:
GEAFOL® dry-type transformer from Siemens Energy
Per default, all Sensformers are equipped
with direct measurement of oil level, top oil
temperature, low voltage winding current,
and GPS location
• Increased reliability, safety, and pro- To what extent has digi­tali­
ductivity by early detection of potential zation and the industry 4.0
problems,
changed the manufacturing
• Decreased CAPEX and OPEX by pre-
ventive asset management, optimiza- of transformers at the
tion of service scheduling and avoiding Siemens Energy factories?
of unplanned outages,
• Improved climate impact by preventive The digitalization level in our factories is
detection of critical situations such as not as high as in other industries as there
oil leakages. is still a lot of specialized manual work
required – e.g., for transformer assembly.
For large distribution transformers, we Nevertheless, I strongly believe digitali-
already offer advanced features like a load zation and automation are key levers to
management app and aging prediction. drive efficiency. There is a lot of activities
This allows customers to run the distri- we are driving: Our customers are able
bution transformers under controlled to visit our factories virtually and attend
overload conditions without aging im- factory acceptance test virtually. By us-
plications for a specific time period – in- ing plant simulation software, we are
creasing performance and profit accord- able to discuss with our customers our
ing to business targets. Besides, we offer production capabilities and simulate and
our customers specific digitalization solu- optimize the production flow. We are in-
tions, including additional sensors and vesting in production equipment with
advanced analytics. higher automation grade and connecting

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 13
INTERVIEW

from the home office. For them, the pan-

demic really accelerated the work digitali-
zation, and the rapid transition was man-
aged very well by our IT staff. But factory
workers cannot stay at home. To make
work safe for them, we needed to keep in
mind the local regulations in every loca-
tion, and we worked out specific hygiene
concepts for every factory to make sure to
keep the distance between the people.

Another challenge was, of course, the

supply chain management. Our suppli-
ers had the same problems we had, and
some supplier factories were even shut
down for a period of time. We needed to
be very flexible and source from different
locations or even different vendors. With-
in the last year, we really benefited from
our global factory network and our global
supply base. We were able to shift projects
or partial projects between our factories in
different parts of the world.

A third challenge was minimizing the

contact also with customers. Digitaliza-
tion helped a lot. For example, we were
able to implement virtual factory tours
and offer our customers to virtually attend
factory acceptance tests.

I am very proud of our people. Together,

we achieved a lot in this last very challeng-
Fluid-immersed FITformer® from Siemens Energy ing year. Despite the pandemic, we were
able to finalize almost every project in
time by supporting each other.
Together, we achieved a lot in this last very
challenging year. Despite the pandemic, we What is your vision of the
distribution transformer
were able to finalize almost every project in industry in the next 10 years?
time by supporting each other What will be market and
technology drivers, and what
are the opportunities for the
key production equipment to an indus- Digital plant simulation was applied to response to these drivers?
try cloud to online monitor, predict and confirm new methods and to optimize the
further optimize process times. But not production lines and the overall factory We expect an ongoing strong increase in
only production processes are subject to layout for distribution transformers. renewable energy generation (wind and
automation and digitalization. Also, in the solar). More and more countries will join
office area, RPA’s (Robot Process Automa- What challenges have come the transition to a more sustainable ener-
tion) are taking over repetitive processes,up in the market and in gy supply. In some countries, wind farm
and intelligent dashboards are replacing operators already start to upgrade existing
the old rather manual reporting systems.
your operations due to the turbines with higher power ratings and
pandemic? How are you higher efficiency. This will lead to a steady
In a few months, we will open our new dis- handling these? demand for distribution transformers in
tribution transformer factory in Guang- the next years – especially in the field of re-
zhou, China, that will apply the highest The biggest challenge during the ongoing newable integration. Besides, the current
industry 4.0 standards. Already before the pandemic is, of course, keeping our staff trend towards sustainable products will
construction of the new factory started, safe and healthy while the factories are up continue, and customers will be especial-
an expert team evaluated new production and running. A lot of our people are work- ly interested in dry-type and ester-filled
methods and digitalization potentials. ing in front of the computer and can work transformers with lower losses. At the

14 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

Traction transformer from Siemens Energy

same time, digitalization will accelerate
with an even greater value for customers.
The trends toward decarbonization, de-
centralization, and digitalization will differ
in intensity between different parts of the
world. While Europe and North America
are challenged by the energy transition and
aging equipment, parts of Asia, Africa, the
Middle East, and Latin America are still
faced growing energy demand and mod-
ernizing grid infrastructure.
Within the worldwide distribution grid
structures, we will see a trend to more
resilience to increase availability and reli-
ability of the grids (e.g., fire protection in At Siemens Energy, we are constantly
rural areas). Also, in this regard, digitali- adapting our portfolio and production
zation will play an important role in sup- footprint to customer needs and are al-
porting the protection, maintenance, and ways at the edge of innovation, keeping
optimization of operation. in mind specific local requirements.
At Siemens Energy, we are constantly adapt-
ing our portfolio and production footprint to
customer needs and are always at the edge
of innovation, keeping in mind specific local
requirements

FITformer® WIND in the nacelle of an offshore wind turbine

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 15
TRACTION TRANSFORMERS Advertorial

ABSTRACT
Rail transportation is a fast growing
sector, and a must have component Innovative
solutions
of every train powered by the AC pow-
er system is the traction transformer.
Today’s modern traction transform-

for rolling
ers have to meet many opposite
demands and specifications like
high energy-efficiency, lightweight,
increased safety and reliability, and

stock traction
many others. Hitachi ABB Power
Grids brings the latest innovative
solutions implemented in their trac-

transformers
tion transformers portfolio.

KEYWORDS:
energy-efficiency, dry-type transform-
ers, natural-cooling, sustainability,
traction transformers

16 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Valter PORCELLATO, Paolo CASTANGIA, Hitachi ABB Power Grids

Hitachi ABB Power Grids has more than

30,000 traction transformers currently in op-
eration across the world in more than half of
the world’s trains, pioneering this technology
for over 100 years

One of the reasons for this is that the rail
sector is widely electrified and contin-
ues to electrify its operations with steady
progress. This increase in electric mo-
bility is supported by gradually reducing
the footprint of diesel power along with
innovations in electrical traction technol-
Onboard traction
transformers
The function of the onboard traction
transformers includes the conversion of
power from the overhead catenary with
high voltage levels ranging 15-25 kV to
those required by the power converter in
the traction system. Thus, driving train
performance and powering the various
auxiliary services on board (like lighting,
heating and ventilation, brakes, signaling,
and communication). Last but not least,
they provide galvanic insulation for safety
and protection purposes.
There are different types of traction trans-
formers used by railways depending on
the application: high-speed, commuter,
and regional trains (electrical multiple

E
lectrification is the key driver for a
carbon-neutral future, especially
with the rapid growth of urban-
ization. Within that context, sus-
tainable transportation and railways in
particular, will have to transform to the
electrified world swiftly.
According to IEA’s “The Future of Rail” [1]
report (January 2019), the global demand
for transport is growing fast. Given the
present trends, passenger and freight ac-
tivity will more than double by 2050.
ogies and solutions. Additional optimism
is generated by next-generation technol-
ogies like hydrogen or battery-powered
trains.
Indeed, rail transport is key in shaping the
sustainable mobility of the future. These
efforts for more sustainable transport are
also backed by the evolution of onboard
traction transformers towards more ef-
ficient solutions regarding energy con-
sumption and total cost of ownership.
units EMUs), locomotives, tram-trains,
and AC metros – each with different de-
sign constraints in terms of size, weight,
and power ratings. The traction trans-
formers can be mounted either in the
machine room of the train, on the roof, or
under the floor.
There are many associated challenges for
the train operators, as onboard traction
transformers must be prepared to with-
stand harsh operating conditions of trains

Rail is among the most energy-efficient
modes of transport for freight and pas-
sengers: rail transport accounts for only
2 % of the global energy demand of the
transport sector. Meanwhile, it accounts
for about 8 % of passenger and 7 % freight
global movements, respectively.
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
According to IEA’s “The Future of Rail” report,
the global demand for transport is growing
fast, with the estimate that the passenger and
freight activity will be more than doubled by
2050
17
TRACTION TRANSFORMERS
Natural Cooling Effilight® Traction Transformer
uses specially designed deflectors that direct
the natural airflow caused by the motion of the
train to the heat exchangers, thereby eliminat-
ing the need for motor fans
while providing high levels of reliability
and ease maintenance operations.
The train manufacturers also pose chal-
lenges associated with weight and dimen-
sions perspectives, with energy efficiency
being an important aspect of consideration.
The specific challenges for traction trans-
formers may differ depending on the ap-
plication, for example:
• For electrical multiple units (EMU):
reduced weight and space for more
equipment and passengers.
• For high-speed trains (HST): reduced
weight and higher power to run faster.
• For locomotives: weight for axle load
limitations.
Those challenges may also vary depending
on the region and the operators, with an
increased focus on the total cost of own-
ership (TCO), energy and life cycle costs.
However, there are some common re-
quirements that traction transformers are
expected to fulfil irrespective of the appli-
cation and geography. The expertise and
advice of the manufacturer are therefore
very valuable for optimizing not only the
transformer but the full traction system.
Regardless of the application, these are
some common features that are expected
from a traction transformer:
1. Lighter or lower-weight solutions.
2. Reduced dimensions of footprint.
3. Less components, so lower complexity.
4. Lower TCO - more energy efficiency,
lower energy costs or
5. lower acquisition.
Natural Cooling Effilight Traction Transform-
er eliminates the need for the electric cooling
fan, thereby reducing operating noise and en-
ergy costs with improved reliability
18
6. Reliability – high availability.
7. Ease of maintenance.
8. Easy end-of-life disposal.
9. Robustness versus the application con-
ditions.
10. Next level of safety.
Hitachi ABB Power Grids has more than
30,000 traction transformers currently in
operation across the world in more than
half of the world’s trains, pioneering this
technology for over 100 years.
Their team of experts, their competen-
cies, and experience have supported the
needs of the industry, optimizing the full
system and transformer innovation and
technology.
Two such innovative traction transform-
ers launched in the recent past are the Ef-
filight® (improved liquid-filled solution)
and the RESIBLOC® Rail (oil free / dry
solution):
• Effilight® traction transformers
enable new rail vehicle design opportu-
nities based on an innovative approach
to mechanical integration, offering en-
ergy efficiency and a lightweight solu-
tion. Effilight® was introduced to the
market at the beginning of 2016 with
a hybrid transformer concept allowing
weight reduction and increased energy
efficiency by having a smaller oil tank
around the winding while the core re-
mains on the air.
The Effilight® transformer reduces the
amount of oil needed by up to 70 per-
cent without compromising function-
ality. With this, there is a clear potential
to reduce the total weight by up to 20
percent.
®
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
This weight optimization can help train
carriages attain the maximum load per
wheelset and reduce wear.
With the weight savings achieved
through the innovative design, higher
quantities of energy-efficient materials
like copper can be used in the trans-
former, resulting in reduced energy
losses by up to 50 percent, compared
to standard solutions of similar weight.
This helps optimize energy consump-
tion and the total cost of ownership.
Since 2016 the Effilight® family has
introduced two new design concepts
which allow similar benefits. The best
solution between all the options avail-
able is selected during the transformer
and train system optimization pro-
cess.
• RESIBLOC® Rail traction trans-
formers are oil-free taking into con-
sideration eco-efficiency and safety
while providing strength, durability,
and high performance.
They are dry-type transformers to
ensure complete protection of people,
property, and the surrounding envi-
ronment. With the removal of oil and
oil-pumps, they are made with eco-ef-
ficient materials without the usage of
oil and fewer parts - which means
leakage-free operations. They are sig-
nificantly safer and more cost-effec-
tive to operate, maintain and recycle
at the end of their lifespan.
The RESIBLOC® Rail transform-
er can perform at nearly mainte-
nance-free operation levels and with
45 % reduced winding losses at the
same weight as traditional units.
They were first introduced in the
market in 2012 with a rating of 6.5 kV
and later with increased ratings.
In 2021, Hitachi ABB Power Grids is
pushing the envelope even further on
traction transformer innovations with
two new solutions, the Natural Cool-
ing Effilight ® and RESIBLOC ® Rail
transformers for ratings up to 25 kV,
which are now commercially available
as well.
Natural Cooling Effilight®
Traction Transformers
(NCETT)
Traditional traction transformers are
subject to substantial energy losses,
which causes heating of their internal
windings. Transformer insulation liq- How it works: (conceptual simulation)
uid is used to transfer heat from the
windings to an external ‘cooling sys-
tem’ with a heat exchanger. The heat-
ed liquid is then pumped into a heat
exchanger and cooled with ‘air-fans’
and subsequently passed back into the
windings as a continuous cycle. Such
an air-fan-based cooling system needs
an additional power supply and regu-
lar maintenance. Thus, causing an in-
crease in cost, maintenance and energy
consumption.

Over the years, the energy efficiency of

traction transformers improved with
the emergence of the new generation
traction transformers, which reduced
energy losses. In the Effilight® family of
traction transformers mentioned earlier,
the energy losses can be reduced, as well
as the dependence on the air-fan-based
cooling system.

After intense research and virtual sim-

ulation, it was confirmed that the nat-
ural airflow caused by the motion of
the train could be well-utilized to re-
place the air-fans of the cooling system
without major modification of the heat
exchanger technology. Moreover, re-
al-world simulations in a wind-tunnel
with a prototype traction transformer
also confirmed this.

This has been achieved through a break-

through solution, Natural Cooling Ef-
filight® Traction Transformer (NCETT).
NCETT uses specially designed de-
flectors that direct the natural airflow
caused by the motion of the train to the
heat exchangers, thereby eliminating the
need for motor fans.

Heated liquid pumped into the heat ex-

changer is cooled with natural air instead
of fans and passed back inside. The heat
exchanger is designed to work in both
directions of the motion of the train.

The NCETT can be placed on the roof

of the train as well as underframe, keep-
ing the internal windings cool without
the need for air fans in the cooling sys-
tem.

Testing and validation of the

solution

Hitachi ABB Power Grids partnered

with Hepia, a leading Swiss engineering Wind Gradient in function of height and ground roughness [2]

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 19
TRACTION TRANSFORMERS
3D rendered image of a Natural Cooling Effilight® Traction Transformer (NCETT)
Hitachi ABB Power Grids has been success-
fully developing and supplying the high-per-
formance technology of RESIBLOC® dry-type
transformers for more than 30 years
school based in Geneva, having access
to powerful simulation computers and a
large-size wind tunnel enabling 1:1 full-
scale validation.
A full-scale test with a corresponding
full scale heat exchanger and surround-
ing equipment (traction transformer,
converters, etc.) was performed in the
Hepia school’s wind tunnel to validate
the simulation results.
Three different heat exchangers, three
different frames, and two different filters
were tested to determine the best config-
uration.
20
Main benefits of NCETT:
Natural Cooling Effilight® Traction
Transformer eliminates the need for the
electric cooling fan, thereby reducing
operating noise and energy costs with
improved reliability.
Here are its main benefits:
Optimized lifecycle ownership cost
• No energy needed to power cool-
ing-motors.
• No failures modes for fan, cooling
motors and their supply system.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
• No maintenance needed for fans and
cooling dampers.
• Less frequent radiator cleaning (2
times less often).
Improved reliability and availability
• No downtime due to motors and their
supply system.
• Reliability improved by 20 %.
• FIT (failure in time) rate decreased by
20 % due to the absence of fans.
Operating noise reduction
• Elimination of fan reduces the result-
ing noise, improves overall passenger
comfort and rail experience by elimi-
nating 10-15 dB(A) of cooling system
noise.
Energy savings
• Savings in energy consumption of
cooling system.
3D rendered image of a RESIBLOC® Rail transformer with its enclosure
RESIBLOC® Rail dry-type traction
transformers up to 25 kV
Hitachi ABB Power Grids has been suc-
cessfully developing and supplying the
high-performance technology of RESI-
BLOC® dry-type transformers for more
than 30 years. These transformers meet
the highest levels of safety and reliable
power supply.
The fiberglass and epoxy resin insulation
in a RESIBLOC® transformer prevents
moisture, dirt, or aggressive environmental
influences from entering the winding and
thus protects it. RESIBLOC® transformers
are valued around the world for their ro-
bustness and durability. They prove their
quality every day under the toughest con-
ditions in a wide variety of industrial appli-
cations like on ships, on oil platforms, or in
underground construction.
These transformers display superior
mechanical strength and application
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
The RESIBLOC® Rail transformer can be as
powerful as a liquid-filled one of the same
weight, but it can achieve up to 45 % lower wind­
ing losses compared to traditional systems
capabilities under harsh climatic con- The RESIBLOC® Rail transformer can be
ditions, even at temperatures as low as as powerful as a traditional liquid filled
-60 °C. one of the same weight (same power rat-
ing), but it can achieve up to 45 % lower
RESIBLOC® Rail traction transformers winding losses compared to traditional
have been continuously developed since systems. This leads to a high degree of
their introduction, and now these trans- efficiency, which can go up to 99 %. Such
formers are made available for ratings up high efficiency can significantly reduce
to 25 kV. the total energy consumption of rail op-
erations. This is a decisive advantage for
Apart from the increased safety of rail operators since energy cost accounts
completely dry and liquid-free oper- for up to 40 % of the total cost in this in-
ations, the RESIBLOC® Rail traction dustry.
transformer further increases the op-
erational efficiency and reliability of Overall, RESIBLOC® Rail enables a
rail vehicles. reduction of total operating cost by
21
TRACTION TRANSFORMERS
15 kV RESIBLOC® Rail
25 kV RESIBLOC® Rail
22 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
up to 10 % as compared to traditional
liquid-filled traction transformers. These
transformers have also passed the vi-
bration test according to IEC 61373
and comply with the requirements of
EN 45545.
Here is a high-level comparison between
a traditional liquid-filled traction trans-
former and a 15 kV RESIBLOC® Rail
with an example of typical traction trans-
former’s data for an EMU or regional
train in a European country like Switzer-
land or Germany (left top image).
Here is another similar comparison be-
tween a traditional liquid-filled traction
transformer and a 25 kV RESIBLOC®
Rail with an example of typical traction
transformer’s data for an EMU or region-
al train in a European country like Hun-
gary or Portugal (left center image).
RESIBLOC® Rail traction
transformers offer a
high level of energy-ef-
ficiency, which, in turn,
lowers CO2 emissions
by up to 38 tons per year
per train
Both graphs show the RESIBLOC® Rail
dry traction transformer (marked as “B”
in the graph) offers substantial weight re-
duction as it is an oil-free solution when
compared to a traditional liquid-filled
traction transformer (marked as “A” in
the graph). If desired, the weight thus
saved can then be “reinvested” by in-
creasing the active material quantities
(copper, E steel, etc.) into a solution “C,”
which will have higher efficiency.
Since most of the traction transformers
used in the rail industry are liquid-filled
transformers, switching to dry-type trac-
tion transformers could have the advan-
tage of reducing the weight while achiev-
ing substantial energy savings.
RESIBLOC® Rail benefits
Sustainable all round
As stated above, RESIBLOC® Rail trac-
tion transformers offer a high level of
energy-efficiency, which, in turn, lowers
carbon dioxide (CO₂) emissions by up
to 38 tons per year per train when com-
pared to traditional liquid-filled traction
transformers (assuming two traction
transformers per train). Even after their
long service life, RESIBLOC® Rail trans-
formers still show an improved ecolog-
ical balance as they do not contain any
hazardous substances. This makes recy-
cling these transformers very easy.
Technical specifications
With RESIBLOC® Rail traction trans-
formers, manufacturers of rail vehicles
can benefit from the numerous advan-
tages of this technology to offer the
end-users better safety, reliability, and
efficiency with an economical and envi-
ronmentally friendly system.
Conclusions
Different traction transformer solutions
are designed to consume fewer resourc-
es in terms of space, weight, and energy,
thereby improving efficiency. This will
allow rail operators to reduce operation
and maintenance costs and, in turn, the
overall cost of ownership.
The recent introduction of innovative,
highly efficient liquid-filled and dry-type
traction transformers further improves
reliability and availability to support the
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Technical specifications for 15 kV, 16 2/3 Hz
Primary: 1100, secondary: 2 x 500,
Capacity / power (in kVA)
tertiary: 100
Primary:15000, secondary: 2 x 385,
Voltage (V)
tertiary: 400
Primary: 73, secondary: 2 x 1299,
Current (A)
tertiary: 250
Included for liquid – Not needed for
Heat exchanger
dry
Approximate weight (in kilograms) Dry: 4040 kg
Dimension (L x W x H) (in mm) Dry: 2150 x 1800 x 700
Standard EN 60310
Imax secondary: 2300 A
For 25 kV, 50 Hz
Capacity / power (in kVA) Primary: 800, secondary: 2 x 400
Voltage (V) Primary: 25000, secondary: 2 x 1050
Current (A) Primary: 32, secondary: 2 x 381
Heat exchanger Included for liquid – not needed for dry
Approximate weight (in kilograms) Dry: 1540 kg
Dimension (L x W x H) (in mm) Dry: 1300 x 1563 x 764
Standard EN 60310
Imax secondary: 905 A
#Can also be designed for 60 Hz frequency
Since most of the traction transformers used
in the rail industry are liquid-filled transform-
ers, switching to dry-type traction transform-
ers could have the advantage of reducing the
weight while achieving substantial energy
savings
rail industry’s move towards reducing Bibliography:
CO2 footprint and assuring a safe and
high-quality energy supply. The inno- [1] IEA’s “The Future of Rail” - https://
vative products should also be comple- www.iea.org/reports/the-future-of-rail
mented by the experience and techno-
logical expertise on the transformers to [2] D. E. J. Walshe, Wind-Excited Oscil-
fulfil the current and future needs of rail lation of Structures, Her Majesty’s Statio-
mobility by sharing valuable advice and nery Office, London, UK, 1972, On Low
consultations to optimize the entire train Altitude Flight through the Atmospheric
system. Boundary Layer (sagepub.com)
23
TECHNOLOGY Advertorial

ABSTRACT
Every industry has its own specialties, Transformers
applications
demands, and set of specifications. A
proper transformer selection is a cru-
cial task for the business operation
in terms of costs and reliability. This

for industry
article brings examples of different
transformer types specially designed
to meet the industrial application re-
quirements.

KEYWORDS:
application, industry, reliability, tech-
nology

24 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Ilario SCIAN, Suhel PATEL, Hitachi ABB Power Grids

Transformers are crucial in the power supply of

the industrial sector that will answer to the new
environments and trends set by Industry 4.0

an ongoing long-term trend of rising pro- 2. Industry needs

duction in energy-intensive subsectors
(i.e., oil & gas, chemicals, iron and steel,
cement, pulp and paper, and aluminum)
coming from the increased demand of
industrial products during the past two
decades.
The industry 4.0 transformation adds
some extra electricity demand, bringing
on top of the continuity of the supply,
which is a must, additional challenges
related to energy efficiency, power qual-
ity, decarbonization, and how industrial
equipment is operated and maintained.
Transformers are key in the power supply
of the industrial sector that will answer to
this new environment and trends set by
Industry 4.0.
This article will provide an overview of
different transformer applications for
the industry, starting from the indus-
trial transformers for energy-intensive
industries that use electrical energy as
a major resource for production, like
electric arc furnaces and high-current
rectifiers, but also converter trans-
formers or transformers feeding motor
drives or industrial processes with a few
examples in practice to illustrate the ap-
plication.
In industrial processes, it is essential to
maximize productivity and profit. Nat-
urally, the reliability and availability, and
power quality of the electricity supply are
key in achieving this. It also minimizes the
service demands of the electrical equip-
ment itself.
The capability to enable predictive main-
tenance whilst ensuring the safety of per-
sonnel, other assets, and the environment
is key for industrial operators. Various im-
portant features ensure that transformers
are gateway to achieve this productivity.
As a part of Industry 4.0, the digitalization
of transformers is becoming increasingly
valuable. While transformers have been
equipped with various sensors and mon-
itoring devices for decades, the industry is
seeing a clear evolution of the technology,
providing greater visibility of transformer
performance and health than ever before.
New sensors and on-asset intelligence en-
able advanced equipment diagnostics and
more exhaustive routine maintenance pro-
cedures. This provides enormous potential
to optimize asset management, enabling
critical maintenance decisions and life cycle
planning via powerful analytical software.

1. Electricity within the

Industry 4.0 revolution
The industry is undergoing a digital trans-
formation, with processes going beyond
automatization and increasingly reliant
on modern information technologies,
known as The “fourth industrial revolu-
tion” or Industry 4.0.

The industry sector accounted for 42 % of

the total electricity consumption world-
wide in 2018, [1] representing a 0.9 %
annual increase in energy consumption
since 2010. [2]

The growth in energy consumption in

the industry has been driven largely by

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 25
TECHNOLOGY
Digitalization in the transformer sector pro-
vides enormous potential to optimize asset
management, enabling critical maintenance
decisions and life cycle planning via power-
ful analytical software
Of course, in many cases, this can be per-
formed at a distance, from a remote con-
trol-room on-site, or potentially from a
laptop anywhere in the world.
Digitalization is an important part of
achieving a step-change in productivi-
ty, yet there are many advantages in us-
ing the latest in transformer hardware,
whether in new units or retrofitted to
existing units. Modern tap-changes
allow for more switching operations
between maintenance, whilst dry-
type bushings can increase reliability
– additionally, optimized maintenance
processes are a fast and cost-effective
solution to minimizing downtime and
resuming production.
26
3. Transformers for the
industry
Reliability is of paramount importance
in the industrial sector, as any downtime
will cost enormously high to industries.
It is expected that industrial transformers
perform with high reliability avoiding any
surprises while operating under unusually
challenging conditions like:
• high intermittent operating cycles,
• operation close to short circuit condi-
tions,
• frequently unbalanced loads,
• overvoltage stresses and harmonics,
• switching transients,
• tough environmental conditions.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
To reliably deliver the necessary power,
industrial transformers must feature a
robust design and construction. They are
the workhorses of numerous industrial
processes, whose long-term continuous
and trouble-free operation is essential to
efficient and profitable production.
Industries in need of industrial trans-
formers are oil and gas, chemicals, metal,
mining & minerals, food and beverage,
pharmaceutical, pulp & paper, water &
wastewater, technology & semiconduc-
tors, amongst other industries.
Industrial transformers are key elements in
the processes into which they are integrated as
they need to secure an uninterrupted power
supply to motors in a wide variety of applica-
tions - pumps, fans, compressors, extruders,
mixers, conveyors, crushers, grinding mills,
roller presses, kiln drives, rolling mill - and to
applications such as furnaces, smelters, data
storage systems, and subsea processes.
Industrial transformers lower the voltage
from the network to the application-level
voltage. The typical industrial transformer
range of application includes: regulating
and rectifier transformers; AC and DC
arc furnace transformers; series / current
limiting reactors; drive / converter trans-
formers; offshore, marine, and subsea
transformers; mobile transformers; plus
dry-type and liquid-filled transformers
used for distributing power to the indus-
trial processes and buildings.
The transformers tailored to industrial
applications are optimized for the total
Life Cycle Cost, including the purchase
(capital expenditure) and the operational
side (operational expenditure). They can
be equipped with digital solutions to en-
hance performance and reduce downtime
thanks to predictive maintenance algo-
rithms for full asset performance manage-
ment with the support of an experienced,
fast, and efficient transformer service.
4. Practical examples
4.1. Digital distribution transformer
to power a bauxite mine in Australia
More than 160 million metric tons of
bauxite are mined each year, with Aus-
tralia being one of the leading producers.
However, mining operations for bauxite
are very challenging, and their power sys-
tems demand special attention.
Power systems in mines must operate in
harsh environments, with dynamic pow-
er loads, cyclic and mobile operations,
and follow stringent safety requirements.
Transformers for mining operations are
uniquely designed to meet such extreme
requirements over their lifetime, which is
generally in decades.
Accordingly, when one of the world’s top
bauxite mining companies was sourc-
ing a transformer for its bauxite mine in
Australia, its key priorities were reliabili-
ty, efficiency, and robustness. After thor-
oughly analyzing their current and future
Industrial transformers are key elements in
the processes into which they are integrat-
ed as they need to secure an uninterrupted
power supply to motors in a wide variety of
applications
type transformers with TVP are already time. The stress from transient voltages is
installed for varied applications across large enough to damage magnetic equip-
the world. ment in the network, including trans-
formers, motors, pumps, and measure-
During unfavorable conditions, fast tran- ment equipment with repeated switching

™
requirements, a TXpert Enabled digital
distribution transformer was proposed to
collect and process transformer data into
sient overvoltages may be produced inside
the transformer’s windings, which gradu-
ally deteriorate the winding insulation,
over time.

The TVP technology protects transformer

actionable insights to help them to save sometimes causing permanent damage windings from any over-voltage caused by
costs, optimize operations and increase that may lead to an arcing failure over virtual current chopping and resonance
revenue.

Some of the benefits of using TXpert En-

abled digital distribution transformers are:™
• Identify failure modes that may occur
between currently scheduled inspec-
tions (e.g., DGA tests and visual in-
spections).
• Optimize maintenance schedule based
on transformer’s condition so that
high-risk transformers get the atten-
tion they deserve while maintenance
for low-risk transformers can be de-
ferred to a more opportune moment –
thus reducing maintenance costs.
• Get additional, reliable, data-driven
visibility, such as the total consumed
the life of the transformer. Data such as
unbalanced load, over / under voltage
can also be used to optimize business
processes.

4.2. Dry transformers with

Transient Voltage Protection (TVP)
helping data centers tackle the
threat from switching transients

Transformers with Transient Voltage

Protection (TVP) technology are specifi-
cally designed to resist any fast transients
overvoltage produced during switching.
They are ideal for installations where re-
liability is the number one importance.
The TVP technology works in any sys-
tem and for any switching environment. Transformers with Transient Voltage Pro-
It does not require a system study. The
solution is completely dry, does not in- tection technology are specifically designed
crease transformer dimensions, has a
lower cost, and is more effective than any
to resist any fast overvoltage transients
other solution. More than 1500 of dry- produced during switching
w w w . t ra n sfo r m e r s - m a g a z i n e . co m 27
TECHNOLOGY
World record installation comprises a sub-
sea transformer operating at 310 me-
ter-deep at Åsgard field in Norwegian terri-
torial waters, with the power of 18 MVA and
running at 120 Hz
amplification. This, in turn, prevents volt-
age peaks from ever reaching levels that
could damage the insulation in trans-
formers. Transformers with Transient
Voltage Protection (TVP) technology
eliminate switching failure modes and
provide the safest form of distribution
transformers. Using strategically placed
winding varistors, TVP technology com-
pletely eliminates the risk of damage from
28
sudden transient peaks and subsequent
downtime and repair costs.
4.3. Subsea electrification of oil and
gas installations improving the capacity
and life span of oil and gas fields
The present state of the art in subsea
power has been defined by the 310 me-
ter-deep Åsgard field in Norwegian terri-
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
torial waters. Here, the operator Equinor
(former Statoil) has installed the world’s
first wet gas seabed compressor to in-
crease pressure in the reservoir. It is es-
timated that it will extend the life of the
Brent field by the equivalent of 306 mil-
lion barrels of oil.
Subsea and topside transformers were
needed to provide power to the com-
pression system, which has a power of
18 MVA and operates at 120 Hz over a
distance of 43 kilometers from the top-
side platform. That sets a new world re-
cord for distance, voltage, and frequency
between a drive on a floating production
facility and a seabed compressor and
points the way to what will be possible
in the increasingly challenging future of
subsea electrical engineering.
4.4. Dedicated electrification
technology to improve efficiency of
aluminum smelters
Different solutions were implemented
in this example for smelter operations in
Canada, considering three main strategies
that could be implemented by aluminum
producers at the substation level:
1. Increasing DC current to provide the
ability to extend shutdowns of other
units for revamping, inspection, and
other maintenance.
2. Revamping the DC output control to
reduce the operational risk.
3. Advanced substation maintenance ser-
vices to manage the risk and keep the
desired system reliable.
All three strategies allowed the increase in DC Multiple types of specially designed trans-
current supply availability with limited in-
vestment, compared to adding new potlines. formers, shunt reactors, and other equipment
After revamping, the production increased
40 %, and the smelter was reported to be one
for the hazardous environment area were in-
of the most efficient and lowest-cost alumi- stalled in oilfields of the United Arab Emirates
num smelters in the world (2015-2016).

4.5. Digitally equipped offshore
hazardous area transformers to
maximize operation and lifetime
The Al Nasr oilfield in the Arabian Gulf is
located about 130 km off the coast of the
United Arab Emirates, close to the same
operator’s long-established Umm Shaif
field.
The electrical system consists of inter-
connected power management and pow-
er-from-shore systems. The facilities are
powered by a 132 kilovolt (kV) AC subsea
ring cable from Das Island, about 160 km
west of Abu Dhabi.
The power management system integrates
a network of transformers and switchgear
and enables operators to control this vast
electrical installation in a safe and con-
sistent manner. It includes an intelligent
asset management system for predictive
maintenance of equipment, reducing op-
erating costs, and extending its service life.
Amongst other equipment, multiple types
of transformers, shunt reactors, and asso-
ciated equipment ranging from 500 kVA
to 100 MVA were used, minimizing losses
through the lifecycle and lowering environ-
mental impact. The transformers and reac-
tors were specially designed for hazardous
areas and challenging environments.
4.6. Dry-type transformers powering
an automobile plant in China
The automobile manufacturer has a state-
of-the-art car manufacturing plant in
China powered by dry-type transformers.
The dry-type transformers were chosen
as energy-efficient, safe, environmen-
tal-friendly maintenance-free, and reli-
able solutions to power up the giant au-
tomobile plant’s operations. Hitachi ABB
Power Grids’ short lead time helped the
customer catch up with a tight project
schedule.
Bibliography
[1] IEA, World electricity final consump-
tion by sector, 2018, IEA, Paris, https://
www.iea.org/data-and-statistics/
charts/world-electricity-final-con-
sumption-by-sector-2018
[2] Tracking Industry 2020 (IEA),
https://www.iea.org/reports/track-
ing-industry-2020
[3] IEA, Key World Energy Statistics 2020,
https://www.iea.org/reports/key-world-­
energy-statistics-2020

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 29
FAILURES

Through faults tend to happen more fre-

quently in overhead systems and are often
transient in nature, resulting in the fault
being cleared in a few milliseconds by the
power system protection

Are through-faults and

slow breakers damaging
your transformer?
ABSTRACT
Much research and testing has been
focused on the question: how much life
remains in my transformer? Testing for
furans dissolved in the oil to infer the
average DP of the paper insulation on
the conductors of the windings has
been a focus for many years. While this
offers some value, furans, by their na-
ture, are volatile and can escape during
any oil processing carried out. There-
fore, it cannot be considered as a sin-
gle test to make major decisions on the
remaining life of a transformer.
There remains the need for further in-
formation on operation of a transform-
er in service to understand not just the
chemical reactions taking place inside
the tank, but what EXTERNAL events
influence the mechanical damage sus-
tained by the windings and the clamp-
ing structure.
These externally induced events include
the impact of harmonics, through-faults,
and slower than normal breaker operation.
KEYWORDS
breakers, harmonics, damage, trans-
former aging, through-faults

30 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Brian SPARLING

1. Harmonics
The increasing implementation of renew-
able energy resources connected (most of
the time) into an existing distribution or
sub-transmission network that was never
designed to handle a two-way power flow
presents an opportunity for accelerated
aging of the paper insulation surround-
ing the conductors of the windings. These
generation sources (which are often in-
verter-fed) together with geomagnetical-
ly induced currents (GIC), are two of the
factors known to introduce undesirable
harmonic frequencies into the grid and
the equipment connected to it.
increased level of condition monitoring,
from the aspect of the rate of insulation
aging and accumulation of the harmonic
content, which is now available with some
online monitoring systems.
2. Through-faults
Potential generation of through-faults
can vary greatly across short spans of any
electrical grid, and factors such as circuit
length, type (overhead, underground),
condition of protective equipment, de-
grading infrastructure, and terrain must
be considered as factors that can affect the
frequency of fault occurrences. Faults are
generally the result of a low impedance
path to the ground being introduced into
a circuit, such as dielectric failure of pro-
tection equipment or tree limbs striking
overhead lines and causing the current to
exceed the transformer’s rated base.
Underground systems are designed to
limit exposure to potential fault sources.
However, when these underground faults
do occur, they are usually persistent, caus-
ing a lockout of the protection system,
which requires a closer investigation be-
fore power can be restored. These faults

A recent article from Transformers Maga-

zine, Volume 7, Issue 2, April 2020, Man-
aging Existing Transformers in the
Grid Transition [1], goes into deeper
details, with case histories presented and
explained. One of the items mentioned
is a suggestion that managing existing
units in these applications will require an
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
The amount of energy flowing through the
transformer during through faults places
excessive mechanical and thermal stresses
on the core and coil assembly of the affect-
ed transformer
31
FAILURES
tend to happen more frequently in over-
head systems and are often transient in
nature, resulting in the fault being cleared
in a few milliseconds by the power system
protection.
The amount of energy flowing through
the transformer (I2T) for the duration of
these transient faults places excessive me-
It is difficult to quantify the level of cumu-
lative I2T a specific transformer can sustain
and remain fit for service due to the wide
range of variables that must be considered
when performing the assessment
Figure 1. Seven cycles 60 Hz at four times nominal RMS
Figure 2. Example of fault counting on the transformer monitor
32
chanical and thermal stresses on the core
and coil assembly of the affected trans-
former. However, due to the power-pro-
tection system operating effectively, little
consideration is given to the weakening of
the transformers clamping system or any
core deformation that may have occurred
because of the increased electromagnetic
force.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
The frequency at which these events occur
can have an aggregated effect (cumula-
tive I2T) on the transformer’s mechanical
structure, ultimately resulting in a de-
crease of the transformer’s fault withstand
capability. The presence of these cumula-
tive effects is problematic in that they are
not easily detected using routine main-
tenance testing such as power factor and
dissolved gas or furan analysis but would
require more in-depth testing procedures
such as sweep frequency response analysis
or winding induction testing.
Nor are existing vintage electro-mechan-
ical relays much help to understand the
amount and duration of through faults.
They react as designed to disconnect a
load (transformer, generator, etc.) in a pre-
set amount of time. They do not have the
capability of modern digital relays that
can capture the events. However, many
existing substations have not had these re-
lays replaced with digital type protection
relays, and even when the digital relays are
present, asset managers are often not able
to access the quantitative data required to
evaluate the damage.
Fig. 1 is an example of a seven-cycle fault
with an RMS at four times nominal cap-
tured and displayed via a through-fault
and harmonics card on a transformer
monitoring system web page.
Though this graph illustrates a seven-cycle
fault, power-protection systems generally
require a minimum of three cycles to clear
excessive fault current. The fault detected
was on a long feeder with low fault levels
in the area. None the less it provides a re-
cord of faults on the transformer.
It is difficult to quantify the level of cumu-
lative I2T a specific transformer can sustain
and remain fit for service due to the wide
range of variables that must be considered
when performing the assessment. The
knowledge that a particular transformer
experienced excessive through-fault levels
could trigger a decision to perform more
in-depth testing such as a sweep frequen-
cy response analysis.
This would allow for slight deformations
of the core and coil assembly to be iden-
tified, which would be undetectable by
more routine testing methods. Through-
faults are a common occurrence on most
electrical systems, yet the cumulative ef-
fects of these events, which can reduce
the withstand capability of a transform-
er’s mechanical systems, are rarely taken
into consideration when determining the
overall equipment condition.
The data provided by the transform-
er monitoring system (see Fig. 2) with
through-fault and harmonics monitor-
ing raises awareness of through-fault and
harmonic distortion’s cumulative values,
allowing for proactive testing and main-
tenance to be implemented before trans-
former failure occurs.
this method improves the detection of
breakers for which the interrupting time
has exceeded the acceptable rating for that
equipment.
This is often missed with routine main-
tenance, as any operation of the circuit
breaker prior to recorded testing can re-
sult in misleading timing results, as the
initial operation (generally referred to as
the First Trip) tends to break loose com-
ponents of the lubrication and bearings,
thereby making the circuit breaker look as
though it is functioning within operation-
al parameters.
This misinterpretation of the circuit break-
er’s performance is critical as slow inter-
rupting times greatly increase the duration
to which transformers are exposed to ex-
cessive fault current, effectively aging the
transformer prematurely as cumulative
fault values are a product of both current
amplitude and duration. Increases in either
of these values place excessive thermal and
mechanical wear on the transformer.

3. Increased risk due to slow

operation of circuit breakers Circuit breaker maintenance is a highly crit-
A key and mandatory component of any
electrical circuit is the circuit breaker. Cir-
ical task in safeguarding the reliability and
cuit breakers are relied upon to protect safety of any power system
power systems from abnormal electrical
conditions. They are found in the power
system from distribution substations to
high voltage transmission systems. They
provide protection against fault current
and are also used for transferring loads
and controlling capacitor banks and other
VAR compensating equipment, ensuring
steady power factor and system reliability.

Circuit breaker maintenance is a highly

critical task in safeguarding the reliability
and safety of any power system. Ensuring
they will perform their function requires
periodic inspections and testing. The is-
sue has always been when to perform this
necessary function. It usually requires an
outage to test circuit breaker functional-
ity, and often these outages are not easily
made available. Figure 3. Percentage of failure modes

The circuit breaker failures can be broken

down into five categories: mechanical, low
SF6 pressure or loss of stored energy in
pneumatic and hydraulic operators, trip
coil problems, and bushing failure. The
graph in Fig. 3 relates the percentages.

4. Limiting through-fault
exposure to transformers and
other equipment

Online circuit breaker monitoring has

proven to be highly effective at detecting
operational abnormalities that may often
go unobserved through traditional main-
tenance testing. Interrupting time is one
of the most critical components of circuit
breaker operation that is more easily ob-
served using online monitoring. Using Figure 4. Breaker slow opening time difference

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 33
FAILURES
Figure 5. Complete failure of transformer and breaker
Online circuit breaker monitoring has prov-
en to be highly effective at detecting oper-
ational abnormalities that may often go un-
observed through traditional maintenance
testing
Fig. 4 provides an illustration of a circuit
breaker that is beginning to demonstrate
slow opening times. While this is a minor
failure, as the breaker would still be able to
perform its primary job of clearing the fault,
without interventive maintenance, it is like-
ly that breaker functionality will degrade to
the point of causing a system event.
• The first trip exceeds specified limits
for this circuit breaker.
• The second trip is 68 ms faster than the
first trip (an indicator of lubrication
degradation).
• Noisy signal at the auxiliary contact
operation indicates a potential prob-
lem developing with auxiliary contacts.
5. A situation of an inoperable
breaker, and the result
An example of the failure to detect the
slowing of circuit breakers rated inter-
rupting times during time-based inspec-
tions and testing could eventually lead to
The failure of the high-side transmission
breaker operation may lead to the complete
failure of a transformer and with the fire in
the control room
34
lubrication and wear of the mechanism
components, where they become degrad-
ed to the point that the breaker is rendered
inoperable.
The photographs in Fig. 5 illustrate a com-
plete failure of a transformer and the re-
sulting fire in the control room due to a
high-side transmission breaker failing to
operate.
During this event, the fault is thought to
have occurred somewhere on the low-side
bus, between the bank breaker and the
transformer. The relay for the high-side
breaker issued a trip signal to the circuit
breaker, which failed to open.
Due to the distance between stations, fault
levels were too low to cause a transmission
breaker trip at the upstream station, leav-
ing the fault present on the transformer
for over six minutes and ultimately re-
sulting in the transformer failure and fire
in the control house. The misoperation
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
of the circuit breaker was determined to
be caused by a seized main bearing of the
operating mechanism, despite this circuit
breaker having passed inspection four
years before this event occurred.
6. Conclusion
Measuring and tracking the harmon-
ic content of both voltage and current is
recommended for existing transformers
connected to DER where inverters are in
place. The Loading guide IEC 60076-1/
2012 includes the definition of normal
service conditions in section 4.2 [3].
The wave shape of the supply voltage:
A sinusoidal supply voltage with a total
harmonic content not exceeding 5 % and
an even harmonic content not exceeding
1 %.
Load current harmonic content:
The total harmonic content of the load
current not exceeding 5 % of the rated
current.
Transformers can operate at rated cur-
rent without excessive loss of life with a
current harmonic content of less than
5 %. However, it should be noted that the
temperature rise will increase for any har-
monic loading and may exceed the rated
temperature rise. This will have the im-
pact of accelerating the aging rate of the
paper insulation on the conductors.
Due to aging equipment and decreased
operating budgets, effective circuit break-
er management by means of offline testing
and time-based maintenance has proven
to be increasingly ineffective. The impact
usually results in increased clearing times
or not at all in some cases of the associat-
ed breakers resulting in a greater number
of unplanned outages and the premature
aging or failure of substation equipment,
including transformers, due to higher lev-
els of cumulative through-fault exposure.
Through the utilisation of online mon-
itoring, many of the failure conditions
common to circuit breaker failure could
be detected before an event occurs. This
allows maintenance resources to be di-
rected towards preventing the occurrence
of substation events as opposed to re-
sponding to unplanned emergency out-
ages, allowing for extended equipment
service life and a reduced impact on the
transformer aging.
Acknowledgements
The author wishes to express his gratitude
for the technical input of Chris Rutledge
of Dynamic Ratings.
Bibliography
[1] Brian Sparling, Managing existing
transformers in the grid transition,
Transformers Magazine, Volume 7, Issue
2, 2020
[2] Chris Rutledge, Breaker monitor-
ing: improving reliability through di-
rected maintenance, TechCon North
America, February 2020
[3] Constantin Moldoveanu, Dr. Ing.,
Considerations on the feasibility of
certain technical provisions of IEC
60076-1/2012 standard
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Measuring and tracking the harmonic con-
tent of both voltage and current is recom-
mended for existing transformers connect-
ed to DER where inverters are in place
Authors
Brian D. Sparling, a Senior Member of IEEE, is a
Senior Technical Advisor with Dynamic Ratings.
Brian has over twenty years of experience in the field
of power and distribution transformers. For the last
28 years, he has been involved in all aspects of online
monitoring, diagnostics, and condition assessment of
power transformers. He has authored and co-authored
more than 33 technical papers on several topics dealing
with the monitoring and diagnostics of transformers. He has worked on
many guides and standards with the Canadian Electricity Association, IEEE
Transformers Committee and, the CIGRÉ A2 Transformer committee.
35
INTERVIEW

36 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

At Prolec, we want to be recognized as the most reliable strategic partner
for innovative and sustainable solutions in the transformation and delivery
of electrical energy. It is time to innovate with cutting-edge products and
solutions in the generation, transmission and distribution of electric power
RICARDO SUAREZ
CEO of Prolec
The structure of Prolec
At Prolec, we want to be recognized as the
most reliable strategic partner for innova-
tive and sustainable solutions in the trans-
formation and delivery of electrical energy
in the Americas. Our products are already
present in 35 countries. We will continue
incorporating new solutions in our portfo-
lio with the firm commitment to contrib-
ute to the progress and well-being of soci-
ety. It is time to innovate with cutting-edge
products and solutions, transmission and
distribution of electric power. We have six
business units and one research and devel-
opment center to serve the entire American
continent (three in Prolec MX, Celeco MX,
Prolec USA, Prolec Brazil and Prolec Labs).
• Prolec GE, with a range of transformers
internationally recognized for its proven
quality and reliable performance, always
seeking to generate value in the market
through solutions we design and im-
plement according to the specific needs
of our clients, through cutting-edge
technology and in collaboration with
our strategic allies. We have facilities in
Mexico, USA and Brazil.
• Prolec Celeco leaders in the design and
manufacture of ceramic and polymer
components and insulation for trans-
formers. We serve Utilities and OEM's
in the T-MEC market with cutting-edge
products such as circuit breakers, nozzles,
lightning rods and other accessories.
• Prolec Energy Solutions is the ideal
vehicle to offer our current, new, and
potential customers the best com-
prehensive solutions aligned to the
challenges of their current and future
needs. At Prolec Energy Solutions, we
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
develop the best responses to the chal-
lenges of the industry.
• Prolec Labs is our research and devel-
opment (R&D) center where we carry
out validation and development tests of
digital and power electronics systems;
magnetic materials for transformers
and insulating materials, liquid and sol-
id; virtual simulation and prototyping.
We are also experts in validation testing
of high temperature insulation systems.
Market segments
Our clients are mainly energy companies
(utilities), renewable and conventional
generation industry, electrical construc-
tion companies (EPC’s), industrial and
commercial segment, as well as coopera-
tives and municipalities. The objective we
have for all our clients is to offer the most
reliable energy supply for its users.
We are leaders in the renewable ener-
gy industry (wind and solar) with more
than 58 GW installed. Our company has
the highest market participation in this
market in North America. We offer a
complete product scope with three-phase
pad-mounted transformers that fit the
needs of renewable energy generation
from solar and wind power step-ups to
collector transformers, providing flexibil-
ity and adaptability. Our dedicated cus-
tomer service is our greatest strength in
a world where transactions, rigidity and
routines override the personal touch ev-
eryone needs. Examples of success stories
in renewable sources:
• Wind: We have recently jointly de-
veloped and launched a transformer
adapted to the new generations of GE’s
WT20, Y 3X wind turbine models.
• Solar: We have jointly developed con-
figurations that fit specific conditions
of solar farm types to reduce CAPEX
and OPEX of photovoltaic generation
projects.
• Safe Harbor model for renewable
energy projects: Providing the nec-
essary assistance to our clients with
options on the “Safe Harbor” compo-
nents of partial construction, storage
methods, historical reporting and
support during all stages of renewable
projects.
Long-term strategic
partnerships
In North America, we are one of the most
important players in the market with
the main utilities, where we have devel-
oped long-term strategic partnerships.
Additionally, we have a relevant partic-
ipation in the development of electrical
infrastructure projects for industrial
and commercial applications. In South
America, we participate in the devel-
opment of projects with public energy
companies, engineering firms develop-
ing turnkey packages, as well as private
sector projects. It is time to innovate with
cutting-edge products and solutions in
the generation, transmission and distri-
bution of electric power. Our commit-
ment is to work as close as possible with
our customers by offering value engi-
neering services to make them successful
and at the same time enabling communi-
cation channels to achieve an outstand-
ing execution of projects on which we
will work together.
37
INTERVIEW

Regardless of the application, all Prolec providing flexibility and reliability to

transformers are designed and manufactured
to the highest standards, combined with high
quality materials and components, providing
superior performance for our customers
It is important to highlight the reasons for
our partnerships.
1. to honor our commitments to our cus-
tomers by managing our value chain
with excellence,
2. maintain the competitiveness of our offer,
with cutting-edge designs and attributes,
3. to continue promoting our innovation
process, seeking to achieve common
goals through co-creation with our
partners, with the purpose of incorpo-
rating new solutions for the delivery of
electric energy to our portfolio.
This is how we have developed long-term
relationships with our customers, allow-
ing us to collaborate with added value,
always seeking to add greater reliability
to the electric grid while ensuring the
well-being of the users.
Our main domestic customers for power
transformers are Mexican government
entities, such as CFE, and / or contractors
for public works. Other domestic cus-
tomers include industrial companies with
expansion projects and renewable energy
developers (wind and solar).
Among our main customers in North
America, we have utility companies such
as American Electric Power, Florida Pow-
er & Light, Duke Energy, Pacific Corp., as
well as commercial partners for the deliv-
ery of our solutions, such as Texas Electric
Cooperatives, TMEIC, Anixter, Stuart
Irby, among others.
Integrated Solutions
We offer a full range of integrated solu-
tions that complement our products,
our customers’ projects. Our task is also
to assist our customers throughout the
entire project cycle from engineering de-
velopment and product manufacturing
to providing services such as transporta-
tion, installation, electrical testing, field
services, spare parts, and training. We
manufacture transformers for all power
generation, transmission and distribu-
tion applications. The applications range
from conventional and renewable ener-
gy generating plants, primary and sec-
ondary substations to transmission and
distribution lines that carry electricity to
end consumers.
• Generation: For renewable energy,
we have step-up pad-mount trans-
formers for wind and solar gener-
ation, as well as collector and GSU
units.
• Transmission: For power transmis-
sion systems we have a line of auto-
transformers, phase shifters, HVDC
regulators, reactors, transformers for
FACTS (flexible AC transmission sys-
tem) applications such as SVC (static
var compensator) and VFT (variable
frequency transformer), which are
necessary to reduce / increase the
voltages used in transmission lines

To offer this value proposition, we must

be very agile in adapting our operations to
meet our product delivery commitments,
which is why we have worked to strengthen
our strategic alliances throughout our value
chain to respond to the needs of the market.
In terms of innovation and development, we
have an important network of partnerships
with universities in Mexico, such as UANL
and ITESM in Monterrey. With universities
in the United States such as MIT, Georgia
Tech and Stanford, we are currently work-
ing on projects for a more efficient energy
delivery and finding a way to increase grid
reliability, among other things.

In the same way, we also collaborate with

specialized domestic and international re-
search centers, industry experts, customers
and suppliers. This is how we have devel-
oped new simulation models, materials and
components that differentiate our solutions.

A word for our business partners: we are

more focused than ever on ensuring your
complete satisfaction. We have the talent
and experience to keep our solutions at
the forefront, as market dynamics dictate.

38 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 and the interconnection of systems
operating different voltage classes.
• Distribution: Our range of sin-
gle-phase and three-phase dis-
tribution transformers includes
pole-mounted, pad-mounted, voltage
regulators, network transformers,
submersibles, substations and power
stations for use in the electrical distri-
bution system.
Regardless of the application, all Prolec
transformers are designed and manufac-
tured to the highest standards, combined
with high quality materials and compo-
nents, providing superior performance
for our customers.
At Prolec Celeco, we manufacture ce-
ramic and polymer components and in-
sulation for transformers, such as circuit
breakers, bushings, arresters and acces-
sories.
Continuous innovation
supported by the TPS
We are a company dedicated to contin-
uous innovation. Our human talent has
experience for working under our cul-
ture of operational excellence in all our
processes, not only relating to manufac-
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Prolec will continue co-creating new solu-
tions with the firm commitment to contrib-
ute to the progress and welfare of society
turing, but also including transaction-
al processes by incorporating our best
practices and making it the DNA of all
our operations.
These best practices are supported by the
TPS (Toyota Production System) that al-
lows us to maintain lean operations under
a synchronized production scheme.
Prolec is recognized for the quality of prod-
ucts, as well as for the competitiveness of
solutions, seeking to strengthen ties with
our partners throughout the value chain.
Always seeking improvement, we are
constantly working on adding attributes
and functionalities to our products and
developing complementary solutions that
allow our customers to have relevant in-
formation for their decision making.
We will continue to promote technolog-
ical development and innovation, to be
always up to date with the main techno-
logical trends in our industry and seek to
be a pioneer in some of them.
Prolec, together with its subsidiaries, is a
very robust company that covers what is
necessary for energy to get where it needs
to go, offering solutions tailored to the
needs of our customers, not only as man-
ufacturers of transformers, but also as cre-
ators of a range of products and services
that offer comprehensive solutions.
We have developed high efficiency and
environmentally friendly products b­ e-
cause our commitment to the protection
and care of the environment is a priority.
Renewed purpose
Today we have a renewed purpose, keep-
ing us on the path to excellence and as-
piring to be an important agent of change
that offers solutions that help the positive
transformation of tomorrow, our new im-
age is consistent with this renewed pur-
pose.
Our new logo and brand design (rebrand-
ing) is not just a makeover. This transfor-
mation means a memorable moment of
renewal for each one of us. As an excep-
tional team, we at Prolec are convinced
that our ultimate goals are related to the
daily life of our communities and society
that is transforming every day, which ur-
gently needs innovative and more effective
solutions for a better present and a brighter
future. Reconstructing our visual identity
is a consequence of the transformation we
are undergoing as a company.
An example is our smart transformer
solution, where we offer our customers
the ability to detect transformer faults in
the field and communicate in real time, in
order to make the user’s operating costs
more efficient by monitoring their assets
at all times.
Another of our solutions is our VG-100®
natural ester dielectric fluid, developed by
Prolec as an environmentally friendly al-
ternative for use in both new and retrofill
transformers.
39
INTERVIEW
We are a company dedicated to continuous
innovation, which, supported by the Toyota
Production System, allows us to maintain
lean operations under a synchronized pro-
duction scheme
This fluid is 100% natural and biodegrad-
able without synthetic antioxidants, ad-
ditives or toxic components derived from
petroleum, complying with international
standards such as: ASTM & IEEE, in ad-
dition to being certified by Factory Mutual
(FM) and Underwriters Laboratories (UL).
Examples such as these are what motivate
us to continue collaborating with our part-
ners to continue transforming ourselves to
offer solutions to tomorrow’s challenges.
The world is changing and so
are we
We must adapt in an agile way to be able
to support our partners in the challenges
they face on a daily basis and collaborate
in the development of solutions for to-
morrow’s challenges.
We know that maintaining responsible
and committed leadership in a changing
world, will only be possible by providing
excellence in our products and services
40
and developing the best comprehensive
solutions that positively impact all the
communities in which we are present.
An innovative way of identifying us and
properly communicating that highlights
our reason to create a better future to-
gether, based on the values that define
us as Prolec, supported by the four key
elements that back up our evolution: cus-
tomer focus, operational excellence, inno-
vation, and our social responsibility based
in a solid humanistic culture.
Prolec is committed to innovation and
a responsible and ethical lifestyle that is
put into practice in everything we do. We
are proud that our daily work becomes
an engine of life, a source of work and
movement to energize the world.
The company is increasingly experienc-
ing new challenges in the market as we
seek to incorporate greater control over
the assets that allow us to increase the re-
liability of the electrical grid.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
Entrepreneurship roots
At the beginning of the second half of the
20th century, a new generation of entrepre-
neurs appeared in Nuevo León, born after
the Mexican Revolution ended. Mr. Jorge L.
Garza belonged to this generation, the soul
of the foundation of Conductores Monter-
rey, the origin of what today is Xignux, an
industrial consortium of which PROLEC
is a member. Mr. Garza had acquired ex-
perience in the commercialization and in-
stallation of electrical products in his first
job at Constructora Eléctrica (later EGZA),
so he decided to start manufacturing the
same cables he had sold. In 1957, with the
instrumental support of his father, Mr. Ro-
mulo Garza, and fifteen other employees,
he launched operations for a bare wire and
low voltage cable factory.
PROLEC
Prolec began its operations in 1969,
with the acquisition of a small trans-
former plant called Ingeniería Eléctri-
ca Industrial (IEI), located in Mexico
City. The products manufactured by
this company were electrical distribu-
tion transformers and, occasionally,
medium power transformers. Once this
company was acquired, we decided to
seek technical assistance from outside
of Mexico in order to participate in the
market for higher capacity equipment.
In 1971, we introduced the CM Trans-
former line in the Mexican domestic
market, confirming the participation of
Conductores Monterrey in the field of
Responsible and committed leadership of-
electrical transformers. We presented fers not only excellence in our products and
different types, voltages and capacities
of transformers, as well as our tech- services, but also comprehensive solutions
nological partner, McGraw Edison. In that positively impact all the communities
1979, the company moved to the state of
Nuevo León, in northwestern Mexico, where we are present
to a new plant.

scope of the joint venture with integration ulators, specialty shunt reactors, HVDC
Total Quality Culture
of two new international business units: and phase-shifting transformers.
Always committed to offering the highest one located in Louisiana, USA and the
level of products and services, we started other in Canoas, Brazil. The acquisition This addition also has allowed us to expand
the then popular Total Quality Culture of these businesses marked a new stage our market and serve the entire American
in the company. The initial steps to create of important growth for the company, continent with our solutions. Today more
this culture were taken with the support as well as incorporation of new products than ever, we must keep moving forward as
and advice of the world’s most renowned such as network transformers, voltage reg- the world is changing, and so are we.
and prestigious institution in the field, the
Japanese Union of Scientists and Engi-
neers (JUSE), along with the assistance of
the Quality Center of the “TEC de Mon-
terrey” university, which aided the compa-
ny in this process.

Prolec GE
With the ultimate goal of expanding our
market share in Mexico and in the Unit-
ed States from 1990 until 1995, our com-
pany underwent a process of expansion
and modernization. It was in 1995 that
Prolec GE was formed—a joint venture
between Xignux, a Mexican consortium
with important participation in the
electrical, infrastructure and food sec-
tors, and General Electric (GE), a world
leader in different sectors of industry
and services. Although we were already
exporting, this alliance expanded our
participation in international markets,
mainly in the Americas. Initially, this
joint venture included only the pow-
er transformer business, but thanks to
excellent results this joint venture con-
tinued to grow. A year later, in 1996,
residential transformers were included,
and three years later the scope was ex-
tended to industrial transformers, while
by 2003 three-phase pad-mount trans-
formers were already a part of the joint
venture. In 2007, in view of the grow-
ing market share of extra-high voltage
transformers, we invested in a new line
for this type of equipment, dedicating a
new building for this purpose.

Portfolio expansion
In May 2020, after 25 years of a successful
relationship, we once again expanded the

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 41
INTERVIEW

Prolec today
With over 50 years of industry experience,
our products are currently installed in
more than 35 countries. Prolec is the leader
in the Mexican market as well as one of the
biggest and most competitive manufactur-
ers in North and Central America. Prolec
headquarters are located in Monterrey,
Nuevo León, as is its main transformer
plant, Prolec, the largest in the Americas.
And as stated above, we own two inter-
national manufacturing facilities, one in
Shreveport, Louisiana (USA) and the other
in Canoas, Brazil. Additionally, Prolec has
two plants in Mexico dedicated to manu-
facturing insulators for the electrical indus-
try, with ceramic and polymer products.

We have approximately 6,000 employees

at our facilities in Mexico, plus approxi-
mately 800 people in PGE USA and PGE
Brazil plants.

Prolec is a company renowned for giving

its employees a job with a value based on
four pillars: culture, leadership, environ-
ment and well-being. In each of them,
we have worked to offer our employees
benefits that contribute to the work-life
balance. We have programs in place to
develop the talent of our people. In addi-
tion, we have two important distinctions
granted by the Ministry of Labor; we are a
family-responsible, diverse, and inclusive
company. All this undoubtedly shapes the
experience of being a Prolec partner, gen-
erating loyalty; and it makes us an appeal-
ing employer.

42 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Ricardo Suarez
For the last 6 years, Ricardo Suarez
has been the CEO of Prolec, a com-
pany dedicated to the transformation
and delivery of electrical energy and
one of the companies in Xignux, an
important conglomerate of Mexican
origin, which provides solutions in two
large industries: electrical energy and
food.
He began his career in the manufac-
turing industry 30 years ago by con-
tributing with his talent to important
companies in the region such as Con-
sorcio Papelero Mexicano, COPAMEX,
and Cigarrera La Moderna, a company
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
that was later acquired by BAT (British
American Tabaco). He was very suc-
cessful in areas like purchasing, sup-
plies and sales.
In 1998 he started at Celeco, anoth-
er Xignux company that designs and
manufactures components for trans-
formers and is also a part of Prolec.
This is the point at which his career
takes off, when he is transferred to
Viakable, yet another of the compa-
nies of the same group in which he
held leadership positions, until he be-
came the general director of the Mag-
net Wire Unit in Sao Marco, Brazil.
He is currently an affiliate member and
partner at NEMA (National Electrical
Manufacturer Association).
He graduated as a Mechanical
Engineer from the I.T.E.S.M (Instituto
Tecnológico de Estudios Superiores de
Monterrey) and continued his master’s
degree in business administration at
the IESE Business School, University of
Navarra. He has completed diplomas
in TQC (Total Quality Control), at
JUSE (Union of Japanese Scientists
& Engineers), as well as marketing,
operations and synchronization in the
city of Monterrey, Mexico.
43
TESTING

ABSTRACT
To meet an ever-demanding market
for reliable insulation condition
analysers, Megger is proud to present
the latest Dielectric Frequency
Response test instrument in the
IDAX family: IDAX 322. It is a robust
hand-carried instrument that has
many features that enable efficient
diagnostic and efficient use of the
testing time.

KEYWORDS
diagnostics, dielectric frequency
response, HV insulation, bushing,
instrument transformer, testing

44 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021


The Megger
IDAX 322
Achieving DFR success for all applications
The Megger IDAX 322 is operated by an easy-to-use software with
assessment guidance informed by international standards and over
25 years of field experience with DFR technology
T
o meet an ever-demanding mar-
ket for reliable insulation condi-
tion analysers, Megger is proud
to present the latest Dielectric
Frequency Response (DFR) test instru-
ment in the IDAX family: IDAX 322.
Since 1997, when the first portable DFR
instrument, the ‘IDA’, was brought to
the field, the analysis of the dielectric re-
sponse of different insulation materials in
the frequency domain has reached several
applications. Among these, the most suc-
cessful to date in the power industry is the
measure of power transformer insulation
systems.
To replicate this success for other critical
components in the power grid, a group
of internationally renowned specialists at
Megger identified the ‘must-have’ require-
ments for hardware and software features
and technical capabilities in an optimised
DFR test instrument. For example, one
named capability was a sufficient test volt-
age. Given the comparatively low capac-
itance of components such as bushings
and current transformers (CTs), a higher
test voltage than a DFR test instrument’s
typical 140 V output is necessary to im-
prove the signal-to-noise ratio and allow
for their accurate measurement, especially
in noisy environments.
Megger’s IDAX 322 has been designed
to ease work and overcome challenges
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
encountered in the field. The instrument
can, of course, be used in a laboratory en-
vironment, but the 322’s state-of-the-art
design and features practically eliminate
the difficulties of achieving reliable, ac-
curate, and fast diagnosis of high voltage
(HV) insulation systems in the field with
its industry-leading 1.4 kV RMS output.
IDAX 322 is optimised for DFR testing of
HV and EHV (extra high voltage) bush-
ings, CTs, and voltage transformers (VTs)
while working equally well for power
transformers.
IDAX 322 is ready for the most demand-
ing field conditions. The instrument is
operated by an easy-to-use software with
assessment guidance informed by inter-
national standards and over 25 years of
field experience with DFR technology.
1. Introduction of DFR
Dielectric Frequency Response (DFR)
is a measurement technique in which
capacitance and losses (dissipation fac-
tor (% DF), tan delta (% TD), or power
factor (% PF)) are measured over a wide
frequency range. Typical DFR test fre-
quencies are 1 kHz to 1 mHz for mois-
ture assessment of power transformers
and 1 kHz to 10 mHz (a 5-minute test)
for other applications, such as CT, VT,
and bushing assessments. These power
grid components work under a variety
of thermal, electrical, and mechanical
Advertorial
stresses, which contribute to the deg-
radation and ageing of their insulation
systems. The detrimental effects are of-
ten imperceptible by basic testing tech-
niques, such as line-frequency % DF or
% PF, so operations and asset managers
must rely on advanced testing techniques
such as DFR to identify proactive actions
for extending the service life of these crit-
ical-power-grid components.
With the introduction of DFR as a corner-
stone of advanced field diagnostics proce-
dures, critical details about the condition
of the insulation systems began to emerge.
DFR’s evolution in the transformer indus-
try is ongoing. The DFR technique has
been described in many technical docu-
ments and is recognised in several inter-
national standards. Today, Megger is the
leader in the ‘field’ DFR technology, and
IDAX users can be found across a wide
spectrum in the power industry, includ-
ing OEMs, academia, utilities, and service
companies.
1.1. DFR applications
“Originally, Megger’s IDAX insula-
tion analyser was used for MV ca-
bles with XLPE and EPR insulation.
Since 1997, the use of HV DFR for
insulation diagnostics of cable insu-
lation was well investigated. IDAX
enabled many researchers across the
world (both in academia and indus-
45
 TESTING
The EMI depends on several different
parameters in the substation, such as
substation voltage level and distance
from disturbance
try) to use DFR as a tool in their re-
search, resulting in new applications
for IDAX where the most prominent
became oil-paper systems where
high voltages were not required
for condition assessment” explains
Dr. Peter Werelius – Megger’s Senior
Applications Specialist and designer
of the first IDA instrument.
A power transformer’s interwinding in-
sulation became the most common DFR
test object. Accurate measurement of
this insulation system’s unique dielec-
tric response facilitates a determination
of the percentage of residual moisture
concentration in the solid insulation as
well as the conductivity of the liquid insu-
lation.
DFR became essential for the definitive
assessment of oil-paper insulation in
Figure 1. IDAX 322 and its new accessories for HV bushing testing
46
transformers, but the evolution of ap-
plications did not stop there. The work
presented by CIGRE regarding reliabil-
ity analysis of power transformers and
bushings evidenced the need to analyse
not only the main transformer insula-
tion but also the insulation of bushings
and instrument transformers in the net-
work. HV and EHV bushings age as any
other insulation system, but their mea-
surement presents different challenges
than those for power transformers. The
measured current of a low capacitance
specimen is quite low and, particularly at
frequencies below 1 Hz, is very sensitive
to electromagnetic interference (EMI).
Megger’s DFR database indicates that in
operational HV substations, the line-fre-
quency AC interference ranges between
0 – 100 µA, and DC interference ranges
between 0 – 50 nA [1]. Interference in the
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
substation cannot be controlled, but its ef-
fect can be minimised, foremost by using
a test instrument that measures entirely
in the frequency domain. Time-domain
(DC) measurements are much more sus-
ceptible to EMI bias. Secondly, a higher
test voltage can be used to improve the
signal-to-noise ratio (SNR).
The negative effect of EMI has been well
documented while testing instrument
transformers in the field. Academic re-
search carried out at both the KHT Royal
Institute of Technology in Sweden and
the Tennessee Technological University
(TTU) in the USA provided some of the
very first DFR test results on instrument
transformers. Since then, a great amount
of work has been implemented to improve
high voltage CT, VT, and capacitive volt-
age transformer (CVT) analyses.
“Megger presented a solution to the
EMI problem several years ago with
VAX020, a high voltage amplifi-
er that allowed the output signal of
140 V RMS from the IDAX to become
10 times greater, stepping up the test
voltage signal to 1.4 kV RMS” adds
Dr. Roberts Neimanis – Megger’s
DFR Product Manager.
2. Effective testing with
reliable results
The IDAX 322 is a combination of both
the IDAX300S and VAX020, built into a
lightweight 13 kg (28 lbs), hand-carried
instrument, making testing very man-
ageable for the user. Available testing
time is limited in a field environment, so
performing an error-free, representative,
and repeatable measurement efficiently
is paramount. Incorrect or inadequate
test connections are often to blame for
test results that prompt the recommen-
dation to repeat the test. While the soft-
ware aids with correct lead placement,
the IDAX 322 arrives with new accesso-
ries (Fig. 1) that minimise the chances for
poor connections of the test leads to the
test specimen.
EMI, of course, is the most prevalent
source of frustration when trying to access
the DFR of a test object. The EMI depends
on several different parameters in the sub-
station, such as substation voltage level
and distance from disturbance. IDAX 322
provides at least 10 times higher SNR as
compared to any other DFR instrument
currently available. Therefore, the instru-
ment guarantees the effective utilisation
of valuable testing time in the field. A field
example shown in Fig. 2 illustrates the
benefit of the 1.4 kV output that IDAX
322 offers.
3. IDAX 322 additional
features
The IDAX 322 incorporates all of the
great features available in the IDAX 300,
including a two-ammeter design. The
benefit of having two available metering
systems is the unique advantage of test-
ing two capacitances simultaneously.
“That means a great reduction of
testing time when multiple capac-
itances can be tested under a sim-
ilar connection or testing two HV
bushings at the same time. No other
instrument is capable of simultane-
ous measurement in the frequen-
cy domain. In some dual-channel
instruments, both channels share
a single ammeter and, with these,
either half as many measurements
are made, or no timesaving is real-
ised” enthuses
Jill Duplessis – Megger’s Global
Technical Marketing Manager.
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
10
% DF @ 0.5 kV
% DF @ 1.4 kV
%DF
1
0.1
0.01 0.1 1 10 100 1000
Frequency [Hz]
Figure 2. Effect of EMI on DFR measurement [2]
ITC allows for comparative analysis of HV
bushings and instrument transformers test-
ed at different temperatures and accurate
verification against limits provided in refer-
ence standards
One of the most indispensable functions The technical brochure CIGRE 755
available in the IDAX family is the indi- -Transformer Bushing Reliability states
vidual temperature correction (ITC) al- that “Recent publications present promis-
gorithm. A material’s percentage power ing FDS or DFR analysis on OIP bushings
factor or dissipation factor measured as based on the individual temperature cor-
a function of frequency is temperature rection (ITC) method.”
and condition dependent. The materi-
al will change its dielectric properties The IDAX 322 provides an accurate
due to contamination, ageing, or deg- DFR curve (black curve in Fig. 3) and,
radation. The insulation temperature through the use of the ITC method, a
varies due to operation and ambient ‘temperature corrected’ DFR curve (red
conditions, and ITC has demonstrated curve in Fig. 3), in addition to a 20 °C
the ability to properly correct not only equivalent % DF/PF value. This means
power frequency but also the entire di- that the test can be performed at a wide
electric response to a normalised tem- range of temperatures, allowing great-
perature of 20 °C. er freedom when deciding upon a test
time.
“The temperature behaviour of % PF
or % DF is unique, as is the dielectric To run IDAX 322, one needs an exter-
response for each bushing. The di- nal PC with the IDAX software, which
electric response in the frequency do- features a user-friendly interface that
main and the temperature response guides the user from start to finish. The
of the insulation in the bushing are software will show the relevant hook-
directly related. ITC allows for com- up for the selected test object, assur-
parative analysis of HV bushings and ing quick and confident connections.
instrument transformers tested at Before starting the test, the software
different temperatures and accurate suggests a stop frequency based on the
verification against limits provid- temperature and test object, which will
ed in reference standards,” affirms provide just enough measuring points
Dr. Diego Robalino – Megger’s Busi- to accurately produce a representative
ness Development Director Power DFR curve while minimising unneces-
Transformers. sary, extended test time. Once the test
47
 TESTING

10 is finished, all the relevant graphs are

presented along with an analysis of rel-
evant test parameters that is easy to read,
DFR - measured interpret and helps the user make correct
conclusions about the asset. The parame-
DFR corrected - ITC ters displayed in the analysis section vary
for different test objects; a bushing is
% DF

1
evaluated by % DF or % PF at 3 different
frequencies, while the analysis of a power
transformer focuses on moisture content
and oil conductivity. The limits used for
the analysis are based on international
standards together with over 25 years
0.1
0.001 0.01 0.1 1 10 100 1000 of experience with DFR measurements.
Frequency [Hz] Limits depend on the insulation type.
For example, an oil-impregnated paper
(OIP) bushing will have different limits
than a resin-impregnated paper (RIP)
bushing.

4. IDAX 322 - Efficient

diagnostics
IDAX technology and DFR have prov-
en their value countless times through-
out the years. For example, in tests
Figure 3: A DFR curve on an HV CT and its corresponding 20 °C temperature-corrected curve done on a population of 800 kV CTs
[3], IDAX was able to detect problems
10 that did not appear in the basic power
factor test at line frequency. In Fig. 4,
three 800 kV CTs of similar construc-
tion exhibit differences in their di-
electric responses even though their
line-frequency % DF test results coin-
%DF

1
cide. CT1 exhibits a typical good re-
sponse, CT2 an aged-service response,
and CT3 displays behaviour commen-
surate with insulation that has a high
degree of contamination.
0.1
0.1 1 10 100 1000 Fig. 5 provides another example of
Frequency [Hz]
DFR test results. This testing was per-
CT1 CT2 CT3 formed on two 110 kV transformer
Figure 4: Dielectric response of HV CTs under different degradation conditions OIP bushings (H1 & H3). At line fre-
quency, a negligible difference in per
10
cent dissipation factor appears, and
the faulty bushing is hard to detect.
However, as test frequencies lower, H3
H1 (Good)
starts to deviate from what is expected
H3 (Bad) (H1), and the fault becomes apparent,
possibly indicating degradation and /
or contamination within the bushing.
%DF

These are a mere two examples that un-

derscore the insightful diagnostics that
DFR offers for HV bushings and instru-
ment transformers, outside of its more
0.1 common use for power transformers.
0. 0 1 0.1 1 10 10 0 10 00 DFR will continue to evolve and cement
Frequency [Hz]
itself as an essential tool in the toolbox
Figure 5: DFR on good and bad 110 kV OIP bushings for diagnostics of HV bushings and in-

48 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

strument transformers. The IDAX fam- IDAX technology and DFR was able to de-
ily, with its latest addition of IDAX 322,
is ready to support this transition, offer- tect problems at the 800 kV CTs that did not
ing unique features that make DFR test-
ing available and reliable for everyone.
appear in the basic power factor test at line
frequency
Bibliography
[1] P. Werelius, M. Ohlen, J. Skoldin, Di- former Failure by Dielectric Conference (EIC), Knoxville, TN,
electric Frequency Response Measure- Frequency Response Technique , USA, 2020, pp. 72-75, doi: 10.1109/
ment Technology for Measurements in 2020 IEEE Electrical Insulation EIC47619.2020.9158762
High Interference AC and HVDC Sub-
stations,” in Techcon Asia-Pacific, 2011

[2] I. Güner, D. M. Robalino, P. Were- Author

lius, HV and EHV bushing condition Olle Benzler, MSc., joined Megger in 2018 in the posi-
assessment – field experience, 2016
CIGRE IEC Colloqium, Montreal, QC, tion of Applications Engineer. He is based in Stockholm,
Canada Sweden. Mr. Benzler’s primary focus is diagnostics of
power transformers and HV-insulation.
[3] D. M. Robalino, I. Güner, Inves-
tigation of EHV Current Trans-

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 49
COLUMN

Currently active nation-

al standards are import-
ant for the transformer
design, manufacturing
and operation - they re-
flect today's transformer
technology

ABSTRACT
Currently active transformer stan-
dards are of the utmost importance
for the selection, design, manufac-
ture, installation, operation and main-
tenance - they reflect today’s modern
transformer technology.

KEYWORDS
application, selection, standards,
transformers

50 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 P. RAMACHANDRAN

Standards relevant to
transformers – Part V
Transformer selection and application IEC 60076-8 Transformer applica-
tion guide provides users with in-
1 Introduction
formation on selection and charac-
teristics of three phase transformer
In the previous four parts of this column, we have explained
the evolution of transformer standards by IEC, IEEE, EN,
connections, zero sequence im-
plus technical brochures by CIGRE bodies. We have also pedance characteristics, tapping
noted the current standards available on transformer speci-
fications. In this part of the series, national standards avail- selection and features, operational
able for the selection and application of transformers are issues (parallel operation and fault
summarised. Numbers in the bracket next to the standard
number indicates the previous edition of the particular currents) and measurement accu-
standard. racy of losses

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 51
COLUMN

2 Standards

Category IEC Standard / CIGRE TB ANSI / IEEE standard EN / Indian standard

Standard terminology for transformers and reactors 60050-421, 1990 C57.12.80-2010 (2002)

IS 2026 (Part 8)
60076-8, Ed. 1.0, 1997 C57.94-2015 (dry-type) 2009 / IEC 60076-8-1997
Transformers – application guide
(606-1978) (1982)
(IS10561-1983)
Converter transformers – application guide 61378-3, Ed. 2.0, 2015 (2006)
60214-2, Ed. 2.0, 2019 60214-2, Ed. 2.0, 2019
Tap-changers – application guide
(dual std. with IEEE) (dual std. with IEC)
IS 2026 (Part 14) –
Transformers using high temperature insulation materi-
60076-14, Ed. 1.0, 2013 C57.154-2012 2018 / IEC 60076-14-
als - design, testing and application
2013
Guide for application of high temperature insulation
1276-2020 (1997)
materials in liquid immersed transformers

Guide for transformers directly connected to generators - C57.116-2014

Phase-shifting transformer – application, specification, (62032, Ed. 2., 2012) (C57.135-2012)

testing guide IEC / IEEE 60076-57-1202:2017 Superseded

Transformer capability for non-sinusoidal currents

- C57.110-2018 (2008)
(loads with harmonics) – liquid filled and dry

Harmonic control in power systems 519-2014 (1992)

Transformers for application in DPV (distributed photo

C57.159-2016
voltaic) power generation system

Transformer capability under geo-magnetic disturbances C57.163-2015

Transformer loss evaluation guide - C57.120- 2017 (1991)

C57.105-2019 (1978)
(Transformer connections
in three-phase electrical
systems)
Terminal marking and connections TR 60616, Ed. 1.0, 1978 IS 2026 (Part 4), 1977
C57.12.70-2020 (2011)
(Terminal markings and
connections for power and
distribution)
Application of power apparatus bushings C57.19.100 2012 (1995)
62271-211, Ed. 1.0, 2014
Direct connection details between transformers and GIS
(TR 61639-1996)
Cable connection for GIS 62271-209, Ed. 2.0, 2019 (2007) 1300-2011 (1996)
60815, 1 to 3, Ed. 1.0, 2008
Selection of insulators for polluted environments
CIGRE brochures 158 and 361
Selection guide for polymeric materials for outdoor use
TR 62039, Ed. 1.0, 2007
under HV stress
Cleaning of insulators 957-2005 (1995)
Bushings – seismic qualification TS 61463-2016 (2000)
693-2018 (2005) (1997)
Seismic design of substations – recommended practice (C57.114-1990 Seismic guide
for transformers and reactors)
Seismic test methods 60068-3-3, Ed. 2.0, 2019 (1991)

Insulation coordination – definitions, principles and rules 60071-1, Ed. 9.0, 2019 C62.82.1-2010 (1313.1-1996)

Application guide 60071-2, Ed. 4.0, 2018 1313.2-1999

Computational guide for insulation coordination and

TR60071-4, Ed. 1.0, 2004
modelling of electrical networks
Procedure for HVDC converter stations TR 60071-5, Ed. 1.0, 2002

Low voltage system 60664-1, Ed. 3.0, 2020

1312-1993
Preferred voltage ratings 60038, Ed. 7.0, 2009 (1983)
ANSI C84.1, 2020 (2016)

52 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Category IEC Standard / CIGRE TB ANSI / IEEE standard EN / Indian standard
Qualifications of Class 1E transformers for nuclear
638-2013 (1992)
generating station

Bar coding of distribution transformers C57.12.35-2013 (2007)

Sound level IS 2026 (Part 10), Sec.
60076-10-1, Ed 2.0, 2016 1-2018 / IEC 60076-10-
Determination of sound level 1-2016
(2005)
Guide for sound abatement and determination C57.136-2000
CIGRE brochure 577 A and
Occurrence and mitigation of switching transients in- B, 2014 C57.142- 2010
duced by transformers
569, 2014, ferroresonance
Guide for conducting a transient voltage analysis of
C57.12.58-2017 (1991)
dry-type transformer coil

Metric conversion of transformer standards C57.144-2004

Determination of hot spot temperature in windings in

1538-2000
liquid filled transformers
Temperature rise of LV switchgear and control gear TR60890, Ed. 2.0, 2014
assemblies by calculation (1987)
Electro-technical equipment – temperatures of touch-
Guide 117, 2010
able hot surfaces

Safety of transformers – EMC requirements 62041, Ed. 3.0, 2017 (2010)

Classification of environmental conditions

Temperature and humidity 60721-2-1, Ed. 2.0, 2013 1982)
Application of neutral grounding in utility system

Introduction C62.92.1- 2016 (2000)

Synchronous generator system C62.92.2-2017 (1989)

Generator auxiliary system C62.92.3-2012 (1993)

Distribution C62.92.4-2014 (1991)

Transmission C62.92.5-2020 (2009)

Grounding
Safety in substation grounding 80-2013 (2000)
Guide for generating station grounding 665-1995 (R2001)
Arc flashover study
1584 and NFPA 70 E
Guide for arc flash hazard calculations
1584-2018 (2002)
Guide for the specifications of scope and deliverable
requirements of a flash over study
1584.1-2013

Short circuit currents in three phase AC systems

60909-0, Ed. 2.0, 2016

Calculation of currents
(2001)
TR60909-1, Ed. 2.0, 2002
Factors for SC calculations
(1991)
TR60909-2, Ed. 2.0, 2008
Data of equipment for SC calculations
(1992)
TR 60909-3, Ed. 3.0, 2009
Current during 2 Nos. LG fault
(2003)

Examples for SC calculations TR60909-4, Ed. 1.0, 2000

Calculation of thermally permissible short circuit cur- 60949, Ed. 1.0, 1988
rents AMD1-2008

Modal components in three-phase AC systems 62428, Ed. 1.0, 2008

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 53
COLUMN

Category IEC Standard / CIGRE TB ANSI / IEEE standard EN / Indian standard

Electrical installations of ships and mobile and fixed

offshore units – Part 1 – procedure for calculation of 61363, Ed. 1.0, 1998
short circuit current in three-phase AC

Short circuit currents in DC auxiliary Installations 61660 (all parts)

Short circuit currents – calculation of effects Cahiers technique, Nos.

158 and 162

60865-1, Ed. 3.0, 2011

Definitions and calculation methods
(1993)

TR 60865-2, Ed 2.0, 2015

Examples of calculations
(1994)

1547-2018 (2003) Inter-

Interconnection of distributed resources with electric
connection and interoper-
power system
ability – 8 parts

Recommended practice for industrial and commercial

power system

Application of power distribution apparatus 3001-5-2013

Grounding and bonding 3003.2-2014

Application of instrument transformers 3004.1-2013

Application of LV breakers 3004.5-2014

Determination of reliability of 7 x 24 continuous power

3006-7-2013
system

Collecting data 3006-9-2013

Operation and management 3007.1-2010

Maintenance 3007.2-2010

Electrical safety 3007.3-2012

Corrosion of metals and alloys

Basic terms and definitions ISO8044-2015 (1999)

Corrosivity of atmospheres-classification, determination

ISO 9223-2012 (1992)
and estimation

Guiding corrosivity values for the corrosivity categories ISO 9224-2012 (1992)

Measurement of environmental parameters affecting

ISO 9225-2012 (1992)
corrosivity of atmosphere

Determination of corrosion rate on standard specimens ISO 9226-2012 (1992)

Salt spray tests ISO 9227-2017 (2012)

ISO 11844-2020, 1 (2006),

Classification of low corrosivity of indoor atmospheres
2 (2005), 3 (2006)

54 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Category IEC Standard / CIGRE TB ANSI / IEEE standard EN / Indian standard

Corrosion protection of iron and steel

Nickel electroplating ISO 1456-2009 (2003)

Hot-dip galvanizing – specs and test methods ISO1461-2009 (1999)

Metallic coating – thickness measurement ISO 1463-2003 (1982)

Thermal spraying – design considerations and quality

ISO 2063-1-2019 (2017)
requirements

Thermal spraying – execution ISO 2063-2-2017 (2005)

Surface treatment and metal coatings – vocabulary ISO 2080-2008 (1981)

Electroplated zinc coating ISO 2081-2018 (2008)

Tin coating ISO 2093-1986 (1973)

Chromate conversion coatings on zinc / cadmium elec-

ISO 3613-2010 (2000)
tro plating – test methods

Fasteners – electroplated coating system ISO 4042-2018 (1999)

Chromate conversion coatings on zinc / cadmium elec-

ISO 4520-1981
tro plating – specifications

Silver plating ISO 4521-2008 (1985)

Metallic coatings – CORR test ISO 4541-1978

Aluminium anodizing-specification ISO 7599-2018 (2010)

Aluminium anodizing – rating system for evaluation ISO 8994-2018 (2011)

Metallic coatings – pre-treatment of iron to reduce

ISO 9587-2007 (1999)
hydrogen embrittlement
Metallic coatings –post-coating treatment of iron to
ISO 9588-2007 (1999)
reduce hydrogen embrittlement

Metallic coating – review of porosity test ISO 10308-2006 (1995)

Fasteners – zinc flake coatings ISO 10683-2018 (2014)

Fasteners – hot dip galvanized coatings ISO 10684-2004 + A1 2008

Guidelines for selection of protection methods against

ISO 11303-2002
corrosion
Mechanically deposited coatings of zinc – specifica-
ISO 12683-2004
tions and test methods
Mechanically deposited coatings – automated con-
trolled shot peening of metallic articles prior to nickel, ISO 12 686-1999
chromium plating

Zinc coatings – guidelines for protection of iron and

steel structures

General principles of design and corrosion resistance ISO 14713-1-2017 (2009)

Hot – dip galvanizing ISO 14713-2-2019 (2009)

Sherardising ISO 14713-3-2017 (2009)

Thermal spraying – terminology and classification ISO 14917-2017 (1999)

Zinc diffusion coatings – sherardising – specifications ISO 17668-2016

Metallic coatings – definitions and conventions con-

ISO 18332-2007
cerning porosity

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 55
COLUMN

ANSI / IEEE EN / Indian

Category IEC Standard / CIGRE TB standard standard
Corrosion protection of iron and steel – paints and varnishes
Introduction ISO 12944-1-2017 (1998)
Classification of environment ISO 12944-2-2017 (1998)
Design considerations ISO 12944-3-2017 (1998)
Types of surface and surface preparation ISO 12944-4-2017 (1998)
Protective paint systems ISO 12 944-5-2019 (2018)
Laboratory performance test methods ISO 12944-6-2018 (1998)
Execution and supervision of paint work ISO 12944-7-2017 (1998)
Development of specifications for new work and maintenance ISO 12944-8-2017 (1998)
Paint system and tests for offshore structures ISO12944-9-2018 (2009)
Cross-cut test ISO 2409-2020 (2013)
Materials for use in H2S containing environment – Petroleum
and gas industries
General principles ISO 15156-1-2020 (2015)

Crack resistant carbon and low alloy steels ISO 15156-2-2020 (2015)

Crack resistant corrosion resistant alloys ISO 15156-3-2020 (2015)

Guide for development of specifications for turnkey substation projects 1267-2019 (1999)

Guide for transformer specifications CIGRE TB 528-2013/156-2000

Guide for transformer design review CIGRE TB 529-2013/204-2002

Guide for transformer factory capability assessment CIGRE TB 530-2013

Conclusion Authors
The authors hope that this comprehen- P. Ramachandran started his career in transformer
sive list of various national standards industry in 1966 at TELK, Kerala, a Hitachi Joint venture,
covering various aspects in the selection in India. He worked with ABB India during 1999-2020.
and application of transformers will be He has more than 50 years of experience in the design
useful for consultants, users and design- and engineering of power products including power
ers of transformers. transformers, bushings, and tap-changers. He received
Bachelor of Science Degree in Electrical Engineering
from the University of Kerala, India, and Master of Business Administration
IEEE C57.116 provides Degree from Cochin University, India. He is a Fellow of Institution of
Engineers (India), and he represented India in CIGRE Study Committee A2
information on the se- for transformers during 2002 – 2010.
lection and application
considerations for the A. S. Jhala started his professional career with T&R
India Limited Ahmedabad in 2005 and is now Deputy
unit power transform- General Manager. He has been associated with various
er and unit auxiliaries functions during his career viz. Testing, Designs and
power transformer Technology Development. He was actively involved with
several development projects including establishment
and institutionalizing licensed technology for 765 kV
transformers and 400 / 765 kV shunt reactors. He has been associated with
Bureau of Indian Standards (BIS) responsible for standardisation activities
in India, Central Board of Irrigation and Power (CBIP) and Indian Electrical
and Electronics Manufacturers Association (IEEMA). He is also on the
board of Managing committee of Electrical Research and Development
Association (ERDA). He has contributed about 30 technical papers in
national / international seminars.

56 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 DTTS
Distrubition Transfomer Test System

The right answer to many questions!

Scan to
learn more!
INTERVIEW

58 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

Coveme is a manufacturer of insulation materials for different
applications, including for dry and oil-filled transformers
Coveme - innovating
insulation materials
MONICA MANARA, Chief Commercial Officer
60 years of know-how
Coveme is a manufacturer of insulation
materials for different applications, includ-
ing for dry-type and oil-filled transformers.
Our headquarters are located in Bologna,
Italy. We are a privately owned business
with 60 years of know-how in converting
films. The company operates two produc-
tion sites in Italy and China with 14 pro-
duction lines equipped with leading edge
lamination and coating technologies such
as UV and Ebeam, and three high tech
R&D labs in Italy, Germany and China.
We employ nearly 300 people and generate
more than €100 million p.a. The business
is organized in eight business units, tar-
geting fast evolving and highly demanding
markets such as automotive, renewable
energies and printed electronics, with own
global commercial and logistic network.
In Europe we are one of the leading sup-
pliers of insulation materials. Our plan
is also to globally expand our business.
Recently, we have had a launch in China,
Zhangjiagang, where we have a produc-
tion plant with four lamination and six
slitting lines. The main application for
production there is insulation materials
for photovoltaics, but with the technology
and available capacity we now started to
supply the transformers and motor mar-
ket, and we plan to develop this business
in China.
On the transformers market, we cooper-
ate with major customers such as Hitachi
ABB, Siemens Energy, SEA, and many
others. We are supplying mainly Euro-
pean facilities and, as already said, we
would also like to expand this business
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
in Asia, offering local distribution and former OEMs, despite the fact that we
service with multinational groups with are not the sole supplier for any of these
production sites in China and for Chinese customers. However, we are open to co-
manufacturers looking for a high-quality operation and we have the strong drive to
product. develop the right product and maintain
the high quality that they request.
Materials for transformers
The part of business relating to transform-
ers and motors insulation makes up 20 %
of our operations, and our plan is to dou-
ble that percentage. There is a strong com-
petition on the market, but we are always
prepared to work hard, and in all markets.
The market is growing, that is a fact, and I
believe there is a place there for high qual-
ity suppliers such as we are.
We are official laminators for DuPont’s
Nomex materials. For transformers, we
also supply non-woven laminates and res-
in-impregnated, high-temperature resis-
tant materials. Furthermore, we have in-
sulation with high-temperature pre-preg,
as well as with polyimide and Kapton film.
Although this material is mainly intended Monica Manara is Chief Commercial
for motors, it can be used in some cases Officer (CCO) of Coveme Electrical
for transformers. Insulation Division since 2019, re-
sponsible for the company’s glob-
Transformer OEMs require high tempera- al business of electrical insulation
ture materials with specific permeability materials for transformers and mo-
and they request high quality and recycla- tors. She joined Coveme almost 40
ble materials. Therefore, we have to study years ago, in 1984, as a purchasing
particular resins in order to improve on manager and has since built up a re-
characteristics, such as mechanical prop- markable career within the compa-
erties of the products. We are working on ny, which culminated in the appoint-
two important projects within which we ment as member of the Coveme
are developing a strong resin to fulfil re- Group Board in 2017. Besides the
quests of some large customers. Electrical Insulation Division, Moni-
ca Manara is also CCO for Coveme’s
We also have joint projects for develop- Photovoltaic Division.
ment of new products with some trans-
59
INTERVIEW
The part of business relating to transform-
ers and motors insulation makes up 20 %
of our operations, and our plan is to double
that percentage
60 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
Sustainability
The idea of a circular economy is to
recycle as many materials as possible
when a product reaches its end of life. I
want to underline that circular econo-
my is something we believe in. After the
end of life of a transformer, it is very im-
portant that we can recycle all the com-
ponents. I think we are at the beginning
of this process in this field, but we want
to be among the first ones who are able
to do that.
We have significant experience in this
area with photovoltaic modules. After
20 years now, there is a problem of re-
cycling these modules. It is important
that each component can be recycled in
some way. We are in a good position, be-
cause our polyester can be recycled. Not
every technology permits that. Building
on that experience, our idea is to expand
that on all the parts of our business. And
as you see, the philosophy is the same
with transformers. What happens at the
end of life of a transformer, after 30 years
operation? How will people be able to re-
cycle these materials then? I think that a
 Circular economy
is something we
believe in
kind of certification, a testing that proves
that those materials are recyclable is re-
ally important. When speaking of resin,
you know very well that many compo-
nents of resin are not so easy to recycle.
So, we are investing a lot into all these
parameters.
So far, the solution was to separate differ-
ent layers of the insulation. The copper is
recyclable, for example, as well as alumin-
ium. Nomex is not so easy to recycle, so it
is important to separate the polyester. We
are open for projects on that matter, and
I have heard of some projects that have
shown results.
It is very clear that we are highly active
in developing the technology, taking the
recycling into account. We are work-
ing with our suppliers in order to use as
much recycled raw material as possible.
This is really important for us, because
we want to focus our operation on being
environmentally conscious. Our plants
are ISO-certified for environmental
management, but our actions go even
further than requirements of this certif-
icate. The energy recovery setup of our
production lines and management of
solvents are stricter than required by the
certifications. All our suppliers are re-
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
quired to follow these regulations, from
materials to the packaging. We work with
a very large group of suppliers and selec-
tion is very important. Normally, we start
a project with them and work continu-
ously in order to achieve the same results,
which also includes sustainability.
Demand is increasing
Last year the pandemic had a significant
impact on the business, for sure, but we
are now recovering. We have noticed
a great advancement in electrical mo-
tors, electrical vehicles, alternative ener-
gy such as wind, all over the world. The
demand is increasing, including the de-
mand for quality and we are confident
that we will achieve our objectives. We
are very flexible in our production and
being a company with a lean organisa-
tion, we can make fast decisions on each
level of our supply chain. For example,
in March we doubled the production
because we put into operation a new
production line within two days. We are
really well positioned with our ability to
follow the market.
Strong relationships we have formed with
our suppliers make it possible for us to
have the raw material readily available.
Focus on long-term business
We entered the market of electrical insula-
tion for motors and transformers in 1965,
therefore we have a very long experience.
This business has been continuously run-
ning ever since. We also plan to introduce
this new change concerning the green
economy and electrical insulation and we
believe in that. We believe the innovation
is the way to keep on going.
I do not believe in short-term growth strat-
egies - it is not in our nature. We are focused
mainly on mid and short-term solutions
and we need our strategies to be built on a
strong supply chain, strong products and
long-term relations with our customers.
Contact:
Monica Manara,
email: mmanara@coveme.com
Coveme Spa
Via Emilia 288
40068 San Lazzaro di Savena (BO)
Italy
Phone: +39 051 6226 111
61
TECHNOLOGY

ABSTRACT
Exactly 100 years ago, today’s region-
al leader in innovations and Croatia’s
industrial growth backbone started
its operation in a small workshop.
Through a century of excellence,
this company, known today as the
KONČAR Group, has developed its
portfolio with many innovations, nov-
elties and thousands of successful
projects and has become a symbol of
tradition, excellence and responsibili-
ty in almost 130 markets worldwide.

KEYWORDS
Croatia, distribution transformers,
history, instrument transformers, me-
dium power transformers, measure-
ment transformers, power transform-
ers, special transformers

62 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Advertorial

KONČAR Group has been destined for greatness

from the very beginning of its foundation, as
demonstrated by the significant breakthroughs

KONCAR Group
- 100 years
of excellence
without
compromise
A small workshop that was
destined for greatness
On 24 January 1921, in Zagreb, the
KONČAR Group began its journey to
reach worldwide markets and to get rec-
ognition and confirmation of important
customers on the global level. The peri-
od of 100 years sounds even longer when
you take into account the fact that, at the
time in which the company was founded,
the Kingdom of Yugoslavia still existed,
and many different country governances
have exchanged on its territory ever since.
However, KONČAR, operating then un-
der the company name “Elektra”, immedi-
ately demonstrated that it was a company
ahead of its time. During that same year,
the company became an integral part of
the globally known company “Siemens”.
By 1930, the first squirrel-cage asynchro-
nous motors with power ranging from
0.25 to 7.5 kW and with enamelled sta-
tor windings, instead of cotton-insulated
wires, were delivered. The ten-thousandth
motor was delivered in October 1940. To-
day, the KONČAR Group is known for
its transformers. In 1947, it began batch
manufacturing the first transformers
rated up to 35 kV. At the same time, the
company also started manufacturing low-
oil instrument transformers intended
for distribution networks and industrial
plants with the highest operating voltage
of up to 35 kV, and the rest is history.
At the forefront of
development, innovations
and quality standards
KONČAR Group has been destined for
greatness from the very beginning, as
demonstrated by the significant break-
throughs that started in 1948. Manufac-
ture of high-voltage pneumatic circuit
breakers for voltages of 110 and 220 kV

In 1970, the electric locomotive was developed,

which had four traction motors with a power of
850 kW and ten asynchronous motors serving
as auxiliary drives
w w w . t ra n sfo r m e r s - m a g a z i n e . co m 63
TECHNOLOGY
Since the very beginning, there has been a
close bond between the KONČAR Group and
academic community
started under the licence of the French
company “Merlin Gerin”, and the first RK
generator with a power of 24 MVA, volt-
age of 10 kV and weight of 220 tonnes was
completed during that same year. This
generator was installed in HPP Maribor-
ski otok in Slovenia. Furthermore, it was
commissioned only 17 months following
the conclusion of the agreement, and it
became a symbol of KONČAR. After 40
years of successful operation, it has now
become a museum piece. The year 1955
marked a special year for the successful
portfolio of the KONČAR Group be-
cause, in 1955, the first prototypes of elec-
tric motors with power ranging from 1 to
25 kW were made. These represented a
new series of motors that were character-
ised by a greater power and lower weight.
The true revolution started in 1958, when
KONČAR made the first prototype of a
Three phase ester immersed distribution transformer
64
special magnetic quadrupole lens in Eu-
rope, after which ten of those lenses were
delivered for the proton synchrotron of
the CERN Nuclear Institute in Switzer-
land. The success of this project is reflect-
ed in the fact that during the very next
year, 20 magnetic lenses were delivered
for the proton synchrotron at CERN, with
two modes of regulating programmed
high-performance electrical pulses used
to control the proton synchrotron mag-
netic lenses.
Ten years later, KONČAR continues to
make successful innovations. Conse-
quently, in 1970, the electric locomotive
was developed, which had four traction
motors with a power of 850 kW and ten
asynchronous motors serving as auxiliary
drives. This marked the beginning of the
golden age of the company and one of the
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
steppingstones for the company’s impres-
sive success in the field of rail transport.
To date, a total of 353 locomotives were
manufactured at KONČAR for various
customers. When talking about the vol-
ume of KONČAR’s rolling stock, it is best
to look at the figures. They indicate that
the KONČAR Group has, up until now,
delivered 180 low-floor trams and trains,
100 trolleybuses and 15,000 tram motors.
Amongst other things, KONČAR is also
globally renowned for its transformers.
This started to come to the fore in 1978,
following KONČAR’s first outstanding
achievement in this field. The achieve-
ment was the sale of transformers to the
Western European market, namely to
Sweden. Since then, distribution and
medium power transformers have con-
tinuously been placed on the Swedish
market every year, becoming the largest
export market of the company KONČAR
– Distribution and Special Transformers.
“Golden age of Croatia’s electrical indus-
try growth” in the 1970s and 1980s was
marked by the delivery of equipment in
more than 150 hydroelectric power plants
and by the manufacture and delivery of
160 turbogenerators. Up to this date, more
than 2000 generators, more than 5000
winch devices and thyristor-controlled
electric motor drives, tens of thousands of
high-voltage devices and a great number
of all types of ship switchboards have been
installed and commissioned.

A tradition of knowledge,
education and top-quality
personnel

In KONČAR Group’s opinion, each inno-

vative idea and the possibility to transform
that idea into reality starts with top-qual-
ity employees. This is why KONČAR has
always devoted special attention to em-
ployee development while also paying
considerable attention to training and
education. In 1961, KONČAR founded
the KONČAR – Electrical Engineering
Institute for scientific research focusing
on developing products, technological
processes and measurement methods in
the field of electrical machinery manufac-
ture. This Institute quickly became a true
“breeding ground” for new top experts,
who then contributed to the subsequent
development of the company and the en-
tire Croatian electrical industry. In 2019,
the Laboratory centre was accredited ac-
cording to standards HRN EN ISO/IEC
17025:2017 and was established as a part
of the Institute, thus confirming the inde-
pendence and competence for laboratory
and field-testing services.
Thanks to the top-quality employees and
commitment to its vision, KONČAR Group
Since the very beginning, there has been a
close bond between the KONČAR Group has grown from a small workshop to a re-
and the academic and university com- gional leader, recognised in 130 markets
munity. Due to the nurture of knowledge
and education, KONČAR paved the way worldwide
for many dignitaries in the field: two ac-
ademics, six deans of faculties, six deans
of polytechnics, two professors emeriti, particular importance due to the fact that the value of its total export amounted to
more than 30 university full and associ- they are all connected to real technical and $142.5 million, due to which KONČAR
ate professors, more than 50 polytechnic technological challenges stemming from became one of the most successful ex-
professors and lecturers, two directors of KONČAR’s manufacture. porters in the region. Moreover, in the pe-
the “Ruđer Bošković” Institute, 90 doc- riod between 1952 and 1990, KONČAR
toral candidates and more than 200 mas- Group’s export reached the value of
Excellence recognised in 130
ters of science. Furthermore, throughout $1.642 billion.
the history of the KONČAR Group, our markets worldwide
top experts have patented more than 120 Thanks to the top-quality employees and
A string of successes even in
original solutions, and 42 of them have commitment to its vision, KONČAR
received the national science award. Two Group has grown from a small workshop the most difficult times
awards of the Croatian Academy of Sci- to a regional leader, recognised in 130 The previous year has put the whole
ences and Arts for scientific contribution markets worldwide. Export has always world to a hitherto unimaginable test.
also represent a special kind of recog- been one of KONČAR Group’s funda- The coronavirus pandemic has radical-
nition. However, all these awards are of mental business determinants. In 1985 ly changed the lives of almost the entire

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 65
TECHNOLOGY
KONČAR – Power Transformers delivered
a 425 MVA, 525/34.5/ (13.8) kV network
transformer to a USA customer, which will
be used for the largest battery electricity
storage system in the world
global population, and even the most
powerful global economies were dealt
blows from which they will be recovering
for years to come. However, in these dif-
ficult circumstances, KONČAR Group
has once again shown its strength and
the ability to adapt to any challenge, as
it had one of its most successful business
years yet.
“It would be difficult to single out any
specific achievement that marked the
business of the KONČAR Group and
opened so many new markets for us,
in which we operate using a unique
approach to each customer, which dis-
tinguishes us from other major global
companies. One of the greatest re-
sources of KONČAR are its employees,
66
who have, on a daily basis, invested
their expertise, knowledge and dedi-
cation to the development and success
of this company”, said Gordan Kolak,
President of KONČAR Management
Board.
With good financial results, KONČAR
was able to realise numerous business
transactions in 2020, not only in the for-
eign markets but also in the Croatian mar-
ket. Share of export in the total revenue
from the sale of products and services was
over 62 %, two-thirds of which pertained
to EU countries. This is a good indicator
of the fact that KONČAR Group’s prod-
ucts and service are certainly competi-
tive in the area of power engineering and
transport.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
When it comes to export by individual
countries, the most significant export vol-
ume pertains to the Swedish market, fol-
lowed by the German and Austrian mar-
ket. Compared to the previous year, apart
from Sweden, a significant increase in rev-
enue from the export sale of products and
services was noted in the markets of Unit-
ed Kingdom, Finland, Iraq, and Bulgaria.
Another in a series of
acknowledgements of global
recognition
Last February, the KONČAR Group real-
ised another achievement of paramount
importance. The achievement pertains to
a successfully completed project of global
reach. Namely, the company KONČAR
– Power Transformers, which KONČAR
and Siemens Energy jointly own, deliv-
ered a network transformer with a rated
power of 425 MVA and a turns ratio of
525/34.5/ (13.8) kV to a customer from
Houston, Texas, which will be used for the
largest battery electricity storage system in
the world, which is located near the Moss
Landing power plant in California. This
transformer, which is intended for the
transmission of electricity from the battery
storage system to 500 kV power line bus-
bars, simultaneously represents the largest
transformer in the world that will be pow-
ered by a battery energy storage system.

Three phase oil immersed

voltage regulation
transformer

In March 2020, KONČAR – Distribu-

tion and Special Transformers (KD&ST)
concluded an agreement on the supply
of two 130 MVA transformers and three
120 MVA transformers – with a voltage
level of 170 kV, with one of the largest elec-
tricity distribution companies in Sweden.
Transformers were contracted for wind
power plant projects, proving KD&ST to
be a reliable supplier in that market seg-
ment as well.

That same month, Croatia saw the begin-

ning of the coronavirus pandemic out-
break, which was soon followed by a dev-
astating earthquake in Zagreb and then
another one in December. Despite such
adversities, KONČAR Group managed
to maintain its high-level performance
and ensure continuous and uninter-
rupted delivery of its solutions, products
and services to its customers. In March,
KONČAR - Generators and Motors suc-
cessfully completed two contracts for the
Austrian customer Global Hydro Energy,
which included delivering one 0.85 MVA
horizontal synchronous generator to Fin-
land and three 3.8 MVA vertical synchro-
nous generators to the Philippines.
In June of the same year, KONČAR –
Instrument Transformers expanded its
product range and supplied nine trans-
formers to a customer in the USA for
substation own power supply, with a volt-
age level of 525 kV and power output of
250 kVA. Those are the largest transform-
ers the company has ever manufactured
and probably the largest transformers of
this type in the world in terms of their
voltage level and power output.
Continuing with a rich
tradition in rolling stock
manufacturing
In April 2020, KONČAR once again
proved to be not just the national but also
In March 2020, KONČAR – Distribution and
Special Transformers concluded an agree-
ment on the supply of two 130 MVA trans-
formers and three 120 MVA transformers
for a wind power plant project in Sweden
the regional leader in rolling stock manu- six trams. The first tram was delivered to
facturing. In April, KONČAR - Electric Ve- Latvia in November 2020, and the project
hicles and HŽ Passenger Transport signed represents a remarkable breakthrough in
an Annex to the 2014 Agreement on deliv- KONČAR’s performance, given that it en-
ery of 32 electromotor trains. Under said tails its first export of low-floor trams to
Annex, they agreed on the delivery of 12 the EU market.
new electromotor trains, six of which for
urban-suburban traffic (UST) and six for This high-technology product features
regional traffic (RT). The project value is KONČAR’s own solutions, such as the
$73.2 million (HRK 465 million). main electric motor drive, auxiliary power
supply, microprocessor and various other
In addition to manufacturing electromo- specifications designed with maximum
tor and diesel-electric trains, KONČAR passenger comfort in mind. For exam-
Group is at the forefront of manufactur- ple, it is equipped with an adjustable hy-
ing premium quality low-floor electric dropneumatic suspension system, which
trains, and the year 2020 was very success- allows the floor height to be adjusted de-
ful for that segment of its product range. pending on tramway tracks. The vehicles
In August 2020, KONČAR – Electric also have an air conditioning system, vid-
Vehicles and the Latvian company Liepā- eo surveillance system and passenger in-
jas Tramvajs signed an agreement on the formation system.
delivery of six additional low-floor trams
for $10.5 million (EUR 8.83 million). This
A summer to remember
represented the continuance of successful
cooperation, which began in 2018, with The successes achieved in 2020, as great
the agreement on the supply of the first as they were, could not match July 2020,

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 67
TECHNOLOGY

contracted equipment and works exceeds

$32.1 million (EUR 27 million). Under
the said contract, KONČAR will manu-
facture and deliver three horizontal syn-
chronous bulb-type generators with an
individual power of 13.8 MVA, with asso-
ciated excitation systems and a generation
unit monitoring system.

July also proved to be successful for

KONČAR - Small Electric Machines,
which delivered to the “3. MAJ” shipyard
in Croatia fans for cargo space, engine and
machinery rooms and additional equip-
ment, including fire dampers, ventilation
grilles, and funnel grilles for the construc-
tion of two new tankers for the transport
of oil and petroleum products, for clients
from Spain and Canada.

The largest solar power plant

In August 2020, KONČAR – Electric Vehicles in Croatia
and the Latvian company Liepājas Tramvajs Vis Solar Power Plant, currently the larg-
signed an agreement on the delivery of six est solar power plant in Croatia, is one
of KONČAR’s most important projects
additional low-floor trams, after successful in the field of renewable energy sources,
cooperation, which began in 2018 in which several KONČAR Group com-
panies took part. In July, five CON SOL
converters were commissioned, each with
the power of 720 kW, directly connected
when KONČAR – Power Plant and Elec- new Mokrice Hydro Power Plant in Slo- to the distribution network via a 10 or
tric Traction Engineering, as a member venia. The customer is “Hidroelektrane 20 kV medium-voltage transformer and
of the Consortium with the companies na spodnji Savi”, and the total value of the medium-voltage switchgear. KONČAR
Litostroj Power and Riko, contracted Group’s scope of works included obtain-
the supply of electrical and mechanical ing all the required permits, drawing up
equipment for the construction of the design documents, and delivering a
turnkey project, which included the
delivery of equipment, construction
and electrical installation works, and
connecting the power plant to the
connection facility TS 35/10 kV Vis.

“The result of joint efforts

of HEP and KONČAR in
the quest for energy auton-
omy and self-sufficiency
of Croatian islands is the
construction of modern
projects such as the first
non-integrated solar power
plant here on Vis. I would
like to emphasise that
through the development
of its KON-SOL convert-
ers, KONČAR ensured this
plant’s direct connection
to the distribution net-
work, thus reducing ener-
gy transformation losses.
Auxiliary transformer I hope that KONČAR will

68 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

continue to work closely together with
HEP in its announced investments
in harvesting energy from the sun by
supplying converters and power plant
operation and supervision systems”,
said Gordan Kolak, Chairman of the
Management Board of KONČAR –
Electrical Industry.
Vis Solar Power Plant, currently the larg-
est solar power plant in Croatia, is one of
KONČAR’s most important projects in the
field of renewable energy sources, in which
several KONČAR Group companies took part

Vis Solar Power Plant was completed and

put into operation last year, in Septem-
ber. It will produce about 5 million kWh
of electricity, which corresponds to the
electricity consumption of about 1,600
households. In 2021, the solution will be
upgraded by installing a battery tank.
Socially responsible
community member
In its daily pursuit of excellence, continu-
ous progress, and successful response to
any challenges, KONČAR Group never
overlooks the community in which it op-
erates. In 2020, in addition to its tradition
of humanitarianism, as one of the com-
pany’s core values, KONČAR gave special
importance to helping those most in need.
Thus, during 2020, donations were or-
ganised for 29 associations that care for
socially disadvantaged families and chil-
dren. In addition, KONČAR showed its
care for the wellbeing of the community,
especially of the youngest, by donating
HRK 1 million for the “Croatia against
Coronavirus” fundraiser. A donation was
also made to the Foundation – Children’s
Oncology Rebro, for the purpose of con-
struction and furnishing of the new De-
partment of Paediatric Haematology and
Oncology at the University Hospital Cen-
tre Zagreb. KONČAR takes special pride
in its Christmas donation to the Spe-
cial Hospital for Children with Chronic
illnesses in Gornja Bistra, for medical
equipment and needed didactic toys. Fi-
nally, members of the Management and
Supervisory Boards of KONČAR Inc.
made a private donation for incubator
purchase to the Parents of Preemies Club
“Palčići” by waving part of their personal
income, and the Group made a significant
donation for “Earthquake Relief ” for relief
efforts after the earthquakes that struck
several Croatian Counties.
www.koncar.hr/en/century-of-excellence/

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

ABSTRACT
German literature on power trans-
Books on power
transformers in
formers is covered from 1888 (first
book on transformers published any-
where, just three years after patent­

German – Part III

ing transformers), up to most recent
publications issued in 2019. The pur-
pose of the compilation of published
books on power transformers is to
give a historical summary on the top-
ic, which may also be useful to other A bibliography 1952 – 2016
specialists in their research.

KEYWORDS
calculation, construction, design,
DIN, historical development, power
transformers, testing, VDE
1952
Emil Pollak, Umwickeln elektrischer
Maschinen und Transformatoren
(Wrapping electrical machines and
transformers), Verlag Österreichischer
Gewerkschaftsbund, Wien, pages 112,
1952
Friedrich Weickert, Krankheiten elek-
trischer Maschinen und Transfor-
matoren (Failure Analysis of electrical

70 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Vitaly GURIN, P. RAMACHANDRAN

The time from the second part of the 20th century

up to the present time can be considered the era of
modern transformer technology which treats the
most advanced topics

machines and transformers), Ed. 11.0,
Fachbuchverlag, Leipzig, pages 228,
1952
1953
VDE-Vorschriften 3. Maschinen,
Transformatoren, Umformer, In-
stallationsmaterial, Schalt- und
Hochspannungsgeräte, Verbrauchs-
geräte. (VDE regulations 3. Machines,
transformers, converters, installation
material, switching and high-voltage
devices, consumer devices), Ed. 2.0,
VDE-Verlag, Wuppertal u. Berlin, pag-
es 771, 1953
1954
F. Ande, Betrieb und Anwendung von
Leistungs- und Regeltransformatoren
(Operation and application of power and
control transformers), Springer, Berlin,
pages 332, 1954
1955
F. Unger, Transformatoren (Transform-
ers), in books: E. V. Rziha, Starkstrom-
technik. Taschenbuch für Elektrotech-
niker, Band l (Heavy current technology.
Paperback for electrical engineers, Vol-
ume l), Ed. 8.0, Wilhelm Ernst & Sohn,
Berlin, pp. 573–620, 1955
1956
Rudolf Küchler, Die Transformatoren,
Grundlagen fur ihre Berechnung und
Konstruktion (The transformers, basics
for their calculation and construction),
Springer, Berlin, pages XI + 321, 1956;
Ed. 2.0, pages XII + 342, 1966; reprint
2013; print on demand book, 2017
Considered as the Bible of transformer
engineering in the German speaking
world. Understanding the theory and
application of transformers is neces-
sary for a successful career in the elec-
trical field, specifically in industrial
fields.
The book consists of the following sec-
tions: magnetic circuit, stray fluxes,
short-circuit stresses, voltage stresses,
load-bearing capacity, auto-transform-
ers, tap-changers , cooling, design of the
transformer, transformer noise.
1959
F. Ande, Die Schaltung der Leistung-
stransformatoren (The circuit of the
power transformers), Springer, Berlin,
pages 322, 1959

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 71
COLUMN
Book by Rudolf Küchler, Die Transforma-
toren, Grundlagen für ihre Berechnung und
Konstruktion is considered the Bible of
transformer engineering
1960
E. Breitenbruch, Transformatoren klein-
er Leistung (Low power transformers),
Friedrich Vieweg & Sohn, Braunschweig,
pages 212, 1960
O. Wolf, Durch magnetostriktive Kräfte
hervorgerufene Wechselverformun-
gen der Kerne von Drehstromtrans-
formatoren. Dissertation. (Variable
deformations of the cores of three-phase
transformers caused by magnetostrictive
forces. Dissertation.), TH Hannover, 1960
72
1961
AEG, Transformator-Differentialschutz
(Transformator-Differentialrelais RQ
4 und Schutzrelaiskombination für
Transformatoren RKT 1 (Transformer
differential protection (transformer dif-
ferential relay RQ 4, and protective relay
combination for transformers RKT 1),
Verlag AEG, pages 26, 1961 [50, 51]
W. Baxmann, Zur Theorie des Trans­
formatorlärms magnetischen Ur-
sprungs. Dissertation. (The theory of
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
transformer noise of magnetic origin.
Dissertation.), TH Hannover, 1961
F. Kümmel, Regel - Transduktoren. Theo-
rie und Anwendungen in der Regelung-
stechnik. (Rules for transducers. Theory
and applications in control engineering.),
Springer, Berlin, pages XI + 455, 1961
František Provazník, Probleme der
Transformatoren für höchste Spannung
und Leistung (Problems of high voltage,
large capacity transformers), Publisher of
the Czechoslovakia Academy of Sciences,
Prague, pages144, 1961 [52]
1963
H. Reinke, Berechnung der mecha-
nischen Eigenfrequenzen von Dreh-
stromkerntransformatoren. Disser-
tation. (Calculation of the mechanical
natural frequencies of three-phase core
type transformers. Dissertation.), TH
Hannover, 1963
1968
J. Reiser, Elektrische Maschinen: I
Grundlagen und Transformatoren (=
Das Fachwissen des Ingenieurs) (Elec-
trical machines: I Basics and trans-
formers (= The specialist knowledge of
the engineer), Carl Hanser, pages 126,
1968
1970
F. Taegen, Einfuhrung in die Theorie der
elektrischen Maschinen I – Transforma-
tor und Gleichstrommachine (Introduc-
tion to the theory of electrical machines
I - Transformer and DC machine), Friedr.
Vieweg & Sohn, Braunschweig, pages 197,
1970
1971
Gerhard Seifert, Stelltransformatoren
(Variable transformers), Huthig, Heiden-
berg, pages 351, 1971
Horst Spanneberg, Ruhende elektrische
Maschinen - Transformatoren und
Wandler - Lehrbuch für die Berufs-
bildung (Electric machines - Trans-
formers and converters - Textbook for
vocational training), Ed. 7.0, VEB Ver-
lag Technik, Berlin, pages 134, 1969;
Ed. 8.0, 1971; Ed. 10.0, 1982; Ed. 14.0,
1987; Ed. 15.0, 1989 [53, 54]
1972
Heinrich Klotz, Verfahren zur Berech-
nung und Entwicklung von Transfor-
matoren (Methods of calculation and
development of transformers), Siemens,
Munich, pages 32, 1972 [55]
1975
G. Aichholzer, Elektromagnetische En-
ergiewandler: Elektrische Maschinen,
Transformatoren, Antriebe (Electro-
magnetic energy converters: Electrical
machines, transformers, drives), Springer,
Wien, pages 860, 1975
1978
N. Boules, Beitrag zur Berechnung klei-
ner Transformatoren und Gleichrich-
terschaltungen. Dissertation. (Con-
tribution to the calculation of small
transformers and rectifier circuits. Dis-
sertation.), TUBraunschweig, pages 171,
1978 [56]
Wolfgang Hinze et al., Stromversorgung-
sanlagen militärischer Nachricht-
engeräte Teil 1 - Verbrennungskraft-
maschinen, Transformatoren und
elektrische Maschinen (Power supply
systems for military communications
equipment Part 1 - Internal combustion
engines, transformers and electrical ma-
chines), Militärverlag, Berlin, pages 162,
1978
1982
Jurgen Goldnau, Edgar Suss, Transfor-
matoren: Transformatorstationen für
Abnehmer - Planen, Errichten, Betrei-
ben (Transformers: Transformer stations
for customers - planning, building, oper-
ating), German publishing house for ba-
sic material industry, Leipzig, pages 222,
1982 [57]
D. J. Kraaij, G. S. Schemel,
F. M. Wegscheider, Die Pruefung von
Leistungs-Transformatoren (Testing
of power transformers), Book publisher
electrical engineering, Aarau / Switzer-
land, pages 100, 1983 [58]
1986
Werner Dietrich, Transformatoren:
Stand der Technik und Tendenzen
(Transformers: State of the art and trends),
VDE-Verlag, Berlin, pages 382, 1986
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Literature topics from the 1950s to 1980s
shaped the modern technology of the trans-
formers we know today
1987 Berechnung der Übertragungsfunktion
Dieter Nührmann, Stromversorgungs- (High frequency modeling of transform-
Praxis: Transformatoren, Gleichrichter- ers to calculate the transfer function),
und Stabilisierungsschaltungen (Power Shaker Verlag, Stuttgart, pages 153, 2001
supply practice: Transformers, rectifiers [64-66]
and stabilisation circuits), Franzis, Mu-
nich, pages 232, 1987 [59]
2002
Jochen Christian, Erkennung mecha-
1990
nischer Wicklungsschäden in Transfor-
Gregor D. Häberle, Heinz O. Häberle, matoren mit der Übertragungsfunktion
Transformatoren und elektrische (Detection of mechanical winding dam-
Maschinen: In Anlagen der Energi- age in transformers using the transfer
etechnik. Bibliothek des Technikers. function), Shaker Verlag, pages 156, 2002
(Transformers and electrical machines: In [67]
energy technology systems. Technician’s
library.), Ed. 2.0, Verlag Europa-Lehrmit-
2005
tel, Haan-Gruiten, pages 286, 1990 [60]
Hermann J. Abts, Verteil-Transforma-
toren / Distribution-Transformers, Hei-
1991
delberg Hüthig, pages 196, 2006; Ed. 2.0,
Wilfried Weißgerber, Elektrotechnik für VDE Verlag, Berlin, pages 206, 2017 (bi-
Ingenieure 2: Wechselstromtechnik, Ort- lingual book)
skurven, Transformator, Mehrpasensys-
teme. Ein Leh- und Arbeitsbuch für das Robert Janus, Hermann Nagel, Transfor-
Grundstudium. (Electrical engineering matoren (Transformers), Ed. 2.0, VDE
for engineers 2: AC technology, locus Verlag, Berlin, pages 80, 2005
curves, transformer, multi-phase sys-
tems. A teaching and workbook for basic
2007 [68-70]
studies.), Vieweg & Sohn, Braunschweig,
1991; Ed. 2.0, 1993; Ed. 3.0, 1996; Ed. 4.0, Michael Meinert, Hohachtemperatur-
pages VIII + 372, 1999; Ed. 7.0, 2009; supraleitende Transformatoren für
Ed. 8.0, 2012 [61, 62] künftige Schienenfahrzeuge (High-tem-
1993
Rudolf Janus, Transformatoren (Trans-
formers), VDE-Verlag, Berlin, pages 188,
1993 [63]
1997
H. Vosen, Kühlung und Belastbarkeit
von Transformatoren: Erlauterungen
zu DIN VDE 0532, VDE - Schriften-
reihe Nr. 72 (Cooling and resilience
of transformers: Explanations of DIN
VDE 0532, VDE - series No. 72), VDE
Verlag, pages 192, 1997
2001
Ebrahim Rahimpour, Hochfrequente
Modellierung von Transformatoren zur
73
COLUMN
Weißgerber’s Elektrotechnik für Ingenieure
2 (Electrical engineering for engineers 2) is
an excellent teaching textbook and work-
book that covers the basics of transformer’s
technology
perature superconducting traction trans-
formers for future rail vehicles), Shaker
Verlag, Aachen, pages 346, 2007
2008
Gerhard Herold, Elektrische Energiev-
ersorgung 2: Parameter elektrischer
Stromkreise, Leitungen, Transforma-
toren (Electrical energy supply 2: Parame-
ters of electrical circuits, lines, transform-
ers), Ed. 2.0, Schlembach, Wilburgstetten,
pages 564, 2008
2009
Ulrich Wagner, Elektrische Kraftwerk-
stechnik 1: Generatoren, Transforma-
toren, Eigenbedarfsanlagen, Schutzein-
richtungen; Vorlesungsskript (Electrical
power plant technology 1: Generators,
transformers, own requirements, protec-
tive devices; Lecture script), Ed. 5.0, Tech-
nical University of Munich, pages 177,
2009 [71]
2010
Peter Baier, Dreiphasen-Leistungstransfor-
matoren - Magnetisierungserscheinun-
gen, Harmonische, Betriebsvorgänge,
Stell- und Stromrichtertransformatoren
(Three-phase power transformers - mag-
netisation phenomena, harmonics, opera-
tions, actuators and converter transform-
ers), VDE Verlag, Berlin, Pages 204, 2010
[72, 73]
2011
André Berger, Entwicklung supra-
leitender, strombegrenzender Transfor-
matoren; Dissertation; (Development of
superconducting, current-limiting trans-
formers; Dissertation), KIT Scientific Pub-
lishing, Karlsruhe, pages 163, 2011 [74]
2014
Bernd Aschendorf, FEM bei elektrischen
Antrieben 1: Grundlagen, Vorgehens-
74
+Transformator-Differentialrelais+RQ
+4+und+Schutzrelaiskombination+f%
C3%BCr+Transformatoren, current on
7 May, 2020
[52] https://www.tib.eu/de/suchen/
id/­­­TIBKAT%3A214440451/Probleme­-der­-
Transformatoren-f%C3%BCr-h%­C3%­
B6chste-Spannung/, current on 7 May,
2020
weise, Transformatoren und Gleich-
strommaschinen (FEM for electrical [53] https://www.booklooker.de/B%­
drives 1: Basics, procedure, transformers C3%BCcher/Angebote/autor=H+­
and DC machines), Vieweg & Teubner Spanneberg, current on 7 May, 2020
Verlag, Wiesbaden, pages 529, 2014 [75]
[54] https://www.booklooker.de/B%­
Leonhard Stiny, Elektrotechnik für Stud- C3%BCcher/Angebote/­t itel=Ruh
ierende: Wechselstrom 2 - Ortskurven, ende+elekt r is che+Mas chinen+-
Mehrphasensysteme, Transformatoren +Transformatoren+und+Wandler+-
und Übertrager - Band 4 (Electrical en- +Lehrbuch+f%C3%BCr+die+Berufsbi
gineering for students: AC 2 - locus, multi- ldung, current on 7 May, 2020
phase systems, transformers and heat ex-
changers - Volume 4), Verlag Christiani, [55] https://www.tib.eu/de/suchen/id/­
pages 256, 2014 [76] TIBKAT%3A054286859/Verfahr­e n-
zur-Berechnung-und-Entwicklung-
von-Transformatoren/, current on 7
2016
May, 2020
Joh. Shlenker-Maier, ISMET Transfor-
matoren 290 (ISMET Transformers 290), [56] https://vufind.techlib.cz/Record­
Joh. Shlenker-Maier, Schwenningen, pag- /­000154588/Details, current on 7 May, 2020
es 88, 2016 [77]
[57] https://www.booklooker.de/B%­
Frank Zinecker, Optimierung eines Tes- C3%­B C cher/Angeb ote/titel=­Tra
la-Transformators - Methoden und nsformatoren+Transformatorstat
Anwendungen (Optimisation of a Tesla ionen+f%C3%B Cr+Abnehmer+-
transformer - methods and applications), +Planen+Errichten+Betreiben, current
AV Akademikerverlag, pages 56, 2016 on 7 May, 2020
[78, 79]
[58] https://books.google.com.ua/books­
/­a bout/Die_Pr%C3%BCfung_von­_
Conclusion
Leistungs_Transformator.html?id=­
While working on the bibliography, the
authors tried to compile a historical sum-
mary of the published books on power
transformers in German language and did
not pursue commercial goals. They hope
that the bibliography will be useful to oth-
er specialists in their research, and also
may create awareness among new-gener-
ation engineers of the path we have trav-
elled so far.
Bibliography
[50] https://www.booklooker.de/B%­
C3%BCcher/Angebote/autor=AEG,
current on 7 May, 2020
[51] https://www.booklooker.­de/­B%­­
C3­%­B Ccher/Angebote/titel=Trans­
f o r m a t o r - D i f f e r e n t­i a l s c h u t z ­
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
FmZpHwAACAAJ&redir_es c=y,
current on 7 May, 2020
[59] https://www.abebooks.de/servlet/
SearchResults?an=n%FChrmann%20
dieter&cm_sp=det-_-bdp-_-author,
current on 7 May, 2020
[60] https://books.google.com.ua/books­/
about/Transformatoren_und_elekt­
rische_Maschine.html?id=OjaitgAA­
CAAJ&redir_esc=y, current on 7 May, 2020
[61] https://www.booklooker.de/B%C3­
%­­B Ccher/Angebote/autor=­Wil­f ried­
+Wei%C3%9Fgerber, current on 7 May, 2020
[62] https://www.booklooker.de/B%­
C3%­­BCcher/Angebote/titel=­Elektrote
chnik+f%C3%BCr+Ingenieure+2+We
chselstromtechnik+Ortskurven+Trans-
formator+Mehrphasensysteme, current
on 7 May, 2020
[63] https://www.amazon.com/Trans­
f o r m­a t o r e n - R u d o l f - J a n u s / d p /­
3800­719630, current on 7 May, 2020
[64] https://www.booklooker.de/B%­
C3%BCcher/Angebote/autor=Ebra-
him+Rahimpour, current on 7 May, 2020
[65] https://www.booklooker.de/B%­
C3%­B Ccher/Angebote/titel=­Hochfre
quente+Modellierung+von+Transfor-
matoren+zur+Berechnung+der+%C3
%9Cbertragungsfunktion, current on 7
May, 2020
[66] https://www.booklooker.de/B%­
C3%­B Ccher/Angebote/verlag=Shak-
er+Verlag, current on 7 May, 2020
[67] https://www.amazon.com/Erken-
nung-mechanischer-Wicklungssch
%C3%A4den-Transformatoren-%C3
%9Cbertragungsfunktion/dp/3832204
806
[68] https://www.booklooker.de/B%­
C3%B Ccher/Angebote/autor=Ja-
nus+Rudolf%3B+Nagel+Hermann,
current on 7 May, 2020
[69] https://www.booklooker.de/B%C3­­
%­­BC­­cher/Angebote/titel=­Trans­­form­
atoren, current on 7 May, 2020
[70] https://www.booklooker.de/B%C3%-
BCcher/Angebote/verlag=VDE+VER-
LAG, current on 7 May, 2020
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Some of today’s hot topics in the German
transformer related literature include anal-
ysis, design or optimisation of transformers
using FEM as well as the development of
superconducting transformers
[71] http://mediatum.ub.tum.de/node?­ nd&cm_sp=det-_-bdp-_-author, cur-
id=­829413, current on 7 May, 2020 rent on 7 May, 2020
[72] https://www.booklooker.de/B%C3­ [76] https://www.abebooks.de/servlet/
%BCcher/Angebote/autor=Peter+­ SearchResults?an=leonhard%20sti-
Baier, current on 7 May, 2020 ny&cm_sp=det-_-bdp-_-author, cur-
rent on 7 May, 2020
[73] https://books.google.com.ua/bo
oks?id=irZpPgAACAAJ&dq=Dreip [77] https://www.booklooker.de/B%C3­
hasen­- Leistungstransformatoren+- %BC­c her/Angebote/titel=ISMET­
+Magnetisierungserscheinungen +Transformatoren+290, current on 7 May,
& h l = u k & s a = X & ve d = 0 a h U K Ew j 2020
W 0 r D C _ a P p A h XQA x A I Hf j w B -
7MQ6AEIKjAA, current on 7 May, [78] https://www.booklooker.de/B%C3%­­­
2020 BC­cher­/Angebote/titel=­­Optimierung­
+eines+­Tesla-Trans­form­ators, current on
[74] https://www.ksp.kit.edu/­978386­­644- 7 May, 2020
6373, current on 7 May, 2020
[79] https://www.booklooker.de/B%­­­­C3-
[75] https://www.abebooks.de/servlet/ ­%­­B C­cher­/Angebote­/verlag=AV+Aka-
SearchResults?an=aschendorf%20ber- demikerverlag, current on ­7 ­May, 2020
Authors
Vitaly Gurin graduated from Kharkov Polytechnic
Institute (1962) and graduate school at the Leningrad
Polytechnic Institute. Candidate of technical sciences
in the Soviet scientific system (1970). For 30 years he
tested transformers up to 1.150 kV at ZTZ, including
the largest one of that time in Europe, and statistically
analysed the test results. For over 25 years he was the Ex-
ecutive Director of Trafoservis Joint-Stock Company in
Sofia (the diagnosis, repair and modernisation in the operating conditions
of transformers 20 – 750 kV). He has authored about 150 publications in
Russian and Bulgarian, and is the main co-author of GOST 21023.
P. Ramachandran started his career in transformer in-
dustry in 1966 at TELK, Kerala, a Hitachi Joint venture,
in India. He worked with ABB India during 1999-2020.
He has more than 50 years of experience in the design
and engineering of power products including power
transformers, bushings, and tap-changers. He received
Bachelor of Science Degree in Electrical Engineering
from the University of Kerala, India, and Master of Busi-
ness Administration Degree from Cochin University, India. He is a Fellow of
Institution of Engineers (India), and he represented India in CIGRE Study
Committee A2 for transformers during 2002 – 2010.
75
INTERVIEW

ABSTRACT
The April issue brings an interview
with Ismail Güner – an experienced
power transformer engineer, current-
ly working at Hydro- Québec, whose
article “The power of sharing knowl-
edge” has been selected by our valu-
able readers as the best article in
2020.

76 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

We have accumulated substantial behavioural data on older and new-
er designs, but we need to do a better job in sharing the transformer
behavioural analytics amongst ourselves for more reliable performance
indicators
ISMAIL GÜNER
The author of TM Best article 2020
Why did you find this topic
interesting / important (how
did you decide to write about
the topic)?
I have always been intrigued by the lack
of knowledge sharing and collaboration
amongst electrical utilities on best prac-
tices of design specifications, condition
assessment, maintenance and maximiz-
ing lifecycles of power transformers.
A significant number of power trans-
formers in operation in North America
and in Europe are in the second half of
their life expectancy. Over the past de-
cades, we have accumulated substantial
behavioural data on older and newer
designs, but we need to a better job in
sharing the transformer behavioural
analytics amongst ourselves for more
reliable performance indicators. This
would let us identify genetic or de-
sign-related problems, predict possible
failure mechanisms and be proactive.
Knowledge and data sharing among
end-users can also help to compensate
for unfamiliarity with a specific type of
critical component, technology or sup-
The explicit or written knowledge is, in a
way, the tip of the iceberg. There is so much
that is unwritten, learned with experience
and difficult to document in guides and
standards
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
plier. Before we purchase a vehicle or
go to a new restaurant, one of the first
things that we do is to read the review
because we value the experiences of
others. Sharing the post-mortem and
failure pattern data between electrical
network operators would provide the
ability to anticipate a failure mechanism
without any prior experience or con-
dition assessment action on a critical
component and to adjust its mainte-
nance strategies accordingly.
Most end users tend to rely on technical
societies such as IEEE, IEC, CIGRÉ to
provide information on evolving equip-
ment issues. Initiatives such as Trans-
formers Academy by Transformers Mag-
azine are important means to connect the
experts with end-users. Even then, it is up
to the utility specialist engineers to stay
current with the latest guides, standards,
publications and trends in order to iden-
tify the issues that may be relevant to their
particular fleet profile. We should work
together to avoid reinventing the wheel.
There is already a substantial amount of
data available waiting to be shared, ana-
lyzed and understood.
The COVID-19 pandemic has shown us
that we need to think, plan, prepare and
act globally in order to deal with such
large-scale functional disruptions. Many
utilities have faced new challenges such
as limiting or cancelling planned outages,
disruptions in the supply chain, adapting
to changes in electricity consumption
patterns, delays in maintenance activi-
ties, and loss of personnel due to self-iso-
lation measures. This pandemic is an
important reminder that collaboration
For the past thirteen years, Ismail
Güner has been a part of the power
transformers community. He has
been involved in all stages of the
life cycle of transformers, from the
design to the end-of-life decision.
Mr. Güner earned his Bachelor of
Engineering in electrical power en-
gineering from École Polytechnique
de Montréal, Canada. After gradu-
ation, he worked as a power trans-
former electrical design engineer
at ABB (ABB Hitachi) Varennes, one
of the world’s leading transformer
manufacturers. He currently holds
the position of power transformer
engineer at Hydro- Québec. He is re-
sponsible for performance analysis,
condition assessment, maintenance
and replacement strategies of power
transformers and shunt reactors up
to 735 kV. He is an active member of
IEEE transformers committee work-
ing groups and IEC Canadian mirror
committees.
77
INTERVIEW
We are steps closer to build reliable digi-
tal models that would evolve in real-time to
account for power transformers’ behaviour
changes
amongst utilities in order the prioritize
maintenance activities for more resilient
power networks is more important than
ever.
What are the biggest
challenges that power
networks face in the context
of power transformer fleet
management?
Capturing and transferring tacit knowledge
on power transformers is one of the biggest
challenges that power networks face. One
of my old technical managers always used
to say that power transformer design is not
an exact science. He was encountering new
challenges even after more than 30 years in
the business. So many like him have inher-
ent skills, intuition and mental models of
how complex parts come together.
“The key to good decision m aking is not
knowledge. It is understanding. We are
swimming in the former. We are desper-
ately lacking in the latter”, writes Malcolm
Gladwell in his book Blink. One of the best
arguments for utilities to work together is
the lack of understanding of power trans-
former behaviour. Since 2012, a significant
number of skilled electrical equipment
specialists have retired from the industry,
so has their valuable knowledge.
The explicit or written knowledge is, in a
way, the tip of the iceberg. There is so much
78
that is unwritten, learned with experience
and difficult to document in guides and
standards. Utilities could have an effective
strategy against the loss of experience and
competency in specific technical fields.
Companies must first decide if the knowl-
edge belongs to an individual or to the
enterprise. If a company starts to see
knowledge as an asset, then it can have a
monetary value and a KPI. Manufacturers
and utilities must improve their organiza-
tional behaviour towards knowledge cre-
ation and transfer.
I tend to agree with the notion that
knowledge belongs to everyone and it
must be public, understanding however
that it is intellectual property. Individuals
with significant tacit knowledge must ask
themselves if it is their ethical responsi-
bility to make sure that their knowledge
and understanding are properly stored
or transferred before they leave the in-
dustry.
Implementing mentorship programs is es-
sential for the future of our industry, more
specifically in standardization activities.
We must introduce programs that will en-
gage young professionals to increase their
participation in standardization and their
technical knowledge. A database of spe-
cialists created within such a program can
match mentors with young professionals
to ensure an efficient transfer of specialist
knowledge.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
Is there anything you would
like to mention about the
current developments in the
industry in connection with
your article?
Our vocabulary is expanding in this new era
of big data and digitalization. We talk more
about data science and artificial intelligence.
We all would like to make the data talk to us
so that we can determine the best possible
life cycle management decision at the right
time. The investment trends in predictive
maintenance models based on condition
assessment data and anticipating the failure
patterns are very encouraging. We are steps
closer to build reliable digital models that
would evolve in real-time to account for
power transformers’ behaviour changes.
Another encouraging trend is the power
system resiliency initiatives. Power grid re-
silience is the ability to avoid, prepare for,
minimize, adapt to, and recover from antici-
pated and unanticipated energy disruptions
in order to ensure grid availability and reli-
ability. Power network operators recognize
that the traditional reliability or health indi-
ces are not as efficient as risk-based and resil-
ience-oriented metrics when high-impact,
low-probability events such as pandemics
take place. International organizations have
already initiated discussions on impact
quantification of high-impact events. Future
working groups will certainly produce tech-
nical criteria for power transformer life cycle
management decision portfolios.
About the company
Our mission is to deliver reliable electric
power and high-quality services. By de-
veloping clean, renewable energy sources,
we make a strong contribution to Québec’s
collective wealth and play a central role in
the emergence of a low-carbon economy.
As recognized leaders in hydropower and
large transmission systems, we export clean,
renewable power and leverage our expertise
and innovations within Québec and around
the world. We operate some 60 hydroelec-
tric generating stations, making us one of
the largest hydroelectricity producers in the
world. Hydro-Québec’s transmission system
is the most extensive in North America: over
34,000 km of high-voltage lines running
from large generating stations in remote ar-
eas to the province’s more populated areas.
Our power transformer fleet is one of the
most diverse in the world in terms of type,
insulation level and operational complexity.
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 REPAIR
Transformer leak repair
story from Polywater®
The fast and effective repair of power transformer
oil or SF6 leaks is an important part of a consistent
power supply that minimise economic losses for
both power utilities and their customers
T
he fast and effective repair of
power transformer oil or SF6
leaks is an important part of a
consistent power supply that
minimises economic losses for both pow-
ABSTRACT
Resilient and cost-effective mainte-
nance of the grid using innovative
technologies like PowerPatch from
Polywater helps sustain the critical
systems in operation. The intrusive
processes required to replace a large
oil tank gasket can take twice as long
and be three times costlier than the
Polywater leak repair option.
KEYWORDS
gasket, leak, oil, repair, SF6
80
er utilities and their customers. Ongoing
transformer maintenance programs are
critical to reliable electrical power gener-
ation and services. When immediate re-
placement of a transformer gasket is not
feasible, a fast and reliable repair solution
is required on location for a gasket oil leak.
The following Leak Repair Story from
Polywater will describe a leak repair sce-
nario often encountered in the field: The
repair of a generating transformer bell
tank gasket leak in India where Polywater®
PowerPatch® Leak Repair system was
used to repair oil leaks to maintain a reli-
able power supply.
Oil leakage problem to be
resolved
An Indian generation utility was preparing
for overhauling its transformer fleet during
a scheduled annual shutdown. However, oil
leakage from the Bell Tank of a 260 MVA
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
generating transformer (GT) gasket and
bolts was a serious concern for its owner.
Customer repair options
The transformer owner had two options
available to fix the gasket leak: gasket
replacement or gasket leak repair. The
former is an intrusive option as the
transformer oil must be removed and
the bell tank needs to be lifted to replace
the gasket. The latter option, gasket leak
repair, is a non-intrusive process where
the leak is repaired from the outside,
eliminating the need for lifting and oil
removal.
In this case, the GT had provided reliable
service for over a decade, but the asset
manager was hesitant to expose the core
of the transformer to atmospheric oxygen
and moisture if traditional gasket replace-
ment practices were to be used. It was also

determined that the costs of lifting the ac-
tive part of the transformer and oil treat-
ment required for the intrusive replace-
ment option would be high. The customer
also needed to minimize the risk of open-
ing a well operating transformer to expose
it to atmospheric moisture. The chosen
option for the upcoming shut-down
needed to be a sealant technology that al-
lowed for the leak to be stopped without
the need for oil treatment and need to lift
the bell tank.
Minimum
expectations / trade offs
The Operations and Maintenance (O&M)
team of the generation utility had some
minimum expectations for the gasket leak
repair system. These were:
• The oil leakage must be stopped com-
pletely
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
• The oil leakage should not reoccur for a
number of years (3-5 years in most cas-
es) OR at least up to the next planned
shutdown
Past experiences
In previous years, the transformer owner
had used its own repair teams to tighten
the bolts on the cover of the transformer
to stem the oil flow. This had been done
enough times that further tightening
would have been counter-productive
due to the potential ageing of the gasket.
The customer had also used its repair
team and outside contractors in past
Transformer gasket leakage can be repaired
without draining transformer oil, using Poly-
water PowerPatch Leak Repair System
Advertorial
shutdowns to stop oil leakage. Different
sealant materials were used for these
repairs, but they did not perform well
with active gasket leaks. The most re-
cent oil leak repair material had started
to leak heavily from multiple points, so
a more effective repair material needed
to be identified and approved.
The generating plant’s maintenance
manager had attended a transformer
maintenance workshop, TRAFOCARE,
where he had seen a presentation and
video of how leakage can be repaired
without draining transformer oil, us-
ing Polywater PowerPatch Leak Repair
81
 REPAIR
If only the oil leak area is sealed, the oil can
migrate to unsealed areas and start to leak
again
System. The maintenance manager
approached Polywater and their local
application team, LeakXpert, for a solu-
tion to seal the gasket leak.
PowerPatch leak repair
system
The application team first presented
the capabilities of the Polywater Pow-
erPatch to ensure that it met the re-
quirements of the repair to be done.
PowerPatch is specially formulated for
use with high-voltage electrical equip-
ment. This advanced sealant is based
on multi-polymer technology and is
used to repair both oil and SF6 leaks. It
offers the physical and electrical char-
acteristics required in generating plant
operations.
Below are some of the features of Pow-
erPatch that made it the right leak re-
pair technology for this application:
• PowerPatch has dielectric properties
similar to other components inside
the transformer, such as oil and solid
insulation. This compatibility reduc-
es the risk of partial discharge and its
damaging effects on transformer per-
formance.
Transformer at time of site visit
82
• Flexible and easily removed - the Pow-
erPatch allows for the expansion and
contraction caused by frequent load
changes and vibrations common for
GTs. Its high adhesion to the repaired
surface resists pressures up to 1.4 MPa
on steel to withstand these high me-
chanical forces. Although strong, it can
be easily removed if used as a short-
term repair.
• PowerPatch is resistant to weathering
such as UV exposure and to tempera-
ture extremes. It has been environmen-
tally aged in extreme conditions, in-
cluding rain, snow, sleet, and UV with
an in-use temperature range of -40 °C
to 150 °C (-40 °F to 300 °F).
These features of PowerPatch met the re-
quirements that the transformer owner
needed to ensure reliable power produc-
tion. But, before making the final decision
if PowerPatch was the right choice for the
gasket repair, an on-site visit to assess the
The sanding or grinding of the metal sur-
face helps to increase the surface area to
which the PowerPatch adheres, giving the
seal greater strength
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
transformer’s physical surroundings was
requested.
Site visit
Each transformer oil leak is different.
Many transformer bell-tank perimeters
can be as long as 18 meters (60 ft.) in
length and can contain over 200 bolts.
When repairing a gasket leak, the en-
tire length of the gasket must be sealed.
If only the oil leak area is sealed, the oil
can migrate to unsealed areas and leak
again. The bolts holding the tank tightly
to the transformer must also be sealed.
If not, once the tank’s full perimeter is
sealed, the oil will follow through the
path with the least resistance and start to
leak through the bolt threads.
With these issues in mind, the LeakX-
pert team visited the generating plant to
survey the transformer to determine the
amount of sealant required and to assess
any points of limited physical access to the
area to be sealed. The repair team found
some areas behind marshalling boxes that
would make the application of the sealant
difficult. The LeakXpert team informed
the customer about these areas, and the
Removal of old sealant

customer agreed to remove the boxes be- The permanent PowerPatch resin has strong
fore the gasket repair began. The visit also
revealed that the previously applied seal- adhesion to the metal surface and cures
ant would require much time and effort to
remove.
quickly - a functional cure can be reached
within one hour after application
Removal of previous sealant
material
The repair process non-leaking lengths of the tank’s pe-
Before the repair process could start, the The application process to seal the bell rimeter and bolts are sealed first. Then
leaking sealant material that was pre- tank leak is very important. Migration lengths adjacent to these non-leaking
viously applied had to be removed. In of oil along the path of least resistance areas are sealed. This process continues,
many cases, this removal process is the is very common. To minimise this moving closer and closer to the points
most time-consuming part of a gasket problem, instead of starting the repair of active leakage. Once the active leak
repair. Various materials have been used process at points of the active leak, point is reached, it is sealed. This seal-
in the past that are difficult to remove.
These range from rubberised materials
to hard resin compounds. They all must
be scraped off with chisels or grinding
wheels, a physically demanding task,
which often leaves residual materials on
the repair surface that then must be re-
moved with strong cleaning solvents.
This makes PowerPatch’s removability an
advantage if used as a temporary seal on
a transformer awaiting replacement parts.

The LeakXpert team removed the old ma-

terial from the GT over two days. Once
removed, the surface was wiped clean
with an environmentally friendly cleaner.
It was then time to start the PowerPatch
application procedure. Step 1: surface preparation

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 83
 REPAIR
PowerPatch cartridge kit
ing process ensures that the leak will be
completely repaired, preventing the oil
from migrating to unsealed areas along
the perimeter of the tank.
Surface preparation
Once the previously applied material
was removed, the steel surface on which
the PowerPatch was to be applied need-
ed to be sanded and wiped clean. This
step’s goal was to remove paint and con-
tamination that can reduce adhesion of
Step 2: sealing non-active leaks with PowerPatch cartridge
84
PowerPatch to the repair area. In addi-
tion, the sanding or grinding of the metal
surface helps to increase the surface area
to which the PowerPatch adheres, giving
the seal greater strength. In many gasket
repairs, the leak appears to arise from
one point when the origin of the gasket
leak may be quite far away. Polywater’s
experienced repair team, LeakXpert,
used the surface preparation step to dis-
tinguish areas of active leaks containing
true points of leakage from those that did
not.
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
Sealing non-active areas
The steps required in the application of
PowerPatch depend on the type of leak,
active or non-active. In a typical gasket
leak repair, most of the main tank pe-
rimeter does not have active leakage, but
there is often the oil that has migrated
from actively leaking areas. The process
for sealing non-active leaks is easier than
for active leaks. Any oil accumulated in
non-active leak areas must be cleaned,
and then the permanent PowerPatch
resin should be applied directly onto the
metal of the transformer. This process
should be done repeatedly at lengths
of 2-3 meters (6-10 ft.) until approach-
ing an active leak area. The permanent
PowerPatch resin has strong adhesion
to the metal surface and cures quickly.
A functional cure can be reached with-
in one hour after application at 20 °C
(68 °F).
PowerPatch Repair Sealant - the Power-
Patch two-part permanent repair resin
was applied from a cartridge and mixing
nozzle in this repair. The application tool
was used to inject resin components from
the cartridge into the mixing nozzle. In the
nozzle, they are accurately metered and
thoroughly mixed to ensure reliable seal-
ing performance. Unlike other sealants
that require proportion measurement and
hand-mixing, all PowerPatch packages are
premeasured to offer consistent curing
times, strength and durability for excellent
sealing results.

Sometimes it is difficult to know if the

presence of oil is a result of an active leak
or oil migration from another leak area. In
the case of the gasket repair on the GT, the
LeakXpert team was not sure of the source
of the oil on certain spots of the tank pe-
rimeter. In these areas, they used the re-
pair process for active leaks described
below.

Sealing active leaks

Step 3: sealing active leak with fast-curing putty
Active leaks can be detected as seepage
accumulating on the surface of the trans-
former or as droplets of oil falling from
the leak area. In the Surface Preparation
photo (Step 1), droplets of oil can be seen
dripping from the prepared surface. Once
adjacent non-leaking areas have been
sealed, active leakage points are now ready
to be repaired.

Sealing active leaks takes an additional

step. This step aims to stop the active leak
from allowing for proper surface prepa-
ration and the application of the perma-
nent PowerPatch material as described
in the previous section. After abrasion
and cleaning the leak area, a fast-curing
putty is applied directly over the active
leak and held under hand-pressure until
it hardens. This takes typically 5-7 min-
utes, depending on temperature. Once Step 4: oil leakage is successfully arrested
hardened, surface preparation is done
again, including sanding, grinding and
cleaning around the putty. When proper- The PowerPatch offered an unintrusive al-
ly prepared and cleaned, the permanent
PowerPatch resin is applied directly over
ternative to traditional gasket replacement
the putty and then spread one (1) cm (0.4 that required less time and money
in.) beyond the edges of the putty at all
points. When the PowerPatch resin hard-
ens and cures, it forms a strong and du-
rable seal. Summary be three times costlier than the Poly-
Resilient and cost-effective maintenance water leak repair option. The Polywater
The repair of an active leak can be diffi- of the grid using innovative technologies PowerPatch Leak Repair System used by
cult, especially for inexperienced repair like PowerPatch from Polywater helps LeakXpert in the repair of the GT was
teams. The LeakXpert team’s extensive sustain the critical systems in operation. less time consuming, less expensive than
experience using PowerPatch putty and The GT’s owner opted for PowerPatch conventional gasket replacement and did
the permanent PowerPatch sealant to stop because of its ability to withstand me- not expose the core to atmospheric gases
active leaks allowed for the GT gasket to chanical expansion / contraction and and moisture.
be sealed quickly and efficiently. More im- its high dielectric strength matching the
portantly, the PowerPatch offered an un- electrical properties of the other compo- For more information on
intrusive alternative to traditional gasket nents within the transformer. The intru- Polywater PowerPatch, scan
replacement that required less time and sive processes required to replace a large the QR code or contact us at
money. oil tank gasket can take twice as long and global@polywater.com

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 85
MONITORING
It is firmly established that DGA is one of
the best methods for detecting internal
faults of the power transformers
ABSTRACT
Over the years, online dissolved gas
analysis (O-DGA) has gained traction
with power transformer asset man-
agers. Many asset engineers have
realized the technical benefits of the
shift from traditional laboratory-based
DGA to O-DGA. However, the main
stumbling block in widespread O-DGA
usage is convincing the commercial
86
team members of the economic ben-
efits gained by installing an O-DGA
device. Usually, with an O-DGA device,
there are different costs associated
- the upfront purchase cost, usage
costs over O-DGA monitor lifetime,
and O-DGA maintenance costs. In this
case study, an investigation is carried
out on the return of investment for
an O-DGA monitor for a service-aged
power transformer, utilizing the princi-
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
ples presented in IEEE c57.143. Two
monitors – a higher-priced O-DGA
monitor with minor maintenance ver-
sus a lower-priced O-DGA with regular
maintenance requirements are com-
pared.
KEYWORDS
cost-benefit, monitoring systems,
online DGA, return on investment

Investigating return on
online DGA investments
for service aged power
transformer
I. Introduction
Power transformers are critical assets that
ensure successful operation of many dif-
ferent applications - commercial plants,
data centers, oil and gas plants, renewable
plants, and utilities, among many. During
their operational years, these transformers
are subjected to stress, which can be cate-
gorized as thermal, mechanical, and elec-
trical. Each of these stresses contributes to
transformer aging. To maintain reliable
operation, different strategies have been
adopted by asset managers - visual inspec-
tions, routine oil sampling, mechanical or
electrical tests, refurbishment (oil filter-
ing, etc.), and replacements (when nec-
essary) to ensure continued operation of
these transformers.
It is now firmly established that dissolved
gas analysis (DGA) is one of the best
methods for detecting internal faults of
the power transformers shortly after it was
introduced [1]. There are international
standards / technical brochures from IEC
[2], IEEE [3], and CIGRE [4] providing
background and assistance in interpret-
ing DGA results. Traditionally, the gas
chromatography (GC) [5] based DGA has
been performed in oil laboratories all over
the world. It is very common to perform
offline DGA once or twice a year. This is
due to different reasons: operational costs,
lack of experienced staff, the complexity
of standards [6] that must be applied to
the extraction, storage, and transportation
of oil samples to laboratories.
There are certain fundamental issues re-
lated to offline DGA analysis:
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
• Yearly DGA sampling only provides a
snapshot of the transformer’s condition
at that time-point.
• There are issues related to laboratory
accuracy and repeatability.
• Contamination (air bubble) of an oil
sample during and / or after sampling.
• Lack of trained sampling staff.
• Degradation of the sample between the
time of analysis and time of sampling.
• Manual sampling in remote locations
is costly.
• The sample verification concept is
hardly followed.
To overcome some of these issues, online
DGA (O-DGA) is now becoming pop-
ular. A major benefit of O-DGA moni-
toring is its ability to detect failures that
are evolving faster than the usual year-
ly sampling interval and which would
otherwise remain undetected. O-DGA
monitors can pick up and alert about
changes in the gas production rates at an
early stage of an incipient fault in near re-
al-time. O-DGA monitors are especially
beneficial when “sick” or “remote” trans-
formers need to be sampled at regular in-
tervals when the significant dissolved gas
levels have already been identified, which
A major benefit of O-DGA monitoring is its
ability to detect failures that are evolving
faster than the usual yearly sampling inter-
val and which would otherwise remain un-
detected
Bhaba DAS
otherwise would not be viable for regular
manual sampling.
Although the advantages of O-DGA are
recognized, many end users are reluctant
to adopt it. Early O-DGA adapters have
tried to resolve the high operational costs
of O-DGA monitors, and some of them
have switched back to the traditional man-
ual DGA. A local survey was carried out by
the author, involving 11 different end-users
of O-DGA monitors to investigate the de-
cision-making process in the procurement
of O-DGA monitors and to understand the
discontinuation of using O-DGA moni-
tors in some cases. In the majority of cases
(70 %), the decision has been made by the
purchasing / commercial teams, while in
only 19 %, it has been the decision of the
engineering team. The engineering team
would evaluate various solutions, and most
of the time, the purchasing team would
pick the lower-priced O-DGA monitor.
With the availability of new O-DGA tech-
nology launched almost every year, specific
and detailed investment calculations are
required. Decisions based on economics
are unbiased and least controversial since
everybody understands dollars and cents.
87
MONITORING

In this case study, an investigation on the tured in 2007 is investigated to determine

return on investment in an O-DGA monitor
for a service aged power transformer is car-
ried out, utilizing the principles presented in
IEEE c57.143
This means assigning the dollar value to
all benefits, even to some intangible ones,
which is very relevant in the current busi-
ness environment as cost optimization and
using assets for a longer lifetime is required.
A very useful guide is the IEEE
C57.143.2012 [7], presenting a compre-
Table 1. Determining critical 2-FAL limits based on different furan-DP models [9]
DP = 400
Chengdong
Burton
De Pablo
Vuarchex
Average
hensive cost-benefit analysis method to
evaluate the economic benefits of online
monitoring. In this case study, an inves-
tigation on the return on investment in
an O-DGA monitor for a service aged
power transformer is carried out, utilizing
the principles presented in IEEE c57.143.
The 40 / 63 MVA transformer manufac-
2-FAL (ppm)
1,29
3,16
8,87
4,37
4.42 ≈ 5 (approx.)
if it is economically worth investing in
an O-DGA monitor, where the trans-
former showed significant 2-FAL values
along with an increasing concentration
of CO2/CO ratio. An unbiased investi-
gation method based on IEEE c57.143
was used to evaluate and compare differ-
ent O-DGA monitors in terms of the net
present value, internal rate of return, and
payback period.
II. TRANSFORMER UNDER
INVESTIGATION
The basic details of the investigated trans-
former are the following:
• rating = 40 / 63 MVA,
• voltage = 150 kV / 21 kV,
• oil type = mineral,
• paper type = kraft,
• year of manufacture = 2007,
• cooling = ONAN / ONAF,
• conservator = free breathing with air
bladder.
Standard oil test, together with the offline
DGA analysis tests, are routinely per-
formed once a year, and the data has been
recorded regularly for this transformer.
Furan measurements have not been per-
formed routinely. Over the service age of
13 years for this transformer, furans have

2-FAL (ppm) approximation

9

8
Condition Assessment Limit 7ppm
7

6
2-FAL (ppm)

Critical Limit 5ppm

5

4 R² = 0.9911 3.87

3
2.92
1.36
2

1
0.82 0.85
0
06-Jul-09 01-Apr-12 27-Dec-14 22-Sep-17 18-Jun-20 15-Mar-23 09-Dec-25 04-Sep-28 01-Jun-31

Figure 1. Straight-line trending of 2-FAL over time to estimate transformer retirement age

88 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

been measured five times. A straight-
line extrapolation plot of 2-FAL values is
shown in Fig. 1, to estimate when 2-FAL
values of 5 ppm (critical) and 7 ppm
(condition assessment required) will be
breached.
Furan measurements have gained pop-
ularity in the past 20 years because they
offer measurements of specific chemical
compounds such as 2-FAL, which can be
directly correlated with the aging of the
transformer’s paper insulation [8]. Several
equations describing a degree of polymer-
ization (DP) as a function of log10 (2-FAL)
for kraft paper have been developed, and it
is shown in [9] that accurate DP estimation
is not always possible. It is advisable not to
apply any furan-DP correlation without
proper analysis directly. Additionally, cer-
tain actions may affect the furan concentra-
tion in the oil, such as oil reclamation and
oil treatment, among others.
Furan measurement is popular because it
offers the measurements of specific chem-
ical compounds such as 2-FAL, which is di-
rectly correlated with the aging of the trans-
former’s paper insulation
quire a complete condition assessment of ment has been carried out for this
the transformer. As listed in Table 2 and 40 / 63 MVA transformer and by analyz-
Fig. 2, the average DP would be around ing the rate of furan production, a rea-
331, which indicates a considerable paper sonable estimate on 2-FAL values cross-
degradation. ing 7 ppm can be made. Utilizing the
five furan measurement results, a rate of
A decision for replacement will be re- furan generation is plotted in Fig. 1, and
quired at this point. As no oil treat- it can be estimated that the transformer
Table 2. Determining average DP @ 2-FAL = 7 ppm using furan-DP models [9]
2-FAL = 7 ppm DP

Typically, a DP = 200 is the end of life. Chengdong 189.9

As such, DP = 400 can be considered as
moderate paper deterioration. A 2-FAL Burton 330.8
> 5 ppm can be considered critical as per
Table 1, where the average 2-FAL value is De Pablo 358.1
determined using different DP models [9]
with DP = 400. Vuarchex 447.38

As such, and considering the logarithm Average 331

relationship, a 2-FAL ≥ 7 ppm would re-

Chengdon Burton Vuarchex De Pablo

1200
Critical Limit 5ppm

Condition Assessmnet Limit 7ppm

1000
Degree of Polymerization

800

600

400

200

0
0.01 0.1 1 10
2-FAL (ppm)

Figure 2. Critical and condition assessment limits based on different DP models [9]

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 89
MONITORING

600
Estimating
500 CO2/CO ratio
400 0
12 300 2006 2008 2010
200
R² = 0.5114
100
10 0
2006 2008 2010 2012 2014 2016 2018 2020

8 CO
CO2/CO ratio

0
2006 2008 2010 2012 2014 2016 2018 2020 2022 2024 2026
Figure 3. A straight-line trending of CO2/CO ratio over the time

With the increasing rate of gas production, by 2025 CO2/CO ≥ 11 (Fig. 3). This is an
indication of cellulose aging, which points
it is easier to install an O-DGA monitor rath- towards the transformer’s end of life. In-
er than increase the frequency of manual oil stalling an O-DGA monitor capable of cor-
relating other gases such as H2, CH4, C2H4,
sampling C2H6 would be ideal at this point.

Hence, any O-DGA monitor that is in-

replacement may be required by 2027
(2-FAL ≥ 7 ppm).
A similar estimation can be obtained by
plotting the CO2/CO ratio. Fig. 3 shows
that the CO2/CO ratio is also increasing
with the service age along with both indi-
vidual gas ppm values crossing 7000 ppm
and 800 ppm in 2019, whereas the CO2/
CO is almost 9 on average, still below 11,
indicating aging due to thermal heating.
A straight-line approximation shows that
stalled in this transformer must have a
payback period of less than approximately
5-7 years. Also, with the increasing rate of
gas production, it will be easier to install
an O-DGA monitor rather than increase
the frequency of manual oil sampling.

Table 3. O-DGA probability of detection calculation

Average CIGRE failure location %
Component O-DGA detection likelihood
(CIGRE 642:2015)

Winding 42% 50%

Bushing 17% 0%

OLTC 22% 0%

Lead exit 10% 25%

Core & magnetic circuit 9% 25%

Others 0% 0%

Overall probability 25.7%

90 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021


Detectable with
existing means :
0.3 30%
0.175
Catastrophic
failure: 10%
Figure 4. Breakdown of failure probabilities as per IEEE c57.143-2012.
III. UTILIZATION OF IEEE
C57.143
IEEE c57.143 guide describes the trans-
former’s operational parameters that can
be monitored, and it provides a cost-
benefit method to evaluate the application
of transformer monitoring. The funda-
mental economics used to calculate any
benefit are based on the equation:
Risk = Consequence x Probability
Probability is defined by a transformer
failure rate, whereas a consequence can
be the cost of major failure, cost of lost
production, cost of early detection of fault
(failure avoidance), etc. The failure rate (λ)
is calculated as:
No of units failed
λ= x 100%
Operating unit years
There are 14 transformers in this plant, with
combined operating unit years of 303 years,
with 3 failures due to which production had
to be stopped. This gives an average failure
rate of 0.99 % (1 % approximately).
The detection rate having installed only
an O-DGA device (in the main tank) can
be evaluated as below – the average failure
location numbers from CIGRE 642:2015
brochure is used in Table 3 to calculate
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Transformer Failure
rate = 1%
Non detectable
with existing
means : 70%
0.7
Not detected: 75%
Online DGA
Efficiency: 25%
(instantaneous 0.525
failures)
Non-catastrophic
failure:
90%
IEEE c57.143 guide describes the trans-
former’s operational parameters that can
be monitored, and it provides a cost-benefit
method to evaluate the application of trans-
former monitoring
the O-DGA probability of detection, i.e., • Yearly manual DGA can detect 30 %,
O-DGA monitoring efficiency. while 70 % of the failures cannot be de-
tected.
As per IEEE c57.143-2012, existing devic- • O-DGA monitor can detect 25 % (Ta-
es such as gas accumulation relays, top oil ble 3) from the rest of the undetected
temperature indicators, and winding tem- 70 % failures.
perature simulators can provide a warn- • 75 % of the undetected 70 % failure can-
ing about developing faults along with not be detected with O-DGA only. It is
periodic oil sampling. The proportion of unrealistic to expect 100 % coverage.
faults that can be detected by these means • The catastrophic failure rate is 10 %
is estimated at 30 % out of the calculated of the total failures, and the non-cata-
average failure rate of 1 %. The impact of strophic failures form 90 % of the total
O-DGA monitoring to reduce the failure failures. Although no catastrophic fail-
rate can be evaluated as below (as shown ure has been observed in this plant, a
in Fig. 4): 10 % likelihood is assumed.
Failure reduction calculations show that with
the O-DGA monitor, it is possible to prevent
47.5 % of all potential failures, while without
the online monitoring, the number is 30 %
91
MONITORING
Table 4. Benefits of O-DGA
With offline DGA
Failure occurring
Failure prevented
IEEE c57.143 states that a transformer is
normally retired if the failure rate is assumed
to be higher than the acceptable failure level
Failure reduction calculations (Table 4
and Fig. 4) show that with the O-DGA
monitor, it is possible to prevent 47.5 %
of all potential failures, while without the
online monitoring, the number is 30 %.
The result is that the O-DGA monitor
improves the failure rate by 45 % (abso-
lute difference), which can be considered
as a remarkable improvement.
The cost / benefit analysis of the trans-
former monitoring is a difficult under-
taking. Calculating the cost is relatively
straight-forward, taking into account
equipment purchase, installation, train-
Another recognized be­nefit from IEEE C57.143
consists of the savings generated from re-
duced repair / maintenance costs
Table 5. Annual benefits due to deferred replacement
Year
2020
2021
2022
2023
2024
2025
2026
2027
92
With O-DGA
70% 52.5%
30% 47.5%
ing, and maintenance costs, etc. The
benefits, however, are more difficult to
assess as the evaluation relies partly on
factors dictated by experience. Some tan-
gible events that can be quantified are the
following:
• reduced inspection and maintenance
costs,
• reduced failure-related repair or re-
placement costs,
• improved real-time transformer load-
ing capability,
• deferred upgrade capital costs due to
load growth,
Extension End balance
0 $500,000.00
1 $520,000.00
2 $540,800.00
3 $562,432.00
4 $584,929.28
5 $608,326.45
6 $632,659.51
7 $657,965.89
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
Relative improvement
Decrease by 28.5 %
Increases by 45 %
• deferred replacement capital costs due
to equipment age or condition,
• reduced cost of lost production.
In this example, the following benefits are
calculated:
A) Deferred replacement capital
costs due to equipment age
IEEE c57.143 states that a transformer is
normally retired if the failure rate is as-
sumed to be higher than the acceptable
failure level. For an aging transformer,
the risk is not so much the residual val-
ue of the transformer but the inconve-
nience (maintenance / lost production)
caused by an unplanned outage. The
benefit from a deferred replacement is
directly proportional to the current in-
terest rate and the capital cost of a new
unit.
• Transformer costs usually vary due to
many factors, a generalized estimate is
$8 k ≤ per MVA ≤ $12 k.
• For a 63 MVA transformer, an approxi-
mate cost is around $500,000.
• Current interest rate = 4 %
Annual benefit
$20,000.00
$20,800.00
$21,632.00
$22,497.28
$23,397.17
$24,333.06
$25,306.38
Table 6. Annual benefits due to reduced failure rate - normal stage

Parameters Values

Transformer cost (TC) $500,000

Predictive repair costs (PRC) 20 %

Failure rate (λ %) 1%

Non-detectable failure % 70 %

O-DGA efficiency (ƞ %) 25 %

X (repair cost – non-catastrophic) 7.5

Y (repair cost - catastrophic) 25

Non-catastrophic failure % 90 %

Catastrophic failure % 10 %

Reduced failure rate cost $1443.75

• Based on extrapolated 2-FAL ppm val-
ue ≥ 5 ppm, life extension can be con-
sidered from 2021 as listed in Table 5.
B) Reduced failure-related repair or
replacement costs
Another recognized benefit from IEEE
C57.143 consists of the savings gen-
erated from reduced repair / mainte-
nance costs. The benefit is calculated by
considering the repair cost for a major
failure with and without O-DGA, re-
placement, and collateral damage costs
with and without O-DGA. A multipli-
er X = 7.5 has been used to reflect that
the repair cost for a major failure, while
a multiplier Y = 25 has been used to
reflect the replacement cost and col-
lateral damage resulting from a cata-
strophic failure as per [7].
C. Reduced manual oil sampling costs
In many cases, additional monitoring can
reduce the frequency of manual inspections.
Direct time savings are achieved during
site visits, manual oil sampling, laboratory
costs, and reporting. The annual benefit of
reduced manual oil sampling costs can be
calculated from a decreased offline oil sam-
pling frequency as shown in Table 9 below
– with an O-DGA monitor. Manual offline
If the O-DGA monitor is installed, the sav-
ings are also achieved by the reduction of
manual oil sampling
Table 7. A typical failure rate increases with age
oil sampling can be carried out once, instead
of 12 x offline DGA samples in a year. In the
case of offline DGA sampling, the approxi-
mate total costs are around $100.
Total offline DGA costs, if the transform-
er is retired at the age of 20 years (i.e., the
year 2027 from today, 2020) is $9600. If an
O-DGA monitor is installed, the offline
DGA costs are $300. Total savings per
year = $1162.50.

Period Failure rate

The annual benefit of reduced failure-re-
lated repair or replacement costs can be
calculated as listed in Table 6. Normal stage 2nd to 16th year, λ = 1 %

The “normal life” stage of industrial trans- Wear-out stage 17th year, λ = 1.06 %
formers is around 16 years [10], after
which the failure rate starts to increase, as
Wear-out stage 18th year, λ = 1.34 %
calculated in Table 7. Typical failure rates
are extracted based on a failure rate = 12 %
at 35 years [10]. Wear-out stage 19th year, λ = 1.55 %

Based on Table 7, the annual benefit can Wear-out stage 20th year, λ = 1.66 %
be calculated and listed in Table 8.

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 93
MONITORING

Table 8. Annual benefit earned with respect to the failure rate

Year Age Failure Rate Annual Benefit Earned

2020 13 1% $1443.75

2021 14 1% $1443.75

2022 15 1% $1443.75

2023 16 1% $1443.75

2024 17 1 .06% $1530.38

2025 18 1.34 % $1934.62

2026 19 1.55 % $2237.81

2027 20 1.66 % $2396.62

The comparison of different O-DGA monitors tronics repairs, site-visits, and annual
inspection costs,
is meaningless unless the costs are brought to • oil piping system maintenance – oil
leaks, pump failures,
the same common economic basis - calculat- • oil line pipe filters,
• remote communication requirements, etc.
ing the net present value and payback period
Once these factors are incorporated, an
economic evaluation must be made. The
IV. INVESTMENT INTO AN price. The highest upfront cost will be the comparison of different O-DGA mon-
cost price of the unit. However, there will itors is meaningless unless the costs are
O-DGA MONITOR be indirect costs such as: brought to the same common economic
In the previous section, the benefits of basis - calculating the net present val-
installing an O-DGA monitor were cal- • consumable costs – carrier gas / cali- ue and payback period. Each O-DGA
culated. However, when purchasing an bration gas, monitor will have different indirect
O-DGA monitor, there will always be • spare parts and repair time costs – parts costs. If the question were to evaluate
additional costs over the actual purchase such as field repair of IR analyzers, elec- two different O-DGA technologies, the
indirect costs need to be factored in the
payback period calculation. Two such
Table 9. Annual benefit earned with reduced manual oil sampling payback period calculations are evaluat-
Year Yearly DGA costs Extended with O-DGA
ed - O-DGA with regular maintenance
requirements and O-DGA monitor with
minor maintenance requirements. All
2020 $1200 $100
costs indicated in this article should be
converted into local costs, which vary
2021 $1200 $000
from country to country.
2022 $1200 $000 A) O-DGA with regular maintenance
requirements
2023 $1200 $100
Regular maintenance requirements would
2024 $1200 $000 include:

2025 $1200 $000 • Visual inspection every 12 months.

Approximately $2000 per visit (local
2026 $1200 $100 visit).
• Carrier gas and calibration gas replace-
2027 $1200 $000 ment every 24 months. Approximately
$2400 per replacement.

94 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

• Oil piping system maintenance every 2
years. Approximately $500 combined
with a visual inspection.
• Minor refurbishment every 3 years
(electronic parts, control circuitry, soft-
ware upgrade, communications). Ap-
proximately $3000 per refurbishment.
• Major refurbishment upon expiry of
10 years (not included in this case, as
10 years is beyond expected transform-
er replacement age).
B) O-DGA with minor maintenance
requirements
Minor maintenance requirements would
include:
• Minor refurbishment every 3 years
(electronic parts, control circuitry, soft-
ware upgrade, communications) Ap-
proximately $3000 per refurbishment.
• Major refurbishment at the end of 10
years (not included in this case as 10
years is beyond the expected trans-
former replacement age).
V. ECONOMIC CALCULATIONS
For a commercial manager, when com-
paring different options and decide which
one to invest in, there are generally three
options available: the internal rate of re-
turn (IRR), payback period, and net pres-
ent value (NPV). Three parameters are:
• NPV is the value of all future cash flows
(positive and negative) over the entire
life of an investment discounted to the
Table 10. Payback calculations for an O-DGA with minor maintenance requirements
Failure Life DGA
Year
rate extension reduction
0 (2020) $0 $0
For a commercial manager, when compar-
ing different options and decide which one
to invest in, there are generally three options
available: IRR, payback period, and NPV
present. Assumed discount rate = 4 %. B) Payback for O-DGA with regular
• IRR is the discount rate that makes the maintenance requirements
NPV = 0. This equates to the expected
compound annual rate of return that Table 11 lists the payback calculations for
will be earned on the O-DGA moni- O-DGA with regular maintenance re-
tor. quirements. The results are as follows:
• The payback period is the time taken to
recover the cost of an investment in an • purchase price = $55,000.00,
O-DGA monitor. For this service aged • IRR = 28.195 %,
transformer, the payback period should • NPV = $64,256.00,
be less than 5-7 years, after which the • payback period is less than 3 years.
transformer may be replaced.
While the payback period is less than 5-7
A) Payback for O-DGA with minor years in both cases, the IRR and NPV are
maintenance requirements higher for an O-DGA with minor main-
tenance requirements. This implies that
Table 10 lists the payback calculations for an O-DGA with minor maintenance re-
an O-DGA with minor maintenance re- quirements is a better choice in terms of
quirements. The results are as follows: yielding a higher rate of return.
• the purchase price = $60,000.00,
VI. CONCLUSIONS
• IRR = 38.38 %,
• NPV = $87,808.00, If a transformer is suspected of a high
• the payback period is less than 3 years. potential of failure, the investment in
For this service aged transformer, the pay-
back period should be less than 5-7 years,
after which the transformer may be replaced
Net Cost of Other Cash Present Cumulative
income DGA costs flow value CF
-$
0 $0 -$60,000 $0 $60,000.00 $60,000.00
60,000.00

1 (2021) $1,443.75 $20,000 $1,162.50 $22,606.25 $0 $0 $22,606.20 $21,736.78 $38,263.22

2 (2022) $1,443.75 $20,800 $1,162.50 $23,406.25 $0 $0 $23,406.25 $21,640.39 $16,622.83

3 (2023) $1,443.75 $21,632 $1,162.50 $24,238.25 $0 -$3,000 $21,238.25 $18,880.73 -$2,257.90

4 (2024) $1,443.75 $22,497 $1,162.50 $25,103.25 $0 $0 $25,103.25 $21,458.36 -$23,716.26

5 (2025) $1,530.38 $23,397 $1,162.50 $26,089.88 $0 $0 $26,089.88 $21,443.98 -$45,160.24

6 (2026) $1,934.62 $24,333 $1,162.50 $27,430.18 $0 -$3,000 $24,430.18 $19,307.53 -$64,467.77

7 (2027) $2,237.81 $25,306 $1,162.50 $28,706.69 $0 $0 $28,706.69 $21,814.73 -$86,282.49

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 95
MONITORING

Table 11. Payback calculations for O-DGA with regular maintenance requirements
Failure Life DGA Net Cost of Other Present Cumulative
Year Cash flow
rate extension reduction income DGA costs value CF
0 (2020) $0 $0 $0 $0 -$55,000.00 -$5,000.00 -$60,000.00 $60,000.00 $60,000.00

1 (2021) $1,443.75 $20,000 $1,162.50 $ 22,606.25 $0 -$2000.00 $ 20,606.20 $19,813.70 $40,186.30

2 (2022) $1,443.75 $20,800 $1,162.50 $ 23,406.25 $0 -$4900.00 $ 18,506.25 $17,110.07 $23,076.23

3 (2023) $1,443.75 $21,632 $1,162.50 $ 24,238.25 $0 -$5,000 $ 19,238.25 $17,102.73 -$5,973.50

4 (2024) $1,443.75 $22,497 $1,162.50 $ 25,103.25 $0 -$4,900.00 $ 20,203.25 $17,269.82 -$11,296.33

5 (2025) $1,530.38 $23,397 $1,162.50 $ 26,089.88 $0 -$2000.00 $ 24,089.88 $19,800.13 -$31,096.45

6 (2026) $1,934.62 $24,333 $1,162.50 $ 27,430.18 $0 -$7,900.00 $ 19,530.18 $15,434.98 -$46,531.44

7 (2027) $2,237.81 $25,306 $1,162.50 $ 28,706.69 $0 -$2,000.00 $ 26,706.69 $20,294.89 -$66,826.33

an O-DGA monitor is justified because
the indirect costs are, in practice, higher
than the price of an online DGA monitor.
Similarly, the cost of lost production or
cost of lost customers should always be
quantified apart from the benefits quan-
tified in this article. The IEEE c57.143
guide provides a comprehensive cost
benefit analysis method and should al-
ways be utilized by the commercial team
when deciding on O-DGA purchases.
For this transformer and based on the
submitted data, the furans levels indicate
significant paper aging. The CO2 and CO
trending should be established by investing
in an O-DGA monitor. Among the choice
for various O-DGA monitors, a compari-
son was made between two choices - a low-
er-priced O-DGA monitor with regular
maintenance requirements versus a high-
er-priced O-DGA monitor with minor
maintenance requirements. Economic cal-
culations show investing in a higher-priced
O-DGA monitor with minor maintenance
requirements yields better returns. A sen-
sitivity analysis for different discount rates
and different transformer life extension pe-
riod should also be considered.
Bibliography
[1] M. Duval, Dissolved gas analysis: It
can save your transformer, IEEE Elec-
trical Insulation Magazine, Vol. 5, No. 6,
1989
[2] IEC 60599:2015, Mineral oil-filled
electrical equipment in service, Guid-
ance on the interpretation of dissolved equipment to liquid-immersed trans-
and free gases analysis formers and components
[3] IEEE C57.104:2019, IEEE Guide [8] I. Hohlein, A. J. Kachler, Aging of cel-
for the Interpretation of Gases Gen- lulose at transformer service tempera-
erated in Oil-Immersed Transformers tures - Part 2.: Influence of moisture
and temperature on degree of polymer-
[4] CIGRE 771: 2019, Advances in DGA ization and formation of furanic com-
interpretation, Working group D1/A2 pounds in free breathing systems, IEEE
Electrical Insulation Magazine, Vol. 21,
[5] ASTM D3612-02:2017, Standard pp. 20–24, 2005
test method for analysis of gases dis-
solved in electrical insulating oil by gas [9] L. Cheim et al., Furan analysis
chromatography for liquid power transformers, IEEE
Electrical Insulation Magazine, Vol. 28,
[6] IEC 60567:2011, Oil-filled electrical pp. 8–21, 2012.
equipment - Sampling of gases and anal-
ysis of free and dissolved gases - Guidance [10] CIGRE ELECTRA, 88:1983, An in-
ternational survey on failures in large
[7] IEEE Std. C57.143-2012 - IEEE power transformers, pp. 21-48, Working
guide for application for monitoring group 12-05.
Author
Bhaba P. Das is the Lead Digital Business Developer for
Transformers Business Line, HUB (Asia-Pacific, Middle
East and Africa), ABB Power Grids, based in Singapore.
He is part of the Application Engineering Team and spear-
heads the digital transformation efforts of transformers
in the Asia Pacific region. Prior to ABB Power Grids,
he worked as the R&D engineer for a major transform-
er manufacturer in New Zealand. He was awarded the
Young Engineer of the Year 2017 by the Electricity Engineers Association of
New Zealand for his work on the design and development of smart distribu-
tion transformers, fibre optics-based sensors for transformers, and diagnostic
software for fleet condition monitoring. He is a Senior Member of IEEE and
Young Professional of IEC. He completed his PhD in Electrical Engineering
from the University of Canterbury, New Zealand.

96 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

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w w w . t ra n sfo r m e r s - m a g a z i n e . co m 97
TRANSPORTATION

Consistent transformer
transport monitoring – detect
damage early and act
ABSTRACT The black box in the logistics tory gate but at the final place where the
Consistent traceability is essential, es- chain product is used. But until then, there is
pecially for sensitive products. In this
a long way.
case, however, the transport from the
In the course of the “Industry 4.0 move-
ment”, traceability is particularly im- When a product leaves the factory, it
storage or production location to the
portant. This means to always know usually also leaves the area that the
customer is usually a non-transparent
where a product can be found, through manufacturer can understand, as many
black box.
which production station it is currently companies are dependent on third-party
Transport data loggers can provide in-
passing, and whether all quality features providers for logistics. It can no longer
sight into this black box and thus signifi-
are present. The traceability is not possi- be traced what condition the product
cantly improve quality management.
ble on the transport route at this depth. currently has. Transport becomes a black
Even if every step, no matter how small, box. However, since innumerable dangers
can be traced in your own factory, com- lurk on the way to the final destination,
KEYWORDS plete traceability does not end at the fac- this can have fatal consequences. Not

data logger, monitoring, risks, shock

recorder, traceability, transportation

98 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021


only impacts due to potholes or careless
loading processes can damage the
quality of a product, changes in external
conditions such as a drop in air pressure,
rapid temperature changes or fluctuations
in humidity can lead to irreparable
damage to the transformer.
If the quality of the product suffers
during transport, in the worst-case
scenario, production downtimes and
customer complaints can arise. In these
cases, the manufacturer has to expect
expensive repair costs, delivery delays,
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Advertorial
or even damage to its reputation. The ability, it is necessary to open the black
black box thus harms the manufacturer box or close the gap in traceability. That
and the customer. In order to avoid the means that it is required to start moni-
risks resulting from incomplete trace- toring the transport as well.
Ask yourself the questions: Where are my
transported goods? Which loads are acting
on the goods, and what conditions have
goods been exposed to? MONILOG® pro-
vides the answers.
99
 TRANSPORTATION

of the individual laminated cores, which

in the case of large transformers leads to
considerable local heating of the core or
even to short circuits. This type of dam-
age requires time-consuming and costly
repairs.

The solution for this is a relative pres-

sure sensor. This pressure sensor can be
screwed directly into the housing wall
of transport containers or machines. In
combination with the MONILOG® RISK
LOGGER ShockDisplay curve plus, the
sensor continuously monitors the filling
during transport and registers any pres-
sure drop. Pressure changes can be recog-
MONILOG® ShockDisplay curve plus with relative pressure sensor © Siemens Berlin. nized quickly on the logger’s display, and
MONILOG® ShockDisplay curve plus is an extremely robust logger with highly sensitive early intervention is possible. In addition
shock sensors, GPS receiver and inclination measurement for an exact proof of to pressure monitoring, the data logger
transport quality. External combination sensor for temperature, humidity, and pressure also records shocks, GPS position, and in-
is particularly suitable for transports under protective gas. clination events.

The latter should not be underestimated,

Risks when transporting the
transformer
Transformers are usually filled with nitro-
gen during transport, which protects the
tank against moisture penetration with
overpressure. In the case of sea freight,
however, the pressurized gas cylinders
that ensure the permanent overpressure
in the transformer must be closed. Con-
tinuous monitoring of the overpressure
inside the transformer is no longer guar-
anteed and there is a risk of moisture pen-
etrating. This moisture leads to corrosion
of the so-called electric sheets.
With the increase in the volume of the
core laminations, the energy losses of the
transformer are also increasing. At the
same time, this can damage the insulation
especially when it comes to sea transport.
The ship sways due to high waves caus-
ing the transformer to continually tilt in
all directions. As a result, the sheet metal
stacks of the core shift, and the windings
rub against one another. This permanent
movement damages the insulation of the
winding wires with the consequence of
turn and winding shorts. At the same time,
the damage to the coating on the copper

© Daher Transkem Spedition GmbH

100 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

leads to faster ageing of the insulating oil
when the transformer is later operated.
Receive data in the real-time
Since transport carries risks at all times,
it seems essential to map this monitoring
in real-time. In addition to the data log-
gers, a tool is required that collects and
processes the recorded data from several
devices. In order to be able to map this,
SMT ELEKTRONIK GmbH developed
the MONILOG® web portal. It represents
a platform-independent access option to
manage your RISK LOGGER efficiently
and to have the data displayed in real-time
and over a longer period at a central point,
and to download it if necessary. With the
help of the registration of alarm events,
exceeding limit values can be precisely
evaluated in the portal. The tracking and
monitoring of the transformer transport
are therefore possible at any time.
When it comes to real-time, the idea is that
you can request all the necessary informa-
tion from the device at any time. Even if
the MONILOG® devices are suitable for
self-sufficient long-term applications of
over two years, every data transmission
from the data logger consumes energy.
Battery life should therefore be used spar-
ingly during long transport routes. In or-
der to influence this, the data request is
not carried out permanently but at time
intervals that can be set by the user. This
ensures that measurement data is record-
ed during the entire duration of the trans-
port.

MONILOG® web portal, route overview with trigger points and threshold value exceedance © SMT ELEKTRONIK GmbH

MONILOG® web portal shows continuous inclination of the three axes (in g) © SMT ELEKTRONIK GmbH

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 101
 TRANSPORTATION

MONILOG® web portal, the sensor detects a decrease in pressure, manual correction of the pressure within a short time
© SMT ELEKTRONIK GmbH

Configure energy MONILOG® data loggers are robust and re-

management / limit values
liable. They record external influences con-
As already mentioned, the time factor
plays an important role in the monitoring
sistently for years.
of transports. Many shipments are on the
way for several weeks. A data logger must
monitor this entire period and must also
be small, compact, and extremely robust
so that it can be easily attached to the
transported goods. This is a challenge for
energy management.

In order to achieve a long runtime, it is ad-

visable to determine different measured
variables in different ways. Temperature,
humidity, or air pressure should be cy-
clically measured as they develop over a
period of time and there are no sudden,
significant changes. The user can set the
time between measurements as required.
However, shocks must not be recorded
as they occur suddenly. This measure-
ment is event-triggered. The user defines
critical limit values such as 3.4 g / 30 ms
and configures them in the device. As
soon as these limit values are reached
during transport, the transport data log-
ger “wakes up” within 2 ms, first evaluates
the event, and then saves any limit values
which were exceeded. This is an extremely
short time compared to competitive prod-
ucts. The transport data logger does not
react to shocks below the set limit / detec- High-performance turbine monitored with the MONILOG® sensor network, © Siemens Berlin

102 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

tion value. This means that the battery is
not charged for events that do not pose a
risk to the transported goods.

MONILOG ® is a brand of SMT

ELEKTRONIK GmbH. The Dresden
company is an E²MS service provider
and manufacturer of the high-precision
RISK LOGGER of the MONILOG®
series for monitoring risk situations.
SMT ELEKTRONIK has been involved
in transport monitoring since 1990. With
its own brand MONILOG®, the Dresden
company offers a balanced range of data
loggers. They measure signals and docu-
ment external influences that represent a
serious situational risk for the value and MONILOG® EnDaL smart, © SMT ELEKTRONIK
functionality of the goods. MONILOG® EnDaL smart is a small, easy-to-use and versatile data logger. It monitors
sensitive goods on long transport routes and in critical environments, such as transformers,
In order to be able to react even faster in generators, switchgear or fragile optics, medical or automotive components. The sensor
the future, the MONILOG® development technology of the data logger measures impact events, temperature, humidity, air pressure
team is working on another convenient and inclination.
solution for seamless transport monitor-
ing: communication via an NFC inter-
face. A passive NFC chip is built into the MONILOG® RISK LOGGER measures signals
MONILOG® RISK LOGGER, which has
the advantage that the device can be read and records the external influences that
when it is switched off and does not con-
sume a battery. The data readout is trans-
represent a serious situational risk for the
mitted into a PDF file via an app and can value and functionality of your goods.

MONILOG® sensor network © SMT ELEKTRONIK

The smart wireless radio network system consists of the MONILOG® data link sensor base station and up to 8 MONILOG® sensor modules of radio
data loggers. The compact, energy-efficient and high sensitivity sensor modules capture data relevant to transport, such as shocks, acceleration,
temperature, humidity, air pressure, inclination and light. All data are collected via a Bluetooth low energy radio interface in the base station. It
transmits them at adjustable intervals via a mobile network as an e-mail to the desired recipient or directly to the MONILOG® web portal.

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 103
 TRANSPORTATION
MONILOG® Connect App shows alarm indication after reading out the data
© SMT ELEKTRONIK GmbH
be further processed. For data security, the
readout is protected with a password so
that no unauthorized person can obtain
this information.
The MONILOG® RISK LOGGER series
described here opens the black box and
shows a possibility to record the trans-
port routes and the current position of a
transport and implement seamless mon-
itoring of the transport quality. Since
the manufacturer can use the loggers
to understand exactly which route the
104
Contact:
SMT ELEKTRONIK GmbH
An der Prießnitzaue 22
01328 Dresden, Germany
Phone: +49 351 26613 0
Email: sales@monilog.de
Thomas Weig
Sales Manager MONILOG®
sales@monilog.de
Phone +49 351 266 13-961
transport took, where the events that
influenced the product occurred and
how strong they occurred, it is possible
to optimize the transport routes. In ad-
dition, the exact tracking of the trans-
ported goods offers the possibility of
creating extensive reporting for the cus-
tomer. Transport delays can be reported
immediately, incorrect deliveries can be
excluded, and the delivery of damaged
Sarah Richter
goods can be significantly minimized.
This service is a real competitive advan- Product Marketing MONILOG®
tage for manufacturers. marketing@smt-elektronik.de
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
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ASSET MANAGEMENT

ABSTRACT
This paper presents the TrafoGrade
system, developed by Energo-Complex
Ltd. The main purpose of this tool is
to aid a decision-making process re-

Transformer
garding the operation of power trans-
formers. The system consists of four
modules, the most important being
a multi-parameter evaluation of the

management
technical condition of a transformer.
The second is an assessment of im-
portance of the unit, which concerns
things such as energy security, tech-

system -
nical possibilities of a transformer
renovation or replacement, as well
as reliability of the power supply and

TrafoGrade
costs of its absence. The third mod-
ule aims to determine prospects for
operation of each unit, with an em-
phasis on technical and economic
factors. Lastly, the data is processed
by a computer system to support the 1. Introduction According to statistics in many countries,
decision-making process for trans-
The power distribution and industrial more than 50 % of transformers have al-
former population management. The
companies operate several thousands of ready been in operation for over 25-30
article presents an example of imple-
medium and high-power transformers. years [1, 3, 9]. Therefore, it is necessary
mentation of this system in a power
Rationalisation of investment costs leads to have in place an approach for optimiz-
distribution company in Poland. to optimization of the operation period of ing transformers’ operation based on a
individual elements in the power system, comprehensive assessment of their tech-
KEYWORDS while maintaining a low risk of failure. nical condition and their importance in
This is particularly important for trans- the power system. Combining those two
asset management, diagnostics, Tra- formers, which are a crucial part of power factors indicates prospects for the further
foGrade, transformer grids [6, 7, 8]. reliable operation of the unit and an eco-

106 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Marek SZROT , Janusz PŁOWUCHA, Paweł MOLENDA

TrafoGrade is a tool for a comprehensive transformer management sys-

tem that allows for an optimal decision-making process in terms of ren-
ovation economy and the investment policy

nomic assessment of profitability of ren- examples of evaluation results for 44 trans- 2. The TrafoGrade structure
ovation works or replacement [2, 3, 4, 7]. formers operated by a Polish distribution
company. An economic analysis of the The TrafoGrade transformer manage-
Based on these considerations, system implementation was also compared ment system consists of four modules,
Energo-Complex has developed a com- with the costs of transformer failure. which are depicted in Fig. 1.
prehensive transformer management sys-
tem known as the TrafoGrade. The idea
of a system that introduces a scoring scale
for assessments of technical condition of
a transformer and its importance in the
power grid is to link the technical aspects
of diagnostics with economic and financial
factors for optimisation of decisions in the
scope of the current operation, mainte-
nance management, and investment strate-
gy. The TrafoGrade system has been devel-
oped in cooperation with researchers from
West Pomeranian University of Technolo-
gy, Szczecin. They have developed unique
combined methods of winding deforma-
tion diagnostics, assessment of moisture
content in the insulation, and evaluation of
the bushing condition based on dynamic
measurement of various physical processes.

This article presents basic information

about the TrafoGrade system and gives Figure 1. The TrafoGrade scheme

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 107
ASSET MANAGEMENT
It is necessary to have in place an approach
for optimization of transformers’ operation
based on a comprehensive assessment of
their technical condition and their impor-
tance in the power system
In the presented system, a point-based
valuation (from 1 to 3) method was ad-
opted for each transformer parameter or
property included in the technical assess-
ment and significance. A three-stage judg-
ment scale was used: good, fair, and poor.
A simple, point-based description of the
transformer’s technical condition allows
for an analysis of test results both by the
engineering staff and economic depart-
ments possessing no technical knowledge.
3. Transformer condition
assessment
The main task of the TrafoGrade system
is a reliable assessment of technical condi-
tion of the transformer carried out using
state-of-the-art diagnostic methods. The
multi-parameter evaluation of the techni-
cal condition includes a number of diag-
nostic criteria.
The key elements of condition
assessment
An assessment of the active part and
insulation system of a transformer
The fitness of the active part and insulation
system of a transformer is considered when
the operation period of a transformer must
be extended or a scope of renovation works
needs to be determined. The evaluation
consists of the following factors:
• condition of electrical and magnetic
circuits,
• existence of partial discharges (PD),
their location and intensity,
• existence of local points of an excessive
temperature-rise in the insulation sys-
tem,
• state of the structure and winding de-
formation,
• water content in solid insulation and
aging of cellulose.
Condition of electrical and magnetic cir-
cuits is assessed based on periodical test
results and dissolved gas analysis (DGA)
in the transformer oil.
108
In operating units, a common problem is
loosening of the clamps on the active part
of a transformer and winding deforma-
tion or displacement. They mostly result
from dynamic forces generated during
short circuits when mechanical properties
of the cellulose are significantly lower than
nominal. A displacement or deformation
of coils does not always lead to immediate
damage to the insulation but substantially
increases the risk of a catastrophic failure
in subsequent events.
The Sweep Frequency Response Analysis
(SFRA) method is used to identify de-
formation in windings. The evaluation is
carried out by comparing recorded char-
acteristics to the model waveforms. This
requires detailed knowledge of methodol-
ogy for determining SFRA characteristics,
including:
• the type of device was used to deter-
mine the reference waveforms,
• the type and method of connection of
measurement cables and screens [10,
11, 12].
Adequate diagnostic experience is also
necessary, as well as a large library of refer-
ence measurements and comparative data
from transformers of identical construc-
tion and similar age.
The degradation rate of the transformer
insulation also depends on the degree of
moisture in the cellulose solid insulation.
The rate of depolymerization process,
which consists in chain shortening of cellu-
lose fibre and results in a loss of mechanical
strength, is several times higher in a moist
cellulose than in a dry one. For example, in
a pressboard with 3 % water content, this
process is five times faster than in a press-
board with approximately 1 % moisture.
Therefore, an important consideration
when deciding to extend the life of trans-
formers is to distinguish between the units
in terms of kinetics of this process and the
degree of cellulose degradation. Generally,
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
it is assumed that transformers with a
moisture content above 2.5 % are at risk of
accelerated and excessive insulation deg-
radation [13, 14, 15].
A practical and effective way to determine
the degree of polymerization (degrada-
tion) of the cellulose is to measure the con-
tent of furan compounds in the oil, mainly
2-furfural (2-FAL), which is a long-lasting
product of thermal degradation of paper
and it accumulates in the oil. However,
interpretation of the measurement result
is a complex issue and requires qualified
personnel.
Another unfavourable phenomenon as-
sociated with a presence of large quanti-
ties of water in the insulation is a possi-
bility of a so-called “bubble effect,” which
consists in rapid evaporation of water
when the critical temperature is exceeded.
As a consequence, in transformers with
excessive water content, it is necessary to
lower the permissible operating tempera-
ture, which requires load reduction. For
example, the rated power of a transformer
with 3.5 % moisture content is decreased
by half, and the unit should not operate
above 60 0C. This is due to reduced heat
transfer between the winding and oil and
the possibility of a “bubble effect” occur-
rence. This fact should also be taken into
account in the management of a medium
and high-power transformer population.
Bushing diagnostics
Statistics from various sources [11, 14]
indicate that bushings account for 20 to
40 % of catastrophic failures in trans-
formers. A typical cost of a repair proce-
dure after bushing malfunction is much
higher than the value of the device. For
example, the total cost of repairing dam-
age caused by a 400 kV bushing explosion
in the Polish transmission system was
about €400,000, while the isolator itself
was worth about €35,000. Dielectric loss
within the bushing insulation may lead
to a significant temperature increase, es-
pecially in layers close to the conductor.
Simulations of temperature distribution
within the 220 kV bushing showed that
the insulation temperature in this area
might be higher than 120 0C on hot sum-
mer days [16]. This value exceeds the ther-
mal strength of the insulating paper lead-
ing to its deterioration. Development of
this process may lead to generation of PD
in individual layers of the insulation, and
consequently to its breakdown.
The analysis of bushings dielectric break-
down mechanisms leads to a conclusion
that standard measurements of the loss
factor at 50 Hz are not a comprehensive
method to assess the insulation system.
At most, they allow identifying a very ad-
vanced state of the aging processes. Much
better results are obtained by dynamic
measurements of the polarization phe-
nomena using the Frequency Domain
Spectroscopy (FDS), which provides fre-
quency-based capacitance and loss factor
characteristics [16].
In case of oil-impregnated paper (OIP)
bushings, an oil sample is taken for a DGA
analysis.
On-load tap changer (OLTC) diagnostics
An assessment of OLTC is generally a part
of basic diagnostics of the transformers’
technical condition. The evaluation needs
to include a thorough visual inspection,
switchover oscillography, and dynamic
contact resistance measurements [17]. On
their basis, a scope of possible renovation
or modernization of OLTC can be esti-
mated [19, 20].
The main task of the TrafoGrade system is a
reliable assessment of technical condition
of the transformer carried out using state-
of-the-art diagnostic methods
the transformer to perform an internal include the way of defining and differen-
revision. tiating values of individual parameters,
as well as a methodology for group and
Group III properties do not concern final scoring. Limit values of individual
problems related to the current oper- parameters have been determined based
ation of a transformer but are rather on international standards and operating
oriented on the expected “lifespan” and instructions, taking into account many
planning of repairs and upgrades. There- years of expert practice of Energo-Com-
fore, even a negative assessment of any plex. They are the know-how of the Trafo-
of them does not exclude the individual Grade system.
from the operation but requires proper
planning of renovation. To this group,
5. Assessment of transformer
such features as the age of a transformer,
condition of paper insulation and trans- importance in the power grid
former oil are assigned. In a decision-making process concern-
ing the investment and renovation policy,
Detailed instructions have been devel- apart from the transformer assessment, its
oped for the TrafoGrade system and they importance in the power network should

4. Parametric evaluation of
a transformer‘s technical
condition

All diagnostic parameters are assigned

into three groups:

• Group I – basic transformer assessment,

• Group II – condition of the active part,
• Group III – degree of the aging processes.

Group I includes the most basic features

of the transformer. Poor technical condi-
tion of any of the parameters does not sig-
nificantly affect their performance. How-
ever, in some extreme cases, it is advised to
withdraw the unit from further operation.
For example, some of the features listed in
this category are visual inspection, auxil-
iary equipment condition check, and eval-
uation of OLTC.

Group II is made of those elements which

play an important role in performance of
the transformer. Poor technical condition
of most of them eliminates the transform-
er from further operation and restoring
to acceptable technical condition usually
requires significant financial and organi-
zational expenses. For example, a negative
result of DGA may require switching off Figure 2. The algorithm of the TrafoGrade system

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 109
ASSET MANAGEMENT
Adequate diagnostic experience is also
necessary, as well as a large library of refer-
ence measurements and comparative data
from transformers of identical construction
and similar age
also be taken into account. This issue is of
particular importance in terms of increas-
ing the reliability of energy supply to con-
sumers, as well as improving the energy
security of the area. In the TrafoGrade sys-
tem, evaluation of the transformer’s im-
portance is expressed in a point scale and
it is implemented through an analysis of:
• power network configuration at the
place of transformer operation, with
particular emphasis on reliability pa-
rameters,
• the consumer profile,
• a possibility of supply redundancy, etc.
A combination of those attributes allows
for assigning the transformer to an appro-
priate operating group.
The final result of a comprehensive as-
sessment of the transformer’s technical
condition is development of operational
perspectives for each unit. This informa-
tion is particularly important for those
who manage the operation of transform-
ers, as it enables the execution of a reliable
diagnostic and repair plan for the follow-
ing years. An exemplary transformer TDR
63000/110 received a score of 16,3/33
points after 33 years of operation, which
Figure 3. The TrafoGrade system – A screen of the tab with results of a technical condition assessment
110
classified it as being in fair technical con-
dition. A 5–7-year plan recommended for
this unit included oil change and insula-
tion drying.
6. Computer management
system
The main part of the TrafoGrade system
is a computer-based decision support
system in which all the aforementioned
modules have been implemented. The
system consists of many extensive data-
base functions, as well as elements indi-
cating the current assessment of technical
condition of a transformer and impor-
tance of the transformer within the net-
work. Apart from the basic characteristics
of a specific unit for each transformer, the
following are entered: incident and distur-
bance records, reports with measurement
results, and other files that can be useful in
the process of a transformer fitness eval-
TrafoGrade has a detailed instruction sys-
tem inbuilt based on transformer assess-
ment, thanks to the many years of expert
practice and know-how
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
uation. An exemplary technical condition
assessment report is shown in Fig. 3.
The system provides recommendations
formulated based on input data, together
with a cost estimation for carrying out re-
pair procedures. The measurement results
are analysed in detail and individually ar-
chived. Fig. 4 shows a graphic window of a
detailed DGA assessment.
The TrafoGrade Inspection application
for mobile devices uses documentation
processing and data archiving on a data-
base server. Implementation of such dig-
ital assistance allows for introduction of a
uniform standard on visual examination
of the transformer’s most important ele-
ments and accessories. During an inspec-
tion, all collected data (pictures, answers
to questions, and other detailed informa-
tion) is automatically saved in a database.
In addition, all photographic records are
simultaneously stored in the memory of a
mobile device.
The mobile application is compatible with
the TrafoGrade system. It enables viewing
and processing of photographic material
and automatically generates a transform-
er inspection card in form of a PDF file.
The editing window of the transformer
inspection card is shown in Fig. 5.
Figure 4. The TrafoGrade system – A screen of the tab with detailed results of a dissolved gas analysis

Figure 5. The TrafoGrade system window – edition of the transformer inspection card

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 111
 ASSET MANAGEMENT
The TrafoGrade Inspection application for
mobile devices uses documentation pro-
cessing and data archiving on a database
server
The layout of the mobile application Tra-
foGrade Inspection is presented in Fig. 6.
Figure 6. Examination form on the TrafoGrade
Inspection for mobile devices
Figure 7. The age distribution of tested transformers
112
7. Implementation of the
TrafoGrade system
The TrafoGrade system was implemented
in a power distribution company where
a comprehensive assessment of 44 trans-
formers was carried out. Fig. 7 presents
the age distribution of the tested trans-
formers population.
The age dependencies presented in Fig. 7
are a typical representation of the medium
power transformer population. Therefore,
it is assumed that characteristics of tech-
nical condition, operational prospects,
and main technical problems obtained by
the TrafoGrade method will also apply to
transformers used by other energy distri-
bution companies.
Out of the 44 tested transformers, 4 units
were in poor technical condition, 33 in
fair condition, and 7 in good condition.
The main elements of a reliable assess-
ment of transformers’ technical condition
are state-of-the-art diagnostic methods.
Fig. 8 shows the population examples of
results from the DGA test, measurement
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
of moisture content in solid insulation,
and evaluation of mechanical deforma-
tions of windings by the Frequency Re-
sponse Analysis (FRA) method.
The DGA, FRA, and moisture content cri-
teria were adopted on the basis of interna-
tional standards and long-term operating
experience.
According to Fig. 8, only a small percent-
age of the examined transformer popu-
lation has major technical problems that
may require significant financial resourc-
es. Fig. 9 presents operational prospects
determined for the analysed population
of 44 transformers with the use of the Tra-
foGrade system.
The operational perspective determined
based on technical condition parameters
is a baseline for an economic analysis.
8. Economic aspects of
the TrafoGrade system
implementation
The classical approach requires the unit
owner to perform a detailed analysis
of data most often collected in several
protocols and, on this basis, draw ap-
propriate conclusions. Integration of all
measurement data in a computer sys-
tem, as well as introduction of a scor-
ing scale of technical condition assess-
ments, facilitates the analysis of results
and allows managers with no detailed
knowledge of transformer diagnostics to
make decisions. Introduction of a com-
prehensive management system based
on a multi-parametric assessment of the
transformer fitness allows for optimiza-
tion of investment expenses.
This approach to transformer population
management makes it easy to capture the
right moment when technical condition of
a given unit can be significantly improved
with a relatively low financial expenditure.
An example can be a transformer with a
substantial moisture content in solid insu-
lation, with poor oil parameters but with
windings in good mechanical condition.
Renovation of such a unit involves the fol-
lowing activities:
• drying and cleaning of the windings,
• re-applying compressive force on the
core and windings,
• oil treatment or refilling,
• replacement of radiators,
• renovation of the OLTC,
• auxiliary equipment upgrade.
The cost of such overhaul is currently es-
timated at 15–20 % of a new transformer.
The unit’s renovation allows the trans-
former to continue performing its duty
for another 10–15 years.
Figure 8. Transformer population analysis with the use of: DGA method (a), moisture content in cellulose insulation (b), and the FRA (c)
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
The TrafoGrade system was implemented in
a power distribution company where a com-
prehensive assessment was carried out on
44 transformers
In case of poor technical condition of a
transformer, repair or replacement of the
unit should be considered. This decision
should take into account the following
factors:
• an analysis of no-load losses, in case of
a transformer core manufactured from
hot-rolled steel the excessive no-load
losses are economically unacceptable,
• evaluating the probability of electricity
demand increase at the place of trans-
former installation,
• the vector group of the transformer.
The main goal of advanced transform-
er diagnostics is to avoid catastrophic
failures. Occurrence of such incident
results not only in damage of the trans-
former itself but it may also impact oth-
er substation equipment. An example is
a failure of a 25 MVA transformer in a
distribution company, which destroyed
medium and high voltage bays as a re-
sult of a fire. The total cost of removing
the effects of this failure amounted to
approximately €1,500,000, which was
about 10 times higher than the cost
of a major overhaul for this type of
unit.
For a typical distribution company, the
cost of implementing the TrafoGrade sys-
tem is amortized when failure of only a
single transformer is prevented.
With the introduction of a scoring scale
in evaluations and adapting transformer
operating instructions to the TrafoGrade
method standards, it is possible to reduce
costs associated with periodic diagnos-
tics. An individual approach to a certain
unit makes it possible to limit the scope of
tests for the least important transformers
and to rationalize the scope of necessary
measurements for devices of particular
significance.
Conclusion
The approach to the transformer pop-
ulation management proposed in the
113
 ASSET MANAGEMENT
Integration of measurement data in the ap-
plication with a scoring system based on
technical condition assessments allows
managers with limited technical knowledge
to make the decisions
publication allows to improve quali-
ty and reliability of units in operation
and significantly reduce the risk of
catastrophic failures. The assessment
of importance of a transformer in the
power system facilitates taking actions
aimed at increasing energy security
of the network. These data, in com-
bination with the technical condition
assessment, allow for a real assess-
ment of failure consequences, includ-
ing costs associated with undelivered
energy.
From distribution companies’ point of
view, preventing interruptions in the
electricity supply is important not only
for economic but also for marketing rea-
sons, taking into account the company’s
reputation. A comprehensive condition
assessment provides a lot of valuable in-
formation for the logistics and financial
policy of companies operating power
transformers.
Figure 9. The operational prospects: oil refilling (a), insulation drying (b), repair-free operation period (c)
114
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[14] M. F. M. Yousof, C. Ekanayake,
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Authors
PhD. Marek Szrot is the owner and president of the
board of Polish company Energo-Complex. He is a
graduate of the Silesian University of Technology. In
2010, he defended his doctoral dissertation on polarising
phenomena. From the beginning of his career, he has
dealt with issues of operation, modernization, and
diagnostics of transformers.
M.Eng. Janusz Płowucha - technical director and
vice president of Energo-Complex. He has many years
of experience in the field of maintenance, repair, and
diagnostic work on transformers on site. He is the
author of several publications on power transformer
diagnostics.
Paweł Molenda - a long-time employee of Energo-
Complex, currently as Deputy Technical Director.
He is the author of several publications on power
transformer diagnostics. Mr. Molenda is responsible
for implementation of new projects and technical
expertise in the field of assessing technical condition of
transformers. He also conducts training programs on
advanced diagnostic methods for power transformers.
115
SUSTAINABILITY

According to "World Energy Outlook 2020",

power generation using renewable energy
resources is expected to grow rapidly over
the next decades

ABSTRACT
Power transmission plays a crucial
role in the future energy transition.
Siemens Energy recognises trends
in energy transition with sustainable
power transmission, thus started
developing technologies that are
actively shaping the path to a cli-
mate-friendly future. Siemens Energy
offers transformers and components
for best-in-class renewables integra-
tion while keeping the transmission
grid reliable and resilient.

KEYWORDS
climate-friendly, eco-friendly, energy
transition, power transmission, sus-
tainability

116 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021


Shaping
the energy
transition with
sustainable
power
transmission
The energy transition is a
tremendous global task
T
he Paris Agreement, a legally
binding international treaty on
climate change, was adopted by
196 parties end of 2015 and en-
tered into force on 4 November 2016. It
was agreed to limit global warming to
well below 2 °C, preferably to 1.5 °C,
compared to pre-industrial levels.
However, the newest UN emission re-
port, published end of 2020, stated that
the world is on course for more than
a 3 °C spike, even if climate commit-
ments are met. In order to limit global
warming, all countries worldwide need
to rapidly reduce global greenhouse
gas emissions as fast as possible. About
42 % of global CO2 emissions in 2018
accrued in electricity and heat pro-
duction (source: IEA in 2018). For the
necessary energy transition, not only
do governments have a special respon-
sibility in creating the right framework
conditions but also the energy sector
has a central role in actively shaping
the path to a climate-friendly future by
providing necessary technologies.
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Advertorial
Power transmission plays
a crucial role in the energy
transition
In their annual report “World Energy
Outlook 2020,” the International Energy
Agency (IEA) draws alternative scenar-
ios of the future energy landscape. The
COVID-19 pandemic has caused an
ongoing huge disruption to the energy
sector, and there is a wide range of en-
ergy future scenarios. According to the
outlook, global energy demand might
rebound to its pre-crisis level in early
2023, or even later, depending on when
the pandemic is brought under control,
and it is still unclear how much efforts
countries and companies will put in in-
creasing the sustainability of the energy
system. However, the outlook at all the
scenarios shows that power generation
using renewable energy resources is
expected to grow rapidly over the next
decades, with solar and wind expecting
the highest growth in global electricity
generation.
117
SUSTAINABILITY
Siemens Energy offers two technologies of
step-up transformers, especially for wind
applications: fire resistant GEAFOL® trans-
formers up to 40.5 kV and FITformer® WIND
transformers up to 66 kV
The IEA points out that the backbone
of today’s power systems, the electricity
grids, might develop as the weak link
in the energy transformation. Even in
the Stated Policies Scenario, without
any additional efforts than already an-
nounced to increase the sustainability
of the energy system, IEA sees an 80 %
increased demand for transmission
and distribution grid expansion in the
next decade compared to the previous
decade. Companies like Siemens Ener-
gy recognised early that energy trans-
mission and distribution would be one
major key to a successful energy trans-
formation, thus also started early to
develop technologies that are actively
shaping the path to a climate-friendly
FITformer® WIND in the nacelle of an offshore wind turbine
118
future – in a sustainable, affordable and
reliable manner.
Siemens Energy offers trans­
formers and components for best-
in-class renewables inte­gration
while keeping the transmission
grid reliable and resilient
Undoubtedly, the society needs a massive
expansion of renewable energies to com-
bat climate change while also meeting the
global energy demand. However, the in-
creased integration of fluctuating resourc-
es also poses new challenges to the grid
resulting in a higher demand for certain
transmission technologies. Power trans-
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
mission grids will be further extended
by implementing a lot more high-voltage
direct current (HVDC) systems, AC- and
DC-offshore grids, and extended AC- and
DC-onshore grid connections. Siemens
Energy’s portfolio already comprises most
of the relevant elements and is continu-
ously expanded through innovation.
To integrate renewable energy sources
into the transmission grid, the generat-
ed electricity needs to be converted to
the requisite voltage level by a step-up
transformer. Siemens Energy offers two
technologies of step-up transformers,
specially designed for wind applica-
tions: fire resistant GEAFOL® cast-resin
transformers of up to 40.5 kilovolts (kV)
and FITformer® WIND transformers
of up to 66 kV, with ester, a flame-re-
tardant, and biodegradable insulating
fluid. Both types are compact, environ-
mentally friendly, and extremely reliable.
The increasing use of renewable energy
sources does not only lead to growing grid
complexity but also to increasing power
fluctuations. Shunt reactors are used for
voltage control and reactive power com-
Siemens Energy offers various products to cope with the increasing power
fluctuations caused by the increasing infeed of renewable energy

Variable shunt reactor

pensation. They continuously adjust reac-

tor power rating to actual needs. Variable
shunt reactors by Siemens Energy are not
only designed as compact units for ongo-
ing adjustment to changes in grid condi-
tions but are also low-maintenance units
with minimal service demands.

To reduce energy loss from long cables

and extended grids, the voltage level
should be maintained on the desired lev-
el. This can be done by means of voltage
regulators. These tapped autotransform-
ers are a highly reliable solution for sta-
bilising voltage fluctuation in the grid.
Siemens Energy voltage regulators come
in 1-phase or 3-phase models. Different
cooling systems are available, and the reg-
ulators can be applied to any electrical sys-
tem to improve voltage quality.

In an increasingly complex power gen-

eration landscape and a growing energy
market, the capability to control the flow
of power is gaining crucial importance.
This is the area where phase-shifting Voltage regulator

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 119
SUSTAINABILITY
Both Sensgear® and Sensformer® can be
enhanced with a digital twin feature, which
simulates the asset performance nearly
in real-time, offering temporary overloads
without compromising on lifetime
transformers are implemented into AC
grids. They protect lines, make grids more
reliable, reduce transmission losses and
thus contribute to the reduction of CO2
emissions. Phase-shifting transform-
ers are among the most economical and
cost-efficient solutions for power-flow
management while avoiding expensive
grid extensions.
Siemens Energy supports
grid operators to increase
transmission efficiency
Siemens Energy has been working hard to
improve the efficiency of its products over
the last decades. Great progress was made,
and to date, large power transformers
have peak efficiencies above 99.5 %. Mini-
mum energy efficiency requirements have
even been defined by authorities (e.g., Eco
design regulation (EU) No. 548/2014).
For transmitting a large amount of power
over long distances, HVDC technology
offers the most efficient means. The solu-
tion can also be used to connect asyn-
Phase-shifting transformer
120
system, a solution for control and protec-
tion of power grids. The collected data of
Sensproducts® are analysed by expert al-
gorithms offering enhanced substation re-
liability and increased asset productivity.
Both Sensgear® and Sensformer® can
be enhanced with a digital twin feature,
which virtually simulates the physical
asset’s performance nearly in real-time
to increase productivity and availability,
chronous grids. Siemens Energy offers a offering temporary overloads without
comprehensive portfolio of fit-to-purpose compromising on lifetime. This innova-
HVDC systems and necessary equip- tion acts as a facilitator for operators and
ment, e.g., highly reliable and tailored-to- managers, as it provides a life consump-
fit HVDC transformers and bushings. tion view of the assets and a full tempera-
ture view of the transformer. In addition,
Another essential lever in transmission the digitalisation of assets enables preven-
efficiency is grid management – there, tive detection of critical situations such
intelligent digital information systems act as gas and oil leakages, thereby avoiding
as a real accelerator. In 2020, Siemens En-
ergy launched Sensproducts® as a conse-
quent evolution of Sensformer®, digitally
enabled transformers, and Sensgear® dig-
itally enabled switchgear products. Sen-
sproducts® combine status information
of Sensformer® and Sensgear® and form
an agile system intelligence platform for
supporting system operators to manage
grids and substations most efficiently. All
assets of a high-voltage substation trans-
mit data to a highly secure cloud-based
platform that offers a near real-time in-
formation channel parallel to the SCADA
(supervisory control and data acquisition)
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
HDVC transformer
unplanned outages and emissions to the
environment.
Siemens Energy goes beyond
product standards for a
greener future
Another step towards a greener power
grid is reduction of hazardous and pollut-
ing materials within existing transmission
equipment. In the past years, manufac-
turers like Siemens Energy came up with
various alternatives that foster the transi-
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
tion to an environmentally conscious and
greenhouse gas-reduced power transmis-
sion.
For centuries, power and distribution
transformers have been filled with min-
eral oil for electrical insulation and cool-
ing. However, if there is any leakage, it
can be harmful to the environment and
in combination with sparks and oxygen,
easily combustible. Siemens Energy has
been a leading transformer manufacturer
using natural or synthetic esters instead
of mineral oil. These biodegradable ester
fluids are environmentally friendly, which
makes them the first choice for places
where high environmental standards are
required, such as offshore wind platforms.
Besides, ester fluids are extremely fire-safe
due to high flame and flashpoint values
and today also meet cold temperature en-
vironment specifications.
In 2020, Trench, a Siemens Energy
subsidiary, launched the first ester-im-
pregnated transformer bushings. These
bushings are filled with synthetic ester
as an insulating liquid, which ultimately
121
 SUSTAINABILITY
Transformer filled with eco-friendly ester oil
improves the aging resistance of the es-
ter bushing portfolio and can prevent
several well-known failure modes of
conventional oil-impregnated bushings.
Besides, they can mitigate the fire risk
and have an improved thermal class al-
lowing many options for overload oper-
ation. Both natural and synthetic esters
Trench products: blue instrument transformer w/o SF6 gas and ester-impregnated
transformer bushings
122
are biodegradable and thereby safe for
the environment.
Another sustainable product is the dry-
type transformer. The Siemens Energy
GEAFOL® cast-resin distribution trans-
formers exceed the highest safety stan-
dards. They have excellent electrical, me-
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
chanical, and thermal characteristics and
have also proven to be particularly com-
patible with the environment. With epoxy
resin insulation instead of a liquid insula-
tor, the GEAFOL® transformers are flame
resistant and self-extinguishing. They are
also completely recyclable.
SF6, the most popular gas to insulate in-
strument transformers, is a very potent
greenhouse gas, with a global warming
potential of 22,800 times that of CO2
over a 100-year period. Trench, a Siemens
E­nergy subsidiary, is one step ahead and
has introduced the world’s first instru-
ment transformers up to 420 kV with zero
global warming potential during opera-
tion. These instrument transformers use
clean air as an insulation medium – this is
not only environmentally friendly and re-
ducing the CO2 footprint, but also makes
the products maintenance-free and suit-
able for low-temperature applications at
-50 °C and below.
In 2020 Siemens Energy launched Pretact
EcoSafeTTM - the world’s first concept of a
fire-safe and explosion-proof substation.
It sets new standards in environment,
health, and safety to achieve a reliable fire-
safe solution for the entire substation and
all its products. Owing to its modular con-
cept, customers can choose from different
performance levels and features to adjust
the products to specific environmental
and safety needs.

The success of the energy

transition depends on
forward-thinking transmission
OEMs – like Siemens Energy

Energy transmission and distribution play

a key role in a successful energy transition.
Companies like Siemens Energy are ex-
panding their transmission technologies
and portfolio with high-efficient products
that go beyond currently valid standards
and enable the integration of renewables
by innovative products for securing grid
stability. At the same time, digitalisation is
implemented to support smarter and more
efficient utilisation of existing resources.
With Sensformer® and Sensgear®, Siemens
Energy is a pioneer in this area and is ex-
tending the portfolio rapidly.

The energy transition is a global task and

demands the commitment of every indi- GEAFOL® cast-resin distribution transformer
vidual. At the same time, everybody prof-
its from it – individuals, societies, but also
economies. The necessary technologies In 2020 Siemens Energy launched Pretact
are already available or are proactively in
development. Now it is up to all of us to
EcoSafeTTM - the world’s first concept of a
speed up the implementation! fire-safe and explosion-proof substation

Pretact EcoSafeTTM concept

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 123
DIAGNOSTICS

Written in the aid of technicians involved in the maintenance of electric equipment

ABSTRACT
Absorption Index (AI) remains valid
Absorption index
of insulation at
for old-aged unsealed transformers
as a simple and effective method of
non-destructive control insulation.
The reasons for AI decrease within
transformer operation are insulation
moistening and contamination. Sev-
en gradation levels of the insulation end of service life
– Part II
condition and algorithm of the oper-
ating procedures are proposed de-
pending on the value of the measured
AI and its variation in time. Along with
AI, it is recommended to measure the Old-aged transformers equipped with silica gel air breather
polarisation index (PI) and the PI-2
(R600/R15 ratio).
5. Oil and AI of Annex 3). This means that for insulation
KEYWORDS It is well known that oil quality has a signif- of the transformer as a whole, the AI and
icant effect on the insulation resistance and PI values will be lower when filling with a
absorption index, cellulose insu- on AI and PI values. The better the quality higher quality oil than when filling with a
lation, contamination, distribution of the oil, the higher the insulation resis- lower quality oil. To quantify this reduc-
transformer, GOST, IEEE, insulation tance, and more reliable the transformer. tion in the AI, the following experiment
resistance, maintenance, moisture, But modern transformer oils with low con- was performed at ZTZ. The Russian old
oil, operation, polarization index, pow- ductivity (including Russian GK oil) have TKp oil (obtained from the oil by acid-base
er transformer AI and PI close to 1 (see the last paragraph treatment) and GK oil (obtained by the

124 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

 Vitaly GURIN

hydrocracking method) were alternately
poured into a three-phase three-winding
transformer. The comparison of the AI at
a voltage of 2.5 kV is shown in Table 4. As
follows from this table, GK oil increases the
insulation resistance by approximately an
order of magnitude, and on average halves
the AI value.
It is noteworthy that when oil is filled
with TKp, the AIs in the schemes
LV - (HV + MV + GND) (1.96 and 2.06
at different temperatures) are less than in
the MV – (HV + LV + GND) schemes
(3.52 and 3.95). And on the contrary,
when pouring the GK oil, AI in the
LV - (HV + MV + GND) scheme is larg-
er than in the MV – (HV + LV + GND)
scheme (1.43 and 1.24, respectively). This
can be explained as follows. It is known
that when changing the oil in a solid in-
sulation of a transformer, up to 10 % of the
old oil remains. The solid insulation near
the LV winding of our transformer has
fewer oil channels, and TKp oil remain-
ing in it is older than in the oil in the solid
insulation near the MV winding, where
there are fewer oil channels.
6. Al dependence on the
temperature
The author’s data indicate that old-aged
transformers with a high moisture content
The quality of the oil affects the insulation
resistance and the AI and PI values - the
more stable these values, the more reliable
the transformer
have the AI value significantly dependent sensors installed at the top oil layers. The
on the temperature. This is valid for both difference between these methods can
the European climate conditions (Fig. 3) exceed 5 °C. It is suggested to use both
and tropical climate (Fig. 5). methods, and for comparison, to apply
the method used during the previous
In an operating transformer, the water testing.
migrates from the solid insulation to
the oil and vice versa, depending on the Various correcting formulas and tables
transformer temperature. Therefore, AI are available for reducing the measure-
values should be compared with earli- ment results to the same temperature
er measured data at the same or at close for IR [15, 16]. According to the author,
temperature values of the transform- there is no point in compiling such tables
er. According to the USSR practice, the for AI values. It is preferable to take mea-
temperature of HV winding phase B is surements during the transformer cool-
assumed as the transformer insulation ing after decommissioning, when the
temperature, which is determined by temperature approaches the level from
DC resistance. For “cold” transformers, previous measurements. Temperature
the temperature can be determined by difference should not exceed 5 °C.
Measured data indicate that old-aged trans-
formers with a high moisture content have
the AI value significantly dependent on the
temperature

Table 4. Transformer 160 MVA 220 / 121 / 35 kV in the testing lab of ZTZ, February 1988
Type of oil, R15, R60,
Test Al
temperature T MΩ MΩ
TKp, 38 °С
HV - (LV + MV +GND) 250 480 1.92

MV – (HV + LV + GND) 270 950 3.52

LV - (HV + MV + GND) 260 510 1.96

TKp, 33 °С
HV - (LV + MV + GND) 330 650 1.97

MV – (HV + LV + GND) 380 1150 3.95

LV - (HV + MV + GND) 340 700 2.06

GK, 35 °С
HV - (LV + MV + GND) 4900 5800 1.18

MV – (HV + LV + GND) 4500 5600 1.24

LV - (HV + MV + GND) 2800 4000 1.43

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 125
 DIAGNOSTICS
During diagnostics, it is important to correct-
ly evaluate the remaining “time to death”,
which depends, on the degree of insulation
moisture content
Figure 5. Temperature-dependence of insulation AI of autotransformer 4T
(125 MVA 242 / 121 / 36 kV) TPP Neyveli at 5 kV. The test was carried out in February
1989. Before the shutdown of the AT, the moisture content in the oil was 40 ppm at 75 %
load. The moisture content in the solid insulation was 4 % (calculated). The AT was man-
ufactured by ZTZ in 1965.
7. Insulation condition
evaluation using AI value and
recommended measures
The problem related to insulation mois-
turizing of both old and new transformers
remains relevant [10]. During diagnostics,
it is important to correctly evaluate the re-
maining “time to death” of a transformer,
which depends, among other things, on
the degree of insulation moisture con-
tent. Over the decades of work in the field
of transformers, the author occasionally
returned in his thoughts on how to rean-
imate the criterion of AI value. The situ-
ation is as follows. Operating staff typi-
cally have the annual data of R15 and R60.
This set of data is maintained throughout
the whole service life of the transformer.
Water and moisture in the transformer in-
sulation can cause a fatal damage, as in the
case of the 200 MVA 230 / 121 / 38.5 kV
transformer in “Varna TPP”
126
However, this data is not used efficient-
ly enough, and the isolation condition
remains underestimated. Therefore, the
relevance of evaluating the permissible
decrease of AI value and the permissi-
ble absolute AI value (previously equal
to ≥ 1.3) was also practically assured. The
author has repeatedly thought about im-
proving the evaluation of the transform-
er insulation condition based on the AI
criteria. In the afternoon of his life, the
author has formulated and suggested the
following simple algorithm of measures
based on AI test results.
First, let us consider a marginal case when
the transformer’s measured AI value was
1.0. In 2001, at S/S “Varna TPP”, Bulgar-
ia, the bushing 220 kV was replaced by a
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
company unqualified for the 200 MVA
230 / 121 / 38.5 kV autotransformer
(АТ) (manufactured by ZTZ in 1977)
after 23 years of successful operation. In
this AT, three single-phase OLTCs type
RNOA 110 / 1000 are located on the
110 kV-side. Typically, over 20 years of
transformer operation, rubber seals be-
come brittle and must be changed. How-
ever, this has not been done. The rainwa-
ter has entered the phase C diverter switch
reservoir through a poor seal between
the transformer cover and the diverter
switch and moistened the insulating parts
of diverter switches. The measured AI in
configuration HV - (LV + GND) was 1.0.
Despite this, the AT was commissioned.
After two months, the AT exploded, re-
sulting in significant damage: a rupture
of the diverter compartment and OLTC
diverter switch of phase C, displacement
of the AT out of the rails, damage of three
HV bushings (the framework of damaged
110 kV bushing of phase c1 is shown in
the foreground of Fig. 6), AT tank defor-
mation, failure of the tank welded joints
at many places, complete failure of two
coolers, etc. During the investigation,
water was also found at the bottom of di-
verter switch reservoirs of phases A and B.
An emergency overhaul was carried out
by Trafoservice company to upgrade and
modernise the AT at the substation site.
The AT was sealed (tank welding and in-
stallation of an air bag) and filled with new
Bulgarian oil “Priesta Trafo A”. During
testing after the overhaul, AI was 1.30 at
35 °C and 1.26 at 55 °C. The AT has been
commissioned and operated without any
problems for almost 5 years. Then the AT
was decommissioned. The annual preven-
tive testing of the AT performed from that
moment has confirmed the AT’s operating
capability until today (April 2020).
This fact indicates the unaccepted value of
AI = 1.0. An assessment of higher AI val-
ues tolerability and the algorithm of pro-
posed measures are provided in Table 5.
Initially, the lowest measured AI value is
brought in correlation with the four grada-
tions listed in column 2 of Table 5. Then ΔAI
variation is calculated using the equation:
ΔAI = (AI1 – AI2) / AI2 x 100 (%), where:
AI1 – test performed a year before,
AI2 – current test.
In the equation, the denominator con-
tains the smaller AI value (AI2 instead of
AI1) for the purpose of a more accurate
consideration of the decrease rate of AI
for a significantly moistened and con-
taminated insulation (when AI is less
than 1.1). For this purpose, different AI
values (10, 5, and 2 %) are also indicated
for different absolute values of AI. Δ val-
ues are the most controversial part of the
proposal and require the most extensive
clarification. It should be emphasized that
the AI decrease revealed in the moistened
and contaminated transformer encour-
ages some degree of optimism because it
ensures a degree of margin for a timely de-
cision on the transformer decommission-
ing in order to prevent an accident.
The algorithm is related to old-aged un-
sealed transformers according to GOST,
without reference to their power and volt-
age rating.
An example of effectiveness of the mea-
sures according to Table 5 is shown in
Fig. 4. Another example is presented in
Table 6.
Figures 6. Damage of the 200 MVA autotransformer at S/S “Varna TPP”, Bulgaria
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
There is an algorithm based on AI and ΔAI
for evaluating the insulation condition of
aged transformers according to GOST,
without reference to their power and volt-
age rating
Transformer 4T (250 MVA 242 / 15.75 kV) the HV – LV section over a long period
AEC Kozloduy, Bulgaria, manufactured of the transformer operation. It is also
by ZTZ in 1974. The moisture content in necessary to accumulate and analyse new
the oil before repair – 26 ppm, after repair data, especially for those transformers
– 6 ppm. Oil spray drying was carried out filled with new oil during an overhaul. By
in April–May 1994 by Research Center virtue of his age, the author himself can
“ZTZ-Service”. no longer do this in practice. He relies on
consideration of other younger special-
The author feels the reliance upon effec- ists.
tiveness of his proposal for diagnostics
of the transformer condition. Improve- 8. Comparison of criteria for
ment of Table 5 is possible and necessary
AI, PI, DAR and R600/R15 ratio
by analysis of AI data accumulated over
many years for unsealed transformers by The typical time-dependence of IR of the
different manufacturers. Priority should old-aged transformer in the range of up to
be paid to the nature of change in AI of 10 minutes is shown in Fig. 7. Table 7 rep-
127
 DIAGNOSTICS

Table 5. Evaluation of insulation condition of the old-aged unsealed transformer and recommended measures
No. Al ΔAI* Insulation What to do
condition (recommended action)

1 > 1.2 < 10 % Excellent No cause for concern. Continue to operate normally.

> 10 % Good Continue to work, but the condition should be checked upon the first
shutdown of T.

2 1.1 < AI ≤ 1.2 < 5% Fair Carry out additional measurements.**

Continue to operate but check the decrease trend.

>5% Questionable Continue to operate with excessive control.***

Check the decrease trend.

3 1.01 < AI ≤ 1.1 < 2% Poor Continue to operate with excessive control.****
Filtration or drying of oil, or replacement of oil within the next 6-12 months.

>2% Very poor Continuation of operation is risky.

Drying or replacement of oil or insulation drying within the next 1-2 months.

4 ≤ 1.01 - Dangerous It is unacceptable to start up the transformer for operation. Insulation

drying.

*Variation of AI value (see the equation in the text) at temperature difference between the tests not exceeding 5 °С.
**Make measurement of insulation IR, AI, PI, tan delta and their dependence on the temperature and voltage testing for all accessible sections of
the transformer insulation. Make measurement of the oil characteristics (moisture content, tan delta, breakdown voltage). Plot graphs of variation
with available data for the complete period of the transformer operation. Contact experts for advice onr evaluation of the transformer condition.
***Excessive control includes taking measurements** at least once per six months to clarify the trends.
****Excessive control includes taking measurements** at least once per quarter. If it is impractical to carry out the testing too frequently, it is
possible to cut to estimation of the transformer condition as “very poor”.

resents the comparison of AI, PI, DAR, and
R60/R15 calculated based on data in Fig. 7.
Let us compare conditions of transform-
er 2GT according to PI and AI criteria. If
PI = 1.6, in line with IEEE (Annex 3 to
this paper), the condition of transform-
er 2GT should be evaluated as “fair”. For
a complete evaluation of the condition
using the AI criterion, there is no data for
the year before 1988. According to the
absolute value of AI = 1.18, the transform-
er condition should be evaluated in the
rough between “fair” and “questionable”.
DAR assumes only a very small-time do-
main in the absorption curve and a pri-
ori provides less information about the
insulation moisture content if compared
with other criteria. Considering also that
a smaller error occurs when comparing
large digital values, DAR should be con-
sidered unpromising for implementation
of field tests in practice. R600/R15 ratio (let
us call this ratio “Polarization Index 2”
PI-2) may be more informative.
The author’s experience shows that a wid-
er point of view that PI is temperature-in-
dependent may not be observed for old-
aged highly moistened transformers. So,
Fig. 8 shows a temperature dependence of
AI, PI, and R600/R15 (PI-2) for the distance
from major solid insulation of the trans-
former 4T at TPP Neyveli (mentioned in
Fig. 5). As can be seen from Fig. 8, PI no-
ticeably decreases at the temperature in-
crease, although to a lesser extent if com-
pared to AI, and especially PI-2.
9. On the possible life span of
old power transformers
By the start of the 1990s, it was found that
power transformers and shunt reactors of
up to 750 kV inclusive are able to operate
reliably beyond the 25-year service life es-
tablished by GOST [17, 18, 19].
The subsequent experience of the au-
thor suggests that transformers can
successfully work for much longer.
Many of the transformers discussed in
this article are still in operation. Some

Table 6. Effect of insulation drying on AI

Before repair After repair

Transformer temperature 38 °С 43 °С

HV – LV 1.30 1.67

HV – tank 1.05 1.41

128 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

of them are over 50 years old. In addi- The absorption index has kept its impor-
tion, more than 100 transformers of up
to and including 400 kV were renovated tance as the most straightforward method
in Bulgaria by modernization. The vast
majority of them continue to work suc-
for evaluation of moisture content and con-
cessfully (as on April 2020). An analysis tamination of the transformer insulation
of this experience is beyond the scope of
this article.

The author considers it incorrect and eco-

nomically unreasonable to replace trans-
formers that have successfully worked
for 25 years with new ones. Just as during
the time of Bratsk HPP (replacing 220 kV
block transformers). Over the past five
years, this vicious practice has been car-
ried out in Ukraine (replacement of trans-
formers of 750 and 330 kV).

Conclusion
The absorption index has kept its impor-
tance as the most straightforward meth-
od for evaluation of moisture content and Figure 7. An insulation absorption curve of transformer 2GT at TPP Neyveli. Measurements
contamination of the transformer insula- at 5 kV were performed on 2/8/1989. The transformer’s temperature was 28 °C.
tion. A practical approach is proposed to
improve this method (Table 5 algorithm,
taking into account AI value and its vari-
ation over time). The approach requires
verification in practice. This is just one of
the methods for evaluation of the insula-
tion condition; it does not substitute the
need for additional testing and detailed
expert analysis of the transformer con-
dition as a whole. However, according to
the author, it would assist in focusing on
priorities of those transformers, which
need to be considered the most.

Performance of AI test once a year is rea-

sonable and sufficient. Along with the
measurement of AI, it is recommended to
measure PI (in order to use the American
experience). DAR does not make sense to
perform. The PI-2 could be more infor-
mative. It is also suggested to gain prac-
tical experience of comparison of AI test
results and DFRT data.

The author expects that after clarification, Figure 8. Temperature dependence of insulation AI, PI, and R600/R15 (PI-2) of LV - HV for
Table 5 can also be applied to old-aged, transformer 4T TPP Neyveli

Table 7. The values of AI, PI, DAR, and PI-2 according to Fig. 7

Time, s 15 30 60 600 Al DAR Pl R600/R15

IRLV-HV, MΩ 1700 2050 2500 4450 1.47 1.22 1.78 2.62

IRHV-tank, MΩ 3450 3750 4075 6500 1.18 1.09 1.60 1.88

w w w . t ra n sfo r m e r s - m a g a z i n e . co m 129
 DIAGNOSTICS

Considering also that a smaller error occurs
when comparing large digital values, DAR
should be considered unpromising for
implementation of field tests in practice
unsealed transformers from other manu-
facturers. The wider application of AI may
be advantageous for oil-filled bushings,
CTs, and VTs.
The author’s experience shows that the
safety margins of insulation of old-aged
USSR oil-filled, free silica gel breathing
power transformers are such that, subject
to proper maintenance, they can be in ser-
vice for the period up to 40–50 years, and
with their modernization with tank seal-
ing maybe even more.
Bibliography
[15] Guide to the adjustment of elec-
trical equipment of power plants and
substations, edited by E. S. Musaelyan,
Energoatomizdat, Moscow, 1984 (in Rus-
sian)
[16] ANSI / NETA MTS-2011 Standard
for maintenance testing specifications for
electrical power equipment and system
[17] V. V. Gurin, S. D. Lizunov, A. K. Lokh-
anin, et al., Service experience and re-
quirements for insulation high-voltage
tests of EHV power transformers and
shunt reactors, CIGRE, 1992, No. 12-202
[18] V. V. Gurin, A. K. Lokhanin, L. L. Gla­
zu­nova, et al. Requirements for testing
the dielectric strength of insulation of
power transformers 330 kV and higher
in the norms of the USSR, USA, Can-
ada and IEC, Electrotechnika, No. 12,
1992 (in Russian)
[19] S. D. Lizunov, A. K. Lokhanin,
V. V. Gurin, et al. Experience of fault de-
tecting, repairing and testing of EHV
transformers and shunt reactors on
site, CIGRE, 1994, No. 12-201
Annex 1. Summary of the factory tests
of new transformers.
Measurements of AI carried on for 484
transformers manufactured by ZTZ rated
for voltage 35-750 kV and capacity from
11 to 630 MVA, filled with new oil type
GK or Nynas have been analyzed. Circuits
HV – (LV + GND), LV – (HV + GND),
and (HV + LV) – GND have been con-
sidered. It turned out that AI values are in
the range 1.17–2.75, and statistically, these
values dependent in a minor way on the
transformer parameters (power and volt-
age class).
The average values AI for
LV – (HV + GND) are higher than for
HV – (LV + GND) (1.79 versus 1.45),
which is to be explained by the lump of
solid insulation adjacent LV windings if
compared to HV windings. At the dis-
patch from the factory, more than the
third part of the transformers have an AI
value less than 1.3.
With temperature increase, the AI val-
ue of new transformers is practically the
same. But if the transformer is filled with
old TKp oil, then AI value decreases sig-
nificantly depending on the temperature,
and this is much obviously for the dis-
tance HV-tank. This once again confirms
the fact that at a distance of HV-tank, the
main role is played by oil and that TKp
oil gives higher AI values than GK and
Nynas.
Annex 2. Other possible test
connections of transformers for AI test
Two winding transformers:
1. LV – tank
2. HV – (LV + GND)
3. LV – (HV + GND)
4. (HV + LV) – GND
Three winding transformers:
1. LV – tank
2. TV – tank
3. HV – TV
4. LV – TV
5. HV – (LV + TV + GND)
6. LV – (HV + TV + GND)
7. TV – (HV + LV + GND)
8. (HV + LV) – (TV + GND)
9. (HV + TV) – (LV + GND)
10. (LV + TV) – (HV + GND)
11. (HV + LV + TV) – tank
Annex 3. Evaluation of T insulation by
PI value (cited from clause 7.2.13.4 of
the standard [1]).
The following are guidelines for evaluat-
ing transformer insulation using polariza-
tion index values:
Less than 1.0 = Dangerous
1.0 to 1.1 = Poor
1.1 to 1.25 = Questionable
1.25 to 2.0 = Fair
Above 2.0 = Good

The polarization index method should

Author
Vitaly Gurin graduated from Kharkov Polytechnic
Institute in (1962) and the Leningrad Polytechnic
Institute. He was a candidate of technical sciences in the
Soviet scientific system (1970). For 30 years he tested
transformers up to 1.150 kV at ZTZ, including the largest
one of that time in Europe, and statistically analysed
the test results. For over 25 years he was the Executive
Director of Trafoservis Joint-Stock Company in Sofia
(the diagnosis, repair, and modernisation in the operating conditions of
transformers 20 – 750 kV). He has authored about 150 publications in Russian
and Bulgarian and is the main co-author of GOST 21023.
not be used to assess insulation condition
in new power transformers.
The polarization index for insulation liq-
uid is always close to 1. Therefore, the po-
larization index for transformers with low
conductivity liquids (e.g., new mineral
oil) may be low in spite of good insulation
condition.
Author’s note: What is PI, see Table 1 in
the article. According to [1] “Test voltag-
es are typically 500 V, 1000 V, 2500 V,
or 5000 V DC”.

130 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

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FLUIDS

ABSTRACT
A comprehensive, detailed report
The role of ester
fluids in Europe's
covering European distribution
grids [1] makes one thing very clear:
huge improvements and invest-

ageing grid
ments are needed to renovate the
continent’s ageing electric grid. Tim
Martin, sales director for MIDEL in
Europe, Middle East and Africa,

infrastructure
takes a look at the report and points
to a clear role for ester transformer
fluids in the upgrading of European

E
grids.
uropean distribution grids will
KEYWORDS need investments of €375-425 bil-
lion until 2030, concludes a study
ester, fluids, modernisation, retrofill- [1] by Eurelectric, Monitor De-
ing loitte and smart grid organisation E.DSO.
Based on detailed empirical data from
ten European countries, Connecting
the Dots: distribution grid investment
to power the energy transition suggests
investments in distribution grids will

132 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021


need to increase by 50-70 %, from 2020
to 2030, compared with the previous de-
cade. That is equivalent to €34-39 billion
a year.
The single biggest investment driver is
modernisation of ageing infrastructure.
The study found that a third of the EU’s
grids are already over 40 years old, a fig-
ure increasing to fifty percent by 2030.
Transformers, designed to step power up
or down, are a critical component of any
power grid. Upgrading or replacing these
assets constitutes a key aspect of any grid
modernisation investment programme.
Liquid filled distribution transformers
are used in medium voltage (MV) and
high voltage (HV) applications - histor-
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
Tim MARTIN
ically using mineral oil as the dielectric in the use of mineral oil as an insulating
insulating and heating media fluid. Liq- fluid – its potential flammability and its
uid filled transformers are robust assets, poor biodegradation characteristics in
with low load losses and long service case of a major failure.
lifetimes of around 35 years [2], making
them a popular option for outdoor as For any distribution network operator
well as indoor environments, compared (DNO), or utility, transformer fleet up-
with dry type, or air cooled, transform- grades can potentially be a costly under-
ers, which require more maintenance. taking, especially from a capital expen-
However, in our experience, there is a diture (Capex) perspective. Utilities will
growing awareness of two critical flaws want to consider solutions that can safely
European distribution grids will need in-
vestments of €375-425 billion until 2030,
concludes a study by Eurelectric, Monitor
Deloitte and smart grid organisation E.DSO
133
FLUIDS
Retrofilling transformers with natural or
synthetic ester fluid to replace mineral oil is
a perfect example of a solution that extends
the asset life and at the same time optimis-
es the loading performance
extend asset life and optimise loading
performance. Retrofilling transformers
with natural or synthetic ester fluid to re-
place mineral oil is a perfect example of
such a solution.
This practice of retrofilling provides sev-
eral key benefits, including:
• Ester fluids have a higher fire point
than mineral oil that virtually elimi-
nates the possibility of a transformer
fire.
• Being readily biodegradable, unlike
mineral oil, ester fluids offer a high
level of environmental protection.
• Ester liquids can allow higher oper-
ational temperature of a transform-
er due to their higher flash and fire
points as well as different chemi-
cal structure which allows a longer
lifetime of cellulose materials. This
phenomenon can be found in IEC
60076-14 and IEEE C57.154. Based
on that it is possible to run trans-
former at higher power rate and at
the same time also run at higher op-
erational temperature [3]. Synthetic
ester fluid is more hygroscopic than
mineral oils. It is capable of absorb-
ing more moisture from the solid
insulation system used within the
transformer (without a reduction
in its breakdown voltage). Doing so
slows down moisture degradation of
the winding paper and extends oper-
ational life.
• Retrofilling liquid filled transform-
ers using an ester fluid is a straight-
forward process, usually being per-
formed in-situ and with minimal
transformer downtime.
Ester fluids have a long and proven track re-
cord in offshore / onshore wind farms where
fire safety and environmental credentials
are paramount
134
Certain forward-looking utilities and
transformer OEMs have already been
pursuing ways to address the challenges
echoed in Connecting the Dots report.
A recent project undertaken by Scottish
Power Energy Networks (SPEN) identi-
fied several capital expenditures (Capex)
and operational expenditure (Opex)
cost savings derived from the use of ester
transformer fluids in its transformer fleet
for 132 kV grid, 33 kV primary and 11 kV
secondary assets [4]. Considerations in
SPEN’s cost-benefit analysis included cap-
ital cost, operation and maintenance cost,
firewall necessity and fire suppression sys-
tem necessity. They found that ester-filled
transformers offer a significant unit cost
saving, particularly for indoor applica-
tions where most saving originates from
the exclusion of a firewall or fire suppres-
sion system.
SPEN found that average unit cost sav-
ings were found to be around £235,000
per indoor installation.
In another example, German trans-
mission system operator TransnetBW
tasked OEM Siemens with supplying
a power transformer with two critical
criteria; namely, the transformer was to
be filled with natural ester fluid rather
than mineral oil. In addition, the trans-
former had to demonstrate robust cold
start capability. The use of a rapeseed
ester fluid satisfied the local authority’s
mandate for the transformer materials
to be locally sourced, the rapeseed be-
ing grown in central Europe. Impor-
tantly, the manufacturer independently
acknowledged the superior cold weath-
er performance of rapeseed ester fluid,
TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021
with its pour point of -31 °C, over soya-
based ester fluid that has a pour point of
around -18 °C.
Dr Beatrix Natter, CEO of Siemens Ener-
gy Transmission commented on this proj-
ect, saying “The innovative cold start
technology in this transformer demon-
strates Siemens’ expertise in combin-
ing industry leading innovations with
eco-friendly solutions for the benefits
of our customers and society” [5].
Accommodating more capacity based
on distributed sources of clean electric-
ity, while ensuring networks can supply
demand for recharging electric vehicles
and for heating, inevitably requires in-
vestment in new physical infrastruc-
ture, including transformers. In densely
populated cities and urban areas, where
utilities may have to install transformers
closer to where people live and work, es-
ter transformer fluids, with their high fire
point, clearly strengthen mandated fire
safety protocols. In addition, the fluids’
biodegradability means they can be used
in transformers installed closer to water-
ways and other environmentally sensi-
tive areas.
Increases in renewable energy gener-
ation, electrification of transport and
electrification of heating and industrial
activity are identified in the Connect-
ing the Dots report as other key drivers
for investment in European distribu-
tion grids to 2030. Ester fluids have a
long and proven track record in off-
shore / onshore wind farms where fire
safety and environmental credentials
are paramount. Ester fluids’ uptake in
the world of solar power – in particu-
lar the growth we see in floating solar
– is increasing at pace. The correlation
is clear: ester filled transformers con-
stitute a wise investment for balance of
plant (BoP) electrical equipment at so-
lar photovoltaic (PV) power plants and
wind farms. BoP equipment is the criti-
cal link for delivering electricity gener-
ated by these renewable energy plants
to the grid. Increasingly wind and solar
plants are being built without subsidy,
earning their income through electricity
sales. Meanwhile, owners of these assets
are also focused on reducing levelised
cost of energy (LCOE) through reduc-
ing BoP equipment Capex and Opex.
Ester fluid transformers can operate at
higher temperatures, maximising the
amount of power distributed and ensur-
ing uptime of BoP equipment and help-
ing to maximise the operator’s return on
investment.
The Connecting the Dots report sets
out clearly, and in granular detail, the
level of investment and work necessary
in the near future for European distribu-
tion grid operators. There are complex
challenges ahead, to be sure. However, by
embracing proven technology such as es-
ter transformer fluids in parallel with de-
ploying smart grid processes and inno-
vations, forward-looking operators and
OEMs will survive, thrive and ultimately
materially contribute to a pan-European
landscape of greener, safer, more reliable
and better performing power networks.
Bibliography
[1] Connecting the Dots: Distribution
grid investment to power the energy
transition by Monitor Deloitte, E.DSO
and Eurelectric, January 2021.
[2] https://www.eurelectric.org/con-
necting-the-dots
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
[3] Electrical Engineering Portal: Shenji Tee, David Walker and Malcolm
https://electrical-engineering-portal. Bebbington, Scottish Power Energy Net-
com/right-choice-of-dry-type-or-liq- works, 2019.
uid-filled-transformer#4
[6] https://ieeexplore.ieee.org/docu-
[4] Overload Distribution Transform- ment/8796812
er with Natural Ester and Aramid-En-
hanced Cellulose: X. Zhang, S. Qian, Y. [7] Siemens selects rapeseed over soya
XU, R. Marek and Q. Lei https://ieeex- on 420 kV transformer: Case study,
plore.ieee.org/document/9166742 MIDEL website: https://www.midel.
com/case-studies/siemens-selects-
[5] Experience of Synthetic Ester Filled rapeseed-over-soya-on-420-kv-trans-
Transformers in SP Energy Networks by former/
Authors
Tim Martin is the EMEA Sales Director for MIDEL
ester transformer fluids at M&I Materials. He has held
various senior board level positions throughout his career
in leading technology providers in both publicly listed
Fortune 500 corporations and SME entities in the UK,
Middle East and Asia Pacific region.
He has experience of the latest technology developments
in the global power and electrical transmission and
distribution markets and is regarded as an expert in Ester Dielectric Fluids used
within these systems. His passion for Corporate and Social Governance and the
green4.economy is the driving force behind Tim’s vision for all transformers to
Figure
be green, safe and ultimately more efficient for operators and the environment.
135
EVENTS

Middle East Energy Dubai

generated over AED18
billion of business in 2020
• Registration is now open for Middle East Energy Dubai 2021
• Live and in-person physical event to take place at Dubai World Trade Centre from 14-16 June
• Online conference series to begin on the 17 May and run for four weeks

M
iddle East Energy Dubai, the
leading global energy indus-
try event formerly known as
Middle East Electricity, has
revealed the 2020 edition of the show gen-
erated more than AED18 billion worth of
business during the three-day showcase,
Middle East Energy 2020 resulted in over
AED 18 billion worth of business deals con-
cluded over the course of the three days of
the show
as registration for the 2021 event goes live
today.
Held under the patronage of HH Sheikh
Maktoum bin Mohammed bin Rashid Al
Maktoum, Deputy Ruler of Dubai, and
hosted by the UAE Ministry of Energy
& Infrastructure, the event, is now in its
46th year and will take place at the Dubai
World Trade Centre (DWTC) from 14-16
June 2021 featuring a new hybrid format.
A three-day live and in-person physical
event promoting face-to-face meetings
will allow visitors to safely conduct busi-
ness while also incorporating four themed
weeks, which can be accessed online from
home or in the office from 17 May - 7 June,
focusing on renewable and clean energy,
transmission and distribution, critical and
backup power, and energy consumption
and management.

136 TRANSFORMERS MAGAZINE | Volume 8, Issue 2 | 2021

The exhibition offers the chance for pub-
lic and private sector entities to showcase
products and innovative technologies that
are driving forward the energy transition
The in-person element of the event will be
held alongside the Global Energy & Utili-
ties Forum and will provide an opportuni-
ty to network and exhibit within the tradi-
tional framework of Middle East Energy,
with rigorous health and safety protocols
and measures in place.
Claudia Konieczna, Exhibition Director,
Middle East Energy, said: “The exhibition
offers the chance for public and private
sector entities to showcase products and
innovative technologies that are driving
forward the energy transition and pro-
viding solutions to meet ambitious
clean energy and net-zero tar-
gets.
“Last year, the exhibi-
tion resulted in over
AED18 billion worth
of business deals con-
cluded over the course
of the three days of the
show. This year, we are
committed to providing a
platform that encourages face-
to-face interaction and builds on the
successes of 2020.”
Middle East Energy has also launched
a steering committee comprising influ-
ential industry leaders providing expert
guidance to maximise exhibitor and vis-
itor participation. A VIP hosted buyer
programme rounds out the new show at-
tributes and will see over 200 global inves-
tors, influencers and high-profile buyers
w w w . t ra n sfo r m e r s - m a g a z i n e . co m
meet through a series of pre-scheduled
meetings.
“Through our live event and the various
new features we have added, we wanted
to create a safe environment that pro-
motes interaction and encourages busi-
ness deals. We’re at the cutting-edge of
the energy industry and remain commit-
ted to providing a platform that supports
development and growth,” concluded
Konieczna.
Each themed week will offer an array of
online and virtual opportunities
for business development,
connecting attendees with
government authori-
ties, utility companies,
and key stakeholders
through unique arti-
ficial intelligence (AI)
networking tools.
The digital events will in-
clude tech talks, interactive
roundtables, panel discussions,
thought leadership sessions and re-
mote interviews. Networking opportuni-
ties will include hosted buyer meetings,
fireside chats, breakout sessions, person-
alised meetings, and speed networking
sessions.
To register for the event please click on the
following link, https://bit.ly/3lJxoKZ.
Middle East Energy (MEE) enjoys a
45-year legacy as a leading global energy
industry event.
By catering to the entire product spec-
trum of the power industry, from critical
and backup power to energy storage and
management, year after year, the event at-
tracts a more diverse audience of profes-
sionals seeking to source products from
multiple sectors, drive cost-effectiveness
and efficiency, and move projects forward.
MEE has been an essential part of the
Middle East's economic expansion, con-
necting business and introducing new
products to the region to build infrastruc-
ture, real estate, and commerce.
MEE is now helping governments, or-
ganisations and SME’s diversify the gen-
eration and supply of energy and build a
sustainable future.
Media Contact
James Lakie
General Manager
Tel : +971 4 365 2711
Mobile : +971 50 153 6544
E-mail: james.lakie@shamalcomms.com
Office 3208, Indigo Icon Tower
Cluster F, Jumeirah Lakes Towers
PO Box 502701, Dubai, United Arab Emirates
Website: www.shamalcomms.com
A member of the ECCO Communica-
tions Network
137
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