AEIJST - June 2016 - Vol 4 - Issue 6 ISSN - 2348 - 6732

Power Transformer and its Challenges A Survey

*A. N. Joshi, S. B. Halbhavi, S. G. Kulkarni, Parag Datar, Vani P. Datar
*Department of Electrical and Electronics Engineering, GIT, Belgaum (India)
Abstract
Power transformers are vital parts of electric energy transmission and distribution system.
Power transformers exist to provide a safe and economical means of transferring electrical
power around a grid system. They are high capital items, with a long lead time on delivery,
requiring much planning and thought to their procurement, operation and maintenance. The
life span of a power transformer is about 30 years, and its failure within its life span and
beyond, creates disruption of power supply to consumers and extent of its effect depends
upon the transformer rating and area of application. This paper summarizes various
challenges, a power transformer encounters, and right from design, procurement and
operation. Brief survey and discussion on few of these challenges arising from insulation
operation, maintenance and possibility of replacement/refurbishment, are dealt with.
Introduction
Transformer is a mature product over 100 years, technology has not changed dramatically.
But challenges for a transformer are many. The concept of electromagnetic induction was
discovered by Sir Micheal Faraday, in 1831. A 1400W, 120/72v, 40Hz, 11.6/19.4A, single
phase shell type transformer with iron core, was designed and fabricated at GANZ factory in
Germany, and later M.O. Dolivo-Dobrowosky, an engineer working at AEG Germany invented
a three phase transformer in 1890. The use of petroleum based oil for insulation and cooling
opened door for construction of larger capacity transformers. At present designers are aiming
at 2000+ MVA ratings at 1500+KV[1]. The basic requirements of a modern transformer are
minimization of losses, reliable high voltage insulation design to withstand system overvoltage, Literature [3] reports controlled manufacturing practices and fabrication aspects to
eliminate hot spots in core, windings and structural parts.
Continuous increase in ratings and size, limitations of weight and space, accurate prediction
of performance/ insulation aspects, precautions against ageing, maintenance, Refurbishment
/ replacement, global competitions, increasing
power system complexities, have thrown
open challenges to power transformers.
Power Transformer Challenges
1. Insulation Aspects
Todays transformer faces more challenges from the point of view of insulation. The
performance of transformer, its life-span depends heavily on insulation, its condition material,
composition and geometry. It all began, with petroleum based oil with paper impregnation.
Petroleum based oil, is a conventional source which might last only till mid 21st century,
further it is not environment friendly and flammable [1]. Literature shows exhaustive attempts
made to find an alternate insulating fluid, which is abundantly available, environment
friendly, inflammable, fire-resistant and sustain high temperatures and electrical stresses.
Further its option to be mixed with conventional oil to deal with higher overvoltage, electric
stresses, both at the time of testing and operation, are also well established.
Research in material science has produced excellent alternatives to cellulose paper, used for
conductor insulation, winding insulation and condenser bushings etc. Literature reports
variety fibrous materials like cotton, silk, jute asbestos, varnished press boards [2]. Various
polymers like Polytetraflouroetheline(PTEE), Polyphenylene Sulphuide(PPS), Polycorbonate(PC)
Polyester film(PET) have been developed.[2] With these developments chances of failure of
transformers by way of thermal degradation, ageing can be controlled.
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AEIJST - June 2016 - Vol 4 - Issue 6 ISSN - 2348 - 6732

2. Demand Based Challenges
With the increased demand of electrical power, the utilities invest in new generation and new
transmission and distribution systems to satisfy the demand. However in some cases already
installed equipment may be upgraded to handle more power than it originally was designed
for. Such upgrade is possible. Literature reports development of new technologies and new
material that allow the equipment to operate at a higher load still within safe design margins.
One factor that may limit the opportunities for upgrade of already installed electrical
equipment is the requirement of very high availability of the power network. Therefore it is
important to develop efficient and reliable processes to minimize the time until upgraded
equipment can be put back to service.
Literature [6] reports that, ABB has now developed technology using BIOTEMP and press
board insulating material developed by DuPont for high voltage transformer and successfully
upgraded the rating of the transformer by more than 60 %. To considerably reduce the time of
unavailability of transformers during repair and Upgrade, ABB has developed an onsite repair
process and implemented it.
3. Preventive Maintenance
Transformer plays a crucial role in a power system (transmission and Distribution) and its
failure creates disruption in power availability to the end users. Healthy condition of the
transformer is to be ensured with careful preventive strategy.
A transformer can be operated through its life-span and even beyond. This needs status and
status assessment of the transformer. Literature [4] reports various factors that affect the
status and condition of the transformer. These factors are e.g. extent of overloading, load limit,
stresses (thermal Electrical and mechanical), atmospheric surges. The market competitions,
also impose severe restrictions, and ultimately bring down the safety margins, just sufficient
to operate at standard specifications with ideal loading conditions. All these pose threats for
transformer failure.
Preventive measures for these, are in form tests that need to be carried out, at the
manufactures site and then at operational site. These tests are Routine Tests, Type Tests (
Manufactures site) and test s after Incipient faults during operation of the transformer (
Insulation Resistance Test, Magnetic Balance Test, Turns Ratio Test, Magnetizing current
Test, Short Circuit Impedance Test Degraded Gas Test (DRG), tan and Capacitance Test and
Break Down Voltage (BDV) Test etc )[3]
The outcome of these tests, helps in analyzing the root-cause of failure and enable to arrive at
comprehensive preventive maintenance schedule on regular basis.
4. Replacement versus Refurbishment
Like any equipment, Transformer also has a life-span which may be 25 to 30 years. It is at the
nominal end of the life, that we may have to make a vital decision: whether we can recondition
the equipment and refurbish the unit or we must replace it completely with a new unit.
Refurbishment or Replacement is a significant in terms of investment and subsequent
reliability of the transformer installed. The decision is quite complex and is based on variety of
parameters e.g.
a)
b)
c)

Maintenance history
On-line condition monitoring
Cost of replacement / refurbishment

All these parameters need to be analyzed in paradigm of risk analysis on probability basis to
arrive at comprehensive decision-making. For a transformer, probability of failure and costs
are associated with contingent network configuration, rate of failure, mode of failure (fire on oil
spillage, fire on tank rupture), and bushing failure. Rate of failure varies with design, role and
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AEIJST - June 2016 - Vol 4 - Issue 6 ISSN - 2348 - 6732

location. Literature [5] reports systematic concepts on decision making mechanism, which is a
financial analysis with following guiding features
a)
b)
c)
d)
e)
f)

Likely hood of failure of a unit after installation

Operational costs associated with each activity
Business Interruption expense
Fines / penalties associated with loss of service
Transport costs associated with removal and reinstallation
Environmental /safety issues associated with decision

Conclusion
Power transformers are vital parts of power system. Ever since its design, fabrication and
subsequent utility, it is thrown open to the challenges. Various challenges arising from the
point
of
insulation
increased
demands,
operationmaintenance
and
replacement/refurbishment aspects are covered. Power transformers might also face
challenges in the light of emerging technology with new concepts of smart grid, solid State
Transformers, Power convertors with wind-mills and traction systems.
References
[1] Jashandeep Signh, Y.R Sood and Piush Verma,History of Transformers and its insulating
materials , August 2010 Electrical India
[2] K.Lee, J. C Durat, Cheng and P Shieh, Advanced Materials Applications in Fluid filled
Transformers IEEE T&D Asia 2009
[3] Prof. Kulkarni. S.V,Khaperde S.A , Challenges and Strategies in Transformer Design and
Practice
[4] Aman Deep,Preventive Maintenance and Checks on failure of transformers, Electrical
India March 2014
[5] Kennelh Elkinson, TanyMcGrail, Power Transformer Decision Analysis, Replacement vs
Refurbishment, Electrical India March 2014
[6] Dr Jos-Carlos, ABB, Mendes Lars Eklund ABB Paolo Capuano,ABB Meet the challenges
of tomorrow: Increase the power of your transformer in record time, Bahrain International
Exhibition Centre 4-6 Feb 2008.

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