Transformer industry undergoes evolution to meet capacity addition

The projected increase of over 433,000 MVA in substation capacity nationwide has served as a guiding force for the transformer sector. Amit Varshney shares his expertise in talks with EPR.

- Amit Varshney Director- VR Engineering & Consultancy Services In partnership with Atlanture Transformer & Switchgear (P) Ltd

How are modern power transformers being designed to handle increased load and bidirectional power flows from renewable energy integration?

Modern transformers are undergoing fundamental design evolution to accommodate India's renewable energy targets. We are implementing advanced core designs with optimised flux distribution to handle variable loading patterns typical of solar and wind generation. The key innovation lies in on-load tap changers (OLTC) with wider voltage regulation ranges—typically ±15% to ±20%—enabling dynamic voltage control as renewable generation fluctuates throughout the day.

Bidirectional power flow capability requires enhanced thermal management since reverse power flow creates different hot-spot temperatures. We are utilising computational fluid dynamics to optimise cooling systems and ensure that the transformer's lifespan is not compromised. Additionally, we are designing for higher short-circuit withstand capability, as integration points for renewables can experience sudden fault currents. At Atlanture, we have incorporated amorphous metal cores into select designs, reducing no-load losses by up to 70 percent, which is crucial when transformers operate at partial load during off-peak periods of renewable generation.

What role do digital and intelligent transformers play in smart substations?

Digital transformers represent a paradigm shift in asset management. These units integrate sensors, communication modules, and edge computing capabilities directly into the transformer tank. Real-time monitoring of critical parameters—oil temperature, winding temperature, moisture content, partial discharge activity, and bushing health—enables predictive maintenance strategies that reduce unplanned outages by 40-50 percent.