Rising use of dry-type transformers boosts demand for high-temp insulation materials

Environment-friendly ester-based oil insulation is gaining traction due to its biodegradability and superior fire safety.

Innovations in insulation, cooling, and smart monitoring are reshaping the reliability and performance standards of transformers in India. Emerging trends highlight a shift toward sustainable materials, advanced thermal management, and intelligent systems. These developments are crucial for supporting modern grid demands, improving operational efficiency, and ensuring long-term transformer resilience in diverse environments. Rahul Shah from Raychem RPG shares his expertise in talks with EPR.

What are the emerging trends in transformer insulation technology to improve durability and efficiency?

If we speak of emerging trends in transformer insulation technology, environment-friendly ester-based oil insulation is gaining traction. This is due to its biodegradability and superior fire safety. High-temperature insulating papers are becoming increasingly popular, supporting the need for enhanced thermal performance. The growing adoption of dry-type transformers in infrastructure and industrial sectors further accelerates the demand for high-temperature insulation materials. These applications drive the shift toward insulation classes such as F, H, N, and R, offering improved heat resistance and reliability. This trend reflects a broader industry move toward sustainability, safety and operational efficiency in transformer design and deployment.  

What innovative cooling techniques are implemented in transformers to enhance performance in adverse conditions?

Modern transformer installations increasingly adopt advanced heat exchange mechanisms to enhance performance and reliability. In dry-type transformers, improved ventilation systems, as outlined in IEC 60076-11, ensure efficient cooling. Pre-set temperature controls are widely implemented for consistent thermal management. In solar farms, oil-filled transformers now feature reduced hot spot temperatures to meet stringent operating conditions. Additionally, air-forced cooling is becoming a standard for variable-speed drive transformers, while oil-cooled converter transformers are commonly equipped with water-cooling systems. These developments strongly emphasise efficient thermal design and regulation to support high-performance and safe transformer operations in diverse applications.

How can smart technologies improve transformer reliability amid grid expansion and maintenance challenges?

Maintaining transformers in an expanding power grid is challenging. Unstable power grids place undue stress on transformers due to frequent switching operations that generate harmful transients, often resulting in premature transformer failures. This issue becomes even more challenging as these transformers are sometimes maintained by unqualified personnel who do not adhere to proper operation and maintenance (O&M) guidelines. To address these concerns, energy-efficient transformers equipped with smart technologies—such as condition monitoring systems, smart breathers and intelligent accessories are being deployed. Additionally, advanced protective accessories, including snubber circuits and combined surge arresters, are increasingly used in sensitive applications like data centres and metro infrastructure projects to ensure reliability.

How can AI and IoT be leveraged for real-time monitoring of transformer performance in substations?

AI and IoT are the most important aspects in advancing transformer performance. The two-way communication and advanced algorithms are set to become pivotal in extending the life cycle of transformers. These technologies ensure continuous monitoring and greater reliability by enabling real-time data exchange. Proactive maintenance driven by intelligent analytics allows early detection of anomalies and efficient fault resolution, minimising the risk of unexpected failures. Moreover, advanced messaging systems streamline alerts and diagnostics, facilitating faster decision-making and reducing overall downtime. This integration of smart communication and predictive insights enhances operational efficiency and supports a more resilient and sustainable power infrastructure.