Advanced Technologies should be adopted for a long-term vision

The environment friendly approach of using Natural Ester fluids in transformers has implemented in India since a decade, ensuring fire safety with a fire point of around 350°C.These fluids are biodegradable, UL certified & approved by FM Globa and GRIHA, enhancing operational life, safety & overloading capacities of Transformer.

Nikhil Pathak of Transfix India Pvt Ltd (CAHORS) Discusses Transformer Business Trends with EPR Magazine

What kind of transformation are you observing as far as the Indian power distribution industry (segment) is concerned?

Today, India is a centre of economic growth in the world, standing as the 5th largest economy & targeting the 3rd largest economy by 2027, wherein almost all sectors like infrastructure (highways, airports, & railways), a variety of industries, hospitals, IT parks, data centres, malls, educational institutes, residential & commercial projects, etc. are raising power demands, including small-scale industries too, wherein the market itself is increasing the potential requirement every year. Recorded Power demands in 2022–23 was 215.88 GW, & power generated around 207.23 GW, with a shortfall of around 8.65 GW (Ref. CEA Report 2022-23). The trend may continue for Power demands & generation in the coming years, & Govt is planning to meet 100 per cent power demands within 2047.  To meet increased power demands, the highest contribution is from wind & solar renewable power generation plants at a consistent, increased rate pace. Looking at increasing maximum demands in India, the renewable wind segment has transformed with a single wind turbine generation (WTG) capacity from 300 KW to 5.2 MW in the last 20 years, which is further projected to develop beyond 6 MW in the next 5 years in India.

During this transformative Renewable Wind Journey in India, we have developed & supplied 5 different transformers, i.e.

• 950 KVA 33/0.400 KV Hermetically Sealed AL wound WTG TRF suitable for 800 KW WTG
• 3 MVA 33/0.69 kV WTG Hermetically Sealed AL wound WTG for 2.7 MW WTG
• 3 MVA 33/0.69 kV WTG Non-Sealed AL wound WTG suitable for 2.7 MW WTG
• 3.6 MVA 33/0.95 kV Non-Sealed AL wound WTG TRF suitable for 3.3 MW WTG
• 3.6 MVA 33/0.95 kV Non-Sealed CU wound WTG TRF rated for 3.3 MW WTG
•  5.6 MVA 33/0.950 KV under development suitable for 5.2 MW WTG

With this, our contribution reaches a significant contribution of 1.26 GW in the wind sector in India. All these TRFOs are technically type-tested and qualified in NABL Labs and have been operating successfully for the last 7 years. Additionally, we are also supplying various ratings in the renewable solar industry, ranging from 1.25 MVA to 5 MVA, contributing to an installed capacity of around 83 MW. With this, we are moving towards completing an installed capacity of 1.35 GW by the end of 2024.

Other than capacity enhancement at Generation end, second Transformation has happened, i.e., Energy Efficient Distribution Transformers and their successful implementation by “The Bureau of Indian Standards and Distribution Transformer OEMs” together. As we all know, “the loss of power saved, is as good as generated” has worked to boost the overall power distribution efficiency in India on a large scale in the last 6-7 years. We have type-tested almost +60 different ratings in Energy Efficiency Levels 1 and 2 in line with IS 1180: Part 1: 2021: Amendment 4. Buyers should always ask for valid test reports and BIS certification in distinguishing categories of Energy Level 1 and 2 of each specific rating, which are differentiated in voltage classes of 11 KV, 22 KV, and 33 KV. Said corrugated, sealed, and conservator-type non-sealed transformers are being supplied to various private projects in India and also to a few Govt and private utility networks in India.

The third and most important transformation is the environmentally friendly and Fire Safe approach, which has been brought about by Natural Ester fluids in India. This fluid is completely biodegradable and environmentally friendly. It has a Fire point of around 350°C, which can ensure the safety of the transformer in case it remains a source of Fire or a victim of fire. As these fluids are approved by FM Global and GRIHA, they enhance the operational life, safety, & overloading capacities of Transformer. For these KNAN type Transformers, IS 1180: Part 3: 2021 is in force up to 2500 KVA; however, its BIS certification process is yet to commence, but the loss compliance area is the same as for Mineral oil filled ONAN Transformers.

What is your contribution to enhancing the safety of the distribution systems (in-house + external)?

Safety is also a wide approach to look at. Safety can be addressed in terms of Design standards, Raw materials based manufacturing standards, operational control safeties, environmental safeties, social safeties, installation and commissioning safeties, etc. So, we are in a continuous process to manufacture Distribution Transformer solutions that are most durable, efficient, and safe using our highly experienced R and Dept for design safeties, QA and SCM for supplier qualification process and Raw Materials, French-based manufacturing facility with all International standard infrastructure, control relays with prescribed control schemes for operational safeties, i.e., uninhibited mineral oil, i.e. PCB-free content, as per IS 335 and IEC 60296 and/or Ester oil in line with IEC 62770 ensure social safety, installation and commissioning safeties w.r.t. flood situations (advise for High heights foundation), Compact substations for space constraint sites, old

Transformer replacement support with our Sealed transformers is also a project undertaken by us.

 What is your message to the Indian power distribution project managers?

Presently, all leading MEP Consultants in India are recommending corrugated fins based Sealed type of Transformers with Mineral and/or ester oil-filled Transformers, due to its distinguished advantages and low opex cost.

I would suggest all Distinguished Qualified project managers and leaders of industry have a well-planned, proactive project schedule, especially for CAPITAL Equipment’s on-time ordering, which will facilitate equal opportunities for all qualified OEMs to bid in terms of standard lead time as per the current occupancy level of suppliers. Additionally, technological upgrades should be adopted for long-term vision so that OEMs can demonstrate their innovation and value additions through their expertise. Instead of a cost-centric approach, overall life cycle costs should be considered to make quality-centric decisions, which will eventually facilitate healthy competition, enhance an industry’s standards, & ultimately ensure operational success in the long term.

Spokesperson: Nikhil Pathak, Marketing & Sales Head, Transformer Division, Transfix India Pvt Ltd (CAHORS)