Worlds Highest Voltage Class Transformer, 1200 kV, 333 MVA Single Phase Autotransfor mer developed successfully

by Vijai Electricals Ltd. Hyderabad with Indigenous Tec hnology.

1200 kV (UHV) AC syst em is being envisaged as next transmission volt age to country. Ultra high voltage (UHV) trans mission schemes are driven by the need to transfer large amounts of electrical power from the generation res ources to far away major load centres. India is one of the most notable examples where in future, several UHV systems at 1200 kV AC shall be needed to transfer large quantum of power Orissa from to various generation in complexes & in Chhattisgar h, regions. meet the long term power transfer requirement in the

Jharkhand,

load

centres

Northern

Western

Presently, 800 kV is the highest trans mission voltage, introduc ed in 2007 with commissioning of first 800 kV line from Sipat (Chhattisgarh) to Seoni (Madhya Prades h).Several 800 kV trans mission corridors are now under construction.In next 5-6 years, 1200 kV AC system , is expected to emerge as main

transmission level along with 800 kV HVD C, integrated with National Grid at 800kV AC and 400kV AC s upported by 500 kV HVDC Network. When 800 kV system was introduced, Indian Transformer Industry did not have sufficient time to develop 800 kV Transformers and Shunt reactors needed in large numbers and therefore country had to import these equipment from Korea, Sweden, Japan, China etc.

1200 kV system is not existing in any part of the World. In late eighties, USSR constructed an 1150 kV line which hardly operated for about 2 years. After disintegration of USSR, the line was operated at 500 kV. In recent time only China has commissioned an 1100 kV line with three substaionc in 2009. In fact, Tec hnology for 1200 kV is yet to be developed. In view of lead time of 5-6 years available ( before commercialization takes place ), POW ERGRID took a

lead to establish a 1200 kV UHV AC Test Station at Bina with experiment al line (1.6 km) to provide a platform to Indian Manufacturers to develop their 1200 kV equipment and obtain first hand experienc e of field testing, trial operation etc. and build A grid for tomorrow.

POWERGRIDs mega initiative in this regard is highly commendable. About 35 Indian Manufacturesrs have signed MoU with POWERGRID to develop

indigenously their various 1200 kV equipment and install them at Bina and obt ain operating experienc e to cons olidate/perfect the 1200 kV Tec hnology. Vijai Electricals was one of the firsts to sign anMoU for development of a 333 MVA 1200 kV Autotransformer. Vijai Electricals created single a history when its magnum opus, with 333 MVA,

1150/400/ 33kV,

phase

Autotransfor mer,

developed

in-hous e

technology, know-how and expertise, passed Routine and Type tests in presenc e of POW ERGRID representatives during 13th to 18th June 2011.

Vijai electrical Ltd, an established leader in Distribution Transformers, made a foray into Power transfor mers in the year 2007- 08 and in just 4 years of operation developed the entire range of Power transfor mers from 66 kV to 132,220,400 and now 1200 kV class.

Vijai Electricals is the only manufacturer in the country to produce entire range of transfor mers from tiniest 5 kVA 11 kV to largest 333300 kVA 1200 kV. Technical Specification Major Technical Specification of 333 MVA Transformer for the 1200 kV Test St ation is as follows Rated Power Voltage Ratio Rated frequency Connection (3 ph.) % Impedance 333/333/ 111 MVA, Single Phase 1150/3/400/3/ 33 kV 50 Hz Ynaod11 HV-IV HV-LV IV-LV Cooling type Cooling equipment Temp. rise BIL - LI 18% 40% 20%

ODAF or OFAF 4 x 33.3% Unit OFAF Coolers 45C :Winding, 40C : T op oil HV 2250 kVp, IV 1300 kVp , LV 325 kVp Neutral 95 kVp

BIL - SI BIL - PD Design Challenges

HV 1800 kVp, IV 1050 kVp 1.5 pu (1.0 pu = 1200/3 kV)

UHV transformers are essentially large rating transformers both in terms of

voltage and current. Trans port limitations pos e the biggest challenge. Problems related to dielectric design of UHV Transfor mers are to be addressed meeting the dimensi onal limitations for the transport. Bec aus e of high current

magnitudes, the problems related to dynamic stability under effects of short circuit currents, hot spot generation etc. get magnified and are to be taken care of adequately. And, above all, Reliability is a key word for suc h transformers. The above design challenges have been adequately addressed by a team of VijaiEngineers.The maximum available trans port dimensions were decided based on extensive route survey and discussions with leading transporters.

Sophisticated software were used to calculate precisely the voltage distribution in the winding under Lightning and Switching Impulse Voltage test conditions. Extensive field plots were done to ensur e maximum stress distribution for a Partial-discharge free performance.

State-of-the-Art software was used to ens ure short-circuit withstand capability under the action of large magnitudes of Axial and Radial forces.br>

Electromagnetic field plots were done to study and control stray field and resultant hot-spots. Manufact uring Challenges The weights of this massive transformer are as follows. CORE & CLAMPS CORE & COIL ASSEMBLY TANK & FIT TINGS OIL TOT AL MASS 125t 160t 74t 77t 311t

To handle these weights and dimensions of the coils, new manufacturing facilities were added eg. Tandem beam to handle 275 tonnes lifting weight, Vertical winding machine and mandr el,40tonnes coil lifting arrangement,500 tonnes coil clamping press ure plates etc.Testing fac ilities wer e also augmented in terms of 30 MVAr capacitor bank and 2m dia Corona Shield etc.

Some of the components like 1200 kV Lead Exit, ODAF coolers, Epoxy bonded (Low-chip) continually transposed cables etc were imported. Testing an d Performance All routine,type and special tests(except short-circuit test which is not possible anywhere in the W orld ) as per & 3 Indian were and International at Ultra high

Electrotec hnicalstandard,IEC 60076-1, 2 Voltage laboratory of Vijai

conducted at

electrical

Hyderabad.

Lightning Impulse test for HV winding was done at 1950 kVp,Switching impulse at 1800 kVp and partial discharge at 1039 kV(1. 5 p.u.)

Temperatur e rise test was conducted to establish steady state temperature rises. The Special tests include Noise level,Harmonic analysis of No-load

current,SwiftFrequenc y Res ponse Analysis,Dissolved Gas analysis etc. Measured perf ormance of a few paramet ers is as under MVA VOLT AGE RATING LOSSES (HV- IV) HV/IV/LV HV/IV/LV NO-LOAD LOAD % IMPEDANCE (333MVA BASE) HV-IV IV-LV HV-LV COOLING TEMPERAT URE RISE ODAF OIL WIDNING NOISE LEVEL 333/333/ 111 1150/3/400/3/ 33 141.32 kW 640.68 kW 17.48% 22.35% 42.51% (4 33% ODAF COOLERS) 29C 44C 77dBA

With the successful development of this prestigious transfor mer, Vijai has

Products indigenously

proved that India has capability to develop sophisticated High

tec hnology