Efficiency Improvements in Transformers by Adoption of New Magnetic Material

Since independence in India there has always been shortage of electricity and at no point of time we have been able to meet the peak demand. The gap between the demand and generation can be bridged/ minimized by either improving the installed capacity or reducing the consumer demand. The gap between availability & demand is of order 6% as on date. If we take into account the issues like environment pollution and global warming, the preferred option is to increase the energy efficiency or minimize the consumer demand, as in the other alternative particularly in India where thermal generation dominates increased environmental pollution is inevitable[1]. The paper covers design of transformer using a new technology superior magnetic material with thin sheets of lazer grade or amorphous core. Iron Boron Silicon amorphous alloy is a unique alloy whose structure of metal atoms occurs in random patters as opposed to conventional CRGO steel which has an organized crystalline structure. The paper covers design of distribution transformer using conventional material and the new technology improved core materials. The reflection on the no-load and load losses due to change in the material have been worked out. Commercial and technical feasibility for adoption of new technology core material has been detailed out and the payback period is quite attractive. By reducing the regular occurred power loss in the transformer, economy of the power sector and global environmental impact can be improved.[8] The paper also covers the working of quantum of electrical power that can be saved if adopted in the state of M.P. The reduced Electrical Power generation requirements due to lower losses have also been translated to reduction in the CO2 emissions polluting the environment. Keywords-Core, Copper, Tank, Steel Radiator, Transformer Oil, Power Factor, Losses, Load Factor, Insulation Material. ,CRGO, Lazer Grade, Amorphous core I. DEFINITION OF THE PROBLEM The demand for electricity in India is enormous and is growing steadily. This growth has been slower than country’s economic growth. To balance this demand and supply of electricity, it is the time to go for improvement in energy efficiency electrical equipment in use by the utilities and also by the consumers. Ways to improve energy efficiency of one of the electrical equipment used by utilities has been discussed in coming pages. The power plant generates electricity at low voltage rating and the generated power has to be transmitted through long transmission line at extra high voltage i.e. 440, 220 & 132 KV to reduce the line losses and conductor size . This extra high voltage power is then stepped down to the desired voltage which is then used in the industrial, commercial, transportation & domestic sectors. The voltage in the entire system can only be step up & down by using transformers of different capacity. The power passes through the transformers involving transformer losses i.e. no-load and load losses. These transformer losses impose heavy financial losses and impact the environment globally. By reducing these losses in the transformer, economy of the power sector and global environmental impact can be improved. [2] Thus our objective is to design the energy efficient transformer which reduces the total transformer loss by 60%. II. ENERGY EFFICIENT TRANSFORMERS No – load loss resulted from the magnetization of core laminations, depends upon the following parameters of core: 1) Thickness varies from 0.23 to 3.0 mm 2) Quality CRGO , HI-B Grade, Lazer Grade, Amorphous 3) Flux density 4) Specific gravity of core Reduction in No-load losses can be achieved by 1) Using better quality core 2) Sharpening the edges of the core at with appropriate angle 3) Building Single strip core building for reduced the air gap. 4) Annealing the core so as to i. Reduce mechanical stress in the lamination to a minimum to yield optimum magnetic proprieties ii. Prevent contamination of the steel with oxygen and or carbon iii. Retain or enhance the insulation quality of the lamination coating. International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013) 795 Iron Boron Silicon amorphous alloy is a unique alloy whose structure of metal atoms occurs in random patters as opposed to conventional CRGO steel which has an organized crystalline structure. The higher resistance to magnetization and demagnetization through the crystalline structure leads to higher core losses in CRGO. Load loss of transformer depends on the load on the transformer. [6] 1) Load Current (I) 2) Resistance of the Wire and strips used to construct the coils. 3) Gap between Cores Coil with tank. Reduction in load losses can be achieved by 1 Using higher size of the conductor. 2 Reducing size of core 3 Reducing Winding Temperature. 4 Improving conductor resistivity. 5 Annealing of Wires & Strips for better performance and life of the transformer as it • Improve the machine-ability • Obtain grain size and produce uniformity. • Increase activity of metal • Modify and improve electric & magnetic properties. • Release internal stresses • Help to produce a definite micro structure III. DESIGN OF ENERGY EFFICIENT TRANSFORMERS