International Copper Association India

Welcome to International Copper Association India

Distribution Transformers

Transformers are among the most efficient machines designed by mankind, primarily constructed using copper or aluminium. Due to copper's conductivity, which is nearly twice that of aluminium, it is often the preferred choice for transformer construction. The largest power transformers achieve efficiencies of up to 99.75%. However, distribution transformers, typically rated between 250 and 1,000 kVA, may lose about 1-2% of energy transferred as heat, while smaller transformers (50-100 kVA) can operate at efficiencies as low as 95%. Unfortunately, many distribution transformers in India, particularly those with lower ratings such as 25 kVA, 63 kVA, and 100 kVA (11kV/415V, 3-phase), utilise conventional materials and manufacturing methods, leading to significant energy losses and high failure rates.

The failure rate for these transformers is concerning, standing at around 16% in government State Electricity Boards (SEBs), far exceeding the international norm of 1-2%. Moreover, the lifespan of conventional transformers is typically only 6-8 years. This high failure rate exacerbates the already substantial Transmission and Distribution (T&D) losses in the power network.

Advantages of Copper in Distribution Transformers

Copper presents several advantages when used in distribution transformers, including:

  • Inherent Low Loss Material: Copper’s superior conductivity means less energy is lost as heat.
  • Simplified Installation: Copper requires no special skills during jointing and termination, minimising failures linked to defective joints.
  • Robust Performance: Copper outperforms aluminium in conductivity, thermal conductivity, and resistance to short circuits.
  • Availability and Cost: Copper is readily available and competitively priced, making it a practical choice for transformer manufacturers.

Transforming the Transformer

Distribution transformers are essential assets for any power distribution network. Their efficient operation leads to long-term benefits for Indian utilities. The high failure rate of distribution transformers—around 12-15% in state utilities—contrasts sharply with a global average of less than 1%. To tackle this issue, ICA India is advocating for active repair methods rather than reactive repairs. Active repair proactively reduces no-load and load losses, which can significantly improve transformer reliability and efficiency.

The benefits of active repair include:

  • Reduction of Technical Losses: Lower energy losses save on power procurement costs.
  • Enhanced Energy Efficiency: Aligns with the Bureau of Energy Efficiency’s (BEE) mandates.
  • Increased Reliability: Minimises downtime and extends transformer lifespan.
  • Improved Capacity: Enables transformers to handle greater kVA loads.
  • Stakeholder Opportunities: Provides avenues for original equipment manufacturers (OEMs) and repairers to engage in ongoing operations and maintenance (O&M).

Transformer Market Scenario

The Indian transformer market was approximately 282,000 MVA in 2016-17 and is expected to grow by around 5% annually, driven by efforts to provide universal access to reliable electricity. ICA India collaborates with the Bureau of Indian Standards (BIS) and the Central Electricity Authority (CEA) to conduct seminars and workshops aimed at enhancing regulatory compliance regarding distribution transformer certification.

Key Objectives of the Program

  • Stakeholder Engagement: Bring together all power distribution stakeholders to address certification issues.
  • Education on Standards: Inform stakeholders about the latest quality control orders and certification requirements.
  • Interactive Discussions: Facilitate dialogue between stakeholders and BIS officials about the certification process.

What We Do

The International Copper Association India (ICA India) is dedicated to improving distribution transformer performance by promoting the use of copper windings in place of aluminium. This shift can reduce no-load losses by up to 75% and load losses by 40%. We engage in standardisation efforts and create awareness about the adoption of new BIS Standards and BEE Energy Efficiency Labels (Star Rating) to ensure the effective implementation of energy-efficient distribution transformers in India.

Resources