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Procedia Engineering 202 (2017) 109–120

4th International Colloquium "Transformer Research and Asset Management”

4th International Colloquium "Transformer Research and Asset Management”
Voltage Regulating Distribution Transformers as new Grid Asset
Voltage Regulating Distribution Transformers as new Grid Asset
Manuel Sojer*
Manuel Sojer*
Maschinenfabrik Reinhausen GmbH, Falkensteinstrasse 8, 93059 Regensburg, Germany
Maschinenfabrik Reinhausen GmbH, Falkensteinstrasse 8, 93059 Regensburg, Germany

Abstract
Abstract
Since 2012 voltage regulation distribution transformers (VRDT), that is distribution transformers equipped with on-load tap-
changers,
Since 2012 have become
voltage a new grid
regulation asset in frequent
distribution use. While
transformers initially
(VRDT), started
that is as a means
distribution to facilitate
transformers the economic
equipped integration
with on-load tap-
of renewable
changers, haveenergies
becomeinto public
a new gridpower grids,
asset in it hasuse.
frequent become
Whileapparent
initiallythat thereasisa ameans
started multitude of use cases
to facilitate for VRDTs
the economic beyond
integration
of renewableintegration
renewables energies into
and public
that thepower grids, is
technology it has becometoapparent
not limited that there
public grids is aalso
but can multitude of use cases
find applications in for VRDTsgrids
industrial beyond
and
become partintegration
renewables of generation
and units. The
that the primary driver
technology behind to
is not limited these newgrids
public foundbutfields of application
can also for distribution
find applications transformers
in industrial grids and
with
becomeon-load tap-changers
part of generation is a new
units. Thegeneration of such
primary driver tap-changers
behind these new which
foundis fields
much of more compact for
application anddistribution
much moretransformers
economical
with traditional
than on-load tap-changers is a new generation of such tap-changers which is much more compact and much more economical
tap-changers.
than traditional tap-changers.
© 2017 The Authors. Published by Elsevier Ltd.
© 2017 The Authors. Published by Elsevier Ltd.
© 2017 The Authors.
Peer-review
Peer-review under Published by
under responsibility
responsibility of Elsevier
of the Ltd. committee
the organizing
organizing committee of
of ICTRAM
ICTRAM 2017.2017.
Peer-review under responsibility of the organizing committee of ICTRAM 2017.
Keywords: Voltage Regulating Distribution Transformer; On-Load Tap-Changer
Keywords: Voltage Regulating Distribution Transformer; On-Load Tap-Changer

1. Introduction
1. Introduction
Since 2012 voltage regulating distribution transformers (VRDT), that is distribution transformers equipped with
Sincetap-changers,
on-load 2012 voltagehaveregulating
become distribution transformers
a central means (VRDT),
for innovative that
grid is distribution
planning [1, 2]. Astransformers
a grid assetequipped with
they facilitate
on-load
the tap-changers,
economic haveof
integration become a central
renewable meansinto
energies for innovative gridgrids,
public power planning
but[1, 2]. find
also As a use
grid beyond
asset they facilitate
renewables
the economic
integration andintegration of renewable
are not limited energies
to public grids only,into public
but can alsopower grids, but in
find application also find use
industrial beyond
grids renewables
and become part
integration
of generationand are not limited to public grids only, but can also find application in industrial grids and become part
units.
of generation
This paper units.
will introduce the technological concepts and principles that make a distribution transformer a VRDT,
linkThis papertowill
VRDTs introducetechnology
established the technological concepts and
in high-voltage principles
grids, that make
explain how VRDTs a distribution
interact withtransformer
the powera grids
VRDT, in
link VRDTs
which to established
they have technology
been deployed and inestablish
high-voltage grids,control
the basic explainstrategies
how VRDTs interact
applied with the power
in VRDTs. Based grids
on thein
which they have been deployed and establish the basic control strategies applied in VRDTs. Based on the

* Corresponding author. Tel.: +49-941-4090-2430; fax: +49-941-4090-902430

E-mail address: m.sojer@reinhausen.com
* Corresponding author. Tel.: +49-941-4090-2430; fax: +49-941-4090-902430
E-mail address: m.sojer@reinhausen.com
1877-7058 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the organizing
Published committee
by Elsevier Ltd. of ICTRAM 2017.
Peer-review under responsibility of the organizing committee of ICTRAM 2017.

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the organizing committee of ICTRAM 2017.
10.1016/j.proeng.2017.09.698
110 Manuel Sojer / Procedia Engineering 202 (2017) 109–120
2 Manuel Sojer / Procedia Engineering 00 (2017) 000–000

foundations different use cases where VRDTs can be helpful will be explained – from public grids, to industrial
ones, to dispersed generation units.

2. VRDTs as Grid Asset

Since their first launch as products available in commercial grade – as opposed to prototypes – in 2012, VRDTs
have become an established grid asset for many operators of public and industrial distribution grids. This is
obviously due to the benefits they realize in the distribution of electrical energy but also because they follow
established principles that have been proven as reliable and stable in power engineering for nearly one hundred
years.

2.1. Trusted Technology Transferred into the Distribution Grid

Since nearly a century power transformers in high voltage grids have been equipped with on-load tap-changers to
dynamically adjust the voltage of such transformers. The underlying technology had originally been industrialized
by Maschinenfabrik Reinhausen and relies on changing the number of active windings of a transformer with an
electro-mechanical system.
Figure 1 shows how this proven concept can generally be applied to the distribution grid through a VRDT. A
secondary substation, e.g., connecting the 20 kV grid with the 400 V grid, is equipped with a special distribution
transformer that comes with an actuator such as an on-load tap-changer that allows changing the voltage of the
transformer dynamically under load [1].

Fig. 1. Layout of the System VRDT.

The market offers different technological concepts for such actuators. Advanced solutions allow an actuator to be
installed without having to change the dimensions of the transformer. This is the only way to ensure that a VRDT
can be used in all existing secondary substations. Particularly with regard to the large installed base of compact
stations, this requirement is a central point for almost all distribution network operators. In addition, an actuator
lifespan that corresponds to that of the transformer with no or only minimum maintenance is usually a primary,
economically based requirement [1]. This requirement is frequently hard to fulfill for concepts based on power
electronics. Moreover, advantageous VRDT concepts facilitate a large regulation bandwidth in that they can
 Manuel Sojer / Procedia Engineering 202 (2017) 109–120 111
Manuel Sojer / Procedia Engineering 00 (2017) 000–000 3

significantly alter the voltage of the transformer while at the same time allowing for fine-grained regulation steps in
order to avoid network effects such as flicker.
In order for the actuator to facilitate the voltage changes required to stabilize the grid some intelligence needs to
determine when which actions are appropriate. This is the role of the voltage regulator which relies on algorithms to
determine the right reactions given the current state of the grid. To assess the latter it relies on sensors which in the
most simple setup measure values on the low voltage bus bar of the secondary substation. In more complex setups
there can also be sensors deployed deeper in the low voltage grid, e.g., at the end of the most critical feeders. For
most situations classical bus bar control is sufficient. In case of remote sensors being deployed they can
communicate with the controller via GSM or Broadband Power Line [1].
The challenge in transferring the idea of transformers with on-load tap-changers from the high voltage to the
medium voltage context lies in meeting the requirements of this new context with regards to economics, dimensions
and weight, and maintenance requirements. Only a few years ago first concepts that matched these demands have
become available. Meanwhile they have proven their value to the operators of public and industrial distribution grids
with the total population of VRDTs estimated at 1.500 units.
In comparison to other conceivable solutions for voltage control in the distribution grid such as distributed energy
storage or inverters providing reactive power, VRDTs seem advantageous since the technology they are based on
has proven itself over many decades in the high voltage grids. Moreover, they seem highly economical since they
facilitate a high degree of compatibility with existing network infrastructures and the processes of network
operators. When a network operator selects an appropriate technical concept there is basically no difference between
the operation of a conventional distribution transformer or a VRDT. Figure 2 shows a photograph of a VRDT which
on the outside is hard to distinguish from a regular distribution transformer.

Fig. 2. Voltage Regulation Distribution Transformer.

In summary, key components of a VRDT are a conventional distribution transformer, an OLTC, a voltage
regulator and sensors. As voltage measurement devices, the sensors can be placed either directly at the substation
busbar or remote in the feeders, depending on the cases of application and local network conditions.
112 Manuel Sojer / Procedia Engineering 202 (2017) 109–120
4 Manuel Sojer / Procedia Engineering 00 (2017) 000–000

2.2. Grid-side effects of a VRDT

Since typically there are no voltage regulation devices in public distribution grids downward of the primary
substation, the available voltage band of typically 20 % has to be distributed amongst all effects that may lead to
voltage increases or decreases until the final connection point [3, 4]. Figure 3 shows an example of such an
allocation. Due to voltage regulation facilities in the primary substation the voltage at this point in the grid can be
assumed to be quite stable independent of the actual load of feed-in. The further down in the grid, however, the
larger the spread between the voltage in maximum feed-in and maximum load case. Of particular importance to the
VRDT case is that with conventional distribution transformers the voltage on the high voltage side and the voltage
on the low voltage side of the transformer are interlinked. A high voltage on the high voltage side will lead to a high
voltage on the low voltage side and vice versa. The same is true for low voltages.

Fig. 3. Voltage Band in Accordance with EN 50160.

By applying a VRDT, however, it is possible to decouple medium and low voltage levels in order to make use of
the complete voltage band of ± 10 % in both voltage levels [9]. This effect can be seen in Figure 4.

Fig.4. Voltage Band in Accordance with EN 50160 with a VRDT.

The VRDT decouples the voltage of the medium voltage grid from that of the low voltage grid in such a way that
the complete voltage band of ±10 % is available in both voltage levels. This is realized by its functionality to “reset”
the voltage in the secondary substation, i.e., no matter what the voltage of the medium voltage grid, the voltage
regulated distribution transformer can ensure that the voltage of the low voltage grid is set to a predefined reference
 Manuel Sojer / Procedia Engineering 202 (2017) 109–120 113
Manuel Sojer / Procedia Engineering 00 (2017) 000–000 5

value [3, 4]. If the voltage of the medium voltage grid is relatively “too high” it can be regulated down. If it is
relatively “too low” it can be regulated up.

2.3. General control strategies

For VRDTs implemented with on-load tap-changers the transmission ratio of the transformer and thus the voltage
can be changed stepwise whenever the voltage regulator detects a secondary voltage that deviates from a pre-defined
set-point. Normally, a VRDT can control the voltage within a range of +/-10 % of the nominal voltage. This range
will be divided into a fixed number of steps of the on-load tap-changer. Typically there are 9 steps which enable
changes of the voltage by 2,5 % with each step. In most cases there are two threshold levels at which a switching
trigger signal is given. First, if the secondary voltage exceeds a determined threshold value, the regulation
bandwidth, for a specific period of time a switching command will be triggered. Second, another voltage threshold,
the high-speed threshold, can be parameterized for fast switching. If the voltage changes by a higher value than the
first level and reaches the second value before the time delay is reached, a switching operation is triggered as well.
In any case the initialization of these delays cannot fall below a minimum value in order to avoid unintended
permanent switching at fast voltage fluctuations or voltage dips. Otherwise a stable and passive operation under grid
disturbances could be threatened [5]. Figure 5 illustrates a typical algorithm to control the switching operations of a
VRDT with on-load tap-changer.

Fig.5. Typical VRDT Control Scheme.

In addition to the switching thresholds discussed such algorithms in many cases contain a further threshold which
serves the purpose of blocking further switching operations of the VRDT once the threshold has been violated. The
rationale of this third level is to make sure that in case of heavy network faults such as voltage collapses the VRDT
does not add further stress in the network by striving to reach a local voltage optimum.

3. Use Cases of VRDTs

Initially VRDTs were developed to support the economic integration of renewable energies into public grids by
helping to avoid or at least reduce conventional measures of grid reinforcement such as reconductoring. Meanwhile,
however, the range of applications for replacing conventional distribution transformers with VRDTs has become
very broad reaching far beyond public grids. VRDTs still allow public distribution network operators to run their
grids with increased efficiency, not only by reducing the need for grid reinforcement, but also by facilitating the
operation of distribution grids with a reduced number of assets. Moreover, in industrial grids VRDTs provide a high
level of voltage stability and thus ensure the reliable operation of industrial processes. Finally, VRDTs allow for the
114 Manuel Sojer / Procedia Engineering 202 (2017) 109–120
6 Manuel Sojer / Procedia Engineering 00 (2017) 000–000

design of more economic power generation units such as windmills for which they facilitate an optimal system
design taking into account various system components such as converters.

3.1. Economically Integrating Renewable Energy and new Forms of Demand into Public Grids

Distribution grid operators face a difficult balancing act: On the one hand, they need to ensure a stable supply
voltage in the medium and low voltage grid and on the other hand, they need to integrate a growing amount of
renewable energy (increase in voltage) and in the future also new types of demand such as electric vehicles
(decrease in voltage) [4].
In accordance with EN 50160, distribution grid operators are generally required to maintain a supply voltage of
± 10 % around the nominal voltage at all points in the grid. As a result, the available bandwidth of 20 %, starting
from the primary substation transformer regulated by the on-load tap-changer, needs to be distributed over the entire
distance of the medium voltage grid, the conventional distribution transformer, and the low voltage grid to the final
connection points. It is not unusual for maximum voltage rises to be limited in such situations. In the low voltage
grid this often is defined as 3 %, due to renewable energy, and in the medium voltage grid as 2 % [1]. The rest of the
bandwidth is reserved for voltage drops and adjustment inaccuracies.
The huge growth in feed-in from renewable energy means that the permitted voltage band (in accordance with
EN 50160) is more and more often at risk of being violated. Likewise, new types of demand are jeopardizing
compliance with the voltage band in the other direction. As a result, distribution grid operators are being forced into
expensive grid reinforcement measures such as reconductoring, even though the thermal capacities of their
equipment in the grid are far from being fully exploited [4].
A VRDT solves the crux of the problem – compliance with the voltage band – by dynamically adapting the
voltage. Thanks to the resulting decoupling of the low- and medium voltage levels, the voltage band available in
accordance with EN 50160 can be re-distributed and therefore used more effectively [1]. Currently, this principle is
primarily used to connect renewable energy; however, it can also be used to integrate additional demand into the
existing grid.
Because this can increase the grid's ability to absorb power by a typical factor of 2 to 4, the other alternative of
expensive grid reinforcement can often be completely avoided or at least put on hold. In consequence, the VRDT
can be used to make greater and therefore more economic use of grid equipment. The actual additional capacity for
renewable energies a VRDT can facilitate in a distribution grid always depends on the specific characteristics of the
grid [6]. In the following the additional capacity is calculated for two exemplary grids.
The first example shown in Figure 6 is a rural grid with a low population density. The secondary substation of the
grid is equipped with a 400 kVA distribution transformer. The grid consists of five feeders with a length of 400 m
and seven connection points each. Four feeders are cables (NAYY-4x150), one is an overhead feeder (70-AL1/11-
ST1A9). In addition to that feeder one is a pure load feeder. The other four feeders are equipped with PV feed-in
which differs between installations in every second household in the first feeder and only one installation in the
middle or at the end of the other feeders. Without use of a VRDT 278 kWp of PV can be integrated with different
potentials for each feeder. The limiting factor for each feeder is the maximum voltage rise of 3 % in the feeders. In
consequence the utilization of the feeders ranges between 12 and 50 %. With the use of a VRDT the PV capacity
increases by a factor of 1.9 for feeder number two and by a factor 2 for feeder number three. For feeders number
four and five the use of a voltage regulated distribution transformer offers the possibility to integrate 3.6 times and
3.7 times more PV, respectively. Depending on the position of the PV installations in the feeder a VRDT can
increase the potential for integration of PV by a factor of at least 2 to even 4.
 Manuel Sojer / Procedia Engineering 202 (2017) 109–120 115
Manuel Sojer / Procedia Engineering 00 (2017) 000–000 7

Fig. 6. Effectiveness of VRDT - Example 1.

Figure 7 also shows a rural grid. But in this example a 1,200 m long extension in the load-only feeder is added
for a consumer like an agricultural business with a load of 14.5 kW in the simulation. With a voltage drop of 7 % the
voltage spread is further raised so that only 1 % instead of the usual 3 % can be used for local feed in. In this
configuration the integration of PV installations is limited to 98 kWp and the different line loads are between 5 %
and 17 % without using a voltage regulated distribution transformer. The use of a VRDT enhances the integration
potential in this extreme situation by a factor between 5.7 and 8.
116 Manuel Sojer / Procedia Engineering 202 (2017) 109–120
8 Manuel Sojer / Procedia Engineering 00 (2017) 000–000

Fig. 7. Effectiveness of VRDT - Example 2.

As well as avoiding infringements of the voltage band in low voltage grids, VRDTs can also be used extensively
and intelligently in the medium voltage grid to make the integration of feed-in and demand more economical [3, 4].

3.2. Optimizing Grid Topologies by Reducing Secondary Substations

An efficient distribution grid has as little equipment as possible. This enables savings of both investment as well
as operating expenses. VRDTs help to improve the efficiency of grid sections. Using them can reduce the total
number of secondary substations. The number of secondary substations needed for a grid area is determined firstly
by the maximum demand to be covered and/or the maximum feed-in to be transported and secondly by the
maximum possible distance between the secondary substation and grid connection points from a voltage standpoint.
VRDTs dynamically adapt the voltage and permit a larger electrical supply radius around each secondary substation.
 Manuel Sojer / Procedia Engineering 202 (2017) 109–120 117
Manuel Sojer / Procedia Engineering 00 (2017) 000–000 9

In this way, even consumers or feed-ins, which are at a great distance from the secondary substation can be
connected as illustrated in Figure 8.
This allows the distribution network operator to combine two secondary substations or spares it from having to
build a new secondary substation. If a supply job can be handled by one secondary substation alone, savings can be
made in rent payments, station maintenance, and investments in replacement or new parts. The only requirement is
that the one transformer is configured such that its performance is sufficient for the load and/or feed-in of the
enlarged grid area.

Fig. 8. Grid Topology Optimization with VRDT.

As an real case example from Germany, assume a street village with around 1,500 inhabitants which was
previously supplied by 12 secondary substations, seven of which were located in the residential part of the village.
Four of these seven secondary substations were more than 40 years old and were due for imminent modernization.
By equipping two of the seven secondary substations with VRDTs, the electric supply radiuses of these secondary
substations could be increased such that the village is now supplied by five rather than seven secondary substations
and quality isn't impaired. This has halved the modernization costs the distribution network operator has had to
incur. Moreover, land could also be returned to its owners. There are now two fewer secondary substations to
maintain.

3.3. Stabilizing Industrial Processes in Volatile Grids

For industrial processes to run stably and reliably, they require a stable voltage supply within a narrowly defined
band. In grids with limited generator power, long distances or volatile consumers and producers, the supplying
medium voltage may be subjected to large fluctuations in voltage. As a result, production cycles may be interrupted,
motors may not start or control systems may crash. This can cause serious damage, especially in sensitive industrial
processes. Hospitals are particularly critical in this respect. In addition to direct impacts on processes, frequent
changes in voltage may also have a negative impact on the life of equipment.
A VRDT in the industrial distribution grid ensures that loads have a stable supply of voltage regardless of the
volatility of the medium voltage as exemplified in Figure 9. VRDTs with a large regulating range which are able to
reliably regulate even large fluctuations in the medium voltage for many years without any maintenance are well
suited to this application. Compact dimensions help to keep costs down because the VRDT can then be installed in
place of the non-regulated one.
118 Manuel Sojer / Procedia Engineering 202 (2017) 109–120
10 Manuel Sojer / Procedia Engineering 00 (2017) 000–000

Fig. 9. Stabilizing Industrial Processes with VRDT.

A VRDT in the industrial distribution grid ensures that consumers have a stable supply of voltage regardless of
the volatility of the medium voltage.

3.4. Complying with Grid Codes Economically

For integration into the grid, dispersed generation units based on renewable energies must meet the respective
requirements of the grid operator in the form of grid codes. The provision of reactive power is particularly critical
[5]. Especially when underexcited, the ability of the generation plants to provide reactive power is limited in the
event of undervoltage. In consequence grid codes can often only be met either by oversizing the inverters or by
requiring the generation plant to operate such that it reduces the amount of active power fed into the grid to suit the
situation [7].
VRDTs can avoid oversizing the inverters or reducing the amount of active power fed to the grid and thus
ultimately make the generation plant more cost-effective [5]. Due to their ability of keeping the low voltage on an
almost constant level the provision of reactive power does not necessarily lead to restriction in inverter capacity
anymore. As an example a Q-V-Profile of a typical wind energy converter is shown in Figure 10.

Fig. 10. Example of a Q-V-Profile for Wind Inverter with and without VRDT.
 Manuel Sojer / Procedia Engineering 202 (2017) 109–120 119
Manuel Sojer / Procedia Engineering 00 (2017) 000–000 11

In particular in terms of underexcited operation (lagging) the capacity shrinks significantly with voltages close to
the thresholds of 90 % and 110 % of nominal voltage. Therefore, an operating voltage close to nominal voltage is
desired when technical modifications with respect to oversizing of components like inverter shall be avoided. For
instance, the transformer accounts for approximately 3 to 4 % of the total costs of a wind turbine whereas the share
of the inverter accounts for ca. 6 to 7 % [5]. Since the costs for a VRDT are only slightly higher compared to
conventional transformers it is worth investing in the modification of the transformer instead of in more expensive
power electronics.
Additionally, in the past it happened that because of the decreased reactive power potential some expensive
reactive power compensation had to be installed in the plants in order to meet the requirements of the code. In this
context, the VRDT can also be a very cost-efficient alternative. As a matter of fact, MV/HV power transformers of
the entire plant (in case of HV connection) have the ability to change their tapping as well. However, this function is
performed normally too slow as every iterative switching step needs about 30 seconds. This time is not sufficient if
the voltage changes occur more rapidly and the wind power plant has to provide a specific amount of reactive power
based on the system operator’s request. The set-points of reactive power, according to the Q-V or cosφ-P
characteristic of the BDEW medium voltage guideline, must be reached within 10 seconds [8]. VRDTs however can
change the tapping within ca. 3 seconds if desired. Lacking capability because of abnormal operation voltages can
be balanced then, and the full capability of the wind turbine in terms of reactive power provision can be used.

4. Summary and conclusion

Initially, VRDTs had been developed as a solution to facilitate economic integration of renewables into
distribution grids. By decoupling the voltage of the medium voltage grid from that of the low voltage grid they
create additional headroom for voltage rises caused by renewables’ feed-in in both low and medium voltage grids.
With a four-digits-figure of units deployed in less than five years already, this functionality has found relevant
acceptance quickly – largely based on the availability of new tap-changers that meet the physical and economical
requirements of the distribution grid.
While using VRDTs, operators of public as well as industrial distribution networks, interestingly, have recently
also identified additional use cases that reach beyond renewables integration. For public distribution network
operators, deploying VRDTs to reduce the number of secondary substations required in their grids by increasing
their electrical supply radii is becoming an interesting application to save on operating as well capital expenditures in
their girds. Industrial operators of distribution transformers leverage VRDTs’ capabilities to change the voltage on
the low voltage side independently of the voltage on the high voltage side. In this way, they manage to stabilize their
industrial processes, despite potentially high voltage volatility in the higher voltage levels. Finally, the manufacturers
of dispersed generation units, that have to ensure that their systems meet various grid code requirements, find
VRDTs helpful in achieving compliance in more economical ways. For example, this can be achieved by optimizing
the reactive power capabilities of their inverter based systems by supplying them with a more stable voltage
optimized by a VRDT.
In summary, while they have only been on the market since 2012, VRDTs have already found use in a wide range
of applications and it seems likely that as more and more operators become familiar with the technology the scope in
which this technology is useful will continue to increase.

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