Transformer insights

A journey through the fascinating world of Siemens Transformers

Focus topic: Transformers in urban areas

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Powerhouses The transformer The energy

in the neigh­ is at the start superhighways
borhood of it all of the future
Transformers in cities: Transformers in power High-voltage direct-current
eco-friendly and with added generation transmission
value

Table of Masterful
performance at
Up close to the
consumer
Reliable
electricity for the
contents network hubs
Transformers in electricity
transmission
Transformers in power
distribution
digital revolution
Siemens continues its
long-standing history of trend-
setting transformer solutions

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Transformers in cities: eco-friendly and

with added value

Power-
houses in
the neigh-
borhood
In terms of the power grid, trans-
formers from Siemens are true pillars
in the storm. They perform reliably
throughout the world – safely,
decade after decade, and practically
unnoticed by the general public.
Their hidden qualities are impressive.
And upon closer inspection, it’s quick-
ly apparent that modern transform-
ers from Siemens are loaded with re-
markable technology. They are much
more than just voltage transformers.

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Despite all their differences, what do London,

Shanghai, and Moscow have in common? Ex­
treme population density, outrageous land prices,
and huge power requirements – with an upward
trend. They pose a real challenge for local power
companies, who do their best to transmit power
to consumers at high voltage levels in order to
keep transmission losses as low as possible. But
how far can they go when the goal is to deliver
electricity – this essential elixir of the modern
world – as efficiently as possible to the vibrant
centers of metropolitan areas? And how does this
affect the population?
The new generation of transformers: ideally
suited for big city centers
Using extremely compact and exceptionally quiet
transformers from Siemens with alternative, envi­
ronmentally friendly insulating materials, it is
now possible to erect a transformer substation in
the heart of a major metropolis. In many cities,
gone are the days of the large transformer build­
ing occupying lots of prime real estate in the
middle of the city and serving – other than its
main purpose – only as a space for advertising
posters. New substations in urban environments
are often hidden from public view and have auxil­
iary uses.
One example is found directly on Seven Sisters
Road in the London Borough of Islington, not far
from Finsbury Park and the Emirates Stadium.
To reliably continue meeting the city’s growing
Highbury Station in
London contains three
ester-filled Siemens
power transformers.
Their heat recovery sys­
tem supplies nearby
houses and a school with
eco-friendly heat.
power requirements, the British transmission sys­ to residential buildings and even in nature con­
tem operator National Grid built a new transform­ servation areas.
er substation right in the middle of the densely The new generation of transformers: ideally
populated Highbury district. This is no longer a suited for big city centers
risky endeavor when Siemens transformers are
filled with alternative insulating fluids. But that’s not all. The Siemens transformers in
Highbury have yet another surprise up their
The new Highbury Station deploys three 400/132- sleeves: They also contribute to a sustainable
kV, 240-MVA transformers with synthetic ester as reduction in carbon emissions. While the trans­
insulating fluid. This fluid is a “very special kind of formers are operating, a heat recovery system
juice.” Compared to conventional, mineral-based captures the waste heat and uses it to supply
transformer fluids, it offers considerable advan­ environmentally friendly heat to the nearby
tages: The liquid is extremely fire-resistant and Montem Primary School as well as to several resi­
completely biodegradable, meaning that the dential buildings.
transformers can be operated in direct proximity

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Advantages of ester-filled power transformers

Higher fire safety Lifetime extension

• Higher flash and fire point • Slower polymerization
• Fire point above 300°C • High capability to absorb water
from cellulose
• K-class rating (IEC 61100 / 61039)
• Dielectric strength unaffected by
• Lower gas conversion factor
water
• Tank rupture prevention
• Higher temperature limits

Smaller footprint Cost savings

• Eliminate rocks, grating, and sup- • Lower annual insurance premiums
port steel
• Lower losses during operation due
• Change containment size to shorter bus duct length
• Shorter bus duct length

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Highest performance with minimum
space requirements
Similar to London’s Highbury Station, the Hong­
yang substation in the Chinese megacity of
Shanghai is centrally located. This is a city where
buildable land is at a premium – which is why the
local power company SGCC decided to put its
new substation completely underground. Here,
six 500-kV single-phase autotransformers from
Siemens with a total capacity of 3,000 MVA are
doing their job. Although they’re the highest-ca­
pacity underground transformers of their type in
the world, they’re also remarkably compact: only
nine meters long, less than seven meters wide,
and just over seven meters tall – ideal for trans­
port and setup in tight spaces such as an under­
ground substation. The three transformers meet
the highest requirements in terms of insulation
and magnetic leakage and can have a short-cir­
cuit impedance of up to 22%. This ensures ex­
treme operating safety, as does the water-cooling
Learn more about the
functionality, setup, and
operation of power-
transformers in our
online training sessions.
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system that was specially developed by Siemens
for these transformers and which guarantees reli­
able cooling even when air circulation is low.
Safe operation and remarkable performance
Change of scene: Moscow on the Moskva River,
only about 400 meters from the Kremlin. The
mayor of Moscow, Sergey Sobyanin, inaugurated
the new Bersenevskaya substation in 2016. For
this project as well, the fire and environmental
protection requirements were remarkably high.
And once again, Siemens provided the solution in
the form of transformers insulated with synthetic
ester. For the new substation, Siemens custom-
built a total of four transformers with a total ca­
pacity of 400 MVA for voltages from six to 110 kV.
The transformers can even be regulated in the
high- and medium-voltage range under load. For
the provider – the United Energy Company – this
means that the substation operates reliably and
flexibly at all times. The transformers in the
Bersenevskaya substation are an exciting example
More information:
Challenges Why alternative?
iPDF:
Alternative
fluids
The energy Masterful
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of the future network hubs
Alternative
Transformer Fluids
Energy Management - Transformers
www.siemens.com/transformers/ester
Product classes Benefits – Technical | Safety | Financial References
The Challenge
Safety, reliability and environmental
impact are crucial for transformers,
especially in large cities. Occupied
premises must be safe from the risk of
fire or explosion from installed
electrical assets, supply disruption
must be avoided though high network
reliability and environmental
considerations are a high priority.
Space constraints also constitute a
critical factor in cities.
British grid operator, National Grid,
requested a high-performance solution
for their 400kV substation in North
London, to combine safety and
National Grid
National Grid is an international
electricity and gas company based in
the UK and northeastern US. The
company plays a vital role in
connecting millions of people safely,
reliably and efficiently to the energy
they use.
National Grid works with all their
stakeholders to promote the
development and implementation of
sustainable, innovative and
affordable energy solutions.
Case study:
Highbury
substation
Power transformer with
waste heat utilization
Economical and safe operation thanks to
ester-isolation
reliability with a heat exchanging
device, to utilize heat loss from
transformers to heat schools and other
buildings in the neighbourhood. The
project is the first of its kind in the UK
using synthetic ester-filled
transformers at 400KV.
The Solution
Siemens has a successful track record
in the use of alternative insulation
fluids for power transformers. The
company’s expertise in this area, based
on their own research and material
tests, combined with excellent
customer relationships made Siemens
the clear partner of choice for this
innovative project.
Together with the customer, National
Grid, Siemens has developed an
economic solution that allows waste
heat from three power transformers to
heat a school located next to the
substation. Depending upon the
electrical energy used in this area,
more than 1MW of waste heat from
the transformers can be recovered to
heat local homes, shops and schools in
the future.
Up close to the
consumer
Ester and heat recovery
of “Ingenuity for life” in practice: innovative engi­
neering that makes our lives a little bit better
each day and provides true added value.
On the following pages, we invite you to an inter­
esting and exciting journey through the power
grids of the world. Experience what Siemens
transformers can do and learn about what makes
them unique.
siemens.com/transformers
„With this transformer project The challenge
Siemens have set a new Shanghai is the China’s biggest city
benchmark for innovation and and a global financial hub. With a
environmental safety. “ population of around 23 million, space
becomes very limited.
Stefan Pieper, Head of the transformer
plant Weiz
Power supply utilities are therefore
faced with the challenge of producing
large high-capacity transformers in
limited space. The Shanghai Hongyang
project presented many of these
exciting challenges to which Siemens
Transformers readily rose.
The customer, State Grid Corporation
of China planned to install a 500-kV
underground substation. This required
two banks of three single-phase auto-
transformers with a total capacity of
3,000 MVA – including some
extremely demanding requirements in
dielectric and heating dissipation.
The task for the Siemens Transformers
plant in Jinan was to deliver an auto
transformer which was specifically
designed and built for underground
use. The space limitation set fixed
conditions from the very beginning –
Power transformer with ester insulation and from the bidding stage and throughout
heat exchanging device in the test field. the entire production process.
Case study:
Shanghai
Underground unit for a
megacity
Shanghai operates high-capacity single-phase
auto transformers
Moreover, the specification set very
high standards for the quality of the
units as well as their ability to
withstand severe conditions,
controlling the hot spot and excessive
losses.
The solution
To meet the high customer demands,
an exceptional transformer design was
created, which included an optimized
insulation design, magnetic leakage
and loss control – a challenging task. A
particularly targeted cooling mode,
equipped with an advanced water
cooling system, was introduced to
ensure safe operation of such a high
capacity transformer.
A series of Lean production workshops
were organized with the aim of
increasing the efficiency as well as
ensuring the highest quality for the
project at all times. Considering the
lead connection for example, an
interdisciplinary Business Excellence
workshop specifically re-organized the
production process to reduce lead
connection times and man-hours by
approximately 50 percent each. Even
more importantly: just as planned,
quality assurance was maximized.
siemens.com/transformers
The mission was accomplished in April
2016 when the six brand new
500MVA/500kV single phase auto
transformer units successfully passed
the tests.
This project is a true example of
ingenuity as despite challenging
circumstances Siemens Transformers
designed an underground transformer
for their customer which is set to
become the highest capacity single-
phase auto transformer of 500kV
worldwide.
“Siemens offers a “slimmed
down” power transmission
solution for Shanghai, this
golden megacity, with the
satisfactory capacity.”
Jiang Jinhua, SGCC Shanghai
Research Institute
Web article:
London
Reliable
electricity for the
digital revolution
Transformers to heat
a London school
The transformer factory in Weiz, Austria, will ship environmentally friendly,
400-kilovolt ester transformers with a waste heat utilization system to London
siemens.com/energy/transformers
In February 2014, a British distribution grid operator
commissioned the Siemens transformer factory in
Weiz and the British regional company »Siemens
Transmission and Distribution Ltd.« to deliver, assem-
ble, and commission three autotransformers.
Due to the location of the new transformer substation
to be built in the British metropolis’ densely populated
downtown area, the entire installation will be completely
encapsulated. A special feature of the components from
Weiz is that the 240-MVA, 400/132-kV transformers
will be filled with ester for both cooling and insulation
purposes – an environmentally friendly alternative to
conventional mineral oil. Ester can be produced from
vegetable oils such as soy, sunflower, or rapeseed oil as
well as by the esterification of alcohol and acids. The
benefits of this environmentally friendly solution are that
the insulating fluid is fully biodegradable, and the residual
risk of an explosion or a fire in the event of a malfunction
is dramatically reduced.
Practical use of waste heat
In conventional cooling systems for transformers, all
thermal losses that arise during idling and operation are
discharged into the environment unused. In the current
project, the waste heat is to be used by a heat recovery
system in order to supply environmentally friendly energy
Siemens AG
Energy Sector
Power Transmission Division
Transformers
Erwin Rauch
Erwin.Rauch@siemens.com
Schematic of the project: The substation building where the trans-
formers will be installed is shown in the middle of the illustration.
The school that will be supplied with waste heat by the heat recovery
system to be delivered is shown at the upper left edge of the image
to an elementary school building adjacent to the trans-
former substation.
The Weiz plant began implementing the project imme-
diately after the contract was awarded in February 2014.
The transformers are scheduled for delivery in the
summer of 2015. Assembly and commissioning by the
customer are expected to take place in March 2016.
Publisher and copyright 2014:
Siemens AG
Energy Sector
Freyeslebenstrasse 1
91058 Erlangen, Germany
Answers for energy.
Web article:
Moscow
Eco-friendly transformers
for Moscow metropolitan area
Siemens Transformers recently helped to increase the
safety, reliability, and eco-friendliness of Moscow’s energy
supply. The leading transformer supplier of alternative
insulation solutions delivered four units of ester-insulated
transformers, in total 400 MVA, from 6 up to 110 kV for
the new substation “Bersenevskaya” of United Energy
Company. This substation is located in the center of Mos-
cow, just 400 m from the Kremlin.
Commissioning a substation in the heart of a megacity
poses extra-strict requirements of the equipment and the
installation. The indoor transformers are equipped with
an extra fire and environmental protection together with
the option to regulate the high and medium voltage side
under load.
As a result of the requirements, the customer opted for Midel-insulated 160 MVA-transformer for Moscow in the testbay at
Midel as an insulation fluid rather than traditional mineral the transformer plant in Voronezh.
oil. Since Siemens Transformers has been manufacturing
transformers with ester insulation for decades, its manu- “The project in Moscow demonstrates how Siemens Trans-
facturing network enables knowledge transfer between formers partners with energy providers all over the world
plants. The order was placed at the transformer plant in to increase grid resilience,” says Dr. Beatrix Natter, Head of
Voronezh, Russia: an excellent example of how Siemens Siemens Transformers. “Our commitment to this global
Transformers is combining its global setup with local goal is reflected in our portfolio with the Pretact® concept
presence. that includes a comprehensive set of services and features
to prevent assets from operational failures, protect them
The importance of this project for the residents of
from harm, and provides a chance to react in case of un-
Moscow was expressed by the personal inauguration of
foreseen events.”
the substation by the mayor, Sergej Sobjanin, acknowl-
edging the commitment of the authorities of Moscow to
the shift towards sustainable power.
Siemens AG
Energy Management Division
Transformers
Katzwanger Strasse 150
90461 Nuremberg, Germany Publisher and Copyright 2016:
Siemens AG
Contact Energy Management Division
Anna Laukhina Freyeslebenstrasse 1
Anna.Laukhina@siemens.com 91058 Erlangen, Germany
siemens.com/transformers
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Transformer insights 01 | 2017
A high level of specialization and a clear
focus on quality, along with internation­
al know-how and innovation leadership
Hidden champions
in a clearly delineated market segment
– that’s what sets typical “hidden cham­
pions” apart. They’re specialists who are
of the power grid largely unknown to the public but
whose actions are highly innovative,
extremely customer-oriented, and tre­
mendously successful. Generally, they’re
of prime importance for the overall con­
text of a system.
Spectacularly unspectacular
In the power system, Siemens trans­
formers act as hidden champions, char­
acterized by quality and innovation in
countless power grids around the world:
Decade after decade, they reliably ren­
der their services, usually unnoticed by
the general public; they are extremely
powerful and strictly focused on cus­
tomer requirements.
Siemens transformers can be found at
every node in the power flow: from the
power plant to the various substations
and all the way to the factory, vehicle,
residential building, and infrastructure
facility.
Well-prepared for new challenges
The increasing complexity of grids and
the growing demands placed on our
power supply infrastructures create
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countless new challenges for power
transmission and distribution. Thanks to
future-oriented technology, efficient
transformers from Siemens ensure that
electricity arrives reliably and safely at
every location where it is needed – to­
day and in the future. These transform­
ers are known especially for their addi­
tional, innovative features that offer
significant added value, such as their
use of alternative, eco-friendly insulat­
ing fluids, their use of waste heat for
heating purposes, and their extremely
low noise levels during operation. All of
this makes Siemens transformers a clas­
sic example of “Ingenuity for life.” And a
contemporary design concept makes
quality leadership in electrical and
mechanical design visible.
More information:
Power transformers
Machine and network transformers
from 30 to over 1,300 MVA
siemens.com/transformers
Brochure:
Power transformers
Machine and network
transformers from 30
to over 1,300 MVA
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Transformers in power generation

The transformer
is at the start of
it all
Regardless of whether power is generated by
conventional means or from renewable energy
sources: Before it even begins its journey from
the generator to the consumer, it flows through
a transformer that increases the comparatively
low generator output voltage to the level required
for efficient transmission.

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Electricity is a highly versatile, clean, and ex­

tremely efficient energy carrier. With electricity,
energy can be made available almost anywhere in
the world at a reasonable cost. Another increas­
ingly important benefit of electricity: Converting
wind and solar power into electricity makes it
immediately usable.
Getting renewable energy to where it’s needed
But for electricity to arrive at the location where it
is needed, it must first be fed into the supply net­
work. This is where transformers come into play.
For central power generation in large power sta­
tions, “step-up transformers” are used – large
power transformers that convert the generated
electricity to the requisite voltage level for power
transmission on high-voltage lines.
Transformers enable grid connection
of renewables
Distributed power generation from renewable
energy sources is becoming increasingly impor­ by adding unwanted DC to the grid. Such distur­
tant in modern energy systems. Electricity is gen­ bances can be effectively managed by special
erated by numerous smaller units, such as photo­ transformers and variable shunt reactors.
voltaic cells or wind turbines. Transformers are
then required to feed this electricity into the sup­
More information:
ply network. On offshore platforms that collect
electricity from several wind turbines, for in­
stance, transformers increase the voltage to the
level required for subsea cable transmission from
Transformers with DC
Compensation
Elimination of DC Effects

siemens.com/transformers

the platform to the point of grid infeed on the The challenge

Nobody wants noisy transformers,
especially not in urban surroundings.
When ordering, many utilities and grid
operators are therefore especially
conscious of noises produced by the
units in subsequent operation. But
what happens when a quiet
transformer in the system manifests
higher noise levels? Or if a transformer
that has already been installed for
The solution
Experts at Siemens Transformers have
long studied the topic of "DC in the
supply grid and its effects on
transformers". There are three
different conventional strategies for
circumventing this problem, but none
of them is perfect:
 Transformer replacement – does
not solve the problem

mainland.
years suddenly becomes so loud that  Installation of external noise
neighbors feel disturbed? protection walls – highly expensive
/ not always possible

Silence is easy
The DC component in the grid is
growing with the increasing electric  Implementation of DC blockers – View inside the DCC­cabinet
power generation from wind and solar ineffective for asymmetric loading
energy sources. But only a few
The approach developed by Siemens is
hundred milliampers can already result
in a significant increase in noise level. not based on eliminating the DC load,
but rather on eliminating its effects on

Ready for DC in the grid

with Siemens DC Compensation
Austrian trans­regional grid operator
APG was confronted with such a
situation. Investigations of the cause
were conducted following the first
complaints from neighbors. It led to
the transformer. Since the DC current
is not blocked, no other transformers
in the grid are subjected to DC loads.
Siemens solutions for DC

and DC ready transformers
siemens.com/transformers
proving that the units had not simply
become louder overnight without
cause: A DC load had resulted in the
otherwise perfectly functioning
transformers becoming a source of
noise pollution.
compensation for single­phase and
three­phase units with three­leg cores
were already available. With a few
adaptations, a satisfactory solution
was also achieved for the 5­leg core
transformers implemented at APG.

Managing the downsides of renewables

Direct current compensation
Renewable energy sources have many advantag­
es, but they can also negatively affect power Brochure: Case study:
Ready for DC in the grid with Transformers
grid stability due to their intermittent nature or Siemens DC Compensation with DC
and DC ready transformers compensation

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Variable shunt
reactors: the key to
efficient and flexible
grid operation
Such fundamental changes as those currently tak­
ing place in the power supply infrastructure have
not been seen since the introduction of compre­
hensive electrification: The number of distributed
power generation units, often based on renew­
able energy, is increasing at an amazing rate. At
the same time, large conventional power plants
are being retired, which also means retiring
sources of reactive power generation.
Reactive power compensation is becoming
a must
Due to their nature, however, wind power and
photovoltaic plants do not provide reactive power Siemens has developed an entirely new solution
and their output is highly intermittent, depending to meet this challenge: the variable shunt reactor
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neighborhood it all
on the time of the day and weather conditions.
Furthermore, in some regions, the existing over­
head lines are being replaced by underground
cables, which require a higher degree of reactive
power compensation. The combined effect of
these factors necessitates additional, highly flexi­
ble reactive power compensation, which helps
equalize load fluctuations in the grid and at the
same time improve a grid’s black-start capabili­
ties.
The variable shunt reactor: a new solution to
the problem
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The challenge
The German energy turnaround is
underway, posing challenges to the
transmission grid operators. The need
for additional reactive power
compensation equipment is increasing,
as conventional power plants are shut
down and TSOs are forced to partially
switch from OHL to HV cables. In
addition equipment needs to become
more flexible because the feed in from
renewable energies (mainly wind and
photovoltaics) is volatile, leading to
seasonal and daily load variations in
the grid.
Amprion and Siemens have jointly
developed an innovative economical
solution, covering not only the current
challenges but also future grid
development. Therefore, in addition to
the latest compensation demand
forecast, they also considered the
interaction with existing MSCDN
equipment and slowly increasing
compensation demand during black
starts.
One pager:
Variable shunt reactor
with 80 percent regula-
tion range
with an extended regulation range. Siemens im­
plemented the world’s first prototype for the Ger­
man transmission system operator Amprion: a
large variable shunt reactor with an extremely
wide regulation range of 80 percent at 400 kV.
Thanks to a tap changer with 33 tappings, it can
cover a rating from 50 to 250 MVAr for a 400-kV
three-phase unit.
Cost-saving and ready for the future
The benefits of the variable shunt reactor are
clear: Flexibility for future network changes, im­
proved blackstart capabilities, and reliable opera­
tion, as the reliability of tap changers has been
combined with the proven design of shunt reac­
tors. Another benefit is that variable shunt reac­
tors can be coordinated with existing capacitor
banks to provide comprehensive reactive power
control. This makes transmission grid operation
much more efficient and stable. On top of that,
the utilization of costly SVC equipment is opti­
mized, as it can be used to the full for dynamic
grid stabilization, which is its original purpose.
Variable Shunt Reactor
with 80 percent
regulation range
Flexible and economic step into the future
siemens.com/transformers
The solution
Siemens Transformers is a trusted
partner to Amprion and developed a
completely new solution in close
cooperation with the customer and
Maschinenfabrik Reinhausen: A large
variable shunt reactor (VSR) with a
Economical
regulation range of 80 percent. It is
equipped with a tap changer with 33
tappings to cover a rating from 50 up
to 250 MVAr at a voltage level of 400
and stable grid
Variable shunt reactor in the test bay.
kV (3­phase­units).
The main challenges for Siemens were
the general layout of the winding
operation
arrangement, the lead concept to the
tap changer, and the huge shunt
reactor dimensions. It weighs 367 t
and has the dimensions of a large Amprion GmbH
Shunt and series reactors for
power transformer
Amprion GmbH operates a
Up to now, two units have been
medium- and high-voltage grids
transmission grid at 380 and 220 kV
successfully manufactured and tested. of approximately 11.000 km with
The first unit was commissioned in about 160 substations. Its main
2016. More units are in Siemens’ order target is to deliver energy at market­
backlog for 2018 and 2019. friendly prices at any time.
siemens.com/transformers
Brochure:
Shunt and series reactors
for medium- and high-volt-
age grids
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Transformer insights 01 | 2017

Transformers
directly in the tower
For years, distribution transformers from Siemens have represented a
high level of safety in operation as well as excellent electrical, mechan­
ical, and thermal properties. That’s why these transformers are also
ideal for use in wind farms. For this type of application, Siemens pro­
duces both GEAFOL cast-resin transformers and FITformer REN-type,
ester-filled distribution transformers. The latest development is the
FITformer REN model that enables transmission at the 66kV level for
even more efficiency and highest proven reliability.
Installed up high to keep costs low
The extremely compact transformers fit directly into the nacelle, where
they convert the power produced by the generator to the voltage re­
quired for the wind farm’s internal grid. Installation in the nacelle re­
duces material and enables the highly efficient connection of the wind
More information:
turbine to the power grid, making power generation from renewable
energy sources even more eco-friendly and economical.
To enable the transformers to withstand the strong vibrations in the Twice the voltage, lower
losses and smaller size

nacelle, Siemens developed a mechanically reinforced version specifi­

First order for 66kV FITformer REN

siemens.com/transformers

The challenge The solution

cally for wind turbines.

While wind turbines were producing
0.5 MW of power at a height of 40
meters in 1990, today’s turbines
produce 7 MW and more. However, the
voltage level output stayed at 33 kV for
quite a long time.
A new offshore wind park in Denmark
is one of the first to be equipped with
7 MW turbines and to be connected to
To operate on a new voltage level, a
brand new transformer type fitting all
new requirements had to be
developed, designed and
manufactured. The new generation of
wind transformer FITformer REN is a
liquid-filled 8.2 MVA transformer for a
grid-voltage level of 66 kV. Unlike their
predecessors, these transformers are
not installed at the bottom of the

Convincing technology
a 66 kV grid voltage of instead of 33
turbines, but inside the nacelle.
kV. With the new capacity levels (the
new SWT-7.0-154 provides 10% more Space being very limited in a turbine, CAD-drawing of the new FITformer REN for wind

creates compact
output than its predecessor), the the new transformers are very compact applications at 7MW.
efficiency of wind power generation is and lightweight, while at the same
also increasing. This is why the new time highly efficient, according to the

performance
generation of wind turbines has a
voltage output of 66 kV, which allows
reduced losses and higher efficiency in
wind turbine operation.
The GEAFOL Neo:
One of the key components in this
the optimum foundation for progress is a new generation of wind
power distribution transformers delivered in 2017.
Eco design directive, and a high
temperature design, according to IEC
60076-14. Moreover, their design has
been optimized to cope with the
hostile conditions of offshore
applications and to keep maintenance
demand as low as possible.

siemens.com/transformers

Brochure: One pager:

The GEAFOL Neo: the First order for 66-kV
optimum foundation FITformer REN
for power distribution

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Transformer insights 01 | 2017

Giants
on the move
Transporting a power transformer from the
Siemens factory to its deployment location is a
logistical tour de force that takes place on a reg­
ular basis. For example, the two transformers
that were produced at the Nuremberg trans­
former factory for the “Fortuna” combined-cycle
power plant block in Düsseldorf’s Lausward dis­
trict heating power station weighed in at 207
tons each. Most of the approximately 700-kilo­
meter-long journey for these behemoths –
measuring 11 meters in length and five meters
in height – was by water. Every meter, from
start to finish, required extreme finesse and
precision work on the part of the specialists
involved.
Experience the journey of these two Siemens
transformers first-hand!

Watch the
video documentation
(in German only)

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Affordable
grid infeed
of offshore
wind power
Large AC transformer platforms are a major cost
factor of offshore wind farms. They collect the
electricity generated by the individual turbines in
the wind farm and convert it for transmission to
the mainland. Construction, transport, installa­
tion, operation, and maintenance of such plat­
forms account for a large portion of the total grid
access costs.
Bringing down grid connection costs by more
than a third
The cost of connecting near-shore wind farms
to the AC grid can be reduced by up to 40 percent
with the new offshore transformer module
(OTM®) from Siemens. An OTM is about a third
of the weight and size of a conventional AC
substation. This means that it can be installed on
the same foundation as a wind turbine – without
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Cost savings of
up to 40 percent
Eco-friendly thanks
to ester insulation
the use of a heavy-lift crane and in much less
time. OTMs are also low-maintenance, making
them less expensive to operate.
Environmental benefits included
The new solution also benefits the environment:
The transformers are filled with flame-retardant,
biodegradable ester insulating fluids, and no
mineral oil is used.
Reliable low-maintenance operation proven in
practice
The first project to use OTMs for grid connection
is the Beatrice wind farm in the Moray Firth
off the north coast of Scotland. All three of the
310-MVA transformers for the 220-kV level are
designed to withstand harsh operating conditions
on the high seas – for example, with a special
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Low-maintenance
fluid
coating – and require a minimum of mainte­
nance. Cooling is especially important: The OTM
is cooled solely by natural convection, without
fans or other moving parts, which significantly
reduces its vulnerability to failure.
More information:
Alternative
Transformer Fluids
Energy Management - Transformers
www.siemens.com/transformers/ester
Challenges Why alternative? Product classes Benefits – Technical | Safety | Financial References
The challenge
In 2016, Siemens got the order to
supply wind turbines and the grid
connection for the Beatrice offshore
project. The wind power plant should
have a total capacity of 588 MW. 7-MW
turbines will be installed.
To be able to transmit the energy
produced (sufficient to supply 400,000
UK households) a heavy-duty offshore
solution is needed. However, to reduce
platform size and cost, and to conserve
the environment, a special transformer
solution is needed.
Beatrice Offshore Windfarm Ltd.
is a partnership formed between SSE
(40 percent), Copenhagen
Infrastructure Partners (35 percent)
and SDIC Power (25 percent). The
project will be one of the largest
private investments ever made in
Scottish infrastructure.
iPDF: One pager:
Alternative Transformers for the off-
fluids shore transformer module
(OTM®) made by Siemens
Reliable
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High performance
at a compact size
Transformers for the offshore transformer
module (OTM®) made by Siemens
siemens.com/transformers
The solution
For the Beatrice wind farm, Siemens
offered, among other products, two
units of its modular OTM concept, that
saves space, weight, and cost.
“Our OTM-transformer
adds to the profitability of
renewable power
generation by reducing
The technical specifications for the footprint and cost.”
three transformer units were to deliver Dr. Beatrix Natter, CEO Siemens
310 MVA units for the 220-kV level in Transformers
heavy-duty design with ONAN (oil-
natural/air-natural) cooling. To
withstand the harsh environmental
conditions, an offshore design and an
earthing transformer were mandatory.
Synthetic ester was chosen as an
insulation fluid to mitigate the impact
of potential pollution on the sea in the
unlikely case of oil spillage.
In close collaboration between the
customer and different Siemens units a
cutting-edge offshore transformer
module was designed. It contains an
ultra-compact offshore transformer
with a built-in earthing transformer
and extremely low maintenance
demand.
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Transformer insights 01 | 2017
Safe and efficient power
flow with phase-shifting
transformers
Modern, meshed grids frequently have several
lines running between two substations, often
even at different voltage levels. The power flow
in such networks usually adapts naturally accord­
ing to the ratio of impedances. Under specific
grid conditions, this can cause an overload of one
line while considerable capacity is still available
in other parallel connections.
Better control of the power flow
A phase shifter can be used to regulate the cur­
rent load, thus inhibiting unplanned power flows
and at the same time improving grid efficiency
and stability by preventing loop flows and line
outages due to overload.
In 2017, Siemens delivered two such phase shift­
ers in the United States. A local power company
in California needed to optimize the power flow
to its 230-kV grid. The goal was to prevent
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unplanned power flows across the border to
Mexico in the event of an overload.
Technology that lives up to the
highest standards
To achieve this, the power company decided to
use two phase shifters from Siemens. The re­
quirements for the devices were especially high:
Network and system regulations in the two coun­
tries required an unusually large asymmetrical
phase angle from –80 to +31.3 degrees, and
placed high demands on controllability and cool­
ing. The transformers also had to conform to the
IEEE 693 standard regarding seismic safety
because California is a region with a high inci­
dence of earthquakes. This was assured by a
finite-element mathematical model was specially
developed that permitted the requisite seismic
analyses of the phase shifters.
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More information:
World’s first phase-shifting
transformer with ester
insulation liquid
Siemens introduces the next level
of eco-friendly transformer technol-
ogy, in this way underpinning its
status as the most innovative sup-
plier of power transformers.
Phase shifters are special transformers
that enable cost-effective load flow
management and grid asset optimiza-
tion in complex grids. With generation
dispatch and transmission grid load
becoming increasingly volatile, the
demand for phase shifters continues
to grow, as circuit overloads need to
be reduced without compromising grid
stability and flexibility.
The need for safe and reliable grid
operation is especially high in densely
populated metropolitan areas for the
overall stability of the grid. However,
transformers that are to be installed in
such areas need to be extremely quiet
and have to meet particularly high
requirements in terms of reliability and
eco-friendliness to protect the envi-
Standard phase-shifting transformer
Use case:
World’s first phase-
shifting transformer
with ester insulation
liquid
ronment in the unlikely case of a
failure.
No surprise, then, that Siemens, the
supplier with most references world-
wide in terms of alternative insulation
liquids for power transformers, has
now received the order for the world’s
first phase shifter that is filled with
ester oil instead of mineral oil. The
organic-based, nontoxic insulating
liquid is biodegradable with an ex-
tremely high flash point.
This enables the cost-efficient installa-
tion of the phase shifter in the direct
vicinity of residential and commercial
buildings.
The 138/138-kV phase shifter now
being manufactured by Siemens will
be installed in a metropolitan area on
the East Coast of the US to help the
local utility control the power flow
and rapidly adjust to changes in the
power demand in the system. The
60 Hz 300-MVA unit will feature a
±20-degrees phase angle and will have
two active parts in one tank. The
entire design ensures a high overload
rating for safe and reliable operation,
and a maximum noise level of only
73 dB(A), which is only a little more
than the noise level of a standard
dishwasher, enables operation in
residential neighborhoods.
The phase-shifting transformer will
be delivered to the US in the fall, and
can be installed in record time thanks
to its innovative plug-in bushings – a
Reliable
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result of Siemens’ modular transform-
er concept called Pretact®. This unique
concept comprises numerous features
that help customers save considerable
time and money during the installa-
tion and operation of Siemens trans-
formers, among them motor-operated
valves to shut off the radiator banks in
case of an emergency, flexi-compo-
nents in the mechanical installation,
and plug-in wiring connections. These
advantages will also tremendously
increase health and safety standards.
The new, eco-friendly phase shifter
that boasts all advantages of the
Pretact® concept emphasizes Siemens’
expertise and experience in designing
and building outstandingly efficient
and reliable transformers. “One of our
core aims is to provide versatile solu-
tions that help our customers mini-
mize their efforts in operating sustain-
able and eco-friendly solutions,” says
Christian Ettl, project manager at
Siemens.
Siemens AG
Energy Management Division
Freyeslebenstrasse 1
91058 Erlangen, Germany
Siemens AG
Energy Management Division
Transformers
Katzwanger Strasse 150
90461 Nuremberg, Germany
Contact:
Alfons Schrammel
alfons.schrammel@siemens.com
Christian Ettl
christian.ettl@siemens.com
siemens.com/transformers
Use case:
Phase-shifting
transformers for
California, USA
The challenge
Connecting grids across countries
always poses challenges for the
utilities on both sides. The power flow
needs to be controlled so that the
energy produced in one country can be
consumed there. However, in the
event of overproduction, the utility
needs to provide the option for
sending the excess power to the
neighboring country.
To transmit the power produced in
California (U.S.A.) to its own customers
instead of the neighbors in Mexico, the
local utility needed a viable solution –
which is either a B2B DC backbone or
phase­shifting transformers (PST).
Legal
information
Providing grid stability
and flexibility
Use case: Phase-shifting transformers
for California, U.S.A.
The solution
The local utility opted for two PSTs as
the go­to solution for optimizing the
grid. They control the power flow in
the transmission network on a 230kV
transmission in an optimal way that
allows them to push more power onto
their 500kV transmission lines instead
of having uncontrolled power trans­
mission. This is especially crucial for
the customer when one of the 500 kV
transmission lines is out of service.
Due to local grid requirements, the
phase shifters needed to provide an
extremely large and asymmetrical
phase angle. However, the physical
size still needed to be as compact as
possible for ease of transportation. The
customer also specified tank­mounted
ONAF cooling and no sound­damping
measures.
siemens.com/transformers
Technical features
1. Phase angle
Due to local grid requirements in both
countries, the phase shifters needed to
provide an extremely large
asymmetrical phase angle from ­80.1°
to 31.3°. This phase angle range
implied that the units would be
extremely large. However, for ease of
transportation and reduced footprint,
the customer asked for the most
compact dimensions possible.
Ultimately, the series and exciter
transformer shipping dimensions were
468.5 x 149.6 x 181.1 inches (11,9 x
3,8 x 4,6 m) and the shipped weight
was 582,000 lbs. (264 tons) and
623,900 lbs. (283 tons) respectively.
2. Two­tank design
Due to the large phase­angle
requirement, it was not possible to
design the phase shifter as a single­
tank unit. Therefore, the PSTs were
designed as a classical two­core/two­
tank unit.
Transformer insights 01 | 2017

High-voltage direct-current transmission

The energy
superhighways
of the future
The share of electricity in the energy mix that comes from
renewable sources is on the rise. This is also changing the
requirements placed on the power grids in many different
ways. One major challenge that must often be overcome
right where the electricity is generated is to bridge –
with low losses – the usually long distances between the
generation sites and the centers of consumption.
High-voltage direct-current transmission is the key
technology to solve this problem. Siemens is constantly
moving the development of this transmission technology
forward.

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Renewable energy sources are often generated
far from the large centers of consumption. One
example is offshore wind farms, which are espe­
cially powerful and efficient. However, the elec­
tricity they generate must first be transmitted
from the open sea to the coast and then on to the
centers of consumption – in Germany, for exam­
ple, from the far north to the south, with its
strong economy and great hunger for energy. The
existing AC grid is reaching the limits of its abili­
ties. The capacities are insufficient, and the pow­
er losses during transmission would not be eco­
nomically justifiable.
Great performance, low losses
That’s why high-voltage direct-current (HVDC)
technology is being used more and more. This
technology makes it possible to connect offshore
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wind farms to the onshore grid with minimal loss.
In addition, it allows electricity to be transmitted
to the load centers over long distances with low
losses. HVDC regularly helps reduce CO2 emis­
sions, since it is no longer necessary to generate
fossil-based power near the load centers. More
and more new transmission voltage records lead
to even greater efficiency.
Efficient, powerful, and maintainable transform­
ers are needed at multiple points in an HVDC sys­
tem. In particular, these are the converter trans­
formers that first transform the alternating
current into direct current and then back into
alternating current at the end of the transmission
link. Siemens is carrying out pioneering work in
this area, as HVDC technology is breaking new
ground in many respects.
Graphic from
“Pictures of the Future,”
the Siemens magazine for
research and innovation
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Record-breaking HVDC transformer technology
from Siemens
The HVDC transformer manufactured in the
Siemens transformer factory in Nuremberg,
Germany, is a particularly impressive example of
this pioneering work. It operates in the heart of
the HelWin1 offshore platform, which went into
service in 2015 – far out in the North Sea, approx­
imately 85 kilometers from the mainland. The
platform connects two offshore wind farms to
the mainland. It transforms up to 576 MW of
alternating current into direct current for this
purpose.
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Transformer insights 01 | 2017
Siemens is setting another record with its con­
verter transformers for the 1,100-kV HVDC link
being built between Changji and Guquan in
China – currently the world’s biggest and most
powerful HVDC project and expected to go into
operation in late 2018. The link is 3,284 kilome­
ters long and achieves the enormous transmis­
sion power of 12 gigawatts – equivalent to the
average output of 12 coal-fired power plant units. that are expected to create an integrated energy
World-leading technology, local added value
Trailblazing technological innovations, which are will establish a connection between the Belgian
used in the next generation of Siemens converter and British power grids. This will increase power
transformers, are what make this transmission
capacity possible. The converter transformers,
whose 587.1 MVA of power make them the most
powerful in the world, are manufactured in the
Siemens factory network, led by the Nuremberg
transformer factory. While the prototypes are
manufactured at the Siemens transformer plant
in Nuremberg, serial production takes place at the designed for a transmission voltage of 400 kV.
Siemens transformer plant in Guangzhou, China.
Several further units are assembled by local Chi­
nese transformer manufacturers that benefit
from the transfer of Siemens’ technology.
The same applies to another new converter trans­
former model, which can be connected directly to
the Chinese 1,050-kV three-phase grid.
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HVDC is bringing Europe’s grids closer together
HVDC technology is also making an increasingly
important contribution to the international ener­
gy trade and to stabilizing the power grids, which
are now subjected to very heavy loads in many
places. One current example is the 1,000-MW
“Nemo Link,” one of the common-interest proj­
ects established by the European Commission
market within the European Union. Nemo Link
supply reliability in both countries and promote
the inclusion of renewable energy sources, such
as offshore wind, into the European power infra­
structure. A total of eight converter transformers
with a nominal power output of 365 MVA each
will be supplied by the Siemens transformer fac­
tory in Nuremberg for this HVDC system, which is
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More information:
The challenge
Our customer National Grid
Interconnector Ltd. needed to ensure
that a failed HVDC transformer would
be able to continue playing its vital
role in providing a safe and reliable
electricity supply. The unit was
assessed by a third­party transformer
testing company that identified the
location of the fault allowing it to be
considered for repair.
Siemens TLM offered a repair to the
damaged unit that would reduce the
potential lack of transmission capacity
in the event of the outage of another
unit. The customer decided to repair
the transformer and mitigate the
possible risk of future failures. In
addition, the customer placed an order
for a new HVDC unit at the HVDC
transformer plant in Nuremberg.
National Grid
National Grid is an international
electricity company based in the U.K.
and the northeastern U.S. that plays a
vital role in connecting millions of
people safely, reliably, and efficiently
to energy. National Grid UK owns the
electricity transmission system in
England and Wales and operates an
HVDC substation in Sellindge.
Case study:
HVDC converter
transformer
repair
Reliable
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As good as new:
Siemens TLM success
HVDC converter transformer repair
The solution
Siemens UK and Siemens TLM in
Germany – well known for excellence
in building new transformer parts and
their repair experience in their
Nuremberg workshop – jointly
presented the customer with an ideal
solution for the task.
The unit was originally manufactured
by Bruce Peebles & Co. Ltd., a former
VA Tech company – just like the
Siemens transformer plant in Weiz.
After the failure was detected, a new,
state­of­the­art winding was
manufactured in Weiz and shipped to
Nuremberg.
The old insulating oil was drained and
all components of the active part were
checked for metal residue and other
damage. After the repair, the converter
was filled with new oil. Several cycles
of oil processing and filtration were
performed to make sure no metal
residue would create operational risks
for the repaired unit.
After successfully testing the repaired
unit, it was shipped to the U.K. for
installation and commissioning by the
local Siemens workforce.
First HVDC transformer with
1,050 kV AC grid connection
arrived in China
Reducing air pollution and CO2 emis-
sions is a top priority in China, where
siemens.com/transformers the “National Air Pollution Control
Action Plan” enforces solutions that
enable environmentally friendly power
transmission and power supply. A
highly ambitious 10 GW transmission
project for energy from renewable
sources from Inner Mongolia to the
province of Shandong is part of the
plan to significantly improve CO2
The dimensions of the unit are enormous, and
a weight of 360 t meant a logistical challenge
for everyone involved. The picture shows the
active part is being removed from the tank.
“We are pleased that it has
been successfully tested
and returned to Sellindge.
The unit will play an
important role in
supporting the HVDC
interconnector with
France.”
James Sheridan, Project Manager at
National Grid
siemens.com/transformers
Web article:
First HVDC
transformer
with 1,050 kV
AC grid connec-
tion arrived in
China
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The design challenges of today’s high
end technology requires the adaption
of facilities, machines, and processes.
The transformer is the largest of its
emissions and air quality. The Ximeng- kind with its enormous 3,200 mm
Taizhou project hereby relies on high- winding diameter and AC bushing
quality transformers from Siemens, length of almost 15 m.
the most innovative supplier of power
Siemens transformers are perfectly
transformers. To meet the demanding
suited to transfer 10 GW transmission
requirements of the project, an excep-
capacities over a distance of 1,620 km.
tionally large transformer had to be
With their reliability and efficiency
built. On February 3, the very first
they will maximize the energy trans-
1,050 kV high-voltage direct-current
mission from renewable sources to
(HVDC) transformer for connection to
the final destination of the Yangtze
the 800 kV UHVDC grid was tested
region. Dr. Beatrix Natter, CEO of
successfully. Two of these units have
Siemens Transformers, is convinced:
arrived in Shanghai to support the
“With our development, we are help-
transmission project, and two more
ing to interconnect the global ultra-
units are in production in the Siemens
high-voltage three-phase grids and
Factory in Guangzhou.
the ultra-high-voltage DC grids at the
Furthermore, Siemens is supplying the 800 kV level.”
key components of the transformer to
local partners to ensure the highest
quality of the products manufactured
in their local factories.
Siemens’ engineers had to develop
a transformer that was subject to
strict test cycles throughout the fac-
tory acceptance test phase. These Siemens AG
cycles were defined by State Grid
Energy Management Division
Corporation of China (SGCC) in the Freyeslebenstrasse 1
equipment specification, and rigor- 91058 Erlangen, Germany
ously applied under the supervision of
SGCC HVDC senior expert Mr. Lu Siemens AG
Energy Management Division
Lichen. The new 1,050 kV HVDC
transformer proved to have impressive Transformers
insulation values for the critical trans- Katzwanger Strasse 150
former section, especially with the 90461 Nuremberg, Germany
1,050 kV alternating current aspect. Contact:
Sabine Ebermann
sabine.ebermann@siemens.com
siemens.com/transformers
Transformer insights 01 | 2017

Transformers in electricity transmission

Masterful
performance at
network hubs
The constantly increasing relevance of electrici-
ty as an energy source means that reliability of
supply and availability are becoming ever more
important. Due to increasing digitalization,
more and more industrial processes and day-to-
day activities depend on the reliable availability
of electricity.

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Although the “blackout baby boom” – the sudden

increase in the birth rate in New York nine
months after the major power failure of 1965 – is
more in the realm of urban legends, large power
failures in today’s world have far-reaching conse­
quences. After all, it’s more than just the lights
that go out. In reality, our entire modern infra­
structure would fail to operate after just a short
period.
That’s why a reliable power supply is more im­
portant today than ever before – for economic as
well as societal reasons. At the same time, decen­
tralization and digitalization of the energy system
create entirely new risks. Security-related de­
mands on grid operators are therefore skyrocket­
ing, since security of operation and of supply are
more paramount today than ever before.
Grid resilience has become a sine qua non
The experts agree unanimously: The key to a
power transmission infrastructure that offers comprehensively protected physically, systemical­ infrastructure. They are the hubs holding every­
maximum reliability is grid resilience. A term de­ ly, and from an IT perspective. The proverbial thing together in a grid infrastructure. But at the
rived from the field of psychology, resilience de­ weakest link must not be substantially more sus­ same time, this is where the grids are particularly
scribes the ability of a system to anticipate risks ceptible than the strongest. vulnerable: if a power transformer in the grid
smartly, learn from previous incidents, and pro­ should fail, it cannot quickly be replaced. It can
Transformers are a key focus
vide a comparatively stable response to disrup­ take weeks or even months to obtain a replace­
tions on this basis. For transmission networks, Transformers deserve particular attention when it ment, since a large transformer is not an off-the-
this means in practice that all elements must be comes to establishing a resilient transmission shelf product.

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Many requirements need to be met
Transformers in transmission grids must therefore
be capable of withstanding many different stresses
and risks for a period of decades. Operational
disruptions such as voltage spikes and climatic
influences like extreme temperatures, hurricanes,
or – in coastal locations, for example – salty air
can present a real challenge. Furthermore, in
many parts of the world, natural disasters like
earthquakes are an ongoing latent risk, while in
other locations, vandalism can be a threat. Ulti­
mately, in state-of-the-art grids with digitalized
operation, it is essential to protect the transform­
ers’ control systems against unauthorized access
and manipulation. There are many aspects to the
operational safety and reliability of transformers,
and Siemens takes them all into account – as ear­
ly as during the transformer layout and design
stage and continuing through construction all the
way to installation and commissioning.
Getting a grip on insidious aging processes
Even so, the list of potential risks is still far from
complete. One factor that is growing in impor­
tance is aging. This is affecting more and more
grid components, while at the same time, de­
mand on transmission performance continues to
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rise. This issue is increasingly causing headaches
for many grid operators, since the components
in their transmission grids are getting along in
years, particularly in the industrialized countries.
In other words, the risk of age-related outages is
also on the rise. This is where continuous status
monitoring comes into play, as part of Transform­
er Life Cycle Management (TLM™). By monitoring
key parameters, transformer experts at Siemens
can recognize aging processes and damage at a
very early stage. Outages become predictable
and can therefore be averted in advance. Repairs
and refurbishments by Siemens can also sub­
stantially extend the potential service life of a
transformer.
The ultimate emergency solution
So, what happens if a transformer fails despite all
the protection and security measures put in
place? Here, too, Siemens has a suitable and
modern answer: mobile, plug-and-play transform­
ers that are ready for immediate use. Thanks to
their compact and light design and their versatili­
ty, they can be installed quickly and easily in the
event of an outage. This restores normal grid op­
Learn more about the
eration much faster than other measures and functionality, setup, and
helps cut the cost of outages quite substantially. operation of power-
transformers in our
online training sessions.
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It’s a scenario feared by energy utilities and grid operators alike: a natural
event like a hurricane or flood that damages a power transformer. Replac­
ing this type of transformer is a complex, costly, and time-consuming pro­
cess that can take weeks, and in most cases even months. But the power
supply must be restored as soon as possible.

Always at the ready: Much faster power supply recovery

This is where the newly developed, mobile, plug-and-play transformers
from Siemens (mobile resilience units) provide a remedy. They enable the
mobile plug-and-play power supply to be restored in just a fraction of the time normally required,
and thus play an important part in ensuring a more reliable energy supply.

transformers from Designed for the utmost flexibility

Plug-and-play transformers are a true multipurpose tool for the grid: They

Siemens
are designed for multiple voltage levels, with high-temperature insulation
material like aramid fiber and a flexible cooling system to keep their weight
and size to a minimum and assure maximum mobility. Special plug-and-play
bushings and cable connections, as well as several other features, cut the
time needed for installation from several weeks to just a few days.
Suitable for environmentally sensitive areas
If required, the transformers can also be filled with environmentally friendly
and flame-retardant esters, enabling them to be used in environmentally
sensitive areas as well as in densely populated locations. Their compact
design makes it possible to transport them filled with oil, so there is no
need for oil handling on-site, which further shortens the installation time.

More information:

Brochure: Picture slideshow:

Grid resiliency Installing a mobile
Installing a Mobile
solutions for power Resilience Unit
within 3 Days
resilience unit with-
transformers Slideshow

© Siemens AG 2017. All rights reserved. siemens.com

in three days

Grid resiliency solutions

for power transformers
Prevent – Protect – React

siemens.com/pretact

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Three pillars of safety

Prevent Protect React

Prevent
Continuous status monitoring is an important element in ensuring safe
transformer operation. By monitoring key parameters, it is possible to
recognize aging processes and damage at a very early stage. Outages
become predictable and can be averted in advance. Perfectly coordinat­
ed refurbishment based on recorded and analyzed measurement data
can help to substantially extend the service life of a transformer and
take action before serious damage occurs.
swiftly to restore the power supply again quickly. The Pretact solution
provided by Siemens to meet present-day needs is its “plug-and-play”
transformers, so-called mobile resilience transformers. These are com­
paratively compact and lightweight, and can be transported and in­
stalled quickly and easily, which helps keep the duration and costs of an
outage to a minimum. Since the mobile resilience transformers
can be extensively adapted to suit individual requirements, there is no
need for grid operators to keep a large number of separate replacement
devices on hand for every voltage level, which makes for a clear cost
Pretact ® – React in advance.
Grid resilience along the entire
energy value chain

Protect
Power Transformer Case

advantage.
The problem: ageing assets in
a strained grid infrastructure A large portion of the installed power
transformers within the U.S. were
600 installed in the 1950s, 60s and 70s
and are now reaching the end of
500 their projected service life.

400

300

Customized solutions from Siemens can provide highly effective protec­

200

Units
100

Example: Power transformers installed per year in the U.S.

1954 1960 1970 1980 1990 2000 2006

Example: Power outages in the U.S. Causes of transformer failures in the U.S.
Pretact ® – React in advance.
3,149 3,071 3,236
3,634
28 % Electrical disturbances
Grid resilience along the entire
2,840 2,808 27 %
energy value chain

tion for transformers against a whole series of risks. Non-magnetic steel

2,769 Other
13 % Lightning
9% Insulation
6% Electrical connection
4% Overload
4% Foreign objects Siemens' distribution transformers are key electrical components
4% Moisture and Siemens is a reliable partner for network operators who are
3% Line disturbance facing growing challenges of maintaining a constant voltage and
2008 2009 2010 2011 2012 2013 2014 avoiding unpredictable events.
2% Stress or fatigue

As a result, power outages in the U.S. are becoming increa- Most power transformers fail in operation, The Siemens Pretact® concept “prevent, protect and react”

inserts, for instance, protect the transformer against overheating

singly more frequent and it is feared that their number will but natural disasters and other forced outages decreases risks of loss of major power flows as well as grid
continuously increase as equipment ages. do occur and harm the equipment. disturbances and improves overall reliability, resilience and
restoration.

More than half the power transformer outings are due to electrical disturbances,
natural disasters (e. g. lightning), insulation failures, and other forced impacts.

Risk factors for grid resilience

Risk factors for grid resilience
More information:
through geomagnetically induced currents during solar storms. Some
Operational issues Natural disasters Other forced outages

Operational issues Natural disasters Other forced outages

protective devices, such as bullet-resistant shielding, can even be retro­

• Network failures • Earthquakes • Physical impacts
• Incorrect operations • Hurricanes • Cyber impacts
• Aged fleet • Flooding
• Network failures • Earthquakes • Physical impacts • Switching load stress and voltage • Fire
• Incorrect operations • Hurricanes • Cyber impacts fluctuations from renewable
• Aged fleet • Flooding energy sources
• Load balancing • Fire
• Geomagnetic storms

Pretact – Siemens grid

®

Infographic: Pretact ® – Siemens grid resilience

concept for dry type and liquid Infographic:
fitted. Alternative insulating fluids like esters with a high ignition point
resilience concept
Most of the aged transformers will need to be replaced by standard power transformers. However, there is
immersed distribution transformers

Grid resilience along Grid resilience along

a strategy beyond replacement. Siemens Transformers‘ cutting edge concept gives operators peace of mind.

Prevent operational risks Protect and

against forced impacts
Prevent operational risks Protect against negative impacts
and excessive heat
excessive heat

markedly reduce the risk of explosion and fire. the entire energy the entire energy
• Transformer Lifecycle Management
• Condition Monitoring
• Repair and Retrofit
• Prevent component failures
(e.g. Bushing service)
• Long Term Program (LTP)
GIC*-safe transformers
• Avoid critical heating
• Up to 200 A extra DC-capacity
• Non-magnetic steel inserts
prevent overheating

* Geomagnetically induced current

Bullet resistant transformers
Special shielding with bullet-
proof materials up to Cal.50 Ball
M2 for new transformers and as
an upgrade for existing units
value chain • Load Balancing: Intelligent FITformer REG® and
voltage regulators with increased switching capacity
• Specific solutions for high duty applications
• Energy & commodity theft prevention
• Flame resistant and self-extinguishing
cast-resin transformers
• Alternative fluids with low flash and
fire points for liquid immersed transformers
value chain
React
• Maintenance free product • Self-protected transformers

(Power (Distribution
• Optional cast-resin transformer housing

React to emergencies
Mobile Versatile Rapid installation React to emergencies
130 kV 80 kV Versatile Rapid installation

Transformers) Transformers)
and replacement

200 kV
345 kV

Compact & lightweight design Covering different ratings Plug & play connections

Outages can never be completely ruled out, even when all precaution­
and bushings

Long term service agreements for storage, transport and maintenance of spare units.

Dual voltage transformer (LiDT) Individual winding exchange for

ary measures have been taken. It’s best to be prepared and able to act
cast-resin transformers, compact
designs and plug & play bushings

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No chance for
trigger-happy vandals
It has long been standard practice to set up
power transformers, depending on their location,
in such a way that they will reliably withstand
potential external effects of natural events –
lightning, earthquakes, or geomagnetically in­
duced currents. The increasing regularity of ex­
treme climate conditions also poses little risk to
the operational safety of transformers in trans­
former substations in most cases. They are also
sufficiently immune to operational disruptions
like voltage spikes.
Substations have become vulnerable targets
But today, a completely different and unpredict­
able risk is taking on disturbing proportions in
some parts of the world: the deliberate destruc­
tion of equipment. In rural areas of North Ameri­
ca, in particular, there are increasing reports of
transformers at power stations and in transform­
er substations being shot at with powerful weap­
ons. For example, unknown individuals in San
Jose, California, shot at a transformer substation
with high-powered rifles in April 2013.
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Within only 20 minutes, the attackers put
17 power transformers out of action, this way
threatening the safe supply of power to the
whole of Silicon Valley.
Transformers in full armour
As part of its unique Pretact® concept, Siemens
has developed a bullet-resistant protection sys­
tem for transformers. The shielding can be fitted
with the transformer ex-factory, and existing
transformers can be retrofitted on-site. The trans­
former is protected against small arms fire by
specially developed panels that are attached with
steel brackets. Additional foundations are not
required. The panels even withstand an assault
from VPAM class 13.50 BMG machine gun projec­
tiles. Some of the panels are moveable to access
pumps and fans for maintenance purposes.
Thanks to Siemens’ innovative development,
transformer operators in the affected areas have
access to a solution that effectively minimizes the
risk of outages caused by vandalism and improves
the security of the power supply.
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A .50 caliber round – representing the highest likely
threat posed by a ballistics attack – being reflected by the
Siemens protection system
More information:
Protecting assets
with Siemens Pretact®
Use case: bullet resistant power transformers
siemens.com/transformers
The challenge The solution
Transformers serve as critical nodes Siemens offered its one-of-a-kind
designed to withstand many bullet resistant shielding to safeguard
operational risks, such as severe the versatile generator step-up
weather events and network power transformer. This product ensures the
fluctuations. Until now, however, there highest safety and reliability by
remained one risk to the assets: human incorporating bullet-resistant panels
impacts. that are mounted directly on the
transformer tank. It not only protects
One of our U.S. customers decided to
the tank and radiator cooling system
address this risk with an innovative
against bullets, it also shields the
concept that does not require further Example of a bullet-resistant tank design with
conservator, turrets, and the bottom of
investment to build a concrete wall protected radiators and conservator
the bushings.
around the premises.
Mounting the system directly on the
For the customer, versatility and
transformer also minimizes the
protection were crucial factors. This is
amount of additional space required
where the Pretact® concept of Siemens
for the transformer. The panels can
Transformers came in handy. It enables
also be adapted to reduce acoustic
a modular combination of approved
emissions, and their positioning allows
technologies and latest innovation.
for both maintenance and the
The customer requested a generator movement of air for efficient cooling.
step-up transformer with 970 MVA at
In this special case, only three sides are
345kV +2x2.5% - 24.8/21.1/17.3kV
covered with bullet resistant panels, A VPAM Class 13, .50 BMG
with a link board to reconnect the low-
because the low-voltage side of the M2 AP round – representing the
voltage side. The three-phase unit also highest likely ballistics threat –
transformer is built right next to the
allows for voltage regulation on the being reflected by the Siemens
generator building. To enable access to
high-voltage side as it needs to fit five protection system.
pumps and fans for maintenance,
different generating stations and nine
some of the panels are designed to be
different locations, and most
removeable.
importantly, must be protected against
high-powered ballistics.
Use case:
Bullet-resistant
transformers
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The Power transformers are valuable capital assets

that usually operate reliably for decades with­
out interruption. It’s all too easy to forget that
The art of transformer rejuvenation
Preventive actions taken in a timely manner can
extend the service life of a power transformer
transformer the solid and liquid insulating materials inside
them are subject to natural aging processes.
appreciably and help protect the investment.
SITRAM® REG oil regeneration and the highly

doctors
A revealing blood count efficient oil drying solution SITRAM® DRY,
which removes detrimental accumulations of
The analysis of a transformer’s insulating liquid
moisture, are just two examples. These services
is particularly helpful in evaluating its internal
can be performed on the energized transformer.
status. The Siemens specialists examine it in
detail as part of Transformer Life Cycle Manage­
ment (TLM™). Just like a blood count, this anal­
ysis can provide important information that –
to continue the medical analogy – can save the
More about Trans-
life of a power transformer.
former Lifecycle
Management and
extending a trans-
former’s service life.

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What happens If the power fails in your own home because a

fuse blows or a residual current circuit breaker
trips, the problem is usually rectified quickly and
represent one of its most vulnerable components.
Despite expanded efforts by industry and Federal
regulators, current programs to address the vul­

during a the consequences remain easily manageable. But

what happens if a large power transformer – one
of these huge giants in a substation, that can
nerability may not be adequate to address the
security and reliability concerns associated with
simultaneous failures of multiple high-voltage

blackout? easily weigh up to 400 tons – fails, possibly leav­

ing an entire part of the city or rural area without
transformers.” That’s why outages must be pre­
vented before they happen. And if a fault occurs,
electricity? The consequences are more serious the power supply has to be restored as quickly as
than many might first imagine. possible.
Outages must be prevented before they happen
The April 2015 Quadrennial Energy Report of the
U.S. Department of Energy concluded: “High-volt­
age transformers are critical to the grid. They

Planned outage Unplanned outage

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Transformers in power distribution

Up close
to the
consumer
A large number and variety of trans-
formers ensure that power flows
from the transmission grid to the re-
gional distribution system and ulti-
mately makes its way reliably to the
consumer. Consumers range from
industrial plants with high power re-
quirements to electrically operated
rail vehicles all the way to residential
households. For a number of years
now, growing volumes of distributed
power generation have also been
part of the mix at the distribution sys-
tem level, creating entirely new de-
mands on the distribution systems.

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A wide range of requirements to be met

Siemens FITformer
liquid-filled transformers
and GEAFOL Neo cast
resin transformers ensure
highly reliable power
distribution.
Distribution transformers guarantee that all con­
sumers are reliably supplied with the right volt­
age for their needs. It may sound simple, but de­
pending on the supply area, grid structure, and
the nature of the consumers, this may actually
involve many complex challenges – and distribu­
tion transformers must handle them successfully
and reliably.
For reasons of cost-efficiency, distribution trans­
formers are installed as close as possible to the
consumers, since the shorter the distance be­
tween the power distribution system and the con­
sumer, the lower the transmission losses. On the
other hand, however, the available space in the
vicinity of the consumers is often very limited. In
addition, the distribution transformers must be
extremely safe and dependable in order to pre­
clude any risks to people and equipment. And
ultimately – in densely populated areas in partic­
ular – they must run as quietly as possible to
avoid noise pollution.
Two tried and tested product lines
The proven distribution transformers from
Siemens, the liquid-filled FITformer and the
GEAFOL Neo cast resin transformers, excel at
meeting these requirements. They also score high
in terms of environmental compatibility, efficien­
cy, and maximized availability. As a result, they
save time and money, while assuring outstanding
grid and application stability.
Canada offers a textbook example of maximum
efficiency, with pole-mounted transformers with
amorphous cores that keep losses to a minimum.
In 2016 alone, Siemens installed 1,200 of these
high-efficiency transformers, with power ratings
of 25 to 100 kVA, for the Saskpower utility compa­
ny in Canada’s Saskatchewan Province.

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Particularly demanding: industrial applications
Industrial firms have an entirely different set of
requirements: For many businesses, electricity is
an essential resource in production, for example
in the iron and steel industry as well as in the
chemical industry, where the power supply is
subject to particularly stringent quality and safety
demands. After all, if a continuous process comes
to a standstill, the losses will quickly run into the
millions. For example, if an aluminum electrolysis
freezes because of an interruption of the power
supply, the metal solidifies and is wasted and the
melting pots have to be repaired. That’s why the
power supply infrastructure for manufacturing
operations is often configured redundantly. And
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since industrial applications often require high
current levels and voltages, they use various spe­
cial industrial transformers in addition to the tra­
ditional power or distribution transformers. Learn more about the
functionality, setup, and
The absolute measure of all things is maximum operation of power
transformers in our
availability and power quality – also for data cen­ online training sessions.
ters, the backbone of today’s information society.
And this will further grow in importance as the
“Internet of Things” develops. Of course, trans­
formers must operate with the same level of
reliability.
True all-rounders that keep the trains running
Tractronic® traction transformers for trains and
locomotives have a special position among
Environmentally
transformers. The particular challenge for these friendly
“mobile” transformers is to provide maximum GEAFOL cast-resin
performance in the smallest possible space and to transformers
cope with the different types of electricity, fre­
quencies, and mains voltages in different coun­
tries. Siemens can look back on more than 100
years of experience in this special field – which is
More information:
a robust base for customized traction transform­
ers that prove their worth based on maximum t
Web article:
reliability, efficiency, and safety in operation. Extremely efficient amorphous
core transformers for Canada
Extremely efficient
Siemens Transformers Canada (STCA), the leader in amor-
phous core transformers in Canada, recently received an
order for the delivery of high-efficiency transformers from
Saskpower, one of the largest public utilities in Canada,
amorphous core
transformers for
serving the province of Saskatchewan. Saskatchewan, at
the center of the prairie provinces, has approx. 1.2 million
inhabitants.
Siemens will supply 1,200 pole-mounted transformers
with ratings from 25 kVA to 100 kVA to Saskpower. From
the capital of the province, Regina, the transformers will
be installed throughout the province. Siemens will supply
all transformers between January and December 2016.
The contract is worth €1.6 million and accounts for 80%
of the entire Saskpower requirement.
Canada
Amorphous core transformers are more efficient than
standard transformers. The randomly arranged molecular
structure of the amorphous core material results in less
friction than traditional silicon iron cores when magne-
tized. This unique property facilitates magnetization and
demagnetization and yields significantly lower remag-
netization losses in amorphous materials. The extreme
thinness of the material also provides lower eddy current all across Canada. Our customer Saskpower was particu-
losses. larly convinced of the Siemens technology and excellent
manufacturing expertise which guarantee short delivery
Francois Faisy, General Manager of Siemens Transformers
times and perfect product quality.”
in Trois-Rivières, says: “Siemens Transformers Canada
invested in dedicated amorphous core production in 2013, Since 2011, STCA has delivered more than 35,000 amor-
leading to a #1 position in Canada for high-efficiency phous core transformers and continues to be very success-
transformers supply for the benefit of our customers ful with this range of products.
Siemens AG
Energy Management Division
Transformers
Katzwanger Strasse 150
90461 Nuremberg, Germany Publisher and Copyright 2015:
Siemens AG
Contact Energy Management Division
Francois Faisy Freyeslebenstrasse 1
francois.faisy@siemens.com 91058 Erlangen, Germany
siemens.com/transformers
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Impressive in all aspects:
transformers for
industrial processes
For many industries, electricity is the key resource for production –
in mining and the metal industry, for example, or in chemical plants,
metalworking, or in the oil and gas industry.
To guarantee the necessary current ranges and voltages, along with a
reliable power supply and maximum safety, the special transformers
used in industry must meet very specific requirements – for instance
delivering high energy volumes at low voltage and high currents, mak­
ing large volumes of DC electricity available for fused-salt electrolysis,
or satisfying special safety requirements associated with the handling
of flammable and explosive materials.
That’s why every individual transformer is customized for its particular
situation, thus enabling it to serve reliably and for many years under
especially tough conditions.
More information:
The challenge
Furnace transformers are essential for
steel production processes. They must
be able to withstand extraordinarily
severe conditions and yet still provide
reliable service.
Our customer, Gerdau, is one of the
largest producers of long steel on the
North American continent. Their
production site in Cartersville, Georgia,
U.S. needed a new furnace transformer
with a higher rating to replace a unit
for expanding production capacities
and improved process reliability.
However, the dimensions needed to be
kept to a size that would enable it to fit
into the existing transformer vault.
Gerdau
Gerdau is the leading manufacturer
of long steel and a major global
supplier of special steel. Gerdau has
industrial operations in 13 countries
with a combined installed capacity
of more than 25 million tons of steel
per year.
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Fit to perform the
toughest tasks
Furnace transformer for steel production
The solution
Siemens designed a 100 MVA (at
65/65/80 K) transformer for Gerdau
Cartersville with a rated voltage ratio
of 34.5 kV / 1150-651 V. The total
weight of the transformer was 96.9
tons – which equals approximately one
ton per MVA.
The unit was designed and manu-
factured at the Siemens transformer
plant in Dresden, Germany – the
center of competence for special
transformers for industrial applica-
tions. The selection, qualification,
audit, and approval of global suppliers
and materials as well as the research
and development was all performed at
this location.
Gerdau put its trust in the German
engineers, knowing that they are
familiar with the industry’s challenges.
These include the expanding
production capacities, which require
higher currents – leading to a need for
ever more powerful transformers that
are even more reliable than their
predecessors.
One pager:
Furnace
transformer
for steel
siemens.com/transformers
production
The challenge
Transformers for industrial applications
often are located close to the working
environment of employees. Converters
for the oil & gas­industry may even be
operated at sea.
Although oil leakage in a transformer
is very unlikely, a risk of oil spilling
remains. But not only environmental
protection needs to be considered.
Also health and safety of the staff are
of uttermost importance. This is why
our customer in the UAE asked for a
converter with synthetic ester
insulation for his application.
The solution
This is why the customer approached
LV connection of the furnace transformer Siemens Transformers, who is a
pioneer in alternative fluids and
“Siemens delivered a world experienced in adjusting transformer
class transformer, from
design to build. The highest
design to the special characteristics of
ester.
quality one could expect.” The decision was to go with MIDEL
Adam Myers, Project Manager, 7131, a synthetic ester fluid that is
Gerdau Cartersville, Georgia proven up to 433 kV. As a high­
performance liquid insulation medium,
it is fire safe and at the same time
robust and biodegradable.
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Up close to the
consumer
One pager: Brochure:
Ester converters Transformers
Safety first in Oil & Gas
Ester converters with Atex certification
with Atex for high-current
certification and large drive
siemens.com/transformers
industrial
The transformers were designed and
manufactured by Siemens
Transformers in Dresden (Germany).
They have a rating of 16 / 4 x 4 MVA at
a voltage level of 33 kV / 4x 2,0 kV ±
5% and are equipped with a no­load
tap­changer.
They have a core with an intermediate
yoke and four low voltage systems in
double tier for feeding a 24 pulse
applications
converter and got an Atex­certification
Tougher than
for Ex­zone 2 IIA/IIB T3.
Converter Transformer for an oil­ and gas­
application in Abu Dhabi, UAE.
To meet the customers’ safety
requirements in terms of explosions, it
any challenge
comes with a Sergi transformer
explosion prevention system.
Transformers for high-
current and large drive
industrial applications
siemens.com/transformers
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Transformer insights 01 | 2017

Siemens continues its long-standing history

of trendsetting transformer solutions

Reliable
electricity for
the digital
revolution
A study by a large, international environmental
organization suggests that, if the Internet were
a country, its electricity consumption would be
the world’s 11th largest. Major data centers, for
example those of online stores, search engine
operators, and cloud storage providers, have a
massive thirst for electricity, and the energy
requirements in this particular sector continue
to grow at a tremendous rate.

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Greater efficiency for

offshore wind power
For experts like Michael Liebreich, chairman of
the advisory board of the research and informa­
tion service Bloomberg New Energy Finance, it
has long been clear that the cost-efficiency, and
ultimately the long-term marketability, of power
generation from renewable sources is determined
by system costs alone. The calculation includes all
investment, operating, and financing costs over
the entire service life of a generating system. This
total is then divided by the electricity revenues.
The result is the system costs, expressed in euros
per megawatt hour.
Transformers to reduce system costs
Important levers to reduce system costs, besides
potential effects of scale, are reduced investment
expenditure and increased efficiency of power
generation and transmission. With the latest gen­
eration of the FITformer REN, an innovative 66-kV
transformer developed especially for offshore
wind farms, Siemens is introducing a further effi­
ciency boost in the area of offshore wind power.
reduces the amount of cable needed for connec­
tion of a wind farm plus the losses in the process
– making wind power even more cost-efficient.
But that’s not all. Despite its power level, the vir­
tually maintenance-free FITformer REN, designed
especially for the tough conditions of offshore
use, weighs less than 20 metric tons and has a
particularly compact structure. That means it can
be installed directly in the nacelle of the wind
turbine.
Smart technology for easy serviceability
For the unlikely case of any service requirement,
all components of the new transformer are ar­
ranged in such a way that they are easily accessi­
ble and replaceable without having to drain the
insulating fluid. Siemens offers special in-house
training during which independent offshore in­
stallers are taught to service the transformers
on-site. In addition, Siemens provides online sup­
port through the use of a so-called “Web eye”:
A trained offshore wind turbine technician is
The new standard: transmission at 66 kV
The first practical application for the FITformer
REN is in an offshore wind farm off the Danish
coast. Wind turbine manufacturer SGRE has
equipped the turbines at the 28-MW wind farm
“Nissum Bredning Vind” with the new Siemens
transformer.
Experts already expect the 66-kV transmission
voltage to become the new standard for offshore
wind projects. After all, the higher voltage means
that more wind turbines within a field can be
connected to a single cable, which translates into
substantial further savings.
More information:
One pager:
First order for 66-kV
Twice the voltage, lower
losses and smaller size Fitformer REN
First order for 66kV FITformer REN

The new, extremely powerful transformer, with a equipped with data goggles and camera and is
siemens.com/transformers

The challenge The solution

While wind turbines were producing
0.5 MW of power at a height of 40
meters in 1990, today’s turbines
produce 7 MW and more. However, the
voltage level output stayed at 33 kV for
To operate on a new voltage level, a
brand new transformer type fitting all
new requirements had to be
developed, designed and
manufactured. The new generation of

capacity of 8.7 MW, is an important contribution
directly connected to the transformer specialists
quite a long time.
A new offshore wind park in Denmark
is one of the first to be equipped with
7 MW turbines and to be connected to
a 66 kV grid voltage of instead of 33
kV. With the new capacity levels (the
new SWT-7.0-154 provides 10% more
output than its predecessor), the
efficiency of wind power generation is
also increasing. This is why the new
generation of wind turbines has a
voltage output of 66 kV, which allows
reduced losses and higher efficiency in
wind transformer FITformer REN is a
liquid-filled 8.2 MVA transformer for a
grid-voltage level of 66 kV. Unlike their
predecessors, these transformers are
not installed at the bottom of the
turbines, but inside the nacelle.
Space being very limited in a turbine, CAD-drawing of the new FITformer REN for wind
the new transformers are very compact applications at 7MW.
and lightweight, while at the same
time highly efficient, according to the
Eco design directive, and a high
temperature design, according to IEC
60076-14. Moreover, their design has

to the transmission of electricity from increasing­
at the Siemens transformer plant for real-time
wind turbine operation. been optimized to cope with the
hostile conditions of offshore
One of the key components in this
applications and to keep maintenance
progress is a new generation of wind
demand as low as possible.
transformers delivered in 2017.

ly powerful wind turbines with minimum losses: support. This enables immediate response to any
With the higher transmission voltage of 66 kV, it servicing requirement that might occur.

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Distributed The constant growth in distributed power gen­

eration represents a significant change in the
energy system. Distributed generation is nor­
Voltage regulation without grid expansion
Specially developed single-phase voltage regu­
lators from Siemens are a highly efficient tech­
power mally fed in at the distribution level. This can
cause bidirectional load flows in distribution
systems, which were not traditionally designed
nical solution that helps keep voltage limits
within the permissible range without further

generation
for such phenomena. Hence, the transforma­
tion of the energy landscape exposes grid oper­
ators to the challenge of creating a powerful
under grid infrastructure that meets present-day
needs and will reliably connect grid customers
grid expansion, especially in medium-voltage
grids. These devices, consisting of a switchable
autotransformer with an on-load tap changer,
offset differing voltage loads and keep the out­
put voltage constant. They are especially suit­
able for use in locations where high volumes of

perfect control
with the generation, load, and storage opportu­
nities the infrastructure offers.
renewable electricity are fed into medium-volt­
age grids and there is strong industrial demand
for electricity or long distances need to be
crossed. Single- or three-phase voltage regula­
tors can be used both for local regulation be­
tween the transformer substation and the
regulator itself, and for long-range voltage
regulation and optimizing the voltage for an
entire grid area.

Intelligence
replaces copper –
making power grids
ready for the future

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Transformers
keep things
moving
Learn more about
the new Siemens
Tractronic® traction
transformers
Siemens offer a wide-ranging product portfolio of
reliable high-quality components for all types of
railway transportation and infrastructure applica­
tions. To enable the connection between the
power network and the special power supply for
the train (e.g. 15 kV / 16.67 Hz) Siemens offers
special, so-called line feeder transformers to be
installed beside the track. They convert the power
from the network to suitable levels for all rolling
stock equipment. The special short-circuit and
overload conditions create very particular de­
mands in terms of reliability for these line
feeder transformers.
As soon as the electricity passes through the pan­
tograph of the train, another onboard traction
transformer that is customized according to the
train’s specific needs in terms of power, weight,
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and size ensures that the drive motors and the
on-board electrics are reliably supplied with the
right voltage and current. Traction transformers
from Siemens are used in AC trains all around the
world, for example for high-speed (HI) and elec­
tric multiple-unit “regional” trains (EMUs) and for
electric locomotives for freight transportation as
well as for passenger service.
The latest innovation from Siemens in the trac­
tion transformer segment is the Tractronic®
Thinity™. Its winning features are the particularly
low weight and its high efficiency. Thanks to its
revolutionary tank design, it can save up to 25
percent in weight. With innovations like this,
Siemens has supported the railway industry for
decades.
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More information:
Tractronic® Thinity
Newly developed innovative
traction transformers
Challenge
Perhaps more than any other factor,
mobility is shaping our globalized and
increasingly urbanized society. Ever-
growing passenger volumes and
demographic changes put pressure on
the demands on local public transport.
By 2030, up to ten million people
will be traveling by rail every day in
Germany alone.
As one of the globally leading train
manufacturers, our customer Siemens
Mobility needed to fulfill a set of requi-
rements when developing their new
train platform called Mireo®: Capacities
needed to be increased while reducing
operating costs. But there are even
more demands: While focusing on
cost-effectiveness, adaptability and
sustainability there can never be
compromises in regards to safety.
Furthermore, passengers place great
value on space and comfort - and want
to arrive at their destinations even
more quickly.
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One pager:
Tractronic® Thinity™
Newly developed
innovative traction
transformers
Solution
Siemens Mobility developed a commuter
train called Mireo® inheriting a new
generation of traction transformers
called Tractronic® Thinity. It is planned
to put the entire Rhine Valley rail
network into operation in June 2020.
Driven by requirements of the train
operator’s needs, Siemens Transformers
developed Tractronic® Thinity, specifi-
cally built for – but not limited to – EMUs.
Lower weight, more freedom of move-
ment, shorter construction times and
optimized components – all of these
requirements come together in the Mireo®
new Tractonic® Thinity. Beginning in 2020, the Mireo will
operate as a regional train (RB)
With 24 train sets ordered in spring
along the Offenburg – Freiburg –
2017 the first units for the Mireo® are
Basel/Neuenburg (Switzerland)
currently manufactured and will be
route as well as in the Kaiserstuhl
delivered in autumn 2017.
area on Sundays between Freiburg
and Endingen/Breisach with appro-
ximately 1.9 million kilometers a
year and will run the distance in
30 minutes less than today’s trains.
siemens.com/transformers
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information
Transformer insights 01 | 2017

A breathtaking
history of
innovation and
success
The history of Siemens’ transformer business Co. were merged in 1903 to form Siemens-Schuck­ time were rated 60 MVA at 110/25 kV. The trans­
dates back to the 1890s, when electrification sud­ ertwerke GmbH – the nucleus of today’s Siemens for­mers for the first European 100 kV transmission
denly kick-started the second industrial Transformers Business Unit. line also came from the Nuremberg transformer
revolution and pushed the development of mod­ 1900–1920 plant.
ern industrial society. From the earliest days of
The demand for transformers increased steadily 1920–1950
electrification, Siemens transformers made it pos­
sible to transmit power over long distances and during this time, while transmission voltages rose The “Roaring Twenties” witnessed great progress
make it available everywhere. and more and more power was required. Siemens- in the development of transformer technology:
Schuckertwerke produced large transformers with Oil transformers were monitored for the first
In 1890, Siegmund Schuckert founded a trans­ overvoltages of up to 110 kV and with outputs up time with a Buchholz relay. In 1923, the first
former factory in Nuremberg. The transformer to 30 MVA. The largest units delivered during this five-legged cores for high-current three-phase
business of Siemens & Halske and Schuckert &

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Table of contents Powerhouses
in the
neighborhood
transformers were produced, and four years later
the manufacture of transformers with tap chang­
ers for uninterrupted voltage adjustment under
load began. At the end of the decade, 60-MVA
three-phase oil transformers were produced for
the 220-kV voltage level. In the thirties, the pro­
duction of 270-kA furnace transformers, whose
voltage was adjustable under load, was started,
and a test transformer for one million volts was
produced in 1933.
1950–1970
The electricity consumption of industrial enter­
prises and private households all over the world
increased strongly in the decade after the Second
World War. In the early 1950s, Siemens-Schuckert­
werke already introduced computers to calculate
and scientifically investigate the performance of
transformers. New technologies and material,
such as cold-rolled, grain-oriented electrical
sheets were introduced in transformer production,
and changeover switches were integrated into
the transformer tanks. In 1957, 660 MVA three-
phase 400/231-kV transformers were built for the
construction of the 380-kV network in Germany.
In 1966 Siemens-Schuckertwerke, Siemens &
Halske, and Siemens-Reiniger-Werke were
merged, and in October, Siemens Aktiengesell­
schaft was founded. Three years later Siemens
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and AEG-Telefunken, the two German pioneers in
electrical engineering, pooled their activities in
the field of transformer construction and set up
the joint subsidiary Transformatoren Union,
which became one of the world’s largest trans­
former manufacturers.
1970–1990
In the 1970s, several production and testing facili­
ties were modernized and expanded. Transform­
ers of more than 1,000 MVA and 1,500 kV were
manufactured and tested, and the export share
of industrial, power, and special transformers as
well as reactor coils grew continuously. At the
same time, HVDC transformers were developed.
The rationalization of production processes, im­
proved transformer reliability and availability,
and consistent quality assurance helped Trans­
formatoren Union keep its international competi­
tive edge in the 1980s. This was an economically
difficult decade that was characterized by world­
wide overcapacities in transformer building. In
the late 1980s, Transformatoren Union was fully
integrated into Siemens.
1990–2000
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The 1990s saw several important technical im­

provements, such as the development of a new,
high-quality corrosion protection that set new
standards in environmental protection. At the
same time, HVDC picked up momentum on the
world market, especially in emerging economies,
and Siemens delivered HVDC transformers for
projects of ever-increasing size, such as the Tian­
shengqiao-Guangzhou HVDC transmission system
in southern China, which has a transmission ca­
pacity of 1,800 MW and operates at 500 kV.
2000–2010
Siemens’ global transformer engineering and 2010–2017
manufacturing network was formed in the early Developments like ester-insulated power trans­
years of the new millennium. VA TECH was inte­ formers, the extremely quiet “whispering trans­
grated into Siemens in 2005, which combined the former,” the highly innovative Pretact® concept,
strengths of two of the world’s top transformer and the extremely powerful offshore transformer
manufacturers. Today, Siemens’ unique, world­ module (OTM™) for offshore wind power plants
wide transformer engineering, production, and underscore Siemens’ performance and competi­
service network with offices, production centers tive position. Since March 2017, a new, shared
and service facilities in more than 190 countries is design for all transformers making the innova­
one of the world’s most effective and innovative tions hidden inside the transformers visible en­
companies in the industry. sures a uniform contemporary look across all
product types.

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Transformers Smart energy management is becoming more

and more important. Digitalization, network­
ing, and the so-called Internet of Things make
and Big Data it possible to tap the full potential of energy
management: increased availability, optimized
operation and maintenance schedules, and
increased energy efficiency.
Data right from the grid nodes
Siemens’ state-of-the-art transformers with
their digital capabilities assume a new, import­
ant role in this context: providing and exploit­
ing digital information. They are positioned at
virtually all nodes of an electrical grid, which
makes them ideal “informational hubs” for the
entire power system.
Real time access to the data that is available
in or on the transformer can be a real game-
changer for grid operators, industrial facilities,
and data centers. Such data includes valuable
information about the condition of the entire
grid.
New perspectives for optimized grid operation
Processing and analyzing this data, for example
in Siemens MindSphere®-based cloud applica­
tions, allows for optimized load management
and consequently enables substantial improve­
ments in the operation of entire power net­
works and industrial plants. As the number of
digitally connected transformers grows, analy­
ses become more and more precise and optimi­
zation opportunities grow further.

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Intelligence for
a longer lifetime
In assets as expensive and crucial as power
transformers, it is key to ensure a long life­
time with constant reliability. For decades,
maintenance within defined intervals was
common – no matter whether the trans­
former really needed inspection or not.
With the use of data collected on the
transformer and sent through intelligent
diagnostics algorithms, condition-based
maintenance has become possible.
A smart cubicle called SITRAM TDCM is an
online monitoring system that provides all
this: It measures, stores, and analyzes in­
dicative values from transformers. The
system is able to provide prognostics and
recommend corrective or improving ac­
tions to be performed.
The SITRAM TDCM system, which incorpo­
rates the domain knowledge of a leading
OEM, assists users in optimizing their asset
management: It helps reduce the risk of
failure and uses maintenance resources
effectively.

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Published by
Siemens AG 2017
Energy Management
Freyeslebenstrasse 1
91058 Erlangen, Germany
For more information, please contact
our Customer Support Center.
Phone: +49 180 524 70 00
Fax: +49 180 524 24 71
(Charges depending on provider)
E-mail: support.energy@siemens.com
Published in Germany
Dispo 19200
fb7547 WS 0917
Subject to change without prior notice.
The information in this document contains
general descriptions of the technical options
available, which may not apply in all cases.
The required technical options should therefore
be specified in the contract.

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