1

Autotransformers evolution, reliability, safety and modelling in the Italian

transmission grid

L. Colla, A. Di Giulio, V. Iuliani, F. Palone, M. Rebolini
1
TERNA - ITALY
)

SUMMARY
The paper briefly recalls the function and the numbers of the power autotransformers in the Italian
transmission grid. The specification and evolution of these strategic components are strictly related to
the power transmission grid reliability.
The evolution of the Italian transmission grid is briefly described in terms of short circuit levels
increase and renewable power developments.
Last review of Terna technical specification of ATRs was issued in 2010. Innovations have been
introduced to increase transformers safety and reliability.
Innovations in autotransformer design and testing are presented. Further developments included the
safety issues. Special devices have been foreseen to carry out maintenance safely, while new
requirements and tests have been specified to cope with internal arc withstand of autotransformers and
bushings. New on-line dissolved gas analysis devices have been included in all units to monitor the
autotransformers during their operation in order to detect incipient faults and to feed the condition
based maintenance.
The thermal design of autotransformers is being considered of even more concern, being the
temperature a major responsible for transformer ageing. In order to better control this issue a thermal
calculation report along with the installation of direct hot spot measurement by optical fibres have
been required. The optical fibres have been be used to measure the hot spot temperature during the
heat run test and to monitor it during the transformer operation.
The short circuit type test, already specified as mandatory on each autotransformer type, was
performed on several units in year 2011, results are reported.
An autotransformer model suitable to study electromagnetic transients has been developed, this is
deemed useful to better understand the possible abnormal conditions that could occur during the
transformer lifetime operation. The model, based on physical quantities, will be used to update the
insulation coordination requirements according to the actual network and the future one.
KEYWORDS
Autotransformer, short circuit, design, testing, ATP-EMTP
1. INTRODUCTION
The Italian transmission network has three voltage levels: 400 kV, 230 kV, 150 kV and 132kV. Each
of them has a specific function.

1)
massimo.rebolini@terna.it


21, rue dArtois, F-75008 PARIS A2-103 CIGRE 2012
http : //www.cigre.org

2
- The 400 kV level (10860 km), interconnected with the European system is the principal
transmission network, collecting the energy produced by the majority of power plants towards
the most important transformer stations.
- The 150 kV or 132 kV (37040 km) plays the role of sub-transmission network, made of
several subtransmission islands with regional extents, usually each fed by two EHV/HV
transformer stations.
- The 230 kV level (9737 km), intended as transmission network before the development of the
400 kV level. It still collect a non negligible amount of energy from power plants and is
partially operated as transmission and partially as sub-transmission network
2
.

Fig. 1 Typical HV sub-transmission network in Italy
In order to interconnect the different voltage levels autotransformers are used, their standardization
began in Italy in early 70ies, after nationalization of electric energy market (birth of ENEL: 1963) the
number of units and their cumulated powers are shown in Table 1. While number of ATR units split
by age classes are reported in Fig. 2.
Table 1 Terna Transformers at 30th June 2011
TYPE NUMBER POWER (MVA)
ATRs 400/230 kV 400 MVA 56 22250
ATRs 400/155 kV 250 MVA 84 21000
ATRs 400/135 kV 250 MVA 164 40900
ATRs 230/155 kV (250 or 160 MVA) 48 8160
ATRs 230/135 kV (250 or 160 MVA) 91 16259
ATRs 155/135 kV (50 MVA) 1 50
HV/MV transformers and converter
transformers
178 11342
PST 400/400 kV 2 3300
PST 230/230 kV 1 370

Autotransformers of common use in Italy are core-type, 3 limbs, without delta connected tertiary
winding. A comprehensive description of the following main technical choices is dealt with in [1]:
- Rated power
- Transformers or autotransformers (ATRs in the following)
- Three phase units or single phase units
- Need and type of on-load voltage regulation
- Need of tertiary winding
3

2
Lines lengths updated at 31 December 2010

3
The main technical choices have been addressed as far as possible to put manufactures in the best
conditions for designing and supplying reliable machines, as simple as possible.

Fig. 2 Number of ATR units split by age classes in the Italian transmission grid
2. AUTOTRANSFORMERS OPERATIONAL EXPERIENCE AND STRATEGY
FOR RELIABILITY
The rate of failure, recorded for all the autotransformers in operation, has been for several years
considerably lower than 1% a year. Most of the failures have usually occurred in windings and HV
leads for bushings connections. In recent years the fault rate has increased while the average age of
failed units is decreasing, as shown in Table 2.
Table 2 Failure rate and average age of failed transformers (blank where exact figure is not available)
YEAR
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
FAILURE RATE
%
0.72 0.59 0.49 0.48 0.53 0.18 0.35 0.18 0.35 0.35 0.17 0.50 1.80 1.31 0,95
AVERAGE AGE
FAILED ATR
25 26 20 35 28 16 16 16


This trend has led Terna to set up a strategy to ensure the required level of reliability and safety of
large power transformers, shown in Fig. 3. This strategy includes three major lines of activity:
- control and reduction of external electrical stress
- specification and testing
- on-line monitoring
These three lines of activity are fed by accurate computer modeling and technological update to align
the transformer design to the best international practice and standards.
In network development there are three main drivers to be considered for large power transformers in
the transmission grid:
- changing network conditions
- market conditions
- perception by public and media in case of catastrophic events
Specification is therefore becoming even more important in an environment with new manufacturers,
new factories, new sub-suppliers, even more stringent targets for network reliability, changing
network conditions, need to reduce the actual and perceived risk for the public.

3
On this issue see also [2]
4

Fig. 3 Strategy adopted by Terna to ensure the required level of reliability and safety of large power
transformers
3. EVOLUTION OF THE ITALIAN TRANSMISSION GRID
The Italian HV and EHV system is facing an increase in maximum short circuit levels, especially in
the northern part of Italy. Some 400 kV substations are being uprated to cope with 63 kA short circuit
current. Full-scale testing has been performed in some substation configurations features to verify and
certify the withstand of the new design. A comprehensive description af the activities carried out for
the uprating is reported in [3].
Italy, especially in its southern part, is rich in renewable energy sources. Nearly of 26% of the total
Italian gross electricity generation in the year 2010 came from renewable sources. The total installed
wind power reached 5814 MW in 2010, increasing by 214 % in 3 years. The corresponding generated
power amounts to 9048 GWh. By the year 2020 a conservative forecast refers to about 12000 MW of
installed wind power. The installed photovoltaic power has reached 3470 MW in 2010 with 1906
GWh of generated energy.
Most of wind power plants are located in the Southern Italy or within the two main islands (Sicily and
Sardinia) where the wind source has the highest availability, but at the same time the transmission and
distribution grids are often inadequate to collect and transmit the generated power toward the load
centers, generally far from the wind farms. Conversely, although the solar source has the highest
availability in the southern part of Italy, the photovoltaic installed power is much more uniformly
distributed over the Country.
Wind farms having a rated power exceeding 10 MVA are usually connected to the national network at
HV level. The produced power is then partly absorbed by nearby load centres connected to the
regional HV network and partly transmitted through the transmission EHV network over the Italian
country. The increasing amount of dispersed generation is leading in some periods to active power
flows from the HV to the EHV network, a new operating condition for ATRs compared with the past.
New 400kV / 150 kV substations are being built in the southern Italy to collect wind power, a typical
sketch of wind power collection network node is shown in Fig. 4.
According to the previous Terna specification, maximum rated power of 400 kV / 155 kV ATRs used
to be 250 MVA. This rating was considered not enough to collect the expected huge increase of wind
power to be connected to Terna substations, therefore a new 400 MVA 400 kV / 155 kV unit has been
specified for this purpose. This large power unit could be effectively used also in substations close to
large load centres as big cities.
5

Fig. 4 Sketch of wind power collection substation
4. THE NEW AUTOTRANSFORMERS SPECIFICATION. DESIGN AND TESTING
INNOVATIONS
Last review of Terna technical specification of ATRs was issued in 2010. Innovations have been
introduced to increase transformers safety and reliability. Repetition of type tests (including short
circuit test) was required because previous prototypes were qualified at least 10 15 years before and
in the following years transformers projects have been in some cases modified by manufacturers. In
some cases factories in which transformers were manufactured changed along with sub-suppliers of
materials and accessories. In Fig. 5 main steps in autotransformers specification. 160 MVA units are
no longer specified while a new 400 MVA 400/155 unit has been introduced.

Fig. 5 Standardization of autotransformers ratings in the Italian transmission grid over 40 years
6
An optimization study has been carried out to determine the fundamental parameters of the new 400
MVA unit for wind power collection (see par. 3). As shown in Table 3, there is a significant scale
effect, thanks to which a 60% increase in rated power can be attained with only 18% cost increase.
4
Table 3 Comparison of main features of 250 MVA and 400 MVA ATRs

ATR 250 MVA
400 kV / 155 kV
ATR 400 MVA
400 kV / 155 kV
Rated power 100 % 160 %
Cost of supply 100 % 130 %
Total cost (including transport, erection, civil
works, bay equipments)
100 % 118 %
No load losses 100 % 128 %
Load losses 100 % 129 %
4.1. AUTOTRANSFORMERS DESIGN
Main innovations on ATRs design, introduced in the new Terna specification, are described in the
following.

On Load Tap Changers (OLTCs)
OLTC diverter switch is required to be vacuum type. The following maintenance requirements are
specified:
- diverter switch maintenance after 250.000 operations
- vacuum interrupters maintenance after 250.000 operations
- vacuum interrupters replacement after 500.000 operations

Bushings
Both Oil Impregnated Paper (OIP) and Resin Impregnated Paper (RIP) condenser bushings are
foreseen in the new specification. In both case only the silicone composite housing is accepted.
Although the operational record of HV and EHV bushings in Italy exhibits a high level of reliability,
composite housing is deemed safer than porcelain in case of internal arc.

Turrets
Turrets and turrets manholes flanges safety devices specified, which have to operate in case of major
failures. In the recent years a major ATR failure occurred in which a turret flange was ejected 300 m
away. To reduce the risks in case of major ATR failure Terna required in the new specification to
design devices which can reinforce or retain turrets or, alternatively, to limit the overpressure in case
of internal faults. The estimated overpressure nearby the turrets zones is about 5000 kPa (50 bar); this
value was obtained by Terna calculation and is higher than values obtained in similar cases [5].
A turret design according to the former ATR specification is shown in Fig. 6 while some
manufacturers proposals, compliant with the new specification, are shown in Fig. 7, Fig. 8
and Fig. 9

Fig. 6 Turret design according to the former specification Fig. 7 Reinforced turret

4
Reliability of adopted schemes should be carefully weighted
7

Fig. 8 Turret with rupture disks (45 bar) Fig. 9 Turret with retain device
Safety system to climb on the transformer during maintenance
The new specification requires the transformers to be provided with a foldable ladder system including
an incorporated fall protection rail to which operator connects his fall arrester system. If transformers
manufacturers deem it necessary, access platform to tank cover is required. Moreover a fixed rail-
based horizontal anchorage device (EN 795 - Class D compliant) is required to move safely on tank
cover during maintenance.

Thermal design
The thermal design of autotransformers is being of even more concern, being the temperature a major
responsible for transformer ageing. The transformer thermal calculations are not yet as accurate as
electric and magnetic fields calculations. In order to better control this issue a thermal calculation
report along with the installation of direct hot spot measurement by optical fibres have been required.
The optical fibres have been be used to measure the hot spot temperature during the heat run test and
to monitor it during the transformer operation.

Paper polymerization degree
Terna specification foresees that paper polymerization Degree (DP) has to be measured according to
[6] after vapor phase. The test is successful if DP 1000.

Transformer oil
In recent years it has been observed on some new transformers an abnormal increase in dissolved
hydrogen, known as stray gassing phenomenon. In the new specification it has been stated that
transformer oil shall not be subject to stray gassing in normal operating conditions. In particular the
value of 50 ppm of H
2
shall not to be exceeded during 16 hours at 120C in the testing conditions
specified in [7].

Dissolved Gas Analyzers
Upgrade of DGA: from simple "gas alarm" system (e.g. Hydran) to gas analyzer operating by gas-
chromatography principles (at least 3 gasses Duval)
In Table 4 it is shown a comparison between two multi-gas analyzers (same model of same
manufacturer) and laboratory results
5
A good global accuracy and reliability can be observed, anyway there are some discrepancies (in red):
. Gases concentrations are expressed in l/l (ppm).
- Hydrogen is always lower than DGA, it seem that approximately 30-40 ppm are constantly
undetected.
- Carbon dioxide is systematically largely overestimated (35-40%).
- Water measurement, even if expressed as relative %, is unsatisfactory

5
Data from Terna chemical laboratory (Padua Regional Area) carried out according to IEC 60567 with Total
Degassing Mercury-Free Pump.
8
Table 4 comparison between two multi-gas analyzers (same model of same manufacturer) and laboratory
results. Discrepancies are marked in red


Trafo 1 substation A Trafo 1 substation B
DGan1 LAB
DGan1-
LAB
DGan1-
LAB% DGan2 LAB DGan2-LAB DGan2-LAB%
H2 31 73 -42 -57,5 0 19 -19 -100,0
CH4 213 203 10 4,9 75 79 -4 -5,1
C2H4 190 168 22 13,1 15 14 1 7,1
C2H6 109 83 26 31,3 46 45 1 2,2
C2H2 0 0 0 0 0 0
CO 291 265 26 9,8 1993 1822 171 9,4
CO2 11939 8632 3307 38,3 6442 4718 1724 36,5
O2 409 472 -63 -13,3 1320 2456 -1136 -46,3
N2 23672 25521 -1849 -7,2 67555 76667 -9112 -11,9
H2O% 4,1 6,4 -2,3 -35,9 8,8 2,1 6,7 319,0


4.2. AUTOTRANSFORMERS TESTING
In the following the main innovations on ATRs testing required in the new TERNA specification are
described.

Short circuit withstand test
Although most of the manufacturers have a good knowledge of up-to-date calculation softwares,
testing is still the most reliable method to guaranty the ability of a transformer to withstand a short
circuit. This kind of test is important to asses both the soundness of the transformer design and the
quality of the factory process.
Italian ATRs are specified with relatively low impedance voltages to keep voltage drops and reactive
power balance within acceptable limits. Due also to this requirement, a prototype short circuit test is to
be performed by the suppliers of the autotransformers. It should be noted that further to the request in
the new specification of short circuit type test some manufacturers modified their autotransformers
designs, generally reducing the design short circuit admissible forces.
At the time of writing, further to the issuing of the new specification, some tests have been performed
in the two existing laboratories in Europe capable to test large power transformers. The accepted
schemes for short circuit testing are the ones foreseen in [8]. In particular single-phase test
arrangements simulating the three-phase test has been always used for three limbs units, while five
limbs units have been tested in three phase when the testing set up did not allow transformer neutral
earthing
6
Table 5
. Results of short circuit tests performed in year 2011 on Terna ATRs prototypes are shown in
. Results are in line with the expected failure rate [9][10].

Table 5 Short circuit tests results on TERNA autotransformers prototypes performed in year 2011
TYPE MANUFACTURER TEST RESULT
250 MVA, 400/155 kV A FAILED
250 MVA, 400/135 kV B FAILED
250 MVA, 400/155 kV C PASSED
250 MVA, 230/135 kV C PASSED
400 MVA, 400/230 kV B PASSED
250 MVA, 400/155 kV B PASSED
250 MVA, 400/135 kV A PASSED



Recent short circuit tests have shown that to ensure short circuit withstand several design details are
important (such as internal connections between windings and bushings or OLTCs) beside the proper
calculation and manufacturing of windings.



6
In five limbs units overvoltage can occur in case of ungrounded neutral due to neutral instability [11]
9
Sweep Frequency Response Analysis (SFRA)
SFRA test is required to be performed across each winding terminals and each phase terminals. The
terminals not being tested are left open circuited. The test is performed in the 20 HZ 2 MHz
frequency range in the following conditions:
- Complete ATR in factory
- ATR before transport
- ATR after transport
- Complete ATR on site
The transformer manufacturer is due to explain any difference in the measured data with the reference
ones.

Direct measurement of winding temperature by optical fibre system during heat run test
Tested units had maximum hot spot temperatures within specified limits with enough margins. The
test confirmed that uncertainties and approximations in thermal calculations are significant since
deviations up to 5C have been found between calculated and measured temperatures
7

.
Short-duration AC withstand voltage test (ACSD)
ACSD routine test was required, in particular this test is useful to check ATRs series windings ability
to withstand short circuits nearby the ATR on the lower voltage side.
In fact in case of short circuit close to the common winding terminals the following phenomena occur
in an autotransformer [1]:
- an instantaneous overvoltage at the series winding terminals due to the primary voltage
suddenly applied to them
- an overvoltage distribution absolutely not uniform with increase of the voltage induced by the
leakage flux in correspondence to the central turns of the windings
Terna foresees the two schemes of Fig. 10 for ACSD testing of autotransformers. In case of 3 limbs
core the left hand side scheme is recommended while in case of 5 limbs core right hand side scheme is
recommended.

1U 1V 1W
U -0.5U -0.5U
2U 2V 2W
N


1U 1V 1W
U 0 0
2U 2V 2W N

Fig. 10 Schemes for ACSD test on autotransformers. Left: 3-limbs units. Right: 5-limbs units.
The adopted schemes ensure the specified testing voltage U is reached on the phase being tested, while
keeping the voltage on the neutral side within acceptable limits.

Internal arcing test on bushings
Internal arcing test has been required as a type test for investigation purpose. Since there is no
reference standard for this test a testing set-up has been agreed between manufacturers and Terna. One
test has been performed on a 420 kV Oil Impregnated Paper (OIP) bushing at CESI test bay in Milan.

7
Having considered a measurement accuracy within 2C
10
Main test data were: Irms =63 kA; peak factor 2.5; duration 0.5 s. A sketch of the bushing test
arrangement is shown in Fig. 11.

Fig. 11 Sketch of internal arcing test on a 420 kV OIP bushing
The test was successful since no fibre glass tube rupture nor parts ejection occurred. At the time of
writing two other tests are foreseen, both on 420 kV Resin Impregnated Paper (RIP) bushings.

Multiple stress test on hollow insulators bushings
A modified multiple stress test on hollow insulators bushings has been required as a type test for
investigation purpose. The test was required to last 5000 h and was meant to test the composite
insulators bushings long term behavior under multiple stresses (salt, fog, sun light, electric field).
Since autotransformer design lifetime is in the order of 40 years, ageing of composite insulator
bushings was deemed to be necessarily investigated, besides it was necessary to qualify the
compounds used by manufacturers to ensure the quality of the hollow insulators bushing product.
The test is performed in accordance with IEC 62217-2005 - Annex B, with the following deviations
prescribed by Terna:
- Test specimens may be larger than those prescribed by the standard (creepage length 500800
mm), with a creepage length of approximately 1200 mm
- The salt fog with an initial salinity value of 14 g/l (twice the value specified in IEC 62217).
- If more than one flashover occurs (regardless over which test object) the salinity is decreased
according to Table 5. The insulators are washed by tap water and the test resumed with the
new salinity value.
- salt fog generated by means of turbo sprayers mounted at the lower part of the testing
chamber directed upwards, towards the roof of the chamber. This because previous Terna
experiences with similar diameters (CTs) using standard salt fog nozzles were
unsatisfactory (not uniform exposure of specimens surface to salt fog).
- Salt fog calibrated according to IEC 62217 2005 clause 9.3.3.1.1.4, that is by means of
measuring the precipitation per hour over a minimum period of 16 hours. The precipitation
shall be between 1,5-2,0 ml/80cm/h.
- Axial rotation of test specimens every 1000 hours

Table 6 Reduction of salinity, according to new Terna specification, versus number of flashovers during
multiple stress test on hollow insulator bushings
Number of flashovers Salinity (g/l)
0 1 14
2 3 10
4 and more 7

At the time of writing one bushings manufacturer began the test on two different types of hollow
insulators (4 specimens) and first inspection after 1000 h was successful.
11
5. AUTOTRANSFORMERS EMTP MODELING
The need of a reliable transformer model suitable for both steady state and transient analysis has been
met by use and development of finite section approach [12], proposed at first by R.J . Meredith [13].
The model is based on circuital representation of transformer magnetic circuit components (limbs,
yokes, flux shields, tank wall, tank cover) with lumped hysteretic circuit elements, whose data are
obtained on the basis of duality principle between magnetic and electric circuits. Every flux path is
thus represented in the electric domain with a ladder non-linear circuit, whose elements are strictly
linked to geometrical and physical data of the path itself. The linear portion of the magnetic circuit,
related to fluxes outside transformer core, is modeled in SCFTRAN by means of a linear array;
attendant inductances have been calculated by means of Finite Element Method analysis. A capacitive
network, based on FEM capacitance calculation and physical data on similar units has been
superimposed to the magnetic circuit in order to extend the frequency range of model application.
Being the model based on physical quantities, windings and core geometry has to be known or
estimated with sufficient accuracy; for this reason TERNA required the transformer manufacturers to
provide the necessary data. The developed model has been compared with full-scale tests on real
units, showing very good agreement up to 10 kHz, as shown in Table 7, Fig. 12, Fig. 13 and in [12].
The same approach has been successfully extended to different transformers [14].
Table 7 Statistic inrush current calculation for a 250MVA 400kV/135kV ATR
Maximum peak inrush current in pu. of peak
rated current without residual flux
Maximum peak inrush current in pu. of peak
rated current with residual flux
ATP Maximum
value
ATP Maximum
(2) value
Formula [3]

ATP Maximum
value
ATP Maximum
(2) value
Formula [3]

2.25 1.95 1.761.95 3.90 3.60 3.33.66


0,0 0,1 0,2 0,3 0,4 0,5 [s]
-800
-460
-120
220
560
900
[A]
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 0,5 1 1,5 2 2,5 3 3,5 4
Inrush current [pu]
With residual flux
Without residual flux

Fig. 12 Left: Phase currents of a typical inrush transient of a 250MVA 400kV/135kV ATR, simulated with
the described model in the ATP-EMTP. Right: cumulative probability distribution of the peak inrush
current simulated with a statistic study in the ATP-EMTP

Fig. 13 Repetitive impulses on a 250 MVA 400kV/135kV ATR. Left: recording from real test. Right:
simulated in ATP-EMTP
12
6. CONCLUSIONS
Specification is a living document, it is constantly changing to be adapted to changing network
conditions, innovation in materials and standards. Reliability and safety are even more important
drivers for transformers and equipment specification. In the update of a technical specification it is
important to seek cooperation from different manufacturers since transformer reliability is often a
result of a design as close as possible to the natural one. Testing is still one of the major drivers of
the design and has to be properly garrisoned.
The new Terna technical specification of ATRs, whose main innovations have been dealt with in this
paper, represents an attempt to conjugate innovation and reliability.
Feedback from operation will be hopefully obtained as an increase in long term reliability and safety.
ACKNOWLEDGEMENTS
The authors wish to thank Mr Fabio Scatiggio, Responsible of Terna chemical Laboratory located in
Venice for his valuable contribution on DG Analyzers data and their comparison with laboratory data.
BIBLIOGRAPHY

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th
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