The number and capacity of transformers and power substations have increased in proportion to the rise in electricity generation, a deputy manager at the state-affiliated Power Generation, Distribution and Transmission Company (Tavanir).
“The capacity of transmission and distribution substations has reached 173,000 megavolt amperes and 119,000 MVA respectively,” Hashem Alipour was also quoted as saying by ISNA.
“Iran's installed power generation capacity is 85,000 megawatts and the national power grid is equipped with 7,000 transformers, including distribution, step-up, step-down, medium and large gas-insulated equipment, whose capacity has exceeded 290,000 MVA,” he said.
“Iran has achieved self-sufficiency in the production of transformers and companies like Iran Transfo export their products to Asian and African countries.”
Referring to the Eighth International Transformer Conference to be held in Tehran on Oct. 21, Alipour noted that ITC2021 is the most important annual event in the transformer industry in Iran.
“More than 500 transformer experts from all over the world, including Ukraine and Germany, have expressed their willingness to participate in this event and share their know-how about the latest developments in this sector,” he added.
ITC is organized by the Energy Ministry and Iran Transformer Magazine and ITC2021will primarily focus on the design, production, installation, security and maintenance of advanced transformers. Companies active in the industry will display their goods and services.
A transformer is a passive electrical device that transfers electrical energy from one electrical circuit to one or more circuits.
Transformers are used for increasing or decreasing alternating voltages in electric power applications and for coupling the stages of signal processing circuits.
Power Sector Challenges
Despite all accomplishments in transformer industry, the power sector is facing challenges, including severe shortage of funds, lack of investment to build new facilities and worn-out equipment such as transformers, Mostafa Rajabi Mashhadi, a Tavanir spokesman, said.
“If the current trend persists, we may be forced to import electricity within 10 years,” he said.
“Of the total transformers in the grid [7,000], 50% are rapidly aging and need to be either replaced or repaired, but financial constraints cause maintenance operations to be postponed.”
The cost of installing new transformers has risen, resulting in aging infrastructure because funding is scarce due to the difficult economic conditions.
“Appropriate solutions have been developed in many countries to improve the life expectancy of transformers. We are working to find ways to do likewise with the help of academia and industry stakeholders,” he added.
Average life expectancy of a transformer is about 25 years, though some in Japan have been in service for more than 50 years.
As the world’s population swells, the need for power is increasing rapidly.
According to the International Energy Agency, global energy demand will grow by 30% between now and 2040, with electricity consumption accounting for 40% of the total increase.
But continued reliability of this flow of electricity into businesses and homes depends on the health of the system that supports it. This includes all links in the electrical power train—circuit breakers, wiring and transformers.
Aging Devices
According to Arash Aqaeifar, a member of Iran Electricity Industry Syndicate, as prices of transformers have shot up 3.5 times compared to last year, replacing the old and aging devices will cost at least $1 billion.
The Energy Ministry owes $2.5 billion to private power producers and other contractors.
“Buying new transformers is not a priority, so instead of replacing the old gadgets, provincial electricity distribution companies should come up with effective solutions such as modern maintenance procedures, status monitoring and timely repairs,” Aqaeifar said.
The industry player said maintenance plans have not worked as expected, as machinery and equipment are usually used up to breaking point and then repairs are undertaken.
“This policy must be rewritten and instead condition-based maintenance should be the norm,” he added.
Condition-based supervision monitors the actual condition of a capital asset to decide what maintenance needs to be done. It dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure.
Aqaeifar noted that such measures reduce costs in the long run and help reduce power loss in the distribution network.
Referring to locally-made distribution transformers, he said, “Foreign engineers and power experts who visit factories in Iran say the country has the ability to manufacture a variety of devices in compliance with global standards. Where we need improvement is in the repair sector.”
Aqaeifar regretted that much of the repair work on transmission equipment is carried out in non-standard workshops that do not uphold standards and do not carry out stringent tests to ensure the quality of the repairs, which have led to a high level of accidents.
