Dry-Type or Liquid-cooled Transformer: Which is better?

 “A transformer is an electrical device without moving parts which, by electromagnetic

induction, transforms power between circuits at the same frequency, usually with changed values
of voltage and current.”

Transformers can be classified into three major groups depending on the type of coolant used: liquid
filled, liquid vapor condensation, and dry-type. Over the last 50 years, transformer technology has
evolved. What was once thought to be the best choice of coolant became an environmental disaster
and we have been seeing much information on retrofits and alternatives to PCB-filled transformers.
The three main contenders for replacing PCB-filled transformers are mineral oil, silicone, and dry-
type transformers.

Types of Transformers

In liquid filled transformers, the cooling and dielectric media is a fluid which remains in a liquid
state during the operation of the transformer.

In liquid vapor condensation transformers, core and coils are immersed in a low boiling point
fluid that evaporates, taking transformer heat away as its latent heat and then returns in liquid form
through condensation in the radiator tubes.

In dry-type transformers, air is used as the cooling and dielectric medium. Most are manufactured
with vacuum pressure impregnation in polyester or silicone varnish. For tougher environmental
conditions, VPI epoxy sealed and cast resin transformers have also been developed.
Considerations for Selecting a Transformer

1) Fire Risks – For cost reasons, transformers are located in habitable areas such as buildings
where fire risk has to be minimized. Also, the fire risks in chemical and mining industries necessitate
the need for non-flammable or self-extinguishing equipment. To minimize fire risk, the coolant
should be non-flammable or exhibit a high flash point and low rate of fire propagation.

2) Health, Safety and Environmental Concerns – Since the early 1970s, PCBs have been linked
with many health risks and their use is banned in almost all environmentally aware countries.

When selecting a transformer solution, you must ensure that it uses biodegradable and
environmentally friendly materials. Dry-Type transformers use air as a coolant, making them
preferred over liquid-cooled transformers as there is no risk of leaks or ground/water contamination.

3) Insulation – The most common insulation sheets used in liquid cooled transformers is
cellulose-based paper. Both mineral oil and silicone have good dielectric characteristics, which
makes them suitable for very high voltages. Dry-type transformers are designed typically with 220 C
insulation systems where aramid paper is the major insulation. Dry-type core and coils are protected
against moisture by vacuum pressure impregnation with polyester or epoxy varnishes.
4) Transformer Construction – When searching for a transformer, one constructed with quality
components is critical. Choose a supplier with an established reputation who incorporates only the
best insulation channels, winding combs, spacer sticks and standoff insulators.

5) Performance Comparison – Two critical considerations are transformer losses and size. Even
though dry-type core and coils are larger than the equivalent liquid cooled transformer, overall
dimensions of dry-type transformers are smaller. This is possible as dry-type transformers do not
require space for cooling radiators or transition coils.

The no-load losses of liquid cooled transformers tend to be slightly lower than dry-types. Dry-type
transformers operate at higher temperatures resulting in higher thermal resistance and moderately
higher load losses.

Since liquid acts as a sound absorbent, liquid cooled transformers have a slightly lower audible sound
level.

6) Installation Costs – As there are no radiator banks used in dry-type transformers, it is easy to
terminate bus work in any desired location making coordination with switchgear extremely simple.
Dry-type transformers can be located closer to the electrical load than liquid units, reducing the
length of cabling required. Dry-type transformers generally weigh less than equivalent liquid-filled
transformer so installation costs are lower.

Disconnecting chambers are often required for liquid filled transformers resulting in additional cost.
Liquid filled transformers also require catch basins or curbs to contain the liquid in case of a leak in
the tank. Other additional costs with a liquid filled transformer may include pressure release valves
for hermetically sealed units, additional air space surrounding the unit, and higher insurance
premiums.

7) Maintenance Considerations – Transformers generally require minimal maintenance. Dry-

type transformers require an annual inspection and cleaning of dust while liquid cooled transformers
require periodic inspections for leaks and rust or monitoring of liquid coolants.

There are pros and cons to each type of transformer and your final choice will depend upon your
application and voltage requirements.
Dry vs. Liquid-Filled Power
Transformers
With the variety of high-voltage power transformers available today, clients must
consider a range of factors before selecting equipment. Although transformers
are still categorized depending on whether they use wet or dry dielectric
materials, numerous options are available for fast track power high -voltage
applications. These are a few variables that will help to determine if dry or liquid
filled power transformers are your best choice to use at new or existing sites.

o Maintenance
o Initial costs
o Operating costs
o Operating noise
o Recyclability
o Required capacity
o Voltage losses
o Site selection
o Equipment size
o Safety requirements
o Environmental risks

Liquid-filled Transformers
The wet-type power transformer have been around for nearly a century, but
recent technical advances have improved the overall practicality of these
products. This proven technology is cost -efficient, versatile and easy to maintain.
With an average lifespan of 25 years and a potential service life of 35 years, they
last longer than dry transformers while offering numerous other benefits.
For decades, flammable and environmentally damaging dielectric fluids were a
major drawback. Oil-filled transformers required containment troughs and other
safety precautions. Indoor installations were regarded as risky due to potential
fire hazards and exposure to the die lectric fluids. However, many alternatives to
mineral oil are now available. Natural esters, silicone and hydrocarbons are
recommended alternatives to flammable mineral oil. Some fluids are renewable,
nontoxic and biodegradable.
Advantages of Liquid-filled Transformers

o New dielectric fluids have high flash points and minimal impact on the
environment.
o High-voltage clients can recycle or remanufacture liquid -filled transformers
easily.
o A wet-type power transformer is smaller and more efficient than dry products.
o Liquid-filled transformers are suitable for indoor use because operating noise
is lower.
o These transformers last longer than dry -type products.
o Numerous recycling options are available.

Disadvantages of Liquid-filled Transformers

o Not all wet-type power transformers have the same safety benefits.
o Fluid testing and on-site maintenance is required for reliability.
o Additional protocols are required to manage fire and environmental risks.
o Oil-filled transformers may have lower cooling ratings than so me cast-coil
products.
o Insulating fluids must be appropriate for the application.
Dry-type Transformers
The dry-type power transformer has been traditionally used for low - and medium-
voltage applications in buildings. Improved safety made dry -type transformers
preferred for indoor power distribution. However, these systems have some
drawbacks and limitations.
Air-cooled transformers are larger than liquid-filled products with the same
capacity and voltage ratings, so they are not the best choice for a mobile
substation or a site where space is limited. Air natural transformers have ratings
up to 3 MVA. W ith higher capacities, dry transformers must use air -blast systems
to cool the core and windings. Due to these limitations, many experts recommend
2.5 MVA as the changeover point for dry and wet products.

Advantages of Dry-type Transformers

o Air-cooled transformers are practical for low - and medium-voltage sites.

o Dry-systems eliminate environmental risks related to leaks and spills.
o Cast coils outperform conventional transformers in extreme conditions.
o Some cast-coil products offer extraordinary resistance to surges and short
circuits.
o Air-cooled systems are often preferred at indoor sites where safety is a
priority.

Disadvantages of Dry-type Transformers

o Dry-type transformers are more expensive to purchase and to operate.

o Repairs are difficult, and end -of-life recycling is limited.
o Coils can pose fire risks when they are not properly cleaned.
o Annual maintenance usually requires deactivation and downtime.
o Electrical losses associated with dry transformers are significantly higher.
o Heat generated by losses must be controlled with a cooling system.
o Dry transformers have high operating noises, so they are not suitable for all
indoor applications.
The advantages and disadvantages of each option depend on the application as
well as the client’s budget, safety requirements and existing infrastructure.