Carbon-Neutral-Ready Solution for 330 kV–500 kV EHV power transformer

Green Grid Core Assets Aligned with Indonesia’s 2060 Net-Zero Commitment

1. Project Background

• High operational losses: IE2/IE3 efficiency levels result in annual no-load losses of 180–220 kW (for a 1000 MVA unit), equivalent to ～1,200 tons of CO₂ emissions per year;
• Non-biodegradable insulation: Mineral oil poses environmental risks upon leakage or decommissioning, violating PLN’s updated ESG procurement guidelines;
• Lack of carbon transparency: Inability to provide verifiable carbon footprint data hinders access to green financing and compliance with international mechanisms like the EU CBAM.

2. Solution

2.1 Full-Lifecycle Low-Carbon Material System

• 100% bio-based insulation: Natural ester oil (derived from palm kernel or rapeseed byproducts) + recycled aramid paper composite insulation, with >98% biodegradability and 90% lower fire toxicity;
• Low-carbon structural components: Grain-oriented electrical steel produced via hydropower (carbon intensity <0.8 tCO₂/ton), tank fabricated from stainless steel with ≥70% recycled content;
• Halogen-free flame-retardant parts: All seals, cables, and auxiliaries comply with RoHS 3 and IEC 62430 eco-design standards.

2.2 Extra-High-Efficiency Design

• IE4+ Extra-low-loss core: B10 high-permeability silicon steel with laser-welded wound core reduces no-load losses by 25% below IEC 60076 baseline;
• Intelligent load-adaptive cooling: ODAF system dynamically adjusts fan/pump speed based on real-time load and ambient conditions, cutting annual energy use by an additional 8%;
• Annual energy savings: A single 500 kV / 1000 MVA transformer saves ～120 MWh/year—equivalent to 85 tons of CO₂ reduction.

2.3 Circular & Recyclable Architecture

• Modular disassembly design: Tank, windings, core, and bushings feature quick-release connections, reducing end-of-life dismantling time by 50%;
• Closed-loop material recovery: Partnerships with local recyclers (e.g., Astra Recycling) ensure >95% recovery of copper, steel, and oil;
• Zero-landfill commitment: End-of-life handling complies with ISO 14001 and Indonesia’s Ministry of Environment Regulation No. P.22/2023.

2.4 Carbon Digital Passport & ESG Integration

• Blockchain-enabled carbon tracking: Each transformer receives a unique digital ID at factory exit, recording verified emissions across raw materials, manufacturing, transport, and operation (per ISO 14067);
• Direct integration with PLN ESG platform: Automated annual carbon performance reporting to PLN’s sustainability dashboard;
• Green finance compatibility: Meets eligibility criteria for ADB and World Bank “Green Grid Loan” programs and supports third-party carbon audits.

3. Implementation Results

3.1 Environmental & Efficiency Gains

• Full lifecycle carbon footprint reduced by 65% (from 1,850 tCO₂e to 650 tCO₂e over 30 years);
• No-load losses ≤135 kW (IE4+), 25% better than IEC standard;
• Sound level ≤68 dB(A), compliant with urban/suburban noise regulations.

3.2 Lifecycle Cost & Compliance Advantages

Note: In PLN’s 2024 green procurement pilot, this solution received a 15% bidding score premium.

3.3 Localization & Standards Leadership

• Established a “Green Transformer Innovation Center” in Bandung, co-developing localized bio-based insulation with Institut Teknologi Bandung (ITB);
• Technical specifications incorporated into PLN’s Green Transmission Equipment Procurement Guidelines (2025 Edition) as a mandatory low-carbon threshold;
• The first batch of 500 kV carbon-neutral-ready transformers has been deployed on the North Sumatra Geothermal Evacuation Corridor, enabling zero-carbon transmission of 500 MW clean power.

4.Conclusion