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Te c h n i q u e s
Tr a n s f o r m e r F a i l u r e R e d u c t i o n
Transformer
Failure Reduction Techniques
At Dr. NTTPS
Project work
Submitted
By
Thanubuddi.Gopinadh Reddy
Tirupathi.Hemanth kumar
Valluru Udai sai
GUIDED BY
CH. RANGA RAO A.D.E
Andhra Pradesh
Power Generation Corporation Limited
Training Institute, Dr. NTTPS
Ibrahimpatnam-521456
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ACKNOWLEDGMENT
T.Gopinadh Raddy
T.Hemanth Kumar
V.Udai Sai
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CERTIFICATE
This is to certify that the Mini Project Report entitled Transformer Failure Reduction Technique
at Dr.NTTPS being Submitted by Tirupathi Hemanth Kumar (312177114145), Valluru Udai Sai
(312177114148), Thanubuddi Gopinadh Reddy (312177114144) in, partial fulfilment of the
award of the Degree of Bachelor of Technology in Electrical and Electronics Engineering to the
Sir C R Reddy college of Engineering is a record of Bonafide work carried out by them under
my Guidance and Supervision.
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Te c h n i q u e s
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I. Introduction
II. Construction and Parts of Power transformers
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ABSTRACT
Transformers are exclusively used in electric power systems to transfer power by
electromagnetic induction between circuits at the same frequency, usually with changed values
of voltage and current. There are numerous types of transformers used in various applications
including audio, radio, instrument, and power. Now we deal exclusively with fault reduction
techniques of power transformer along with the protection and the pre commissioning tests
conducted on power transformers.
An electrical installation work is complete only when the prescribed pre-commission
tests are conducted on different components and the test results are found satisfactory. By
carrying out the pre-commission tests, it is ensured that different components of the system have
their declared specifications/characteristics and also the system is fit for safe and reliable
operation. The pre-commission tests are broadly classified into pre-commission checks meant for
initial inspection covering visual inspection for damages, quality of workmanship, mechanical
operation etc. and the pre-commission tests meant for measurement or testing of various safety
parameters like insulation resistance, earth resistance, breakdown voltage of insulation, relay
characteristics etc. In addition to describing the procedure for checks and tests, attempt is also
made to give essential information about the specifications and characteristics of different parts
and components. For measurement of insulation resistance and earth resistance, detailed
description of the measuring instruments, test procedures and interpretation of the test results are
given on Transformers. While carrying out the measurement of insulation resistance and earth
resistance of other parts and components, we must have better understanding of the instruments,
test procedures and interpretation of the test results. Before carrying out the pre-commission tests
it is always advisable to refer to the manufacturers' instructions. Products of different
manufactures may have special features and characteristics and it is necessary to have a good
knowledge of these special features before carrying out the tests.
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CHAPTER I
INTRODUCTION
Transformers transfers electrical energy between circuits completely insulated from each
other. During this transfer of energy voltage level may be stepped up/down (depending on the
tums) with consequent decrease/increase currents from primary to secondary windings, thus
maintaining the power transferred constant. Therefore when voltage is stepped up the current is
stepped down. This makes it possible to use very high voltages for transmission lines resulting in
a lower current. Higher voltage and lower current reduce the conductor size, transmission line
losses and improves the voltage regulation as well. Transformers have made possible economic
delivery of electric power over long distances.
In our country the electrical energy is usually generated at 11 or 15.75 or 2l kv, stepped
upto l32;220;400 or 765 kV with the help of step up transformers for transmission and then
stepped down the voltage to ll kV for feeding distributing transformers stepping down the
voltage further to 400/230 volts for the consumer uses.
PRINCIPLE OF TRANSFORMER:
The physical basis of the transformer involves the Faradays laws of electro magnetism in
which an alternating flux induces voltage in the coil and Lenz Law which states that the effect
produced will oppose the cause. It consists of two inductive coils which are electrically separated
but magnetically linked through a path of low reluctance by mutual induction. If one coil is
connected to the source of alternating voltage an alternating flux is set up in the laminated core
most of which is linked with the other coil produces mutually induced emf. If the second coil
circuit is closed, a current flows in it and so electric energy is transferred from the primary to
secondary coil.
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CHAPTER ll
CONSTRUCTION and PARTS OF TRANSFORMER
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The use of steel in magnetic circuit introduces iron or core loss but ensures a high
permeability of the magnetic circuit. Because of the high permeability the magnitude of exciting
current necessary to create the required flux in the core is small. The presence of steel core
causes 100% of the magnetic flux created by the primary o be linked with secondary. The
magnetic frame of the transformer is built up of laminated hot rolled or cold rolled oriented steel
consisting of 3.5% silicon. The higher content of silicon increases the resistivity of the core,
thereby reducing the eddy
current core loss.
As the flux in the core is pulsating one ,it becomes necessary that the transformer cores
are laminated and the laminations should be insulated and made as thin as possible in order to
minimize the eddy current loss.
2.3. Winding Assembly:
The most important features that the windings of a transformer should possess are:
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a) The winding should be economical both as regards initial cost, with a view to the market
availability of copper
b) The efficiency of the transformer in Service
c) The heating conditions of the windings should meet standard requirements
d) The winding should be mechanically stable in respect to the forces appearing when sudden
short circuit of the transformer occurs
e) The winding should have the necessary electrical strength in respect to the over voltages.
2.4 Bushings:
Bushings are incorporated to bring the Extra High voltage winding terminations through
the cover of the transformer tank. Variety of bushings used for various voltage classes were
mentioned below:
Voltage
Type of bushing
Class
<33KV
Porcelain bushing
<l32KV
>l32KV
Oil impregnated
Paper (OlP) Condenser
Bushing
The oil filled bushing consists of hollow porcelain cylinder with a conductor through its
center. The space between the conductor and the porcelain is filled with oil, the dielectric
strength of which is greater than that of air
The OIP Condenser bushing is constructed of thick layers of bakelized paper alternating
with thin graded layer of tin foil. The result is a series of capacitors formed by the conductor and
the first tin-foil layer, the first and second tin foil layers ...and so on. The bakelized paper and the
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tin foil are arranged in such a way that the capacitances of the capacitors and hence dielectric
stress across each capacitor are uniform throughout the radial depth of the insulator.
The last tin foil of the insulating medium of bushing is terminated to Voltage tap called as
Tan () tap of bushing used to measure the Capacitance and dissipation factor of the bushing.
l. Oil impregnated core
2. Center metal tube
3. Fixing flange
4. Porcelain upper
5. Porcelain lower
6. Gaskets
7. Springs
8. Expansion bowl
9. Cable bolt
10. Air releasing screw
11. Test tap
12. Top terminal
13. Oil filling plug
l4. Oil sight glass
15. Base plate/stress shield
16. Upper arcing horn
17. Lower arcing horn
18. Nitrogen filling plug
NOTE: The Tan () tap must always be earthed by the screwed on cap and should never be
removed during operation
Oil in the transformer construction serves the double purpose of cooling and insulatmg.
The heat is produced from the metal of the transformer passes through the insulation and raises
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the temperature of oil and is then conducted either through the radiators of the tank to the
surrounding air by means of cooler fans.
Transformer oil has to fulfill certain specifications:
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Type of
Description
Cooling
ON
Natural on cooling
AN
ONAN
ONAF
OFAF
2.7 Conservator:
The oil level of a transformer changes with the changes in the temperature of the oil
which in turn depends upon the load on the transformer. The oil expands with the increase in
load and contracts when the load decreases. Large transformers are also liable to overloads which
may overheat the oil and consequently there is a sludge formation if air is present. This causes
the vaporization of a part of the oil. The oil vapours forms explosive mixture with air that ignites
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and may cause a considerable damage. For these reasons it is necessary to prevent the oil from
having contact with air as well as the moisture. For this purpose conservators are employed
Conservator is a small auxiliary oil tank that may be mounted above the transformer and
connected to the main tank by a pipe. Its function is to keep the main tank of the transformer
completely filled with oil in all circumstances despite expansion or contraction of oil with the
changes in the temperature. Conservator is partly filled with oil and absorbs the expansion and
contraction of oil and keeps the main tank full of oil. It also reduces the rate of oxidation of oil,
partly because less oil surface is exposed to air and partly because of the reduced temperature of
the oil exposed to air. Thus the sludge formation is considerably reduced.
Normally the capacity of conservator should be approximately 10-l2% of the oil volume
of the main tank. The conservator tank is usually insulated on the low voltage side of the
transformer tank above the level of the transformer cover on supporting frame. A small pipe
connection between the gas space in the expansion tank and the cover of the transformer tank
permits the gas above the oil in the transformer to pass into the expansion tank so that the
transformer main tank will be completely filled with the oil
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Construction:
The On load Tap changer consists of a high speed resistor transition diverter switch, Tap
selector switch, driving mechanism and external driving shaft.
Diverter Switch:
The driver switch consists of contact compartment, transition resistors, and spring acting
mechanism. A perfect oil tight structure is employed between diverter switch and the transformer
tank, to prevent mixing of oil outside the driver switch chamber with the oil inside, which will be
contaminated due to switching operations.
The tips of arcing contacts are made of copper-tungsten alloy which has got excellent are
resisting characteristics. Current limiting resistors consist of nickel chromium wire wound on
heat resisting bobbins held at both ends by the insulating plates.
Oil in the diverter switch is maintained under a seperate conservator head. The pipe
leading to the conservator from the diverter switch chamber is filled with a gas and oil operated
relay, the normally open velocity actuated contact of which is connected to trip circuit of the
transformer.
Selector switch:
The tap selector operates under no load condition and therefore, there need not be any
fear of arc generation, damage of contacts or deterioration of main transformer oil.
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The tap lead Wires rom the winding of the transformer are brought and terminated at the
fixed contacts of the tap selector. Tap change operation requires two rotary switches per phase.
The odd numbered tappings are connected to one switch and even numbered tappings to the
other in such away that the two switches come into use alternately.
The selected odd and even numbered contacts are fitted on either insulating bars mounted
vertically to diverter switch chamber.
Principle of Operation:
The odd moving contact is on tap 7 and even side contact on tap 8 of the tap selector. The
odd and even collector contacts are connected to the diverter switch contacts O&E respectively.
Since Diverter switch is making contacts at O (Odd) flow of current will be through tap 7.When
a signal is given to the driving mechanism for changing the tap from 07 to 06, it will first operate
the even contact of tap selector from tap O8 to 06 without changing the position of odd contact.
Simultaneously with the operation of the tap selector, the spring mechanism, which is the energy
accumulator mounted on the top of the diverter switch will be charged.
CHAPTER III
A power transformer is subjected to various faults through-out its life time. The
protection of power transformer should be effective enough to isolate the power transformer
from internal and external faults of the transformer minimizing the fault clearing time as well as
increasing the life time of transformer. The protection incorporated for an oil immersed type
power transformer is as follows
Buchholz relay:
The gas actuated Buchholz relay is a protective device designed to give indication faults
occurring in oil field conservator type transformers, on load rap changers. All types of faults
occurring within an oil field transformers are accompanied by gas generation. This phenomenon
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has been effectively utilized by buchholz relays to provide the best known protection
arrangement for transformers.
The high sensitivity and capability of the relay has been successfully proved to detect
faults stated below:
Construction:
The relay
housing detachable
box, toughened glass
tripping device with
and
valves
for
setting. The alarm
device consist of 2
aluminum buckets
the tilting of these
mercury switches.
comprises of flanged
front cover, terminal,
windows, alarm and
mercury
switches
venting and relay
and the tripping
counter
balanced
which are hinged and
buckets operates the
Air release
the top of the
the trapped air and
samples. One more
introducing air inside
the gas volume and surge tests.
valve is provided at
housing for releasing
for taking out the gas
valve is provided for
the relay to carry out
The front inspection glass is provided with scale to allow reading the accumulated
volume of the gas and observe color of the gas for fault analysis.IN Service/Test lock can be
selected in the form of movement of red indicator on the reading scale.
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Operation:
When any fault occurs the bas formation takes place in the transformer and accumulates
in the Bucholz relay on its way to conservator in consequence, oil level in the relay drops and the
upper counter balanced and hinged bucket moves down tilting the mercury switch to activate
alarm circuit. If the oil level drops further lower bucket also operates and closes the contact for
tip circuit.
Commissioning:
While mounting the relay care should be taken to see that the arrow on the relay is
pointing towards the conservator and the air vent valve at top. Ensure that pipe ascends to
conservator at angle between 1 -9 as per specification of manufacturer & the relay is kept in
service position.
After installation of the relay and when the transformer has been filled with oil up to the
oil conservator the air trapped in the gas chamber must be allowed to escape through the air vent
valve at top.
Gas Analysis:
Depending on the nature of fault i.e. with winding, paper insulation, oil flashover in the
transformer the nature of gases formed will vary. The type of fault formed in the transformer can
be detected by diagnosing the gases collected in the Bucholz relay.
Gases collected in the Bucholz relay is allowed to pass through a test tube filled with
Silver Nitrate (AgNO3) solution by releasing the Air release plug .The precipitate formed on the
walls of the test tube is observed for diagnosing the fault in the transformer as stated below.
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Nature of gas
Probable fault
Flammable
Yellowish
inflammable
of wood insulation
Decomposing
Dark
grey
inflammable
oil or due to excessive
Flash over in
Overheating
or
core.
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OPERATION:
The protective relay is energized by an oil surges from the tap changer to the oil
conservator only. The oil flow operates the flap valve being trapped in to the OFF position. At
that moment the contact is actuated, the circuit breakers are operated and the transformer is
switched OFF the line. It is not energized by the tap changer being subject to nominal load or
permissible overload.
Commissioning:
The protective relay has to be mounted in the pipe leading from the tap changer head to
the oil conservator. The relay must be located as near as possible to the tap changer head. Pipe
work rising to the conservator should be arranged at an angle of 5 above the horizontal to ensure
the effective operation of the protective relay with the test push buttons in the top of the housing.
The arrow on the terminal box cover must point towards the oil conservator.
Pressure relief valve:
The pressure relief valve is protective device for oil filled transformer. It is designed to
relieve the excessive pressure which may build up by fault or an arcing inside the transformer
tank.
S. No
Description
1.
Base
2.
Gasket
3.
O Ring
4.
Diaphragm
5.
Cover
6.
Springs
7.
8.
Lock nut
9.
10.
Visual indicator
11.
Stopper
12.
Visual indicator
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The diaphragm resets to its original position as soon as the pressure inside the tank drops
below the set limit.
Oil and Winding Temperature Indicators:
The temperature indicator is used as an Oil temperature Indicator (OTI) or as a Winding
Temperature Indicator (WTI) for the protection of liquid immersed power transformers.
Construction:
A Sensing bulb (20) a measuring bellow (2) and a small bore capillary tube (19)
connecting the two form the measuring system. A second bellow called as compensating bellows
connected with a second capillary (19) running parallel to the first capillary and terminated at the
head of the bulb form the temperature compensation system. The bellows are linked to a
compensating lever (17) in such a manner that the effect of ambient temperature changes on the
capillary line and measuring bellows is compensated. The movement of measuring bellows is
related only to temperature being measured by sensing bulb. This movement is amplified by the
link and lever mechanism (4) which directly drives the rotating disc (l3) carrying the control
switches and pointer indicating the temperature.
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A heater coil (3-Bellows heater) is fitted around the measuring bellows (2) and supplied
from a current transformer mounted in the busing of the transformer. The heater coil indicates the
hot spot temperature of the windings over top oil temperature for a given load. The measuring
bellows reacts to this simulated temperature rise in addition to the top oil temperature measured
by the sensing bulb and the instrument functions as WTI indicating the temperature of the
winding
An adjustable shunt resistor is provided for shunting a portion of current through the
heater coil to obtain precise thermal image. All internal electril contact of mercury switches are
wired to terminal blocks.
Switches are identified by marking 5 S1, S2, S3, S4 on them. Terminal no's wired to each circuit
are detailed below:
Terminal No's
Switch No's
Wired to
Department Of Electrical and Electronics
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1, 2
Sl
Alarm
3, 4
S2
Tip
5, 6
S3
Cooler Control-l
7, 8
S4
Cooler Control-2
9, 10, 11
The float is hinged and swings up or down when oil level raises or falls. This rise or fall
rotates the bevel gear and thus the pinion of the gear assembly. The pinion in turn rotates the
driving magnet inside the conservator. The follower magnet positioned outside carries a pointer
and a cam. The pointer reads oil level and the cam set 0 operate the mercury switch at a
predetermined low level.
Differential Protection:
Differential protection also called as unit protection, is the Main Protection of Power
Transformer as it faults on the unit it is protecting, which is situated between the CTS. The relay
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therefore can be instantaneous in operation, as it does not have to coordinate with any other relay
on the network. This differential protection, as its name implies, compares currents entering and
leaving the protected zone and operates when the differential current between these currents
exceed a predetermined level.
The type of differential scheme normally applied to a transformer is called the current
balance or circulating current scheme as shown in Figure *** below:
Fig:
scheme
faults
Circulating
current
in the case of through
The CTs and relay were connected in such a way that the relay is operated by circulating
current between secondary of CT. Differential current does not arise and hence the relay does not
operate for external faults as shown in the fig.***
Under internal fault conditions (i.e. faults between the CTs) the relay operates
Since both the CT secondary currents add up and pass through the relay as seen in Fig: *** 111)
Fig: Circulating
Unfortunately the circulating current protection mentioned above may operate even for
through faults due to the following factors which need careful consideration:
(a) Transformer vector group (i.e. phase shift between HV and LV)
(b) The possibility of zero sequence current entering the relay may destabilize the
differential for an External earth fault.
(c) Magnetizing in-rush currents (from one side only)
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Most transformer differential relays have a bias slope setting of 20%, 30% and 40% as
shown in fig ***. The desired setting is dictated by the operating range of the OLTC, which is
responsible for the biggest current unbalance under healthy conditions;
Over Current and Earth Fault Protection:
Over current and Earth Fault protection is the Back Up protection for power
transformer. Unlike Differential Protection which operates for internal faults (between CTs),
Over current protection will operate even for through faults, above the pickup current setting,
thus isolating the transformer from feeding the fault.
Over current and earth fault protection is provided on both HV and LV Side of the
winding and hence proper time gradation is to be provided for relay operation starting from the
feeders connected to LV side of transformer to the Over Current protection on HV Side, to avoid
complete black out for an fault on feeder connected to LV Side of transformer.
To achieve selectivity and coordination by time grading two philosophies are
available, namely:
1. Definite time lag (DTL), or
2. Inverse definite minimum time (1DMT).
(1).Definite Time Characteristic:
The relays are graded using a definite time interval of approximately 0.5 s. The relay R3
at the extremity of the network is set to operate in the fastest possible time, whilst its upstream
relay R2 is set 0.5 s higher. Relay operating times increase sequentially at 0.5 s intervals on each
section moving back towards the source as shown in Fig.***
Draw Back:
The problem with this philosophy is, the closer the fault to the source the higher the
Fault current, the slower the clearing time exactly the opposite to what we should be trying to
achieve.
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IEC Standard Normal Inverse 3.0 sec curve is used for the Over current and Earth Fault
protection of power transformer and the characteristic curve can be expressed as:
Relay Operating time (in sees) = (0.14*TL) / (PSM0.02 -1)
Where TL=Time Setting Multiplier adopted.
PSM=Plug Setting Multiplier =
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For protection of power transformer proper time gradation is to be provided for I-1V and
LV side IDMT relays.
For an HV winding fault the UV breaker is tripped but the fault can continue to be fed via the
Low voltage side, the back-feed coming from the, adjacent transformer(s) as shown in Fig
****where the LV
Protection is set high to 'coordinate with downstream requirements. Thus, the Transformer
Protection should always trip both HV and LV circuit breakers for operation of HV Side IDMT
Relay as shown in Fig: ****
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CHAPTER-4
PRE COMISSIONING TESTS OF A POWER TRANSFORMER
Introduction:
Various tests are performed on power transformer at various stages starting from the first
stage of i.e. transformer construction to the commissioning stage at the site. The tests conducted
can be classified as Type Tests, Routine Tests, etc. The test results obtained for various tests at
the time of commissioning were used as reference values for diagnosing the transformer during
any faults in the life time of transformer. Among various tests, Routine tests performed on power
transformer were mentioned in detail.
Routine Test performed on Power Transformer at site at the time of commissioning
includes:
Configuration
HV-LV
HV-body
LV-body
60 sec
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IU-IV Phase
415Volts
IU phase
--------
IV-IW phase
415 Volts
IV phase
--------
IW-IU phase
415 Volts
IW phase
--------
Similarly apply 3 Phase, 4 wire 415 volts AC from LV side & keep HV, neutral isolated.
Measure magnetizing current in u, v &w phases of LV winding.
Voltage applied
..
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UN
VN
WN
Supply
Measured voltage
Measured voltage
Measured voltage
Measured voltage
Supply
Measured voltage
Measured voltage
Supply
Test Arrangement:
Short circuit test is conducted by shorting the LV windings and applying the 3Ph supply
to HV winding. Ensure that the LV Winding phase terminals are shorted to its corresponding
neutral and apply 3ph, 4 wire 440V AC supplies to the HV winding and measure the HV & LV
winding line currents.
Short Circuit Test
HV Winding cut-rents (Amps)
____
____
____
N
____
u
____
v
____
____
____
The measured currents in HV and LV windings should be in agreement with calculated values for
a particular applied voltage. )
HV Current at Applied voltage= (Rated HV Current/Impedance in volts)* Applied Voltage
Where Impedance volts= (% Impedance* HV Volts)/100.
NOTE: (1) Conducting the short circuit test by shorting the HV winding and applying the 3ph
supply to LV winding may result in heavy currents on LV side which cannot be supplied by the
LT 3ph Source.
(2)Measurement of currents during short circuit test should be done quickly as the magnitude of
currents produced would be of large value.
(6).Vector Group Test:
Vector group test is conducted to check the HV and LV windings arrangement was in agreement
with the vector group specified by the manufacturer. Various test patterns are to be followed for
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various vector groups. The following test arrangement is to be followed for testing a power
transformer having YNynO vector group.
Test Arrangement:
Connect the primary and secondary of one phase together and then apply 3Ph,
4wire 440Volts AC supply to the HV winding of power transformer and measure thd voltages as
specified below. ,
Supply applied on HV Side:
1U1V:
IV1 W:
IWIU:
Sl.NO
Verifying conditions
1U2n-I-IN2n=lUIN
1 W2w= I V2v
1 W2w<1W2v
measured values
Tap
No
HV
1 to 25
LV
Phase U
Phase V
Phase W
The test results obtained from this test should be in agreement with the factory test
results.
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NOTE: Winding resistance test is to be conducted after conducting all the above mentioned tests
failing which the test results occurred would be erratic due to core magnetization in a particular
direction with the injected DC Current during this test.
Transformer Failures
To devise or strategy in order to control the transformer failures, it is very
essential to understand the complete product fundamentally by knowing its internal construction
details, the mechanism of manufacturing each internal component, material composition and
parameters of process required to be controlled while manufacturing alone with quality aspects
during material procurement, manufacturing assembly and testing. The above process is to be
followed by important aspect of transportation, site storage, care during erection and
commissioning and finally the critical requirements during operation and maintenance phase of
the equipment Since large number of transformer failures was taking place it became important
to study and analyze every individual failure through feedback mechanism and take the
necessary corrective action. In the above process the failure data was generated and described in
the subsequent paragraphs
Reasons for Failure
Insulation failure due to aging
Failure due to short circuit forces
Failure due to Design deficiencies
Failure due to manufacturing defects
Failure due to Maintenance problems
Failure due to Quality Problems
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variation in current. These changes can be due to normal changes in load current or due to faults
in the system externally to the transformer or switching operation of the transformer itself.
In transformers the axial flux in limbs interacts with the current in the windings to produce radial
forces in the windings. Whether these forces create hoop stress or compressive stress in windings
depend upon the polarity of the respective windings chosen. This is, by convention, in such a
way to generate hoop stress in the outer winding and compressive stress in the inner windings
In addition to above forces, axial forces are generated in the windings due to two factors
Leakage flux
Difference in the heights of the windings
All efforts are made in the design itself to keep the leakage flux as low as possible. Symmetry in
the windings is due to the difference in no of turns, insulation and cross section of the conductors
this asymmetry is made up by using permali wood blocks, insulation packing etc. and symmetry
is achieved during assembly stage in the shop floor. However, since the insulation paper is used
in the transformer shrinks in course of the time while transformer is in service, it can give rise to
asymmetry also any deficiency ignored during manufacturing makes the possibility of axial
forces in the transformer windings. the disturbance caused due to axial forces cause further
asymmetry in the windings resulting into increase in the intensity of subsequent axial forces
every time I thus any slackness in the windings has a compounding effect on the axial forces To
prevent the movement of the windings explained as above and thus to ensure the trouble free
operation of the transformers during the entire expected life, coil clamping arrangement is
provided the clamping is such as not to allow even minor movements of the windings which
otherwise may cause so damage to the windings insulation at a vulnerable points the clamping
arrangements in general consist of circular wooden blocks placed on top of the windings force
applied over this blocks using screws supported from yoke structure the arrangement ensures that
clamping of the windings is uniform all above the periphery.
For checking mechanical strength of a transformer to withstand short circuit forces, presently
adequate facilities are not available in the country. A transformer designer takes care of this
aspect based on certain guidelines as per NEMA/IEEE standards. However the short circuit
testing has been incorporated in the transformer specifications as type test for which the large
capacity transformers are being sent abroad where such facilities are available.
Failure due to Design deficiencies
While designing a transformer mainly two aspects need to be tackled very carefully.
These are dielectric length of the transformer and mechanical strength of the support structure so
that various parts and windings tlo not get dislodge or deformed due to axial and radial forces
produced during service. For ensuring the dielectric strength the transformer is subjected to
various voltage stress tests in shop floor these test are
f) Induced Over Voltage withstand test
g) Lightning impulse test
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sludge formation thereby causing the oil properties to deteriorate very fast. The dissolved oxygen
also plays major part in accelerating the insulation aging. Thus, any air ingress is to be avoided
and should be attended at the earliest.
Another crucial aspect to avoid sudden transformer failures is to take proper care of bushings.
The high voltage condenser bushings are built up around a center pipe which is called the core.
The insulating paper is wound around the core under heat and pressure. During winding of paper
insulation on the core, the grading layers of aluminum are integrated to achieve uniform voltage
distribution. The core is then dried under heat, vacuum and oil impregnation is done. The
impregnated core is assembled in outer shell consisting of lower and upper hollow porcelain,
mounting flange and top conservator. The entire bushing assembly is then sealed and. filled with
oil.
All condenser bushings are provided with a test tap, which is used for measurement of
capacitance and tan delta. When the cap of this test tap is screwed on, the tapping from the outer
layer of condenser is earthed. This earth connection is very critical and in case it is broken, the
entire voltage distribution across the condenser bushing, will get disturbed and lead to bushing
failure.
The tan delta and capacitance values of the bushings are to be monitored annually and the limit is
0.7% maximum for tan delta value for oil impregnated paper (01P) bushings and maximum
allowable capacitance is 110% of shop test results.
Quality Problems
Certain components used in the transformer, if not of the desired quality, can
result in serious damage to the transformer. Terminal bushings, copper conductor and OLTC are
main components which have resulted into failures during the past. Special care is mechanism
for the bought out items used in transformer manufacturing pan from this, process control for
stabilization of the coils during manufacturing to achieve uniform height of each coil is very
important. As explained previously, any discrepancy in the heights of different coils in a
transformer will result into large axial forces and eventual failure during service.
STEPS TO REDUCE TRANSFORMER FAILURES
To reduce transformer failures, various steps were taken at different stages
covering the aspects of deficiencies during manufacturing quality control, finalization of design,
operation and maintenance etc. The details of such steps taken in past by NTPC are as follows:
BASIC INSULATION LEVEL (BIL)
For 400 KV class transformers, the earlier specified B1L was 1300 KV which
was increased 1425 KV. long with this the switching impulse of 1050 KV has been increased to
1180 KV and induced over voltage with partial discharge measurement has been changed from
420/364 KV for 5 seconds/30 minutes to 460/510 KV for 5 seconds/1 hour. With this DEL, the
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manufacturer shall be forced to keep larger internal clearances and eventually the safety margins
shall increase.
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