Govt.

of National Capital Territory of Delhi

PUSA INSTITUTE OF
TECHNOLOGY
PUSA, NEW DELHI- 110012

Submitted by: Deepesh

3rd Year, 6th Semester
B. Voc (Power Distribution Management)
 Report on
Transformer
 CONTENT

S. No Particulars Page No.

1. Introduction 04
2. Construction of Transformer 05
3. Working Principle of Transformer 06
4. Types of Transformer 07
5. Components of Transformer 09
6. Advantages & Disadvantages of 19
Transformer
7. Failure & Causes of Transformer 20

8. Troubleshooting Transformer in Power 26

Substation

9. Investigation into causes of failure of 31

transformer
Introduction:
What is a Transformer
A Transformer is a static electrical machine which transfers AC electrical power
from one circuit to the other circuit at the constant frequency, but the voltage level
can be altered that means voltage can be increased or decreased according to the
requirement.

It works on the principle of Faraday’s Law of Electromagnetic

Induction which states that “the magnitude of voltage is directly proportional to
the rate of change of flux.”

Necessity of a Transformer
Usually, electrical power is generated at 11Kv. For economic reasons AC power
is transmitted at very high voltages say 220 kV or 440 kV over long distances.
Therefore, a step-up transformer is applied at the generating stations.

Now for safety reasons the voltage is stepped down to different levels by step
down transformer at various substations to feed the power to the different
locations and thus the utilisation of power is done at 400/230 V.

If (V2 > V1) the voltage is raised on the output side and is known as Step-up
transformer
If (V2 < V1) the voltage level is lowered on the output side and is known as Step
down transformer.

Construction of Transformer

Basically, a transformer consists of two inductive windings and a laminated steel

core. The coils are insulated from each other as well as from the steel core. A
transformer may also consist of a container for winding and core assembly (called
as tank), suitable bushings to take the terminals, oil conservator to provide oil in
the transformer tank for cooling purposes etc. The given figure illustrates the
basic construction of a transformer.
In all types of transformers, core is constructed by assembling (stacking)
laminated sheets of steel, with minimum air-gap between them (to achieve
continuous magnetic path). The steel used is having high silicon content and
sometimes heat treated, to provide high permeability and low hysteresis loss.
Laminated sheets of steel are used to reduce eddy current loss. The sheets are cut
in the shape as E, I and L. To avoid high reluctance at joints, laminations are
stacked by alternating the sides of joint. That is, if joints of first sheet assembly
are at front face, the joints of following assemble are kept at back face.

Working Principle of Transformer

 The basic principle behind working of a transformer is the phenomenon of
mutual induction between two windings linked by common magnetic flux. The
figure at right shows the simplest form of a transformer. Basically, a transformer
consists of two inductive coils; primary winding and secondary winding. The
coils are electrically separated but magnetically linked to each other. When,
primary winding is connected to a source of alternating voltage,
alternating magnetic flux is produced around the winding. The core provides
magnetic path for the flux, to get linked with the secondary winding. Most of the
flux gets linked with the secondary winding which is called as 'useful flux' or
main 'flux', and the flux which does not get linked with secondary winding is
called as 'leakage flux'. As the flux produced is alternating (the direction of it is
continuously changing), EMF gets induced in the secondary winding according
to Faraday's law of electromagnetic induction. This emf is called 'mutually
induced emf', and the frequency of mutually induced emf is same as that of
supplied emf. If the secondary winding is closed circuit, then mutually induced
current flows through it, and hence the electrical energy is transferred from one
circuit (primary) to another circuit (secondary).

Types of Transformers
Transformers can be classified on different basis, like types of construction, types
of cooling etc.

(A) On the basis of construction, transformers can

be classified into two.
(i) Core Type Transformer
In core type transformer, windings are cylindrical former wound,
mounted on the core limbs as shown in the figure above. The
cylindrical coils have different layers and each layer is insulated from
each other. Materials like paper, cloth or mica can be used for
insulation. Low voltage windings are placed nearer to the core, as
they are easier to insulate.

(ii) Shell Type Transformer

The coils are former wound and mounted in layers stacked with
insulation between them. A shell type transformer may have simple
rectangular form (as shown in above fig), or it may have a distributed
form.

(B) On the basis of their purpose

1. Step up transformer: Voltage increases (with subsequent decrease in
current) at secondary.
2. Step down transformer: Voltage decreases (with subsequent increase
in current) at secondary.
(C) On the basis of type of supply
1. Single phase transformer
2. Three phase transformers

(D) On the basis of their use

1. Power transformer: Used in transmission network, high rating
2. Distribution transformer: Used in distribution network, comparatively
lower rating than that of power transformers.
3. Instrument transformer: Used in relay and protection purpose in
different instruments in industries

▪ Current transformer (CT)

▪ Potential transformer (PT)

(E) On the basis of cooling employed

1. Air Natural (AN) or Self air-cooled or dry type
2. Air Forced (AF) or Air Blast type
3. Oil Natural Air Natural (ONAN)
4. Oil Natural Air Forced (ONAF)
5. Oil Forced Air Forced (OFAF)
6. Oil Natural Water Forced (ONWF)
7. Oil Forced Water Forced (OFWF)
COMPONENTS OF TRANSFORMER

These are the basic components of a transformer.

1. Core:
The core acts as support to the winding in the transformer. It also provides a low
reluctance path to the flow of magnetic flux. It is made of laminated soft iron core
in order to reduce eddy current loss and Hysteresis loss. The composition of a
transformer core depends on such as factors voltage, current, and frequency. The
diameter of the transformer core is directly proportional to copper loss and is
inversely proportional to iron loss. If the diameter of the core is decreased, the
weight of the steel in the core is reduced, which leads to less core loss of the
transformer and the copper loss increase. When the diameter of the core is
increased, the vice versa occurs.
Why Are Windings Made of Copper?
• Copper has high conductivity. This minimizes losses as well as the amount of
copper needed for the winding (volume & weight of winding).
• Copper has high ductility. This means it is easy to bend conductors into tight
windings around the transformer’s core, thus minimizing the amount of copper
needed as well as the overall volume of the winding.

2. Winding:
Two sets of winding are made over the transformer core and are insulated from
each other. Winding consists of several turns of copper conductors bundled
together, and connected in series.
Winding can be classified in two different ways:
1. Based on the input and output supply
2. Based on the voltage range

Within the input/output supply classification, winding is further categorized:

1. Primary winding – These are the winding to which the input voltage is
applied.
2. Secondary winding – These are the winding to which the output voltage is
applied.

Within the voltage range classification, winding is further categorized:

1. High voltage winding – It is made of copper conductor. The number of turns
made shall be the multiple of the number of turns in the low voltage winding.
The conductor used will be thinner than that of the low voltage winding.
2. Low voltage winding – It consists of fewer number of turns than the high
voltage winding. It is made of thick copper conductors. This is because the
current in the low voltage winding is higher than that of high voltage winding.

According to capacity of transformer three types of coils are usually designed:

• Square wound
• continuous
• Disk wound

Input supply to the transformers can be applied from either low voltage (LV) or
high voltage (HV) winding based on the requirement.

3. Insulating Materials:
Insulating paper and cardboard are used in transformers to isolate primary and
secondary winding from each other and from the transformer core.

Transformer oil is another insulating material. Transformer oil performs two

important functions: in addition to insulating function, it can also cool the core
and coil assembly. The transformer’s core and winding must be completely
immersed in the oil. Normally, hydrocarbon mineral oils are used as transformer
oil. Oil contamination is a serious problem because contamination robs the oil of
its dielectric properties and renders it useless as an insulating medium.
4. Transformer oil:
Transformer oil or insulating oil is an oil that is stable at high temperatures and
has excellent electrical insulating properties. It is used in oil-filled transformers,
some types of high-voltage capacitors, fluorescent lamp ballasts, and some types
of high-voltage switches and circuit breakers. Its functions are to insulate,
suppress corona discharge and arcing, and to serve as a coolant.
5. Conservator Tank:
It is a small tank which used in high power transformers. It is connected above
the main tank of transformer. It has cylindrical shape. Main tank and conservator
tank connected to each other through a pipe. Buchholz relay is used between
conservator tank and main tank in transformers having capacity more than one
MVA. Conservator tank have following functions in transformer:

• It provides place for hot transformer oil to expand. It also provides oil in
transformer after oil become cool.
• It also use to decrease oxidation by reducing area of oil around air.
• Oxidized oil remain in conservator tank. Mirror tube is also connected with
conservator tank to read oil level in transformers. A pre marked gauge is also
present in mirror tube. It is necessary to have cool oil level up to mark of gauge.

6. Breather:
The breather controls the moisture level in the transformer. Moisture can arise
when temperature variations cause expansion and contraction of the insulating
oil, which then causes the pressure to change inside the conservator. Pressure
changes are balanced by a flow of atmospheric air in and out of the conservator,
which is how moisture can enter the system.
If the insulating oil encounters moisture, it can affect the paper insulation or
may even lead to internal faults. Therefore, it is necessary that the air entering
the tank is moisture-free.
The transformer’s breather is a cylindrical container that is filled with silica gel.
When the atmospheric air passes through the silica gel of the breather, the air’s
moisture is absorbed by the silica crystals. The breather acts like an air filter for
the transformer and controls the moisture level inside a transformer. It is
connected to the end of breather pipe.

7. Tap Changer:
The output voltage of transformers varies according to its input voltage and the
load. During loaded conditions, the voltage on the output terminal decreases,
whereas during off-load conditions the output voltage increases. In order to
balance the voltage variations, tap changers are used. Tap changers can be either
on-load tap changers or off-load tap changers. In an on-load tap changer, the
tapping can be changed without isolating the transformer from the supply. In an
off-load tap changer, it is done after disconnecting the transformer. Automatic tap
changers are also available.

Tap changer switch is used to regulate secondary voltage in case of low voltage
in primary side of transformer. Two type of tap changing switches are used:

1. Off load switch: - It is used to change winding voltage ratio. Tap changing
switch are connected with high voltage side of transformer. As it name suggest
off load tap changing switch used only in transformer off condition.
2. On Load Switch: - On load tap changer switch can be used with on load
transformer.

8. Cooling Tubes:
Cooling tubes are used to cool the transformer oil. The transformer oil is
circulated through the cooling tubes. The circulation of the oil may either be
natural or forced. In natural circulation, when the temperature of the oil rises the
hot oil naturally rises to the top and the cold oil sinks downward. Thus, the oil
naturally circulates through the tubes. In forced circulation, an external pump is
used to circulate the oil.

9. Buchholz Relay:
The Buchholz Relay is a protective device container housed over the connecting
pipe from the main tank to the conservator tank. It is used to sense the faults
occurring inside the transformer. It is a simple relay that is operated by the gases
emitted during the decomposition of transformer oil during internal faults. It helps
in sensing and protecting the transformer from internal faults.
10. Explosion Vent:
The explosion vent is used to expel boiling oil in the transformer during heavy
internal faults in order to avoid the explosion of the transformer. During heavy
faults, the oil rushes out of the vent. The level of the explosion vent is normally
maintained above the level of the conservatory tank.

11. Radiator:
In 50KVA above transformers, radiators are used with main tank of transformer
for cooling purpose. It is like a pipes or tubes. It increases the surface area of
transformer. Radiator makes cooling in transformer more effective. This method
of cooling is called ONAN (oil natural air natural).

12. Cooling fans:

In 26MVA and above transformers, cooling fans are also used on radiator. Oil
temperature gauge provide on or off signal for cooling fans. When temperature
becomes greater than 75º, temperature oil gauge turns on cooling fans. This
method of cooling is called ONAF (oil natural and air forced).

13. Oil pumps:

In 26 MVA above transformers oil pumps are also used along with cooling fans
and radiator oil pumps used to rotate oil in transformer. This method of cooling
is called OFAF (oil forced and air forced.)
14. Oil gauge:
Oil gauge is used for the measurement of oil in transformer. It displays oil level.
Oil gauge is usually of dial type. Pointer on dial type gauge used to measure oil
level. It is used with medium level to high voltage transformers.
15. Bushings:
Bushings are used to bring windings terminals out of tank and also use for
insulation. For example, porcelain, oil filled and capacitor type bushings. Arching
horns are also connected to bushings to provide protection from lightning. In
above 34 KV transformer, completely sealed condenser type bushings are used.
In less than 25KV transformer plain bushings are used.

16. Thermometer:
Thermometer is also used in above 50KVA transformers. It is used to measure
temperature of oil. In high power transformers, thermometer is also used inside
windings which measure temperature of windings. Whenever temperature
increase up to dangerous level, it activates alarum signal.

Advantages of Three Phase Transformer

over a Single-Phase Transformer
Following are the advantages of a 3-Φ transformer over a 1-Φ transformer.
• Less costly
• Lesser weight
• Less in size
• Less time required to assembling
• Require less space
 • Deliver more power
• Higher efficiency
• Easier to install
• Easy transportation and installation
• Easy to repair
• Easy assembling
• The cost of a three-phase transformer is lesser than the three single phase
transformers having the same rating.

Disadvantages of Three Phase Transformer

over a Single-Phase Transformer
Following are the disadvantages of a 3-Φ transformer over a 1-Φ transformer.
• Higher cost of standby units.
• More costly and repairing inconveniences.
• In case of fault or failure of a three-phase transformer, the power
supply shutdowns in the whole connected load areas. Hence, the definite
and immediate power restoration is not possible.
• A three-phase transformer can’t be operated temporarily in open
delta connection, while it is possible in three single phase unit
transformer (in case of fault at single unit).
The whole unit needed to be replaced in case of failure, while in case of single-
phase transformers, only the fault ones should be replaced with a new one

Failure & Causes of Transformer

Faults may occur in different parts and components of the transformer due to
mechanical, electrical or thermal stress caused due to different conditions. Some
of the most commonly occurring failures of the transformer and their causes are
listed below.

1. Winding failure
Windings are an important part of a transformer. In distribution side transformers
there are commonly two windings. One on the primary side and the second on the
secondary side.
High voltage/low current flows in the primary side winding and through
electromagnetic induction voltage is stepped down and current stepped up in the
secondary side winding. These windings withstand dielectric, thermal and
mechanical stress during this process. The faults that occur in the winding are due
to these stresses. This causes the breaking of the windings or the burn-out. The
winding fault PN number is usually between 6 to 30.
A. Dielectric faults occur in the winding due to turn-to-turn insulation breakdown.
These are the insulation between the turns of the winding. Insulation breakdown
commonly occur due to high current and voltage which are high above the rated
values. The breakdown of the insulation results in the flashover of the winding
turns and cause short circuit.
B. The windings are usually of copper. Due to the copper line resistance thermal
losses occur. These thermal losses make hotspots in the winding due to bad or
lack of maintenance. This over time causes wear and tear and the decrease of the
physical strength up to the point of breaking of the winding.
C. Mechanical faults are the distortion, loosening or displacement of the
windings. This results in the decrease of the performance of the transformer and
the tearing of the turn-to-turn ratio. The main reasons that cause this fault are the
improper repair, bad maintenance, corrosion, manufacturing deficiencies,
vibration and mechanical movement within the transformer.

2. Bushing Failure
Bushes are insulating devices that insulate a high voltage electrical conductor to
pass through an earth conductor. In transformers it provides a current path
through the tank wall. Inside the transformer paper insulators are used which are
surrounded by oil that provides further insulation. Bushing failure usually occurs
over time. Bushes failure PN number is between 24 to 48. Some of the main
reasons for bushing failure are discussed below.
A. Loosening of conductors is caused by transformer vibrations which results in
overheating. This heat damage the insulating paper and the oil used.
B. Sudden high fault voltages causes’ partial discharge (breakdown of solid/liquid
electrical insulators) which damage the bushes and causes its degeneration and
complete breakdown within hours.
C. Seal breaking of bushes happen due to ingress of water, aging or excessive
dielectric losses. Due to this fault core failure of the transformer occurs.
D. Not replacing of old oil over long time or its deficiency due to leakage causes
internal over-flashing.

3. Tap Changer Failure

The tap changer function in the transformer is to regulate the voltage level. This
is done by either adding or removing turns from the secondary transformer
winding. It is the most complex part of the transformer and also an important one.
Even the smallest fault results in the wrong power output. The PN number is
usually between 28 to 52. Some fault and causes are
A. In Run-Through fault the tap changer takes time and after a delay changes the
turn ratio. The main reason for it is the relay responsible for the tap change has
residue flux because of polluted oil, therefore taking time to change. The other
reason for run-through fault is the spring becoming fragile over time.
B. Lack of maintenance causes the shaft connection between the tap and the motor
driver of the tap changer to be not synchronous. Because of this the tap changer
is not in the position where it needs to be.
C. Old capacitors or burned-out capacitor in the motor causes the tap changer to
fail to control its direction movement.
D. Regular use of the tap changer causes the spring in it to slowly become fragile
over time and then finally break. Because of this the tap changer is not able to
change the turn ratio of the winding.
E. Breakdown of the motor in the tap changer because of over voltage or miss-
use also causes the tap changer to fail to change the turn ratio of the winding.

4. Core failure
The transformers have laminated steel cores in the middle surrounded by the
transformer windings. The function of the core is to concentrate the magnetic
flux. Fault in the core directly affect the transformer windings, causing faults in
them. The cores of the transformers are laminated to reduce eddy-current. The
lamination of the core can become defected by poor maintenance, old oil or
corrosion. The breakdown of the smallest part of the lamination results in increase
of thermal heat due to eddy-current. The effects of this overheating are
A. The over-heating reaches the core surface which is in direct contact with the
windings. As a result of this the windings are damaged by the heat.
B. This heat also damages the oil in the transformers resulting in the release of a
gas from the oil that damages other parts of the transformer.
The PN number of the core failure is often 6.

5. Tank Failures
The function of the tank in the transformer is to be a container for the oil used in
it. The oil in the tank is used for insulation and cooling. The tank can also be used
as a support for other equipment of the transformer. The PN number for the failure
is 18.
The fault in the tank occurs due to environmental stress, corrosion, high humidity
and sun radiation resulting in a leakage or cracks in the tank walls. From these
leakages and cracks oil spill from the tank causing the reduction of oil.
A. The reduction in oil level results in the reduction of insulation in the
transformer and affecting the windings.
B. The oil is also used for cooling purposes so the reduction of oil causes over-
heating with damages different parts of the transformer.

6. Protection system Failure

The main function of the protection system is to protect the transformer from
faults by first detecting the fault and then resolving it as fast as possible. If it
cannot fix the fault, it isolates it so that it may not damage the transformer.
Protection systems include the Buchholz protection, pressure relief valve
circuitry, surge protection and Sudden Pressure Relays.
This is the most occurring failure with a PN between 22 to 64.
A. Buchholz protection is a protective device that is sensitive to dielectric faults
in the transformer. Overheating of the relay occurs because of accumulation of
gasses over time, which reduces its sensitivity to dielectric faults. Low level oil
due to leakage causes the Buchholz protection to come into action even if there
is not a fault which is not needed and waste of energy.
B. Pressure relief valve circuitry protects the transformer from exploding due to
gas pressure. The gas pressure is produced due to overheating of oil. Pressure
relief valve circuitry slowly reduces the pressure of the gasses. Fault in this
circuitry mainly occurs due to the spring in it becoming fragile over time resulting
in the circuitry not being able to reduce pressure quickly. This circuitry also fails
when gas pressure increases quickly as this is only able to release pressure slowly.
C. Surge protector protects the transformer from over voltage by allowing
specific magnitude of voltage to go to transformer and for the rest alternate route
is found. Failure in surge protection causes high voltage to pass to the windings
which becomes damaged because of it. Moisture, heat and corrosion are the main
reasons of the failure of surge protection as it causes overheating and short circuit
in it.
D. Sudden Pressure Relays protects the transformers from blowing up from
sudden exponential increase of gas pressure. If it fails to release the sudden
pressure the transformer blows up. Relay fails due to humidity and moisture
affecting its internal circuitry.

7. Cooling system failure

Cooling system reduces the heat produced in transformers due to copper and iron
losses. The cooling system contains cooling fans, oil pumps and water-cooled
heat exchangers. The failure in the cooling system causes the heat to build up in
the transformer which effect different parts of the transformer and also causes
more gas pressure to be built inside which may cause the transformer to blow.
The PN is between 26 to 48. Some of the main reasons for failure are discussed
below.
A. One of the biggest reasons of cooling system failure is leak in the oil/water
pipes. This causes the reduction in the fluids which results in low heat exchange
which is not good for the transformer. Leakage happens because of environmental
stress, corrosion, high humidity and sun radiation.
B. Some failure occurs due to fault in the cooling fans which rush-in cool air into
the tanks for cooling purpose. The fans create faults because of poor maintenance,
over use or motor wear-out.
Cooling system can perform wrong due to bad thermostats which measure the
heat in the transformer. Faulty thermostats show wrong temperature causing the
cooling system to operate accordingly and not in the way needed
Troubleshooting Transformer in Power
Substation

Causes of failures and their remedies

Some of the common failures/ defects occurred in transformer are as

under:

1. Oil leakage
Location Possible Causes Remedial Action

From screw Foreign material in Remove the foreign material

joints threads

Poor threads Check the threads & replace if

required

Improper assembly Ensure proper assembly

From gasket Insufficient or uneven Tight gasket joints uniformly

joints compression

Improper preparation of Provide proper gaskets

gaskets and gasket
surfaces

Old gaskets Provide new gaskets

From weld Shipping strains, Repair welds following proper

joints imperfect weld procedure

From couplings Cracks in couplings Replace couplings and secure the

& their joints pipe lines near couplings
properly

Defective coupling joints Make proper couplings joints and

tight screws
From drain Defective thread portion Check the threaded portion
plugs
Defective oil seal Replace the oil seal and tight the
drain plug

2. Low break down voltage (BDV)

Type of Possible Causes Remedial Action
Failure

Low Moisture contamination in Reactivate silica gel crystals or

BDV transformer oil due to inactive replace them. Purify the transformer
silica gel (pink colour) oil to restore dielectric strength

Leaks around cover accessories, Attend leaks, replace gasket if

breathing air from leaks necessary. Purify the transformer oil
to restore dielectric strength

Humid atmosphere in rainy Purify the transformer oil to restore

season dielectric strength and check the
BDV & water content

3. Bushing failure
Types of Failure Possible Causes Remedial Action

HV Bushing flashover Lightning It may be a break in the turns or

discharge or end lead, flash marks on the end
overvoltage coil and earthed parts close to it

Dirty bushing Ensure cleaning of porcelain

bushing during each inspection
HV Bushing porcelain External hitting Ensure proper cleaning and visual
insulator petticoat checking of porcelain bushing
broken / cracked during each inspection

4. Winding failures
Types of Failure Possible Causes Remedial Action

Primary Due to overload or Check the winding in one or all phases

winding leads brazing failure would show signs of overheating and
open circuited / charring
earthed

Bulging and Coils shrink and in Investigate for overloading and take
inter turn short, between insulation corrective action accordingly
inter layer short failure
or inter coils
short

Shorting Insulation failure During manufacturing / rewinding of the

between LV and transformer, the coils should be pressed
HV coils down, heated and cooled repeatedly until
the coil height stabilizes

Flash mark on Dead short circuit Nomex paper insulation sheet should be
the core and due to lateral or provided between H.V. and L.V. coils so
support displacement of the as to strengthen the insulation level.
coil Ensure that this insulation sheet does not
cause any obstruction in the passage of
oil flow

Winding loose on Replace the transformer and core to be

the core lifted for thoroughly checking and take
corrective action accordingly

Repair the winding if possible

5. Excessive overheating of oil
Type of Failure Possible Causes Remedial Action

Temperature Any internal fault such Replace the transformer and core to
rise of as short-circuited core, be lifted for thoroughly checking.
transformer oil core bolts/ clamps Take corrective action according to
insulation failure etc. observations and oil test report.

Low oil level in Check the oil level in

conservator conservator and top up if required

Slugged oil Carry out purification of oil to

remove sludge

Overloading Adjust the load

6. Low IR value
Type of Possible Causes Remedial Action
Failure

Low IR Moisture in oil Purify the oil with high vacuum type oil
Value purification plant and test the oil for electrical
strength and water content

Insulation failure Replace the transformer. Lift the active part and
between winding check the winding thoroughly for insulation
and core damage and take corrective action accordingly.

Internal connection Check the internal connection leads by lifting the

leads insulation active part and re-tape insulation paper of
damage damaged portion
 Weak brazing Clean the joint and braze properly

7. Humming sound
Type of Possible Causes Remedial Action
Failure

Humming Loose core Lift the active part and tight all the pressure bolts
sound and clamping bolts.

Winding loose During manufacturing/ rewinding of the

due to shrinkage transformer, the coils should be pressed down,
of coils heated and cooled repeatedly until the coil height
stabilizes.

The winding pressure bolts and core clamping

bolts should be tightened during the first
periodical overhauling after commissioning to
take care of shrinkage.
Investigation into causes of failures of
transformer

The following notes may be helpful in identifying the causes:

1. Failure due to Lightning Discharge or Overvoltage

This is characterized by break down of the end turns close to the line terminal. There
may be a break in the turns or end lead, and also flash marks on the end coil and
earthed parts close to it, but the rest of the coils will be found to be healthy.

2. Sustain Overloads
The windings in one or all phases would show signs of overheating and charring.
The insulation would be very brittle and would have lost all its elasticity.

3. Inter-turn short, Inter-layer short, or Inter coils short

The same signs as for indicated for sustained overload would be noticed, but only on
affected coils, the rest of the coils being intact.

This is likely if the differential relay or the Buchholz relay has operated.

4. Dead Short-circuit
This can be identified by the unmistakable, lateral or axial displacement of the coils.
The coils may be loose on the core, some turns on the outermost layer may have
burst outwards and broken as if under tension.

If, in addition to these signs, the windings are also completely charred, it is conclusive
evidence that the short circuit has continued for an appreciable period, not having been
cleared quickly by the protective relays.
5. Buchholz Relay Tripping
If the upper chamber of the Buchholz relay alone has tripped, check the insulation of
core bolts, by applying a voltage of 230V to 1000V between the core and each bolt.
If it fails, renew the insulating bush.

Observe also all the joints, and tap-changer contacts, for overheating and arcing.

6. Internal Flashover
If the oil shows a low break down voltage (BDV), it does not necessarily mean it has
caused the breakdown. At high voltage ratings, excessive moisture content in the oil
may result an internal flashover between the live parts and earth, which all leave
corresponding tell-tale marks.

Do’s & Don’ts

Do’ s
1. Ensure all safety arrangement while working on electrical
installation. Ensure that all tools and tackles are in good and working
condition.
2. Check and thoroughly investigate the transformer whenever any
alarm or protection is operated.
3. Check the protection system periodically.
4. Ensure every employee is familiar with the instructions for
restoration of persons suffering from electric shock.
5. Trained the staff in operating the fire-fighting equipment.
6. Do earthing of all points before starting maintenance.
7. Keep all spares away from dirt.
8. Work with full confidence.
9. Ensure thorough and full cleaning of insulators, since partial cleaning
is worse than no cleaning.
10. Ensure perfect isolation of supply before commencement of
maintenance work. Put a caution board when on work.
Don’ts
1. Don’t use low-capacity lifting jacks on transformer.
2. Don’t leave circuit tap switch unlock.
3. Don’t leave any loose connection.
4. Don’t meddle with protection system.
5. Don’t allow conservator oil level to fall below minimum level mark
of indicator.
6. Don’t parallel transformers which do not full fill the necessary
requirement.
7. Don’t allow unauthorised entry in the sub-station.
8. Don’t overload the transformer other than the specified limit
mentioned.
9. Don’t tight the nuts & bolts in excess to arrest any leakage.
10. Don’t avoid any unusual noise / occurrence noticed in the substation.
11.Never use fuses higher than the prescribed ratings on HV and LV
sides.
12. Earthing connections should never be done in loose manner.
Simply twisting of galvanized iron (GI) wires would be
dangerous! The earthing connections should as far as possible be
done by using continuous wire or providing suitable connectors. It
should be ensured that these connections are tightened rigid.
13. Never keep the breather pipe open or exposed.
14.Don’t ignore safety rules during maintenance work.