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VOLUME 12 z ISSUE NO. 7z MARCH 2021 z PGS. (! ISSN 0970-2946 z Rs. 100/-

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EventsandEventualities

CASE STUDY

On Transformer’s Abnormal Situation (Part-2)

Introduction the continuation of this series with few other case

studies in this month. These studies shall be the
TRANSFORMER is the only inter-linking Electrical
continuation of the last month’s technical case study
Device between two voltage levels that plays the vital
series on the technical note to abnormal behavior of
role to connect the power players in the system and
Power Transformers.
to establish correct use of electrical power as per
the required voltage level. Reliability of the electrical Each case study is of practical in nature, has covered
system depends upon the healthiness of this device, the actual incidences occurred in the electrical system.
as because, any eventuality on this device delinks 7KLVKDVEHHQGHVFULEHGZLWKWKHSUHVHQWDWLRQÁRZRI
the electrical network dragging the situation towards describing the S5ituation with Observations, Action
blackout. taken, Analysis and Final recommendations to the
reader. These studies could be quite helpful for the
Hence, considering the importance of this element,
operation, testing and commissioning engineers to
the EVENT and EVENTUAL series had been started in
develop awareness regarding the smooth control and
this journal. We have completed few segments about
operation of electrical system in the Grid Sub-Station.
this element like studies on instrument transformers,
tripping analysis of transformers etc... Recent We urge all our esteem readers to please share
VHULHV LV RQ WKH ÀHOG FDVH VWXGLHV ZLWK WHFKQLFDO your suggestion and feedback, which shall be the
notes on the abnormal behavior of the transformer motivational factor to improve further.
with subsequent caution note with necessary
recommendations. First part of this series had been Non-passing of Oil to OLTC tank
published during February 2021 and response of
'XULQJWKHÀOWUDWLRQRID09$.9WUDQVIRUPHU
readers on this subject is in exponential trend.
LW ZDV REVHUYHG ZLWK QR ÁRZ RI RLO WR 2/7& WDQN
On the basis of the positive response and suggestive IURPWKHPDLQWDQNHTXDOL]DWLRQSLSHEHLQJLQRSHQ
feedback from the readers, we have considered FRQGLWLRQEHWZHHQWKHP

March 2021 65
EventsandEventualities

Observation: 5. Then when the air was released from the required
valves, the oil started rushing to the space to
 %HIRUHWRWKHÀOWUDWLRQWKHHTXDOL]DWLRQSLSHEHLQJ PDLQWDLQOHYHORIRLODQGUHVXOWHGWKHÀOOLQJRI2/7&
in open condition, the vacuumisation had been conservator tank.
done. Then oil was pushed to the main tank and
DOVRWRWKH2/7&WDQNWKURXJKHTXDOL]DWLRQSLSH  7KHQWKHHTXDOL]DWLRQSLSHZDVFORVHGDQGÀOWUDWLRQ
was done for the oil in the MAIN tank only.
 7KHRLOZDVÀOOHGWRWKHOHYHORISLSHOLQHFRQQHFWHG
between main tank and conservator. Recommendation:
3. This level was above to the OLTC tank and its 1. During vacuumisation of the main and OLTC tank,
conservator. WKH HTXDOL]DWLRQ SLSH XVHG LQ EHWZHHQ PXVW EH
4. But on observation it was found with no oil on the kept in OPEN condition.
OLTC conservator tank.  $IWHUYDFXXPLVDWLRQDQGEHIRUHÀOOLQJRIRLOWRWKH
5HFWLÀFDWLRQ main tank, none of the valve should be opened to
cause the trap of air, otherwise due to air trap, the
1. 7KH YDOYH XVHG LQ WKH HTXDOL]DWLRQ SLSH ZDV oil circulation shall be hampered.
checked and found in open condition.  'XULQJÀOWUDWLRQWKH2/7&WDQNEHLQJÀOOHGZLWKRLO
2. The valve used between the OLTC tank and its should be separated from the main by closing the
conservator was checked and found in open YDOYHRIWKHHTXDOL]DWLRQSLSH
condition.
3. Now the air release point on top of the OLTC tank
was vented and found with release of trap air and Crack development on barrier Board
WKHQRR]LQJRIRLORXWRILW 2QH RI WKH ROG  .9  09$ WUDQVIRUPHU ZDV
4. Similarly, top valve of the OLTC conservator tank DVNHGIRUWKHYDFXXPLVDWLRQEXWDIWHUYDFXXPLVDWLRQ
was also opened to release of the air out of it. LWZDVREVHUYHGZLWK&UDFNRQWKHEDUULHUERDUG
5. Of doing this activities, oil started passing to the
2/7&FRQVHUYDWRUWDQNDQGTXLFNO\ÀOOHGZLWKWKH Actual Observation with Analysis:
oil. a) This transformer was designed with tank mounted
Analysis: OLTC chamber being separated by the main tank
1. On inquiry of the process of vacuumisation it was by means of barrier board.
FRQÀUPHGWKDWWKHHTXDOL]DWLRQ SLSH ZDV LQ RSHQ b) The terminals from the main winding had been
condition and valve between the OLTC tank and routed through the insulated studs arranged in the
its conservator was in closed condition. barrier board.
 $IWHUYDFXPXLVDWLRQDQGEHIRUHÀOOLQJWKHRLOWRWKH F 2QWKHGD\RIYDFXXPLVDWLRQWKHHTXDOL]DWLRQSLSH
main tank, the valve between the OLTC tank and its between the main tank and OLTC tank was not
conservator was opened. used.
3. So the air in the OLTC conservator now rushed to d) So the OLTC tank was left without oil and with air of
the conservator tank and trapped to certain level. certain pressure.
 6R GXULQJ ÀOOLQJ RI WKH RLO UHTXLUHG OHYHO LQ WKH e) When the vacumisation was attempted on the main
OLTC tank got maintained due to trap of air and its tank, the greater pressure value exert the stress on
pressure, but not to the level of OLTC tank. the barrier board.

Equalizing Pipe

Valve used in the

Equalizing pipe for
connection link between
main and OLTC tank

circulation shall be hampered.

66 March 2021
EventsandEventualities

f) Now due to unbalance of the pressure (air in the Abnormal temperature on the
OLTC tank and vacuum in the main tank), the
barrier board started breaking with crack on it. Transformer
,Q D  JULG VXEVWDWLRQ WKHUH ZHUH WZR HTXDO
Recommendation: UDWLQJ RI WKH WUDQVIRUPHUV FRQQHFWHG LQ SDUDOOHO 
,WLVDOZD\VUHFRPPHQGHGWRXVHHTXDOL]DWLRQYDOYH 09$.9RIVDPHSHUFHQWDJHLPSHGDQFH%XW
or pipe between main tank and OLTC Tank during LWZDVIRXQGZLWKDEQRUPDOUHDGLQJRIWKH27,PHWHU
the vacuumisation process. RIRQHRIWKHWUDQVIRUPHUDVFRPSDUHGWRWKHRWKHU
7KHGLIIHUHQFHZDVREVHUYHGZLWKGHJ&HQWLJUDGH
Noise in the Transformer DPRQJ WKHVH WZR WUDQVIRUPHU WKRXJK ERWK ZHUH
'XULQJ WKH LQLWLDO FRPPLVVLRQLQJ RI D N9 VKDULQJHTXDOORDGGXHWRWKHLUVLPLODUUDWLQJV
[09$ WUDQVIRUPHU EDQN LW ZDV REVHUYHG ZLWK
1RLVH LQ WKH WUDQVIRUPHU HYHQ ZLWK WKH ORDG RI  Actual observation with Analysis:
09$/RDG%XWWKLVQRLVHYDQLVKHVLQGXHFRXUVH 1. Both the transformers were kept for observation for
few days.
Actual observation:
2. The OTI meters of both were calibrated with the
 7KLV [09$ WUDQVIRUPHU EDQN ZDV HQHUJL]HG standard and found alright.
with voltage of 765 KV. 3. Then on availing shut down, the temperature probe
2. The noise at the time of energisation was ignored was checked along with its thermometer pocket.
as it happens in general. 4. Surprisingly it was found with no oil on one of the
3. But when it was loaded of 150- 200 MVA, the noise transformer thermometer pocket.
level persisted few days. 5. This was the reason of resulting with the difference
4. When the second bank was charged, the noise of the temperature readings of the OTI. As the
was alternately transferred. probe was of no oil, the air being heated may cause
5. But the same was vanished after few days of the probe to develop with abnormal temperature.
remaining in parallel mode. 6. Then oil was topped with the temperature bath and
SUREHZDVÀWWHGZLWKWLJKWQHVVRIWKHNQRE
Technical Analysis:
7. Then both the transformers were loaded and found
1. When the transformer bank was charged, due with similar rise of the temperature on both OTI.
to initial inrush current, the noise level becomes
prominent and as the magnetic circuit is of big Non-trip of Auto-Transformer on Primary
volume this takes time to subside.
protection
2. But when the second transformer was charged, the
sympathetic inrush due to availability of another
7ZR09$$XWRWUDQVIRUPHUVZHUHUXQQLQJSDUDOOHO
transformer in parallel, the noise level again rises %XVKLQJ RI RQH RI WKH WUDQVIRUPHU $7 IDLOHG
DQGDOWHUQDWHVGXHWRLWVFXUUHQWÁRZLQWKHV\VWHP FDXVLQJWKHWULSSLQJRISULPDU\SURWHFWLRQGLIIHUHQWLDO
5HOD\ DQG RWKHU SURWHFWLRQ DQG RXWDJH RI WKH
3. But when these banks remain in charged condition
WUDQVIRUPHUEXWRWKHUWUDQVIRUPHU$7ZLQGLQJZDV
for few days, the effect was reduced due to settle
of the magnetic path and noise got reduced. DOVRVWUHVVHGGXHWRWKLVVXUJHDQGUHVXOWZLWKLQWHU
WXUQIDXOWEXWQRWWULSSHGRQ'LIIHUHQWLDOUHOD\DQGZDV
 %XWWKHLPSDFWRIÁX[DOVRFDXVHVWKHGHYHORSPHQW
WULSSHGRQ359
RIQRLVHOHYHOLQWKHWUDQVIRUPHU7KLVÁX[DYDLODELOLW\
depends upon the application voltage with respect
to frequency. The factor V/f shall cause the
Analysis Extended as follows:
GHYHORSPHQWRIÁX[ 1. Case of Di-electric failure of Bushing that leads
5. So during running condition if it is being found with to an earth fault in the form of arcing between the
abnormal V/f factor, then noise level may also go bottom of the bushing and transformer tank and
high. due to voltage surge.
2. Now due to parallel operation and propagation of
Recommendation: this voltage rise, causes stress upon the winding of
1. So it is always advisable to use CSD for higher affected Y phase and results inter-turn short.
voltage rating transformer for closing of the 3. Short circuit of few turns on the winding may give
equipment at peak point of sinusoidal supply. rise of higher fault current but restricted to the
 2YHU ÁX[LQJ PRQLWRULQJ UHOD\ WR EH XVHG IRU affected turns. But its effect on primary side due to
isolation of this device during abnormal factor of KLJKHU5DWLRPD\QRWEHVXIÀFLHQWIRUGHWHFWLRQE\
V/f value. differential relay.

March 2021 67
EventsandEventualities

4. However, the oil surge due this effect becomes Technical Solution
VXIÀFLHQW IRU WKH DFWXDWLRQ RI 359 DQG RXWDJH RI
the transformer. From Protection point of view, we should have the
followings.
5. The type of fault that occurred in Auto1, which
was external to transformer winding, but inside the a) Use High Set Instant element on back up Relay
]RQHRI&7IRUZKLFKSULPDU\SURWHFWLRQRSHUDWHG with Non-directional feature.
to isolate the fault.
E +LJK YROWDJH VHWWLQJ ZLWK GHÀQLWH WULS KDV WR EH
6. But the type of fault being external for the AUTO2, activated.
shall neither cause the actuation of its directional
c) Soon Impedance relay with Zone selection has to
2&5HOD\QRUUHVWULFWHG]RQHGLIIRU5()UHOD\V
be used in the system.
7. But doubt comes if Auto1, where the fault had been
G 8VHRIQRV35'VRIPPVL]HDWGLDJRQDOO\
occurred, if successfully had cleared the faulty part
opposite positions to give max coverage.
due to actuation of its primary relays, then how the
other AUTO got affected ( May be due buckling,
ZERO Insulation resistance between C-F
twist or deviation of the winding for the inter-turn
fault. and C-T for Transformer:
8. So this incident clearly indicates regarding the $W .9 *ULG 6XEVWDWLRQ LW ZDV UHSRUWHG ZLWK
impact of load outage and sudden rise of load on WKH JHQHUDWLRQ RI REMHFWLRQDEOH JDVHV RQ LQWHUYDO
this available Auto2 with abnormal appearance of FDXVLQJ WKH LQWHUPLWWHQW WULSSLQJ RI %XFKKROW] UHOD\
voltage on the system. 'XULQJVXFKVLWXDWLRQQRHOHFWULFDOSURWHFWLRQXVHGWR
9. For strong analysis thought we can add information LQLWLDWH
that this station is nearby a 400KV PGCIL system
being fed with HV source network. So this strong Observations
source could be the reason of abnormal electrical
1. This situation was causing on every 3-4 months of
parameters and distortion of winding on the
AUTO2. But the inter-turn short as very small on LQWHUYDO DQG WULSSLQJ WR FDXVH RQ %XFKKROW] UHOD\
the affected Y phase might not have resulted the after causing alarm.
required abnormal current on differential relay. But 2. The gas as accumulated was taken for the
the oil surge being high has resulted the tripping of testing for DGA and found with the generation
PRV relay of ACETYLENE gas. Generation of ACETYLENE

68 March 2021
EventsandEventualities

gas indicates the burning of metal parts but certain IR values between the terminals.
non-actuation of any electrical protection was 8. So the decision was again taken to use the LINKS
indicating that the fault is not on the active part of to run the transformer till the arrangement of Lifting
the winding. So each time due to the requirement device for detail checking of the Core, Frame and
of the system, the said transformer was allowed to Tank.
charge and taken into the circuit for catering the
9. On doing such, the evolution of C2H2 gas again
load to the system.
stopped and the unit was allowed to run with full
3. The test results as obtained after the occurrence load for study.
of such incidences were also found within the limit
10. Finally, the job was decided to be checked
of allowable values including Tan-delta, winding
thoroughly on lifting the CORE, FRAME.
resistance, TTR etc..
 2Q SK\VLFDO YHULÀFDWLRQ LW ZDV REVHUYHG ZLWK D
4. After occurrence of such repeated faults, at one
temporary link between CORE and its frame which
of the attempt it was decided to check the IR
was found with total burning of the bolts and
(Insulation Resistance) value of the Core, Tank and
disconnected.
Frame.
5. On checking the IR value, it was observed with 12. So this temporary link was removed completely.
C-T, C-F value came ZERO. Such results indicate Then the transformer was allowed to be taken into
that the core, frame and tank might have been the system with connection of actual links on the
shorted (Earthed) internally at any other points. So top of the cubicle.
on doing the connection of the actual links, multi 13. Then onwards no such abnormality gets observed
paths were getting established in the system. on this transformer and this unit was kept in the
6. The paths other than the actual links might not be service with its actual loads.
perfect as compared to the links to be provided. Recommendations
So such path on technical reason may cause the
LRQL]DWLRQ RI WKH V\VWHP DURXQG DQG UHVXOW WKH 1. Always measure the Insulation Resistance of
heating of the metal parts of the non-electrical CORE, FRAME and TANK just before erection at
parts. So the acetylene gas, as the consequence site. The results of IR value should be at least of 25
of metal burning was evolving. Mohm.
6. As this effect was not on the actual part 2. During every routine test after keeping the
of the winding or on the active part of
the transformer system, so electrical
relays were not actuating in the system.

Actions Taken
1. On trial it was decided to remove the
links of the CORE, TANK and FRAME as
provided on the top of the transformer
inside a cabinet box.
 7KHOLQNVZHUHUHPRYHGDQGHQHUJL]HG
for loading of the transformer with the
allowable loads for the trial running of
the transformer.
3. This time it was found with no such
abnormal evolution of ACITYLENE gas
as it was resulting before.
4. The tripping on BUCHOLTZ relay also
stopped.
5. Then the transformer was loaded to its
maximum for study and found with no
such abnormality for few months.
6. Again after 6 to 7 months, the
accumulation of C2H2 (Acetylene gas)
resulted.
7. This time on availing shutdown, the
testing of Core, Frame and Tank was
done. The results as found were of

March 2021 69
EventsandEventualities

transformer in the circuit, also measure this IR Action Taken:

value to ensure of no such parallel path other than 1. Transformer no 3 was availed shut down for detailed
the links. checking of the Tap condition on matching the
Transformer heating on LOW Load indicators on the TOP diverter switch compartment
and bottom Drive mechanism compartment.
condition 2. It was found with Top indicator with 10(TEN) but
$WRQHRIWKH.9JULGVXEVWDWLRQWKHUHZHUH bottom indicator being at 7(Seven).
WUDQVIRUPHUVFRQQHFWHGLQSDUDOOHOIRUPHHWLQJWKH  6RLWZDVFRQÀUPHGWKDW7UDQVIRUPHUDQGWDS
ORDGV RQ  .9 V\VWHP 2QH GD\ LW ZDV REVHUYHG position is 7(Seven) but transformer no 3 at 10
ZLWKKHDWLQJRIRQHWUDQVIRUPHUDVFRPSDUHGWRWKH (TEN).
RWKHUWZRLQWKHV\VWHPGXULQJWKHVLWXDWLRQRI/2:
4. The reason of such mismatch of the tap position
/2$' FRQGLWLRQ )HZ RXWJRLQJ IHHGHUV KDG EHHQ
was studied on changing the tap of this transformer
GLVFRQQHFWHGGXHWRIDXOWRXWDJHLQWKHV\VWHP.
3, which was under SHUTDOWN.
Observations and Analysis: 5. It was observed with the problem of the BEVEL
GEAR ARRANGEMENT between the drive rod
1. These transformers were of similar type of rating from DM (Drive mechanism) to the rod for Diverter
being 63.5 MVA with same % impedance. switch.
2. The taps of these transformers were also observed 6. The Gear box was opened and found with the
with same number 7 (SEVEN) from the TPI (Tap problem on the teeth mismatch, for which the
position Indicator). down rod used to rotate as per the command
3. The power recordings were compared and found given from the drive mechanism. But the actual
as follows. Tap changer does not get operated and remain at
the same position of 10(TEN).
Readings TFR-1 TFR-2 TFR-3
7. This mismatch could not have been compared due
Watt 2.812 2.786 2.832 to the non-practice of checking the detail parameters
after parallel operation of the transformer.
MVAR -0.987 -0.896 2.987
8. Moreover, the situation was not prominent as
Power 0.9435 0.9518 0.6875 these transformers were remaining in SYSTEM
factor (Lag) LOADING always.
(Lead) (Lead)
9. But due to LIGHT LOAD (LOW LOAD) situation
1. In this situation Transformer-1 and 2 were recording when the transformer taps were attended to
Leading Power Factor and Transformer-3 was bring down from the running tap of 10(TEN) to
recording of leading Power factor. This concept desired tap no 7(SEVEN), transformer no 1 and 2
of recording “Lead” and “Lag” indicates as one being in correct running caused running down to
transformer being the VAR producer and other two desired tap.
are the VAR consumers. 10. The transformer no 3, due to faulty GEAR
2. So it is considered that Transformer-3 is the source ARRANGEMENT does not cause of coming down
and Transformer 1 and 2 are the Loads. to desired tap 7(seven).

3. The temperature of Transformer-3 was found more 11. So only such situation resulted.
as compared to rest two. It was recording around 12. The bevel gear was replaced by a good one and
81 degree centigrade and rest two was with 68 and testing of tap running and TTR (Transformer Turn
69 deg centigrade. Ratio) was also done and found with correct value.

4. OTI alarm was also obtained on transformer no-3. Recommendation:

7KLVVLWXDWLRQZDVGXHWRWKHDEQRUPDOPDJQHWL]LQJ 1. It is recommended to check the parameters of
current sharing by the transformer. So it was transformers after each tap operation.
suspected upon the terminal induced voltage of
2. Especially on Power factor comparison and
these transformers. In this condition, transformer
this should be nearer to one and lagging for
no 3 could be inducing more voltage as compared
transformers being in parallel.
with other TWO. This condition is the phenomenon
RIFLUFXODWLQJFXUUHQWÁRZWRWKHWUDQVIRUPHUV The load sharing has also to be checked by each
transformer as compared to its % impedance. Ɠ
 1RZ GXH WR ÁRZ RI FLUFXODWLQJ FXUUHQW WKH
magnetic core of one transformer got heated and Er. PK Pattanaik
resulted with higher temperature as compared GM (Elect), at Odisha Power Transmission
with others TWO. Corporation Ltd. – Odisha

70 March 2021