Power Transformer

S.k.Mishra
 INDUCED
ALTERNATING E.M.F

SECONDARY
WINDING
FLUX LINKING
BOTH COILS

IRON
CORE

PRIMARY
WINDING

AC EXCITATION
SOURCE
 conservator
Hv bushing
Air cell
Lv bushing

radiator
buchholz

PRV

fans

Oil tank

pump
Silica gel
breather
 VOLVO MAKE TRUCK WITH 40 MT
COUNTER WEIGHT
IS USED FOR GT TRANSPORTATION
12 AXCEL TRAILER HAVING 96 WHEELS AND CAPACITY OF 250 MT
FIXXING WOODEN SLEEPER PACKING FOR UNLOADING OF GT
WOODEN PLATFORM IS PREPARED TO SLIDE GT FROM TRAILER
GT IS BEING LIFTED WITH 2X100 MT HYDRAULIC JACK
TO INSERT RAIL LINE BELOW GT AND TRAILOR
4 NOS RAIL LINES ARE INSERTED BETWEEN TRAILER AND WOODEN PLATFORM
GT IS BEING PULLED BY 2X10 MT CHAIN PULLEY BLOCK AND STEEL ROPES
TWO CHAIN PULLEY BLOCKS ARE ANCHORED WITH ANCHOR POINT
ICT 400 /220 kv /33 kv
Generator Transformer
Damaged Transformer
 GT 3 (250 MVA, 3PH), BHEL MAKE
ON 26/04/1997
• On 26/04/1997 transformer was taken out of
service on appearance of buccholz alarm.
• DGA result showed acetylene gas above normal
limit.
• Internal inspection of transformer revealed copper
globules inside the tank, black marks on outer
winding insulation wraps , carbonisation on inner
layers of winding wraps and other layers of
winding.
• As winding failure was suspected the transformer
was shifted to BHEL Bhopal.
• All windings were replaced and tested.
 GT 8Y (T8557/6, 200MVA,1PH, CGL
MAKE ) ON 19/05/2001.
o Transformer tripped & caught fire.
• Tank got bulged and deformed at the bell tank flange
location along with the left side (viewed HV side).
• Flash marks were observed inside the HV turret and
inside the tank facing HV bushing carona shield.
• Transformer oil was heavily carbonized.
• Lower end of HV bushing porcelain shattered and
damaged badly. Pieces of porcelain found inside the
tank.
• All windings show large amount of soot deposits.
The soot particles penetrated in all the areas of
windings.
• LV bushings, tap changer, core were apparently found
Damaged Gen Bus Duct
HV Bushing damage
View of HV Bushing shield
HV Bushing damage
Inner view of Tank at HV turret
 GT # 3 Transformer Failure
(04/12/2002)
• Transformer had failed on 04-12-02, at 0607 Hrs. while unit
was running at 205 MW & 25 MVAR, system voltage was 405
KV and frequency 48.8 Hz.
• The transformer oil & wdg temp.- 460 C & 650 C before failure.
• GT-3 was manufactured by BHEL, and first
commissioned in 1989. On 26-04-97 Transformer
withdrawn from service due to appearance of
buchholz alarm which is already been discussed
• Transformer was in service since 27-12-97
satisfactorily, however since October'2001 a rising
trend of fault gases was observed in DGA
 DGA History
Date H2 CH4 CO CO2 C2H4 C2H6 C2H2 C3’s
18-10-01 40 110 350 1850 146 60 0 30
08-11-01 55 150 390 2010 192 70 0 71
17-11-01 58 170 395 2108 220 75 0 78
08-12-01 60 214 409 2151 335 104 0 90
22-12-01 10 5 30 280 10 5 0 4
14-01-02 12 7 35 316 15 8 0 7
16-01-02 12 17 45 360 18 8 0 6
29-01-02 10 20 54 379 34 8 0 6
14-02-02 10 20 63 711 80 11 0 14
06-03-02 13 45 90 945 125 16 0 20
08-04-02 15 48 95 960 122 15 0 18
11-05-02 35 55 115 1770 245 50 0 40
15-06-02 38 78 190 1833 242 48 0 38
08-07-02 35 75 198 1860 240 46 0 40
10-09-02 30 70 208 1862 235 42 0 38
18-10-02 10 10 20 389 6 4 0 5
 OBSERVATIONS
Heavy carbon deposit and burning marks were
seen specially towards cooler side wall and U-
phase.
Heavy fire in the transformer resulted into extensive
damage to coolers.
Molded insulation block of R-phase HV line lead
has come out from the root of insulation cylinder
and has damaged completely.
Carbon deposits visible on outermost pressboard
insulation cylinders, top yoke, top ring washer and
winding leads.
The insulation was found brittle & discoloured.
Tan delta test tap earth connection found snapped
 EXTENT OF DAMAGE
• All windings have carbon deposits as confirmed during
internal inspection. it was decided to replace all
windings.
 The complete tank needs to be replaced.
 All three phases bushing needs replacement.
 Core can be re-used after dismantling and thorough
cleaning.
 OLTC can be re-used after cleaning and testing.
 All the cooler banks need replacement due to extensive
damage. Fans and pumps can be re-used only after
complete servicing and testing.
 PRVs, OTI, WTI and buchholz relays etc. are safety
equipment, thus may be replaced.
 All control cables need replacement wherever required.
 Transformer oil needs replacement.
Damaged Cooler banks
View of Damaged Tank
Tank damage
View of Oil pumps
Transformer Top view
Transformer Inner view
Transformer Inner view
Transformer Inner view
R-Phase Bushing oil end
R-Ph Bushing Tan delta test tap connection
Flash mark in R-ph bushing oil end
 GT # 7B Transformer (200 MVA TELK GT)
Failure(07/02/2003)
• The transformer failed on 07-02-03, at 11: 08
Hrs., while unit was running at 442 MW and
84 MVAR, System voltage - KV & freq – 49.85
Hz.
• GT-7B manufactured by TELK, and first
commissioned in Farakka.
• Transformer failed at Farakka & HV bushing &
tap coils were damaged.
• HV bushing & tap coils replaced at TELK, &
was kept as spare at Farakka.
 GT # 7B Transformer (200 MVA TELK GT)
Failure(07/02/2003)
• Due to 2 nos of CGL Xmer failure at
VSTPS, this Xmer brought to VSTPS &
commissioned as GT#7B on 03/10/2001.
• Xmer was operating normal except for LV
turret bolts temp rise which was attended
in Mar 02.
 DGA History
Date H2 CH4 CO CO2 C2H4 C2H C2H C3s
6 2
18/10/0 10 0 0 274 0 0 0 0
1
29/10/0 12 0 8 236 0 0 0 0
1
11/11/0 10 2 35 293 0 0 0 0
1
08/12/0 10 21 97 409 51 15 0 20
1
29/01/0 12 29 98 445 53 22 0 19
2
01/06/0 10 50 260 1110 50 21 0 23
2
19/08/0 12 52 268 1117 47 20 0 20
Damaged Transformer
Damaged Transformer
Damaged Transformer
Damaged Transformer
Damaged Transformer
Damaged Transformer
Damaged Transformer
Damaged Transformer
 OBSERVATIONS
The inspection at site observations:
• TANK
 Tank found bulged extensively towards HV side & inner
tank shield laminations separated.
 The tank rupture caused the oil to come out which had
drained into the oil pit.
• COOLERS
 Unit coolers had been thrown out due to explosion.
• HV BUSHING
 HV bushing bottom porcelain broken & separated from its
assembly.
 Condenser body, upper porcelain & top tank have no
damage.
 Bushing top terminal sealing is O.K.
 OBSERVATIONS
• WINDING ASSEMBLY
Supporting insulation cylinder between top &
bottom sections of Tap coil completely burnt &
distorted on HV side. Tap coils displaced
downwards. Tap coil insulation is burnt.
Both shield rings broken. Lead connection of
shield rings to tap wdg is intact.
Press board insulation ring & blocks
supporting the total coil assembly at bottom is
intact, whereas at the top it is displaced &
burnt.
50
 OBSERVATIONS
 HV line take-out insulation from the coil & lead
insulation to Bushing are in order except
consequential displacements. However HV lead
support found broken.
 Tap lead arrangement with its supports & connections
to OLTC are found clear & undisturbed.
 OLTC is physically OK.
 Mech clamping arrangement of core assy is OK. Inner
surfaces of both yokes blackened due to insulation
burns.
 RECOMMENDATIONS
It was recommended to discard this transformer completely.
¨ The failure observations were jointly discussed with the manufacturer
and M/s TELK were asked to send the details of shield ring, which has failed
in this GT. Although the purpose of shield ring is to reduce the voltage stress
developed because of the sharp corners of tap winding conductors near line
end, the shield ring itself has failed. Increasing clearance between tapping
coils and avoidance of shield ring may be reviewed for future transformers of
TELK since only TELK is using such a shield ring in their tap windings.

¨ The transformer was damaged on previous occasion at FSTPP where only

tap winding was replaced. Because of part replacement of winding, the testing
of the transformer could be done at 75 % of full level as per IS. For GTs, in
case of even one winding failure, all the windings may be replaced to have a
reliable transformer.
¨ Since the LA counter has advanced for 12 times, it is essential to check
its characteristics prior to re-use.
¨ New GT should be ordered urgently since this GT was taken from FSTPP
and there is no spare GT available at FSTPP presently.
 FAILURE OF GT#7B (T8557/5, CGL MAKE)
200 MVA TRANSFORMER

• On 02.04.03, at 01:54 Hrs., Unit # 7 was operating at 489

MW and 58.98 MVAR load while the system voltage was
408.45 KV and frequency was 49.68 Hz.

• GT-7B has S.No. T 8557/5 was 8R on 26.02.2000. This

Transformer at GT # 8R had also tripped on 19th May 2001
along with GT # 8Y when GT # 8Y had failed. Fault gases
were detected in both the transformers.
BRIEF HISTORY OF THE FAILED TRANSFORMER

GT-7B has S.No. T 8557/5 was 8R on 26.02.2000. This

Transformer at GT # 8R had also tripped on 19th May 2001
along with GT # 8Y when GT # 8Y had failed. Fault gases
were detected in both the transformers.

GT # 8R was inspected at site & arc marks were there between

Top Yoke frame bracket & Yoke frame in front of HV bushing
bottom portion. The arcing was due to displacement of the
bracket, which reduced the clearance between the frame
bracket & frame. Positive connection was provided between
frame bracket & frame with copper lead. This modification
has been carried out on all transformers.
GT # 8R after modification was charged on
09/07/2001 and had to be shut down again on
24/07/2001 due to sudden increase in Acetylene gas
formation. Transformer was opened & inspected
jointly with CGL. Reason for Acetylene formation
could not be established.
Transformer was dried out and assembled. After
assembly the transformer was dried out, tested and
kept as standby from December 2001.
When TELK GT failed on 07/02/03, this transformer
was installed and commissioned on 21/02/03 but
failed on 02/04/03.
After precommissioning checks (including SCC test)
and monitoring the transformer at no load, the Unit
was synchronized to the grid on 22/02/03 at 16:00 hrs.

The winding and oil temperature of the said

Transformer was monitored on hourly basis and the
DGA of oil was monitored at every 100 MW
incremental load till the transformer was loaded fully.
Subsequently, the DGA has been checked after 16
hours and 24 hours.
On 23/02/03, complete IR Thermography was done on
the transformer and no abnormal hotspots were
observed.
 Extent of damage & observation
• HV BUSHING
•  HV bushing oil end shield showed flash marks
and distortion. There were holes formed on the shield.
 One no. fixing screw of the bottom corona shield
was missing and was probably sheared off. Bottom
porcelain of bushing found cracked bur in position.
 The 2 remaining fixing screws of the corona
shield were in their place. These were set screws, and
not Allen screws as envisaged in design. They were
found blackened.
 There was play between the setscrews and the
fixing arms of the shield. The holes on these fixing
arms were found to have widened, possibly due to the
jerk experienced during the fault.
 Extent of damage & observation

• A portion of the HV bushing bottom terminal (a metallic

disc on the which the bushing shield is fixed), found
melted.
• Pitting and melting was observed on HV bushing at
following points:
a) The air end terminal bottom.
b) The plate on the bushing conservator on which
the air end terminal sits.
c) The countersunk, unthreaded portion of the air
end terminal, where the pin is accommodated.
d) The bushing pin, both ends.
e) The HV lead top terminal.
 Extent of damage & observation
• TANK
•
 Tank was bulged on shorter side
opposite to OLTC end & the RHS stiffener
was found cracked at the bottom.
• During the failure, oil gushed out from the
PRV & the bottom flange of the tank.
 Extent of damage & observation
• GENERAL
•
 Marshalling Box of the transformer
was damaged by the fire and control
cables were burnt.
 The bus duct of 2.1 LV terminal was
distorted, due to heat from fire. The bus
duct and the LV bus bars were covered
with soot.
Extent of damage & observation

• Windings
•
 The windings were removed from the
core and separated for inspection & carbon
deposits were found on all windings.
 The top yoke shield bracket was also
examined and pitting marks with
carbonization was seen on the metallic
surface of the shield bracket.
• CORE
 Found to be healthy.
Damaged Bushing
DEFINITION OF TRANSFORMER

Transformers are stationary

electrical machines which
transmit energy from systems
with certain current and voltage
values into systems with
generally different current and
voltage values but with identical
frequency.
IEC Definition of Power transformer
• A static piece of apparatus with two or
more windings which, by electromagnetic
induction, transforms a system of
alternating voltage and current into
another system of voltage and current
usually of different values and at the same
frequency for the purpose of transmitting
electrical power
 Terminologies
• booster transformer
• a transformer of which one winding is intended to be connected in series
with a circuit in orderto alter its voltage and/or shift its phase. The other
winding is an energizing winding

• oil-immersed type transformer

• a transformer of which the magnetic circuit and windings are immersed in oil
• NOTE For the purpose of this part any insulating liquid, mineral oil or other
product, is regarded as oil.

• dry-type transformer
• a transformer of which the magnetic circuit and windings are not immersed
in an insulating
• liquid
 Terminologies
• oil preservation system
• the system in an oil-immersed transformer
by which the thermal expansion of the oil
is accommodated. Contact between the oil
and external air may sometimes be
diminished or prevented
 Terminologies
Terminals and neutral point
• terminal
• a conducting element intended for connecting a winding to external
conductors
• 3.2.2
• line terminal
• a terminal intended for connection to a line conductor of a network
• neutral terminal
• a) For three-phase transformers and three-phase banks of single-
phase transformers:
• The terminal or terminals connected to the common point (the
neutral point) of a star connected or zigzag connected winding.
• b) For single-phase transformers:
• The terminal intended for connection to a neutral point of a network
 Terminologies
• high-voltage winding*
• the winding having the highest rated voltage
• low-voltage winding*
• the winding having the lowest rated voltage
• NOTE For a booster transformer, the winding
having the lower rated voltage may be that
having the higher
• insulation level.
 Terminologies
• intermediate-voltage winding*
• a winding of a multi-winding transformer
having a rated voltage intermediate
between the highest and lowest winding
rated voltages
• auxiliary winding
• a winding intended only for a small load
compared with the rated power of the
transformer
 Terminologies
• stabilizing winding
• a supplementary delta-connected winding
provided in a star-star-connected or star- zigzag
connected transformer to decrease its zero-
sequence impedance, NOTE A winding is
referred to as a stabilizing winding only if it is not
intended for three-phase connection to an
external circuit.
• common winding
• the common part of the windings of an auto-
transformer
 Terminologies
• 3.3 Windings
• winding
• the assembly of turns forming an electrical circuit
associated with one of the voltages assigned to the
transformer
• NOTE For a three-phase transformer, the 'winding' is the
combination of the phase windings
• tapped winding
• a winding in which the effective number of turns can be
changed in steps
• phase winding
• the assembly of turns forming one phase of a three-
phase winding
 Essential Information of Power
Transformers
• Information to be given in all cases
• a) Kind of transformer (for example transformer,
auto-transformer, booster transformer, etc.).
• b) Number of this standard.
• c) Manufacturer's name.
• d) Manufacturer's serial number.
• e) Year of manufacture.
• f) Number of phases.
 Essential Information of Power
Transformers
• g) Rated power (in kVA or MVA). (For multi-
winding transformers, the rated power of each
• winding should be given. The loading
combinations should also be indicated unless
the
• rated power of one of the windings is the sum of
the rated powers of the other windings.)
• h) Rated frequency (in Hz).
• i) Rated voltages (in V or kV) and tapping range.
• j) Rated currents (in A or kA).
• k) Connection symbol.
 Essential Information of Power
Transformers
• l) Short-circuit impedance, measured value in
percentage. For multi-winding transformers,
• several impedances for different two-winding
combinations are to be given with the
• respective reference power values. For
transformers having a tapped winding, see also
• 5.5 and item b) of 7.2.
• m) Type of cooling. (If the transformer has
several assigned cooling methods, the
respective
 Essential Information of Power
Transformers
• power values may be expressed as percentages
of rated power, for example ONAN/ONAF
• 70/100 %.)
• n) Total mass.
• o) Mass of insulating oil.
• If the transformer has more than one set of
ratings, depending upon different connections of
windings which have been specifically allowed
for in the design, the additional ratings shall all
be given on the rating plate, or separate rating
plates shall be fitted for each set.
 Oil Preservation system
• 8.2 Oil preservation system
• For oil-immersed transformers the type of oil
preservation system shall be specified in the
• enquiry and order. The following types are distinguished:
• – Freely breathing system or conservator system where
there is free communication
• between the ambient air and an air-filled expansion
space above the surface of the oil, in
• the tank or in a separate expansion vessel (conservator).
A moisture-removing breather is
• usually fitted in the connection to the atmosphere.
 AS OIL EXPANDS IN TRANSFORMER
TANK AIR CELL WILL SQUEEZE
AND FLOAT WILL LIFT TO SHOW
MORE OIL IN CONSERVATOR AND
VICE VERSA

CONSERVATOR

AIR GAUGE
AIR CELL GLASS

OIL
MOG

FLOAT
BRTEATHER
SILICA GEL
TO TRANSFORMER
TRANSORMER CONSERVATOR
 Oil Preservation system
• 8.2 Oil preservation system
• – Diaphragm-type oil preservation system where
an expansion volume of air at atmospheric
pressure is provided above the oil but prevented
from direct contact with the oil by a flexible
diaphragm or bladder.
• – Inert gas pressure system where an expansion
space above the oil is filled with dry inert gas at
slight over-pressure, being connected to either a
pressure controlled source or an elastic bladder.
 Oil Preservation system
• 8.2 Oil preservation system
• Sealed-tank system with gas cushion, in
which a volume of gas above the oil
surface in a stiff tank accommodates the
oil expansion under variable pressure.
• – Sealed, completely filled system in which
the expansion of the oil is taken up by
elastic movement of the permanently
sealed, usually corrugated tank.
 Generator Transformer
• 8.3 Load rejection on generator transformers
• Transformers intended to be connected directly
to generators in such a way that they may be
• subjected to load rejection conditions shall be
able to withstand 1,4 times rated voltage for 5 s
• at the transformer terminals to which the
generator is to be connected.
 internal
• Phase to ground
• Phase to phase fault
• Core heating
• Moisture /water ingress inside oil tank
• Bushing failure
• Tap changer failure
• Hot spot in power connectors
• Core insulation failure.
Protection against internal faults
• Winding temp alarm and trip.
• Oil temp. alarm and trip
• Buchholz alarm and trip
• REF
• HV over current directional.
• LV over current directional.
• Pressurization of oil tank
• Moisture in oil
 external
• Transmission line ground fault.
• Transmission line ph-ph fault.
• Over voltage
• Over flux
• Over load
• Switching surges.
• Lightening suges.
Protection against external fault

• Overall differential.
• Over flux.
• Breaker failure
• Lightening surges
• Switching surges.
• Ground fault in transmission lines
• Ph faults in transmission lines.
 WTI/OTI protection
• Winding temp • 90 deg
alarm
• Winding temp • 110 deg
trip
• Oil temp alarm • 85 deg
• Oil temp trip • 105 deg
 A Buchholz relay will detect:
Gas produced within the transformer

An oil surge from the tank to the

conservator
A complete loss of oil from the
conservator (very low oil level)

Fault conditions within a transformer produce gases such as carbon

monoxide, hydrogen and a range of hydrocarbons (Tutorial T3). A small
fault produces a small volume of gas that is deliberately trapped in the
gas collection chamber (A) built into the relay. Typically, as the oil is
displaced a float (B) falls and a switch operates - normally to send an
alarm. A large fault produces a large volume of gas which drives a
surge of oil towards the conservator. This surge moves a flap (D) in the
relay to operate a switch and send a trip signal. A severe reduction in
the oil level will also result in a float falling. Where two floats are
available these are normally arranged in two stages, alarm (B) followed
by trip (C).
ALARM FLOAT TRIP FLOAT

BROKEN
GLASS

MAGNETIC
SWITCH
TRIP

OIL

MAGNETIC SWITH
ALARM
Online Monitoring of Transformer Dissolved Gas

Sensor
 Pressure Relief Valve

Failure of PRV
 SOURCE OF OVERVOLTAGE
• EXTERNAL:-
– LIGHTENING
– GEOMAGNETIC STORM.
• INTERNAL
– SWITCHING
• LINE/CAPACITOR SWITCHING.
• INDUCTIVE CURRENT BREAKING.
• TRANSFORMER FEEDER ENERGISATION.
• TEMPORARY OVERVOLTAGE
– 1 PHASE FAULT.
– RESONANCE (SUB HARMONIC)
– TRANSFORMER INRUSH CURRENT
 LIGHTENING ARRESTORS
• NON LINEAR RESISTANCE(ZnO)
• USED TO PROTECT SWITCH
YARD EQUIPMENTS FROM
SWITCHING SURGES AND
LIGHTENING STROKES.
IMPORTANCE OF LIGHTENING/SURGE
ARRESTER
PROTECTS
SUBSTATTION
EQUIPMENT FROM

•SWITCHING
OVERVOLTAGE
•LIGHTENING
OVERVOLTAGE
 THERMAL IMAGE OF DEFECTIVE LA.
CASE STUDY :1 DADRI-MANDULA1 -Y-
PH

DELTA
>8C
 LA- FUNDAMENTALS
NORMAL
CURRENT
•LIMIT OVER
VOLTAGE .
•ACT AS INSULATOR
FOR NORMAL
VOLTAGE . Un

mA kA
Cross section of LA Sealing
gasket

MO LIGHTENING
element ARRESTER
CROSS
SECTON
 Existing Technologies

Generator/Transformers/CT/CVT/LA/Motors

Offline Online
– Dissipation Factor • Vibration
– DGA • Operating data
– Insulation tests • Periodic
– Winding tests – IR Thermography
– ELCID – Current signature
– Acoustic Partial
– RSO Discharge
FAILURE OF TRANSFORMER

50 No,s
40

BUSHING
30
OLTC
20
CORE/WINDING
10

0
1988-2001
 IR IMAGING
BUSHING
LIGHTENING
ARRESTER

TANK
 SOURCE OF OVERVOLTAGE
• EXTERNAL:-
– LIGHTENING
– GEOMAGNETIC STORM.
• INTERNAL
– SWITCHING
• LINE/CAPACITOR SWITCHING.
• INDUCTIVE CURRENT BREAKING.
• TRANSFORMER FEEDER ENERGISATION.
• TEMPORARY OVERVOLTAGE
– 1 PHASE FAULT.
– RESONANCE (SUB HARMONIC)
– TRANSFORMER INRUSH CURRENT
 400 KV system component
• ABCB
• 400 KV CT.
• Insulator
• post insulator
• isolator
 CT
• Resin cast ring type
CT .
• Metering class
• protection class.
• Accuracy .
• Burden .
• Knee point voltage
 LV Transformers
• 3 phase transformers
• Aux transformers.
• Control transformers.
• Interposing
transformers.
• Cell type
• core type
 Generator VT
• Resin cast .
• Protection
• metering
• AVR.
• There are 16 failures
till date
 Current transformers 6.6 KV
• Ring type .
• Bar primary
• resin cast
 Generator Surge capacitor
• Protects from overv-
oltage