INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3.

May 2010

INVESTIGATING FAILED TRANSFORMER:

CASE STUDY OF A 100KVA, 11/0.415Kv BURNT-OUT DISTRIBUTION
TRANSFORMER, BENIN CITY, NIGERIA
S.O. Igbinovia1, N. Igbinovia2
1
Electrical/Electronic Engineering Dept. Faculty of Engineering, University of Benin
2
Procurement Section, Power Holding Company of Nigeria,
Benin Electricity Distribution Company, Benin City (NIGERIA)
samigbinovia2006@yahoo.com, ngigbinovia@yahoo.com

ABSTRACT

A burnt–out 100KVA, 11/0.415Kv distribution transformer with 26.51 voltage and current transformation ratios
respectively have been investigated in this work.
The methodology is based on the concept of copy creativity and the development of technology within. Routine
and type tests were adopted to find out the probable causes of its failure and extent of damage. The tests results could
not be adjudged to definitive type of fault, hence we had to dismantle the transformer, unblande the yoke and on
thorough investigation, the first two segments of the four layers coils group on the yellow-phase limb had inter-turn short
circuit and completely burnt. The re-wound segments had taps at the 134 and 200 turn’s positions from the top. The re-
assembled transformer was subjected to pre-commissioning test with the secondary circuit indicating sharp flash-over on
the blue-phase an indication of short-circuit when 2.5 Kv was injected, while the primary circuit withstood the 4.5 Kv
injected into it. This outcome prevented subjecting the rehabilitated transformer to further final tests.
The reasons attributed to the cause of damage to the high-voltage blue–phase windings segment could be
manufacturer error due to damping of the blue–phase coils with an iron channel thus leading to gradual winding
insulation failure resulting from the transformer oil overheating. The flash experienced from the secondary circuit when
pressure tested indicated ether inexperience in re-assembling, connecting the joints and tap change contacts. The
calculated transformer equivalent circuit parameters from the no-load and on-load tests gave constant no-loss of
20watts; enable the performance characteristics of the devices.

Key words: Unblade yoke, reblade yoke, coils, insulation, oil overheating, transformer laminations, segments,
performance characteristics

1. INTRODUCTION

Electric energy generating stations are sited near their primary huge re- sources to reduce production cost and
transmission lines losses. The generating units in most cases for technical reasons are built for not higher than 15 to 25
kilo volts and their associated power can be transmitted over a few kilometres [ Faulkenberry L.M and Coffer W, 1996,
Olle E.I, 1925]. Since the energy generated cannot be totally consumed by the industries and its environ, the large bulks
of power for full utilisation has to be transported to localities which lie hundreds and thousands of kilometres away from
power sources where high demand for it exist to large industrial centres and districts. To technically, safely and
economically evacuates quality power over several thousand kilometres, pylons, conductors, insulators, switchgears,
reactive power compensators, power factor connection equipment, switching devices, protection schemes and
transformers are some of the associated equipment required in the circuits to achieve high tension transmission lines
(like 66Kv, 132Kv, 330Kv, 450Kv, 500Kv, 750Kv, etc.) depending on the countries electricity regulatory act. In power
systems, transformers built in few volts – amperes to several thousand kilovolt-amperes are static electromagnetic
devices that transform voltage from higher level to lower level and vice versa. (i.e. step–up the voltage at the generating
end and step-down the voltage at the consumer’s end). In these wise transformers are very important links between
generation stations and the end users of the generated energy which cannot be conserved [Glover J.D and Sarma M.S,
2001] as shown in figure1, must be given due engineering, installation, maintenance and repairs in case of failures to
guarantee adequate and reliable power supply. Since this is the backbone of technological revolution and developmental
sustainability, this work was started with the following key desire;
 The technological development of a country depends to some extent on the development from within
 Practical realisations of technical concepts and in so doing if some relevant skills, crafts and practices of
engineering and technology we be acquired
 Economic use of natural available resources/materials for making or improving parts or the whole device
(research and development)
 Practical awareness of engineering designs and related problems and how these problems are overcome
 The need for on-the-job training as necessary repair techniques and experiences are being gained and
developed
 Experimental effort to find out what technologies (apart from usual transformers space theory) are involved in
the manufactures, construction and design factors
Therefore all over the world, the dissatisfaction in the mind of consumers of electric energy from power utilities
insist ant power disruption and breakdown of power systems key components like generators, transformers, switchgears,
relays, etc. mostly in developing countries which lacks the technological know-how and thus very far from self-
sustenance, value engineering and the principle of break-even and cost benefit analysis must be the watch dog of

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 INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3. May 2010

nations utilities like Nigeria National Electric Power Authority (NEPA) now Power Holding Company of Nigeria (PHCN)
that now have the mandate not to practice monopolised vertically structured electricity body. From value analysis the unit
cost and selling price in naira of a given device (like transformers, generators, switch-gears etc.) can be expressed as [
Kuale P.A and Chuku A.U, 1980];

Where = Total number of items manufactured for a given period

= All conceivable cost items (labour, management, energy, research and development, materials, charges on
capital investment, interest etc.)
= Sellers profit
= Market inflation factor
= No. of locations (in zones) into which the country is divided for estimating the broken-down items
If such reparable devices breakdown per year in an ith location, the total breakdown of the same type in a
given country becomes;

To effectively be able to repair some of or all these failed devices economically mean the development of some of
the skills and practices involved in the technology of manufacturing of these devices/equipment /apparatus, otherwise the
mean time to restoration will be so discouraging and frustrating. In other to avoid these colossal losses utility boards
specify capitalisation formulae along with enquiries as [Singh B, 1982];

Capitalised costs in naira = quoted cost of transformer in naira + (no- load loss in watts) x 13.2 + (load loss in
watts) x 4.6 ………………………………………….…… (4)

Equation 4 represents the operating cost over a certain period of time, and in this way offers by various
manufactures are compared. Factors compound rate of interest, depreciation, load factor etc affects capitalised cost and
best selected values for the losses are used to give minimum capitalised cost. The cost optimisation of these devices
depends on the economic selection of the core area, current density, other design features and technology developed.
Therefore in general the distribution transformer cost can be classified as (1) the cost of investment, (2) the cost of lost of
energy due to losses in the transformer and (3) the cost of demand cost (i.e. the cost of lost capacity) due to the losses in
the transformer [Gonen T, 1986].

2. PRINCIPLE OF OPERATION OF TRANSFORMER

Faraday’s law of electromagnetic induction (1831) manifest itself in the operation of this static electromagnetic
device using the following relationships; [ Faulkenberry L.M and Coffer W, 1996, Glover J.D and Sarma M.S, 2001, Singh
B, 1982, Deshpande M.V, 1994, Deshpande M.V, 1986, Say M.G, 1958, Symonds A, 1980, Mehta D.P and Thumann
A, Matsch L.W, 1977, Gebert K.L and Edwards K.R, 1974, Theraja B.L and Theraja A.K, 2008];
V1 N 1
  n ...... ............................................................................................................(5)
V2 N 2
2 2  
 V1 Cost  V1 Sin t  , Weber ................................................(6)
N 1 N 1  2
2
m  V1 , weber  S r 10 3 /( 4.44 f ), weber …………………………….……(7)
N 1
From equation 7, the voltage per turn (VPT) an important design parameter is given as;
V1 V2  max 2fABmax
Et      4.44 fAi Bmax , volts...................................(8)
N1 N2 2 2
= k S …………………………………………………………………………………………..(9)
Where,
V1 = voltage induced in the primary winding, volts
V2 = voltage induced in the secondary winding, volts
N1 = number of turns in the primary circuit
N2 = number of turns in the secondary circuit

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 INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3. May 2010

n = transformation ratio
 
Sin t   = sinusoidal wave form of the sinusoidal excited electromagnetic device
 2
= sinusoid ally vary flux of amplitude and frequency f, Weber’s
 = angular frequency rad/sec
r = ratio of  m / IN , constant for a type of transformer of a given type, service and method of
construction

K =constant ( 4.44 fr10  ), which depends on type, material and labour

3

cost, factory organisation, etc

S = KVA rating of transformer
f = supply frequency, HZ
 max = amplitude of sinusoidal flux density, which depends on the type of magnetic

material and the losses ratio , Telsa

A = net cross–sectional area of the iron core

The same assumptions are used in analysing ideal and practical transformers in which the core material is
characterised by infinite magnetic permeability and zero core reluctance (   0 )), and infinite resistivity, a finite value
of flux requires an magneto motive force (mmf) of zero such that whether under no-load and under loading conditions,
the following relationships holds for the mutually coupled circuit; (Gonen T, 1986, Say M.G, 1958, Matsch L.W, 1977,
Theraja B.L and Theraja A.K, 2008 )
I 1 N 1  I 2 N 2  0 ......................................................................................................... (10)
I1 N 2 1
  ................................................................................................................(11)
I L N1 n
While the obtainable power from the device is given by; ( Symonds A, 1980, Mehta D.P and Thumann A,
Theraja B.L and Theraja A.K, 2008, Draper A, 1971,)
P= = 3V L I L Cos , watts........................................... ……………. ..(12)
Where:
= Ampere – turn balance
= current flowing in the primary circuit, amps.
(=-I L )= current flowing in the secondary circuit, amps.
VL , I L = supply line voltage and current respectively
Cos  = the load power factor
 = the no-load phase angle
This power is not limited in ideal transformer but in the practical (i.e real) transformer, the actual losses which
occur although relatively small set a definite limit to its power capability [ Deshpand M.V, 1994, Say M.G, 1976]

3. DESIGN EQUATIONS

One of the outlined objectives of this study was to be able to design for any of the failed designed features and
return the failed system back to its initial functional state. Thus from the very small rating,  IVA to very large rating,
 500MVA the basic design equations applied are [ Deshpand M.V, 1994, Deshpand M.V, 1986]:
10 3 S ………………………………....................................……………(13)
Ai Aw 3 
2.22 fFC JBmax 
103 S ……………………………………………………………………….(14)
Ai Aw1 
2.22 fFC JBmax 
The empirical formula for Fc is;
 VA 
FC  0.1  0.08 ln    0.2 ln KV  …………………………………………………(15)
 10 
While the ratio of magnetic loading to electric loading is;
f
n ………………………………………………………………………………………..(16)
N1 I 1
Where,

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Ai Aw = Core-section and window core areas respectively, m2

FC = Copper space factor, found in transformer textbooks
J = current density,

4. CONSTRUCTIONAL FEATURES

To obtain the desired capability the following features make up the complete transformer: [Singh B, 1982,
Deshpand M.V, 1994, Say M.G, 1976, Gebert K.L and Edwards K.R, 1974, Theraja B.L and Theraja A.K, 2008, Draper
A, 1971]

1. Ratio or tap charger

2. Tank
3. Terminal bushings/mounting flange
4. Cooling fins/conservator
5. Insulating materials
6. Transformer core with minimum air-gap
7. Copper conductor (i.e. H.V $ L.V coils)
8. Oil level gauge
9. Temperature sensors
10. Current/voltage transformers
11. Breather for large sized transformers

In practical transformers, two forms of magnetic circuit are found, the core-type and the shell–type and each has
its own merits and demerits. In the three-phase 100KVA, 11/0.415Kv, 50Hz, burnt-out distribution transformer, the core
construction is the core-type made up of steel sheet with 4% silicon laminations insulated with a costing of insulated
varnish between them as shown in Figures 1a & b.

P RIM A R Y A N D
SE C O N D A R Y O F hw PRIM A R Y A N D
P H A SE -1
PH A SE -3

Ww
P RIM A R Y A N D
SE C O N D A R Y O F
P H A SE -2

Fig 1a. three-phase transformer core-type

P
P P
Ph 1 O 1 Ph 2 O 2 Ph 3 O 3

S S S

Fig 1b. Three- phase transformer core type balance fluxes

The fluxes in the core arrangement for balance voltages transformation as shown in figure 1b is expressed as:
 2   2 
   1   2   3   m  cos t   m cos t     m cos t  0 (17)
 3   3 
Equation (17) shows that for the three-phase symmetry, there is no need for a magnetic return path. This design
saves transformer core, and consequently also saves core losses [ Olle E.I, 1925, Draper A, 1971].
It was found in our investigation that the windings were well positioned not to allow movement in the axial
direction. The limbs carried multi-step cruciform section approaching a circle (i.e cylindrical or spiral windings (4)) in the
high voltage circuit with the two inner coils suitably tapped, while the low voltage circuit had one coil group per phase. In
this investigation we found that cross over, continuous disc and helical winding formations [Singh B, 1982] could be used
in distribution transformers. The 0.4mm cores limbs laminations were stacked together in steps, so as to interlock the

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 INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3. May 2010

yoke laminations in a circle of predetermined diameter shown in figure 2. The cross members (yokes) served to complete
the magnetic circuit. These top yokes shown in figure3 were unbladed to remove the burnt coil and rebladed after the
coils were rewound and assembled. The studied transformer uses mineral oil as the cooling medium for transferring the
thermal power generated (losses) in the core and windings to ambient air, while in power transformers the losses are
dissipated to running water by thermosyphon actions and pumps. It was also found that major and minor types of
insulations were used in the transformer manufacture. Suitable ducts were kept between the core and coil as well as
between coils. This particular transformer has tapping range of 20% in 16 steps of 1.25%. The coarse/fine tapping
arrangement has a modified version with a linear switch arrangement for four coarse sections each equivalent to four fine
sections. The disadvantage of this arrangement is that high surge voltage can occur on the tap charger at transition.
Other types of tapping winding arrangement used in transformers are linear – tapping winding arrangement and reverse
– tapping winding arrangement.

OIL
. ..
.. .. ..... .... . .
A HIGHH VOLTAGE
. .. ......... . .. ............. COIL
... .... ........ INSULATION
. ..... . . . BETWEEN HV COIL AND LV COIL
.. . . . . .. .... .. INSULATING
. ... .. ... ..... ... .
. .. ... .. . . BOARD

IRON-CORE

Fig 2. Shows core-section of a 3- transformer with circuiting strip AB

TAP - ADJUSTER
TAP CHANGER CHORD

PRIMARY
TERMINAL
LEAD

PRIMARY
END BOX

TAN
K

STALK OF LAMINATINGS

SECONDARY TERMINAL LEADS

SECONDARY END BOX

Fig 3. Shows the top view of a 100KVa, 3-o
burnt-out (11/0.415KV) distribution transformer

5. DETERMINATION OF THE CAUSE OF FAULT AND REPAIR

The failed transformer was subjected to routine defects determination, results obtained is as presented in
Tables1, while Table2 presents other measurements taken.

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Table1. Insulation resistance test

High – Voltage windings test High – Voltage windings and body of transformer (tank)
Description Reading Description Reading
Red – Yellow 0.75 ohms Red phase – earth 1000 ohms
Yellow – Blue 0.75 ohms Yellow phase – earth 1000 ohms
Red – Blue 0.75 ohms Blue phase – earth 1000 ohms
Continuity Test
Low Voltage Windings to Earth Low Voltage to High Voltage Side
Description Reading Description Readings
Red phase to earth ohms Red phase – red phase Mohms
Yellow phase to earth ohms Yellow phase – yellow phase Mohms
Blue phase to earth ohms Blue phase to blue phase Mohms
Red phase – lamination core ohms
Yellow phase – core lamination ohms
Blue phase – core lamination ohms
Between phases – core ohms
Core -core 0.0 ohms
Remarks Readings suggest that
transformer is okay
Low voltage side after unblading Continuity test of the high voltage side to low voltage side
after unblading
Description Reading Description Reading
Red phase – yellow phase 1.0 ohms Red phase – red phase ohms
Yellow phase – blue phase 1.0 ohms Yellow phase – yellow phase ohms
Red phase – blue phase 1.0 ohms Blue phase – blue phase ohms
All Phases to earth ohms All phases to earth ohms
Remarks Readings suggest that
transformer is okay

Table 2. Other measurements taken after unblading

S/N Description Measurement

”
1 Diameter of coil 1.295mm (0.048 , SWG 18)
2 Diameter of lamination 1.00mm
3 Lamination triangular groove length 11cm
4 Length of lamination 58.00cm
5 Length to centre of groove 29cm
6 From end of lamination to the diagonal 10cm
7 Number of coil – turns in each segments 748 (actual ±10)
rd
8 Tapping positions in the 3 segment 134 & 200 turns position from the top
9 Wood packing insulation found in between coils segments with
cringed paper
10 Break-down dielectric strength voltage of the transformer oil Average of (22, 32 and 30Kv) gave 28Kv, which is okay
since its above 25Kv for old samples
O
11 Temperature of the transformer oil that have been off – load for 31 C
over a year
12 Wooden former of 180mm diameter and 40mm height was used
in rewinding the transformer

From the tests results, there were no clear indications of the extent of damage. Determination of the defects
therefore involved my dismantling, unblading and manual unwinding of burnt coils in the transformer. We found out that
two segments of the blue-phase high voltage assembly were completely burnt. After thorough examination, we
concluded that the failure could be due: to incorrect assembly of the high voltage winding coils which probably came in
contact with the laminations thus causing inter–turn short-circuit resulting in over heating of the cooling oil causing it
natural ageing and wear of the winding insulation, periodic overloading of the transformer and dynamic stresses resulting
from through short–circuit currents and the burnt contact surfaces of the tap–charger attributed to excessive–arcing from
frequent switching currents. Considering the efforts it took to localise the faults, the faults in the transformer would have
been identified by the colour of the gas in the electromagnetic relay if the transformer had one.
O
The wound dried windings were impregnated while still hot at temperature of 75 C by immersing them for about
O
thirty minutes in a bath filled with glyptic varnish before they were baked in an oven at a temperature about 100 C for 24
hours to increase the winding electric strength, make the winding monolithic and increase in the mechanical strength
O
after which they were stored at room temperature of ±5 C. Spot welding equipment was used in the soldering process to
the compensators and ends of the windings. After the coupling, the immersed transformer core and coil properly dried in
a heat chamber to expire the moisture contained in the winding and core insulation having been left opened for quite
some time was then subjected to pre –commissioning test.

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 INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3. May 2010

6. EXPERIMENTAL TEST RESULTS AND ANALYSIS

Transformers either in new or repaired state is usually subjected to routine, special and type tests to confirm if the
device will meet up with the required specifications in conformity with designer and IS 2026 (part 1) – 1977 “ specification
for power transformer” and users desire. These tests include [Singh B, 1982, Gonen T, 1986, Deshpande M.V, 1994,
Say M.G, 1958, Symonds A, 1980, Mehta D.P and Thumann A, Umeojiaka A.O, 2009, Stigant S.A, Lacey H.C, and
Franklin A.C, 1973]:
1. Core insulation tests to prove that the magnetic circuit is positive
2. Ratio tests: ±0.5% of the declared ratio or ±10% of the percentage impedance whichever is the
smaller is considered
3. Phasing/Additive and subtractive polarity(Flick)/Vector group verification tests
4. Insulation/Earth resistance tests
5. Resistance of windings test (continuity test), not applicable to zig-zag transformer windings
6. Surge – voltage withstand test; (a)Full- wave test, (b)Chopped – wave test (type test)
7. Separate – source – voltage withstand tests
8. Induced – over – voltage withstand and internal discharge tests.
9. No load loss and no – load magnetising current test
10. Noise test
11. Load loss and leakage impedance voltage test
12. Zero – sequence impedance test (special test)
13. Top oil temperature rise test (type test) or Heat run test
14. Capacity confirmation test
It is important to note that a transformer Basic Insulation Level (BIL) between 5 and 30 times the insulation class
is the peak transient voltage level that the transformer can withstand for a specified time. While the insulation class of a
transformer is the maximum root mean square working voltage of the transformer [Faulkenberry L.M and Coffer, 1996].
To buttress this fact the high voltage test of the repaired transformer is presented in Table3.

Table 3. High Voltage Flash Test

Voltage applied Description Remark

4.5 KV Between core and bolts No break-down of insulation
Between high voltage phases No break-down of insulation
2.5KV Between low voltage phases Break-down occurred due to short-circuit

The sudden abrupt short–circuit fault was not apparent at the time we ascertained the causes of the transformer
break-down. It was suspected this could have resulted due:
i, to inexperience in handling the essential components after the burnt H. V. layers rewound in NEPA Ijora
Electrical Central workshop for a week and assembly
ii none use of adequate testing instrument/equipment, special repair/ assembly tools and
iii since the other parts were left in the workshop and the layers I brought back from Lagos must have
accumulated dust and moisture, not dried and transformer oil not filtered due to unequipped laboratory, and hurriedly
assembled to carry out the final tests.
From the no-load and on-load tests carried out and the equivalent transformers parameters calculated the
simplified equivalent circuit as shown in figure 4 can be used in evaluating the performance characteristics of the device
having constant no-loss of 20 watts at different loading conditions.

Fig. 4. Simple equivalent circuit of the practical transformer

Where,
V1, V2 = the primary and secondary voltages respectively
IP = current drawn from the source of supply
IO = no- load current
IC = copper loss current component, amps, in phase with V1

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0
Im = magnetising current, amps, lags 90 behind V1
1
IP = active current component, amps
IL = load current, amps
Using Figure 4 the following relationships can be determined [Glover J.D and Sarma M.S, 2001, Singh B, 1982,
Deshpande M.V, 1986, Matsch L.W, 1977, Draper A, 1971];
2
The device percentage impedance, %Z = % R   % X 
eq eq
2
, ohms………… .(18)
2
N 
Where the equivalent circuit resistance R = R1    R2 …, ohms………………(19)
N 
 
2
N 
While the equivalent circuit reactance X eq = X 1 +   X 2 …, ohms……………….(20)
N 
 
The voltage regulation of this device at a specified time and power factor, the primary voltage remaining constant
is;
E s  V2 I L Req Cos  L  X eq Sin L 
= X 100  ……………………………….(21)
Es Es
While the efficiency of the practical transformer can be determined using the relationship;
Losses
Efficiency () = 1- …………………………… ……………(22)
Output  Losses
The total losses include electric circuit loss, magnetic loss and dielectric loss. The load at which the efficiency is
highest can be found from [Singh B, 1982, Gonen T, 1986];
1
 ironloss  2
%Load = 
 copperloss  X 100 …………………………………………………………(23)
 
Where;
R 1 , R 2 = primary and secondary resistance respectively
X 1 , X 2 = primary and secondary reactance respectively
Es = secondary no-load voltage
3
The losses in a transformer are roughly proportional to its weight, that is, to (length) , and the surface area
2
through which the dissipation of the losses takes place depends on (length) , it then follows that the larger the
transformer the more difficult is the problem of heat dissipation unless material is to be used in uneconomic proportion].
The practical transformer depending on the operating conditions, the calculated copper temperature rise must not
0 0 0
exceed 250 c starting from an initial temperature value of 90 c for water cooling and 105 c for air cooling. The
temperature rise is calculated from [Say M.G, 1958];
0
 2T  at 620 K d 
  at  1  C ………………………………………………...…..(24)
 2T1 2T1  at 
Where,
t = time in sec.
T1=  1 +234.5 0 C
1 = initial temperature in 0 C
0
K d = eddy-loss ratio at 75 C
2 2 5
a = 0.0025 x loss in W. per kg. at 1 , or in terms of current density  in A. per mm , a = 1.9  T 1 x10 .
With all these parameter values affecting the efficiency value the all day efficiency of a practical transformer is
given by the relationship[Deshpand M.V, 1994];
Outputofthetransformerinkwhin 24hrs
All the efficiency = ……………………(25)
Inputofthetransformerinkwhin 24hrs
6.1 Precautions

To operate a transformer close to the normal life span of about 30years depends on the operational condition and
the maintenance procedures adopted. Thus service life of the oil in a practical transformer is halved if its temperature is

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 INTERNATIONAL JOURNAL Of ACADEMIC RESEARCH Vol. 2. No. 3. May 2010

O
10 C above normal [Singh B, 1982, Gonen T, Deshpande M.V, Deshpande M.V, 1986, Say M.G, 1958]. Therefore if the
O
oil is to have a longer service life, transformers should be operated so that top-oil temperature does not exceed 85 C
O O
(i.e. should not exceed 50 C above an ambient temperature of +35 C). Installation of The Internal Fault Dectector (IFD)
which functions incorporates the pressure-relief device(PRD} and provides a visual indication on whether the transformer
has faulted internally from IFD Corp.(Vancouver, Canada)[ Desrosiers D, 2006] to improve worker productivity, enhance
customer service and increase overall safety associated with transformer failures as found on pole-mounted transformers
should be incorporated in distribution transformers to improve electric energy consumption and remove the decision
whether to re-fuse a transformer and put it back in service.

7. FACTORS THAT CAN IMPAIR TRANSFORMER PERFORMANCE

 Careless handling of lamination (blows, mechanical hymy, scored insulation) during unblading and
reblading
 Cooling arrangement (i.e. areas of maximum temperature in the core windings, the so – called hot
spots, always below specified maximum values)
 Over- heating of the transformer core and windings can damage the core (burning of the core) and
accurate ageing of the laminations and thus reduction of the life cycle of the transformer
 Lowered flash point caused by cracking (decomposition) of oil due to local overheating due to several
internal faults (like breakdown of the internal insulation between the core steel laminations, poor
contact in the trap changer switch, surge voltages which can develop particularly across the tapping
range, windings or terminals under the cover, partial turn – to – turn short-circuit in winding which
provides a short – circuit for a heavy current) that can result in very serious overheating.
 Mechanical impurities
 Increased viscosity of the oil
 Reduced electric strength(breakdown voltage)of the oil (28KV when tested for the burnt transformer)
 Increased acidity of the oil as a result of oil deterioration
 Moisture continent increase
 Inability to carryout the required maintenances
 Unavailability of testing equipments/tools

8. EXPERIENCES GAINED

Experiences acquired in this work include:

 Dismantling and blading techniques acquired
 Re-winding skill and repair techniques acquired
 Designing for any of the faulty components to achieve new system was acquired
 The best maintenance procedures to be adopted for practical transformers was also acquired

9. CONCLUSION

The investigation of the burnt 100KVA, 11/0.415kV distribution with 26.51 voltage and current transformation
ratios has been successful in this work. The burnt two segments of the high voltage blue-phase having 748 turns
rewound with standard wire gauge (SWG) 18 subjected to routine and final tests tested okay but when the re-assembled
transformer was pressure tested on the low voltage side flashed at 2.5KV indicating short circuit of the inter-turns
windings a fault that did not present itself before we took the burnt segment to NEPA rewinding section at Ijora Lagos for
rewinding. The investigation was very interesting and challenging because of the enormous skills, techniques and
experiences required in carrying out perfect repairs and refurbishment of power equipments like transformers a very
important link in power transmission and utilization. Though we were able to determine the machine equivalent circuit
parameters that enabled the performance characteristics to be analysed, putting the re-assembled transformer on load
became unrealistic because of the flash-over experienced. If tertiary institutions laboratories are equipped with modern
power equipments/tools, carrying out investigations of this nature will go a long way in our nation self reliance and
technological break through.

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