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1. TRANSFORMER FAILURE
Damages can far exceed the cost of a replacement sometimes. The added expenses may
include the loss of production time, damaged credibility, regulatory fines and civil lawsuits.
Many experts describe failure occurrences in terms of the “Bathtub curve” (shown in Fig 1)
where it is predicted that “transformer failures increase with time”.
The following graph describes the relative failure rate of a transformer. During their life cycle,
transformers will go through three different periods of failure rates, which explains the “Bathtub”
shape.
• Infant Mortality: Failures are the least expected. Design, manufacturing or material defects
are common causes and require from the manufacturer a deep analysis of the incidents.
• Normal Life: Also called useful life where random failures may occur. This is the lowest
constant failure.
• End of Life Wear-out: Wear and tear make products fail more often and signal the end of life.
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1.2 PREVENTIVE MEASURES
Maintenance is the key to avoid transformer failure. A preventive maintenance schedule consists
of regular inspections and component replacements according to the product-specific maintenance
schedule. Additional measure-+s may include:
• On liquid-cooled units, check the radiators for leaks, rust, accumulation of dirt and
mechanical damage that would restrict the oil flow
• Keep the bushings and insulators clean
• Keep electrical connections tight
• Inspect tap changers on a regular basis
• Transformer windings, bushings and arresters should have a power factor test on a 3-year
basis
2. TYPES OF FAULTS
Faults in the transformer are classified as internal faults and external faults.
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• DETERIORATION OF THE INSULATING OIL, OIL LEAKAGE & OIL
CONTAMINATION
The primary function of transformer oil is to insulate and cool a transformer. The insulating oil
deteriorates gradually with use. The main cause is the absorption of the moisture in the oil. Each
time the moisture is doubled in a transformer, the life of the insulation is halved.
Paper insulation has a much greater affinity for water than does the oil. The water is absorbed by
the paper even from the oil, making it dry.
In addition to serving as insulation, oil serves to transfer the heat generated in the windings and
the core toward the walls of the tank and the radiators. If the oil leaks from the transformer tank
due to some reason, the oil level in the tank will drop. In power transformer, the conservator tank
is provided with an oil level indicator having an alarm facility. If the oil level drops below a
predetermined level, the alarm will ring. It allows the operator to initiate necessary actions.
• COOLING SYSTEM FAILURE
The 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 affects different parts of
the transformer and also it causes more gas pressure to be built inside which may cause the
transformer to blow.
The more easily the heat can be dissipated, the better the working of the transformer. The
role of the cooling system is to increase the capacity of the transformer to carry the load without
reaching critical hot spot temperature.
• CORE OVERHEATING
The transformer core provides a magnetic path to channel flux. Fault in the core directly affect the
transformer windings, causing faults in them. The lamination of the core can become defected by
poor maintenance, old oil or corrosion.
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. 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.
• PHASE-TO-PHASE FAULTS
Phase-to-phase faults are rare in occurrence. Short circuits between the phases will give rise to
substantial fault current.
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• PHASE TO GROUND FAULTS
The impulse voltage or the deterioration of the insulation can cause a short circuit to the grounding
of the winding or of its terminal to the core or to the tank.
Interesting Facts:
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2.2.1 CAUSE OF EXTERNAL FAULT
1. OVERLOADING
Overloads cause the transformer to overheat and have the potential to cause permanent damage or
loss of life to the unit. The time constant for overheating is long, however, and it may take many
hours of exposure for the condition to become serious. In most cases, no protection is provided for
overload, but an alarm will often be used to warn operating personnel of the condition. One cause
of overload may be due to unequal load sharing of parallel transformers or unbalanced loading of
three-phase banks.
2. OVERVOLTAGE
Over-voltage can be either due to short-term transient conditions or long-term power-frequency
conditions. These transients are protected against by surge protective devices that are designed
for this purpose. Such conditions of the over-voltage result in rapid heating of the iron circuits of
the transformer, with possible damage to core lamination insulation and even to winding
insulation.
3. EXTERNAL SYSTEM SHORT CIRCUITS
System faults that are external to the transformer protection zone, but causes high transformer
currents, can cause transformer winding damage. Large external fault currents cause high
mechanical stress in the transformer windings. This short time frame makes it almost impossible
to protect the transformer from experiencing these stresses. The protection strategy for these events
is, therefore, a matter of transformer design.
Usually, the ratio of voltage to frequency should not be allowed to exceed 1.1 per unit, which
is usually called a "Volts per hertz" limit.
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3.1.1 CAUSE OF INRUSH CURRENTS
Any event on the power system that causes a significant increase in the magnetizing voltage of the
transformer core result in magnetic inrush current.
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Fig 5. Fault current Vs Time
• The transformer core flux is directly proportional to the voltage and inversely proportional to
the frequency. The measured V/Hz ratio is, therefore, an excitation indication. When the
allowable V/Hz ratio is exceeded, the magnetic core saturates.
• During saturation, excessive core flux increases the inter-lamination voltages, causing iron
damage (burning, pitting). At this high level, the normal magnetic path cannot accommodate
the increased flux, which flows in leakage paths not designed (not laminated) to carry it,
causing heat damage.
• For almost all transformers, damage occurs at an overexcitation (volts-per-hertz) level of1.25
p.u.
• The type 59F volts per hertz relay is used to protect the transformer against overexcitation.
4. TRANSFORMER PROTECTION
Depending upon the nature and degree of the transformer faults, the suitable protection schemes
need to be selected. According to the magnitude of fault current Transformer faults can be
classified into -
1. Low-Level Internal Fault
2. High-Level Internal Fault
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4.1 PROTECTION FOR LOW-LEVEL INTERNAL FAULTS
A small arc (at the initial stage of insulation failure) may cause heat inside the oil immersed
transformer which results in gas formation inside the transformer. We have two mechanical
Inbuilt relays to detect this type of condition and protect our transformer.
1. Buchholz Relay Protection
2. Pressure Relay Protection
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Working of Buccholz Relay
Whenever a minor fault occurs inside the transformer, heat is produced by the fault currents. The
produced heat causes decomposition of transformer oil and gas bubbles are produced. These gas
bubbles flow in an upward direction and get collected in the Buchholz relay. The collected gas
displaces the oil in Buchholz relay and the displacement is equivalent to the volume of gas
collected. The displacement of oil causes the upper float to close the upper mercury switch which
is connected to an alarm circuit. Hence, when a minor fault occurs, the connected alarm gets
activated. The collected amount of gas indicates the severity of the fault occurred. During minor
faults, the production of gas is not enough to move the lower float. Hence, during minor faults, the
lower float is unaffected.
During severe faults the heat generated is high and a large amount of gas is produced. This large
amount of gas will flow upward, but its motion is strong enough to tilt the lower float in the
Buchholz relay. In this case, the lower float will cause the lower mercury switch to close which
will trip the transformer from the supply. So, the transformer is isolated from the supply.
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• By providing the transformer with a pressure relief valve, the overpressure can be limited to a
magnitude harmless to the transformer.
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4.2.1.1 Need of Differential Protection of Transformer
• Buchholz relay detects the velocity of the gas and works on the principle of mechanical
working and time taken, which is considerable for low-level fault. But for high-level fault, the
fault must be cleared in a very short time which is not possible by Buchholz relay. Hence, we
need the differential relay.
• The differential relays normally respond to those faults which occur inside the differential
protection zone of the transformer.
For comparing the value of primary current and secondary current, two major factors we need to
take care of.
1. Phasing Compensation
2. Magnitude Compensation
• Phasing Compensation
In the past, the phase shift compensation has been done externally, by connecting the CTs from
the Wye winding in Delta, and the ones from the Delta winding in Wye as shown in Fig 9.
The impact of the Delta and the Wye connected CTs placed respectively on both the Wye and the
Delta sides of the transformer is as follow:
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• Perform external phase shift compensation introducing currents with 180° phase shift to the
relay ready for magnitude matching and differential summation.
• Eliminate zero sequence currents (Delta connected CTs) from the grounded Wye winding
and match the zero sequence free currents measured from the Wye connected CTs on the
Delta winding.
Star connected windings have current lagging that of the delta connected winding current by 30
degrees as shown in the above figure.
Since there is a 180-degree phase difference between the two current transformers, current through
CT will be inverted as shown in the above figure.
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Star connected winding transformer is always connected to the delta type current transformer and
hence current will again lead by 30 degrees and phasing is done.
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• Magnitude Compensation
The second most important factor to take in to consideration is magnitude compensation, otherwise
instead of having correct phasing, mismatch current will flow through operating coil and trip off
the primary and secondary circuit breaker of the transformer. The magnitude of the current can be
compensated by the tap settings of the current transformer, which is the CT ratio. CT ratio can be
set on comparing the ratio of secondary current and primary current as shown in the figure.
Always it is not possible to have the correct CT ratio corresponding to secondary and primary
current ratio, so there may exist slight mismatch between them. Mismatch factor can be calculated
as shown in the figure given below. This mismatch factor should not exceed 30% of base current
in normal working condition, otherwise considered as a fault condition.
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4.2.1.3 Limitation of Differential Protection Scheme in Transformer
There are situations when a differential current flow through the relay in normal operation also
and this current is enough to trip the coil though it is not a fault condition.
Because of the above reasons, a differential current will flow through the Differential Protection
Relay. So Differential Protection will operate which is not expected to operate for the above-said
reasons. So, what to do to prevent tripping because of the differential current caused by the
above-mentioned reasons?
To prevent the Differential Protection scheme from picking up under such conditions, a
Percentage Differential Protection scheme is used.
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Significance of Restraining Coil
The restraining coil controls the sensitive characteristic of the relay and ensures the security of the
system in the cost of sensitivity. It restricts the unwanted tripping of the transformer due to the
imbalance current. The restraining coil also restrains the harmonics in the inrush current.
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4.2.2.3 Limitation of Percentage Differential Protection in Grounding Fault
• A percentage differential relay has a certain minimum value of pick-up for internal faults.
Faults with fault current below this value are not detected by the percentage differential relay.
• Winding-to-core faults (as shown
in Fig 13), which are of the single
phase-to-ground type, involving
high resistance, fall in this
category.
• Therefore, we must have a more
sensitive relaying scheme to cater
for high resistance ground faults.
Further, the reach of such protection
must be restricted to the winding of
the transformer; otherwise, it may
operate for any ground fault,
anywhere in the system, beyond the Fig 13: Winding-Ground Fault in Transformer
transformer. Hence, such protection is known as Restricted Earth Fault Protection.
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4.2.3.1 Operation of REF Protection Scheme
• An external fault (Fig 15) in the star side will result in current flowing in the line current
transformer of the affected phase and at the same time, a balancing current flow in the neutral
current transformer, hence the resultant current in the relay is zero. So, this REF relay will not
be actuated for external earth fault.
• But during an internal fault (Figure 16), the neutral current transformer only carries the
unbalance fault current and operation of Restricted Earth Fault Relay takes place. This
scheme of restricted earth fault protection is very sensitive for internal earth fault of the
electrical power transformer.
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Fig 16: Operation of REF for external fault
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4.2.3.3 High Resistance Ground Faults on the Star Side
Fig 18 shows the restricted earth fault protection whose reach is limited to the star side of the
transformer. Ground faults beyond the star side CTs, anywhere in the system, do cause current to
flow on the secondary of the CTs. However, the currents circulate through the CT in the neutral
path and the CT in the faulted phase. Thus, no unbalanced current flows and the scheme remains
stable on external faults.
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