TRANSFORMER TRANSFORMER

PROTECTOR PROTECTOR

Copyright © SERGI – Non Contractual Document referenced fTPq09a

www.sergi-france.com The only solution

Technoparc - 3 rue Gustave Eiffel - 78306 Poissy Cedex - France
Phone: 33 1 39 22 48 40 - Fax: 33 1 39 22 11 11 - E-mail: sergi@sergi-france.com
against transformer explosions
Company profile Why transformers need to be
Foundation
EFFICIENTLY PROTECTED
SERGI “Société Générale d’Etudes et de
Statistics
A 7 months Internet search conducted by the SERGI Research Department led to the discovery of 620 transformer
Réalisations Industrielles” was created in
explosions in the USA alone. Explosion and fire costs and production losses have risen up to hundreds of millions of US
1955 for the design and manufacture of oil- Dollars. An article will be published on this work in collaboration with an insurance company and a consultant company.
filled transformer fire extinguishing systems.
Since then, the company has been specialised
in the transformer fire protection business. Costs involved
In the event of a transformer explosion and fire, the human, economic, political
In 1957, SERGI and Electricité de France and ecological consequences can be dramatic. Consequences include:
invented the Transformer Nitrogen • death or severe injury to people;
“Drain and Stir” Fire Protection. • electricity production loss and economic loss from the importation of energy
resources;
• replacement of the transformer and of the affected substation or power plant
equipment;
Research Programme • reduction of productivity;
• pollution to the environment;
In 1992 the company started intense • bad publicity for the company through media and shareholders.
investigation in order to understand all
parameters related to transformer explosions
and fire. SERGI built up a Database of The TRANSFORMER PROTECTOR acts before any damage is done
transformer explosions, compiling all
information gathered since 1955.
SERGI has investigated the causes of transformer explosions to
design a system able to protect all kinds of transformers efficiently
In 1995, after analysing the Database, and avoid the massive consequences of their explosions. Purchasing
SERGI decided to launch the TRANSFORMER PROTECTOR:
an extensive Research Programme. • saves all equipment and building that surround transformers from
explosion and fire, since the danger is channelled far away from
the transformer environment;
TRANSFORMER PROTECTOR • enables the quick internal repair of the transformer;
• leaves the environment unharmed in case of incident.
As a result of the Research Programme,
a transformer explosion prevention technique
was invented in 1999 and patented worldwide.
Today, the TRANSFORMER PROTECTOR is the For how long are you going to endanger
sole technology that saves transformers from
explosion and fire.
your plant and company ?
TRANSFORMER PROTECTOR documentation
Transformer Protector Vertical Depressurisation Set,
used for retrofitting Publications Technical Documents
[1] Development of a Magneto-Thermo-Hydrodynamic Model and Design of a [6] TRANSFORMER PROTECTOR Presentation, ref. fdcb
Transformer, On load Tap Changer and Bushing Oil Cable Box, Explosion [7] Adaptation on New Transformers, ref. fTPb
and Fire Prevention, IEEE Publication, ref. rpiip01a dated 02/05/99 [8] Adaptation on Existing Transformers, ref. fTPc
[2] Comparison of the SERGI developed Magneto-Thermo-Hydrodynamic [9] On Site Erection, Commissioning and Testing, ref. fTPi
Model results with measurements made on a 160KVA Transformer, IEEE [10] System description to be used for Customer Technical Specifications, ref.
Publication, ref. rpijp01a dated 29/05/00 fTPd
SERGI expertise in transformer explosion [3] Study and Design of Power Plant Transformers Explosion and Fire
Prevention, Australia, TechCon 2001, ref. rpitp05a dated 19/04/01
[11] Comparison with Fire Extinguishing and Water Spray systems, ref. fTPg
[12] On Load Tap Changer Rupture Disk Testing, made with Maschinenfabrik
[4] Pressure Relief Valve efficiency calculations by comparison to the SERGI Reinhausen in Mexico on December 4-8 2000, ref. eq4d
prevention is recognised worldwide TRANSFORMER PROTECTOR during transformer short-circuit, ref. rpisp01a
dated 20/06/01
[13] Conservator Shutter, ref. fTLa

[5] TRANSFORMER PROTECTOR tests, to be published by the end of 2002.

The information supplied in this brochure only relates to severe incidents,

CAUTION and does not apply to normal transformer operation. 3
 Research Research
The MTH Model [1], [2] TRANSFORMER PROTECTOR and
Temperature in F
800 1200 1600 2000 2400 2800

5
1,2 year 70
1 month

In 1995, an extensive research programme on the energetic transfer phenomenon that occurs
within a transformer during a short-circuit was implemented by SERGI. The mechanism of oil
4 days
10 hours

1 hour
Pressure Relief Valve comparison [4] 4 Pressure limit
Without protection
With a 6" Pressure Relief Valve
With a 6" TP
60

50

decomposition under thermal effects was analysed and resulted in the development of a 6 mn

Pressure in psi
Pressure in bar
36 s 3

Magneto-Thermo-Hydrodynamic model (MTH) [1]. 3,6 s The TRANSFORMER PROTECTOR and Pressure Relief Valve behaviours 40
0,036 s
0,0036 s
have been simulated under the same short-circuit conditions in order to 30
2
Accurate calculations were performed on transformers whose operational characteristics were 300 400 500 600 700 800 900 1000 1100
compare their performances. In each simulated case:
20
previously measured experimentally. SERGI therefore successfully validated the MTH model Temperature in C
• the TRANSFORMER PROTECTOR surpassed the Pressure Relief Valve 1
calculation in collaboration with a transformer manufacturer [2]. Time for mineral oil to generate:
and prevented the transformer tank explosion; 10
• one litre of gas versus temperature, °C.
• one gallon of gas versus temperature, °F. • the Pressure Relief Valve never avoided transformer tank explosion. 0 0
200 210 220 230 240 250 260 270 280

Time in ms

Power Plant transformers [3] Evolution of pressure with different protection systems for

Due to the generator inertia, power plant transformers suffer harsher fault conditions than
TRANSFORMER PROTECTOR tests [5] a small 60 bar/second (870 psi/s) pressure gradient

transmission and distribution transformers. Therefore, SERGI decided to investigate the explosion A total of 28 tests have been performed at the Electricité de France High Voltage Laboratory with the TRANSFORMER PROTECTOR to
of a power plant step-up transformer to design a system capable of preventing any kind of demonstrate the successful operation of the system and to prove its efficiency. Short-circuit conditions were simulated in a transformer tank
incident on any kind of transformer. full of dielectric oil. Electrical arcs were ignited with currents from 2 500 to 7 500 amperes and the arc energies were as high as 300 kilojoules.
During this investigation, SERGI discovered that electrical arcs inside transformer oil could The arcs were ignited by a fuse between two electrodes, creating short-circuits within the oil tank. These conditions were chosen to provoke
produce pressure gradients from 300 up to 930 bar/second (4 000 to 13 500 psi/s) and developed pressure gradients up to 930 bar/second (13 500 psi/s) calculated for power plants, when the generator inertia carries on feeding the short-
Computerised transformer design using a technique able to relieve internal overpressure before tank explosion. circuit [3]. During the 28 tests, pressure gradients ranging from 200 to 1 200 bar/second (2 900 to 17 400 psi/s) were measured.
the MTH model

The pressure gradients and tank depressurisation aspects encountered in the tests are in agreement
Pressure Relief Valve [4] with the values calculated using the MTH model before. In some tests, a combination of a
TRANSFORMER PROTECTOR and a Pressure Relief Valve was used to determine the difference in
For more than 30 years, Pressure Relief Valves have been used to protect Diaphragm
opening times of both devices. Every test confirmed that the TRANSFORMER PROTECTOR always
transformer tanks. However, all transformers that explode are equipped with activates before the Pressure Relief Valve. Buchholz measurements were taken to verify the
this device. The incapability of Pressure Relief Valves to release the pressure in behaviour of normal transformer instrumentation during strong short-circuit conditions. It was found
these cases led SERGI to conduct their dynamic mechanical study. In fact, such Oil that the Buchholz pressure signal always occurred 20 ms after the TRANSFORMER PROTECTOR had
calculation could not be conducted until the pressure gradients during short- exhaust
activated. Also, the Buchholz was unable to detect any of the gases generated by the electrical arc
circuit conditions had not been determined, and SERGI discovered them [1], [3]. section
throughout its duration of 80 milliseconds.

Performances of Pressure Relief Valves rely on their response time, Pressure

Relief Valve The TRANSFORMER PROTECTOR was shown to operate successfully during each test, and is able to
Gas generated by the electrical arc
depressurisation speed and capacity to maintain a low pressure inside the eliminate the strong pressure gradients that develop in the oil tank. In addition, the flammable gases
Body inside the tank
tank during short-circuit conditions. Their performances are strongly bound to created by the electrical arc were exhausted to atmosphere, avoiding any fire in the laboratory.
their geometry.
Symmetry axis Fluid entrance
SERGI therefore verified the dynamic behaviour of Pressure Relief Valves for
2-D Pressure Relief Valve fluid flow image,
pressure gradients calculated during low impedance faults, such as power Depressurisation
60% opened Set efficiency
plant step-up transformer faults [3].

14000
Pressure Relief Valve 1000
250
20 evacuation section
12000
18 versus opening 800
TP Section 12" 200
Time, millisecond 0 ms 2 ms 4 ms 6 ms Fully opened
Evacuation section (inch2)

Flow in gallon / second

16 TP Section 10"
Flow in litre / second
Evacuation section (mm2)

10000
14
TP Section 8"
600
TP Section 6" 150
8000 12 PRV section 6" Oil expulsion to the
10
6000
TRANSFORMER 400
100
Oil-Gases
8
4000 6 PROTECTOR and Pressure Separation Tank
200
2000
4 Relief Valve dynamic flow 50
Average velocity:
2
comparison under a 0.8 16.8 meters/s
0 0 0 0
0 4 8 12 16 20 24 28 32 36 40 44 bar (11.6 psi) pressure 0 1 2 3 4 (55.1 feet/s)
Diaphragm opening height (mm) step Time in milliseconds

Time, millisecond 10 ms 20 ms 30 ms 40 ms
SERGI determined the Pressure Relief Valve spring inertia and energy losses, depending on its geometry and pressure gradients. The evacuation
section area and flow rate were calculated for various cases using finite element analysis. This enabled the understanding and quantifying of
the Pressure Relief Valve hydraulic behaviour throughout depressurisation, while subjected to different pressure gradients. A series of tests was also performed with an obstruction made of Bakelite between the arc and the Depressurisation Set, covering a third of
the tank surface area. The purpose of these tests was to verify the theory of the pressure wave delay inside the tank, due to the core and
The TRANSFORMER PROTECTOR was subjected to the same complete study, including mechanical and hydraulic finite element analysis of the windings. The presence of this obstruction did not interfere at all with the proper behaviour of the TRANSFORMER PROTECTOR. The light
whole depressurisation process. These calculations determined the performances of the TRANSFORMER PROTECTOR Depressurisation Set, obstruction remained unaffected and the depressurisation efficiency was unaltered. This therefore confirms that pressure always
including its opening parameters, according to its geometry and physical material properties. equalises before tank rupture occurs, since transformers always explode at their weakest point.
4 5
 TRANSFORMER PROTECTOR TRANSFORMER PROTECTOR
1-2 Transformer and On Load Tap Changer
Description Depressurisation Sets
All Depressurisation Sets include a Rupture Disk to relieve overpressure
Principles and a Decompression Chamber to favour high-speed depressurisation.
The TRANSFORMER PROTECTOR is a concept that can be applied to all transformers from 0.1MVA [6]. It enables to: Their diameter is calculated individually for each transformer and On
• depressurise tanks within milliseconds; Load Tap Changer types. In addition, transformer tanks Depressurisation
• avoid contact between air (oxygen) and the evacuated explosive gases; Sets also include an Isolation Valve and an Expansion and Vibration
• separate gases from the oil; Absorber.
• channel the gases far from the transformer environment to a remote area where they can burn
safely, such as in an oil refinery;
• eliminate the generation of explosive gases by making use of nitrogen injection.
7 Conservator Shutter
The Conservator Shutter prevents the
The TRANSFORMER PROTECTOR is a passive mechanical system, which can only be activated conservator tank from draining as it
by the level of transformer tank internal pressure reached during short-circuits. automatically closes when an unusual oil
The TRANSFORMER PROTECTOR has therefore a very high reliability, as false activation is impossible. flow is detected. It avoids to oversize the
TRANSFORMER PROTECTOR MTP Type
Oil-Gases Separation Set.
Different designs can be applied to this concept, according to the transformer characteristics and grid location. protecting 2 transformer tanks.

8 Control Box
Located in the plant Control
Room, it ensures the logic of the
system. The Control Box is
TRANSFORMER PROTECTOR MTPA Type
connected to all transformer
protections and to the
TRANSFORMER PROTECTOR. A - Isolation Valve Flange
B - Isolation Valve
6 C - Absorber
8 D - Rupture Disk
7 2 E - Decompression Chamber
F - Shock Wave Protection
Shutter

5-6 Oil-Gases Separation Set

The Oil-Gases Separation Tank (5) collects a
mixture of the depressurised oil and flammable
gases. Then it separates gases from the oil, as
they are channelled through the Explosive
Gases Evacuation Pipe (6) to a remote area

4 1 where they can burn safely, such as in an oil

refinery. Only one Oil-Gases Separation Set is
5 necessary for several transformers, if they are
not located too far from each other.

3
3 - 4 Transformer and On Load Tap
Changer Explosive Gases Elimination Sets
They create a safe environment inside the transformer and
On Load Tap Changer oil capacities by injecting a
strong nitrogen flow, after depressurisation occurs.
The number of nitrogen injection points varies
according to the transformer size.

SERGI does not recommend to limit the amount of conventional mechanical As important mistakes are often made during site design,
6 CAUTION or electrical protection devices when the TRANSPORTER PROTECTOR is used. CAUTION important recommendations regarding civil works are supplied in document [9]. 7
 OLTC & OBCB protection Logic Diagram
On Load Tap Changers and Oil Bushing Cable How the TRANSFORMER PROTECTOR works
Boxes Explosion and Fire Prevention Explosion Prevention
Depressurisation Set
Activation
Instantaneous
Depressurisation

Logic Diagram
In addition to the tank, SERGI strongly recommends to protect the On Load Tap Changers and the Oil Bushings Cable Boxes with As soon as a critical level of pressure is reached inside a transformer oil capacity Signal
the TRANSFORMER PROTECTOR. For that purpose, a Depressurisation Set and a specific Explosive Gas Elimination Set are used. Explosive Gases
protected by the TRANSFORMER PROTECTOR, the Depressurisation Set is AND
Elimination
Protecting all transformer oil capacities prevents the short-circuit from damaging the On Load Tap Changer or the Oil Bushing Cable Box, and automatically and mechanically activated, which enables an instantaneous Buchholz
spreading the fire to the transformer itself as well as to the whole power plant or substation. The TRANSFORMER PROTECTOR therefore offers depressurisation. When activated, a signal is sent to the Control Box, which, in Differential o

complete protection of the transformer for a minor additional price. addition to one of the transformer electrical protections, initiates the Explosive Earth Fault r

Gas Elimination Set. Over Current

On Load Tap Changer (OLTC) Explosion and Fire Prevention [12]

OLTCs have a higher probability of failure than transformer tanks. Examples exist where as 6 Principle
little as 200 litres of burning oil from the OLTC have destroyed a complete substation. 1. Pressure rises.
2-3 4
When not connected to the TRANSFORMER PROTECTOR, OLTCs are protected against 2. Depressurisation Set activation.
overpressure with a diaphragm or a Pressure Relief Valve, which are not calibrated and do not 3. Instantaneous Depressurisation.
allow oil channelling during an explosion. In fact, during short-circuits the OLTC cover is always 1
1 4. Shock Wave Protection Shutter opens.
forced off and burning oil then spreads onto the
transformer, floor and surrounding equipment, N2 5. Oil-Gases mixture evacuation to the Oil-Gases Separation
Depressurisation 5
leading to a fire expansion to the whole plant. Set
Nitrogen Injection Pipe
to the bottom
Tank (MTP and STP types).
of OLTC
Hence, short-circuit consequences are more severe when transformers are located underground, 6. Conservator Shutter closes.
inside industrial plants with high explosion risks or in sensitive environmental areas. They must
therefore absolutely be protected.
SERGI’s long collaboration with major OLTC manufacturers has resulted in the protection of every 7. Oxygen cannot be in contact with the self flammable oil-gases 10
type of OLTC. This is why SERGI strongly recommends to protect all of them, using a flange to On Load Tap Changer mixture as the Air Isolation Shutter is closed.
depressurise the OLTC (the Pressure Relief Valve flange can be used with a T piece) and a pipe that
8. One of the Depressurisation Set Burst indicators, in addition to
goes to the bottom of the OLTC to eliminate explosive gases. 7
any electrical protection, initiates nitrogen injection. 8
9
9. Nitrogen injection ends explosive gas generation.
9
10. Explosive and flammable gases open the Air Isolation Shutter N2
Oil Bushing Cable Box (OBCB) Explosion and Fire Prevention and are channelled to a remote area or outside the building
OBCBs also have a higher failure probability than transformer tanks. Examples where they can burn safely, such as in an oil refinery.
Isolation Valve
exist where 0.3m3 of burning oil from OBCBs have destroyed a complete plant.
Depressurisation OBCBs are not protected at all against explosion, as they are never equipped
Set
with pressure relief devices. Therefore, burning oil is often expelled onto the
transformer and onto the floor, which results in the fire spreading. 12

To protect the OBCB, 2 flanges are necessary for the TRANSFORMER

Nitrogen
Injection Pipe PROTECTOR adaptation, one to depressurise the OBCB and the other to inject 11. The protected oil capacities are immediately confined under a
nitrogen in order to eliminate the explosive gases. safe nitrogen atmosphere.
11 12. Nitrogen extinguishes the gas fire outside the building.
N2
11 11
13. Nitrogen injection runs for 45 minutes to ensure the cooling of
the protected oil capacities.
14. Damaged parts can be repaired.
Optional items
• Autonomous Dry Battery with Associated Low Reserve Alarm;
• System Actuation Audible Warning;
• Cabinet Heater with associated thermostat; Fire Extinction Fire
Detector
• Decompression Chamber Heater for very cold climates; AND Nitrogen Injection
• Manual Nitrogen Injection Valve; Logic Diagram
Buchholz
• Adaptation for OLTC Oil Filtration Unit. The Nitrogen Drain and Stir Fire Extinguishing system is used as back-up to the
Differential
TRANSFORMER PROTECTOR explosion prevention. The Fire Extinction is o
r
Earth Fault
activated by a signal received by one of the Fire Detectors and by one of the
Over Current
transformer electrical protections.
TRANSFORMER PROTECTOR MTPAB Type protecting tank, OLTC and OBCBs.
8 9
 Different applications Adaptation to transformers
MTP Type Explosive gases burn
in remote area Required interfaces on the transformer tank
As it requires very few interfaces, the TRANSFORMER PROTECTOR can be easily
adapted to any existing or new transformers.

For new transformers [7]

For more information on the Document [7] details every interface required for adaptation on new transformers.
different applications of the During the design stage, transformer manufacturers are informed of the necessary interfaces in
TRANSFORMER PROTECTOR, Oil Drain Pipe
order to equip the transformer tank with:
please refer to [6]. from other
transformers • 1 flange, ideally on side of the tank, 20 cm below the cover. Its diameter varies according to
the Depressurisation Set selected according to the transformer characteristics. 2 flanges may
be requested in some cases.
N2 • 1 support for the Depressurisation Set.
• 1 or several valves for nitrogen injection, located at the bottom of the transformer.

Applications Characteristics
For all transformers from 5 to 1 000 MVA or above such as: 1- Every Depressurisation Set has a Decompression Chamber.
• hydro power plants; 2- The explosive Oil-Gases mixture is evacuated to an Oil-Gases
• outdoor substations located near buildings or habitations or outdoor Separation Tank.
substations when not equipped with Oil Collecting Ducts and Remote Oil 3- The explosive gases are channelled to a remote area where For existing transformers [8]
Storage Pit; they can burn safely, such as in an oil refinery. Document [8] details every possible configuration for adaptation
• industrial plants with high explosion risks (oil refineries, offshore plants, mines); 4- The Oil-Gases Separation Set can be shared between several on transformers already in service.
• underground substations; transformers when not located too far from each other.
• environmental sensitive areas. SERGI always uses existing
transformer interfaces in
order to avoid tank drilling

STP Type LTP Type and machining.

Oil sampling or filtering valves
Differences with the MTP Differences with the MTP at the bottom of the tank are
The STP only protects small transformers. This is why the Oil-Gases There is no Oil-Gases Separation Tank as the depressurised oil- adapted to inject nitrogen
Separation Tank is used as a Decompression Chamber called gases mixture is channelled through the oil drainage system of inside the transformer through
Depressurisation Tank. Explosives gases the plant. suitable T-pieces.
burn outside

If existing transformer tanks are not equipped with a flange or

N2
a manhole on the side of the transformer, the Depressurisation
Set is adapted to the Pressure Relief Valve flange (A) with a
T-piece (B).
In that case, the Vertical Decompression Chamber is slightly
Adaptation to transformer On Load Tap different as it contains 2 pipes: for the explosive gases (G) and
Applications Applications Changers and Oil Cable Boxes for the oil (F).
For all small indoor transformers from 0.1 to 5 MVA such as: For outdoor transformers from 5 to 1 000 MVA located in plants Please refer to page 8.
• residential and office buildings, towers; equipped with well-designed Oil Collecting Duct and Remote Oil
• schools, universities, hotels, airports, hospitals; Storage Pit.
• underground substations;
On site installation [9]
The application of the LTP Type should be limited to transformers
• indoor and outdoor industrial plants with high explosion risks located far from buildings and sensitive equipment. The Control Box is mounted in the plant control room. A wall is required to mount the Cabinet, close to the transformer. Please refer to pages 6
(oil refineries, offshore plants, mines); and 7 for further details.
• railway network power supply station; A week is necessary for an electrician and a welder to install the TRANSFORMER PROTECTOR. The transformer must be made available for one
• environmental sensitive areas. day for mechanical and electrical connections, testing and commissioning.

With the LTP type, the customer must accept the risk of oil fire inside the Oil Collecting Ducts and the Oil Storage Pit, as the depressurised SERGI strongly recommends the MTP type installation for existing substations or power plants,
10 CAUTION explosive gases are expelled together with the oil to the atmosphere. Therefore, special care must be given to the plant civil work design [9]. CAUTION as, when existing, the Oil Storage Pit is often located under the transformer tank. 11