Transformers

Don't Die of Old age

But Are
Always killed !!!!

By Neglect
 Transformer failure

Discussion points
Power system Vs Transformer failure
Transformer failures – reasons
Trend of failure
Old age
Old design vs. new design
Types of neglect
Discussion on typical failure
& trouble shooting
 Power System Failure
Cables
8
3 10
Transformers
12%

Switchgear

OverHead Lines

CT/PT 15
Control Equipment

Misc.
 Transformer failure

F
a
I
l
u A C
r
e B
R
a
t
Age in Years
e
A : Failures due to manuf. , shipping,Installation B: Random
Failure Rate ( OP & Maint. ) C: Ageing
Transformer failure

Old Age
Ageing or gradual degradation is
the result of several chemical
reactions within the
transformer The solid insulation
is one part of the transformer
that is an ageing characteristic
that is irreversible.
 Transformer failure

Failures in Tap Changer

Failure of joints
Core bolt insulation failure
Interturn insulation failure
 Bushing Failure
 Presence of Foreign material during
manufacturing/repair
Deposit of oil sludge on coils
 Improper commissioning
 Transformer failure

Maintenance failure
 Oil
 Bushings
 Heat Exchanger
Protection Failure
 Failure of Bucholz
 Feeding Fault because of not tripping
Design Failure
 Rectifier Duty
 Rolling mill duty – overall thermal loading
 Transformer failure
Old Vs New Design
Old Design
Minimum volts per turn,Full insulation & maximum
voltage per Kva.
Estimated theoretical life of properly assembled
and adequately small oil filled distribution
transformer was 400 years
New Design
Optimizes the minimum use of materials and space
with maximum stressing of conductor , iron, and
insulation
They perform according to the nameplate
specifications,but it is acknowledged there are
no built-in excesses that will tolerate
operational or maintenance abuses
 Transformer failure
Neglect
Under user’s control
Improper Preventive & Predictive
maintenance.
A transformer damaged through insufficient
preventive maintenance cannot perform to its
original design.
Unable to sustain operational accidents
Startup,Switching surges,Controlled short
circuits,Lightning strikes,Physically moving
transformers.
 Transformer failure
Neglect

Reasons beyond user’s control

Faulty workmanship/Inferior
materials
Poor Shipping techniques
Negligent Installation
New design parameter
User Applications
 Major Causes of Power
Transformer Failure
Insulation-620

Short Circuit -302

Tap Changer-221

Lighning/switching
surges -150
Manufacturing defects-
66
Core --57

Other--914

Other includes operator error,ruptured tank,mechanical

failure,unknown causes,vandalism etc.
 Transformer failure

Furnace & rectifier

transformers have rates
approximately six times greater
than the average rates of power
and distribution transformers
Primary Causes of Distribution
& power transformers
Lightning Surges
Ext. Shortcircuiting
Poor workmanship
Insul.deterioration
Overloading
Moisture
Operation & maint
Sabotage
Other
Primary Causes of Distribution
& power transformers
Poor workmanship 9% 9 during first year of operation)
Insulation deterioration 10%
Overloading – 6%
Moisture – 9%
Inadequate operation & maintenance –10%
Sabotage 4 %
Other 22%
 Transformer failure

Maintenance failure
 Oil
 Bushings
 Heat Exchanger
Protection Failure
 Failure of Bucholz
 Feeding Fault because of not tripping
Design Failure
 Rectifier Duty
 Rolling mill duty – overall thermal loading
 Transformer failure
Reasons of Failures as observed in our Shop
Bushing failure
Core bolt Loosening/insulation failure
Joint failure
 Tap changer contacts / lead connection
 Presence of Foreign material during
manufacturing/repair
Deposit of oil sludge on coils
Water ingress/leaking gaskets
 Transformer failure
Case Study
HSM coiler drive tripping
 Initial suspicion on Thyristor controller
 Subsequently it was found that Thyristor
drive I drawing unbalance current.
 Transformer was isolated , Ir test ,ratio
test, magnetizing current – all found normal
at running tap
 Short circuit test was conducted & found
taking unbalance current at running tap .
 Kept in another tap & released
 Brought to repair shop & found one tap lead
almost flashed & loosely connected.
 Transformer failure
Case Study
Transformer suspected thermal
fault
No tripping, normal operation
Oil BDV ok, IR value ok
Magnetizing current,ratio test ok
Dismantled
Discoloration in a particular joints
High current test Abnormal heating
Dry soldering
Reconditioning of Transformer

Why?
When?
How?
Reconditioning of Transformer

Why & When ?

Condition Monitoring
RLA
Recommends corrective maintenance steps
Site Oil filtering
Site oil changing
Does not give desired result
or
Scheduled preventive reconditioning
Reconditioning of Transformer

How?
Process followed
1. Initial Testing
2. Dismantling
3. Testing coil core assembly
4. Cleaning
5. Physical inspection of all parts
Reconditioning of Transformer

How ?
Process followed (contd.
6. Tightening and reinsulating
7. Heat cycle
8. Assembly
9. Oil filling & treatment
10. Final testing & charging
Reconditioning of Transformer
What we get ?
Improving dielectric strength of oil
Improving I/r value of windings
Drier winding
Cleaner tank
Tightening of core bolts and other
bracings
Improving core bolt insulation
Changing all gaskets & seals
Reconditioning of Transformer
What we get ?
Taking care of some incipient fault
 Loose bolts/nuts
 Dry soldering
 Defective tap changer
 Cracked bushings
 Foreign particles