Title of the study: Reduction in Distribution

Transformer (DTR) failure

rate at Doddaballapur Sub
Division
Site address: Doddaballapur Sub
Division, Bangalore
Electricity Supply Company
Limited
Period of study: June 2005 to June 09
Rating: ****

Contents Page Nos

1. Introduction 2

2. Analysis of reasons for failure of DTRs 6

3. Implementation 9

4. Results 10

5. Cost Benefit analysis 14

6. Conclusions 15

7. Guide lines for repeatability in other distribution areas 16

a. Benefits
b. Challenges
c. Key Pitfalls/Precautions

1
1. Introduction
Distribution Transformer is costly and critical equipment in electricity
distribution network. Its outage due to failure causes immense
inconvenience in network management and involves high expenditure
on account of repair/replacement. Any Distribution Utility, therefore,
takes all possible actions to reduce downtime / failure of transformers
to a minimum and to enlarge their lives, at the most economic cost.
BESCOM has about 1.25 lakh distribution transformers of different
capacities and the DTRs failure rate over the years has come down
from 13% in FY 04 to less than 9% in FY 09. On an average BESCOM
spends Rs. 14-15 crs. annually on repairs to distribution transformers
alone, constituting about 40-45% of the R&M expenses of the
Company.

Distribution Transformer is a static Electrical device which steps down

11KV (Primary) voltage to 440 Volts between Phases & 230 Volts
between Phase & Neutral (secondary) through Delta–Star Windings by
electromagnetic induction, which feeds different types of loads such as
Domestic, Commercial, Agriculture, Industrial etc. Hence Distribution
Transformers form the essential link between power utility & large
number of consumers. This can also be called as Distribution
Transformer sub-station or Distribution Transformer centre. Studies
have shown that the salient parts of Distribution Transformers which
are likely to affect damage & failures when exposed to abnormal
conditions are :-

• Laminated iron core for magnetic circuit.

• Primary & Secondary windings for electric circuit.
• Main tank to house the core & windings with cooling
arrangement, conservator tank, Breather & Explosion vent.

2
 • Transformer oil in the tank acts as an insulation and cooling
media.
• HV & LV Bushings to bring out the terminal connections of the
windings.

The protective devices provided to the Distribution Transformer sub-

station are:-

Table -1

Sl.No. Protective Device Protection given

1 Horn-gap (H-G) fuse Against over current on Primary side

2 Open type fuses/ LT Against over current on Secondary
protection kit/ side.
Distribution box
3 11KV Lightning Against lightning strokes or surges
Arresters on Primary side
4 Explosion vent with a protect the main tank from bursting
thin diaphragm by itself acting as a relief valve
5 Breather with slicagel Absorbs moisture in the
Transformer
6 Earthing system Transformer neutral earthing
provides a path for the earth fault
current

Reasons for the failure of Distribution Transformers are due to :-

• Ageing
• Manufacturing defects
• Utility side defects
• Natural calamities

In order to improve the performance efficiency, Utilities throughout the

world are now forced to drastically reduce their expenditure and as a
consequence of this, budget for fresh investment is often reduced to a
bare minimum. It, therefore, becomes imperative to extract as much life
as possible from the existing capital-intensive equipments. Transformers
being one of the costliest equipment in a Distribution network, it is a
common practice, amongst the Utilities, to maximize their service lives

3
 by taking timely precautionary measures and adopting good
maintenance practices. Hence in the pilot site at Doddaballapur,
Distribution Transformers failure rate has been considered as one of the
parameters of KPIs (Key Performance Indicator) and is aimed to be
brought to Zero.

In Doddaballapura Sub-division, 3245 Distribution Transformers are

existing as at the end of June-2009. The number of Distribution
Transformers failed & percentage of failure from 2004-05 to June-2009
is shown in the Table below.
Table -2
Sl.No. Year Transformers Trs. failed % of Annualized %
Existing failure
1 2004-2005 1615 271 16.78 17.46
2 2005-2006 1746 172 9.85 10.24
3 2006-2007 2017 145 7.19 7.71
4 2007-2008 2329 115 4.94 5.29
5 2008-2009 3194 93 2.91 3.37
6 Apl./09-Jun/09 3245 24 0.74 2.91

Month wise % failure of DTRs at Doddaballapur sub-division is shown in

the following graph, which shows a gradual decline in the failure %

DT Failure Rate at BESCOM's Pilot Site

% Age Target Linear (% Age)

16.0
14.0
14.0
13.6
12.6
12.0 Trend
11.8 11.4

10.0 9.3 9.7 9.5

9.2
DT % F ailu re

8.2 8.7 7.9

8.0 7.3 8.3 8.2
8.5

7.4 6.8 5.4

6.0 7.0 7.0 6.8 7.0 5.0
5.6
4.5 4.0
4.9
5.0 4.7 3.4 3.7 3.7 3.4
4.0 3.2
4.3 4.3 2.9 2.7
3.9 3.9
3.4 3.0 3.3 3.5
2.0 3.0 3.2 2.4
1.8
0.0
9
Ju 06

Ju '0 7

Ju 08
A u l' 05

N o t '0 5
D e ' 05

A u l' 06

N o t '0 6
D e v' 06

A u y' 07

N o t '0 7
D e v' 07

A u l' 08

N o t '0 8
D e v' 08
Fe 6

F e '0 7

F e '0 8

F e '0 9
A p '06

J u '0 6

A p '07

J u '0 7

A p r '08

J u '0 8

A p '09

J u y '0 9
J u '0 9
S e ' 05

M r' 0 6

S e ' 06

M r' 0 7

S e g' 07

S e g' 08

M r' 0 9
M il '0 8
M '06

M '07

M '08

M '09
Oc ' 05

Ja ' 05

Oc ' 06

Ja ' 06

O c '0 7

Ja ' 07

O c '0 8

Ja ' 08

l- 0
n '0

n'

n'
n
v

n
ar

ar

ar
g

ne
ay

ay

ay
b

b
p

pt

pt
c

c
Ju

a
l

Month

4
 Details of age wise failure of Distribution Transformers are shown in the
Table below.

Table -3

<1Yr 1-2Yr 2-5Yr 5-10Yr 10-15Yr 15-20Yr 20-25Yr 25-30Yr >30Yr

Sl.no. Year Total

1 04-05 85 95 44 40 2 1 2 1 1 271

2 05-06 36 61 45 20 6 2 1 1 0 172

3 06-07 31 42 36 23 7 4 1 1 0 145

4 07-08 8 36 40 24 5 1 0 1 0 115

5 08-09 19 34 19 16 4 0 0 1 0 93

6 4/09 -6/09 2 8 6 7 0 1 0 0 0 24

Age wise analysis of DTRs failure at DRUM Project site

No.s of DTRs failed

100

75

50

25

0
< 1 year 1 to 2 Yrs 2 to 5 Yrs 5 to 10Yrs 10 to 15 Yrs > 15 years

2004-05 2005-06 2006-07 2007-08 2008-09 04/09 to 06/09

Analysis shows that out of the DTR’s failed in each year more than 90%
of the DTR’s have failed with in the first 10 years of their commission
and more than 50% in the first two year of their commission. For the
purpose of providing depreciation in books of accounts the average life
of a DTRs is considered as 25-35 years, where as most of the
transformers are failing before 10 years of their commissioning, thereby
putting severe strain on the cash flows of the company. This could be

5
 due to the reason that earlier the DTR manufacturers were allowing
more factor of safety in design, where as in recent years manufacturers
are adopting cost-benefit ratio in the design by just satisfying the
requirements of IS specification. Hence many transformers are not
serving for the expected full life period. It is learnt that in the pilot site
still there are a few transformers (copper wound) that are in service for
over 40 years, thus justifying the argument that old DTRs are more
sturdy and durable.

2. Analysis of reasons for failure of DTRs

As per the analysis carried out, the main reasons for the Transformers
failure are:
1. Over loading:- Most of the Transformers have failed due to over
loading ie., adding more loads or due to unauthorized connection of
loads. The overloading can be avoided by proactively identifying the
transformer loading by taking readings periodically during peak
hours using Tong Tester.

2. LT line loose span:- This is also the main reason for failure of
large number of Transformers. Because of loose spans (more sag)
there are always shorting of LT lines & also conductor snapping
since proper size of fuses are not used. This problem can be
overcome by adopting proper maintenance techniques and practices
as part of maintenance plan.

3. Usage of improper size of fuse wire:- H-G fuse is the only

reliable protection for Distribution Transformers under fault
condition in LT distribution. Almost all Transformers are provided
with heavy size fuses (Some times ACSR conductor strands are
used) in the LT side, the chances of blowing of LT fuses in short
time is less. If higher size H-G fuse is used, the fault will sustain for

6
 large period until heavy size fuse blows causing failure of
Distribution Transformers. Good engineering practices always yield
good results. Awareness, availability of proper material and
responsiveness and accountability are key drivers to address this
problem.

4. Tree branches touching LT lines:- Tree branches touching LT

lines continuously will result snapping of conductor causes heavy
earth fault current which leads to failure of Transformers. Timely
tree pruning mechanism followed based on the results of periodic
field survey and line patrolling report.

5. Improper maintenance of Breathers:- If it is not maintained

properly moistured air will enter in to the Transformer tank causes
failure of Transformers.

6. Oil leakage:-Oil leakage is mainly due to excessive heat or

pressure developed in the bushings, this will bring down the oil
level in the tank & also moisture enter in to the tank through the oil
oozing gap causing contamination of transformer oil resulting in
deterioration of HV/LV insulation (low IR value) ultimately to
Transformers failure.

7. Non topping of oil:- There will be leakage of oil from the

transformers due to heating of the oil especially during peak load
conditions and results in decrease in oil level over a period of time,
which is not being watched and set right regularly by topping up the
level.

8. Improper earthing:- Condition of the earthing electrode and the

loose connections of the earthing conductor are not being checked
regularly. As a result, due to improper earthing the flow of fault

7
 current is obstructed affecting windings, which causes failure of
DTRs. Besides, improper earthing will result in electrical accidents
due to development of high voltages in the earthing conductor
which is in open condition and accessible to passers by.

9. Not connecting the Lightning Arresters:- Because of not

properly fixing & not adequately earthing the Lightning Arresters ,
they fails to divert the direct lightning stroke or surges due to
discontinuity in earthing system results either failure of HV winding
due to surge voltage or bursting of Lightning Arrester itself. The
importance of earthing becomes imperative under such
circumstances and moreover for safety aspects perspective too.

10. Using Two Phase supply in Rural areas:- During roastering

period IP set consumers have invented so many methods to run the
motor under Three phase conditions contributing unbalanced
overload in Two phases. This will also cause failure of Transformer.

11. Un-standard methods adopted:-

a) Use of Aluminum ACSR conductor either bare or enclosed in PVC

pipes from the Transformer bushing instead of PVC insulated
cables.

b) Use of open type fuse in the LT side of the Transformers instead

of standard porcelain cutouts or LT protection kits.

c) Use of Aluminum ACSR conductor strands as fuses in LT side &

HG fuses instead of Tinned copper fuse wire.

8
3. Implementation
To reduce the failure rate of Distribution Transformers, following
implementation action was considered.

a) In the DPR approved for DRUM works at pilot site, more focus
was given towards refurbishment of DTCs, so that all the
inadequacies are addressed. The activities include
• Rectification of oil leakages
• Replacement of damaged bushings/ busing rods
• Proper alignment of the GOS
• Providing DOLO/HG fuse units on the HT side of the
DTC
• Replacement of breathers
• Reconditioning of LT connections by replacing
deteriorated LT PVC wires and providing proper lugs
• Improvement of earthing system wherever the earth
resistance is more than 10 Ohms
• Renewal of HT jumps
• Providing LT protection kit/distribution box
• Providing surge arrestors

b) Refurbishment works on Distribution Transformers was entrusted

to the outside agencies on RC rates & Turn key basis during the
year 2007. In the beginning out of 55 feeders 24 feeders were
selected for Refurbishment works on Distribution Transformers.
Till now the works for only eight feeders are completed and the
the number of DTRs covered is shown in the table below, for
which the cost incurred is Rs. 0.52 Crs.

9
 Table -4
Sl.no. Feeder No. & name No. of DTRs
R&M works
carried out
1 DBF-1(B) Nicholus 82
2 DBF-2 Doddabelavangala 52
3 DBF-5 Hulikunte 59
4 DBF-6 S.G.Hally 70
5 KLF-8 Kolala 23
6 TBF-8 G.Hosahally 68
7 SDLF-4 Soladevanahally 03
8 KF-8 Semi Urban 8
TOTAL 365

For the remaining feeders i.e. 47 (55 numbers-8 already

completed) tenders have been invited & it is under process.

c) Trimming of tree branches touching the LT and HT lines on a

regular basis and tightening of loose spans were taken up as per
the maintenance schedule drawn up

d) Tong tester readings are being taken regularly and load

balancing works carried out. Weekly targets were fixed O&M unit
wise for each of the section officers and monitored closely at the
level of Superintending Engineer.

e) Requirement of additional transformers to release the load on

the existing overloaded transformers was reviewed regularly and
the approval for providing additional DTCs was communicated
from time to time along with the necessary budgetary support.

4. Result
After carrying out the Refurbishment works on Distribution
Transformers, Load balancing, providing the additional Distribution
Transformers to avoid over loading based on the Tong Tester readings

10
 taken during peak hours & after providing 665 Nos. 25KVA Distribution
Transformers on 4 Rural 11KV feeders under HVDS, the failure of
Distribution Transformers has drastically reduced, from 17.46% in
2004-05 to 3.37% in 2008-09, as could be seen from Table -2 above.

The following graph shows how the year on year reduction has been
achieved in the project area bettering the reduction achieved by the
Company as a whole.

Photo of a 63 KVA DTC before refurbishment Photo of a 63 KVA DTC after refurbishment

Com parative analysis of DTRs failure rate in BESCOM vis-a-vis DRUM

Project site

20.00%
16.78% 12.76%
% failure

9.39% 8.45% 8.72%

13.27%
9.85%
7.19%
4.94% 2.91%
0.00%
2004-05 2005-06 2006-07 2007-08 2008-08

BESCOM Doddaballapur sub-dvn.

11
The failure rate can be further reduced if the remaining Refurbishment
works are carried out on all the Distribution Transformers & proper
action as mentioned below are taken.

1. DOLO / H-G fuse units are to be provided compulsorily with

proper size Tinned copper fuse wire depending upon the capacity
of Distribution Transformers as H-G fuse is the only main reliable
protection for the faults in LT side.

2. Lightning Arresters are to be provided & they have to be

replaced immediately if found flashed over.

3. Transformer oil to be topped up if it is found less in the

conservator tank & oil leakage to be arrested.

4. Earthing (Grounding) should be kept in good condition and Guy

wire to be used with lugs on both ends for neutral earthing.

5. Drawing LT line beneath the 11KV line on the same support

should be avoided.

6. Overloading of Transformers should be avoided (Transferring the

load to the nearby Transformer if it is Under loaded or
new/additional Transformer to be proposed)

7. Tree branches which are touching LT lines are to be trimmed in

routine manner

8. Adequate protection to be provided on the LT side of

Transformer by providing either LT protection kit or LT
Distribution box with MCB switch facility

12
 9. Sag on LT line to be avoided by providing intermediate poles,
restringing of loose spans and also providing LT spacers where
ever it is required

10. Tong Tester readings during peak hours are to be taken to know
the load condition of Transformer & load to be balanced on all
the phases by redistributing among phases to avoid over loading
in one phase

11. Additional Transformers are to be installed where ever the

existing Transformers are found over loaded

12. First span of LT line on each circuit of the Transformer should be

made small

13. First 10 spans of LT lines on each circuit should be provided with

Rabbit ACSR conductor to avoid snapping of conductor

14. IP set consumers are to be advised not to run the motors by

providing condensers during rostering

15. Bimetallic clamps with proper size GI bolts nuts & Washers are
to be provided (connected) to the LT bushings to reduce
excessive heat & damage to bushing rods due to loose contacts.

13
5. Cost Benefit Analysis
Investments made in the project area towards achieving reduction
transformer failure rate include the following:-

Table -5
Sl Area of Investment Amount
No. (Rs in crs)
(a) Direct Expenses
1 Additional Transformer cost: Providing 0.30
additional DTRs for releasing the load on
overloaded DTRs (Assumed to be about 30
DTCs per annum sanctioned under
Extension and Improvement Head at an
approximate cost of Rs. 1.0 lakhs/ DTC)
2 Refurbishment and renovation cost: 0.52
Expenditure incurred towards DTR
refurbishment works (based on sectioned
estimates)
Total Direct Investment Made 0.82
(b) Indirect Expenses
1 DTR maintenance, Peak load 0.06
monitoring and load balancing cost:
Taking tong tester readings and load
balancing for overloaded DTRs, Topping up
of oil, Replacement of burnt out PVC cable
etc. (Assumed at Rs 25,000/employee/
month for six months for fifteen persons at
25% of the working time in a day)
Total of Indirect expenses made 0.06
Grand Total of (a+b) 0.88
Cost benefit analysis
1 Savings in dismantling and erection cost 0.02
of DTRs including transportation at the rate of
3.5% per annum i.e. about 75 DTRs at an approximate
cost of Rs 3,000/DTR
2 (a) Savings in DTR repair cost considering 0.05
40% of the failed DTRs are repairable i.e.
30 DTRs (40% of 75) at an approximate cost of Rs
15,000/DTR
(b) Savings in purchase of new DTRs 60% 0.27
of the failed DTRs are not repairable i.e. 45
DTRs (60% of 75) at an approximate cost of Rs
60,000/DTR (net of salvage value)

Total Benefit 0.32

Payback Period ( in years) 2.75 years

14
6. Conclusions
At the field it shall be the endeavour of every technical and
maintenance staff to focus on three key areas of distribution
transformers maintenance i.e.

(a) To find out the load on each DTR through tong tester readings
and taking action to provide additional DTCs if found
overloaded or transferring some of the loads to the nearby
transformer if it is feasible

(b) Based on tong tester readings to take action for load balancing
by redistribution of loads among the phases

(c) Carrying out of regular maintenance works as per the schedule

prescribed
At the management level in the Corporate office, reasons for
distribution transformer failures make wise, age-wise, capacity-wise
needs to be analyzed more scientifically so that transformers with
higher degree of safety factor are procured.

Currently the transformer load details and LT net work details are
manually entered in the “Transformers Maintenance Register”
kept at the O&M unit offices. Accuracy of the information maintained
lacks authenticity and does not provide full information about the live
status of the network, DTRs and meters. This can be over come by
implementation of GIS mapping of the net work in the pilot area. This
enables capturing of accurate data of HT/LT network and easy
updation regularly. Obtaining of metering data can also be built in as
an additional feature. Transformer Management system (TMS) can also

15
 be introduced to track the asset details and to plan the load
management at the distribution level.

To enable the technical and maintenance staff to carry out minor

repair works of DTRs, BESCOM should consider imparting proper
training. This will help the field staff to repair the transformer at the
site itself which would in turn avoid unnecessary expenditure on
transportation of DTRs to the repair centre. This will also significantly
reduce the interruptions to consumers. BESCOM should consider
providing necessary spare parts viz., HV/LV bushing shells, HV/LV
bushing rods, Bimetallic clamps/ copper plates for connecting to the LV
bushing rods, PG clamps, Slicagel, transformer oil for topping up,
earthing materials for neutral earthing, lightning arrestors, standard
size fuses etc., to the section officers for routine maintenance and
emergency use.

7. Guide lines for repeatability in other distribution areas

a) Benefits
By better management of fixed assets in general and DTRs in
particular there will be huge cost savings to the utilities besides
helping in improved quality of supply and service to consumers.

b) Challenges
Following are some of the challenges experienced at project
site:-
• Resistance from consumers/general public from passing
through their land/street/building for drawing the 11 KV
lines to install additional DTRs.

• Selection of suitable location to install additional DTRs

especially in the town area as there is no right of way
since the streets are very narrow

16
 • As the work of providing of additional DTRs and
refurbishment works are being done through contract
agency, there will be more interruptions to consumers (in
addition to the scheduled outage), that too during day
time, at the time of execution of work. Consumer
generally resist for such interruptions.

c) Key pitfalls/precautions
Though maintenance of DTRs is a very important work as for as
the O&M units are concerned, due to other priorities and
shortage of maintenance staff, routine maintenance of DTRs are
not being done as per the schedule prescribed. As a result,
DTRs get overloaded, unbalanced, reduction of oil level due to
leakage, entry of moisture through oil oozing gap, formation of
heat in the LT busing rods etc., If these aspects are strictly
ensured, both the utility and the consumers would gain
significantly in terms of cost savings and quality of supply and
service.

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