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POWER TRANSFORMER FAULTS
Faults in a Transformer
1. Internal Faults
2. External faults
3. Auxiliary Faults
Transformer failure rates
Acknowledgement
6
Introduction
WG A2.37 was formed with an objective of
Review of all existing surveys and study different
practice
Conduct new International survey
Compiling and analysis of collected data
Interpreting the results
Calculation of failure rates
Classification of failure locations
Failure causes and modes
7
Failure definition
Only transformers/reactors > 60 kV considered
Major failure
Situation requires removal from service > 7 days
Involves major repair – factory or repair bay
Opening of transformer, tap changer or exchange of
bushing
< 7 days, but with extensive oil processing
8
Failure Rates
9
Failure locations > 100 kV
Substation Transformers (536 Failures)
10
Failure Locations > 100kV
GSUs (127 Failures)
11
Failure Locations > 100kV
Manufactured before 1980 (333 Failures)
12
Failure Mode all Voltage class
964 Failures (SS and GSU)
13
Failure Modes all Voltage Class
799 Failures (SS transformers)
14
Failure Mode analysis according to
Voltage Class
15
Failure Cause
964 Failures
16
External effect Analysis
76.5 % of failures did not result
into any external effects
7.1 % failures resulted in Fire
5.1 % failures are related with
explosions or blasts
17
External Failure effects
964 Failures
18
Failures with Fire or explosions
(126 Failures)
19
External effects of Bushing failures
115 Failures
20
Action taken analysis
964 Failures
21
Failure location analysis
of 242 scrapped transformers
22
Failure location analysis of
465 repaired transformers
23
CIGRE WG-Conclusions
Overall failure rates remained < 1 %
GSU failure rate marginally higher than
SS X’mer failure rate - difference is <
0.5%
GSU (300-500kV)failure rate exceeded 1%
Winding, tap changer, bushings
followed by lead exits – major
contributors
24
CIGRE WG Conclusions
GSU contribute higher winding and lead failures
SS transformers contributed more towards tap
changer failure
Both type had similar contribution in bushing
failures
Bushing and Lead exit failures tend to have
increasing trend with higher voltage upto 700 kV
25
CIGRE WG Conclusions
Dielectric failures – highest contributors
Design and manufacturing, ageing and external
short circuits - major contributors
Bushing failures most often result in fire and
explosions
Large contributors being ‘unknown’, results should be
treated with caution
26
POWERGRID, India
Power Transformer/Shunt Reactor Asset
Performance & Preventive Actions
Asset Growth in POWERGRID, India
Growth of 765kV Transformers in
POWERGRID, India
300
250
200
Quantity
150
100
50
0
Till 2011 2012 2013 2014 As on date
Period
Growth of 765kV Reactors in
POWERGRID, India
600
500
400
Quantity
300
200
100
0
Till 2011 2012 2013 2014 As on date
Period
Failures of AC Transformers
2011-12 2012-13 2013-14 2014-15 2015-16
1)Original data in IEC60422, annex A, are presented as relative saturation in percentage. ”Dry”, ”Moderately wet”, ”Wet”
and ”Extremely wet” are recalculated to percent moisture in cellulose.
2)Original data in IEC60422 for new transformers is presented as percent moisture in cellulose
insulation.
3)Original data in CIGRE349 is by categories. “Good, “Fair”, “Probably wet” and “Wet” are relabeled to “Good/New”,
“Dry” and “Wet”.
Transformer drying –
Methods/Examples
Two major techniques are used:
Drying the insulation by drying the oil – Field
Drying the insulation with heat and vacuum – Field and
factory
Drying the oil
Molecular sieves
Cellulose filters
Cold traps
Combined oil regeneration and degassing
Drying the insulation
Vacuum and heat
Pulsation drying through oil circulation
A. Gruber, ”Online Treatment of Transformers and
Hot oil spray drying Regeneration of Insulating Oil”, TechCon
AsiaPacific 2009
Low frequency heating
Vapour phase drying
TESTING OF POWER TRANSFORMERS
Tests on Transformer
Tests on Transformer
Healthy
HV &
LV
winding
s
TESTING OF POWER TRANSFORMERS
Tests on Transformer
U-phase
shorted
turn
TESTING OF POWER TRANSFORMERS
Tests on Transformer
Thermometer
Thermal image type OTI and WTI. Fiber optic thermal sensors
Trend
Figure showing Mobile power transformer and substation Figure showing compact 3 phase 930 MVA 550
kV GT
Milestones in Indian Power
Transformer Industry