INVESTIGATING TRANSFORMER FAILURE

By: Munidev Tyagi, Dy. G M (Q A) & Vishal Mahire , Dy. G M (Testing) EMCO LTD
Failure of a Transformer is a major set back for the user as well as for the manufacturer.
It is very costly and devastating experience as well. It is generally believed that failure
occurs when a Transformer component or structure is no longer able to withstand the
stresses imposed on it during operation. In most of the cases we find that, the exact root
cause of the transformer failure is rarely detected. However for general guidance various
hypotheses are available. In order to prepare an accurate failure analysis report, and to
develop proper recommendations to avoid recurrence, more in depth analysis of failure
is required. There are guiding international standards available for such kind of analysis
During the course of life of the transformer, it experiences impact of Electrical, Thermal,
and Mechanical stresses during normal and transient conditions. Gradual impact of
these three factors results in
a) Reduction in Dielectric strength (i.e its capability to withstand the electrical
stresses)
b) Reduction in the mechanical strength (i.e lowers its SC withstand capability)
c) Reduction in thermal integrity of the current carrying parts ( lowers the ability to
withstand the overload conditions)
In short major reasons for Transformer failure can be divided in three factors i.e.
Electrical, Mechanical or Thermal.
Some of the reasons responsible for transformer failures can be categorized as under.
1) Electrically Induced factors
Electrically induced factors typically result in damage to transformer insulation
system. Some of those factors can be listed as
a) Operation of Transformer under transient or sustained over voltage
b) Insulation stressing due to Lightning and Switching Surges
c) Deterioration of insulation due to Partial Discharges (Voltage Tracking/
Treeing)
d) Static Electrification this phenomenon is very much limited to large
rating transformer where large amount of insulation and transformer oil
friction is involved.
Electrical failure should be analyzed properly along with the combination of
evidences of mechanical or thermal damage to the transformer.
2) Mechanically Induced factors
Mechanically induced factors typically results in deformation of transformer
windings, which further results in damages in the insulation system or may be
damages to the tank parts.. Winding deformation can occur due to transit
damage or due to electromechanical forces in fault conditions.

The most common impacts of mechanically induced factors are

a) Hoop bucking of the winding.
b) Telescoping of the discs/ conductors
c) Failure of clamping structure.
d) Conductor tipping
e) Spiral tightening or unscrewing effect
f) Axial collapse of the winding
g) Failure of clamping structure (including the CCR & BSR)
h) Displacement of leads.
Moreover these kinds of mechanical factors can be results of the different actual
fault. Hence detection of such things should not be concluded as detection of
actual fault.
3) Thermally Induced factors
Normal heating generated by the loading of the transformer will slowly degrade
the insulation. In case of poor design or obstructions in the cooling path, it will
accelerate the process of thermal degradation of the insulation, making it
vulnerable to failure under system fault conditions. These Thermal factors are as
under
a)
b)
c)
d)
e)

Overloading of the transformer beyond its designed capabilities

Failure of transformer cooling system
Blockage in axial or radial oil ducts
Transformer operations at over excited conditions for long durations
Operation of transformers in excessive ambient temperatures

If evidence of thermally induced problems is found, it must be investigated along

with other detected electrical and mechanical factors to develop different hypothesis for
failure analysis.
Investigation of a transformer failure involves data collection and analysis to arrive at the
root cause. In the event of failure of transformer in service the failure investigation
constitutes four factors viz. Preparation, Testing, Inspection and Conclusions which are
described below.
Preparation / Collection of Data
Preparation or data collection is important part of investigation. If following information is
ready before arrival of the investigating engineer it will save lot of time and efforts.
a) Periodic test data of Dissolved Gas Analysis, Breakdown Voltage, and PPM
performed on transformer oil in the past
b) Periodic test data of Insulation Resistance, Polarization Index, Winding
resistance, Capacitance and Tan delta values of Windings and Bushings
which are normally performed during preventive maintenance
c) Copy of Rating and Diagram plate.
d) Copy of transformer maintenance history
e) Copy of Factory test report
f) Record of weather conditions at the time of failure
g) Record of loading of the transformer at the time of failure
h) Single line diagram of protection scheme

i) Detailed Record and sequence of operation of Protection relays

j) Copy of log book of substation pertaining to the failure period.
k) Details of any faults (including faults of CT, PT and LAs) / surges or
abnormalities prior to the failure
l) Surge count reading of each Surge arrester
This data gives the history of the transformer and it may give some indications of the
system conditions that may have contributed to the failure.
Inspection at Site
Next step in the investigation is the factual data site inspection and interview, the service
Engineer visiting the site should interact with operating staff, to gather information
related to the failure event. The information should further be supplemented by visual
external inspection, investigative electrical tests and internal inspection of the Core coil
assembly.
External visual inspection : it should be done along with the photographs, which will
help for the records and for the discussions with others during the root cause analysis,
hence it is recommended to take as many as possible relevant photographs for the
record purpose Other factors to examine are
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)

Tap position of the tap changer.

Oil level in Main tank, Conservator and in Tap changer compartment.
Bulging or Rupturing of the transformer tank
Oil Spillage surrounding the transformer.
Any evidence of fire.
Operation of PRV, Buccholz relay
Operation of LA
Damage to bushings or surge arrestors
Damage to Radiators / Pumps / Fans / Panels
Evidence of any over heating (eg. Tank surface/ Bolted Joints /Bushing
Terminals / Earth pits/ Neutral Earthing busbars etc.)
k) Evidence of any contact of foreign object or Animal to live part or near by
conductors.
l) Evidence of any sabotage
Diagnostic Testing :
Many a times there is no evidence of any significant external damage to the transformer
In such situations diagnostic testing becomes crucial to know the health of the
transformer. Proper analysis of the test result can give a direction to investigate further.
Following diagnostic tests are suggested to perform in case of transformer failure but
before performing any test it is advised to perform the DGA test on oil.
a)
b)
c)
d)
e)
f)

Tests on oil, especially DGA, BDV and water content

Measurement of Voltage Ratio at all taps
Magnetic balance test and measurement of magnetizing current
Measurement of Winding Resistance
Measurement of Insulation Resistance and polarization Index
Measurement of Capacitance and Tan delta

g) Sweep Frequency Response Analysis (SFRA)

If necessary, expert guidance could be taken for interpretation of the test results.
Experience shows that no single test can predict the exact nature of fault. Therefore a
series of tests are performed to aid properly analyze the problem.
Internal Inspection:
Generally in order to assess the extent of damage and its location, internal inspection of
the active part is necessary, which involves draining of oil partly or fully. During the
internal inspection following safety precautions shall be ensured before entering the
transformer tank.
a) Open the top inspection covers and allow sufficient time for the combustible
fault gases to escape as they are dangerous. Sometimes it is advisable to
evacuate the gases from the tank by pulling the vacuum. If possible, provide
free flowing dry air in the tank.
b) The person entering the tank for inspection should not carry any loose items
in the pockets, and should remove jewelry if any.
c) Inspecting person should carry one torch, knife, note pad and pen along with
him during internal inspection, but it is advisable to list the tools before
entering in the tank and after coming out, all the tools shall be matched with
the earlier list
d) Always keep a person at the inspection window so that he keeps on talking to
the person inside the tank. And provides any help required inside.
e) After periodic intervals say 15 to 20 minutes, inspecting person should come
out of the tank to breathe in fresh air.
f) Use of safety belt is advisable to avoid falling of inspecting person in the tank
g) If inspecting person is carrying any tools with him, it should be tied to the tank
cover before entering in the tank to avoid its falling.
Besides specific areas of inspection, the person should also observe the following
aspects,
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)

The odour of burnt insulation

Colour or appearance of the insulating oil
Presence of copper globules or other loose metallic particles.
Check for insulation burning and carbon spread out
Check for any physical damage to the Coils, Leads, OLTC and Core.
Damage to the clamping structure,
Any flash marks on Tank, Coils, leads or OLTC
Check for any arcing between turns or windings.
Evidence of free water at the tank base.
Any other loose parts lying in the tank like spanner, knife, hardware etc.
Check integrity of earthing system of active part.

Therefore if internal inspection does not provide sufficient information regarding the
failure, it may be necessary to un-tank and teardown the Core Coil assembly for further
investigations.

Failure Analysis Report :

Failure investigations are aimed at analyzing the failure data to identify the root cause of
failure, taking the disposal action to rectify the damaged parts and facilitate restoration of
the transformer in service in shortest possible time. Besides this, each failure gives
learning for taking appropriate corrective and preventive actions at works to prevent
occurrence of such failures in future. Therefore recommendations covering corrective
and preventive actions always form part of a failure analysis report.
Conclusions :
Final Conclusions of the transformer failures cannot be formulated without all the
Preparatory Data; The diagnostic tests and Interpretation of the test results. After all the
information is gathered, an in-depth analysis of the failure will allow us to prepare an
accurate analysis report and most important to develop proper recommendations to
prevent recurrence.
Reference:
IEEE C57.125-1991 - Guide for Failure Investigation, Documentation, and Analysis for
power transformers and Shunt Reactors