Investigating

Transformer Failures
by William Bartley P.E.
Hartford Steam Boiler
Inspection & Insurance Co.

Weidmann ACTI
5th Annual Technical Conference
November 13-15, 2006

Transformer Failure

Challenges

Challenges

Session Objectives
 Discuss 3 Modes of Failure
 Examine the cause of failures
/with frequency-severity
 Illustrate the effect of age and our
forecast of future failures
 Examine Case Studies

Transformer Failure Modes

8Electrically Induced
8Mechanically Induced
8Thermally induced

Transformer Failure Modes

Electrically
Induced

Over Voltage
Surges
Partial Discharge
Static Electrification

Transformer Failure Modes

Mechanically Induced
Conductor telescoping
Conductor tipping
Hoop buckling

Transformer Failure Modes

Thermally Induced
Overloading
Failure of cooling system
Blockage of axial spaces
Over-excitation

(over-voltage or under-frequency)

Cause of Failures
Moisture
7%

Overload
2%

Other
2%
Electrical
Disturbances
29%

Loose
Connection
13%

Maintenance
issues
13%
Lightning
16%

Insulation
issues
18%
20 years of claims

an ounce of prevention
"The dielectric strength of transformer oil
decreases rapidly with the absorption of moisture.
Oil samples from each tank, except of course
small distribution transformers, should be given a
break-down test at least once each year so that
moisture may be promptly detected and removed
by filtering."

J.B. Swering, HSBs Chief Electrical Engineer ,

The Locomotive, 1925
over eighty years ago!!!!

Frequency & Severity of Cause

Frequency vs Severity for Cause

Millions of Dollars

Electrical
Disturbances

Insulation
issues
Lightning
Maintenance
issues
Loose
Connections
Moisture

Other
-

Overload
Sabotage

0.005

0.010

0.015

Frequency of Failure

0.020

0.025

Aging Transformer Fleet

Base GVA per Year Additions
200

Transformer GVA Installed

180
160
140
120
100
80
60
40
20
0
1964 1966 1968 1970 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996
Year

Aging Forecast
Our latest forecast model ..

f(t) = A +

e
K+e

100%
90%
70%
60%
50%
40%
30%
20%
10%

Age

74

68

62

56

50

44

38

32

26

20

14

0%
2

Hazard Function

80%

perspective !!
Base GVA per Year Additions
200

Transformer GVA Installed

180
160
140
120
100
80
60
40
20
0
1964 1966 1968 1970 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996
Year

Conducting the Investigation

C57.125-1991

IEEE Guide for Failure Investigation,

Documentation, and Analysis for Power
Transformers and Shunt Reactors
sponsor

Transformers Committee
of the
IEEE Power Engineering Society
approved January 27, 1991
IEEE Standards Board

Case Studies

Case #1
University Substation
12 /16 /20 MVA
69 /13.8kV

Case #1
Sample
Date

03/18/02 07/23/02 12/31/02 5/16/03

Hydrogen

19

35

50

55

Methane

31

33

Ethylene

15

15

25

27

Ethane

15

13

35

38

Acetylene

20

42

40

51

Case #1
Transformer hit by lightning in Spring 02
Tripped off line, differential relay, 8/23/03
Manufacturer
called in for
inspection.

Case #1
Repairs were made
for about $11,000
Replacement would
have been
approx. $300,000

Case #2
6 MVA Aux Unit
At MidWest
powerplant
13.2 /2.4kV

Case #2
Oil Test Results
Sample
Date
Hydrogen

11/22/02 1/27/03

2/19/03

4/22/03

428

374

295

231

Methane

3509

3495

3370

3485

Ethylene

3988

3932

4010

4444

Ethane

1804

1800

1850

2118

Acetylene

Case #2
Unit was taken
out of service
on 4/30/03
Opened for
Inspection .

Case #2
Repairs were made for
about $74,000
(including downtime)

Forced Outage
Replacement would
have been at least
$650,000

Case #3
New Gen Step Up
In Southeast Asia
Failed core megger test
during installation
Mfr called in to inspect
Shipped back to Europe

Case #3
Unit
De-tanked

Case #3

Core
Shift ?

Case #4
Northeast US powerplant
180MVA Step-Up Transformer
13.8 /138kV

Case #4
138kV Phase to ground fault +oil spill + fire

Case #4

Path of the fire and

auxiliary transformer

Case #4
Remains of transformer
and its LV bushings

Case #4
These photos show some of the other equipment damaged in the side yard and gas pipeline area.

Tool Crib (note the sledge hammer handle is melted

Remains of a portable air compressor

Rotor Cradle

Scorched Gas Pipeline

Case #4

Case #5
30 MVA /23 kV
Voltage Regulator
1. Load Tap Changer
Compartment
2. Position Indicator
3. Cam Switch Air
Compartment
4. Operating Mechanism
Compartment
5. Automatic Reseating
Relief Device
6. Compartment Vent
Piping
7. Liquid Level Guage
8. Unidirectional Breather
9. Hinged Inspection
Doors
10. Filling and Drain Valve
11. Control Cabinet

23kVGroundFaultinLTC

Case #5
Tap Changer
compartment damage

Case #5

Case #5

Case #5
Core & Coil assembly
survived !

Case #6
Powerplant Northeast US 2003
120MVA Step-Up Transformer 13.8 /138kV
4 -Generators
(28 MVA ea.)

Case #6

Case #6
Generator Switchgear Photos
Photo#1 is an overall view of the switchgear, the auxiliary transformer, the 480v breaker cabinet, and
turbine generator; (looking North)

480v Breaker
Cabinet

Damaged Switchgear Auxiliary

Cabinet
Transformer

Air Inlet
for Gas Turbine

Case #6
Gen Breaker

PTs

Bus PT

APD

Case #7
Powerplant in MidWest US
800 MVA Generator Step Up
23kV /230kV

Case #7
Gantry crane to move

500 Tons !

Case #7
Inside the tank .very little damage

Case #7
Powerplant economics
Cost of lost power =
800MW x ($20/MW-hr) x (720hrs/month)

= $ 11,520,000 per

month

Client rented a spare unit from neighbor

for just $1 million /month

Repair or Replace ?
Rewind: $7 million 9 months expedite + delivery
New unit (from Korea) $8 million
8 months delivery
Transformer was cut up for scrap,
because it was too expensive to move 500 tons

Case #8
Powerplant in southern US
Generator Step up 400 MVA
13.8kV /345kV

Case #8
Bushing problem

Case #8
345kV Ground fault on C-phase

Thank You
Questions?