RECOMMENDED APPROACH FOR

INVESTIGATION OF FAILURE OF
TRANSFORMERS

Bhaavya Pandey, Assistant Director

Faraz, Assistant Director
Y. K. Swarnkar, Director
S. K. Ray Mohapatra, Chief Engineer

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CONTENTS
Introduction:
Causes of Transformer Failure
Standing Committee of Experts for Investigation of Failures
Summary of Transformer Failures
Collection of failure data
Checklist of General Observations
Checklist for Observations of Relays and Recorders
Electrical Tests
Internal Inspection
Documents relating to Installation, Operation, Maintenance and Repair History
General Recommendations
References and Disclaimer

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Introduction:
1. The transformer is a critical and expensive components of the Power system
2. Considered to be the HEART of the substation/switchyard.
3. For realizing the dream of 24x7 Power for all, it becomes pertinent that
transformers are kept in best of their health.
4. The failure of transformer due to various reasons are required to be analyzed
properly so that repetition of such failure is averted in future.
5. Thus, collection of data and evidence is of utmost importance for carrying
out failure analysis.
6. In the paper, the information required for analysis of failure, precautions to
be taken during investigation, diagnostic tests to be carried out and
necessity of maintaining proper records of Operation & Maintenance (O&M)
History including test results have been highlighted.

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Causes of transformer failure
1. Transformers are subjected to electric, thermal, mechanical, chemical,
environmental and combined stresses over its life time.
2. The transformer is expected to serve for the life of a substation / switchyard
(about 35 years).
3. The premature failures due to system faults, overloading, poor design, poor
workmanship, use of sub-standard material, lack of proper maintenance,
operation beyond design limits etc. are matter of concern.
4. In case of failure of transformer during warranty period, very little effort is
made by utilities to understand the root cause of failure.
5. The manufacturer should accept the feedback from the utilities without any
prejudice and take remedial measures, while the users, on their part, should
ensure that the equipment is not abused, and correct feedback on the
products performance is passed on to the manufacturer.

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Section 73 of the Electricity Act 2003 states:

The Authority shall perform such functions and duties as the Central
Government may prescribe or direct, and in particular to
.
.
.
(i) collect and record the data concerning the generation, transmission,
trading, distribution and utilization of electricity and carry out studies
relating to cost, efficiency, competitiveness and such like matters;
.
.

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 Standing Committee of experts for investigation of failure of 220 kV and above voltage class
substation equipment

Pursuant to Section 73 of the Act, a Standing Committee comprising of

experts in the field of design and operation of EHV substations from
Central Electricity Authority (CEA), various power utilities and research/
academic institutes has been constituted in CEA with objective to
investigate the failure of 220 kV and above voltage class substation
equipment and recommend remedial measures to avert such failures in
the future.
The Committee meets periodically to discus and deliberate on the failure
reports received by CEA.
Utilities are required to report failure of transformers and other
substation equipment to CEA within 24 hours of the occurrence of failure
and provide detailed information about failure within a Month.
{Regulation: ..}
Based on the reports received in CEA from utilities across the Nation, it
has been observed that the frequency of premature failures of power
transformers has increased.
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Summary of Transformer failures
Forty-six (46) cases of failures of Power Transformers and Generator Transformers (GTs) were
reported to CEA between October 2011 and December 2016.
Out of these Forty-six (46) transformers/GTs, twenty-one (21) have failed within ten (10) years of
service.
Failures

12 13

6
8
7

<5 years 5-10 years 10-15 years 15-20 years >20 years
In absence of adequate information/ relevant data, test results, past O&M history, time stamped
disturbance recorder & event logger data etc., it becomes very difficult to pinpoint exact cause of
failure.

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Collection of failure data
1. The collection of relevant information/data is the first step.
2. Original Equipment Manufacturer (OEM) must be informed,
especially when the equipment is within the warranty period.
3. Even if equipment warranty period is over,
consultation/involvement of OEM is useful in investigating the
failure and taking the correct decision.
4. There is every possibility that Data/evidence could be destroyed
due to movement / shifting / internal inspection of the
transformer etc. Before carrying out such activities, relevant
information / data should be collected and diagnostic tests (if
possible to carry out after failure) should be conducted for
further analysis.
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Checklist of General Observations (IEEE
C57.125-1991)
(a)External Conditions
()Storms or lightning in area
()Unusual sounds, odors
()Debris expelled from transformer or accessories
()Foreign objects in area
()Load on transformer
()System disturbances
()Switching configuration in station at time of event
()Transformer fire protection system
()Evidence of animal contact/dead animal on and around transformer
()Interview of witnesses or station operators present when unit
tripped or failed
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(b) Main Tank
Bulged
Cracked
Leaks
Signs of overheating
Oil level in conservator
Gaskets or seals, leaks, etc.
Gas pressure on sealed transformer

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(c) Bushings
Leaks
Broken porcelain
Holes in cap
Tracking
Oil level
(d) Tap Changer
Position of LTC - as found
Oil level in LTC compartment

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(e) Surge arrester
Surge arrester operation
Surge arrester counter reading
Physical condition
Electrical condition
Surge arrester ground connection

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Checklist for Observations of Relays
and Recorders
(a)Protective Relay Targets
()Differential
()Overcurrent
()Ground fault
()Over excitation
()Meter indications (overloads, unbalances, open phases)
()Operation of Buchholz Relay
()Operation of Oil Surge Relay (OSR)
()Operation of Pressure Relief Device (PRD)
()Operation of Sudden Pressure Rise Relay
()Oil Temperature Indicator (Alarm or trip)
()Winding Temperature Indicator (Alarm or trip)

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(b) Temperature (as found and maximum)
Top Oil
Winding (or hot spot)

(c) Oil Level

Main tank
OLTC
Conservator

(d) Disturbance Recorder and Event Logger Data

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Electrical Tests
1. In some of the failure cases, the transformer gets completely damaged due
to fire or there is extensive damage to the tank, bushings, windings etc.
and thus, it is not possible to perform electrical tests on the transformer.
2. However, for cases where damage to the transformer is not severe, it is
possible to perform various diagnostic tests.
3. Before performing any tests, all precautions should be taken to ensure
isolation of the transformer from all power and auxiliary sources and proper
grounding.
4. Dissolved Gas Analysis (DGA) / tests for combustible gases should be
conducted prior to low voltage electrical tests.
5. It is recommended to carry out following tests preferably in the presence of
representative of OEM or after consulting the manufacturer's instruction
manual.

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6. Various Diagnostic Tests
Magnetic Balance Test
Magnetizing Current Measurement
Insulation Resistance (IR) Measurement
Turns Ratio (TR) Test
Winding Resistance Measurement
Sweep Frequency Response Analysis (SFRA)
Tan delta and capacitance measurement of winding and
bushings
Tests on oil
Dissolved Gas Analysis

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Internal Inspection
1. An internal inspection of the failed transformer on-site is warranted at times to
locate fault inside the transformer and to assess the extent of damage.
2. As far as possible, internal inspection should be carried out in association with OEM /
in presence of representative of OEM.
3. All safety precautions must be observed at all times. Internal inspection must be
performed by experienced staff with proper training.
4. In cases where it is possible to repair transformer on site, the internal inspection
should not cause any further damage to the transformer and precaution should be
taken to prevent ingress of moisture and any foreign material into the transformer.
5. General areas of concern: Sludging, loose wedges, loose coils, any poor electrical
connections, particularly bushings internal lead connection with windings, burned
contacts on tap changers, localized overheating signified by carbon buildup,
displaced wedging or insulation, and other foreign material.
6. The photographs or video of internal inspection may be kept as record for future
reference.

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Documents required for failure Investigation
1. Information relating to technical parameters, design, drawings, results
of tests carried out before & after failure incidences, O&M and repair
history of transformer etc. are valuable information required for
objective failure analysis.
2. Transformer installation, commissioning, Operation & Maintenance
(O&M) instruction manual of OEM
3. Transformer test reports (Factory Acceptance Test reports, and all site
test results including pre-commissioning test results)
4. Routine inspection reports
5. Single-line diagram of substation
6. Relaying/protection scheme
7. Settings of the relays, and measuring devices
8. Records of maintenance, repair, replacement and major overhaul
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General Recommendations
(a)Records of all test results including maintenance tests and tests carried out before &
after failure incidences should be properly maintained for the benefit of O&M
personnel.
(b)Disturbance recording of the substation should be time stamped with Global Common
Time Reference using Time Synchronizing Equipment.
(c) All necessary precautions as per relevant standard must be taken before taking any
sample / conducting any test.
(d)Consistency with previous testing condition should be maintained as far as possible.
Details of test kits should be maintained, required correction factors should be
incorporated for temperature variation and calibrated testing instruments should be
employed for reliability.
(e)Any transformer failure due to internal fault, requiring internal inspection should be
carried out in association with OEM / in presence of representative of OEM to ascertain
the cause of failure. This would help OEM to take corrective action in design of
transformers.
(f) Health indexing of transformer may be done based on which Run-Refurbish-
Replacement decision can be planned effectively.

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(g) In order to minimize errors due to subjective
reporting, failure reporting proforma may be standardized
by the utilities.
(h) In case a decision to scrap the transformer is taken
after its failure, the same may be dismantled so that
thorough internal inspection may be carried out for exact
ascertainment of the cause of failure. Pics/videos of
internal parts of the equipment may be recorded for
future reference and documentation purposes.
(i) Failure and relevant information should be provided to
the manufacturer too; it would help it better designing of
the product.
(j) Storage of the transformer for the period between
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 Draft CEA (Technical Standard for Construction of Electrical Lines and
Electric Plants) Regulations has been prepared and the same is in public
domain for suggestions. The last date of submission of suggestions is
26th May, 2017.

A Committee for standardization of Power Transformer Specifications has

been constituted under Chairmanship of Member(Power System), CEA.

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References:
IEEE C57.125-1991 IEEE; Guide for Failure Investigation,
Documentation, and Analysis for Power Transformers
and Shunt Reactors
Transformer Diagnostics; Facilities Instructions,
Standards, and Techniques Volume 3-31, United States
Department of The Interior Bureau of Reclamation

Disclaimer:
The views expressed in the paper are of the Authors and
not of the Central Electricity Authority.
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 THANK YOU.

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