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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
8Electrically Induced
8Mechanically Induced
8Thermally induced
Over Voltage
Surges
Partial Discharge
Static Electrification
(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."
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
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
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
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
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
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.
Rotor Cradle
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
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
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?