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A Distribution Transformer (DT) is utilized to step down the voltage from 11 KV to 0.433
KV/0.250KV so that the electrical power is usable for providing supply to the customers such as
domestic, commercial, industrial, LT, etc. A registered consumer expects uninterrupted power supply
because during the failure of power supply, all works be it domestic, official, commercial or industrial
comes to a standstill. Hence, transformer failure leads to consumer complaints and unnecessary
emergency for the Utility to restore the power supply. In urban areas, the reason for failure of power
supply due to failure of transformer is not too frequent, whereas in rural areas most of the power
failures are attributable to the failure of distribution transformers.
Failure of distribution transformers results in considerable revenue loss and entails heavy
expenditure for replacement.
This manual on DT maintenance and reduction of failure does not describe the engineering
know-how of prevention but ensures the use of these skills from the huge collective knowledge of our
vast human resources.
Reasons for failure of Distribution Transformers and the remedial measures thereof:
The reasons for failure of Distribution Transformers in both urban and rural areas are the following:
Sl Probable Causes
No
Factors
Remedial Measures
1.
Overloading
2.
Imbalance loading
Low transformer
oil level
A) Leakage of oil
B) Theft of oil
4.
5.
Poor earthing
or
absence
earthing
A) Overheating of transformer.
B) Entry of moisture and
contaminants.
C) Burnt out insulation in the
winding & core.
D) Acidity formation due to the
combined effect of heat,
dissolution of varnishes &
cellulose.
E) Sludge formation due to
continuous
heating
and
thereby decomposition of the
insulation material which then
gets dissolved in the oil.
A) High soil resistivity of the A) Periodical checking of the soil
earth pit
resistivity. Renovation of earth pit or
B) Disconnected earth wire or
making a new earth pit.
rusted earth wire.
B) Periodical
checking
of
earth
connections. Tightening of the terminal
connections.
A) High soil resistivity of the A) Periodical checking of the soil
earth pit
resistivity. Renovation of earth pit or
B) Undersized loop, especially
making a new earth pit.
from the conductor to the B) Usage of the appropriate size of
L.A.
earthing loop
C) Disconnection earth wire and C) Periodical checking of earth wire
rusted earth wire.
and earth connection.
D) Common earthing.
D) Tightening of the terminal connections.
E) Absence
of
lightning E) Earthing loop of LAs is to be
arrestors / damaged lightning
separate.
arrestors.
F) Installation/ replacement of LAs
A) Loose connection
A) Proper
tightening
of
terminal
B) Poor lugging
connections.
B) Proper lugging and usage of
appropriate size of lugs.
A) Leakage of oil at terminals.
A) Proper tightening of terminals and
B) Short circuit between cables
joints, and replacement of loose burnt
due to failure of insulation.
out gaskets
C) Fire due to weeds/ jungles etc B) Regular check of the insulation of
cables.
C) Periodical cleaning of substation.
A) Long LT line span
A) Erection of intermediary poles where
B) Poor safety clearance.
necessary.
C) Sagging of conductors.
B) Place spacers where necessary and
of
6.
Lightning
7.
Improper or poor
cable terminal
8.
Burning
transformer
9.
External
circuit
of
short
10.
Overrated fuses
11.
Flash over
12.
Lack of testing of
transformer and
sub-station
equipments
13.
Vandalism
D) Accumulation of dust on
maintain safety clearance between
bushings.
conductors.
E) Contact of the conductor with C) Maintain sag of conductors as per
trees / branches.
standard.
D) Cleaning of bushings
E) Regular jungle clearing
A) Non availability of rated
A) Prompt requisition and procurement of
fuse.
fuse.
B) Ignorance of the field staff on B) Training of staff on the purpose of
the appropriate ratings.
fuse, correct size and implications of
C) Use of conductor as fuse
overrating.
C) Discourage the use of conductor as
fuse wire
A) Absence of arcing horn or
A) Proper fitting of arcing horns.
arcing horns are not fitted
B) Periodical cleaning of bushings.
properly.
B) Dirty bushings
A) Non availability of megger
A) Each sub-division should have megger,
earth tester, filter machine, oil
tong tester, and earth tester and each
testing kit.
division should have an oil filter
B) Absence of a routine for
machine and oil testing kit.
testing.
B) Testing schedule to be compiled and
C) Shortage of staff
implemented.
C) Outsourcing of the testing.
A) Unsecured sub-station
A) Proper fencing and the gate(with lock
B) Lack of awareness among the
if needed).
public
B) Danger plate in the substation.
C) Public awareness through media and
meetings.
From the table above it can be seen that the main factors which contribute to Distribution Transformer
failure are:
1. Non implementation of the construction standards.
2. Absence of records on number of consumers, loading and history of the sub-station.
3. Absence of a well prepared action plan for distribution transformer failure reduction.
4. Absence of inspection, testing and maintenance schedule and non-implementation thereof.
5. Absence of inspection, testing and maintenance record on every sub-station.
6. Irresponsibility and carelessness on the part of some personnel.
7. Absence of proper reporting and clear guidelines at different levels.
8. Shortage of staff.
2.
Sl
Inspection
frequency
Items to be inspected
Inspection notes
1.
Fortnightly
(i) Dehydrating
Breather
2.
Monthly
3.
Quarterly
4.
Half yearly
(iii) Physical
Condition
(i) Connections (HT & LT
terminals)
(ii) Explosion vent
(iii) Diaphragm (Pressure
relief device)
Bushings
Check tightness
Check for cracks/
damages
Check for any oil
spillage
Examine for cracks
and dirt deposits
Check for external
connection
Check for moisture
under cover
Inspect
Clean or replace
Tighten, if required
Improve ventilation
Maintenance of breathers to be
ensured
Take remedial measures
5.
paint work
(i) Oil in transformer
Yearly
(ii)Earth resistance
3.
Communication
a.
b.
c.
Quarterly meetings convened by the CE (Distribution) with the Zonal ACEs, ACE
(MM), CEOs & EEs.
d.
e.
NOTE :
It has also been observed that one of the reasons for failure of distribution transformers is
the supply of sub-standard transformers, which is a result of improper vendor rating and lack of
routine test prior to dispatch by the manufacturer & issue for use. It is therefore proposed as
follows:
a. Vendors should be approved only after confirming the adequacy of the manufacturing &
testing facilities at the works.
b. Procurement should be on the guaranteed technical particulars and not necessarily L-I rate.
c. Routine tests should be observed at the works and the transformer should be tested prior to
issue for utilization.
4.
Inspection & Maintenance of transformer and accessories within the sub-station and its
proximity.
A. Overall Sub-station Inspection cum Maintenance Report.
(to be filled up by the concerned inspector viz. Lineman/ES/JE/AE/AEE)
a.
b.
c.
d.
e.
Sl
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Name of Sub-station
Code of Sub-station
Capacity of Transformer
Number of LT feeders
Date of inspection
Items to be inspected
Physical condition of the transformer
DOs/Main switch/Cut-Out
LT feeders
Cable Lugs
Earthing, Earthing Leads, etc
Lightening Arrestor
Arching Horn
Transformer Bushing
Breather
Condition of silica gel
Radiator
Oil level
Oil leakage in any
HT Terminal
LT Terminal
Current (Amps)
Peak Hours
Condition/Observations/Remarks
a. R-phase
b. Y-phase
c. B-phase
Off-Peak Hours
a. R-phase
b. Y-phase
c. B-phase
a.
HT-LT
I R Value
b.
HT-E
c.
LT-E
Number of illegal consumers receiving supply from DT
Number of illegal consumers disconnected from the DT
General upkeep and overall cleanliness of substation
(weeds, litter, etc)
21
22
23
Action
required
if
inspection shows unsactisfactory conditions
HT & LT Fuses
LAs
Earthing
DOs Main switch, Cut out
Cleanliness of sub-station
Checking of sub-station station loading
by tong tester or DT metering
C. HT /LT Lines in the proximity of the substation:
Sl
1.
2.
3.
4.
5.
6.
NOTES:
Action
required
if
inspection shows unsactisfactory conditions