OVERVIEW OF POWER PLANT AND

TRANSFORMER PROTECTION

Submitted by:-

ARPAN KUMAR RUDRA

ELECTRICAL AND ELECTRONICS ENGINEERING

AMITY UNIVERSITY, NOIDA

CERTIFICATE

This is to certify that Mr Gaurav Kumar, a student of Bachelor of

Technology in Electrical Engineering of 4th semester from Indian Institute
Of Engineering Science And Technology, Shibpur ,Howrah has
successfully completed his Vocational Training at Tata Power Co. Ltd.
Jojobera Power Plant, Jamshedpur under guidance of undersigned &
successfully completed project on “Overview of Power Plant and
Transformer Protection” from 10 December 2017 to 9th January 2018.

We wish him all the best for his future endeavours.

Mr. G.P SASTRY Mr.BinayKhalkho

(Head, EMD)(Hr Manager)

Mr.DeepuMinz Mr. Somnath Chatterjee

(Hr executive) (Asst. Manager, EMD)

ACKNOWLEDGEMENT

This project would not have been possible without the kind support and
help of many individuals. I would like to extend my sincere thanks to all of
them.

I am highly indebted to my project mentor Mr P.K. Choudhary for his

guidance and constant supervision as well as for providing necessary
information regarding the project and also for his support in this project.

I would like to express my gratitude towards my parents and Electrical

Maintenance Department (EMD) for their kind co-operation and
encouragement, which helped me a lot in this project.

I would like to express my special gratitude and thanks to the Hr manager

Mr.BinayKhalkho and Hr executive Mr.DeepuMinz for providing me
opportunity to do Summer training at Tata Power Co. Ltd. Jojobera,
Jamshedpur.

My thanks and appreciation also goes to my colleagues for helping me the

project and also to people who have willing helped me out with their
abilities.

Thanking you,

Gaurav Kumar
About the TATA jojobera plant

The Tata power company limited is one of oldest power sector utility in India. The Tata
power group (TEC) comprised of three companies:-

 Tata power -set up in 1919

 Andhra valley - set up in 1916
 Tata hydro -set up in 1910

These companies were merged in the year 2000 to form Tata power. Now Tata power
manages around 3200MW of generation, transmission and distribution business at
present and has set goals to take this level to 5000MW by the year 2008.

Tata power started its operation in Jharkhand with the acquisition of 67.5MW of coal
based captive power unit of Tata Steel in April, 1996. Tata power added three units of
120MW capacities each at Jamshedpur. The first unit began commercial operation in
February 2001 followed by the second unit in February 2002 while the third became
operational by 2005.

UNIT COMMISSIONING:

UNIT# 1: 67.5MW

UNIT# 2: 120MW

UNIT# 3: 120MW

UNIT# 4: 120MW

UNIT# 5: 120MW

NET GENERATION: 547.5 MW at JOJOBERA plant, Jamshedpur

The principle customer of Tata Power is Tata Steel with whom the business transactions
are done on Power Purchase Agreement (PPA) basis. The entire power generated is sold
to Tata Steel, which in turn utilizes it for its own use as well as for supplying it to other
local industries and township. Tata Power earns its revenue from Tata Steel.

FUEL

a) Coal

The primary fuel is Coal, of which 60% is procured from Tata Steel. The remaining is
obtained from MAHANANDI COAL FIELDS LIMITED (MCL) and West Bokaro.
b) Secondary Fuel

The secondary fuel used is Light Diesel oil and is the sources are Indian Oil Corporation
Limited or HPCH or BPCL.

c) Water

The water comes from the river Swarnarekha and is supplied by JUSCO(Jamshedpur
Utilities & Services Company Ltd).

WASTE DISPOSAL

In the power generation process coal ash is generated in two forms-Fly Ash and Bottom
Ash. Fly ash is conveyed pneumatically to Lafarge Plant and through bunker to ACC
and Grasim for cement making. Bottom ash is disposed to ash pond for setting and
water is recovered, recycled and reused.

PROCESS

Steam is generated in tangentially fire, pulverized coal generator (Boiler). In the process
coal is fired in the Boiler to convert water into superheated steam. Then the thermal
energy stored in steam is utilized in the turbine-generator set to generate electrical
power. After passing through the turbine, steam comes into condenser where it is
condensed into water. The condenser water is reutilized in the steam generator for
producing further steam and the system runs in a closed cycle.

A small percentage of make-up water is required to compensate the losses in the

process. To convert turbine exhaust steam into condensate water in the condenser,
circulating water system is provided. Coal is used as primary fuel and LDO firing
system is provided for starting up/Shut down/low load operations. Coal is received from
in the coal yard and after primary and secondary crushing; coal is fed to the coal
bunkers through conveyors. From the coal bunkers, it is fed into coal mills where
pulverisation takes place and coal primary air mixture is pneumatically fed into the
boiler furnace through coal burners.
The product of coal/LDO consumption i.e. flue gas comes out through boiler stack after
passing through air pre-heater and economizer. Bottom ash thus generated is collected
in bottom ash hopper beneath steam generator. To evacuate the Fly ash and Bottom ash,
a mechanised ash evacuation system is provided. All three units are provided through
Electrostatic Precipitator (ESP) to bring down the fly ash and Suspended Particulate
Matter (SPM) level in conformity with the pollution control norms.

Important parameters are monitored on continuous basis through DCS, SCADA and
other systematic. All the important control loops run in auto-mode along with self-
correcting characteristics. The power is generated at 11 KV level and is then stepped up
a 132 KV by generator transformer. Electrical power is supplied to Tata Steel at two
voltage levels-132 KV and 33 KV .

The power at 132 KV level is fed directly to the main grid of Tata Steel at GOLMURI
Substation. The division feds the 33KV power to local industries through a 33KV
substation directly as per guidelines given by the Tata Steel. Power generation, in-house
consumption and power supply to consumer is monitored on-line through VISTA
system.

TATA POWER PLANT can be roughly divided into five main areas of operation:-
 Coal Handling Plant
 Boiler And Turbine Area
 Electrostatic Precipitator
 Transformer Yard
 Switch Yard
  COAL HANDLING PLANT

Coal handling plant in thermal power comprises the process from coal unloading till
filling bunkers of respective coal miles in different units.

Brief Description of Coal Handling Plant:

Rated conveying capacity 1176TPH

Unloading Method Wagon Tippling

Tripling Capacity 4 Km (approx.)

Total Length of conveyer 300 m

6.5 KV H.T Motor 17

Function, Capacity and Sources of CHP:

. Procurement of coal

. Unloading, sizing and storing of coal

. Feeding of coal

. The design capacity of CHP is 1176 TPH and rated capacity is 100 TPH

. Middling coal from TISCO West Bokaro collieries

Unloading, sizing and storing of coal

Based on clearance received from Railway “B” cabin, coal rakes arrive at Railway
Peripheral Yard. The locomotive drag out coal rake containing coal loaded wagons, are
placed at Wagon Tippler to be handled by Side Arm Charger.
 1. Tata Power receives the Coal through WAGON.
2. The unloading of the coal is done through the WAGON TRIPPLER.
3. Then through conveyer belt the coal goes to the primary crusher, where the
primary crushing of the coal is done.
4. Then the Uncrushed coal and Rejected coal are separated from crushed coal.
5. Then the Crushed Coal goes from the Primary crusher to the Secondary crusher
through Junction#5. The size of the Crushed Coal from the Secondary Crusher is
about 25mm.
6. Then from Junction#4 the crushed coal is stored in the crushed coalyard#1 and
crushed coalyard#2.
7. Then through Reclaim Hopper#1 and Reclaim Hopper#2 the crushed coal is
again loaded into the conveyer belt and through the Junction#3, Junction#2 &
Junction#1 it goes to the Tripper Floor.
8. From the tripper floor the crushed coal enters into the Bunker.

Wagon Tippler

The Wagon Tipplers driven by 110 KV motor and the top lamping device is actuated by
hydraulic power pack which gives necessary fluid flow and pressure by means of 30
KV hydraulic motor to operate the hydraulic cylinder. All these motors are PLC
controlled.

Wagons arriving at CHP are placed by hydraulic operated Side Arm Charger on wagon
Tippler which is driven by 415V a.c, 125KV induction motor. Tata Honeywell PLC
performs the entire operation of Wagon Tippling. Individual coal loaded wagons are
placed on Wagon Tippler cradle. Wagon Tippler raise command is given by the
operator and sequence of tippling operation is started in auto-mode controlled by PLC.
  BOILER AND TURBINE AREA (OPERATION OF STEAM CYCLE)

The steam cycle is working on a non-heat regeneration cycle. Feed water is supplied to
the drum through the economizer outer limbs. Water in the boiler tubes absorbs heat
from the furnaces. The mixture of water and steam is discharged into the boiler drums.
The separated saturated steam is let to the super-heater where it is heated to about 810
Kelvin.

Super-heated steam from the boiler is fed to the turbine via the turbine top valve,
emergency stop and governing valve. Steam first enters the HP turbine, gets expanded
here and then it is directed to the inlet of the LP turbine for further expansion. In the
process the turbine starts rotating which in turn rotates the prime mover of the generator
,thus producing electricity.

The various components used are:-

 Condensate Extraction Pump

 Hotwell Makeup Pump
 Surface Condenser
 Extraction Steam System
a. LP Heater
b. HP Heater
c. Deaerator
Steam undergoing expansion n the turbine is allowed to flow through the condenser
where the steam is condensed by the cooling water supplied by the C.W Pumps. The
condensate collected is pumped by the vertical condensate extraction pumps to the
Deaerator through air-ejector, drain cooler and LP heater. From the Deaerator feed
water storage tank, feed water is pumped to the economiser inlet header through the two
HP heaters. During this process, the condensate steam collected in different system.
Heat is recovered at various points and is fed to the main feed water system.

TURBO-GENERATORS

MAKE BHEL

RATING 75MVA

VOLTAGE 132/33/6.6KV

OIL QUANTITY 32250 LITERS

COOLING ONAF/ONAN

CONNECTION HV-STAR,MV-STAR,LV-DELTA

VECTOR GROUP HV-MV YNyn0,HV-LV YNd1

INSULATION LEVEL HV MV LV
a) IMPULSE WITHSTAND 550 75 60
VOLTAGE 230 28 20
b) 1s MINUTE POWER FREQUENCY
WITHSTAND VOLTAGE

FLUE GAS CYCLE

  ELECTROSTATIC PRECIPITATOR (ESP)

An electrostatic precipitator (ESP) is a particle control device that uses electrical forces
to move the dust particles out of the flowing gas stream and collected onto collector
plates. The particles are given an electrical charge by forcing them to pass through a
corona, a region in which gaseous ions flow. It is used to:-

a) To control atmospheric pollution caused by fly ash.

b) To meet statutory requirement of pollution control (maximum permissible 50

mg/Nm3).

c) To get fly ash as a by-product. Tata Power is doing partial evacuation to cement
companies and partially dumping in ash pond by slurry.

d) To stop air pollution that will damage to agriculture, material & human health.

Principle of Operation

There are two electrodes:

i) Collecting Electrode (Positively charged)

ii) Emitting Electrode (Negatively charged)

  Emitting electrode is charged at high voltage DC negative.
 Collecting Electrode (plate) is at ground potential (positive).
 Electrical field is perpendicular to flue gas flow.
 Emitting electrodes sprays negative ions towards positive plate (corona
discharge).
 They collide with ash particles and transfer the charge to them.
 Ash particles get negatively charged.
 The positive collecting plate attracts negative ash particles. On reaching the
collecting plate, the particles get electrically neutralized and remain there.
 After a layer of ash is collected on the collecting plate, it is mechanically rapped
so that the ash falls into the hopper for disposal through ash handling system.

ADVANTAGES

• Very high collection efficiency.

• Low pressure drop.

• Less maintenance.

• Longer Life.

• Capacity to collect sub-micron particle.

 TATA POWER SWITCHYARD AND TRANSFORMER YARD

There are 9 lines and 2 buses (bus A and bus B) receiving power from 5 generator-
transformer unit (GT). There are 3 station transformers (ST) and 5 Unit Auxiliary
transformers (UAT).

The present total capacity is 547.5 MW. The main customer is TATA STEEL (132
KV). Besides this TATA CUMMINS (33 KV), LAFARGE (33 KV) and TATA
MOTORS (33 KV) also receives power from it.

DETAILS OF LINES

LINE 1 132 KV GOLMURI BUS B

LINE 2 132 KV GOLMURI BUS B

LINE 3 132 KV GOLMURI BUS B

LINE 4 132 KV GOLMURI BUS B

LINE 5 132 KV BLOWER HOUSE BUS B

LINE 6 132 KV SONARI BUS B

SUBSTATION
LINE 7 132 KV MPDS BUS B

LINE 8 132 KV MPDS BUS B

LINE 9 132 KV JUSCO(Radial BUS B

feeder)

DETAILS OF GENERATOR TRANSFORMERS

GT# 1 10.5KV/132KV (67.5MW) BUS B

GT# 2 11KV/132KV (120MW) BUS B

GT# 3 11KV/132KV (120MW) BUS A

GT# 4 11KV/132KV (120MW) BUS B

GT# 5 11KV/132KV (120MW) BUS B

GENERATOR TRANSFORMER RATINGS

GT# 1

RATING 90/55 MVA

VOLTAGE 10.5/132 KV

OIL QUANTITY 32250 LITRES

MAKE BHEL

GT# 2

RATING 150/120/90 MVA

VOLTAGE 11/132 KV

OIL QUANTITY 49000 LITRES

MAKE BHEL

GT# 3

RATING 150/120/90 MVA

VOLTAGE 11/132 KV

OIL QUANTITY 49000 LITRES

MAKE BHEL

GT# 4

RATING 150/120/90 MVA

VOLTAGE 11/132 KV

OIL QUANTITY 49000 LITRES

MAKE BHEL

GT# 5

RATING 150/120/90 MVA

VOLTAGE 11/220 KV

OIL QUANTITY 50000 LITRES

MAKE BHEL

STATION TRANSFORMERS

ST# 1

RATING 75 MVA

VOLTAGE 132/33/6.6 KV

OIL QUANTITY 32250 LITRES

MAKE BHEL

ST# 2

RATING 75 MVA

VOLTAGE 132/33/6.6 KV

OIL QUANTITY 32250 LITRES

MAKE BHEL

ST# 3

RATING 75 MVA

VOLTAGE 132/33/6.6 KV

OIL QUANTITY 32250 LITRES

MAKE BHEL

UNIT AUXILLARY TRANSFORMERS

UAT# 1

RATING 12.5 MVA

VOLTAGE 10.5/6.6 KV

OIL QUANTITY 4050 LITRES

MAKE EMCO

UAT# 2

RATING 12.5 MVA

VOLTAGE 10.5/6.6 KV

OIL QUANTITY 4050 LITRES

MAKE EMCO

UAT# 3

RATING 12.5 MVA

VOLTAGE 10.5/6.6 KV
OIL QUANTITY 4050 LITRES

MAKE EMCO

UAT# 4

RATING 14.5 MVA

VOLTAGE 11/6.6 KV

OIL QUANTITY 7200 LITRES

MAKE CROMPTON GREAVES

UAT# 5

RATING 14.5 MVA

VOLTAGE 11/6.6 KV

OIL QUANTITY 7200 LITRES

MAKE CROMPTON GREAVES

FD FAN

CAPACITY 29.3 m3/sec

SPECIFIC WEIGHT OF MEDIUM 1.071
TOTAL HEAD DEVELOPED 430 mmwc
TEMPRATURE OF MEDIUM 500 C
FAN WEIGHT 9837 Kg/FAN
SPEED 980 rpm
RATING 180 KW

ID FAN

SPEED 150 rpm(variable)

RATING 680 KW/743 rpm/6600 V/3 HP
PURPOSE FLUE GAS EXTRACTION FROM
BOILER
MAKE BHEL
PA FAN

TYPE AP2 17/12

SPEED 1480 rpm
CAPACITY 44-23 m3/HR
TOTAL HEAD DEVELOPED 1179 mmwc
TYPE OF REGULATION BLADE PITCH
RATING 675 KW

CIRCUIT BREAKER RATING

RATED VOLTAGE 12 KV
RATED FREQUENCY 50 Hz
RATED CURRENT 2500 A
BREAKING CURRENT 40 KA
INSULATION LEVEL 28/75 KV, 75/35 KV
MOTOR 220 V DC(SF6 at 200 C)
INTRODUCTION

The primary objective of the Transformer Protection is to detect internal faults in the
transformer with a high degree of sensitivity and cause subsequent de-energisation and,
at the same time be immune to faults external to the transformer i.e. through faults.
Sensitive detection and deenergisation enables the fault damage and hence necessary
repairs to be limited. However, it should be able to provide backup protection in case of
through faults on the system, as these could lead to deterioration and accelerated aging,
and/or failure of the transformer winding insulation due to overheating and high impact
forces caused in the windings due to high fault currents. In addition to the internal
faults, abnormal system conditions such as over excitation, over voltage and loss of
cooling can lead to deterioration and accelerated aging or internal failure of the
transformer. Hence protection again these failures should be considered in as part of the
comprehensive transformer protection scheme.

Transformer protection can be broadly categorized as electrical protection implemented

by sensing mainly the current through it, but also voltage and frequency and, as
mechanical protection implemented by sensing operational parameters like oil pressure/
level, gas evolved, oil & winding temperature.

Like in most things in Transformer Protection too, the extent of protective devices
applied to a particular Transformer is dictated by the economics of the protection
scheme along with the probability of a particular type of failure and the cost of
replacing and repairing the transformer as well the possibility of the failure leading to
damage of adjacent equipment or infrastructure. Failure costs include all the direct and
indirect costs associated with it. The protection scheme cost includes the cost of the
protective device but is mainly the cost of the disconnecting device i.e. the Circuit
Breaker and other auxiliaries like batteries and necessary infrastructure. Further the life
cycle cost is taken into account.There are no strict guidelines as to what protection
devices should be used for a particular transformer. However, typically Transformers
below 5000 KVA are protected using Fuses. Transformers above 10,000KVA have
more sensitive internal fault detection by using a combination of protective devices as
shown in Figure 1. For ratings between the above a protection scheme is designed
considering the service criticality, availability of standby transformers, potential of
hazardous damage to adjacent equipment and people etc.

There are three general categories of protective relay technology that arise in the
discussions to follow:

•Electromechanical: uses magnetic flux created from current and voltage to create
torques on movable disks and relays, which is the source of the term “relay.” Usually
single device number functionality.

•Solid State: uses low voltage analog signals created from sensed currents and voltages;
uses discrete electronics and basic logic circuits; may contain a basic microprocessor for
logic and some math. Usually single or dual device number functionality.
•Numeric: a multifunction, programmable logic relay; digitizes sensed current and
voltage, then calculates an RMS or phasor equivalent value; uses a high-end
microprocessor. Usually incorporates many device number functions.

Figure1. Use of relays in a large industrial load.

In this example system, the protection scheme described applies to solidly ground (as
well as impedance grounded) systems. The phase and ground differential (87P and 87N)
and sudden pressure relay (63) provide the primary transformer fault protection. The
overcurrent elements (51) are generally considered backup transformer protection, or
for protection of the bus and backup protection for the feeder relays.

These elements are part of the transformerprotection in that they limit the
accumulateddamage that occurs from a transformer feedinghigh current into
downstream faults. Hot spot monitoring (49) is indicated, but is likely an alarm only
scheme.If there is a possibility of over voltage on theunits due to local generation or a
transformer being placed at the end of a long line (the “Ferranti” effect), voltage relays
(24) may be included. Another possible backup protection scheme is low voltage or
unbalanced voltage detection.
TRANSFORMERS

Transformer is a static electromagnetic device which raises or lowers the voltage in a circuit
without any changes in frequency but with a corresponding decrease and increase in current.

Transformer works on mutual induction between two electrical circuit linked by a common
magnetic flux. It consists of two inductive coils which are electrically separated but
magnetically linked through a path of low reluctance.

According to uses and types transformers can be divided into different category- Power
transformer, Current transformer, Rectifier transformer, Auto transformer etc.

According to winding configuration it can be- core type and shell type transformer.

According to cooling system can be classified as ONAN, ONAF, OFAF, OFWF etc.

TRANSFORMER CORE:-

Transformer provides continuous path for electromagnetic flux and are made of cold rolled
grain oriented alloy steel (CRGO), which reduces Hysteresis loss and enable the core to operate
at higher flux density. Generally it has limbs which metered with top and bottom yokes. CRGO
steel has a feature that has specific loss in Watt/kg is lowest in the direction of rolling.

Cores are laminated and each lamination is coated with phosphorous glass type coating to
reduce the Eddy Current losses in the core. Laminations built to form a stepped limb (cross
section) having as near as possible a circular section are metered at 45% with top and bottom
yoke.

RADIATORS AND COOLING:-

Radiators are provided to enlarge the cooling surface area of the oil filled transformer. It is
made of mild steel but not designed for vacuum. For ONAF and OFAF type, electrically driven
cooling fans are provided to cool the radiators. They are mounted either below or at side of the
radiator. For OFAF type of cooling, OIL pumps are also provided to circulate the oil between
Main Tank and Radiator to improve the cooling. Hot oil comes from top of the Main Tank in
the Radiator and cold pushed from bottom in the Main Tank.

TRANSFORMER OIL:-

Transformer oil protects the core and coil assembly from chemical attack. It provides dielectric
strength of the transformer insulation system. It provides efficient cooling system of
transformer. Transformer oil is pure hydrocarbon mineral oil and generally paraffin base.

There are different kinds of transformers such as two winding or three winding power
transformers, auto transformer, regulating transformers, earthing transformers, rectifier
transformers etc. Different transformers demand different schemes of transformer
protection depending upon their importance, winding connections, earthing methods
and mode of operation etc.

It is common practice to provide Buchholz relay protection to all 0.5 MVA and above
transformers. While for all small size distribution transformers, only HV fuses are used
as main protective device. For all larger rated and important distribution transformers,
over current protection along with restricted earth fault protection is applied.
Differential protection should be provided in the transformers rated above 5 MVA.

Depending upon the normal service condition, nature of transformer faults, degree of
sustained over load, scheme of tap changing, and many other factors, the suitable
transformer protection schemes are chosen.

Nature of Transformer Faults

Although an electrical transformer is a static device, but internal stresses arising from
abnormal system conditions, must be taken into consideration. A transformer generally
suffers from following types of transformer fault:-

1. Overcurrent due to overloads and external short circuits.

2. Terminal faults

3. Winding faults

4. Incipient faults

The transformer faults cause mechanical and thermal stresses inside the transformer
winding and its connecting terminals. Thermal stresses lead to overheating which
ultimately affect the insulation system of transformer. Deterioration of insulation leads
to winding faults. Sometime failure of transformer cooling system, leads to overheating
of transformer. So the transformer protection schemes are very much required.

The general winding faults in transformer are either earth faults or inter-turns faults.
Phase to phase winding faults in a transformer is rare. The phase faults in an electrical
transformer may be occurred due to bushing flash over and faults in tap changer
equipment. Whatever may be the faults, the transformer must be isolated instantly
during fault otherwise major breakdown may occur in the electrical power system.

Incipient faults are internal faults which constitute no immediate hazard. But if these
faults are over looked and not taken care of, these may lead to major faults. The faults in
this group are mainly inter-lamination short circuit due to insulation failure between
core lamination, lowering the oil level due to oil leakage, blockage of oil flow paths. All
these faults lead to overheating. So transformer protection scheme is required for
incipient transformer faults also. The earth fault, very nearer to neutral point of
transformer star winding may also be considered as an incipient fault.

This is essential to protect high value transformer against external and internal
electrical faults.

External Faults in Power Transformer

External Short – Circuit of Power Transformer

The short – circuit may occur in two or three phases of electrical power system. The
level of fault current is always high enough. It depends upon the voltage which has been
short – circuited and upon the impedance of the circuit up to the fault point. The copper
loss of the fault feeding transformer is abruptly increased. This increasing copper loss
causes internal heating in the transformer. Large fault current also produces severe
mechanical stresses in the transformer. The maximum mechanical stresses occur during
first cycle of symmetrical fault current.

High Voltage Disturbance in Power Transformer is of two kinds,

(1) Transient Surge Voltage

(2) Power Frequency Over-Voltage

(1) Transient Surge Voltage

High voltage and high frequency surge may arise in the power system due to any of the
following causes:

(a) Arcing ground if neutral point is isolated.

(b) Switching operation of different electrical equipment.

(c) Atmospheric Lightening Impulse.

Whatever may be the causes of surge voltage, it is after all a traveling wave having high
and steep wave form and also having high frequency. This wave travels in the electrical
power system network, upon reaching in the power transformer; it causes breakdown
the insulation between turns adjacent to line terminal, which may create short circuit
between turns.

(2) Power Frequency Over-Voltage

There may be always a chance of system over voltage due to sudden disconnection of
large load. Although the amplitude of this voltage is higher than its normal level but
frequency is same as it was in normal condition. Over voltage in the system causes an
increase in stress on the insulation of transformer. As we know that, voltage V =
4.44Φ.f.T ⇒ V ∝ Φ, increased voltage causes proportionate increase in the working
flux. This therefore causes, increased in iron loss and dis – proportionately large
increase in magnetizing current. The increase flux is diverted from the transformer core
to other steel structural parts of the transformer. Core bolts which normally carry little
flux, may be subjected to a large component of flux diverted from saturated region of
the core alongside. Under such condition, the bolt may be rapidly heated up and
destroys their own insulation as well as winding insulation.

Under Frequency effect in Power Transformer

As, voltage V = 4.44Φ.f.T ⇒ V ∝Φ.f as the number of turns in the winding is fixed.

Therefore, Φ ∝ V/f

From, this equation it is clear that if frequency reduces in a system, the flux in the core
increases, the effect are more or less similar to that of the over voltage.

Internal Faults in Power Transformer

The principle faults which occurs inside a power transformer are categorized as,

(1) Insulation breakdown between winding and earth

(2) Insulation breakdown in between different phases

(3) Insulation breakdown in between adjacent turns i.e. inter – turn fault

(4) Transformer core fault

Internal Earth Faults in Power Transformer

Internal Earth Faults in a Star connected winding with neutral point earthed through
impedance. In this case the fault current is dependent on the value of earthing
impedance and is also proportional to the distance of the fault point from neutral point
as the voltage at the point depends upon, the number of winding turns come under
across neutral and fault point. If the distance between fault point and neutral point is
more, the number of turns come under this distance is also more, hence voltage across
the neutral point and fault point is high which causes higher fault current. So, in few
words it can be said that, the value of fault current depends on the value of earthing
impedance as well as the distance between the faulty point and neutral point. The fault
current also depends up on leakage reactance of the portion of the winding across the
fault point and neutral. But compared to the earthing impedance, it is very low and it is
obviously ignored as it comes in series with comparatively much higher earthing
impedance.

Internal Earth Faults in a Star connected winding with neutral point solidly
earthed

In this case, earthing impedance is ideally zero. The fault current is dependent up on
leakage reactance of the portion of winding comes across faulty point and neutral point
of transformer. The fault current is also dependent on the distance between neutral point
and fault point in the transformer. As said in previous case the voltage across these two
points depends upon the number of winding turn comes across faulty point and neutral
point. So in star connected winding with neutral point solidly earthed, the fault current
depends upon two main factors, first the leakage reactance of the winding comes across
faulty point and neutral point and secondly the distance between faulty point and neutral
point. But the leakage reactance of the winding varies in complex manner with position
of the fault in the winding. It is seen that the reactance decreases very rapidly for fault
point approaching the neutral and hence the fault current is highest for the fault near the
neutral end. So at this point, the voltage available for fault current is low and at the
same time the reactance opposes the fault current is also low, hence the value of fault
current is high enough. Again at fault point away from the neutral point, the voltage
available for fault current is high but at the same time reactance offered by the winding
portion between fault point and neutral point is high. It can be noticed that the fault
current stays a very high level throughout the winding. In other word, the fault current
maintain a very high magnitude irrelevant to the position of the fault on winding.

Internal Phase to Phase Faults in Power Transformer

Phase to phase fault in the transformer are rare. If such a fault does occur, it will give
rise to substantial electric current to operate instantaneous over current relay on the
primary side as well as the differential relay.

Inter turns fault in Power Transformer

Power Transformer connected with electrical extra high voltage transmission system, is
very likely to be subjected to high magnitude, steep fronted and high frequency impulse
voltage due to lightening surge on the transmission line. The voltage stresses between
winding turns become so large, it cannot sustain the stress and causing insulation failure
between inter – turns in some points. Also LV winding is stressed because of the
transferred surge voltage. Very large number of Power Transformer failure arises from
fault between turns. Inter turn fault may also be occurred due to mechanical forces
between turns originated by external short circuit.

Core fault in Power Transformer

In any portion of the core lamination is damaged, or lamination of the core is bridged by
any conducting material cause‟s sufficient eddy current to flow, hence, this part of the
core becomes over heated. Sometimes, insulation of bolts (Used for tightening the core
lamination together) fails which also permits sufficient eddy current to flow through the
bolt and causing overheating. This insulation failure in lamination and core bolts causes
severe local heating. Although these local heating, causes additional core loss but
cannot create any noticeable change in input and output electric current in the
transformer, hence these faults cannot be detected by normal electrical protection
scheme. This is desirable to detect the local over heating condition of the transformer
core before any major fault occurs. Excessive over heating leads to breakdown of
transformer insulating oil with evolution of gases. These gases are accumulated in
Buchholz relay and actuating Buchholz Alarm.

BASIC SAFETY DEVICES IN POWER TRANSFORMERS

1) BUCHHOLZ RELAY

Buchholz Relay in transformer is an oil container housed the connecting pipe from
main tank to conservator tank. It has mainly two elements. The upper element consists
of a float. The float is attached to a hinge in such a way that it can move up and down
depending upon the oil level in the Buchholz Relay Container. One mercury switch is
fixed on the float. The alignment of mercury switch hence depends upon the position of
the float.

Buchholz Relay

The lower element consists of a baffle plate and mercury switch. This plate is fitted on a
hinge just in front of the inlet (main tank side ) of Buchholz Relay in transformer in
such a way that when oil enters in the relay from that inlet in high pressure the
alignment of the baffle plate along with the mercury switch attached to it, will change.

Fig. Location of Buchholz relay

In addition to these main elements a Buchholz Relay has gas release pockets on top.
The electrical leads from both mercury switches are taken out through a molded
terminal block.
Buchholz Relay principle

The Buchholz Relay working principle of is very simple. Buchholz Relay function is
based on very simple mechanical phenomenon. It is mechanically actuated. Whenever
there will be a minor internal fault in the transformer such as an insulation faults
between turns, break down of core of transformer, core heating, the transformer
insulating oil will be decomposed in different hydrocarbon gases, CO2 and CO. The
gases produced due to decomposition of transformer insulating oil will accumulate in
the upper part the Buchholz Container which causes fall of oil level in it.

Fall of oil level means lowering the position of float and thereby tilting the mercury
switch. The contacts of this mercury switch are closed and an alarm circuit energized.
Sometime due to oil leakage on the main tank air bubbles may be accumulated in the
upper part the Buchholz Container which may also cause fall of oil level in it and alarm
circuit will be energized. By collecting the accumulated gases from the gas release
pockets on the top of the relay and by analyzing them one can predict the type of fault in
the transformer.

More severe types of faults, such as short circuit between phases or to earth and faults in
the tap changing equipment, are accompanied by a surge of oil which strikes the baffle
plate and causes the mercury switch of the lower element to close. This switch
energized the trip circuit of the Circuit Breakers associated with the transformer and
immediately isolate the faulty transformer from the rest of the electrical power system
by inter tripping the Circuit Breakers associated with both LV and HV sides of the
transformer. This is how Buchholz Relay functions.

Buchholz Relay Operation – Certain Precaution

The Buchholz Relay operation may be actuated without any fault in the transformer. For
instance, when oil is added to a transformer, air may get in together with oil,
accumulated under the relay cover and thus cause a false Buchholz Relay
operation.That is why mechanical lock is provided in that relay so that one can lock the
movement of mercury switches when oil is topping up in the transformer. This
mechanical locking also helps to prevent unnecessary movement of breakable glass bulb
of mercury switches during transportation of the Buchholz Relays.

The lower float may also falsely operate if the oil velocity in the connection pipe
through, not due to internal fault, is sufficient to trip over the float. This can occurs in
the event of external short circuit when over currents flowing through the winding cause
overheated the copper and the oil and cause the oil to expand.

2) Pressure Relief Devices

When it is required to limit the pressure rise inside a tank, in order to prevent an
excessive mechanical stress of the walls, it is necessary to use a safety valve set at a
precise overpressure value.

Fig. During normal position and during internal pressure

The tank of oil-immersed transformers is usually fit with this kind of protecting device.
In case of short circuit due to an insulation failure, the dielectric arc between live parts
vaporises the surrounding insulating fluid which generates a quick rise of the pressure
inside the tank, with the risk of permanent deformations, or, even, of the failure of the
tank walls with the consequent flow-out of hot oil.

Due to the rapidity of this event, it is necessary to mount on the transformer an adequate
protecting device which relieves quite suddenly the excess of pressure generated inside
the tank by the above mentioned failure.
WORKING

The way of working is very simple: each time the pressure inside the transformer tank
reach the operating pressure of the PRD, the shutter lift slowly from its rest position
disjoining from the main tightening gasket (pos 9 of the diagram); in this condition the
excess of pressure can‟t be released in the environment, being the shutter still in contact
with the external gasket (pos 10 of the diagram). Now the internal overpressure operates
on the whole internal surface of the shutter, which is bigger than the initial surface.
Consequently, the strength acting on the shutter is much higher than the spring-load on
the other side; this brings to a quick and high lifting of the shutter followed by an
equally fast reclosure as the excess of pressure is released in a very short time through
the big opening created by the shutter lifting.

3) Magnetic Oil Gauge (MOG)

MOG is used to show on line oil level inside any tank or vessel. In case of transformer,
it is used to show analogic indication of oil level inside the conservator tank & upon
requirement it also gives alarm signal when the oil level reduces below minimum and /
or maximum admitted level.

The float fastened to the inside of the transformer tank moves a magnet as the oil level
changes. The movement of the magnet is sensed outside of the tank by the gauge( using
another magnet). That way there is no need for a penetration of the tank wall to measure
the oil level, reducing the number of locations where a leak could occur.

4) Transformer Winding Temperature Thermometer

These devices are supposed to indicate hottest spot in the winding based on the
manufacturers heat run tests. At best, this device is only accurate at top nameplate rated
load and then only if it is not out of calibration. They are not what their name implies
and can be misleading. They are only winding hottest-spot simulators and not very
accurate.

There is no temperature sensor imbedded in the winding hot spot. At best, they provide
only a rough approximation of hot spot winding temperature and should not be relied on
for accuracy. They can be used to turn on additional cooling or activate alarms as the
top oil thermometers do.
Winding temperature thermometers work the same as the top oil thermometer, except
that the bulb is in a separate thermometer well near the top of the tank. A wire-type
heater coil is either inserted into or wrapped around the thermometer well which
surrounds the temperature sensitive bulb. In some transformers, a current transformer
(CT) is around one of the three winding leads and provides current directly to the heater
coil in proportion to winding current.

In other transformers, the CT supplies current to an auto-transformer that supplies

current to the heater coil. The heater warms the bulb and the dial indicates a
temperature, but it is not the true hottest-spot temperature.

These devices are calibrated at the factory by changing taps either on the CT or on the
autotransformer, or by adjusting the calibration resistors in the control cabinet. They
normally cannot be field calibrated or tested, other than testing the thermometer, as
mentioned. The calibration resistors can be adjusted in the field if the manufacturer
provides calibration curves for the transformer. In practice, most winding temperature
indicators are out of calibration, and their readings are meaningless. These temperature
indications should not be relied upon for loading operations or maintenance decisions.

Fiber optic temperature sensors can be imbedded directly into the winding as the
transformer is being built and are much more accurate. This system is available as an
option on new transformers at an increased cost, which may be worth it since the true
winding “hottest-spot” temperature is critical when higher loading is required.
Thermometers can be removed without lowering the transformer oil if they are in a
thermometer well. Check your transformer instruction manual. Look carefully at the
capillary tubing between the thermometer well and dial indicator. If the tubing has been
pinched or accidently struck, it may be restricted. This is not an obvious defect, and it
can cause the dial pointer to lock in one position. If this defect is found, the whole gage
must be returned to the factory for repair or replacement; it cannot be repaired in the
field. Look for a leak in the tubing system; the gage will be reading very low and must
be replaced if a leak is discovered.

5) Transformer temperature, oil level and pressure gauges

Temperature controls are required in order to turn on and off the cooling equipment.
These controls are usually combined with a visible dial-type gauge that measures
„winding temperature‟.

This is really a misnomer because the gauge does not actually contact the winding.
Instead; it measures the top oil temperature plus a temperature gradient produced by a
small heater surrounding the thermometer bulb. This heater is connected to a current
transformer on one of the phases of the secondary leads, so as the secondary load
increases, so does the current through the heater resistance.
The heater then becomes a mimic of the actual transformer winding with the winding
temperature gauge measuring a temperature that is roughly equivalent to the true
winding temperature.

In addition to (or instead of ) the winding temperature gauge, most transformers have an
oil temperature gauge that measures the actual top oil temperature. The difference in
temperature between the winding temperature gauge and the top oil temperature gauge
is one indication of how heavily the transformer is loaded.

One example of this was a case of an OA cooling class transformer operating with a
very high oil temperature. Further investigation revealed that a leak in the radiator had
caused the oil level to drop below the radiator inlet, resulting in a virtual total loss of
cooling. In other cases, investigations of elevated transformer temperatures have
revealed blocked coolers and malfunctioning cooler controls.

An oil level gauge is required so that the correct oil level can be maintained. There is
usually a mark on the gauge that indicates the 25°C level, which is the proper oil level
at that temperature. Maintaining the proper oil level is extremely important because if
the oil level falls below the level of the radiator inlet, flow through the radiator will
cease and the transformer will overheat.

A very low oil level can expose energized and current-carrying components that are
designed to operate in oil and could result in overheating or an electrical flashover. If
the oil level is too high, it could cause over pressurization when the oil expands.
Electrical Protection
The electrical protection of the Transformer comprises of the following and each is
elaborated further.

1) Over Current Protection

2) Fused Protection
3) Differential Current Protection
4) Over Excitation Protection
5) Over Voltage Protection

1) Transformer Over Current Protection

Over Current Protectionis commonly used for protection from phase and ground faults.
It‟s used as primary protection where differential protection is not used and as backup
protection if differential protection has been used. The protection zone of over current
devices is normally more than the transformer. Hence they are part of the system
protection and need to be coordinated with the other system protection devices.

Backup protection of electrical transformer is simple Over Current and Earth Fault
protection applied against external short circuit and excessive over loads. These over
current and earth Fault relays may be of Inverse Definite Minimum Time (IDMT).

The over current relays cannot distinguish between external short circuit, over load and
internal faults of the transformer. For any of the above fault, backup protection i.e. over
current and earth fault protection connected to in-feed side of the transformer will
operate. Backup protection is although generally installed at in feed side of the
transformer, but it should trip both the primary and secondary circuit breakers of the
transformer.
Over Current and Earth Fault protection relays may be also provided in load side of the
transformer too, but it should not inter trip the primary side Circuit Breaker like the case
of backup protection at in-feed side. The operation is governed primarily by current and
time settings and the characteristic curve of the relay. To permit use of over load
capacity of the transformer and co- ordination with other similar relays at about 125 to
150% of full load current of the transformer but below the minimum short circuit
current.

Backup protection of transformer has four elements; three over current relays connected
each in each phase and one earth fault relay connected to the common point of three
over current relays as shown in the figure. The normal range of current settings
available on IDMT over current relays is50% to 200% and on earth fault relay 20% to
80%.

Another range of setting on earth fault relay is also available and may be selected where
the earth fault current is restricted due to insertion of impedance in the neutral
grounding. In the case of transformer winding with neutral earthed, unrestricted earth
fault protection is obtained by connecting an ordinary earth fault relay across a neutral
current transformer.
The unrestricted over current and earth fault relays should have proper time lag to co –
ordinate with the protective relays of other circuit to avoid indiscriminate tripping.

Restricted Earth Fault Protection of Transformer

2) Fuses
Typically, fuses are used as primary protection for transformers below 10MVA. Above
10MVA over current relays are used as back up along with differential relays as primary
protection for transformers. Fuses are economical, require little maintenance, and do not
need an external power source to clear a fault, which is of great cost and maintenance
benefit. Fuses are probably the predominant choice for transformers below 10 MVA.
The use of fuses creates some notable protection compromises. Fuses are not as precise
in operating characteristics. Characteristics change slightly with temperature, pre-fault
loading, and reclose timing. Fuses are subject to gradual damage from heavy through
faults, leading to an eventual fast trip for a low magnitude fault.

Fuses are insensitive and relatively slow except at very high current levels. Fuses will
not sense low level faults, such as near the neutral of the transformer, and hence trip
only after the fault has evolved into a high current event. To allow short overloads, a
transformer fuse is typically selected to carry 150-300% of the transformer rated
current. Most fuses can carry over 125% of rated current for very long times, and just
begin to reliably trip for faults in the range of 150-200% of the fuse rating, and at this
level generally take tens of seconds to trip. The effect is that a fuse might carry current
in the range of 3 to 5 times transformer rated current for an extended period. At
moderate currents, fuses are still relatively slow.

A fuse has some protection benefits. If fault current is extremely high, a fuse can be
faster than a breaker and can clear faults within 0.5-2 cycles after inception. The fastest
type, called a “current limiting fuse” (CLF), available at medium and low voltages, can
clear a fault in half a cycle and can reduce the first half cycle peak current to a level
notably below the available fault current.

The CLF fuse can be damaged by inrush current if not properly selected. If a fuse is
selected that has fast clearing at peak currents, it can clear a fault faster than any circuit
breaker. It is recommended that, on fused transformers, protection should employ a low-
side circuit breaker with phase and ground overcurrent relays for backup protection of
secondary faults.

3) Differential Relaying
Differential relays sense the unbalance in the flow of currents in various apparatus or
buses. In the absence of a fault in the protected zone, this unbalance tends to be small
and the flows into the zone are closely matched to the flows leaving. Accordingly, such
relays can be more sensitive than phase overcurrent relays and need not be delayed to
coordinate with other relays during external faults, except for some issues associated
with transient CT saturation.
 Figure 2 - Basic Differential Concept

Figure 3 Differential Protection in three winding transformers

The simplest implementation of differentialprotection merely parallels the CTs on all

the connections to the zone, and the relay monitors the current summation. The basic
differential concept above will not work with transformers. When the protected zone in
is a transformer, there are several additional components that are required, or at least
commonly implemented, for proper performance:

•Current Matching Scheme

•Through Current Restraint and MinimumOperate Logic

•Delta/Wye Compensation Logic (may beimplemented in CT connections rather than in

the relay)

•Magnetizing Inrush Blocking Scheme, commonly using harmonics

Figure 3 - Transformer Differential Concept

2.1. Current Matching Scheme

The relay‟s current matching scheme allowsdifferent currents on each input to the relay
to be seen as effectively the same current. In electromechanical relays, the scheme uses
tapped transformers (hence, the source of the term “tap”), where each tap adjusts the
number of turns used on the input transformer. In electromechanical relays, the tap
selection is much more limited, and resultant error seen by the relay tends to be
substantially more significant.

Current matching in three winding transformer applications must, in effect, be analyzed

two windings at a time. One assumes identical power in windings 1 and 2 (and 0 in
winding 3), which sets taps 1 and 2, and then one assumes identical power in windings
1 and 3 (and 0 in winding 2), which sets tap 3. This will force winding 2 and 3 taps to
work correctly for the case of power flowing from winding 2 to winding 3. In this
approach, the constant power that is assumed can appear to be more than winding 2 or 3
can handle, but since this power level does not flow in actual application, the high
current flow seen in the calculations does not affect the validity of the setting.
Figure 4 - Current Matching in a Solid State Relay

When installed per the relay instruction manual, the current will flow in opposite
polarity on input 1 and input 2. The taps will be set so that the magnitude of the voltage
presented to the op-amps is the same RMS value. The voltage at point C, the summation
point, will beat the midpoint between A and B, and in normaloperation, since A and B
are opposite in polarity but equal in magnitude, the voltage at C will be 0 throughout the
current sine wave, indicating no error current. If current at input 1 increase, voltage at A
increases, but not B, and now point C sees a voltage above 0. Depending on the relay
settings, the relay may trip.

Current matching settings normally are calculated under the assumption that the load
tap changer is at the nominal / neutral position. The relay percentage restraint and
minimum operate settings then are configured to accommodate the unbalance current
that the relay will see when the load tap changer is at the full boost or buck position, and
commonly with some additional accommodation for the no-load tap being changed
from nominal.

2.2. Percentage Restraint and MinimumOperate

Typically, there is some small difference in thesummation of the sensed currents so that,
evenafter appropriate tap settings, currents sensed by the relay do not sum to an
effective 0A. Theerror (or difference) current becomes the operate current which, if it
rises too high, will cause relayoperation. The operate current arises due todissimilar CT
performance during a through fault or large load inrush differences inthe transformer
no-load tap that is in use vs. theno-load tap assumed when the relay settingswere
calculated; the operation of the transformer

To compensate for operate current rising duringhigh load currents or through faults, it
includes a restraint function. As through currentincreases, the restraint function causes
anincrease in the level of operate current required for a trip. Each current input is
monitored andbecomes part of the overall restraint of the relay.

Fig.4 Percentage restraint characteristics

The concept is that operating (or "differential") current is plotted against the maximum
(i.e., largest) restraint current. The scaling is in "multiples of tap." The slope of the
characteristic can be set from 15 to 60%. The relay becomes desensitized at the higher
restraint currents in order to remain secure in the presence of the various sources of
error.

4.3 Delta/Wye Compensation

A delta wye bank introduces a phase shift inbalanced voltages and currents of
typically±30°, depending on system rotation andtransformer connections. In
electromechanicalrelays, the common approach to the delta wyewinding compensation
is to connect the CTs inwye-delta, the CT on the delta transformer winding is connected
in wye,and the CT on the wye transformer winding is connected in delta. The same
concept could beused with solid state and numeric relays, but normally such relays have
internal delta wyecompensation logic. The preferred approach is to connect CTs in wye
and allow the relay toperform the delta wye compensation. There are several benefits to
connecting the CTsin wye. With wye CTs, metering and eventreports give actual line
currents, rather than the summation of two phases as seen in delta CTs.Power metering
is more accurate when CTs are in wye. Wye connections allow monitoringground
current in the lines and the use of ground

Figure 7 - Delta Wye Compensation with CT

Difficulties relating to the Differential Protection in Power Transformers

1) Transformation ratio and the coupling method

The primary and secondary currents have different amplitudes owing to the
transformation ratio and different phases depending on the coupling method (delta-star
transformer makes a phase displacement of 30°). Therefore, the current values measured
must be readjusted so that the signals compared are equal during normal operation.

This is done using matching auxiliary transformers whose role is to balance the
amplitudes and phases.When one side of the transformer is star-connected with an
earthed neutral, the matching transformers located on this side are delta-connected, so
that the residual currents that would be detected upon occurrence of an earth fault
outside the transformer are cleared.
 2) Transformer inrush current

Transformer switching causes a very high transient current, which only flows through
the primary winding and lasts several tenths of a second.

It is thus detected by the protection as a differential current and it lasts far longer than
the protection operating time (30 ms). Detection based only on the difference between
the transformer primary and secondary currents would cause the protection to be
activated. Therefore, the protection must be able to distinguish between a differential
current due to a fault and a differential inrush current.

The inrush current wave contains at least 20% of second harmonic components
(current at a frequency of 100 Hz), while this percentage is never higher than 5% upon
occurrence of an overcurrent due to a fault inside the transformer.

The protection must therefore simply be locked when the percentage of second
harmonic component in relation to the fundamental harmonic component (current at 50
Hz) is higher than 15%, i.e. I2/I1 > 15%.

3) Magnetizing current upon occurrence of an overvoltage of external origin

The magnetizing current constitutes a difference between the transformer primary and
secondary currents. It is therefore detected as a fault current by the differential
protection even though it is not due to a fault.

In normal operating conditions, this magnetizing current is very low and does not reach
the protection operating threshold. However, when an overvoltage occurs outside the
transformer, the magnetic material saturates (in general the transformers are
dimensioned to be able to operate at saturation limit for the nominal supply voltage),
and the magnetizing current value greatly increases. The protection operating threshold
can therefore be reached.

The magnetizing current due to the magnetic saturation has a high rate of fifth harmonic
components (current at a frequency of 250 Hz).

To prevent spurious tripping upon occurrence of an overvoltage of external origin,

there are two solutions:

1) Detect a rise in voltage that locks the protection;

2) Detect saturation using the presence of fifth harmonic current that locks the
protection.

Transformer differential protection therefore requires fairly complex functions as it

must be able to measure second and fifth harmonic currents or, in order to avoid
measuring fifth harmonic currents, it must be able to detect over voltages of external
origin.
 DGA or Dissolved Gas Analysis of Transformer Oil

Whenever electrical power transformer goes under abnormal thermal and electrical
stresses, certain gases are produced due to decomposition of transformer insulating oil,
when the fault is major, the production of decomposed gases are more and they get
collected in Buchholz relay. But when abnormal thermal and electrical stresses are not
significantly high the gasses due to decomposition of transformer insulating oil will get
enough time to dissolve in the oil. Hence by only monitoring the Buchholz relay it is not
possible to predict the condition of the total internal healthiness of electrical power
transformer. That is why it becomes necessary to analyse the quantity of different gasses
dissolved in transformer oil in service. From Dissolved Gas Analysis of Transformer
Oil or DGA of Transformer Oil , one can predict the actual condition of internal health
of a transformer. It is preferable to conduct the DGA test of transformer oil in routine
manner to get prior information about the trend of deterioration of transformer health
and life.

Actually in Dissolved Gas Analysis of Transformer Oil or DGA of Transformer Oil test,
the gases in oil are extracted from oil and analyse the quantity of gasses in a specific
amount of oil. By observing percentages of different gasses present in the oil, one can
predict the internal condition of transformer.

Generally the gasses found in the oil in service are hydrogen (H2), methane (CH4),
Ethane (C2H6), ethylene (C2H4), acetylene (C2H3), carbon monoxide (CO), carbon
dioxide (CO2), nitrogen (N2) and oxygen (O2).

Most commonly used method of determining the content of these gases in oil, is using a
Vacuum Gas Extraction Apparatus and Gas Chronographs. By this apparatus first
gasses are extracted from oil by stirring it under vacuum. These extracted gasses are
then introduced in gas Chronographs for measurement of each component.

Generally it is found that hydrogen and methane are produced in large quantity if
internal temperature of power transformer rises up to 150oC to 300oC due to abnormal
thermal stresses. If temperature goes above 300oC, ethylene (C2H4) is produced in
large quantity. At the temperature is higher than 700oC large amount of hydrogen (H2)
and ethylene (C2H4) are produced. Ethylene (C2H4) is indication of very high
temperature hot spot inside electrical transformer. If during DGA test of transformer oil,
CO and CO2 are found in large quantity it is predicted that there is decomposition of
proper insulation.

Furfural Test or Furfur aldehyde Analysis of Transformer Oil

Transformer core and winding have mainly paper insulation. Base of paper is cellulose.
The Cellulose has a structure of long chain of molecules. As the paper becomes aged,
these long chains are broken into number of shorter parts. This phenomenon we often
observe in our home. The pages of very old books become very much brittle. In
transformer, the aging effect of paper insulation is accelerated due to oxidation occurs in
oil. When insulating paper becomes mechanically weak, it cannot withstand the
mechanical stresses applied during electrical short circuit and leads to electrical
breakdown.

It is therefore necessary to monitor the condition of paper insulation inside a power

transformer. It is not possible to bring out a piece of paper insulation from a transformer
in service for testing purpose. But we are lucky enough, that there is a testing technique
developed, where we can examine the condition of paper insulation without touching it.
The method is called Furfuradehyde Analysis of in short Furfural test.

Although by Dissolved Gas Analysis one can predict the condition of the paper
insulation primarily, but it is not very sensitive method. There is a guide line in IEC –
599, where it is told that if the ratio of CO2 and CO in DGA results is more than 11, it is
predicted that the condition of paper insulation inside the transformer is not good.
Healthy cellulose insulation gives that ratio in a range of 4 to 11. But still it is not a very
sensitive way of monitoring the condition of paper insulation. Because CO2 and CO
gases also produced during oil breakdown and sometimes the ratio may misleads the
prediction.

When oil is soaked into paper, it is damaged by heat and some unique oil soluble
compounds are realized and dissolved in the oil along with CO2 and CO. These
compounds belong to the Furfur aldehyde group. These are sometimes called Furfural in
short. Among all Furfurals compounds 2 – Furfural is the most predominant. This
Furfural family compound can only be released from destructive heating of cellulose or
paper. Furfur aldehyde Analysis is very sensitive as because damage of few grams of
paper is noticeable in the oil even of a very large size transformer. It is a very significant
diagnostic test. It is best test for assessing life of transformer. The rate of rise of
percentage of Furfurals products in oil, with respect to time, is used for assessing the
condition and remaining life of paper insulation in power transformer.