th
THE 8 INTERNATIONAL SYMPOSIUM ON ADVANCED TOPICS IN ELECTRICAL ENGINEERING
May 23-25, 2013
Bucharest, Romania
An Improved Method for the Inrush Current
Evaluation in Single Phase Power Transformers
Emil Cazacu, Valentin Ioniţă, Member IEEE, Lucian Petrescu, Member IEEE
University Politehnica of Bucharest, Electrical Engineering Department
313 Splaiul Independentei, 060042, Bucharest, Romania
emil.cazacu@upb.ro, valentin.ionita@upb.ro, lucian.petrescu@upb.ro
Abstract- The paper presents an automatic procedure for
quantitative evaluation of energizing inrush current of a specific
range of single phase power transformers: 1.2–25 kVA. Starting
from transformer main rated data and core magnetic H-B
characterization, the first peak value of inrush current is
accurately estimated. Additionally, the harmonic content of its
waveform is also investigated offering valuable indicators of this
transient phenomenon. The predetermination of the main inrush
current characteristics becomes very useful in avoiding its
countless undesirable effects on both the transformer and the
installation where the device operates. The proposed method
offers a fast and flexible solution of the energizing inrush
current problem for the main general purpose single phase
transformers.
Keywords: inrush current, transformer modeling, saturation.
I. INTRODUCTION
The transient current that occurs as a result of any sudden
change in the voltage on a transformers winding is termed as
inrush current [1]. According to the main phenomenon that
leads to the voltage variation, the inrush currents are
commonly divided in three categories [2]. The first refers to
energizing inrush current that occurs when a no-loaded or a
light loaded transformer is switch on. A recovery inrush
current arises when the transformer voltage is restored after a
reduction of its amplitude due to a nearby network
malfunction (e.g. short circuit). Finally, the sympathetic
inrush current is experimented by an already energized
transformer connected in parallel with another unit that
switches on. Our study is limited to a quantitative
investigation of the energizing inrush current of a certain
range of single phase power transformers widely used in low
voltage electric installations.
As electromagnetic devices of paramount importance in the
power delivery process, transformers must be strictly
protected from any kind of overcurrent or overvoltage that
could occur during their operation. Energizing inrush current
(IC) is characterized by extreme high values of its first
amplitude (up to 20 times more than rated load current) and
additionally an even harmonic content is present in the IC
waveform spectrum [3-5]. This behavior leads to many
unfavorable consequences over the transformer and the
network where the device operates. Firstly, the
electrodynamic and thermal stresses on the transformer
windings and other construction components are similar to
those generated by short circuits [6, 7]. Secondly, this
transient current could further determine inadvertent
978-1-4673-5980-1/13/$31.00 ©2013 IEEE
operation of the transformer protecting equipment and cause
their nuisance tripping. Thus, the protective devices, (fuses,
circuit breakers or relays) should be able to discriminate the
IC from any other fault currents [8-9]. Supplementary, inrush
current particularities generate, during the energizing process,
major power quality problems that spread out in the entire
network [10]. Thus, a high level of current unbalances and
harmonics affects all the other power devices that already
operate in the proximity of the switched transformer [11].
Taking into account all these unwanted effects an accurate
predetermination of the IC characteristics along with methods
for the first IC amplitude limitation are demanded.
Various computation techniques have been developed in
order to estimate the IC feature for a certain network
configuration, transformer parameters and exciting supply
voltage. Thus, analytical or semianalytical solutions were
suggested in [12, 13] for the IC amplitude estimation, which
rely on the circuit model of the transformer. Others studies
[14, 15] propose numerical methods such two or three
dimensional FEM computations. Recently, a special attention
was paid to the magnetic description of the transformer core
material. So, different advanced characterization of B-H
dependency for core materials was adopted in order to
accurately model the examined transient process [16-20].
Considerable research effort was dedicated for developing
methods of reduction IC first amplitude. Thereby, many
approaches use external field sources [21- 23], or devices
[24], in order to limit the IC peak value. Others mitigations
procedures focus on controlling the supply voltage switching-
on angle [25, 26] or using a sequential phase energizing
procedure [27, 28] (applicable only for three phase power
transformers). Finally, particular design aspects of the power
transformers (e.g. changing the distribution of primary coil
winding) could lead to an important reduction of IC first
amplitude [29]. This paper is focused on the main IC
characteristics analysis for a particular power range (1.2-
25 kVA) and core types (UI shape) single phase transformers.
Thus, a flexible algorithm of the IC first amplitude and
waveform predetermination is suggested. Additionally, a
complete harmonic investigation of the IC spectrum is carried
out. The reported procedure only requires the main rated data
of the investigated transformers and its magnetic core H-B
characteristic. The computation method relies on the solution
of a nonlinear system of equations derived from mathematical
description of the transient phenomenon.
 II. FUNDAMENTALS OF INRUSH CURRENT
Under normal condition and in continuous-mode operation,
the transformers work close to the saturation knee of the
magnetic material core. During the energizing process, due to
the voltage variation applied to the windings, the core
magnetic flux could reach, after a half of period, twice its
normal peak value [30]. More over, the residual flux,
generated by the core magnet remnant magnetization, adds to
the flux value, driving the core to the heavy saturation state as
Fig. 1 illustrates. In this area, the core magnetic permeability
is very close to the vacuum value and consequently the
primary coil inductance is very small. Thus, an extremely
high value of the first amplitude of the IC is reached, which
could be more than twenty times the transformer rated
current. During the transient process, the core repeatedly gets
in and out the saturation area and hence the IC has distinct
peak values in every cycle. Finally, the IC decays rapidly
(after a few cycles) so that its steady state value, called
magnetization current, is usually around one percent of the
transformer rated current.
The fist amplitude of the IC and its duration are function of
various transformers parameters (rated power, magnetic core
properties, and residual flux just before the connection), but
also of network characteristics where the transformer works
(short circuit power at the coupling point, distance between
substation bus and the transformer etc.). At a certain effective
value and frequency of the applied voltage, the switching
angle at the instant of energizing is essential in establishing
the IC first magnitude. So, the worst case appears when at the
connection moment the remnant flux in the transformer core
has its maximum positive value and the AC voltage starts
from zero (no initial phase angle). As it was mentioned, in
order to rigorously predetermine the IC features of a known
transformer, other network parameters should be also taken
into account. That makes the IC calculation (no matter how
precise would be) to be valid only for a specific installation
configuration. Fortunately, most of the time, the network adds
inductors or/and resistors to the transformers circuit model,
witch limit the IC peak value.
Φ (t ) Φ (t )
2Φ m + Φ r
2Φ m
Φr
i (t )
t
t
Φ (t )
Φr
Φm
i (t )
Fig. 1. The generation of the energizing inrush current along with residual
magnetic flux core effect.
III. INRUSH CURRENT EVALUATION PROCEDURE
Single phase power transformers are widely used in low
voltage installations mainly for delivering energy at different
parameters to a large variety of electric appliances.
Unfortunately, they experience a transient phenomenon by
being often switched during their operating time. The
evaluation of IC parameters becomes also necessary in order
to properly design the protective devices that could
unpredictably trip during the commutation process.
The further presented study concerns common devices
found in large scale applications: transformers with a rated
power between 1.2 and 2.5 kVA with UI shape form of the
magnetic core - Fig.2.
Mathematical description of the transformer energizing
process mainly derives from the transient state equation of the
device circuit model. Additionally the Amper’s law applied to
the transformer magnetic circuit completes the quantitative
device characterization. Considering the primary winding
resistance R1 and the magnetic core nonlinearity mainly
described by its magnetization curve, one can analytically
express the inrush current i(t) and magnetic flux Ф(t) time
dependency:
⎧ d Φ(t ) R1i (t ) − u(t )
⎪ dt = N1
,
⎧⎪u(t ) = U 2 sin( ωt + ϕ ),
⎪
⎨ ⎨ (1)
⎪i (t ) = H (Φ(t ) / Ac )lm ⎪⎩Φ(t ) = B(t ) Ac ,
⎪⎩ N1
where u(t) is the supply AC voltage of effective value U,
angular frequency ω and initial phase φ, while H and B are
the core magnetic field strength and flux density,
respectively. Accordingly, Ac is the effective cross section of
the core, lm represents the mean magnetic path length and N1
is the primary windings numbers.
The above equations system requires, along with the
detailed core geometrical description, a representation of the
magnetic core characteristic in terms of H-B dependency.
That can be accomplished using different approaches. For a
better illustration of the magnetic core heavy saturation area a
simple first order spline interpolation was here adopted.
Fig. 2. UI magnetic core shape power transformers and its geometrical
dimensions.
 In order to numerically solve the nonlinear differential Finally, using (3), each harmonic level of the first peak IC
algebraic equations system (1), Runge–Kutta–Fehlberg waveform is quantitatively evaluated in order to later estimate
(RKF) method [31] was chosen. The initial value parameter is their contribution to the spectrum relative to the fundamental:
imposed by the remnant magnetization of the magnetic core n
Bro before the energizing process being expressed in terms of i (t ) = ∑ [a k cos(kωt ) + bk sin (kωt )],
initial magnetic flux Ф0 = BroAc. k =0 (4)
However, in our further computation we always considered ck
ck = a k2 bk2
+ , hk [%] = ⋅ 100.
the worst case scenario, in terms of remnant core c1
magnetization and point of voltage weave commutation The flow chart shown in Fig. 3 illustrates the proposed
(switching angle), respectively. algorithm, which mainly requires the transformer rated data
If not available, some of the important transformer and magnetic core characteristics.
parameter, such winding turn number N1 and its resistance R1,
can be easily extracted from device rated data. Thus, along
with the transformer rated power Sn, many manufacturers also
indicate the rated voltage drop Δun as a percentage value of
the transformer primary or secondary rated voltage. The latter
is being indicated for a resistive load (no voltage-current
phase shift occurs in the secondary winding: cosφ2 = 1), and
an unitary value load factor β =1 (defined as the apparent
power S required by transformer load relative to its rated
value Sn). Furthermore, the magnetic core material
description and its operating flux density Bn are also provided
by the transformer manufacturers. Accordingly, considering
the expression of transformer voltage regulation [30], one can
easily evaluate the requested parameters:
ΔU
Δu = = β(u a cos ϕ 2 + u r sin ϕ 2 )[%],
Un
S P 2
β= ; u a = Jn ; u r = u sc − u a2 ;
Sn Sn
Sn
PJn = 2 R1 I 12n ; I 1n = ; (2)
U
2
1 Δu nU U
R1 ≅ ; N1 ≅ ,
2 Sn 2ωAc Bn
Fig. 3. Flow chart of the proposed procedure for evaluating the inrush
where Δu is the percentage voltage regulation expressed in current parameters.
terms of load factor β, active ua and reactive ur component of
IV. NUMERICAL EXAMPLE
the transformers rated short circuit percentage voltage usc.
The rated Joule losses PJn were evaluated in terms of primary The proposed algorithm was systematically tested on
winding resistance R1 and rated primary current I1n. numerous UI core shape single phase power transformers,
Aiming to investigate also the first IC peak waveform with rated powers up to 25 kVA. Both the IC first cycle
spectrum, a numerical harmonic analysis is carried out by amplitude and the wave harmonic content were qualitatively
computing Fourier coefficients during a period investigated under the most unfavorable operating conditions:
time (T = 2π ω) . This analysis is particularly useful for the energizing process occurs when the applied voltage
protection devices in separating the IC from any other fault crosses the zero line and remnant magnetization flux has its
currents (e. g. short circuit). Therefore, the corresponding maximum. In order to illustrate the method performances,
terms of the Fourier series are accordingly evaluated: one may use a transformer whose main data are indicated in
Appendix I. The magnetic core material used by the
T T transformer manufacturer is a non-oriented grain silicon steel
1 2
a0 = ∫i (t ) d t ; ak = i (t ) cos(kωt )d t ,
∫ M19, whose magnetization curve is shown in Fig. 4. Since
T 0 T 0 the necessary H-B function is being indicated for a finite
(3) number of measured pair of points, a first order piecewise
T
2
bk = i (t ) sin (kωt )d t ,
∫ k = 1, 2 ,3... . spline interpolation method was selected for covering the
T 0 entire core operating area during the transient process.
Figure 4 also represents these interpolation function variation.
 Fig. 4 Transformer core magnetization curve (red marker) and the adopted
first order piecewise spline interpolation functions representation (blue
curve).
An accurate description of the transformer core magnetic
characteristic becomes crucial in analyzing IC features
(magnitude, waveform and duration). Thus, for this algorithm
an accurate H-B representation is required.
Figure 5 represents the IC variation during five period time
(T0 = 5/f = 100 ms), while Fig. 6 quantitatively shows the first
peak IC harmonic content, highlighting the level of each
harmonic.
The amplitude of the IC first cycle is Iˆ = 1446.73 A , being
reached 7.5 ms after the energizing process. For comparison
reasons, is useful to recall that the transformer rated current
value is I1n = S n U1n = 20 A . Supplementary, after the decay
of the transient phenomenon (within a few periods) the
magnetization current is only limited to I 0 = i0 × I1n = 0.26 A .
The harmonic analysis of the first IC peak waveform,
whose results are depicted in Fig. 6, reveals both the DC and
even harmonics attendance into its spectrum.
Fig. 5 Transformer inrush current variation during five period time.
Fig. 6 First peak IC harmonic spectrum hystrogram.
According to (4) the DC component (zero harmonic) and
the second harmonic percentage level with respect to the
fundamental are:
⎧ c0
⎪h0 [%] = c ⋅ 100 = 59.6 %,
⎪ 1
⎨ (5)
c
⎪h [%] = 2 ⋅ 100 = 55.63 %.
⎪⎩ 2 c1
One can notice that the contributions of the above
evaluated harmonics to the IC spectrum are considerable.
This particular feature of IC waveform has generated
different techniques that manage to discriminate the IC from
other network’s overcurrents (especially from short-circuits).
The magnetic core stress during the transformer switching
is also significant. In that respect, Fig. 7 visualizes the
magnetic flux variation immediately after commutation for
five period time interval.
Fig. 7 Transformer core magnetic flux variation during five period time.
 V. CONCLUSIONS APPENDIX I
A flexible and robust procedure for IC evaluation in the The core geometry for one of investigated transformers
case of a certain single phase power transformer class is (with a rated power of 8 kVA) is presented in Fig. 8 and its
proposed. The algorithm inputs are the main transformer main technical data are indicated in Table 1.
rated data along with the core magnetic characteristics and
delivers the most significant IC features: its first cycle peak
value and harmonic content. The computation methods rely
on the numerical solution of a simple nonlinear algebraic
system of equations that models the transient state. Although
the procedure targets transformers with some particular core
geometry, it could be correspondingly adapted to any other
core shape device.
The analysis of a large variety of transformers reveals
numerous factors that directly influence the IC major
parameters: magnitude, harmonic spectrum content and
duration. Thus, for certain rated power, applied voltage and
core geometry, the magnetic materials properties significantly
affect the IC characteristics. New core magnetic materials,
such highly grain oriented or domain refined electrical steel,
are nowadays used in modern transformers. These materials
have completely different properties than the classical regular
non-oriented grain or even oriented lamination steel types.
They operate at higher flux density, have a higher value of
saturation induction, present a larger linear portion of the Fig. 8. Magnetic core shape of the investigated power transformers and
its geometrical dimensions.
magnetization curve and shows lower remnance flux density.
Additionally, in order to reduce the core joints reluctance, the TABLE I
DATA FOR THE INVESTIGATED SINGLE PHASE POWER TRANSFORMER
step lap joint type is commonly adopted. Therefore, it
becomes very difficult to aggregate all these new materials Sn = 8 kVA Rated power
properties and add them to all other design parameters and U1n = 0.40 kV Primary rated voltage
theoretically predict the IC characteristic. In spite of all these U2n = 0.23 kV Secondary rated voltage
drawbacks, the numerical computation applied on different No load power losses
P0 = 95 W
transformer transient models along with a precise core
Psc = 192 W Short circuit power losses
magnetic characterization could offer satisfactory results for
the IC prediction problem. Consequently, the suggested i0 = 1.3 % Magnetization current
method could be further improved in terms of its accuracy by usc = 4. 5 % Short circuit voltage
developing different advanced characterizations of these new Δun = 2.4 % Rated voltage regulation
materials, especially for describing their saturation area. Number of turns in primary
N1 = 259
Transformer installed at certain points of the distribution
N2 = 149 Number of turns in secondary
networks could have IC magnitude comparable to the short
circuit peak value at that location, demanding additional IC R1 = 0.2400 Ω Primary copper loss resistance
mitigations techniques or limitation equipment. For the R2 = 0.0794 Ω Secondary copper loss resistance
transformers power class investigated here, a simple Bn = 1.25 T Operating magnetic core induction
additional resistance connected at the energized windings
Br = 1.01 T Core remnant magnetization
significantly attenuates the IC first amplitude. For other units
Ac = ab = 0.00558 m2 Magnetic core area
with greater rated power, special IC reduction apparatus or
methods may be required. Thus, NTC (negative temperature lm = 12a= 0.72 m Magnetic path mean length
coefficient) devices or electronic soft starter could a = 0.060 m UI Core main reference dimension
successfully manage to limit the value of IC first magnitude b = 0.093 m Core thickness
of a large power class of single phase transformers.
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