NFPA TODAY 

- OCTOBER 29, 2021

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Transformer Fire Protection

BY BRIAN O'CONNOR

While superheroes and the big box office may have everything thinking about robots when we
talk about transformers, they are actually a much more important device that is essential for the
transmission, distribution, and utilization of alternating current electric power.

What are transformers and what do they do?

In basic terms a transformer is a device that transfers electric energy from one AC circuit to
another, either increasing or reducing the voltage. This is done for several reasons, but two main
purposes are to reduce the voltage of conventional power circuits to operate low-voltage devices
and to raise the voltage from electric generators so that electric power can be transmitted over
long distances. They have been in use for a long time and are an essential piece of our electrical
infrastructure. The most common transformer that people often see are located on telephone
poles.

Why are transformers hazardous?

Transformers are often times filled with oil for insulation, to prevent electrical arcing and to
serve as a coolant. This oil is similar to mineral oil and very flammable. When a transformer fails
it can lead to an intense fire and violent explosion (feel free to check out one of the many videos
online on exploding transformers). Transformers can hold anywhere between a few gallons to
thousands of gallons. Transformers can be installed indoors or outdoors, but indoor transformers
typically are not filled with oil while outdoor transformers often are.

Oil insulated transformer protection methods

Some of the main considerations when talking about transformer fire protection are fire walls &
separation, water based fire protection systems, containment, drainage and lightning protection.

Fire Wall & Separation

Ideally, we want to prevent transformers from catching fire, but in the event one does catch fire
or explode we want to limit the damage and potential spread of fire. This can be done by several
means, the most common being physical separation and fire walls. NFPA 850, Recommended
Practice for Fire Protection for Electric Generating Plants and High Voltage Direct Current
Converter Stations,  recommends that transformers with more than 500 gallons (1900 L) of oil be
protected by a fire wall rated for 2 hours that is extended 1ft (300 mm) vertically and 2ft (600
mm) horizontally beyond the transformer. In lieu of a fire wall, physical separation is
recommended anywhere from 5 to 25 ft (1.5 to 15 m) based on the oil capacity of the
transformer.
Fire Protection Systems

NFPA 15, Standard for Water Spray Fixed Systems for Fire Protection, contains requirement on
how transformers should be protected using a water spray system. If requires  0.25 gpm/ft2 [10.2
(L/min)/m2] of water to be discharged onto the envelope of the transformer itself and 0.15
gpm/ft2 [6.1 (L/min)/m2]  on the surrounding area for exposure protection. The water supply for
such a system needs to be able to keep up with the designed flow rate of the system as well as
250 gpm (946 L/min) for a hose for the duration of 1 hour.
Another important protection feature is a containment pit and drainage system to help retain any
spilt transformer oil or discharge from a fixed water spray system. If a containment area is
designated, then the fire wall should at least extend to the edge of that area.

Since lightning is a potential ignition source for a transformer fire lightning protection should
also be provided. For more information on how lightning protection works see NFPA
780, Standard for the Installation of Lightning Protection Systems.

Transformer failures can be extremely dangerous but with the right precautions in place fires can
be controlled to limit damage to the surrounding components, minimize plant downtime and
improve survivability of plant staff. There is a lot more that goes into panning and designing a
safe transformer installation, but this addresses the main concepts and ideas. For more
information on fire protection recommendation for power generating plants check out NFPA
850, Recommended Practice for Fire Protection for Electric Generating Plants and High
Voltage Direct Current Converter Stations.

Important Notice: Any opinion expressed in this column (blog, article) is the opinion of the author and does not necessarily
represent the official position of NFPA or its Technical Committees. In addition, this piece is neither intended, nor should it be
relied upon, to provide professional consultation or services.
Transformer fire suppression system

Problem:
 High voltage transformers are subject to the risk of fire and
explosion as a result of an electrical short circuit.
 Such events are sudden in their nature and thus the lack of a
permanent fire suppression system may result in a total
destruction of the transformer.
 This also poses a risk of fire spreading onto the remaining parts
of the installation.
Solution:
 We have applied a fire detection system based on a sensor cable
which detects the increase of temperature in thousands of
locations within the transformer simultaneously.
 We have designed a sprinkler system in the form of self-
supporting cages surrounding two transformers – the system
ensures even coverage of the equipment with water mist.
Exemplary transformer sprinkler system
 

Objective
The objective was to build a fire detection and a sprinkler-based fire
suppression system for oil transformers. The installation was designed to
protect two 110 kV transformers. Additionally, the system had to be
upgradable to cover a third transformer when needed.
The task was carried out for a chemical company as part of the construction
of a transformer and distribution station.
Sprinkler system for transformers
A so-called cage, i.e. a spatial structure made of pipes equipped with 56
sprinklers was installed at each station. The sprinklers were positioned in
such a manner as to make sure  the transformer and its equipment is evenly
covered with water mist. The cage is a self-supporting element and thus
required no additional support structure.
An exemplary test of a sprinkler system designed to protect a transformer
against fire
 

With this approach, it was is not possible to connect pipes with quick
couplings, which enable on-site cutting of pipes to fit and thus streamlines the
work considerably. Instead, we used bolted flange joints which guarantee the
required rigidity of the self-supporting cage. In this case, however, each
element is prefabricated in advance. This means that high precision is
required – if one of the elements does not fit the others, a new one must be
made. This in turn could delay the works by up to several weeks. This is
mainly due to the anti-corrosion technology used – more on that in the
following sections.
All components used were certified and approved as required. They also met
the investor’s specific requirements with regard to anti-corrosion protection.
For example, the pipes used were hot-dip galvanized on both sides and then
covered with special anti-corrosion coatings designed for use in harsh
conditions typical of the chemical industry (resistant to, e.g. acid and lye
vapours)..
The system features two actuator stations (flood valve stations), designed to
ensure an immediate supply of fire extinguishing water to the sprinkler
system. Diaphragm flood valves with national approvals as well as VdS and
FM Global approvals were fitted.

A diaphragm flood valve fitted in the transformer fire suppression system

 

The fire extinguishing procedure for the transformer was initiated in the
following three ways:
1. manual activation of the fire suppression system by means of a
push button located in the control room,
2. automatic activation of the fire suppression system by means of
an electric signal from the transformer detection systems,
3. manual opening of the flood valves.

Transformer fire detection

The fire detection system has two activation thresholds:
 transformer temperature increase above 80oC – detected with a
special sensor cable,
 detection of anomalies in the cooling oil tank (short circuit,
insulation breakdown, leakage) – a Buchholz relay installed in
the transformer.
If any one of the above-mentioned events occurs, a sound alarm is activated
and information about this fact is transmitted to the control room. At this
point, the fire suppression system can be activated manually. If both tripping
events occur simultaneously, the fire suppression system is activated
automatically.
 

As mentioned above, a sensor cable was used for fire detection purposes. The
sensor cable is maintenance-free and requires no special protection, therefore
it is suitable for use in locations with no or limited access in the course of
standard operation.
Testing and acceptance of the system
The works were completed with a system pressure test. For this purpose, a
pressure of 0.8 MPa was maintained in the piping throughout 24 hours. The
system pressure was examined after this time and its value was unchanged.
Subsequently, the pressure was increased to 1.6 MPa for 30 min. This test
was also passed successfully.
The pressure tests were followed by an operational test, which consisted in
activation of the sprinkler system. This test was also passed successfully.
Assembly works and acceptance tests were performed in according to
obligatory standards
Transformer fires and explosions
Fires and explosions of transformers are not uncommon. In February, the
Polish Press Agency reported on a transformer fire at the Siekierki CHP Plant
in Warsaw. The causes of the fire are yet to be determined. The following
section also includes other examples from the previous year.
Preventive measures turned out to be insufficient
in the Rybnik power plant
Prevention in the form of safety automation is an essential necessity.
Unfortunately, as practice demonstrates, such solutions are not 100%
effective. This was confirmed by the case of Rybnik power plant, where
preventive safety devices worked properly, and yet there was a serious
incident… an incident which was costly but more importantly which posed a
direct threat to the the power unit.
This is how the incident was described by Bolesław Słowiński in the
document entitled “Damaged high voltage insulating passage in a unit
transformer causes a major breakdown in the power plant”:
An electrical short circuit resulted in an explosion in the transformer tank.
As a result of the force of the explosion in the transformer, the welded upper
cover of the tank was torn open, with the opening size of approx. 80 mm,
along approx. 50% of its circumference. There was an ejection and leakage
of transformer oil, which caught fire; subsequently, the fire engulfed the
entire unit transformer.
The increase in the current up to the value of12.445 kA occurred in 2.8 ms,
which, based on the rated current of the 8TB transformer, means that its
value was: 33.5 x the rated current  of the 8TB transformer. Such a rapid
increase in the current value caused an immediate tripping of the differential
protection and the associated electrical safety devices as well as
disconnection of the circuit breakers for unit 8, unit 7 and the 400 kV power
output lead. The current surge was caused by a single-phase electrical short-
circuit of L2 phase of the 400 kV side to the earth caused by a damage to the
insulating passage of the 8TB transformer.
TRANSFORMERS FIRE PROTECTION
 Published on March 8, 2017

Manuel Bolotinha

Electrical Engineer - IST; MSc - FCT/UNL

199 articles Follow

Excessive overheating, extremely severe short circuits, faults in the oil and lightning
strokes may cause a fire on transformers.

Transformer fires are rare but the impact is great. Even though a transformer involved
in a fire likely will be destroyed almost immediately, as seen in the figure below, the
fire’s effect on adjacent equipment and structures can be mitigated and therefore must
be considered.
An uncontained fire can do a significant amount of damage and result in a prolonged,
unscheduled outage.

For transformers of high rated power and voltages above 123 kV is usual to provide a
fire protection, using water spray fixed systems, commonly called transformer
“deluge” or “fire water” systems, as shown in Figure 1.

Figure 1 – Transformer fire protection system

This system is activated through flame detectors if the transformer is installed

outdoors, or by smoke detectors, if the transformer is installed indoors.

The fire protection system of a transformer may be divided into:

 Water Based and Mist Systems: fire pumps; water spray fixed system/nozzles; valves;
valves components; piping.
 Fire Detection System: fire detectors; control panel; cabling.

The fire suppression requirement may be mitigated when the transformer is located,
or the burning oil can be contained, remotely from the structure and other equipment.
Protection of the plant structure and adjacent equipment, as well as reducing hazards
to personnel, warrants fire suppression in most cases.

In some cases, use of less-flammable insulating fluids may mitigate the need for fire
suppression and should be considered as an alternative.

Is common practice that industry standards and insurance requirements include fire
suppression and barrier walls for transformers containing as little as about 1,900 liters
of combustible oil where acceptable separation/barriers from buildings and other
equipment cannot be achieved.

Summarizing, the basic principles are:

 New facilities with large, mineral-oil-filled transformers located near the plant
structure or other equipment should include active transformer fire suppression
systems to protect the structure and adjacent equipment and properly designed
containment systems to protect the environment.
 For new facilities, and where justified at existing plants, serious consideration should
be given to locating mineral-oil-filled transformers away from the plant, other
equipment, and waterways as a way of reducing fire and environmental risks. In these
cases, active fire suppression may not be necessary if other considerations allow.
 Existing, functional fire suppression systems should continue to be used to protect
plant structure and other equipment but should be reviewed for adequacy and
compliance with current codes and standards.
 Inactive fire suppression systems should be reviewed for adequacy and compliance
with current codes and standards and restored to service.
 Fire suppression systems should be added to existing facilities (where none currently
exist) and where required to protect the plant structure or other equipment.
 Transformers should have periodic condition assessments in addition to routine
inspection, testing, and maintenance. Transformers with low condition indices should
be programmed for rehabilitation or replacement.
 Fire barrier walls between adjacent transformers, between transformers and the plant
structure, between single-phase transformers, or between transformers and other
equipment should be added where feasible and appropriate to contain a fire and
explosion, thus reducing collateral damage.
 Fire suppression systems must be adequately operated, maintained, and tested.
 Containment and oil-water separation structures must comply with all applicable laws,
regulations, and standards (see Section 10).
 Access to transformers will be limited only to those having official business in the area.
Proximity of the public to transformers will be restricted.
 Applicable environmental laws must be accommodated.
Figure 2 – Fire barrier walls