Inrush Current in Transformers

10
10.1 INTRODUCTION
When a transformer works normally, the flux produced in the core is orthogonal to the applied
voltage. When the voltage is zero, the flux waveform is at its negative peak. When a transformer is
switched on from the primary by keeping the secondary open circulated, it acts as a simple induc-
tance and the flux will start from zero as shown in Figure 10.1
If the switching on is at the instant of voltage zero, the flux is initiated from the same origin of
the voltage. The flux is the integral of the voltage, and the value of flux at time π can be written as
π

∫
φ = φm sin wt dwt
0

= 2φm

The excessive demand of flux would saturate the core and result in a sharp increase of the magne-
tizing current. This increased current is termed as inrush current, and its magnitude can become
several times of the full load current.
When the transformer is switched off, magnetizing current will follow a hysteresis loop and
some residual flux may be retained in the core. If the residual flux, φ r , is in the direction of the
flux build-up, the peak flux would become 2φ m + φ r , resulting in much higher inrush current.
The waveform of the inrush current is a half-cycle sinusoidal wave superimposed by a DC component.

2ɸm
flux

ɸm

time 2π
Em sin ωt

FIGURE 10.1 Voltage and flux.

143
144 Power and Distribution Transformers

10.2 PROBLEMS OF TRANSFORMER INRUSH CURRENT

10.2.1 MECHANICAL STRESSES
The amplitude of the first peak of the inrush current can reach high value, and the consequent
mechanical forces on the winding can cause excessive stresses on the windings. If there is fre-
quent switching on of the transformer, the recurring surges can cause mechanical weakness of the
winding.

10.2.2 OVERVOLTAGE DUE TO HARMONIC RESONANCE

The inrush current has very high harmonic content where the even harmonics are predominant.
When any of the harmonics is close to the natural frequency of the system, there is a possibility of
harmful resonant overvoltage.
A power system can experience harmonic resonance in some of the following situations:

• A black start of a system to a remote transformer

• Energization of HV converter transformers
• Energization of off-shore wind farms

10.2.3 NUISANCE TRIPPING OF TRANSFORMER

When the transformer is energized, the inrush current flows through one winding only and there is
no balancing equivalent current on the energized winding. Even if second harmonic restraint is avail-
able on the differential relay, extreme core saturation can cause tripping of a healthy transformer.

10.2.4 TEMPORARY VOLTAGE DIP

The inrush current may cause temporary voltage dips in connected system, which can take few
cycles to return back to normalcy.

10.2.5 SYMPATHETIC INRUSH

When a transformer is switched on to the system, another transformer connected to the system can
experience unexpected saturation and “sympathetic” inrush.

10.3 CALCULATION OF INRUSH CURRENT

10.3.1 APPROXIMATE VALUE OF THE FIRST PEAK OF INRUSH CURRENT
The first peak of the inrush current can be estimated by

1.15 2 Vph
I in = (10.1)
X air

where

I in = first peak of the inrush current (A)

Vph = phase voltage
X air = air core reactance (ohms)
Inrush Current in Transformers 145

8π 2 f AN 2 × 10 −7
=
H
f = frequency (Hz)
π
A = Dm2
4
Dm = mean diameter of winding to which power is switched on (m)
(For step-down transformer Dm = mean diameter of HV winding
and for step-up transformer Dm = mean diameter of LV winding)
N = number of turns of winding to which power is switched on
H = axial height of winding to which power is switched on (m)

• Alternate formula for calculation of air core reactance

X air = 2π f L (10.2)

where
6.4 × 4π × 10 −7 × N 2 D 2  D − 2.25 T 
L=  
(3.5 D + 8 H )  D 
N = number of turns
D = outside diameter of winding m
H = height of winding m
T = radial depth of winding m

Estimation of transformer air core inductance from short-circuit inductance

CIGRE Study Committee 33 gives guidelines for estimating air core inductance from trans-
former short-circuit inductance by the following formula:

• Step-down transformer (outer winding)

Laircore = 2 ~ 2.5 Lsc

• Step-up transformer (inner winding)

Laircore = 1  1.5 Lsc

• Autotransformer (high-voltage side)

Laircore = 4 ~ 5 Lsc

where
L aircore = air core inductance
L sc = short-circuit inductance of transformer
From L sc, Xair in ohms is calculated by

X air = 2π f Lair core (10.3)

146 Power and Distribution Transformers

10.3.2 FIRST PEAK OF INRUSH CURRENT CONSIDERING

SWITCHING ANGLE AND CIRCUIT RESISTANCE
An improved estimate of the first peak of inrush current is calculated by considering the effect of
the switching angle and the resistance of the circuit to which it is switched on.

2 Vph K 2
I First peak = 1 (1 − Cos θ ) (10.4)
 R 2 + X air
2
 2

where

Vph = phase voltage

R = resistance of winding and system (ohms)
X air = air core reactance (ohms)
Br = residual flux density (Tesla)
(For CRGO, this can be taken as 0.8 Bmax )
Bs = saturation flux density (Tesla)
(2.03 for CRGO)
Bm = peak working flux density (Tesla)
θ = initial phase angle of the voltage (radians)

 B − Br − Bma
= K1 Cos−1  s
 Bmax
K1 = correction factor for saturation angle = 0.9
K2 = correction factor for peak value = 1.15

10.3.3 ESTIMATION OF INITIAL FEW PEAKS OF INRUSH CURRENT

The first peak and the subsequent peaks of the inrush current can be calculated by the following
procedure.

Step 1
Calculate the air core reactance of the winding to which power is switched on in ohms
Step 2
Calculate saturation angle θ in radians

 B − Bmax − Br 
θ sat = K1 Cos−1  s  (10.5)
 Bmax 

K1 = correction factor for saturation angle

= 0.90
Step 3
Estimate the first peak of inrush current

2 Vph K 2
I peak = 1 [1 − Cos θsat ] (10.6)
 R 2 + X air
2 2


K 2 = correction factor for peak value = 1.15

Inrush Current in Transformers 147

Step 4
Calculate the new residual flux

R K3
Br ( new ) = Br ( old ) − Bmax × 2 ( Sin θ sat − θ sat Cos θ sat ) (10.7)
X air

K3 = correction factor for inrush decay

With the updated Br , repeat steps 2, 3 and 4 to get the subsequent peaks.

The above procedure calculates the inrush current peaks of a single-phase transformer. For three-
phase transformer, the peaks calculated as above can be multiplied by 2/3.

10.3.4 CALCULATION EXAMPLE

To calculate the inrush current peaks of the first 5 cycles of a 25 MVA 132/33 kV star/star connected
50 Hz transformer when energized from 132 kV side.

• Design data of the transformer

Turns/phase of 132 kV winding = 1020

Mean diameter of 132 kV winding = 0.95 m
Area of cross section of core = 0.20 m2
Peak working flux density = 1.7 Tesla
Saturation flux density of core = 2.03 Tesla
Residual flux density of core = 0.8 × 1.7 = 1.36 Tesla
Axial height of winding = 1.1 m
System + winding resistance = 2 Ω
K1 = 0.9, K2 = 1.15, K3 = 2.26

Step 1
Calculate the air core reactance in ohms
8π 2 f AN 2 × 10 −7
X air =
H
π π
A= × D 2 = × 0.952 = 0.7088 m 2
4 4
H = 1.1 m

8π 2 × 50 × 0.7088 × 1020 2 × 10 −7
X air =
1.1
= 264.6 Ω
Step 2
Calculate the core saturation angle of the first peak

 B − Bm − Br 
θ = K1 Cos−1  s 
 Bs 

 2.03 − 1.7 − 1.7 ×.8 

θ = K1 Cos−1  
 1.7
= 2 radians
148 Power and Distribution Transformers

Step 3
First peak of inrush current
K 2 Vph 2
The first peak = [1 − Cosθ ]
X air
13200 2
= 1.15 x 1.15 × × [1 − Cosθ ]
3 264.6
= 663.28 Amps
Step 4
Residual flux density at end of first cycle

K3R 
Br ( new) = Br (old ) − Bm 2 (Sinθ − θ sat Cosθ )
X air

1.7 × 2.26 × 2 
= 1.36 − 2 (Sin 2 − 2 Cos 2)
264.6

= 1.26 Tesla

Steps 2, 3 and 4 are now repeated to get the peak values of next cycles.
These results as per the above calculation are single-phase values. The three-phase values are
2
× single-phase values calculated.
3
2
The first peak for three phases is × 663.28 = 442.2 A
3
25,000
Rated line current of transformers = = 109.35 A
3 × 132
442
∴ The first peak is = 4 Times rated full load current
109.35

10.4 FREQUENCY RANGE OF INRUSH CURRENT

AND OTHER TRANSIENTS
The transients on the transformers can be from switching and other sources, which can broadly be
divided into the four frequency ranges.

• Low-frequency transients – 0.1 Hz to 3 kHz

• Slow front transients – from power frequency to 20 kHz
• Fast transients – 10 kHz to 3 MHz
• Very fast transients – 100 kHz to 50 MHz

The source of various transients and the frequency range are given in Table 10.1.

10.5 INFLUENCE OF DESIGN ON INRUSH CURRENT

The main parameters of the design affecting the inrush current are as follows:

a. Working flux density of core

Peak inrush current increases and the ratio of the second harmonic to the peak inrush
decreases, with increase in working flux density.
b. Core material
Inrush Current in Transformers 149

TABLE 10.1
Origin of Transients and Frequency Range
Origin of Transients Frequency Range
Transformer switching 0.1 Hz–1 KHz
Transients due to VCB switching Up to 1 MHz
Load rejection 0.1 Hz–3 KHz
Fault clearing Power frequency – 3 kHz
Fault initiation Power frequency – 20 kHz
Line switching on Power frequency – 20 kHz
Line reclosing Power frequency – 20 kHz
Multiple restrikes of circuit breaker 10 kHz–1 MHz
Lightning surges 10 kHz–3 MHz

The Hi-B core material and domain refined (DR) material have higher values of satu-
ration flux density and lower remnant flux density when compared to the normal CRGO
steels similar to M4 grade. The Hi-B and DR materials have low inrush currents when
working at the same flux density as M4.
c. Core joint geometry
Core joints give higher reluctance and reduce the residual flux when compared to the
remnant flux of the core material. The step-lap joints have less reluctance when compared
to mitred joints and therefore produce higher inrush current and lower second harmonics.
d. Whether power is switched on to inner winding or outer winding
The inrush current is inversely proportional to the air core reactance which is low for
the inner winding. Thus, the inrush current will be higher, if the power is switched on
to the inner winding.

10.6 METHODS FOR REDUCTION OF INRUSH CURRENT

Some of the methods employed to reduce the magnitude of switching inrush currents are as follows:

• Pre-insertion resistors
Pre-insertion resistors are installed in parallel to the main circuit breaker. The resis-
tance value and the pre-insertion time need to be optimally selected.
• Controlled switching
Controlled switching is used to energize transformers to reduce the inrush current. The
strategy involves energizing the first phase at its voltage peak and delays the energization
1
of the two phases by th of a cycle.
4

10.7 EFFECT OF SYSTEM AND SWITCHING

PARAMETERS ON INRUSH CURRENT
10.7.1 SOURCE RESISTANCE
Increase of the source resistance will decrease the amplitude of inrush current, and it also causes
faster decay of the amplitude of inrush current. When the system fault level at the transformer
primary side is high, the source impedance and therefore the source resistance are low. Such a
transformer will have higher magnitudes of inrush current lasting much longer than a transformer
installed where the fault level is low.
150 Power and Distribution Transformers

10.7.2 SWITCHING ANGLE

The higher amplitude of inrush current is at 0°. Increasing the switching angle will decrease the
amplitude of inrush current. Also, increasing of the switching angle decreases the percentage sec-
ond harmonic content of the inrush current. Though the highest amplitude of the inrush current is in
the first cycle, the highest percentage second harmonic does not necessarily appear in the first cycle.

10.7.3 EFFECT OF REMNANT FLUX ON THE FIRST CYCLE PEAK CURRENT

When the remnant flux changes, the first peak changes considerably. Switching at the zero residual
flux and 90° switching angle necessarily need not reduce the magnitude of the inrush current. The
optimum angle will have to be selected, based on the remnant flux direction and magnitude.