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Failure Root Cause Analysis Tesla Transformer

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26 views6 pages

Failure Root Cause Analysis Tesla Transformer

Uploaded by

Venkatesh
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Failure Root cause Analysis for 1700 KVA –M/s Tesla

03.12.12
Transformer- Vaspet Site

Material description : 1700 KVA 0.62/33KV Distribution Transformer

Site : Vaspet Site

Date of Failure : 01.10.12

Make : M/s Tesla Transformer

Dt of Transformer Dismantling : 28.11.12

Failure of Transformer site at Vaspet :


Failure Root cause Analysis for 1700 KVA –M/s Tesla
03.12.12
Transformer- Vaspet Site

Before Dismantling of Transformer at M/s Tesla Transformer, Bhopal :

Active Part of the Transformer after Dismantling : (No Failure of winding &
Core Coil Assembly)
Failure Root cause Analysis for 1700 KVA –M/s Tesla
03.12.12
Transformer- Vaspet Site

Root Cause Analysis for 1700 KVA Transformer Failure:

S. No Failure Cause Effect of Cause in Failure Remarks


Transformer
1. Short Circuit in L.V Cable In this Case, It was not occurred
because if any short circuit occurs,
2. Short Circuit in H.V Line asymmetrical current will induce
and damage the Transformer coil.
3. System Over Voltage or This cause was not occurred since
Voltage fluctuation (Lightning Coil Insulation was not damaged
or Impulse Voltage) and Lightning Arrestor does not got
failured in System.
4. Over Current & Earth fault It was not occurred because
Generation was found to be 100 KW
5. Transformer Winding interturn Magnetic Balance Test was
Short. Conducted and found Satisfied.
6. Core saturation. Thus Occurrence of this cause was
not possible.
7. Earthed HV Winding Terminal

8. Earthed LV Winding Terminal


Insulation Resistance Test was
9. Low Breakdown Voltage of Carried out at Site during
Oil. PreCommissioning and found
10. Low Insulation Resistance in Satisfactory.
Transformer.
11. Low Level of Oil in Oil level was found to be 30˚ C as
Transformer Tank. per the Pre Commissioning Check
List.
12. Haiir Crack in H.V Bushing Due to Hair Crack in H.V Root Cause for
Bushing, an arc will be formed the Blasted
between Live Part to nearest Transformer
Earth Point and High Pressure
will be developed inside the
Bushing which results in Blasting
of Transformer.
Failure Root cause Analysis for 1700 KVA –M/s Tesla
03.12.12
Transformer- Vaspet Site

Faiure of H.V Bushing Photos:

33 KV Phase to Earth minimum Clearance in air 320 mm.

Reasons of HV Bushing Failure:

1. Manufactring Defect
2. Transport Defect
3. Handling & Erection Defect

1. Manufacturing Defect:

 Manufacturing Defect will occurs due to improper Process of Bushings.

 During Storage & Packing, Air Crack in Bushing will be possible.

During Testing(H.V Test & DVDF Test) of Transformers, Manufacturing Defect


of Bushings can be found and eliminated.
Failure Root cause Analysis for 1700 KVA –M/s Tesla
03.12.12
Transformer- Vaspet Site

2. Transport Defect :

• During Transportation, Damage of H.V Bushing might be possible.

3. Handling & Erection Defect :

• During Handling & Erection, Damage of H.V Bushing might be


possible.

• Damage of H.V Bushing might be possible if H.V Bushing stud &


Bushing Support Clamps were Over tightened.

SPOTS OF AIR RELEASE IN TRANSFORMER

• Before Commissioning of the Transformer, Air Release should be done on


Air Release Plug, Bucholz Relay and H.V Bushing.

• If Air Release was not done on the Inspection Cover of the Tank, If any
Air Block occurs between Live Part (H.V Lead, Tap Switch Lead) and
Tank Cover Plate, an high arc will be produced due to High Pressure. In
this Case, Air Block was not occurred between Live Part and Tank Cover
Plate since there is no Carbon occurred inside of the Tank.

• If Air Release was not done on the Bushing, if any Air Block occurs
between Live Part (H.V Lead) and nearby Earthing Point, an high arc
will be produced due to high pressure. This might be the cause of the
Blasted Transformer (Air Crack may be happened in Bushing as photos
shown above)

FLAME INSTIGATION IN TRANSFORMER

• Point, Flammable gases such as Ethylene, Ethane, and Methane present


in Transformer Oil will initiate the flame which results in Blasting of the
Bushing.

• Transformer got blasted due to spreading of Continuous flame


throughout the Transformer.
Failure Root cause Analysis for 1700 KVA –M/s Tesla
03.12.12
Transformer- Vaspet Site

• During the above Condition, Bucholz RelDue to high Pressure developed


between Bushing and nearby Earthing ay Alarm was only indicated but
there was no trip occurs in Bucholz Relay and PRV since there might be
chance of unhealthy protection.

Root Cause Analysis for Blast Transformer:

 Before Commissioning of the Transformer, Air Release should be


done on Air Release Plug, Bucholz Relay and H.V Bushing.

 If Air Release was not done on the Inspection Cover of the Tank, If
any Air Block occurs between Live Part (H.V Lead, Tap Switch Lead)
and Tank Cover Plate, an high arc will be produced due to High
Pressure. In this Case, Air Block was not occurred between Live Part
and Tank Cover Plate since there is no Carbon occurred inside of the
Tank.

 If Air Release was not done on the Bushing, if any Air Block occurs
between Live Part (H.V Lead) and nearby Earthing Point, an high arc
will be produced due to high pressure. This might be the cause of the
Blasted Transformer since there might be the chance of the Air Crack
in the Bushing.

Reason for Blast due to arc produced between Bushing and Earthing
Point :

 Due to high Pressure developed between Bushing and nearby


Earthing Point, Flammable gases such as Ethylene, Ethane, and
Methane present in Transformer Oil will initiate the flame which
results in Blasting of the Bushing.

 Transformer got blasted due to spreading of Continuous flame


throughout the Transformer.

 During the above Condition, Bucholz Relay Alarm was only


indicated but there was no trip occurs in Bucholz Relay and PRV
since there might be chance of unhealthy protection.

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