Transformer Protection:

K. Thanaraj, MSAE, MASME, FIE(IEI)

Why Is Transformer Protection Important?

"An ounce of prevention is worth a pound of cure."

Transformer manufacturers, testing laboratories, and utilities worldwide utilize the IEC 60076
standard to ensure power transformers' safe and reliable operation. Adhering to this standard
ensures that transformers are designed and manufactured according to the required
specifications and performance benchmarks.

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 1) While we’ve discussed the financial benefits of keeping technicians informed about
transformer faults, additional considerations must be considered. Faults can impact your
bottom line beyond replacement costs, as downtime can be expensive.

2) Protection systems are essential for minimizing disconnection time and reducing the risk
of catastrophic failure. The longer a transformer operates under suboptimal conditions,
the greater the risk of compromising its lifespan.

3) The primary objective of transformer protection is to detect internal faults within the
transformer with high sensitivity, leading to its de-energization when necessary. At the
same time, it should remain unaffected by external faults, such as outside the transformer.

4) When a transformer experiences overload, the temperature of its oil and windings
increases, which can reduce its lifespan. To protect against overloads, a dedicated device
known as a thermal overload relay is typically used.

5) Differential protection is highly sensitive to internal transformer faults. Comparing the

current entering and exiting of the transformer can identify discrepancies that may
indicate issues like winding short circuits or inter-turn faults.

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 6) Overloading occurs when the transformer is subjected to voltages and/or currents that
exceed its design specifications. Under such conditions, excessive heat can lead to the
breakdown of the insulation system, thereby decreasing the transformer's life expectancy

7) The breakdown of electrical insulating materials and related components inside a

transformer generates gases within the unit.

8) A fast protection system for transformers is essential to minimize damage in the event of
an internal fault. It should be accompanied by a suitable backup protection scheme to
handle unresolved system faults.

9) The Buchholz relay protects transformers from internal faults. Short-circuit faults, such as
inter-turn faults, incipient winding faults, and core faults, can arise due to the impulse
breakdown of the insulating oil or the transformer oil itself.

10) Overheating occurs when a transformer generates more heat than it can dissipate. This
can happen due to higher loads, reduced airflow, or a combination of both factors.

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 1) Transformers are generally well-protected against faults, but failures can still occur and
lead to significant issues. Read on to learn more about transformer protection systems.
2) Transformers are essential tools for manipulating voltage in distribution systems. They are
among the most critical and expensive components, making their repair and replacement
costly endeavors’ that must be executed quickly.
3) Fortunately, transformers are housed in static devices, and wet transformers are
submerged in oil, which typically limits faults significantly. However, even the best plans
can go awry, making it crucial to implement transformer protection. Let's explore the
common types of transformer protection systems.

What Is Transformer Protection?

1) Although internal faults in transformers are rare, they can lead to substantial damage
when they do occur. Transformer protection encompasses a variety of enhancements and
systems designed to safeguard the transformer. These systems are equipped to detect
internal faults with varying sensitivity levels and can provide backup protection in the
event of a fault. They can monitor various factors, including current, voltage, frequency, oil
pressure, and temperature.
2) Not all transformers have the same protection systems, and many facilities must consider
their budget when determining which systems are essential. Certain types of faults are
more likely to occur than others and should be prioritized when designing protection
systems. Remembering that transformer failure can damage nearby equipment and
infrastructure is vital.
3) Lastly, weighing the cost of protective devices against the potential expenses of replacing
or repairing a transformer is important. In some cases, the expense of additional
protection may exceed the repair cost, and these factors should be considered when
selecting protective systems.

Types of Protections:
1) Overcurrent Protection

a) Overcurrent protection is crucial when phase or ground faults occur. Under normal
circumstances, electricity flows without generating excessive heat, providing power to the
transformer. However, transformers can experience overloads or short circuits when this
flow exceeds the average load.
b) Fusible links, fuses, and circuit breakers are the simplest means of providing overcurrent
protection. These devices limit or disable the electrical current flow but do not correct the
underlying overcurrent issue. Instead, they stop the electricity flow by tripping circuit
breakers or blowing fusible links.

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 2) Overheating Protection

a) Overheating is one of the most significant issues that protection systems must address.
Overheating can be devastating, whether caused by a short circuit or an overload. Most
transformers have a maximum safe temperature of around 95 °C. When the transformer
approaches this temperature, an overheating protection system should activate to alert
you and shut the transformer down.
b) Prolonged operation above this maximum temperature can degrade its lifespan and
potentially damage wire insulation, leading to further problems. In many transformers,
Fiber-optic cables monitor the temperature in the core, with the highest temperatures
typically found at the center.

3) Over-Fluxing Protection

a) Like overcurrent violations, over-fluxing occurs when the magnetic flux density exceeds
normal levels, leading to overheating and internal faults. Over-fluxing protection works
similarly to overcurrent protection; when the flux density ratio reaches a dangerous level,
the system sends a signal to the circuit breaker to trip. This action shuts down the
transformer, preventing further damage.
b) Facilities can help ensure the reliability and longevity of their transformers by identifying
and implementing appropriate transformer protection systems, minimizing downtime, and
reducing repair costs.

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 4) Buchholz Gas Detection Relay:
A Buchholz relay is a specialized device that protects transformers from minor and major faults.
Under normal operating conditions, this relay is filled with oil. However, when an internal fault
occurs, gas bubbles are generated within the transformer tank, causing the relay to fill with gas
instead.

a) As these gas bubbles accumulate, they eventually trigger an alarm within the Buchholz
relay. The relay activates a trip mechanism if the issue is not addressed promptly. This
function is especially crucial in rapid oil loss due to severe faults.
b) The Buchholz gas detection relay helps identify problems before they escalate while
providing a fail-safe in case the issue cannot be resolved.

Now that these common types of transformer protection systems are available, ensure your
facility has all the necessary protective measures. As the saying goes, "An ounce of prevention is
worth a pound of cure." Being proactive can save you significant costs in the long run.

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Transformer Oil Analysis:
Dissolved gas analysis (DGA), oil quality tests, functional tests, and conditions monitoring will
further protect your Power Transformer assets.

NOTE:
1) This article reviews literature from various magazines and books about transformers. It
aims to help non-electrical engineers and technicians understand key aspects of
transformer protection while working on-site.

2) Many individuals interact with transformers, either directly or indirectly, without being
aware of the safety risks and concerns associated with working at transformer stations.

3) Additionally, this article serves as an educational resource for students and non-electrical
professionals, enhancing their knowledge of the subject. It is not intended for commercial
purposes but aims to support the engineering community and benefit humanity.

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