International Conference on Innovative Mechanisms for Industry Applications

(ICIMIA 2017)

Distribution Transformer Failure in India

Root Causes and Remedies
Narasimha Pandit1, R.L.Chakrasali2
#
Bangalore Electricity Supply Company,
##
Dept.of EEE, SDMCET, Dharwad
1
[email protected]
2
[email protected]

Abstract— Transformers play an important role in a

power distribution utility. They have a long life of 25 to 30 Number of Transformers
years; but they fail in large numbers, within 3 years itself,
existing as at the
due to various reasons, causing huge economic and service
impact on the distribution utilities as well the power end of March 15
consumers. In this paper, causes of failure of distribution 10% 10/15 KVA
1%
transformers and possible solutions to overcome these 0% 25KVA
problems have been discussed. Some of the problems may 50/63 KVA
be particular to distribution utilities of Karnataka state, 41% 100 KVA
23% 160/200KVA
but most of them are generally, Indian problems.
250 KVA
25%
Keywords— Distribution, transformer, overload, failure,
mitigation Fig.1
The number of distribution transformers currently in
service in India is nearly 4.3 million and the number is
I. INTRODUCTION increasing at an annual rate of approximately 10%. [1]
Distribution Transformer failure rate in India is in the
Consumers of electricity from different sectors need and order of 12 to 15 %, as against 0.8% in USA, 3% in
like reliable power supply. In providing reliable service Canada, and 1 % in Australia, which is a cause of worry
to all power distribution utilities. The failure rate of
distribution transformers, the heart of the distribution
repaired transformers is about twice that of a new
system plays a major role. The failure of the transformer, which is mainly due to improper repairs.
transformers causes inconvenience and financial loss to IEEE standards 100/1980 and 500/1984 allows
both the consumers as well as to the distribution power maximum annual failure rate of 3 % for distribution
transformers.[ 2]. Reports says that every year
utility. The magnitude of the loss depends upon the distribution transformers worth rupees 200 Crores fail;
rating of the transformer; higher the rating more is the which is a great financial loss to the nation and which
effect. A case study has been carried out considering can be minimized [1]. Distribution transformers installed
in rural areas form the bulk of these transformers which
transformers of ratings.10/15 KVA: 2758 25 KVA:
are very much exposed to vulnerable weather conditions
84313 50/63 KVA: 51936 100 KVA : 47473 particularly lightning. These transformers feed long Low
160/200 KVA: 782 250 KVA and above: 19598 Tension (LT) lines which are more prone to faults
because of atmospheric conditions.
Number of Transformers existing in Bangalore
Electricity Supply Company along with the KVA ratings
as at the end of March 15 is depicted in:

978-1-5090-5960-7/17/$31.00 ©2017 IEEE 106

 International Conference on Innovative Mechanisms for Industry Applications
(ICIMIA 2017)

II. CAUSES OF FREQUENTFAILURE OF

DISTRIBUTION TRANSFORMERS: UTILITY SIDE
The following are some of the causes of failure of
distribution transformers in service, being attributed to
the utility. Probable remedial measures have been
highlighted to reduce the rate of failure.
A. PROLONGED OVERLOADING

The overloading is observed in urban areas due to

increasing population and in rural areas due to increase
The reason for failure can be improper maintenance of in number of irrigation pump sets and unauthorized loads.
transformer and lines, overload, unbalanced load, etc The Distribution Transformers are not recommended for
(from utility side), and bad design, usage of poor continuous overloading as it affects the winding
materials, etc (from manufacturer side).Table 1 depicts insulation strength causing the failure. Table 2 gives
the failure details of the transformers in different regions. shortage of transformers to cope up with the load
Table 1 requirement.
Number of transformer failed in three different regions
in three years End
Table 2 of 2006-07 End of 2010-11
Transfor Connec Transfor Connec Average Average
mation ted mation ted load Percenta Percentage
capacity load capacity Increase Increase
JU YE TOT NU FAI M TO TOT MI
In In
RIS AR AL MBE LUR IN TA AL NO
Transfor Connec
DIC NUM R OF E O L FAI R
Capacity shortage of transformers(Capacity ation
in MVA) tedLoad
TIO BER TRA PER R FAI LUR RE
Capacity During
N OF NSF CEN RE LU E PAI
During 2007-11
TRA OR TAG PA RE PER R
2007-11
NSFO MER E IR CEN TR
RME S TAG AN BESCOM 10052.87 9970.78 13421.07 13895.31 8.38 9.84
BA 201 3802 0 0 76 76 1.99 0 CESC 2571.00 2178.90 3164.49 2766.41 5.77 6.74
NG 3- 0 0 0 GESCOM 2576.82 3427.07 3175.38 3963.98 5.81 3.92
AL HESCOM 4906.47 5341.41 5729.66 7351.00 4.19 9.41
201 4130 0 0 64 64 1.5 0 MESCOM1902.97 2686.41 2399.23 3226.58 6.52 5.03
OR
4- 6 5 5 22010.13 23604.50 27889.83 31203.28 6.68 8.05
E
UR 201 4416 0 0 63 63 1.4 0
BA 5- 2 3 3
BA 201 7384 523 7.08 62 11 15.6 33
Source: Karnataka Commercials; audited reports[6].
NG 3- 9 5 97 53
AL Year Transformat Connected Gap in in *Ratio of
201 8285 462 5.5 40 86 10.4 23
OR Capacity Load Transformation Transformation
4- 1 9 12 41
E Capacity Capacity to
RU 201 9056 562 6.21 38 94 10.4 55
Connected load
RA 5- 1 7 01 28
2006-07 22010.13 23604.50 1594.37 0.93:1
CH 201 8207 105 12.8 80 18 22.6 30
ITR 3- 9 19 1 47 56 2007-08 23394.22 25723.32 2329.10 0.91:1
AD
UR
201 8713 119 13.7 98 21 25.0 12
4- 0 86 5 00 78 2 2008-09 24858.20 27161.14 2302.94 0.92:1
GA
ZO 201 1019 129 12.7 93 22 21.8 40 2009-10 26395.76 29067.42 2671.66 0.91:1
NE 5- 49 55 0 13 26
16 8 2010-11 27889.83 31203.28 3313.45 0.89:1
Courtesy: BESCOM corporate office A. Page Layout

978-1-5090-5960-7/17/$31.00 ©2017 IEEE 107

 International Conference on Innovative Mechanisms for Industry Applications
(ICIMIA 2017)

*The ratio is excluding the unauthorized loads. These figures E. FAULTY TERMINATIONS
are audited ones. Though they are old figures, but can be
an indicative, the transformation ratio remains more or less the Many times it is observed there will be spark from the
same even now. bushing termination joints especially on L.V connections due
The problems faced by the utilities to provide additional to loose contacts sparks are because of loose terminations
transformers: Huge investments: In urban area, an during the course of installation or else have been loosen due
investment to be made in providing one additional transformer to bad service conditions. Once spark Occurs at the cable
of 250 KVA,100 KVA and 25 KVA is 10 lakhs, 5 Lakhs, 3 termination, it causes melting of the busing sealing gaskets,
lakhs respectively and depends on the length. A effecting oil leakage from the bushing top, resulting failure of
typical distribution utility in Karnataka, at present needs at transformer in due course of time because of low oil level.
least 1000 number each of above ratings of transformers,
amounting to 140 crores to 180 crores!
Lack of space to provide transformers in urban areas
without creating problems to pedestrians

B. IMPROPER LT and HT PROTECTION

When transformer fuses are blown off frequently, the

maintenance staff replace the fuse element of higher
rating to avoid frequent interruption of supply and
frequent replacement of fuses. This happens due to less
number of skilled staff who are always overloaded. The
supervisory staff is also overloaded! The solution to
overcome this is to recruit adequate number of skilled The incoming and outgoing termination should be done
staff and supervisors.Measurement of load current with a through proper connectors. ISS and REC have recommended
Tong Tester at frequent intervals, especially during peak such details with drawings of lugs and connectors. Users
loading hours, will give a fair idea about the load must ensure that the cable connections have been done with
demand of the locality. In case the overloading is more proper lugs and connectors. Direct Connection of
than 20% during peak hours and if it persists for days cable/conductor to the bushing terminal stud, should be
together, it is recommended to replace the existing avoided.
transformer with a higher rating, or else bring in a
second unit parallel. During termination, we should not forget the effect of bi-
C. SINGLE PHASE LOADING metallic action. If aluminum cable or conductors are to be
connected with brass/copper terminal or vise-versa, a proper
A distribution transformer should be connected with a bi-metal should remain in between. Otherwise due to bi-
balanced load. But in the rural areas, running irrigation metallic action, a milli-volt will generate causing a localized
pumpsets with phase conversion causes overloading and current and may deteriorate the current carrying thread.
thus the transformers fail. The primary reason for the above
act is scarcity of power. One of the immediate solutions is F. . USAGE OF REPAIRED TRANSFORMERS
regular monitoring
Whenever the transformer fails with minor faults, they
D. UNBALANCE LOADING are repaired in a short duration. This is a cost effective
method of bringing the transformer back toservice. Each
The maintenance staff or the supervisory staff seldom checks
the load on each phase of a transformer. The new distribution transformer is repaired 2 to 3 times in its life
connections span of 25 years (due to paucity of fund) reducing the
are also given randomly, causing more un-balance and thus efficiency further with each repair. The direct economic
neutral shiftingSince the neutral is solidly earthed through impact of distribution transformer failure is in terms of
external link, a circulating current will flow through the loop cost of repair or replacement whereas indirect economic
of deltawinding. This additional circulating current
willsuperimpose on the main branch current of the delta impact comes in the form of revenue loss due to supply
winding and will cause additional heat, which may lead to interruption and increased losses.
the failure of the winding insulation. The reality is shortage
of staff. The solution is recruit required number of staff and
train them to keep the neutral current within 10% of the total
current.

978-1-5090-5960-7/17/$31.00 ©2017 IEEE 108

 International Conference on Innovative Mechanisms for Industry Applications
(ICIMIA 2017)

G. POWER THEFT AND HOOKING OF MAINS As per ITMA, inadequate supply of prime quality Cold
Rolled Grain Oriented (CRGO) steel is the biggest
This usually occursduring special occasionsin challenge faced by transformer manufacturers in the country.
the unauthorized.Since such hooking make the transformers CRGO requirement is completely met through imports; it is
to run in overload/unbalance load and may cause failure in in fact challenging to assess the true quality of the material
due course of time.This is one of the major causes of failure that is used by the transformer manufacturers in India. India
of distribution transformers for which the needs 3 lakh ton of CRGO every year and an appalling 70
manufacturers areaccounted all the time. To minimize per cent of this is scrap grade material.
this, regular monitoring, stringent actions against theft
cases, energy audit, initiating stringent actions,etc.can be IV. DIFFERENT TYPES OF CATEGORISATION OF
taken up. FAILURES
a) If transformer is taken as an entity, the above failure of
H. WRONG OR NO EARTH CONNECTION various types may be segregated as Internal Cause and
External Cause.
The earthing of neutral will prevent the presence of any
voltage above the normal appearing in the circuit. INTERNAL CAUSE EXTERNAL CAUSE
This will protection to staff as well as transformer life.
x OVERLOADING x EXTREME WEATHE
I. LESS OR NO MAINTENANCE x LIGHTNING SURGE x LINE SURGES,
SHORT CIRCUIT
A Transformer needsregularand scheduled x DETERIORATION x POOR WORKMANSH
maintenance.Checking of oil level, tightening of INSULATION
terminals, etc should be done as per the schedule. The x IMPROPER COOLIN x HIGHVOLTAGE
ground reality is less staff; accessibility to remote areas DISTURBANCE
in rural sections. x MOISTURE x MALICIOUSACTS

J. Other Causes b) If transformer is considered as separate circuits,

segregation can be done as
Low transformer oil level, Low break down value ( BDV) x Failure due to mechanical damages: due to oil
of
leakage and bushing flashover
the transformer oil and poor insulation resistance (IR)
values, Lightning, External short circuit (through faults), x Failure in Dielectric circuits due to deterioration of
Flash over, and Vandalism. oil and moisture entering the oil
x Failure in Electric circuits leading to short circuit in
turns
III. CAUSES OF FAILURE OF DISTRIBUTION
x Failure in magnetic circuits
TRANSFORMERS: MANUFACTURER SIDE

Some of the reasons attributed to manufacturer are:

x Improperdesign
x Use of poor quality of material
x Unskilledworkmanship
x Improper transportation
x Incomplete drying
x Poor insulation covering on conductor
x Improper joints or connection

These are due to the low entry barriers in the distribution

transformer market leading to unorganizedvendors entering
the market, and competing on the price factor. State
Electricity Board historically follows L1 vendor selection
criterion, which has led to proliferation of many small
players that compromise on the quality of transformers
manufactured.

978-1-5090-5960-7/17/$31.00 ©2017 IEEE 109

 International Conference on Innovative Mechanisms for Industry Applications
(ICIMIA 2017)

tests are to be conducted:

a) Megger Test: To be conducted between HV & body
V. CAUSE OF FAILURE IN PERCENTAGES [7] and LV & body. If satisfactory values are not
obtained, declare it as faulty.
b) Ratio Test: If satisfactory values are obtained in the
REASON FOR FAILURE RAT CAUSES above test, then ratio test is to be conducted. If
FAILURE unequal voltages are obtained, transformer is faulty.
x COMPRESSED WINDINGS
DAMAGE TO LT C 65% APPROX. VII. CONCLUSIONS
x INTER TURN INSULATION
FAILURE
x DISLODGED SPACERS; AND Distribution transformers are very important components in
x BROKEN SUPPORT/INADEQUA
a power distribution network. The number is also large in a
BOLTS utility. The failure of transformers causes lot of
inconvenience to consumers in terms of power disruption
x OVERLOADING and lot more to utility in terms of finance. Distribution
DAMAGE TO HV 5% APPROX.
x DEFECTIVE TERMINATION transformers usually fail because of a) Manufacturing
OF COILS, AND Defects, b) Poor Maintenance and Supervision, and c)
x OVER SIZES FUSES Natural Calamities. Field officers must note that an action
x ANY OF THE ABOVE plan in this regard is the need of the hour. This must start
DAMAGE TO 10% APPROX.
with maintaining of a transformer history book which must
BOTH contain details of transformer make, date of manufacturing,
x POOR CONSTRUCTION OF TAN connected load etc. The history book must be updated
OTHER REASONS 20% APPROX. regularly. The higher level officers must recruit enough staff
x DEFECTIVE JOINTS
x OIL LEAKAGE to maintain the transformers and fix responsibility on the
x PUNCTURED RADIATORS AND field staff for dereliction of duty.
BUSHING GASKETS VIII. REFERENCES
x OIL PILFERAGE 1. Power Transmission: Failure of Distribution Transformers
x POOR OIL CONDITION in India. Manojbpl.blogspot.com/2014/19
2. Electric power Distribution by A S Pabla, pabla 2012
3. “Innovative Business Model for Refurbishment of
Distribution Transformers” 8yh annual conference on
“Power Distribution in India” Issues and Challenges;
Strategies and solutions, organized by India Infrastructure
Publishing
VI. TESTS TO BE CONDUCTED BEFORE 4. ‘Causes of Failure of Distribution Transformer and
DECLARING THE TRANSFORMER FAULTY [8] Remedial Measures’ By Hitendrasinh C. Chawda;
www.worldwidejournals.com
5. ‘Case Studies of the transformer Failure Analysis’, Manish
Sometimes, when, the HT fuses blow frequently, the N Sinha and others; Electrical India, July 5, 2015
section officers may hand over a good transformer as sick 6. Performance Review Relating to Government Companies;
unit. The frequent fuse blow out may be because of www.saiindia.gov.in
7. ‘Modern Plants and Best Practices Used in Distribution
placing a lower gauge fuse wire, or the fuse wire may not be System’; Asia Institute of Management
connected correctly, or a temporary fault. In such cases, 8. ‘Practical Approach for Detection of Failure of Distribution
before declaring the transformer as faulty, following simple Transformer and Their Remedies’ ; B Ashok Kumar; IOSR
Journal of Engineering, 7.7.2014

978-1-5090-5960-7/17/$31.00 ©2017 IEEE 110