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Comprehensive Guide to Transformer Operation, Maintenance, and Fault Prevention

Comprehensive Guide to Transformer Operation, Maintenance, and Fault Prevention

1/15/2025

01 Importance of Transformer Core Grounding

During the normal operation of power transformers, it is crucial to ensure that the transformer core has a single reliable grounding point. If the core is not grounded, it may develop a floating potential, leading to intermittent ground breakdown discharge. A single-point grounding effectively eliminates this floating potential. However, if the core is grounded at multiple points, a circulating current may form between the grounding points, potentially causing core overheating faults. In severe cases, this could damage the transformer, requiring the replacement of silicon steel sheets for repair. Therefore, the transformer core must be grounded at only one point.

 

02 Protection Scope of Gas Relay (Buchholz Relay)

The gas relay primarily protects transformers against the following faults:

  • Internal multi-phase short circuits within the transformer
  • Inter-turn short circuits, and short circuits between windings, cores, or the casing
  • Core faults
  • Oil level drops or oil leakage
  • Poor contact in tap changers or weak soldered joints of conductors

 

03 Handling of Main Transformer Cooler Faults

When the main transformer cooler malfunctions, the following actions should be taken:

  • If both power sources I and II fail, report to dispatch immediately and disable the associated protections.
  • In case of failure to switch the power source, report to dispatch and manually switch to the alternate source.
  • If any loop in the cooling circuit fails, isolate the faulty loop.

 

04 Conditions for Parallel Operation of Transformers

The following conditions must be met to ensure safe parallel operation of transformers; otherwise, circulating currents or short circuits may occur:

  • Identical transformation ratios
  • Matching percentage impedance
  • Same winding connection group

 

05 Causes of Abnormal Transformer Noise

Abnormal transformer noise may be caused by the following:

  • Overload operation
  • Internal poor contact or discharge arcing
  • Loose components
  • System grounding or short circuits
  • Large load changes due to motor startup

 

06 Restrictions on Tap Changer Adjustments for On-Load Tap-Changing Transformers

Tap changer adjustments are prohibited under the following conditions:

  • Transformer is operating under overload (except in special cases)
  • Frequent light gas relay signals
  • Oil level indicator shows no oil
  • Adjustment frequency exceeds the prescribed limit
  • Abnormalities in the tap-changing mechanism

 

07 Meaning of Transformer Nameplate Ratings

Transformer nameplate ratings include the following:

  • Rated capacity: The guaranteed output capacity under rated conditions
  • Rated voltage: The guaranteed no-load terminal voltage
  • Rated current: The line current calculated based on the rated capacity and rated voltage
  • No-load current: The percentage of rated current consumed as excitation current under no-load operation
  • Short-circuit loss: Active power loss when one winding is short-circuited, and the other winding carries rated current
  • No-load loss: Active power loss during no-load operation
  • Short-circuit voltage: The percentage of rated voltage required to apply to one winding while short-circuiting the other winding with rated current
  • Connection group: Winding connection type and the phase angle difference between line voltages

 

08 Relationship Between Current Source Inverters and Transformer Capacity

Current source inverters require larger transformer capacities because the input-side power factor is, at most, equal to the power factor of the load's asynchronous motor. Compared to voltage source inverters, the rated capacity is significantly higher.

 

09 Factors Affecting Transformer Capacity

The transformer’s capacity is mainly related to heat generation, with the core selection determined by voltage and conductor selection influenced by current. Additionally, the rated capacity is constrained by permissible temperature rise.

 

10 Methods to Improve Transformer Efficiency

To enhance transformer efficiency, the following methods can be adopted:

  • Use low-loss, high-efficiency energy-saving transformers.
  • Select transformers with reasonable capacities based on load conditions.
  • Maintain an average load factor above 70%.
  • Replace with smaller transformers when the load factor is below 30%.
  • Improve load power factors.
  • Optimize load distribution to reduce the number of operating transformers.

 

11 Technical Upgrades for High Energy-Consuming Distribution Transformers

High energy-consuming distribution transformers (e.g., SJ, SJL, SL7, S7 series) have higher iron and copper losses than S9 series transformers. Replacing them with new-generation transformers (e.g., S10, S11 series, or amorphous alloy transformers) can significantly improve energy conversion efficiency and save electricity.

 

12 Generation and Hazards of Eddy Currents

Eddy currents are induced currents generated within a solid conductor when alternating current passes through it, producing an alternating magnetic field around it. Eddy currents waste energy, reduce equipment efficiency, and cause overheating, which can severely impact equipment performance.

 

13 Selectivity of Transformer Instantaneous Protection

Transformer instantaneous protection must avoid low-voltage side short-circuit currents to ensure the selectivity of relay protection. Failure to avoid maximum short-circuit currents on the low-voltage side may extend the protection zone to the low-voltage outgoing lines, compromising selectivity.

 

14 Neutral Point Grounding in Parallel Transformers

The neutral points of two parallel transformers must not be simultaneously grounded to avoid issues with zero-sequence current and voltage protection coordination. Partial neutral point grounding in transformers can limit ground fault current levels and enhance the sensitivity of zero-sequence current protection.

 

15 Purpose of Energization Testing for Newly Installed or Overhauled Transformers

Newly installed or overhauled transformers must undergo energization testing before commissioning to verify whether the insulation can withstand rated voltage and operational overvoltages. Additionally, the test evaluates the mechanical strength of the transformer and the impact of magnetizing inrush current on relay protection.