Why Transformers Explode

WHY TRANSFORMERS EXPLODE
THE PHENOMENON
During a transformer short-circuit, the electrical arc vaporizes oil and creates a Dynamic
Pressure Peak which travels at the speed of 1,200 meters per second (4,000 feet per
second). This phenomenon occurs within a few milliseconds. Because of reflections in
the tank the pressure peak will generate pressure waves. The integration of all of the
waves pressure peaks creates static pressure. Then, the pressure becomes equal
throughout the entire transformer tank within 50 to 100 milliseconds after the electrical
arc, and causes the transformer tank to rupture.
LACK OF INTERNATIONAL TRANSFORMER STANDARDS AND

REGULATIONS
Transformers can only withstand a small overpressure and are not designed as
pressure vessels according to ASME Codes and Controls. Consequently, transformers
have proven to be very dangerous. Because transformer standards describe electrical
requirements but do not cover mechanical design.
TRANSFORMER ELECTRICAL AND MECHANICAL PROTECTION

LIMITS
Pressure Relief Valve inadequacy: Pressure Relief Valves are suitable for slow
pressure rise whereas pressure gradients developed during low impedance faults
are extremely fast. Transformers that have exploded were usually equipped with
Pressure Relief Valves.
Buchholz
and
Rapid
Pressure
Relay
inefficiency: transformer
electrical
protections are not designed to react to sharp pressure gradients. During the 62
TRANSFORMER PROTECTOR tests, the Buchholz always failed to detect any gas
and oil movement or pressure variation.
Electrical Breaker opening time: the best breaker technology trips in 50

milliseconds, far too late to prevent the explosion because most of the gases are
generated within milliseconds after short-circuit. Consequently, the tank pressure
keeps increasing even after the breaker has opened.
CAN PROPER MAINTENANCE GUARANTEE A TRANSFORMER WILL NOT

EXPLODE?
As transformers are typically the most expensive and vital piece of equipment located in
power plants and substations, they require a comprehensive maintenance plan to
ensure their proper functioning and longevity. These maintenance procedures are
usually detailed in lengthy manuals which can easily reach several hundred pages.
Furthermore, these maintenance standards are multiplied in highly regulated industries,
such as Nuclear Power Plants.
Following these meticulous maintenance guidelines can reduce the occurrence and
possibility of a transformer explosion, however, it does not nullify this risk. In fact,
numerous explosions have occurred on extremely well-maintained transformers. For
example, lets look at the transformer fire that the James FitzPatrick Nuclear Power
Plant experienced in November of 2012. Upon investigation, it was confirmed that this
incident was caused by an internal fault, regardless of proper testing and maintenance.
A FitzPatrick Plant spokesperson stated that*:
All test results and monitoring data prior to the transformer failure indicated it was
operating appropriately. There was nothing observed that would indicate the transformer
would fail.
Just a few other examples of incidents occurring at Nuclear Power Plants in the US
include: Bay City in Texas, Limerick in Pennsylvania , Indian Point in New York ,
and Brunswick in North Carolina . These cases confirm that even following the high
maintenance standards of Nuclear facilities, transformer explosions cannot be
prevented.
*Source: Syracuse.com, Nuclear experts work to figure out why a transformer caught
fire at the James FitzPatrick Nuclear Power Plant .
WHY CANT OIL AND GAS ANALYSIS PREVENT TRANSFORMER

EXPLOSIONS?
Most transformers are equipped with an On-Line Dissolved Gas Analyzer to measure
the concentration of gases such as hydrogen, acetylene, ethylene, methane, carbon
monoxide, etc. This equipment is used as a preventive action for slow moving changes
in the dielectric properties of the oil due to humidity, moisture and particles from the
winding insulation degradation. On-Line DGAs are ideal for checking the long-term
evolution of transformer corposant from oil to paper, etc.
However, transformer short-circuits occur without warning every day, producing
catastrophic explosions and fires. Most of these incidents occur on transformers that
are equipped or monitored by DGAs, proving that oil and gas analysis cant prevent an
explosion. The response time of the sensors used for analyzing the oil and gas can vary
from 10 to 40 minutes. Since a transformer explodes within milliseconds of a short
circuit, it is simply not possible to receive the On-Line DGA results and decide whether
to trip the transformer before an explosion occurs.
Furthermore, when most transformer explosions occur, the oil and gas analysis results
are normal, even perfect. An example of this is the transformer explosion which
happened at the James FitzPatrick Nuclear Power Plant. It was reported* that:
All test results and monitoring data prior to the transformer failure indicated it was
operating appropriately. There was nothing observed that would indicate the transformer
would fail.
Basically, a short circuit can occur at any time and the best way to prevent the
transformer tank from explosion is to equip it with a TRANSFORMER PROTECTOR
(TP). During the first milliseconds of the short circuit, the first Mega Joule creates a
volume of 2.3m3 of explosives gases inside the transformer tank. At the same time, a
dynamic pressure peak travels inside the tank at the speed of sound inside the oil,
4,000 ft/sec (1200 m/sec). The dynamic pressure peak activates the TRANSFORMER
PROTECTOR (TP) within milliseconds and creates an opening for the oil and gas to be
evacuated before static pressure increases.
*Source: Syracuse.com, Nuclear experts work to figure out why a transformer caught
fire at the James FitzPatrick Nuclear Power Plant
HOW TRANSFORMER PROTECTOR

WORKS
TRANSFORMER PROTECTOR OPERATION
As shown in the video diagram above:
The TRANSFORMER PROTECTOR activates within milliseconds depressurizing

the transformer main tank.
Once the depressurization is complete, to avoid the bazooka effect from killing
maintenance technicians during tank opening, the transformer is then injected with
inert gas to evacuate the remaining explosive gases.
After the explosive gases have been cleared, the transformer is then safe and ready
for repair.
The TRANSFORMER PROTECTOR is the only proven solution to transformer

explosion and fire. 20 years of extensive high-level mechanical research and tests were
necessary to design the TRANSFORMER PROTECTOR.
The TRANSFORMER PROTECTOR is a transformer explosion and fire prevention
system suitable for any type of oil-immersed transformer and including surrounding
equipment such as the On Load Tap Changer (OLTC), Oil Cable Box (OCB), and Oil
Bushing Cable Box (OBCB).
TRANSFORMER PROTECTOR COMPONENTS

Watch the slideshow below to learn more about some of the components of
the TRANSFORMER
PROTECTOR.
CONFIGURATIONS
Standard
The Pictures below show some examples of standard configurations for new
transformers.
TP3A VDS SOGST
TPA VDS SOGST
2TP3A6B VDS SOGST
TPA6B VDS SOGST
TP VDS SOGST
Small-TP
Non-Standard
The Pictures below show some examples of non-standard configurations used for retrofitting.
TP-HDS-EOGST
TPA-HDS-SOGST
TPA3B-HDS-WOGST
CLIENT INSTALLATIONS
Since 2005, the TRANSFORMER PROTECTOR has been included in the technical
specifications of 171 companies in 65 countries. It currently protects thousands of
transformers manufactured by 175 different transformer manufacturers and has also
achieved the following:
Thousands of TPs sold worldwide
CEPEL, Brazil, one of the worlds top High Voltage laboratories has performed 34
successful live tests on three different large transformers
Electricity De France (EDF), High Voltage Laboratory has performed 28 successful live tests
on a small transformer
Power-Gen Europe Best Paper Award 2008
The NFPA recommends Fast Depressurization Systems for all Power Plant and
Substation transformers the following Civil Codes which the TRANSFORMER
PROTECTOR (TP) complies with:
NFPA 850 (Recommended Practice for Fire Protection for Electric Generating Plants and
High Voltage Direct Current Converter Stations)
NFPA 851 (Recommended Practice for Fire Protection for Hydroelectric Generating Plants)
Client installation examples:
United States
Great Britain
Mexico
Brazil
Panama
Philippines
FINANCIAL BENEFIT
A GROWING CONCERN FOR CORPORATE RISK MANAGERS

AND INSURANCE COMPANIES
Transformers are considered by Corporate Risk Managers and Insurers as the most
critical equipment inside plants because of the large quantity of oil in contact with high
voltage elements.
DAMAGE COST OF TRANSFORMER EXPLOSION AND FIRE

The cost to replace a transformer unit is several million dollars (USD) and the cost of
the outage in the tens of millions (USD) with potential to reach hundreds of millions
(USD). Transformer explosions and fire result in: lost income, purchase of high-priced
replacement power, replacement of transformers and surrounding equipment, polluting
the environment and negative public relations, etc.
The damage caused depends on the transformer location:
Power plant incidents result in very high loss of revenue and can lead to company
bankruptcies if not insured. For insurers, the projected cost reference can approach
USD 500,000 per MVA.
Transmission substation incidents can result in the complete blackout of a region

or a country. Several well-known cases have been recorded recently (USA, UK,
Italy, Spain, etc.).
Distribution transformer explosions in urban areas can have disastrous financial

consequences in related pollution and litigation costs.
PURCHASING THE TRANSFORMER PROTECTOR

The TRANSFORMER PROTECTOR comes with a liability insurance policy with
coverage up to 20 million USD (2013) per occurrence should an incident occur.
Equipping your transformers with the TRANSFORMER PROTECTOR:
Decreases the risk to surrounding equipment and buildings.
Enables the quick internal repair of the transformer and sharply reduces plant
outages.
Leaves the environment unharmed.
RESEARCH & TESTS

Since 1999, our Research Department has released 59 scientific
articles about transformer short-circuit calculations, tests,
mathematical
models,
simulations
and TRANSFORMER
PROTECTOR efficiency to avoid transformer tank explosions and

oil fires (list available upon request).
In order to study the energetic transfer phenomenon that occurs during a short circuit in
transformers 2 experimental test campaigns were carried out; the first by Electricit de France in
2002 and the second by the Brazilian high voltage laboratory CEPEL, in 2004 on large scale
transformers.
These 62 experimental tests consisted in creating low impedance faults in oil filled
transformers equipped with the TRANSFORMER PROTECTOR. The tests showed that
the arc first creates a huge volume of gas that is quickly pressurized, generating one
high pressure peak that propagates through the oil. This First Dynamic Pressure Peak
activates the TP within milliseconds preventing the transformer from exploding.
In addition to the experiments, a compressible two-phase flow numerical simulation tool
has been developed. The experimental results have been used to validate the
simulation model. Adding to this model a dynamic structural analysis package has been
coupled to create a fluid structure interaction. These simulations definitively show the
efficiency of theTRANSFORMER PROTECTOR to prevent explosion and fire.
The arc used in the simulation, located at the base of the right bushing, has parameters
given in the table below and total energy of 7.19 MJ.
Current(Peak)
Voltage (Peak)
Frequency
Duration
Total Energy
2,000 A
80,000 V
50.0 Hz
0.110 s
7.1986 MJ
CONSERVATOR SHUTTER
When a transformer is under normal operation, the CONSERVATOR SHUTTER is
open, enabling oil volume expansion or retraction from the conservator.
As
soon
as
the
CONSERVATOR
SHUTTER detects an abnormal high oil flow, it quickly and effectively isolates the
conservator. If this activation is caused by a transformer tank explosion, the
CONSERVATOR SHUTTER prevents oil from the conservator, from pouring onto the
transformer tank or ground surrounding the transformer.
IN ADDITION, THE CONSERVATOR SHUTTER:

Is used by electric utilities located in earthquake and hurricane risk areas where
movement causes pipe ruptures or leaks
AVAILABLE TYPES
TL
24
Type
for
2-inch
piping
(DN
50)
TL 34 Type for 3-inch piping (SN 80)
PRINCIPLES
1. The Conservator Shutter, a flow sensitive device, is as essential to transformer
safety as a Buchholz relay.
2. While the transformer is operating normally, the Shutter is open. When the Buchholz
detects the presence of gases, the Shutter quickly isolates the conservator tank, as
soon as it detects abnormal oil flow.
3. When a short-circuit occurs, the resulting pressure increase forces the transformer
cover off and the oil catches fire. The conservator oil causes oil overflow which
burns the main tank. The resultant oil flow between the conservator and tank closes
the Shutter.
4. The Shutter is equipped with an integrated magnetic switch. When the Shutter
closes, the magnetic contact sends an alarm signal to the control room.

Why Transformers Explode

Uploaded by

Copyright:

Available Formats

Why Transformers Explode

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Why Transformers Explode

Uploaded by

Copyright:

Available Formats

WHY TRANSFORMERS EXPLODE

LACK OF INTERNATIONAL TRANSFORMER STANDARDS AND

TRANSFORMER ELECTRICAL AND MECHANICAL PROTECTION

Electrical Breaker opening time: the best breaker technology trips in 50

CAN PROPER MAINTENANCE GUARANTEE A TRANSFORMER WILL NOT

WHY CANT OIL AND GAS ANALYSIS PREVENT TRANSFORMER

HOW TRANSFORMER PROTECTOR

The TRANSFORMER PROTECTOR activates within milliseconds depressurizing

The TRANSFORMER PROTECTOR is the only proven solution to transformer

TRANSFORMER PROTECTOR COMPONENTS

TP3A VDS SOGST

TPA VDS SOGST

2TP3A6B VDS SOGST

TPA6B VDS SOGST

Thousands of TPs sold worldwide

Power-Gen Europe Best Paper Award 2008

Client installation examples:

A GROWING CONCERN FOR CORPORATE RISK MANAGERS

DAMAGE COST OF TRANSFORMER EXPLOSION AND FIRE

Transmission substation incidents can result in the complete blackout of a region

Distribution transformer explosions in urban areas can have disastrous financial

PURCHASING THE TRANSFORMER PROTECTOR

Decreases the risk to surrounding equipment and buildings.

Leaves the environment unharmed.

RESEARCH & TESTS

PROTECTOR efficiency to avoid transformer tank explosions and

IN ADDITION, THE CONSERVATOR SHUTTER:

TL 34 Type for 3-inch piping (SN 80)

You might also like