S08 Short Circuit Presentation

Short-Circuit Strength and
Short Circuit Testing of Power

and Distribution Transformers
Charlotte, North Carolina, March 17, 2008
Presented by: Marcel Fortin (Consultant), Pierre Riffon (Hydro-

Québec), Juergen Gerth (ABB) and Richard P.
McLaughlin (Kema Powertest)
Marcel Fortin Eng, Charlotte, SC, March

17, 2008
Introduction
Presented by: Marcel Fortin Eng

Test specialist
Consultant

17, 2008
Contributors
Marcel Fortin: test specialist retired
from Hydro-Québec High Power
Laboratory
Juergen Gerth: Technical Manager of
ABB Inc. Power Transformer Division
at Varennes, Quebec, Canada.
Pierre Riffon: test specialist for the
Hydro-Québec Quality Control
Department
Richard P. McLaughlin: Test Engineer
Supervisor, KEMA Powertest.

17, 2008
Presentations
Standard Status – M Fortin
Designing Transformers to Withstand Short-
Circuit Forces – J Gerth
Short-Circuit Withstand of Power Transformers,
Utility Perspective – P Riffon
Short-Circuit Testing of Liquid Filled
Transformers – R McLaughlin
Some Particular Cases – M Fortin

17, 2008
Standard Requirements
and Status

Test specialist
Consultant

17, 2008
Continuous revision of C57.12.00
and C57.12.90
C57.12.00 sets requirements for short
circuit withstand of oil filled transformers,
clause 7 and table 21
C57.12.90 sets the short-circuit test
procedure, including the pass criteria and
diagnostic tools, clause 12.
A TF chaired by myself is responsible for
reviewing clause 12 of C57.12.90
17, 2008
Short Circuit withstand
requirements
IEEE C57.12.00-2006, clause 7.1.1, states:
"Liquid-filled transformers shall be designed and
constructed to withstand the mechanical and
thermal stresses produced by external short
circuits under the conditions specified in 7.1.3,
7.1.4, and 7.1.5. The external short circuits shall
include three-phase, single line-to-ground,
double line-to-ground, and line-to-line faults on
any one set of terminals at a time.“
IEC 60076-5 has the same design requirements

17, 2008
Short Circuit testing
requirements
IEEE C57.12.00, clause 8.2 and table 21, states
that short circuit test is:
A design test for transformers rated 500 kVA and
below
A test that may be specified by the purchaser (other)
for transformers rated 501 kVA and higher (clause
8.2.3).
IEC 60076-5 has also the same design
requirements

17, 2008
Status of changes recommended
by the Task Force
No changes to C57.12.00
Abandon of work on a short circuit test
guide (PC57.133)
This guide project covered interpretation of
LVI (low voltage impulse) diagnostic method
The proposed change to C57.12.90 include
removal of LVI as a diagnostic method

17, 2008
Status of changes recommended
by the Task Force
Major changes proposed to C57.12.90 are:
Withdrawal of LVI
Make dissolved gas analysis (DGA) a compulsory diagnostic
tool
Introduction of other diagnostic tools: FRA, FRSL, TOP
Make the pre-set method the preferred one and keep the post-
set method as an alternative
Introduce requirements and guidance for testing special
transformers as axial split
Add informative notes and figures to clarify the requirements
Add an informative annex giving test circuit diagrams for single
phase testing of 3 phase transformers

17, 2008
Jürgen Gerth
Technical Manager
Designing Transformers to
ABB Inc. withstand
Varennes, Quebec Short-Circuit Forces
Canada
- 1/14 -
Designing Transformers to withstand Short-Circuit Forces
In case of external short-circuits the first peak of the fault current over
the transformer will increase to a multiple of the rated current.
The fault current is

governed by:
Open-circuit voltage
Source and transformer

impedance
Instant of fault onset

- 2/14 -
Displacement of current
2D Plot of the magnetic stray field lines

of a two winding transformer.
Radial direction
The stray flux has

components in axial and
radial direction.
Axial
direction
There are field compoments
outside the windings.
- 3/14 -
The direction of forces is always

directed perpendicular to the
magnetic field lines
Forces usually are split into the two

components
• Radial forces
• Axial forces
Electromagnetic forces tend to

increase the main insulation duct and to
increase existing un-symmetries.
- 4/14 -
Radial forces failure modes:

• Buckling of the inner winding
• Diameter increase of the outer winding, rupture of cable
• Spiralling of end turns in helical winding
Spiralling:
Buckling:
Characteristic
Characteristic failure mode
failure mode
for inner and
for inner outer winding
winding
- 5/14 -
Axial forces failure modes:
Telescoping of windings
Damage of conductor insulation
Collapse of end support
Conductor tilting
Bending of cables
- 6/14 -
Steps to design transformers to survive short-circuits
Step 1: Run fault current calculations, covering all external fault modes:
• Three phase fault on HV, LV and Tertiary side

• Line to line fault on HV, LV and Tertiary side
• Line to ground fault on HV and LV side
Consider the network impedance in line with the Standard or the spec.
Consider different tap changer positions
Consider that impedances are subject of tolerances
Consider that current limiting reactors may show saturation effects
- 7/14 -
Step 2: Calculate the forces and the stresses
• Radial forces and copper stresses in all windings

• Spiralling forces on the exits
• Axial compression forces and:
• Bending stresses in the cables
• Stresses on the paper of the winding conductors
• Critical tilting stresses of the winding conductors
• Axial forces on the end supports and stresses in the mechanical
support structure
The highest fault current will not always lead to the highest forces in a
winding. Superimposed fields of other windings may create higher
stresses
- 8/14 -
Step 3: Take the right design measures
• Design the windings radially self supporting

• Select the cable dimensions, copper yield strength and epoxy
bonding to meet the stresses
• Focus on axial ampere-turn balancing optimization of all
windings,
• Require close manufacturing tolerances,
• Provide solid clamping of the windings,
• Provide safe fastening of the winding exits and connection leads.
- 9/14 -
Which simplifications are applied during design?
• The forces alternate with the square of the current. During design only
the peak force is calculated and considered as a static force. A
dynamic factor may be used to consider the dynamic effects.
• Core and coils are a 3 D arrangement. The routine field calculations
are ran with 2 D programs,
• Layer and helical windings have a pitch creating variable
displacements. It depends on the manufacturer’s rules which
displacement is considered,
• The calculation of the forces on the winding exits is based on a
simplified model.
• The mechanical withstand limits of helical windings against spiralling
forces are based on limited number of experiments.
- 10/14 -
Which improvements have been achieved over the last 20 years?
• Computer programs run fault current and force calculations for all
fault conditions and all winding connections automatically,
• 3 D magnetic tools have been applied for R&D work,
• Epoxy bonding of winding conductors has become available and
the application became a standard practice,
• Hard and very hard drawn copper is applied more frequently,
• Pre-compressed pressboard is exclusively used,
• There is more focus on the short circuit strength during the design
stage,
• More experience has been gained in the field and by testing.
- 11/14 -
Why do transformers fail testing?
• Due to design weakness because:

• The rules did not fully cover the case,
• There are effects which have not been considered,
• Due to shortcomings during manufacturing,
• Due to transportation issues or poor test preparations,
- 12/14 -
Benefit and risk of testing
Test results are an important feedback and a valuable source for

improvements. Due to the high cost and the limited number of test
facilities the number of tests will remain limited.
Submitting a transformer to a short-circuit test is always connected to

high expenses for the purchaser. In case of a failure the expenses
become very high for purchaser and manufacturer.
A short-circuit test therefore involves a risk for both parties.

- 13/14 -
Personal observations after 40 years in business
• Designing for short-circuit strength was not high on the list 40 and
30 years ago,
• Radial buckling, axial winding collapse and broken press rings were
a non-rare experience,
• In the meantime the design philosophy has changed,
• More experience has been gained, mainly after performing tests,
• There are better design rules, the calculation tools were improved,
and there are better materials to strengthen windings and winding
supports,
• I did not see a winding with buckling, collapsing, tilting indication for
more than 10 years in a transformer designed during that period.
- 14/14 -
Short Circuit Withstand of Power
Transformers, Utility Perspective
Presented by: Pierre Riffon Eng.

Test Specialist
Hydro-Quebec
Pierre Riffon, Eng.,

Charlotte, SC, March 17, 2008
Type of faults to be considered
All type of external faults such as:
¾ Line faults, 1φ, 2φ, 3φ (not so severe if far

from transformer).
¾ Substation faults 1φ, 2φ, 3φ, Severe cases,
highest fault current, not frequent.
¾ Worst case: 3 phases short-circuit caused by
forgotten safety grounding devices after
maintenance…

Fault occurrence – utility experience
Line faults statistics (IEC 62271-310), more
frequent than substation faults, approximately 4 to
6 faults per year per line, typically due to lightning
strokes.

Transformers failures caused by
short circuit events – Hydro-Québec
Hydro-Quebec transformer short-circuit failures have been
compiled for the period of 1970 to 1998. The results are:
System Number of Number Number Failure Failure Comparison Comparison

voltage transformer of faults of faults rate rate HQ/CIGRE HQ/CIGRE
- years 1970 - 1993 - 1970 - 1993 – 1970 – 1998 1993 - 1997
1998 1997 1998 1997
% %
145 -170 6912 10 1 0,145 0,015 11,15 1,15
765 3255 6 3 0,184 0,092 9,20 4,60
A CIGRE TF with WG 12.19 made survey in 1997 (18 utilities in 11 countries). Time frame
of the results: 1993 – 1997 (5 years)

Transformers failures caused by
short circuit events – Hydro-Québec
Well spread among 7 different manufacturers
(no specific manufacturer nor design).
Hydro-Quebec short-circuit related failure rates
significantly higher than the figures reported by
CIGRE.
Short-circuit failure rates improved in the last 5
years (1993- 1998).
Average age of transformers when failing: 19
years (CIGRÉ), 17 years (HQ).

Transformer failure during short-
circuit tests - CIGRÉ
CIGRE SC12 has conducted in 1998 a worldwide survey among high-power
laboratories (12 labs). The results are:
Average failure rate during tests

Transformer power rating (MVA)
%
≤ 2,5 22,9
> 2,5 and ≤ 40 22,3
> 40 and ≤ 100 12,1
> 100 41,9
Transformer impedances for units rated 25 to 200 MVA were in the range of
14,3% to 19,5%.

Demonstration of transformer ability
to withstand short-circuit currents
Manufacturer: Calculations at the design
stage. Calculation methods should be based on
experience gained on similar transformer testing
(not always the case). IEC 60076-5 does accept
calculations and does give calculations guidance
and criteria.
User: Shall review the manufacturer short-circuit
calculation results and transformer design and
decide if a test is needed.

Is a short-circuit test to be considered?
Technical aspects to consider:
Mandatory for distribution transformers (≤ 500

kVA)
Is the test possible? Not possible for large units (
>400 MVA). Only few laboratories (outside North
America) are able to test units rated over 100
MVA.
What is the application (normal substation, GSU,
interconnections between two systems (phase-
shifter or HVDC), etc..)

Is a spare available?
Is that a single and unique order or this is an
order that can be related to several identical
units (e.g. distribution transformers or
standardisation of a specific design);
Can the power be fed through a parallel path
(generally possible in power substations but not
in generating plants).

Short-circuit occurrence and amplitude;

Utility service experience;
Manufacturer performance in service;
Manufacturer experience of short-circuit tests;
Risky design, small safety margins, new design,
etc…

Economical aspects to consider:
Testing costs (including transport costs) and

associated risks (project delays in case of a failure);
Evaluation of revenue losses, mainly for bulk power
applications like interconnections, generating power
stations, large industrial plants, etc.;
Large number of units to be ordered e.g. distribution
transformers

Economical aspects to consider:
Duration of an outage;
For GSU applications, is it possible to store the
energy e.g. in a water reservoir for hydro power;
Time needed to replace the failed transformer;
Costs for transformer replacement;
Costs of energy replacement;
Costs of power replacement.

A composite evaluation of all aspects

(technical and economical) shall be done.
Costs of performing a short-circuit test
series shall then be compared with the
costs, inconveniences and risk of having a
failure in service.

Hydro-Quebec policy regarding the need
of performing short-circuit tests
Short-circuit tests on critical power transformers since
1997.
Short-circuit tests on small power transformers and
distribution transformers are still performed. Can be
easily tested in North American Laboratories without
excessive transport costs.
Nowadays, short-circuit tests on large power
transformers can be hardly justified because of the
extreme transport costs for sending transformers to
laboratories outside North America.

Tests performed on Hydro-Quebec's
power transformers since 1997
Description Manufacturer Succeed Modifications Failure has been observed by
at the made on the
first trial initial design
2,5 MVA, A No Yes 1st test series:
Special Impedance variation: Yes
application Visual inspection: Yes, axial failure
2nd test series:

Impedance variation: No, less than
2%
Dissolved gas-in-oil analysis: Yes,
presence of acetylene.
Visual inspection: Yes, axial failure
47 MVA, 170 kV / B Yes No N/A
25 kV

Tests performed on Hydro-Quebec's
power transformers since 1997
Description Manufacturer Succeed Modifications Failure has been observed by
at the made on the
first trial initial design
102 MVA, C No Yes Arcing fault to the tank
GSU Impedance variation: Yes
Axial-split Dissolved gas-in-oil analysis: Yes,
230 kV /11 kV / presence of acetylene.
13,8 kV Visual inspection: Yes, axial failure
775 MVA, C No Yes Impedance variation: No less than
230 kV / 24 kV 2% but more than 1%
GSU Dissolved gas-in-oil analysis: Yes,
presence of acetylene.
Visual inspection: Yes, spiralling
failure of the LV winding

Benefits of performing short-
circuit tests
Feedback for improving calculations, design
evaluation and manufacturing methods;
Changes and improvements made on a design
which has initially failed a short-circuit test are
normally implemented as a common
manufacturing practice.
Increase manufacturer and utility knowledge.
Long-term improved reliability for all similar
transformers.

Does a short-circuit test damage
the transformer?
Hydro-Quebec have not seen any service
problems on the units which have been short-
circuit tested.
EDF (France) and ENEL (Italy) who did perform
extensive short-circuit test campaigns did not
report any particular problems with these units.

How to be sure that a transformer
subjected to a short-circuit test has no
internal damages
By doing additional diagnostic tests such as FRA
or FRSL;
By adding a dissolved gas-in-oil analysis after
tests;
By doing a mandatory and detailed out-of-tank
active part inspection;

How to be sure that a transformer
subjected to a short-circuit test has no
internal damages
By requesting a temperature rise test at
maximum rating after the active part inspection;
By requesting dielectric type tests to be
performed after the active part inspection at
100% of the rated test levels;
By requesting all other type and routine test at
100% of the various ratings.

Conclusions
Short-circuit failures represent only a few
percentage of total transformer failures but do
generally result in catastrophic failures.
Test is the only method to guaranty the ability of
a transformer to withstand a short-circuit.
Tests are providing valuable inputs to designers
and utilities for improving actual and future
designs and service continuity.

Conclusions
Short-circuit tests are expensive and an
extensive technical, economical and risk
evaluation should be conducted before requiring
a test.
Adequate diagnostic methods, active part
inspection and final type and routine tests at
100% of the rated levels are needed to insure
that a short-circuit test did not damage the
transformer.

SHORT-CIRCUIT TESTING OF
LIQUID-FILLED
TRANSFORMERS
Presented by: Richard P. McLaughlin

Supervising Test Engineer
Kema Powertest, LLC
Richard P. McLaughlin, Charlotte, SC,

March 17, 2008
CONSIDERATIONS BEFORE
TESTING
¾ SPECIFY WHICH TESTS TO
PERFORM
Dictated by the client as to which
tests are to be witnessed and/or
performed by the test lab.

March 17, 2008
CONSIDERATIONS BEFORE
TESTING
¾ SCHEDULING OF SUFFICIENT
TEST TIME
Depending on the above specified
tests to be performed the test lab will
submit an estimated time quotation
to perform all tests for approval.

March 17, 2008
INFORMATION NECESSARY
FOR SHORT-CIRCUIT TEST
¾ TRANSFORMER NAMEPLATE
INFORMATION
Require the MVA, voltage ratings,
and total percent impedance to
calculate the necessary short-circuit
test levels. Each test transformer is
calculated on an individual basis.
March 17, 2008
INFORMATION NECESSARY
FOR SHORT-CIRCUIT TEST
¾ POST-SET VS. PRE-SET
Typically perform most short-circuit tests
with the pre-set method due to a generator
fed source (2250MVA short-circuit
generator).
Post-set testing can be performed on a
strict individual basis depending on the
test transformer voltage, short-circuit
current ratings, and no-load losses.
March 17, 2008
PERFORMANCE OF SHORT-
CIRCUIT TESTING
¾ SET-UP
Depending on the calculated
impedance and short-circuit test
levels will dictate how extensive
the set-up needs to be. Typically
is a minimum of a ½ to ¾ of a
work-shift.
March 17, 2008
CIRCUIT TESTING
¾ INITIAL IMPEDANCE
MEASUREMENTS
Measure on all necessary taps
that the short-circuit tests are to
be apllied to. Typically only takes
a several minutes for each tap
position.
March 17, 2008
CIRCUIT TESTING
¾ SHORT-CIRCUIT CURRENT
CALCULATIONS
Calculate the required short-
circuit current values based on
the limitations and equations in
IEEE C57.12.00 and C57.12.90.

March 17, 2008
CIRCUIT TESTING
¾ SHORT-CIRCUIT TEST
PROCEDURE
Typical procedure for each winding
of a three-phase unit:
Impedance - 2 full-level short-
circuit current tests - Impedance.

March 17, 2008
CIRCUIT TESTING
PROCEDURE
Alternate procedure for each
winding of a three-phase unit:
Impedance - 6 full-level short-
circuit current tests - Impedance.

March 17, 2008
CIRCUIT TESTING
PROCEDURE
Typically it takes a minimum of 1
work-shift to perform the typical
short-circuit test procedure. This is
depending on the performance of the
test transformer and the test station.
March 17, 2008
CIRCUIT TESTING
¾ POST IMPEDANCE
MEASUREMENTS
Measure on all necessary taps
that the short-circuit tests were
apllied to. Typically only takes a
several minutes for each tap
position.
March 17, 2008
CONCLUSIONS
¾ The impedance variation larger

than that specified in the test
standard is the most common
after the short-circuit tests.

March 17, 2008
CONCLUSIONS
¾ KEMA (Arnhem) shows that in 11

years of testing (of 77) large
transformers (25 - 440 MVA, 20 -
500 kV), 31% fails initially to pass
the short-circuit test, mostly because
an unacceptable increase in
reactance. 1
1 KEMA'S TEST EXPERIENCES WITH SHORT-CIRCUI T WI THSTAND CAPABILI TY OF LARGE POWER TRANSFORMERS : R. P. P.
Smeets, L. H. te Paske, P.P. Leufkens - KEMA T&D Testing Services, Arnhem, the Netherlands

March 17, 2008
CONCLUSIONS
¾ Every tested transformer

provides many levels of concern,
all must be accounted for with
every short-circuit test.

March 17, 2008
CONCLUSIONS
¾ Each test facility shall make

accommodations for the areas
covered, and not covered, in this
tutorial depending on their
circumstances presented to them
at the time of the test.

March 17, 2008
Some Particular Cases

Test specialist
Consultant

17, 2008
Content
Low X/R transformers
Multi winding autotransformers
Non-circular coils
Axial split transformers

17, 2008
Axial split
Axial-split transformers
comprise transformers
having 3 or more H1
windings with 2 or more load 1
windings physically
superimposed axially one source
the same magnetic leg.
Each of the axial-split
windings can be load 2
connected to different
sources and/or loads by
different sets of bushings.

17, 2008
Axial split
Fault shall be applied
to only 1 axial split H1
winding load 1
To lower the source

magnetizing inrush
the post-set method is load 2
preferred
Clause 12.2.3.1 of the draft and
CIGRE paper 12-104

17, 2008
Non circular coils
Many lower size and distribution transformers are built
using non-circular coils (square or rectangular)
On the first asymmetry, somethime on the calibration,
these windings will bulge radially and show a high
impedance variation
Usually, after the first maximum peak test the windings
have bulged to their limit and most of the time no
impedance variation, or very light, is observed on
following tests
Heat run test and visual inspection is of prime
importance to ascertain that the transformer have
passed the test.

17, 2008
Other multiwinding transformers
Single phase 120/240 V transformers
Single phase multiple connection
transformers/ autotransformers
HV: 14400 V
LV: 3 x 2400 V windings
Transformer connection: 14400/2400 or 7200

V
Autotransformer connection: 14400/7200 V

17, 2008
Other multiwinding transformers
During testing, each winding shall be subjected
to its maximum calculated fault current on at
least one test. In general, a given fault type and
location will not produce the maximum fault
current in more than one winding, so it will be
necessary to make tests with several different
connections to fully evaluate the capability of all
windings. (clause 12.2.2.1 of C57.12.90 – 2006)

17, 2008

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Short-Circuit Strength and

Short Circuit Testing of Power

Presented by: Marcel Fortin (Consultant), Pierre Riffon (Hydro-

Marcel Fortin Eng, Charlotte, SC, March

Charlotte, North Carolina, March 17, 2008

Presented by: Marcel Fortin Eng

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

Presented by: Marcel Fortin Eng

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

Marcel Fortin Eng, Charlotte, SC, March

The fault current is

 Source and transformer

 Instant of fault onset

2D Plot of the magnetic stray field lines

The stray flux has

The direction of forces is always

Forces usually are split into the two

Electromagnetic forces tend to

Radial forces failure modes:

Axial forces failure modes:

Collapse of end support

Steps to design transformers to survive short-circuits

• Three phase fault on HV, LV and Tertiary side

Step 2: Calculate the forces and the stresses

• Radial forces and copper stresses in all windings

Step 3: Take the right design measures

• Design the windings radially self supporting

Which simplifications are applied during design?

Which improvements have been achieved over the last 20 years?

Why do transformers fail testing?

• Due to design weakness because:

Benefit and risk of testing

Test results are an important feedback and a valuable source for

Submitting a transformer to a short-circuit test is always connected to

A short-circuit test therefore involves a risk for both parties.

Personal observations after 40 years in business

Charlotte, North Carolina, March 17, 2008

Presented by: Pierre Riffon Eng.

Pierre Riffon, Eng.,

¾ Line faults, 1φ, 2φ, 3φ (not so severe if far

Pierre Riffon, Eng.,

Pierre Riffon, Eng.,

System Number of Number Number Failure Failure Comparison Comparison

145 -170 6912 10 1 0,145 0,015 11,15 1,15

765 3255 6 3 0,184 0,092 9,20 4,60

Pierre Riffon, Eng.,

Pierre Riffon, Eng.,

Average failure rate during tests

> 2,5 and ≤ 40 22,3

> 40 and ≤ 100 12,1

> 100 41,9

Pierre Riffon, Eng.,

Pierre Riffon, Eng.,

Source and transformer

Instant of fault onset

Mandatory for distribution transformers (≤ 500

Short-circuit occurrence and amplitude;

Testing costs (including transport costs) and

To lower the source