Pablo Borbon

Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

EE- 414

TRANSMISSION DISTRIBUTION SYSTEM AND SUBSTATION DESIGN

CASE STUDY

A STUDY OF THE ROOT CAUSES OF HIGH FAILURE RATE OF DISTRIBUTION

TRANSFORMER

Deveza, Carl Joshua H.

20-08853
EE – 4204

Engr. Rosalynn G. Hernandez

Instructor

January 30, 2024

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph
 Pablo Borbon
Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

I. CASE 1

A Study of the Root Causes of High Failure Rate of Distribution Transformer

Updated: February 25, 2017

1. Distribution Transformers:
Distribution transformers are indispensable components of the power distribution

system, facilitating the transfer of electrical energy between power utilities and end-users.

However, in recent times, there has been a surge in the premature failure of distribution

transformers in Kenya, leading to substantial economic losses for the power utility. This

case study aims to investigate the root causes of these premature failures and proposes

mitigation strategies to enhance the reliability and longevity of distribution transformers.

2. Facts about its background:

Traditionally, distribution transformers have served for over sixty years. However,

a concerning trend has emerged in recent years, with an increasing number of transformers

failing within a few years of commissioning. In Kenya, the reported failure rate stands at

approximately 10-12% per annum, significantly higher than the 1-2% failure rate in

developed countries. The rise in failures is attributed to factors such as the growing number

of transformers due to electrification projects, vandalism, and a relative lack of effort in

identifying the root causes.

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph
 Pablo Borbon
Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

3. Facts about the root causes of premature failure:
Research has identified several factors contributing to the premature failure of

distribution transformers. Electrically induced factors include exposure to transients,

sustained over-voltage conditions, lightning surges, and switching surges. Mechanically

induced factors involve issues such as looping of inner windings, conductor tipping, and

failure of coil clamping systems. Thermal factors result from overload beyond design

capacity, cold load pickup, cooling system failure, and operating under excessive ambient

temperatures.

Bushing failures, associated with poor workmanship and maintenance, are caused by

loosening conductors, sudden over-voltage leading to partial discharge, water ingress at the

transformer seal, and neglecting oil replacement.

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph
 Pablo Borbon
Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

From the table, it is shown that lack of installation LAs on the HV side of transformer results

in premature failure of the transformers as lightning strikes and transient travelling waves

causes HV windings insulation to give in due to high surge voltages. Further, it was noted that

most of the transformers arc horns were not well aligned. This was caused by poor

workmanship and lack of knowledge of field marshal the purpose of the arc horns. It

paramount noting that due to rampant vandalism of the earthing wire and earth rods, even

properly aligned arc horns and installed surge diverters are rendered ineffective. From the

investigation, a substantial number of the transformers (45%) had direct wire instead of graded

fuses on the low voltage side. This caused the transformer to be overloaded for prolonged

period of time due to high impedance fault (which may be caused by a tree branch touching a

phase) or cold load pickup. The high current increases transformer thermal heating (losses)

that raise windings and insulation oil temperature leading to decrease of the life of the

transformer. The heat also accelerates the aging of cellulose of oil and hence lowering the

degree of polymerization (DP) of solid insulation that provides dielectric and mechanical

isolation of the windings

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph
 Pablo Borbon
Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

II. REACTION:
The case study on the premature failure of distribution transformers in Kenya offers

valuable insights into the multifaceted challenges faced by the power distribution system. The

identification of root causes, ranging from electrical and mechanical factors to poor workmanship,

highlights the complexity of the issue. The proposed mitigation strategies, including the use of

concrete poles, proper fuse grading, and enhanced operational and maintenance practices, present

a comprehensive approach to address these challenges.

The study's emphasis on the impact of non-linear loads, especially in industrial settings,

adds a nuanced perspective to the discussion. It underscores the importance of considering evolving

energy demands and harmonics in ensuring the longevity and efficiency of distribution

transformers.

Overall, the case study provides a thoughtful analysis and practical recommendations that,

if implemented, could significantly improve the reliability of distribution transformers in Kenya. It

calls for a concerted effort from the power utility, manufacturers, and other stakeholders to address

the identified issues and contribute to the sustainable growth of the country's energy infrastructure.

III. CONCLUSION:
This case study underscores the critical importance of addressing the root causes of
premature distribution transformer failure in Kenya. By implementing the proposed
mitigation strategies, it is anticipated that the power utility can minimize economic losses,
improve reliability, and contribute to sustained economic growth in the country. Continued
efforts in research, design improvement, and proactive maintenance will be crucial in
ensuring the longevity and efficiency of distribution transformers in the evolving energy
landscape of Kenya.

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph
 Pablo Borbon
Alangilan Campus
Campus

College of Engineering – Department of Electrical Engineering

IV. RECOMMENDATIONS:
• Avoid transformer overload by properly grading the LV fuses.

• Concrete Poles with Appended Earth Wires.

• Regular Operational and Maintenance (O&M)

• Enhanced Design and Manufacturing Practices

• Monitoring and Clearing High Impedance Faults

Alangilan, Batangas City, Philippines +63 43 425 - 0139 loc. 2121

www.batstate-u.edu.ph coe.alangilan@g.batstate-u.edu.ph