ANALYSIS OF CAUSE OF

ABNORMAL NOISE OF MAIN

POWER TRANFORMER AND
POTENTIAL SOLUTIONS
Md. Mosiur Rahman.
AGM,Electrical-HT.
Potential Reason of the Abnormal Noise
1. Harmonics: High levels of harmonics generated by nonlinear loads, such as electric arc furnaces, can contribute to
abnormal noise in the transformer due to core saturation, mechanical vibrations, loose components, insulation
deterioration, resonance effects, and electrical faults.
2. Mechanical Vibrations: Mechanical vibrations caused by electromagnetic forces, loose parts, or poor assembly can
result in abnormal noise in the transformer.
3. Loose Connections: Loose electrical connections within the transformer can cause arcing and sparking, leading to
abnormal noise.
4. Magnetic Forces: Interactions between the transformer windings and core can generate mechanical stress and vibrations,
contributing to abnormal noise.
5. Core Laminations: Damaged or poorly assembled core laminations can create gaps, causing magnetic flux leakage and
resulting in abnormal noise.
6. Insulation Issues: Deterioration or breakdown of transformer insulation can lead to partial discharges, arcing, or corona
effects, generating abnormal noise.
7. Cooling System: Inadequate cooling or malfunctioning cooling channels can lead to increased temperatures, causing
expansion or contraction of components and contributing to abnormal noise.
8. Overloading: Operating the transformer beyond its rated capacity can subject it to increased electrical and thermal
stress, resulting in abnormal noise.
9. Structural Resonance: Resonance between the transformer and its support structure or surrounding equipment can
amplify vibrations and noise.
10. Transformer Design or Manufacturing Defects: Poor design, manufacturing defects, or inadequate material quality can
Tests done as per the advice of
Transformer Manufacturer
1. All kinds of Oil Test of the Transformer: Oil tests are conducted to assess the condition and properties of
the transformer oil, such as dielectric strength, moisture content, acidity, and breakdown voltage.
2. Magnetic Balance Test: The magnetic balance test is performed to ensure that the magnetic flux is evenly
distributed between the primary and secondary windings of the transformer.
3. Transformer Turn Ratio Test: The turn ratio test is conducted to measure the ratio of primary to secondary
turns in the transformer. This test helps verify the transformer's voltage transformation capability.
4. Winding Resistance Test per Tap: The winding resistance test measures the resistance of each winding in
the transformer, including resistance measurements at different tap positions. This test helps assess the
electrical integrity of the windings.
5. Insulation Resistance Test: The insulation resistance test determines the resistance offered by the insulation
between conductive parts of the transformer. It helps evaluate the insulation's condition and detect any
potential insulation breakdown or degradation.
6. Capacitance and Tan Delta: The capacitance and tan delta tests measure the capacitance and power factor
of the transformer insulation. These tests provide information about the condition of the insulation and
potential defects.
7. Sweep Frequency Response Analysis (SFRA): SFRA is a diagnostic test that measures the frequency
response of the transformer's windings. It helps identify any mechanical or electrical changes within the
windings, such as deformation, short circuits, or winding movement.
Confirmation from the Transformer
Manufacturer
GPH 230/33 KV GIS MRSS SLD

Abnormal
Noise

Dirty Bus Clean Bus

Harmonics Traveling back to the
Transformer
 Harmonics generated by the EAF have the potential to travel back through the
electrical network to the main power transformer.
 The harmonics are expected to be absorbed by the static VAR compensator (SVC)
installed in the system.
 If the SVC is unable to fully absorb all the harmonics, some may pass through to the
transformer, contributing to the abnormal noise.
Travel Paths of Harmonics and It’s effect
100/125
MVA TR

TRAVEL PATH OF
HARMONICS

EAF SVC
Harmonics Generated by the Electric ARC Furnace
and it’s effect
• The operation of the EAF involves high-intensity electrical currents and voltage fluctuations.
• These fluctuations can lead to the generation of harmonics, which are high-frequency components of the
electrical waveform.
• Harmonics can induce additional magnetic flux and eddy currents in the transformer, resulting in increased
mechanical stress and abnormal noise.
• High levels of harmonics in the electrical system can lead to transformer core saturation.
• Transformer core saturation occurs when the magnetic flux reaches its maximum limit and cannot increase
further.
• This saturation can result in waveform distortion and increased mechanical stress, leading to audible noise
production.
• The presence of harmonics and excessive electrical currents can induce mechanical vibrations in the
transformer.
• These vibrations can cause loose components, such as bolts or screws, to vibrate and produce abnormal
noise.
• Harmonics and high electrical stresses can accelerate the deterioration of the transformer's insulation.
• Deteriorated insulation can lead to increased electrical discharges, arcing, and buzzing noises.
• Resonance or coupling effects between the harmonics generated by the EAF and the transformer's natural
frequency can amplify the abnormal noise.
Visit from NR Electric for Transformer
Abnormal Noise Issue
 Reason of Visit:
• For the measurements of Harmonics at 230 KV and 33KV system due to the Electric ARC
furnace and performance of SVC to address the issue of 125 MVA Transformer abnormal noise.

 Tests Carried out during visit:

• Transformer high-voltage side load 48-hour power quality test.
• Transformer high-voltage side (without load) grid background power quality test.
• EAF branch, transformer low-voltage side power quality test.
• 33kV four branches (EAF, Incomer-01, SVC-1 & SVC-2) at the same time different phase
monitoring test.
• Transformer high voltage and low voltage side Neutral phase monitoring test.
• FC branch capacitor, reactor parameter review.
• SVC capacitors capacitance check.
Factors deciding a standby 100/125 MVA
Transformer in GPH 230/33KV MRSS and
Strategic Decision and Mitigation of Risk

 Power Transformer is one of the capital and critical item of a Steel Plant like
GPH
 Lead time of a power transformer is 12-15 month at least
 Installing a power transformer also having the cost involvement with the 230
KV GIS, 33KV GIS, HV and MV Power cables etc.
 Having the investment for the above equipment for a standby transformer is
like a lock of investment of huge money without any immediate return.
 Keeping a spare power transformer with energizing have a significant amount
of no load losses.
 Risk factor of having no standby transformer for a steel plant is crucial.
Possibilities of Storing a Spare 100/125
MVA Transformer without Charging
 Checking the possibilities and recommendations from different manufacturer regarding
storing a 100/125 MVA Transformer without charging for a long time.
 Checking the Potential risk associated with it.
 Checking the procedures to maintain for such storing for a long time.
 Communicating with different manufacturer and International Organization associated
with it.
 Find out any other solution of having new transformer without the cost of 230 KV GIS,
33KV GIS.