Transformer Failure Due to Circuit Breaker Induced Switching Transients

Transformer Failure Due to Circuit Breaker Induced Switching Transients

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  1 Transformer Failure Dueto Circuit Breaker Induced Switching Transients David D. Shipp, PE Fellow, IEEE Eaton Electrical Group 130 Commonwealth Dr. Warrendale, PA 15086 Thomas J. Dionise, PE Senior Member, IEEE Eaton Electrical Group 130 Commonwealth Dr. Warrendale, PA 15086 Visuth Lorch Eaton Electrical Group 130 Commonwealth Dr. Warrendale, PA 15086 Bill G Mac Farlane, PE Member, IEEE Eaton Electrical Group 130 Commonwealth Dr. Warrendale, PA 15086 2 2 Introduction • Switching transients associated with circuit breakers observed for many years • Breaking opening/closing interacts with the circuit elements producing a transient • The severity of the transient is magnified by breaker characteristics • Current chopping on opening • Pre-strike or re-ignition on closing • In limited instances, the transient overvoltage exceeds transformer BIL resulting in failure • RC snubber in combination with surge arrester mitigates the transient
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  2 3 3 Introduction • Forensic evidenceand history of failures • Underlying concepts • Predicting performance with simulations • Mitigating the transients with snubbers • Concerns for the pulp and paper industry • Custom designing the snubber • Snubber performance measurements 4 4 Unique Case – Forensic Evidence • Four electricians “simultaneously” opened four 26kV VCBs • simulate utility outage • systems transferred to standby generation • “loud pop” in Sub Rm B • the relay for VCB feeding transformer TB3 signaled trip • Minutes later, two electricians “simultaneously” closed two 26kV VCBs • breakers to Sub Rm A • transformer TA3 failed catastrophically
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  3 5 5 Transformer Failure #2- Energization • Examination of primary windings • Coil-to-coil tap burn off • Winding showed an upward twist • Burn marks from the initial blast • Transient on first turns of windings 6 6 Transformer Failure #1 – De-energization • Examination of primary windings • Flash and burn marks on b-phase at bottom & middle • Bottom - Indicate a coil-to-coil flashover (high dv/dt) • Middle – cable used to make delta swung free (lack of support) • Transformer passed BIL test at 150kV but failed at 162kV Both failed units: • 40 feet of cable • High efficiency design • VCB switching
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  4 7 7 History of Failures– Forensic Review Case Facility Voltage Cable Feet Bil Type Arrester Failure Mode Vendor Switching 1* Hydro Dam 13.80 20 50 Dry No 1st turn A Close 2 Hospital 13.80 27 95 Dry No 1st turn A Close 3 Railroad 26.40 37 150 Liquid N/A middle A Open 4 Data Center 26.40 40 150 Cast coil Yes 1st turn B Close/Open 80 150 Cast coil Yes None B Close 5 Oil Field 33.00 7 Dry No 1st turn C Close 6** Oil Drill Ship 11.00 <30 75 Cast coil Yes 1st turn C Close Notes: * = 40-50yrs. old with new breaker. ** = 2 yrs. old. All others new. *** = All transformers unloaded or lightly loaded when switched. Circuit Vacuum BreakerTransformer*** 8 8 Common Parameters “Rules of Thumb” to screen applications: • Generally, short distance between circuit breaker and transformer • about 200 feet or less • Dry-type transformer • oil filled and cast coil not immune and low BIL • Inductive load being switched • transformer, motor, etc. (light load or no load) • Circuit breaker switching characteristics: • chop (vacuum or SF6) or restrike (vacuum)
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  5 9 9 Underlying Concepts -Current Chop • VCB opens, arc burns metal vapor • Heat supplied by current • As current goes to zero, metal vapor ceases • Arc ceases or “chops” • All breaker chop current • low end 3 – 5A • high end 21A Contact Material Average (A) Maximum (A) CU 15 21 Ag 4 7 Cr 7 16 W 14 50 Cr-Cu (75 wt %) 3 5 Cr-Cu-Bi (5 wt %) 1 3 Cr-Cu-Sb (9 wt %) 4 11 Cu-Bi (0.15 wt %) 6 21 WC-Ag (50 wt %) 1.5 2.5 W-Cu (30 wt %) 5 10 Co-AG-SE 0.4 0.8 Cu-Bi-Pb 1 9 6A current chop Modern VI Older VI 10 10 Reignition and Voltage Escalation • Current chop plus system C and L imposes high frequency TRV on VCB contacts • If TRV exceeds breaker rated TRV, then reignition occurs • VCB closes and then opens high frequency current • Multiple reignitions lead to voltage escalation
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  6 11 11 Switching inductive circuits •Current cannot change instantaneously in an inductor (conservation of energy) • Energy Equation ½ LI2 = ½ CV2 or V = I L/C • Vtransient = Venergy + Vdc + Vosc • Venergy is from the Energy Equation • Vdc = DC Off-set due to system X/R • Vosc = the Oscillatory Ring Wave 12 12 Predicting Performance – EMTP Simulations TRANSFORMER RLRG LTRANRTRAN T1T2 CHCL N:1 CABLE 13.8KV C1LCABLERCABLEC2 C/2 C/2 SYSTEM SOURCE AT 13.8 KV XUTIL RUTIL VUTIL UN UUT VCB BKR • For purposes of screening applications for damaging TOVs • Source, breaker, cable and transformer modeled • Breaker models for current chop and re-ignition
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  7 13 13 Matching model tomeasurements Vacuum Breaker Short Cable 30KV BIL V max of 4.96kV < 30kV BIL Oscillation of 20.2kHz 3 x 2865KW Gens 1865KW motors 1185KVA 630A 14 14 Transient Mitigation • Surge Arrester • Overvoltage protection (magnitude only) • Surge Arrester + Surge Capacitor • Overvoltage protection • Slows down rate-of-rise • Surge Arrester + RC Snubber • Overvoltage protection • Slows down rate-of-rise • Reduces DC offset and provides damping
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  8 15 15 Breaker opening followedby reignition R = 40ohm C = 0.5uF TRV exceeds limit TRV within limit C37.011 C37.011 16 16 A Borderline Case • Tier III Data Center • 2x 24.8kV lines • 2 x 12.5MVA service • 13.2kV ring bus • 2 x 2250KW generators • 6 x 3750KVA cast-coil transformers 90kV BIL • VCBs on primary side • 109 – 249 ft. cables 123kV 969Hz 38.6kV 215Hz R = 30ohm C = 0.25uF
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  9 17 17 Switching a HighlyInductive Circuit 386kV 1217Hz 56.4kV 200Hz R = 100ohm C = 0.25uF 138KV UTILITY 4713MVA 3PH SC 9.26 X/R 50/66/83MVA 135.3/26.4KV 7.5%Z SF-6 BREAKER 2000A 1600A 27KV 13OHM AUTO LTC 56MVA 27-10KV 3.3%Z ALUMINUM IPS BUS 53FEET VACUUM BREAKER 1200A LMF XFMR 50/56MVA 25/.53KV 2.5%Z HEAVYDUTY COPPER PIPE 28FEET LMF 20MW Vacuum Breaker Short Bus 200KV BIL 18 18 Concerns for the Pulp & Paper Industry • VCB retrofit for primary load break switch (LBS) • Units subs with LBS and no secondary main • Arc flash issues on sec main (no room to install secondary main breaker) • Retrofit VCB in LBS box solves AF issue • VCB for rectifier (or isolation) transformer • DC drives for feed water pumps • VCB on primary • Short run of cable to transformer (often dry type) • New unit sub with primary VCB • Metal enclosed vacuum switchgear • 7500KVA transformer for gen boilers to meet EPA requirement • 5 feet of bus
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  10 19 19 Designing the Snubber •15kV typical snubber & arrester • transformer protection • non-inductive ceramic resistor • 25 ohms to 50 ohms • surge capacitor • Standard capacitor ratings 0.15 μF to 0.35 μF • 3-phase 13.8kV solidly ground • 1-phase 13.8kV LRG R C SA TX Surge Arrester Resistor Surge Cap 20 20 Top hat and switchgear designs 15kV snubber above the transformer (top hat) 15kV snubber in MV switchgear 13.8kV snubber in metal enclosed switchgear
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  11 21 21 Design Options –Detect Functionality • nothing (oversized but treated like a lightning arrester) • Glow tube indicators • visible through a window in the switchgear door • provide a visual indication of snubber continuity • current sensors • monitor the continuity of the resistor and fuse • alarm on loss of continuity • Some industries mandate fused protection • alarm signal can be sent to the plant DCS or SCADA system • alert the operating personnel that these snubber components have failed Glow Tube Current Sensor 22 22 Custom Designs for Pulp & Paper • 13.8 kV solidly grounded system • VCB retrofit for load break switch • 3-phase surge cap • 13.8 kV low resistance grounded • VCB retrofit for Load break switch • 1-phase surge cap • 2 x resistors in parallel • 13.8 kV low resistance grounded • new VCB • New 13.8/2.4kV 7500 KVA transformer • 1-phase surge caps and single resistors
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  12 23 23 Snubber Performance Measurements Hookupat arrester 24 24 Conclusions • Not all VCB primary switching of transformers require snubbers • Transformer failures due to primary VCB switching transients do occur • Current chop and re-ignition combine with unique circuit parameters • “Rule of Thumb” - Vacuum breaker, short cable or bus and dry type transformer (aged or low BIL liquid filled) • Snubbers plus arresters mitigate the transient • Retrofits require custom design of snubber • Field measurements confirm snubber performance