PITFALLS OF FUSING POWER TRANSFORMERS

Presented at the 36th Annual Western Protective Relaying Conference

Spokane, Washington, October 20-22, 2009

Mike Jensen, Pacific Gas & Electric Company

Abstract
Fusing of power transformers is commonly used as an economical and convenient means of
providing transformer protection. At Pacific Gas and Electric (PG&E), transformer fusing is used
on transformers that are rated 12.5 MVA and below at 60/70kV and 16MVA and below at 115kV.
Fusing a transformer provides the following advantages; a fault interrupting device is not required
thereby, simplifying the DC system and station controls, simplification of outdoor construction,
providing for an economical and quick installation. However as with everything in life it comes at
a price and the disadvantages may not be as obvious as first thought. In addition to slower clearing
times and the one time operation of the fuse resulting in increased customer outage minutes, there
are other less obvious issues related to winding configuration and grounding that can have
significant impact on the ability of fuses to detect and clear the fault, leading to catastrophic
failure. This paper will cover the advantages, disadvantages, and less obvious winding
configurations that should be avoided to allow fuses to properly protect the transformer, and
examples of how the various winding configurations affect the ability of fuses to clear a
transformer fault. Various forms of auxiliary protection will be included to help protect the load
and transformer if fusing is utilized, such as negative sequence relays, tertiary fuse and tertiary
overcorrect protection.

Background
PG&E is one of the largest combination electric and gas utilities in the United States. It serves
about 15 million customers in the northern and central California. Approximately 20,000
employees serve its 70,000 square mile territory. It is a vertically integrated utility with
Generation, Transmission and Distribution assets. Its transmission system is made up of
approximately 18,610 miles of 500, 230, 115, 70 and 60kV lines.
Introduction
Power transformers are one of the most expensive and difficult to replace components in a power
system. Transformers can be protected by various methods, using circuit breakers, circuit
switchers, Transruptors and fuses. However, there are instances where the infrastructure for
providing full transformer protection cannot be used. The use of circuit breakers requires the
installation of protective relays, a DC system, battery and charger and other associated equipment
such as a control building and, additionally, there may not be room for the installation. In these
cases fuses may be the protection of choice.

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Transformer Fusing Considerations

Before the choice can be made several factors should be taken into account as noted below:
Fault interrupting capability For voltages 60kV and above the typical maximum fault
interrupting capability of fuses is 10kA.
Coordination with upstream and downstream protective devices. Many times the fuse may
not adequately coordinate with upstream ground overcurrent devices.
Ability to adequately protect the transformer Is there enough fault duty to adequately
operate the fuse for the worst-case low voltage fault.
Transformer inrush considerations. Typical fuse size of 1.5 to 2 times rated OA rating will
address the inrush concerns.
Cold load pick-up.
Fault clearing considerations
All though a fuse can be sized to properly protect the transformer for most faults, there are certain
winding configurations that can continue to feed a fault after the faulted phase fuse operates.
Several winding configurations are listed below with the currents before and after the fuse
operates. The values of current for the two winding transformers are based on a rating of 13MVA,
70/12.47kV, Z = 11% and were obtained using the Aspen Oneliner fault simulation program. The
three winding transformer values were based on a rating of 10MVA 70/7.2/12.47kV Z = 8%.
HV

LV

HV Before Fuse
Operates
DLG AB flt
IA = 877 @-84
IB = 439@96
IC = 439 @96
DLG AB flt
IA = 877 @-84
IB = 528@131
IC = 519 @62

HV After First Fuse

Operates
DLG AB flt
IA = 0
IB = 0
IC = 0
DLG AB flt
IA = 0@128
IB = 286 @6
IC = 286 @-52

DLG AB flt
IA = 439 @-23
IB = 877 @ 157
IC = 439 @ -23
DLG AB flt
IA = 439 @-23
IB = 877 @ 157
IC = 439 @ -23
SLG A phase
IA = 800 @ -86
IB = 300 @ 94
IC = 300 @ 94
IA = 465 @ -86
IB = 233 @ 94
IC = 233 @ 94

DLG AB flt
IA = 0
IB = 0
IC = 0
DLG AB flt
IA = 386 @157
IB = 0
IC = 386 @157
SLG A phase
IA = 0
IB = 233 @ -86
IC = 233 @ -86
IA = 0
IB = 0
IC = 0

LV After Fuse
Operates
DLG AB flt
Ia = 0
Ib = 0
Ic = 0
DLG AB flt
Ia = 2780 @ 6
Ib = 2780 @ 6
Ic = 0
3Io = 5561 @ 6
Ia = 0
Ib = 0
Ic = 0
DLG AB flt
Ia = 1251 @157
Ib = 1251 @ -23
Ic = 0
SLG A phase
Ia = 1350 @94
Ib = 0
Ic = 0
Ia = 0
Ib = 0
Ic = 0

Table 1

Fault Currents for Different Winding Configurations

2/16

As shown in Table 1 for Double Line to Ground (DLG) faults, the two winding configurations
have current in the intact phases after the first fuse operates, however there is enough fault current
to allow the remaining fuses to operate thereby clearing the fault. The same cannot be said for the
three winding transformers for a sustained SLG fault.

Delta Wye Grounded.

The sequence network for a DLG fault for this winding configuration is illustrated below:
Z1

V1

Z2

Z0

_
+

Z0 h-l
Zsys2

Zsys1
Z2 h-l
Z1 h-l

Figure 1
Delta Wye DLG fault

Shown below is an AB phase DLG fault simulation with the resulting fault current distribution
before and after the fuse operates.
Ia = 5046 amps

IA = 877 amps

Ib = 5136 amps

IB = 528 amps

12kv bus SLG

fault
5561 amps

Ic = 0 amps
IC = 519 amps

Figure 2

70/12.47kV XFMR Grounded HV Wye w/ 125E Fuse

DLG fault before fuse operates

Ia = 2780 amps

IA = 0 amps

Ib = 2780 amps

IB = 289 amps

Ic = 0 amps

12kv bus SLG

fault 3Io
5561 amps

IC = 286

Figure 3
70/12.47kV XFMR Grounded HV Wye w/ 125E Fuse
DLG fault after fuse operates

3/16

As can be seen in Figures 2 and 3, for the Delta Wye gnd connection for an A-B phase DLG
fault causes one of the 70kV phase fuses to operate after which the current in remaining two
phases increases, causing those fuses to operate. The fuse should be sized adequately to operate
for the resulting fault currents.
Wye Grounded Delta Wye Grounded.

This is one of the most common transformer winding configurations on the PG&E system. The
three winding configurations with the delta tertiary are the configurations in which fault clearing
after the faulted phase fuse operates can be a potential problem. This issue is identified in the
following sections.
A phase SLG Fault
The sequence network for this winding configuration during an A phase SLG fault is illustrated in
Figure 4 below:

Z1

V1

_
+

I1
Zsys1

Z1 h-l

Io

Z2

3Z f

I2
Zsys2

Z2 h-l

Z0

Itr
Zsys0

Z0 t-l

Z0 h-t

Itert
Z0 l-t

Figure 4
A phase SLG Fault

4/16

After the faulted phase fuse operates, the delta tertiary will continue to feed the fault, and the
resulting High Voltage (HV) fault current is not high enough to operate the fuses in the two
remaining phases. The resulting tertiary current can be over five times the rated current resulting in
eventual failure of the transformer if no further mitigating actions are taken The sequence network
model with load impedance neglected, and the solution with matrix equations are shown below as
well. Current values are shown below for a typical fused transformer 10 MVA. The current
values were derived using the Aspen Oneliner Simultaneous faults feature.

Z1
_
+

V1

I1
Zsy

1:1

I1

Z1 h-l

Z2
I1
Z0

Zsy

1:1

I1

Z2 h-l

2I1
Zsy

Z0 t-l
Z0 h-t

3I1 1:1
I1

I1

Z0 l-t

Figure 5
Sequence network for open HV A phase fuse and sustained LV SLG fault

Figure 6 shows a simplification of the above network where the system impedance has been
removed and only reactance is shown:

5/16

j1.0 pu
+-

I1

I1

L4

j0.8345

+
V2
-

I1

V2

L2
+

j0.8345

V1

L1

+
- V1

-j0.0983

j0.9333

V0
I1
j0.5738
L3

2I1

+
V0
-

3I1 (I tertiary)
Figure 6
Simplified sequence network

From the above network the following equations are derived:

L1
1.0 = -V1+j0.8345 j0.8345+V2
L2
0 = -V2+j0.8345*I1+ (j0.9333)(2I1) (-j.0983)I1+V0
0 = -V2+j2.79*I1+V0
L3
0 = -V0+(-j0.0983)I1+(j0.5738)(3I1)

0 = -V0+j1.62*(2I1)

L4
0 = V1 +V2+V0
Solving the above equations for v1,v2, v0, and I1 on a per
unit basis

v1
v2
v0
I1

:=

1
0
0
1

1
1 1 2.79
0

0
0 1 1.62

0
1 1
0

The resulting per unit values are shown below

v1
v2
v0
I1

0.578
0.422
0.155
0.096

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Per Unit Current Value

amps pu

I1 = 0.096

Convert to phase current values

IA
IB

IC

:=

1 1 1 I1
1 a2 a I1

1 a a2 2I1

IA
IB

IC

a2 := .5 .866i

arg ( a2 ) = 120.001 deg

a := .5 + .866i

arg ( a ) = 120.001 deg

0.144 0.249i

0.144 + 0.249i

Per Unit HV Current @ 100MVA, 70kV

100000000

= 825.764

1.73 70000

HV phase currents
IB 825 = 237

amps

IC 825 = 237

amps

Per Unit Tertiary Current @ 100MVA, 7.2kV

ITERTpu :=

100000000
1.73 7200

ITERTpu = 8028

amps

Resulting tertiary fault current:

ITERT := ITERTpu 3I1
ITERT
= 1334 amps
1.73
Itertrated :=

2940000
1.73 7200

Itertrated = 236

amps

Fault current percentage over rated

ITERT
1.73 Itertrated

7/16

= 565%

Figures 7 and 8 below show the resulting fault currents before and after the fuse operates.
Ia = 6000 amps

IA = 800 amps

Ib = 0 amps

IB = 300 amps

12kv bus SLG

fault
6000 amps

Ic = 0 amps
IC = 300 amps

1485 amps

Figure 7
70/7.2/12.47kV XFMR Grounded HV Wye w/ 125E Fuse
SLG fault before fuse operates
Ia = 1350

IA = 0 amps

Ib = 0 amps
12kV bus SLG
fault
1350 amps

IB = 233 amps
Ic = 0 amps
1334 amps

IC = 233 amps

Figure 8
70/7.2/12.47kV XFMR Grounded HV Wye w/ 125E Fuse
SLG fault after fuse operates

Transmission Line Open Phase with SLG Fault

Another potential problem with this winding configuration is for an open phase on the HV side of
the transformer with a sustained SLG fault, such a parted conductor where one side stays
suspended on the tower and the other side falls to the ground creating a SLG fault, refer to Figure9 below.
Station B
70kV breaker remained closed
70kV T-Line

IC = 155A @ 94 deg

Station B Voltages
VAN = 42.1kV @ 0 deg
VBN = 42.1kV @ - 120 deg
VCN = 42.1kV @ 120 deg

IB = 155 A @ 94 deg
IA = 155 A @ 94 deg

If = 155 A

Open conductor with

one end faulted to
ground.

Figure-9

IB = 155 A @
94 deg

IA = 155 A @
94 deg

Station A
70kVbreaker is open
after tripping on SLG
fault

IC = 155 A @
94 deg
3I0 = 465 A

Tert. Curr = 860 A

Rated Curr = 236 A

70/7.2/12.47kV XFMR Grounded HV Wye w/ 125E Fuse

Transmission line falls to ground Station A breaker trips

Station B breaker remains closed

Ia = 0 A

Ic = 0 A

8/16

Ib = 0 A

The example in Figure -9 is the same transformer as used in Figure -7 and 8, tapped on a 70kV

transmission line. The current values were obtained using the Aspen Oneliner Simultaneous

Fault feature. As can be seen in Figure-9 the resulting SLG fault trips the 70kV circuit breaker at

Station A, since the conductor on the other side of the opened phase is still suspended on the tower

the relays on the Station B side of the line do not detect the fault. The fault continues to be back

fed from the HV ground and tertiary winding of the transformer. The resulting fault current is not

high enough to operate the transformer fuses, but the resulting tertiary current can be many times

the rated value resulting in eventual transformer failure. The mitigation features listed below can

be used to prevent this type of failure.

Mitigation Methods:

The following methods can be used to mitigate this protection deficiency.

Unground the HV winding this will remove the zero sequence path from the HV
winding thereby removing the fault.
o If this method is used ensure the HV winding, H0 bushing, and lightning
arrestors are rated for L-L voltage (For transformers 69KV and above
graded insulation toward the neutral, therefore this is not an option).
Trip station HV circuit breaker (if available).
o A tertiary relay can be installed to trip the station breakers (this may not be
an option if the bank was fused in the first place).
Fuse the tertiary winding This will also open the zero sequence path thereby
removing the fault after the faulted phase fuse operates.
o Ensure the fuse coordinates with transmission and distribution ground
relays. Due to the size of the fuse and the magnitude of the resulting tertiary
fault current there may be a problem coordinating with downstream and up
stream ground protective devices. Subsequent operation of this fuse may
not be detected resulting in an open tertiary winding resulting in power
quality problems, notably triple harmonic distortion on the loads served by
this transformer.
Open the tertiary winding.
o Discuss with the transformer manufacturer whether the transformer can be
operated with the tertiary winding open.
o Since this winding is used to suppress third harmonic currents from the
transmission system operation of this winding open should be discussed
with the distribution engineer to determine if there have been power quality
issues or complaints related to electrical noise on the feeders served by this
transformer.
Transformers with a virtual tertiary winding configuration where the tertiary
is not accessible. For transformers with a virtual tertiary opening the tertiary
winding is not an option. The following alternatives are available:
o Do not fuse the bank, install circuit interrupting device.
o Install CT and relay on HV neutral and trip station HV breakers, if available
or trip LV feeder breakers.
It should be noted with the tertiary winding open either intentionally or when the tertiary
fuse operates the tertiary winding will no longer feed the fault, however load will continue
to be supplied from the remaining two phases resulting in single phasing the load.

9/16

Wye Ungrounded Delta Wye Grounded.

The Wye Ungrounded Delta Wye grounded configuration is another one of the more common
configurations on the PG&E system. Operating with the HV winding ungrounded is limited to
70kV and below, where the HV winding and Ho bushing is fully insulated for the LineLine
voltage. At 70kV and above windings generally cannot operate with the neutral lifted since the
windings consist of graded insulation, where the H0 portion of the winding is rated at 12kV.
For a single line to ground fault on this type of winding configuration when the fuse operates the
lifted HV ground opens the zero sequence path thereby extinguishing the fault. It should be noted
the loads supplied by this transformer will be single phased. The sequence network for this
winding configuration for an A phase SLG fault is shown in Figure 10.

Z1

V1

_
+
Zsys1

Z1 h-l

Z2

3Z f
Zsys2

Z2 h-l

Z0

Z0 t-l

Zsys0

Z0 h-t

Z0 l-t

Figure 10
A phase SLG with HV winding H0 lifted, before the fuse operates

10/16

Z1

V1

_
+

1:1

I1
Zsy

I1

Z1 h-l

Z2
I1
Z0

Zsy

I1

1:1

Z2 h-l
1:1
Z0 t-l

Zsy

I1

I1

Z0 h-t

Z0 l-t

Figure 11
SLG after A phase HV fuse Operates

Figure 11 shows the sequence network after the fuse operates, in which I1 will go to zero. Figures
12 and 13 show the fault current simulation associated with the fault for an A phase single line to
ground fault, before and after the fuse operates.
Ia = 5800 amps

IA = 600 amps

Ib = 0 amps

IB = 300

12kv bus SLG

fault
5800 amps

Ic = 0 amps
IC = 300 amps

1941

Figure 12
70/7.2/12.47kV XFMR Ungrounded HV Wye w/ 125E Fuse
SLG fault before fuse blows
IA = 0 amps

Ia = 0 amps

Ib = 0 amps

IB = 0 amps

12kv bus SLG

fault
0 amps

Ic = 0 amps
IC = 0 amps

0 amps

Figure 13
70/7.2/12.47kV XFMR Ungrounded HV Wye
SLG fault after fuse blows, fault is cleared.

11/16

Single Phase Mitigation Methods

Voltage Unbalance Scheme
Single phasing the LV distribution circuits can result in damage to three phase loads, before
operating personnel can take corrective actions, therefore a method of mitigating the single phase
condition is to install a negative sequence voltage relay. This relay will detect the negative
sequence voltage due to the open fuse trip and lockout the affected feeders. The resulting voltage
vectors for the open fuse are shown below in Figure 14.

Open phase

VA

VB
3VBN
2

3VBN
2

0 volts

VC

Vb

Va

o
Vc

Figure 14
Effects of open phase on LV winding voltage
Primary Winding
voltages
VBC = 3VBN

Secondary Winding
voltages
Vbc = 3VBN

VBN = 3VBN
2
VCN = 3VBN
2
VAO = 0 volts

VbN = 3VBN
2
VcN = 3VBN
2
Vao = 0 volts

Resulting Secondary Per Unit voltages for open A phase

3 + 0i

VC:=

VB:=

VA := 0

( 0) i

a := .5 + .866

a2 := .5 .866

arg ( a) = 120.001deg
arg ( a2) = 120.001deg

VB = 0.866
arg ( VB) = 180deg

arg ( VC) = 0 deg

12/16

Per Unit Value for Sequence Components

va0
1 1 1 VA
va1 := 1 1 a2 a VB

va2

1 a a2 VC

va0 0
va1 = 0.5i

va2

0.5i

Resulting Positive and Negative Sequence Voltages

va2 = 0.5

arg ( va2) = 90deg

va1 = 0.5

arg ( va1) = 90deg

Resulting phase and sequence vectors for an open HV winding A phase fuse.

12kV Phase Voltages for

an A phase SLG Fault

Resulting Sequence Voltages

Va1 3.8kV @ 90 deg

Vb 6.6kV @- 180 deg

Vc 6.6kV @ 0 deg
Va2 3.8kV @ -90

13/16

Negative phase Sequence Overvoltage Scheme

The above negative sequence voltage can be detected by the installation of a negative sequence
relay on the Low Voltage (LV) bus The negative sequence relay will pick-up once the HV
winding fuse operates tripping the feeder breakers connected to the LV bus. This element can be
time delayed on the order of seconds thereby protecting the single phase loads and allowing
coordination with transmission and distribution protective devices.
The use of the negative sequence relay can also be used on transformer configuration with the
fused tertiary; once the HV winding fuse and tertiary fuse operates the negative phase voltage relay
will also operate tripping the feeders prevent single phasing of the connected loads.

Feeder

Breakers

12MVA
70/12.47kV
HV Wdg
Ungrounded

52-1

52-2

52-3

Negative Sequence Voltage

relay installed to tri p and
lock out feeder breakers.

47

Figure 15
Example of Phase Voltage Negative Sequence Tripping for fuse
protected XFMR

14/16

Tertiary Overcurrent Scheme

Another alternative to the voltage unbalance relay is the installation of a tertiary overcurrent relay.
In this scheme a CT and time overcurrent relay is placed in the tertiary delta to monitor tertiary
current. See Figure 16. During an open phase or severe unbalance condition the tertiary winding
will have circulating current. The overcurrent relay will be set at a percentage above the tertiary
rating and trip the feeder breakers when the pick-up value is reached. Operation of this relay will
protect the tertiary winding from overload due to an unbalanced or blown HV fuse condition. It
should be noted that for a sustained SLG fault on the LV bus, tripping the feeder breakers will not
protect the transformer.

12MVA
70/12.47kV
HV Winding
Grounded

52-1

52-2

52-3

51TT

Figure 16
Tertiary over current relay installed to trip and lock out feeder breakers

HV Neutral Overcurrent relay

If the tertiary CT is not available or for a three phase transformer with a virtual tertiary a CT in the
HV neutral can be installed and the same time overcurrent relay can be installed. The setting for
the HV neutral relay should be based on the HV neutral current that flows when rated current
flows in the tertiary. The bank OA rating can be used to determine the relay setting. If the tertiary
rating is not listed on the nameplate, or if there is no tertiary winding, assume a capability of 20%
of the main winding. The neutral overcurrent relay will only detect zero sequence current the
resultant current will be 3Io. As with the tertiary overcurrent relay this relay trips the feeders
protecting the tertiary from an overload due to a blown fuse, it will not protect the transformer
from a sustained LV fault.

15/16

Summary
Fusing transformers is not as straight foreword as it seems, certain winding configurations can lead

to sustained faults that cannot be cleared even after the faulted phase fuse operates. Care should be

taken to ensure fault simulations take into account the unique winding configurations to ensure the

transformer is fully protected with the designated fuses, both before and after the fuse operates.

For those transformer configurations where fusing may not adequately clear a sustained fault there

are mitigation measures that can be taken to eliminate the issue. If these methods cannot be

applied fuses should not be used and a three phase interrupting device should be applied.

Author: Mike Jensen

Affiliation: Pacific Gas and Electric Company

References:

Protective Relaying Principals and Applications by J. Lewis Blackburn 1st edition.

IEEE Std C37.91 2008 IEEE Guide for Protecting Power Transformers

Biography:

Mike Jensen is a Supervising Protection Engineer with Pacific Gas and Electric, with 17 years of

transmission protection, substation design, nuclear power plant maintenance and design

experience. Served 6 years in the U.S. Navy on board nuclear submarines. Received a BS in

Electrical Engineering from California Polytechnic University, San Luis Obispo in 1992 and is a

registered professional engineer in the state of California

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