Contribution of inrush current to mechanical failure of power transformers windings

This work presents a study regarding the contribution of inrush current to the occurrence of mechanical fatigue in windings of a power transformer and, consequently, the impact of that phenomenon on the equipment's lifetime. In order to perform the study, electromagnetic transient simulations were used to determine the inrush current in a three-phase transformer model. Then, three-dimensional simulations, based on the finite element method, were performed to determine the electromechanical stresses in the equipment windings, under the effect of the inrush current. Next, the methods of critical plans and Palmgren–Miner were applied to perform the fatigue study. From the results, the impact of inrush current on the integrity of the transformer's windings was determined, as well as, to estimate the reduction of lifespan of the equipment due to inrush occurrence. The number of inrushes needed for the total reduction of lifespan of the equipment due to mechanical fatigue was also determined. The results can be used in the transformers design stage, with the purpose of assisting the evaluation of mechanical withstand of equipment, which can minimise the possibility of failure and increase its lifespan.