When a transformer is energised, the core can saturate. When the core saturates, the magnetising current becomes non-sinusoidal. This current is called inrush current, and it contains harmonics.
Transformer inrush current is usually dominated by the 2nd harmonic, with DC offset and also significant 3rd, 4th, and 5th harmonic components.
The DC offset matters because it shifts the flux in the core and can push it further into saturation. The 2nd harmonic is typically dominant during energisation, and is one of the reasons transformer inrush looks so different from normal load current.
If one of these harmonic currents meets a high network impedance at the same harmonic frequency, a TOV can occur. The process is:
The same principle applies to magnetic-core shunt reactors — a shunt reactor built with an iron core. Like a transformer, it can saturate during energisation and draw a non-sinusoidal magnetising current rich in harmonics.
Resonance frequency and impedance peak. A resonance close to an inrush harmonic can be dangerous. In a 50 Hz system, 100 Hz is the 2nd harmonic and 150 Hz is the 3rd harmonic. If the network has a high impedance peak near one of these frequencies, the TOV can be higher and last longer. A tall and sharp impedance peak means the system has low damping.
Saturation characteristic. The transformer core design affects how much harmonic current is produced during energisation. A transformer that saturates more strongly can produce higher harmonic current.
Remanent flux. When a transformer is switched off, some magnetic flux can remain in the core. When the transformer is energised again, this remanent flux can increase the saturation level. The worst case happens when the remanent flux and the new flux caused by switching are in the same direction. In that case, the core can go deeper into saturation and produce a larger inrush current.
Adjacent transformers. Other transformers connected nearby can also be affected during energisation. They may saturate through the shared coupling impedance. This is called sympathetic inrush. Sympathetic inrush can make the TOV worse.
Switch closing instant. The instant when the breaker closes affects the maximum flux in the transformer core. For three-phase breakers, the three poles may not close at exactly the same time. This non-simultaneous closing can make the inrush current and the TOV more difficult to predict.
Loading. A loaded transformer usually has lower inrush current and better damping. Therefore, no-load or light-load energisation is usually more severe.
The worst case is not always exactly at an integer harmonic. During transformer saturation, the effective inductance of the transformer changes. Because of this, the resonance frequency can shift during the event.
This means that a resonance slightly below an integer harmonic can still be dangerous. For example, a resonance slightly below the 3rd harmonic may still be excited during transformer energisation.