Classical Maintenance Thinking

Conditional probability of failure

Bath Tub Curve

Infant mortality
Design, Reliability and manufacturing

Useful life period

Preventive and Condition based maintenance

Phase out period

RLA

Age

Indirect Costs in Maintenance

COST OF MAINTENANCE

Types of Faults Random

Non-observable

Time Induced
observable Non-observable

Maintenance Strategies for combating the Above Fault Types

Accept breakdowns Readiness to repair Improve reliability Design out maintenance Condition Monitoring Continuous monitoring Periodic monitoring Periodic overhauls Periodic replacements Reconditioning

MAINTENANCE TERMINOLOGIES

Swedish Standard SS-EN 13306, 2001

Figure-1: Impact of maintenance philosophy on failure rate

Maintenance of Transformer Any equipment in service, specially electrical equipment needs regular maintenance. Electrical equipments in service are subject to electrical, mechanical and thermal stresses. Periodical check necessary to monitor condition. Measure to be taken to rectify defects to avoid total failure. This process of checking and taking corrective action is known as maintenance. Types of maintenance: a.Breakdown maintenance though not best inevitable. b Periodical/preventive maintenance based on periodical tests. c. Proactive maintenance The very cause which affects the transformer is anticipated and avoided.

Predictive maintenance modern technique consisting of tests done using special equipments

These tests can be termed as condition monitoring tests.

No single test can confirm the fault in the transformer. Hence integrated approach is required taking into account results of various tests.

Expertise and experience required to interpret the test results.

BREAKDOWN MAINTENANCE
Equipment Productivity
High downtime Frequent failures Poor quality Reduced safety

Employee Productivity
High work time High waiting time Low morale

PREVENTIVE MAINTENANCE
Planned Maintenance periodicity Advantages
Reduction in failures Enables planning

based

on

Disadvantages
Over maintenance Human intervention technology in equipment

PREDICTIVE MAINTENANCE
Maintenance condition Advantages based on machine

Better availability Reduced maintenance costs Safety and quality Operation and maintenance planning Design Improvements

CONDITION MONITORING
CONDITION MONITORING

SUBJECTIVE (70%)

OBJECTIVE (30%)

SIMPLE AIDS

INSTRUMENTAL TECHNIQUES

CONDITION ASSESSMENT OF POWER TRANSFORMER DEGRADATION OF DIELECTRIC SYSTEM Ageing of Oil and Solid insulation Degradation of oil by oxidation

Oxidation - Acids, sludge and water

CONDITION ASSESSMENT OF POWER TRANSFORMER

DGA - method for detecting incipient faults Degree of Polymerization (DP) test is another method for cellulose insulation health Advanced diagnostic tests - FRA and Dielectric Loss Angle (Tan Delta) measurement

CONDITION ASSESSMENT OF POWER TRANSFORMER Ageing of winding conductor insulation

Dielectric, thermal, electromechanical stresses DP of new insulation >1100 DP of degraded insulation is <=200 Knowledge about water content in insulation and oil both important

CONDITION ASSESSMENT OF POWER TRANSFORMER

Decrease in DP - reduction in mechanical strength Drying of old insulation - brittleness increases Pressing of aged insulation - insulation damage

CONDITION ASSESSMENT OF POWER TRANSFORMER

BUSHINGS i.

ii. Test tap

Typical defects and failure mode

iii. Danger due to tap connection not properly earthed iv. Corrosion of threads on tap connection cap causes high resistance arcing v. Moisture absorption by test tap vi. thermal overloads

Condition Based Maintenance (CBM)

1. CBM is based on Failure Mode and Effects analysis (FMEA) 2. FMEA gives a structured and systematic analysis of critical failure modes. 3. CBM applies diagnostic techniques that link to FEMA like DCRM, DGA, Capacitance and Tan Delta 4. Some utilities claim considerable reduction in O&M costs after implementation of CBM.

Failure Modes and Effect Analysis

1. Understanding the Equipment i.e. its design weaknesses and likelihood of associated malfunctions listing all known malfunctions where they actually winding, oil, tank, bushing etc. originate in each equipment like Transformer Core, 2. Identifying the effects of the weaknesses, particularly 3. Relating the developing fault to diagnostics, fault development

the rate at which a weakness can develop into a fault. particularly to diagnostics that can reflect the rate of

4. Developing and applying diagnostics, using the outcomes to trigger next activities.

Reliability Centered Maintenance (RCM)

(a) RCM methodology requires an intimate knowledge of equipment design and manufacturing standards, various condition assessment parameters, maintenance functions and their impact on equipment performance. RCM applies combination of all techniques including timed based maintenance & breakdown maintenance.

(b) (c)

RCM may show that breakdown maintenance may be the best method for a particular asset / equipment but for other equipment, predictive maintenance may be the best fitted technique.

CBM and RCM concepts

1. Almost all utilities in India carry out Time Based Maintenance (Preventive Maintenance) 2. Need for increased Maintenance use of Condition Based

3. Implementation of Off line and Online diagnostic techniques for assessing deteriorating performance or condition of the Equipment for necessary correction / rectifications before forced outage / failure.

4. CBM and RCM emphasizes need to identify the reasons of forced outages for initiating preventive measures in advance

Reliability Centered Maintenance (RCM)

1. Preventive / Routine Maintenance may be over doing Equipment maintenance. 2. But anything less than required maintenance may lead to unplanned outages

3. Many utilities have stopped doing Time Based Maintenance and introduced Focused Maintenance

4. RCM and CBM both rely on knowledge of reliability & condition to indicate what to do and when.

Benefits of Condition Monitoring

1. Economic Adaptive Maintenance Reduction of Maintenance personnel Minimum period of outage Minimum cost of outage

2. Safety Reduction of risk by early warning Timely technical input Less stress on service personnel

3. Technical Optimum use of operation Optimum use of systems Registration of system problems for future action Better correlation of testing & symptoms Upgradation of standards for tests Life extension & planned replacement

POWER TRANSFORMERS
DIAGNOSTIC TESTS
Tests
IR/PI Tan delta & cap.

Detection capability
Index dryness Dielectric losses

Recovery Voltage Measurement In-homogeneities & Moisture (RVM) level in paper insulation Magnetic balance Turns ratio Winding resistance Dielectric Spectroscopy
(Frequency domain analysis)

Healthiness of core Inter turn shorts Loose or bad conductor joints Level of deterioration of Paper and Oil Detection of incipient faults Continued

Partial Discharge Test (HFCT Technique)

Tests
Frequency Response Analysis (FRA) Surge comparison ONLINE TESTING Acoustic Technique

Detection capability
Mechanical condition, Winding deformation & displacement Inter turn faults Detection and location of Partial Discharge site Detection of Hot spots Healthiness oil * Internal condition By-products of paper ageing

Infrared Thermo-Vision Tests on oil * DGA * Furan analysis

RECOVERY VOLTAGE MEASUREMENT

Paper is a cellulosic material consisting chains of cellulose molecules Ageing causes breaking up of cellulose chains Main byproduct of paper/pressboard ageing is water Paper being hygroscopic retains major part of the water RVM Provides polarisation spectrum of the insulation Polarisation spectrum indicates homogeneity/ inhomogeneity Provides information on moisture content

RVM .Continued
Principle is based on Polarization & De-polarization processes Methodology involves four steps 1. Charging of the insulation by applying a DC voltage (tc) 2. Discharging for a limited time interval (td) (tc/ td=2) 3. Opening of the short circuit & allowing remaining polarization to build up recovery voltage (Vr) 4. Measurement of the recovery voltage Change tc in a time range from 0.02 Sec. To 10,000 Sec. Repeat steps (1) to (4) to get series of Vr values Plot Vr versus tc to get polarization spectrum

Frequency Response Analysis

:

* Reliable tool for mechanical condition assessment of the windings * Transformers subjected to mechanical stresses during transportation short circuit faults near the transformer Transient over voltages such as switching, lightening etc. * Mechanical Stresses cause Winding displacement or deformation Winding collapse in extreme cases Such mechanical defects eventually lead to dielectric faults in the winding
FRA capable of detecting
Core movement Winding deformation and displacement Faulty core grounds Partial winding collapse Hoop buckling Broken or loosened clamping structures Shorted turns and open windings

Principle: * Each winding turn is linked to the other inductively or capacitively Each winding exhibits a characteristic frequency response which acts as the finger print Any winding movement results in substantial changes in the values of L & C at the local level Any winding movement causes changes in the characteristic frequency response Transformer is a complicated network of distributed inductance, capacitance & resistance (LCR network)

Test method: * Consists of application of a sinusoidal signal (2V) to one end of the winding
Typical Test Circuit

* Output voltage is measured at the other end of the winding * Other windings are left open

* Transfer function (Vo/Vi) is measured for three frequency ranges # Low frequency range 50 Hz to 2 kHz # Medium frequency range 50Hz to 20 kHz # High frequency range 5 kHz to 2 MHz

Deteriorating Factors

Bushing insulation integrity degrades due to : Internal Moisture Internal PD & tracking External corona, flashover and tracking Ageing Physical damage

HV Bushings
Condenser Type
Typical condenser bushing design * Insulation Strategically placed conducting wrappings or layers to equalise axial and radial voltage stresses

Degrading factors

Voids conducting particles wet fibers gas bubbles sharp conductors Tracking

Moisture level, Local over stressing

Increased Dielectric Losses Oxidation of paper and oil Chemical decomposition of oil and paper

Partial Discharges

The gases generated inside the transformers are hydrogen and hydrocarbon gases. The causes are: a. Thermal decomposition. b. Electrical stress. c. Electrolysis. d. Vapourisatoin. e. Chemical reaction

DGA FOR NEW TRANSFORMERS

Useful quality control test for new transformers Gas analysis before & after factory tests (heat run test, H.V. Test, temperature raise test) can reveal the internal condition For New Transformers Gas Concentration Are Very Low 2 PPM

Advantage of DGA technique

Avoidance of unplanned outage as transformer defects are detected at incipient stages itself so that timely remedial measures can be undertaken to prevent damage or total loss of equipment Status of health check for transformer periodically Is a quality test for new transformer / repaired transformer before dispatch, installation & commissioning Several cases where transformers have been saved from total destruction, the confidence in DGA technique is so high that the transformers are sent to repairs by no other evidence other than that of DGA

Standards applicable
Sampling of oil IEC 567-971 IS 9434-1992
Extraction of gases

ASTM-831-41 IS 9434-1992

Analysis of gases By gas Chromograph Interpretation of Data -

IS 10593-1992

Assembly & erection

Measurement of winding resistance Measurement of voltage ratio Polarity test Measurement of no-load loss & no-load current Measurement of load-loss & short-circuit impedance Measurement of insulation resistance Dielectric tests

Measurement of winding resistance Measurement of voltage ratio Polarity test Measurement of no-load loss & no-load current Measurement of load-loss & short-circuit impedance Measurement of insulation resistance Dielectric tests Temperature-rise test

Dielectric test Short-circuit test Measurement of zero-sequence impedance of three phase transformers Measurement of acoustic noise level Measurement of harmonics of the noload current Measurement of power taken by the fans & oil pumps

 Separate source voltage withstand test Induced over voltage withstand test Impulse voltage withstand test

 Prior to the short-circuit, transformer is subjected to routine tests. Asymmetrical current The peak current that transformer is required to withstand = Isc(peak)=K Isc
Value of K : x/r 1 1.5 K 1.51 1.64 2 3 4 5 6 8 2.38 10 2.46 >14 2.55

1.76 1.95

2.09 2.19 2.27

This is to ascertain that transformer & its cooling arrangements are effectively designed so that temp. rise of winding & cooling medium does not exceed the permissible limits. Temp. rise limits for Dry type transformers
Class of insulation A E B F H C Temp. rise C 50 65 70 90 115 140

Short Time Withstand Current Test

tests to prove the capability of the CB to withstand the dynamic and thermal stresses due to short circuits. The thermal stresses are determined by the duration and magnitude of the current. The short time current specified is equal to at least the breaking capacity of the Circuit Breaker with time duration ranging from 1.0 to 3.0 seconds. The rated peak withstand current is equal to 2.5 times the rated short time withstand current (i.e., equal to rated short circuit making current of the breaker).

Partial Discharge Tests

AN

100pC 500pC

Standards
IEC 76-1 (1993) IEC 76-2 (1993) IEC 76-3 (1980) tests IEC 76-3-1 (1980) tests, IEC 76-4 (1976) IEC 76-5 (1976) IEC 606 (1978) IEC 616 (1978) IEC 214 (1976) IEC 722 (1982) IEC 726 (1982) IEC 742 (1983) Power Transformers, General Power Transformers, Temperature rise Power Transformers, Insulation levels & Dielectric Power Transformers, Insulation levels & Dielectric External Clearances in Air, Power Transformers, Tapping & Connections Power Transformers, Ability to withstand short circuit Application Guide for Power Transformers Terminal & tapping markings for Power Transformers On-load tap changers Guide to the Lighting Impulse & Switching Impulse Testing of Power Transformers & Reactors Dry type Power Transformers Isolating transformers & Safety isolating transformers Requirements

IEEE C57.12.00-1993 IEEE Standard General Requirements for Liquid Immersed Distribution, Power & Regulating Transformers