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15-108

Session 2002
CIGR

EHV CURRENT TRANSFORMERS - FAILURE MODE ANALYSIS & EVALUATION

LEADING TO CORRECTIVE AND PREVENTIVE ACTIONS FOR RELIABILITY
ENHANCEMENT
PRAMOD RAO*
J.G.KULKARNI
CROMPTON GREAVES LIMITED
(INDIA)

V.K.PRASHER
POWERGRID
(INDIA)

P.J.THAKKAR
POWERGRID
(INDIA)

y Evaluation of Oil Samples from all the CTs for

1.Introduction
The Instrument Transformers (CTs , VTs , CVTs ) &
Condenser Bushings are the important components of
the EHV Substations & the Power Systems and are
expected to be maintenance free , and have a troublefree
service life higher than 25 years. Many times the
catastrophic failure of the equipment involves damage to
the other nearby equipments. This leads to the outage of
power , and also leads to the costly reconditioning /
repairs / replacement of the defective equipments. In
majority of the cases , the defective equipments have to
be sent to the manufacturers works . In all such cases it
is necessary for the utility & the manufacturer to jointly
arrive at the corrections , corrective actions &
preventive actions. The joint working by the utility &
the manufacturer leads to shortening the time to
investigate & time to implement the corrective &
preventive actions.
This paper presents the results of a systematic
investigative work on 420kV Class Current
Transformers jointly carried out by the utility and the
manufacturer.Three Numbers of Current Transformers
had failed within 24 hours of commissioning them.The
investigation of failure phenomenon was necessary from
the view point of assessing the health of about 69
balance CTs , which were required to be put into service
immediately.The broad steps taken during the
investigation process were ;

y Strip Down Analysis of the Failed CTs.

* Crompton Greaves Ltd. ,
A3-MIDC , Ambad , Nashik , India

BDV , TanDelta , Moisture Content , Dissolved

Gas Analysis.

y Based on the database generated , Identifying the

CTs , which need correction at works.

y Evolving new tests to support the investigation &

identifying the correction procedure.

y Service DGA Analysis and evolving the norms.

The joint investigation resulted in effectively completing
the investigation process in a period of six months.
Key Words - Current Transformer (CT) , DGA , PD ,
TanDelta.
2. The Failure Phenomenon
Three Numbers of 420kV Current Transformers failed
within 24 hours of commissioning the system. It was
also observed that the CTs undergone day & night
temperature variation cycle , before the failure took
place. There was no abnormality (such as overvoltages /
surges ) noticed in the system at the time of failure. This
means that the CTs were working at rated voltage. All
the three CTs were installed in Y Phase. In all the CTs
the Stainless Steel Bellows (provided for compensating
the oil volume variations) had expanded to its elastic
limit.
After stripdown analysis of the failure it was found that
the Insulation failure has been seen on the P1 side of
the insulation provided on the aluminium shell which
houses secondary cores.

On the P1 side , the insulation was also observed to be

flattened. The CTs are packed and transported with P1
side on the bottom. In one of the CTs , it was found that
the shell , which is a aluminium cast component , had
rough surface finish. The Porcelain Insulator was found
to be intact & the paper insulation in the region of
porcelain insulator was found to be intact i.e. It didnot
have any burn marks / puncture marks. The Secondary
Winding & all other connections were found intact and
this was confirmed by electromagnetic tests on the
secondary windings.
3. Oil Sample Evaluation
Subsequent to the CT failures , it was decided to takeout
oil samples from all the balance CTs , after minimum 2
hours of trial charging. The main interest was to findout
and ascertain whether the two hours of charging results
into generation of gases.
The Averages Oil Test Results are summarised below ;
y BDV of Oil = 58kV.
y PPM Content of Oil = 8 ppm.
y Tan Delta at 90 Deg. Cent. = 0.0024.
y DGA Results

H2 = 20 ppm.

CH4 = 2.4 ppm.

C2H2 , C2H4 , C2H6 = Less than 1 ppm.

CO = Less than 150 ppm.

CO2 = Less than 150 ppm.

y CT Serial Number 1 :- PD , Capacitance &

TanDelta are within limits.

y CT Serial Number 2 & 3 :- PD Inception Voltage

was found to be around 70kV (much lower than
rated voltage) & PD at 267kV was around 200 to
300 pC.
It was decided to apply 630kV for one minute & repeat
the measurements of PD , Capacitance & TanDelta. All
the three CTs withstood the application of 630kV ,
without any change in PD , Capacitance & TanDelta. All
the three CTs , before they were despatched to site had
shown partial dischargefree performance & after about 2
years of storage at site , two CTs had shown high PD.
In order to simulate the condition of failure , it was
decided to carryout long duration voltage evaluation test
on one of the CT (CT Serial Number 2). It was decided
to apply 267kV (1.1 x HSV/Root3) for a period of 12
hours in the night time. A metal stick with markings for
bellow level was fixed nearer to the bellow , to observe
the bellow level during the test. In view of this metal
stick , shield was not placed on the CT & hence PD
Values were recorded for information only.
The test was started at 21.30 Hours (in the night time to
simulate extreme variation in the ambient temperature).
After about 5 hours of voltage application , the bellow
expanded beyond its elastic limit & Voltage Source
Transformer tripped on overcurrent protection. The
Capacitance , TanDelta measurements didnot show any
variation.

All the CTs had the Oil Results within acceptable limits
, except for three CTs. The healthy CTs were cleared for
charging & it was decided to monitor the bellow levels
during the first 24 hours. The bellow level would have
gone up compared to the balance CTs if there would
have been gas generation.

Hence it was decided to increase the voltage to get the

failure marks in the CT. However the system tripped at
125kV. The CT was opened for detailed investigation of
the failure. The observations are summarised below ;

Three CTs showed abnormal Dissolved Gas Contents ,

described below ;
CT Number 1 :- CH4 = 16 ppm.
CT Number 2 :- H2 = 240 ppm.
CT Number 3 :- H2 = 284 ppm.

side & puncture was observed in the insulation

right upto the shell.
y Nearer to the failure end point a sharp point was
observed on the aluminium cast shell.
y Paper burning marks were seen on P1 side of the
insulation. However they vanished after removing
about 20% of the insulation.
y During the long duration test , about one and half
hour before the failure , the PD values suddenly
started rising at a higher rate & this was
accompanied by corresponding rise in bellow level.

These three CTs were decided to be withdrawn from

service & were brought back to manufacturers works
for further investigation.
4. Investigation on CTs with High Gas Contents
After the CTs were brought back to works , electrical
tests were decided to be conducted. Capacitance ,
TanDelta , Partial Discharge measurements were carried
out. The test results are summarised below ;

y Burnt Oil smell was felt , while removing oil.

y Burning marks were seen on the insulation on P2

Bellow Level

Bellow Level Visual Observations

35
25
15
5
21.30 23.30 01.30 03.00
22.30 00.30 02.30
Hours

PD Observations
60

PD in Thousands

50

It was also found that inspite of PD & presence of gas

saturated oil , the CTs withstood the 630kV application
for one minute. Hence it was decided to remove the
suspected gas saturated oil from CT No. 1 & 3 and
reflood the CTs with a freshly degassed new oil under
vacuum.
After this oil change process , CT No.3 was subjected to
long duration test like CT No.2. The CT successfully
withstood the Long Duration Voltage Evaluation test in
the night time for a duration of 12 hours. DGA analysis
was carried out to confirm the health of CT after the test.
The results showed all gas contents within limits.
Subsequently all routine dielectric tests were carried out
and the DGA was repeated. The CT withstood all the
tests satisfactorily. The CT was then despatched to the
site & is in satisfactory service for more than one year.
This confirmed that Air / Gas Saturated Oil in the CT ,
can lead to product failure within first few hours / days
of charging.

40

5. Repeat DGA to confirm health of CTs in Service

30
20
10
0
21.30

22.30

23.30

00.30

01.30

02.30

03.00

Hours

In the conclusion after this long duration voltage

evaluation test , it was found that ;
y PD Behaviour of CT No.2 & 3 , as observed on the
oscilloscope , is attributed to discharges in oil due
to gas / air saturated oil.
PD Waveform - CT 2 , 3

In order to evaluate the health of CTs which were in

satifactory service , it was decided to carryout the
second DGA after a service period of one to three
months. In order to limit the Oil Quantity drawn from
the CT , a special 250mL Stainless Steel Bottle was
specially developed. Before this analysis was carried out
, based on the experience and analysis of technical
literatures below given limits were set for absolute
values of various gases , when the sample is drawn after
one to three months of service ;
y H2 = 70 ppm.
y CH4 = 10 ppm.
y C2H2 , C2H4 , C2H6 = 10 ppm.
y CO = 280 ppm.
y CO2 = 560 ppm.
DGA Results of Two Typical CTs (Before & After
Service) are shown in the table given below ;
Gas
H2
CH4
C2H2
C2H4
C2H6
CO
CO2

The sudden increase in PD & Bellow level in last

hours of testing indicates that there has been
cascading of discharges in oil combined with
lowering of the ambient temperature during the test.

Before
22
2.69
0.17
0.32
0.88
74
135

CT-A
After
23.7
2.74
0.33
0.41
0.96
69
113

CT-B
Before
After
35.2
38.3
1.76
1.44
0.16
0.11
0.2
0.15
0.15
0.11
166
145
161
118

It was observed that for all the CTs the DGA were well
within the limits mentioned above. However majority
CTs showed that the DGA was well within the limits set
for new CTs given below ;

y H2 = 50 ppm.
y CH4 = 5 ppm.
y C2H2 , C2H4 , C2H6 = 5 ppm.
y CO = 250 ppm.
y CO2 = 500 ppm.
One more conclusion was drawn based on the analysis
that only when the Absolute Limits set are exceeded
even for one gas , then only the analysis should be
carried based on various gas ratios.
It was also decided that the DGA should be repeated
after about 18 months of service and the limits set for
the DGA are as under ;
y H2 = 150 ppm.
y CH4 = 20 ppm.
y C2H2 = 15 ppm. , C2H4 & C2H6 = 20 ppm.
y CO = 400 ppm.
y CO2 = 800 ppm.
6. Investigation Type Tests
In order to confirm that only Air / Gas Saturated oil was
the reason for failure of CTs , it was decided withdraw
one CT after about 2 months of satisfactory service.
This CT was routine tested & despatched 2 years prior
to the date of investigation testing. The Series of Tests
carried out were ;

y Capacitance , TanDelta & PD Measurements.

y Measurement of Coefficient of TanDelta.
y Thermal Stability Test ( Application of Voltage &
Current Together ).

y Lightning Impulse Test.

y Chopped Lightning Impulse Test.
y Dry & Wet Switching Impulse Test
y Capacitance , TanDelta & PD Measurements after
the Investigation Tests.
Since the standards do not prescribe the Impulse Test
procedure & test levels for a two year old CT , below
given procedure was adopted ;
y Lightning Impulse Test
y 3+ve & 3-ve Shots at 1140kVp (80% of 1425)
y 3+ve & 3-ve Shots at 1282kVp (90% of 1425)
y 3+ve Shots at 1425kVp , 1-ve Shot at 1425kVp
, 2-ve Chopped Impulse Shots at 1638kVp
(115% of 1425) , 2 -ve shots at 1425kVp.
y Switching Impulse Test
y Dry - 5+ve Shots at 840kVp (80% of 1050).
y Dry - 5+ve Shots at 945kVp (90% of 1050).
y Dry - 5+ve & 5-ve Shots at 1050kVp.
y Wet - 15+ve & 15-ve Shots at 1050kVp.

The CT withstood the entire series of tests successfully .

This was confirmed by DGA carried out after the
Investigation Tests.
The Observations on the Test Results are summarised
below ;
y The Alpha Value calculated based on the results of
Temperature Coefficient Test was -0.001676 ,
which is well within the normal acceptance value of
0.01. This confirmed that the drying &
impregnation cycle has effectively removed the
moisture from paper insulation & there has been no
moisture ingress.
y The CT successfully withstood the stringent
application of Switching Impulse Voltages at rated
levels of 1050kVp , although as per IEC 44-1
correction factor of 10% could have been applied to
reduce the level of voltage.
y Although for wet switching impulse test could have
been carried out only for +ve polarity , it was
decided to apply 15 -ve Polarity shots at 1050kVp.
The CT has successfully withstood the stringent
impulse application.
7. Design Improvements as Preventive Actions
Based on the analysis of various evaluation tests
conducted , the most probable cause of CT failure was
identified as Air / Gas Saturated Oil in the CT at the
time of commissioning the CTs. It was identified that the
gas / air saturation of oil could have taken place during
the transportation of the CTs from works to the site.
Based on the evidences found , design improvements
were taken up & implemented on the products to
prevent recurrence of this phenomenon. Important
design improvement actions are highlighted below ;

y Stainless Steel Bellows clamping area to the top of

tank was widened. In the CTs returned from site for
investigation oil traces were found from this
clamping & sealing locations.

BELLOW

CLAMP NUT
TANK

OLD DESIGN-NARROW CLAMPING FOR BELLOW

y Wider Support mechanism has been provided

BELLOW

CLAMP PLATE

between the active part (i.e. Insulation) & the Tank.

This has been implemented to prevent localised
damage to the insulation during transportation due
to jerks.
8. New Checks / Tests Introduced on the CTs

TANK

NEW DESIGN-WIDER CLAMPING FOR BELLOW

y All Aluminium construction has been adopted on

the CTs in order to eliminate the Gas Generation
due to non electrical activities.
y Flange Type Clamping has been provided for
Aluminium Hood. This Hood covers & supports the
SS Bellows during transportation. It was found that
the earlier Hood clamping construction was not
effective to support the bellows completely filled
with oil , during the transportation.

HOOD

BELLOW

TANK

OLD DESIGN-SIDE WAY CLAMPING OF HOOD

As a result of the investigation & the database generated

following additional checks / tests were introduced on
the Current Transformers ;

y After completing all Routine Tests , Oil Sample to

be taken out of CT & should be evaluated for below
given parameters and should confirm to below
given acceptance criteria ( A routine test for 420kV
CTs & a sample test on one per batch of six 245kV
CTs ) ;
y BDV of Oil = 50 kV (Minimum).
y TanDelta of Oil at 90 Deg.Cent. = 0.005
(Maximum).
y PPM of Oil = 15 ppm (Maximum).
y Resistivity of Oil at 90 Deg.Cent. = 1 x 10 to the
power 12 Ohm-cm (Minimum).
y DGA Analysis ;
 H2 = 50 ppm (Maximum).
 CH4 = 5 ppm (Maximum).
 C2H2 ,C2H4,C2H6 = 5 ppm (Maximum)
 CO = 250 ppm (Maximum).
 CO2 = 500 ppm (Maximum).
The Measurement of Partial Discharges at Highest
System Voltage & 1.2 x Highest System Voltage /
Root3 was implemented as a routine test with 10pC & 5
pC as a limiting criteria.
9. Conclusion

HOOD

BELLOW

TANK

NEW DESIGN-FLANGE TYPE CLAMPING OF HOOD

y Reinforcement of Radial & Axial Cushion Between

Bellow & Hood. This was carried out to restrict the
bellow movement during transport.

As a result of the joint investigation process by the

manufacturer & user , the entire investigation process of
analysing the failure mode & arriving at corrective &
preventive actions has been completed in a shorter
period of six months.
New Testing Procedures were evolved to identify the
defect , like Long Duration Voltage Evaluation Tests ,
using DGA as a tool to identify the health of CT before
commissioning. Also an important learning has been
gained that , one should first verify that the DGA are
within the absolute limits & if any gas exceeds the limits
then only key gas ratios should be used as a tool.
Through extensive database generation on DGA , new
acceptance limits were arrived at for the product before
commissioning & also after service period of 18 months.

Experience has been gained on type testing the product

(which was manufactured two years back & was in
service for 2 months) at its rated insulation levels.
The Design Improvements implemented have
substantially improved the product reliability & new
checks / tests added have been added to assure the
product reliability at product out stage.
10. References
/1/ A.Vaz & M.Silvestre - Instrument Transformers
Field & HV Laboratory Study and Test Program To
Prevent Failures - CIGRE Session 1998 - 12-103
/2/ V.V.Sokolov & Co Authors - Development of
Diagnostic System of 330-750kV Current Transformer
Based on Service Experiences and Endurance Tests CIGRE Session 1998 - 12-107
/3/ A.Mollmann and B.Pahalavanpour - New Guidelines
for Interpretation of Dissolved Gas Analysis in Oil
Filled Transformers - Electra No.186 (Oct.1999).