CESCs EXPERIENCE WITH ON-SITE DRYING &

REFURBISHMENT OF LARGE POWER TRANSFORMERS

S. Kar Chowdhury
Assistant Manager, CESC Limited, Kolkata.

Abstract:
Power Transformers are the central and most vital components in a substation and are essential to
efficient operation of Transmission & Distribution System of a power utility. To ensure that power
transformers provide long & trouble-free service, varieties of diagnostic tests are carried out and
remedial actions initiated throughout their operational lifetime. One such procedure that is necessary to
ensure that a power transformer continues to serve, as it should, is to do dehydration. The paper
presents our experience with on-site dehydration & refurbishment of power transformers.
1.0

INTRODUCTION:

Power Transformers are one of the most important components of electric power distribution & transmission
systems. Therefore their reliable and efficient operation for many years is of basic importance for a reliable
power utility. The reliability of a power transformer is limited by the reliability of the winding insulation system
mainly, which operates additionally as a heat transfer medium. From the age-old days, the most frequently used
insulations in these devices are the oil immersed paper & pressboard insulations. Due to cost aspects, a
combination of cellulose paper and mineral oil has emerged as the favourite choice, although the longevity of
the insulation depends on the operating conditions, presence of catalysts, oxygen and most importantly water.
Ageing of the oil/paper insulation system of power transformers is influenced by various stresses thermal,
electromechanical and chemical. Thermal stress leads to a major degradation process of both oil and cellulose
paper. Under the effect of all the above conditions, the paper becomes brittle and durability against mechanical
stress is sharply reduced. The process of breaking cellulose molecule chains produces water in the solid
insulation, which acts as a catalyst for further breakdown. Further, the breakdown voltage of the insulating oil
and paper is reduced with increasing moisture content of the oil. The conductivity of a material is a property,
which can be directly related to the moisture content. Thus the knowledge about the conductivity and hence the
moisture contents of the oil and paper can be used as an important basis for onsite drying and oil reclamations.
2.0

ASSESSMENT OF MOISTURE IN TRANSFORMER WINDING:

The paper / pressboard insulation system is very hygroscopic and can still contain moisture, even if the oil has
been completely dried out. As of now indirect methods are available to estimate moisture content of paper.
However, paper ageing and moisture can only be reliably measured by paper samples collected at critical
locations (leads, outer windings etc.) and analyzing them in laboratory. Therefore, solid insulation components
can be examined by opening the transformer and taking samples from the insulation. Obviously this is not
possible in most cases. As of now there is no commonly accepted method for a non-destructive evaluation of
solid insulation.
At present there is cluster / group of methods based on the measurement & analysis of dielectric properties of
insulation available. Diagnosis with these methods is based on the fact that paper and oil change their dielectric
properties with change in moisture levels. Therefore, by measuring parameters like dissipation factor,
polarization & depolarization currents (PDC) and residual voltage (RVM) in the frequency and time domains, it
is possible to relate these changes to water concentration in paper oil system. In our system we are following the
age old methods like dielectric dissipation factor (tan delta) and simple IR & PI values. We have initiated steps
in our transformer preventive maintenance programme, to record the water content in the oil as well as the paper
insulation.
3.0

ADVANTAGES OF ON SITE DRYING OUT

There had been lot of discussions & debates on whether to carryout repairs of power transformers involving
removing entire oil and opening tank covers- exposing the active components. Loss in tariff may be too high to
allow for the application of traditional drying out involving shutting down the transformer for several months
and shifting the same to manufacturers / repairers premises. The transformer insulation may age to the point
where it becomes risky to move the unit. The transformers are risky to be moved because aged insulation
becomes brittle. Shipping the transformer may cause winding displacement and permanent insulation failure. As
far as CESC is concerned, evacuation of bulk power from recently commissioned Generating Station at Budge

Budge to the city centre had been a difficult proposition, considering paucity of space and non-availability of
free hold land within the city precints for installation of power transformers. The existing power transformers in
the 132 kV substations forming the N-S power corridor had nearly outlived their useful life and required major
refurbishment to infuse fresh lease of life. Considering the nature of consumers being served from these
substations, the transformers could not be taken out of service for more than a month at a stretch. On-site drying
out has proved to be beneficial in our case where most of the power transformers have attained 20 years of age
or more.
4.0

SELECTION OF THE TRANSFORMER

Station: Titagarh Receiving Station

Transformer: 50 MVA, 132/33 KV, % Impedance- 10.2, Year of Commissioning 1983
Pre-dehydration parameters:
IR Values: HV/LV/HV-LV= 10/15/10 M-ohms at 55 deg C.
PI Values(600 sec reading / 60 sec reading): HV=1.0; LV=1.0
The oil test results conducted just before dehydration and 5 months prior are given below.

Date of Test
Break Down Voltage (KV)
Acidity
Water Content (at 65 deg C)
Resistivity
DDF (tan delta)

01/01/2004

30/07/2003

60

66

0.355

0.35

55
0.03x10
0.45

48
12

0.055x1012
0.4

Table 1: Oil test result just before & 5 months prior to drying out
Although the health of the insulating oil of the transformer was meeting the requirement of prescribed standards,
the acidity & resistivity were however not up to the acceptable limit. DGA results, carried out 15 days prior to
shutdown indicated no abnormalities. The transformer with total oil volume of approximately 27 KL was
subjected to nearly 25 cycles through a 3000 litre/hr. high vacuum on-line oil filter machine about 5 months
back, without any tangible improvement in IR values of the windings, leaving us with no options but to go in for
complete dehydration for improvement the health of the liquid insulation to a respectable level.
This transformer serves an important link in N-S power corridor. The power from Budge Budge Generating
station is wheeled to the extreme northern limits of the city via Prinsep Street Substation, B.T. Road Switching
Station to Titagarh Receiving Station. The transformer, as the network demands, could only be taken out of
service during the peak winter for about a month. Taking cognizance of the network requirements and system
demands, our team of engineers putting their head together came out with a solution for carrying out thorough
dehydration & complete refurbishment taking into consideration the age of the transformer.
5.0

METHODOLOGY

We, in CESC, during the last 5/7 years have developed our own methodology for on-site drying out of power
transformers of 145 KV class having capacity 50 MVA. Over the years the methodology has been fine tuned to
reduce the shutdown period and at the same time suit our requirement. A few case studies are discussed to throw
light on the practices of on-site drying out & refurbishment of power transformers of 145 KV class.
5.1

Main Tank

The transformer was taken out of service and initial tests like IR values, PI values, tan delta, and separate source
voltage test at 30 KV for both windings conducted. The high voltage test had been conducted in steps of 5 KV
and leakage currents at each test voltage had been noted.
Before the drying out process was started, entire oil was drained out and all fittings & accessories like
conservator, Buchholz relay, bushing turrets, PRV, OLTC DM box, Marshalling box, temperature & oil level
indicators, Radiators & Header pipes, cooling fans & pumps including the HV & LV bushings were removed,
packed separately and stored under shed. The HV bushings were stored in vertical position mounted on suitable

stands. All openings on the fittings and accessories were closed with suitable blanking plates & working
gaskets. All the openings on transformer main tank body were blanked off suitably using blank off plates &
gaskets. Care to be taken to ensure that equalizing connection was made between main tank & OLTC tank.
Suitable dummy bushing were fitted and connected to HV & LV windings. The tap was maintained at position
1, corresponding to maximum winding. At this tap impedance was around 15%.
The process of drying out a transformer is one requiring utmost care and good judgement. If the drying out
process is carelessly or lackadaisically performed, irrepairable damage may result to the transformer insulation
through overheating. In no case shall the transformer be left unattended during any part of the dry out period.
Strict vigil to be ensured and all the observation shall be carefully recorded. As a safety & precautionary
measure, a suitable fire fighting equipment shall be made available near the transformer.
Once the transformer was ready for drying out process, the main tank was jacked up on one side creating a
downward tilt towards the drain plug. Complete washing of Core & Coil assembly was carried out with hot
transformer oil jet to flush out sludge deposit from yoke, oil ducts and base channels. The drain plug was then
opened to drain out sludge and water collected at the bottom of the tank. This procedure was carried out for 3 / 4
times till clean oil was collected at the drain plug. IR reading taken at this juncture reveals substantial increase
in IR values of both HV & LV windings (HV/LV/HV-LV=50/50/50 M-ohms at 20 deg C). Necessary
precaution was to be taken to ensure that tilt angle did not exceed 5-7 degrees. The main tank was then placed
on level plinth. A temperature sensor was inserted into the main tank and positioned just touching the top of the
LV coil, connections taken out through spare terminals of WTI CT board.
The actual drying out procedure was started by gradually drawing vacuum. The vacuum was slowly drawn
from the top of the tank, from zero to 750/755 mm of Hg in a span of 24 hours. The deflection of the main tank
longitudinal walls was noted at vacuum level of 400, 500, 600 & 700 mm of Hg. Once the full vacuum was
reached and deflection of tank wall was within limit, impedance heating of the windings was started by
circulating around 7-8% of rated full load current in the windings. An intermediate transformer was used to
achieve the requisite voltage of around 2000 to 2200 volts, to be applied to HV winding. Since the tank was put
under vacuum, there was no need to put blanket / jacket around the main tank. The outlet air from vacuum pump
was taken through a moisture condensation trap the temperature of the trap was maintained at near zero to
ensure complete trapping of the moisture drawn out from the tank. The near zero temperature was ensured by
solid blocks of ice mixed with common salt. The transformer was kept under this condition till the IR values of
HV & LV windings reached steady state values and also the condensate collection rate tapered out to less than
10ml per day. The daily records of IR values, condensate collected and host of other parameters like core
temperature, ambient temperature, average vacuum etc. were maintained as shown in chart. The IR values when
plotted on time scale exhibited Bath Tub characteristic, as expected.
On reaching steady state IR values of HV & LV windings, the impedance heating was stopped and vacuum was
broken by injecting dry nitrogen and maintaining a positive pressure of 0.10 Kg/sq.cm. The tank filled with
nitrogen was kept for 48 hours after which the tank was again put under full vacuum and simultaneous
impedance heating. At this juncture sharp rise in IR values of both HV & LV windings were observed and every
time N2 charging and vacuum drawing was resorted to, IR values also increased substantially. This cycle of N2
filling and vacuum-heating continued for 3 / 4 cycles till steady state in IR values were obtained.
The main tank was then filled with Hot oil under vacuum with the temperature of oil maintained around 40 deg
C. Before filling in the main tank, the oil should be tested as per IS 335. In case the oil does not meet the
requirement, it should be processed and shall only be used upon meeting laid down norms. When filling a
transformer with oil, it is preferable to pump in the oil from the bottom while drawing vacuum from top, using a
streamline filter machine. The oil level was maintained just above pressing rings / boards of the windings. The
main tank top lid was removed for checking of looseness of pressing ring fasteners and core bolts. Tightness of
Core Earth Connection was also checked at this stage. The sealing gasket of the top lid was renewed before
putting it back. The main tank was then filled with processed oil. The OLTC unit was also filled with clean dry
oil. It is advisable to carryout hot oil circulation in the main tank and selector switch / diverter switch tank
simultaneously to remove moisture from tap changer terminal board / diverter switch cylinder provided in the
main tank. On completion of all schedule activities, all the accessories & fittings that were dismantled were
fitted back after necessary maintenance. Filling of processed oil in radiators, conservators, header pipes, bushing
turrets were carried out through a streamline filter machine. The transformer was then allowed to settle for
nearly 24 hours during which air release from all possible venting points was carried out. The transformer was
thoroughly tested and re-commissioned and kept on light load for 24 hours. During this period behaviour of the
transformer was closely monitored and air release from all venting points carried out after taking shutdown. The
transformer was then put on normal load and subjected to on-line high vacuum filtration by 3000 lit/hr machine
for 7 days.

5.2

Maintenance of Accessories & Fittings

Cooling Radiators:

The radiators, header pipes and associated pipe work and fittings were
thoroughly cleaned, using clean dry oil. Each individual radiator was repeatedly
flushed with clean hot oil to remove deposits of sludge from inside of the
radiator fins. The external surface was thoroughly checked for rust & oil leaks.
The leaking joints were repaired using inert gas welding while rusts were
removed and surfaces cleaned. A fresh coat of primer & synthetic enamel paint
was applied.

LV Bushings:

Plain porcelain bushings are used for connections to LV windings.

The bushings were checked for any cracks & chirpings. In the event of any sorts
of damages found, the bushings are replaced by new ones. The stems were
cleaned and re-fitted with the bushings

HV Bushings:

OIP condenser bushings are used for connections to HV windings. The draw
lead was given a fresh wrap of dry insulating cloth tape. The bushing surface
was checked for cracks & chirps and tested for DDF at 10 KV and IR by 5 kV
insulation tester. Any deviation from accepted values will render the bushings
unsuitable for use.

Buchholz Relay:

The relay was checked for correct operation of mercury switches by injecting
air through the test petcock when full of oil. After mounting, the angle of
inclination was maintained between 5-7 degrees.

Conservator:

The conservator inside surface was thoroughly cleaned and a fresh coat of anti
acid paint was applied. The conservator was retrofitted to accommodate air
cell(atmoseal). The breather pipe line was also modified for correct fit. The
breather pipe line was also checked for internal blockages / obstructions.

Turret/bushing CTs:

The bushing CTs after being dismantled were put in hot box where temperature
was maintained constant at 35 to 40 deg. C. The LT class CTs were given a
fresh wrap of dry insulating cloth tape and again put in hot chamber before reassembly into turrets. The conventional Cast Resin secondary terminal boards
were replaced by oil resistant fibre glass boards, while the secondary terminal
studs were replaced by new ones. The secondary studs were developed in-house
employing double-side sealing arrangement to minimize chances of oil leakage
through the terminal board.

Cooler Fans & Pumps:

Cooler fans were generally checked for damages & low IR in terminal blocks.
In the event of any unwarranted noise from bearings, the same were replaced
and lubricated. The blades were cleaned to remove dust. All the fans were given
a fresh coat of primer & synthetic enamel paint. The pumps were checked for
damages & low IR of terminal blocks.

Temperature Indicators:

Temperature Indicators were mainly cleaned by blow cleaning. The capillary

bulbs were cleaned by buffing. Both Oil and Winding temperature indicators
were calibrated afresh with standard thermometers immersed in hot oil bath.

Magnetic Oil Gauges:

The float levels were checked for smooth up-down movement between the end
positions. Making of mercury contact in Low Oil Level condition was checked
before fitting onto conservator.

Valves & Drain Plugs:

The valves were checked for smooth operation after replacement of the oil seals
of the spindle. The oil seals of the drain plugs were replaced by fresh ones.

6.0

RESULTS ACHIEVED

The water content in the oil before dehydration was 55 ppm, which corresponds to 1.485 litres of water in

approx. 27 Kl of oil. Oil temperature at the time of sampling was 65 deg C.

Applying IEEE empirical curves for moisture saturation in oil, the corresponding moisture saturation in oil was
found to be around 15%. But the moisture content in the solid insulation was observed to be 2.2%. Assuming
that ratio of solid insulation to liquid insulation by weight is 1:10 and assuming density of oil to be 0.89 gm/cc
then weight of solid insulation is estimated to be 2400 Kgs. and moisture content in solid insulation as estimated
was approximately 52.8 litres.
In the drying out process, 13.2 litres of water was collected in moisture trap. Then the balance quantity of 39.6
litres of water remained in the solid insulation, accounting for 1.65%. Consequent improvements in IR & PI
values are as shown below. The IR readings were taken with 1000 V Insulation Tester while the PI readings
were taken with motorized 5000 V Insulation Tester.

HV-LV+E

Before
Drying out
10 Meg Ohms at
65 deg. C

After
Drying out
1100 Meg Ohms
at 30 deg. C

LV-HV+E

15 Meg Ohms at
65 deg. C

880 Meg Ohms at

30 deg. C

HV - LV

10 Meg Ohms at
65 deg. C

880 Meg Ohms at

30 deg. C

Parameters

Table 2: IR values before & after drying out

Parameters

Before
Drying out

After
Drying out

HV-LV+E

1.0

1.54

LV-HV+E

1.0

1.92

Table 3: PI values before & after drying out

Post dehydration oil sampling was carried out after 10 days of putting the transformer on load and also upon
completion of 15 cycles of oil filtration through the oil filter machine. The oil test results are given below.

Parameters
Break Down Voltage (KV)
Acidity
Water Content
Resistivity
DDF (tan delta) at 90 deg. C

Before
Drying out

After
Drying out

60

76

0.355

0.05

55

18

0.03x1012

7.2x1012

0.45

0.005

Table 4: Oil test results before & after drying out

7.0

CONCLUSION

A power Transformer is a costly item in present day terms, not only by way of the capital cost of the equipment
but also by way of loss of revenue and goodwill to a power utility, in the event of its outage. If a transformer is

to render trouble free service during its lifetime, it becomes imperative that it should receive sufficient and
periodic maintenance. A stringent & comprehensive maintenance procedure can ensure a long & trouble free
service life. The principal objective is to maintain the insulation in good stead, which in turn will ensure a longer
service life. Effective maintenance primarily focuses on regular & periodic maintenance, diagnostic testing and
reconditioning, whenever necessary. Condition based maintenance practices need to be adopted where utilities
can ill afford long outage of transformers. Renovation of transformers by drying-out and subsequent
refurbishment at site has proved to be cost effective in infusing fresh life to old transformers. For on-site drying
out by vacuum pulling with simultaneous impedance heating at low currents (7% to 8% of FLC) has proved to
cost effective and time saving. However, utmost care and proper control & monitoring to be exercised during
the entire process of drying out.
8.0

REFERENCE
a) A Guide to Transformer Maintenance by S.D. Myers, J.J. Kelly & R.H. Parrish.
b) Condition Monitoring of Transformer Insulation by Polarisation and Depolaristaion Current
Measurement by Prof. T.K. Saha, Dr. P. Purkait & Z.T. Yao, University of Queensland, Australia.
c) Moisture Measurement during Electric Substation Maintenance a publication of Soluciones
Tecnologicas Avanzadas.

About the Author

S. Kar Chowdhury, graduated in Electrical Engineering from Jadavpur University in 1987. He obtained M. Tech
in Electrical Enginering, specializing in Power System from IIT Kharagpur in 1989. From 1989 to 1990 he
worked as Design Engineer with Development Consultants Ltd. In 1990 he joined CESC Ltd as Engineer, in
Substations Department looking after maintenance of all types of plants & equipments associated with
Transmission & Distribution network. Presently he is looking after Installation & Commissioning of all types of
electrical equipments.

DATE

IR VALUES IN MEG OHMS

LVHV+E
1000+
1000+

HV-LV

08/01/04
09/01/04

HVLV+E
1000+
1000+

CORE
TEMP
O
C

1000+
1000+

24
20

22
20

10/01/04
11/01/04
12/01/04
13/01/04
14/01/04
15/01/04
16/01/04

1000+
1000
950
900
800
200+
750

850
800
800
750
650
200
750

1000+
1000+
1000+
1000+
1000
175
1000+

24
24
25.8
28
29.9
31.8
33.8

20
20
20
22
22.5
21.5
22.0

17/01/04
18/01/04
19/01/04
20/01/04
21/01/04
22/01/04
23/01/04
24/01/04
25/01/04
26/01/04
27/01/04
28/01/04
28/01/04
28/01/04
29/01/04
30/01/04

700
1000+
1000+
1000
1000
1000+
1000+
1000+
1000+
1000+
2000+
2000+

550
1000+
1000
900
900
1000
1000+
1000+
1000+
1000+
1554
1600
N2
1880
2000+
2000+

900+
1000+
1000+
1000+
1000++
1000++
1000+
1000+
1000+
1000+
2000+
2000+
CHAR
2000+
2000+
2000+

34.3
35.3
36.9
39.9
37.4
39.1
37.5
37.7
35.0
35.0
34.0
35.5
GING
38.3
39.9
34.5

20.0
24.0
25
31
24.5
26.5
23.5
23.0
21.5
17.0
17.5
24.0
DONE
28.0
28.0
24.0

31/01/04
01/02/04
02/02/04
03/02/04
04/02/04
05/04/04
06/02/04
07/02/04
08/02/04
09/02/04

2000+
2000+
2000+

2000+
2000+
2000+
N2
2000+
2000+
2000+
2000+
N2
Heating

2000+
2000+
2000+
CHAR
2000+
2000+
2000+
2000+
CHAR
Stopped

32.8
32.8
31.2
GING
33.0
33.0
30.1
29.2
GING
Tank

24.0
24.0
30.5
DONE
23.0
23.0
24
24.0
DONE
Kept

2000+
2000+
2000+

2000+
2000+
2000+
2000+
Imp.

AMB.
TEMP
O
C

CONDENSATE
COLLECTED (ml)
DAILY
CUM.
-Imp.
Heating
550
850
750
500
500
500
450

-Started

AV.
VAC.
mm
Hg.
640
720

550
1400
2150
2650
3150
3650
4100

720
740
745
745
740
740
740

400
450
400
450
400
400
450
350
350
250
200
200

4500
4950
5350
5800
6200
6600
7050
7400
7750
8000
8200
8400
10-30
FILLED
8850
9300

740
740
740
740
740
740
740
740
740
740
740
740
HRS
TANK
750
750

9750
10150
10550
11-00
11050
11500
11700
11850
08-30
Vacuum

750
750
750
HRS
750
750
750
750
HRS

AT (*)
N2
450
450
450
400
400
AT (*)
500
450
200
150
AT (*)
Under

Table 5: Daily Chart showing IR values & water extracted from core & winding

Note: (*) Water collected at Vacuum pump sump (500 + 500 + 350) = 1350 ml.
Total Water collected = (11850 + 1350) = 13200 ml.
Impedance heating Transformer Primary side(400 V) Current : 115 Amps
50 MVA Transformer Primary side current
: 20 Amps
50 MVA Transformer 33 KV side circulating Current
: 85 Amps