3 Guide For Maintence and Diagnostic Approaches

3/16/2012
Transformer Diagnostic
Measurements
Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis, Degree of Polymerisation
(DP) & Furan Analysis
Overview of CPC100 and Operating Software (Toolset)
Electrical Measurements
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary
1
3/16/2012
Topics Guide for Transformer Maintenance
> What is Cigre?

> Overview of Guide
> Maintenance Strategy
> Maintenance Process
> Transformer Component Selection and
Maintenance
> Maintenance Action Catalogue
> Major Work Transformer Repair
> Appendix
OMICRON Page 2
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3/16/2012
What is Cigre?
CIGRE (International Council on Large Electric Systems) is one of the
leading worldwide Organizations on Electric Power Systems, covering
technical, economic, environmental, organisational and regulatory
aspects.
A permanent, non-governmental and non-profit International Association,

based in France, CIGRE was founded in 1921 and aims to:
Facilitate the exchange of information between engineering personnel and

specialists in all countries and develop knowledge in power systems.
Add value to the knowledge and information exchanged by synthesizing
state-of-the-art world practices.
Make managers, decision-makers and regulators aware of the synthesis of
CIGRE's work, in the area of electric power.
OMICRON Page 3
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3/16/2012
What is Cigre?
Through the years, CIGRE has become a meeting place for senior engineers in the field of electrical
energy: researchers, solution providers, utilities, regulators and normalisation institutions, and
generally all electrical engineers involved with electrical power.
Internal Organisation
The work at CIGRE is divided in study committees :
A1 Rotating Electrical Machines A2 Transformers A3 High Voltage Equipment
------------------------------------------------------------------------------------------------------------------------------------------
B1 Insulated Cables B2 Overhead Lines B3 Substations
B4 HVDC and Power Electronics B5 Protection and Automation
------------------------------------------------------------------------------------------------------------------------------------------
C1 System Development and Economics C2 System Operation and Control
C3 System Environmental Performance C4 Systema Technical Performance
C5 Electricity Markets and Regulation C6 Distribution Systems and Dispersed Generation
------------------------------------------------------------------------------------------------------------------------------------------
D1 Materials and Emerging Test Techniques D2 Information Systems and Telecommunications
OMICRON Page 4
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3/16/2012
What is Cigre?
More specifically, issues related to

planning and operation of power systems,
as well as design, construction, maintenance
and disposal of HV equipment and plants
are at the core of CIGRE's mission.
Problems related to protection of power systems,

telecontrol,
telecommunication equipment
and information systems
are also part of CIGRE's area of concern
OMICRON Page 5
5
3/16/2012
> What is Cigre?
> Overview of Guide

Maintenance
> Appendix
OMICRON Page 6
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3/16/2012
Overview of Guide
The guide is a condensed documentation of all activities associated

with transformer maintenance.
It is intended to help transformer users define and apply best practice

for transformer maintence.
The document was prepared with a focus on liquid immersed

transformers rated 69kV and above and larger than 25 MVA can
be applied wider.
Not intended to mandate levels of maintenance. Required

maintenance documentation should be supplied with new
transformers.
OMICRON Page 7
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3/16/2012
Transformer
Operation and
Maintenance
Cycle
OMICRON Page 8
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3/16/2012
Time Based Maintenance (TBM)
Maintenance performed at predetermined intervals to

reduce the likelyhood of equipment failing in service.
Includes routine maintenance actions ( lubrication, oil

change etc.)
Actioned at fixed time intervals.
Provides a high level of risk management if manufacturers

recomendations are followed.
Easiest to plan but most expensive, particularly when an

outage is required.
OMICRON Page 9
9
3/16/2012
Time Based Condition Monitoring (TBCM)
Condition of equipment is evaluated by visual checks,

measurements and tests at regular intervals.
Often performed in conjunction with minor routine

maintenance that requires an outage.
Results of TBCM set the extent of future maintenance

programs.
Information limited to snap shots
OMICRON Page 10
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3/16/2012
Condition Based Maintenance (CBM)
Scheduled according to equipment condition.
Also called Conditional Preventive Maintenance.
Based on assessing the actual physical condition taking

into account its usage, occurrence of events, possible wear
of moving parts and performance of similar equipment.
Use TBCM, OLCM and continuous monitoring to determine

plant condition.
CBM is used when technical conditions can be assessed.
Goal to reduce costs, requires more complicated planning.
OMICRON Page 11
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3/16/2012
On Line Condition Monitoring (OLCM)
Techniques, method or measurement performed while

the transformer is in operation that provide
information about its condition.
May include oil sampling for DGA, infra-red thermal

scanning, load and temperature monitoring or
making visual observations e.g. oil levels or oil leaks.
OMICRON Page 12
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3/16/2012
Continuous On-Line Monitoring (COLCM)
Refinement of OLCM measurements are continuously

recorded.
The monitoring device can initiate an alarm or message when

an abnormal condition arises.
Should be able to reliably predict a likely failure or fault

developing before the event.
Can form the basis for Condition Based Maintenance.
OMICRON Page 13
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3/16/2012
Reliability Centred Maintenance (RCM)
An optimised strategy that accounts for operation time,

technical condition, its location, operational importance
together with safety and environmental factors.
The transformer is assigned a criticality index value.
The interval, content and priority of maintenance tasks are

determined by the index.
Assets in risky or critical positions are maintained in a more

intensive manner.
Usually used inconjunction with a health index.
OMICRON Page 14
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3/16/2012
Standards and Cigre References.
OMICRON Page 15
15
3/16/2012
> What is Cigre?

> Overview of Guide

Maintenance
> Appendix
OMICRON Page 16
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3/16/2012
Maintenance Strategy
For the lifetime of a transformer (>40 years) the

maintenance strategy should aim to provide:
Highest Reliability
+
Minimimal Maintenance
This requires strategies to deal with a variety of

technologies, each needing different levels and scope
of maintenance.
OMICRON Page 17
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3/16/2012
Maintenance Strategy - Importance of Maintenance
Possible impacts of a lack of

maintenance as a function of
age.
Many degradation or failure

mechanisms can be
detacted and eliminated or
minimised by appropriate
maintenance.
Good commissioning
procedures and tests are
essential to build a
foundation for a long service
life.
OMICRON Page 18
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3/16/2012
Maintenance Strategy Early Life
Good Commissioning practices are essential for a sound foundation of early

life maintenance.
Should focus on:

Oil quality.
Functionality of auxiliaries (cooling and tap changer).
Baseline measurements and tests for future comparisions and diagnostics.
Communications, alarms and monoitoring functions.
Little maintenace should be required in the first 5 years except for possibly
OLTC and DGA ( before and after energisation and short intervals
weekly until there is obviously no problems)
OMICRON Page 19
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3/16/2012
Maintenance Strategy - Condition Monitoring
A cost effective maintenance strategy relies on information showing

the condition of the transformer.
Condition monitoring must be technically and economically feasible.
OMICRON Page 20
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Maintenance Strategy - Typical Maintenance Intervals
OMICRON Page 21
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3/16/2012
Oil Tests an example of Condition Based Maintenance
OMICRON Page 22
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Maintenance Strategy Evaluating DGA Results
OMICRON Page 23
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Maintenance Strategy - Continuous On-Line Monitoring
On-Line
Periodic data collection monitoring the transformer condition while it is in
service under normal operation conditions e.g commonly DGA samples or
in special cases Partial Discharge.
Continuous On-Line
Ongoing monitoring to
generate early warnings,
develop a basis for setting maintenance periods
Closely monitor known faults for early warning
Act as a Black Box when a fault occurs with before and after data.
OMICRON Page 24
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3/16/2012
> What is Cigre?

> Overview of Guide

Maintenance
> Appendix
OMICRON Page 25
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3/16/2012
Maintenance Processes
Maintenance Process
Good planning requires guidelines to specify What, When and How.
Organisation answers Who, When, How Long, Access and
Resources
Execution can be either Internal or External resources.
Optimisation by refining processes based on quality data and developments
in diagnostic techniques.
OMICRON Page 26
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> What is Cigre?

> Overview of Guide
> Transformer Component Selection

and Maintenance
> Appendix
OMICRON Page 27
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3/16/2012
Transformer Component Selection and Maintenance
Bushings
Oil Impregnated Paper (OIP)
OMICRON Page 28
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Resin Bonded Paper ( RBP)
OMICRON Page 29
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Resin Impregnated Paper (RIP)
OMICRON Page 30
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Oil Systems
Pressure Regulated Gas Blanket
Conservator Systems
Sealed Tank
Free Breathing
OMICRON Page 31
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Cooling Systems
Pumps, fans, radiators, heat exchangers, gaskets.
Gauges, Indicators and Relays

Oil Level Indicators
Buchholz Relay
Pressure Relief Device
Rapid Pressure Relay
Oil Flow Indicators
OMICRON Page 32
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Controls
Wiring and connections
CT terminations, sensors, fuses, contactors and relays
Filters, heaters, ventilation
Local status indications
Monitoring Devices
OMICRON Page 33
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On Load Tap Changer (OLTC) Typical Maintenance

issues with Drive Mechanism
OMICRON Page 34
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OLTC Typical Manufacture Recomended Maintenance Periods
OMICRON Page 35
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Duty Cycle of an OLTC
OMICRON Page 36
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Transformer Active Parts
Windings
No routine maintenance required.

Older transformers may require the clamping pressures checked especially
after a drying process.
OMICRON Page 37
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Transformer Oil
OMICRON Page 38
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Transformer Oil
OMICRON Page 39
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Transformer Oil
OMICRON Page 40
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Transformer Oil
OMICRON Page 41
41
3/16/2012
> What is Cigre?

> Overview of Guide
Maintenance

> Appendix
OMICRON Page 42
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3/16/2012
Maintenance Action Catalogue
Reasons for Tests

Fingerprint measurement for future reference
Routine tests for determiing trends
Early detect of problems through monitoring
Fault location and troubleshooting
OMICRON Page 43
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3/16/2012
Main focus of on-site tests
Limit the aging effects on insulation oil and insulation material by heat and
dielectric stress.
Identification of failures as thermal or dielectric
Measurement and location of Partial Discharge.
Control of mechanical changes thrugh internal forces.
Trending of moisture content
OMICRON Page 44
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OMICRON Page 45
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Electrical Measurements Basic Measurements - Winding Ratio
Detects Shorted Turns or Winding Sections.

Indication: Buchholz Trip, OLTC Repair
Reference: Intial Test or Nameplate Details
Interpretation: +/- 0.5% of Nameplate
Comments: Some test equipment may allow magnetising current to be
measured concurrently.
Avoid performing resistance test before ratio measurement.
Residual flux could impact the measurement.
Normal after any works that disturbed connections.
OMICRON Page 46
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Electrical Measurements Basic Measurements Winding Resistance
Detects Contact problems on OLTC, diverter switch, broken conductors

or strands, shorted layer or poor bushing connections.
Indication: High internal temperatures, DGA results
Reference: Factory tests, commissioning tests
Interpretation: Within 1% of factory resultstemperature corrected.
Differences between phases 2- 3%. Comparison between
HV and LV approximately square of the ratio.
Comments: HV resistance much higher than LV, there identification of
contact problems more difficult. Need to stablise current
before reading which can take tens of minutes.
OMICRON Page 47
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Electrical Measurements Basic Measurements - Magnetising Current
Detects core faults (shorted laminations) or shorted turns or winding parts.

Indication: Buchholz trip or DGA.
Reference: Comparison of phases, factory or commissioning tests.
Interpetation: Outer phases within 5%, middle phase up to 30% lower.
Comments: Magnetising current at rated voltage is only 0.1 to 0.3 % of
rated current. Voltage dependancy of magnetising current
requires testing at same voltage and tap position.
Avoid winding resistance test before magnetising current
measurement. Residual flux could influence measurement.
OMICRON Page 48
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Electrical Measurements Basic Tests Capacitance and Dissipation

Factor
Detects Capacitance winding change in geometry.

- core to ground mechanical damage.
- Dielectric Dissapation Factor (Tan Delta) deterioration or
contamination of insulation materials.
Indication Moisture, Routine test
Reference Initial tests, trend analysis, comparision to idential units,
nameplate details.
OMICRON Page 49
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Factor
What is Dissipation Factor?
OMICRON Page 50
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Factor
Interpretation For windings 0.5% normal, above 1% questionable

For Bushings
OMICRON Page 51
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3/16/2012

Factor
Additional Information Permissible change varies with make and type.
A doubling of initial values warrants investiagtion or replacement.
A 10% change in capacitance also warrants replacement.
Temperature can affect the Dissipation Factor.
OMICRON Page 52
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3/16/2012
Electrical Measurements Basic Tests Leakage Reactance
Detects deformation of windings

Indication High through currents, high inrush current, Buchholz trip,
protection trip.
Reference Initial tests, comparision to identical units.
Interpretation Within 2% of factory tests, differences between phases
<2%. Changes above 1% should be investigated with other
tests e.g. FRA. Care to be taken when comparing singal
phase to three phase tests.
Comments If measured from LV side results to be corrected by square
of winding ratio.
OMICRON Page 53
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Electrical Measurements Basic Tests Insulation Resistance
Detects insulation deterioration or failures in the winding to core

Indication Buchholz trip, DGA
Reference Initial tests, comparions to identical units
Interpretation Transformers > 69kV, > 1 Gohm, < 69KV, >500 Mohm @
20 deg C
Comments An additional measurement with IR is the Polarisation
Index PI. PI is the IR after 1 minute compared to the
reading after 10 minutes. Initially used on motors. Can be
misinterpretated in complex oil-cellulous insulations.
FDS/PDC measurements preferred.
Can influence FDS/PDC measurements if done prior.
OMICRON Page 54
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Electrical Measurements Basic Tests - Core Grounding
Detects multiple core grounding faults.

Indication High internal temperatures shown via DGA.
Reference Initial tests
Interpretation Normally >10Mohm, less than 100Kohm indactes problem.
Sometimes core lamination packets are separated by
resistors of approximately several Kohm.
Comments In service current from core to tank is mAs. If a fault
develops the current is several amps or higher.
OMICRON Page 55
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3/16/2012
Electrical Measurements Special Tests Frequency Response Analysis

(FRA)
Detects shorted turns, core faults, winding deformations and displacement,
faulty core grounding,faulty screen connections, damage during transport.
Indication High through fault currents, Buchholz trip, DGA, Impact
recorder results.
Reference Time based comparing to previous results
Type based comparing to equivalent type
Phase comparision
Interpretation No defined limits, comparisions indicate changes.
Comments For transport checks measure before departure and on arrival
Winding resistance measurements can influence results.
OMICRON Page 56
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3/16/2012

Electrical Measurements Advanced Tests Dissipation Factor -
Polaristation Depolarisation (PDC) Method
Detects water content in solid insulation of oil paper insulation, insulation

failures, ageing of insulation, contamination of insulation liquids, partial
break down of capacitive bushing layers.
Indication High moisture in oil, general assessment.
Reference Moisture determination by modelling, comparison to
fingerprints.
Interpretation Moisture determination by comparision to a modelled
dielectric response. An algorithm rearranges the modelled
dielectric response and determines moisture content and oil
conductivity.
Comments Also considers the effect of aged pressboard to
compensate for the influence of aging.
OMICRON Page 57
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3/16/2012
Electrical Measurements Advanced Tests Frequency Domain

Spectroscopy (FDS)
Detects water content in solid cellulous insulation, insulation failures,
contaminations of oil.
Indication High moisture in oil, general assessment.
Reference Moisture determination by modelling, comparison to
fingerprints. Moisture limit in IEC 60422.
Interpretation Moisture determination by comparision to a modelled
dielectric response. An algorithm rearranges the modelled
dielectric response and determines moisture content and oil
conductivity.
Comments The combination of PDC and FDS reduces the test duration.
OMICRON Page 58
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Electrical Measurements Advanced Tests Dissipation Factor at

Different frequencies.
Measurement of Dissipation Factor at low frequencies, between 20 and 400
Hz, enables the detection of moisture in bushing with high sensitivity.
OMICRON Page 59
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3/16/2012
Electrical Measurements Advanced Tests Dissipation Factor at

Different frequencies.
Indicative limits for Dissipation Factor in new and aged bushings at 15Hz,
50/60 Hz and 400 Hz.
OMICRON Page 60
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3/16/2012
Electrical Measurements- Advanced Tests Partial Discharge
Detects partial discharge, single insulation faults.

Indication DGA
Reference Factory results, trend analysis
Interpretation Not able to define limits for on-site tests. Used
inconjunction with acoustic methods to localise PD.
Comments PD is important to detect and locate a weakness in the
insulation.The long term effect of PD is distructive. A
significant increase in PD can provide early warning for
developing defects. PD generate electromagnetic waves,
acoustic signals, chemicals reaction, heat and light.
OMICRON Page 61
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3/16/2012
Electrical Measurements Advanced Tests Frequency Response of

Stray Losses (FRSL)
Detects local overheating due to excessive eddy currents losses, short
circuits between parallel strands of Continuously Transposed Conductors
(CPC).
Indication High temperature indentified by DGA.
Reference Comparision of three phases, factory / commissioning tests
Indications Reactance less than 2.5% between phases.
Resistance less than 15% between phases.
Comments Can be performed on LV if corrected by square of winding
ratio.
OMICRON Page 62
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3/16/2012
Electrical Measurements Advanced Tests Recovery Voltage Method
Detects moisture or aging in oil-paper insulation.

Indication High moisture in oil.
Reference Fingerprint, trend analysis
Interpretation RVM in its present form can only be used for trend
indication
OMICRON Page 63
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3/16/2012
Dissolved Gas Annalysis

DGA is a very useful diagnostic tool and is universally applied.
Normal gases measured are Hydrogen H2, Methane CH4, Ethane C2H6,
Ethlyene C2H4, Acetlene C2H2, Carbon Monoxide CO, Oxygen O and
Nitrogen N2.
No consus on absolute maximum levels.
The ratio of gases present can indicate particular problems whithin the
transformer.
The ratio method is discussed in detail in IEC60599.
The Duval Triangle is also a popular tool to assist with the interpretation.
OMICRON Page 64
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Oil Tests
OMICRON Page 65
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3/16/2012
OnLoad Tap Changer
OMICRON Page 66
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3/16/2012
Dynamic Resistance
Measurement
OMICRON Page 67
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3/16/2012
Dissolved Gas Analysis of Tap Changer Oil
OMICRON Page 68
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3/16/2012
Additional OLTC Measurements
Motor Torque Measurement
Vibro-Acoustic Signature
OLTC Oil Tests
OMICRON Page 69
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3/16/2012
Maintenance Inspection Tasks
> Thermography
> Main Tank and Conservator
> Cooling System
Oil Pumps
Radiators and Fans
Forced Oil-Air Coolers
> Accessories (TIs, Level Indicators, Rapid Pressure Rise Relay, Pressure Relief Valves etc.)
> Cabinets
> OLTC
> Buchholz Relay
OMICRON Page 70
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3/16/2012
Insulation Drying
Risks and Consequences of Not Drying Insulation
OMICRON Page 71
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3/16/2012
Insulation Drying
Moisture is generated by:

Remaining moisture when manufactured
Humid air during transport and installation
Humid air through breather
Moisture ingress through gaskets
Chemical decomposition of cellulose
During maintenance
Top up oil has moisture
To dry from 3% to 1 %
OMICRON Page 72
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Insulation Drying
OMICRON Page 73
73
3/16/2012
> What is Cigre?

> Overview of Guide
Maintenance

> Appendix
OMICRON Page 74
74
3/16/2012
Major Work Transformer Repairs
On-Site Repair
Minor replace bushings or OLTC, repair connections
Major Exchange windings, repair core, upgrade
Advantages
Avoid transport problems and risks
Transport costs high
Reduced down time depending on location.
OMICRON Page 75
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3/16/2012
Transformers are classed in 4 catagories to determine appropriate tests
OMICRON Page 76
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3/16/2012
Recomended Tests per Category
OMICRON Page 77
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3/16/2012
> What is Cigre?

> Overview of Guide
Maintenance
> Appendix
> Summary of Diagnostic Tests and Criteria
OMICRON Page 78
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3/16/2012
Appendix 1
Survey results of Systematic Preventive Maintenance Practices
OMICRON Page 79
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3/16/2012
Appendix 2
Summary of SF6 Transformer Particularities
OMICRON Page 80
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3/16/2012
Appendix 3
Operation and Maintenance Manual Content
OMICRON Page 81
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3/16/2012
Appendix 4
Maintenance Recording
OMICRON Page 82
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3/16/2012
Transformer Diagnostic
Measurements
Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis, Degree of Polymerisation
(DP) & Furan Analysis
Overview of CPC100 and Operating Software (Toolset)
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary
83
83

3 Guide For Maintence and Diagnostic Approaches

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3/16/2012

Topics Guide for Transformer Maintenance

> What is Cigre?

A permanent, non-governmental and non-profit International Association,

Facilitate the exchange of information between engineering personnel and

More specifically, issues related to

Problems related to protection of power systems,

Topics Guide for Transformer Maintenance

> What is Cigre?

> Overview of Guide

The guide is a condensed documentation of all activities associated

It is intended to help transformer users define and apply best practice

The document was prepared with a focus on liquid immersed

Not intended to mandate levels of maintenance. Required

Time Based Maintenance (TBM)

Maintenance performed at predetermined intervals to

Includes routine maintenance actions ( lubrication, oil

Actioned at fixed time intervals.

Provides a high level of risk management if manufacturers

Easiest to plan but most expensive, particularly when an

Time Based Condition Monitoring (TBCM)

Condition of equipment is evaluated by visual checks,

Often performed in conjunction with minor routine

Results of TBCM set the extent of future maintenance

Information limited to snap shots

Condition Based Maintenance (CBM)

Scheduled according to equipment condition.

Also called Conditional Preventive Maintenance.

Based on assessing the actual physical condition taking

Use TBCM, OLCM and continuous monitoring to determine

CBM is used when technical conditions can be assessed.

Goal to reduce costs, requires more complicated planning.

On Line Condition Monitoring (OLCM)

Techniques, method or measurement performed while

May include oil sampling for DGA, infra-red thermal

Continuous On-Line Monitoring (COLCM)

Refinement of OLCM measurements are continuously

The monitoring device can initiate an alarm or message when

Should be able to reliably predict a likely failure or fault

Can form the basis for Condition Based Maintenance.

Reliability Centred Maintenance (RCM)

An optimised strategy that accounts for operation time,

The transformer is assigned a criticality index value.

The interval, content and priority of maintenance tasks are

Assets in risky or critical positions are maintained in a more

Usually used inconjunction with a health index.

Standards and Cigre References.

Topics Guide for Transformer Maintenance

> What is Cigre?

> Maintenance Strategy

For the lifetime of a transformer (>40 years) the

This requires strategies to deal with a variety of

Maintenance Strategy - Importance of Maintenance

Possible impacts of a lack of

Many degradation or failure

Maintenance Strategy Early Life

Good Commissioning practices are essential for a sound foundation of early

Should focus on:

Maintenance Strategy - Condition Monitoring

A cost effective maintenance strategy relies on information showing

Condition monitoring must be technically and economically feasible.

Maintenance Strategy - Typical Maintenance Intervals

Oil Tests an example of Condition Based Maintenance