Condition Monitoring of

Transformers

to manage their life

& Detecting abnormalities

By : Jiten Jesing
Utility Power Test
Authorised Serive Provider
Doble Engg Co of USA
INTRODUCTION

Managing the life of transformers is very crucial for a power

generating and transmission company.

Availability of key electrical assets is a key.

Health of vital electrical apparatus keeps business in good health.

Regular testing, monitoring and trending the health gives a good

picture of how electrical apparatus are performing against their
design parameters.
parameters

CM tests involves a mix of on line and off line as well as laboratory

t t
tests.
 Expected outcome

Expected
p outcome from the CM testing g exercise is to know the
present status of key electrical equipments

Developp an insight
g into remainingg life of equipment/insulation,
q p if it is
to experience normal operating conditions.
Set priorities for maintenance, if any.

Known health status of equipments will help target the right

equipments which requires immediate attention and hence optimize
use of resources and cost incurred.
incurred

Reduce the unexpected or forced maintenance as well as equipment

outage.
outage
Will help improve the over all reliability of operating assets, which is
of importance in Generation plant
Conditionassessmentofelectricalequipments

ConditionmonitoringofEHVclassequipmentwillrequirethe
assessmentsofkeyitem!
.insulation.

LifeofinsulationinEHVapparatusislifeofequipment.

Conditionandlifeassessmentofthetransformerswillinvolve

Mechanicalconditionassessmenttest.
ElectricalTest.
Oil and paper related tests
Oilandpaperrelatedtests.
Typesoftestperformed

DIELECTRIC THERMAL
MECHANICAL
DGA DGA SFRA
Tan Delta Furan Capacitance
Capacitance DC Winding Resistance Exciting
Current
Exciting Current
DC Winding Resistance
TTR
Insulation Resistance
Moisture RS/PPM
Partial Discharge Test
Paper DP
F
ObjectiveofVariousTest: Cap&TanDelta

Capacitance value of insulation is function of insulation

insulationss geometry.
geometry

It is dependant on size of insulation. But once equipment is built, should

remain constant through g out the life.
Regular testing and conformation of test data will prove the structural
integrity of electrical insulation i.e. mechanical condition of the insulation.
Evaluation criteria : To see if test data conforms to previous data or with sister units

Tan Delta test is to know the fundamental electrical characteristics of

insulation.
It describes the phase angle relationship between the applied voltages and
current passing through a specimen.
It represents the quality of insulation and is independent of the equipment
size.
Evaluation criteria : Comparison with Limit Values derived from a large data bank
based on transformer make and class.
 ObjectiveofVariousTest: PartialDischarge

Partial Discharge Detection test is performed on transformers for knowing

the condition of oilpaper insulation in the transformer.

Thermal degradation of insulation, mechanical changes, voltage stress or

other external factors can cause deteriorating condition in EHV insulation.
insulation
Insulation is then vulnerable to premature failures.
Deteriorating conditions or defects within the transformer insulation can
cause partial discharge.

Undetected PD, if persists for a long period, can create permanent damage
to the insulation.
insulation In most cases it results into catastrophic failure of
insulation.

RFI detecting tool can be used to identify electrical PD in a live switchyard

as well on transformers out side switchyard. This tool is very effective in
detecting emerging problems in wide ranging apparatus like
Trafo, Bushings, CT, LA, PTs etc.
SampleData : PDDetectionTrace

Measured RFI trace is from 220KV Transformer

No significant
g PD activity
y observed.
ObjectiveofVariousTest : SFRA

Strong dependence on geometry of internal components.

Detects the movement inside the transformer.

It is like a fingerprint of each transformer.

Very useful test as a baseline because each transformer is unique,

unique tailor
tailor
made.

It can be
b used d as investigative
i ti ti tool
t l to
t check
h k the
th mechanical
h i l integrity
i t it off
transformers.

Very sensitive
V i i and d can detect
d even a smallll change
h within
i hi transformer
f
components like core, windings, tap windings, leads etc.
Sample Data : SFRA

Comparison of three phases among themselves - (As an example )

All three phases should exhibit similar trace and resonance over the range of
test frequency.
frequency This would indicate the sameness
sameness in manufacturing process
as well as winding design. And unchanged condition throughout its service life.
If change in resonant frequency is observed, something has moved ! within
transformer.
Sample Data : SFRA

Comparison between sister units TR-1 & TR-2

Rpphase of TR1 comparedp with R pphase of TR2,, in absence of p
past
test data. Availability of past test data makes assessment accurate
and easy, minor movement can be detected with precision.
Case Example of ICT - Winding
failure

ICT transformer of 220/400KV, 167MVA single

phase

Tripped on a line fault

fault. Re-energized
Re energized and
tripped again on various protections.

First few site tests declared the unit as Failed

and required removal of transformer
transformer.
 SFRA HV to MV Response
13
HV winding response

HV short ckt like response

Comparison with sister unit

 SFRA MV to Neutral Response
p
14

HV short ckt like response

Winding Deformation

Comparison with sister unit

 Case Study 1 (cont.)
15
ShortWinding
Circuitdeformation
response

Inter turn short

Case Example
p of Healthy
y Transformer

Bank of single
g pphase GSU of 630MVA base load
station. Yr-2003, 420/21 KV

Comparison of four identical transformers

Background
Unit tripped on external flashover at W phase Bushing

Protection Operated
Differential

Test
es Performed:
e o ed
-SFRA, C & PF, low voltage tests
Case study (cont.)

External Flashover at W phase bushing

17
Case study (cont.)

External Flashover at W phase bushing

18
 SFRA - HV open ckt Response
19

Magnetized Core

Comparison of 4 identical unit

 SFRA HV short ckt Response
p
20

Nicely Superimposed over freq. band

Comparison of 4 identical unit

 SFRA - LV open ckt Response
21

Magnetized Core

Comparison of 4 identical unit

 Observation
22

Few site tests like Capacitance

p & T D Tests and others were
indicating unchanged conditions of transformer windings.

SFRA traces of four single phase units present similarity of

their mechanical conditions. Clearly there is very good
correspondence between the four units.

Transformer was declared healthyy and returned to service in

two days.
ObjectiveofVariousTest : DGA

Dissolved gases in oil are used to characterize the problem conditions

in operating transformer.

Its a reactive test. Problem occurs first and known later through DGA.
But in most cases it offers plenty of time to prepare for remedial
actions.

Types and amount of gases present in the oil can indicate the type
probable defects and intensity of problem as well

Very well researched diagnostic tool worldwide to know the condition

of transformers
ObjectiveofVariousTest:MoistureinOil/Paper

On line measurement of moisture in oil is performed at site when transformer

is in service.
service
Avoids sampling error, testing errors, sampling valve related issues.
Takes care of moisture dynamics within transformer to a great extent.
Measurement of Relative Saturation of water at a given temperature of
insulating oil.
Moisture in oil is reported instantly at site while transformer is on load. (ideal
condition for measurement)
Water in insulation paper is calculated from RS, PPM and equilibrium curves

Evaluationcriteria:Followinglimitvalues
Condition PPM RS
Good <15<5
Fair15<205<8
ProbablyWet20<308<12
Wet>30>12
Sources of water in transformer

Water may be absorbed by the insulation from

various sources

Exposure to atmosphere during installation and

inspection
From aging of the insulation paper

From Leaks

Ingress through conservator, breather pipelines and

joints, breather etc
From factory when transformer is not sufficiently
dried.
ObjectiveofVariousTest : Furan

When insulation paper degrades, the cellulose glycosidic bonds

start to break apart and release glucose into the oil. Glucose is an
unstable molecule, so it is quickly converted into furfurals.

2FAL is by far the most abundant of the furanic derivatives, and

others are occasionally found in large enough concentrations to
indicate significant paper degradation. Concentration of 2FAL
increases quicker at lower DP as inter fiber bonding begins to
collapse. IMP

High furfurals in oil indicate the cellulose and paper insulation is

overheating First work suggested by Burton et al.
overheating. al in
1984, practiced by Utilities worldwide.
ObjectiveofVariousTest : Furan

the concentration of the chemical furfural in transformer oil has

been well known to be an indicator of the extent to which the paper
insulation of the windings has deteriorated ( and hence the
consumed LIFE )

High concentrations of 2-furfural [2FAL], the predominant

compound, are a clear indication of cellulose paper degradation, as
this is the only
onl type
t pe of material in transformers that yields
ields this by-
b
product.

Measurements are done by High-Performance Liquid

Chromatography (HPLC) method. ASTM D 5837-99
DegreeofPolymerization(DP)Testforpaper

Cellulose material used in transformer insulation is made from

hardwood, softwood and plant fiber.

They offer excellent dielectric property, mechanical strength and ability to be

dried and impregnated with liquid.
liquid

They also are responsible for key weaknesses of the material like it deteriorates at
90 deg C temp and is also Hydrophilic. Offering more challenges to keep it at low
moisture
it l l and
level d achieving
hi i longer
l lif as a result.
life lt

Paper deterioration occurs mainly because of three mechanisms of

deterioration,, Thermal,, Hydrolytic
y y and Oxidative.

Degree of polymerization (DP) test has been used for more than 40 years as a
measure of the ageing condition of the transformer Kraft paper.

It is wellknown fact that the DP provides an estimate of the average polymer size
of the cellulose molecules in paper.
 Generally, Kraft paper in new transformers has a DP of about 1000. Aged
Kraft paper with a DP of about 200 has very low remaining mechanical
strength.

DP value of 200 is considered End of Life for paper insulation. Paper

looses mechanical strength and becomes more vulnerable. Insulation
condition is categorized
g to be in Imminent or High
g risk to failure

The DP can be determined from the measured change of the intrinsic

viscosity using the MarkHouwink
Mark Houwink equation as per ASTM D 424399
4243 99
standard.
COandCO2gases

With deterioration of Kraft insulation paper, degree of

polymerization decreases and CO & CO2 are also generated.

Rate of gas generation increases with operating temperature

of transformer insulation

When insulation paper ( DP value towards 200) is in last leg

of its life,
life CO and CO2 gases rise disproportionately.
disproportionately
Accelerated aging of
transformers
Insulation ageing
g g Paper
p
What about having higher Moisture ( Water ) in
the transformer ?

Lets see some cases how it can affect the

aging of insulation paper

All transformers in case examples are not

more than 14 yrs old and operate at only 40%
of rated load
Case Examples - Deteriorating Transformer
condition

A large number of transformers, nearly 60 of

them, installed at a single location were
suffering from higher moisture.
Maintenance Engineers were unaware about
accelerated ageing, because of higher moisture
present in their transformers
Couple of transformers were running huge
failure risks.
Such failures will cause severe cost
i li ti
implications.
TestData:waterPPMinoil

Water ppm
70
59
60
50 44
40 33 31 36
31 30 30
30 24 26
20
9 12
10 7
0
TR-21
1

TR-22
2

TR-31
1

TR-32
2

TR-41
1

TR-42
2

TR-43
3

TR-44
4

TR-46
6

TR-51
1

TR-52
2

TR-70
0

TR-72
2
Limit values
al es from IS
IS-1866
1866 yrr 2000
72.5KV 20 ppm / 170KV 15 ppm, above 170KV- 10 ppm
TestData:RelativeSaturationofwaterinoil

RS (%)
50
45
40 38
36
35
30
25
25 23
20 19
17 17
15 13 15 15
10
5 5 4
5
0
TR21

TR22

TR31

TR32

TR41

TR42

TR43

TR44

TR46

TR51

TR52

TR70

TR72
RS measurement at temp higher than 55 C, used to
calculate water in paper.
MoistureContentinPaperInsulation Estimated
MoistureContentinPaperInsulation

Excessive moisture
6.0 & Accelerated ageing
4.9
5.0
4.0 39
3.9 4.1
4.0
3.5
3.0 2.7 2.9
3.0
2.3 2.5
2.0
1.3 1.4
1.0
1.0

0.0
TR-21

TR-22

TR-31

TR-32

TR-41

TR-42

TR-43

TR-44

TR-46

TR-51

TR-52

TR-70

TR-72
InsulationResistancedata

IR in Mega Ohms
1000000
136000
100000

10000 6390
2290 2980 2510
1200
1000
294 185 220
85 55 51 106
100

10

1
R-21

R-22

R-31

R-32

R-41

R-42

R-43

R-44

R-46

R-51

R-52

R-70

R-72
TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR
Test data : Tan Delta - CHL

CHL (%)
6
5 03
5.03

4
3.54

1.96 1.75 1.84 1.79

2
1.24 1.46

0.65 0.78
0.59
0.18 0.17
0
21

22

31

32

41

42

43

44

46

51

52

70

72
TR2

TR2

TR3

TR3

TR4

TR4

TR4

TR4

TR4

TR5

TR5

TR7

TR7
Testdata : PolarizationIndex

PI
1.82
1.75
1.7
1.58
1.52

1.32
1.19 1.16
1.2
1.06 1.08 1.06 1.06
1.03 1.01

0.7
TTR21

TTR22

TTR31

TTR32

TTR41

TTR42

TTR43

TTR44

TTR46

TTR51

TTR52

TTR70

TTR72
Test data : Furan level in oil ( 2FAL )

2FAL
1884
729 796 905
425 418
400
192

23 21
20 13
8
5 5

1
TR21

TR22

TR31

TR32

TR41

TR42

TR43

TR44

TR46

TR51

TR52

TR70

TR72
 Estimated DP

Estimated DP
Ageing
1150 1086 1086 faster
1028
1050 967 than
950 897 908 others
close
850 to
750 end
633 of
650 535 537 life
550 457
468 441
450
350
350
250
150
R-21

R-22

R-31

R-32

R-41

R-42

R-43

R-44

R-46

R-51

R-52

R-70

R-72
TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR

TR
End
of
life
 Overview of all transformers
Transfo IR(M) (%) Remain
Estimat
rmers
rmers % RS
%RS ppm CHL PI 2 FAL Moistur
2FAL ing Life
ingLife
1min 10min edDP
ID e (%)
TR21 16.8 31 0.65 1920 2290 1.19 13 3.5 967 100
TR22
TR 22 5.0 9 0.18 4190 6390 1.52 8 1.3 1028 100
TR31 13.5 24 0.59 2260 2980 1.32 23 2.3 897 97
TR32 14.6 30 0.78 686 1200 1.75 5 2.5 1086 100
TR41
TR 41 17 2
17.2 33 1 24
1.24 74 85 1 16
1.16 425 30
3.0 535 71
TR42 5.5 12 1.46 1590 2510 1.58 21 1.4 908 98
TR43 14.8 31 1.96 52 55 1.06 729 2.7 468 62
TR44 18 6
18.6 26 1 75
1.75 49 51 1 08
1.08 796 29
2.9 457 60
TR46 3.6 7 0.17 74700 136000 1.82 5 1.0 1086 100
TR51 22.8 30 1.84 286 294 1.03 192 4.0 633 81
TR 52
TR52 37 6
37.6 44 5 03
5.03 184 185 1 01
1.01 905 49
4.9 441 58
TR70 25.1 36 1.79 207 220 1.06 418 3.9 537 72
TR72 35.6 59 3.54 100 106 1.06 1884 4.1 350 41
ThankYouAll.

JitenJesing
p @g
uptbaroda@gmail.com