LIFI E EVALUATION OF POWER TRANSFORMERS IN SERVICE Zeneral: Power transformers are used to reduce the cost of power transmission by transforming the voltage at which the current is transmitted. The insulation generally used in power transformers is based on oil-impregnated kraft paper as a turn to turn insulation and kraft based pressboard as major insulation between windings and from windings and earth. Mineral insulating oil is used as an impregnate for dielectric and cooling purposes. 1.1 Stresses acting on power transformers: The main stresses aeting on the windings of a power transformer, cither individually or in conjunction, are the following: 1. Mechanical stresses between conductors, leads and windings, duc to fault currents, mainly caused by system short circuits. 2. Thermal stresses caused due to local over heating, over load currents and leakage flux when loading above name plate rating or due to malfunction of the cooling system. Dielectric stresses, due to system over voltages, transient impulse conditions or internal resonance within a winding, 1.2 Deterioration factors and failure mechanisms: The life of the transformer insulation system is governed by the oxidation and thermal decomposition of the cellulose, oxidation of the oil and catalytic effects of the degradation products. During these processes some gases like acetylene (C2Hs), methane (CHa), carbon dioxide, carbon monoxide ete. are generated. ‘The gas bubbles thus formed in the oil, initiate and aggravate partial discharge activity and more and more gases are generated. The processes become cumulative and cause deterioration of the basic insulation of the transformer. The power transformers in operation usually fail as a consequence of the following i) Short cireait faults ii) Local over heating due to circulating currents or the effects of leakage Mux, iii) Insulation failure under electrical stresses.LIFE EVALUATION / E: ‘TENSION PROGRAMME, The important components that have direct bearing on the service reliability and life of the power transformers are the following 1. HIV windings 2. LV windings 3. Bushings 4. Mineral oil The life evaluation of the transformers is a complicated process as it involves several possible failure mechanisms of theit components. Further there is no unique diagnosis method, which can indicate extent of agcing of the insulation under all possible degrading factors. It is essential to understand the basic deterioration processes associated with the various stresses mainly, thermal, electrical and mechanical. In addition, the symptoms, which accompany the deterioration processes, must also be known. The life evaluation programme can be carried out in the following sequence: . Collect historical data on the operation and maintenance of the transformer. 2. Perform visual inspection and examination of the components. 3. Carry out condition monitoring tests on the components 3.1 Historical data: Collection of historical data is a critical step to select the type of tests and inspections, which are sensitive to the likely failure mechanisms. Careful analysis of the data warn of problems which are generic as well as developed over the years due to ageing, ‘A survey of the literature indicates that there are more failures of transformers due to poor maintenance, improper operation, severe weather conditions and manufacturing and design defects due to insulation ageing. By studying the causes of these failures, one can develop strategies to extend the life of the other old transformers. ‘The historical data include the following factor Age of the equipment # Service hours + Number of start-ups Load levels Over loading Major electrical disturbances and faults Vibration and temperature abnormality + Record of repair and replacement of components * Factory and commissioning test results + Results of the diagnostic tests carried out on the equipment from time to timeBy reviewing the operating practices, maintenance data and common mode failures and taking appropriate steps, the remaining useful service life of the transformers can be extended beyond their normal life. 3.2 Visua wspeetion and examination: Visual inspection and examination is an important step in detecting the symptoms of deterioration associated with different stresses. The HV and LV windings of the transformer are not accessible for the inspection. The HV and LV bushings ean be inspected for the following symptoms of deterioration, = Contamination + Symptoms of electrical tracki ng Change in colour due to time-temperature effects + Symptoms of arcing "Change in colour of the oil * Oil leakages + Corrosion * Audible noise / vibrations Electrical tests on wi ing insulation including oil: The progressive deterioration of the insulation of the transformers could be assessed by carrying out certain non-destructive tests. ‘The test parameters will give useful information regarding state and quality of the insulation. By monitoring these parameters periodically, trend in the ageing of the insulation could be assessed. ‘The data obtained over the years could be utilised to estimate the remaining useful life of the transformer to some extent. tion resistan (IR) measurement: The IR indicates whether the transformer insulation is moist (contaminated) or not. The IR values will be usually high (several hundred mega ohms) for a dry insulation system. Mostly the IR reflects the surface conditions of the insulation and can be used as an index of dryness of the insulation. 2. Diclectrie loss angle (tan delta) measurement: ‘The dissipation factor (tan delta) represents the gross defects and overall dielectric losses in the insulation, Fig. | shows the schematic diagram of the HV transformer ratio arm bridge used for the measurement of tan delta and capacitance. In order to, assess thestate and quality of the entire mass of the transformer insulation, following four test schemes are used during the measurement of the tan delta, 2) HV winding versus LV winding grounded to tank. b) LV winding versus HV winding grounded to tank. c) HV winding versus I.V winding (ungrounded), 4) Bushing insulation with respect to test tap. 3 tial discharge (PD) measuremen Partial discharges occur in oil filled transformers due to presenes Voids or cavities in the solid insulation ii) Conducting particles in paper or oil iii) Wet fibres in oil iv) Gas bubbles in oil ¥) Sharp conductor of electrode edges against solid insulation PD may occur due to poor processing, ingress of moisture, trapped air due to incorreet oil filling, fong-term degradation of insulation including tracking and design features Which may produce localised over stressing, Although initially transformers are discharge free. bubbling of oil may take place due to transient over voltages generated during system faults, short circuits etc. and discharges start occurring in the gas bubbles formed [rom the liquid breakdown, These discharges cause chemical decomposition of the oil and carbonisation of the paper High Hydrogen content in oil is usually an indication of internal pattial discharges in the transformer insulation, PD measurement can be applied in the field cither electrically or acoustically. Fig. 2 shows the schematic diagram of the PD measurement on the power transformers, 4, Recovery voltage measurements (RVM): RVM method is an important diz snostic test for power transformers. Polarisation process that occur in an insulating material on application of a DC field is well known in physies. It is believed that the polarisation spectrum together with the conductivity can give a comprehensive picture of the state and condition of the insulating material. In other words. the polarisation spectrum reflects the most significant changes associated with the deterioration process in the insulation. ‘The RVM method is based on the determination of polarisation spectrum by applying DC charging and discharging the transformer insulation as summarised below (Fig. 3).Step 1: ‘The insulation to be tested is charged with a DC voltage of 2.0KV for a certain predetermined time of te. Step 2: The insulation is then discharged through a short circuit for a predetermined time of ty Step 3: Opening the short circuit and allowing the remained polarisation phenomenon to build up a relaxation voltage (V,— recovery or return voltage). Step 4: Measurement of the peak value of the recovery voltage and its time constant Step 5: Changing t, and ty in a range of 0.02 sec to 10,000 sees and repeating the steps I-4, a Scries of values of V, are obtained. Plotting V; as a function of 1c to obtain polarisation spectrum. 5, Surge comparison test: The surge comparison test is an accurate method of identifying interturn faults. A surge voltage is applied to two phases of the HV winding. While testing the HIV winding the terminals of the LV winding are shorted together and grounded to the transformer tank. The ringing pattern is seen on the CRT. The fast rising pulse of the surge voltage spreads along the coil and creates a voltage gradient along the turns. Since the three phases of the winding are wound identically, comparing any two phases will show the same single pattern (Fig. 4). In case of fault in any one of the phases, the wave pattern gel separated indicating the fault 6. Magnetic Balance Test (low voltage exci tion current): The magnetic balance test is carried out on transformers for detection of shorted tums and extensive core problems such as shorted laminations or core bolt insulation breakdown. For carrying out this test the transformer should be de-energised and disconnected from the rest of the system both on FIV and 1.V sides. The HV winding is energised from a 230V or 400V source. The excitation current and the voltages induced on the LV side are recorded. This test is done on individual phases of the 3 - phase transformer. ‘The test voltages should be same for each phase. The results recorded on the individual phases are compared. For a 3-phase transformer, a pattern of two similar currents and one low current is expected. The lower current for one of the phases is usually associated with that winding which is wound on the centre leg of a three legged core, The magnetic reluctance of this phase is lower than the other two phases and therefore results in @ lower excitation current value. The results of this test shall be ‘compared with the factor test results for analysis[ = = lie es Tors ’ vq bots) I ae - Renstrs © Capac: raring Mo. — Wa ndagtle.2 Under test 81 & S21. Synchronous emehing 250 #2 iagram of Surge Comparison test ¥ A-Y Transformers st leads “Test lead Tumper Ht 12 XO 10 X2 HL 13, XO XT Hz Hi X01 X2 HD, SscasaseH| X01 x3 1S. Ti X00 18) Ha Ow XI ¥—Y Transformers ci Ho. XO He HO XO 10 X2 1 Ho XO XS,alle Soper Connection for Surge Comparison test 1, Insulation resistance (IR) measurement: ‘The IR indicates whether the transformer insulation is moist (contaminated) of not. The IR values will be usually high (several hundred mega ohms) for a dry insulation system. Mostly the IR reflects the surface conditions of the insulation and can be used as an index of dryness of the insulati 2. Dicleetric loss angle (tan delta) measurement: The dissipation factor (tan delta) represents the gross defects and overall dielectric losses in the insulation, In order to, assess the state and quality of the entire mass of the transformer insulation, following four test schemes are used during the measurement of, the tan delta. a) HV winding versus LV winding grounded to tank. b) LV winding versus HIV winding grounded to tank. ©) HV winding versus LV winding (ungrounded). 4) Bushing insulation with respect to test tap. 3. Recovery voltage measurements (RVM| RVM method is an important diagnostic test for power transformers, Polarisation process that occur in an insulating material on application of a DC field is well known in physics, It is believed that the polarisation spectrum together with the conductivity can give a comprehensive picture of the state and condition of the insulating material. In other words, the polarisation spectrum reflects the most significant changes associated with the deterioration process in the insulation. The RVM method is based on the determination of polarisation spectrum by applying DC charging and discharging the transformer insulation as summarised belowStep |: The insulation to be tested is charged with a DC voltage of 2.0kV for a certain predetermined time of Step 2: The insulation is then discharged through a short circuit for a predetermined time of ty Step 3: Opening the short circuit and allowing the remained polarisation phenomenon to build up a relaxation voltage (V-— recovery or return voltage). Step 4: Measurement of the peak value of the recovery voltage and its time constant Step 5: Changing t, and ty in a range of 0.02 sec to 10,000 secs and repeating the steps 1-4, a seties of values of V, are obtained. Plotting V, as a function of 1. to obtain polarisation spectrum, nt): 4 Magnetic Balanee Test (low voltage excitation c ‘The magnetic balance test is eartied out on transformers for detection of shorted tums and extensive core problems such as shorted laminations or core bolt insulation breakdown. For carrying out this test the transformer should be de-cnergised and disconnected from the rest of the system both on HV and LV sides. The HV winding is energised from a 230V or 400V source. The excitation current and the voltages induced oon the LLV side are recorded. ‘This test is done on individual phases of the 3 - phase transformer. ‘The test voltages should be same for each phase. The results recorded on the individual phases are compared. For a 3-phase transformer, a pattern of two similar currents and one low current is expected. The lower current for one of the phases is uswally associated with that winding which is wound on the centre leg of a three legged core. The magnetic reluctance of this phase is lower than the other two phases and therefore results in a lower excitation current value. The results of this test shall be compared with the factor test resulis for analysis