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60C
40
40C
3. Condition Monitoring
35
25C In order to be able to choose the correct maintenance
activity and specific actions to be carried out, the true
w a te r in o il (p p m )
30
condition of the oil and solid insulation must be known.
25 Regular DGA, though not the subject of this paper, is of
20
course essential, however, tests more directly aimed at
assessing the condition of the oil (and paper) are more
15 valuable.
10
When assessing the degree of ageing of the oil, the most
5
relevant oil tests are acidity, colour, dielectric dissipation
0
factor and interfacial tension. For inhibited oil it is very
0 1 2 3 4 5 useful to monitor the inhibitor content, since very little
water in paper (%)
degradation of oil will occur as long as there is sufficient
Figure 1. Water in Oil versus Water in Paper Equilibrium Curves from inhibitor left. 6
ASEA 1972 Study.
A useful parameter to assess the degree of degradation of
The most important conclusion is that at all realistic oil is the “Oxidation Index” (not to be confused with DP
temperatures, the bulk of the water will reside in the solid of paper). The Oxidation Index is obtained by dividing
insulation. This has several important implications. Most the interfacial tension by the acidity. It has been
importantly, it means that drying a transformer by drying suggested that oil should be reclaimed or replaced when
the oil alone will be a very inefficient and time- this values is lower than 300. 2
consuming business. It also means that estimating total
water content in a transformer from determining the The water content in the oil is strictly speaking just a
amount of water in the oil is complicated and may be reflection of the water content in the solid insulation,
quite uncertain, as will be discussed later. since that is where the bulk of the water resides. A rough
estimate of water content in the solid insulation can be
Let us consider an extremely simplified case, just to made if the temperature is known, and has been stable for
illustrate the difficulties of drying a large transformer by some time. However, there is great uncertainty in the
continuous drying of the oil by degassing. Let us assume accuracy of such an estimate, for several reasons. 3
we have a large transformer, with 10000 kg of cellulose
and that we want to reduce the water content in the solid • It can rarely safely be assumed that equilibrium
insulation from 3% down to 1 %. This means that we has been established. With a cyclic load it will
want to remove 200 kg of water. Let us further assume never be attained.
that we have a constant average temperature of 40C. We
would then have a water content in the oil of 15 ppm. If • There is not a uniform temperature distribution
we reach the desired end-point we would at equilibrium in an operating transformer. The water content in
find approx. 2 ppm in the oil. If we have during the whole different regions will therefore be different. The
treatment an average water content of 7 ppm (very difference between the coldest and hottest areas
optimistic, considering the slow transport of water from can be large.
thick structures!) and treat 3000 kg of oil per hour with a
degasser removing all the water from the oil (also very • Several water in oil versus water in paper curves
optimistic), then we would remove 0.021 kg per hour, or exist. These will differ depending on type of
0.5 kg per day. It would then take 400 days of round-the- paper and oil and the degree of ageing of both.
clock drying of oil to achieve the set goal, even with the
very optimistic assumptions made in this example. In
reality the time would surely take much longer. It is more However, in spite of these difficulties, a rough estimate is
likely to take few years, with a vacuum degasser tied up better than just a “raw” value of water content, especially
full-time and during that period there would be no one without any reference to temperature. If water
possibility to do DGA with any accurate interpretation. content values are converted into a corresponding value at
a reference temperature or a water content of the solid
Water is not the only substance that is distributed insulation, it is more or less a matter of taste, since these
between oil and paper. It is a similar situation with small two approaches really amount to the same thing.
carboxylic acids, furanic compounds and carbon oxides
(CO and CO2), to mention just a few. In all condition It is possible to estimate the water content in the solid
assessments it is important to know if anything has upset insulation in other ways. One approach is to use sensors
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quantity of spent sorbent is problem-free from a disposal request, metal passivator can also be added in the same
point of view, since the last reactivation leaves it free manner, to further improve the oxidation stability.
from oil.
During reclaiming of the oil in a transformer, samples are
drawn regularly to monitor the progress. Changes of
some properties of the oil during treatment are shown in
Fig. 5. N.B That the drying effect is only temporary, since
water will redistribute from the solid insulation into the
oil.
70
60 Colour number x 10
According to legend
40
30
20
10
Table I.
Data from 247 transformers treated in Norway and
Sweden. DDF is Dielectric Dissipation Factor, BDV is
Breakdown Voltage, IFT is Interfacial Tension, DBPC is
content of antioxidant di-t-butylparacresol. A comparison
is included with the recommended limits for unused
mineral insulating oil filled in new power transformers,
before energisation (from IEC 60422).
Figure 4. Simplified Scheme for On-Line Reclaiming Of Acidity Colo BDV DDF IFT
Transformer Oil. (mgKOH ur (kV/2,5m at (mN/
/g) m) 90°C m)
During the reactivation phase the columns are by-passed Befor 0,157 4,1 68 0,081
23,5
(indicated by the dotted line) and the oil only circulates e 2
through the filter/degasser. After 0,009 1,5 80 0,003
46,0
3
The final step is re-additivation. It is essential to restore Follo 0,014 1,6 74
the inhibitor content to the range 0.3-0.4 %, which is 0,006
w-up 42,3
considered the optimal for inhibited oil. The appropriate 3
amount is dissolved in a portion of the newly treated oil. IEC 0,03 2,0 55-60 0,010
This stock solution is introduced in the main oil flow and 60422 - 35
then circulated until it is well blended. Upon a customer’s 0,015
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3.2 Removal of Moisture from the Paper insulation insulation as with a factory process (applying vapour
phase), within 1 to 2 weeks. Compared to “conventional”
Oil analyses normally include also the measurement of systems like hot oil circulation or hot oil spray, this is a
the moisture in oil. As shown earlier in the paper, the time reduction by approximately a factor of 2-4 . 7
amount of moisture in the oil is in relation to the amount
of moisture in the paper. However, it is very important to
remember that the moisture in oil is only an indicator of
Short circuit HV.
the total moisture content and not a moisture reservoir, as
LV.
over 99% of the moisture is absorbed by the paper
Vacuum control
insulation. Thus any oil change or short time oil treatment valve
will not be able to remove any considerable amount of LFH Converter
water from the transformer.
Spray
A typical drying process for power transformers includes nozzles
vacuum and heat (as it was earlier shown that the drying
through the oil is not very efficient). Preferably, one
should have both carried out at the same time. But as
vacuum is thermally insulating the inner part of the
transformer (like in a thermos bottle), the heat transfer to Oil treatment plant
the windings is almost impossible with external heating. Vacuum
Conventional site drying processes normally include a pumps
heat cycle without vacuum followed by a vacuum cycle.
These processes have different disadvantages:
3.2.2 Effect on low molecular weight acids. Drying time to dry a 400 MVA transformer with 14 tonn
insulation from 3% down to 1,5 % average humidity
Not only water is removed by the process. The low Online oil degassing
200 lt/h average oil
molecular weight acids have only a slightly higher boiling 100
temp. 30°C
°C with the combination of vacuum will also evaporate Online oil degassing
temp. 50°C
years
temp. 50°C
extracted water during the LFH drying process. It
contains large amounts of acids. The typical values for 0.1 Hot oil circulation +
vacuum cycles
LFH + oil circulation
3.2.3 Combination of LFH drying and reclaiming A quick drying reduces the ageing effect immediately,
Quite often transformers with acidic oil that needs to be where as with slower systems, the same effect can only
reclaimed are also in need of drying, and vice versa. LFH be seen after several years. Whenever an online degassing
and reclaiming can then be combined. There is already system is used, it makes it nearly impossible to detect
extensive experience of this practice. Since this combined failures with DGA analyses. This will increase the risk of
treatment removes a large fraction of the main a major failure on the unit. This fact beside others needs
accelerating factors in the ageing of paper (water and low to be considered when choosing a drying procedure.
molecular weight acids) and also the acids in the oil, the
long-term effect on paper ageing is even greater. The 3.3.1 Life time extension of the insulation system
drying and reclaiming processes can in part run in parallel With the appropriate measures one can extend the
which reduces the total process time and cost. technical lifetime of the organic insulation system
substantially. The removal of the ageing accelerators like
moisture and acid will slow down the degradation
3.3 Comparison of different drying technologies process. In addition the formation of further ageing
As mentioned before, different procedures are available accelerators will be reduced. All this is leading to an
to “dry out” transformers on site or in a factory. Two extension of the time it takes for the insulation to reach a
major techniques are used: state where it is no longer withstanding the stresses
applied to it.
- Drying the insulation by drying the oil
- Drying the insulation with heat and vacuum However, by keeping the insulation system in a good
shape, one has also a larger margin when it comes to
The indirect drying through the oil is much slower as the daily stresses upon the system (stronger paper, better
oil contains only a very small part of the total water, <1% insulation capability of the oil…). This is results in a
(see also the example under the paragraph Distribution of higher reliability of the whole system. It is also important
Degradation Products between Oil and Paper). On the to understand that the degradation of the paper is
other hand, it is not necessary to stop the transformer accelerated by the by-products formed from it. Conditions
when drying it through the oil. are thus gradually getting worse as the transformer ages.
Continuous oil dryers are very convenient whenever a Exactly how much the removal of water will slow down
transformer needs to be kept dry or as an emergency the ageing is difficult to predict. However, recent
measure when there is a risk of formation of water research results suggest that within the range of water
droplets when the transformer is cooled down. However, contents that can reasonably be expected in real
for the dry out of humid bulk insulation in an aged transformer windings, a halving of the water content (e.g.
transformer these systems will hardly be able to remove from 2% to 1%) should lead to at least a halving of the
sufficient moisture to change the speed of degradation ageing rate. 1 The effects of acids are even more difficult
and thus extend the remaining lifetime. to predict, since different acids have different activities.
However, oil reclaiming as well as the removal of acids
that takes place during LFH drying will certainly have
significant effects.
• Actual amount of degradation accelerators is • Act before large amounts of moisture and acids
known (moisture, acids) are formed inside the transformer
• Future load pattern is resembling the historical
transformer load
From this information one can simulate the estimated life Conclusions
time extension by applying the different counter actions. Proper oil maintenance coupled with the removal of water
Of course such a simulation will always be a rough from the solid insulation, when required, will improve the
estimation. In the very simplified example in Fig. 9 the long-term reliability of the insulating system and thus
kinetic parameters suggested by Lundgaard (for initially help prolong the technical life of the transformer.
dry paper under oxygen-poor conditions) have been
applied. 9 Arrows indicate the time to reach an end-of life It is important to know that oil and paper interact and
criterion of DP 200, without and with removal of half the what is carried out for one will influence the future of the
water content after a certain time. In real life, water other. The distribution of degradation products, such as
ingress would contribute to build-up of water and the water, between the two will influence strongly what
effect of oxidation would also make conditions in the maintenance actions that are beneficial, especially in the
windings progressively worse. Models can of course be longer term.
made that take also this into account.
A proper condition assessment, based mainly (but not
exclusively) on oil tests, is the basis for sound decisions
about what maintenance activities should be carried out
on the insulating system.
600
with drying
after 15 years
4.0 On-Site Repair Process
DP no drying
400
Power transformer factories and workshops are
characterized by their orderliness, cleanliness and well
controlled atmospheres which are important conditions
200
required for manufacturing and repair of high voltage
equipment. They are also equipped with heavy lifting
equipment, special tools and fixtures, high voltage test
0 laboratories and highly skilled operators for each step of
0 10 20 30 40 50 60
the process.
years
To perform a site repair of a transformer, the same
capabilities have to be set up on site in order to meet the
Figure 9. DP versus time curve based on kinetic data from individual circumstances of each case. The concept
laboratory ageing experiments. requires the following:
Drying with 50% reduction of water content after 15 years.
In order to perform a site repair a controlled environment
facility will be required, where cleanliness and orderliness
The main points for an optimal result are: can be achieved. The facility should meet all the criteria’s
required to perform the necessary repairs. If the customer
• Don’t wait too long. When less of the original does not have a repair area a temporary workshop can be
lifetime is left, there is less to gain. set up on site.
• Effective removal of moisture and acids is a Heavy lifting equipment will be required on the site. The
must for the life time extension of an already largest transformers may require a capacity of up to 400
aged system (if the moisture removal takes metric tons and above for un-tanking and tanking of the
several years it might be already too late) core and coil assembly.
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4.1 Facilities for Temporary Workshops Another very flexible and economical solution is to use a
large tent consisting of a steel structure and claddings. This
Based on the experience gained globally within the structure could achieve and maintain clean and dry
Service centers that have performed site repair projects it environment for the repair work to be performed on the
was noted that a maintenance shop owned by the customer active part of the transformer. These types of tents can be
is available for approximately 50% of the repair projects set up in very short time, normally less than a week and are
completed. designed to withstand severe weather conditions such
The available shop may also be equipped with an strong winds and snow load.
overhead crane for lifting of core and coil assembly and
winding blocks. For the remaining 50% of the projects it
was necessary to set up a temporary facility. When a
permanent facility is available at site for transformer repair
it should be separated from the rest of the facility to
maintain the cleanliness required.
A temporary workshop may be set up based on a steel
structure with a cladding of corrugated sheets of steel .
This type of building is primarily used when more than one
transformer will be repaired at the same site or when there
is a desire to keep the building for any future repair or
maintenance work by the owner.
Spray
nozzles
MobileHighVoltageTest System
Frequency Adaptation
transformer HVfilter Test object
Converter
Measuringandrecording
Converter control equipment Figure 19: Temporary site repair 93 MVA, 240/13.8 kV
PD
The power plant is owned by the National Power
Corporation (NPC) in the Philippines and operated by
Figure 17: Mobile High Voltage Test System set up for Induced Alstom Power. The power plant did not have any spare
voltage test transformers and required the quickest option to repair
and return the existing GSU to service.
The Mobile High Voltage Test System is designed and Initial electrical diagnostics testing and oil analysis
built in order to be transported in a standard 40 feet indicated that the windings of the transformer were
container for easy transportation by truck, by sea or by damaged and needed to be replaced.
air. The Fig. 18 shows the test system set up at a The original transformer design data significantly
substation for test of a large single phase transformer. reduced the design time for the replacement windings.
The manufacturing of the new windings and
preassembling of the winding blocks were completed in
Thailand, in accordance with the guidelines for new
transformers. The winding blocks were dried and
assembled in the transportation tank sealed with positive
dry air pressure. The winding tanks were shipped to site
in Philippines.
Figure 21: The Mobile High Voltage Test system set up at site
for testing of the repaired transformer
Figure 20: New windings received on site in tank with dry air After the successful completion of all tests and
One of the key and most important challenges was to acceptance by the customer the transformer was
create factory environment on site. This was achieved by successfully put back into service.
erecting a temporary workshop equipped with an air
conditioner and dehumidifier.
8.0 Project References
After delivery of the windings from the factory in
Thailand to site, the skilled team successfully replaced In total more than 300 transformers have been repaired
the windings and repaired the transformer to new on-site. The largest transformer repaired on site is rated
condition. at 750 MVA, 800 kV ac. More than 60 transformers
After tanking of the core and coil assembly, a vacuum above 200 MVA including several HVDC transformers
drying process along with hot oil circulation method was rated up to 600 kV dc have been repaired successfully
applied. The quality of the drying process was monitored on-site.
by Frequency-Domain-Spectroscopy (FDS) As it relates to transportation costs and risks, the large
measurements. power transformers are the likely candidates to be
One of the most important scope of the project considered for on site repair. The total repair time in most
successfully performed was the High voltage testing on of the cases were reduced by 12 to 14 weeks depending
site after repair. on the geographical condition of the transformer and site.
However several transformers below 50 MVA and 30
A Mobile High Voltage test system was brought to site MVA were also repaired or refurbished on site.
in order to perform dielectric tests including Applied
Voltage test, Induced Voltage test and Partial Discharge
measurement. All tests were performed according to the 9.0 Conclusions
international standards.
Proper oil maintenance coupled with the removal of water
from the solid insulation, when required, will improve the
long-term reliability of the insulating system and thus
help prolong the technical life of the transformer.
The electrical market in most of the countries, not to repair time by several weeks or even months while
say all, value more and more the quality of the energy ensuring a highly reliable repair.
supplied to the end-users. One of the important
Condition Assessment and on site repair help industries
challenges for industries and utilities is therefore to
and utilities keeping a high standard of energy delivery
ensure no interruption in the delivery which means a high
through improved availability of transformers.
availability and reliability of the different equipment
installed in the networks. After several years of Today all the necessary maintenance actions and
experience in many countries the condition assessment procedures are available, ranging from simply adding
survey and on site repair helps transformer owners to more oxidation inhibitor before oil starts to deteriorate, to
reduce the downtime of their equipment. combining oil reclaiming and LFH drying in the cases
where there is both strongly aged acidic oil and a high
Condition Assessment provide relevant information to
water content.
support informed decisions needed to implement
condition based maintenance and reduce repair time by
better planning the repair tasks and ordering of material.
On site repair based on a proven process and strong
project management combined with state-of-the-art
technology and strict quality control allows reducing
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