The Secrets of Transformer Cooling

Jon L. Giesecke
Director
JLG Associates, LLC

ABSTRACT
As our transformer fleet continues to age, caring for these units requires a high level of expertise.
This is due to the level of complexity of the cooling systems and subsystems involved. In order to help you
better understand how you can maintain your own systems, I will explain maintenance tips and secrets I’ve
learned, including, how to do a functional test of the cooling systems. Heat exchange is critical for these
systems and knowing the expected inlet-to-outlet temperatures can save many transformers from failure.

INTRODUCTION
Proper understanding of the cooling system of your transformer will go a long way in protecting your
investment
in your transformer fleet. The service life of a transformer can be improved when the utility owner and the
predictive maintenance (PdM) specialist execute effective management and control of the system.

There are subsystems of a transformer, which may destroy your transformer. Those subsystems are often
misunderstood and sometimes overlooked.

These subsystems are:

• load tap changer
• bushings
• lightning arresters
• control cabinet
• the cooling system.

The cooling system consists of radiators, valves, pumps, fans, gauges, and controls. I will address each of
these and cover the specifics of each component.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

FACTS AND IMPORTANCE OF TRANSFORMER COOLING
• Needed to maintain and regulate the proper cooling for the core and coil assembly of the transformer.
• Heat is directly related to moisture
• Paper insulation is destroyed by heat and moisture
• The life expectancy of a transformer is largely based on moisture and heat management.
• Figure 1 shows the loss of life of paper insulation just from heat alone.

Winding insulation life relative to operating temperature

65C rise design

160

140

120
Operating temperature (C)

100

80

60

40

20

0
Years 40 20 10 8 6 4 2

Estimated life expectancy

Figure 1. Transformer life expectancy as a function of operating temperature. Note: The column to the
far right shows only two years left in the life of this transformer while the far left indicates a full 40-year
life expectancy.

DETECTABLE PROBLEMS FOUND ON COOLING SYSTEMS

• Low oil
• Dirty fins
• Closed valves
• Faulty pumps
• Faulty fans
• Direction of fans and pumps reversed
• Leaks
• Wiring and contactor issues

TOOLS USED TO INSPECT THE COOLING SYSTEM

• Eyes, ears, nose, touch – AKA the Visual Exam
• Infrared thermography
• TP500A for acoustic pump signature
• VB 1000 for vibration signature of pump bearings
• Ultraprobe 9000 or suitable ultrasonic listening device

InfraMation 2007 Proceedings ITC 121A 2007-05-24

COOLING SYSTEM CONFIGURATIONS (SEE TABLE 1)
• There are many different cooling system configurations. OA/FA/FOA/FOW are some of the A.N.S.I.
abbreviations found on transformer nameplates. The C.S.A. designation is now being recognized
over ANSI. ONAN or OA stands for Oil/Air: This means the cooling system uses oil to air for the
transfer of heat energy without the use of pumps or fans.
• ONAF or FA or Forced Air means that the cooling is aided by fans, but without any pumps to circulate
the oil. With both of these systems the oil circulates through the radiators or heat exchangers by
normal convection only.
• OFAF or FOA or Forced Oil and Air mean that the system uses both pumps and fans for the cooling
of oil.
• OFWF or FOW or Forced Oil and Water mean that the heat exchanger on this type is water-cooled
and does not have the typical radiator configuration. The cooler is normally a chamber with many
tubes inside where the oil and water exchange heat energy. Some of the older FOW’s had the water
cooling tubes running inside the main tank. This works well but the repair of leaks can be costly and
difficult.
• Although the new CSA designation is in effect, the ANSI standard will be used during this paper
based on the author’s preference.

Table 1. Transformer ratings and cooling methods.

SECRET #1~ COOLING SYSTEM OIL FLOW PATH

Loading produces heating the core and coil assembly which in turn heats the oil as depicted in Figure 2.
The heated oil rises and pulls cooler oil from the bottom of the radiator. Why this is a secret is a secret in
itself, but as I travel across this great land of ours I find many of engineers and technicians who think that the
cooling flow is the opposite of the graphic in Figure 2.

Add pumps to this configuration and the flow path is the same just faster.
■ OA mode ~ approx 60 gpm of convective oil flow
Inlet to Outlet delta T = 10-30C depending on load

■ FOA mode ~ approx 600 gpm of oil flow

Inlet to Outlet delta = 1-10C depending on load

If the load is light, you may get a zero delta T in the FOA mode. Why? Because the heating is slight and the
flow mixes the oil into one big even temperature mass. But if the load is heavy and the delta T is zero,
something is wrong. Most like dirty fins are the culprit and it’s time to clean them.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

Figure 2.The oil flow path through all transformer-cooling systems is top to bottom whether the
flow is natural or pumped.

SECRET #2~DRAG HANDS

• The red hands on the gauges shown in Figure 3 are called drag hands. They indicate the maximum
temperature that the transformer oil/winding had reached since the last reset of the drag hand
• The drag hand temperature needs to be recorded and tracked (this can be done remotely)
• The drag hands need to be reset after each inspection
• If the drag hands are way above normal expected temperature, you must determine the cause.
Is the drag hand loose and vibrating upward? Is the cooling system not working properly?
These are questions which must be answered prior to moving on with the inspection.

Figure 3. Temperature gauges showing drag hands.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

SECRET #3~THE GAUGES READ IN CELSIUS
• Scan using Celsius, why? The gauges are in C; this makes it easy to do a mini-calibration.
• Set your emissivity to that of the transformer paint (usually 0.9 will be close enough)
• Compare the temperature of the transformer shell on the shady side near the top, with the
temperature of the top oil gauge. This is a mini calibration and should give you confidence in the
accuracy of your gauge reading.
• The winding gauge should be equal to or greater than the top oil gauge.

SECRET #4~THE WINDING TEMPERATURE IS SIMULATED

• The winding temperature is obtained using a heater wrapped around the bulb in the heater well. The
heater is hooked to the current transformer. The higher the load of the transformer, the hotter the
heater gets, which simulates the winding temperature. The temperature read on the winding gauge is
from a combination of the oil temperature and the heater.

SECRET #5~ THE 25C MARK ON THE LEVEL GAUGE

• The 25C mark is used as a reference point to let you know that if the oil temperature was 25C (77F)
and the oil was filled correctly during initial install, then the oil level in the transformer is correct and
normal.
• Point to remember….as the oil heats up and cools down, it expands and contracts; so if the level
gauge needle points to the 25C mark and the top oil temperature is 45C, you have low oil in your
transformer.
• When deciding whether the oil level is low or high, you must always take into consideration the
temperature of the oil.
• When a transformer cools and the oil volume shrinks, the level may drop below the inlet of the
radiator.

SECRET #6~ SMALL HOLES IN THE PUMP MOTORS ALLOW TRANSFORMER OIL TO ENTER THE MOTOR FOR
COOLING
• The motors for the pumps are oil cooled. This means that when a pump motor burns out, fault
gasses get mixed into the transformer oil and cause a false positive. Many times the transformer
engineer thinks that his transformer is in trouble when it is only the pump. Careful inspections using
the below list can prevent this occurrence.
.
SECRET #7~ FUNCTIONAL TESTING IS EASY
• Run Fans & Pumps for 30 minutes
Feel air flow – direction & temperature
Use IR to see air flow indication
Verify flow gauge operation is steady and ON
Use IR and Visual to check overloads, contactors, wiring & terminations
Infrared and record inlet & outlet delta T
Do Ultrasonic pump signature
Do Vibration signature of axial thrust bearing

FUNCTIONAL TESTING EXPANDED (A FEW EXAMPLES FROM EACH TECHNOLGY)

IR analysis - As-found condition, Figure 4: two pumps running, one pump natural flow, one pump no flow.
Problem solved: closed valve on pump #4 (foreground).

InfraMation 2007 Proceedings ITC 121A 2007-05-24

 *>65.0°C

65.0

60.0

55.0

50.0

45.0

40.0

*<37.3°C

Figure 4. IR image of transformer pumps

IR analysis - As found condition, Figure 5: One radiator (right) normal pumped flow, one radiator no flow;
pump running low gauge indicating flow, valves open.
Problem solved: Broken “Woodward key” on the impeller shaft. Used ultrasonics and motor current to
confirm. Notice the pump motor temperatures.

*>26.3°C

26.0
24.0
22.0
20.0
18.0
16.0
14.0
12.0
10.0
8.0
6.0
4.0
2.0

*<0.4°C

Figure 5. IR image of transformer radiators

Vibration analysis - As found condition, Figure 6: #1 Pump axial thrust bearing normal (yellow trace);
#2 pump axial thrust bearing (green trace) at first alarm point.
Problem solved: Inspect and repair during next outage.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

Figure 6. Vibration spectrum of transformer pumps.

Ultrasonic signature - The acoustic sensors are placed on the pump housing for this inspection. This is a
normal signature.

Figure 7. Normal ultrasonic signature of pump.

Ultrasonic signature - The acoustic sensors are placed on the pump housing for this inspection. This is an
abnormal signature. When this kind of impeller rub is present, small metal particles may be wearing and are
being pumped into the transformer.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

Figure 8. Abnormal ultrasonic signature of pump.

SUMMARY
The life of a transformer depends on its cooling system. A good PdM program for transformers and
substations is a must, especially with new load demands being placed on the equipment each time a new
housing project or mall is built. Remember, aging equipment that has years of abuse will only last so long.
Only a good monitoring program can determine the next action step to prevent unexpected failures.

ACKNOWLEDGEMENTS
The author wishes to thank the Infrared Training Center at FLIR Systems; PowerPD Inc.; Commtest
Instruments and U.E. Systems for providing the resources and test equipment to make this work possible. I
also want to recognize my varied list of clients who made all the data collection and learning possible. I
apologize if I have inadvertently omitted your name from this list.

PECO Energy, PSE&G Nuclear,

SCE&G, PP&L,
TVA, Northeast Utilities,
CPL, First Energy,
Duquesne Light, Hawaiian Electric,
Israel Electric, SCE Nuclear,
Chugach Electric Association, SMUD,
Entergy, Southern Company,
City Public Service, WAPA,
Alabama Elect Coop. Progress Energy,
Constellation Energy, Florida Power & Light,
Duke Power, LADWP
OPPD, Powergen, Trinidad
NPPD

InfraMation 2007 Proceedings ITC 121A 2007-05-24

ABOUT THE AUTHOR
Jon is the director of operations and owner of JLG Associates; LLC. He is an ITC level III thermographer and
is certified in power transformer diagnostics. He also served on the board of directors of the International
Society of Professional Thermographers, Inc. (ISPoT). He has over 14 years of experience in
transformer/substation predictive maintenance and over 30 years in substation maintenance.

Prior to forming JLG Associates LLC, he was employed by the Electric Power Research Institute’s solution
division, (EPRI Solutions) as a senior project manager in the Substation Predictive Maintenance business
area.

Contact Info:
Phone (610) 518-1615
Cell (610) 662-1656
Email jlgassociatesllc@yahoo.com

InfraMation 2007 Proceedings ITC 121A 2007-05-24

InfraMation 2007 Proceedings ITC 121A 2007-05-24