Best Maintenance Practices/ Condition Monitoring for Reliability of EHV Substation Equipments

S. Victor P. Selvakumar Power Grid Corporation of India Ltd.

Maintenance Practices

Breakdown Maintenance Preventive Maintenance Total Productive Maintenance (TPM) Condition Based Maintenance (CBM) Pro-Active Maintenance Reliability Centered Maintenance (RCM) Maintenance Prevention

Condition Based Maintenance

Equipment condition is assessed

Periodic Assessment On-Line continuous assessment

Maintenance based on assessment Maintenance based on criticality

Switchyard Equipments

Transformers/ Reactors Circuit Breakers Current Transformers Capacitive Voltage Transformers Surge Arresters Disconnectors

Transformers

Core Coil Solid Insulation Liquid Insulation Cooling System Bushings

Expected Problems in Transformers

Core/ Winding Movement Bad joints Wet Insulation Winding Insulation Deterioration Bushing Insulation Deterioration Deterioration of oil quality Blocked cooling system Partial Discharge and Over Heating

Transformer Failure Statistics of Transformer Failure Statitcs POWERGRID

Winding 19% Tap Changer 6% Shields and Leads 6%

Bushing 69%

Core/ Winding Movement

Magnetic Balance Test Excitation Current Measurement Short Circuit Impedance Measurement Frequency Response Analysis

Magnetic Balance Test

This test is conducted only in three phase transformers to identify imbalance in the magnetic circuit After removing neutral from ground, apply single phase 230V across one of the winding and measure voltage in other two windings. Repeat test for each winding. Ensure V1 = V2+V3 Very negligible voltage induced to be investigated

Magnetizing current measurement

To detect shifting of winding, Core, failure of turn to turn insulation Apply 3 phase voltage on HV/IV terminal & measure current in each phase To be carried out before DC resistance measurement Voltage to be equal and Current for each set of measurement to be equal

Interpretation

Test results on the outside legs should be within 15% of each other Value for center leg should not be more than either outside For 1Phase transformer value should not be more than 10% variation. Not more than 5% on the previous reading

FREQUENCY RESPONSE ANALYSIS (FRA)

Mechanical movement of winding may occur during transportation shocks or Short Circuit forces or due to ageing and may result in dielectric failure of transformer Such winding displacement may not be detected by DGA, winding resistance or C &Tan measurement Techniques available to detect such changes are FRA or Vibration Measurement

PRINCIPLE OF FRA

Applied impulse signal and the corresponding winding responses are recorded using a high performance digitizer Results transformed into frequency domain by Fast Fourier Transform calculation

A response function is obtained which is dependent almost entirely on the test object and is independent of applied signal and test circuit.
The changes in the test object can be more clearly and consistently identified. The technique used for FRA analysis is a sweep frequency technique which is suitable for site use and has a superior signal to noise performance at high frequencies.

FRA TEST SET-UP

Sinusoidal signal output of approximately 2 V rms from the Frequency Response Analyser is applied One measuring input (R1) is connected to the end of a winding and the other measuring input (T1) is connected to the other end of the winding. Tank earthed The voltage transfer function T1/R1 is measured for each winding for five standard frequency scans from 5 Hz to 10 MHz

SFRA Variation with Tap position

Main winding responses unchanged

Tap winding responses show stepwise variation

FRA Interpretation

FRA : Change in original signature

AMPLITUDE
0 -10 -20

-30

-40

-50

-60

-70

-80

-90

-100 0 200 400 600 800 1000 1200 1400 1600 1800 2000

FREQUENCY
AMP(dB) after failure AMP(db)before failure

213 kV LV Delta Winding

FRA : Change in original signature

Advantages of FRA

FRA detects winding movement, which cannot be ascertained by any other commonly known test FRA test is sensitive and very repeatable

FRA is very powerful and effective tool and capable of detecting a range of transformer faults, it is nevertheless primarily a mechanical condition assessment test and must be used in conjunction with other diagnostic tests if a complete picture of the condition of the transformer is to be obtained.

Winding Resistance Measurement to detect bad joints

Measured in the field in order to check for abnormalities due to loose connections. Interpretation of results is based on comparison with previous results Within 5% deviation in result is accepted Measured values to be converted to the reference temperature

Winding Resistance

Winding Resistance is very sensitive to temperature Hence temperature to be noted at the time of measurement Resistance is converted to base temperature for comparison R75 = Rm (75 + 235) ( Tm + 235)

Wet Insulation

Oil ppm Recovery Voltage Measurement Measurement of Relative Saturation Winding Capacitance tan measurement

Typical Values of Water Content in Oil & Paper

Water Content at the Time of Commissioning

In Paper In oil

0.5% 5 ppm

30 Liters 0.4 Liters

After 25 years of service In Paper In Oil 2.5% 20 ppm 150 Liters 1.6 Liters

Dependency between the water content in mineral oil and cellulose paper

RECOVERY VOLTAGE MEASUREMENT (RVM)

Physics behind RVM

Applying DC Voltage to the insulation, molecules are polarized and turn in the direction of the Electric Field. A short circuit is subsequently applied for a short period of time and molecules are partially depolarized. Opening the short circuit, a voltage due to remaining charge will build up between the terminals of the insulation. This is called Recovery Voltage. The equivalent circuit which best describes the phenomenon of the polarization is serial R-C circuit.

RECOVERY VOLTAGE MEASUREMENT

Test Setup

Recovery Voltage Measurement

Method of Measurement

2 kV DC is applied across the insulation for a particular time Insulation is shorted for half the time Then recovery voltage is measured till the maximum recovery voltage is reached Maximum recovery voltage against time is plotted

RVM Graphs
Different ages of Transformers

Analysis of test result

Multiple peaks indicate non-homogeneous dryness of winding More time constant indicates healthiness of insulation Less time constant indicates wetness of winding

Before and after dry out

ON-LINE MOISTURE MEASUREMENT

ON-LINE MOISTURE MEASUREMENT THROUGH DOMINO

DOMINO test is used to determine the moisture content of oil in Transformers and Reactors The sensor made of Thin Polymer film measures Capacitance The Capacitance changes proportional to the change in relative saturation of water in oil

DOMINO PRINCIPLE
Relative Saturation (RS) is

RS = Wc * 100/S (%) Where Wc is concentration of water in oil & S is Solubility of water in oil that can be held at a given temperature
Solubility of water in oil (S) at a given temperature is computed from, logS = -1567/K + 7.0895 Where K is temperature in K

Relative Saturation
Moisture content Temp. Solubility of water in oil %RS

30ppm

100C

772ppm

4%

30ppm

20C

60ppm

50%

30ppm

0C

22ppm

>100% (free water)

DOMINO

The instrument measures RS and ppm of water The output is locally displayed as well downloaded to PC through RS-232 port.

The equipment

Water content in Oil and Condition of Paper insulation

Water in Oil at 60-70C Condition of Cellulose insulation
< 15ppm >15<20ppm >20<30ppm Good Fair Probably wet

>30ppm

Wet

Deterioration of Winding Insulation

Capacitance and tan Measurement

Problems with the measurement

Results are affected by external interference Interference suppression methods Non-Repeatability of test results Proper knowledge on connection and measurement Trend Analysis

Basic Insulation

Insulation

Capacitance of Insulation

Effect of Medium

Dielectric Constants of different Mediums

Equivalent Circuit

HV Lead

Interference

EQUIVALENT CIRCUIT FOR TWO WINDING TRANSFORMERS

CHL CAPACITANCE BETWEEN HV AND LV WINDINGS

CH CAPACITANCE BETWEEN HV AND TANK CL CAPACITANCE BETWEEN LV AND TANK

Precautions for Cap and Tan Delta Measurement

Reliable instrument Jumpers to be disconnected for Transformer/ Reactor winding capacitance and Tan Delta measurement It should not be a rainy day Porcelain surface needs to be cleaned thoroughly

Transformer Windings

Shorting of Jumpers

UST Mode of Measurement

Earth will be connected to N Point Hence only CHL will be measured

GST Mode of Measurement

Here measurement is made for the Parallel combination of CH and CHL

GSTg Mode of Measurement

Here measurement is done for CHE as L is guarded

Condition Monitoring of Bushings

Construction of Bushings Grading of insulation C1 and C2 Tan delta measurement

CT Insulation

C1 and C2 Tan delta measurement

For C1: Apply 10kV between HV and test tap on UST mode. For C2: Apply 500 V between Test tap and Ground with HV Guarded on GSTg mode

Dissolved Gas Analysis

SUMMERY OF VARIOUS INTERPRETATION TECHNIQUE FOR DGA DATA

Individual Fault Gases Acceptable Norms
Total Dissolved Combustible Gas (TDCG) limits IEC 60599 Method IEEE Standard C: 57.104/1995 Key Gas Method Ratio Methods Doernenberg Ratio Method Rogers Ratio Method Trend Analysis

KEY TO SUCCESSFUL DGA INTERPRETATION

WELL DOCUMENTED SAMPLING PROCEDURE BASED ON IEC 60567 EFFICIENT GAS EXTRACTION SYSTEM (WITH MORE THAN 98% OF GAS EXTRACTION) ACUURATE AND PRECISE GAS CHROMATOGRAPH WELL TRAINED MANPOWER TO CONDUCT THE TESTS DOCUMENTATION OF DGA DATA AND ITS INTERPRETATION

POWERGRID PRACTICE
SAMPLING FREQUENCIES
BEFORE COMMISSIONING 24 HOURS AFTER 1ST CHARGING 15 DAYS AFTER 1ST CHARGING ONE MONTH AFTER 1ST CHARGING 3 MONTHS AFTER 1ST CHARGING THEREAFTER EVERY SIX MONTHS

BASICS OF DGA
ORIGIN OF FAULT GASES 1. CORONA OR PARTIAL DISCHARGE 2. PYROLYSIS OR THERMAL HEATING 3. ARCING THESE THREE CAUSES DIFFER MAINLY IN THE INTENSITY OF ENERGY DISSIPATION PER UNIT TIME PER UNIT VOLUME BY FAULT. MOST SEVERE INTENSITY OF ENERGY DISSIPATION OCCURS WITH ARCING LESS WITH HEATING AND LEAST WITH CORONA

TEMPERATURES AT WHICH GASES EVOLVE

> 1200 C > 1200 C > 1500 C > 7000 C

METHANE (CH4) ETHANE (C2H6) ETHYLENE (C2H4) ACETYLENE (C2H2)

FAULT GASES
CLASSIFIED IN 3 GROUPS 1. HYDROCARBONS AND HYDROGEN METHANE CH4 ETHANE C2H6 ETHYLENE C2H4 ACETYLENE C2H2 HYDROGEN H2 CARBON OXIDES CARBON MONOXIDE CARBON DIAOXIDE NON-FAULT GASES NITROGEN

2.

CO CO2

3.

N2

OXYGEN

02

FAULT GASES Vs TYPE OF MATERIAL INVOLVED AND TYPE OF FAULT

1. CORONA A) OIL B) CELLULOSE

H2 H2, CO, CO2

2. PYROLYSIS LOW TEMP. HIGH TEMP. A) OIL CH4, C2H6 C2H4,H2(CH4,C2H2) B) CELLULOSE CO2 (CO) CO (CO2) 3. ARCING H2, C2H2 (CH4, C2H6, C2H4)

SOLUBILITY OF GASES IN TRANSFORMER OIL BY VOLUME

HYDROGEN 7.0% (LEAST SOLUBLE) NITROGEN 8.6% CARBON MONOXIDE 9.0% OXYGEN 16.0% METHANE 30.0% CARBONDIAOXIDE 120.0% ETHANE 280.0% ETHYLENE 280.0% ACETYLENE 400.0% (MOST SOLUBLE)

FURAN ANALYSIS

Furan analysis in oil

Monitoring of Cellulose (paper) insulation is important for in-service transformers to know the condition of paper Taking paper samples from charged transformer not practicable or rather impossible Furans are soluble by product which is produced due to ageing or cellulose decomposition/ overheating. Experimental tests have shown that DP of paper insulation is inversely proportional to FFA level and FFA level of 5 ppm corresponds to a DP of 250 which is reckoned to be the lower limit for insulation strength

Furan analysis in oil

The Furfuraldehyde in oil analysis is recognized as a very significant diagnostic test for paper condition assessment The FFA content of the oil from an aged equipment can be measured using a High Performance Liquid Chromatograph (HPLC). Another method is using Spectrophotometer The concentration of Furfuraldehyde in the oil and rate of generation of furfural can be used for assessing the condition and remaining life of the paper insulation in the transformer

Blocked Cooling System

Thermo scanning of Radiators Differential Temperature High oil and Winding Temperature

Questions?