Tanega Nasional Condition Monitoring Method

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1
Diagnostic Techniques for Diagnostic Techniques for
Condition Monitoring Condition Monitoring
of Transformers of Transformers
Young Zaidey bin Yang Ghazali Young Zaidey bin Yang Ghazali
Technical Expert Technical Expert
(Transformer Performance & Diagnostic) (Transformer Performance & Diagnostic)
Engineering Department Engineering Department
TNB Distribution Division TNB Distribution Division
ARSEPE 2008 ARSEPE 2008
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1. INTRODUCTION
Electrical distribution equipment is generally
designed for a certain economic service life.
Equipment life is dependent on operating
environment, maintenance program and the quality
of the original manufacture and installation.
Beyond this service life period they are not expected
to render their services up to expectation with
desired efficiency.
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1. INTRODUCTION
Generally due to poor quality of raw material,
workmanship and manufacturing techniques or due
to frequent electrical, mechanical and thermal
stresses during the operation, many equipment fail
much earlier than their expected economic life span.
The concept of simple replacement of failed power
equipments in the system either before or after their
economic service life, is no more valid in the present
scenario of financial constraints.
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1. INTRODUCTION
Explore new approaches/techniques of monitoring,
diagnosis, life assessment and condition evaluation,
and possibility of extending the life of existing assets
(i.e. circuit breaker, cables, transformers, etc.)
Minimization of the service life cycle cost is one of
the stated tasks of the electrical power system
engineers. For electrical utilities this implies for
example to fulfill requirements from customers and
authorities on reliability in power supply at a minimal
total cost.
The main goal is therefore to reach a cost effective
solution using available resources which is captured
by the concept of Asset Management.
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6
ASSET
MANAGEMENT
Operate Operate Operate Operate
efficiently efficiently efficiently efficiently
High Performance High Performance High Performance High Performance
Reasonable Reasonable Reasonable Reasonable
returns returns returns returns
Low Cost Low Cost Low Cost Low Cost
SAIFI, SAIDI
Power quality
Power availability
Reduced Loss etc.
Investment
O&M
Stocking etc.
Balancing cost, risk,
and performance in
the context of asset
full life cycle
Asset Management Mechanism
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T&D ASSET MANAGEMENT
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Maintenance Management
With the increasing age of the population of power
system equipment utilities are making efforts to
assess the internal condition of the equipment while
in service before catastrophic failures can take place
Different types of maintenance being done on
equipment are:
Breakdown maintenance
Time or Calendar Based maintenance
Condition based maintenance
Reliability centered maintenance
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Today the paradigm has changed from traditional
calendar based to condition based maintenance and
efforts are being channeled to explore techniques to
monitor, diagnose and assess condition of power
system equipment
This has led to the development of various on- and
off-line non-intrusive tests in recent years that allow
diagnosing the integrity of power system equipment
to optimize the maintenance effort thereby ensuring
maximum availability and reliability
Maintenance Management
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Why Condition Based?
Ageing asset population
Age by itself is not a good predictor of
future performance
Must be able to fully justify decisions in
terms of proven engineering principles
Cannot make sound asset management
decisions unless you understand asset
condition!
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What is CBM?
Combining all available practical and theoretical
knowledge and experience of assets to:
Define current condition and use this to estimate future
condition and performance
Provide a sound engineering basis for evaluating risks and
benefits of potential investment strategies
Uses a well developed methodology (with practical
experience of successful application)
Provides a framework for continual improvement
(information and definition of condition)
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Why condition based?
Ageing asset population
Pressures to maintain/improve performance and to
reduce costs
Age (by itself) is not an acceptable reason to replace
assets
Must demonstrate need and consequences, condition
and future performance
Cannot make good Asset Management decisions
unless you understand asset condition!
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Condition Based Management
Define asset condition (Health Index)
Link condition to performance & probability of failure
(PoF)
Calibrate Health Index/PoF against historic fault rates
Estimate future condition and performance
Evaluate effect of investment programmes on future
condition and performance
Provides an ENGINEERING basis to evaluate risk and
determine investment requirements
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Defining condition and future performance
Need understanding of:
Degradation and failure processes
Condition assessment techniques
Practical knowledge of assets,
Operating context
Everything is related back to physical condition and
degradation processes - maximising the value of
available experience of the assets
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A health index is:
A consistent and logical means of combining
relatively complex information
A way to rank assets (on basis of proximity to
EOL or probability of failure)
Relatively simplistic
It is NOT a substitute for engineering expertise
and judgement it is an additional aid to
engineers
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Health Index Mechanism
A Health Index is a means to define proximity to EOL
by combining varied and relatively complex condition
information as a single number
Define significant condition criteria
Code information numerically,
Apply weightings
Develop a simple algorithm to generate a HI for
each asset
Rank and apply calibration
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Health Index - Ranking
Condition Remnant Life (years) Probability of
failure
5 - 10
Poor
Fair
Good
At EOL (<5 years) Bad
10 - 20
>20
High
Medium
Low
Very Low
10
0
9
18
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Health Index
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Information to derive a condition based
Health Index
Actual condition information
Risk factors with direct condition implications -
failure rates, specific or generic problems,
design issues etc
Other non condition based risk factors can be
mapped on later to evaluate overall risk
(Criticality, load, obsolescence etc)
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Condition based health index
Means of determining probability of failure
It does not consider consequences of failure
Ultimately require combination of both to
evaluate overall risk
CBHI is the 1st step (phase 1)
Phase 2 use of results in a risk model
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Phase 1 - Condition and Probability of
Failure (for each asset group)
Define
Assets
Define
EOL
Issues
Review
Condition
Assessment
Techniques
Data and
Information
Analysis
Formulation
and Population
of HI
HI to
Probability
of Failure
Change of
HI (PF) with
time
Documentation
Conclusions
Report
CONSEQUENCES
Phase 2
Define
Assets
Define
EOL
Issues
Review
Condition
Assessment
Techniques
Data and
Information
Analysis
Formulation
and Population
of HI
HI to
Probability
of Failure
Change of
HI (PF) with
time
Documentation
Conclusions
Report
CONSEQUENCES
Phase 2
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Transformer Design
& Construction
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Transformer Design & Construction
Types of Transformers
Core Type
Shell Type
Oil-Immersed Type,
Dry Type
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Core Type Transformers
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5
Shell Type Transformers
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Typical Winding Connections
Delta Star
Star - Delta
Star Star
Delta Delta
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Other Winding Connections
Zig Zag Connections
Tertiary Windings
Double Secondary
Scott (T-T) Connections
Autotransformers
Earthing Transformers
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DESIGN CONCEPT
The transformer has been designed,
manufactured and tested according to
IEC 60076 part 1 to 5. Power Transformer
It consist of : core, winding, insulation, core
and winding assembly, tank.
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CORE
Grain Oriented Electrical Steel
Type M5 (0.3mm), M4 (0.27mm) and ZDKH
(0.23mm)
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WINDING
Are designed to meet three fundamental requirement :
1. Electrical
2. Mechanical
3. Thermal
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Round, Oval or rectangular in shape
and are wound concentrically.
LV winding is wound with foil
conductor (Distribution)
HV winding is wound with rectangular
strip conductor.
HV winding is wound on LV winding.
WINDING
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INSULATION
The interlayer insulation are of high quality epoxy
coated kraft paper (DDP)
Corrugated pressboards are placed within the
coil for cooling within the coil.
Thickness of layer insulation
in accordance with voltage
and number of layers.
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CORE & WINDING ASSEMBLY
Arrangement of windings with respect to the core :
CORE - LV WINDING - HV WINDING
For tapping lead connection normally use stranded copper or
round conductor.
Bushing Lead :-
1. HV - stranded copper
2. LV - copper bar or flexible copper base on LV rated
current.
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TANK
It is hermetically sealed type and full fill with insulation liquid.
Oil expansion or contraction due to the change in the
transformer load is accommodated by the corrugated finwall
of the transformer tank.
Corrugated fins are use to
provide sufficient cooling
surface to dissipate the heat
generated by the windings.
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TERMINATION
Both HV & LV is open bushing termination.
Cable Box
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MANUFACTURING PROCESS
FLOW CHART
Core Cutting
Core
Building
Tanking
Process
Despatch Finishing Testing
Paper Covering
High Voltage
Winding
Drying
Process
1. Rectangular copper
2. Foil Sheet
Fabrication
Vacuum & Oil
Filling
Low Voltage
Winding
Core Winding
Assembly
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Phasor Relationships
Transformer winding connections
produced a Phase Shift between primary
& secondary
Angle of phase shift depend upon the
winding connection method adopted for
primary and secondary
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Phasor Relationships
Eg.
Phase Shift of secondary
windings is +30 wrt primary
designated with Dyn11
Significant of Phase Shift
Paralleling of Transformer &
interconnection of system
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Tapping & Tap Changers
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Tapping & Tap Changers Functions
To compensate for changes in the applied
voltage on bulk supply
To compensate for regulation within the
transformer & maintain the output voltage
constant
To assist in the control of system VArs flows
To allow for compensation for factors not
accurately known at the time of planning
To allow for future changes in system conditions
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Type of Tap Changers
On-Load Tap Changer (OLTC)
Off Circuit Tap Changer (OCTC)
Tap Changer Mounting
Internal (In-tank)
External (Side mounted)
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OLTC Technology
Oil Type OLTC
Vacuum Type OLTC (Vacutap)
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OLTC Main Components
Tap Selector
Diverter Switch
Selector Switch
Change-over selector
Transition Impedance
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Motor Drive Mechanism to operate OLTC
Step-by-step control
Tap Position Indicator
Limiting Devices
Parallel Control Devices
Emergency Tripping Device
Overcurrent Blocking Device
Restarting Device
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Transformer Ancillary Equipment
Pressure Relief Device
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Gas & Oil Actuated Relays (Buchholz)
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Temperature Indicators
Winding HV & LV
Top Oil
Fans Control
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Oil Level Indicators
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Other Ancillary Equipment
Conservator Tank
Cooling System/Radiators
Bushings
Cable Box
Oil Valves
Thermometer Pockets
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Transformer Insulating Oil
& Paper Diagnostics
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Oil & Paper Tests in Main Tank & OLTC
1. Oil Quality Test
Physical Properties
Visual Appearance
Colour
Flash Point
Viscosity
Density
Pour Point
IFT
Particle Count
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1. Oil Quality Test
Chemical Properties
Moisture Content
Acidity
Corrosive Sulphur
Oxidation Stability
Sludge Sediment
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1. Oil Quality Test
Electrical Properties
Breakdown Voltage
Dissipation Power Factor
2. DGA
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Insulation Condition Assessment
Life Span of Power Transformers Depends on Integrity of Insulation
Most Commonly Used Insulations for Power Transformers
OIL
Provides overall insulation to the transformers
Acts as coolant in extinguishing arcs
Provides the means to monitor insulation condition and operation of
transformers
PAPER
Provides insulation to the conductor in the transformer windings
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PRIMARY STRESSES
1. Stresses applied on the transformer due to normal
operation:
Thermal
Electrical
Mechanical
2. Application of these stresses can be:
Continuous
Cyclic
Intermittent
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SECONDARY STRESSES
1. Factors that can influence the ageing rate when primary
stresses are applied
2. Simply known as Ageing Factors
Examples of these Ageing Factors can be:
3. Operational factors of the transformers
Environmental factors i.e. radiation, moisture or
water, oxidative agents and corrosive materials
Technological factors i.e. type of oil and paper used
Tests done on the transformers that can influence
the performance of the insulation system
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Oil Insulation Deterioration Reversible
1. Oil insulation condition can be reversed through on-line filtration
2. Can reduce the effect of the Ageing Factors
3. Can prolong serviceability of the oil insulation
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Paper Insulation Degradation Irreversible
Paper insulation degradation is irreversible
Oil filtration has negligible effect on reversibility of paper
degradation
Ageing of paper directly linked to its mechanical
strength
Loss of mechanical strength eventually leads to loss of
dielectric strength
Once paper loses its dielectric strength, the transformer
is deemed to have reached the end of its service life
Thus, the life of a transformer can be effectively
determined by the life of its paper insulation
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Three most common degradation factors of cellulose:
Thermal
1. When exposed to heat up to 220C, the glycosidic bond tend to
break and open the glucose molecule rings
2. By-products:
Free glucose
H
2
0
CO
CO
2
Organic acids
Glycosidic
bonds broken
and glucose
rings opened
Generates the
following:
H
2
0 CO CO
2
H
O
OH
Heat
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Three most common degradation factors of cellulose:
Oxidative
1. Presence of oxygen promotes oxidation
2. Glycosidic bond weakens
3. Causes scission to the cellulose chain
4. By-products include H
2
0
Hydrolytic
1. Presence of water and acids
2. Glycosidic bond exposed to slicing
3. Causes scission to the cellulose chain
4. By-products include free glucose
Glycosidic
bonds
weakened
and
moisture
produced
CH2OH
COOH COOH
CHO
O
2
Free glucose
produced
HO OH
CH2OH
H
2
0 or acids
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Degradation By-Products
1. It can be observed that by-products related to paper degradation
can include the followings:
CO
CO
2
H
2
O
Organic acids
Free glucose molecules
2. With H
2
O and organic acids present in the oil, the free glucose
molecules can degrade to 5-hydroxymethyl-2-furfuryl or 5H2F
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Degradation By-Products
3. 5H2F is an unstable free glucose molecule and can decompose
further to other furaldehyde as follows:
2-furfuryl alcohol (2FOL)
2-furaldehyde (2FAL)
2-acetyl furan (2ACF)
5-methyl-2-furfuryl (5M2F)
4. All these 5 compounds of glucose or degradation of glucose are
known as Furans.
5. 2FAL is the most stable in the group
6. Furan generation is exclusively due to paper degradation unlike
CO, CO
2
, H
2
O or acids which can also be produced through oil
oxidation or breakdown.
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When taking an oil sample from a sealed tank
transformer, ensure that the transformer is not under
vacuum by checking the vacuum/pressure gauge
Use a clean glass syringe/beaker (provided by the
laboratory) and follow the proper sampling procedure
ASTM D923 & D3613 (IEC 60475 & IEC 60567)
Interpret the quantified results to help determine the
relative health of the transformer, offer clues to the origin
of potential problems and develop a strategy to avoid
catastrophic failure IEEE C57.106
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Important factors to be considered prior to taking a
sample:
1. Sample Containers
2. Sampling Technique
3. Weather condition
4. Sample storage and transport
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Characteristic of Sample Containers:
500 ml or 1 liter (Duplicate)
Syringe DGA
Seal the sample from external contamination
Store samples in the dark to prevent from photo-
degradation
Cleaning and preparation of valves
Avoid liquid spillage, some oil may still contains PCBs
Identification of the sample and apparatus information
Sampling outdoors in rain, strong wind and night time
should be avoided
Should not be stored longer than a few days before
sending to the laboratory for analysis
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Dark Brown
Bottle
500 mL
Valve
Adaptor
Plastic
tube
Cap
Transformer
Seal
Waste
Vessel
Filled
Sample
bottle
Use correct vessel (good cap and seal)
Sufficient sample
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Valve
Adaptor
Plastic
tube
Syringe
Transformer
Waste
Vessel
Sufficient sample
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To effectively interpret DGA results requires insights in
the characteristics of dissolved gas in oil evolution, an
understanding of transformer design, and knowledge of
materials used by transformer manufacturer and
operating conditions ASTM D3612
ASTM D3612 Test methods for analysis of dissolved
gases by gas chromatography
IEEE C57.104 Guide for interpretation of gases
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On-Line Assessment of Insulation Condition
1. Oil Quality Tests to assess the physical, electrical and
chemical properties of the oil
2. Dissolved Gas-in-oil Analysis to detect and identify
incipient faults
3. Furan Compound Analysis to detect and identify
degradation of paper insulation (on-line test)
4. Degree of Polymerization Test to measure
degradation of paper insulation (intrusive mechanism)
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Oil Screening Tests
1. Colour serious contamination
2. IFT moisture in oil (> 15 mN/ m)
3. Neutralization Number level of acidity (< 0.2 mg KOH / gm)
4. Dielectric Strength contaminants (water & conducting
particles) ( > 30 kV)
5. 5. Water Content amount of dissolved water in ppm
(< 30 ppm)
12
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IEEE C57.106 Limits Oil Quality Tests
Colour 0.5
IFT > 25 mN/ m for 69 kV
Neutralization Number < 0.2 mg KOH / gm
Dielectric Strength > 20 kV for 69 kV for 1 mm gap
Water Content < 27 ppm for 69 kV at 50
0
C
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Other Oil Quality Tests
Specific Gravity
Viscosity
Power Factor
Resistivity
Flash Point
Visual
PCB Content
Inhibitor Content
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Oil Quality Screening Tests
Water Content (D 1533 / IEC 733) A low water content
is necessary to obtain and maintain acceptable electrical
strength and low dielectric losses in insulation systems.
Color (D 1500) The color of a new oil is generally
accepted as an index of the degree of refinement. For
oils in service, an increasing or high color number is an
indication of contamination, deterioration, or both.
Dielectric Breakdown (D 877 / D 1816 / IEC 156) It is a
measure of the ability of an oil to withstand electrical
stress at power frequencies without failure. A low value
for the dielectric-breakdown voltage generally serves to
indicate the presence of contaminants such as water,
dirt, or other conducting particles in the oil.
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Neutralization Number, NN (D 664) A used oil having a high
neutralization number indicates that the oil is either oxidized
or contaminated with materials such as varnish, paint, or other
foreign matter.
Interfacial Tension, IFT (D 971) The interfacial tension of an
oil is the force in dynes per centimeter or millinewton per
meter required to rupture the oil film existing at an oil-water
interface. When certain contaminants such as soaps, paints,
varnishes, and oxidation products are present in the oil, the
film strength of the oil is weakened, thus requiring less force
to rupture. For oils in service, a decreasing value indicates the
accumulation of contaminants, oxidation products, or both.
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Index = IFT/NN. This index provides a more sensitive and
reliable guide in determining the remaining useful life of a
transformer oil. A Index below 100 indicates that the oil is
significantly oxidized and that the oil needs to be replaced in
the near future.
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Non-fault gases - Oxygen (O2) & Nitrogen (N2)
Note: If the ratio O2/N2 is less than 0.3 then it indicates overheating
of oil. This is not a standard, use with caution.
Fault gases - Hydrogen (H2), Acetylene (C2H2)
Carbon Monoxide (CO), Carbon Dioxide
(CO2) Ethylene (C2H4), Ethane (C2H6)
Methane (CH4)
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Dissolved Gas-in-oil Analysis
Fault Condition Key Gases
Overheated Oil Methane, Ethane & Ethylene
Partial Discharge Hydrogen & Acetylene
Overheated Cellulose Carbon Monoxide & Carbon
Dioxide
Non-Fault Gases are Oxygen & Nitrogen
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Fault Condition Key Gases
Thermal Oil Major Ethylene & Methane
Minor Ethane & Hydrogen
Electrical low energy Major Hydrogen & Methane
Minor Ethane & Ethylene
Electrical high energy Major Acetylene & Hydrogen
Minor Ethylene & Methane
Thermal Cellulose Major Carbon monoxide & Carbon dioxide
Minor Methane & Ethylene
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IEEE Limit
Hydrogen (H2) 100 ppm
Oxygen (O2) N/A
Nitrogen (N2) N/A
Carbon Monoxide (CO) 350
Methane (CH4) 120
Carbon Dioxide (CO2) 2500
Ethylene (C2H4) 50
Ethane (C2H6) 65
Acetylene (C2H2) 35
34
Ratio Method is used for fault analyzing, not for fault detection.
Ratio Method Ratios
Rogers C
2
H
2
/C
2
H
4
, CH
4
/H
2
& C
2
H
4
/ C
2
H
6
IEEE CH
4
/H
2
, C
2
H
2
/C
2
H
4
, C
2
H
2
/ CH
4
, C
2
H
6
/ C
2
H
2
,
C
2
H
4
/ C
2
H
6
Never make a decision based on only ratio. Take into consideration
the gas generation rates and amount of total combustible gases.
18
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Rogers Ratio comparison methods look at pairs of gases, and
develop a coding system to help define potential fault conditions
Rogers Ratio Code
C2H2 / C2H4 CH4 / H2 C2 H4 / C2H6
< 0.1 0 1 0
0.1 -<1.0 1 0 0
1.0 - <=3.0 1 2 1
> 3.0 2 2 2
36

IEC DGA Ratios

C
2
H
2
CH
4
C
2
H
4

Case C
2
H
4
H
2
C
2
H
6

0 0 0 0 No Fault, Normal

1 0 1 0 Partial discharges of low energy

2 1 1 0 Partial discharges of high energy density

3 1 0 1 Discharges of low energy, Arcing



4 1 0 2 Discharges of high energy, Arcing

5 0 0 1 Thermal Fault, 150 C, Conductor Overheating
6 0 2 0 Thermal Fault, 150 - 300 C, Oil Overheating, Mild
7 0 2 1 Thermal Fault, 300 - 700 C, Oil Overheating, Moderate
8 0 2 2 Thermal Fault, 700 C, Oil Overheating, Severe

19
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TDCG (ppm) Status Remark
720 Condition 1 Transformer working satisfactorily. Look
for individual gas exceeding respective limit.
721-1920 Condition 2 Faults may be present. Additional
investigation required based on individual
gas exceeding respective limit.
1921-4630 Condition 3 Faults probably present. Additional
investigation required based on individual
gas exceeding respective limit.
> 4630 Condition 4 Continued operation could result in failure of
the transformer
As per IEEE C57.104
38
CO2/ CO ratio indicates cellulose degradation
CO2 / CO ratio Condition of Cellulose
< 3 Severe Arcing & Short circuit damage
3 -<5 Indicates concern
5 - <=11 Normal
> 11 Indicates damage due to general
overheating
According to IEEE C57.104 the normal value is 7
20
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Exercise (Oil Condition)
Transformer Gas Analysis
Component ppm in oil
HYDROGEN (H2) 10
OXYGEN (O2) 26200
NITROGEN (N2) 48500
CARBON MONOXIDE (CO) 41
METHANE (CH4) 5
CARBON DIOXIDE (CO2) 570
ETHYLENE (C2H4) 2
ETHANE (C2H6) 2
ACETYLENE (C2H2) 1
40
HYDROGEN (H2) 720
OXYGEN & ARGON (O2 + A) 17000
NITROGEN (N2) 45400
METHANE (CH4) 1310
ETHYLENE (C2H4) 5200
ETHANE (C2H6) 1810
ACETYLENE (C2H2) 256
Exercise (Oil Condition)
21
41
HYDROGEN (H2) 105
OXYGEN & ARGON (O2) 18000
NITROGEN (N2) 33400
METHANE (CH4) 400
CARBON DIOXIDE (CO2) 12,100
ETHYLENE (C2H4) 260
ETHANE (C2H6) 28
ACETYLENE (C2H2) 52
ppb in oil
2FAL 195
Exercise (Paper Condition)
42
HYDROGEN (H2) 103
OXYGEN & ARGON (O2 + A) 16762
NITROGEN (N2) 20458
METHANE (CH4) 814
ETHYLENE (C2H4) 109
ETHANE (C2H6) 75
ACETYLENE (C2H2) 118
ppb in oil
2FAL 225
Exercise (Oil + Paper Condition)
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Furanic Compound Analysis
Fault Condition Furan Compound
Overheating or Short circuit 2FAL
Excessive Moisture 2FOL
Lightning Strikes 2ACF
Intense Overheating 5M2F
Oxidation 5H2F
Concentration limits of furan compounds must be supported by
CO
2
/CO Ratio to assess paper degradation
44
2FAL limits (ppb in oil):
58 292 Normal Aging
654 2021 Accelerated Aging
2374 3277 Excessive Aging
3851 4524 High Risk of Failure
23
45
Criteria to select transformers for further investigation
Transformer Age
Operational Criterion number of faults, switching, lightning, etc.
DGA Criterion (oil) Individual concentrations of CH4, C2H2,
C2H4, C2H6 & H2 in ppm & Rogers/IEEE Ratio
DGA Criterion (paper) Individual concentrations of CO
2
& CO in
ppm & CO
2
/CO Ratio
Furan Criterion 2FAL concentration in ppb & others if detected
46
Correlation between TS, DP and Furan
Ageing of paper insulation is related to the decrease in
TS.
TS is directly related to DP ASTM D 4243.
Decrease in DP is directly related to the increase in
Furan.
Thus, as paper aged, it loses its TS. Loss of TS
indicates decrease of DP. Decrease of DP causes
increase in Furan in the insulating oil. It can be deduced
that as paper aged towards its end of service life, the
level of Furan content increases.
24
47
Degree of Polymerization
One of the most dependable means of determining
paper deterioration and remaining life of the cellulose.
The cellulose molecules is made up of a long chain of
glucose rings which form the mechanical strength of the
molecule and the paper.
DP is the average number of these rings in the
molecule.
As paper ages or deteriorates from heat, acids, oxygen
and water the number of these rings decrease.
48
Degree of Polymerization
Following Table has been developed by EPRI to estimate
remaining paper life
1. New insulation 1000 DP to 1400 DP
2. 60% to 66% life remaining 500 DP
3. 30% life remaining 300 DP
4. 0 life remaining 200 DP
25
49
The life of a transformer can be effectively determined by the life of its
paper insulation.
DP is considered direct approach to determine the paper insulation
condition but it is intrusive. Some are skeptical since integrity of paper
insulation may be disturbed and may further damage the paper insulation.
Alternatively, it can be achieved through the use of paper degradation by-
products e.g. CO, CO
2
, CO
2
/CO, 2 FAL, H
2
as indicators. It is non-intrusive
and requires only samples of the transformer oil which can be obtained
without any shutdown.
The challenge is to develop a Mathematical Model to Estimate DP Value of
Paper Insulation based on the Paper Degradation By-Products i.e.
DP = f (CO, CO
2
, CO
2
/CO, 2 FAL, H
2
)
50
LTC OIL ANALYSIS
By plotting the relative percentages of methane, ethylene
and acetylene onto a special triangular coordinate
system, a graphical output of the likely cause of gassing
is generated.
The causes are categorized as follows.
D1 Discharges of low energy
D2 Discharges of high energy
T1 Thermal faults < 300C
T2 Thermal faults 300C to 700C
T3 - Thermal faults > 700C
DT Mixture of thermal and electrical faults
PD Partial discharge (No samples indicated this type
of fault)
26
51
Case Study
The following gas levels were detected via DGA on the
oil from the load tap changer:
42 ppm of methane
17 ppm of Ethylene
0 ppm of acetylene
Calculate percentages of each gas and use Duvals
triangle approach to find the cause
52
LTC OIL ANALYSIS
27
53
LTC OIL ANALYSIS
Guideline set by an US Utility
When the acetylene or hydrogen reaches a threshold level of
500ppm the unit is put to monthly DGA testing schedule
DGA monthly testing schedule
Hydrogen > 1500 ppm
Acetylene > 1000 ppm
Ethylene > 1000 ppm
When Ethylene level exceeds the maximum value the unit is
removed from service
54
Exercise
The following gas levels were detected via DGA on the
oil from the load tap changer:
319 ppm of methane
181 ppm of Ethylene
1351 ppm of acetylene
Calculate percentages of each gas and use Duvals
triangle approach to find the cause
1
1
2
Transformer Basic On-Site &
Off Line Diagnostic Testing
2
3
Electrical Tests
1. Basic Electrical Tests
Insulation Resistance
Traditional Polarization Index (PI) test
to detect moisture content
Tan Delta
To detect water in cellulose
and chemical contamination
Winding Resistance
To detect open or short circuits or poor electrical connection in
the windings
Turns Ratio
To detect Shorted Turns
Insulation Condition
Assessment
4
Electrical Tests
2. Advanced DiagnosticTests
Frequency Response Analysis (FRA)
Recovery Voltage Measurement (RVM)
Polarization Depolarization (PDC)
Frequency Dielectric Spectroscopy (FDS)
Partial Discharge (PD)
OLTC Motor Current Signature Analysis (MCSA)
OLTC Vibration Signature Analysis (VSA)
3
5
Categorization of On-site Tests
Destructive off-line tests are go/no go tests
Non destructive off-line tests are diagnostic
tests
Non destructive on-line tests are condition
monitoring tests
On-site Testing
6
These on-site tests are performed individually or in
combination :
Before energizing a new equipment as a
commissioning test
After maintenance
After network alteration
On-site Testing
4
7
Damaging Factors of Insulation
8
Fig 4-4
5
9
105
130
155
180
220
Class A Class B Class F Class H Class C
100
125
150
175
200
225
250
D
e
g
r
e
e
s

C
e
n
t
i
g
r
a
d
e
Insulation Classes by Degrees Centigrade
Class S Class R
240 240+
Class N
200
Thermal Withstandibility of Insulation Medium
According to Classes
10
Insulation resistance test (a)
Insulation current test (b)
Power factor (c)
DC voltage withstand (d)
AC voltage with-stand (e)
6
11
Method (e) is primarily used in factory tests
Method (d) is primarily used as commissioning test
Practically all routine field tests are made using
nondestructive methods (a), (b) and (c)
Methods (a) and (c) must also be used as
commissioning test
No single test method can be relied upon for
indicating all conditions of weakened insulation
12
Basic Electrical Tests
Reading corrected to 20
o
C
Insulation resistance varies inversely with temperature for
most insulting materials
To properly compare periodic measurements of insulation
resistance, it is necessary either to take each measurement
at the same temperature, or to convert each measurement to
the same base temperature i.e. 20
0
C
Polarisation Index is the ratio of the IR reading after 10
minutes to the IR reading after 1minute
PI is used as an index of dryness
Discharge the winding after a Polarisation Index Test for
sufficient time before handling or performing other tests
7
13
Polarization Index
Interpretation of Polarization Index (PI) Measurements
PI Value Interpretation
> 4.0 Healthy
4.0 2.0 OK
2.0 1.5 Marginal Pass
1.5 1.0 Deteriorated condition
< 1.0 Failure
14
8
15
Insulation Resistance Test
16
Volume Current
Tester
Surface leakage
current
9
17
Capacitive
Current
Dielectric
Absorption
Current
Conduction
Current
Total
current
Time
A
18
10
19
Guard Connections
20
3 Terminal Insulation Resistance Tester
11
21
Spot Any Difference? Why?
22
Inaccuracies can occur during IR measurement
due to the following
Effect of Previous Charge
Effect of Temperature
Effect of Moisture
Effect of Age and Curing
12
23
Test procedures
Hot resistance test - at least 4 hours after shutdown from full-load
operation, or until temperature is stabilized:
Disconnect the equipment to be tested from other equipment
Ground the winding to be tested for at least 10 minutes
Remove the ground connection and connect the insulation
resistance tester
Take readings at 1 -minute and at 10 minutes
Record the temperature of equipment being tested
Ground the winding again for at least 10 minutes
Cold resistance test - Four to eight hours after the hot resistance test or
when equipment has cooled to approximately ambient temperature
Use same procedure as outlined for the hot resistance test
24
Spot Reading
13
25
Temperature Correction
Dry type insulation 40C ambient
Liquid type insulation 20C ambient
Insulating materials have negative resistance
characteristics
Spot test reading must be corrected to a base
temperature
26
Conversion Factors For Converting
Insulation Resistance Test Temperature to 20 C
Temperature Multiplier
C F
Apparatus
Containing Immersed
Oil Insulations
Apparatus
Containing Solid
Insulations
0 32 0.25 0.40
5 41 0.36 0.45
10 50 0.50 0.50
15 59 0.75 0.75
20 68 1.00 1.00
25 77 1.40 1.30
30 86 1.98 1.60
35 95 2.80 2.05
40 104 3.95 2.50
45 113 5.60 3.25
50 122 7.85 4.00
55 131 11.20 5.20
60 140 15.85 6.40
65 149 22.40 8.70
70 158 31.75 10.00
75 167 44.70 13.00
80 176 63.50 16.00
14
27
28
Polarization Index
Polarization index = R10/R1 = I1/I10
(keeping voltage constant)
where:
R10 = megohms insulation resistance at 10 minutes
R1 = megohms insulation resistanceI at 1 minute
I1 = insulation current at 1 minute
I10 = insulation current at 10 minutes
15
29
Polarization Index
30
INSULATION 60/30 SECOND RATIO 10/1 MINUTE RATIO
CONDITION Dielectric Absorption Ratio Polarization Index
Dangerous Less than 1 Less than 1
Poor Less than 1.1 Less than 1.5
Questionable 1.1 to 1.25 1.5 to 2
Fair 1.25 to 1.4 2 to 3
Good 1.4 to 1.6 3 to 4
Excellent Above 1.6 Above 4
Interpretation
16
31
Step Voltage Test
32
Step Voltage Test
17
33
PI & DLF
PI
If a PI falls by 30% or more from the previous value then remedial
action such as cleaning, oil-filtering or further investigation should
be considered.
Tan Delta
If the IFT and oil moisture content exceed their respective limits
then Tan Delta test is recommended. This is a good complement to
PI test and as remedial action drying is usually performed.
Field test results must be corrected to 20
o
C before comparison.
34
Tan Delta (DLF) test
In on site tan delta measurement there are two modes namely Grounded
Specimen Test (GST) and Ungrounded Specimen Test (UST). During GST
mode, the dielectric loss of insulation between one of the windings to
ground will be measured depending on the winding that is being excited.
Under UST mode, dielectric loss of insulation between the two windings
will be measured irrespective of the winding being excited.
The ratio obtained from the field test should agree with nameplate
value within 0.2% for the insulation system between the high
voltage and low voltage winding at all taps. Otherwise, winding
repair is recommended.
The ratio obtained from the field test should be within the limit of
0.5% for the insulation system between the high voltage winding
and ground. Otherwise, winding repair is recommended.
18
35
Power Factor Test
Power Factor = cos = i
r
/ i
t
90
0
=
Dissipation Factor = tan = i
r
/ i
c
36
Power Factor Test
For small , Cos (90 ) = tan
tan = i
r
/ i
c
i
c
= CV
i
r
= CV tan
Power loss (dielectric loss) = V i
r
= CV
2
tan watt
Dielectric loss is dependent on voltage and frequency
Variation of tan with voltage is an important diagnostic method
and will be part of this course
19
37
Power Factor Test
Power factor or dissipation factor is a measure of insulation
dielectric power loss
Not a direct measure of dielectric strength
Power-factor values are independent of insulation area or
thickness
Increase in dielectric loss may accelerate insulation
deterioration because of the increased heating
Insulation power factor increases directly with temperature
Temperature corrections to a base temperature must be
made, usually to 20 degree C
38
Power Factor Test
Windings not at test potential should be grounded
Refer to IEEE Standard No. 262, 1973
Test sets consist of a completely shielded, high-voltage,
50-Hz power supply which applies up to 10 kV to the
equipment being tested
Much simpler and less expensive tester is also available
which applies about 80 volts to the equipment being
tested but not sufficiently shielded against induced
voltages
20
39
40
Power Factor Test Set up
21
41
Temperature correction factors for the power factor
of power transformer windings
From IEEE Standard No. 262, 1973
where:
FP20 = power factor corrected to 20 degree C
FPT = power factor measured at T degree C
T = test temperature
K = correction factor from table
42
Temperature correction factors for the power factor
of power transformer windings
22
43
Material Power Factor approx.)
Bakelite 2 - 10%
Vulcanized Fibre 5%
Varnished Cambric 6 - 8%
Mica 2%
Polyethylene 0.03%
New Insulating Oil 0.01-0.2%
Power Factor of Some Common Materials
44
Insulation Current Test
High Voltage DC/AC Test
The voltage is slowly raised in discrete steps, allowing
the leakage current to stabilize for a predetermined time
A plot of the leakage current as a function of test voltage
yields information on the condition of the insulation
If the curve is a straight line, it indicates good condition
of the cable
If the current begins to increase at a rapid rate, indicates
degradation / defects in the cable insulation
After the completion of the test, the cable under test is
grounded for sufficient time to discharge the voltage
build up due to effects of absorption currents
23
45
46
Insulation Current Test
HVDC
A
Applied Voltage (% of Maximum Voltage)
20 40 60 80 100
20
40
60
80
100
120
Healthy Indicates
Concern
24
47
48
HIGH-VOLTAGE, DC/AC TESTS
Very little supply power is required to operate the DC
test set
The DC test set is portable and smaller than an ac, high-
voltage tester
Disconnect the buswork from the unit
The dc breakdown voltage may range from 1.41 times
the rms ac breakdown voltage to 2.5 times the rms ac
puncture voltage
Cases have indicated that on winding insulation with
some deterioration, the application of overpotential tests
may cause further deterioration, even though the
insulation may not puncture
25
49
Test Procedure
The machine winding should be grounded for at least 1
hour before conducting the test
The phases should be separated and tested individually
Lightning arresters and capacitors must be disconnected
Cables and/or buswork should be disconnected if it is
convenient to do so
If the separation of phases is difficult then separation is
needed once for the benchmark tests, and thereafter the
phases may be tested together until deviation from normal
is detected
50
Test procedure
The voltage should be raised abruptly to the first voltage
level with the start of timing for the test.
The ratio of the 1-minute to the l0-minute reading of
insulation current will afford useful indication of
polarization index
This gives the test engineer an idea of insulation dryness
early in the test
The test schedules are arranged to include a minimum of
three points up to and including the maximum voltage
26
51
Test procedure
If the insulation microampere versus voltage plots are
straight lines, the test may be continued to the maximum
test voltages
The quality of the insulation may be judged by the
position of any curvature or knee in the plot of insulation
current versus test voltage
If curvature or knee appears, the test should be stopped
Upon completion of the dc, high- voltage test, the
winding should be discharged through the special
discharge resistor usually provided with the test set
The winding may be solidly grounded when the voltage
has dropped to zero or after a few minutes of discharge
have occurred
A winding should remain solidly grounded long enough
before restoring the machine to service
52
HIGH-VOLTAGE, DC TESTS - RAMPED VOLTAGE METHOD
The ramped technique of insulation testing uses a
programmable dc, high-voltage test set and
automatically ramps the high voltage at a preselected
rate (usually 1 kV/min)
Insulation current versus applied voltage is plotted on an
x-y recorder providing continuous observation and
analysis of insulation current response as the test
progresses
The principal advantages of the ramp test over the
conventional step method is the elimination of the human
factor which makes it much more accurate and
repeatable
27
53
Destructive go/no go tests
High Voltage DC/AC
Less capable of revealing voids or cavities left inside the
accessories
Useful in detecting the defects related to contamination
along the interface between the different components of
the insulation system
Voltage applied is usually three to four times the nominal
phase-to earth voltage for 15 minutes or more
This is destructive test
54
Turns Ratio test
This test only needs to be performed if a problem is suspected
from the DGA.
It indicates shorted turns.
Shorted turns may result from short circuits or dielectric
(insulation) failures.
The ratio obtained from the field test should agree with the factory
within 0.5%. Otherwise winding repair is recommended.
28
55
Turns Ratio test
56
Turns Ratio test
29
57
Winding Resistance test
This test only needs to be performed if there is a high rate of generation
of ethylene and ethane.
Turns ratio test give indications that winding resistance testing is
warranted.
Resistances measured in the field can be compared to the original
factory measurements or to sister transformers.
Agreement within 5% for any of the above comparisons is considered
satisfactory.
If winding resistances are to be compared to factory values, resistances
measurements will have to be converted to the reference temperature
used at the factory.
58
Since the winding resistance changes with temperature, the winding and oil
temperatures must be recorded at the time of measurement and all test
readings must be converted to common temperature to give meaningful results.
Most factory test data are converted to 75C which has become the most
commonly used temperature.
Rs = Resistance at the factory reference temperature (found in the transformer
manual)
Rm = Resistance you actually measured
Ts = Factory reference temperature (usually 75 C)
Tm = Temperature at which you took the measurements
Tk = A constant for the particular metal the winding is made from:
234.5 C for copper
225 C for aluminum

30
59
Four terminal testing set up
V
I
P1 P2 C1 C2
Measured Resistance (R) = V/I
1
1
2
Transformer Advanced Off-Line
Diagnostic Testing
2
3
Advanced Diagnostic Testing
Most of the techniques, whether chemical or electrical
methods, or destructive or non-destructive methods, only
provide partial information about the state of the
insulation condition of power transformers.
More advanced condition monitoring or condition
assessment techniques have been developed and are
now starting to come into more general use.
They have been developed in response to the need for
new materials assessment methods.
However, in some advanced diagnotics tools are still in
the developmental stage, either in the technical
development or, more likely, in the methods of analysis
and interpretation of the test data.
4
Polarization and Depolarization Current Measurement (PDC)
Frequency Domain Dielectric Spectroscopy (FDS)
Frequency Response Analysis (FRA)
Partial Discharge (PD) Measurement
RVM, PDC & FDS are based on the used of the dielectric
response of insulating materials to the application of electric
fields Conductivity, Polarization & Dielectric Response
3
5
When a dielectric material with polar molecular structure is
subjected to a DC voltage, the electric dipoles are oriented within
the material in response to the applied electric field.
There is thus a polarization charge induced by the dipole
movement and realignment and this will effectively give a voltage
across the capacitance. When the dielectric is short circuited, the
stored charge in the dielectric capacitance is dissipated by a
current discharge with a time constant determined by the
effective intrinsic resistance and capacitance.
During the short circuit the voltage across the dielectric is zero,
but when the short circuit is removed before total charge to
equilibrium occurs, then a voltage will appear across the
dielectric. This measured voltage is known as the recovery
voltage.
6
4
7
Recovery Voltage Measurement (RVM) - TETTEX 5461
8
A dielectric material becomes polarized when exposed to an electric field.
Polarization is proportional to the intensity of the electric field and by
measuring the current, polarization process can be observed. The current
density is the sum of the conduction current and the displacement current.
When the insulating material is exposed to a step voltage, polarization
current is obtained. If the step voltage is removed, a reverse polarity current
known as depolarization current is obtained. These two currents can be
used to determine the response function and the conductivity of the
dielectric material.
The PDC is a DC testing method which determining the polarization
spectrum in time constant domain between 10e-3 10e3 seconds in which
the interface polarization phenomena of long time constant are active. The
range of polarization is strongly influenced by the absorbed moisture and
the deterioration by product content of the paper insulation. It applies a
500V step of DC voltage to the high or low voltage winding insulations of
transformers. Time of voltage application is typically up to 10000 seconds.
Both the polarization and depolarization times are performed for the same
period of time.
Polarization & Depolarization Current (PDC)
5
9
The polarization current pulse has a peak magnitude, a final
steady state level and a time constant and duration that are
determined by the quality of the oil including both the moisture
level and the electrical conductivity. In genera the electrical
conductivity affects the peak current in the first 100 seconds or
so of the current pulse. The moisture in the insulation affects the
longer term polarization current level after about 1000 seconds.
[Figure 8.6]
Polarization and depolarization current measurement method
gives general information about the state of insulation condition.
This technique is proved to be a useful testing method in
predicting of moisture and development of ageing phenomena.
10
Effect of moisture in oil and cellulose paper on the polarization
depolarization current measurement
6
11
In the FDS technique, a known sinusoidal voltage is applied and
measured together with the current passing across the insulation
material.
The measurement is repeated for several frequency sweeps -
from high frequency to low frequency for minimizing the memory
effects.
Advantage - the complete diagnostic on the property change in
the material can be discerned
By dividing the current by the voltage and comparing the phase
difference, both the capacitance and the loss at the particular
frequency and amplitude can be calculated.
Frequency Dielectric Spectroscopy Measurement (FDS)
12
The advantage of an analysis of the dissipation factor frequency
as compare at fixed frequency:
Behaviour of insulation caused by moisture affects can be evaluated.
At higher frequencies the pressboard and the oil volume determine
the dielectric loss, at medium frequencies the oil conductivity is the
dominant factor and the lower frequency range is dominated by the
pressboard dielectric loss.
7
13
Example on how moisture affects the dissipation factor of kraft
paper at 20C
14
Measurement results of the insulation between primary and
secondary to tertiary windings on a power transformer.
8
15
PROGRAMMA IDA 200
16
Frequency Response Analysis
How do you know whether you can energize A
TRANSFORMER after transportation to site or
after a protection trip?
Check Mechanical Integrity
9
17
When does Mechanical Integrity matter?
Re-location
Short Circuit
Lightning
Tap-changer fault
Transportation damage can occur if the clamping and
restraints are inadequate; such damage may lead to core
and winding movement.
Radial buckling or axial deformation may occur due to
excessive short circuit forces while in service.
18
What you can identify by checking mechanical integrity?
Core Movement
Winding Deformation
Faulty Core Grounds
Partial Winding Collapse
Hoop Buckling
Broken or Loosened Clamping Structures
Shorted Turns and Open Windings
10
19
What Test can be Done?
Frequency response analysis (FRA) using a
low voltage AC wave of varying frequency to
identify changes in natural resonance
20
Why FRA?
FRA Technique: The technique covers the full dynamic range and
maintains the same energy level for each frequency, providing results
that are repeatable and accurate.
Impulse Technique: This technique requires high sampling rates and
high resolution to obtain a valid measurement. The applied impulse does
not produce constant energy across the specified frequency, which can
cause poor repeatability that is influenced by the non-linear properties of
the test specimen.
11
21
What is FRA ?
FRA is a tool that can give an indication of core or winding
movement in transformers.
This is done by performing a measurement to look at how well
a transformer winding transmits a low voltage signal that varies
in frequency.
Transformer does this in relation to its impedance, the
capacitive and inductive elements which are intimately related
to the physical construction of the transformer.
Changes in frequency response as measured by FRA
techniques may indicate a physical change inside the
transformer, the cause of which then needs to be identified and
investigated.
22
12
23
24
Test Equipment
13
25
26
14
27
28
What is the frequency range?
The measured frequency range is normally very large,
which can be from 5Hz up to 10MHz
This frequency range covers the most important
diagnostic areas:
Core and Magnetic Properties
Winding Movement and Deformation
Interconnections-Leads and Load Tap Changer
15
29
30
The magnitude and the angle of the complex transfer function
can be obtained using a network-analyzer
The resulting amplitude of the measurement can be expressed
as,
H (dB) = 20 log10 [(ZS)/(ZS+ZT)]
The resulting phase is defined by
H () = tan-1 [(ZS)/(ZS+ZT)]
16
31
32
17
33
What are the ANALYZING TECHNIQUES?
Signature
Difference
Transfer Function
Statistical
FRA Signatures are analyzed based on 3 band
methods
34
What do the 3 Bands mean?
5Hz up to 10KHz defect in core and magnetic
circuit
10KHz up to 600KHz deformation in winding
geometry
600KHz up to 10MHz abnormalities in the
inter-connection and test
system
18
35
SIGNATURE TECHNIQUE
36
SIGNATURE TECHNIQUE
19
37
SIGNATURE TECHNIQUE
38
DIFFERENCE TECHNIQUE
(Phase A before)
20
39
(Phase A after)
40
This technique can analyze the windings phase by phase, which is not
possible in the signature technique
21
41
Historical data or Baseline Reference are, undoubtedly,
the best reference to be used for FRA analysis
However, it is not practically easy to get historical data due
to constraints of outages
Criteria to choose reference FRA measurements in the
absence of historical data or baseline reference
42
Different Different Same Same Peer
Different Same Same Same Sister
Same Same Same Same Twin
S/S
LOCATION
MANU-
FACTURER
MVA
RATING
KV RATIO
CATEGORY
22
43
Partial Discharge
What is PD Electric discharge that do not completely
bridge the electrodes
Discharge magnitude is usually small but can cause
progressive deterioration and lead to failure
Overeating of dielectric boundary
Charges trapped in the surface
Attack by ultraviolet rays & soft X-rays
Formation of chemicals such as nitric acid & ozone
Therefore presence of PD need to be detected in a
non-destructive test
44
Partial Discharge
PD Classification
23
45
Partial Discharge
PD Classification
46
Partial Discharge
Occurrence of PD Inception Voltage
24
47
Partial Discharge
Occurrence of PD Inception Voltage
48
Partial Discharge
Occurrence & Recognition
Detection
Measurement
Location
Evaluation
25
49
Partial Discharge
Evaluation
Amplitude in dB
Energy or charge in pC
Duration in ms
50
Partial Discharge
On-line acoustic PD Detection - Physical Acoustic DISP-24
26
51
Why SFRA in a factory environment?
Quality assurance
Baseline reference
Relocation and commissioning preparation
Manufacturers are using SFRA as part of their quality program to ensure
transformer production is identical between units in a batch
52
Why SFRA in a field environment?
Relocation and commissioning validation
Post incident: lightning, fault, short circuit, seismic event
etc
Once a transformer arrives on site after relocation it must be tested
immediately, to gain confidence in the mechanical integrity of the
unit prior to commissioning
27
53
Frequency Response Analysis is a very effective tool for
diagnosing transformer mechanical integrity both in the
factory and in the field,
which cannot always be detected using other means
The best way to obtain baseline reference results is,
undoubtedly, on completion of the manufacturing
process at the factory
However, in the absence of baseline reference the
proposed criterion of twin, sister, and peer transformers
can be used as references with reasonable degree of
accuracy
54
Transformer Maintenance (Dry Type)
Electrical Tests
Perform insulation-resistance tests winding-to-winding
and each winding-to-ground
Perform turns ratio tests at the designated tap position
Perform power-factor or dissipation-factor tests
Measure the resistance of each winding at the
designated tap position
Measure core insulation-resistance at 500 volts dc if
core is insulated
28
55
Insulator Maintenance
Inspection - look for cracks, dirt etc., tracking, copper wash,
mechanical damage
Cleaning - Wash, dry wipe
Repairs - Usually replace except special cases
Testing - Megger & Power Factor test
Do not climb on or use for personal support!
56
Transformer Maintenance (Liquid filled)
Visual inspection
Inspect physical condition for evidence of moisture and corona
Verify operation of cooling fans
Verify operation of temperature and level indicators, pressure
relief device, and gas relay
Verify correct liquid level in all tanks and bushings
Verify correct equipment grounding
Verify the presence of transformer surge arresters
Test load tap-changer
Inspect all bolted electrical connections for high resistance using
one of the following methods:
1. Use of low-resistance ohmmeter
2. Perform thermographic survey
29
57
Transformer Maintenance (Liquid filled)
Electrical Tests
Perform turns ratio tests at all tap positions
Perform power-factor or dissipation-factor tests
Measure the resistance of each winding at all tap positions
Perform insulation-resistance tests winding-to-winding and each
winding-to-ground
If core ground strap is accessible, measure core insulation
resistance at 500 volts dc
Remove a sample of insulating liquid in accordance with ASTM
D923
Test for Oil Quality, DGA and Furan
58
Diagnostic Testing provides a powerful tool for the
complete and economic assessment of the transformer
condition
There is nevertheless still a lack on how to integrate the
information obtained by the on-line monitoring into the
actions taken onto the service of the transformer
The supplementary information obtained by the off-line
diagnostic after the detection of an abnormal condition is a
worth-full information to be integrated into future on-line
monitoring systems
Conclusion
1
1
2
Test Results
Interpretation
2
3
1. Scoring
Scoring can be applied to test results to indicate
acceptable condition level of transformers.
Transformer condition indicator scoring is somewhat
subjective, relying on transformer condition experts.
Relative terms are used and compared to industry
accepted levels; or to baseline or previous
(acceptable) levels on this transformer; or to
transformers of similar design, construction, or age
operating in a similar environment.
4
2. Weighting Factors
Weighting factors is used to recognize that some
condition indicators, affects the Condition Index to a
greater or lesser degree than other indicators.
These weighting factors were arrived at by
consensus among transformer design and
maintenance personnel with extensive experience.
3
5
3. Mitigating Factors
Every transformer is unique and, therefore cannot
quantify all factors that affect individual transformer
condition.
It is important that the Transformer Condition Index
arrived at be scrutinized by experts.
Mitigating factors specific to the utility may determine
the final Transformer Condition Index and the final
decision on transformer replacement or
rehabilitation.
6
1. Tan Delta for Main Tank
Perform appropriate advanced
electrical tests tests as recommended
by the expert or internal inspection of
main tank immediately.
0 % tan > 5
The monitoring frequency should be
revised to 3 months. Make arrangement
for advanced electrical tests tests.
1 4 <% tan < 5
revised to 6 months.
2 2 <% tan < 4
Normal. The monitoring frequency of
24 months can be maintained.
3 %tan < 2
Action Score Results
This test is done on the transformer at regular interval under normal condition. This test results
are considered for condition assessment of an in-service transformer.
4
7
2. Turns-Ratio Test
Perform appropriate advanced
electrical tests tests as recommended
by the expert or internal inspection of
main tank and OLTC tank
immediately.
0 % deviation >0.5
revised to 3 months. Make
arrangement for advanced electrical
tests tests.
1 0.3 <% deviation < 0.5
2 0.2 <% deviation < 0.3
Normal. The monitoring frequency of
3 % deviation < 0.2
This test is done on transformer at regular interval of 24 months under normal condition. This
test results are considered for condition assessment of an in-service transformer.
8
3. Winding Resistance Test
Perform appropriate
advanced electrical tests tests
as recommended by the
expert or internal inspection
of main tank immediately.
0 More than 10% difference
between phases or from
factory tests
The monitoring frequency
should be revised to 3
months. Make arrangement
for advanced electrical tests
tests.
1 7 to 10% difference between
phases or from factory tests
The monitoring frequency
should be revised to 6
months.
2 5 to 7% difference between
phases or from factory tests
Normal. The monitoring
frequency of 24 months can
be maintained.
3 No more than 5% difference
between phases or from
factory tests
This test is done on transformer at regular interval of 24 months under normal condition. This
5
9
4. Main Winding Insulation
Resistance Test
Perform appropriate advanced electrical tests
tests as recommended by the expert or
internal inspection of main tank
immediately.
0 PI value < 1.0
The monitoring periodicity should be revised
to 3 months. Make arrangement for
advanced electrical tests tests.
1 1.0< PI value < 1.5
The monitoring periodicity should be revised
to 6 months.
2 1.0< PI value < 3.0
Normal. The monitoring periodicity of 24
months can be maintained.
3 PI value 3.0
This test is done on transformer tail at regular interval of 24 months under normal condition. This
10
5(i). Oil Quality Test
0.2
0.4
0.1
0.3
Weightage
Power factor 4
Acidity 3
BDV 2
Moisture 1
Criteria No
6
11
5(ii). Oil Quality Test
> 0.5
0.31 0.5
0.21 0.3
0.11 0.2
0.091 0.1
0.071 0.09
0.051 0.07
0.031 0.05
0.01 0.03
< 0.010
IFT
>0.31
0.25-0.3
0.21-0.24
0.17-0.20
0.13-0.16
0.1-0.12
0.07-0.09
0.05-0.06
0.02-0.04
<0.01
Acidity
<15
15-19
20-24
25-29
30-35
36-40
41-45
46-50
51-55
>56
BDV
(kV)
1 >50
2 46-50
3 41-45
4 36-40
5 31-35
6 26-30
7 21-25
8 16-20
9 11-15
10 0-10
Condition Indicator
Score
Moisture
(ppm)
12
6. Fault Gases Limit
> 4000 > 1400 > 800 > 150 > 150 > 80 > 1420 Condition 4
1916 -
4000
571 -
1400
401 -
800
101 -
150
101 -
150
46 - 80 701
1420
Condition 3
721 -
1915
351 -
570
121 -
400
66 -
100
51 - 100 36 - 45 101
700
Condition 2
720 350 120 65 50 35 100 Condition 1
TDCG CO CH
4
C
2
H
6
C
2
H
4
C
2
H
2
H
2
Status
7
13
7. Key Gases Analysis
1
2
2
3
4
5
5
6
7
8
8
9
10
Condition
Indicator Score
7
5-6
3-4
<2 Condition 4
7
5-6
3-4
<2 Condition 3
7
5-6
3-4
<2 Condition 2
0 Condition 1
Per unit exceeded Individual fault gases exceed
limit
14
8. Furanic Analysis
1 <373 >1800
2 374-387 1601-1800
3 388-404 1401-1600
4 405-423 1201-1400
5 424-446 1001-1200
6 447-474 801-1000
7 475-509 601-800
8 510-559 401-600
9 560-645 201-400
10 646-1300 0-200
Condition Indicator Score Estimated DP Furanic
8
15
9. Oil Quality, Key Gases & Furan
Analysis Score
Seek immediate advice from the expert
to perform advanced electrical test or
internal inspection
0 Overall ranking 1.5
The monitoring periodicity should be
revised to 3 months. Make
arrangement for advanced electrical
tests.
1 1.5 Overall ranking 4.0
The monitoring periodicity should be
2 4.0 Overall ranking 7.5
Normal. The monitoring periodicity of
3 7.5 Overall ranking 10
This test is done on transformer at regular interval under normal condition. This test results are
considered for condition assessment of an in-service transformer.
16
10. FRA
Indicates serious problem requiring immediate
evaluation, additional testing (if applicable)
and immediate consultation with experts
Subtract 1.5 Significant deviation
Comparison between phases (using Cross-
correlation Index):
CCI at low freq zone <0.6
Retest the transformer for FRA after 3
months. Arrange for replacement of defective
section(s).
Subtract 1.0 Moderate deviation
correlation Index):
0.6<CCI at low freq zone <1.0
CCI at mid freq zone < 0.6
Retest the transformer for FRA after 6
months. The monitoring periodicity of all
basic electrical tests tests should be
maintained at 6 months.
Subtract 0.5 Minor deviation
correlation Index):
1.0<CCI at low freq zone <2.0
0.6<CCI at mid freq zone < 1.0
The monitoring periodicity of all basic
electrical tests tests should be maintained at 6
months. Practice FRA test if necessary.
Subtract 0 No deviation
correlation Index, CCI):
CCI at low freq zone >2.0
CCI at mid freq zone > 1.0
CCI at high freq zone > 0.6
Action Score
Adjustment
Results
9
17
11. FDS
Indicates serious problem requiring
immediate evaluation, additional
testing (if applicable) and immediate
consultation with experts
Subtract 1.5 % moisture in paper > 4
Retest the transformer for FDS after 3
months. Arrange for replacement of
defective section(s).
Subtract 1.0 2 < % moisture in paper < 4
Retest the transformer for FDS after 6
months. The monitoring periodicity of
all basic electrical tests tests should be
maintained at 6 months.
Subtract 0.5 1.5 < % moisture in paper < 2
The monitoring periodicity of all basic
electrical tests tests should be
maintained at 6 months. Practice FDS
test if necessary.
Subtract 0 % moisture in paper < 1.5
Action Score
Adjustment Results
18
12. PD
Indicates serious problem requiring
immediate evaluation, additional
testing and immediate consultation
with expert. Recommendation is to
remove the transformer from service
immediately.
Subtract 1.5 Amplitude 80-90 dB
Energy 400-500
Duration 4000 ms-5000 ms
Retest the transformer for PD after 3
months. Arrange for replacement of
defective section(s).
Energy 200-400
Retest the transformer for PD after 6
months. The monitoring periodicity
of all basic electrical tests tests should
be maintained at 6 months.
Energy 200-300
The monitoring periodicity of all
basic electrical tests tests should be
maintained at 6 months. Practice PD
test if necessary.
Subtract 0 Amplitude 40-60 dB
Energy 1-200
Action Score
Adjustment Results*
10
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