SESSION I-2

International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009
CONDITION MONITORING AND RESIDUAL LIFE ANALYSIS OF THE
CIRCUIT BREAKERS, POWER TRANSFORMERS, CURRENT
TRANSFORMERS AND LIGHTNING ARRESTERS

D.R.Dharmadhikari
1
, Sameeksha Raina
2
, B. Karunakaran
3
and Ravindra Bhanage
4
North Delhi Power Ltd, Delhi, India
1
dr.dharmadhikari@ndpl.com;
2
sameeksha.raina@ndpl.com;
3
b.karunakaran@ndpl.com;
4
ravindra.bhanage@ndpl.com

Abstract: The focus of this paper centers on the Condition Monitoring and Residual Life
Assessment. These are the modern scientific tools which provide accurate measurement on the
condition of the critical equipments like power transformers, Circuit breakers, CTs, LAs etc.The
need of the RLA is based on the idea of operating the equipments till the end of their useful life,
rather than its design life. This paves way for the performance based management of the assets.
A systematic approach is adopted for carrying out the study. To assess the condition of the
equipment, it requires the deployment of Non destructive techniques and procedures For RLA, as
a first step, the available data for all the equipments under study is collected. In the second step
the actual On-line and off-line testing with the required parameters is carried out and data
compared and analysed with available data and the limits specified. Immediate corrective action
if required is taken to correct the minor deviations. If any major deviations are detected, the
corrective action is planned in consultation with the manufacturer. Also, for RLA study the
tripping data is collected along with the magnitude of fault current during the fault. The results of
the tests performed on the equipments are compared against the manufacturer standards and
plotted against this tripping data. The results are interpreted to match the fault data and fault
levels of grid stations recorded in the recent past. The knowledge and understanding of the
satisfactory and unsatisfactory condition of the equipments is gained and made explicit from the
analysis of various on-line and off-line test results.

I. Introduction:
The increasing demand for quality and reliable power necessitates zero tolerance to any
kind of defects. In order to achieve maximum reliability the critical equipments like Circuit
Breakers, Power Transformers, Current Transformers, and Lightning Arresters are to be
monitored and maintained at regular intervals. In 2002 Distribution in Delhi was privatized
which led to formation of three Distribution companies, NDPL (NORTH DELHI POWER
LIMITED - A joint venture of TATA POWER & DELHI Govt.) was one of them. After
formation of NDPL, health check on various equipments across the network had been carried
out, based on which it was decided to run, repair & replacement of the equipments. The
preliminary phase of repairing & replacing of the critical equipments was completed. These
equipments had also completed 2-3 years of service, during which certain equipments had been
stressed by feeding faults of considerable magnitude.
As part of life assessment of the equipments, a study is undertaken on grid station
equipments especially on Circuit breakers, Power Transformers, Current Transformers, and
Lightning Arresters. This paper deals with the analysis made on the Tripping data and fault
current seen by the breaker under fault conditions and various tests performed on the equipment.
The tests performed on these equipments are mostly OFF-Line and thermal scanning an effective
ON-Line tool was used to monitor the performance of the equipments.
SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009
II. HOLISTIC APPROACH TO CONDITION MONITORING AND RLA:
Significant amount of money and time are spent in managing critical assets each year and a
variety of approach has been employed, yet there are high profile failures that hit the headlines.
Any occurrence in the system and operation costs lots of money, in the forms of:
Operational disruption
Loss of lives
Injuries
Assets damaged
Damage to corporate reputation
Environmental damage and pollution

What are the sources of problem?
Lack of maintenance
Ageing equipment
Inadequate design
Poor specification
Time constraints
Poor safety / operational management
O&M Manual not up to date
Poor / inadequate training
Inadequate consideration of environment and human
Performance interaction
Things are no longer running as we planned
Poor construction quality

Performance management:
The need to adopt more effective performance and asset management regimes is one of the
important topic for the utility industries. The universal question is: how can we strike the right
balance between reliability and quality of supply, and capital and operational expenditure?
Commonly used processes adopt a reliability based approach to managing systems. These are
based on understanding the failure rates of equipments and implementing interventions based on
that knowledge. Key elements missing from this approach are the understanding of the
consequences of the failures and risk that such failures present to the operations.

Methodology:
! Identify Problems
! Analyze the Problems
! Evaluate
! Treat
! Track and Monitor
! Review
! Communicate and Document

SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009


PROCEDURE ADOPTED for RLA:
The following procedure is adopted for circuit breakers:
(1) The tripping record of each and every breaker for past 2 years was collected (almost all the
breakers were replaced starting from first half of 2005) and the fault current recorded by the
Numerical relays on the breaker in the recent past were noted down, the average value was taken
as reference and multiplied to the tripping and cumulative fault current seen by the breaker was
obtained.
(2) The various Offline tests are performed on the breaker included PI, Contact resistance,
Breaker operating time and Dynamic contact resistance.
(3) Thermal scanning on breaker poles with very high contact resistance was used for monitoring
the same.
(4) The condition of operating mechanism and auxiliary contacts was also assessed by the timing
and coil signatures.

The following procedure is adopted for Power Transformers:
(1) DGA analysis of oil is carried out once in 6 months.
(2) As part of ON-Line monitoring thermal scanning of the transformers were done.
(3) The various test performed on transformer included IR, PI, Magnetic balance,Tan delta,
TTR, Winding resistance and Device checks.
The results were analyzed to assess the condition of the Equipment and remedial actions were
taken.

The following procedure is adopted for Current Transformers:
(1) The OFF-Line test performed are , Capacitance and tan delta , Ratio test , knee point voltage
test , IR of Primary and secondary circuits , resistance of secondary windings , Primary current
injection testing.
(2) The As part of ON-Line monitoring thermal scanning of the CTs is done.
The trend of the results is monitored and necessary corrective actions are taken.

The following procedure is adopted for Lightning Arresters:
(1) The OFF-Line test performed is Insulation Resistance testing
(2) As a part of ON-Line testing Leakage current Measurement is carried out.
The trend of the results is monitored and necessary corrective actions are taken.

SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009
III A. Methodology followed for Condition Based Monitoring and Result Analysis
Circuit Breakers:
CBs are expected to protect circuits and plant by interrupting Short-Circuit current within
a time in the range of 80-150ms. The significance of Dynamic contact resistance is that it
determines the condition of the arcing tip which never gets reflected in the conventional tests. In
principle DCRM injects100A DC through the power contacts of Circuit breakers while breaker is
undergoing close-open operation. During this short time span it measures the voltage drop across
the contacts dynamically and relays it to the CB operational analyzer. The classical four wire
measurement method is employed to measure contact resistance. Change in Micro Ohm values
as moving and fixed contacts engage and disengage is plotted against time and a graphical record
is obtained through the analyzer. This dynamic record of micro ohm signature helps to analyze
the condition of the arcing contacts.
The significance of trip coil signatures is aimed on the concept that the deterioration in CB
condition also results from its inertia, where the effects of Stiction arising due to non operation
or rusting of mechanical parts can also result in CB failure or slow operation of the breaker when
it is most needed. The deterioration of mechanical parts resulting from frictional forces,
coagulation of lubricants, etc. remains disguised and subsequently neglected. Measurement of
CBs trip signature provides a useful insight into the operation of the CB and its condition. In
addition to its primary function of controlling of the breaker trip operation, the trip coil performs
a secondary role as a noninvasive condition monitoring sensor. Capturing the trip coil current
signature from the breaker at first trip will serve as record for subsequent breaker condition
assessment. The control or trip unit of the CB transforms the trip signal into the physical
operation of the breaker mechanism.

Power Transformers:
Dissolved gas analysis of Transformer oil is based on the breakdown of the molecules of
oil locally, in certain types of electrical faults such as ionisation, heating, arcing and pyrolysis of
cellulose. It is a powerful diagnostic technique for on line monitoring the internal conditions of
Transformers due to its capability to detect defects in the early stages before they develop into
major faults. In this method it is possible to check whether a Transformer is subjected to a
normal amount of ageing and heating or whether there are incipient defects. In order to make the
interpretations applicable to those cases of condition monitoring, where rise in concentration of
one or more individual gases is being observed. The simplified approach, which forms the new
method of interpretation, is given in the table.

Sr.
No.
Rise in gas concentration Interpretation
1 Nil Normal Ageing
2 H2 Corona Partial Discharge
3 CH4 and C2H6 Thermal fault of low temperature range up to 300

C

4 C2H4 With or without
CH4, C2H6, & H2
Thermal fault of 300

C or 700

C or above
5 C2H2 with without H2,
C2H4, C2H6
Arc or flash over or persistent sparking may be along with
overheating.
SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009
The two commonly used interpretation techniques of DGA were used:
! Rogers Ratio Method
! IEC 599 Method
The trending of DGA results along with electrical test results and thermovision scanning reports
form the basis of analysis of Power Transformers.

Current Transformers:
Electrical testing along with thermovision scanning reports form the basis of analysis of Current
Transformers.

Lightning Arresters:
The Leakage Current Monitoring (LCM) and Insulation resistance testing form the basis of
analysis of Lightning arrester. During the LCM testing , the third harmonic resistive currents and
total leakage current are measured and compared with the limits specified by the manufacturer
and as given in standards.

III B: Use Thermography as a major tool for RLA studies:

Few examples of using Thermography as a major tool for analysis are given below:

CASE 1: At RG-3 Grid station, the LV winding resistance of B phase of 66/11kV, 25 MVA
Power Transformer was found high compared to other two phases. To arrive at a precise
conclusion, Thermography was done and a hot spot was detected at the bottom of B phase LV
bushing. On inspection it was found that the bottom connecting rod B ph bushing was loose. The
same was attended.


CASE 2: At Jahangirpuri grid, as routine process under RLA, the thermography of 50 MVA,
66/33kV Power Transformer was carried out. The temperature of OLTC was found higher than
the main tank temperature by around 10 degrees. Immediately, the OLTC of transformer was
opened for inspection. Pitting marks and carbon deposits were found on the collector ring of the
OLTC. The collector ring was replaced.


CASE 3: At Rewari Line grid, as routine process under RLA, the thermography of 20 MVA,
33/11kV Power Transformer was carried out. The temperature of radiators was found less by 8
degrees than that of the main tank. The outage was arranged and it was found that the radiator
valves were in closed position.

SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009
IV TREND ANALYSIS

The following are the details of RLA study carried out:

(1) Circuit Breakers


(2) Power Transformers

Pow.tx Equip Equipments Exceptions
Service Tested % Detected
Breakup of exceptions
(nos) Completed (nos) Win.tand Win.res Oltc Pi/ir Bus.tand Dclo
66/33KV 5 1 20 3 1 0 0 0 1
66/11KV 51 38 74.5 42 5 4 3 2 8
33/11KV 68 44 64.7 42 14 13 0 2 0

Breakup of exceptions
CB
Eq in
Service
Equipments
Tested(nos)
%
Completed
Exceptions
Detected(nos) Timing Crm Dcrm Pi/ir
66KV 167 87 52.09 7 4 2 1 0
33KV 235 69 29.36 37 16 11 9 1
11KV 946 258 27.27 42 28 3 8 3
SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009


Manufacture wise issues


(3) Current Transformers
Ct Eq.ser Equipments % Exceptions Breakup of exceptions
Nos Tested(nos) Completed Detected(nos) Tandelta Ir Sec.res Kneepoint
66KV 241 66 51 14 1 0
33KV 1054 123 34.53 61 46 14 0 1

SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009




(4) Lightning Arresters

Eq.ser Equipments % Exceptions
Breakup of
exceptions
La Nos Tested(nos) Completed Detected(nos) Ir Leakage current
11KV 33 5 0 5
33KV 725 66 36.55 3 3 0
66KV 166 3 2 1

SESSION I-2
International Conference on Condition Monitoring & Diagnostic Engineering Management of Power Station / Substation Equipment - 2009


V. Conclusion:
By carrying out the RLA/RLE substantial saving is obtained in terms of avoiding the possible
damage to equipment and thereby enhancing the reliability. The saving obtained till date is
approximately seven crore rupees.
The maintenance related defects noticed during the study are rectified locally. Critical problems
like of pole discrepancy, timing etc which required high level expertise are referred to the
manufacturer and corrective action are taken accordingly. The data obtained from the study is
loaded onto the software supplied by our vendor for further review, trend analysis. The
corrective action is also logged into the software for further reference Those equipments where
the values were found on threshold of crossing the limits are marked for special attention and
frequency of next monitoring is fixed. These equipments are monitored at regular intervals for
physical and thermal properties. The following benefits are harnessed from the study.
1. To understand the condition of the assets and evaluate the risk involved in the operations.
2. Tracking of assets.
3. Provides focus on the control measures and the causes.
4. Helps to measure the effectiveness of controls mechanism in treating the problems.
5. Provides an effective tool to compare the performance of different products in system.

References:

1. IEEE transaction on power delivery.