2008 Field Presentation

WEIDMANN DIAGNOSTIC SOLUTIONS
Condition Assessment of
Electrostatic Precipitator
Transformer/Rectifiers
Using Dissolved Gas Analysis
New Orleans, LA
September 17, 2008
Norman Field
A Member of the Group
1
Condition Assessment of
ESP T/Rs
Using DGA
New Orleans, LA
September 17, 2008

2
Presentation Overview
Function & Operation of a T/R

Failure Modes
Condition Assessment using DGA

3
Part 1:
Function & Operation of a
Transformer/Rectifier

4
What is an ESP
Transformer/Rectifier?

5
What is an ESP

6
What is an ESP

7
What is an ESP
The T/R is a major component of the ESP
power supply system
Provides a DC voltage source for the ESP
discharge electrodes

8
Why is an ESP T/R important?
The Enviromental Protection Agency is

enforcing compliance with its Clean Air Act
The ESP keeps flue gas exhaust clean so that the

power plant is permitted to continue operation

9
Transformer/Rectifier Operation
The major components of the ESP power

supply system are:
Automatic Voltage Controller
Current Limiting Reactor
Feedback signals from T/R to AVC

10
Block Diagram of ESP Power Supply Components
Voltage Current Limiting Transformer/

Controller Reactor Rectifier ESP
Feedback Measurements

11
The T/R tank contains:

Single-phase Step-up Transformer
Current Limiting Reactor (sometimes)
Diode Bridge Rectifier
Resistor for voltage divider
Air Core Reactor
Mineral Oil or Silicone Fluid

12
What is an ESP

13
Typical characteristics of a T/R
Input Voltage = 400 V AC to 480 V AC
Output Voltage = 50 kV DC to 100 kV DC
Output Current = 0.5 A DC to 1.5 A DC
Power Capacity = 50 kVA to 100 kVA

14
Schematic of Transformer/Rectifier Circuit

15
T/R with D2 & D3 Diodes Conducting

16
T/R with D1 & D4 Diodes Conducting

17
Rectifier Input Voltage Waveshape
Rectifier Output Voltage Waveshape

18
T/R Diodes

19
Part 2:
Failure Modes

20
Transformer/Rectifier Failure Modes
Understanding failure modes helps to:
Interpret the dissolved gas analysis
Prepare a case for taking T/R out of service
Make a more informed choice of on-site tests

21
Causes of Excessive Dissolved Gas:
Overheating
Key Gases: Methane, Ethane, Ethylene, Carbon Monoxide
Partial Discharges (Sparking or Corona)

Key Gas: Hydrogen
Sustained Discharges (Arcing)

Key Gases: Acetylene, Hydrogen

22
Common Causes of Overheating of T/R

Components:
Overloading T/R by powering too many ESP

discharge electrodes
Excessive hotspots in transformer windings and current
limiting reactor windings
Dynamic load of ESP Arcing to Ground

Winding overheating from short-circuits
Diode failure at solder joint or diode junction

23

Common Cause of Partial Discharges within T/R:
Air Core Reactor insulation is highly stressed during
ESP arcs to ground

24
Other Causes of Partial Discharges within T/R:
Any improperly made or inadequately insulated

electrical connection
AVC not functioning correctly, creating an

overvoltage
Can affect transformer windings, CLR windings, air core
reactor, and rectifier diodes

25
Common Cause of Arcing within T/R:
Failing / Failed Diodes

Melted solder connection
Diode junction failed to open state

26
Other Cause of Arcing within T/R:
Failed Diodes
Unequal Peak Inverse Voltage between diodes
Only common in old T/Rs
Causes diodes to fail in domino fashion

27
Part 3:
Condition Assessment
Using
Dissolved Gas Analysis

28
T/R Condition Assessment using DGA
The Procedure:
Choose a database of T/R DGA results
Apply statistical method to analyze the data
Establish dissolved gas limits for Good
Caution and Warning categories
Establish Gas Ratio limits for Good
Caution and Warning categories

29
Database chosen from WDS T/R customers

Data spanned 9 years, from 1998 to 2007
Mineral oil: 519 samples, 398 T/Rs
Silicone fluid: 340 samples, 287 T/Rs
T/Rs from 24 kVA to 115 kVA

30

Summary of Raw Data

31
Process the raw data using the following steps:

(this method used by IEEE TC Working Group
on LTC DGA thank you Jim Dukarm)
Transform ppm data into their natural log values
Apply rules to identify and exclude outliers
Use interquartile range of distribution to reconstruct
a normal distribution
Choose Good Caution and Warning limits
from normal distribution
Calculate the inverse-log of these limits to transform
them back to ppm values
32
Methane (CH4) gas dissolved in mineral oil will be

used as an example to illustrate how to apply
this procedure...

33

Probability Plot of all 519 CH4 Data Points

34

Probability Plot of 517 Data Points

35

Probability Plot of Natural Log of 519 Data Points

36
From this data set we calculate:

Third quartile point, Q3 = 3.14
Median point, Mdn = 2.30
Interquartile Range, IQR = (Q3 Mdn)x2 = 1.68
Upper Outlier Limit, U1 = Q3 + 1.5 x IQR = 5.66

37

Probability Plot & Upper Outlier Limit

38
The outlier data points are removed, and Q3,

IQR, and U1 are recalculated.
This iterative process continues until no data
points are greater than the Upper Outlier Limit.
This process removed 9 outliers.

39

Probability Plot of Natural Log of 510 Data Points

40

From this final data set we have:
Q3 = 3.09 , Mdn = 2.30 , IQR = 1.58 , U1 = 5.46
Since for a Normal Distribution:
Standard Deviation, S = IQR / 1.35
Mean = Median
then
S = 1.17 and Mean = 2.30

These two values define our final Normal
Distribution
41

Final Normal Distribution

42
With the final Normal Distribution defined, we

choose the Good Caution and Warning
limits as follows:
Good limit = 90th Percentile Point of ND
Caution limit = 98th Percentile Point of ND
Warning limit = Any value > Caution limit

43
Since for a Normal Distribution:

90th Percentile Point, C0.90 = Mean + 1.28 x S
98th Percentile Point, C0.98 = Mean + 2.05 x S
then
C0.90 = 3.80 and C0.98 = 4.70

44
To convert these values back to ppm values,

we calculate their Inverse-Log:
C0.90 in ppm = exp(3.80) = 45 ppm of CH4
C0.98 in ppm = exp(4.70) = 110 ppm of CH4

45
Therefore the gas limit categories for Methane

are as follows:
CH4 in ppm is Good if
CH4 45 ppm
CH4 in ppm is in Caution range if
45 ppm < CH4 110 ppm
CH4 in ppm is in Warning range if
CH4 > 110 ppm
46
Using the described method, similar

calculations can be made for
H2, C2H6, C2H4, C2H2, and CO

for both mineral oil filled and silicone fluid
filled Transformer/Rectifiers.
(For Silicone Fluid filled T/Rs,
C0.90 = 127 ppm & C0.98 = 284 ppm
for CH4)
47
Once a given DGA result is assessed in terms

of Good Caution and Warning for each
gas, a ratio analysis can be applied to help
define the type of fault that may be occuring
inside the Transformer/Rectifier.

48
Apply Rogers Ratios:

CH4 / H2
C2H2 / C2H4
C2H4 / C2H6
if one or more gases were in Caution or
Warning range

49
Limits for Rogers Ratios are developed in the

same manner as for gas limits, by analyzing
the log-normal distribution of the ratio values
from the data set.
From the data set, use ratio values only when

both gases are at least 10x their respective
detection limit.

50

Using CH4 / H2 Ratio as an example:

51
From the final Normal Distribution:

98th Percentile Point, C0.98 = 1.2
2nd Percentile Point, C0.02 = 0.06
These CH4 / H2 ratio values can then be used as a

guide for providing diagnostic messages regarding
possible fault type

52
CH4 / H2 Value Diagnostic Message

> 1.2 Strong indication of excessive
internal heating
> 0.7 , 1.2 Moderate indication of excessive
internal heating
0.06 , < 0.1 Moderate indication of partial
discharge activity
< 0.06 Strong indication of partial
discharge activity

53
Using the described method, similar

calculations and other diagnostic messages
can be created for the other two ratios

54
In Summary:
Using a known statitical method,
applied to an extensive database,
one can establish guidelines to help
assess the condition of T/Rs using
DGA test results.

55

56
Thank you
For
Listening

57

2008 Field Presentation

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WEIDMANN DIAGNOSTIC SOLUTIONS

A Member of the Group

Function & Operation of a T/R

A Member of the Group

A Member of the Group

A Member of the Group

A Member of the Group

A Member of the Group

A Member of the Group

Why is an ESP T/R important?

The Enviromental Protection Agency is

The ESP keeps flue gas exhaust clean so that the

A Member of the Group

The major components of the ESP power

Automatic Voltage Controller

Current Limiting Reactor

Feedback signals from T/R to AVC

A Member of the Group

Block Diagram of ESP Power Supply Components

Voltage Current Limiting Transformer/

A Member of the Group

The T/R tank contains:

A Member of the Group

A Member of the Group

Typical characteristics of a T/R

Input Voltage = 400 V AC to 480 V AC

Output Voltage = 50 kV DC to 100 kV DC

Output Current = 0.5 A DC to 1.5 A DC

Power Capacity = 50 kVA to 100 kVA

A Member of the Group

A Member of the Group

A Member of the Group

A Member of the Group

Rectifier Output Voltage Waveshape

A Member of the Group

A Member of the Group

A Member of the Group

Transformer/Rectifier Failure Modes

Understanding failure modes helps to:

Interpret the dissolved gas analysis

Prepare a case for taking T/R out of service

Make a more informed choice of on-site tests

A Member of the Group

Transformer/Rectifier Failure Modes

Causes of Excessive Dissolved Gas:

Partial Discharges (Sparking or Corona)

Sustained Discharges (Arcing)

A Member of the Group

Transformer/Rectifier Failure Modes

Common Causes of Overheating of T/R

Overloading T/R by powering too many ESP

Dynamic load of ESP Arcing to Ground

A Member of the Group

Transformer/Rectifier Failure Modes

A Member of the Group

Transformer/Rectifier Failure Modes

Other Causes of Partial Discharges within T/R:

Any improperly made or inadequately insulated

AVC not functioning correctly, creating an

A Member of the Group

Transformer/Rectifier Failure Modes

Common Cause of Arcing within T/R:

Failing / Failed Diodes

A Member of the Group