IEEE Guide For The Application of Insulation Coordination PDF

IEEE Standard Test Procedure for
Thermal Evaluation of Insulation
Systems for Liquid-Immersed
Distribution and Power Transformers
IEEE Power & Energy Society
Sponsored by the
Transformers Committee
IEEE
3 Park Avenue IEEE Std C57.100™2011
(Revision of
New York, NY 10016-5997
IEEE Std C57.100-1999)
USA
27 January 2012
Authorized licensed use limited to: University of Stellenbosch. Downloaded on November 06,2014 at 18:34:27 UTC from IEEE Xplore. Restrictions apply.
IEEE Std C57.100™-2011
(Revision of
IEEE Std C57.100-1999)

Sponsor
Transformers Committee
of the
IEEE Power & Energy Society
Approved 7 December 2011
IEEE-SA Standards Board
Abstract: A test procedure to provide a uniform method for investigating the effect of operating
temperature on the life expectancy of liquid-immersed transformers is provided. The test
procedures are intended to provide data for the selection of a limiting hottest-spot temperature for
rating purposes, provide data which may serve as the basis for a guide for loading, and permit the
comparative evaluation of a proposed insulation system with reference to a system that has
proven to be acceptable in service.
Keywords: aging, distribution transformers, IEEE C57.100, life tests, liquid immersed, power
transformers, test procedures, thermal evaluation
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Introduction
This introduction is not part of IEEE Std C57.100-2011, IEEE Standard Test Procedure for Thermal Evaluation of
Insulation Systems for Liquid-Immersed Distribution and Power Transformers.
This standard is intended to establish test procedures for evaluating the insulation systems of liquid-
immersed transformers. The electrical insulation of transformers is subject to electrical, mechanical, and
thermal stresses occurring in different parts of the structure. How long the insulation system will be
serviceable depends on the transformer design and the severity of the stresses acting on it, as well as on the
materials themselves and the service environment. Therefore, the length of useful life of the insulation
system depends on the way that its individual components are arranged, their interactions upon each other,
the contribution of each component to the electrical and mechanical integrity of the system, and the way the
transformer is manufactured and operated.
Experience has shown that the thermal life characteristics of composite insulation systems cannot be
reliably inferred solely from information concerning individual component materials. To assure satisfactory
service life, transformer designs need to be verified by service experience or accelerated life tests. Tests on
complete insulation systems, representative of each transformer design, are necessary to confirm the
performance of materials for their specific functions in the transformer.
During the preparation of prior editions of this standard, manufacturers built and tested more than one
hundred complete distribution transformers. The results of these tests, while not specifically published,
confirmed the practicality of the test procedures in this standard for liquid-immersed distribution
transformers. Subsequent to this work, it was recognized by prior working groups that a need existed for a
similar test procedure for power transformers. To fulfill this need, two projects on “Basic Transformer Life
Characteristics” were completed by the Electric Power Research Institute (EPRI) in 1982 [B6], [B7].a
Limited testing was performed on insulated coils, models, and model assemblies. The information obtained
from these EPRI projects was used to extend the test procedures in this standard to power transformers.
Manufacturers occasionally make changes in the insulation used in transformers. This occurs due to the
development of a new material or a change in vendors. In some cases, a preferred material will no longer be
available, or a preliminary evaluation of the potential of a new insulation system is needed. It is reasonable
to permit a reduced scale thermal test to determine that the change will not reduce the life of the
transformer. For this situation, a single point aging test described in Annex A is specified using the
procedure outlined in Annex B (similar to the Annex A from IEEE Std C57.100-1999). In situations where
more than a minor change to the insulation system is made, a comparison to the industry-proven system
must be made. This revision deals with how such a comparison is to be conducted.
In addition to the use of a comparison test to the industry-proven system, this revision of IEEE Std C57.100
deals with issues raised during the ballot for the 1999 revision of this document, as well as issues that have
developed during the intervening time period. These issues included the need for a simplified model test for
power transformers, as well as the need for evaluation methods for materials of dissimilar thermal
capability. The old Annex A from IEEE Std C57.100-1999 has been modified to become part of the
materials testing section in the new annex, which will also include a new dual-temperature sealed tube test
method in Annex C. In the case of the distribution transformer and power transformer model test, the
difference in performance between the candidate system and the industry-proven system can be compared
directly by test. In the case of the materials tests described in Annex B and Annex C, the difference
between the industry-proven system and the candidate system are also obtained, but the correlation of this
difference to transformer life may require confirmation from industry experience. The scope of this
document notes that the dielectric liquid is part of the insulation system, but evaluations of the fluid portion
of the insulation system are not part of this test procedure. While fluids are a critical part of the insulation
system, since they can be reprocessed or exchanged, this document only investigates the solid insulation
components as the limiting factor of the insulation system.
a
The numbers in brackets correspond to those of the bibliography in Annex E.
iv
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v
Participants
At the time this draft standard was completed, the Thermal Evaluation of Power and Distribution
Transformers C57.100 Working Group had the following membership:
Roger Wicks, Chair

Tom Prevost, Vice-chair
Richard Amos Michael Franchek Verena Pellon

Roberto Asano George Frimpong Donald Platts
William Boettger Robert Ganser Oleg Roizman
Kent Brown Eduardo Garcia H. Jin Sim
Juan Castellanos Peter Heinzig Sanjib Som
C. Clair Claiborne John Luksich Craig Stiegemeier
Jerry Corkran William Mangum Susmitha Tarlapally
Rick Dong Terence Martin Jim Thompson
Terry Drees C. Patrick McShane Mark Tostrud
Pierre Feghali T. V. Oommen Hanxin Zhu
Bruce Forsyth Abderrahmane Zouaghi
The Thermal Evaluation of Power and Distribution Transformers C57.100 Working Group acknowledge
and thank the following individuals for their support and contribution to the development of this standard:
Donald Cherry Richard Marek Tim Raymond

Valery Davydov Hasse Nordman R. William Simpson, Jr.
Gustav Preininger
The following members of the balloting committee voted on this standard. Balloters may have voted for
approval, disapproval, or abstention.
William J. Ackerman Jalal Gohari John Luksich

Michael Adams Edwin Goodwin Greg Luri
Satish Aggarwal James Graham Richard Marek
Samuel Aguirre William Griesacker John W. Matthews
Stan Arnot Randall Groves William McBride
Adam Bagby Bal Gupta Susan McNelly
Barry Beaster Jeffrey Hartenberger C. Patrick McShane
Steven Bezner Peter Heinzig Gary Michel
Thomas Blackburn Gary Hoffman Daniel Mulkey
William Boettger Thomas Holifield Jerry Murphy
Steven Brockschink Philip Hopkinson Ryan Musgrove
Chris Brooks Richard Jackson Michael S. Newman
Carl Bush Clark Jacobson Mohamed Omran
Juan Castellanos Charles Johnson Lorraine Padden
Donald Cherry Wayne Johnson Bansi Patel
C. Clair Claiborne Laszlo Kadar Jesse Patton
Jerry Corkran C. J. Kalra Brian Penny
John Crouse Gael Kennedy Howard Penrose
Gary Donner Sheldon Kennedy Paul Pillitteri
Terry Drees Morteza Khodaie Donald Platts
Gary Engmann Chad Kiger Alvaro Portillo
James Fairris Gary King Lewis Powell
Joseph Foldi James Kinney Gustav Preininger
Bruce Forsyth Joseph L. Koepfinger Tom Prevost
Marcel Fortin Jim Kulchisky Jeffrey Ray
Michael Franchek Saumen Kundu John Rossetti
Fredric Friend Chung-Yiu Lam Marnie Roussell
George Frimpong Aleksandr Levin Thomas Rozek
Eduardo Garcia Hua Liu Dinesh Sankarakurup
vi
Bartien Sayogo David Stankes Jane Verner
Gil Shultz Gary Stoedter David Wallach
H. Jin Sim John Sullivan Joe Watson
James Smith S. Thamilarasan Roger Wicks
Jerry Smith Alan Traut Alan Wilks
Steve Snyder John Vergis James Wilson
When the IEEE-SA Standards Board approved this standard on 7 December 2011, it had the following
membership:
Richard H. Hulett, Chair
John Kulick, Vice Chair
Robert M. Grow, Past Chair
Judith Gorman, Secretary
Masayuki Ariyoshi Jim Hughes Gary Robinson

William Bartley Joseph L. Koepfinger* Jon Rosdahl
Ted Burse David Law Sam Sciacca
Clint Chaplin Thomas Lee Mike Seavey
Wael Diab Hung Ling Curtis Siller
Jean-Philippe Faure Oleg Logvinov Phil Winston
Alex Gelman Ted Olsen Howard Wolfman
Paul Houzé Don Wright
* Member Emeritus
Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Satish Aggarwal, NRC Representative
Richard DeBlasio, DOE Representative
Michael Janezic, NIST Representative
Catherine Berger
IEEE Standards Project Editor
Erin Spiewak
IEEE Standards Program Manager, Technical Program Development
vii
Contents
1. Overview .................................................................................................................................................... 1
1.1 Scope ................................................................................................................................................... 1

1.2 Purpose ................................................................................................................................................ 1
2. Normative references.................................................................................................................................. 2
3. Definitions .................................................................................................................................................. 2
3.1 Industry-proven insulation system....................................................................................................... 2
4. Aging influences......................................................................................................................................... 3
5. Minimum life expectancy........................................................................................................................... 3
6. Criteria for end of life—Distribution transformer and power transformer model ...................................... 4
7. Test temperatures........................................................................................................................................ 4
8. Test methods and specimens ...................................................................................................................... 5
8.1 Distribution transformer ...................................................................................................................... 5

8.2 Power transformer model .................................................................................................................... 5
8.3 Relative testing specimens................................................................................................................... 6
9. Test period.................................................................................................................................................. 6
9.1 Hottest spot test temperature ............................................................................................................... 6

9.2 Temperature of liquid .......................................................................................................................... 6
9.3 Duration of test period ......................................................................................................................... 7
9.4 Cycling ................................................................................................................................................ 7
9.5 Calculation of aging caused by heating and cooling............................................................................ 7
10. End-point tests .......................................................................................................................................... 8
10.1 Distribution transformers................................................................................................................... 8

10.2 Power transformers............................................................................................................................ 8
10.3 Abnormalities .................................................................................................................................... 8
11. Test results................................................................................................................................................ 8
11.1 Data presentation ............................................................................................................................... 9

11.2 Test report.......................................................................................................................................... 9
11.3 Example calculation of life equation ............................................................................................... 10
12. Applicability of test results..................................................................................................................... 11
viii
Annex A (normative) Materials testing for aging of liquid-immersed transformer insulation ..................... 13
A.1 Purpose ............................................................................................................................................. 13

A.2 Test temperatures and test periods.................................................................................................... 13
A.3 Limiting factor—insulation system .................................................................................................. 15
A.4 Comparative evaluation .................................................................................................................... 15
Annex B (normative) Materials testing—standard test procedure for sealed tube aging of
liquid-immersed transformer insulation ....................................................................................................... 19
B.1 Test samples...................................................................................................................................... 19
Annex C (normative) Materials testing—standard test procedure for dual-temperature sealed tube
aging of liquid-immersed transformer insulation ......................................................................................... 20
C.1 Purpose.............................................................................................................................................. 20
C.2 Test samples...................................................................................................................................... 20
Annex D (informative) Historical background information ......................................................................... 22
D.1 Distribution transformer and power transformer model test result discussion from
IEEE Std C57.100-1999 [B12] ................................................................................................................ 22
D.2 Background discussion from references ........................................................................................... 22
Annex E (informative) Bibliography............................................................................................................ 25
ix
IMPORTANT NOTICE: This standard is not intended to ensure safety, security, health, or
environmental protection. Implementers of the standard are responsible for determining appropriate
safety, security, environmental, and health practices or regulatory requirements.
This IEEE document is made available for use subject to important notices and legal disclaimers.
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http://standards.ieee.org/IPR/disclaimers.html.
1. Overview
1.1 Scope
This standard applies to the insulation systems used in all liquid-immersed distribution and power
transformers. This standard provides test procedures to evaluate the thermal aging characteristics of
insulation systems used in liquid-immersed distribution or power transformers. The dielectric liquid is part
of the insulation system.
1.2 Purpose
The objective of this test procedure is to establish uniform methods for investigating the effects of
operating temperature on the life expectancy of liquid-immersed transformer insulation systems. The
results of these test procedures are expected to
a) Provide the basis for the selection of a limiting hottest-spot temperature for rating purposes
b) Provide life curves that may serve as the basis for a guide for loading
c) Permit the comparative evaluation of a proposed insulation system with reference to an industry-
proven system that has been shown to be acceptable in service
1
IEEE Std C57.100-2011
IEEE STANDARD TEST PROCEDURE FOR THERMAL EVALUATION OF INSULATION SYSTEMS FOR LIQUID-
IMMERSED DISTRIBUTION AND POWER TRANSFORMERS
2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
explained). For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments or corrigenda) applies.
IEC TS 62332-1—Electrical Insulation Systems (EIS) —Thermal Evaluation of Combined Liquid and
Solid Components—Part 1: General Requirements.1
IEEE Std C57.12.00™, IEEE Standard General Requirements for Liquid-Immersed Distribution, Power,
and Regulating Transformers.2, 3
IEEE Std C57.12.90™, IEEE Standard Test Code for Liquid-Immersed Distribution, Power, and
Regulating Transformers.
IEEE Std C57.91™, IEEE Guide for Loading Mineral-Oil-Immersed Transformers.
IEEE Std 1™, IEEE General Principles for Temperature Limits in the Rating of Electrical Equipment and
for the Evaluation of Electrical Insulation.
IEEE Std 99™, IEEE Recommended Practice for the Preparation of Test Procedure for the Thermal
Evaluation of Insulation Systems for Electric Equipment.
IEEE Std 101™, IEEE Guide for the Statistical Analysis of Thermal Life Test Data.
3. Definitions
For the purposes of this document, the following terms and definitions apply. The IEEE Standards
Dictionary: Glossary of Terms & Definitions should be referenced for terms not defined in this clause.4
3.1 Industry-proven insulation system
Decades of operating equipment manufactured using an insulation system including thermally upgraded
kraft paper, cellulosic pressboard, and mineral oil has shown that a minimum life expectancy of at least
20.5 years (180 000 hours) may be assumed if the hottest-spot temperature, at rated load as defined in IEEE
Std C57.12.00, is maintained. This proven insulation system includes a manufacturing process, which
provides initial drying to a moisture content of 0.25% to 0.50% moisture by weight, and after processing,
the insulation system will be sealed to prevent the ingress of air (oxygen) and moisture.
The minimum life expectancy curve from IEEE Std C57.12.00 to be used for comparison purposes is
repeated here by Equation (1) and displayed in Figure 1.
ª 15000 º
« T 273 27.064 »
¬ ¼
LIFE EXP (1)
1
IEC publications are available from the Sales Department of the International Electrotechnical Commission, Case Postale 131, 3, rue
de Varembé, CH-1211, Genève 20, Switzerland/Suisse (http://www.iec.ch). IEC publications are also available in the United States
from the Sales Department, American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, USA.
2
IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08854,
USA (http://standards.ieee.org/).
3
The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc.
4
The IEEE Standards Dictionary: Glossary of Terms & Definitions is available at http://shop.ieee.org/.
2
IEEE Std C57.100-2011
where
LIFE is the life in hours

T is the aging temperature in °C
Figure 1 —Minimum life expectancy curve for liquid-immersed distribution and power
transformers as defined in IEEE Std C57.12.00, 65 ºC average rise, 80 ºC hottest-spot rise
4. Aging influences
The primary aging factors employed in this procedure are temperature and time. Since few transformers
operate for extended periods at constant temperatures, provision is made for thermal cycling in this
procedure. For the sealed tube test procedure and the dual temperature test described in Annex A, Annex B
and Annex C, cyclical loading is not part of the standard test method.
It is recognized that environmental conditions, such as corrosive atmosphere and excessive vibration, can
affect actual service life. It seems appropriate to evaluate such extraneous influences separately from the
effects of temperature, and they are therefore not included in this procedure. However, for all insulation
system testing covered under this requirement, moisture content of the insulation system should be
monitored at the beginning of the testing, as it should be representative of the upper limit of factory oil
processing equipment (typically in the range of 0.25 to 0.50% moisture by weight of the solid).
5. Minimum life expectancy

The load on most transformers is cyclic, with both daily and annual cycles. For this reason, the peak
thermal loading (which develops the highest temperature in the transformer windings) occurs on relatively
few days during the year and for a relatively small portion of each of these days. Thus, the cumulative time
at or above the rated hottest-spot temperature is considerably less than the total elapsed time. Further, it is
generally agreed that thermal degradation of insulation is a function of both temperature and time at the
temperature. Consequently, the life expectancy in actual service may differ greatly from the life determined
by the essentially continuous loading procedure prescribed in this standard.
3
IEEE Std C57.100-2011
Experience and experimental evidence indicate that an insulation system capable of operating 180 000
hours, (approximately 20.5 years) at rated hottest-spot temperature should give satisfactory life expectancy
under the normal operating conditions described in the preceding paragraph.
6. Criteria for end of life—Distribution transformer and power transformer

model
In these tests, the life of a particular test specimen is considered to be ended when the degradation of the
insulation system has progressed to a point such that the test specimen cannot withstand any one of a series
of tests intended to simulate the abnormal currents or voltages that are commonly experienced in actual
service. The degradation or aging is produced by a series of temperature cycles, each consisting of a
specified time at a specified hottest-spot temperature followed by a return to approximately ambient
temperature. Such a series of temperature cycles, followed by end of life tests, will hereafter be referred to
as a test period. Since it is impractical to determine the exact point in the test period procedure when the
sample reached the level at which it could not withstand the end-point tests, its life at the test temperature
should be considered to be the duration of one test period multiplied by the number of periods to failure
less one half of one period.
Because of the nature of this test, the word failure, as used herein, assumes a special connotation. It is used
here to describe an insulation breakdown such that a service outage would result if it occurred in the field.
Consequently, some of the criteria of failure that are commonly used in tests on new transformers do not
apply. For example, minor disturbances in the oscillograms obtained on impulse tests or increases in the
leakage current on applied potential tests are not necessarily indicative of failure as defined here. Specific
instructions for the treatment of such marginal cases are given in 10.3.
If a test sample should fail prematurely, that is, long before its anticipated life expectancy and if subsequent
examination conclusively shows the failure to be the result of defects in material or workmanship, rather
than thermal degradation, failure of this sample may be ignored in determining the test results and another
sample substituted for it.
7. Test temperatures
The accuracy of an evaluation will increase as the number of test temperatures increases but its cost will
also increase. In general, tests should be made at the maximum number of temperatures that can be justified
economically with the following qualifications:
a) When insufficient previous information exists regarding the shape of the life expectancy
temperature curve for the system being evaluated, tests should be made at a minimum of three
temperatures selected as recommended in IEEE Std 99. This requirement of three temperature
points, 20 °C intervals, which should be extrapolated no more than 20 °C, would require very
long test times to permit the necessary extrapolation with confidence. As this may be
impractical, tests at additional temperatures should be made.
b) As an alternative, industry experience with testing following this standard test method has
shown that 15 °C intervals and extrapolations up to 40 °C may be suitable assuming that a
comparison to the industry-proven system is made, using a relative thermal index evaluation as
is described in IEEE Std 1. For this evaluation, the industry-proven system would be evaluated
using this standard at 150 °C, 165 °C, and 180 °C and then the result compared to the results of
the candidate system at alternative temperatures. For example, for a candidate system that is
expected to have 30 °C better thermal performance than the industry-proven system, the aging
temperatures would be 180 °C, 195 °C, and 210 °C. Table 1 shows other possible combinations.
An example of such a comparison is shown in 11.1, part b).
4
IEEE Std C57.100-2011
Table 1 —Aging temperatures for three-point aging

Aging Aging Aging
Expected increase in
Insulation system temperature temperature temperature
thermal rating
number 1 number 2 number 3
Industry proven system 150 ºC 165 ºC 180 ºC
Candidate system 10 ºC 160 ºC 175 ºC 190 ºC

20 ºC 170 ºC 185 ºC 200 ºC
30 ºC 180 ºC 195 ºC 210 ºC
40 ºC 190 ºC 205 ºC 220 ºC
50 ºC 200 ºC 215 ºC 230 ºC
60 ºC 210 ºC 225 ºC 240 ºC
8. Test methods and specimens
8.1 Distribution transformer
Test samples should be complete transformers and should be typical of the design being evaluated insofar
as insulation structure and processing, liquid content and manner of sealing are concerned. To avoid
venting due to the larger than normal temperature range involved, a larger than standard gas expansion
space and/or higher pressure ranges are allowed. A minimum of three samples should be tested at each test
temperature.
The test procedure involves subjecting the test samples to repeated test periods consisting of the following
two parts:
a) Exposure to elevated temperature while excited at rated voltage.

b) Application of end-point tests to determine end of life, as defined in Clause 6 and 10.1.
8.2 Power transformer model
It will normally be impracticable to test full-size transformers for thermal evaluation of their insulation
systems. However, transformer experts believe that model winding configurations utilizing typical
conductors, insulation, and supporting structures can provide performance representative of power
transformer thermal endurance. The models are based on the assumption that the conductor turn insulation
is subjected to the most critical thermal degradation and therefore limits the transformers’ dielectric and/or
through-fault withstand.
The models shall be calibrated and monitored to establish accurate thermal gradients and hottest-spot
temperatures so that correlation of time and temperature can be established over the duration of the aging
period. Preliminary models should be tested to dielectric breakdown and through-fault displacement in
order to establish the model rating. The model rating is the benchmark for establishing the “end point” test
levels.
It is recommended that the test tanks containing the aging models use a conservator (or other constant
pressure) liquid preservation system. Experience has demonstrated that temperature cycling of models with
a gas blanket liquid preservation system can introduce gas into the insulation and result in premature
dielectric failure. (See Annex E, EPRI [B6] and McNutt and Kaufmann [B16].)
5
IEEE Std C57.100-2011
The test procedure, like the procedure for distribution transformers, involves subjecting the samples to
repeated test periods consisting of the following two parts:
a) Exposure to elevated temperatures by circulating current through the windings, i.e., the
conductor resistance provides the heat source.
b) Application of end-point tests to determine end of life, as defined in Clause 6 and 10.2.
Dielectric tests should be performed at or near room temperature and at an appropriate time
after aging to assure that free gasses evolved at higher temperatures will not affect the test
results.
8.3 Relative testing specimens
If the relative thermal evaluation described in Clause 7, part b) is utilized, both the industry-proven system
and the candidate system shall be tested in an identical fashion, other than the times and temperatures used.
They shall both be processed using the same equipment to the same moisture content (as measured as a
percentage of the solid in the insulation system). Where practical, the common insulation materials used in
the system shall be identical (for example in evaluating a new liquid-based system, the same lot of paper
and boards should be used for this comparison or when evaluating a new solid material, liquid meeting the
same specification should be used). The industry-proven insulation system requires nitrogen blanketing or a
conservator (or other constant pressure) liquid preservation system. This should also be done for the
evaluation of this comparative test. However, the pressurization system of the candidate system may differ
if that is the intention of the user of the new system. For example, for a free-breathing insulation system,
the candidate system would need to be evaluated in the model tests by using a free breathing set-up.
9. Test period
9.1 Hottest spot test temperature
The test temperature should be produced by circulating alternating current of rated frequency through the
windings for the power and distribution model tests. The test temperature should be maintained constant
within plus or minus 1.5% during the aging period in all samples. It should be the temperature indicated by
a sensing means located at the hottest spot within the insulation structure.
One method of meeting these requirements is to construct a monitor unit identical to the test samples,
except that it has a thermocouple embedded in the transformer winding at the hottest insulation spot. The
thermocouple leads are brought out of the sample through a suitable sealed plug in the tank to an
appropriate measuring and control device. To ensure equal current in all samples, corresponding windings
of all test samples and those of the monitor unit are connected in series. Other methods of controlling
hottest spot temperature in the test samples can be used if desired.
9.2 Temperature of liquid
CAUTION
During the aging period, the liquid temperature in the distribution transformer and power transformer
model tests should be allowed to attain its natural value as determined by the transformer design unless this
will produce a fire or explosion hazard. To avoid these hazards, higher hot spot gradients are permissible
for the sake of consistency with other test points. External (or artificial) cooling may be used, when
required. However, the amount of artificial cooling should be no more than that required to hold the top
liquid temperature in the test samples to a safe temperature.
6
IEEE Std C57.100-2011
In the presentation of test data, points obtained with artificial cooling should be so identified, and the top
oil temperature used in each test shall be recorded.
9.3 Duration of test period
The duration of each test period should be approximately 10% of the anticipated life expectancy of the
sample at the test temperature with the following two permissible exceptions:
a) When the test period thus determined is long, it may be desirable to perform a set of end-point
tests before the end of the first test period in order to eliminate samples with gross defects
before the test has proceeded too far.
b) If no failure has occurred by the end of the tenth test period, the length of succeeding periods
may be increased to increase the number of hours at temperature obtained per unit of elapsed
time.
NOTE—If the failure occurs before the fifth test period, the statistical validity of this test is less than would be desired.
A new series of tests at this test temperature will be required, utilizing a shorter test period per cycle.5
The measured time-to-failure of the test specimens, aged at each temperature, shall be considered to be
equal to the cumulative duration of temperature exposure during all test periods (Clause 6) less one-half of
the length of the last test period.
9.4 Cycling
At least four times during each test period for the power and distribution model tests, and also prior to
making end-point tests, the power supply to the test samples should be disconnected and the samples
allowed to cool to a top oil temperature between 25 °C and 40 °C. No thermal cycling is required for the
sealed tube or for the dual-temperature tests described in Annex A, Annex B, and Annex C.
9.5 Calculation of aging caused by heating and cooling
Some aging will occur during the heating and cooling periods involved in each temperature cycle so the
actual life will be somewhat greater than the total elapsed time at temperature as defined in Clause 6. In
general, aging during the cooling period will be a negligible fraction of the total aging per cycle.
Aging during the heating period (and the total duration of the test program) will be substantially reduced if
the initial value of the load current is chosen as 1.5 to 2.0 per unit of the value required to maintain the
hottest-spot temperature at the desired value. Aging due to heating and cooling will then be a negligible
fraction of the total aging per cycle.
A rough calculation of the error involved in neglecting the aging during transient heating and cooling
should be made using the method and equations found in IEEE Std C57.91-1995, Clause 5 [B11], using the
planned load cycle, the known thermal characteristics of the test specimen, and an aging curve based on
previous tests or anticipated test results. If the error so calculated exceeds 5%, either
a) The preheating rate should be further accelerated to reduce the error below 5%, or
b) The hottest-spot temperature should be monitored during a typical temperature cycle and actual
correction computed using the uncorrected life-expectancy data obtained from the test results.
The computed correction should then be added to the test results obtained, per IEEE Std
C57.91-1995, Clause 5 [B11].
5
Notes in text, tables, and figures are given for information only and do not contain requirements needed to implement the standard.
7
IEEE Std C57.100-2011
10. End-point tests
10.1 Distribution transformers
At the end of each test period, each sample should be given the following end-point tests in the indicated
order. For more information on the specifics of these tests, refer to IEEE Std C57.12.90 and IEEE Std
C57.12.00 as noted in the footnotes.
a) Short-circuit test (symmetrical) at 25 times rated current for 2 seconds6

b) Full-wave impulse test at 65% of the values specified for a new transformer7
c) Applied potential test at 65% of the values specified for new transformers8
d) Induced potential tests at 130% of rated voltage for 7200 cycles9
10.2 Power transformers
At the end of each test period, each sample should be given the following end-point tests in the indicated
order:
a) Short-circuit test. The current level should apply stresses to the windings which are
representative of those experienced in the full size transformers represented by the model. The
short-circuit duration should be at least one second and provide an asymmetrical offset of at
least 130% of symmetrical.
b) The dielectric test should be at least 65% of the design level of the model. Design level is
defined as 70% of the mean breakdown voltage between turns, turn sections, or layers, as
appropriate to the model. Either two applications of full-wave impulse test voltage or two
applications of a one minute low frequency test voltage are acceptable for end-point tests.
10.3 Abnormalities
If a major abnormality occurs on any of these tests, the unit shall be considered to have failed.
In marginal cases, as defined in Clause 6, the unit may be returned to life test with the provision that,
should a definite failure occur on the next series at end-point tests, the reported end of life shall be as of the
preceding test period.
11. Test results

The tests specified herein are of an accelerated nature as compared to normal service. Hence, extrapolation
of the life-temperature relationship obtained by the tests will usually be necessary. Furthermore, some
variation in the life of individual samples tested at the same temperature is to be expected. The evaluation
procedure must demonstrate the attainment of a minimum life expectancy of 180 000 hours at the
continuously rated hottest-spot temperature. For each of these methods, the test data that is to be evaluated
is provided by utilizing one of the methods in Clause 10.
6
See IEEE Std C57.12.90.
7
See IEEE Std C57.12.00 for specified test values for new transformers.
8
9
8
IEEE Std C57.100-2011
11.1 Data presentation
Two methods for presentation of test results are as follows:
a) When all units have been tested to failure and the test results are sufficiently consistent,
statistical analysis as indicated in IEEE Std 101 may be employed. Rated hottest-spot
temperatures and life-expectancy claims should be based on the resulting lower 95% confidence
bound. This is the method that should be applied if the insulation systems are tested per Clause
7, part a).
b) If the relative evaluation method from IEEE Std 1, as described in Clause 7 part b) is employed,
the analysis of the data is different. In this case, time-temperature points (as described in Clause
7 part b) from the industry-proven insulation system are first plotted as shown in Figure 2. The
data is then extrapolated to the temperature at which a lifetime of 180 000 hours is reached,
which will likely be different than the assigned temperature class for the industry-proven system
(110 °C). Then, each of the time-temperature points for the candidate system are plotted on the
same graph, and the data is also extrapolated to 180 000 hours. Because both of these tests are
comparing test data of similar time duration and the extrapolation for both sets of data are
similar the relative thermal capability of each system, tested using the same method with the
same set of parameters, can be directly compared.
Figure 2 —Relative temperature index example
11.2 Test report
A test report outlining the results of the testing according to this test procedure shall include the following:
a) Candidate system evaluated, including a listing of the following items:

1) Conductor insulation (primary)
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IEEE Std C57.100-2011
2) Conductor insulation (secondary)

3) Other solid insulation components (layer, cylinders, etc.)
4) Dielectric fluid
5) Sealing method (nitrogen blanket, conservator, free breather, etc.)
6) kVA/MVA of design evaluated
b) The duration of temperature exposure, expressed in terms of the total number of hours to failure,
in accordance with Clause 6 for each temperature. The time to failure for each temperature shall
be the average of the specimens tested at each temperature, with the number of specimens as
outlined in Clause 8.
c) The life equation is derived from three time-temperature points resulting from the experiments.
Report the life equation of the candidate insulation system, in a form similar to Equation (1) as
shown as Equation (2):
ª B º
« A»
LIFE EXP ¬ T 273 ¼
(2)
where

A is a constant
B is a constant
d) If the relative evaluation method from IEEE Std 1, as described in Clause 7 part b) is employed,
then each of the items described above in parts a), b), and c) should be described for the
industry-proven system used in the evaluation.
11.3 Example calculation of life equation
As is described in 11.2, a life equation can be developed from conducting experiments utilizing either the
distribution transformer or power transformer models at multiple temperatures as is described in Clause 7.
To demonstrate the methodology, the hypothetical example from aging distribution transformers shown in
Figure 2 resulted in the following results.
Table 2 —Test report—aging results
Candidate system Temperature Aging time/cycle Cycle of Failure time Average
failure failure
Test 1 210 °C 84.8 hours 10 805.6 hours 975.2 hours
Test 2 210 °C 84.8 hours 14 1144.8 hours
Test 1 195 °C 263.2 hours 11 2763.6 hours 2763.6
Test 2 195 °C 263.2 hours 12 3026.8 hours hours
Test 1 180 °C 886.8 hours 16 13745.4 hours 11085.0
Test 2 180 °C 886.8 hours 12 10198.2 hours hours
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IEEE Std C57.100-2011
Figure 3 —Example of distribution transformer aging—life curve
Therefore, the life equation for the new system, based on this hypothetical testing would be as follows in
Equation (3):
ª 17749 º
« T 273 29.911»
¬ ¼
LIFE EXP (3)
where

If the correlation coefficient for this life equation is less than 0.95, additional testing is required, until the
coefficient reaches 0.95.
12. Applicability of test results

For insulation systems where temperature ratings are at least 10 °C higher than the industry-proven
insulation system by the test methods described in Clause 8, a higher hottest spot temperature is warranted
based on the test result from this standard test method. However, unlike the industry-proven insulation
system, the candidate system will have had limited life experience from operating transformers. For this
reason, a comparison test to the industry-proven insulation system is required if a higher hottest spot
temperature is to be utilized. In addition, in order to demonstrate that the industry-proven insulation system
is constructed of materials that meet the requirements of IEEE Std C57.12.00, a single-point sealed tube
test as described in Annex A and Annex B, should be conducted of the materials that composed the
industry-proven insulation system in the comparison test. This sealed tube test must show performance as is
described in A.4.1 to confirm the validity of the comparison to the industry-proven insulation system.
Additionally, caution should be exercised in taking full advantage of these higher operating temperatures to
the fullest extent.
Also, while the effects of electrical and mechanical stresses on the life expectancy of an insulation structure
have not been clearly established, it seems reasonable to expect that failure may occur sooner if these
stresses are high. Furthermore, the temperature distribution through structures of different designs may be
different at the same hottest-spot temperature. For these reasons, caution should be exercised in applying
the results of thermal evaluation tests to designs other than those actually tested in the distribution
transformer and power transformer model tests. In particular, when it is intended that an evaluation apply to
a number of different transformer ratings, the test samples shall be of the rating in which the design stresses
11
IEEE Std C57.100-2011
are the highest. Because these test results are transformer design specific, test results covered in this
document are only pertinent to the manufacturer whose equipment was tested using this methodology.
Finally, all of the test methods described in this document will likely give different results due to
differences in the test methodologies. Care must then be taken when comparing results from this testing to
established life curves in IEEE Std C57.12.00. The materials tests described in Annex A, Annex B, and
Annex C are not transformer tests, but have proven useful tools to compare insulation systems for liquid-
immersed transformers. Use of these methods to develop a new life curve vs. the industry-proven system is
described in A.4.2; however, the correlation of this new life curve to transformer life may require
confirmation from industry experience.
12
IEEE Std C57.100-2011
Annex A
(normative)
Materials testing for aging of liquid-immersed transformer insulation
A.1 Purpose
Manufacturers occasionally make changes in the insulation materials used in their transformers. This
occurs due to a modification, or refinement, to the insulation product, a change in vendors, or due to the
unavailability of a preferred material. If the change is minor, or a routine quality control check is needed, it
is reasonable to permit a reduced scale thermal test to determine that the change does not reduce the life of
the transformer.
Under these limited conditions, it is appropriate to perform a simplified single-point test sealed tube aging
procedure. This procedure is also an effective method for making a preliminary evaluation of the potential
of a new insulation system, as is outlined in A.2.1. A sealed tube aging procedure is more rapid, less
expensive, and provides samples with a controlled thermal history. Annex B describes this test method.
In the case of the introduction of a new material, or a significantly modified insulation system, it would be
useful to conduct a materials test to provide insight into the approximate thermal capability of the new
system as it compares to the industry-proven system. This would also be useful prior to conducting an
evaluation as described in the main body of this standard. This standard provides two methods that can be
used to understand this relative thermal capability. With both of these test methods, detailed in Annex B
and Annex C, three-point aging as described in A.2.2 is conducted and a comparison of the results as
described in A.4 provides the relative thermal capability based on the test. How the life of the transformer
will compare to ones built with the industry-proven system will likely be based on years of experience in
operating the new insulation system under actual use conditions.
At this time, there is only limited experience with performing this type of evaluation with a coated wire
insulation. Coated wires include enamel coating, powder epoxy coating, or extruded polymer coatings as
examples. If a manufacturer has been successfully using coated wires in their existing transformer products
and wishes to evaluate a new material, the three-point aging could potentially be used to develop an end-
point criteria, which could then be used to evaluate new wire coatings. Such a criteria might be dielectric
strength retention as an example.
A.2 Test temperatures and test periods
A.2.1 Single-point sealed tube aging
In the situation where a minor change in materials is being considered, a single-point test is warranted. The
test samples should be prepared as is described in B.1. The test should be conducted at 160 ºC and the
aging time should be 706 hours, as determined from Equation (A.1) at this aging temperature. When this
procedure is utilized for verifying minor changes to an insulation system for transformers rated in
accordance with IEEE Std C57.12.00, 65 °C average rise, 80 °C hottest spot rise, the tested life shall be
equal to, or exceed the life expectancy curve displayed in Figure A.1, which is defined by Equation (A.1).
13
IEEE Std C57.100-2011
ª 15000 º
« 28.082 »
LIFE EXP ¬ T 273 ¼
(A.1)
where

Figure A.1— Minimum life expectancy curve for sealed tube tests of liquid-immersed
cellulose insulating materials (50% reduction of tensile strength)
NOTE—The life curves shown for Figure 1 and Figure A.1 are different due the nature of the evaluation methods being
used, even when identical insulation systems are being evaluated. The above life curve is based on a 50% reduction of
tensile strength of cellulosic insulation papers used in the industry-proven insulation system.
A.2.2 Three-point aging
In the situation where a significant change in materials is expected, especially in the case where operation
at higher winding temperatures is expected a series of three-point aging is required. In order to better
understand the relative thermal capability of this new insulation system to the industry-proven system, both
systems must be evaluated using the same test methodology under three specific temperatures. The test
temperatures are selected as is described in Clause 7, part b). In both cases, the aging temperatures are 15
°C apart, and the test results, when complete, cannot be extrapolated more than 40 °C. To enable
comparison of the results from the materials tests described in both Annex B and Annex C, the aging times
that will be used in the comparative three-point aging will be derived from Equation (1) in the main body of
this document. Table A.1 provides the aging times and temperatures for both the industry-proven system
and for the candidate system. The temperatures chosen for the candidate system are based on the expected
temperature difference between this system and the industry-proven system.
14
IEEE Std C57.100-2011
Table A.1—Aging times and temperatures for three-point aging

Aging time Aging time Aging time
Expected increase in
Insulation system number 1 number 2 number 3
thermal rating
4434 hours 1316 hours 424 hours
Industry-proven system 150 ºC 165 ºC 180 ºC
Candidate system 10 ºC 160 ºC 175 ºC 190 ºC

20 ºC 170 ºC 185 ºC 200 ºC
30 ºC 180 ºC 195 ºC 210 ºC
40 ºC 190 ºC 205 ºC 220 ºC
50 ºC 200 ºC 215 ºC 230 ºC
60 ºC 210 ºC 225 ºC 240 ºC
A.3 Limiting factor—insulation system
In the distribution transformer or power transformer model tests, the product is tested to failure of the
insulation system. This failure may occur in the same component in each stage of the evaluation or it may
be a failure of another component, or even a different failure mode. Similarly, this may be the case of one
of the two methods described in Annex B or Annex C; however, for simplicity sake, these methods are set
up with an assumption of which component of the insulation system is the weak link. For example, for
power transformers, the assumption is that the wire insulation will see the highest temperatures, so the wire
insulation should be evaluated by an end-of-life criteria that works for both the industry-proven system as
well as the candidate system. For CTC windings, the enamel-coated wire may be the weak link in the
insulation system. For distribution transformers, the weak link could be either the wire insulation (typically
enamel coating) or the layer paper. For these transformers, the layer paper should be evaluated; however,
should the wire coating also be of concern, the wire coatings could also be evaluated.
A.4 Comparative evaluation
For both of the materials tests described in Annex B and Annex C, a wide variety of test methods could be
considered as part of the evaluation and correspondingly a wide variety of end-of-life criteria chosen.
Examples of this wide variety are shown in IEEE Std C57.91, which include 50% tensile strength, 25%
tensile strength, and 200 DP. Each of these criterion likely would provide a different result in any aging
program. In order to avoid this potential confusion, for this standard the test result from the aging
conducted using the industry-proven system will determine the end-of-life criteria for the candidate system.
Care must be taken to ensure that the end-of-life criteria selected is possible for both the industry-proven
system as well as the candidate system.
As is described in A.3, coated wires such as enamel coated wires can be used in both power and
distribution transformer designs. Experience has shown that twisted pairs of small round wires can be
included in a test as described in ASTM D-1676 [B2], and a comparison could be made of the polyvinyl
formal enamel used in conjunction with the industry-proven system to an enamel or wire coating used in
the candidate system. For this comparison, a method such as dielectric strength retention could be used.
NOTE—Limited testing using enamel coated wires have also been done using the method described in Annex C;
however, the dielectric testing of rectangular enamel coated wires is more variable than that seen with small round
wires. Results using this method with enamel coated wires should be used with caution due to the lack of experience.
A.4.1 Single point aging
Since the basis of the single point test is to compare minor changes to the industry-proven system using a
simplified test and the time-temperature point selected is based on Equation (A.1), the evaluation of this
aging protocol is very simple. Equation (A.1) is based on 50% tensile strength reduction of cellulosic
insulation papers, which means the end-of-life criteria is this 50% value. Compare the percent retention of
15
IEEE Std C57.100-2011
the tensile strength of the conductor insulation portion of the power transformer sealed tube test or the layer
paper insulation portion of the distribution transformer sealed tube test to 50%. If the material tested has
greater than a 50% retained tensile strength, the system is expected to be at least as good as the industry-
proven system.
NOTE—For wire coatings, since there is no baseline curve, a simplified test is not possible.
A.4.2 Three-point aging
A.4.2.1 Determination of end-of-life criteria for candidate system
The aging times required in Table A.1 are derived from the insulation life expected for liquid-immersed
transformers as shown in Figure 1 of this document, which is defined in IEEE Std C57.12.00. Since each of
the time-temperature conditions for the industry-proven system is derived from Equation (1), aging of the
industry-proven system by either of the materials tests in Annex B or Annex C should be correlated to the
insulation life of equipment.
A minimum of three samples for each time-temperature condition must be tested for the industry-proven
system. The average of the test values from aging of the industry-proven system at each of the aging time-
temperature conditions is used to determine the end-of-life criteria for the candidate system.
The values in Table A.2 are a fictitious example of the results from a test using the method described in
Annex B.
Table A.2—Calculation of end-of-life criteria for comparative evaluation
Aging time Aging time Aging time
150 ºC 165 ºC 180 ºC
Insulation system 4434 hours 1316 hours 424 hours
Industry-proven system Test One Percentage 23.3 24.0 22.4
Test Two Percentage 17.0 26.5 18.0
Test Three Percentage 25.3 15.0 25.6
Average result 21.9%
In this particular example, the end-of-life criteria is 21.9% retained tensile strength, which is the average of
the results shown in Table A.2.
A.4.2.1.1 Test program for the candidate system
A.4.2.1.2 Determination of time-temperature points
Once the end-of-life criteria for the test program has been determined from the industry-proven system
evaluation, then the aging of the candidate system can be conducted. Of course, both sets of aging can be
conducted concurrently, but the full analysis of the candidate system is not possible until the end-of-life
criteria has been established based on the industry-proven system evaluation.
For the aging of the candidate system, the temperatures chosen are based on the expected improvement in
candidate insulation system performance versus the industry-proven system. This improvement estimate
then becomes a guide to selecting the aging temperatures for the candidate system as shown in Table A.1.
However, the aging times listed in the table are only the target life times, at each aging temperature. The
actual aging times must be determined by experiment. For the candidate system, a series of aging tests must
be conducted at each aging temperature until one of the aging tests exceeds the end of life criteria
determined in A.4.2.1. Additionally, to allow the proper statistical evaluation of the aging data, at least
16
IEEE Std C57.100-2011
three aging tests must be conducted at each temperature, so that the actual time to reach the end-of-life
criteria can be interpolated from the aging data. Extrapolation is not allowed. Therefore, in order to have at
least one test sample for each test temperature end up with a result poorer than the end-of-life criteria, at
least one extra sample for each temperature should be included in the test program. Table A.3 shows a
fictitious example of such an aging experiment.
Figure A.2 shows how the interpolation is conducted for one of the aging temperatures.
Table A.3—Example of aging experiment

Aging tests
Temperature, ºC Time, hours Tensile strength, %
210 168 65.0
210 336 40.0
210 512 20.0
195 512 70.0
195 1024 45.0
195 1536 27.0
195 2184 18.0
180 1536 67.0
180 3072 48.0
180 4608 30.0
180 5880 19.5
Figure A.2—Example of aging result
For this example, the statistical treatment used is a second order polynomial fit. The time calculated for
21.9% tensile retention is 1801 hours. Other potential statistical treatments could include a simple linear fit
or an exponential fit. The treatment that gives the best correlation coefficient should be used. If the
correlation coefficient of this test is less than 0.95, additional testing is required, until the coefficient
reaches 0.95.
17
IEEE Std C57.100-2011
A.4.2.1.3 Determination of the life equation
Once the three time-temperature points for the aging experiment have been obtained based on the aging
experiments of the candidate system, then the life equation can be derived. To derive a life equation in the
form similar to Equation (1), the results of the aging experiment can be plotted in the form of Ln (life) vs.
the 1/T (where temperature is in degrees Kelvin) to obtain the A and B coefficients of the aging
experiment. To continue the above example, the interpolation of all three of the sets of data provide the
following time-temperature points, which then can be used to develop a life curve and subsequent life
equation.
210 ºC 492.6 hours 195 ºC 1801 hours 180 ºC 5565 hours
Figure A.3—Example of life curve based on test
So the life equation for the new system, based on this hypothetical testing would be as follows in Equation
(A.2):
ª 17664 º
« T 273 30.330 »
¬ ¼
LIFE EXP (A.2)
where

If the correlation coefficient for this life equation is less than 0.95, additional testing is required, until the
coefficient reaches 0.95.
18
IEEE Std C57.100-2011
Annex B
(normative)
Materials testing—standard test procedure for sealed tube aging of

liquid-immersed transformer insulation
B.1 Test samples
The test tubes are typically of stainless steel, but alternatively may be of glass. The tubes are typically
about 28 cm long with an inside diameter of 4.0 cm, and a wall thickness of 5.0 mm. Larger tubes may be
required if testing of the fluids is considered as part of the evaluation. The tubes have gasketed screw-on
caps or bolted-on gasketed flanges and may be fitted with a valve for venting.
NOTE—Test tubes of mild steel have also been used, with the mild steel tube replacing the addition of core steel
described later in this annex.
The insulation shall be dried to approximate the treatment that is used for a full scale transformer. A
minimum moisture content of 0.25% and a maximum of 0.50% by weight is required as measured by the
Karl Fischer method (ASTM D-1533 [B1]). The insulation in each tube should be apportioned to
approximate their relative content in a full scale transformer. Accordingly, all of the materials used in the
transformer type being simulated should be represented in each tube—including paper of the type used in
the transformer as well as pressboards and other components including core steel and conductor (copper or
aluminum).
To standardize the ratio of materials in the sealed tube tests two specified ratios of materials are provided in
Table B.1. One set of materials simulates a power transformer insulation system and the second set of
materials simulates a distribution transformer due to the different materials of construction. The ratio of
materials for power transformers is taken from IEC 62332-1 and the ratio of materials for distribution
transformers is from NEMA MW-1000 [B18]. The ratio that most closely simulates the insulation system
under evaluation should be used.
Table B.1—Sealed tube materials ratios
Transformer type
Material Power Distribution
Insulating liquid 200 cm3 200 cm3
3
0.05 to 0.10 mm conductor insulation 6.4 cm
0.13 to 0.38 mm layer insulation 11.2 cm3
1.00 to 3.00 mm low-density pressboard 1.2 cm3
2.00 to 8.00 mm high-density pressboard 16.4 cm3
Ratio—liquid to solid 8.8 to 1 16.3 to 1
NOTE—For insulation systems that contain coated wires (such as enamel), a dielectric breakdown test as is described
in ASTM D-1676 [B2] could be conducted. The volume of wires added for this test would be in addition to the other
materials in the sealed tube test.
An appropriate air, or gas space, should be left in each tube. The gas used to seal the system should be
representative of the insulation system under evaluation. For the industry-proven system, this should be
sealed with nitrogen.
A minimum of three samples shall be aged at each aging temperature for both the industry-proven system
and candidate system.
19
IEEE Std C57.100-2011
Annex C
(normative)
Materials testing—standard test procedure for dual-temperature sealed
tube aging of liquid-immersed transformer insulation
C.1 Purpose
Sealed tube testing as described in Annex B has been shown to be a simple, easy to implement test,
especially for solid and liquid components of similar thermal capability. When one of the components of
the insulation system has a higher temperature capability than the rest of the system, aging at a single
temperature as is conducted in the sealed tube test is constrained by the lower temperature component. For
this reason, a dual-temperature sealed tube test was developed, and has been described in IEC 62332-1.
This thermal evaluation test procedure utilizes a dual-temperature arrangement to independently control the
hottest spot temperature of the conductor insulation from the top oil temperature of the insulation system.
This allows different combinations of materials used in a liquid-immersed power or distribution
transformers to be evaluated because the evaluation temperatures are independent of each other and can be
established based on the relative thermal capabilities of the individual components of the system (solid and
liquid).
C.2 Test samples
For the purpose of this test method, the limiting hottest spot temperature for the solid insulation is assumed
to be present in conductor insulation. The conductor loop shown in Figure C.1 will be insulated with
material to be used in the insulation system under evaluation, and will be evaluated as was described in
A.4.2. For this conductor insulation, elevated temperatures should be produced by circulating alternating
current of rated frequency through the conductor loop. To facilitate the technical evaluation of the
conductor insulation, precut tensile strips should be installed in direct contact with the conductor loop so
the strips are exposed to the controlled temperature of the conductor loop. For the insulating liquid, the top
oil temperature shall be maintained at the same temperature for all of the hottest spot temperatures used for
determining the life curve. This temperature shall then determine the maximum top oil temperature for the
insulation system under evaluation. For the industry-proven system, this temperature should be 105 ºC, as
outlined in IEEE Std C57.91.
20
IEEE Std C57.100-2011
Figure C.1—Dual-temperature test set-up
The insulation shall be dried to approximate the treatment that is used for a full scale transformer. A
minimum moisture content of 0.25% and a maximum of 0.50% by weight is required as measured by the
Karl Fischer method (ASTM D-1533 [B1]).
The insulation in each tube should be apportioned according to Table B.1. Additionally, all of the materials
used in the transformer type being simulated should be represented in each tube—including paper of the
type used in the transformer as well as pressboards and other components including core steel and
conductor (copper or aluminum). Since the temperatures are independently controlled, the conductor loop
should be exposed to pressboard components typical to those used in the transformer that would be in
contact with the hot conductor (such as spacers). The bulk pressboard parts in the dual temperature cell
should be made of the type of materials used in the transformer that are not in direct contact with the
conductors (such as oil flow barriers, etc.).
An appropriate air, or gas space, should be left in each tube. The gas used to seal the system should be
representative of the insulation system under evaluation.
NOTE—For testing where a comparison is being made to the industry-proven system (for either a higher hottest spot
temperature or when using the shorter duration relative comparison), and end-of-life criteria other than those mentioned
above could be used, as long as it applies to the materials in both insulation systems being evaluated. For example, this
could allow 25% retained tensile strength or 200 DP for cellulose insulating materials. The decision to use a different
end-of-life criteria must, however, be made prior to the start of the testing.
21
IEEE Std C57.100-2011
Annex D
(informative)
Historical background information
D.1 Distribution transformer and power transformer model test result discussion
from IEEE Std C57.100-1999 [B12]
The tests specified herein are of an accelerated nature as compared to normal service. Hence, extrapolation
of the life-temperature relationship obtained by the tests will usually be necessary. Furthermore, some
variation in the life of individual samples tested at the same temperature is to be expected. The evaluation
procedure must demonstrate the attainment of a minimum life expectancy of 180 000 hours at the
continuously rated hottest-spot temperature. Three methods for presentation of test results are as follows:
a) When all units have been tested to failure and the test results are sufficiently consistent,
statistical analysis as indicated in IEEE Std 101 may be employed. Rated hottest-spot
temperatures and life-expectancy claims should be based on the resulting lower 95%
confidence bound.
b) When the difference between the elapsed times to failure of the tested samples at the various
test temperatures is so great as to make statistical analysis of the test results impractical, a
relationship between life expectancy and temperature may be assumed. This relationship
should be of the form described in IEEE Std 101 and should be so selected that no failure at
any test temperature should have occurred at less than five times the life expectancy indicated
by the assumed relationship for distribution transformers, and two times for power
transformers (see NOTE). Such a relationship should be designated as minimum life
expectancy and may be used to establish maximum rating temperature, or as the basis for
guides for loading.
c) When the purpose of the evaluation tests is solely to demonstrate that the tested design has
achieved a pre-selected minimum life expectancy, the tests should continue until the total
elapsed time at each test temperature is at least five times the pre-selected value at that
temperature for distribution transformers, and two times for power transformers (see NOTE).
If no failure (as qualified in Clause 5) has occurred by this time at any test temperature,
demonstration of the pre-selected minimum life expectancy may be claimed.
The report of tests made under this standard shall clearly identify the method that was employed.
NOTE—The 5:1 ratio of elapsed time at test temperature for distribution transformers, and 2:1 ratio for power transformers, between
minimum time to failure and the pre-selected, or assumed life expectancy, is intended to allow for the effects of a limited number of
samples and the necessity for some extrapolation. This criteria is believed to be conservative. The ratios are based on demonstrated
withstand of actual tests of distribution transformers, and model power transformers.
D.2 Background discussion from references
In reference [B19], “Progress Report on Test Procedures for Thermal Evaluation of Oil-Immersed
Distribution Transformers,” a discussion related to this five times multiplier is provided. There is a section
titled “Demonstrated Life Concept,” which is presented here in its entirety, along with the referenced figure
from that paper (adjusting the figure reference to be consistent with this document—Figure D.1). It should
also be noted that when this testing was conducted (and from which life curves were developed), thermally
non-upgraded kraft papers were in use.
22
IEEE Std C57.100-2011
After the tests at 220 °C, 180 °C, and 160 °C hot spot temperature had been under way for some time, it
became apparent that the life of the insulation systems being tested, at these temperatures and under the
chosen test conditions, had been grossly underestimated. It seemed likely that the test at 160 °C might last
for years, thereby seriously delaying the achievement of concrete results by the Subgroup.
Consideration was given to increasing the severity of the end-point tests, or to replacing the 160 °C test
with one at a temperature above 220 °C. It was felt, however, that the former would make the end-point
tests unrealistically severe, and that the latter would require too much extrapolation between test
temperatures and normal operating temperatures. At this point, a new approach to the problem was
proposed.
It was suggested:
1. That the relationship between life expectancy and hot-spot temperature for the systems under
test be assumed to be of the well-known Arrhenius form:
B
Log L A (D.1)
T
where
L = Life Expectancy in hours

T = Absolute temperature in degrees Kelvin
A and B are constants for the systems being evaluated
2. That the constant “B” be assumed to be a value typical of those found in various experiments on
thermal degradation of cellulosic materials.
3. That the constant “A” be selected so that the life of all test specimens would be beyond the
resulting life-expectancy curve by an amount sufficient to allow for the small number of units
tested, the need for some extrapolation of test results to lower temperatures, and the desirability
of conservatism.
4. That the relationship so selected be designated as a “Demonstrated Minimum Life-Expectancy
Curve.”
Since this proposal appeared to offer a means of obtaining significant information in a reasonable time, it
was adopted by the Subgroup. The agreed-upon objective was a Demonstrated Minimum Life-Expectancy
Curve as shown in Figure D.1. This would show minimum life expectancies of about ten times those
indicated in the existing loading guide.10 It was felt that the validity of this curve could be adequately
“demonstrated” if all samples on test exceeded five times the indicated life expectancies. This meant the
first failure in any laboratory at any temperature must be beyond the “minimum test level” of Figure D.1.
At a meeting of the Subgroup in March 1961, each participating manufacturer turned in an anonymous test
report showing, at each test temperature, the time at temperature at which the first failure occurred or, if no
failures, the time at temperature attained as of the date of the meeting. A utility representative on the
Subgroup examined the reports and certified to the Subgroup that all units of all manufacturers and at each
test temperature, had exceeded the “minimum test level.”
10
At the time of this document, this was Guide for Loading Oil-Immersed Distribution and Power Transformers, ASA C57.92. This
curve is also shown in Figure D.1.
23
IEEE Std C57.100-2011
Figure D.1—Figure 1 from historical paper

—
The document then goes on to report that “a new loading guide be prepared, applicable to distribution
transformers only, based on the life expectancies indicated by the “Demonstrated Minimum Life
Expectancy Curve” of Figure D.1, rather than Figure 92.02.110 of ASA C57.92.
24
IEEE Std C57.100-2011
Annex E
(informative)
Bibliography
[B1] ASTM D-1533, “Standard Test Method for Water in Insulating Liquids by Coulometric Karl Fischer
Titration.”
[B2] ASTM D-1676, “Standard Test Methods for Film-Insulated Magnet Wire.”
[B3] ASTM D-4243-86, “Standard Method for Measurement of Average Viscometric Degree of
Polymerization of New and Aged Electrical Papers and Boards.”
[B4] Berberich, L. J., and Dakin, T. W., Guiding Principles in the Thermal Evaluation of Electrical
Insulation, AIEE Transactions (Power Apparatus and Systems), vol. 75, pp 752–761, Aug. 1956.
[B5] Dakin, T. W., “Electric Insulation Deterioration Treated as a Chemical Rate Phenomenon,”, AIEE
Transactions, vol. 67, pt. 1, pp. 113–122, 1948.
[B6] Electric Power Research Institute, “Basic Transformer Life Characteristics Vol. 1: Overload
Characteristics and Life Test Evaluation,” EPRI E1-2443, Project 1289-1 Final Report, June 1982.
[B7] Electric Power Research Institute, “"Basic Research on Transformer Life Characteristics,” EPRI EL-
2622, Project 1289-2, Final Report, Sept. 1982.
[B8] Electric Power Research Institute, “Evaluation of Alternative Insulating Oils for use in Transformers
and other Electrical Apparatus,” EPRI EL-809-S4, Project 562-1, Summary Report, Feb., 1980.
[B9] Fessler, W. A., Nichols, F. S., and Rouse, T. O., “Tube Aging and Oxidation of Napthenic and
Paraffinic Transformer Oils,” 1978 IEEE International Symposium on Electrical Insulation, Philadelphia,
June 12–14, 1978, IEEE Pub. 78CH1287-2EI, pp. 265–274.
[B10] Fessler, W. A., Kaufmann, G. H., and Rouse, T. O., “Accelerated Aging Studies of Distribution
Transformers Containing Naphthenic and Paraffinic Mineral Oils,” 1978 IEEE International Symposium on
Electrical Insulation, Philadelphia, June 12–14, 1978, IEEE Pub. 78CH1287-2EI, pp. 279–290.
[B11] IEEE Std C57.91-1995, IEEE Guide for Loading Mineral-Oil-Immersed Transformers.
[B12] IEEE Std C57.100-1999, IEEE Standard Test Procedure for Thermal Evaluation of Liquid-Immersed
Distribution and Power Transformers.
[B13] Kaufmann, G. H., “Impulse Testing of Distribution Transformers Under Load,” IEEE Transactions
on Power Apparatus and Systems, vol. PAS-96, no. 5, Sept/Oct 1977 pp. 1583-1595 (ERDA CONS/2151-1
National Technical Information Serv. U. S. Dept of Commerce, Sept. 1976).
[B14] McNutt, W. J., “A Proposed Functional Life Test Model for Power Transformers,” IEEE
Transactions on Power Apparatus and Systems, vol. PAS-96, No. 5, pp. 1648-1658, Sept./Oct. 1977.
[B15] McNutt, W. J., “Insulation Thermal Life Considerations for Transformer Loading Guides,” IEEE
Transactions on Power Delivery, vol. 7, No. 1, pp. 392–401, Jan. 1992.
25
IEEE Std C57.100-2011
[B16] McNutt, W. J., and Kaufmann, G. H., “Evaluation of a Functional Life Test Model for Power
Transformers,” IEEE Transactions on Power Apparatus and Systems, vol. PAS-102, No. 5, pp. 1151–1162,
May 1983.
[B17] Morrison, E. L., “Evaluation of the Thermal Stability of Electrical Insulating Paper,” IEEE
Transactions on Electrical Insulation, Vol. EI-3, No. 3, pp. 76-82, Aug. 1968.
[B18] NEMA MW-1000, “Magnet Wire,” Transformer Oil Resistance and Hydrolytic Stability, Long
Term Exposure Test.
[B19] “Progress Report on Test Procedures for Thermal Evaluation of Oil-Immersed Distribution
Transformers,” IEEE Transactions on Power Apparatus and Systems, Special Supplement, vol. 82S, pp.
58–66, 1963.
[B20] “Proposed IEEE Test Procedure for Thermal Evaluation of Oil-Immersed Distribution Transformer,”
IEEE Transactions on Power Apparatus and Systems, Special Supplement, vol. 82S, pp. 67–71 1963.
[B21] Summer, W. A., Stein, G. M., and Lockie, A. M., “Life Expectancy of Oil-Immersed Insulation
Structures,” AIEE Transactions (Power Apparatus and Systems), vol. 72, pp. 924–929, Oct. 1953.
26

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IEEE Power & Energy Society

IEEE Standard Test Procedure for

Approved 7 December 2011

IEEE-SA Standards Board

The Institute of Electrical and Electronics Engineers, Inc.

Copyright © 2012 by the Institute of Electrical and Electronics Engineers, Inc.

PDF: ISBN 978-0-7381-7196-8 STD97203

Comments on standards should be submitted to the following address:

Laws and regulations

Updating of IEEE documents

Roger Wicks, Chair

Richard Amos Michael Franchek Verena Pellon

Donald Cherry Richard Marek Tim Raymond

William J. Ackerman Jalal Gohari John Luksich

Masayuki Ariyoshi Jim Hughes Gary Robinson

1.1 Scope ................................................................................................................................................... 1

3.1 Industry-proven insulation system....................................................................................................... 2

5. Minimum life expectancy........................................................................................................................... 3

8. Test methods and specimens ...................................................................................................................... 5

8.1 Distribution transformer ...................................................................................................................... 5

9.1 Hottest spot test temperature ............................................................................................................... 6

10. End-point tests .......................................................................................................................................... 8

10.1 Distribution transformers................................................................................................................... 8

11. Test results................................................................................................................................................ 8

11.1 Data presentation ............................................................................................................................... 9

12. Applicability of test results..................................................................................................................... 11

A.1 Purpose ............................................................................................................................................. 13

B.1 Test samples...................................................................................................................................... 19

Annex D (informative) Historical background information ......................................................................... 22

Annex E (informative) Bibliography............................................................................................................ 25

IEEE Std C57.91™, IEEE Guide for Loading Mineral-Oil-Immersed Transformers.

3.1 Industry-proven insulation system

LIFE is the life in hours

5. Minimum life expectancy

6. Criteria for end of life—Distribution transformer and power transformer

Table 1 —Aging temperatures for three-point aging

Candidate system 10 ºC 160 ºC 175 ºC 190 ºC

8. Test methods and specimens

8.1 Distribution transformer

a) Exposure to elevated temperature while excited at rated voltage.

8.2 Power transformer model

8.3 Relative testing specimens

9.1 Hottest spot test temperature

9.2 Temperature of liquid

9.3 Duration of test period

9.5 Calculation of aging caused by heating and cooling

10. End-point tests

10.1 Distribution transformers

a) Short-circuit test (symmetrical) at 25 times rated current for 2 seconds6

10.2 Power transformers

11. Test results

11.1 Data presentation

Two methods for presentation of test results are as follows:

Figure 2 —Relative temperature index example

11.2 Test report

a) Candidate system evaluated, including a listing of the following items:

2) Conductor insulation (secondary)

LIFE is the life in hours

11.3 Example calculation of life equation

Figure 3 —Example of distribution transformer aging—life curve

LIFE is the life in hours

12. Applicability of test results

Materials testing for aging of liquid-immersed transformer insulation