CAGRE 2015

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Aging of DTE/Sétif Power Transformers Assets

- Case Studies -
Benlahneche Saâd-eddine
Transmission chief engineer – DTE / ST
GRTE - SONELGAZ - ALGERIA
E-Mail: benlahneche.saadeddine@grte.dz

SUMMARY

Nowadays, power transformers population is getting older; face to this issue, electrical
utilities, especially the ones involved in transmission systems are forced to assess the state
and the level of aging of their assets. This assessment, which is included generally in the
condition based maintenance philosophy, is necessary for predicting the remnant life of
transformers in order to undertake a strategic decision about the associated risk when they still
operate in service. All the guides and protocols used in diagnostics over the world for
predicting the residual life of transformers are based on models which include the cellulosic
insulation, their characteristics, the loading temperature, the hot spot point and its location,
the age and the level of contamination by water and oxygen. Thermal, chemical and electrical
constraints applied on solid insulation lead to its deterioration and weaken then the
mechanical withstand which is able to support the several short circuits magnitudes during the
life of transformers.
In this paper, we outline the different mechanisms of paper degradation, the methods of
diagnostics, their forces and their limits with the special emphasis on empirical correlations
relating the different components of decomposition such furanic products, moisture, acid, CO
and CO2 to the degree of polymerisation and the mechanical withstand used systematically
for predicting the remnant life of transformers and their reliability.
Finally, two examples taken from DTE/SETIF transformers fleet will be deeply discussed
and how critical cases will be treated in a global vision integrated within HV asset
management

KEYWORDS

Cellulosic degradation – aging – DTE/ Setif transformers fleet assessment – Furanic analysis
– Life assessment

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1. INTRODUCTION

Failure of transformers leads generally to irreversible and internal damages which have
negative adverse effects. They are becoming a source of long outage times with: important
losses on revenues, a costly reactive unscheduled maintenance, interruption penalties and
collateral damages. To minimize the unwanted reinvestments and the associated risk, it is
essential to understand the mechanisms of degradation and the ageing kinetics and to assess
how and when they may be controlled after in the aim to extend the life of transformers.
The windings of transformer constitute the most vulnerable part; their insulation system is
always subjected to irreversible and significant ageing. It has been viewed all over the world
that the transformer can survive with a serious and an advanced ageing without any failure,
but this case is so far to be ideal, because its ability to withstand the mechanical stresses is
always affected when inrush currents and external short-circuits are occurring. The change in
operational conditions such loading temperature, acidity, oxygen and moisture increasing can
negatively contribute to accelerate the rate of ageing.
During this communication, we discuss in details the solid insulation behaviour against
ageing (Kraft paper, up-grated paper …) from one side; and from the other side, the limits of
direct and indirect methods of measurements and diagnostics used to assess the real condition
of the paper. Some examples brought from DTE/SETIF transformers fleet will be discussed,
followed by the appropriated maintenance actions undertaken to preserve an acceptable level
of reliability within the network.
.

2. CELLULOSE CHEMISTRY AND MECHANISMS OF DEGRADATION

Ageing aspects of oil impregnated system used for transformers have generated a great
attention during last decades. This famous biopolymer is formed by a composite of materials
well ranked in a wonderful structure. The cellulose consists of linear polymeric chains of
cyclic, ß-D-glycopyranosyl units (figure 1-a). The number of such units per chain is called the
degree of polymerisation (DP).
These chains are associated in both crystalline and amorphous regions giving a birth to
micro fibrils done from micelles (every micelle consists of 10000 glucose units). The
organisation of micro fibrils in the bulk material leads to the formation of fibrils and then the
cellulosic fibres [1] (figure 1-b). The dominant part of the mechanical withstand of paper is
procured either by the repartition density of the fibres and the fibrils in the polymeric
material.

(a) (b)

Fig. 1: (a) Structural formula of cellulose and (b) microstructure of fibrils and micro fibrils

The hemicecellulose and the lignin which enter in the chemical paper construction form
amorphous and three-dimensional zones that act simultaneously as gummy substance and
reinforcing material. When the cellulose chains are degrading, the depolymerisation reaction
is then involved and the DP values decrease systematically.

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 The ageing process is often a result at least of one of these causes coming from acid-
hydrolysis, pyrolysis or oxidation.
Depolymerisation of the cellulose chain lowers the chain length and mechanical strength;
the insulation finally becomes brittle and carbonaceceous with no short circuit withstand
capability. We may call this the absolute end of life. The degradation factor of Knosp
(β = DP0/DP – 1) which express the number of chain scissions is always used to describe the
ageing process [2].
Generally, the degradation is initiated in the amorphous regions rather than the crystalline
ones where the attack starts chemically or thermally. When the paper is new, the DP value
varies between 1400 and 1200, but after the drying out process done in the factory; this value
becomes approximately 1100 with about moisture content of 0.5%.
All the specialists working in the dielectric solid insulation have retained 200 as the lower
limit where the mechanical withstand is only at 25 % of its initial value which is synonym of
the end of life reached by the transformer (figure 2).

Fig. 2: Relation between DP and the mechanical withstand of paper insulation

A - Degradation by acid- hydrolysis

The decomposition process is generally achieved through three steps; the moisture
existing in the insulation dissolves acids (coming from the oil and the paper) and the
hydrogen ions resulting from this mechanism will act as catalysis to depolymerise the paper
through the inter-unit linkages in cellulose (glycosidic bond). One molecule of water is
consumed for every linkage cleaved, followed by a series of acid catalyzed dehydration
reactions leading to the release of three molecules of water from every monosaccharidic unit
[3].
There is therefore a net production of two molecules of water per unit. The carbon
skeleton of the sugar is then converted into a derivative furan. So, the principal products of
the degradation by hydrolysis are finally water and furans.
The energy of activation associated to hydrolysis is 26-38.4 Kcal/mol. Apparently;
hydrolysis is a dominant mechanism in the range of transformer operating temperature.

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B- Degradation by oxidation and pyrolysis:

The second factor of degradation is certainly the oxygen which leads to the cellulose
oxidation.

Four types of oxidation could be possible:

- Oxidation of primary OH group to aldehyde and one water molecule.
- Oxidation of secondary group OH to acid R-COOH.
- Oxidation of secondary group OH to cetogroups and two water molecules.
- Unanimous oxidation of secondary OH groups to aldehyde and one water molecule that
may be followed with the break of a ring. This is the least probable case.

Pyrolysis is always produced by the abnormal or sudden increase in temperature

which leads to the glycosidic cycle destruction of the cellulose molecule. The energy of
activation related to this mechanism is about 54.3 Kcal/mol. The decomposition products
are: furans, acids, sugar, ketones, aldehydes, water, CO2 and CO [4].

3 - INSULATION CONDITION ASSESSMENT THROUGH DECOMPOSITION

PRODUCTS (INDIRECT METHODS)

As we have discussed before, the different products of degradation for cellulosic

insulation are: acids, sugar, ketones, aldehydes, water, CO2, CO and furans such (5-
hydroxymethyl -2- furaldehyde, 2-furfurol, 2-furaldéhyde, 2-acetylfurane, and 5-methyl-2-
furaldéhyde). Normally, in order to have a real picture of the level of degradation inside the
transformer, it is essential to know the concentrations of each component, their limits and
the mathematical correlation that may relate them. Unfortunately, until now there is no
model available doing this mission; especially if we consider either the problem coming
from the instable character of certain products of decomposition observed when they are
dissolved both in oil and in paper.
We can summarize these difficulties; even though extensive researches are done to reach
the unified model with all the variables, as follows:
- The moisture produced by degradation is difficult to quantify and separate it from the
residual one
- Furans instability and their decomposition under the loading conditions, moisture,
metals and acids presence [5].
- Furans repartition both in paper and oil.
- Oil type and presence of oxidation inhibitors
- Type and percentage of the different solid insulation in the transformer
- Weight Paper/oil ratio which is related to the transformer design.
- History and number of oil treatments and changes done on the transformer.

We can conclude through these evolved remarks that only CO, CO2 and furans may be
used as indicators of the paper condition; because these gases are strongly stable and the
furans are highly soluble in oil and they derive only from paper degradation; that is why three
approaches in diagnostic are practiced generally in the assessment:
- Assessment using only CO and CO2 :

The concentrations of the both gases can be directly estimated from chromatographic
analysis (DGA – Dissolved Gases Analysis). The ratio 11≤CO2/CO≤3 serving in the
diagnostic demonstrates the cellulose involvement in the degradation process according to
IEC standard 60-599 [6].
The rate variation of these concentrations and their exceeding of certain values
consolidate this ratio through the condition margins displayed in the IEEE .C57.104
standard in order to assess the gravity affecting the transformer [7].

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 The main disadvantage of this assessment is provided from its incapability to be
correlated with the degree of polymerization; it is a more qualitative approach than a
representative one, but it serves as a precursor to another analysis like furanic ones.

- Assessment using only derivative furans:

The furans components display however a direct correlation to a degree of

polymerization and then the mechanical properties of the paper through empirical equations
that will be developed after.
They are assessed by using high performance liquid chromatography (HPLC) according
to conditions described in the IEC standard 61-198 [8]. The phase solid extraction (PSA)
could separate rapidly all the furanic components existing in the oil by the right
manipulation of the appropriated solvent (pentane) (figure 3).

(a) ( b)

Fig. 3: HPLC Chromatograph type (a) and PSA (b)

Practical experiences have shown that among the five derivative components, only the 2-
furaldéhyde is often present in sufficient amount. Its stability in oil has pushed all the
specialists working in this field to design their models with its concentration. Perhaps, the
unique handicap coming from furanic diagnostics is the global representation of DP which
concerns all the dielectric system, but its value may change from one point to another like in
the case of transformer windings (figure 4) [9].

Fig. 4: Repartition of DP in different points of windings [9].

The Combined Assessment :

This evaluation is recent and still in research. Many efforts are done to link all the
concentrations of CO, CO2 and furanic components in the same time into mathematical

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models in order to get a degree of polymerisation the most representative of the paper
condition of transformers in service [10], [11], [12]. These models are in initial phase and
they may be either affined before they will be settled in the standards for application.

4 - PAPER INSULATION CONDITION ASSESSMENT THROUGH PAPER

SAMPLING (DIRECT METHODS)
The examination of paper samples during service is often impossible. This method is used
only in the diagnostic of posmortem type where transformers subjected to the expertise,
replacement or rehabilitation are concerned in order to improve the weak points observed for
the same units existing in service or even for dielectric system revision considerations or the
reverse engineering done generally by manufacturers and consulting groups. Two methods of
analysis are possible: one viscometric according to the standard ASTM D 4243 [13] where a
macromolecular solution is prepared from paper insulation dissolved in the
cupridiéthylamine, the DP value that may be calculated varies against the viscosity of the
solution by using the modified equations of Mark - Houwink; the second is realised through
the size exclusion chromatography (SEC). The molecules are separated according to their size
and we can follow then both the molecular distribution of the paper and its ageing process.

5 - CRITERIA OF END OF LIFE AND REMNENT LIFE OF POWER

TRANSFORMER
The design life of power transformer is approximately twenty years old. They are many
transformers still operating over the world and their age exceeds widely fifty years old. We
have seen that the life of transformers depends on the life of its solid insulation which is
defined by chemical processes described above and affected by the simultaneous existence of:
the several contaminants, the temperature, the moisture and the oxygen. Over the hot spot
point (110° C for up grated paper and 98° C for the other), each increase of 7° C, it decreases
the life of transformer by half [14]; and we lead to the same result if we double the moisture
concentration in paper. The end life criteria of transformer is related to the degree of
polymerisation and especially when this value reaches 200 correlated with one of equations
given in the table 1. According to the sources of statistics from the international organisations
and laboratories, the solid insulation is one the most causes of failure with a high percentage
degree. The statistics of ZTZ achieved between 2000 and 2005 demonstrate that 14.3 % and
17.3 % of failures are originally deriving from the minor insulation and the major insulation
and 4.8 % from leads degradation. So, about 35 % of the registered failures are attributed to
solid insulation even though the bushings insulation is not considered here, and we know
that’s always subjected to high electrical and thermal stresses resulting from the lack of
impregnation which increases systematically the probability of failure within the insulation.

Method Evaluation of DP/ Equation of Evaluation of remnant life (RL in (%)

Log [2FAL] = 2.5 -0.005DP - Burton

Log [2FAL] = 2.6 -0.0049DP - Vuarchex
Indirect Log [2FAL] = 1.5 -0.0035DP - Chendong
DP ([2FAL] + 2.3) = 1850 - DePablo
Log [2FAL] = 1.5655 -0.035DP* - Stebbin
RL = - 381.91574 +72.053012 ln DP
DP = 1.9 - ASTM D 4243

Direct DP0.9 = 1.65 - R. Evans [15]

0.9
DP = 1.22 - M. Marx

Tab. 1: Equations for measurement of DP and (RL)

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 In overloaded transformers, the failure will occur through two modes related to the
localized or generalized overheating of the insulation (figure 5).

(a) (b)
Fig. 5. Degradation by localized overheating (a) generalized overheating (b)

The Observations done by electronic microscopy reveal a structural de-cohesion at

molecular level of degraded cellulosic samples taken from an aged transformer comparatively
to others coming from a new transformer (figure 6).

(a) ( b)

Fig. 6. New paper sample (a) and degraded paper sample (b)

6 - DIAGNOSTIC OF SETIF LOCATION TRANSFORMERS FLEET ( DTE/SETIF) –

MAINTENANCE ACTIONS – CASE STUDIES

The condition of the active parts and the insulation of power transformers of Sétif
location is summarized by the following tables where we find according to the standard
IEEE.C57.104.1991 a certain number taken from the 70 units is situated in the condition 3
(23.18 % of CO2 gas) giving a clear idea about the rate of ageing. Furanic analysis shows
approximately 3 % (2 transformers) that are in end of their lives and 8.5 % in accelerated
ageing situation (6 transformers) which consolidate strongly the observations extracted from
DGA.

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 GAS Condition 1 (%) Condition 2 (%) Condition 3 (%) Condition 4 (%)
H2 84.05 8.6 7.24 0
CH4 79.71 10.14 5.79 4.34
C2H6 69.6 5.79 5.79 18.84
C2H4 72.46 18.69 3.34 5.79
C2H2 79.71 4.34 4.79 11.59
CO2 36.23 36.23 23.18 3.44

Tab. 2: Repartition of dissolved gases according to the standard IEEE.C57.104.1991 of

Sétif location transformers fleet [16].

Age Profile DP
U (kV) (years) 950 - 500 500 - 350 350 – 250 250 - 200
10 - 20 07 01 - 01
220 20 - 30 07 03 01 -
 30 05 04 - -
10 - 20 13 - 01 -
 220 20 - 30 09 05 - 01
 30 05 04 04 -

Tab. 3: Repartition of DP for The 70 transformers

As a conclusion derived from the lecture of these tables, the ageing is ranked in the third
position in gravity after the defects by partial discharges and oil overheating.
Face to this issue, a great orientation was applied at DTE/SETIF and it has concerned the
establishment of a plan for life management of the critical units. The developed points of this
plan were as follows:
- Verify the regularity of all transformers protections in service with units having a DP
situated between 400 and 200 in order to avoid external damages caused by short-circuits
until they will be replaced, and set loading margins for their operating conditions.
- Maintain and conserve all the transformers with DP between 500 and 600 by reducing
the rate and the speed of ageing through specific actions applied to solid insulation for
minimizing a further decline in their properties.
- Monitor the solid insulation of the newest units in order to arrest prematurely any
deviation able to initiate the ageing.
This particular plan for life management takes into account the number and types of
treatments to be implemented for a certain transformer population, including the time and
location to their implementation
Among this population, we are going to discuss the situation and the state of two units
strongly affected by ageing:

A - Mobile station 220/60 kV 40 MVA of Sidi Aiche:

This transformer presented a high value of the dielectric loss factor of the oil (= 0.23)
even though the moisture content was normal (= 11 ppm). The DGA revealed abnormal
proportions of CO, CO2, CH4 and C2H6 in the following respective quantities 597 PPM,
1944 PPM, 101 PPM and 110 PPM giving thus an idea about the loading conditions of the
transformer ( CO2/ CO = 3.25 ). Furanic compounds analysis confirmed the existence of a
2-FAL in a dangerous amount 5.79 PPM produced as consequence of an advanced ageing
process of the solid insulation. The elapsed life of the transformer was estimated at 80%. It
was then very necessary to check the reliability of transformer protections and to rate it at a

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moderate loading until its internal inspection. It was finally retired from service where another
substation fitted with two units has brought the entire load to feed the customers.

B - Transformer 60/10 kV 24 MVA in SCH - Sétif :

This transformer exhibited two modes of defects; the first is coming from the existence of
partial discharges caused by the high moisture content in paper (≈ 6 %) and the second from
the accelerated ageing generated by the loading conditions and the moisture action. The
dielectric strength of the transformers always decreases to lower values less than 30 kV
despite the different treatments realised for several times to improve it; the diffusion
mechanism of moisture from paper to oil tends to increase its concentration in order to reach
the equilibrium state under the loading conditions. The concentration of composite gases (H2
+ CO) monitored by HYDRAN during the six months shows a slight increase from 100 PPM
to 134 PPM.

Our major worry associated to the risk on this unit is linked to three unknowns:

- The partial discharges location and gravity ( lack of appropriated tests)

The moisture concentration repartition, both in the paper insulation of windings and in a hot
spot point position (HSP).
- The margin temperature for bubbling generation in windings spires ( no monitoring
system used)

In order to undertake a specific action in maintenance which concerns the drying out all
of the dielectric system of the transformer and to decide about the option to be used, a furanic
analysis was performed in 09/10/2006 where the 2FAL concentration was evaluated at 3.11
PPM corresponding to 60% of the elapsed life; a year before, this concentration was estimated
at 0.86 PPM corresponding only to 40% of the consumed life. So, the rate of ageing was
really consistent that‘s why, one of these three alternatives was considered consequently to
preserve the dielectric system and to extend the life of the transformer:

- On line processing of the oil where the diffusion flux works in the same sense with the
thermal one in order to remove moisture from the paper ( best option)
- Drying out processing of the transformer which takes a long period (we must check
carefully the process in order to avoid: added degradation, over drying, paper
delamination and release in clamping forces).
- The retro filling of the mineral oil of the transformer by a vegetal ester one able to
absorb all the paper moisture without any decrease in the dielectric strength.

7 – CONCLUSION;

Furanic analysis is a great mean to assess the condition of the paper insulation and through
it the transformer reliability. With the progress of other equipments of diagnostic, the
interpretation models for insulation behaviour will be affined. Other instruments such on-line
ones may be helpful if their availability will be confirmed in the future. The concept of the
unique model relating CO2, CO and the furanic components to the degree of polymerisation
will allow to avoid errors on diagnostics and to assess strongly the kinetic of ageing and the
associated causes.

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8 – SYMBOLS AND NOMENCLATURES:

DTE/ST : Direction de transport d’Electricité de Sétif

DGA : Dissolved Gases Analysis
PPM : Parts Per Millions
DP : Degree of Polymerization

9 - REFERENCES

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