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Practice of IEC 60422 in ageing assessment of in-service transformers

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 The 19th International Symposium on High Voltage Engineering, Pilsen, Czech Republic, August, 23 – 28, 2015

PRACTICE OF IEC 60422 IN AGEING ASSESSMENT OF

IN-SERVICE TRANSFORMERS
1 1* 1 2 2 2 3 4
S.J. Tee , Q. Liu , Z.D. Wang , G. Wilson , P. Jarman , R. Hooton , P. Dyer and D. Walker
1
The University of Manchester, Manchester, M13 9PL, UK
2
The National Grid Company, Warwick, CV34 6DA, UK
3
UK Power Networks, Crawley, RH10 0FL, UK
4
Scottish Power, Blantyre, G72 0HT, UK
*Email: qiang.liu@manchester.ac.uk

Abstract: Ageing assessment of transformer insulation is essential towards proposing

asset management strategies. IEC 60422 is a standard that recommends not only a list of
oil test parameters along with value ranges indicating good, fair and poor conditions; but
also actions that can be employed. Nonetheless, the interpretation and implementation of
IEC 60422 largely depend on utilities’ own experience and expertise. Through analysing
oil test databases of field transformers at 33 kV, 132 kV, 275 kV and 400 kV in the UK,
the common parameters used for different utilities are found to be breakdown voltage,
moisture, acidity and 2-furfural. Among them, acidity seems to be the most essential
parameter in oil ageing assessment both from graphical analysis and statistical analysis
in the form of Spearman’s correlation. By comparing the acidity trends, higher voltage
units exhibit lower values implying better design and maintenance. Higher voltage units
also tend to be tested more frequently as well as tested for more parameters such as
dielectric dissipation factor, resistivity, interfacial tension and colour. All these parameters
exhibit different ageing sensitivities and their essence together with IEC 60422 could be
included in a health index formulation to facilitate ageing assessment of in-service units.

1 INTRODUCTION These parameters can generally be grouped into

It is well understood that power transformer
insulation system deteriorates in service. Oxidation
is the primary ageing mechanism for the liquid part
of the insulation system, typically mineral oil.
Oxygen first extracts a hydrogen atom from a
hydrocarbon molecule, subsequently forming
radicals that undergo propagation, branching and
termination stages of oxidation [1-3]. These
reactions will eventually increase the concentration
of acidity, moisture and other polar compounds
such as hydroperoxides and alcohols [1-3].
Degradation of the solid part of the insulation
system, the paper, is believed to start with
oxidation but, at normal operating temperatures, it
is then dominated by hydrolysis [4-7]. Generally,
acids and moisture produced from oxidation of
paper and oil will initiate hydrolysis that increases
further the concentrations of acidity and moisture
[4-7]. The process of hydrolysis is self-accelerated,
which ultimately produces carbon oxides and
furans in addition to moisture and acidity [4-9].
electrical, chemical and physical categories as
shown in Figure 1. Moreover, superscript numbers
show IEC 60422 routine, complementary and
special investigative tests with smaller numbers
denoting greater importance [10]. Among these
parameters, those with star-shaped symbols are
more widely measured by the UK utilities.
It is noteworthy that relative permittivity is not in
IEC 60422. Nonetheless, it is also a dielectric
parameter and commonly obtained together with
dielectric dissipation factor tests without additional
cost [11-14]. Furan is also not an IEC 60422
parameter but since it directly relates to paper
ageing, it manifests as an essential parameter if
paper condition is of interest [15, 16]. In addition,
both parameters are recorded by the UK utilities.

With deterioration of oil and paper both producing

traceable compounds and considering oil-paper
partitioning as well as oil accessibility, transformer
oil is tested for multiple parameters for ageing
assessment. With many parameters measurable,
an international standard commonly referred to is
IEC 60422 which provides recommended value
ranges to be compared with test results for
interpreting good, fair and poor conditions [10].
Figure 1: Parameters for ageing assessment
With multiple parameters, there is a need for The value tabulated means the average number of
interpreting test records into transformer condition. tests done on each unit per year, aggregated from
Table 1 shows IEC 60422 condition classification the relevant databases at a specific voltage level.
for six of the more widely measured parameters For example, a value of 0.33 would mean there is
[10]. They are dielectric dissipation factor (DDF), an average of 1 measurement per unit per 3 years.
resistivity, breakdown voltage (BDV), acidity, As for the databases, they are grouped into three
moisture and interfacial tension (IFT). Note DDF classes: 33 kV, 132 kV and a combination of 275
and resistivity are testable at various temperatures kV & 400 kV; as both 275 kV and 400 kV units are
but 90 °C records are generally used in the UK. As treated identically when considering the condition
for IFT, focus is on the uninhibited case as most classification and actions to be taken [10].
field units are still filled with uninhibited mineral oil.
Table 2: Aggregated average testing frequencies
From Table 1, a good condition indicates normal oil
condition and normal sampling is suggested [10]. If Average Testing Frequency
a fair condition is interpreted, more frequent (No. of Tests/No. of Units)/Testing Period
Parameter
sampling is suggested in the light of detectable oil 33 kV 132 kV 275 & 400 kV
3 Databases 3 Databases 2 Databases
deterioration [10]. Finally a poor condition implies BDV 0.3457 0.6927 0.5493
abnormal oil deterioration and actions like oil Moisture 0.3553 0.6908 0.9521
reconditioning or reclamation are needed [10]. It Acidity 0.3537 0.6508 0.7954
should be noted that action is not recommended 2-FAL 0.3530 0.6529 0.5717
based on a single test result or a single parameter. DDF X X 0.2727*
Resistivity X X 0.3545*
IFT X X 0.2404*
Table 1: IEC 60422 condition classification [10] Colour X X 1.1985*
Permittivity X X 0.2730*

Parameter
Voltage Condition Classification * from one database
(kV) Good Fair Poor
DDF (40 Hz – 60 >170 < 0.1 0.1 – 0.2 > 0.2 Among the many parameters, the common ones
Hz at 90 °C) ≤ 170 < 0.1 0.1 – 0.5 > 0.5
recorded by utility databases are BDV, moisture,
Resistivity >170 > 10 3 – 10 <3
(GΩm, at 90 °C) ≤ 170 >3 0.2 – 3 < 0.2 acidity and 2-furfural (2-FAL) which is the dominant
>170 > 60 50 – 60 < 50 type of furans. Although BDV and 2-FAL average
BDV (kV, 2.5
mm gap)
72.5 – 170 > 50 40 – 50 < 40 testing frequencies of 275 kV & 400 kV class are
≤ 72.5 > 40 30 – 40 < 30 lower than those of 132 kV, higher voltage units
>170 < 0.1 0.1 – 0.15 > 0.15 are generally tested more frequently as suggested
Acidity (mg
72.5 – 170 < 0.1 0.1 – 0.2 > 0.2
KOH/g oil) by the increasing average testing frequencies. In
≤ 72.5 < 0.15 0.15 – 0.3 > 0.3
Moisture (ppm at >170 < 15 15 – 20 > 20 fact, the average of the four average testing
operating 72.5 – 170 < 20 20 – 30 > 30 frequencies for BDV, moisture, acidity and 2-FAL
temperature) ≤ 72.5 < 30 30 – 40 > 40 reveals a definite increase with voltage level.
IFT (mN/m,
All > 25 20 – 25 < 20
uninhibited) This insinuates the greater attention and
importance on higher voltage units which can also
be reflected from IEC 60422 suggested testing
With multiple parameters, questions remain on frequencies for units at different voltages. Due to
which could be more representative of transformer the higher criticality of higher voltage units in
ageing. Also, there exists doubt on the IEC 60422 supplying a larger downstream area in the network,
recommended values [11]. In addition, IEC 60422 utilities tend to test them more frequently to help
includes only oil condition classification. As paper perhaps obtain a clearer view on the evolution of
is also integral to insulation, it is worth analysing parameters over a certain period of time and also
furans even though their reference values are still provide timely indications of abnormal conditions.
unclear [15, 17]. In this paper, population and
correlation analyses with age are done on eight oil The greater attention on higher voltage units can
test databases of the UK transformers at primary also be deduced from the greater number of
voltages of 33 kV, 132 kV, 275 kV and 400 kV. parameters in a database related to 275 kV & 400
kV. In alphabetical order to represent the eight
2 ANALYSES ON OIL TEST DATABASES databases, this database is named as Database
G_275kV_400kV. From Table 2, DDF, resistivity,
By analysing eight oil test databases, some of the IFT, colour and permittivity are measured apart
basic fields of information are manufacturing year, from the four common parameters. For DDF and
commissioning year, testing date etc. With resistivity, they are categorised as routine tests just
reference to the parameters measurable, the like acidity but are tested less frequently.
extraction of information on the number of oil test Nevertheless, even with lower testing frequencies,
entries and number of transformers along with the the measurement of more parameters would
testing period could reveal testing frequency. This provide utilities with a more comprehensive and
derivative information is presented in Table 2. diverse information span on transformer condition.
3 POPULATION AGEING TRENDS
(a)
After knowing some basic information from the
databases, this section explores ageing trends.
With focus on populations, Figure 2 shows the box
plot trends with age. Although only Database
C_33kV is considered for Figure 2, all the other
databases do portray similar trends for the four
common parameters. Besides the four common
parameters, Figure 3 depicts the population ageing
trends of DDF, resistivity, IFT and colour only
recorded in Database G_275kV_400kV.
(b)
(a)

(c)
(b)

(c)

(d)

Figure 3: Database G_275kV_400kV ageing

(d)
Figure 2: Database C_33kV ageing trends, (a)
BDV, (b) moisture, (c) acidity, (d) 2-FAL
trends, (a) DDF, (b) resistivity, (c) IFT, (d) colour
Note that permittivity which is also measured for
Database G_275kV_400kV as seen from Table 2
is not shown in Figure 3 as it remains constant
throughout ageing. Also, it is noteworthy that
resistivity as shown in Figure 3(b) is expressed
logarithmically with age. Besides that, among the
parameters shown in Figure 3, colour is the only
non-numerical and subjective measurement where
the y-axis in Figure 3(d) is represented in terms of
New (N), Light (L), Gold (G), Amber (A), Dark (D)
and Very Dark (VD). A value between two adjacent
steps would just mean an intermediate level.
With understanding on the nature of the plots in
both Figure 2 and Figure 3, the correlation of the
different parameters with age will be discussed
from graphical and statistical perspectives.
3.1 Correlation analysis – Graphic
Firstly on the common parameters shown in Figure
2, for indicating paper condition, there is only a
choice of 2-FAL which only increases towards the
very late stages of ageing. Such a late ageing
sensitivity substantiates the need for an alternative
paper ageing indicator, with research currently
being done on methanol [18].
In Figure 4, only the magnitude of Spearman’s
correlation with age is shown to collate the degree
of representing transformer ageing by different
parameters. Nevertheless, it is known that
breakdown voltage (BDV), resistivity and interfacial
tension (IFT) will decrease with ageing. Hence, if
the sign of their Spearman’s correlations was to be
included, it would have been negative.
(a)

As for indicating oil condition, BDV tends to stay

relatively constant before dropping towards the
very late stage of ageing whereas both moisture
and acidity show a progressive increase with age.
Besides these three parameters, other parameters
capable of indicating oil ageing are as illustrated in
Figure 3. Generally, DDF gradually increases with
age whereas resistivity, IFT and colour appear to
change more noticeably in the early ageing stages (b)
before stabilising from mid-ageing onwards.

3.2 Correlation analysis – Statistic

As a tool to supplement the correlation analyses

perceived from a graphical perspective, the
correlation with age of the different parameters will
be explored from a statistical perspective in the
form of Spearman’s correlation. In a concise
manner, Spearman’s correlation is similar to the
widely used Pearson’s correlation [19], having
exactly the same form as shown in Equation (1).
Instead of having actual values for evaluating ρ in (c)
Equation (1), Spearman’s correlation involves
conversion of actual values for both independent
and dependent variables into ranks [19].

  x  x  y  y 
n

i i
 i 1
(1)
 x  x  y  y
n 2 n 2
i i
i 1 i 1

Where: xi : each value of the independent variable

Figure 4: Magnitude of Spearman’s correlation, (a)
yi : each value of the dependent variable 33 kV, (b) 132 kV, (c) 275 kV and 400 kV

x, y : average values Focusing firstly on the four common parameters,

n : number of observations
Like Pearson’s, a magnitude of Spearman’s
correlation that is closer to unity implies a strong
relation whereas the sign denotes an increasing or
decreasing tendency [20]. Spearman’s correlation
is statistically more powerful than Pearson’s as it is
less susceptible to outliers and allows both linear
and nonlinear monotonic relations as well as rank-
ordered variables like colour [19, 21].
the only paper ageing indicator, 2-FAL has an
average magnitude of Spearman’s correlation of
0.49 across the eight databases. More interestingly
for oil ageing indicator, acidity in general
consistently outperforms moisture and BDV in the
various databases considered. In fact, acidity has
the highest average magnitude of Spearman’s
correlation in 0.64, to be followed by moisture
(0.41) and BDV (0.20). This implies acidity perhaps
is the most essential for indicating oil ageing.
As for other parameters only recorded for
Database G with transformers at primary voltages
of 275 kV and 400 kV, the exclusion of permittivity
in the ageing trends in Figure 3 is further verified
as it has a magnitude of Spearman’s correlation of
just 0.01. Other than that, DDF, resistivity, IFT and
colour have generally high magnitudes of
Spearman’s correlation with age. In fact, IFT
appears slightly better than acidity whereas DDF
seems similar to acidity in representing ageing.
3.3 Correlation analysis – Implications
As interpreted from the two preceding subsections,
for asset managers whom are already equipped
with databases or for those intending to build a
database from scratch, perhaps the most essential
parameter for indicating oil ageing is acidity. This is
because it has perhaps the best correlation with
age both graphically and statistically.
Other than that, it is worthwhile analysing moisture.
Although not shown, moisture has the longest
testing history across all the databases, possibly
due to lower cost or a more matured technique.
With an adequate representation of ageing shown
graphically and statistically, the long testing history
could aid analyses of individual unit trends from
early until late ageing stages especially for older
units. Care however needs to be taken as moisture
measurements are prone to external factors such
as temperature influence [11]. This concern is also
applicable to BDV as moisture affects BDV [11].
Shifting from suggesting the essential parameter
for oil ageing indicator to paper ageing indicator,
owing to its direct relationship to paper
degradation, 2-FAL is the current option but recent
research on methanol usability could offer an
alternative in the near future [18, 22].
Besides suggesting acidity and 2-FAL as the
essential parameters for oil and paper ageing, if
resources in terms of time and cost are less of an
issue and if more information is required as a
supplement, parameters like DDF, resistivity, IFT
and colour could be measured, perhaps more
frequently if they are already being measured.
DDF could have a similar degree of representing
oil ageing to acidity, judging by their similar
Spearman’s correlations for a database as shown
in Figure 4(c). Interestingly for resistivity, though
normally measured together with DDF, it has a
lower Spearman’s correlation potentially due to its
low sensitivity to polarisation component of the
dielectric loss [11]. From the same Figure 4(c), with
a higher magnitude of Spearman’s correlation, IFT
appears better than acidity. However by combining
a graphical perspective as seen in Figure 3(c), IFT
changes less from mid-ageing onwards due to
micelle formations [11] and difficult separation of
two layers (water and oil) in IFT measurement.
Thus, there is always a need for combining both
graphical and statistical perspectives in selecting
the appropriate ageing indicators for different
periods of interest in the whole ageing span. An
extension to having multiple parameters is to
perhaps utilise the different sensitivities of those
parameters to different ageing stages in better
interpreting the ageing condition of transformer
fleets. This may mean a synergistic combination of
parameters [11] or asset health index formulation.
4 VOLTAGE LEVEL COMPARISON
It is always of interest to observe differences
among transformers operating at different voltages.
With acidity identified as perhaps the most
essential ageing indicator, Figure 5 shows the
median value representation of acidity records at
each age related to all the eight databases.
Figure 5: Acidity median value trends with age
across eight databases at three voltage classes
Figure 5 reveals 33 kV and 132 kV units seem to
have very similar acidities throughout the whole
transformer ageing span. In terms of condition
interpreted, even with similar ageing trends, the
condition classification criteria based on acidity for
132 kV units are stricter if to be compared with
their 33 kV counterparts as indicated in Table 1.
Based on the aforementioned observation, even
though 33 kV and 132 kV units generally age
similarly, asset managers are perhaps more
inclined to impart a more conservative or a more
cautious approach towards higher voltage units.
Expanding on that, as perceived from Figure 5,
275 kV and 400 kV transformers evidently exhibit
lower acidity values if to be compared with both 33
kV and 132 kV transformers. Apart from perhaps a
stricter design requirement for those higher voltage
transformers, the difference observed could also
be related to the greater care or maintenance
imparted on them. This bodes well with the higher
testing frequency and greater number of oil test
parameters associated with higher voltage
transformers, further alluding to the greater
attention they receive from electrical utilities.
 5 CONCLUSION
Transformer ageing assessment is a complex
issue involving interpretation of individual oil test
parameters as recommended in IEC 60422. By
analysing oil databases of the UK transformers,
testing frequencies and ageing trends of different
parameters can be observed. Common parameters
measured for different voltage units are breakdown
voltage (BDV), moisture, acidity and 2-furfural (2-
FAL) with acidity and 2-FAL perhaps the essential
parameters for representing oil and paper ageing
respectively. With greater number of newer units
filled with inhibited mineral oil or even alternative
liquids in the future, other parameters like inhibitor
content might also need to be considered. Apart
from that, database analyses also revealed greater
attention on higher voltage units as well as the
potential need for incorporating different parameter
information and sensitivities in the form of health
index to facilitate transformer ageing assessment.
ACKNOWLEDGMENTS
The authors would like to express their gratitude to
M&I Materials, National Grid, Scottish Power, Shell
Global Solutions, TJ|H2b Analytical Services, UK
Power Network and WEIDMANN Electrical
Technology for their financial and technical
contributions to the transformer research
consortium at The University of Manchester.
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