MORGANTM

SCHAFFER
Transformers – The Inside View

Transformer Tests

Oil tests and on-line monitoring can

increase transformer life expectancy

By: William Morse

Morgan Schaffer Inc.
Transformers
 The heart of a
substation
 Needed to transmit
electricity over long
distances
 Steps up or steps down
voltage
 The Inside View

Ready to work again Ready for repair

Oil, the Blood of the Transformer
 Part of the Insulation
System
– Excellent dielectric
properties

 Cools the transformer

– Excellent heat transfer
properties

 Ease of access
Standard ASTM Tests for Insulating Oil
Description ASTM Number
Dielectric Strength D-877/D-1816
Acidity D-974
Interfacial tension D-971
Color D-1500
Water Content D-1533
Density D-1298
Visual examination D-1524
Power factor D-924
Dissolved gas analysis D-3612
Inhibitor content D-4768
Furan Analysis D-5837
Metals Analysis ICP
 Dielectric Strength

Acceptable limit for serviced aged oil: 25 kV

Interfacial Tension

Acceptable limit for serviced

aged oil: 18 dynes/cm
 Water Content

The Past And The Present

Limit for serviced aged oil: 35 ppm

 Dissolved Gas Analysis

The most important test you can perform on your transformer

Dissolved Gas Analysis
 High vacuum gas
extraction apparatus
– Extracts all dissolved
gases found in the oil
sample
– Determines dissolved
water in ppm as well
– Extraction of all gases
in less than 2 minutes
Gas Chromatographic Analysis

CO2

CO C2H4
CH4
C2H6
C2H2
Oil Breakdown Products
Partial Discharge
Overheating
Arcing
 Two More Important Tests
 Furan analysis
– Determines the state of the solid insulation

 Metals analysis
– Used to pin point the location of a fault
 Predictive Maintenance
 On-site analyzers
– Increase the frequency of testing
– More data points – Better decisions

 On-line monitors
– Needed for critical transformers
– Warn of developing problems between routine
maintenance
PHA-1000 Hydrogen Analyzer
Fastest way of
screening transformers.
Analyzes Hydrogen -
A key gas produced by
all fault types
High sensitivity and
wide range
Simple operation
 Accurate H2 readings in 60 seconds
Analysis of H2 only = No cross contamination
No special training required
MYRKOS Fault Gas Analyzer

A Full DGA Lab in the field

Typical Gas Extraction
Apparatus
 High vacuum gas
extraction apparatus
– Fragile
– Not very portable
– Special training
required
 The Shake Test Syringe

Completely portable
Syringe must be filled so that
No special training metering pin is completely
required outside of syringe cap.
An exact amount of oil is measured using a metering
pin located on the syringe piston shaft.

Eject the excess oil by pushing the piston

until the metering pin hits the syringe cap.
Mixing the oil with CO2 free ambient air:
Ambient CO2 free air is pulled into the
syringe which is then vigorously
shaken to speed up gas diffusion from
the liquid phase to the gas phase.

• Connect syringe to CO2 trap

• Open syringe and CO2 trap
• Slowly pull syringe piston to the end
• Close syringe and CO2 trap
• Disconnect CO2 trap
Method accepted by IEC 60567
and ASTM D-3612

Complete DGA in 2 minutes on-site

Once the test is initiated, automatic sampling occurs and outputs are
obtained from both modules (A & B) simultaneously. Calibration is then
performed at a click of the mouse button.
 On-line Monitors

 Continuously measure gas concentration

 Store data and trigger alarms
 Calisto
Dissolved Hydrogen and Water Monitor

Intelligent Electronic Device IED

Highly Accurate and Precise
Monitors Oil-Filled Transformers
Designed for Extreme Environments
Communicates with the World
Oil circulation and gas extraction circuits
Gas Extraction Technology
 H2 detection cell

Specially designed thermal

conductivity detector
Specific to Hydrogen
No interference from other gases
Gas extraction chamber H2 detector port

Oil
circulation
pump

Water sensor

Primary Heat exchanger

Heat Generation and Removal System
 Calisto
Dissolved Hydrogen and Water Monitor

Continuous Hydrogen measurement

Two alarm levels
H2 Data storage and trending software

Why Hydrogen?
Hydrogen is produced in all transformer faults. Calisto will detect
the fault before the Bucholz relay is tripped.
 Calisto
Dissolved Hydrogen and Water Monitor

Continuous dissolved water measurement

Two alarm levels
Data storage and trending software
H2O Reported in ppm or %RS at 25C

Why water?
Along with polar compounds and acids water can adversely
affect the dielectric properties of the solid insulation
 Installation

Salt River Project Phoenix, Arizona, USA GE 20 MVA 69 Kv

Installation
Installation
 Installations

MPEB Bhopal, India DUBAL Dubai, UAE

Communication
Ethernet
RS-232
Modem
Fiber Optic
Wireless
RS-485
Gas Trending
Benefits
Easy to install

Maintenance free

Fastest response to developing faults

Accurate & reliable measurements

Monitors faults AND insulation

integrity

Will integrate to ANY data

acquisition system or LAN using
STANDARD protocols
Case Study 650 MVA GSU Transformer
failure and Repair
DGA results as of November 11th,
2001
Table 2: H2 generating rates from May 30th to Sept. 26th 2002
Dissolved water
Sudden increase in hydrogen generating rate
 Source of incipient fault

Nov. 2001
Initial source of high electrical resistance (e.g. bad connection)

May 2002 to Sept. 17th 2002

Resistive hot spot of increasing resistance (H2, CH4, and C2H4)

Between Sept. 17th and Sept. 30th (Sept. 27th ?)

Additional energy probably through circulating currents

Burned high voltage lead

 Overheated
Connector

Burnt Lead
Mirant GSU – Update as of February 19th, 2003

Constant H2 level at approx. 30 ppm

 50 MVA NPC Philippines

Inspection Loose diverter switch contacts

 The Future
 More intelligent monitors
 More gases measured
 Cost and size reduced
 Integration with a full substation monitoring
system
 Equipment that integrates with diagnostic
software
 Ease of access through the internet
Preventive Maintenance It Pays

Thank you