Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Dielectric conditions (continuous and over voltages/system

inherent and transient/atmospheric over voltages, frequency of occurrence and amplitude) The thermal conditions (Loading/Overloading cycles, ambient temperatures) The dynamic stresses due to system short circuit stresses (shrinkage of insulation (normal ageing) and increase of dynamic stresses) Chemical changes due to the effect of agents Figure 1: Operational stresses

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany
Condition Normal Definition No obvious problems. No actions justified. No evidence of degradation Acceptable, but does not imply defect-free

Aged? Normal in service? Defective

No significant impact on short-term reliability but asset life may be affected in long terms, unless remedial action is carried out

Faulty

Can remain in service, but short-term reliability may be reduced. Remedial actions may or may not be successful

Failed

Has lost its functionality, cannot remain in service. Remedial action required before being returned to service (may be inexpensive repair or requiring replacement).

Figure 2: Definition of condition classification, acc. to CIGRE A2 WG 12.18

ARWtr 2004

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

The main insulation ageing factors are: Air/Oxygen Moisture Temperature Mechanical/Electrical Stress Insulation Contamination These factors are strongly interlinked and act together Figure 3: Main Ageing Factors

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Impact of Air
Air/oxygen ingress causes: Ageing of the oil already at service temperatures (<7590C) and Ageing of the solid insulation Figure 4: Impact of Air

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Impact of Moisture Water/Moisture in a transformer is developed from: Ageing of cellulose To some extent from oil ageing and Mainly through diffusion/ingress external moisture Once water has penetrated and distributed in oil and solid insulation it causes: Accelerated ageing of cellulose Reduction of dielectric strength of oil and solid insulation Risk of bubble formation causing partial discharges
Figure 5: Impact of Moisture

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

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1% moisture
1,2 1 0,8 0,6 0,4 0,2 0 0 2 4 6 8 10

4% moisture

Ti me ( mont hs)

10% moisture

Additional moisture ingress

Figure 6: Degree of polymerization of pressboard under different moisture contents at 95C

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Figure 7: Ageing of pressboard under moisture temp. Under the ingren of moisture DP-Values of < 200 are reached even at operating temperatures < 90 C

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Air Humidity Temperatu re Contamina tion Electrical and Mechanica

Ageing of oil and Paper

Acids Sludge Humidity Conductive Particles

l
Overstress

Figure 8: Interaction between the various ageing factors

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

A transformer is defined by the following subsystems [5] - Electromagnetic circuit - Current carrying circuit - Dielectric system - Mechanical structure - Cooling system - Bushings - OLTC - Oil preservation and expansion system - Protection and Controls / Monitoring
Figure 9: Definition of functional Subsystems

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Electro-magnetic ability and integrity to transfer energy under specified conditions Integrity of current carrying circuits Dielectric withstand strength under specified stresses and normal ageing Mechanical withstand strength (short circuit fault current conditions). The Diagnostics must consider: What defects / faults can be expected in the transformer core and coil assembly What is the possible defect evolution into a failure
Figure 10: Service-Ability Requirements

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Summary of Functional related Diagnostics Generally applicable diagnostics (6.3.1) for Dielectric failure recognition in magnetic circuits (6.3.2) for Dielectric failure recognition in windings / main insulation (6.3.3) for Thermal failure recognition (6.3.4) for Critical ageing of oil and celluloses (6.3.5) for mechanical failure recognition (6.3.6) for Dielectric / thermal / mechanical failure in OLTC (6.3.7) for Dielectric / thermal failure in bushings (6.3.8)
Figure 11: Overview of diagnostic procedures

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Dielectric failure Recognition in Windings / main insulation DGA Oil analysis (BDV, dissipation, neutralization, etc.) Interfacial tension Humidity in oil Dielectric response (PDC / FDS) measurement for moisture / ageing Karl Fischer for moisture Degree of Depolymerisation (DP) Power factor and capacitance Winding resistance Dew-point measurement Partial discharge measurement and localization Transfer function analysis Frequency response Analysis Humidity in oil by sampling / On-line Monitoring
ARWtr 2004 Figure 12: Diagnostics of Dielectric failures in windings and main insulation
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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Thermal Failures detection DGA Oil Analysis Interfacial tension FURAN Derivate Analysis Control of winding temperatures / oil temperatures Dielectric Response measurements (PDC, FDS) - for excess moisture control Hotspot controls by Thermo-Vision Magnetizing current control for core and/or winding thermal defect (depending DGA in Oil Analysis results
Figure 13: Thermal Ageing / defect recognition

ARWtr 2004

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

DGA Oil Analysis Interfacial tension Moisture in oil Moisture in solid insulation by - Karl Fischer Titration - Dielectric Response Measurement (PDC / FDS) Power factor and capacitance Degree of depolymerisation (DP) FURAN DERIVAT-Analysis Thermo vision of hotspots in tanks or magnetic shields Winding hotspot measurement On-Line Monitoring of operational conditions PD-Measurement and localization

Critical Ageing due to thermal and / or dielectric problems

Figure 14: Some of the most important diagnostic procedures for critical ageing ARWtr 2004
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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

For mechanical defect recognition

3-dimensional Shock recorder monitoring for excess dynamic impacts during transport Impedance measurement with low voltage (LV) precision instrumentation Low voltage impulse injection (LVI) response measurements DC-resistance measurements / solder joint control on multi-strand conductors FRA comparison with fingerprint and phase wise Transfer function analysis Clamping force control Noise and vibration measurement Visual inspection Repeat of dielectric test at 80 100 % U test
Figure 15: Mechanical defect recognition

ARWtr 2004

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany Principles of Condition Assessment:
One of the most demanding engineering tasks is to derive from the symptoms of deficits the nature of the fault, the location of the faulty / defective component. But even more important is the validation of continued service-ability or of the involved risks. Is it normal Is it serious or or is there a fault is it fit for service

what is the reliability or the risk? These are the key questions for Condition Assessment. One quite successful way of condition assessment is: Definition of characteristics of defective conditions By fingerprinting from the factory By trend analysis.

With all the diagnostic procedures given in 6.3 above we now need good identification of defective symptoms - but more important we need to develop guidelines in limitations of diagnostic signatures. Examples see 10, Annex 1. Figure 16: Condition Assessment

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

DGA-Analysis Guidelines
100 Cellulose

Electrical Fault Normal Ageing

Discharge Discharge PD PD with with with high en. with low high energy low energy density en. density lower than 300C

Thermal Fault
from 300C higher than to 1000C 1000C

El. + Therm. Fault

overheating overheatinga and nd discharge PD

Concentration ratios

10

0,1 C2H2/C2H6 H2/CH4 C2H4 /C2H6 C2H4/C3H6 CO2/CO

Figure 17: MSS / VDE DGA Interpretation Scheme

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

3 2,5 2 2-FAL 1,5 1 0,5 0 0

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1% Humidity

4% Humidity

10% Humidity

200

400 DP

600

800

1000

Figure 18: 2 FAL/DP Development at 95 C for different starting moisture content

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Case Nr. 10.3: 234 MVA-, 345 kV - ST, make in 1991. Defective winding Fault Symptom: Elevated DC-Resistance Detected by: DGA, DC-Resistance Measurement History: After 11 years of service, rising amounts of fault gases from thermal oil decomposition with small amounts of acetylene have been detected by DGA (Table IV). Furthermore the ratio carbon monoxide/carbon dioxide was < 3, which suggested an electrical degradation of cellulose. The transformer was inspected on site. A resistance measurement was carried out. There was a remarkable increase in the DC-resistance. The transformer was sent for repair to the factory.
Figure 19: Example 1, page 1: Defective Windings

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany One broken twin conductor of two twins with burnt out insulation paper was detected. The damage was a defective solder joint at the outmost turn of the ground end disc.
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Figure 20: Examlple 1, page 2 - A broken twin conductor as a consequence of a defective solder joint

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany
Table IV: Last DGA before taking out of service Type of gas Hydrogen Methane Ethane Ethylene Acetylene Carbon monoxide Carbon dioxide ppm (v/v) 1060 2481 703 2187 4 450 995

Diagnosis: Defective solder joint Action taken: The winding was repaired and the transformer was taken in service again and is working trouble free. Figure 21: Example 1, page 3

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

Case Nr. 10.4: 60 MVA-, 123 kV- Compensating Reactor, make 1979. Defective insulation system Fault Symptom: Sludge in oil Detected by: DP, furanes, oil analysis History: After 20 years of successful operation, time-based maintenance (DGA, oil and furane analysis) indicated severe ageing of oil and insulation. The reactor was brought back in the factory for refurbishment of the cooling system. DGA showed no failure indications (MSS Code 01002), but suggested a severe ageing of the solid insulation. The oil analysis revealed also a strongly aged oil (Colour 5,5, Neutralisation value 0,18 mg KOH/g oil) with sludge formation. The oil sludge has plugged the cooling ducts of the radiators and led to overheating. The paper samples of the winding were covered heavily with sludge and the DP-value was only 200. The measured furanes showed values of 2-FAL of 11,5 mg/kg oil. The solid insulation has reached the end of life. Diagnosis: accelerated ageing of the insulating system as a consequence of inadequate cooling. Action taken: A complete refurbishment was carried out winding, oil, cooling system. Figure 22; Example 2, Aged Compensator Reactor

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

1) The most powerful diagnostic tool is the DGA. It may be used to identify dielectric, thermal and chemical ageing problems. 2) Oil analysis as established in all facts is the second most powerful diagnostic tool. 3) It normally takes 2 or more different diagnostic approaches to really identify the nature of the defect. 4) The existing diagnostic procedures are mature and can also be used to identify defects in peripheral components (cooling plant, bushings etc.) 5) Both off-line and on-line diagnostics can be extremely successful to avoid catastrophic and costly outages, if applied consequently.
Figure 23: Conclusions page 1

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Transformers

ARWtr 04, VIGO, Spain, Oct. 28 - 30, 2004 - FUNCTIONAL and COMPONENT RELATED DIAGNOSTICS for POWER TRANSFORMERS, a Basis for successful Transformer Life Management Key Note Speech by Dr. A. J. Kachler, Siemens, Germany

6) Consequent maintenance, with fingerprinting, trend analysis and ad hoc on site diagnostic testing as well as life extension measures are indispensable for transformer life management 7) Chapter 8 suggests the future research. 8) The state of the art in Transformer diagnostics allows to identify dielectric, thermal and chemical ageing and defective problems. 9) For the impact of air, moisture and temperature closed system transformers are less susceptible to ageing than open breathers.
Figure 24: Conclusions page 2

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