NTPC Limited

(CORPORATE OPERATION SERVICES)

OPERATIONAL MEMORANDUM
REF.NO. OS/ELECT/OM/742/10/2007-08

DATED: 25-09-07

GUIDELINES FOR RESIDUAL LIFE ASSESSMENT OF

OIL FILLED TRANSFORMERS
1.0 INTRODUCTION
Oil filled transformers in power plant application are used for variety of
applications staring from most critical application for generator transformers
to unit auxiliary transformers, station transformers, inter connecting
transformers, tie transformers to service transformers for feeding power
supply to different category of equipment. Availability of all these transformers
is essential for smooth functioning of power plant.
Various diagnostic techniques are used to scan the health of the
transformers. However, only general health monitoring is not adequate since
failure of any of the component can result into transformer outage. It is
therefore important to assess the health of all critical components individually
apart from total health assessment of transformer for ensuring complete
reliability.
Major components and activities which need to be assessed for residual life
of transformers are as follows:

Residual life of winding and insulation

Residual life of oil impregnated bushings
Mechanical integrity of transformer windings from short circuit forces
view point
Residual life of transformer oil

2.0
The program for assessment of each of the above components is
described below:
2.1

WINDINGS AND INSULATION QUALITY

The most important and realistic life assessment of a transformer can be done by
monitoring the health of winding insulation paper. This can be done by testing
either degree of polymerization (DP) of paper sample or by furfural content of
insulating oil. Better judgment of insulation health is possible from the DP test;
however there are certain limitations in this test. The paper sample for this test is
to be taken from the inner layers of windings where maximum heating is
expected which results into maximum aging of insulation paper. But since it is not
possible to take out paper sample from inner layers of windings, the assessment
is not perfect. Normally we take paper sample from the neutral lead and that too
from outer most layers presuming that the transformer internals are generally at
constant temperature after it acquires stability.
The second method of finding the insulation quality or to be more precise, the
residual life of transformer insulation is by way of determining the furfural content
from the transformer oil. Since it is very easy to draw oil sample from a
transformer for furfural content test and also this test can be done without deenergizing the transformer unlike DP test, this method has become more
acceptable. Chemical experts have found out that furfural content in oil does not
change even if the oil is degassed or filtered during routine maintenance of
transformer.
Since furfural content test is indirect method of insulation life assessment, I
Chendong of EPRI China found the relationship between furfural content or 2furfuraldehyde concentration in oil and degree of polymerization of insulation
paper. This relationship is as follows:
1) Log (Fur) = 1.51 - 0.0035 DP
where
(Fur)

= 2-furfuraldehyde concentration in oil in ppm

DP

= Degree of polymerization of insulation paper

2) Log (Fur) = - 1.83 + 0.058 T

where
(Fur)

= 2-furfuraldehyde concentration in oil in ppm

= Operating times in years

With above conversion equations we can find out DP from furfural content test of
oil and thus the residual life of insulation paper can be found.

The norms for residual life assessment were studied and given by Paul J Griffin
during his presentation on Assessment of paper insulation and other cellulose
materials in service - aged transformers at the Southeastern Electric Exchange
on 24-06-1999 as per the following values:
LIMIT OF 2-FURFURALDEHYDE CONTENT:

NORMAL
MID LIFE
ppm
LAST 1/3 rd LIFE

- LESS THAN OR EQUAL TO 10 ppb OR < 0.01 ppm

- BETWEEN 10 AND 1000 ppb OR 0.01 ppm TO 1.0
- MORE THAN 1000 ppb OR >1 ppm

LIMIT OF DEGREE OF POLYMERIZATION:

2.2

DP

DP

< 800 400 MID LIFE OF INSULATION

DP

< 400

LAST THIRD LIFE OF INSULATION

DP

< 200

END OF INSULATION LIFE

800 GOOD CONDITION OF INSULATION

OIL QUALITY

The life of the transformer is actually the life of the internal insulation system.
The most widely used systems are liquid insulation (transformer oil) and solid
insulation (Kraft paper, pressboard, seasoned wood i.e. cellulose products). The
insulating oil provides approximately 80% of the dielectric strength of a transformer. Transformer oil is a good insulating medium and when impregnated in
paper, press board and cloth, increases the dielectric strength of it further. The
low viscosity of oil also allows it to penetrate the solid insulation setting up
convection currents for conveying the heat from the core materials to the
radiators. The liquid insulation therefore also serves as a coolant and its oxidation
stability allows it to operate at high temperatures for long periods. Therefore, it is
essential that the insulating oil inside the transformer is having good dielectric
strength and stability so as to ensure overall adequacy of required dielectric
strength and residual life. The residual life of insulating oil can be determined by
three properties namely specific resistivity, tan delta and acidity. By periodic
monitoring of the trend the requirement of replacement can be estimated and
accordingly the program is to be made to avoid any emergency on account of
aged oil.

2.3

HEALTH OF ACCESSORIES

The transformer is capital equipment and no utility can afford to loose the
transformer since these are very costly. Therefore, a number of protection
devices are used to protect the transformer from damage. It is therefore
necessary to ensure that these protection devices are healthy and do the
necessary function as and when required. Buchholz relay, pressure relief device,
sudden pressure relay, OTI / WTI, MOG etc. are such devices which trip the
transformer in case of internal fault. Current transformers are also provided to
protect the transformer and trip it in case of internal as well as external fault.
Being low cost items, complete replacement is a better option for these
accessories rather than carrying out any residual life assessment. The
replacement decision can be based on the past performance of these
accessories.
2.4

SUPPORT STRUCTURE STRENGTH TO WITHSTAND THE FORCE

DURING FAULTS

The mechanism of forces experienced by the transformer can be explained as

follows:
A current carrying coil placed in a magnetic field experiences a force whose
magnitude is proportional to the flux density and current and the direction is as
decided by Flemings left hand rule.
In transformers the HV and LV coils are surrounded by a common
electromagnetic field and thus are known to experience forces while in service as
well as during fault conditions. When the current becomes large, the forces
generated become very large since the forces are proportional to square of the
current.
In transformers, the main flux is by and large axial (this is so, as the design of
transformer is such as to minimize the leakage flux in the transformer, which
introduces the radial component in the total flux) and the currents in the HV and
LV coils are circulating in the opposite direction. The electromagnetic forces
acting on coils thus are radial in nature and tend to repel the windings from each
other. Hence, the outer winding experience bursting forces and inner winding
experience compressive forces.
The magnitude of axial force which is due to radial leakage flux is generally small.
Theoretically axial forces shall be zero if the coils on a core limb are concentric,
but due to manufacturing process and tolerances, it is not possible to achieve
this. Above can be attributed either due to inadequate skills in shop floor during
assembly or due to the slackness in the coils because of shrinkage of insulating
material of coils etc.

The magnitude of the current during the period when it is feeding the external
fault is very high and the forces that the windings are subjected to because of the
rush of fault current also are quite enormous and cause distortion of transformer
windings. The windings inside a transformer are tightly pressed and securely
clamped in place in order to prevent distortion / deformation. The supporting
system is designed with adequate safety margins to take care of any such
eventuality.
During service life of a transformer, it feeds system faults some of which are very
close to the transformer. Thus the faults inside the switchyard create maximum
short circuit forces because of low impedance and some distant faults on
transmission line create relatively lesser short circuit forces. It is therefore
essential to assess the movement of transformer internals due to each external
fault. The frequency response analysis (FRA) gives the relative movement of
windings with respect to each other and also with respect to magnetic core. The
trend observed during periodic FRA testing can be a good tool to find out the
movement of transformer internals as compared to previous test history.
Effectively, we can assess the degree of susceptibility of the transformer to fail
during next short circuit in the system.
3.0
With above background, the proposed test schedule along with test
frequency and acceptance limits for residual life assessment for aging
transformers is as per Table-1 below:
TABLE-1
RLA TEST SCHEDULE FOR AGING TRANSFORMERS
S.N.
1.

COMPONENT
Winding
insulation

TEST
Furan
Analysis

FREQUENCY
First Test: After
5
years
of
service
Second Test:
After 10 years of
service
Third
Test:
After 15 years of
service
Fourth
Test:
After 20 years of
service
Fifth Test: After
25 years of
service
Subsequent
Tests: Yearly

LIMITS
NORMAL
10 ppb OR
0.01 ppm
MID LIFE
10 to 1000
ppb
OR 0.01
ppm to 1.0
ppm
LAST 1/3rd
LIFE >1000
ppb OR >1
ppm

REMARKS
The
test
standard
for
Furan
Analysis
is
IEC-1198-993.

S.N.
2.

COMPONENT
Winding
insulation

TEST
FREQUENCY
Degree of
First Test: After
Polymerization 10 years of
service
Second Test:
After 20 years of
service
Third
Test:
After 25 years of
service
Subsequent
Tests: 5 Yearly

LIMITS
DP 800
Good
condition of
insulation
DP < 800
400 Mid life
of insulation
DP < 400
Last 1/3rd
life
DP < 200
End of
insulation life

3.

Winding
insulation

Tan test

4.

Winding
insulation

Winding
Capacitance
Measurement

5.

OIP Bushing

Yearly

Tan <
1%

Yearly

Tan and
Yearly
Capacitance
Measurement
test
Measurement
should be
done at 2 kV,
5 kV and 10
kV.
Also calculate
tan delta tip up

Max.
capacitance
110% of
factory test
value
1. Compare
the
test
result
with
factory
test/previous
site
test
results.
2.
Max.
allowable
Tan for
OIP

REMARKS
The
test
schedule
is
subject to the
opportunity
available
at
the time of any
transformer
internal work.
Location:
Insulation
paper for DP
test is to be
taken out from
neutral
lead
taking care not
to
affect
transformer
healthiness.
Tan is to be
checked
for
all
winding
configurations
and trend is to
be compared
in similar test
conditions
Comparison of
capacitance is
to be done in
same winding
configuration
and at same
test voltage
Trend is to be
compared in
similar
test
conditions.
If the value
exceeds, the
bushing
should
be
replaced
at
the earliest.

S.N.

6.

7.

COMPONENT

TEST
value where:
Tan delta tip
value = Tan
delta at 10 kV
Tan delta at
2 kV
.

FREQUENCY

Transformer
clamping
structure

Sweep
Frequency
Response
Analysis
(SFRA)

First Test: At
factory
by
supplier
Second Test:
During
commissioning
at
site
by
supplier
Third
Test:
During suitable
opportunity
before expiry of
warrantee
by
NTPC
Subsequent
Tests: 5 Yearly
till 25 years of
service
Subsequent
Tests after 25
years: Yearly
Normal
frequency: Six
Monthly
In case value
exceeds
the
limit:
Three
monthly

Insulating Oil

Dielectric
dissipation
factor at 90oC
and 40 to 60
Hz

LIMITS
bushings is
0.7%.
3.
Max.
allowable
Tan tip up
value for OIP
bushings is
0.001
or
0.1%.
4.
Max.
allowable
capacitance
is 110% of
factory test
results.
Comparison
of frequency
v/s
percentage
impedance
variation for
frequency
band from
10 Hz to 10
MHz gives
any
distortion of
windings or
core from
the original
signature

Max. 0.2 for

transformers
above 170
kV
Max. 0.5 for
transformers
below 170
kV

REMARKS
Care needs to
be taken to
ensure
bushings are
clean and free
of dust and
moisture.
Also
ensure
that
the
transformer is
disconnected
from
other
associated
equipment.
If
the
transformer
feeds
short
circuit current
due to fault in
the
near
vicinity,
additional
SFRA test is
to be planned
during
next
unit overhaul.
Test record is
to be kept for
any
future
reference and
comparison.

If the value of
any
two
parameters
out of three
indicated
at
S.N.8, 9 and
10 exceed the
limit; the oil

S.N.
8.

COMPONENT
Insulating Oil

TEST
Resisitivity

9.

Insulating Oil

Acidity or
Neutralization
Value

10.

Comprehensive
RLA study

As given in
section 4.0

4.0 STANDARD TESTS

TRANSFORMERS

FOR

FREQUENCY
Normal
frequency: Six
Monthly
In case value is
beyond
the
permissible
limit:
Three
monthly
Normal
frequency: Six
Monthly
In case value
exceeds
the
limit:
Three
monthly
10 Yearly

COMPREHENSIVE

LIMITS
Min. 0.1 X
1012 ohmcm at 90oC

REMARKS
should
be
replaced
at
the earliest.

Max. 0.25
mg KOH/gm

As per
applicable
standards

RLA

STUDIES

OF

Following tests are to be carried out for comprehensive RLA studies of

transformers after 10 years along with the schedule of tests given in Table-1 at
section 3.0:

4.1

LOW VOLTAGE TESTS ON TRANSFORMERS

Measurement of winding resistance at all taps

Measurement of voltage ratio at all taps

Measurement of winding impedance

Measurement of IR and PI of windings

Vector group checking

Magnetic balance test

Check of core insulation

Measurement of magnetizing current

Check of turret CTs healthiness including Ratio, IR and Polarity

measurement

10

Checking of all protections and alarms for functional check and by

injection

11

Checks on OLTC and Off circuit tap changer including continuity from first
to last tap

12

Measurement of winding tan delta and capacitance

4.2

TESTS ON BUSHINGS

Measurement of tan delta and capacitance

4.3

TESTS ON TRANSFORMER OIL

1
2
3
4
5
6
7

BDV
Moisture
Tan Delta
Specific Resistivity
Acidity
IFT
DGA

4.4

SPECIAL TESTS ON TRANSFORMER OIL / WINDING INSULATION

1
2
3
4
5

Degree of polymerization test of winding insulation paper

Furfural content in transformer oil
Paper moisture measurement
Air ingress in transformer to be assessed through oil DGA
Frequency response analysis

(Prakash Hirani)
AGM (COS)

AGM (COS-Elec)

GM (COS)