Transformer Diagnostics

and Condition Assessment

OMICRON Australia 16 March 2012

Pag

 Transformer Diagnostic
Measurements

Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis, Degree of
Polymerisation (DP) & Furan Analysis
Overview of CPC100 and Operating Software (Toolset)
Electrical Measurements
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary

2
Types of Transformers

Distribution Transformers

3
Types of Transformers

Industrial and Commerical

4
 Types of Transformers

Supply Networks

5
 Transformer Design Considerations

Loss Capitalisation and Optimum Transformer Design

Total cost hast two main components:

Initial Cost (manufacture)+ lifetime operational costs (Losses)

Losses > No load at rated voltage and Load Losses at rated current

6
 Transformer Design Considerations

Loss Capitalisation and Optimum Transformer Design

Manufacture cost + Loss $

Manufacturing Losses
Cost

7
Transformer Design Considerations

Lower losses also mean a longer life for

the same operating conditions

8
 Transformer Design Considerations

Design considerations

Core Structure

Windings

style of transposition to reduce eddy currents

Winding types layer / helical / disc / foil

Cooling

Mechanical and electrical strengths

9
3-Phase Core in the Factory

Page: 10
 How a Transformer Works

Mutual inductance is where the magnetic flux of two or more inductors

are linked so that voltage is induced in one coil proportional to the rate-
of-change of current in another.

A transformer is a device made of two or more inductors, one of which is

powered by AC, inducing an AC voltage across the second inductor. If
the second inductor is connected to a load, power will be
electromagnetically coupled from the first inductor's power source to that
load.

11
Winding Bank

Page: 12
 How a Transformer Works

The powered inductor in a transformer is called

the primary winding. The unpowered inductor in a
transformer is called the secondary winding.

Magnetic flux in the core () lags 90o behind the

source voltage waveform. The current drawn by
the primary coil from the source to produce this
flux is called the magnetizing current, and it also
lags the supply voltage by 90o.

13
Assembling of Windings

Page: 14
OLTC (3-Phase)

Page: 15
Active Part of Transformer
 How a Transformer Works
Total primary current in an unloaded transformer is called the exciting
current, and is comprised of magnetizing current plus any additional
current necessary to overcome core. It is never perfectly sinusoidal in
a real transformer. The distortion (= harmonics) is minimised if the
transformer is designed and operated so that magnetic flux density is
kept to a minimum.

Core flux induces a voltage in any coil wrapped around the core. The
induces voltage(s) are ideally in- phase with the primary winding
source voltage and share the same waveshape.

Any current drawn through the secondary winding by a load will be

reflected to the primary winding and drawn from the voltage source,
as if the source were directly powering a similar load.

17
Mounting of a 400 kV Bushing

Page: 18
Transformer Faults
Transformer Faults

20
 Transformer Faults

3/16/2012
Transformer Faults

22
 Why Perform Diagnostic
Measurements on Transformers

Transformers are a key item in a supply system can only be

replaced by equivalent unit.
Transformers are expensive ($Ms) and should have a long
service life.
A long lead time is required to produce a replacement.
Rarely are spares available.
Catastrophic failure can cause death and serious damage to
other plant.
Commissioning tests show that it is safe to energise the
transformer and provide a sound basis for future condition
assessment.

23
Condition Assessment & Asset Health
Reviews

1. There is now a Guide for Transformer

Maintenance available Cigre Working
Group A2.34.

2. What is appropriate depends on:

History of performance.

Past test results.

Criticality of the installation.

Number of units in population.

24
 Condition assessment & Asset
health reviews

With defined processes, a numerical outcome condition

assessment can be achieved in a consistent manner

Enables decisions to be made

Expenditure can be focused

Removes opinion content

25
 Transformer Failure Modes
Winding & connections Thermal/Ageing
Winding Dielectric
Winding Mechanical
Core & frame earths and circulating current
overheating
Oil deterioration & contamination
OLTC malfunction
Bushings/ surge arresters malfunction
External tank, indicators

26
Faults in Transformers

Changer
Tap
Vessel & Oil

Accessories
Winding

Bushing
Core

Source: Cigre_WG 12-05 An international

survey on failures in large power
transformers in service, Electra No. 88, 1983
Condition Assessment is MORE than Testing

On-line,
Identify SURVEY &
diagnostics to non-invasive Outage
match relevant testing investigative
failure modes testing

Assess
FMECA & Obtain Condition Current Maintenance
manufacturers & RLA Work, future plans &
design Residual Life Assessment operational
performance environment
(Failure Mode, Effects and critical
Assessment)

Identify
priority
actions

28
 Condition Classification
CONDITION DEFINITION REMARK

As New no damage, deterioration

Normal Reasonable for age- no actions

ageing/ required
performance
Aged/ some Some ageing, - in need of some
Issues with monitoring- but not urgent
performance

Suspect/ Identified ageing, significant

Major issues risk for failure, safety, coolant
Performance alarms. Plan for rectification
Unacceptable Unacceptable ageing
deficiencies- need fix now

29
 Transformer History

A large percentage of transformers are in service for

more than 25 years with the health of many
transformers not often known

About 35% - 40% of all transformer faults are caused

by breakdowns in the aged insulation

30
 Generator Transformer 27/400kV

HV Bushing
LV Bushing
Measuring Tap

Diverter Switch
Tapped Winding
Tap Selector
Core High Voltage Winding
Low Voltage Winding

31
 Transformer Diagnostic
Measurements

Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis, Degree of
Polymerisation (DP) & Furan Analysis
Overview of CPC100 and Operating Software (Toolset)
Electrical Measurements
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary

32
Causes of Ageing

Dielectric causes

Electromagnetic causes

Thermal causes

Chemical causes

33
 Dielectric Causes of Ageing

Electrical stress particularly in areas with high electrical

field strengths

Dielectric losses produce heat

Decomposition of solid and liquid insulation by partial

discharges

Generation of gases

Generation of acids and sludge

Generation of X-wax

34
 Electromagnetic Causes of Ageing

High currents (e.g. due to short circuits nearby the

transformer) produce high mechanical forces

Deformation of the winding

Damage to paper insulation (cracks), particularly on aged

parts

Initiation of partial discharges

Initiation of partial break-downs

35
 Thermal Causes of Ageing

High currents (e.g. due to short circuits nearby the

transformer) produce high mechanical forces

Hysteresis losses in the magnetic core

Shorted laminates
Ohmic losses in the windings
Dielectric losses in the insulation
Load changes will cause warming up and cooling down -
negative influence on the lifetime of the insulation
The ageing of the insulation is accelerated by a factor 2,
if the temperature is increased by 7C (valid for normal
operation temperatures)

36
 Chemical Causes of Ageing

Organic acids are produced as a result of ageing

In particular, they affect the paper insulation

-> accelerated ageing

Metals like Copper, Iron, Aluminium and Zinc are

behaving like catalysts
-> accelerated ageing

37
 Ageing of the Cellulose by Acids

Microstructure of paper with Neutralization Number [mg/kg]

(from left to right) 0.05 0.1 0.2 0.3

38
 Ageing in the Cellulose

Ageing of the Cellulose is caused by:

- the influence of oxygen

Oxidation

- the influence of water

Hydrolysis

- the influence of heat

Pyrolysis

39
 Ageing of Paper
As the cellulose ages, the glucose ring chains break
(depolymerisation). The following substances are produced:
Water
Gases (CO, CO2)
Aldehyde Groups (Alkaline)
Carboxyl Groups (organic acids)

H 2O
H 2COOH H
OH

C O O C C

H H
CH H CH CH OH CH
OH H2COOH

C C C O

H OH H

40
 Water as Ageing Factor
Water accelerates the ageing of the Cellulose:
1000

Rel ative Dep ol ymerisa ti onsg eschwi ndi gke it

80 C

100 C
100 120 C

10

1
0 1 2 3 [%] 4
Wassergehalt im Papier

To extend the lifetime, the water has to be removed

from the insulation!

41
 Main Risks of Water in OIP insulations

1. Dielectric strength decreases

- PD inception voltage
- Breakdown voltage
1000
Increase of 1%

Life expectance / a
Dr
y halves the life
100 1%
time!
2. Accelerated aging of cellulose
- water is a ageing byproduct 10 2%
- water content increases during life 3%
1
4%

0,1
80C
50 70 90 110 130
Temperature / C
L. E. Lundgaard,Aging of oil-impregnated paper
in power transformers,
IEEE Transactions on Power Delivery, Jan. 2004

3. Bubble evolution from wet paper

PD or breakdown may occur
42
 Oil

Oil is the life blood of a transformer.

Oil directly provides electrical insulation - ageing

impurities and moisture decrease the quality of
insulation.

Oil is the main coolant to keep the transformer within

its long term operating parameters.

Dissolved gases provide a window into the condition

of a transformer.
43
 Effects of Partial Discharge

Partial Discharge is a localised discharge.

PD produces an emf signal, heat, light and

causes chemical and gas products.

PD is the beginings of an insulation

breakdown.

44
 Risks with Bushing

Failure of Oil / paper insulated bushing is a

major cause of catastrophe failures of
transformers

45
 On Load Tap Changer

Regulates the output voltage to compensate for

internal and line losses.

Is the only moving part of a transformer.

Has internal switching and drive mechanisms which

require constant maintenance.

The condition of electrical contacts a key component

in the reliability of the transformer.

46
 Summary

Transformers are a combination of complex

electrical, mechanical and chemical systems.

The level of maintence required depends on

the criticality of the transformer as a source
and its physical location.

Monitoring and diagnostic analysis provides

the basis for planning the appropriate
maintenance requirements.

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