Methodology and methods

for transformer condition

assessment
Victor Sokolov
Transformer history is about 120

The first transformer - GANZ , Budapest- 1886

The generation by the end of XX century

Three phase: 1000-1300 MVA/500

Single phase: 600-667 MVA /
800-1150 kV
 The generation by the end of XX century

The Dryformer Mobil 56 MVA Gas-insulated

 Rate of development for 120 years

2000 MVA
1000
MVA
1150kV
100 1000kV
MVA

10
100kV
MVA
25kV
1
10kV
MVA
150kVA
100 1kV
kVA
1880 1900 1920 1940 1960 1980 2000

By Dennis Allan
 Rate of developments for 120 years

Childhood Progress Optimization

 Progressive Reduction of Losses
for a 200 MVA 220 kV Transformer
No-Load Loss Load Loss
Po(kW) Pk(kW)
220 800

180 700

140 600

100 500

60 400

20 300
1950 1960 1970 1980 1990 1950 1960 1970 1980 1990

By Prof.Dennis Allan
Relative volume of oil over transformer
history

By Prof.Pahlavanpour
 Historical design deficiencies
♦ Underestimation of stray loss impact (high
circulating currents in the windings)

♦ Inadequate thermal performance

♦ Inadequate short-circuit performance

♦ Poor components performance

Many of old Transformers have Hot Spot Rise
above Specified 80C
Hot Spot Observed Units
Temperature Rise,C Number %
< 80 24 30

81-90 32 40

91-100 17 21

> 100 7 9

From ABB presentation at the DOBLE Conference 2003

 How many critical transmission
transformers?
Total Critical

World 96,093 24,000

North 29,250 7,300

America
Newton-Evans Research data, 2000
 Transformer Population in USA
Total Additional Capacity

>1,000 GVA
>25 years

Year of commissioning
By Hartford Steam Boiler Inspection & Insurance Co
 Transformer Population of single capacity over
100 MVA in the USSR

120
>600 GVA
100 >25 years
80

60

40

20

0
64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98

Year of commissioning
 A challenge of present-day period

The global task of the electric power industry

in the first quarter of the 21st century
to manage the serviceability of a huge aged
transformer population
Conditions of transformer over life cycle
 Guide for life management techniques

Transformer Life

Mechanism of Insulation Degradation

Dangerous Effect of Degradation

Condition Assessment Operations & Correction

Methods
Methods & Methodologies Processing Programs
Condition Assessment
Recomendations
 The life cycle
SAFETY
MARGIN

CRITICAL
LEVEL

NORMAL DEFECTIVE FAULTY

FAILED
 Definitions
Condition Definition

Normal No obvious problems;No remedial action

Reversible change justified;No evidence of degradation

Defective No significant impact on short-term reliability, but

asset life may be adversely affected in long term
Irreversible change unless remedial actions carried out

Faulty Can remain in service, but short-term reliability likely

to be reduced.May or may not be possible to improve
condition by remedial action
Failed Cannot remain in service. Remedial action required
before equipment cab be returned in service (may not
be cost effective,necessitating replacement)
 Normal condition

Defect free condition

Normal Service aged condition

Condition that typical for 90%

of normal operating transformers
Examples of condition
 Dielectric system
Nature and Defects Faults
location
Dielectric Excessive water Destructive PD
Contamination Tracking
Winding Surface Creeping
insulation contamination discharge
leads Aged oil Heated cellulose
insulation Cellulose aging
PD of low energy
Electrostatic
shields
 Mechanical system

Nature and Defects Faults

location
Mechanical Loosening Radial distortion
clamping Axial distortion
Windings Coils bending
Leads Twisting
 Electromagnetic system
Nature and Defects Faults
location
Core Loosening Hot spot in oil
clamping Sparking/
Magnetic Short/open-circuit Discharge
shields in grounding
circuit
Circulating
current
Floating potential
 Current-carrying system
Nature and Defects Faults
location
Electric Poor joint Localized hot
Poor contacts spot
Wires joints Contact Open-circuit
Leads deterioration Short-circuit

connection
Contacts
 Conditions of a transformer in the course of
life
Incomplete

Normal Defective Faulty Complete

Failed

Abnormal Incipient Short

Unavailability
Critical
Critical Imminient
Imminent Long
failure Unavailability

Abnormal Catastrophic
event
Failures mode related to aging
phenomena
Ageing of transformer insulation systems is
a complex phenomenon

♦ Thermal Life:Time to critical decomposition DP<200

(Mechanical life of paper)

♦ Dielectric Life: Time span to critical reduction of

dielectric safety margin
♦ Mechanical life: Time to critical mechanical weakness
and deformation of windings
♦ Life of accessories (bushings,LTC)
 Major failures over 100 MVA
Component Doble GSU Transmi
1996-98 2000-05 ssion
2000-05
Insulation 36.4 49 31.6
dielectric
Conductors aging 5.8 13.3 4.8
Winding 12.5 4.4 9.5
distortion
Bushings+OLTC 28.8 19.8 45.9
 Conclusion from failures analysis

♦ Average age of failed transformer is between 20-22 years

♦ Contribution of generation “after 25” is becoming
more weighty
♦ Average failure rate retains on the level of 1-2%
♦ Predominant failure-mode- Insulation dielectric
(a trend to increase)
♦Conductor aging failure still low
♦ Failure profile consists of wear-in (weak design
and its components) and random failures
 There is a trend of increasing dielectric –
mode failures with time

Total
Winding dielectric
70
60
50
16
40 14
30 12
20
10
10
0
8
0-3 3…5 5…10 10..15 15-20 20-25 25-30 30-35 35-40
6
4
2
0
0-3 3…5 5…10 10..15 15-20 20-25 25-30

ZTZ-Service statistics
 Diagnostic methodology
Traditional Time-based methodology
Two Steps Condition based methodology
Condition based Functional methodology
Traditional Time-based methodology
e.g. IEEE Guide for Diagnostic Field Testing
of Electric Power Apparatus )

Considers condition of of six

transformer components separately

1.Windings, including major insulation

2.Fluid as a separate component
3 Core
4 Bushings
5. Tap Changer
6.Tank & associated devices
 Considers Characteristics Monitoring

♦ Specified test scope

♦ Definition of limited and critical values for each tested
parameter
♦ Looking for change against nameplate/previous
♦ Deviation of each specified parameter a subject of concern
♦ Upgrading by adding new methods
 IEEE Guide for Diagnostic Field Testing

Parameters Deviation) Test purpose

•Resistance < 5% Connections,contacts

•Ratio <0.5 % Turns,loops
•Excitation current <10% between Core,turns,taps
phases
•Short-Circuit <3% Winding movement
•Impedance
•Insulation R /R=1.1-1.3 Moisture
•Resistance
•PF <1% Moisture
 Limits EPRI

Limits 100% good 100% bad

Insulation PF,% <0.4 >0.9

Oxygen content >2000ppm

Oil acidity,mg <0.1 >0.18

KOH/g
Oil PF,% at 25C <0.2 >0.4
Trend to toughen limited values for important equipment
Sludge None

Tan Delta <0.15

Acidity (mg KOH/g Oil) <0.05

Relative Saturation % <5

Interfacial tension >32

Colour Grading <2.5

Furanic content (mg/kg) <50/year

 Interpretationon “Good” and “Bad”based
on experience
Good and Bad in terms of DGA

H2 CH4 C2H4 C2H2

IEC 60 40 60 3-50

IEEE 100 120 50 65

Japan 400 100 10 0.5

CIS,750kV 30 20 10 5
Disadvantages of traditional approach

♦ Questionable correlation between

tested parameters and defective condition.

♦ Uncertain or false diagnosis is possible

♦ Unnecessary tests are often carried out
Two Steps Condition based Methodology
The first step : Monitoring or Detection

The main purpose is to filter out those items

of equipment which are operating normally

Key diagnostic parameters are used

considering experience

The second step:Diagnosis

The objective of this step is to identify the problem

from the symptoms
 Two Steps Condition based Methodology
Condition Monitoring Condition Assessement
detect fault diagnosis

No Yes
Is it Is it
Start 10%
Normal? Serious?
2%

Yes No

90% 8%

Do Do
Nothing something
else else

Broadband technique Focused technique

applied routinely applied as required
Condition based Functional
methodology
Key properties of Functional Serviceability

♦ Electromagnetic ability and integrity-

transfer electromagnetic energy without
overheating, excessive losses, vibration and sound
♦ Integrity of current carrying circuit
♦ Dielectric withstand strength,
considering a permissible level of deterioration
♦ Mechanical withstand strength
under the effect of specified short-circuit currents
Concepts of Functional based methodology

♦ Functional subsystems (instead of components)

♦ Failure model :What to look for?
♦ Condition Assessment is an inquiry about
possible defects utilizing
: Group of methods

: Multi-step diagnostic procedures:

 Functional Failure Model

A functional failure model has to answer the questions:

What defects and faults can be expected

in particular transformer components related
to the particular functional subsystem?

What is the possible path of defect evolution

into the malfunction, and then failure?
Condition Assessment Approach

♦ Definition of Defective and Faulty conditions

♦ The typical failure scenario

♦ Characteristics of defective/faulty condition

♦ Condition assessment procedures

considering On-Line and Off-Line Techniques
 Condition assessment approach

Transformer life assessment

Design Review Historical review Operation condition

Failure model Operating status

Condition Assessment
 Condition Assessment flowchart

Condition Assessment

General Dielectric Aging Mechanical LTC Bushings

State State State State State State

Electrom Cooling Oil expansion Current

agnetic system & Carrying
circuit preservation
circuit

Transformer is gassing
What to do?