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 de-
energizing 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 2-
furfuraldehyde 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
T = 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 - LESS THAN OR EQUAL TO 10 ppb OR < 0.01 ppm
• MID LIFE - BETWEEN 10 AND 1000 ppb OR 0.01 ppm TO 1.0
ppm
• LAST 1/3 rd LIFE - MORE THAN 1000 ppb OR >1 ppm

LIMIT OF DEGREE OF POLYMERIZATION:

• DP ≥ 800 GOOD CONDITION OF INSULATION
• DP < 800 ≥ 400 MID LIFE OF INSULATION
• DP < 400 LAST THIRD LIFE OF INSULATION
• DP < 200 END OF INSULATION LIFE

2.2 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 trans-
former. 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 Fleming’s 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. COMPONENT TEST FREQUENCY LIMITS REMARKS

1. Winding Furan First Test: After NORMAL The test
insulation Analysis 5 years of ≤ 10 ppb OR standard for
service ≤ 0.01 ppm Furan
Second Test: Analysis is
MID LIFE
After 10 years of IEC-1198-993.
service 10 to 1000
Third Test: ppb
After 15 years of OR 0.01
service ppm to 1.0
Fourth Test: ppm
After 20 years of
service LAST 1/3rd
Fifth Test: After LIFE >1000
25 years of ppb OR >1
service ppm
Subsequent
Tests: Yearly
S.N. COMPONENT TEST FREQUENCY LIMITS REMARKS
2. Winding Degree of First Test: After DP ≥ 800 The test
insulation Polymerization 10 years of Good schedule is
service condition of subject to the
Second Test: insulation opportunity
After 20 years of available at
service the time of any
Third Test: DP < 800 ≥ transformer
After 25 years of 400 Mid life internal work.
service of insulation
Subsequent Location:
Tests: 5 Yearly Insulation
DP < 400 paper for DP
Last 1/3rd test is to be
life taken out from
neutral lead
taking care not
DP < 200 to affect
End of transformer
insulation life healthiness.
3. Winding Tan δ test Yearly Tan δ < Tan δ is to be
insulation checked for
1%
all winding
configurations
and trend is to
be compared
in similar test
conditions
4. Winding Winding Yearly Max. Comparison of
insulation Capacitance capacitance capacitance is
Measurement 110% of to be done in
factory test same winding
value configuration
and at same
test voltage
5. OIP Bushing Tan δ and Yearly 1. Compare Trend is to be
Capacitance the test compared in
Measurement result with similar test
test factory conditions.
Measurement test/previous
should be site test If the value
done at 2 kV, results. exceeds, the
5 kV and 10 2. Max. bushing
kV. allowable should be
Also calculate Tan δ for replaced at
tan delta tip up OIP the earliest.
S.N. COMPONENT TEST FREQUENCY LIMITS REMARKS
value where: bushings is Care needs to
Tan delta tip 0.7%. be taken to
value = Tan 3. Max. ensure
delta at 10 kV allowable bushings are
– Tan delta at Tan δ tip up clean and free
2 kV value for OIP of dust and
. bushings is moisture.
0.001 or Also ensure
0.1%. that the
4. Max. transformer is
allowable disconnected
capacitance from other
is 110% of associated
factory test equipment.
results.
6. Transformer Sweep First Test: At Comparison If the
clamping Frequency factory by of frequency transformer
structure Response supplier v/s feeds short
Analysis Second Test: percentage circuit current
(SFRA) During impedance due to fault in
commissioning variation for the near
at site by frequency vicinity,
supplier band from additional
Third Test: 10 Hz to 10 SFRA test is
During suitable MHz gives to be planned
opportunity any during next
before expiry of distortion of unit overhaul.
warrantee by windings or
NTPC core from Test record is
Subsequent the original to be kept for
Tests: 5 Yearly signature any future
till 25 years of reference and
service comparison.
Subsequent
Tests after 25
years: Yearly
7. Insulating Oil Dielectric Normal Max. 0.2 for If the value of
dissipation frequency: Six transformers any two
factor at 90oC Monthly above 170 parameters
and 40 to 60 In case value kV out of three
Hz exceeds the indicated at
Max. 0.5 for
limit: Three S.N.8, 9 and
transformers
monthly 10 exceed the
below 170
limit; the oil
kV
S.N. COMPONENT TEST FREQUENCY LIMITS REMARKS
8. Insulating Oil Resisitivity Normal Min. 0.1 X should be
frequency: Six 1012 ohm- replaced at
Monthly cm at 90oC the earliest.
In case value is
beyond the
permissible
limit: Three
monthly
9. Insulating Oil Acidity or Normal Max. 0.25
Neutralization frequency: Six mg KOH/gm
Value Monthly
In case value
exceeds the
limit: Three
monthly
10. Comprehensive As given in 10 Yearly As per
RLA study section 4.0 applicable
standards

4.0 STANDARD TESTS FOR COMPREHENSIVE RLA STUDIES OF

TRANSFORMERS

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

1 Measurement of winding resistance at all taps

2 Measurement of voltage ratio at all taps
3 Measurement of winding impedance
4 Measurement of IR and PI of windings
5 Vector group checking
6 Magnetic balance test
7 Check of core insulation
8 Measurement of magnetizing current
9 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

1 Measurement of tan delta and capacitance

4.3 TESTS ON TRANSFORMER OIL

1 BDV
2 Moisture
3 Tan Delta
4 Specific Resistivity
5 Acidity
6 IFT
7 DGA

4.4 SPECIAL TESTS ON TRANSFORMER OIL / WINDING INSULATION

1 Degree of polymerization test of winding insulation paper

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

(Prakash Hirani)
AGM (COS)

AGM (COS-Elec)

GM (COS)