FIBER OPTIC TRANSFORMER WINDING TEMPERATURE

DETERMINATION TECHNOLOGY REVIEW

Loading capability of power transformers is limited by winding temperatures. When a new

transformer is put in service, a temperature rise test is done to evaluate the average winding
temperature, to insure it is within industry standards. However, temperature of windings is not
uniform, and the real limiting factor is the hottest portion of the winding, called hot spot; it is
located near the top of the winding, and thus not accessible for measurement using conventional
methods.

The temperature of paper insulation dictates the transformer aging. With time and heat, the paper
loses its tensile strength and elasticity. Eventually, it becomes brittle and cannot support forces
due to short circuits and normal transformer vibrations. This process is irreversible.

Efforts have been made to monitor hot spot temperatures to take advantage of cool ambient
temperature, to extend the transformer life while offering emergency overloading margins, and to
exploit market opportunities. The rated hot spot temperature of modern insulation paper is
110 oC and each increase of 6 oC doubles the aging acceleration factor. In addition, water trapped
in the paper runs the risk of forming bubbles at higher temperature, and creates a threat for
insulation breakdown. No wonder transformer owners attempt to monitor hot spot temperature
with the best tools available.

Recent IEEE and IEC works have shown that conventional equations that have been used to
evaluate hot spot temperatures are inadequate. Indeed, these models are based on a number of
assumptions that have shown to be incorrect. The recent changes made to the IEEE and IEC
loading guides indicate that hot spot evaluation methods previous known were not adequate to
assess accurately winding hot spot temperature. Wide use of computers now allows for
sophisticated calculation methods but it demonstrates that the quest of winding hot spot
temperature is not trivial and it raises new doubts considering the number of additional values
that need to be collected to run the calculation. No wonder that direct measurement of winding
temperature using fiber optic sensors is the recommended practice for all large transformers.

Recent development on direct measurement of winding hot spot temperature

For more than 30 years, fiber optic temperature sensors have been available for measurement in
high voltage transformer. First units were fragile and needed delicate handling during
manufacturing. In the last ten years, significant development took place to improve ruggedness
and facilitate connection through tank walls.

The fiber optic probe on the Qualitrol/Neoptix T/Guard™ systems consists of a 200-micron glass
fiber sheathed with permeable protection Teflon tube. This probe is designed to endure
manufacturing conditions, including kerosene desorption as well as long term immersion in
transformer oil. The temperature-sensing element is based on the proven GaAs technology; an
original algorithm is used to extract temperature information, to provide accurate and
reproducible measurements, even when probes are interchanged.
Experience has shown that radial spacers are preventing oil circulation locally; the temperature
gradient in the spacer is very small. This is illustrated below where we compare temperatures
from two sensors in contact with the winding and one inserted in the spacer below the same
winding disk. It can be seen that the temperature measured in the spacer is actually higher than
the measured conductor temperature, due to restricted local oil flow.

100 2.2
FO in spacer
2.0
FO in contact with conductor (top)
80 1.8
FO in contact with conductor (bottom)
Temperature (°C)

1.6
60 1.4
1.2
40 1.0

Load (p.u.)
0.8
20 0.6
Load 0.4
0 0.2
0 12 24 36 48 60 72
Time (h)

This discovery has lead transformer designers to install probes in radial spacers, between
adjacent disks, with results that installation of probes has resulted in a much improved success
rate. This method avoids the delicate task of breaking and restoring the conductor insulation. The
figure below shows a probe installed this way (left). Many other improvements have been done
in recent year, such as simplified through-wall connection, also shown below (right).

With these improvements, the survival rate of fiber optic sensors is now reaching 100%.
Overloading Capability
Power transformers have inherent overloading margins. The rated capacity of a unit is basically
the load that will result in internal temperatures not exceeding the limits set forth by industry
standard. Loads that exceed the nameplate rating involve some risk and accelerated aging.

It is generally recognized that the risks associated with overloading can be significantly reduced
if the transformer conditions are closely monitored throughout the overload period. Monitoring
of hot-spot temperatures and dissolved gas-in-oil and furan-in-oil provides a major support to the
operator when the transformer faces overload conditions. On-line monitoring of winding
temperature can provide a dynamic evaluation of insulation degradation and the relative loss of
life can be converted into cost. The cost attributed to loss of life needs to be subtracted from the
apparent benefits achieved from the extra load. Monitoring places the asset user in control.

Conclusions
Loading capability of power transformers is limited mainly by winding temperatures. It has been
the practice to assess this temperature from a measurement of oil temperature at the top of the
tank with an added value calculated from load current and winding characteristics. With more
frequent occurrence of overloading, it has been found that this simplified approach is not suitable
for several types of overloads and transformer designs.

In an attempt to close this gap, IEEE and IEC loading guides have been revised with more
sophisticated models aiming at a better representation of oil temperature inside the winding,
considering variations in winding resistance, oil viscosity and oil inertia. Still, direct
measurement of winding temperature with fiber optic sensor provides a definitive advantage over
a value calculated from uncertain parameters provided by the manufacturer and uncertain
equations characterizing the cooling pattern.

In response to this important need, fiber optic sensors have significantly improved to the point
that direct measurement of winding temperature is now becoming the preferred method to
measure this critical parameter. Compatibility of fragile fiber optic sensor with transformer
factory environment has been a problem in the past but is now resolved with sturdy fiber jackets,
proper spooling of sensor during factory work, and simplified through-wall connection.

Fiber optic sensors have reached maturity for application in power transformers and should
become a standard feature for new transformers. Immediate knowledge of winding hot-spot
temperature provides the necessary confidence to carry through overload occurrences and reaps
full benefit from this asset.

As a market and technology leader, with tens of thousands installed probes in transformers,
Qualitrol/Neoptix is well positioned to offer components and systems to address all hot spot
measurement requirements.
Authors

Jean-Noël Bérubé is Global Fiber Optic Product Specialist at Neoptix, a Division of Qualitrol
Company LLC. A founding member of Neoptix, he is heavily involved in design and
application of fiber optic temperature probes used for hot spot temperature monitoring in power
transformers. Bérubé travels worldwide to train transformer manufacturers on how best to install
and use fiber optic probes. An electrical engineer and IEEE member with 40+ years of
experience, his field of expertise has been instrument design and applications where optic,
electronics and software are applied together.

Jacques Aubin is a transformer consultant especially active in the field of thermal behavior and
insulation aging. He was until recently with GE Energy in Montreal where he was mainly
involved in development and testing of advance monitoring systems for power transformers.
Until1998, Jacques was with Hydro-Quebec in Canada where he directed research activities
related to overloading, short circuit strength and acceptance tests on power transformers. Mr.
Aubin graduated in 1962 from École Polytechnique de Montréal.

Bill McDermid graduated from the University of Manitoba in 1961 with a B.Sc. in electrical
engineering. Since 1962 he has been working with Manitoba Hydro where he is involved in the
diagnostic testing of electrical insulation applied to all types of apparatus. He has been a
technical advisor on a number of CEA research projects over the past many years related to on-
line partial discharge measurements. Bill was honored with the 2009 Institute of Electrical and
Electronics Engineers Canada Power Engineering Award for his contributions to the
development of diagnostic test methods for the insulation systems of rotating machines. Bill’s
innovations in the field have been adopted as industry standards and, without a doubt, have
contributed to the enhanced reliability of electric power generation.