Transformer Maintenance and Service

Transformer Asset
Management
 Why Manage Your Transformer Assets?
 According to a major insurance company, substation transformer failures
are expected to rise 500% over the next ten years.

 In a recent study, operational life cycles appear to be decreasing.

Failures due to insulation deterioration are occurring in transformers with
an average age of just 17.8 years vs. the average expected life of around
40 years.

 Premature failure and replacement of transformers can cost companies

millions of dollars in capital outlays, downtime and lost production.
Visual Inspections:
 Corrosion
 Bushings
 Radiators
 Gaskets
 Oil level
 Valves
 Oil temperature
 Silica gel
 Gauges
 Etc.
Sampling Program:
Standard oil quality tests:
 Dielectric strength
 Moisture content
 Acid number
 Interfacial tension
 Power factor

Dissolved gas analysis

Oxidation inhibitor
Parameters for Analysis:
Standard Oil Quality Tests: IEEE
Questionable Unacceptable
Dielectric Breakdown (kV) ASTM D877 < 30 < 26

Acid Neutralization Number (mg KOH/g) ASTM D974 > 0.05 > 0.20 *

Interfacial Tension (mN/M ASTM D971 < 30 < 26

Moisture Content (ppm) ASTM D1533 > 20 > 25

Oxidation Inhibitor (%) < 0.10 < 0.05

* Acid will begin to form sludge at 0.06 mg KOH/g and may start to cause
irreversible damage to the paper insulation.
Parameters for Analysis:
Dissolved Gases: IEEE
Questionable Unacceptable
Hydrogen (H2) (ppm) > 75 > 100

Carbon Monoxide (CO) (ppm) > 250 > 350

Carbon Dioxide (CO2) (ppm) > 1,750 > 2,500

Methane (CH4) (ppm) > 90 > 120

Ethylene (C2H4) (ppm) > 35

> 50

Ethane (C2H6) (ppm) > 40 > 65

Acetylene (C2H2) (ppm) > 15 > 35

Analyze Results:
Dielectric breakdown: Low dielectric strength
indicates the electrical insulating quality of the
oil is diminished due to contamination, which
can lead to the following problems:
 Reduced resistance to arcing and electrical stress.

 Increased gases.

 Degradation of the paper insulation.

 Overall reduction in the useful life of the transformer.

Analyze Results:
Moisture content: High ppm of moisture can
lead to the following:
 Reduced dielectric strength.

 Accelerated oil oxidation and related paper degradation

through decomposition.

 Increased risk of free water coming in contact with

energized conductors, which could cause immediate and
catastrophic failure.

 Overall reduction in the useful life of the transformer.

Analyze Results:
Acid (neutralization) number: High acid levels indicate
the formation of oxidation by-products and the possible
presence of sludge on the solid insulation. This can
cause the following:

 Increased rate of oil oxidation and paper degradation due

to decomposition and loss of tensile strength.

 Overall reduction in the useful life of the transformer.

Analyze Results:

Interfacial tension: Low interfacial tension indicates the

presence of oxidation by-products, which results in the
oil having reduced ability to repel moisture. This can
cause the following:
 Increased rate of oil oxidation.

 Increased rate of insulating paper decomposition.

 Overall reduction in the useful life of the transformer.

Analyze Results:

Power factor: High power factor indicates

dielectric loss of the oil and is generally affected
by all types of contamination, (ie. Oxidation by-
products, moisture, particulate). It is an indicator
of the overall quality of the insulating fluid.
Increased power factor can lead to the following:

 Reduced efficiency through current leakage

Analyze Results:
Dissolved gases: Unacceptable levels of individual
gases and/or gas combinations must be interpreted
carefully and can indicate any number of the following:
 Arcing
 Sparking and minor faults
 Overloading of the transformer
 Operating hot
 Hot spots
 Poor connections
 Turn to turn shorts
 Partial discharge
 Thermal decomposition of cellulose
 Thermal decomposition of oil
Analyze Results:
Oxidation inhibitor: An unacceptable level of oxidation
inhibitor is detrimental to the transformer and will lead
to the following:
 Accelerated oxidation by-product contamination and
sludge formation.

 Degradation of paper insulation.

 Overall reduction in the useful life of the transformer.

Analyze Results:
Load Tap Changers (LTC):
 Parameters for analysis of standard oil tests very similar to transformers with the exception of acid and
interfacial tension where the LTC is not as susceptible and will not diminish useful life in the same way.

 Color very useful tool as carbon particulate will be visible which suggests carbon build up on the
contacts and a requirement for oil change and contact cleaning.

 DGA more difficult due to unique expected DGA profile of each type (model) of LTC

 In general, acetylene is expected as it is created when the taps change and the contacts separate and
reconnect.

Ethylene, ethane and methane appear when there is a poor connection or hotspot.

 It is normally more economic to change the oil than to degasify, and while doing so electrical tests and
internal visual inspections and repairs can be carried out.
Once results of visual inspections, standard oil tests,
dissolved gases and oxidation inhibitor have been
analyzed, what does it mean for maintenance
requirements?
Maintenance Requirements:
Degasification treatment:

 Restores dielectric strength of the oil.

 Dehydrates oil to lower ppm moisture.

 Removes dissolved gases.

 Improves power factor.

 Removes free particles.

Maintenance Requirements:
Re-inhibit treatment:
 Adds oxidation inhibitor to the oil.

 Restores dielectric strength of the oil.

 Dehydrates oil to lower ppm moisture.

 Removes dissolved gases.

 Improves power factor.

 Removes free particles.

Maintenance Requirements:
Oil Reclamation Treatment:
 Removes oxidation by-products

 Lowers acid number

 Improves interfacial tension

 Improves power factor

 Removes sludge from paper insulation

 Improves color
Maintenance Requirements:

Retro-fill Treatment:

 Replaces poor quality oil with

new or reclaimed oil

 Oil meets or exceeds all IEEE

standards
Maintenance Requirements:
Electrical Testing: Depending on dissolved gas
analysis, certain electrical tests may be required to
better determine repairs and maintenance required.
Common tests are as follows:
AC Tests DC Tests
 Insulation Power Factor/Dissipation Factor  Insulation Resistance Tests (Megger)
Test (Doble)  Dielectric Absorption
 Power Factor Tip-up Test  Polarization Index (PI)
 Single-Phase Excitation Current Test  Step Voltage Test
 Transformer Turns Ratio Test (TTR)  Core Ground Test
 Bushing Power Factor Test  Overpotential test (Hi-Pot)
 Liquid Insulation Power Factor Test  Winding Resistance
Maintenance Requirements:
Further Oil Sampling: Depending on dissolved gas
analysis, original sample reliability, acid levels or
interfacial tension, further sampling may be required.
 Furans Analysis – Used to determine the remaining useful life of
the paper insulation. Usually recommended prior to oil rejuvenation
treatment or a retro-fill.

 Dissolved Gas Analysis – Further testing at shorter intervals is

often recommended to determine trends prior to making additional
maintenance or electrical testing recommendations.

 Standard Oil Tests – An additional test can be recommended to

verify results if sample contamination is suspected.
Maintenance Requirements:
Based on the results of visual inspections, a number of
maintenance and repair requirements may be evident:

 Painting
 Radiator repair or replacement
 Valve repair or replacement
 Gasket replacement
 Gauge replacement
 Cleaning of bushings, radiators, etc.
 Silica gel replacement
 Oil top-up
 Bushing repair or replacement
 Grounding repairs
 Once maintenance and repair requirements are
determined, how do you prioritize to ensure for the
most efficient and effective use of resources?
Prioritizing Maintenance and Repairs:
Specific circumstances will dictate what repairs and
maintenance will take precedence, however, the
following represents a typical order of prioritization:
Additional testing:
 Electrical testing due to dissolved gas analysis

 Additional tests to verify results due to risk of original sample

contamination

 Dissolved gas analysis to track trends

 Furans analysis oil rejuvenation or retro-fill is recommended

Prioritizing Maintenance and Repairs:
Repairs resulting from visual inspections: Often these
repairs will take precedence over oil treatments due to the
continued damage to the oil and paper insulation that can be
caused if these problems are not addressed. Most times
they can be repaired in combination with any related oil
treatments.
 Leaky bushings or gaskets
 Valve repairs or replacements
 Radiator repairs or replacements
 Oil top-ups
 Silica gel replacement
Prioritizing Maintenance and Repairs:
Oil treatments resulting from standard oil tests:
 Oil rejuvenation (or retro-fill) due to high acid and/or low
interfacial tension
 Degasification due to low dielectric strength and/or higher
ppm moisture
 Re-inhibit treatment – either on its own or in combination with
one or both of the above
 Degasification to remove dissolved gases subsequent to
repairs related to the source of the gases.
Budgeting for Required Repairs and Maintenance:

 Seek quotes for the related work

 Schedule prioritized maintenance based on availability of

maintenance budget
Good management of your transformer assets will
save your company money, downtime and lost
production.

Properly analyzing test data to ensure necessary

maintenance and repairs are determined will extend
the useful lives of your transformers and prevent
premature failures and replacements.
QUESTIONS?