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Condition and life assessment of transformers with


specific application to power station transformers
Hannah Ahmad Rosli, Mohd Aizam Talib
TNB Research Sdn Bhd
No. 1, Lorong Ayer Hitam,
Kawasan Institusi Penyelidikan
43000 Kajang
MALAYSIA

Keywords: Transformer, diagnostic assessment, excellent high voltage insulation this oil-
condition monitoring, life assessment impregnated paper system provides, it is
unfortunately susceptible to degradation due to
Abstract many factors namely thermal, electrical,
electromagnetic and mechanical stresses, presence
Transformer is an important component in an of water, oxygen and heat that causes chemical
electrical system. Inadvertent malfunction of this degradation reaction (hydrolytic, oxidative or
equipment will lead to undesirable repercussions on pyrolytic) and also contamination by particles of
the system reliability besides entailing economic different origins. [1, 2]
loss both to utilities and to society.
This paper features several diagnostic techniques
With many aging transformers in service, the employed to assess the insulation condition and
concern of the utilities is inevitably focused not just remaining life of transformers. The estimation of
on the health condition, but also on the remaining the remaining life is based on the assessment of the
life of these transformers as this relates to the mechanical integrity of the paper insulation which
serviceability of the aged units. will be described further, supported by the results
from the integrated diagnostic approach involving
The diagnostic activities for assessing the the physical inspection and several diagnostic tests.
transformer condition and estimating transformer
remnant life are of interest and widely practised. 2. Transformer diagnostic techniques
The present study is focused on the evaluation of
transformer condition and the remaining life of the Several transformer diagnostic techniques used in
transformer with specific applications to the the study are described in this section. They can be
transformers at Sultan Ismail Power Station in grouped into electrical tests applied to the
Paka, Malaysia. The transformer life estimation transformers on-site and chemical tests conducted
activities are approached holistically involving a on the transformer oil samples. The methodology
combination of physical inspection as well as the to estimate transformer life expectancy is also
assessment of the electrical and chemical testing included in this section.
results. The results highlight the significance of the
diagnostic tools used and are analysed as a basis of 2.1 Electrical diagnostic method
life estimation and also life extension
recommendations. Turns ratio test

1. Introduction Using a ratio-meter, the turns ratio test is performed


on all tap positions to identify short-circuited turns,
The health of a transformer is closely related to the open winding circuits or failure in tap changers.
health of its insulation. Failure in insulation causes The measured ratio should compare with the ratio
faults such as short circuit between turns or of the rated voltages on any given tap as given on
windings, overheating and arcing to occur. Mineral the nameplate within ±5%.
oil and cellulose-based paper are the principal
insulation components in most power transformers.
These materials are organic, and despite the

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Winding resistance
cause dielectric loss to increase. Contamination of
This is a DC test made using a low resistance insulation by moisture or chemical substances may
ohmmeter. It can indicate a change in winding cause losses to be higher than normal.
resistance when there are shorted turns, poor
connections or joints or tap changer contact The power factor value of 0.5% was used as
problems. When possible, the reading should be acceptance criteria for new transformers. Sudden
compared to the factory test data or previous test increases in value of power factor over time are
data. If this were not available, the data obtained taken as a sign of deterioration of the insulation
can be compared between phases or to another condition. The power factor on serviced-aged
identical unit. The readings of the different phases transformer in good condition should be in the
should exhibit similar value with each other at all range of 0.5% to 1.5% [5, 6]
tap positions.
Excitation current
Insulation resistance
The excitation current measurement provides
The insulation resistance test is one of the least means of detecting incipient damage to a
costly one to perform in terms of test equipment transformer winding and core such as loose or
and is one of the oldest techniques in testing. The shorted laminations, winding problems, poor joints
insulation resistance test provides useful indicator or contacts and discontinuity of the transformer
of contamination and moisture on the insulation windings due to transportation or short circuit
surfaces of the winding, especially when there are forces during a nearby external fault. The excitation
cracks, pinholes or fissures in the insulation. For a current, at no load, excites the magnetic flux in the
new transformer, the insulation resistance for 1 iron core. Its magnitude depends on the applied
minute should be greater than 200 MΩ [3]. voltage and the number of turns in the winding, the
dimensions, the reluctance and other conditions of
During the test, when dc voltage is applied, the total the core. An excessive current may be due to a
current flowing through and along the insulation is partial short circuit between one or more turns in
made up of three components; a charging the winding or it may be due to some defects in the
component into the capacitance of the winding, a magnetic circuit which alters the reluctance of the
polarization or absorption current involving various core.
molecular mechanisms in the insulation and a
leakage component over the surface between For three-phase core transformers, a pattern of two
exposed conductor and ground. similar currents and one lower current can be
expected which the center leg has lower excitation
The polarization index is a variation on the dc current than the other two phases. The test values
insulation resistance test. This value helps to on the outside legs should be within 15% of each
determine how dry and clean the winding insulation other, and the center leg should not be greater than
is. The charging current is measured at two either outside leg. Results compared to prior tests
moments, often 1 minute and 10 minute after should not vary more than 5% [5, 6, 7].
energizing the winding with the dc voltage. A ratio
of R10/R1 < 1.2 indicates the presence of polarisable 2.2 Chemical diagnostic method
materials such as water [4, 5].
Oil quality analysis
Insulation power factor test
This analysis comprises of six tests, aimed at
Power factor is a ratio of dielectric loss (or watt evaluating the physical, chemical and electrical
loss) to the charging volt-amperes (or apparent integrity of the oil insulation. These tests and their
power input). It is a property of the electrical significance are summarised in the following Table
insulation system and a measure of the electrical 1 [8, 9]:
losses in the insulation when subjected to an
applied alternating voltage. Power factor testing is
the single most valuable method of obtaining data
for determining insulation quality. A high loss may
indicate problems in the insulation structure.
Normal ageing of an insulating material will also

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• Hydrocarbon gases and hydrogen: hydrogen (H2),


Test Significance methane (CH4), ethane (C2H6), ethylene (C2H4)
Moisture content Moisture content is and acetylene (C2H2).
accurately determined from
Karl Fischer titration • Carbon oxides: carbon monoxide (CO) and
method. carbon dioxide (CO2)

Moisture in oil causes a • Non-fault gases: nitrogen (N2) and oxygen (O2)
decrease in the dielectric
strength of insulation, The identity and relation of the individual gases are
formation of bubble under indicative of the type of faults occurring while the
high load conditions and rate of gas generation can indicate the severity of
accelerated ageing of the fault [13, 14, 15].
cellulose insulation.
Colour A rapidly increasing or a Type of fault Gases evolved
high colour number (darker Corona of oil and Hydrogen
colour) may be an indica- cellulose
tion of oil degradation or Overheating (or
contamination. pyrolysis) of oil
Acidity Acids are products of oil a. Low temperature Methane, ethane
(Neutralization oxidation. High acidity b. High temperature Methane, ethane,
value) value indicates degree of ethylene, hydrogen
oil ageing, and rate of Arcing Acytelene, methane,
increase in acidity indicates ethane, ethylene
ageing rate. Overheating of cellulose
Interfacial tension Low value is related to the a. Low temperature Carbon dioxide
presence of degradation b. High temperature Carbon monoxide
products and imminent
sludge. Table 2: Gases evolved by faults occurring in a
Dielectric Low value indicates the transformer
breakdown voltage presence of contaminants
such as water or particles. By themselves, the DGA data do not always
Power factor The parameter is sensitive provide sufficient information to evaluate the
to the presence of soluble integrity of a transformer. The history of the
polar or ionisable transformer in terms of maintenance, previous
contaminants and ageing faults etc are an important part of the information
products. High power required to make a more accurate evaluation.
factor implies poor
insulation resistance. Generally the following diagnostic methods are
employed for the interpretation of the DGA results
Table 1: Oil quality tests and their significance [16]:

Dissolved gas analysis • IEEE C57.104


• Key Gases
For more than 25 years, dissolved gas analysis • Rogers Ratios
(DGA) and its interpretation has become a reliable • Doernenburg’s method
and widely accepted tool for the condition • IEC 60599
monitoring of oil-filled transformers [10, 11, 12].
• Duval method
Thermal and electrical faults in a transformer lead
to insulating oil degradation, resulting in the
formation of gaseous products that dissolve in the
oil. By applying DGA on an oil sample, the
dissolved gases could be extracted to be quantified.
The important gases produced from the transformer
are listed as follow:

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Furfural analysis

The furfural analysis is an important test in the


present study, as it directly relates to the estimation
of the transformer remaining life. This relationship
is explained further in sub-section 2.4.

Kraft paper is widely used as solid insulation in Figure 2: Molecular structure of 2 FAL.
transformers [17]. The major constituent (about
90%) of the paper is cellulose. Cellulose is a linear Furans are currently detected by manually
polymer of glucose, comprising D- extracting oil samples from the transformer. Their
anhydroglucopyranose units joined together by concentration is then determined in a laboratory
glycosidic bonds [18] (refer Figure 1). A single using techniques such as HPLC (high performance
cellulose fiber is formed from a number of these liquid chromatography) of the oil [21].
chains held together by hydrogen bonds.
The concentration of these furans gives an
indication of the condition of the paper in terms of
CH2OH OH CH2OH the degree of polymerization, while the rate of
OH change of furan concentration can indicate the rate
OH of aging of paper [22]. The types and
concentrations of furans in oil sample can also
OH CH2OH OH indicate the occurrence of abnormal stresses in a
Glycosidic
transformer whether short duration overheating of
bond D-anhydroglu-copyranose the insulation or prolonged general overheating [23,
monomer 24, 25]

Figure 1: Structural formula of cellulose The main advantage of using this technique as a
tool for diagnostics is that these furan compounds
Under the combination of thermal, moisture and are degradation by-products specific to paper, and
oxidising stress, the hydrogen bonds and other cannot be produced by the oil. As such, furan
chemical bonds will break yielding breakdown analysis can be used to confirm the gas
products such as hydrogen, short chain chromatography analysis where the carbon
hydrocarbons, carbon monoxide, carbon dioxide monoxide present indicates problems with the solid
and water. Degradation also releases larger insulation.
molecules known as furan into the insulation oil.
Commonly, five furanic compounds are found in 2.3 Advanced diagnostic test
oil:
• 2-furhraldehyde (2FAL) Frequency Response Analysis
• 5 methyl-2-furaldehyde (5M2F)
• 5-hydroxymethyl-2-furaldehyde (5H2F) The Frequency Response Analysis (FRA)
• 2-acetylfuran (2ACF) measurement is a diagnostic test that is helpful in
• furfuryl alcohol (2-FOL) determining possible deformations and movements
in the transformer’s core and coil assembly. The
It has been shown that all of these compounds deformation could result during equipment
except 2FAL are not very stable under operating transportation, from mechanical stresses due to high
conditions found in transformers [19, 20]. These through fault currents and from ageing of paper that
compounds apparently form and then further reduces the transformer’s withstand strength due to
degrade to 2FAL over a time span of a few months. insulation shrinkage and lost clamping pressure
2FAL is apparently stable for several years under [26].
the same condition. The molecular structure of this
compound is shown in Figure 2. Winding deformations in transformers are difficult
to establish by conventional methods of diagnostic
tests like ratio, impedance/inductance, magnetizing
current, etc. FRA has been found to be suitable tool
to recognize the deformation in a transformer [27,
28, 29]. The basis of the FRA technique is the

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modeling of transformer as a linear, bilateral, known as the dominant time constant. The value is
complex and passive network of impedance dependent on the properties of the insulating
(resistive, inductive and capacitive) that is related material. More precisely, this value directly reflects
to the construction and geometry of the windings. the moisture content of the oil and paper insulation
Deformation and movements have an effect on both system. An increasing moisture or humidity level
inductance and capacitance that may be reflected in displaces the peak of the spectrum towards a
the resulting frequency response. smaller time constant.

Recovery Voltage Measurement 2.4 Evaluation of transformer remaining life

The Recovery Voltage Measurement (RVM) Many factors contribute to the degradation of
method is a known method to assess the state of the transformer insulation system. Acting singly or in
insulation system [30-34]. RVM detects the combination, the degradation agents further
presence of water in the oil/paper insulation, either accelerate the natural ageing process of the
created through ageing of the insulation system or insulation. Ageing is said to occur when the
from external sources. properties of the insulation system experience
irreversible negative changes. The end of life of the
The principle of the recovery voltage measurements insulation is technically reached when these
requires a sample of discharged insulation to be properties have changed beyond the acceptable
initially charged with a DC voltage for a time tc. limits. [1]
The sample is then short-circuited for a pre-
determined period of time td (usually for half the Manifestations of insulation ageing process include
charging time) after which the short-circuit is the weakening of the mechanical strength of the
removed and the voltage across the open-circuit cellulosic materials. This is due to the scission of
terminals of the insulation sample is recorded. The the long molecular chains of the cellulose polymer.
charge/discharge procedure is repeated using a Over time, the weakened paper will not be able to
sequence of increasing charging times ranging from provide the insulation and mechanical strength it is
fractions of a second to thousands of seconds. designed for, and transformer could malfunction
Three characteristic parameters of the recovery when this stage is reached.
voltage curve are of prime interest and are shown
below (Figure 3): Therefore, the cellulose paper is the most critical
component of the insulation system. The oil,
• The peak value of recovery voltage, ‘Vr’, although important, is not as critical because it can
• The time to reach the peak, ‘tpeak,’ be easily reconditioned to remove water and
• The initial gradient of the recovery particles, reclaimed to remove degradation products
voltage, ‘Sr’ or replaced. Paper, once has been destroyed, is not
easily and economically replaceable. As such, the
V
actual life of a transformer is governed by the life
Vc
of the paper insulation. The mechanical strength of
the paper is the determining factor for assessing
Sr remaining life of a transformer [35].
Vr
Paper derives its mechanical strength from its
next fibrous nature, which arises from intro- and inter-
cycle molecular hydrogen bonding within and between
the cellulose chains and the formation of micro
tc td tpeak relaxation t crystalline structure [2]. This strength is critically
dependent on the degree of polymerisation (or DP)
Figure 3: The parameters of a recovery voltage of the cellulose.
measurement
DP refers to number of monomer units in a
The above parameters are displayed as a function of polymeric cellulose chain. New Kraft paper has an
the charging time, tc, and give what is termed the average chain length of 1000 to 1500. After a long
polarisation spectra for the insulation system under period of service at high temperature with high
test. A significant characteristic of the polarization moisture content and oxygen, the paper becomes
spectrum is the time at which the peak occurs,

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brittle, changes colour to dark brown and has a With the transformers ageing up to 22 years old, the
reduced DP of 200 to 250. study was undertaken with the aim to evaluate the
condition and remaining life of the transformers
The furan analysis results can be used and hence to establish a plan for the continued
quantitatively to evaluate the rate and degree of operation of these equipment.
ageing of a transformer’s solid insulation, which is
directly related to the assessment of a transformer’s 4. Results and discussion
remaining life. This method uses the 2FAL or the
total content of furanic compounds to calculate a The life assessment of the transformers in the
predicted degree of polymerisation (DP). present study is based on the comprehensive
evaluation of the external physical condition via
The following is the equation used to predict DP visual inspection and the internal condition from
from 2FAL content [35]: the electrical and chemical diagnostic test results.
The expected remaining life of the transformers is
DP= [log10 (2FAL x 0.88)-4.51] / -0.0035 (1) subsequently estimated from the calculated degree
of polymerisation of the paper insulation obtained
The percentage of life used is then estimated from via furfural analysis.
the calculated DP:
4.1 Physical inspection
% Life Used = [log10 (DP)-2.903] / -0.006021] (2)
Physical inspection was done covering the main
In a different study [36], the formula of elapsed life tank including the wall and top cover, tap changer,
(in years) of a transformer is given by the following bushing, cooling radiators and accessories. From
empirical formula: the observation, presence of rust spots were noted
on the top cover of the main tank and on the
Elapsed life (in years) = 20.5 x ln [1100/DP] (3) radiator cooling fins of some units. Minor oil
leakages were also detected on connecting valves
3. Equipment under study and top covers of the tap changer compartments
(Figure 4).
Seven transformers at the Sultan Ismail Power
Station (SJSI) in Paka were involved for the life a)
assessment study. These units are summarised in
Table 3.

Transformer Unit Rating Age


type designation (MVA)
Station ST-B 24 22
transformer
b)
Generator GT-3B 138.3 22
transformer
GT-3C 124 21

Unit UT-3B 0.8 22


transformer
UT-3C 5 21

Excitation ET-3A 1.2 22 Figure 4: a) Corrosion on cooling fins


transformer b) Oil leaking from tap changer compartment
ET-3B 1.2 22
Old anti-corrosive protective paint and marine
ambience due to the station’s proximity to the sea
Table 3: Summary of the transformer fleet at SJSI are some of the factors that encourage the corrosion
activity. Although generally these physical defects
are not severe, remedial actions should be taken to
prevent further corrosion and leakage which could

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introduce moisture into the units that will winding value for a 3-core transformer is a sign of a
consequently harm the insulation. Repainting the fault-free unit. However, the H1-H0 connection
units with new protective layer and replacing reading for ET-3A, even though is well within the
corroded parts are some steps that could be adopted 15% tolerance limit with H3-H0 reading, is lower
as part of the life extension initiatives. than the measured excitation current of the centre
leg. A possibly deformed core is thus detected for
4.2 Assessment of electrical testing ET-3A. Unit UT-3B also displays similar result
pattern, which similarly suggests abnormality to its
Transformers GT-3B and GT-3C are in satisfactory core. A refurbishment of the core assembly of these
conditions as the electrical test results fall within affected units is recommended and careful
the acceptable limits. The winding resistance monitoring of any further deterioration must be
measurement detects a sign of abnormal condition done in the mean time.
of the tap changer in UT-3C. As shown below in
Table 4, the readings for connection H1-H3 are
found to be approximately 30% lower than the
corresponding readings in the other 2 phases at tap
position 4 and 5. Tap changer contact problem is
the most probable explanation for this observation.
Based on this, it is recommended for the diverter
and tap selector switch to be serviced.

Tap Test Lead Connection f


position H1-H3 H2-H1 H3-H2
(mΩ) (mΩ) (mΩ)
1 124.9 126.3 122.4
2 122.2 122.4 121.0
3 118.3 118.0 114.5
4 115.3 162.3 162.5
5 110.5 160.1 157.1

Table 4: Winding resistance results of UT-3C

The FRA result plots of high voltage (HV)


windings for two identical units of ET-3A and ET-
3B are shown in Figure 5. Comparing the two plots
reveals a deviation in the red phase of the HV
winding of ET-3A. This deviation is observed at the
low frequency range. Theoretically variation at low
frequency is associated with the problem in the
magnetic core structure within a transformer.

To further confirm this finding, the results of the


excitation current for ET-3A and ET-3B are Figure 5: Frequency response of high voltage
studied. The following Table 5 shows the results winding of ET-3A and ET-3B
from the excitation test of these two units:
Comparatively, the frequency response of ET-3B is
Transformer Test Lead Connection consistent with each other for all phases in the low
H1-H0 H2-H0 H3-H0 frequency range, which corresponds well with the
(mA) (mA) (mA) results from the excitation current measurement.
ET-3A 104.4 106.7 109.9 These indicate that the core for this unit has not
ET-3B 102.7 99.7 103.3 experienced any defect or deformation.

Table 5: Excitation current of ET-3A and ET-3B From the RVM, the percentage by dry weight of
moisture in the paper insulation could be estimated.
A pattern of two similar (within 15%) values on the The winding insulation for both GT-3B and GT-3C
outer windings which are higher than the centre are found to be dry at 1.5% and 1.4% respectively.

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The moisture levels of other units fall in the 2-3% The presence of carbon monoxide in transformer oil
range, indicating that the paper insulation appears is associated with the overheating of the cellulose
to be wet. However, it is pertinent to also assess the material at high temperature. This is confirmed by
quality of the insulation in terms of its dielectric the detection of high concentration of ethylene gas
loss and insulation resistance. The power factor that is usually related to the thermal fault at high
measurement results indicate that the insulation temperature.
system of all tested units is in good condition since
the loss factor value of the high and low voltage For this unit, it is recommended that the oil is
winding to ground as well as the inter-winding sampled again within 6 months instead of 12
insulation is below the specified limit. In addition, months as scheduled to monitor the rising rate of
the polarization index of insulation resistance of the fault gas production.
these configurations is observed to be more than
1.25 for all transformer units. To gauge the extent of this overheating in
degrading the paper insulation, it is insightful to
4.3 Assessment of oil testing look at the result of the furfural analysis. For ST-B,
the furan level is found to be below the maximum
The oil samples were sent to the transformer oil lab specified limit. This suggests that the overheating
of TNB Research for analysis. The tests were does not severely affect the cellulose. The high
conducted to determine the quality of the oil in carbon dioxide level could be formed by general
service, detect any incipient faults and determine oxidation of the oil and by the action of partial
the ageing condition of the transformers. discharges in the oil [37].

The oil quality analysis shows that all the units are High level of 2FAL is detected for GT-3B. This is
in satisfactory condition as the physical, chemical indicative of general overheating and significant
and electrical properties of the oil are within the ageing of the paper insulation [35].
specified limits. Both the generator transformers
and the station unit have undergone oil reclamation 4.4 Assessment of transformer life expectancy
in the recent years. The moisture, acidity, interfacial
tension (IFT) and dielectric breakdown voltage are The application of the calculations presented in
maintained at acceptable values since the section 2.4 enables the remaining life of the
reclamation process. transformers under study to be estimated. Table 7
shows the life assessment of UT-3B and GT-3B.
The DGA data of ST-B reveals that the The percentage of the remaining life and the
concentration of ethylene and carbon monoxide is knowledge of the estimated transformer design life
slightly above the specified limit. Table 6 lists the as given by the manufacturers can be used to
current and previous fault-gases data obtained via estimate the number of years the transformers can
DGA for ST-B. The rate of rise of ethylene and be expected to be operational.
carbon monoxide from the previous reading is
0.388 and 0.911 ppm/day respectively. Transformer Furanic % Life
DP
unit compounds used
Fault Gases GT-3B 3171 ppb 304 70%
(Specified 22/9/04 2/3/05 8/9/05 UT-3B 44 ppb 835 3%
limit)
H2 (100) ND 1 3 Table 7: Life assessment results of 2 units with the
ND ND 8 least and highest life expectancy
CH4 (120)
C2H6 (65) ND 1 3 Based on this result, it is reasonable to conclude
C2H4 (50) 1 13 83 that in the case of GT-3B, the transformer paper
ND ND ND
insulation has badly deteriorated and aged. The DP
C2H2 (35) gives a sign that the life expectancy and thus the
CO (350) 5 189 353 serviceability of this unit are questionable. In the
CO2 (5000) 225 744 2171 case of UT-3B, the high DP suggests that this unit
is free from any advanced or abnormal aging of the
cellulosic insulation which can limit its life
Table 6: DGA results obtained for ST-B expectancy. It is essential to note that the
degradation rate of the paper insulation increases

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with the increase in moisture, oxygen, acidity and [12] M.Duval, F.Langdeau, “Acceptable Gas-
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