Guide Transformer Spec Issues PDF

Guide to Power Transformer
Specification Issues
www.epecentre.ac.nz
Electric Power Engineering Centre – Guide to Power Transformer Specification Issues Edition 2, January 2009
DISCLAIMER
This document was prepared by the Electric Power Engineering Centre (EPECentre) at the University of Canterbury
in Christchurch, New Zealand. The content included in this document is based on a power transformer specification
workshop held in July 2007. The EPECentre takes no responsibility for damages or other liability whatsoever from the
use of this document. This includes any consequential damages resulting from interpretation of material.
Electric Power Engineering Centre, University of Canterbury
Published by Electric Power Engineering Centre (EPECentre), University of Canterbury
1st Edition 1, August 2007 [revised January 2008]
Reviewed & edited by: Wade G. Enright BE(Hons), PhD, MIPENZ, MCIGRE
Produced & co-edited by: Joseph D. Lawrence BE, MEM, PMP, MPMINZ, MNZIM
Acknowledgements: Sponsors and participants of the EPECentre Power Transformer Conference 2007, Workshop:
Guide to Transformer Technical Specification, 3 July 2007, University of Canterbury, Christchurch, New Zealand
Electric Power Engineering Centre

University of Canterbury
Private Bag 4800
Christchurch
New Zealand
T: +64 3 366 7001

E: info@epecentre.ac.nz
www.epecentre.ac.nz
© 2008 Electric Power Engineering Centre, University of Canterbury, Christchurch, New Zealand. All rights reserved,
no part of this publication may be reproduced or circulated without written permission from the Publisher.
1
Electric Power Engineering Centre -
GUIDE TO POWER TRANSFORMER

SPECIFICATION ISSUES
CONTENTS
FOREWORD ...................................................................................................................................3
INTRODUCTION .............................................................................................................................4
SETTING THE SCENE....................................................................................................................6
PART 1. FIRE & EXPLOSION PROTECTION ................................................................................7
PART 2.THE DETAILED DESIGN REVIEW ...................................................................................9
PART 3. TECHNICAL SPECIFICATION EXPERIENCES ............................................................11
APPENDIX A. REFURBISHMENT & REPAIR OF POWER TRANSFORMERS*…………………13
APPENDIX B. DRIVEN FACTORS FOR TRANSFORMER LONG LIFE** ………………………..30
APPENDIX C. EPECENTRE ELECTRIC POWER R&D CAPABILITY ......………………………..92
* Courtesy of Transfield Services Limited ©
** Courtesy of Pauwels Trafo Asia Limited ©
2
FOREWORD
Tēnᾱ koutou te whᾱnau,
Nga mihi ki koutou mana, koutou korero, koutou whakaaro,

koutou awhina. Kua mutu te wᾱnanga. No reira tēnᾱ koutou,
tēnᾱ koutou, tēnᾱ koutou katoa.
The power transformer technical specification workshop is

completed. Thank you to all that attended, for your
presence, discussions, thoughts and support.
Australasia is currently most active in the processes

associated with purchasing power transformers. July 2007
was a good time to peer review some important
components within this process, and some of the present
practices. It was also fantastic to have representatives from
Indonesia, France, Australia and Aotearoa involved in the
workshop. The Electric Power Engineering Centre
(EPECentre) has prepared a summary of the workshop for
Dr. Wade Enright and Prof. Pat Bodger (EPECentre
each of you, enjoy. Director) pictured with the 15kVA, single phase, prototype
superconducting transformer, designed and built at the
Hei kōna, University of Canterbury in Christchurch, New Zealand.
Wade Enright
Dr. Wade G. Enright
Associate, Electric Power Engineering Centre, University of Canterbury
August 2007
3
INTRODUCTION
Power Transformer Technical Specification
During 2006 and 2007 to date, an unusually high number of requests have arrived for Technical Specification
reviews, both in New Zealand and Australia.
More than six power transformer Technical Specifications for machines over 200MVA in New Zealand alone.
The challenges of a significantly loaded electrical network reliant on service aged equipment: refurbish and/or
replace.
The challenges of increasing load and “new” generation types e.g. wind turbines.
The commodity price issues (copper, electrical steel, structural steel and oil).
The changes from well established European factories to new South East Asian manufacturing sites.
The need for form relationships with new people (new manufacturer personnel, new employers/clients).
It may be that power transformer Technical Specifications has become cumbersome, out of focus and needs a
“spring clean”.
The peer review process: are our ideas good ones?
Published Documents
Published documents that contain guidelines specific to power transformer Technical Specification:
CIGRE Working Group 12.15., “Guide for Customers Specifications for Transformers 100MVA and 123kV and
above”, Technical Brochure 156, April 2000.
ABB, “Transformer Handbook”, ABB Power Technologies Management Ltd, 2004.
Heathcote, M.J., “The J&P Transformer Book”, Twelfth Edition, Newnes, 1998, ISBN 07506 1158 8.
ABB, “Testing of Power Transformers, Routine Tests, Type Tests and Special Tests”, 1st Edition, ABB Business
Area Power Transformers, 2003, ISBN 3 00 010400 3.
4
Refocus: Why Have a Technical Specification?
From an Employer (Client) perspective:
To formally and fairly communicate exactly what you want the Contractor to deliver.
From a Contractor perspective:
To be able to accurately offer services and products which provide a satisfactory solution
(technical/commercial) to an Employer (Client); while remaining a long-term profitable
business.
For both Contractors and Employers (Clients):
To avoid relationship mishaps associated with costly Variation work misunderstandings.
5
The repair bill is significant.

SETTING THE SCENE
What is the Industry going to do about it?
1. The Use of International Standards –
Example: Australian Standards
3. Partial Discharge Testing of Refurbished
AS60076.1-2005: “Power Transformers – General.” Power Transformers in New Zealand
AS2374.2-1997: “Power Transformers – This is an expensive and time consuming test.

Temperature rise.”
It could commonly be the case that the original power
AS2374.3.0 – 1982 “Power Transformers – Insulation transformers were not designed to be subjected to
levels and dielectric tests, General Requirements.” the Partial Discharge test.
Including Amendment 1 – 1992.
Why are expected Partial Discharge pass levels
AS2374.3.1 – 1992 “Power Transformers – Insulation being set at 50% of the value specified in the IEC
levels and dielectric tests, external clearances in air.” International Standard for new transformers?
AS60076.4 – 2006 “Power Transformers – Guide to What is the plan if the Partial Discharge fails?
the lightning impulse and switching impulse testing –
power transformers and reactors.” The Partial Discharge test initially failed but has now
passed, how does this make you feel?
AS2374.5 - 1982 “Power Transformers – Ability to
withstand short-circuit.”
AS2374.6 - 1994 “Power Transformers – 4. On-Load Tap-Changers on Generator

Determination of transformer and reactor sound Step-Up Transformers
levels.” Including Amendment 1 – 2000.
More and more tapping ranges.
AS2374.7-1997 “Power Transformers – Loading
guide for oil immersed power transformers.” Including Lower and lower tap sizes.
Amendment 1 – 1998.
Why – the generator has an Automatic Voltage
AS2374.8 – 2000 “Power Transformers – Application Regulator?
Guide.”
Has system simulation taken over the importance of
AS1265 – 1990: “Bushings for alternating voltages reliable machine design?
above 1000V.”
What is the impact upon short-circuit with-stand e.g.
AS60214.1 – 2005: “Tap-changers, Performance multi-start, layer wound tapping windings?
requirements and test methods.”
AS60214.2 – 2006 “Tap-changers, Application

guide.”
5. Transformer Cooling
ONAN/ONAF/ODAF versus ODW versus ONAN?
2. The Single-Point Earthing of Power When should we buy straight ONAN machines?
Transformer Cores, Frames and Tanks Reliable, not dependent on l.v. systems, and simple.
The insulation is failing. ONAN/ODAF may be significantly more cost effective

above 65MVA?
Dissolved Gas Analysis tests are being over-run with Will specifying ODW significantly reduce the number
alarming gas signatures. of Contractors who will tender for the work?
6
steam and gas plant than hydro. All money and

PART 1. FIRE & EXPLOSION susceptible to damage.
PROTECTION Nitrogen.
Enclosure.
Fire Wall.
What is considered an acceptable level of Blast walls in all critical areas.
Design of location.
fire and explosion protection that should be Fast acting protection.
specified for power transformers in the c) A generator step-up transformer connected to a

following scenarios? hydro-turbine unit
Environmental risks - oil contamination of lakes /
rivers, etc.
a) A remote outdoor substation
Containment of full volume of oil.
Physical separation (firewalls if duplicate units). Buchholz relay.
Buchholz relay. Pressure relief.
Pressure relief. Vented cable box.
Separate cable terminations > 100MVA. Generator circuit breaker.
Vented cable box. Bushing monitoring.
Generator circuit breaker. Conservator tank isolation.
Bushing plus monitoring. Choice of oil.
Conservator tank isolation >100MVA. Temperature indicators.
Temperature indicators. Fire protection (foam).
Single unit (rural) - let it burn! GSU transformer - generator CB – required.
Double unit - physical separation / + blast wall. Water sprinklers and oil interceptor.
Sump flame trap - Important substations. Hydro in environment sensitive areas, must
Control consequential damage. consider heat and oil.
Consider the layout of the surroundings. Environmental issues are important, especially oil
Consider building materials. containment.
Consider neighbouring natural environment. Deluge.
Dependent on size use pressure relief valve and
shut off valve on conservator.
Blast walls for smaller critical areas.
d) Any power transformer greater than 100MVA
Physical separation (firewalls if duplicate
b) A generator step-up transformer connected to a
units).
steam or gas turbine unit Possible use of ‘Sergi’ protection, etc.
Positioning transformers away from station.
Possible use of Sergi protection, etc.
However, look at the economics.
Positioning transformers away from station.
Environmental risks - oil contamination of
However, look at the economics.
lakes / rivers, etc.
Buchholz relay.
Containment of full volume of oil.
Pressure relief.
Buchholz relay.
Vented cable box.
Pressure relief.
Generator circuit breaker.
Vented cable box.
Bushing monitoring.
Generator circuit breaker.
Conservator tank isolation.
Bushing plus monitoring.
Choice of oil.
Temperature indicators.
Choice of oil.
Fire protection (foam).
GSU (Generator Step Up) transformer -
Generator CB (Circuit Breaker) – preferred.
Blast walls and sprinklers on wall.
Blast walls and deflectors.
Conservator shut off valves.
Water sprinklers on the walls.
Options: foam, water curtain, CO2, FR3™.
More likely to provide fire fighting equipment for
Sergi system economical for larger units.
7
High velocity water spray system.

C02 for sealed enclosures.
Fast acting digital protection.
Sergi transformer protection or gas insulated
transformer.
e) Indoor substation
Buchholz relay.
Pressure relief.
Vented cable box.
Generator Circuit Breaker.
Bushing monitoring.
Choice of oil.
General Notes:
All scenarios require risk assessment.
Consider use of polymer bushing i.e. GSA, etc.
All scenarios depend on transformer size and blast
wall requirements.
Oil containment bunding with fire-traps/ drainage.
Situational considerations – not one answer for all
remote transformers or all hydro, etc.
All situations consider:
NFPA850 Guidelines – but these are only
guidelines, but you must go through and specify.
Blast walls for specified separation.
Bunding w/ drainage to suffocate fire.
Shutter valves on conservators.
Differential Protection.
8
Provide alternatives.
Assurance that the design will work and meet
PART 2.THE DETAILED DESIGN specifications.
REVIEW Provides assurance that the employer is getting
what we want.
Facilitates forum for improvements in design that
may impact on overall cost and performance.
When the Detailed Design Review process is
Gain understanding of the design so we can gain
specified: understanding of test results.
Find any steps in design/manufacture that you
want to witness to help with maintenance.
a) Employers (Clients), what Detailed Design
Review (DDR) outputs do you require and why?
b) Contractors (suppliers), what are the key matters
Using knowledge of supplier to tailor client
requirements. that will influence the power transformer detailed
Adding value to project. design that you need the Employer (Client) to
clarify?
Specifically reviewing: component mounting,
footprints, weights, shape, oil volumes etc. Ensuring spec following best practice.
Reconfirmation of 'no surprises' / confirmation Possible provision of future on-line monitoring
that supplier has the ability to deliver. equipment.
Compatibility with existing spares / stock, inter- What is important to client i.e. on time, cost, etc?
compatibility with existing network.
Confirmation of spec / deviations.
Key scope requirements.
QA (Quality Assurance) requirements.
Fit for purpose.
Drawing, documentation, manuals, maintenance
Delivery. procedures.
Inspection process. Required specs.
Transport / shipping to site. Seismic requirements.
Site constraints. Weight - gross, transport.
Performance criteria. Dimensions - centre of gravity.
Cooling plus interlock systems. Terminations.
Material listing. Specification does not cover all details. Need
DDR these details, Allows agreement on these
Acceptance tests.
details.
Type tests / compliance. No DDR for standard transformers only one
off/New Designs.
Special tests.
Also discussed customer acceptance
Material quality. Clarification of:
Out of date standards included in spec.
Review of mechanical design.
Standard Designs i.e. 6MVA spec but a
Review of loss calculations. 7.5MVA standard – cheaper, faster, and
easier.
Scope of DDR and timing of review at supplier. Component specification – e.g. bushings,
Compare DDR outputs to specification clauses. colour, tap changer type – This may effect
delivery and cost.
Special transformers need proper DDR. Transport issues.
Report on basis of IEC and CIGRE DDR guide Paint colour.
documents. Factors relating to delivery and cost.
Result is confidence in the transformer design.
9
Need to know in spec if employer wants

influence on design e.g. stress levels or
specific short circuit.
Need employer to have expertise or a

contractor to be brought in.
General Notes:
Should a detailed spec be required? How about the
customer saying we need a transformer to fill this
space, these are the connections, go to it. However,
still a lot of things need to be known. Different
tolerances are not always required, overbuilding, etc.
It’s about relationship/confidence in supplier. QA
systems, review, etc. should be done before
specifications i.e. due diligence.
Standardisation of one set of designs does not
always work, as component costs may change
meaning the set design is no longer the most
economical.
Where is the innovation coming from? Suppliers or
Clients? Probably a combination of both. Clients
drive adoption of certain items e.g. condition
monitoring. Suppliers drive changes in winding types,
materials, etc.
In general, this is a very important process that is
important for both parties. It aids clarification and
understanding of how to proceed with design
(contractor) and provides a certain level of
optimisation for the employer (client) i.e. relationship
building.
10
Refer to AS60076.1 appendix A as a minimum

requirement.
PART 3. TECHNICAL
Site requirements – Footprint, Transport etc.,
SPECIFICATION EXPERIENCES MVA, Voltage, Losses, Vector group. Bushing
types, taps, terminations, SCADA interfaces,
protection devices, auxiliaries, voltage, and
a) From an Employer (Client) and / or Contractor
cooling and seismic requirements.
(Supplier) perspective, what information must be
Finishing – Painting, galvanising, wielded or
given in a 2007 Technical Specification? bolted.
Refer to standard lists. Documentation for transfer and timetable.
MVA, voltage, impulse, tap changer, connection, As built, maintenance manuals, specs, wiring
vector group, and seismic. specs and code. Standards AS/NZ and IEC.
Intended application. Relevant standards.
General characteristics / performance criteria
Rating, MVA, kV.
Auxiliary components / systems.
Vector group. Arrangement of transformer; dimensions;
bushing/terminal layouts; site requirements;
Cooling, type of oil.
system requirements.
Impedance. Voltage, vector group, frequency, noise
requirements (sound pressure, sound power,
Tap-changer, plus minus percentage. distance), loss’s, rating, list of standards that it
Load profile. must comply to, Overload rating, ambient
temperature, earthing, fault level, environment,
Regulation. seismic requirement, altitude, typical rang of
Standards (manufacturers). impedance, tap rang, type of entry.
List of accessories.
b) Employers (Clients) and Contracts (Suppliers),
Type of bushing.
what times have you witnessed recently in
Short circuit withstand capability.
Technical Specifications that have been
Seismic.
unhelpful to the process?
System earthing.
Clearances - often specified when standards are
BIL (Basic Insulation Level). in place (Designer wants a different clearance for
Loss evaluation formula. some reason?)
Guaranteed losses. Too prescriptive specs i.e. 'old school'
Corrosion protection. Too many standards.
Tank strength. Insistence on copper winding.
Noise level. Totally useless offload sufficient.

Specification of duplicate/overlapping test
Phase clearance, spacing. requirements ( contributes to additional cost/time)
Creepage distances. e.g. stating two test methods to gain same result,
such as meggar vs. sweep frequency tests.
Surge arrestors. Irrelevant/out of date standards.
Cable box, open bushings. PD (Partial Discharge) test requirements NZ/AUS
very low – almost impractical.
CT (Current Transformer) requirements, Radiator specified to be both galvanised and
protection. painted.
Remote tap changing. Colour of bushing in cable box.
Items that are contradictory.
Station voltage. Items that are out of date.
11
c) Why are on-load tap changers being fitted to e) When transformers over 150MVA are specified,
generator step-up transformers and what are the how should they be livened if the high voltage
implications of increasing tapping ranges and network must be used? What are some
decreasing step sizes? experiences with such livening?
Insurance policy. Point on wave switching.
Guarantees and flexibility? 480MVA back livening, audible complaint from
other transformer for 10– 15 minutes.
Transformer design.
Pre-Insertion resistors.
Old school, conservative.
Asset owner compliance.
More voltage regulation required. f) What are the key acceptance criteria that will
Near load centres. allow an Employer (Client) and Contractor
Increase tap range: extreme ends of tap settings (Supplier) to close-out a project?
are not used. Setting of maintenance procedures.
Totally useless offload sufficient. Drawings.
More leads and more introduced points of
potential failure. Documentation.
EGR (Electricity Governance Rules) Defects.
requirements impact on generators ability to
support/import reactive power is severe. Warranty, commercial bonds, etc.
Tap changers are not needed on generator
Successful livening.
transformers with an AVR (Automatic Voltage
Regulator). Handover of drawings, manuals, test certificates,
etc.
d) Is single-point earthing of core, frames, and tanks Clear communication and well defined procedure
needed.
a good approach? What happens when the single
Define in contract.
point earthing fails? Pass site acceptance test.
Good idea! Cost trade-off on insulation maybe.
Agreed acceptance testing completed.
General Notes:
In service for specified period and handed over.
Single point earthing lives! Need better construction
On site install / commissioning completed and to withstand transport failures, lamination failures etc,
documentation complete. not necessarily insulation failure. Need better access
for repair, replacement.
Fence sitting: cost of coping with circulating
current vs. single point. On-Load Tap Changer (OLTC) - AVR might be all
Want device that is reliable regardless of design good, but if it has a problem, the OLTC provides
Choice of single point earthing or not is a trade good backup. But it may still not be needed as it
off between equipment costs and losses. The won't be in operation if AVR is out.
“best” will vary with circumstances.
May need OLTC to allow for future system
expansion/change. Lowers system reliability but
increases system flexibility. System planners should
consider this more. OLTC alters voltage seen by
generator, but AVR can withstand plus minus 5%
typically anyway (sometimes!).
12
Electric Power Engineering Centre – Guide to Transformer Technical Specification Edition 1, August 2007
APPENDIX A
REFURBISHMENT & REPAIR OF POWER TRANSFORMERS*
* Courtesy of Transfield Services Limited ©
Page 13 of 94
Refurbishment & Repair of Power Transformers-
A review of current practices in New Zealand
Conference- Christchurch,2-3 July 2007
Presented by – Ramesh Gopalan
Transfield Services Partners for Change

Overview
General Principles of Refurbishment

What is being done at present
Specific aspects
What could be done during refurbishment
Review of specifications
Repair of Power Transformers
- What could be done – An overview from the contractor

2
Refurbishment of transformers

3
General Principles of Refurbishment
Power Transformers worldwide are ageing

The average age in New Zealand is about 36 years
Grid & Network operators have an ongoing programme of
refurbishment for life extension.
Refurbishment includes
Testing the average DP of transformer insulation
De-tank & Inspection of core & windings
Minor modifications to blocking arrangement
Changes to insulation structure- paper wound cylinders to solid cylinders
Single point Earthing modifications- not always practical

4
Refurbishment of Transformers
Dry-out of core & windings using heat and vacuum

Re-tightening and clamping windings.
Replacement of accessories- OTI, WTI, Buchholz Relay etc
Replace Explosion Vent to PRV .
Install Flexible Separators in Conservators
OLTC replacements
Corrosion control of tank and enclosures
Oil reclamation to improve physical and dielectric properties.
Routine Low Voltage testing following refurbishment

5
EPRI Guidelines for residual life estimates
DP Value % Life Left
1000 to 1400 100%
500 60 to 66%
300 30%
200 0%
Source: Guidelines for the Life Extension of Substations, 2002 Update,

Electric Power Research Institute( EPRI), California, USA

6
Residual Life Estimates-NZ network transformers
»Remaining life estimates are favourable for up-rating
Mid Year of No. of Average % Life Left # of years Total
Decade of Samples tested DP of service Service
Manufacture tested value life left Life
1955 35 520 60% 30 80
1965 110 543 60% 30 70
1975 39 505 60% 30 65
1990* 9 719 80% 40 55

1. DP Values tested during refurbishment, Residual Life Assessment based on EPRI
Guidelines.
2. The above figures affirm the assessment of post 1970 transformers will have a
lower life than those manufactured during 50-60’s

7
Refurbishment Specifications should
include
A review of cooling arrangement
Older transformers have different
style of radiators
Not necessarily efficient
Could be changed to more efficient
Plate-fin type radiators with
symmetrical arrangement
ONWF arrangement could be
changed to ONAN instead of OFWF

8
Up-rate transformers during
refurbishment
Generally not called for
Review original Heat-run test
reports
Most of the transformers are
ONAN cooled
Could be changed to
ONAN/ONAF and increase
capacity

9
Dry-out of windings
Dry-out is under-taken using Hot-air heating and vacuum drying
thereafter
Vapour phase drying is not under-taken as set up cost is prohibitive
The termination of dry-out is generally based
on volume of water collected per hour and
a certain minimum value of vacuum
usually less than 1 mbar
Recommend this be changed to standard Moisture-Equilibrium curves
published by IEEE
Dr.Oommen curves are used by most manufacturers
Eliminates the need for collecting water and monitoring water collection
Cumbersome

10
Testing of transformers

11
Testing of Transformers
Post refurbishment, testing is done only at low voltage
Emphasis on Insulation resistance test post refurbishment
Minimum acceptable value is specified based on TMI-US guidelines
IR & PI values are often not achievable due to the transformer capacitance
IEC standards do not specify a minimum value
Minimum value for Insulation Resistance should be specified independent of
kVA Rating
We recommend
50Hz separate source voltage test at 75% rated value for refurbished
transformers
No-load excitation at 100% voltage for 30 minutes for refurbished transformers

12
Partial Discharge test
Post repair, a partial discharge test is specified
IEC 60076 recommends PD test for transformers with
Um>300kV
Some clients insist on this test for lower voltages
Values specified are 50% of IEC recommended values
The transformer is manufactured 25-30 years ago
Only part of the winding is replaced
The transformer was originally not subjected to a PD test
Is it practical to achieve such low levels?
The PD test is conducted in an unshielded environment

13
Repair of transformers

14
Repair of Transformers
While choosing to repair, some Transformer Price Variation
clients
Based on internal economic models, 2.400
prefer the least cost option. 2.200
2.000
The purchase price of transformers 1.800
has doubled in the last three years 1.600
Cost of repair likely to be 20-25% of 1.400
P r ic e In d e x
the cost of new transformer. 1.200 Pq/Po
Lead times for new transformers 1.000
exceeds 12 months 0.800
Repair should consider existing risk 0.600
Generally recommended to replace 0.400
whole windings 0.200
0.000
At least the complete winding of the Jan-04 Aug-04 Feb-05 Sep-05 Mar-06 Oct-06 Apr-07 Nov-07 Jun-08
faulted phase Month-Year
Minimises risk

15
Repair of Transformers
While formulating repair specifications, we recommend
Testing of the replacement winding for turns ratio, resistance and inter-strand
tests
prior to shipping the windings to New Zealand
This will involve the windings be put on a transformer core
But it is recommended
We have had failures of replacement windings having
Centre entry and two halves in parallel
Unequal turns between parallel halves
Recommend the involvement of replacement contractor in inspecting the
winding prior to shipping
to avoid surprises / delays upon arrival in New Zealand
Specify PD levels to which transformer will be tested to the replacement
winding manufacturer

16
APPENDIX B
DRIVEN FACTORS FOR TRANSFORMER LONG LIFE**
* Courtesy of Pauwels Trafo Asia ©
Page 30 of 94
ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION
ELECTRICAL DEPARTMENT – PAUWELS TRAFO ASIA

Contact person ; Didik Susilo Widianto (+62.21.8230430.ext 230)
Transformer life time
The Transformer life expectation is measured by

the Rate of Degradation of the Insulation

normally this Insulation is cellulose paper.
The expectation of transformer end life can be

indicated by the degree polymerization of paper
approximate 200 (and other indications).
Tuesday, August 21, 2007 Introduction Power Transformer 2

Two important design driven factors
Transformer temperature behavior ;
IEC 60076 – part 2 and IEC 600354 indicate the limits based on
temperature of this life time expectation. The normal life
time/temperature rise & emergency capabilities at particular ambient
temperatures have to be considered.
Partial discharge levels ;

IEC 60076 – part 3 indicates the standard limits of partial
discharges for 130% Um (300 pC) and 150% Um (500 pC). These
levels seem to be are very high and we would not manufacture to
them. One must have low PD as with increasing moisture content,
the PD rises quite dramatically at 20 ppm, 20oC moisture content
mineral oil (see diagram for moisture content) while the transformer
is normally tested at very good oil condition.

Why is temperature important for

transformer life time ???

Cellulose Conductor Insulation Ageing

TRANSFORMER LIFE TIME – CELLULOSE DESIGN
IEC 354 – Loading Guide

• Section 1.2; The hottest part of the winding is used
for evaluation of a relative value for rate of thermal

ageing. Conductor insulation ageing
• Section 2.6.2; Relative thermal ageing based on
20oC ambient + 78oC hot spot rise = 98oC.

TRANSFORMER LIFE TIME – CELLULOSE
DESIGN
yearly average hot spot 98oC

TRANSFORMER LIFE TIME – CELLULOSE
DESIGN
Θh Relative ageing rate

(θh-98)/6
V=2 92oC 0.5
98oC 1.0
104oC 2.0
110oC 4.0
yearly average hot spot 98oC
134oC 64

Temperature Rise and Driven Factors
Temperature Rise for Class A (IEC 60076-2/ ANSI C57);
Top oil rise ; = 60K / 55 K or 65 K.
Average oil rise ; = 65 K / 55 K or 65 K (By resistance method)
Hot spot rise ; = 78 K / 65K or 80K.
Site elevation height;

The standard elevation height is 1000 m above sea level.
Climatic temperature behaviors;

Yearly average ambient temperature (IEC std = 20oC) Î transformer life time.
Hot monthly average ambient temperature (IEC std = 30oC)
Maximum ambient temperature (IEC std = 40oC) Î transformer loading capability
Temperature class;
Insulation class A E B F H
Operating temperature 105oC 120oC 125oC 145oC 220oC
Temperature Identification
Hf x gradient
core
cooler
gradient
winding
Bottom oil
Mean oil
Average winding
Top oil
Hot spot
Hot spot factor is normally presented between
1.1 to 1.5 depending on winding design.
Cooling Medium
INTERNAL COOLING MEDIUM
Besides the thermal absorption, the internal cooling medium
also functions as the insulation medium.
Class A;
9Mineral oil (Inhibited or Un-inhibited oil).

Class K;
9Silicon oil
9Synthetic ester
9Hi-Temp natural liquid (seeds).
EXTERNAL COOLING MEDIUM

9Air
9Water
Terminology Of Cooling System
Directed Cooling ;
Indicates that the oil is flowing in the winding by zig-zag
paths. This Directed Cooling is using Oil Barriers in several
sections of winding to guide the oil flow.
Non Directed Cooling ;

Indicates that the oil is flowing in the winding axially.
Normally, clack bands are used to improve the cooling
performance.
Pumped unit – Fully Directed Cooling ;
Indicates that the principal part of the pumped oil from heat
exchangers or radiators is forced to flow through the
windings arrangement.
Winding Cooling System
Directed Cooling Non-directed Cooling

Pumped - Fully Directed Flow
In order to avoid > 60% of cold oil leakage, the Fully Directed
Cooling is the only recommended cooling for Pumped unit.
Windings ; 80% oil flow core

cooler
Core & leakage ;
20% oil flow
winding
Oil Chamber for oil

flow distribution
Pump
Class A Standard Temperature Limits
*) suitable for Maximum temperature design limit [oC]

thermally up graded
paper insulation Oil Winding Metal part Consequences
Annual average 80 98 / 110 * 110 Life time
Long Emergency 105 140 140 Gas generation
Short emergency 115 160 160 Gas generation
Thermal short circuit

Conductor
1.Copper 115 250 160
softening
2.Aluminum 115 200 160

Conservative Temperature Limits
Temperature limits for mineral oil filled transformer with conservative safety
margin to avoid any insulation degradation;
1. 125oC for maximum winding hotspot temperature during short
emergency at max. 30 minutes.
2. 115oC for maximum winding hotspot temperature during

continuous emergency (above time constant).
Pumped - Fully Directed oil flow cooling is the most effective solution
to fulfill those conservative temperature limit requirements for medium
& large power transformer.
The 50/100% for ONAN/ODAF cooling is the optimum combination
in the case of pumped, finned radiator & fan combination (external
cooling).

Recommended Cooling Method
Directed cooling;
For pumped unit (OD), the Fully Directed windings with oil
Directed to the windings and through the windings is the most
optimum for medium & large transformer with conservative

temperature limits & severe overloading requirements.
For in case natural oil flow unit, we also produce Directed in the
windings only. Some time ago (up to 2000), we had built Non
Directed/Axial cooling with Clack band cooling systems.
Value for money in any system, Fully Directed Oil flow gives the
most effective commercial result and provides significant design
benefits in fully fitting the severe overloading requirements.

Directed cooling;
1. As there is an oil gap in the middle of the winding due to
clack band which is required for additional cooling, the
buckling withstand is more difficult to control. There are

difficulties controlling alignment of the clack band due to
the fixed distance between the clacks.
2. The usage of clack band for the axial cooling duct of Non
Directed cooling reduces the series capacitance of the
winding. Due to this reduction in series capacitance, more
insulation is required to strengthen the insulation
coordination against impulse switching surges and high
frequency voltage spikes inherent in the system.

Directed cooling;
3. Under OD, we are more able to accurately predict and control
our low gradients. A low gradient allows one to more easily
control the temperature behavior and cater for severe
overloading conditions.
The value of the gradient is that as the current increases, the
gradient rises by the power of 1.6 for Non-Directed cooling,
1.2 for natural flow Directed cooling and 2.0 for Fully
Directed pumped oil flow.
The gradient of a competitive unit of Non Directed cooling is
typically almost double the Fully Directed (OD) unit and ,if
one overloads, the gradient temperature increase can be quite
dramatic and limits overload capacity.
Directed cooling;
4. Fully Directed flow units can be made electrically stronger
than Non Directed flow units as the duct size on either side
of the winding can be significantly reduced (increased
strength per mm). In naturally cooled units ie ONAN and
ONAF, the duct normally need to be increased for cooling
considerations due to very low thermosyphonic oil flow.
5. It is the fact that the pumped – fully Directed flow unit will
eliminate the local overheated oil around the hot spot area.
This system is suitable for Hybrid design technology in
mobile transformer application or other compact transformer.
Directed cooling;
6. Due to it’s high cooling effectiveness, the Fully Directed flow
pumped units in combination with low RPM big fans is mostly

able to minimize the cooling noise fitting with extremely low
noise requirements. This solution is the most preferred
solution rather than reducing the induction and increasing the
active material (core & copper) as consequences. ODAN
cooling gives practically lower noise increase at approx. 20%
rating above ONAN in comparison with ONAF solution.
Note :
- we build all types of units, ONAN, ONAF and ODAF
Winding Gradient
Grad. = Function (q, 1/ψ , 1/ρ , 1/c ,η)
“Grad.” Liquid to conductor gradient temperature [K]

“q” Distributed losses density [W/mm2]

“ψ” Distributed liquid mass flow rate [mm/s]
”ρ” Liquid mass density [kg/mm3]
“c” Specific heat capacity [J/kg.K]
“η” Coefficient of convective heat transfer [W/mm2]

Surface Heat Transfer Coefficient
η (surface heat transferred coefficient) is a

function of duct size, oil flow length & velocity.
For directed (zig-zag) cooling ;

The axial and radial surface of the winding conductor
are considered as the surfaces for heat transfer. This can
be quite accurately calculated to determine the winding
gradient of the winding.
For non-directed (axial) cooling ;

The axial surface of the winding conductor section is
predominantly considered as the main heat transfer surface.
Mass Flow Rate
ON Cooling
1. Determined by thermosyphonic principle of Buoyancy effect.
2. Driven by winding heat due to losses (I2R + eddy losses) and
cooling medium properties (mass density, viscosity).
OD Cooling
1. Determined by thermo-hydrodynamic calculation at
equilibrium hydraulic pressure.
2. Driven by winding heat due to losses (I2R + eddy losses),
designed oil speed, pump capacity and cooling medium
properties (mass density, viscosity, specific heat capacity).

Typical OD Mass Flow Rate Distribution
270 mm/s
180 mm/s
110 mm/s
OD design

Flow Barrier in Directed Cooled Winding
Outside Flapped type barrier
Inside Flapped type barrier

Partition Ring to Control Thermal
Balance Between Windings

Fully Oil Directed Cooled All Windings
Oil Directed
Twin Boosters

Gradient Comparison Of Directed vs
Non-directed Cooling In Natural Flow
60/90 MVA, 132/33 kV Directed Non-directed
ONAN/ONAF + 150% CMR
two hours emergency
Calc. Meas. Calc. A Calc. B
LV AN 0.67 pu 12.6 oC 11.0 oC 19.5 oC 7.9 oC
AF 1.00 pu 15.6 oC 14.2 oC 29.4 oC 15.0 oC

AF 1.50 pu 24.3 oC 23.4 oC 43.8 oC 28.7 oC
CU net weight 2092 kgs 2092 kgs 2550 kgs
# Clack band NA NA 3 pcs
HV AN 0.67 pu 10.7 oC 10.3 oC 22.3 oC 7.9 oC
AF 1.00 pu 16.7 oC 15.0 oC 33.7 oC 15.1 oC
AF 1.50 pu 26.6 oC 25.0 oC 55.5 oC 28.9 oC
CU net weight 2816 kgs 2816 kgs 3450 kgs
# Clack band NA NA 2 pcs
Comparison Of Experienced Cooling System
Factory Test Results ONAN/ONAF ONAN/ODAF
Transformer Rating 150 MVA 230/115 kV 250 MVA 220/114 kV
Type Of Transformer Double Wound Auto Transformer
LV Top Oil Rise 42.65 oC 46.8 oC
Winding Gradient 19.2 oC 12.6 oC

Hot Spot Rise 67.6 oC 63.2 oC
Winding Cooling Non-Directed Fully Directed
# Clack band 5 x 5.4 mm thick. NA
HV Top Oil Rise 42.65 oC 46.8 oC
Winding Gradient 22.5 oC 18.9 oC
Hot Spot Rise 71.9 oC 71.4 oC
Winding Cooling Non-Directed Fully Directed
# Clack band 4 x 5.9 mm thick. NA
External Cooling 12 rad. + 30 small fans 1(+1) pumps + 8 rad.+ 4 fans
150 MVA DOUBLE WOUND TRANSFORMER
NON DIRECTED COOLING
End user : CHEVRON Indonesia. (Energized 2000)

90/150 MVA ONAN/ONAF DOUBLE WOUND TRANSFORMER
HV : 230 + 16 x 0.625% kV OLTC.
IV : 115 kV / LV : 13.8 + 2 x 2.5% kV DETC
250 MVA AUTOTRAFO – FULLY DIRECTED
End user : TransPower New Zealand. (Energized 2005)

250 MVA ONAN/ODAF AUTOTRANSFORMER
HV : 220 + 8 x 1.25% kV OLTC.
IV : 114 kV / LV : 11 + 2 x 2.5% kV (capacitive load)
Fiber Optic Installation
Purpose :
To directly measure the Hot Spot temperature, fibre optics can be used to measure temperatures in
cores and tank walls - not only the windings of the transformer.

Infra Red Thermal Investigation
Typical Infra Red Thermal Check
To avoid local overheating

Extendable Plate type Water Cooler
Possibility to extend the cooler capacity at
site to reduce the transformer temperature

Why is Partial Discharge important for

transformer life time ???

Partial Discharge
Partial Discharge level will measure the activity of
electron discharging from the conductive materials
thru the dielectric medium. Inside the transformer, the
cellulose insulation and mineral oil are the dielectric
medium and this partial discharge will ionize their

hydrocarbon molecules.
High Partial Discharge Level will destroy the

hydrocarbon chains of the transformer insulation
and cause the electric breakdown ignition. When
there is moisture involved, the insulation
degradation rate will be much faster.
Six Categories Of Partial Discharges
Partial Discharge indicates the defects existence prior to
dielectric breakdown.
breakdown
1. Corona discharges occurs due to the sharp edge electrode.

2. Surface discharges (creepage) occurs due to overstress component

parallel to the dielectric medium surface.
3. Internal discharges occurs due to the non-homogenous dielectric
medium.
4. Electric trees due to the particle or cavity in the solid insulation.
5. Floating discharging occurs due to badly grounded component.
6. Contact noise occur in case bad contact terminal.
Optimized Oil Duct Thickness
The oil duct thickness has to not only provide reliable cooling
but has to provide electrical insulation. The diagram shows
how a smaller duct provides higher voltage strength per mm.

Equilibrium Of Moisture Content In Oil vs. Paper
Moisture Content In Paper [%weight]
The transformer is tested normally at less

than 5 ppm moisture content in oil
Moisture Content In Mineral Oil [ppm weight]

Oil Moisture Content vs Dielectric Strength
Power Freq. Withstand Voltage [%]
Moisture Content In Oil [ppm]

Paper Moisture Content vs Dielectric Strength
Power Freq. Withstand Voltage [%]
Moisture Content In Oil Impregnated Paper [%]

ENERGY IS OUR BUSINESS, QUALITY IS OUR MISSION Typical Of Low Partial Discharge

Discharging Circle Prior To Flashover
High Partial Insulation

Discharge Ionization
Insulation
weakening Gassing

CONCLUSION FOR MINERAL OIL XMER
Temperature limits;
The temperature limits and the type of overloading at particular ambient
temperature have to be indicated.
New class A cellulose paper covered conductor immersed in new mineral
oil will start gassing at hot spot temperature of 145oC.
Cooling system;
Fully directed cooling with pump is the most suitable for medium & large
transformer. The directed cooling with no pump can be used for cost
effectivenes consideration on small/medium transformer.
Conductor paper ;
The cellulose paper should have Degree Polymerization min. 950.
Low partial discharge product shall be performanced at factory test;
=> 40 pC up to 120% Voltage for 30 minutes.
=> 75 pC up to 150% Voltage for 30 minutes.
=> to monitor the partial discharge at induced level, 1min.

Doubled Capacity On Existing Foundation
End User : COMALCO ALUMINIUM SMELTER AUSTRALIA

168 MVA ODAF, 220 kV / 2.7 to 40.4 kV in 3 x 52 steps via 2 x OLTCs + DETC.
This was installed on existing foundation of a 110 MVA regulator .
FUTURE
FUTURE SOLUTIONS
SOLUTIONS ??

Hybrid Design
CALENDERED
KRAFT BOARD Angle Rings
and Caps
CALENDERED
KRAFT BOARD Support Washers
NOMEX® T-993 Static Rings

Creped NOMEX®
CALENDERED Cylinders
KRAFT BOARD
Conductor
NOMEX® T-410 Insulation
Axial & Radial

NOMEX® T-994 Spacers
PRECOMPRESSED Clamping Rings, Blocks

KRAFT BOARD

Hybrid Design – Engineering Transformer
97oC hot spot rise
Capacity = 12.5 MVA (ONAN)
Voltage = 115 + 1.4 / 21.5 kV
BIL HV/LV = 550 / 125 kV
Cellulose pressboard Vector group = YNd11
HV winding = Disc / PI 0.8 / ksp. 2.0

LV winding = Disc / PI 0.5 / ksp. 1.5
Cooling = ONAN in 10 radiators

Top oil rise = 57 K
Average HV rise = 62.1 K Cellulose insulated lead outs
Average LV rise = 70.1 K
Measured HV grad. = 25 K
Measured LV grad. = 33 K
Hot spot factor = 1.2
CASE STUDY – 30 MVA for PG&E
Built by Pauwels for Pacific Gas & Electric

Hybrid design Cellulose design Cellulose design
with same MVA with same MVA with same weight
Power (MVA) 45 45 31,5
Weight (T) 44,1 57,5 44,1
IZ (%) 19,1 10,0 10,0
No load losses 11,9 10 8

(kW)
Load losses 752 225 110

(kW)
Temperature 95 65 65
rises (K)

Hybrid Design In Mobile Transformer
Under Substation Installation

Hybrid Design In Mobile Transformer
Test Drive

DGA Report – Typical Hybrid design
The gas generation produced by Hybrid transformers
after temperature rise test at PAUWELS factory.
50 MVA, 161-115/13.8-34.5 kV, Inert air system, Nitro 10XT oil
Temperature rise test (8 hours) Increment Cellulose
Gas Symbol
Before After unit in ppm/hour Typical
Hydrogen H2 < 0.8 10.13 ppm 1.27 <2
Oxygen O2 0.96 0.77 % -
Nitrogen N2 2.15 1.61 % -
Carbon monoxide CO 7.17 9.40 ppm 0.27 <2
Carbon dioxide CO2 122.32 205.78 ppm 10.43 < 11
Methane CH4 1.75 2.01 ppm 0.03 < 0.25
Acetylene C2H2 0.08 0.11 ppm - < 0.25
Ethylene C2H4 0.11 0.10 ppm - < 0.25
Ethane C2H6 0.12 0.11 ppm - < 0.25
Future – Environmental Friendly Liquid
• Environmental liquid = Enviro-Temp FR3 by COOPER
• Inhibited oil = Nitro 10XT by NYNAS
Property – typical values Inhibited oil FR3
Antioxidant, phenols 0.08% per Wt n.a.

Oxidation stability by 120oC 500 hours continuous
Biodegradable in 21 days 25% 100%
Saturated moisture at 25oC 80 ppm 1200 ppm
Temp. rise for unity life time *) 60/65/78 K 80/110/130 K
Flash point 145oC 330oC
Pour point -57oC -18oC
*) Top oil/Average winding/hot spot rise (+ Hybrid design for FR3)
Water Saturation of Mineral oil vs FR3

Liquid Water Absorption versus Time Exposure
Water Absorption of Dielectric Fluids

Exposed to Ambient Air (2 of 2)
100
R e la tiv e W a te r C o n te n t ( % s a tu ra tio n )
Envirotemp FR3 fluid

conventional transformer oil
80
60
Water Absorption of Dielectric Fluids
Exposed to Ambient Air (1 of 2)
600
40
500
Absolute Water Content (ppm)

20
400
0
0 500 1000 1500 2000 2500 3000 3500 300
Exposure Time (hrs)

200 conventional transformer oil
100
0
0 500 1000 1500 2000 2500 3000 3500
100% Saturation =
Exposure Time (hrs)
FR3, 1200 ppm
Mineral Oil, 80 ppm

Liquid Dielectric Strength vs. Water Content
Dielectric Strength versus Water Content
80
70
D 1816 Dielectric Breakdown (kV)
60
50
40
30

20
conventional transformer oil
10
0
0 100 200 300 400 500 600
Water Content (ppm)

Partial Discharge Of FR3 Filled
Transformer

Prototype transformer filled with FR3
12/17 MVA, 33kV,ONAN/ONAF + provision for future ODAF

Measured PD = 25 pC max. at induced voltage level.
Liquid Main tank = Enviro Temp - FR3
(Hi-Temp natural – ester based 100% biodegradable)

Low partial discharge product ;
ÎAssists to increase a units life from overvoltage spikes
and prolongs oil quality
• Typical guaranteed partial discharge ;
9 75 pC at 150% Un, IEC 60076 500 pC at 150% Um
9 40 pC at 120% Un, IEC 60076 100 pC at 110% Um
• Typical achievement , by rating voltage = 220 kV (950 kVp BIL);
914 pC at 150% voltage.

927 pC at 200% voltage.
Dirrected cooling path ;
Î Assists life time expectation under overloading
conditions and suitable for Low noise requirement.
Compact design, safety and enviromental friendly;
Î Usage Hybrid design and Vegetable liquid to minimize
the land space required, less flammable risk and
enviromental friendly unit.
APPENDIX C
EPECENTRE ELECTRIC POWER R&D CAPABILITY
Page 92 of 94
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Guide to Power Transformer

Electric Power Engineering Centre, University of Canterbury

Published by Electric Power Engineering Centre (EPECentre), University of Canterbury

1st Edition 1, August 2007 [revised January 2008]

Electric Power Engineering Centre

T: +64 3 366 7001

Electric Power Engineering Centre -

GUIDE TO POWER TRANSFORMER

SETTING THE SCENE....................................................................................................................6

PART 1. FIRE & EXPLOSION PROTECTION ................................................................................7

PART 2.THE DETAILED DESIGN REVIEW ...................................................................................9

PART 3. TECHNICAL SPECIFICATION EXPERIENCES ............................................................11

APPENDIX A. REFURBISHMENT & REPAIR OF POWER TRANSFORMERS*…………………13

APPENDIX B. DRIVEN FACTORS FOR TRANSFORMER LONG LIFE** ………………………..30

APPENDIX C. EPECENTRE ELECTRIC POWER R&D CAPABILITY ......………………………..92

* Courtesy of Transfield Services Limited ©

** Courtesy of Pauwels Trafo Asia Limited ©

Tēnᾱ koutou te whᾱnau,

Nga mihi ki koutou mana, koutou korero, koutou whakaaro,

The power transformer technical specification workshop is

Australasia is currently most active in the processes

Associate, Electric Power Engineering Centre, University of Canterbury

Power Transformer Technical Specification

The peer review process: are our ideas good ones?

ABB, “Transformer Handbook”, ABB Power Technologies Management Ltd, 2004.

Refocus: Why Have a Technical Specification?

From an Employer (Client) perspective:

From a Contractor perspective:

For both Contractors and Employers (Clients):

To avoid relationship mishaps associated with costly Variation work misunderstandings.

The repair bill is significant.

AS2374.2-1997: “Power Transformers – This is an expensive and time consuming test.

AS2374.6 - 1994 “Power Transformers – 4. On-Load Tap-Changers on Generator

AS60214.2 – 2006 “Tap-changers, Application

The insulation is failing. ONAN/ODAF may be significantly more cost effective

steam and gas plant than hydro. All money and

specified for power transformers in the c) A generator step-up transformer connected to a

High velocity water spray system.

 Need to know in spec if employer wants

 Need employer to have expertise or a

Refer to AS60076.1 appendix A as a minimum

Guaranteed losses. Too prescriptive specs i.e. 'old school'

Corrosion protection. Too many standards.

Tank strength. Insistence on copper winding.

Noise level. Totally useless offload sufficient.

REFURBISHMENT & REPAIR OF POWER TRANSFORMERS*

* Courtesy of Transfield Services Limited ©

Conference- Christchurch,2-3 July 2007

Presented by – Ramesh Gopalan

Transfield Services Partners for Change

 General Principles of Refurbishment

Transfield Services Partners for Change

Transfield Services Partners for Change

 Power Transformers worldwide are ageing

Transfield Services Partners for Change

 Dry-out of core & windings using heat and vacuum

Transfield Services Partners for Change

DP Value % Life Left

1000 to 1400 100%

Source: Guidelines for the Life Extension of Substations, 2002 Update,

Transfield Services Partners for Change

1955 35 520 60% 30 80

1965 110 543 60% 30 70

Need to know in spec if employer wants

Need employer to have expertise or a

General Principles of Refurbishment

Power Transformers worldwide are ageing

Dry-out of core & windings using heat and vacuum

Repair should consider existing risk 0.600

Generally recommended to replace 0.400