Book - Post

Workshop On
Transformer
Residual Life
Enhancement
Presented By:
Er. Georg Daemisch - Germany

Mumbai - India
June 02 & 03-2014
Monday & Tuesday
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 Defect
Workshop On
Transformer Residual
Transformer Degradation
Detection of faults at incipient stage.
Estimation of Elapsed Life If not Residual Life.

Life Enhancement Residual Life Diagnosis and decision making on course of pre-emptive
corrective action will require:
Monitoring of several parameters.

Enhancement
History of operational problems and maintenance,
Mumbai design, process information and finger print.

Unfortunately, measured quantities often do not have a

June 02 & 03-2014 Presented By:
Er. Georg P. Daemisch-Germany
direct correlation with defects and ageing, decision
making will need deployment of:
Installation of high voltage distribution and transmission Trend analysis with prior data.
Monday & Tuesday equipment has increased significantly over the years due
to ongoing global demand for power as a result of
Signal processing and statistical tools.
Comparison with experimentally developed models.
proliferation of energy guzzling industries. As a result, the Expert Systems.

Terms: need to ensure the reliability as well as availability of

Registration Fee:
INR 25,000
All applicable taxes and levies will be payable extra at
current rates.
How to Register?
Please provide us the names of your candidates. We will
send you the invoice that will guide you through the
registration procedure.
Registration Cancellation
Cancellation requests received more than 14 calendar
days before the start of the workshop will receive a refund
minus 50% administration fee. Cancellation requests
received within 14 days prior to the start of workshop will
not be entertained.
Registration Fee will cover only:
Participation in the event
Tutorial Material
Refreshments & Lunch
Substitutions:
If you are unable to attend the workshop for which you
have registered, you may designate a substitute from your
organization.
Event Venue
Event will be held in a hotel. Venue address will be
intimated to registered candidates two weeks before event
date.
Event Cancellation
If for any reason the event is cancelled, our liability will be
limited to refund of the Registration Fee paid by you.
Academic Discounts
50% discount for candidates from academic institutions.
Team Discount
Register three or more individuals from your organization
at the same time and receive 50% off of the regular
workshop rate.
Government Discount
To allow employees of Federal, State and Local
Governments to take advantage of the unique learning
opportunities offered by these workshops, we offer a 50%
discount off of the regular workshop rate. Government
discounts cannot be combined with any other discount.
On-Site Registration
Please call or email to check seat availability.
25% extra payment.
Cash payment will be accepted.
Special Discounts
We feel that the registration fee should not be a barrier for
an otherwise deserving candidate to attend these
educative events. If you feel you are eligible for a discount
by virtue of any reason other than those specified above,
please contact us.
operation of power systems has achieved paramount
importance.
Complexity of a transformer:
You’ve any idea of the complexity of a transformer? In
searching for a fault, you’re searching for a needle in a
Transformers are among the most important and most haystack! Yes, we can help you find that needle!!
expensive components of power systems and their failure Core-80,000 SQM for 800MVA, 525kVA transformer.
can impose extraordinary high costs on plants, factories Copper-285 kilometers of copper wire.
and utilities of all descriptions. Insulation-10MT of paper; 40MT of Oil
4,500 SQM of Board.
This practical workshop provides knowledge on both the Structure - Frame and Tank-16,000 SQM core plate
theory and operation of power transformers. The course
surface.
will develop and enhance the understanding of what is Bushings.
involved in the maintenance of these essential Tap Changer.
components of the power systems, through the tips and Radiators.
tricks learnt and developed by some of the world’s pre- Fans.
eminent electrical engineers. Pumps.
It is critical that all personnel operating and working with
Transformer Ageing:
such equipment have a sound knowledge of their
Paper Ageing.
operational requirements and maintenance. At the end of
Oil Ageing.
this workshop, those who attended this workshop will
Ageing by Products.
have gained:
Importance of O2 & H2O.
Sources of H2O.
What are the objectives of transformer condition
Moisture in Paper vs Oil.
assessment?
Furan Compounds.
Minimize unplanned transformer outages
Degree of Polymerization.
Minimize outage time when an outage occurs
Estimating Ageing.
Minimize maintenance costs
Failure Ratio vs Probability of Failure.
Eliminate catastrophic faults.
Extend life of the asset.
Create and develop an adequate data base. Diagnostic Techniques:
Implement improvements to equipments for greater Dissolved Gas Analysis [DGA].
reliability. IEEE Reference Gas Levels.
Ratio of Gas Formation.
Transformers these days are subjected to severe stress as DGA Periodicity.
a result of continuous over-loading as well as extremely DGA Accuracy and Lab Deviations.
poor maintenance besides a host of other reasons. These
naturally accelerate the ageing process. As an Asset Oil Quality Analysis:
Manager, you naturally would want to know the residual life Reference Levels.
remaining of your asset. Moisture Content.
Dielectric Strength.
Do you believe the end of life of a transformer is brought Interfacial Tension.
about by the ageing of the equipment? Most likely, end of Power Factor.
life of a transformer can be brought about by escalating Neutralization Number.
local defects than to faults.
It is possible to run a transformer under a defect for short
Maintenance Criteria:
Corrective Maintenance.
or long periods depending upon the nature and severity of
Preventive Maintenance.
the defect. If appropriate measures are taken, it is also
possible to reverse some defects before they turn into
Reliability Centered Maintenance-RCM
Increased Reliability through Condition Assessments.
faults.
Managing and Extending life of Ageing Assets.
Complementing Existing Maintenance Practices for
Under a fault, it may still be possible to run a transformer
Better Understanding of Health of Fleet of Transformers.
for a short period of time before a failure occurred. If the
Statistical Comparison of Transformer Fleet to determine
deterioration is irreversible, you’ll have to resort to either
which transformers are most at Risk of Failure.
repairs or a replacement.
Replacement and Repair Recommendations to Optimize
Transformer Expenses.
You can prevent a total failure of your transformer if you’re
Avoiding Unplanned Outages through Reliability-Based
vigilant enough and avoid a degeneration of a defect
Maintenance.
resulting into a fault which in turn escalates into a failure.
Our experts will tell you how you can do this.
What Can Condition-Based Maintenance do for
What is Transformer Condition Assessment your transformers:
Improve Asset Utilization.
Process? Provide Actionable data to support decisions.
In short, following are the ingredients of a simple
Allow Capital Expenditure to be deferred.
assessment process:
Shift from Time-Based to Condition-Based Maintenance
Monitoring of stress and defect levels.
should reduce overall maintenance activity.
Estimation of extent of :
Proactive “as needed” maintenance-less time-based.
 Improve efficiency of maintenance activities.
Reduction in time required to complete maintenance on
equipment through better knowledge of equipment
condition.
Reduction in unplanned maintenance work.
Reduction in cost to collect condition data by manual
means.
Reduction of field equipment inspections.
Oil Treatment
Filtration
Oil Reclamation
Drying Method can be considered as any process that
reduces and maintains at a low level the material’s water
vapor pressure.
Purification or Reconditioning of insulating oil is the
process of removing moisture, dissolved combustible gas
and particulate matter, as determined by oil and
transformer’s tests.
Regeneration or Reclaiming of insulating oil is the
process of removal of contaminants and products of
degradation such as polar, acidic or colloidal material, as
determined by oil and transformer tests.
What considerations should be taken into account to
decide whether purification of reclamation is suitable for
your equipment will be dealt with in detail.
Normal vs Abnormal Operation.
Under normal conditions, a transformer should last for
more than 30 years. But they do not. We will examine in
great detail the causes for the premature death of the
transformer as well as corrective actions that can prolog
the life.
What constitutes Normal Operation and what will be
Abnormal Operation will be examined threadbare.
Abnormal conditions such as overloading, short circuits
and their impact on the normal life of a transformer will be
examined.
Oil Analysis.
Analysis of oil samples is the standard technique in the
electricity industry for monitoring the condition of oil filled
equipment. Samples are typically taken annually, with
more frequent sampling when there is a possible problem.
Analyses performed on the oil include:
Dissolved Gas Analysis-DGA
Color
Moisture Level
Acidity
Breakdown Voltage
Furaldehyde Content-FFA
In DGA, the gases usually considered are:
Hydrogen
Methane
Ehane
Ethylene
Acetyelene
Carbon Monoxide
Variations in the levels of individual gases, or ratios of
particular gases may indicate a problem with the
equipment. The situation is complicated by the fact that the
levels of dissolved gas measured can be affected by the
sampling technique and conditions, the laboratory
performing the analysis and the duration of sample
storage prior to analysis.
Authorities now agree that careless sampling and testing
techniques has been the source of 99% of “bad” dielectric
readings. What is the correct sampling procedure will be
explained in un-ambigous terms.
Transformer Operation and Loading:
Transformers are designed and tested to standards when
they leave the factory and are placed in service. The
transformers are loaded and operated based on the user’s
loading guide lines and maintenance practices.
We’ll highlight how to load and operate transformers by
reviewing factory thermal data and asset health to
determine the loading factor.
We’ll also discuss how to load legacy transformers and
how to be certain your new transformers are meeting your
requirements.
Field Processing of Power Transformers. Maintenance Programs:
Whether due to atmospheric contamination or the by-
Basic Maintenance:
products of ageing, the water content of the transformer To ensure that a transformer operates reliably, it is
will increase with age. At some point, it may be desirable to important to do routine maintenance when the unit is in
remove this moisture as well as any particles from the service. The basic maintenance will include visual
transformer. We’ll discuss in detail the pros and cons of inspections, checking silica-gel status, checking oil
different methods of field processing of transformers. leakages, checking cleanliness of bushings, checking
pumps, fans, motors and other accessories. This will not
What happens to ageing Dielectric Oils? need an expert; only basic transformer knowledge will be
sufficient.
The transformer's insulation is the root of the problem. Its
two components, oil and cellulose paper, interact to create
by-products that decompose the insulation system. Not Advanced maintenance:
only that, the byproducts will increase moisture levels and Advanced Maintenance Program offered will include oil
create an environment that will overheat the transformer, cleaning, active part cleaning and drying, and re-clamping
which will eventually cause the transformer to fail. of the windings.
You must first understand the problem before you can
treat it. In the presence of a catalyst, such as copper, Monitoring:
oxygen will react to form those byproducts that attack the If a unit is found to be in a critical condition but still usable,
transformer's insulation paper. Ironically, paper has an it may be recommended to instal a suitable monitoring
affinity for the very by-products that contribute to its device. This will help to detect potential faults as well help
destruction, compounding the problem. In time, further the customer to effectively plan their maintenance for
reactions will create other destructive byproducts like optimization of performance of the equipment.
acids, alcohols, and sludge. After saturating the paper, Transformer accessories such as tap changer and
these byproducts will precipitate out and contaminate the bushings should also be monitored. The output from the
oil. installed monitoring device will give an indication when
such maintenance or repairs will have to be undertaken.
Inhibitor
Transformer oil often includes an inhibitor additive, which
aids in the resistance of oxidation. The reclamation
process can remove inhibitor, so during the last pass it's
important to add it back as the oil leaves the HORP rig and
returns to the transformer.
Contamination is the major cause of transformer oil
About Er Georg P.Daemisch
breakdown and subsequent transformer failure. Water and Managing Director
particulate contamination challenge the effectiveness of Daemisch Transformer Consult
dielectric properties to maintain minimum 33KV Regensburg-Germany.
performance to assure expected device life and service daemisch@t-online.de
reliability. Water is the acid enabling mechanism that
reduces TAN [Total Acid Number]. Particulate Georg is an internationally acclaimed expert on Transformer
Residual Life Management as well as Transformer Population
contaminates decrease IFT [Interfacial Tension] and Power Management.
Factor. Oil color testing is directly related to particle
contamination. He has an intimate knowledge of the causes of premature aging of
It is a proven fact that the moisture accumulated in a transformers and has specialized in the diagnosis, treatment and
prognosis aspects. He has published several scholarly articles on
transformer`s cellulose insulation causes it to age the geriatrics of transformers and is a regular speaker at
prematurely. A moisture content that goes from an initial EuroTechon. Throughout the world, he has conducted workshops
factory level of 0.5% to 2.0% after a few years in operation on the ageing of transformers and trained several hundreds of
will cause a ten-fold increase in the ageing of the cellulose engineers and technicians to equip them with necessary skills for
insulation. deriving better reliability, availability and efficiency. Please visit
www.didee.de to know more about his background, achievements
When the moisture content is high, the concentration of and capabilities.
dissolved water in the oil increases proportionately,
thereby potentially compromising the dielectric strength
of the oil. As the dielectric oils age, you are likely to
experience any or all of the following:
Considerable decrease in Break Down Voltage.
Considerable decrease in Insulation Resistance.
Increase in Dielectric Loss Factor.
Conditioning will eliminate:
Solid Impurities.
Dissolved Water.
Dissolved Gases.
Conditioning will Improve:
Break Down Voltage.
A dehydrator makes it possible to lower the moisture
content to standard levels, thereby increasing the
transformer`s service life. Conditioning saves the cost of
using new oil frequently and also increases the useful life
of the transformer.
Even commercial oil is seldom sufficiently pure for direct
use in high voltage equipment, being subject to
contamination in transport container and very liable to
absorb unacceptable contaminants and moisture.
Indeed, an exhaustive analysis of the insulating oil will
throw a lot of light on the ailments of the transformer as a
whole. However, treating the oil alone for its problems will
not result in the effective treatment of the transformer as a
whole.
In short, attempt should be made to treat the entire
transformer and not the oil alone. This approach insures
enhancement of transformer life by several years and
reliable performance.
Extract reproduced from Bahrain
Petroleum Refinery House Magazine:
A training workshop was held for 50 employees from
Electrical Maintenance and P&U Engineering last month.
The workshop sessions, held from October 18 to 22 and
organized by Plant Maintenance Department's Electrical
Maintenance Section, covered the topic of Transformer
Residual Life Enhancement, and was provided by U.K..
based Power Consultancy, led by Chief Consultant Georg
P. Daemisch, an internationally acclaimed expert on
Transformer Residual Life Management, plus two other
recognized experts in the respective fields of Transformer
Measurements and Transformer Cooling. Manager-Plant
maintenance Mahmood Mirza spoke at the start of the
workshop, which was facilitated by Superintendent-
Electrical maintenance Andy Doherty along with Thaslim
Kaja and K. N. Abdul Jabbar from Power Consultancy U.K.
The sessions consisted of two day workshops held at the
training center and a one-day on-site training session at
the LSFO Substation.
Bapco Refinery has a fleet of over 300 oil-filled
transformers. The continuous availability of these
transformers is crucial to the safe and reliable operation of
the Refinery's Power Plant, Oil processing Units, Oil
Storage and Export facilities, and ancillary services such
as Refinery Clinic, Security Building, Finance & Admin,
Maintenance Workshops, Engineering Building, Training reliability-centred maintenance when applied to power
Center, Cafeteria and Awali. Many of these essential transformers.
assets have reached or passed their manufacturer's
stated life expectancy, however such transformers are This training workshop was a first for BAPCO In this
often still in good condition physically and can often last subject field, and the consultants expressed their
for decades more. appreciation of BAPCO's world-class preventive
maintenance programs for all its high-voltage assets.
Paramount to maintaining transformer long life is a
managed program of condition assessment. An essential
factor in the condition assessment process is the ability
of Maintenance staff to understand the tell-tale signs of
aging and degradation of the transformers. Of equal
importance is their ability to distinguish the fundamental
aspects of corrective, preventive and condition-based
maintenance as well as understand the concepts of

Transformer Fault Finding
Any fault that impairs the proper functioning of a
transformer must be expediently identified
and rectified. Incorrect decisions would result
in further damage to the transformer and
inevitable increase in the cost of repairs and
extended downtime. Decisions making is often
invested into operational or maintenance
personnel with limited fault diagnostic skills.
This course explains main causes of
transformer failure, types of faults that may
occur, as well as the types of tests and their
application in a fault finding process. Through
a number of case studies, it provides guidance
on how to interpret the test results. This
course will improve the diagnostic skills and to
enable the attendees to make informed
decision for appropriate corrective action.
Learning outcomes:
Understand the main causes of transformer
failure, examine various types of faults and their
effect on transformers and learn how to
diagnose them.
Understand what are the various types of
tests, what is their purpose and their
application in a fault finding process.
Learn how to interpret the test results to
identify a probable cause of failure and make
informed decisions on the appropriate course
of action.
Discuss a number of case studies to learn
how to practically apply the knowledge
obtained during this course.
Transformer Testing and Oil
Analysis.
From manufacturing to decommissioning,
transformers undergo a variety of tests that
are appropriate for various stages of
transformer life cycle. Oil deteriorates with
time and the aging process may be accelerated
by a number of factors. The oil itself can be
used as a diagnostic tool to monitor the
condition of transformer interior and allow
timely corrective action to extend
transformer's life. This course discusses
various types of testing and their applications.
It covers detailed testing procedures, what
kind of testing is available to monitor the state
of oil and paper and how to interpret the test
results in order to make a decision for
appropriate corrective action. Through a
number of case studies, it provides guidance
on what are the key parameters that should be
checked during testing and what kind of
results should be expected.
Learning outcomes:
Understand the various types of tests, what
is their purpose and application. better understand their options and GVK Power Plant
Learn a number of procedures for electrical requirements in order to make purchasing Government Bank Note Press
testing used during factory testing, decisions that would give them the best return Gujarat Electricity Board
commissioning and maintenance. for their investment. This course is focusing Himachal Pradesh Electricity Board
Explore various oil tests and how to interpret on technical and economic issues that should Hindalco Industries Limited
their results to make decisions regarding be considered before purchasing a Hirakud Power Station
transformer serviceability and which transformer. Transformer specification must Hospet Steels Limited
corrective measures to apply. be compiled to ensure that all performance Indian Institute of Technology
Discuss a number of case studies to learn requirements are met but also to allow Indian Metals and Ferro Alloys Limited
how to interpret the test result data. manufacturers to offer the best design and Karnataka Power Transmission Corporation
most cost effective solution. Guidelines for KRIBHCO Fertilizer Limited
Transformer Operation and planning transformer installation and ensuring Madukkara Cement Factory
Maintenance. optimum operating conditions are also Monnet Ispat Limited
Modern transformers are much more efficient, advised. National Hydro Electric Corporation Limited
Neyveli Thermal Power Plant
but much less robust than they were half a Learning Outcomes: NSaria-Iran
century ago. The best policy against Identify key aspects of transformer planning,
transformer failure is to ensure that they are Tenga Nasional Bhd-Malaysia
installation and procurement and learn how to Power Grid Corporation of India Limited
properly operated and maintained. For all provide adequate input into transformer
practical purposes transformer life expectancy Punjab State Electricity Board
specification and design. Orient paper Mills Limited
beyond 20 years significantly depends on the Become familiar with transformer design,
quality of maintenance applied to it. basic components, transformer terminology
Rayalaseema Thermal Power Plant
This course is focusing on critical issues that Reliance Energy Limited
and materials that are used in the Reliance Industries Limited
should be considered in establishing good manufacturing of transformers.
operating practices and implementing an Renukoot Power Station
Learn how to calculate and specify critical Renusagar Power Station
effective transformer maintenance program. It design parameters, components and fittings,
provides very practical guidance for Saurashtra Cement Works
how to choose appropriate transformer type, Sirpur Paper Mills Limited
maintenance scheduling, operational and cooling system etc.
testing procedures to achieve long service life Spectrum Power Limited
Understand transformer losses and TATA Power Limited
of power and distribution transformers. efficiency, how they impact on the total cost of
TATA Steels Limited
owning a transformer and how to evaluate the Vardhaman Steel Limited
Learning outcomes: bidders based on this total cost. Vijayawada Thermal Power Plant
Learn about transformer construction, Understand the purpose and objective of a West Bengal Power Development Corporation
transformer specification and what aspects of
critical transformer parameters, operating Konaseema Thermal Power Station
conditions and how to control aging installation, transformer testing and service Kothagudem Thermal power Station
conditions need to be specified
accelerators to ensure long life of Prai Power Station-Malaysia
transformers.
Understand underlying causes of Customer List-Partial
transformer failures, how to investigate and Customer List-Partial Dedicated On-Site Workshops
prevent failures through various testing
General Workshops Saudi Electric Company
techniques and how to interpret test data. Shuweihat Theraml Power Plant-UAE
Explore various maintenance strategies, ABB
Andhra Pradesh State Electricity Board Dubai Electricity & Water Authority
technical and organizational aspects of Bahrain Petroleum Refinery
maintenance and maintenance activities that Andhra Pradesh Power Transmission
Corporation Limited Bahrain Aluminum Limited
would ensure an effective transformer Durgapur Steel Plant
maintenance program. AREVA
Atomic Power Station-Kalpakkam Madras Aluminum Limited
Discuss testing procedures, various case National Aluminum Company Limited
studies and a typical maintenance schedule Badarpur Thermal Power Station
Balasore Alloys Limited
through an interactive workshop.
Bhakra Beas Management Board
Bhutan Ferro Alloys Limited
Contact
Bhutan Power Corportion
Transformer Design Bhutan Carbides and Chemicals Limited
Jagdish Sandhanshiv
Planning, Installation and Birla Cement Factory Mob : +91 9867976570
Carborandum Universal Limited
Procurement. Chennai Petroleum Corporation
Email : jagdish@kcluster.com
Purchasing, operating and maintenance Chukkah Power Station Skype : jagyamanmad
decisions must be made in order to spend the Electro Steel Castings Limited
least amount of money while still yielding the EMCO Transformers Limited
most performance of a unit. However the ESSAR Power Limited
KNOWLEDGE CLUSTER PVT LTD
lowest cost option up front often results in a ESSAR Steel Limited FB - 31, First Floor, Highland Corporate Centre,
highest cost option over time. Utilities have to GMR Power Plant Kapurbawadi, Thane West, India 400607
better understand their options and GMR Ferro Alloys Limited www.kcluster.com