24th International Conference & Exhibition on Electricity Distribution (CIRED)

12-15 June 2017

Session 1: Network components

Managing on-load tap changer life cycle in

tenaga nasional berhad (TNB) distribution
power transformers ISSN 2515-0855
doi: 10.1049/oap-cired.2017.1308
www.ietdl.org

Young Zaidey Yang Ghazali ✉

Asset Management Department, Tenaga Nasional Berhad, Petaling Jaya, Selangor, Malaysia
✉ E-mail: young@tnb.com.my

Abstract: TNB has developed an asset management framework in accordance with ISO 55001:2014. One of the key
elements of the framework is the asset life cycle management. This study presents TNB experience in managing the
on-load tap changers (OLTC) over their complete lifecycle to improve performance and reliability. Using failure mode,
effect and criticality analysis based on the previous failure data, lifecycle management strategies for OLTC have been
identified. It covers the main activities over the lifecycle stages namely design, operation and maintenance. Adoption
of new technology in the design, enhancement in condition assessment and effective implementation of condition-
based maintenance were amongst the strategies implemented. Finally, these strategies were validated through field
evaluation and lifecycle cost analysis prior to the successful implementation throughout TNB.

1 Introduction condition of such phenomenon may result in excessive arcing that

Presently, there are 1260 power transformers rated up to 33 kV with
on-load tap changer (OLTC), installed in TNB medium-voltage
distribution network with capacity ranging from 7.5 to 30 MVA.
About 70% of the power transformers and their respective OLTC
are aged between 15 and 25 years. Out of the total population,
95% of the OLTC is of in-tank oil-immersed selector switch type
with transition resistors or also known as oil-switch-type OLTC as
shown in Fig. 1, which combines both functions of tap selector
and diverter switch in one oil-filled compartment. The typical
number of tap change operation of the OLTC in TNB distribution
ranged between 2000 and 5000 tap change per year.
Most power transformers studies indicated that the main cause of
power transformers failures is the OLTC [1] since it has mechanical
parts that are in constant movement. In TNB distribution network,
there are seven cases involving permanent damage of OLTC since
2005. In most failure cases, it has caused prolonged power
interruption, often due to severity of damage and timely
replacement, as the result of unavailability of spares and
incompatibility with the existing design. The root causes of
failures are often attributed to degradation and carbonization of oil
as well as contact problems as illustrated in Fig. 2.
During normal tap change operation, switching arcs occur in oil
due to the making and breaking of currents. These arcs cause
degradation and carbonization that contaminate and reduce the
dielectric strength of the oil [2]. The carbonization over time
causes accumulation of carbon deposits on the surface of the
fiberglass cylinder that resulted in the formation of electrical
treeing (Fig. 3).
Without proper maintenance, the electrical treeing develops into
tracking and finally phase-to-phase arcing in OLTC. This is the
common mode of failure found in most of the cases resulting in
the permanent damage of the OLTC involved. On the other hand,
coking or low conductivity film buildup was often observed on
fixed and roller contacts during OLTC maintenance. This film
consists of layer of pyrolytic carbon formation that bond to the
oxide layer, which was formed as the result of surface oxidation of
the contacts [2]. In some cases, coking has led to erosion or
contact ware and pitted marks can be visibly observed. This
occurs as the result of continuous overheating, as coking worsen
over time due to increased contact resistance [3]. Prolonged
could trip the transformer protection (Fig. 4).
Realising the needs to reduce the risk of OLTC failures, asset
management strategies for OLTC have been proposed and
implemented over its complete lifecycle. Thus, this paper
describes TNB approach and experience in managing the lifecycle
of OLTC in distribution power transformer to improve its
performance and reliability.
2 Failure mode effect and criticality analysis
(FMECA)
FMECA as shown in Table 1 has been used to determine the most
appropriate asset lifecycle management strategy for OLTC based
on the actual findings on OLTC failures [4]. FMECA evaluation
on other components of the OLTC such as motor drive and oil
surge relay are not discussed in this paper since severity of failure
of these components are still low. In addition, these components
follow the standard design based on the manufacturer and type of
OLTC. Furthermore, the operation and maintenance requirement of
these components only involve visual inspection and functional
check, which are very minimal.
3 OLTC lifecycle management strategies
The complete lifecycle of an asset in accordance with asset
management requirements of ISO 55001:2014 is illustrated in Fig. 5,
where the activities at every stage of the lifecycle are also shown.
Based on the FMECA in Table 1, TNB has identified the key
activities at various lifecycle stages that can contribute to mitigate
the causes of failure and improve the performance and reliability
of power transformers as a whole. The lifecycle management
strategies for OLTC based on these key activities are further
discussed in the following subchapters.
3.1 Improving design and specification
3.1.1 Adoption of vacuum switch OLTC to mitigate the
degradation and carbonization of oil in the OLTC

CIRED, Open Access Proc. J., 2017, Vol. 2017, Iss. 1, pp. 303–307
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Fig. 1 In-tank oil-immersed selector switch type OLTC with transition
resistors used in TNB distribution
Fig. 2 Root cause analysis of typical OLTC failures in TNB distribution
power transformers
Fig. 3 Formation of electrical treeing on the cylinder’s surface transition
resistors used in TNB distribution resulted in tracking and arcing between
phases
Fig. 4 Erosion and pitted marks on the roller contacts (left) as well as
carbon buildup on the fixed contacts (right) were observed during
maintenance
304 This is an open access article published by the IET under the Creative Commons
compartment as well as coking of arcing
contacts: Degradation and carbonization of oil as described
above are the most common causes of failure that has resulted in
failure and permanent damage of the OLTC. In order to mitigate
this problem, TNB has adopted the use of vacuum switch OLTC,
shown in Fig. 6, that confines switching in interrupted vacuum
bottles. As the results, this helps to prevent contamination of oil
due to carbonization and hence lower the rate of oil degradation
due to switching arcs. Furthermore, with the absence of oil inside
the vacuum switch, formation of low conductivity film and
deposition of carbon that lead to coking on the contacts’ surface
will no longer occur. With the arc quenching property of the
vacuum switch, contact erosion and thus contact wear is
minimised and thus reduces maintenance costs. Prior to the
adoption of the use of vacuum switch type OLTC in 2011, a field
trial was conducted in 2007 to evaluate its performance.
3.1.2 Adoption of free maintenance self-dehydrating
breather to mitigate the degradation of oil in the OLTC
compartment: Degradation of oil in the OLTC is not only
influenced by the switching arcs that occur due to making and
braking of currents during on-load tap change operation, but also
affected by the presence of moisture in the oil. Even with the use
of vacuum switch type OLTC, moisture can still be presence due
to leakage or in most cases due to lack of maintenance of the
OLTC dehydrating breather (Fig. 7).
In order to mitigate this problem, TNB has adopted the use of
maintenance free self-dehydrating breather as depicted in Fig. 8.
The breather has a heating element mounted within the container
to heat the desiccant at selected intervals with temperature sensor
to monitor the correct operation of the heater. A moisture sensor
measure the humidity of the air to ensure only dehydrated air goes
through the piping into the OLTC conservator. Both sensors are
controlled by an electronic controller. The condensed moisture
formed on the surface of the container will be expelled outwards
by gravity. A field trial on the use of the self-dehydrating breather
was conducted in 2007 prior to its adoption in 2011.
3.1.3 Lifecycle cost analysis: Prior to the adoption on the use
of vacuum switch type OLTC together with maintenance free
self-dehydrating breather, a lifecycle cost analysis (LCCA) over
the expected transformer life span of 40 years is performed to
validate and compare the net present value of the total lifecycle
cost of using vacuum switch type OLTC together with
self-dehydrating breather, and the oil switch type OLTC. The
LCCA of the two systems shown in Table 2 reveals that the use of
vacuum switch type OLTC together with self-dehydrating breather
could generate saving of more than RM 600,000 a year for the
entire transformer population, not including saving on the
avoidance of loss revenue due to OLTC failure.
3.2 Enhancing methods for condition assessment
The adoption of vacuum switch OLTC is only applied for the new
power transformers. Therefore, for the existing in-service power
transformers, emphasis is given on the utilisation (operation) and
maintenance lifecycle stages which are discussed below.
3.2.1 Condition assessment using oil quality analysis to
detect degradation of oil in OLTC: The implementation of
the condition assessment for OLTC by means of oil quality
analysis involved breakdown voltage and moisture content has
started since 2007. Table 3 summarises the oil quality indicator
limits used for OLTC.
3.2.2 Condition assessment using dissolved gas analysis
(DGA) to detect coking of contacts: DGA has been applied
to assess the condition of the OLTC since 2007. However, the
health condition of the OLTC then was not truly understood due
to unavailable guide for interpretation of DGA results. In 2011,
with the issue of IEEE Std. C57.139-2010 [5], a more enhanced
condition assessment method using DGA data was formulated to
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Table 1 FMECA based on common findings of OLTC failures
Failure mode Failure effect S Failure cause Failure mechanism Failure consequence P C

arcing between † permanent tracking H degradation and tracking as the result of accumulation of transformer trip by H H
phases on fibreglass cylinder carbonisation of oil carbon deposits on the surface of protection relays
† damage of metal cylinder
parts
excessive arcing † damage of contact M coking of contacts overheating due to increased contact transformer trip by M M
between contacts † contact wear off resistance protection relays

Note: S = Severity of failure, P = Probability of failure, C = Criticality, H = High, M = Medium, L = Low.

Fig. 8 Use of maintenance free self-dehydrating breather

Fig. 5 Lifecycle activities of an asset

Table 2 Comparison of the net present value of the total lifecycle cost
over the life span of 40 years per OLTC system

OLTC system Initial cost, Operation and Total

RM maintenance lifecycle
cost, RM cost, RM

oil switch type OLTC 160,814.00 69,652.23 230,466.23

and conventional
breather
vacuum switch type 196,145.00 15,198.46 211,343.46
OLTC and
self-dehydrating
breather

Table 3 Condition indicators for OLTC oil quality analysis

Fig. 6 Vacuum switch type OLTC used in TNB distribution power Property Limits
transformers
Good Fair Poor Bad

breakdown voltage, kV >50 40–50 30–39 <30

water content, ppm <15 15–30 31–45 >45

type OLTC in accordance with IEEE Std. C57.139-2010

Fig. 7 Lack of maintenance of silica gel in the dehydrating breather of the
OLTC
interpret the health condition of the OLTC. The statistical model
used follows the method described in Annex B of IEEE Std.
C57.139-2010 to determine two types of condition indicator limits
i.e. gas concentration and gas ratio limits. The model was initially
based on DGA data up to the year 2011 taken from 503 units of
oil-immersed selector switch type OLTC classified as ‘ARAB’
classification scheme.
The gas concentration limits is defined in terms of a statistical
outlier limit identifying extreme values of gas concentration
suspected to be the results of faults or unusual stresses. The gases
that are used as indicators to discriminate between normal and
faulty conditions are C2H2, C2H4 and CH4 together with the sum
of CH4, C2H6 and C2H4 called the total dissolved heating gases.
The upper outlier limits U1, U2 and U3 were calculated for each
set of gas concentration data. U3 is introduced to represent the
extreme values requiring the highest attention (U3 = Q3 + 4.5IQR
where Q3: third quartile, IQR: interquartile range). Table 4
summarises the gas concentration limits for OLTC.
The gas ratios that are used as indicators to discriminate between
normal and faulty conditions are C2H4/C2H2 and TDHG/C2H2. The
gas ratio values of non-faulty OLTC operating under normal

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Table 4 OLTC gas concentration limits
Concentration, ppm Condition codes

Generic CH4 C2H4 C2H2 TDHG

C ≤ U1 C ≤ 2083 C ≤ 3522 C ≤ 14598 C ≤ 7000 normal (1)

U1 > C ≤ U2 2083 > C ≤ 3254 3522 > C ≤ 5569 14,598 > C ≤ 23004 7000 > C ≤ 11029 caution (2)
U2 > C ≤ U3 3254 > C ≤ 4423 5569 > C ≤ 7617 23,004 > C ≤ 31410 11,029 > C ≤ 15058 warning (3)
C > U3 C > 4423 C > 7617 > 31410 > 15058 danger (4)

Note: C = gas concentration.

Table 5 OLTC gas ratio limits Table 6 gives the overall interpretation to facilitate the
understanding on the condition of the arcing contacts based on the
Ratio Condition codes results of the gas concentrations and ratios.
Table 7 compares the outcome of the DGA results on 745 units
Generic C2H4/C2H2 TDHG/C2H2
of OLTC interpreted using the above method with the same
R ≤ C090 R ≤ 0.378 R ≤ 0.684 normal (1) DGA results using the Duval’s triangle method for load tap
C090 > R ≤ C095 0.378 > R ≤ 0.480 0.684 > R ≤ 0.843 caution (2) changers [6].
C095 > R ≤ C099 0.480 > R ≤ 0.743 0.843 > R ≤ 1.234 warning (3)
R > C099 R > 0.743 R > 1.234 danger (4)

Note: R = gas ratio.

3.3 Effective implementation of condition-based
maintenance

Based on the enhanced condition assessment method above, an

Table 6 Interpretation of DGA results for OLTC
overall health condition of the OLTC is derived as shown in
Table 8 that provides recommended actions for mitigations as
Results Interpretation tabulated in Table 9.
Based on the health condition and recommended mitigating
Condition Condition actions, more effective maintenance planning can be executed
codes indicator
where maintenance work can now be prioritised according to the
R = 1 and C ≤ 2 good † normal OLTC operation criticality of the OLTC condition as shown in the example given
R = 1 and fair † light coking or deterioration of arcing in Table 10.
2<C≤4 contacts, or The assessment was validated through visual inspection of the
† unusually high frequency of tap OLTC condition. Fig. 9 shows typical observations found during
change operation or high load current
causing heating of transition resistors maintenance. Validation of the assessment was also carried out by
1 < R ≤ 3 and poor † coking or increased deterioration of means of dynamic current measurement using dynamic winding
2<C≤4 arcing contacts resistance technique and it is discussed elsewhere [7].
R = 4 and bad † heavy coking or severe deterioration
2<C≤4 of arcing contacts

Table 8 Overall health condition of the OLTC

Overall health Oil quality analysis results

condition
Table 7 Comparison on the number of problematic OLTCs detected
using TNB condition assessment method derived from IEEE Std. Good Fair Poor Bad
C57.139-2010 and Duval’s triangle for OLTC
DGA results good 1 2 3 3
Fault identification TNB OLTC OLTC Duval’s fair 2 2 3 3
assessment triangle poor 3 3 3 4
method method bad 3 3 4 4

total no. of possible faults 59 55

detected
no. of severe thermal faults with 41 22
moderate or heavy coking
no. of thermal faults in progress 18 33 Table 9 Recommended mitigating actions based on the overall health
with light coking or heating of condition of the OLTC
transition resistors
Condition Condition Recommended actions
codes indicator

1 normal continue oil sampling at 12 month

conditions are described by the percentiles of the lognormal interval
distribution representing the non-outlier gas ratios. The gas ratio 2 caution continue oil sampling at 6 month interval
limits calculated for the study are based on 90th (C090), 95th 3 warning inspect for leaks and condition of silica
gels. Conduct internal inspection on
(C095), and 99th (C099) percentiles of the lognormal distribution arcing contacts. Perform overhaul and
with significance level of 0.1, 0.05 and 0.01, respectively. Table 5 replace oil
summarises the gas ratio limits for OLTC. 4 danger inspect for leaks and silica gels’
It should be noted that the ratio limits in Table 5 are applied only condition. Possible replacement of arcing
contacts. Perform overhaul and replace
when any of the gas concentration has reached ‘warning’ limit or oil
‘condition 3’ in Table 4.

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Table 10 Example of maintenance planning sheet based on the criticality of the OLTC health condition
State Site TX TNB OLTC assessment Duval’ s triangle method DGA Oil Health
no. quality condition

selangor commerce T1 heavy coking or severe severe thermal fault (T3) bad bad danger
square deterioration of arcing contacts heavy coking
selangor commerce T2 heavy coking or severe severe thermal fault (T3) bad bad danger
square deterioration of arcing contacts heavy coking
selangor proton T2 heavy coking or severe severe thermal fault (T3) bad bad danger
deterioration of arcing contacts heavy coking
selangor taman T2 coking or increased deterioration fault T3 or T2 in progress or severe arcing D2 (X3) bad bad warning
berjaya of arcing contacts light contact or increased contact resistance
klang
selangor labur bina T1 heavy coking or severe fault T3 or T2 in progress or severe arcing D2 (X3) bad poor warning
deterioration of arcing contacts light contact or increased contact resistance
selangor subang T2 heavy coking or severe fault T3 orT2 in progress or severe arcing D2 (X3) bad poor warning
jaya TC deterioration of arcing contacts light coking or increased contact resistance
selangor taman T1 coking or increased deterioration fault T3 or T2 in progress or severe arcing D2 (X3) bad poor warning
berjaya of arcing contacts light coking or increased contact resistance
klang

have been identified for the implementation of the lifecycle

strategy, which includes design, operation and maintenance of
OLTC. Finally, validation through field evaluation and LCCA was
performed to evaluate for technical and economic feasibility of the
proposed technologies and methodology, prior to the successful
adoption of all the strategies throughout TNB since 2011.

Fig. 9 Surface erosion with pitted marks and coking of the roller contacts
(left) and carbon deposits on the cylinder (right) were observed during OLTC
maintenance at several sites
4 Conclusions
Managing asset lifecycle is the main focus of asset management
system starting from the creation of the asset, utilisation,
maintenance up to its retirement. Thus, each aspect of the lifecycle
activities must be strategised to optimise the usage of the asset and
to strike a balance between cost, risk and performance of the asset.
This paper has presented all possible mitigating actions that have
become the OLTC asset management strategy at various stages of
its lifecycle. Based on the FMECA, three main lifecycle activities
5 References
1 Jongen, R., Morshuis, P., Smit, J., et al.: ‘A statistical approach to processing power
transformer failure data’. CIRED 19th Int. Conf., Paper 546, 2007
2 Erbrink, J.J., Gulski, E., Seitz, P.P.: ‘Advanced on-site diagnosis of transformer
OLTC’. IEEE Int. Symp. on Electrical Insulation, 2008, pp. 252–256
3 Erbrink, J.J., Gulski, E., Smit, J.J.: ‘Condition assessment of OLTC using dynamic
resistance measurements’. Int. Conf. on HV Engineering, 2010, pp. 433–436
4 BS 5760-5: ‘Guide to failure modes, effects and criticality analysis (FMEA and
FMECA)’
5 IEEE Std C57.139: ‘IEEE guide for dissolved gas analysis in transformer load tap
changers’, 2010
6 Duval, M.: ‘The Duval triangle for load tap changers, non-mineral oils and low
temperature faults in transformers’, IEEE Electr. Insul. Mag., 2008, 24, (6),
pp. 22–29
7 Shahril, M., Hanum, Y., Zaidey, Y., et al.: ‘Diagnosis of OLTC via Duval triangle
method and dynamic current measurement’, Proc. Eng., 2013, 68, pp. 477–483

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