MYTHS & FACTS

ON DIAGNOSTIC TESTS ON ELECTRICAL INSULATION

ASHESH PADHY
15 April 2019, Butibori
 Myth - 1
Megger value of the motor
is 10 M Ohm. Hence, Motor
Insulation is good.
 INSIGHT INTO DEGRADATION MECHANISM
Mechanisms which govern life of insulation are -

TYPE OF INSULATION MATERIALS

• Resin-Rich
• Resin-Poor / VPI

OPERATING STRESSES

• Thermal Stress
• Electrical Stress
• Mechanical Stress
• Chemical Stress

UNFORESEEN RANDOM STRESSES

• DOL Starting
• Steep-fronted Switching Over-voltage
 REVIEW OF INSULATION SYSTEM

MICA in form of thin

INSULATION flakes or paper

BACKING OR since mica has poor

SUPPORTING mechanical strength
MATERIAL

Bitumen / Shellac /
BONDING
Asphalt (class B),
MEDIUM
Epoxy resin (Class
F), Glass tape (Class
H)

Backing and bonding materials being thermoplastic soften at high temperature.

MICA swells, cracks, deforms giving rise to PD.
In new system, SYNTHETIC EPOXY is used as the Backing Material &
SYNTHETIC RESIN as Bonding Agent for HV Mica Insulation.
• Resin Dip – RESIN RICH SYSTEM
• Resin with VPI – RESIN POOR SYSTEM

Straight portion of the Bar is coated with a Conductive Paint for effective
conduction of Capacitive Currents in insulation to Ground.

The Overhang portion is provided with

a Stress Grading Paint for achieving
Uniform Distribution of Voltage at the
end of coil and hence to suppress the
surface discharges.
Failure mechanism of Thermoplastic (asphalt-mica) are -

• Crack in insulation because of Mechanical Stress (caused by short circuit

current, thermal expansion & contraction of conductor, vibration); insulation

becomes brittle & develops cracks, followed by electrical breakdown.

• Migration of the asphalt compound when operating temp reaches the

flow point of the asphalt. This leaves space occupied by asphalt a void,

subject to localized interior corona.

Failure mechanism of Thermosetting (polyester-mica or epoxy-mica) is

• generally governed by vibration due to looseness in the slots.
• also prone to developing loose wedges and slot discharge, especially in
Newer epoxy-mica, because the "hard“ nature of the insulation system does
not mold itself to fit the slot as the old asphalt-mica system did.
 ELECTRICAL STRESS

Stress at local points occur due to voids, imperfections, defects.

Origins of PARTIAL DISCHARGE are Voids enclosed in the slot insulation.

• Partial discharges in these cavities are always a source of degradation.
• Two other types of degrading phenomena are –
• Slot Discharge
• End Discharge.

Slot Discharge is between Main Ground Insulation and slot wall.

• Due to poor contact between the semi-conducting paint of stator bar & iron.
• also comes at the damaged spot of the paint, where the electric field along the
surface becomes too high.
End Discharges occurs at –
• Coil exit from the slot – if the stress-grading paint is not provided on the
overhang to achieve uniform distribution of stress.
• between the non-linear and highly resistive stress-grading paint at the slot
entry and the low resistance coating on the bar.

Causes of Ageing due to Electrical Stress are –

• Electrical tracking due to surface build-up of moisture, oil, carbon dust, etc.
• Effect of operating dielectric stress over a period of time
• Effect of high dielectric stress during over-voltage
• Treeing and corona
DIAGNOSTIC TESTS ON SOLID
INSULATION
 INSULATION RESISTANCE TEST

Insulation resistance test is a ‘spot check’ only. Dielctric absorption

characteristics reveals more information !

Only the surface condition of the insulation

is reflected and this cannot be used for
assessing the quality of the insulation.

IR is principally a pass / fail criterion

and cannot be relied upon to predict the
condition of the main insulation. Other
tests are far superior.

IR is sensitive to humidity and temperature.

1. Take Trend at fixed interval, same voltage. Do not depend on absolute value.
2. Correct reading to 200 C for trending.
3. “Polarizing Index” is a better Figure of Merit
4. Insulation Resistance indicates Surface condition, e.g. Moisture, Dirt.
For knowing volumetric condition – go for Tan Delta

A = test value, B = test value corrected to 20 0C, a Warning

Multiplying Factor Nomograph
 ABSORPTION CHARACTERISTICS
“Polarizing Index” is a better Figure of Merit.

When voltage is applied, Total current that flows are 3 separate currents –
1. Capacitive Current
2. Absorption Current
3. Leakage Current
 DIELECTRIC ABSORPTION CHARACTERISTICS
DRY, CLEAN
BFP - B MOTOR
INSULATION
12

10
IR value in Giga Ohm

0
0 1 2 3 4 5 6 7 8 9 10
IR 0 2.96 4.6 5.8 6.76 7.65 8.3 9.05 9.65 10.2 10.7

Motor SL No Date Insulation Temp Megger DC KV PI Capa

MINUTES
401-21-01 17.05.02 35 BM 25 2.5 3.62 0.24 mF

DIELECTRIC ABSORPTION CHARACTERISTICS

ID FAN MOTOR

2.5
IR value in Giga Ohm

1.5

0.5

0
0 1 2 3 4 5 6 7 8 9 10
DAMP / DIRTY IR 0 1.84 1.95 1.98 2.02 2.04 2.05 2.06 2.06 2.08 2.08

INSULATION Motor SL No Date Insulation Temp Megger DC KV PI Capa

14810700 12.06.02 35 MINUTES
BM 25 2.5 1.12 0.25 mF
PI is a figure of merit for dryness and cleanliness of the insulation.

No one can give general rules for the interpretation of results !

Meaning varies with different equipment.

PI gives clues to aid to other information, e.g.

• Comparison with other similar apparatus
• Previous history of the apparatus
• Results of careful visual inspection
• Manufacturers’ recommendation

IEEE recommends minimum PI as follows –

PI = 1.5 for Class 105 Insulation ( CLASS - A )

PI = 2.0 for Class 130 Insulation ( CLASS – B )
 STEP VOLTAGE TEST
An ideal insulator will produce identical IR readings at all voltages while an
insulator which is over-stressed will show lower value at higher voltages.

IR values for clean and dry insulation will be, in general, slightly less for the
higher test voltages due to Dielectric Absorption effect. But a large decrease in
IR with higher Test Voltage is usually indicative that the insulation is in a less
satisfctory condition – perhaps due to Dirt or Moisture

The step voltage test is the best way to test the insulation on high capacitance
equipment. This is not suitable for low capacitance equipment.

If a weakness exists in the ground wall, breakdown is often preceded by a

sudden, non-linear increase of current ( or drop in IR ) with further voltage
increase. Interrupt the test at the first sign of such warning.
DC Ramp Test
Or
Step Voltage Test
 DISSIPATION FACTOR AND TIP UP

Increase in Dissipation Factor :

1. Incorrect composition, or if insulation is not fully cured or manufacturing
defect such as voids. Ionisation (air void)
2. Chemical deterioration (e.g. by high temp or time)
2. Contaminations e.g. Water, carbon deposits, oil, dirt
3. Severe leakage through cracks & over surface
(Bushings, terminal connections etc must be clean thoroughly.
Else Surface leakage current will mask Volumetric leakage. false indication)

The tip-up is normally the difference between 25% and 100% of rated line-to-
ground voltage.

Tan  tip-up = (Tan  at Vph - Tan  at 25% Vph)/2

INTERPRETATION OF TAN-DELTA TEST

1. Follow typical values as general guideline

It is more meaningful when used for trending than as absolute values.
2. A low DF is generally desirable, but a high DF does not necessarily imply that
the insulation is inferior. For example, the DF for epoxy-mica insulation is
typically around 0.5% whereas for good asphaltic insulation, it is around 3%.
3. It is not prudent to infer insulation condition on the basis of a single
measurement of DF or tip-up. This is due to effect of stress-grading coatings.
4. Trend of test on same equipment over fixed interval.
5. Test on similar equipment or similar part of same equipment.
6. Test at different voltage (high value at some high voltage indicates Ionisation)
7. DF is a summated value.
• Increase in DF + increase in Cap = indicates Moisture in insulation
• Increase in DF but constant Cap = Reason other than Moisture
0.5% - 1% (20 0C)Power factor of older
transformer may be Acceptable, but >1%
(20 0C) should be investigated.
Dissipation Factor of Generator / Motor :
1. Drastic reduction in Capacitance of new winding indicates incomplete curing.
2. Tip-up is more useful. High Tip-up indicates presence of Voids.
3. Tip-up should be applied to individual stator coils to check Quality confirms.

Dissipation Factor of Transformer :

1. DF + Excitation Current can detect Winding and Core problems.
2. DF > 0.5% (20 0C) should be investigated.
3. Increase in DF + increase in Capacitance indicate presence of Moisture.
4. When Oil is Filtered, repeated DF tests shall indicate removal of Moisture.
5. Sludge & Oil Oxidation affect DF. If DF value decreases after treatment, it
indicates sludge is removed.

Dissipation Factor of Transformer Bushings :

1. DF for modern Bushings should be within 0.5% after correction to 20 0C.
2. Capacitance should be within 5 to 10% of nameplate value
 CURRENT SIGNATURE ANALYSIS

Spectrum analysis of motor current & voltage to detect

• Rotor bar damage
• Misalignment / unbalance
• Core damage
• Loose wedges
• Static and dynamic eccentricity
• Inter-turn shorts

It acquires current and voltage signals. Uses a FFT analyser to convert the
signals from time domain to frequency domain. Then it analyses various
harmonics signal conditioning to detect the faults.
 PROOF TEST
It provides no diagnostic information or data which can be recorded for future
use – it tells what is going on at the moment of test.

AC VOLTAGE IS MORE MEANINGFUL AND REVEALING

The DC tests in general are sensitive indicators of the presence of dirt,

moisture, cracks, fissures and reduced creepage paths.

AC tests are usually more revealing of the insulation condition.

When moisture is there, it affects the insulation properties such as – (a)

conductivity (b) dissipation factor (c) dielectric constant
While DC voltage tests can measure only conductivity, AC tests can measure all
three properties. Electrical stress distribution over a winding is governed by
resistivity in case of DC and permitivity for AC voltage.

Actual service conditions are not simulated during DC test, as stress distribution
is governed by resistivity and the insulation hence is unevenly stressed.

DC VOLTAGE TESTING IS MORE POPULAR

DC is far less damaging to insulation than AC, because of the virtual absence of
partial discharge.

DC test equipment is relatively lighter and compact.

 PROOF TEST : DC HI-POT

The DC Hipot test is not a diagnostic test, but a go – no go test, since the
outcome is simply pass or fail.

A successful Hi-pot test indicates that no serious cracks have yet appeared in the
ground-wall. Gives some assurance that the ground-wall may be safely stressed
to normal operating voltage.

WHAT SHOULD BE THE TEST VOLTAGE ?

DC test voltage = AC phase-to-ground voltage x 1.414

x multiplier

Multipliers typically vary from 1.1 to 2.0 or higher.

The DC puncture voltage may range from 1.41 times the rms AC puncture
voltage (for a cracked winding where the puncture path is essentially an air
gap)to 2.5 times the rms AC puncture voltage for well-compacted and
impregnated mica insulation.

IEEE mentions the factor 1.7 as appropriate for used insulation.

 PROOF TEST : AC HI-POT

The electric stress distribution within the stator ground-wall insulation and in
the end winding is more realistic with AC than DC.

WHAT SHOULD BE THE TEST VOLTAGE ?

The typical RMS test voltage is 1.25 VL-L to 1.5 VL-L for stator winding tests,
although this voltage may be reduced for older windings.

Since severe partial discharge can occur during the AC test, test duration should
be as short as possible
 SURGE COMPARISON TEST

This also is GO - NO GO test ! detects inter-turn faults.

Controlled electrical surges from discharging of capacitors are fed into the motor
windings. Instability in the damped return wave is evaluated by means of an
oscilloscope to indicate change in inductive reactance, which is result of of failure
of turn insulation.
 CABLE TESTING

• Cable insulation is less prone to Cracking, ionisation, erosion than rotating machine.
Higher Voltage will be needed to show up defects.

• AC Hi-Pot is impractical on long cables because of high charging KV amps.

Even Tan Delta is not feasible.
• AC Hi-Pot can be destructive.

• DC Hi-Pot causes no deterioration of insulation.

• With DC Hi-Pot, Much less damage is done if breakdown occurs because capacity of
test equipment is small.
• DC Hi-Pot Test kit is small, it has to be supply on Leakage current
• However , drain off the charge will take time with DC Hi-Pot test.
HV DC Test on
Cable
 Myth – 2

I tested BDV, it came 40

KV. My Transformer is
safe
 FACTS :

D I E L E C T R I C S T R E N G T H I S A P H Y S I C A L T E S T,
AND NOT A ELECTRICAL TEST

WHAT THE DIELECTRIC TEST TELLS US ?

• Cellulosic fibers
• Rust or other metallic cuttings
• Filter dust / Dirt
• Free water

A BAD DIELECTRIC COULD THUS MEAN :

• Significant solid contamination
• An arcing condition
• Presence of combustible gases
• Tank or water leak
A GOOD DIELECTRIC VALUE DOES NOT :

• Detect dissolved water in oil

• Certify that moisture trapped in cellulose is within safe limit.

Don’t keep unmerited confidence on Dielectric test.

A good result might mask a serious hazard !
Erroneous conclusions can be drawn from Di-electric test if the oil is tested at
a temp above 40 0C because of the phenomenon of Water Solubility. Dilectric
Strength is not affected by Dissolved Moisture.

At 50 0C, oil can hold 100 ppm. At 60 0C,

CLOUD_ POINT CURVE
even with 200 ppm oil will be clear.
BDV test may show around 50 KV.

If temp falls to 40 0C, oil becomes

cloudy.

A : Under_ refined oil

B : Normally_refined oil

A : Highly_refined oil
Well over 99% of the Moisture is locked up in its Cellulose Insulation, while
Moisture in the oil is less than 1 %. Di-electric Test of the Oil reveals nothing
about the condition of the Solid Insulation where stress is maximum.
 OXYGEN – THE SOURCE OF ALL DETERIORATIONS

Unstable hydrocarbons
(in oil)
+
Oxygen
(from dissolved air in oil and degraded cellulose)
+
Catalysts
(moisture, copper, and dissolved metallic compounds)
+
Accelerators
(heat, vibration, shock-loading, surge voltages, high electrical stress)

=
Oxidation by-product
(peroxide gases, acids, alcohols, aldehydes, ketones, metallic soaps, moisture)
1. The Peroxides so formed react with Cellulose to produce ‘Oxy-Cellulose’.
Acids react with Cellulose to produces ‘Hydro-Cellulose’.
Oxy-Cellulose lacks in mechanical strength & makes insulation embrittled.

2. Sludge occurs after the Oxidation products held in solution finally saturate the
oil and any additional products settle down in solid form.

Sludge may choke the oil ducts in the Transformer, preventing circulation of
the oil and thereby interfering with the removal of Heat.
 MOISTURE - THE ENEMY NUMBER ONE !

Moisture is available to Oil & cellulose from following sources –

• Residual absorbed moisture left by manufacturer (0.25 % - over 1 % by wt).

• Moisture formed from the thermal decomposition of the cellulose – as
combination of hydrogen & hydroxyl (OH).
• As one product of oil oxidation :
(a typical transformer with 10 tons of cellulose & 8000 gallons of oil when
oxidized to 1 mg KOH / gram, can produce between 2 to 20 gallons of water !
This increases moisture content of cellulose between 0.1 to 1% by dry wt)
• Breathing of damp air.
• Leaks in the tank – around bushings / gaskets / suction side of oil pump
CELLULOSE IS STRONGLY HYGROSCOPIC WHILE OIL IS HYDROPHOBIC.

• Due to this strong affinity, cellulose does not share the moisture equally with oil.

In equilibrium state, the moisture content of cellulose is about 800 times of oil !

• While pure Water is a polar liquid with high dielectric constant (permittivity)

between 79.5 and 81, most commercial insulating materials have dielectric

constant between 2 to 7. So, water gets attracted to areas of strong electric field

and does not distribute uniformly throughout insulating system.

• Moisture is Primarily responsible for reduction of Mechanical Str. of Cellulose.

• Moisture increases Ageing Rate. Insulating Paper with 1% Moisture content

ages 10 times faster than one with 0.1%.

• At high temp, Residual Moisture in Insulation can trigger release of Gas bubbles.
PRESSURIZED BREATHING
TRANSFORMER

FREE BREATHING
TRANSFORMER
 FREE BREATHING
CONSERVATOR

CONSERVATOR WITH BLADDER

 HEAT – TAKES IRREVERSIBLE TOLL ON
CELLULOSE LIFE !

Approx 90% of Cellulose deterioraion is Thermal in origin. Elevated temp

accelerates ageing by reduction of Mechanical & Di-electric Strength.

Heating severes the linkage bonds within Cellulose (Glucose) molecule,

breaking down with formation of Water. This Water causes continuous new
molecular Fission and weakens Hydrogen bonds of the molecular chains of
Pulp Fibre.

Secondary effects include paper decomposition (De-Polymerization or ‘DP’,

and production of CO & CO2.
 FOREIGN MATTERS – THE VICIOUS ELEMENTS !

Many substances like Dust & Cotton Fibres that are non-conducting when dry,
can absorb moisture from oil and become conducting.

In Moist condition, they have higher permistivity (Di-electric Constant) than

oil. Under the influence of Electrical Stress, they form chains or bridges
through oil which may result Arcing. This is more probable with stagnant oil.
This is why electric strength greatly reduces when both Fibre & Moisture are
present in oil.
 WHAT MAKES A GOOD OIL GO BAD?

OXYGEN CATALYSTS ACCELERATORS

From dissolved air in oil, Moisture, copper, & Heat, electrical stress,
degraded cellulose dissolved metallic surge voltage,
compounds shock loading, etc

UNSTABLE HYDROCARBONS IN OIL

OXIDATION BY-PRODUCTS

(peroxide, acid, alcohol, aldehyde, ketone, metallic soaps, moisture)

PRODUCTS OF CORROSION, PAINT,

VARNISH, CELLULOSE INSULATION SLUDGE
 WHAT MAKES A GOOD CELLULOSE GO BAD?

MOISTURE HEAT

OIL-IMPREGNATED CELLULOSE
(O2 present)

CHEMICAL DEGRADATION
(acids, peroxides, more O2 , more H2O)

Added moisture Mechanical Dielectric Acidic polar

degradation degradation material

CONDUCTION & IONISATION (PD)

CORONA (GLOW DISCHARGE)

OI L TESTING PROGRAM
 KARL–FISCHER TEST IS THE ONLY WAY TO
MEASURE TOTAL MOISTURE IN OIL

MOISTURE CAN EXIST IN FOUR FORMS IN SOLUTION ( DISSOLVED )

IN SUSPENSION

BOUND

FREE

DISSOLVED WATER IS IN SIMPLE SOLUTION.

OIL DISSOLVE MORE MOISTURE AT HIGHER TEMPERATURE THAN AT LOWER

TEMPERATURE. HOT OIL HOLDS MORE WATER.

COOLING THE TRANSFORMER GIVES OIL THE OPPORTUNITY TO UNLOAD ITS WATER
TO CELLULOSE.
MAX MOISTURE IN OIL AS A FUNCTION OF TEMP
AGED OIL HOLDS MORE WATER IN SOLUTION THAN THE NEW OIL (AS WATER GETS
ABSORBED INTO THE OIL DECAY PRODUCTS).

FREE WATER EXISTS WHEN OIL IS COMPLETELY SATURATED. IT CAN BE IN THE

FORM OF DROPLETS OR LIQUID AT THE BOTTOM OF THE TANK.

A HOT TRANSFORMER OIL CAN CONTAIN AN APPRECIABLE AMOUNT OF WATER IN

SOLUTION, THIS DISSOLVED WATER WOULD HAVE NO OR APPRECIABLE EFFECT ON
THE OVERALL POWER FACTOR OR THE DIELECTRIC STRENGTH OF THE OIL.

KARL FISHER IS THE ONLY WAY TO MEASURE THE TOTAL MOISTURE IN THE OIL -
WATER IN SOLUTION, WATER IN THE EMULSIVE STATE AND FREE WATER.

BREAKDOWN VOLTAGE IS ONLY SENSITIVE TO THE FREE WATER.

 N E U T R A L I Z A T I O N N O. I S M E A S U R E O F A C I D, S O
SPEAKS OF PROGRESS OF OXIDATION

MEASURES DIRECTLY THE FREE & INORGANIC ACID PRESENT TOGETHER, HENCE
PROGRESS OF OXIDATION.

A USED OIL HAVING A HIGH ‘NN’ INDICATES THAT THE OIL IS EITHER OXIDIZED OR
CONTAMINATED WITH MATERIALS SUCH AS VARNISH, PAINT, OR OTHER MATTER.

NN < 0.3 mG KOH / gm : SATISFCATORY

NN > 0.2 mG KOH / gm : SLUDGE FORMING PROBABILITY INCREASES

NN > 0.5 mG KOH / gm : OIL SHOULD BE REPLACED

 INTERFACIAL TENSION TEST CAN TELL
HOW MUCH LIFE IS LEFT IN THE OIL

‘IFT’ IS SENSITIVE TO PRESENCE OF OIL DECAY PRODUCTS AND SOLUBLE POLAR

CONTAMINANTS FROM SOLID INSULATING MATERIAL. HIGH ‘IFT’ MEANS
RELATIVELY SLUDGE-FREE OR PURER OIL. ‘IFT’ IS A MEASURE OF REMAINING LIFE
OF OIL.

SLUDGE IS A RESINOUS, POLYMERIC TYPE SUBSTANCE THAT IS PARTIALLY

CONDUCTIVE, HYGROSCOPIC, AND A HEAT INSULATOR. THE PRESENCE OF SOLUBLE
SLUDGE IS INDICATION OF APPROACH OF END-LIFE FOR OIL AND NEED FOR OIL
RESTORATION OR REPLACEMENT.

• IFT 18-22 DYNES / CM ( 0.18 – 0.22 N / M ) : NO SLUDGE

• IFT < 18 DYNES / CM, SLUDGE FORMATION POSSIBLE

• IFT < 15 DYNES / CM, SLUDGE ALREADY FORMED

HIGH ‘IFT’ OIL IS SLUDGE-FREE OIL. HIGH ‘NN’ INDICATES HIGH ACID
CONTENT AND A BADLY DETERIORATED OIL.
 O I L PO W E R F A C T O R I S N O T S P E C I F I C O F
WHAT IT DETECTS

IT INDICATES PRESENCE OF POLAR SUBSTANCES i.e. WATER / OIL - SOLUBLE

COMPOUNDS / AGING PRODUCT (WHICH MAY BE DUE TO OXIDATION / EXTERNAL
CONTAMINANTS / MATERIALS USED IN THE CONSTRUCTION SUCH AS PAPER,
GASKET, RESINS, ADHESIVES, CORE LAMINATION INSULATION). OTHER TESTS MUST
BE MADE TO DETERMINE WHAT POLAR COMPOUNDS ARE PRESENT.

0.05% AT 20 0C IS OK, > 0.5% AT 20 0C IS CONCERN, 0.5 – 2% NEEDS INVESTIGATION

• IF THE TAN_DELTA IS HIGH SUPPORTED BY A HIGH ‘NN’, IT CONFIRMS THAT

DETERIORATION IS DUE TO OXIDATION PRODUCT - POLAR SUBSTANCES.

• IF TAN-DELTA IS HIGH & MOISTURE IS HIGH, THEN CAUSE IS MOISTURE.

• IF TAN-DELTA AT 100 0C > 7 TIMES TAN-DELTA AT 25 0C, THEN CAUSE IS SOLUBLE

COMPOUNDS OTHER THAN MOISTURE.
 RESISTIVITY TEST MONITORS AMOUNT OF
CONDUCTIVE CONTAMINANTS

RESISTIVITY OF OIL MONITORS THE AMOUNT OF CONDUCTIVE CONTAMINANTS –

SUCH AS METAL SALTS, ACIDITY, MOISTURE, ALDEHYDES, KETONES AND ALCOHOLS.

GENERALLY, IF THE DISSIPATION FACTOR INCREASES THAN RESISTIVITY

DECREASES.

IF RESISTIVITY AT 900 C COMES TO BE BETTER THAN RESISTIVITY AT 200 C, IT

INDICATES PRESENCE OF MOISTURE OR COLD PRECIPITABLE MATERIALS.
 OIL TESTING PROGRAM

MOISTURE IN PPM
Reveals total water content. Tells at
what temp water dissolved in oil will
condense.

NEUTRALIZATION NUMBER INTERFACIAL TENSION

Detects acid present in oil. Detects sludges present in oil or
excessive polar contaminants from
the cellulose material.

POWER FACTOR AT 25 0C DIELECTRIC BREAKDOWN ST.

Reveals presence of resin, moisture, Detects conductive contaminants

varnishes, or other product of oxidation present in the oil such as metallic
in oil or of foreign contaminants, e.g. cuttings, or free water.
motor oil or fuel oil.
CELLULOSE TESTING PROGRAM
MOISTURE IN CELLULOSE
HOW MUCH IS TOO MUCH MOISTURE ?
MOISTURE REDUCES TENSILE STRENGTH OF INSULATION.

• 2% MOISTURE CAUSES 6 TO 16 TIMES AGEING RATE AT 0.3% INITIAL MOISTURE

• 4% MOISTURE CAUSES 12 TO 45 TIMES AGEING RATE AT 0.3% INITIAL MOISTURE

SO, TRANSFORMER MAY NOT HANDLE HIGH SHORT-CKT / SHOCK LOADING.

MOISTURE REDUCES BASIC IMPULSE STRENGTH (BIL REDUCES DRASTICALLY EVEN

AT 0.13% MOISTURE !), SO CRACKS MAY DEVELOP WHEN IT MEETS SURGE VOLTAGE.

TOTAL MOISTURE = 0.3 TO 1% (MAX DURING MANUFACTURING)

+ 0.5 TO 2.5% (MAX LIBERATED FROM PAPERS)
+ 0.1 TO 1.0% (MAX FROM OIL OXIDATION)
---------------
0.9 TO 4.5 %
• ELECTRICAL BREAKDOWN IS UNLIKELY IF MOISTURE DOES NOT EXCEED 4.5%.

• OLD TRANSFORMERS STILL CAN OPERATE WITH CONTENTS OF 5 TO 6%.

• CONSENSUS OPINION IS FOR MAX 2% - TO KEEP DIELECTRIC STRENGTH MARGIN

MOISTURE IN CELLULOSE CAN BE CALCULTED FROM THE PPM-IN-OIL AND SAMPLE

TEMPERATURE.

AT 20 0C, OIL WITH 10 PPM MOISTURE CAN BE IN STATE OF EQUILIBRIUM WITH AN

INSULATION SYSTEM THAT CONTAINS 4% OF ITS WEIGHT IN WATER, e.g. A 33 MVA
TRANSFORMER CAN HAVE 400 lb WATER LOCKED UP IN ITS CELLULOSE. THUS, OIL
WILL PASS BDV EASILY, BUT TRANSFORMER HAS SERIOUS THREAT !
MOISTURE CONTENT HAS A DIRECT BEARING ON POWER FACTOR (TAN-DELTA) OF
SLOID INSULATION. POWER FACTOR (TAN-DELTA) OF SOLID INSULATION IS THE
CONFIRMATORY TEST OF MOISTURE TRAPPED IN CELLULOSE.

INSULATION RESISTANCE TEST ALSO REVEALS MOISTURE IN CELLULOSE, BUT IS

SENSITIVE TO SURFACE CONTAMINATION. RECOVERY VOLTAGE MEASUREMENT (RVM)
IS ALSO A RELIABLE TEST.

• TAN-DELTA FOR NEW TRANSFORMER SHOULD BE 0.004 (0.4%).

• MAX ALLOWED FOR NEW TRANSFORMER IS 0.5% (IEEE/C57, IEC 186).

• TRANSFORMERS WITH TAN-DELTA > 0.7% IS MOST LIKELY UNDERGOING

ACCELERATED AGEING.

• FOR IN-SERVICE TRANSFORMERS, TAN-DELTA >2 % IS SUSPECT CASE.

• EVEN FOR OLD TRANSFORMERS, TAN DELTA SHOULD NOT EXCEED 4%.
SOME GENERAL CONDITIONS SUCH AS CONTAMINATED OIL ALSO CAN RESULT IN
INCREASED TAN-DELTA. AN INCREASE IN TAN-DELTA AS WELL AS CAPACITANCE
INDICATES THAT CONTAMINATION IS MOST LIKELY BY WATER.

IF POWER-FACTOR IS HIGH, GO FOR ‘TIP-UP’ TEST.

IF TIP-UP TEST READING DOES NOT VARY WITH INCREASE IN VOLTAGE, THEN
MOISTURE IS PROBABLE CAUSE.

IF TIP-UP TEST READING VARIES WITH INCREASE IN VOLTAGE, THEN IONIZATION IS

PROBABLY OCCURING, CAUSING CARBONIZATION OF OIL. IF TIP-UP READING
EXCEEDS 0.1%, IT INDICATES PARTIAL DISCHARGE OF ORDER OF 500 – 1000 pC.
 AGEING INDICATORS

FURAN TEST

DEGRADATION OF CELLULOSE PRODUCES FURANS.

ITALIAN EXPERIENCE : < 0.2 ppm UPTO 10 YEARS

UPTO 2 ppm FOR > 10 YEARS

DP TEST

DEGREE OF POLYMERIZATION INDICATES PAPER DEGRADATION.

TYPICAL VALUE OF GOOD DRIED PAPER IS 750 – 800.

WHEN DP REACHES 200, IT MAY BE TAKEN AS END OF LIFE.

 D I S S O L V E D G A S A N A L Y S I S : A M U S T_H A V E T O O L
KEY GAS METHOD

IN ALL CASES OF INCIPIENT OR INTERNAL TRANSFORMER PROBLEMS, THERE WILL

BE A KEY GAS WHICH CAN BE RELATED TO A TYPE OF FAULT.

KEY GAS METHOD APPLIED TO IN-

IN-OIL FAULTS

ARCING ACETYLENE
CORONA HYDROGEN
LOW-TEMP OVERHEATING METHANE
HIGH TEMP OVERHEATING ETHYLENE

KEY GAS GENERATED FOR CELLULOSE FAULT ARE CO & CO2.

RATE OF GAS PRODUCTION (EXCEPT C2H2) IS MORE IMPORTANT THAN THE

AMOUNT OF GAS IS MORE IMPORTANT IN EVALUATING THE HEALTH. 30 PPM / DAY
IS USUALLY TAKEN TO BE INDICATIVE OF AN ACTIVE FAULT.
IEEE GUIDELINES FOR KEY GAS IN PPM

CONDITION 1 : NORMAL GAS LEVEL

CONDITION 2 : GREATER THAN NORMAL. FAULT MAY BE PRESENT.

CONDITION 3 : HIGH LEVEL DECOMPOSITION. CALCULATE GAS / DAY.

CONDITION 4 : EXCESSIVE DECOMPOSITION. COULD CAUSE FAILURE.

Status H2 CH4 C2 H2 C2H4 C2H6 CO CO21 TDCG

Cond.1 100 120 35 50 65 350 2,500 720

Cond. 2 101-700 121-400 36-50 51- 66- 351-570 2,500- 721-

100 100 4,000 1,920

Cond. 3 701- 401- 51-80 101- 101- 571- 4,001- 1,921-

1,800 1,000 200 150 1,400 10,000 4,630

Cond. 4 > > > > > > > >

1800 1,000 80 200 150 1,400 10,000 4,630
1
CO2 is not included TDCG as it is not a combustible gas.
 RATE OF RISE OF GAS CONCENTRATION

INITIAL GAS CONTENTS SHOULD SERVE AS “BENCHMARK” AND SUCCESSIVE

READINGS SHOULD BE COMPARED WITH THE PREVIOUS READINGS TO ESTABLISH A
TREND AND ANALYSIS.

IF THE RATE OF INCREASE IN GAS GENERATION IS HIGH OR IF THE GAS RATIOS ARE
DIFFERENT FROM THOSE FOR THE PREVIOUS ANALYSIS, A NEW FAULT MAY BE
THOUGHT TO SUPERIMPOSE OVER AN EXISTING ONE OR AGEING

Correctly speak about the incipient fault.

Confirm whether the fault, that generated gas previously, is an active

one

Forms the basis for deciding on the period of testing or loading on the
transformer, etc.
ROGER’S AND IEC RATIO METHOD

ROGERS RATIO METHOD USES THE FOLLOWING FOUR RATIOS.

C2H2 / C2H4 C2H4 / C2H6 C2H6 / CH4 CH4 / H2,

IEC RATIO METHOD USES THE FOLLOWING THREE RATIOS.

C2H2 / C2H4 C2H4 / C2H6 CH4 / H2,

RATIO METHODS ARE NOT “SURE THINGS”, BUT ONLY ADDITIONAL TOOLS TO
ANALYSE THE PROBLEMS. RATIO METHODS ARE FOR “FAULT ANALYZING” AND NOT
FOR “FAULT DETECTION”. IT MAY NOT TELL IF YOU HAVE A PROBLEM.

NEVER MAKE A DECISION BASED ONLY ON A RATIO IF EITHER OF 2 GASES USED IN

RATIO IS LESS THAN 10 TIMES THE AMOUNT GAS CHROMATOGRAPHY CAN DETECT.
 CORRECT SAMPLING IS THE FIRST STEP

Careless sampling technique has been the source of 99% of “bad” dielectric readings.

Sampling must be done in a relatively dry atmosphere.

Dry, clean apparatus and hands, a normal day ( < 50% humidity ).

Sample must be protected from contact with light, air, & moisture.

The sample should be drawn quickly, kept in a sealed container, and tested within few
hours.

Sample should not be exposed to the ultra-

violet rays of sunlight.

Allow a little oil to flow as waste before

collecting oil in bottle.
Bottom-most valve is preferred.
 CONDITION- MONITORING PLATFORM

OIL QUALITY TESTS

OXIDATION OF MAIN MOISTURE IN CONDITION OF OLTC

TANK OIL CELLULOSE TANK OIL
NN KF MOISTURE NN & IFT
IFT CELLULOSE TAN MOISTURE
OIL TAN-DELTA -DELTA & TIP-UP OIL TAN-DELTA

INCIPIENT FAULT INSULATION OF AGEING INDICATORS

BUSHING

DGA : TAN-DELTA AND FURAN

ROGER & IEC RATIO TIP-UP DP

KEY GAS (IEEE)

 CONVENTIONAL ELECTRICAL DIAGNOSTIC TESTS
WINDING RESISTANCE TEST :

RESISTANCE VARIATION SHOULD NOT EXCEED 5% FROM PHASE – TO – PHASE OR 5%

FROM FACTORY TEST RESULTS (IEEE 62/1995).

DETECTS LOOSE CONNECTIONS, BROKEN STRANDS, BRIDGING OF WINDING PARTS,

HIGH CONTACT-RESISTANCE OF TAP CHANGERS.

DC TEST IS DONE AFTER EXCITING CURRRENT TEST TO EXCLUDE EFFECT OF RESIDUAL

MAGNETISM WHICH OTHERWISE REQUIRES DE-MAGNETISATION OF CORE.

TRUNS RATIO TEST :

TURNS RATIO TOLERANCES SHOULD BE WITHIN 0.5% OF NAMEPLATE SPECIFICATION.

DEVIATION INDICATES TURN-TO-TURN FAULT OR INTERNAL SHORT-CIRCUIT OR
WRONG TAP CHANGER CONNECTIONS
EXCITATION CURRENT TEST :

EXPECTED PATTERN IS TWO SIMILAR HIGH CURRENTS ON OUTER PHASES AND ONE
LOWER READING ON THE CENTRE PHASE.

DETECTS CHANGE IN THE EFFECTIVE RELUCTANCE OF MAGNETIC CIRCUIT WHICH

AFFECTS CURRENT REQUIRED TO FORCE A GIVEN FLUX THROUGH THE CORE. THIS CAN
BE CAUSED BY :

• SHIFTING OF THE WINDING

• DEFECTS IN MAGNETIC CORE STRUCTURE

• FAILURES IN TURN-TO-TURN INSULATION

• PROBLEMS IN THE TAP-CHANGING DEVICE

 MODERN DIAGNOSTIC TECHNIQUES
FRA / LVI :
TO CHECK DYNAMIC MOVEMENTS & DETECTION OF WINDING MECHANICAL
DISTORTION

PARTIAL DISCHARGE (ON-LINE) :

CAN BE ACOUSTIC OR UHF.
TO DETECT PARTIAL DISCHARGE INSIDE TRANSFORMER

RVM :
TO GET GENERAL INDICATION OF MOISTURE IN CELLULOSE
TO GET IDEA ABOUT AGEING OF PAPER & OIL CONDITION

ON-LINE HYDRAN / HYDROGEN / MOISTURE CONTENT :

TO MAINTAIN CONTINUITY BETWEEN TWO PERIODIC LABORATORY TESTS
ON-LINE HOT SPOT MEASUREMENT (BY FIBRE OPTICS SENSORS) :
EXPLORING OTHER MYTHS
“Transformer is static equipment; does not need much attention.”

Wrong !
Transformer has no functional moving parts,
yet is moving continuously while energized.
The magnitude of the movement under
stress can be as high as three inches ( 76
mm ) for “stationary windings” !

“Dielectric Strength of my oil is 40 KV. Why should I worry ?

No !
Dielectric strength does not speak about the dissolved moisture. A good
BDV often masks a grave moisture problem in the oil and cellulose. Oil
which is significantly oxidized but does not contain free moisture shall
show a good dielectric strength.
“Moisture in my oil is less than 20 ppm; and my transformer is safe.”

Grossly mistaken !
It is not absolute moisture in oil of concern; question is 20 ppm at what
temperature ppm at 60 0C can certainly be a reasonably good value, but
20 ppm at 30 0C is a very bad value.

“Look, I checked DGA readings thoroughly by Roger’s ratio. The ratio does not
detect a fault . “

Roger’s Ratio is a fault-analysing tool, not a fault detection tool. Even if gas
ratios donot fall into Fault Codes, Faults could still be there which can go
unnoticed.
“I am filtering my transformer as frequent as every year; what better could be
done ? “

Unnecessary filtration does more harms to the transformer than any good.
Filtration decision should be based on many test readings ( such as
moisture, cellulose tan-delta and IR, oil tan-delta, etc ) which confirm
presence of moisture.

“You can see the color of silica gel in my transformer; It’s always blue. So how
moisture can go in?”

Hold on ! There are many other entry passes for moisture. The suction side
of your oil pump for instance. Are they perfectly sealed ? What about the
oil – are they not sufficiently oxidized ? Deterioration of oil and cellulose
can produce a lot more moisture inside the transformer !
THANK YOU
1. Name 5 diagnostic tests in order of usefulness (from most useful to least
useful) in evaluating a HT motor insulation.

2. Give at least 2 limitations of BDV test in diagnosis of Transformer Oil.

3. What is the general range of Dissipation Factor of a good Thermo-plastic

insulation?
4. Beyond what value the Tan – Delta of a Transformer Cellulose, the condition
can be said to be quationable.

5. Give at least 3 means by which moisture can get into Transformer Oil?

6. Out of DC HV Test and AC HV Test, which one is more revealing and why?

Which one is more popular and why?