Proceedings of the International Electrical Engineering Congress 2014

Asset Management of Power Transformer:

Optimization of Operation and Maintenance Costs

Thanapong Suwnansri
The Sirindhorn International Thai German Graduate School of Engineering (TGGS)
King Mongkut's University of Technology North Bangkok
1518 Pracharat 1 Rd, Wongsawang, Bangsue, Bangkok, Thailand 10800
thanapongs@kmutnb.ac.th

Abstract- This paper proposes asset management of power cannot detect and fix the problem in time, the catastrophic
transformer in order to diminish operating and maintenance failure will occur, which leads to tremendous damage and
costs. The strategy for the asset management consists of failure outage cost to electric utility. Therefore, high voltage
statistic analysis, assessment on power transformer condition and equipment must be maintained its satisfactory operating
importance, and inventory management of power transformer condition by applying an effective maintenance strategy.
spare part. To determine the critical components and failure
causes, the failure statistics of power transformer are analyzed. Maintenance, availability and reliability are closely related
The failure data is used for estimating lifetime of main power so that a level of maintenance should be specified to ensure an
transformer components by Weibull distribution technique. To acceptable level of transformer reliability. Maintenance
manage maintenance tasks of power transformer, risk-based strategies are mainly classified into corrective, preventive,
maintenance is developed by a combination of condition and condition-based and risk-based. The preventive maintenance is
importance assessment of each transformer. The condition routine and basic maintenance in fixed intervals for inspections
assessment is performed by analysis of electrical test, insulating and maintenance. Advantages are lifecycle increasing and fault
oil test and visual inspection. The importance is evaluated from inception detecting. However, disadvantages are that if some
load criticality, impact on system stability, possibility of failure,
parts of the equipment might be lately maintained, damages
failure consequence, damage to property, as well as social impact
might occur before the maintenance. If the parts are too early
and environmental concern. Subsequently, risk-based
maintained, it will be expensive due to such maintenance and
maintenance in form of risk matrix is developed for evaluating
unnecessary shutdowns. The condition-based maintenance is
the risk of each transformer. The transformer with high risk will
performed according to its known condition. All major
be focused firstly. To optimize spare parts and minimize
parameters such as diagnostic methods are considered in order
inventory cost, inventory management strategies are applied to
components of power transformer by using Statistical
to determine the condition with maximized accuracy.
distribution technique and economic order quantity. Therefore, a
Advantages are that the maintenance is done when needed; and
suitable time period for reordering and optimum ordering costs as well as manpower are saved. Disadvantages are that
quantity are determined. Besides, computerized web-application experienced people and suitable data are required. The risk­
program is developed for practical use. Finally, maintenance of based maintenance considers the condition as well as the
power transformer fleet can be effectively managed. The importance of equipment. It evaluates priority for maintenance
proposed method will be further applied to other high voltage actions and ranks the replacement and refurbishment activities.
equipments. Even if the risk-based maintenance is cost optimizing method
based on risk and unnecessary shutdown but disadvantages are
Index Terms- Asset Management, Power Transformer, complicated for the complex power system with lots of
Failure Analysis, Maintenance Strategy numbers of equipment and data required. However, the risk­
Introduction based maintenance provides the most accurate actual condition
of equipment and the highest system reliability comparing to
Nowadays, the demands on high system reliability, power other maintenance strategies.
quality and cost benefits from electrical asset in power system
have forced many utilities to focus on the better asset Therefore, this paper proposes an innovative risk-based
management. To gain more benefit with the limitation of maintenance strategy for power transformer in order to
revenue, the cost reduction is now of prime concern, especially maintain the best condition of power transformer. This risk­
maintenance costs. According to high acquisition and based maintenance is a formal and systematic method, which
maintenance cost as well as catastrophic failure consequences, includes the condition and importance of power transformer.
risk assessment for power transformer should be firstly For condition assessment, several diagnostic tests of power
focused. Power transformer is gradually deteriorated over transformer components such as windings, insulating oil,
chronological time such as shortened lifetime due to oxidation, bushing, arrester, on-load tap changer, tank and protective
moisture and temperature, acidity and contamination of devices are evaluated. Similarly for important assessment,
insulating oil, seal and gasket deterioration. If the maintenance different criteria such as loading criticality, impact on system

978-1-4799-3174-3/14/$31.00 ©2014 IEEE

stability, possibility of failure, failure consequence, damage to (11) is Weibull characteristic life as a measure of the scale or
property, as well as social and environmental impacts are spread in data distribution. Gamma parameter (y) is the
evaluated. The combination of condition and importance location parameter indicating the time shift from the origin of
criteria creates the risk-based maintenance in form of risk the distribution. According to these parameters, Weibull
matrix. Then, the risk of each power transformer is evaluated statistical properties in terms of probability distribution,
and identified. Subsequently, the maintenance task is cumulative distribution functions, reliability, failure rate, as
effectively managed.
well as Mean Time between Failure (MTBF) or expected life
To optimize spare parts and mmlmlze inventory cost, time can be calculated as follows.
inventory management strategies are applied to components of
Probability Distribution Function (PDF)
power transformer in ABC classes categorized by using Pareto
analysis. Statistical distribution technique comprising Normal
and Poisson distributions is applied for Class A items.
Economic Order Quantity is applied for Class B items, while
J(t) =
(�)( � r-l -(,;rr
t r
e ,t z r

two-bin policy is applied for Class C items. Therefore, a

suitable time period for reordering and optimum ordering Cumulative Distribution Function (CDF)

(,-rr
quantity are determined.
'7
F(t) =
1- e ,t z r
I. WORKING PRO CEDURE
The asset management process of power transformer is
Reliability; R(t)

( 7r ,t z r
shown in Fig. 1. Historical test records are analyze to
-
determine the actual condition of power transformer, while R(t)=I-F(t)=e
network data is used to evaluate the importance of transformers
Failure Rate; A (t)

( (
in the system. The transformer risk is obtained from combining
the condition and the importance. In addition, economic aspect f3-1

J J
regarding financial information should be taken into account.
= J(t) = !3 t-r
A(t)
Subsequently, the decision with the most cost-effective task R(t) 17 17
can be made; and the asset management strategies are fmally
planned appropriately. Mean Time between Failures (MTBF)

l:t at�]
1
work d
MTBF= r+ryr[l+ ]
p
where 1[1 + �] is the gamma function evaluated at the value
p
of[l+ � ].
P
Odler:;, In:mlating
l3.34}o oil, 13.3�6

Optmized maintenance strategies ,-----�----,

Fig. 1 Power transformer asset management

Protecrion.
�. .$%
II. FAILURE STATISTICS

Fig. 2 Defective components of tie-transformer 230/115 kV. 200 MVA

Failure events of power transformers should be
systematically recorded and analyzed in order to determine
critical components and failure causes. The components of
Others, 20.3%
power transformer are classified into seven categories e.g., ---- .-.
active part, insulating oil, bushing, arrester, on load tap
3.4�b
changer, tanl<- and protective devices. For accurate failure
analysis and forecasting as well as aging and reliability
assessment, the well-known Weibull distribution method is
applied [I]. The three main Weibull parameters are Beta, Eta,
and G amma. Beta parameter (�) indicates type of failure
modes as burn-in, random or wear-out period. Eta parameter
Fig. 3 Defective components of loading transformer 115/22 kV. 50 MVA
 Power transfonners in Thailand are mainly used in
transmission system as tie-transformer in 500 kV and 230 kV
levels; whereas loading transformers are used in 115 kY.
Failures and their causes of each main component are
calculated and shown as a percentage for tie transformer rated
230/115 kV, 200 MVA and loading transformer rated 115/22
kV, 50 MY A. The number of the tie transformer population is
117 units with 30 failure records, whereas a loading
transformer population is 186 units with 59 failure records.
Thus, the total 89 failure events of 303 power transformers are
systematically recorded and analyzed for the critical
component and failure causes. The largest proportion of the
200 MVA tie transformer as shown in Fig. 2 is tank with 40%,
while the smallest proportion is self-protective devices or
protection with 3. 3%. However, active part and arrester have
not failed during the last 10 years. For the 50 MYA loading
transformers as shown in Fig. 3, the largest proportion is
OL TC with 25. 4%, while the smallest proportion is insulating
oil with l. 7%.
TTT. DATABASE MANAGEMENT
It is necessary to develop a decision support tool for risk­
based maintenance of power transformer. The tool consists of
database management system for a convenient and systematic
data record in the central database server, analytical process
and user interface module via web application. Therefore with
this decision support tool, the maintenance can be effectively
planned. The database management program and software
development are presented in Fig. 4.
Bru'Wtll.!'r UI Clil."fll
1 FoIW�rd.
1 load.
--­
Renders
Fig. 4 Database management program
It is separated into client and server parts. To achieve the
aims of power transformer risk assessment, the historical
records of routine diagnosis test and measurement during
inspection and overhaul together with visual inspection as well
as some technically significant data of electrical network are
migrated into database for risk-based maintenance. Key
parameters are clearly defined to manage only useful data and
prevent duplicated tasks. Database was developed by using
Microsoft SQL Server program while JAVA was used as the
system programming language for supporting the database,
dynamic link library, graphics and visual interface. Database
management system was based on access database, which is
the connection of access database using Open Database
Connectivity (ODBC) to interface between client side and
server side. The JAVA Persistence API (JPA) provides an
Object Relational Mapping (ORM) facility to Java developers
for managing relational data in Java applications. The web
application is developed for risk-based assessment for
maintenance system of power transformer in order to retrieve
the infonnation trom database for analyzing and back­
recording the data. Then, the condition and importance data of
power transformer can be on-line recorded and analyzed. Web
application is created by using Spring MVC framework with
JAVA language application.
IV. CONDITION ASSESSMENT
To assess the overall condition of power transformer, the
condition of transfonner's component is firstly evaluated. The
components include active part as winding and magnetic core,
OL TC, bushing, insulating oil, arrester, protective device, and
main tank. The condition is calculated in terms of "Health
Index of Component (HIC)" of each component based on the
important of test results of diagnostic tests. Subsequently, the
percentage of component health index is ranked within the
determined intervals in order to indicate the component [2].
The component health index can be interpreted in form of color
indicators: green, yellow and red, which stands for good,
suspect and poor conditions, respectively.
V. RISK ASSESSMENT
The risk-based maintenance is an optimized strategy based
on risk for unnecessary shutdown, but it is a complicated
strategy with lots of data and experienced analyst required [3].
Risk Matrix The risk-based maintenance is created in form of
risk matrix from the relationship of condition and importance
assessment of power transformer as shown in Fig. 5.
Condition
Importance
Fig. 5 Risk matrix with maintenance strategy.
In the risk matrix, the condition is classified into three
levels that each level is suggested to maintain the tasks as
inspection, maintenance and replacement, respectively.
Similarly, the importance is also divided into three levels and
suggested for corrective maintenance (CM), time-based
maintenance (TBM), and lastly time-based maintenance
together with condition-based maintenance (TBM+CBM),
respectively. Therefore, the risk can be totally differentiated
into nine categories. In addition, the risk can be measured by
using distance 'd' technique with respect to 45 degree
reference line, which specifies the equal weighting between
condition and importance. The transformer with longer
distance 'd' encounters higher risk and should be firstly
maintained. By using this method, the systematic maintenance
task of transformer fleet can be scheduled.
 VI. RISK ASSESSMENT FOR POWER TRANSFORMERS
The risk of total 598 power transformers in 115 kV, 230
kV, and 500 kV Thailand's transmission network is assessed
based on the condition and importance of individual power
transformer. However, the setting of scoring and weighting
factor depends on the individual judgement of each utility. The
transformers in red and orange zones will be thoroughly
investigated to mitigate the risk. The investigation results will
be also used to verity and adjust the weighting factor of each
criterion according to the actual condition of power
transformer.
100%
80%
60% ••••
"
• transformer management is achieved by the condition
0 •
.p
'is
"
U
0 40%
20%
0%
0% 20% 40% 60% 80% 100%
Importance
Fig. 6 Risk of power transformers
VIT. SPARE PART MANAGEMENT
Pareto diagram is a general method to c1assity spare parts
or item listed in the inventory into A, B, C classes according to
the cost of items and amount of usage [4]. Using Pareto
analysis in Fig. 7, the components of power transformer can be
classified into ABC classes. Class A items are account for 80%
of the total inventory cost but about 20% of total inventory
items. This class needs a high capital investment and requires a
close control. Then it will be ordered based on calculations of
the most economic order quantities by using statistical
techniques comprising Normal and Poisson distributions [5].
Due to high cost of these items, a minimum safety stock is
maintained. The components of power transformer classified as
class A are busing, arrester and on-load tap changer. Class B
items are account for 20% to 30% of the total cost but about
20% to 30% of total items. Compared to class A, the larger
safety stocks may be maintained and do not need a special
control. The class B item of power transformer is insulating oil.
Class C items are account for 20% of the total cost but about
80% of total items. This item has the cheapest price and needs
a minimal control, e.g. seal, gasket, bolt and nut. After the
items are classified into three different ABC classes, different
inventory policy has been applied for each class. For class A, it
needs a close control and number of spare parts is based on
minimum safety stock with acceptable stock availability the
statistical distribution techniques are applied to this class.
Economic order quantity is usually employed with class B item
to minimize inventory cost, while class C item is managed by a
simple two-bin policy.
c
...-,. -tot. >C .
J...
....---
.. >O -----.iJI
PEIICENTAI3E or INVENTORT ITErAS
Fig. 7 ABC Classes in Pareto Diagram
VITI. CONCLUSION
The condition-based maintenance strategy of power
evaluation using scoring and weighting technique, which is
verified by accessing the actual condition of transformer. The
importance of each transformer in the network is also assessed.
The combination of condition and importance develops the
risk-based maintenance in form of risk matrix. Since there are a
large number of power transformers in the utility network, the
computerized web-application program was developed as a
tool to facilitate the maintenance tasks. In this paper, only 19
transformers are presented as examples. The obtained risk of
each transformer is useful information for risk-based
maintenance. Moreover, the spare part management by
classifYing the component into 3 classes with different
inventory policy is proposed. Therefore, the effective
maintenance tasks can be setup, which results in high
availability, low risk of failure, lower overall maintenance
costs and ability to extend the useful lifetime. Finally, this
method can be applied for other high voltage equipment in the
system.
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Monitoring and Diagnosis, Japan
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Schorn; "Selection of an Optimal Maintenance and
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