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Drying time for transformer core and winding assembly

Article · August 2005

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 Drying Time for Transformer Core and Winding Assembly
J.R.Lucas*, P.D.C.Wijayatunga*, Kosala Gunawardhana#, Rukshika Pathberiya#
N.H.K.L.Sirisena*, J.A.Vitharana*, K.R.S.Dematagolla*, J.A.I.T.Jagoda*

*Department of Electrical Engineering, University of Moratuwa,

#
Lanka Transformer Limited, Angulana

ABSTRACT This mainly consists of insulation materials such as

The drying time of distribution transformer core- pressboard, paper, wood and insulating tape.
winding assembly, at the transformer plant, Lanka Degradation of transformer insulation which reduces
Transformers Limited is presently based on the high the withstand capability of insulation for mechanical
voltage rating. It is the normal practice to dry out the and electrical stresses is the main factor for
transformer core-winding assembly for twenty-four transformer failures, and presence of moisture leads
hours for 11 kV distribution transformers and thirty- to increase the rate of degradation.
six hours for 33 kV distribution transformers,
irrespective of the capacity. This has been decided
considering the total capacity of transformers kept in
the oven during the drying process. This achieves a
larger than required drying time, which has been
considered to have a higher safety margin. But, if the
exact drying time can be found by means of an
acceptable method then an efficient drying is
possible. Thus an in depth study has been carried out
which gives optimum drying out times for typical
distribution transformers.

Index Terms
Transformer, drying time, insulation, winding, core,
loss factor

1.0 Introduction

Figure 2 – Transformer Oven

The transformer core-winding assembly is put into

the oven (figure 2) for up to 36 hours to remove this
moisture.

It is required that the temperature inside the oven

Figure 1 – Core-winding assembly ready for ovening
Drying out of the transformer core-winding assembly
(shown in figure 1) is an extremely important aspect
in transformer manufacturing. This should be done in
order to remove moisture from the core-winding
assembly.
should be kept at a defined value through out the
drying process in order to get complete bonding
between windings and insulation and also to remove
the moisture inside the core-winding assembly.
Since moisture evaporates at over 100oC, the oven
temperature is set between 112oC to 120oC. It is
heated up to a temperature above the ambient before
loading the transformer core assemblies.

Annual Conference of the IEE Sri Lanka – September 2003

 14000
In s u l a t io n r e s is ta n c e - 1 0 0 / 3 3
Meggar reading(MΩ)
H V -E
(A v e r a g e c o r e t e m p e r a t u r e : 1 4 2 .3 2 )
12000
L V -E

10000 H V -L V

6 p e r. M o v . A v g .
8000 (H V -E )

6 p e r. M o v . A v g .
6000 ( L V -E )

6 p e r. M o v . A v g .
(H V -L V )
4000

2000

0
0 3 6 9 12 15 18 21 24 27 30 33 36 39 42

ti m e ( h r s )

6000
In s u la tio n R e s is ta n c e -8 0 0 /1 1
o
(A v e r a g e c o re te m p e ra tu re :1 3 3 .4 1 C )
5000
H V -E
Meggar reading (MOhm)

4000 L V -E

H V -L V
3000
6 p e r. M o v . A v g . (H V -E )

6 p e r. M o v . A v g . (H V -L V )
2000

6 p e r. M o v . A v g . (L V -E )

1000

0
0 3 6 9 12 15 18 21 24 27 30 33 36 39 42
t im e ( h r s )

Figure 3a: Insulation Resistance variation for 100 kVA/33 kV and 800 kVA/11 kV transformers

160

140
Temperature (oC)

120

100

80

60

40

20

0
0 5 10 15 20 25 30 35 40
Time (hrs)
Figure 3b: Temperature variation Inside the Oven for transformers in Figure 3a

Annual Conference of the IEE Sri Lanka – September 2003

1.1 Loss Factor of Insulation
2500
Insulation Resistance100KVA/33 (1)
The loss factor of the transformer Insulation is a

Meggar Reading (M Ohm)

2000

measure of its dielectric power loss. With the 1500

removal of moisture the dielectric power loss 1000

decreases and the insulation resistance will increase. 500

It thus provides information about the quality of the
0
insulation. The loss factor is independent of 0 3 6 9 12 15 18 21 24 27 30 33 36 39

insulation area or thickness, and increase with Time(Hrs)

contamination by moisture. In practice, however, it

is difficult to measure the loss factor during the 2000

drying out process. Thus the decrease in the moisture Insulation Resistance-100KVA/33 (2)

Meggar Reading (M Ohm)

content of the insulation is assessed by measuring 1500

insulation resistance. 1000

500

1.2 Transformer selection

0
0 3 6 9 12 15 18 21 24 27 30 33 36 39
Time (Hrs)
Distribution Transformers were selected for the
study, considering their high voltage ratings (11 kV
and 33 kV) and their capacities (100 kVA, 250 2500 LV-E
kVA,400 kVA,630 kVA,800 kVA). Insulation Resistance-630KVA/33

Meggar Reading (M Ohm)

2000 HV-E

1500
1.3 Performance
LV-HV

1000 6 per. Mov. Avg. (LV-HV)

o 500
The oven temperature was set at 120 C as it is 6 per. Mov. Avg. (HV-E)

required to maintain a safe bond between the 0

0 3 6 9 12 15 18 21 24 27 30 33 36 39
6 per. Mov. Avg. (LV-E)

conductor and the layer insulation. Temperature Time (Hrs)

variation inside the oven was observed through out

the experiment. This was done using temperature
2500
sensors placed inside the oven. The data obtained Insulation Resistance-250KVA/11

was stored in a Data Logger. The Insulation

Meggar Reading (M Ohm)

2000

Resistances throughout the drying process were 1500

measured using the Meggar Test Set. Drying was 1000

continued for 36 hours.
500

First the test was conducted for 2 types of 0

0 3 6 9 12 15 18 21 24 27 30 33 36 39
transformers while the normal production process Time(Hrs)

was going on. The test results were given in the

figure3a, and from that it can be observed that
insulation resistance has increased with time and after 3500
Insulation Resistance-400KVA/33

that tends to drop. 3000

Meggar Reading (M Ohm)

2500

During the test period oven was switched off after 2000

1500
about 16 hours to take out another set of transformers 1000
for tanking. Therefore temperature inside the oven 500
was dropped rapidly as shown in the figure 3b. It was 0

evident that the sudden increases in resistance of both 0 3 6 9 12 15 18 21

Time (Hrs)
24 27 30 33 36 39

transformers have occurred almost at the same time

as the switching off the oven.
160
When the oven is opened the moisture trapped inside 140

the oven can be released to the outside quickly and 120

100

this can be a reason for the above observation. In 80

order to clarify whether there is any relation between 60

40
the above observations, the test was repeated with 20

another set of transformers. Throughout the test the 0

0 3 6 9 12 15 18 21 24 27 30 33 36
oven was not switched off or opened. Results Ti me(hr s)
obtained for the tested transformers are shown in
Figure 4.
Figure 4: Insulation Resistance Variation
&Temperature variation inside the Oven

Annual Conference of the IEE Sri Lanka – September 2003

 Although there is a peak in all of the above graphs
the insulation resistance value at the peak is not high
as the first set of transformers. So it was obvious that
the sudden increase in insulation resistance is due to
the opening of the oven.
Theoretically the insulation resistance should
increase up to a maximum value and thereafter it
should remain at that value with further drying. But
according to the above graphs it is observed that the
insulation resistances of all the tested transformers
were reached to a maximum value and with further
drying the theoretically expected variation couldn’t
be obtained.
As transformer core and winding assembly is highly
packed, the removed moisture can be trapped inside
the assembly itself and this may be a reason for the
above deviation of the results from the theory.
From the test results it is reasonable to decide the
required drying time to be the time when the
insulation resistance rises to the peak value. It can be
concluded that the drying time for the tested
transformers to be in the range of 15 hours to 20
hours.
In order to confirm this, another set of transformers
of the same ratings were dried for the pre-determined
period, and they were subjected to the required
Routine Tests according to the IEC 60076 Standard.
The results were up to the standard and thereby it can
be concluded that the drying time can be reduced by a
significant time period.
Annual Conference of the IEE Sri Lanka – September 2003
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2.0 Conclusion
With finding out the required drying time for the
transformer core-winding assembly it is possible to
save the energy in the oven at the same time
achieving effective drying of transformer core-
winding assembly.
Further studies should be carried out on the
transformer drying process in order to supplement the
conclusion about the required drying time of
transformer core-winding assembly.
3.0 Acknowledgements
The authors wish to thank Dr.Rahula Athalage, Head
Department of Mechanical Engineering, University
of Moratuwa for providing the data logger. They also
wish to express their gratitude to Mr.Ruwan
Welagedara, Production Engineer, Mr. K.A.I.
Gunathunga, Testing Manager and the Technical staff
of the transformer factory of Lanka Transformers
Limited for their valuable support. Last but not the
least, they would like to thank the staff and
colleagues at the Department of Electrical
Engineering, University of Moratuwa who provided
help in numerous ways.
4.0 References
J&P Transformer Handbook, Martin J
Heatchote, 12th Edition