Off-Line Testing Options

using Doble / Vanguard

Solutions

Manila March 22, 2018

©2016 Doble Engineering Company. All Rights Reserved 1

Separate Components of Tx

Oil insulation
& Cooling
System
Bushings

Tap Changer

Magnetic Circuit
Windings, Insulation structure
Core
and paper
Transformer Components - Windings

Conducting Circuit

Paper and Pressboard

Insulating Fluid
Core -- Magnetic Circuit
Tap Changers
Bushings
Objectives of Testing

➢ Determine Condition
– Good / Bad / Deteriorated
➢ Life Extension
➢ Maximize Assets
– Safe and Productive Operation
➢ Insure Reliability
➢ Industry Compliance
➢ Insurance Requirement
➢ Inspire Informed Decisions
Failure Statistics

Bushings
19%
LTC
16% Miscellaneous (13%) Insulation aging (10%)

Other
Overvoltage (3%)
10%
Core insulation failure
(10%)
Winding deformation due
to short circuit forces
(30%)

Main Tank
Contamination of insulation
55% (34%)
Transformer Bushings cause 10~30% of all transformer failures
reported.
50-75 % of transformer fires are due to bushing failure. Source ABB
Bushing failures
 Bushing Failure

200m from
bushing
 A range of thermal failures

Stress Core
rings

Winding Frame- tank

Core bolt insulation Connections

21
Examples: 220 kV TX,
DGA abnormal – What to do next ?
Online Survey shows problems, How to validate results?

-30 TP RFI Survey -

-40

-50
dB

-60

-70

-80

50 CVT Parraburdo
240 Line 430 Frequenc 620
Background Middle of810
Yard 1000
Isolator-Corona audible y MHz
Asea_CT 2922
 Objectives of Testing

❖ Determine Condition
– Good / Bad / Deteriorated
❖ Life Extension
Maximize Assets
– Safe and Productive Operation
❖ Insure Reliability
❖ Industry Compliance
❖ Insurance Requirement
❖ Inspire Informed Decisions
Transformer Testing Energized State Online
On-line Detection
1.Bushing Power Factor and Capacitance – Doble Prime IDD

1. Partial Discharge- - PDsmart, PDS100, DFA300, DoblePrimePDguard

2. Infrared Imaging
3. Acoustic Emission - DFA300
4. Oil Analytics – Morgan Schaffer Range
– Dissolved Gas Analysis -
– Moisture by dry weight
– Furan Analysis (Indirect Degree of Polymerization estimate)
Failure Statistics

Bushings
19%
LTC
16%
Other
10%

Main Tank
55%
Miscellaneous (13%) Insulation aging (10%)

Overvoltage (3%)

Core insulation failure

(10%)
Winding deformation due
to short circuit forces
(30%)

Contamination of insulation
(34%)
Examples: 220 kV TX,
DGA abnormal – What to do next ?
Separate Components of Tx

Oil insulation
& Cooling
System
Bushings

Tap Changer

Magnetic Circuit
Windings, Insulation structure
Core
and paper
Transformer Testing De-Energized State – Off-line

1. Capacitance and Power Factor

• Windings to ground and to each other
• Oil ?
• Bushings
2. Single phase excitation of primary windings
3. Leakage Reactance (Impedance)
4. Sweep Frequency Response Analysis (SFRA)
5. Dielectric Frequency Response
6. Turns ratio tests (HV, LV)
7. Insulation resistance (DC) including Core Ground
8. Winding Resistance (Ohm - DC)
9. Dielectric Response tests (RVM, PDC, FDS)
Transformer Testing Options

M4100 Based Option

• M4100 M7100 Based Option
• HV-TTR Capacitor
• M4110 Leakage Reactance Module • M7100
• M5400 SFRA • M5400 SFRA
• Vanguard instruments • Third party test instruments
• Insulation Resistance Tester • Insulation Resistance Tester
• LV-TTR Instrument • DTAWeb –Data Storage
• Winding Resistance Test Instrument • Options DTA6
(including demagnetizing capability) • PD-SMART DTA7
• OLTC-DRM Test Instrument • DUC DTAWeb
• DTAWeb - Data Storage SFRA
M7100 - Test Capabilities

In the Box Accessory Other

PF/Tan-Delta & Cap DUC Ethernet
Variable Frequency M7-Truck USB
PF/Tan-Delta MFL Oil Cell
3/1-Phase 10kV Iex Type-C Resonator
1-Phase 10kV TTR
3-Phase LV TTR Accessories
3-Phase LV Iex M110 AC AMP
1/3-Phase WR M120 DC AMP
3-Phase LR M140 Cap Bank
1-Phase LR
Demagnetization
OLTC Control Coming soon
DFR for Transformers
DRM for Load Tap Changers
CT RatioV
CT Excitation
 Meter Group - LV
4 measuring leads, including ground/earth

LV Group - HI
4 LV Source & Measure Umbilical Cables
1 multipurpose accessory interface (N)

HV Group - LI
2 HV Source or Measure Leads

Proprietary & Confidential 33

The Back Of The M7100

Strobe Temp/Humidity sensor LTC Control Cable Guard/Ground

Comm Panel (Ethernet, USB, IEC 61850) Safety switches On/Off

NOTE THAT THE M7100 REMAINS IN ITS OWN SHIPPING CASE AT ALL TIMES
The Front Of The M7100

MG Ground Connector 3 M connectors

This side towards the
specimen under test

4 LV/HI Connectors

Accessory Port

2 HV Cables
Power Factor - Dissipation Factor

IC IT
I
Power Factor = COS Q = R

d I T

I
Dissipation Factor = TAN d = R

Q I C

IR E
Q % PF (% COS Q) d % DF (% TAN )
90 0 0 0
89.71 .500 .29 .500
84.26 10.00 5.74 10.05
0 100.00 90 INFINITY
Model Transformer Insulation

High • For Overall tests,

Voltage transformer insulation
Windings is sectioned into three
groups:
• CH
CH
CHL • CL
• CHL
CL
• Reasons
• Better assessment of
Low the individual
Voltage components.
Windings • Reduces the delusion
of the influence of an
individual component
due to “averaging”
DTA On-screen Help Menu

HV-1
H H H
1 2 3

X X X
HV-2
X
0 1 2 3

M-G
Transformer Test Procedures: Three-Phase Two Winding
HV1 lead

CH
CHL
Ground lead CL

HV2 lead

Test connections for test Nos. 1, 2 and 3

Test Line #1 Measurement CH + CHL
ICHL
HV1 Lead HV2 lead
High Low
ICH
HV1: HV2, MG Tank & Core

Test-set ICHL
ICH Ground lead MG
transformer

ICH + ICHL
Guard

Test ground
Measurement
circuit
Verification of the HV Results – DTAPro

Line #1 Measures CH+CHL , Tank and LV Winding Grounded

Line #2 Measures CH only to Ground, CHL Guarded
Line #3 Measures CHL only using UST Lead, CL Grounded
Line #4 Calculated from Lines 1 minus 2. Compare to Line #3 etc
Significance of Capacitance
Variable Frequency Power Factor and Capacitance

©2018 Doble Engineering Company. All Rights Reserved 43

Evaluation of CH Power
Data Interpretation
• Capacitance
• ∆C > + 5% - requires investigation
• % Power Factor:
• Need to assess both absolute value and change from initial and previous
• Liquid filled power transformers
• ≤230 KV: ≤0.5% Good, ≤0.7% Deteriorated
• >230 KV: ≤0.4% Good, ≤0.6% Deteriorated
• Liquid filled small distribution transformers
• ≤1.0% Good, ≤2.0% Deteriorated
 Bushing Failure

200m from
bushing
Condenser Bushing Construction
DTA Help Menu: Test Connections C1 Test

M4100 based
HV- connections
1
H H H
1 2 3
HV-1

HV-
2
X X X X
0 1 2 3

HV-
2 M-
G

M7100
Main Insulation C1 Test
HV1 Lead

Test Includes
•Main C1 Core Insulation

Test Mode: HV1: HV2

HV2 Lead
Guard

Measurement Circuit
MG Ground Lead

Bushing and
Apparatus Ground
Tap Insulation C2 Test

HV1 Lead

Test includes
•Tap insulator
•Core insulation between tapped layer and bushing
ground sleeve
•Portion of liquid or compound filler
•Portion of weathershed near flange

HV2 Lead

Test Mode: HV2: MG

IC2
Guard MG Ground Lead

Measurement
Circuit
Case Study: Bushings Failure investigation

• Catastrophic failure of 420kV OTF bushing

• Power station shut down to check all other
bushings
• Electrical tests: capacitance / loss angle
• Chemical tests: Bushing oil DGA

• Two further suspect bushings found

HV Bushing electrical results

Capacitance, pF % PF % PF 1995
11A 423 0.25
11B 419 0.24
11C 421 0.24
21A 425 0.35 0.25
21B 426 0.22 0.24
21C 424 0.33 0.25
22A 424 0.23
22B 425 0.22
22C 424 0.22
Excitation Current Testing: Finding a Turn-to-Turn Fault

Imag+ If fmag+ ffault

HV ffault X1
H1
E1 + Ifault
- LV
H0 X0

1) If a fault develops in the secondary windings, this fault will act as

a load across the faulted windings drawing a current Ifault.

2) As a result, the Excitation Current will go up due to the opposing

flux created by the fault [ffault].

Result: A Fault will cause Excitation Current to Increase

Excitation Current Testing Results

When analyzing Excitation Current,

you expect to see a pattern of
**Two Similar Highs and One Low
**Reference Paper:
A Further Study of Excitation Current Patterns
Spring Conference 2002
Excitation Current - The Pattern

In a magnetic core, the Reluctance of the steel acts much

the same to resist magnetic flux as a resistor does to current.

A magnetic core can be represented by a reluctance circuit

Core Sections

=
(a) Ferrous Core (b) Reluctance Circuit
Delta Winding

HV-1 HV-2 M-3

H H H
1 2 3

X X X X
0 1 2 3

M-G

M7200 based setup M4100 based setup

Test Connections - Delta Winding (H1-H2)

HV1 Lead
H1

ITest No.1 Test No. Energize - Measure

HV1: HV2 1 H1-H2
2 H2-H3
HV2 Lead 3 H1-H3
H3

H2

M3 Lead

*Any connected lead not designated as “Energize” or

“Measure” is automatically connected to the Guard point
Test Connections - Delta Winding (H1-H2)

HV1 Lead
H1

Test No. Energize - Measure

HV2: M3 1 H1-H2
2 H2-H3
HV2 Lead 3 H1-H3
H3

H2 ITest No.2

M3 Lead

*Any connected lead not designated as “Energize” or

“Measure” is automatically connected to the Guard point
Test Connections - Delta Winding (H1-H2)

HV1 Lead
H1

ITest No.3 Test No. Energize - Measure

HV1: M3 1 H1-H2
2 H2-H3
HV2 Lead 3 H1-H3
H3

H2

M3 Lead

*Any connected lead not designated as “Energize” or

“Measure” is automatically connected to the Guard point
Analysis Abnormal Pattern

• High current on one phase

A cat got in contact with the C (H3) bushing which tripped unit.
The bushing was replaced, and the equipment was put back into
service after a series of tests. Shortly thereafter, they noticed the
transformer running hot.
Performed a DGA and the TCG was very high.
Cap and %PF did not reveal any real problem but the Exciting
current did.
Turns Ratio Test
• Turns ratio test is used to detect one or more open or short-
circuited turns in a transformer winding. It can also detect
problems with tap changer connections and is a requirement
after LTC Maintenance
• The ratio for each winding should be within ± 0.5% of
nameplate values
• A single phase high voltage (10 kV) test may detect more
incipient problems as it places greater stress on the insulation
than the low voltage (50-250 volts) three-phase test. This
takes longer to perform.
Two Types Of Turns Ratio (TTR) Tests

High Voltage, Single-Phase TTR (“Doble” Ratio or “Doble” TTR)

• Higher Stress on Insulation - good for troubleshooting/investigative testing
• Performed at 10 kV or the maximum voltage the energized winding can
withstand (line-to-ground), whichever is less.
• With the M4100 a Doble capacitor is required. The M7100 does not require one!

Low Voltage, Three Phases TTR

• Faster - good for routine testing
• Performed at much lower voltage (50-250 volts)
• No change in test connections required after initial setup using
Doble TTR – Test 1, Three Phase D-Y

• Test 1: vector diagram

shows H1-H3
corresponds to X1-X0
M4100
• Place HV1 on H1, HV2 using TTR
on X1. Capacitor

• Ground H3 and X0.

• Energize HV1, apply
voltage across H1-H3
• Measure HV2
Three Phase, Low Voltage Turns Ratio Test Y-D
• Observe standard
safety and test
procedures.
• Assure solid
connections, including
ground.
• Energize LV and
measure M cables.
• Test performed in 50 -
250 volt range.
 Transformer Turns Ratio Testing: Tri-Phase

• Generates its own 3-phase test voltage from single-phase

• Test: Three-phase 8V@1 A, 40V@0.2A, 100V@0.1A
• Tests phase-shifting transformers
• Detecting 130 different 3-phase transformer types
• Excitation current reading range: 0-2 A
• Built-in LTC controller
• Ratio range: 0.8 to 15,000
• Stand-alone or computer-controlled

©2015 Doble Engineering Company. All Rights Reserved 66

Transformer Turns Ratio
What Tests to Do – Winding Resistance
• Widely performed on new transformers on installation, mainly
to check all leads disconnected for transport have been
reconnected correctly
• Widely performed after major maintenance on tapchanger to
check all connections restored correctly
• Also performed as part of to normal condition assessment
tests, especially if there are indications of overheating
• Dynamic winding resistance measurements can be used to
investigate tapchanger problems
DTA Quick Help: Test Connections – LV Wye Winding

H1 H2 H3

LV-N

LV-1 LV-2 LV-3

X0 X1 X2 X3

M-G
DTA Test Template
 Vanguard options
• Three-phase transformer resistance
meter
• 20 A and 40 A max test currents
• Calculates equivalent resistance value
• Auto discharge and demagnetises
• Dynamic Resistance measurements
for LTC

©2015 Doble Engineering Company. All Rights Reserved 72

 Dynamic Winding Resistance

• The dynamic winding resistance test measures the changing

resistive over time during the tap changer operation.
• Since OLTC works on a principal of make-before-break, which
implies no loss in continuity during a tap change operation.
• Dynamic resistance measurements identifies loss of continuity
during tapping which is typically the result of contact wear,
misalignment, loss of string tension etc.
• Typically on the diverter contacts

©2015 Doble Engineering Company. All Rights Reserved 73

Dynamic Winding Resistance

Contact Opened

©2015 Doble Engineering Company. All Rights Reserved 74

What Tests to Do – Winding Resistance

Contact problems on tapchanger barrier board

0.34

0.32

0.3
Resistance (ohm)

0.28
a-Na
b-Nb
c-Nc
0.26

0.24

0.22

0.2
1 3 5 7 9 11 13 15 17 19
Tap
Simplified Model of a Two-Winding Transformer
Leakage Reactance – Short Circuit Impedance
Primary winding dc Leakage reactance and loss Secondary winding dc
resistance measurement measurement, ZL resistance measurement

I1 I2

R DC-1 R L-1 L1 IL IC IR L2 R L-2 R DC-2

V1
L m CUST Rm V2
Exciting current and loss
measurement, ZM
 Leakage Reactance
• Test Sequence
• The measurement of the transformer impedance with the secondary
winding short circuited by applying a voltage to the primary and
measuring the corresponding current. With the secondary shorted the
current drawn by the primary is essential the result of the leakage flux.
• Purpose
• Detect winding movement: Measurements are sensitive to geometrical
changes in the leakage flux path.
• Radial dimension of winding
• Distance between inner and outer winding
• Height of winding
• Confirm nameplate impedance
Per-Phase Test Connections (Y-Y) – Phase B

©2015 Doble Engineering Company. All Rights Reserved 78

Three-Phase Equivalent Test Results
LR Interpretation
• Initial Test
• Three phase equivalent:
• Compare % Reactance with nameplate (factory test).
• Assumes that tests performed on same tap position as factory
• Limit – ≤3% if exceeded: Requires investigation and confirmation from other
tests before condemning transformer. In other words don’t condemn
transformer sole on this limit.
• Compare resistance to total impedance should be 15% or less, if
exceeded increase amount of copper used to short the windings.
• Per phase test
• Compare % reactance among phases
• ≤2% of average of the three readings, if exceeded
• Compare resistance of three reading, if there is an outlier, verify integrity
of short between two bushings and repeat test
A 1966 GE, 3,GSU-Y/D, 114/13.2 kV - 80 MVA subjected to
two out of phase synchronization events (180o), with 26kA during about 3 seconds.

All test results (DGA, oil quality, Exciting Current, TTR, and
Winding Resistance) were acceptable, with exception:
Power Factor test provided CL decreased 5.5% (from 42371 to
40028 pF) from previous year test. Internal Inspection?
LRT provides clearer information: NP %Z= 10.02%.
Measured %Z: 11.26% ( 12% off NP %Z) in 3-phase equivalent.
Measured %Z per phase: H1-H0 = 11.97%, H2-H0 = 10.81%, and
H3-H0 = 9.12%.
Bad synchronization...
 What Tests to Do – DFR
Some ideas about dielectric frequency response :
• Family of different tests, of which dielectric frequency sweep is
now the most widely used.
• Claim to be able to assess moisture content.
• Good additional check on dielectric condition
• Widely performed as part of condition assessment tests on
transformers in the field, especially older transformers with
higher moisture
What Tests to Do – DFR (dielectric Frequency response) methods
Typical results for 132kV transformer built 1967

These dielectric response methods work well for newer transformers with the oil in good conditions. Once the
oil and paper are aged the dielectric response methods are uncertain and often overestimate moisture content.
Low and High Molecular Weight Carboxylic Acids (LMWA and HMWA, respectively) appear in transformers
as by-products of insulating liquid and cellulose aging and effect the moisture estimation. Doble is beta
testing this feature for the M7series now with a correction for the Carboxylic acids for release in 2018.
 M7100 - Fast & Safe

• 4X+ Faster
• Designed to minimize lead movements
• Test set and software do all the work
• Dual HV lead that also measure (patent pending)
• Get more tests done
• New 3-Phase Iex Test
• OLTC Control
• 4X Safer
• 30+ Ladder & Bucket trips reduced to just 7
• 5-7 hours of testing in 90 minutes
 The M7100: In Summary - NEW CABLE SET

• Two HV cables enable reducing test times and ladder

trips; either one can energize or measure
• Four LV cables can run low voltage / high current tests,
eliminating the need for other test accessories for
Leakage Reactance or LV three phase TTR
• There are four measuring (M) cables including ground
(MG).
• An LTC control cable speeds up testing transformers with
on-load tap changers
The M7100: In Summary
More Tests With One Instrument and One Set Of Cables -
• Power Factor and Capacitance
• HV TTR
• LV TTR
• Excitation Current
• Leakage Reactance
• Winding Resistance
• Demagnetization
• DFR
• (Coming soon: Contact Resistance tests, Cap Bank tests, primary injection tests)
The M4100: In Summary
Can do 80% of tests but needs to be supplemented by Vanguard
portable instrumentation for transformer Diagnostics
✓ Power Factor and Capacitance
✓ HV TTR (with TDR Capacitor)
LV TTR using Vanguard Ratio Meters
✓ Excitation Current
✓ Leakage Reactance using M4110 module
✓ Static and Dynamic Winding Resistance using Vanguard WDR
instruments
✓ Demagnetization using Vanguard WDR instruments
Mechanical Failure
SFRA

• SFRA is a tool that can give us an indication of winding

movement or electrical short circuits in transformers
Doble SFRA TEST – CONNECTIONS

Red Lead: Source & Reference (Vi) Three Lead Test

Green clip:
Ground

Black Lead: Response (Vo)

Case Study

• SFRA
• High Side shots w/ Low side open
• H2-H0 (center phase) identical to H1-
H0, with significant shift in H3-H0
• High Side shots w/ Low side short circuited
• Approx. .7 dB difference between H1-
H0 and H3-H0
• Low Side shots
• X1-X2 phase (outer phase; H1-H0 phase
pair) similar to X2-X3 (center phase),
with significant shift of X3-X1 phase in
lower freq.
• Significant differences between the
traces at higher frequencies
Case Study

‘C’ phase LV coil

moved downward
axially. This is likely
responsible for
differences in LV
SFRA tests and LR.

Evidence of Radial Buckling on ‘C’

HV winding, and axial movement
of HV and LV coils. This is likely
responsible for the differences in
the HV SFRA shots with the LV
short circuited and LR.
Why Choose Doble?

• Doble Quality
• Ease of use
• Training & Field Support: Client Service/Application
Engineering
• Software – reports and data management
• DTAWeb for organization & test result file storage
• DTA/Off-Line Testing Users Group for issue discussion with
peers, latest downloads and resources
• When you have to make a decision – we are there with you!
Questions?