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Operation, Maintenance and Condition Monitoring Practices for Long Service

Life of Transformers : Tata Power experience

Conference Paper · December 2018

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 Operation, Maintenance and Condition Monitoring Practices for Long Service Life of
Transformers : Tata Power experience

S.G. Patki, M.V. Kini, T. Muralikrishna, A.Mukherji, S.K.Prasad

The Tata Power Company Limited, Mumbai

The Tata Power Company is the largest integrated power utility in private sector in India and has a
presence in all segments of power sector viz. generation (Thermal, Hydro, Solar and wind),
transmission, distribution and trading. The company has an installed capacity of 7700 MW. It is one
of the largest renewable energy players in India and is developing country’s first 4000MW Ultra
mega power plant at Mundra (Gujarat) based on super critical technology.

Tata Power completed more than 95 years of operation in Mumbai area with a track record of
reliability of power supply. There are large numbers of transformers which are in service for more
than 50 yrs with 2 nos. of transformers crossing 75 yrs of life and still in satisfactory service. Good
operation and maintenance practices supplemented by condition monitoring are the critical factors
which have led to the long service of these assets. This paper presents the statistical analysis of the
vital parameters of the transformers over their service life.

The present practices of condition monitoring and maintenance are described in the paper along
with its evolution over a period of time. The practices include online and offline methods and the
experience of Tata Power in diagnosis as well as predictive assessment of transformer are described
with some case studies. The online measurement of some of the parameters like oil temperature,
winding temperatures and physical observation like oil leakages and condition of the breather,
installation of conservator oil preservation system (COPS) goes a long way in preserving oil quality.
The online diagnostic condition monitoring though desirable should be used judiciously so that the
meaningful maintenance decision can be taken.

Performance of the protection systems also improved over the years in clearing the faults faster
than before by adoption of new technology and improvements in protection scheme designs. The
paper concludes that long service life can be achieved by good operational practices that reduce the
stress on the transformers by thermal overload as well as electro-mechanical stresses experienced
by the transformers during through faults and nearby faults. This has to be supplemented by
monitoring of vital parameters and condition based maintenance. Statistical analysis of condition
monitoring parameters over service life of Transformer has been presented.

Overview of Transformers in Tata Power

Tata Power started with a vision to supply cheap and abundant power to Consumers of Mumbai
from remote hydro plants situated nearly 100 km away. Transformer is one of the important
equipment in the keychain of Power Supply. At Tata Power Mumbai Operations, more than 150
power transformers are in service of various rating, make and age. Some of the transformers have
served more than 75 years and are still in service. Normally the average life of a Transformer is
considered to be around 25 to 30 years. At Tata Power, about 40 % transformers are in service for
more than 25 years; which is due to good practices adopted in condition monitoring and protection
philosophy.

Page 1 of 10
 Table-1: Population of Transformer MVA Table-2: Population of Transformer Age wise
capacity wise
MVA Count % Type Service Year Count %
> 200 27 21.3% GT, ICT <5 17 13.4%
100 -199 5 3.9% DT, GT 5 - 15 13 10.2%
60 - 99 51 40.2% DT 16 - 25 44 34.6%
31 - 59 14 11.0% DT 26 - 40 28 22.0%
11 - 30 28 22.0% DT 40 - 50 19 15.0%
7 - 10 2 1.6% DT 51 - 75 2 1.6%
Total 127 > 75 4 3.1%
Total 127
#
GT-Generator Trf, ICT-Interconnected Trf, DT-
Distribution Transformer 4 Transformers have served more than 75 years.

Above data is from Mumbai Operation area only

Power Transformers are the most vital components in a sub-station / Receiving station. Failure of a
Transformer leads to loss of Revenue to the Utility besides affecting reliability of power supply to
consumers. The failure can lead to non-availability of Power Supply for long durations. Transformer
failures can be classified in two categories, Current related failures and voltage related failures. As
per statistics, 95 % failures can be attributed to current related failure and only 5 % are voltage
related failure. Most of the fault starts with current related problem like hot spots or
electromagnetic forces created while feeding external short circuit that results into failure of
insulation between the turns (while feeding through faults). High energy generated during internal
short circuit can lead to deformity of winding, core or tank.

Current related failures are due to lack of ability to withstand short circuit, loose connections,
Overloading/Overheating (non flow of oil) and opening/shortening of magnetic circuit. Voltage
related failure is due to lack of availability to withstand switching and lighting impulse, deterioration
of insulation and partial discharge. Transformer accessories like bushing, tap changer are integral
part for operation of transformer and its failure will also cause non availability of transformer.

Table-3: Failure Of transformer in last 3 decades Table-4: Age of Transformer at Failure

Type of Fault Trf. Failed % Service Year Trf. Failed %

Winding fault* 15 52% <5 6 21%
Core heating 5 17% 5 - 15 8 28%
Bushing 3 10% 16 - 25 8 28%
Fire@ 4 14% 26 - 40 1 3%
Tap Changer 2 7% 41 - 49 3 10%
Total 29 > 50 3 10%
Total 29
*
Winding Fault is Interturn fault, winding
movement, and contact with tank.
@
Fire- Over Heating, continuous overloading

Page 2 of 10
The failures indicated in above tables are not total failure but, had to be taken out for attending to
the defects (except in few cases). Main reasons for current related problems are Poor
Design/Workmanship/Material, Looseness in the winding due to ageing, brittleness of winding
insulation winding due to improper filtration and drying out process of transformer, frequent
switching ON of the transformer on Faulty feeders.

Voltage related problem are due to Switching and Lightning Impulse, Bushing failure, Flashover of
Bushing leads on tank, Failure at lead take-off position in HV side, Inter-turn faults developed due to
partial discharge, Stressing and failure of insulation due to moisture. Failure of core bolt insulation or
multiple grounds in core could also result in damage to core.

Operation & Maintenance Practices:

In order to ensure that Power Transformers have long and trouble-free service, adverse operating
condition for transformers is generally avoided. They are
a) Operating temperature should be preferably less than 70oC (OTI).
b) Avoid Long duration overloading of transformer.
c) Heavy overloading is avoided by installation of Over Load trimming Scheme (OLTS) to
remove non-critical loads.
d) Reduction in Short Circuit level by opening bus section breaker (where the SC level is
reaching up to Circuit Breaker rating). Reduction in fault clearance time by the protection
system so that stress on transformer is minimal.
e) Providing surge arresters to take care of Transient Overvoltage (Lightening and Switching)
f) Use of tap changer to prevent Over fluxing of transformers

For maximising utilisation of assets; several diagnostic tests are carried out and remedial actions are
initiated; throughout operational life of transformer. These practices are
a) Operating the transformer at 2/3 of its maximum capacity (MVA).
b) Parallel operation of transformer for reliability of Power Supply.
c) Load trimming schemes for shedding non important load, during overloading of transforms.
d) Integration of WTI, OTI, Buchholz and other important transformer alarm with plant control
system. (DCS, SCADA)
e) Commissioning of neutral grounding reactors for limiting the single phase to ground fault
current, without losing the sensitivity of over current protection.
f) Replacement of conventional oil conservators of transformers with COPS.
g) Changing of tap position of ‘OFF circuit Tap changer’ as per seasonal requirement.
h) Surge Arrestors for Transformers.
i) Checking healthiness of transformer bushing, calibration of devices at regular interval

Good Preventive maintenance practices have increased the useful life of transformer at Tata Power.
a) Arresting oil leakages
i) Change of gaskets based on condition
ii) Complete overhaul once in 15 years or condition based.
b) Refurbishment / Replacement of oil, if chemical or electrical properties have violated limits.
c) Reconditioning of Earth pits based on test values.
d) Monitoring Insulation resistance of winding whenever Transformer is cut out for any reason
/ every year.
Page 3 of 10
 e) Replacement of defective transformer devices like MOG (Magnetic Oil gauge), WTI, OTI, PRD
(Pressure relive device), OSR (oil Surge relay) if found non-functional during device trials.
f) Replacement of transformer bushing based on absolute value & trend of tan delta and
capacitance value.
g) Replacement of Surge Arrester based on leakage current measurement.

Tata Power’s practices of Operation and Maintenance of Transformer are due to experience and
technical expertise gained over last 90 years. These include daily rounds of Switchyard Inspection
which covers transformers, practicing OEM guidelines, interactions with field experts in conferences
and by adopting latest diagnostic technique available. Periodic checking of healthiness of
transformer associated devices like Surge arrester, bushing, WTI (Winding Temperature Indicator),
OTI (Oil Temperature Indicator), Silica gel (breathers) has enhanced the working life of transformers.

Table-5: Online and Off line diagnostic testing of transformer

ON Line Test Off line Test

Observation/test Frequency Observation/test Frequency
WTI, OTI, Oil Leakage Daily Resistance of earth pit Yearly
Silica Gel Daily IR & PI of Transformer, Yearly
DGA & Moisture of oil Half yearly IR of Core & Frame Yearly
Trf. Oil DF & Resistivity Half yearly Surge Arrester Yearly
Trf. Oil BDV Half yearly Bushing Cap. & DF Yearly
On Line H2 gas Monitor 4 hours Capacitance & DF 5 year
On Line Multiple Gas DGA 4 Hours Magnetic Balance 5 year
Thermo vision Scanning Need base Core Losses 5 year
Acoustic Partial Discharge Need Base Device Trails 5 Year
Oil Line Oil Filtration Need Base Winding resistance 5 year
CCTV continuous SFRA 5 Year
Furan 6 Year

Transformer condition monitoring practices have evolved over a period of time. Earlier it was time
based low voltage diagnostic testing. Condition based testing of transformer is a new trend.
Condition of transformer can be judged by monitoring and trending transformer oil DGA & moisture,
acidity, Tan delta and resistivity, number and severity of fault feed, overloading, age of transformer
etc. At Tata Power about 40% of transformers are in service for more than 25 years. Since a large
population of the Transformers is in service beyond 25 years, it was felt that we should also assess
the residual life of the Transformers, so that appropriate and timely action can be initiated for their
refurbishment / replacement. This would also help in avoiding unforeseen failure of any
Transformer, which could result in interruption of power supply.

As a first step, the Furan content measurement for all the Power Transformers was carried out in
2006. The Furan test gives the approximate value of DP of paper on the winding and thus the
remnant life of the transformer can be estimated.

Page 4 of 10
Risk & Failure Indices:

In order to monitor the condition of Electrical equipment, two new indices have been developed viz.
a) Equipment Failure Rate and
b) Equipment Risk Rate.

Electrical Equipment such as Transformers, Circuit Breakers, outdoor Instrument Transformers,

Bushings, Lightning Arrestors, Motors and Generators are covered for monitoring purpose. The base
equipment data which is required for calculation of above indices are derived from respective
Condition Monitoring Schedule and are captured as per their voltage class (220kV to 3.3kV). This
classification gives more clarity on concern area from Operation & Maintenance point of view.

The “Equipment Failure rate” is calculated based on number of units failed in a financial year with
respect to total number of units in service. Equipment failure does not necessarily mean total
failure; it may be that the equipment is removed from service for repairs/replacement.

No of Equipments failed in FY
% FailureRate = x 100
Total No of Equipments in the system

Similarly the “Equipment Risk Index” is calculated based on number units remaining in service with
condition monitoring parameter limits violated with respect to total number of units in service i.e.

No of Equipments in service with lim its violated

Equipment Risk Index = x 100
Total no of equipments in the system

Table-6: Examples of Limit Violation

Parameter Limits

Tan Delta 3.0 % for power transformer; 5.0 % for Distribution transformer
Oil DGA As per guidelines
Oil Tan delta & Resistivity 20 % & 0.2 Tohm-cm
Oil PPM > 50 ppm
Winding Resistance 2 % Variation from previous reading as well as between phases
Bushing Tan Delta > 0.7, Change in Tan delta=10%, Change in Cap=50 %

The Equipment Risk Index is a lead indicator for Equipment failure. Hence, preferably no equipment
shall remain in service with its parameter limits violated. Else, appropriate risk mitigation plan shall
be evolved to take care of the above.

Page 5 of 10
 Figure-1: Chart for Failure Risk Indices of Transformer.

Figure-2: Chart of transformer that has violated limit V/S Total No of Transformer

Integration of power system is the need of time. Concept of national grid is booming for reliability of
supply to consumer. This integration has increased the fault levels of station. Existing switchgear are
not able to handle these fault levels and frequent rate of failure of switchgears have increase in last
5 years. These failures are a source of stress to transformers. Fast responding numerical relays are
boon to transformers as they help in faster isolation of fault, reducing the stress on transformer.
Accurate temperature sensing and other monitoring devices having networking facility are helping
utilities for optimal use of transformers. Trending and maintaining historian is helpful in condition
assessment of transformers.

Oil preservation:

Oil in transformer acts as an insulation as well as cooling medium. Contamination of this oil is mainly
due to moisture ingress from outside or moisture during decomposition of paper and other material
used for assembling transformers coils and core. Oil preservation practices are
a) Use of COPs for transformer above 10 MVA rating
b) Two breathers per pipe ensuring reliable moisture extraction and for breather maintenance.
c) Filtration of oil when moisture is higher than 50 ppm.
d) Replacement of oil, when acidity is higher than 0.30 mgKOH/g.
e) Breathers with heater arrangement, for continuous recondition of silica gel.

Page 6 of 10
Transformer Overhaul:

Transformer overhaul carried out in last decade are ICT-1&2 at Bhira, ICT-4 at Trombay, Trf-2 at
Mahalaxmi, DT-1&2 at Saki, Trf-1 at Chembur, Trf-1 at Borivli, DT-5 at Trombay and Trf-1 at
Ambernath. Decision regarding transformer overhaul is dependent on many parameters like
leakages in tank, deviation in electrical diagnostic test, oil test results (DGA, moisture, Furan) of
transformer oil. Transformer overhaul process includes Inspection of windings and core, sludge
removal from bottom of the tank, Oil cleaning (filtration), Gasket replacement, and defective devices
replacement, attending radiator leakages, tap changer overhaul or replacement.

Remnant Life of Transformer:

At Tata Power, since the transformers are in service for more than 25 years, need was felt to assess
the residual life of the Transformers so that appropriate and timely action can be initiated for their
refurbishment / replacement. This would also help us in avoiding unforeseen tripping of any
transformer, which could result in interruption of power supply. As a first step, the Furan content
measurement for all the Power Transformers was carried out in 2006.

Table-7: Furan content of transformer

Avg. Age of
Trf. During
Furan (mg/Kg) DP Count % failure Interpretation
> 5.315 < 240 6 5% 38 End Of expected life of paper
3.277 - 5.315 300-240 5 4% 51 High Risk Failure Zone
2.021 - 3.277 360-300 13 11% 43 Excessive ageing, Danger Zone
0.292 - 2.021 600-360 34 30% 34 Accelerated Ageing rate
< 0.292 > 600 56 49% 18 Normal Ageing Rate
Transformer in service in Mumbai Operation (Total trf-114)

DP of paper used in transformer gives good information about the life of transformer. DP of paper
can be estimated from 2-Furfural content in oil using well established Chendong’s Formula. Two
Cases are shown below were DP of paper was estimated from 2-Furfual contents of oil. These
estimations were found different from actual DP of Paper measured after taking samples from
various locations in transformers.
Case 1: Saki R/S, Trf-2, 72 MVA, 110/23.1 kV
Furan Content (mg/Kg) Aug-06 Jan-08 Feb-08 Apr-08
Hydroxymethyl 0.043 0.028 0.14 0
Furfuryalcohol 0.013 0.026 0 0
Furfural 1.127 1.308 8.39 12.739
Acetyl furan 0.014 0.011 0 0
Methyl 2 furfural 0.029 0.031 0 0
Total furan cont. in oil 1.226 1.404 8.53 12.739
Estimated Value 417 398 167 116
Paper Insulation Average Average Deteriorated Deteriorated
Actual Avg. DP of paper 645

Page 7 of 10
Actual DP of paper is better than estimated value. The carbonized tap changer barrier cylinder was
replaced during overhaul.
Case 2: Mahalaxmi R/S, Trf-2, 90 MVA, 110/23.1 kV

Furan Content (mg/Kg) 20.8.2006 19.11.2007 19.1.2012

Hydroxymethyl 0.53 0.22 -
Furfuryalcohol Nil Nil -
Furfural 8.06 7.52 -
Acetyl furan 0.15 0.08 -
Methyl 2 furfural 0.28 0.24 -
Total furan cont. in oil 9.02 8.06 -
Estimated Value 172 181 -
Paper Insulation Deteriorated Deteriorated
Actual Avg. DP of paper 440
Actual DP of paper is better than estimated value.

DGA for Condition Monitoring

Off-Line DGA testing of transformer oil is being done annually for all transformers in the system as
part of condition monitoring. In addition, Transformers which have fed nearby or multiple faults are
being tested for DGA quite frequently. Periodic gas analysis has its own advantages but it may not
be effective always, as seen in some of the cases where the transformers developed serious faults,
though the DGA test done few months before the incident did not reveal any abnormality. Open
Circuit of one of the Distribution Transformers (DT) over a period of time and failure of a DT
subsequent to fault on an outgoing feeder are few examples.

Case-1: 250 MVA, 220kV/110kV ICT, at one of the receiving stations, which had a gassing history was
selected. The DGA results were indicating that there could be some hot spots in the core. The gas
concentrations on the ICT were increasing but had not yet reached alarming levels. Below Table-7
shows trends of various gasses in the ICT which were increasing abnormally. The Duval Triangle
methodology shows T3 region indicating thermal fault in the Transformer (> 700 degree Celsius).

Graph showing trend of relevant gasses from 2008 onwards till it was cut out in Feb’10.

Page 8 of 10
 Figure-3: Trend of relevant gasses

As the gas concentrations had increased abnormally, the transformer was cut out in Feb 2010 for
detailed investigation. The transformer was un-tanked at the repair agency’s workshop and the
following observations were noted.

The top yoke laminations were removed & reassembled in 1997 to replace one of the LV
windings which developed an inter-turn fault. The laminations were not inserted / aligned
properly during assembly leading to bending at the edges and getting shorted with adjacent
laminations while inserting the core bolts with force. These shorted laminations developed hot
spots and started gradually damaging the insulating sleeves of the core bolts, ultimately
puncturing one of them. This might have led to circulating currents in the core and contributed
to generation of gasses.
The transformer was repaired by replacing all top yoke laminations and core bolt insulation and
was successfully taken into service in Sept’10. Some of the photographs taken during investigation
and repairs are shown below.

Figure-5: Damage of laminations Figure-6: Core lamination Figure-7: Burn marks on the core
near core bolt guiding hole damages at edges bolt sleeve

Buchholz Relay operation

Buchholz relay is a safety and protection device for oil filled transformers equipped with external
overhead conservator detecting incipient faults in transformers. The Buchholz Relay is sensitive to
the effects of dielectric failure inside the equipment. Relay operation is also experienced due to oil
surge created while transformer feeds external short circuits. In below table, number of transformer
tripping due to operation of Buchholz relay is given, where no fault was found in transformer. The
SFRA results were found normal and matching to earlier signature. The reason for Buchholz relay
operation for nearby faults could not be ascertained from these SFRA or other diagnostic tests. It is
expected that due to looseness of winding / core clamping, oil surge gets created while feeding fault

Page 9 of 10
 current, however this was not corroborated by SFRA test since there is no permanent distortion of
winding.

Table-8: Transformer tripping due to Buchholz relay wrong operation.

No. of
Year Instances Reason Action
FY-07 2 Operated for O/G Feeder fault Bz relay replaced
FY-08 1 Operated for O/G Feeder fault Bz relay replaced
FY-09 4 Operated for O/G Feeder fault Bz relay replaced
FY-10 4 Problem in cooling oil circulation scheme Modification in scheme
FY-11 Nil
FY-12 Nil

Conclusion:

The paper analyses performance of transformers in Tata Power System.

a) It is important to minimize hazardous condition experienced in service life of transformer.
The stress can be minimized by management of loading, voltage levels, cooling and
protection system.
b) Sound condition monitoring practices, preventive maintenance schedule as well as condition
based maintenance practices at Tata Power has ensured trouble free life of transformer and
optimal use of these assets.
c) Transformers should have better design specification and utility specific practices eg. COPS,
Dual silica gel breathers, online and offline DGA trending etc.
d) Old transformer show better performance, possibly due to abundant design margin.

Page 10 of 10

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