KRUEGER Transformer Health Assessment Presentation

Transformer Health Assessment
Michael Krueger
OMICRON, Austria
• Introduction
• Diagnostic on Power Transformers
– Oil
– Main Insulation
– Magnetic Core and Coil
– Diagnostic of the Bushings
– Diagnostic of the Tap Changer
• Case Study – Health Assessment of a Transformer
2
Work of Cigre - Transformer Health Assessment
Cigre WG Topic Brochure Year
A2.18 Life Management Techniques for Power Transformers 227 2003
Recommendations for Condition Monitoring and
A2.27 343 2008
Conditioning Assessment for Transformers
A2.34 Guide for Transformer Maintenance 445 2011
A2.37 Transformer Reliability Survey 642 2015
A2.43 Bushing Reliability
A2.44 Intelligent Conditioning Monitoring Systems 630 2015
A2.45 Transformer Failure Investigation and Post-Mortem Analysis
A2.49 Condition Assessment of Power Transformers
A2.55 Life Extension of Oil Filled Transformers and Shunt Reactors
3
Assessment of Transformer Health
Diagnostic Ageing Models Experience of
Measurements Manufacturer
Monitoring Failure Statistics

Health
Analysis of Assessment Factory
Operation Data Acceptance Tests
Visual Checks Voltage Tests
History of  Normal Operation Service

Assessments  Treatment/Repair Experience
 Exchange
5
Components of a Generator Step-Up Transformer
HV Bushing
LV Bushing
Cooling
Diverter Switch
Tapped Winding
Tap Selector
Core High Voltage Winding
Low Voltage Winding
6
Indicators used to Estimate the Health Index
P. Picher et. al. „Use of Health and Reliability Dta for Transformer Condtioning Assessment and Fleet Ranking“, A2-101, Cigre Paris 2014
7
Assessment of Risks
8
Transformer Assessment
Date of assessment 2016-12-30
Responsible xxx Transformer Assessment
Location/Substation xxx
Transformer ID xxx Assessment 2
Serial number xxx Exchange priority 2
Year of manufacturing 1983
Expected life time (years) 45
new old
10 9 8 7 6 5 4 3 2 1
Transformer age 33 Years X
excellent bad
10 9 8 7 6 5 4 3 2 1
X Remarks
Core X
Winding X
Cellulose insulation X no ageing detectible
Oil X normal ageing
HV bushings X 1N -> increased capacitance and tan
LV bushings X 2W -> increased capacitance
Tap changer X
Motor drive X
Cooling system X 1 cooling group renewed
Oil leak X
Corrosion protection X
LV wiring and protection X
Source: VKW Bregenz Austria
9
10 9 8 7 6
Excellent condition Excellent condition Very good condition Good condition Satisfactory condition
no diagnostic and repair measures in long-term no diagnostic and repair long-term no diagnostic and repair no immediate action required no immediate action required
the long term measures measures expected
No recognizable defects exist No notable defects exist Negligible deficiencies exist Small deficiencies present, long term Major deficiencies exist, medium-
measures required term measures necessary
5 4 3 2 1
Moderate condition Sufficient condition Poor condition Insufficient condition Very bad condition
no immediate action required partial repair necessary partial repair necessary partial repair necessary, increased immediate general repair necessary
operating risk
Major deficiencies exist, short-term Severe shortcomings, operation of Severe shortcomings, operation of Safe operation of the system Safe operation of the system no
measures necessary the plant in the medium term with the system in the short term with without online monitoring no longer longer ensured
increased operational risk increased operational risk ensured

10
Bathtube Curve of Failure Rate
Source: Wikipedia Feb. 2014
11
Failure Locations
of Substation Transformers > 100kV
Source: Cigre WG A2.37

“Transformer Reliability“, Cigre
Brochure 642
12
Failure Locations
of Generator Step-up Transformers > 100kV
Source: Cigre WG A2.37

“Transformer Reliability“, Cigre
Brochure 642
13
Causes of Ageing
• Dielectric causes
• Electromagnetic causes
• Thermal causes
• Chemical causes
14
Electromagnetic Causes of Ageing
High currents (e.g. due to short circuits nearby the transformer)

produce high mechanical forces
• Deformation of the winding

• Damage of the paper insulation (cracks) , particularly on aged parts
• Initiation of partial discharges
• Initiation of partial break-downs
15
Thermal Causes of Ageing
• Hysteresis losses in the magnetic core

• Shorted laminates
• Resistive losses in the windings
• Dielectric losses in the insulation
• Load changes will cause warming up and cooling down - negative
influence on the lifetime of the insulation
• The ageing of the insulation is accelerated by a factor 2, if the
temperature is increased by 7°C (valid for normal operation temperatures)
16
Chemical Causes of Ageing
Organic acids are produced as a result of ageing
• In particular, they affect the paper insulation

-> accelerated ageing
• Metals like Copper, Iron, Aluminium and Zinc are behaving like catalysts
-> accelerated ageing
17
Ageing of the Cellulose by Acids
Microstructure of paper with Neutralization Number [mg/kg]

(from left to right) 0.05 0.1 0.2 0.3
18
Ageing in the Cellulose
• Ageing of Cellulose is caused by:
• the influence of oxygen

 Oxidation
• the influence of water

 Hydrolysis
• the influence of heat

 Pyrolysis
19
Ageing of Paper
As the cellulose ages, the glucose ring chains break (depolymerisation).

The following substances are produced:
H 2O
Water H 2COOH
OH
H
Gases (CO, CO2) C O O C C
Furanes CH
H
H CH CH
H
OH CH
OH H2COOH
Carboxyl Groups (organic acids) C C C O
H OH H
20
Water as Ageing Factor
Water and heat accelerate the ageing of the Cellulose
10 00
ti onsg eschwi ndi gke it

80 °C
of depolymerisation
10 0 °C
ol ymerisa
ative Depspeed 10 0 12 0 °C
10
Rel Relative
1
0 1 2 3 [%] 4
Wa sse rgcontent
Water eha lt iminPpaper
api er
To extend the lifetime, the water has

to be removed from the insulation!
21
• Introduction
– Oil
– Main Insulation
22
Information from Oil Analysis
Information about
DGA
the transformer
Chemical and Information

Electrical Tests about the oil
Furan Analysis
Information about
Methanol Analysis
the ageing of the
Ethanol Analysis
solid insulation
23
IEC 60422
24
IEC 60422
Water Saturation in Oil
25
Gases in Oil caused by PD
26
Gases in Oil caused by PD
27
Gases
Combustible Gases
Envirom. Paper
Propylene C3H6
Propane C3H8 28
• thermal
• electrical
Fault Gas Formation
Hydrogen
• mechanical Oil Molecules
Methane
• chemical Ethane
Ethylene
Acetylene
Propane
Propylene
ENERGY
Cellulose Carbon Monoxide

Molecules Carbon Dioxide
29
Gas Formation from Oil Dependent on the Temperature
30
Gas Formation from Cellulose Dependent on the Temperature
31
1. Partial discharges
Key Gases
32
Cigre Brochure 296 – Typical Gas Values
33
Cigre Brochure 443
Oil Sampling Intervals versus Gas Concentrations
34
IEEE Std C57.104
Table 1: Dissolved Gas Concentrations
35
Furane Analysis
Source: B.Yves, et al.: “MV/LV distribution transformers: Research on paper ageing markers”, Cigre D1.103, 2012
36
Warning Levels
Paper Degradation
Cigre Brochure
227 - 2003
37
Methanole MeOH Analysis
Source: B.Yves, et al.: “MV/LV distribution transformers: Research on paper ageing markers”, Cigre D1.103, 2012
38
• Introduction
– Oil
– Main Insulation
39
Main Insulation
• Water Content Measurement with Dielectric Frequency Response
• Insulation Resistance Measurement
• Capacitance and Dielectric Dissipation Factor Measurement
• Partial Discharge Measurement
40
Water Distribution in Transformers
Source: J. Aubin
W-ACTI Conference
San Antonio 2005
Source: Weidmann AG
41
Equivalent Circuit Diagram
b. Model for the
a. Plate condenser behaviour of a
as a model for dielectric with
dielectric insulation polarisation
characteristic and
c. Part of the cross conductivity
section of a power
transformer main d. Simplified geometry
insulation system model for the main
between HV and LV components oil,
windings barriers and spacers
e: Dielectric model
for the insulation
system of power
transformers
42
Interpretation and
Interfacial Polarisation
and Transition from
Analysis
Capacitive to Resistive
Pressboard: Voltage Distribution
Water, lwm Oil: Carbon, Sludge hwm
Acids Acids
Dissipation factor
10
1
Pressboard
0.1 Overall Response
1%, 1pS/m, X30, Y15
0.01
0.001
0.0001
0.0001 0.001 0.01 0.1 1.0 10 100 1000
f/Hz
43
Analysis of the Water Content by Comparison to Model Results
Measurement Laboratory Results
Temperature
Oil XY-Model
Y
Oil Spacers
Barriers X
Comparison
Fitting
10
Tangent Delta
Water Content
0,1
Oil Conductivity
Source: Weidmann
0,01
0,0001 0,01 Frequency [Hz] 100
44
Check box:
Assessment Settings Variable calculated by software
Required:
Oil temperature
Optional:
Geometry XY
Optional:
Oil conductivity
45
Moisture Assessment
before fitting
T = 20°C
Barriers: 40 %
Spacers: 40 %
WC: 0,5 %
after fitting
T = 30°C
Barriers: 35 %
Spacers: 24 %
WC: 1,2 %
46
DFR Measurement on a 200 MVA Transformer
Transformer DFR Instrument (DIRANA)

47
Before Drying
2,5%
48
Measurement on a 200 MVA Transformer
Decision:
Drying of the
transformer
49
After Drying
1,3%
50
DFR Measurement Before and After Drying
2,5%
1,3%
51
Main Insulation
52
Insulation Resistance Measurement
220kV Transformer before and after Drying
Measurement s A Ri PI DAR
CHL before drying 60 s 355,0379 nA 0,5633 GΩ 1,813 1,41
CHL after drying 60 s 120,0924 nA 1,6654 GΩ 3,947 1,45
Measurement s RiCLT before drying PI60 s 190,8125

DAR nA 1,0481 GΩ 3,021 1,51
CLT after drying 60 s 91,4022 nA 2,1881 GΩ 4,977 1,61
CHL before drying 600 s 1,0212 GΩ 1,813 1,41

Measurement s A Ri PI DAR
CHL after drying 600 s 6,5739 GΩdrying3,947

CHL before 1,45
600 s 195,8481 nA 1,0212 GΩ 1,813 1,41
CHL after drying 600 s 30,4232 nA 6,5739 GΩ 3,947 1,45
CLT before drying 600 s 63,1595 nA 3,1666 GΩ 3,021 1,51
DIRANA CLT after drying 600 s 18,3631 nA 10,8914 GΩ 4,977 1,61
53
Main Insulation
54
Capacitance and Dissipation Factor Measurement @ 50Hz
220kV Transformer Before and after Drying
C(10mHz) /
Measurement Tan δ C
C(50Hz)
CHL before drying 0,00811 12,0551 nF 4,4579
CHL after drying 0,00375 11,6719 nF 1,6735
CLT before drying 0,00779 14,0735 nF 3,8066

DIRANA CLT after drying 0,00383 13,6873 nF 1,6937
55
Main Insulation
56
PD Damages
57
Electrical Treeing
58
PD Coupling Possibilities
59
Measurement at the Bushing Taps
60
Measurement with Coupling Capacitors
61
Acoustical PD Location
62
PD Location
Piezo Sensors for the Acoustical PD Location
red yellow black blue
63
Fault
Piezo Sensors
64
65
• Introduction
– Oil
– Main Insulation
66
Magnetic Core and Coil
• Insulation Resistance Measurement Core to Frame and Tank
• Ratio, Magnetising Current and Flux Balance Test
• Capacitance Measurement Coils to Ground
• Short Circuit Impedance
• Frequency Response Analysis
67
Ratio Measurement HV-LV
68
Magnetising Currents HV Side
69
Flux Balance Test
70
Magnetic Core and Coil
• Insulation Resistance Measurement Core to Frame and Tank
• Ratio, Magnetising Current and Flux Balance Test
• Capacitance Measurement Coils to Ground
• Short Circuit Impedance
• Frequency Response Analysis
71
Swept Frequency Response Analysis (SFRA)
5.0 5.0
Transformer U0*(1-K(f 1))
3.0 3.0
1.0 1 1 1 1 1.0 1/f1

N U V W
-1.0 0 0.2 0.4 0.6 0.8 1 1.2 -1.0 0 0.2 0.4 0.6 0.8 1 1.2
-3.0 -3.0
(f1)
-5.0 complex RLCM-Network -5.0
sine generator
(f1)
(variable frequency)
K(f1)
Magnitude Phase
2.5 transfer function (magnitude) 3.0

transfer function (phase)
2.0 2.0
1.0
1.5
K(f)
1.0
(f) 0.0
-1.0
0.5 -2.0
0.0 -3.0
0.0 0.2 0.4 0.6 0.8 1.0 1.2
MHz 1.4 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
MHz
Frequenz f Frequenz f
frequency f frequency f
72
End to End FRA Measurement
73
FRA LV Winding – Comparison of the 3 Phases
74
Failure Modes due to Radial Forces
B phase with buckling

C phase without buckling
Source: Cigre Brochure 342 “ MECHANICAL-CONDITION ASSESSMENT OF TRANSFORMER WINDINGS USING FREQUENCY RESPONSE ANALYSIS (FRA)”
75
Buckling
76
• Introduction
– Oil
– Main Insulation
77
Cigre A2.37 Transformer Failure Statistics
22.000 grid transformers with 150.000 sercice years
Causes for transformer breakdowns

Bushings = 17,16 %
Tenbohlen et. al.: „ DEVELOPMENT AND RESULTS OF A WORLDWIDE

TRANSFORMER RELIABILITY SURVEY” CIGRE SC A2 COLLOQUIUM
2015, Shanghai
78
Cigre A2.37 Transformer Failure Statistics
External effects of bushing failures

Fire 30 %
Explosion, Burst 10 %
Tenbohlen et. al.: „ DEVELOPMENT AND RESULTS OF A WORLDWIDE

TRANSFORMER RELIABILITY SURVEY” CIGRE SC A2 COLLOQUIUM
2015, Shanghai
79
Insulation Systems of High Voltage Bushings
OIP
Oil Impregnated Paper
RBP Resin Bonded Paper
RIP Resin Impregnated Paper

80
Capacitive Bushings
Current at the Measurement Tap

50𝐻𝑧 → 𝐼𝐶 = 𝑈 𝜔 𝐶 = 10 … 100𝑚𝐴
𝐵𝐼𝐿 1.2μ𝑠 → 𝐼𝐶 = 𝐶 𝑑𝑈/𝑑𝑡 = 200𝐴
81
Arcing at the Measurement Tap
Source: Norbert Koch „Diagnoseverfahren an Hochspannungsdurchführungen aus Herstellersicht“, HdT Essen 2013
82
Infrared Thermography
Source: ABB Brochure „Bushing diagnostics and conditioning“, 2750 515-142 en
83
Fault Mechanisms and Diagnosis
• Partial breakdowns
– Measurement of
capacitance
– TanDelta measurement Voltage No. of % change
– PD measurement [kV] layers
• Voids, cracks 123 14 7.1
– Measurement of 245 30 3.3
capacitance (RBP)
– PD measurement
420 40 2.5
• Contact problems on measurement taps 550 55 1.8
– Tan Delta voltage sweep (tip-up test)
• Ageing, moisture
– Dielectric response measurements
– TanDelta
84
Definitions of Dielectric Losses
85
Standards
86
Cigre WG A2.34 Brochure 445
Guide for Transformer Maintenance
RBP Bushing Oil-Filled Cracks
Oil Ingress by Capillare Effect
88
RBP – Bushings
Cracks in the Insulation
89
Measurement on 220kV RBP Bushings (1971)
90
TanDelta 15-400Hz
91
RBP Bushing 123kV (1963)
PF (f) A, B, C
1.2%
1.0%
Influence of Moisture
0.8%
0.6% A
0.4%
0.2%
0.0%
0.0Hz
50.0Hz
150.0Hz
200.0Hz
250.0Hz
300.0Hz
350.0Hz
450.0Hz
100.0Hz
400.0Hz
92
OIP Bushings
• Paper of the OIP bushings ages particularly at high
temperatures
• Through aging the dielectric losses will increase

-> this increases the dissipation factor
• Temperature dependent aging decomposes the

paper and produces additional water
-> this accellerates the aging
93
OIP Bushing
Breakdown at the Sharp Edge of the Foil
Source: Hubert Goebel GmbH
94
Tan Delta (T) at 50Hz (OIP DF)
95
Tan Delta (f) at 30°C (33kV OIP DF)
96
RIP Bushings
97
Partial Breakdown on a RIP Bushing
Source: B. Heil, „Diagnose und Bewertung von Durchführungen”, OMICRON AWT Germany 2010
98
220kV RIP Bushing, Stored Outside
PAGE 99
220kV RIP Bushing, Stored Outside
0.85 %
after removing from TR
0.75 % 3 months after removing
Minimum 6 months afetr removing
0.65 %
Tan Delta
0.55 %
Minimum
0.45 %
0.35 %
Minimum
0.25 %
0.0 Hz 100.0 Hz 200.0 Hz 300.0 Hz 400.0 Hz 500.0 Hz
100
Dielectric Response on RIP, RBP and OIP Bushings
RBP
RIP
OIP
PAGE 101
Dielectric Response with Dry and Wet Surface
wet surface 50Hz tanδ

equal
dry surface
Source: G. Kopp, „ Measurement of the dielectric response on HV bushings “
PAGE 102
• Introduction
– Oil
– Main Insulation
103
On Load Tap Changers
Diverter
Switch
Tap
Selector
Maschinenfabrik Reinhausen
104
Static Winding Resistance Measurement HV on all Taps
for Tap Selector Diagnosis
105
up Coarse selector
contacts
down
Reference
106
Difference between up and down -> fine selector contacts

up
down
Reference
107
Dynamic Winding Resistance Measurement HV 1-19
for Diverter Switch Diagnosis
108
Vibroacoustic Measurements on OLTC
U. Seltsam, „Vibroacoustic Measurements

on OLTC“, CEPED Dubai, 2016
109
• Introduction
– Oil
– Main Insulation
110
Health Assessment of a 220 kV / 300 MVA Transformer
Man. Year 1993
Counter OLTC 39.414
111
• Oil Analysis
• Measuement of the Moisture in the solid Insulation
• Capacitance and tan δ Measurement of the Bushings
• Measurement of Turns Ratio and the Magnetising Currents
• Winding Resistance Measurements of the HV Windings on all Taps
• Measurement of the Short Circuit Impedance
112
DGA 2016
PTM 114
DGA 2016
PTM 115
DGA Trend from 2014 to 2016
PTM 116
• Oil Analysis
• Measuement of the Moisture in the Solid Insulation
117
Measurement of the Relative Moisture in Oilr
T = 47,8°C
RH = 6,3 %
Water Content
RH WCCell
New 1-2 0,5
Fair 5-10 1,5-2
Wet 10-15 3-4,5
118
Measurement of the Moisture in the Solid Insulation
Measurement HV to LV
C = 11,708 nF
Tan δ = 0,29 %
Moisture = 1,5%
119
• Oil Analysis
120
C- und Tan δ of the HV Bushings
PTM 121
C- und Tan δ of the LV Bushings
PTM 122
• Oil Analysis
123
Ratio Measurement HV - LV
PTM 124
Magnetising Current HV
PTM 125
• Oil Analysis
126
Static Winding Resistance Measurement HV
PTM 127
Dynamic Winding Resistance Measurement HV
PTM 128
• Oil Analysis
129
Short Circuit Impedance
130
Date of assessment 2017-02-20
Responsible xxx Transformer Assessment
Location/Substation xxx
Transformer ID xxx Assessment 8
Serial number xxx Exchange priority 3
Year of manufacturing 1993
Expected life time (years) 45
new old
10 9 8 7 6 5 4 3 2 1
Transformer age 24 Years X
excellent bad
10 9 8 7 6 5 4 3 2 1
X Remarks
Core X
Winding X
Cellulose insulation X
Oil X
HV bushings X
LV bushings X
Tap changer X
Motor drive X
Cooling system X
Oil leak X
Corrosion protection X
LV wiring and protection X
131
Thank You !
michael.krueger@omicronenergy.com
132

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Transformer Health Assessment

Monitoring Failure Statistics

Visual Checks Voltage Tests

History of  Normal Operation Service

Source: VKW Bregenz Austria

Source: Wikipedia Feb. 2014

Source: Cigre WG A2.37

Source: Cigre WG A2.37

High currents (e.g. due to short circuits nearby the transformer)

• Deformation of the winding

• Hysteresis losses in the magnetic core

Organic acids are produced as a result of ageing

• In particular, they affect the paper insulation

Microstructure of paper with Neutralization Number [mg/kg]

• Ageing of Cellulose is caused by:

• the influence of oxygen

• the influence of water

• the influence of heat

As the cellulose ages, the glucose ring chains break (depolymerisation).

Gases (CO, CO2) C O O C C

ti onsg eschwi ndi gke it

To extend the lifetime, the water has

Chemical and Information

Cellulose Carbon Monoxide

• Water Content Measurement with Dielectric Frequency Response

• Insulation Resistance Measurement

• Capacitance and Dielectric Dissipation Factor Measurement

• Partial Discharge Measurement

Measurement Laboratory Results

Transformer DFR Instrument (DIRANA)

• Water Content Measurement with Dielectric Frequency Response

• Insulation Resistance Measurement

• Capacitance and Dielectric Dissipation Factor Measurement

• Partial Discharge Measurement

CHL before drying 60 s 355,0379 nA 0,5633 GΩ 1,813 1,41

CHL after drying 60 s 120,0924 nA 1,6654 GΩ 3,947 1,45

Measurement s RiCLT before drying PI60 s 190,8125

CLT after drying 60 s 91,4022 nA 2,1881 GΩ 4,977 1,61

CHL before drying 600 s 1,0212 GΩ 1,813 1,41

CHL after drying 600 s 6,5739 GΩdrying3,947

CHL after drying 600 s 30,4232 nA 6,5739 GΩ 3,947 1,45

CLT before drying 600 s 63,1595 nA 3,1666 GΩ 3,021 1,51

DIRANA CLT after drying 600 s 18,3631 nA 10,8914 GΩ 4,977 1,61

• Water Content Measurement with Dielectric Frequency Response

• Insulation Resistance Measurement

• Capacitance and Dielectric Dissipation Factor Measurement

• Partial Discharge Measurement

CLT before drying 0,00779 14,0735 nF 3,8066

• Water Content Measurement with Dielectric Frequency Response

• Insulation Resistance Measurement

• Capacitance and Dielectric Dissipation Factor Measurement

• Partial Discharge Measurement

red yellow black blue

• Insulation Resistance Measurement Core to Frame and Tank

• Ratio, Magnetising Current and Flux Balance Test

• Capacitance Measurement Coils to Ground

• Short Circuit Impedance

• Frequency Response Analysis

• Insulation Resistance Measurement Core to Frame and Tank

• Ratio, Magnetising Current and Flux Balance Test

• Capacitance Measurement Coils to Ground

• Short Circuit Impedance

• Frequency Response Analysis

1.0 1 1 1 1 1.0 1/f1