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04scatiggio English Final Draft
04scatiggio English Final Draft
UNDERSTANDING
AND MANAGEMENT
OF SULFUR
CORROSION FROM
INSULATING OIL
0
TSN (Transmissora Sudeste Nordeste)
1
34 Reactors - Areva 55 MVAr
Start-up 2004
40% filled with Nynas oil e 60% filled with Petrobras
oil
Analysis on May 2004 Non
Corrosive
Corrosive
ASTM
D1275 13 21
19 h
Nynas Petrobras
10GBN - A AV58
2
March 2005 (~1 years after energisation): a not failed
reactor was retired and completely dissembled for
inspection
Extended sections of
the upper half of the
winding showed severe
corrosion and insulation
contamination
3
Copper - 20th turn of 40 P a pe r - 20th turn of 40
60
60
59
59
58
58
57
57
56
56
55
55
Disk
54
Disk
54
53
53
52
52
51
51
41
41
24
24
12
12
0 4 8 12
0 1 2 3
4
After 3 – 9 months of exercise the corrosive oil
(13 units) was changed with other non-corrosive
5
Reactors Areva 33,3 MVAr: 8
Reactors Areva 45,3 MVAr: 5
Reactors Siemens 50 MVAr: 12
Reactors Siemens 66 MVAr: 15
Transformers Siemens 83,3 MVA: 4
Transformers Toshiba 100 MVA: 7
Transformers Areva 200 MVA: 7
Start-up 2003
6
Results for the TSN system were
more articulated and difficult to
handle in the light of knowledge
available at the time
ASTM Corrosive
D1275 %
19 h 0
48 h 25
72 h 59
120 h 100
7
5
3
Faults N°
2
TSN
0
2° Sem. 1° Sem. 2° Sem. 1° Sem. 2° Sem.
2004 2005 2005 2006 2006
The faults didn’t affect the service quality of grid, thanks to the
presence of spare reactors in each station and the quickly actions of
operating Transener, TSN and Terna technicians
8
N° of reactors -
Reactors Nº of faults
TSN
50 MVAr Siemens 12 4
9
Reactors 50 MVAr total n0 : 11 (+1 bought)
10
Reactors 66,6 MVAr total n0 : 14 (+1 bought)
11
Reactors 45,3 MVAr total n0 : 4 (+1 bought)
12
B
COPPER CONTAMINATION
A
100,
99,5
99,1
98,6
98,1
97,7 Copper contamination –
vertical axis (ASTM D130)
97,2
92,6
88,0
83,3
78,7
74,1
71,8
HEIGHT %
71,3 100 %
70,8
69,4
64,8
60,2
55,6
50,9
46,3
A B
41,7
37,0
32,4
27,8
23,1
18,5
0%
13,9
4,6
0,5
0 4 8 12
13
Paper contamination – vertical axis
B
INSULATING PAPER OF SINGLE PAPER A+B
A
ELEMENTAL CONDUCTOR
100,
100,0 99,5
99,5 99,1
99,1 98,6
98,6 98,1
98,1 97,7
97,7 97,2
97,2 92,6
92,6 88,0
88,0 83,3
83,3 78,7
78,7 74,1
74,1 71,8
HEIGHT %
71,8 71,3
HEIGHT%
71,3 70,8
70,8 69,4
69,4 A B 64,8
64,8
60,2
60,2
55,6
55,6
50,9
50,9
46,3
46,3
41,7
41,7
37,0
37,0
32,4
32,4
27,8
27,8
23,1 23,1
18,5 18,5
13,9 13,9
4,6 4,6
0,5 0,5
0 1 2 3 4 0 2 4 6 8 10
6
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
<---- INTERNAL EXTERNAL --->
TURN N°
4
L iv e llo in q u in a m e n to d a
2
1
1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
<---- INTERNAL 22
TURN N° EXTERNAL --->
15
RELATIONSHIP BETWEEN
DEPOSITION AND DEGREE OF
POLIMERISATION OF PAPER COPPER CONTAMINATION
B
A
100,
100,0 993 99,5
99,1
99,5 974 98,6
99,1 983 98,1
97,7
98,6 975 97,2
92,6
98,1 1014
88,0
97,7 1002 83,3
78,7
97,2 982 74,1
92,6 1079 71,8
HIGHT %
HIGHT %
71,3
88,0 1082 70,8
69,4
83,3 1091 64,8
74,1 1084 60,2
55,6
64,8 1104 50,9
55,6 46,3
1167
41,7
46,3 1178 37,0
32,4
32,4 1185 27,8
18,5 1200 23,1
18,5
0,5 1185 13,9
4,6
800 900 1000 1100 1200 0,5
DP UNITS 0 4 8 12
16
A B
COPPER DISC 71%
12
Liv ello inquinam ento da
10
8
s olfuro
6
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1003 1095
DP UNITS
1100
1002 993
1016 970
974 982 964 958 962 984 973
1000
941 960 952
933 926
901
900
800
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Contaminated paper
Uncontaminated copper
contaminated copper
19
• Owner of 97 % of Italian Transmission Electric Grid
• 38.987 km of electric lines
– 380 kV: 9.538 km
– 220 kV: 10.280 km
– < 150 kV: 19.169 km
• 350 Substations
• 600 Power Transformers
20
Terna
Terna Oil
Oil Census
Census
Population of 650 operating transmission transformers,
from 130 to 380 KV, including breathing and sealed
equipment, tested by ASTM D1275 at 19 e 48 hours
19 h 48 h
NO Corrosive % 2 20
CORROSIVE %
100 40
80
30
Corrosivity %
60
19
40 48 19 h
20
20 48 h
0
10
< 1970 1970-1979 1980-1989 1990-1999 2000-2005
0
ISO-PAR PAR NAPH
NAKED
DIN 51353 ASTM D 1275 DOBLE
COPPER and COPPER
Oil PAPER OF (cables,
Ag 100°C Cu 140°C Cu 150°C
WINDINGS contacts,
18 168 19 48 72 19 48 etc)
22
All the metallic
surfaces of
naked copper
result covered
by an adherent
layer of black
dust of Cu2S
23
Copper windings are less corroded then naked copper
surfaces, because at low temperature paper acts as
protective film
24
Actions
Actions
Specifications for New Oils:
1. standard grade quality oils passing the TERNA or
DOBLE test
2. high-grade quality
3. passivated oils
26
Not all the sulfur species present in mineral oil are
corrosive in the same way
FORMULA REACTIVITY
Table from: Lance R. Lewand “The Role of Corrosive Sulfur in Transformers and
Transformer Oil” - Proceedings of the Sixty-Ninth Annual International Conference of
Doble Clients, Boston, MA, USA, 2002.
27
C C C C SH C C S C C
alchil-mercaptano dialchil-solfuro
C SH C SH
C C SH
C C C C
C C
C C C C
C C C
S
ciclopentantiolo S
cicloesantiolo tiofenolo
C C
C C C C C
C C C C
C C C C C
C C C C
S S C
S S
28
International standard
organizations have
adopted, since the ’50s,
a simple ON/OFF test to
detect the corrosiveness
of the oils
Method Description
oils. 7000
mg/kg
90% cum.
6000 average value
it is very interesting
4000
to discover that
3000
2000
an increase in the
1964
1966
1968
1970
1972
1974
1976
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
Year
presence of corrosive
sulfur and related 1995:
faults “miles
stone”
year
33
The
The refining
refining process
process
Other process
CRUDE
OIL
Furfural Hydrogenation
FUEL cut treatment
Gas (H2)
Diesel Dewaxing Spindle OIL
Gasoline
Kerosene Kerosene (insulating oil base)
Gasoline Diesel
Gas combustibile Fuel oil LMO
Paraffine & others HMO
BS
Bitumen Lubricants
34
ADVANTAGES:
1. High yield of production
2. Low pour point
3. Low PCA
4. Better impact on
environment (low waste)
HP Hydrogenation
(> 180 atm)
35
Main
Main analytical
analytical techniques
techniques applied
applied
To verify the presence of sulfur compounds in new and used oils
it was decided to apply a powerful technique, GC-AED (Gas
Chromatography - Atomic Emission Detection).
GC-AED is widely used in petroleum industry for its unique
capability to detect and quantify molecules with heteroatoms, in
the presence of a complex matrix (hydrocarbon background).
200
300
400
500
600
700
800
900
-0.2
004 c010
c006
Other
007 c009
005 c008
[c014]
c019
0
[c030
c018
c015 c017
c016 c032
[C023]
c026
c031
c028
c020 c033 c053 [c021]
c022 c051
*ECD1 A, (06-10-06\1917.D) [ERRT Calculation]
c045
c046 c069 [c039
c052 [c038
c049 c073]
c048 c075 c043]
c047 [c062 c065]
cc044
037 c042 c059
c041
c040 [c057 c103]
c067 c100
c074 [c061 c094] c070 [c076 c098]
c066 c095 [c080 c088 c093 c102]
c091
C 30
0.2
c099 [c079 c113]
c097 [c086 c152]
c087
c085 c115 [c081 c111 c116 c117 c125 c145]
c136 [c120
c077 c148]
c110
c082 c151
c135 [c124 c144]
c118 c123
[c139c149
c140][c106]
0.4
c158 [c186]
Other technique
technique
c174 [c181]
c177
c156 c171
c180
0.6
c170
c199
c196 c203
0.8
C 209
c195 c208
c194
DBDS is overlapped to PCB C70 congener
c206
1
c209
choice because of its widespread availability for PCB
with high sensitivity and will probably be the method of
min
The electron capture detector (ECD) responds to DBDS
37
AED reveals the constant presence
of a sulfur peak towering above a
sea of uniformly sized peaks of
sulfur compounds residual from
deep hydro-treating
38
Confirmations
Confirmations
All the samples were then analyzed by GC-MS, and the presence of DBDS
was confirmed in each sample that showed one major sulfur peak with GC-
AED detection.
10ng_060606205844 #1686 RT: 18.90 AV: 1 NL: 2.85E6
T: + c Full ms [ 50.00-650.00]
91.1
85
80
75
70
65
60
Relative Abundance
S 55
S 50
45 S
S
40
35
30 181.1
25
65.0
20
15
10
92.1 246.0
5 121.1 182.2
165.2 203.2 247.1
337.0 369.6 427.0 477.8 524.5 604.3
0
100 200 300 400 500 600
m/z
39
DBDS
DBDS’’ behaviour
behaviour with
with copper
copper
Oils containing DBDS were subjected to copper-to-oil reaction under the
conditions prescribed in ASTM D 1275.
S
S
Before the
reaction with Before the
copper reaction with
copper
40
On new oil, DBDS “naturrally” present On used oil, DBDS “naturrally” present
DBDS was spiked into a white oil (S < 0,0003%) to verify its
behaviour in absence of other sources of sulfur or aromatics.
41
DBDS
DBDS and
and oxidation
oxidation stability
stability
Oxidation stability tests were performed accordingly with IEC
61125 C, on unused oils containing DBDS. The same oil was tested
again for oxidative stability.
1,2 AS WELL: oil with DBDS, untreated
1,0 HEAT: oil with DBDS pretreated 3
0,8 AS WELL days at 140°C
COPPER: oil with DBDS pretreated
VA
0,6 HEAT
0,4
COPPER 3 days at 140°C with copper
0,2
0,0
0 5 10 15
DAYS
2,0 SLUDGE
44
Of course, the blame is not on the passivator CIBA®
Irgamet 39 but on the ill-advised notion it can cure
corrosion and contamination that have progressed
sufficiently.
Some confirmations come from:
• Brazil, 7 shunt reactors (TSN) failed in a range of
1 ÷ 18 months after passivation
• Brazil, 1 GSU (hydraulic) failed after passivation
• USA, 1 GSU (thermal) failed after 1 year from
passivation
45
Highlights
Highlights on
on DBDS/corrosivity
DBDS/corrosivity
• DBDS is present in most of the oils which exhibit
corrosive behaviour
• DBDS is related to some representative faults
• DBDS acts as anti-oxidant
• DBDS is a corrosive sulfur compound, it “shall not
be present in new oils”
from IEC 60296 Ed. 3-2003-11 “Unused mineral insulating oils for transformer and
switchgear”, par. 6.10: Corrosive sulfur.
Some sulfur compounds, e.g. mercaptans, are very corrosive to metal
surfaces, i.e. steel, copper and silver (switchgear contacts) and shall not be
present in new oil
46
Failure
Failure Mechanisms
Mechanisms
Two different mechanism was observed:
1. ABB:
• Copper dissolve into oil, react with mercaptans and then break
down to copper sulfide.
• Conductive sulfide deposit onto the outer surface of the
insulation and help the inception of partial discharges by steep-
front transients.
• Partial discharge sustain at rated stress until breakdown of the
insulation ultimately takes place.
PD’s should be easily monitored, but they never was measured and
even no H2 by DGA
47
Failure
Failure Mechanisms
Mechanisms
48
Failure
Failure Mechanisms
Mechanisms
Despite the decay of Breakdown Voltage (BDV) on individual paper
tapes, the withhold voltage of turn insulations remains much
higher than rated stress.
[Tamyres L. M. J. “Corrosive
Sulphur” 2005 IEEE/PES
Elemental Turn Common Turn Transformer Commiettee –
Memphis Tennesse (USA)]
49
Condition
Condition monitoring
monitoring
No evidence of Cu2S contamination from:
50
Condition
Condition monitoring
monitoring (RVM)
(RVM)
52
Condition
Condition monitoring
monitoring (SFRA)
(SFRA)
Little influence of
electromagnetic induction
from live lines
90
80 REACTOR A
REACTOR B
70
REACTOR C
60 SPARE
50
0 6 12 15 18
months
20 ppm/year of DBDS →
100 grams of elemental S → a pound of
highly conductive copper sulfide
54
Remediation
Remediation
Passivation (often fails)
Retro-filling (never failed)
Winding substitution (high economic impact)
Improve the cooling efficiency (only in limited cases)
Winding Tem perature
108
106 Forced Air Cooling
104 Natural Cooling
102
100
°C
98
96
94
92
90
0.00 4.48 9.36 14.24 19.12 0.00
time
55
What
What we
we aspect
aspect from
from insulation
insulation oil
oil
56
What
What we
we aspect
aspect from
from insulation
insulation oil
oil
Overestimation on oxidation stability importance
0,30 breathing
IEC 60422 limit
NN
0,20
0,10
0,00
<10 15-10 20-15 25-20 30-25 35-30 40-35 > 40
age (years)
57
What
What we
we aspect
aspect from
from insulation
insulation oil
oil
Revision of current specifications to prevent similar incidents in
the future
Sulphur specification:
1. Total amount
2. Splitting in sulphur families (Speciation) :
• Mercaptans
• Sulfides,
• Disulfides
• Thiophenes
• Etc.
58
Contacts:
Contacts:
Fabio Scatiggio e-mail: fabio.scatiggio@terna.it
Claudio Marchiori e-mail: claudio.marchiori@terna.com.br
Paulo Botelho e-mail: paulo.botelho@terna.com.br
59