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Mositure ingress in free breathing transformers

Conference Paper · May 2008

DOI: 10.1109/CMD.2008.4580369 · Source: IEEE Xplore

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 1

MOISTURE INGRESS IN
FREE BREATHING TRANSFORMERS
Maik Koch1*, Stefan Tenbohlen2, Michael Rösner3
1
Omicron Electronics, Oberes Ried 1, 6833 Klaus, Austria
2
Universität Stuttgart, IEH, Pfaffenwaldring 47, 70569 Stuttgart, Germany
3
Areva Energietechnik GmbH, Transformers, Rheinstrasse 73, 41065 Mönchengladbach, Germany
*E-mail : maik.koch@omicron.at

Abstract – This paper determines the moisture ingress in free cellulose materials leads to molecular chain scissions and the
breathing transformers by analysis of on-line monitoring data formation of by-products such as water and furanic com-
and by laboratory measurements. A grid transformer, a trans- pounds. Fig. 1 illustrates the sources of moisture contamina-
former equipped with a heat recovery system and a generator
tion at transformers in service.
step-up unit served as example transformers. The large grid Hot thin structure, hot spot,
transformer with moderate temperature changes enter approxi- water from cellulose aging
mately 1,6 kg of water during one year. The transformer with the
heat recovery system suffers from rapid temperature changes,
thus approximately a water mass of around 16 kg/a increase its Leaky seals
moisture concentration. The constant load of the generator step- Conservator air
up transformer let nearly no water contaminate it. Laboratory
investigations on dehydrating breathers proofed the drying Breather Cold thin structures,
capability of these systems. They achieve at average volume flows water accumulation
a drying efficiency of 99 %. To conclude, the water mass entering
transformers strictly depends on the operation mode and breather
condition of the specific transformer.

Index Terms – Breathing, Conservator, Humidity, Moisture, Oil pump

Moisture sensors, Power transformers

I. MOISTURE IN TRANSFORMERS Wet air

W ater in power transformers evolved into a frequently

discussed problem due to three reasons: Firstly a large
population of equipment operates under aged conditions,
Fig. 1. Sources of moisture contamination at free breathing transformers
At first glance and according to traditional assumptions
breathing appears to be a major source of moisture contamina-
secondly new online sensors for continuous online monitoring tion. However this article tries to systematically investigate the
became available and thirdly water causes various dangerous effect of free breathing by evaluating online monitoring data
effects. Moisture in the liquid and solid insulation decreases and measuring the efficiency of dehydrating systems.
the dielectric withstand strength, accelerates cellulose decom-
position and causes the emission of bubbles at high tempera- II. ANALYSIS OF ON-LINE MONITORING DATA
ture. A. Investigated Transformers
A new transformer leaves the factory having 0,4-1 % mois-
On-line monitoring data of three power transformers were
ture by weight in the cellulose insulation. The overall water
evaluated: one grid transformer, one grid transformer equipped
contamination during service of around 0,1 % per year results
with a heat recovery system and a generator step-up unit. The
into approximately 3 % for a 30 years old transformer.
transformer with the heat recovery system faces rapid tempera-
The atmosphere is considered to be the main source for
ture changes. In order to increase the efficiency of the heat
moisture [1], three mechanisms contribute: Firstly air humidity
recovery system the transformer is operated in a oil tempera-
becomes adsorbed during direct exposure to air, which hap-
ture range between 60 and 70°C. Because the usual loading is
pens at installation and repair. Secondly moisture can contam-
quiet low, the normal cooling system is switched off and only
inate the tank due to the difference in water vapour pressure in
switched on at temperature higher than 70°C. Due to the high
the atmosphere and the transformer gas space or oil. Thirdly at
cooling power the oil temperature decreases rapidly. When an
temperature drop of open breathing transformers the atmos-
oil temperature of 60°C is reached, the cooling system is
pheric pressure is higher than the pressure inside the tank.
switched off again. This cycle is repeated around three times a
Thus air ingresses and also moisture, if the dehydrating breath-
day.
er cannot completely dry the air. Additional water comes
All transformers were equipped with online sensors measur-
through typical leaks. Oil pumps can suck in air because of the
ing the relative humidity of the air directly behind the dehy-
“negative” pressure created before the pumps. Aging of
drating breather and in the gaseous space of the conservator.
 2

Temperature sensors provided the ambient air temperature and Fig. 2. Top oil temperature and relative humidity in both conservator gas
spaces of the grid transformer
the top oil temperature.
The oil and the air in the conservator try to reach equilibri-
Table 1 shows various parameters of the transformers and
um i.e. the same relative humidity / relative saturation and
the available moisture sensors.
TABLE I temperature in both mediums [3]. With increasing temperature
TRANSFORMER DATA AND MOISTURE SENSING EQUIPMENT the relative humidity decreases, which is typical for gases and
Grid transformer Grid heat recovery GSU (C) liquids.
(A) (B)
Fig. 3 impressively reveals that the relative humidity in the
Rated power 600 MVA 150 MVA 850 MVA
Oil volume @ 20°C 101 m³ 45 m³ 100 m³ conservator gas space is with 27 % much higher than that of
No. of conservators 2/2 1/1 2/2 the other transformers. The service connected to the heat
and breathers exchanger "pumps" air and thus water into the tank.
Moisture sensors 1 per conservator and 1 per breather 3 40

Air volume [m³]

Relative humidity [%]

Relative humidity
B. Analysis of Online Data 2,5
35

Temperature changes of the bulk oil volume cause breath- 30

ing of transformers. To determine the amount of incoming 2
25
moisture, the following calculations were performed: 1,5 20
1. Bulk oil volume variations based on top oil temperature,
15
2. Difference between minimal and maximal level (incoming 1
Air volume 10
air volume) and corresponding time,
3. Incoming water mass considering ambient temperature 0,5
5
and relative humidity of the air behind the breather, 0 0
4. Difference between maximal and minimal oil level (out- 01.01 14.05 26.09 08.02
going air volume), Time [day.month]
5. Outgoing water mass considering the relative humidity of Fig. 3. Air volume entering the transformer with heat exchanger and relative
the air at the breather, humidity in the conservator gas space
6. The difference between incoming and outgoing water The law of moisture equilibrium allows for a rough estima-
mass gives the water mass remaining in the transformer tion of water content in paper based on relative saturation in
and thus contributing to water contamination. the conservator gas space. Under equilibrium conditions the
Air contains a specific mass of water depending on temper- relative humidity (gases) or relative saturation (liquids, solids)
ature and relative humidity. Equation (1) calculates the water becomes equal. The condition, that the same temperature and
mass mH2O in a volume Vd at temperature υ having a relative pressure rules, is here not fulfilled, however a rough estimation
humidity RH. The equation combines the ideal gas law and an is possible. Using a moisture sorption isotherm for aged
empiric expression describing water saturation in air (Magnus cellulose materials [3] the relative humidity of 27 % in the
formula), [2]. conservator gas space points on a moisture content in paper of
3,5-5 %. Thus IEC 60422 classifies this transformer as wet.
RH  Vd   17,62 ⋅υ 
m H 2O = ⋅ 216,7  ⋅ 6,112 ⋅ exp  (1) Fig. 4 shows the top oil temperature and the relative humid-
100  273,15 + υ   243,12 + υ  ity in the gas space of the conservators of the generator step-up
transformer. Both conservators have similar readings of
C. Moisture in the Conservator System around 5 %.
40 10

Relative humidity [%]

Oil temperature [°C]

Fig. 2 shows the top oil temperature and the relative humid- Top oil temperature
35 9
ity in the gas space of the conservator for the grid transformer 8
(A). Both conservators have similar readings of around 5 %; 30
RH conservator 1 7
the deviations are within the accuracy of RH sensors of typi- 25 6
cally ± 2 %. 20 5
30 16
Top oil temperature 4
Temperature [°C]

15
Relative humidity [%]

14 RH conservator 2 3
25 10
12 2
20 5 1
10
0 0
15 RH conservator 2 8 27.12 6.4 15.7 23.10
Time [day.month]
6 Fig. 4. Top oil temperature and relative humidity in both conservator gas
10
spaces of the generator step-up transformer
4
5
2 D. Air Volume Entering the Transformers
RH conservator 1
0 0 For the grid transformer data of one year were evaluated
18.08. 28.08. 07.09. 17.09.
Time [day.month] (01.01.2004 to 30.12.2004). Fig. 5 depicts the varying oil
 3

volume and the air volume entering the transformer. because of the higher temperatures and therefore higher water
104 2,4 masses in air. The transformer with the heat exchanger again
Oil volume suffers from an immense moisture contamination.

Penetrating air volume [m³]

600

Water mass [g]

103 1,8
Oil volume [m³]

500

Air 400
102 1,2
volume
300

200
101 0,6

100

100 0 0
04.1. 04.3. 04.5. 04.7. 04.9. 04.11. GT GT HE Feb HE GSU GSU
Time [day.month] Feb May May Feb May
Fig. 5. Oil volume and penetrating air volume of the grid transformer during Fig. 7. Moisture ingress at the grid transformer (GT), the transformer with
one year heat exchanger (HE) and the generator step-up transformer in a period of two
The smallest oil volume existed in winter with 101,3 m³ at weeks
an oil temperature of 22,1°C, the highest in summer with Within this time interval no water entered the generator
103,6 m3 at 55,4°C. The daily load variations caused a typical step-up transformer, which seams to be incredible on a first
volume change of 0,05 m³/h, however the maximum came up glance. However, provided the dehydrating breather is very
to 0,8 m³/h. dry (relative saturation below the materials inside the trans-
At the grid transformer with the heat recovery system the former) and the volume flow of air is low, the breather dries
daily load variations caused a typical volume change of not only the atmospheric air, but the conservator air as well
0,15 m³/h, peak volume changes came up to 4,2 m³/h (time and therefore the transformer itself.
interval 14.11.97-13.11.98). The operational mode of the heat In Fig. 8 the values of Fig. 7 are extrapolated to a time in-
recovery system causes rapid temperature and therefore terval of one respectively 10 years. This is of course only
volume changes. estimation, it however indicates how different operation modes
The nearly constant load of the generator step-up trans- effect the moisture contamination in power transformers. For
former causes typical volume exchanges of only 0,005 m³/h example the service with the heat exchanger would result into
and maximums of around 0,1 m³/h (time interval 01.01.- approximately 160 kg water in ten years. Supposed an solid
31.12.2001). insulation mass of 7 t its water content would increase in this
Fig. 6 compares the air volumes sucked in by the trans- time period from 0,5 % (new) to 2,7 %.
formers during a time interval of two weeks in February and 20 180
163
Water mass [kg/10a]

two in May. Obviously in May more air came in. The genera-
Water mass [kg/a]

18 16 160
tor step-up transformer has the lowest breathing activity. Since 16
140
the oil volume of the transformer with heat exchanger amounts 14
120
only 45 % of that of the other transformers, more air per oil 12
100
volume is entering this transformer. 10
80
10 8
60
Air volume [m³]

9 6
8 4 40
7 1,5 15,1
2 20
6 0 0
0 0
5
GT HE GSU GT HE GSU
4
3 Fig. 8. Estimated moisture ingress at the grid transformer (GT), the trans-
2 former with heat exchanger (HE) and the generator step-up transformer in a
1 period of one year (left) and ten years (right)
0
GT GT HE Feb HE May GSU GSU
F. Accuracy of the Results
Feb May Feb May The accuracy of the measurement itself and the analysis
Fig. 6. Air volume entering the grid transformer (GT), the transformer with algorithm determine the accuracy of the findings above. The
heat exchanger (HE) and the generator step-up transformer within two weeks relative humidity probes have an accuracy of ± 2 %. This
E. Moisture Ingress results into considerable errors for the measurements at the
rather dry transformers (grid and generator step-up transformer
Fig. 7 depicts the water masses entering into the transform-
having around 5 % relative humidity).
ers during a time interval of two weeks in February and two in
The temperature used for moisture calculation was that of
May. In May more water contaminates the transformers
 4

the ambient, lower then in the breather or the conservator. 100

Drying efficiency [%]

The data basis used for the estimation of moisture content 99
during longer periods is small, however the analysis of online 98
monitoring data consumes a lot of time and automated algo- 97
rithms are highly appreciated.
96
In all, the here presented evaluation results of online moni- 20% 40%
95
toring data are qualitatively profound, but limited in their 60% 80%
94
quantitative accuracy.
0 2 4 6
Volume flow [m³/h]
III. EFFICIENCY OF DEHYDRATING BREATHERS Fig. 11. Drying efficiency of the new dehydrating breather with heating
A. Test Setup element
Fig. 12 depicts the drying efficiency of both breathers dur-
The test setup as displayed in Fig. 9 compared two dehy-
ing 21 hours with 4,3 m³/h and 80 % relative humidity. In that
drating breathers of different construction, a conventional
time the breathers adsorbed 1,0 / 1,2 kg of water.
breather with three chambers containing silica gel and a new 100

Drying efficiency [%]

version with a build-in heating element that dries the silica gel 90
automatically. new breather with
80
The set-up generates air with different relative humidity heating element
70
(20, 40, 60, 80, 100 %) and volume flows (0,5; 2,0; 3,6; 4,3
60
and 5,1 m³/h). The air temperature ranged from 22 to 25°C.
50
compressed conventional
air, RH 4% Mixer 40
breather breather
air outlet
30
0:00 4:48 9:36 14:24 19:12
RH RH volume flow Time [h:min]
probe probe probe
Fig. 12. Drying efficiency of both breathers after long term service
100% The question might arise, after which time the conventional
RH
breather needs to be dried during service. If one desires an
incoming relative humidity of less than 5 %, the conventional
Fig. 9. Test setup to investigate the efficiency of dehydrating breathers
breather can dry approximately 10 m³ of air having 80 %
B. Influence of Air Humidity and Volume Flow relative humidity at 24°C. For the grid transformer of section
To investigate the performance of the two breathers the pa- II this would mean that the silica gel should be recycled after
rameter "drying efficiency" was used. This parameter relates around three weeks of service (Fig. 6). However, this approx-
the difference between the relative humidity of the incoming imation will undervalue the breathers drying capacity since
air and that of the outgoing air to that of the incoming air. For volume flow, temperature and relative humidity are unusually
example in Fig. 10 at a volume flow of 5,1 m³/h and 80 % high.
relative humidity the drying degree is 97 %, thus the incoming
80 % are dried to 2,4 % relative humidity. IV. CONCLUSION
100 To conclude, the moisture ingress into transformers because
Drying efficiency [%]

99 of breathing depends on the operation conditions of the specif-

98
97
96
20%
95
60%
94
0 2
Fig. 10. Drying efficiency of the conventional dehydrating breather
Fig. 10 and Fig. 11 compare the drying efficiency of both
breathers filled with dry silica gel depending on volume flow
and relative humidity. The figures display the average value
after one hour with the same volume flow and relative humidi-
ty. Clearly the new breather with heating element performs
better, of course the build-in heating element was not used
during the measurements, but only to regenerate the silica gel.
To sum up, both breathers provide a very high drying efficien-
cy as long as they are filled with dry silica gel.
ic transformer. Rapid temperature changes contribute a con-
siderably to the moisture level. However, a well-maintained
breathing system together with moderate temperature changes
40% let appear moisture ingress through the breathing system as to
80% be of minor importance among reasons for water contamina-
tion.
4 6
Volume flow [m³/h]
V. REFERENCES
[1] V. Sokolov et al.: “Moisture Equilibrium and Moisture Migration within
Transformer Insulation Systems” Cigré Working Group A2.30, Tech-
nical Brochure, Paris 2008
[2] Humidity, relative humidity, online available, 15.01.2008,
http://en.wikipedia.org/wiki/Humidity
[3] M. Koch, S. Tenbohlen, T. Stirl: “Advanced Online Moisture Measure-
ments in Power Transformers” CMD 2006 International Conference on
Condition Monitoring and Diagnosis, Changwon, Korea, 2006

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