DCW Limited manufactures chemicals for industries

DCW LIMITED
Sahupuram
“Manufacturers of Chemicals that make industries hum”
T. Chandru,
Sr. GM (Electrical)
CARTOGRAPHIC LOCATION OF
SAHUPURAM
SAHUPURAM WORKS
SALT : 1,50,000 TPA CAUSTIC SODA : 1,00,000 TPA LIQUID CHLORINE : 36,000 TPA
TRICHLORETHYELENE: 7,200 TPA DG Based Power Plant, 2 x 6 MW
Co-Gen 58.27 MW Power Plant SYNTHETIC RUTILE: 48,000 TPA PVC RESIN : 90,000 TPA
OVERVIEW
- Past and Present System
of Loading in
Rectifier Transformer No. 1
OVERVIEW OF THE PAST SYSTEM
Mercury Cell till October 2007

11KV Bus
6.15
8.08 8.08 8.08 8.08 MVA
RT- RT- RT- RT- RT-
MVA MVA MVA MVA
2 3 4 5 5th 7th 11th
1 HFB HFB HFB
Yr. of Mfg
1995 1995 1995 1995 1971
6-Pulse 6-Pulse 6-Pulse 6-Pulse 12-Pulse
Thyrister Thyrister Thyrister Thyrister Diode
Rectifier-1 Rectifier-2 Rectifier-3 Rectifier- Rectifier-5
(20KA / (20KA / (20KA / 4 (20KA / (18KA /
345 V DC) 345 V DC) 345 V DC) 345 V DC) 315 V DC)
72KA Totalizer
DC Bus
Mercury Cell
Mercury Cell
Mercury Cell
Mercury Cell
Mercury Cell
Mercury Cell
Mercury Cell
72KA / 300 V
No-70
No-72
No-71
No-3
No-4
No-2
No-1
72 Cells & 176 TPD

RT – 1 LOADING PATTERN
DURING MERCURY CELL OPERATION 1996 – 2007
500 40
Rated AC Current 450 Amps
35
400
Av. AC Current during Mercury Cell Operations 30
300 25
320 320 320 325 325 325 325 325 325 330 330
20
Rated DC Load Current during Mercury Cell – 20
200 15
15 15 15 15 15 15 15 15 15 15 15 15
Av. DC Load Current during Mercury Cell Operation 10
100
5
0 0
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Till
Oct
2007
DURING MERCURY CELL OPERATION (1996 – 2007)
100%
81.0% 80.0% 81.0% 81.0% 81.0%
Percentage loading
77.0% 76.0%
80%
82.0% 79.0% 82.0% 80.0%
78.0%
60%
40%
20%
0%
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Till
Oct
2007
OVERVIEW OF THE PRESENT SYSTEM
Membrane Cell From November 2007
11KV Bus
Same
Rectifier
RT- RT- RT- 8.08 RT-
System 8.08 8.08 8.08
5th 7th 11th
MVA 1 MVA 2 MVA 3 MVA 4
used for HFB HFB HFB
Membrane
Operation 6-Pulse 6-Pulse 6-Pulse 6-Pulse
Thyrister Thyrister Thyrister Thyrister
Rectifier-1 Rectifier-2 Rectifier-3 Rectifier-4
(20KA / (20KA / (20KA / (20KA /
345 V DC) 345 V DC) 345 V DC) 345 V DC)
20KA 20KA 20KA
80KA Totalizer
80KA / 345 V DC Bus
Electrolyser-A Electrolyser-B Electrolyser-C Electrolyser-D Electrolyser-E Electrolyser-F

(103 Elements)\ 103 Elements) 103 Elements) 103 Elements) 103 Elements) 103 Elements)
6 Electrolysers & 283 TPD

DURING MEMBRANE CELL OPERATION From Nov 2007
500 40
Rated AC Current 450 AMPS 434
35
400 431 432
410 Av. AC Current 30
385 385
300 25
Av. DC Load Current
20
200 20 20 20 20 20 20
15
10
100
5
0 0
From Nov 2008 2009 2010 2011 2012
2007
DURING MEMBRANE CELL OPERATION From Nov. 2007
95.8% 96.0% 96.4%
100% 91.1%
85.6% 87.8%
Percentage loading
80%
60%
40%
20%
0%
2007 2008 2009 2010 2011 Till Mar
2012
10
WHAT HAS HAPPENED
TO RT -1
What Has Happened to RT -1
DATE OBSERVATIONS / ACTIONS

Bucholtz alarm appeared on Rectifier Transformer 1.
Gas accumulation noticed and since there was no other
17.03.12
abnormalities, it was released & Transformer put on line
DAY 1
After 2 hrs of operation same alarm appeared, so transformer
switched off.
Gases in the Bucholtz relay checked for acetylene and found
nil.
Voltage Ratio, Magnetic Balance tests done. The test results
18.03.12
concluded that the transformer winding is in healthy
DAY 2
condition. We have decided to carry out Dissolved Gas
Analysis on transformer oil to find out the presence of
dissolved gases.
19.03.12
Oil Sample collected and send to NABL Accredited Lab
DAY 3
at Chennai for Dissolved Gas Analysis (DGA).
Oil Sample Report after failure

Sl. DISSOLVED GAS LIMITS TEST
No ANALYSIS Min - Max RESULTS
1 Methane ppm 25 – 80 4519 ppm
2 Ethylene ppm 20 - 150 3983 ppm
3 Ethane ppm 10 – 35 2771 ppm
4 Acetylene ppm ANSI / IEEE 15 – 70 ND
5 Carbon monoxide ppm C57.104 500 – 1000 783 ppm
Standard
6 Carbon –di-oxide ppm 10000 - 15000 9818 ppm
7 Hydrogen ppm 150 - 1000 1203 ppm
Total Gas Content %
8 13.50%
by Volume

The results received from the lab shows the presence of
Methane, Ethylene, Ethane, Carbon Mono Oxide &
Carbon Di Oxide, much higher than permissible limits.
On Scrutinizing the test results OEM recommended to
20.03.12
send the transformer to their premises for further
DAY 4
analysis, since the removal of transformer from service
should be considered for exceeding limits of DGA
Analysis of Transformer Oil and added to it the top
cover is totally welded, which specifically needs to be
taken to OEM premises.
Transformer dispatched to OEM Ahmedabad.
24.03.12
DAY 8
Transformer Top was opened at OEM premises

Ahmedabad.
12.04.12
DAY 27

On inspection we noticed failure of „crimped joints‟
between the Transformer copper strip winding and
multi-strand copper lead wires in two places at 5th Tap
changer take off point and common wire take off point to
tap changer. No other abnormalities noted inside the
transformer, visibly as well as in other tests carried out.
12.04.12
DAY 27

The joints at 2 places (5th Tap take off point & common
take off point between flat winding & multi stranded
lead wire) inside the transformer repaired & crimped
with new lead wires and blackened paper insulation also
replaced. After re-assembling, transformer filled up with
new transformer oil & filtered.
14.05.12
DAY 59
The Transformer received back in our site & re-installed.
28.05.12
DAY 73
03.06.12
Transformer re-commissioned.
DAY 81
Determine the
Causes
20
Determine the Causes
Loading of RT – 1 increased to continuous Full Load Operation
After 13 Years of Service with Membrane Technology
100%
95.8% 96.4%
Percentage loading
96.0%
91.1%
82.0% 82.0%
85.6%
80.0%
79.0%
80% 77.0%
76.0% 81.0%
81.0% 80.0% 81.0% 81.0%
78.0%
60%
21
No of Tripping at full load for Load Shedding & Switching
Surges per year increased in RT-1 from 2008
60
52
49 47
50 45
40
40 35 34 32
32 31 30 28 32 29
30
21
20
10
5
0
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 14th
Mar
2012
No of Trippings during Mercury Cell Operation

No of Trippings during Membrane Cell Operation
INSTANT LOAD SHEDDING OF RECTIFIER TRANSFOMER THROUGH POWER
MANAGEMENT SYSTEM FOR STABLE OPERATION OF CPP,
as it is the single largest load
RT1 RT2 RT3 RT4

DGA Analysis carried out on 30.03.2011
One Year before the failure of RT - 1
Key Gas Concentration (in ppm)
Gas Description Our Oil

Normal Action
sample Potential fault type
Limits * Limits **
results
Hydrogen H2 150 1000 45 Corona, Arcing
Methane CH4 25 80 10 Sparking
Acetylene C2H2 15 70 ND Arcing
Ethylene C2H4 20 150 ND Severe Overheating
Ethane C2H6 10 35 ND Local Overheating
Carbon monoxide CO 500 1000 235 Severe Overheating

Carbon dioxide CO2 10000 15000 55 Severe overheating
Total Gas Content % TGC % 8.77
*As the value exceeds this limit, sample frequency should be increased with consideration given to
planned outage in near term for further evaluation.
** As value exceeds this limit, removal of transformer from service should be considered
This table is derived from information provided within ANSI/IEEE c57.104
Analysis of Furon Compounds carried out on 30.03.2011
One Year before the failure of RT - 1
Sl.
RT 1 TESTS on 30.03.2011 Sample TEST METHOD TEST VALUE
No
1 ANALYSIS OF FURANIC COMPOUNDS
a 5 Hydroxymethyl-2 furfural, mg/kg 0
b 2-Furfury Alcohol, mg/kgl 0
c 2-Furfural, mg/kg 40
IEC-1198-1993
d 2-Acetylfuran, mg/kg 0
e 5-Methyl-2-furfural, mg/kg 0
Total Furan content in PPB 40
Note : Furan content between 0 to 100 PPB in oil, indicates Normal Transformer.
Total Furan in PPB` Condition
0-100 Normal
101 - 250 Questionable
251 - 1000 Deteriorated
1001 - 2500 Low reliability
>2500 Rewind / Replace solid insulation
DGA Analysis after the failure of RT - 1
Key Gas Concentration (in ppm)
Our Oil
Gas Description sample
Normal Action
results Potential fault type
Limits * Limits **
during
failure
Hydrogen H2 150 1000 1203 Corona, Arcing
Methane CH4 25 80 4519 Sparking
Acetylene C2H2 15 70 0 Arcing
Ethylene C2H4 20 150 3983 Severe Overheating
Ethane C2H6 10 35 2771 Local Overheating
Carbon monoxide CO 500 1000 783 Severe Overheating

Carbon dioxide CO2 10000 15000 9818 Severe overheating
Total Combustibles TDCG 720 4630
*As the value exceeds this limit, sample frequency should be increased with consideration given to
planned outage in near term for further evaluation.
** As value exceeds this limit, removal of transformer from service should be considered
This table is derived from information provided within ANSI/IEEE c57.104
Doernenberg Ratios, Rogers Ratios – Equivalent to the “Basic
Gas Ratios” in IEC (International Electrotechnical Commission) Standards
Fault Type
Ratio is warranted due to
T1 T2 T3 D1 D2
the varying rates of the
combustible gas Low
Thermal Thermal
generation with energy Thermal Energy / High Energy
Gas Ratio Fault 300°C - Fault
variations for different Fault <300°C Partial Discharge
700°C >700°C
fault modes Discharge
Doerenenberg Ratios
R1 - Methane/Hydrogen CH4 / H2 R1 > 1.0 R1 < 0.1 0.1 < R1 <1.0
R2 - Acetylene/Ethylene C2H2/ C2H4 R2 < 0.75 R3 < 0.3 0.75 < R2
R3 - Acetylene/Methane C2H2/ CH4 R3 < 0.3 0.4 < R4 0.3 < R3
R4 - Ethane / Acetylene C2H6/ C2H2 R4 < 0.4 R4 < 0.4
Rogers Ratios
R1 - Methane/Hydrogen CH4 / H2 1.0 < R1 R1 > 1.0 1.0 < R1 R1 < 0.1 0.1 < R1 <1.0
R2 - Acetylene/Ethylene C2H2/ C2H4 R2 < 0.1 R2 < 0.1 R2 < 0.1 R2 < 0.1 1.0 < R2 <3.0
RS - Ethylene / Ethane C2H4/ C2H6 1.0 < R1 < 3.0 1.0 < RS<3.0 3.0 < RS RS < 1.0 3.0 < RS
Actual DGA Values R1 - 3.756, R2 - 0, R3 - 0 & RS - 1.437

LEGEND
Duval‟s Triangle Model PD – Partial Discharge
T1 = Thermal Fault Less than 300° C
T2 = Thermal Fault Less than 300° C and 700 ° C .
T1 = Thermal Fault greater than 700° C
D1 = Low Energy Discharge (Sparking)
D2 = High Energy Discharge (Arcing)
DT = Mix of Thermal and Electrical Faults.
T2
Our Values
%CH4 - 53%
% C2H2 - 0
D1
% C2H4 - 47%
Our values plotted
in triangle
From Duval‟s Triangle our values indicated Low energy discharge
and Thermal fault between 300 – 700 degree C.
Bucholtz
Alarm
Gas
Produced
Local heating
of Oil
Flat Winding & Multi

Strand Lead Wire
Crimping failure
Continuous Full Frequent Tripping at full

Load Operation for Load due to Load
4 Years with Membrane Cells Shedding for Stable
after 13 Years of Service Operation of Power Plant
with Mercury Cells & Switching Surges
Development of Solutions
1. Operate the 17 Years Old Rectifier Transformer

continuously at reduced loads than the rated load (90%
Max), so that the local heating that could develop in the
Crimped Joints could be avoided, as the key gases
produced depends upon mainly on temperature rise. Select
other Rectifier Transformers also for Load Shedding in
turn to reduce the stress in one Transformer.
•Operate Either at Lesser KA or Lesser DC Voltage to

produce 260 TPD against rated 283 TPD
2. Monitor DGA results of transformer oil concentration

every month once the life of the transformer crosses 10
Years of Service and evaluate the “basic gas ratios” to find
out whether any abnormality exists.
3. Carry out Furan Analysis on Transformer Oil once in a

year or whenever the ratio of CO2 / CO gases is 3 or under
or above 11, to determine the thermal decomposition of
cellulose in the paper insulation of the windings & ensure
Furan content is less than 100 PPB in Oil
4. Yearly or Regular Filtration of Transformer Oil based on

the DGA results of concentration of gases, to keep the
values within the permissible limits and also ensure “basic
gas ratios” as per IEC are within the suggested limits.
Evaluate the Solutions
34
Percentage of Loading in RT 1 before & after the failure

100.0%
96.7% 96.7%
90.0%
RT – 1
88.0% 88.0%
Failure 86.0% 86.0%
83.8%
86.0% 86.0% 86.0%
80.0% 82.0%
80.0%
75.0% 74.0%
73.0%
72.0%
68.5%
60.0%
Carbon Monoxide content in PPM in RT 1

1,200 100%
90%
88% 88%
86% 86% 86% 86% 86%
84%
90%
80% 82%
1,000
Oil Filtration done after repairing the
% Loading of transformer
75% 74% 80%
72% 73%
Oil Filtration done

CO content in PPM
70%
800 Normal Limit <500 69%
Action Limit > 1000 PPM 60%
Oil Filtration done

transformer
600 50%
40%
927
916
853
848
400
30%
595
569
499
485
20%
397
390
200
363
359
339
319
301
299
293
10%
-
- 0%
36
14,000
Carbon di oxide content in PPM in RT 1 100%
Oil Filtration done after repairing the

90%
88% 88%
86% 86% 86% 86% 86%
84% 90%
12,000 80%
82%
% Loading of transformer
75% 74% 80%
72% 73%
CO2 content in PPM
69%
10,000 transformer
70%
Normal Limit <10000
Action Limit > 15000 PPM 60%
Oil Filtration done

8,000
Oil Filtration done

50%
6,000
40%
4,000 30%
5,151
5,134
4,969
20%
4,303
3,666
2,000
3,056
3,018
2,489
2,072
2,016
1,658
1,899
1,875
10%
559
716
986
-
-
-
- 0%
37
CO2 / CO Gas ratio is an indicator of thermal decomposition of Cellulose.
If ratio is > 11 or < 3 along with increase in other gases methane, ethane,
acetylene indicate excessive oil degradation 100%
14 88%
90%
88%
86% 86% 86%
84%
90%
80%
82% 86% 86%
12 Oil Filtration done after repairing the
75% 74%
80%
72% 73%
69%
70%
10
Normal Zone for CO2 / CO 60%
Oil Filtration done

transformer
8
50%
6 40%
6.2 30%
5.1
5.2
4
5.5
5.4
5.5
4.7
6.4
6.1
6.1
20%
5.1
5.0
2.2
2.7
10%
1.9
2.2
-
-
- 0%
38
Methane content in PPM

90
80 Oil Filtration done after repairing the
70
60
transformer
50
Oil Filtration done

Normal Limit < 25 PPM
Action Limit > 80 PPM
40
30
20
10
3
4
-
-
-
RT-1 Norms
39
40
Ethane content in PPM
35 0 Oil Filtration done after repairing the
30
transformer
25
Oil Filtration done

20
15 Normal Limit < 10 PPM
10
5
1
3
-
0
1
0
RT-1 Norms
40
160
Ethylene content in PPM
140 -Oil Filtration done after repairing the
120
100
transformer
Oil Filtration done

80
40
20
27
27
20
20
17
17
12
14
1
5
-
RT-1 Norms
41
Acetylene content in PPM
80
Not Detectable
70
- Filtration done after repairing the

60
50 transformer
Oil Filtration done

40
30
20
10
Oil
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
RT-1 Norms
42
after re-commissioning of RT - 1
Sl.
No
a 5 Hydroxymethyl-2 furfural, mg/kg 21.962
b 2-Furfury Alcohol, mg/kgl 0.917
c 2-Furfural, mg/kg 4.916
IEC-1198-1993
d 2-Acetylfuran, mg/kg 38.171
e 5-Methyl-2-furfural, mg/kg 0.721
Total Furan content in PPB 66.687
Note : Furan content between 0 to 100 PPB in oil, indicates Normal Transformer.

0-100 Normal
Filtration of Rectifier Transformer carried out on 29.06.2013 in RT - 1

11,000
1,000
3,000
7,000
9,000
5,000
13,000
11,051 11,534
11,797
12,318 12,104
12,692
12,793 12,888
12,677
4,529 Oil Filtration done in

4,176
5,735 Rect. Transformers
RT-2
– 2, 3 & 4 in June 2012
6,974 7,202
8,002
5,959 5,254
RT-3
6,158
4,795 4,669
4,846
RT-4
3,810 4,927
5,306
4,743 4,952
4,359
Norms
Carbon Dioxide content in PPM
7,075 8,263
7,677
8,301 9,350
10,204
Oil Filtration done in
6,198 5,549
5,250 Rect. Transformers
– 2, 3 & 4 in Feb 2013
6,222 5,503
5,613
Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13
44
200
2,200
4,200
6,200
8,200
10,200
6,222 5,503
12,200
5,613
6,648 5,922
5,683
4,051
3,308
3,786
RT-2
5,047
5,013
4,879
5,013
6,695
6,351
516 6,795 Oil Filtration done in
RT-3
Rect. Transformers
4,056
– 2, 3 & 4 in Aug 2013
642
1,302
4,766
RT-4
Carbon Dioxide content in PPM
Norms
45
-
200
400
600
800
1,000
1,200
1,400
1,600
1,188
1,800
1,383
93%
1,211
1,205
1,439
92%
1,404
1,213
1,455
90%
1,711
338
RT-2
273 Oil Filtration done in all Rect.
80%
282 Transformers 2, 3 & 4
226
147
75%
237
401
418
72%
263
290
345
73%
263
RT-3
275
441
74%
333
417
82% 561
416
689
736
88%
760
971
Carbon Monoxide content in PPM
1,027
90%
1,141
RT-4
416
448 Oil Filtration done in Rect.
88%
339 Transformers 2, 3 & 4

496
528
86%
522
Preventive Action to avoid such incidences in future
46
1,200
Carbon Monoxide content in PPM
Oil Filtration done in Rect.
1,000
Transformer-2, 3 & 4
1,000
822
800
680
645
642
641
612
581
576
548
544
600
522
528
348
400
621
615
599
590
496
172
200 205
184
-
Mar.13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14
RT-2 RT-3 RT-4 Norms

47

90
80
70
60
40
30
21
20
19
18
18
18
16
20
11
11
8
10
7
6
6
6
6
5
4
4
4
4
4
3
3
3
3
2
2
2
2
1
-
-
-
-
-
Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13

48
90
80
70
60
50
30
20
10
7
6
4
4
4
4
3
3
2
2
2
1
-
-

49
40 Ethane content in PPM
35
30
25
20
10
7
5
5
5
5
5
5
5
4
4
5
4
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
-

50
40
Ethane content in PPM
35
30
25
20
10
4
4
5
3
3
3
3
3
3
3
3
2
2
2
2
2
1
1
1
1

51
160
140
120
100
80
40
15
14
13
13
13
13
12
12
12
20
11
11
10
9
8
8
9
7
6
6
5
5
5
6
3
3
3
3
3
3
3
2
1
-

52

160
140
120
100
80
40
16
16
15
13
13
13
20
11
10
8
7
6
5
4
5
3
2
-

53
80
Not Detectable
70
60
50
40
30
20
10
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-

54
80 Not Detectable
70
60
50

30
20
10
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-

55
Sl.
No
c 2-Furfural, mg/kg 0
IEC-1198-1993
Note : Furan content between 101 to 250 PPB in oil, indicates Questionable of
Transformer.
0-100 Normal

Sl.
No
IEC-1198-1993
Note : Furan content between 101 to 250 PPB in oil, indicates Questionable of
Transformer.
0-100 Normal
Filtration of Rectifier Transformer carried out on23.08.2013 in RT - 3

Sl.
No
IEC-1198-1993
Note : Furan content between 251 to 1000 PPB in oil, indicates Deterioration of
Transformer.
0-100 Normal

Upgrading Transformer Oil Filter Machine
Existing Filter Machine Proposed Filter Machine
Nirmal make JHVR 2400 LPH

Nirmal make JMHV 2400 LPH
Ultra High Vacuum
with IRC Column
with IRC Column
Key Oil parameters guaranteed after 5 passing
Dielectric Strength – 60KV Dielectric Strength – 75 KV
Water Content – 10 ppm Water Content – 2 ppm
Gas Content – 5 % by Volume Gas Content – 0.05 % by Volume

Formulate Recommendations
1. In summary the greatest indicator of

potential problems within transformers
should not be limited to the concentration
levels of the key dissolved gases. By
trending the dissolved gas levels, problems
can be identified and evaluated further
before they cause a catastrophic failure of
the transformer
Formulate Recommendations
2. To Safely Operate at reduced load limiting to 90 %

maximum of the transformer capacity, particularly,
• For aged transformers more than 10 years of
continuous service
• For Transformers subjected to load shedding &
switching surges, which could not be avoided in a
system having 100% Captive Consumption through
Captive Power Plants, handling multiple chemical
hazardous raw materials & products

We thank
AMAI
for giving us this
opportunity
62

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DCW LIMITED

TRICHLORETHYELENE: 7,200 TPA DG Based Power Plant, 2 x 6 MW

Mercury Cell till October 2007

72 Cells & 176 TPD

Electrolyser-A Electrolyser-B Electrolyser-C Electrolyser-D Electrolyser-E Electrolyser-F

6 Electrolysers & 283 TPD

DATE OBSERVATIONS / ACTIONS

Oil Sample Report after failure

DATE OBSERVATIONS / ACTIONS

DATE OBSERVATIONS / ACTIONS

Transformer dispatched to OEM Ahmedabad.

DATE OBSERVATIONS / ACTIONS

Transformer Top was opened at OEM premises

DATE OBSERVATIONS / ACTIONS

DATE OBSERVATIONS / ACTIONS

The Transformer received back in our site & re-installed.

No of Trippings during Mercury Cell Operation

RT1 RT2 RT3 RT4

Gas Description Our Oil

Ethane C2H6 10 35 ND Local Overheating

Carbon monoxide CO 500 1000 235 Severe Overheating

Ethane C2H6 10 35 2771 Local Overheating

Carbon monoxide CO 500 1000 783 Severe Overheating

Actual DGA Values R1 - 3.756, R2 - 0, R3 - 0 & RS - 1.437

Flat Winding & Multi

Continuous Full Frequent Tripping at full

1. Operate the 17 Years Old Rectifier Transformer

•Operate Either at Lesser KA or Lesser DC Voltage to

2. Monitor DGA results of transformer oil concentration

3. Carry out Furan Analysis on Transformer Oil once in a

4. Yearly or Regular Filtration of Transformer Oil based on

Percentage of Loading in RT 1 before & after the failure

Carbon Monoxide content in PPM in RT 1

Oil Filtration done

Oil Filtration done

Oil Filtration done after repairing the

Oil Filtration done

Oil Filtration done

Oil Filtration done

Methane content in PPM

Oil Filtration done

35 0 Oil Filtration done after repairing the

Oil Filtration done

140 -Oil Filtration done after repairing the

Oil Filtration done

- Filtration done after repairing the

Oil Filtration done

Total Furan in PPB` Condition

Filtration of Rectifier Transformer carried out on 29.06.2013 in RT - 1

4,529 Oil Filtration done in

516 6,795 Oil Filtration done in

339 Transformers 2, 3 & 4

RT-2 RT-3 RT-4 Norms

Methane content in PPM

RT-2 RT-3 RT-4 Norms

RT-2 RT-3 RT-4 Norms

40 Ethane content in PPM

RT-2 RT-3 RT-4 Norms

RT-2 RT-3 RT-4 Norms

RT-2 RT-3 RT-4 Norms

Ethylene content in PPM

RT-2 RT-3 RT-4 Norms