21, rue d'Artois, F-75008 Paris
http://www.cigre.org 12/23/34-05
POWER TRANSFORMER ON-SITE CONDITION ASSESSMENT TESTING
TIM NOONAN*
ESB International
IRELAND
1. INTRODUCTION
Medium and large power transformers are high capital
cost and critical plant items in the generation,
transmission and distribution of electrical power. Their
expected lives can vary from thirty to fifty years. Cost
of failure can be high not only due to high repair and
replacement costs but also due to penalties arising from
loss of supply or costs associated with alternative
supply / generation.
A life management policy is essential in maintaining
continued serviceability of these costly and critical
plant items during their lifetimes and will also provide
data that may enable the implementation of life
extension programmes. Life management begins at the
specification stage i.e. quality of materials, good design
and quality of construction are all vital elements in
maintaining the transformers serviceability throughout
its life. When the transformer is placed in service its
continued serviceability depends on its operational,
maintenance and fault histories. Condition monitoring
tests are applied on several occasions throughout the
life of the transformer to provide data that enables the
transformer’s life to be effectively managed.
An initial set of tests is performed at the manufacturer’s
works or on site during commissioning. These are
called fingerprint tests and data generated act as a base
line set of test results with which subsequent tests
throughout the life of the transformer can be compared.
This initial set of tests also act as a quality assurance
check and ensures the transformer has been
manufactured and erected on site to an acceptable
quality.
When the transformer is placed in service, low cost
routine / continuous monitoring is used to monitor the
* STEPHEN COURT, 18 / 21 ST STEPHEN’S GREEN, DUBLIN 2
Session 2000
© CIGRÉ
transformer’s condition and ensure its continuing
serviceability.
Throughout the life of the transformer, a more extensive
set of testing is performed at different stages to enable
decisions on its continuing serviceability. This tests are
generally known as condition assessment tests and are
carried out (i) routinely to enable implementation of
condition based corrective maintenance tasks, (ii) after
a system incident, defect / fault on a transformer
identified by monitoring / protection devices, (iii) prior
to a change in operational requirements to determine if
the transformer’s condition will permit this change i.e.
increased loading / overloading, and (iv) towards the
expected end of the transformers life to determine
continuing serviceability / cost of refurbishment to
extend the transformer’s life.
2. TRANSFORMER LIFE MANAGEMENT
TESTS
As already stated, there are three categories of
transformer life management tests i.e. fingerprint, low
cost routine / continuous monitoring, and condition
assessment tests.
2.1 Fingerprint Tests
Fingerprint tests are performed at the manufacturer’s
works / on-site during commissioning. Ideally a
separate set of tests should be performed in both
locations with the transformer fully erected. These tests
not only provide a base line set of test data but also (i)
act as a quality assurance check after manufacture, (ii)
ensure no defects have been introduced during
transportation to site and site erection and, (iii) act as a
quality insurance check after site erection.
MC/TN5234.REP
Some of the transformer acceptance tests performed at
the transformer manufacturer’s works may act as
fingerprint tests, i.e. partial discharge, winding
resistance, tan delta or % power factor and capacitance
measurements.
Fingerprint tests performed by ESBI include the
following:
• Oil screen tests (breakdown voltage, moisture
content, neutralisation value, colour, resistivity, and
relative permittivity).
• Oil dissolved gas analysis [1] [2].
• Interwinding and winding to ground % power
factor measurements [3].
• Interwinding and winding to ground capacitance
measurements [3].
• Bushing main insulation and test tap insulation to
ground % power factor and capacitance
measurements [3].
• Magnetising current measurements [3].
• Leakage reactance measurements [4].
• Spectrum of polarisation measurement by recovery
voltage meter [5] [6].
• Frequency response analysis using the swept
frequency method [7] [8].
2.2 Low Cost Routine / Continuous Monitoring
The low cost routine / continuous monitoring set of
tests to monitor the ongoing condition of the
transformer, can vary considerably between utilities. In
general, European utilities favour routine on-line oil
screen tests and dissolved gas analysis with continuous
on line gas in oil monitoring on strategic units. Other
utilities, in particular in the U.S., include off-line
insulation % power factor testing as a routine test.
ESBI recommend the following for ESB transformers:
(i) Routine on-line oil screen tests and dissolved gas
analysis varying from 6 months to 2 yearly intervals
depending on the voltage rating and strategic
importance of the transformer and (ii) on-line
continuous gas in oil monitors (carbon monoxide and
hydrogen) depending on the voltage rating and strategic
importance / present condition of the transformer.
2.3 Condition Assessment Tests
Condition assessment tests performed by ESBI are as
follows:
• Oil screen tests.
• Oil dissolved gas analysis.
• Oil furan analysis.
• Paper sample degree of polymerisation
measurements [9].
• Paper sample moisture content test [10].
• Interwinding and winding to ground % power
factor measurements.
• Interwinding and winding to ground capacitance
measurements.
• Bushing main insulation and test tap insulation to
ground % power factor and capacitance
measurements.
• Winding resistance.
• Magnetising current measurements.
• Leakage reactance measurements.
• Spectrum of polarisation measurements by
recovery voltage meter.
• Frequency response analysis using the swept
frequency method.
• Infrared thermal vision.
The paper sample degree of polymerisation
measurements and moisture content tests are carried out
on paper samples removed from leads / top of windings.
Paper samples are taken through bushing / inspection
plate openings (or after untanking). This is done only
when an oil reconditioning, oil change out or a major
refurbishment / repair is being carried out.
A transformer condition assessment also involves a
detailed site inspection (external and diverter switch)
and an assessment of the transformer’s operational,
maintenance and fault histories as well as an assessment
of auxiliaries and spares availability.
3. CASE HISTORIES
The following case histories are examples of the
effectiveness of fingerprint and condition assessment
testing in the transformer life management policy.
MC/TN5234.REP

The following corrective maintenance was carried out

3.1 Case History 1 (New Transformer Quality on Unit 1:
Assurance)
• HV phase bushings changed out.
Fingerprint tests on two 110 / 20kV, 20 MVA • Transformer oil reconditioned.
transformers indicate % power factor values of
winding insulation as in Table I. The table The LV bushings on Unit 1 also had some deterioration.
headings CH, CHL, CL, CHT, CLT, and CT are These are being monitored on a routine basis.
respectively the high voltage winding to ground,
high to low voltage winding, low voltage winding
to ground, high to tertiary voltage winding, low to 3.3 Case History 3 (Repair Decision)
tertiary voltage winding and the tertiary voltage
winding to ground insulations. A 110 / 38kV, 63 MVA transformer tripped on
differential and Bucholz protection. A 38kV-system
Table I: % PF test values on main insulation. earth fault, which developed into a 38kV short circuit
on one of the 38kV circuits fed from the station
% PF immediately preceded the transformer trip. Bucholz gas
Unit and dissolved gas analysis indicated an internal fault
CH CHL CL CHT CLT CT had occurred in the transformer.
1 .32 .24 1.38 - .23 .38
Table IV shows the dissolved gas analysis results after
2 .42 .2 9.67 - .19 .39 the fault. Low values of CO indicate that paper
insulation was not involved in the fault.
Further investigation into the high value of CL
(acceptable values should be lee than 0.5) revealed Table IV: Dissolved gas analysis results.
cracking and moisture ingress on the LV bushings.
H2 CO CO2 CH4 C2H4 C2H6 C2H2
3.2 Case History 2 (Corrective Maintenance 329 250 1495 77 97 10 322
Decision)
The transformer was taken out of service. Condition
Condition assessment tests were carried out on two assessment tests were carried out. Condition
sister transformers in the same substation. Table II and assessment tests had previously been carried out on this
III indicate winding and bushing % PF tests from both transformer in 1996.
transformers.
Table V indicates results from both condition
Table II: % PF test values on main insulation. assessments.

% PF Condition assessment tests after the fault indicated:

Unit
CH CHL CL CHT CLT CT • An open circuit in the LV winding r phase near the
1 1.18 .22 .78 .22 .33 .26 r phase bushing.

2 .35 .22 .27 .23 .25 .26 • No other mechanical deformation in the
transformer.

Table III: % PF test values on HV bushing • Paper insulation was not involved in the fault.
insulation.
These results indicated the transformer could easily be
% PF repaired. The transformer was sent to a workshop,
Unit where it was untanked. The fault found was an open
R S T N circuit at a burnt connector to the LV r phase bushing.
1 1.91 2.8 3.51 .6 The transformer was repaired. Figure 1 shows the FRA
scans indicating the fault at the bushing end of the
2 .72 .74 .73 .70 winding. (Figure 3 shows FRA scans when the fault is
at the neutral end of the winding.) Figure 2 shows the
burnt connector at the LV winding r phase bushing.
The oil was also wet in Unit l i.e. moisture 30ppm and
breakdown voltage of 59kV / 2.5mm were recorded.
MC/TN5234.REP

Table V: Condition assessment results prior to and after the fault.

DP % PF / Capacitance (pF)
CH CL CT CHL CLT CHT
PREFAULT 662/601 .27/ .33/ .25/ .20/ .22/ -/
4537 1527 13874 8601 13509 74
POSTFAULT 781/893 .76/ .99/ .36/ .29/ .31/ -/
4567 1525 13925 8634 13562 75
Magnetising Currents (mA) Furan Analysis

HV Winding LV Winding
1 Furaldehyde 5 Methyl-2-Furfural
R-N S-N T-N r-n s-n t-n

PREFAULT 60 50 63.5 73 16
POSTFAULT 55 41.8 57.3 .048 319 439 33 4
HV Winding Resistance (m5) LV Winding Resistance (m5)
R–N S–N T-N r–n s–n t-n
PREFAULT 395 391 392 36 36 36
POSTFAULT 395 391 392 0 36.2 36.3
Frequency Response Analysis Leakage Reactance Measurements
Nameplate 22%
R–N S–N T-N
PREFAULT No defect indicated.

POSTFAULT Open circuit on LV winding r phase near the 1630 21.9 27.5
phase bushing end of the winding.

Figure 1: FRA scans showing open circuit at R phase

Bushing end of winding Figure 2: Burnt connector to phase bushing
MC/TN5234.REP

overloading guide based on the ransformer’s present

condition. Values of transformer interwinding % PF and
RVM data are given for the three categories of paper
insulation moisture levels.

Transformer overload rating guides and top oil and

winding hot spot temperature indicator trip and alarm
settings are also given.

%PF data ( INTER

8

WINDING)
6
4
2
Figure 3: Open circuit on T phase near neutral end of 0
winding 0 2
R V M data
4 6

3.4 Case History 4 (Transformer Operational Figure 4:Transform er R V M data V % P F

Decisions) data

Condition assessment tests are used to determine the

present condition of transformers so that overloading
guides determined by the transformer’s present Other data derived from the condition assessment i.e.
condition can be provided. Recovery voltage meter paper sample DP, oil screen tests, DGA, furan analysis,
(RVM) data and % power factors (%PF) of FRA, etc. is also used in applying the overloading
interwinding insulation are both used to allocate a rating if the data indicates a significant loss of paper life
wetness rating to the transformer’s paper insulation. / electrical-mechanical integrity.
Three categories are established in this way, i.e. dry,
medium and wet paper insulation. Figure 4 shows
transformer RVM test data versus % PF test data for in
service transformers. Table VI shows a transformer

Table VI: Transformer overloading guide based on condition assessment.

Transformer % PF RVM Reading Overloading Top Oil Winding Hot Spot

Category (Interwinding) Guide Temperature Temperature
Indicator Indicator
Alarm / Trip Alarm / Trip

Dry <.5 <2.5 IEC 354 90 / 1050C 120 / 1350C

Medium <1.5 3-4 1.25% limit 75 / 900C 105 / 1200C

Wet >1.5 >4 Do not overload 65 / 800C 85 / 1000C

MC/TN5234.REP

for a New Power Technology Inspection Policy”,

4. CONCLUSIONS Doble Client Conference Proceedings, April 1993.

Medium and large power transformers are high capital
cost and critical plant items in the generation,
transmission and distribution of electrical power. To
ensure continued serviceability, a life management
policy involving on site condition assessment testing is
essential. This ensures:
• The high quality of equipment being put into
service.
• Continued effective monitoring of equipment in
service.
• Present condition trending while in service.
• Identification of required corrective maintenance
tasks for continued serviceability.
• Speedy repair and return of equipment to service
after fault.
• Generation of data to enable refurbishment and life
extension decisions to be implemented.
[6] Bognar, Kalocsai, Csepes, Nemeth, Schmidt:
“Diagnostic tests of high voltage oil-paper
insulating systems (in particular transformer
insulation) using DC dielectromectrics” CIGRE,
1990 Session, paper 15/33-08
[7] Dick, EP and Erven, CC: “Transformer Diagnostic
Testing by Frequency Response Analysis”, IEE
Trans, Vol. PAS-97, No. 6, PP.2144-2153,
November 1978.
[8] Noonan, TJ and Lapworth JA: “Mechanical
Condition Assessment of Power Transformers
using Frequency Response Analysis”, Doble Client
Conference Proceedings, April 1995.
[9] IEC Publication 450: “Measurement of the
Average Visiometric Degree of Polymerisation of
New and Aged Electrical Papers”, 1974.
[10] ASTM Designation: D3277: “Standard Test
Method for Moisture Content of Oil-Impregnated
Cellulose Insulation”, 1992.

• Generation of data to enable operational changes,

relocation, retirement decisions to be implemented.

5. REFERENCES

[1] IEC Publication 567: “Guide for the Sampling of

Gases and Oil from Oil Filled Electrical Equipment
and for the Analysis of Free and Dissolved Gases”,
2nd Edition 1992.

[2] IEC Publication 599: “Interpretation of the

Analysis of Gases in Transformers and Other Oil-
Filled Electrical Equipment in Service”, 1978.

[3] Kopaczynski, D:“AC Dielectric-Loss, Power-

Factor and Capacitance Measurements as applied
to insulation systems of High-Voltage power
apparatus in the field. Part 1: Dielectric Theory.
Part 2: Practical Applications Doble Testing”,
Doble Client Conference Proceedings, April 1993.

[4] Lackman, MF:“Low-Voltage Single-Phase

Leakage Reactance Measurements on Transformers
– Significance and Application Part I” – Doble
Client Conference Proceedings, April 1994.

[5] Guuinic, P, Mauyean, J-M, Legrand, C, Sanches,

G, Luccion, P Patelli, J-P and Cohard, O, “The
EdF Diagnostic Method Evaluation: A Program