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34 HARMONICS

New Loads, New Problems:

Why Harmonics Destroy


Transformers
by Gabe Paoletti, P.E.

Don’t move one step forward with new


loads that save money or improve
capabilities, and then one step backward
with outages and transformer failures.
New Transformer Technology includes
being aware of the new problems
associated with new high-tech loads;
and understanding how they can impact
the life of a transformer.

Photo by Shutterstock
Transformer Technology March 2019 35

Issue 1

Being involved in root-cause failure waveforms superimposed upon it,


evaluations and harmonic studies creating multiple frequencies within
provides a history of practical the normal 60 Hz sine wave. The
experience related to why harmonics multiple frequencies are harmonics
destroy transformers. New of the fundamental frequency.
Transformer Technology includes
Gabe Paoletti has applied his 40-plus years being aware of the new problems Examples of nonlinear loads are
of electrical power distribution experience associated with new loads; and uninterruptable power supplies
to support the electrical power industry by understanding how they can impact (UPSs), adjustable speed drives,
providing professional engineering servic- the life of a transformer. battery chargers, electronic ballasts,
es to increase system reliability, resiliency, variable frequency drives, and
equipment life extension, personal safety, Some examples of new loads, which switching mode power supplies
power system personnel training, failure are implemented for very good (normally used in computer
and root-cause analysis, feasibility studies, reasons are: adjustable speed drives loads and other data processing
quality systems and new solution creation. and/or electronic ballasts both equipment). As nonlinear currents
He is a Registered Professional Engineer resulting in reduced electrical power ͥRZWKURXJKDIDFLOLW\̵VHOHFWULFDO
in New York, Pennsylvania and Delaware demand and the associated cost system and the distribution-
and has authored and presented numer- savings; improving the capabilities transmission lines, additional
ous technical publications for IEEE and by installing new data processing voltage distortions are produced
other organizations. He received his BSEE HTXLSPHQWLQRͦFHEXLOGLQJV due to the impedance associated
in Electrical Engineering at Drexel Univer- industrial sites and institutions. with the electrical network. Thus,
sity in 1976 (Magna Cum Laude), and an When these new loads are being as electrical power is generated,
MBA from Rutgers in 2009 (Summa Cum planned, it is imperative that distributed and utilized, voltage and
Laude). Mr. Paoletti has also been on the harmonics be reviewed. current waveform distortions are
forefront of many power system innova- produced.
tions and was awarded the IEEE Engineer There has been substantial
of the Year Award for 2009 (Northern New research and publications regarding Power systems designed to function
Jersey Chapter) for new product and ser- the effects of harmonics on at the fundamental frequency, which
vice innovation which improved the effi- transformers. While harmonics can is 60 Hz in the United States, are
cient distribution of electrical power. He be linked to overloading neutral prone to unsatisfactory operation
currently provides services such as failure conductors and causing nuisance and, at times, failure when subjected
analysis, project engineering, owners rep- tripping of circuit breakers, we’re to voltages and currents that contain
resentative and engineering and feasibil- focusing on the impact of harmonics substantial harmonic frequency
ity studies, with his company Paoletti En- on transformers. This background elements. Very often, the operation
gineering PLLC. has been extracted from an excellent of electrical equipment may
article by C. Sankaran [1]. seem normal, but under a certain
combination of conditions, the
Harmonics impact of harmonics is enhanced,
with damaging results.
Some loads cause the current to
vary disproportionately with the As previously discussed, changes
voltage during each half cycle. to a system that will lead to the
7KHVHORDGVDUHFODVVLͤHGDV potential of failure due to harmonics
nonlinear loads, and the current could include installation of
and voltage have waveforms that variable frequency drives, electronic
are non-sinusoidal, containing ballasts, power factor improvement
distortions, whereby the 60 Hz capacitors, arc furnaces, or the
waveform has numerous additional addition or removal of large motors.
36 HARMONICS

Eddy Currents

Application of non-sinusoidal due to the crowding effect of the The resultant increase in eddy
excitation voltages to transformers OHDNDJHPDJQHWLFͤHOGVDWWKHFRLO currents increases the operating
increase the iron losses in the extremities. The eddy current losses temperature of the core iron, which
magnetic core of the transformer in increase as the square of the current in turn begins to deteriorate the
much the same way as in a motor. in the conductor and the square insulation between the core iron
A more serious effect of harmonic of its frequency. The increase in laminations. This leads to greatly
loads served by transformers transformer eddy current loss due to increased I2R losses, beyond the
is due to an increase in winding KDUPRQLFVKDVDVLJQLͤFDQWHIIHFW design limits of the transformer,
eddy current losses. Eddy currents on the operating temperature of the and overheating of the actual
are circulating currents in the transformer. Transformers that are winding insulation. Once the winding
conductors induced by the sweeping required to supply power to nonlinear insulation allows the energized
DFWLRQRIWKHOHDNDJHPDJQHWLFͤHOG loads must be de-rated based copper winding to contact the
on the conductors. Eddy current on the percentages of harmonic grounded core-iron, an internal
concentrations are higher at the components in the load current and failure will result. This process is
ends of the transformer windings the rated winding eddy current loss. illustrated in Figure 1.

The harmonic related increase in eddy currents


increases the operating temperature of the core
iron, which in turn begins to deteriorate the
insulation between the core iron laminations.
This leads to greatly increased I2R losses,
beyond the design limits of the transformer, and
overheating of the actual winding insulation, and
eventual failure.

The insulation between the


laminations is deteriorated
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and damaged.
Transformer Technology March 2019 37

Issue 1

Figure 1. Pathway from harmonics


to transformer failure

Increased Increased Damage Overheat


Transformer
Harmonics Eddy Core Iron Lamination Winding
Failure
Currents Heating Insulation Insulation

Figure 2. 5-Why analysis of harmonics related


transformer failure

As previously stated, the eddy laminations are insulated from each


current losses increase as the other with an insulating coating that
square of the current in the is applied to both sides of the thin
conductor and the square of its metal laminations. The purpose of
frequency; therefore, with higher and insulating the laminations is to limit
higher harmonics, this heating is the heating effect of eddy currents
further increased. during normal operation.

When looking at a transformer, Even without taking into account


it appears that the high and low the increased heating effect of the
voltage winding are wrapped around harmonic’s higher frequencies,
a solid iron core; but, if you look Figure 3 clearly illustrates the effect
more closely, you’ll see that the on the I2R, heating losses that
“solid” iron core is made up of a occur within the core-iron as the
series of thin laminations, usually insulation between the laminations
of silicon steel, and these thin is deteriorated and damaged.
38 HARMONICS

In the second illustration, we have


the same 10 amperes of eddy
currents, but now the
insulation membrane
Many end-users are familiar with protection for between the iron
transformer voltage surges, therefore they do core laminations has
been deteriorated and
DSSO\WUDQVLHQWYROWDJHVXUJHVXSSUHVVLRQDQG damaged to the point
that all ten sections
or lightening arrestors, but many do not fully of the iron core are
in contact with each
address the potential high harmonic currents other. As shown, the
total heating effect has
of new, or added, computer loads or solid-state increased from 5.0 watts
drive systems. to 50.0 watts, or a 900%
increase heating.

This increased heating effect, which


does not include the added effect of
the increased frequency associated
with harmonics will overheat the
primary and/or secondary winding
Figure 3. Illustrative effect of deteriorated iron-core insulation, resulting in a transformer
lamination insulation failure internal winding failure.

Eddy
1 1 1 1 1 1 1 1 1 1
Current

Impedance 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Heating

I2R 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 5.0

Eddy
1 1 1 1 10 1 1 1 1 1
Current

Impedance 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Heating

I2R 0 0 0 0 50 0 0 0 0 0 50.0
Transformer Technology March 2019 39

Issue 1

Solutions

Many end-users are familiar with Once the level of harmonics is


protection for voltage surges, determined, you should disconnect
therefore they do apply transient them from the transformer and
YROWDJHVXUJHVXSSUHVVLRQDQGRU determine your next steps.
lightening arrestors, but many do A solution can be to install
not fully address the potential high KDUPRQLFͤOWHULQJRUUHFRQͤJXULQJ
harmonic currents of new, or added, transformers connections to allow References
computer loads or solid-state drive for cancellation of harmonics, [1] C. Sankaran, Effects of Harmonics
systems. or changing the transformer to on Power Systems, 1999, retrieved
accommodate the harmonics. from https://www.ecmweb.com/
7KHͤUVWVWHSZKHQUHGHVLJQLQJ power-quality/effects-harmonics-
or altering your current power Another option to support long-term power-systems
distribution system to support diagnostics is to install a permanent [2] IEEE standard 519-1992,
new power loads is to model your harmonics meter. Should you have Recommended Practice and
electrical system to simulate the a transformer failure, and you have Requirements for Harmonic
harmonics from the new loads. not applied the types of new loads Control in Electric Power Systems
It is also highly recommended discussed above, then a review of
to measure the actual current harmonics should be part of the
harmonics that exists, and after root-cause analysis. As an example,
the new loads are installed, to then IEEE standard 519-1992 [2] states
again measure the actual current the total harmonic distortion (THD)
harmonics. of the voltage waveform provided
by the utility cannot exceed 3%
If the changes are being made of the ideal sine wave. To ensure
to an existing power distribution that harmonics are not generated
system, you can cautiously add the by the utility, you would obtain
new loads and then immediately this measurement at the point of
obtain the harmonic measurements common coupling (PCC). This is
resulting from these new loads. where the utility and facility wiring
A transformer supplying these meet (usually at the meter box). If
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new loads will hopefully not fail the voltage distortion exceeds 3%,
within days of the new loads being the utility should provide some form
installed. of mitigation to correct the problem.
40 DIELECTRIC
RESPONSE

Dielectric Frequency Response:

A New IEEE Guide for Field Test on


Power and Distribution Transformers
by Diego Robalino
and Roberts Neimanis

Photo by Shutterstock
Transformer Technology March 2019 41

Issue 1

Since the invention of the non-destructive testing method to


transformer, the design, quality better understand the condition of
DQGHͦFLHQF\RIWKLVPDJQLͤFHQW the insulation system of power and
machine has been improved thanks distribution transformers.
to the development of electro-
magnetic materials, computer Introduction
Diego Robalino currently works for Meg- design algorithms, insulation
ger as Principal Engineer, where he special- materials, cooling systems, During the last two decades, other
izes in the diagnosis of complex electrical structural design, etc. Nowadays, a technical references presented the
testing procedures. While doing research in vast number of transformers operate development of DFR (Dielectric
power system optimization with a focus on worldwide aiming to provide reliable Frequency Response) a.k.a.
aging equipment at Tennessee Technologi- and safe operation under the most Frequency Domain Spectroscopy
cal University, Robalino received his electri- cumbersome environmental and )'6 DLPLQJVSHFLͤFDOO\WR
cal engineering PhD from that institution. operational conditions. its application for power and
Robalino has over 20 years of involvement distribution transformers with oil-
in the electrical engineering profession with Even though the materials, design impregnated paper insulation. CIGRE
management responsibilities in the power and manufacturing processes Technical Brochures 254, 414 and
systems, oil and gas, and research arenas. have improved, the most common 445 as well as IEEE Std. C57.152
He is a Senior Member of the IEEE, member insulation system is a combination addressed the importance, the
of the IEEE/PES transformers main commit- of liquid insulation, cellulose and UHVHDUFKFDUULHGRXWDQGWKHEHQHͤWV
VGGCPFCEGTVKƒGF2TQLGEV/CPCIGOGPV2TQ- impregnated in oil cellulose. These of the method as applied to power
fessional with the PMI. He is an active mem- components of the overall insulation and distribution transformers.
ber of the IEEE/DEIS Electrical Insulation system go through an inevitable
Conference. Author and co-author of multi- aging process that leads to the In the IEEE Transformer Committee,
ple technical articles related to power, dis- end of the service life of power and a Task Force was initially formed
tribution and instrument transformer condi- distribution transformers. One can to recommend (or not) the need
tion assessment. expand this statement into other to develop a guide describing
components with similar insulation the application of DFR on oil-
construction such as bushings and impregnated transformers. From
instrument transformer with oil- the initial step of forming the
impregnated paper insulation. Task Force to the publication
of the guide, the contribution
The Institute of Electrical and and participation of specialists,
Electronic Engineers (IEEE) end-users, testing equipment
Standards Association approved manufacturers, transformer
the publication of IEEE C57.161- manufacturers and academia
2018 – “Guide for Dielectric made possible the production of a
Frequency Response Test”. The practical and comprehensive guide
work was developed within the IEEE for the use of DFR technology and
Transformers Committee and the interpretation of transformer’s
Dielectrics Sub-committee. A needed insulation dielectric response in
document for a non-intrusive and the frequency domain.

In 1996, WaBtech AB in Sweden brings to the market


WKH̨UVWSRUWDEOHGHYLFHIRU')5WHVWLQWKH̨HOG
'U3HWHU:HUHOLXVDQG%MRUQ%HQJWVVRQLQWURGXFHG
IDA (Insulation Diagnostics Analyzer) mainly for
cable and transformer testing.
42 DIELECTRIC
RESPONSE

DFR References

As mentioned previously, since the The practical application of DFR in the solid insulation by dielectric
beginning of the use of insulation LQWKHͤHOGJHQHUDWHGWKHLQWHUHVW response methods.
materials, a method to determine in the industry and international
an acceptable condition for its organizations took lead on Considering the great acceptance
use in electrical applications was the investigation of this “new RIWKHWHFKQRORJ\LQWKHͤHOGWKH
required. The dielectric response technology” revolutionizing the CIGRE Working Group (WG) A2.34
of any insulation material can be WHVWLQJSUDFWLFHVLQWKHͤHOG incorporates dielectric response
obtained in the time domain or in methods in time and frequency
the frequency domain. Time domain In 2002, CIGRE developed the domain in section 5.1.3 in the
dielectric response has been in Technical Brochure 254 – “Dielectric Technical Brochure 454 published
place for over 100 years and the Response Methods for Diagnostics in 2011. Dielectric response
typical “Insulation Resistance” test of Power Transformers”. This report methods are included as “Special
became, by far, the easiest and most from the Task Force (TF) D1.01.09 or Advanced Measurements”. DFR
practical approach to understand the focused on three dielectric response or FDS is an advanced testing
condition of the solid insulation. techniques: WHFKQLTXHXVHGLQWKHͤHOGWR
determine the water content in the
̽Return Voltage solid cellulose insulation of oil-
The complex impedance Measurements (RVM) paper insulation, insulation failures,

of the dielectric system


̽Dielectric
Spectroscopy in Time
and contamination of insulation.
Moisture content in the solid
Domain (PDC) LQVXODWLRQGHULYHGIURPͤHOGWHVWLQJ
is measured at different ̽Dielectric Frequency mathematical modelling and data
Domain Spectroscopy base source is compared against
frequencies and the (FDS) limits given for dry, moderately wet
dielectric response To summarize the text
and extremely wet insulation given
in IEC 60422. As a reminder, IEC
LV̨QDOO\SORWWHGDV of this document, the
TF concluded that all
60422 states that the determination
of the water content in the paper of a
percentage dissipation WKUHHPHWKRGVUHͥHFW transformer by the measurement of
the same fundamental the water in oil has been frequently
factor, permittivity polarization and described, but practical results are
conduction phenomena often not in line with the theoretical
or capacitance as a in transformer predictions. All calculations and
function of frequency. insulation and that the
GHͤQLWLRQRIPRLVWXUH
correlations of the water content
in oil and the water content in the
in the solid insulation oil/paper-system depend on the
by time domain and equilibrium state between the
Nevertheless, around the mid-1900s, frequency domain responses insulating oil and the oil/paper
the frequency domain response was required mathematical modelling system and vice versa.
JUHDWO\VWXGLHGDQGWKHGHͤQLWLRQ and good understanding of dielectric
of dielectric losses at power or line properties of the insulation system
frequency (50/60 Hz) turned to be components.
a great success for transformer
manufacturers, end-users and In 2010, CIGRE continued the
testing service companies. work and published the Technical
Nevertheless, technology evolved Brochure 414 – “Dielectric Response
and with that, electronic components Diagnoses for Transformer
and control devices opened the door Windings”. In this document, CIGRE
to a wider band frequency spectrum combines the practical experience
to analyze different insulation acquired with the mathematical
materials. modelling approach to determine
best testing practices. The
In 1996, WaBtech AB in Sweden document covers the fundamentals
EULQJVWRWKHPDUNHWWKHͤUVWSRUWDEOH of the X-Y model, measurement
GHYLFHIRU')5WHVWLQWKHͤHOG'U FRQͤJXUDWLRQVWHVWSHUIRUPDQFHDQG
Photo by Shutterstock

Peter Werelius and Bjorn Bengtsson maybe the most important part, case
introduced IDA (Insulation Diagnostics studies and comparative analysis
Analyzer) mainly for cable and using Karl Fisher Titration (KFT) to
transformer testing. validate the moisture estimation
Transformer Technology March 2019 43

Issue 1

In the North American world, the IEEE The work carried out by the IEEE
Transformer Committee revised the transformer committee ended up
document IEEE 62 Part 1– “Guide for with the publication in 2013 of
Diagnostic Field Testing of Electric the IEEE Std. C57.152 – “Guide
Power Apparatus – OilͤOOHG3RZHU for Diagnostic Field Testing of
Transformers, Regulators, and Fluid-Filled Power Transformers,
Reactors”. One of the fundamental Regulators and Reactors”. The
reasons to revise this document amount of information put together
was the application of new testing LQWKLVGRFXPHQWLVGLͦFXOWWR
techniques not described in this describe in just a few lines, but
document and considered important this guide added the Informative
for the current requirements of ANNEX G introducing to the IEEE
manufacturers and end-users references the Dielectric Frequency
HVSHFLDOO\LQWKHͤHOG,WLVLQWHUHVWLQJ Response Method. Annex G provides
to notice that IEEE 62 (R2005) a brief description of the DFR
provided in section 6.3.12 two method and its interpretation for oil-
tables with general guidelines for paper insulation systems in power
interpreting data expressed in transformers.
percent saturation of water in oil and Enough about history. Let us focus
in percent moisture by dry weight of now on the recently published guide
paper. for DFR testing.
44 DIELECTRIC
RESPONSE

IEEE Guide for Dielectric


Frequency Response Test

The continuous work of IEEE and


LWVPHPEHUVLVZHOOUHͥHFWHGLQ
the guide for dielectric frequency
response test applicable for liquid-
immersed transformers. The guide
includes a thorough description
of the DFR method, a comparative
analysis between line-frequency
power factor and the dielectric
response in a wide frequency
spectrum, recommendations for
instrumentation, procedures for
performing the tests, and guidelines
for interpretation of the data. The
application of DFR allows testing in
IDFWRU\DQGLQWKHͤHOG

After a general overview, Section


4 introduces the DFR method.
DFR is a non-intrusive and non-
destructive off-line testing technique
performed in the frequency domain
to determine the moisture content
of the transformer’s solid insulation temperature of the specimen at the
and the conductivity of the liquid time of the test. Second, DFR follows
insulation. This paragraph covers the same measurement principle as
one very important characteristic line – frequency power factor test,
of the dielectric response; it can but the excitation signal applied by
discriminate between the effect of DFR instruments varies frequency in
moisture or contamination in the the range from 1 kHz down to 1 mHz
liquid or solid insulation. (typical range at 20°C). The complex
impedance of the dielectric system
In Section 4, some important facts is measured at different frequencies
are described. First, DFR as any other DQGWKHGLHOHFWULFUHVSRQVHLVͤQDOO\
dielectric response method depends plotted as percentage dissipation
on the unique dielectric properties of factor, permittivity or capacitance as
WKHPDWHULDOWKHHOHFWULFͤHOGDQGWKH a function of frequency.

After a clear understanding of the behavior of the


materials under an alternating excitation signal in a
wide frequency spectrum, different factors affecting
the dielectric response are described. One of the
most important factors to take into account is the
presence of EMI in the surrounding test area.
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Transformer Technology March 2019 45

Issue 1

The modelling algorithm requires Besides the modelling part, it is As any other electrical test, the
VSHFLͤFLQIRUPDWLRQWRHYDOXDWHWKH important to understand that the test YHU\ͤUVWUHFRPPHQGDWLRQVDUH
condition of the insulation system. LVSHUIRUPHGLQWKHͤHOGIROORZLQJWKH related to safety. For many readers,
7KHQRUPDOO\ͤ[HGLQIRUPDWLRQLV same instrument-to-object hook up safety is not just a best practice
a. Liquid Insulation relative principles as those used for power but also a life style. Therefore, local
SHUPLWWLYLW\Ər factor / dissipation factor testing at and federal regulations required to
b. Thermal activation energy for line frequency. Figure 1 shows the perform the test as well as safety
solid and liquid insulation hook up diagram of the DFR test set instructions provided by the test set
c. Temperature of the insulation to a commonly used two-winding manufacturer must be followed. One
under test transformer. more advantage of DFR is that the
test involves a LV excitation signal
The outcome of the test will provide: Section 5 provides the best practices W\SLFDOO\͠9RMS.
D/LTXLGLQVXODWLRQFRQGXFWLYLW\ Ɲ DQGFRQͤJXUDWLRQVWRSHUIRUPWKHWHVW
b. Moisture in solid insulation (m) LQWKHͤHOG

Figure 1. Hook up diagram between a DFR test


set and a two-winding transformer
46 DIELECTRIC
RESPONSE

,QWKHͤHOGZRUNLQJFRQGLWLRQV Section 6 provides the guidelines to Overcome the effect of noise (EMI)
might not be optimal. Section 5 generate the test report, including an on the measurement signal, the use
provides guidelines to minimize example of the report. RIDYROWDJHDPSOLͤHULVFRQVLGHUHG
the effect of external factors on DVRSWLRQDOLQWKHͤHOGHVSHFLDOO\
the test performance as well as the Maybe the most important part for low capacitance specimens and
PHDVXUHPHQWFRQͤJXUDWLRQV$WWKLV of the guide is without a doubt tests at temperatures close to zero
stage, the reader should be aware Section 7 – Measurement Analysis degrees Celsius.
that the most accurate estimation and Interpretation. In this section,
of moisture in the solid insulation the guide provides the differences The Annexes included in the
is related to the test between between the dielectric response document cover:
windings in a UST (ungrounded of liquid and solid insulation A. Dielectric Frequency Response
specimen test) test mode. In a two- graphically represented in Figure 2. Analysis – Theory and validation
winding transformer, the capacitance The liquid insulation dielectric B. Non-moisture related
of interest is the inter-winding properties can be described by IDFWRUVLQͥXHQFLQJWKH')5
insulation between high and low a simple parallel RC-circuit, the measurements
voltage windings represented in capacitance representing the liquid C. Examples of typical measurement
Figure 1 as CHL. Other insulation permittivity and the resistance the challenges
systems, between high voltage liquid conductivity. The dielectric D. Bibliography
winding and ground (CH) or between properties of solid insulation are
the low voltage winding and ground more complex, both capacitance Closing Note
(CL DUHVXVFHSWLEOHWRWKHLQͥXHQFH and losses vary with frequency in a
of bushings and sometimes-other manner that cannot be described by This article is a brief summary
components inside the transformer a simple parallel or series RC-circuit. of a well-developed document
such as tap changers. Nevertheless, provided by IEEE and its members.
the GST measurements are often After a clear understanding of the Authors consider imperative for
taken to identify non-typical behavior of the materials under an asset managers, utility operators,
responses related to contamination alternating excitation signal in a wide transformer manufacturers and
or degradation of the insulation frequency spectrum, different factors testing service providers to acquire
system. affecting the dielectric response are this document and follow the
described. One of the most important guidelines given.
factors to take into account is the The article is co-authored by Dr.
Figure 2. DFR of mineral oil (left); presence of EMI in the surrounding Roberts Neimanis, Product Manager
DFR of paper only (right) test area. at Megger Sweden.

10000 100

1000

100
10
10

1
1
0.1

0.01
Photo by Shutterstock

0.001 0.1
0.0010 0..010 0..1 11 01 00 1000 0.0010 0..010 0..1 11 01 00 1000

Frequency [Hz] OIL ONLY Frequency [Hz] PAPER ONLY

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