MAINTENANCE AND LIFE TIME EXTENSION OF POWER TRANSFORMERS

Kari Heinonen Infratek Finland Oy

2010 EuroDoble Colloquium 18-20 October 2010 Birmingham, United Kingdom

ABSTRACT
Visual inspections Oil testing Oil filtering Bushings OLTC Transformer refurbishment Copper corrosion Failure investigation
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kpl 100 10 20 30 40 50 60 70 80 90

Fig. 1.

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Perushuolletut Huoltamattomat

Vuosimalli

Finnish 110 kV 400 kV transformer population. /2/.

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1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

1 Visual inspections

1 to 6 months interval Bushings: Oil level, Leakages etc. Corrective actions immediately with dangerous findings

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2 Oil analysis
There are not any excuses why not to apply frequent oil analysing. DGA and break down voltage test: 2 years period Other analysis: 10 year period Warranty period: more frequent monitoring
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2 Oil analysis continues

Bushings with oilpaper insulation: DGA 10 years interval, OR Power Factor measurement, 10 years interval

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2 Oil analysis continues FIELD TESTING RESULTS, Bushing

ASEA GOB 650, 123 kV, 800 A Ser. Numb. PF1
104807 IEC -60137 < 0,7 %

PF2

C1

C2

0,14 % 80,5 %

180 pF 190 pF

DGA results ppm (KELMAN Transport X)

H2 CO2 27 3819 CO 964 C2H4 4 C2H6 9 CH4 18 C2H2 <0,5 TCG 1022

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2 Oil analysis continues

BUSHINGS 110 kV DGA results ppm (KELMAN Transport X and Lab.
analysis)
Serial Numb 104807

TYPE GOB 650 145 kV GOA 650 145 kV

H2 27

CO2 3819

CO 964

C2H4 4

C2H6 9

CH4 18

C2H2 <0,5

TCG 1022

129481 129482 129484 130805

27 28 27 23

1604 1278 1458 755

491 422 471 280

29 20 24 8

3 3 3 5

12 10 13 11

0 0 0 0

562 483 538 327

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3 On-site and on-line gas analysis 280 MVA, 400/15 kV On-line gas monitoring

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4 Oil filtering, degassing and regeneration

On-site oil filtering: Start of repair activities needs to be delayed Not any corrective action Low break down voltage: Filtering and oil degassing Continuous degassing Oil regeneration: Aged oil as good as new oil.
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5 Monitoring of transformer bushings Oil sampling or power factor measurement 10 year period When refurbishingTrafo: Lab. Testing: voltage test, tan delta, partial discharges, capacitance. 2,0 % of all 110 kV bushings tested had minor failures and 2,5 % of bushings had to be scrapped immediately
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5 Monitoring of transformer bushings continue

LAB. TESTING RESULTS ASEA GOB 550, 123 kV, 800 A

PD Ser. Numb. . 141399 141341 141334 141335 IEC -60137 Tan d 0,45 % 0,46 % 0,45 % 0,50 %
< 0,7 %
0,61 x Un

PD
1,0 x Un

< 3 pC < 3 pC < 3 pC < 3 pC

< 5 pC

< 3 pC < 3 pC < 3 pC < 3 pC

< 10 pC

Voltage test 0,75 x 230 kV, 50 Hz, 1 min

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6 On-load tap-changer service

Five to six years period Oil sampling, visual inspections, relay testing, bushing and transformer power factor testing etc. during the same outage.
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7 Transformer refurbishment
Refurbishment: Lifting of active part
(core and windings; untanking)

On-site, power plant, repair shop, at the manufacturer Finland ca. 30 % of all 110 kV 400 kV transformers (ca. 2000 pcs.) revised WHY: Better reliability, Longer lifetime, Environment Cost 1520 % of new price.

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7 Transformer refurbishment continues 110 kV transformers: Trailer transportation to workshop 4 to 6 weeks including transportations On-site refurbishment: * 110 kV, 100 MVA + * (220 kV transformers) * 400 kV transformers
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7 Transformer refurbishment continues

Tightening of windings Drying of paper insulation Revision and modifications of tap-changer including selector Oil degassing and filtering High-voltage testing of bushings Replacement of gaskets Replacement of protection relays and devices Addition of a separate expansion vessel for on-load tap-changer etc. Painting Documentation
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7 Transformer refurbishment continues Findings 1 / 120 kV, 63 MVA, 1974

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7 Transformer refurbishment continues Findings 2 / 121 kV, 50 MVA, 1969

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8 Refurbishment of distribution and special transformers

50 kVA 1000 kVA: When moving the transformer Electric filter rectifier transformers: Oil sampling with five years interval and revision by lifting the active part with ten years interval.

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9 Other maintenance methods Thermocamera: Local surface hotspots, loose contacts Low voltage transformer busbars: plastic coating against animals Replacement of old type surge arresters
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10 Copper corrosion Some oils are more risky than the others. Identify risky trafos Start actions to reduce the risk (lower temperature, passivator addition).
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11 Failure investigations
Data: protection relays, fault recorders, visual and audible observations etc.. Electrical measurements and oil testing False alarm? Can we repair it onsite? Active part lifting is needed? Transport is needed?
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11 Failure investigations continues

FAILURE STUDY CHECK LIST
Date and time of failure (hour, minutes and seconds, if also seconds are available)) Which protection relays / which functions have activated and how (alarm or/and tripping; gas relay tripping before alarm etc.)? Take the oil sample for laboratory analysis (bottom valve) immediately after the failure and about 24 hours after the failure. For 220 and 400 kV transformers also top valve sampling immediately after the failure. Is there gas in gas relay, how much, what color, is it air or flammable gas? Take gas sample also for laboratory analysis. What indications do fault recorders have related to tripping (also nearby substations)? Transformer load when tripping and mean load 1 hour and 24 hour prior tripping? On-load tap-changer (OLTC) position when tripping? Has OLTC operated during tripping and to which direction? OLTC counter reading and operations from previous OLTC-revision? Temperature indicators (oil, winding) indication: indication when tripping and max. pointer indications? All abnormal findings according to visual inspection (tank or/and radiator deformations etc.)? Marks of arching: Bushings, transformer cover, cables etc.? Cleanness of porcelain insulators? Dead animals and other debris on transformer cover? Abnormal sounds from transformer before failure? Has there been breaker or disconnector operations near the transformer before tripping (same or nearby substations)? Have there been transmission or distribution network disturbances or over voltages just before or during tripping? Weather conditions during and before tripping? Is there some abnormal according to visual inspection with surge arresters, protection capacitors, disconnectors, circuit breakers and other equipment near the transformer?

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12 Conclusions
Utilize the existing transformer capacity as long time as possible There are not any excuses why not to apply frequent oil analysing Bushings shall be oil sampled or power factor measured every 10th year Transformer refurbishment / untanking Once during lifetime
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Thank you for your attention

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