Guide to Power Transformer

Specification Issues

Engr. Md. Ismail Hossain PEng.

Superintending Engineer
NPTND Project
PGCB, Dhaka

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Power Transformer Technical Specification
During 2006 and 2007 to date, an unusually high number of requests have arrived for
Technical Specification reviews, both in New Zealand and Australia.
More than six power transformer Technical Specifications for machines over 200MVA in
New Zealand alone.
The challenges of a significantly loaded electrical network reliant on service aged
equipment: refurbish and/or replace.
The challenges of increasing load and “new” generation types e.g. wind turbines.
The commodity price issues (copper, electrical steel, structural steel and oil).
The changes from well established European factories to new South East Asian
manufacturing sites.
The need for form relationships with new people (new manufacturer personnel, new
employers/clients).
It may be that power transformer Technical Specifications has become cumbersome,
out of focus and needs a
“spring clean”.
The peer review process: are our ideas good ones?

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Why Have a Technical Specification?

From an Employer (Client) perspective:

To formally and fairly communicate exactly what you want the Contractor to deliver.

From a Contractor perspective:

To be able to accurately offer services and products which provide a satisfactory solution
(technical/commercial) to an Employer (Client); while remaining a long-term profitable
business.

For both Contractors and Employers (Clients):

To avoid relationship mishaps associated with costly Variation work misunderstandings.

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2. The Single-Point Earthing of Power
Transformer Cores, Frames and Tanks
The insulation is failing.
Dissolved Gas Analysis tests are being over-run withalarming gas signatures. repair bill
is significant.
What is the Industry going to do about it?

3. Partial Discharge Testing of Refurbished

Power Transformers in New Zealand
This is an expensive and time consuming test.
It could commonly be the case that the original power transformers were not designed to
be subjected to the Partial Discharge test.

Why are expected Partial Discharge pass levels being set at 50% of the value specified
in the IEC International Standard for new transformers?

What is the plan if the Partial Discharge fails?

The Partial Discharge test initially failed but has now passed, how does this make you
feel?

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4. On-Load Tap-Changers on Generator
Step-Up Transformers
More and more tapping ranges. Lower and lower tap sizes.
Why – the generator has an Automatic Voltage
Regulator?

Has system simulation taken over the importance of

reliable machine design?
What is the impact upon short-circuit with-stand e.g. multi-start, layer wound tapping
windings?

5. Transformer Cooling
ONAN/ONAF/ODAF versus ODW versus ONAN? When should we buy straight ONAN
machines?
Reliable, not dependent on l.v. systems, and simple.
ONAN/ODAF may be significantly more cost effective above 65MVA?

Will specifying ODW significantly reduce the number

of Contractors who will tender for the work?

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PART 1. FIRE & EXPLOSION
PROTECTION
What is considered an acceptable level of fire and explosion protection that
should be specified for power transformers in thefollowing scenarios?

a) A remote outdoor substation

Physical separation (firewalls if duplicate units).
Buchholz relay.
Pressure relief.
Separate cable terminations > 100MVA.
Vented cable box.
Generator circuit breaker.
Bushing plus monitoring.
Conservator tank isolation >100MVA.
Temperature indicators.
Single unit (rural) - let it burn!
Double unit - physical separation / + blast wall.
Sump flame trap - Important substations.
Control consequential damage.
Consider the layout of the surroundings.
Consider building materials.
Consider neighbouring natural environment.
Dependent on size use pressure relief valve and shut off valve on conservator.
Blast walls for smaller critical areas.
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b) A generator step-up transformer connected to a
steam or gas turbine unit
Possible use of Sergi protection, etc.
Positioning transformers away from station.
However, look at the economics.
Buchholz relay.
Pressure relief.
Vented cable box.
Generator circuit breaker.
Bushing monitoring.
Conservator tank isolation.
Choice of oil.
Temperature indicators.
Fire protection (foam).
GSU (Generator Step Up) transformer -
Generator CB (Circuit Breaker) – preferred.
Blast walls and deflectors.
Water sprinklers on the walls.
More likely to provide fire fighting equipment for

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steam and gas plant than hydro. All money and susceptible to damage.
Nitrogen.
Enclosure.
Fire Wall.
Blast walls in all critical areas.
Design of location.
Fast acting protection
c) A generator step-up transformer connected to a
hydro-turbine unit
Environmental risks - oil contamination of lakes / rivers, etc. Containment of full volume of
oil.
Buchholz relay.Pressure relief.Vented cable box.Generator circuit breaker.
Bushing monitoring. Conservator tank isolation.
Choice of oil.Temperature indicators.Fire protection (foam).GSU transformer - generator
CB – required.
Water sprinklers and oil interceptor.
Hydro in environment sensitive areas, must
consider heat and oil.
Environmental issues are important, especially oil
containment.Deluge.
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 Condition Based Management
Define asset condition (Health Index)
Link condition to performance & probability of failure
(PoF)
Calibrate Health Index/PoF against historic fault
rates
Estimate future condition and performance
Evaluate effect of investment programmes on future
condition and performance
Provides an ENGINEERING basis to evaluate risk
and determine investment requirements

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d) Any power transformer greater than 100MVA
Physical separation (firewalls if duplicate units). Possible use of
‘Sergi’ protection, etc.
Positioning transformers away from station. However, look at the
economics.
Environmental risks - oil contamination of lakes / rivers, etc.
Containment of full volume of oil.
Buchholz relay. Pressure relief.Vented cable box.Generator circuit
breaker.
Bushing plus monitoring. Conservator tank isolation.Choice of
oil.Temperature indicators.Fire protection (foam). Blast walls and
sprinklers on wall.
Conservator shut off valves. Options: foam, water curtain, CO2,
FR3™.
Sergi system economical for larger units.

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High velocity water spray system. C02 for sealed enclosures.Fast acting digital
protection.Sergi transformer protection or gas insulated transformer.
High velocity water spray system.C02 for sealed enclosures.Fast acting digital
protection. Sergi transformer protection or gas insulated transformer.

General Notes:
All scenarios require risk assessment. Consider use of polymer bushing i.e.
GSA, etc.
All scenarios depend on transformer size and blast wall requirements.
Oil containment bunding with fire-traps/ drainage.
Situational considerations – not one answer for all remote transformers or all
hydro, etc. All situations consider:
􀂃 NFPA850 Guidelines – but these are only guidelines, but you must go
through and specify.
􀂃 Blast walls for specified separation.
􀂃 Bunding w/ drainage to suffocate fire.
􀂃 Shutter valves on conservators.
􀂃 Differential Protection.
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PART 2.THE DETAILED DESIGN
REVIEW
When the Detailed Design Review process is specified: a) Employers
(Clients), what Detailed Design
Review (DDR) outputs do you require and why?
Using knowledge of supplier to tailor client requirements.
Adding value to project.
Specifically reviewing: component mounting,
footprints, weights, shape, oil volumes etc.
Reconfirmation of 'no surprises' / confirmation that supplier has the ability to
deliver.
Compatibility with existing spares / stock, intercompatibility with existing
network.
Key scope requirements.
Fit for purpose.
Delivery.
Inspection process.
Transport / shipping to site.
Site constraints.
Performance criteria. 13
Cooling plus interlock systems.
Material listing.
Acceptance tests.
Type tests / compliance.
Special tests.
Material quality.
Review of mechanical design.
Review of loss calculations.
Scope of DDR and timing of review at supplier.
Compare DDR outputs to specification clauses.
Special transformers need proper DDR.
Report on basis of IEC and CIGRE DDR guide documents.
Result is confidence in the transformer design.

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Provide alternatives.
Assurance that the design will work and meet specifications.
Provides assurance that the employer is getting what we want.
Facilitates forum for improvements in design that may impact on
overall cost and performance.
Gain understanding of the design so we can gain understanding of
test results.
Find any steps in design/manufacture that you want to witness to
help with maintenance

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b) Contractors (suppliers), what are the key matters that will
influence the power transformer detailed design that you
need the Employer (Client) to clarify?
Ensuring spec following best practice.
Possible provision of future on-line monitoring equipment.
What is important to client i.e. on time, cost, etc?
Confirmation of spec / deviations.
QA (Quality Assurance) requirements.
Drawing, documentation, manuals, maintenance procedures.
Required specs.
Seismic requirements.
Weight - gross, transport.
Dimensions - centre of gravity.
Terminations.
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Specification does not cover all details. Need DDR these details,
Allows agreement on these details.
No DDR for standard transformers only one off/New Designs.
Also discussed customer acceptance Clarification of:
􀂃 Out of date standards included in spec.
􀂃 Standard Designs i.e. 6MVA spec but a 7.5MVA standard –
cheaper, faster, and easier.
􀂃 Component specification – e.g. bushings, colour, tap changer
type – This may effect delivery and cost.
􀂃 Transport issues.
􀂃 Paint colour.
􀂃 Factors relating to delivery and cost.
􀂃 Component specification – e.g. bushings, colour, tap changer
type – This may effect delivery and cost.
􀂃 Transport issues.
􀂃 Paint colour.
􀂃 Factors relating to delivery and cost.
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􀂃 Need to know in spec if employer wants In general, this is a
very important process that is important for both parties. It aids
clarification andunderstanding of how to proceed with
designb(contractor) and provides a certain level of
optimisation for the employer (client) i.e. relationship influence on
design e.g. stress levels or specific short circuit.
􀂃 Need employer to have expertise or a contractor to be brought
in.
General Notes:
Should a detailed spec be required? How about the customer
saying we need a transformer to fill this space, these are the
connections, go to it. However, still a lot of things need to be
known. Different tolerances are not always required, overbuilding,
etc. It’s about relationship/confidence in supplier. QA systems,
review, etc. should be done before specifications i.e. due
diligence.
Standardisation of one set of designs does not always work, as
component costs may change meaning the set design is no longer 18
PART 3. TECHNICAL
SPECIFICATION EXPERIENCES
a) From an Employer (Client) and / or Contractor
(Supplier) perspective, what information must be
given in a 2007 Technical Specification?
Refer to standard lists. MVA, voltage, impulse, tap changer,
connection, vector group, and seismic. Intended application.
Rating, MVA, kV. Vector group. Cooling, type of oil.
Impedance. Tap-changer, plus minus percentage.
Load profile.
Regulation.
Standards (manufacturers).
List of accessories.
Type of bushing.
Short circuit withstand capability.
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Seismic.
System earthing.
BIL (Basic Insulation Level).
Loss evaluation formula.
Guaranteed losses.
Corrosion protection.
Tank strength.
Noise level.
Phase clearance, spacing.
Creepage distances.
Surge arrestors.
Cable box, open bushings.
CT (Current Transformer) requirements,
protection.
Remote tap changing.
Station voltage
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Refer to AS60076.1 appendix A as a minimum requirement.
Site requirements – Footprint, Transport etc.,
MVA, Voltage, Losses, Vector group. Bushing types, taps,
terminations, SCADA interfaces, protection devices, auxiliaries,
voltage, and cooling and seismic requirements.
Finishing – Painting, galvanising, wielded or bolted.
Documentation for transfer and timetable.
As built, maintenance manuals, specs, wiring specs and code.
Standards AS/NZ and IEC.
Relevant standards.
General characteristics / performance criteria
Auxiliary components / systems.
Arrangement of transformer; dimensions; bushing/terminal
layouts; site requirements;
system requirements.
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Voltage, vector group, frequency, noise requirements (sound
pressure, sound power,
distance), loss’s, rating, list of standards that it must comply to,
Overload rating, ambient temperature, earthing, fault level,
environment, seismic requirement, altitude, typical rang of
impedance, tap rang, type of entry.

b) Employers (Clients) and Contracts (Suppliers),

what times have you witnessed recently in
Technical Specifications that have been
unhelpful to the process?
Clearances - often specified when standards are in place
(Designer wants a different clearance for some reason?)

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Too prescriptive specs i.e. 'old school'
Too many standards.
Insistence on copper winding.
Totally useless offload sufficient.
Specification of duplicate/overlapping test
requirements ( contributes to additional cost/time) e.g.
stating two test methods to gain same result,
such as megger vs. sweep frequency tests.
Irrelevant/out of date standards.
PD (Partial Discharge) test requirements NZ/AUS
very low – almost impractical.
Radiator specified to be both galvanized and
painted.
Colour of bushing in cable box.
Items that are contradictory. 23
Items that are out of date.
c) Why are on-load tap changers being fitted to generator
step-up transformers and what are the implications of
increasing tapping ranges and decreasing step sizes?
Insurance policy.
Guarantees and flexibility?
Transformer design.
Old school, conservative.
Asset owner compliance.
More voltage regulation required.
Near load centres.
Increase tap range: extreme ends of tap settings are not used.
Totally useless offload sufficient.
More leads and more introduced points of potential failure.

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EGR (Electricity Governance Rules) requirements impact on generators
ability to
support/import reactive power is severe.
Tap changers are not needed on generator transformers with an AVR
(Automatic Voltage Regulator).
d) Is single-point earthing of core, frames, and tanks
a good approach? What happens when the single
point earthing fails?
Good idea! Cost trade-off on insulation may be agreed acceptance testing
completed.
In service for specified period and handed over.
On site install / commissioning completed and documentation complete.
Fence sitting: cost of coping with circulating current vs. single point.
Want device that is reliable regardless of design
Choice of single point earthing or not is a trade
off between equipment costs and losses. The “best” will vary with
circumstances.
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Residual Life Estimates-NZ network transformers

Remaining life estimates are favourable for up-rating

1. DP Values tested during refurbishment, Residual Life Assessment based on

EPRIGuidelines.
2. The above figures affirm the assessment of post 1970 transformers will have a
lower life than those manufactured during 50-60’s
What could be done during refurbishment

􀂃 Refurbishment Specifications should

include
􀂃 A review of cooling arrangement
􀂃 Older transformers have different
style of radiators
􀂃 Not necessarily efficient
􀂃 Could be changed to more efficient
Plate-fin type radiators with
symmetrical arrangement
􀂃 ONWF arrangement could be
changed to ONAN instead of OFWF

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What could be done during refurbishment

􀂃 Up-rate transformers during

refurbishment
􀂃 Generally not called for
􀂃 Review original Heat-run test
reports
􀂃 Most of the transformers are
ONAN cooled
􀂃 Could be changed to
ONAN/ONAF and increase
capacity
Dry-out of windings

􀂃 Dry-out is under-taken using Hot-air heating and vacuum drying

thereafter
􀂃 Vapour phase drying is not under-taken as set up cost is prohibitive
􀂃 The termination of dry-out is generally based
􀂃 on volume of water collected per hour and
􀂃 a certain minimum value of vacuum
􀂃 usually less than 1 mbar
􀂃 Recommend this be changed to standard Moisture-Equilibrium curves
published by IEEE
􀂃 Dr.Oommen curves are used by most manufacturers
􀂃 Eliminates the need for collecting water and monitoring water collection
􀂃 Cumbersome

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Testing of
transformers

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Testing of Transformers
􀂃 Post refurbishment, testing is done only at low voltage
􀂃 Emphasis on Insulation resistance test post refurbishment
􀂃 Minimum acceptable value is specified based on TMI-US guidelines
􀂃 IR & PI values are often not achievable due to the transformer capacitance
􀂃 IEC standards do not specify a minimum value
􀂃 Minimum value for Insulation Resistance should be specified independent of
kVA Rating
􀂃 We recommend
􀂃 50Hz separate source voltage test at 75% rated value for refurbished
transformers
􀂃 No-load excitation at 100% voltage for 30 minutes for refurbished transformers

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Partial Discharge test
􀂃 Post repair, a partial discharge test is specified
􀂃 IEC 60076 recommends PD test for transformers with
Um>300kV
􀂃 Some clients insist on this test for lower voltages
􀂃 Values specified are 50% of IEC recommended values
􀂃 The transformer is manufactured 25-30 years ago
􀂃 Only part of the winding is replaced
􀂃 The transformer was originally not subjected to a PD test
􀂃 Is it practical to achieve such low levels?
􀂃 The PD test is conducted in an unshielded environment

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Repair of transformers

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Repair of Transformers
􀂃 While formulating repair specifications, we recommend
􀂃 Testing of the replacement winding for turns ratio, resistance and inter-strand
tests
􀂃 prior to shipping the windings to New Zealand
􀂃 This will involve the windings be put on a transformer core
􀂃 But it is recommended
􀂃 We have had failures of replacement windings having
􀂃 Centre entry and two halves in parallel
􀂃 Unequal turns between parallel halves
􀂃 Recommend the involvement of replacement contractor in inspecting the
winding prior to shipping
􀂃 to avoid surprises / delays upon arrival in New Zealand
􀂃 Specify PD levels to which transformer will be tested to the replacement
winding manufacturer

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Transformer life time
The Transformer life expectation is measured by
the Rate of Degradation of the Insulation
normally this Insulation is cellulose paper.
The expectation of transformer end life can be
indicated by the degree polymerization of paper
approximate 200 (and other indications).

Two important design driven factors

Transformer temperature behavior ;
IEC 60076 – part 2 and IEC 600354 indicate the limits based on
temperature of this life time expectation. The normal life
time/temperature rise & emergency capabilities at particular ambient
temperatures have to be considered.
Partial discharge levels ;
IEC 60076 – part 3 indicates the standard limits of partial
discharges for 130% Um (300 pC) and 150% Um (500 pC). These
levels seem to be are very high and we would not manufacture to
them. One must have low PD as with increasing moisture content,
the PD rises quite dramatically at 20 ppm, 20oC moisture content
mineral oil (see diagram for moisture content) while the transformer
is normally tested at very good oil condition.
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Why is temperature important for
transformer life time ???

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Cellulose Conductor Insulation Ageing

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 TRANSFORMER LIFE TIME – CELLULOSE DESIGN

IEC 354 – Loading Guide

• Section 1.2; The hottest part of the winding is used for evaluation of a
relative value for rate of thermal ageing. Conductor insulation ageing
• Section 2.6.2; Relative thermal ageing based on 20oC ambient + 78oC
hot spot rise = 98oC
TRANSFORMER LIFE TIME – CELLULOSE
DESIGN

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TRANSFORMER LIFE TIME – CELLULOSE
DESIGN

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Temperature Rise and Driven Factors
Temperature Rise for Class A (IEC 60076-2/ ANSI C57);
Top oil rise ; = 60K / 55 K or 65 K.
Average oil rise ; = 65 K / 55 K or 65 K (By resistance method)
Hot spot rise ; = 78 K / 65K or 80K.
Site elevation height;
The standard elevation height is 1000 m above sea level.
Climatic temperature behaviors;
Yearly average ambient temperature (IEC std = 20oC) 􀃎transformer life time.
Hot monthly average ambient temperature (IEC std = 30oC)
Maximum ambient temperature (IEC std = 40oC) 􀃎transformer loading capability

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