Residual Life Assessment

and
Life Enhancement Programme ( LEP )
of Transformer
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Foreword
Power Transformer are widely used in power transmission and distribution as they are static
machines which are capable of handling large amount of power and have an ease of stepping up
and down the voltages and even the voltages can be controlled on live loads, to take care-of the
voltageload variation! "ver a period of time transformers have found their place in the industry and
the importance in achieving uninterrupted power supply to the consumer whether in #ndustry or civil
life!
$ore and more efforts are being made to minimise the Transmission and distribution losses for
which the $ain e%uipment to be used is Transformer for stepping-up the voltage levels and then
transmitting the power over large transmission lines and then again stepping down to the desired
level which can be used &co-friendly and which has minimum danger to life! "therwise as in
conventional system either the voltage levels were so high that they are very dangerous to life or
using at lower level which are having more transmission losses which is not economical!
The use of Transformers have increased in %uite good amount and for reliable availability of power
we need to maintain the system reliability and should have programs to minimise the down time
and to enhance the residual life of the e%uipment! 'nd looking into the present economic
conditions of high capital investment and long gestation period, the option to e(tend the service life
of e%uipment beyond the originally anticipated commercial life ac%uires immense importance!
)esidual *ife 'ssessment is an effective tool to achieve this ob+ective! The procedure is to e(tend
the life of the component beyond it,s design limit by replacing or modifying or overhauling of critical
sub-components and or by modifying it,s operating and maintenance procedures!
#n this study and survey we have made efforts to study the )esidual *ife for Transformers! The
various tests conducted on the transformer give an idea of e(pected life of the Transformers! 'fter
carefully studying the test results and the physical inspection of the Transformers the guidelines
program is made for carrying out the overhauling! #n this the critical mechanical and electrical works
to performed on the Transformers are laid down and handed over to the shop floors for carrying out
the overhauling works to enhance the life of Transformers!
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Procedure for Residual Life Assessment (RLA) of Transformers
The condition monitoring of industrial transformers has for long been restricted to monitoring
parameters like current, temperature, and insulation resistance values only, to give an indication of
any repair or re-conditioning needs of the transformer! There has been little effort in the direction of
predicting future failures in their incipient stages and therefore avoid them by condition monitoring
measures!
$ost surveys conducted in the past on the industrial transformers failure indicate that 3-.
transformers fail due to leakage related problems, 2/. transformers fail due to poor maintenance
problems, 20. fail due to overheating and cooling system failure related problems and balance
11. fail due to reasons like core and winding problems etc!
The major faults of electrical transformers can be broadly classified as under:
a2 *eakages - on +oints, bushings etc!
b2 "verheating of 3nit caused by blockages in the cooling system, overloading!
c2 *ow #) values due to "verheating moisture ingress from leaking points!
d2 4ushing failures!
e2 5ore and winding failures!
These faults produce one or more of the symptoms as given below6
a2 )egular top-up of oil!
b2 "verloading of cooling system!
c2 Fre%uent tripping of the 3nit!
d2 #ncreased losses and reduction in efficiency!
e2 'bnormal and increased humming sound vibration!
f2 Fre%uent tripping on "il and 7as )elays!
The condition monitoring and diagnostic methods available for electrical maintenance personnel
can be enumerated as below6
1) Offline monitoring of critical !arameters of transformer li"e :
8inding resistance inductance capacitance
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#nsulation resistance
Polari9ation inde(
:i-electric absorption Tan delta value of $ain unit 8indings and bushings!
5ore health assessment ; <ormally done by )esidual =oltage measurement!
#nsulation health assessment ; <ormally done by testing the #nsulating paper in laboratory!
Testing of cooling system and other routine tests like ; =ector group, $agnetising current
at low voltage, $agnetic balance, *osses at low voltage, turn ratio tests etc!
#) Online monitoring of the follo$ing electrical !arameters
Power %uality- voltage measurements, current measurements, power factor etc!
#mpedance se%uence imbalance
Thermal profile temperature rise!
>ealthiness of cooling system and au(iliary power consumption!
:iagnostic tools utili9ed to perform "ff-line monitoring of transformers are described below6
1) Tan delta
For assessing the condition of the :i-electric strength of the electrical insulation, tan delta test is by
all means the accepted mode of condition monitoring! #t is carried out at various voltages to
ascertain the behaviour of the insulation under varying voltages! #t is a measure of the energy
spent in the di-electric medium by way of discharges! The discharge inception voltage is also a
broad indicator of the region in which the discharge activity is high! Fre%uency of this test for
trending purposes is decided very carefully after going through the trend of other parameters like
insulation resistance ?#)2 value and polari9ation inde( ?P#2 value!
#n practice, an insulating material, when stressed in an '5 field, draws both charging current and a
small dissipative or loss current component, thus total current # @ #c A #r, which leads the voltage
vector by a phase angle which is less than B0 degrees and lags the #c current by a loss angle of
delta! The tangent of this angle directly indicates the heat dissipation that takes place inside the
insulation system!
The variation of Tan delta, also known as dissipation factor with the applied voltage ?tan delta tip-
up2 provides useful information about the source of any imperfections in the insulation system! '
high :i-electric loss will result in the thermal breakdown of the insulation at a lower voltage! #f the
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di-electric loss starts to increase at a certain applied voltage, it indicates the void content in the
insulation and the inception of partial discharges at this voltage! #f the value of the tan-delta goes on
increasing with passage of time, it indicates the deterioration of insulation! The test results of tan
delta measurements are evaluated on the basis of following6
a2 $agnitude of tan delta at various voltages and the ma(imum increment of tan delta values
with increment of test voltage!
b2 Dteeper slope of tan delta versus test voltage shows defect in insulation system!
c2 )ise in tan delta versus test voltage with passing time indicate deterioration of insulation!
d2 5omparison of test results of e%uipment with manufacturing data if any, or the past record!
e2 5omparison of insulation behaviour of similar e%uipment working under similar
environment and application!
'bsolute value of tan delta is un-important! #t will vary due to different class of insulation and
different construction of transformers! )ate of change of tan-delta with time and incremental
voltage, is important and significant deviation in rate of change of tan-delta is an indication of
trouble! Tan delta remaining constant over the entire range of voltage and over a period of time
signifies good %uality of insulation!
Though absolute value is not important, nevertheless values below 2. are considered as healthy
and safe!
#) %agnetic &alance Test
This test normally tells us the problems if any in the core and magnetic circuit of transformer!
3nbalance usually results from impedance mismatch between the transformer phase windings and
stampings! #mpedance change occurs mainly due to transformer winding degradation ?turn-to-turn
or phase-to-phase short2 and or the development of high resistance connections anywhere in the
winding circuit or the stampings failures! ' balanced single phase voltage is applied between the
two phase or phase to neutral and then the voltage induced in the other windings is measured in
normal circumstances the voltage should get divided into two other limbs in such a way that the
total of these two limbs should be e%ual to the voltage applied, if this sum is not e%ual to the voltage
applied that means that there is some problem in either the winding or the magnetic circuit!
<ormally the voltage division when the voltage is applied on the outer limbs is in the ratio 23 and
13 on the other two winding, 23 voltage is normally on the central limb and 13 on the other limb,
'nd when the voltage is applied on the central limb the division is E on each, but this phenomena
may vary according to the construction of transformer and one must match the results with the
Factory test reports or the last report available!
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') (ie Penetration Testing
:ie Penetration test is normally conducted on the welding +oints of the main tank and the cooling
circuit pipes and flanges, to ascertain hairline cracks for leakage points! #t works on the principal of
differential absorption leading to colour contrast and is applied on the test ob+ect by spraying! The
solvent is allowed to dry and then visually tested for differential absorption!
This test helps ascertain mechanical fatigue failure on the load bearing walls and +oints of
transformers!
)) %echanical measurements and !hysical ins!ection of *ore and $indings+
$echanical measurements and physical inspection of the critical dimensions of the $ain tank unit
and core and windings assembly are essential to check the dislocation of 5ore and windings!
These dimensions are then matched with the original manufactured measurements for any
dislocation! 'ny dislocation of core and windings will give rise to uneven voltage at the terminal and
loading of the subse%uent phase physically as well as electrically! Dome essential dimensions
re%uiring measurements are as follows6
&nd wall clearance of core and windings from $ain tank!
The position of 5ore coil w!r!t the original location!
The thickness of core at various location, which should be e%ual at all location and should
match with "&$ measurements!
The thickness and circular shape ovality of $ain coils should be checked and should be in
permissible limits and should match with "&$ results! 'lso the packers inserted in coil
assembly and between the coil and the core should be checked for any movement or
looseness, this will lead to undue humming, power loss due to less flu( linkage and
vibrations!
$easurement of #nner :iameter of pipes which may have gone down due to choking or
blockages by sludge and other e%uipments in cooling circuit!
,) -ector .rou! Test
To ascertain the physical position and dislocation of transformer and interturn faults normally this
test is carried out! #n this the voltage is applied on phase and neutral on >= winding and two
phases are shorted and then the voltage across other windings in different combinations are
measured and then compared with actual theoretical values by applying the vector group as
mentioned on the name plate of the transformer and if the same does not match then it needs
corrective action and needs physical inspection of transformer from inside! <o a days sophisticated
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testing e%uipments are available which will tell the =ector group of transformer once all the leads of
the transformer are connected to the kit and if deviation in any! The following e%uations are handy
to find out the most commonly used vector groups of transformer 6
/solate !rimary 0 secondary neutral earth+
Dhort 13 - 23! 'pply 3 Phase C1- = to 13 - 1= - 18 terminals!
$easure following voltages 6
13-1= @ GGGGGGGGGGH 1=-18 @ GGGGGGGGGGH 18-13 @ GGGGGGGGGG!
13-1< @ GGGGGGGGGGH 1=-1< @ GGGGGGGGGGH 18-1< @ GGGGGGGGGG!
13-2< @ GGGGGGGGGGH 2<-1< @ GGGGGGGGGGH 2<-1= @ GGGGGGGGGG!
1=-2= @ GGGGGGGGGGH 1=-28 @ GGGGGGGGGGH 18
18-2= @ GGGGGGGGGGH 1=-28 @ GGGGGGGGGGH
$atch the voltages with the following 5onditions6
-ector grou! -oltage E1uation
:yn11
18-28 I 18-2=
?13-2<2 A ?2<-1=2 @ 13-1=
:yn1
1=-2= I 1=-28
?13-2<2 A ?2<-182 @ 13-18
Jnyn0
?13-2<2 A ?2<-1<2 @ 13-1<
18-28 @ 1=-2=
The voltage e%uation for other vector groups can also be determined by drawing the vector
diagram! This test tells us that the transformer can have following problems6
i2 #nterturn short-circuit inside the transformer!
ii2 8rong connection inside tap changer made during overhauling!
iii2 Physical dislocation of 5ore and winding due to overheating or some other mechanical
damage inside main tank core coil assembly!
2) %agnetising *urrent %easurement
' low voltage is applied on the >=*= winding of transformer and the current being taken by the
circuit is measured and matched with the "&$ results! #f this is found to be abnormal then we can
predict following6
i2 #nterturn short-circuit in windings!
ii2 "verheating of *amination and failures of inter-lamination insulation!
iii2 *oose +oints failure of interconnection +oints!
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'bove mentioned tests are performed on transformer and we can generally analyse the condition of
core and winding from the outside of transformer! "il and #nsulating paper which form the main
component of the transformer are not fully tested and analysed in these tests! For )esidual life
assessment of Transformer some tests are performed on #nsulating "il and #nsulating paper !
These are the most important and effective tool for analysing the )esidual *ife of Transformer
and careful investigation of the test results we can make a "verhauling procedure program
for *ife &nhancement of the Transformer! 4efore performing the tests we must understand the
type of faults occurring in the transformer! These are as follows6
3ault Ty!es
#dentification of fault type is a critical component to dissolved gas analysis and assessing a
transformerKs condition! Fault conditions occur primarily from the thermal and electrical deterioration
of oil and electrical insulation! &ach combustible gas level will vary depending upon the fault
process!
AR*/4.
'rcing is the most severe of all fault processes! *arge amounts of hydrogen and acetylene are
produced, with minor %uantities of methane and ethylene! 'rcing occurs through high current and
high temperature conditions! 5arbon dio(ide and carbon mono(ide may also be formed if the fault
involved in cellulose! #n some instances, the oil may become carboni9ed!
*ORO4A
5orona is a low-energy electrical fault! *ow-energy electrical discharges produce hydrogen and
methane, with small %uantities of ethane and ethylene! 5omparable amounts of carbon mono(ide
and dio(ide may result from discharge in cellulose!
5PAR6/4.
Dparking occurs as an intermittent high voltage flashover without high current! #ncreased levels of
methane and ethane are detected without concurrent increases in acetylene, ethylene or hydrogen!
O-ER7EAT/4.
:ecomposition products include ethylene and methane, together with smaller %uantities of
hydrogen and ethane! Traces of acetylene may be formed if the fault is severe or involves electrical
contacts!
O-ER7EATE( *ELL8LO5E
*arge %uantities of carbon dio(ide and carbon mono(ide are evolved from overheated cellulose!
>ydrocarbon gases, such as methane and ethylene, will be formed if the fault involved an oil-
impregnated structure! ' furanic compound andor degree of polymeri9ation analysis may be
performed to further assess the condition of the insulating paper!
Following are the test and which are done on #nsulating "il and #nsulating paper!
/458LAT/4. O/L
(issol9ed .as Analysis
$a+or power transformers are filled with a fluid that serves several purposes! The fluid acts as a
dielectric media, an insulator, and as a heat transfer agent! The most common type of fluid used in
transformers is of a mineral oil origin! "ther types that are not as common include the askerals and
silicone types! This brief discussion will be limited to those units that utili9e the mineral oil type
fluids!
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:uring normal use there is usually a slow degradation of the mineral oil to yield certain gases that
collect in the oil! >owever, when there is an electrical fault within the transformer, gases are
generated at a much more rapid rate! There are three ma+or types of electrical faults that differ in
their severity! The least severe is a partial discharge or corona, locali9ed hot spots are ne(t in
severity, and the most severe is arcing! There are typically nine fault gases that are analy9ed and
each of the above faults generates certain key gases and a distribution pattern of these gases!
Thus by determining the various gases present and their amounts, one can infer the nature of the
fault giving rise to them!
There are a couple of different types of transformers 6 those that have a gas blanket above the oil
and those that are completely oil filled! For those units that have a gas blanket one could analy9e a
sample of gas from the gas blanket! >owever there are some disadvantages to this method! Firstly
the electrical faults usually occur beneath the surface of the oil and the gases that are produced
must saturate the oil, diffuse to the surface, and then collect in the gas blanket! These processes
introduce a time factor into the early detection of a fault that is undesirable! Decondly gas blanket
analysis is not applicable to those units that are completely oil filled! "n the other hand dissolved
gas analysis is applicable to all types of transformers and gives the earliest possible detection of
the fault gases! This procedure only re%uires proper collection of a sample of the transformer oil,
e(tracting the gases from the oil via a high vacuum apparatus, and then analy9ing the e(tracted
gases for their identities and amounts!
:issolved gas analysis is probably the most widely used preventative maintenance techni%ue in
use today to monitor the operation of transformers! Properly used it can be a powerful tool in a well
disciplined maintenance program! :epending on the location of a transformer and the nature of its
usage, an appropriate dissolved gas analysis schedule can be set up! The more critical the unit is
the more fre%uently it should be sampled! 8hen an adverse situation is detected the sampling
fre%uency should also be increased! This latter philosophy allows one to determine how rapidly the
gases are being generated and thus how serious the problem might be so that proper action can be
taken before the unit suffers additional damage! #t is also %uite important to maintain a history of
each unit so that one can determine if any gases are residual ones from a previous fault or are they
due to a newly developing situation!
#f a fault is detected in a transformer there are other tests that might be recommended that can help
to locate the site of the fault within the unit! The more information that can be obtained before
repairing a unit, the less down time will be re%uired! 8orking with laboratory personnel that are
familiar with the various methods of interpreting dissolved gas analysis in con+unction with other
tests and the history of the unit are essential to properly utili9e this techni%ue in a preventative
maintenance program!
#nsulating materials within transformers and related e%uipment break down to liberate gases within
the unit! The distribution of these gases can be related to the type of electrical fault and the rate of
gas generation can indicate the severity of the fault! The identity of the gases being generated by a
particular unit can be very useful information in any preventative maintenance program! This
techni%ue is being used %uite successfully throughout the world! This paper deals with the basics
underlying this techni%ue and deals only with those insulating fluids of mineral oil origin!
"bvious advantages that fault gas analyses can provide are6
1! 'dvance warning of developing faults
2! :etermining the improper use of units
3! Dtatus checks on new and repaired units
C! 5onvenient scheduling of repairs
-! $onitoring of units under overload
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The following sections will deal with the origins of the fault gases, methods for their detection,
interpretation of the results, and philosophies on the use of this techni%ue! Dome limitations and
considerations that should be kept in mind concerning the use of this techni%ue will also be
discussed! Finally an appendi( containing some actual case histories will be covered!
3ault .ases
The causes of fault gases can be divided into three categoriesH corona or partial discharge,
pyrolysis or thermal heating, and arcing! These three categories differ mainly in the intensity of
energy that is dissipated per unit time per unit volume by the fault! The most severe intensity of
energy dissipation occurs with arcing, less with heating, and least with corona!
' partial list of fault gases that can be found within a unit are shown in the following three groups6
1+ 7ydrocarbons and hydrogen
$ethane 5>C
&thane 52>F
&thylene 52>C
'cetylene 52>2
>ydrogen >2
#+ *arbon o:ides
5arbon mono(ide 5"
5arbon dio(ide 5"2
'+ 4onfault gases
<itrogen <2
"(ygen "2
These gases will accumulate in the oil, as well as in the gas blanket of those units with a head
space, as a result of various faults! Their distribution will be effected by the nature of the insulating
materials involved in the fault and the nature of the fault itself! The ma+or ?minor2 fault gases can be
categori9ed as follows by the type of material that is involved and the type of fault present6
1+ *orona
a! "il >2
b! 5ellulose >2 , 5" , 5"2
2! Pyrolysis
a! "il
*ow temperature 5>C , 52>F
>igh temperature 52>C , >2 ? 5>C , 52>F 2
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b! 5ellulose
*ow temperature 5"2 ? 5" 2
>igh temperature 5" ? 5"2 2
'+ Arcing >2, 52>2 ?5>C, 52>F, 52>C2
$ineral oil insulating fluids are composed essentially of saturated hydrocarbons called paraffins,
whose general molecular formula is 5n>2nA2 with n in the range of 20 to C0! The cellulosic insulation
material is a polymeric substance whose general molecular formula is L512>1C"C?">2FMn with n in the
range of 300 to /-0!
The structural formula of the mineral oil and those of the hydrocarbons and hydrogen fault gases
are shown in Figure 1!
3igure 1+ Dtructure of insulating oil and fault gases!
$ineral "il 5n>2nA2
>ydrogen >2
$ethane 5>C
&thane 52>F
&thylene 52>C
'cetylene 52>2
5arbon :io(ide 5"2
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5arbon $ono(ide 5"
"(ygen "2
<itrogen <2
Figures 2, 3, C, and - illustrate the processes occurring with corona, pyrolysis, and arcing in oil and
pyrolysis of cellulose respectively! Typical fault gas distributions are also shown!
3igure #+ 5orona in "il
>2 11.
502 1
50 1
5>C F
52>F 1
52>C 0!1
52>2 0!2
3igure '+ Pyrolysis in "il
>2 1F.
502 trace
50 trace
5>C 1F
52>F F
52>C C1
52>2 trace
3igure )+ 'rcing in "il
>2 3B.
502 2
50 C
5>C 10
52>C F
52>2 3-
3igure ,+ Pyrolysis of 5ellulose
>2 B.
502 2-
50 -0
5>C 1
52>C C
52>2 0!3
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The Dolubilities of the fault gases in mineral oil as well as their temperature dependence are also
important factors for consideration in fault gas analyses! Table 1 lists the saturation Dolubilities for
the fault gases! #t should be noted that there is almost two orders of magnitude difference
Table 1+ Dolubility of 7ases in Transformer "il!
>ydrogen / . by volume
<itrogen 1!F .
5arbon mono(ide B .
"(ygen 1F .
$ethane 30 .
5arbon dio(ide 120 .
&thane 210 .
&thylene 210 .
'cetylene C00 .
Dtatic &%uilibrium at /F0 mm >g and 2-
o
5 between the least soluble ?hydrogen2 and the most
soluble ?acetylene2 gas! The ma+ority of gases that are indicative of faults are also those that are in
general the more soluble in the oil! 8hen rates of gas generation are being followed it is important
to take into account the solubilities of these gases as a function of the oil temperature ?Fig! F2! "ver
a temperature range of 0 to 10
o
5 some gases increase in solubility up to /B. while others
decrease their solubility up to FF.!
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Figure F! )elative Dolubilities as a Function of Temperature!
%ethods of 3ault .as (etection
Three methods will be discussed and their advantages and disadvantages will be compared! The
first method and probably the most widely used techni%ue at the present time is the one that
determines the total combustible gases ? T57 2 that are present in the gas above the oil! The ma+or
advantage of the T57 method compared to the others that will be covered is that it is fast and
applicable to use in the field! #n fact it can be used to continuously monitor a unit! >owever, there
are a number of disadvantages to the T57 method! 'lthough it detects the combustible fault gases
?hydrogen, carbon mono(ide, methane, ethane, ethylene, and acetylene2, it does not detect the
noncombustible ones ?carbon dio(ide, nitrogen, and o(ygen2! This method is only applicable to
those units that have a gas blanket and not to the completely oil-filled units of the conservator type!
Dince most faults occur under the surface of the oil, the gases must first saturate the oil and diffuse
to the surface before accumulating in the gas blanket above the oil! These processes take time,
which delays the early detection of the fault! The ma+or disadvantage of the T57 method is that it
gives only a single value for the percentage of combustible gases but does not identify which gases
are actually present! #t is this latter information that is most useful in determining the type of fault
that has occurred!
The second method for the detection of fault gases is the gas blanket analysis in which a sample of
the gas in the space above the oil is analy9ed for its composition! This method detects all of the
1C of 32
individual componentsH however, it is also not applicable to the oil-filled conservator type units and it
also suffers from the disadvantage that the gases must first diffuse into the gas blanket! #n addition,
this method is not at present best done in the field! ' properly e%uipped laboratory is preferred for
the re%uired separation, identification, and %uantitative determination of these gases at the part per
million level! The third and most informative method for the detection of fault gases is the dissolved
gas analysis ? :7' 2 techni%ue! #n this method a sample of the oil is taken from the unit and the
dissolved gases are e(tracted! Then the e(tracted gases are separated, identified, and
%uantitatively determined! 't present this entire techni%ue is best done in the laboratory since it
re%uires precision operations! Dince this method uses an oil sample it is applicable to all type units
and like the gas blanket method it detects all the individual components! The main advantage of the
:7' techni%ue is that it detects the gases in the oil phase giving the earliest possible detection of
an incipient fault! This advantage alone outweighs any disadvantages of this techni%ue!
$ethods of #nterpretation
The most important aspect of fault gas analysis is taking the data that has been generated and
correctly diagnosing the fault that is generating the gases that have been detected! Deveral
methods that are currently in use will be covered!
"ne of the earliest methods is that of :ornenburg
3
in which two ratios of gases are plotted on log-
log a(es ?Fig! /2! The area in which the plotted point falls is indicative of the type of fault that has
developed!
Figure /! :Nrnenburg Plot!
The 5entral &lectric 7enerating 4oard ? 5&74 2 of 7reat 4ritain has been using a method
developed by )ogers
C
in which the magnitudes of four ratios of gases are used to generate a four
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digit code as shown in Table 2! The code number that is generated can be related to a diagnostic
interpretation as shown in Table 3!
Table C shows the guidelines developed at 5alifornia Dtate 3niversity-Dacramento ?5D3D2 in
cooperation with Pacific 7as O &lectric 5ompany to indicate the normal and abnormal levels of the
individual gases!
Table 2! 5! &! 7! 4! Fault 7as )atios!
C

)'T#" )'<7& 5":&
5>C>2
I@ 0!1
P 0!1 I 1
P@ 1 I 3
P@ 3
-
0
1
2
52>F5>C
I 1
P@ 1
0
1
52>C52>F
I 1
P@ 1 I 3
P@ 3
0
1
2
52>252>C
I 0!-
P@ 0!- I 3
P@ 3
0
1
2
Table 3! 5! &! 7! 4! :iagnostics!
5":& :#'7<"D#D
0 0 0 0 <ormal
- 0 0 0 Partial discharge
1,2 0 0 0 Dlight overheating I 1-0
o
5
1,2 1 0 0 Dlight overheating 1-0 - 200
o
5
0 1 0 0 Dlight overheating 200 - 300
o
5
0 0 1 0 7eneral conductor overheating
1 0 1 0 8inding circulating currents
1 0 2 0 5ore and tank circulating currents, overheated +oints
0 0 0 1 Flashover, no power follow through
0 0 1,2 1,2 'rc, with power follow through
0 0 2 2 5ontinuous sparking to floating potential
- 0 0 1,2 Partial discharge with tracking ?note 5"2
5"2 5" P 11 >igher than normal temperature in insulation
1F of 32
Table C! 5! D! 3! D! 7uidelines!
/

7as <ormal ?I2 'bnormal ?P2 #nterpretation
>ydrogen 1-0 ppm 1000 ppm 5orona, 'rcing
$ethane 2- 10 Dparking
&thane 10 3- *ocal overheating
&thylene 20 1-0 Devere overheating
'cetylene 1- /0 'rcing
5arbon mono(ide -00 1000 Devere overheating
5arbon dio(ide 10,000 1-,000 Devere overheating
<itrogen 1 to 10 . <!'! <!'!
"(ygen 0!2 to 3!-. <!'! <!'!
Total 5ombustibles 0!03 . 0!- . <!'!
5urrently <orthern Technology O Testing is using the following flag points for the various fault gases
shown below in Table -!
Table -! <! T! T! Flagpoints
7as Flagpoint ?P2
>ydrogen 1-00 ppm
$ethane 10
&thane 3-
&thylene 1-0
'cetylene /
5arbon mono(ide 1000
5arbon dio(ide 10,000

Limitations and *onsiderations
#t has to be recogni9ed that conditions within a transformer are not homogeneous and the system is
never at true e%uilibrium! Temperature and pressure gradients as well as different types of flow
characteristics contribute to the overall comple(ity of the system! 8ith these limitations one would
not e(pect duplicate samples to agree better than to about ten percent and in some cases the
agreement may be poorer!
' unit with an active fault generates gases at rates considerably greater than one undergoing
normal aging! 8e have observed wide variations in duplicate samples from units with active faults
and it was thus apparent that the system was far from homogeneous! 3nder such conditions
perhaps it is more meaningful to look at trends rather than absolute values of individual gases! #n
contrast, duplicate samples from units without active faults have shown more consistent agreement!
There have been efforts made to relate the rate of generation of gas with the severity of a
developing fault! The volume of the system has to be considered when talking about rates of gas
evolution! The gases are reported in terms of concentration ?e!g!ppm2 and the total gas generated
1/ of 32
by a fault will be dependent on the total volume of the system when calculated from the
concentrations that were determined! For e(ample if two units, one with a small total volume and
the other with a large total volume of oil, are sub+ected to e%ually severe faults that generate the
same amounts of gases, the concentration of these gases in the smaller unit will be higher than the
same gases in the larger unit!
To determine rates of gas generation it is necessary to collect samples at different times! <ormal
aging of the insulating oil will give rise to a slow accumulation of gases over a semiannual sampling
period! ' moderate accumulation of gases over a monthly interval can indicate an incipient fault,
while a rapid accumulation ?i!e! over 10. per month2 of gases is indication of an active fault!
' number of our customers who have applied )ogersK method for analy9ing their data have
informed us that they seldom if ever see a QnormalQ unit! #t is well to remember that this method was
developed for use within the 5!&!7!4! system and their norm may not be the same as for another
operating system! "ne problem that arises in using this method is that no significance is given to
the magnitude of the numbers used to calculate the ratio and then to generate the code digit! Thus
when the numbers themselves are small, fluctuations in the values can cause a very large change
in the ratio and hence the generated digit! The nomographic method described earlier in essence is
the same type of analysis as that of )ogers but the imposition of the threshold values limits the
significance of the results when the individual values themselves are small!
'nother consideration that can not be stressed enough is the knowledge of the past history of a unit
and the operating philosophies of the customer! "ften we have been consulted regarding certain
results that were indicative of a fault only to find that when the history of the unit was revealed the
results could be rationali9ed by a past occurrence and were not the result of a continuing fault!
Dome clients have to operate their units at or above rated capacities while others may be more
conservative in their operation! 3nder these different operating conditions, gas evolution from
QnormalQ aging of the insulating fluid will be greater in the former case than in that of the latter case!
Finally it should be kept in mind that when a fault is indicated there are other techni%ues that can be
brought to bear on the problem to assist in the interpretation! For instance if arcing is indicated then
analysis of the fluid for trace amounts of metals dispersed in the fluid can be indicative of the
location of the fault within the unit! The presence of aluminum can indicate arcing near the bushings
or windings, copper can come from the windings, and iron can come from the core and the shell of
the unit! These three metals are considered to be those that comprise the ma+or construction of a
unit! "ther metals such as tin, lead, 9inc, and silver are minor components and their presence can
indicate the involvement of such things as connectors and solder +oints!
*onclusion
The technology presently e(ists and is being used to detect and determine fault gases below the
part per million level! >owever there is still much room for improvement in the techni%ue, especially
in developing the methods of interpreting the results and correlating them with incipient faults! #t is
also important to reali9e that even though there is further need for improvement in the techni%ue,
the analysis of dissolved fault gases represents a practical and effective method for the detection of
incipient faults and the determination of their severity! #n addition to utility companies, many
industries and installations that have on-site transformers are recogni9ing that the techni%ue of
dissolved fault gas analysis is an e(tremely useful, if not essential, part of a well developed
preventative maintenance program!
PAPER /458LAT/O4
The solid insulation of power transformers consists basically of paper in form of sheets, tapes, and
other pressed shapes!
>eat, moisture, and o(ygen, as well as oil decay products, adversely affect the life of the paper!
:egradation of the paper causes it to lose its tensile strength and results in the release of furans!
11 of 32
&arly detection of paper insulation breakdown can prevent ma+or damage or failure!
7as-in-oil analysis was the only non-invasive test performed on transformers that could indicate
internal problems! 4y monitoring the 5" and 5"2 found dissolved in the oil, some assertions could
be made about the condition of the paper! 4y 'nalysis of #nsulating Paper more accurate life,s can
be predicted! Following are the tests performed on #nsulating paper
3uran Analysis
The main goal of furan testing is to determine whether the paper in a given transformer has been or
is being damaged by heat! Furans produced from temperature buildups are generated in two ways6
the first being a locali9ed area of high heat and paper damage, and the second being the general
overall heating of the entire insulation system!
Thermal, o(idative and hydrolytic breakdown of paper insulation can be detected through furan
analysis! This test, in con+unction with dissolved fault gas analysis, gives you the best overview of
the state of your transformer! ' furan test should be included with yearly maintenance and trends
developed to monitor the condition of the paper!
:iagnostics6
Presently, there are no limit values or normal values for these compounds! 'nnual tests should be
performed to determine baselines and trending patterns!
8hen the cellulosic insulation materials within a transformer undergo degradation some of the
products formed are derivatives of the aromatic compound called furan! Furan is a heterocyclic
aromatic system consisting of four carbons and one o(ygen in a five membered ring with each of
the carbons having a hydrogen attached, hence the molecular formula is 5C>C"! The five most
prevalent derivatives of furan that arise from the degradation of the cellulose and that are soluble in
the oil to an appreciable degree are the following6 2-Furaldehyde H Furfuryl alcohol H 2-'cetylfuran H
--$ethyl-2-furaldehyde H and -->ydro(ymethyl-2-furaldehyde!
Procedure6
The entire details of the procedure for determining the %uantity of furanoid compounds in an
insulating fluid are given in the 'DT$ : -13/ method and are only briefly mentioned here! '
sample of the oil is e(tracted with either another li%uid such as acetonitrile or with a solid phase
e(traction ?DP&2 device! The e(tract is then analy9ed using high performance li%uid
chromatography ?>P*52! The five compounds mentioned above are separated on an appropriate
column and each is detected by use of an ultraviolet detector that is ad+usted automatically to the
appropriate wavelength for each of the five components! 5alibration solutions are made up for each
of the components to be analy9ed and these are used to standardi9e the instrument responses!
From the data on the standard solutions, the e(traction efficiencies for each component can be
calculated and corrections can be made accordingly! The results are usually reported in terms of
parts per billion ?ppb2!
Dignificance6
The five furanic materials normally analy9ed in this procedure are aromatic compounds that arise
from the degradation of the cellulosic materials within a transformer either by normal aging or from
being involved with an incipient fault! Thus the amount of these products present in the oil might be
a good indication of the condition of the cellulosic insulation! 't the present time there have been no
limits or normal values established for these components either individually or in combination!
)esearch is being carried out to find if there are any useful correlations that can be used but at the
present it might only be useful to follow trends rather than absolute amounts in the oil! 'nother test
that can be used to assess the condition of the cellulose within a transformer is to determine the
average degree of polymeri9ation! >owever, this is an intrusive test that re%uires a sample of the
cellulose! "ne has to take the unit out of service to obtain the sample and a portion of the unit is
1B of 32
destroyed in the process! #f a good correlation can be found between the average degree of
polymeri9ation and the concentration of the furanic compounds either individually or in combination,
then this would have a number of advantages for evaluating the condition of the cellulosic insulation
within a unit! First it is a non-intrusive procedure! Decond it does not re%uire interuption of service to
obtain a sample! Third the laboratory analysis re%uires less time and it is a more sensitive
determination! &fforts are progressing toward this end!
(egree of Polymeri;ation
To assess the aging of insulating paper from service-aged power transformers and voltage
regulators, samples can be analy9ed to determine the degree of polymeri9ation! This, however, is
an invasive test re%uiring a sample of the paper which may present some difficulties such as taking
the unit out of service!
&ach cellulose fiber of paper is composed by a bundle of cellulose molecules of different lengths,
laying side by side! These molecules are held together due to hydrogen bonds between the
hydro(yl groups ?-">2 e(isting in their structure! The cellulose molecule is a linear polymer formed
by a chain of glucose rings linked by glycosidic bonds! 's paper ages, the glycosidic bonds break,
and the molecule is shortened! 5onse%uently, paper loses its mechanical strength, and the useful
life of the transformer is reduced!
:iagnostics6
<ew Rraft paper typically has a :P range of 1100 to 1-00! Paper at the end of its useful life has a
:P for around 1-0! Partial rewinding occurs around a :P of 2-0!
4ackground6
5ellulose is used throughout transformers in the form of insulating papers and boards! 5ellulose is
a polymeric material of cellobiose, -L512>1C"C?">2FMn- , where n is in the range of 300 to /00 units!
5ellobiose itself is made up of two glucose units, 5F>/"?">2- ! #n a sample of cellulose there is a
variety of different si9e molecules of the polymeric material! There are a number of methods
available to determine the average molecular weight of such samples! The method described
herein uses the determination of the intrinsic viscosity, LhM , and the value obtained is referred to as
the average viscometric degree of polymeri9ation, GPv ! #n order to measure the viscosity of a
cellulose sample it must first be dissolved in a suitable solvent system! Duch a solvent system that
works well for dissolving cellulose is a cupriethylene-diamine solution!
Procedure6
The entire details for determining the average viscometric degree of polymeri9ation are given in the
'DT$ : C2C3 method and are only briefly mentioned here! ' sample of the cellulose is degreased
with he(ane in a Do(hlet e(tractor, dried, and conditioned in a controlled humidity environment! '
weighed sample of the cellulose is then dissolved in the cupriethylene-diamine solution by tumbling
it in a sealed flask with glass balls! The dynamic viscosity of the resulting solution is determined and
by comparing it with the viscosity of the cupriethylene-diamine solvent, one can calculate the
intrinsic viscosity and the average viscometric degree of polymeri9ation!
Dignificance6
The average viscometric degree of polymeri9ation represents the average number of glucose units
in the cellulose polymer and these values can range from 100 to 1F00 units with the most probable
value being about 1200! 's the paper undergoes aging these polymer chains degrade into smaller
units or if the paper is sub+ected to a severe fault such as overheating or arcing the polymers will
also be degraded! 's shorter length chains are formed this lowers the average degree of
20 of 32
polymeri9ation! Thus this method allows one to assess the condition of the cellulose insulation
within the unit! Dince these values do represent averages, when evaluating a sample of cellulose it
should be compared to a fresh sample of the same origin! 3resh 6raft !a!er $ill ha9e a (P9
around 11<< to 1#<<+ After factory drying tests this 9alue $ill dro! to =<< to 1<<< and then
decreases e:!onentially $ith time+ A tentati9e 9alue of about 1,< is used to indicate the end
of the useful life of the cellulose+ 3or !artial re$inding of failed coils> a minimum 9alue of
#,< has been used+
#t should be pointed out that this test re%uires a sample of paper, which means that the unit must be
taken out of service to be sampled! Furthermore it is an intrusive test that destroys the sample
being tested and decreases the amount of the material left in the unit, which might be deleterious to
the unit! $ethods that sample the oil and look for degradation products of the paper, such as furanic
type compounds, are under development at the present time!
For accurate testing being performed at factory the procedure for taking the samples is also very
important! 8e hereby suggest the following procedures to be adopted for taking the oil 6
"il Dampling Procedures
3se of $etal 5ylinders for the 5ollection of 7as-in-"il Damples
$etal cylinders can be used effectively to collect oil samples from transformers! To obtain a
representative sample it is necessary to use the proper sampling techni%ue! Following the
procedure below will ensure that the sample received by the laboratory is reflective of the oil in the
main tank of the transformer!
>old the cylinder in a vertical position at all times!
This will ensure all air bubbles rise to the top and e(it the container!
:rain the Dampling =alve - Dtagnant oil from the lower drain valve of the transformer must
be removed before the sample is collected! 'lso moisture that may be present in the
depression of the drain valve must be removed! To achieve this, remove the plug from the
drain valve and drain appro(imately one-half to one gallon of oil into an oil-waste container!
To the drain valve, attach a plug fitted with a tubing connector and a section of clear plastic
tubing!
'ttach the Tubing to the 5ontainer
'ttach the cylinderKs lower valve fitting to the tubing connected the transformer! 'ttach the
cylinderKs upper valve fitting to the tubing discharging to the waste oil container!
"pen =alves in "rdered De%uence
o "pen the valve on the transformer!
o "pen the lower cylinder valve ?'2!
o "pen the upper cylinder valve
o 'llow about 1 %uart of oil to flow through the cylinder into the waste container! Tap
the sides of the cylinder with a tool to dislodge air bubbles! "il running though the
tubing should be free of air bubbles!
Dhut =alves in )everse "rder
o Dhut the upper cylinder valve?42!
o Dhut the lower cylinder valve ?'2!
o Dhut the transformer drain valve!
o Dhake the cylinder then listen and feel for signs of incomplete filling! #f not
completely filled, redo from step 1 of "pen =alves in "rdered De%uence!
21 of 32
)e-'ssemble Transformer =alve and Plug
:isconnect the tubing and remove the connector from the drain valve! )eplace the original
plug on the drain valve! 'pply pipe dope or Teflon tape on the plug threads to insure a good
seal and to prevent rust!
' typical picture of the steel container which is used for collecting the oil samples is shown in
above
22 of 32
The above figure shows how to hold the steel container and connect it to main tank of transformer!
'fter taking the samples the container is labeled with the details of transformer like the rating , year
of manufacture, type of oil, last date of oil filtration, age of oil ? when was the oil replaced2!
23 of 32
Re!air and O9erhauling
'fter completing the )*' study of the Transformers the overhauling and modification work to be
performed are laid down, which generally has following procedures6
1) /dentification
The Transformers are first given an identification tags with document no! made for )epairs and
reports! The numbers are permanently embossed or inscribed painted ad+acent to the nameplate
on the frame for future reference! <ormally the first numbering is to be done by the laboratory which
is carrying out the )*'! 'fter which the transformers comes to repair shop where the shop
supervisor gives proper numbers in line with the laboratory numbers to match the se%uence to the
sub-components which are opened at shop floor!
'll nameplate data, electrical test data ?both before and after repairs2, mechanical measurements,
and original winding data, final winding data and details of replaced parts are recorded diligently!
#) *leaning
'll the accessories are firstly thoroughly cleaned made free from unwanted dust and dirt and
carbon deposit! These are normally cleaned with non-abrasive solvents, and cleaning agents
should be removed thoroughly! 3se of Tri-5hloro-&thylene ?T5&2 is recommended for cleaning the
internals of transformer instead of 5arbon Tetra 5hloride ?5T52! 5T5 is discouraged owing to
presence of carbon! <o abrasive tool should be used on the internals as to avoid damage to inside
oil resistant paint!
The outside surface is normally scratched and made free from the aged paint and check for hair
cracks and blow holes at welded +oints!
') Radiators and Oil Pi!ing
'll the radiators and oil piping is removed from the main tank and then these are sub+ected to
thorough cleaning and after completion of cleaning these are sub+ected to pressure tests normally
2!-kgcm
2
! For this the radiators are closed from one end through dummy plates which can
withstand the pressure and then these are normally filled with water and the pressure is applied and
kept for 1 hours and the drop in pressure is measured and logged! #f the pressure drops then the
place of leakage is identified and the same is arrested! For arresting the leakages cold welding
compound like 4el9onna are used ! For better arrestation on leakages during the application of the
cold welding compound a partial vacuum is applied on the radiators, this helps to suck the cold
welding compound inside the crack and fills the cavity and the vacuum is hold till the setting time of
compound! This procedure arrests the leakage and does not break at high temperatures and
pressure!
2C of 32
'fter this the radiators are again sub+ected to pressure test and checked for pressure drop, and if
the same is found then we have to identify the leakage and arrest the same as mentioned above!
&lectric 'rc 8elding or 4ra9ing cannot be performed on the radiators as the sheet with which these
are fabricated are very thin and gets melt during welding! 'nd one should never try these
procedure! 'nd moreover radiators are painted with "il resistant paint which deteriorates with high
welding temperatures and cannot be redone at site !
)) Oil Pi!ing+
'fter cleaning of the oil piping from inside and outside these are also sub+ected to pressure test!
'nd if the leakage is observed in flanges and welded +oints the same can be cut and rewelded to
arrest the leakage! 'nd after this these are painted with oil resistant paint ? Sinc chromate primer
paint 2!
,) .as and Oil surge Relays
These relays are dismantled from the main tank piping and dismantled internally to clean and check
for proper functioning! 8ith age the inside moving parts get stuck-up due to dust and carbon
deposit and it starts maloperation and in some cases absolutely no operation ! Do the hinged parts
inside these should be removed and cleaned thoroughly with cleaning agents and made free from
deposit! 'ny defective parts if possible should be replaced! <ormally the $ercury contacts develop
leaks at the termination points which is never repairable, so these should be removed and replaced
with new one!
'fter overhauling the same these should be bo(ed up with use of new gaskets as per the "&$
specification! 'nd should be checked for leakage and proper functioning!
2) &ushings
The bushings from the transformer should be removed with due care to protect the damage to
bushing and should be placed on the bushing stand and should never be placed on ground! These
should be stored vertically! 's per the )*' tests these should be overhauled! #f the Tan delta values
are very low and oil leakage is observed from the bushing then these should be dismantled and
should be handled with outmost care!
'fter dismantling the bushings these should be cleaned from inside preferably with new insulating
oil and the internal leads should be checked for any overheating and damages! #f the leads are not
found to be in order the same should be replaced and one should not take any risk by repairing
them! The new 4ushing oil should be called from "&$ for filling in the bushing and the same
should be filtered and tested for 4:= ? 4reakdown voltage 2 and once the 4:= is achieved
depending upon the voltage rating of transformer the same should be filled in the bushing under
2- of 32
full vacuum! 'll the gaskets of the bushings should be replaced with new one and in no case the old
gaskets should be used!
<ormally condenser bushings which uses special oil and $ica filled oil should not be opened at site
for overhauling as it re%uires special process for overhauling which can be done only at factory!
?) *ore and @indings
The 5ore and windings of the transformer are main area where a lot of work is normally done
during *&P ! :epending upon the )*' report one has to move further! #f the :7' and Paper
analysis say that arcing has occurred in main coils then the transformer has to straight away go to
rewinding shop where the coils are removed and reminded as per the original drawings and coil
si9es! 4ut if the :7' does not say any ma+or problem and suggest only oil replacement ? oil has
decomposed 2 then we should arrange complete oil for filling the same after completion of *&P! 'nd
if the paper analysis report say that the paper has got aged and does not meet the re%uirement
then also the same has to undergo rewinding! 4ut if the paper reports are also ok and does not say
any overheating and aging then we have to carry out the *&P at site and for this normally following
procedure is carried out!
Transformer,s $ain tank and core and winding are dismantled and the physical inspection is done
on the same and then the procedure is laid down and carried down!
5omplete main tank is disassembled from all the accessories and cooling bank and depending
upon the facility at site the work location is decided! #f sufficient space and crane is available near
the original service location then a temporary room is constructed around the main tank , the area
to be covered should be normally 2!- to 3 times the area of the $ain tank, to take care of storing
the core and coils assembly and free movement area!
#f these are not available on service location then we must shift the transformer to service bays
where sufficient capacity of cranes and storing and working area is available!
"nce these are arranged then the $ain tank covers are removed and the core O 8dgs! are
removed from $ain Tank and following is to be observed and noted down for further analysis and
making program for works to be performed!
1! 4efore lifting the core coil assembly following should be noted down or better take
photographs if permitted 6
a! =isual #nspection to be carried out for 5ore and wdg! and the take physical
dimensions of core and coils for any bulging or dislocation should be recorded!
b! )ecord the location and number of earthings ? <ormally only one point 2 done vi9!
core to tank, yoke to core, coil tightening fasteners to core yoke, yoke bolts! This
will be visible on top of the core coil assembly and if possible one person should go
2F of 32
inside the tank and check for any fastening and earthing at bottom! 'lso after
removing the earthing record the #) values vi9! 5ore to $ain tank and Joke to core!
The #) check should be done with -00= #nsulation tester and the permissible
values are min! 1$T! #f the #) value is Sero in case of &>= class transformer
?P132k=2 then it has to analy9ed and consulted with the "&$ and it should be
brought under the permissible limits!
c! The internal condition of the main tank bottom is clean or not ! 'mount of sludge
and carbon deposits must be noted and if re%uired must be sent to *aboratory for
analysis!
2! 5heck for any >"T Dpot or *ocal 4urns abnormality in 8dgs!
3! 5heck for any arc fumes at following locations6
a! Top 5hannel of Joke near guides rails!
b! 7uide and *ocking clamps of yoke in top cover of transformer!
c! Top yoke clamps and bolts!
d! "*T5 chamber!
C! 'fter the core and coils are taken the #) ? #nsulation )esistance 2 of following can be taken
very easily and rectified if re%d!
a! Joke 4olt to 5ore
b! 5ore to Joke 5lamps
c! Joke clamps with bottom pads
'll these values should be min! 1 $ "hms! #f these values are not in the above limits then the
corrective action has to be taken and we must find out the point of earthing from where the earth
contact is being generated! The philosophy is that the 5ore is single point earthed to avoid
circulation of eddy currents! The 5ore consists of lot of steel parts and bolts and nuts and if proper
care is not taken and not insulated then it forms a big path to eddy current at very low resistance!
'nd with due course or time it generates lot of heat and circulating current and during voltage surge
and switching on it generates voltage spikes and causes arcing inside transformer and
decomposes oil! Do we must check the #) values and ensure proper insulation of core and coils
from tank and once the values are achieved then the core should be earthed at one point!
<ormally the area where the problem arises are as follows6
#nsulation failure at Joke bolts!
#nsulation failure at base pad with main tank!
#nsulation failure at top yoke clamps and tank cover!
Failure of &arthing bushings through which the earthing of $ain core is achieved!
7uide and locking clamps of yoke!
2/ of 32
The 4olts and nuts of complete core and coils should be checked for tightness as per the tor%ue
table to ensure proper fastening of core and coils in transformer! #f the bolts and core and coils are
not properly secure it gives rise to unwanted vibrations and noise during service!
The outgoing >T*T leads should be checked for proper insulation and normally whenever ma+or
overhauling is taken we must remove top two layers of paper insulation and reinsulated them with
new insulating paper, as during performing other general works on core and coils these top layers
are sub+ected to unwanted dust, dirt and physical damage!
Pressboards covering the core and coils should also be checked and if the same are found
damaged the same may be replaced with new one and must be secured properly with cotton! P=5
insulation tapes should not be used in any case! The paper insulation should be secured at the end
with the help of Dynthetic 7lue used for sticking purpose ordinary glue should not be used!
"nce these works are performed the core and coils should be bo(ed up in $ain Tank! The $ain
tank should be thoroughly cleaned with the help of cleaning agents and then it should be applied
with two coats of "il resistant paint and after that the core and coils should be placed in main tank!
'nd once the core and coils are placed inside main tank and finally positioned then we should
again measure the #) value of 5ore with respect to main tank!
=) Ta! *hangers+
Tap-changers are the main part of transformer which forms the series current carrying main circuit
path for the Power!
The off-circuit tap changers are least prone to aging as they are used on <o-load and <o-Potential
they +ust acts as off load switch are normally not aged! >owever we must check the condition of
contacts, contact pressure, proper alignments of male female contacts and the operating
mechanism! #f any +amming is found in operation mechanism then the same needs attention and
should be rectified!
The "n-*oad tap changers are the one which are aged and needs too much attention during ma+or
overhauling and repairs! The circuit continuity of the tap changer should be checked with help of
'nalog multimeter! The multimeter should be connected across the e(ternal points of mating
contacts and the tap changer should be operated and the multimeter should show the circuit
continuity all the times and should never go towards 9ero scale even for a fraction of second,
practically there should not be any movement on the multimeter pointer! #f it shows flickering results
that means the circuit is getting discontinued which is not at all acceptable in "*T5 ? "n-*oad Tap
changer 2! This could be due to following reasons 6
Faulty resistance in the diverter switch!
8orn-out contacts in diverter switch!
:efective springs in the diverter switch!
21 of 32
"nce this is test is done on all three phases and the results recorded, then we should act
accordingly and take necessary action if any defect is found! 'fter this the diverter switch
should be opened and checked physically the condition of contacts and resistance and the
operating gears inside the diverter switch! #f necessary we must change all the contacts!
The springs should also be checked for necessary pressure and replaced if necessary! 'ny
overheating observed in the diverter switch must be checked and rectified!
The gear mechanism of the "*T5 should also be checked for any worn-out parts and
gears and if re%uired we must change the same! The 7ear mechanism normally does not
re%uire any greasing inside and outside as the material with which the gears are made are
self greasing and anti friction! The "*T5 should be completely cleaned with new "il and
hot oil washing should be done to ensure cleaning of any trapped sludge at corners and
hidden points!
'fter complete overhauling the "*T5 must be assembled in main tank and the leads
should be connected in proper se%uence to ensure proper circuit diagram as per name
plate!
'fter final assembly of main tank with "*T5 and lead connection we should perform vector
group, ratio and winding resistance test so that any wrong connections done during
overhauling the same are noted and we need not open the transformer again after dryout
and final assembly at location!
A) Terminal &o:es
Terminal bo(es form the part of termination from where the power is taken inside the transformer
and taken out from the transformer! These normally consists of >= bushings and busbar
arrangements! 8e should completely dismantle the *=>= cable chambers and see the physical
condition of bushings and busbar and if any cracks and overheating is observed the same must be
taken care of and rectified! 4ushings should be checked for #) =alue and replaced if re%uired!
Terminal bo(es should accommodate the connections without crowding and proper arrangement
should be made to support the leads and all the tensions and twists must be removed and the leads
should be well supported in the terminal bo(! :amaged terminals bo(es should be repaired
replaced! #n case of Phase Degregated Terminal 4o(es ?PDT42, proper phase segregation
shrouding should be maintained! #nsulators in the terminal bo(es should be checked for insulation
value and physical healthiness!
1<) Tem!erature monitoring
Temperature monitoring of transformers is normally done through "T# and 8T# ? "il8inding
temperature #ndicators 2! These should be checked for healthy working by proper calibration in *ab
as per the "&$ procedures!
(ryOut Process
'fter completing the overhauling of all the e%uipments and accessories the $ain tank of
transformer is bo(ed up with using new gaskets at all location and flanges! <ow during this
complete process the transformer winding absorbs moisture from the atmosphere as it is open air
and the insulating paper is an hygroscopic material which absorbs moisture very fast and the same
is trapped inside the winding and insulation! To takeout this moisture normally <itrogen dryout
process is used at site! For carrying out the dryout process following arrangement is done at site 6
2B of 32
The $ain tank is completely all around covered with 7# sheets at distance of appro(! 3-C feet from
$ain body and also from top, this is done to avoid ingress of rain water and glass wool or other
insulating media is applied all along the wall of 7# sheet to avoid loss of heat! #ndustrial heaters are
mounted at a distance appro(imately F-1 inches from the $ain body with the help of 7# wires and
the same are connected with 3-ph C1-= '5 supply! The no! heaters depends upon the si9e of
transformer! The heaters should be sufficient to maintain F0
o
- /0
o
5 temperature inside the $ain
Tank! The 8T# and "T# probes are inserted in the thermometer pocket of the transformer to record
the inside temperature of the main tank! "n the top filter valve an arrangement is made to pull the
vacuum from the main tank! The capacity of vacuum pump also depends upon the rating of
transformer normally it should be 2000 ltrsmin! ' differential pressure gauge is also mounted on
one the flanges of main body to record the positive pressure of <itrogen and vacuum inside main
tank if available or otherwise separate gauge to record <itrogen pressure and =acuum in main tank!
The vacuum pump should be sufficient to maintain full vacuum in the transformer! 'lso is the
condensation unit is possible the same should be arranged and installed with the vacuum pump to
record the water coming out the transformer! "nce all the arrangements are made then the
<itrogen is filled at 2!- PD# and the heating of transformer is started! The #) values are to be taken
during dryout process and for this purpose the >=*= leads are connected with Teflon insulated
>igh temperature leads to give accurate readings of winding! 'fter this following steps are done to
ensure proper dry out of Transformer 6
"nce the Temperature reaches F0
o
5 we should measure the :ew point of the <itrogen
inside transformer! This generally comes to be positive and one very higher side during first
cycle! 8e should record this reading! 'nd also the #) values!
'fter this the vacuum pulling should be started and it should be hold for 2C hrs! and the
amount of water should be measured and recorded and again the <itrogen filling should be
done at 2!- PD# and the heating of transformer should be continued and maintained at
F0o5 for another 2C >rs!
'gain the dew point reading should be taken and recorded and the #) values!
This process is repeated till the desired #) values and dew points are not achieved! <ormally for
fully dried out windings the dew point of the <itrogen inside main tank is ?-230-3-
o
5! 't this dew
point the windings are considered to be fully dried out and <o-moisture is supposed to be trapped
inside the transformer! The #) value and P# values should also be recorded at the end of this
process and if we match the same with original values we will see that the values have improved!
'lso the water collected during the last cycle will be appro(imately <il! The P# values should be
normally more than or e%ual to min 1!3! "nce this dryout cycle is completed the "il is to be filled
inside the transformer!
For filling the "il inside the transformer the "il should be separately filtered and made ready in tank
and tested before pouring in the transformer! The typical values are as under 6
$oisture content I 10 ppm
4reak down voltage P /0k=!
For filling the "il inside the transformer the $ain tank should be under vacuum and we should filling
the oil from bottom filter valve and run continuously the vacuum pump to avoid any air trapped
inside the winding which will give erratic #) values and can cause <uisance tripping during first
charging of transformer!
"nce the "il is filled in main tank the 7# sheet arrangement should be removed and the transformer
should be completely assembled with all the accessories and cooling bank and all piping and
bushings! 'nd should be finally painted with made ready for charging!
Testing after repairs
1! #nsulation )esistance Test
The recommended minimum insulation resistance to ground measured at /0
o
5 temperature is
given by the formula
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)min @ nA1 in $ega "hms!
8here n is the rated voltage of the transformer in R=!
' -00= meggar is suitable for testing of transformers rated upto 1100=! 'bove this voltage, 1000=
meggar is recommended! Test voltage is applied for 1 minute!
2! Polari9ation #nde( ?P#2 test
The P# test should be performed at the same voltage as that for the #) and should be continued for
10 minutes! The ratio of the 10-minute reading to the 1-minute reading is defined as Polari9ation
#nde(, which should be more than or e%ual to 1!3! >owever, P# by itself does not indicate
healthiness if the basic #) value is not within permissible range!
3! #nsulation Power Factor Tan :elta
#nsulation power factor, dissipation factor and tan delta tests are performed on large machines!
#nterpretation of results is by comparison with results of tests on similar machines! <o standard
interpretation of results has been established!
C! )atio Test
This is done to check the voltage ratio of transformer and healthiness of the inside leads and to
check any wrong connections done during overhauling!
-! $agnetising 5urrent
<o load current magnetising current test is done to check healthiness of core and windings and any
loose connections and the healthiness or 5ore and laminations!
.eneral Precautions for O9erhauling of Transformers
12 :uring dismantling the pipes should be properly numbered or punched in order to ensure
proper fi(ing during final assembly!
22 =alves should also be numbered and punched and the direction of mounting should be
noted during dismantling!
32 :uring the taping of the internal leads care is to be taken that the tape is not loose during
covering and synthetic glue is used for +oining the paper insulation and at last ends, #n no
case normal glue should be use or P=5 tapes should be applied at ends!
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C2 :uring final assembly one should take care that no tools and tackles are left inside main
tank!
-2 'll gaskets on the transformer should be replaced to provide immunity against dust
ingress! 'll sealing plates especially on the terminal bo( foundation bolts area should be
replenished with proper gasketing!
F2 Power leads in the terminal bo(es should be re-insulated remade with new ferrules lugs
to avoid insulation breakdown and loose connections!
/2 'll holes should be tapped and cleaned!
12 4efore charging of transformer 'ir should be released from transformer in orderly manner
to avoid unnecessary trippings!
' table is made for ease of making maintenance schedules and the e(pected life of various
e%uipments with no! of days normally re%uired to replace the same!
'ccessories
)ecommended
update period
<umber of days for
replacement
Power outage
necessarynot
necessary
"il thermometer 10 years 1 day <ecessary
Pressure relief device 10 years 1 day <ecessary
#nternal fault detection
?4uchhol9 relay, Dudden oil
pressure relay2
10 years 1 day <ecessary
4ushing 10 years 2 days <ecessary
5ooler
10!?)adiator, 8ater cooler,
3nit cooler2
1- years 3;-days <ecessary
"il pump 1- years 2 days <ecessary
5ooling fan motor 1- years 1 day <ecessary
:ial type oil level gauge 1- years 1 day <ecessary
7as detector 1- years 2 days <ecessary
"il flow indicator <ecessary
5ompound gauge 1- years 1 day <ecessary
)ubber cell for conservator 1- years 2 days <ecessary
:ehydrating filter breather 1- years 1 day <ecessary
Dtop valve 1- years C days <ecessary
4all bearing ?open type2 3 years 1 day <ecessary
4all bearing ?shield type2 10 years 1 day <ecessary
7asket ?nitrile rubber2 1- years
:epending on the
location and number
used
<ecessary
7asket ?cork prene2 10 years
:epending on the
location and number
used
<ecessary
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