1010 Basics of Transformer CM

TRANSFORMER CONDITION MONITORING
BASICS of TRANSFORMER CM
1. Introduction to TRANSFORMER MAINTENANCE 2. TEMPERATURE SENSING 3. VIBRATION MONITORING 4. PARTIAL DISCHARGES (ACOUSTIC EMISSION) 5. MOISTURE MONITORING 6. GAS MONITORING DGA 7. Examples of SYSTEM SOLUTIONS 8. ENDING
TYPES OF TRANSFORMER FAULT

Phase-ground faults - from winding to core or winding to tank Phase-phase faults - between windings Interturn faults - between single turns or adjacent layers of the same winding Arcing contacts Local hotspots caused by shorted laminations External faults causing thermal or mechanical damage Overloads
Ver. 2011-12-01 Ryszard.Nowicki@ge.com : 00:01 Page: 4 of 80; Part 10.1 Basics of TRANSFORMER CM
TYPES OF TRANSFORMER FAULT

Low level internal partial discharges (moisture ingress or design problems) Bushing faults (internal to the tank) Tapchanger faults (often housed in a separate tank) Terminal faults (external to the tank, but inside the transformer zone)
Role of the Transformer
No Transformer
No Power Delivery
Impact of Transformer Failure
No Power Delivery = Loss of Revenue $$$ Power may have to be purchased to meet contractual obligations $$$ Direct Replacement Cost $$$ Bad Publicity & Environmental Damage
Typical Utility Transformer Fleet

Approx 60% are >35yo (End of Life region)
Approx 8% are <10yo (Design Flaw Region)
Transformer Failure
There are 3 types of Transformer Failure: 1. Sudden/unexpected due to outside influences 2. Design flaw 3. End of Life Failure risk can be reduced by monitoring the Transformer Condition
Predicted End of Life Failure Rate

Failure distribution for a fleet of Transformers installed between 1964 and 1992
Significant Rise in # of Failures
Source: William H Bartley & Rowland I James Jr.
Transformer Users Pain

{ evaluation from beg of 2000s }
There were typically 730 transformer fire and explosions per year in the USA. Many experts anticipate that this number to go up from 1% at beginning of 2000s to 2% after 2010. The emphasis on renewable will put more burden on the existing Transformers
A growing concern for Corporate Risk Managers and Insurance Companies
Why do Transformers Explode?
Transformers are considered by Corporate Risk Managers and Insurers as the most critical equipment inside plants because of the large quantity of oil in contact with high voltage elements.
Loose international transformer norms and lack of regulation
The Norm IEC 76 only includes basic electrical measurements and does not cover mechanical design or protection. By comparison, pressure vessels have to comply with adequate rules and controls. Such directives do not exist for transformers that have proven to be more dangerous
Transformer electrical and mechanical protection limits
Pressure Relief Valve inadequacy: pressure gradients developed during low impedance faults are too fast for mechanical devices. All transformers that have exploded have been protected with Pressure Relief Valves.
Buchholz and Rapid Pressure Relay inefficiency: Transformer electrical protections are not designed to react to sharp pressure gradients. During the 62 Transformer Protector tests, the Buchholz always failed to detect any gas and oil movement or pressure variation.
Electrical Breaker opening time: the best breaker technology trips in 50 ms far too late to prevent the explosion, which occurs 10 to 50 ms after the low impedance fault. Additionally, the tank pressure keeps increasing after breaker opening
Transformer Monitoring can Mitigate
1 Transformer / FAILURE
Various systems
Temperature Monitor
Every 6 to 8 C rise in operating temperatures, the expected life of the transformer will go down by half These temperature build-ups cause localized area of high heat and paper damage, followed by events of partial discharge . One needs to have a long term trending of the operating temperature inside the transformer. Should be performed distributed temperature sensing of all the windings
Overtemperature Monitoring
Two temperatures must be monitored:
> Winding temperature (WT) - this can rise rapidly, without much of an increase in oil temperature > Oil temperature (OT) - this can rise slowly to a critical point without an unacceptable winding temperature increase
(dependent on asset management policy)

winding alarm - 90C to 110 C winding trip - 110C to 135C oil alarm - 80C to 95C oil trip - 95C to 115C Oil trip may be disabled if transformer is readily accessible by maintenance crews on the grounds they can visit sub and may be able to remedy problem this is a controversial practice.
Typical alarm and trip levels
Temperature vs life
Economic gains are possible from short time overloads - life used calculations may permit higher temperatures for short periods, but WT trip needs to be more complex or monitored 110 C winding hot spot temperature gives standard 20-25 year life of insulation Roughly every 7 C increase in temperature doubles the rate of loss of life for paper in oil insulation
END WINDING TEMPERATURE SENSING

By incorporating fiber-optic sensors into transformer windings temperature data can be used to monitor for hot spots within the transformer and to provide ratings based on safe operating temperatures. Alternatively, a fiber-optic cable can be installed after the windings have been wound on the core, or fiber-optic point sensors can be placed at strategic locations.
FO Cable part of Distributed Temperature Monitoring
Various systems
How about Vibration monitoring

There are significant differences in the low frequency vibration signal amplitudes and frequency content, dependent on the degree of winding looseness.
Low frequency vibration measurement ..... symptoms:

I. Detection of significant difference in low frequency response, II. Shift of existing resonance, III. Creation of new resonance, IV. Change in shape of various plots would potentially indicate mechanical or electrical problem with
I. II. the winding and transformer core
Vibration Severity Criteria for Transformers

{velocity sensor data - Eng units: ips }
Started with the following overall levels.

0.25-.50 ips-Minor 0.50-.75 ips- Intermediate Watch list (further investigate) 0.75-1.0 ips- Serious Look for oil leaks, hot metal gasses and increasing sound levels. 1.00 ips or greater-Critical Oil leaks, gas generation rates and hot spots.
Vibration Severity Criteria for Transformers

{velocity sensor data - metric units: mm/s }
Started with the following overall levels:

4,5 9,0 mm/s-Minor 9,0-13,5 mm/s - Intermediate Watch list (further investigate) 13,5-18,0 mm/s - Serious Look for oil leaks, hot metal gasses and increasing sound levels. > 18,00 mm/s -Critical Oil leaks, gas generation rates and hot spots.
Vibration Severity Criteria

Alarm Parameters for Transformers [ips]
Nominal Freq / Hz Frequency / Hz 5 to 115 Label Name Sub-sync One Times 1st Odd Two Times 2nd Odd Three Times 3rd Odd Four Times Hi End Warning 0.05 0.25 0.1 0.15 0.1 0.15 0.1 0.1 0.1 Alert 0.1 0.5 0.2 0.25 0.2 0.25 0.2 0.2 0.2 Danger 0.25 1.0 0.3 0.5 0.3 0.5 0.3 0.3 0.3
120 240 360 480
115 to 125 125 to 235 235 to 245 245 to 355 355 to 365 365 to 375 375 to 485 485 to 1000
Vibration Severity Criteria

Alarm Parameters for Transformers [mm/s]
Nominal Freq / Hz Frequency / Hz
5 to (2*fLINE 5)
Label Name Sub-sync One Times 1st Odd Two Times 2nd Odd Three Times 3rd Odd Four Times Hi End
Warning 0.9 4,5 1,8 2,7 1,8 2,7 1,8 1,8 1,8
Alert 1,8 9,0 3,6 4,5 3,6 4,5 3,6 3,6 3,6
Danger 4,5 18 5,4 9,0 5,4 9,0 5,4 5,4 5,4
2*fLINE 4*fLINE 6*fLINE 8*fLINE
(2*fLINE 5) to (2*fLINE + 5) (2*fLINE + 5) to (4*fLINE 5) (4*fLINE 5) to (4*fLINE + 5) (4*fLINE + 5) to (6*fLINE 5) (6*fLINE 5) to (6*fLINE + 5) (6*fLINE + 5) to (8*fLINE 5) (8*fLINE 5) to (8*fLINE + 5) (8*fLINE + 5) to 1000
Where to measure the vibrations

H IG H S ID E
LT C S ID E #2
25C LO HI
X
X
X
X
X
X
S ID E #4
Shell Form
S ID E #3
Eight readings ~ Approx 1,6 m from bottom of core, and 45 cm from corner
Where to measure the vibrations

0.15@240 0.09@360
0.22ips Side 3L 0.9ips
Side 3R
Side 4L
Overhead View of Transformer

Snd=78db AE=30Cts Snd=80db AE=35Cts
Side 2R
Side 4R Side 1L
High Voltage Side Side1R
0.05ip s Side 2L
1. Introduction to TRANSFORMER MAINTENANCE 2. TEMPERATURE SENSING 3. VIBRATION MONITORING 4. PARTIAL DISCHARGES 5. MOISTURE MONITORING 6. GAS MONITORING DGA 7. Examples of SYSTEM SOLUTIONS 8. ENDING (ACOUSTIC EMISSION)
Major Failure Mechanisms

Aging of paper Moisture in oil Looseness movement of the windings
For the Aging of Paper

The occurrence of PD reveals the existence of dielectric insulation problems within the circuit breaker and the windings. Typically the higher the emitted power and frequency of occurrence, the higher the chance of failure by dielectric breakdown. PD can be measured: On-Line or Off-Line.
Electrical PD diagnostic techniques

PD measuring circuits according to IEC 60270 often applied in onsite/on-line PD investigations frequently used circuit in test laboratories
[Knig, 1993]
a) coupling device in series with the coupling capacitor
b) measurement at a bushing tap
Components: AC voltage source U, optional blocking impedance Z, coupling capacitor CK, measuring impedance Zm, a measuring instrument M and generalized test object Ca.

PD Measuring Impedance for Bushing Tap Installation Decoupling of PD signals from the bushing tap in a wide frequency range up to 30 MHz Lower cut-off frequency < 60 kHz
500 kV Transformer Bushing
Additional voltage signal for phase-resolved measurements Superimposed PD and test voltage signal Very fast and safe over-voltage protection TNC-socket for signal output Special feature for continuous PD monitoring (IP 68)

Advanced solution: ACOUSTIC EMISSION added
Electromagnetic (UHF) method
PD (partial discharge) Sound field (acoustic wave)
Acoustic method
))
)) ))
)
))
PiezoSensor
measuring system
Key characteristics:
non-destructive on-line application of the sensors (no bushing tap necessary) immunity against a wide range of disturbing signals on-site (e.g. corona) in principle immun against electric noises signal attenuation depends on PD site very low noise level (faradays cage) very low attenuation in oil and solid insulation
geometric PD location possible PRPD patterns possible short arrival times no apparent charge information is delivered so far
))
Electromagnetic wave example sensor monopole
measuring system
IEC 62478 - IEC Proposal, now already Draft level

"Non-conventional PD-measurements"
In the past few years, there has been the development of many so-called nonconventional PD measurement methods. Partial discharges (PDs) generate pressure waves, sound, light and electromagnetic waves. These physical effects can be detected by different sensors and so there is the possibility to detect PDs with non-conventional methods besides the conventional electrical measurement. The main method for PD measurement is electromagnetic (HF/VHF/UHF) and acoustic measurements. Also, there have been a lot of papers published using these methods. Therefore, IEC TC42 has in the meeting of September 1st , 2005 in Beijing, decided to proceed with this new work item called Measurement of PDs by electromagnetic (e.g. UHF) and acoustic methods and to form a new working group for this task. (......) The task of this new WG is to collect all the used applications of these methods to compare them with each other and to look at their frequency range. Another differentiation of the measuring technique is if it is a narrow bandwidth or a wide band frequency measurement technique. This work will also include the use and the techniques of the different sensors, their frequency range and their sensitivity. Also, it will investigate the issue of the methods, the possibility of PD location and if a calibration or in minimum a sensitivity check is possible. The WG will start with the electromagnetic methods and after finishing will move forward to the acoustic methods.
System Check for UHF (on transformers)
Performance Check
Functional check of the whole measuring path including sensors and partial discharge (PD) acquisition system not necessarily transmission of electromagnetic waves through the test object , one-port solutions are possible
Sensitivity Check
Emission of electromagnetic waves into the test object necessary and known distance between sensors and injection location Pulse Generator injection necessary to determine relation between the apparent charge (pC) and measured quantities (e.g. V,W,J) through simultaneous measurement one-port solutions might be possible in relation to the wave length (for compact objects, not for extended objects)
Instruments classification based on Bandwidth

Class
Mode
Frequency Domain Measurement Zero Span Full Spectra
Time Domain Measurem.
Ultra Wide Band
Frequency Band
PD Pattern
Advanced tools for PD monitoring Electromagn. PD Tests

Cone-shaped active drain valve UHF-sensors
for the decoupling of electromagnetic PD signals from the inner of an oil-paper-insulated transformer PD-signals in the UHF frequency range (mainly 300 MHz 1 GHz) sensors support Performance/Sensitivity Check (high-frequency test impulses can be injected with additionally integrated electrode) sensor head is grounded (for lower frequencies) sensor application at oil valves, which are available e.g. for oil filling or draining (liquid tightness is tested for 120C warm oil with 5 bar compression)
View from inside the transformer

Type-Test Cone-shaped active drain valve UHF-sensors
Oil pressure estimation
Combined temperature/pressure test
1. Introduction to TRANSFORMER MAINTENANCE 2. TEMPERATURE SENSING 3. VIBRATION MONITORING 4. PARTIAL DISCHARGES 5. MOISTURE MONITORING 6. GAS MONITORING DGA 7. Examples of SYSTEM SOLUTIONS 8. ENDING (ACOUSTIC EMISSION)
Advanced tools for PD monitoring Acoustic PD location

Alternatives of arrival time based positioning
1. Mixed-acoustic methods:
electro-acoustic (test laboratory or on-site/off-line) electromagnetic- acoustic (test laboratory or on-site, off-line or on-line)
sensor 3 PD sensor 1
2 s1 s
sensor 3 sensor 2 sensor 2 sensor 1 electrical PD triangulation
Observation equations:
(x x ) + (y y ) + (z z ) = (v
2 2 s1 s1
( x x s 2 )2 + ( y y s 2 )2 + ( z z s 2 )2 = (v s T S 2 )2 (x x s 3 )2 + ( y y s 3 )2 + (z z s 3 )2 = (v s TS 3 )2
T S1 )
t
S3 (xs3 , ys3, zs3 )
unknowns x, y, z
Input parameters: sensor coordinates, sound velocity, meas. time difference

Si (xsi , ysi , zsi )
S4 (xs4 , ys4 , zs4 )

Di
D3
D4
D2 D1
2. All-acoustic methods:
all-acoustic (test laboratory or onsite, off-line or on-line with reduced sensitivity)
PD (x, y, z)
S2 (xs2 , ys2 , zs2 )
S1 (xs1, ys1, zs1 )
schematic view of a transformer tank with acoustic sensors

Vibration measurements extended with: sound & AE

0.15@240 0.09@360
0.22ips Side 3L 0.9ips
Side 3R
Side 4L
Overhead View of Transformer

Snd=78db AE=30Cts Snd=80db AE=35Cts
Side 2R
Side 4R Side 1L
High Voltage Side Side1R
0.05ip s Side 2L
Major Failure Mechanisms

Aging of paper Moisture in oil Looseness movement of the windings
Moisture In Oil
Moisture in oil is destructive to cellulose, especially in the presence of oxygen. Presence of moisture will facilitate partial discharge. Fiberoptics moisture sensor can be a part of a CM solution
Various systems
Dissolved Gas Analysis (DGA)

Commonly accepted as the most effective method of Transformer Assessment
Power Transformers contain insulating oil When a fault occurs, the oil breaks down generating gas These gases dissolve into the oil Fault type/severity are indicated by gases present
1. 2. 3. 4. Samples collected manually from Transformers Analysis performed by specialist oil laboratories Sample collection to analysis ranges from days -> weeks Performed on an regular (6 12 month) basis
Traditional Methods of DGA
The most important aspects of DGA
The type of gas created indicates the nature of the fault. The rate of increase in these gases indicate the severity of the fault.
Oil pyrolysis (Thermal Heating)

HYDRO GEN H 2
GAS CONSTITUENTS
METH ANE
CH 4
ETH ANE
C2 H 6
ETH YL ENE C 2 H4 ACE TYLENE C 2 H2
R eferences: M . Duval, El ect ra,133, 40 (1990 ). T. V. Oommen, Ga s Generat ion in Power T ra nsformers
250
500
Fault Temperature ( C )
750
1000
1250
1500
1750
2000
Cellulose pyrolysis (Thermal Heating) Life of paper ~ Life of transformer

GAS CONSTITUENTS
CARBON MONOXIDE CO
CARBON DIO XIDE CO2
R eferences: M . D uva l, Ele ct ra ,133,40 (1990 ). T. V. Oomm en, G as Ge ne ra ti on i n Power Transforme rs
100
200
250
300
400
500
The problem with manual sampling...

A fault can develop and cause failure between samples. A single sample cannot provide rate of change or fault severity. Human error sampling & analysis. These weaknesses are relatively insignificant given:
Transformer catastrophic failure can occur in hours, days or weeks

Online DGA
for a Transformer
Online Monitoring
Monitoring unit is connected to Transformer Unit automatically samples oil from Transformer Gas extracted from oil, concentration measured Oil sample returned to Transformer Process repeated
Benefits
Early fault detection Extend Transformer life
Save Money $$$$
Condition Based Maintenance Defer Capital Expenditure Avoid catastrophic failures

Examples of Discrete Monitoring Products
TRANSPORT X*
Portable DGA 7 fault gases + moisture Simple & reliable
HYDRAN M2
MINITRANS*
TRANSFIX*
On-line Integrated Monitor Cost-Effective on-line DGA Full 8 gas + Gas & Moisture in oil Discrete gas measurement moisture on-line DGA On-line Models/Data storage (H2, CO, C2H2 + H2O)
Intellix MO150
MULTITRANS*
TAPTRANS*
Full 8 gas on-line DGA for main tank & LTC in one unit
SIGMA TX* (TBC)

Comprehensive transformer monitoring & modelling Full 8 Gas DGA Bushing/PD/Cooling System/FO hot spot
Low Cost Transformer Full 8 gas multi tank DGA Monitoring System
*Kelman Products
Online DGA
for a Transformer an EXAMPLE.....
Transformer Failure Case Study

Normal DGA gas levels
Gas ppm value
Sample Date/Time
Gas ppm value
Gases rise over 3 days as fault occurs sampling frequency automatically increases
Sample Date/Time

Fault severity high Transformer removed from service
Gas ppm value
Fault occurs rapidly over 8 days manual sampling would not have been sufficient to detect
Sample Date/Time
A COMPLEX
MONITORING
SYSTEM
A 300MVA transformer with a DGA system and a PD On-Line monitoring installed
FARADAY tMEDIC
Purpose: Transformer Monitoring and Diagnostics
Product: System 1 Integrated Substation
HYDRAN
FARADAY, tMEDIC or TMCS Units
Chosen KELMAN products
WAN / LAN
Process: Monitoring Modbus Ethernet Scanning Display Exception Alarm Decision SupportSM
Payoff: Typically 5 to 8 years added life expectancy

Recommended products for Power Generation Area
SIGMA TX (TBC) TRANSFIX

Full 8 gas (+ moisture) On-Line DGA Comprehensive transformer monitoring & modelling Full 8 Gas (+ moisture) On-Line DGA Bushing/PD/Cooling System/FO hot spot
At less than 1% of the initial Transformer cost: both solutions provide the vital information to protect & maximise Power Station critical assets
DGA en Transformadores de Poder

PT1 PT2
Minitrans DGA Monitor
Minitrans DGA Monitor
Ethernet
System 1
Perception Express
Parmetro Hidrgeno (H2) Acetileno (C2H2) Agua (H2O)
Rango 5 5,000 ppm 0.5 50,000 ppm 1-100% de Humedad Relativa
Monxido de Carbono (CO) 2 50,000 ppm
Descargas Parciales en Transformadores de Poder

TP1 3 x HFCTs ( High Frequency Current Transformers TP2 3 x HFCTs ( High Frequency Current Transformers
PDCheck - Techimp
PDCheck - Techimp
Ethernet
System 1
A SERVER OF
A HS DIAGNOSTIC SYSTEM:
An example with TRANSFIX from KELMAN
UNIT #1 PROTECTION SYSTEM / ESD

{ from BINARY OUTPUTS of the M&PS SYSTEM }


Unit 1
Unit 2
...
Unit N
The Cost of Transformer Failure

A study by The Hartford Steam Boiler Inspection and Insurance Company (HSB) estimates the cost of Transformer failure at approx $10,000 per MVA
HSB has been founded in 1866
The Cost of Transformer Failure

A study by The Hartford Steam Boiler Inspection and Insurance Company (HSB) estimates the cost of Transformer failure at approx $10,000 per MVA Online DGA monitoring can cost less than 1% of the initial Transformer Cost
HSB has been founded in 1866
COST OF PREVENTION
Transformer Life Management
Questions

1010 Basics of Transformer CM

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TRANSFORMER CONDITION MONITORING

TYPES OF TRANSFORMER FAULT

TYPES OF TRANSFORMER FAULT

Role of the Transformer

Impact of Transformer Failure

Typical Utility Transformer Fleet

Approx 8% are <10yo (Design Flaw Region)

Predicted End of Life Failure Rate

Significant Rise in # of Failures

Source: William H Bartley & Rowland I James Jr.

Transformer Users Pain

A growing concern for Corporate Risk Managers and Insurance Companies

Why do Transformers Explode?

Loose international transformer norms and lack of regulation

Why do Transformers Explode?

Transformer electrical and mechanical protection limits

Why do Transformers Explode?

Transformer electrical and mechanical protection limits

Why do Transformers Explode?

Transformer electrical and mechanical protection limits

Why do Transformers Explode?

Transformer Monitoring can Mitigate

(dependent on asset management policy)

Typical alarm and trip levels

END WINDING TEMPERATURE SENSING

FO Cable part of Distributed Temperature Monitoring

How about Vibration monitoring

Low frequency vibration measurement ..... symptoms:

Vibration Severity Criteria for Transformers

Started with the following overall levels.

Vibration Severity Criteria for Transformers

Started with the following overall levels:

Vibration Severity Criteria

120 240 360 480

Vibration Severity Criteria

Danger 4,5 18 5,4 9,0 5,4 9,0 5,4 5,4 5,4

2*fLINE 4*fLINE 6*fLINE 8*fLINE

Where to measure the vibrations

Where to measure the vibrations

0.22ips Side 3L 0.9ips

Overhead View of Transformer

High Voltage Side Side1R

Major Failure Mechanisms

For the Aging of Paper

Electrical PD diagnostic techniques

a) coupling device in series with the coupling capacitor

b) measurement at a bushing tap

Electrical PD diagnostic techniques

Electrical PD diagnostic techniques

Electromagnetic wave example sensor monopole

IEC 62478 - IEC Proposal, now already Draft level

System Check for UHF (on transformers)

Instruments classification based on Bandwidth

Frequency Domain Measurement Zero Span Full Spectra

Time Domain Measurem.

Ultra Wide Band

Advanced tools for PD monitoring Electromagn. PD Tests

View from inside the transformer

Type-Test Cone-shaped active drain valve UHF-sensors

Oil pressure estimation

Combined temperature/pressure test

Advanced tools for PD monitoring Acoustic PD location

2fLINE 4fLINE 6fLINE 8fLINE