Transformer Moisture Assessment Method

Lessons-Learned Documentation

Technical Report

Transformer Moisture Assessment Method

Lessons-Learned Documentation
1001774

Interim Report, March 2003

Cosponsors Australian Research Council (ARC) Victoria State Office PO Box 1820Q Melbourne 3001 Australia Commonwealth Dept of Education, Science and Training Casseldon Place 24/2 Lonsdale Street Melbourne 3000 Australia Dept of Electrical and Computer Systems Engineering Monash University Clayton 3800 Victoria Australia Project Manager V. Davydov

EPRI Project Manager B. Ward

EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA 800.313.3774 650.855.2121 askepri@epri.com www.epri.com

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT. ORGANIZATION(S) THAT PREPARED THIS DOCUMENT Monash University IntellPower Pty. Ltd.

ORDERING INFORMATION
Requests for copies of this report should be directed to EPRI Orders and Conferences, 1355 Willow Way, Suite 278, Concord, CA 94520, (800) 313-3774, press 2 or internally x5379, (925) 609-9169, (925) 609-1310 (fax). Electric Power Research Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc. EPRI. ELECTRIFY THE WORLD is a service mark of the Electric Power Research Institute, Inc. Copyright 2003 Electric Power Research Institute, Inc. All rights reserved.

CITATIONS
This report was prepared by Centre for Electrical Power Engineering Monash University Clayton 3800 Victoria Australia Principal Investigator V. Davydov IntellPower Pty. Ltd. 2/10 Warina Road Carnegie 3163 Victoria Australia Principal Investigator O. Roizman This report describes research sponsored by EPRI, Australian Research Council, and Monash University. The report is a corporate document that should be cited in the literature in the following manner: Transformer Moisture Assessment Method: Lessons-Learned Documentation, EPRI, Palo Alto, CA, Australian Research Council, Melbourne, Australia, and Monash University, Clayton, Australia: 2003. 1001774.

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PRODUCT DESCRIPTION

Utilities throughout the world have experienced the damaging effects of moisture in power transformers. Some of these damaging effects result in long-term outages, prolonged filtering processes, and even catastrophic failures. Prior EPRI studies have been performed to define the consequences of water contamination. Many of these studies define adverse transformer impacts ranging from decreased dielectric strength, loss of life, tank and core corrosion to vapor bubble evolution. Other EPRI studies have defined acceptable levels of moisture, mechanisms of moisture ingress, the dynamics and interactions between the oil and variables such as winding insulation, temperature, and load as well as safe operating limits for wet transformers. In order to put this knowledge to use, diagnostic tests and condition assessment tools have been developed. These can be either on-line or off-line, but all require measurement of parameters related to the moisture content of oil. However, many factors, such as the dynamics of moisture movement back and forth between the paper and the oil during temperature cycling, must be taken into consideration, otherwise extreme errors in moisture assessment will result. In addition, the actual determination of the moisture content of oil is fraught with uncertainties. Despite the fact that the Karl Fischer method is the de facto standard for measuring the water content of oil, human errors and a number of uncertainties associated with the oil sampling procedure deteriorate the reliability of measurements and could lead to deceptive conclusions. This report describes procedures and gives instruction on avoiding common pitfalls in moisture assessment of transformers. Results & Findings The key outcomes of the work for 2002 are as follows: An understanding of the factors affecting moisture and gas dynamics in aged transformer oil Completion of a new classification procedure for ranking power transformers by the level of moisture Development of guidelines for an improved procedure of sampling oil from operating transformers for evaluating water content of oil Development of a new test method for evaluating water solubility in oil Improvements to the stand-alone software program Transformer Moisture Monitor (TMM) Implementation of the water-in-paper algorithm into EPRIs Maintenance Management Workstation (MMW) Delivery of a course on moisture assessment in power transformers.

Challenges & Objectives This report includes critical and practical information for engineering, maintenance, and laboratory personnel on all aspects of moisture measurement on operating transformers. Using the procedures in this report will ensure that moisture assessments and ranking of power transformers in terms of moisture condition are valid. Without this knowledge and correct use of the available tools, it is very possible that results obtained can give a false impression of transformer insulation integrity. Applications, Values & Use The tools developed during this research can be used to monitor transformer insulation continuously, assess and rank transformers in terms of moisture content, and assist in the efficient dryout of insulation, both on-line and off-line. EPRI Perspective Since the beginning of the transformer industry, the definition of nameplate current-carrying capacity has been related to temperature rise and ambient temperature in recognition that operation beyond thermal limits jeopardizes transformer life. However, aging of transformer insulation is highly dependent on moisture and oxygen content. If both are low, thermal degradation is minimal except with very high temperatures. Although moisture and oxygen effects have been thoroughly explored, they have not received much attention by users. Reports are limited; however, there is a strong possibility that paper insulation life in heavily loaded transformers, such as generator step-up transformers, may be gone after 30 years. Insulation degradation is probably most severe in air-breathing conservator units that accumulate oxygen and moisture, somewhat less severe in conservator units with membranes, and least severe in properly maintained nitrogen-blanketed transformers. Regardless, maintaining low oxygen and moisture content is an effective strategy for extending insulation life. Monitoring and continuous oil filtration on-line are ways to address this. Approach The focus of the work in 2002 was to provide practical aids to industry for evaluating moisturerelated conditions of transformer insulation. This was accomplished by developing guidelines, procedures, and software to assist with moisture assessment. These are based on previous EPRI research targeted at understanding the dynamic behavior and effects of moisture in transformer insulation systems. For additional information on this ongoing research, the following reports are available: Power Transformer Insulation Behavior During OverloadPhase 1: Dynamic Behavior of Moisture (TR-113390), Transformer Moisture-in-Paper Assessment MethodField Trial (TR114075), Green-Yellow-Red Diagnostic MethodTransformer H2O Assessment Method (1000724), Transformer Moisture Assessment Method: Phase3: Testing of Nitrogen Blanketed Transformer Insulation and Development of Software Application (1001939), and Transformer Condition Assessment and Diagnostic Methods: Phase 4: Green-Yellow-Red Diagnostic Method (1001940). Keywords Transformer insulation Moisture Oil sampling Condition assessment Diagnostics vi

ABSTRACT
Work related to EPRI funded project Transformer Insulation Behavior during Overload has been underway since 1994. Prior to the current stage, called Part 4, three other stages of activity, called Parts 1, 2 and 3, have taken place from 1994 to 2000. The previous work has provided a basis for the work in 2001 and 2002. The 2001-2002 work was funded by the following three granting bodies: EPRI (72.1%), Australian Government (18.3%) and CEPE, Monash University (9.6%). The aim of the work reported below was to provide practical aids to industry in evaluation of conditions of transformer insulation. The following is a brief summary of the key outcomes of the work for 2002. Investigation into factors affecting moisture and gas dynamics in aged transformer oil: Establishment of effect of temperature on evolution and absorption of moisture and gases in oil. Further advancing of the hypothesis proposed in 2001 suggesting that the cellulose particles caused the observed changes in the concentrations of moisture and gases. Examination of decomposition of contamination particles in aged oil before and after thermal stress and comparison with contaminants in new oil.

Completion of the new classification procedure for ranking of power transformers by the level of moisture: The traditional approach to the moisture assessment in operating transformers is based on a number of assumptions. In the most cases, some or even all of these assumptions are wrong. As a result, the moisture assessment is incorrect.

The new classification procedure allows ranking of critical transformers in terms of moisture from a population of power transformers for further continuous monitoring. A requirement to evaluate the water solubility characteristic of oil for the accurate ranking of aged transformers has been shown. Development of guidelines for an improved procedure of oil sampling from operating transformers for evaluation of water content of oil: This document guides operators on how and when sampling oil from a transformer to obtain reliable results, and how to obtain reliable measurement of oil temperature during sampling.

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Development of a new test method for evaluation of water solubility in oil: A set-up for the water solubility test is shown. Description of the theory for solubility of water in oil is provided.

The new test method developed is proposed as a future ASTM standard test method for evaluation of water solubility in oil. Improvement of the stand-alone software application Transformer Moisture Monitor (TMM): A list of features of an upgraded version of the TMM is provided. Implementation of the Monash water-in-paper (WIP) algorithm in the MMW: An overview of integration of the WIP into the MMW is provided. Investigation to determine whether moisture has an effect on frequency response analysis (FRA) signatures using a newly factory built power transformer: The FRA study was conducted on a real transformer with a layer type winding. The study on the transformer has shown that moisture does have an effect on the FRA signatures. Also, the FRA study has shown that the other two factors, mechanical displacement and oil impregnation of insulation, have an effect on the FRA signatures. Delivery of a course on moisture assessment in power transformers: The EPRI Seminar Moisture Management in Transformers has been delivered to a workshop held in Edison, New Jersey on October 30 November 1, 2002.

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ACKNOWLEDGMENTS
The work of the following university contributors to the contract is gratefully acknowledged: Mr. Seamus Delaney Prof. Greg Egan Ms. Sarina Kennedy Mr. Martin Linzner Mr. Nick Lelekakis Dr. Andrew Reykherdt Prof. Peter Wallace

The considerable assistance of the following external personnel is also acknowledged: Mr. Larry Johnson Mr. Martin Thomas PSE&G, New Jersey, USA Wilson Transformer Company, Melbourne, Australia.

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CONTENTS

1 INTRODUCTION ................................................................................................................. 1-1 Background ........................................................................................................................ 1-1 General Description of Project............................................................................................ 1-1 Objectives of Project for 2002............................................................................................. 1-3 Reference........................................................................................................................... 1-3 2 DEVELOPMENT OF A NEW EPRI PROJECT LABORATORY AT MONASH UNIVERSITY .......................................................................................................................... 2-1 Background ........................................................................................................................ 2-1 General Description of New EPRI Project Laboratory......................................................... 2-2 Reference........................................................................................................................... 2-3 3 TESTING OF AGED OIL AT MONASH ............................................................................... 3-1 Introduction ........................................................................................................................ 3-1 Dynamics of Moisture ......................................................................................................... 3-1 Dynamics of Dissolved Gases ............................................................................................ 3-2 Analysis of Results of Tests 2, 3 and 4............................................................................... 3-4 Microscopic Study into Contamination of Aged and New Transformer Oil .......................... 3-4 Investigation Parameters ............................................................................................... 3-4 Results from Contamination Analysis............................................................................. 3-5 Reference........................................................................................................................... 3-8 4 NEW PROCEDURE FOR CLASSIFICATION AND RANKING OF OPERATING POWER TRANSFORMERS ON THE BASIS OF WATER CONTAMINATION....................... 4-1 Background ........................................................................................................................ 4-1 Moisture Equilibrium in Transformer Paper/Oil System....................................................... 4-2 Diffusion of Moisture within Oil Impregnated Insulation....................................................... 4-5 Classification Procedure..................................................................................................... 4-6 Case Study......................................................................................................................... 4-9

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Sampling Port Location, Oil Characteristics, Cooling Mode, and Oil Preservation System Considerations......................................................................................................4-10 Effect of Sampling Port Location...................................................................................4-10 Effect of Water in Oil Solubility......................................................................................4-10 Effect of Cooling Mode..................................................................................................4-11 Effect of Oil Preservation System .................................................................................4-11 Conclusions.......................................................................................................................4-11 References........................................................................................................................4-11 5 DEVELOPMENT OF GUIDELINES FOR IMPROVED PROCEDURE OF OIL SAMPLING FROM OPERATING TRANSFORMERS FOR EVALUATION OF WATER CONTENT OF OIL.................................................................................................... 5-1 Introduction ........................................................................................................................ 5-1 Scope ............................................................................................................................ 5-1 Limitation ....................................................................................................................... 5-1 References .................................................................................................................... 5-2 Sampling of Oil from Operating Transformers .................................................................... 5-2 Oil Sampling at a Higher Temperature........................................................................... 5-2 Measurement of Oil Temperature During Oil Sampling....................................................... 5-3 Transformers with Forced Oil Circulation ....................................................................... 5-3 Transformers with Natural Oil Circulation....................................................................... 5-3 Means for Temperature Measurement During Oil Sampling........................................... 5-3 Handling of Oil Samples ..................................................................................................... 5-3 In the Field..................................................................................................................... 5-3 In the Laboratory............................................................................................................ 5-4 References......................................................................................................................... 5-4 6 DEVELOPMENT OF A NEW TEST METHOD FOR SOLUBILITY OF WATER IN TRANSFORMER OIL, PROPOSED AS THE FUTURE ASTM STANDARD TEST METHOD ................................................................................................................................ 6-1 Introduction ........................................................................................................................ 6-1 Background ................................................................................................................... 6-1 General Theory.............................................................................................................. 6-2 Development of a New Test Method .............................................................................. 6-3 Background and Brief Description ............................................................................. 6-3 Choosing the Most Appropriate Ranges of Test Parameters for New Test Method................................................................................................. 6-3

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Proposal for ASTM Standard Test Method for Solubility of Water in Transformer Oil.......... 6-5 Scope ............................................................................................................................ 6-5 Referenced Documents ................................................................................................. 6-5 Terminology................................................................................................................... 6-5 Definitions ................................................................................................................. 6-5 Symbols .................................................................................................................... 6-5 Summary of Test Method............................................................................................... 6-6 Significance and Use ..................................................................................................... 6-6 Apparatus ...................................................................................................................... 6-7 Acquisition of Test Data ................................................................................................. 6-8 Sampling........................................................................................................................ 6-9 Procedure ...................................................................................................................... 6-9 References........................................................................................................................6-10 7 TMM IMPROVEMENTS ....................................................................................................... 7-1 Reference........................................................................................................................... 7-2 8 IMPLEMENTATION OF WATER-IN-PAPER ALGORITHM IN MMW: USERS GUIDE....... 8-1 9 FEASIBILITY STUDY TO DETERMINE WHETHER MOISTURE HAS AN EFFECT ON FREQUENCY RESPONSE ANALYSIS (FRA) SIGNATURES IN A TRANSFORMER USING A FACTORY DRYOUT PROCESS ........................................ 9-1 Objective ............................................................................................................................ 9-1 Introduction ........................................................................................................................ 9-1 Basic Principle of the Transfer Function (TF) Method ......................................................... 9-2 Theoretical Background ................................................................................................. 9-2 Frequency Ranges and Frequency Resolution .............................................................. 9-3 Signal Processing .......................................................................................................... 9-4 Test Set-Up for FRA Testing of Transformers .................................................................... 9-4 FRA Testing of Transformer undergoing Dryout in Conventional Oven .............................. 9-5 Description of Transformer ............................................................................................ 9-5 Description of Oven and Dryout Process ....................................................................... 9-6 Results of Capacitance and Tan Delta Measurement During Dryout of Transformer ..... 9-7 FRA Test Results........................................................................................................... 9-8 Effect of Moisture on FRA Signatures ....................................................................... 9-8 Effect of Re-clamping on FRA Signatures ................................................................9-11

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Effect of Oil Impregnation on FRA Signatures ..........................................................9-13 Conclusions.......................................................................................................................9-15 References........................................................................................................................9-15 10 EPRI SEMINAR MOISTURE MANAGEMENT IN TRANSFORMERS ...........................10-1 A MONASH EXPERIENCE WITH MEASUREMENT OF WATER CONTENT OF OIL USING MITSUBISHI KARL FISCHER MOISTURE METER MODEL CA-06 ................... A-1 Effect of Air Bubbles on WCO Measurement...................................................................... A-1 Effect of Excessive Quantity of Oil Added to Titration Cell.................................................. A-2 Effect of Oil Sample Quantity on Accuracy of WCO Measurement ..................................... A-3 Injection of Oil Sample into Cell of KFMM CA-06................................................................ A-4 Evaluation of Performance of KFMM CA-06 ....................................................................... A-4 Trouble Shooting and Handy Tips ...................................................................................... A-5 Reference........................................................................................................................... A-5

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LIST OF FIGURES
Figure 3-1 Dynamics of Moisture in Tests 2, 3 and 4............................................................... 3-2 Figure 3-2 DGA Results for Tests 2, 3 and 4........................................................................... 3-3 Figure 3-3 Microscope and Slides Analyzed for Dark Field Microscopy................................... 3-5 Figure 3-4 Examples of Contamination in Aged Oil ................................................................. 3-6 Figure 3-5 Examples of Contamination Present in Aged Oil after Thermal Stress of 98C ...... 3-7 Figure 3-6 Examples of Contamination Present in New Oil ..................................................... 3-8 Figure 4-1 Set of Equilibrium Curves WCO as a Function of Oil Temperature for Different WCP................................................................................................................................ 4-4 Figure 4-2 Diffusion Time for a 1 mm Pressboard Plate .......................................................... 4-5 Figure 4-3 Color Chart for Transformer Classification Procedure ............................................ 4-6 Figure 4-4 Flow Diagram of Classification Procedure.............................................................. 4-8 Figure 4-5 Trajectories for Utility Transformers in WCO and T Domain ..................................4-10 Figure 6-1 Set-up for Test Method for Solubility of Water in Transformer Oil........................... 6-7 Figure 7-1 TMM v1.01 Graphic User Interface ........................................................................ 7-2 Figure 8-1 MMW Start Menu ................................................................................................... 8-1 Figure 8-2 Main Menu of Performance Assessment Module ................................................... 8-2 Figure 8-3 Tabbed Query Dialog; Common Tab...................................................................... 8-2 Figure 8-4 Tabbed Query Dialog for Selection of Top Oil Temperature................................... 8-3 Figure 8-5 Top Oil Temperature Graph by MMW Query.......................................................... 8-4 Figure 8-6 Tabbed Query Dialog for Selection of Relative Saturation...................................... 8-5 Figure 8-7 Top Oil Relative Saturation Graph by MMW Query ................................................ 8-6 Figure 8-8 Equation Editor Dialog Box showing WCO Equation.............................................. 8-6 Figure 8-9 Result of the Query to Calculate WCO................................................................... 8-7 Figure 8-10 WCO Plot after Executing the Graph Query ......................................................... 8-8 Figure 8-11 Equation Editor Dialog Box Showing WCP Equation............................................ 8-8 Figure 8-12 Calculated WCP (4.526) and Confidence Level (0.7649) for given T and RS....... 8-9 Figure 9-1 TF Method as a Linear Two-port Network .............................................................. 9-2 Figure 9-2 Principle of Transfer Function Calculation .............................................................. 9-2 Figure 9-3 Winding Connections for FRA Testing ................................................................... 9-4 Figure 9-4 FRA Test Diagram ................................................................................................. 9-4 Figure 9-5 Configuration of Phases of HV Winding for FRA Measurements............................ 9-5

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Figure 9-6 Change of Ratio C(x)/C(f) During Drying Process, where C(f) is a Final Capacitance Measured on Day 6 of Dryout (C(f) = 9,305 pF)............................................ 9-7 Figure 9-7 Change of Ratio tan(x)/tan(f) During Drying Process, where tan(f) is a Final Tan Delta Measured on Day 6 of Dryout (Tan(f) = 0.39%) .................................... 9-7 Figure 9-8 Effect of Moisture on FRA Signatures within the Five Frequency Sweeps for the 1st Day of Dryout (Comparison between FRA 1 and FRA 2, See Table 9.1 for Details)....................................................................................................................... 9-9 Figure 9-9 Effect of Moisture on FRA Signatures within the Five Frequency Sweeps for the Remaining Five Days of Dryout (Comparison between FRA 2 and FRA 5, See Table 9-1 for Details)...............................................................................................9-10 Figure 9-10 Effect of Re-Clamping on FRA Signatures within the Five Frequency Sweeps (Comparison between FRA 5 and FRA 6, See Table 9-1 for Details)................9-12 Figure 9-11 Effect of Oil on FRA Signatures within the Five Frequency Sweeps (Comparison between FRA 6 and FRA 7, See Table 9-1 for Details) .............................9-14

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LIST OF TABLES
Table 1-1 Granting Bodies and Distribution of Costs for Part 4 Work ...................................... 1-2 Table 4-1 Nameplate Data of Transformer Units ..................................................................... 4-9 Table 4-2 Temperature (C) and WCO (ppm) Records for the Three Selected Transformers................................................................................................................... 4-9 Table 6-1 Relative Saturation at 30C and 80C at Different Levels of WCO for New Oil ........ 6-4 Table 9-1 Time Schedule of FRA Test .................................................................................... 9-6 Table A-1 Measurement of WCO with and without Introduced Air Bubble ............................... A-2 Table A-2 Measurement of WCO for Five Concessive Samples of Oil .................................... A-2 Table A-3 Effect of Oil Quantity on a % Accuracy for WCO=10 ppm....................................... A-3 Table A-4 Quantities of Oil to Obtain 3% Accuracy of WCO Measurement ........................... A-3 Table A-5 Evaluation of Performance of KFMM CA-06 using Standard 1.0............................. A-4

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1
INTRODUCTION
Background
Utilities throughout the world have experienced the damaging effects of moisture in power transformers. Some of these damaging effects result in long-term outages, prolonged filtering processes and even catastrophic failures. Many studies have been performed to define the consequences of water contamination. Many of these studies define adverse transformer impacts ranging from decreased dielectric strength, loss of life, tank and core corrosion to vapor bubble evolution. Other studies have defined acceptable levels of moisture, mechanisms of moisture ingress, the dynamics and interactions between the oil, winding insulation, temperature, load, etc., as well as safe operating limits for wet transformers. These studies, theories, and models typically utilize and require manual methods of sampling, recording, analyzing, and evaluating test data for theory verification. These manual processes require the Utility to spend an inordinate amount of time and resources for this process. Moisture in oil-paper insulating systems continues to plague the Utility Industry and continues to have an adverse affect on the long-term health of transformers. To protect this expensive asset it was determined the Monash research should provide technical solutions under real life conditions utilizing new tools, technologies and systems in hopes of eliminating the resource intensive methods currently utilized. Under EPRI sponsorship, Monash University and a number of utilities and other companies have partnered to utilize the dynamic behavior of moisture in oil-paper insulation systems from previous studies and apply the findings to operating transformers. The intent of utilizing the results from this new concept of water-in-paper activity is to accurately assess water content in transformer insulation systems.

General Description of Project

Work related to EPRI funded project Transformer Insulation Behavior during Overload has been underway since 1994. Prior to the current stage, called Part 4, the three other stages of activity have taken place, consisting of the Part 1 work program (1994-1996), Part 2 work program (1996-1998) and Part 3 work program (1999-2000). The key results of the previous work are: Extended knowledge and expertise on moisture and gas dynamics in transformers. High quality experimental facilities. Criteria for formation of bubbles and free water in transformer insulation. 1-1

Introduction

A new method for WIP assessment of transformer insulation. The successful application of the WIP algorithm on a number of operating and new transformers. Development of the Transformer Moisture Monitor TMM software application for the assessment of moisture condition in transformer insulation utilizing the WIP algorithm. Positive feedback from the industry on the results obtained.

The current (Part 4) work program commenced in January 2001. The report on work completed in 2001 is available [1]. Also in 2001 the EPRI-Monash Project research team has been awarded an Australian Research Council (ARC) Strategic Partnership with Industry Research and Training (SPIRT) Scheme Grant on a research project entitled: Continuous Assessment and Dynamic Rating of Power Transformers using Dynamics of Dissolved Gases. The SPIRT Scheme is an initiative of the Australian Government and it provided a three-year contribution (2001, 2002 and 2003) towards the project. EPRI acts as an Industrial Partner on the Scheme with an equal contribution towards the project. The SPIRT scheme covers projects having roughly equal funding from Australian Government and industrial sources. The project described here has two components from EPRI, the industrial collaborator, one to cover an appropriate amount to match the SPIRT funding and a separate amount to fund the additional activity necessary to achieve the enhanced project goals. The Centre for Electrical Power Engineering (CEPE), Monash University, is also providing input in the form of some equipment and the secondment of Dr Valery Davydov towards the Part 4 work program. A distribution of costs between the granting bodies for Part 4 work is given in Table 1-1.
Table 1-1 Granting Bodies and Distribution of Costs for Part 4 Work Granting Body EPRI (including EPRI SPIRT) Australian Government, SPIRT Monash University Total Source of Funding Agreement EP-P5289/C2622 Continuous Assessment and Dynamic Rating of Power Transformers Using Dynamics of Dissolved Gases CEPE Distribution of Costs, % 72.1 18.3

9.6 100

In addition to the mentioned above contribution towards the project, the management of Monash University provides funds to built a new larger and more sophisticated EPRI-Monash Project Laboratory in 2002-2003. The funds are covered by non-EPRI related sources. The new laboratory is designed to replace the existing laboratory, which has insufficient space to house the project further. Development of the new laboratory is described in Chapter 2 of this report. 1-2

Introduction

Objectives of Project for 2002

The aims of the project for 2002 were to: Conduct a study into factors affecting moisture and gas dynamics in aged transformer oil. Complete the new classification procedure for ranking of power transformers by the level of moisture. Develop guidelines for an improved procedure of oil sampling from operating transformers for evaluation of water content of oil. Develop a new test method for evaluation of water solubility in oil, to be proposed as a future ASTM standard test method. Improve the stand-alone software application Transformer Moisture Monitor (TMM). Implement the Monash water-in-paper (WIP) algorithm in the MMW. Conduct a feasibility study to determine whether moisture has an effect on frequency response analysis (FRA) signatures using a newly factory built power transformer. Deliver a course (seminar) on moisture assessment in power transformers.

Sections below present report on work done in 2002.

Reference
1. Transformer Condition Assessment and Diagnostic Methods: Phase 4: Green-Yellow-Red Diagnostic Methods, EPRI, Palo Alto, CA: 2002. 1001940.

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2
DEVELOPMENT OF A NEW EPRI PROJECT LABORATORY AT MONASH UNIVERSITY

Background
The existing EPRI-Monash Project Laboratory is located in a corner of the High Voltage Laboratory of Monash University, Building 36. The EPRI-Monash Project Laboratory was built in 1994 specifically for the EPRI funded research project on power transformers. Initially the laboratory consisted of a shielded room of 4.6 meters x 3.3 meters and called EPRI Project Electrical Testing Laboratory [2]. The room was screened with aluminum foil. Considerable effort was given to reducing the background interference in the Testing Laboratory: the noise level achieved in the laboratory was less than the equivalent to a partial discharge magnitude of 2 pC. At a later stage the air conditioner was installed in the room to continuously maintain the temperature level within the range of 20 to 22C. All main test rigs and computerized data acquisition and control systems are located here, and all continuous real-time experiments are conducted in this room. Another laboratory, called EPRI Project Processing Laboratory, was developed in the area of 4.0 meters x 4.0 meters adjacent to the Testing Laboratory. The purpose of this laboratory was to carry out non-electrical experimental work for the contract. Most chemical analysis work, particularly water content measurement using the Karl Fisher titration apparatus, mass measurement using balances, and rig experiments involving heat and vacuum moisture removal from transformer oil and paper, were carried out in this laboratory [2]. However, over the years an increased workload has led to a situation, where the currently available laboratory space has become overcrowded. It does not always provide the necessary environment for experiments with transformer oils where proper ventilation is vital. Fume cupboards and proper storage are also absent in the current laboratory space. At the end of 2001, taking into account the importance of the on-going EPRI-Monash Project, the management of Monash University has decided to build a new larger laboratory fitted with all necessary features to house the project. It was decided to locate the new Laboratory in the premises of the former Wet Laboratory of Monash University, Building 35. The Project team completed the initial design of the new Laboratory in February 2002. Division of Facilities and Services of Monash University has produced floor and sealing plans on architectural, structural, chemical, mechanical and electrical aspects of the new Laboratory. A tender process for construction of the new Laboratory was closed in June 2002 and a recommendation was made for the acceptance of a builder for the construction. 2-1

Development of a New EPRI Project Laboratory at Monash University

Currently, the construction works are in progress. The expected total cost of the development has been estimated at $355,000 AUD. The cost is being covered by non-EPRI related sources.

General Description of New EPRI Project Laboratory

The new EPRI Project Laboratory is located in the premises of the former Wet Laboratory, Building 35, with an area floor of approximately. 16 meters x 6 meters. The new Laboratory will have the following three rooms: Room A: Shielded room Room B: Processing and storage room Room C: Office

The shielded room (Room A) will be built as a Faraday cage. Copper foil will be used for the Faraday cage. The foil will be applied to the walls, ceiling and floor. Copper foil will cover the door. A flexible copper wire will connect the foil on the door to the foil on the walls. A false ceiling will be installed in the shielded room to allow for pipes above it and to provide a support for the copper foil at the ceiling. A timber frame will be used to support the foil on the walls. Strips of the copper foil will be joined as follows: the edges of the strips will be overlapped by approx. 100 mm and soldered. The Faraday cage will be connected to a grounding system at a single point, which will be located close to the HV transformer. A copper strip for the grounding of instruments will be positioned along the four walls of the room and connected to the grounding system at the same single point. Temperature control (e.g. 201C) will be maintained in the Laboratory continuously. An inlet and an outlet of the air-conditioning system of the shielded room will be built as a standard honeycomb item. Proper air ventilation for efficient removal of oil fumes will be provided for the oil testing area. A fume cupboard with a proper ventilation system will be installed in the new Laboratory. A proper chain fixture will be made for a few gas cylinders to be kept in Rooms A and B. A water sink and an eye-washing facility will be installed in Room B. The new Laboratory will require a three-phase filtered power supply at the two voltage levels of 415V and 240V. A main 240V switchboard will contain separate switches for all electrical circuits of the Laboratory. Lighting will consist partly of luminescent lamps and partly of filament lamps; both connected to separate switches. Electrical power to important pieces of equipment will be supplied via an uninterruptible power source (UPS). Each room will have a number of computer terminals connected to a computer network. Room A will be connected to the network with a fiber optic cable, while Rooms B and C with a conventional cable. Each room will have a telephone line. Compressed air outlets will be located in rooms A and B. 2-2

Development of a New EPRI Project Laboratory at Monash University

A new gas chromatograph (GC) has arrived. A new rig for gas-from-oil extraction for dissolved gas analysis (DGA) has also arrived. The new Laboratory is not complete, and the available laboratory has no free space to accommodate this equipment. Thus, an additional room has been allocated, where the GC and the gas extraction rig were temporary assembled and tested.

Reference
2. V.G. Davydov and W.J. Bonwick, Power Transformer Behavior During Overload: Phase 1: Dynamic Behavior of Moisture, EPRI, Palo Alto, CA: 1999. TR-113390.

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3
TESTING OF AGED OIL AT MONASH
Introduction
The work presented in this chapter is a continuation of the study commenced at Monash in 2001. The initial results of the testing of aged oil were reported in the previous report [3], Chapter 3. A few liters of oil were sampled from an old transformer operating in a US utility for more than 60 years and sent to Monash for testing. During the testing, a strange behavior of dissolved moisture and gases was observed. While testing a vessel containing the oil only, it was found that with the stirring of the oil, first at room temperature, and then at an elevated temperature, the content of dissolved water and some gases had risen, while the content of other gases had fallen or had not changed [3]. The three tests, Test 1, Test 2 and Test 3 were reported in [3], Chapter 3. Test 4, started on 20 December 2001 and continued in January and February 2002, is the continuation of Tests 2 and 3. Results of Test 4 are reported in this chapter. In Test 2 (refer to [3], Chapter 3) the oil was stirred at the temperature of 22-23C for three weeks. In Test 3 the temperature of this oil was raised from 22C to 98C and kept at this level for one week. In Test 4 the temperature was dropped from 98C back to 22C and kept at this temperature for seven weeks. Thus, the total duration of Tests 2, 3 and 4 was 11 weeks. The joint results of the three tests, Test 2, Test 3 and Test 4, are shown below.

Dynamics of Moisture
Dynamics of moisture in Tests 2, 3 and 4 is shown in Figure 3-1. From Figure 3-1 we can see, that during the high temperature course (98C, Test 3) and then during the low temperature course (22C, Test 4), moisture content of oil changed significantly. At the end of Test 2 at 22C the value of the relative saturation (RS) was 50% and the value of the water content of oil (WCO) was 52 ppm. Following the temperature rise to 98C, the RS had dropped to 8.3% and then started to rise gradually. The WCO started to rise with the rise of temperature. By the end of Test 3 (day 7 at 98C) the RS had risen to 11.5%. The WCO, calculated from the sensors data, had risen to 124 ppm, while the WCO measured by KF had risen to 105-110 ppm (see Figure 3-1). 3-1

Testing of Aged Oil at Monash

Tests 2, 3 and 4 100 T oil, C T, C 50

100 75 RS, % 50 RS 25 0 RS=100%

120 WCO, ppm 100 80 60 40 23-Nov-01

KF

WCO

7-Dec-01

21-Dec-01 Date

4-Jan-02

18-Jan-02

1-Feb-02

Figure 3-1 Dynamics of Moisture in Tests 2, 3 and 4

In Test 4, following the temperature drop from 98C back to 22C, the RS had jumped to 100%, and the oil was cloudy for the following three days (see the blue triangles in the RS graph in Figure 3-1). The moisture sensor had become saturated at RS>84% and did not respond to a true value of relative saturation for the cloudy oil. In the three days the oil became clear and the moisture sensor started to show accurate readings again. The RS had decreased to 79% and stabilized at this level by the end of Test 4. For the temperature drop from 98C to 22C, the WCO had dropped form 124 to 90 ppm with the speed of drop of the temperature, i.e. within three hours. After that, during the following three weeks, the WCO was gradually decreasing to 79 ppm, and finally had stabilized at this level for the remaining four weeks of Test 4 (see Figure 3-1).

Dynamics of Dissolved Gases

DGA results for Tests 2, 3 and 4 are shown in Figure 3-2. 3-2

Testing of Aged Oil at Monash

Tests 2, 3 and 4 T oil 50 0

100 T, deg C

400 H2 and CH4 200 H2 0 CH4

C2H4 and C2H6

300 150 C2H6 0

5400

C2H4

CO and CO2

2700 0 80000

CO2

CO

N2

60000 N2 40000

26000 O2 13000 0 23-Nov-01 O2

7-Dec-01

21-Dec-01 Date

4-Jan-02

18-Jan-02

1-Feb-02

Figure 3-2 DGA Results for Tests 2, 3 and 4

Analysis of Figure 3-2 shows the following. The content of the dissolved combustible gases (H2, CH4, C2H4, C2H6 and CO) and carbon dioxide (CO2) rose insignificantly during the course of Test 2 (22C), but rose dramatically during the course of Test 3 (98C). In Test 4, following the temperature drop from 98 to 22C, a minor drop in the concentration of these gases had been noted (see Figure 3-2). Most probably, this was due to the dilution of the tested oil in the flask with low-gas-content oil from the conservator. However, in contrast to the concentration of water in oil, the concentration of these gases did not change much over the seven weeks of Test 4 at 22C.

3-3

Testing of Aged Oil at Monash

In Test 2 the level of oxygen had dropped from 22,000 ppm to 9,118 ppm. In Test 3 the level of oxygen had dropped further to a few tens of ppm and stayed at this low level during the whole duration of Test 4 (see Figure 3-2). The level of nitrogen in Tests 2, 3 and 4 varied around an average value and was not affected by the temperature changes (see Figure 3-2).

Analysis of Results of Tests 2, 3 and 4

A hypothesis has been proposed in [3]: The hypothesis assumes that the changes in concentrations of the dissolved in oil moisture and gases were caused by the following two mechanisms: (1) Cellulose particles have released moisture and gases into the oil (2) Decomposition of oil and cellulose due to the mechanical and thermal stresses has resulted in the production of moisture, combustible gases and carbon dioxide, and in the consumption of oxygen The new test results reported above for Test 4 add some knowledge to the phenomenon and allow advancing the proposed hypothesis further. The difference between the final WCO at the end of Test 4 and the initial WCO at the beginning of Test 3 is calculated as 79-52=27 ppm. This result shows that a certain amount of water has been generated in oil during the test and remains there permanently, thus, supporting mechanism (2). For the temperature drop from 98C to 22C at the beginning of Test 4, the WCO has dropped form 124 to 90 ppm within three hours, i.e. 124-90=34 ppm of water were absorbed immediately by some substances in the oil, most probably by the fiber particles. This observation supports mechanism (1). However, during the two weeks at 22C following the temperature drop in Test 4, the WCO was gradually decreasing from 90 ppm to the final level of 79 ppm. This is a relatively slow process. What may cause this slow decrease in the WCO? Fiber particles would release and adsorb water much faster (note a minor temperature fluctuation in the second last week of Test 4 and an immediate response in the fluctuations of RS and WCO caused by the cellulose fibers). At the moment this question remains unanswered. Results of the dissolved gas analysis support mechanism (2) and do not reject mechanism (1).

Microscopic Study into Contamination of Aged and New Transformer Oil

Investigation Parameters Contamination in transformer insulation can be a serious problem. Paper insulation degrades over time due to temperature, moisture and oxidation. Wear and tear of paper insulation reduces its mechanical strength and allows fibers to break off and deposit in the oil. Moisture (and presumably gases) can be bound to the fibers, such that they are stored, to be released at a later time due to increased temperatures, forced oil circulation, etc. 3-4

Testing of Aged Oil at Monash

The intention of this investigation then was two fold; first, to investigate the types of contamination found in transformer oil samples, and discuss possible origins for them, and second, to find any evidence that moisture and gases bound previously to paper fibers are released into the oil due to temperature, stirring etc., thereby increasing the moisture and gas levels seen in the oil tested. This was done by viewing the contaminated aged oil samples using dark field microscopy. The study was conducted using a facility available at Department of Anatomy, Faculty of Medicine of Monash University. A small droplet of the oil sample was flattened out between two glass slides, and sealed using a Teflon base to minimize air exposure (see Figure 3-3).

Figure 3-3 Microscope and Slides Analyzed for Dark Field Microscopy

The paper fibers (and other types of contamination) could then be easily distinguished, and the level of paper fiber degradation analyzed. Results from Contamination Analysis The microscopy study was conducted for the following three samples of oil: Aged oil sampled from the operating 60+-year-old transformer, representing conditions that the oil had prior to Test 2 Aged oil sampled following Test 4, after significant thermal stress at 98C was applied to the oil New unfiltered oil 3-5

Testing of Aged Oil at Monash

The figures below show a selection of microscopic pictures (scale: approx. 17.5 m in 10 mm). Figure 3-4 shows examples of contamination found in the oil sampled from the operating old transformer.

Figure 3-4 Examples of Contamination in Aged Oil

Paper fibers present in the aged oil were for the most part structurally stable, with their edges either congealed or smoothed over, presumably from spending a good portion of time in the oil. Any evidence of tearing or shredding presumably was due to when the fiber was torn away from the bulk paper insulation. The fibers appeared to be elastic and swelled, signifying moisture presence. Metal contamination found also appeared very stable, relative to metal samples seen after heating. Figure 3-5 shows examples of contamination found in the oil sampled following Test 4, after significant thermal stress at 98C was applied to the oil.

3-6

Testing of Aged Oil at Monash

Torn fibre - incomplete

Torn fibre complete

Torn fibre shredded

Metal chard broken up

Figure 3-5 Examples of Contamination Present in Aged Oil after Thermal Stress of 98C

The paper fibers seen above appeared to have been significantly degraded due to the thermal stress. One could see that the fibers present in the oil have been torn, shredded, twisted, and in some cases completely shredded. Metal contamination has also been broken up. It is therefore not hard to imagine that any moisture (or gases) previously bound to the paper fibers would have been released into the oil, thereby resulting in a higher dissolved gas and moisture content. Figure 3-6 shows examples of contamination found in new unfiltered oil, sampled from a 200-litre drum supplied by the oil manufacturer. Comparing the contamination level in a new oil sample, it was remarkable to see that there is substantial contamination even in unused transformer oil. Glass chards, paper fibers, metals, vinyls, and other indistinguishable types appear in the oil. This reiterates the fact that any effect, contamination presence has on the gas dynamics and gas evolution at low temperatures, needs to be accounted for in new transformers, not only in aged transformers.

3-7

Testing of Aged Oil at Monash

Fibre and metal

Glass chard

Large piece of junk

Figure 3-6 Examples of Contamination Present in New Oil

Metal chard

Reference
3. Transformer Condition Assessment and Diagnostic Methods: Phase 4: Green-Yellow-Red Diagnostic Methods, EPRI, Palo Alto, CA: 2002. 1001940.

3-8

4
NEW PROCEDURE FOR CLASSIFICATION AND RANKING OF OPERATING POWER TRANSFORMERS ON THE BASIS OF WATER CONTAMINATION

Background
On-line continuous moisture monitoring has been used for moisture evaluation for the past few years and has proved to be one of the most advanced techniques of moisture assessment in a transformer oil/paper insulation complex. Although this approach is becoming more and more utilized in industry there are a number of points for consideration: Installation of additional monitors and data communication systems on every transformer across a utility might not be practical The majority of transformers are still in good condition as far as moisture is concerned Moisture meters are relatively inexpensive, however installation, service and maintenance needs should be taken into consideration It is always a challenge to identify the most critical units for moisture monitoring

Given all of the above, we can conclude that not every transformer in the utility requires online moisture monitoring. A set of moisture equilibrium curves relating water content of oil (WCO) to water content of paper (WCP) applicable to transformer insulation has been known for decades [4-6]. Due to the fact that a transformer is never in equilibrium the applicability of these curves in practice have always been questionable. In spite of the precautions made by many practical engineers these curves are still being widely used for the estimation of dryness of transformers during operational and storage stages. It is important to understand that a number of assumptions are put in place when suggesting the use of moisture equilibrium curves. These assumptions are often either not valid or misinterpreted and therefore used incorrectly. Among the most common incorrect assumptions are the following: Assumption 1: Moisture equilibrium is readily attainable. Thus, water-in-paper content can be evaluated from the measurement of water-in-oil content with the help of the moisture equilibrium charts. 4-1

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Assumption 2: Water content of oil in the transformer is uniformly distributed across the transformer tank. Thus, the top oil temperature can be used when relating the moisture-in-oil taken from the bottom drain valve to moisture in cellulose insulation. Assumption 3: The water solubility characteristic of oil in the operational transformer is unique for all new mineral oils and does not change with aging. Thus, well-known moisture equilibrium charts are applicable to any mineral transformer oil. Assumption 4: Value of WCP obtained from the moisture equilibrium chart corresponds to the moisture content by dry weight of the bulk cellulose insulation. Assumption 5: Absorption and desorption of water from paper can be described by the same equations. Thus, the phenomenon of hysteresis is ignored. Assumption 6: The time constant to attain moisture equilibrium is the same as that of time constant to achieve temperature equilibrium. Assumption 7: The sorption isotherms Equilibrium Relative Humidity (ERH) versus WCP, which were used to generate the WCP versus WCO curves, are universal for all kinds of cellulose material used in a transformer. Thus, 1mm barrier insulation would have the same sorption isotherms as 30-40 mm supporting wood rings.

In most cases these assumptions are not valid. As a result, the moisture assessment based on the published equilibrium charts may not correspond to the true value of water content of paper (WCP). Over years of research on an EPRI supported project on power transformers, extensive new theoretical and practical knowledge has been gained at Monash University, Australia. At present knowledge is available to the industry in the form of practical applications and software tools, which are described in the further sections.

Moisture Equilibrium in Transformer Paper/Oil System

To evaluate the amount of water present in paper by measuring water in oil, knowledge of a basic relationship between the two media has to be utilized. Under equilibrium conditions this relationship is known as moisture equilibrium curves or moisture equilibrium charts. There are two different approaches to devise the equilibrium charts. The first method is described in detail in [7, 8] and provides the technique for indirect construction of the water-in-oil versus water-inpaper equilibrium curves. The authors method combined WCO versus % RH curves and moisture-in-wood pulp versus % RH made from Jeffries experimental data [9] to generate WCP versus WCO curves, which were experimentally obtained in early 1960s by French scientists [4]. Another approach to construct WCO vs. WCP curves is based on approximation of known empirical equations relating WCP and % RH, such as Freundlich type WCP=k pw m [10], where pw is the water vapor pressure and m is less than 1.

4-2

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

This formulation is known to have increased error for the values of RS exceeding 50%. As it is known, the fluctuation of RS in the range of 50% and above is already an indication of very wet transformer insulation. No further analysis is required to confirm this. Therefore developing the classification procedure for moisture assessment, we adopted the later approach, as it allowed us to derive mathematically the classification chart discussed further in the chapter. Our goal in the development of this classification procedure was to utilize the methods of measurement of WCO and T with the knowledge of equilibrium curves, to account for moisture dynamics. The first step in this approach was to derive the relationship between WCO and T for different values of WCP. The formulation presented here is the approximation of the methods used for derivations of equilibrium curves, developed earlier by Fessler et al [10]. This approximation has a good agreement with published [11] curves in the relative saturation range of 0 - 40%. This range is often considered as the most practical range for moisture assessment. The equilibrium moisture concentration of paper or water content of paper (WCP) is defined as a function of moisture partial pressure and temperature by the Freundlich relationship as:

WCP = K1 pw

1/ n

[4-1]

where pw is the moisture partial pressure, K1 is a constant and n is an integer.

K1 = A exp( B / T ) ,

[4-2]

where A and B are constants and T is the absolute temperature. The constants A, B and 1/n are taken from the Fesslers bubble model [10] and numerically equal to 2.173 x 10 7, 4725 and 0.6685. Water concentration in oil WCO is proportional to the partial water pressure and is defined according to the Henrys Law as: WCO = K 2 p w , where, K2 is the Henrys Law constant. When the water solubility characteristics S(T) are known the Henrys Law constant is determined as
K2 = S (T ) , pS ( T )

[4-3]

[4-4]

where pS(T) saturated vapor pressure. 4-3

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

The water solubility in dielectric liquid are given by: S(T)=S exp(Ea/RT), [4-5]

where Ea is the activation energy, R is the gas constant and S is the solubility value when T approaches infinity. Performing regression analysis on the data from [12] it was found that S = 1.94E+07 and Ea/R = -3750.30. Then combining [4-1] and [4-2] we obtain for pw pw = 9.2683 109 WCP1.4959 e(-7069/T) Substitution [4-6] and [4-4] into [4-3] yields WCO as a function of T: WCO = 19.4 106exp(-3750/T)/ps 9.2683 x 109 WCP1.4959 e(-7069/T) The family of these curves for the WCP = 1, 2 ,3 ,4 and 5% is shown in Figure 4-1.
50

[4-6]

[4-7]

5%
45

4%

3% 2%

40 35
WCO, ppm

30

1%
25 20 15 10 5 0 20

25

30

35

40

45

50

55 60 T, C

65

70

75

80

85

90

Figure 4-1 Set of Equilibrium Curves WCO as a Function of Oil Temperature for Different WCP

Representation of the water equilibrium chart in the form of WCO = f(T) provides an alternative way to examine the moisture content in the cellulose insulation. 4-4

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Diffusion of Moisture within Oil Impregnated Insulation

Moisture diffusion in oil-impregnated cellulose insulation is closely connected to the mechanism of moisture equilibrium. To evaluate a time interval required to bring thin transformer insulation to a near-equilibrium state, the moisture diffusion parameters have to be known for this type of insulation. The diffusion coefficient depends on temperature and moisture content of paper in accordance with formulae suggested by Foss et al [13] and was applied in [14] for investigation of a power transformer drying model as follows: D = D0 exp[k WCP + Ea (1/T0 1/T)], [4-8]

where T0 = 298K, k = 0.5, Ea = 8074K, D0 = 1.34 x 10-13 m2/s for oil impregnated paper. According to [14] the diffusion time constant for moisture diffusing from both sides of a 1 mm thick pressboard plate is calculated as:

= d2/(2 D)

[4-9]

Figure 4-2 shows the calculated diffusion time in days for a 1 mm pressboard plate over a wide range of temperatures and water content of paper in percent. The knowledge of diffusion time helps to understand the moisture dynamics and can be used for making a better decision on a period of oil sampling from an operating transformer.

30.0

25.0

20.0 Time, days

15.0

10.0

5.0

0.0 10 20 30 40 T, C

3.30 2.80 2.60 2.40 WCP, % 1.90 1.40 50 60 70 0.50 80 90

Figure 4-2 Diffusion Time for a 1 mm Pressboard Plate

4-5

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Indeed, from Figure 4-2 it can be seen that to shorten the period between the consecutive oil samplings and to bring the system closer to the near-equilibrium state faster, temperatures over 50C should be attained.

Classification Procedure
It is the purpose of the proposed classification procedure to assess the moisture content of solid insulation and to classify a transformer as being in good, satisfactory or critical shape, in terms of moisture. By applying the three-color set and combining the diffusion data obtained for a 1mm pressboard plate, the Color Chart in Figure 4-3 has been created.

Figure 4-3 Color Chart for Transformer Classification Procedure

To assess the moisture state and to classify and rank a transformer using the Color Chart in Figure 4-3, it is recommended to implement the following steps:

Measure water content of oil at low temperature, i.e. when the oil temperature indicator reads a minimum value for the day (e.g. at 9 a.m.). Measure water content of oil taken from the same port at a higher temperature. Depending on the oil temperature cycle, the measurement can be taken either on the same day (e.g. at 4 p.m.) or on another day at a higher ambient temperature and/or higher load.

4-6

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Plot results of the two consecutive measurements on the Color Chart of Figure 4-3. Follow the analysis part of the flow diagram shown in Figure 4-4 and determine what color area the transformer is in. Observe where the rate of change in ppm vector is headed. The direction of the vector is indicative of the moisture state of the transformer. If both measurements fall into an uncertain area repeat the measurements during the higher temperature season or during the load increase period.

The new classification procedure is based on a method of moisture assessment developed earlier [11, 15]. The method evaluates a so-called active water content of paper insulation WCPa. The word active is associated with the term of water-in-paper activity (Awp) a concept proposed in [11] to reflect free water available for exchange between paper and oil. RED in Figure 4-3 means transformer is critical and requires immediate attention. YELLOW transformer is questionable (does not require immediate action), although further periodic monitoring is recommended. GREEN - transformer is in good moisture condition. The shaded cells are the area of high level of uncertainty with low degree of confidence in diagnostics. The numbers in the cells represent the diffusion time constant for moisture across a 1 mm pressboard plate exposed to the oil from both sides. The flow diagram of the proposed procedure is depicted in Figure 4-4. The 1 mm pressboard plate was chosen to reflect the concept of active water. It was shown earlier [11, 12] that moisture accumulated in the wrapping/conductor paper and in the pressboard equal to or less than 1mm in thickness is active. The approach utilizing the concept of water-inpaper activity is applied throughout the proposed classification procedure. This means that equilibrium charts relate the WCO to WCPa, where a stands for active. At an oil temperature below 45C and WCO below 20 ppm the moisture diffusion time is too long for reliable diagnosis, according to the proposed procedure.

4-7

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination
Start

Do it

Measure T top and WCOtop

Yes

Yes

Is T top<50o and WCOto <20 ppm ?

No

Is oil temperature increase at sampling point possible?

Apply Color Chart

No Apply Color Chart (Result is not reliable)

Stop No Is transformer in green area? Yes

Yes Is transformer in yellow area? Repeat measurements at increased temperature

Repeat measurements at increased temperature

Is transformer in green area? Is transformer in yellow area? No Yes Transformer is RED Transformer is YELLOW Transformer is GREEN No Yes

No

Stop

Figure 4-4 Flow Diagram of Classification Procedure

4-8

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Case Study
Consider a case of three transformers to be classified in terms of moisture content with the use of the presented procedure. These transformers were extensively monitored and discussed in [16-18]. The nameplate data of these units are shown in Table 4-1.
Table 4-1 Nameplate Data of Transformer Units Description Size and year of manuf. Cooling system Oil preservation Remarks Kendal (ESCOM) 8,000 kVA/1990 ONAN COPS Rahway (PSE&G) 4,000 kVA/1930es ONAN COPS Fairlawn (PSE&G) 550,000 kVA/1980 ODAF Conservator bladder Oil reprocessed

The temperature and WCO records for the selected transformers are presented in Table 4-2.
Table 4-2 Temperature (C) and WCO (ppm) Records for the Three Selected Transformers Kendal (KNDL) Sample # T 1 2 3 11 26 31 WCO 20 27 30.5 T 11 25 30 WCO 38 42 50 T 40 70 WCO 4 10 Rahway (RAHW) Fairlawn (FRLN)

Based on the data in Table 4-2 all the three transformers trajectories are depicted in the Color Chart of Figure 4-5. From this chart it is clear that the condition of the FAIRLAWN transformer is much better than that of the RAHWAY and KENDAL transformers. According to the classification procedure the FAIRLAWN unit does not require any additional attention while both RAHWAY and KENDAL are in critical condition as far as insulation wetness is concerned. The RAHWAY transformer is the worst of the three. It should be noted that the Color Chart in Figure 4-5 is not a one size fits all type of diagram, as the color assignment depends on the oil solubility characteristics. Therefore, ideally, the color chart should be constructed for each transformer with oil having marginally different water-in-oil solubility characteristics.

4-9

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

RAHW

KNDL

FRLN

Figure 4-5 Trajectories for Utility Transformers in WCO and T Domain

Sampling Port Location, Oil Characteristics, Cooling Mode, and Oil Preservation System Considerations
Effect of Sampling Port Location The major advantage of the proposed approach is that the final diagnosis and classification are not affected by the sampling port location (see Chapter 5 for details). Due to the dynamic nature of the procedure the rate of change should remain constant no matter from where the oil sample is taken. Effect of Water in Oil Solubility This point was discussed earlier in this chapter. To apply the classification procedure the oil (especially aged) should be carefully examined and subjected to a water-in-oil solubility test. Then a corrected chart can be applied for the diagnostics and classification.

4-10

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

Effect of Cooling Mode Transformer cooling regime has no effect on the proposed classification. However, in most cases, the forced directed oil flow system is more favorable for diagnosis and classification as compared to the natural oil flow system. Effect of Oil Preservation System Oil preservation system should have no effect on the classification. However, it is naturally expected that nitrogen-blanketed transformers would be usually drier at the same conditions.

Conclusions
The new classification procedure is proposed for the ranking of power transformers by the level of moisture. Red, yellow and green colors would indicate the wet, attention and dry states of moisture in transformers. The new classification procedure aims to identify critical units for further continuous monitoring. The procedure provides guidelines for obtaining conditions close to a quasi-equilibrium state in terms of moisture in a transformer. Reliable results would be obtained for the oil temperatures above 50C and/or for the values of the water content of oil of more than 20 ppm. The classification chart in Figure 4-3 is valid for oil, which has the water solubility characteristic close to that of new oil. For the accurate ranking of aged transformers, the evaluation of the water solubility characteristic of the oil is required.

References
4. J. Fabre and A. Pichon, Deteriorating Processes and Products of Paper in Oil. Application to Transformers. 1960 International Conference on Large High Voltage Electric System (CIGRE). Paris, France, Paper 137. E. T. Norris, High Voltage Power Transformer Insulation, Proceedings I.E.E., Vol. 110, No.2, Feb. 1963, pp.433. J.D. Piper, Moisture Equilibrium Between Gas Space and Fibrous Materials in Enclosed Electric Equipment, AIEE Transactions, Dec. 1946, Vol. 65, pp. 791-797. T. V. Oommen, Moisture Equilibrium in Paper-Qil Systems, Proceedings of the Electrical/Electronics Insulation Conference. Chicago, IL, October 3-6, 1983, pp. 162-166. T. V. Oommen, Moisture Equilibrium Charts for Transformer Insulation Drying Practice, IEEE Transaction on Power Apparatus and Systems, Vol. PAS-103, No.10, Oct. 1984, pp. 3063-3067. 4-11

5. 6. 7.

8.

New Procedure for Classification and Ranking of Operating Power Transformers on the Basis of Water Contamination

9. 10. 11.

R. Jeffries, The Sorption of Water by Cellulose and Eight Other Textile Polymers, Journal of the Textile Institute Transactions. Vol. 51, No. 9, 1960, pp. 339-74. W. A. Fessler, W. J. McNutt and T. O. Rouse, Bubble Formation in Transformers, EPRI, Palo Alto, CA: August 1987, EPRI Report EL-5384. V.G. Davydov, O.M. Roizman and W.J. Bonwick, Moisture Evaluation in Oil and Paper for Sealed Transformer Insulation System. Proceedings of EPRI Substation Equipment Diagnostics Conference VII, New Orleans, 1999, p. II-5-1 to II-5-15. SOC: 39-95. Technical Bulletin. SHELL DIALA OILS Electrical insulating oils for rapid heat transmission with high oxidation stability. S.D. Foss, Power Transformer Drying Model, Report prepared for General Electric Company, Large Transformer Operation, Pittsfield, MA, and Consolidated Edison Corporation, New York, NY, by Dynamic Systems, Pittsfield, MA, 1987. Y. Du, M. Zahn, B.C. Lesieutre, A.V. Mamishev, and S.R. Lindgren, A Review of Moisture Equilibrium in Transformer Paper-Oil Systems, IEEE Electrical Insulation Magazine, Vol. 15, No. 1, pp. 11-20, January-February 1999. Transformer Condition Assessment and Diagnostic Methods: Phase 4: Green-Yellow-Red Diagnostic Methods, EPRI, Palo Alto, CA: 2002.1001940. V.G. Davydov, O.M. Roizman, P.J. de Klerk and M. Thomas, Field Experience with Moisture Assessment in Power Transformers, Proceedings of EPRI Substation Equipment Diagnostics Conference VIII, New Orleans, 2000. Transformer Moisture-in-Paper Assessment Method Field Trial, EPRI, Palo Alto, CA: 1999, TR-114075. L. Johnson, O. Roizman and V.G. Davydov, Moisture Assessment of Power Transformers: Moving Theory into Practice, EuroTechCon 2002, Birmingham, UK, October 2002, 19 p.

12. 13.

14.

15. 16.

17. 18.

4-12

5
DEVELOPMENT OF GUIDELINES FOR IMPROVED PROCEDURE OF OIL SAMPLING FROM OPERATING TRANSFORMERS FOR EVALUATION OF WATER CONTENT OF OIL

Introduction
These Guidelines form a part of the proposed Procedure for Classification and Ranking of Power Transformers on the Basis of Water Contamination, described in the previous chapter. Measurement of water content of oil in operating oil-filled power transformers is required for assessment of dryness and dielectric integrity of transformer insulation. The ASTM Standards D923 and D3613 cover the oil sampling methods and the ASTM Standard D1533 covers the Karl Fischer reaction method. New knowledge gained over years of research at the EPRI-Monash Project Research Laboratory, combined with experience of numerous utilities from around the world [19-21], indicates that the procedure of oil sampling for water content of oil measurement needs improvement. It was found that values of water content of oil evaluated using the existing procedures and practices do not reflect true moisture state of transformer insulation and are prone to an error, which sometimes reaches an unacceptably high level. These guidelines address the issue by improving the procedure of oil sampling. Scope These Guidelines apply to oil-filled power transformers and address:

Sampling of oil from operating transformers Measurement of oil temperature during oil sampling Handling of oil samples in the field and laboratory

Limitation The guidelines are an advisory document. Application of these guidelines is linked to the Procedure for Classification and Ranking of Power Transformers on the Basis of Water Contamination (further referred to as Classification Procedure), described in the previous chapter. 5-1

Development of Guidelines for Improved Procedure of Oil Sampling from Operating Transformers for Evaluation of Water Content of Oil

References The following references should be used in conjunction with this document:

D923 Standard Practices for Sampling Electrical Insulating Liquids D3613 Standard Test Methods of Sampling Electrical Insulating Oils for Gas Analysis and Determination of Water Content D1533 Standard Test Methods for Water in Insulating Liquids (Karl Fischer Reaction Method)

Sampling of Oil from Operating Transformers

It is imperative to properly sample oil for water content analysis. The reliability of the Classification Procedure is largely affected by the results of oil analysis. In accordance with ASTM D3613 the following practices are recommended while sampling the oil:

In existing practice, an oil sample for water content measurement is usually taken from the bottom drain valve of the transformer. Drain a few liters of oil to flush the drain valve and drain valve extension Use dry and clean gas-tight syringes (e.g.: of a 100-ml capacity), stainless steel bottles or flexible-sided metal cans for oil sampling Avoid exposure of the oil to the atmospheric air during sampling by connecting the syringe, bottle or can to the drain valve via a sample adapter and tubing Extract a bubble-free sample of oil

Note: In some transformers with poor oil circulation in the vicinity of the bottom drain valve (e.g.: some old transformers with natural oil circulation and a buffer above the bottom drain valve inlet inside the tank) oil should be sampled from an alternative port in order to avoid sampling of the stagnant bottom drain valve oil. Oil Sampling at a Higher Temperature To sample oil at a higher temperature in order to move out of the shaded area of high uncertainty in the Color Chart of the Classification Procedure in Figure 4-3, it is recommended to sample oil from the top of the transformer (subject to availability of a suitable port for oil sampling). Another way to obtain a sample of oil at a higher temperature is to sample oil during a certain time of the day when the oil temperature reaches its maximum due to the ambient temperature rise (e.g. at 4 pm instead of 9 am). Alternatively, an oil sample can be taken when the oil temperature reaches its maximum either during high loading of the transformer or during summer season.

5-2

Development of Guidelines for Improved Procedure of Oil Sampling from Operating Transformers for Evaluation of Water Content of Oil

Measurement of Oil Temperature During Oil Sampling

The ASTM Standard D1533, Section 8, Note 1, specifies: The temperature of the liquid at the time of sampling should be recorded and included in the final report. () the percent saturation with water rather than the water content of the liquid per se that is most significant. However, in practice the bottom oil temperature at the moment of sampling is never recorded; i.e. the actual temperature of the oil sample is not available. To assess the moisture state of a transformer using the proposed Classification Procedure it is important to measure oil temperature during the sample extraction at the position of the sample extraction. Transformers with Forced Oil Circulation In some practices, the top oil temperature indicator reading is recorded at the moment of sampling. The recorded temperature has value for transformers with an activated forced oil circulation only, because the small difference between the recorded top oil temperature and the sampled bottom oil temperature can be neglected in application to the proposed Classification Procedure. Transformers with Natural Oil Circulation In transformers with natural oil circulation the difference between the top and bottom oil temperatures is significant and usually exceeds 10C or even more. Thus, in these transformers the top oil indicator temperature has no value for the proposed Classification Procedure and the oil temperature should be measured during the sample extraction at the position of the sample extraction. Means for Temperature Measurement During Oil Sampling It is proposed to use an infrared pointer for the temperature measurement. An error of a few degrees centigrade, which might be introduced due to the measurement of the tank wall temperature instead of the actual oil temperature, can be accepted for the proposed classification procedure due to the 5-degree step of a cell of the Classification Procedure (see Figure 4-3). Another proposed solution is a magnetic thermocouple equipped with a readout display and attached to the wall of the tank close to the bottom drain valve. Still another proposed solution is a thermocouple built in a sampling device described in the ASTM Standard D 3613 (e.g. stainless steel bottle and flexible-sided metal can) and equipped with means for connection to a readout display.

Handling of Oil Samples

In the Field To eliminate some factors that can lead to an inaccuracy in the WCO measurement (e.g. possible changes in the water content of oil during handling, transportation, shelf-life and sampling in the 5-3

Development of Guidelines for Improved Procedure of Oil Sampling from Operating Transformers for Evaluation of Water Content of Oil

laboratory, etc.), it is recommended [22] to perform the test in the field immediately after the oil sample was taken using a portable Karl Fischer test set. If the portable set is not available the test should be done in the laboratory as soon as possible. For proper handling of the extracted oil samples, ASTM D923 and ASTM 3613 recommend the following practices:

As soon as samples are taken properly identify them Carefully package each container for forwarding to the laboratory for analysis Do not expose the oil to sunlight Keep containers sealed until immediately before sampling in the laboratory, and seal again as the sample is taken to prevent contamination by moisture

In the Laboratory For sampling in the laboratory it is strongly recommend sampling the oil directly from the sample container, not from an intermediate open cup. A bubble-free sample of oil should be extracted by a syringe for injection into the titration cell of a Karl Fischer moisture meter. An acceptable accuracy of the Karl Fischer water content of oil measurement is 10% for the Classification Procedure. The minimum amount of water titrated by the Karl Fischer moisture meter should be sufficient to fulfill this requirement. For this purpose use a hypodermic syringe with a capacity of up to 10 ml, and in the case of dry oil use up to 80% of its volume. Monash experience with measurement of water content of oil using the available Karl Fischer moisture meter is given in the Appendix, which describes correct practices and handy tips on operation of the instrument.

References
19. V.G. Davydov, O.Roizman and W.J.Bonwick, Moisture Evaluation in Oil and Paper for Sealed Transformer Insulation System. Proceedings of EPRI Substation Equipment Diagnostics Conf. VII, New Orleans, February 1999, 15 p. V.G. Davydov, O.Roizman, P.J.De Klerk and M.Thomas, Field Experience with Moisture Assessment in Power Transformers, Proceedings of EPRI Substation Equipment Diagnostics Conference VIII, 13 p., New Orleans, February 2000. L. Johnson, O.Roizman and V.G. Davydov, Monitoring of Power Transformers PSE&G Experience, Proceedings of EPRI Substation Equipment Diagnostics Conference X, 14 p., San Antonio, Texas, February 2002. SOC: 39-95. Technical Bulletin. SHELL DIALA OILS Electrical insulating oils for rapid heat transmission with high oxidation stability.

20.

21.

22.

5-4

6
DEVELOPMENT OF A NEW TEST METHOD FOR SOLUBILITY OF WATER IN TRANSFORMER OIL, PROPOSED AS THE FUTURE ASTM STANDARD TEST METHOD

Introduction
Background The water solubility of oil shows a saturation limit of water in oil. It is expressed in the units of g/g or parts per million (ppm). The water solubility indicates the maximum amount of water, which could be dissolved in oil. An excess of water in oil would form a water-oil emulsion. The water solubility of oil is a function of temperature only. Importance of the water solubility characteristic of oil has been demonstrated in the previous report [23]. Knowledge of the solubility of water in oil is important for the accurate determination of the water content of paper insulation inferred from moisture-in-oil measurements in oil-filled power transformers. A relationship between the water content of oil (WCO), ppm, the oil temperature, C and the water content of paper (WCP), % exists in form of a well-known moisture equilibrium chart [24]. The moisture equilibrium chart in [24] was developed for normally refined naphthenic oil. Change in the water solubility would change the appearance of the moisture equilibrium chart. Knowing the water solubility of oil accurately would prevent introducing a significant error during moisture assessment in a particular transformer. Moisture sensors are widely used for continuous transformer condition monitoring. The moisture sensors measure the relative saturation (RS) of oil, %. Following the installation of a moisture sensor in the transformer, the performance of the sensor should be validated. The Karl Fischer titration method is described in the ASTM Standard D 1533 and is the common method to check the performance of the installed sensor. The Karl Fischer method gives the value of the water content of oil (WCO) in ppm, while moisture sensors measure the relative saturation (RS) in percent. To compare the sensors measurement with the Karl Fischer measurement, the solubility of water in oil S(T) has to be known. Different laboratories described various methods for experimental evaluation of solubility of water in oil [25, 26].

6-1

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

In [25] a constant stream of air bubbles saturated with water flowed through an oil sample. The oil and an air headspace above it were kept at a constant temperature during a few hours of the wet air flow. The wet air bubbles saturated the oil and the headspace, until a stable maximum level of water content of oil was reached. The measured water content of oil (WCO) in ppm at the 100% relative saturation (RS) of the oil at this temperature provided the solubility limit of the oil at this temperature. The procedure was repeated at three temperature levels. Following the measurements an Arrhenius plot of the solubility of water in oil versus the reciprocal of temperature in degrees Kelvin was built. The water solubility curve was expressed as a logarithmic equation for the common logarithm. In [26] in order to provide an infinite reservoir of moisture for the oil tested, a piece of a 1-mm pressboard plate was impregnated under vacuum with deionised water and its surface was padded dry. The piece of pressboard was then attached to the stem of a thermometer, which was immersed in a flask full of oil. The bubble-free oil flask was sealed at the desired temperature. The experiment was allowed to reach equilibrium for 24 hours while a magnetic stirrer provided a means for the mass-transfer process. The flask was then opened at the 100% relative saturation of the oil and the water content of oil in ppm was measured using a moisture meter. The procedure was repeated at three temperature levels. The water solubility curve of the Arrhenius plot was expressed as a logarithmic equation for the natural logarithm. General Theory Relative saturation of oil is calculated as follows: RS(T)=100*WCO(T)/S(T), % [6-1]

where RS(T) is the relative saturation of oil at temperature T, WCO(T) is the water content of oil at temperature T, and S(T) is the solubility of water in oil at temperature T. The saturation water content of oil as a function of temperature S(T) can be represented in the form of an Arrhenius plot [26], i.e. as the plot of the natural logarithm of the S(T) versus the reciprocal of the temperature T in Kelvin. The plot fits to the following Arrhenius expression:
S (T ) = S exp( Ea / kT ) ,
T

[6-2]

where S is the lim S (T ) in ppm, Ea is the activation energy for the tested oil in Joules, k is the Boltzman gas constant and T is the absolute temperature of oil in K. The equation [6-2] can be rewritten as following:
ln( S (T )) = A B / T ,

[6-3]

where A = ln(S) and B = Ea / k.

6-2

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

It can be seen from [6-3] that the ln S(T) is a linear function of the oil temperature. From the equation [6-3] the solubility of water in oil can be expressed as following: S(T)=exp(A-B/T). [6-4]

Thus, the aim of the testing of solubility of water in oil is determination of the coefficients A and B for the formula [6-4]. Development of a New Test Method Background and Brief Description The methods [25, 26] utilize the common approach of the WCO measurement at the 100% relative saturation of the oil. The method described in [26] was slightly modified and used for water solubility tests conducted at Monash in 1997-1998 [27]. Following this study the development and testing of a new test method has commenced at Monash. The development of the new test method has been completed recently and presented publicly at the EPRI Seminar Moisture Management in Transformers, held in Edison, New Jersey on October 30 November 1, 2002 (see Chapter 10 of this report). The new test method is described in detail in the sections below. The difference between the new method developed and existing methods is that the new method does not require establishing the condition with the 100% relative saturation of water in oil. Instead, the new method uses a relative saturation sensor for the measurement of the relative saturation of oil at any given moment of time. Also, the new method requires a temperature sensor and a Karl Fisher moisture meter. Choosing the Most Appropriate Ranges of Test Parameters for New Test Method The most important test parameters of the new test method are the oil temperature, relative saturation and water content of oil. The saturation water content of oil S(T) is a function of temperature only as per formula [6-4]. Thus, determination of the oil temperature range for the water solubility test is of primary importance. Normal working oil temperatures in power transformers loaded within the nameplate rating vary from an ambient temperature to high tens of degrees centigrade. Knowledge on the water solubility for this temperature range is desirable. Normal working temperatures for commercially available moisture sensors vary approximately in the same temperature range. However, a long exposure of a moisture sensor to the oil temperature exceeding 80C leads to a shift in the sensors output [28], and the sensor may require re-calibration. Moreover, at high temperature the sensing element deteriorates rapidly. For these reasons the upper temperature limit for the new test method was set at 80C. 6-3

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

On the other hand at oil temperature below 30C the response time of the commercially available moisture sensors tested [29, 30] increases. For example, more than ten hours were required to obtain a true output reading of a moisture sensor immersed in oil stirred at a constant room temperature [29]. Moreover, the accuracy of a moisture sensor output deteriorates at temperatures below 30C [31]. Thus, the lower temperature limit for the new test method was set at 30C. The linearity of output of some moisture sensors deteriorates at relative saturation values exceeding 80% [29]. Water content of oil is measured using a Karl Fischer titration method. Many of the commercially available Karl Fischer moisture meters have the measurable lower limit of water of 10 g and the precision of 3 g for a water quantity of 10 to 1000 g. This means that for the water quantity of 10 g the accuracy of the water content of oil (WCO) measurement is 30% and for the water quantity of 1000 g the accuracy is 0.3%. To obtain an acceptable for a standard test method accuracy of the WCO measurement of, say, 3%, the minimum amount of water titrated by the Karl Fischer moisture meter should be 100 g. This fact enables choosing an appropriate size of the oil sample to be injected into the titration cell of the Karl Fischer moisture meter. For example, 1 g of oil of 30 ppm contains only 30 g of water, which is below the required minimum amount of 100 g. The result should be rejected, because the accuracy of the measurement is 10%, not the desired 3%. To titrate the required 100 g of water, the sample size of the 30-ppm oil should be 3.3 g or approx 4 ml, while the sample size of the 20-ppm oil should be 5 g or approx 6 ml. In other words, more economical WCO measurement would be achieved for the wetter oil. Table 6-1 shows values of RS that would be measured at the two set temperatures of 30C and 80C at five different levels of WCO in new oil, where RS=WCO/S(T)*100, %.
Table 6-1 Relative Saturation at 30C and 80C at Different Levels of WCO for New Oil No 1 2 3 4 5 WCO, ppm 20 30 40 50 60 RS, % at 30C 27.3 40.9 54.6 68.2 81.9 RS, % at 80C 4.5 6.7 8.9 11.2 13.4

At the WCO=20 ppm the sample size is not economical, as it was shown above, while at the WCO=60 ppm the RS>80%, where the linearity of output of the moisture sensor may deteriorate. Thus, the most appropriate range of the WCO for new oil is approximately between 30 and 50 ppm (see Table 6-1). For aged oil the solubility of water is higher, thus the most appropriate range of the WCO would be approx. between 30 and 70 ppm, and even higher for some very old oils. 6-4

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

Currently, no standard method is available for the determination of solubility of water in transformer oil. It is proposed to fill up this gap using the new test method developed.

Proposal for ASTM Standard Test Method for Solubility of Water in Transformer Oil
Scope This test method covers the determination of the solubility of water present in transformer insulating oils. The solubility of water can be estimated over the temperature range 303 K (30C) to 353 K (80C). Referenced Documents ASTM Standards:

D 1533 Test Methods for Water in Insulating Liquids (Karl Fischer Reaction Method) D 923 Standard Practices for Sampling Electrical Insulating Liquids D 3613 Method for Sampling Electrical Insulating Liquids for Gas Analysis and Determination of Water Content

Terminology Definitions Water Content of Oil the mass of water in g dissolved in one gram of the oil and expressed in parts per million (ppm). Solubility of Water in Oil (Saturation Water Content of Oil) the mass of water in g dissolved in one gram of the oil at saturation and expressed in parts per million (ppm). Relative Saturation the ratio between the water content of oil and solubility of water in oil, expressed in percent. Symbols WCO water content of oil S(T) T RS solubility of water in oil (saturation water content of oil) temperature of oil relative saturation of water in oil 6-5

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

A B

constant constant

Summary of Test Method The test method is based on changing the oil temperature by steps in a flask containing the oil with the value of water content of oil in the range of 30-50 ppm for new oil and 30-70 ppm for old oil. The number of the temperature steps is i. The minimum number of the temperature steps is three. At each temperature step the ultimate values of the temperature Ti, relative saturation RSi, and water content of oil WCOi are measured. The ultimate values of the S(Ti) are calculated for each step of the temperature from the formula S(Ti)=100*WCOi/RSi. A straight line, resulted from the regression analysis of the Arrhenius plot obtained, is expressed by the linear equation S(T)=exp(A-B/T), from which the coefficients A and B are evaluated. Significance and Use This test is suitable for use in evaluating of condition of transformer insulating oils in service. Knowledge of water solubility in oil is of importance for the accurate assessment of water content of solid insulation inferred from moisture-in-oil measurements in oil-filled power transformers. Also, knowledge of water solubility in oil is important for validation of performance of moisture-in-oil monitors installed in transformers.

6-6

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

Apparatus
Probe with Moisture and Temperature Sensors To and from moisture protected conservator Lid

Tap

Flask KF Sampling Port

Oil

Stirrer Bar

Hot-Plate Stirrer Unit

Figure 6-1 Set-up for Test Method for Solubility of Water in Transformer Oil

Flask for Oil The flask for oil shall be of approximately 1-L capacity and shall be protected against atmospheric moisture. A gaseous headspace and gas bubbles shall be removed from the flask filled with the oil. The bottom of the flask shall be suitable for the heating using a hot plate. Lid The lid for the flask shall contain at least three sealable penetrations suitable for housing of the following items: a port for a probe with the moisture and temperature sensors, a port with a tap for connection to the conservator, and a port for oil bleeding while removing gas bubbles from the flask and for sampling of oil for Karl Fischer measurement of water content of oil.

6-7

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

Probe with Moisture and Temperature Sensors The moisture and temperature sensors shall be accurately calibrated prior to the water solubility test. The probe shall be fixed in one of the ports of the lid and sealed. The tip of the probe with the moisture and temperature sensing elements shall be positioned approximately in the middle of the flask. Port for Oil Sampling The port for oil sampling for the Karl Fischer measurement of water content of oil shall be sealed, for example, with a suba seal. The seal shall be suitable for the numerous penetrations with a needle. Conservator for Oil The conservator for oil shall be of approximately 1-L capacity and shall be protected against atmospheric moisture by either a silica gel breather, dry air or nitrogen. The conservator shall be connected to the port with the tap. The conservator shall contain the same oil and shall be filled to approximately 80% of its volume. A gaseous headspace above the oil in the conservator shall contain either dry air or dry nitrogen. Stirrer Means for agitation of oil during water solubility test shall consist of a magnetic stirrer with a glass or TFE-fluorocarbon covered stirrer bar of 3 to 4 cm long. Hot-plate Means for heating of oil during the water solubility test shall provide a number of controllable steady levels of oil temperature. Silicon Tubes Flexible means for the connections between the separate items of the test set-up. Syringe A syringe of approximately 10-ml capacity shall be used as an oil sample container while sampling oil from the sampling port of the test set-up for the Karl Fischer measurement of water content of oil. Needle A needle of the syringe shall be of a length suitable to sample the oil in the vicinity of 1 to 2 cm from the moisture and temperature sensing elements. Three-tap Vessel for Dry Air or Nitrogen (optional) The vessel for dry air or nitrogen shall be of approximately 0.5 L capacity and shall contain three taps: one for the filling and release of the dry gas, another for the connection to the conservator and the third for the connection to an expansion rubber bag. Expansion Rubber Bag (optional) The expansion rubber bag shall be connected to the gaseous headspace of the conservator and shall contain either dry air or dry nitrogen. Acquisition of Test Data Means for the monitoring and acquisition of the oil temperature and the oil relative saturation shall be provided. A computerized data acquisition system is desirable. However, manual recording of test data is acceptable. 6-8

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

Sampling Sampling of the insulating oils for the Karl Fischer measurement of water content of oil should be in accordance with Methods D 923 and D 3613. Care must be exercised to avoid introduction of water into the sample from the atmosphere or from the syringe and needle. Exposure of the sample to the air should be avoided, and the syringe and needle must be thoroughly cleaned and dried prior to use. Procedure 1. 2. 3. 4. 5. 6. Assemble the test set-up. Fill the flask and conservator with oil. Bring the WCO to approx. 30-50 ppm. Release all air bubbles from the oil and seal the set-up. Switch on the magnetic stirrer unit and keep the oil stirred during the whole duration of the test. Switch on the heating unit of the hot plate aiming to reach the ultimate oil temperature of approx. 70-80C. Once the temperature has reached the ultimate value, keep the oil at this temperature for at least one hour to obtain a stable reading of the moisture sensor. Measure WCO using the Karl Fischer moisture meter three times and record the values of the oil temperature and relative saturation prior to each sampling of oil. Calculate average values of the parameters obtained for step 1 and record them as WCO1, T1 and RS1. Reduce the setting of the heating unit, aiming to reach the ultimate oil temperature of approx. 50-60C. Once the temperature has reached the ultimate value, keep the oil at this temperature for at least one hour to obtain a stable reading of the moisture sensor.

7. 8. 9.

10. Measure WCO using the Karl Fischer moisture meter three times and record the values of the oil temperature and relative saturation prior to each sampling of oil. 11. Calculate average values of the parameters obtained for step 2 and record them as WCO2, T2 and RS2. 12. Reduce the setting of the heating unit, aiming to reach the ultimate oil temperature of approx. 30-40C. Once the temperature has reached the ultimate value, keep the oil at this temperature for at least one hour to obtain a stable reading of the moisture sensor. 13. Measure WCO using the Karl Fischer moisture meter three times and record the values of the oil temperature and relative saturation prior to each sampling of oil. 6-9

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

14. Calculate average values of the parameters obtained for step 3 and record them as WCO3, T3 and RS3. 15. Create a spreadsheet (e.g. using the Microsoft Excel or similar software application) with the following eight columns:

16.

Step number (i). Oil temperature Ti in C from 9.8, 9.11 and 9.14. Oil temperature Ti in K (T, K = T, C + 273.16). Reciprocal of the temperature Ti, K, multiplied by 1000 (1000/Ti, K). Relative saturation RSi in % from 9.8, 9.11 and 9.14. Water content of oil WCO in ppm from 9.8, 9.11 and 9.14. S(Ti) in ppm calculated from the formula S(Ti)=WCOi/RSi*100 for each of i steps. Natural logarithm of the S(Ti) for each of i steps.

Plot the ln(S(Ti)) vs 1000/Ti, K.

17. Perform a linear regression analysis. For example, while in Excel use the following path: select the chart, click on the Chart button, choose the Add Trendline palette, choose the Linear Trend/Regression Type option, click the Options sub-folder, choose the Display Equation on Chart option and click OK. The equation would have the form of y=-Cx+D. 18. Evaluate the coefficients A and B as follows: A=D, B=-1000*C.

References
23. 24. 25. 26. Transformer Condition Assessment and Diagnostic Methods: Phase 4: Green-Yellow-Red Diagnostic Methods, EPRI, Palo Alto, CA: 2002. 1001940. TV Oommen, Moisture Equilibrium Charts for Transformer Insulating Drying Practice, IEEE Trans. on Power Apparatus and Systems, Vol. PAS-103, 10, 1984, pp. 3063-3067. P.J. Griffin, C.M. Bruce and J.D. Christie, Comparison of Water Equilibrium in Silicone and Mineral Oil Transformers, 55AIC88, Doble Engineering, 1988, 10-9.110-9.12. P. A. von Guggenberg and J R Melcher, An Immersible Relative Saturation Moisture Sensor with Application to Transformer Oil, Proceedings of the 3rd International Conference on Properties and Applications of Dielectric Materials, Tokyo, July 8-12, 1991, pp. 1258-1261. V. G. Davydov, O. M. Roizman and W. J. Bonwick, Evaluation of Water Content in Transformer Insulation Systems, Proceedings of EPRI Substation Equipment Diagnostics Conference VI, New Orleans, 1998, 15 p.

27.

6-10

Development of a New Test Method for Solubility of Water in Transformer Oil, Proposed as the Future ASTM Standard Test Method

28. 29.

T. V. Oommen, On-Line Moisture Monitoring in Transformers and Oil Processing Systems, CIGRE Symposium, Berlin 1993, Paper 110-03, pp. 1-4. V.G. Davydov, O. Roizman and W.J. Bonwick, Moisture Evaluation in Oil and Paper for Sealed Transformer Insulation System. Proceedings of EPRI Substation Equipment Diagnostics Conf. VII, New Orleans, February 1999, 15 p. V.G. Davydov and O. Roizman, Transformer Moisture Assessment Method: Phase 3: Testing of Nitrogen Blanketed Transformer Insulation and Development of Software Application, EPRI, Palo Alto, CA: 2001. 1001939. PPM-Calculation for Transformer Oils, HMP228 Users Guide M010010-A, Vaisala, August 2000.

30.

31.

6-11

7
TMM IMPROVEMENTS
A detailed description of the Transformer Moisture Monitor (TMM) stand-alone software application was given in the previous EPRI report [32]. A beta testing of the initial version of the TMM is in progress in one of the US utilities. Since then, the TMM has been upgraded to a version 1.01. The following changes have been introduced to the TMM:

The TMM v1.01 has been adopted for LabVIEW 6i (see Figure 7-1), while the initial version of the TMM was developed for LabVIEW 5 In the diagnostic window a description State was replaced by Moisture State Now it is possible to enter values of the A and B coefficients for the water solubility formulae directly into the appropriate fields marked as A and B An Open File dialog box appears after clicking on the Open File dialog button. The prior version required the input file path to be entered implicitly in the appropriate field A Date/Time format has been introduced on each time axis for better identification of the time frame for the input data In the graph trending window all chart objects have been replaced by an XY Graph having more functionality and a new look New calculations for the confidence level were incorporated and now values of Confidence are distributed within the range of [0, 1]. This represents a more logical approach to ranging the confidence level.

7-1

TMM Improvements

Figure 7-1 TMM v1.01 Graphic User Interface

Reference
32. Transformer Condition Assessment and Diagnostic Methods: Phase4: Green-Yellow-Red Diagnostic Methods, EPRI, Palo Alto, CA: 2002. 1001940.

7-2

8
IMPLEMENTATION OF WATER-IN-PAPER ALGORITHM IN MMW: USERS GUIDE
The following section presents the overview of integration of the Water-in-Paper (WIP) Algorithm into the EPRI developed software Maintenance Management Workstation (MMW). In order to demonstrate how to use new user defined functions dealing with determination of Water Content in Paper (WCP) and Water Content in Oil (WCO) lets start by selecting the PAM-Performance Assessment Module icon from the MMW folder from the Start/Programs/MMW directory. If the user name and the password are not known when at the login screen, type in Demo for both User Name and Password, as seen Figure 8-1 and then OK.

Figure 8-1 MMW Start Menu

This will bring you to the screen shown in Figure 8-2.

In this section term WCP means active part of water content of paper insulation. Definition and detailed explanation of active water and water activity are given elsewhere [].

8-1

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Figure 8-2 Main Menu of Performance Assessment Module

By pressing the Query button you can open the Tabbed Query dialog shown in Figure 8-3. In the Tabbed Query Dialog box double click Parameters Query folder and then select ParametersByStation.

Figure 8-3 Tabbed Query Dialog; Common Tab

8-2

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

On the right side of this dialog, you will find a list of user-selectable criteria in a hierarchical layout. The data in each subsequent combo-box is restricted by the previous field selection. In this way, you narrow (filter) the parameters for which the query will run. It is not necessary to fill in every combo-box. However, you must make selections for the Station and Parameter boxes. Note that the Region and Work Center have already been selected for you by default. In this example, select Alvarado for the Station filter and Transformer for the Equip Type filter. For the Equipment ID filter, select the one available choice given. Once you have done that, select Temperature for the Measure filter and the one available choice for Parameter. It is also required to enter the period of monitoring. In our example this is one days worth of data. When you have completed your selections, the dialog should appear similar to that shown in Figure 8-4.

Figure 8-4 Tabbed Query Dialog for Selection of Top Oil Temperature

8-3

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Once you have completed all of your selections, click the Add button, then click the Query List tab of the Tabbed Query Dialog and verify that your query is added to that list. There should now be one query in the Query List. Then click back to the Common tab of the Tabbed Query Dialog and click on the OK button to perform a query. A graph like that shown in Figure 8-5 will appear, based on the information selected.

Figure 8-5 Top Oil Temperature Graph by MMW Query

The next step is to perform selection and plotting of Relative Saturation for the same transformer. Following similar procedure as for the temperature selection you can retrieve and plot the Relative Saturation data. The tabbed query dialog for selection of relative saturation is shown in Figure 8-6.

8-4

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Figure 8-6 Tabbed Query Dialog for Selection of Relative Saturation

After adding this query to the query list you can plot the relative saturation trend as shown in Figure 8-7. Once you have retrieved the results of your queries and adjusted graph layouts you may save your results to a file. The entire contents including the data returned and the layout information can be saved in either a Performa (*.prf extension) document or a template (*.tpl extension). When you open a template file, the program will rerun the queries and display new results in the formatting associated with that template. This is especially useful, as you will need that information when performing the WCO and WCP calculations. To calculate Water Content of Oil you will need to open the Equation Editor dialog box as shown in Figure 8-8.

8-5

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Figure 8-7 Top Oil Relative Saturation Graph by MMW Query

Figure 8-8 Equation Editor Dialog Box showing WCO Equation

8-6

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Then in the field labeled Equation enter WCO for Water Content in Oil. In the bottom middle window called Functions select folder WIP and double click it to access the two user defined functions CalcWco and DetermWcp. Click on the CalcWco icon and observe that in the left side bottom window, labeled Variables, the appropriate list of variables will appear. Now you have to return to the Equation right side window to enter the arguments for the WCO function. Green light will indicate that the equation was constructed correctly. By pressing the OK button you can get the calculated WCO values being the last column shown in Figure 8-9 table. Also included in this table are the date/time stamp, top oil temperature and the relative saturation values. To plot the calculated values for WCO you will need to run the Graph query and obtain the plot shown in Figure 8-10. In order to determine the water content in paper value you must open the Equation Editor and select the DetermWcp function from the Functions window (see Figure 8-11).

Figure 8-9 Result of the Query to Calculate WCO

8-7

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Figure 8-10 WCO Plot after Executing the Graph Query

Figure 8-11 Equation Editor Dialog Box Showing WCP Equation

8-8

Implementation of Water-in-Paper Algorithm in MMW: Users Guide

Once the Equation Editor dialog is completed for the DetermWcp function you can get the WCP and the confidence level associated with that value in the two top fields of the last column in the table shown in Figure 8-12.

Figure 8-12 Calculated WCP (4.526) and Confidence Level (0.7649) for given T and RS

These two values represent the predicted Water Content in Paper and the Confidence Level associated with WCP. This concludes this section of the report.

8-9

9
FEASIBILITY STUDY TO DETERMINE WHETHER MOISTURE HAS AN EFFECT ON FREQUENCY RESPONSE ANALYSIS (FRA) SIGNATURES IN A TRANSFORMER USING A FACTORY DRYOUT PROCESS

Objective
The objective of the research reported below was determination on whether moisture has an effect on frequency response analysis (FRA) signatures in a transformer using a factory dryout process. An agreement on the tests to be conducted for the study has been reached with a local transformer manufacturer, the Wilson Transformer Company (WTC), Australia, in April 2002. The aims of the tests were to study the following phenomena: first, effect of moisture on the FRA signatures, second, effect of the coil re-clamping on the FRA signatures and third, effect of the oil impregnation of insulation on the FRA signatures.

Introduction
A basic idea of the wide-band examination by frequency response analysis (FRA) is a more sensitive detection of changes in the winding geometry, since even a minor change in the internal inductance and capacitance have an effect on the characteristic frequencies [33-42]. However, it was proposed and shown theoretically in the previous report [43] that increase in the moisture content of transformer paper insulation during the lifetime of a transformer would result in some change of an internal capacitance of the transformer winding and, accordingly, some changes in the FRA signatures. This report describes FRA tests conducted on a newly built power transformer at the Wilson Transformer Company during dryout using a conventional heat-and-vacuum method. To obtain frequency response signatures of the transformer, a low-voltage sinusoidal test signal of variable frequency was applied to a certain winding of the transformer at different stages of the dryout, re-clamping and oil-filling procedures.

9-1

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Basic Principle of the Transfer Function (TF) Method

Theoretical Background According to control theory the behavior of a linear single-input/single-output system can be described with Transfer Function (TF). The TF method is based on the two-port network theory allowing defining one input force and several output gates, Figure 9-1 [33].

x ( j )

Transformer
complex RLCM - Network

y ( j )

Figure 9-1 TF Method as a Linear Two-port Network

In Figure 9-1 the transformer is presented as a passive RLCM network with resistors R, winding inductances L and capacitances C and a mutual inductance and capacitance M, where: j x( j ) = Ax ( ) e j x and y ( j ) = Ay ( ) e y - complex numbers in exponential form of input and output signals such as vectors of voltages x and y (for example: u = 2 sin(t + 20) u = 2e j 20 ); - circular frequency, j - imaginary variable; A( ) - magnitude of signals and - phase. The TF is calculated in the frequency domain as the quotient of an input signal and a system response. The principles of the TF calculation are shown in Figure 9-2.

x ( j )
Transformer (winding)
sampled

y ( j )

TF ( j )
Figure 9-2 Principle of Transfer Function Calculation

9-2

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

The transfer function for swept magnitudes and phases is calculated according to the following formula:

TF ( j ) =

y ( j ) , x ( j )

[9-1]

where TF ( j ) is a complex value of the Transfer Function (TF). A LabVIEW software program has been developed to record and convert these input and output voltages into their frequency spectra in polar coordinates. Frequency Ranges and Frequency Resolution The frequency dependant impedance and/or admittance are evaluated in magnitude and phase for five sweep frequency ranges [34]:

5 Hz to 2 kHz 50 Hz to 20 kHz 500 Hz to 200 kHz 5 kHz to 2 MHz 25 kHz to 10 MHz

A frequency resolution f is determined as

f =

f final N samp

[9-2]

where f final - final frequency in each range swept; N samp - number of samples in each range swept. The frequency resolution for each of the five ranges is shown below:

5 Hz 50 Hz 500 Hz 5 kHz 25 kHz

9-3

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Signal Processing The main problem with digital recording of response signals and with transfer functions is a phenomenon called aliasing (noise) by low response signal. As result a low repeatability of an output signal by amplitude lower than 50 dB could be observed. To prevent the aliasing a special LabVIEW program with median filters has been developed. The filtration of signals was used for the first and second frequency ranges.

Test Set-Up for FRA Testing of Transformers

An FRA measurement configuration varies for different applications. Figure 9-3 shows a direct connection to the winding carried out with coaxial cables [36]. In this application all other windings in the transformer were left floating (the two resistors R were used for compensation of the cable effect).
Signal Reference

Transformer
HV1 HV2

Test

LV1

LV2

Figure 9-3 Winding Connections for FRA Testing

Digital records of input and output voltages were taken simultaneously using apparatus shown in the test diagram in Figure 9-4.
B coaxial cable A

FG
GP - IB port DAQ Card
signal processing

DO

FG Function Generator DO Digital Oscilloscope

save

PC

Figure 9-4 FRA Test Diagram

9-4

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

In all tests a swept sinusoidal signal of 4 V (peak to peak) was applied to windings from the function generator. The following software and measuring instruments have been used for the FRA tests:

Software application LabVIEW-6 Function Generator HP 33120A Digital Oscilloscope Tektronix TDS 540 (four channels, 100 MHz) 50 cables IBM PS/2 Pentium 1, 90 MHz with DAQ GPIB card

A special program using LabVIEW system has been developed to control the function generator and the digital oscilloscope.

FRA Testing of Transformer undergoing Dryout in Conventional Oven

Description of Transformer An FRA test was conducted on the three-phase 15 MVA 33kV/11kV transformer. The HV and LV windings of the transformer represented a so-called layer type, known as a shielded layer winding. In a layer winding the turns are wound axially and arranged between a pair of inner and outer shields. The winding conductors were covered with enamel insulation. The HV (33 kV) winding was connected in delta, while the LV (11 kV) winding was connected in star. Five FRA measurements were taken during the drying process, one FRA measurement was taken following the re-clamping procedure and another FRA measurement was taken following the oil filling procedure. The HV (33 kV) winding has been used for the FRA measurements. The phase between the connectors A and C of the delta-connected HV winding was short-circuited for the factory routine capacitance and tan delta measurements; as a result the other two phases were connected in parallel (see Figure 9-5).
A

winding

Figure 9-5 Configuration of Phases of HV Winding for FRA Measurements

9-5

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Description of Oven and Dryout Process A plate with connectors for signal cables for the capacitance and tan delta measurements is available on the wall of the oven used at the WTC for the conventional heat-and-vacuum dryout. A few spare connectors were provided for the connection of the FRA coaxial cables. The plate has enabled the connection of the transformer winding terminals inside the oven (the length of the coaxial heat-proof cables was 4 m) to the measuring instruments outside the oven (the length of the standard coaxial cables was 1.2 m). Thus, the FRA tests on the transformer were conducted at different stages of the dryout without interruption of the process. The drying process of the transformer insulation in the oven included a number of steps of heating of insulation to 80110C using a hot air blow set up, followed by steps of vacuum application to the level of absolute pressure of down to 0.1 mmHg. The time schedule of the FRA tests conducted for the dryout process and for the followed 7re-clamping and oil filling procedures is shown in Table 9-1.
Table 9-1 Time Schedule of FRA Test Description of Winding Condition Wet, day 0 (atm pressure) 1-day-dry (vacuum) 4-day-dry (vacuum) 4-day-dry (atm pressure) 6-day-dry (vacuum) re-clamped (vacuum)

FRA Test No. FRA 1

Time of Start of FRA Test 2:30pm th 16 May 02

Description of Stage and Parameters of Processing The measurement was taken prior to dryout on the winding positioned inside the oven at P = 760 mmHg, T air = 17 C The measurement was taken at P = 1.4 mmHg, T = 75 C The measurement was taken at P = 0.2 mmHg, T = 95 C The measurement was taken at P = 760 mmHg, T = 80 C The measurement was taken at P = 0.13 mmHg, T = 95 C Windings were positioned in the transformer tank and bushings were installed. The tank was sealed at 6 pm. The windings were in the tank under vacuum for two hours at T air = 20 C Measurement was taken on the oil-filled tank during oil circulation for filtering of the oil at T oil = 50 C

FRA 2

10:15am th 17 May 02 10:20am th 20 May 02 2:20pm th 20 May 02 2:30pm nd 22 May 02 8:05pm rd 23 May 02

FRA 3

FRA 4

FRA 5

FRA 6

FRA 7

11:30am th 24 May 02

oil-impregnated (atm pressure)

Note: P absolute pressure, T temperature of insulation

9-6

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Results of Capacitance and Tan Delta Measurement During Dryout of Transformer Relative changes in the capacitance and tan delta of the HV winding of Transformer 1 during the drying process are shown in Figure 9-6 and Figure 9-7.

1.09 HV-Tank 1.06 C(x)/C(f)

1.03

1.00 16-May-02

18-May-02

20-May-02 Date

22-May-02

24-May-02

Figure 9-6 Change of Ratio C(x)/C(f) During Drying Process, where C(f) is a Final Capacitance Measured on Day 6 of Dryout (C(f) = 9,305 pF)

10

tan d(x) / tan d(f)

67 deg C
7

HV-Tank

96 deg C
1 16-May-02

94 deg C

95 deg C

78 deg C
24-May-02

18-May-02

20-May-02 Date

22-May-02

Figure 9-7 Change of Ratio tan(x)/tan(f) During Drying Process, where tan(f) is a Final Tan Delta Measured on Day 6 of Dryout (Tan(f) = 0.39%)

Apparently, the changes of the capacitance and tan delta of the insulation system, i.e. the changes in its dielectric permittivity, have an influence on the changes of the frequency response signals.

9-7

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

FRA Test Results The FRA signatures of the transformer were studied to discover the following effects: 1. Effect of moisture removal, which has resulted in the decrease of the dielectric permittivity of solid insulation 2. Effect of re-clamping, which has resulted in the mechanical displacement of the windings 3. Effect of oil impregnation, which has resulted in the increase of the dielectric permittivity of dry solid insulation. Magnitude and phase for the five sweep frequency ranges were measured in each of the seven FRA tests, described in Table 9-1 above. Comparisons between FRA tests taken at different stages of the transformer manufacture, are shown in Figures 9-8, 9-9, 9-10 and 9-11 below, where the magnitude and phase for each designated frequency range is shown as a picture labeled as a, b, c, d and e. Effect of Moisture on FRA Signatures Effect of moisture on FRA signatures for the five sweep frequency ranges is shown in Figures 9-8 and 9-9. Figure 9-8 a-e, shows the effect of moisture on FRA signatures for the 1st day of dryout. Figure 9-9 a-e, shows the effect of moisture on FRA signatures for the remaining five days of dryout.

9-8

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process a) 0.005 2 kHz
0
Magnitude (dB)
Magnitude (dB)

b) 0.05 20 kHz
0

-1 5 W e t a n d 1 -d a y-d ry -3 0
0 0 .5 1 1 .5 f, k H z 2

-2 5 Wet
0 5
Wet

-5 0

1 -d a y-d ry
10 15 f, kH z 20

Phase (degr.)

W e t a n d 1 -d a y-d ry -5 0 -1 0 0

Phase (degr.)

100 50 0 -5 0 -1 0 0

1 -d a y-d ry

c) 0.5 200 kHz

0

d) 5 2000 kHz
0

Magnitude (dB)

Wet -3 0 1 -d a y-d ry -6 0 0
100

Magnitude (dB)

-3 0

Wet

1 -d a y-d ry

-6 0 0
100

50

100

1 5 0 f, kH z 2 0 0
Phase (degr.)

500

1000

1500

2000
f, kH z

Phase (degr.)

50 0 -5 0 -1 0 0
We t

1 -d a y-d ry

50 0 -5 0 -1 0 0 Wet

1 -d a y-d ry

e) 25 10,000 kHz
0

Magnitude (dB)

Wet
1 -d a y-d ry

-2 0

-4 0 0 2000 4000 6000 8000 10000

200 100 0 1 -d a y-d ry
Wet
f, kH z

Phase (degr.)

-1 0 0 -2 0 0

Figure 9-8 st Effect of Moisture on FRA Signatures within the Five Frequency Sweeps for the 1 Day of Dryout (Comparison between FRA 1 and FRA 2, See Table 9.1 for Details)

9-9

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

a) 0.005 2 kHz
0

b) 0.05 20 kHz
0

Magnitude (dB)

Magnitude (dB)

1 -d a y-d ry a n d 6 -d a y-d ry -2 5

-1 5 1 -d a y-d ry a n d 6 -d a y-d ry -3 0
0 0 .5 1 1 .5 0 -4 0 -8 0 1 -d a y-d ry a n d 6 -d a y-d ry f, kH z 2

-5 0
0 5
6 -d a y-d ry

10

15

f, kH z 2 0

Phase (degr.)

Phase (degr.)

100 50 0 -5 0 -1 0 0 1 -d a y-d ry

c) 0.5 200 kHz

0

d) 5 2000 kHz
0

Magnitude (dB)

Magnitude (dB)

-25 1-d a y-d ry a nd 6 -da y-d ry -50

-25

1-d a y-d ry a nd 6 -da y-d ry

-50

50

10 0

1 50

Phase (degr.)

Phase (degr.)

1 00 50 0 -50 -1 00 1 -d a y-d ry an d 6-d a y-d ry

f, kH z

200

0 100 50 0 -50 -100

500

1000

1500

f, kH z

2000

6 -da y-d ry

1 -d a y-d ry

e) 25 10,000 kHz
Magnitude (dB)
0

1-day-dry
-20 6-day-dry -40

0 200 100 0 -100 -200

2000

4000

6000

8000

f, kH z

10000

Phase (degr.)

6-day-dry

1-day-dry

Figure 9-9 Effect of Moisture on FRA Signatures within the Five Frequency Sweeps for the Remaining Five Days of Dryout (Comparison between FRA 2 and FRA 5, See Table 9-1 for Details)

9-10

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

From the comparison of Figures 9-8 and 9-9 it appears that for the ranges (a) to (d) of up to 2 MHz changes in the magnitude and phase responses were more pronounced during the first day of dryout, rather than during the remaining five days of dryout. However, for the range (e) of up to 10 MHz some equally noticeable changes were recorded for frequencies 6-10MHz for the first day and for the remaining five days of dryout. A change in the polarity of the phase response should be noted for the following three frequency ranges:

5-15 kHz, when the phase response crosses the zero line and changes from 75 to +75 degrees (see Figures 9-8 and 9-9, b and c) 0.2-0.7 MHz, when the phase response crosses the zero line a few times and gradually changes the polarity from being positive before 0.2 MHz to being negative following 0.7 MHz (see Figures 9-8 and 9-9, d and e) 7.8-8 MHz, when the phase response crosses the zero line and changes from 180 to +180 degrees (see Figures 9-8 and 9-9, e).

The change in the polarity of the phase response described above is characteristic for this particular transformer with a layer type winding. Effect of Re-clamping on FRA Signatures Figure 9-10 a-e, shows the effect of the re-clamping on the FRA signatures. In Figure 9-10 a) the phase diagram for the frequency range 0.005-2 kHz was omitted, because in this range a very low response signal was detected and the measurement of the phase angle by the oscilloscope was inaccurate. Comparison of the FRA signatures, recorded in Figure 9-10 for the dry non-oily transformer before and after the re-clamping, shows the following. For the ranges (a) and (b) of up to 20 kHz, there was a significant shift in the magnitude and phase responses from the frequencies of approx. 5-15 kHz to the frequencies of approx. 0.5-2 kHz. For the range (c) of up to 200 kHz, there were some changes in the magnitude and phase responses between frequencies of approx. 30 kHz and 80 kHz. For the ranges (d) and (e) of up to 10 MHz, there were noticeable changes in the magnitude and phase responses between frequencies of approx. 0.5 MHz and 3 MHz and between frequencies of approx. 4 MHz and 10 MHz. A change in the polarity of the phase response, characteristic for the mechanically displaced winding, has been observed for the following two frequency ranges:

0.5-2 kHz, when the phase response crosses the zero line and changes from 70 to +90 degrees (see Figure 9-10, b) 1.1-1.2 MHz, when the phase response crosses the zero line and changes from 50 to +40 degrees (see Figure 9-10, d and e).

9-11

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

a) 0.005 2 kHz
0 Magnitude (dB)

b) 0.05 20 kHz
0

Magnitude (dB)

before re-clam ping -30

before re-clamping -40 after re-clamping -80 0 0.5 1 1.5 f, kHz 2

-60

after re-clam ping

10

15

20

Phase (degr.)

100 50 0 -50

f, kHz
after re-clam ping

before re-clam ping

-100

c) 0.5 200 kHz

0
Magnitude (dB)

d) 5 2000 kHz
0
Magnitude (dB)

a fter re -cla m pin g

-3 0 b e fo re re-clam p ing -6 0

-3 0
a fte r re -cla m p in g

be fo re re -cla m pin g -6 0
0 500 1 0 00 15 0 0 2000 f, kH z

0
Phase (degr.)

50

100

15 0

Phase (degr.)

150 75 0 -7 5 -1 5 0

f, kH z

200
10 0 50 0 -5 0

afte r re-clam p ing be fo re re -cla m .

b efo re re -cla m p in g a fte r re-clam p ing

-10 0

e) 25 10,000 kHz
Magnitude (dB)
0

-2 0

a fte r re -cla m pin g

-4 0

be fo re re -cla m p.

2 0 00

4000

6000

Phase (degr.)

2 00 1 00 0 -1 00 -2 00

8000 10 0 0 0 f, kH z

a fte r re-clam p . b e fo re re-cla m p in g

Figure 9-10 Effect of Re-Clamping on FRA Signatures within the Five Frequency Sweeps (Comparison between FRA 5 and FRA 6, See Table 9-1 for Details)

9-12

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Effect of Oil Impregnation on FRA Signatures Figure 9-11 a-e, shows the effect of oil impregnation on the FRA signatures. In Figure 9-11a) the phase diagram for the frequency range 0.005-2 kHz was omitted, because in this range a very low response signal was detected and the measurement of the phase angle by the oscilloscope was inaccurate. Comparison of the FRA signatures in Figure 9-11, recorded on the dry and re-clamped transformer before and after the oil impregnation, shows the following. For the ranges (a) and (b) of up to 20 kHz, there was a shift in the magnitude and phase responses from the frequencies of approx. 0.5-2 kHz to the frequencies of approx. 0.2-0.5 kHz. For the range (c) of up to 200 kHz, there were some changes in the magnitude and phase responses in the whole range of the frequencies. For the ranges (d) and (e) of up to 10 MHz, there were noticeable changes in the magnitude and phase responses between frequencies of approx. 0.2 MHz and 1.2 MHz and between frequencies of approx. 4 MHz and 10 MHz. A change in the polarity of the phase response, characteristic for the oil-impregnated insulation, has been observed for the following three frequency ranges:

0.2-0.5 kHz, when the phase response crosses the zero line and changes from 75 to +90 degrees (see Figure 9-11, b) 0.8-0.85 MHz, when the phase response crosses the zero line and changes from 70 to +50 degrees (see Figure 9-11, d and e) 6.6-6.7 MHz, when the phase response crosses the zero line and changes from 180 to +180 degrees (see Figure 9-11, e).

9-13

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

a) 0.005 2 kHz
0 Magnitude (dB) with Oil -40 without Oil

b) 0.05 20 kHz
0
Magnitude (dB)

w ith Oil
-40

w ith o u t Oil
-80

-80 0 0.5 1

0
Phase (degr.)

10

15

1.5 f, kHz

100 50 0 -5 0 -1 0 0 w ith Oil

w ith o ut Oil

f, kH z

20

c) 0.5 200 kHz

0
Magnitude (dB)

d) 5 2000 kHz
0
Magnitude (dB)

w ith O il

-4 0

w ith o u t O il

-3 0 w ith O il -6 0

w ith o u t O il

-8 0

0
Phase (degr.)

50

100

150

Phase (degr.)

100 50 0 -5 0 -1 0 0

f, kH z

200
100 50 0 -5 0

500 w ith O il

1000

1500
f, kH z

2000

w ith o u t O il

w ith o u t O il

w ith O il

-1 0 0

e) 25 10,000 kHz
Magnitude (dB)

0 w ith Oil

-20

w ithout Oil
-40

0 200 100 0 -100 -200

Phase (degr.)

2000

4000

6000

8000

f, kH z

10000

w ith Oil w ithout Oil

Figure 9-11 Effect of Oil on FRA Signatures within the Five Frequency Sweeps (Comparison between FRA 6 and FRA 7, See Table 9-1 for Details)

9-14

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

Conclusions
A study on whether moisture has an effect on frequency response analysis (FRA) signatures in a transformer using a factory dry out process has been conducted in 2002. The study was conducted at the factory floor of a local transformer manufacturer, the Wilson Transformer Company, Australia. A comprehensive study was conducted on a new transformer with a layer type enameled winding, dried using a conventional heat-and-vacuum method. During dryout of the transformer the capacitance of the tested winding has decreased by 7.5%. Moisture content in the transformer insulation has decreased from approx. 6-8% to approx. 0.5%. This means that the decrease in water content by 1% corresponds to approx. a 1% decrease in capacitance of the transformer winding. The FRA study on the transformer has shown that the three factors, such as moisture, mechanical displacement and oil impregnation of insulation, have an effect on the FRA signatures. The study on the transformer has shown that certain patterns could be recognized for the FRA signatures due to changes in the dielectric and mechanical properties of the winding. Further tests are required to study the effect of moisture on the FRA signatures for a disk type winding.

References
33. K. Feser, J. Christian, T. Leibfried and others, The Transfer Function Method for Detection of Winding Displacements on Power Transformers after transport, short circuit or 30 years of service, 12/33-04, CIGRE Session 2000. B. Finlay and M. Stace, Advanced Techniques in power transformer condition monitoring recovery voltage and frequency response analysis. Pacific Power International/Advanced Technology Centre, University of Newcastle, Australia, 1997. J. Bak-Jensen, B. Bak-Jensen and S.D. Mikkelsen, Detection of Faults and Ageing Phenomena in Transformers by Transfer Functions. IEEE Transactions on Power Delivery, Vol. 10, No.1, Jan 1995. O. Moreau, Y. Guillot and B. Barre, FRA diagnosis method: Simulation Applied to Feasibility Study and Efficiency Improvement, Electricite de France, 1999. J. Fuhr and others, Development and Application of new condition assessment methods for power transformers, 12-207, CIGRE Session 1998.

34.

35.

36. 37.

9-15

Feasibility Study to Determine whether Moisture has an Effect on Frequency Response Analysis (FRA) Signatures in a Transformer using a Factory Dryout Process

38.

A.J. Vandermaar and M. Wang, Transformer condition monitoring by frequency response analysis, Substation Equipment diagnostics Conference VI, Power Labs Inc, Canada, 1998. P.T.M. Vaessen, E. Hanique, A new Frequency Response Analysis for Power Transformers, IEEE Transactions on Power Delivery, Vol. 7, No.1, Jan 1992. T. Leibfried and K. Feser, Monitoring of Power Transformer using the Transfer Function Method, IEEE Transactions on Power Delivery, Vol. 14, No.4, Oct 1999. P. Leemans, M. Randoux, A. Even and others, Control, Diagnostic and Monitoring of Power Transformers, 12-213, CIGRE Session 1998. S. Tenbohlen, H. Borsi and U. Sundermann, Enhanced Diagnosis of Power Transformers using On- and Off-line Methods: Results, Examples and Future Trends, 12-204, CIGRE Session 2000. Interim report 2001. M.J. Heathcote, The J&P Transformer Book, 12th edition, 945 p., Newness, UK, 1998.

39. 40. 41. 42.

43. 44.

9-16

10
EPRI SEMINAR MOISTURE MANAGEMENT IN TRANSFORMERS
The EPRI Seminar Moisture Management in Transformers has been designed, prepared and delivered to a workshop held in Edison, New Jersey on October 30 November 1, 2002; instructors: TV Oommen, O. Roizman and V. Davydov. Representatives of a number of utilities and vendors have attended the Seminar. The Seminar had the following content: 1. 2. 3. 4. 5. 6. 7. 8. 9. Moisture Management in Transformers Water in Transformers Sources of Water Contamination Ageing Decomposition of Cellulose Ageing Decomposition of Oil Release of Bound Water from Oil and Particles Effects of Moisture on Transformer Insulation and Loading Accelerated Aging of Paper and Oil by Moisture Monash Work on Release of Water, Bubbling and PD

10. Moisture Parameters of a Paper-Oil-Gas Complex 11. Air Humidity Parameters 12. 13. Moisture Potential Moisture Equilibrium in Paper-Oil-Gas System

14. Diffusion of Water into Paper 15. Different Types of Cellulose 16. Distribution of Moisture in Transformers 10-1

EPRI Seminar Moisture Management in Transformers

17. Known Methods of Moisture Measurement 18. Karl Fischer Titration Method 19. Instrumentation for Moisture Assessment 20. Selection of Moisture Sensors and Transducers 21. Experimental Comparison of Available Sensors 22. Monash Experimental Comparison and Testing of Commercially Available Moisture Sensors 23. On-line Moisture Monitoring 24. New Test Method for Evaluation of Water Solubility in Oil: ASTM Proposal 25. Classification and Ranking of Power Transformers on the Basis of Water Contamination

26. Guide for the Improved Procedure of Oil Sampling from Operating Power Transformers for Determination of Water Content of Oil 27. Drying of Transformer Insulation 28. Software Tools for Moisture Management The following vendors have made presentations at the workshop: 1. 2. 3. 4. 5. 6. 7. 8. 9. Baron USA, Inc. Doble DryKeep EPRI GE Power Systems Kinectrics Inc. MS Morgan Schaffer PALL Serveron Corporation

10. Velcon Copies of the Seminar and vendors presentations are available at EPRI on a CD. 10-2

A
MONASH EXPERIENCE WITH MEASUREMENT OF WATER CONTENT OF OIL USING MITSUBISHI KARL FISCHER MOISTURE METER MODEL CA-06

This Appendix summarizes an extensive experience on the measurement of water content in oil (WCO) gained at EPRI Project Research Laboratory at Monash University, Australia. A study was undertaken at the Laboratory to improve the quality of WCO measurements taken by the Mitsubishi Karl Fischer Moisture Meter (KFMM), model CA-06. The KFMM model CA-06 consists of a main unit and a titration cell [45]. The main unit provides a user-friendly operating system for processing, display and printing data. The titration cell has two separate cells: a generator (anode) solution cell and a cathode solution cell. A sample of oil is injected into the generator solution cell where electrolysis takes place. It was found that the following actions improved the measurement reliability:

Reagents in KFMM were changed regularly to prevent the use of an expired reagent Introduction of air bubbles avoided in a syringe during the oil sampling. Tested oil removed from KFMM titration cell after the total volume of the injected oil reached 15 milliliters (i.e. approx. 13.5 grams) Quantity of the oil sample chosen between 2 and 15 milliliters (i.e. approx. between 1.9 and 13.5 grams)

The sections below provide more details to illustrate the necessity of the above listed actions and also provides other important information.

Effect of Air Bubbles on WCO Measurement

To check the effect of air bubbles on the WCO measurements, an air bubble was taken by the syringe from the ambient air at room temperature and relative humidity of 53.7% during the oil sampling. Another measurement was taken for the oil properly sampled from the same container. Measurement results are shown in Table A-1.

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Monash Experience with Measurement of Water Content of Oil using Mitsubishi Karl Fischer Moisture Meter Model CA-06 Table A-1 Measurement of WCO with and without Introduced Air Bubble Tamb C 22.7 22.7 Toil C 22.8 22.8 Oil mass g 4.49 4.44 Water mass g 157.5 115.7 WCO ppm 35 26

Condition With air bubble Without air bubble

The comparison of data in Table A-1 shows that the moist air had increased the value of the WCO from 26 to 35 ppm, i.e. by 35%.

Effect of Excessive Quantity of Oil Added to Titration Cell

Only a certain quantity of oil should be added to the titration cell of the KFMM to obtain valid measurements of WCO. To study the effect of the excessive oil quantity on the quality of the WCO measurement, the following test was carried out. Five oil samples of approx. 5 ml each were drawn from a container of the 15-ppm oil and injected one-by-one into the titration cell. The values of WCO were evaluated for each sample. The results of the test are shown in Table A-2.
Table A-2 Measurement of WCO for Five Concessive Samples of Oil Sample No. 1 2 3 4 5 Oil Sample mass, g 4.44 4.41 4.42 4.35 4.41 Total Oil mass Injected into Cell g 4.44 8.85 13.27 17.62 22.03 Water mass g 69.3 63.9 67.2 52.2 38.8 WCO ppm 15.6 14.5 15.2 12.0 8.8

It is seen from Table A-2 that the WCO values for the first three samples are very close to 15 ppm. For the 4th and 5th samples the WCO values have dropped because the total quantity of oil injected into the cell has become excessive and the oil did not mix properly with the titration solution. This has resulted in the lower readings of water quantities and, subsequently, in the erroneous values of WCO. This test showed that the total amount of oil injected into the cell of this particular instrument should not exceed approx. 13.5 g (i.e. approx. 15 ml). A number of similar tests confirmed the validity of this value. To remove the oil from the cell, the KFMM should be turned off and the oil allowed separating from the titration solution for approx. 10-15 minutes. The oil can be collected from the top of the solution using a syringe via the sampling port. A-2

Monash Experience with Measurement of Water Content of Oil using Mitsubishi Karl Fischer Moisture Meter Model CA-06

Effect of Oil Sample Quantity on Accuracy of WCO Measurement

The KFMM CA-06 has the following limitations. The measurable lower limit of water is 10 g. The upper limit of oil, which can be injected into the cell, is approx. 13.5 g (see the previous section). Precision is 3 g for a water quantity of 10 to 1000 g. This means that for the water quantity of 10 g the accuracy of the WCO measurement is 30% and for the water quantity of 1000 g the accuracy is 0.3%. Table A-3 illustrates how the % accuracy of the WCO measurement depends on the size of the oil sample, provided that WCO=10 ppm.
Table A-3 Effect of Oil Quantity on a % Accuracy for WCO=10 ppm Oil mass g 0.5 2 5 10 13.5 WCO ppm 10 As above As above As above As above Water mass g 5 20 50 100 135 Precision g Accuracy % Comment 5 g is below lower limit. Discard the result 13.5 g is upper limit

3
As above As above As above As above

15 6 3 2.2

To obtain an acceptable for the laboratory precision of the WCO measurement of, say, 3%, the minimum amount of water titrated by the KFMM should be 100 g. This fact allows choosing an appropriate size of the oil sample to be injected into the cell. Table A-4 indicates quantities of oil sufficient for the accuracy of 3%.
Table A-4 Quantities of Oil to Obtain 3% Accuracy of WCO Measurement WCO Ppm 5 10 15 20 30 40 50 Oil mass g 13.5 10.0 6.7 5.0 3.3 2.5 2.0 Water mass g 67.5 100 100 As above As above As above As above Accuracy % Comment 13.5 g is the upper limit Oil mass is within the limit Oil mass is within the limit As above As above As above As above

4.4 3 3
As above As above As above As above

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Monash Experience with Measurement of Water Content of Oil using Mitsubishi Karl Fischer Moisture Meter Model CA-06

Injection of Oil Sample into Cell of KFMM CA-06

Care should be taken while injecting oil into the titration cell of the instrument. The following rules were developed to reduce an error of the WCO measurement:

Flush the inside of the syringe and the needle with the oil to be measured When a dry oil sample follows the wet one, replace the used needle and syringe with the clean and dry ones Draw up at least 1 ml more oil than the desired amount so that some oil can be rejected from the syringe together with air bubbles Remove air bubbles from syringe Insert the needle tip of the syringe as closely as possible to the level of the anode solution. Do not immerse the tip of the needle into the solution. Do not inject the oil sample onto the wall of the cell or electrodes

Evaluation of Performance of KFMM CA-06

The performance of the instrument can be evaluated using standard check solutions. For the range of interest of 100 to 1000 g of water titrated, the two following solutions should be used:

Hydranal-water standard 1.0, which contains about 1000 g of water per gram of solution Hydranal-water standard 0.1, which contains about 100 g of water per gram of solution

Hydranal can be obtained in 4-ml ampoules. Break the ampoule open at the white ring carefully by hand. Wash the syringe with approx. 1 ml of the solution and then carry out 3x1 ml titrations with the remainder. The result is acceptable if the average deviation of the three measurements is within the precision of the instrument of 3 g. Table A-5 illustrates the evaluation of performance of KFMM CA-06 using standard 1.0. It was specified that 1 g of the solution contained 996 g of water.
Table A-5 Evaluation of Performance of KFMM CA-06 using Standard 1.0 Sample No. 1 2 3 Average Check Solution mass g 0.8035 0.9439 0.9471 Expected Water mass g 800.3 940.1 943.3 Titrated Water mass g 802.5 935.1 941.6 Absolute Deviation g 2.2 5.0 1.7 2.97

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Monash Experience with Measurement of Water Content of Oil using Mitsubishi Karl Fischer Moisture Meter Model CA-06

Despite the deviation for sample 2 exceeding 3 g, the average deviation was within the 3 g range (see Table A-5).

Trouble Shooting and Handy Tips

The most common source of trouble with KFMM is high background, i.e. background above 0.3 g/s. There are several possible causes for the high background:

Overused or contaminated solutions. Record the total amounts of water titrated by the cathode solution each day and replace the reagents when 150 mg of water has been titrated or when the background exceeds 0.3 g/s. Alternatively, use the reagent life calendar on the instrument to record the amount of water titrated automatically The cathode solution cells wire screens may have contaminant built up. Clean the cathode solution cell Overused nitrogen carrier gas desiccant (i.e. phosphorus pentoxide). Replace the desiccant Levels of cathode and anode solutions are unequal. Level up the solutions.

It is normal for the background to be high if the instrument has not been used for several days, e.g. for a weekend. It may take as long as one hour for the background to drop to 0.3 g/s and below. The cathode solution turns a dark brown color if the solutions are not stirred during titration. The drain cock should be tied onto the cell using a rubber band to prevent it from loosening and draining anode solution. If the potential is ever negative check the electrode (anode). You may find the two sensors are touching, causing this problem. The stirrer bar knocking the electrode would have caused this. Do not leave the sample port open for too long, to prevent moisture from air entering the system.

Reference
45 Instruction Manual Mitsubishi Moisture Meter Model CA Series, Mitsubishi Kasei Corporation, Tokyo, Japan, 1992 and onwards.

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