Jasenko Kosorcic

KONAR Distribution and Special Transformers, Inc.
MAINTENANCE AND REPAIR OF

MEDIUM POWER TRANSFORMERS
WAPIC, Lagos, Nigeria , 27.11.2013
Jasenko Kosori M.Sc.Mech. Eng.
Project manager
Strategic commercial department
Konar Distribution and special transformers Inc.
Address: J. Mokrovica 8; p.p. 100; HR-10090 Zagreb, Croatia
Phone:+385 1 3783 715 Fax: + 385 1 3794 051
E-mail: jasenko.kosorcic@koncar-dst.hr Web: www.koncar-dst.hr
Content
1.Why transformers are important ?
2. Why is necessary to maintaining transformers ?
3. Aging of the transformers
4. Parts of transformer important from maintenance point of view
5. Electrical tests of transformers
6. Maitenance of the transformers
7. Repair of the transformers
Maintenance and repair of

medium power transformers
1.Why transformers are important?

Transformers are essential pieces of electrical equipment that help to
transmit and distribute electricity efficiently and reliably. They also
help maintain power quality and control, and facilitate electrical
networks. In the substations they are most expensive part of the
equipment

2. Why is necessary to maintaining transformers?

Regardless a fact the transformers do not have any major
rotaitng parts it is necessary to maintaining them.
Reasons:
1. Aging (internal condition of transformers degrades)
2. Overvolatges and short circuits in the electical network
3. Weak points in the transformers design
As transformers aging, their insulation strength can
degrade to the point that they cannot withstand system
events such as short-circuit faults or transient
overvoltages.
To prevent failures and to maintain transformers in good
operating condition it is very important to perform
maintenance programs combined with regular testing.

Stress on transformers
General cause
LOAD
VOLTAGE
AMBIENT
CONDITIONS
HANDLING
Particular cause Influence on transformer

Overload
Heat
Cyclic loading
Thermal expansion
Short circuit
Mech. Winding stress
Transients
Over voltages
Lightning
Over voltage
Sun radiation
Degradation of painting
Humidity
Corrosion
Transportation
Acceleration damages


Aging of insulation
Degree of polymeraization
Cellulose is a polymer made from glucose. It's made from glucose molecules and the polymer molecules are 'straight'.
Degree of polymerization (DP) is a number of single

molecules of glucose connected in the one chain.
Fresh Kraft paper will have DP around 1100 to 1200. After
factory drying this value will drop up to 1000 and then
decreases exponentially with time.


Aging of insulation
In IEC 60076-7 is given
a chart of DP changing
over time of
non-thermally and
thermally upgraded
paper exposed to a
temperature of 150
(Sealed tube
accelerated ageing in
mineral oil at 150 C )


Aging of insulation
Mechanical strenght is determined by lenght of cellulose molecules [4]:


Aging of insulation
Aging or deterioration of insulation is a time function

of temperature, moisture content, oxygen content and
acid content
In reaction with water the cellulose molecule is split
up and the process of depolymerization goes on, the
number of glucosic units is reduced. The length of the
cellulose molecule gives an objective information
about the paper condition and so for the mechanical
strength of the
transformer insulation system. Determination of the
degree of polymerization (DP) can be done by
chemical analysis of the paper.


Aging of insulation
Measurment of DP is defined by
IEC 60450 ed 2.1 Consol. with am1
Measurement of the average viscometric degree of
polymerization of new and aged cellulosic electrically insulating
materials
This methodis not applied for transformers in operation, but it
delivers good results to determine the electrical and
mechanical residual strength of paper insulation.

3. Ageing of the transformers

Ageing of insulation
Distribution of DP values
generator step up transformer after 40 years of service [3]


Aging of insulation
DP values for estimating remaining paper life [7]
New insulation
1.000 DP to 1.400 DP
60% to 66% life

remaining
500 DP
30% life remanining
300 DP
0 life remanining
200 DP


Aging of transformer oil
[2]
The main force of oil aging is oxidation.

For oxidation to take place there has to be something to oxidize
(oil), oxygen, and heat to providethe activation energy.
Oxidation of oil generate a water and acids which accelerate the
[2]
insulation aging.


Aging of transformer oil without addition of solid insulation
Water content of oil as function of time [5]

Aging of oil with open expansion system
Aging of oil with closed expansion system

Acid number of oil as function of time [5]


Colour number of oil as function of time [5]


Loss factor tan of oil as function of time [5]

Temperature of measurment 90C f=50Hz

Aging of transformer oil without additon of solid insulation
Break down voltage of oil as function of time [5]

Temperature of measurment 20C acc. IEC
4. Parts of transformer important from maintenance

point of view
Content
4.1 Position on the transformer
4.2.Transformer oil
4.3 Dehydrating breather with oil barier
4.4. Buchholz relay
4.5. Pressure relief device
4.6. Oil level indicator
4.7 Temperature indicators
4.8 Cooling fans
4.9. On load tap changer (OLTC)

4.1 Postion on the transformer



4.2 Transformer oil

Content:
4.2.1 Function of transformer oil in transformer
4.2.2 Groups of tests for mineral insulating oils according IEC 60422
4.2.3 Colour test
4.2.4 Break down voltage test
4.2.5 Water content test
4.2.6. Acidity (neutralization) value test
4.2.7 Dielectric dissipation factor and resisitvity test
4.2.8. Desolved gas analysis test (DGA)

4.2 Transformer oil

4.2.9 Properties of insulating mineral oil for transformers during bulk
delivery
4.2.10 Recommended limits for mineral insulating oils after filling in
new electrical equipment prior to energization
4.2.11 Evaulation of oil in service according IEC 60422

4.2.1 Function of transformer oil in transformer
Function of transformer oil in transformer is to insulate

and to serve as a coolant.

4.2.2 Groups of tests for mineral insulating oils according

IEC 60422
According IEC
60422
Article 6.1. tests of
mineral oils are
divided in routine
tests (1),
complementary
tests (2) and
special
investigative tests
(3) Here is missing
DGA test.

4.2.3 Colour test
Number
Colour
number
According ISO 2049:1996, Petroleum products -- Determination

of colour (ASTM scale)
4.2.4 Breakdown voltage test
Test is performed according IEC 60156:Insulating liquids Determination of the breakdown voltage at power frequency Test method
Breakdown volatge is a measure of the abiliy of oil to withstand
electric stree
Low value of BDV indicates presence of moisture content and
conducting substances in the oil.

Breakdown votlage vs. Water content [6]

Sample of BDV
test

Test is performed according IEC 60814 : Insulating liquids Oilimpregnated paper and pressboard Determination of water by
automatic coulometric Karl- Fischer titration
The water content in oil is measured as mgH2O/kg oil or ppm of
water
During oxidation acid are formed in the oil give rise the solubility
of water in the oil.
Acid coupled with water further decompose the oil forming more
acid and water. In this way rate of degradation of oil increases.

Test is performed according IEC 62021-1 ed1.0 Insulating liquids

- Determination of acidity - Part 1: Automatic potentiometric
titration


Acidity of transformer oil, is harmful property.
If oil becomes acidic, water content in the oil becomes more soluble to
the oil.
Acidity of oil deteriorates the insulation property of paper insulation of
winding.
Acidity accelerates the oxidation process in the oil.
Acid also includes rusting of iron in presence of moisture.
The acidity of transformer oil is measure of its acidic constituents of
contaminants.
Acidity of oil is expressed in mg of KOH (potassium hydroxide)
required to neutralize the acid present in a gram of oil. This is also
known as neutralization number.

Test is performed according IEC 60247: Insulating liquids

Measurement of relative permittivity, dielectric dissipation factor
(tan ) and d.c. Resistivity
Test temperature is 90 C


Dielectric Dissipation Factor is also
known as loss factor or tan delta of
transformer oil.
If value of which is also known as
loss angle,is smaller, means resistive
component of the current IR is smaller
which indicates high resistive property
of the insulating material. High resistive
insulation is good insulator.
There is a clear relationship between
tan and resistivity of insulating oil.
If resistivity of the insulating oil is
decreased, the value of tan-delta
increases and vice verse

Specific Resistance ( Resistivity ) of Transformer Oil

This is another important property of transformer oil. This is
measure of DC resistance between two opposite sides of one
block of oil. Its unit is taken as Gm at specific temperature.
With increase in temperature the resistivity of oil decreases
rapidly.


4.2.8. Dissolved gas analysis test (DGA)
Test is performed according:

IEC 61181 ed2.0 Mineral oil-filled electrical equipment Application of dissolved gas analysis (DGA) to factory tests on
electrical equipment





IEC 60599 ed2.0 Mineral oil-impregnated electrical

equipment in service - Guide to the interpretation
of dissolved and free gases analysis
IEEE C57.104 - Guide for the Interpretation of
Gases Generated in Oil-Immersed Transformers

Sample of DGA
test report

4.2.9 Properties of insulating mineral oil for

transformers during bulk delivery
According IEC 60296: Fluids for electro technical applications Unused

mineral insulating oils for transformers and switchgear
4.2.9 Properties of insulating mineral oil for

transformers during bulk delivery
Sample of
incoming oil test
report
4.2.10 Recommended limits for mineral insulating oils after

filling in new electrical equipment prior to energization
According IEC 60422

Mineral insulation oils in electrical equipmentSupervision and matenance guidance
Article 9.


Decisions about corrective actions

STATUS
Required
level of
oil
Type 1. of
silica
gel
Type 2. of silica
gel
Silica gel
completely
dry
Amber
yellow
Orange
(Salmon)
Silica gel moist
Turquoise
blue
Transparent
white
Silica gel
saturated by
moisture
Light green
Light rosy
Note:
1. The line in the middle of the container did not mark the oil level in the cup.
2. Fill the oil to the specified recommendation.
3. When 2/3 of silica gel becomes saturated by moisture, it has to be dried or replaced.
4. Drying silica gel is performed on the way that silica-gel is placed in the oven and heated to
120-130C for about 1 hour, after that silica-gel is dried and has recovered color to the dry.

Type 1 silicagel-dry
Type 2 silicagel-dry
Dehydrating breather with too

much oil in barier
Dehydrating breather with

proper amount of oil in barier

4.4 Buchholz relay

4.4 Buchholz relay- Construction

Buchholz Relay is an oil container housed the
connecting pipe from main tank to conservator
tank. It has mainly two elements. The upper
element consists of a float. The float is attached to
a hinge in such a way that it can move up and
down depending upon the oil level in the Buchholz
Relay Container. One mercury switch is fixed on
the float. The alignment of mercury switch hence
depends upon the position of the float.
The lower element consists of a baffle plate and
mercury switch. This plate is fitted on a hinge just
in front of the inlet (main tank side ) of Buchholz
Relay in transformer in such a way that when oil
enters in the relay from that inlet in high pressure
the alignment of the baffle plate along with the
mercury switch attached to it, will change.
In addition to these main elements a Buchholz
Relay has gas release pockets on top.
4.4 Buchholz relay- Functions
Gas accumulation
Alarm
Surge of oil
Trip
Oil loss
1. Alarm
2.Trip

4.4 Buchholz relay- Installation

4.4 Buchholz relay-Testing by means of function key

4.4 Buchholz relay-Sampling of gases from Buchholz

relay
Defined by:
IEC 60422 Oil-filled electrical equipment Sampling of gases and of
oil for analysis of free and dissolved gases Guidance
Chapter 3 Sampling of gases from gas-collecting (Buchholz) relays

4.5 Pressure relief device
Drawing of
pressure relief
device in open
position


Pressure relief device is spring loaded valve that automatically
reclose following a pressure release. The spring is held in
compression by the protective cover and press on a disc which
selas an opening in the tank top. If pressure in the tank excides
operating pressure (0,5 bar), the disc moves upward and relieves
pressure. As pressure decrease, the spring reclose the valve. After
operating , this device leaves a brightly colored rod (yellow for oil)
exposed about 5 cm above the top .The rod may be reset by
pressing on the top until it is again recessed into the device. The
switch must me manually reset. In a case of activation switch sends
a signal for disconnection of the transformer from the grid.

Testing a signal for disconnection

4.6 Oil level indicator

READING THE INDICATIONS OF THE OIL
LEVELS
- Minimum level: when the dial shows all red.
- Maximum level: when the dial shows all white.
- Intermediate indications between MAX and
MIN: the dial shows part white and part red.
Remember that the amount of red shown
indicates, in proportion,the part of the
conservator left without liquid

4.7 Temperature indicators
Trip

Trip
4.8 Cooling fans
Push buttons for start and stop fans in control cabinet

4.9. On load tap changer (OLTC)

4.9. OLTC
OLTC allows to change the ratio of a transformer
by adding turns to or subtracting turns from
primary winding
For this purpose transformer is equipped
withregulating or tap winding, which is
connected to the OLTC terminals

4.9. OLTC-Design principle of resistor OLTC

4.9. OLTC-Installation
4.9. OLTC-Protective relay

4.9. OLTC-Burst membrane

4.9. OLTC-Motor drive unit


Electrical test of medium power transformers are divided
in three groups:
1. Routine tests- - a test to which each individual
transformer is subjected(performed on each
produced transformer)
2. Type tests- a test made on a transformer which is
representative to other transformers (performed on
one transformer of same type /construction)
3. Special test- a test other than a type test or a routine
test, agreed by the manufacturer and the purchaser



Sample of
Transformer
Test Report
- contains all
measuring results


INTRODUCTION
Transformer is very important part of the electrical power
system. The primary purpose of the transformer maintenance
is to ensure that the internal and external parts of the
transformer and accessories are kept in good condition and
able to operate safely at all times.
Transformer maintenance can be done in three ways:
1. Maintenance by failure
2. Preventive maintenance
3. Maintenace by conditions


CONDITION MAINTENANCE PROGRAM
Condition based maintenance is usually the most economical
way of doing maintenance. Recommended maintenance are
done based on one or more of the following: visual
inspections, analysis of oil samples, electrical measurements,
test of equipment, measurements of temperatures, monitoring.
ATTENTION:
If transformer is going to be used as a spare or stand-by unit, it
maintenance must be equal to the transformer in service.
Special care must be taken in monitoring the conditions of the
oil.
In periodic schedule, the frequency of inspection and
maintenance procedures will vary with the rating of the
transformer, but the intervals suggested in this presentation
are recommended as minimum.


CONDITION MAINTENANCE PROGRAM
In most cases operators are familiar with the noise and
behaviour that can occur during transformer normal operation,
which can help to discover some defects. It is very important to
write down the readings from the meters or gauges that are
generally installed. These readings can be very useful. If the
readings are very different from the ones obtained in normal
conditions, careful revision should be performed.
In addition, you should pay attention to the following:
- the temperature of the transformer is directly related to the life
span of the insulating materials, so it is necessary to pay
close attention,
- oil level and volume changes in relationship to the
temperature,
- in some instances some abnormal noise can be perceived,
- checking of loose pieces and valves,
- oil leaks.

POWER TRANSFORMER AND ASSOCIATED EQUIPMENT
MAINTENANCE INSPECTION INTERVALS FOR ENERGIZED
TRANSFORMERS
INTERVAL
Every site visit

(monthly)
CHECK AND MAINTENANCE LIST

Check transformer load currents and
voltages.
Check transformer for possible oil
leakage.
Observe any abnormal noises from the
transformer.
Check of ambient, oil and winding
temperature.
Observe cooling fans.
Check of oil level.
Check condition of silica gel in the
breathers.
Visual check of cable connections.
Visual check of control cabinets.

TRANSFORMERS
INTERVAL
Quarterly
Observation and registration of counter

information or operation time of
transformer, pumps, fans, OLTC, etc.
Check and record readings on all
indicating instruments.
Examine the piping to the coolers or
radiators and bolted pipe joints for signs of
oil leakage.
Check the coolers or radiators for
accumulation of dirt and foreign material
that might obstruct air flow.
Inspect control cabinets of the
transformer and the OLTC.


TRANSFORMERS
INTERVAL
Annually
Check bushing cleanliness in polluted

environments and visual check for cracks
and unscrewed hardware.
Check switchgear cable termination for
pollution and electrical tracking.
Check transformer cables for deformation
distance to grounded metal parts.
Protective relay trip check, calibration of
monitoring equipment.
Grounding system check for loose,
damaged or corroded connections.
Dissolved gas analysis and routine
analysis of oil.

MAINTENANCE INSPECTION INTERVALS FOR DE-ENERGIZED
TRANSFORMERS
INTERVAL
Annually
(optimal)

For the transformer equipped with forced oil cooling, check the oil circulating
pumps for any unusual noise or flutter of the oil flow gauge.
For transformers equipped with fans check functionality of the fans and ensure
there is no debris covering them or are in the way of the blades.
Take an oil sample from the main tank and any other oil-filled compartment for
DGA analysis.
Perform same electrical test that were made at commissioning.
Examine all bushings and interconnecting hardware for contamination and signs
of electrical tracking, perform power factor and capacitance measurement on the
bushings (Only for condenser type bushings).
Inspect on load tap changer according to manufacturer instructions.
Inspect breathers and pressure relief valves or devices.
Examine paint finish, particularly around welded joints.
De-energize the auxiliary power source and inspect the control equipment inside
control cabinet.
General repairs e.g. tightening bolts, replacement of gaskets.


TRANSFORMERS
INTERVAL
3 years
Complete series of transformer

electrical tests that were done at
commissioning.
OLTC according to manufacturers
instructions, if any.
Inspect alarm functionality for
pressure relief device.
Cleaning of complete switch gear,
inspection and lubrication of all
associated devices including circuit
breaker, wiring, buses.
All "annual" items not considered at
one or two year interval.

TRANSFORMERS
INTERVAL
6 years *

Complete service on OLTC (only certified
personnel are allowed to do this). *Depends on
whether tap-changer is oil or vacuum type.


BUSHING AND JOINTS
Bushings generally do not require maintenance. Surface
contamination is caused by natural deposits (such as early
morning dew, salt fog in sea coast areas,etc.) and industrial
pollution. Such contamination has often resulted in noisy
substations, damage of insulating surfaces, partial
discharge, tracking flashover, and loss of power. The
porcelain insulators of the transformer bushings ought to be
cleaned during service outages as often as necessary. Use
recommended cleaning agents for cleaning the bushings.
The condition of the external conductor and bus bar joints of
the transformer bushings shall be checked at regular
intervals. Maintenance of the bushings shall be performed
according to the instructions given by the bushings
manufacturer.

TRANSFORMER ACCESSORIES
Depending on customer requirements transformer can be
equipped with accessories (oil and winding temperture
indicator, pressure relief device, oil level indicator, bladder,
silicagel breather, current transformers, etc.) that are not
standard for each transformer. For all transformer
accessories it is recommended to be tested yearly. Relays
should be cleaned, lubricated and calibrated periodically in
accordance with manufacturers instructions. It is also
necessary to check apparatus, electric cables and
conductors, signal and control devices in the control room.
For detailed informations please refer to manufacturer
maintenance instructions.
.


COOLING SYSTEM
The cooling equipment is the most important part in the
normal daily operation of a transformer. Special care,
maintenance and inspection is necessary, since any
abnormality can reduce the life time of the transformer or
cause serious defects.
For radiator type cooling system (ONAN) check for oil
leakage. If the radiators are detechable, check that the
valves are open.
If the transformer is equipped with forced oil cooling (OF),
check the oil circulating pumps for any unusual noise or
flutter in the oil flow gauge.
If the transformer is equipped with air cooling (AF), examine
the fans to ensure there is no debris covering them or that
the blades are blocked. Check to make sure each fan is
operational and that the blade rotation is correct.
.

TRANSFORMER AND OLTC CONTROL CABINET
De energize the auxiliary power source and inspect the
control devices in the control cabinet. Remove grease, oil or
other contaminants. Do not soak the parts with a cleaner,
but use just enough to loosen grease or dirt so that it can be
wiped off. For cleaning small parts a small paint brush
dipped into the cleaning solution is good for getting into
corners and crevices. Repair or replace any broken or
malfunctioning part, tighten all loose connections and
eliminate any oil or water leaks into the compartment.
ATTENTION:If the transformer is de-energized, heather
inside the control cabinet should be turned on, especially in
case of low ambient temperatures.

1.Repair of transformers on the site

2. Repair of transformers in the repair workshop


1.Repair of transformers on the site
Replacement of bushings
Replacement of the sealing (gaskets)
Replacement of transformer accessories
Maintenance of the cooling system
Cleaning and painting of the outside surfaces and the fittings
Stopping of oil leakage
Replacement of oil
Oil conditioning


2. Repair of transformers in the repair workshop
Making new windings
Replacement of the insulation
Repair or replacement of the core
Replacement of the wiring
Replacement of the OLTC
Replacement of valves
Sandblasting and painting of tank, cover and conservator
Vacuum or Kerosene drying of windings and active parts
All electrical test of transformers according IEC standards


Testing a transformers after repair
Dielectric tests are defined by IEC 60076-3:2010 article 8

Sources
[1] Moisture Determination and Degradation of Solid Insulation System of
Power Transformers, C.Sumereder and M. Muhr, Graz University of
Technology
[2] Properties of Mineral Insulating Oils in Service, P. Wiklund and B.
Pahlavanpour
[3] Service and maintenance of transformers, M.Scaefer, Transnet BW.
[4] Dejan Susa, Sintef
[5] Transformerboard II , H.P.Moser and V.Dahinden
[6] Transforme diagnostic Common used and new methods , G.J.Puckel
[7] Facilities instructions, standards and techniques volume 3- 31, United
States Department of Interior,Bureau of Reclamation, June 2003

Thank you for your attention!

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Jasenko Kosorcic

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KONAR Distribution and Special Transformers, Inc.

MAINTENANCE AND REPAIR OF

Maintenance and repair of

1.Why transformers are important?

Maintenance and repair of

2. Why is necessary to maintaining transformers?

3. Aging of the transformers

Particular cause Influence on transformer

Mech. Winding stress

Maintenance and repair of

3. Aging of the transformers

Degree of polymerization (DP) is a number of single

Maintenance and repair of

3. Aging of the transformers

Maintenance and repair of

3. Aging of the transformers

Maintenance and repair of

3. Aging of the transformers

Aging or deterioration of insulation is a time function

Maintenance and repair of

3. Aging of the transformers

Maintenance and repair of

3. Ageing of the transformers

Maintenance and repair of

3. Aging of the transformers

60% to 66% life

30% life remanining

Maintenance and repair of

3. Aging of the transformers

The main force of oil aging is oxidation.

Maintenance and repair of

3. Aging of the transformers

Water content of oil as function of time [5]

3. Aging of the transformers

Acid number of oil as function of time [5]

3. Aging of the transformers

Colour number of oil as function of time [5]

3. Aging of the transformers

Loss factor tan of oil as function of time [5]

3. Aging of the transformers

Break down voltage of oil as function of time [5]

4. Parts of transformer important from maintenance

Maintenance and repair of

4.1 Postion on the transformer

Maintenance and repair of

4.1 Postion on the transformer

Maintenance and repair of

4.1 Postion on the transformer

Maintenance and repair of

4.2 Transformer oil

Maintenance and repair of

4.2 Transformer oil

Maintenance and repair of

4.2.1 Function of transformer oil in transformer

Function of transformer oil in transformer is to insulate

Maintenance and repair of

4.2.2 Groups of tests for mineral insulating oils according

Maintenance and repair of

4.2.3 Colour test

According ISO 2049:1996, Petroleum products -- Determination

4.2.4 Breakdown voltage test

Maintenance and repair of

4.2.4 Breakdown voltage test