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I. GENERAL:
Maintenance of transformers in these days has become prime importance,
since the cost of new equipments has considerably increased thereby increasing
the cost operation for restoration of power supply in addition to loss of revenue.
This has led the ESCOMS to adopt condition-based maintenance of the
transformers than the preventive maintenance. The general maintenance, which is
normally required to be done on transformer is as under.
a. Regular inspection of the external surface of the transformer for any dirt &
dust and when required the same shall be cleaned.
b. Regular inspection of the external surface for any damage
due to rust.
c. Possible rust damages when noticed are to be removed and surface treatment
restored in the original state by means of primer and finished paints for
minimizing the risk of corrosion and its subsequent spreading.
d. Check for any oil leakage.
e. Check for any mechanical damage.
f. Check for oil levels.
g. Check that the surrounding area is kept clean & tidy.
h. Check for the conditions of bushings for damages if any.
i. Check for connectors both on HV & LV side for their
tightness and
formation of sulphate formation if any.
j. Before carrying out any maintenance work ensure proper safety procedures.
II. TYPES OF MAINTENANCE:
Based on the above principle the types of maintenance may be classified as
under.
a. Breakdown maintenance: The nomenclature itself indicates that, the
maintenance is to be carried out when the transformer fails. In this case, as such
no maintenance is carried out, but the quantum of loss to the equipment can be
assessed, repaired and re-use the equipment. This will in no way reduce the loss
of revenue. As many as 5% of transformer failures are because of poor
maintenance.
b. Preventive maintenance: This type of maintenance is being carried out by
almost all ESCOMS. In this type of maintenance, all the transformers are
inspected at regular defined intervals. The determination of the maintenance
intervals are based on various reasons like, the life of the transformer already
served, different guide lines issued by the manufacturer and on the previous
experience.
c. Condition based monitoring: This type of maintenance is adopted to assess
the condition of the transformer, which is assessed based on different condition
monitoring tests at well determined periodicity.
Periodicity
Monthly
Monthly
Monthly
Monthly
Yearly
Monthly
Monthly
Half yearly
Half yearly
If required.
Yearly
Yearly
3 yearly
3 yearly
3 yearly
If required.
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
If required.
If required.
If required
Procedure:
1. For filtration of the transformer, first the inlet to the machine is taken from the
bottom of the transformer tank and the outlet is connected to the top of the
tank. These connections will be reversed at every 12 hours interval for better
results.
2. Ensure that all hose connections are air tight.
3. The inlet and outlet valves of the transformer to the plant are open after
evacuating the system for some time.
4. The oil first enters the preliminary filter where the coarse particles are filtered,
after which the oil enters heating chamber where the moisture is removed.
5. After this the oil enters degassing chamber wherein the dissolved gasses are
degassed.
VI.
Drying of the transformer:
Whenever, either the transformer is taken out for repairs or IR values have
gone down because of deterioration of cellulose material the moisture entered in
the paper insulation, the transformer needs drying.
Procedure:
1. Coolers are to be isolated to avoid heat loss in addition to the transformer be
covered with tarpaulin.
2. Additional room heaters may be provided for accelerating the drying process.
3. Oil level to be topped up to just above the winding in case of normal drying
process and totally drained in case of vacuum drying.
4. Care shall be taken that, all leaks are properly sealed by replacing the gaskets.
5. Drying process will be commenced by filtering the oil through a streamline
filter.
6. For speedy operation short circuit may be done simultaneously by shorting
LV side and connecting 415 Volts supply to HV side.
7. In case of the transformer core is opened for major repairs in the repair bay
vacuum drying is advised.
8. The IR values are measured at regular intervals ae same temperature and
noted down.
9. In case of power transformers of capacity 50 MVA & above, and in case the
moisture is absorbed in core & winding, drying process needs to be more
effective. Under such circumstances rigorous vacuum drying is done by using
dry ice. (Carbon dioxide in solid state)
Dangerous
Poor
Questionable
Fair
Good
3. Ratio Test:
This test is conducted by applying 400 V AC across HV terminals
keeping LV open. Voltage both on HV & LV side are recorded for
each tap position of the transformer and compared with the factory test
results or with the name plate, wherein the variation in the voltages at
each tap positions are indicated.
4. Winding Resistance Test:
This test is done with a separate kit called the winding resistance test
kit. The resistance is measured and then computed at 75C for all
practical purposes of comparison with the design specified values,
previous values and diagnostics. The cold temperature of winding shall
be determined as accurately as possible when measuring the cold
resistance.
The results of transformation/voltage ratio are absolute and may be
compared with the specified values measured during factory testing.
The acceptance criteria should be that the measured values are within
0.5% of the specified values for all windings. One should also consider
the trend of voltage ratio values with reference to voltage ratio values
measured during commissioning tests. The results of this test will help
to identify whether there is open circuit in any of the tap position.
5. Short Circuit Test:
This test is conducted by applying 400 V AC across HV terminals
keeping LV short circuited. Current both on HV & LV side are
recorded for each tap position of the transformer and compared with
the factory test results. Care shall be taken to see that suitable size
shorting wire shall be used for shorting, which can be calculated based
on the impedance voltage, mentioned on the name plate and it is in
percentage. This indicates the voltage that needs to be applied to allow
the full load current to flow. The proportionate current can be
calculated, since the maximum voltage that is available for
testing/handling is limited to 440 volts.
The results of this test will help to identify whether there is
open
circuit or short circuit in any of the tapping winding or main winding.
6. Magnetic Balance Test:
This test is conducted only on three phase transformers to check the
imbalance in the magnetic circuit, mainly when the transformer is
transported or the transformer has sustained severe faults.
a) Keep the transformer in normal tap position.
b) Disconnect the neutral earthing.
9. Pre-commissioning Checks:
a) Checking of Magnetic Oil gauge. (MOG): This is located on the
conservator tank. The function is to indicate the oil level in the
conservator tank. There are two NO contacts. Alarm is given for
low & high trip. The circuit is to be checked.
in a container called the cell. Oil required for this purchase is about 0.5 ltr.
First oil is collected allow it settle for one minute so that it does not contain
any air bubbles or floating impurities or impurities settle down. As the kit
is motorized, voltage is slowly built up at the rate of 2 kV/Sec. when the
kit is switched on. At certain voltage, the kit trips when the oil sample
under test attains break down value. Note the value. Repeat the test on the
same sample six times. The average of these six readings is the BDV value
of the oil under test.
b) Moisture Content/Water content Test: Water, in minute quantities, is
harmful in power equipment because it is attracted to the places of greatest
electrical stress and this is where it is the most dangerous. Water
accelerates the deterioration of both the insulating oil and the paper
insulation, liberating more water in the process (heat catalysed).There are
different kits available for conducting this test. The results are directly
available from the kit,
when the oil sample under test. There is a relation with the values
of BDV & Moisture Content values. If the BDV value
decreases, the Moisture content value increases and vice versa.
c) Tan Delta & Resistivity Test: Also called the Dissipation test measures
the leakage current through an oil, which is the measure of the
contamination or deterioration i.e. Reveals the presence of moisture resin,
varnishes or other products of oxidation oil or of foreign contaminants
such as motor oil or fuel oil. The test is not specific in what it detects i.e. is
more a screening test. Both these tests are conducted in one set of testing
kit and are simultaneously.
d) Acidity or Neutralization number: Acids in the oil originate from oil
decomposition/oxidation products. Acids can also come from external
sources such as atmospheric contamination. These organic acids are
detrimental to the insulation system and can induce corrosion inside the
transformer when water is present. An increase in the acidity is an
indication of the rate of deterioration of the oil with SLUDGE as the
inevitable by-product of an acid situation which is neglected.
e) The Interfacial Tension (IFT): This test measures the tension at the
interface between two liquid (oil and water) which do not mix and is
expressed in dyne/cm. The test is sensitive to the presence of oil decay
products and soluble polar contaminants from solid insulating materials.
f) Flash point: Flash point measures the oil at which the oil may catch fire
because of internal fault of the transformer.
g) Sludge/Sediment: This measures the quantity of sludge present in the oil,
which is not supposed to be. During test, if sludge is detected, then it will
be recommended for replacement of transformer oil.
Reference
IS 1866
IS 1866
IS 1866
IS 1866
IS 1866
IS 1866
IS 1866
IS 1866
Sl.No.
1
2
3
4
5
6
7
Gases
Period of Service
4 Years 4 to 10 Yrs.
Methane (CH4) PPM
50/70
100/150
Ethylene (C2H4) PPM
100/150
150/200
Ethane (C2H6) PPM
30/50
100/150
Acetylene (C2H2) PPM
20/30
30/50
Carbon Monoxide (CO) 200/300
400/500
PPM
Carbon Dioxide (CO2) 3000/3500 4000/5000
PPM
Hydrogen (H2) PPM
100/150
200/300
10 Years
200/300
200/400
800/1000
150/200
600/700
9000/12000
200/300
But as per IS 10593:1992, the following are the specified values of gas
concentrations. These are the values that have been arrived at, by conducting DGA
test on 15000 power transformers, in 15 different utilities, where are transformers
are in service.
Sl. No.
Gasses
Test results
1
Methane (CH4) PPM
40-110
2
Ethylene (C2H4) PPM
60-280
3
Ethane (C2H6) PPM
50-90
4
Acetylene (C2H2) PPM
3-50
5
Carbon Monoxide (CO) PPM
540-900
6
Carbon Dioxide (CO2) PPM
5100-13000
7
Hydrogen (H2) PPM
60-150
There are different methods adopted for analyzing the DGA results.
1. IEC 599
C2H2
CH4
C2H4
C2H4
H2
C2H6
Ratios of
characteristic gases
0.1
0.1-1.0
0
1
0
1.0-3.0
1
0
0
3.0
1
2
1
2
2
2
Case Characteristic fault
Typical examples
No.
0
No fault
0
0
0
Normal ageing
1
Partial discharges
0
1
0
Discharges in gasof Low energy
But not
filled cavities
density.
significant
Partial discharges
of Low energy
density.
Discharges of low
energy
1-2
1-2
Discharges of High
Energy
Thermal fault of
Low Temperature
<150C
Thermal Fault of
Low Temperature
range 150C-300C
Thermal fault of
Medium
temperature
range 300C-700C
Thermal fault of
high temperature
>700C
resulting
from incomplete
impregnation, or
super saturation
or cavitations or high
humidity.
As above, but leading
to tracking or
perforation
of solid insulation.
Continuous sparking
in oil between bad
connections of
different potential or
to floating potential.
Breakdown of oil
between solid
materials.
Discharges with
power followthrough.
Arcing-breakdown of
oil between windings
or coils, or between
coils to earth.
Selector breaking
current.
General insulated
conductor
overheating
Local overheating of
the core due to
concentrations
of flux. Increasing hot
spot temperatures;
varying from small
hot spots in core,
overheating of copper
due to eddy currents,
bad
contacts/joints
(pyrolitic carbon
formation)
up to core and tank
circulating currents.
2. SUGGESTED DIAGNOSIS FROM GAS RATIOS-ROGERS
RATIO METHOD
CH4
H2
>0.1
<1.0
0.1
C2H6
CH4
<1.0
C2H4
C2H6
<1.0
C2H2
C2H4
<0.5
Suggested Diagnosis
<1.0
<1.0
<0.5
0.1
<1.0
1.0
>0.1
<1.0
>1.0
<1.0
<1.0
3.0
0.5 or
3.0
<3.0
3.0
Partial Discharge
corona
Partial
Dischargecorona
with tracking
Continuous discharge
<1.0
1.0 or
3.0
<3.0
<1.0
>1.0
<1.0
1.0 or
3.0
<3.0
1.0 or
3.0
<3.0
>0.1
<1.0
>0.1
<1.0
1.0
<3.0
1.0
<3.0
Normal
<1.0
<1.0
<1.0
0.5 or
3.0
<3.0
0.5
<3.0
<0.5
1.0
<1.0
<0.5
Overheating
150-200C
1.0 <1.0
1.0 <1.0
<0.5
>1.0
1.0
<3.0
1.0
<3.0
3.0
<0.5
Overheating 200300C
General conductor
Overheating
Circulating currents
in windings
Circulating currents
core and tank;
overloaded joints
<1.0
<1.0
<0.5
<0.5
There are methods like Key gas method of analysis, in which reports are given based
on the prominent gasses generated and Dornenburg Ratio Method, wherein it is
indicated that, minimum gas concentration shall be 100 ppm, otherwise no gas ratio
method can be adopted.
ORIGIN OF GASES IN TRANSFORMER OIL
Fault gases are caused by corona (partial discharge), thermal heating (pyrolysis) and
arcing.
PARTIAL DISCHARGE is a fault of low level energy which usually occurs in
gas-filled voids surrounded by oil impregnated material.
The main cause of decomposition in partial discharges is ionic bombardment of the
oil molecules.
The major gas produced is Hydrogen. The minor gas produced is Methane.
THERMAL FAULTS. A small amount of decomposition occurs at normal
operating temperatures. As the fault temperature rises, the formation of the
degradation gases change from Methane (CH4) to Ethane (C2H6) to Ethylene
(C2H4).
A thermal fault at low temperature (<300deg/C) produces mainly Methane and
Ethane and some Ethylene.
A thermal fault at higher temperatures (>300deg/C) produces Ethylene. The higher
the temperature becomes the
greater the production of Ethylene.
ARCING is a fault caused by high energy discharge.
The major gas produced during arcing is acetylene. Power arcing can cause
temperatures of over 3000deg/C to
be developed.
NOTE : If the cellulose material (insulating paper etc.) is involved , carbon
monoxide and carbon dioxide are
generated.
A normally aging conservator type transformer having a CO2/CO ratio above 11 or
below 3 should be regarded as perhaps indicating a
fault involving cellulose, provided the other gas analysis results also indicate
excessive oil degradation.
EARTHING OF THE TRANSFORMER CENTERS.
1. The earthing pipe shall be of 40 mm diameter and 2.5 mtr. Long and is a
galvanized pipe.
2. The pits shall be dug to the complete depth and at a distance of twice the
length of the electrode.
3. The earth electrodes can be laid in triangular configuration if the space is
insufficient.
4. These earth pits shall be back filled, after inserting the earth electrode, by
means of alternate layers of Charcoal, Salt, sand with excavated stuff, if it is
soft soil. Borrowed stuff shall be laid if the excavated stuff is hard soil/rocky
soil. Sufficient watering shall be done to get good results.
5. Earthing leads may be multi strand GI wire or MS flat shall be run from i)
Neutral, ii) body and all the structure included and iii) lightening arrestors, to
independent electrodes and shall be firmly joined.
6. All the three earth electrodes shall be interconnected in the ground.
7. The earth resistance of all the electrodes shall be less than 5 ohms.
8. If the results are above the acceptable values, proper strengthening shall be
done by using bentonite clay or cast iron pipes or plate earthing may be
proposed. On the other hand, an earth mat also be designed and provided.
Space between any two electrodes is twice the length of the electrode