01 - Power Transformer Saudi Arbia

ASTUDYTODETERMINETHEROOT
CAUSESOFREPEATEDFAILURESONMV
CABLETERMINATIONSATNATIONAL
GRIDSASYSTEM
12May2013
Jeddah SaudiArabia
Hussain Mueidh AlYami

LinesMaintenanceDepartmentManager
1
TheMainGoaloftheElectricUtilitiesis
TheworldIllumination!
ButthereisanaggressiveEnemy
Whichis
ElectricalEquipmentFailures!
TableofContents
Introduction
DataCollection
BrainStorming
DataAnalysis
SubstationswithHighFailureRate
SamplesInvestigationsandSiteVisit
ConclusionandRecommendations
Introduction
NationalGridSAhasmorethantwothousandtransformers(2012transformersupto
midofMarch2013)initssystem.
MVCrosslinkedPolyethylene(XLPE)insulatedcables cablesareusedtoconnect
thesestepdowntransformerstoMVswitchgears.
NationalGridSAnetworkwereinterruptedbyseveralMVcablefailures.
MVcableterminationswerethesourceofthesecablefailures.
Inadditiontothehighcostofrepairingthesefailures,theycauseanegativeeffecton
theavailabilityandreliabilityofNationalGridSAnetwork.
Itwasdecidedtostudythisproblemtofindouttherootcauseofthesefailuresand
recommendthesolution.
4
DataCollection
Before starting the study, the problem size must be identified
by collecting the statistical data of the MV cable termination
failures from all Operating Areas. The failures numbers were
collected from the following areas:
CentralOperatingArea(COA)
EasternOperatingArea(EOA)
WesternOperatingArea(WOA)
SouthernOperatingArea(SOA)
DataCollection
The collected data were covering the last 5 years.
In terms of the number of failures, the following chart shows a comparison
between these different working areas.
The great deal of termination failures were concentrated in COA.

As a result, the study focused on that Area.
6
DataCollection
The COA consists of three subareas, namely Riyadh, Qassim and Hail.
The following chart shows a comparison between these three subareas.
All Sub Areas have significant failures . As a result, all sub areas will be studied .
7
BrainStorming
A brain storming for the main possible root causes that may affect the service
lifetime of the MV cable terminations and may lead to the MV cable termination
failure was done. The possible causes were as follow:
Bad workmanship.
Overheat ( overloaded )
Overvoltage.
Termination Design problems..
Manufacturer Installation Instruction problem.
Wrong selection for the termination size.
Wrong Grounding and /or high grounding resistance.
Cable lug design.
Improper design of transformer's LV cable box.
BrainStorming
Since these terminations were manufactured by the same manufacturer
in all areas and the failures were concentrated in COA only, so all causes
related to termination materials and design were eliminated. The study
focused on the following root causes:
Bad workmanship.
Overheat ( overloaded )
Overvoltage.
Manufacturer Installation Instruction problem.
Improper design of transformer's LV cable box.
DataAnalysis
The data were collected for both 33 kV and 13.8 kV. 13.8 kV termination
failures present only (approx. 6%). The design principle and operational
conditions are the same, the two voltage levels can be considered together
neglecting the factor of voltage level.
The concern was taken about dimensions of transformer LV cable boxes
which might introduce electrical stress on cable terminations. Drawings of
cable boxes were selected randomly for reviewed and they were found
complying with the specifications.
The data of transformers loads and voltage profiles of 33kV & 13.8kV bus
bars were requested in order to use them in the study. The available data
was not comprehensive and not sufficient as it was expected to be.
However, the available data gives some hints about where to look.
10
DataAnalysis
The entire failures in COA for the last five years ( 112 failures ) were
concentrated at 39 substations out of 227 substations (100 % of Faults
occurred at 17.2% of Sub. ) .
About 68% of these interruptions occurred in 11 substations out of these
227 substations (68 % of Faults occurred at 4.85 % of Sub. )
These substations with high failure rate were reviewed, case by case.
11
RiyadhArea
In Riyadh area, the entire 34 interruptions in the last five years occurred in 19
substations out of 162 substations ( 100 % of Faults at 11.7% of Sub.).
47% of these interruptions occurred in 3 substations out of all ( 47 % of Faults at
less than 2% of Sub.).
These substations are 8508, 8505 and 8034.
12
8075
8047
8033
8129
8605
8036
8026
8019
9013
1 1
8705
1 1
8010
1 1 1
8096
1 1 1 1
8014
1 1
8021
8038
8027
8034
2 2
8508
2%
6 6
8505
7
6
5
4
3
2
1
0
47%
RiyadhArea Substation:8508
BarChartshowingtheNumberofFailuresonaMonthly Basisduring
thelastFiveYears
2.5
2
2
66%ofFailuresoccurinthewinterandspring
1.5
1
0.5
0
It was having a very light load ( 2001 to 2007).

Rapid increasing in the infrastructure development.
BarChartshowingtheNumberofFailuresonanIncidentTimeBasis
The load of the substation was also on the rise.
duringthelastFiveYears
Late 2010, all terminations were replaced.
As a result, no failures occurred after that.
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
2.5
66%ofFailuresoccurin(AM)
1.5
0.5
0 0 0 0
BarChartshowingtheNumberofFailuresonaYearly Basisduring
thelastFiveYears
0 0 0 0 0
0 0 0 0 0 0
4
2
1
0
0
2008
13
0 0
2009
2010
2011
2012
1
0 0
thelastFiveYears
4
3
83.3%ofFailuresoccurinthewinter
2
1
Radial Substation
All MV cables were replaced at late 2010.
But it is still showing interruptions.
More investigation is needed.
2.5
83%ofFailuresoccurin(PM)
1.5
1 1
0.5
0 0 0
0 0 0 0 0 0 0 0 0 0
0 0
0 0 0
2.5
thelastFiveYears
1.5
1
0.5
14
2008
2009
2010
2011
2012
thelastFiveYears
100%ofFailuresoccurintheautumn&winter(justaftersummer)
3
2
Was subjected to a fire incident mid of 2006.

MV cables were affected and replaced in 2006.
Heavily loaded in the last three years.
Out of firm capacity in the last year.
This situation leads to accelerate the failure.
2.5
1.5
0.5
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
thelastFiveYears
3
2
1
1
0
15
2008
0
2009
2010
2011
2012
0 0 0
QassimArea
In Qassim area, the entire 37 interruptions in the last five years occurred in 14
substations out of 37 substations. (100 % of Faults at 37.8% of Sub. )
57% of these interruptions occurred in 4 substations out of all. (57 % of Faults
at 11 % of Sub. )
These substations are 8818, 8606, 8811 and 8802.
57%
10
8
6
4
2
0
11%
16
8
5
4
2
QassimArea Substation:8818
87.5%ofFailuresoccurinthesummer&earlyautumn
3.5
3
2.5
2
1.5
1
0.5
0
Heavily loaded.
2
BarChartshowingtheNumberofFailuresonaMonthly
Basisduring
The tap changers were operated manually.
1
1
1
thelastFiveYears
From the failed terminations investigation and site visit , there were a clear
0 0
0
0
0
0
0
evidences of :
A. Bad workmanship
1 1
1 1 1 1
1 1
B. Overvoltage at the LV side of the transformer
C. Over heat inside the cable box.
Examine all terminations physically and replace the defective.
0 0
0 0 0 0 0 0 0 0
0
0 0 0 0 0
Notify the Dispatcher about the sign of overvoltage.
Monitor the situation.
4
1.2
0.8
0.6
0.4
0.2
thelastFiveYears
3
2
1
1
0
0
2008
17
2009
2010
2011
2012
thelastFiveYears
100%ofFailuresoccurinthesummer
2.5
1.5
1
1
All MV cables were replaced at late 2010.
But it is still showing interruptions. 0.50 0 0 0 0 0
0
0
0 0
The dimensions of cable boxes at the auxiliary
transformers were
not as per the standards.
BarChartshowingtheNumberofFailuresonAnIncidentTimeBasis
The manufacturer was called to study the case.
The cable boxes of the auxiliary transformers were replaced.
No fault occurred after this correction.
1.2
1
1
0.8
0.6
0.4
0.2
0 0 0 0
0 0
0 0 0 0 0 0
0 0 0
thelastFiveYears
3
2
0
2008
18
2009
2010
2011
2012
0 0 0 0
thelastFiveYears
75%ofFailuresoccurintheWinter
2.5
2
2
1.5
1
0.5
1
1.2
1 1
Radial Substation
No failed terminations were available for investigation.
0.8
0.6
0.4
0.2
0 0 0 0
thelastFiveYears
0 0 0 0 0 0 0 0 0
0 0 0 0
3
2
2
1
1
0
19
0 0 0
1
0
0
2008
2009
2010
2011
2012
thelastFiveYears
2.5
75%ofFailuresoccurinthesummer&autumn
2
1.5
0.5
0
2.5
Heavily loaded in the last five years.

Out of firm capacity in the last three years.
2
1.5
0.5
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
2.5
thelastFiveYears
2
1.5
1
0.5
0
20
2011
2012
0
2008
2009
2010
HailArea
In Hail area, the entire 41 interruptions in the last five years occurred in 6 switching
substations out of 28 switching substations (100 % of Faults at 21.4% of Sub.).
95 % of these interruptions occurred in 4 substations out of all (95% of Faults at
14.3 % of Sub. ) .
These substations are 8901, 8914 , 8915 and 8913.
20
95%
18
15
11
10
5
0
14.3%
21
7
3
HailArea Substation:8901
66.6%ofFailuresoccurinthesummer
3.5
2.5
thelastFiveYears
1.5
1
0.5
0
Radial Substation.
The MV cables were replaced at late 2009.
But it is still showing interruptions
More Investigation is needed.
0
66.6%ofFailuresoccurin(PM)
2.5
1.5
1 1 1
1 1
0.5
thelastFiveYears
0 0
0 0
0 0
10
6
4
2
2
1
22
0 0
2008
2009
2010
2011
2012
thelastFiveYears
2.5
85.7%ofFailuresoccurinthesummer
2
1.5
1
Radial Substation.
The MV cables were replaced at late 2009.
0.5
1.2
1
1
1
0.8
0.6
0.4
0.2
thelastFiveYears
23
3.5
3
2.5
2
1.5
1
0.5
0
0 0 0 0
0 0 0
0 0 0
0 0
3
2
0
2008
2009
2010
2011
2012
0 0
66%ofFailuresoccurinthesummer
1.2
0.8
thelastFiveYears
0.6
0.4
0.2
0
The cables were newly energized (2012).

Failed terminations were investigated.
There were a clear sign of Bad workmanship.
All cables and cable terminations were replaced.
No fault recorded since the time of replacement.
0
1.2
0.8
0.6
0.4
0.2
thelastFiveYears
2.5
2
1.5
1
0.5
0
24
0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
2008
2009
2010
2011
2012
0 0
thelastFiveYears
90%ofFailuresoccurinthesummer&autumn
4
3
3
2
1
1
0
2.5
The MV cables were replaced in 2008.

2 54.5%ofFailuresoccurin(PM)
1.5
0.5
0 0 0 0
thelastFiveYears
0 0
0 0 0 0
5
4
2
1
1
0
25
2008
2009
2010
2011
2012
A site visit was made to Substation 8818 which is one of the substations that has high
failure concentration, in order to have a close look to the operational environment and
try to find some clues about possible root causes.
It was noticed that the tap changers of the transformers were operated manually
which affects the accuracy of voltage control at the low voltage side.
26
Voltage stresses were suspected on the terminations of that substation since there were a clear
spark between connection bar and cable boxs wall. This evidence was obtained from some previous
pictures.
Substation8818
Flashovers on the cable box wall

indicates overvoltage that breaks
the gap between connecting bar and
box's walls.
The edges of the connecting bar

were melted because of arcs.
27
Healthy termination removed from Substation 8818 for investigation . It shows non
compliance of installation instructions and effect of overheating or improper
application of stress control tube
Failure due to bad workmanship. Non
compliance of the installation instruction
led to failures
Substation8818
Brown color due to loose stress control tube (SCT).

Improper application of SCT or overheating of
cables affects termination's mechanical integrity.
28
Failed termination removed from Substation 8915 in Hail area, shows the use of the
wrong tool to cut the semiconducting layer.
Failure due to bad workmanship.
The use of wrong tools led to
failure.
29
It can be inferred that the termination is most likely to fail if it is operated in
an environment that has one the following characteristics:
A. Radial Substation.
B. Heavily loaded Substation .
C. Lightly loaded Substation.
Because of lack of data, identifying an exact contribution of each factor on the
failures was difficult. Thus, informative database must be built starting from 2013.
However, it was obvious that the installation instructions were not followed exactly
and human errors is the greatest among other factors in all investigated
terminations.
30
Confirmation that all terminations were brought from the correct source is needed.
The Batch No. of each termination must be provided and recorded in the AsBuilt
Drawing.
The installation of each termination must be performed by a Certified Jointer.
The installation of each termination must be supervised by the COMPANY personal.
Each termination must have a name plate.
The name plate should consist (Contract Information, Name of jointer, SEC
Supervisor Name, Installation Date, Manufacture Date and Enegization Date).
31
More investigation is needed in the following Substations :
Riyadh Area ( 8505 , 8034 )

Qassim Area ( 8802 , 8811 , 8818 ( Monitor Only after the correction ) )
Hail Area ( 8901 , 8913 , 8914 )
In term of the following aspects :
32
Does it subjected to Over loading? Record from Jan 2013 to Dec 2013
Does it subjected to Over voltage? Record from Jan 2013 to Dec 2013
Does the actual cables ampacity within the rated value ?
Does the terminations import from the main source?
Investigate each single faulty termination and record the result.
Cable and Substation earthing system.
ThanksForyourKindAttention
Q&A
33
In order to contain the failures by building an informative database and enhancing
installation and maintenance procedures, the following recommendations are to be
followed:
1. The contractor must provide proof that all terminations were brought from the
correct source. The Batch No. of each termination must be provided and recorded in
the AsBuilt Drawing.
2. The installation of each termination must be performed by a Certified Jointer and
the contractor must comply with this. The contractor must submit a name plate for
each termination. The name plate should consist (Contract Information, Name of
jointer, SEC Supervisor Name, Installation Date, Manufacture Date and Enegization
Date). This name plate must be provided and recorded in the AsBuilt Drawing.
34
3. The installation of each termination must be supervised by the COMPANY personal.
The COMPANY supervisor name must be added to the name plate of each termination.
4. Each sample is an evidence and therefore, samples should be preserved and
documented in a correct way that keeps the sample integrity as it was, when
removed.
5. Accurate data about the incidents, events that happened at the same time and
weather and operational records are very important in the analysis stage. In
addition, terminations that are installed under the same contract or by the same
contractor should be stored together because they are more likely to have the
same failure cause.
35
6. Installation instructions should be clear and easy to follow and read. Manufacturers
shall be called to conduct short courses about their products and installation
instructions. In the case of unclear or missing instruction, feedback should be sent to
the manufacturer to update their instructions and make them clearer.
7. After the samples are collected and documented properly, a group of experts shall
analyze the failure and identify the possible root cause. As a result, an informative
database will be built and recommendation shall be made to improve the service life of
terminations. In case of human errors, the most common human errors should be
presented to SEC personnel in order to consider them carefully in the new projects and
maintenance work. In addition, feedback should be sent to manufacturer in case of
design errors or unclear instructions.
36
8. All findings should be reported and documented in order to build a strong
experience about this subject. By building the experience, we will gain many benefits
such as; training improvement, outages reduction, cost reduction and reduction of the
need of diagnostics. In addition, we will be able to predict failures and increase the
network reliability.
9. A database for the over voltage and the over load on the 33kV & 13.8 KV
transformers should be available and easy to access in order to have an idea about the
maximum voltage and maximum load that might affect the termination service life.
Moreover, all transformers with manual tap changer should be modified to be
automatic controlled tap changer.
37

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ASTUDYTODETERMINETHEROOT

Hussain Mueidh AlYami

The great deal of termination failures were concentrated in COA.

It was having a very light load ( 2001 to 2007).

Was subjected to a fire incident mid of 2006.

Heavily loaded in the last five years.

The cables were newly energized (2012).

The MV cables were replaced in 2008.

Flashovers on the cable box wall

The edges of the connecting bar

Brown color due to loose stress control tube (SCT).

Riyadh Area ( 8505 , 8034 )

In term of the following aspects :

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