A Solution for Maintenance of Power Transformer Operating

Under Frequent Overloads

Jean-Claude Duart
DuPont de Nemours International S.A., Geneva-Switzerland

David J. Woodcock
Weidmann Systems International Inc, Lyndonville, VT-USA

Keywords Overload management - uprating - transformer useful life - hybrid insulation - maintenance
- modernisation - economics - contingency load

Abstract Changes in the way utilities manage their transmission and distribution assets, as well as
increases in peak load demand, has led to the need to subject more and more substation transformers
to overload conditions. This paper will present the concept of utilizing a high temperature insulation
system, also called a hybrid insulation system, as a way for enhancing the performance and load
capability during the transformer repair process.

Hybrid insulation systems are becoming more common, particularly in the transformer repair industry, as
they provide an opportunity to add load capability and reliability to failed units. The high dependence of
electrical properties of cellulose on its moisture content, the mechanical behaviour under compression,
the reduced life expectancy at hot spot temperatures (140°C to 160°C is generally accepted for overload
conditions), the water generation as it ages (reducing oil quality) and the gas creation are discussed in
this technical paper.

The availability of insulation materials with both improved temperature and dielectric properties, has
allowed transformer manufacturers to replace the cellulose in the transformer windings. New
applications like traction transformers, mobile units or rectifiers have extensively used this high power-
density advantage. In the case of re-engineering failed or under-utilized transformer, significant
improvements can be made to the existing design when utilizing the same core dimensions. By taking
advantage of properties of high temperature insulating materials, the windings of such
units can be redesigned to allow an increase in average winding rise. In so doing, the normal and
overload capability of the transformer can be significantly increased. In addition, reduced load losses
can be achieved resulting in cooler windings at existing load levels.

The repair unit's windings can be redesigned to include more active material, thereby making better use
of the available space within the core window. The typical transformer is then designed with a 95 K
winding rise and a 105°C maximum top oil temperature. Depending on the original design, the power
rating can usually be increased 20% to 100%, with 50% being an average value. Increased capacity,
enhanced system flexibility in loading, reduced losses and improved reliability are all key advantages for
this concept, which has been applied in more than two hundred rebuilt transformers around the world.
Examples of rebuilt transformers will be presented with some of the economical aspects. High
contingency of load capability, with minimal loss of insulation life, will also be discussed.

IEEE P.E.S. Transformers Committee in the USA established a Working Group to investigate what
standards or guides could be formulated. A Trial Use Guide for the application of high temperature
insulation materials in liquid immersed power transformers has been issued and it was confirmed last
year as a full standard. This guide provides information guidelines for applying existing qualified high
temperature materials to insulation systems suitable for high temperature liquid immersed power
transformers. It also gives recommendations regarding the loading of high temperature liquid immersed
power transformers and technical information for insulation system temperature rating and test
procedures for qualifying new high temperature materials as they become available. These points will be
detailed in the paper.
Introduction In the middle of the 1980's, introduction of a pressboard material suitable for high
temperature operation made possible the concept of insulating systems for liquid filled power
transformers different than the conventional cellulose-mineral oil system.

One example is the development of high temperature insulating systems, which combine high
temperature solid insulation and high temperature fluid. These systems have found interest for
applications such as traction transformers [1], and pole distribution transformers [2]. But another system,
called a hybrid insulation system, has been developed, which combines high temperature solid
insulating materials with cellulose based materials and mineral oil. This paper will describe technical and
economical advantages of such a system for power transformers, especially in the area of
modernization and repair of power transformers. This approach has provided utilities with another option
in transformer life management, especially for those units that see frequent overloads. Application in the
case of short or long term contingency loading is also possible with a negligible loss of insulation life
when compared to conventional cellulose systems. Utilities and transformer manufacturers in the USA,
where the technology has been used for several years, have worked together to develop a standard that
provides guidance in the application of hybrid insulating systems in power transformers.

Increased Demand for Normal and Contingency Loading

New rules in the deregulated electric utility business require Transmission and Distribution companies to
find ways to improve their competitive position. Maximizing return on investment (ROI) is often a key
financial driver when formulating a profitable operating financial strategy.

Increased equipment utilization, deferred capital expenditure and reduced maintenance expense are all
a part of the guidelines for today's T & D asset strategists and managers. Although tighter operating
budgets and reduced spending are nothing new to utility engineers and planners, today's increased
need to leverage more out of existing equipment must be achieved with an aged asset base.

At many electric transmission and distribution companies in the United States, the majority of substation
assets are on average 30 years old. Installed power transformer capacity has reduced from 185 GVA
(giga Volt Amperes) to 50 GVA per year over the past twenty-five years (Figure 1). [3]

Figure 1
Installed Power Transformers Per Year

During the same period, average load growth moved slowly upward at a rate of approximately 2% per
year [4]. When replacement transformers are deducted from the total installed, a shortfall in additions for
real growth of the system can be found. Obviously system growth is uneven and regionally skewed
toward the South and Western USA, but on average transformer utilization (load factor) has increased
by 22% (Figure 2). For most substation transformers a 22% increase in load equates to approximately a
48% increase in oil hot spot temperature, at normal peak load [5]. For 65% of transformers in service,
which are 30 years and older, if the average hot spot temperature rise above ambient was 50°C in 1974,
then today the average would be 73°C. This gradual increase in temperature has the effect of reducing
the peak load insulation life by approximately a factor of 8 [6]. Compared to the time when the average
substation transformer was new, there have been substantial changes in the way utilities purchase,
operate and maintain transformers. These changes have, in turn, resulted in a difference in the way new
transformer specifications are optimized, and in the need to enhance some existing designs in the field
to deal with high normal and contingency loading requirements.
 Figure 2
USA Load Growth vs. Utilization and Temperature Increase

This paper touches on changes in design practice for new transformers, but its focus is on design
enhancements to existing units which will have a positive impact on life and loading capability.

Hybrid Insulation Systems

Hybrid insulation systems are based on the advantages of the high temperature materials. Such a
system utilizes high temperature insulation only where it really provides benefits. This means paper for
conductor insulation and board for spacers in cooling ducts (see Figure 3). The rest of the solid
insulation is kept in cellulose, and mineral oil can be used for cooling.

The advantages come from a synthetic aramid fiber discovered in the early 1960's. Aramid fibers and
pulp have long been used in paper and pressboard forms suitable for a continuous operating
temperature of 220°C in air. The thermal stability is related to the strong chemical links we can find in
the molecule. These links also provide a very good chemical stability and compatibility of the polymer
versus all kinds of oil and resins used as insulating materials. Unlike cellulose, no off gases or water are
released due to thermal degradation at temperatures up to 750°C.

From a mechanical standpoint, aramid sheet products have shown better stability and toughness than
cellulose based products when submitted to compression stresses. Extensive testing has shown the low
impact of temperature in insulating liquids compared to cellulose [7]. The Figure 4 provides comparative
results between cellulose pressboard and aramid pressboard. This provides the possibility to retain
extremely tight windings, reducing the risk of failure due to short-circuit forces.

Electrical properties of aramid paper and board have also been demonstrated as being superior to those
of the Kraft materials [8]. Tests on paper wrapped conductors have shown that, under AC conditions
(power frequencies), dielectric strength is similar to Kraft, but under impulse conditions aramid paper
shows a 25% better behavior [9]. As a consequence, aramid insulation can be electrically stressed
under the same levels as oil-impregnated cellulose insulation. Such properties have resulted in a rapidly
growing use of aramid insulation in hybrid insulation systems for power transformers.

Figure 3
Description of solid insulation in a hybrid insulation coil
 Figure 4
Static compression of cellulose board and aramid board under 10 MPa

Allowing higher temperatures on the conductor provides the possibility to reduce cooling. Cooling ducts
can then be redesigned to match electrical limits rather than thermal limits. Two approaches can be
taken. First, one can realize the benefits in utilizing the new space available by adding copper. This will
produce a new design of the coil allowing much greater output with a reduction of losses and better
reliability due to the outstanding properties of the aramid insulation. The second approach takes
advantage of this space available to reduce the size of the coil allowing a transformer with lighter weight
and smaller dimensions. The first approach is the one generally adopted for repair transformers, while
the second approach is generally used for new transformers such as in mobile substations [10].
Advantages of Hybrid Insulation in Transformer Repair

Whenever a failure occurs, this always puts stress on the end-user, utility or private industry, to replace
the transformer as soon as possible. The stress put on the manufacturer is more on delivery time rather
than enhancement of the transformer. However, in certain conditions, the end-user has interest in the
enhancement approach. Actually, the increase of the load on the transformer due to a higher demand
may have been the major contributor to the failure. Confronted with the dilemma of buying a power
transformer with higher capacity or repairing the failed one leads to a debate where cost and
manufacturing time of new equipment are the main limitations. A power transformer designed with a
hybrid insulation system can then provide a unique opportunity, which is to increase the capacity of the
failed transformer within the shorter time required for repair. The residual value of the core and tank can
then be utilized.

To increase capacity of a transformer, conductor must be worked harder, which in turn increases
temperature rise. Due to the use of cellulose based materials, this average temperature rise has been
limited to 55 K or 65 K. With the use of thermally stable insulation like aramid or high temperature
enamels on the conductor, temperature rise can be increased. The system limitation is now transferred
from the conductor to the oil. This is shown in the following table describing a design comparison
between a typical 12/20 MVA substation transformer and the same redesigned unit with hybrid insulation
[11].

Table 1
Temperature rises comparison between original unit and
re-designed unit with hybrid insulation system

Original Unit Re-designed Unit

Cooling Mode ONAN ONAF ONAN ONAF
MVA 12 20 18 30
Av. Oil rise / Amb. (K) 38 28 55.7 45.4
Av. Wind. rise / Amb. (K) 50 55 71.5 81.1
Top Oil rise / Amb. (K) 44 37 64.5 60

The limitation in this original unit was due to average winding rise over ambient temperature under forced
air conditions (ONAF), 55 K. Cellulose insulation required that continuous temperature rise had to be
kept below 55 K. Top oil rise under natural or forced cooling operation is well below the limit of 65 K. The
re-designed unit takes advantage of the aramid material, increasing the limit on the conductor. By
increasing the current and/or reducing the cooling close to the conductors, the temperature rise reaches
values well above 55 K, namely 71.5 K and 81.1 K under ONAN and ONAF conditions, respectively. The
limit of the system is now set by the top oil rise under natural cooling mode, 64.5 K. This has allowed a
gain of 50% capacity in both ONAN and ONAF cooling modes.

Recently a breakthrough has been achieved in South America as the first unit operating under 220 kV
was uprated by Ande, the local utility in Paraguay [12]. The modernization has been done by Los Conce
in Argentina. The transformer was a BBC 30/35/10 MVA - 220/66/23 kV built in 1986 that was uprated to
40/30/15 MVA - 220/66/23 kV.

As Table 2 shows a final price of 70% of a new transformer with the same capacity was achieved with
the transformer insulated with hybrid insulation. But compared to a new 40/30/15 MVA - 220/66/23 kV the
savings were about 60% and the utility has gained a 33 % overload capability with lifetime extension
over 25 years.

Table 2
Economics Comparison

Transformer replacement options Price ($) Comparison vs conv. rep

Replacement by a new 30/25/10 MVA - 220/66/23 kV 300 000 62 % 43 %
Replacement by a repaired 30/25/10 MVA - 220/66/23 185 000 1 13 %
Replacement by a repaired 30/25/10 MVA - 220/66/23 210 000 - 12 % 1
Replacement by a new 40/30/15 MVA - 220/66/23 kV 500 000 Not applicable 140 %
New Loading Practices and Effect on Operation

In today's electric utility systems, equipment such as power transformers are required to operate at
higher loading levels during both normal and contingency conditions than in the past. This is reflected in
the added flexibility provided to load planners in the 1995 revision of ANSI/IEEE C57.19.100. The
inclusion of the Planned Loading Beyond Nameplate condition permits higher temperature for periodic or
daily cyclical limits. However, the revised limits require the user to be more rigorous in calculating the
loss of insulation life for various loading criteria. A typical transformer loading policy may include
suggested loading criteria and limits as shown in Table 3.

Life Loading Emergency 1-3 Emergency 1

Insulated Conductor IEEE 120°C 130°C 140°C 180°C
Hottest Temperature IEC 120°C (N/A) 130°C 160°C
Other Metallic (supports, core,IEEE 140°C 150°C 160°C 200°C
etc) IEC (N/A) (N/A) (N/A) (N/A)
IEEE 105°C 110°C 110°C 110°C
Top Oil Temperature
IEC 105°C (N/A) 115°C 115°C
IEEE (N/A) (N/A) (N/A) 1.5 p.u.
Load Factor Per Unit Current
IEC 1.3 p.u. (N/A) 1.3 p.u. 1.5 p.u.

As previously discussed, hybrid insulated units are limited in load capability by their top-oil temperature.
The top-oil temperature is limited to 105° - 110° C in IEEE/ANSI because of the ancillary equipment
located in the top oil of the transformers. Bushings which do not utilize thermally uprated insulating paper
are components which typically set this upper limit. Transformer loading studies should include, in
addition to winding, hottest spot and top oil temperatures, calculation for loss of the insulation life and
temperature rise of the other current carrying components such as: bushings, tap changers, cables, etc.

To establish the loading limits for any given transformer it is necessary to calculate the above criteria or
whichever limit occurs first, for the expected seasonally adjusted loading cycle and ambient temperature.
The temperature calculations (in degrees C) should also include:

a) Top oil
b) Top duct oil
c) Bottom oil
d) Winding hot spot
e) Average oil rise
f) Average winding rise
g) Winding hot spot gradient
h) Average winding gradient
i) Bushing gradient
j) Cable gradient
k) Tap changer contact gradient

It is also important that the above data be available for any specific transformer when considering design
modification to existing equipment. During long or short term contingent loading, the calculated loss-of-
life per cycle is often the limiting factor for units with cellulose insulation.

In many cases, the adoption of planned loading above nameplate, along with seasonally adjusted
loading and ambient temperature cycles, has provided planners with new criteria for considering
transformer replacements or additions to their system. Improvements in transformer utilization have been
gained by the ability to switch load from one substation to another more quickly and with greater
flexibility. This has resulted from investment in automation controls and equipment. This added switching
flexibility enables greater utilization of the overall transformer contingent load capability. The above factor
has had an impact on increasing normal transformer loading and has in a number of cases switched the
criteria for replacement from the normal to the contingent load limit. In these cases, the replacement unit
can be re-engineered with a Hybrid System in order to mitigate this limiting factor.

A major Western USA utility with high load growth, had several substations which were at or above the
utilities loading criteria. The results of a thermal loading study identified options they may have when
faced with the decision to rewind with hybrid insulation or replace the existing units with a larger size.
Example Thermal Loading Analysis for Normal and Contingency Situations

Transformer Type: Three-phase, Autotransformer

MVA & Cooling: 224/298/374, MVA at 65°C AWR LTC 65°, OA/FA/FOA
Voltage: 230,000v Grd Y/132,800 - 69,000Y/39480

Limiting Criteria for Loading

Operating temperature and loss of insulation life limits were used in this example study for normal and
contingency operation (Table 4). These limiting criteria were agreed limits of the utility for the operation of
this type of transmission substation transformer. These limits may vary substantially between other utility
companies.

Table 4
Load Limiting Criteria

Parameter Normal Loading Above Long-Time Short-Time

Max Hot Spot Temp 120° C 140° C 160° C
Max Top Oil Temp (Priority 105° C 110° C 110° C
Max Loss Of Life/Cycle 0.037% 0.5% 0.75%

The thermal load study considered the summer time ambient temperature and the associated peak
loading cycle shown in Figures 5 and 6.

Figure 5
Peak Ambient Temperature

Figure 6
Peak Load Cycle

The maximum peak load limit for normal loading above nameplate, at a hot spot of 120°C was
determined to be 1.14 P.U. with a top oil temperature of 88.5°C and loss of insulation life for cellulose
calculated at 0.03 per cycle. The related temperature curves are shown on Figure 7.

The utility criteria dictated a possible long term contingency loading condition anticipated to be from days
to several weeks. In this condition, the study determined that with a 110°C top oil limit, a 1.3 P.U. load
and with a cellulose insulation system, a maximum peak hot spot temperature of 159 would be reached
with an associated 0.8% loss of insulation life per cycle. The thermal conditions are shown in Figure 8.

The short term (4 hour) contingency study, with a 1.5 p.u. peak load, reached a peak hot spot of 174°C
and 110°C top oil limit and an associated 0.9% loss of insulation life per cycle. The analysis was based
on the unit operating at 100% load and a 4 hour contingency occurring at 2 hours before the peak of load
and ambient temperature cycle (Figure 9).

Figure 7
24-Hour, Normal Peak Load Above Nameplate

Figure 8
24-Hour, Long Term Contingency Load
 Figure 9
4-Hour, Short Term Contingency Load

Thermal Load Study Conclusions

A comparison of the overall thermal study is given in Table 5. The study demonstrates that in short or
long term contingency conditions, limited by top oil temperature, that an unacceptably high loss of
insulation life would occur with a cellulose insulation system and that a rewind with a Hybrid insulation
system would resolve this problem. Given that the rewind unit would most probably have an improved
winding space factor, because of the previously discussed hybrid insulation cooling criteria, a reduction
in load losses of approximately 15% could be expected in normal operating condition. The anticipated
reduction in load loss of 58 kW at maximum nameplate rating had an approximate Total Owning Cost
(T.O.C.) saving of $100,000. These combined factors are most important in developing an enhanced
repair or replacement strategy.

Table 5
Maximum Load Capability vs. Loss of Life

Operating Cycle Max. Summer Max. Max. Top Oil Hot SpotTemp., Equivalent Cellulose
Nameplate Max. 40 374 1.0 65 105 0.03 (continuous)
24 Max. Load 41 426 1.14 89 120 0.03
24 Hr. Max. L.T. 41 508 1.36 110 159 0.8
4 Hr. Max. S.T. 41 561 1.50 110 174 0.9

Standardization

The development in recent years of transformers utilizing high temperature materials in power
transformers [13] led to the establishment of a working group within the IEEE Transformer Committee
whose scope was to establish directions for a standard. After a first step of documenting the materials
and their application [14], the working group developed a guide [15]. The intent of this standard is to
provide information on the application and use of high-temperature insulation in liquid-immersed power
transformers and guidance on the use of these transformers. Systems with 65 K average temperature
rise are taken as a reference. In these systems, average winding rise over ambient temperature must not
exceed 65 K and the typical hot-spot differential temperature is 15 K. This produces a maximum hottest-
spot temperature of 120°C, according to IEEE Std C57.91-1995. Based on industry experience with
hybrid insulation systems, two ratings for temperature have been listed (Table 6).
 Table 6
Maximum Temperature Limits for Insulation Systems

Insulation system temperature 65°C rise High temperature rise systems

Average winding rise over ambient temperature (K) 65 95 115
Winding hottest-spot rise over ambient temperature (K) 80 130 150
Ambient temperature (maximum) (°C) 40 40 40
Winding hottest-spot temperature (°C) 120 170 190
Top oil temperature rise over ambient temperature (K) 65 65 65
Top oil temperature at maximum ambient (°C) 105 105 105
Cellulose hottest-spot rise (K) 80 80 80
Cellulose hottest-spot temperature (°C) 120 120 120

The allowable top oil temperature in these transformers has been limited to 105°C, as in conventional
systems. There is a difference when considering transformers according to IEC 76 [16]. Top oil
temperature rise is only 60 K. But the approach has been the same, which means that advantage is
taken of the difference between conductors and oil and without a change in the top oil temperature. This
allows continued use of mineral oil as the cooling medium. The operation at high temperature (above the
flash point of oil, 145°C) is justified because of the lack of free oxygen near the winding hottest-spot. The
risk of bubbling is also limited as the main factor is water content in the conductor insulation [17]. Aramid
insulation doesn't generate water when thermally stressed and it picks up less moisture than cellulose
when exposed to the same conditions.

In order to qualify hybrid insulation systems, the standard recommends the use of a dual-temperature
aging model. This allows the aging of a combination of materials with significantly different thermal
capabilities. Insulation around a conductor is heated at a much higher temperature than bulk solid and
liquid insulation. Recent tests have shown the superior life characteristics of hybrid insulation systems
compared to conventional all cellulose ones [18].

Conclusion

The concept described in this paper allows much greater flexibility when repairing failed transformers,
but it can also be utilized by power companies for upgrading old conventional mineral oil filled units prior
to failure. This may be especially attractive when emergency or high contingency loading conditions are
frequent on such units. It brings the advantage of giving more value to the rebuilt units by increasing their
operating range with negligible loss of insulation life, reduced losses at normal operating conditions and
increase in overall reliability. Standardization is now helping users and manufacturers to take better
advantage of this new insulation concept. There are future plans to submit the dual temperature aging
model and the IEEE Guide to IEC for standardization but already adoptions around the world are
showing the attractiveness of such a technology.

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Nomex® is a registered trademark of E.I. du Pont de Nemours and Company

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