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Abnormal Failure Rate on High Voltage Current

Transformers Affected by Environmental
Conditions

Conference Paper in Electrical Insulation, 1988., Conference Record of the 1988 IEEE International Symposium on ·
July 2008
DOI: 10.1109/ELINSL.2008.4570321 · Source: IEEE Xplore

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 Abnormal Failure Rate on High Voltage Current
Transformers Affected by Environmental Conditions
O. Reyes, V. R. Garcia-Colon H. Lara, E. Robles M. Guzmán, F. Elizarraraz, J.C. Martínez
Instituto de Investigaciones Eléctricas Comisión Federal de Electricidad LAPEM
Cuernavaca, Mor., México México, DF Irapuato, Gto., México

There are more than 20 thousand high voltage Current

Abstract- The Mexican Grid has been severely affected by Transformers (CT´s) installed in the Mexican Transmission
numerous failures on 230 kV and 400 kV Substations Current substations. Thirty eight violent failures, in twelve of those
Transformers (CT’s). The failure rate increased in the latter substations occurred in 2006, most of the affected substations
years and became extremely critical. Several studies and
laboratory tests on aged CT’s were carried out to identify the
are in coasts of the Gulf of Mexico. Twenty failures occurred
main factors and mechanisms that contribute to the progressive in just one week, during the hottest season.
deterioration of the oil paper insulation system. It is important to The common factor on all the failures was the environmental
identify those apparatus with a high failures risk; therefore, an operating conditions, where high humidity and high marine
attempt to classify their conditions was performed. The results pollution are present in almost every failure. In general, they
are shown in this paper.
occurred at night after about 3 to 5 hours of the substation
I. INTRODUCTION peak load and also after a very hot day, with temperatures
above 40 ºC. Therefore, it can be concluded that temperature
High Voltage Current Transformers, like any power plays an important role in the failure mechanism.
electrical piece of equipment, are designed and manufactured Due to the construction characteristics and operating
to operate for at least 20 years. Extensive laboratory and conditions of the current transformers, failures are extremely
factory tests are performed in new equipment to ensure this violent and always involve an explosion that frequently results
[1]. In Mexico, those tests have been also applied in in a fire (Fig. 1). The CT’s are located close to a circuit
instrument transformers retired from service; it was found that breaker operating mechanism, therefore the fire usually
most of them fulfilled the test criteria established on engulfs the control cabinet and much of the wiring associated
international standards as new. In the last five years, several with those controls. The explosive nature of the CT failures
current transformers have been replaced, but still a high failure ejects porcelain pieces at very long distances (up to 100 m)
rate has been experienced, this rate is similar to those reported and results in extensive damage to nearby equipment.
all over the world [2, 3] but a notorious increment has been Frequently, other CT’s and breakers have to be replaced due to
observed in the latter years (see Tables I and II). the damaged caused by the porcelain debrites. Disconnect
TABLE I
switch operating rods have been broken, bent and damaged
INSTRUMENT TRANSFORMERS FAILURES REPORTED IN MEXICO extensively.
Failures The great amount of failures reported in Mexico, have been
Year of great concern to Comisión Federal de Electricidad (CFE)
PT CT CVT
authorities, therefore extensive field and laboratory testing
2006 25 38 2
was performed to define the primary causes of failures. Also
2005 33 20 2
an attempt to classify the CT´s to retire those with a high risk
2004 15 6 0
of failure was performed in some critical substations.
2003 14 21 0
2002 8 25 2
2001 8 5 0
2000 14 0 0
Total 117 115 6

TABLE II
CURRENT TRANSFORMERS FAILURES REPORTED IN MEXICO

Failures
Operating voltage
1985-1999 2000-2006
400 kV 27 57
230 kV 67 28
115 kV 96 30

Fig. 1. Violent failure of a 400 kV current transformer. Damaged switchgear

978-1-4244-2092-6/08/$25.00 ©2008 IEEE 247

 II. DAMAGES DUE ENVIRONMENTAL CONDITIONS
Although CT´s are designed for outdoor operation, in
several cases it has been found that some materials are not
adequate for this service or they aged prematurely under
normal operating conditions.
Oil-filled freestanding CT’s have a porcelain body that
protects them from environmental conditions, like rain, dust,
heat, etc. Most manufacturers use stainless steel bolts and top
covers in its assembly. The expansion bellows of modern
transformers are made of stainless steel too. However, this
material gets easily rust in marine environments due to the
high salinity and humidity levels. In few years, the
components become corrode and hot spots and corona
discharge activity are produced (Fig. 2).
One of the most critical problems occurred when the rubber
membranes or the expansion bellows, traditionally made of
rubber, cracks by the environmental conditions or by the
ozone produced due to external discharges (see Fig. 3.). As a
consequence, humidity ingresses into the oil paper insulation
system affecting its normal operation.
In some transformers have been found that the humidity can
also ingress through its lower section (see Fig. 4). The bolts
used to fix the porcelain to the base become loose so the air
tightness in the CT is lost.
Fig. 2. Effects of environmental conditions in high voltage CT’s
Fig. 3. Membrane damaged
248
Fig. 4. Looseness of the lower section of a CT
III. CAUSES OF INSULATION DEGRADATION
The reliability of CT’s depends mainly on maintaining the
integrity of their oil-impregnated paper insulation system.
Despite its inherent outstanding properties as a dielectric, oil-
impregnated cellulose is subject to serious and fast
degradation when its limitations are not clearly recognized and
respected within the requirements of each specific area of use.
Its most severe limitation is the sensitivity to the combined
influence of heat, humidity and high voltage stress [3]. These
factors acquire special significance in high voltage CT’s as the
insulation structure consists of a compact wrapping of paper
tapes.
Nowadays, because of the new materials, the CT’s are rather
compact and in many cases, their electrical gradients are
nearby its operating limits. Two 400 kV CT designs were
analyzed using FEM; the first one was built in two modules
and the second had just a single module. As it is shown in
Fig. 5, the maximum gradient in the analyzed CT is around
8.6 kV/mm. This gradient appeared in the stress relieving zone
at the high voltage electrode immersed in oil. As a reference,
the oil dielectric strength is 10 kV/mm.
Highest air gradient = 1.5 kV/mm
Highest bushing gradient = 8.6 kV/mm
Fig. 5. Gradient distribution in a high voltage current transformer
 Some manufactures use equipotencial rings in the inverted 100 100
CT bushing to reduce the electrical stress concentration, but it 90 Voltage up 90
is a shortcoming that does not solve the problem. The cause of 80
83ºC
80
70 66ºC 70
this is the small amount of foils used for the manufacturers. As Voltage up

Temperature (C)
Qmáx. (pC)
60 60
a reference, in 400 kV CT’s the number of foils are in the 50 Voltage down 61ºC
50
order of 12 to 19; meanwhile, in 400 kV power transformer 40 40
bushings, they use around 100 aluminum foils. 30 30
20 PD level PD level 20
Nevertheless, it is assumed that the high operating gradient 10 10
levels are not the main cause of failure of the CT’s alone. The 0 0

10:19:12

10:48:00

11:16:48

11:45:36

12:14:24

12:43:12

13:12:00
materials used in their construction can operate properly under
normal operating conditions. However, it has been observed
Time
the seals and gaskets employed by the manufacturer do not
withstand UV and corona. Therefore those seals crack and Qmáx. (pC) CT Temp. (ºC)

break allowing moisture ingress. This causes that in adverse

weather conditions, high temperature, humidity and pollution,
this equipment are not able to withstand normal operating
gradients and will fail consequentially.
The thermal stability of electrical insulation of the CT’s
depends on the ability to adequately dissipate the heat
generated within the equipment. In the CT´s a significant part
of the total losses is represented by dielectric losses [3] which
increase with temperature, as it is shown in Fig. 6.
Partial discharge tests were also carried out to evaluate the
temperature effect in the CT main insulation. Such tests were
performed in new equipment with a PD level < 5 pC at 400 kV
and 2.1 ppm of H2O. As it is shown in Fig. 7, no partial
discharge activity was observed during the test.
Moisture and soluble polar contaminants are the most
common causes of increased dielectric losses at elevated
temperature. Sometimes the contamination can be traced back
to the manufacturing process, either to incorrect selection of
materials or inadequate processing. In other instances, ionic
compounds form during normal use of the CT as a result of
several degradation processes involving the oil and cellulose.
As it was mentioned before, in the coastal zones, the most
common cause of moisture ingress in the CT’s is due to the
membrane failures as they crack. The presence of moisture in
the transformer reduces the oil and paper dielectric strength.
Also an important increased in the dielectric losses and partial
discharge activity is produced at high operating temperature.
0.5
Fig. 7. Partial discharge characteristics registered in a new 400 kV CT
Some 400 kV CT, with different moisture and temperature
levels, were evaluated in the laboratory. A special heat
chamber was built for this purpose. The results obtained show
that the dielectric losses increase exponentially with
temperature. In Fig. 8., can be observed that the losses are
0.5% and 4.5% at 36 ºC and 80 ºC, respectively.
A similar behavior was observed during partial discharge
tests. Fig. 9 shows the PD response of a 400 kV CT with 50
ppm of H2O. A PD level lower than 5 pC, was registered at
30 ºC. The transformer was heated up to 83 ºC in the oil and a
constant voltage of 250 kV was applied. As it can be observed
in Fig. 9, the PD level tends to increase exponentially. After
1.5 hours, the PD increase to 10,000 pC; at this moment it was
decided to stop applying test voltage to avoid a failure. When
the oil temperature was in the order of 70 ºC, the test was
started again and it was observed that the PD activity ceases as
soon as the oil temperature decreases to 50 ºC.
The experience demonstrates that the CT failure takes place
when the PD level is higher than 100,000 pC. In the worst
case, just a few hours are required for a CT failure once the
PD activity appears in the equipment. Due to the fast
deterioration mechanism it is rather difficult to establish a
diagnostic method to determine the degree of deterioration of
CT on site.
40
35
30
tan d (%)

0.4 25
20
tan d (%)

0.3 15
10
0.2
5
0.1 0
0 50 100 150 200 250 300 350
0
Voltage (kV)
40 90 140 190 240
Voltage (kV) Temp=96 C Temp=88 C Temp=80 C Temp=72 C
Temp=66 C Temp=36 C
Tmem. = 82.5 C Tmem. = 75 C Tmem. = 63 C
Tmem. = 58 C Tmem. = 53 C Tmem. = 49 C Fig. 8. Loss tangent characteristics of a 400 kV CT with moisture
Fig. 6. Loss tangent characteristics registered in a new 400 kV CT as a
function of temperature

249
 Voltage up IV. FIELD TESTS RESULTS
12000 90
85ºC 74ºC 80
10000 Voltage up Due to the many 400 kV failures reported, a field test
70
Voltage down 67ºC 59ºC Voltage up program was initiated to be able to classify the current

Temperature (C)
8000 60
transformers and retire those with a high risk of failure; the
Qmáx. (pC)

Voltage down 50
6000
PD level
40 initial program was applied in 4 of the most critical
4000 30 substations. Oil moisture measurements and chromatography
PD level
20 analysis was carried out but some difficulties were
2000
10 experienced due to the lack of a sampling valve and the
0 0 reduced oil volume.
12:43:12

13:26:24

14:09:36

14:52:48

15:36:00

16:19:12

17:02:24

17:45:36

18:28:48

Time
Qmáx. (pC)
Fig. 9. Partial discharge behavior registered in a 400 kV CT with moisture
In the field, when critical conditions are achieved, the
insulation of the inverted bushing is not able to withstand the
normal working electrical stress and a failure is produced. The
available short circuit current on the electrical system
generates explosive gases within the CT´s and a violent failure
is produced. It has been observed that in most cases, failures
are produced in the CT grading zones that are exposed at high
electrical gradients. Sometimes the failure take place in the
equipotencial rings area (Fig. 10a), When those are not used
for stress relieving, the fault occur in its head (Fig. 10b).
19:12:00
Tan d, partial discharge and AC Hipot tests were also
performed. On-line partial discharge measurements were
Oil temperature ( C)
registered with an ultrasonic probe at different periods of time,
in the morning, in the afternoon and at noon. Some relevant
results registered in one of the substations, are shown in
Tables III and IV.
The evaluated transformers are of the two modules type,
each module is of the same height and their operating voltage
is 115 kV. It is worth mention that the rubber membrane was
replaced two years ago in all transformers as the original
membrane got damaged on all 24 equipment. As can be seen
in Table III, the CO2 levels exceed the limits in all CT’s and in
most of them the CO values are extremely high. It is important
to notice that moisture at saturation levels were found in all
the transformers.
No partial discharge activity was registered during off-line
testing but some external discharge (noise) was measured on-
line in some transformers. Field experience demonstrates that
the high voltage power factor test gives the most relevant
information. In this case, a tan d value under 0.75% was
considered as acceptable. As it is shown in Table IV, the tan d
limit was exceeded in six of the tested modules.

TABLE III
MOISTURE AND CHROMATOGRAPHY ANALYSIS IN ELECTRICAL SUBSTATION A
(ppm)
Id Phase Pos. H H2 O CO2 CO
(<300) (<70) (<900) (<300)
TGC

(a) s 62 69 1912 343 414

A
i 185 67 1597 272 447
s 57 63 1808 338 406
CHM-A3260 B
i 152 67 1720 260 426
s 101 63 1778 371 485
C
i 169 69 1790 380 539
s 162 54 1786 303 474
A
i 387 55 2016 314 713
s 98 57 1981 383 491
CHM-A8110 B
i 246 53 2053 430 693
s 55 54 1867 310 376
C
i 249 57 1849 312 569
s 79 61 1926 370 462
A
i 152 67 1777 308 473
s 157 56 1667 281 449
CHM-A2010 B
i 223 59 1881 290 524
s 46 60 2062 394 451
C
i 246 57 1843 288 547
(b)
Fig. 10. Common failure zones detected in current transformers

250
 An attempt to classify the CT deterioration condition was TABLE IV
RELEVANT ELECTRICAL TEST RESULTS IN ELECTRICAL SUBSTATION A
prepared; four deterioration levels (DL) were defined. Number
1 represents the transformers in the worst conditions; tan d(1) Qmáx.(2) noise
Po Cx(1)
meanwhile number 4 are classified as being in the best Id Phase <0.75 <300 <20 DL
s. (%) (pF) (pC) (dB)
operating conditions. As it is shown in Table IV, in Substation
A were found six modules with the highest deterioration level A
s 0.6400 551.33 --
7.5
4
and they had to be replaced; the others CT´s must be evaluated i 0.7154 570.68 20 3
periodically. CHM- s 0.5820 562.65 -- 4
B 20
A3260 i 0.7440 575.40 -- 3
Nowadays, some efforts are doing to measure the moisture s 0.6250 565.45 -- 4
C <5
level on CT insulation paper. The experience demonstrates i 0.8580 590.55 -- 1
that low frequency tan d test is one of the most promising A
s 0.6862 575.36 <15
20
4
i 0.6829 589.94 <15 4
techniques. It was found that the conventional oil humidity CHM- s 0.7892 581.55 <15 1
measurements do not reflect the paper moisture level due to B <5
A8110 i 0.9217 595.43 <15 1
oil saturation capacity. To obtain real paper moisture value the s 0.7752 566.31 <15 1
C <5
transformer should be heating, but it becomes quite difficult in i 0.7735 578.25 <15 1
practice for operating equipment. s 0.8200 567.23 <20 1
A 27
i 0.7356 584.99 <15 4
CHM- s 0.7362 584.64 <15 3
V. CONCLUSIONS A2010
B 2.5
i 0.6126 588.68 <15 3
s 0.6400 566.12 <15 4
In general, aged high voltage current transformers satisfy the C
i 0.5575 569.35 <15
<5
3
international tests criteria but an important number of failures (1)
Test voltage 121 kV
(2)
are reported everywhere. Test voltage 210 kV
Most transformers operate with high electrical gradients. In
normal operating conditions it does not represent a real
problem but when moisture ingress and high temperature
levels are present, a catastrophic failure can occurred.
Both on-site chemical and high voltage tests must be
performed to reduce the CT failure rate. It is very important to
put a special attention in the CO, CO2 and tan d values.
However, new paper moisture measurements techniques must
be develop for better diagnosis.

REFERENCES
[1] IEC 60044-1, "Instrument transformers - Part 1: Current transformers"
[2] A. Kozlovski, R. Neimanis, B. Holmgren, “Diagnostic measurements of
oil-paper insulation in current transformers”, Nordic Insulation
Symposium, Bergen, June 10-12, 1996, pp. 131-138.
[3] A.F. Kurbatova, O.N. Grechko, et al, “Development of diagnostic
system of 330-750 kV current transformer base don service experiences
and endurance tests”, CIGRE 12-107, 1998.
[4] John R. Boyle, Cummings Harold, Barry Arp, “The Tennessee Valley
authority’s (TVA’s) experience and actions plans with freestanding oil-
filled current transformers (CT’s)”, IEEE Tans. on Power Delivery,
Vol.3, No. 4, 1988, pp. 1769-1775.

251

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