Online Drying Systems with Moisture

Monitoring, IEC 61850 Integration and

Online OLTC Filtration Systems for
Un-manned Substations

Yogesh Sood, Advisor (Application Technology)

PTss-Velcon (www.ptssglobal.com)
M- +91-9417302966, yogeshsood@ptssglobal.com,
Talking Points:
1. Transformer winding insulation (Solid and Liquid), overview.
2. Some important points on contamination in liquid insulation.
3. Online Transformer Dryout System & OLTC filter system details.
4. Few Transformer Health assessment tips.
5. Few Case Studies.
6. IEC 61850 communication integration.
 50+ Years of Oil Reclamation & Fuel Fluid
Decontamination
Filtration experience Specialists

Industrial
Advanced industrial
filtration equipments
for oils, fuels and
Aviation solvents. Electrical Utility
Worlds largest Proven cost effective
supplier of Jet fuel systems for ensuring
Filtration equipments. clean and dry
transformer,circuit
breaker, switch gear
and turbine oil.
 Appointed by Velcon Filters in 2002
Fluid
Decontamination
Power Transformers Sales and Services, Specialists

COIMBATORE, INDIA (An ISO 9001 Co.)

manufactures oil processing equipment with Velcon technical
know how and distribute entire range of filters from US.
 Focus on Electric Utility Product Application
Advanced Filtering Technolgy

TDS for Transformers

- Transformer Dryout Systems - TDS - Online Processing.
- Specialised Catridges for removal of Water, Insulation
Moisture.

TPF/TP-3/TFS for Onload Tap Changers

- Automatic Online System for Carbon and Water removal.
- Special Catridges for Onload Tap Changers Filteration.
Transformer Inside View
 Transformer Winding Insulation
The insulation between the windings in a transformer
consists of a solid and a liquid part. The solid part
Outer layers – O2 and Water affects
consists of barriers and spacers to create an oil duct for Inner layers – Temp. affects

cooling purposes.
➢ Moisture in the insulation significantly accelerates the
aging process. The insulation system of power
transformers consists of oil and cellulose.
➢ Among factors contributing mostly to the degradation
of transformer insulation, moisture plays an important
role.
➢ Presence of water in solid part of the insulation, even
in small concentrations-
✓ increases its aging rate
✓ increases the risk of bubble formation
✓ reduces the dielectric strength of transformer oil

➢ Most utilities consider moisture content above 3% as

warning level.

➢ Upto 99% of the total moisture is located in solid

insulation & only 1% is in oil.
WATER INGRESS POINTS
 SOME IMPORTANT POINTS ON CONTAMINATION
• Particle nature and mode classification

Particle origin Mode of contaminant

Contaminants resulting from Cellulose fibers, sand
manufacturing processes iron, aluminum, copper.

Contaminants resulting from assembly
in field- (Dress and test dirt)
Operating passive-mode contaminants:
Oil aging
Wear cellulose
Peeling off of the paint
Operating active-mode contaminants
Overheating of metals
The carbon particles produced in the
OLTC
wear of bearings of the pumps peeling
off metals (from coolers)
sand, dust ,crumb of clay; calx(A powdery
metallic oxide formed when an ore or mineral has
been heated), welding slag
sludge particles ("polymeric" in nature)
Cellulose fibers
Polymer films, paint
Crumb of sorbent
Soot, coke (films and three dimensional
structures)
Wear metals: copper or bronze, iron, aluminum
Weld residue or arc debris (Organic and Metallic)
 SOME IMPORTANT POINTS ON CONTAMINATION

• CIGRE WG 12.17 “Particles in Oil” collected approximately 50 major failures

predominantly of Transformers 400-800KV that attributed to particles contamination.
• Particle contamination is the main factor of degradation of dielectric strength of
Transformer Insulation. The most dangerous are conductive mode particles (metals,
carbon, wet fibers etc.)
• Shunt Reactors with high electromagnetic field strongly attracts particles, depositing
them on the barrier closest to the winding surfaces & bushing porcelain.
• Fewer the particles, the weaker the effect of water on the dielectric strength of the oil.
Hence removing particles could be a task of priority to maintain dielectric safety
margin of insulation having an excessive level of moisture contamination.
• Particles counting in the range of 2-150micrometer & that particles 2-10micrometer
range may detect and somewhat quantify carbon particles.
• The difference between the PF and Resistivity tests before and after oil filtration gives
Particle Contamination Identification.
• Some Filters (particularly paper) can be a source of particle generation itself.
• Efficient processing shall incorporate drying and filtering procedures simultaneously.
 Parameters of Ageing Assessment
IEC 60422 – Ageing Assessment of In-Service
Transformers.
 WHAT IS LIFE OF THE
TRANSFORMER
CIGRE WG 12.18 “Transformer Life Management”
has studied possible condition of aged transformers,
dangerous effect of insulation degradation factors
as well as different techniques of insulation
rehabilitation and reconditioning including On-line
Processing.
Paper and oil life defines the life of the
Transformer, therefore emphasis are given to
reclamation of oil and regeneration of Insulation.
 CONTROLING FACTORS

DISSOLVED WATER HEAT

-
OIL-IMPREGNATED CELLULOSIC INSULATION

- -
---CELLULOSE DEGRADATION---

---CELLULOSE DEGRADATION---
CHEMICAL DEGRADATION
(acids, peroxides, O2, H2O, etc.)

ADDED MECHANICAL DIELECTRIC ACIDIC POLAR

DEGRADATIONK DEGRADATION MATERIALS
MOISTURE

CONDUCTION AND IONIZATION (Partial Discharge)

- -
CORONA (Glow Discharge)

INSULATION FAILURE
 The Chemistry of Oil Deterioration: --

• Water and oxygen are the most common contaminants always present
in the oil. In the presence of catalysts, oxidation of mineral transformer
oil comprises a whole series of separate chemical reactions, some of
which have little if any relation to the actual sludge precipitation.
Sludge formation is usually looked upon as a secondary reaction
involving condensation or polymerization of previously formed
oxidation products.

• Moisture can enter the insulation system externally via oil, as leak or
as condensation; or internally through the chemical process of
oxidation. In addition to metals, water is also a catalyst in oil
oxidation. All forms of water contain oxygen.

• Oxygen is present in oil in solution as a component of dissolved air in

a higher ratio, due to its higher solubility as compared with
nitrogen(16% versus 7%). All oxygen cannot be removed, even by
vacuum filling. Further degrading cellulose supplies a source of
oxygen.
 SOLUTIONS FOR REMOVING TOO MUCH WATER FROM THE CELLULOSE

There are 5 processes practiced to achieve the complete drying of wet Power
1. VAPOUR PHASE SYSTEM (OFF LINE)
• CAN BE USED IN WORKSHOP ENVIRONMENT ONLY.
• LOT OF PIPING, GASCUTTING AND BOLTING WORKS REQUIRED.
• REQUIRED TO DISMENTLE THE TRANSFORMER, TRANSPORTING TO WORKSHOP FROM SITE AND BACK
TO SITE FOR RE ERECTION.
• DOWN TIME AND INTERRUPTION.
• MANPOWER REQUIRED.
2. CONVENTIONAL OFF LINE DRY OUT SYSTEM (STREAM LINE FILTER)
• INTERRUPTION REQUIRED.
• LONG TIME MULTIPLE CIRCULATIONS WITH HIGH TEMPERATURE AND VACUUM WILL REMOVE THE
AROMATIC FRACTIONS FROM THE TRANSFORMER OIL (i.e.) NATURAL OXIDITATION INHIBITORS.
• WINDING SHRINKAGE.
• REDUCTION OF WINDING COMPRESSION PRESSURE AFTER MULTICIRCULATIONS.
• FOR MANY TRANSFORMERS JACKING OF WINDING AT SITE POSES CERTAIN RISKS.
• MANPOWER REQUIRED.
• IR & TANDELTA OF INSLUATION CANNOT BE ACHIEVED TO THE DESIRED LEVEL.
3. LOW FREQUENCY HEATING (OFFLINE DRY OUT)
• SERVICE INTERRUPTION.
• WINDING SHRINKAGE.
• CUMBERSOME PROCESS
• MANPOWER REQUIRED.
4. OVEN HEATING DRY OUT
• THIS OPTION INCLUDES SHIPPING AND UN-TANKING.
• DRYING CORE AND COIL IN VACUUM OVEN.
• INSULATION MAY BE IN THE END OF ITS USEFUL LIFE.
• OVER DRYING IN OVEN WOULD CAUSE THE INSULATION TO BECOME MORE BRITTLE. • INCREASE THE
RISK OF INSULATION DAMAGE DURING RE-TANKING.
5. HEATING THE WINDING BY CIRCULATING CURRENT (SHORT CIRCUITING SECONDARY WINDING)
• APPLICABLE ONLY FOR SMALL TRANSFORMERS.
• 1/3 OF NAME PLATE KVA AND IMPEDENCE VOLTAGE IS REQUIRED AT SITE.
• NOT SUITABLE FOR EHV TRANSFORMERS
 Fluid
Decontamination

Velcon TDS - Transformer Dry Out Specialists

System

• Removes Water from Insulation & oil of a

Transformer in energized condition. Helps in
maintaining IR values of Insulation and BDV
value of Oil to desired levels.

• Continuous online monitoring of dissolved

water in oil and insulation and automatic
activation for removal to the desired values.
Why do we need TDS ?

1. Insulation & Oil Absorbs

Water when exposed . Water is
thus formed when exposed or
thro’ Leakages.
2. Water is also formed when
Oil Oxidizes and due to Thermal
Aging of Insulation.
4. For E.g. 50% RH in
Environment would mean 8%
Water by Wt of Paper. In Kraft
Paper it would be up to 16%.
Where is this Water Present ?
3. Insulation has > 98% of Total
Water. Oil will have <2%
depending on Temperature and
Relative Saturation of Water in
Oil.
 Comparison of methods
• Conventional method: • Online sensing and monitoring

o Snap shot only. o Several thousand individual sample

results analysed.

o Sample is probably not o Measurements taken over a range of

representative of moisture transformer operating conditions
equilibrium conditions. (loading, temperature).

o Relative saturation independent of oil

o Charts relate to oil with specific characteristics.
characteristics.

o Potential for large errors. o Results give a good understanding of

the moisture movement in the
transformer.
Principle under which the TDS functions
Effectively
Online Transformer Dryout System –
Portable as well as stationary.
Online Transformer Dry out System- Inner View

1. SYSTEM STATUS

2. OIL SAFE CONDITION

3. CHANGE CARTRIDGE ALARM

4. INLET PPM

5. OUTLET PPM

6. OIL TEMPERATURE

7. WATER ACTIVITY/RS

8. %M/DWi

9. OIL FLOW TRANSMITTER 1

10. OIL FLOW TRANSMITTER 2

SCHEMATIC FLOW OF ONLINE DRYOUT SYSTEM
IEC 61850 data from Online Dryout System
 Specialised Catridges/Pre-filled Molecular
Sieves Cylinder for Transformer Dry Out
System
Superdri Catridges
For Dissolved water removal
Function:
Remove dissolved water from transformer oil.
Reduce Moisture Oil to <10ppm without Heat & Vaccum
Features:
• Unique Construction - Specifically designed for transformer oil dehydration.
• Efficient - Single pass water removal to less than 10ppm total water, or better.
• Safe - Will not remove oxidation inhibitors.
• Cost Effective.
 Superdri Catridges
Fluid
Decontamination
Specialists

Application

 New distribution and EHV transformers are typically oil-filled under vaccum. If
the insulating oil has a high total water content, it is also processed through a
heat and vaccum system. Superdri catridges can be used instead of heat and
vaccum to dry the oil.
 Repaired transformers are often oil filled under vaccum. Flowing the oil through
Superdri catridges eliminates the need to vaccum process the oil.
 Insulating oil in storage tanks, and tankers of oil that have accumulated a high
level of dissolved water can be recirculated and dried to less than 10ppm total
water using Superdri catridges.
 Superdri catridges are used for processing oil in other high voltage apparatus
that is sensitive to dissolved water.
 Superdri catridges are used to meet processing specifications where dissolved
water sensitive dielectric breakdown voltage test ASTM D-1816 is used, or
required.
•Benefits of the Energized processing with the
Online TDS:-
•Transformer remains in service
•No switching scheduling or costs.
•No transformer downtime.
•No auxiliary power equipment needed.
•Reduced transformer drying expense.
•Less costly compared to heat and vacuum.
•Minimal energy consumption.
•Unattended operation saves labor expense.
•Improved Transformer Condition
•Insulation Tan Delta/IR/PI values improvement after drying.
•Increased BDV/Oil dielectric strength.
•Increased protection from hot spot damage.
•Increased safety margin for higher transformer loading.
•Oil power factor, Sp. Resistivity, IFT and acidity improvement.
•Removing moisture retards insulation degradation.
•Transformer Life extended.
•Oil life extended.
 MOISTURE IN SOLID INSULATION

• Moisture being the main culprit in the ageing of paper, it

is important to measure it accurately.
• Polarization phenomena relevant to moisture induced
ageing are orientation, interfacial and hopping
polarizations, which have a large time constant
• Hence, the measurements are made at very low
frequencies, 100nHz – 10Hz or over very long times
• Complex permittivity is obtained and correlated with
moisture content with the help of controlled and
exhaustive experiments done on so called X-Y models
of the insulation system
[Walter S. Zaengl, ‘Dielectric spectroscopy in time and frequency domain for HV power
equipment’ ISH 2001]
 CASE STUDY OF ONE REACTOR OF PGCIL

S.No. PARTICULARS BEFORE AFTER

01. Moisture (PPM) 12ppm 6ppm

02. RS (Water Activity) 8% 5%

03. %M/DWi 2.0% 1.6%

04. Insulation Tan Delta/Capacitance 0.621/8587 0.402/8562

05. Oil Tan Delta/PF 0.02296 0.0143

06. IFT (Interfacial Tension) 28.8Dynes/cm 31.3Dynes/cm

07. Sp. Resistivity @90DegC 0.819x1012 Ohm-cm 1.9x1012 Ohm-cm

08. Acidity (NN) 0.039407 0.024

09. Weight of Cartridges 47.45Kgs 66.8Kgs

POWER FACTOR OF PRESS BOARD BEFORE & AFTER
Performance results of TDS from USA Utilities
Another TDS1GA6X Machine results
CGL 1993 make 16.67MVAR 420KV REACTOR, 14730Ltrs

Temperature Inlet ppm Outlet ppm RS %M/DWi

(Inlet/Outlet)

As on 45 DegC 25ppm 3ppm 17%/2% 3.9%

09-09-2016

As on 46 DegC 11ppm 2ppm 7%/1.2% 2.13%

27/09/2016

As on 46 DegC 7ppm 2ppm 4%/1.2% 1.7%

19-10-2016
Another Case Studies from Transmission Co of Punjab.
Another Case Studies from Transmission Co of Punjab.
Another Case Studies from Transmission Co of Punjab.
 Fluid
Decontamination
PTSS-VELCON is an approved vendor for the supply of Online Transformer Dryout Specialists
Systems to Indian Utilities like PGCIL, NTPC, BBMB, DVB, TANGEDCO,
APTRANSCO, PSPCL, HPSEBL directly and through global Transformer
manufacturers like BHEL, GE, SIEMENS, ABB, TOSHIBA, PRIME MEIDEIN, TELK,
BHARAT BIJLEE, CROMPTON GREAVES etc and a recently received best vendor
award from BHEL speaks about our performance and quality.
 On line On load Tap changer
Filtration System

Online Oil filtration for Load Tap changer Compartments.

Why Online OLTC TP-3 Filtration?

The effect of Onload Tap Changer switching operation is a

direct accumulation of carbon.

Temperature and other variables cause the formation of

condensation of water.

Carbon and water mix with insulating oil decreasing

the Dielectric strength.

Result
Castrographic failure of Tap changer and in turn transformer
also.
 On line On load Tap changer
Filtration System

Online Oil filtration for Load Tap changer Compartments.

Benefits

Increase in the tap changer’s life.

Consistent high dielectric strength of the oil.

Extends the oil life.

Contact wear and coking becomes reduced.

Maintenance and inspection requirements becomes reduced.

Reduction of contact erosion reduces restrikes during tap

change.
Cost saving due to reduced maintenance and extended life.
 Fluid
Decontamination

Catridges for the tap changers filter system Specialists

The following catridges are recommended for Tap changer

Superdri tap changer Catridge- SD- 718P3

Removes carbon and dissolved water.

Aquacon Catridge- AC 718 1/2

Removes carbon and free water.

FO 718 PL 1/2
Removes carbon only.
 OLTC oil filtration results using
PTss_Velcon Filters SD-718P3
SITE DETAILS BEFORE AFTER
PPM/BDV PPM/BDV
PGCIL, Jalandhar ICT-2, B-Phase 29.0KV 53.9KV

PGCIL, Kishenpur ICT-1, Y-Phase 22.8KV 72.5KV

PGCIL , Abdullapur ICT-3 41KV 55KV

PGCIL, Moga ICT-3 R-Phase 28ppm/33.2KV 12ppm/64.4KV

PGCIL, Moga ICT-3 Y-Phase 22ppm/53.8KV 16ppm/66.6KV

PGCIL, Moga ICT-3 B-Phase 19ppm/51.9KV 13ppm/68.6KV

PGCIL, Moga ICT-4 Y-Phase 36ppm/26.1KV 16ppm/67.7KV

PGCIL, Moga ICT-2 B-Phase 51ppm/34.5KV 12ppm/62.2KV

Connections with the Transformer and OLTC
Oil Improvement using Superdri
technology
Minimum IR, PI, RS, %M/Dwi limits
 Chengdong Equation
Estimation of DP using Furan Analysis
Estimated avg DP = {[Log of 2-FAL mg/l] – 1.5}
-0.0035
• 2-Furfaral accumulation rate <50ug/L/year = Normal Ageing
• If estimating DP from 2-FAL content using Chengdong equation:
>=800 Good Condition (1000-2000 New Insulation)
<800>=400 Midlife
<400 Last third of life

Carbon Oxide Gases and Ratios

CO2/CO > 4
High CO2 with low CO – lack of Cooling /general
overheating
 Adsorbent Media catridges - Fuller’s Earth
and Activated Alumina
For Gums, Acids and Oxidation products

Function

Adsorbent media catridges remove,

Gums, Acids, Surfactants, Varnishes, Soaps, Colour bodies,
Corrosive gases, Polar compounds and Oxidation products
from hydrocarbon and synthetic oil.
They also remove moisture and filter particulates to a
nominal 10 micrometer level.

Application

Insulating oil, Quench oil, Mineral oil, Transformer oil,

Heat transfer fluids, Vaccum pump oils, Synthetic oils,
Hydrocarbon base, Perfluoropolyethers, Phosphate Ester
oils.
Evidences are generated for the application of On-line processing for
Transformer main tank for not only the removal of moisture but more
importantly the removal of particles. It is considered as an effective means
of prolonging transformer life and reliability.
TRANSFORMER LOSS ESTIMATION TOOL
•When purchasing transformers, it is important to compare the cost of the losses over the entire
lifetime of the various types considered.
•DNV GL's Transformer Loss Calculation Tool enables the user to choose the economically most
efficient transformer based on lifetime parameters such as capitalized cost, CO2 emissions, payback
time and internal rate of return.
•In a clear summary table and intuitive graphs, the tool provides the user with additional
information about the no-load and load loss evaluation (A and B factors), in case these are not
known in advance. It calculates transformer losses when there are harmonics in the loading.
 How Transformer Loss Estimation Tool looks

Download link for the tool:

http://copperindia.org/distribution-transformers/

Also request to register at www.apqi.org to listen to the archieved

webinar on the same.
 References of Tests conducted during the Demonstration.

OIL TESTS PGCIL LAB, KARTARPUR AND INHOUSE BDV KIT.

PTSS M/C HMI FOR PPM, RS, %M/DWI AND TEMP.
REACTOR TESTS BY PGCIL USING MEGGER IDX 300(FDS KIT) FOR
%M/DWI AND INSULATION TANDELTA/POWER FACTOR
MEASUREMENT.
MOISTURE PTSS SOFTWARE
CALCULATIONS
DOBLE PAPERS FOR ASSESSING MOISTURE CONTENT
IN PAPER
OOMEN CURVES ‘Moisture distribution – Paper & Oil’
SD MYER’S NOMOGRAM AND TUTORIALS
CIGRE REFERENCE FROM VICTOR SOKOLOV’S & BEN
TAYLOR’S ARTICLE ‘Consideration of Online processing of
High Voltage Transformers’
POWER FACTOR OF PRESSBOARD
PGCIL, MOGA REACTOR DRYOUT CALCULATIONS ;-
TAN DELTA TESTING ON 50MVAR REACTOR using
MEGGER IDAX 300 Insulation Diagnostic Analyzer.
Moisture Content in the paper in %
(DOBLE)