CONDITION MONITORING OF POWER TRANSFORMERS

CHAPTER.I BRIEF HISTORY OF KOTHAGUDEM THERMAL POWER STATION:

1.1 INTRODUCTION TO APGENCO:
Andhra Pradesh Power Generation Corporation Limited (APGENCO) is the electricity generation company of the Government of Andhra Pradesh found in the year 1998 as a part of the network of APSEB (Andhra Pradesh State Electricity Board) in India. It has an installed capacity of 7048.4 MW which makes it the third largest power generation company in India. Andhra Pradesh Power Generation Corporation Limited is one of the pivotal organizations of Andhra Pradesh, engaged in the business of Power generation. Apart from operation & Maintenance of the power plants it has undertaken the execution of the ongoing & new power projects scheduled under capacity addition programme and is taking up renovation & modernization works of the old power stations. APGENCO came into existence on 28.12.1998 and commenced operations from 01.02.1999. This was a sequel to Governments reforms in Power Sector to unbundle the activities relating to Generation, Transmission and Distribution of Power. All the Generating Stations owned by erstwhile APSEB were transferred to the control of APGENCO. The installed capacity of APGENCO as on September 30, 2010 is 8135.9 MW comprising 4382.50 MW Thermal, 3751.40 MW Hydro and 2 MW Wind power stations, and contributes about half the total Energy Requirement of Andhra Pradesh. APGENCO is third largest power generating utility in the Country next to NTPC and Maharashtra. It's installed Hydro capacity of 3703.4 MW is the second highest among the Country.

Types of power plants APGENCO operates: Source Installed Capacity (MW) Thermal Hydel 4382.5 MW 3751.40 MW
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CONDITION MONITORING OF POWER TRANSFORMERS

Wind 2.00 MW

Table1.1: Statistical Information Regarding Different Thermal Power Plants Operating Under APGENCO:

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CONDITION MONITORING OF POWER TRANSFORMERS

Power Station

Operat or

Location

District

Unit Wise capacit y

162.5

Installe d capacit y
62.5

Plant Coordinates

Ramagund am B thermal Power Station Kothagud em Thermal Power Station Kothagud em Thermal Power Station V&IV Stage Dr Narla Tatarao TPS Rayalasee ma Thermal Power Station Kakatiya Thermal Power

APGENC O

Ramagunda m

karimnag ar

184331N79304 7E

APGENC O

Paloncha

Khamma m

460, 4120

720

173718N8041 ,15E

APGENC O

Paloncha

Khamma m

2250 1500

500 500

173724N8042 060E

APGENC O

Ibrahinpatn am

Krishna

6210, 1500

1760

163558N80321 2E

APGENC O

Cuddapah

YSR

4210

840

144214N78272 9E

APGENC O

Chelpur

Warangal

1500

500

182302N79494 2E

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CONDITION MONITORING OF POWER TRANSFORMERS 1.2 ABOUT KTPS:

Electricity is being produced at thermal, nuclear, hydel generating stations. Kothagudem

thermal power station is one of the major power generating stations of the Andhra Pradesh. The main raw material is coal is supplied by singereni collieries, Kothagudem and a water source is from kinnerasani project, which is about 12kms. From paloncha. For the power generation with 2x110 MW and 3x210 MW of K.T.P.S. authorities are required to be operative to active full operation. The auxiliaries are basically operation either on L.T. System i.e. 415 V 3 power supply is made available to the system after providing the station transformer of 3x50 MVA capacity with voltage 220 KV/ 7.2/7.2 KV & different service transformers of capacity 1.0 MVA, 1.5 MVA, 2.0 MVA, which are located near the load centre as the transformer having the voltage of 6.6 KV /415 V. The 6.6 KV power is distributed through 6.6 KV interconnected Bus System for all the five units with a control through DC of 220 V. The 415 V power supply is done through a L.T. SWGR (Switchgear) which are located nearby the distribution transformer as well as the load centers. The all in -comers, which are breaker controlled , are having the control the L.T. SWGR are having the control system on 110/ 220 V AC. The 6.6 KV power supply which are either MOCB (Minimum Oil Circuit Breaker) of JYOTI MAKE or Air Circuit Breakers. The 6.6 KV power supply to various draining equipments i.e. more is made through breakers which are either MOCB of jyothi make air circuit breaker which are either of voltage makers as well as SF 6 of NGEF make. The LT supply is also controlled through air break circuit breaker which are either L&T make or English Electric Company of India. The various H.T. motors are switched on / started through on direct ON line (DOL) in order to inverse the availability of equipment at full efficiency without time gap. Further , the 6.6 KV system which is normally in delta configuration and terms as an unearthed system so also to keep the running motor complete in operating condition in case of any one .phase of motor winding is earthed due to any one reason. Earthling is detected by an protection system with alarm facility to take remedial measures immediately and at the same time to maintain the generation level in the same condition, prior to occurring the earth fault the single phase earth fault is detected in due course till the motor is not earthed to other or another phase. Soot Blowers are there in the boiler area on the furnace side or Zone which helps in blowing the soot / ash deposition regularly of the furnace wall / economizer tubes to keep heat transfer at the required parameter. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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In April 1973, Central Electricity Authority prepared a Project Report for power station comprising of the two units of each of capacity 110 MW for RSEB subsequently in September, 1975 this was revised by the Consultant Thermal Design Organization , Central Electricity Authority for invention of 2x110 MW units being manufactured by BHEL, Hyderabad in 1st Stage. The planning commission cleared the project report in Sept., 1976 for installation of two units each of 110 MW in first estimated cost of Rs. 143 Chores

Table 1.2: total installed capacity:

NAME Station A Station B Station C Stage V Stage VI TOTAL

NOOF UNITS 4 2 2 2 1

Individual capacity 60 MW 120 MW 120 MW 250 MW 500 MW

Total capacity 240 MW 240 MW 240 MW 500 MW 500 MW 1720 MW

1.3 General Layout & Basic Idea:

A control system of station basically works on Rankin Cycle. Steam is produced in Boiler is exported in prime mover and is condensed in condenser to be fed into the boiler again. In practice of good number of modifications are affected so as to have heat economy and to increase the thermal efficiency of plant. The Kothagudem Thermal Power Station is divided into four main circuits: Fuel and Ash Circuit. Air and Gas Circuit. Feed water and Steam Circuit. Cooling Water Circuit.

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Objectives
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CONDITION MONITORING OF POWER TRANSFORMERS

One of the important objectives of K.T.P.S. is to generate thermal power efficiently and economically. It is also fulfilling the role of social responsibility objective by encouraging local small-scale industries, providing employment to the people of the backward and tribal areas. It has crores of rupees controlling pollution by installing Electrostatic Precipitators (ESP).

LOCATION:
The Kota Thermal Power Station is ideally on the left bank of Chambal River at Up Stream of Kota Barrage. The large expanse of water reached by the barrage provides an efficient direct circulation of cooling system for the power station. The 220 KV GSS is within km \ from the power station.

LAND:
Land measuring approx. 250 hectares was required for the project in 1976, For disposal of ash tank very near to power station is acquired which the ash in slurry form is disposed off through ash and slurry disposal plants.

1.4 BASIC IDEA OF OPERATION:

The basic principle involved is Faradays law of electro-magnetic induction i.e. whenever a conductor cuts a magnetic flux emf is

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induced across its ends.

The very first thing we need to provide is a conductor cutting magnetic flux. So this can be done in two basic ways i.e. either the conductor can be moved in the magnetic field or the field can be varied according to the required emf that is to be generated. The process we follow here is we rotate the rotor of a generator in the magnetic field and emf is generator at the stator and this generated emf is further utilized according to the purpose. To meet the purpose of rotating the rotor of a generator, the rotating shaft is in turn connected to a turbine which is made to rotate at a rated speed by an external energy source. So we need an energy source to rotate the turbine. To rotate the turbine energy must be transferred from a medium to the turbine so DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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that energy from the external source is converted to rotational energy of turbine. In general to rotate an object which is mounted we need to apply some torque. To produce torque we need to apply force in the tangential direction. For the purpose of application of force we chose steam as a medium of transfer. For hydel plants water is directly allowed from a very great height to collide with the turbine blades with a great force. In the same way we need to send the steam with a greater force in turn with a greater pressure to make the turbine rotate. The basic physics involved in this is the internal energy and enthalpy of the steam gets converted to mechanical energy that rotates the turbine. Our target is to produce steam at a very high pressure. Pressure of the steam can be increased by various auxiliaries through different mechanisms. So basically we need to produce steam. For the production of steam water is to be heated to high temperatures with the help of available fuel. Combustion of fuel is done and evolved heat is utilized for production of steam. Total idea is to be implemented in a highly efficient way to balance the finance and economy. Environmental protection should also be the point of concern because burning of fuel may evolve gases which are responsible for harmful effects that distract our ambience.

1.5 BASIC REQUIREMENTS:

Fuel Water Heating system Steam circuit Regenerating system Steam turbine Generator Transformer

COAL:

Coal India limited owns and operates all the major coal fields in India through its coal

producing subsidiary companies viz. Eastern Coal Fields Limited, Western Coal Fields Limited/Coal India limited is supply coal from its coal mines of coal producing subsidiaries BCCL, SECL & ECL

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to Kota Thermal Power Station through railway wagons. The average distances of SECL, ECL & BCCL are 800, 950 and 1350 Kms. respectively.

WATER:

The source of water for power station is reservoir formed by Kota Barrage on the

Chambal River. In case of large capacity plants huge quantities of coal and water is required. The cost of transporting coal and water is particularly high. Therefore, as far as possible, the plant must be located near the pit rather than at load centre for load above 200 MW and 375 MW. The transportation of electrical energy is more economical as compared to the transportation of coal. The design of steam power station requires wide experience as the subsequent operation and maintenance are greatly affected by its design. The most efficient design consist of properly sized component designed to operate safely and conveniently along with its auxiliaries and installation.

HEATING SYSTEM:
plant.

A heating system is a mechanism for maintaining

temperatures at an acceptable level; by using thermal energy within a power

REGENERATIVE SYSTEM:

It is a designed loop for effective utilization of

energy to increase the efficiency of the process. In general furnace is meant to produce the steam from water. But total energy evolved from combustion of coal is excessive for this. So this heat energy from the furnace is repeatedly utilized wherever necessary through SUPER HEATER COILS REHEATER COILS ECONOMISER To generate EMF the rotor of the generator need to be

STEAM TURBINE:
turbines.

rotated which in turn is operated by a shaft which is rotated with the help of three HIGH PREESSURE TURBINE (HP TURBINE) INTERMEDIATE /MEDIUM PRESSURE TURBINE (IP TURBINE) LOW PRESSURE TURBINE

Each turbine has its own operating temperature and pressure

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CONDITION MONITORING OF POWER TRANSFORMERS GENERATOR:

It converts mechanical energy to electrical energy. As we have

discussed the 3 turbines rotate a single shaft at a rated speed of 3000 RPM. This shaft is in turn connected to a TURBO GENERATOR which can generate an EMF of 11 KV.

TRANSFORMER:

Transformers are static devices used for transferring

power from one circuit to another without change in frequency. Different types of transformers are used for stepping up and stepping down the generated voltage either for supplying to the grid or for self utilization.

1. 2. 3.

GENERATOR TRANSFORMER UNIT AUXILIARY TRANSFORMER STATION TRANSFORMER

1.6 SOME IMPORTANT POINTS:

Hydrogen is used as cooling medium in large capacity generator due to its high capacity of heat carrying and low density. But in view of its forming an explosive mixture with oxygen, proper sealing system has to be provided and see that there is no escape of hydrogen from the generator. Mainly oil sealing is used to seal hydrogen. Power plant furnaces may have a re heater section containing tubes heated by hot flue gases
outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the re heater tubes to pickup more energy to go drive intermediate or lower pressure turbines.

A de-aerator is a device that is widely used for the removal of air and other dissolved gases from the feed water to steam-generating boiler. In will cause serious particular, dissolved oxygen in boiler feed water

corrosion damage in steam systems by attaching to the walls of metal piping and other metallic equipment and forming oxides (rust). Water from the condenser pipes are pumped in to a sump called HOT WELL. Water in this well is around 50o C. From here water will be sent to cooling towers for cooling. Barring gear (or "turning gear") is the mechanism provided to rotate the turbine generator shaft at a very low speed after unit stoppages. Once the unit is "tripped" (i.e., the steam inlet valve is closed), the turbine coasts DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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CONDITION MONITORING OF POWER TRANSFORMERS

down towards standstill. When it stops completely, there is a tendency for the turbine shaft to deflect or bend if allowed to remain in one position too long. This small shaft deflection, only detectable by eccentricity meters, would be enough to cause damaging vibrations to the entire steam turbine generator unit when it is restarted. The shaft is therefore automatically turned at low speed (about one percent rated speed) by the barring gear until it has cooled sufficiently to permit a complete stop.

CHAPTER.II Transformers
2.1 Introduction:
A transformer is a device with two or more stationary electrical circuits that are conductively disjointed magnetically coupled by a common time-varying magnetic field. Transformers are static devices used for transferring power from one circuit to another without change in frequency. Transformers are basically passive devices for transforming voltage and current. It can raise or lower the voltage corresponding decrease or increase in current. One of the windings, generally termed as secondary windings, transforms energy through the principle of mutual inductance and delivers power to the load. The voltage levels at the primary and the secondary windings are usually different and any increase or decrease of the secondary voltage is accompanied by corresponding increase or decrease in current. Transformers are among the most efficient machines 95% efficiency being common in

lower capacity ranges, while an efficiency of 95% is achievable in high capacity ranges. Theoretically, there is no upper limit to the power handling capacity; transport constraints, handling facilities, etc. being the limiting factors. The lower limit is governed by the allowable no-load losses. The physical basis of a transformer is mutual induction between two circuits linked by a common magnetic field. The primary circuit carrying a current has associated with it, as a manifestation of electrical phenomenon of current flow, a magnetic field in its immediate vicinity. When the circuit is alternating, the magnetic field at any point in the surrounding medium will vary in both magnitude and direction I accordance with the change of current with time. The secondary being in the vicinity the primary circuit will link with some of the primary magnetic flux produced. With an alternating primary current, and therefore flux, the changing linkages will produce in secondary winding an emf. The more closely the primary and the
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CONDITION MONITORING OF POWER TRANSFORMERS

secondary circuits are mutually linked, the more direct becomes the change of energy between them. Major electrical parameters of a transformer are iron and copper losses, hysteresis losses, efficiency, regulation. Essentially the chief elements of construction of a transformer comprise materials for magnetic circuit, terminals, tapping switches, oil as well as cooling devices.

2.2 Working principle of a transformer:

The physical basis of a transformer is mutual inductance between two circuits linked by a common magnetic flux through a path of low reluctance. The two coils named primary and secondary posses high mutual inductance. If one coil connected to a source of alternating voltage, alternating flux is set up in laminated core, most of which is linked up with the other coil in which it produces mutually induced emf according to the faradays law of electromagnetic induction, ie

E=M*(di/dt)
Where E=induced emf, M=mutual inductance. EMF induced in a transformer is given by the equation E=4.44 m f N volts, m=BmA If second circuit is closed, a current flow in it and so electrical energy is transferred entirely magnetically from the first coil to the second coil.

2.3 Different Parts of transformer: Core:

The core forms the magnetic circuits of a transformers. There are two 1) core type and 2) shell type. In core type transformer, the windings surround a considerable part of core where as in shell type transformers; the core surrounds a considerable part of windings. In both core and shell type transformers, the individual laminations are cut in the form of long strips of Ls, Es, Is and the laminations are butted against each other.

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The material used are COLD ROLLED GRAIN ORIENTED ELECTRICAL STEEL SHEETS (CRGO). CRGO made from ferrous base present maximum magnetisability i.e. permitting high induction. Iron crystallizes into body centre cubic lattice with the cube edges of lattice pointing in the direction of easiest magnetizability and lowest core loss. Grain oriented electrical sheets consists of silicon-iron alloy, with the crystallites being predominately oriented by the means of a specific manufacturing process, in such a way as to have four cube edges pointing the rolling direction and diagonal plain being parallel to the sheets surface. In this way the rolling direction becomes the direction of maximum magnetic properties direction and approaching the ideal properties of the individual crystallite. The CRGO has the following properties such as maximum magnetic properties, minimum specific core loss, low apparent power input, low magnetostriction, high grade surface insulation, good mechanical processing properties.

Insulating oil:
Insulating oil forms a very significant parts of a transformer insulation system and has the important function of acting as an electrical insulation as well as coolant to the dissipate heat losses. This basic raw material for the production of transformer oil is a low viscosity lube termed as TRANSFORMER OIL BASE STOCK (TOBS) which is normally obtained by fractional distillation and subsequent treatment of crude petroleum. TOBS is further refined by acid treatment process to yield transformer oil.

Chemical Properties:
Transformer oil consist of four major generic classes of organic compounds, namely paraffins, naphthenes, aromatics and olefins. All these are hydrocarbons and hence insulating oil is called a pure hydrocarbon mineral oil. For good fresh insulating oil, it is desirable to have more of saturated paraffin, less of aromatic or naphthenes and none of olefins. However, for better stability of DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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CONDITION MONITORING OF POWER TRANSFORMERS

properties, it is necessary to have optimum aromatic or naphthenes hydrocarbons. Such as optimum balance is carefully struck by a carefully controlled refining process. Depending upon the predominance, oil is usually termed as of paraffinic base or naphthenic base.

Electrical properties:

Electric strength (Breakdown voltage): BDV is the voltage at which breakdown occurs
between two electrodes when oil is subjected to an electric field under prescribed conditions. Electric strength is the basic parameter for insulation system design of a transformer. It serves to indicate the presence of contaminating agents like moisture, fibrous material, carbon particles, perceptible sludge and sediment.

Resistivity (specific resistance):

This is the most sensitive property of oil requiring

utmost care for its proper determination. Resistivity in ohm-cm is numerically equivalent to the resistance between opposite phases of a centimeter cube of liquid. Insulation resistance of windings of a transformer is also dependent upon the resistivity of oil. A low value indicates the presence of moisture and conductive contaminants.

Dielectric dissipation factor (DDF): DDF is numerically equal to sign of the loss angle
(approx. equal to tangent of loss angle for dielectrics) and is a good tool to indicate the quality of insulation. A high value of DDF is an indication of the presence of contaminations or deterioration products such as water, oxidation produced.

Table 2.1: Characteristics of oil:

Characteristic
Density at 27c, max Kinematics viscosity at 27c, max Interfacial tension at 27c, mini Flash point, mini Pour point, max Neutralization value, max Corrosive sulphur Electric strength as received Electric strength after filtration Dielectric dissipation factor(tan delta) at 90c, max Specific resistance at 90c Specific resistance at 27c Oxidation stability neutralization value after oxidation, max Total sludge after oxidation Presence of oxidation inhibitor

Requirement as per standards

0.89g/cu.cm 27cSt 0.04N/m 140c -9c 0.03mg KOH/g Non-corrosive 30KV(rms) 50KV(rms) 0.005 30*10^12ohm cm 500*10^ohm cm 0.4mg KOH/g 0.1%by weight The oil shall not contain antioxidant

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CONDITION MONITORING OF POWER TRANSFORMERS

Water content as received, max additives 50 ppm by weight

Winding:
The transformer consists of two coils called WINDINGS which are wrapped around a core. The transformer operates when a source of ac voltage is connected to one of the windings and a load device is connected to the other. The winding that is connected to the source is called the PRIMARY WINDING. The winding that is connected to the load is called the SECONDARY WINDING.

High Voltage Coil:

It has more number of turns. Thickness of the wire is less. Tapings are taken from this coil because of low currents.

Low Voltage Coil:

It has less number of turns. Thickness of the wire is high. Tapings are not taken from this coil because of high currents.

Tap-Changing: There is considerable voltage drop between generating sources and consumers in
modern electricity supply. So transformers provided with number of taps at the ends of the lowcurrent winding i.e. H.V side so that the voltage ratio can be adjusted to suit loading conditions. There are two types of tap-changers, they are Off-load Tap- changer On-load Tap-changer

Off-load Tap-changer: The transformer is normally fitted with a off-load tap changing to obtain
required tap voltage. It can be hand operated by a switch handle mounted in tank. Locking device is DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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CONDITION MONITORING OF POWER TRANSFORMERS

fitted to handle to padlock it on any tap position and also to prevent any unauthorized operation of switch. The switch mechanism is such that it can be locked only when it is bridging two contacts on any particular tapping position and cannot be locked in any intermediate position. It is important that the transformer should be isolated from the live line before moving the switch. Operating the switch when the transformer is energized, will damage the switch contacts due to serve arching between the contacts, and may damage the winding also.

On-load Tap-changer: On-load tap changers are employed to change turn ratio of transformer to
regulate system voltage while the transformer is delivering normal load. With the introduction of onload tap changer , the operating efficiency of electrical system has considerably improved. Now-adays, almost all large transformers are fitted with on-load tap changer. All forms of on-load tap changing circuit posses impedance, which is introduced to prevent short circuiting of tapping section during, tap changer operation. The impedance can be either a resistor or a center tapped reactor. The on-load tap changer can be classified as two types i.e. resistor type and reactor type.

Conservator:

Conservator is a sort of a drum, mounted on the top of the transformer. A level

indicator is fixed to it.

Conservator is connected through a pipe to the transformer tank containing oil. This oil expands and contracts depending upon the heat produced and so the oil level in the conservator rises and falls. Pipe connected to the conservator is left open to the atmosphere through a breather so that the extra air may go out or come in.

Breather:
The breather is a box containing calcium chloride or silica gell to absorb moisture of air entering the conservator as it is a will known fact that the insulating property of the transformer oil is lost if a small amount of moisture enters in it, so dry air is allowed to pass in through this breather.

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Breather should be inspected

frequently

especially in a situation where temperature and humidity changes are considerable and when transformer is subjected to fluctuating loads. So long as silica gel is in active stage, it color is dark blue but as it becomes saturated moisture, its color changes to pale blue/pink when it should be reactivated.

valves:

Transformer is equipped with drain cum filter valve at the bottom of the tank and filter

valve at the top of the tank. Valves are fitted with plug/blanking plates to stop the dirt or moisture entering inside the valve and avoid the contamination of the transformer oil. Types of valves: Plug type Wheel valve with female screw threads Wheel valve with flanges - Up to 500 KVA units - 501 to 2000 KVA units - Above 2001 KVA units

Buchholz relay: This relay gas actuated relay which is meant for the protection of oil immersed
transformer from insulation failure, core heating or any type of internal fault which may cause the heating of coil beyond the specified temperature.

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Due to any internal fault, oil is heated up and oil vapour so formed causes either the alarm circuit(for less fault) or the trip circuit (for severe faults). The relay is situated in the pipe connected between the transformer and the conservator.

Explosion Vent:

It is also a safety device of a transformer which protects the transformer tank

from the gases induced by any type of short circuit in the transformer.

Temperature gauge:

It is also a

protection device fitted to a transformer to indicate the temperature of transformer and operates the alarm, trip and cooler control contacts. The instrument is provided with a maximum temperature indicator .

Radiators: Radiators are commonly used for cooling. ONAN, ONAF and OFAF are the types of
cooling. Radiators consist of elements joined to top and bottom headers.

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Elements are made by welding two previously rolled and pressed thin steel sheets to from a number of channels or flutes through which oil flows. These radiators can be either mounted directly on the transformer tank or in the form of a bank or connected to tank through pipes. The surface area available for dissipation heat is multiplied manifolds by using various elements in parallel. As oil passes downwards, either due to natural circulation or force of a pump in the cooling circuit, heat is carried away by the surrounding atmosphere air There are two types of radiators named tank mounted radiators and bank mounted radiators. The total number of radiators required for the cooling of transformer can be arranged in many ways. Usually one bank of radiators for 100% capacity is sufficient. However, if desired 2-50% banks can be formed by dividing number of radiators into two equal parts. But each part is completed with separate auxiliary cooling equipment like fans and a pump. So if we divide the bank into number of parts then the auxiliary parts increase and ultimate in increase of cost. .

Bushings:
Porcelain insulators and connectors should be cleaned at convenient intervals and minutely examined for the cracks or other defects. Small or narrow cracks are difficult to detect. However, they are likely to develop rapidly. All such bushings should be replaced. Similarly oil communicating type bushings top. The cause of any serious loss of oil should be investigated. In case of any sign of oil DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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2.4 TYPES OF TRANSFORMER:

Depending upon the type of construction used, the transformers are classified into two categories, they are Core type transformer Shell type transformer

Core type transformer:

It has one magnetic path only. Average length of core is more. Here area of cross-section is less, so more turns are required.

On every leg both primary and secondary windings are there so leakage flux is less.

It is used for high voltage and less output.

Most portion of winding is visible so it is easy to insulate and repair. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

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CONDITION MONITORING OF POWER TRANSFORMERS

Shell type transformer:

In this type core encloses the winding, so the cooling is good for core. It has two magnetic paths. Average length of core is less. Area cross-section is more. So less turns are required. It is used for low voltage and high output.

To reduce losses here the winding is done in PANCAKES-primary, secondary windings are on the central limb.

In this transformer most of winding is enclosed by the iron. so, difficulty is experienced in repairs.

Depending upon the cooling medium. The transformers are classified into two types. They are Dry type transformers Oil filled transformers

Dry type transformer: These are further classified as air cooled transformers and air blast
transformers. The air cool transformers are of very small output (say 5or 10 KVA) and cooled by circulation of air. Air blast transformers are cooled by a forced circulation of air through core and windings. Such transformers are limited to voltages not exceeding 25 KV. These are used in substations located in thickly populated areas where oil is considered a fire hazard.

Oil filled transformer: in general transformers are of oil-immersed type. The oil used for this
purpose is mineral one which provides better insulation in addition to cooling. These transformers are further classified as oil immersed natural cooled, oil immersed forced air cooled, oil immersed water cooled, oil immersed forced oil cooled transformers.

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CONDITION MONITORING OF POWER TRANSFORMERS

Depending upon the power rating, the transformers are classified into two categories, they are Distribution Transformers Power Transformers

Distribution Transformers: Transformers of rating up to 200KVA , used to step down the

distribution voltage to a standard service voltage are known as distribution transformers. They are kept in operation all the 24 hours a day whether they are carrying any load or not. They are of the self cooling type and are almost invariably oil-immersed. Energy is lost in iron losses throughout the day while the copper losses account for ioss in energy when the transformer is loaded. Therefore distribution transformers should have their iron losses small as compared to full load(about 50%). Owing to low iron loss, the distribution transformers have good all-day efficiency. These transformers should have a good voltage regulation.

Power transformers: The transformers of rating above 200KVA used in generating station and
substations at each end of a power transmission line for stepping up or stepping down the voltage are known as power transformers. They are put in operation during load hours and disconnected during light load hours. Therefore, power transformers should be designed to have maximum efficiency at or near full load. Power transformers are designed to have considerably greater leakage reactance than is permissible in distribution transformers because in the case of power transformers, voltage regulation is less important than the current limiting effect of higher leakage reactance. They may be self oil cooled, forced air cooled or forced water cooled.

2.5 Faults and failures:

Although failure in transformers is rare, faults do occur and the reasons may be broadly classified as: Failure in magnetic circuit Failure in electric circuit Failure in dielectric circuit Failure in structural and mechanical fittings.

Failure in magnetic circuit:

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CONDITION MONITORING OF POWER TRANSFORMERS

Common causes for this failure are

Breakdown of insulation of core bolt. High flux density in the core resulting in large magnetizing current increase during switching.

Failure in electric circuit:

Common causes of this failure are Presence of sharp edges on conductors. Drying of a transformer is not carried out properly If moisture penetrates into the winding insulation Incorrect pressure on windings resulting in dislodging of turns Switching, lightening surges producing high voltage at the end turns Loose connections, bolted joints Sustained overloads resulting in over heating

Failure in dielectric circuit:

Common causes of this failure are Moisture entering oil due to breathing Narrow oil ducts in winding causing insufficient cooling Sustained overloading resulting in deterioration due to excessive oil temperature

Failure in structural and mechanical fittings:

Common causes of this failure are

Inadequate clamping of leads from windings to terminal boards resulting in short circuit.

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CONDITION MONITORING OF POWER TRANSFORMERS

Poor welding, leaky fittings cause leakage of oil resulting in overheating. Improper ventilation causes overheating of oil.

Dos for power transformers:

1. Connect gas cylinder with automatic regulator if transformer is to be stored for long

duration, in order to maintain positive pressure. 2. Fill the oil in the transformer at the earliest opportunity at site and follow storage instructions. It must be commissioned as soon as possible.
3. Open the equalizing valve between tank and OLTC diverter compartment, whenever

provided, at the time of filling the oil in the tank and close the same during operation.
4. Clean the oil conservator thoroughly before erecting. 5. Check the pointers of all gauges for their free movement before erection. 6. Inspect the painting and if necessary do retouching.

7. If inspection covers are opened or any gasket joint is tightened, tighten the bolts evenly with the proper sequence to avoid uneven pressure. 8. Clean the buchholz relay and check the operation of alarm and trip contacts.
9. Check the oil level in oil cup and ensure that the air passages are free in the breather. If

oil is less, make up the oil level. 10. Check the oil in the transformer and OLTC for the dielectric and moisture content, and take suitable action for restoring the quality of oil. 11. Attend to leakages on the bushing immediately. 12. Check the diaphragm of the relief vent. If cracked or broken, replace it. 13. Remove the air from vent plug of the diverter switch before energizing the transformer.
14. Check the gear box oil level in the tap changer. If less, top up with specified oil.

15. Check the OTI and WTI pockets and replenish the oil, if required.
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CONDITION MONITORING OF POWER TRANSFORMERS

16. Examine the diverter and selector contacts of tap changer and if found burnt or worn out, replace the same.
17. Check and thoroughly investigate the transformer whenever any alarm or protection is

operated. 18. Examine the bushing for dirt deposits and coats and clean them periodically. 19. Check all bearings and operating mechanism of the tap changer and lubricate as per schedule.
20. Keep the wall connected between the conservator of tap changer and its diverter

compartment open, during transformer operation.

Donts for transformer:

1. Do not allow WTI, OTI temperature to exceed 75c during dry out of transformer, and

filter machine temperature beyond 85c. 2. Do not re-energize the transformer, unless the buchholz gas is analyzed.
3. Do not re-energize the transformer without pre-commissioning checks.

4. Do not energize the transformer, unless the off-circuit tap switch handle is in locked position. 5. Do not leave off-circuit tap switch handle unlocked. 6. Do not leave tertiary terminals unprotected outside the tank. 7. Do not leave any connection loose. 8. Do not meddle with the protection circuit. 9. Do not leave maximum temperature indicating pointer behind the other pointer in OTI and WTI. 10. Do not change the setting of WTI and OTI alarm and trip frequently.
11. Do not allow oil level in bushings to fall, they must immediately top up.

12. Do not allow conservator oil level to fall below one-fourth level.
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CONDITION MONITORING OF POWER TRANSFORMERS

13. Do not leave secondary terminals on an unloaded CT open.

2.6 Transformer losses:

In transformer as there is no rotating part, there is no friction and wind age losses. Hence, the only losses occurring are-

Core losses:

Core losses are caused by alternating flux in the core. These are also called as iron

losses. The iron losses are constant on every load. These losses can be found out by open circuit test on the transformer. It consist of Hysteresis losses Eddy current losses Hysteresis losses: Each time the magnetic field is reversed, a small amount of energy is lost due the hysteresis within the core. For a given core material, the loss is proportional to the frequency, and is a function of the peak flux density to which it is subjected. Eddy current losses: due to variation in magnetic flux eddy currents are induced on the surface of iron core which in turn produce heating and therefore reduce the amount of power to the secondary coil. In order to avoid eddy currents, the core is laminated, made of thin sheets of soft iron. Each sheet is separated from the next by a layer of insulating varnish.

Copper losses: These losses are due to resistance of winding and are proportional to (current)^2
or (KVA)^2. These can be obtained experimentally by means of short circuit test. Copper Loss = I2R Where I is the current flowing in the conductor and R the resistance of the conductor. With I in ampere and R in ohms, the calculated power loss is given in watts. With high-frequency currents, winding loss is affected by proximity effect and skin effect, and cannot be calculated as simply. For low-frequency applications, the power lost can be minimized by employing conductors with a large cross-sectional area, made from low-resistivity metals.

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CONDITION MONITORING OF POWER TRANSFORMERS

CHAPTER.III Condition monitoring

3.1 Introduction:
Reliable and quality power is need of the hour for the economic development of a country. For providing reliable electrical energy, it is very necessary to have highly reliable associated electrical equipment. The transformer, being a key element in the transmission and distribution of electrical energy, improving its reliability is of utmost importance. System abnormalities, loading, switching and ambient condition normally contributes towards accelerated aging and sudden failure, hence, it is, all the more essential, to employ continuous monitoring techniques and on-site

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CONDITION MONITORING OF POWER TRANSFORMERS

diagnostics followed by quality maintenance for having trouble-free and reliable operation with minimum outage. Continuous monitoring of the condition of high voltage power apparatus is necessary to ensure reliable supply of electrical power. The purposes of condition monitoring are the following Detecting incipient faults and thereby avoiding catastrophic failure of the equipment and developing a data base which helps in more accurate failure analysis thereby improving reliability of service. Condition monitoring can be done in energized as well as de-energized condition and can be done off-line or on-line. Ideally, online monitoring with HV equipments energized is the best as it has the potential to detect faults at the incipient stage and does not involve any down time.

The article, being submitted, shall present a survey of new monitoring and diagnostic technologies in power transformer for the purpose of condition assessment. Also, life assessment and extension program for transformer in service will be highlighted. Case studies citing site experiences of problem faced on transformer in service and various diagnostic tools employed for finding solutions will be cited.

Insulation monitoring: Insulation is the major component, which plays an important role in
the life expectancy of the transformer. Transformer life known to us is based on the designed parameter with respect to normal operation and climate conditions. To determine the performance and aging of the asset, insulation behavior is a main indicator [1]. Most of the transformers in a system, around the world are exceeding their designed life. In the absence of insulation assessment, good number of transformer failed due to insulation problems, before reaching to their designed technical life. It is important to investigate the cause(s) of the insulation degradation with respect to age. Average age of the transformers that failed due to insulation deterioration during the last ten years was 17.8 years [2]. A good number of aged transformers are still performing well, it is vital to monitor the insulation behavior rather than replacing with new one. Transformer insulation behavior is different with respect to operation mode, climate (ambient condition) and frequency of subjected faults. Load growth has influence on the insulation degradation. The insulation degradation trend needs regular assessment. An accurate analysis of the insulation can suggest operating condition, de-rating of the transformer will increase the life expectancy [3, 4]. The unit can be proposed for relocation, subjected to less stress. Cost effective maintenance strategies can be developed. Insulation aging in transformer DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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is a complex and irreversible phenomena. To ensure higher reliability and safety, insulation condition monitoring and trend analysis are of major concern. Insulation trend analysis will conclude type of failure as well as severity of the fault. This will make easy to understand type of maintenance required, loading constraints and future management required. The analysis will predict the life expectancy of the asset. It is significant to recommend insulation assessment for the aged and suspicious behavior transformers. With perfect condition monitoring the rate of aging can be reduced. Online insulation condition monitoring, proper diagnostics and accurate interpretation/ analysis will provide realistic decision for economical operation and cost effective maintenance strategies. The overall integrity of the asset can be assessed, with minimum risk of sudden failure. The environmental risk can be reduced. Effect of aging rate on the life expectancy can be established. Condition monitoring provides information on the developing insulation problems and incipient faults [5, 6]. Thus early warning of any abnormality can avert the catastrophic failure.

Purpose of condition monitoring:

To avoid forced outages To minimize failures and optimize the maintenance cost

Monitoring scheme must be:

Simple Low cost Without disruption of power

Data must be focused on results to:

Prevent problems Define the severity of a problem Provide information to take action Provide on-line and off-line diagnostics Enable trending of data Avoid intrusive maintenance

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CONDITION MONITORING OF POWER TRANSFORMERS 3.2 TRANSFORMER ASSESSMENT:

Since 1885 transformers (0.15 MVA) are serving the power industry and are being produced with higher rating (> 2000MVA). Majority of transformer population is serving in many of the transmission and distribution utilities are 20 to 40 years old. As an example the installed power transformer (United States) capacity has reduced from 185 GVA (Giga Volt Amperes) to 50 GVA per year over the past twenty-five years [7]. The average load growth rate observed is approximately 2% [7]. Transformer utilization has increased by 22% on average, causing oil hot spot temperature to increase by approximately a 48%, at normal peak load [7, 8]. Due to gradual increase in the temperature, peak load insulation life will be reduced by a factor of approximately 8 [7, 9]. Economic pressures and factors such as an increasing proportion of aged power transformers are combining to dictate more efficient plant maintenance management. Life assessment is becoming increasingly important as the average age of the asset increases, due to economic pressures and a relatively low load growth, with fewer major re-development projects. A scientific remnant life assessment would be an important tool towards higher reliability of the system and asset management. After determining the critical indicator responsible for aging as well as asset technical assessment, the rate of ageing can be reduced by implementing the correct operational and maintenance strategies. The early and failures due to aging can be effectively minimized. Better asset management system can be implemented (timely relocation / replacement can be planned).

The transformer's condition assessment can be broken down into the following areas of concern:
Operating performance to design criteria. Aging of insulating materials due to stress imposed both thermal and electrical. Chemical deterioration from moisture, oxygen and acidity and other contaminations. Mechanical strength of the solid insulating and bracing materials.

3.3 Critical Components: Core, windings, insulation oil, bushing and on-load tap-changer
are the main active parts of the transformer insulation chain . The degradation of insulation systems is accompanied by phenomenon of changing physical parameters or the behavior of insulation systems. The degradation of insulation systems is a complex physical process. Many parameters act at the same time thus making the interpretation extremely difficult. The aging process in the oil/cellulose DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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insulation system under thermal stress and their measurable effects are due to chemical reactions in the dielectric. The temperature of the oil/paper dielectric is the critical aging parameter to cause enough change in the mechanical and electrical properties of the material. Apart from high temperatures, other important parameters affecting the aging of the solid and liquid insulation include the presence of water and oxygen in the system . The monitoring and assessment of such components is vital to achieve better reliability of the system. By implementing correct operational and maintenance strategies the insulation aging/ degradation process can be controlled and the asset life can be extended effectively. Assets critical component monitoring (strict) is required for the technical assessment (normal to end of life) to ensure economical and safe operation. Also better asset management policies can be implemented .

3.4 Types of Major Failures:

Following are the major components, which have a direct bearing on reliability of the transformers Winding and electrical circuit, Core and clamping structure, Bushings and external connections, Tap chargers, Coolers and cooling medium, Control and supervisory equipment The types of failure which occur on transformer are many, one with serious concerns to condition monitoring techniques are listed below -

Core:
Breakdown in core bolt insulation, core plate insulation or insulation between core and core clamps leads to circulating currents and usually sparking at the fault. Gases are evolved, which dissolve in oil. These can be monitored by Dissolved Gas Analysis (DGA).

Windings and Inter-winding Insulation:

Overheating due to poor joints is a common fault in any part of the electrical circuit. Breakdown of inter-strand insulation results in circulating current causing overheating of insulation and hot spots at point of fault. This can be a result of winding movement. A turn-to-turn fault produces a similar effect but with much more energy and can usually be detected and identified. Partial discharge faults can develop between various parts of the insulation structure as a result of contamination (including moisture) or due to poor impregnation or overstressing. Over heating of stress shields results in DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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CONDITION MONITORING OF POWER TRANSFORMERS

breakdown and circulating current. A fault between windings and a fault from line-to-ground usually results in serious damage.

Tanks, Flux shields and Fittings:

The breakdown of insulation between portions of the tank shields or between the shields and tank can lead to circulating current, which is a function of load current. Circulating current in the tank due to proximity of heavy current conductors can produce hot spots in the tank and across gasket joints.

Bushings:
Ingress of moisture, loosed/bad joints may lead to failure of bushings.

Deterioration and failure factors:

deterioration are categorized as: Operating Environment (electrical)

The factors responsible for failures and accelerated

Transient over-voltages, load current, short circuit (fault currents), lightening and switching surges. Operating Environment (physical) Temperature (operating full load with high ambient temperature-humidity index), wind, rain, seismic and pollution Operating Time Time in service and time under abnormal conditions or extreme condition (load variation, change in thermal stresses). Number of Operations of Tap-changer Number of on-load tap-changer operation. Vibration Effect Sound and material fatigue. Contaminants Moisture (water content in oil), presence of oxygen and particles in oil.

3.5 Condition Monitoring and Online/Off-line Diagnostics:

There is an increasing need for power utilities to use assets to their fullest while maintaining system reliability. Transformers, which have exceeded their design life or are approaching the end of their operating life, require all the more attention as compared to new transformers. Due to increasing failure of large power transformers, the maintenance engineers are seriously reviewing their O&M procedure in order to prevent forced outages, incur less maintenance cost, and to have longer life of equipment. To assess the extent of deterioration within the transformer, it is necessary to employ the appropriate diagnostic tool. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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A few decades ago, Tan delta/Insulation Resistance measurement of winding/bushing, monitoring of oil/winding temperature, checking of BDV of oil and fault gas analysis, formed the part of condition monitoring strategy. Later on, Dissolved Gas Analysis (DGA) and Furan analysis of oil were added and proved to be effective tools in the condition monitoring of transformers. However, presently, due to the marked improvement of technology, following additional diagnostic tests have been included for condition assessment of transformers, which have saved power transformers from undergoing major damages. Partial Discharge Measurement, Frequency Response Analysis (FRA), Recovery Voltage Measurement (RVM), Thermo vision Measurements.

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CONDITION MONITORING OF POWER TRANSFORMERS

CHAPTER.IV TRANSFORMER TESTS

4.1 INTRODUCTION:
A Transformer is very vital equipment in a power system & its availability, reliability is very important. The transformer primarily comprises of core, winding, and insulation. The insulation comprises of solid, liquid and combination of oil and cellulose paper. The condition monitoring of oil is performed by prescribed tests as below-

Things to be monitored:
Winding resistance measurements Capacitance and tan for winding Insulation resistance(IR) and Polarization index(PI) measurement Oil parameters Furan Analysis Degree of polymerization(DP) Partial Discharge(PD) Measurements Frequency Response Analysis(FRA) Recovery voltage measurement(RVM) Surge comparison test Dc step voltage measurement Capacitance and tan for bushings Dissolved Gas Analysis(DGA)

4.2 Winding Resistance Measurements:

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This is nothing but the resistance measurement of the windings by applying a small d.c. voltage to the winding and measuring the current through the same. The ratio gives the winding resistance, more commonly feasible with high voltage windings. For low voltage windings a resistance-bridge method can be used. From the d.c resistance one can get the a.c resistance by applying skin effect corrections. Winding resistance is measured by using MEGGER. Megger used: To measure resistance of windings. To compare with factory results. As part of a regular maintenance program. To help locate the presence of defects in transformers, such as loose connections. To check the make-before-break operation of on-load tap-changers.

PURPOSE OF TESTING:
Winding resistance measurements in transformers are of fundamental importance for the following purposes: Calculations of the I2R component of conductor losses. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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Calculation of winding temperature at the end of a temperature test cycle. As a base for assessing possible damage in the field.

Increase in resistance indicates:

Loose joints- leads to local hot spots and eventual melting of joints. Worn out contacts- leads to contact erosion.

4.3 Capacitance and tan for winding:

This test measures and records the capacitance between the high and low voltage windings, between the high voltage winding and the tank (ground), and between the low voltage winding and the tank (ground). Changes in these values as the transformer ages and events occur, such as nearby lightning strikes or through faults, indicate winding deformation and structural problems such as displaced wedging and winding support. Similarly in a Dielectric material when a cavity or deterioration starts, the life of the material starts deteriorating, as there is a resistance getting added and hence leakage current increases In tan Delta we find the difference in the angle and periodically note down the pace at which deterioration takes place. Measure capacitance and tan of each pair of windings and windings with respect to earth. Compare with factory results It indicates healthiness of insulation system-paper, press-board and oil.

Increase in tan indicates :

Deterioration of insulation system. Contamination. Moisture absorption.

4.4 Insulation resistance(IR) and Polarization index:

Insulation failure can cause electrical shocks, creating a real hazard to personnel and machinery. A regular program of testing insulation resistance is strongly recommended to prevent this danger, as well as to allow timely maintenance and repair work to take place before catastrophic failure. All new equipment, motors, transformers, switch gears, and wiring should be tested before being put into service. This test record will be useful for future comparisons in regular maintenance testing. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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Some of the more common causes of insulation failure include excessive heat or cold, moisture, aging, corrosive atmospheres and vibration. Insulation values are in ohms, and insulation values change according to temperature. Take all of your readings at 20 C. A general rule is to take 1/2 the resistance reading for every 10 deg C increase, and double the resistance for every 10 deg C decrease. For instance, if you measure 10 mega ohms at 30 deg C, a 10 deg increase, your true reading is 5 mega ohms. Measure the insulation resistance values of each pair and with respect to earth. Compare with factory results. To determine gradual decrease in insulation resistance. This provides a means for predicting future insulation failure. Lower values indicate poor insulation.

PI: It is ratio of insulation resistance (IR )for 10 minutes to insulation resistance for 1 minute. Measure PI values of each winding in pairs and with respect to earth. I t should be 1.5 Table 4.1: range of polarization index

PI(Ratio of 10 min to 1min) Less than 1 1.0-1.1 1.1-1.25 1.25-2.0

condition
Dangerous poor Questionable fair

4.5 Oil parameters:

Transformer oils are subject to electrical and mechanical stresses while a transformer is in operation. In addition there are contaminations caused due to chemical interactions with windings and other solid insulations, catalyzed by high operating temperature. As a result the original chemical properties of transformer oil changes gradually, rendering it ineffective for its intended purpose after many years. Hence this oil has to be periodically tested to ascertain its basic electrical properties, and make sure it is suitable for further use or necessary actions like filtration/regeneration has to be done. This testing done on the basis of different methods like IEC, ASTM, IS and other recognize transformer oils analytical procedure. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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CONDITION MONITORING OF POWER TRANSFORMERS BDV Test:

The dielectric strength of insulating oil is a measure of the oils ability to withstand

electrical stress without failure. The test involves applying a ac voltage at a controlled rate to two electrodes immersed in the insulating fluid. The gap is a specified distance. When the current arcs across this gap the voltage recorded at that instant is the dielectric strength or breakdown strength of the insulating liquid. Contaminants such as water, sediment and conducting particles reduce the dielectric strength of insulating oil. Combination of these tends to reduce the dielectric strength to a greater degree.

Neutralization or Acidity Test: 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. The acidity of oil in a transformer should never be allowed to exceed 0.25mg KOH/g oil. This is the CRITICAL ACID NUMBER and deterioration increases rapidly once this level is exceed.

Dissipation factor:

The Dissipation test measures the leakage current through 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.

Flash point Test: Flash

Point is the lowest temperature at which the vapors of a combustible

liquid will ignite momentarily in air. Low diesel fuel flash points indicate contamination by more volatile fuels such as gasoline. Flash point for oils is typically tested by Cleveland Open Cup. Refer to ASTM guidelines for minimum flash point requirements.

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CONDITION MONITORING OF POWER TRANSFORMERS

Interfacial tension: The Interfacial Tension (IFT) measures the tension at the interface between
two liquid (oil and water) which do not mix and is expressed in dyne/cm. The mineral oil insulating Fluid is essentially a non-polar saturated hydrocarbon; however, when the sample undergoes oxidative degradation there are formed oxygenated species such as carboxylic acids, which are hydrophilic in nature. The presence of these hydrophilic materials in the insulating fluid can affect the chemical (acidity), electrical (dielectric strength), and physical (interfacial tension) properties of the fluid. The test is sensitive to the presence of oil decay products and soluble polar contaminants from solid insulating materials. Good oil will have an interfacial tension of between 40 and 50 dynes/cm. The greater the concentration of contaminants, the lower the IFT, with a badly deteriorated oil having an IFT of 18 dynes/cm or less.

Table 4.2: Oil parameters:

Test

Acceptable Questionable Unacceptable Purpose

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CONDITION MONITORING OF POWER TRANSFORMERS

BDV KV (ASTMD-877)

30

29-25

<25

Ability of oil to withstand electric stress

Interfacial tension dyne/cm (ASTMD971)

32.0

31.9-28

<27.9

Measures tension between oil & water layer. Used to detect polar contamination and insulating ageing

Neutralization No mg KOH/g (ASTMD974)

<0.05

0.06-0.1

>0.1

Acidic compounds produced by oxidation of oil and degradation of solid insulation

Color ASTMD 1500 & 1524

3.5

--

>3.5

Visual indication of serious contamination or degradation

Dissipation factor At 25 At 100

<0.1% <2.99%

0.1-0.3% 3.0-3.99%

>0.3% >3.0%

Healthiness of insulation system

Table 4.3: moisture content in oil:

Voltage limit
Less than 72.5KV 72.5-145KV Above 145KV

Permissible limits of water in oil:

25ppm 20ppm 10ppm

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CONDITION MONITORING OF POWER TRANSFORMERS Resistivity and Tan permissible values

Resistivity ohm-cm at 90c Tan at 90c

IS 335
3510^12 0.002

IS 1866
110^12 0.05

Oil Properties:

Good dielectric properties resulting in minimum power loss High resistivity gives better insulation values between windings High flash point resulting in low evaporation losses due to high thermal stability Excellent interfacial tension for quick water separation High electrical strength Low viscosity improves cooling Remarkably low sludge and acidity formation in both ageing and oxidation tests gives longer life to oil and equipment during storage and service.

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CONDITION MONITORING OF POWER TRANSFORMERS 4.6 Furan Analysis:

Insulating material (mainly cellulose paper) in a transformer is subjected

to different type of stresses, depending upon the service conditions. The ageing of cellulose is influenced by overloads, lighting surges, and internal faults leading to thermal stresses. Ageing of insulation result in de-polymerization of insulating material and Furan and other compounds are produced. These compounds are extracted from oil and their concentration is analyzed using High performance Liquid Chromatography (HPLC). Rate of change of furan concentration indicates the rate of ageing of paper. Therefore many laboratories carry this test on a routine basis. It is recommended to test the oil sample at least once in a year and collect the data. This test facility is available at CPRI, Bangalore, and ERDA Mumbai/Baroda etc. Acceptable levels of furfural in transformer oil: <0.1 mg/l acceptable >0.1 mg/l questionable and 0.25 mg/l unacceptable.

4.7 Degree of polymerization: One of the most dependable means of determining paper
deterioration and remaining life is the DP test of the cellulose. The cellulose molecule is made up of a long chain of glucose rings which form the mechanical strength of the molecule and the paper. DP is the average number of these rings in the molecule. As paper ages or deteriorates from heat, acids, oxygen, and water, the number of these rings decrease. When the insulation is new, the DP is typically between 1,000 and 1,400.As paper deteriorates, bonds between the rings begin to break. When the DP reaches around 200, the insulation has reached the end of life. All mechanical strength of the insulation has been lost; the transformer must be replaced. Table 4.4: Correlation between Furan concentration and DP: Total furan level(ppb) Range of DP Recommended retest period (months) 12 6 3 1

100 101-250 251-1000 1001-2500

444-1200 333-443 237-332 217-236

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>2500 <217 Failure likely

4.8 Partial discharge test:

Partial discharge occurs in oil filled transformers due to the following reasons. Voids in the solid insulation Conducting particles in paper or in oil Wet fibers in oil Gas bubbles in the oil, Sharp conductor edges.

PD measurements are done in following ways:

Electrical method, Accounts method. Generally, acoustic method is being used at sites since it is cheaper, simpler and on-line measurement. By taking measurements at a number of places on the transformer tank, PD activity region can be identified. Acoustic PD method employs a sensor that converts sound signals into electrical pulses. Sound being emitted by partial discharge inside the transformer is picked up by the sensor and is converted into electrical sensor, which is further amplified by in the main equipment. The equipment amplifier is tuned to the normal acoustic discharge frequency, hence the unwanted signals due to core vibration, noise produced by cooling system etc are eliminated. The number of peaks in the signal available for one second is stored as counts per second. Partial discharges may not cause a failure immediately. However it is a parameter, which shall assess the healthiness of the transformer. PD measurements will also aid in the DGA results.

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Table4.5: PD Level and their Critical Stage (as per CIGRE WG 12.18):

Classification to be developed to support caution and alarm levels Dielectric Condition PD Levels Caution Levels

Critical stage and alarms

Alarm levels

Defect-free Normal deterioration Poor impregnation Long term destructive ionization

10-50pC <500pC 1000-2000pC 2500 p C in paper >10,000pC in oil 1000-10,000pC

First warning signal: q>500-1000pC

First fault signal: q>>2500pC

Signal of defective condition: q>1000-2500pC

Critical condition: q>>1,00,000pC

Large (3-5mm in dia) Air/gas bubbles in oil

Paper moisture up to 34% and relevant level in oil

2000-4000pC and reduction of PD inception voltage by 20%

4.9 Frequency response analysis:

Frequency response analysis is a reliable tool for

mechanical condition assessment of the winding. Transformers are subjected to mechanical stresses during transportation, short circuit faults near the transformer, transient over voltages such as switching lighting etc. mechanical stresses cause winding displacement or deformation, winding collapse in extreme cases, such mechanical defects eventually lead to dielectric faults in the winding. FRA is capable of detecting core movement, winding deformation and displacement, faulty core ground, partial winding collapse broken or loosened clamping structures, shorted turns and open

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windings. The principle in frequency response analysis of transformer as a complicated network of a distributed inductance, capacitance and resistance (RLC network).

4.10 Recovery Voltage Measurement:

The RVM has been proved to be an important

diagnostic test for power transformer polarization processes that occurs in an insulating material, on application of D.C. field is well known in physics. Dielectric polarization in paper oil insulation system is the process by which the mobile charge carries defuse across the more conducting portion up to the interface with the less conducting components. Impurities such as moisture, ageing byproducts etc. tend to collect at the interface between the components of the composites and increase the conductance at the interface. The increased conductivity leads to an increase in dielectric losses. The polarization is a complex phenomenon, resulting from several elementary processes, each of the density of certain types of charge carriers alters due to some ageing of deterioration of the insulation, and the intensity of the elementary polarization will change as well. As the time constant associated with the polarization effects is inversely proportional to the dielectric losses in paper oil, any processes or conditions that affect the dielectric losses have an inverse corresponding effect on the polarization time constant. Since chemical agent tends to increase the dielectric losses both paper and oil, the polarization time constant tends to shift towards lower values for aging of paper-oil insulation. If composite paper-oil insulation is subjected to a sequence of charging and discharging process and measuring corresponding recovery voltages, then a plot of recovery voltages against charging times put a exhibit on dominant peak. The polarization that has the time constant equal to one of the charging times in the sequence undergo maximum excitation and corresponding recovery voltage would have a maximum moisture content in the paper. The increasing moisture content in the transformer insulation can also due to leakage or small repair with temper all and partial discharge of oil or due to defects in the breathing system/filter extra as the moisture accelerates the degradation processes in the cellulosic paper, the if is the strong mead for monitoring its level in the paper. value. The dominant time constant is therefore, a function of

4.11 SURGE COMPARISION TEST: The surge comparison test is accurate method of
identifying inter turn faults. A surge voltage is applied to two phases of the HV winding. While testing the HV winding the terminals of the LV winding are shorted together and grounded to the transformer tank.

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The ringing pattern is seen on the CRT. The fast rising pulse of the surge voltage spreads along the coil and creates a voltage along the turns. Since the three phases winding are wound identically, comparing any two phases will show the same single pattern.

4.12 DC STEP VOLTAGE MEASURMENT: Step voltage testing is another standard

technical is used in recording the insulation resistance. Faults in insulation may have effect on the overall resistance when subjected higher cast voltage. Therefore principle of a step voltage test is to show whether overall insulation resistance is maintained or falls as the voltage is increased. If the resistance falls then there is a incipient weakness in the insulation which is potential cause of problems.

4.13 Capacitance and tan for bushings: Capacitance and tan measurements of
condenser bushings give indication of the condition of the insulation in the bushing. A new bushing will have a tan value less than 0.5%Capacitance value of bushing in service need to be compared with factory test result value for deciding the extent of degradation. High Tan delta (between0.007 and 0.01): Ingress of moisture in bushing insulation Very High Tan delta (Beyond 0.01): High humidity, Strong ageing of insulation Low Tan delta: Weak Potential connection High Capacitance: Partial Breakdown.

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CHAPTER.V DISSOLVED GAS ANALYSIS

5.1 INTRODUCTION: Transformers are vital components in both the transmission and
distribution of electrical power. The early detection of incipient faults in transformers is extremely cost effective by reducing unplanned outages. The most sensitive and reliable technique used for evaluating the health of oil filled electrical equipment is dissolved gas analysis (DGA). Insulating oils under abnormal electrical or thermal stresses break down to liberate small quantities of gases. The qualitative composition of the breakdown gases is dependent upon the type of fault. By means of dissolved gas analysis (DGA), it is possible to distinguish faults such as partial discharge (corona), overheating (pyrolysis) and arcing in a great variety of oil-filled equipment. Information from the analysis of gasses dissolved in insulating oils is valuable in a preventative maintenance program. A number of Samples must be taken over a period of time for developing trends.

Data from DGA can provide

Advance warning of developing faults. A means for conveniently scheduling repairs. Monitor the rate of fault development NOTE: A sudden large release of gas will not dissolve in the oil and this will cause the Buchholz relay to activate. Transformer insulating oils consists of different hydrogen molecules splitting some of hydrocarbon bonds occur due to electrical and thermal faults, forming gases Hydrogen (H2) Methane(CH4) Ethane(C2H6) Ethylene(C2H4) Acetylene(C2H2)

Low energy faults(like partial discharges) sufficient to split weak H-C bonds result in hydrogen as main gas. Higher temperatures are needed for splitting of C-C bonds .Higher temperature results in Ethane, methane and ethylene at 500C Acetylene requires temperature 800-1200C

Carbon particles from at 500 to800C as results of arcing in oil or around very hot spots.

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5.2 SOME METHODS FOR ANALYSIS:

Table 5.1: The condition for formation of key gases by the degradation of cellulose and oil: Material Condition Key gas

Cellulose

Overheated>150C

XO,CO2 and H2O

Oil

Overheated 300C 1000C

Methane(CH4),Ethane(C2H6) Ethylene(C2H4) Organic acids

Oil

Electrical stress(partial discharge) arcing to 1000C

Hydrogen(H2) Acetylene(C2H2)

Table 5.2: Categories of key gases and general fault conditions:

General fault condition

Key gases

Thermal condition involving the oil

Methane, Ethane, Ethylene, and small amount of Acetylene

Partial discharge

Hydrogen, Methane and small amount of Acetylene and Ethylene

Sustained arcing

Hydrogen, Acetylene and Ethylene

Thermal condition involving the paper

Carbon Monoxide and carbon Dioxide

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Table 5.3: CIGRE Method (Electra No. 186, Oct 99)-key gas concentration and indication: Characteristic gas C2H2 H2 CxHy Concentration(ppm) >20 >100 >1000 >500 Cox >10000 Cellulose Degradation Indication Power discharge Partial discharge Thermal fault

Gas concentration ratios Ratio C2H2/C2H6 H2/CH4 CO2/CO Value >1 >10 >10 <3 Indication Discharge Partial discharge Cellulose Overheating Cellulose Degradation Fault gases from OLTC

C2H2/H2

>2(with C2H2>30)

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Table 5.4: Rogers method:

Ratio
CH4/H2 0 C2H6/CH4 0 C2H4/C2H6 0 C2H2/C2H4 0

Evaluation

If CH4/H2<0.1 , PD Otherwise normal ageing Slight overheating below 1500C Slight overheating 150-2000C Slight overheating2003000C General conductor overheating Circulating current/overheated joints Flashover without power flow OLTC selector breaking current Arc with power flow through or persistent sparking.

Ratios < 1 are designated as 0; ratios > 1 are designated as 1

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Table 5.5: DGA-IEC: 599 Method;

Code of range of ratios C2H2/C2H4 CH4/ H2 C2H4/C 2H6

Ratio of characteristics gases < 0.1 0.1-1 1-3 >3 Case no 0 1 Characteristic fault No Fault PD of low energy density 0 0 0 1 0 0 0 1 1 2 1 0 2 2 0 0 1 2 Typical examples Normal ageing Discharges in gas filled cavities 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. Breakdown coils to earth. Selector breaking current. Discharges with power follow-through.

PD of high energy density

Discharges of low energy (see note 1)

1-2

1-2

Discharge of high energy

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Arcing-breakdown of oil between windings or coils to earth. Selector breaking current.

Thermal fault of low temp. <150c(see note 2) Thermal fault of low temp. Range 150-300c. (see note3) Thermal fault of medium temp. 300-700c Thermal fault of high temp. > 700c (see note 4)

General insulated conductor overheating. Local overheating of the core due to concentration of flux. Increasing hot spot temperatures; Varying from small hot spots in core, shorting links in core, overheating of copper due to eddy currents, bad contacts/joints up to core and tank circulating currents

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CHAPTER.VI TROUBLE SHOOTING CHART FOR ALL TRANSFORMERS

Trouble (1)
Rise in Temperature
High Temperatures

Cause (2)
Over voltage Over current

Remedy (3)
Change the circuit voltage or transformer connection to avoid over excitation. If possible, reduce load. Heating can often be reduced by improving power factor load. Check parallel circuits for circulating currents which may be caused by improper rations or impedances. See Electrical Trouble, below. Either improve ventilation or relocate transfer in lower ambient temperature. If unit is artificially cooled, make sure cooling is adequate. Fill to proper level. Use filter press to wash off core and coils. Filter oil to remove sludge. Test exciting current and no-load loss. If high, inspect core and repair. See Electrical Trouble, below.

High ambient temperatures Insufficient Cooling Lower liquid level Sledged oil Short-circuited core

Electrical Troubles
Lightning, short-circuit. Winding failure Overload. Oil of low Directive Foreign Material Usually, when a transformer winding fails, the transformer is automatically disconnected from the power source by the opening of the supply breaker of fuse. DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
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Trouble (1)
Core failure

Cause (2)
Core insulation breakdown (core, bolts, clamps or between laminations)

Remedy (3)
Smoke or cooling liquid may be expelled from the case, accompanied by When there is any such evidence of a winding failure, the transformer should not be re-energized at full rated voltage, because this might result in additional internal damage. Also it would introduce a fire hazard in transformers. After disconnection from both source and load, the following observations and tests are recommended: a) External mechanical or electrical damage to bushings, leads, patheads, disconnection switches, or other accessories. b) Level of insulating liquid in all compartments. c) Temperature of insulating liquid whenever it can be measured. d) Evidence of leakage of insulating liquid or sealing compound.

High exciting current

Short-circulated core

Test core loss. If high, it is probably due to a short-circuited core. Test core insulation. Repair if damaged. If laminations are welded together, refer

Open core joints

matter to the company. Core-loss test will show no appreciable increase. Pound joints together and retighten clamping

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structure.

Trouble (1)
Incorrect voltage

Cause (2)
Improper ratio

Remedy (3)
Change terminal-board connection or ratioadjuster position to give correct voltage.

Audible internal arching

Supply voltage abnormal Isolated metallic part

Change tap connections or readjust supply voltage. The source should be immediately determined. Make certain that all normally grounded parts are grounded, such as the clamps and core.

Loose connection Same as above. Tighten all connections. Low liquid level, Exposing live parts Maintain proper liquid level.

Bushing flash over

Lightning Dirty bushings

Provide adequate lightning protection. Clean bushing porcelains, frequency depending on dirt accumulation.

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Mechanical Troubles.
Leakage through screw Joints

Foreign materials in threads. Oval nipples. Poor threads. Improper Filler. Improper assembly

Make tight screw joints or gasket joints.

Trouble (1)

Cause (2)
Poor scarped joints Insufficient or uneven Compression improper Preparation of gaskets and Gasket surfaces

Remedy (3)
Make tight screw joints or gasket joints

Leakage at gaskets

Leakage in welds

Shipping strains, imperfect Weld

Repair leaks in weld

Pressure-relief diaphragm

Improper assembly. Mechanical damage

Replace diaphragm. Inspect inside or pipe for evidence of rust or moisture. Be sure to dry out transformer if there is a chance that drops of water may have settled directly on winding or other vulnerable locations, as oil test

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may not always reveal presence of free water.

Pressure-relief diaphragm

Internal fault in conservator transformer obstructed oil flow or breathing. In gas-seal transformer obstructed pressure relief value. In sealed transformer liquid level too high.

Check to see that valve between conservator and tank is open and that ventilator on conservator is not blocked. Make certain that relief valve functions and that values in discharge line are open. Liquid level should be adjusted to that corresponding with liquid temperature to allow ample space for expansion of liquid.

Trouble (1)
Moisture condensation in open type transformer and air filled compartments

Cause (2)
Improper or insufficient ventilators

Remedy (3)
Make sure that all ventilator openings are free .

Moisture condensation in sealed transformers

Cracked diaphragm. moisture in oil

See remedies above for cracked and ruptured diaphragms. Filter oil.

Audio noise

Leaky gaskets and joints . Accessories and external transformer parts are set giving off loud noise.

Make certain all joints are tight. Tighten loose parts. In some cases parts may be stressed into resonant state. Releasing pressure and shimming will remedy this condition.

Rusting and

Abraded surfaces and

Bare metal of mechanical parts should be covered

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deterioration of paint finish Fractured metal are porcelain parts of bushings Unusual strains placed on terminal connection. Cables and bus-bars attached to transformer terminals should be adequately supported. In the case of heavy leads, flexible connections should be provided to remove strain on the terminal and bushing porcelain. weathering. with grease.

Trouble (1)
Oil troubles
Low dielectric strength

Cause (2)
Condensation in open type transformers from improper ventilation. Broken relief diaphragm

Remedy (3)
Make sure that ventilating openings are unobstructed.

Replace diaphragms. Leaks around cover Replace gaskets if necessary. Leaky cooling oil Test cooling and repair. Badly discolored oil. Contaminated by Varnishes Carbonized oil due to switching winding or core failure. Retain oil if dielectric strength is satisfactory.

Oxidation (sludge of acidity)

Exposure to air High operating temperature

wash down core and coils and tank. Filter and reclaim or replace oil. wash down core and coils and tank. Either reduce load or improve cooling.

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CHAPTER.VII CASE STUDIES

CASE STUDY 1:
1. 125MVA, 11kv/ 220 kv , 50Hz, 3 generator transformer: Sl . No. Make Year of manufacture Oil Temp. Winding Temp. Ambient Temp. Date of test : 6002681 : Heavy Electricals (INDIA) Ltd, Bhopal : 1973 : 28C : 28C : 28C : 11.10.2010 & 12.10.2010

ANALYSIS: HV& LV Windings: Results of IR,PI and Tan test obtained on the generator transformer are presented below; Table 6.1: case study of generator transformer: Insulation section Insulation resistance 60 sec (G ) Polarization index Tan (%) @10 KV

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HV vs LV connected to grounded tank HV vs LV ungrounded LV vs HV connected to grounded tank 1.72 2.24 0.249

1.76 1.19

2.83 3.23

0.243 0.248

The IR and PI values obtained are in the normal acceptable range. The PI is regarded as index of dryness of the insulation system. For a good, healthy and dry paper-oil insulation system the PI shall be higher than 1.5. The Tan test values obtained on three insulation sections of the transformer are low and lie in the normal permissible range. These results indicated low dielectric losses in the transformer insulation system. Typical values of Tan for a new transformer are 0.5%. the maximum permissible value of Tan for an in-service and aged transformer is 2%.

CASE STUDY FOR DGA:

2. 750KVA, 11KV/ 433V, 50HZ failed transformer: Commissioning & filtration date of analysis TGC CH4 C2H6 C2H4 C2H2 H2 CO2 3.11.1999 8.45 237 54 588 2961 1982 1548

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Observation: DGA indicates that the failure was due to severe arcing in the transformer.

CASE STUDY 3:
3. 20MVA POWER TRNASFORMER

ROUTINE MAINTAINCE TGC CH4 C2H6 C2H4 C2H2 H2 CO2 6.90 53 4 28 437 140 1125

Observation: Rogerss ratio (0011) indicates arc with persistent sparking, IEC ratio (202) indicates continuous sparking in oil.

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CONCLUSION
In the conditional monitoring, we test the transformer for reliability of the equipment and also to avoid the forced outage. If faults are found to be occurring outages can be planned and the fault can be rectified before major occur. With strict monitoring, accurate diagnostics interpretations and realistic operational/ maintenance Strategies implementation the following would be achieved effectively: Asset economic loading conditions identification and assessment for maximum practicable operating efficiency. Premature failures risk minimization. Remnant life estimation and timely asset replacement/ retiring planning. Asset life extension by implementing correct operational and cost effective maintenance strategies Improvement in the system performance ensuring good reliability as well as plant availability. Minimization of the long-term operational cost. Cost saving by eliminating the unplanned maintenance. Minimizing the outage period. Relocation/ retirement planning. In time procurement of spare parts to get

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BIBOLOGRAPHY
Hand Book Of Transformers, BHEL, Tata McGraw Hill Basic Electrical Engineering by M.L.Anwani Electrical Technology by B.L.Theraja Electrical Machines by J.B.Guptha Electrical Machines by P.S.Bhimbra

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