Craig L.

Stiegemeier; Technology & Marketing Director; ABB Transformer Remanufacturing & Engineering Services

NEPPA Engineering & Technical

Roundtable – October 14, 2009
Lifecycle Management Process for
Power Transformers
© ABB Inc. 2009
Lifecycle Management Process for Power
Transformers
Intelligence Based Transformer Services
ƒ Maintenance Actions Should be Driven by Transformer Condition
ƒ Basic Message: Time is a Factor, but by far not the only Factor

Today We Will Cover:

ƒ ABB’s Transformer Service Overview
ƒ Importance of Condition Based Actions
ƒ Transformer Lifecycle Support
ƒ How Transformers Break
ƒ Tools for Assessing Transformer Condition – Fleet Assessment Approach
ƒ Options When Everything is not Okay

ƒ Advanced Diagnostics

SFRA, DFR, Advanced DGA

ƒ Transformer Assessments

Design Studies, 3D Field Simulation

ƒ Actions to Extend Transformer Life - Field Service Support Actions

ƒ Transformer Improvement Actions

ƒ Actions to Improve the Condition of Key Components (LTC’s & Cooling Systems)
and Natural Ester overview
ƒ Transformer End of Life Options - Remanufacturing

ABB TRES North America

© ABB Inc. 2009; Slide 2
ABB Power Product Services
Scope of Support

ƒ Transformers
ƒ >70% of installed power transformers are ABB legacy
ƒ Risk assessment and life extension
ƒ Advanced diagnostics and testing
ƒ Factory repair and remanufacturing
ƒ High Voltage Breakers
ƒ Support capability for 60-70% of installed base
ƒ Refurbishment and retrofit
ƒ Advanced diagnostics – radiography and SF6 leak detection
ƒ Low- and Medium-Voltage Switchgear
ƒ Over 1 million breakers in service in US
ƒ Refurbishment, retrofit, roll-in replacement breakers
ƒ Protection & Control assessment and upgrades

ABB TRES North America

© ABB Inc. 2009; Slide 3
Transformer Remanufacturing & Engineering Services
TRES Portfolio Overview

Engineering Solutions
ƒ MTMProgram™ - Tools for Effective Asset Management &
Maintenance Action Planning
ƒ Engineering Solutions & Studies – Design, Thermal, Condition &
Life Assessments, etc.
ƒ Diagnostic and Assessment Services, including performing/
supporting field or factory testing and test result analysis
Field Service and Retrofit
ƒ Preventative and Corrective Maintenance
ƒ Engineered Retrofit/Repair Solutions
ƒ LTC & Cooling System Refurbishment & Retrofit
ƒ Transportation, Relocation & Logistics Services
ƒ Installation & Commissioning Services
ƒ TrafoOilRenewal™ Oil Upgrading/Processing (on-line capability)
ƒ ABB BioTemp™ Retrofils
ƒ Technical Assistance and Training
ƒ Replacement and Spare Parts

Factory & Site Repair/Remanufacturing

ƒ Repair to original performance
ƒ Remanufacture to achieve higher ratings or to eliminate problems
ƒ All types, all manufacturers, including Industrial/Specialty
ƒ Focus Factories based on scope of project
ABB TRES North America
© ABB Inc. 2009; Slide 4
Transformer Remanufacturing & Engineering Services
TRES – Localized Services, Global Support

Edmonton (SPT Repair, Field Service)

Varennes (LPT Repair, Field Service)
Brampton (Field Service, Engineering)

St. Louis (MPT Repair, Field Service, Engineering) South Boston (SPT Repair, Field Service)
Nashville (Field Service)
Crystal Springs (Field Service)

San Luis Potosi

Mexico City

ABB TRES North America

© ABB Inc. 2009; Slide 5
ABB Transformer Service Centers

Important: in addition to the service centers listed below

ABB can provide on a case by case basis repair options directly at site

Vaasa, Finland
Drammen, Norway Ludvika, Sweden
Brampton, Canada Varennes, Canada Hefei, China
Halle, Germany
Edmonton, Canada Daresbury, UK Zongshan, China
Geneva, Switzerland
St. Louis, USA Monselice, Italy
Nashville, USA South Cordoba,
Boston, Istanbul, Turkey
Bilbao,
San Luis Potosi, Mexico USA Khobar, Riyad, Saudi Arabia
Zaragoza,
Spain Bangkok, Thailand
Vadodara,
India
Lima, Peru Arusha, Tanzania
Sao Paulo,
Brazil Moorebank, Australia
Pretoria,
Cape Town,
Focus Factory South Africa
Service Facility

Detailed contacts can be found at

ABB TRES North America
© ABB Inc. 2009; Slide 6 www.abb.com/transformers
ABB Transformers Worldwide
Legacy Products and Support Capabilities

ƒ Consistently high transformer quality available from

many factories world-wide
ƒ The combined experience of 700 years of transformer
manufacturing
Asea Ansaldo BBC
GE, USA & CA Kuhlman Moloney
National Industri Strömberg Westinghouse
And more ....
ƒ TRES has access to all design, manufacturing and
test records from these legacy companies, and
agreements with other manufacturers
ƒ In North America, ABB legacy brands account for
more than 70% of the installed base of power
transformers
ƒ Backup of more than 50 Factories and service centers
in 28 countries
ƒ Service support teams available 24 hours a day

ABB TRES North America

© ABB Inc. 2009; Slide 7
ABB TRES Mission Statement
ABB Transformer Services...
providing a new level of “intelligence based” service
that improves the performance, availability, and
efficiency of our customer’s transformer base.

ABB TRES North America

© ABB Inc. 2009; Slide 8
Transformer Owner Best Practices
Fleet Assessment Process

ƒ Maintenance Actions Should be Driven by Transformer Condition

ƒ Transformer Owners Save Money and Improve Reliability by
Taking only Value-Driven Actions
ƒ Basic Lesson: Time is a Factor, but by far not the only Factor
ƒ Transformer Lifecycle Support
ƒ Accurate Condition Assessment is Essential
ƒ ABB MTMProgram™ (Mature Transformer Management
Program™) is a structured condition assessment approach
ƒ A Condition Evaluation must recommend Maintenance Actions
to Lower the Risk of Failure and/or Extend Transformer Life
ƒ Advanced Diagnostics can be used to Augment Missing Data
ƒ Getting to the Next Level of Transformer Condition
Understanding

ABB TRES North America

© ABB Inc. 2009; Slide 9
MTMProgram™
ABB Transformer Asset Management Program

The ABB Mature Transformer

Management Program involves a
series of assessments to provide
optimal asset decisions …
ƒ Phase I – Fleet Risk Screening
ƒ Phase II – Condition & Design
Evaluation of Critical Assets
ƒ Phase III – Life Profiling
ƒ Phase IV - Implementation

ABB TRES North America

© ABB Inc. 2009; Slide 10
 MTMProgram™
ABB Transformer Asset Management Program

T ra n s fo rm e r
F le e t

Fleet Screening

Design/ ConditionAssessment
Advanced
Diagnostics

AdvancedLife
Assessment

Engineered
Solutions

Replacement Refurbishment Cooling

U d

Corrective Maintenance Actions

ABB TRES North America

© ABB Inc. 2009; Slide 11
Core Form Transformer

ABB TRES North America

© ABB Inc. 2009; Slide 12
Why Should You Be Concerned?
Aging Transformers and Accessories
How many
Doble Statistics on Transformer failures are caused by:
Failures poor maintenance?
ƒ 43% winding insulation short circuits?
ƒ 16% load tap changers
overloading?
ƒ 19% bushings

In 1999, Hartford Steam Boiler

Insurance projected:
ƒ 2% annual failure rate of
existing installed base of
transformers by the end of 2008
ƒ 5% failures by the year 2013!!!!

ABB TRES North America

© ABB Inc. 2009; Slide 13
Stresses Acting on Power Transformers
Understanding These Allows Development of an
Effective Transformer Maintenance Plan
Mechanical Stresses
ƒ Forces between conductors, leads and windings due to
overcurrents or fault currents caused by short circuits
and inrush currents

Thermal Stresses
ƒ Due to local overheating, overload currents and leakage
fluxes when loading above nameplate ratings;
malfunction of cooling equipment

Dielectric Stresses
ƒ Due to system overvoltages, transient impulse
conditions or internal resonance of windings

ABB TRES North America

© ABB Inc. 2009; Slide 14
Mechanical Stresses in Power Transformers
Due to: Short Circuits / Through Faults, Motor Starting

A short circuit gives rise to:

ƒ Mechanical forces
ƒ Temperature rise
The transformer must be designed so that
permanent damage does not take place
Electromagnetic forces tend to increase
the volume of high magnetic flux,
causing mechanical forces that force:
ƒ Inner winding to reduced radius
ƒ Outer winding towards increased radius
ƒ Winding height reduction

ABB TRES North America

© ABB Inc. 2009; Slide 15
Mechanical Stresses in Power Transformers
Radial forces result in:

Inner Winding Outer Winding

Buckling of inner windings Increased radius for

outer windings

ABB TRES North America

© ABB Inc. 2009; Slide 16
Mechanical Stresses in Power Transformers
Axial forces cause:

Stress mechanical Increase risk of tilting

withstand limits of
insulation and support
materials

ABB TRES North America

© ABB Inc. 2009; Slide 17
Risk: Short Circuit Forces & Stress Failures
Through faults often Initiate Transformer Failures

ƒ Many older designs have

insufficient margin for today’s fault
currents
ƒ Loose coils due to aging can cause
failures
ƒ Normal aging results in brittle
insulation and increased failures
ƒ Even brief overloading may cause
significant aging
ƒ Oxygen in the oil can double the
aging rate
ƒ Moisture in the insulation increases
aging rate 2-5 times depending on
the amount of moisture

ABB TRES North America

© ABB Inc. 2009; Slide 18
Mechanical Stresses in Power Transformers
Short Circuit Failure Example:

ABB TRES North America

© ABB Inc. 2009; Slide 19
Mechanical Stresses in Power Transformers
Mechanical Risk: Short Circuit Forces & Stresses

Little Risk of Failure

Each different
design has its
own performance
characteristics
Design Margin

Slight Risk of Failure

Design #1
Design #2
Design #3
High Risk of Failure
Design #4

HV Radial HV Axial LV Radial LV Axial LTC LTC

(Hoop) (tipping or (Buckling) (tipping or Winding Winding
crushing) crushing) Radial Axial
(Buckling) (tipping)
ABB TRES North America
© ABB Inc. 2009; Slide 20
Thermal Stresses in Power Transformers
Maximum Loading is Limited by Thermal Limits

Loading is primarily limited by highest permissible

temperatures in the transformer, especially within the
windings
ƒ Temperature limits are based on:
ƒ Expected lifetime
ƒ The risk for oil vaporization
Permissible temperatures are generally expressed as
temperature rises above ambient
Ambient temperature is defined by current standards, but
local conditions can vary significantly
ƒ In accordance to Standards:
ƒ Winding temperature rise 65 K
ƒ Top oil temperature rise 65 K
ƒ Hot spot temperature rise 80 K

ABB TRES North America

© ABB Inc. 2009; Slide 21
Thermal Stresses in Power Transformers
Winding Temperature Rise and HS Calculation
Hot spot calculation
Winding hot spot
Top oil rise

r
pe
oi l
hot spot rise

p
o il

in g

co
k

nd

in g
Tan

Wi

nd
Wi
Winding average rise

Copper over tank oil gradient

Copper over winding oil gradient

Winding Ambient Bottom oil

ABB TRES North America

© ABB Inc. 2009; Slide 22
Temperature
Thermal Stresses in Power Transformers
Thermography – What and Why?

ƒ Thermography is a method of inspecting electrical and mechanical

equipment by obtaining heat distribution pictures.
ƒ Most components in a system show an increase in temperature when
malfunctioning
ƒ By observing the heat patterns in operational system components, infrared
thermography can be used to detect:
ƒ loose connections

ƒ unbalanced load and overload conditions

ƒ component deterioration

ƒ Oil flow and oil level problems

ƒ Criteria for Evaluating Infrared Measurements

ƒ Faults are often identified by comparing heat patterns in similar
components operating under similar loads
ƒ The temperature rises of all objects above a reference point are recorded

ƒ Severity of hotspots are evaluated in regards to how high they are above
the reference temperature

ABB TRES North America

© ABB Inc. 2009; Slide 23
Thermal Stresses in Power Transformers
Thermal Scans are Valuable

ABB TRES North America

© ABB Inc. 2009; Slide 24
Thermal Scan Value
Example – Loose Bushing Terminal Connection

ƒ When there is a loose connection at the terminal from the

bushing to the bus work, it will lead to overheating of the
bushing top terminal when under load.
ƒ The thermograph will show the bushing terminal as hot,
while the body of the porcelain will show normal
temperatures.

ABB TRES North America

© ABB Inc. 2009; Slide 25
Thermal Scan Value
Example – Blocked Oil Flow in Radiators

ƒ In case of a malfunction that stops or restricts the flow of oil

through a radiator, this will show up on an infrared scan.
ƒ The image will reveal dim areas where the oil flow is
restricted and brighter areas where normal oil flow is taking
place

ABB TRES North America

© ABB Inc. 2009; Slide 26
Thermal Scan Value
Example – Low oil Level in Transformer or Bushing

ƒ If a transformer (or especially a bushing) has a low oil

level, a thermograph will show a dim image for the region
without oil and a much brighter image in the areas with oil

ABB TRES North America

© ABB Inc. 2009; Slide 27
Thermal Stresses in Power Transformers
Loss distribution in the tank wall caused by LV current

ABB TRES North America

© ABB Inc. 2009; Slide 28
Thermal Stresses in Power Transformers
Thermal Risk: Intensive Aging

ABB TRES North America

© ABB Inc. 2009; Slide 29
Thermal Stresses in Power Transformers
Thermal Risk: Intensive Aging

ABB TRES North America

© ABB Inc. 2009; Slide 30
Insulation Life Evaluation - Results

ABB TRES North America

© ABB Inc. 2009; Slide 31
Intelligence Based Maintenance Practices
The best designed and manufactured transformer . . .

ƒ Must withstand severe mechanical strain

ƒ Is subjected to extended high temperatures or load
conditions and limited by the current condition of its cooling
system
ƒ May experience unusually high or frequent overvoltages

ƒ A condition based periodic maintenance plan and

diagnostic tools are available from ABB to identify when the
transformer is at an unusually high failure risk if operation is
continued

ABB TRES North America

© ABB Inc. 2009; Slide 32
Transformer Condition Must Drive Maintenance
Practices
Actual Curves are Determined by Maintenance Actions
or Inactions
Actual Withstand Design Withstand

Field action or factory repair

Stress / Withstand Level

X
Incidents
Failure

Actual
Stress

X X
Normal Life Extended
Age Expectancy Life
ABB TRES North America
© ABB Inc. 2009; Slide 33
Diagnostic Techniques for Power Transformers
Highly Effective On-line Actions are Best
SERVICE CONDITIONS PROVEN
PROBLEMS DIAGNOSTIC TECHNIQUES [1] [2]
OF THE EQUIPMENT EFFECTIVENESS

1. Excitation Current OFF-S M

2. Low-voltage impulse OFF-S L
MECHANICAL 3. Frequency response analysis OFF-S H
4. Leakage inductance measurement OFF-S M/H
5. Capacitance OFF-S H

GAS-IN-OIL ANALYSIS
ON H
6. Gas chromatography
ON M
7. Equivalent Hydrogen method

OIL-PAPER DETERIORATION
ON M/H
THERMAL 8. Liquid chromatography-DP method
ON M/H
9. Furan Analysis

HOTSPOT DETECTION
ON L
10. Invasive sensors
ON H
11. Infrared thermography

OIL ANALYSIS
ON M
12. Moisture, electric strength, resistivity, etc.

13. Turns ratio OFF-S L

DIELECTRIC PD MEASUREMENT
ON M/H
14. Ultrasonic method
ON M/H
15. Electrical method

16. Power Factor and Capacitance OFF-S H

17. Dielectric Frequency Response OFF-S H

ABB Service Handbook for Transformers, Table 3-1, Page 72

[1] OFF-S = equipment out of service at site, OFF-L = equipment out of service in laboratory, ON = equipment in service
ABB TRES North America
[2] H=High, M=Medium, L=Low
© ABB Inc. 2009; Slide 34
Advanced Life Assessment – Transformer Monitoring
TEC – Monitoring the Entire Transformer
TEC Provides the Following Capabilities:
9 Monitoring & diagnostic
9 Thermal ageing of insulation
9 Overload forecasts can be made, where estimated thermal ageing is taken into
account.
9 Calculates to what extent the transformer can be overloaded

9 Gives a base to calculate the economical aspect of the overloading due to

the accelerated ageing of the insulation
9 The enhanced cooling control can start coolers earlier

ABB TRES North America

© ABB Inc. 2009; Slide 35
Advanced Life Assessment
Monitoring & Diagnostics
Goal - Few sensors, but used for many purposes
• Thermal ageing
• Hot-spot forecast
• Overload capacity
• Contact wear in tap-changer
• Transformer temperature balance
• Tap-changer temperature balance
• Hydrogen in transformer oil
• Moisture in transformer oil
• Moisture in tap-changer oil
• Condition in TEC cabinet
• Voltage measurement

ABB TRES North America

© ABB Inc. 2009; Slide 36
Advanced Life Assessment
Monitoring & Diagnostics - ABB TEC Installation

ABB TRES North America

© ABB Inc. 2009; Slide 37
MTMProgram™
ABB Transformer Asset Management Program
Risk of Failure Assessment
ƒ Risk of short-circuit failure
based on assessment of the short-circuit strength of the windings and
clamping structure and the incidence and magnitude of short-circuit
through fault events.
ƒ Winding thermal condition
based on the condition of the paper insulation since aged, brittle insulation
is more likely to fail under the mechanical and electrical stress conditions
ƒ Risk of dielectric failure
based on the assessment of the dielectric withstand capability of the
transformer insulation system (oil, paper, etc.) and the electrical stress
imposed by the power system and naturally occurring events
ƒ Accessory failures
failure of a transformer accessory such as a bushing, pump, or tap
changer, may cause a failure, or loss of service of the transformer.
ƒ Miscellaneous or Random Failure risk
due to other causes of Failure or Loss of service

ABB TRES North America

© ABB Inc. 2009; Slide 38
MTMProgram™
Risk Of Failure Determination
Input Data Risk Categories ROF
Nameplate Information
Short-Circuit Risk
Application Information
Loading History
Service Record
Mechanical Design Information
Electrical Design Information Thermal Risk
Thermal Design Information
Through-Fault History
Site Inspection Information
Bushing type and Diagnostic Data
Dielectric Risk ROF
Conservator type and Condition
Load Tap Changer Type and Diagnostics
Cooling Equipment Type and Condition
DGA and Oil Quality Data
Electrical Test Data (PF, Resistance, PD.) Accessory Risk
Maintenance History
Failure History of Similar Units
Leaks and Environmental Concerns
Relative Importance to System Miscellaneous Risk
ABB TRES North America
© ABB Inc. 2009; Slide 39
MTMProgram™
ABB Transformer Asset Management Program
Program Processes
Probability of failure / Risk
Step 1: Fleet Screening High
Before assessment Medium

After program implementation Low

Transformers

Step 2: Detailed Assessment

Step 3: Life Profiling
•
Condition Engineering
Assessment Life Solutions:
Solutions
-Retrofit/Upgrade
Assessment
- Remanufacturing
Design (Profiling) - Maintenance
Assessment - Adv. Diagnostics
- Monitoring
- Spares/New units
ABB TRES North America
© ABB Inc. 2009; Slide 41
MTMProgram™
RISK OF FAILURE PER TRANSFORMER
MAINTENANCE $$$ PER TRANSFORMER

30-50% OF MAINTENANCE
$$ ACTIVITY IS UNNECESSARY
$ (CIGRE-2000)
UNDERSPENDING $
US

OVERSPENDING
OS
OS=US - balanced budget
OS>US - lower maintenance $$$

TRANSFORMERS
ABB TRES North America
© ABB Inc. 2009; Slide 42
 MTMProgram™: Risk Mitigation Process

Risk Mitigation Plan L4

ABB TRES

L1 – ASAP
L2 – 1 year Risk Mitigation Plan L3 Transformer
L3 – 2-3 years ABB TRES fleet
L4 – 3-5 years
Risk Mitigation Plan L1+L2
ABB TRES

Data input
(manual)
MTMProgram™
ABB TRES
Electronic data
Manual data
collection
collection
(AssetSentry)

System importance Transformers data

Automated
Data input
(TEC,Serveron)

ABB TRES North America

© ABB Inc. 2009; Slide 43
 Craig L. Stiegemeier; Technology & Marketing Director; ABB Transformer Remanufacturing & Engineering Services

Substation Transformer Maintenance

Best Practices – Execute The Plan
Understanding Transformer Stresses,
Failure Modes and Aging
© ABB Inc. 2009
Actions to Verify Health of Power Transformers
Preventive Maintenance Action Options

ƒ Transformer
ƒ General Oil tests
ƒ General external inspection
ƒ DGA of transformers and Tap Changers
ƒ Dielectric tests (power factor, Dielectric Frequency Response (DFR))
ƒ Mechanical Structure/Condition of Coils
ƒ Leakage Reactance test
ƒ 10kV AC excitation
ƒ Frequency Response Analysis (FRA)
ƒ Low Voltage Excitation test
ƒ Degree of Polymerization (DP)
ƒ Internal CT’s - Test ratio and polarity
ƒ Tap Changers – ratio, contact condition, timing, sequence, alignment,
lubrication, oil condition, mechanical fatigue/damage, wiring, contactors,
switches, gauges, indicators
ƒ Bushings – visual inspection, thermal imaging, dielectric testing (power
factor, capacitance, Dielectric Response)
ABB TRES North America
© ABB Inc. 2009; Slide 46
Preventive Maintenance Actions
Monthly Maintenance Recommendations

ƒ Check and record the ambient temperature.

ƒ Check and record the transformer liquid temperature and note the
maximum value since the last reading.
ƒ Check and record the transformer winding temperature and note the
maximum value since the last reading.
ƒ Check and record the transformer load current and note the maximum
value since the previous reading.
ƒ Check and record the line voltage and note any variation from rated
value since the previous check.
ƒ For transformers equipped with Sealedaire®, check and record the
reading of the pressure-vacuum gauge. If the gauge remains at or near
zero when the oil temperature varies, the transformer should be
checked for leaks. This is an important maintenance check which will
verify the integrity of the transformer seal.
ƒ Review this month’s results and confirm either normal or abnormal
trending

ABB TRES North America

© ABB Inc. 2009; Slide 47
Preventive Maintenance Actions
Quarterly Maintenance Recommendations

ƒ Check and record the readings on all indicating instruments, such as the liquid level of the main tank, all oil-filled
compartments, top oil temperature, and winding temperature. The maximum reading and the present reading should be noted
on the temperature indicators. If the transformer is equipped with an Inertaire® oil preservation system, check and record the
tank pressure and the remaining pressure in the nitrogen bottle feeding the system. Examine the piping to the coolers or
radiators and all bolted pipe joints for signs of oil leakage. Tighten any loose fittings and repair any oil leaks.
ƒ Examine the coolers or radiators for accumulation of dirt and foreign material that might impede airflow. The coolers or
radiators can be cleaned by directing a stream of low-pressure water over the surfaces. On FOA coolers, the water should be
directed to the front (exhaust) side of the cooler to wash any dirt toward the rear(intake). Be certain the fans are shut off before
starting any cleaning operation.
ƒ The frequency of cleaning will vary depending on the conditions at the installation site
ƒ Annual cleaning is generally sufficient, but installation subjected to salt spray or heavy dust and dirt or other contamination
will require a more frequent schedule.
ƒ Inspect the control cabinet for any of the following conditions:
ƒ Control-circuit voltage problems
ƒ Collections of dirt or gum
ƒ Excess heating of parts (evidenced by discoloration of metal parts, charred insulation, or odor)
ƒ Binding or sticking of moving parts
ƒ Corrosion of metal parts
ƒ Remaining wear allowance on contacts
ƒ Excess slam on pickup
ƒ Proper contact pressure
ƒ Loose connections
ƒ Condition of flexible shunts
ƒ Worn or broken mechanical parts
ƒ Excessive arcing in opening circuits
ƒ Excessive noise in ac magnets
ƒ Evidence of dripping water or liquids falling on controls
ƒ Operation, including proper functioning of timing devices and sequencing of devices
ƒ Review these results and confirm either normal or abnormal trending

ABB TRES North America

© ABB Inc. 2009; Slide 48
Preventive Maintenance Actions
Annual Maintenance Recommendations

ƒ If the transformer is equipped with forced oil cooling, check the oil circulating pumps, noting any unusual noise or flutter of the
oil flow gauge. Evidence of noise, uneven oil flow, unbalanced phase current, or heating of the pump motor may require
removal of the pump from the transformer. Disassembly and inspection procedures are given in the pump instruction leaflet.
ƒ If the transformer is equipped with air cooling, examine the fans to ensure that there is no debris covering them or between the
blades. Check to make sure that each fan is operational and that the blade rotation is correct. If the cooling banks are staged,
check that the proper set of fans come on for each stage. Measure line currents on the fan motor and check for any
imbalances.
ƒ Examine the pump valves for evidence of leaking around the gland seals. Close and open the flapper-operating arm. There
should be some restriction to the flapper arm movement if the packing is properly tightened. Tighten the gland nut if necessary
to eliminate any leaks. Take oil samples from the main tank and any other oil-filled compartment, such as the load tap
changer. Perform general oil quality analyses on the oil sample. Oil samples may also be taken at this time for gas-in-oil or
metal particle analysis. If any test results are questionable, contact ABB. Perform insulation resistance tests on each winding to
the other winding and to ground and from all windings to ground and compare with the previous test values. Measure the
insulation power factor and compare with previous test values. Contact the Technical Support Section if any of the tested
values vary significantly from the initial tests.
ƒ Examine all bushings, arresters, and all the interconnecting hardware for contamination and signs of electrical tracking. Clean
any contaminated areas with a soft cloth and suitable solvent, then wipe the area dry. Perform power factor and capacitance
measurement on the bushings and compare the values to the test results made when the transformer was installed.
ƒ If the transformer is equipped with a load tap changer, inspect the tap changer as noted in the tap changer instruction leaflet.
Detailed information for the inspection procedures and the frequency of inspection is supplied as part of the transformer
instruction book.
ƒ Inspect any breathers and small screen openings in pressure-relief valves or a pressure-vacuum breather to be certain they
are clean and in operating condition.
ƒ If the transformer is equipped with a COPS oil-preservation system, remove the expansion tank breather and check for oil
leakage into the bladder. The procedure for making this inspection is explained in the instruction leaflet for the oil preservation
system.
ƒ Examine the paint finish, particularly around welded joints and on accessory items such as the radiators, coolers, and
associated piping. Check for paint peeling or cracking and evidence of rust. Clean the affected areas by wire brushing, then
wipe with a clean dry cloth. Paint the area with the touch-up primer and finish coat supplied in the transformer details shipment
box. De-energize the auxiliary power source and inspect the control devices in the control cabinet. Remove grease, oil, or
other contaminants with a lint-free cloth moistened in a nonflammable cleaning fluid. Do not soak the parts with the cleaner, but
use just enough to loosen grease or dirt so that it can be wiped off. For cleaning small parts, a small paintbrush dipped into the
cleaning solution is good for getting into corners and crevices. Repair or replace any broken or malfunctioning parts, tighten all
loose connections, and eliminate any oil or water leaks into the compartment. More frequent inspections may be needed in
heavily contaminated installations.
ABB TRES North America
© ABB Inc. 2009; Slide 49
Effective Analysis Depends on Design Understanding
Oil Expansion / Oil Preservation Systems
Bladder

Air

Oil
Gas Space

Buchholz Buchholz
Oil Relay Oil Relay
Oil

II III
I
Conservator type Conservator type
Non-conservator type
with bleeder bag with open expansion tank
Gas-blanketed
(COPS Sealed) (COPS Open)

ABB TRES North America

© ABB Inc. 2009; Slide 50
Oil is the Life Blood of a Transformer
Maintenance/Oil Sampling Tips

ƒ When taking oil samples for moisture in oil, take sample

when transformer temperature is over 60oC.
ƒ If the unit is a COPS or free breather, don’t forget to check
oxygen inhibitor content.
ƒ If unit is a COPS with breather, don’t forget to check the
bag for leaks.
ƒ If oil is degassed, establish a new baseline for Furan
content.
ƒ Pumps should be replaced or refurbished every 10 years.
ƒ Don’t forget to check condition of coolers. You can lose
cooler efficiency which will accelerate transformer ageing.

ABB TRES North America

© ABB Inc. 2009; Slide 51
Why Test at Every Outage?
Every Test Establishes a Baseline for Comparison

Establishment of a trend is a key to prevent this kind of result

ABB TRES North America

© ABB Inc. 2009; Slide 52
When Routine Checks Identify a Problem . . .
On-Site Services Can Improve Reliability
ƒ Engineering Assessments (MTMP™) ƒ Control system upgrade
ƒ Advanced Diagnostic Testing ƒ Internal Inspections
ƒ Bushing Replacement ƒ Insulation system maintenance
ƒ Tap Changer Services or Retrofit ƒ Reblocking / rewedging
ƒ Unit Uprates / Cooling Systems Upgrades ƒ Biodegradable fluid retrofills
ƒ COPS tank modifications ƒ Partial or full winding replacement

ABB TRES North America

© ABB Inc. 2009; Slide 53
Condition Understanding Allows Identification of
Possible Options for Reducing Risk

System Actions:
ƒ Modifying auto-reclosing practice
ƒ Measures for reducing close-in faults
ƒ Fault overcurrent limiters
ƒ Neutral reactor application (system applicability)
Transformer Service/Replacement Actions:
ƒ Proactive maintenance practices
ƒ Advanced diagnostics testing
ƒ On line monitoring
ƒ Relocating units
ƒ Factory winding upgrade
ƒ Need for spare transformers

ABB TRES North America

© ABB Inc. 2009; Slide 54
A Thorough Condition Evaluation Should Include Possible Risk
Mitigation for Urgent Ranked Transformers

Possible Risk Mitigation Actions

ID Serial Reasons for
Location Manufacturer [L1] = ASAP, [L2] = 1 Yr.
# Number Higher Risk
[L3] = 2 - 3 Yrs., [L4] = 3 – 5 Yrs

• Investigate for possible PD including installing Hydran

[L1]
• Perform Acoustic PD measurements [L1]
• Increase DGA sampling to trend H2 production [L1]
• Perform complete oil screening test from samples taken
Through-Fault failure, when transformer is hot [L1]
2 AR 2 702282 Federal Pacific dielectric failure • Condition Assessment [L2]
• SFRA test [L2]
• Review PF and capacitance history [L2]
• Implement measures to reduce number of through faults
such as tree trimming [L2]
• Limit auto-reclosing to 1 reclose [L3]

• Resample oil in tap changer for DGA. If Acetylene is

Possible Arcing in the tap
6 BA 5 MLL939216 ABB changer compartment
confirmed, then remove from service and perform internal
inspection on LTC compartment [L1].

ABB TRES North America

© ABB Inc. 2009; Slide 55
 Reduced Increased Estimated
Upgrade Task ROF,% Insulation
Life, Years
Cost

1. Replacing the oil in the transformers with new oil with lower charging
tendency. This will reduce the risk of streaming electrification failure. 30 0
$
2. Replacing the cooling system with a new, more efficient system.
This will reduce the risk of a forced outage due to component failure
and lower the oil temperatures in the transformer. Lower oil
temperatures will reduce the future aging rate and also reduce the hot
spot temperatures, thus reducing the risk of catestrophic failure caused
18 8 $$$
by the overheating condition. The new cooling system will have to take
into account the risk of streaming electrification caused by excessive oil
velocity in the windings.

3. Removing the sound enclosure – This will improve the cooling

efficiency somewhat and allow better diagnostic measurement of the
tank wall temperatures using infrared thermography.
<2 1
$

4. Converting the oil preservation system from inertaire to Constant Oil

Preservation System (COPS). This will eliminate the need to have a
nitrogen line going to each transformer and will keep the the oil in a
degassed state. Oil with a lower gas content will not have the
33 0 $$
possibility of nitrogen bubble formation, which can lead to failure in the

ABB TRES North America

© ABB Inc. 2009; Slide 56
Advanced Diagnostic Testing
Allows Determination of Condition Based Actions
For critical issues, state-of-the-art testing
methods should be used to detect operating
difficulties and pinpoint specific activities to
speed restoration of service
ƒ Materials and Oil Testing
ƒ Metal in Oil Testing
ƒ CCD Testing for Sulfur contamination
ƒ Particle count
ƒ Oxidation Inhibitor Testing
ƒ Furanic Analysis
ƒ Degree of Polymerization Testing
ƒ Advanced Diagnostics
ƒ Advanced DGA
ƒ FRA Measurements
ƒ Dielectric Spectroscopy
ƒ Acoustics
ƒ Field Induced Testing
ƒ Recurrent Surge Testing

ABB TRES North America

© ABB Inc. 2009; Slide 57
Advanced Diagnostic Testing
There’s More To It Than Data Collection

ƒ Typically part of a field project

ƒ Field technician performs the test
ƒ Diagnostic Engineer analyzes the data to assit in turning it
into actionable information
ƒ Customer should be provided a clear report of findings and
potential improvement actions

ABB TRES North America

© ABB Inc. 2009; Slide 58
Advanced Diagnostic Testing
Tests and Equipment Requirements

ƒ Tests Performed
ƒ Advanced DGA

ƒ Acoustics

ƒ SFRA Measurements

ƒ Dielectric Spectroscopy (DFR)

ƒ Field Induced Testing

ƒ Recurrent Surge Testing

ƒ Equipment Available
ƒ SFRA: Doble M5100

ƒ DFR: Programma (GE) IDA 200; PAX IDAX 206

ƒ Biddle/IREQ PD measuring equipment

ƒ Used on production test floor

ƒ Used on phase angle regulator tap changer

replacement project
ƒ PD localization equipment – acoustic wall-mounted
sensors

ABB TRES North America

© ABB Inc. 2009; Slide 59
Frequency Response Analysis
Diagnostic Benefits

ƒ Frequency Response Analysis (FRA) is a method of measuring

the transfer function of the windings of a transformer
ƒ The SFRA is a plot of the swept frequency response of the
transformer circuit
ƒ This circuit is comprised of the inductance and capacitance
characteristic of the transformer winding being measured
ƒ One key use of the measurement is to compare a winding's
response to either similar windings (other identical phases or
other identical transformers) or to previous measurements of
that winding
ƒ The comparison can detect unusual movement in the winding
of the type experienced during hard transportation or an
excessive through fault
ƒ Changes in the transfer function reveal a wide range of failure
modes, for example:
ƒ Axial Winding Collapse

ƒ Clamping Failure

ƒ Hoop Buckling

ƒ Shorted Turns
ABB TRES North America
© ABB Inc. 2009; Slide 60
FRA Diagnostic Example
Axial Collapse Identification

Axial winding collapse is likely to have the following characteristics:

ƒ Produced within a transformer winding due to excessive axial forces during a fault
ƒ Windings shift relative to each other
ƒ Gassing may result
ƒ Transformer integrity is compromised
ƒ Failure likely to be catastrophic if transformer continues in service

ABB TRES North America

© ABB Inc. 2009; Slide 61
FRA Diagnostic Example
Hoop Buckling Identification

Hoop buckling is produced within a transformer winding due to

excessive compressive forces on inner windings during a fault.

ABB TRES North America

© ABB Inc. 2009; Slide 62
FRA Diagnostic Example
Hoop Buckling

ABB TRES North America

© ABB Inc. 2009; Slide 63
FRA Diagnostic Example
Clamping Failure

A clamping failure may be produced within a transformer

winding due to bulk winding movement.

ABB TRES North America

© ABB Inc. 2009; Slide 64
FRA Diagnostic Example
Shorted Turns

Shorted turns in transformers are produced by turn-to-turn faults

and may have the following characteristics:
ƒ Adjacent turns lose paper and braze/weld together
ƒ They result in a solid loop around the core

ABB TRES North America

© ABB Inc. 2009; Slide 65
Dielectric Frequency Response Testing
Power Factor at More Than 60 Hz

Hi The DFR test is a series of power factor

measurements at multiple frequencies.
Lo It provides more information about the
dielectric behavior of the insulation
system than a 60Hz test.
Ground The method can be used to diagnose
the following conditions:
ƒ Moisture in the cellulose insulation
ƒ High oil conductivity due to aging or overheating
of the oil
Hi
ƒ Chemical contamination of cellulose insulation
Lo
ƒ Carbon tracking in cellulose
ƒ High resistance in the magnetic core steel circuit

ABB TRES North America

© ABB Inc. 2009; Slide 66
Dielectric Frequency Response (DFR) Analysis
DFR- Purpose of Measurement

ƒ Diagnostic test of insulation system

ƒ Moisture content
ƒ Contamination
ƒ Carbon Tracking
ƒ Diagnose high PF or tan δ
ƒ Resistance in core ground circuit
ƒ Instrumentation
ƒ Sinusoidal signal of amplitude up to 200V peak
ƒ Frequency sweep range
ƒ 0.0001 – 1000 Hz maximum (<12 hrs)
ƒ 0.001 – 1000 Hz typical (1.25 hours)
ƒ 0.01 – 1000 Hz minimum (0.25 hours)
ƒ Three-electrode set up: the voltage electrode “Hi”, the
current sense electrode “Lo” and the ground
ƒ Measurement setup is identical to typical power factor
measurements
ABB TRES North America
© ABB Inc. 2009; Slide 67
Dielectric Frequency Response Testing
Distinguishing Between Aged Oil and Moisture
1.000

Aged Oil, 0.5%

Moisture

Good Oil 1.3%

0.100
Moisture
Tan D

PF =. 00324

0.010

0.001 1 1 8 3 5

.001 .01 .1 1 10 60 100 1000

Frequency, Hz
ABB TRES North America
© ABB Inc. 2009; Slide 68
Dielectric Frequency Response Testing
Fitting the Right Dielectric Parameters
1.000

Aged Oil, 0.5%

Moisture
Good Oil 1.3%
Moisture
0.100
PF =. 00324
Tan D

Measured DR
0.7% Moisture

0.010

0.001 1 1 8 3 5

.001 .01 .1 1 10 60 100 1000

Frequency, Hz
ABB TRES North America
© ABB Inc. 2009; Slide 69
Dielectric Frequency Response Testing
DFR Signature Examples & Effectiveness
Dielectric Response Fingerprint Function DFR Fingerprint of Chemical
Showing the Effect of High Moisture Contamination of the Windings

Normal Moisture(.7%)

High Moisture(1.7%)

.01 .10 1 10 100 1000 .01 .10 1 10 100 1000

Frequency, Hz
Surface Moisture in Paper - Moisture in
Frequency, Hz

Oil vs. Volume Moisture From DFR Loading Limits Based On Moisture Content
Cellulose Overload Level
Temp Oil Cond Moist by Oil Moist. by DR Hottest Spot
Xfrmr # Type Constr. o Moisture Overload Type with 40°C
(o C) (pS/m) Sat (%wt) (%wt) Temperature( C)
(% ) Ambient

1 23 GSU Core 0.381 2.5 0.9 120 3.5 Normal Loading 0%

2 28 GSU Core 0.492 1.8 0.9

130 2.4 Planned O/L Beyond N/P 6%
3 23 GSU Core 0.412 1.4 0.9
4 23 GSU Core 1.34 2.8 0.7 140 1.7 Long Time Emergency (1-3 mo.) 12%
5 13 3-wdg Shell 1.5 * 1.2
180 0.8 Short-Time Emergency (½ -2hr) 40%
6 27 Auto Core 3 3.5 2
7 27 Auto Shell 0.3 3.3 1
ABB TRES North America
© ABB Inc. 2009; Slide 70
Dielectric Frequency Response Signature Example
Another Use: High Core Ground Resistance

XV to Ground

XV to Ground after Repair

Frequency, Hz
.01 .10 1 10 100 1000

Dielectric Response Fingerprint Function caused by a High

Core to Ground Resistance in Auxiliary Transformer

ABB TRES North America

© ABB Inc. 2009; Slide 71
Degree of Polymerization – DP
Measures Insulating Paper Strength

Degree of polymerization is a measure of the number of

intact chains in a cellulose fiber. It provides an indication of
the ability of the transformer insulation to withstand
mechanical force (due to through-faults, etc).
Cellulose Fiber Chain

ABB TRES North America

© ABB Inc. 2009; Slide 72
Degree of Polymerization – DP
Factors affecting DP and Measurement Method

ƒ The DP of the insulation is affected by the following

conditions:
ƒ Moisture content
ƒ Acidity of the oil
ƒ Oxygen content
ƒ Temperature
ƒ The DP is measured by viscosity measurements according
an ASTM method after dissolving the paper samples in
cupriethylene diamine solvent.
ƒ Paper samples must be taken from enough different
areas in a transformer in order to get a profile of
deterioration of the cellulose
ƒ When combined with detailed design knowledge,
measurements in one area of the transformer can give
information on the condition of paper in inaccessible
areas of the windings.
ABB TRES North America
© ABB Inc. 2009; Slide 73
Degree of Polymerization – DP
Life Expectancy Based on DP and Other Factors
For long insulation life expectancy, it is important to keep the insulation dry,
keep acidity and oxygen concentration of oil low and provide good cooling
10000.0
Dry & Clean (Insuldur)
Acidic Oil (Insuldur)
1000.0 1% Water Content (Insuldur)
3-4% Water Content (Insuldur)
L ife E x p e c ta n c y (y e a rs )

100.0

10.0

1.0

0.1
50 60 70 80 90 100 110 120 130 140 150
Temperature [o C]
It is assumed that the DP of transformer insulation is approx. 1,000
at the start of life and approx. 200 at the end of life. This graph
shows the expected life of thermally upgraded insulation (Insuldur)
ABB TRES North America
© ABB Inc. 2009; Slide 74 under various conditions.
Dissolved Gas Analysis
Advanced DGA Diagnosis

ƒ Close observation of dissolved gases in the oil and other

oil properties provides the most valuable information about
transformer health
ƒ ABB’s Dissolved combustible Gas in oil Analysis tools
takes the following into consideration:
ƒ Gassing rates of increase for each key gas detected
ƒ Historical trend of gassing
ƒ Various ratios of key gases
ƒ Estimated temperature of the hottest spot temperature
ƒ Gas solubility depending on preservation system
ƒ Concentration and ratios of carbon oxides
ƒ Detailed design knowledge of the transformer, such as
stray flux management, clamping and cooling system
details.

ABB TRES North America

© ABB Inc. 2009; Slide 75
Advanced DGA Diagnosis
Results are Compared to Known Issues

ABB TRES North America

© ABB Inc. 2009; Slide 76
Advanced DGA Diagnosis
Condition Data Assessment Value

ƒ The history of the condition data is reviewed:

ƒ Dissolved Gas in oil Analysis (DGA)
ƒ Oil Quality (including moisture in cellulose)
ƒ Furans
ƒ Power Factor
ƒ Increasing trends and abnormalities are explored
ƒ Many problems can be detected, leading to actions prior to failure
50 Hydrogen (H2)
45 Methane (CH4)
40 Ethane (C2H6)
35 Ethylene (C2H4)
Conc. (ppm)

30 Acetylene (C2H2)
25
20
15
10
5
ABB TRES North America
0
© ABB Inc. 2009; Slide 77
Advanced DGA Analysis
Typical Problems Diagnosed using DGA Analysis

ƒ Overloaded transformers
ƒ Overheating caused by problems with cooling systems
ƒ Local overheating caused by blocked oil duct inside the transformer
ƒ Overheating due to oil circulating pump problems (bearing wear, impeller loose or worn)
ƒ Overheating due to circulating stray currents in the core, structure, and/or tank
ƒ An unintentional core ground may cause heating by providing a path for stray currents.
ƒ Bad connections in the leads or by a poor contact in the tap changer can cause a hotspot
ƒ Discharges of static electrical charges that build up on shields or core and structures that
are not properly grounded may cause hotspots that produce gassing
ƒ Hotspots that may be caused by electrical arcing between windings and ground, between
windings of different potential, or in areas of different potential on the same winding, due to
deteriorated or damaged insulation
ƒ Windings and insulation that may be damaged by faults downstream (through faults),
causing large current surges through the windings
ƒ Voltage surges caused by nearby lightning strike or switching surge or closing out of step
may result in immediate arcing or arcing that develops later
ƒ Aged insulation that may be damaged by a voltage surge. When this happens, clearances
and dielectric strength are reduced. Partial discharges and arcing may develop. during a
through fault and cause total mechanical and electrical failure
ƒ High noise level (hum due to loose windings) can generate gas due to heat from friction

ABB TRES North America

© ABB Inc. 2009; Slide 78
ABB TRES Field Service Capabilities
Capital Equipment Resources

ƒ ABB maintains a fleet of field oil processing units

ƒ 30-80 gpm, 164-224 KW resistive heating elements, 1150-2250 cfm vacuum
pumps, and cold traps
ƒ 50 cfm dry air generator
ƒ Motor-generator set
ƒ Fixtures, rigging & safety equipment
ƒ Oil lab and electrical test equipment
ƒ Semi-tractors with cranes
ƒ Man lifts, fork trucks & oil storage tanks
ƒ Modular equipment
ƒ Clay filter towers
ƒ Auxiliary vacuum pumps, oil heaters, filter presses
ƒ Degassing units and cold traps
ƒ Electrical and oil test equipment

ABB TRES North America

© ABB Inc. 2009; Slide 79
Transformer Cooling System Upgrades
FOA Oil Coolers

Fact: Most FOA coolers >20 years old are inefficient

(do not have the same heat transfer capabilities as
originally manufactured)

Reasons:
A) Inefficient fans and shroud arrangements
B) Oxidation of aluminum tubes.
C) Debris trapped within cooler.
D) If water sprayed, evaporation will coat the tubes with layers
of minerals.

Result: Overheating prematurely ages transformer

insulation, shortening transformer life
ABB TRES North America
© ABB Inc. 2009; Slide 86
Transformer Cooling System Upgrades
New nameplate supplied as part of project

A design evaluation must be performed to determine the

‘weakest link’ – without it any uprating is very dangerous
Unit shown was uprated from 610 to 660 MVA, and the hot spot temperature was lowered

ABB TRES North America

© ABB Inc. 2009; Slide 87
Transformer Condition Improvements
On Site Controls & Cooling Retrofit

ƒ Turn-Key Services
ƒ Example below - 350MVA GSU transformer
ƒ Legacy design information speeds up project and allows a “turn-key”
approach to the field services
ƒ Customer Value: Modernized control and cooling systems

ABB TRES North America

© ABB Inc. 2009; Slide 88
Transformer Condition Improvements
On Site Controls & Cooling Retrofit

ƒ ABB TRES is able to utilize legacy design information to offer turn-key services
ƒ Modernization of control and cooling systems returns cooling system
performance to like-new and dramatically slows transformer aging rate

ABB TRES North America

© ABB Inc. 2009; Slide 89
LTC Condition Evaluation
Possible Malfunctions Diagnosed Using Effective
Maintenance Techniques

ABB TRES North America

© ABB Inc. 2009; Slide 90
Load Tap Changers
Maintenance Guidelines
ƒ Mechanical movement and arcing creates wear and tear
ƒ Various tests, inspections, and/or adjustments are often made on the basis
of load tap changer operations or elapsed time
ƒ Wear is also very dependant on the load being interrupted by the LTC
ƒ Every LTC model is unique
ƒ The specific transformer application even makes it more unique
ƒ Consult the LTC & Transformer manufacturer’s instruction literature for
information on each specific unit
ƒ Maintenance Specific to Arc-in-Oil LTC’s
ƒ The arc-in-oil compartment will require thorough cleaning

ƒ Attention must be given to mechanical wear and arcing contact wear -

abrasive particles are in the oil
ƒ Check resistors in resistance type LTC

ƒ Maintenance Specific to Non-Oil Arcing LTC’s

ƒ The oil is expected to be found relatively clean

ƒ Vacuum interrupters will have a wear gauge to check contact erosion

ƒ Vacuum interrupters need to be pull tested to verify that the unit is still
under vacuum and not oil filled
ƒ Vacuum interrupters must be given an AC hi-pot test

ABB TRES North America

ƒ Perform Dynamic Voltage Excitation Test prior to returning to service
© ABB Inc. 2009; Slide 91
Load Tap Changers – Maintenance
LTC Field Service Considerations

ƒ Many tap changers were/are good designs

ƒ Specialists can successfully rebuild LTC’s through
a complete maintenance & overhaul cycle
ƒ OEM-or-better quality parts are available for many
LTC models
ƒ LTC OEM Products Supported in the US Market
Include:
ƒ Reinhausen
ƒ ABB
ƒ GE
ƒ Westinghouse
ƒ A/C
ƒ FPE
ƒ LTC Retrofit should be considered for problem
units
ƒ Troubleshooting & Timing Verification is critical
ABB TRES North America
© ABB Inc. 2009; Slide 92
Load Tap Changers – Maintenance
LTC Services that Improve Reliability

ƒ Troubleshooting
ƒ Inspection
ƒ General Maintenance
ƒ Timing Verification
ƒ Rebuild
ƒ Parts Identification & Replacement
ƒ Turnkey Service with all Oil Handling and Testing
ƒ LTC Retrofits - Upgrades & Replacement

ABB TRES North America

© ABB Inc. 2009; Slide 94
Many old LTC’s are Still Supported
OEM-Grade (or better) Parts and Services are still
available for many old tap changers, including the
following models:
Westinghouse General Electric Reinhausen ABB Moloney Federal Ferranti
UVT UTR LR9 LR67 RMS-I BUE MA, -1,-2 Pacific Packard
UTT-A,A70,B UR LR10 LR68 RMT-I UZE MB, -1, -2 TC-15 138RT32
URT UB LR15 LR69 RMV-I,II UZF MC TC-25 25RT32
URT-ATS UC LR17 LR72 TYPE M UCG MH TC-515 34RT32
URT-DTG UVW (-A) LR19 LR79 TYPE T UCC MJ TC-525 69RT32
URT-46,69 URL-4,8,16 LR21 LR81 TYPE G UCD TC-546
URT-HC URF LR27 LR83 TYPE R UBB
URS URH LR29 LR85 TYPE F UCL
UTH LR LR31 LR89 TYPE MS UZD
UNR URV LR38 LR91 Allis McGraw
UTN VR LR40 LR92 Chalmers Edison
UT SDR LR41 LR95 TLB 220
UT-ATS PDR LR45 LR96 TLH 397
LR47 LR200 TLS 500
LR48 LR300 550
LR59 LR400 996
LR63 LR500 V2A
LR65 LR700

ABB TRES North America

© ABB Inc. 2009; Slide 95
Load Tap Changers
Quality Check: Dynamic Voltage Excitation Test

The purpose of this test is to verify the correct operation of the load
tap changer circuit. This includes the RV lead connections, P.A.
lead connections, and the LTC assembly and mechanism timing
TEST PROCEDURE:
ƒ This test is performed by applying a three phase voltage (240 or 480V)
to the high voltage bushings
ƒ Three single phase ANALOG voltmeters are connected to the LV
bushings, phase to phase if delta connected or phase to neutral if wye
connected
ƒ The LTC mechanism is then hand cranked through all of its positions
while monitoring the output voltages
ƒ The voltmeters should be observed for signs of problems:
ƒ The voltage falling to zero for any time period is an indication of a
open circuit
ƒ The volt meter moving in different directions during a tap change is
an indication of RV or P.A. lead connection problems
ƒ Any other changes in voltmeter readings which are different from
one phase to the other

ABB TRES North America

© ABB Inc. 2009; Slide 96
Load Tap Changer Condition Improvements
When does an LTC Retrofit make sense?

A load tap changer (LTC) replacement or retrofit may be

the best option to economically solve operating problems
inherent in existing tap changers such as:
ƒ LTC mechanisms that have reached the end of their
useful mechanical life
ƒ Availability of parts and qualified service personnel on
vintage equipment is rapidly diminishing
ƒ Design may be obsolete or built by former
manufacturers forcing reliance on expensive and
sometimes questionable quality parts
ƒ Cost of unplanned outages has risen dramatically
ƒ Confidence in basic design is not high

ABB TRES North America

© ABB Inc. 2009; Slide 97
Load Tap Changer Condition Improvements
LTC Retrofit Considerations

ƒ All mechanical parts must be designed and tested for the

specific application
ƒ The retrofit designer must understand both the
transformer and the LTC application
ƒ A choice must be made to use either vacuum or resistive
technology
ƒ Modern designs have higher reliability and spare parts
availability
ƒ A substantial engineering and detailing effort is required,
including field modification drawings, new controls, wiring
diagrams, parts, materials, old LTC removal and new LTC
installation

ABB TRES North America

© ABB Inc. 2009; Slide 98
Load Tap Changer Condition Improvements
LTC Retrofit Benefits

ƒ Increased transformer life – up to 25 (or more) years in

some cases
ƒ Reduced maintenance costs – longer intervals & more
readily available spare parts
ƒ Improved reliability of operation – particularly under
demanding conditions
ƒ Increased contact life available from modern, proven tap
changers
ƒ Avoid cost of shipping large power transformers to repair
shop
ƒ Reduced downtime as compared to repair shop LTC
replacements
ƒ Field LTC retrofit is an economical alternative to replace
large power transformers

ABB TRES North America

© ABB Inc. 2009; Slide 99
Load Tap Changer Condition Improvements
Sampling of Tap Changer Retrofit Projects:

ƒ Westinghouse URT Æ UVT

ƒ Federal Pacific TC-25 Æ UVT
ƒ W URT-HC Æ Reinhausen RMV-I
ƒ GE LRT Æ Westinghouse UVT
ƒ Ferranti Packard RT Æ UVT
ƒ Westinghouse URT Æ RMV-II
ƒ Moloney MC Æ Reinhausen RMV-I
ƒ FP TC-25 Æ Reinhausen RMT-I
ƒ FP LR-525 Æ Reinhausen RMT-I
ƒ GE LRT-500 Æ Reinhausen M (in-tank)
ƒ Westinghouse URH Æ Reinhausen M
ƒ Westinghouse UNR Æ RMV-II
ƒ GE LR-83 Æ Reinhausen RMV-II
ƒ Installation of Westinghouse UVT to non-
LTC transformer

ABB TRES North America

© ABB Inc. 2009; Slide 100
Load Tap Changer Condition Improvements
Case Study: On Site Tap Changer Retrofit

ƒ LTC Retrofit – GE to RMVII

ƒ 21MVA, GE, 1ph, arc-furnace transformer
ƒ LTC experience, turn-key capabilities
ƒ Reduced maintenance, reduced downtime, more
production output

ABB TRES North America

© ABB Inc. 2009; Slide 101
Load Tap Changer Condition Improvements
Case Study: On Site Tap Changer Retrofit

GE

RMV
II

ABB TRES North America

© ABB Inc. 2009; Slide 102
Load Tap Changer Retrofit Kits
McGraw Edison 550B load tap changers

ABB TRES North America

© ABB Inc. 2009; Slide 103
Load Tap Changer Retrofit Kits
McGraw Edison 550B load tap changers

ƒ Prevents heating and coking with:

ƒ Six contact points on the stationary contacts
ƒ Six contact points on the moving contacts
ƒ Rides on rails for moving and stationary contacts
ƒ Silver inlay material

ƒ Success factors:
ƒ Reduced force on contact points
ƒ Thermal Tested (experienced less than 8°C temperature
rise at 1500 amps, ANSI standard is 10°C at lower
amperage)
ƒ Technology mechanically tested
ƒ Compliance with 1986 McGraw Edison 550B product
advisory requiring ¼ hp motor (ABB can provide a quote
for this motor upgrade)

ABB TRES North America

© ABB Inc. 2009; Slide 104
LTC Condition Evaluation
New Development ƒ Accelerometer

ƒ Tap-4 device

ƒ Current
sensor

ABB TRES North America

© ABB Inc. 2009; Slide 105
Natural Ester Retrofilling Power Transformers
BIOTEMP® - ABB Sensible Solution

With BIOTEMP®, ABB aims at offering a

complete and reliable solution for distribution and
power transformers associating environmental
friendliness with enhanced fire safety, longer
lifetime, and higher overload capacity.

ABB TRES North America

© ABB Inc. 2009; Slide 106
Natural Ester Retrofilling Power Transformers
Reasons to Consider a Natural Ester like ABB
BIOTEMP®
ƒ Biodegradable and from renewable resources
ƒ Potential regulatory relief on spill cleanup

ƒ BIOTEMP® fluid is vegetable-based oil produced

from oil seed crops readily available
ƒ BIOTEMP® fluid has a high fire point (above 300oC
vs. 180oC for mineral oil)
ƒ Increased fire safety and potential for lower
insurance premiums
ƒ BIOTEMP® fluid has a much greater ability to hold
moisture
ƒ Increased insulation system life and transformer
overload capacity
ƒ BIOTEMP® fluid exhibits excellent dielectric
performance
ƒ Dielectric constant is closer to cellulose lowering
stresses in oil ducts
ƒ Overall, excellent alternative to petroleum products

ABB TRES North America

© ABB Inc. 2009; Slide 107
Natural Ester Retrofilling Power Transformers
ABB BIOTEMP® - A proven insulating fluid

ƒ ABB has produced more than 2,000

distribution transformers (up to 5 MVA and
36 kV) and more than 20 small power
transformers (up to 20 MVA and 69 kV) in the
US since 2005.
ƒ 15 small power transformers (10 MVA, 34.5
kV) have been successfully retrofilled with
Natural Ester fluid in the US.

ƒ Four small power transformers (up to 25 MVA and 145 kV) have been
successfully refurbished with Natural Ester in Brazil.
ƒ One of which was a 15 MVA unit upgraded to 25 MVA with an extremely high
and reliable overload capacity of up to 37.5 MVA for 6 hours (i.e., 150%) or up to
42 MVA for 4 hours (i.e., 170%).
ƒ This unit has been operating safely with heavy loads and frequent overloads for
2 years now in Brazil.

ABB TRES North America

© ABB Inc. 2009; Slide 108
Natural Ester Retrofilling Power Transformers
Biodegradability* of various insulating & cooling fluids

100%
99%
90%
80%
80%
70%
60%
50%
40%
30%
30%
20%
20%
10% 5%

0%
*Based on the BIOTEMP® Synthetic Mineral Oil H.T.H. Silicone
CEC L-33-A-93 Esters
21-day test

ABB TRES North America

© ABB Inc. 2009; Slide 109
Extend Transformer Life by Improving the Oil
Characteristics
BIOTEMP® Retro-fill Option
ƒ Total turnkey retrofill service utilizing the
latest biodegradable dielectric coolant
BIOTEMP®.

ƒ Retro-fill candidates
ƒ Mineral oil

ƒ Wecosol (Perchloroethylene)
Kailua-Kona, Hawaii
ƒ Askarel (PCB)

ƒ Benefits
ƒ Longer equipment life

ƒ Improved Safety – virtually eliminates the

possibility of costly oil fires
ƒ Lower insurance and liability costs due to
greatly reduced risk of fires
ƒ Environmentally friendly
Hilo, Hawaii

ABB TRES North America

© ABB Inc. 2009; Slide 110
OEM Transformer Remanufacturing
Repair Can Begin Before the Transformer is Received
at the Factory
Repair/Remanufacturing Focused Factories
ƒ >30 Years Experience
ƒ Dedicated “State of the Art” Remanufacturing Facilities
ƒ Dedicated Engineering, Drafting, and Manufacturing
Resources
ƒ “Cutting Edge” Technology That Meets Present Day New
Transformer Standards
ƒ Remanufacturing Takes Advantage of Design
Enhancement & Capacity Upgrade Possibilities
ƒ Reverse Engineering Capabilities
ƒ Transformer Life Renewal/Extension by replacing
organic materials and reusing materials that do not age
ƒ Advance Design, Material Ordering, and Manufacturing
Capabilities
ƒ ABB Engineers can assist in providing data for the repair
versus replace decision
ƒ Understanding of All OEM Designs through hands-on
experience
ƒ ISO 9001 and 14000 Certified
ƒ Established Quality Plans

ABB TRES North America

© ABB Inc. 2009; Slide 111
Case Study
Transformer Remanufacturing Project

ƒ 1972 Asea transformer fails at a Major Utility Generating Station

in February, 2006
ƒ Rating: 250 MVA, 345kV Auxiliary transformer
ƒ This transformer had little or no history of operating problems
ƒ The failure was of a catastrophic type requiring return to a factory
ƒ The Station was now operating with “sister-unit” to the failed
transformer
ƒ Major concerns throughout the utility’s management team

ABB TRES North America

© ABB Inc. 2009; Slide 112
Case Study
Transformer Remanufacturing Project

ƒ Damaged tank as received

ABB TRES North America

© ABB Inc. 2009; Slide 113
Case Study
Transformer Remanufacturing Project

ƒ Overhead view of Active Part in tank

ABB TRES North America

© ABB Inc. 2009; Slide 114
Case Study
Transformer Remanufacturing Project

ƒ Overhead view of contamination

ABB TRES North America

© ABB Inc. 2009; Slide 115
Case Study
Transformer Remanufacturing Project

ƒ Tank deflect as a result of explosion

ABB TRES North America

© ABB Inc. 2009; Slide 116
Case Study
Transformer Remanufacturing Project

ƒ Failed active part as seen at untanking

ABB TRES North America

© ABB Inc. 2009; Slide 117
Case Study
Transformer Remanufacturing Project

ƒ Remanufactured active part – HV Side

ABB TRES North America

© ABB Inc. 2009; Slide 118
Case Study
Transformer Remanufacturing Project

ƒ Completed active part – LV side

ABB TRES North America

© ABB Inc. 2009; Slide 119
Case Study
Transformer Remanufacturing Project

ƒ Repaired tank “ready ship”

ABB TRES North America

© ABB Inc. 2009; Slide 120
Case Study
Transformer Remanufacturing Project

ƒ Repaired cover at “ready ship”

ABB TRES North America

© ABB Inc. 2009; Slide 121
Case Study
Transformer Remanufacturing Project

ƒ ABB TRES Engineering updated the original design to meet

today’s technology and standards
ƒ The project moved forward without any issues
ƒ The project completed (10) days early – 17 weeks from initial
phone call to breaker closing
ƒ The logistics plan was flawless……………….

ABB TRES North America

© ABB Inc. 2009; Slide 122
Transformer Remanufacturing
Contingency Program Supports Fast Response

ƒ Pre-Engineered Solutions
ƒ Critical path transformers can be designed and in
some cases upgraded in advance
ƒ Reserved Factory Capacity
ƒ A proactive plan allows ABB to provide our
customers “factory reservations”
ƒ Advanced Procurement
ƒ Long-lead time commodities will no longer control
the project
ƒ Compressed Cycle Times
ƒ A proactive plan can provide significant reductions
in the factory production schedule
ƒ Pre-Determined Logistics Plan
ƒ No surprises and identified costs

ABB TRES North America

© ABB Inc. 2009; Slide 123
ABB TRES Remanufacturing Option
TrafoSiteRepair™ Program

ƒ TrafoSiteRepairTM may offer clear savings in time compared with factory

repair. It also solves “untransportable” cases
ƒ ABB is the global leader in site repair with more than 20 years
international experience
ƒ Some 200 transformers of various brands have been successfully repaired
on-site by ABB across the globe
ƒ All kinds of repairs can be performed, including replacement of windings
and repair of the core, with the highest levels of quality assured

ABB TRES North America

© ABB Inc. 2009; Slide 124
Transformer Remanufacturing & Engineering Services
TRES Working Safely

ABB TRES North America

© ABB Inc. 2009; Slide 125
ABB TRES Leads the Industry
Transformer Service Handbook
ƒ Copies are available from your ABB account manager or at: http://www.abb.com/transformers

ABB TRES North America

© ABB Inc. 2009; Slide 126
ABB TRES North America
© ABB Inc. 2009; Slide 127