ISSUE 3

SEPTEMBER 2019 transformer-technology.com ISSN 2642-2689

Best Practices
Transformer
Testing, Maintenance
and Monitoring

Interview with John McDonald Testing and Maintenance: Tips for Reducing Wasted Time
GE Grid Solutions Best Practices for a Half Century When Testing Transformers
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4 Table of
contents

Index Contents

Table of
Table of Contents_04

Editors & Impressum_08

24
Feature
Editor’s Letter_10
Interview
At a Glance_12
Interview with
Coming Events_16 John McDonald
GE Grid Solutions
Interview with John McDonald,

Smart Grid Business Development

Leader at GE Grid Solutions_24

Best Practices for Transformer

Testing and Maintenance_30

Three Tips for Reducing

Wasted Time When Testing

Transformers_40 30
Bringing Clarity to the Complexity of Best Practices
Condition Monitoring_46 for a Half Century
Transformer Aging, Degradation A well-maintained transformer can last more
than 50 years. If you catch a fault condition
and Online Oil Maintenance_48 early, there are corrective actions you can
take to prevent further damage to the
Balancing the naphthenic, transformer and avoid costly downtime
from catastrophic
paraffinic, and aromatic carbon failure.

contents of transformer oils to

improve performance and extend

transformer life_54
Transformer Technology September 2019 5

Issue 2

40 48
Better Testing Methods Reduced Oil
This article identifies the electrical Degradation & Aging
transformer tests that test equipment
users often struggle to perform efficiently Electric utilities should continually monitor and
and correctly, offering three field-testing reduce the level of contaminants and oil degradation
tips to address the transformer tests that products in transformers in order to maintain the
are often “time-suckers”. equipment’s performance, prevent failure, and
prolong the equipment life. Studies show that by
removing these promoters from the oil, the life of
a transformer can be significantly extended. This
article provides an overview of the aging process
of transformers, the chemistry involved, and which
compounds and byproducts further promote aging.

46
Bringing Clarity to
the Complexity of
Condition Monitoring

54
Transformer
Oil Properties
The composition of transformer oils can play an
important role in determining the performance
and lifespan of transformers. This article
highlights the key properties of transformer oils
with different chemical compositions and the
tests that were undertaken in determining if
oils with a higher paraffinic carbon content can
deliver enhanced performance versus those with
a higher naphthenic carbon content.
6 Table of
contents

Index Contents 62
Transformer

Table of
Transformer Hot Spot Hot Spot
Hunting_62 Hunting
Properly Categorizing Developing

Faults via Dissolved Gas

Analysis_66

The Successful Short Circuit

Withstand Test_72

Best Practices for Transformer

66
Testing & Inspection Upon Arrival_76

Keeping the Fleet in View_82

Adding Value with Truly Integrated Better DGA

Transformer Monitoring_88
Categorization
While much of the chemistry
Tecsystem: Make a Safer World_98 behind DGA is complex and
important for industry chemists
Automated Substation Monitoring to understand, the day-to-day
review of DGA by the utility need
with Thermal Imaging_100 not be complex. This article
offers some simple guidelines
Face-to-Face in a Digital World - The to assist in identifying what is
involved in the fault, and to help
Value of Industry Events_108 simplify the analytics when it
comes to categorizing developing
Discover the Latest Transformer faults within oil filled power
transformers.
Tech Innovations_112

Coming in December_114

72
Tironi 400 kV Natural
Ester Autotransformer:
The Successful Short
Circuit Withstand Test
Transformer Technology September 2019 7

Issue 3

88
Integrated Monitoring
Managing and mitigating the increased and changing risk
profile requires new methodologies for asset owners. Only
when monitoring all the key components and parameters
can the factors of health, risk and reliability be better
understood. A more holistic approach to transformer
monitoring can lead to converting data into more actionable
insights and, ultimately, optimize the maintenance cost and
effectively manage risk.

98
Tecsystem:
76 Make a Safer
World
Better Testing
& Inspections

100
Actions taken (or neglected) in the first
hours after a transformer’s delivery can
have long-term consequences. Here are
some in-depth inspection and testing
precautions that can help maximize
Automated
the transformer’s service life. Thermal
Monitoring

82
This article outlines how the latest
thermal imaging technology can
automate the thermal scanning process
Keeping the providing data that is constant and
more consistent. This allows several
Fleet in View opportunities for utility cost savings
including reduced travel and extended
asset life through conditioned based
maintenance.
8 Editors &
IMPRESSUM

Impressum Editors

ISSN 2642-2689 (Print)

ISSN 2642-2697 (Online)

Editor in Chief
Alan M. Ross, CRL, CMRP
Editor in Chief
Associate Editor Alan M. Ross CRL, CMRP
Lee Murray Transformer maintenance
Transformer reliability content editor and reliability
26 years industry
Contributing Editors experience
Diego Robalino, PhD, PMP, IEEE Senior
Member
Corné Dames, Independent transformer
consultant
Jon Trout, PE, Electric utility
Alan Sbravati, Global Technical Manager,
Insulating liquids
Contributing Editor
Diego Robalino PhD, PMP
Graphic design
IEEE Senior Member
Bekoncept Communication Boutique
Transformer condition
assessment and
Photo
diagnostics
Shutterstock.com
20+ years industry
Cover Photo Courtesy of The Snell Group,
experience
Barre, VT

Sales & Marketing

Kevan Sears
[email protected]

Marketing Global Contributing Editor

Marin Dugandzic Lee Murray
[email protected] Transformer reliability
content editor
Member of IEEE
Professional
Communication Society
and the Society for
Technical Communication
Transformer Technology September 2019 9

Issue 3

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published by APC MEDIA LLC, 11210 West Rd, Corné Dames
Roswell, GA 30075, USA. Published content does Transformer oil
not represent official position of APC MEDIA LLC. 20+ years industry
Responsibility for the content rests upon the experience
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Electric utility
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transformer-technology.com

Contributing Editor
Alan Sbravati ME, MBA
Transformer insulating
materials
18 years of experience
10 Editor’s
Letter

A Changing Landscape

This issue might well be a keepsake for anyone Being involved with Transformer Technology has
interested in “Best Practices for Testing, Mainte- stretched me much more than I thought it would
nance and Monitoring” of transformers. There is and it has done so in three very distinct ways:
past, current and future “Best Practices”. How can
we have future ones? If they are future practices, 1. I am being challenged technically. While our
then they have not yet been proven or industry- Contributing Editors add technical expertise in
wide accepted. That is what defines a best practice areas I cannot, I am making a commitment to at
by the way. Proven and accepted practices! least understand what our authors are sharing,
to grasp the fundamentals and make sure they
But in the face of advancing technology and new will be of interest to the average reader. We
methodologies, we have to know when to let go are not writing to only the technologists but
of the past and accept new advances. As I read to a broad array of transformer professionals.
Richard Harada with his article on the use of re- To do that, we must be relevant, reliable and
mote infrared monitoring, it is clear that he is make sure we don’t ever use the magazine arti-
sharing a future best practice. Bob Rasor, Jason cles as filler. Our goal is to create a publication
Dennison and Brandon Dupuis shared the best that lives on, one that is shared digitally and in
of the past and current and of course, the moni- print because of the value of the information
toring article from Marco Tozzi hit the nail on the we publish. That leads me to my second area of
head in both current and future technology for growth.
monitoring.

If, like me, you are inundated

with emails, blogs, magazines
and conferences to attend,
it can be overwhelming.
How do we rise above all that
clutter? We make it enjoyable,
shareable and challenging
to become part of our
community online and
in print.
2. It would be much easier if all we did was pub-
lish a few magazines a year. But that is not our
vision for Transformer Technologies; it is to cre-
ate a “collaborative community” of profession-
als within the transformer industry to learn,
do and teach. While I have experience build-
ing this kind of community in the past, the chal-
lenge is to do that around a subject as technical
as transformers. And to do it at a time when we
are awash in information. If, like me, you are in-
undated with emails, blogs, magazines and con-
ferences to attend, it can be overwhelming. How
do we rise above all that clutter? We make it en-
joyable, shareable and challenging to become
part of our community online and in print. As I
just wrote this I thought, “and you thought this
would be easy?” It is a testament to the amazing
support I get from my team that we can attempt
to pull this off. Thank you to all of you.
Transformer Technology September 2019 11

Issue 3

3. The future of information exchange is going

digital and moving away from print. How can I
even think that when we are the publishers of
a printed magazine? I don’t want us to become
Blockbuster in the face of Netflix or Sears in

Alan M Ross
the face of Amazon, so accept the change and
embrace it for the opportunity it creates. Every
printed issue is what we aim at to complete a
theme. The first three have been New Technol-
ogy, The Dry Type Revolution and now this edi-
tion themed, Best Practices of Testing, Mainte-
nance and Monitoring.

I’d like to challenge you to help us deliver the

best themes of the future by contacting me at
[email protected] and let
me know what themes you would like to see
for 2020 and beyond.

How will we make this change from a print pub-

lication to an online collaborative community?
We have already begun with the addition of our
news feed and commentary on important news
items. We don’t want to just bring you the impor-
tant news but also want to go behind the press
releases to what it means. For instance, Siemens
announced layoffs. We went behind the scenes
to look at what that means as they adjust their
business to new realities. It’s opinion, but well in-
formed and well intentioned.

We also added two podcast features: One on

Transformer Technology and one called Legends.
Podcasts might also show up as written inter-
views in future issues. You will see many more
posts, sharing insights into the articles and pod-
casts we publish, and we welcome your feedback.

Please let us know when we meet or exceed your

expectations, but also when we fall short. Engage
with the community. Collaborate. Share your tho-
ughts, ideas and technology of the future. I promi-
se, we are listening… and learning.
Transformer Technology
Editor in Chief
Alan M Ross
CRL, CMRP

Magazine
12 AT A GLANCE

At a Glance

Pioneer Power Solutions closes sale of transformer business

Pioneer Power Solutions, Fort Lee-based manufacturer of

electrical transmission, distribution and on-site power generation
equipment, completed the sale of its liquid filled and dry type
transformer businesses to Mill Point Capital, a middle-market
private equity firm, for a base purchase price of $68 million.

Pursuant to the transaction, Pioneer sold all of Pioneer

Transformers Ltd. and the companies comprising its Dry Type
Transformer Group, which included Jefferson Electric Inc., Bemag
Transformer Inc. and Harmonics Limited LLC.

Pioneer Power manufactures, sells and services electrical

transmission, distribution and on-site power generation equipment.
Its transformer businesses make specialty electrical transformers
for utility, commercial power, industrial manufacturing and
construction users. It has locations in the U.S., Canada and Mexico.

Mill Point executive partner Antony Besso will become chairman of

Pioneer Transformers.

Source: Pioneer Power Solutions

Sunbelt Transformer merges with Solomon Corporation

Trilantic North America, a private equity firm, has announced

the merger of Solomon Corporation, a provider of maintenance
and repair services for electrical transformers, with Sunbelt
Transformer.

The combined entity will address a critical segment of the electrical

power equipment and services market, serving the transformer
and related needs of commercial, industrial and electric utilities
customers throughout North America.

As part of the transaction, Tom Smith, CEO of Sunbelt, has been

appointed Chairman and CEO of the combined entity, with key
leaders from both organizations remaining on board to guide the
business’ next phase of growth.

“Sunbelt and Solomon are both companies with entrepreneurial

roots that have grown through an emphasis on delivering quality
solutions, superior customer service and cultures of collaboration
and rigor,” said Mr. Smith.

Tom Hemmer, former CEO of Solomon Corporation, will serve as

Group President of Solomon going forward.

“I am tremendously proud of Solomon’s growth to date and look

forward to partnering with the team at Sunbelt in order to more
effectively serve our customers as a joint platform,” said Hemmer.

Source: BusinessWire; Photo: Solomon Corporation

Transformer Technology September 2019 13

Issue 3

Georgia Power to rebuild 380 substations over next 3 years

Georgia Power filed a request with the Georgia Public Service

Commission (PSC) to increase customer rates by approximately
7% in 2020 to enable the company to continue making
investments in Georgia’s energy future.

In the filing, the company highlighted nearly $18 billion in recent

and future investments that are made to strengthen the reliability
and resiliency of the state’s electrical system and to comply with
federal regulations.

Since 2013, Georgia Power has invested more than $4.1 billion in
expanding transmission and distribution infrastructure, replacing
aging transmission assets and strengthening the reliability and
resiliency of the electric grid, and plans to invest an additional
$1.3 billion in a grid investment plan over the next three years.

This plan includes rebuilding 380 substations to continue

strengthening transmission and distribution infrastructure.

Source: Georgia Power

Emerald Transformer names new GM of Lexington plant and

announces expansion

Emerald Transformer (Emerald) has named Jim Palmer as the

company’s new general manager of the Lexington, Mississippi,
plant.

Palmer brings over 30 years of experience in organizational

development, operations management and safety and
environmental protection within multi-state and multi-plant
production.

As general manager, Palmer is responsible for overseeing the

performance, compliance, productivity, efficiency and profitability
of Emerald Transformer.

The company also announced it is increasing its footprint in the

Mississippi region and expanding its primary service territory from
four to eight states.

“Emerald Transformer is fully committed to growing our business

and creating new jobs in Mississippi,” said Stuart Prior, CEO and
president of Emerald Transformer, adding that the company plans
to “further enhance and expand our customer relationships in
Holmes County and throughout the southeast.”

Source, Photo: Emerald Transformer

14

US DOE selects companies to develop transformer sensor

technology

The U.S. Department of Energy’s Office of Electricity Delivery and

Energy Reliability (OE) has selected three companies to develop,
prototype, and demonstrate TRANSENSOR, a low-cost optically
based smart monitoring system.

PARC, Con Edison and General Electric will cooperate to develop

and test TRANSENSOR (Transformer Real-time Assessment
INtelligent System with Embedded Network of Sensors and Optical
Readout), which will increase reliability and safety by providing real
time asset health.

“It’s been predicted that the smart grid sensor market will reach
$39 billion by 2019,” said Ajay Raghavan, PARC research area
manager and principal investigator leading the effort. “We are
working on innovative low-cost embedded fiber-optic sensors
that can reliably monitor conditions in a broad variety of harsh
environments, including those seen in smart grids, so that we can
understand the real-time state of critical systems.”

Con Edison personnel will lead the final field demonstration of

TRANSENSOR.

GE personnel will play a support role in the testing for qualifying

TRANSENSOR on its Safe-NET network transformers leading to
the planned field demonstration with Con Edison.

Source: Printed Electronics

GRID 20/20 releases new distribution transformer monitoring

technology

Richmond, Virginia-based provider of distribution transformer

monitoring solutions, GRID20/20, announced the release of
its latest monitoring technology designed to facilitate grid
modernization within the US, Ontario Canada, and abroad.

“Advanced Transformer Infrastructure is the required next step to

improve grid reliability and resilience,” said Alan Snook, President
of GRID20/20.

“As our insatiable desire to adopt clean (renewable) energy

accelerates, and related mandates continue to be enacted,
Distributed Energy Resources (DER) is growing rapidly. The
undeniable problem is that our aging transformer fleets were never
designed, nor even conceived to handle reverse energy impacts
commonly introduced by DER. This reality sets the stage for a
series of costly grid reliability, safety and resilience concerns,”
added Snook.

According to the press statement, the new IoT turnkey solution

with sensors and a suite of robust analytics capability provides
operators with intra-grid information enabling them to reduce
power outages, lessen serious fire/wildfire risk, and avoid damaging
financial liability.

Source: GRID 20/20

Transformer Technology September 2019 15

Issue 3

ABB names Björn Rosengren as CEO

The Board of ABB has appointed Björn Rosengren as Chief

Executive Officer.

He will join ABB on February 1, 2020 and succeed CEO, Peter Voser,
in this role on March 1, 2020. At that time Peter Voser will revert to
his position at ABB solely as Chairman of the Board.

Björn Rosengren (60), a Swedish citizen, has been the CEO of

Sandvik, a high-tech global engineering group, since 2015. Prior to
that, he was CEO of Wärtsilä Corporation, and spent some thirteen
years (1998-2011) in a variety of management roles at Atlas Copco.

“The Board is pleased that Björn Rosengren will be taking the lead
at ABB, bringing with him a proven track record of value creation
and exactly the managerial skills ABB needs during the next stage
of its transformation,” said ABB Chairman and current CEO, Peter
Voser. “After undertaking a thorough search, the Board is convinced
that Björn Rosengren is the best candidate for the role.”

CEO-designate, Björn Rosengren, said: “I am honored to have the

opportunity to join ABB, a truly global technology leader, after I
have completed my current commitments. At such a pivotal time
for manufacturing industries, ABB must continue to best serve the
needs of global customers with a unique technology and digital
solutions portfolio to help enhance their productivity.”

Source, Photo: ABB

New research substation opened for testing and online monitoring

Electric Power Research Institute (EPRI) has designed,

constructed and commissioned a full-scale, three-phase, outdoor
138 kV substation at its High-Voltage Laboratory in Lenox,
Massachusetts.

The research substation includes all the key components of a

utility substation: transformer bushings, an SF6 circuit breaker,
a disconnect, buswork, arresters, post insulators, and composite
poles.

The substation is now operational, with the transformer bushings

both energized and subjected to high current.

The substation is a tool for rapid and cost-effective knowledge

gathering on how new substation components (such as new,
oil-free bushings) perform over time and how on-line monitoring
technologies (such as on-line bushing monitoring and on-line partial
discharge detection) respond to a wide range of scenarios.

The Lenox location provides conditions for the assets to experience

cold winters with ice and snow, warm springs, and summers with
fog from the adjacent river. A spray system has also been installed
to increase the wetting rate.

Source: T&D World

16 Coming
Events

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AND KNOWLEDGE
ARE IMPORTANT
TO US

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 Transformer Technology September 2019 17

Issue 3

Coming CWIEME Americas

September 17-18, 2019

Events
CHICAGO, IL

Electric Power
Reliability Summit
September 17-18, 2019
AUSTIN, TX

Coiltech 2019
September 25-26, 2019
PORDENONE, ITALY

Advanced Research
Workshop on
Transformers -
ARWtr 2019
October (6)7-9, 2019
CORDOBA, SPAIN

EuroDoble
Colloquium 2019
October 20–23, 2019
PORTO, PORTUGAL

IEEE Transformers
Committee - Fall
Meeting
October 27 - 31, 2019
COLUMBUS, OH

The Transformer
Experience –
Weidmann 18th
Annual Technology
Photo by Shutterstock

Conference
November 5-7, 2019
SAN ANTONIO, TX
18 AT A GLANCE

TIRONI successfully completes short circuit test on ester-filled 400

kV transformer and a new 400 kV autotransformer

Italian transformer manufacturer TIRONI has successfully

completed the short circuit withstand test on its first 400 kV
prototype filled with natural ester.

The 250 MVA, 400 kV autotransformer was tested at the CESI lab in
Rondissone, Italy. The company will now start a series production
of these autotransformers that will be in service in the Italian
transmission network.

The manufacturer has also successfully short-circuit tested their

first prototype of the 250 MVA, 400/135 kV autotransformer that
was manufactured for the Italian transmission system operator
Terna.

The test was performed at the lab in Rondissone and the

transformer, once the final checks at the factory are complete, will
be certified according to client’s requirements.

Source, Photo: TIRONI

Siemens to cut 2,700 jobs and optimize power transmission

products business

Siemens has informed its employee representatives about further

long-term measures related to the establishment of Siemens’ Gas
and Power (GP) Operating Company that has led to significant
synergies and optimization of support functions.

The plans, as they have now been presented, call for reducing
approximately 2,700 jobs worldwide over the course of several
years, with around 1,400 of these jobs being in Germany.

At the same time, Siemens highlighted that the growth-oriented

Vision 2020+ strategy concept will also be reflected in workforce
development, with an expected net increase of around 10,000 jobs
worldwide within the same time period.

Other new measures also address the power transmission products

and systems business.

Siemens says the transformers and switching technology markets

are burdened by excess capacities, requiring measures for
optimizing cost structures and capacities at all locations. Doing
so will help preserve the competitiveness of these locations, the
release said.

In addition, across the GP Operating Company, bundling and

optimization has reduced the need for some of the services
provided by support functions.

Source, Photo: Siemens

Transformer Technology September 2019 19

Issue 3

China’s longest 1,100 kV transmission line goes online

China has launched its longest extra-high voltage (EHV) power

transmission line, connecting the far western region of Xinjiang
and the eastern province of Anhui.

The 2,065-mile (3,324-km) transmission line with voltage of

1,100 kV is designed to transmit 66 billion kilowatt-hours (kWh) of
electricity a year.

Most of the electricity transmitted by the line will come from the
Zhundong coal-fired power plant in northern Xinjiang.

This project will help meet increasing power demand in

industrialized eastern regions and reduce the amount of wasted
electricity in the west.

According to the State Grid Corporation of China, by the end of June

the country had 18 EHV lines with overall transmission length of
17,131 miles.

Source: Reuters

Manitoba Hydro completes one of the largest HVDC projects in

North America

A provincial Crown Corp., Manitoba Hydro commissioned the

Bipole III project, completing its third HVDC transmission line that
will deliver renewable hydroelectric power produced in northern
Manitoba to customers in southern Manitoba, Canada.

This 860-mile (1388 km), 500 kV HVDC transmission project took

five years to construct and it was one of the largest construction
projects in North America.

The new line interconnects two new converter stations – the

Keewatinohk converter station located on Fox Lake traditional
territory, northwest of the town of Gillam in northern Manitoba, and
the Riel converter station, just east of Winnipeg. The design and
construction of the converter equipment was completed by the
consortium of Siemens Canada Ltd. and Mortenson Construction.

With temperatures in Manitoba nearing 40°C (100°F) summertime

and going as low as -50°C (-58°F) in winter, all equipment used
within the converter stations had to meet these challenging
temperature extremes, including the large HVDC converter
transformers, which were manufactured and delivered from
Germany.

Source, Photo: T&D World

20 AT A GLANCE

Brazil transmission companies start removing GE current

transformers

After an unusual number of explosions involving the same

transformer model, several Brazilian power transmission
companies started removing transformers made by General
Electric.

Brazil’s grid operator ONS recommended replacing the CTH-

550 transformer model after registering 53 explosions, saying
the equipment showed “a failure rate that is superior to what is
expected” for this equipment, reports Reuters.

There are approximately 700 pieces of these units in Brazil’s grid.

Power transmission companies have already launched tenders
to buy replacement transformers as they discuss the costs and a
schedule for the changes with GE and regulators.

GE is investigating what caused the equipment failure in Brazil.

In a statement to Reuters, GE said: “GE Grid Solutions performed
a series of checks in the equipment with its clients and, as of this
moment, there is no evidence that the problems were caused by the
design, components or production processes.”

Brazil’s electrical energy regulator Aneel said that, after conducting

a detailed analysis, it has determined the problem is with the
manufacturer.

Taesa, one of Brazil’s largest power transmission companies, and

Colombia’s ISA ISA.CN already started replacing this model of
transformers in their networks. Due to the changes and lead times,
the process is expected to take one year.

Source: Reuters

ABB to supply 100 transformers for offshore wind project in

North Sea

ABB has won an order from MHI Vestas Offshore Wind for
the supply of its compact WindSTAR transformers for
installation in wind turbines in the North Sea.

Under the project, 100 transformers manufactured in the

transformer factory in Vaasa, Finland, will be supplied for Moray
Offshore Renewable Power’s Moray East offshore wind project.

The 295 square kilometer windfarm will contain wind turbines

up to 670 foot (204 meters) tall to the turbine’s blade-tip, each
with the capacity to generate 9.5 MW of electricity at 66 kilovolts.
This will be made possible by the transformers that are compact
enough to be placed inside the wind turbine.

The windfarm will have a capacity to generate 950 MW of

renewable wind power in Moray Firth (an inlet of the North Sea)
off the coast of Scotland, and be capable of providing
enough clean energy to power up to a million households.

Source, Photo: ABB

Transformer Technology September 2019 21

Issue 3

South Korea awards large HVDC order

Korea Electric Power Corporation (KEPCO), South Korean largest

electric utility, awarded ABB Power Grid’s business with an order
to build two new HVDC converter stations.

One substation will be located on the mainland to convert the

power from alternative current (AC) to direct current and transfer
the electricity by undersea cable with almost no losses to Jeju
Island, South Korea’s largest island, where the other substation will
convert the current back to AC for distribution.

The high voltage direct current (HVDC) converter stations will

provide an additional 200 MW of power to Jeju island, enough to
provide electricity to 500,000 homes.

Additionally, the voltage source conversion (VSC) technology will

also be implemented to help the utility to operate the island’s
existing interconnections more efficiently by providing additional
stability and by minimizing the risk of power outages.

Source, Photo: ABB

MPF Weidmann paper factory increases production of

transformer board

Weidmann Malyn paper factory (MPF Weidmann), Ukraine’s only

producer of electrical insulating board for power engineering
machines including transformers, announced it increased
production by 8.6% in the period of January-May 2019.

According to the UkrPapir association, the paper mills’ output of

transformer board rose by 29.7% to 2,190 tonnes.

MPF Weidmann is a member of the WICOR international group, and

it is the only company in Eastern Europe that can supply almost
all kinds of electrical insulating paper and cardboard that meet
regional and international standards.

Source: Open4business.com
22 AT A GLANCE

Qualitrol appoints new President

Qualitrol announced that Andrew McCauley has been appointed

president.

With over 20 years of experience in leadership across multiple

industries and with Qualitrol’s parent company, Andrew McCauley
has a proven track record of being a trusted leader with a
commitment to the customer experience which will be an asset as
Qualitrol continues to accelerate growth, the company said in the
press statement.

Prior to accepting the role of President of Qualitrol, Andrew held

senior roles at Pacific Scientific and Kollmorgen in addition to
his most recent position as the President of Specialty Products
Technologies Company in Elizabethtown, NC.

Andrew has a BS in Electrical Engineering from Virginia Tech and an

MBA from the University of North Carolina, Chapel Hill.

Source: Qualitrol

PFIFFNER International acquires Swiss high-voltage test

systems developer

HIRSCHTHAL, SWITZERLAND – PFIFFNER International AG, a

solution supplier for customers in the sectors of electrical energy
and rolling stock, announced the acquisition of HAEFELY TEST
AG, member of the HUBBELL Group prior to the transaction.

HAEFELY is a Swiss high-voltage test systems and instrumentation

producer and developer based in Basel, Switzerland, whose
customers are electric utilities, industrial manufacturers of products
for the electric energy sector and general industrial manufacturers.

HAEFELY will remain active on the market under the HAEFELY

brand.

„I’m very pleased to welcome all employees at PFIFFNER

International. Both companies share the passion for current and
voltage as well as for innovative technology and products for the
electric energy sector what will ease the integration of HAEFELY in
our Group” said Fritz Hunziker, the chairman of the board and the
owner of the PFIFFNER Group.

With this acquisition, four Swiss brands – PFIFFNER Instrument

Transformers, MOSER GLASER, ALPHA-ET and HAEFELY are now
aligned under one roof.

Source: Pfiffner Group; Photo: HEAFELY

Transformer Technology September 2019 23

Issue 3

Siemens successfully tests one of the world’s largest

autotransformers

Siemens has successfully short-circuit tested and certified a

single-phase 500 kV autotransformer with a power rating of
300 MVA.

The tested unit is one of the largest short-circuit tested

autotransformers in the world and has been certified by a third-
party testing laboratory in the Netherlands.

The 225-ton autotransformer was manufactured in Siemens

Transformers factory in Guangzhou, China from where it was
transported to the Netherlands for testing.

After the initial test in the Netherlands, the transformer was shipped
back to China for further customer acceptance tests and visual
inspection of the active part, before it received a certificate of short-
circuit performance.

The design and service application for this type of transformer is to

be typically used for areas with large transmission distances, such
as those in Asian and South American countries.

Source, Photo: Siemens

Shermco Industries acquires Electrical Manufacturing and

Distributors

Shermco Industries, Inc., an independent provider of electrical

testing, maintenance, and repair services in North America,
announced that it has acquired Electrical Manufacturing and
Distributors, Inc. (EMD).

EMD is a provider of process controls services including automated

control systems design, systems integration, electrical engineering,
custom programming, and fabrication of power distribution centers,
electrical racks, and control panels.

Shermco is majority-owned by San Francisco-based Gryphon

Investors, a middle-market private equity firm. Terms of the
transaction were not disclosed.

Source: PR Newswire
 24

Smart Grid Business Development

Interview with John McDonald Leader at GE Grid Solutions

John McDonald
Feature
Interview

Photo: GE
Transformer Technology September 2019 25

Issue 3

John McDonald was in sixth grade when he realized he wanted to be an electrical engineer. A half century
I started adding
intelligence to
the grid in the
work I was doing later, he is a legend in the industry.

going back to 1974

when I started
doing my full-time
engineering work.
26 Feature
Interview

John McDonald was in sixth grade when he realized he wanted to be an electrical

engineer. A half century later, he is a legend in the industry. McDonald is an active
member of the IEEE Power & Energy Society, a subcommittee chair of the society’s
Long Range Planning Committee, and a mentor to young professionals entering
the field. McDonald has authored and co-authored more than 100 technical
papers and articles and five books. Alan Ross spoke with McDonald about the
smart grid (both past and present) and what seasoned professionals can do to
help young generations enter the ever-changing field of transformer technology.

Transformer Technology: What are your with me and I don’t work with others.” We will
thoughts on the Smart Grid, and how have you not have a smart grid with proprietarization.
seen technology progress towards that goal How have you been able to bring more of
recently and in the past? an integrated approach to it through your
involvement with IEEE?
John McDonald: About 12, 13, or 14 years ago we
started hearing the term “Smart Grid,” but a lot
of us that had been in the industry a long time
initially kind of took offense to it, because this
JM The days of standalone devices
are long gone. But it only works if
the different vendors with their technology
wasn’t new. I started adding intelligence to the components all comply with the same set of
grid in the work I was doing going back to 1974 standards. There’s much more emphasis today
when I started doing my full-time engineering on industry standards and that’s why IEEE
work. is so important as a standards development
organization. Even though there are 39 societies,
I actually call it the “Smarter Grid.” and 7 councils in IEEE, the Power & Energy
I differentiate what intelligence we have been Society writes over 50 percent of the standards.
adding to the grid over the past 20 to 30 It just shows, with respect to the grid, how
years, and what is so different [now]. The important standards are.
biggest difference is that we have a lot of new
technology that is being developed much more I have chaired the substations committee,
quickly than ever before, and it gives us much and we have 500 experts writing all the
more functionality. There are many, many more standards for the substation. Up until about
things that we can do on the grid than we were the mid-90s, everything was proprietary. The
able to do before. communications and automation were all
proprietary, because we didn’t have standards

TT What are some examples of the

advancements that define the
“Smarter Grid?”
that we could point to that were accepted for
the industry and that were mutually agreed
upon. That changed in the mid-90s, and
from then on, the industry requires industry

JM For a long time, we were getting data

from the field every two to four
standards that are not proprietary.

seconds. And that’s what we call the scan rate

of the SCADA master station—the Supervisory
Control and Data Acquisition system. But
TT In what ways do you help young
professionals and students in IEEE
enter the field?
now, with synchrophasers, we can get 40 to 50
samples per second compared to one sample
every two to four seconds. We get so much
more insight into how the grid operates and it
JM I tell students and young professionals
the three things that you can really
benefit from when you are involved with IEEE.
just gives us much more capability to do more. One is technology. Two is your network. Three is
leadership experience.

TT I have a personal passion against

proprietarization—when software or
equipment sellers say “buy my thing, it’s the
First, the best way to learn technology, and to
truly learn in depth, is to volunteer to write a
only thing, and I control it; you have to work standard on that technology.
 Transformer Technology September 2019 27

Issue 3

I differentiate the
intelligence we have
been adding to the
grid over the past 20
to 30 years from the
technologies that we
have now. What we
have now I call the
“Smarter Grid”.

You don’t write a standard about what you’ve

done in the past, or what you’re doing today—
but you do have to have a vision for the future.

You are in a room with lots of industry experts

from different organizations. You’re learning
from everybody and everybody is learning
from you. When you write a standard you can
get that input from all the people there. It is
so valuable and so rich—it’s information that
you would never get just by going to work every
day at your own company. You really learn the
technology in depth and you also learn where
the technology is going because you’re writing
the standard for the future.

Second, you expand your network with really

key industry context. These people that you’re
working with become lifelong friends, and if
you ever get into a situation with your work
where you’re stumped and you’re not sure
what decision to make, or you need some
more information, you have a vast network of
industry people that you can always talk to.

Third, IEEE is a volunteer organization and in

my 48 years being an IEEE member I’ve grown
as an engineer and industry leader, gaining
Photo: GE

valuable leadership experience through many

leadership positions I’ve held.
28 Feature
Interview

TT How can IEEE help you grow as an

engineer and an industry leader, and
do so at your own pace?

JM You really cannot do it in your own

company, because it takes time
to advance in a company. But at IEEE you
could do it instantaneously. Volunteer for
Up until the leadership positions. If you’re interested
in developing a particular standard, find
mid-90s, everything out where the next meeting is, attend the
meeting, and volunteer to write a part of a
was proprietary chapter for a new standard.

because we didn’t I started in the substations committee in 1987

as a working group member, but within one
have standards that year our working group chair moved on and
we had an opening to chair that working group
we could point to and I volunteered. Within a year I was the
chairman of the working group, and I had just
that were accepted joined the year before. There are unlimited
opportunities to get really good leadership
for the industry and experience.

mutually agreed
upon. That changed
TT Many of the Legends I have spoken to
as part of this series are Eagle Scouts,
and so are you and your son. Tell us about that
part of your life.
in the mid-90s, and
from then on, the JM My father went through scouts
himself and he really, really enjoyed
the benefits of it. My grandparents were
industry requires active, and my dad took my [younger] brother
and me and made sure we were in Cub Scouts.
industry standards My mom was our den mother, so my mom had
the den meetings in the afternoon. My dad
that are not was Scoutmaster for a while in Boy Scouts.
We went through Boy Scouts
proprietary. with a lot of support from
our parents. I’m a kind of
a very driven person, very
competitive. I’m the type of
person who always wants
to see things through. The
challenge of getting the ranks
and the merit badges… that
was important to me.
I became an Eagle Scout and
I found that it really helps.
[It] not only helps you with
your resume, but it also helps
you. In Scouts you’re not only
managing peers, but you’re
also managing adults, the
leaders of the troop. I said that
when I hopefully got married
and had kids of my own, I’d
hopefully have a son, and I
would make sure my son had
the same opportunities [my
parents] gave to my brother
and me.
 Transformer Technology September 2019 29

Issue 3

TT You’ve run a
program called
Key Insights in Career
Management for IEEE PES
student members and young
professionals. How did you
do it, and why?

I tell students and young

professionals the three
JM I was going to be
talking to all of
the IEEE PES student members in the US and
Canada at the IEEE PES student congress.
things that you can really We always have technical talks on different
technical subjects, but it is very important
benefit from when you for students and young professionals to get
some mentorship and some guidance in their
are involved with IEEE. career. I went through 45 years of my full-time
engineering career and thought about key
One is technology. Two decisions and key things that really influenced
the rest of my career, and I found that there
is your network. Three is were 12. I laid out those 12, but I wanted to
present them in a way that was fun and
leadership experience. entertaining, but still impactful, so I used a lot
of family photos, business photos, and some
photos from IEEE PES meetings and trips.
The impact has been great both within IEEE
and with my own company, as a webinar or in
person. There’s a link on the IEEE PES Resource
Photo: GE

Center so that anyone in the world can access

it and hear what I had to say.
30 BEST PRACTICES
FOR A HALF
CENTURY

Best Practices
for Transformer
Testing and A well-maintained transformer
can last more than 50 years. If you

Maintenance
catch a fault condition early, there
are corrective actions you can
take to prevent further damage to
the transformer and avoid costly
downtime from catastrophic
by Jason Dennison failure.
and Bob Rasor

Most of the time the transformer

“just sits there and hums like it
always does” behind a fence, out of
sight, out of mind, which can give a
false sense of security of just how
much risk resides in the transformer
Photo: SDMyers

should things goes awry and in

terms of business expense and
production loss.
Transformer Technology September 2019 31

Issue 3

Jason Dennison is the Senior Manager of Di-

agnostic and Analytical Services at SDMyers,
LLC. Dennison leads the world’s largest trans-
former liquid testing laboratory with a team
focused on safe operation while generating
high volume data analysis and diagnostics.
He obtained a bachelor’s degree in Chemical
Engineering from the University of Akron with
Polymer Specialization and is a Lean/Six Sig-
ma Black Belt with project management ex-
perience spanning industries such as rubber
processing, metal machining, petrochemi-
cals, compliance, software development, lab-
oratory chemical hygiene and processes, and
data analytics and diagnostics. He is a mem-
Sampling and Inspection ber of IEEE and ASTM and presents nationally
as an authority on transformer fluid analysis.
Liquid sampling and visual A thorough inspection should also
inspections are crucial parts of any include infrared (IR) scanning of
effective transformer maintenance key areas such as the bushings,
program. It’s most efficient to connections, radiators, cables,
schedule inspections at the same the transformer tank, and the
time as liquid sampling because the preservation system to look for
person pulling the sample is already inconsistencies in the thermal profile
on site. After taking a fluid sample, of the unit. Infrared scanning is
the technician can inspect and record not as cost prohibitive as it once
the vital pieces of information about was. The cost of IR equipment has
the transformer, such as: dropped dramatically over the past
• Gauge readings – Record
temperature and liquid levels.
several years, and there are many
service companies that provide
Robert T. Rasor is Director of Transformer
Services at SDMyers, where has been a ded-

• Preservation system – Check gas

pressure, desiccant condition, and
IR scanning as a service, with
some also offering diagnostic
icated member of the engineering team for
41 years. Rasor has worked in several posi-
pressure relief devices. information. tions from a product design and field com-

• Radiators – Check for corrosion,

fan operation, and pumps. When pulling the liquid sample, it
missioning engineer to his current role di-
recting field service, operations, and plant

• Surfaces – Check for corrosion,

assess the condition of the paint,
is crucial to do so in a manner that
ensures the sample is representative
management. He supervised global PCB
operations facilities in eight countries and
and check the seals. of the entire volume of liquid in led a manufacturing group that designed

• Bushings – Check for corrosion

and issues with connections and
the transformer. This is key to
ensuring the quality of the liquid
and delivered hundreds of pieces of cus-
tom and production oil process equipment.
coatings. analysis. ASTM D923 provides basic He is active in technical societies such as

• General area condition – Observe

and record vegetation control,
instruction on proper sampling
practices, and most labs will provide
IEEE, and is the active chair for C57.106,
the Guide for Acceptance and Maintenance
check for pests, and assess the sampling instructions on how to of Insulating Mineral Oil in Electrical Equip-
condition of the substation fence. draw accurate samples. ment. Bob is the Technical Director for SDM.
32 BEST PRACTICES
FOR A HALF
CENTURY

Typically, the sampling process starts

at the sample valve , located near the
bottom of most transformers. The first
step is to flush liquid through the valve
in order to clear out stagnant liquid
in the valve body that may not be
representative of the rest of the liquid
inside the transformer. This liquid is
waste and must be handled according
to regulations from bodies such
as the EPA, and according to your
organization’s spill containment plan. Transformer oil sampling

Did you know? Convective and conductive forces inside the transformer play a
key role in homogenizing the liquid and its characteristics inside the tank of the
transformer. This homogenous liquid is what you want to send as a representative
sample to an analytical lab.

Transformer oil Sample containers vary based on the

testing lab test performed. Containers for tests
such as liquid screen, power factor,
moisture analysis, and dissolved gas
analysis will include a plastic bottle,
a glass bottle, and a glass syringe.
It is considered best practice to
fill the containers in the order of
the sensitivity of the analysis.
The container for DGA testing,
for example, should be filled last,
because it allows as much liquid to
flow through the sample valve as
possible to get the most representative Oil sampling
sample of the liquid inside the containers
transformer. All sample containers
Photo: SDMyers

should also be clearly labeled to pair

the sample with the transformer from
which it came.
Transformer Technology September 2019 33

Issue 3

Accurate data alone is not enough to keep an

electric power system viable. You need to be able
to make good decisions based on that data.

Transformer oil
testing lab

Liquid Testing

There are a great number of tests that This group of tests is the foundation Other specialized tests exist to
can be performed on dielectric liquids for assessing the health of a determine certain impurities or to
that can help assess the health of a transformer. Depending on the confirm physical properties of the
transformer. The most common tests criticality of a transformer—the liquid, such as Corrosive Sulfur, Flash
are indicators of general aging and estimated impact of potential loss— and Fire Point, Particle Counts, and
contamination, moisture incursion, further testing may be required. Filming Compounds.
and incipient faults. These tests are: These tests can be performed during
• Liquid Screen – A group of tests
that looks for premature aging of
routine testing or when diagnostics
suggest that an issue is present.
This is not an exhaustive list of tests
available, and there are other tests
the dielectric fluid. A liquid screen Some of these tests include: that may be useful too. These tests
can also point to contamination
from internal issues such as
• Power Factor – This test can
indicate liquid breakdown,
are typically ordered based upon
the results from regularly scheduled
coking or sludge, or external issues contamination, and, in some cases, testing.
such as contamination from other moisture.
liquids. • Inhibitor – Transformer oil typically Ultimately, which tests to perform at
• Karl Fischer – This test
determines the presence of
includes an inhibitor to help
prevent oxidation, which can lead
what interval is a decision that asset
owners should make through the
moisture in the dielectric liquid, and to premature aging of the liquid. lens of maximizing the reliable life of
the liquid temperature determines The weight percentage can be the transformer.
the percent saturation of water. determined by this test.
This is an important test because
moisture in dielectric liquids can
• Furan Analysis – A byproduct of
paper degradation is the formation
A transformer powering the light in
the parking lot, for example, would
lead to oxidation and formation of certain compounds, called be considered less critical than a
of acids that degrade the solid furans, which can be correlated transformer that powers a data
insulation. to the tensile strength of the solid center or operating room. It’s also
• Dissolved Gas Analysis (DGA) – insulation in the transformer. important to view the power system
A DGA detects the presence of key
gases that can identify incipient
• Metals in Oil – By burning off
organics in the liquid, this test can
as a whole. Performing an impact
assessment across the power
faults from low- to high-energy determine very low quantities of system can identify opportunities
events and can point towards issues metals such as aluminum, copper, to shore up the reliability in any
with the solid insulation. and iron. operation.
34 BEST PRACTICES
FOR A HALF
CENTURY

Diagnostics

The key
Accurate data alone is not enough is left over from the welding process
to keep an electric power system during manufacturing. Pairing to useful
viable. You don’t need just the the guide recommendations with
data; you need to be able to make practical knowledge, it is possible
good decisions based on that data. to make an informed decision on diagnostics is
Translating data into insights requires whether to perform ongoing DGA to
expertise. be sure that the result is not indicative
of a fault and to establish in understanding
While industry organizations like a baseline for future analysis.
NFPA have standards on manual
sampling, and ASTM has standards Diagnostics should be action the actual
on sampling liquids and performing oriented. It is common for experts
tests, many standards are available
that can assist in diagnosing the
to see early warning indications of
problems in test data, and for them
transformer so
condition of a transformer. IEEE to recommend further action. Often,
guides such as C57.106 and C57.104, however, these warnings are ignored. that the guides,
and IEC guides such as 60567 and Many failures could have been
60599, pertain to acceptance criteria avoided if they had been addressed
and result interpretation. earlier. standards,
The key to useful diagnostics There are thousands of transformers
is in understanding the actual in our database that are more than and practical
transformer so that the guides, 50-years-old. Achieving this length
standards, and practical experience
can be used in concert to assess its
of service depends on the people
responsible for maintenance having a experience
health. For example, without practical reliability mindset and the capability
knowledge of the transformer, the
recommendations in the guides
to address warning signs as early
as possible. Some issues can be
can be used
might state that the level of acetylene fixed without an outage, though
in a DGA of a new oil-filled cabinet many issues do require planning in concert to
transformer is a concern, and a shutdown. While inconvenient, a
recommendations range from “test it planned outage is much more cost-
again” to “purchase a DGA monitor” effective and manageable than assess its
to “shut it down immediately.” an unplanned event that could
But it is possible that the acetylene severely disrupt operations for an
inside the new cabinet transformer undetermined period of time. health.

Monitoring

The field of remote transformer

monitoring devices and services has
been developing for many years.
However, as our industry better
understands the capabilities and as
communication technologies become
more cost effective, the field is gaining
traction. System security is improving
but will continue to be a key issue
for the advancement of monitoring
devices that require connectivity,
particularly as more of what is traditio-
nally “Operations work” leans more
heavily on IT infrastructure and support.

It is common to test a transformer via

laboratory analysis one to four times
per year at routine intervals. DGA monitoring
 Transformer Technology September 2019 35

Issue 3

Laboratory testing and continuous monitoring are both

here for the long haul. The best reliability plans will exhibit
the flexibility to capitalize on both types of data.

The advent of continuous monitoring analysis. The best reliability plans will related to its tensile strength.
changes the landscape on the exhibit the flexibility to capitalize on Shorter cellulose molecular chains
quantity of data available by orders both types of data; the pairing of all mean lower tensile strength and
of magnitude. This volume of that data with in-depth knowledge will weaker paper.
data can be a powerful asset for drive an organization toward more
understanding the ongoing condition intelligent decision-making. Oxidation and moisture degradation
of a transformer. It does, of course, weaken the paper insulation. Acids
change some of the skillsets required Oxidation, Aging and are created in transformers due
to care for critical assets. The Reliability to oxidation and will weaken/age
job market for business and data the insulation. Since the insulation
analysts is exploding as companies The paper insulation is what gives strength (DP) is based on the
come on board with data-rich the transformer its mechanical cellulose molecular chain length,
applications. It is no longer enough strength. This remains the most damage from acids (created during
to just acquire data; you must also be prominent factor in the reliable life of oxidation) to the chain results in
able to make it understandable and your transformer. The term “reliable lowered tensile strength for the
actionable. life” refers to the transformer’s ability transformer’s eventual inability to
to take on expected stresses— withstand original design stresses.
Laboratory testing and continuous load variations, surges, lightning, The damage is irreversible.
monitoring are both here for the and temperature variations—
long haul. Traditional laboratory and maintain servicing levels and The paper insulation exists in a
analysis generates high quality, high frequency. mineral oil environment. If the oil
integrity data from systems and stays in acceptable condition, the
processes that have been honed over How Does the Insulation paper has an optimal environment
decades against methods that are Weaken? to maximize its life and reliability.
defined by standards bodies such However, oil is a hydrocarbon
as ASTM. Continuous monitoring Short answer: oxidation and and subject to the chemical laws
as an emerging technology is going moisture degradation. Strength governing it. Heat, moisture, and
to play an increasingly larger role in is measured by the Degree of oxygen are present in transformers
helping asset owners make faster Polymerization (DP). DP is a and cause oxidation where acid is
maintenance decisions, and the measurement of the average length formed, as well as other destructive
volume of the data can be used for of the cellulose molecule chains that oxidation byproducts, including more
trending and for more sophisticated make up the paper and is directly moisture.

These acid compounds are polar

and are attracted to the paper and
absorbed by it — even as they are
created. The acid builds up and
weakens the paper by breaking bonds
and shortening the cellulose chains
(lowering DP), meaning the tensile
strength lowers. As noted, moisture
is also destructive to paper, so
keeping moisture levels in acceptable
Photo: SDMyers

ranges is also important (see IEEE

Field Reconditioning Guide C57.140,
Section 7.2).
36 BEST PRACTICES
FOR A HALF
CENTURY

What Are Aging

Indicators?

Regular intervals of fluid testing true, however, that the paper can a transformer, moisture and heat
are economical and also still the also oxidize independently of the oil. can be reduced. Passive dryers
most commonly used means to 2. Initial small amounts of this acid work, but if load and ambient
monitor transformer reliability. Aging are first absorbed by the paper are driving up temperatures,
indicators include elevated acid, insulation. Oil levels remain in the additional auxiliary cooling may
lowered IFT, elevated moisture and “acceptable” range. At this point, also be needed to reduce these
Liquid Power Factor along with the keeping oxidation inhibitor at the components to oxidation.
creation and presence of furanic proper levels will continue to retard 3. Apply Oxidation Inhibitor to
compounds. When cellulose paper oxidation. the oil. Inhibitor is a primary
degrades, furans are liberated. Furans 3. The “questionable” range is when way to combat oxidation and is
are created from the paper and to take action with oil processing. supported by IEEE C57.106. As
found in the oil. They are measured Keeping the acid below the the oil produces free radicals, the
in parts per billion. Additionally, there damaging range will avoid loss of oxidation inhibitor will react with
are more chronic aging dissolved the paper insulation’s strength. and stabilize them, thus stopping
gases present, such as carbon 4. Once the acid has reached 0.1 mg the oxidation chain reaction in its
monoxide (CO). Electrical testing and KOH/g, damage has begun, and earliest stages. Ideally, oxidation
the strength of the insulation also action is vital. Stop further damage inhibitor levels should be kept at
correlate to Insulation Power Factor. with Hot Oil Cleaning. Despite the 0.3 percent or greater.
name, Hot Oil Cleaning cleans
Typically, the age of a transformer the insulation, not just the oil, by What about damage already done?
does not necessarily affect its ridding the insulation of destructive Once the cellulose is damaged,
performance—unless there is a acids and sludges. At this stage, insulation life cannot be restored. The
fault condition. Severely overheated furans can be rising and may be damage is irreversible. Here are some
transformers can degrade rapidly. 500 ppb or greater. points to consider:
It is important to make sure cooling
packages are working properly and
5. Once furans are over 1,000 ppb,
the paper will show significant
• Hot Oil Cleaning improves the
condition of the insulation. The
levels are maintained. If fluid levels damage. Any action taken can slow smaller the amount of acid in the
drop below the cooling ports, severe further damage but will not recover insulation, the lower and slower is
damage can happen quickly. Visual what has been lost. its destructive effect.
inspections of all the mechanical
aspects of a transformer must be a How is the acid in the transformer
• There is a point whereby, looking
at the condition of the insulation,
part of all sampling and services. corrected? Hot Oil Cleaning and the oil, and results from other
absorptive clay treatments can create important indicators such as IR
Can the Damage from a solvent-like action to dissolve and and electrical testing, the best
Acids Be Limited? remove the acid and sludge. As the oil course of action is to replace the
is heated and cleaned, it also cleans transformer.
Yes, at first. But as time goes on
and corrective action is deferred, the
the paper insulation when done with
the proper treatment recipes. The
• Consider the past furan and DP
levels prior to oil reclamation. Most
acids and other oxidation products controlling factors for effectiveness oil processing with clay filtration
eventually form sludge, which leads are heat, dwell time, and adsorbent such as Hot Oil Cleaning will strip
to localized overheating. Heat is clay in a vacuum oil purifier. furans from the oil.
one of the necessary conditions for
oxidation. Therefore, additional heat How can you slow or prevent Consider the time and temperatures
further intensifies the oxidation, oxidation? Processing services needed for proper and complete
and again, results in more water exist to prevent, slow, or even stop cleaning. Oil can be cleaned in just a
that further intensifies oxidation. oxidation. Here are a few common few passes in lower temperatures.
Servicing the still reliable paper approaches in our industry: It takes more passes at a higher heat
insulation early will limit damage. 1. Control the moisture. Moisture to provide adequate cleaning of the
The acid, being polar, is quickly reduction is key to slowing and paper. If the oil only is cleaned and the
absorbed into the paper and leads stopping oxidation. As much as paper left untreated, within months
to detrimental effects, namely small 75 percent of transformers with the acids will come back out of the
and larger amounts of acid that will oxidation issues in our database paper and oil qualities will again move
eventually cause damage and have an accompanying moisture away from the “acceptable” range.
can be corrected. There are widely presence. It can be a little confusing
accepted stages to this aging as to which came first, since Healthy insulation is promoted by
process: moisture not only causes oxidation, controlling the harmful byproducts
1. Acid is usually first generated in the but is also a byproduct of oxidation. of oil oxidation. This optimizes the
oil by oxidation from the presence 2. Dry and cool the oil. Where strength of the paper insulation which
of heat, oxygen, and moisture. It is oxygen from the air is present in is the reliable life of the transformer.
 Transformer Technology September 2019 37

Issue 3

As the oil is
heated and
cleaned, it
also cleans the
paper insulation
The reliable life of the
transformer depends on the
integrity of its paper insulation.
when done
with the proper
Combustible Gas Issues
treatment
Combustible gas levels are an Some leach back is expected for the
indicator of an abnormal condition first several months.
in a transformer. They are created recipes. The
by excessive localized or general Staying ahead of leaks and
overheating. Extreme temperatures
and arcing are identified by a key
maintaining the correct level
is another important aspect of controlling
gas: acetylene. These conditions are reliability in transformers. The regular
typically acute and must be dealt with
immediately. The following are typical
visual inspection assures this. It is
recommended to perform a visual
factors for
steps taken to correct them: inspection no fewer than four times
1. Retest to confirm the condition. a year. The following are some of the effectiveness
2. Arrange an immediate inspection aspects of the inspection:
and include electrical testing,
depending upon the severity. Many
• Level in the transformer. Keep in
mind, some training is required are heat, dwell
issues can be field-corrected. to interpret the level gauge with
Untanking is rarely done in the field, respect to the temperature of the oil.
so there are repairs that require Oil expands 1 percent for every 10 time, and
taking the unit out of service and degrees Celsius. A 25-degree Celsius
shipping it to a repair facility.
3. Drain and perform an internal
measurement is “normal” or “low” if
the oil temperature is significantly adsorbent clay
inspection. higher than 25 degrees Celsius.
4. Make repairs in the field, when • Leak inspections.
in a vacuum oil
possible.
5. Refill the transformer. Care must
• Gauge information. A consistent
“zero” psi on a pressure vacuum
be taken to fill with the proper gauge often indicates a leak, as the purifier.
procedures. Vacuum rated transformer is not holding pressure
transformers must be vacuum or vacuum. A transformer with a
filled if the core has been exposed. leak is “breathing” ambient air and,
UHV units require a complete drain therefore, humidity in and out of
and fill any time the oil is lowered. the transformer. The moisture is
however typically only “in” as the oil
If refilling a lower voltage unit, and insulation have a high affinity
cleaning can be performed with a for moisture.
cartridge filter. Consult with OEM • Paint and rust condition.
requirements. In this case, the oil
will still contain combustible gases
• Bushing and insulator surface
condition.
•
Photo: SDMyers

and it must be degassed with a Overgrown vegetation in the

vacuum oil purifier. This will reset the substation that could lead to a
gas levels. flashover.
38 BEST PRACTICES
FOR A HALF
CENTURY

Best Practices Reliability Outcomes

Whether you’re conducting oil handle changes discovered while Data supports the principles and
processing, doing transformer repair, on site. action-related reliability steps in this
or electrical testing, there are best
practices that are important to follow
• Ask that the provider have an
equipment reliability program to
paper. In a paper published by CIGRE
and the IEEE, which considered 1,500
for safety and reliability. assure excellence in the equipment transformers, the transformers with
being sent including safety gear services to combat oxidation and
It is helpful to define procedures inspection and key calibration moisture showed more than six years
and equipment to optimize the records. of extended life per service rendering.
services rendered. For instance, in
oil processing, it is important to not
• Refer to C57.106, the “Oil Guide,”
which can be used for oil quality
This doubled the life of the average
transformer, which was reported in
just filter oil, but also to address requirements. many studies to be under 20 years.
cleaning the paper insulation. When
oil processing, require pumping
• Follow IEEE C57.93 and C57.140
for field drying and vacuum filling. Additionally, by maintaining frequent
records to assure the temperature Be aware of the required set times visual inspections and regular fluid
and passes will achieve the required after filling before energizing when and electrical testing, the probability
results. Reaching 70 degrees Celsius the core is exposed. of a surprise lapse in reliability is very
is optimal to allow the oil to reach the
aniline point where it can dissolve oil
• Ask that the provider have an
equipment reliability program to
small. As indicators trend toward
aging, plans for contingency and an
generated sludge and acid assure excellence in the equipment acceptable timetable for a planned
being sent, including safety outage will negate further concerns
Additionally, moisture cannot gear inspection (PPE) and key for a lapse in power provision.
be corrected by “pumping” on a calibration records.
transformer, as there is approximately There are transformers backed up
100 times more moisture in the paper Environmental by spares or double-ended subs. We
insulation than there is in the oil. Considerations refer to these more important units as
Instead, use either vacuum dryout being system critical. Units that shut
techniques or online moisture dryers,
as defined by the Field Guide of IEEE,
• Be sure the provider has Field
SPCC (Spill Prevention Control
down operations, or huge segments
of your operation, are considered
C57.140.7. Online dryers are effective and Countermeasures) training, mission critical. This reality takes the
in moisture reduction. including the use of spill berms, units with the mission-critical rank
and that they have a spill kit on and looks at condition or monitoring
Selecting and Working with site. and moves them to the top of the
a Contractor • Process units from lowest to
highest so as to never add to
priority list. Meanwhile, a system-
critical unit in bad shape will also be
It is always important to contract with the PCB content of the next
an experienced provider with a proven transformers. If you have PCBs,
safety record and a well-documented expect some surcharges—there are
training program. There are a number legitimate costs to do it right.
of contractor-related criteria to be
included in the scope of the project.
• Be aware of the advantages of
the new Ester liquids. These are
Always create a written, clear scope popular for a reason as they hold
of work for any bidding purposes. up well. They are fire resistant
This will help avoid short cuts and (Fire Point of 300 degrees Celsius)
define expectations. and they are eco-friendly. Ester
fluids can be processed in most
As mentioned, you should require equipment with a pre- and post-
pumping records to achieve the flushing adder. Getting some
required results when oil processing. esters in oil is not much of an
When electrical testing, make sure it issue, but too much oil (>6 percent)
is defined as who is disconnecting will lower the flash point.
and grounding. When hiring a
contractor, you should:
• Use a filtering clay when oil
processing equipment that
• Define work hours and how
to handle changes that are
improves acid. There are
environmentally friendly solutions
discovered while on site. At a for regeneration that avoid landfill
minimum, have the provider control or incineration of the oily waste.
and monitor moisture and the In general, you can expect a drum
acidity of the oil. of waste for every 3,000 pumping
• Define work hours and how to gallons of oil.
 Transformer Technology September 2019 39

Issue 3

a top priority and warrant a spare or

double-ended sub.

When power and people’s lives are

at stake, a backup electric source
might be in order, as well as a backup
generator and reliable fuel source.
Hospitals and mines are good at
this. There are product and service
providers who have designed levels
of commitment based on non-
critical and system or mission-critical
transformers.

Even reliable transformers need

contingency plans. On mission-
critical units, the need and timeliness
for the required power restoration
leads to double-ended subs, spares,
and generators — all components
of contingency plans. Some main
By maintaining frequent visual
transformers are supported by
the power supplier with spares inspections and regular fluid and
or mobile substations to restore
power in four to eight hours. Some
operations cannot live with any electrical testing, the probability of a
power interruptions and need a
generator and an adequate fuel
supply. Production, engineering surprise lapse in reliability is
and finance departments play
roles in determining the best fit
for a reliability program and the
very small.
contingency programs for each
power system.
Photo: SDMyers
40 BETTER
TESTING METHODS

Three Tips
for Reducing
Wasted Time
When Testing
Transformers Brandon Dupuis received a B.S. Electrical
Engineering from the University of Maine.
He joined OMICRON electronics Corp. in 2013,
by Brandon Dupuis where he presently holds the position of
Regional Application Specialist for trans-
former testing. Brandon’s focus is currently
on standard and advanced electrical diag-
nostics for power transformers and circuit
breakers. Presently, Brandon is a well-known
OMICRON instructor teaching electrical trans-
former diagnostic testing theory, applica-
tion, and test result analysis, which includes
both presentations and hands-on training.
Brandon is an active member of the IEEE
PES Transformers Committee.

The transformer test that

customers most struggle
with is the transformer
Power Factor test.
 Transformer Technology September 2019 41

Issue 3

Review the “Power Factor Performing offline electrical tests on transformers can be time-consuming,
Checklist” Prior to Testing especially when the field measurements are not captured correctly the first
time. This article identifies the electrical transformer tests that test equipment
Without a doubt, the transformer users often struggle to perform efficiently and correctly. Three field-testing
test that customers most struggle tips will be provided, to address the transformer tests that are often “time-
with is the transformer Power Factor suckers”. By building awareness, test equipment users can better avoid
test (which includes the Overall the situations where a significant amount of time is lost due to retesting,
Test, the Bushing C1 Test, and the troubleshooting, and collaborating with test equipment manufacturers.
Bushing C2 Test). Unfortunately, the
Power Factor test is highly sensitive
to the test environment, to the test
lead connections, and to the test
• Are the surfaces of the bushings
dry (and reasonably clean)?
in resistor”, which has been
known to influence the Power
specimen’s earth-ground connection, Moisture on the surfaces of Factor measurements, when the
among other things. Since the the bushings can significantly transformer is tested in the neutral
Power Factor measurement is highly influence a Power Factor tap-position. Specifically, Federal
sensitive, obtaining the correct (i.e. the measurement. In most cases, Pioneer Electric and Federal Pacific
valid) Power Factor measurements in using a clean, dry rag to dry Electric transformers with LTCs
the field is challenging. the surfaces of the bushings have been known to exhibit this
is sufficient. In cases where behavior.
The high sensitivity of the Power Factor excessive surface contamination
test is a double-edged sword: On one
hand, the high sensitivity makes the
on the bushing surfaces is
present, using Windex or Collinite
• Ensure that the exterior surface of
the test equipment’s high-voltage
Power Factor test a powerful tool for may be used to clean the surfaces cable is not touching any surface
identifying compromised insulation of the bushings, and thus, of the transformer, at the “far end”
(e.g. moisture ingress, contaminated may improve the Power Factor where the test terminal is being
oil, a “bad bushing”, etc.). On the other measurements. energized.
hand, the high sensitivity makes A conservative approach is to
the Power Factor test prone to
measurement error.
• Are the groups of bushing
terminals short-circuited together?
ensure that the last two feet of
the far end of the test equipment’s
All primary side (H) bushing high-voltage cable is not touching
To save wasted time and prevent terminals must be shorted the transformer tank, the surfaces
from retesting, troubleshooting, and together, and all secondary side of the bushings, etc.
collaborating with test equipment (X) bushing terminals must be
manufacturers, the following Power
Factor Checklist should always be
shorted together. Always use
NON-insulated conductor(s) to
• Be aware that the test
environment can significantly
reviewed, prior to executing any short-circuit the bushing terminals influence a Power Factor
Power Factor measurement: together when performing a Power measurement.
Factor measurement – Do NOT - Do not Power Factor test in the
• Are the transformer tank and the
test-equipment solidly grounded
use insulated shorting leads. If
insulated conductor(s) are used,
rain.
- Avoid testing in high-humidity
to earth-ground potential? then the conductor’s insulation can situations (where excessive
Not connecting the test specimen easily become part of the Power moisture is present).
and the test equipment to a solid Factor insulation measurement. - Avoid Power Factor testing
earth-ground reference is the most Also, connect the shorting when the temperature of the
common mistake test equipment jumpers as tightly as possible transformer oil is below 0°C.
users make in the field. from bushing-terminal to bushing- - Power Factor test after lunch, if
terminal (in other words, do not let possible (which is typically when
• Are the bushing terminals of
the transformer completely
the shorting jumpers sag and/or
touch any surface other than the
the least amount of moisture/
humidity is present).
disconnected and isolated from all terminal being energized).
cable, bus-bar, support insulators, The Power Factor Checklist is
surge arrestors, etc.?
When applying a test-voltage of
• Remove all in-service grounds
from any neutral bushing
intended to help test equipment users
“get the measurement right the first
10 kV, a minimum clearance of 3 terminals. time”, which is the most practical
in. should be established (between For example, remove the in-service strategy to saving wasted time when
the terminal(s) that is energized ground-connection from the X0 testing transformers. In conjunction
and all other surfaces). Avoid bushing terminal, if applicable. with the Power Factor Checklist, the
using a rubber blanket, insulated Variable Frequency Power Factor
gloves, etc. to isolate the bushing • Place the LTC in any off-neutral test can be utilized by test equipment
Photo: Omicron

terminals from external surfaces – tap-position. users, to quickly and easily confirm
the best insulator for Power Factor Some transformer Load-Tap- that the Power Factor measurements
testing is air! Changers (LTCs) utilize a “tie- obtained are indeed correct.
42 BETTER
TESTING METHODS

Identify Incorrect Power

Factor Measurements
Before Leaving the Job Site

One of the most common scenarios Table 1.

we encounter as a test equipment
manufacturer is when a customer Case Study - Lapp POC 138 kV Bushings (1998)
contacts us to review a set of power
transformer test results. Often, the Measured Power Factor Nameplate Power Factor
data set is provided after the test (10 kV - 60 Hz) (10 kV - 60 Hz)
equipment user has left the job site
H1 0.36% 0.29%
and returned to the office. Upon
reviewing the data, we (OMICRON) H2 0.24% 0.23%
frequently identify incorrect
Power Factor measurements, and H3 0.35% 0.23%
recommend that the customer retest,
to obtain the correct results.
Consider the bushing C1 Power Factor
Regardless of whether the measurements shown in Table 1,
transformer is still offline or has which were obtained from testing
been re-energized, once this scenario three Lapp POC 138 kV bushings. By
occurs, a significant amount of a only analyzing the 10 kV-60 Hz Power
company’s time and resources have Factor values, it is not obvious that
been wasted. If the crew returns to the the Power Factor measurements are
field to retest, then time and resources incorrect; however, notice that the
are wasted testing a second time. Variable Frequency Power Factor
If the transformer has already been traces for the three bushings in Figure 1
re-energized, then the company are erratic and jagged. In general,
invested time and resources to obtain jagged frequency-sweep tra-
invalid test-results that cannot be ces are indicative of inva- “Getting the measurement
used to assess the condition of the lid Power Factor measure-
transformer. ments. In this case, the cus- right the first time” is the
To quickly identify and correct “bad”
tomer determined that they
did not short-circuit the pri- most practical strategy to
Power Factor measurements before
they leave the job site with the incorrect
mary side (H) bushing ter-
minals of the transformer,
saving wasted time when
test results, test equipment users can when the C1 Power Factor
measurements were perfor-
testing transformers.
utilize the Variable Frequency Power
Factor measurement. With a Power med on the bushings.
Factor measurement at one test-
voltage and at one test-frequency
(in other words, with one Power Factor Figure 1. Variable Frequency Power
percentage value), it is difficult for the Factor results for three Lapp POC
test equipment user to verify that the 138 kV bushings
measurement is even valid; however,
invalid measurements often become 0.60%
obvious when the Variable Frequency H1 H2 H3
Power Factor measurement is 0.55%
performed and analyzed.
0.50%
Power Factor (%)

The Variable Frequency Power Factor 0.45%

test involves performing Power Factor
measurements at a series of different 0.40%
test frequencies (e.g. 15 Hz, 30 Hz,
0.35%
45 Hz, 60 Hz, 150 Hz, 200 Hz, 300 Hz,
and 400 Hz). The general guidelines 0.30%
used to assess the Variable Frequency
Power Factor test (along with several 0.25%
case studies) are provided in the paper
0.20%
Photo: Omicron

titled “The Value of Performing Power

0 100 200 300 400
Factor Sweep Measurements on
Bushings” [1]. Frequency (Hz)
Transformer Technology September 2019 43

Issue 3

To quickly identify and

correct “bad” Power
Factor measurements
before they leave the job
Consider the Overall Power Factor Table 2.
site with the incorrect test
measurements shown in Table 2 and
Figure 2, which were performed on a
results, test equipment
Overall Power Factor
Kuhlman 118 kV oil-filled transformer. Measurements users can utilize the
The 10 kV-60 Hz Power Factor
measurements look “normal” for an Kuhlman 118 kV transformer
Variable Frequency Power
oil-filled transformer, but upon
reviewing the Variable Frequency
Measured Power Factor
(10 kV - 60 Hz)
Factor measurement.
Power Factor traces, the customer
CH 0.16%
noticed that the CH frequency-sweep
trace looked abnormal. Notice that as CHL 0.22%
the test frequency increases, the CH
trace approaches 0% Power Factor,
and even becomes negative. Negative
Power Factor measurements are Figure 2. Variable Frequency Power Factor
typically a tell-tale sign of an invalid results for a Kuhlman 118 kV transformer
measurement.
0.30%
If the test equipment user only
had the 10 kV-60 Hz Power Factor
measurements on-hand, then it is 0.20%
conceivable that they would have CH CHL
Power Factor (%)

overlooked the incorrect measurement.

In this case, the customer determined 0.10%
that the transformer tank and the test
equipment were not connected to a
solid earth-ground reference potential. 0.00%
0 100 200 300 400
With the Variable Frequency Power
Factor traces on-hand, test equipment -0.10%
users can quickly identify invalid
measurements, and can retest
before they leave the job site with the -0.20%
incorrect test results. Frequency (Hz)
44 BETTER
TESTING METHODS

Select the Appropriate

Test Current – DC Winding
Resistance

The field transformer test that test

equipment users most struggle with
(other than the Power Factor Test) is
the DC Winding Resistance Test. The
DC Winding Resistance Test is the
offline measurement for identifying
bad connections and discontinuities
along the current carrying path of a
transformer winding [2]. Specifically,
the DC Winding Resistance Test is
an invaluable tool for identifying bad
connections associated with tap-
changers, which includes both De-
Energized Tap-Changers (DETCs) and
Load-Tap-Changers (LTCs).

In theory, the DC Winding Resistance

Test is a simple concept that relies
on the fundamental application of
Ohm’s Law (V = I x R) [2]; however,
in practice, obtaining the correct
transformer resistance measurements
is challenging, because to obtain
the correct measurements, the
transformer’s core must be saturated.
The most common mistake that
test equipment users make when
performing the DC Winding Resistance
Test is not waiting long enough for
the core to fully saturate (in other
words, the resistance measurements
are captured “too soon”). Typically,
when the resistance measurements
are captured “too soon”, the measured
resistance values are higher than
expected, which makes it appear that
there is a bad connection, even when
no fault exists.

The best strategy for saturating the test current in the range of 5-10 A secondary side, a test equipment
transformer core quickly, and in turn, is sufficient – most resistance user often has anywhere from
obtaining the correct resistance measurements performed on 57-99 resistance measurements
measurements quickly, is to inject as the primary side (H) winding of a to obtain (that are often well
high of a DC current as possible into transformer have resistance values below 100 mΩ in magnitude). In
the winding under test. The higher the greater than 100 mΩ. these cases, it is important that a
injected test current, the faster the
transformer core saturates, the faster
• Typically, when testing winding
resistances less than 100 mΩ, a
sizeable test-current (e.g. 20-30 A)
is available to the test equipment
the test is performed. The following test current in the range of user, so that they may perform the
guidelines are intended to assist test 20-30 A is ideal – most resistance lengthy test-sequence as quickly,
equipment users with selecting the measurements performed on the and accurately, as possible.
appropriate test current for a given
winding resistance measurement:
secondary side (X) winding of a
transformer have resistance values
• The test-current should not exceed
10% of the rating of the winding
less than 100 mΩ. under test.
• The lower the resistance of the
winding under test, the higher the
• Load-Tap-Changers (LTCs) in
North America are most often
• The test-current multiplied by
the resistance (of the winding
Photo: Omicron

test-current should be. applied to the secondary side (X) under test) should not exceed the
• Typically, when testing winding
resistances greater than 100 mΩ, a
winding of a transformer. In cases
where the LTC is located on the
maximum compliance voltage
rating of the test instrument’s DC
Transformer Technology September 2019 45

Issue 3

The best strategy

for saturating the
transformer core
quickly, and in
turn, obtaining the
correct resistance
measurements
quickly, is to inject as
high of a DC current
as possible into the
winding under test.
current source. In general, the more for the primary side test, and one for References
power (VA) the test instrument’s the secondary side test) should be [1] B. Dupuis, “The Value of Performing
DC current source is rated for, the applied when performing both tests. Power Factor Sweep Measurements
higher the test current that can be The most common mistake made is on Bushings,” Transformer
injected into a given winding, the NOT injecting enough current when Technology, Issue 1, pp. 56-64, June
faster the DC Winding Resistance performing the DC Winding Resistance 2019.
Test can be performed. X test, which often leads to a lengthier [2] C. L. Sweetser, “Obstacles
core-saturation time, and inaccurate Associated with Winding
To summarize, test equipment users measurements (especially when an Resistance Measurements of Power
often attempt to apply the same LTC is involved). Transformers,” Omicron.
magnitude of test current for both
the DC Winding Resistance H and DC Again, the best way to reduce
Winding Resistance X tests; however, wasted time when testing
since the magnitude of winding transformers is to get the
resistance is often significantly measurement right the first time.
different when comparing the DC
Winding Resistance H and DC Winding
Resistance X tests, it is conceivable
that two different test currents (one
46 ADVERTORIAL

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Identify Problems | Prevent Failures | Manage Risk
Transformer Technology September 2019 47

Issue 3

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This allows you to effectively identify developing
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48 REDUCED OIL
DEGRADATION
& AGING

Transformer Aging, Degradation

and Online Oil Maintenance
by Jean Saayman
Stuart Chambers
and Bruce Sunga

During a transformer’s service life, numerous electrical

phenomena and other stresses can occur that degrade
the physical and dielectric properties of its oil and
paper. The degradation processes are primarily chemical
in nature and are accelerated by the presence of
promoters, such as acids, oxygen, water, and other
contaminants. If the degradation processes are left
unchecked, it will eventually compromise the integrity
of the equipment. Electric utilities should continually
monitor and reduce the level of contaminants and
oil degradation products in transformers in order to
maintain the equipment’s performance, prevent failure,
and prolong the equipment life. Studies show that by
removing these promoters from the oil, the life of a
transformer can be significantly extended.
 Transformer Technology September 2019 49

Issue 3

Dr. Jean Saayman is a Process Engineer in

Powertech’s R&D, Investigation & Consulting
department, where he is responsible for con-
tinued research in online decontamination
and reconditioning of insulating oils. His ar-
eas of expertise include transfer processes,
experimental design, transformer diagnos-
tics, and insulation degradation and aging.
He also manages Powertech projects for im-
plementing online oil reconditioning services
and conducts failure investigations of electri-
cal utility assets.

Dr. Bruce Sunga is the Director of the Sub- Dr. Stuart Chambers is the manager of R&D,
stations Technology and Testing sector at Investigation & Consulting, as well as a lead
Powertech Labs. He brings more than 25 for the polymer and materials investigation
years of commercial, industrial and electric facility in Powertech’s Substations Technol-
utility experience in areas of stations and sys- ogy & Testing group. His areas of research
tem planning, analytical studies, asset manage- and development include transformer diag-
ment, project management, design, automa- nostics, insulating paper degradation, aging
tion, R&D, construction, testing, commissioning properties of insulating oils, and polychlorin-
and acceptance, failure investigation and main- ated biphenyls (PCB) decontamination. He
tenance. The Substations Technology and Test- has completed substantial research into in-
Photo: Powertech Labs

ing sector is comprised of two world-renowned sulating solids, fluids and gases for the Elec-
labs, a prestigious R&D and investigations tric Power Research Institute (EPRI), Canadi-
group, a substations studies group, and field an Electrical Association (CEATI), BC Hydro
testing services and asset management group. and other research organizations.
50 REDUCED OIL
DEGRADATION
& AGING

The benefits of maintaining low The

moisture concentrations are
established knowledge in the electrical degradation
industry; however, as a greater
understanding of the degradation
processes
process has been gained via research
and development, the benefits of
are primarily
removing the other contaminants
has come to light. Powertech Labs
chemical in
has conducted several laboratory nature and are
investigations into the formation of
these byproducts and the benefits of accelerated by
removing them, and has successfully
developed, studied, and implemented the presence
novel online purification techniques
on operational field transformers. of promoters,
This article provides an overview of
the aging process of transformers,
such as acids,
the chemistry involved, and which
compounds and byproducts further
oxygen, water,
promote aging. and other
Transformer Aging contaminants.
There are five prominent
contaminants present in transformer
insulating oils: Moisture
• Moisture Furan, moisture and dissolved CO and moisture content has been identified
• Acids CO2 are the main byproducts of cellu- as a critical parameter to maintain
• Polar Compounds lose (paper) degradation (Figure 1). assets. L.E. Lundgaard et al [1]
• Corrosive Sulfur Cellulose based degradation typically correlated the life expectancy of a
• Dissolved Gases occurs due to overheating of the
paper, which ranges from low energy
transformer to the Water Content of
the Paper (WCP). Figure 2 illustrates
The focus of this article will be on items such as hotspots to high the logarithmic nature of this effect.
moisture, acids, polar compounds, energy events such as arcing. The
and corrosive sulfur and the resulting decomposition compounds,
formation of sludge. Dissolved gases and water from degrading
gases can also promote the aging cellulose dissolve into the oil as they Not only
process, however the benefit of are being formed. Oil has a saturation
gases as a fault tracking method capacity for water and acts as a do these
can outweigh this effect. Elevated carrier of the water to the paper
levels of dissolved gases also present where it gets re-absorbed into the contaminants
other operational issues unrelated
to transformer aging and, for these
paper. This absorbed water “attacks”
the cellulose and thus promotes deteriorate
reasons, there are limits at which
the benefits do not outweigh the
further degradation which in turn
produces more water and other
oil quality
drawbacks. contaminants. The process creates
a positive feedback effect and can
and promote
Figure 1. Furan, moisture and
results in a rapid deterioration of the
paper’s Degree of Polymerization
further aging
dissolved CO and CO2 are the
main byproducts of cellulose (DP). It is for this reason that the of the paper,
they are also
(paper) degradation

precursors to
sludge.
Photo: Powertech Labs
Transformer Technology September 2019 51

Issue 3

Figure 2. Correlation of the life expectancy of a transformer form from the laminates, spacers,
to the Water Content of the Paper (WCP) glues, and wood. Like moisture,
these contaminants also promote
10000
Adopted from: Lars E. Lundgaard
and increase the rate of aging.
et al, Aging of oil-impregnated A simplified yet comprehensive
paper in power transformers,
IEEE Transactions on Dielectrics
overview of the various contaminants
1000 and Electrical Insulation, Volume that can form is shown in Figure 3,
Life Epectancy (years)

19, Issue 1, Jan. 2004 Page(s):

230 - 239 which includes details on the types of
Dry Paper stress and components that generate
1% WCP these contaminants.
100
2% WCP
3% WCP Not only do these contaminants
deteriorate oil quality and promote
10 further aging of the paper, they are
also precursors to sludge [2]. In
particular, polar functional groups like
peroxides, organic acids, alcohols,
1
aldehydes, ketones, and furans are
50 60 70 80 90 100 110 120 130
the culprits. The precursors tend to
o
Temperature ( C) polymerize to form larger and larger
molecules. Eventually the molecules
Acids, Polar Compounds cannot dissolved or suspended in the
and Sludge oil, and crash out as solid deposits,
Although moisture is a significant a.k.a. sludge. Sludge in a system
problem and well understood, there can inhibit the flow of oil causing
are other contaminants that are the core to overheat and, in turn,
generated in an aging transformer increase the rate of aging. Once
with affects as detrimental, or sludge has formed, it is impossible
worse, than moisture. These other to remove without shutting down
contaminants that are generated the transformer, draining the oil and
from paper and oil include; acids, physically removing sludge from
acetone, methanol, polar compounds, the internals. This is an involved,
and other oxidation products. costly, and difficult process and can
Phenolic compounds, acids, and be avoided by simply managing the
additional polar compounds can dissolved sludge precursors.

Figure 3. An overview of various contaminants

generated in an aging transformer

COMPONENT STRESS PROCESS/ INITIAL PRODuCTS PRODuCTS

GAS PHASE
ARCING
MINERAL OIL CORONA H2, CH4, C2H2,
ELECTRICAL H2, CH4, C2H6,
H2, C2H2, C,
CO2, Co, C2Hy,
(CxHy) CH4, Co, CO2,
(Ionizing Electrons) Co, CO2, C3Hx
Aromatics
CELLULOSE
Paper DECOMP PYROLYSIS LIQUID
Pressboard THERMAL DEHYDRATION H2, C2H4, CH4, Unsaturates, PHASE
H2O C2H6, Furans, Aromatics, Furals,
(Heat) Co, CO2 Co, CO2 Phenols,
METALS Acids,
Iron Ketones,
CATALYTIC OXIDATIVE
Copper Free Radials, Ketones, Metals, H2O,
OXIDATIvE Polar, Other
Peroxides, Acids, CO2, H2O,
OTHER (O2, Peroxides) Reduced DP Furans
Resin SOLIDS/
Glue CATALYTIC HYDROLYSIS SUSPENDED
Enamel HyDROLyTIC Acids, Furans, Sludge,
Moisture Lower DP, CO2, Phenols, Particles,
(H2O, Acids) Furans Acids Fibers,
Sugars,
Metals
50 100 200 500 1000 1500

Increasing Temperature C, (energy) O

52 REDUCED OIL
DEGRADATION
& AGING

Corrosive Sulfur The traditional

An additional contaminant that is
harmful to transformers is corrosive methodology
sulfur. Certain sulfur species attack
copper, creating copper sulfides which
of maintaining
dissolve or deposit onto the paper.
These deposits cause an increase
oil quality is to
in conductivity of the paper and will
eventually result in a breakdown of
replace the oil,
the insulation. There are pass or but new online
fail (qualitative) oil tests, like ASTM
D1275, which identify corrosiveness; technologies
however, it gives no information on
the responsible sulfur species. It is for have now been
this reason that the general term of
“corrosive sulfur” is used. Note: not all developed,
sulfur species are corrosive.
meaning an
There is one specific corrosive
sulfur species that was identified
extended
over a decade ago when a sudden
increase in transformer failures was
outage is not
observed. The qualitative tests failed required.
to identify problematic oil, and no
obvious pattern to the failures could
be discerned. Powertech Labs (and
several other organizations) performed and Powertech Labs proceeded to Extending the Life of a
investigations to identify the corrosive developed methods to selectively Transformer
sulfur species and ultimately remove DBDS and other corrosive As the science behind some of
discovered that Dibenzyl Disulfide sulfur species from transformer oil. the aging processes has become
(DBDS) was the common denominator Of all the contaminants which can apparent, methods to slow the process
in the failures. When referring to eventually lead to the demise of a and extend the life of a transformer
corrosive sulfur, the electrical industry transformer, corrosive sulfur is the only have become clearer. In practical
typically and historically solely refers one which doesn’t continuously form terms, one of the main methods to
to DBDS. This contaminant had but can go undetected in standard oil slowing the aging of a transformer is
significant cost implications for utilities testing programs. to maintain the oil in a good state—

Figure 4. One platform, multiple uses

Corrosive
LTC Oil Sulfur
Dehydration Regeneration Degassing Purification and
Unit Unit Unit Contaminant
Removal Unit

Common platform, different cartridges for different functions

 Transformer Technology September 2019 53

Issue 3

not only for the purposes of good demonstrated results showing that
dielectric properties, but also for the the transformer oil was cleaned to as
purposes of controlling the promoters. new condition in terms of dielectric
The traditional methodology of strength, acid content, power factor,
maintaining oil quality is to replace color, interfacial tension (IFT), and
the oil, but new online technologies other oil quality parameters. The
have now been developed, meaning an advantages of this technology are:
extended outage is no longer required.
Most of these online technologies
• It can operate online with an in-
service transformer, avoiding
are comparable to the concept of system shutdown.
dialysis—they are devices that are
connected to a transformer in a loop
• It allows for significantly lower cost
than other methods.
arrangement, taking out a small flow
rate of oil, processing it, and returning
• It can be installed in a few hours and
left unattended.
the clean oil to the transformer. The
method by which the oil is processed Specific benefits Powertech added to
is selective adsorption, which allows their Online Oil Decontamination Unit
it to remove specific contaminants. (OODU) system are:
Removing the contaminants not
only reduces the promoters but it
• Safety features which include leak
detection sensors, flow disruption
also improves and regenerates the sensors and solenoid valves as
dielectric oil quality. ways to safely and automatically
shut down the unit.
The Online Maintenance
Industry
• Capability to selectively perform one
or more functions, including removal
of acids, moisture, corrosive sulfur,
Services and equipment that utilize PCBs, or degassing of the oil.
these online oil treatment technologies
to restore oil quality without requiring Conclusions
equipment outages are becoming
more prevalent. However, the majority
By eliminating Many assets were originally designed
of suppliers offer online options only
for dehydration or use a non-selective
moisture, with a lifespan of a few decades in
mind. With aging assets and tighter
adsorbent material for removing the acids, operational and capital budgets,
contaminants from the oil, requiring extending the life of a transformer has
significant amounts of time and and polar been a key topic of research for many
adsorbent. Newer offerings include electrical utilities. Research has found
online oil decontamination systems compounds, that by eliminating moisture, acids, and
which use proprietary absorbent
technologies to selectively remove the life of the polar compounds, the life of the paper
can be extend by several decades. By
other contaminants from the oil of
in-service transformers. These
paper can eliminating acids and polar compounds
the production of sludge can be
systems selectively remove all oil and
paper decomposition products (acids,
potentially prevented. All these contaminants can
be controlled by maintaining the oil in a
polar components, furans, moisture,
particulate matter, and corrosive
be extend pure state, and new technologies have
been developed to do this in an online
sulfur), restoring the oil quality to by several and continuous way.
near new conditions. After restoring
oil properties, the units keep the oil decades. By References
clean and dry at all times, preventing
eliminating
[1] “Aging of oil-impregnated paper
the accumulation of moisture and in power transformers,” IEEE
degradation products from reaching
harmful levels, thereby extending the acids and polar Transactions on Dielectrics and
Electrical Insulation, Volume 19,
life of the transformer.
compounds Issue 1, pp. 230-239, Jan. 2004.
[2] L. Lewand, “What is sludge,” NETA
Powertech has successfully
demonstrated this newer technology
from the oil, World Journal, 2006.

at several BC Hydro facilities, the production

Photo: Powertech Labs

including Kent substation, G.M.

Shrum Peace Canyon, and Stave of sludge can
Falls Generating Stations, as well as
several U.S. utilities. These field trials be prevented.
54 Transformer
Oil Properties

Balancing the naphthenic,

paraffinic, and aromatic carbon
contents of transformer oils
to improve performance and
extend transformer life
by Ronald R. Hill
and Zachary C. Patterson

Although
traditional
naphthenic oils
have provided
generally
acceptable
properties for
transformer
oils, tests have
proven that an
oil with a higher
paraffinic carbon
content can
deliver improved
performance
and extended
Photo: Exxon Mobil

transformer life.
Transformer Technology September 2019 55

Issue 3

Introduction

The composition of transformer Although traditional naphthenic oils

oils, in particular the balance have provided generally acceptable
between naphthenic, paraffinic, and properties for transformer oils, tests
aromatic carbon contents, can play have proven that an oil with a higher
an important role in determining paraffinic carbon content can deliver
the performance and lifespan of improved performance and extended
transformers. transformer life.

Ronald R. Hill is currently Global Fluids Pro-

duct Development Supervisor, ExxonMobil
Chemical Company. Employed by the com-
pany since 1992, he has previously held po-
sitions in process technology, field sales,
marketing, and marketing technical service.
Dr. Hill received his B.S., M.S., and Ph.D. de-
grees in Chemical Engineering from The Ohio
State University. Ronald can be contacted with
questions at [email protected].

Zachary C. Patterson is currently Global Flu-

ids Market Developer, ExxonMobil Chemical
Company. Employed by the company since
2007, he has previously held positions in pro-
cess technology, sales, and manufacturing.
Zachary received his B.S. in Chemical En-
gineering from The Ohio State University.
Zachary can be contacted with questions
at [email protected].
 56 Transformer
Oil Properties

The transformer oils being

compared

This article highlights the key Several typical transformer oils, all
properties of transformer oils with with a significant naphthenic carbon
different chemical compositions content (represented by the blue bars)
and the tests that were undertaken – see were compared to a new oil
in determining if oils with a higher with a much higher paraffinic carbon
paraffinic carbon content can deliver content (as shown by the green bars),
enhanced performance versus those see Figure 1. The new transformer oil
with a higher naphthenic carbon Figure 1. Percentage of aromatic with higher paraffinic carbon content
carbon content (Ca), naphthenic
content. carbon content (Cn),
was developed to provide improved
and paraffinic carbon content (Cp), properties versus typical naphthenic oil
These key properties include: based on ASTM D2140 performance.

• Oxidation stability which can

affect transformer lifespan.
70

• Gassing tendency which can

influence the ability of an oil to
60

adsorb gas under partial 50

discharge conditions.
Percent, %

• Aromatics content which can

contribute to SHE benefits and
40

negative gassing tendency. 30

• Low-temperature viscosities which

can impact cold temperature 20
operability.
• Heat transfer capabilities which
can determine transformer
10

0
loadings and size.
• Material compatibility which can
affect leak prevention.
NapOil2 NapOil4 NapOil3 ParOil

Ca, % Cn, % Cp, %

Improved oxidation stability

Figure 2. Paraffinic oil response to
BHT compared to typical naphthenic
for greater transformer
oil, based on ASTM D2112 lifespan

600 An important property of transformer

oils, and a requirement of ASTM
D3487, is oxidation stability. In
500 testing, the paraffinic oil (illustrated
by the green dots) exhibited a very
400 good response to BHT, a common
anti-oxidant used with inhibited oils,
compared to a typical naphthenic
Minutes

300
oil (shown by the black dot), as
demonstrated in Figure 2. A higher
200 paraffinic carbon content and lower
aromatic carbon content can improve
100 the oxidative stability of the oil to help
maximize transformer lifespan.

0 Figure 3 shows that the oxidation

0.00 0.10 0.20 0.30 0.40 stability of the paraffinic oil improved
BHT Measured, % by about 20% to 100% compared to
three naphthenic oils with similar anti-
ParOil NapOil1 BHT Spec D2112 Spec oxidant contents.
Transformer Technology September 2019 57

Issue 3

Negative gassing Figure 3. Oxidation stability of paraffinic oil versus

tendency three naphthenic oils, based on ASTM D2112

Another key requirement of ASTM 600

D3487 is the gassing tendency or
“degassing” performance. 500
A transformer oil with a negative
gassing tendency indicates that it 400
can adsorb gas while under electrical

Minutes
stress. A negative gassing tendency
300
is advantageous, therefore, in
minimizing the build-up of hydrogen
200
gas because the oil can adsorb gas
under partial discharge conditions in
the presence of gas bubbles. 100

The new paraffinic oil has a greater 0

negative gassing tendency than typical ParOil NapOil2 NapOil3 NapOil4
naphthenic oils, as shown in Figure 4.
Figure 4. Gassing tendency of paraffinic oil versus
The new paraffinic oil achieves strong typical naphthenic oils, based on ASTM D2300
negative gassing performance with
only a minimal aromatic carbon 20
content, as shown in Figure 5.
10
ParOil NapOil5 NapOil3
0
NapOil2 NapOil4
A transformer oil -10
Minutes

with a negative
-20

-30
gassing tendency -40
indicates that -50
it can adsorb -60

gas while under

electrical stress. Figure 5. Gassing tendency (ASTM
D2300) of paraffinic oil versus
aromatic carbon content (based on
ASTM D2140)

60

40 FAIL

20 PASS
Gassing Tendency, uL/min

-20

-40

-60

-80

-100
0 1 2 3 4 5 6 7
Ca, %
ParOil Spec
58 Transformer
Oil Properties

Figure 6. Paraffinic carbon content, naphthenic

Low aromatics content for carbon content, and aromatic carbon content,
based on ASTM D2140
SHE benefits
70 67
Naphthenic transformer oils can
contain embedded aromatic rings in 60
the molecular chain of the oil, which
can lead to a high aromatics content 50 48
46
and variability in gassing tendency.
Additionally, some naphthenic 40

Weight, %
molecules may also emit hydrogen. 31
As a result, product composition and 30
degassing performance can suffer.
20
To help counter this, the new paraffinic
oil has been developed with a very low 10 6
aromatic carbon content, as shown in 2
Figure 6. This delivers potential safety, 0
health, and environmental (SHE) NapOil2 ParOil
benefits due to lower exposure to Paraffinic Carbon Content Naphthenic Carbon Content
aromatics. Importantly, the aromatics Aromatic Carbon Content
content of the paraffinic oil is also very
consistent, providing a more constant
gassing tendency. Table 1. Viscosity dependence on temperature and composition

Low viscosities for cold

temperature operability Temperature
Viscosity, cSt (ASTM D445)
°C
Another important transformer NapOil2 NapOil3 NapOil4 ParOil
oil property is low viscosity at low
100 2.4 2.3 2.6 2.3
temperatures. The new paraffinic
oil has a very low viscosity at low 40 9.4 9.5 10.4 8
temperatures, as demonstrated
in Table 1. At -40°C (-40°F), the 0 63.7 50.7 68.2 40.6
viscosity of the paraffinic oil is about
-30 996 713 1,005 371
1,500 cSt, compared to 3,000-5,000
cSt for the three naphthenic oils, -40 3,876 3,065 5,300 1,546
based on ASTM D445.
Composition (Based on ASTM D2140), wt%
The low viscosity of the paraffinic oil
at low temperatures can be beneficial
for the cold-start of transformers in Ca 5.8 9.9 0.9 2.6
cold climates. The higher paraffinic
Cn 46 43.6 45.9 30.5
carbon content of the oil contributes
to its lower viscosity, while the higher Cp 48.2 46.5 53.2 66.9
naphthenic carbon contents of the
other oils results in much higher
viscosity.

Lower viscosity can also improve Figure 7. Mouromtseff number and importance
heat transfer by providing better oil of low viscosity
circulation inside the transformer
to facilitate effective cooling. Figure Mouromtseff Number for comparing
7 illustrates the importance of the heat transfer rates of liquid coolants:
Mouromtseff number and low viscosity.
ρ = density
An oil with a high Mouromtseff ρaKbCpd K = thermal conductivity
number equates to an oil with a good Mo =
Cp = specific heat
heat transfer rate. Because viscosity μe
μ = viscosity
appears in the denominator of the
equation, an oil with a lower viscosity
exhibits better heat transfer and more
effective cooling.
Transformer Technology September 2019 59

Issue 3

Effective heat transfer for

higher loadings or smaller Good material compatibility
transformers can prevent leaks
When considering effective heat Good material compatibility between
transfer, the thermal conductivity transformer oils and gasket materials
(k) and specific heat (Cp) of the is another important property of oils,
transformer oil are important as it can help to prevent leaks. The
properties that need to be considered. compatibility of different oils with
These properties were measured and different gasket materials was tested
compared for the paraffinic oil and using ASTM D3455. The gasket
different naphthenic oils. materials were immersed in the oils
and heated to 100°C (212°F) for 164
The new paraffinic oil exhibited hours.
higher thermal conductivity (k)
and specific heat (Cp) compared
to the more naphthenic oils tested,
as shown in Figure 8 and Figure
9. These improved heat transfer
properties allow transformers to
operate at lower temperatures, run
at higher loadings, or allow a smaller
transformer size to be used. Figure 8. Thermal conductivity at 80°C by
PLTL-73

0.155

0.150
Thermal Conductivity, W/m.K

0.145

0.140

0.135
The low viscosity
of the paraffinic
0.130
oil at low
0.125 temperatures can
NapOil2 NapOil4 ParOil
be beneficial for
Figure 9. Specific heat versus temperature
by ASTM E1269
the cold-start of
2.20 transformers in
2.15 cold climates.
2.10
Specific Heat, kJ/kg.K

2.05

2.00

1.95

1.90

1.85

1.80

1.75
20 30 40 50 60 70 80 90
Temperature, C
NapOil2 NapOil4 ParOil
60 Transformer
Oil Properties

Figure 10. Power factor by ASTM D924 at 100°C

(PF100) after gasket immersion by ASTM D3455
Figure 10 shows the measured
Power Factor of the oils at 100°C 0.35 8.0
(PF100) after immersion of the gasket 0.30 7.0
materials. While the naphthenic 0.25 6.0

PF 100

PF 100
oils and the paraffinic oil performed 0.20 5.0
similarly in the overall compatibility 4.0
0.15
testing, the paraffinic oil exhibited a 3.0
0.10 2.0
similar or lower Power Factor @ 100°C 0.05 1.0
(212°F) after the immersion. A lower 0.00 0.0
PF100 is desired because it indicates
Corkprene Nitrile - Comm
lower impurities and, therefore, less
attack on the elastomers. 0.45 0.18
0.40 0.16
0.35 0.14
This is a result of the paraffinic oil 0.30 0.12
PF 100

PF 100
having lower aromatic and naphthenic 0.25 0.10
carbon contents than most naphthenic 0.20 0.08
oils, which decreases the “solvency” 0.15 0.06
0.10 0.04
strength of the oil. The lower solvency 0.05 0.02
strength is also reflected by the 0.00 0.00
higher aniline point of the paraffinic VitonTM Nitrile - High
oil, compared to the naphthenic oils
(which is not shown here). Improved NapOil2 NapOil3 NapOil4 ParOil
material compatibility is a result of
lower solvency strength.

New paraffinic oils have demonstrated the ability to meet

requirements of ASTM D3487 and have shown capability of
exceeding performance in key tests. As a result, transformer
performance can be enhanced and its lifespan extended.

New paraffinic oil for

enhanced transformer
performance Acknowledgements
Traditional naphthenic oils have
historically provided generally
• Over 5% improvement in thermal
properties
The author of the paper would like
to express gratitude to the following
acceptable properties for use in
transformers. A new paraffinic oil
• Improved material compatibility for
less risk of leaks
employees of ExxonMobil for their
contributions and review of the article:
has been developed, however, which Caterina Tran, Aisha Mehmood,
delivers improved properties The composition of transformer oils, Andrew Broenen, Martijn Burgers and
compared to those naphthenic oils in particular the balance between Shaival Mehta.
tested: naphthenic, paraffinic,
and aromatic carbon contents, can
• Up to 2x higher oxidative stability for
extended service life
play an important role in determining
the performance and lifespan of
• More than 100% lower negative
gassing to adsorb gas under partial
transformers. New paraffinic oils
have demonstrated the ability
discharge conditions to meet requirements of ASTM
• Up to 75% less aromatics, which
offers more consistent quality and
D3487 and as discussed above,
have shown capability of exceeding
safety, health and environmental performance in key tests. As a
benefits result, transformer performance
• 40% lower viscosity at 0°C (32°F) for
better low temperature performance
can be enhanced and its lifespan
extended.
 54
Transformer Technology September 2019 61

Issue 3

After 54 years in the

transformer business,
you could say we’ve
learned a thing or two.

By 1965, Stanley D. Myers already knew

Dale Bissonette transformers like the back of his hand.
President, SDMyers
He used his expertise to maximize the
reliable life of his customers’ transformers
through oil testing and maintenance.

It helped them save money, maintain

production rates, and stay safe.

That legacy of knowledge still drives us

today. Fifty million test results later, and
we’re still discovering and innovating
new ways to help our customers create
reliable, low-cost electric systems.

Benefit from what we’ve learned.

SDMyers.com

INTELLIGENT TRANSFORMER MANAGEMENT

62 advertorial

Transformer
By Marius Marinoiu
Global Product Manager,

Hot Spot Hunting

Weidmann Electrical
Technology

Increasing need to monitor transformer hot spot

Transformer owners are increasingly operating under tighter maintenance
and capital expenditure budgets. The time has passed when transformers
were specified with hefty design margins. Today, to control costs and increase
efficiency, transformers are designed in sizes and capabilities closely aligned
with operating needs. However, at the same time utilities face an increasing
demand for high levels of network reliability and reduced interruptions. There are
many situations when the electrical system, along with its most important asset
– the power transformer – is subject to stress. For example, with the increasing
number of extreme weather events and supplying peak power in emergency
situations. In many cases there is no room for error or equipment failure.

It is widely acknowledged that the wind-

ing temperature limits the transform- As the global leader in
er loading capability. Having the abili-
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hot spot is key when operating the
transformer close to its design limita- design and manufacturing,
tions, while also ensuring the situation
is kept under control regarding trans- and a fiber optic The SmartSpacer®can
former insulation life and health.
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Use of fiber optic sensors Weidmann has the of the transformer OEM
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Fiber optic technology was applied in
transformer hot spot monitoring sev- design, produce and test ensuring that it is
eral decades ago and is continually
being improved and refined. State-of- fiber optic temperature designed specifically for
the-art design and electronic compo-
nents are increasingly used in fiber probes and insulation the transformer type,
optic monitors and controllers. With
appropriate configuration by transfor- assemblies, leading to the and tested to the highest
mer manufacturing personnel and pro-
per installation in the windings, the fiber lowest fiber failure rate. standards.
optic is capable of operating long after
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For example, a utility ordering transformers from multiple manufacturers and

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do an excellent job in installing the fiber optic monitoring systems on their
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same way, having been tested equivalently and respecting the same criteria?

The answer is consistency.

Transformer Technology September 2019 63

Issue 3

A consistent approach
Given the level of standardization applicable to
this topic and existent in industry today, the con-
sistency can be guaranteed only if the assembly
of the fiber optic temperature probe with insula-
tion component is manufactured and tested by
one, specialized entity. This in its turn guarantees
that fiber optic-insulation assemblies perform per
specifications, in the same way, while being sub-
jected to stressing elements specific to trans-
former winding, whether these elements are elec-
tromagnetic stress or physical.

SmartSpacer®

Weidmann SmartSpacer®
As the global leader in transformer insulation design and manufacturing, and
undergoes a rigorous a fiber optic monitoring supplier, Weidmann has the capability and expertise
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electrical, and for some Improper installation of the fiber-optic probes in the transformer windings can
result in inaccurate data or can potentially increase localized stresses in the
designs X ray tests to insulation system. Any discontinuity must be avoided during installation, as
well as incompatible materials such as some adhesives, and voids that can
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SmartSpacer® provides the manufacturer and end user with the confidence to
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64 advertorial

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the winding and support insulation system designs.

Functional Testing: Insulation components and embedded sensors are tested in the
Weidmann or equivalent high-voltage laboratory to demonstrate the output metrics
and applicable tolerances required for the sensor. They are suitable for use in the Marius Marinoiu has almost 20 years tech-
transformer internal environment, in both alternating voltage and impulse conditions, nical and sales experience at a global level
applicable to the BIL voltage class as specified by the power transformer operator. in transformer monitoring applications and
analytical services. He holds an Engineering
Manufacturing Processes: All components meet strict manufacturing process con- degree in Industrial Automation and Robot-
trols in compliance with drawings and specifications that preclude the possibility of ics, and a Master’s Degree in Non-Conven-
electric field stress concentration or negative impact on the transformer dielectric tional Control Systems. At Weidmann he is
system or performance. responsible for assisting in the development
and implementation of strategic sales plans
Quality: Strict conformance to written quality assurance system standards are met for the Transformer Lifecycle Product (TLP)
for components and matching sensors throughout the manufacturing, assembly, Market Segments in North America. Previ-
packaging, and shipping stages. The Weidmann Quality Management System is cer- ously he managed implementation of turn-key
tified to the ISO 9001 Standard. transformer monitoring solutions globally.
Transformer Technology September 2019 65

Issue 3

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66 BETTER DGA
CATEGORIZATION

Power Transformers:

Properly Categorizing
Developing Faults via
Dissolved Gas Analysis
by Randy Cox

What we need to know

initially is the amount
of paper involved in a
given fault, if any.
Operating an electric grid has its challenges, not the least of which is finding Randy Cox is the Domain Expertise Manag-
er for GE Grid Solutions. His current duties
additional time locating potential problems before they turn into the evening include interfacing with the industry, writing
and presenting industry related technical
news. Whether you are a District Manager, Engineering Support, Operations papers, committee work and education of
customers on the technical advantages of
Supervisor or Substation Technician, transformer Dissolved Gas Analysis GE M&D technology, products, software and
solutions. Prior to being employed by GE
(DGA) is simply one aspect of a busy day for which you are likely responsible. Grid Solutions, Randy was employed by SPX
Transformer Solutions, Inc. as the Opera-
For this reason anything that can be made easier, should be, and under normal tions Supervisor for the Texas Service Cent-
er, which included staffing and implementing
circumstances is most welcomed. While much of the chemistry behind DGA a new service center to perform transformer
installations, repair and LTC maintenance.
is complex and important for our industry chemists to understand, the day Randy has published many industry techni-
cal papers related to substation transformer
to day review of DGA by the utility need not be complex. In cases where we and circuit breaker diagnostics. He is a cur-
rent member of IEEE & a Fellow at General
may struggle to make sense of the information, there’s a wealth of industry Electric.

chemists and experts willing to assist, with regards to further, or a deeper in-

terpretation.

In this article we will identify some simple guidelines that may be applied

to assist in identifying what is involved in the fault. What we need to know

initially is the amount of paper involved in a given fault, if any. These steps

of interpretation will most certainly help to simplify the analytics regarding,

what many consider to be, a very complicated subject; categorizing (or dis-

tinguishing) developing faults within oil filled power transformers. If these

answers can be rapidly obtained, it can mean the difference between a less

costly onsite repair versus a total replacement of the transformer.

Transformer Technology September 2019 67

Issue 3
68 BETTER DGA
CATEGORIZATION

Figure 1. Similar arcing profiles for two

transformers that tripped on a transformer
differential relay operation

36 MVA Post Fault

40
The Facts
35

30
There are “knowns” in DGA. The
industry is very proficient at
25 identifying overheating in oil filled
20 power transformers. Measuring the
internal oil temperature at 150°C+
15 temperatures is accomplished by
10 the measurement of what is referred
to as the “hot metal gasses.” These
5
gasses are, in order of their initial
0 thermal generation, hydrogen (H2),
H2 CH4 C2H6 C2H4 C2H2 methane (CH4), ethane (C2H6),
ethylene (C2H4) and acetylene (C2H2).
What is not quite as well understood
30 MVA Post Fault
is the diagnosis of paper (the carbon
40
oxide gasses: CO2 and CO). It can be
35 even more challenging if the issue
exists on a paper wrapped lead.
30
To better understand how to arrive at
25 a conclusion regarding an issue, it is
20 important to note that at all working
temperatures, CO is less soluble than
15 CO2 and the higher the temperature,
10 the more CO2 remains in solution
(it will be absorbed from atmosphere
5
if partial pressure of CO2 in
0 atmosphere is greater than partial
H2 CH4 C2H6 C2H4 C2H2 pressure in the oil).

This is an important point, since

identifying “categorically” where a
problem exists, the CO2/CO ratio must
be trended.

The industry is very proficient

at identifying overheating in oil
filled power transformers. What
is not quite as well understood is
the diagnosis of paper (the car-
bon oxide gasses: CO2 and CO).
Transformer Technology September 2019 69

Issue 3

Figure 2. Post event impact on the CO2/CO ratio

in the 36 MVA transformer (top) and 30 MVA
transformer (bottom)

CO2 /CO
140

120
Trending provides critical data for
decision making, as opposed to data 100
that is a simple snapshot in time. In
80
other words, what was it prior to the
problem, or where is its norm? This 60
thinking is new to our industry, as this
ratio is typically referred to in many 40
technical publications and industry 20
guides as a single value for diagnostic
purposes. To demonstrate this more 0
fully, the following transformers both Pre Fault Post Fault
tripped on a transformer differential
relay operation with a very similar CO2 /CO
arcing profile. There’s no question
8
that a flashover occurred in both
transformers as seen in Figure 1 [1]. 7

6
These transformers had very different
problems, evidenced by the post 5
event impact on the CO2/CO ratio 4
as seen in Figure 2, maintaining the
order of these transformers. 3

2
What we now know is that the more
1
paper involved in a fault, the greater
the impact on the CO2/CO ratio. 0
Pre Fault Post Fault
Where the ratio dropped significantly,
a low side winding failure occurred
and where a paper wrapped primary
lead flashed over (minimal paper),
much less impact.

The CO2/CO ratio trending

provides critical data for de-
cision making.
70

To further illustrate the value of this generated, it did not have a negative
ratio, Table 1 presents the data of impact on the CO2/CO ratio. An
a 10 MVA transformer that tripped internal inspection revealed a failed
on a transformer differential relay de-energized high side tap changer.
operation, to which there was Even though there was no paper
absolutely no impact on this ratio, involved in the fault, when the ratio is
verifying that there was no paper compared to generation of hot metal
involved in the presence of the hot gas, the lack of impact actually tells
metal gas generated, post fault. the story. The issue was in an area
that did not support any paper being
As can be plainly seen in the above involved, thus bare metal, such as a
example, once the hot metal gas de-energized tap changer contact.

Table 1. 10 MVA transformer data

Test Date Hydrogen Methane Ethane Ethylene Acetylene CO2 CO CO2/CO Nitrogen Oxygen

9/5/2002 2 0 0 0 0 1820 221 8.235294 68476 9186

8/19/2004 4 o 0 0 0 1875 249 7.53012 80061 7268

6/16/2005 2 1 0 0 0 1951 231 8.445887 79140 7284

8/14/2006 6 3 0 0 0 3450 322 10.71429 82900 7507

8/7/2008 2119 736 44 666 1405 2530 239 10.58577 67189 7881

Testing the Theory

To better understand the effect that as the temperature continued to be

thermal, or lack thereof, has on the raised up to 180°C. The ratio had
CO2/CO ratio, an experiment was declined to 48.23:1, and at this point
conducted by Memphis Light Gas & the heating element was moved
Water on a 25 KVA transformer with so that it was no longer in contact
mineral oil and Kraft paper. A thermal with the paper insulation and was
well was installed through the wall only directly heating the oil. The
of the transformer and inserted to temperature of the heating element
a depth of 5” into the windings. A was maintained at 180°C. After the
small heating element was then element was positioned to only be in
placed into the well and raised to direct contact with the oil, the
temperatures ranging from 100°C CO2/CO ratio began to steadily rise,
to 180°C over a period of 22 days. apart from the 11/21/2014 sample,
The CO2/CO ratio started at 55.60:1 until it reached 52.55:1 at the end
at 100°C and as the temperature of the experiment. The 11/21/2014
was increased in 10-degree sample was determined to be
increments, the ratio displayed a erroneous due to all gas levels being
steady increase until 150°C was approximately half the value of the
reached. At this point, the ratio was samples taken immediately before
at 78.51:1, but began to decrease and after that date [1].
Transformer Technology September 2019 71

Issue 3

The more paper involved in

a fault, the greater the im-
pact on the CO2/CO ratio.

Why Does It Work? Summary

CO will never remain dissolved in Transformers have a home as

the oil equal to, or more than CO2. it relates to the CO2/CO ratio.
Because CO seeks to leave solution Additionally, these ratios are not
at all working temperatures relative to all the same. In some publications
CO2, the CO2/CO ratio cannot drop in it is noted that they should be
the absence of CO creation. Therefore, between 3:1 and 11:1, while other
if both gasses are decreasing relative publications say that it should
to prior samples and the ratio drops be above 7:1. The truth is that
it must be because CO is being transformers can, for the most part,
generated more than CO2, but both be just about any value. The key is
are being generated at lower levels not “what value” they display when
than are leaving the oil. Looking at the all is well, but rather what happens
design of a transformer, we can better to these ratios when issues develop
understand why the ratio of CO2 and proportional to their norm. What we
CO can be used to identify the general have learned is that where heavy
fault location. In other words, does the paper is involved (inner-winding),
problem that exists have heavy paper the ratio drops to a minimum
involvement, light paper involvement value of 65% or greater. Where
or no paper involvement. The relative less paper is involved, such as a
availability of oil to contact the paper paper wrapped lead or even outer- References
determines the available O2. The more winding, which has greater access [1] C. Rutledge, Assistant Manager,
oil that is available, the more cooling to available 02, the value drops to Memphis Light Gas & Water
and O2 available. In the windings, between 25% and 50%. Where no [2} T. Rhodes, Sr Engineering
where paper is tightly wrapped, oil paper is involved, the ratio may Technologist, Asset Information &
has less contact per volume of paper actually increase, or it may Intelligence, Duke Energy
than a lead [2]. decrease slightly.

In terms of CO 2/CO ratio,

transformers can, for the
most part, be just about any
value. The key is not “what
value” they display when all
is well, but rather what hap-
pens to these ratios when
issues develop proportional
to their norm.
72 advertorial

Tironi 400 kV Natural Ester Autotransformer:

The Successful
Short Circuit Withstand Test
The summer of 2019 has been a tremendous one
for Elettromeccanica Tironi with two very important
achievements having been accomplished within a mere
60-day period in June and July.
Transformer Technology September 2019 73

Issue 3

Cargill FR3 fluid is a natural ester

derived from renewable vegetable
oils – providing improved fire
safety, transformer life/capability,
and environmental benefits that
are superior to mineral oil and
unsurpassed by any other dielectric
coolant. Because it is derived from
renewable raw materials, it has a
The first accomplishment was a successful short circuit withstand test
neutral carbon footprint – unequalled
performed on a 400 kV autotransformer, an important step to becoming
by any other dielectric fluid option.
recognized as one of the few large autotransformers’ manufacturers to have
done so. But Elettromeccanica Tironi enters into a very reduced elite class
A transformer filled with FR3 fluid can
with the second consecutive success: Another short circuit withstand test
operate 20°C warmer than the mineral
successfully passed, on the first attempt, of a 400 kV autotransformer filled
oil equivalent while maintaining the
with Cargill’s Envirotemp FR3 natural ester fluid derived from renewable
same life expectancy of the insulating
vegetable oils.
materials. Compared to mineral oil at
the same operating temperature,
This 250 MVA, 400/135±5x2% kV, KFAF autotransformer, successfully tested
FR3 fluid actually protects the
at the CESI lab in Rondissone, Turin (Italy), is one of the largest high voltage
insulating paper up 7.4 times longer
transformers filled with natural ester. Ordered 20 months before the testing,
than mineral oil.
this unit is the prototype for Terna Rete Italia, the Italian grid management
This high temperature capability
and transmission operator.
enables:
In less than two years Tironi – the Italian transformer manufacturer estab- • Increased load capability in about
20% in comparison to traditional
lished in 1960 in Modena – was able to design and manufacture the proto-
transformers
type, overcoming several difficult challenges that required both engineering
and technological/industrial innovations. • For space constrained locations,
utilities can increase capacity while
keeping same footprint
New engineering was necessary to de-
sign a completely new unit taking In • For growing population areas,
utilities have increased load
into consideration the character- less than two
capability to better handle the
istics of FR3 natural ester in com- years Tironi was increasing demand, especially for
parison to the historically used able to design and
mineral oil. Investment in the peak hours
Modena plant was necessary
manufacture the prototype
of a 400 kV autotransformer
• Design smaller, more efficient
transformers that could use less
in order to have a fully sepa-
rated and dedicated oil plant filled with natural ester, fluid and less construction materials
for natural ester along with a overcoming several difficult
new Oil Lab. FR3 fluid has a fire point of 360°C,
challenges that required
more than twice the fire point of
both engineering and mineral oil. This greatly improves the
New Design technological/industrial
innovations.
fire safety for any transformer, either
indoors or outdoors installations.
The main goal for Tironi engineers This is particularly important in heavily
was to develop a new design of the populated areas such as restaurants,
400 kV auto-transformer, taking into con- malls, and urban communities.
sideration allof the peculiarities of Cargill’s
Envirotemp FR3 fluid. Tironi was able to accomplish this by using their internal FR3 fluid not only provides reliable
experience and design skills to produce a completely original Tironi design. performance and increased fire safety,
but it is also an excellent option to help
The main design implications that the engineers had to overcome were twofold: utilities protect the environment in their
1. The different viscosity and dielectric permittivity of the Envirotemp FR3 communities:
compared to mineral oil
2. The different stability of FR3 relative to oxidation
• Made from 100% renewable
engineered vegetable oil;

Dielectric design
• Readily biodegradable as
designated by the Environmental
As to the dielectric design considerations, the main characteristic considered Protection Agency (EPA);
was the greater dielectric permittivity εr of natural ester compared to that of
mineral oil (typically 3.2 vs 2.2). This leads to a more uniform distribution of the
• Non-toxic in both oral toxicity tests
and aquatic toxicity tests;
electric field throughout the insulation, with a reduction of the electric field in the
oil channels and an increase in the electric field in the paper. This gives different
• Has a neutral carbon footprint –
56x less carbon emissions than
proportions between oil and solid insulation if we compare it with an identical mineral oil.
unit in mineral oil.
74 advertorial

Thermal design
The thermal design of the autotransformer is considerably influenced by the
higher viscosity of the natural ester fluid which reduces the flow speed and
therefore the flow rate. This aspect is partially compensated for by the higher
thermal conductivity compared to that of mineral oil; but to maintain an equiva-
lent thermal dissipation with the same temperature gradients, it is necessary to
dimension the oil channels differently.

Mechanical design
Considering the different stability to oxidation of natural ester fluids compared to
mineral oils, it was also necessary to take some precautions in the mechanical
design, foreseeing the use of the rubber bag membrane in the conservator or
an airtight tank with nitrogen cushion. Large power transformers, like this for
Terna, already have the rubber bag but it is also important to remember to install
a “membrane rupture relay” with an alarm to the control associated with the
urgent intervention signalling (IU).

Compared with the “sister unit” with mineral oil, with the same power and voltages,
this new design – which was made with Tironi’s own software and also verified
through third party finite elements software – shows some minor differences in
the oil and overall weights (approx. 55 and 200 tons) while assuring the benefit
of using a natural ester fluid like the Cargill’s Envirotemp FR3.

Oil Plant
A new important investment allows Tironi to have a completely separate oil
plant for natural ester fluids, which allows for a fully independent storage and
treatment plant with separate oil pipes to the filling area. The storage is com-
posed of three separate compartments of 25,000 litres each, with heating ele-
ments and nitrogen generators. The treatment is composed of an adjustable
OTP up to 6,000 lt/h.

This investment has created a duplicate, although of smaller dimensions, of the

existing system for mineral oils, which assures excellent conservation of the oil.
This in turn avoids any possible contamination between the two oils.
Transformer Technology September 2019 75

Issue 3

Tironi Lab
Another significant new asset of Tironi is their new Oil Lab, a full capability
chemical lab operating within their Quality Management structure. This new lab
has been instrumental in testing new natural esters.

Lab tests, including 11 gas DGA tests, are performed in real-time, and results
immediately shared and analysed with plant technicians. These tests proved
extremely valuable in assisting the decision process during all development
phases. Fine-tuning of treatment settings, definition of operational procedures,
monitoring dielectric efficiency during each treatment step; all took advantage
of the Tironi Lab’s readily available data.

This analytical support has proven priceless, resulting in both steady

development of treatment practices and straightforward, error free transition
from experimental to operational phases.

Finally, analytics performed during the experimental phase turned into first-
hand “knowhow”, which is currently being applied to production parameter
monitoring, ensuring the processes keep within fixed boundaries.

Today, the Tironi Lab has developed fundamental competencies in natural

esters dielectric features and has grown into a prominent facility capable of
supplying consistent, real-time diagnostics.

Thanks to the accomplishments outlined above, Elettromeccanica Tironi enters

into a very elite group of companies capable of designing, manufacturing and
testing a 400 kV unit filled with natural ester. With these accomplishments
Tironi enters into an even more selective club of companies who are capable of
passing a short circuit test for such a high voltage level.

This remarkable success describes very well Tironi’s capabilities in engineering

and manufacturing and it marks a great starting point for 2020, a year in which
Elettromeccanica Tironi will celebrate its 60th Anniversary. That is a remarkable
achievement in and of itself.

ELETTROMECCANICA
C ontact

TIRONI S.r.l.
Via Emilia Est, 1303/D
41122 Modena, Italy
+39 059 282282
[email protected]
76 BETTER TESTING
& INSPECTIONS

Right from the Start:

Best Practices for Transformer

Testing & Inspection Upon Arrival
by Shane Smith

Shane Smith received his BSEE from Virginia

Tech and started his career with Delta Star in
1997. He has worked in the electrical industry
for over 20 years with expertise in transform-
er testing and controls while simultaneously
playing a critical role in the development
of technical relationships. He is currently
employed as the Director of Quality for Delta
Star, is a certified Six Sigma Black Belt and a
member of IEEE.
 Transformer Technology September 2019 77

Issue 3

Receiving a new transformer is a familiar

event in this industry.

However, it is important to remember that

decisions made immediately upon a new
unit’s arrival can affect costs and labor for
years to come.

Taking the right steps initially can pay

off in the long run through reductions in
maintenance costs and downtime.

Here are some best practices to observe as

soon as the new transformer arrives.
Photo: Delta Star
78 BETTER TESTING
& INSPECTIONS

A Thorough “Once-Over”

First, did the transformer truly arrive

safely? If the unit shipped with an
impact recorder, check to ensure
that it had a smooth trip. Impacts
on any axis of 4 Gs or greater may
indicate rough handling that could
potentially have caused damage to
the transformer. Exercising due diligence in the
Otherwise, inspect closely for any initial inspection and testing
signs of damage that may have
occurred during transit. Scuffs, dents, process can pinpoint issues that
and scrapes in the paint are obvious
clues, but take a careful look at all of
could lead to unplanned outages
the following: down the road.
• Tie rods or chains used to secure
unit to trailer or rail car
• Tank pressure level – See Slidebar 1
• Signs of leaks on the main tank
(for units shipped with oil) and
bushings
• Attached fittings, conduits,
cabinets, boxes, terminals, gauges,
valves and switches
• Condition of all accessories,
such as radiators, fans, bushings,
etc. (Loose condenser bushings
can also undergo power factor
testing upon receipt outside the
transformer, provided they are
properly configured with test taps,
and are upright and stabilized.) –
See Slidebar 2

Photo: Delta Star

Transformer Technology September 2019 79

Issue 3

Looking Deeper
Sidebar 1
Once the external condition has
Perform Pressure Check
In order to maximize the life of the
been assessed, it’s time to examine
transformer, we must keep moisture key internal and functional details—
out of the insulation system. Tank all of which further confirm that the
pressure is a critical factor to observe transformer is properly fit for service.
because it serves as an indicator of (Note: Do not attempt electrical
potential moisture ingress into the testing on units in a vacuum state.)
winding insulation.

Check the gas pressure in the

transformer as soon as possible
after arrival. The transformer will
have been pressurized at the factory
(commonly to approximately 5
psig, but this can vary according to
manufacturer)—so if gas in the tank
is at atmospheric pressure, there Confirm Core to Ground Insulation
could be a leak in the tank. Resistance
Using an insulation resistance meter
When a unit ships empty, the
(usually at 1000 Vdc), check the
pressure that was initially applied at
the factory will vary based on thermal
resistance from the core ground Sweep Frequency Response Analysis
changes, but normally a unit should bushing or grounding strap. A reading (SFRA)
not arrive at zero pressure or in a below 100 Meg Ohms should be For units that arrive with bushings
vacuum state. reported to the manufacturer. installed (temporary shipping
bushings work as well), SFRA testing
When a unit ships oil filled, there is It is also important to identify whether is another preliminary test that can
a much smaller gas space, and the the unit is gas filled or oil filled so the help determine if there has been any
pressure changes relative to the results can be properly compared to mechanical change or damage during
factory benchmark can be more
the manufacturer’s original readings transportation. Sweep Frequency
substantial as the oil level varies with
temperature changes. The pressure
in the same condition. Testing can be performed prior to
may transition to a vacuum state (if removal from the truck or railcar and
the temperature drops) or increase compared to factory results.
to the point where the pressure relief
device actuates (if the temperature If external damage or impacts greater
increases). than 4Gs are noted, an internal
inspection may be justified to look for
If there has been no pressure change signs of movement or shifting. Contact
since the unit left the factory, then
the manufacturer to discuss the
there has been no opportunity for
moisture to enter the unit, and you
Verify Moisture Levels findings that led to inspection, and to
can rely on the manufacture’s original For units shipped without oil and identify the specific features to inspect.
dew point, which was captured under filled with dry air or nitrogen, there is
stable, controlled conditions. little chance the insulation system Before undertaking any internal
has picked up any moisture if investigation, remove pressure slowly.
positive pressure is present upon Purge the unit with dry air to minimize
arrival. To be certain, check the dew moisture ingress and verify the air
Sidebar 2 point of dry gas in the transformer quality inside the unit per OSHA and
and compare it to the factory safety requirements, as some will ship
Perform Power Factor Test
For units that arrive fully assembled
results. filled with nitrogen.
and oil filled, Power Factor testing
should be a priority. Performing The factory dew point readings are All of these precautions should be
capacitance and dissipation tests often taken indoors and therefore in taken before the unit is removed from
on the bushing insulation can be an a stable thermal environment. the truck or railcar, and any concerns
extremely valuable precaution. Thermal stability can be difficult should be documented in photos and
to replicate in the field due to reported to both the manufacturer and
Capacitance readings from the constantly changing ambient the carrier.
bushings can show whether
conditions, but early morning is
moisture acquired during shipment
has compromised the performance
generally the best time. Keep all materials in the shipment
of the capacitive layers. (A rise in together; if components are damaged
capacitance of more than 10% points For units shipped in oil, it is advisable to and must be replaced, be sure to reunite
to a potentially hazardous condition.) take an oil sample in a syringe and have those replacements with the original
an oil lab measure its moisture content. shipment.
80 BETTER TESTING
& INSPECTIONS

Preparing for the Future

The next steps of the receiving

process are determined by the
transformer’s assignment status.
Specifically, is it headed into storage,
or immediately into service?

Ideally, the transformer would be

completely assembled and filled with
oil immediately upon arrival, but if the
unit is destined for storage, this may
not be practical. In those cases, the
methods to employ will be based on
the expected duration of storage and
will largely revolve around guarding
against condensation and rust.

Short-Term Storage
For units that will be stored for one
to three months, pressurize the tank
with dry gas at approximately 5 psi.
Record the initial pressure, then
check and log pressure levels at least
monthly—with weekly measurements
being preferable. Supply power to
the control cabinet and energize the
heater to prevent condensation – See
Slidebar 3.

Long-Term Storage
For storage periods greater than four
months, the transformer should be
completely assembled (including
radiators), vacuum processed, and Leaving transformers empty
filled with oil above the 77°F/25°C
level, leaving at least 6 inches for oil for an extended period of time
expansion. Pressurize the tank to
approximately 5 psi. Pressure should
is a major risk, due to the threat
be checked and logged at least of moisture damage to the
monthly to ensure that this pressure
is maintained. (All readings should insulation.
Photo: Delta Star

indicate either positive or negative

pressure.) Supply power to the control
cabinet and energize the heater.
Transformer Technology September 2019 81

Issue 3

Assemble and Oil Fill as

Sidebar 3 Soon as Possible
General Storage Tips:
• Units stored outside should have
Leaving transformers empty for an throughout the storage period
their bushings and tank properly extended period of time is a major becomes essential to keep the spares
grounded to help prevent damage risk, due to the threat of moisture ready for prompt deployment.
during electrical storms. damage to the insulation.
• Fill radiators with oil or pressurize Coming out of Storage
with dry gas to prevent rust. Oil filling and assembling the units
• Remove protective covers from fans promptly not only protects and When the transformer is removed
and gauges; store accessories in a preserves the solid insulation, it also from short-term storage, measure
dry location.
enables prompt testing such as: the empty unit’s dew point and
compare to the figures obtained
• Baseline DGA upon arrival. If the moisture exceeds
• Turns RatioTesting
Oil Quality the manufacturer’s allowable range,
• 10 kV Excitation follow the manufacturer’s dry-out
• Power Factor & Capacitance procedures.
• Bushing Power Factor &
• Capacitance Another critical post-storage
consideration is tank pressure. Take
• Insulation Resistance of Windings a final reading prior to installation
• Winding Resistance
Insulation Resistance of Core and compare to the readings
• Control Functions compiled over the storage period. All
• Current Transformer Ratio and readings should show either positive
• Polarity or negative pressure (or both) but
should not have dropped to zero and
remained there. A sustained zero
Keep those points in mind when pressure level likely indicates a leak,
evaluating storage plans. For which will have to be repaired before
many utilities, maintaining a spare installation.
transformer fleet has become a top
priority. Given the fact that those Careful Installation
spares may not be fully assembled,
filled and dressed out, careful and Installation and commissioning can
consistent testing and evaluation now be accomplished following the
manufacturer’s instructions.

Repeating the Basics

Exercising due diligence in the initial

inspection and testing process can
pinpoint issues that could lead to
unplanned outages down the road.
And when units have to be removed
from service unexpectedly, it can
trigger a domino effect that impacts
secondary assets and systems.
Addressing those issues right from the
start can help reduce downtime and
extend transformer lifespans.
The precautions presented here may
not be revolutionary, but even the most
experienced industry veteran can
sometimes benefit from a review of
the basics. Getting the unit inspected,
assembled, processed and filled with
oil as quickly as possible sets the
stage for prompt, thorough testing.

The goal of the entire process is to help

ensure that whenever the transformer
is needed, it will truly be ready.
82

Keeping the
Fleet in View
Transformer Technology September 2019 83

Issue 3

All
around the world, grid operators are being confronted with
the same challenge: the fact that their equipment is reaching
old age. It is no longer uncommon to see power transformers
with a service life of 50 years or more. One of the questions that every
grid operator is faced with is therefore ‘What sort of shape is my fleet in?’
Finding an answer to this question is becoming more and more urgent:
Fluctuating and higher loads resulting from renewable energy sources are
increasingly causing the crucial pieces of equipment needed to ensure a
stable power supply to reach their limits.

To combat this, Maschinenfabrik Reinhausen has developed a condition-

based method to identify critical units at an early stage: FLEETSCAN 2D.
The two-dimensional assessment matrix incorporates, firstly, the likeli-
hood of functions failing in order to model the reliability of the fleet. The
second dimension then considers the loss-of-life and is important for
making long-term investment decisions. The manufacturer-independent
evaluation tool is a lean solution on which operators can rely to keep
their fleets in shape.
 84 advertorial

Fleetscan 2D How is my transformer fleet doing?

The fleet management solution from MR
provides the answer in just a few steps.

Collect Data
A sufficient database is essential to carry out
the condition assessment. To keep disruption
times and assessment work to a minimum,
FLEETSCAN 2D offers three assessment stages.
Depending on how detailed the assessment
needs to be, not all three stages have to be
carried out. Transformer data is already
available in many cases, so the work involved in
recording the data is minimal.

1 2
1st stage: existing data
Everything at a Glance
The operator provides the data which is already
FLEETSCAN 2D makes it possible to clearly
available. This includes, for example, the master
save all collected data using browser-based
data of the transformers, measurements that
software. This enables grid operators to retrieve
have already been carried out, and maintenance
all relevant information for any transformer in
history information.
the fleet at any time.

2nd stage: on-site appraisal

The second stage involves an on-site appraisal ASSET ASSESSMENT

which is carried out during operation. In a visual

Home Assessment Analysis Transformer 3

Regensburg UW CP 1

inspection, an MR expert uses a checklist to Visual Inspection IR Thermography Oil Analysis Measurements

examine the transformer for signs of corrosion,

leaks, and visible damage to the bushings and
fans. The expert then carries out infrared Status: 50 %

Continue
Status: 0 %

Start
Status: 0 %

Start
Status: 0 %

Start

thermography and a complete oil analysis.

3rd stage: complete testing ASSET ASSESSMENT

Home Asset

If, after the first two stages, there are any Transformer Management

Transformer Name Substation Manufacturer Year of M. Rated Voltage (HV) Rated Power Primary Serial Number

indications of more significant damage, MR T1

T2
UW AB

UW AB
Siemens

ABB
1963

1951
110 kV

110 kV
45 MVA

24 MVA
92456278

21725394

performs targeted testing involving extensive T3 UW AB SGB 1972 110 kV 39 MVA 42521378

T4 UW CP Schorch 1982 110 kV 80 MVA 32445562

measurements. These include dynamic T5 UW CP ABB 1991 110 kV 35 MVA 71246844

resistance and partial discharge measurements

T6 UW CP ABB 2002 110 kV 66 MVA 95721681

T7 UW CP Siemens 2004 110 kV 65 MVA 31514796

which require the transformer to be taken

Map List
Add Transformer Map List

off the grid.

 Transformer Technology September 2019 85

Issue 3

Evaluation
Following data recording, it is time to move on to
the core element of FLEETSCAN 2D : the

Failure risk index

evaluation. Using an algorithm developed by MR Take out of operation
and the University of Wuppertal, the condition
analysis is carried out in two indices:
• The failure risk index measures the likelihood of Plan repair measures
functions failing.
Arrange for
These values provide important reference replacement
Perform
points for the maintenance strategy, which is maintenance work Test service-life
crucial for the OPEX budget. extension measures
• The loss-of-life index is a key variable when Normal operation
making long-term investment decisions, and is
therefore relevant for the CAPEX budget. Transformer Loss-of-life index
For the assessment, the results of the two
indices are transferred into an XY diagram. The
condition of the fleet can thus be visualized
simply: The more transformers that are located
in the quadrants near the origin, the better the
condition of the fleet and vice versa.

3 4
Recommendations
FLEETS
CAN 2D
lottenbe
wertung
nach der
Fleetsca
n2D-Me
thod e

Once the assessment is complete, an MR expert will

mator-F

take a detailed look at the results, check the

Transfor

en
rmation
iche Info
Zusätzl te
3.4 der Flot

plausibility of the data, and offer recommendations.

rteilung
Altersve
3.4.1

FLEETSCAN 2D
Transformator-Flottenbewertung nach der Fleetscan2D-Methode

3.3 Auffälligkeiten Thermografie

The grid operator will then receive a comprehensive
report from which the measures that need to be
Von den 42 Transformatoren wurden bei 1 abgeschalteten Transformator keine Thermogra-
fieaufnahmen gemacht. Bei den restlichen 41 Transformatoren wurden bei 4 Transformatoren
Auffälligkeiten festgestellt. Nachfolgend eine Aufstellung:den
hfolgen -
en nac gsdring
UW Trafo Die beid Wartun Bemerkung ist
Jahre. uch und hode
ägt 43,7 erverbra tscan2D Met
betr13

taken, such as maintenance tasks and investment

Flotte dau
abgeschaltet, Flee Aufnahmen
keine
Athenried
erteten Lebens h der
ng von ertung nac
lter der bew Bewertu Bew FLEETS
ittsa n die te. Die
chschn hauliche r der Flot
Gendorf 11 0,4kV, Lüftermotor, Motor CAN 2D Strom messen
überprüfen,
Das Dur me veransc mators. Transfor
ram ber dem Alte sfor mat
Diag gegenü r des Tran or-Flotte
nbewer werden etwas wärmer, viel-
lichkeit ngig vom Alte Genland 12
Lüftermotoren beidseitig, einige Lüftermotoren
tung nac
unabhä leicht Lager defekt, Motoren überprüfen h der

decisions, can be derived. Depending on the

Fleetsca
n2D-Me
x (L1), könnte Verschraubung auf Durchfüh-
10,5KV, Trafodurchführung, thode
Urgstadt 12
rung sein, auch Öl- Gasanalyse durchführen (65% Auslastung)
10,5KV Trafodurchführung, y (L2), Temperatur nimmt zum Trafo geringfü-
Wegrund 11 gig zu, könnte sich also um eine Fehlerstelle im Trafo handeln - Öl- Gasana-
lyse vornehmen! (15% Auslastung)

Die Auffälligkeiten sind in den nachfolgenden Bildern dargestellt und beschrieben:

Genland, Trafo 12: Lüfertmotoren beidseitig, einige Lüftermotoren werden etwas wärmer, ggf.
Lager defekt, Motoren überprüfen
condition of the fleet, MR recommends that the
Alter.
Die
lichen Alter zu:
Streuun
g FLEETSCAN 2D assessment be repeated every
tatsäch

three to five years.

hen
mit dem em physisc 18
gend Seite
t zwin ehmend
gt nich ch mit zun
uch stei jedo
erverbra uchs nimmt
ensdau rbra
Der Leb ensdauerve
des Leb

Seite 16

Seite
1

Your Contact
Photo: Maschinenfabrik Reinhausen

Would you like to use FLEETSCAN 2D to assess your fleet of

transformers? Alexei Babizki would be delighted to advise you:
[email protected]
86 advertorial

“The FLEETSCAN 2D method enables us to objectively assess

the technical condition of our transformers. The detailed
recommendations and the 2D matrix help us to make operational
and strategic decisions relating to asset management”
Martin Hentschel, Head of the Power Supply department at Stadtwerke Mosbach GmbH

One System—Many Advantages

Overview of the Entire Fleet
Asset managers obtain a clear overview of the condition of their fleet,
enabling them to plan their OPEX and CAPEX budgets effectively.
Thanks to the results of the condition assessment, strategic planning can
be carried out in a simpler and more structured manner.

Increased Service Life

Thanks to the detailed, pragmatic, and independent recommendations
provided by the MR expert for each transformer, the service life of the
fleet can be increased by implementing targeted measures, without large
investments necessarily being required.

Practice-Oriented
Thanks to a flexible choice of test stages, downtimes are minimal.
Only the tests that are absolutely necessary are carried out. Following
the assessment, service managers and asset managers are presented
with results which they can transfer directly into practice.

ISO 55000 Standard

FLEETSCAN 2D and its extensive documentation help grid operators to
meet the requirements of the ISO 55000 process. This industry standard
structures and assists asset management activities and in many countries
is becoming the benchmark for utility and industrial companies.

Digital Solution, Simple Handling

Users of FLEETSCAN 2D are able to manage all relevant information
about the transformer themselves thanks to web-based software.
All of the data that is collected and the assessments that are performed
on each piece of equipment are available at any time.
Transformer Technology September 2019 87

Issue 3

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88 INTEGRATED
MONITORING

Risk Management
Requires Actionable Insight:

Adding Value with Truly Integrated

Transformer Monitoring
by Marco Tozzi

Introduction

Power transformers are integral Managing and mitigating

to the flow of energy and dynamic this increased and changing
communication and could be risk profile requires new
viewed as the nerve centre in the methodologies for asset
era of digitalization of energy owners. The way to improve the
systems. However, environmental transformer reliability and gain
and operational factors can real insight into its condition is
affect the health of an aged to address its critical components
transformer fleet and reduce the in real operating conditions.
capabilities and readiness for the
technological change.

A more holistic approach to transformer

monitoring can lead to converting data
into more actionable insights and,
ultimately, optimize the maintenance
cost and effectively manage risk.
Dr. Marco Tozzi is Sr. Product Manager for
The concerns of Subject Only when monitoring all the key CAMLIN POWER, responsible for product
Matter Experts (SMEs) in the components and parameters, portfolio and an expert in diagnostic meth-
electrical energy environment in synergy, can the factors of ods for high-voltage asset monitoring. After
are increasingly devoted health, risk and reliability be receiving his Ph.D. degree in electrical engi-
to transformer health and better understood. It is not neering in 2010 on methods for analysing
maintenance cost optimization. enough to perform time based partial discharges in medium-voltage asset,
The intention is to extend the offline measurements as it he worked as Project Manager and Techni-
lifespan of transformers, but is important to consider the cal Advisor in Techimp Srl, Italy, where he was
quality and reliability do not circumstances and environmental involved in research on diagnostics of insu-
always follow this extension as and operational influences that lating systems through partial discharges
production is often affected by can lead to a defective condition. analysis. In 2012 he joined Camlin based in
economical constraints due to Many of the crucial phenomena Northern Ireland, where he was initially in-
aggressive competition pushing to be monitored are stochastic volved in developing partial discharge per-
for reducing material costs. in nature, meaning online manent monitoring systems for transform-
In addition, the integration of monitoring is essential. A more ers and rotating machines. He is author or
renewable energies is creating holistic approach to transformer co-author of more than 40 technical and sci-
scenarios where the effects of monitoring can lead to converting entific papers, co-owner of patents on par-
harmonics, switching transients data into more actionable insights tial discharge denoising technique and UHF
and intermittent load on the and, ultimately, optimize the detectors, and an active IEEE Transformer
transformer insulation are very maintenance cost and effectively Committee member.
often unknown and unpredictable. manage risk.
 Transformer Technology September 2019 89

Issue 3

Online monitors must:

• Be reliable in terms of hardware
• Be cost effective
• Provide reliable warnings and
alarms

The way to improve the transformer

• Provide synchronized, consistent
and meaningful data using open
standards
reliability and gain real insight into
Online monitors should be designed to:
its condition is to address its critical • Highlight anomalies under real
components in real operating conditions. operating conditions
• Detect anomalies and developing
problems at the earliest possible
stage

A Holistic Approach
• Provide integrated data to Subject
Matter Experts (SMEs) and
Operation & Maintenance (O&M)
A 2015 transformer reliability survey if we are to consider the key managers that can be easily
published by CIGRE [1] shows components, parameters, external correlated to extract meaningful
that more than 60% of failures in events and operational conditions information
transmission transformers involves
one of the following components:
that can contribute to failure. Figure
1 provides an overall picture of what
• Help the SME and O&M manager
to plan appropriate maintenance
high voltage windings, on-load tap this holistic approach should be, and offline tests
changers (OLTC) and bushings. A
similar percentage can be found
monitoring bushings, main tank,
OLTC, oil conservator and cooling
• Contribute to the identification
of most probable failure mode
in generation transformers with system. In addition, advanced by combining online results with
the difference being that the three modelling and analytics can be offline results and transformer
main components are: low voltage used to aggregate the through fault maintenance history
windings, high voltage windings current events [2], [3], estimate the • Reduce maintenance costs
and bushings. In addition to this,
external short circuits have been
aging factor, hot spots, overloading
capabilities [4], [5] and probability of
• Ultimately allow the asset owner
to manage and mitigate risk
highlighted as one of the major transformer failure.
Photo by Camlin Power

contributors to failure. Online monitors are not designed to:

It is clear, therefore, that a more It is important to understand a few • Replace all offline tests
comprehensive approach to
transformer monitoring is needed
key points about the nature and
goal of online monitors.
• Replicate offline testing standards
and processes
90 INTEGRATED
MONITORING

Figure 1. Example of a holistic

transformer monitoring approach

BUSHINGS CONSERVATOR
• Capacitance AND OIL PROTECTION
• Tan delta / Power factor • Oil levels
• Partial discharges • Status
• High energy events • Pressure
• Voltage • Air humidity
• Levels • Buchholz status
• Pressure • Buchholz levels

OLTC COOLING SYSTEM

• Tap position Total Transformer • Coolers in/out
• Differential Monitoring temperature
temperature • Oil flow
• Levels • Status
• Status • Differential
• DGA temperature
• Motor current • Motor current
• Tap count consumption
• Switching count • Operating hours
• Cooling efficiency
(thermal
resistance)

ANALYTICS MAIN TANK

• Load/Voltage • DGA (G1, G5, G9)
• Through fault currents • Moisture in oil
• Hot spots • Partial discharges
• Apparent power • High energy events
• Overloading capabilities • Temperatures
• Aging/Remaining life • Levels
• Losses • Auxiliary equipment
• Moisture in paper status/Alarms
• Bubbling temperature • Fiber optic direct
• Transformer condition hot spots
• GIC

Only when monitoring all the key

components and parameters, in synergy,
can the factors of health, risk and reliability
be better understood.
 Transformer Technology September 2019 91

Issue 3

Case Studies

The following case studies demonstrate successful examples when the utility was able to
plan preventive actions and maintenance thanks to the study of the correlation of two or more
parameters.

Case Study #1
KEPCO successfully replaces 345 kV bushing thanks to online monitor
showing capacitance increase and high energy events

Bushing and partial discharge monitoring was installed in 2015 on a single-phase transformer
bank in Ulsan, South Korea. The installed device was continuously monitoring the currents from
the bushings and the partial discharges from both the main tank and bushings using properly
designed tap adaptors installed at the bushing test taps. The acquisition was continuous
(not scheduled) and simultaneous in all phases with the results summarized every hour. The
bushings, from NGK, were 30 years old, OIP, 345 kV, around 430 pF of capacitance.

On February 2015, a sudden step increase of the capacitance (C1) in bushing A was detected by
the monitoring system, estimating a capacitance change in the order of 1.7% which corresponds
to a rough increase of 7 pF. Such a small change could have been caused by a partial short circuit
between two layers in the condenser core, considering >60 control layers for 345 kV bushings.
KEPCO planned an offline test to confirm the online readings, but the results proved difficult to
interpret. Indeed, the absolute value of bushing A capacitance had not changed significantly
from the previous measurements, as shown in Table 1.

Table 1. Offline results before (2012, 2104) and after (2015) the online alarm

345 kV NGK Bushing OFFLINE Capacitance C1 [pf] 345 kV NGK Bushing OFFLINE Capacitance C1 [pf]

Increase Increase
2012 2014 2015 2012 2014 2015
since 2012 since 2012

Bushing A 435 429 438 0.60% Bushing A 435 429 438 0.60%

Figure 2. Regional
Bushing B market
433for dry-type
430 426 -1.60% Bushing B 433 430 426 -1.60%
transformers, 2019
Bushing C 432 NA 430 -0.46% A-B +2 pF -1 pF +12 pF 2.7%

However, it was noticed that while the increase of capacitance in bushing A was quite small, both
bushings B and C were showing a decrease of capacitance. This led to the assumption that the
test setup was different when readings were taken. In order to take this into consideration, the
relative difference between capacitance A and B was analysed over time. It was then possible
to spot that this difference was quite constant in 2012 and 2014 (below 2 pF), while it was
significantly high in 2015, exceeding 12 pF (roughly equal to 2.7% of capacitance increase).

This offline test was not conclusive but led to further investigation of the online data.

Figure 2. Capacitance increase in bushing A1

and high energy event recorded at the same time
Photo by Camlin Power
92 INTEGRATED
MONITORING

It was then found that at the precise moment of the bushing capacitance increase, a high energy
event (partial discharge activity with significantly high magnitude, generally equal or higher than
20 V peak-peak [6]) was recorded in the same phase (from same sensor) by the online monitoring
system. In this case, the recorded event had just 8 pulses per second and it happened just once.
The fact that this event was recorded in conjunction with the capacitance increase was an
important detail that prompted an additional offline test: oil sampling from the bushing and
Dissolved Gas Analysis (DGA). Table 2 reports the results of the DGA analysis for bushings A and C.
It can be clearly seen that the amount of acetylene in bushing A is well above the tolerance
values, being 76 ppm; while level of acetylene in bushing C was zero, as expected.

Following the results shown in Table 2, KEPCO promptly planned and executed the bushing
replacement within a few months, thus saving the bushing from a potentially catastrophic
incident. It must be noted that the repetition rate for both the capacitance change and the
high energy event were quite small in terms of absolute magnitude. But being able to detect
both these phenomena online and see that they occurred in the same moment provided crucial
information enabling KEPCO to take a very successful action.

Table 2. Offline DGA results for bushings A and C

OFFLINE DGA results for Phase A and C bushings

KEPCO was able to take a
Phase A Phase C very succesful action thanks
H2 17 28
to the correlation of online
CH4 40 39
data showing small variations
C2H2 76 0
of capacitance and partial
discharges.
C2H4 44 1

C2H6 32 62

CO 71 53

CO2 564 789

N2 150.862 156.665

O2 10.280 4.337

Case Study #2
345 kV bushing in North America replaced for capacitance increase and high
energy events

Bushing and partial discharge monitoring was installed in 2018 on 504 MVA three-phase
transformer in North America. The installed device had the same characteristics of the asset in
Case #1 and was installed on a voltage tap on Westinghouse 1979 OIP bushings.

Similarly to Case #1, a sudden step increase of the capacitance (C1) in bushing H2 was detected
by the monitoring system, estimating a capacitance change in the order of 2.9%, which can
correspond to a short circuit between two layers.

By looking at the data it was observed, once again, that a high energy event was recorded in
conjunction with the capacitance increase in the same phase. Figure 4 shows the recorded
data (not averaged, published every hour) and the partial discharge pattern. The event was
characterized by impulses with significant magnitude (60 V peak-peak) and very small repetition
rate (just 6 pulses per second), almost describing a sudden arcing activity. Recognizing the
same correlation pattern (capacitance change + high energy event) seen in the KEPCO case, it
was then suggested to the utility to take an oil sample of the bushings.
 Transformer Technology September 2019 93

Issue 3

Figure 3. Bushing tap adaptor for partial

discharge and bushing monitoring

Table 3. Offline DGA results for bushings H1 and H2

OFFLINE DGA results for H1 and H2 bushings

H1 H2

H2 20 85

CH4 8 167

C2H2 <2 21

C2H4 <2 645

C2H6 14 65

CO 75 714

CO2 1.460 2.790

N2 51.800 84.300

O2 7.490 29.600

TDCG 117 1697

TDG% 6,07 11,79

The correlation of partial discharges

and bushing monitoring data,
along with proper offline tests, was
successful in identifying the problem
at a very early stage, optimizing the
maintenance and ultimately saving
the transformer.

Figure 4. Capacitance increase in bushing H2

and high energy event recorded at the same time
Photo by Camlin Power
94 INTEGRATED
MONITORING

Table 3 reports the comparison between the DGA from bushing H2 and H1, showing the
acetylene concentration exceeding 20 ppm in the bushing where the capacitance change and
high energy events have been detected, confirming the online analysis and enabling the utility
to immediately plan the bushing replacement. The correlation of partial discharges and bushing
monitoring data, along with proper offline tests, was successful in identifying the problem at a
very early stage, optimizing the maintenance (in this case truly condition-based) and ultimately
saving the transformer.

Most important:
•The absolute intensity of the capacitance increase and the partial discharges were so small that
if they were only considered individually and separately they would cause little concern.
•The combination of the two small deviations/anomalies occurring at the same time, plus
the experience from previous similar cases, suggested the choice of the DGA oil sampling as
confirmation test.
•It must be noted that DGA on bushings is not a routine test for the utility’s policy and it is carried
out only in very exceptional cases.

Case Study #3
25 MVA GSU with unknown defect under investigation through DGA, partial
discharge, and temperature and bushing monitoring
A 25 MVA GSU transformer was installed in 1986 in a hydro plant in Europe. In 2018 the
transformer underwent regular maintenance with the OEM who carried out the following actions:
• Oil degassing. The transformer had a history of abnormal but stable levels of hot gases due to
a thermal issue such ethylene and methane. The fact that the gases were stable for a long time
indicated that the defect was likely not active anymore.
• Replacement of the glass inspection window in the bushings.

The transformer was originally not equipped with any monitoring system. After the maintenance,
an oil sample was taken which showed abnormal levels of H2 in the range of a few hundred ppm.
The OEM speculated that this could have been related to the same defect that generated the
ethylene increase previously and was likely to be associated with hot spots.

Figure 5. Online holistic monitoring system installed in 25 MVA GSU

 Transformer Technology September 2019 95

Issue 3

Since the new gas pattern was not actually showing “hot metal” gases and considering that
the H2 increase was significant and coincidently occurring right after the maintenance, the
generation company suspected that the defect was somehow related to the latest maintenance.
The utility equipped the transformer with a comprehensive transformer monitoring system
that included a five-gas monitor and modules for monitoring moisture, partial discharges, and
bushings, as well as analytics capabilities and temperature readings.

After two months of results the following results were observed:

• After a first H2 increase of about 4 ppm/day, the subsequent two months showed that the H2
was still increasing but with a lower rate, at about 1.6 ppm/day, reaching an absolute ppm level of
roughly 700 ppm. All other gases had normal concentrations. There was clearly an active defect.
• The partial discharge module immediately detected a persistent active partial discharge source in
phase A. This activity had two components, likely indicating two different defects:
• The first is always present and constant in amplitude and repetition rate (5000 pps) with indirect
polarity and typical for defects inside the main tank (including the bushing turrets, i.e. whatever is
outside the bushing core). This activity has no cross coupling with the other phases which means
that the source is far from the other two phases or very close to the partial discharge sensor.
• The second is sporadic, with smaller repetition rate (in the range of 1000-2000 pps) and with
direct polarity indicating that it could be inside or very close to bushing A.The overall partial
discharge activity was increasing over time in terms of repetition rate, indicating that the active
defect was in phase A.
• From the phase-resolved partial discharge (PRPD) pattern it was difficult to identify the partial
discharge source, however similar shapes of the pattern had been recorded when the oil treatment
was not conducted properly leaving small air bubbles trapped, or when small puncturing activities
were present in the paper insulation on the top of the winding column (e.g. in the stress ring).
• Looking at all the data collected by the holistic monitoring system, it is possible to see that there
is almost no correlation between data. The gas generation and partial discharge activity are not
influenced by the load, nor by temperatures and humidity.

Figure 6. Online results synchronized and visualized in a way

to enable further investigation on the possible correlation

The first speculative analysis, after having looked at the online data, was leading towards the
Photo by Camlin Power

possibility that the defect was likely to be due to the last oil filling process that apparently had
not been carried out under vacuum (due to the fact that gaskets are not suitable for the vacuum
process).
96 INTEGRATED
MONITORING

Due to an absence of hot and arcing gases, the perfect condition of the bushings (in terms of
capacitance and tan delta) as well as the absence of a clear correlation with load or temperature,
the utility decided to:
• Keep the transformer monitored and under control in order to analyse the gas and partial discharge
development during the next few months.
• Plan the gasket replacements in order to perform a proper oil treatment and refilling under vacuum
to remove any possible trapped bubble.
• Agree that maintenance was to be planned. However, this could be deferred to the next stop of the
generator considering that:
• the overall picture provided by the online monitor indicated that the transformer was not in a
critical condition, and
• the transformer was continuously monitored so any unexpected change in the condition would
promptly notify the Subject Matter Expert.
In this case (which still under investigation at the time of publication) the use of the total
transformer monitoring not only aims at optimizing and deferring the maintenance to the best
possible moment (generator annual stop) but is also a means to resolve the controversy between
the OEM, responsible for the maintenance and oil process, and the transformer owner.

Figure 7. PRPD pattern of the stable partial discharge activity in Phase A1 (left) and the sporadic activity overlap (right)

Conclusion References
[1] Transformer Reliability Survey,
The use of a more holistic and The correlation of the different CIGRE TB 642, WG A2.37.
integrated approach to transformer parameters such as DGA, partial [2] F. Scatiggio, C.A. Serafino, M. Tozzi,
monitoring can significantly help discharges, bushing capacitance E. Savorelli and A. Salsi, “TERNA
to optimize maintenance and etc. plays a fundamental role. Transformer Fleet Knowledge
mitigate risk. Holistic means the However, the key point that has Management through the use of
treatment of the whole transformer, been shown in the case studies is on-line Monitors,” presented at D1-
taking into account operational that the correlation and occurrence 313, CIGRE, Paris, France, 2018.
data, environmental data, external of these events can sometimes [3] K. Yule, D. Brock and J. Purdy,
factors and previous experiences, be even more important than “Accountability and Evaluation
rather than just a single diagnostic their absolute magnitude. A small of Aggregate Effects of Through
parameter such as DGA. The capacitance increase and a few Faults on Power Transformers,”
chances of identifying the failure partial discharge pulses can be Unclassified Open Source.
mode or defect can dramatically easily neglected, ignored, or treated [4] IEEE Guide for Loading Mineral-Oil-
increase, allowing asset owners to as insignificant if considered Immersed Transformers and Step-
understand their risk and ultimately individually. The outcome obtained Voltage Regulators, IEEE C57.91-2011.
make prompt and better-informed by the correlation of all these small [5] Power transformers - Part 7: Loading
decisions. The planning and the events can have a huge impact guide for mineral-oil-immersed
use of valuable offline techniques on risk assessment process and power transformers, IEC 60076-6.
(DGA in bushings, SFRA, DFR, failure identification processes, and [6] M. Tozzi, C. McIlrory, C. A. Serafino
etc.) can be better informed by facilitate better decision making. and M. Rebolini, “Condition
the information provided by the Based Maintenance on 400 MVA
monitors. The monitor’s role is Autotransformers: A Case Study,”
not to replace the offline methods presented at CIGRE VII Workspot,
but to optimize their use and A2, PS1, Rio de Janeiro, Brazil, 2014.
effectiveness.
Transformer Technology September 2019 97

Issue 3
98 advertorial

Tecsystem World Make a Safer

BRASILE - BRAZIL ITALIA - ITALY EGITTO - EGYPT CINA - CHINA

Brhitec LTDA HQ Tecsystem Orient IIC Tecsystem SH
Rua Joao Wiest Junior, 655 Via L. Da Vinci, 54/56 10 Ramadan City 3rd Floor, Block No.5,
Chico de Paulo 20094 Corsico (MI) Industrial Zone C6/67 Forward High-tech Industrial
Jaragua' do Sul - SC, 89254-500 ITALIA EL SHARKIA - EGYPT Park, No.33 Fuhua Road,
BRAZIL Jiading District,
Postal Code 201818
SHANGHAI - CHINA

Since 1980, Tecsystem SRL – an Our R&D department designs and implements solutions suitable for all electric
Italian factory - has continued to machine types with the ability to operate in any application sector (railway, air-
develop technologies aimed at port, shipping, building, construction, food, subway, alternative energy and others).
temperature control - data collection
and analysis of electrical machines. Security and reliability are our guidelines, granted by ISO 9001 certification and by
specific certification related to each product.
With headquarters in Italy and
branches in Egypt, China and Brazil, Thanks to the progressive evolution of our temperature monitoring technologies,
we are positioned in strategic places we are now working to create increasingly digitalized devices that interface easily
around the world so we can respond and immediately with any kind of existing systems.
promptly to every need of our local
customers. We have created a network In this case, digitalization is a technological progress which revolutionizes the ap-
of services suitable for accompanying proach to parameter control and allows the operator to act remotely, planning
every user in their projects. maintenance interventions in advance (predictive / preventive maintenance).

Thanks to the dual connection method (Ethernet or Wi-Fi), our devices can be im-
plemented in any system, immediately and without changes to the existing one.

Data flows are immediately usable and manageable in an intuitive and simple way
(in some cases even from Mobile or Tablet), thanks to specially designed graphic
interfaces.
Transformer Technology September 2019 99

Issue 3

CONNECTIVITY AND
DATA MANAGEMENT:
INDUSTRY 4.0

From the concept of simple remote In this way the User, using the wide range of data in a predictive way, can work to
control, we have moved on to a wider improve the basic concepts of Reliability, Maintenance and Efficiency.
reality more attentive to the needs
of today and tomorrow: supplying At Tecsystem, we are able to keep abreast of the times, and we have developed
information according to a standard two product lines which meet the new needs:
valid for all models, using the
most widespread communication
protocols and technologies (Modbus,
• ETH(ernet) LINE: equipped with Ethernet output with Modbus TCP / IP
protocol - to display, program and collect temperature parameters. Suitable
Ethernet, WiFi). This allows for the for systems where wired networks for the acquisition and remote control
implementation of results and data of information are available: it is a widely used technology for industrial
coming from centralized processing networks.
and analytic systems.
Among this LINE we present the T1048 ETH * which is UL certified and best fea-
tures are the following:

- IntelliFan: to reduce the thermal shock of the transformer

anticipating partially (one bar at a time) the activation
of the ventilation system.
- Voting: this function comes from the concept
of redundancy, that consists in duplication of
components of a system with the intention
of increasing reliability. Taking advantage
of this principle, we use the probes in-
stalled on the three phases to monitor
the operation of the transformer but at
the same time ensure the proper func-
tioning of the probes themselves, dis-
criminating any false alarms
- FailSafe: The T1048 has n.o. se-
lection (normally open contact)/
n.c. (normally closed contact) for
alarm and trip relays. The selection of
the setting n.o./ n.c. introduces func-
tions Fail Safe and No Fail Safe.
- Ethernet Output: It allows you to di-
rectly implement the functionality of
Tecsystem’s control units in your mon-
itoring system. The integrated module of-
fers all the features of essential networks, in-
cluding an Ethernet 10BaseT / 100Base-TX, full
TCP / IP stack, suited to work as a Modbus TCP
slave. Web functionality can be used for remote con-
figuration of the limits of protection, the real-time moni-
toring or troubleshooting.

• WS LINE: equipped with a simple graphic interface for displaying and ana-
lyzing the temperature information detected, as well as a small antenna for
Wi-Fi connection, it offers the possibility of intervening for the programming
and configuration of the system, without having to install dedicated Apps or
Software, on any Internet Browser.

New “SMART” products for a market even more attentive to an energy wastage
both in the environment and resources, as well as being sensitive to a now ne-
tecsystem.it cessary concept such as predictive maintenance!

Tecsystem, make a Safer World!

100 Automated Thermal
Monitoring

Automated Substation Monitoring

with Thermal Imaging
by Richard Harada

Introduction

Infrared technology is widely used of excessive heat in the electrical

by utilities to find heat related system, or the absence of it in some
anomalies in the electrical system cases, allows the utility to schedule
that could indicate potential maintenance and correct issues
problems. Portable infrared before an expensive failure occurs.
cameras have been typically used While periodic scanning is useful,
by thermographers to periodically it is subject to many changing
inspect substations and other key variabilities including changing
areas of the grid. Early detection environmental and load conditions.

Automating thermal inspections

can greatly reduce the costs to utilities
through reduction of travel while
increasing employee safety and the
amount and quality of data that is
collected.

Photo: Systems With Intelligence Inc.

Transformer Technology September 2019 101

Issue 3

Being able
to monitor your
substation
Richard Harada has more than 20 years of
remotely is one
experience in industrial networking commu-
nications and applications. Prior to joining
of the keys to
Systems With Intelligence, Richard worked
at RUGGEDCOM and Siemens Canada, where
going touchless.
he focused on industrial communications
in the electric power market. Richard is an
electronic engineering technologist and has
a Bachelor of Science degree in computer
science from York University in Toronto.
102 Automated Thermal
Monitoring

Automating thermal inspections can transformer shows temperatures of

greatly reduce the costs to utilities transformer components and allows
through reduction of travel while thermographers to define areas
increasing employee safety and the to take temperature readings. The
amount and quality of data that is readings are digitized and converted
collected. Furthermore, the data can to temperature points.
be made available to SCADA and
asset management applications
as part of a condition-based
Utilities such as PPL Electric Utilities
and PSE&G [1], [2] are implementing
Advancements
maintenance program to increase the
utility’s bottom line through improved
touchless substation projects
that involve remote monitoring to
in infrared
asset life, efficiency and reduced gather the health information on technology
outages. substation equipment and condition-
based maintenance (CBM) to plan and the
Automated and remote inspections
can lead to more efficiencies and cost
and prioritize service work. Remote
monitoring can involve many types communications
savings for utilities by allowing them
to go “touchless.”
of connected sensors such as
those that measure current, voltage,
around it make
Figure 1 shows a thermal monitoring
temperature, dissolved gas, etc.
Some of the key areas to monitor with
thermal imaging
camera that can be programmed to sensors are transformer components more widely
automatically monitor equipment in such as bushings, cooling fans and
the substation. A thermal image of a load tap changers. available through
reduced cost,
ease of use and
accessibility to
the data.

Figure 1. Substation rated, infrared

monitoring sensors can be permanently
installed on pan-tilt mounts to automate
the thermal scanning process.

Photo: Systems With Intelligence Inc.

Transformer Technology September 2019 103

Issue 3

system runs on three phases, so As outlined in Table 1, NETA has

in many cases inside a substation recommendations for actions to take
it is possible to measure like when comparative readings reach
components on different phases, defined levels.
i.e. measuring the temperature
difference between the A, B and C Thermal imaging is useful to find
phase transformer bushings [2]. heat related anomalies in many
Background In this case, instead of trying areas of a substation, such as
on Thermal Imaging to calculate what an absolute connection points, disconnect
temperature value should be, it is switches, breakers, insulators and
Thermal imaging is the technique simpler and more meaningful to arrestors.
of measuring infrared radiation compare temperatures between
from an object and converting phases. Typically, the temperature Around transformers the key
it into a temperature value. An of like components should be within points to monitor are:
important feature of thermal 1°C of each other. If not, there could
imaging is that it is non-invasive — be a load problem or a component Bushings and surge arrestors –
it uses a sensor that can measure problem in the system. Hots spots on the connection
temperature values without point could be due to loose or dirty
physically touching the object. The International Electrical Testing connections. Hot spots on the body
It is not required to power down Association (NETA) has established could indicate a breakdown of the
equipment to install the sensor or a guideline of comparative insulation.
to make the measurements. The measurements and relative
measured value can be affected comparisons to ambient temperature. Cooling Systems – Cool spots on
by many environmental factors radiators could indicate blockages
including ambient temperature, or low coolant levels. Cool or hot
humidity, wind and emissivity areas in fans can indicate electrical
of the target object. With these Thermal imaging or mechanical problems that require
factors in mind, it is often more
meaningful to use comparative is useful to find maintenance.

measurement; comparing the

temperature differences between
heat related Load Tap Changers (LTCs) – The
LTC tank should be the same or lower
like components instead of trying to anomalies in temperature than the body of the
measure an absolute temperature transformer. A bad connection on the
value on each, effectively cancelling many areas of a tap changer will heat the tank only if it
out the environmental variables. is carrying load. A faulty tap may not
An advantage in the electric substation. show up in a thermal scan if it is not
power industry is that the power connected at the time of the reading.

Table 1. Recommended temperature thresholds and actions for monitoring

electrical components.
(Source: NETA World - Infrared Inspections and Applications)

Temperature difference (∆T) Temperature difference (∆T)

based on comparisons between based upon comparisons between Recommended
similar components under similar component and ambient air Action
loading temperatures

Possible deficiency; warrants

1ºC - 3ºC 1ºC - 10ºC
investigation.

Indicates probable deficiency;

1ºC - 3ºC 11ºC - 20ºC
repair as time permits.

Monitor until corrective measures

------ 21ºC - 40ºC
can be accomplished.

Major discrepancy; repair

>15ºC >40ºC
immediately.
104 Automated Thermal
Monitoring

and efficiency. The system analytics Data points can be trended over
automatically detect temperature time to establish a health index and
abnormalities in the system and the graphs and current readings
send alarm messages. The data can be accessed via an information
can be stored locally at the site dashboard (Figure 2). Visual and
and communicated directly to the thermal sensors can send their data
control center SCADA or to asset wirelessly to the cloud for remote
management systems for real time sites that have limited connectivity
situational awareness. (Figure 3).

Reliability

Infrared sensor technology has

Figure 2. Continuous temperature values can be trended over time and shifted from analog imaging to
correlated with weather and load conditions.
digital imaging resulting in improved
(Source: Systems With Intelligence Cloud Dashboard)
image quality, more efficient
methods for transmitting data, and
simpler processes for storing and
analyzing the data. The previous
generation of thermal cameras
used analog communications to
transport information making it
susceptible to degradation and
loss. When used in a substation the
interference effect was increased
due to the presence of high levels of
electromagnetic interference (EMI).
New, network-connected imagers
now digitize the signal at the source
and can transmit the data over fiber
optic cable which is immune to the
effects of EMI. Storage technology
has improved so that data can
Communications be saved to solid state drives,
eliminating the need for mechanical
Major improvements in network spinning drives. Substation rated
communications have been a equipment is required to meet
Advancements in Thermal huge benefit to thermal imaging high levels of reliability and the
Imaging Technology technology. In the past, with components and designs can
handheld cameras, the data was now meet these requirements
Processing Power stored in the camera and transferred while maintaining a high level of
to a computer system manually. performance.
Thermal imaging runs on computing Now, with modern Internet Protocol
power. As advancements in thermal (IP) based systems, the temperature The Advantages of
imaging technology continues, the measurements are digitized, Automated vs. Manual
performance of thermal imaging stored on solid state memory and Thermal Scanning
is increasing while the price of transferred to storage and control
the technology is decreasing. An center systems in real time. Many Utilities have been doing manual
automated thermal sensor can utilities have high speed connectivity thermal scanning for years, and they
capture high, low and average to their substation, but even those are aware of the problems that can
temperatures from hundreds of pre- with little or no connectivity can be uncovered with the technology.
set points while cycling and scanning still take advantage of the edge Utilities have thermographers on
Photo: Systems With Intelligence Inc.

through areas of a substation. Using processing that minimizes the staff (or they use professional
high resolution imaging and the amount of traffic that needs to flow contractors) to perform thermal
appropriate lens, the temperature on over the network. Utilities with no site inspections. However, there
even a small object can be measured wired connection to their remote are many advantages to using
from up to 50 meters away. Data sites can utilize modern 3G and 4G continuous, automated thermal
processing can be done at the edge wireless networks that provide high scanning given the advancements
of the network to improve reliability speed connectivity. in thermal scanning technology.
Transformer Technology September 2019 105

Issue 3

Weather – Environmental conditions

can have a major impact on
the accuracy of thermal sensor
measurements. If a thermographer
is scanning a substation a few times
a year, the readings can be quite Figure 3. New
different depending on the weather technology allows
thermal and visual
conditions, and even the time of sensors to send data
year and time of day can affect the wirelessly for sites
readings. With an automated system, without network
the readings are continuous and connectivity
can be graphed so trending can be
established that will account for
weather abnormalities and will even There are many Continuous thermal data – Manual
show how temperatures vary daily thermal scanning doesn’t provide
and seasonally. advantages to continuous data. By its nature, data
from manual scans is infrequent
Accuracy of data entry – A ther- using continuous, and can be less accurate unless the
mographer using a handheld
thermal imager will at some point
automated same experienced thermographer is
doing the scan each time. Continuous
need to transfer the readings to a
computer system. The transfer of
thermal scanning thermal data allows for trending
of temperature data and relating it
data can be prone to error when a given the latest to weather, seasonal changes and
manual operation is involved. An system load. The thermal data can
automated system records the data advancements in help asset managers establish asset
to a database and has an interface health indexes for the purposes of
to send the data in real-time to technology. condition-based maintenance.
SCADA, asset management or data
aggregation applications, eliminating Timing - Periodic inspections are
the possibility of human error. System load – The amount of current valuable for finding hotspots, but
being drawn can have a major effect they can miss problems if the timing
Consistency and interpretation on the thermal scanning results due is off. As and example, a substation
of results – Thermal scanning to the I2R factor. If current is leaking that is inspected today may be struck
results from the substation can through an insulator, or if there is by lightning tomorrow, damaging an
vary over time. Aside from the a poor or loose high resistance arrestor. That damage may not be
changing environmental conditions, connection, that point will heat up discovered until the arrestor fails.
variations in the angle, position and more when there is greater current
distance to the object may affect flow. A faulty tap on an LTC will only Connection to Management Systems –
the consistency of the readings. show up when that particular tap With automated thermal imaging, data
Different thermographers may use is connected. Some hotspots may transfer happens seamlessly. As the
different imagers and interpret only show up during times of peak temperature data is collected, it can be
settings and readings differently. load, so if the thermographer is not uploaded directly to connected
An installed thermal imager will be performing the scan during this time SCADA systems, data aggregation sys-
installed in a fixed location and will be the hot spot will remain undetected. tems such as OSISoft, or asset manage-
programmed by the thermographer Conversely, the continuous scanning ment systems using industry protocols
to scan the substation at predefined, system will find the hotspot during such as DNP, Modbus or IEC 61850.
pre-set positions with high accuracy each time the system hits peak load This type of connectivity provides ope-
and consistent parameter settings. or when a faulty tap on the LTC is rators with real time data and asset
This guarantees consistent readings connected. This will generate an managers with data that can be used to
and interpretation of results. alarm about the condition. track asset health and condition.
106 Automated Thermal
Monitoring

perform remote visual inspections

of equipment and conditions in the
substation. Utilities benefit from
remote inspections by:

• Reducing the frequency of truck

rolls by eliminating the need to be
Figure 4. Reduction in O&M costs using condition-based maintenance.
(Source: The Future is a Touchless Substation [2]) on-site for inspection.
• Increasing safety by reducing
the amount of exposure that
100
employees have to hazardous
90 areas.
•
Travel Time
Monitoring crews on site, which
80
can influence behaviour and
System Wide O&M Benefits

70 ensure that crew follow safety

procedures. If any incidents occur,
60 a video recording can provide
valuable evidence and training for
50 Corrective
Travel Time the future.
40
Maintenance
• Increasing the volume of
inspections, which ensures that
30 the substation is in top condition,
Corrective
20 Maintenance animals are not moving in, and
the substation remains a safe
10 Planned environment for the public and for
Maintenance employees.
Planned Maintenance
0
Before Touchless After Touchless • Allowing remote troubleshooting
and visualization, which informs
the crew of equipment condition
Condition Based or and failures before going to the
Preventative Maintenance Summary site. This may allow them to have
the right parts on the truck before
As utilities strive to get the most Utilities know the benefits of thermal rolling out.
out their assets while making the
most efficient use of maintenance
monitoring, and new technology
can now make it automated and
• Providing constant and consistent
data for condition-based
resources, they are turning to more affordable. While there is an maintenance.
condition based maintenance to try initial capital expense to install a
and achieve these goals. As shown continuous thermal monitoring References
is Figure 4, CBM saves a utility system, there are many benefits that [1] E. Rosenberger, M. Coyle, PPL
money by reducing trips to the field a utility can realize in a relatively Touchless Substation Project, 2017.
by alerting crews to equipment short amount of time that can save [2] D. O’Rourke, R. C. Alvarez, M.
problems before failures occur. CBM operations and maintenance costs, Khan, “The Future is a Touchless
can extend the life of assets by help prevent outages and extend the Substation,” T&D World Magazine,
allowing crews to perform repairs life of high value assets. 2019.
before costly failures occur [3]. [3] D. A. Genutis, NETA World – Infrared
With constant monitoring, utilities Thermographers can set up the Inspections and Applications, 2006.
know the condition of their assets system to perform automated [4] J. Lonneker, B. Baker, “SDG&E
and can schedule maintenance thermal scans of the substation. Takes a Proactive Approach to
only when required instead of on a The thermal cameras can be Maintenance,” T&D World Magazine,
time-based schedule. This makes programmed to take temperature 2013.
the most efficient use of personnel measurements on hundreds of
and materials. Automated thermal points with thresholds set to
monitoring provides a constant determine if the readings are within
source of timestamped temperature tolerance. The thermographer can
data that can be connected directly also take control of the system
with asset management databases remotely for focus on specific areas
and correlated with weather, load of interest. Since the system will
and other situational conditions in typically include visual cameras,
the substation. substation managers can also
Transformer Technology September 2019 107

Issue 3

SAVE THE DATE

IEEE PES Transformers Committee Fall 2019 Meeting
Hosted by American Electric Power

27–31,
OCTOBER
2019

Columbus, Ohio Accommodations:

Hyatt Regency Columbus
Named one of its 52 Places to Visit in 2019 350 North High Street
by The New York Times, Columbus is truly Columbus, Ohio 43215 USA
made unforgettable by its diversity and Reservations, call: +1.614.463.1234
energetic blend of arts and culture. With a
revitalized riverfront, booming downtown Group room rate: starting at US$168/night,
and an open-minded approach to life, single or double. Use link on Committee’s
business and ideas, the Buckeye State’s website or call hotel directly and mention
capital has cultivated a unique environment the group name “IEEE Transformers”
of thriving communities, companies, Cut-off date for group rate is October 4,
institutions and entertainment that has lead 2019, but hotel will sell out before then.
to it being one of the fastest-growing cities
in the U.S. as well as a center of knowledge John Glenn Columbus International Airport (code “CMH”)
Located approx. 6 miles/10 km east of the hotel
and innovation. Estimated taxi fare to/from hotel (one way): US$25 from
CMH. Estimated lyft/uber fare (one way): US$14–$18
www.experiencecolumbus.com from CMH ( no hotel shuttle)

HOTEL | Hyatt Regency (see above)

TECHNICAL TOURS | AEP Transmission Training Center | Weidmann Electrical Grade Paper Mill
SPOUSE/COMPANION TOURS | Art & Animals (with Interactive Workshop) | Historic Bricks & Gardens
WEDNESDAY NIGHT SOCIAL | COSI: nation’s top science center

Saturday night early bird venue TBD — details on all to follow.

TRANSFORMERSCOMMITTEE.ORG
108 PRE-EVENT

Face-to-face
in a digital world – the value
of industry events

In an ever increasing virtual world,

where do industry events fit?
Can we gain the knowledge we need
to do our jobs today and in the
future from the digital world alone?
Or should we also realize the value
of stepping away from the screen?
This article explores the benefits In the March 2019 edition of Transformer
Technology magazine, Alan Ross, Editor in
of sharing knowledge face-to face
Chief, asked the question “What if much of that
through industry events, investing legacy knowledge isn’t worth passing on in the
first place? What if things have changed and
in people for their personal
are changing so rapidly in our field of electrical
development and, ultimately, system reliability that much of that legacy
knowledge is outdated, or even worse, what if it
realizing how organizations are
is flat out wrong? Would we want to make sure
reaping the rewards. the next generation learned it?”

This question on the surface appears easy to

answer. But how do you continue to ensure
Shutterstock

individuals and organizations gain the knowledge

Photo by Shutterstock

and skills required to be successful?

Photo:

Choosing and attending the right industry events

can be an important starting point.
Transformer Technology September 2019 109

Issue 3

Motivation!
Some events are considered expensive, requiring time
away from the office, and the return-on-investment isn’t
always clear. But they provide opportunities that you
simply cannot get elsewhere.

Having the opportunity to learn, meet with experts and

peers, and have a bit of fun(!) is a great way to motivate
people. From time to time, everyone’s motivation dips,
especially when facing the same routine and set of
challenges each day. An industry event provides a great
opportunity to free your mind from day-to-day tasks and
experience something refreshing and motivating.

An organization with motivated, proactive employees,

contributing new ideas is always more likely to succeed.

Networking, in person!
In a digital world, networking in person is becoming
more and more difficult. We often forget how effective
in-person interaction can be.

We cannot expect that an individual has the answer for

every challenge today’s world throws at them. Having a
strong network of experts and peers from within a given
industry to call upon can provide a leverage to solve new
problems, discover best practice and learn from similar
challenges. Events provide valuable time to network
and socialize as an industry. Investing in building an
individual’s network reaps benefits for employers and
organizations for years to come when new challenges
inevitably present themselves.

Attending industry events should be part of all

organizations overall improvement and growth
strategy. Understanding industry trends and
current developments is key to being successful and
competitive. Having motivated, engaged individuals in
Learn something new an organization can only lead to additional benefits, now
and imagine new ideas! and in the future.
Reading industry publications, blogs and whitepapers can
certainly contribute to a better understanding of new de- So referring back to Alan Ross’s question, lets
velopments and trends in our industry. However, watch- equip ourselves and future generations with the
ing, listening and interacting with experts face-to-face knowledge and skills required to ensure our industry
is invaluable. Attending an event allows people to ask of transformers, power generation, transmission and
questions and make important connections with indus- distribution can be successful for years to come – and
try experts and peers. Attendees learn new skills and best it is evident industry events play a leading role in
practices, leading to practical ways to achieve long-term confidently knowing that up-to-date research and ideas
success as an individual and organization. are being discussed and passed on.

Industry events also present the opportunity to meet like-

minded people who share similar interests and face simi-
lar challenges in the workplace. Stepping away from daily
work life and networking with peers can generate fresh,
new ways of thinking and learning, translating into ideas
and concepts that provide a strong ROI to organizations.
110 PRE-EVENT

Francis Fisher
is the Head of Global Marketing at
Weidmann Electrical Technology.
Since receiving his bachelor’s degree
in business from the University of
Huddersfield, UK in 2002, he has
worked in a variety of commercial
roles within the energy sector
spanning multiple continents and
regions, including Asia Pacific,
Americas and Europe, Middle East
& Africa

About Weidmann
Electrical Technology:
Weidmann has been at the heart
of the global transformer industry
for over 140 years. With deep
rooted knowledge in the design,
development and operation of
transformers, Weidmann is a leading
integrated solutions provider for
specialized product and services in
the energy sector. Working closely
with our customers, Weidmann
continues to lead the global market
delivering high quality, innovative
product and service solutions.

THE TRANSFORMER EXPERIENCE

NOVEMBER 5 --- 7, 2019
OMNI LA MANSIÓN DEL RIO ON THE RIVER WALK, SAN ANTONIO, TEXAS

JOIN US ON THE SAN ANTONIO RIVER WALK FOR THE 18TH WEIDMANN ANNUAL TECHNICAL CONFERENCE

Informative presentations from EMERGING technologies and services EXPO featuring leading Manufacturers
industry EXPERTS for transformer life extension from around the world

Feature presentations on alternative Insider look & information from Expert panel discussions &
transformer fluids with audience Q&A contributors to the new IEEE DGA GUIDE NETWORKING EVENTS

For more information, the full agenda and registration details please visit:
https://www.weidmann-electrical.com/the-transformer-experience
or search: ‘Weidmann Transformer Experience’ Official Media Partner
Transformer Technology September 2019 111

Issue 3

It’s easy
to keep in
the loop!
WITH

Sign up for our newsletter at

transformer-technology.com
112 PRE-EVENT

Discover
the latest transformer
tech innovations at
2019

Amongst the over 90 exhibitors, many will

showcase the latest transformer components,
materials and process machinery innovations,
including Acme Mechatronics, Alliance LLC,
CWIEME Americas, North America’s Elsan Elektrik, Gorman Machine Corp, Jovil,
Metalux, Nishimoto and V&C GmbH – to name
only dedicated event for the supply but a few.
chain of coil winding, electric motors,
CWIEME Connect App matches
transformers and generators, will your business with suitable suppliers
be held in Chicago at the Donald The new networking and connect tool CWIEME
Connect allows you to source suitable suppliers
E. Stephens Convention Center on even before the show starts. Search and
September 17-18, 2019. contact suppliers or have the matchmaking app
recommend the most relevant exhibitors for
your business, based on your preferences.

CWIEME Americas gives you access to:

• About 100 innovative coil winding, electric motor, transformer
and generator manufacturers under one roof
• 20+ senior industry experts and influencers providing leading
technical and commercial sessions with the latest engineering
insights, trends and analysis in a two-day conference program
• The new networking and content tool - CWIEME Connect App
– to maximise your time out of the office
Transformer Technology September 2019 113

Issue 3

Senior industry experts

present transformer trends
& market intelligence
Besides connections to new and existing suppliers,
OPS Workshop CWIEME Americas is an all-in-one-place providing
Feel confident to design without any application visitors with networking opportunities and a highly-
tools or software programs. This year OPS and curated free-to-attend conference program to boot.
CWIEME Americas invite you to attend the Basic The Innovation Talks will focus on how transformer
Principles of Transformer Design Seminar. This design and manufacturing are evolving, for example in
seminar is intended for technical personnel who a content session with Saqib Saeed, Principal Analyst –
want to learn and review the basic principles of Grid and Power Semiconductors at Power Technology
transformer design, enabling a transition to using Research LLC, presented by Transformer Technology
the OPS programs more effectively. Editor in Chief Alan Ross.

Make sure you attend: For the most part we are redesigning systems,
DESCC, Wednesday 09/18/2019 - 9:00am – 4:30pm
not designing from scratch, adding technological
Pre-booking required.
advances while integrating new technology
into old systems. Transformer Technology

Presentation by Alan M Ross

The application of Reliability Engineering disciplines and
principles provides a unique perspective to a smart grid
transmission & distribution system. In this presentation
we will look at how technology, UIoT, Machine Learning
and Condition Based Monitoring can positively affect the
long-term reliability of these critical systems.

While reliability engineering starts at the design phase

for asset management decisions, an even greater impact
will be on the system those assets comprise. We will look
at the best practice approach for a Reliability Centered
Maintenance program for transformers as an example of
how to apply system approaches to reliability.

As the Editor in Chief of Transformer Technology, Vice President of

Strategic Development for SDMyers and active IEEE Power Energy Society
and Reliability Society contributor and member, Ross is passionate about
reliability of electrical systems. His presentation at CWIEME is sure to
engage, encourage and educate.

WHERE AND WHEN?

CWIEME Americas will take place

September 17-18, 2019

Venue
Donald E. Stephens Convention Center
5555 North River Road
Rosemont Illinois 60018 USA

Opening times
September 17, 2019 – 10am – 5pm
September 18, 2019 – 9am – 3pm

You can register

for the event on the show website
coilwindingexpo.com/americas
114 Coming
in DECEMBER

Transformer
Failures:
Causes and
Prevention

The factory of the future will have only

two employees, a man and a dog.
The man will be there to feed the dog.
The dog will be there to keep the man
from touching the equipment.
Warren Bennis

We aren’t quite where Warren Bennis joked we might be

in the future, but there is a lot of truth to the idea that
equipment is becoming more complex and more automated.
With Artificial Intelligence (AI) and Machine Learning (ML)
as growing influences, transformers are becoming smarter.

What does this have to do with transformer failures? Given

the large aging installed base of transformers in the grid, in
industry and in commercial applications, we don’t have as
many smart assets as we will have in the future; especially
as the Internet of Things (IoT) makes real time condition
monitoring of transformers and transformer components
a reality. So, we are experiencing a growing failure rate,
sometimes preventable if the dog had not kept us away
from the equipment.

Our December issue is a must read for anyone tasked with

the design, manufacturing, testing installation, operation,
maintenance, monitoring or life cycle management of
transformers. In short, if you have anything to do with
transformers, this is a must read and “must keep for future
reference” edition.

Alan Ross, Editor in Chief

Thinking about
strengthening
your position
in the market?
THINK ABOUT YOUR PRODUCT

THINK ABOUT YOUR COMPETITION

THINK ABOUT YOUR SERVICE

THINK ABOUT YOUR TIME

THINK ABOUT...

Don`t
think
about
MARKETING
LET US DO IT FOR YOU

Contact us to find out more:

[email protected]
www.apc.media
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