The Value of Post-Mortem

Investigations for the Condition

Assessment of Power Transformers

Weidmann-ACTI Inc. Sixth Annual Technical

Conference
St. Petersburg, FL Nov. 12-14, 2007

Presented By:

Thomas A. Prevost
Weidmann-ACTI
A Member of the Group
The Value of Post-Mortem Investigations for the
Condition Assessment of Power Transformers

• Introduction
• Background
• Sample Procedures
• Post Mortem Investigations
• Conclusion

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Life of transformer is determined by condition of
insulation at the winding hot spot.

Typical Hot Spot Location

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 Degree of Polymerization

Measurement of intrinsic viscosity after dissolving the cellulose

in a specific solvent.
Gives an average measurement of the number of glucose units
per molecular chain.

•DP of Insulation Components prior to processing ~1200

•DP of Insulation Components following processing ~1000
•DP level considered as “over-processed” ~800
•DP level considered end of life ~200

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 Degradation of Cellulose Insulation
Causes:
•Moisture
•Oxygen
•Temperature
Effects:
•Breakdown of the Cellulose Polymer
•Reduced Mechanical Strength
•Shrinkage (Under compression)

Byproducts:
•Moisture
•Gas
•Carbon Monoxide/ Carbon Dioxide
•Acids
•Furans
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A Portion of the Cellulose Molecule

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Cellulose Decomposition Compounds Found in Oil

2-Furaldehyde 2-Furoic Acid

5-Hydroxymethyl- 5-Methyl-2-Furaldehyde
2-Furfuraldehyde

Furfuryl Alcohol 2-Acetyl Furan

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Generation of furanic compounds is influenced by:
•Temperature
•Moisture content
•Amount of paper involved / oil volume
•Type of equipment (power Xfmrs, measuring xfmrs,
reactors, etc)
•Type of paper (Kraft papers vs thermally upgraded
papers)
•Type of system (sealed / breathing )
•Type of oil
•Cooling mode
•Loading (substation/generating xfmrs)
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2-FURFURAL IN OIL HAS A GOOD
CORRELATION TO THE POLYMERISATION
VALUE OF PAPER UNDER WELL DEFINED
LABORATORY CONDITIONS

BUT IN THE FIELD...

ONE VALID CORRELATION DP/2-FAL IS
HARDLY POSSIBLE FOR ALL CASES AND
CONDITIONS

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For a typical power transformer, with an oil to paper ratio of 20:1, the 2-
furaldehyde levels have the significance shown in the following table.
2-Furaldehyde Content (PPM) DP Value Significance
<0.1 700 - 1,200 Healthy
0.1 - 1 450 - 700 Moderate Deterioration
1 - 10 250 - 450 Extensive Deterioration
>10 <250 End of Life

Ref Powertech labs

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 Log 2-furaldehyde vs. Paper DP
Kraft DP TU Kraft DP Linear (TU Kraft DP) Linear (Kraft DP)

4 .5

4
Log (2-FAL - ppb)

3 .5

2 .5

1.5

0 .5

0
0 .0 10 0 .0 2 0 0 .0 3 0 0 .0 4 0 0 .0 50 0 .0 6 0 0 .0 70 0 .0

Paper DP

Log 2-FAL versus DP for Thermally Upgraded and Non-Thermally

Upgraded Paper
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Oil to cellulose ratio ~12:1

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Oil to cellulose ratio ~ 6:1
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 Data Collection
Oil Sample
• DGA
• Furans
• Oil Quality

Transformer Load and Maintenance History

• Load as a percent of nameplate
• Ambient temperature

Maintenance
• Leaking Gasket
• Cooling failure
• Defective expansion bladder
• Oil conditioning
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Ideal sample location

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 Transformer A
Operator: Cement factory
Year of manufacture: 1973
Power: 5 MVA
Voltage: 21 / 5.3 kV
Current: 138 / 545 A
Frequency: 50 Hz
Impedance: 6.9 %
Short circuit time: 4s
Ambient temperature: 40°C
Connection: Yd5
Cooling: ONAN
Free breathing via Silicagel
Total weight: 9.66 t
Oil weight: 2.34 t

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Transformer A
Oil analysis
Oil sampling temperature 25 °C Saponification 0.79 mg
number: KOH/g
Breakdown voltage: 14.8 kV Sludge: no sludge
Dissipation factor 90°C: 0.0701 Solids > 0.45 μm: 0.005 %
Interfacial tension: 16 mN/m Viscosity 40°C: 9.3 mm²/s
Water content 25°C: 69 mg/kg Furan content: 8.02 mg/kg
Acid number: 0.4 mg KOH/g 2-FAL content: 7.59 mg/kg

Dissolved gas analysis (DGA)

Total gas 138'649 ppm Methane CH4 3'782 ppm
Nitrogen N2 84'249 ppm Acetylene C2H2 18 ppm
Oxygen O2 3'239 ppm Ethylene C2H4 7'081 ppm
Carbon dioxide CO2 12'263 ppm Ethane C2H6 5'073 ppm
Carbon monoxide CO 1'103 ppm Propylene C3H6 17'472 ppm
Hydrogen H2 867 ppm Propane C3H8 3'502 ppm

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Transformer A
Interpretation Coefficients as per IEC 60599 2-FAL: 8 ppm
C2H2 C2H2
C2H4 C2H4
D1 D1

2.5 2.5
D1/D D1/D
1.0 2 1.0 2
D2 D2
0.6 0.6

0.2 0.2
T3
0.1 0.1

T2 T3

T2
0.01 0.01
PD T1 PD/T T1
CH4 1 C2H4
0.1 0.5 1.0 0.1 0.2 1.0 2.0 4.0 C2H6
H2

T1 = Thermal fault < 300 °C T2 = Thermal fault 300 °C < T < 700°C T3 = Thermal
H2 867 ppm C 2H 4 7‘081 ppm H2 Æ partial discharges fault > 700 °C
CH4 3‘782 ppm C2H6 5‘073 ppm C2H4 & C3H6 Æ local overheating (contact)
C 2H 2 18 ppm C 3H 6 17‘472 ppm CO2 / furans Æ extensive cellulose degradation

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Transformer A

Interpretation according to IEEE C57.104-99

Rogers Ratio – Thermal Fault < 700 °C

Doernenburg Ratio – Thermal Fault

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 Transformer A

hot contacts

partial discharges

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Transformer A

Measured DP values of the lead exit and the end insulation

Paper Cu Paper oil Block Block HV Block LV Washer
side side side side
(high) (low)
Lead exit HV 232 289
Top HV 486 434
Top LV 436 419
Bottom 574 563 461
HV/LV

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Transformer A
Measured DP values of the coils and the inter coil insulation
Designation Position Top Middle Bottom
Sheet between phases Pressboard 436 481 504
2. Turn Paper oil side 261 342 347
Paper copper side 216 278 285
11. Turn Paper oil side 251 287 322
Paper copper side 214 237 258
20. Turn Paper oil side 303 285 318
Paper copper side 251 236 253
Main insulation Strip HV side 423 404 442
2. Layer Board 405 402 361
Strip LV side 416 480 556
Conductor insulation 2. Layer Paper oil side 278 325 351
LV Paper copper side 231 256 257
2./3. Layer Strip 362 398 430
5. Layer Paper oil side 284 327 371
Paper copper side 237 254 302
LV to core Strip 427 507 540
Board core side 346 374 379

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Transformer A DP-Measurements: Overview
LV HV Degree of Polymerisation
10
> 900

Number of samples
801 - 900
701 - 800 8
601 - 700
501 - 600
401 - 500 6
301 - 400
201 - 300
Core

< 200
4

Windings 2

0
0 250 DP 500
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 Transformer A DP Profile
600

LV Winding HV Winding

500
Degree of Polymerisation

Bottom
400
Middle
Top
Cylinder 1 mm
300
Strip 3-5 mm
Paper inside
Paper outside
200
LV to Core Main insulation Between Phases

100

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Transformer A DP Distribution
10

8
Number of samples

0
0 250 500 750 1000
Degree of polymerization
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Transformer A
Furan Analysis

Chendong Relationship

Log(c2-FAL) = 1.51 – 0.0035 * DP

2- FAL content was 7.58 mg/kg

Equation gives DP value of 180

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 Transformer B
Operation: Substation, typical
load 40% nominal
Year of manufacture: 1988
Power: 30 MVA
Voltage: 69 / 13.8 / 8 kV
Frequency: 60 Hz
Connection: Dy5
Cooling: OFAF
Nitrogen blanket
ƒ No indications of insulation degradation based on oil analysis
ƒ Event: overload 133 – 150 % of nominal rating for 6 hours
ƒ Ambient temperature was unusually high during overload
ƒ Electric failure after 6 hours!
Failure hypothesis: Thermal degradation of the cellulose insulation due to temporary
overload
Disassembly of Phase A: no signs of a problem
Disassembly of Phase B: LV winding stuck

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Transformer B
Oil properties
Temp* H2O N2 O2 CO2 CO H2 CH4 C2H2 C2H4 C2H6 Furan
Date
°C ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppb
11/18/1996 14 5.8 59019 4926 270 2 0 1 0 0 2
9/9/1997 28 8 111684 4931 426 1 0 1 1 2 4
7/20/1998 36 11.1 80956 3374 401 0 0 1 0 1 2
11/9/2000 23 1 95375 6256 411 1 0 2 0 0 2
10/2/2001 27 10 196743 40268 687 0 0 0 0 0 0
10/29/2002 14 8 146260 22468 633 0 0 0 0 0 0 5
12/10/2003 15 6 112907 33515 597 0 0 0 0 0 0
1/4/2005 25 7 72202 0 522 0 0 0 0 0 0
2/16/2006 30 2 70985 25276 615 0 0 0 0 0 0 19
5/30/2006 80 21 89581 2730 881 38 25 9 0 3 0
6/12006 33 9 72389 2375 915 39 17 9 0 3 0 33
*Oil temperature at sampling

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Transformer B
DP values
Winding Axial height Material Turn oil side copper side
HV middle / top Conductor insulation 2 1060 1043
14 1099 1060
25 1119 1088
Spacer 1151
middle Conductor insulation 2 1104 1089
14 1118 1097
25 1119 1102
Spacer 1176
bottom Conductor insulation 2 1116 1113
11 1109 1096

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 Transformer B
Spacing spiral strip Collapsed strip
made of DDP paper
wrap

Phase A tap winding

Phase B tap winding

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 Conclusion
• Oil diagnostics are empirical in nature. Based on
historical data.
• Diagnostic algorithms have been established on entire
transformer populations.
• A post-mortem investigation can refine these
diagnostics for like transformer on the system.
• Post-mortem investigations can validate the relationship
of furans in the oil to the insulation age for the family of
transformers.
• A DP map gives the engineer a useful tool for the
correlation of furan to DP as well as to identify cooling or
design deficiencies within this family of transformers.
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 Conclusion
• Transformer A
• Removed from service based on oil diagnostics.
• Post-mortem investigation verified diagnostics.
• Insulation age.
• Partial discharge.
• Contact overheating.
• Transformer B
• Failed in service.
• Customer suspected thermal fault due to sudden load
increase.
• Post-mortem indicated that failure was mechanical.
• Insulation condition was essentially as shipped.
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Thank you for your attention!

Questions?

tom.prevost @ wicor.com

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