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Young Zaidey bin Yang Ghazali Technical Expert (Transformer Performance & Diagnostic) Engineering Department TNB Distribution Division
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ARSEPE 2008
1. INTRODUCTION
Electrical distribution equipment is generally designed for a certain economic service life. Equipment life is dependent on operating environment, maintenance program and the quality of the original manufacture and installation. Beyond this service life period they are not expected to render their services up to expectation with desired efficiency.
1. INTRODUCTION
Generally due to poor quality of raw material, workmanship and manufacturing techniques or due to frequent electrical, mechanical and thermal stresses during the operation, many equipment fail much earlier than their expected economic life span. The concept of simple replacement of failed power equipments in the system either before or after their economic service life, is no more valid in the present scenario of financial constraints.
1. INTRODUCTION
Explore new approaches/techniques of monitoring, diagnosis, life assessment and condition evaluation, and possibility of extending the life of existing assets (i.e. circuit breaker, cables, transformers, etc.) Minimization of the service life cycle cost is one of the stated tasks of the electrical power system engineers. For electrical utilities this implies for example to fulfill requirements from customers and authorities on reliability in power supply at a minimal total cost. The main goal is therefore to reach a cost effective solution using available resources which is captured by the concept of Asset Management.
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Reasonable returns
Low Cost
ASSET MANAGEMENT
Balancing cost, risk, and performance in the context of asset full life cycle
Maintenance Management
With the increasing age of the population of power system equipment utilities are making efforts to assess the internal condition of the equipment while in service before catastrophic failures can take place Different types of maintenance being done on equipment are: Breakdown maintenance Time or Calendar Based maintenance Condition based maintenance Reliability centered maintenance
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Maintenance Management
Today the paradigm has changed from traditional calendar based to condition based maintenance and efforts are being channeled to explore techniques to monitor, diagnose and assess condition of power system equipment This has led to the development of various on- and off-line non-intrusive tests in recent years that allow diagnosing the integrity of power system equipment to optimize the maintenance effort thereby ensuring maximum availability and reliability
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What is CBM?
Combining all available practical and theoretical knowledge and experience of assets to:
Define current condition and use this to estimate future condition and performance Provide a sound engineering basis for evaluating risks and benefits of potential investment strategies
Uses a well developed methodology (with practical experience of successful application) Provides a framework for continual improvement (information and definition of condition)
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Everything is related back to physical condition and degradation processes - maximising the value of available experience of the assets
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5 Health Index
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HI to Probability of Failure
CONSEQUENCES Phase 2
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ARSEPE 2008
DESIGN CONCEPT
The transformer has been designed, manufactured and tested according to IEC 60076 part 1 to 5. Power Transformer It consist of : core, winding, insulation, core and winding assembly, tank.
CORE
Grain Oriented Electrical Steel Type M5 (0.3mm), M4 (0.27mm) and ZDKH (0.23mm)
WINDING
Are designed to meet three fundamental requirement : 1. Electrical 2. Mechanical 3. Thermal
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WINDING
Round, Oval or rectangular in shape and are wound concentrically. LV winding is wound with foil conductor (Distribution) HV winding is wound with rectangular strip conductor. HV winding is wound on LV winding.
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INSULATION
The interlayer insulation are of high quality epoxy coated kraft paper (DDP) Corrugated pressboards are placed within the coil for cooling within the coil. Thickness of layer insulation in accordance with voltage and number of layers.
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TANK
It is hermetically sealed type and full fill with insulation liquid. Oil expansion or contraction due to the change in the transformer load is accommodated by the corrugated finwall of the transformer tank. Corrugated fins are use to provide sufficient cooling surface to dissipate the heat generated by the windings.
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TERMINATION
Both HV & LV is open bushing termination. Cable Box
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Core Building
Drying Process
Tanking Process
Despatch
Finishing
Testing
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Fans Control
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ARSEPE 2008
2. DGA
Most Commonly Used Insulations for Power Transformers OIL Provides overall insulation to the transformers Acts as coolant in extinguishing arcs Provides the means to monitor insulation condition and operation of transformers
H O
OH
H20
CO
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O2
COOH
COOH
CHO
1. 2. 3. 4.
Presence of water and acids Glycosidic bond exposed to slicing Causes scission to the cellulose chain By-products include free glucose
CH2OH HO OH
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2. With H2O and organic acids present in the oil, the free glucose molecules can degrade to 5-hydroxymethyl-2-furfuryl or 5H2F
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4. All these 5 compounds of glucose or degradation of glucose are known as Furans. 5. 2FAL is the most stable in the group 6. Furan generation is exclusively due to paper degradation unlike CO, CO2, H2O or acids which can also be produced through oil oxidation or breakdown.
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Cap Seal
Waste Vessel
Sufficient sample
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Syringe
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Fault gases - Hydrogen (H2), Acetylene (C2H2) Carbon Monoxide (CO), Carbon Dioxide (CO2) Ethylene (C2H4), Ethane (C2H6) Methane (CH4)
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Fault Condition
Thermal Oil
Key Gases
Major Ethylene & Methane Minor Ethane & Hydrogen
Electrical low energy Major Hydrogen & Methane Minor Ethane & Ethylene Electrical high energy Major Acetylene & Hydrogen Minor Ethylene & Methane Thermal Cellulose Major Carbon monoxide & Carbon dioxide Minor Methane & Ethylene
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IEEE Limit
Hydrogen (H2) Oxygen (O2) Nitrogen (N2) Carbon Monoxide (CO) Methane (CH4) Carbon Dioxide (CO2) Ethylene (C2H4) Ethane (C2H6) Acetylene (C2H2) 100 ppm N/A N/A 350 120 2500 50 65 35
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Never make a decision based on only ratio. Take into consideration the gas generation rates and amount of total combustible gases.
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CH4 / H2 1 0 2 2
C2 H4 / C2H6 0 0 1 2
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Status
Condition 1
Remark
Transformer working satisfactorily. Look for individual gas exceeding respective limit. Faults may be present. Additional investigation required based on individual gas exceeding respective limit. Faults probably present. Additional investigation required based on individual gas exceeding respective limit.
721-1920
Condition 2
1921-4630
Condition 3
> 4630
Condition 4
Continued operation could result in failure of the transformer As per IEEE C57.104
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Concentration limits of furan compounds must be supported by CO2/CO Ratio to assess paper degradation
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2FAL limits (ppb in oil): 58 292 Normal Aging 654 2021 Accelerated Aging 2374 3277 Excessive Aging 3851 4524 High Risk of Failure
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Transformer Age Operational Criterion number of faults, switching, lightning, etc. DGA Criterion (oil) Individual concentrations of CH4, C2H2, C2H4, C2H6 & H2 in ppm & Rogers/IEEE Ratio DGA Criterion (paper) Individual concentrations of CO2 & CO in ppm & CO2/CO Ratio Furan Criterion 2FAL concentration in ppb & others if detected
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Case Study
The following gas levels were detected via DGA on the oil from the load tap changer: 42 ppm of methane 17 ppm of Ethylene 0 ppm of acetylene Calculate percentages of each gas and use Duvals triangle approach to find the cause
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Hydrogen > 1500 ppm Acetylene > 1000 ppm Ethylene > 1000 ppm
When Ethylene level exceeds the maximum value the unit is removed from service
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Exercise
The following gas levels were detected via DGA on the oil from the load tap changer: 319 ppm of methane 181 ppm of Ethylene 1351 ppm of acetylene Calculate percentages of each gas and use Duvals triangle approach to find the cause
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ARSEPE 2008
Electrical Tests
1.
Tan Delta
To detect water in cellulose and chemical contamination
Winding Resistance
To detect open or short circuits or poor electrical connection in the windings
Turns Ratio
Electrical Tests
2. Advanced DiagnosticTests
Frequency Response Analysis (FRA) Recovery Voltage Measurement (RVM) Polarization Depolarization (PDC) Frequency Dielectric Spectroscopy (FDS) Partial Discharge (PD) OLTC Motor Current Signature Analysis (MCSA) OLTC Vibration Signature Analysis (VSA)
On-site Testing
Categorization of On-site Tests Destructive off-line tests are go/no go tests Non destructive off-line tests are diagnostic tests Non destructive on-line tests are condition monitoring tests
On-site Testing
These on-site tests are performed individually or in combination : Before energizing a new equipment as a commissioning test After maintenance After network alteration
Fig 4-4
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Degrees Centigrade
155 150 130 125 105 100 Class A Class B Class F Class H Class N Class R Class S Class C
Insulation resistance test (a) Insulation current test (b) Power factor (c) DC voltage withstand (d) AC voltage with-stand (e)
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Insulation resistance varies inversely with temperature for most insulting materials To properly compare periodic measurements of insulation resistance, it is necessary either to take each measurement at the same temperature, or to convert each measurement to the same base temperature i.e. 200C Polarisation Index is the ratio of the IR reading after 10 minutes to the IR reading after 1minute PI is used as an index of dryness Discharge the winding after a Polarisation Index Test for sufficient time before handling or performing other tests
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PI Value
> 4.0 4.0 2.0 2.0 1.5 1.5 1.0 < 1.0
Interpretation
Healthy OK Marginal Pass Deteriorated condition Failure
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Total current
Time
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Guard Connections
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Test procedures
Hot resistance test - at least 4 hours after shutdown from full-load operation, or until temperature is stabilized:
Disconnect the equipment to be tested from other equipment Ground the winding to be tested for at least 10 minutes Remove the ground connection and connect the insulation resistance tester Take readings at 1 -minute and at 10 minutes Record the temperature of equipment being tested Ground the winding again for at least 10 minutes
Cold resistance test - Four to eight hours after the hot resistance test or when equipment has cooled to approximately ambient temperature
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Spot Reading
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Temperature Correction
Dry type insulation 40C ambient Liquid type insulation 20C ambient Insulating materials have negative resistance characteristics Spot test reading must be corrected to a base temperature
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Conversion Factors For Converting Insulation Resistance Test Temperature to 20 C Temperature C 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 F 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 Multiplier Apparatus Containing Immersed Oil Insulations 0.25 0.36 0.50 0.75 1.00 1.40 1.98 2.80 3.95 5.60 7.85 11.20 15.85 22.40 31.75 44.70 63.50 Apparatus Containing Solid Insulations 0.40 0.45 0.50 0.75 1.00 1.30 1.60 2.05 2.50 3.25 4.00 5.20 6.40 8.70 10.00 13.00 16.00
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Polarization Index
Polarization index = R10/R1 = I1/I10 (keeping voltage constant) where: R10 = megohms insulation resistance at 10 minutes R1 = megohms insulation resistanceI at 1 minute I1 = insulation current at 1 minute I10 = insulation current at 10 minutes
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Polarization Index
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Interpretation
INSULATION CONDITION 60/30 SECOND RATIO Dielectric Absorption Ratio 10/1 MINUTE RATIO Polarization Index
Less than 1 Less than 1.1 1.1 to 1.25 1.25 to 1.4 1.4 to 1.6 Above 1.6
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In on site tan delta measurement there are two modes namely Grounded Specimen Test (GST) and Ungrounded Specimen Test (UST). During GST mode, the dielectric loss of insulation between one of the windings to ground will be measured depending on the winding that is being excited. Under UST mode, dielectric loss of insulation between the two windings will be measured irrespective of the winding being excited.
The ratio obtained from the field test should agree with nameplate value within 0.2% for the insulation system between the high voltage and low voltage winding at all taps. Otherwise, winding repair is recommended. The ratio obtained from the field test should be within the limit of 0.5% for the insulation system between the high voltage winding and ground. Otherwise, winding repair is recommended.
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Temperature
where: FP20 = power factor corrected to 20 degree C FPT = power factor measured at T degree C T = test temperature K = correction factor from table
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Temperature correction factors for the power factor of power transformer windings
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60
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Test Procedure
The machine winding should be grounded for at least 1 hour before conducting the test The phases should be separated and tested individually Lightning arresters and capacitors must be disconnected Cables and/or buswork should be disconnected if it is convenient to do so If the separation of phases is difficult then separation is needed once for the benchmark tests, and thereafter the phases may be tested together until deviation from normal is detected
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Test procedure
The voltage should be raised abruptly to the first voltage level with the start of timing for the test. The ratio of the 1-minute to the l0-minute reading of insulation current will afford useful indication of polarization index This gives the test engineer an idea of insulation dryness early in the test The test schedules are arranged to include a minimum of three points up to and including the maximum voltage
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Test procedure
If the insulation microampere versus voltage plots are straight lines, the test may be continued to the maximum test voltages The quality of the insulation may be judged by the position of any curvature or knee in the plot of insulation current versus test voltage If curvature or knee appears, the test should be stopped Upon completion of the dc, high- voltage test, the winding should be discharged through the special discharge resistor usually provided with the test set The winding may be solidly grounded when the voltage has dropped to zero or after a few minutes of discharge have occurred A winding should remain solidly grounded long enough before restoring the machine to service
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The ramped technique of insulation testing uses a programmable dc, high-voltage test set and automatically ramps the high voltage at a preselected rate (usually 1 kV/min) Insulation current versus applied voltage is plotted on an x-y recorder providing continuous observation and analysis of insulation current response as the test progresses The principal advantages of the ramp test over the conventional step method is the elimination of the human factor which makes it much more accurate and repeatable
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Rs Rm Ts Tm Tk
= = = = =
Resistance at the factory reference temperature (found in the transformer manual) Resistance you actually measured Factory reference temperature (usually 75 C) Temperature at which you took the measurements A constant for the particular metal the winding is made from: 234.5 C for copper 225 C for aluminum
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ARSEPE 2008
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By dividing the current by the voltage and comparing the phase difference, both the capacitance and the loss at the particular frequency and amplitude can be calculated.
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How do you know whether you can energize A TRANSFORMER after transportation to site or after a protection trip? Check Mechanical Integrity
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Transportation damage can occur if the clamping and restraints are inadequate; such damage may lead to core and winding movement. Radial buckling or axial deformation may occur due to excessive short circuit forces while in service.
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What Test can be Done? Frequency response analysis (FRA) using a low voltage AC wave of varying frequency to identify changes in natural resonance
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Why FRA?
FRA Technique: The technique covers the full dynamic range and maintains the same energy level for each frequency, providing results that are repeatable and accurate. Impulse Technique: This technique requires high sampling rates and high resolution to obtain a valid measurement. The applied impulse does not produce constant energy across the specified frequency, which can cause poor repeatability that is influenced by the non-linear properties of the test specimen.
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Test Equipment
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Historical data or Baseline Reference are, undoubtedly, the best reference to be used for FRA analysis However, it is not practically easy to get historical data due to constraints of outages Criteria to choose reference FRA measurements in the absence of historical data or baseline reference
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Partial Discharge
What is PD Electric discharge that do not completely bridge the electrodes Discharge magnitude is usually small but can cause progressive deterioration and lead to failure
Overeating of dielectric boundary Charges trapped in the surface Attack by ultraviolet rays & soft X-rays Formation of chemicals such as nitric acid & ozone
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Partial Discharge
PD Classification
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Partial Discharge
PD Classification
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Partial Discharge
Occurrence of PD Inception Voltage
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Partial Discharge
Occurrence of PD Inception Voltage
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Partial Discharge
Occurrence & Recognition Detection Measurement Location Evaluation
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Partial Discharge
Evaluation
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Partial Discharge
On-line acoustic PD Detection - Physical Acoustic DISP-24
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Manufacturers are using SFRA as part of their quality program to ensure transformer production is identical between units in a batch
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Insulator Maintenance
Inspection - look for cracks, dirt etc., tracking, copper wash, mechanical damage Cleaning - Wash, dry wipe Repairs - Usually replace except special cases Testing - Megger & Power Factor test Do not climb on or use for personal support!
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Inspect physical condition for evidence of moisture and corona Verify operation of cooling fans Verify operation of temperature and level indicators, pressure relief device, and gas relay Verify correct liquid level in all tanks and bushings Verify correct equipment grounding Verify the presence of transformer surge arresters Test load tap-changer Inspect all bolted electrical connections for high resistance using one of the following methods: 1. Use of low-resistance ohmmeter 2. Perform thermographic survey
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Perform turns ratio tests at all tap positions Perform power-factor or dissipation-factor tests Measure the resistance of each winding at all tap positions Perform insulation-resistance tests winding-to-winding and each winding-to-ground If core ground strap is accessible, measure core insulation resistance at 500 volts dc Remove a sample of insulating liquid in accordance with ASTM D923 Test for Oil Quality, DGA and Furan
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Conclusion
Diagnostic Testing provides a powerful tool for the complete and economic assessment of the transformer condition There is nevertheless still a lack on how to integrate the information obtained by the on-line monitoring into the actions taken onto the service of the transformer The supplementary information obtained by the off-line diagnostic after the detection of an abnormal condition is a worth-full information to be integrated into future on-line monitoring systems
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ARSEPE 2008
1. Scoring
Scoring can be applied to test results to indicate acceptable condition level of transformers. Transformer condition indicator scoring is somewhat subjective, relying on transformer condition experts. Relative terms are used and compared to industry accepted levels; or to baseline or previous (acceptable) levels on this transformer; or to transformers of similar design, construction, or age operating in a similar environment.
2. Weighting Factors
Weighting factors is used to recognize that some condition indicators, affects the Condition Index to a greater or lesser degree than other indicators. These weighting factors were arrived at by consensus among transformer design and maintenance personnel with extensive experience.
3. Mitigating Factors
Every transformer is unique and, therefore cannot quantify all factors that affect individual transformer condition. It is important that the Transformer Condition Index arrived at be scrutinized by experts. Mitigating factors specific to the utility may determine the final Transformer Condition Index and the final decision on transformer replacement or rehabilitation.
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% tan > 5
2. Turns-Ratio Test
This test is done on transformer at regular interval of 24 months under normal condition. This test results are considered for condition assessment of an in-service transformer. Results % deviation < 0.2 0.2 <% deviation < 0.3 0.3 <% deviation < 0.5 Score 3 2 1 Action Normal. The monitoring frequency of 24 months can be maintained. The monitoring frequency should be revised to 6 months. The monitoring frequency should be revised to 3 months. Make arrangement for advanced electrical tests tests. Perform appropriate advanced electrical tests tests as recommended by the expert or internal inspection of main tank and OLTC tank immediately.
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% deviation >0.5
BDV
0.1
Acidity
0.4
Power factor
0.2
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5(ii).
Moisture (ppm) 0-10 11-15 16-20 21-25 26-30 31-35 36-40 41-45 46-50 >50
36 - 45 51 - 100
Condition 3
701 1420
46 - 80
101 150
101 150
401 800
571 1400
1916 4000
Condition 4
> 1420
> 80
> 150
> 150
> 800
> 1400
> 4000
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8. Furanic Analysis
Furanic 0-200 201-400 401-600 601-800 801-1000 1001-1200 1201-1400 1401-1600 1601-1800 >1800 Estimated DP 646-1300 560-645 510-559 475-509 447-474 424-446 405-423 388-404 374-387 <373 Condition Indicator Score 10 9 8 7 6 5 4 3 2 1
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10. FRA
Results No deviation Comparison between phases (using Crosscorrelation Index, CCI): CCI at low freq zone >2.0 CCI at mid freq zone > 1.0 CCI at high freq zone > 0.6 Minor deviation Comparison between phases (using Crosscorrelation Index): 1.0<CCI at low freq zone <2.0 0.6<CCI at mid freq zone < 1.0 Moderate deviation Comparison between phases (using Crosscorrelation Index): 0.6<CCI at low freq zone <1.0 CCI at mid freq zone < 0.6 Significant deviation Comparison between phases (using Crosscorrelation Index): CCI at low freq zone <0.6 Score Adjustment Subtract 0 Action The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Practice FRA test if necessary.
Subtract 0.5
Retest the transformer for FRA after 6 months. The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Retest the transformer for FRA after 3 months. Arrange for replacement of defective section(s).
Subtract 1.0
Subtract 1.5
Indicates serious problem requiring immediate evaluation, additional testing (if applicable) and immediate consultation with experts
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11. FDS
Results % moisture in paper < 1.5 Score Adjustment Subtract 0 Action The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Practice FDS test if necessary. Retest the transformer for FDS after 6 months. The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Retest the transformer for FDS after 3 months. Arrange for replacement of defective section(s). Indicates serious problem requiring immediate evaluation, additional testing (if applicable) and immediate consultation with experts
Subtract 0.5
Subtract 1.0
Subtract 1.5
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12. PD
Results* Amplitude 40-60 dB Energy 1-200 Duration 100 ms-2000 ms Amplitude 60-70 dB Energy 200-300 Duration 200 ms-3000 ms Amplitude 70-80 dB Energy 200-400 Duration 3000 ms-4000 ms Amplitude 80-90 dB Energy 400-500 Duration 4000 ms-5000 ms Score Adjustment Subtract 0 Action The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Practice PD test if necessary. Retest the transformer for PD after 6 months. The monitoring periodicity of all basic electrical tests tests should be maintained at 6 months. Retest the transformer for PD after 3 months. Arrange for replacement of defective section(s). Indicates serious problem requiring immediate evaluation, additional testing and immediate consultation with expert. Recommendation is to remove the transformer from service immediately.
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Subtract 0.5
Subtract 1.0
Subtract 1.5
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