Complex

diagnostic methods for lifetime extension of

power transformers

Balint Nemeth*, Tibor Benyo*, Andras Jager*, Gusztav Csepes**, Gaibor Woynairovich Dr.
*: Ovit Ltd.

**

Hungary-1 158, Budapest, Korvasuit sor 105.

**:

MAVIR Ltd.

Hungary- Ot1 1, Budapest, Iskola u. 13.

Abstract- Power transformer, the most expensive equipment in
the power networks, is one of the key components from the point
of view of reliability. A failure of the transformer can result in
high cost due to repair or replacement and outage costs. Ageing is
often thought to be the most important cause of the component
failures. That is why the proper determination of the degree of
ageing is so important. A significant part of the typical
transformers population is 20-30 years old, when the reliability of
the transformers comes questionable. Asset managers are moved
from time based maintenance (TBM) to condition based
maintenance (CBM), or even reliability centered maintenance
(RCM). In RCM decisions are no longer driven by an average
time-frame defined by observation and statistical experiences,
but the actual conditions of the equipment and the level of the
reliability are taken into account. The paper shows the main
elements of the complex diagnostics of the transformer used by
the National Power Line (Ovit) Co. Ltd. and by the Hungarian
Transmission System Operator (Mavir) Co. Ltd. According to
the experts suggestions and the statistical results of the
"fingerprint" data, the different refurbishment and repair
methods (in field or in factory) for high voltage transformers are
shown.

where it has been established that the parameter correlates

with initial failure conditions. Thus detailed information via
diagnostic methods or monitoring systems should be available
and finally assessed.
Reliability Centered Maintenance (RCM): in addition to the
condition of an equipment this strategy also pays attention to
the importance of that item for the grid. One of the relevant
importance factors may be the reliability of the grid or
unavailability of electrical energy.
While the first three options involve a number of relevant
disadvantages, more and more attention is recently given to
the fourth approach. The concept of RCM involves the
definition of a maintenance program based on the use of
operational reliability techniques and the formalization of
identified objectives [1].
CBM and RCM both need on-line monitoring and on-site
measurement results with database and trends.
The goal is to achieve the "perfect balance" between
maintenance and operation to optimize both availability and
cost.

I. INTRODUCTION

III. FAILURE OF POWER TRANSFORMERS

Significance of testing, monitoring, and diagnostics the

condition of transformers insulating system is growing every
year, together with the growth of production, transition,
distribution and consumption of electricity. Utilities are
finding the average age of the transformer population is now
exceeding or will soon exceed 25 years. The degradation
mechanisms of oil-paper insulation are complex and
complicated, the transformer faults are often difficult to
diagnose.

The failures can be divided into groups based upon the

origins of the different components. This is done by making
groups of the component according to CIGRE:
-Tap-changer: this includes the off-load as well the
on-load tap changers,
- Leakage: problems conceming the tank and the
dielectric fluid,
- Bushing,
- Windings:
short circuit of the windings of a
transformer,
- Core: problems concerning the magnetic circuit,
- Other: e.g. temperature problem.
The occurrence of failures in power transformers as reported
in [2,3] is graphically shown in Fig. 1.

II. MAINTENANCE STRATEGIES

There are different strategies for solving maintenance issues.
Corrective Maintenance (CM): replacement or repair is
fulfilled only if a failure has been occurred.
Time Based Maintenance (TBM): components are
maintained or replaced after a specified period.
Condition Based Maintenance (CBM): is to detect its
beginning and predict the point in time where failure is likely
to occur in the future by measuring parameters over time

978-1-4244-2092-6/08/$25.00 2008 IEEE

132

Other

12% _M

between the stresses. Interactions may be positive or negative.

The aging of a practical electrical insulation system can be
complex and failure is usually caused by a combination of
aging mechanisms, even though there may be only one
dominant aging factor [4].

Core

3%

Tap-changer
41i

19%

Bushn
12%

DMSA

__
Leakage
13

:)

Fig. 1. Failure statistics of different transformer components

reported by CIGRE
Core, windings, insulation oil, bushing, and on-load tap
changer are the main active parts of the transformer insulation
chain. The degradation of insulation systems is accompanied
by phenomenon of changing physical parameters or behavior
of insulation components. More over, the degradation of
insulation systems is a complex physical, chemical and
mechanical process. Many parameters act at the same time
thus making the interpretation and diagnostics extremely
difficult.

5ff
0?7 f

'D

Mtchaniea1

~t

pres

~ Agigftic-

Fwto
process

Fig.2. Condition assessment

There are same examples to measure the complex behavior
of the insulation.
Mechanical process: one of the most common types of failure
in HV transformers (Fig. 1.) is a winding failure caused by the
forces associated with the through-fault. To detect mechanical
failure in winding FRA can be used, winding vibration
measurement, leakage inductance measurement, excitation
current and capacitance measurement.
Thermal process: The common tests used in detection of
thermal risk are dissolved gas-in-oil analysis, estimation of
degree of polymerization, furan analysis. Another thermal risk
factor is hot spots in metallic materials such as a core or
current carrying contacts.
Electrical process: Conditions such as the dissipation factor
of the insulation, oil quality results (moisture, dielectric
strength), the amount and distribution of dissolved gases in oil,
recovery voltage, on-site induced AC test with PD
measurement may be used in the evaluation of the dielectric
failures.

IV. MEASUREMENT

A.

Methods and techniques

Most
diagnostic
systems
(including laboratory
measurements, off-line testing, periodical on-line, and
continuous on-line monitoring) serve to detect changes in the
insulation system and inform of early warning system.
Conditions and defects that could be detected by appropriate
measurement methods and techniques are: hotspots,
degradation of the insulation, excess moisture in paper and oil
insulation, partial discharges, localized faults, mechanical
defects (partial rupture) and chemical or thermal ageing.
Mainly, none of these defects can be detected by one singular
measurement or monitoring procedure. Therefore we need to
apply a multitude of different methods.
From the large number of measurement and monitoring
methods and techniques we select those that are currently in
use in National Power Line Co. Ltd. and by the Hungarian
Transmission System Operator Co. Ltd. 1 - insulation
resistance/polarization index (Ri/PI), 2 - power loss factor
(PF), 3 - partial discharge (PD), 4 - frequency response
analysis (FRA), 5 - dielectric response measurement (RVM),
6 -DGA-analysis (DGA), 9 - Oil-analysis (OA), 10 - degree
of polymerization (DP), 11 - winding vibration measurement,
12 - tg6/C measurement, 13 - tap-changer measurement, 14 furan analysis, 15 - on-site induced AC test and PD
measurement.
The aging factors produce electrical, thermal, mechanical,
or environmental aging mechanisms that eventually lead to
failure (Fig 2.). During aging applied stresses, which initially
may not affect the electrical insulation system, can come aging
factors that, as a result, modify the rate of the degradation.
When aging is dominated by one aging factor, this is referred
to as single-factor aging. Multifactor aging occurs when more
then one aging factor substantially affects the performance of
the electrical insulation system. Aging factors may act
synergistically, that is, there may be direct interactions

B. On-line monitoring
After 2004 all new high voltage transformers have on-line
monitoring systems and starting the older transformers
implementation part of the branch work reconstruction.
Main functions are hot spot temperature measured or
calculation, apparent power, over-voltages on HV bushings (3
or 6 bushings), HV bushing capacitance monitoring, operating
and short-circuit currents on HV and LV side, overload
capacity, bubbling temperature, gas in oil content, cooling
system running hours, tap changer position, drive mechanical
quality monitoring, summing of tap changer switched load
current and duration of changing, vibration monitoring, paper
moisture content calculation, ageing and lifetime calculation,
ability to use off-line measurement results.
Fig.3. shows the structure of the applied system. The
software is built up of two main parts: communication and
data logging unit (which collects information from the Data
Processing Unit and from the local SCADA) and the Expert
System (visualization and evaluation). The computer in the

133

control room with large storing capacity and wide

communication abilities forms the heart of the expert system.
The up-to-date information is available from the control room
and optionally from remote access (modem, internet). The
system offers communication with the local SCADA system.
Main information for the operator can appear together with the
standard substation information.

With using on-line monitoring systems you can forecast and

prevent the failure then for locating the defect part you can use
off-line measurements (on site tests). There are possibilities to
use the failure suspicion transformer with the on-line
monitoring system, but the risk of damages is much higher in
this case. Using the results of the off-line measurements and
the data-, knowledge base we can give a decision for the aging
factors.
IV. REPAIR AND REFURBISHMENT
In Hungary the majority of the HV transformer was installed
in 70's and 80's. Replacing them with new ones - only
because their age - would be clearly uneconomic.
The degradation of oil-paper insulation is complex and
complicated mechanism and the transformer faults are often
difficult to diagnose. It is well known problem with the older
transformers that significant winding shrinkage can occur after
a long-term service, leading to reduction in clamping pressure
and short circuit withstand strength.
The rate of transformer failure caused directly or indirectly
by the winding deformation is relatively high. In such cases it
would be desirable to monitor the mechanical condition of
transformers not only periodically but on-line during their
service life to provide an early warning of such a failure.
In order to minimize the cost of operation of transformer
throughout its life, it is important to periodically check the
internal conditions, diagnose the degree of its deterioration
and carry out proper cost-effective preventive/corrective
maintenance, repair or refurbishment on-site or in factory
taking into consideration its remaining life.
The time and the cost of the transportation of the transformer
to the factory is very considerable, therefore the place of the
refurbishment is very important. Number of technical and
economical aspects must be assessed.
To good decision making it is essential that advanced
suitable on-site diagnostic tools are readily available to assess
the condition or localize the damage in the transformer. Lots
of on-site test, refurbishment and repairs on power
transformers have been performed since many years.
However, it is only recently that induced AC test with PD
measurement and an on-line vibration measurement have been
carried out. The Hungarian on-line vibration measurement
system had a hydrophone checking the vibration directly
through the oil. The hydrophone is mounted onto the drain
valve of the transformer with adapters. The hydrophone
detects pressure waves propagated in the oil, caused by the
vibration of the winding. Using computerized analysis of
measurement results (Fast Fourier Transformation, FFT)
enables early detection of weekend components [5].
Hungarian and international experiences show that only a
small number of transformers demanded an immediate repair
and "as a rule". An individual approach is necessary to the
repair or refurbishment of each transformer, that are strict
observation of technology requirements, a permanent control
the oil parameters and insulating properties of windings, as

K
Fig.3. Structure of the on-line monitoring system

C. Diagnostic procedures
The aging of a practical electrical insulation system, as
mentioned before, can be complex and failure is usually
caused by a combination of aging mechanisms, even though
there may be only one dominant aging factor. Mainly, none of
these defects can be detected by a singular measurement or
monitoring procedure. Therefore we need to apply a multitude
of different methods together with diagnostics procedures like
fingerprinting and trend analysis to identify the velocity of
change, the rate of progressiveness etc. Data and knowledge
base are the key elements of modern IT use in planning,
exploitation, and managing the power supply system in
technical and business sense. Using the benefits of modern ITtechnology, the closed loop, up-to-date and high effective
testing-monitoring-diagnostics management system, presented
in fig. 4, is realized.

Off-line measurements:

On-line monitoring system

~ ~ Ri/P,

- hot spottemperatureX

tg6iG

HV b-sig capac,it-

-opefating anld shott ciffuit

current
g

ir
il

-FRA

-vibra~tion .-rit.finlg
-aging andlifetime cluaIol-

MIechanical
| process

DOA, OA

cotent

RVM

DP

ta~p,-cager

Thermal

|Electrical

process

process

esree

Decision

Fig. 4. Complex transformer diagnostics

134

well as accumulated experience in repair on the basis of

advanced technologies.
Each HV power transformer is individually analyzed to
determine the real condition for setting up the optimal
solutions from the technical-economic point of view to keep in
operation for as long as possible. The comparison the cost of
new transformer and higher risk of failure a possibly higher
running costs and others, the Hungarian experiences show that
the on-site repair or refurbishment of a transformers probably
were economic (the on-site repair cost was approximately 1315% of new transformer price).
During the last years there were two successful on-site repair
and refurbishment the investigated unit was a 22 and a 28
years old, 250 MVA, 400/120 kV autotransformers [5].
At the end of 2007 there was another on-site repair. The
investigated autotransformer has been in operation for 21
years, and after 21 years operation had carried out a
refurbishment in factory. After putting into operation again the
transformer had undergone some very close short circuit, but it
has remained in service for 9 years. According to vibration
measurement the winding were loosed, and the DGA has
showed light PD activity. For lack of serious problem, the
result of the decision making was "on-site refurbishment and
repair". Since the beginning of on-site repair there has not
been abnormal rate of failure of transformers, the on-site tests
were successful included the induced voltage test with PD
measurement, they had carried out the on-site repair. After the
on-site repair during the new induced voltage test the PD level
in phase "B" was enormous (the amplitude was of 100.000
pC, before the repair PD level was below of 100 pC). During
the parallel acoustic and electrical PD measurement it was
observed that the source of PD activities should be in phase
"B", the type of PD should probably be "conductor on floating
potential", and with the acoustic methods it was possible
localizing the source of PD (Fig. 5., Fig. 6.). After repairing
the wrong connection all tests were successful, the transformer
was switched back into service and has operated without any
further problem ever since.

Fig. 6. Conductor on floating potential

VI. CONCLUSION

The degradation of insulation system is a complex physical,

mechanical and chemical process. Many parameters act at the
same time, thus making the interpretation extremely difficult.
Based upon the results of the complex diagnostics
measurement, the owner of the transformer have to decide
repair or refurbishment of damaged or poor condition unit in
factory or nowadays more commonly on site. The choice of
repair site depends on a structured technical, operational and
economical evaluation of possible alternatives: technical
viability of performing on site repair, available time for repair,
time and cost for site-factory-site transportation, cost and risk
of additional damage associated with transportation.
Hungarian Transmission System Operator Co. Ltd. repaired
or refurbished the large power transformers mainly in factory,
only during the last years decided to do on site when the
decision processes are technically and economically
established.
REFERENCES
[1] C. Basille, J. Aupied and G. Sanchis, "Application of RCM to high
Voltage Substation" Proc. of the Reliability of Transmission and Distribution
Equipment, March 1995, No. 406, pp 186-191
[2] R-A. Jongen, P.H.F Morshuis et al., "Failure data power transformers as
input for statistical failure analysis", 15th International Symposium on High
Voltage Engineering, Ljubljana, Slovenia, August 2007, pp. T6-207
[3] A. Bossi, J.E. Dind, J.M. Frisson et al., ,, An International Survey of
Failure in Power Transformer Failure Data", Final Report of the Cigre
Working Group 12.05, Electra, 1983, no. 88, pp.21-48
[4] Evaluation and Qualification of Electrical Insulation Systems", IEC
Committee, Tech. Rep. 98/60 505/ed. 2, 1998
[5] G. Csepes, G. Woynarovich, Gy. Morva et al., "On-site high voltage
tests, repair and refurbishment on HV power transformers" MATPOST 2007.

Fig. 5. Acoustic measurement

135