Transformer Lecture

The Transformer and its Maintenance

CJC V30 Transformer Oil Vacuum Filtration Unit & Ion Exchange Filtration Units

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture
The V30 Vacuum Filter
Installed at Rathkeale Power Station, Ireland

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture V30 Mo I Rana, Norway

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture
V30 Production
C.C.JENSEN A/S Svendborg

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture Hypothesis

Oil O2
Acids are formed by oxidation

H2O
Paper ageing: Water & acids

Acids

accelerates ageing. Water is formed

Oil reclaiming Transformer refurbishment

H2O

Source: L. Lundgaard, SINTEF Energiforskning AS

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture Ageing Factors

Catalysts: Water. Copper. Oxygen. Accelerators: Heat. Ageing products. Dirt. Vibrations / overload. Electrical stress / voltage waves.

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture Ageing Processes

Pyrolysis
(heat)

Hydrolysis
(reactions with water)

Oxidation
(reactions with O2)

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture
The Transformer and its Maintenance
When oil (CxHy) and O2 react chemically the oil starts to deteriorate (oxidize, age).

During this reaction the following compounds are formed:

Sludge: Reduces the break-down voltage. Reduces the cooling effect. Deteriorates the cellulose. Acts as catalyst for further oxidation. Acids: Create corrosion Acts as catalyst for further oxidation Water: Deteriorates the cellulose. Reduces the break-down voltage. Acts as catalyst for further oxidation. Gasses: Among others CO, CO2, O2, H2, CH4 , C2H4, C4H6, C6H8.

The aging process dramatically increases the higher the oil temperature is and if catalysts are present (sludge, water, acids, cupper).
C.C.JENSEN A/S - Kim Kjr March 2005 8

Transformer Lecture
Development in Transformer Design
Year 1915 1930 1945 1960 1975 1977 1979 Ltrs of oil / kVa 9,00 4,50 2,25 1,50 0,75 0,65 0,50

Source: Grestad Diag. & Rehab. AS - SDMyers.

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture Causes of Failure

70 % of all failures happens on transformers older than 30 years. 50 % of the failures originates in OLTC and lead-in bushings. 15-20 % are due to reduced stability; water and particles in the isolation. 3-5 % due to far progressed ageing. 10-15 % due to core mechanically weakened by twisting. Old constructions may have gas problems due to induction loss.
Source: Grestad Diag. & Rehab. AS Doble og ZTZ

C.C.JENSEN A/S - Kim Kjr March 2005

10

Transformer Lecture
Lowering the Oxygen Concentration slows Down Oxidation
Depolymerisation of Cellulose. Accelerated Ageing (130 C) With/Without Presence of Oxygen
1200 1100 1000 900 800

DP-value

700 600 500 400 300 200 100 0 0 20 40 60 80 100 120 140 160 180 200

Oxygen

No Oxygen

Time [days]

C.C.JENSEN A/S - Kim Kjr March 2005

11

Transformer Lecture
Ageing of Cellulose No Oxygen Present

Ageing under a Nitrogen blanket. These curves are interesting because they show the effect of no oxygen (same as having an efficient Nitrogen blanket). Please note the relative speed of the ageing btw. 0% and 1% moisture. This change in reduction of DP is much more severe than from 1-2% moisture.
Source: Roland Agnemo

C.C.JENSEN A/S - Kim Kjr March 2005

12

Transformer Lecture
Oxygen
- affecting Transformer Life Length
100,00 30,00

Year

10,00 3,00 1,00 0,30 0,10 0,03 0,01

90 110 O 130 150 170 190

Low

Hig h

con ten t

con te

nt

C
Source: Grestad Diag. & Rehab. AS . / SDMyers.

C.C.JENSEN A/S - Kim Kjr March 2005

13

Transformer Lecture
The Oxygen-Free Transformer
DEOX - ASEA 1977 (today ABB)
In the years 1976 & 1977 ASEA published articles about the oxygen-free transformer. It was tested on a transformer with rubber membrane and continuous degassed including filtration. Specification: Oxygen: Water: Particles: < 300 l/l. < 0,5 %. < 5 m. Conclusions: Higher dielectric strength of the oil. Reduced ageing. Continuous monitoring of the gassing rate. These features are achieved with a a new apparatus which incorporates: Continuous filtration (freedom from fibres and metal particles in the oil).

Gas-free oil: 200 N/m2, <1 Torr (1.33 mBar).

Ageing rate reduced by a factor of 5.

C.C.JENSEN A/S - Kim Kjr March 2005

Continuous degassing (freedom from water and oxygen, gas-hungry oil). Continuous monitoring of the gassing rate for total and combustible gases.
Source: TG Diagnostikk & Lampe et al.

14

Transformer Lecture
Life Expectancy can be Calculated from Water Content and Temperature.

Expected Life

1 1 13350 DPEnd 1000 * e T 273 year A * 24 * 365

Source: L. Lundgaard, SINTEF Energiforskning AS

C.C.JENSEN A/S - Kim Kjr March 2005

15

Transformer Lecture
The Model Facilitiates Analyses of Impact from Temperature and Water.

20oC gives acceleration of e2 = 7.4. Dry to wet gives acceleration of e3 = 20. Wet and 20oC gives acceleration of e2+3 = 7.4 x 20 = 148.

Source: L. Lundgaard, SINTEF Energiforskning AS

C.C.JENSEN A/S - Kim Kjr March 2005

16

Transformer Lecture
Acid generation accelerates when water and oxygen are present. Acid in turn causes acid-hydrolysis.

C.C.JENSEN A/S - Kim Kjr March 2005

17

Transformer Lecture
Gases generated during a Fault
Combustible Gas Generation vs. approximate Oil Decomposition Temperature.

C.C.JENSEN A/S - Kim Kjr March 2005

18

Transformer Lecture
The Transformer and its Maintenance
Gas Analysis
Gas
H2 CH4 CO CO2 CH4 C2H6 C2H4 H2 C2H2 CO CO2 Hydrogen Methane Carbonmonoxide Carbon dioxide Methane Ethane Ethylene Hydrogen Acethylene Carbonmonoxide Carbon dioxide Decomposition of cellulose
19

Reason
Normal ageing

High oil temp. Partial discharges Arcing

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture
CO and CO2
is produced through paper Ageing
CO / CO2:
1/10 = normal oil ageing 1/1 = very hot 2/1 = very very hot 1/5 = normal ageing of paper

water 8% vann

v 0,5% ann water

CO2: More than 2,000 ppm is alarming!

C.C.JENSEN A/S - Kim Kjr March 2005 20

Transformer Lecture
CO / CO2 Ratio
CO/CO2 Ratio

CO/CO2 ratio

CO/CO2 Ratio curve for recorded failures in Canada on conservator type transformers without tap changers communicating with the main body. Acceptable dissolved gas-in-oil concentration levels in power and instrument transformers as function of age. 2,500 transformers.

2.5

1.5

0.5
C O/C O2 Ratio

0 0 5 10 15 20 Probability of failure [%] 25

Source: Lars Arvidsson. M.Duval, F.Langdeau,P.Gervais,G.Belanger.

C.C.JENSEN A/S - Kim Kjr March 2005

21

Transformer Lecture
Oil Regeneration & Reclaiming

Will remove some moisture from paper.

But with oil in the transformer the moisture transport takes time.

Will remove some acids from paper.

Oil acidity is reported to be stable and low after fluidex treatment (how many passes).

C.C.JENSEN A/S - Kim Kjr March 2005

Source: L. Lundgaard, SINTEF Energiforskning AS.

22

Transformer Lecture
Transformer Features:
Working at 20C 1 ton of paper 10 tons of oil 10 ppm water measured in oil

Degasser Features:
Flow 1000 l/h Removal efficiency 100%

Calculation:
We can clean 24 tons in per 24 hours - we have 10 g per ton, so we can remove 240 g per 24 hours. We have totally 46,100 g of water in the transformer 46,100 g / 240 g = it takes 192 days to remove all water in this transformer.

Calculation:
10 ppm of water 10 mg/kg 10 g/ton in 10 tons of oil: 100 g of water. 4,6% of 1 ton of paper 46 kg of water. 100 g of water in oil and 46 kg of water in paper 99,8% of water in cellulose.

C.C.JENSEN A/S - Kim Kjr March 2005

23

Transformer Lecture
Water in Oil Water in Cellulose Relation
T (C)
0 10 20 30 40 50 60 70 80 90

Commen
20 33 53 82 122 179 255 358 491 663 880

Griffin
23 36 56 83 122 174 243 334 450 596 777

Shell
22 35 55 84 124 180 255 355 484 648 855

Log(Water ppm) = A B/T

Where A=7.09-7.42; B=1567-1670 C.C.JENSEN A/S - Kim Kjr March 2005

100

24

Transformer Lecture
The Transformer and its Maintenance
Oil/Cellulose Humidity Correlation - at different oil temperatures
10
W a t e r i n ce ll u l o se ( W % )

20 C O

30 C O

8 6 4 2 0

50 C O

70 C 90 C

20 40 Water in oil (ppm)

60

80

C.C.JENSEN A/S - Kim Kjr March 2005

25

Transformer Lecture
Summarizing
End-of-life of transformer = End-of-life of cellulose isolation. Heat, water, oxygen and ageing products are severely contributing to transformer ageing. The possibilities of reconditioning transformers on site are good: drying, continuous degassing and regeneration.
C.C.JENSEN A/S - Kim Kjr March 2005 26

Transformer Lecture
Conclusion
By lowering the Oxygen concentration in the oil, the oxidation (degradation) of the cellulose is reduced. By removing water from the transformer the remaining life time is increased. By removing particles the break down voltage is increased. By reducing acidity levels the transformer cellulose is better protected against ageing acceleration.

C.C.JENSEN A/S - Kim Kjr March 2005

27

Transformer Lecture
Vacuum Filtration Unit
Highly efficient Deaeration & Drying of Power Transformer Oils.

C.C.JENSEN A/S - Kim Kjr March 2005

28

Transformer Lecture
V30 Vacuum Filter - Principle of Operation

A = Oil Inlet B = Oil Outlet C = Gas Outlet D = Oil Drain

C.C.JENSEN A/S - Kim Kjr March 2005

B A

29

Transformer Lecture

C.C.JENSEN A/S - Kim Kjr March 2005

30

Transformer Lecture
V30 Efficiency of Water Removal
Example: 20 ppm in >> 6 ppm out

The V30 will remove moisture down to 4 ppm given time enough. The curve above shows the efficiency of full flow and minimum pressure of 2 mBar.
C.C.JENSEN A/S - Kim Kjr March 2005 31

Transformer Lecture
Water Removal
on a very dry Transformer, Stubbekbing

water content in/out [ppm]

6 5 4 3 2
ppm in ppm out

1 0 06-06-03 07-06-03 08-06-03 09-06-03 10-06-03 11-06-03 12-06-03 13-06-03

32

tim e

C.C.JENSEN A/S - Kim Kjr March 2005

Transformer Lecture
Oxygen Removal
V30 Stubbekbing
O2 Concentration vs time. Stubbekbing, Denmark. 8000L oil in transformer.
22000 20000 18000 Oxygen concentration in oil [ppm] 16000 14000 12000
V30 Started

20910
V30 Started

10000 8000
V30 Stopped

6000 4000 2000 0 02-03-2003

5870 1940 200

11-04-2003 01-05-2003 21-05-2003 10-06-2003 30-06-2003 20-07-2003

720 580
22-03-2003

1307
09-08-2003

Time

C.C.JENSEN A/S - Kim Kjr March 2005

33

Gas in oil concentration [ppm] 10000 12000 14000 16000 18000 20000 2000 4000 6000 8000

0 24-07-1998 01-11-1998 09-02-1999 20-05-1999 28-08-1999 06-12-1999 15-03-2000 23-06-2000 01-10-2000 09-01-2001 Tim e 19-04-2001 28-07-2001 05-11-2001 13-02-2002 24-05-2002 01-09-2002 10-12-2002 20-03-2003 28-06-2003 06-10-2003 14-01-2004

C.C.JENSEN A/S - Kim Kjr March 2005

O2 Concentration INLET
V30 Degasser Started

CO2 Concentration INLET

Oxygen Removal
with V30, Ljusdal

Transformer Lecture

34

Transformer Lecture
Oxygen Content & Carbon Monoxide Generation
i.e. Rate of Paper Degradation
12 22000

V30 Started
Koncentrationsforhold [O2 ppm/ CO2 ppm]

20000 18000
Koncentration O2 [ppm]

10

16000 8 14000 12000 6 10000 4 8000 6000 2 4000

O2/C O2 O2 C oncentration IND

2000 0

0 01-12-1996 30-05-1997 26-11-1997 25-05-1998 21-11-1998 20-05-1999 16-11-1999 14-05-2000 10-11-2000 09-05-2001 05-11-2001 04-05-2002 31-10-2002 29-04-2003 26-10-2003

Tid

C.C.JENSEN A/S - Kim Kjr March 2005

35

Transformer Lecture
V30 Advantages
Removes OXYGEN from the transformer oil. Down to 200 ppm. Removes WATER from the transformer oil. Down to 4 ppm. Removes PARTICLES from the oil. Down to 0.4 micron. With an ion exchange filter ACID is removed. Down to 0.01 mg KOH/g.

C.C.JENSEN A/S - Kim Kjr March 2005

36

Transformer Lecture
Results using a V30 / Ion Exchange Filter
Typical value for aged system Water in oil Water in cellulose Particles, ISO Breakdown Voltage/2.5mm Bubble Formation Temp Oxygen Tan delta@ 90C Acid 20 - 40 ppm 2-7% 14/10 - 16/13 35 - 60 Kv 95C 20,000 25,000 ppm 0.0500 - 0.1500 0.10 - 0.25 mg KOH/g After filtration 4 ppm 0.6 - 1.1% 11/8 >75 kV 170C 200 2,000 ppm 0.0050 0.01 - 0.02 mg KOH/g Time frame years years days days weeks weeks months months

ISO-standard. The old 5 my and 15 my standard.

Source: EFFECT OF PARTICLES ON TRANSFORMER DIELECTRIC STRENGTH Working Group 12.17 - CIGRE

C.C.JENSEN A/S - Kim Kjr March 2005

37

Transformer Lecture
CJC V30 Safety Features
High pressure alarm.
In case the vacuum pump fails to keep the pressure below a preset value. In case the transformer starts gassing and the gas content of the oil increases rapidly. Adjustable from 2-250 mBar (down to 500 ppm gas in oil increase. A Buchholz relay can only detect free gas >70,000ppm H2 ).

Low level alarm.

In case the oil level inside the vacuum chamber falls below a preset value. Medium level stops the oil pump, low level stops the system.

Vacuum pump low vacuum oil level alarm. Drip pan oil sensor.
In the unlikely case of leakage. The system shuts itself off.

Foam sensor that shuts vacuum off.

Oil in (as foam) cannot leave the system.

One way valve on vacuum pump.

Air/fluids cannot enter only leave the system.

All alarms on potential free relay.

C.C.JENSEN A/S - Kim Kjr March 2005 38

Transformer Lecture
Optional CJC V30 Safety Features
Shut off valves operated by differential oil pressure monitoring system on inlet. Non return valve on outlet.
C.C.JENSEN A/S - Kim Kjr March 2005 39

Transformer Lecture
V30 Vacuum Filter
Early Warning Systems
The CJC V30 Vacuum Filtration Unit equipped with standard as well as optional sensors will operate as an early warning system for the transformer. This includes:

1. Gassing alarm on V30 indication of a high thermal fault in the transformer. 2. Increased water in oil detection indication of a low thermal fault. 3. Specific gasses produced high thermal fault more sensitive than gassing level. Direct online gas measurement. Hydrogen, Methane, Carbon Monoxide. 4. Abnormal rise in oil temperature detects large scale heating. 5. ComPosIT GSM datalogger. Alarm via sms. Data on WWW. Especially the gas sensor will yield important information and a very early warning for a possible fault.
C.C.JENSEN A/S - Kim Kjr March 2005 40

Transformer Lecture
Filaret T3 Filaret, Bukarest, Romania
Results obtained running a CJC V30 for 5.5 Months on a Power Transformer.
Data for the transformer:
Distribution transformer 40 MVA 110/10.5 kV Oil: TR 25 A Oil weight: 20,000 kg Cooling system: OFAF Conservator: Open/Shared, no tap changer Produced by: Electroputere Craiova, 1970
The CJC V30 Vacuum Filter was started up on 26/2-2004.

C.C.JENSEN A/S - Kim Kjr March 2005

41

Transformer Lecture
Moisture
This curve shows the saturation of the oil with terms of water. A curve which corresponds to the relative humidity in air.
Water activity in oil [absolute water saturation of the oil]
0.340 0.320 0.300 0.280 0.260 Water activity [%/100] 0.240 0.220 0.200 0.180 0.160 0.140 0.120 0.100 0.080 0.060 0.040 0.020 0.000 2004-02-13 2004-02-23 2004-03-04 2004-03-14 2004-03-24 2004-04-03 2004-04-13 2004-04-23 2004-05-03 2004-05-13 2004-05-23 2004-06-02 2004-06-12 2004-06-22 2004-07-02 2004-07-12 2004-07-22 2004-08-01 2004-08-11 2004-08-21 aw [%/100] 25 per. Mov. Avg. (aw [%/100])

Time

When the CJC V30 was first installed (26/2-2004) the saturation of water in oil was about 18%, now it has been lowered to below 6%.
C.C.JENSEN A/S - Kim Kjr March 2005 42

Transformer Lecture
Water Content in ppm
This curve shows when the saturation values have been converted into ppm.
20.00 18.00 16.00 Water in oil [ppm] 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00
2004-02-23 2004-03-04 2004-03-14 2004-03-24 2004-04-03 2004-04-13 2004-04-23 2004-05-03 2004-05-13 2004-05-23 2004-06-02 2004-06-12 2004-06-22 2004-07-02 2004-07-12 2004-07-22 2004-08-01 2004-08-11
ppm calculated 20 per. Mov. Avg. (ppm calculated)

Time

From startup values of about 14-18 ppm we have now reached values down to 6 ppm. When the unit was started the transformer had been shut down for a few days and the temperature was only 4 C. Hence the initial rise in water content.
C.C.JENSEN A/S - Kim Kjr March 2005 43

Transformer Lecture
Water Concentration
Water content in oil [ppm] and oil temperature [C]
50.00 45.00 40.00 12.00 35.00 30.00 25.00 20.00 15.00
Oil temperature [C]

16.00

14.00

10.00

8.00

6.00

4.00

10.00 5.00 0.00

2004-07-09 2004-07-11

ppm calculated 30 per. Mov. Avg. (ppm calculated) 30 per. Mov. Avg. (Oil temperature [C])

2.00

0.00
2004-07-13 2004-07-15 2004-07-17 2004-07-19 2004-07-21 2004-07-23 2004-07-25 2004-07-27 2004-07-29 2004-07-31 2004-08-02 2004-08-04 2004-08-06 2004-08-08 2004-08-10

Time

Water concentration during the latest month. As can be seen from the curve the water content is still falling, but since the values are very low the water removal rate has somewhat slowed. Note the daily fluctuations in oil temperature.
C.C.JENSEN A/S - Kim Kjr March 2005 44

Water content [PPM]

Oil Temperature [C]

Transformer Lecture
Accumulated Removed Water
Accumulated amount of water removed from the transformer insulation [Liters]
5.0
Removed Water (accumulated) [L]

4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0
Accumulated Removed Water [L]

2004-02-23

2004-03-04

2004-03-14

2004-03-24

2004-04-03

2004-04-13

2004-04-23

2004-05-03

2004-05-13

2004-05-23

2004-06-02

2004-06-12

2004-06-22

2004-07-02

2004-07-12

2004-07-22

2004-08-01

Time

This curve is calculated based on the known efficiency of the V30. So far about 4.5 Liters of water have been removed.
C.C.JENSEN A/S - Kim Kjr March 2005 45

2004-08-11

Transformer Lecture
Acid
Organic acidity mg KOH/g oil. The CJC V30 removes water from the oil. Since some acids are water soluble som acid is also removed from the transformer.
0.25 Startup of CJC V30 0.21 0.2 0.178 TAN [mg KOH/g] 0.204 0.208 0.188 0.178

0.15

0.148 0.118

0.1 Organic acidity mg KOH/g oil 0.05

0 24-07-1998

06-12-1999

19-04-2001 Date

01-09-2002

14-01-2004

28-05-2005

From the curve it can be seen that the TAN has been lowered since startup of the CJC V30 vacuum filter.

C.C.JENSEN A/S - Kim Kjr March 2005

46

Transformer Lecture
Water Removal on T3
Water removal on T3, Filaret, Bucarest, Romania. 20000L oil. 40MVA. Water Content in oil at T=36 C. 16.00 14.00
Water Content [ppm]

12.00 10.00 8.00 6.00 4.00 2.00 0.00 2004-02-22 2004-03-07 2004-03-21 2004-04-04 2004-04-18 2004-05-02 2004-05-16 2004-05-30 2004-06-13 2004-06-27 2004-07-11 2004-07-25 2004-08-08 2004-08-22

The water content of the oil is highly temperature dependent due to the equilibrium with the transformer cellulose. The graph shows the water content at 36 C. I.e. measurements taken each time the oil temperature was exactly 36 C. As can easily be seen from the curve the V30 has lowered the water content in the oil to roughly 6-7 ppm. Variations are caused by daily temperature fluctuations. A moisture reading at 36 C when the temperature is rising (positive gradient, i.e. transformer heating up) tends to yield lower moisture contents than a reading when the temperature is falling (negative gradient, i.e. transformer cooling down).

Time

Measurements taken at a temperature of 36 C.

C.C.JENSEN A/S - Kim Kjr March 2005 47

Transformer Lecture
Water Removal on T3
Other parameters that have been improved though only slightly are:
Density: Color: Inflammability: Breakdown voltage: Dissipation factor (tan d) at 90 C [%]: Index of refraction: From 0.887 g/mL at startup to 0.884 g/mL on 2004-05-06 (relative density at 20 C). From deep low red at startup to low red on 2004-05-06. From 142 C at startup to 144 C on 2004-05-06.

From 232 kV/cm at startup to 250 kv/cm on 2004-05-06.

From 16.9 at startup to 12.36 on 2004-05-06. From 1.4904 at startup to 1.4883 on 2004-05-06.

C.C.JENSEN A/S - Kim Kjr March 2005

48

Transformer Lecture
Water Removal on T3
Calculated data from the transformer degassing and drying monitoring: The average oil temperature is 36.4 C The CJC V30 has so far removed 4.48 L of water from the cellulosic insulation That corresponds to 27.02 mL/day (7.2% of the total moisture) The output water content of the V30 is 3 ppm at the current input of 6 ppm Based on estimations of the insulation mass, water measurements and water in oil/water in cellulose equilibrium curves the total amount of water at startup was 61.92 L. Now 57.4 L remain. At the current rate of drying the CJC V30 will have removed 50% of the moisture in 3.1 years. 2.7 remaining.

C.C.JENSEN A/S - Kim Kjr March 2005

49

Transformer Lecture
Water Removal on T3
The literature states that reducing the moisture by 50% will double the remaining life time of a transformer. If the remaining life time of the transformer at startup was 15 years then removing 7.2 % of the moisture, assuming a linearity between water removal and life extension, will extend the life time by: 50% reduction = > 15 years life extension 7.2% reduction = > 2.25 years life extension (achieved in 166 days) If we rate the price per MW at the Danish 1990 level (100,000 DKK per 1MW), then a new transformer of 40MW would cost 4,000,000 DKK or roughly 0.5 mio. EUROS. Interest levels in Europe are roughly 4%. Thus postponing an investment of 0.5 mio. EUROS by 2.25 years would mean a saving of 4% of 0.5 mio EUROS in 2.25 years.

This corresponds to 45,000 EUROS. Thus by running only 166 days the V30 has saved the transformer owner 45,000 EUROS. Thus the payback time for a V30 is far lower than 166 days.
C.C.JENSEN A/S - Kim Kjr March 2005 50