Water in Transformers

TVPPA E&O CONFERENCE AUGUST 79, 2013

SPX TRANSFORMER SOLUTIONS, INC.

Water in Transformers
Rich Simonelli
Territory General Manager Southeast
SPX Transformer Solutions, Inc.
Office 919-300-1522
Email Rich.Simonelli@spx.com
Water in Transformers August 2013
Rich joined SPX in January 2005, bringing with him
over 20 years of experience in the power systems
industry. As the national service manager, Rich was
responsible for leading the Waukesha Service group
in providing and implementing creative field service
solutions on electrical equipment used in power
generation, transmission and distribution, mass transit
and industrial processes, while maintaining customer
satisfaction, quality, environmental and safety systems
and processes. In 2011, Rich was promoted to
Territory General Manager where he has complete
commercial responsibility for all products and services,
business development, sales strategies and customer
relationships in the southeast region.
TRANSFORMERS | SERVICE | TRAINING | COMPONENTS
Agenda

Effects of water in
transformers
How does water get in?
How to estimate water
content in transformers
What can you do about it?

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 3

Effects of Water in Transformers

Water in Transformers August 2013

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

4
Water in Transformers is Bad

Cellulose is highly hygroscopic.

Influence of the temperature over water absorption of 3 mm

high-density pressboard at 50% relative humidity

Source: Water Absorption of Cellulosic Insulating Materials used in Power Transformers

HP. Gasser, Ch. Krause and T. Prevost, Weidmann Transformer Board Systems TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 5

Water in Transformers is Bad (cont.)

Moisture lowers the dielectric strength of oil.

Source: ABB IL 48-500-11, 2002

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 6

Water in Transformers is Bad (cont.)

Moisture lowers the dielectric strength of solid insulation.

Source: Tom Prevost, EHV Weidmann, 2006

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 7

Water in Transformers is Bad (cont.)

Moisture raises the dielectric power factor and increases

the risk of thermal breakdown of solid insulation.

Source: Tom Prevost, EHV Weidmann, 2006

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 8

 Water in Transformers is Bad (cont.)

Moisture lowers the lowest hot-spot temperature range for

possible bubble formation.
190
Kobayashi rapid heating
Kobayashi slow heating
170

150
Davydov

Temperature
130
Oommen gas free
110
Oommen gas saturated
90

70

50
0 2 4 6 8 10
WCP % w/w

Source: TV Oommen, EPRI Reports: Comparison of critical bubble temperature vs.

EL-6761, March 1990; EL-7291, March 1992 water content in paper by three researchers

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 9

 TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 10

Water in Transformers is Bad (cont.)

Moisture accelerates thermal aging of paper insulation.

10
9
Aging Acceleration Factor

8
7
6
5
4
3
2
1
0.5 1.5 2.5 3.5 4.5 5.5
Moisture in Paper (%)

IEEE Std C57.91-1995 Source: Sam Mehta, Tom Golner, SPX Transformer
Solutions, 2000 TJH2B presentation

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 11

Water in Transformers is Bad (cont.)

Moisture can be the root cause of a catastrophic failure.

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 12

How Does Water Get In?

Water in Transformers August 2013

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

13
Many Ways for Water to Enter Transformers

Inadequate dry-out at factory

Leaks gaskets and welds
Breathing in outside air during
oil temperature changes
Defective oil preservation
system

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 14

Water is Also Produced as a By-Product

Even if a transformer
is leak-free and the
Carbon Monoxide Carbon Dioxide
oil preservation C O O C O

system is performing
Heating
flawlessly, water is H OH CH2OH

PRODUCED as H H
O
Section of OH H
a BY-PRODUCT of Cellulose
Molecule
O
H OH H
O
H O H
the normal cellulose O
CH2O H O
aging process! Heating

O
H H
Water

Degradation of Cellulose

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 15

Once Inside, Where Does It Go?

Once water is inside, the molecules are stored in various

parts of the insulation:

Thin
Winding
Thick 2%
3%
5% Oil
1%
Winding
22%

Thick
Thin 55%
22%
Oil
90%

Water Distribution
Insulation Weight Distribution

Source: J. Aubin, 2005 Weidmann-ACTI Conference, San Antonio, TX

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 16

How Do We Measure / Estimate Water Content
in Transformers?

Water in Transformers August 2013

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

17
Variety of Assessment Methods Available

Different methods can be used to assess water content

in transformers:
Karl Fischer Titration of Insulation Sample
Moisture Equilibrium Curves
Dew point
Vapor Pressure Curve
Recovery Voltage Method
Dielectric Frequency Response
Power Factor
Cold Trap
IEEE C57.106 Limits

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 18

Moisture Equilibrium Curves

Moisture in Paper ( %)

Temperature ( C )
Moisture in Oil (ppm)

Source: Oommen 1983/2003

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 19

Moisture Equilibrium Curves (cont.)

Challenges with Moisture Equilibrium Curves

Source: IEEE C57.106-2008

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 20

Dew Point

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 21

Dew Point (cont.)

Challenges with dew point to moisture content conversion:

At best, calculation is only an average surface moisture
content measurement
Difficult to achieve equilibrium due to temperature changes;
conversion is temperature and pressure sensitive
Difficult to measure/estimate insulation temperature
Moisture distribution is not uniform in insulation
Transformer must be without oil to get measurement
Despite these issues, dew point to moisture content
conversion is widely used as an acceptance test because
calculations are done without having to open the transformer.

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 22

Vapor Pressure Curve

Vapor Pressure Rise/

Vacuum Drop Loss Method
Developed to monitor progress during
vacuum dry out operations.
Equilibrium vapor pressure from the absolute
pressure in the transformer tank can be obtained
during the time condensed moisture is being
removed from the vapor trap. The transformer is
isolated from the vacuum pump and vapor trap.
A pressure rise (vacuum loss) test is then
conducted:
1. Leak rate of the transformer tank.
2. Outgassing rate for insulation and solid
components inside transformer (from change
in slope of pressure rise curve).
3. Pressure rise during the first minute after the
isolation valve is shut (rate of moisture
evaporation).
4. Intercept of the pressure rise curve with zero
time axis (equilibrium vapor pressure).

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc.

Vapor Pressure Curve (cont.)

Challenges with Vapor Pressure Rise / Vacuum Drop Loss

Problems/Factors directly
effect equilibrium of the vapor
pressure measurement:
Atmospheric air leaking into
transformer tank
Dissolved gas (air) released
from residual oil on the tank
bottom and/or oil-
impregnated insulation,
causing a rise in absolute
pressure (outgassing)
Moisture evaporating out of
the insulation
Application and calibration
errors in pressure and temp
measuring sensors
Temperature variations

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc.

RVM / DFR Tests

Recovery Voltage Method (RVM)

Testing the dielectric properties of the
oilpaper insulation.
DC voltage (usually 2000V) is applied
across the insulation for a period of time
(charge time)
This DC voltage causes polarization of
the molecules in the insulation material
Test piece is then discharged via short
circuit for a period equal to half the
charge time
Polarized insulation material then tries to
revert to the original state which gives
a characteristic response, known as the
recovery voltage
Recovery voltage is measured and key
points are notedvoltage, time and slope
Specimen is then discharged, ready for the next test cycle

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 25

RVM / DFR Tests (cont.)

Recovery Voltage Method (cont.)

Tests are repeated for charge times
ranging from 20 ms up to
10,000 seconds
These points can then be plotted on
a series of graphs with varying
charge times
The most important of these graphs
is called the polarization spectrum,
which is obtained by plotting peak
recovery voltage vs. charge time
The time at which this peak occurs is known as a dominant time
constant and is dependent on properties of the insulating materials
This value directly reflects the moisture content of the oil-paper
insulation system

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 26

RVM / DFR Tests (cont.)

Dielectric Frequency Response test

Used to assess the integrity of a transformers
insulation system. The test attempts to determine the
volume of moisture and presence of contaminants in the
solid insulation as well as the conductivity and power
factor of the oil
With the support of Omicron, DFR test have gained popularity
in recent years as a diagnostic tool for transformer insulation
system testing. The DIRANA uses a combination of the time
and frequency range method (Polarization Depolarization
Current [PDC] and Frequency Domain Spectroscopy [FDS]).

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 27

RVM / DFR Tests (cont.)

Challenges with RVM and DFR:

Difficult to achieve equilibrium due to temperature changes
Difficult to get accurate insulation temperature
Oil permittivity and conductivity change with aging of
insulation system
Moisture distribution is not uniform in insulation
Construction details are not always available
Transformer must be de-energized for a long time before
reaching equilibrium, making for a long test time duration

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 28

Transformer Power Factor

Power Factor has been used for many decades to assess the
drying process of transformers using a low voltage test or by the
use of probes and models to assess the condition of the solid
insulation.
Pros and Cons
Can be used for acceptance testing and at completion
of field drying after oil filling to ensure a dry unit
Can be used to detect pockets of water that may be deeply
imbedded and missed by other methods that
rely on equilibrium conditions to be accurate
No direct correlation between power factor and
moisture content

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 29

Cold Trap Method

The Cold Trap method involves measuring the amount of water

collected in a trap over a four to six hour period and then calculating
the amount of water collected per hour. If the amount of insulation
and its initial moisture content are known, the
amount of water removed can provide
a sense of the insulation dryness.

Pros and Cons

Collecting the water in a trap prevents
it from collecting in the vacuum pump
Sometimes initial dryness and mass of insulation is difficult
to ascertain
Must have a cold trap available that efficiently catches the
majority of the water so it can be measured

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 30

Classification of Service Aged Oils
Test Standard Unit Voltage Group 1 Group 2 Group 3 Group 4

Dielectric ASTM-D1816 < 69 kV 23 <23 - -

min, kV
Breakdown w/ 1mm gap 69 - 288 kV 28 <28 - -
> 345 kV 30 <30 - -
< 69 kV 0.2 - >0.2 >0.5
Neutralization max, mg
ASTM-D974 69 - 288 kV 0.15 - >0.15 >0.5
Number KOH/g
> 345 kV 0.1 - >0.10 >0.5
< 69 kV 25 - <25 <18
Interfacial min,
ASTM-D971 69 - 288 kV 30 - <30 <18
Tension Dynes/cm
> 345 kV 32 - <32 <18

max, PPM
Moisture < 69 kV 35 >35 - -
ASTM-D1533 @60C Avg.
Content 69 - 288 kV 20 >20 - -
Oil Temp.
> 345 kV 12 >12 - -
< 69 kV 0.5 - >0.5 >1.0
Power Factor ASTM-D921 max, % 69 - 288 kV 0.5 - >0.5 >1.0
> 345 kV 0.5 - >0.5 >1.0

Source: IEEE C57.106-2006

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 31

Why is Moisture Content So Difficult to Measure?

Current measurement practices assume a state of equilibrium.

Does Equilibrium
Ever Occur?

Varying Temperatures:
Top oil temp
Bottom oil temp
Winding temp

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 32

Does Equilibrium Ever Occur? (cont.)

Source : Transformer Moisture Content/Cold Weather Dew Point Measurement,

Doble Client Conference 2009; Rich Simonelli, SPX / Phil Prout, NGRID / Lance
Lewand, Doble / Brian Anderson, CSU TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 33

Does Equilibrium Ever Occur?

Factors Directly Affecting Equilibrium

Equilibrium, by definition, is a state of balance between opposing forces or
actions that is either static (as in a body acted on by forces whose resultant is
zero) or dynamic (as in a reversible chemical reaction when the rates of reaction
in both directions are equal).
Where continuously varying conditions exist (internal and external), the
equilibrium curves cannot be applied directly.

In a Transformer:
Temperature stratification/unstable thermal environment
Non-uniform moisture distribution in the insulation
Only an average surface moisture content measurement
achievable with any method (best case scenario)
Varying thicknesses of insulation structures directly affecting
the rates of diffusion and adsorption

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 34

Does Equilibrium Ever Occur? (cont.)

Factors Directly Affecting Equilibrium in a Transformer (cont.)

Under Ideal Conditions:
Vapor Diffusion is already impeded because water
molecules are physically deterred from moving rapidly by
the labyrinth of micro capillaries
De-sorption of water molecules from the surface of active
sites on the cellulose surface occurs more slowly
because energy is required to break the bond
The film of oil coating the surfaces of the insulation adds
another diffusion process

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 35

What Can Be Done About Water in
Transformers?

Water in Transformers August 2013

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

36
What Should You Do About the Moisture?

Select the most suitable measurement method that

allows you to minimize error-producing variables,
continue using the same method over a long period of
time and monitor changes
Support industry-wide R&D initiatives to develop ways
to measure moisture content of working transformers
accurately and reliably

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 37

What Can Be Done to Limit Water Ingress?

For a new unit:

Specify maximum
allowable moisture
content at delivery
and determination
method
Specify proper oil
preservation system
Specify raised
flange for
all openings
Specify gasket material and suitable seal design
Consider specifying optional accessories that help maintain integrity
of the unit

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 38

What Can Be Done to Limit Water Ingress? (cont.)

For an existing unit:

Maintain the integrity of the unit keep it sealed
Standardize on methods to monitor moisture content monitor,
observe, record
Implement loading policy to minimize
the aging process
Consider adding accessories that
help maintain integrity of the unit
Corrective Actions:
If it tests wet for your application,
dry it out
Off-line field drying: Fast, but costly
On-line field drying: Slow, but economical
Natural ester retrofill

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 39

Transformer Drying Theory

Vapor Pressure
At atmospheric
pressure, you must
heat water in a
transformer to higher
than 212F (100C)
for water to boil off
When lowering the
pressure by pulling
vacuum, we can boil
water off without
heating (as long as
the temperature is
above freezing)

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 40

Transformer Drying Theory (cont.)

Why Add Heat?

Heat required for a phase change
comes from the surrounding
oil and transformer parts
As heat moves from the
insulation into the water, the
temperature of the insulation
and transformer drops
Therefore, replacement heat is
added by continuously reheating
the oil and pumping it into the
transformer
If the heat is not replaced,
VIDEO
freezing can eventually occur

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 41

Off-Line Field Dry Out Methods

Multiple methods exist for field drying a transformer if the

moisture content is found to be above acceptable limits:
Vacuum
Vacuum with hot air
Short circuit and vacuum
High vacuum with hot oil

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 42

Off-Line Field Dry Out Methods (cont.)

Vacuum
Good method for
removing small amounts
of residual moisture
Transformer is subjected
to high vacuum and held
for a period of time
Efficiency of method is
increased at higher temperatures
Cold traps can be used in vacuum line to measure
moisture extraction

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 43

Off-Line Field Dry Out Methods (cont.)

High vacuum and hot oil

Evacuate tank
Introduce oil to heat core/coil
assembly
If capable, limit oil volume to
10% of total or enough to
establish oil circulation
Otherwise, cover core/coil
assembly
Circulate oil under vacuum until
outlet oil temperature reaches
desired temperature
Drain oil from transformer
Continue to pull vacuum and monitor moisture through cold trap,
if desired

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 44

On-Line Field Dry Out Methods

Dry out process is slow

due to the diffusion rate of
water from cellulose to oil
Moisture content of oil
will decrease quickly
Higher operating
temperatures make
process more effective
Safety concerns should
be considered

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 45

Natural Ester Fluid Retrofill

Natural ester fluid holds Water Absorption of Dielectric Fluids

Exposed to Ambient Air (1 of 2)
more water in solution, 600

enhancing moisture 500

Absolute Water Content (ppm)

migration into the fluid
400

Hydrolysis converts
moisture and natural 300

ester fluid into long 200

Envirotemp FR3 fluid
conventional transformer oil

chain free fatty acids 100

Trans-esterification 0

combines some of these Exposure Time (hrs)

0 500 1000 1500 2000 2500 3000 3500

fatty acids with the OH group

in cellulose, strengthening the cellulose chain and making it
less likely to break

Source: Cooper Power Systems (prior to FR3 product line purchase by Cargill)
TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 46

 Natural Ester Fluid Retrofill (cont.)

Water Saturation Dielectric Strength

5000 80
B

D1816 Dielectric Breakdown Strength (kV)

A
273 T
Saturation(T ) 10 70 FR3 Fluid
Water Saturation Point (mg/kg)

4000 Mineral Oil

Envirotemp FR3 fluid: A = 5.3318, B = 684
from Doble Engineering 60
mineral oil: A = 7.0895, B = 1567
from IEEE C57.106 50
3000

40

2000
30

20
1000
10

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

Temperature (oC) Water Content (mg/kg)

Source: Cooper Power Systems (prior to FR3 product line purchase by Cargill)
TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 47

Natural Ester Fluid Retrofill (cont.)
Aged Paper at 3% Water Content
o
(aged at 85 C)

5 800

Paper in FR3 Fluid

4 Water in FR3 Fluid

Dissolved Water in Fluid (ppm)

Water in Mineral Oil 600
Paper in Mineral Oil
% Water in Paper

400

200
1

0
0
0 500 1000 1500 2000

Aging Time at 85oC (hrs)

Source: Steve Moore, Transformer Insulation Dry Out By Retrofilling With Natural Ester
Dielectric Coolant, IEEE 2012 TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 48

Natural Ester Fluid Retrofill (cont.)

Envirotemp FR3 fluid - water content

600
6 Envirotemp FR3 fluid - acid number 6
water in paper

Acid Number (mg KOH/g)

Water in Fluid (mg/kg)

Water in Paper (wt%)

400
4 4

200
2 2

0 0
0 500 1000 1500 2000 2500 3000

Time at 85oC (hr)

Source: Steve Moore, Transformer Insulation Dry Out By Retrofilling With Natural Ester
Dielectric Coolant, IEEE 2012 TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 49

Natural Ester Fluid Retrofill (cont.)

Life Extension Potential with Natural Ester Fluids

Natural Ester Mineral Oil Natural Ester Mineral Oil Natural Ester Mineral Oil Natural Ester Mineral Oil
Sealed Tube Test - ML 152-2000 Sealed Tube Test - ML 152-2000 Sealed Tube Test - ML 152-2000 Sealed Tube Test - ML 152-2000
Upgraded Paper 500 hr @ 170C Upgraded Paper 1000 hr @ 170C Upgraded Paper 2000 hr @ 170C Upgraded Paper 4000 hr @ 170C

Source: Cooper Power Systems (prior to FR3 product line purchase by Cargill)
TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

Water in Transformers August 2013 SPX Transformer Solutions, Inc. 50

Questions?

Water in Transformers August 2013

TRANSFORMERS | SERVICE | TRAINING | COMPONENTS

51