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Preventive and Corrective Maintenance for Transformers in Operation

Conference Paper · March 2023

DOI: 10.1109/ATEE58038.2023.10108196

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 THE 13th INTERNATIONAL SYMPOSIUM ON ADVANCED TOPICS IN ELECTRICAL ENGINEERING
March 23-25, 2023
Bucharest, Romania

Preventive and Corrective Maintenance for

Transformers in Operation
Maria-Cristina Niţu, Ancuța-Mihaela Aciu, Dan Ştefan
Research Department Division
National Institute for Research, Development and Testing in Electrical Engineering
ICMET Craiova, Craiova, Romania
cristinamarianitu@yahoo.com, ancutu13@yahoo.com, danstefan@icmet.ro

Abstract The purpose of this paper is to highlight the
advantages of applying a preventive and corrective maintenance
method in relation to the life of the insulation system of the
transformers in operation. This paper proposes a maintenance
method based on the revitalization of the insulation of power
transformers, in order to extend their life. Two case studies are
presented, and the results of the measurements made before and
after the revitalization process support the requirements of a
preventive and corrective maintenance method.
Keywords: transformer, insulation, oil, revitalisation,
mentenance
I. INTRODUCTION
Extending the life of electrical equipment has become a
primary condition in ensuring energy efficiency at the SEN
(National Energy System) level.
Transformers are essential elements in electrical power
distribution systems, thus in the last decades, there has been a
shift from time-based maintenance strategy to condition-
based and risk-based maintenance. In this context, asset
managers are constantly looking to optimize their use. As
transformer diagnostic techniques have improved in recent
years, operators have sought techniques, measures and
methods to extend the life of transformers installed in the
system.
From these considerations, the margin is currently applied
to the application of predictive and corrective maintenance in
order to extend their life and ensure an acceptable level of
reliability of the transformer in particular [1-7].
The life of power transformers is generally determined by
the life of the paper-oil insulation system, if the mechanical
stability of the electrical insulating paper is lost, there is a risk
of dielectric defects and total shutdowns of the transformer.
The aging of solid insulation must be monitored
continuously or at least periodically because its degradation
process is final compared to the degradation of oils.
Preventive and corrective maintenance is encouraged in order
to extend its life.
Insulating oil is of essential importance in ensuring the
efficient operation of the transformer, which due to the
specific production technology has high costs.
The primary resources from which these oils are derived
are limited and thus, in order to save them, it is necessary to
carry out reconditioning/regeneration/revitalization processes
in order to extend their useful life or to be able to be reused
[7-12].
Insulating oils in operating equipment undergo a slow but
constant degradation process. Progressive degradation and
premature aging result from various phenomena that occur
during the operation of electrical equipment.
Dissolved and suspended metal and cellulosic particles
along with other polar degradation products are impurities
that increase the rate of degradation and shorten the useful
life of electrical equipment. Therefore, the failure potential of
electrical equipment is directly related to the liquid insulating
material.
Treating the insulating liquid can extend the lifetime of the
transformer and ensure its optimal operation. Oil treatment
methods are presented in specialized literature and applied by
the companies that deal with the maintenance of transformers
in operation, this work presents two case studies, which prove
the effectiveness of the application of treatment processes in
the case of transformers in operation to ensure a maintenance
efficient.
The treatment process whose results are presented was
carried out with an installation based on synthetic adsorbents
that uses the principle of adsorption to remove water and
polar elements from oil and solid insulation, applying the
percolation method under pressure.
The work supports a maintenance based on the
revitalization of the insulation of power transformers, in order
to extend their life. The installation used to remove water and
polar elements from the transformer insulation uses synthetic
adsorbents [13-14].
Transformer oil regeneration is an important preventive
maintenance tool, and therefore transformer oil must be
treated before it reaches levels of deterioration known to
cause transformer insulation failure [15-19].
The purpose of this work is to highlight the advantages of
applying a preventive and corrective maintenance in terms of
the lifetime of the insulation system of the transformers in
operation.
The application of reconditioning/regeneration/revitaliza-
tion processes to extend the lifetime of transformers has a
major economic impact, and by reusing used oil, primary
natural resources are preserved and environmental
contamination with such residual waste is avoided.

ISBN: 979-8-3503-3193-6/23/$31.00 ©2023 IEEE

 II. THE MECHANISM OF THE DEGRADATION OF THE
INSULATION SYSTEM IN TRANSFORMERS
A. The mechanism of paper degradation
The mechanism of paper degradation is complex and
highly dependent on the operating conditions. Degradation
occurs by breaking glycosidic bonds. These chain splits result
in a decrease in DP (degree of polymerization) and a
reduction in tensile strength. The typical by-products that can
be detected in the oil are also formed, namely: carbon
monoxide, carbon dioxide, detectable by oil gas analysis
(DGA), as well as furanic compounds.
In the specialized literature, there are detailed studies on
cellulose aging [8-13]. However, several experiments were
performed at temperatures of 100°C due to shorter reaction
times under laboratory conditions. Aging products from
typical transformer operating temperatures have not been
studied in detail. Furthermore, the aging process is
completely different in open and closed systems. Closed
systems do not allow moisture and other by-products to
escape. It is possible that a free-breathing transformer will
behave more like a closed system rather than an open system,
especially with respect to moisture [8], [10-12].
Monitoring this part of the insulation system is very
difficult and can be conducted during the inspection work.
Thanks to the gas separation method, monitoring has become
precise and particularly useful. CO2, CO and CH4 indicate the
evolution of the aging process of the solid insulation, but the
conclusions are not quite clear because the gases are also the
products of oil degradation. Using high-performance liquid
chromatography (HPLC), it was possible to detect the
molecules of elements that appear in smaller quantities than
H2O, CO2, CO and CH4 during the depolymerization of
cellulose molecules. Furan and its compounds appear only as
degradation products of cellulose - paper.
B. Mechanism of insulating oil degradation
Aging or deterioration of insulating oil is normally
associated with oxidation. Due to the omnipresence of
oxygen and water, insulating oil oxidizes even under ideal
conditions. The insulating properties of the oil are also
affected by impurities in the solid materials in the transformer
that dissolve in the oil. The reaction between the unstable
hydrocarbons in the oil, oxygen and other catalysts such as
moisture, with the help of accelerators such as heat results in
the formation of decomposition products (oxidation by-
products) in the oil.
Sludge formation is the final stage of the degradation
process. The acids formed in the oxidation process attack
cellulose fibers and metals, forming metallic soaps, varnishes,
aldehydes, alcohol and ketones, which precipitate as an acid
sludge (a heavy substance, with the appearance of tar) on the
insulation, tank sidewalls, ventilation ducts, cooling fins, etc.
Mud appears more quickly in transformers that are
overloaded, overheated (by operation) and misused. Mud
increases the viscosity of the oil, thus reducing its ability to
cool. Mud causes the insulation to shrink and is also partially
conductive, hygroscopic and thermally insulating. Mud
deposits on the core and windings will therefore cause an
unwanted increase in the operating temperature of the
transformer [3-4], [7-9].
Mineral transformer oils are refined from crude oil. The
refining process includes acid treatment, solvent extraction,
dewaxing, hydrogen treatment, or a combination of these
methods to obtain insulating mineral oils that meet
specifications. Essentially, transformer oil is a mixture of
hydrocarbon compounds of three categories: alkanes,
naphthene and aromatic hydrocarbons. These molecules have
weak polarity or no polarity at all. Polar and ionic species are
a small part of the constituents that can greatly influence the
chemical and electrical properties of the oil.
The reliable performance of an insulating mineral oil in an
insulation system depends on certain basic properties of the
oil that can affect the overall performance of the electrical
equipment. In order to fulfill its multiple roles as a dielectric,
coolant and arc quencher, the oil must have certain properties,
namely:
- high dielectric strength to withstand the electrical stresses
during operation;
- sufficiently low viscosity that does not affect the heat
circulation and does not reduce the heat transfer;
- adequate properties at low temperatures, down to the
lowest temperature expected at the installation site;
- a resistance to oxidation to maximize service life.
During operation, mineral oil degrades due to operating
conditions. In many applications, insulating oil comes into
contact with air and is therefore subject to oxidation. High
temperatures accelerate degradation. The presence of metals
and/or organometallic compounds may act as a catalyst for
oxidation. Color change, formation of acidic products and, in
advanced stages of oxidation, precipitation of residues may
occur. Dielectric properties and, in extreme cases, thermal
properties may be affected. In addition to oxidation products,
many other unwanted contaminants such as water, solid
particles, or oil-soluble polar compounds can accumulate in
the oil during operation and affect its electrical properties.
The presence of such contaminants and any other oil
degradation products is indicated by a change in one or more
properties (see Fig.1) [10-13].
Fig. 1. Transformer aging circuit
 III. REVITALIZATION OF THE INSULATION SYSTEM OF Case 1 - transformer type TTUS-ONAF, 40MVA, 110/6.3 kV
OPERATING TRANSFORMERS After the scheduled periodic tests, the results presented in
In order to highlight the importance of applying a table I were obtained, and the following has been noted:
predictive maintenance in order to extend the life of the - the insulation resistances and tanδ have values close to
mixed paper-oil insulation system, two cases of its the allowed limits;
revitalization are presented below. - the moisture in the solid insulation is above the maximum
The installation used for the treatment/revitalization of the allowed for the voltage class;
insulating oil uses the principle of adsorption to remove water - the breakdown voltage is below the allowed limit;
and polar elements from the oil and from the solid insulation, - the interfacial tension and the moisture in the oil are very
applying the pressure percolation method [11]. close to the allowed limits.
To extract the water and polar elements from the oil, the Based on these findings, it was concluded that the solid
oil is forced through the adsorber container without being insulation is wet and the oil is damaged, so it is necessary to
additionally heated, the installation working at the normal subject this transformer to a revitalization process in order to
operating temperature of the transformer, and the revitalized/ eliminate water and polar elements and improve its physico-
regenerated oil is reintroduced into the transformer. chemical/electrical parameters.
The installation used, in addition to the adsorber The method chosen was the use of an installation based on
cartridges, is also provided with coarse mechanical filters at synthetic adsorbents [11-12]. After the revitalization/
the entrance to the installation and fine filters at the exit from regeneration process, it can be concluded from table 1 that the
it, to remove particles from the oil. Thus, the correction of the insulation resistance values and tanδ improved significantly
physico-chemical parameters of the insulating oil is also and the moisture in the solid insulation decreased
achieved. significantly. With regard to the oil, it can be noted that the
Revitalization of the insulation system means the acidity index decreased, and the values of the breakdown
regeneration of the oil (bringing its parameters to the level of voltage and the interfacial tension increased, which indicates
a new one) and the purification of the solid insulation. that the applied treatment fulfills the purpose of the proposed
revitalization process.
TABLE I
PRESENTATION OF MEASUREMENTS PERFORMED BEFORE AND AFTER TREATMENT - TRANSFORMER TTUS-ONAF 40 MVA
Values Transformer
Unit of accepted 40 MVA, 110/6.3 kV
Characteristics
measure according to Before After
regulations treatment treatment
The insulation system
Insulation resistance of windings (R60) at 20°C
HV - LV MΩ > 600 1072 16440
LV - HV 1299 16970
Absorption index (R60/R15)
HV - LV > 1.2 1.35 1.53
LV - HV 1.29 1.47
Tan δ for windings at 20°C
HV - LV % max. 0.5 0.40 0.29
LV - HV 0.44 0.31
Water content in solid insulation at 20°C
HV - LV % max. 2 3.3 1.2
LV - HV 3.7 1.6
The oil insulation
Breakdown voltage kV > 60 47.9 79.41
Tan δ for oil at 90°C < 0.005 0.0286 0.0032
Interfacial tension dyne/cm min. 28 27.32 45.46
Neutralization number mgKOH/g max. 0.05 0.037 0.015
Water content ppm max. 20 15.83 2.7
Particles content φ > 5µm/100 ml ≤ 10000 10907 5890

through the formation of the arc, which could have occurred

Case II - transformer type TTUS-ONAN, 40 MVA, 110/6.6 kV
between the coils/between the coils and earth, or arc in the
After the gas analyzer signaled a fault, a series of
on-load tap-changer across contacts during switching with oil
measurements were made, as shown in tables II and III.
drain in the main sump).
The failure signal was due to exceeding the limit for
Based on the C2H2/H2 ratio, which has a value of 2.14,
acetylene (C2H2). Using the 1st Duval Triangle and 1st Duval
according to [5], it is clearly emphasized that the main source
Pentagon methods to analyze the defects, it is found that
of combustible gases dissolved in the oil is the oil leakage
discharges with the formation of a high energy arc (D2)
from the on-load tap changer to the main transformer tank.
occurred in the transformer, followed by: oil penetration
 TABLE II
PRESENTATION OF MEASUREMENTS PERFORMED BEFORE AND AFTER TREATMENT - TRANSFORMER TTUS-ONAN 40 MVA
Values Transformer
Unit of accepted 40 MVA, 110/6.6 kV
Characteristics
measure according to Before After
regulations treatment treatment
The insulation system
Insulation resistance of windings
(R60) at 20°C
MΩ > 600
HV - (LV- g) 1120 41091
LV - (HV- g) 752 28872
Absorption index (R60/R15)
HV - (LV- g) > 1.2 1.19 1.45
LV - (HV- g) 1.09 1.32
Tan δ for windings at 20°C
HV - (LV- g) % max. 0.5 0.45 0.28
LV - (HV- g) 0.48 0.30
The solid insulation
Water content at 20°C % max. 2 3.2 1.03
The oil insulation
Breakdown voltage kV > 60 52.65 81.52
Tan δ for oil at 90°C < 0.005 0.0407 0.0035
Interfacial tension dyne/cm min. 28 23.34 44.64
Neutralization number mgKOH/g max. 0.05 0.034 0.029
Water content ppm max. 20 15.62 2.065
Particles content φ > 5µm/100 ml ≤ 10000 9410 4189
TABLE III
VALUES DETERMINED BEFORE AND AFTER TREATMENT FOR DGA AND FURAN COMPOUNDS
Values Values determined
Unit of accepted
Characteristics Before After
measure according to
treatment treatment
regulations
Dissolved gas analysis (DGA)
Hydrogen H2 100 42 0
Methane CH4 120 37 6
Acetylene C2H2 1 90 n/d
Ethylene C2H4 50 47 n/d
ppm
Ethan C2H6 65 16 7
Carbon monoxide CO 350 493 9
Carbon dioxide CO2 2500 3875 87
Total dissolved combustible gases (TDCG) 720 1125 22
The content of furan compounds
5HMF - caused by oxidation of paper 0.35 0.0223
2FOL - caused by high paper moisture 1.37 -
2FAL - caused by overheating 0-0.1 0.31 0.0057
ppm
2ACF - caused by lightning - -
5MEF - caused by severe local overheating 0.04 -
Total furans <2 2.07 0.028

According to the DGA, the CO2/CO ratio has a value that
indicates a moderate state of paper degradation. This
indicates a moderate aging of the solid insulation system, the
causes of which, high humidity and the oxidative process, are
determined by the analysis of furan compounds.
The results of the electrical and physicochemical
measurements presented in table II indicate that the
transformer has a high humidity level, which requires the
treatment of the insulation system.
Before carrying out the treatment process, the necessary
repairs were made to the OLTC to eliminate the leakage
problems of its tank relative to the main tank of the
transformer.
The applied treatment brings an important contribution to
the improvement of the physico-chemical/electrical
parameters of the insulation system (see tables II and III).
IV. CONCLUSIONS
Whether the treatment of the transformer oil is done inside
or outside the tank, and on-line or off-line, depends mainly on
economic and production considerations.
Regenerating transformer oil in the transformer tank should
be at least 30% - 60% cheaper than the alternative of
draining, washing and refilling the transformer with
regenerated oil. By following an oil maintenance program,
the accumulation of moisture and sludge in the solid
insulation of the transformer can be prevented.
It has been shown that the regeneration process is less
demanding on the insulation of the transformer than the
alternative process of draining, washing and refilling the
transformer with new oil, thus avoiding long periods of
interruption and consequently loss of profit.
 Extending the life of a transformer, by implementing a
preventive transformer maintenance strategy from the ouset is
the most cost-effective approach.
The results obtained in the case of the two studies
presented in this paper support the implementation of
predictive and corrective maintenance to extend the life of the
insulation system.
If the transformer oil is regenerated/revitalized as soon as
the acidity level exceeds the minimum permissible limits set
by the standards, the degradation of the transformer oil, the
wet condition of the core, the formation of sludge and the
subsequent breakdown of the transformer insulation can be
prevented and the life of the transformer can be extended.
ACKNOWLEDGMENT
This work was carried out through the Core Program
within the National Research Development and Innovation
Plan 2022-2027, carried out with the support of MCID,
project no. PN 23 33 02 03.
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