4 th International Conference on Instrument

Transformers

LEARNINGS FROM FAILURE ANALYSIS AND FMEA OF INSTRUMENT

TRANSFORMERS LEADING TO IMPROVED SYSTEM RELIABILTY

Pramod Tupe. Prajjwala Patil.

The Tata Power Company Limited, Mumbai

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

INTRODUCTION

The population of 145 / 245 / 400kV Instrument Transformers in Tata Power system is
approx. 1500

Based on our experience, it is found that many CTs / CVTs have failed during service
without any major clues. Comparatively lesser failures of PTs are observed

Forced outages due to failure of Instrument Transformers lead to costly reconditioning /

repairs / replacement of the defective equipment
.
A need was felt to review existing maintenance / condition monitoring practices and
adopt new practices / standards / techniques for maintenance as well as condition
monitoring of Instrument Transformers as corrective / preventive measures because of
clueless failures of CT/CVTS

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

METHODOLOGY ADOPTED FOR ANALYSIS OF INSTRUMENT
TRANSFORMER FAILURES

•Data of failed (new and old) Instrument Transformers from year 2011 was compiled to
understand trends / patterns.

RCA of failed Instrument Transformers to identify root causes with focus on critical
condition monitoring parameters and maintenance history.

Failure Mode and Effect Analysis to determine pain areas and suggest probable
mitigation actions.

Relevant international / national technical standards and papers were also referred to
know the best practices in ‘Technical specification’ and ‘Condition Monitoring &
Maintenance’ followed by other utilities.

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

Based on inputs from RCAs and FMEA, Maintenance and Condition monitoring
guidelines of EHV oil filled Instrument Transformers were reviewed and finalized.

Key objectives of guidelines are -

•To follow a simplified approach for condition monitoring of Instrument Transformer thus
reduce maintenance and monitoring efforts
.
•Improve safety by eliminating the hazards associated with equipment failures.

•Adopt common practices and standards for equipment replacement based on

performance rather than age of assets.

•To reduce the risk of failure through proactive condition assessment thus ensuring
reliable operation with reduction of forced outages.

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

IMPROVEMENTS INTRODUCED THROUGH GUIDELINES

Introduction of DGA testing for CT oil as a standard practice and monitoring CT

parameters such as Capacitance & Tan-Delta with respect to reference values during
service life of CT.

•Introduction of on-line measurement of CVT secondary voltages as a standard practice

and monitoring PT / CVT parameters such as Capacitance & Tan-Delta with respect to
reference values during service life of PT / CVT.

•Inclusion of Thermo-vision and RF PD survey for oil filled Instrument Transformers.

•Replacement of Instrument Transformer rather than repairing / conditioning.

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

Recommended Maintenance schedule for the oil filled CT
.
S No. Checks / Activity FRQ Remarks

1 Checking of bellow expansion (level - high / low / normal) and freeness of bellow expansion QY High / low bellow level to be investigated.

Visual inspection of CT for oil leakages /seepages from:

Dead tank gasket joint
Oil sampling valve with plug
Primary conductor sealing gasket CT to be replaced at the first sighting of heavy oil leakage.
2 Gauge glass M In case minor oil leakage, necessary corrective action to be taken and CT need
Metal bellows to be put under close observation.
Insulator cemented joint
Secondary terminal box
Capacitance tap point

CT to be replaced if there is a major crack.

3 Visual inspection of CT for cracks on porcelain insulator M
If not healthy, replace gasket / apply sealant as necessary
4 Checking healthiness of gaskets and sealant in Secondary terminal box Y

5 Thermo vision scanning of CT body and primary connections 2M / QY Shall be within acceptable limits

6 Checking of correct primary connection strips and tightness, if provided externally Y Ensure correctness and firm connection

7 N2 pressure checking (if applicable) Y As per OEM’s recommendation

2Y or
8 Cleaning and Checking the tightness of PF terminal earthing connection. Ensure earthing
Unit S/D
2Y or
9 Measurement of Tan δ and capacitance (C1) Shall be within acceptable limits
Unit S/D
≤ 0.007 Tan δ for 220 KV and above 2Y or
a.  
≤ 0.010 Tan δ for 110 KV Unit S/D
> 0.007 Tan δ for 220 KV and above
b. 1Y Close monitoring
> 0.010 Tan δ for 110 KV
Δ Tan δ (Tip up test at 2,4,6,8 & 10KV) 2Y or Shall be within acceptable limits
10
This test is applicable for HV Tan δ test Unit S/D
2Y or Shall be within acceptable limits
11 IR measurement
Unit S/D
12 DGA of oil sample SOS Shall be within acceptable limits

13 Oil tests (BDV, Moisture contents, Resistivity and Tan- delta) SOS Shall be within acceptable limits

14 Measurement of CT secondary resistance SOS

15 Magnetization characteristics SOS
As per equipment datasheet/ FAT reports
16 CT ratio test SOS
17 Checking of burden on the secondary winding SOS
18 On line acoustic PD measurement SOS RFI survey of the Switch yard

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

Recommended Maintenance schedule for the oil filled CVT & PT
.
S No. Checks / Activity FRQ Remarks

Checking of bellow expansion

1 Daily High / low bellow level to be investigated.
(level - high / low / normal)

Visual inspection of PT / CVT for oil leakages /seepages from:

Tank gasket joint
Oil sampling valve with plug
Primary conductor sealing gasket PT / CVT to be replaced at the first sighting of heavy oil leakage.
2 Gauge glass Daily In case minor oil leakage, necessary corrective action to be taken and PT / CVT need to be
Metal bellows put under close observation.
Insulator cemented joint
Capacitance tap point
Secondary Terminal box

3 Visual inspection of PT / CVT for cracks on porcelain insulator Daily PT / CVT to be replaced if there is a major crack.

4 On-line measurement of PT / CVT secondary voltages on SCADA and generate alarm for deviation. Capture voltage trend on SCADA Online Set alarm for any deviation beyond 5%

a Compare voltage of one phase w.r.t. other two phases (if PT / CVTs are provided on all phases)  
In case of alarm, perform actual measurement with accurate meter. Analysis voltage
trends.
b Compare phase voltages between Bus & line side PT / CVTs  

5 Thermo-vision scanning of PT / CVT body and primary connections QY Shall be within acceptable limits

2Y or
6 Inspection of PT / CVT installation  
Unit S/D
a. Checking primary, secondary and earthing connections   Ensure firm connection

b. N2 pressure checking(if applicable)   N2 pressure as per OEM’s recommendation

c. Cleaning of insulators   PT / CVT to be replaced if there is a major crack.

 
Checking of secondary terminal box
d. Check healthiness of gaskets   Replace gasket if found damaged.
Check oil leakage in terminal box

e. Cleaning and Checking the tightness of PF terminal / HF terminal (in case it is not being used for PLCC) earthing connection.   Ensure earthing

7 Measurement of Tan δ and capacitance (upto 2 kV due limitation of graded insulation / neutral bushing) for CVT / PT having “Neutral” point which can be isolated.   Shall be within acceptable limits

Tan δ:
2Y or
a. ≤ 0.7% @ 20°C Tan δ for 220 kV and above  
Unit S/D
≤ 1.0% @ 20°C Tan δ for 110 & 132 kV
Tan δ:
b. > 0.7% @ 20°C Tan δ for 220 KV and above 1Y Close monitoring
> 1.0% @ 20°C Tan δ for 110 & 132 kV
c. Rate of rise in Tan δ: 50% rise w.r.t earlier test value 1Y  

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India

IMPROVEMENT IN TECHNICAL SPECIFICATIONS

•Composite insulator housed CT in place of Porcelain insulator housed CT for 145-245kV

class.

•Composite insulator housed SF6 filled CT for 400kV class

•Procurement of Oil sampling kit for DGA along with CT

•Tan Delta acceptable limit during FAT - 0.4% for CT and 0.5% for PT

•Use of PT in place of CVT (except where PLCC facility required)

•Ingress Protection Secondary TBs /JBs IP 55 with additional rain protection

•Standardization of Instrument Transformer parameters

13-14 December 2018, Hotel Crown Plaza, Gurgaon, NCR, India