Professional Documents
Culture Documents
Mechanical Stresses
Between conductors, leads and windings due to overcurrents or fault currents caused by short circuits and inrush currents Due to local overheating, overload currents and leakage fluxes when loading above nameplate ratings; malfunction of cooling equipment Due to system overvoltages, transient impulse conditions or internal resonance of windings
Thermal Stresses
Dielectric Stresses
Displacement of current
ABB Inc. 2012
A short circuit gives rise to: Mechanical forces Temperature rise The transformer must be designed so that permanent damage does not take place Electromagnetic forces tend to increase the volume of high flux Inner winding to reduced radius Outer winding towards increased radius Winding height reduction
Transformer Failure Modes Mechanical Stresses in Power Transformers Effect of the radial forces on windings
Fmean
Inner winding
Outer winding
Radial forces result in: Buckling for inner windings Increased radius for outer windings Spiraling of end turns in helical winding
Inner winding
ABB Inc. 2012
Outer winding
Transformer Failure Modes Mechanical Stresses in Power Transformers Effect of the axial forces on windings
The radial component of the leakage flux creates forces in axial direction
Fax
Fax
Transformer Failure Modes Mechanical Stresses in Power Transformers Two examples showing buckling of inner windings
Axial forces cause: Mechanical stress on insulation material Risk for conductor tilting
Unit Auxiliary Test Transformer Failure Internal High Speed Film Camera Footage
ABB Inc. Originally taken by The General Electric Company at Pittsfield, Massachusetts
Movies should be screened in the grey area as featured here, size proportion 4:3. No titles should be used.
Transformer Failure Modes Mechanical Risk: Short Circuit Forces & Stresses
Little Risk of Failure
Design Margin
Design #1 Design #2
High Risk of Failure
Design #3 Design #4
HV Radial HV Axial LV Radial LV Axial (Hoop) (tipping or (Buckling) (tipping or crushing) crushing)
Figure 3. Results of the Short-Circuit Strength Design Analysis used in a Life Assessment Study
ABB Inc. 2012
Loading is primarily limited by highest permissible temperatures in the transformer, especially within the windings Temperature limits are based on: Expected lifetime The risk for oil vaporization Permissible temperatures are generally expressed as temperature rises above ambient Ambient temperature is in turn defined by current standards 24 hour ambient temperature average 30 C Maximum ambient 40 C In accordance to Standards: Winding temperature rise 65 K Top oil temperature rise 65 K Hot spot temperature rise 80 K
Winding
Ambient
Bottom oil
Temperature
ABB Inc. 2012
Cellulose insulation is a polymer of glucose molecules. The glucose molecules are joined together to form a long chain. These chains form the fiber used to make insulation. Natural chains may be up to 1400 elements long. Reduction of this Polymerization number occurs during manufacture of the insulation material and the transformer.
Degree of polymerization is a measure of the number of intact chains in a cellulose fiber. It provides an indication of the ability of the transformer insulation to withstand mechanical force (due to through-faults, etc). New transformer insulation is about 1200 -1000 DP.
Chemical reactions cause de-polymerization (breaking of polymer chains): Hydrolysis due to water. (Moisture in transformer) Pyrolysis due to heat. (Hot spots, overloads,etc.) Oxidation due to Oxygen. (Oxygen in oil) Acidity of the oil also accelerates this process. Aging occurs at normal load and ambient temperature but it is accelerated by high insulation temperature, humidity and oxygen. This reduces the insulation mechanical strength and the windings become more vulnerable to physical damage or dielectric failure during through-faults. Windings hot spots are more affected than the insulation between the windings as the host spot areas age faster. Insulation between windings may however loose some dielectric strength due to absorbing moisture.
10.0
1.0
For long insulation life expectancy, it is important to keep the insulation dry, keep acidity and oxygen concentration of oil low and provide good cooling for insulation
ABB Inc. 2012
Transformer Failure Modes Thermal Stresses in Power Transformers Life Expectancy Based on DP and Other Factors
The DP is measured by viscosity measurements according an ASTM method after dissolving the paper samples in cupriethylene diamine solvent.
Paper samples must be taken from enough different areas in a transformer in order to get a profile of deterioration of the cellulose When combined with detailed design knowledge, measurements in one area of the transformer can give information on the condition of paper in inaccessible areas of the windings.
Continuous overvoltage is related to the core and its magnetization (normal 50Hz or 60 Hz stresses) Transitory overvoltage refers to intermittent stresses placed on the insulation system, usually at much higher levels than the power frequency stresses
Voltage
0,2 0 0 0,1 0,2
0,4
0,6
1,0
0,3
Winding
Winding length
0,4
2 4
h/H
2 D field plots can be used to check the design of the main insulation
525 kV unit assumed bushing failure Simulation showed electric stress was greatest on the paper insulation around the shield ring Used simulation to redesign insulation barriers
FLC evaluation
CAD-model
ABB Inc. 2012
Top transformer failures (78%) from Doble: 43% winding insulation 19% bushings 16% tap changers Other areas of concern: Pollution, dust & debris affecting bushings & cooling systems Cooling System inefficiency COPS Tank elevation Blocking or Wedging In 1998, Hartford Steam Boiler projected: 2% annual failure rate of existing installed base in 2008 5% annual failure rate of existing installed base by 2013
Transformer Failure Modes / Diagnostic Techniques Highly Effective On-line Actions are Best
PROBLEMS DIAGNOSTIC TECHNIQUES SERVICE CONDITIONS OF THE EQUIPMENT[1] OFF-S OFF-S OFF-S OFF-S OFF-S ON ON ON ON ON ON ON OFF-S ON ON OFF-S OFF-S PROVEN EFFECTIVENESS[2] M L H M/H H H M M/H M/H L H M L M/H M/H H H 1. Excitation Current 2. Low-voltage impulse 3. Frequency response analysis 4. Leakage inductance measurement 5. Capacitance GAS-IN-OIL ANALYSIS 6. Gas chromatography 7. Equivalent Hydrogen method THERMAL OIL-PAPER DETERIORATION 8. Liquid chromatography-DP method 9. Furan Analysis HOTSPOT DETECTION 10. Invasive sensors 11. Infrared thermography OIL ANALYSIS 12. Moisture, electric strength, resistivity, etc. 13. Turns ratio DIELECTRIC PD MEASUREMENT 14. Ultrasonic method 15. Electrical method 16. Power Factor and Capacitance 17. Dielectric Frequency Response
MECHANICAL
Streaming Electrification Nitrogen Gas Bubble Evolution COPS System Elevation GE Mark II Clamping Shell Form Rewedging GE Type U Bushings Cooling Problems LTC Problems
FRA tests were performed on a 42-MVA transformer, 115/46 kV (delta-wye), to investigate high acetylene level in the DGA End-to-end measurements on HV windings and capacitive interwinding tests between HV and LV showed a problem on phase B
The fault was a loose electric contact of the copper bonding braid on the aluminum shield strips which caused the strips to float electrically
The measurements were performed on a three-phase transformer rated 250 MVA, 212 kV/ 110 kV/ 10.5 kV, before and after the repair of the core. The first core-related resonance is clearly modified by the fault: the shorted laminations caused a decrease in the core magnetizing inductance (increase in resonance frequency) and an increase in the eddy currents in the core (increased damping).
FRA responses of the series windings of a 140-MVA autotransformer (220/69 kV with tertiary winding). The fault was located on phase C of the tertiary winding. In this condition, the low-frequency measurement on the HV winding of the same phase was influenced because of the lower inductance due to the shorted turns on a winding of the same phase (increased first resonance frequency).
Produced within a transformer winding due to excessive axial forces during a fault Windings shift relative to each other Gassing may result Transformer integrity is compromised Failure likely to be catastrophic if transformer continues in service
The DFR test is a series of power factor measurements at multiple frequencies. It provides more information about the dielectric behavior of the insulation system. The method be used to diagnose the following conditions in transformers:
Ground
Lo
Moisture in the cellulose insulation High oil conductivity due to aging or overheating of the oil Chemical contamination of cellulose insulation Carbon tracking in cellulose High resistance in the magnetic core steel circuit
Hi Lo
Transformer Failure Modes DFR Testing Distinguishing Between Aged Oil and Moisture
1.000
Tan D
0.010 0.001
.001
.01
.1
10
60 100
1000
Frequency, Hz
ABB Inc. 2012
Transformer Failure Modes DFR Analysis Fitting the Right Dielectric Parameters
1.000
0.100
Aged Oil, 0.5% Moisture Good Oil 1.3% Moisture PF =. 00324 Measured DR 0.7% Moisture
Tan D
0.010 0.001
.001
.01
.1
10
60 100 1000
Frequency, Hz
ABB Inc. 2012
.01
.10
1 Frequency, Hz
10
100
1000
Dielectric Response Fingerprint Function caused by a High Core to Ground Resistance in Auxiliary Transformer
.01
.10
1 Frequency, Hz
10
100
1000
Normal Moisture(.7%)
High Moisture(1.7%)
.01
.10
10
100
1000
Frequency, Hz
Transformer Failure Modes DFR Moisture Analysis versus Moisture Equilibrium Method
Volume Moisture in Paper
Xfrmr # 1 2 3 4 5 6 7 Temp (o C) 23 28 23 23 13 27 27 Type GSU GSU GSU GSU 3-wdg Auto Auto Constr. Core Core Core Core Shell Core Shell Oil Cond (pS/m) 0.381 0.492 0.412 1.34 1.5 3 0.3 Moist by Oil Moist. by DR Sat (%wt) (%wt) 2.5 1.8 1.4 2.8 * 3.5 3.3 0.9 0.9 0.9 0.7 1.2 2 1
Surface Moisture in Paper Estimated Only From Moisture in Oil Against Volume Moisture From DFR
ABB Inc. 2012
Overload Type
Normal Loading Planned O/L Beyond N/P Long Time Emergency (1-3 mo.) Short-Time Emergency ( -2hr)