PdMSA 2010 Conference

LIFE EXTENSION OF POWER TRANSFORMERS

OIL REGENERATION, ON SITE DRYING AND ONSITE REPAIR

Mats Dahlund, Paul Koestinger, Per Meyer
Pravin Khanna
ABB


































PdMSA 2010 Conference

1. Abstract

Poorly maintained transformer oil will significantly
reduce the life of a transformer. The oil in a
transformer can have a very long technical life but
only if it is cared for properly. Even though during the
life of a transformer several things can happen to
jeopardize the function of the oil and consequently the
function of the transformer, this can in most cases be
corrected by appropriate maintenance activities.

Poor dielectric strength due to particle content and/or
high water content can be mitigated by
reconditioning, i.e. filtering and degassing. This can
be carried out on-line or off-line. Drying of not only
the oil, but also the solid insulation by methods
involving vacuum and low frequency heating, will
ensure a longer lasting effect and therefore is a better
long-term solution.

Some of the properties of transformer oil change as it
ages, especially if by oxidative processes. If, as a
consequence, acidifies and sludges form, the dielectric
properties slowly deteriorate. However the oil can be
restored to nearly as-new condition by on-line
reclaiming. Today this is a very efficient and
environmentally friendly form of treatment, with the
absorbent being reactivated hundreds of times before
disposal, keeping waste products to a minimum. Oil
reclaiming should always be followed by the addition
of an inhibitor, to ensure that the oil stays in good
condition for many years. If carried out in time, both
the proper drying and oil reclaiming activities will add
a significant number of years to the transformers
technical life. With originally inhibited oil it is
advisable to add new inhibitor before the initial
content has been consumed. This very simple measure
will not really improve the actual condition of the oil
but if carried out in time it will significantly retard the
oxidation processes and therefore prolong the time
before more costly actions are required.

The purpose of this paper is to put the complexity of
degrading processes into context and to give guidance
on the remedial actions that will significant improve
the reliability and life of a transformer.

If a transformer has to be repaired in a factory, the
transportation time from the end-user site to factory
and return plays a major influence on the duration of
the project and putting transformer back in service to
resume power. Also the cost and risks associated with
heavy transport must be considered.
To date a total of more than 300 transformers
including utility, industrial, HVDC transformers and
reactors have been successfully repaired on site. In
many cases transformer output power were also
upgraded to provide an increased rating using present
advanced design tools.

2. Introduction/ Background
A transformer has many components that require
maintenance. The insulating system is a truly vital part,
consisting of the oil and the solid insulation. The solid
insulation may not be so readily accessible, but the oil
certainly is. Oil can be kept in a good condition for a very
long time and with proper care, probably for an indefinite
period of time. However, poorly maintained oil will
significantly reduce the technical life of the transformer

It is sometimes stated that the end of life of a transformer
is ultimately decided by the end of life of the solid
insulation. Even though it is true that many transformers
are taken out of service before the solid insulation is so
severely degraded, it is still true that the condition of the
cellulosic insulation sets a limit for how long a
transformer can be safely and reliably operated. For this
reason alone, it is wise to carry out preventive
maintenance.
2.1 Ageing of Oil and Cellulosic Materials
Oil is both the coolant and part of the insulation together
with oil-impregnated paper and board. Both types of
material are affected by several different ageing
processes, and both materials are affected by each other.
They can not really be treated independently of each
other. They function together; age together, a bit like
Siamese twins. Nevertheless, this paper will discuss the
main degradation mechanisms of each separately, as far
as it is possible.
2.1.1 Oil
Transformer oil is at the same time both very simple and
very complex. It consists mainly (>99%) of
hydrocarbons, a mix that is not very different from diesel
fuel. However, it has thousands of different components;
however, some of the minor components have a major
impact on its properties.

The main degradation mechanism is oxidation. This is a
very complex process, especially since in real life the
degradation of oil and of paper interacts with each other
to a large degree. Some of the important features are
listed below:

The rate of degradation is dependant on
temperature (as all chemical reactions are).

It also depends on access to oxygen. This
cannot however be eliminated unless the oxygen
is completely excluded, which is unrealistic to
achieve.

It is a chain reaction. Free radicals and
peroxides are the most important intermediates
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The oxidation is catalyzed by metal ions. It
should be noted that copper can be dissolved in
oil by the action of some of the oxidation
products.

The presence of substances acting as radical
scavengers, peroxide scavengers and metal
deactivators will retard the process.

There are both inhibited and uninhibited oils. This
refers to the use or non-use of synthetic peroxide
scavenging antioxidants. When the use of such an
additive is accepted, the oil can have a very high degree
of refining and relies mainly on the ability of the phenolic
antioxidant to suppress the oxidation process by halting
the process at a very early stage. Uninhibited oils, on
the other hand, must contain a certain amount of sulphur
compounds to act as peroxide scavengers and some
aromatic and polyaromatic hydrocarbons as natural
precursors to radical scavengers formed by oxidation. A
correctly formulated inhibited oil has a very long
technical life, with very little production of detectable
oxidation products as long as there is sufficient inhibitor
left. The uninhibited oil will start to oxidize and produce
acids early in its life but will age in a fairly predictable
way.

The most important products from the oxidation are acids
and sludge, and to some extent water. Sludge is a mix of
strongly polar compounds with poor solubility in oil,
which causes it to precipitate, forming deposits. How the
acids and water produced in the ageing process will
influence the cellulosic material will be discussed later,
though it should be mentioned here that the amount of
water produced from the ageing of a well maintained oil
system is probably insignificant compared to the
contributions from water ingress and what is produced in
the paper.

Besides oxidation, there are other possible reasons for the
degradation of oil. Local overheating may produce small
hydrocarbons and hydrogen. Electric discharges will give
rise to similar products (though with more acetylene and
hydrogen present). This is extremely important for the
detection of incipient faults using DGA (dissolved gas in
oil analysis). However, for the long-term stability of the
oil, these mechanisms are of minor importance. If there is
some fault condition that causes significant production of
such gases, that is a bigger and much more urgent
problem than the normal ageing of oil.
2.1.2 Paper.
Board and paper have three main components, cellulose,
hemicellulose and lignin. All components influence the
properties of the material. However, it is the degradation
of the main component cellulose (and to some extent
hemicellulose) that has the greatest effect on its
mechanical properties.

The most important degradation mechanism of paper and
board is the specific acid-catalyzed hydrolysis of the
cellulose. Hydrolysis means decay under the influence
of water and specific acid-catalyzedmeans that the
process is accelerated by dissociated acids that provide
free hydrogen ions. Laboratory ageing experiments with
paper in oil indicate that the degradation rate is nearly
proportional to the water content, at least within the range
of water content that it is realistic to encounter in
transformers windings.
1
However, the rate-determining
reactions depends more on the amount of dissociated
acids than access to water. Hence, the effect of water
content is to increase the availability of hydrogen ions,
since the acids with most impact, small carboxylic acids
like formic and acetic acids, are more dissociated the
higher the water content is. The hydrolysis itself will
consume some water but this process is followed by
dehydration reactions that produce water. Oxidative
processes also contribute, probably mainly by producing
water and acids, and by activating the cellulose molecule,
introducing functional groups making it more susceptible
to hydrolysis. At very high temperatures pyrolysis will
contribute but this should only be significant in case of a
thermal fault.
1


The dielectric strength is not very much affected by the
ageing process. With the paper it is mainly the changes in
mechanical properties that is a cause for concern. When
the paper is too degraded, the ability to withstand
vibrations and short-circuit stresses reduces dramatically.
High water content will of course influence the dielectric
properties but this can be corrected. However, the
changes in mechanical properties due to degradation of
the cellulose chains are irreversible.

2.1.3 Other sources of water
The degradation of paper and board produces significant
amounts of water. However, there are other contributing
factors. There will always be some residual water in the
solid insulation of a new transformer. Even though the
active part is dried before oil impregnation, there may be
in the region of 0.5 % residual water. Ingress of water by
several different mechanisms may also be a major
contribution and is considered to be the most important in
many cases.
3

2.1.4 Distribution of Degradation Products between Oil
and Paper
It is very important to understand that many polar
compounds, including the most important degradation
products, are distributed between oil and paper,
sometimes very unevenly so. This is especially important
for water but actually applies to many other substances as
well.

Many studies have been made on the equilibrium between
water in paper and water in oil. Fig. 1 below shows the
results from a study carried out by ASEA in Ludvika in
1972. It serves well to illustrate the phenomenon.

PdMSA 2010 Conference
Water distribution; Nyns oil - Munksj Kraft paper
0
5
10
15
20
25
30
35
40
45
50
0 1 2 3 4 5
water i n paper (%)
w
a
t
e
r

i
n

o
i
l

(
p
p
m
)
100C
80C
60C
40C
25C

Figure 1. Water in Oil versus Water in Paper EquilibriumCurves from
ASEA 1972 Study.

The most important conclusion is that at all realistic
temperatures, the bulk of the water will reside in the solid
insulation. This has several important implications. Most
importantly, it means that drying a transformer by drying
the oil alone will be a very inefficient and time-
consuming business. It also means that estimating total
water content in a transformer from determining the
amount of water in the oil is complicated and may be
quite uncertain, as will be discussed later.

Let us consider an extremely simplified case, just to
illustrate the difficulties of drying a large transformer by
continuous drying of the oil by degassing. Let us assume
we have a large transformer, with 10000 kg of cellulose
and that we want to reduce the water content in the solid
insulation from 3% down to 1 %. This means that we
want to remove 200 kg of water. Let us further assume
that we have a constant average temperature of 40C. We
would then have a water content in the oil of 15 ppm. If
we reach the desired end-point we would at equilibrium
find approx. 2 ppm in the oil. If we have during the whole
treatment an average water content of 7 ppm (very
optimistic, considering the slow transport of water from
thick structures!) and treat 3000 kg of oil per hour with a
degasser removing all the water from the oil (also very
optimistic), then we would remove 0.021 kg per hour, or
0.5 kg per day. It would then take 400 days of round-the-
clock drying of oil to achieve the set goal, even with the
very optimistic assumptions made in this example. In
reality the time would surely take much longer. It is more
likely to take few years, with a vacuum degasser tied up
full-time and during that period there would be no
possibility to do DGA with any accurate interpretation.

Water is not the only substance that is distributed
between oil and paper. It is a similar situation with small
carboxylic acids, furanic compounds and carbon oxides
(CO and CO
2
), to mention just a few. In all condition
assessments it is important to know if anything has upset
this balance. E.g. after reconditioning or reclaiming of oil,
it may be months until equilibrium is re-established, and
the apparent production rates of gases and furanes are
near the true values.
3. Condition Monitoring
In order to be able to choose the correct maintenance
activity and specific actions to be carried out, the true
condition of the oil and solid insulation must be known.
Regular DGA, though not the subject of this paper, is of
course essential, however, tests more directly aimed at
assessing the condition of the oil (and paper) are more
valuable.

When assessing the degree of ageing of the oil, the most
relevant oil tests are acidity, colour, dielectric dissipation
factor and interfacial tension. For inhibited oil it is very
useful to monitor the inhibitor content, since very little
degradation of oil will occur as long as there is sufficient
inhibitor left.
6


A useful parameter to assess the degree of degradation of
oil is the Oxidation Index (not to be confused with DP
of paper). The Oxidation Index is obtained by dividing
the interfacial tension by the acidity. It has been
suggested that oil should be reclaimed or replaced when
this values is lower than 300.
2


The water content in the oil is strictly speaking just a
reflection of the water content in the solid insulation,
since that is where the bulk of the water resides. A rough
estimate of water content in the solid insulation can be
made if the temperature is known, and has been stable for
some time. However, there is great uncertainty in the
accuracy of such an estimate, for several reasons.
3


It can rarely safely be assumed that equilibrium
has been established. With a cyclic load it will
never be attained.

There is not a uniform temperature distribution
in an operating transformer. The water content in
different regions will therefore be different. The
difference between the coldest and hottest areas
can be large.

Several water in oil versus water in paper curves
exist. These will differ depending on type of
paper and oil and the degree of ageing of both.


However, in spite of these difficulties, a rough estimate is
better than just a raw value of water content, especially
one without any reference to temperature. If water
content values are converted into a corresponding value at
a reference temperature or a water content of the solid
insulation, it is more or less a matter of taste, since these
two approaches really amount to the same thing.

It is possible to estimate the water content in the solid
insulation in other ways. One approach is to use sensors
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that give readings of the degree of saturation with water
(relative humidity). This will overcome some of the
problems. An even more advanced method is dielectric
frequency response (DFR). This requires special
equipment and some knowledge of design and geometries
to obtain a meaningful interpretation. On the other hand
it will provide more accurate estimates, if the
interpretation is done correctly.
4
Even a test so
seemingly straight-forward as the dielectric breakdown
voltage of the oil, may in some cases be misleading.
Many poor breakdown values are the result of improper
sampling and handling of the samples, such values should
always be confirmed before any remedial action is taken.

In spite of all the difficulties, and in order to end this
section on a more optimistic note, it must be said the
water content by Karl Fischer titration and the dielectric
breakdown voltage will usually together give a fair idea
of if a transformer is wet or not, at least if historical data
for the unit in question is available.

3.1 Remedial actions
There is a whole range of maintenance actions at our
disposal, depending on what conditions need to be
corrected. Decisions should always to be made on a case-
by-case basis and should use as much information as
possible, including any data from oil tests, DGA, etc..

3.1.1 Oil reconditioning
Reconditioning is a process that eliminates or reduces
physical contamination by means of
physical processes (filtration, de-humidification, de-
gasification, etc.).
6
Typically this means a combination
of mechanical filtration and vacuum degassing. It can be
done both off-line and on-line. The effect is normally an
efficient removal of particles larger than a certain size
and removal of most of the dissolved water and gases in
the oil. It is usually sufficient to correct a poor breakdown
value of oil, due to a combination of particles and high
water content, which is not a very unusual condition.

It will sometimes be necessary to carry out such a
treatment. However, it is not a long-term solution for a
wet transformer, since only a small fraction of the total
water content is removed. To obtain a significant
reduction of the water content in a transformer, a more
powerful technique must be applied. This will be
discussed in more detail later.



Figure 2. Oil reconditioning on site.
3.1.2 Oil reclaiming
Oil reclaiming is, according to IEC, a process that
eliminates or reduces soluble and insoluble polar
contaminants from the oil by chemical and physical
processing.
6
This very wide definition covers many
different treatments, but we will limit the discussion to
the case when aged acidic oil is restored to nearly as new
condition by state-of-the-art on-line treatment.

The essential elements of modern reclaiming technology
are that relatively small amounts of sorbent packed in
columns are used and that the sorbent is reactivated after
each treatment cycle. In the simplest (but fully sufficient)
execution no chemical pre-treatment is involved. The
process is run in two alternating modes:

3.1.2.1. A Treatment mode

Where the oil is:
1. Pumped from the bottom of the tank
2. Heated (if needed)
3. Run through the sorbent columns
4. Filtered and degassed
5. Returned to the transformer

After some time the sorbent will get saturated and ceases
to remove very efficiently acids and other polar
substances from the oil. Then the system is switched to
reactivation mode.

3.1.2.2. B Reactivation mode
In this stage, the sorbent columns are by-passed, and the
oil led directly to the filter-degasser. The sorbent is
reactivated by in situ incineration of the organic material
collected on the columns. Meanwhile it is possible to
continue to circulate the oil, in order to lower even further
the water content and the amount of dissolved gases.

This sequence A-B is repeated until the desired oil quality
is achieved. The sorbent can be reactivated several
hundred times. This means that the amount of waste per
ton of oil treated is very small. Furthermore, this minute
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quantity of spent sorbent is problem-free from a disposal
point of view, since the last reactivation leaves it free
from oil.




Figure 3: Mobile oil reclamation plant in action


Figure 4. Simplified Scheme for On-Line Reclaiming Of
Transformer Oil.

During the reactivation phase the columns are by-passed
(indicated by the dotted line) and the oil only circulates
through the filter/degasser.

The final step is re-additivation. It is essential to restore
the inhibitor content to the range 0.3-0.4 %, which is
considered the optimal for inhibited oil. The appropriate
amount is dissolved in a portion of the newly treated oil.
This stock solution is introduced in the main oil flow and
then circulated until it is well blended. Upon a customers
request, metal passivator can also be added in the same
manner, to further improve the oxidation stability.

During reclaiming of the oil in a transformer, samples are
drawn regularly to monitor the progress. Changes of
some properties of the oil during treatment are shown in
Fig. 5. N.B That the drying effect is only temporary, since
water will redistribute from the solid insulation into the
oil.


0
10
20
30
40
50
60
70
0 1 2 3 4 5 6 7 8 9 1
No. of circulations
A
c
c
o
r
d
i
n
g

t
o

l
e
g
e
n
d
0
Colour number x10
Water content(mg/kg)
Acidity x100 (mgKOH/g)


Figure 5. Acidity, Colour And Water Content Measured During
On-Line Reclaiming.
No of circulations is the treated volume expressed as an
equivalent number
of total oil volumes of the transformer in question.


Extensive oil tests are routinely carried out before and
immediately after treatment. A follow-up sample is taken
after a few months. Data from three mobile units in
Scandinavia have been compiled in Table I.

Table I.
Data from 247 transformers treated in Norway and
Sweden. DDF is Dielectric Dissipation Factor, BDV is
Breakdown Voltage, IFT is Interfacial Tension, DBPC is
content of antioxidant di-t-butylparacresol. A comparison
is included with the recommended limits for unused
mineral insulating oil filled in new power transformers,
before energisation (from IEC 60422).

Acidity
(mgKOH
/g)
Colo
ur
BDV
(kV/2,5m
m)
DDF
at
90C
IFT
(mN/
m)
Befor
e
0,157 4,1 68 0,081
2
23,5
After 0,009 1,5 80 0,003
3
46,0
Follo
w-up

0,014 1,6 74
0,006
3
42,3
IEC
60422
0,03 2,0 55-60 0,010
-
0,015
35
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Figure 6: Evolution of total acidity in oil after online
reclamation,
oil change and reclamation with insufficient absorbent


The oxidation stability of reclaimed oil can not be
expected to be quite as good as that of the highest quality
inhibited oils produced today. After all, there have been
advances in refining technology.

However, it has been found that with re-inihibiting the
oxidation stability of reclaimed oil is on par with oils
fulfilling the requirements for inhibited oils in IEC
60296:1982, which is a fair comparison, considering what
the vintages are of oil that are normally the subject of
reclaiming.
5


There are several attractive features of reclaiming,
compared to exchange of the oil. Although for safety
reasons sometimes it is necessary to de-energise the
transformer when the reclaiming equipment is being
connected and disconnected, the process can (and indeed
should) be run when transformers are loaded. This may
have a major impact on total costs, depending on how
production losses are valued.

From a technical point of view, the repeated or
continuous washing of the solid insulation represents a
major advantage. First of all, in the case of oil exchange,
there are several % of the old oil in the solid insulation
that will contaminate the new oil.

Furthermore, during aging of the oil and paper,
significant amounts of acids, sludge and other
degradation products are accumulated in the paper and
board. They can later be partially re-dissolved by clean
oil. In the case of reclaiming, this happens to a large
extent already during the process, in which they are
permanently removed shortly after being extracted from
the cellulose. In the case of oil replacement without
proper cleaning of the active part, residual degradation
products in oil and paper can cause rapidly enhancing
levels of contamination of the new oil as well.
Ageingof transformer oil after reclamationandoil change
0
0,05
0,1
0,15
0,2
0,25
0,3
Time
m
g
K
O
H
/
g
A
c
i
d
i
t
y
l
e
v
e
l
ABBmethod Lessabsorbent Oilchange
FrReg.
Before 3mnd. 1year 2years 4years 6years 9years
Sevearly
ageadoil
Newoil

To summarize the effects of on-line reclaiming with
modern technology, we conclude:

On-line reclaiming restores the oils properties
to close to those of new oil.

The oxidation stability of the reclaimed oil is
good when the treatment is combined with
reinhibiting.

New oil
The changes in properties (due to
recontamination from degradation products in
the solid insulation) during the first years in
service after treatment are small.

From an environmental point of view, the
advantages compared to oil exchange or
traditional reclaiming technologies are
indisputable. The most important reasons are
that oil is not a renewable resource and the new
technology causes much less waste of oil and
sorbent than traditional methods.

More than 700 transformers successfully treated
in the Scandinavian countries alone



3.2 Reinhibiting as stand-alone action
Reinhibiting is not only an indispensable part of the oil
reclaiming process. With originally inhibited oils, it will
sometimes be possible to replenish the phenolic inhibitor
content before the on-set of oxidation at a significant rate.

This may prolong by many years the time before more
costly maintenance actions such as reclaiming are needed.
However, it needs to be done in good time. The IEC
insulating oil supervision and maintenance guide
recommends that this is done when 40-60% of the
original content has been consumed.
6


In absolute numbers this corresponds to the range 0.12%
to 0.24%. However, it may be worthwhile to do this even
at lower inhibitor contents, even below 0.10 %, provided
that the oil is still in good condition. However, it should
be stressed that reinhibiting will not restore the oils
properties; it will only further retard the oxidation
process.



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3.2 Removal of Moisture from the Paper insulation

Oil analyses normally include also the measurement of
the moisture in oil. As shown earlier in the paper, the
amount of moisture in the oil is in relation to the amount
of moisture in the paper. However, it is very important to
remember that the moisture in oil is only an indicator of
the total moisture content and not a moisture reservoir, as
over 99% of the moisture is absorbed by the paper
insulation. Thus any oil change or short time oil treatment
will not be able to remove any considerable amount of
water from the transformer.

A typical drying process for power transformers includes
vacuum and heat (as it was earlier shown that the drying
through the oil is not very efficient). Preferably, one
should have both carried out at the same time. But as
vacuum is thermally insulating the inner part of the
transformer (like in a thermos bottle), the heat transfer to
the windings is almost impossible with external heating.
Conventional site drying processes normally include a
heat cycle without vacuum followed by a vacuum cycle.
These processes have different disadvantages:

Limited drying temperature as the heat transfer
media is oil.

Substantial temperature drop during the vacuum
cycles due to the energy needed to evaporate the
moisture.

Several heating cycles are needed were the
insulation is exposed to heat as well as oxygen
(potential stress for the insulation paper).
Long drying processes are needed to achieve a
substantial reduction of the moisture content in
the insulation (typically several weeks).

Oil spray processes cannot reach the inner part
of the windings due to the covering of the
winding blocks in the power transformers.

To overcome these disadvantages, ABB has developed a
new on site transformer drying process equipment that is
based on the heating of the windings with a low
frequency current (LFH system). The goal was to heat up
the whole transformer uniformly under a vacuum.

To achieve this, a mobile solid state low frequent current
source was developed. In order to heat up the low and
high voltage windings, a frequency of approx. 1 Hz is
applied to the transformer. With the combination of LFH
drying process and the conventional hot oil spray method,
the whole transformer can be heated very uniformly. The
LFH system is heating the windings from the inside and
the hot oil spray supports the heating process by heating
outer parts of the insulation system.

The LFH process combined with hot oil spray allows us
to reduce the drying time substantially. It is possible to
reach the same low levels of moisture in the whole
insulation as with a factory process (applying vapour
phase), within 1 to 2 weeks. Compared to conventional
systems like hot oil circulation or hot oil spray, this is a
time reduction by approximately a factor of 2-4 .
7



LFH Converter
Oil treatmentplant
Short circuit
LV.
HV.
Vacuum
pumps
Vacuumcontrol
valve
Spray
nozzles
LFH Converter
Oil treatmentplant
Short circuit
LV.
HV.
Vacuum
pumps
Vacuumcontrol
valve
Spray
nozzles




Figure 7 LFH Plant Concept

3.2.1 Drying results.
Over 60 power transformers have been dried on site with
the LFH technology. The range varies from 6 MVA/12,5
kV to 750 MVA/500 kV transformers. According to the
actual requirements and the process control, the average
drying result could vary from 1,5 % down to 0,5 %
residual humidity in the insulation. Such low values could
only previously be achieved when the transformers were
dried in a workshop with a vapour phase drying oven.

The target moisture level is dependent on:
Transformer voltage level
Age (degree of paper depolymerisation)
Original moisture level
Re-clamping possibilities of the windings after
drying

Due to the water extraction the clamping pressure on the
windings will be reduced.
8
However, research carried
out on large power transformers showed that this
reduction effect is limited to approx. 5% of the original
clamping pressure while staying above a moisture level of
1%. An additional 7% were lost when drying the
transformer down to 0,5% residual moisture. Therefore,
the drying on site is stopped at around 1%, whenever re-
clamping is not a viable option.
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3.2.2 Effect on low molecular weight acids.
Not only water is removed by the process. The low
molecular weight acids have only a slightly higher boiling
point then water. Thus heating the transformer over 100
C with the combination of vacuum will also evaporate
these acids. This can clearly be seen when analysing the
extracted water during the LFH drying process. It
contains large amounts of acids. The typical values for
the neutralisation value in the condensed water are
between 5 20 mgKOH/g (the typical content of low
molecular acids in the oil 0.02 mgKOH/g).

3.2.3 Combination of LFH drying and reclaiming
Quite often transformers with acidic oil that needs to be
reclaimed are also in need of drying, and vice versa. LFH
and reclaiming can then be combined. There is already
extensive experience of this practice. Since this combined
treatment removes a large fraction of the main
accelerating factors in the ageing of paper (water and low
molecular weight acids) and also the acids in the oil, the
long-term effect on paper ageing is even greater. The
drying and reclaiming processes can in part run in parallel
which reduces the total process time and cost.

3.3 Comparison of different drying technologies
As mentioned before, different procedures are available
to dry out transformers on site or in a factory. Two
major techniques are used:

- Drying the insulation by drying the oil
- Drying the insulation with heat and vacuum

The indirect drying through the oil is much slower as the
oil contains only a very small part of the total water, <1%
(see also the example under the paragraph Distribution of
Degradation Products between Oil and Paper). On the
other hand, it is not necessary to stop the transformer
when drying it through the oil.

Continuous oil dryers are very convenient whenever a
transformer needs to be kept dry or as an emergency
measure when there is a risk of formation of water
droplets when the transformer is cooled down. However,
for the dry out of humid bulk insulation in an aged
transformer these systems will hardly be able to remove
sufficient moisture to change the speed of degradation
and thus extend the remaining lifetime.

Drying time to dry a 400 MVA transformer with 14 tonn
insulation from 3% down to 1,5 % average humidity
LFH +oil circulation
LFH +Hot oil spray
Vapour phase
Online oil degassing
200 lt/h average oil
temp. 50C
Online oil degassing
200 lt/h average oil
temp. 30C
Molecular sieve
Hot oil circulation +
vacuumcycles
Online oil degassing
6000 lt/h average oil
temp. 50C
Online oil degassing
6000 lt/h average oil
temp. 30C
0.001
0.01
0.1
1
10
100
y
e
a
r
s

Figure 8: Comparison of different transformer drying methods

A quick drying reduces the ageing effect immediately,
where as with slower systems, the same effect can only
be seen after several years. Whenever an online degassing
system is used, it makes it nearly impossible to detect
failures with DGA analyses. This will increase the risk of
a major failure on the unit. This fact beside others needs
to be considered when choosing a drying procedure.
3.3.1 Life time extension of the insulation system
With the appropriate measures one can extend the
technical lifetime of the organic insulation system
substantially. The removal of the ageing accelerators like
moisture and acid will slow down the degradation
process. In addition the formation of further ageing
accelerators will be reduced. All this is leading to an
extension of the time it takes for the insulation to reach a
state where it is no longer withstanding the stresses
applied to it.

However, by keeping the insulation system in a good
shape, one has also a larger margin when it comes to
daily stresses upon the system (stronger paper, better
insulation capability of the oil). This is results in a
higher reliability of the whole system. It is also important
to understand that the degradation of the paper is
accelerated by the by-products formed from it. Conditions
are thus gradually getting worse as the transformer ages.

Exactly how much the removal of water will slow down
the ageing is difficult to predict. However, recent
research results suggest that within the range of water
contents that can reasonably be expected in real
transformer windings, a halving of the water content (e.g.
from 2% to 1%) should lead to at least a halving of the
ageing rate.
1
The effects of acids are even more difficult
to predict, since different acids have different activities.
However, oil reclaiming as well as the removal of acids
that takes place during LFH drying will certainly have
significant effects.

It is thus not possible to give a simple figure for all
transformers, however, one can make some estimates for
single units if the:

Actual state of the degradation is known (how
far has it come)
PdMSA 2010 Conference
Actual amount of degradation accelerators is
known (moisture, acids)
Future load pattern is resembling the historical
transformer load

From this information one can simulate the estimated life
time extension by applying the different counter actions.
Of course such a simulation will always be a rough
estimation. In the very simplified example in Fig. 9 the
kinetic parameters suggested by Lundgaard (for initially
dry paper under oxygen-poor conditions) have been
applied
. 9


Arrows indicate the time to reach an end-of life
criterion of DP 200, without and with removal of half the
water content after a certain time. In real life, water
ingress would contribute to build-up of water and the
effect of oxidation would also make conditions in the
windings progressively worse. Models can of course be
made that take also this into account.



0
200
400
600
800
1000
0 10 20 30 40 50
years
DP
60
no drying
with drying
after 15 years


Figure 9. DP versus time curve based on kinetic data from
laboratory ageing experiments.
Drying with 50% reduction of water content after 15 years.


The main points for an optimal result are:

Dont wait too long. When less of the original
lifetime is left, there is less to gain.

Effective removal of moisture and acids is a
must for the life time extension of an already
aged system (if the moisture removal takes
several years it might be already too late)

Act before large amounts of moisture and acids

are formed inside the transformer


Conclusions
Proper oil maintenance coupled with the removal of water
from the solid insulation, when required, will improve the
long-term reliability of the insulating system and thus
help prolong the technical life of the transformer.

It is important to know that oil and paper interact and
what is carried out for one will influence the future of the
other. The distribution of degradation products, such as
water, between the two will influence strongly what
maintenance actions that are beneficial, especially in the
longer term.

A proper condition assessment, based mainly (but not
exclusively) on oil tests, is the basis for sound decisions
about what maintenance activities should be carried out
on the insulating system.

Today all the necessary maintenance actions and
procedures are available, ranging from simply adding
more oxidation inhibitor before oil starts to deteriorate, to
combining oil reclaiming and LFH drying in the cases
where there is both strongly aged acidic oil and a high
water content.


4.0 On-Site Repair Process
Power transformer factories and workshops are
characterized by their orderliness, cleanliness and well
controlled atmospheres which are important conditions
required for manufacturing and repair of high voltage
equipment. They are also equipped with heavy lifting
equipment, special tools and fixtures, high voltage test
laboratories and highly skilled operators for each step of
the process.
To perform a site repair of a transformer, the same
capabilities have to be set up on site in order to meet the
individual circumstances of each case. The concept
requires the following:
In order to perform a site repair a controlled environment
facility will be required, where cleanliness and orderliness
can be achieved. The facility should meet all the criterias
required to perform the necessary repairs. If the customer
does not have a repair area a temporary workshop can be
set up on site.

Heavy lifting equipment will be required on the site. The
largest transformers may require a capacity of up to 400
metric tons and above for un-tanking and tanking of the
core and coil assembly.



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Windings and insulation components are manufactured at
a transformer factory and are dried and oil impregnated
prior to shipment. They are then specially packed to
maintain the low moisture content during shipment and are
stored on site in a controlled environment.

After assembly of core and coils the active part is placed in
the transformer tank and prepared for final drying. The
On-Site Drying processes used can reduce the moisture
levels to below 1 %. There are several methods available
for On-Site drying to reduce the total time required for
drying a large power transformer.

High voltage test of the assembled transformer is carried
out on-site according to the agreed test plan. To meet the
requirement of portability and flexibility an On-Site High
Voltage test system has been developed together with a test
equipment supplier.

4.1 Facilities for Temporary Workshops
Based on the experience gained globally within the
Service centers that have performed site repair projects it
was noted that a maintenance shop owned by the customer
is available for approximately 50% of the repair projects
completed.
The available shop may also be equipped with an
overhead crane for lifting of core and coil assembly and
winding blocks. For the remaining 50% of the projects it
was necessary to set up a temporary facility. When a
permanent facility is available at site for transformer repair
it should be separated from the rest of the facility to
maintain the cleanliness required.
A temporary workshop may be set up based on a steel
structure with a cladding of corrugated sheets of steel .
This type of building is primarily used when more than one
transformer will be repaired at the same site or when there
is a desire to keep the building for any future repair or
maintenance work by the owner.



Figure 10: A steel building used as temporary workshop in Brazil




Figure 11: A steel building used as temporary workshop in Brazil

Another very flexible and economical solution is to use a
large tent consisting of a steel structure and claddings. This
structure could achieve and maintain clean and dry
environment for the repair work to be performed on the
active part of the transformer. These types of tents can be
set up in very short time, normally less than a week and are
designed to withstand severe weather conditions such
strong winds and snow load.



Figure 12: Typical tent structure that may be used as temporary
workshop

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4.3 Heavy Lifting At Site
One of the major heavy lifting required during repair of a
core type transformer is the lifting of the core and coil
assembly for un-tanking and tanking of the transformer.
The core and coil assembly of the largest transformers may
weigh up to 400 metric tons and above. To handle this
weight, mobile compact lifting systems are available from
global suppliers. For smaller transformers, the lifting of
the active part may be performed with mobile cranes which
are also used for lifting of windings and other components
for disassembly and reassembly of the active part and the
transformer


Figure 13: Tanking of large power transformer using mobile
lifting equipment

4.4. The Factory Is Brought To Site
For achieving the same quality standards of repair at site
as repair in factory Bring the factory to site.
That means that the repairs are performed in the same
way on site as in the factory. The same processes, tools,
fixtures and equipment are applied as far as possible.
One of the processes used in factory which is not
presently used on site is the drying of the core and coil
assembly using the vapor-phase process. However based
on the experience and detailed investigations of the result
from a large number of projects, the drying result of the
alternative processes used on site meets the required
maximum level of moisture content. These alternative
processes are described below.

5.0 On-Site Drying

Initially, all new windings and insulating components
internal to the transformer are dried and impregnated while
still in the factory using standard vapor phase drying
process. The oil impregnation of the windings and
insulation components minimizes the moisture absorption
when handling the parts. In addition all parts are then
specially packed and transported in special containers that
are filled with dry transformer oil or positive dry air
pressure. On site the new parts and the transformer are
stored under controlled climatic conditions. Air drying
units guarantee the best possible condition to prevent
moisture ingress during the repair.
Once the repair on the core and coil is completed, an on
site drying process is initiated after the assembly and
tanking of the transformers active part. The on site drying
includes a heating of the whole transformer succeeded by
vacuum cycles.

Typical processes used:
5.1 Hot oil circulation:

Hot oil is circulated through the transformer and once the
desired temperature is reached the oil is drained into a tank
and vacuum is applied to the transformer tank. Based on
the kV class of the transformer and moisture content
vacuum cycles are maintained till the necessary drying
criterias are met. Also the maximum allowed oil
temperature may limit the maximum drying temperature.

5.2. Hot oil spray:

Spray nozzles are installed at the available flanges and hot
oil is sprayed over the active part at the same time as
vacuum is applied. This allows limiting the temperature
reduction during the vacuum cycles. But due to design of
the core type transformers with press plates and shielding,
it might be difficult to heat up the core and coil assembly
uniformly. For shell type transformer this method is more
often used as the main insulation can be easily reached by
the hot oil spray.

5.3 Low Frequency current Heating (LFH)

In order to heat up both low and high voltage windings, a
frequency of approximately 1 Hz is applied to the
transformer. With the combination of LFH drying and the
conventional hot oil spray method, the active part can be
uniformly heated. The LFH system heats the windings
from the inside and the hot oil spray supports the heating
process by heating outer parts of the insulation system.

The LFH process combined with hot oil spray reduces
the total drying time of the transformer on site. It is also
possible to meet the same low levels of moisture in the
insulation as compared to factory repair within short period
of time. The savings in time compared to conventional hot
oil spray method and LFH method could be between 3 to 4
weeks.
PdMSA 2010 Conference


LFH Converter
Oil treatment plant
Short circuit
LV.
HV.
Vacuum
pumps
Vacuum control
valve
Spray
nozzles
LFH Converter
Oil treatment plant
Short circuit
LV.
HV.
Vacuum
pumps
Vacuum control
valve
Spray
nozzles

Figure 14: Plant concept for a mobile LFH drying process in
combination with hot oil spray


Using the most advanced techniques, the repair process
including on-site drying, ensures low final moisture and
high-quality insulation of the transformer, compatible with
advanced on-factory drying processes.

6.0 On-Site High Voltage Testing
For most of the projects the quality and dielectric of the
repair has been verified by high voltage tests including
applied voltage test and induced voltage test with
measurement of partial discharge. These tests are in
addition to all other type of quality control tests which are
normally performed when manufacturing new transformers
or repairing transformers in a factory.
The performance of the projects repaired and tested after
site repairs has been excellent. This confirms that the
quality of the process performed on site meets the
standards of a factory repair.
On-site high voltage testing can also be used for
verifying the quality of a refurbishment projects for:
o As a part of a diagnostic procedure to confirm that
the dielectric strength of the main insulation is free
from defects and or provide reference values for
future tests or to confirm results from earlier test
o As a commissioning test to confirm the condition of
the transformer after shipment and the installation
on site

In order to perform on-site high voltage tests, a test
system that can be easily transported to any remote site and
set up in short time is required. The test system should
also be flexible and be able to test at different voltage
levels as required for different transformers. So far the
mobile high voltage test equipment has been built based on
motor generator sets completed with adaptation
transformers, components for reactive compensation and
measurement and recording equipment. To improve the
portability and flexibility of such equipment we have
developed a new concept for on-site high voltage test based
on high power electronics as a variable frequency power
source.





Figure 15: Mobile High Voltage Test Systembuilt on a 40
container arrive to the site for test

The new mobile high voltage system is equipped to
perform Applied Voltage test and Induced voltage test with
measurement of Partial discharge. In addition,
measurement of Load Losses and No-Load losses can be
performed at reduced levels. The test system is designed
and is capable of testing most of the HV transformers
installed globally
For performing applied voltage test a resonance circuit
is set up between the capacitance of the test object and
the resonance reactor supplied with the test set up as
shown in Fig. 16. The resonance circuit is fed by the
frequency converter through the adaptation transformer.
The block diagram below show schematically the test set
up for a standard applied voltage test.










Frequency
Converter
Adaptation
transformer
Resonance
reactor
Testobject
Measuringandrecording
equipment
Convertercontrol
MobileHighVoltageTest System
=
Frequency
Converter
Adaptation
transformer
Resonance
reactor
Testobject
Measuringandrecording
equipment
Convertercontrol
MobileHighVoltageTest System
=
Figure 16: Mobile High Voltage Test System set up for applied
voltage test


For performing an induced voltage test the advantage
of the variable frequency converter is used to find the
frequency of self compensation of the test object.

This frequency of a power transformer is normally
between 50 and 150 Hz. By performing the test at the
self compensation frequency the power consumption of
the test circuit will be limited to the active losses of the
transformer and the size of the converter can be reduced.
The adaptation transformer is designed to match the
normal voltage range applied for tertiary voltage
windings of power transformers.
PdMSA 2010 Conference
The block diagram Figure 17: below show schematically the
test set up for Induced voltage test.











Figure 17: Mobile High Voltage Test System set up for Induced
voltage test

The Mobile High Voltage Test System is designed and
built in order to be transported in a standard 40 feet
container for easy transportation by truck, by sea or by
air. The Fig. 18 shows the test system set up at a
substation for test of a large single phase transformer.








Figure 18: High voltage testing performed of a power
transformer after site repair. The temporary workshop can be
seen in the background


7.0 Transformer Repaired On Site
A Generator Step Up Transformer (GSU) located in
Limay Bataan, Philippines failed in service.


Frequency
Converter
Adaptation
transformer
HVfilter Test object
Measuringandrecording
equipment
Convertercontrol
PD
MobileHighVoltageTest System
Frequency
Converter
Adaptation
transformer
HVfilter Test object
Measuringandrecording
equipment
Convertercontrol
PD
MobileHighVoltageTest System
The power plant is owned by the National Power
Corporation (NPC) in the Philippines and operated by
Alstom Power. The power plant did not have any spare
transformers and required the quickest option to repair
and return the existing GSU to service.
Figure 19: Temporary site repair 93 MVA, 240/13.8 kV
Initial electrical diagnostics testing and oil analysis
indicated that the windings of the transformer were
damaged and needed to be replaced.
The original transformer design data significantly
reduced the design time for the replacement windings.
The manufacturing of the new windings and
preassembling of the winding blocks were completed in
Thailand, in accordance with the guidelines for new
transformers. The winding blocks were dried and
assembled in the transportation tank sealed with positive
dry air pressure. The winding tanks were shipped to site
in Philippines.


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Figure 20: New windings received on site in tank with dry air
One of the key and most important challenges was to
create factory environment on site. This was achieved by
erecting a temporary workshop equipped with an air
conditioner and dehumidifier.
After delivery of the windings from the factory in
Thailand to site, the skilled team successfully replaced
the windings and repaired the transformer to new
condition.
After tanking of the core and coil assembly, a vacuum
drying process along with hot oil circulation method was
applied. The quality of the drying process was monitored
by Frequency-Domain-Spectroscopy (FDS)
measurements.
One of the most important scope of the project
successfully performed was the High voltage testing on
site after repair.
A Mobile High Voltage test system was brought to site
in order to perform dielectric tests including Applied
Voltage test, Induced Voltage test and Partial Discharge
measurement. All tests were performed according to the
international standards.




Figure 21: The Mobile High Voltage Test system set up at site
for testing of the repaired transformer
After the successful completion of all tests and
acceptance by the customer the transformer was
successfully put back into service.

8.0 Project References

In total more than 300 transformers have been repaired
on-site. The largest transformer repaired on site is rated
at 750 MVA, 800 kV ac. More than 60 transformers
above 200 MVA including several HVDC transformers
rated up to 600 kV dc have been repaired successfully
on-site.
As it relates to transportation costs and risks, the large
power transformers are the likely candidates to be
considered for on site repair. The total repair time in most
of the cases were reduced by 12 to 14 weeks depending
on the geographical condition of the transformer and site.
However several transformers below 50 MVA and 30
MVA were also repaired or refurbished on site.

9.0 Conclusions
Proper oil maintenance coupled with the removal of water
from the solid insulation, when required, will improve the
long-term reliability of the insulating system and thus
help prolong the technical life of the transformer.

It is important to know that oil and paper interact and
what is carried out for one will influence the future of the
other. The distribution of degradation products, such as
water, between the two will influence strongly what
maintenance actions that are beneficial, especially in the
longer term.

A proper condition assessment, based mainly (but not
exclusively) on oil tests, is the basis for sound decisions
about what maintenance activities should be carried out
on the insulating system.

PdMSA 2010 Conference
The electrical market in most of the countries, not to
say all, value more and more the quality of the energy
supplied to the end-users. One of the important
challenges for industries and utilities is therefore to
ensure no interruption in the delivery which means a high
availability and reliability of the different equipment
installed in the networks. After several years of
experience in many countries the condition assessment
survey and on site repair helps transformer owners to
reduce the downtime of their equipment.
Condition Assessment provide relevant information to
support informed decisions needed to implement
condition based maintenance and reduce repair time by
better planning the repair tasks and ordering of material.
On site repair based on a proven process and strong
project management combined with state-of-the-art
technology and strict quality control allows reducing
repair time by several weeks or even months while
ensuring a highly reliable repair.
Condition Assessment and on site repair help industries
and utilities keeping a high standard of energy delivery
through improved availability of transformers.
Today all the necessary maintenance actions and
procedures are available, ranging from simply adding
more oxidation inhibitor before oil starts to deteriorate, to
combining oil reclaiming and LFH drying in the cases
where there is both strongly aged acidic oil and a high
water content.






































































PdMSA 2010 Conference

10.0 References


[1]
1
Ageing Of Cellulose In Mineral-Oil Insulated
Transformers, CIGRE Broschure #323, Task
Force D1.01.10

[2]
2
A Guide to Transformer Maintenance, S.D.
Myers, J .J . Kelly, R.H. Parrish, Transformer
Maintenace Inst., 1988

[3]
3
Moisture Equilibrium And Moisture Migration
Within Transformer Insulating Systems, CIGRE
Working Group A2-30, Final Report to be
published in Electra J anuary 2008

[4]
4
Dielectric Response Methods for Diagnostics
of Power Transformers, CIGRE Task Force
15.01.09, Report in Electra Nr 202 (Juni 2002)

[5]
5
. Berg, M. Dahlund, A. Danielsen, K.
Herdlevar, K. Renstrm and U. Thiess,
Experiences From On-Site Transformer Oil
Reclaiming, Paper 12-103 CIGRE Session 2002,
Paris

[6]
6
IEC 60422, 3
rd
Edition

[7]
7
P. Koestinger, Drying Of Power Transformers
In The Field, Applying The LFH-Technology In
Combination With Reclaiming, EuroTechCon
2005

[8]
8
Ch. Krause, M. Prevost and D. Woodcock,
The effects on winding clamping pressure due to
changes in moisture, temperature and insulation
age, sixty-seventh Annual International Conf. of
Doble Clients, March 2000

[9]
9
L. Lundgaard et al., Ageing and Restoration of
Transformer Windings, SINTEF Energy
Research Report TR A5540, December 2001

[10] K.Carrander, L.Pettersson L.Melzer, N.Fantana,
P.Lorin, Methodology for life assessment on
power transformers,TRAFOTECH-2002, Sixth
International Conference on Transformers, 24-25
J anuary 2002, Mumbai, India.

[11] A. Fazlagic , M. Perkins, P.Lorin, Transformer
life assessment and advanced diagnostics as tools
in pro-active and advanced risk asset
management, Seventh European Electric
Steelmaking conference, Venise, Italy, May 2002

[12] R. Marek, J C. Duart and al, Power Transformer
Refurbishment: The Benefits of Hybrid
Insulation, CIGRE Paris Session 2004


[13] R. Albuquerque, J .C. Mendes, R. Marcondes,
On-Site Repair of an HVDC Transformer,
CIGRE Paris Session 2004

[14] J .C. Mendes, R.A. Marcondes, J . Nakamura,
On-Site Tests on HV Power Transformers,
CIGRE Paris Session 2004

[15] P. Koestinger, T. Bruary, "Drying of power
transformers in the field, applying the LFH-
Technology in combination with oil reclamation",
CIGRE Paris Session 2006

[16] O. Berg, K. Herdlevar, M. Dahlund, K.
Renstrm, A. Danielsen, U. Thiess, Experiences
from on-site transformer oil reclaiming, CIGRE
Paris Conference Paper 12-103, 2002 Session

[17] P. Koestinger, E. Aronsen, P. Boss, Practical
experience with the drying of power transformers
in the field, applying the Low Frequency Heating
Technology (LFH) , CIGRE Paris Session 2004.

[18] J .C. Mendes, L. Eklund, P. Capuano, Meet the
challenges of tomorrow: Increase the power of
your transformer in record time, Power-Gen
Middle East, Bahrain 2008.

[19] W. Bartley, Analysis of Transformer Failures,
Proceedings of the 67
th
Annual Int. Conf. of
Doble Clients, Paper 8N, March 2000.