Detection of Winding Movement and Geometric Changes in Power Transformers by Frequency Response Analysis (FRA) (Hungarian Experience)

Gusztv Cspes Istvn Kispl

Hungarian Power Companies Ltd. B&C Diagnostics Ltd.

Why does the FRA diagnostic tool need ?

Dielectric and mechanical failures in large power transformers are preceded by mechanical changes in the winding structure. - These changes or movements in the winding conductors may be - the results of transportation damage, - the results of short circuit forces (fault occurring close to the transformer), - results of natural effects of aging on the insulation structures => significant winding shrinkage (the initial compression of winding in the factory tends to disappear as the paper is aged during years of operation at a high temperature)

Why does the FRA diagnostic tool need ? (cont.)

-The FRA is an sensitive diagnostic tool to show changes in the winding geometry, - Detection of these displacements in advance of dielectric failure can reduce unplanned maintenance costs, and provide the possibility to improve system reliability by preventing outage, - There are a number of sensors and monitors that have been developed to improve the data available for diagnostics on transformers, but at present time there is

no commercial monitors in use on operating transformers to detect changes in the winding geometry

Case Study - Between 2000-2003, a 215 MVA, 132/15 kV, relatively new
(made in 1999) generator set-up transformer has been investigated - This transformer was sent to the factory in order to repair - in the factory

3 FRA tests were performed (fingerprints !!!)

- FRA 1: before the first repair (06.11.2000) - FRA 2: after the first repair (07.12.2000) - FRA 3: after the second repair (30.01.2001 - Vibration test 1: after one year service (07.03.2002) - FRA 4: the 4th FRA test (25.03.2002) was performed because the vibration test has been indicating the probability of looseness in the phase C of the

Case Study (cont.) -Two further FRA tests and one vibration test were performed on-site: - FRA 5: half year later after the 1st vibration test (27.09.2002) - FRA 6: half year later after the previous FRA 5 test (18.06.2003) - Vibration test 2: Parallel with the 6th FRA test another vibration test was carried out directly through the oil

- This unit is a gas turbine generator set-up transformer,

consequently it has got numerous of mechanical shocks, mostly during switch-on process - The history of our case study has started with a warning signal: one year after of repairing action, they were hearing an unusual noise in this transformer -After hearing this unusual noise a vibro-acoustic test was performed on wall with piezoelectric sensors - Procedure of the first vibration test: There were 7 piezoelectric sensors installed on the transformer: 4 piezoelectric sensors (V vertical type movement meter) were installed on the bottom at the roller of the transformer, and 3 piezoelectric accelerometers were installed on three sides of the tank.

- The first vibro-acoustic tests were carried out once in the

no-load mode, and three times in the switch-on mode. - In the no-load mode the electrodynamics forces in windings are practically absent, so the vibration test relates to the magnetic core conditions only. -Final result of the first vibration test: -Results of the first vibration test have showed that the core is good mechanical condition. Analysing the test results of this vibro-acoustic

measurements and the recorded in-rush current during the three switch-on processes, the experts have announced that there would be looseness in the winding, maybe in the phase C.

Short description of the FRA measurement - The test was carried out with a gain/phase analyser (TRAFTEK) - Before the test the terminals should be disconnected - There is a double coaxial cable: - One of the cables is used to carry the swept-frequency output voltage from the analyser to one end of a winding (excitation voltage) - The other brings back the output voltage from the other terminal of winding -The cable is terminated with their characteristic impedance (75 Ohm) at the analyser output in order to eliminate reflection problems - The analyser performs a frequency sweep in a selected frequency range at the number of points per sweep can be specified on either a linear or logarithmic scale

TRAFTEK
6 4 0 x 4 8 0 T F T D is p la y
O p to Is o la tio n

486 D X 100 C P U

Sine wave generator 50Hz ... 1MHz A D C o n v e rs io n Voltage input signal conditioner Voltage input signal conditioner

75Ohm

In te rfa c e

FRA connector on the front panel

Ap

75Ohm

K e y b o a rd

Test Cable
75Ohm

F lo p p y

20m triple koax 75 Ohm

Hydrophone signal conditioner

6m Hydrophone cable (Bruel-Kjaer)

Tank Np

Oil immersed Hydrophone

T ra n s fo rm e r w in d in g

M a in s P ow er

Pow er s u p p ly

Measuring Primary winding C phase

Voltage out Clips Np Cp Cs Bp Bs Ap As Ns

Termination Clips

Voltage Out at Cp, Termination at Np.

TrafTek

Three possible cases of interpretation of FRA results: The FRA diagnostic technique is not based on absolute measurements but rather on curve comparison. We have an earlier FRA curve of the same transformer

(Fingerprint) and we can compare the results phase-by-phase winding-by-winding. After some practice and the knowledge of the transformer construction we can make a decision that this movement was important (dangerous) or not. - We have no fingerprint but we have measurements on same type (or construction) transformers. We know the distribution of curves (peaks) within the units of the same transformer type, and we can evaluate our FRA curves. - We have neither fingerprint and nor reference data. We can compare the three phases usually the shape of the curves of a transformer is similar at the three phase windings. We can compare them to each other. (We have to be careful because not all transformer construction has symmetrical phase response)

Some examples of test arrangements on a two winding three phase transformer Excitation Grounded Termination voltage Open terminals (short circuited) Measured impedance at at terminals Ap Np As,Bs,Cs,Ns,Bp,Cp Primary winding x phase Bp Np As,Bs,Cs,Ns,Ap,Cp Cp Np As,Bs,Cs,Ns,Ap,Bp Ap Np Bp,Cp As,Bs,Cs,Ns Primary winding x phase Bp Np Ap,Cp As,Bs,Cs,Ns (+ effect of leakage imp. between primary and secondary winding) Cp Np Ap,Bp As,Bs,Cs,Ns As Ns Ap,Bp,Cp,Np,Bs,Cs Secondary winding x phase Bs Ns Ap,Bp,Cp,Np,As,Cs Cs Ns Ap,Bp,Cp,Np,As,Bs As Ns Bs,Cs Ap,Bp,Cp,Np Secondary winding x phase Bs Ns As,Cs Ap,Bp,Cp,Np (+ effect of leakage imp. between Cs Ns As,Bs Ap,Bp,Cp,Np primary and secondary winding) Ap As Bp,Cp,Bs,Cs Np,Ns Leakage impedance between Bp Bs Ap,Cp,As,Cs Np,Ns primary and secondary Cp Cs Ap,Bp,As,Bs Np,Ns If the transformer has Delta winding it can be measured as AsBs, BsCs and CsAs in a circle.

4.1. Measuring on the 132 kV windings (Ap, Bp, Cp , Np), 15 kV windings (As,Bs,Cs) were floating or open"
Z (O h m ) 1 .0 0 0 M
2002.03.25.

Ap----Np Bp----Np Cp----Np

1 0 0 .0 k

1 0 .0 0 k

1 .0 0 0 k

1 0 0 .0

1 0 .0 0

1 .0 0 0 k

1 0 .0 0 k f (H z )

1 0 0 .0 k

1 .0 0 0 M

4.2. Measuring on the 120 kV windings (Ap, Bp, Cp , Np), 15 kV windings (As,Bs,Cs) were "short circuited
Z (O h m ) 1 .0 0 0 M
2002.03.25. Low Voltage side Short Circuited

Ap----Np Bp----Np Cp----Np

1 0 0 .0 k

1 0 .0 0 k

1 .0 0 0 k

1 0 0 .0

1 0 .0 0

1 .0 0 0 k

1 0 .0 0 k f (H z )

1 0 0 .0 k

1 .0 0 0 M

4.3/A: Comparing of the curves of 132 kV side as function of service time: the first 4 FRA tests of Ap-Np, floating15 kV side, magnified central part
Z (O h m ) 1 .0 0 0 M
Ap...Np

1 0 0 .0 k

2000.11.06. 2000.12.07. 2001.01.30. 2002.03.25.

1 0 .0 0 k

1 .0 0 0 k

1 0 0 .0

1 0 .0 0

1 0 .0 0 k f (H z )

1 0 0 .0 k

4.3/C: Comparing of the curves of 132 kV side as function of service time: the first 4 FRA tests of Cp-Np, floating15 kV side, magnified central part
Z (O h m ) 1 .0 0 0 M
Cp...Np

1 0 0 .0 k

2000.11.06. 2000.12.07. 2001.01.30. 2002.03.25.

1 0 .0 0 k

1 .0 0 0 k

1 0 0 .0

1 0 .0 0

1 0 .0 0 k f (H z )

1 0 0 .0 k

4.4/A: Comparing of the curves of 132 kV side as function of service time: the latest 3 FRA tests of AN-Np, "open15 kV terminals

4.4/C: Comparing of the curves of 132 kV side as function of service time: the latest 3 FRA tests of CN-Np, "open15 kV terminals

Conclusions - FRA technique is really easy to perform

- Sensitive and repeatable - Operation, data storage, comparing the curves, etc. can be semi automated (software)

-FRA technique is relatively new method so there has not been a guide line or something similar
-Although both methods (FRA and vibro-acoustic) seem to be sensitive alone, but results show that the efficiency of the application and the reliability of result interpretation can be increased by using them simultaneity, and not separately. -Interpretation of the results is not too easy, the full scale of interpretation of result has been missing yet