Aging Transformer: A Matter of Concern

It's a challenge that is now common to many utilities in the US: managing aging substation transformers
installed in the 1960s and 1970s and fast approaching the end of their 'life'. These transformers didn't
cause a blip in the radar during the last two decades, but with every year of the 21st century, their failure
rates have become increasingly difficult to predict. This means that resource allocation and
repair/replacement decisions are also becoming more and more exigent.

Transformer Aging Factors

The main factors responsible for transformer aging are given underneath. Controlling these variables can
maximize the life of a transformer:

 Temperature
 Oxygen
 Moisture

Other factors can include extreme operational conditions, and adverse conditions within its surroundings
(such as a high temperature and humidity index), through faults and electrical surges.)

Degrading Insulation

The cumulative effect of elevated temperature over time will adversely affect the useful life of electrical
devices in general, and transformers in particular. For the duration of a transformer's life, the combination
of elevated operating temperature and high ambient temperatures will have a slow degrading effect on its
insulation. Insulation degradation can ultimately lead to catastrophic failures in the transformer.

Moisture in a transformer's insulation system can cause molecular chains to decompose, speed up the
cellulose aging process and adversely affect the tensile and dielectric properties of the insulation.

One source of moisture is from humidity in the ambient air surrounding the transformer. Improper or aged
transformer gaskets and seals will allow moisture, present in the atmosphere, to penetrate through to the
insulation when the pressure gradient changes. This invading moisture speeds up the transformers aging
process. Additionally, water vapor is a by-product of the degradation of cellulose insulation. Aging
insulation, itself, contributes moisture to the problem, since dielectric strength diminishes with every
increase in moisture level.

Moisture and oxygen levels are both temperature dependent, increasing as the temperature rises. High
levels of moisture and oxygen can lead to the formation of bubbles, which, when trapped within
the insulating materials can cause voids and localized stress, leading to flashovers and failures.
Water present in the insulation can also impact the insulation's dielectric properties. Insulation
power factor increases with increases in moisture content. In order to function reliably, a
transformer must stay within acceptable moisture limits, which vary with load and temperature.
The moisture content of an oil sample is normally measured with the Karal Fischer reaction test.
This has been adopted by the industry as a standard test due to its high selectivity, sensitivity,
repeatability and reliability.

The Importance of Constant Monitoring

The physical parameters and behavior of an insulation system change as it degrades. The degradation of
insulation paper and oil leads to the production of moisture and furan, which can both cause further
accelerated aging. Overheating of the insulation system, partial discharge and arcing can all lead to the
release of gases. Moisture within the insulation chain can help lead to its degradation and failure.
Temperature can have an effect on moisture content, and how it moves between the cellulose and the oil.
One way to minimize damage in an aging transformer is through constant monitoring of fault gases,

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temperature and water content. This data can help in detecting the type of fault, its intensity and, to some
extent, its location.

Insulating Paper

The mechanical properties of insulating paper are greatly reduced as it ages, although electrical
properties may not show significant change. Insulating paper's mechanical strength can be degraded by
increasing temperatures within the windings. The mechanical failure of aging insulating paper can lead to
electrical breakdown. This in turn may adversely impact the insulation's performance, which can lead to
transformer failure. Consequently, the condition of the insulation should be monitored regularly, as a
measure of the state of the transformer as a whole. Insulating paper can be tested directly by measuring
the degree of its polymerization.

Proper Maintenance and Fault Diagnosis

Transformer aging may also accelerate if the transformer does not undergo proper maintenance and fault
diagnosis. Proper fault diagnosis plays a vital role in enhancing the life of a transformer. The percentage
of transformer failures caused by dielectric problems may be as high as 75%. Dielectric problems can be
caught by testing for the presence of furanic compounds in the oil, which are an indication of solid
dielectric deterioration.

The dielectric temperature of an oil/cellulose insulation system can impact the aging process, leading to
thermal stress that changes the mechanical and electrical properties of the material. If transformer faults
are detected at an early stage, it can greatly reduce unplanned outages and the costs that accompany
them. As insulating oils deteriorate, the chance that this deterioration will negatively impact the
transformer increases. Additionally, oil discharges may seriously damage other insulating materials. It is
therefore important to regularly monitor the transformer's insulation.

Dissolved Gas Analysis

One way to deduce the type and severity of a transformer fault is through dissolved gas analysis. The
decomposition of insulating oils and cellulose materials leads to the production of fault gases. These
combustible gases are produced when insulating oils and cellulose materials are subjected to excess
electrical or thermal stresses. As a fault slowly evolves these gases will build up, dissolved within the oil.
Initial gas quantities are very small, and it takes time for free gas to migrate to, and accumulate, in the
gas relay. Therefore, it is important to analyze the oil for dissolved gases. This data allows one to
determine the condition of the transformer, and catch faults early. If a fault is detected, a variety of
analysis methods can be used to predict the type of fault. Multiple dissolved gas analysis tests should be
taken over time so that the rate of increase of fault gases can be monitored, and with that the progress of
the fault.

Life Extensions

If a transformer is assessed with regularity and thoroughness, its aging process may be controlled and its
life extended. An extended life for the transformer, along with the increased safety and reliability which
accompany that, may in turn cut costs. This is possible only with the help of good diagnostic methods and
realistic interpretation of data. The usefulness of an old transformer may be improved if proper
operational criteria are implemented and its insulation system is effectively maintained.