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TRANSFORMER CONDITION ASSESSMENT

Project No:

File:

Valco Aluminium_ZBU-53151

DOBLE ENGINEERING AFRICA

TRANSFORMER DIAGNOSTIC TESTING


AT VALCO ALUMINIUM

th

This report was prepared on the 25 May 2015 by:

Kamendren Govender
Principal Engineer

CLIENT:

VALCO ALUMINIUM

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TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

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REPORT DETAILS
CLIENT
ADDRESSEE
SITE
JOB DESCRIPTION
REPORT PREPARED BY
DATE REPORT COMPLETED
REPORT AUTHORISED BY
CLIENT ORDER NUMBER

Volta Aluminium Company Limited


Line 2
Transformer Condition Assessment
Kamendren Govender
25th May 2015
Luwendran Moodley

Copyright 2007 Doble Engineering Africa Limited


All rights reserved. No part of this publication may be produced stored in a retrieval system or
transmitted in any form by any means electronic mechanical photocopying recording or
otherwise without the prior written permission of Doble.
Indemnity
This document may not be distributed or used outside the client for whom it is prepared except
with written authorization from Doble. Doble disclaims all liability for any loss damage injury or
other consequence whatsoever arising from any unauthorized use howsoever caused
including any such resulting from error omission or negligence in its application.

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

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Table of Contents
1. Executive Summary...............................................................................................4
1.1. Findings ..............................................................................................................4
1.2. Recommendations ..............................................................................................4
2. Analysis and Observations ......................................................................................5
2.1. Transformer Details ..........................................................................................5
2.2. Condition Analysis ...........................................................................................5
2.2.1. Electrical Test Findings......................................................................................5

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

Page 4 of 11

1. Executive Summary
1.1.

Findings

Doble Engineering Africa was requested by Valco Aluminium to perform diagnostic tests and analysis
on a transformer based on electrical tests. This report covers the final findings based on our studies of
the transformer with serial number: ZBU-53151 manufactured by Westinghouse Electric.
All winding power factor and capacitance results are within acceptable limits.
From our experience the high power factors on the LV1 and LV2 windings does not allude to
insulation deterioration but rather the effect of surge capacitors.
The low power factor and low capacitance between LV1 and LV2 winding is the result of an earth
screen between the windings.
The excitation currents are within acceptable limits.
The ratio test revealed no significant concerns with all ratios being within the acceptable limits.
The DC winding resistance tests results are within acceptable limits.
The Sweep Frequency Response Analysis (SFRA) revealed no winding deformation on the 13.8/0.39
kV windings for all phases.
The moisture content is at acceptable values.
The acidity is at acceptable values.
The DGA signature is indicative of a normal operating transformer.

1.2 Recommendations
The transformer demonstrates acceptable test results and may be suitable for continued service with
routine maintenance and diagnostic testing.

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

Page 5 of 11

2. Analysis and Observations


2.1 Transformer Details
The transformers details are given in Table 1.
Table 1: Transformers Details
Substation
Unit
Serial Number
Manufacturer
Year of Manufacturer
Voltage
VA Rating

Line 2
R22
ZBU-53151
Westinghouse Electric
1965
13.8/0.39 kV
16.45 MVA

2.2 Condition Analysis


2.2.1 Electrical Test Findings
2.2.1.1 Windings Insulation
Results and Analysis
The winding power factor values are given in Table 2.
Table 2: Winding Power Factor and Capacitance Test Results
Measured
HV winding to earth
Between HV and LV1 winding
LV1 winding to earth
Between LV1 and LV2 winding
LV2 winding to earth
Between LV2 and HV winding

Voltage (kV)
8
8
0.2
0.2
0.2
0.2

Power Factor (%) Capacitance (pF)


0.49
5 551.94
0.16
5 242.60
32.56
5 774.10
0.18
217.41
12.61
5 064.88
0.14
5 476.40

All winding power factor and capacitance results are within acceptable limits.
From our experience the high power factors on the LV1 and LV2 windings does not allude to
insulation deterioration but rather the effect of surge capacitors.
The low power factor and low capacitance between LV1 and LV2 winding is the result of an earth
screen between the windings.

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

Page 6 of 11

2.2.1.2 Excitation Current Tests


Results and Analysis
The results from the excitation current tests are shown in Table 3.
Table 3: Excitation Current Test Results
Tap
3

Red Phase
Yellow Phase
Blue Phase
Current (mA) Loss (W) Current (mA) Loss (W) Current (mA) Loss (W)
857.99
6 258.95
767.00
5 660.62
692.08
5 026.37

The excitation currents are within acceptable limits.


2.2.1.3 Ratio Test
Results and Analysis
The results of the ratio test for each phase and tap position shall be within 0.5 % of the nameplate
data. The results from the ratio tests are given in Table 4.
a) HV to LV Winding
Table 4: Ratio Test Results
Ratio Red Phase Yellow Phase Blue Phase
H - 11
7.22
7.38
7.39
H - 13
7.21
7.38
7.39
H-8
9.22
8.85
7.54
H - 10
9.16
8.61
7.52
The ratio measurements are within acceptable limits.
2.2.1.4 DC Winding Resistance
Results and Analysis
The DC winding resistance tests were performed on all windings and are shown on Tables 5, 6 and 7.
a) HV Winding
Table 5: HV DC Winding Resistance Test Results
Tap
3

Red Phase
Yellow Phase
Blue Phase
Resistance (m) Resistance (m) Resistance (m)
92.16
90.56
91.72

The DC winding resistance test results are within acceptable limits.

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

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b) LV1 Winding
Table 6: LV1 DC Winding Resistance Test Results
Tap
3

Red Phase
Yellow Phase
Blue Phase
Resistance () Resistance () Resistance ()

164

167

160

The DC winding resistance test results are within acceptable limits.

c) LV2 Winding
Table 7: LV2 DC Winding Resistance Test Results
Tap
3

Red Phase
Yellow Phase
Blue Phase
Resistance () Resistance () Resistance ()
161
170
175

The DC winding resistance test results are within acceptable limits.

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

Page 8 of 11

2.2.1.5 SFRA Test


Results and Analysis
The results from the SFRA tests are given in Figures 1 to 3.
a) HV Winding Open Circuit
Figure 1: HV Winding Open Circuit

The comparison between the phases finds that the responses demonstrate a characteristic pattern
and has good correspondence across the entire frequency range. These responses do not indicate
winding deformation

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

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b) LV1 Winding Open Circuit


Figure 3: LV1 Winding Open Circuit

The comparison between the phases finds that the responses demonstrate a characteristic pattern
and has good correspondence across the entire frequency range. These responses do not indicate
winding deformation

TRANSFORMER CONDITION ASSESSMENT


Project No:

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Valco Aluminium_ZBU-53151

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c) LV2 Winding Open Circuit


Figure 3: LV2 Winding Open Circuit

The comparison between the phases finds that the responses demonstrate a characteristic pattern
and has good correspondence across the entire frequency range. These responses do not indicate
winding deformation

TRANSFORMER CONDITION ASSESSMENT


Project No:

File:

Valco Aluminium_ZBU-53151

2.2.1.6 Oil Analysis


a)

Moisture Content
The moisture content (16 ppm) is at acceptable values.

b)

Acidity
The acidity content (0.03) is at acceptable values.

c)

DGA
Figure 4 below shows the DGA history of the oil.
Figure 4: DGA Signature

The DGA signature is indicative of a normal operating transformer.

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