Fifteenth National Power Systems Conference (NPSC), IIT Bombay, December 2008
Assessing Remnant Life of Transformer based on Furan Content in
Transformer Oil and Degree of Polymerization of Solid insulation
Sanjay.G.Patki, S.G.Patil, Jaspal. S. Wadhwa, The Tata Power Company Limited, Mumbai
email: jwadhwa@tatapower.com
Abstract - Power Transformers are the most vital
components in a sub-station / Receiving station. Failure
of a Transformer leads to loss of Revenue besides
affecting reliability of power supply to consumers. It
can lead to non-availability of the Transformer for long
durations. In order to ensure that Power Transformers
provide long and trouble-free service, several
diagnostic tests are carried out and remedial actions
initiated throughout their operational lifetime. For the
oil-filled Transformers, more particularly which are in
service for more than 15 years, it is advisable that we
should also estimate the residual life of the
Transformers. It can be done by assessing the extent of
degradation of the cellulosic paper insulation through
Furan content in Transformer oil and degree of
polymerization of paper insulation. This can help the
utilities in making optimum use of the Transformers
and also taking timely decisions regarding
refurbishment / replacement of Transformers, The
paper presents the real life case study of assessing the
health of cellulosic paper insulation of a 72.5 MVA
Power Transformer, which is in service for the last 31
years.
I. Introduction
Power Transformers are the most vital and costliest
components of Electrical Power system. In order to ensure
reliable and economic power supply, it is essential that we
should utilize the installed transformers optimally. At Tata
Power, we have detailed Condition Monitoring plan for
Power Transformers, in order to assess the condition of
windings, insulation, core, Transformer oil. The condition
Monitoring Tests includes IR, Tan-delta, Mag-Balance,
Winding resistance, Turns ratio, Bushing Tan-delta, DGA,
Oil BDV, etc. About 4 years back we have also started
carrying out SFRA (Sweep Frequency Response test). We
have also installed COPS (Constant Oil Pressure system)
on most of the Transformers, which separates the
Transformer oil from the atmosphere, preventing gas /
moisture contamination of oil.
Though the life of a Transformer is generally accepted to
be 25 to 30 years, at Tata Power about
40 % of our Transformers are in service for more than 25
years because of the elaborate condition Monitoring
process. Since a large population of the Transformers is
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in service beyond 25 years, it was felt that we should also assess
the residual life of the Transformers, so that appropriate and
timely action can be initiated for their refurbishment /
replacement. This would also help us in avoiding unforeseen
tripping of any Transformer, which could result in interruption
of power supply.
As a first step, the Furan content measurement for all the Power
Transformers was carried out in 2006. The Total Furan content
of a 72.5 MVA Transformer at our Saki s/s was the highest i.e.
1226 ppb, indicating that the paper insulation has deteriorated.
This Transformer has been in service since 1977. The Total
Furan content of the Transformer was monitored since then. It
increased to 1404 ppb within the next 4 months. In Feb 2008,
when the Test was carried, the Furan content had increased to
8530 ppb. The Furan content in the Transformer oil had reached
12739 ppb by April 2008. This set the alarm bell ringing.
Reference [1] indicates that in case the total Furan content is
more than 2500 ppb, the winding needs to be replaced /
rewound.
We also carried out FDS (Frequency Domain Spectroscopy)
Test, in order to ascertain the moisture content in the solid
insulation. The moisture content in the solid insulation was
found to be 3.5 %, which was on the higher side.
As the Furan content in oil had increased at a rapid rate, the
moisture content in solid insulation was high and the
Transformer was in service for 31 years, we decided to carry out
the DP test in order to ascertain the extent of degradation of
solid insulation.
II Transformer Details and History
The 72.5 MVA, 110 KV/ 23.1 KV Transformer Sr. No: 23976,
manufactured in 1976, has been is in service at our Saki s/s sine
Dec 1977. The Transformer is provided with Off load Tap-
changer.
The Transformer was up rated from 60 MVA to 72.5 MVA in
April 1985 with the installation of oil pumps and additional
radiators. In Nov 1993, Transformer oil was replaced. In March
1997, “B” phase Tap changer assembly was replaced and “A”
and “C” phase Tap changer moving contacts were replaced as
they were damaged. In March 2004, the conservator was
replaced with COPS.
During 1983-1995, the above Transformer was 90 % loaded for
4 hours daily on week days and the Max. winding Temperature
reached 90 deg C. During 1995-2006, the Transformer was
loaded upto 50-60 % of its rated capacity during peak hours.
The peak load progressively increased thereafter and in the
 Fifteenth National Power Systems Conference (NPSC), IIT Bombay, December 2008

summer month of May 2007, the peak load was 80-85 %
of its rated capacity for 4 hours. However the minimum
load on the Transformer dropped to 20 MW during the
night. The maximum and minimum winding temperatures
were recorded as 90 deg C and 55 deg C respectively.
As the Transformer was in service for more than 31 years, it was
necessary that we should evaluate the remnant life of the solid
insulation and plan further suitable action for its replacement /
refurbishment. We decided to carry out the DP test to ascertain
the extent of degradation of the paper insulation.

III Analysis and Discussion The DP test involved availing the outage of Transformer for 10
days. The peak load of our Saki s/s was in the range of 173
The Diagnostic Tests were done regularly for the above MVA, whereas the firm capacity was only 145 MVA. As the
Transformer and no abnormality was indicated. Furan content in oil had reached such alarming levels and
moisture content in solid insulation was also high, we could not
The DGA of Transformer oil was done regularly and no afford to wait any longer. The failure of Transformer would
abnormality was indicated till Oct 2007. The values of the have resulted in load shedding of about 33 MVA load during
dissolved gases are tabulated in Table I. peak hours. Hence we decided to carry out the DP test in the last
week of April 2008. We had to transfer 25 MVA load of REL
Table I – Dissolved gases in Transformer Oil (ppm) and 8 MVA load of TPC-D for availing the outage of The
Transformer for the DP Test.
13/09/06 22/10/07 08/04/08
Methane 58.5 75 87.41 The Transformer oil was drained, bell tank lifted and paper
Ethane 24.7 38 40.54 samples were taken from 25 different locations for the DP test.
Ethylene 11.5 13 8.95 The paper samples from top 2-3 layers of the winding leads and
Acetylene 0 0 0 the pressboard samples were taken for the measurement of DP
Propane + 35.2 79 87 from various locations. The winding leads were retaped with the
Propylene fresh paper insulation, from wherever the paper samples were
Hydrogen 88 336 260 cut. The sample locations and test results are given in Table III
CO 115 14 488
CO2 3328 0 14011 Table III – DP Test Results
Total Gas 8.19 7.12 14.44
content % v/v Sr.No. Paper sample taken from DP value
in oil 1 R phase winding, Top lead 767
(Outer layer)
The DGA result of April 2008 indicated general 2 R phase winding, Center lead 515
overheating involving cellulose insulation. (Outer layer)
3 R phase winding, Center 821
The Furan Content in the Transformer oil was measured (Innermost layer)
for the first time in 2006 and it was monitored since then, 4 Barrier board between R & Y 704
as the values were the highest amongst all the Power phase (Top)
Transformers in Tata Power. 5 Barrier board between R & Y 556
The Furan Content details are tabulated in Table II. phase (Center)
6 Barrier board between R & Y 539
Table II – Furan Content in Transformer Oil (ppb) phase (Bottom)
7 Y phase winding, Top lead 782
Aug Jan Feb Apr (Outer layer)
06 08 08 08 8 Y phase winding, Bottom lead 343
5- Hydroxymethyl-2 43 28 140 0 (Outer layer)
Furfural 9 Y phase winding, Bottom lead 868
2-Furfuryl Alcohol 13 26 0 0 (1st inner layer)
2-Furfural 1127 1308 8390 12739 10 Y phase winding, Bottom lead 892
2-Acetyl Furan 14 11 0 0 (Innermost layer)
5-Methyl 2-Furfural 29 31 0 0 11 Old barrier board between Y & 1244
Total Furan content 1226 1404 8530 12739 B phase (Top)
12 Old barrier board between Y & 603
The Furan content above 2500 ppb indicates that the solid B phase (Center)
insulation has deteriorated.

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 Fifteenth National Power Systems Conference (NPSC), IIT Bombay, December 2008

Sr.No. Paper sample taken from DP value Table III is extracted from “An Introduction to the Hal-Century
Transformer by the Transformer Maintenance Institute,
13 Old barrier board between Y & 719 S.D.Meyers Co. 2002.
B phase (Bottom)
14 New barrier board between Y 1318 Table IV is converted into graph DP vs Remnant life for finding
& B phase (Top) out the intermediate values by interpolation. The graphs is given
15 New barrier board between Y 1193 below,
& B phase (Center)
16 New barrier board between Y 1017
& B phase (Bottom)
17 B phase winding, Top lead 456 DP Vs % Remnant life
(Outer layer)
18 B phase winding, Center lead 469
(Outer layer) 120
19 B phase winding, Center lead 890 100 100
(Innermost layer)

% Remnant life
90
20 B phase winding, Bottom lead 473 79 80
(Outer layer) 66
21 B phase winding, Bottom lead 764 60
50
(Innermost layer) 46 42 40
38
Note: DP values are based on the viscometric method.
20
The average DP value of paper insulation is 645,
indicating normal ageing of the paper insulation. The 0
average DP of pressboard is 877, indicating good condition 800 700 600 500 400 380 360 340
with minimum life consumption.
DP
Estimation of the remaining life of the Transformer is
evaluated according to the Table IV
The average DP value of thin insulation (paper) was 645,
Table IV – Furan, DP and % of Remaining life corresponds to remaining life of nearly 82 %, as per the
above graph. The DP value of pressboard was 877, indicating
2FAL DP Estimated Suggested good condition of the pressboard with minimum life
(ppb) Value percentage of Interpretation consumption. This has given us an assurance that the solid
remaining life insulation has not deteriorated much and the Transformer can
58 800 100 Normal continue to remain in service.
130 700 90 Ageing Rate
292 600 79 Though the solid insulation had not deteriorated, the high Furan
654 500 66 Accelerated content in oil could be traced to a damaged pressboard, which
1464 400 50 Ageing Rate was replaced along with the Tap changer contacts in 1998. The
1720 380 46 moisture content in the Transformer oil was 44.8 ppm, which
2021 360 42 might have also contributed to the high furan levels.
2374 340 38 Excessive
2789 320 33 Ageing We have filtered the oil and filled the Transformer oil under
Danger Zone vacuum, which has reduced the moisture content in oil.
3277 300 29
However, the moisture content in the solid insulation of
3851 280 24 High Risk of
Transformer was 3.5 %. We propose to dry out the Transformer
4524 260 19 Failure
immediately after monsoon and reduce the moisture content; in
5315 240 13 End of order to avoid ageing of the solid insulation.
6245 220 7 expected life
7337 200 0 of paper The Degree of polymerization test (DP) was useful for
Insulation confirming that the solid insulation still has 82 % of remaining
and life and the Transformer can continue to serve for many more
Transformer years.

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 Fifteenth National Power Systems Conference (NPSC), IIT Bombay, December 2008

IV CONCLUSION. Transformers : Few Case Studies” , Session 2000, CIGRE.

On the basis of our experience, the authors feel that the [3] CIGRE guide for Life Management Techniques for Power
following points should be considered for the condition Transformers –prepared by CIGRE WG 2.18.
monitoring of the Transformers.
[4] Pablo A.DE : Furanic Compounds Analysis as a Tool for
Diagnostic and Maintenance of Oil-Paper Insulation
1. The approach followed in carrying out the Systems’ CIGRE Symposium, Berlin, 1993, Paper 110-09.
measurement of Furan Content and the DP Test has
helped in concluding that the solid insulation of the
Transformer was in good condition and replacement /
refurbishment is not immediately warranted.

2. The Furan content in oil is a non-invasive test, which

does not involve taking outage of the Transformer.
Hence it should be monitored for all Transformers.
However, the frequency of monitoring may be varied
depending on the quantum of the Furan content and
rate of rise.

3. The Total Furan Content in oil alone cannot be used

for estimating the remaining life of the paper
insulation. It is only an indicative test. It has to be
corroborated by the DP Test of the solid insulation
samples.

4. The FDS test may be done once in 2 years for those

transformers which are more than 15 years old. This
will help in knowing the moisture content in the solid
insulation, which contributes to its accelerated aging.
In case moisture content is more than 2 %,
Transformer drying can be planned in order to avoid
further deterioration of the paper insulation.

ACKNOWLEDGMENT

The authors are thankful to the management of The Tata

Power Company Limited for encouraging us to write this
paper for the 15th National Power Systems Conference
organized by IIT Bombay.

REFERENCES

[1] “Large Scale survey of furanic compounds in operating

transformers & implications for estimating service
life” – Conference Record of the 1998 IEEE
International Symposium on Electrical Insulation,
Arlington, Virginia, USA, June 1998.

[2] V.Shrinet, M.J.Patel and M.Ramoorty: “Role of Furan

and DP Analysis for Refurbishment of Power

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