1 Inoxidable Oil-Paper Insulation in Free Breathing Power Transformers Authors: John Sabau, (Insoil Canada Ltd, Canada) Issouf Fofana, (ISOLIME, UQAC, Canada) S Gal, ( Transelectrica, Romania ) M. Oltean (SC Smart SA, Romania)

2 Introduction Power transformers the most valuable asset in a substation or plant, Indispensable components of high-voltage equipment for power generation plants, transmission systems and large industrial plants. Unexpected failures  major disturbances to operating systems,  unscheduled outages and power delivery problems. Such failures can be the insulation degradation/aging, result of poor maintenance, poor operation, poor protection, undetected faults, or even severe lightning or short circuits Outages affect revenue, incur penalties and can cost a company its reputation and its customers. in extreme cases, they can leave a company facing financial ruin

3 The Service Reliability of aging transformers decreases while the number of failing transformers is growing Aging Power Transformers pose an increased risk of failures and blackouts “Power Transformers built in the ’60s and ‘70s pose a serious strategic issue worldwide. Catastrophic failures are escalating both in number and cost including environmental impacts” IEEE Electrical Insulation Magazine 2001 The problem

4 The consequence Environmental cleanup$500,000 Lost revenue ($500,000/day)$10 million Installation labor and processing$100,000 – $300,000 Additional modifications and site work$300,000 New transformer unit$2 million – $4 million *Doble Life of a Transformer Seminar - Clearwater, FL, United States *Cost estimates of an unplanned replacement of a typical generator step-up transformer  Transformer failures can cost up to $15 million, in addition to an operator’s reputation.  Incentive for electric companies to ensure reliability and availability throughout the life cycle of these key assets.

5 Oil Decaying (1) BREAKDOWN of COVALENT BONDS MULTIPLES STRESS ELECTRICAL STRESS CHEMICAL STRESS THERMAL STRESS Some of the hydrocarbon bonds may break and form free radicals: H*, CH 3 *, CH 2 * and CH*,… which then recombine to form: soluble/insoluble decay products fault gases observed in oil.

6 Oil Decaying (2)

7 The dissolved Oxygen Oil in contact with air at atmospheric pressure dissolves 10% air by volume (Henry’s law). The dissolved oxygen content of an oil sample, taken from the tank of a free-breathing transformer, shows values, between 5,000 and 40,000 ppm The omnipresence of oxygen (with the catalytic effect of copper), heat and water will promote insulating liquid oxidation even under normal conditions According to Fabre and Pichon [1] oxygen increases the rate of degradation of paper in oil containing 0.3-5% moisture by a factor of 2.5 and water increases the rate in simple proportion to its concentration. Reducing the oxygen from saturation level in the oil (30,000 ppm) to less than 300 ppm reduces the ageing by a factor of 16! [1] J. Fabre and A. Pichon, “Deteriorating processes and products of paper in oil. Application to transformers”, CIGRE, Paper 137, pp. 1-18, 1960.

8 Limitations of current preventive procedures Aggressiveness of oxygen  negatively affects the chemical stability of oil by generating decay products (detrimental to the solid insulation)  researchers have developed various technical solutions. Nitrogen sealed type Conservator (Fig 1) Diaphragm sealed type Conservator (Fig 2) The Use of Oxidation Inhibitors Fig 1 Oil Transformer tank Fig 2 Oil level indicator Dehydrating breather Rubber bladder Oil

9 Dissolved Oxygen and Moisture Removal System To shorten the experimental time frame, a relatively small unit was suitable. Two 5 MVA distribution transformer were utilized Silica Gel Power Transformer Tank Nitrogen Generator Expansion Chamber

10 Dissolved Oxygen and Moisture Removal System  this innovative nitrogen blanketing system gradually decreases the dissolved oxygen from insulating oil over the experimental period, while maintaining the “freely breathing” character of the transformer.

11 Transformer #1  The level of dissolved carbon dioxide and combustible fault gases also decreased. The absorbance curves along with the turbidity of the 5 MVA blanketed unit show little change. Dissolved gas Analysis and relative decay products and Turbidity results after 8 years blanketing. Gas ComponentConcentration (ppm) Hydrogen (H 2 ):<5 Oxygen (O 2 ):1450 Nitrogen (N 2 ):83257 Methane (CH 4 ):2 Carbon Monoxide (CO):<25 Carbon Dioxide (CO 2 ):191 Ethylene (C 2 H 4 ):1 Ethane (C 2 H 6 ):<1 Acetylene (C 2 H 2 ):<1 Total Gas Content % v/v:8.47

12 Transformer #2  These analyses confirm the theoretical premises that motivated the experiment. Dissolved gas Analysis and relative decay products and Turbidity results after 8 years blanketing. Gas ComponentConcentration (ppm) Hydrogen (H 2 ):<5 Oxygen (O 2 ):1083 Nitrogen (N 2 ):80484 Methane (CH 4 ):2 Carbon Monoxide (CO):<25 Carbon Dioxide (CO 2 ):200 Ethylene (C 2 H 4 ):<1 Ethane (C 2 H 6 ):<1 Acetylene (C 2 H 2 ):<1 Total Gas Content % v/v:8.15

13 the Total Acid Number (TAN) shows slight change while the interfacial tension (IFT) is still not a reason for concern. However, an increase the dissipation factor is observed. This might be related to the ability of free radicals to capture a free electron and become a charge carrier Additional testings

14 Dissolved Oxygen and Moisture Removal System (DORS) Enhances the service reliability Eliminates oxidation decay Reduces the cost of maintenance Proven technology Low cost of deployment Lower maintenance cost Enhanced service reliability (of current transformers) Excellent ROI Economic and Technical considerations

15 Contrary to breathing units: Since the nitrogen supplied by the membrane generator is moisture free and its flow is in one direction only, frequent changing of depleted silicagel in the air desiccators filters is no longer necessary. With the removal of dissolved oxygen in the oil, secondary chemical reactions with the gases generated under the effect of electrical stress become impossible which might therefore allows a better reproducibility and interpretation of dissolved gas analysis (DGA). The expenses imposed by the reclamation and reconditioning of the oil may be reduced once the very cause of oxidation of the decay process affecting the composite solid-liquid insulation is reduced. The use of antioxidant inhibitors may be unnecessary, including the laboratory analysis to monitor their declining concentration and the costs involved in periodic replenishment. Economic and Technical considerations

16 Contrary to sealed or rubber bladder units: Fault gases can freely escape from the transformer. The system is reparable in situ. Old transformers may be easily retrofitted.  The life expectancy of aging transformers is extended. Among all, the low initial cost and almost maintenance free operation of membrane nitrogen generators makes this prevention technique economically affordable. Economic considerations

17 Conclusions Unlike the current use of oxidation inhibitors which are able only to retard the oil-paper insulation deterioration process; this economically affordable procedure successfully prevents the premature aging of these expensive machines Rather than reconditioning or reclaiming service-aged oil in order to restore its initial properties, the Dissolved Oxygen and Moisture Removal System (DORMS) open the possibility of maintaining the initial physical and chemical properties of a liquid dielectric throughout the lifetime of a power transformer By using this system, the oxidation decay of oil-paper insulation will be hindered and the life expectancy of these expensive machines considered capital investments in every country infrastructure, extended, while the mineral insulating oil, a non- renewable resource, could be given a practically endless life expectancy.

18 Thank you… Questions & Answers? Thank you… Questions & Answers?