ISSUE 7

SEPTEMBER 2020 transformer-technology.com ISSN 2642-2689

Part 1
Bushings
Design, Maintenance
and Monitoring

Interview with Ronald Schmid, GM of Siemens Transformers Linz, Austria Bushings Breakdown Mechanism
and the Appropriate Life-cycle Maintenance Implementation Three Steps for Diagnostic Testing of Bushings
TOTUS BUSHING MONITOR
Designed to detect and diagnose problems at the earliest stage, the TOTUS Bushing
Monitor uses integrated intelligence and analytics to provide reliable and intuitive
information to asset managers about bushing health.
Combining Partial Discharges, High Energy Events, Leakage Current Angles and
Magnitude, Temperature, Load and Bushing Properties, the TOTUS allows for
correlation and causation to determine failure modes, driving prescriptive actions.
Built to fit your monitoring program, the system can operate as a standalone device or
as part of our TOTUS Total Transformer Monitoring Solution for a deeper understanding
of transformer health.

DETECT DIAGNOSE DECISION

Anomalies under real Risk, condition Quick and
operating conditions & failure mode actionable insight

camlingroup.com/power/ [email protected]
SEARCHING FOR
NEW CUSTOMERS?
LET THEM FIND YOU!

LOOKING FOR
NEW MARKETS?
WE WILL SHOW YOU HOW.

Advertize
with TT
and strengthen your presence
in the transformer market.

Contact
transformer-technology.com
4 TABLE OF
CONTENTS

Index Contents

Table of
Table of Contents_04

16
Editors & Impressum_08

Editor’s Letter_12

Coming Events_14 FR3: Past,

FR3: Past, Present and Future_16
Present
and Future
Bushing Monitoring Case Study:
Natural ester liquids
Rapid Changes in the Bushing’s have been used
as an insulator in
Health_24 power transformers
for nearly three
Interview with Ronald Schmid, decades. They are
the third generation
General Manager of Siemens of fire-resistant
fluids – or “k-class”
Transformers Linz, Austria_26 liquids – used in
transformers, but
The Benefits of Online Bushing their fire resistance
was not their only
Monitoring_32 benefit. In fact, it is
outshined by the
MSENSE® BM – Early Detection of fluid performance.
Considering the data
Errors on High-Voltage Bushings_38 and information
now available on
Bushing Failure Prevention Through their properties and
functionality, could
Online Monitoring_42 natural ester liquids
be the future go-to
insulation liquid?

24
Bushing
Monitoring Case
Study: Rapid
Changes in the
Bushing’s Health
Transformer Technology September 2020 5
Issue 7

26 38
Interview with MSENSE® BM – Early Detection of
Ronald Schmid Errors on High-Voltage Bushings
General Manager of Siemens
Transformers Linz, Austria

32
The Benefits of
Online Bushing
Monitoring
While time-based testing programs
for bushings and offline power factor
measurements are widely used bushing
monitoring methods, this case study aims
to show why online bushing monitoring is
a great solution for anyone looking to
mitigate surprise failures of these critical
transformer components.

42
Bushing Failure
Prevention Through
Online Monitoring
In another excellent article, Marco Tozzi
leads us through a primer of bushings, their
failure modes and online and offline ways of
monitoring bushings. Marco’s vast experience
in transformer and power system monitoring
makes him uniquely qualified to share on this
important topic. Enjoy! Learn! Apply!
6 TABLE OF
CONTENTS

Index Contents

Table of
Transformer Bushings Breakdown

Mechanism and the Appropriate

Life-cycle Maintenance

Implementation _50

Managing the Reliability of an

Industrial or Commercial Electrical

Power System: #4_60

Transformer, Grid and Power Plant

Monitoring Revisited_68

Three Steps for Diagnostic Testing

of Bushings_72

Touchless Transformer Monitoring

with Energy 4.0 Technology_80

Coming in October_87

50
Technology Insights:
by Corné Dames
Effective transformer bushings
diagnostic tools are of the utmost
importance and should be an integral
part of the life-cycle oriented preventative
maintenance strategy. In this article, we
will discuss the Dielectric Frequency
Response (DFR) measurements as a
supporting diagnostic tool for bushing
condition assessment.
Transformer Technology September 2020 7
Issue 7

72
Three Steps for Diagnostic
Testing of Bushings
60 In this informative and illustrative article we learn about
three different methods to monitor the health of transformer
Managing the bushings, which combined provide the most informed results.

Reliability of
an Industrial or
Commercial Electrical
Power System: #4
In this episode of Chuck Baker’s
continuing saga of the implementation of
best practices for testing, maintenance
and monitoring of a high voltage system,
Andy, the Reliability Manager, begins
to integrate The Reliability Plan of the
power system into the plans for the Arc
Flash Study.
80
Touchless
Transformer
68 Monitoring with
Energy 4.0
Transformer,
Grid and
Technology
What are the challenges
Power Plant utilities are facing to reduce
Monitoring operating costs? This
article presents the latest
Revisited Industrial IoT technology
with sensors to monitor
transformers and assets
in the substation that can
help reduce those costs.
8 EDITORS &
IMPRESSUM

Impressum Editors

ISSN 2642-2689 (Print) Editor in Chief

ISSN 2642-2697 (Online) Alan M. Ross CRL, CMRP
Transformer maintenance
Editor in Chief and reliability
Alan M. Ross, CRL, CMRP 26 years industry
experience
Associate Editor in Chief
Corné Dames
Independent transformer consultant

Associate Editor
Rachel Linke
Member of Electric Power Reliability Alliance
Associate Editor in Chief
Corné Dames
Contributing Editors Independent transformer
Diego Robalino, PhD, PMP consultant
IEEE Senior Member
Transformer oils
Jon Trout, PE 20+ years industry
Electric utility
experience
Alan Sbravati, ME, MBA
Transformer insulating materials
Marco Tozzi, PhD
Diagnostics and asset monitoring
Curtus Duff Contributing Editor
Power transformer design Diego Robalino PhD, PMP
IEEE Senior Member
Graphic design Transformer condition
Bekoncept Communication Boutique assessment and
diagnostics
Photo Cover 20+ years industry
Photo by Shutterstock experience

Sales & Marketing

Kevan Sears
[email protected]

Sales & Marketing Americas

Maria Salamanca
[email protected]

Sales & Marketing Mexico Associate Editor

Fernando Campos Rachel Linke
[email protected] Member of Electric Power
Reliability Alliance
Sales & Marketing Brazil
Marcelo Braga
[email protected]

Marketing Global
Marin Dugandzic
[email protected]
Transformer Technology September 2020 9
Issue 7

DIGITAL Membership
Free
Contributing Editor
Transformer Technology magazine is a quarterly Jon Trout PE
magazine published by APC MEDIA LLC, 11210 Electric utility
West Rd, Roswell, GA 30075, USA. Published 14 years of experience
content does not represent official position of APC
MEDIA LLC. Responsibility for the content rests
upon the authors of the articles and advertisers,
and not on APC MEDIA LLC. APC MEDIA LLC
maintains the right to keep the textual and
graphical documents submitted for publication.

Copyright and reprint permission

Abstracting is permitted with credit to the source. Contributing Editor
Libraries are permitted to photocopy isolated Alan Sbravati ME, MBA
pages for private use of their patrons. Transformer insulating
For other copying, reprint or republication materials
permission requests should be addressed to 18 years of experience
[email protected]

Publisher:
APC MEDIA LLC
1317 Winding River Trail
Woodstock GA 30075, USA

transformer-technology.com
Contributing Editor
Marco Tozzi ME, MBA
Diagnostics and asset
monitoring
15+ years of experience

Contributing Editor
Curtus Duff
Power transformer design
4 years of experience
 10
TOPIC
MISSING

Photo: Shutterstock
Transformer Technology September 2020 11
Issue 7

SUB
SCR
I B E TO

DIGITAL

FREE
MEMBERSHIP

To subscribe visit transformer-technology.com

12 LETTER FROM
THE EDITOR

Dear Readers and Members of TT Community,

At a recent video conference with a group of mar-

keting professionals, I told them. “Great content is
at the heart of, and powers, great Digital Commu-
nications.” At our Transformer Technology com-
munity, we couldn’t agree more. But there can be
an issue when you attempt to transform a mag-
azine, with its time deadlines, into a community
with information free-flow, well beyond merely
printing interviews and articles separated by pro-
motional pieces.

You may have noticed that we now feature arti-

cles and interviews on a weekly basis, along with
news, webinar information and more, through-
Welcome to the September
out every week, making frequent visits to the site issue of Transformer
more important than ever. Then we curated all of
the previous weeks’ interviews and articles into
Technology, focused on
the Summer issue. Bushings.
As the final piece of that transformation, we are
introducing a “content-driven” strategy of con- The seven fundamentals these interviews will
tinuing to feature weekly articles or interviews focus on are:
and curating them into a monthly issue.
1. Leadership commitment to reliability and
Now all of the previous weeks’ content from great safety. How does your company align with the
authors like Corné Dames, Alan Sbravati, Chuck need to engage the marketplace into thinking
Baker, Marco Tozzi, Elm Costa and his team and this way? What is their commitment to safety
more, and the insightful interview with Ronald and how do they approach it within their orga-
Schmid of Siemens, is compiled into this, the first nization?
monthly issue of Transformer Technology.
2. Vision and Mission Commitment. How does
Because bushings are so important to transform- your vision/mission align with the vision of TT?
ers and one of the leading causes of transformer
failures, we will continue to feature articles and 3. Quality. How do you address the need for pro-
interviews on this topic in October, and then cu- viding quality in your products or services for
rate our second monthly edition called Bushings: TT members? What methods do they use to
Part II. I know that’s not a very excitingly themed insure it?
title, but it is the best way we know how to theme
the issue. 4. Continuous Improvement. How do you apply
the principles of Continuous Improvement
As a preview of what is to come, we will com- and/or Innovation within your organization?
bine November and December with the theme
of Oils & Fluids. We have already lined up articles 5. Lifelong Learning & Lifelong Sharing. “In order
from the very best experts on the subject, and of to know, you must first learn.” How do you en-
course another feature from Corné Dames and gage your employees in continuous learning
Chuck Baker. and how committed are you to sharing new
knowledge, technology or methods with practi-
Finally, a new digital feature that we believe will tioners without regard to financial incentive?
take us into the next phase of our transition into
being the “go-to” place for transformer knowledge 6. Generational Transition. Both within your com-
and information, is the introduction of our Video pany and supporting the industry; what is the
Content Feature with exclusive interviews with commitment to preparing the next generation
leaders from all aspects of power systems and of electric power and/or transformer profes-
transformers, focusing on the seven fundamentals sionals?
of the Electric Power Reliability Alliance (EPRA).
We will feature these Alliance Member interviews 7. Legacy. What is the lasting imprint your com-
as a way of showcasing the important changes the pany wants to have? Marketplace perspective?
future brings, with the leaders who are making How do you make a good place for people to
these changes happen. thrive at work?
Transformer Technology September 2020 13
Issue 7

We hope you enjoy these changes and become a

contributing member of our community. Give us
your feedback and stay informed. It has not been
easy making the transition from a quarterly mag-
azine to an up-to-date, web-based digital commu-

Alan M Ross
nity and I would like to thank our team members
who have made this happen and who have sup-
ported this vision from the start. I would also like
to thank all of our contributors, from podcasts, to
interviews and articles, because they are the power
and source behind great content. I would also like
to thank our advertisers and sponsors who have
joined us in this journey and captured the vision
for making the Transformer Technology commu-
nity a significant part of their digital communica-
tions strategy.

And finally, I want to thank you, our readers, who

are the motivation and who supply the energy we
need to serve you on this journey. We will continue
to build on our own seven fundamentals with the
vision for making the TT community your trusted
source for the best BoK (Body of Knowledge) on
transformer design, application, life-cycle, main-
tenance, testing, monitoring, and critical compo-
nents.

Thank You!
Transformer Technology
Editor in Chief
Alan M Ross
CRL, CMRP

Please feel free to contact me directly at

[email protected],
[email protected] or by phone at
+1 404-992-5111.
It is time to lead.
It is time for a change.
14 EVENTS
WATCH

YOUR PASSION
AND KNOWLEDGE
ARE IMPORTANT
TO US

JOIN OUR
#COLLABORATIVE COMMUNITY

Are you passionate and knowledgeable

about your area of business or expertise?

Now You can contribute to knowledge

sharing in the transformer industry by

sharing your field experiences, case

studies, research results, or simply your

knowledgeable opinion on a topic of

interest to the industry.

Contact us at
[email protected]
to find out how you can
become part of the
Transformer Technology
community.
Transformer Technology September 2020 15
Issue 7

Events Watch

IEEE Transformers
Committee - Fall Meeting
October 18 – 22, 2020 / VIRTUAL
https://www.
transformerscommittee.
org/meetings/2020-fall-
virtualmeeting/

CIGRE Canada
Conference & Expo 2020
October 20 – 21, 2020 / VIRTUAL
https://cigreconference.ca/2020/
en/about-cigre/cigre-canada/

EuroDoble
Colloquium 2020
October 20 – 22, 2020 / VIRTUAL
https://web.cvent.com/
event/59f2753e-46c8-
41ea-a077-5c12108749e7/
websitePage:74af9572-128f-46db-
a6b3-52d0a0535120?rp=
16 FR3: PAST,
PRESENT AND
FUTURE

Natural ester liquids have been

used as an insulator in power
transformers for nearly three
decades. They are the third
generation of fire-resistant fluids
– or “k-class” liquids – used
in transformers, but their fire Tried & Tested:

How FR3 Fluid

resistance was not their only
benefit. In fact, it is outshined by
the fluid performance. Prior to

Performance
the introduction of natural ester
liquids, mineral oil was the go-to
transformer insulator, despite its

Testing Has
known limitations, and the fact that
it is highly flammable. The synthetic
ester liquids were introduced more

Demonstrated It
than 10 years before natural, but the
seasonal availability of carboxylic
acids (derived from petroleum), and

Offers More Than

its inherently higher cost limited its
use to niche applications. To have
an effective superior alternative

Fire Safety and

for its transformers, Copper Power
Systems (CPS at that time, now
Eaton) began exploring alternatives.

Sustainability
In 1991, Eaton’s research found
that vegetable oil was also an ester,
but they needed a formulation that
would assure long-term transformer
performance. And so began a four- by Alan Sbravati
year research and development and Kevin Rapp
journey involving the evaluation of
over 40 different vegetable oils and
blends. From these, Eaton narrowed
the list down to seven possible
formulation candidates, taking
into consideration many prototype
pole and pad-mounted distribution
transformers, ultimately resulting in
what is now known as FR3 fluid.

The immense amount of

data and information now
available on natural ester
liquids has demonstrated
their functionality.
Add to that the other
undeniable advantages
flash and fire point
Photo courtesy of Cargill Bioindustrial

and environmental
characteristics, and it’s With contributions from:

clear that natural ester

Stefan Tenbohlen, IEH / Stuttgart University
Moritz Kuhnke, Leibniz University of Hannover
liquids may be the future Massimo Pompili, La Sapienza / University of Rome

go-to insulation liquid. and John Vandermaar, BC Hydro

Transformer Technology September 2020 17
Issue 7

Alan Sbravati started his career working for

a transformer manufacturer, mainly develop-
ing calculation and design tools for power
transformers. After almost 9.5 years in the
same company, he was the R&D&E manager
for power transformers in Brazil and respon-
sible for two global R&D projects directly
related to transformer design and thermal
calculation. After three years in a commer-
cial role, he moved back to a more technical
position at Cargill. Over the last six years he
has been working with the development and
application of alternative insulating liquids,
especially natural ester fluid (Envirotemp™
FR3™), holding the position of Global Tech-
nical Manager since 2018. Alan chaired the
Brazilian Standards Committee from 2012
to 2016, prior to moving to USA. He par-
ticipates in IEC TC 14 and Cigre working
groups. Currently he is a member of IEEE
Transformers Committee, and he is active
in many subcommittees and task forces.

Kevin J. Rapp is the Principal Chemist for

Global Dielectric Fluids of Cargill Bioindus-
trial. With over 40 years in the electrical in-
dustry, including 27 years in R&D where he
invented Envirotemp™ FR3™ fluid and found
that ester liquids enhance the life of cellu-
lose insulation in transformers. Kevin is in-
volved in standards as Technical Advisor/
Chairman of USNC of ANSI/IEC TC10, ASTM
D27.15 and D27.91 Subcommittees. Kevin
was awarded IEC 1906 Award in 2011, US-EPA
Presidential Green Chemistry Award in 2013,
ASTM Service Award in 2015 and installed as
ASTM Fellow with Distinguished Merit Award
in May 2018. He holds many patents and
has published numerous papers as a mem-
ber of ACS, AOCS, ASTM, CIGRE, IEC and IEEE.
18 FR3: PAST,
PRESENT AND
FUTURE

But First, Due Diligence structure, followed by lightning fluid were commissioned, including
Testing impulse, applied voltage and two units that provided power to the
induced voltage tests. Eaton plant core annealing ovens,
Before it could be commercialized, the • The transformer containing the and another installed in a large
natural ester liquid underwent a series insulation system under test had amusement park in Florida. In the
of required “due diligence” testing, to survive the entire test duration years to follow, also motivated by
including the electrical industry’s representing five times the IEEE the outstanding results of the Lockie
Lockie Test (IEEE C57.100). This nominal life expectancy period to Test, production of 36 kV voltage
three-year functional test consisted be approved. class transformers was accelerated
of three groups of transformers: by Eaton.
All mineral oil and the natural ester
• Each group of transformers had filled units completed five units of Expanding Manufacturers,
different thermal cycles of high life successfully, in all three hotspot Expanded Testing
peak temperature accelerated temperatures. Since the test duration
aging periods. was shorter for the group aged at the In order to expand the technology
• The aging periods were evenly highest temperature, CPS decided to to other manufacturers, Eaton had
divided into 10 test periods with extend the test beyond the required to verify the standard dielectric
mechanical and dielectric testing time. While the mineral oil unit failed design curves for the insulation
performed at the end of each in the subsequent period, the last system design. Transformer
period, composed by four thermal failure of the four natural ester units experts (including the one of the
cycles (from ambient temperature happened only after 19.5 times the reference transformer designers,
to the defined hotspot temperature, unit of life, almost four times longer Harold Moore, who was the
accumulating only the hours at than the five units of life that were engineering manager in
peak temperature). required. Westinghouse when the design
• The dielectric tests include a curves were originally developed)
short-circuit test for generating While the test was still running, the helped to develop a testing matrix
mechanical stress to the insulating first transformers filled with FR3 in the early 2000s.

Figure 1. Three “generations” of electrodes designed for testing the breakdown voltage of the insulating liquid gaps for the transformer windings.

Turn to turn oil gaps, Stress between discs Oil gaps

from 3 mm to 12 mm up to 12 mm, with radial spacers up to 50 mm

Figure 2. Test setup and electrodes for testing the interfacial creep breakdowns.
Transformer Technology September 2020 19
Issue 7

Insulation design experts identified of power factor for insulation their transformers. Thus, the
what they would classify “essential models, and even the volumes of transformer designers were a very
validation points” to allow the use gas formation under severe arcing demanding first internal customer
of mineral oil design curves for the conditions (flashovers). for the application of the fluid,
natural ester filled transformers. requiring a thoughtful validation
The matrix included dielectric tests These tests often had to be of the fluid performance for new
for validating the dielectric capacity repeated and modified to ensure transformers and on long term
in comparison to mineral oil, as the accuracy of the results. As perspective. When their new fluid
well as detailed measurement of a transformer manufacturer, started to be offered to other
its properties, such as: permittivity Eaton’s highest priority was transformer manufacturers, the
(dielectric constant), differences the high-quality standards of road was already very well paved.

Figure 3. Tap changer selector rods and contacts used for comparative tests of FR3 fluid and mineral oil.

Figure 4. Electrode and test setup used for testing gaps up to 150 mm.

Steel ground plate 463 mm

diameter, raised 310 mm
off tank bottom

Bare bushing shield Bushing shield electrode

216 mm diameter x 38 mm connected to 550 kV bushing
thick, top/bottom edge (1800 kV BIL). Sealed steel test
radius of 4.3 mm tank volume at 12,500 liters
20 FR3: PAST,
PRESENT AND
FUTURE

The full test matrix was completed to be taken into consideration for Cargill supported and joined the
in 2010, totaling over seven years higher voltage levels. testing phase of the lead exit with
and millions of dollars across several • Special attention is required for EHV Weidmann, wherein the final
research institutes and experts. The designing and performing the tests, configuration had the same diameter
detailed results and insights from the avoiding the presence of sharp of the solution used for mineral
test allowed for the optimization of edges, oil wedges, gas bubbles and oil, validating the equivalency of
a natural ester transformer design, increasing the time for purging the the dielectric capacity of the two
alleviating the use and expense of gases formed after each flashover. insulating liquids. Moreover, the
additional safety margins. Most of successfully performed tests
the test details and results were exceeded IEC test protocols, including
published and are available in IEEE More Data, More Testing basic impulse levels applied for 765
Xplore library, but the overall test kV transformers, and the achieved
conclusions were: The comprehensive testing program level of partial discharge was
offered the required confidence level extremely low, outperforming what
• The dielectric capacity of FR3 fluid, for the application of the natural ester was obtained when testing the lead
for all construction elements of liquids in higher voltage classes, exit with mineral oil.
a properly designed transformer, achieving the first 420 kV transformer
is equivalent to mineral oil. No in 2013, before any other alternative To understand the differences for
additional safety margins are liquid. This also drove the application highly divergent field configurations,
required. of natural ester in instrument a two-year investigation was initiated,
• The different dielectric constant transformers used to monitor the exploring a sequence of sharp
or permittivity of a natural ester voltage of the transmission line, and electrodes, ranging from sphere-to-
liquid affects the distribution of the development of a standard “lead sphere configuration to needle-to-
the electrical field in a transformer. exit” for transformers of such voltage sphere configuration. The tests were
While the impact may be small for class, used to connect the high performed with different variables (i.e.
lower voltage classes, it is essential voltage winding exit to the bushing. gaps, electrodes, moisture contents

Figure 5. Images showing the position of the “lead exit” in a power transformer and a full representation of the final structure developed to be
used with FR3 natural ester liquid.

Figure 6. Electrodes designed for the investigation of the highly divergent fields behavior.

∅ 13 mm ∅ 3 mm ∅ 0.8 mm ∅ 0.6 mm ∅ 0.12 mm

sphere blunt point blunt point blunt point Gramophone needle
Transformer Technology September 2020 21
Issue 7

and particle contents), testing the like substance identified in failed

natural ester side-by-side with transformers, especially lately in wind
mineral oil. The obtained breakdown generators, is directly related to the
voltage for the different electrodes presence of partial discharges, as
when tested in natural ester and in reported by the published papers from
mineral oil were equivalent down Schering-Institute (Leibniz University
to the 0.4 mm radius for a 25 mm of Hannover). Relevant advantages
gap. Since this is sharper than what were identified when natural ester
would be acceptable for any medium behavior was investigated, triggered
and high voltage transformer, it does exactly by the difficulties in reaching
not imply larger gaps nor increased a stable level of partial discharges
design clearances. activities. While the tests with mineral
oil and synthetic ester allowed
The most recent investigation projects for keeping the discharges along
are around the “pre-discharge” several days, with natural ester
process, namely the inception and liquids the partial discharges were
effects of partial discharges. Identified self-extinguished in a few hours,
as a failure mode since a while, regardless of increasing the voltage
the generation of x-wax, a wax- almost to the breakdown level.

Figure 7. Results of Partial Discharge Inception Voltage (PDIV).

Lower values indicate higher susceptibility to high voltage.
22 FR3: PAST,
PRESENT AND
FUTURE

To date, the investment A deeper understanding of the driver for maintaining investments in
to test and validate the inception and extinguishing process research and development.
is expected as an outcome of the
performance of natural currently active project with Rome There is inherently a high level of
ester liquids exceeds all University. The differences of the responsibility with the design of
other alternative liquids molecular structure of esters may be power transformers, either due to
key parameters for understanding the the expense and complexity, or the
by far, totaling over “quenching” behavior, as a side effect decades-long life expectancy. But
25 years of research. of the presence of double bonds. over time, transformer designers have
The potential of natural increased their confidence level in
The knowledge acquired from applying transformer design limits
ester liquids to transition research and development activities with natural ester liquids, similar to
from an “alternative continues to drive new tests and those used with traditional mineral
liquid” to a mainstream investigations. To date, the investment oil filled transformers. The immense
to test and validate the performance of amount of data and information now
material – as the market natural ester liquids exceeds all other available on natural ester liquids has
share in some regions alternative liquids by far, totaling over demonstrated their functionality.
already indicates – is the 25 years of research. The potential of Add to that the other undeniable
driver for maintaining natural ester liquids to transition from advantages flash and fire point and
an “alternative liquid” to a mainstream environmental characteristics, and it’s
investments in research material – as the market share in clear that natural ester liquids may be
and development. some regions already indicates – is the the future go-to insulation liquid.

Figure 8. The charts (left) present the different profile for the partial discharges. The photos (right) show the solidified materials formed after the
200 h of ageing under PDs.

Voltage and PD
activity during a
typical test with
syntethic ester

X-Wax
formed from
synthetic
ester

Voltage and PD
activity during a
typical test with
natural ester

Traces of
solidified
product from
natural ester
Transformer Technology September 2020 23
Issue 7

IT’S EASY
TO KEEP IN
THE LOOP!
WITH

Sign up for our newsletter at

transformer-technology.com
24 ADVERTORIAL

Bushing Monitoring Case Study:

Rapid Changes in the Bushing’s Health

Photo: Dynamic Ratings

Transformer Technology September 2020 25
Issue 7

Continuous online monitoring Challenge: A Major Alarm

of bushings with the C50 A prominent U.S. utility was looking for a way to improve system reliability for their
138 kV assets. They researched and reviewed options available on the market that
Transformer Monitor offers included affordable bushing monitoring. After review, the utility chose to pilot the
Dynamic Ratings’ C50 Transformer Monitor to see if it was worth the investment
real-time information of to become part of the overall solution.

bushing capacitance and The C50 Transformer Monitors were installed and serviced on the transformers
by Dynamic Ratings Field Engineers. One day, after about two years in service, the
power factor. It provides utility received notification of a major alarm happening at one of the C50 installation
sites. Upon further review of the online web pages, the C50 indicated that there
• Temperature correlation was a rapid change happening in the health of a bushing on the transformer.
• Discrete readings Solution: Engineer Collaboration
• Diagnostic web pages
Dynamic Ratings engineering team took a closer look at the data and recommended
• Diagnostic Software that the utility inspect the bushings for a possible oil leak. Low oil in the bushing
would explain the decrease in the C1 capacitance of the bushing.
• Superior Sensor Design
The utility dispatched an engineer to investigate the alarm and to look for any
signs of an oil leak. During the investigation, the engineer noticed there was no oil
present in the site glass.

Upon further inspection, he saw that oil had leaked out of the bushing and down
the side of the transformer.

Result: C50 Transformer Monitor Prevents Potential Bushing Failure

Dynamic Ratings C50 Transformer Monitor was able to detect and notify the utility
of a problem with the bushing. Dynamic Ratings team of experts worked closely
with the utility to determine the problem and prevent a potential bushing failure.
The utility was satisfied with their investment into bushing monitoring because it
helped to potentially extend the life of their asset, improve situational awareness,
save money and improve safety for workers.

To learn more about the C50 Transformer Monitor,

visit our website at www.dynamicratings.com/C50.
26 FEATURE
INTERVIEW

of Siemens Transformers Linz, Austria

General Manager

I’m proud to be part

of a company that
makes a difference
to society – locally
and also globally –
and that’s helping
its customers
around the globe to
Interview with Ronald Schmid

transition to a more
sustainable world
Photo: Siemens / Siemens Energy is a registered trademark licensed by Siemens AG

using innovative
technologies.
Transformer Technology September 2020 27
Issue 7

Ronald Schmid
28 FEATURE
INTERVIEW

My personal highlight was in 2016, when I started my first General Manager

position at the Siemens traction transformer site. Working with my colleagues,
we almost doubled our output in less than two years. I feel the same great
team spirit now at Siemens Energy Transformers Linz.

Transformer Technology: Ronald, thank you tool that uses artificial intelligence to analyze
for taking the time to share your knowledge and market, customer, and product-specific
insights about Siemens Transformers and your lessons learned from built units that will be
very successful career within our industry. First, automatically integrated in future designs. By
tell me a little about the Linz factory, which is one closing the feedback loop with production and
of the oldest in the world for the manufacture quality management, we’re able to constantly
of transformers. I believe you became General improve the reliability of our designs in the
Manager in October of 2018, correct? engineering phase.

Ronald Schmid: Yes, I became General Manager

in October 2018 and now have the privilege
of shaping the factory for STL’s next century
TT What are some of the biggest
challenges you see facing the global
market for transformers in the years and
of business. As you mentioned, we’re a long- decades ahead?
established factory with a 100-year tradition
of delivering high-quality transformers. Our
business managed to successfully thrive during
inflation and the Great Depression, and it was
RS There’s no doubt that decarbonization
will play a central role in the decades
to come. At Siemens Energy, we’re committed
bombed during World War II and rebuilt soon to carbon-neutral operations. With regard to
after. Ever since, we’ve basically transitioned the energy market, the most pressing challenge
from a regional transformer provider to a is the integration of energy generation by
global market player with an export quota renewables in the existing power grids and
above 80 percent. providing solutions for a smooth transition to
a more decentralized power supply. With the

TT Ronald, what is the specialty focus

of the Linz plant? What range of
transformers are produced there?
ecological footprint gaining in importance,
we’re also noticing an increased demand for
our experience in designing transformers with
alternative insulation liquids.

RS Our main business is the development

and production of innovative solutions
for special customer demands. Nearly every TT How has Covid-19 affected or changed
the approach you are taking in regard
transformer delivered out of Linz is unique. to these challenges?
Special environmental conditions (like low/high
temperatures and seismic zones), low noise-
level requirements, restrictions in dimensions/
weight, alternative insulation media, rupture-
RS The trends as such are neither sped
up nor slowed down by COVID-19. By
implementing stringent measures, we’ve been
resistant designs, and many more special able to stay at full operation throughout the
applications are integrated based on our crisis. At Transformers Linz, the real change
customers’ requirements. Our design range caused by COVID-19 was an acceptance of new
comprises transformers, both mineral oil as well technologies in the way we work together.
as synthetic and natural ester from 10 MVA to Our clients came to accept and appreciate the
300 MVA and up to 500 kV. advantages of remote inspections and FATs, and
on the internal level, many prejudices about the

TT One of the changes we see taking

place in our industry is the focus on
home office diminished.

Reliability Engineering by Design or RED.

How does Siemens integrate all aspects of the
process from design to engineering, and from
TT Ronald, you have spent a great deal
of your time at Siemens working in
the Distribution Transformer market, so share
engineering to integrating production, quality with us what you have seen changing in that
control, testing, and commissioning? specific marketplace over the past few years?
Is there a regional response to market forces
Photo: Siemens

RS We’re aware of the importance of

reliability engineering. That’s why the
Linz factory and a local IT partner developed a
or is it a truly global approach? For instance,
do you see changes between the US, Latin
American, European, or Asian markets?
Transformer Technology September 2020 29
Issue 7

The Siemens transformer factory in Linz (Austria)

can look back on an eventful history of 100 years.

1920 is the year it all started with the foundation of the O.Ö.
Elektro Bau Gmbh (EBG). In the picture: EBG share, 1937.

This year we’re proud to deliver the one-hundredth unit to an important U.S.
business partner.
30 FEATURE
INTERVIEW

Nearly every transformer delivered out of Linz is unique. Special

environmental conditions, low noise-level requirements, restric-
tions in dimensions and weight, alternative insulation media,
rupture-resistant designs, and many more special applications are
integrated based on our customers’ requirements.

RS My perception about the distribution

transformer marketplace is that
it’s quite a local business. Nevertheless, the
challenges have been the same globally, with a
differing focus and intensity: Energy-efficiency,
environmental sustainability, and integrating
renewable power generation, just to name a
few. In the upcoming years, digitalization will
play a major role in every industry and every
country.

TT I see that you were the head of

R&D in Budapest and then working
in Innovation management in Nuremberg.
That must have been fascinating. Tell us a
little about your time there and give us some
insight into where innovation and R&D is
affecting the future of transformer design,
engineering or manufacturing?

RS Indeed, this has been a fascinating

time and a great experience for me.
I appreciate working in a strong global team
and bringing expert and practical knowledge
together. We’ve worked with our customers
to make transformers more energy-efficient,
reliable, and environmentally friendly. Our
engineering and design processes entered a
new era thanks to 3D modeling and simulation
capabilities. It’s now impossible to imagine
transformer manufacturing without the support
of digitalization. But manual work still plays an
important role in the transformer business, and
this will continue into the future.

Siemens Transformers Linz plant, around 1954 Siemens transformer factory

with new built high-rise building. in Linz, Austria, today.
 Transformer Technology September 2020 31
Issue 7

Our engineering and design processes entered a new era thanks

to 3D modeling and simulation capabilities. It’s now impossible
to imagine transformer manufacturing without the support of
digitalization. But manual work still plays an important role in
the transformer business, and this will continue into the future.

– and that’s helping its customers around the

TT You must have seen a great deal

during your career with Siemens.
What would be one or two of the significant
globe to transition to a more sustainable world
using innovative technologies.

highlights of your career thus far?

TT Any final thoughts or advice you
would give young engineers just

RS My personal highlight was in 2016,

when I started my first General
Manager position at the Siemens traction
starting their careers, thinking back to when
you had just graduated from the University of
Applied Sciences in Mittweida, Germany?
transformer site. Working with my colleagues,
we almost doubled our output in less than two
years. RS The advice I would give to any graduate
is to seek a field of employment that
they’re really interested in and passionate
I feel the same great team spirit now at Siemens about. I never once regretted my choice of
Energy Transformers Linz. This year we’re Siemens because it offers a wide range of
proud to deliver the one-hundredth unit to an exciting opportunities for personal growth, as
important U.S. business partner. long as you’re flexible in terms of relocation.
Photo: Siemens

I’m proud to be part of a company that makes a

difference to society – locally and also globally TT Thank you, Ronald. We greatly
appreciate your time.
32 BENEFITS
OF BUSHING
MONITORING

The Benefits of Online

Bushing Monitoring
by Neil Hutchins
Alfonso Ambrosone
Kwasi Yeboah
and Dr. Elm Costa

Introduction of the existing fleet. In addition to

these benefits the end user realizes
As utilities move from traditional improved integration of relevant
offline, routine testing of power information so that operations
transformer towards online managers are better positioned to
continuous monitoring, many benefits make more informed decisions.
are realized. Online monitoring As a result of this, online monitoring
enhances the safe, reliable operation affords utilities the ability to refocus
of substation power equipment, resources in the form of O&M and
Photo: Shutterstock

measured performance, reduced capital expenditures, which leads to

failure rates and provides more operating flexibility with improved
consistent and frequent information reliability.
Transformer Technology September 2020 33
Issue 7

Neil Hutchins has over 21 years of expe- Elm Costa is a Sr Lead Electrical Engineer with-
rience in transmission/substation mainte- in the GE Renewable Energy group, and current-
nance. Neil is the Supervisor of the Southern ly is and has been the Technical Lead for sever-
Company Services, T&PS Equipment Ser- al NPI projects. He is the subject matter expert
vices Group, which provides support to on online bushing monitoring, partial discharge
Southern Company OpCos and affiliates on and transformer models. Elm obtained his bach-
major equipment. He is also the Chair of the elor's degree in physics from the Universitat de
Southern Company Major Equipment Com- Barcelona, and a PhD in physics at the Queen’s
mittee and a Member of Southern Company University, Belfast. After several years working
Breaker and Substation Maintenance Com- as a Research Fellow at QUB, he moved to An-
mittees. Neil is an IEEE Senior Member, Mem- dor Technologies Ltd. In January 2008 he joined
ber of IEEE/PES Switchgear Committee and Kelman Ltd (later acquired by GE) working in
a Member of IEEE Alternative Gases to SF6 the field of high voltage asset monitoring using
Task Force and Working Group. He is also a electrical signals, and later specialised in capac-
Past Member EPRI Substation Task Force. itive bushing and partial discharge monitoring.

Alfonso Ambrosone holds a degree in Ana- Kwasi Yeboah has been with the GE Mon-
lytical Instrumentation and Controls. He has itoring and Diagnostics business for the
worked in the field of online transformer mon- last 14 years supporting customers in vari-
itoring for 15 years. His career in transform- ous roles while based in Montreal, Canada.
nnnnn A bushing monitoring er monitoring began with Syprotec and then He holds a BSc in Mechanical Engineering

system is an online system further evolved within GE, specializing in dis- and certificate in Management and Qual-

that continuously monitors

solved gas analysis using the Hydran tech- ity Assurance, both from École de Tech-
nology and transformer online modelling. nologie Supérieure. Kwasi is also a Six Sig-
the condition of the Alfonso has extensive technical and practi- ma Green Belt certified and RCA Leader.

transformer bushings by cal experience in using online transformer

monitoring systems. In 2013, Alfonso moved
monitoring the capacitance to the position of Product Applications Spe-
change of C1 and the relative cialist, focusing on understanding the tech-

power factor change nological benefits and limitations of all tech-

nologies industry wide, as well as looking
(tan delta) of each bushing. to the future and emerging technologies.
34 BENEFITS
OF BUSHING
MONITORING

Eliminating, or at a minimum information regarding the condition indication that the dielectric is not as
mitigating typical time-based of a bushing. Offline power factor efficient due to internal contamination
maintenance/testing schedules testing is a time honored and proven of the insulation where the capacitive
via online monitoring and moving test. However, it is limited to the layers have been affected.
towards a more diagnostic driven frequency with which it is performed.
maintenance program will allow for Online bushing monitoring is a A bushing monitoring system is an
a more focused effort, as opposed great solution for anyone looking to online system that continuously
to the typical time-based response mitigate surprise failures of these monitors the condition of the
of the past. After all, why work on critical transformer components. transformer bushings by monitoring
something that doesn’t have a the capacitance change of C1 and
problem? To perform offline power The Facts the relative power factor change (tan
factor testing on bushings, the delta) of each bushing. A system
transformer must be removed from Oil impregnated condenser type that has the ability to detect PD
service, grounded, disconnected and bushings have a central conductor (partial discharge) activity generated
then prepared for test. The bushings, wound with alternating layers of in the transformer utilizing the
transformer and typically the lightning paper insulation and conductive foil same bushing adaptors (sensors)
arrestors are also tested during this (known as condenser or capacitive connected at the bushing tapping
downtime. On average, this takes a layers). These capacitive layers are point, without any additional
full eight-hour day with a minimum of housed in a protective weather casing hardware mounted to the transformer,
two employees and often can include (typically porcelain) and filled with will provide further vital health
up to a total of four employees for this insulating oil. There are two main information on the bushings and the
task. The cost of this just for the labor capacitances in a bushing, identified transformer.
can be as high as 32 hours, not to as C1 and C2 (Figure 1). C1 is the total
mention the cost of equipment in the capacitance between the center Bushing monitors should
form of tools, vehicles, etc. Monitoring conductor and the test tap. Where continuously measure the individual
the transformer via online dissolved the test tap is connected to the outer leakage currents of each of the
gas and bushing monitoring will allow most capacitive layer, this is the point bushings. A change in magnitude
crews to find much better use of their at which bushing measurements are of the leakage current indicates a
time working to correct other, more made. C2 is the capacitance from change in bushing capacitance.
pressing issues. The end goal is to the test tap to ground, where C2 is The change in bushing capacitance
reshape the current maintenance not part of the circuit during normal is then compared to the original
and testing programs of the utility’s operation of the bushing. nameplate capacitance to determine
substation equipment fleet with video, the bushing condition. The initial
as opposed to pictures, so to speak. The layers are designed to provide capacitance may be different from
uniform voltage drops between each bushing to bushing. What is of
Time-based testing programs for capacitive layer, effectively acting as interest is how much this capacitance
bushings are a snapshot in time a voltage divider. When a capacitive has changed compared to when it
and there are no guarantees that layer shorts, the voltage across was new.
a problem, or even a catastrophic each layer increases, increasing
failure, will not occur before the next the leakage current proportionally. Moisture is an enemy for bushings.
testing cycle. This one single fact The magnitude of the current is a Ingress of moisture into the bushing
should cause us to hit the pause measure of the capacitance of the will deteriorate the bushing insulation,
button in our approach to past, time- bushing, and a change of current which will cause the dielectric losses
based diagnostic testing as our magnitude indicates a change to increase, driving an increase in the
only avenue of securing valuable of capacitance of C1, which is an bushing dissipation factor (power
factory; tan delta). Temperature and
transients are also important factors
that can also affect the bushing
Test Tap
insulation, thus increasing the power
Capacitive Layers for
Voltage Gradient factor.
Main High Voltage Conductor

Online relative power factor

Main High Voltage Conductor

Insulation C2
measurement has the timing
Grounded Layer
differences among the three bushing
leakage current phases, which
translates to phase angle differences
relative to each other. Since a change
Main Insulation C1 of phase delay equates to a change
Photo: General Electric

in power factor, we can determine for

each bushing the relative (compared to
the others) change of power factor as
Figure 1. Two main capacitances in a bushing, identified as C1 and C2 a percentage of the nameplate value.
Transformer Technology September 2020 35
Issue 7

nnnnn Eliminating, or at a
minimum mitigating typical
time-based maintenance
and testing schedules
via online monitoring
and moving towards a
more diagnostic driven
maintenance program will
allow for a more focused
effort, as opposed to the
typical time-based response
of the past. After all, why
work on something that
doesn’t have a problem?
Typical Requirements

The installation of the bushing monitor

requires information which can be
found on the nameplate, in addition to
the transformer’s operating voltage.
This information consists of the
mechanical aspect of the bushing
tapping point, where the bushing
monitor adaptor will be inserted.
This is to ensure a secured installation
and uncompromised contact with the Figure 2. When installing a bushing monitor, it is important to ensure a
test tap (Figure 2). secured installation and uncompromised contact with the test tap

With an expanded library of bushing Success Story Their 102-megawatt Henrietta Solar
types, the bushing model will generally Project in Kings County, California,
suffice. However, the availability of Southern Power, a subsidiary of USA (Figure 3) achieved commercial
drawings, which include the flange, Southern Company, is a leading operation in October 2016. Southern
can be beneficial. The electrical wholesale energy provider that operates Power had the foresight to install
characteristics, such as the % power 49 generating facilities with more a bushing monitoring system
factor (tan delta) and C1 capacitance than 11,200 megawatts of electricity from GE to monitor a key 50 MVA
values located on the nameplate, are generating capacity all over the USA. transformer.
used to configure the bushing system.
The nameplate values also serve as
the starting point of the bushing’s
life, in terms of its capacitance and
relative % power factor change.
In short, the mechanical and
electrical parameters of a bushing
are the key elements for a successful
installation of a bushing monitor.

nnnnn The end goal is

to reshape the current
maintenance and testing
programs of the utility’s
substation equipment fleet
with video, as opposed to
pictures, so to speak. Henrietta Solar Farm (Photo: Southern Company)
36 BENEFITS
OF BUSHING
MONITORING

Figure 3. Bushing adapters (left); screenshot of SCADA screen (centre); picture of the bushing monitor (right)

Figure 4. Polar Plots showing Relative % Change of Power Factor Figure 5. Polar Plots showing % Change of Capacitance C1

The Problem very large and significant increase the secondary side, data points
in the %PF generated by the phase show a change of ~1.5% on phase
On 26 March 2019, the data being B bushing. This increase in %PF A, but the concerning element is
received from the bushing monitor started in February 2019. the progression for phase B which
through the SCADA system showed reaches 4.2% on March 28th, 2019.
an alarm coming from the phase B Figure 5 below shows the polar
bushing on the LV secondary side. plots for the primary and secondary Based on the data from the bushing
It was indicating an increase of the bushing with respect to the % monitor, Southern Power decided to
relative percent change in take the transformer offline to
Power Factor (PF) from avoid a possible catastrophic
311% on February 27th to
above 895% on March 26th, nnnnn Online bushing failure of the bushing. They
replaced the suspicious
2019. monitoring affords utilities bushing and returned the
the ability to refocus transformer to service.
Analysis resources in the form
of O&M and capital Subsequent offline tests on the
Figure 4 compares the expenditures, which leads suspicious bushing confirmed
primary and secondary polar
plots for the relative percent
to operating flexibility with that the bushing had indeed
significantly deteriorated from
Power Factor change. The improved reliability. its original values and that the
data on the Primary side operational decision taken had
does not show any abnormal been correct.
behaviour. Although the data points change in Capacitance C1.
are not tightly packed together, they The data points on the left polar plot The bushing monitor had correctly
are in the same region and within from the primary side are neatly highlighted that the Power Factor of
Photo: General Electric

normal range. packed and stable which is expected that bushing was starting to change
in normal operation. at a fast rate in the last month and
Compare this to the secondary side that a precautionary replacement
where the data clearly shows a However, on the right polar plot for should take place whenever possible.
Transformer Technology September 2020 37
Issue 7

GEGridSolutions.com/MD

Take the Guess Work Out of

Transformer Bushing Monitoring

Intellix™ BMT 330 Kelman™ DGA 900 PLUS

Standalone Bushing Monitor Comprehensive Transformer Management System

Realtime monitoring systems for

DGA, Bushings, PD and more
• C1 capacitance and Power Factor (Tan delta)
• PD (partial discharge) and PRPD diagnostics
• Marine grade IP66 rated bushing sensor
• Safety system integrated within sensor
• Extensive library of adaptors (sensors) to retrofit on
Perception Fleet any transformer bushings
Transformer Fleet Management System
• Data Diagnostics via Perception software

GE, the GE monogram, Intellix, Kelman and Perception are trademarks of the General Electric Company.
© Copyright 2020, General Electric Company. All Rights Reserved.
38 ADVERTORIAL

MSENSE® BM
EARLY DETECTION OF
ERRORS ON HIGH-VOLTAGE
BUSHINGS
Availability and reliability requirements for power transformers are becoming
increasingly demanding, while at the same time, the installed transformers are
getting older, which can lead to critical problems. A good 17% (Source: Cigré MSENSE® BM ONLINE
A2.37) of transformer failures can be traced back to a defect in the bushings, MONITORING SYSTEM
which is also the main cause of transformer fires. The typical manufacturer- CONTINUOUSLY MEASURES
specific service life of capacitance-controlled high-voltage bushings is CONDITION-RELEVANT
between 25 and 30 years and is therefore generally shorter than the service life DIMENSIONS DIRECTLY ON
of the transformer. Online condition monitoring and evaluation of bushings is OIL-IMPREGNATED (OIP) OR
RESIN-IMPREGNATED (RIP)
therefore recommended. MSENSE® BM from Maschinenfabrik Reinhausen (MR)
PAPER BUSHINGS IN THE
allows you to detect faults in the bushings early on so that you can intervene VOLTAGE LEVELS
before the transformer sustains major damage. UM = 123–765 KV. CONTINUOUS
ONLINE CONDITION
For electrical field grading, high-voltage bushings above a certain voltage level MONITORING ENABLES EARLY
are almost exclusively equipped with capacitive grading layers. These are exposed DETECTION OF CHANGES
to high electrical, thermal, and mechanical loads during operation. Bushings can IN THE CONDITION OF THE
age prematurely due to transient overvoltages, increased temperatures, tempera- INSULATION.
ture fluctuations, or the ingress of moisture. This can result, for example, in partial
flashovers which can lead in a short period of time to failure of the insulation in the
bushing or even to serious transformer failure.

Photo: Maschinenfabrik Reinhausen (MR)

Transformer Technology September 2020 39
Issue 7

To optimally prevent this kind of damage, the MSENSE® BM online monitoring

system continuously measures condition-relevant dimensions directly on oil-im-
pregnated (OIP) or resin-impregnated (RIP) paper bushings in the voltage levels
Um = 123–765 kV. Continuous online condition monitoring enables early detec-
tion of changes in the condition of the insulation.

RIP, RIS or OIP

Bushings from
123 KV to 765

Bushing Bushing adapter

coupling
unit
40 ADVERTORIAL

Several methods for online monitoring of the condition of bushings have been
developed in recent years. Along with oil analyses and partial-discharge measure-
ments, the main capacitance (C1) and the dissipation factor (tan δ¬) are the two de- MSENSE® BM USES AN
cisive dielectric parameters for determining the insulation condition of high-volt- INNOVATIVE, FIELD-TESTED
age bushings. With online monitoring, it is important to consider two things in 2/3 REFERENCE METHOD THAT
particular. Firstly, a suitable reference system that functions under field condi- MONITORS THE CONDITION
tions is needed. Secondly, the dielectric parameters of the bushings are heavily OF THE INNER CAPACITANCE
dependent on the operating conditions, e.g. temperature, which makes it difficult LAYERS OF THE BUSHING
and complex to monitor an individual bushing online using specific temperature FIELD GRADING IN TERMS OF
A CHANGE IN CAPACITANCE
reference curves.
(C1) AND DISSIPATION FACTOR
(TAN Δ).
MSENSE® BM uses an innovative, field-tested 2/3 reference method that mon-
itors the condition of the inner capacitance layers of the bushing field grading in
terms of a change in capacitance (C1) and dissi-pation factor (tan δ). The key as-
pect of this process is that because the algorithm continuously incorporates all
three bushings in the mutual monitoring, the temperature dependence of other
processes is eliminated due to the globally patented 2/3 reference method. Fur-
thermore, the signals from the re-spective voltage transformers are used as a ref-
erence for detecting the symmetry of the three-phase current system. The mea-
surement is checked for validity, and grid asymmetries are effectively equalized
and eliminated. The 2/3 reference method ensures that the influence of tem-
perature and voltage fluctuations on the bushing monitoring system are effec-
tively limited.

Changes in the capacitance and the dissipation factor of the bushings are com-
pared with limit values. Only the measurement of system-side voltage transform-
ers is required to determine the symmetry of the line voltage. Thus, a reliable and
clear evaluation of the condition of the high-voltage bushings can be ensured –
regardless of grid asymmetries or voltage fluctuations. If the bushing values of
one phase (C1 or tan δ¬) deviate from the specifications, the user is alerted via a
two-stage limit-value process. This means that faults in the insulation system can
be effectively detected and the user can intervene in good time, before a fatal fail-
ure occurs.

MONITORING OF THREE HIGH-VOLTAGE AND THREE LOW-VOLTAGE

BUSHINGS WITH REFERENCE SYSTEM

Voltage transformer Voltage transformer

(high-voltage side) (low-voltage side)

ΔC1comp

Δtan δ1comp
t

t
MSENSE® BM

Voltages at bushings
Voltages at reference system
Transformer Technology September 2020 41
Issue 7

CONTINUOUS MONITORING OF HIGH-VOLTAGE BUSHINGS

WITH MSENSE® BM

Standard: With MSENSE® BM:

Transformer is only checked Data is sent continuously
once a year to ETOS®

0V 380,000 V

permanently
1x/year online

Data to
ETOS®

MSENSE® BM essentially consists of three bushing coupling units (one for each
bushing), three bushing adapters (one for each bushing) and the evaluation unit.
The bushing adapter accesses the measured voltage at the test tap of the bush-
ings. The bushing coupling unit with suitable capacity is responsible for adapting
the measured voltage and sends the values to the ETOS®.

All elements have an IP66 degree of protection. Communication takes place in

all common control system standards (e.g. IEC 61850). The modern graphical dis-
play and intuitive user interface support the user and make the system easy to use.

YOUR BENEFITS:
LOWER OPERATING COSTS AND FEWER MALFUNCTIONS

| Continuous, reliable online monitoring

| Modular design, optional packages available for individual expansion

| Significant savings during operation

| Reduced downtime, even with an aging transformer fleet

| Condition-based maintenance

| Early detection and quick rectification of errors

Further Questions:
[email protected]
42 BUSHING
FAILURE MODES

Bushing Failure
Prevention Through
Online Monitoring
by Marco Tozzi

The role of online monitors is not to eliminate standard Capacitance/Power

Factor test or to provide identical results as offline tests. The real benefit of online
monitors is their ability to detect anomalies under real operating conditions that
otherwise would not be detected, and then follow it up with the
best suitable offline test for investigation.

Dr. Marco Tozzi is Sr. Product Manager for

CAMLIN POWER, responsible for product
portfolio and an expert in diagnostic meth-
ods for high-voltage asset monitoring. After
receiving his Ph.D. degree in electrical engi-
neering in 2010 on methods for analysing
partial discharges in medium-voltage asset,
he worked as Project Manager and Techni-
cal Advisor in Techimp Srl, Italy, where he was
involved in research on diagnostics of insu-
lating systems through partial discharges
analysis. In 2012 he joined Camlin based in
Northern Ireland, where he was initially in-
volved in developing partial discharge per-
manent monitoring systems for transform-
Photo: Shutterstock

ers and rotating machines. He is author or

co-author of more than 40 technical and sci-
entific papers, co-owner of patents on par-
tial discharge denoising technique and UHF
detectors, and an active IEEE Transformer
Committee member.
Transformer Technology September 2020 43
Issue 7
44 BUSHING
FAILURE MODES

Introduction detachment of the conductive strip in the future when specifying a new
that connects the first foil layer [2]. bushing.
According to statistics published The bushing was showing perfect
in IEEE, IEC and CIGRE, bushings Capacitance and Power Factor Successful cases have already
contribute to roughly 15-30% of values in the offline test and it would been published, showing the ability
transformer failures worldwide. In have been returned to service based of online monitors to detect early
more than 40% of cases the failure solely on these results. However, DGA stage of degradation due to sudden
is of violent nature followed by showed >3000 ppm of C2H2 clearly capacitance changes [3] or internal
catastrophic consequences, such as indicating that the bushing needed contamination from metallic
fire, tank rupture and explosions. In immediate replacement. particles [4]. In this article, we will
particular, 30% of generator step-up focus on a case study highlighting
transformer failures are caused by Thus, it is not only about C1/PF. moisture contamination, where
a bushing malfunction and not only the bushing was
more generally, bushings saved but where the online
are the third single cause monitor reacted to the real
of transformer failures operating condition and
after winding and OLTC [1]. provided a more accurate
diagnosis than standard
While DGA can help in offline tests.
assessing the condition
of the main tank, it fails For the sake of clarity, the
to provide any valuable terms Power Factor (PF),
information about the Tandelta, Tangent-delta
bushing health. Therefore, and Dissipation Factor are
dedicated monitoring used interchangeably in
systems must be applied. this paper.
These systems are
connected to the test or Figure 1. Discharge within bushing not Bushings and
voltage tap to measure and detected by standard offline C1/PF test [2]. Diagnostic Procedures
analyse the current flowing Basics
in the main capacitance C1,
which varies in amplitude Transformer bushings
and phase angle depending are made of a central
on the issues found in the conductor wound with
bushings. insulating paper and
conductive layers. The
It must be understood succession of insulation
that the role of online and conductive foils forms
monitors is not to eliminate a cylindric condenser
completely standard which controls the
Capacitance/Power Factor electrical field along
(C1/PF) test, nor to provide the length and radius.
the same identical results. The conductive layers
The real benefit of online are typically made of
monitors is their ability to aluminium foils but, in
detect anomalies under some cases, they might
Figure 2. Bushing adaptor connected to voltage tap
real operating conditions be manufactured with
that otherwise could not conductive paint, printed
be detected, and then trigger the best Indeed, selecting the proper offline semi-conductive ink or semi-
suitable offline test for investigation. test and combining the results conductive paper. There should be
with the online data will provide no air or bubbles present between
Some typical questions that are a more complete picture of the the layers, so the paper/foil system is
raised are, “Would you expect the failure mode. Knowing not only first dried and then impregnated with
offline measurement to be identical that there is a problem but also either oil (Oil Impregnated Paper –
to the results of the online monitor?” what the problem is, can help the OIP type) or resin (Resin Impregnated
The answer is: Potentially yes, but it asset manager to prevent failures Paper – RIP type). From the electrical
depends on what the defect is, which in similar bushings (from the point of view, regardless of the type,
offline measurement and in which same OEM, or of the same age or the bushing appears as a capacitor
testing condition, since there is not voltage, etc.) earlier by recognizing made of a number of capacitances
a single test or a single failure mode. the failure mode whenever similar in series, one in each layer, with the
Figure 1 shows a bushing which conditions are detected, and total equivalent capacitance C1 in the
is in a critical condition due to the ultimately, to make better choices range of hundreds of pico-Farad.
 Transformer Technology September 2020 45
Issue 7

Causes of bushing failures are related • Bushing is replaced when the so-called Relative Method. This
to the loss of bushing properties, i.e. measured PF is more than twice method is based on the analysis
an inability for a bushing to act as an the nameplate value of the amplitude and angle of the
“ideal” insulating medium between • Bushing is replaced when there is current that flows in the bushing C1
the high voltage and the ground. This acetylene in the bushing oil and through the impedance at the
can happen for multiple reasons, • Bushing is replaced when the test tap and its comparison with
such as: measured Capacitance is X% bushings in the same transformer
higher than nameplate value, or in other transformer connected to
• Ingress of moisture – increases where X depends on the number same busbars.
the losses and causes the of layers. Since the number of
capacitor to become conductive layers is not known and different The principle is that whenever the
• Ingress of solid contaminants tables are provided by bushing bushing properties are changing,
– increases the losses and OEMs, a general rule of thumb due to an internal short circuit or
causes the capacitor to become is to take an action whenever increased losses, the current of
conductive X=10 regardless of the bushing that specific bushing (and, thus, the
• Oil leakage (OIP type) – leads to voltage, while further investigation voltage at the test tap) will increase
electrical discharges (and contact with OEM) is accordingly, while the current of the
• Electrical short circuit between the recommended when X is between other bushings will not. At the same
layers – increases capacitance 1 and 5 for bushings >100 kV, and time, the angle between the current
and creates a conductive channel between 5 and 10 for bushings of the failing bushing and the
• Presence of voids, cracks and <100 kV. current of the other two bushings in
delamination between the same winding (ideally
layers – causes 120 degrees) will change.
Partial Discharges and The proportion between
insulation erosion, the change in the current
ultimately creating amplitude and the change
conductive channel in the angles depends on
and short circuit of the both the failure mode and
layers the degradation stage.
• Surface cracks on the
porcelain So, the relative method
implies applying averages
Visual inspection and to reduce the day-to-
Thermal/IR scan are day fluctuations due
typically conducted on to grid imbalances and
Figure 3. Bushing A failing due to increased losses – Angles AB
a monthly and annual and AC change to the same degree (one increases, the other
calculating a footprint
basis, respectively, while decreases) with respect to the footprint. after a learning period
traditional electrical tests (after an hour, a day, a
are performed according week or a month).
to the time-based schedule, typically Online Bushing Monitor The new readings are then compared
in four-to-eight-year intervals, Principle to the footprint in order to determine
including: relative variations.
Bushings can be monitored by
• Offline capacitance measurement installing an adaptor at the bushing The challenge of the relative method
• Offline PF measurement test/voltage tap, where an impedance is mainly on the PF side and lies in
is connected between the pin and understanding whether the increase
Additional tests are done the ground (typically a resistor of the phase angle is caused by a
exceptionally, not as a routine: or a capacitor, depending on the failure or by normal fluctuations in
vendors), thus in parallel to Bushing the grid. Indeed, the angles between
• Dissolved Gas Analysis, including C 2
and in series to Bushing C 1
. The the bushings can normally swing
moisture voltage/test tap pin must always be between +/-0.5 degrees, whereas
• Oil quality grounded, either directly or through if there is a problem in the bushing,
• Dielectric Spectroscopy the impedance to prevent it from the angle variation could be only
• Partial Discharges floating, at free potential. For this 0.1-0.2 degrees, and potentially
• Tandelta tip up reason, additional protection must masked by normal fluctuations. For
• Tandelta at different temperatures be included inside the body of the this reason, bushings in the same
adaptor (not just in the monitoring winding and bushings in the same
In terms of actions, there are no system at ground level). phase (in Y-Y or Δ-Δ connection)
Photo: Camlin Power

standards defining what action needs are used as a reference under the
to be taken depending on the results The cases described in [2], [4] and hypothesis that three bushings
of the tests. However, there are a few in this paper were captured with a of the same winding cannot fail
rules that utilities commonly follow: monitoring system that uses the together simultaneously.
46 BUSHING
FAILURE MODES

Despite the challenges, the relative contamination process can last for modes (capacitance increase
method presents significant weeks or even months. and PF increase), there is also
advantages in comparison to the more than one way to assess the
other available method, known as Data Interpretation: Building bushing offline.
Referenced Method or, misleadingly, Trust
Absolute Method. This method These three principles are extremely
consists of collecting the reference The relative method shows a very important to understand before
directly from the Voltage (VT) or positive cost-benefit balance. It is, applying an online monitoring
Potential Transformer (PT), in the however, important that the results program. Indeed, there is a general
following manner: that the system provides are well misconception that online monitors
understood to build the required should report data that perfectly align
• Relative method allows the bushing confidence in managing the information with the results of a standard C1/PF
monitoring to be applied in every and alarms. In particular, there are three offline test. However, an increase in the
situation (provided test/voltage taps important things to understand: monitored current does not necessarily
are available), while the referenced mean that there is a capacitance
method requires the accessibility 1. The online monitor does not change, just as a change in the
to the voltage transformer, which measure C1/PF quantities, nor does current angle does not
is not always possible. mean there is a definite
• Relative method has There is a general misconception that moisture ingress. There is
significantly lower actually a significant variety
cost, considering that online monitors should report data that of possible failure modes
the reference method and defects that could lead
requires additional perfectly align with the results of a standard to a change in the monitored
hardware, very long
cables to connect to
Capacitance/Power Factor offline test. current, not just short circuits
and moisture ingress.
VTs and higher cost Failures can happen in each
of installation (nine of the bushing components,
bushings would require with a multitude of failure
connection, one per modes depending on the
phase, in three separate nature of the contaminant,
VTs), all contributing the location of the defect,
to a higher cost of the the amount of insulation
solution. involved and the root cause
(thermo, electric, mechanical
stress, ageing, constructive
defect, etc.).
Furthermore, some defects
could lead to a temporary change
in bushing properties during real
operating conditions as a result
of temporary changes in the load,
temperature, pressure or humidity,
and it could be difficult to spot
the defective condition during the
standard C1/PF offline test, which
is typically carried out at just one
Figure 4. Bushing tap leaking due to worn gasket behind the test tap, detected temperature (ambient) and one
by online monitoring and not by standard C1/PF test
voltage.

In terms of performance, the relative it replace the C1/PF test typically To illustrate, Figure 4 shows a test
method is comparable with the done offline. The measured tap leaking oil: This was found in six
reference method with respect to the parameters are different, and the bushings and in three of them it was
detection of capacitance changes [2] measuring conditions are different. captured through online monitoring.
(the % change in the current due to 2. What the online monitor measures The symptom was a continuously
a short circuit is higher than typical and monitors is the bushing dropping leakage current. The system
voltage fluctuation) or significant current (sometimes called leakage gave an alarm of low current and this
PF changes, while it can be slower current) at the test tap, under the triggered an inspection where the
in detecting small PF changes due assumption that the majority of the problem was identified. Again, the
to the effect of averaging. However, issues in the bushing will reflect standard test here would not have
it must be stressed that the PF in a change of the current in either highlighted any issue since both PF
changes are typically caused by amplitude or phase angle. and capacitance measured offline
slowly developing failures since the 3. Not only are there two failure were matching the nameplate values.
 Transformer Technology September 2020 47
Issue 7

CASE STUDY: OIP bushing angle readings in relative changes Offline Investigation
replacement after PF increase of Capacitance and Power Factor.
due to moisture ingress It was estimated that the change The utility switched off the transform-
occurred only in bushing B, er to perform an offline test and the
Online Data showing a relative increment of PF was found to be about four times
around 5.5% from the footprint, higher than the nameplate, with a
A bushing and partial discharge which means that if the nameplate measured value of 1.99% while the
monitoring system was installed in value is 0.53%, the actual tan delta nameplate is 0.53%, clearly justifying
2015 on a three-phase transformer is estimated to be higher than 6%. a decision for a bushing replacement.
in North America. The
monitor was applied
only to LV bushings due
to a higher failure rate
experienced in recent
years and as part of a
replacement plan of LV
bushings, in particular the
U-Type.

The installed device was

continuously monitoring
the bushing currents and
partial discharges from
both the main tank and
bushings using properly
designed tap adaptors
Figure 5. Bushing adaptor connected at the 34.5 kV OIP bushings
installed at the test
taps. The acquisition
was continuous (not scheduled),
simultaneous in all phases and
results were summarized every
hour. The bushings, as shown in
Figure 5, were from McGraw Edison
1988, OIP, 34.5 kV, around 590 pF
of Capacitance.

Figure 6 shows the unprocessed

data of the leakage current
amplitude (top chart) and angles
between bushings A and B (bottom
chart, black line) and between
bushings A and C (bottom chart,
red line). It is easy to note that
for several months the readings Figure 6. Test tap current magnitude (top) and angles recorded and summarized every hour
were very stable. After May, the (bottom). AB angle increased by about 4 degrees in 6 months.
angle between the bushings A
and B started to increase while
the angle between bushings A
and C remained constant, thus
suggesting that the change was
related to some issue in bushing
B. Looking at the readings of
the current we notice that the
leakage current of the bushing B
also started to increase slightly
after June, confirming something
happening in bushing B.
Photo: Camlin Power

Figure 7 shows the processed data

using the algorithms embedded
in the online monitoring system
aimed at converting the current and Figure 7. Relative PF increase displayed on the monitor.
48 BUSHING
FAILURE MODES

However, although the offline Quite the opposite, the PF reading at above 4% (Figure 11). In particular, the
measurement confirmed the the real operating temperatures were sample at 2°C would fall outside the
presence of an anomaly as triggered correctly estimated and reported, chart suggesting more than 10% of
by the online system, it is interesting while the offline test was done in a moisture.
to note that the measured value different condition and with lower oil
is three times lower than the one temperature. Conclusions
indicated by the online monitor.
In order to further investigate this Failure Mode Investigation Application of online bushing
difference, the bushing was removed monitoring can prevent catastrophic
and sent to a third-party laboratory to Whenever bushing PF exponentially failures which are responsible for
perform additional tests: up to 30% of transformer
failures.
• Partial Discharges
• Dissolved Gas Analysis Cases have already been
• IR Scan published [3,4] showing the
• Moisture Analysis, and online monitoring system
• PF vs. Temperature was able to detect fast
capacitance changes or
The partial discharge power factor increases
test, DGA and IR scan plus partial discharges
did not show any critical due to metallic particles
values. However, the contamination. The
other two tests showed Figure 8. Offline test result showing bushing B having high PF case described in this
very interesting results. paper shows the online
The bushing was tested monitoring system is
at ambient temperature capable of detecting a
(15°C) measuring 1.8% for failure due to moisture
PF, which was very similar ingress, which increased
to the values measured the bushing power
offline by the utility. factor up to 10 times the
nameplate value.
Then the bushing was
immersed in oil and the Not only that, this case
oil was heated up to 60°C demonstrates the need
for two hours. After 1.5 to build trust in online
hours the bushing was monitoring systems since
tested again showing they can detect anomalies
Figure 9. Offline PF test results at different ambient and oil
PF equal to about 9%, in real time under real
temperatures showing that at normal operating oil temperatures
i.e. almost 20 times the (30-40°C) the PF readings match the online results. operating conditions.
nameplate value. After Such anomalies do not
reaching the maximum temperature increases with temperature, this necessarily lead to a permanent
the bushing was left to cool down might indicate high conductive losses power factor or capacitance change,
and PF was measured again at due to the presence of moisture [5]. and in many cases, could not be
different temperatures. The final As an example, it has been published detected using the standard approach
profile of the PF with temperature that the power factor can increase of testing offline C1/PF at just one
is shown in Figure 9, where both from 0.3% at 20°C to 1.0% at 70°C temperature and one voltage.
oil and bushing temperatures are with 2% water content [6]. By looking
reported. The exponential rise with at the curves published in [7] and [8] Relative changes of the monitored
temperature confirmed the critical and comparing it to the lab current, whether in amplitude or
stage of the insulation and, most measurement of the busing under angle, should trigger alarms aimed
importantly, the values measured investigation, it is possible to speculate at reviewing the data and then
at 30-40°C range were perfectly that the bushing had an excess of selecting the most appropriate offline
aligned with the variation measured moisture above 4% (Figure 10). test and method among a variety
by the online monitoring system in of possibilities, including DGA, DFR,
real conditions. Indeed, after May A similar conclusion can be drawn Tandelta Tip Up, etc. Thus, online
the ambient temperature started to from the oil result. An oil sample from monitors do not eliminate or replace
rise, well exceeding 30°C, and thus the bushing was analysed at different offline tests. As a matter of fact, by
causing the bushing PF to increase temperatures, showing 12 ppm at combining online and offline results
up to 6 -7%. The test demonstrated 15°C and 19 ppm at 2°C. Putting it is possible to better understand
that the difference between the online the recorded value in the moisture the failure mode and provide clear
and offline results were not caused by equilibrium plot from Oommen [9] it is prescriptive actions for the most
deficiencies in the monitoring system. clear that again the moisture is well effective decision-making process.
 Transformer Technology September 2020 49
Issue 7

0.1-0.3 % 0.4-0.5 % 1% 4% EUT

References 10
[1] CIGRE TB 755, Transformer
Bushing Reliability,
February 2019
[2] C. Clark, M. Lau, “Evaluation
of Effectiveness of Dissolved

PF [%]
1
Gas Analysis on Bushings,”
Weidmann Conference on
Advanced Diagnostic Methods,
Sacramento, CA, 2004
[3] M. Tozzi, “Risk Management
requires Actionable Insight: 0.1
20 30 40 50 60 70 80 90
Adding Value with Truly Temperature [°C]
Integrated Transformer
Figure 10. Bushing PF versus temperature. Redrawing of [8]
Monitoring,” Transformer comparing the results of the Equipment Under Test (EUT)
Technology, Issue 3,
pp 88-96, 2019
[4] C. Clark, B. Di Marco, M.
Tozzi, “Online Monitoring and
Investigation Examples for
ABB O+C Bushings,” Doble
Conference, Boston, 2020
[5] Gussenbauer, Examination
of humidity distribution in
transformer models by means
of dielectric measurements,
CIGRE Vol 1. Sec 15-02, 1980
[6] V. V. Sokolov and B. V. Vanin,
"Evaluation and identification Figure 11. Moisture equilibrium isotherms (redrawing from
of typical defects and failure Oommen curves [9]) showing that estimated water for the tested
modes in 110-750 kV bushing exceeds 4%
bushings," 64th Int’l. Conf.
Doble clients, 1997
[7] Matz Ohlen, Peter Werelius,
Online monitoring systems should
“Dielectric Frequency not eliminate or replace offline tests.
Response and temperature
dependence of power factor,” By combining online and offline
2010 IEEE International
Symposium on Electrical measurements it is possible to better
understand the failure mode and provide
Insulation
[8] “Swedish Bushings Plant Sees
Growth in RIP Designs,” INMR
Quarterly, Issue 68, 2005
clear prescriptive actions for the most
[9] T. V. Oommen, “Moisture
Equilibrium in Paper-Oil
effective decision-making process.
Systems,” Proceedings of the
Electrical/Electronic Insulation
Conference, Chicago, IL, pp.
162-166, October 3-6, 1983
Photo: Camlin Power
50 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Transformer Bushings:

Breakdown Mechanism and the

Appropriate Life-cycle Maintenance
Implementation

Corné Dames is the Managing Director of

Independent Transformer Consultants, al-
ways striving to keep on top of new devel-
opments and research. She has expertise
as Laboratory Manager in the analysis of
transformer oils and as diagnostician identi-
fying problem areas in transformers, as well
as profiling of transformers according to
available results thus empowering the cus-
tomer to take preventative steps in mainte-
nance. Corné has vast practical and theo-
retical knowledge on reliability maintenance
programs. Coming from a strong chemical
background she has insight in all the chemi-
cal processes that is part of the transformer
system coupled with technical insight helps
customers optimize their reliability mainte-
nance and electrical asset lifetime.
 Transformer Technology September 2020 51
Issue 7

Bushings cause 17% of all power transformer

failures and are the third most common
reason for transformer breakdowns.

Introduction

According to studies, bushings

cause 17% of all power transformer
failures and are the third most
common reason for transformer
breakdowns. High-voltage bushings
contribute 30% to all fires and
explosions associated with power
transformer breakdowns. Effective
diagnostic tools are therefore of the
utmost importance and should be an
integral part of the life-cycle oriented
preventative maintenance strategy.

In this article, we will discuss the

Dielectric Frequency Response (DFR)
measurements as a supporting
diagnostic tool for bushing condition
assessment. The DFR method
has proven to be very valuable to
diagnose the bushing condition, plus
has identified potential insulation
system damage before a breakdown
in various cases.

It is important to gain insight and

understanding of the process of aging
and the condition of the bushing.
Photo: Shutterstock
52 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Life-cycle Orientated they can be free from partial They tend to show higher procure-
Diagnostics and Monitoring discharges. The condenser core ment cost levels compared to OIP.
that is in a liquid environment may They have lower life-cycle costs with
Available Bushing Technologies cause some leakage problems reduced maintenance and monitoring
around the gaskets when the design efforts over the expected lifetime.
Four main categories were developed is not properly done. If an internal These bushings are prone to moisture
over the years for condenser electrical breakdown takes place ingress into the paper layers of the
bushings. (which is very rare) a high internal insulation material if not stored or
pressure can build up which can handled in the appropriate manner.
One of the first technologies was result in explosions of the bushings. This result in an increased loss
Resin Bonded Paper (RBP) used for Resulting from the explosion an arc factor which can cause a bushing to
more than 100 years. The production usually originates, and this can result become unsuitable for operation.
process causes partial discharge to in a fire.
occur in the bushings and therefore Resin Impregnated Synthetics (RIS)
shows high DDF values. This The Resin Impregnated Paper (RIP) technology where the hygroscopic
technology has been mostly phased technology is state of the art and paper has been replaced with non-
out due to technical reasons. consist of a wound core made of hygroscopic synthetic materials.
untreated crepe paper, which is They are characterized by very low
Second is Oil Impregnated Paper (OIP) then impregnated with a curable dielectric loss factor (tan delta),
technology, which is still used in epoxy resin. For outdoor use, either lowest possible partial discharge
about 60% of the market today. The porcelain or composite insulators levels due to both the void free
condenser core is impregnated with are used. These bushings provide impregnation process and the
transformer grade mineral oil and significant technical advantages electrical design. These bushings are
placed inside an insulating envelope such as being fully dry and pressure- almost immune to moisture ingress
built up from porcelain or composite free, feature a high-temperature and therefore does not require
material to seal the bushing against class, normally stable and low partial special precautionary measures
moisture ingress. These bushings can discharge levels, low dielectric losses, while being stored. These are
be manufactured at high quality with fire-resistant, and outstanding expected to have the lowest lifecycle
low capacitance losses and mechanical properties. cost of all the bushings.

Close to 50%
Figure 1. of serious
Constructive details of a
condenser bushing
transformer fires
are initiated by Oil
Impregnated Paper
bushings and
they are the most
common cause of
transformer fires.

The typical life expectation of any bushing type

can be reduced by the following factors: excessive
stress, voltage oscillations imposed by lightning
strikes, frequent shunt reactor switching, and
continuous high levels of harmonics.
Transformer Technology September 2020 53
Issue 7

One of the key

factors in the
Figure 2.
successful
Bushings cause 17% of all
power transformer failures and
Bushings
management of
are the third most common
bushings is to
17%

reason for breakdowns [1]. Electrical Screen

1%
Tap Changer
31%

firstly avoid, but

Insulation
2%

Lead Exit
6%

CT
also detect PD
0%
Cooling Unit
1%
Tank
1%
activities to avoid
breakdown.
Winding Flux Shunts
38% 0%
Core and Magnetic circuit
3%

Figure 3. Collateral damages Others

Bushing failures are the most 1% 8%

common cause of transformer HV Winding

9%
fires and explosions: Failures
Unknown
with fire and explosion (left); 23%
LV Winding
5%
Fire
30%
Bushing failures (right) [1]. Tapping Winding
2%
HV Lead Exit
6% Phase to phase
isolation
2%

Winding ground
Tap changer
isolator
13%
1% None
45%

Core and magnetic HV Bushings

MV Bushings Explosion burst
circuit 30%
6% 11%
1%
LV Bushings
2% Leakages
5%

Bushings as the Main Contributors specified limits. This happens if One of the key factors in the
to Transformer Failures the deterioration of the bushing’s successful management of
internal insulation system was not bushings is to firstly avoid, but
Close to 50% of serious transformer detected in time to act. All bushings also detect PD activities to
fires are initiated by oil impregnated will lose their electrical stress avoid breakdown. PD activity
paper bushings and they are the most withstand capability over time – usually originates from excessive
common cause of transformer fires. some quicker, other slower. mechanical or electrical stress as
well as the thermal ageing of the
Breakdown Mechanism of Over time the failure risk will insulation material. Low quality
Transformer Bushings increase because the capability to bushings may show PD activity from
withstand stress will decrease as the the start. Bushings displaying PD
The typical life expectation of any equipment ages. activity at normal operating voltages
bushing type can be reduced by the should be avoided as they greatly
following factors: excessive stress, Often, the deterioration process of increase the risk of premature
voltage oscillations imposed by the bushing will start with Partial failure. It is vitally important to
lightning strikes, frequent shunt Discharge (PD), which initiates determine the reliability of the
reactor switching, and continuous ‘treeing’ – small cracks. The infrastructure on a regular basis,
high levels of harmonics. This may discharge channels resulting from and especially before exposing it
trigger premature breakdown of the the treeing will carbonize further and to increased electrical stress. One
bushings. the PD activity will increase up to a way to reduce electrical stress
point where the inner foils of the field would be by installing appropriate
The characteristics of a distribution grading condenser core are being surge arrestors or by improving the
system may change due to short-circuited. This will result in an grounding system.
expansion or a greater harmonic increase of the electrical field stress
load due to installation on new on the remaining inner foils Identifying the true state of
equipment. A bushing breakdown of the condenser core, and an the bushings is of the utmost
can occur even when a transformer interval flashover will finally occur importance to ensure a reliable
is operated within its maximum and destroy the bushing. network.
54 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

The tan δ measurement is a very strong tool

to diagnose the bushing condition with
respect to moisture ingress and the
insulation deterioration resulting from this.
Establishing Diagnostic maximum permitted temperature for the condition of a bushing that has
Methods to Determine Status that specific type of insulation material, been installed on a transformer.
of the Bushing’s Insulation to ensure thermal stability of the The most important factors for
System bushing under demanding operational optimized lifecycle-oriented condition
conditions and to identify possible assessment of Capacitance and tan δ
a) Measurement of the Dielectric moisture ingress. The practical can be summarized as follows:
Dissipation Factor Tan δ application of this is sometimes not
possible after the bushing has been • Direct after installation an initial
An increased dielectric dissipation installed in a transformer, here the ‘fingerprint’ measurement
factor (DDF) leads to higher dielectric DFR – dielectric frequency test has should be done at a defined
losses within the bushings. The demonstrated that this method can and recorded temperature – if
temperature of the bushing will deliver similar useful results at ambient possible – at different frequencies
increase with higher dielectric temperatures, provided the relevant (DFR measurements) to ensure
losses and this will then increase the material specific technical data and meaningful future diagnostics.
Dielectric Dissipation Factor again properties from the bushing OEM is • The measuring of C and tan δ
– creating a continuous cycle of available and correctly incorporated. are performed at relatively
degradation. A bushing of good design This might not be as easy, as only a low measuring currents and
in good condition will have a capped few bushing manufacturers have these voltages, therefore other sources
temperature rise and the temperature data available. of electromagnetic interference
rise will stop at an acceptable value can significantly impact the
without causing damage. The DDF (tan δ) should be measured measurement results and cannot
over a broader voltage range from be avoided in most cases. These
Frequently, when a bushing is in a about 2 kV to 12 kV. If the loss factor interferences are caused by
bad condition – often due to moisture is not constant with an increasing circulating currents in grounding
ingress over time – the positive voltage, this will typically indicate systems and radio interference
feedback mechanism may not be problems in high voltage or ground and other sources. Ensure to
stable anymore and the temperature foil conditions. document the setup for the initial
will increase beyond the thermal measurement very accurately and
stability limit. Now the busing will b) Capacitance C Measurement repeat the follow up measurements
experience dielectric breakdown under the same circumstances,
within the condenser core. Higher If the capacitance value increases, if possible, with the same test
rated voltage bushings are generally this is usually an indication of the equipment to achieve comparable
more prone to this phenomenon. partial breakdown on the inside of the meaningful results.
condenser core. Due to this the field • Ensure identical temperature as
Typical causes for an increased DDF stress inside the bushing will increase during initial measurement: the
(tan δ) over time include: and will lead to eventual breakdown condenser core temperature can
of the condenser core of the bushing. take up to 48 hours to stabilize,
• Moisture ingress due to leakage Causes for this inner breakdown which needs to be considered
• Moisture ingress originating from include: when performing follow up testing.
the transformer oil If this is not possible, an OEM
• Moisture ingress due to improper • Over voltages – lightning strikes, for interpretation of results is
storage reactor switching operations, recommended as they might have
• Ageing of paper (OIP, RBP and RIP harmonics the model and tools necessary
technology) [1] • Continuous PD activity for the correction of temperature
• Contamination and bubbles measurement.
The tan δ measurement is a very remaining from the production • Because increased DDF and C1/C2
strong tool to diagnose the bushing process may indicate increased moisture
condition with respect to moisture • Deterioration of the insulating content with high probability, the
ingress and the insulation deterioration material lack of increase cannot guarantee
resulting from this. the condition of the bushing
Photo: Shutterstock

The DDF and the Capacitance insulation material to be acceptable.

The DDF measurement should be C measurement are probably the most Therefore, the use of the DFR test
done at high temperatures, close to the powerful diagnostic tools for assessing method is recommended.
Transformer Technology September 2020 55
Issue 7
56 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Photo: Shutterstock
Transformer Technology September 2020 57
Issue 7

The DDF and the

capacitance C measurement
are probably the most
powerful diagnostic tools
for assessing the condition
of a bushing that has been
installed on a transformer.

c) Dissolved Gas Analysis (DGA) o Bushing Sensors electrical signals. The individual
PD patterns do not allow for a
This test can only be performed on The mechanical installation of an pattern classification. After their
OIP bushings. Some OIP bushings online bushing sensor replaces combination, where the UHF signals
are equipped with an oil release the cap’s function of rounding serve as gating signals, a PD pattern
valve, where a small oil sample can the insulation layers as well can be recognized. The UHF signals
be taken. However, there is great as protecting the taps internal that correspond to the partial
concern about this method as the components from contaminants. discharge are transmitted to a
bushing might fail after taking an At the same time, the sensor creates display or measuring device. Online
oil sample due to moisture ingress an excellent electrical connection monitoring algorithms are used to
because the gasket was damaged that allows the measurement of decode the signals. The monitoring
and not replaced. The oil level voltage and/or current present at algorithm tells the users when there
will also decrease when taking oil the tap. With these measurements, is any damage in the bushings of
samples. This can result in low oil changes in capacitance and partial the transformers by measuring and
levels in the bushing. Special limits discharge can be determined and sensing the partial discharge.
and interpretation of results are trended.
applied to bushing DGA analysis [2]. o Online Capacitance Measurement
o Online Partial Discharge
d) Online Monitoring Systems for Measurement Partial breakdowns between field
Bushings grading layers result in an increase
Partial Discharge (PD) is a localized of capacitance. This change in the
This method is effective for use over dielectric breakdown of a small capacitance can be measured by
short periods. It is not recommended portion of a solid electrical insulation electrical sensors.
for long term use because the system.
sensor tap is incorporated directly o Sensing Capacitance Change
into the bushing’s structure and Since partial discharges are early
well into the condenser core that indicators of incipient faults, their An electric sensor can indicate the
is otherwise hermetically sealed. online observation is of prominent change in the capacitance. When
This might lead to bushing failure interest. the sensor senses a change in
due to the continued moisture capacitance in the bushing setup,
ingress. Incorporating the online o Electromagnetic Measurements the voltage signal corresponding
monitoring unit might cause the with UHF Sensors to the change in capacitance is
RIP/RIS bushings, which are usually given by the sensor. These voltage
very reliable, to prematurely fail due The transformer tank functions signals are then transmitted to
to the additional component added as a shield against external partial a display or a measuring device.
to the bushing which decreases discharge, thus internal partial They are decoded and evaluated
the reliability and stability of the discharges can be detected relatively using various online monitoring
bushings. undisturbed by the electromagnetic algorithms. This will be shown
waves. The combination of signals to the users by the intelligent
If deciding on the online monitoring in the UHF range with electrical system and the problem can be
system, care should be taken during signals from the bushing tap easily cleared without any major
installation to ensure that the unit provides a high sensitivity together damage. Thus, the damage in the
is sealed properly not allowing any with suppression of external noise transformer bushings is measured
moisture to penetrate and cause like corona. The UHF signal serves and sensed by the change in the
harm to the system. as a trigger or gating signal for the capacitance using this algorithm.
58 TECHNOLOGY
INSIGHTS BY
CORNÉ DAMES

Some utilities have already

started to apply regular DFR
testing on their bushings, but the
lack of knowledge to interpret
the deviations over time from the
original test causes a void in the
application value of this test.
Table 1.
Useful diagnostic methods for transformer bushings

Partial Visual Thermal DFR

tan δ Capacitance DGA
discharge inspection survey (C & tan δ)

On site, transformer not energized X X X (if appl.) - X - X

On site, transformer energized (X)* (X)* - (X)* X X -

High voltage test lab X X X (if appl.) X X - (X)

*Only possible with appropriate on-line measurement equipment

e) Partial Discharges Summary of Diagnostic Systems is compromised. This test is also more
for Bushings accurate to determine moisture levels.
Partial discharges will lead to the
degradation of electrical insulation Four main categories were developed Some utilities have already started
material. This phenomenon Follow-up measurements should to apply regular DFR testing on their
occurs when there are defects in be performed at time intervals bushings, but the lack of knowledge
the electrical insulation like voids, recommended for the specific to interpret the deviations over time
cracks, and delamination. PD bushing type, the age of the bushing from the original test causes a void in
measurements are very difficult and the impact on the system if the application value of this test. If the
to perform on bushings that are failure occurs. If the bushing was measurements and deviations can be
installed on transformers. Online exposed to severe stress, it might pinpointed to identify problem areas
PD measurements may pick up on require more attention to ensure that and show the degradation in the
bushing issues that show high PD the internal insulation system has system, this can be a very valuable
activity, but still, this will increase the not suffered in any way. tool in the diagnostic chain [4].
risk of premature failure [3].
DFR Measurements to Determine Difficulties Experienced with DFR
f) Visual Inspection the Status of the Bushing’s Measurements
Insulation System
When assessments on bushings Because of the frequency range for
are done, a visual inspection is The Dielectric Frequency Response these tests, DFR measurements
suggested. Any oil leaks, low oil level, is done over a broader frequency require a much longer measurement
damage to insulator should be noted range. This test is conducted when it time. The additional testing hours
and the impact assessed. is suspected that the bushings might increase the total working hours
have been damaged by exposure allocated to the field maintenance
g) Thermal Survey to excessive stress. The internal crew. Limited guidelines and models
insulation system needs to be checked were developed to decrease the test
A handheld infrared scanner can for damage to ensure that factory time and to interpret the results of
be used to perform a unit baseload tested electrical insulation capabilities measurement. Operational asset
temperature measurement. This can was not unduly compromised. If performance leaders are currently
be useful to detect hot joints, high the withstand capability to grid developing guidelines in predicting
stress areas and possible electrical disturbances is compromised, the remaining in-service life of an
breakdown. overall reliability of the transformer unit ageing bushing fleet.
 Transformer Technology September 2020 59
Issue 7

References
[1] Th. Schuette, E. Santos,
Understanding the Breakdown
Mechanism of Bushings and
Implementing Appropriate Life-cycle
Orientated Maintenance Strategies
[2] IEC 61464-1998, “Guide for the
interpretation of dissolved gas
analysis (DGA) in bushings where oil
is the impregnation medium of the
main insulation”
[3] IEC 60270, “High voltage test
techniques – Partial discharge
measurements”
[4] C. Sumereder, A. Gumpinger, “Latest
findings at transformer bushings
Photo: Shutterstock

condition evaluation by dielectric

response methods,” Graz University
of Technology, Austria
60 AND THE SERIES
CONTINUES

Managing the Reliability of an

Industrial or Commercial Electrical
Power System / E 04
by Chuck Baker

Cast

Brian ........................................................................ Regional Vice President

(head person for this plant)
Andy ................................ Reliability Manager of Electrical Power System Chuck Baker is the President of PowerPro 360,
(recently hired by Brian, the Plant RVP) a company offering power system reliability
Kevin ............................................................................ Director of Reliability assessment and reliability maintenance pro-
grams for Industrial and commercial organiza-
Jill ............................................................................ Director of Operations tions. Chuck entered the world of Substation
and Power System Maintenance 36 years ago
Tina ............................................................................ Maintenance Manager and has spent a majority of that career on the
(who reports to Brian also) operations side of power and distribution sys-
Tim .................................................................................... Electrical Engineer tem maintenance and the development of
(who reports to Andy) power system maintenance programs.

In the last article, Brian (Regional

VP) let us know that Andy (Reliability
Manager) would begin to integrate
The Reliability Plan of the power
system into the plans for the Arc
Flash Study. Take it away Andy.
Photo: Shutterstock
Transformer Technology September 2020 61
Issue 7

Hello to everybody. A quick update: room between our two offices, and it the meeting; it filled both today and
I have talked with the key players was perfect for our all-day meeting. I tomorrow on her Outlook. I explained
involved in the reliability movement brought the coffee and doughnuts and that I was not sure and wanted to
within Smith Industries. As you recall, figured we would need a break and make sure nothing conflicted with all of
under the direction and expertise going out to lunch would work. us getting on the same page. Any other
of Brian, most of the plant is in questions?
the process of building reliability I set up a small projector, hooked my
programs. The area that lags is the surface up to it, brought up my very Both had a cup of coffee, sat back, and
power system and that is why Brian short, three-slide Power Point. Within said: “Let’s do it!”.
brought me on board. a couple of minutes I was ready, and
both Tim and Tina had arrived and - First, let me tell you my definition of
I explained about the upcoming were settling in. an RCM program. Brian and I agree,
scheduled outage and the need to and I think you will too:
perform an arc flash study as the last I started the morning with a quick
one completed was over five years overview: An RCM approach is a corporate
ago, and we are required by code to do driven program to optimize the
it – now. I introduced the need to start - Good morning all. Excited that we maintenance program so that
to walk through the reliability program can get started on looking at what we the productivity of the plant is
for the power system at the same time. want and need for a power system maintained using highly effective,
Brian, Kevin (Director of Reliability) and Reliability Centered Maintenance priority and risk based, cost-
Jill (Director of Operations) have given (RCM) program. Tina, I know you have effective techniques. When done
us the thumbs up, and so now it’s time been working on this for other portions correctly, the program will allow
to take the first step – and that will be of the plant, and Tim, I know your you to control what we have
tomorrow morning with the core team: background centers on power system assumed was uncontrollable in
Tim (my EE) and Tina (Maintenance maintenance, so let me take a couple the past.
Manager). The three of us must be of minutes and communicate the way I
unified, maintain a clear understanding, think about this. Tina, let me walk you through my
and everything else Brian explained to program strategy and we can see if
us in last month’s article. Tina interrupted and asked about how it is compatible with your plant RCM
long the meeting is. She said a strange program. We cannot have any conflicts
Tim and I have a small conference thing happened when she accepted between the two.
62 AND THE SERIES
CONTINUES

Secure your Secure your Final stage:

Power Fundation Power Reliability Implement
Program Program & Maintain

I break it down into arc flash investigation to collect all When we get through these 8, we will
three key stages: data required for a program. have a strong foundation to begin
Foundation, Reliability, and to build the reliability side of the
Implementation. The first step, Secure you Power program. As with any new program,
Foundation Program, has 8 key we need to stay on the same page.
When we talk about our plants power stages that we will use to secure the
system, we are talking about 25 program foundation: With that said, and before we start
individual components. The sum of 1. One-Line Diagram walking through each of the eight, we
these are the power system. Each 2. Short Circuit Study need to talk about the CMMS system
component has its own key factors 3. Coordination Study the plant is currently using. I was not
such as age, quality, health, load, or 4. Arc Flash Study familiar with your program, but have
heat, etc. To build the program, we 5. Maintenance Standards looked at it, and see it is a good one
Photo: Shutterstock

must go out into the plant, go through 6. Service History – Current Status for plant maintenance. I have used
the engineered drawings, and utilize 7. Required Actions a different program that is specially
the information gathered during our 8. Implementation designed for the power system and
Transformer Technology September 2020 63
Issue 7

is set up with standards, work plans

and methods to rate the value and
reliability assignment for each piece.
A Reliability Centered Maintenance (RCM)
This would work in conjunction
approach is a corporate driven program to optimize
with your current one. The reason
the maintenance program so that the productivity
I mention this is that the exercise
of the plant is maintained using highly effective,
of the first 8 will generate critical
priority and risk based, cost-effective techniques.
information for our reliability program,
When done correctly, the program will allow you to
and we want to have the right place
control what we have assumed was uncontrollable
and program to collect and organize
in the past.
what we generate.

Once we get through these 8, and reliability step. When we get there, OK, let’s walk through each of the
have all data collected and entered, we will have our 8 Reliability Steps to eight steps and make sure we are on
we will take the fun step – the complete the program. the same page.
64 AND THE SERIES
CONTINUES

One Line Diagram Obviously, there will be continual provide necessary documentation
changes that will require for the one and back up data for the PE.
This is a diagram that takes your line to be updated.
three-phase power system and with I agreed with Tim and thanked him
single lines, component symbols show Tina jumped in and reminded me that for updating us on those key points.
all arrangement of all components they do in fact have a good one line, I continued by saying that this is where
including key data (voltage, resistance, and then Tim jumped in before I could it gets interesting.
etc.), main connections, switching, say anything and explained to her that
etc. This is a key document in the although they do have one, it is out of - Think about this. We will review
management and servicing of your date. Regulations and codes require every component, its rating, etc.,
power system. More importantly, this the one line to be reviewed and and will put all of that data into our
is a critical document for maintenance updated every five years or when a power reliability CMMS. In a couple of
of the system. A critical safety significant change is made. minutes we are going to walk through
component is to verify switching, lock the Short Circuit Study, Coordination
out etc. This is for our electricians, and I was pleased that Tim was onboard Study and Arc Flash Study, which is
just as importantly, our contractors and was becoming a spokesman for also a requirement for program review
who are servicing our system. They the reliability program. He went on every five years. And gang, these
need to see the circuit and switching to explain that we would contract a three all require the data that will be
flow to assure the equipment is down PE to come in and perform this and gathered in the one line, a perfect
before they ground it for service. that Tim would walk the system and package.

Photo: Shutterstock
Transformer Technology September 2020 65
Issue 7

So, you can see why the updating of line to ground fault currents that • The Arc Flash Study is critical,
this document is important. Let us go could be generated. This tells us not just because it is a regulated
over the other three that we will be about the available power and looks requirement, but because it provides
doing to build our Power Foundation at the protective device duty rating safety for those who are working on
Program. that is responsible to clear the fault. or around our Power System.
When the PE performs this, we will
Short Circuit Study – use the updated one line diagram o The first step in performing the
Coordination Study – and use the information for these arc flash is to gather all data
Arc Flash Study calculations from that. on the equipment and system.
It will start with the utility
The reason I want to walk through • The Coordination Study takes the company’s available short-
these three simultaneously is available fault current and looks circuit current and protective
because they will all work hand in at the nearest protective device devices. We will then gather all
hand and be performed as a part of upstream. It calculates if that device data from components such as
this requirement. will do its job, isolating the fault and conductors and transformers
not allowing the impact to harm the and other sources of short
A quick summary: feeder upstream. The PE will look at circuit power. You can see how
the time vs. current characteristics all the work done on updating
• The Short Circuit Study will look at of each device and compare it to the one line is important for all
protective devices and calculate the the protective devices upstream. of this.
66 AND THE SERIES
CONTINUES

o The PE will then take all that o Now that we know the energy Tim did a great summary of the first
data and calculate the potential and time that would be present four steps to a Power Foundation
“arcing” short-circuit current. The in the event of an arc flash, Program, saying that these four key
arcing current results when the we will calculate the arc flash requirements work in conjunction
short-circuit current jumps across boundaries. This begins to with each other. All the data is shared,
an air gap. Again, remember we narrow down as each location key calculations are performed,
gathered a lot of relevant data when will be labeled for safe working and the results will work for each of
completed the short circuit analysis. distance. these, allowing us to pull this into
o The next calculation is to o A part of the calculation for compliance. He also reminded Tina
determine the Arc Flash Duration. distance also calculates the level and I, I think mostly me, that not only
This takes the amount of short of Personal Protective Equipment would we be gathering key data,
circuit energy available and (PPE) that is required at that but we would also find settings and
calculates how long it will take location. Length and strength of equipment that needed to be adjusted
the protective device to open and the potential arc helps determine or replaced as we did each of these.
end the short circuit. the required PPE. He also pointed out that all the base
o We will calculate the incident o The PE performing the study data we needed for our reliability
energy which tells us what the safe places arc flash warning labels program would be gathered during
working distance is. If this switch where required. This label this phase.
were to arc, the person would need is what communicates the
to be 18 inches, or 24 inches, or 36 requirement for distance and I agreed and proposed we run out for
inches, etc. from the source. PPE to the person performing some lunch and a little fresh air; they
the work. were great with that.
Tina jumped in and pointed out that o The last step is training the
the time, temperature, and damage all crews and those who could be I believe this is the end of this month’s
the way up to fatality was talked about exposed to an arc flash. article. This afternoon, or I should
in our first meeting with Brian and the I mentioned that the arc flash say the next edition, will be our team
gang. Tim jumped in and pointed out study was due every five years. walking through the last four items:
that this is regulated and required, The other part of the program is
but for all the right reasons pointing the crew training which needs to • Maintenance Standards
out the number of deaths and serious be performed every three years. • Service History – Current Status
burns that happen every year from arc I know that the power group • Required Actions
flash incidents. does annual OSHA safety • Implementation
training and I am certified to
Photo: Shutterstock

I was encouraged that they were provide this arc flash training. These sound simple, but they are not.
engaged and following the outline We will schedule that with this These are tough, but necessary steps for
logic. I continue: annual training every third year. the foundation of the reliability program.
Transformer Technology September 2020 67
Issue 7

THINKING ABOUT
STRENGTHENING
YOUR POSITION
IN THE MARKET?
THINK ABOUT YOUR PRODUCT

THINK ABOUT YOUR COMPETITION

THINK ABOUT YOUR SERVICE

THINK ABOUT YOUR TIME

THINK ABOUT...

DON`T
THINK
ABOUT
MARKETING
LET US DO IT FOR YOU

Contact us to find out more:

[email protected]
www.apc.media
68 ADVERTORIAL

TRANSFORMER,
GRID AND POWER
PLANT MONITORING
REVISITED
EFFICIENTLY LINK, MONITOR AND
CONTROL YOUR UTILITY WITH OUR The use of
EZY DEVICES, SERVICES AND diagnostically
SOLUTIONS – AT A REMARKABLE supported
ACCURACY LEVEL maintenance
requires reliable
By Dr. Bernhard Fruth with contributions from: Thomas Finstermann and Javis Chiu
condition monitoring
systems, reliable
diagnostic results
and extensive
The implementation of a risk-oriented maintenance strategy based on mea-
sured data requires a high degree of plant-specific knowledge and highly de- experience in
veloped sensor technology, sophisticated data processing, and information determining
mining. Using suitable monitoring techniques allows operators to determine
and know the condition of the plants, machines, and components at all times. the relationship
between the
Risk Identification – Risk Elimination – Reliability Increase
If you want to avoid unplanned downtimes, it is imperative to forecast possible measurement result
remaining running times until you will need to carry out a maintenance action. and the condition
With the right technology, it is possible to plan future investments in detail, hire
an expert (if necessary) and execute maintenance during planned operational of the component.
downtime.

Machine Learning and Artificial Intelligence

We tackle the abundance of time-synchronized, real-time data of various origins
with AI and Machine Learning tools. Our curiosity drives us to pioneer solutions.
With a passion for sophisticated products, we create pioneer solutions to power
the world, effortlessly and dependably.
WITH A PASSION FOR
SOPHISTICATED PRODUCTS,
Our mission is to make our customers’ decisions easy and reliable. We synchro- WE CREATE PIONEER
nise big data in order to simplify our customers’ decision-making and ensure SOLUTIONS TO POWER THE
reliability. WORLD, EFFORTLESSLY AND
DEPENDABLY.
Synchronisation of data across systems provides a unique and unified evalua-
tion of raw data. Our pioneering products offer our customers all the information
necessary to integrate previously incompatible data and enable more economi-
cal processes.

International experts have come together to develop a unique solution to moni-

tor and control your utility. The newly established EZY Family is fusing knowledge,
experience and products to give customers a competitive industry advantage. By
drawing on our individuality, we enable our customers to tap into the unused
potential of their investment data.

Experience Counts
Our EZY family monitors over 15,000 objects, seamlessly 3,500 monitoring sys-
tems report seamlessly to our server and we monitor and control more than 400
gas turbines.
 Transformer Technology September 2020 69
Issue 7

GO BEYOND
You need an individual power plant solution information system which provides a
unique state-of-the-art to the split second ‘big picture’ to efficiently monitor and
control your utility.

• EZY Family devices conduct measurements that enable full data sharing
between devices.
• This helps you to recognize correlations of events and signals based on fully
automated assessments.
• EZY Family devices offer a unique analytical accuracy level with joint view and
optimal evaluation capabilities.

Imagine having a network of devices, collecting and analyzing a full spectrum of

information.

• With our ‘Plug & Work’ application, we aim to make connectivity easy – simply
plug in your device without any setup requirements.
• The EZY devices provide a unique, state-of-the-art snapshot of your working
environment – on one single screen.
Dr. Bernhard Fruth is currently CEO of Power • The high-level security of all EZY Family devices provides the efficiency and
Diagnostic Service Switzerland and R&D safety that every utility needs to push beyond the limit.
Manager of the EZY Monitoring group. He • Extensively tested embedded software/systems
obtained his PhD in 1986 from University of • Robust and fault-tolerant product design
Technology in Aachen and worked in ABB • Full integration into TMOS SCADA system over Ethernet
Corporate Research in Switzerland where he • User-friendly operator interface with individualized charts
designed the first commercial PRPDA 1988 • Accurate device-specific as well as customized limits
for discharge pattern acquisition. He was • Event-based audiovisual alarms
one of the co-founders of Power Diagnostix • Fully customizable long term data logging
in Aachen, and PDTECH in Switzerland, • Customized control sequence
where he pioneered a line of monitoring de- • Remote monitoring and configuration possible
vices. He authored more than 60 papers on
PD Physics and monitoring. It is necessary to have global expertise and human resources within the com-
pany to monitor a power plant 24/7 efficiently. If this is not achievable for your
company, we offer comprehensive remote monitoring at numerous locations in
highly specialized diagnose centres worldwide.
Photo: Shutterstock, SDA
70 ADVERTORIAL

Here industry experts, with many years of experience, accurately monitor your IT IS NECESSARY TO HAVE
utility around the clock. Benefit from extensive know-how and unique diagnos- GLOBAL EXPERTISE AND
tic tools that compile a detailed report with recommendations. Highly specific HUMAN RESOURCES
WITHIN THE COMPANY TO
diagnoses, industry innovations as well as statistic data are considered in the
MONITOR A POWER PLANT
reporting. 24/7 EFFICIENTLY. IF THIS
IS NOT ACHIEVABLE FOR
“The customer is always in full control of their data.” YOUR COMPANY, WE OFFER
COMPREHENSIVE REMOTE
It is possible to send the data manually or allow the expert remote access to spe- MONITORING AT NUMEROUS
cific data areas. LOCATIONS IN HIGHLY
SPECIALIZED DIAGNOSTIC
The Bushing and Transformer Monitor CENTRES WORLDWIDE.
The bushing of a transformer is a key source of trouble. EZY bushing monitoring
allows measuring the dielectric properties of a bushing using real-time phasor di-
agrams to calculate capacitance and tan delta imbalance.

Phasor Diagram shows the instantaneous currents of each phase and the summed currents in angular domain.
Note: The NETT (sum of current) vector shown is post-multiplied 10 times for visual amplification purposes.
Phasor Magnitudes Trend shows the magnitude trends of the current of each phase over the last hour.
Sum of Current Magnitude Trend shows the magnitude trend of the unbalanced current, and the alarm thresholds.
Alarm Table shows active and inactive alarms and allows user to act on them. Button functions are shown in
the picture below.
Offline Data shows the initial bushing capacitances of each phase and allows user to adjust after offline test.

Combine this with UHF Partial Discharge Monitoring using our non-intrusve sen-
sor design and you see the insulation state of the complete high voltage network.
Transformer Technology September 2020 71
Issue 7

Unbalance vector and

current raw signal
in each phase in
three different power
transformers in a
powerplant with two
gas turbines and one
steam turbine.

Or hook up our fault recorder

and network analyser, and
why not synchronise it with
our gas combustion monitor
or infrared monitor.

Everything is synchronised in real-time seamlessly and our artificial intelligence

and machine learning algorithms keep it together, including third party devices –
the possibilities are endless.

All at a glance...
72 JUST
THREE
STEPS

Three Steps for Diagnostic

Testing of Bushings
by Sanket Bolar
and Ankit Porwal

While periodic
testing of capacitance and power factor
has been done on bushings for close
to a century now, in recent times, the
use of dielectric frequency response
has become an increasingly popular
and effective method for bushing diag-
nostics.
 Transformer Technology September 2020 73
Issue 7

Introduction
In the early 1900s, it was
demonstrated that a capacitance-
graded design helps achieve a
better radial voltage distribution,
thus enabling relatively smaller
bushings to be used in higher
voltage applications. Today,
condenser bushings are used
everywhere in applications
exceeding 25 kV. Based on the
materials used in the insulation
system, condenser bushings can
be classified into – oil impregnated
paper (OIP), resin impregnated
paper (RIP), resin bonded paper
(RBP) and resin impregnated
synthetic (RIS) bushings. Among
these technologies, OIP is perhaps
the most widely used. OIP relies on
the combination of mineral oil with
kraft paper to make a composite
dielectric with superior insulating
characteristics.

In the substation, bushings serve

as the interface between the
transformer and the rest of the
system. They are designed to
withstand high voltage stress
during operation, to carry a high
amount of current, and to operate
under high temperatures. Being
external, they are exposed to
atmospheric conditions which
can be harsh at times. Before
installation, they can be easily
damaged during transportation
and once installed are a target for
vandalism.

Because of these factors, bushing

failure is, alongside tap-changers,
one of the main causes of
Sanket Bolar, MSc is a Substation Applica- Ankit Porwal works for Megger India and is transformer failure. A transformer
tions engineer at Megger. From the begin- responsible for the power transformer seg- failure can be an expensive affair.
ning of his professional career, Sanket was ment in South Asia. More than ten years of Hence, bushing insulation health
directly involved with testing and condition experience in the area of substation appa- needs to be monitored effectively
assessment of power transformers work- ratus testing allowed him to successfully during its service life to ensure bad
ing for Siemens Ltd (India). While working support a large customer community in dif- bushings are replaced in a timely
on his Master’s Degree, Sanket became part ferent commercial and technical topics. For manner. Several online and offline
of Megger as part of the internship educa- the last 8 years working for Megger, Ankit testing methods exist to monitor the
tional program. In 2015 upon graduation, has provided engineering consultation and condition of transformer bushings.
he joined Megger as Applications Engineer recommendations to better test and evalu- Periodic testing of capacitance and
covering a broad spectrum of substation ate the condition of substation equipment power factor has been done on
products from transformer to power quality with special focus on power and distribu- bushings for close to a century now.
applications. Sanket graduated from Mumbai tion transformers. His expertise with rou- In recent times, the use of dielectric
University, India in 2009 with a Bachelor’s tine and advance diagnostic methods led frequency response, an advanced
application of power factor testing,
Photo: Shutterstock

in Electrical Engineering and received his him to author and co-author several techni-
Master’s in Electrical Engineering specializing cal articles. Ankit received his Engineering has become an increasingly popular
in Power Systems from North Carolina State degree from the University Uttar Pradesh in and effective method for bushing
University in 2015. He is a member of IEEE. Lucknow (India) in 2009. diagnostics.
74 JUST
THREE
STEPS

Step 1: Condenser bushing insulation system The following standards provide

Line Frequency Power Factor has two capacitance components acceptance limits for C1 power factor:
Testing (LFPF) on OIP – C1 and C2. In an OIP bushing, the
Bushings capacitance grading is achieved by IEEE C57.19.01 – IEEE Standard
The term power factor is used wrapping a conductive foil in oil- Performance Characteristics and
historically in the US, but the term impregnated kraft paper multiple Dimensions for Outdoor Apparatus
dissipation factor or tanδ is used times around the conductor core. Bushings [2]; and
in other parts of the world. It is One of the outermost layers is
important to note that while power connected to a test tap. The multiple IEC 60137 – Insulated bushings for
factor and dissipation factor are layers of capacitors between the alternating voltages above 1000 V [3]
mathematically two different terms, conductor core and the test tap can
they have numerically equivalent be represented by a single equivalent The limits are specified in Table 1.
values when it comes to insulation. term C1. The test tap itself is isolated
Hence, these terms can be used from the grounded flange and this Table 1. Bushing C1 acceptance %pf limits
interchangeably for practical insulation can be represented by the specified in standards
purposes with regards to insulation. term C2. In service, the test tap is
These terms are related to each other grounded. Capacitance and power
C1 C1
through the formulae below: factor measurement involves the
acceptance acceptance
measurement of dielectric losses in Bushing Power factor Power factor
Power factor = cos φ the C1 insulation that lies between the type limits as limits as per
Dissipation factor = tan δ conductor core and the test tap at 10 per IEEE IEC 60137
Delta = 90° – φ kV. Power factor values obtained are C57.19.01 [2] [3]
numerically low numbers and hence
are expressed in % instead of absolute OIP 0.5% 0.7%
Figure 1. The relationship between φ and δ values. Typical factory values lie in
the range of 0.2 – 0.4% [1]. Factory RIP 0.85% 0.7%
testing yields reference values
which are etched on the nameplates
RBP 2% 1.5%
of bushings. Field test values are
I compared to these nameplate
Ic values. Any significant change in C1
power factor values points towards All of the limits specified in Table 1 are
δ insulation deterioration of bushings. meant for power factors measured at
20°C or normalized to 20°C.
φ Additional measurements may
be done on the C2 insulation that IEEE C57.152 – IEEE Guide for
Ir V lies between the test tap and the Diagnostic Field Testing of Fluid-Filled
grounded bushing flange. A fair C2 Power Transformers, Regulators, and
comparison may not be possible as Reactors [4] says:
Figure 2. Insulation system of condenser different values could be obtained
bushing
when the bushing is on a stand, and • A change from the initial reading
when it is mounted on a transformer. by 1.5 to 2 times warrants more
Central conductor Besides, most of the time the C2 frequent testing of bushings;
values are not even provided on the • A change from the initial reading
nameplate of the bushing. There are by more than 3 times warrants
several other reasons why people tend removing the bushing from service;
to stay away from C2 analysis and • A change in capacitance by more
focus on the C1 power factor values. than 5% is a cause to investigate
Test tap the suitability of bushing for
It is important to look for changes continued service;
in C1 capacitance too. An increase • These guidelines are in line with
Test tap in capacitance can be a result of the guidelines provided in IEEE
shorted layers, whereas a decrease in C57.19.100 – IEEE Guide for
C2 capacitance most commonly results Application of Power Apparatus
from a test tap connection problem. Bushings [5].

C1 There are several documents As can be seen from these

available that provide guidelines on guidelines, validation involves either
interpretation and validation of power comparing power factor values
factor test results, both during factory against the set limits or observing
acceptance testing (FAT) and field the change in power factor over time.
testing. One point that is often overlooked
Transformer Technology September 2020 75
Issue 7

while analyzing power factor

results is the effect of temperature.
Measuring at different temperatures
can yield different values, so it is Figure 3. Dielectric frequency response
important to normalize the measured
power factor values by correcting
them to a reference temperature
(20°C). There are correction factors
1000
DFR NB DFR
available from manufacturers or
other references, but those are 100

generic and cannot be relied upon in

all cases.

%DF
10

Step 2: 1
Narrowband Dielectric
Frequency Response
(NBDFR) on OIP Bushings 0.1
0.001 0.01 0.1 1 10 100 1000
Standard 10 kV power factor test
Frequency, Hz OIP
sets with expanded capabilities of
frequencies from 1 Hz to 505 Hz
can run power factor measurements
at multiple frequencies. The curve Measuring at
obtained by plotting these power
factor values, called Narrowband
different temperatures can yield different
Dielectric Frequency Response values, so it is important to normalize the
(NBDFR), gives us additional
information on the overall insulation measured power factor values by correct-
condition of the bushing. This
reduced frequency band does not
ing them to a reference temperature (20°C).
provide the level of moisture in The correction factors that are available
the insulation, but it does point to
the presence of moisture and/or from manufacturers or other references
impurities in the insulation.
are generic and cannot be relied upon in
NBDFR is a continuum in the
evolution of power factor testing.
all cases.
In about three minutes, valuable
information is added to the routine
power factor test. It provides early than line-frequency (50/60 Hz) i.e. change in temperature, without any
indication of changes in the dielectric 1 Hz and 10 Hz. change in the shape of the curve itself.
response, potentially related to
aging and insulation degradation. NBDFR also provides the means Using Arrhenius equation, it is
This measurement can reveal an to determine a specific insulation possible to determine the exact
emerging problem in the insulation system sensitivity to temperature horizontal shift that would occur
at an early stage and represents and an accurate temperature in a curve for a certain change in
a proactive way to prioritize correction factor (ITC) to correct to temperature.
maintenance activities and dedicate an equivalent 20°C power factor. −𝐸𝐸𝑥𝑥,𝑦𝑦 1 1
resources to more advanced testing 𝐴𝐴𝑥𝑥,𝑦𝑦 (𝑇𝑇1 , 𝑇𝑇2 ) =
[ − ]
𝑒𝑒 𝑘𝑘𝐵𝐵 𝑇𝑇1 𝑇𝑇2
practices. Effect of Temperature
IEEE C57.12.90 section 10.10.4
NBDFR is typically performed at a Note 3 (b) states that “Experience has This enables us to determine
low voltage of 250 V. As a low energy shown that the variation in dissipation the power factor that would be
test, it is safer to perform so that it factor with temperature is substantial obtained at 20°C, while running a
𝜀𝜀 ∗ = 𝜀𝜀′ −
allows visualization of the unique and erratic so that no single correction DFR measurement at any other
dielectric signature of the object curve will fit all cases.” [6] temperature. Figure 5 shows
under test. Therefore, a graphical dielectric frequency response curve
comparative analysis between sister Power factor is temperature obtained with the temperature
bushings mounted on one common dependent. It has been found that correction applied, alongside the
object is possible and it also provides the frequency response and thermal measured curve. Figure 6 shows 𝜀𝜀"
tan 𝛿𝛿 =
the opportunity to set limits and response of a dielectric are related. the temperature dependence curve 𝜀𝜀′
analyze the dielectric behavior in The dielectric frequency response of obtained for the same bushing
other frequencies more sensitive an OIP system shifts horizontally with utilizing the data obtained from DFR.
𝐼𝐼𝑐𝑐 = 2𝜋𝜋𝜋𝜋 ×
 76 JUST
THREE
STEPS

Getting temperature corrected DFR Figure 5. Measured and temperature corrected

DFR curves
curves enables us to assess the
correct values at 1 Hz, 10 Hz and
60 Hz without having to worry about Temperature correction of DFR
100
the effect of temperature on the Measured Corrected
assessment. There is no need to wait
until the temperature is close to 20°C
to test the bushings, or to rely on 10
generic correction factors which may
or may not be apt depending on the

%DF
insulation condition of the bushings.
1

This method is known as Individual

Temperature Correction (ITC). More
information about ITC is provided in 0.1
0.001 0.01 0.1 1 10 100 1000
[7] and [8]. Frequency, Hz

Figure 4. DFR curves obtained at different Figure 6. Temperature dependence of bushing

temperatures dissipation factor determined from DFR
measurement

% DF vs Temperature
0.8

0.7

0.6

0.5
% DF

0.4

0.3

−𝐸𝐸𝑥𝑥,𝑦𝑦 1 1 0.2
[ − ]
𝐴𝐴𝑥𝑥,𝑦𝑦 (𝑇𝑇1 , 𝑇𝑇2 ) = 𝑒𝑒 𝑘𝑘𝐵𝐵 𝑇𝑇1 𝑇𝑇2 0.1

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Temperature, C

𝜀𝜀 ∗ = 𝜀𝜀′ − 𝑗𝑗𝑗𝑗"
Step 3: • The dissipation factor is related range of frequencies. Analysis of
Dielectric Frequency to the permittivity by the following DFR curves can yield important
Response Measurements on equation: information such as moisture
Bushings content or contamination in the
The insulation system of an OIP 𝜀𝜀"(𝜔𝜔) paper, and conductivity of the oil.
bushing is made up of multiple tan 𝛿𝛿 = The presence of contamination or
𝜀𝜀′(𝜔𝜔)
layers of capacitors formed by other physical issues can result in
conductive foil wrapped in oil atypical responses with the most
impregnated kraft paper. The oil and The dissipation factor varies prominent deviations seen in the
paper form a composite dielectric 𝐼𝐼𝑐𝑐 =frequency
with 2𝜋𝜋𝜋𝜋 × 𝐶𝐶 as
× 𝑉𝑉
both dielectric lower frequencies.
system, and the dielectric frequency constants are frequency dependent.
response obtained from the bushing The behavior of these constants Effect of Noise
is a combination of the individual differs for oil and paper. Figures DFR measurements are typically
responses from the oil and paper 7 and 8 illustrate how the typical carried out at a low voltage of 140
insulation. The permittivity of the response obtained from a bushing V. Because of the test involving a
insulation can be expressed as a is an amalgamation of the individual wide range of frequencies and low
complex term: responses from oil and paper. currents, the presence of noise can
1 1
− ] adversely affect the accuracy of the
𝑇𝑇1 𝑇𝑇2
• The relative permittivity of a In cases where it is not possible measurements. This can happen
dielectric is a complex term and to get definitive answers through in highly noisy environments even
can be represented as narrowband dielectric frequency though the instrument may have a
testing, a more in-depth analysis high signal-noise ratio. The influence
can be carried out by measuring of noise can easily be observed in
𝜀𝜀 ∗ = 𝜀𝜀′ − 𝑗𝑗𝑗𝑗" the dissipation factor over a wider the obtained DFR curves.
Transformer Technology September 2020 77
Issue 7

Figure 7. DFR responses from individual Figure 8. Dielectric Frequency Response of an

dielectrics and composite dielectric OIP bushing

OIP system OIP bushing DFR at 20°C

10000 2.5
OIL ONLY PAPER ONLY OIP
1000
2
100

10 1.5
%DF

% PF
1
1
0.1

0.01 0.5

0.001
0.001 0.01 0.1 1 10 100 1000 0
0.01 0.1 1 10 100 1000
Frequency, Hz Frequency, Hz

Figure 9. DFR measurement under the Figure 10. The noise was overcome by
influence of noise conducting a DFR test at a higher voltage of
1.4 kV rms

Influence of noise on DFR measurement Influence of noise on DFR measurement

20 9
140 Vrms 1.4 kVrms
18 8
16 7
14
6
12
5
%DF

%DF

10
4
8
3
6

4 2

2 1

0 0
Frequency, Hz Frequency, Hz

Noise disturbances can be overcome

by testing at a higher voltage. The use In cases where
of a voltage amplifier in conjunction
with the DFR measurement device it is not possible to get definitive answers
can significantly improve the signal-
noise ratio, resulting in accurate and
through narrowband dielectric frequency
reliable DFR measurements.
−𝐸𝐸𝑥𝑥,𝑦𝑦 1 1
testing, a more in-depth analysis can be car-
𝑥𝑥,𝑦𝑦 (𝑇𝑇1the
Figure 9𝐴𝐴shows , 𝑇𝑇2 )measurement
[ − ]
= 𝑒𝑒 𝑘𝑘𝐵𝐵 𝑇𝑇1 𝑇𝑇2 ried out by measuring the dissipation factor
curve on the B phase bushing
obtained through a DFR test that was over a wider range of frequencies. Analysis
carried out on the line bushings of a of DFR curves can provide important infor-
50 MVAr reactor using an IDAX. As
can be seen, there is a fluctuation in 𝜀𝜀mation
∗
on the moisture content or contam-
= 𝜀𝜀′ − 𝑗𝑗𝑗𝑗"
the measured power factor values due
to the presence of noise. The effect ination in the paper, and conductivity of
of noise is more commonly observed
while testing objects with low
the oil.
capacitance like bushings, instrument 𝜀𝜀"(𝜔𝜔)
transformers, etc. because in these tan 𝛿𝛿 =
𝜀𝜀′(𝜔𝜔)
cases the magnitude of the measured the current is given by the following The DFR test was repeated on the
current is lower, and hence more equation: same bushing at a voltage of 1.4 kVrms
susceptible to noise. The magnitude by using a voltage amplifier VAX. The
of the capacitive component of 𝐼𝐼𝑐𝑐 = 2𝜋𝜋𝜋𝜋 × 𝐶𝐶 × 𝑉𝑉 results are shown in Figure 10.
78 JUST
THREE
STEPS

Field Experience Step 2: X1 & X2. An increased dissipation

Narrowband DFR Analysis factor at higher temperatures is a good
Step 1: NBDFR test was carried out on three indicator of bushing problems.
PF Analysis bushings from 1 Hz to 500 Hz. Figure
Out of three OIP HV bushings, an 11 shows an increase in %power As per the studies carried out by Megger
increase in the power factor was factor for the bushings X1 and X3 at based on over 20 years of expertise in
observed on two bushings: X1 and lower frequencies. DFR, the limits shown in Table 4 have
X3, at line frequency as illustrated in been proposed for analysis of %pf
Table 2. The obtained thermal response measured at the frequency of 1 Hz.
curves were different for each bushing
Table 2. Nameplate and measured pf values because of the variations in dielectric Table 4. Proposed limits for %pf at 20°C
for three bushings frequency responses. These are and 1 Hz
shown in Figure 12.

Nameplate % Measured % The temperature corrected power Bushing

Bushing %PF at 20°C and 1Hz
power factor power factor condition
factor values obtained at different
frequencies are shown in Table 3.
X1 0.23 0.47 Good 0.2 – 0.5
Table 3. Temperature corrected %pf values
obtained for three bushings at different
X2 0.23 0.27 Moderate 0.5 – 0.75
frequencies

X3 0.24 1.40 Severe 0.15 – 0.2 and 0.75 – 1.25

%pf at %pf at %pf at 1
Bushing
60 Hz 15 Hz Hz
Extreme <0.15 and >1.25

a. According to IEEE C57.152, the Extreme <0.15 and >1.25

X1 0.454 0.514 1.32

line frequency power factor values
for X1 and X3 at 20°C exceed A high power factor measured on
acceptable limits. X2 0.271 0.278 0.660 bushings X1 and X3 at 1 Hz indicates
b. According to CIGRE TB 445, the insulation-related problems. But we
power factors of the bushing X1 X3 1.14 2.76 11.9 do not know if the cause lies in the
and X2 come within limits, while solid insulation or the liquid insulation.
only bushing X3 comes outside In order to establish this, a further
acceptable limits. For a “good” component, the analysis can be carried out by doing
c. Based only on the line frequency temperature dependence is weak. a full dielectric frequency response
power factor values, we may say When the component gets older measurement.
that the bushings X1 and X3 are and/or deteriorates, the temperature
not in good condition, and the correction factor becomes much Step 3:
bushing X2 should be investigated higher, which means that the DFR Analysis
further. temperature dependence is directly The results that were obtained from
d. Hence, we move onto step 2 and related to the dielectric response of the full DFR analysis are shown
run a narrowband DFR test to the bushing. In the above example, the in Table 5. The limits for %mc and
evaluate power factor at other bushing X3 shows a huge temperature conductivity of the oil proposed by
frequencies (20°C corrected). dependency as compared to bushings Megger are shown in Table 6.

Figure 11. NB DFR measurements on all Figure 12. Temperature dependence curves for
three bushings all three bushings

NBDFR on X1, X2 and X3 Temperature dependence of bushings

100 10

Bushing X1 Bushing X2 Bushing X3 9

8
7
10
6
%DF

5
4
1
3
2
1
0.1 0
1 2 5 10 20 40 70 110 220 470 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Frequency, Hz Bushing X1 Bushing X2 Bushing X3
 Transformer Technology September 2020 79
Issue 7

Figure 13. DFR measurements on all three of temperature dependence of

bushings X1, X2, X3 the power factor, enabling us to
get values for the power factor
DFR on X1, X2 and X3 corrected at 20°C. Testing in
100 a noisy environment can lead
X1 X2 X3 to disturbances in the DFR
measurement caused by the
10 frequency range and the low currents
involved. In this case, testing at
% DF

higher voltages (1.4 kV rms) enables

1 us to get better DFR results.

0.1 References
0.02 0.04 0.1 0.2 0.5 1 2 5 10 20 40 70 110 220 470 1000
[1] W. A2.34, "Guide for transformer
maintenance," Cigre, 2011
Frequency, Hz
[2] IEEE C57.19.01-2017 - IEEE
Standard for Performance
Table 5. %mc estimation and conductivity of Overall diagnostics Characteristics and Dimensions
the oil obtained from full DFR analysis
Table 7 summarizes the final for Power Transformer and
assessment that is obtained from Reactor Bushings
Conductivity the combination of all discussed [3] IEC 60137:2017 - Insulated
%mc or
Bushing
contamination
of the oil at measurements. bushings for alternating voltages
25°C (pS/m) above 1 000 V
Conclusion [4] IEEE C57.152-2013 - IEEE Guide
X1 2.5 0.185
The line frequency power factor for Diagnostic Field Testing of
testing, which has traditionally been Fluid-Filled Power Transformers,
X2 1.9 0.05 used for the bushing condition Regulators, and Reactors
assessment, has its limitations. [5] IEEE C57.19.100-2012 - IEEE
X3 4.8 0.034 These limitations can be overcome Guide for Application of Power
by conducting dielectric frequency Apparatus Bushings

Table 6. Proposed limits for %mc and response tests. Owing to the [6] IEEE C57.12.90-2015 - IEEE
conductivity of the oil by Megger increased sensitivity of power factor Standard Test Code for Liquid-
to moisture and contamination at Immersed Distribution, Power, and
lower frequencies, DFR enables Regulating Transformers
Conductivity
Bushing %MC or us to detect bushing insulation [7] Dr. P. Werelius, Dr. D. Robalino,
of the oil
condition contamination problems at an earlier stage. Any J. Cheng and M. Ohlen,
(pS/m)
indecisiveness over the course "Dielectric Frequency Response
Good 0.15 – 0.5 0.001 – 0.37 of action to be taken after the Measurements and Dissipation
conducted narrowband dielectric Factor Temperature Dependence,"
frequency response test can be 2012
Moderate 0.5 – 1 0.37 – 3.7
eliminated by conducting a full [8] Dr. D. Robalino, "Accurate
dielectric frequency response test, Temperature Correction of
Severe 1 – 2.5 3.7 – 37
which enables us to estimate the Dissipation Factor Data for Oil-
presence of moisture in the solid Impregnated Paper Insulation
Extreme >2.5 >37 insulation and conductivity of the oil. Bushings: Field Experience," 2011
DFR also solves the problem

Table 7. Final assessment based on all

measurements

LFPF as per LFPF as per Conductivity of the FINAL

Bushing %LFPF %PF at 1Hz %PF at 10Hz %mc
IEEEC57.152 Cigré TB 445 oil (pS/m) at 25°C DECISION

X1 0.454 Bad Good 1.32 0.55 2.5 0.185 Severe

X2 0.271 Good Good 0.660 0.29 1.9 0.058 Severe

X3 1.14 Bad Bad 11.9 3.6 4.8 0.034 Extreme

80 MONITORING,
DIAGNOSTICS &
DIGITALIZATION

Touchless Transformer Monitoring

with Energy 4.0 Technology
by Richard Harada

This article outlines the challenges that

utilities are facing to reduce operating costs
and how the latest Industrial IoT technology
with sensors to monitor transformers and
assets in the substation can help to reduce
those costs.
Some utilities are hesitant to adopt IoT
due to security concerns but others see the
benefits and are embracing the technology.
The article will cover the technologies
available and the inevitable shift to their
adoption as well as why the technology is
secure and economical.
 Transformer Technology September 2020 81
Issue 7

Introduction the magnitude of the transformation

they expect it will bring to the
The Internet of Things is reaching electric power industry. However,
into many industrial areas including given the traditional slow rate of
the electric power segment. Some adoption of new technologies as
utilities are already deploying the well as the high reliability standards
same emerging technologies that in this sector, it is not unreasonable
are driving the fourth industrial to doubt the massive adoption of
revolution in the manufacturing these technologies to the point of
sector. The Industrial Internet of calling it a revolution. On the other
Things, (IIoT), machine learning, hand, the electric energy market
and cloud computing together are in developed countries is at the
among the new technologies being verge of experiencing dramatic
called Industry 4.0 and they are changes that will affect the capacity
already being used by a few electric of utilities to be self sustainable.
companies around the globe for The emerging technologies that
asset monitoring [1], smart metering are making possible Industry 4.0 in
Richard Harada has more than 20 years of [2] [3], predictive maintenance [4] the manufacturing market, can be
experience in industrial networking commu- and the operations of distributed a lifesaver for electric companies,
nications and applications. Prior to joining energy resources, (DER) [5]. Some helping them adapt to what may be
Systems with Intelligence, Richard worked industry experts have started calling soon the new normal in the electric
at RuggedCom and Siemens Canada, where this trend Energy 4.0, to highlight energy market.
he focused on industrial communications
in the electric power market. Richard is an
electronic engineering technologist and has
a Bachelor of Science degree in computer
science from York University in Toronto.

Some utilities are hesitant to

adopt IoT due to security concerns
but others see the benefits and are
embracing the technology.
Photo: Systems With Intelligence
82 MONITORING,
DIAGNOSTICS &
DIGITALIZATION

Maximizing Profits while Businesses that are high electricity energy costs [9]. As the use of these
the Market Slows Down consumers are also leveraging solutions becomes more popular,
Industry 4.0 technologies to the global consumption of electricity
The continuous demand for minimize their energy costs. among businesses during a year
electricity that fueled the growth Energy management systems will eventually flatten out, reducing
of the electric industry during the based on Artificial Intelligence (AI) even more the revenue of utilities
20th century seems to be coming analyze the electricity market, the and leaving them with under utilized
to an end. Despite the increase in global electricity consumption assets.
population and the fact that we are and the business’ energy needs
living in a time when most activities to automatically decide when it With decreasing consumption,
depend 100% on electricity, its is a good time to buy electricity and since it is not easy to increase
demand in developed countries from the distribution company, and electricity rates in regulated
is plateauing [6], mostly due to when it is better to get it from an markets, electric companies are
more energy efficient appliances alternative source of energy, like left with only one option in the
and buildings, as well as the off- storage devices or solar panels. short and medium term to maintain
shoring of power-intense industries In jurisdictions where the annual their current profits: reduce their
[7]. Electric companies have felt cost of electricity for businesses is operations and capital expenses.
the impact of this decline in their based on their contribution to the Something very difficult to achieve
revenues, which have not increased major global peaks of consumption in the coming years given the
for the past 10 years, as shown in during the year, AI systems can reliability demands from customers
Figure 1 [8]. provide up to 30% reduction in and regulatory bodies, and the

$450.00

$400.00

$350.00

$300.00

$250.00

$200.00

$150.00

$100.00

Figure 1. Revenue of the electric $50.00

power industry in the United States
from 1970 to 2017 $0.00
(in billion U.S. dollars) [8] 1970 1980 1990 1995 2000 2005 2010 2011 2012 2013 2014 2015 2016 2017

The Industrial Internet of Things, machine learning,

and cloud computing together are among the new
technologies being called Industry 4.0 and they are already
being used by electric companies for asset monitoring,
smart metering, predictive maintenance and operations of
distributed energy resources.
Some industry experts have started calling this trend
Energy 4.0.
Transformer Technology September 2020 83
Issue 7

fact that many assets in the grid the data from the rest of the power oil viscosity among other parameters,
are reaching their end of life and network using machine learning and provide SCADA operators an early
will soon need to be replaced. algorithms and big data techniques, warning of the malfunction of specific
Many utilities have implemented to predict issues and help operations equipment. There are however two
preventive maintenance managers decide the right time to main differences between the existing
plans, based on manufacturer maintain or replace an asset. The sensing and actuating devices in the
recommendations of each approach of predicting the time when power grid and IIoT devices proposed
equipment, in an effort to maximize equipment will need maintenance not in Industry 4.0: First, the smaller size
the lifetime of their assets, reducing only maximizes its lifetime, but also as well as lower power requirements
this way their capital expenses and reduces the amount of truck rolls, and price of IIoT devices, compared
the losses from asset downtime; personnel deployed in the field and to incumbent technologies, make
however the labour costs involved material stock, which all translates them much easier to deploy in larger
in these plans can easily offset the into savings for the utility, Figure 2. quantities in any equipment or at
savings in capital. It is here that the any point in the network. Given that
emerging technologies of Industry It is important to note that the use of most legacy equipment does not
4.0 can provide a solution. sensing devices to monitor assets is have embedded sensing devices,
not a novelty for electric companies. IIoT sensors are the best solution to
Electric companies can use IIoT They have been using sensors in acquire the data needed for predictive
sensors to gather behavioural their operations for decades already. maintenance plans for older assets,
information about their assets that These sensors are used to monitor as well as areas in the network that
can then be analyzed together with load, voltage, phase, temperature and were not previously monitored.

There are two main differences between the existing

sensing and actuating devices in the power grid and IIoT
devices proposed in Industry 4.0.
First, the smaller size as well as lower power requirements
and price of IIoT devices, and second, the use of the Internet
for communication instead of private networks to bring the
data from the sensors.

Figure 2. Using Industry 4.0 technologies to enable predictive maintenance in

the electric industry.
84 MONITORING,
DIAGNOSTICS &
DIGITALIZATION

The second main difference is the means that utilities will have to look of DER into the grid. Therefore,
use of the Internet for communication for faster and more efficient ways to overvoltage problems and power
instead of private networks to bring operate their power networks. quality issues will be introduced to
the data from the sensors. This the grid when the use of DER starts
characteristic is crucial to deploy Physical constraints for electricity scaling. The growing popularity
these devices in a fast and cost- transmission as well as the high of electric vehicles, (EV), adds
effective way all over the power grid. amount of capital required for another level of complexity to the
It is estimated that in order to manage infrastructure and operations, topology of a future electric grid
the number of sensors and amount limited the number of sellers in with multiple sellers of electricity.
of data needed for an application like the market since the beginning EV can use their batteries to buy
this one, the investment required to of the electric industry. However, or sell electricity from the grid
upgrade an existing communication technological developments in or a building, depending on their
network will be at least 60% its initial recent years have resulted in energy needs and the electricity
cost [10]. By relying on Internet cost reductions and increase in rates, and behave as a mobile DER,
Service Providers, (ISP), to manage efficiency in the technologies transforming the topology of the
the communications, utilities are involved in the use of, Distributed grid from a static to a dynamic one
diverging the enormous cost involved Energy Resources, (DER), favouring [12]. Electric companies will then
in building up, upgrading and the adoption not only in utility have to monitor and control voltage
maintaining a private communication and industrial sites, but also and power flow at every potential
network, to a third-party company in commercial and residential point of connection with DER’s
whose core competency is buildings. Many of these buildings to eliminate their impact to the
communications, and therefore can and houses can now generate and reliability of the grid, creating a wave
provide a better service at a lower store electricity and can decide of petabytes of data that must be
price. when to consume the electricity stored and processed.
they generate and when to consume
Emerging technologies like IIoT and electricity from the power grid. Utilities will have to rely on better
machine learning are thus the best Sometimes they will generate more technological tools than the ones
options electric companies have electricity than they can consume, currently in use to adapt their
when they migrate to predictive which means they have the potential operations to the new power grid. The
maintenance plans. No legacy to become sellers of electricity. capital and maintenance cost involved
technology can match what these Although the current regulatory in deploying sensors all over the
technologies can offer today at the environment in most countries will grid and building a communication
same cost, reliability and time of not allow individuals to become infrastructure to support them can
implementation. sellers of electricity at their will, at be extremely high, so it is a dead-
least not using the power grid, the end road for many companies. As
Dealing with The political support for an open market previously mentioned, IIoT technology
Democratization of Energy of electricity is gaining momentum would be the perfect solution to
as it is seen as the only way to monitor the entire grid at almost
The electric energy market, that achieve the commitments made an atomic level while minimizing
has been an oligopoly for the past regarding climate change [11]. costs and deployment time. IIoT
hundred years, might soon resemble sensors and actuators, designed to
a perfect competition with multiple A democratization of energy will consume very low power and using
buyers and sellers, exponentially create enormous challenges the Internet for communication, can
increasing the complexity of for electrical companies, as be deployed very fast, most of the
operating and maintaining the grid the distribution grid was never time without causing any disruption
to levels beyond the capabilities of conceived or designed to convey to the grid, and without having to build
the current monitoring and control power in two directions, as it is a communication infrastructure to
systems. This shift in the market required for the incorporation support them.

Utilities will have to rely on better technological tools

than the ones currently in use to adapt their operations to
the new power grid. IIoT technology would be the perfect
solution to monitor the entire grid at almost an atomic
level while minimizing costs and deployment time.
Transformer Technology September 2020 85
Issue 7

Electric companies will also have Figure 3 [13]. Reputable providers

to deal with the constant petabytes of cloud computing services, like
of data generated from these Google, Microsoft or Amazon, have
devices, a task that will require a secure facilities with many reliable
computational power that most and powerful computers that can
of these companies can’t support. be used on demand by people,
Some of the operations needed businesses and institutions to
for data analysis use peaks of process high amounts of data at a
computational power, meaning a fast speed. The several distributed
utility will have to own expensive locations of these facilities and
hardware that will probably be under the use of the Internet to receive
utilized most of the time. The best and transmit data, ensures the
solution would be to share this availability of the service. The high-
resource with other companies tech cybersecurity tools and strict
in the same situation, something physical security policies guarantees
difficult to do with in-house the integrity and anonymity of
servers and computers, but easily the data. Cloud computing also
done with cloud computing. After allows for easy and cost-effective
accounting for hardware, software scalability and technology upgrades,
and maintenance, the cost of sharing making it the best option to deal
a computing resource on the cloud with the processing requirements
can be around 20% of the cost of of managing the new grid, from a
owning it on-premise, as shown in technical and economic view.

$35,000.00

$30,000.00

$25,000.00

$20,000.00

$15,000.00

$10,000.00
Figure 3. Cost comparison exercise
$5,000.00 between On-premise and Cloud
computing. The cost of accessory
hardware and space required for
$0.00 On-premise service (Environment)
Adminstra on Environment Network Server Storage as well as the Network makes this
On-Premise Cloud option the most expensive [13].

There is enough evidence to believe that the revolution

some people are calling Energy 4.0 is happening.
It is not just about the implementation of novel, nice-to-
have technologies, but it is a response to real changes
in the electric market, to which electric companies will
have to adapt if they want to remain self sustainable.
86 MONITORING,
DIAGNOSTICS &
DIGITALIZATION

References
[1] M. Rebolini, A. Valant and F. Pepe,
“Terna’s approach for on-line
monitoring system Intelligent
management of Assets in a large
scale infrastructures,” in AEIT
International Annual Conference
(AEIT), Cagliari, ITALY, 2017.
[2] P. Gordon, “Swedish telco to
connect 900,000 IoT-enabled
smart meters,” 25 04 2019.
[Online]. Available: https://www.
smart-energy.com/industry-
sectors/smart-meters/swedish-
telco-to-connect-900000-iot-
enabled-smart-meters/.
What’s Next [3] T&DWorld, “Ameren Missouri
to Deploy 1.4 Million Advanced
The previous paragraphs provided Meters,” 30 04 2019. [Online].
arguments to support the adoption Available: https://www.
of Industry 4.0 technologies by iotworldtoday.com/2019/04/30/
the electric industry. There is ameren-missouri-to-deploy-1-4-
enough evidence to believe that the million-advanced-meters/.
revolution some people are calling [4] ECG, Inc., “TEPCO to Implement
Energy 4.0 is happening. It is not ECG’s Predict-It™ Analytics
just about the implementation of Solution,” 24 04 2019. [Online]. [10] F. Grijpink, A. Ménard, H.
novel, nice-to-have technologies, Available: https://www. Sigurdsson and N. Vucevic,
but it is a response to real changes prnewswire.com/news-releases/ “The road to 5G: The inevitable
in the electric market, to which tepco-to-implement-ecgs-predict- growth of infrastructure cost,”
electric companies will have to it-analytics-solution-300836700. 02 2018. [Online]. Available:
adapt if they want to remain self html. https://www.mckinsey.com/
sustainable. It is now clear why some [5] P. Darrell, “Innovative Microgrid industries/telecommunications/
electric companies around the world Will Power Finnish Distribution our-insights/the-road-to-
have already started to try these Center,” 01 01 2019. [Online]. 5g-the-inevitable-growth-of-
technologies in their operations, Available: https://www.powermag. infrastructure-cost. [Accessed
despite the risks involved. com/innovative-microgrid-will- 21 05 2019].
power-finnish-distribution-center/. [11] C. Hubbuch, “As utilities embrace
The applications of Industry 4.0 [6] J. Fox, “Americans Keep Using clean energy, some lobby for
technologies shown previously (i.e. Less Electricity,” 01 03 2018. a more democratic solution,”
IIoT and Cloud computing) are just [Online]. Available: https:// 20 05 2019. [Online]. Available:
two examples of how these new www.bloomberg.com/opinion/ https://madison.com/wsj/
technologies can become extremely articles/2018-03-01/americans- news/local/environment/
valuable for electric companies in electricity-use-just-keeps-falling. as-utilities-embrace-clean-
the coming years. However, there [7] W. Richter and W. Street, “Demand energy-some-lobby-for-a-more/
are still some very important issues for electricity is dropping — and article_e8aaeed5-eb89-5896-
regarding the implementation that could shake the power b272-1aa988be4abe.html.
of these technologies that must industry to its core,” 4 December [12] P. Dzikiy, “Honda, GM blockchain
be addressed before they will be 2017. [Online]. Available: https:// project to examine how EV
adopted massively within this www.businessinsider.com/ owners could earn revenue
industry. Issues like cybersecurity, electricity-demand-dropping- from smart grids,” 20 05 2019.
service availability, reliability and data power-industry-negative- [Online]. Available: https://
ownership are among the common impact-2017-12. electrek.co/2019/05/20/honda-
concerns raised by operations and [8] U.S. Energy Information gm-blockchain-smart-grids/.
information technology stakeholders Administration, “Electric Power [13] R. Vidhyalakshmi and V.
Photo: Systems With Intelligence

in utilities. While these issues have Annual,” EIA, 2018. Kumar, “Determinants of cloud
been accounted for and accepted by [9] Stem Inc., “Reduce Global computing adoption by SMEs,”
most other industries and by some Adjustment charges with the International Journal of Business
in the electric power industry, it may world leader in energy storage,” Information Systems, vol. 22,
take a while longer before Energy 4.0 Stem Inc., 2019. [Online]. Available: no. 3, pp. 375-395, 2016.
becomes widely accepted. https://www.stem.com/canada/.
Transformer Technology COMING September 2020 87
Issue 7 IN OCTOBER

Bushings
Part 2
Why Bushings: Part 2?

Well, quite simply... Bushings: Part 1 couldn’t handle the

volume of great articles and interviews we had.

Because bushings are so important to transform­ers and

one of the leading causes of transformer failures, we will
continue to feature articles and interviews on this topic
in October, and then cu­rate our second monthly edition
dedicated to this topic.

There will be plenty of content for all of us to learn from

and enjoy.
 BODY
OF
KNOWLEDGE
Transformer Technology
has launched a keyword

B ecause we are
searchable library of the
best information and
knowledge exchanged
through our publication
and platforms that is
committed to our
made available to all our
Members to use, learn
Mission – to help the
from and guide them in
their practice or work. next generation by
capturing the legacy
knowledge of the
current generation.

Start your search now:

transformer-technology.com/bok