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ABSTRACT
The fact that copper ions from conductor surfaces are taken into solution in some mineral transformer oils and then deposited onto paper insulation in bushings and transformers has been well documented. These deposits have been implicated in a number of instances of equipment failure. Corrosive sulfur in transformer oil has been suggested as the cause for both the migration and the deposition of copper on the paper insulation in these instances even though the oil has consistently tested as non-corrosive. The migration and deposition of copper in transformer oils has been demonstrated to be independent of sulfur, corrosive or otherwise. The process of taking copper into solution and then depositing the copper as a fixed, stable compound on paper insulation is dependent upon the formation of copper-organic polar compounds in solution in the oil, attraction of these compounds to the surface of Kraft paper, and the formation of stable copper compounds in a pattern that decreases the dielectric strength of the paper insulation [1]. This paper presents one case of a copper migration induced failure in three separate transformer bushings manufactured by Trench France and oil filled with Shell Diala D mineral oil.
INTRODUCTION
In May and June of 2006, two Trench COTA 750-F012-27-AG3-01-ADP bushings failed on two separate transformers on the Southern Companys system. Inspection of the failed bushings revealed very similar details: The failures were below the flange and the air-side porcelain insulator remained intact. The epoxy inboard end insulator was shattered. Arc marks were evident from the same point on the ground sleeve to the copper conductor 5-8 inches above the bottom terminal (breaker plate). Arc marks were also evident to the breaker plate and/or the shield. Preliminary Investigation revealed further similarities between the failed bushings: The bushings were identical 750kV BIL copper conductor bushings. The bushings were manufactured in the Trench France facility. The bushings were of similar age (5-6 years service). The bushings were applied on 230kV transformers. The transformers were produced by the same transformer manufacturer. Both transformers were relatively lightly loaded and the transformer service data indicated they had not seen excessive temperatures. Although the bushing nameplate rating is 1200 Amps, these bushings were physically built as 2000 Amps units and only saw service duties of maximum of 800 Amps. Shell Diala D was the mineral oil used. There was no identifiable cause of failure from the site investigation. For reference, the first failed bushing, which failed May 2006 at Georgia Power, was identified as A. The sister bushings from this bank were identified as B and C. The second failed bushing, which failed June 2006 at Alabama Power, was identified as D and the sister bushings from the bank were identified as E and F.
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Bushings A, B, and D were dismantled and inspected at the Georgia Power Forest Park repair facility. No oil remained in the failed bushings (A and D). Unfortunately, no oil was collected from bushing B. The paper and foil in the vicinity of each failure was badly damaged and presented no clear identifiable cause of failure. Georgia Power Bushing A S/N 99A6424 Failed May 2006 Bushing B S/N 99A6427 No failure - field tear down Bushing C S/N 99A6429 No failure Trench Canada tear down Alabama Power Bushing D S/N 01A3930 Failed June 2006 Bushing E S/N 01A3931 No failure returned to Trench Canada Bushing F S/N 01A3933 No failure returned to Trench Canada Review of historical data revealed that the bushings from the Georgia Power bank, bushings A, B and C, had been tested in January 2006 and were found to have elevated power factors. Subsequent to the failures and after dielectric tests had been performed on bushing C, Alabama Power bushings E and F were field tested and also found to have increased power factors leading to their removal from service [2].
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Oil Analysis
Oil samples were analyzed before and after the dielectric test and the results are included in Table 2, below:
Although some discrepancy was evident in the test results, there were no significant gases that could indicate electrical discharges within the bushing and the moisture in the oil was relatively normal at 9 to 12 ppm. However the oil power factor showed high values at 25C and 100C. This was determined to be significant to this investigation, since an increase in oil power factor is an indicator of contamination. Additional oil samples were taken from bushing C in order to verify the questionable oil power factor results; these results are shown in Table 3. Pilot clay treatment done by Doble on one of the samples was successful in removing some degradation byproducts and/or contamination of the oil resulting in improved interfacial tension (IFT) and 25C power factor; this is indication that polar material was removed from the oil by the clay as this test is greatly affected by such compounds. Because of the type of containers used to collect the samples, this test was deemed inconclusive since the contamination could have been introduced from the materials of the sealing system of the jars.
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The bushing was dismantled while collecting samples for suspect materials including the o-rings and flat gaskets, cast epoxy parts, Belleville compression washers. Collected samples were sent for analysis failing to pinpoint the source of contamination.
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Paper fibers
Burn Hole
2010 Doble Engineering Company -77th Annual International Doble Client Conference All Rights Reserved
2010 Doble Engineering Company -77th Annual International Doble Client Conference All Rights Reserved
Behavior of the Oil Conductivity versus Temperature Figure 5 Analysis of Copper Core Sections
Two sections of copper core from bushing D were analyzed. Pictures of the blackened copper core are shown in Figure 6.
2010 Doble Engineering Company -77th Annual International Doble Client Conference All Rights Reserved
the electrostatic field and collects more particles at greater distance from the aluminum foil forming fractal agglomerates and chains along the edges of single paper fibers and resulting in very low level energy discharges. The discharge patterns follow the edges of paper fibers in the same pattern seen for the deposited particles. Finally, a discharge path is created along the particles on the surface of the paper fibers not affecting the fiber itself.
Copper and sulfur are associated with the discharge paths but they form following the discharge and are not the cause of the discharge. Copper sulfide forms on the surface of the discharge as very small filamentous fragments. That indicates the mobility of both copper and sulfur ions in the system. Figure 11 is a photomicrograph taken with a scanning electron microscope of one part of one of the traces. The individual paper fibers can be clearly seen as smooth-walled structures. Some of the fibers show a dark grainy deposit on their surface. This is the trace line, which is made up of carbonaceous debris primarily from the oil. On top of this debris are a number of white threadlike deposits. These white thread-like deposits are the copper sulfide deposits. They form after the trace has formed. The area between these threads is deficient in copper and sulfur. The trace is not the result of copper sulfide but seems to provide a sight where copper and sulfur are brought together.
2010 Doble Engineering Company -77th Annual International Doble Client Conference All Rights Reserved
Heating of the oil or the paper has not been identified as a contributing factor from dissolved gas analysis performed. Arcing has not been identified as an active incipient fault process from dissolved gas analysis performed. Oxygen levels in tested oils were found to be consistent with vacuum processed oils. The one directly measurable oxidation product, total acid number, was at low levels in the tested oils. Moisture levels were acceptable for both paper and oil samples collected during the dismantling and inspection of bushing C. The moisture in the paper in the vicinity of the puncture hole was an acceptable 1.2%. The moisture in oil for oil sampled from bushing E was comparable to values obtained for bushing C oil. Acid levels were found to be low in tested oils. Broad surface contamination with sludges, waxes, films, or sediments was not observed. Fluid particle counts were not unacceptable in the fluids tested, although some of the ASTM D1816 dielectric breakdown voltage measurements of the fluid samples were unacceptable. This particular dielectric breakdown voltage method is sensitive to particles and moisture and typically shows more variation than other methods. Corrosive sulfur was not identified in any of the tested fluids by any existing standard or method. A determined effort was made to produce a positive CCD corrosive sulfur test result for the tested oil. To produce a positive result, it was required that the sample be subjected to a temperature of 140C for 15 days. It should be noted that under these conditions other serious issues would arise within the equipment.
5. 6. 7.
8.
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9. 10.
Copper and sulfur have been identified on paper surfaces, but copper sulfide formations have not been specifically identified on any of the paper samples. Polar compounds have observed and directly related to elevated fluid power factor measurements for the fluid from bushing E and another service aged Diala D. High fluid power factor measurements have been observed for all of the bushing fluids tested. Observation of elevated power factor and the Garton Effect in power factor testing on bushing E also demonstrated the presence of polar compounds in the fluid. Elevated power factors have been observed for all of the bushings. Ionic species transported by ligands are possibly indicated by some of the SEM measurements Discharge like treeing patterns were observed in bushings C, E, F and G. Also, discharge like lines were found in one inspected bushing from the Georgia Power Dorchester substation failure [7].
11. 12.
CONCLUSIONS
It could not been determined if the tree pattern seen on the paper of the examined sister or failed bushings are related to the cause of the actual failure in the Trench bushings A and D; however, the puncture hole found at the edge of the foil in bushing C, which coincides with the treeing line, is a good indication that the area had become a weak point in the bushings insulation. The following conclusions have been drawn from this investigation. The preponderance of information indicates the failures are due to insulation failure. The failures are related to insulation compromising phenomena linked with the oil. Shell Diala D is the identified oil that has developed the features allowing this type of failure to occur. Not all Shell Diala D develops these features. The specific features are a high power factor that displays the Garton Effect and elevated levels of oil soluble copper. Some copper conductor bushings with Shell Diala D will be at risk for this type of failure. Most copper conductor bushings with Shell Diala D will not be at risk for this type of failure The copper conductor bushings without Shell Diala D are not at risk for this type of failure. The aluminum conductor bushings with Shell Diala D are not at risk for this type of failure. Compromised bushings can be identified by routine field tests. Recommendations: Identify those Trench France copper conductor bushings that contain Shell Diala D, manufactured between 1998 and 2003. Identify which of these bushings has an increasing power factor. When the C1 power factor increase is 1.5 to 2 x nameplate value and when the power factor indicates a tip up, typically: Test KV 2 4 6 8 10 replace the bushing. PF % 0.39 0.40 0.42 0.43 0.55
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ACKNOWLEDGEMENTS
The authors would like to express gratitude to Russ Crutcher, Microlab Northwest; Dave Hanson, TJH2b; Danny Bates, Alabama Power; Joseph Benefield, Georgia Power, for their contributions during this investigation.
REFERENCES
[1] E. R. Crutcher, E. R. and Warner, Ken, Copper Mobility and Failure in Electrical Equipment: It Is Not Corrosive Sulfur, Proceedings of EuroTechCon, 2009. [2] Bates, D., Back to Back Bushings Failures - An Ongoing Investigation, Proceedings of TechCon USA 2008. [3] Doble Laboratory Test Analysis Report 71090, November 30, 2006. [4] Doble Materials Report 72486, March 2007. [5] Doble Materials Report 75585, August 2007. [6] Siemens Test Report MCSL 068/07, April 2007. [7] Del Rio, Arturo and Hanson, Dave, Copper Migration in Bushings: Update to Southern Co.Trench Bushing Failure Investigation, Siemens Transforming Know-how into Solutions Conference, 2008.
BIOGRAPHY
Arturo Del Rio started his professional career as a Field Engineer in the oil fields of Colombia and as an Electrical Engineer for Hatch Associates consulting firm in Toronto, Canada, were he was involved in several projects and studies related to electric arc furnaces and the metallurgical industry. He joined Trench Canada in 1991 where he has held various design and engineering positions in the fields of instrument transformers, power electronics and air-core reactors. He is currently Engineering Manager at the Trench Transformer Bushing Division in Ajax, ON, Canada. Arturo holds a bachelors degree in Electrical Engineering from the Universidad Industrial de Santander, Colombia, and an M.A.Sc. degree in the field of power devices and systems from the University of Toronto, Canada. He has been an IEEE member since 1988 and is a registered Professional Engineer in Ontario.
Keith P. Ellis is responsible for the development, promotion, sales and technical support for bushings for the Trench Bushing Group including HSP, serving as Bushing Product Manager and OEM Sales Manager, Americas. Before joining Trench Keith was Sales Manager for the ABB Power T & D Companys Components Division. This position was also held under the company names of Westinghouse/ABB and ASEA Electric. Before assuming the Sales and Marketing responsibilities of transformer components, Keith was Senior Sales Representative for RTE and RTE-ASEA in Upstate New York. Keith began his career in the power transformer industry with RTE/ASEA as an Application Engineer. Keith graduated from Mare Island Naval Shipyard with a journeyman certificate in Machine Technology. Attended the University of California, where he majored in Mechanical Engineering. After serving with distinctions in the US Navy during the Vietnam War he continued his education at the University of Wisconsin, Milwaukee. He is a member of IEEE, PES, Transformers Committee and Working Group Chairman for C57.19.00. He takes particular interest in component applications to power transformers with special interest in high voltage bushings and on-load tap changers.
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Doble Test Results Service Aged Diala D from Bushing G TABLE A1 DGA Analysis , ASTM D 3612, ppm v/v
GAS Hydrogen Oxygen Nitrogen Methane Carbon Monoxide Ethane Carbon Dioxide Ethylene Acetylene Total Combustible Gas Syr. 2759 Conc, 2.7 3,960 50,500 3.5 100 0.0 2,183 0.0 0.0 106 Syr. 2013 Conc, 3.0 3,700 50,600 3.6 102 0.0 2,234 0.0 0.0 109
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TABLE A4 Additional Sulfur Test Results on the Oil As received, Doble CCD Test at 140C
4-day Testing, 18 gauge needle CCD Test by Air Ingress - Paper Dielectric Strength of Paper used in CCD test (Air Ingress) CCD Test by Air Ingress - Copper CCD Test by Air Ingress Copper Tarnish Level CCD Test, Sealed Dielectric Strength of Paper used in CCD test (Sealed) CCD Test, Sealed- Copper CCD Test, Sealed- Copper Tarnish level Method Doble Method ASTM D 149* Doble Method ASTM D 130 Doble Method ASTM D 149* Doble Method ASTM D 130 Result Light Deposit, dull in color Non-corrosive 1b Moderate Deposit, dull in color Non-corrosive 2b Result Moderate Deposit, dull in color Non-corrosive 2b Moderate Deposit, dull in color Non-corrosive 2c
6-day Testing, 20 gauge needle Method CCD Test by Air Ingress - Paper Doble Method Dielectric Strength of Paper used in CCD test (Air Ingress) ASTM D 149* CCD Test by Air Ingress - Copper Doble Method CCD Test by Air Ingress Copper Tarnish Level ASTM D 130 CCD Test, Sealed Doble Method Dielectric Strength of Paper used in CCD test (Sealed) ASTM D 149* CCD Test, Sealed- Copper Doble Method CCD Test, Sealed- Copper Tarnish level ASTM D 130 *Analysis was performed under the following conditions: Sample Preparation: Paper dried for 16 hours at 80C and then oil impregnated Electrodes: brass, 0.25 inch diameter Voltage Rise: 500 volts/second Temperature: C Material Thickness: 6 mils (paper was in 2 layers to get an accurate result)
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