Understanding Power Factor Testing Results

relative to

Modern Instrument Transformer Insulation Designs

Spring 2009, Doble Conference Nick S. Powers ABB Kuhlman Rolando Gomez Arteche
Introduction: Power factor testing of insulation systems is a well understood concept, but applying it to instrument transformers of all types and sizes can be difficult as it is not necessarily intuitive. This paper will provide insight into the different transformer insulation structures, and how best to apply power factor testing to truly measure the dielectric integrity of the transformers. Designs to be detailed areSingle Stage Inductive Voltage Transformers Multi-Stage or Cascade Inductive Voltage Transformers Coupling Capacitor Voltage Transformers Station Service Voltage Transformers (Test similar to VTs) Current Transformers Single Phase Combination Current/Voltage Transformers (Test similar to VTs)

From experienced gained over the last several years, a review of some difficult testing issues will be discussed and solutions for proper testing proposed. Modern Instrument Transformer Insulation Designs: Although the primary purpose for instrument transformers is to accurately transform the voltage and current information from a high level primary down to a standardized low power output, the most critical criteria that defines long term survival is the major insulation system. This task is made even more difficult as these devices not only must survive both the steady state operating condition, but also must function satisfactorily up to even higher level transient conditions. Oilfilled insulated instrument transformers have operated satisfactorily under these conditions for many decades, and their reliability is not only designed and built into the device at the manufacturing facilities, but also confirmed via testing at both the factory as well as in the field by the end users.

Instrument transformers are generally considered to be stable passive units, requiring little or no maintenance throughout their lifetime, which can be in the range of 25 to 30 years. It is difficult to know, however, the actual condition of the installed transformer and if it fails, it can fail unexpectedly and in some instances violently.

As the confirmation of the insulation state is of such critical importance, users primarily use some form of insulation power factor testing to provide benchmarks for initial acceptance (generally 0.5% power factor or less), and for continued acceptance of the condition of the installed base of instrument transformers. Different test configurations have been used in order to measure the Power Factor for various type of instrument transformers. Experiences, customs and usage have determined the approaches taken by the users. These different approaches have been a reason for disagreement with the customers due to inaccurate measured values. So to provide necessary information to reach the common goal of insuring reliable performance of the critical high voltage instrument transformers on the utility grid, we must first define fully the insulation system. High voltage insulation systems: Inductive voltage transformer (VT)- These transformers are also called magnetic voltage transformers and can be classified into two basic forms. The first configuration is called the single stage inductive voltage transformer where the unit consists of a single primary coil coupled through an steel core to secondary windings (Figure 1). In well designed units, the primary and secondary windings are separated with an insulation structure that is conservatively design to control the dielectric stress both between the windings, as well as over the insulators surface. This is done using high quality kraft paper and intermediate shield layers, along with relatively large smooth line and ground shields or electrodes as shown in Figures 2, 3, and 4.To Fig 4 Fig 2 prevent high voltages from being capacitive Fig 3 coupled into the secondary windings from the high primary voltage, a reliable inductive design also includes a ground shield placed between the two windings. The placement of this shield, while helping to contain the high voltage dielectric stress to the major insulation, can also be problematic for interpreting power factor results due to its proximity to the low end of the high voltage winding. This will be discussed later in this paper. The second design configuration is shown in Figure 5, and is a multi-stage inductive voltage transformer that is referred to as a cascade design inductive voltage transformer. In this unit, two or more coils with individual insulation structures as shown in the previous photos are coupled together through the steel core. This allows reasonable sized insulation structures to be unit in tandem to distribute the stress line to ground through the voltage transformer. With these multiple insulation structures, power factor testing can be complicated and with some tests, misleading.
Fig. 5

Fig. 1

Fig. 6

Coupling capacitor voltage transformer (CCVT) This design differs from the inductive design in that it uses a capacitive stack as a voltage divider so as to introduce a controlled voltage into the base region of the CCVT shown in Figure 6. In the base, which can either be air insulated or oil-filled, the voltage is applied to a reactor that shifts the voltage signal back into phase with the primary signal and then this medium voltage is Fig. 7 transformed down to the final output voltage rated for the instrumentation equipment. A detail is shown in Figure 7.

Station Service Voltage Transformer (SSVT) Figure 8 This design is a variation of the single stage inductive transformer that uses the same condenser style conservative design of kraft paper and shield layers to distributed the dielectric stress from line to ground across the insulator surface, as well as through the major insulation to ground. The SSVT can have either circular disc wound coils connected together, or a layer wound design with kraft paper inner layers and special resin coated paper to improve short-circuit strength. Figure 9 shows a condenser bushing ready to be applied to an assembled core/coil, and Figure 10 is an assembled core/coil inside the SSVT Tank.
Fig. 9

Fig. 8

Fig. 10

The condenser style inner bushing extending from the dome to the primary coil located in the base region has smooth line electrodes, as well as ground electrodes to fully control the voltage stress within the major insulation of the transformer. The transformer inner condenser bushing normally does not have a test tap to fully isolate the insulation structure within the transformer housing, but a variation of this type tap has been optionally offered at the 230kV level for the SSVT. This design has a relatively large core and increased secondary copper cross section for supplying power requirements for substation auxiliary power. From a dielectric perspective, this device can be treated as an inductive voltage transformer and tested in a similar manner.

Current Transformer (CT) There are two distinctly different configurations of wound oil-filled current transformers available in the market today. In a design where the primary conductor is fully insulated with the major insulation, and is routed down into the lower section of the transformer where partially insulated steel cores and secondary windings are applied over the primary is called a hairpin design. If the major insulation is applied directly to the secondary windings and steel cores in a toroidal fashion, with an downward inner condenser bushing, this design is call a head or inverted eyebolt design. Both are tested in a similar manner, so for simplicity, we will use the inverted eyebolt design shown in Figure 11 for illustration purposes in this paper. In the inverted eyebolt design, the toroidal cores are located up in the dome region of the current transformer, and the secondary leads are taken from the dome down to the low voltage box at the base of the CT via a hollow electrode that provides the form over
Fig. 11 Figure 5 Fig. 13

Fig. 12

which the inner bushing major insulation is applied. The core shield and the CT secondary winding on toroidal core are shown in Figure 12. Figure 13 illustrates a fully taped insulated coil ready for assembly. The electrode in the center of the insulated coil is either solidly grounded at the base, or is supplied with a tap that has a jumper to ground that can be isolated and used for power factor or dissipation factor testing. This normally grounded tap tied to the hollow electrode provides safe passage for the secondary leads down the high voltage insulated inner bushing. In CTs where this dissipation tap is supplied, this helps isolate the major insulation from the base and secondary windings in the CT for ease in obtaining a reliable power factor reading. Details on this test format will be discussed later.

Combination Single Phase Metering Units (MU or CT/VT)- Where the users want to reduce the size of the metering transformer footprint within the substation, manufacturers produce a metering transformer that consists of both a single stage inductive voltage transformer and a current transformers. The majority of the voltage transformer is located in the base where the unit consists of a single primary coil coupled through an steel core to secondary windings (Figure 14). The high voltage electrode that supports the inner condenser bushing is taken up through the porcelain adjacent to the inner bushing electrode of the current transformer. An inverted eyebolt current transformer design is located up in the dome, with its inner bushing electrode running downward next to the inner bushing of the voltage transformer. To insure reliable long term performance free of partial discharges, these electrodes must be aligned such that the dielectric field plots from each of the two insulation structures are equal so as not to stress one to the other and cause extreme voltage stress. With the dielectric stresses properly controlled, the single phase metering units have given reliable insulation performance comparable to the separate CT and VT. With this nesting of the two insulation structures, substantial space savings are achieved, which greatly reduces the real estate needed for installation of the metering transformers.

Fig. 14

Proper Power Factor Testing of the Instrument Transformer Insulation: Inductive Voltage Transformers - Testing of inductive voltage transformers are tested in accordance with the following test format. This generally gives reasonable results in evaluating the insulation conditions on these transformers.

However, there have been reported cases of test readings on the Test 1 (Overall) test where some of the inductive transformers show greater than 0.5% PF results. The results from this overall test reflect not only the loss current from the inner bushing insulation at reasonable levels, but the high dielectric losses from the high capacitance pressboard insulation at the low end of the HV winding to ground due to the proximity of the H0(H2) shield/bushing to insulation ground shield. Inductive (magnetic) voltage transformers for 115kV and higher application are only supplied as line to ground connected transformers, and as such have an isolated H0 bushing to Ca =Insulator Capacitance allow for separating the primary C1 =Major Insulation Capacitance winding from base/ground for testing C1=Capacitance between Ground the insulation. The insulation that must Shield & Coil Shield be verified to meet dielectric requirements is that found in the inner a bushing controlling the stresses line ground across the surface of the insulator and also the turn to turn and layer to layer insulation inside the 1 primary coil. This can be viewed as the Fig 15 1 capacitances shown in Figure 15.

H0

As can be seen, the C1 capacitance of the inner bushing insulation is impacted

by the C1 capacitance which has the most impact on the power factor results on this unit. Power factor, of course, is also impacted by environmental issues and how they affect Ca insulator capacitance. Insulator cleanliness, humidity conditions and insulator moisture is critical power factor measurements. Even altitude can have an impact on the Ca power factor. This issue has been particularly serious when dealing with cascade transformers, however this problem can also be noticed on single stage inductive voltage transformers. The goal of this information is to provide a specific testing configuration for newer design inductive designs that will truly reflect the major insulation and not be impacted by the non-energized low end insulation. In general, there are 4 configurations for testing the line to ground connected inductive voltage transformer on site shown in Figure 16. Inductive VT Measurement Configurations in the field:

5kV

UST
Test set

5kV

GST
Overall
Test set

Floating tank
CONFIGURATION 1

CONFIGURATION 2

UST
Test set 5kV
CONFIGURATION 3

Fig. 16

5kV

GST
Test set

Guard H0

CONFIGURATION 4

Configuration 1Represents the best practical configuration that is actually used in the factory, which requires isolating the equipment base from ground. Configuration 2Matches the Doble overall test/Test 1, but the reading will be impacted by the H0 (non-energized) insulation to ground shield. Configuration 3Configuration measures mainly losses of the H0- base is isolated during test. Configuration 4 This format is the H1 Cross Check method and will give best practical method for testing the single stage inductive VTs.

Inductive VT Equivalent Circuits: Test configuration equivalent circuits for the above are as follows:
Configuration 1: (Recommended with actual designs and per factory test). Measures the major insulation Sensible to the physical state of the porcelain and its parasitecapacitances.

 The transformer must be completely insulated from ground in order to measure Configuration 2: Measures the major insulation and the pressboard cylinder located at the end of the HV coil. (This pressboard cylinder has a very high capacitance value and high dielectric losses. This format is not representative of the major insulation condition). Sensible to the physical state of the porcelain and its parasite-capacitance.

Inductive VT Equivalent Circuits: (Contd)

Configuration 3: Measures the dielectric losses only of the HV coil on the pasteboard cylinder (This pressboard cylinder has a very high capacitance value and high dielectric losses. And its not representative of the Major insulation condition.) The transformer must be completely insulated from ground in order to measure Configuration 4: Measures the major insulation Its insensitive to the physical state of the porcelain and its parasitecapacitance. The transformer does not have to be completely isolated from the ground to take the measurements This feature is not presently available on most inductive VTs. It will require modification to the design of the transformer

Proper Inductive VT Physical Test Connections: For testing power factor results in the field, Figure 17 is per the Configuration 1 given above and will provide the closest results to the factory values. This requires that the base be isolated from the ground, the H0 bushing and the secondary terminals are grounded, and with the LV Lead attached to the base, and the H1 is energized.

5kV

Fig. 17

LV Lead To meter

Gnd H0 Gnd X1, Y1

Proper Inductive VT Physical Test Connections: (contd) The closest Doble test that will yield results comparable to factory test results, when the overall test GST Test 1 is indicating high power factor results in the field, would be per Figure 18 below, the H1 Cross Check test. By guarding out the H0 terminal, and connecting the LV Lead to the grounded base and energizing the H1 terminal, this test removes the effect of the high capacitance pressboard cylinder between the H0 and ground shield from the reading. Fig. 18
High capacitance pressboard cylinder

5kV

LV Lead To meter Guard H0

Gnd Base, X1, Y1

Station Service Voltage Transformer and Combined CT/VT: As station service voltage transformers and current/voltage combined units are structured electrically similar to the single stage VT, they can be tested per the instruction noted above and as shown in Figures 19 and 20, respectively. Shown are examples of the units being 5kV tested using the Doble GST H1 cross check test which gives a reasonable Temporarily remove approximation for insulation lead from power factor in each of these tank and guard H0 two designs.
Guard H0

LV Lead To meter

Fig. 19

5kV
H0 affected by high PF pressboard cylinder Fig. 20

Guard H0

Ground Base, X1, Y1, Z1 LV Terminals

LV Lead To meter

A field test for PF Test that will best test insulation equivalent to the factory test for the SSVT and the CT/VT combination unit is the standard Doble GST H1 Cross check test that gives accurate results for power factor and removes the effect of the H0 insulation issues. In summary, here is the test setup that corresponds to Figures 19 and 20. Removes the effect of H0 insulation Guard H0 Ground base and X1, Y1, Z1 Energize Primary H1@ 5kV Cascade Inductive VT Physical Test Connections: Cascade VTs offer a more challenging, if not impossible task to obtain representative power factor results. In these designs with multiple insulation structures, there exists a very complex equivalent circuit that is very dependant upon the environmental conditions, and the parasitic capacitance effect upon the external insulators. Figure 21 shows the capacitance that must be considered when evaluating the readings on these multi-stage design VTs. The techniques given for the single stage inductive VT will not necessarily work for the Cascade design due to the intermediate core coupling the coil sections together. These tests will tend to energize the core and result in excitation current flow, which adds greatly to the normal capacitance currents and give Fig. 21 unacceptable power factor readings. Two variations of these tests are shown in Figure 22.

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5kV 5kV

Fig. 22

LV Lead To meter

LV Lead To meter

Guard H0 Gnd H0 Gnd X1, Y1

Test with Isolated Base will Energize the Core!

Gnd Base, X1, Y1

Test with Grounded Base will Energize the Core!

Both the isolated base technique that is used on single stage VTs at the factory for obtaining representative results for the major insulation power factor testing, as well as the GST Doble H1 Cross Check test both excite the core 5kV and will result in energized current flow. The main concern with the Cascade Inductive transformer is Jumper and that many of the power factor energize H1 & H0 connections will excite the core, and in those cases the measured losses will include excitation current, with no possibility of Fig. 23 guarding it. This is because the end lead of the upper winding is internally attached to the intermediate tank, as well as the LV Lead To start lead of the lower winding. The only practical method in testing the Cascade design is that shown in Gnd Base X1,Y1 Figure 23, but this will be impacted by the insulation between the secondary winding and its own ground shield!

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H0 bushing is isolated from ground, and connected to H1, the base is grounded and as well as X1 and Y1 LV terminals are grounded, and the H1-H0 are energized at 5kV. Power factor values obtained by this method will be quite high, as well as the capacitance value because the insulation between the secondary winding and ground consists of a relatively short thickness pressboard cylinder. Typical pressboard power factor values will be around 1% or 1.5%. So results can be confusing. Contact the manufacturer to discuss any discrepancy. In addition, Cascade VTs have very low internal capacitance values that force the measured values to be completely dependant on the environment conditions and the parasite-developing capacitance, yielding completely inaccurate results. These conditions can prevent the customer from testing the true insulating capacitance of the high tension winding. Coupling capacitor voltage transformer Physical Test Connections: Testing on the coupling capacitor voltage transformers can be performed using typical information from prior Doble test instructions. A complete test definition was provided in a Doble paper given in 2004 International Conference of Doble Clients*. In summary, the test information is as follows and is illustrated in Figure 24. CCVT Power Factor and Capacitance Test Preparation

External link for high frequency carrier injection removed Identify C1-2+ C1-1 + C2 values on stack nameplates Potential grounding switch position

H1
Fig. 24

C1
Cn Total
AF Switch

C2
Voltage Gnd Sw

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Coupling capacitor voltage transformers can be tested per the following table defining the tests required, and the connections to be made based upon the number of capacitor sections on the CCVT being tested. This table and the illustration in Figure 24 supplies complete details for performing power factor tests that will represent the insulation of the transformer.
Measure Test Mode
GST-Gnd GST-Gnd GST-Gnd

Energize

Ground

Voltage Gnd Switch

Open Closed Closed

Test kV
10kV 10kV 2kV

Cn C1 C2

H1(HVTerm) H1 (HV Term) Carrier Pt/AF

Carrier Pt /AF* Carrier Pt /AF* ---- *

In the event of multiple stack designs (C1 = C1-1 + C1-2 + .)

C1-1
stack/Bottom

GST-Gnd UST

Midpoint Midpoint

Carrier Pt/AF Carrier Pt/AF

Closed Closed

10kV 10kV

C1-2 stack/Top .

*Carrier Link Opened

*Table obtained from a prior Doble report presented on CCVT testing.

H1
Fig. 24

C1
Cn Total
AF Switch

C2
Voltage Gnd Sw

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Current Transformer Physical Test Connections: In general, current transformer insulation testing is simpler to perform and the major insulation is relatively accessible for power factor tests. As the major insulation is supplied between the primary and the ground shield, and the secondary winding is not involved in the testing of the major insulation, connections are easier to perform. In some cases, the current transformers are equipped with dissipation factor or power factor taps as shown in Figure 25, and some do not have a shield ground external to the Fig. 25 transformer. Both designs will be reviewed and test format provided. When viewing the CT insulation relative to capacitances, noted in Figure 26 the C1 is the major capacitance and can be checked using the Overall Test No. 1. Keep in mind that this test is also sensitive to insulator capacitance Ca. Any high reading on PF on the test, it may be necessary to perform a hot collar test on the insulation.

C1
Ca
Fig. 26

5kV

In current transformers not equipped with an isolated dissipation factor or test tap, the typical connections can be made as shown in Figure 27 for proper PF results. With this test, a jumper is placed across H1 to H2, the secondary winding and base are connected to ground, and the LV lead is connected to the base of the CT. With the H1/H2 connection energized at 5kV, good PF results can be obtained. In the case of this overall test showing high on power factor, then a hot collar test can be performed to guard out any impact of the insulator capacitance.

Fig. 27

LV Lead To meter

Gnd Base & X1 LV Terminal

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Current transformers with a test tap will allow isolating the major insulation ground electrode so as to only check the C1 capacitance of the design. Figure 28 shows the connections required for the CT with test tap. The test tap can be isolated from the metal base, the base and the LV terminal grounded, with the H1/H2 terminals jumpered together, 5kV can be applied on the primary of the current transformer, with the LV lead connected to the tap. This is an overall Test 1 configuration. With the test tap design, to fully isolate the insulator capacitance Ca from the C1 major insulation value, a UST can be performed on the Test tap, with the LV terminal grounded, the primary H1/H2 conductor energized at 5kV, and the LV Lead to the meter on the tap. This is a preferred method of obtaining true power factor of the major insulation. The tap insulation (C2) can also be measured by energizing the tap with 2kV maximum, ground the LV terminal, and guard the H1/H2 primary. Upon completion of all tests, insure that the test tap is firmly connected back to the base for safe use.

Fig. 28

5kV

Ground X1 LV Terminal

Temporarily Remove Ground Connection

LV Lead To meter

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Common Problems to Watch Out For: Some testing issues that we have seen repeatedly in application of instrument transformers are: 1. VT Overall PF & Importance of cross-check tests

If Overall PF Test (Test 1) is High, verify condition with Cross Check tests Always check overall test against H1 Cross-Check Believe in the H1 cross-check value

2. Cleanliness of insulators and relative humidity

Epoxy surface on H0 (Moisture/Contamination) Wipe Porcelain Surfaces Perform Hot-Collar test as needed to check Insulator Never use alcohol to wipe insulators Condensation

3. Effect of Radiated High Voltage EMF on Excitation Readings

Pickup of Energy Possible Highest reading under H0/H2 energized direction H1 terminal picks-up radiated energy

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Transformer excitation tested with energized 138kV line nearby. 138kV line was 30 above grade and 13 away from VT-

Test results with EMF impacting the H1 terminal

Dissimilar excitation readings due to radiated field effect

Test results without EMF impacting the same transformer

Excitation readings equal away from any radiated field

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Understanding Power Factor Testing Results

relative to Modern Instrument Transformer Insulation Designs

Presented by Nick Powers - ABB Kuhlman & Rolando Gomez-Arteche DOBLE CONFERENCE March 2009

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