A Novel Condition Monitoring Procedure for Early Detection of Copper Corrosion Problems in Oil-Filled Electrical Transformers
Abstract
:1. Introduction
2. Materials and Methods
2.1. The CM Procedure
- 1.
- Monitoring the measurable variables: The mechanism of the corrosion reaction was established in [3] as two reactions. Reaction (1): dibenzyl disulfide (DBDS) depletes to benzyl mercaptan (BM) at the overheating condition and presence of proton H+. Reaction (2): The BM decomposes in the presence of Cu ions as a catalyst and proton H+ at overheating conditions to form sulfur deposits as copper sulfide (Cu2S) on the copper windings associated with the by-products, H2S gas and toluene; see Figure 2.
- 2.
- Applying the Early Fault Diagnosis (EFD) Model: After identifying the transformers with suspected copper corrosion propagation where H2S gas and toluene are generated coinciding with depleting DBDS and BM, a fault trend chart can be created based on measured values of H2S gas and toluene. This chart can track the corrosion fault progression during the useful life of the transformers. The regular periodic schedule of oil analysis in a normal condition is annually [37]. As soon the H2S gas and toluene are generated in the oil, the recommended periodic schedule could be within a three month interval [3,6] or according to the maintenance plan. The fault trend chart is based on a novel numerical method in order to track the copper corrosion problems and select the correct time of corrective actions [6]. The numerical method includes the following calculations:
- Caution Limit (CL) of the H2S gas and toluene, which were defined as 1 and 2 ppm, respectively [3].
- Warning Limit (WL), which was estimated as 50% of the CL value as an indication of starting a fault [6].
- Alarm Limit (AL), which was estimated as 80% of the CL based on an experimental investigation, showed that the acceptable relative error in the oil analysis and uncertainty could be up to 20% [38].
- Relative Fault Detection Value (RFDV), which is the difference between the first measured value (w1) of H2S gas or toluene and WL relative to the WL [6]; see Equation (2):
- Daily Trend (DT%) is the trend of the increase of the measured value per day and is calculated based on first measured value (w1) and second one (w2); see Equation (3):
- 3.
- Carrying out corrective action: The main corrective action is adding benzene triazole-type metal passivators, an anticorrosion additive, to the insulating oil in-service; Benzo Triazole (called BTA) or Toluiltriazole-dialkylamine (called Irgamet-39). These passivators are usually recommended to suppress the corrosion reaction throughout by neutralizing the activity of the catalyst Cu ions [40,41,42], see Figure 3. The optimal concentration limit value of BTA and Irgamet-39 are 50 and 150 ppm, respectively [40]. However, exceeding the mentioned optimal concentration limit value can lead to the formation of a high amount of undesirable flammable hydrogen gas (H2) in the oil, especially with Irgamet-39 compared with lower amounts when using BTA [43], see Figure 3, and acceleration of oxidation process in transformers [40]. Hence, an optimal amount of a passivator should be added at the correct time. On the other hand, adding a passivator after the values of the H2S gas and toluene have exceeded their caution limits will suppress further anticipated corrosion reaction but will not reduce the sulfur deposits which have already occurred on the copper windings [40].
2.2. Empirical Study Design
3. Results
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
AL | Alarm Limit |
BTA | Benzo Triazole |
CBM | Condition-Based Maintenance |
CCD | Covered Conductor Deposition |
CL | Caution Limit |
CM | Condition Monitoring |
DBDS | Dibenzyl disulfide |
DT | Daily Trend % |
EFD | Early Fault Diagnosis |
HI | Health Index % |
H2S | Hydrogen sulfide gas |
Irgamet 39 | Toluiltriazole-dialkylamine |
MPM | Markov Prediction Model |
PCB | Polychlorinated biphenyl |
PPM | Part per million |
PSMD | Primary Substation Maintenance Department |
RAT | Relative Alarm Threshold |
RFDV | Relative Fault Detection Value |
RSD | Relative Standard Deviation % |
SDM | Statistical Distribution Model |
Uexp. | Expanded uncertainty |
WL | Warning Limit |
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Measurable Variable | CL | WL | AL | RAT |
---|---|---|---|---|
H2S gas | 1.0 ppm | 0.50 | 0.80 | 0.60 |
Toluene | 2.0 ppm | 1.00 | 1.60 | 0.60 |
No. | Transformer Serial Number/ID | Voltage HV/LV, kV | Power Rating, MVA | Substation Name | DBDS (ppm) | BM (ppm) | H2S Gas w1 (ppm) | Toluene w1 (ppm) | RFDV |
---|---|---|---|---|---|---|---|---|---|
1 | 8235120102/Tr2 | 132/33 | 300 | Fifth ring road | 1.0 | <0.1 | 0.20 | 0.30 | <0.60 |
2 | S251625/Tr1 | 132/11.5 | 30 | Mahbola-A | 3.0 | <0.1 | 0.42 | 0.25 | <0.60 |
3 | 111353/Tr1 | 132/33 | 300 | Omirya-W | <0.1 | 0.23 | 0.30 | 0.93 | <0.60 |
4 | 07MD970101/Tr1 | 132/11.5 | 30 | S. Alabdullah | <0.1 | 0.33 | 0.10 | 0.45 | <0.60 |
5 | M0036/Tr1 | 132/11.5 | 30 | Mishref-A | 9.0 | 0.90 | 0.83 | 1.62 | >0.60 |
6 | M0037/Tr2 | 132/11.5 | 30 | Mishref-A | 6.0 | 0.80 | 0.81 | 1.70 | >0.60 |
7 | M0038/Tr3 | 132/11.5 | 30 | Mishref-A | 4.3 | <0.1 | 0.88 | 1.68 | >0.60 |
No. | Transformer Serial Number/ID | Toluene w2 (ppm) | H2S Gas w2 (ppm) | DT (%) |
---|---|---|---|---|
5 | M0036/Tr1 | 1.93 | 0.92 | >0.33 |
6 | M0037/Tr2 | 1.90 | 0.90 | >0.33 |
7 | M0038/Tr3 | 1.69 | 0.92 | <0.33 |
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Jadim, R.; Kans, M.; Alhattab, M.; Alhendi, M. A Novel Condition Monitoring Procedure for Early Detection of Copper Corrosion Problems in Oil-Filled Electrical Transformers. Energies 2021, 14, 4266. https://doi.org/10.3390/en14144266
Jadim R, Kans M, Alhattab M, Alhendi M. A Novel Condition Monitoring Procedure for Early Detection of Copper Corrosion Problems in Oil-Filled Electrical Transformers. Energies. 2021; 14(14):4266. https://doi.org/10.3390/en14144266
Chicago/Turabian StyleJadim, Ramsey, Mirka Kans, Mohammed Alhattab, and May Alhendi. 2021. "A Novel Condition Monitoring Procedure for Early Detection of Copper Corrosion Problems in Oil-Filled Electrical Transformers" Energies 14, no. 14: 4266. https://doi.org/10.3390/en14144266