Transformer Diagnostic

Measurements

Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis,
Degree of Polymerisation (DP) & Furan
Analysis
Overview of CPC100 and Operating Software (Toolset)
Electrical Measurements
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary

1
 Insulation Oil Analysis

Measurements Conclusions
Dielectric measurements
Physical measurements Condition of the oil
Chemical measurements
Gas in oil-Analysis Electrical condition of the transformer
Furane analysis Condition of the Cellulose

2
Dielectric, Physical and Chemical Analysis (Intl)

Dielectric measurements Standard

Breakdown voltage IEC 60156
Dielectric dissipation factor IEC 60247

Physical properties Standard

Refraction number DIN 51423
Density DIN 51757
Kinematic viscosity DIN 51526-1
Flash point DIN EN 22719
Pour Point DIN ISO 3016
Interfacial tension ISO 6296
Colour and Purity ISO 2049 / IEC 60296

Chemical properties Standard

Water content in oil DIN IEC 814 = IEC 60814
Neutralization number DIN 51558 T2 IEC 60296
Saponification number DIN 51559-2
Sulphur content DIN 51400-6
Chloride content DIN 51577-3
Inhibitor content (IR Meth.) IEC 666

3
Dielectric, Physical and Chemical Analysis (USA)
Dielectric measurements
Break down voltage ASTM D 877
Break down voltage ASTM D 1816
Power factor ASTM D 924

Physical properties
Interfacial tension ASTM D 97
Interfacial tension ASTM D 2285
Particle count N/A
Sludge ASTM D 1698
Water content ASTM D 1533
Visual ASTM D 1500
Specic gravity ASTM D 1298
Color (lab) ASTM D 1500
Color (eld) ASTM D 1524

Chemical properties
Polychlorinated biphenyl ASTM D 4059
Acidity ASTM D 974
Dissolved gas ASTM D 3612

4
Measurement of PF in Oil

5
Power Transformer Diagnosis

Insulating Fluids (Oil Test Cell) Power and Dissipation Factor (Tan Delta)
Testing the Insulation Condition of Oil
Power Transformer Diagnosis
Insulating Fluids (Oil Test Cell) Power and Dissipation Factor (Tan Delta)

Typical Test Setup

 Recommended Limits according to IEC 60422

Transformers & Transformers

VTs from
VT upto
170 kV
Breakdown Voltage
Dielectric PF @ 90 C
Neutralisation #
Interfacial Tension
Water Content (mg/kg)

8
Recommended Limits acc. to IEEE Std. 62-1995

Power Power Power

Transformers Transformers Transformers
<69kV 69kV-288kV >345kV
Breakdown Voltage > 26 kV > 26 kV > 26 kV
[kV] ASTM 877

Dielectic PF @ 25C 0.5 % 0.5 % 0.5 % (0.3 %)

Neutralization < 0.2 < 0.2 < 0.1

Number [mg KOH/g]

Interfacial Tension > 24 > 26 > 30

[mN/m]

Water Content - - -
[mg/kg]

9
 Dissolved Gas Analysis

Chemical breakdown of insulation oil and

cellulous material due to stress

Gases formed get dissolved in oil

10
 Dissolved Gas Analysis

Advantages:

Precise concentration of the gases present in the

oil.
Theoretically an exact state of the insulation
can be known

This is a time tested method

Reasonable amount of agreement has been

reached between various standard maintaining
bodies such as IEC and IEEE

11
 Dissolved Gas Analysis

Limitations:

Exact level of gases that can be considered harmful

or dangerous for the insulation debated issue

Agreement on the levels considered harmful

Based on historical data
May not be on physical understanding of processes

Off-line method
Sampling of oil
Taking to lab
Testing by gas chromatography

Transformer quite vulnerable period between

successive tests

12
 Dissolved Gas Analysis

 Proven condition assessment method to indicate the

health of a transformer.

 Analogous to pathological testing of humans to detect

various bio-Logical abnormalities.

 Expertise is needed for Analysis of dissolved gases in

transformer oil.

13
 Dissolved Gas Analysis

 Mineral Oil is composed of Hydrocarbons

 Molecular Structure of Mineral Oil

 Molecular Structure of Cellulose Insulation

14
 Dissolved Gas Analysis

 Under Thermal and Electrical stresses, mineral oil

decomposed in to hydrocarbons and hydrogen.
Methane CH4
Ethane C2H6
 Hydrocarbons forms the following gases Ethylene C2H4
Acetylene
C2H2
CH4, C2H6, C2H4, C2H2, C3H6, C3H8, C4H10 Propane C3H8
Propene C3H6
Butane C4H10

 If Cellulose involved, CO, CO2,O2,N2 and H2O are

produced Nitrogen N
2
Oxygen O2
Water H20
Carbon monoxide CO
Carbon dioxide CO2

15
 Dissolved Gas Analysis

H2 (Hydrogen) PD in Oil & Normal ageing

H2,CH4 (plus Methane) Thermal Fault (<150 o C)

H2,CH4,C2H6 (plus Ethane) Thermal Fault (150 300oC)

H2,CH4,C2H6,C2H4 (+ Ethelene) Thermal fault (300 700oC)

H2,C2H2 (Hydrogen + Acetylene) Arcing

H2,CH4,C2H6,C2H4,C2H2 Thermal Fault (>700oC)

and Electrical fault

H2,CO,CO2 PD in Cellulose

CO,CO2 (Carbon Monoxide & Dioxide) Deterioration of cellulose

16
 Condition for Normal
(IEEE Std.C57.104-1991)

1. H2 Hydrogen - 100 ppm

2. CH4 Methane - 120 ppm
3. CO Carbon Monoxide - 350 ppm
4. CO2 Carbon Dioxide - 2500 ppm
5. C2H4 Ethylene - 50 ppm
6. C2H6 Ethane - 65 ppm
7. C2H2 Acetylene - 35 ppm

17
 Interpretation of Faults

Gas ratio methods

 Dornenburgs ratio methods
 Rogers ratio method
 IEC 599

Key Gas Method

TDCG Method

Duval Triangle Method

18
 Dornenburgs Ratio Method
(IEEE Std.C57.104-1991)

Methane CH4
Ethane C2H6 R1= CH4/H2 Methane / Hydrogen
Ethylene C2H4
Acetylene
C2H2
R2=C2H2/C2H4 Acetylene / Ethylene
Propane C3H8
Propene C3H6
R3=C2H2/CH4 Actylene / Methane
Butane C4H10 R4=C2H6/C2H2 Ethane / Acetylene

Dornenburgs L1 limit

Gas H2 CH4 CO C 2 H2 C 2 H4 C 2 H6
L1 Limits
100 120 250 35 50 65
(ppm)

19
Ratio Limits - Dornenburgs Ratio Method
(IEEE Std.C57.104-1991)

20
 Rogers Code Determination Criteria
(IEEE Std.C57.104-1991)

Gas Ratio Range Code

Not greater than 0.1 5
Methane CH4
Ethane C2H6
CH4/H2 Between 0.1 and 1.0 0
Ethylene C2H4
Acetylene (R1) Between 1.0 and 3.0 1
C2H2
Propane C3H8 Not less than 3.0 2
Propene C3H6
Butane C4H10 C2H6/CH4 Less than 1.0 0
(R4) Not less than 1.0 1
Less than 1.0 0
C2H4/C2H6
Between 1.0 and 3.0 1
(R5)
Not less than 3.0 2
Less than 0.5 0
C2H2 /C2H4
Between 0.5 and 3.0 1
(R2)
Not less than 3.0 2

21
 Fault Diagnosis using Rogers Ratio Codes
(IEEE Std.C57.104-1991)

R1 R4 R5 R2 Diagnosis
0 0 0 0 Normal deterioration
5 0 0 0 Partial discharge
1 or 2 0 0 0 Slight overheating below 150 o C
1 or 2 1 0 0 Slight overheating 150 -200 o C
0 1 0 0 Slight over heating 200 -300 o C
0 0 1 0 General conductor overheating
1 0 1 0 Winding circulating currents
Core and tank circulating currents, over
1 0 2 0
heated joints
0 0 0 1 Flashover without power follow through
0 0 1 or 2 1 or 2 Arc with power follow through
0 0 2 2 Continuous sparking to floating potential
5 0 0 1 or 2 Partial discharge with tracking (note CO)

22
 IEC Code Determination Criteria

Gas Ratio Range Code

<0.1 0
C2H2 /C2H4 0.1 1.0 1
(R2) 1.0 3.0 1
>3.0 2
<0.1 1
CH4/H2 0.1 1.0 0
(R1) 1.0 3.0 2
>3.0 2
<0.1 0
C2H4/C2H6 0.1 1.0 0
(R5) 1.0 3.0 1
>3.0 2

23
 Fault Diagnosis using IEC Ratio Codes

R2 R1 R5 Diagnosis
0 0 0 Normal ageing

* 1 0 Partial discharge of low energy density

1 1 0 Partial discharge of high energy density

Discharge of low energy density

1 -2 0 1 -2
(Continuous sparking)
Discharge of high energy density
1 0 2
(Arc with power flow through)
0 0 1 Thermal fault <150 o C
0 2 0 Thermal fault 150 -300 o C
0 2 1 Thermal fault 300 -700 o C
0 2 2 Thermal fault >700 o C

24
Key Gas Method
(IEEE Std.C57.104-1991)

25
 TDCG Method
(Total Dissolved Combustible Gases)

(IEEE Std.C57.104-1991)

TDCG = H2 + CH4 + CO+ C2H4 + C2H6 + C2H2 (in ppm)

IF TDCG < 720 Normal

IF TDCG 720 1920 Caution, Oil Decomposition
IF TDCG 1920 4630 Caution, Oil Highly
decomposed
IF TDCG > 4630 IF service continues,
Transformer will fail

TDCG Rate /Day

(Old sample New sample)

R= ppm
Time in days

26
 Dissolved Key Gas Concentration Limits
by TDCG (ppm)
(IEEE Std.C57.104-1991)

C2H C2H
H2 CH4 C2H6 CO CO2 TDCG
Status 2 4
ppm ppm ppm ppm ppm ppm
ppm ppm

Condition 1 100 120 35 50 65 350 2500 720

101- 121- 36- 61- 66- 351- 2501- 721-

Condition 2
700 400 50 100 100 570 4000 1920

701- 401- 51- 101- 101- 571- 4001- 1921-

Condition 3
1800 1000 80 200 150 1400 10000 4630

>18
Condition 4 >1000 >80 >200 >150 >1400 >10000 >4630
00

27
 TDCG Method (Recommendation Frequencies)
(IEEE Std.C57.104-1991)
Sampling Interval and Operating Procedures
TDCG TDCG For gas generation rates
Status Level Rating
(ppm) ppm/day Sampling
Operating procedure
Interval
>30 Daily
Consider removal from service.
Condition 4 >4630 10-30 Daily
Advise manufacturer.
<10 Weekly
>30 Weekly Exercise extreme caution.
Analyze for individual gases.
Condition 3 1921-4630 10-30 Weekly
Plan outage.
<10 Monthly Advise manufacturer
>30 Monthly
Exercise extreme caution.
Condition 2 721-1920 10-30 Monthly Analyze for individual gases.
Determine load dependence.
<10 Monthly
>30 Monthly Exercise caution.
Analyze for individual gases.
Condition 1 <=720 10-30 Quarterly Determine load dependence.
<10 Annual Continue normal operation

28
 Duval Triangle Method

Fault %CH4 %C2H2 %C2H4

Methane Acetylene Ethylene
PD 98 ----- -----
D1 ----- 13 23
D2 ----- 13 to 29 23 to 40
T1 ----- 4 20
T2 ----- 4 20 to 50
T3 ----- 15 50

29
 Duval Triangle

PD

Thermal <300 0C
80 80

Thermal 300-700 0C
%CH4 60
60
%C2H4

40 40
H E Discharge (Arcing) Thermal >700 0C
20 Thermal/ 20
Electrical
L E Discharge (Sparking)
80 60 40 20
%C2H2
30
Duval Triangle Method (continued...)

31
Duval Triangle Method (continued...)

32
 Historical Information

 Nameplate information including age.

 Loading of unit- heavily loaded or overloaded?

 Previous dissolved gas-in-oil test data.

 Any bushing or the transformer failure in past with

the repair and oil filtration history.

 Has the Total Combustible Gas risen or oil risen

suddenly at any time?

 Visual checks (Oil leakage, Colour of silica gel, gas

accumulated in Buchholz)

33
 Dissolved Gas Analysis

Procedure:

Sampling, Labeling

Extraction

Analysis

Interpretation

34
 Oil Analysis
Gas-in-Oil Analysis (DGA, Dissolved Gas Analysis)
Toepler pump for gas extraction
Nitrogen N2
Oxygen O2
Water H2
Carbon monoxide CO
Carbon dioxide CO2
Methane CH4
Ethane C2H6
Ethylene C2H4
Acetylene C2H2
Propane C3H8
Propene C3H6

35
 Gas Chromatograph

(mercury)

36
Sampling and Labeling Procedure of Oil for
DGA test

 Dry Weather, avoid contamination.

 Clean, dry, leak proof glass or stainless steel

container.

 Take safety precautions.

 Sample bottle (Glass/ SS) must be full without any

air trap completely sealed and should be properly
labeled.

37
 Insulation System in Power Transformers

Degree of Polymerization (DP):

Source: Thomas A.Prevost EHV Weidmann Industries, Inc 2005

38
Cellulose

Structure of
Cellulose

Decomposition
products of
Cellulose

39
Solid Insulation : Life Line of Transformers

Solid Insulation: Cellulose Degradation:

40
Solid Insulation in Power Transformers

Solid Insulation: Cellulose Degradation:

Source:GE Energy RVP-AI 2005

41
 Solid Insulation : Cellulose Degradation

Furan Analysis ASTM D 5837

DP Analysis ASTM D 4242

Source: Thomas A.Prevost EHV Weidmann Industries, Inc 2005

42
 Furan Analysis

Some of the products formed when the cellulous materials in

a transformer degrade are derivatives of the aromatic
compound called furan.

Furan is a heterocyclic aromatic system (C4H4O) consisting of

four carbons and one oxygen in a five membered ring with
each of the carbons having a hydrogen attached.

The five most prevalent derivatives of furan are: 2-

Furaldehyde ; Furfuryl alcohol ; 2-Acetylfuran ; 5-Methyl-2-
furaldehyde ; and 5-Hydroxymethyl-2-furaldehyde.

43
 Furan Analysis

The main goal of Furan Analysis is to determine whether the

paper in a given transformer has been or is being damaged by
heat.

Furans produced from temperature buildups are generated in two

ways:

 localized area of high heat and paper damage,

 general overall heating of the entire insulation system.

Thermal, oxidative and hydrolytic breakdown of paper insulation

can be detected through furan analysis.

44
 Furan Analysis

Procedure:

An oil sample is extracted with either another liquid such

as acetonitrile or with a solid phase extraction (SPE)
device.

The extract is analyzed using high performance liquid

chromatography (HPLC). The five most common Furan
compounds are separated and each is detected by use of
an ultraviolet detector adjusted to the appropriate
wavelength for each of the five components.

The results are usually reported in terms of parts per

billion (ppb).

Furan Analysis is more of an indication rather than a

precise measure.

45
 Furan Analysis

Furane derivates

5-hydroxylmethyl-2-furfural (5HMF)
furfuryl alcohol (2FOL)
2-furfural (2FAL)
2-acetyl furan (2ACF)
5-methyl-2-furfural (5MEF)

46
 Furan Compounds

O CHO O COCH3

2-FURFURALDEHYDE 2-ACETYL FURAN

2-FURFURAL (2-FURYL METHYL KETONE)
2-FURALDEHYDE

O CH3 O CHO
COOH

5-METHYL-2-FURFURALDEHYDE
2 FUROIC ACID

O CH2OH
CH2OH O CHO

2 FURFUROL
(FURFURYL ALCOHOL) 5-HYDROXYMETHYL-2-FURFURALDEHYDE

47
 Furan Analysis

Cigr Proceedings WG D1.01.03 (formerly WG 15-01):

48
Furan Analysis

49
Insulation System in Power Transformers

50
DP Values and Remaining Paper Life
according to Fist 3.31
(DP-Degree of Polymerization)

51
 Furan Analysis (FKH)

Example: damaged transformer

Concentration
Furan derivative
[mg / kg] (ppm)

5-hydroxylmethyl-2-furfuran 0.03

2-furfural 3.44

2-acetyl furan 0.02

5-methyl-2-furfural 0.11

furfuryl alcohol 0.48

Total 4.1

DP value in accordance with Cigr Proceedings = 289

52
 Paper Ageing Areas of Uncertainty

State of paper insulation is key assessment for ageing

transformer populations, but there are still considerable
uncertainties arising from:

Uncertain End of Life criterion for DP

DP variations within transformers

[2FAL] v. DP correlation for real transformers

Effects of moisture, other ageing products and [2FAL]

distribution between solid and liquid, e.g. temperature
and oil processing

53
 Standards

The procedure for assessing DP is described in IEC

Publication 450 and ASTM D 4242.

The concentration of 2-furfural (2FAL) in oil can be

assessed according to:
1. IEC 61198 1993 : Mineral insulating oils Methods for the
determination of 2- furfural and related compounds.
2. ASTM D 5837

Furans were extracted from a known volume of oil by

means of liquid / liquid extraction.

A High Performance Liquid Chromatograph (HPLC) with a

diode array detector is used in the measurement.

A portion of the oil extract was analyzed into HPLC.

54
 Transformer Diagnostic
Measurements

Transformer Overview
Life Span and Operating Conditions
Cigre Guide for Transformer Maintenance
Oil Tests Dissolved Gas Analysis,
Degree of Polymerisation (DP) & Furan
Analysis
Overview of CPC100 and Operating Software (Toolset)
Electrical Measurements
Dielectric Dissipation Factor Tan Delta
Dielectric Dissipation Factor - Moisture Content
Partial Discharge
Sweep Frequency Response
Testing Current Transformers
Summary

55