CASE STUDY ABOUT TRANSFORMER OIL TESTING

Introduction
In power supply utilities and industrial consumers of electricity, the fault-free operation of power transformers is
a factor of significant economic importance and safety. In the current economic climate, industries/supply utilities
tighten their control on capital spending and make reductions in maintenance, and an increased awareness is placed
on the reliability of the existing electric power supply. Downtime is extremely rare. The loading of current units is
frequently increased because doing so delays the need to buy more plant capacity. As a result, the transformer is put
under more stress. To ensure reliability, the net total effect of the thermal, electrical, and mechanical stress caused
by increased service must be tracked. Regular insulation oil sampling and testing from transformers is a useful
technique in a preventative maintenance program.
Transformer oil, commonly referred to as insulating oil, is a unique kind of oil with exceptional electrical
insulating qualities and great temperature stability. In oil-filled electrical power transformers, transformer oil is
used to insulate, prevent arcing and corona discharge, and to disperse heat.
The transformer's core and windings, which are completely submerged in the oil, are likewise preserved using
transformer oil. The insulating oil's capacity to stop the oxidation of cellulose-based paper insulation is another
crucial quality. The transformer oil functions as a barrier to prevent direct contact between the oxygen in the air and
the cellulose, so reducing oxidation. Utilizing a MOG, the level of transformer oil is routinely determined
(Magnetic Oil level Guage).

Problem
Transformers play a crucial role in both the distribution and transmission of electrical power. Early transformer
problem detection saves a ton of money by preventing unanticipated outages. Small amounts of gases are released
when insulating oils breakdown as a result of anomalous electrical or thermal stresses; the type of fault determines
the breakdown gases' qualitative composition.
Here are some of the most typical problems that can happen when checking transformer oil:

Fault. Key Gas Results

Corona discharge Hydrogen Low energy discharges create methane and hydrogen and smaller
quantities of
ethylene and ethane.
Arcing Acetylene Large amounts of hydrogen or acetylene or minor quantities of ethylene and methane can
be produced.
Overheated Cellulose Carbon Monoxide If cellulose is overheated, then it will produce carbon monoxide
Overheated Oil Methane and EthyleneOverheating oil will produce methane and ethylene (300 degrees F) or
methane and hydrogen (1,112 degrees F). Traces of acetylene might be created if the unit has electrical contacts or
if the problem is severe

Testing transformer oil is crucial for

Identify the fundamental electrical characteristics of transformer oil.

Determine whether a particular oil can be used in the future.
Determine whether filtration or regeneration is required.
Reduce the price of oil and lengthen component life
Reduce unforeseen breakdowns and increase safety

Solution

The most sensitive and reliable technique used for evaluating the health of oil filled electrical equipment is
dissolved gas analysis (DGA).
The investigation of dissolved gases in transformer oil is known as dissolved gas analysis (DGA). It’s also known
as a DGA test. Due to the breakdown of the transformer oil, certain gases are created whenever an extraordinary
amount of thermal and electrical stress is placed on a transformer. When a fault is severe, there is a substantial
amount of decomposed gas generation, and this gas is collected in a Buchholz relay. The gasses caused by the
breakdown of transformer insulating oil, however, will have ample time to dissolve in the oil when abnormal
thermal and electrical stresses are not significantly high.
Therefore, it is not possible to forecast the state of the electrical power transformer’s overall internal health by
simply monitoring the Buchholz relay. This makes it vital to examine the variety of gases dissolved in transformer.
oil that is currently in use. One can forecast the actual state of a transformer’s internal health using DGA of
transformer oil.
To gather historical data on the internal condition of a transformer over its lifetime, it is recommended to routinely
perform the DGA test on transformer oil. During a DGA test, the gases in oil are separated and studied to ascertain
how many gases are present in a given volume of oil. You may determine the transformer’s internal state by
looking at the proportions of the various gases in the oil.

INTERPRETATION OF GAS ANALYSIS RESULTS

There are various international guidelines on interpreting dissolved gas analysis (DGA) data. These guidelines show that the interpretation
of DGA is more of an art than an exact science.

Some of these guidelines are :

Dornenburg Ratio Method

Rogers Ratio Method (Table 1)
BS 5800/iec 599 Ratio Method (Figure 1)
Key Gas Method - Doble Engineering (Figure 1)
Amount of Key Gases - CSUS (Table 2)
Total Combustible Gases-Westinghouse (Table 3)
Combustible Concentration Limits
CEGB/ANSI/IEEE (Table 4)
HYDRO QUEBEC – Canada (Table 5)
BBC - Switzerland (Table 5)
OY STROMBERG - Finland (Table 5)
SECR - Japan (Table 5)
EDF - France (Table 7)

The combustible Concentration Limits differ from country to country, continent to continent and transformer to transformer. It is not
practical to set concentration limits because of the many variations involved.

The Gas Concentrations in the oil depend upon :

The volume of oil involved (dilution factors)

The age of the transformer (new or old)
The type of transformer (Generator or Transmission)
(Sealed or free breathing)
(Construction of Tap changer)

Interpretation and Historical Data

TCS has one of the most comprehensive insulating oil data management systems and interpretation guide. This system
does graphical trend analysis for gas-in-oil data. The reports contain recommended action based on the latest accepted
guidelines and TCS's extensive experience. TCS will maintain all customers historical records. These data are used to update
and improve the diagnostic process. Results
All reports this included Graphs can be e-mailed to the customer ie full integration with Microsoft Office 2000.

Transformer Chemistry Services method of interpretation is based upon :

• Key gases : CSUS values (Age compensated)

• BS 5800/IEC 599 ratios (providing the Total Combustible Gases present are above 300 ppm)

• Rogers Ratio’s

• Trend (Production rates of gases) Morgan-Schaffer Tables

• Total Combustible Gas Production Rates TDCG(c57.104-1991)

• Total Combustible Gas Westinghouse Guidelines

• Age of transformer.
• History of transformer (Repaired, degasses, etc).

TABLE 2
CALIFORNIA STATE UNIVERSITY
SACREMENTO
GUIDELINES FOR COMBUSTIBLE GAS

GAS NORMAL ABNORMAL INTERPRETATION

H2 < 150 ppm > 1000 ppm Arcing corona
CH4 < 25 ppm > 80 ppm Sparking
C2H6 < 10 ppm > 35 ppm Local Overheating
C2H4 < 20 ppm > 100 ppm Severe Overheating
C2H2 < 15 ppm > 70 ppm Arcing
CO < 500 ppm > 1000 ppm Severe Overloading
CO2 < 10 000 ppm > 15 000ppm Severe Overloading
N2 1-10 % NA -
O2 0.03 % > 0.5 % Combustibles

Recommended Safe Fault Gas Levels in Oil Immersed Equipment (max., ppm)
Gas Dornenburg/Stritt. IEEE Bureau of Reclam. Age Compensated
Hydrogen 200 100 500 20n+50
Methane 50 120 125 20n+50
Ethane 35 65 75 20n+50
Ethylene 80 50 175 20n+50
Acetylene 5 35 7 5n+10
Carbon 500 350 750 25+500
Monoxide 720 110n+710
TDCG(tot. 6000 2500 10000 100n+1500
above) n=yrs in service
Carbon
Dioxide
 TABLE 3

WESTINGHOUSE
GUIDELINES ON
TOTAL COMBUSTIBLE GASES(TCG)

TOTAL COMBUSTIBLE RECOMMENDED ACTION

GASSES

0 - 500 ppm Normal Aging

Analyse again in 6-12 months

501 to 1200 ppm Decomposition maybe in excess of

normal aging
Analyse again in 3 months

1201 to 2500 ppm More than normal decomposition

Analyse in 1 month

2500 ppm and above Make weekly analysis to determine

gas production rates
Contact manufacturer

Combustible gas generation in service also has to be determined. A generation of above 100ppm combustible gases in a
24hour period merits attention. Weekly or monthly samples may be necessary.

Actions based on TDCG(c57.104-1991)

Sampling intervals and Operating for Corresponding Gas Generation Rates

TDCG Levels TDCG rates Sampling Operating Procedure

(ppm) (ppm/day) Interval
>30 Daily Consider removal of service

10-30 Daily Advise Manufacturer

Condition 4 >4630
Exercise extreme Caution.
<10 Weekly Analyse for individual gases
Plan outage. Advise manufacturer
>30 Weekly Exercise extreme caution
Plan outage
Condition 3 1921-4630
10-30 Weekly Analyse for individual gases

<10 Monthly Advise manufacturer

>30 Monthly Exercise extreme caution
Plan outage
Condition 2 721-1920
10-30 Monthly Analyse for individual gases
 <10 Quarterly Advise manufacturer
>30 Monthly Exercise extreme Caution.
Analyse for individual gases
Determine load dependence
Condition 1 ≤ 720
10-30 Quarterly Exercise extreme Caution.
Analyse for individual gases
Determine load dependence

<10 Annually Continue a normal operation

TABLE 4
CEGB/ANSI/1EEE GUIDE FOR GAS CONCENTRATION LIMITS IN PPM V/V

GAS GENERATOR TRANSMISSION

TRANSFORMERS
H2 240y 100
C0 580 350
CH4 160 120
C2H6 115 65
C2H4 190 30
C2H2 11 35

TABLE 5
OTHER INTERNATIONAL GAS CONCENTRATION LIMITS
IN PPM V/V

GAS HYDRO QUEBEC BBC OY STROMBERG

CANADA SWITZERLAND FINLAND
H2 250 200 100
CO 850 1000 500
CH4 33 50 100
C2H6 15 15 150
C2H4 40 60 100
C2H2 25 15 30

TABLE 6
SECR - JAPAN
LIMITING VALUES
IN PPM V/V

GAS TRANSFORMERS TRANSFORMERS TRANSFORMERS

>275kV & >10MVA >275kV & <10MVA >500 kV
H2 400 400 300
CO 300 300 200
CH4 150 200 100
C2H6 150 150 50
C2H4 200 300 100
TCG 700 1000 400

TABLE 7
EDF - FRANCE
TRANSMISSION TRANSFORMERS WITHOUT ON-LOAD TAP CHANGERS

GAS GENERATOR TRANSMISSION

TRANSFORMERS TRANSFORMERS
H2 33 130
C0 770 1000
CH4 44 130
 C2H6 33 150
C2H4 11 44
C2H2 0.4 0.4

TABLE 1

Notes 1. - For the purpose of this table there will be a tendency for the ratio C2H2 to rise from a value between 0.1 and 3 to above 3 and
C2H4

for the ratio C2H4 from a value between 0.1 and 3 as the spark develops in intensity.
C2H6

2. - In this case the gases come mainly from the decomposition of the solid insulation, this explains the value of the ratio C2H4
 C2H6

3. - This fault condition is normally indicated by increasing gas concentrations. Ratio CH4 is normally about 1; the actual level of
H2

temperature and oil quality.

4. - An increasing value of the amount of C2H2 may indicate that the hot point temperature is higher than 1000°C
.
General remarks: 1) Significant values quoted for ratios should be regarded as typical only.
2) Transformers fitted with in-tank on-load tap-changers may indicates faults of Type 202/102 depending on
seepage or transmission of arc decomposition products in the diverter switchtank into the transformer tank oil. 3)
Combinations of the ratios not included in Table 1 may occur in practice. Consideration is being given to the
interpretation of such combinations.

SUGGESTED DIAGNOSIS FROM GAS RATIOS-ROGERS

RATIO METHOD

CH 4 C2H6 C2H4 C2H2

H2 CH4 C2H6 C2H4 Suggested Diagnosis

>0.1 <1.0 <1.0 <0.5 Normal

<1.0
≤0.1 <1.0 <1.0 <0.5 Partial Discharge corona

≤0.1 <1.0 1.0 ≥0.5 or ≥3.0 Partial Discharge- corona

<3.0 with tracking
>0.1 <1.0 ≥3.0 ≥3.0 Continuous discharge
<1.0
>1.0 <1.0 ≥1.0 or ≥3.0 ≥0.5 or ≥3.0 Arc - with power follow through
<1.0 <3.0 <3.0
>1.0 <1.0 <1.0 ≥0.5 Arc - no power follow through
<1.0 <3.0
≥1.0 or ≥3.0 <1.0 <1.0 <0.5 Slight Overheating- to
<3.0 150°c
≥1.0 or ≥3.0 ≥1.0 <1.0 <0.5 Overheating 150°-200°C
<3.0
>0.1 ≥1.0 <1.0 <0.5 Overheating 200°-300°C
<1.0
>0.1 >1.0 ≥1.0 <0.5 General conductor overheating
<1.0 <3.0
≥1.0 <1.0 ≥1.0 <0.5 Circulating currents in
<3.0 <3.0 windings
≥1.0 <1.0 ≥3.0 <0.5 Circulating currents core
<3.0 and tank; overloaded
joints

Fault gas generation rates for transformer

with 50 m3 of oil
Normal Serious
H2 Less than 0.1 ppm/day more than 2ppm/day
CH4 0.05 6
C2H2 0.05 6
C2H4 0.05 6
 C2H6 0.05 1
CO 2 10
CO2 6 20

CONCLUSION

A novel method for locating issues within a transformer is to examine the insulating oil removed from them.

The transformer’s status can be tracked by detecting and measuring the gases present in the oil.

If flaws are discovered, outages can be planned and the defect fixed before more significant damage occurs.

Transformer oil gas analysis interpretation is still an art and not a precise science. It is best to let a professional interpret the results, and to
heed his suggestions. Regular sample collection and record keeping are required.