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Review of Transformer On-Line Condition Monitoring

Technical Report · August 2012

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 Review of Transformer On-Line Condition Monitoring
Mohamad Makky, Member, IEEE

Abstract Z is a stochastic vector with m elements, each one

The need to monitor the power transformers corresponding to the impact of a maintenance action
conditions while in operation is crucial for utilities on the lifetime.
due to the importance of transformers in the Electric
Grid. Numerous papers and technical literatures were It is possible that some of the Y 's depend on time or
produced by specialists and scholars addressing for example the magnitude of a short circuit current.
subjects related to Condition Monitoring of power Y can for example depend on the time until the fault
transformers. In this review, transformer failure is discovered or the time until maintenance is done to
patterns and causes will be surveyed. Then a review correct the fault.
of the various techniques of monitoring Dissolved
Gases, Temperature, and Bushing status will be Failure hazard rates of transformers based on thermal
made. modeling and degree of Polymerization (DP) Value
Keywords: Transformer, Transformer lifetime, were elaborated in [2]. Transformers are designed to
Transformer failures, Online Monitoring, Dissolved operate for long period of time (25 to 30 years). A
Gas Analysis, Winding Temperature, Bushing realistic representation of the likelihood of failure of
transformer is shown in the distribution below [3].
Transformer Lifetime
The transformer construction involves many parts
and components that are subject to various physical
phenomena. Therefore the technical life of a
transformer is subject to many variables. The
practical approach is to define study the various lives
related to each physical phenomenon or component
separately. A transformer life can be seen as a sum of
the following lives [1]:

 Thermal Life: Time to critical

decomposition of conductor insulation
 Dielectric Life: Time span to critical
reduction of dielectric safety margin
 Mechanical life: Time to critical mechanical
weakness and deformation of windings
 Life of accessories, especially bushings and
LTC
A lifetime is proposed [2] where the life T, of the
transformer is a stochastic variable, i.e. a stochastic
function that depends on a couple of stochastic
variables with different distributions:
Figure 1: Failure distributions for an onset of
unreliability at 20 years [3]
Transformer Failure Causes
Each of the above transformer life has a set of faults
associated with it depending on the type of function
achieved. In order to draw overall fault trees for the
transformer, we have to go down to the
subcomponent level within the categorized lifetimes
and study the faults of each subcomponent separately.

A fault tree the transformer can be divided into the

following subcomponents:
1- Windings
2- Tank
Where,
3- Bushings
4- Cellulose isolation
X is the lifetime according to the design of the
5- Cooler and oil insulation
transformer measured from the moment when the
6- Tap Changer (if any)
transformer is put into operation until it is shutdown.
Y is a stochastic vector with n elements, each one
corresponding to the impact of one \fault" type on the
lifetime.
The tap changer is also included although this part is Figure 3: Conditions of a transformer in the course of
seen as steering equipment rather than a part of the its life cycle [6]
transformer [4].
Many recorded experiences indicates that the
majority of transformer failure are not due to old age
but due to localized damage or ageing due to some
limitations in design and manufacture, application
and maintenance. Even, sometimes a power
transformer does fail without any warning notice. [7]

On-Line Condition Monitoring

Due to its criticality within the electric power grid,
transformer failures are considered very dangerous,
Figure 2: Fault tree for a transformer, the and utilities try their best to avoid such happening by
transformer's parts [4] applying condition monitoring technologies. The
application of computational intelligence techniques
It worth mentioning that most power distribution [8] and available advanced telecommunication
grids contain lots of transformers that are fitted with technology provided the capability to monitor what is
On Load Tap Changers (OLTC) for the purpose of happening inside the transformer and to interpret that
voltage regulation. Due to their large number of to allow taking the proper decision.
moving parts, OLTCs are also one of the main causes
of failure in High Voltage transformers, leading to
unplanned outages and interruption of supply [5].
A failure in any of the subcomponents will
immediately or gradually lead to a transformer failure
which can cause power outages and other damages
such as fire.

The causes of failure in transformer vary too much as

show below [6]:

 Inherent deficiency: Inadequate

specification, Inadequate design
 Inherited deficiency: Inherent material
defect, Improper factory assembly, Improper Figure 4: Transformer condition assessment
site assembly, Improper maintenance, flowchart [1]
Improper repair, Improper adjustment
 System event: Overload, Load removal, The following conditions can be monitored online
Over-voltage, Resonance, Short-circuit [9]:
 External Event: Vandalism, Impact of  Dissolved Gas in Insulation Oil
external object  Temperature (Top Oil, Winding, Hot Spot,
 Environmental: Lightning, High ambient LTC)
temperature, Low ambient temperature,  Partial Discharge
Rain, water ingress Wind, Seismic and  Voltage and Current
Geomagnetic induced currents.

Dissolved Gas in Insulation Oil

The dissolved gas analysis (DGA) is one of the most
important used diagnostic method to assess the status
of a transformer. The gas is formed in the insulation
oil of an operating transformer due to either electrical
disturbances or thermal decomposition. However,
transformers still generate gases to some extent at
normal operating temperatures. Due to the fact that
the insulating mineral oils of transformers are made
of many different hydrocarbon molecules, they
decompose when are subject to thermal or electrical
faults following a rather complex process which
involves the breaking of carbon-hydrogen and
carbon-carbon bonds. During this process, active
hydrogen atoms and hydrocarbon fragments are
formed. The decomposed atoms will combine with
others and form gases. Also the cellulose insulation
will be subject to decomposition due to heat which in
turn causes the generation of gases.

The key generated gases are hydrogen (H2), methane

(CH4), acetylene (C2H2), ethylene (C2H4), and
ethane (C2H6), carbon monoxide (CO), and carbon
dioxide (CO2) [9].

The most commonly used DGA diagnostic methods

include the following [10][11][12]: Figure 6: Online Oil Monitoring Instruments
Available from Various Vendors [14]
 IEEE C57.104-1991
 IEC 60599
 Duval’s triangle
 Doernenberg method
 Rogers’ method
 Key Gas

Figure 7: Oil Circulation and Gas Extraction

Schematic [15]

Temperature Online Monitoring

Figure 5: Transformer condition assessment
flowchart [13]
Available in market Transformer Online Monitoring
can provide Precise online monitoring of
transformers using multiple fault gas Dissolved Gas
Analysis (DGA). These products offer detailed
IEEE/IEC standards-based diagnostics of any issue
detected.
The thermal performance of the power transformer is
a crucial indicator when we assess its load ability and
usable life. In fact, the condition of winding
temperature is required under all loading conditions
in order for the operator to take the right decision
especially at events such as rapid dynamic load
changes. Also, the accurate measurement of the
winding’s hottest temperature is critical for
calculating the insulation’s rate of aging. The hot spot
temperature is also important in assessing the risk of
bubble evolution and in the short term forecasting of
overload capability. Through on-line comparison of a
measured value such as top-oil temperature and its
calculated value, which is obtained by means of a
physical model, operational problems such as the
malfunction of pumps or fans or pollution of coolers
can be detected [16].

Figure 8: Transformer Online Temperature
Measurements [17]
The winding hot spot temperature within a
transformer is measured using fiber optic sensors
[18]. The Winding temperature is estimated using
existing load current (from Current Transformer), the
oil temperature and other key transformer parameters.
The IEEE C57.91:1995 is the basis of the calculation
and the related algorithm [18].
Temperatures in one, two or three windings are
calculated and displayed based on each winding’s
characteristics. Online Temperature Monitoring
systems can measure main tank and Load Tap
Changer tank temperatures. Both a difference and
deviation difference trend are calculated to detect
contact wear, misalignment, coking, overloading,
locked rotor and other heat generating conditions.
LTC degradation is a long-term effect. Sophisticated
digital filtering techniques and a proprietary LTC
tailoring function are used to avoid false alarms from
short-term changes [17].
Bushing Online Monitoring
Transformer’s Reliability statistics show that on-load
tap changers (OLTC) and bushings are at the origin
of two-thirds of transformer failures [20].
Figure 9: Classification of major failures by
transformer components [20]
The need to online monitor the high voltage bushings
of power transformers being the most endangered
components of the transformer is also important. The
measurement of bushing insulator capacitances and
measurement of the dissipation factor are processed
using advance computation intelligence and
evaluation algorism to determine the operational state
of bushing online [21]. The bushing status can be
assessed as well by monitoring and measurement of
the tan δ which gives an indication of the quality of
the insulation and its sensitivity to temperature and
voltage changes [22].
Combined Online Monitoring
Many manufacturers have proposed combined online
monitoring systems for transformers which offer
comprehensive solution. Utilities are still cautious
when it comes to such systems due to that that these
systems either have being operating for relatively
short time or have never been tried before.
Figure 10: Oil Circulation and Gas Extraction
Schematic [23]
Conclusion
The available transformer online condition
monitoring systems play a good role in the preventive
maintenance and life extension. Great deal of studies,
experiments and applications were done in this
expanding field. With the fast paced technological
development in telecommunication, signal processing
and data management which makes economical
superior system available to us, we expect that
Transformer Condition Monitoring to reach new
heights. The area of providing comprehensive
condition monitoring system covering all components
and lifetimes of the transformers is still lagging
behind. With the collaboration and efforts of
researchers, manufacturers and utilities’ operators we
may see convenient commercial overall transformer
condition monitoring in the market soon.
References
[1] Victor Sokolov, Zalya Berler, "Transformer
Condition- Based Ranking On The Basis Of
Design Review And Comprehensive Oil
Analysis"
[2] P. JARMAN, Z. WANG, Q. ZHONG, T.
ISHAK, “End-Of-Life Modelling For Power
Transformers In Aged Power System
Networks” CIGRE Paper C105
[3] J. A. LAPWORTH, "Transformer Reliability
 Surveys" CIGRE A2-114 Changer and Insulation System"
[4] Anna Franzén, Sabina Karlsson, "Failure [22] George Binas, Jeff Benach, "Transformer
Modes and Effects Analysis of Transformers" Bushing Monitoring - A Case History"
[23] QUALITROL® 509 DW "Intelligent
[5] D. McPhail, "Condition Analysis and transformer monitor with direct winding"
Assessment of On Load Tap Changer Acoustic
Monitoring Principles and Techniques" Mohamad Makky, received the B.S. degree in electrical
engineering from the American University of Beirut and
[6] CIGRE Working Group 12.18, “Guidelines for pursuing M. Eng. in Quality Systems Engineering at
Life Management Techniques for Power Concordia University, Montreal. He worked in the domain
Transformers” of construction of Switchyards and other transmission
projects with ABB and other contractors. Currently, he is
[7] H. Ding, R. Heywood, J. Lapworth, and S. working in the project management of the AC Substations
of the Lower Churchill Project in Newfoundland Canada .
Ryder, “Why Transformers Fail”
[8] Tang, W.H., Wu, Q.H., "Condition Monitoring
and Assessment of Power Transformers Using
Computational Intelligence", Springer
[9] A. Kingsmill, S. Jones, J.G. Zhu, "Application
Of New Condition Monitoring Technologies
In The Electricity Transmission Industry"
[10] Tapan K. Saha, "Review of Modern
Diagnostic Techniques for Assessing
Insulation Condition in Aged Transformers"
[11] N.A. Muhamad, B.T. Phung, T.R. Blackburn,
K.X Lai, "Comparative Study and Analysis of
DGA Methods for Transformer Mineral Oil"
[12] C57.104.1991, I., IEEE Guide for
Interpretation of Gases Generated in Oil-
Immersed Transformer
[13] Adam Junid, Simin Li, Lingfeng Li,
"Dissolved Gas Analysis and Its Interpretation
Techniques for Power Transformers"
[14] Tim Catgol, "An Overview of Online Oil
Monitoring Technolohies"
[15] SEVERON, "On-Line Transformer Monitor
Installation Guide Model TM Series"
[16] Rummiya Vilaithong, Stefan Tenbohlen,
Tobias Stirl, "Investigation of Different Top-
oil Temperature Models for On-line
Monitoring System of Power Transformer"
[17] QUALITROL® 509 ITM Brochure
[18] M. Sun, T. Stapleton, L. Shaver, “Monitoring
of Power Transformer Winding Temperature
Using Robust Fiberoptic Sensing System,”
[19] C57.91-1995 - IEEE Guide for Loading
Mineral-Oil-Immersed Transformers
[20] P. Picher, S. Riendeau, M. Gauvin, F.
Léonard, L. Dupont, J. Goulet, C. Rajotte
“New technologies for monitoring transformer
tap-changers and bushings and their
integration into a modern IT infrastructure”
CIGRE A2.101
[21] Tobias Stirl, Raimund Skrzypek, Stefan
Tenbohlen*, Rummiya Vilaithong, "On-line
Condition Monitoring and Diagnosis for
Power Transformers their Bushings, Tap

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