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Real State Gas-Monitoring Better diagnosis of transformers!

Air entrained and gaseous reactants generated when the insulation system is loaded, form the transformer gases. Transformer gases whether solved or not solved in oil are subject to gas exchange processes and represent, in their entirety, the gas balance of the oil transformers. Measurement and evaluation of the transformer gas for the purpose of condition monitoring are summarised under the term "transformer diagnosis by gas analysis". Among the various diagnostic procedures available the above method is the preferred method for the early detection of faults because it ensures an integral approach to the condition of the core-andcoil assembly. The company's concept covers an integral approach to the transformer gases both with regard to the diagnostic laboratory procedure and the customised development of efficient online monitoring systems. Real State Gas-Monitoring Better diagnosis of transformers! Air entrained and gaseous reactants generated when the insulation system is loaded, form the transformer gases. Transformer gases whether solved or not solved in oil are subject to gas exchange processes and represent, in their entirety, the gas balance of the oil transformers. Measurement and evaluation of the transformer gas for the purpose of condition monitoring are summarised under the term "transformer diagnosis by gas analysis". Among the various diagnostic procedures available the above method is the preferred method for the early detection of faults because it ensures an integral approach to the condition of the core-andcoil assembly. The company's concept covers an integral approach to the transformer gases both with regard to the diagnostic laboratory procedure and the customised development of efficient online monitoring systems.

Improved evaluation of open type transformers according to IEC 60599 1.Starting situation The norm for the interpretation of the analysis of dissolved and free gases is aimed at closed transformers. The differences

between open and closed transformers are only small, so that uniform criteria apply, whose value ranges were defined without consideration of differences. A remark in Section 6.1 of course admits the influence of the open type construction, which then, according to the norm, affect all criteria. The desirable identification of possible influences of the open type construction requires its quantification. 2.Quantification of the open type construction Many years of experience with TGM resaturation measurements after degassing give a detailed insight into the gas household. Fig.1 shows the typical concentration slopes of selected gases till nitrogen saturation. The saturation concentration is nearly 66,000 ppm N2 10% and corresponds to the solubility of the nitrogen of the air, which means that the air composition is nearly given for the gas room of the conservator. The saturation concentration depends on the altitude of the transformer location as well as on the oil temperature. The time till the saturation is determined by the constructive features of the transformer, the installation conditions as well as the main operating regime. The N2 concentration slope can described sufficiently accurately with an exponential function. So the inert gas nitrogen fulfils all prerequisites to enable the open type construction to be quantified.

Fig.1 Resaturation measurement on an open type transformer In practice, very different resaturation times are measured. They are dependent on the starting N2 emission rate. The standardisation of the rate for the transformer found to be the least open leads to the transformer openness number (TON), which represents a dimensionless measuring number for the quantification of the open type construction. It is individual and fundamental both for the transport of the atmospheric gases into the tank and for transport of the fault gases into the conservator. For the investigated transformers, the TONs vary from 1 (little open) to 9.2 (very open). In comparison to this, the TON for transformers with a tight air bag is nearly 0.01. Transformer openness number allows the gas consumption or gas emission rates from stationary gas concentration levels to be determined. 3.Oxygen consumption (OCR) Fig.1 also shows the behaviour of oxygen. The concentration of

the chemically active oxygen shows, in difference to nitrogen, dependencies on the aging state of the insulating system, which can lead to a significant decrease to less than the saturation concentration (nearly 32,000 ppm). Load/temperature changes are visible through reversible concentration changes (e.g. summer/winter) influences. The oxygen decrease is checked in the norm with the help of the quotient O2/N2 < 0.3 (identical < 20,000 ppm O2 as an orientation value) and evaluated (accelerated oxidation reaction). This reflects the balance between oxygen entry and consumption, the latter quantifies the oxidation reactions. The oxygen entry can be determined from the exponential function for nitrogen with the help of the difference between calculated saturation concentration and measured concentration of oxygen (cO2). Fig.2 shows the curves for the oxygen consumption (ppm O2/week) determined OCR values for the investigated calculated on this basis as a function of TON and CO2.

Fig.2 Oxygen consumption in open transformers The transformers are between 3 ppm O2/w (new start) and 2860 ppm O2/w (stressed industry transformer). The risk of raised OCR values (> 500 1000 ppm O2/w) begins at cO2 < 28,000 ppm. In this case, it is recommended to make an accurate determination with the known TON. For open type transformers, instead of an orientation value for the oxygen concentration, the oxygen consumption is used as an individual measure of the aging acceleration for the first time. This can be used for activities of substance conservation.

4.Gas emission rate (GER) for fault gases of little solubility in oil Fig.1 shows the different behaviour of the fault gases. The carbon dioxide, which is well soluble in oil, increases steadily during the monitoring time, in the same way as in a closed transformer, which would also apply to the hydrocarbons, which are well soluble in oil. However, due to the losses caused by the open type construction, the fault gases hydrogen and carbon monoxide, which dissolve only little, show stationary levels. So it is not possible to determine the GER through difference measurements according to the norm. The functional relation between fault gas concentration (cFG) and gas emission rate can be inferred on basis of the transformer openness number. The curves for hydrogen and carbon monoxide (Fig.3) result from suspect cFG values and post installation hermetic sealing of determined GER values. The risk of increased GER values (> 5 ppm H2/w or > 50 ppm CO/w) begins with cH2 > 40 ppm or cCO > 400 ppm. In this case, the accurate determination with the known TON is recommended.

Fig.3 Gas emission rate of small oil soluble fault gases Practical examples for quotients of fault gases with good oil solubility and little oil solubility (C2H2/H2, CO2/CO) show suitable diagnostic results on the basis of GER values. Concentration quotients can be too high up to factor 10. The same has to be considered for each diagnostic scheme in which is hydrogen involved. Concentrations of fault gases with little solubility in oil are not suitable for diagnoses; however the gas emission rates

which show the presence of the fault and allow the determination of the fault type, are.

Fault Gas Triangle for Transformer Diagnostics 1. Situation for Diagnostics IEC 60599 describes transformer diagnostics on the basis of gases which are dissolved in oil and free. The study of several years of statistics of gas chromatographic laboratory analyses (DGA) with 5 (H , CH , C H , C H , C H ) or 7 (additionally C H , C H ) fault gases has led to value ranges for three quotients dependent on types of fault. The practical application with the help DGA interpretation tables for the determination of the six types of faults is supported by diagrams showing these quotients. What is visually more interesting is the Duval triangle which is also listed and uses a diagram of the fault gases CH , C H and C H that is transformed to 100%, thus using the different energy densities of formation for diagnostics. The triangle can be used directly in its visual form and shows that diagnostics is also possible with three fault gases only. In practice, this can lead to diagnostic problems, e.g. in case of partial discharge and of leakages in OLTC vessels. The reason is that hydrogen is not included.
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2. Online Diagnostics with the Fault Gas Triangle A new, powerful tool for diagnostics has been developed. It is based on the assignment of the gases to the main fault types: H - partial discharge CH - electrical discharge CH + - thermal fault Here CH + is the newly introduced parameter "monitoring sum of hydrocarbons". It is the weighted sum of the hydrocarbons CH , C H , C H , C H and C H . This sum can be measured directly with a sensor or calculated from a full analysis. Using the three dominant fault gases of the main fault types allows the fault gas triangle (FGT) shown in Fig. 1 to be created.
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Fig. 1 Fault Gas Triangle for the diagnostics after IEC 60599 diagnostic point of the operating example The result is a closed diagram which includes all fault gases. For the practical application of the gas triangle, it makes no difference whether the monitoring sum is measured with a sensor or calculated with the help of laboratory analyses. The concentrations of CH +, H and C H are transformed to 100% and then the registration in the fault gas triangle made. The conditions of use are the ones laid down in the standard: typical concentration values of the fault gases, additionally online CH + > 200 ppm and the gas production rates known. For free gases of the Buchholz relay, it is necessary to use a modified procedure: first they are tested in terms of the equilibrium criterion, then they are corrected to the original composition on the fault location and finally the CH + content is calculated from them. For diagnoses it is necessary to visualise the fault types. This can be done using the .diagnostic schemes (IEC 60599, MSS, Rogers, etc.) known. The marked areas in the fault gas triangle in Fig. 1 were calculated for the six fault types from the value ranges of IEC 60599.
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TGM-D) "/> Fig. 2 Operating diagram for the online diagnostics (TGM-D )
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3. Practical use The typical application of the fault gas triangle can be demonstrated by a practical example. The operating diagram of a suspect industrial transformer is shown in Fig. 2. The TGM-D contains a sensor block which can measure the CH + content directly. Additionally, an external laboratory analysis of the first fault period (EGS ), 09.07.2008) is shown in the diagram. On 02.09.2008, the second fault period begins, first seen in the operating diagram through the presence of CH + and then later of H . The measured results are displayed in the fault gas triangle: TGM-D of 09.07.2008 1, EGS of 09.07.2008 2, TGM-D of 20.09.2008 3). Fig. 1 shows that all three diagnostic points are in area T3. The EGS analysis of 09.07.2008 on basis of IEC 60599 with the evaluating procedure known leads to the same result T3. The fault gas triangle offers the following advantages for diagnostic purposes:
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reduced number of sensors for online gas monitoring with visualised diagnostics (TGM-D ) visualised presentation of laboratory analyses of suspect transformers
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The discussion about the influences which analytical mistakes, the open type of transformers or accumulated faults as well as the tightness of the OLTC vessel may have becomes easier. The application of the fault gas triangle will lead to statistics of the fault types which are independent of the diagnostic schemes known. This will open up new possibilities for better diagnostic

performance.
1) Transformer Gas Monitor TGM-D and Extraction Gas Sampler EGS are GATRON products, which are quality controlled (N2IS based ! ).

Post-installation hermetic sealing of oil transformers with the Breathing Buffer Box G3B 1.Starting point Apart from water, also oxygen is known as an aging accelerator which must be kept away from thermally or electrically stressed oil/cellulose insulations. The influence of oxygen on the aging of the oil can be suppressed through inhibitors. The acceleration of the degradation of cellulose begins with advanced thermal degradation and is thus dependent on the stress at an increased age. Therefore post-installation hermetic sealing for transformers of the open type can also have the effect of preserving the substance in later operating years. Post-installation hermetic sealing is also of interest where hermetic sealing that is no longer tight needs to be replaced or secured. At newly built transformers, hermetic sealing techniques have been known for a long time, such as N2 cushion, airbag and stretching radiator. However techniques of post-installation hermetic sealing are current innovative solutions, such as Trafoseal and OxyBan. These solutions substitute the short connection from the top of the vessel with a longer one from the bottom of the vessel to the conservator. This is the basis for a diffusion barrier, which stops the continued supply of oxygen from the atmosphere. As a result, vessel oils with an oxygen deficit can show oxygen reduction up to complete disappearance. Trafoseal and OxyBan can be cheap alternatives to retrofitting airbags. Such a reconstruction requires the shutdown of the transformer and changes to the safety-relevant concept of the Buchholz relay position. 2.The principle of the Breathing Buffer Box

In connection with the transformer with an N2 cushion, also

transformers of the open type with a conservator can be changed into this operation mode. Fig. 1 shows the principle of the Breathing Buffer Box (G3B of GATRON GmbH) for this purpose. This is integrated in the breathing line between the conservator and moisture adsorber in such a way that an outer cylinder with the conservator and a bottomless inner cylinder with the moisture adsorber are connected. The box is partly filled with oil. A vertically fixed pipe on the mantle of the inner cylinder which extends into the inner cylinder at the top and is shorter than the mantle at the bottom takes over the gas transport when the upper (u) or lower (l) end position of the inner oil level is reached. Changes in the oil level in the conservator due to changes of the vessel oil temperature cause a modification of the pressure in the connected gas room conservator/outer cylinder (inner air), which leads to a shift of the oil levels in the inner and outer cylinders between the end positions. The design of the G3B is such that one unit can accommodate the thermally-caused volume change of 5 m3 oil for a temperature difference (Tu - Tl) of 30 C. Dependent on the oil volume of the transformer, this can be done by connecting several G3Bs in parallel. The oil filling of G3B provides the storage volume for minimal changes in pressure (up to 50 mbar) and serves at the same time as a diffusion barrier for gases, particularly oxygen, as well as for moisture. The latter may be additionally supported by floats in the inner cylinder. Dependent on the oxygen deficit, the G3B installation on transformers of the open type in the state of air saturation leads to a decrease in the O2 concentration in the vessel oil. This also includes the inner air which has expanded contact with the conservator oil exchanging with the vessel oil through convection. So, in turn, the O2 deficit in the vessel oil has an effect on the inner air. Hermetic sealing is reached when the O2 concentration is <2000 ppm and the inner air practically consists of nitrogen. 3.Practical application

Because of little available space, a system of 4 x G3B equipment was installed on a transformer as a column (Fig. 2) for a target volume of 18.7 m3 of oil. The total weight of about 800 kg required a reinforced ground grid. Moreover, insulation was necessary for protection against weather influences. All this is possible without shutting down the transformer. Fig. 3 shows the operating diagram of the TGM monitoring since the G3B installation on 18.09.2008. After degassing, the transformer was considered to be in the resaturation phase till the middle of January 2009 (N2 70,000 ppm) with a typical O2 deficit of nearly 18,000 ppm. This phase is characterised by the fact that the oil level in the inner cylinder of the G3B reaches the lower end position as the vessel oil constantly absorbs air, which generates an underpressure and a supply of outer air. This is almost the same as the operation without G3B.

After nitrogen saturation, the vessel oil only absorbs oxygen, which decreases the supply of outer air significantly.

Fig. 3 Resaturation slope with G3B The visible O2 decrease in the oil begins now and leads to < 2000 ppm if sufficient operating time is allowed. In the opposite direction, N2 partial pressure increases in the inner air, which leads to increased N2 concentrations in the oil, up to the saturation value for nitrogen at atmospheric pressure. This is where the real hermetic sealing begins. The G3B technique can be coupled with an N2 pressure gas bottle via a level measurement in the inner cylinder. In the lower end position, dry N2 gas can be fed in instead of outer air getting in. This combination allows the number of G3Bs to be minimized at given transformers as well as the hermetic sealing of newly built transformers to be guaranteed from the beginning.

Determination of the fault type from Buchholz gas analyses 1.Practice of the Buchholz gas IEC 60599 describes the Buchholz gas in detail. The conditions of formation and the gas exchange determine the composition of the Buchholz gases. While the fault type and spontaneity are of decisive importance for the formation, the gas exchange is dependent on the way the bubbles take through the oil and the degree of gas saturation. As the free original gas is not accessible for direct analysis on the fault location, the well-known quotient criterion is used for the diagnosis of dissolved gases. The composition of the original fault gas is identical to its composition when completely dissolved in the oil. Despite the gas exchange, each Buchholz gas actually provides information direct from the fault location as long as the equilibrium state of the oil is still far way enough from being reached. According to the standard, this is checked with the help of the equilibrium criterion by calculating the concentrations in the oil from the Buchholz gas analysis using solubility coefficients and by comparing with a simultaneous gas-in-oil analysis (DGA). This is hard to achieve in practice because organisational and technical measures prior to sampling often take several hours. The standard states that the Buchholz gases need to be sampled immediately after signalisation. Consequently, there is a risk that gases which dissolve well are lost for analysis. The calculation of fault gas quotients which the standard uses to determine the fault type is based on the oil concentrations of the fault gases derived from the Buchholz gas, which applies in equilibrium state. This means that the direct information from the Buchholz gas on the fault location remains unused. 2.Use of the diagnostic potential

The diagnostic potential of the Buchholz gas cannot be used completely unless the time after sampling is short and a correction to the original composition on the fault location is made. The techniques for the sampling of Buchholz gases which IEC 60567 describes have no influence on the time that elapses between sampling and signalisation. This can partly be achieved using the gas extraction device ZG 1.1 (EMB GmbH), which is installed on the transformer yet has to be operated manually. Only gas collectors which work automatically can meet the requirements completely. Fig.1 shows the TGM (GATRON GmbH) as an integrated solution. The Buchholz gas is transferred to the gas collector from the Buchholz relay immediately after signalisation and made available for sampling at the foot of the transformer separated from the oil. For this purpose, the TGM contains a Buchholz Gas Sampler (BGS). In order to consider the actual gas exchange of the Buchholz gases with the vessel oil for a correction, a model of bubble rising in air-containing oil been developed. The model is based on the fact that the air is desorbed from the oil in the same way as the fault gases are absorbed by the oil. Extensive model calculations consider the parameters initial bubble size and composition as well as oil quantity, air saturation and temperature. The point of interest is the graphs of the absorption and desorption quotients. The quotient of the fault gases increases logarithmically with the oil quantity whereas the O2 / N2 quotient falls in linear way. This formed the basis for the development of a correction procedure (E. Brsel et.al.; Neue Hilfsmittel zur Diagnoseeignung von Gasen aus dem Buchholzrelais; Elektrizittswirtschaft 25/99, S. 1624).

3.Practical application In case of a gas alarm, the transfer of Buchholz gas into the gas collector via a potential-free contact is started on the TGM location. Simultaneously, the Buchholz gas is transported direct into the gas space of the equilibrium column. A quick analysis on the basis of an online hydrogen difference measurement compared to the equilibrium gas is made. This yields the result fault gas or air. The TGM functionality also includes the daily check of the Buchholz relay in terms of gas collection and automatic hydrogen measuring. In case of Buchholz warning, the total accumulated gas volume is also determined when the automatic de-airing is finally performed. For the determination of the fault type, the BGS is used to take a sample from the gas collector which is then analysed in the laboratory together with an oil sample. The results serve to determine all the fault gases involved in the fault on the basis of the equilibrium criterion and to establish the number of oil contacts from the air quotients in the Buchholz gas and oil. Starting from the Buchholz gas, this number allows the quotients of the original fault gas to be calculated.

Fig. 2 shows the changes in the fault gas quotients including the quotients for carbon oxides which are used in IEC 60599. The quotients of all gases are set on bubble start to the standardised value 1. From the number of oil contacts (model parameters) to the Buchholz relay, the quotients change differently, which is due to the differences in their solubility coefficients. As an example of a correction, a number of 40 oil contacts can be assumed to be representative for a spontaneous gas collection on the Buchholz relay. With the help of the quotient lines, the reciprocal correction factors have to be calculated. The

quotients determined in the Buchholz gas are then divided by them to obtain the quotients on the fault location. In the present case, the fault gas quotients of the fault location and the Buchholz relay would differ by up to two times power of 10. The diagnostic limits set do not consider this. Thus it is only the quotients on the fault location (original fault gas) which are suited to determine the fault type according to Table 2 of the standard or to show the fault type with the help of the Fault Gas Triangle (GATRON GmbH).

EGS-Method (EP 1790965) Sampling Integrated Extraction according to IEC 60475 / 60567

EGS filling Rotary oil flow

EGS sealing Exact air volume

Stop:

No opening for oil dosing in gas extraction unit ! Check of sealing ring Laboratory registration

Go!

Gas extraction helper Defined equilibrium

Measuring of gas pressure Before direct dosing in the gas chromatograph

Advantages of Evaluation of EGS Results: Accuracy / Correctness N IS based ! (hermetical conditions) simultaneous supposition for:
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Autosampler / GC Coupling

high temporal resolution (actuality) determination of openness (correction with TON)

Fehlerdiagnostik Current original fault gas Gas Emission Rate (GER)

Aging Diagnostics Current oxygen decrease Oxygen Consumption Rate (OCR) Fault Gas Triangle according to IEC 6059

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Diagnoses according to IEC 60599

Risk factors DGA: coordinates = original rates 1. non-hermetical sampling NIS based (control) 2. openness resaturation slope (correction) coordinates = original concentrations 3. oil way / standing time gas / oil separation (correction) + CO2 / CO correction + solution pressure + oxygen consumption rate Risk of false diagnoses according to IEC 60599 Quality assured gas analyses for transformer diagnostics are necessary to include all gases in the diagnostics. Only in this way can its complete efficiency be ensured. In practice there is

BGA:

a risk of false diagnoses through the big differences in the solubility of the fault gases. The little soluble fault gases H2, CO and to a lesser extent CH4 are of special importance. An electrical and a thermal fault are used in order to illustrate the risks inherent in false diagnoses. The FGT shown herein was developed on the basis of the DGA interpretation table of IEC 60599 (the C3 hydrocarbons have been taken into account additionally)[1]. The blue/red dot in the FGT represents the precise and real-time gas emission rate quotients of the dissolved gases in a closed transformer exhibiting a suspect condition. 1. Non-hermetical sampling [2] CIGRE TF 15, in its recommendations for how to rule out false diagnoses resulting from analysis errors during non-hermetical sampling, suggests to forego the testing for hydrogen (and to consequently also forego the testing for O2, N2, CO) (Duval triangle). However, an alternative criterion for hermetical conditions (NIS) has been developed. This is met by both the TGM and the EGS method. Otherwise there is a risk of failure points migrating down. 2. Openness [3] Practical experience has shown that hydrogen (as well as CO and to a lesser extent CH4) escapes from open transformers. It is also possible to quantify openness by way of TON determination. Based on this quantification, correction procedures have been developed for the purpose of determining the H2 and CO emission rates while CH4 is contained through summation in CH4 is contained through summation in CH4+. Otherwise there is a risk of the failure points migrating down (or of the CO2 / CO ratio rising). Additionally, it is possible to determine the solution pressure and the oxygen consumption rate. Moreover, the blue and red dots in FGT also serve to represent the original composition of a Buchholz gas. 3. Oil way / standing time [4] Continuous oil contact leads to a gas exchange which in turn leads to the accumulation of hydrogen (and/or also of CO and to a lesser extent of CH4). Safekeeping in the TGM and/or in the AGT (diagnostic accessories)1) as an adjunct to the Buchholz relay allows the separation of oil way / standing-time and hence

paves the way for applying a correction procedure for the oil way. Otherwise there is a risk of the failure points migrating up. [1] EW Jg. 108 (2009) Heft 17-18, S. 70-75 [2] EW Jg. 111 (2012) H.14, S. 50-55 [3] EW Jg. 109 (2010) H.14-15, S. 56-59 [4] EW Jg. 98 (1999) H. 25, S. 16-24

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