Transformer testing

7.2.1.1 Transformers, Dry Type, Air-Cooled,

Low-Voltage, Small * Optional Page 28
ANSI/NETA MTS-2011
Power Transformer testing NOTE: This category consists of power
and losses transformers with windings rated 600 volts or
less and sizes equal to or less than 167 kVA
(MODULE 3) single-phase or 500 kVA three-phase.

5 February 2024 Prepared By: Engr. Cyril S. Felix 9

Transformer testing Transformer testing

5 February 2024 Prepared By: Engr. Cyril S. Felix 10 5 February 2024 Prepared By: Engr. Cyril S. Felix 11
Transformer testing

5 February 2024 Prepared By: Engr. June Santos 12 5 February 2024 Prepared By: Engr. Joshua Hernandez 13

7.2.2 Transformers, 7.2.2 Transformers,

Liquid-Filled Liquid-Filled

5 February 2024 Prepared By: Engr. Joshua Hernandez 14 5 February 2024 Prepared By: Engr. June Santos 15
7.2.2 Transformers, 7.2.2 Transformers,
Liquid-Filled Liquid-Filled

5 February 2024 Prepared By: Engr. June Santos 16 5 February 2024 Prepared By: Engr. June Santos 17

7.2.2 Transformers,
Group 3 Assignment
Liquid-Filled
• What is Dissolved Gas Analysis
• What are the function of transformer oil?
• Why need to test transformer Oil?
• Method and tools in oil sampling? Provide pictures.
• What are the Key Gases formed by degradation of oil
and paper insulation?
• What are the Dissolved Gas in Oil Analysis
IEEE Limit?
• What are the four main types of transformer loss?
• What is transformer efficiency?

5 February 2024 Prepared By: Engr. June Santos 18 5 February 2024 Prepared By: Engr. Joshua Hernandez 19
 Course Outline
• Purpose
• Transformer Oil Testing
• Oil Function
• Why there is a need to test the oil
• Sampling of oil
• Dissolve Gas Analysis
TRANSFORMER
.
OIL TESTING •
•
Key Gasses and Interpretations
Dissolved gas interpretation standards

AND DISSOLVE GAS •

•
Examples of DGA interpretation
Oil Quality Tests
ANALYSIS • Summary

Transformer Oil Function Why need to test transformer Oil?

• As insulation
• As coolant • Know the condition of the transformer.
• Helps extinguish arc • To Predict developing faults .
• Dissolves gases generated by oil degradation, moisture • Established routine maintenance and repair schedule.
and gas from cellulose insulations, deterioration and
gases and moisture from whatever atmosphere the oil is •Ensure Transformer Health
exposed.
Transformer Oil Sampling Oil Sampling
• Follow procedure ASTM D923 & D3613 (IEC 60475 & • A test is ONLY as good as the sample!
IEC 60567) • Start with good, clean syringes!

Oil Sampling Proper Oil Sampling

 Proper Oil Sampling Proper Oil Sampling

• Do not pull back

on the syringe
barrel.

• Apply slight
resistance and
allow fluid
pressure to fill the
syringe.

Dissolve Gas Analysis Dissolve Gas Analysis

Dissolved gas analysis (DGA) is the most important tool ❑ Close observation of dissolve gases (DGA) in the oil and other
in properties provides the most valuable information about the
determining the condition of a transformer. It is the first transformer Condition.
indicator of a problem and can identify deteriorating
❑ Looking for trends by comparing information provided in several
insulation and oil, overheating, hot spots, partial DGAs and understanding its meaning is the important transformer
discharge, diagnostic tool.
and arcing. The “health” of the oil is reflective of the ❑ DGA after 1 month of service and once each year. And more often if a
health of the transformer itself. problem is encountered.
Note :
The most important indicators are the individual and DGA is unreliable if the transformer is de-energized and has cooled. If
total the transformer is new or it has less than 1 to 2 weeks of continuous
combustible gas (TCG) generation rates based on IEC service after oil processing.

60599 [3] and IEEE C 57104™ [4] standards and ASTM

standards.
 Key Gases formed by degradation of Dissolved Gas in Oil Analysis
oil and paper insulation IEEE Limit

❑ Hydrogen (H2) ■ Hydrogen (H2) 100ppm

❑ Methane (CH4)
❑ Ethane (C2H6) ■ Carbon Monoxide (CO) 350
❑ Ethylene (C2H4)
❑ Acetylene (C2H2) ■ Methane (CH4) 120
❑ Carbon Monoxide (CO)
❑ Carbon Dioxide ( CO2) ■ Carbon Dioxide (CO2) 250
❑ Carbon monoxide, carbon dioxide, and oxygen are formed ■ Ethylene (C2H4) 50
from degradation of cellulose (paper) insulation.
■ Ethane (C2H6) 65
❑ If there is leak in the tank Carbon Dioxide, Oxygen, Nitrogen and
Moisture can also absorbed from the air
■ Acetylene (C2H2) 35

Transformer Diagnosis Using Individual

Total Dissolved Key Gas Concentrations: Sample of DGA Report
Test Description Symbols Limits As Found Test Description Units Limits As Found ASTM Method

CONDTION 1: Total dissolved combustible gas (TDCG) below this level Cond. 1 in PPM in PPM in PPM

indicates the transformer is operating satisfactorily. Any individual * Hydrogen H2 Water Content
100 90 ppm <35 11 D1533
combustible gas exceeding specified levels in table should have
additional investigation. * Methane CH4
120 41
Color
<4 <2.0 D1500

* Ethane C2H6 Interfacial Tension

65 54 dynes/cm >24 37.8 D971

* Ethylene C2H4 Neutralization Number

50 46 mg KOH/g <0.2 0.015 D974

C2H2 Dielectric Strength

* Acetylene 35 32 kV >26 51 D877

* Carbon Monoxide CO Oil Power Factor

Action Based on Dissolved Combustible Gas 350 36 %

Carbon Dioxide CO2 Resistivity

2500 898 Ohm-cm
TDCG Level or Sampling Interval and Operating Action for
TDCG generation Gases Generation Rate Nitrogen N2 Specific Gravity
Condition Highest Individual 30,278
rates ( ppm/day)
Gas Sampling Interval Operating Procedure Oxygen O2 Viscosity
12,710 cSt
< 10 Annual
Continue operation Total Diss. Gas TDG Flash Point o
10 -30 Quarterly 44,185 C
< or = 720 ppm of
TDCG or High Exercise Caution:
Condition 1
Condition based on the
individual gas > 30 Monthly
Analyze individual
gases to find cause,
Total Diss. Com. Gas TDCG
720 299 Fire Point
o
C

Determine load ** ESTIMATED TCG %

dependence
 Transformer Diagnosis Using Individual Sample of DGA Report
Total Dissolved Key Gas Concentrations:
Test Description Symbols Limits As Found Test Description Units Limits As Found ASTM Method
CONDTION 2: TDCG within this range indicates greater than normal
combustible gas level. Any individual combustible gas exceeding Cond. 1 in PPM in PPM in PPM

specified levels in table 4 should have additional investigation. A * Hydrogen H2

100 138
Water Content
ppm >35 53 D1533

fault may be present. Take DGA samples at least often enough to * Methane CH4 Color
120 76 >4 <3.5 D1500
calculate the amount of gas generation per day for each gas.
* Ethane C2H6 Interfacial Tension
65 177 dynes/cm <24 33.8 D971

* Ethylene C2H4 Neutralization Number

50 120 mg KOH/g >0.2 0.030 D974

C2H2 Dielectric Strength

* Acetylene 35 0 kV <26 32 D877

* Carbon Monoxide CO Oil Power Factor

350 590 %

Carbon Dioxide CO2 Resistivity

2500 3,187 Ohm-cm

Nitrogen N2 Specific Gravity

70,515
Action Based on Dissolved Combustible Gas
Oxygen O2 Viscosity
13,553 cSt
TDCG Level or Sampling Interval and Operating Action for
TDCG generation Gases Generation Rate Total Diss. Gas TDG Flash Point
Condition Highest Individual 88,356 o
C
rates ( ppm/day)
Gas Sampling Interval Operating Procedure Total Diss. Com. Gas TDCG 720 1,101 Fire Point o
C
Condition 2 721-1,920 ppm of <10 Quarterly Exercise caution:
** ESTIMATED TCG %
TDCG or based on Analyze individual
individual gas 10-30 Monthly gases to find cause.
> 30 Monthly Determine load
dependence

Transformer Diagnosis Using Individual

Total Dissolved Key Gas Concentrations: Sample of DGA Report
CONDTION 3: Total Dissolve Combustible Gas, TDCG within the range, Test Description Symbols Limits As Found Test Description Units Limits As Found
ASTM
Method
indicates a high level of decomposition of cellulose insulation
and/or oil. Any individual combustible gases exceeding specified Cond. 1 in PPM in PPM in PPM

level in the table should have an additional investigation. A fault or * Hydrogen H2

100 2,537
Water Content
ppm >35 27 D1533

faults are probably present. Take another sample.. * Methane CH4 Color
120 19 >4 2.0 D1500

* Ethane C2H6 Interfacial Tension

65 6 dynes/cm <24 38.2 D971

* Ethylene C2H4 Neutralization Number

50 5 mg KOH/g >0.2 0.015 D974

C2H2 Dielectric Strength

* Acetylene 35 0 kV <26 48 D877

* Carbon Monoxide CO Oil Power Factor

350 424 %

Carbon Dioxide CO2 Resistivity

2500 1,655 Ohm-cm
Action Based on Dissolved Combustible Gas
Nitrogen N2 Specific Gravity
Sampling Interval and Operating Action for 57,680
TDCG Level or
TDCG generation Gases Generation Rate
Condition Highest Individual Oxygen O2
2,171
Viscosity
cSt
rates ( ppm/day)
Gas Sampling Interval Operating Procedure
Total Diss. Gas TDG Flash Point o
64,497 C
Condition 3 1,941- 2630 ppm of <10 Monthly Exercise extreme
Total Diss. Com. Gas TDCG Fire Point
TDCG or based on caution: Analyze 720 2,991 o
C
individual gas 10-30 Weekly individual gases to find
** ESTIMATED TCG %
> 30 Weekly cause. Plan for shut
down. Call manufacturer
Transformer Diagnosis Using Individual Transformer Diagnosis Using Individual
Total Dissolved Key Gas Concentrations: Total Dissolved Key Gas Concentrations:
CONDTION 4: Total Dissolve Combustible Gas, TDCG within the range,
indicates excessive decomposition of cellulose insulation and/or • There some transformer operating safely under this
oil. Continue operation could result in failure of the transformer. condition, however gases are stable
Need to retest.

• If TDCG and individual gases are increasing

significantly (more than 30ppm/day), the fault is active
and the transformer should be de-energized when
Condition 4 levels are reached.

• A sudden increase in key gases and the rate of gas

production is more important in evaluating a
transformer than the amount of gas.

Transformer Diagnosis Using Individual

Total Dissolved Key Gas Concentrations: Sample of DGA Monitoring
❑ Any generation of amount of gas in ppm indicate high energy arcing.
DGA UNITS 12/1/2003 11/24/2004 roc/day
Can generate a very hot thermal fault (500oC)
HYDROGEN H2 ppm 104 1,387 3.61
❑ Acetylene generated by internal arcing, sampling should be taken
METHANE CH4 ppm 72 105 0.09
weekly to determine if there is an additional generation of gas.
ACETYLENE C2H2 ppm 4 0 (0.01)
❑ If no additional acetylene is found and level is with in standard the
ETHYLENE C2H4 ppm 52 2 (0.14)
transformer may continue in service.
ETHANE C2H6 ppm 68 17 (0.14)
❑ Increase of Acetylene level, the transformer has an internal arc and
CARBON MONOXIDE
should be taken out of service. CO ppm 320 568 0.70

CARBON DIOXIDE CO2 ppm 1962 2,178 0.61

❑ Operating transformer with high value of acetylene is extremely
hazardous. OXYGEN O2 ppm 6942 2,886 (11.43)

NITROGEN N2
 TRANSFORMER OIL ANALYST METHOD,( TOA )
Transformer Diagnosis Using Individual Delta X Research (International Electrotechnical
Commission, IEC 60599)
Total Dissolved Key Gas Concentrations:
Notes:
HOT METAL GAS: Gas generated due to bad internal connection,
Tap changer has poor contact. • If one or more gas generation rates are
Windings connection equal to or exceed G1 limits (10% of L1
limits per month) you should begin to
❑ Ethane and Ethylene are Sample of Hot Metal Gas pay attention to this transformer
•If one or more combustible gas
ATMOSPHERIC GASES: product of moisture and oil temperature generation rates are equal to or exceed
Transformer leak G2 limits (50% of limits per month) this
transformer should be consider in critical
❑ Nitrogen , Carbon Dioxide, Oxygen condition.
✔ This reveal possible leak
✔ Nitrogen gas came from the shipment of transformer. •If active arcing present, Acetylene
✔ Carbon Dioxide and Oxygen are formed by degradation of generation or if other gases are high
cellulose insulation. above condition 4 in table 4 and G2
✔ Moisture and atmospheric gases will leak inside when the limits are exceed the transformer should
transformer is off and ambient temperature drops. be remove from service.

TRANSFORMER OIL ANALYST METHOD, TOA

Delta X Research (International Electrotechnical TRANSFORMER OIL ANALYST METHOD, TOA
Commission, IEC 60599) Delta X Research (International Electrotechnical Commission, IEC
60599)

Key Gases Possible Fault Possible Findings

Key Gases Possible Fault Possible Findings
Hydrogen, Methane , Partial Discharges (corona) Weakened insulation from
Ethane & possible carbon aging and electrical stress. Hydrogen, carbon monoxide Thermal fault less than Discoloration of paper
monoxide 300oC in the area close to insulation. Overload and or
Hydrogen, Methane (carbon Low energy discharges Pinhole punctures in paper paper insulation ( paper is cooling problem.
monoxide if the discharges (sparking) insulation with carbon and being heated Bad connection of leads or
involve paper insulation) May be static discharge carbon tracking. Possible tap changer. Stray current
Possible trace amount of carbon particle in oil. path and or stray magnetic
Ethane Possible loose shield, poor flux.
grounding Hydrogen, Methane, Thermal fault between Damage paper insulation.
Hydrogen, Methane, High energy discharges Metal fusion, (poor contacts Ethane, Ethylene, Carbon 300oC and 700oC Oil heavily carbonized.
Ethane, Ethylene present in (sparking) in tap changer or lead Monoxide
large amount. If Acetylene is ACTIVE ARCING connections) Weak
be generated, arcing still insulation from aging and All the above gases and High energy electrical arcing Same as above with metal
active. Carbon Monoxide electrical stress. Carbonized acetylene in large amount 700oC and above discoloration. Arcing may
will be present if paper is oil. Paper destruction if it is have cause a thermal fault.
being heated. in the arc path or
overheated
TRANSFORMER OIL ANALYST METHOD, TOA TRANSFORMER OIL ANALYST METHOD, TOA
Delta X Research (International Electrotechnical Commission, IEC 60599) Delta X Research (International Electrotechnical Commission, IEC 60599)

Additional Possible Faults: Additional Possible Faults:

✔ Gases are generated by normal operation and aging. Mostly hydrogen
and Carbon Monoxide with some Methane. ✔ A hot –spot can be cause by bad connection in the leads or by a poor
contact in the tap changer.
✔ Operating transformers at sustained overload will generated combustible
gases. ✔ A hot spot may also cause by discharge of static electric charge that
build up on shields or core and structures which are not properly
✔ Problem with cooling system, can cause overheating. grounded.

✔ A block oil duct inside the transformer can causes local overheating, ✔ Hot spots may be cause by electrical arcing between winding and
generating gases. ground, between windings of different potential, or in area of different
potential on the same winding, due to deterioration or damage insulation.
✔ Sludge in the transformer and cooling system.
✔ Winding and insulation can be damage by faults downstream, causing
✔ Circulating stray current may occur in the core, structure and/or tank. large current surges through the windings. Through faults cause extreme
magnetic and physical force that can distort and loosen windings. The
✔ An unintentional core ground may cause heating by providing a path for result arcing in the transformer, beginning at the of fault, or insulation
stray current. may be weakened and arcing may develop later.

TRANSFORMER OIL ANALYST METHOD, TOA

Delta X Research (International Electrotechnical Commission, IEC 60599) Oil Quality Test
Additional Possible Faults:
✔ Insulation can also be damaged by voltage surge such as a nearby
• PHYSICAL PROPERTIES ■ CHEMICAL PROPERTIES
lightning strikes or switch surge or closing out of step, which may result
in immediate arcing or arcing that develops later. • Visual appearance ❑ Moisture content
• Colour ❑ Acidity
✔ High noise level (hum due to loose windings) can generated gas due to • Flash Point ❑ Corrosive Sulphur
heat from friction . Compare the noise to sister transformers, if possible. • Viscosity
Sound level meter are available for diagnostic comparison and to ❑ Oxidation stability
establish baseline noise levels for future comparison. • Density ❑ Sludge Sediment
• Pour Point
• IFT ■ CHEMICAL PROPERTIES
• Particle Count ❑ DBV
❑ PF
 Oil Quality Test Oil Quality Test
• INTERFACIAL TENSION • ACID NUMBER/NEUTRALIZATION NUMBER

• As test/measurement of the strength of the molecular • Is the amount of potassium hydroxide in milligrams that it takes to
attractive force between the oil and distilled water at the neutralized the acid in milligram of the transformer oil
interface. This indicate the degree of contamination present • Is the measure of oxidation.
in the oil. • The higher the acid number the more acid in the oil.
• Low IFT is an indication of formation sludge, presence of • New transformer oil contains no acid.
solid particles in the transformer • The oxidation of the insulation and oil form an acid as the transformer
• A clear/ clean oil IFT from 40 -50 dynes/cm ages.
• Acids attacks metals inside the transformer and form more sludge
• 25 dynes /cm recommended the oil to be reclaimed.
• Acids attacks cellulose and accelerate insulation degradation.
• Note (IFT and Acid Number together are the excellent • 0.40 mg KOH/gm start to form a sludge
indication of when the oil is about to reclaimed.)
• 0.20 mg KOH / gm oil should be reclaimed – Critical condition
• 22 dynes / cm oil is very contaminated to prevent sludge. • Affects Dielectric and Cooling.
• Decreasing IFT = Increasing Contamination
• Can be corrected

Relationship of IFT and Acid Number Oil Quality Test

• WATER/MOISTURE CONTENT

• Moisture is given in the DGA in ppm, and some laboratory also give
percent saturation
• Percentage is how much water is in the oil compared with the maximum
amount of water the oil can hold.
• 2% M/DW ( moisture by dry weight) paper need to dry out.
• Never allow M/DW to go above 2.5% in the paper or 30% oil
saturation.
• Each time moisture is doubled in a transformer, the life of the insulation
is cut by ½ . Keep in mind that the life of the transformer is in the paper.
The purpose of the paper is to keep out moisture and oxygen.
• Decreases Dielectric and IFT
• Degrades Cellulose
• Less than 69 kV – 35ppm is still acceptable
• New transformer with 0.5% M/DW In a 10,000 pounds of paper, means
that 10,000 x 0.005 = 50 Pounds of water ( about 6 gallons) is in the
paper.
 STANDARD IN ABSENCE OF MANAUFACTURER STANDARD
STANDARD IN ABSENCE OF MANUFACTURER STANDARD

REFERENCE: INTERNATIONAL ELECTRIC TESTING ASSOCIATION INC 97 MAINTENANCE INSPECTION

FOR ELECTRIC POWER DISTRIBUTIONEQUIPMENT AND SYSTEM REFERENCE: INTERNATIONAL ELECTRIC TESTING ASSOCIATION INC 97 MAINTENANCE INSPECTION
FOR ELECTRIC POWER DISTRIBUTIONEQUIPMENT AND SYSTEM

Oil Quality Test Qualitative Test Analysis

• OIL POWER FACTOR • DIELECTRIC STRENGHT.
• Indicates the dielectric loss (leakage current) of the oil
• This measures the voltage at which the oil electrically breaks
• High power factor indicates deterioration and/ or down.
contamination by products such as water, carbon or • Voltage at which oil began to conduct.
other conducting particles; metal soaps caused by
acids • Is reduced by moisture and contaminants.
• This test gives a good indication of the amount of
• If power factor is greater than 0.5% and less than contaminants (water and oxidation particles) in the oil.
1.0% further investigation is required. May required • Don’t base any decision on one test result, on one type of
replacement or filtering. test, instead look at all the information over several DGAs and
• If power factor is greater than 1.0% at 25o C the oil establish trend before making any decision.
may cause failure, replacement is required. • DS test is not extremely valuable; moisture in combination
with oxygen and heat will destroy the cellulose insulation long
• Above 2% high probability of transformer failure. before the DS of oil has given a clue that anything is going
wrong.
 Qualitative Test Analysis Summary
• Color
• The higher the number the darker the oil.
• The darker the oil, the more contamination and
deterioration.
• Oil with number of 5 is almost black.

Transformer losses: Transformer losses:

• The four main types of loss are resistive loss, eddy • Resistive losses:
currents, hysteresis, and flux loss.
• Efficiency of a transformer will be maximum when copper
loss and iron losses are equal. That is Copper loss = Iron
loss.
• Resistive losses- Resistive loss, or I2R loss, or copper loss,
is the power loss in a transformer caused by the
resistance of the copper wire used to make the windings.
Since higher frequencies cause the electrons to travel
more toward the outer circumference of the conductor
(skin effect), electrical disturbances called harmonics
have the effect of reducing the wire size and increasing
resistive loss. These losses are the same as the power
losses in any conductor and are calculated as follows:

5 February 2024 Prepared By: Engr. Joshua Hernandez 62 5 February 2024 Prepared By: Engr. Joshua Hernandez 63
 Transformer losses: Transformer losses:
• Eddy current losses: • Eddy current losses:
• Eddy current loss is power loss in a transformer or motor • Constructing the core from thin sheets of iron laminated
due to currents induced in the metal parts of the system together can minimize this loss. The thin sheet-iron
from the changing magnetic field. Any conductor that is layers shorten the current path and minimize the eddy
in a moving magnetic field has a voltage and current currents
induced in it. The iron core offers a low reluctance to the
magnetic flux for mutual induction. The magnetic flux
induces current at right angles to the flux. This means
that current is induced across the core. This current
causes heating in the core. The heat produced by eddy
currents increases as the square of the frequency. For
example, the third harmonic (180 Hz) has nine (32) times
the heating effect of the fundamental (60 Hz) frequency.

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Hysteresis losses: Hysteresis losses:

• Hysteresis loss is loss caused by the magnetism that • When the polarity changes twice each cycle, power is
remains (lags) in a material after the magnetizing force consumed by this realignment, and this reduces the
has been removed. Magnetic domains are small sections efficiency of the transformer. This movement of the
of a magnetic material that act together when subject to molecules produces friction in the iron, and thus heat is a
an applied magnetic field. Magnetic domains have result. Harmonics can cause the current to reverse
magnetic properties and move in iron when subjected to direction more frequently, leading to more hysteresis
a magnetic field. When the iron is subjected to a loss. Hysteresis is reduced through the use of highly
magnetic field in one polarity, the magnetic domains will permeable magnetic core material.
be forced into alignment with the field.

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 Flux losses Flux losses
• Flux loss occurs in a transformer when some of the flux • The lines of flux then travel through the air and are not
lines from the primary do not pass through the core to cut by the secondary. Second, the ratio of the reluctance
the secondary, resulting in a power loss. There are two of the air and the core in the unsaturated region is
main reasons for flux lines to travel through the air typically about 10,000:1. This means that for every
instead of through the core. First, the iron core can 10,000 lines of flux through the core, there is 1 line of
become saturated so that the core cannot accept any flux through the air. Flux loss is generally small in a
more flux lines. well-designed transformer.

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Transformer Efficiency: Transformer Efficiency:

• The ratio of a transformer's output power to its input
power is known as transformer efficiency. The effect of
transformer losses is measured by transformer efficiency,
which is typically expressed as a percentage. The
following formula is used to measure transformer
efficiency:

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