Digital Energy
05 June 2013, Argentina
Dissolved Gas Analysis & Monitoring
Technology, Products and applications
GE Monitoring & Diagnostics
June 2013 Donal Skelly
Introduction & Monitoring
Two factors are important to assess transformers:
Dissolved gas
The change in gas concentration
This may be indicative that there is an active fault. If concentrations are changing faster than normal aging would result in, a fault may be present.
The change in relative gas concentrations
If gas concentrations or gas concentration changes indicate that there is a fault a look at the relative concentrations of one gas to an other can be used to diagnose the nature of the fault
Moisture content
The relative saturation level of moisture in the oil
As a general rule, for every doubling of moisture in oil (and my inference moisture in the paper) the life of the transformer will be halved. Additionally increased moisture exposes the transformer to increased risk of short circuit
6/5/2013
Periodic testing
If a customer does not have on-line monitoring the only way to verify a transformer is to
perform periodic off line DGA and moisture analysis. This involves:
• Manually collecting 2 separate oil samples from the transformer and ship to a
laboratory.
• Wait for analysis (several days normally) • Laboratory GC for analysis of dissolved gas.
• Karl Fischer titration for determination of moisture content.
You then compared the measured values with the values from previous tests looking for any
increase and for the trend of this increase.
Disadvantages of periodic testing: • Periodic testing is not without cost: it takes time, ties up workers and requires
the transformer to be drained of some oil.
• Because of the requirement to visit the transformer to collect the sample, tests are generally carried out only every 1 to 2 yrs.
• It is performed on a sample that is normally several days removed from the condition when the sample was collected resulting in possible loss of sample integrity.
• Significant or even critical transformer faults can develop in a fairly short period time and in between annual offline tests check. Periodic tests will not detect quickly progressing problems.
On-line dissolved gas analysis systems can now continuously monitor dissolved gas content and relative saturation of moisture, detect developing faults at an early stage, enabling to schedule an outage for maintenance /replacement and prevent a catastrophic failure from occurring
Why do on line Monitoring
Dissolved Gas Analysis (DGA) is the industry defacto standard for transformer main tank and tap changer health assessment.
• Normal paper aging indicated by slow rise in CO2 – Accelerated or abnormal aging indicated by rapid rise in Carbon Monoxide
• Local low temperature hot spot indicated by rise in CH4
• Local High temperature hot spots indicated by rise in C2H4
• Detection of increasing quantities of Acetylene show arching occurring within transformer.
• Rules available to allow for quick and accurate determination of the presence of a fault and the nature and severity of that fault
Why Dissolved Gas Analysis?
GE Multigas Products - History
o Product line developed by a private company named Kelman
o Kelman looked at all available technology for measurement of gas and for gas extraction from oil.
o Decision was to employ Infra-red spectroscopy and headspace gas extraction. Many reasons why.
o All multigas products now based on these two core techniques.
o Kelman went on to dominate the market for multigas DGA – were acquired by GE in 2007
o GE product are now market leader in almost every country global and are overall global leaded for online monitoring.
GE Multigas DGA Products
TRANSPORT X* • Portable DGA
• 7 fault gases + moisture
• Simple & reliable
TRANSFIX* • Full 8 gas +
moisture on-line DGA
MINITRANS* • Cost-Effective on-line DGA
• Discrete gas measurement
(H2, CO, C2H2 + H2O)
MULTITRANS* • Full 8 gas multi tank DGA
TAPTRANS* • Full 8 gas on-line DGA for
main tank & LTC in one
unit
All based on Photoacoustic Spectroscopy and Headspace gas extraction
Photoacoustic Spectroscopy
Photoacoustics - Basics
• Photo-acoustic affect discovered by A. G. Bell
• Measures individual gas in a mixture without physical separation.
• Spectral domain identification
• Photo-acoustic effect quantification
• No carrier gases - operates in ambient environment.
Photoacoustic Spectroscopy - History
– 1960s environmental monitoring (CO, NOx, SOx)
– 1970s Operating theatre (Nitrous Oxide, CO2)
– 1990s Auto and construction industry (Sox, Nox, CO, CO2, H20, Hydrocarbons)
– 2000s Dissolved Gas Analysis - KELMAN (CO, CO2, CH4, C2H2, C2H4, C2H6, H2O)
– 200,000 PAS based detectors worldwide for all the above application, and others
– There are 7000+ GE PAS instruments worldwide
What is IR
Infrared absorption
• Almost every compound in the universe will absorb IR energy
– Every compound in existence has a unique absorption profile – like a finger print.
– If we target a region of the IR energy spectra that is unique for a compound we can measure its concentration.
– For DGA application, compounds are all simple gases
Photo-Acoustics – Basic Components
• Radiation Source at approx 900oC.
• Chopper pulses radiation at 29.5hz
• Filters optically distinguish one gas in a mixture.
• Sample sealed in analysis chamber.
• Microphones measure intensity of pressure pulse.
Acoustic Intensity + Filter selected = Gas Concentration (ppm)
Evolution of Photoacoustic Signal
START: Optical IR
Absorption
Heating of gas
Thermal expansion of
gas
Pressure waves
END:
Acoustic detection
Simple IR Spectrum – CO2
Photoacoustic IR Filters
IR-light pulses Sound wave proportional to gas
concentration
GAS
Photo-acoustic affect discovered by A. G. Bell Measures individual gas in a mixture without physical separation. Spectral domain identification Photo-acoustic effect quantification Employs one detector and no carrier gases Operated in ambient environment.
PAS Layout
DGA Gases Spectra – Simple broad absorption peaks
DGA Gases Spectra
#5 methane CH4 #0 water
#2 CO
#1 CO2
#4 ethane C2H6
#6 acetylene
C2H2
# 3 Ethylene
C2H4 LW
# 8 Ethylene
C2H4 SW
Full Spectrum & Filter positions for DGA
IR-active vib modes (rough guide)
#5 methane CH4 #0 water
#2 CO
#1 CO2
#4 ethane C2H6
#6 acetylene
C2H2
# 3 Ethylene
C2H4 LW
# 8 Ethylene
C2H4 SW
Full Spectrum & Filter positions for DGA
IR-active vib modes (rough guide)
Where are Hydrogen, Nitrogen and Oxygen?
Benefits of PAS
•No regular calibration or maintenance required
•No costly consumables such as calibration or carrier gases
•Capable of measuring at very low detection levels (e.g. 0.5ppm for acetylene) and very high detection levels (>50,000ppm)
•Capable of measuring individual gases in a mixture
•Ability to move from high gas levels to lower gas levels without cross contamination (TRANSPORT X, Tap TRANS
•Direct measurement of both CO & CO2, vital gases for understanding cellulose condition, giving increased accuracy & repeatability
User Benefits of choosing PAS
•Minimal maintenance required so not an O&M burden – with no ongoing support costs of either parts or labor
•Through rugged technology, repeatability is enhanced – this is vital for online monitoring as it is trend changes we are looking for
•Ability to monitor both multiple compartments (TapTrans) and multiple tanks (MultiTrans)
•No requirement for carrier or calibration gases – these can be expensive and difficult to transport
Gas Extraction from oil
Gas Extraction Techniques
• No technique allows for measurement of the gas while it is still a component of the oil.
• The gas must be removed from the oil or a representative sample of it removed prior to analysis.
• After removal the gas is passed to the detector eg, GC, PAS, solid state sensors etc.
Gas Extraction by online monitoring equipment
• All online equipment use headspace technique for gas extraction.
• Coil = Cgas X Partition Coefficient x Volumetric Ratio
• A membrane is a type of headspace extraction
• but there Is no volumetric ratio to consider
• GE use headspace as laid out in ASTM 3612 : Standard Test Method for Analysis of Gases Dissolved in Electrical Insulating Oil by Gas Chromatography.
Transfix Plumbing Basic
Transfix Plumbing Visualisation
TRANSPORT X Schematic
Products
What is it?
An on-line system that continuously monitors: • The concentration of 9 key gases in the
insulating oil of electrical equipment. • The concentration of moisture in
insulating oil. • Optionally transformer load and tank
temperatures around others
It will alert personnel of fault conditions at an early stage and provide vital health information on the transformer or tap changer.
TRANSFIX
Product Summary
Differentiated Value
• An integrated solution from a sole supplier.
• When the TRANSFIX is integrated with a BMT 300 bushing monitor unit, GE can offer a unique all-in-one solution that provides a more in-depth view of the transformer's health
• Enabling more condition based maintenance, resulting in reduced maintenance costs.
What does the TRANSFIX measure
Using separate oil collection and return point for
sampling, TRANSFIX can collect a discreet
representative oil sample up to once every hour for
analysis
• DGA: Measurement of 9 key gases
o Hydrogen
o Methane
o Ethane
o Ethylene
o Acetylene
o Carbon Dioxide
o Carbon Monoxide
o Oxygen
o Nitrogen
• Oil moisture analysis
o Moisture (ppm)
o Relative Saturation
DGA is measured as follows:
Oil pumped through the TRANSFIX unit, past an oil immersed Oxygen and Moisture sensor and on to fill a sample chamber to a predetermined volume. Gas extracted out of sample in sample chamber and analysis of this gas using a photo-acoustic gas analyzer
Moisture is measured as follows:
Oil flows over a capacitance moisture sensor and during sampling and together with oil temperature (if recorded) ppm and RS are determined
TRANSFIX – View of an Installed Unit
TRANSFIX – Complete DGA
Real-time Online DGA
8 gas + moisture analyser
Hourly Measurements*
Extensive communication/alarm options
No consumables or calibration
6 Analog Inputs, 3 Digital inputs
Full PERCEPTION integration
Can be upgraded to include fibre optic temperature sensors
TRANSFIX – Technical Specifications
TRANSFIX – Technical Specifications
TRANSFIX – Technical Specifications
Oil Manifold: 1. Takes oil sample from
Transformer 2. Extracts Gas from oil
PGA: 1. Performs measurement
on extracted gas
System Board: 1. Provision of I/O 2. Provision for communications
modules
Host Board: 1. Controls unit measurement
scheduling 2. Stores records
Simplified Overview of TRANSFIX
MINITRANS is similar - simplified manifold, PGA & system board
Standard • Two separate channels for remote
communications, local USB connection and Ethernet connection.
Protocols supported • MODBUS®, • MODBUS/TCP, • DNP3.0, • IEC61850®. Modules options available for connection • RS232, RS485, • Ethernet, PSTN modem and GSM or
CDMA wireless modems. • 16 channel 4-20mA analogue output
TRANSFIX Communications options
(All options are mounted inside TRANSFIX enclosure)
Fiber Convertors available
• Ethernet to Fiber, Singlemode
• Ethernet to Fiber, Multimode
• RS232 to Fiber, Singlemode
• RS232 to Fiber, Multimode
• RS485 to Fiber, Singlemode
• RS485 to Fiber, Multimode
TRANSFIX Communications options
(All options are mounted inside TRANSFIX enclosure)
TRANSFIX – View of Installed Units
MINITRANS – Cost Effective DGA
Real-time Online DGA
Measures
• Hydrogen
• Carbon Monoxide
• Acetylene
• Moisture
Hourly Measurements*
Extensive communication/alarm options
Load Sensor input
No consumables or calibration
Full PERCEPTION integration
MINITRANS – Cost Effective DGA
MINITRANS – Cost Effective DGA
MiniTrans
PG
A
Simplified
PGA and
simplified
construction
Measureme
nt of:
H2
C2H2
H2O
CO
ΣCnHn
MULTITRANS – Multi tank DGA
Multi tank Real-time Online Transformer Monitoring
Monitors up to 3 separate single phase tanks
8 gas + moisture analyser
Hourly Measurements*
Extensive communication/alarm options
No consumables or calibration
6 Analog Inputs, 3 Digital inputs
Full PERCEPTION integration
MULTITRANS – Multi tank DGA
MULTITRANS – Multi tank DGA
Oil Manifold: 1. Takes oil sample from
Transformer 2. Extracts Gas from oil
PGA: 1. Performs measurement
on extracted gas
System Board: 1. Provision of I/O 2. Provision for communications
modules
Host Board: 1. Controls unit measurement
scheduling 2. Stores records
Simplified Overview of MULTITRANS
Oil Switching: 1. Selects tank
PGA
TAPTRANS – DGA for LTCs
Complete Online DGA for Transformer & Load Tap Changer
Monitors Main, Selector & Diverter tanks in one unit
8 gas + moisture analyser
Hourly Measurements
Extensive communication/alarm options
No consumables or calibration
6 Analog Inputs, 3 Digital inputs
Full PERCEPTION integration
TAPTRANS – DGA for LTCs
TAPTRANS – DGA for LTCs
Oil Manifold 1: Main & Selector 1. Takes oil sample from
Transformer 2. Extracts Gas from oil
PGA: 1. Performs measurement
on extracted gas
System Board: 1. Provision of I/O 2. Provision for communications
modules
Host Board: 1. Controls unit measurement
scheduling 2. Stores records
Simplified Overview of TAPTRANS
Oil Switching: 1. Selects Main or Selector tank
Oil Manifold 2: Divertor 1. Takes oil sample from
Transformer 2. Extracts Gas from oil
Failure Modes
Australia and New Zealand 457 failures over 10 years
0
5
10
15
20
25
30
Windings
Windings accessories
Core
Tap Changer
Motor driv
es parts
Bushings
Cooling
Others
%
0
5
10
15
20
25
30
35
Windings
Core
Tap Changer
Main tank &
oil syst.
Bushings
Auxiliarie
s
Others
ESKOM 1996 to 2006 136 severe and intermediate failures
%
CEA outages between 1997 to 2006
0
5
10
15
20
25
30
35
Bushings
Windings
OLTCCore
Leads
Cooling E
quipment
Auxiliary
Equipment
Other
%
Combining the 3 set of data along transformer elements
• Core and coils (including leads and winding accessory)
• Tap changer (including driving mechanism)
• Bushings
• Cooling system (including main tank)
• Others (including auxiliary components)
Relative importance of each component as a contributing factor
0
5
10
15
20
25
30
35
40
Core and
coils
Tap
Changer
Bushings Cooling
System
Other
Perc
enta
ge (
%)
Australia
Eskom
CEA
TAPTRANS – DGA for LTCs
Complete Online DGA for Transformer & Load Tap Changer
Monitors Main, Selector & Diverter tanks in one unit
8 gas + moisture analyser
Hourly Measurements
Extensive communication/alarm options
No consumables or calibration
6 Analog Inputs, 3 Digital inputs
Full PERCEPTION integration
Control room
Data transfer to control room
Reliable uninterrupted power is the lifeblood of many industries,
transformers are a critical tool in the production cycle
Solutions
Monitoring transformer health using TRANSFIX can reduce the
requirement for routine transformer maintenance and provide for
condition based maintenance and early fault detection.
TRANSFIX - Application Example
TRANSFIX Features & Benefits
Feature Benefit
On-line DGA Advance warning of Transformer needing maintenance/replacement
Enables Condition Based Maintenance (CBM)
Avoids catastrophic failure and /or transformer loss
Avoids need for routine visits to site and manual sampling
Early warning of possible arcing in main transformer tank
Tracks load current, moisture content and ambient temperature for advanced trending capabilities
Integration with MO150 (TRNSFIX Plus) Addition of models data for a more complete view of transformer internal faulth activity
Integration with BMT300 Bushing monitor Provides a complete transformer solution to effectively monitor
the majority of root causes of transformer failures.
Uses same PERCEPTION software to visualize data
Less vendors installing equipment in your switchyard
Single vendor integrated solution that works/communicates
• Combines TRANSFIX and MO150 in one enclosure
• Ethernet switch available for combined communications
• Will be integrated into PERCEPTION at next release (Feb 2011)
.
TRANSFIX Plus Online DGA with Models
.
TRANSFIX with BMT300
M&D’s Integrated Solution
The GE’s Intellix BMT 300 can easily be integrated with a GE’s TRANSFIX DGA analyzer, giving the end user a unique all-in-one solution that provides a more comprehensive view of the
transformer's overall condition: from bushing diagnostic and PD to complete main tank
monitoring.
Having an all-in-one GE integrated solution will significantly increase the ability to detect
potential transformer problems at an early stage, decreasing the risk of unplanned
downtime and improving asset reliability.
The integrated solution will provide:
o Developing key fault gases H2, CO, C2H2, C2H4, C2H6 as well as O2, CO2, CH4
o Moisture content in oil o Partial discharge activity
o Deterioration of the bushing insulating
All this information can be downloaded and visualized on the same PERCEPTION software as
with TRANSFIX, thus increasing familiarity and reducing learning curve.
Finally, the solution comes from a single supplier, ensuring reliable communication between
components and reducing the number of vendors working in the customer’s switchyard.
M&D Integrated Solution – Substation Application
BMT 300 – associated with
TRANSFIX multigas
Perception - Software
BMT 300 – standalone
Diagnostics
Main Tank 30%
OLTC 35%
Bushing 15%
Cooling System 5%
Others 15%
Main Tank: Windings failure, Partial Discharge, Excessive H2O, surface contamination, connection failure,
circulating currents, overloading hazard.
OLTC: contact overheating and coking, desynchronization, excessive number of operations, mechanical damage,
neutral switch inactivity
Bushing: moisture penetration, oil leak, partial discharge
Cooling System: clogged coolers by pollen or dust, fan/pump failure, sludge, oil leak
DGA can provide for detection of the majority of the above faults by tracking changing gas concentrations
or gas ratios
Other Failure Modes not detectable by on-line monitoring: External, such as lightning, animal interference,
operation error,
Location of Transformer Failure
Main tank
LTC
Bushing
Cooling system
Other
Transformer failure locations & modes
Key DGA gasses, and what they indicate
H2 Hydrogen Nearly all fault conditions, low energy PD
CH4 Methane Oil overheating between 200ºC and 500ºC
C2H6 Ethane Oil overheating between 300ºC and 500ºC
C2H4 Ethylene
Oil overheating over 500ºC, possible formation of carbon particles
C2H2 Acetylene High energy arcing, oil overheating over 800ºC, strong formation of carbon particles, metal melting
CO Carbon Monoxide Paper insulation overheating
CO2 Carbon Dioxide Oil oxidation, paper degradation
O2 Oxygen Oxidation, leak
Bushing – Power Factor
• Transfix is equipped with a direct connection, via USB
for data download capability
• Remote download available when utilizing one of the
various communication protocols
• TransConnect is used for Transfix settings and the
configuration of Alarm limits
Perception is used for data downloading and analysis of
DGA results to provide a diagnosis of the fault, if one is
detected
TRANSFIX – DGA for Fault detection
Utility value
Advanced Transformer Management Software • Specially designed for the power industry • Provides simplified trending • Provides advanced transformer diagnostics • Intuitive/configurable interface
What is Perception
6/5/2013
Utility value
What is Perception
• Shipped with Transfix unit • Designed for single user/local
database • Requires manual result
download • Recommended for low
number of DGA units
Enterprise version of Perception. In addition to Express features: • Multiple users • Central database • Scheduler (Console) for
automated results download • Email alarm notification
6/5/2013
Transformer Services
Transformer Field Services
Team of transformer design and test experts available to perform
• In-depth condition assessments • Condition based ranking of fleet • Design reviews • Training.
Our methodology uses extensive On-Line
testing. • test the transformer in its real life state. • less reliance on outages and less
disruption to the customer.