Energies 15 03379
Energies 15 03379
* Correspondence: [email protected]
Abstract: A power transformer is one of the most critical and expensive assets in electric power
systems. Failure of a power transformer would not only result in a downtime to the entire transmis-
sion and distribution networks but may also cause personnel and environmental hazards due to oil
leak and fire. Hence, to enhance a transformer’s reliability and extend its lifespan, a cost-effective
and reliable condition monitoring technique should be adopted from day one of its installation. This
will help detect incipient faults, extend a transformer’s operational life, and avoid potential conse-
quences. With the global trend to establish digital substation automation systems, transformer
online condition monitoring has been given much attention by utilities and researchers alike. Sev-
eral online and offline condition monitoring techniques have been recently proposed for oil-im-
mersed power transformers. This paper is aimed at providing a state-of-the-art review for the vari-
ous condition monitoring technologies used for oil-immersed power transformers. Concept of
measurements and analysis of the results along with the future trend of condition monitoring tech-
niques are presented.
Citation: Jin, L.; Kim, D.; Keywords: oil-immersed power transformer; condition monitoring; asset management; transformer
Abu-Siada, A.; Kumar, S. Oil- failure; operational life estimation
Immersed Power Transformer
Condition Monitoring
Methodologies: A Review. Energies
2022, 15, 3379. https://doi.org/
1. Introduction
10.3390/en15093379
Oil-immersed power transformers are widely used in the power systems due to their
Academic Editor: Sérgio Cruz
ability to handle higher voltage levels than dry-type transformers. Owing to the fact that
Received: 1 April 2022 power transformers are constantly operating under harsh thermal, electrical, and mechan-
Accepted: 1 May 2022 ical stresses, they are prone to several types of faults. Faults such as windings and core
Published: 6 May 2022 mechanical deformation, partial discharge, overheating, and arcing result in deterioration
Publisher’s Note: MDPI stays neu-
to the transformer’s mechanical integrity and/or degradation to the dielectric insulation
tral with regard to jurisdictional
system [1]. While the transformer may operate normally with incipient faults, some faults
claims in published maps and institu- such as winding axial displacement can progress rapidly and lead to catastrophic conse-
tional affiliations. quences if not detected and rectified at an early stage [2]. Short-circuit faults and over-
loading can further increase the probability of unexpected failures of power transformers.
A survey on the power transformer failures within Australia was conducted by the
University of Queensland in the year 2017 [3]. The survey was conducted on 6057 power
Copyright: © 2022 by the authors. Li- transformers that represented 98% of the Australian fleet. Collected data show that 199
censee MDPI, Basel, Switzerland. transformer failures, representing 3.29% of the analyzed transformers, were reported dur-
This article is an open access article ing the period 2000 to 2015. The statistics reveal a high number of non-catastrophic fail-
distributed under the terms and con- ures occurred in the 30 to 49 years age group while a higher catastrophic failure rate oc-
ditions of the Creative Commons At- curs in age groups 0 to 9 years and above 49 years. The causes of the failures have been
tribution (CC BY) license (https://cre-
divided into five major groups: bushings, on-load tap changer (OLTC), windings, insula-
ativecommons.org/licenses/by/4.0/).
tion system, and others, with the failure distribution profile as shown in Figure 1 [3]. This
survey shows the necessity to adopt a reliable condition monitoring technique for various
power transformer components. Figure 2 shows the main components of the power trans-
former along with the required parameters to monitor each component [4,5].
Figure 1. Distribution of failures for Australian power transformers during the period 2000 to 2015.
Over the years, a wide variety of sensor technologies that can be used for online or
offline fault diagnostic methods have been developed for power transformer condition
monitoring systems [6]. In Section 2 of this paper, nine typical offline power transformer
diagnostic methods are presented.
Compared to offline testing methods, online condition monitoring has several ad-
vantages including timely information about transformer health conditions, incipient
fault detection that helps asset managers make a proper and timely decision, reduction of
the probability of unplanned downtime due to catastrophic failures, decrease the loss of
production costs due to transformer outage, and minimize the risk for personnel since
they need less frequent access to the high voltage substation. Therefore, it is necessary to
keep improving the online condition monitoring methods for oil-immersed power
Energies 2022, 15, 3379 3 of 32
transformers. Four commonly known online methods are presented in Section 3 of this
paper. Figure 3 shows all offline and online condition monitoring methods for oil-im-
mersed power transformers currently used by the industry. The purpose of this compre-
hensive review is to present and discuss various online/offline condition monitoring
methods for power transformers.
Figure 3. Offline and online condition monitoring methods for an oil-immersed power trans-
former.
of the transformer’s life [9]. To measure the DP, paper samples are collected from different
spots of the transformer windings, which is impractical for operating transformers. There-
fore, this method is only performed during planning for transformer replacement. Other
indirect methods, such as Furan analysis, can be used to estimate the paper DP value.
The concentration of these furan compounds in parts per million (ppm) can be meas-
ured using high-performance liquid chromatography (HPLC) or gas chromatography-
mass spectrometry (GC/MS) in a laboratory environment [12,13]. From industry practice,
2-FAL is considered as the main compound due to its high generation rate and stability in
the oil [10]. A strong correlation between 2-FAL measurements and DP value as shown in
Table 2 has been reported in the literatures and IEEE guides [12,14]. This correlation facil-
itates a non-intrusive diagnostic option to replace the DP test. However, this test is nor-
mally performed in the lab by trained personnel and expensive equipment. Additionally,
there is no standard code correlating furan to DP for biodegradable oil and thermally up-
graded paper yet.
A new method based on ultraviolet-to-visible (UV-Vis) spectroscopic technology
along with artificial intelligence is proposed in [15] to estimate the concentration of the 2-
FAL compound in a transformer oil sample. UV-Vis spectroscopic diagnostic is based on
the absorbance of the light by the contaminations in transformer oil [16]. Hence, this tech-
nology can also be used to assess the quality of transformer oil and quantify the reduction
in its lifetime [16,17]. The proposed UV-Vis spectroscopic method is low cost, easy to per-
form by unexperienced personnel, and can be conducted onsite or implemented online.
However, this method has not been tested widely on operational transformers.
Table 2. The correlation between 2-FAL and DP for paper insulation with condition level.
through the oil–water interface [18]. IFT analysis is detailed in standard ASTM D971. In
general, transformers ≤ 69 kV with IFT ≤ 22 dynes/cm; and transformers > 69 kV with
IFT ≤ 25 dynes/cm are considered to approach the end of insulating oil service life. The
conventional IFT test requires a trained person and expensive equipment to conduct the
measurements. Therefore, the test is normally performed in a laboratory environment.
There has been research on using UV-Vis spectrum method to determine the IFT value of
a transformer oil sample [19]. This spectroscopic measurement is based on measuring en-
ergy level in atoms and molecules. The measurements can then be analyzed using an ar-
tificially intelligent software tool to estimate the IFT value. This method has an online
application feasibility but has not been tested in the practical field yet.
Acidity number, also known as neutralization number (NN), is a reflection of the
acids in the insulating oil. The measurement represents the mass of potassium hydroxide
(KOH) in milligrams (mg) needed to neutralize the acid in one gram (gm) of the oil. The
NN increases as the transformer ages. The limitation of NN is stated in standard ASTM
D974. In general, transformers ≤ 69 kV with NN ≥ 0.20 mg KOH/gm; transformers of rated
voltage between 69 kV, 230 kV with NN ≥ 0.15 mg KOH/gm; and transformers ≥ 230 kV
with NN ≥ 0.10 mg KOH/gm are considered to be in critical condition in terms of oil qual-
ity.
IR MΩ
PI = (1)
IR MΩ
The limitation of the IR test is its inability to identify the IR value of each individual
insulation system such as bushings, paper, and oil.
(a) (b)
Figure 6. (a) Equivalent circuit represents a dielectric and (b) phasor diagram.
The DF and power factor (PF) calculations are given by (2) and (3),(3) respectively
[29,30]. Any changes in these values indicate power dissipated in the insulation. Lower
DF and PF means lower dielectric losses [13]. For mineral-oil-immersed power transform-
ers in normal condition, PF is lower than 0.5%. PF value between 0.5% and 1% could be
acceptable, whereas a PF value over 1% is an indication of insulation degradation [13].
𝐼 (3)
% Power Factor PF = % cos θ = × 100%
𝐼
The value of DF represents the average index of the dielectric integrity considering
both capacitive and resistive currents in the apparatus. For detailed analysis of insulation
quality, the trend of IC and IR variation is investigated. The main drawback of DF analysis
is that it provides an average condition of insulation integrity, and the results are sensitive
to the ambient temperature [13]. This test is generally performed on-site during commis-
sioning, regular maintenance, or malfunction investigation. The results of DF measure-
ment are compared to previous DF rates for analyzing the trend of insulation degradation.
Online PF measurement is available for assessing the insulation condition of bush-
ings. Figure 7 shows the equivalent circuit for a bushing’s PF setup [29]. The bushing has
dielectric resistance RX shunted by a capacitance CX, with bushing tap U2 connected to the
ground through an impedance ZM. The voltage U2 is compared to a reference voltage U1.
Bushing condition changes result in changes in the amplitude and phase of U2 with respect
to the reference voltage.
(a)
(b)
Figure 8. (a) Basic RVM measuring circuit and (b) measurements.
Energies 2022, 15, 3379 9 of 32
(a)
(b)
Figure 10. (a) Basic PDC measuring circuit and (b) waveform of polarization and depolarization
currents.
Energies 2022, 15, 3379 10 of 32
FDS was found to be of good consistency with other chemical and electrical analysis
methods, and hence, it has been a preferred method among the three dielectric response
analysis techniques [42]. In addition, FDS detection method exhibits less sensitivity to ex-
ternal noise than PDC [38].
(a)
(b)
Figure 12. (a) Basic FDS measuring circuit and (b) typical FDS response.
Energies 2022, 15, 3379 11 of 32
(a)
(b)
Figure 13. FRA measurement example; (a) transfer function amplitude. (b) Transfer function phase
angle.
While the SFRA measurement is well developed and standardized, analysis of the
obtained results is still a challenging task. Some attempts have been published in the lit-
erature in order to identify and quantify mechanical faults based on SFRA signature. Most
of these techniques are developed based on artificial intelligence [45], statistical coeffi-
cients [46], and the estimation of transformer equivalent circuit parameters [47]. While the
current industry practice only looks at the SFRA magnitude signature, some studies pro-
posed the integration of SFRA magnitude and phase angle plots into 2D or 3D plots to
facilitate the application of digital signal processing techniques and improve the accuracy
of the interpretation process [48].
The main drawback of the SFRA measurement technique is its offline nature that calls
for taking operating transformers out of service. Some attempts were published in the
Energies 2022, 15, 3379 12 of 32
literature for the possibilities of using the natural switching operation, lightning, and im-
pulse signal for online SFRA measurements [49,50]. However, none of these techniques
has been implemented in real field applications yet. The main issue of implementing
online SFRA measurements is the requirement to impose a signal of a wide frequency
range to the electricity grid in which the power frequency should be maintained at 50 or
60 Hz. Some studies proposed the use of transformer I–V Lissajous patterns at the power
frequency [51] as an alternative online technique to the offline SFRA method. However,
this method has not been tested in real field applications yet.
V = = (4)
The measurements are compared to the ratios on the nameplate for all windings and
tap positions. The limitation of the difference ∆ratio given by (5) should be within 0.5%, and
for new transformers, this tolerance is within 0.1% [30].
V −V (5)
%∆ = × 100%
V
The TTR is a popular offline method due to the availability of test devices [54]. It is
also an important test for transformers operating in parallel. If the turns ratio of two par-
allel transformers is not equal, the voltage difference between transformer outputs will
generate circulating current through busbars. Even small turns ratio error will cause sig-
nificant equalization current and result in excess heat and power losses [54].
To perform online DGA, the monitoring sensor is placed in direct contact with the
transformer and a pump is required to circulate the oil through the measuring unit. It
usually takes three steps: gas extraction, gas detection, and data analysis.
Temperature at Which
Gas–Formula Molecular Source of Gases
Gas Forms
<150 °C—corona effect in Partial discharge
oil thermal faults
Hydrogen–H2
>250 °C—thermal and elec-
Power discharges
trical faults
Corona, partial dis-
charge, low to/and
Methane–CH4 <150 °C–300 °C
medium tempera-
ture faults
High-temperature
Ethylene–C2H4 300 °C–700 °C
thermal faults
Low to/and me-
Ethane–C2H6 200 °C–400 °C dium temperature
faults
High hot spot. Low
Acetylene–C2H2 >700 °C
energy discharge
Thermal faults in-
105 °C–300 °C
Carbon Monox- volving paper press
ide–CO >300 °C complete decom- board, wood and
position etc.
Normal ageing,
Carbon Dioxide–
100 °C–300 °C thermal fault in-
CO2
volving cellulose
Indicator of system
Vacuum when temperature leaks, over pressur-
Nitrogen–N2
drops ization or changes
in temperature
Exposure to air,
Vacuum when temperature leaky gasket, air
Oxygen–O2
drops breathing through
conservator
Figure 16. Example of voltage signal output of SOFC detector equivalent to gas concentrations.
Energies 2022, 15, 3379 15 of 32
The schematic diagram of a PAS unit is shown in Figure 18 [59]. In this system, the
light from the laser source passes through the light chopper and is measured using a
photo-acoustic cell. The light chopper wheel rotates and switches the light on and off. The
frequency of the light chopper is measured with a photo detector and is used as a reference
frequency. The performance of the PAS detection unit mainly depends on the laser light
source characteristics. If the frequency of the light coincides with the gas absorption band,
the gas molecules will absorb part of the light. According to the Beer Lambert Law, the
higher the concentration of the gas in the cell, the more light will be absorbed. Figure 19
shows the electromagnetic spectrum of light. The spectrum includes γ-radiation, X-ray,
ultraviolet (UV), visible light, infrared red light, microwaves, and radio waves. The ab-
sorption spectrum for gas molecules mostly falls into three regions: near infrared (NIR),
middle infrared (MIR), and far infrared (FIR) [69]. The system uses various types of laser
light sources to increase the detection sensitivity. An optical microphone is used to reduce
the electromagnetic interference from the harsh environment around the transformer. It
also uses an optical power meter to monitor and avoid the power drift of the light source
under long operational periods [70].
Figure 19. The electromagnetic spectrum for various wavelength regions of light.
irreversible structural changes in the Pd layer [76]. This affects the sensor performance
and results in a loss of long-term stability. Hence, a variety of Pd alloys such as Pd–Mg,
Pd–Au, Pd–Ag, and Pd–Ni have been studied [71]. Pd combined with Ni has already been
implemented in industrial hydrogen sensors, e.g., Siemens Energy’s SITRAM Guard hy-
drogen sensor.
The limitation of KGM is its conservative nature as it relies more on the absolute
concentration of the gas rather than gas evolution. The failure rate is about 50% for incon-
clusive or wrong fault identification [77]. Additionally, CO is not always a good indicator
for thermal fault in insulating paper.
(b) Rogers’ Ratio Method
Rogers’ ratio method (RRM) uses the three gas ratios C2H2/C2H4, CH4/H2, and
C2H4/C2H6 to identify five different faults as shown in Table 6. Compared to KGM, RRM
can further diagnose three levels of thermal faults: low temperature, temperatures less
than 700 °C, and temperatures over 700 °C. For instance, if the ratio of C2H4/C2H6 falls
between 1.0 to 3.0 and the ratio CH4/H2 is larger than 1.0, then the transformer health
condition is considered to be in case 4—thermal fault less than 700 °C. RRM has limited
capabilities to identify faults even when the concentration of some gases is high [77].
Energies 2022, 15, 3379 18 of 32
Ratio 4 (R4)
Ratio 1 (R1) CH4/H2 Ratio 2 (R2) C2H2/C2H4 Ratio 3 (R3) C2H2/CH4
Suggested Fault Diag- C2H6/C2H2 Extracted
Extracted from Min- Extracted from Mineral Extracted from Min-
nosis from Mineral
eral Oil|Gas Space Oil|Gas Space eral Oil|Gas Space
Oil|Gas Space
1—Thermal decompo-
>1.0 >0.1 <0.75 <1.0 <0.3 <0.1 >0.4 >0.2
sition
2—Corona (low inten-
<0.1 <0.01 Not significant <0.3 <0.1 >0.4 >0.2
sity PD)
3—Arcing (high inten- >0.01,
>0.1, <1.0 >0.75 >1.0 >0.3 >0.1 <0.4 <0.2
sity PD) <0.1
%CH = (6)
%C H = (7)
%C H = (8)
Symbol Fault
PD Partial discharge
D1 Discharge of low energy
D2 Discharge of high energy
T1 Thermal fualts of less than 300 °C
T2 Thermal fault between 300 °C and 700 °C
T3 Thermal faults greater than 700 °C
DT Mixture of themal and electrical faults
Although the classic Duval Triangle can diagnose the basic faults, misclassification
can happen when the located point is close to the boundaries between adjacent sections.
Additionally, the analysis of the Duval Triangle can be inaccurate for a transformer with
a load tap changer and a non-mineral liquid transformer. Hence, various modified Duval
Triangles along with other geometrical shapes such as the pentagon have been introduced
[6,59,77,78].
Duval pentagon method (DPM) is similar to DTM. Instead of three key gases, DPM
employs five key gases: H2, CH4, C2H2, C2H4, and C2H6 and can diagnose six fault types
(PD, D1, D2, T1, T2, and T3) along with stray gassing (S) in mineral oil as shown in Figure
22. This method also exhibits misdiagnosing for faults close to the boundaries between
adjacent sections.
Online DGA method has been implemented for the online condition monitoring sys-
tem. However, all diagnostic methods are initially designed to determine a single fault.
When the transformers experience multiple faults, they are difficult to identify with cer-
tainty [77]. Therefore, developing new diagnostic methods based on artificial intelligent
methods can improve the accuracy of such systems [58,69].
UHF has two common methods: tuned UHF narrowband or medium band measure-
ment with variable centre frequency; and UHF broadband measurement with fixed band-
width [92,93]. Figure 24a shows an example of PD signal measured by tuned UHF nar-
rowband/medium band method [92]. The lower trace in the figure is the background noise
while the upper trace is the actual PD signal. It is worth mentioning that the interference
noise disturbs both the upper and lower traces [92]. Figure 24b shows a PD signal meas-
ured by the broadband UHF method with fixed bandwidth [92]. The setting of this is easy
to adapt, however, it has lower signal-to-noise ratio (SNR) [92].
Energies 2022, 15, 3379 21 of 32
(a)
(b)
Figure 24. (a) Signal of tuned UHF narrowband method and (b) bandwidth of UHF broadband
method.
Figure 26. Example of the electrical signal output from the Fabry–Perot optical sensor.
structure, the light in fibre coupler 1 is divided into two beams, through reference and
sensing fibres, and interfere again in fibre coupler 2 as shown in Figure 27.
Different from the Mach–Zehnder sensor, in the Michelson sensor structure, the two
light beams pass through the reference and sensing fibres, then are reflected by a Faraday
rotating mirror back to the previous path as shown in Figure 28. So, when the sensing
fibre is deformed by PD, it causes a phase difference between the two light beams [83].
In the Sagnac sensor structure, the light is divided at the fibre coupler as shown in
Figure 29. The two beams of light are travelling in opposite directions through the sensing
fibre. Then, the two light beams interfere at the fibre coupler. The PD event results in a
phase difference between the two optical signals [83,98].
Different from interferometers, Fibre Bragg Grating (FBG) sensors have a diffraction
optical structure. This detection technology is of a reflective structure in the core of an
optical fibre as shown in Figure 30 [99]. It reflects particular wavelengths of light and
transmits all others.
The optical sensors have advantages of being able to survive in harsh environments
such as in high temperatures and against chemical corrosion [96]. This offers an option to
install the optical sensors inside the transformer, which further reduces the external noise
interference. The geometric PD sensors’ location can be determined by utilizing multiple
optical sensors either around the transformer tank or in a sensor array [100–102]. Overall,
optical sensors have been proven to be effective techniques for PD detection.
a significant impact on the transformer condition monitoring and fault diagnosis tech-
niques. For example, if the oil is sampled for DGA measurement during a ramping period
in the generation and/or load, inaccurate values will be revealed [80,123]. On the other
hand, the harmonics in the voltage signal can be employed for online frequency response
analysis.
The use of multi-sensors to measure different diagnostic parameters may also call for
active research on wireless energy transfer to charge such sensors [124]. While the power
required by each individual sensor is small, the use of a large number of online sensors
may represent an additional burden to the network.
It is worth mentioning that with the worldwide efforts to reduce greenhouse gas
emissions and establish more DC and smart grids, the adoption of solid-state transformers
and advanced power electronic interfacing systems will be given much attention in the
very near future and the use of classical magnetic-core based transformers may be dimin-
ished [125,126].
5. Conclusions
Oil-immersed power transformer is a critical and expensive asset in power systems.
Failures of power transformers result in huge repair costs, environment disaster, and hu-
man injury or death. Therefore, reliable condition monitoring techniques must be adopted
to avoid such consequences. The conventional offline condition monitoring techniques
have been used for many years. Due to the offline line nature, the tests can only be per-
formed during scheduled maintenance and the opportunity to detect incipient faults
could be missed. The online condition monitoring technologies are relatively new and
have been given much attention by the industry and researchers. In addition, the power
industry is moving towards digital operation, which calls for more stable and accurate
online condition monitoring systems. Over the years, researchers and developers have
invented various online monitoring sensors and diagnostic methods such as DGA, PD,
thermal measurements, and vibration analysis.
This paper covers working principles of commonly used offline and online methods.
To design a most suitable condition monitoring system for a power transformer, it is im-
portant to understand the functions, measuring ranges, suitable diagnostic methods, and
advantages and limitations of each technique. The future generations of condition moni-
toring systems would be comprehensive and could provide users with more precise in-
formation. In such systems, it is expected to not only provide information about the health
condition of the transformer, but also to suggest a reliable asset management scheme and
estimate transformer remnant life based on the measured parameters.
Author Contributions: Methodology, L.J.; software, L.J.; validation, L.J., D.K. and A.A.-S.; formal
analysis, L.J., D.K. and A.A.-S.; investigation, D.K.; resources, L.J. and A.A.-S.; data curation, A.A.-
S.; writing—original draft preparation, L.J.; writing—review and editing, L.J., D.K. and A.A.-S.; su-
pervision, A.A.-S.; project administration, A.A.-S.; funding acquisition, S.K. All authors have read
and agreed to the published version of the manuscript.
Funding: This research received no external funding
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Acknowledgments: Authors sincerely acknowledge the support from BHP for providing a scholar-
ship to the first author to conduct her research on high voltage assets condition monitoring meth-
odologies. Authors also acknowledge the support from Curtin University, Australia for facilitating
research resources.
Conflicts of Interest: The authors declare no conflict of interest.
Energies 2022, 15, 3379 28 of 32
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