Benefit of sensors for on-line
Mots clés
H41
monitoring systems for Power Transformer,
Condition
power transformers
Assessment,
On-line Monitoring
Internet
Par S. Tenbohlen *, T. Stirl *, M. Rösner *
* Alstom T&D, Germany
To increase availability and to achieve optimised operating management on-line
condition monitoring for power transformers is useful and necessary.
L ‘ ESSENTIEL
L‘essentiel
Pour augmenter la disponibilité et obtenir une gestion opérationnelle optimum, un système de surveillance d’état en ligne est utile et
nécessaire pour les transformateurs de puissance. Basé sur des expériences faisant appel à un nombre très important de systèmes
en fonctionnement, un ensemble de capteurs généralement utilisés est proposé. Ensuite, sont décrits le mode d’acquisition de
données ainsi que l’analyse et la distribution en utilisant un système moderne de surveillance d’état connecté à Internet.
Au moyen de modèles mathématiques, les données acquises par mesure sont converties en informations utiles pour un diagnostic
fiable. L’évaluation des données acquises sur site montre la possibilité de détecter des problèmes concernant la partie active, les
traversées, le changeur de prises ou les réfrigérants avant qu’un incident grave se développe. En particulier, les algorithmes de
calcul de la capacité de surcharge sont d’importance grandissante.
Synopsis
To increase availability and to achieve optimised operating management on-line condition monitoring for power transformers is useful
and necessary. Based on the experiences with a considerable amount of systems in operation a generally applicable set-up of
sensors is proposed. Furthermore the way of data acquisition, analysis and distribution by using a modern monitoring system
connected to the internet is described.
By means of mathematical models the acquired measured data are converted to useful information for a reliable condition diagnosis.
The evaluation of data acquired on-site shows the capability to detect problems within active part, bushings, on-load tap changer and
cooling unit before they develop into major failures. Especially algorithms for the calculation of overload capacity are of increasing
importance.
these data allows the early detection of an oncoming
1 Introduction fault. In order to enable a consistent utilisation of the
technically possible load capacity of the transformer,
Transformer outages have a considerable economic statements regarding the current overload capacity, for
impact on the operation of an electrical network. example, can be made.
Therefore it is the aim to ensure an accurate assessment
of the transformer condition. Techniques that allow 2 Description of Monitoring System
diagnosing the integrity through non-intrusive tests can
be used to optimise the maintenance effort and to ensure
maximum availability and reliability. With the 2.1 Sensor Set-up
increasing average age of the transformer population A multitude of different measurable variables can be
there is an increasing need to know the internal collected for on-line monitoring [1]. However, it is very
condition. For this purpose on- and off-line methods and rarely useful to use the entire spectrum. Therefore,
systems have been developed in recent years. On-line sensor technology must be adjusted to the specific
monitoring can be used continuously during the requirements of a particular transformer or transformer
operation of transformers and offers in that way a bank, depending on their age and condition. From the
possibility to record different relevant stresses which experience of more than 150 monitoring systems the
can affect the lifetime. The automatic evaluation of
following general set-up of sensors for example is The user expects from a monitoring system an easy and
proposed for the use at a 400 kV power transformer: safe access to all necessary information about the
• PT100 for measurement of top oil temperature installed electrical equipment. This means not only
power transformers, also GIS, circuit breakers,
• PT100 for measurement of ambient temperature disconnectors are of fundamental importance [3]. The
• C.T. for measurement of load current (single phase) dispatching centre should be informed about loading
• Measurement of voltage at measurement tap of capacity (overload calculation). The operation and
bushing (three phase) maintenance department should perform condition
assessment and plan maintenance procedures exactly
• Measurement of oil pressure of bushing (Fig. 1).
• Sensor for measurement of oil humidity This wide distribution of information can be done by a
• Sensor for measurement of gas-in-oil content web-based solution. An additional module installed on
• Tap changer position the monitoring server allows to generate HTML-based
web pages, which show both on-line and historical data
• Power consumption of motor drive (Fig. 2). If the monitoring server is connected to the
• Digital inputs for switching status of fans and local area network (Intranet) of the utility, all
pumps departments will receive the necessary information.
Therefore the number of users directly connected to the
2.2 Architecture monitoring server is practically unlimited. Password
With the Alstom monitoring system MS 2000 the protection gives only specific users the right of data
outputs of the above mentioned sensors are wired onto access. By use of a firewall it is also possible to have
field bus terminals in the monitoring module installed at access to the complete substation by use of the Internet.
the transformer. Within these data acquisition units the
analogue signals are digitised and send via a field bus to
the monitoring server. By means of this industrial
proven technology it is possible to monitor all
transformers in one substation with a single system
which is extremely cost effective. The erection of the
server in an operating building offers the advantage that
the ambient conditions (e.g. temperature, vibrations) are
much more suitable for a PC. The connection to the
protection and control system can be done either by dry
relay contacts or a digital protocol according to IEC
60870-5-101 [1,2].
2.3 Distribution and visualisation of monitoring
data
In order to prevent outages and save maintenance
Fig. 2: Web-based visualisation of transformer condition
expenditures on-line monitoring systems are installed at
the main equipment of the substation (power
transformers, circuit breaker, disconnectors). The access
to the monitoring data should be done by means of a
3 Practical Experience
standardised platform which is the Internet Explorer.
This prevents that on each desktop PC individual The begin of on-line monitoring was characterised
software has to be installed. by the use of some individual sensors which were
dedicated to monitor only a small part of the power
transformer. For example a hydrogen sensor is used to
detect problems within the active part such as partial
discharges or hot spots. The philosophy of concentration
on a specific part of the transformer was forced by the
individual experience of specific failures within an
utility. This means if a utility experienced problems
with bushings, the main efforts were related to the
diagnostic of bushings.
But the analysis of reasons for failures of a larger
population of transformers than these of a single utility
showed that majors failures occur in all parts of the
transformer [16]. So the wish of having a
comprehensive system which not only monitors the
Fig. 1: Data access by use of the Internet
active part but also other important and failure reluctant
components such as on-load tap changer and bushings is in accordance with the output of the Hydran sensor
understandable. During the last years the monitoring (108 ppm). So the reason for the increased gas-in-oil
system MS 2000 was installed world-wide at power content was the increased value of CO, which was
transformers of all major manufacturers. In the generated because of the normal increase of oil
beginning utilities started to test the system with grid- temperature. Thus for exact interpretation of the Hydran
coupling transformers of minor importance. Due to the signal the knowledge of load and temperature is needed.
good experience it is now operating at such strategical
important points as nuclear power stations, pumped
storage power stations, coal power stations and aluminia
industry. Most of these installations were retrofitted on-
site at already aged transformers. Normally the
installation of sensors requires no welding at the
transformer and takes about two days. The transformer
has to be taken out of operation only for half a day to
install the voltage sensors and the tap changer
monitoring module.
3.1 Active Part
For early failure detection, the monitoring of the
active part is of particular importance. It is fundamental Fig. 3: Gas-in-oil amount dependent on load and top oil
to measure the electrical variables load current and temperature of a 80 MVA grid transformer
operating voltage directly at the transformer. A
bushing-type current transformers is used for load 3.3 Oil humidity
current measurement. The load current and top oil A capacitive thin film sensor is used for the
temperature are the starting variables for calculation of detection of moisture in oil. There are several causes
hot-spot temperature according to IEC 60354 and for an increase of water-in-oil content. After improper
ageing rate of active part insulation [5]. This enables the shipping and erection of the transformer on-site the oil
evaluation not only of information regarding lifetime can be contaminated with water. Breathing of the
consumption but also of the temporary overload transformer can cause absorption of moisture by the oil
capacity of the transformer [4]. in the conservator. Due to the fact that water is a result
For the assessment of the mechanical condition of and also an origin of paper degradation the water-in-oil
the windings the knowledge of number and amplitude of content is an important indicator for the condition of
short circuit currents is of tremendous importance. winding insulation. It is reported that 4 % water content
These are detected and evaluated by using a high in paper for example increases the ageing rate by a
sampling rate for the load current signal. factor of about 20 [7]. So measurement of oil humidity
is recommended in particular for transformers which are
3.2 Gas-in-oil amount already aged or operate usually at high oil temperatures,
For the gas-in-oil detection a Hydran sensor is because accurate calculation of ageing rate requires the
used which reads a composite value of gases in ppm (H2 input of moisture content. Up to now the transformers
(100%), CO (18%), C2H2 (8%), C2H4 (1,5%)). As equipped with a sensor for oil humidity are uncritical
hydrogen is a key gas for problems in the active part, an regarding moisture in oil. So practical experience in
increase in the output signal of the sensor is an detecting moisture problems on-line is limited, but
indication for irregularities such as partial discharge or nevertheless the sensors are needed for accurate
hot spots [6]. The evaluation of this measuring signal, calculation of ageing rate.
together with the dependency on the temperature of the As the transformer warms up, moisture migrates
oil and the load current, provides a reliable basis for the from the paper into the oil. From this so called
continuous operation of the transformer. In the event of equilibrium of moisture in oil and paper also the water
an increase of gas-in-oil content, an immediate reaction content in the paper can be calculated by the monitoring
can be effected via an off-line dissolved gas analysis system [8, 9]. This value is needed for the calculation of
(DGA) to determine the concentration of the other the emergency overload time. Moisture in paper restricts
components dissolved in the oil in order to clarify the the loading capacity because of the risk of bubble
cause of the potential damage. emission. Also the release of water drops from winding
In Fig. 3 the gas-in-oil amount of a 80 MVA grid paper to oil can occur. So the acceptable limit for the
coupling transformer for an aluminia plant is shown for hot spot temperature is dependent on the water content
the time interval of one year. The monitoring system in the paper [10].
detected an increase of gas-in-oil content. The reason
was assumed to be the temperature increase during
summer. A DGA performed in August revealed a CO
content of 427 ppm of CO and 27 ppm of H2 which is
3.4 Bushings
3.4.1 Detection of overvoltages
The voltage applied to the transformer is acquired at
the measuring tap of the capacitor bushing by means of
a voltage sensor. It acts with the capacity of the bushing
as a voltage divider. This enables not only the
measurement of the operational voltage but also the
detection of overvoltages, because due to its design the
voltage sensor has a bandwidth up to some MHz. The
output of the voltage sensor is connected to a peak
sampler to detect the amplitude of overvoltages by the
monitoring system. Overvoltages represent an essential
risk potential for the insulation of transformer windings.
Fig: 4: Voltage and change of capacitance of 400 kV
Taking into account the volume of noxious gases which
bushings
are dissolved in oil deductions can be drawn about the
possible damage to the insulation of the active part after
3.5 On-load Tap Changer
the occurrence of overvoltages.
3.4.2 Change of capacitance An important component of a power transformer
Failure of condenser bushings occurs often because and also a frequent reason for severe failures is the on-
of partial flashover of the metallic foils which are used load tap changer [13]. Therefore the monitoring of this
for controlling the electrical field within the bushing. highly stressed element is a necessity.
Such partial flashovers do not lead to a sudden failure of 3.5.1 Tap changer position
the bushing, but they are growing from layer to layer Recordings of the tap changer position and the
until the voltage stress of the remaining layers is so high operating current help to determine the number of tap
that complete breakdown occurs. If a partial flashover switching operations and the total switched current.
of one layer occurs, the capacitance of the bushing will As the contact wear of the diverter switch contacts is a
be increased according to table 1 by ∆C. function of the switched load current this information is
needed for performing a condition based maintenance
Voltage [kV] Number of foils ∆C for the diverter switch [14]. If an excessive wear
123 28 3.6 % situation is undetected, the contacts may burn open or
245 42 2.4 % weld together. To avoid these problems limiting values
400 60 1.7 % for the time in service, number of operations and total
550 70 1.4 % switched load current, can be pre-set in accordance with
Tab. 1: ∆C for partial flashover of one layer for oil- the maintenance instructions of the OLTC
impregnated bushings [9] manufacturer.
The change of the capacitance ∆C of the bushings 3.5.2 Assessment of mechanical condition
can be detected by the monitoring system by comparing OLTC failures are often dominated by mechanical
the output of one voltage sensor with the average value faults in nature. Such defects can be for example broken
of the other two phases. The result is processed by linkage, failure of springs, binding of contacts, worn
averaging algorithms to eliminate imbalances of the grid gears and problems with the drive mechanism [15].
voltage and variations due to temperature changes. This Mechanical and control problems can be detected by
is assumed to be possible, because the deterioration measurement of the power consumption of the OLTC
process normally has a considerable longer time drive, because additional friction, extended changer
constant. This triggers an alarm and a warning operation times and other abnormalities have a
In Fig. 4 the change of capacitance of a 400 kV grid significant influence on the drive current. An event
coupling transformer is shown for a time interval of two record of the power consumption is captured during
month. It can be seen that variations due to unbalanced each tap changing process and analysed by evaluation of
voltages and temperature variations is in the range of 6 characteristic parameters which are:
0.4 %. The signal to noise ratio is therefore sufficient to 1. Time of inrush current:
assess the insulation condition reliably. At a warning The inrush current flows during a period of about
level of 1 % the monitoring system triggers a message 300 ms. It is related to the static friction and backlash in
for inspection of the bushing. the linkages.
2. Total switching time:
Variation of time required for a tap changing
process indicates problems with the control of the
OLTC.
3. Power consumption index: 3.6 Cooling Unit
The energy consumed by the motor drive during a 3.6.1 Thermal resistance
tap changing process divided by the total switching time The thermal resistance Rth describes the efficiency
is represented as the power consumption index. This of the cooling unit. For air-cooled power transformers
value is dependent on the operation temperature and the actual thermal resistance can be calculated by the
characterises the average running conditions. following equation:
4. Maximum sector 1 (S1):
ϑoil − ϑ air
During the motion of the selector contacts, the Rth , act =
amplitude of the power consumption is monitored. This P0 + Pk , n ⋅ k 2
value represents the maximum during opening and The result has to be averaged to eliminate variations
moving of the selector contacts. due to the dynamic behaviour of load factor oil and
5. Maximum sector 2 (S2): ambient temperature. Furthermore the number of fans
This value is the maximum during the closing of the and pumps in operation has to be taken into account to
selector contacts. calculate the nominal thermal resistance Rth.
6. Maximum Sector 3 (S3): On-line monitoring of the cooling unit of a 420kV /
600MVA grid-coupling transformer by calculation of
The amplitude of the power consumption is the nominal thermal resistance Rth showed a strong
recorded during diverter switch action. increase after switching on of two additional fans which
These six parameters characterise each tap changing was signalled by the control system (Fig. 6). This
process and in case of deviations warning messages are increase triggered a warning message by the monitoring
generated. In Fig. 5 such a situation is presented for system. A local check in the substation revealed that due
three successive tap changing processes recorded during to a failure of energy supply only half of the cooling
maintenance of the OLTC. The first two signatures (A, unit (3 fans) was in operation and therefore only three
B) show a regular tap changing process. The peaks on fans were running. This status was not in accordance
the curves are caused by the friction of opening, with the information of the control system and led to the
revolution and closing of selector switch [2]. Because strong increase of nominal thermal resistance. With the
tap changing process C differed significantly from a present load and half of the cooling power the
normal tap changing, the parameters for total switching transformer could be kept in service. But it would not be
time, maximum sector 2 and 3 and power consumption possible to operate the transformer with nominal load
index showed abnormal variations. Based on this the due to the missing cooling power. This scenario shows
monitoring system sent an alarm message to the the importance of detecting also minor failures to avoid
responsible engineer. the risk of not delivering energy
The root cause analysis revealed that during the tap
changing process C the handcrank was inserted into the
drive mechanism which interrupted the process and 80 Toil 18
therefore triggered the warning message. So this 70
RthN
16
problem was caused by incorrect operation and not an 14
internal problem, but this event illustrates the 60
No. of Fans
Rth [K/MW ], Toil[°C]
12
capabilities as an early warning system for mechanical 50
anomalies. 40
10
8
30
6
20
4
10 2
0 0
7.1. 17.1. 27.1. 6.2. 16.2. 26.2. 8.3.
Fig 6: Abnormal condition of cooling unit detected by
increase of thermal resistance Rth
4 Conclusion
The justification for on-line monitoring of power
transformers is driven by the need of the electrical
Fig. 5: Faulty tap changing process utilities to reduce operating costs and enhance the
availability and reliability of their equipment. The
evaluation of data acquired by an on-line monitoring
system shows the capability to detect oncoming failures
within active part, bushings, on-load tap changer and
cooling unit. Using the benefits of modern IT- Symposium on High Voltage Engineering,
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[9] Y. Du et al.: “Moisture equilibrium in
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Insulation Magazine, 1999, Vol. 15, No 1
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