World Academy of Science, Engineering and Technology

Vol:6 2012-08-20

An Elin Load Tap Changer Diagnosis by DGA

Hoda Molavi, Alireza Zahiri, Katayoon Anvarizadeh
AbstractDissolved gas analysis has been accepted as a
sensitive, informative and reliable technique for incipient faults
detection in power transformers and is widely used. In the last few
years this method, which has been recommended by IEEE Power &
Energy society, has been applied for fault detection in load tap
changers. Regarding the critical role of load tap changers in electrical
network and essential of catastrophic failures prevention, it is
necessary to choose "condition based preventative maintenance
strategy" which leads to reduction in costs, the number of
unnecessary visits as well as the probability of interruptions and also
increment in equipment reliability. In current work, considering the
condition based preventative maintenance strategy, condition
assessment of an Elin tap changer was carried out using dissolved gas
analysis.

International Science Index Vol:6, No:8, 2012 waset.org/Publication/15633

KeywordsCondition Assessment, Dissolved Gas Analysis,

Load Tap Changer
I. INTRODUCTION

OAD tap changers (LTCs) for power transformers are

essential components of the electrical networks. It has
been estimated that a third of all transformer failures can be
traced to faulty LTCs [1], [2].
Since LTCs are the only movable part of power
transformers, they suffer from various aging mechanisms [3].
Common LTC failures are being caused by mechanical
malfunction, increased contact resistance, localized thermal
stress, material failure, breakdown of the insulating oil
(coking), contact wear, improper design or high loads
[1].Utilities seek new methods and technologies to extend the
service intervals and monitor equipment condition to avert
catastrophic failures, reduce maintenance costs and increase
the reliability of power delivery and distribution [1].Corrective
maintenance, Period based preventative maintenance and
Condition based preventative maintenance are three classical
maintenance strategies [4]. The concept of corrective
maintenance is generally considered unacceptable for LTCs,
considering their important role on running the distribution
system. Regarding the variation in duty between different tap
changers in a same utility and the recognition of the high
reliability of in service tap changers, the traditionally using
"period based preventative maintenance" is going to be
replaced by "condition based maintenance" which offers
several advantages to the utility as following [5]:

Reduction in the required number of maintenance

visits
Reduction in maintenance costs
Reduction in the possible interruptions to supply
Reduction in the number of catastrophic failures
Increment in the reliability of power delivery and
distribution

H. Molavi is with chemistry and process group, Niroo Research Institute,

Tehran, Iran (e-mail:hmolavi@nri.ac.ir)
A. Zahiri is with chemistry and process group, Niroo Research Institute,
Tehran, Iran (e-mail:azahiri@nri.ac.ir).
K. Anvarizadeh was with chemistry and process group, Niroo Research
Institute, Tehran, Iran.

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There are several methods which are used as condition

monitoring and diagnostic methods for LTCs, some of which
are mentioned bellow. These techniques could detect the
incipient signs of deterioration which enables utilities to
choose "condition based maintenance" as their maintenance
strategy.

Dissolved gas analysis (DGA) of oil [6]-[8]

Dissolved metals in oil analysis [8]-[10]
Suspended particles in oil analysis [8]-[10]
Acoustic and vibration fingerprints [7], [8], [11]
Motor power fingerprints [11]
Position measurement of the driving axis [11]
Static and dynamic resistance measurements [7], [11] [13]
Temperature difference measurement [7], [11]
Infrared thermography [6]
Chemical implants [14], [15]

In current study, condition monitoring of an Elin load tap

changer was done using dissolved gas analysis for a threemonth interval by sampling in two stages. The obtained results
from two stages were compared and interpreted.
II. PERFORMANCE PROCEDURE
A. The Selected LTC
An Elin load tap changer of a 125 MVA power transformer
in a 230/63 substation was selected as the experimental pilot.
It is worth noting that 230/63 kV transformers are considered
as the most frequent used power transformers in Iran.The pilot
LTC had a sampling valve in the bottom of the equipment
which facilitated sampling procedure. Furthermore it was
possible to have overhaul over the equipment in the near
future which enables the authors to have eye inspection over
the selected LTC to compare their predictions with the results
from inspection. After choosing the LTC, a form containing
characteristic information of the selected LTC and its
transformer was filled. The information included the
company's name, the substation name and address,
transformer's name, voltage level range etc. It also comprised
LTC's information such as tap changer's type, its manufacture,
oil volume, breathing type, sampling valve position etc. Some
of the characteristics of the selected LTC have been presented
in Table I.
TABLE I
THE CHARACTERISTICS OF THE SELECTED LTC
LTC's type
MLG3.720
Operating time
26 years
Last Overhaul date
2003

Regarding the information in Table I and the recommended

maintenance interval by manufacturer, the overhaul operation
should be performed over the equipment at least 2-5 years
ago.It is worth noting that according to manufacturer advice,
overhaul operation should be performed every 5-7 years or the
number of operation of 70,000, depending on which is reached
first.

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World Academy of Science, Engineering and Technology

Vol:6 2012-08-20

International Science Index Vol:6, No:8, 2012 waset.org/Publication/15633

It should be noted that oil sampling was performed

according to ASTM D 3613 standard. The samples were
tagged, packed and forwarded to the laboratory considering
the mentioned standard [16].
III. ANALYSIS PROCEDURE
Dissolved gas analysis was carried out considering ASTM
D 3612 standard in a reliable laboratory [17].

16421.7

15546.4
15062.6

16000

1st stage

14218.4

2nd stage

14000
Concentration (ppm)

TABLE II
THE INFORMATION FOR EACH SAMPLING STAGE
1st stage sampling 2nd stage sampling
Sampling date
March 2012
June 2012
Number of operation since
203030
203528
last overhaul
Tap position
20
22
Oil temperature
28C
29C
Environment temperature
18C
21C

18000

12000
10000
6307.767

8000
5852.439
6000
4000
2000
0
H2

C2H2

C2H4

Fig. 1 Dissolved key gases concentrations for the selected LTC for
the 1st and 2nd stages of sampling
45000
1st stage

40000

2nd stage

35000
Concentration (ppm)

B. Experimental Work and Sampling

Before each sampling a form containing some essential
information such sampling date, number of operation since the
last overhaul, oil and environment temperature etc. was filled.
In Table II, the mentioned data has been presented for each
sampling stage.

30000
25000
20000
15000
10000
5000
0

IV. RESULTS INTERPRETATION

DGA data interpretation was performed by comparison of
each sampling stage data to the LTC monthly watch criteria
presented by Youngblood et al. [18]. If none of the
concentrations exceeds the threshold values, the LTC
performance is determined as normal operation.
In case of exceeding one of the gas concentrations from its
threshold value, the possibility of fault presence was
investigated by gas concentration ratio method presented in
reference [19]. If the ratios are in the "Needs attention" range,
the equipment is in normal operating condition. In the case
laying data in the "Possible damage" or "Detected damage"
range fault exists in the equipment. In this condition using the
Duval triangle 2, the fault type would be identified [20].
In addition of mentioned interpretation, a comparision
between DGA results from two sampling stages was
performed.
V. RESULTS AND DISCUSSION
In Figs. 1 and 2 dissolved key gases concentrations and
other dissolved gases concentrations including total dissolved
combustible gases concentration (TDCG) in oil for each
sampling stage are presented, respectively. Moreover, the
results from two sampling stages were compared in these
figures. For both sampling stages, the concentrations of
hydrogen, ethylene and acetylene (key gases) are beyond the
LTC monthly watch criteria; therefore the gas ratio method
was applied.

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CO

CH4

CO2

C2H6

O2

N2

T DCG

Fig. 2 Other dissolved gases concentrations for the selected LTC for
the 1st and 2nd stages of sampling

In order to use mentioned method, the following ratios were

calculated.
C2 H 2 + H 2
CH 4 + C 2 H 6 + C 2 H 4 + C 2 H 2 + CO + H 2
CH 4 + C2 H 6 + C 2 H 4
R1 =
CH 4 + C2 H 6 + C2 H 4 + C2 H 2

FR =

CH 4 + C2 H 6 + C2 H 4
C2 H 2
C2 H 4
R3 =
C2 H 2
R2 =

(1)
(2)
(3)
(4)

For obtained data from both sampling stages, all ratios were
laid in "Needs attention" range.
To ensure the fault absence in the equipment, the Duval
triangle 2 was applied for each sampling stage, as shown in
Figs. 3 and 4. The Triangle coordinates corresponding to DGA
results can be calculated as follows:
%CH 4 =

1890

CH 4
100
CH 4 + C 2 H 4 + C 2 H 2

(5)

%C 2 H 4 =

C2 H 4
100
CH 4 + C 2 H 4 + C 2 H 2

(6)

%C 2 H 2 =

C2 H 2
100
CH 4 + C 2 H 4 + C 2 H 2

(7)

World Academy of Science, Engineering and Technology

Vol:6 2012-08-20

International Science Index Vol:6, No:8, 2012 waset.org/Publication/15633

Fig. 3 Conditioon assessment oof the selected LTC

L
using the Duval
D
triangle 2 for thhe 1st stage sam
mpling

VI. SUMMARY
Since the "condition
"
based preventative maintenance
strrategy" is acccepted as thee most convvenient maintenance
strrategy, condition monitorinng over an Ellin load tap changer
waas performed using Dissollved Gas Analysis (DGA)) for a
thrree-month innterval by saampling in two
t
stages.T
The oil
sam
mpling was done
d
accordingg to ASTM D 3613 standarrd, and
sam
mples were annalyzed considering ASTM
M D 3612. DG
GA data
intterpretation was
w carried ouut using Thresshold value method,
m
Gaas concentratioon ratio methood as well as the Duval triaangle 2
meethod. Data innterpretation ffor the 1st sam
mpling stage showed
s
noo fault existennce. However, the results off 2nd samplingg stage
revvealed the exiistence of in progress
p
cokin
ng and heavy coking
or increased reesistance of thhe contacts or
o severe arciing. In
conclusion, the equipment neeeds to be testt or inspect foor signs
off faults. In casee of impossibiility for this recommendation it is
onth intervals which
addvised to repeaat the DGA teest in three-mo
helps to be awarre of the equippment conditiion and also to avert
cattastrophic faillures.
ACKNOW
WLEDGMENT
The authors gratefully
g
ackknowledge thee colleagues inn NRI:
Mrr. Zhaam, Mrr. Ahmadi, M
Mr. Ghadimi and
a also Dr. Porkar
froom IGMC. Wee also would llike to acknow
wledge NRI an
nd also
Mrr. Marjanmehhr and Mr. Fathhi for supporting this researrch.
[1]

[2]

[3]

[4]
[5]

Fig. 4 Conditioon assessment oof the selected LTC

L
using the Duval
D
triangle 2 for thhe 2nd stage sam
mpling

Regarding Fig.
F 3 for the 1st sampling
g stage, the crossing
c
pooint is located in N sectioon which corrresponds to normal
opperation and fault
f
absence. For the 2nd sampling stagge (Fig.
4)), the crossiing point is placed in X3 section which
coorresponds to
o in progresss coking andd heavy cokking or
inncreased resisttance of the coontacts or seveere arcing.
Considering the obtainned results from DGA
A data
innterpretation, in
i the first sam
mpling stage the
t equipmentt was in
goood conditioon. Howeverr regarding the recomm
mended
ovverhaul criterria by manufacturer, the overhaul opperation
shhould have performed at least 2-5 yeaars ago. For the 2nd
saampling stage,, there exist siigns of defectss in the equipm
ment. It
is recommendeed to test or innspect the LTC
C for signs off faults.
Inn case of impoossibility of innspection in neear future, in order
o
to
prrevention of catastrophic
c
faailures it is addvised to perfoorm the
DGA test in thrree-month inteervals.

[6]

[7]

[8]
[9]
[10]

[111]

[122]

[133]
[144]

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NRI (Niroo Research Institute) of Iran started its activities in 1997. It has
played a leading role in developing new technologies for Electric Power
Industry ever since. NRI is the major research organization affiliated to the
Ministry of Energy of Iran. NRI is performing the dual task of meeting the
present and future demands of electric power industry, while making a better
use of available resources, preserving the environmental and maintenance
costs as low as possible. NRI has invested considerably in providing adequate
conditions to achieve its objectives. The main building and laboratories of this
institute are located in the north-west of Tehran. Research activities are
carried out in 6 various research centers, consisting of 18 technical research
departments, using the facilities of 9 advanced laboratories.
Hoda Molavi is an assistant professor in Chemical Engineering at NRI.
She received her PhD degree in Chemical Engineering in 2010 from
University of Tehran. Furthermore, she received her MSc (2006) and BSc
(2004) degrees from University of Tehran and University of Mazandaran,
respectively. She is a member of Iranian Nanotechnology Society (INS). She
has been awarded as top graduating student of nanotechnology in 2011.Her
current research area is condition monitoring of electrical equipments using
oil analyses, application of nanotechnology in increment of equipment's
efficiency.
Alireza Zahiri is a researcher in Chemical Engineering at NRI since 2002.
He received his MSc (2004) and BSc (2002) degrees in Chemical Engineering
from University of Mazandaran and Amirkabir University, respectively.He is
a member of Iranian Corrosion Association (ICA) and Iranian Association of
Chemical Engineering (ICHE). His current research interests are condition
monitoring of equipment by oil analyses, life assessment, bi-metallic catalysts,
PCBs' destruction, paint and coating, failure analysis.
Katayoon Anvarizadeh was a researcher in Chemistry in NRI (19962011). She received her MSc and BSc degrees in Chemistry from Azad
University and Al-zahra University, respectively. Her research area was
condition monitoring of equipments using oil analysis.

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