Photo-acoustics for DGA.

Developments and a Utilities Perspective

Michael Cunningham Kelman Ltd Randy Cox TXU Electric Delivery Dr Colin McIlroy Kelman Ltd
Presented at EPRI Substation Equipment Diagnostics Conference New Orleans, LA, USA March 6-9, 2005

Abstract
The application of Photo Acoustic Spectroscopy to Dissolved Gas Analysis and initial field and lab results are summarised. Developments in the implementation of a practical portable measuring device (Transport X) and user experiences from field trials are given. Subsequent enhancements to both operating practices and system software are described. The development of a permanent on-line transformer monitoring system (Transfix) using the same core technology is summarised and the results of initial field testing given on both Transformer main tank and LTC oil.

Introduction The importance of Dissolved Gas Analysis (DGA) in the diagnosis of transformer condition has been long recognised, and is commonly regarded as the single most important test for transformer asset management. Conventional techniques use Gas Chromatography (GC) to detect seven key gases present in the insulating oil, which traditionally entails taking samples from the transformer and transporting these to a laboratory. With the contention that the GC is designed for laboratory use and is not suitable for practical use in the field, Kelman decided to approach dissolved gas analysis from another direction. The aim was to provide the electrical industry with equipment that was accurate, reliable and easy to use, for both the portable application and for permanently installed on-line monitoring. Recently Kelman has described how Photo-Acoustic Spectroscopy can be used to perform DGA1, and how this new technology can be adapted to provide reliable DGA in a genuinely portable device, the Transport X2. This paper describes the further testing and developments of this technique to include moisture measurement, diagnostic algorithms and the development of on-line DGA.

The Photo-Acoustic Effect The photo-acoustic effect is caused by the ability of a gas to absorb electromagnetic radiation (e.g. infrared light). In absorbing the radiation the temperature of the gas will increase and, if the gas is held in a sealed container, this temperature rise will produce a proportional rise in pressure. If the light source is pulsed the pressure of the gas fluctuates in sympathy and these pressure waves can then be detected using sensitive microphones. There are two key facts that permit this effect be used for analytical measurements. The first is that each gas has a unique absorption spectrum, thereby allowing the frequency of the infrared source to be tuned to excite a given substance. The second is that the level of absorption is directly proportional to the concentration of the given gas. Therefore by selecting an appropriate wavelength and measuring the level of the resultant signal it is possible to detect, not only the presence but also the concentration of any given gas, even in a complex cocktail of other compounds. This forms the central principle of Photo-Acoustic Spectroscopy (PAS).

Photo-Acoustic Spectroscopy for DGA The conceptual design of a practical PAS measurement module is shown below. A simple hot wire source produces broad band radiation across the IR range that is focused into the measurement cell using a parabolic mirror. The chopper wheel rotates at a constant speed giving a stroboscopic effect to the light source. Before reaching the measurement cell the radiation is passed through one of a number of optical filters. These filters are designed to transmit the specific wavelengths chosen to excite one of the compounds under investigation. The sample is introduced into the measurement cell and the signal level is recorded from the microphones as each optical filter is indexed into the light path. The series of readings produced then gives the concentration of the desired compounds in the sample.

Figure 1. Photo-Acoustic Spectrometer Concept.

Photo-Acoustic Spectrometer Module Kelman has developed the module shown in Figure 2 to provide the core of both the portable and fixed instrumentation for performing DGA on transformer oil.

Figure 2. Photo-Acoustic Spectrometer Module. The module measures approximately 160 x 150 x 140 mm (6.5 x 6 x 5.5 in), weighing less than 2 kg (5lb). It is entirely self-contained with all the electronic processing required to make the measurement and control the system. The Transport X uses this module coupled with a custom-designed system for the extraction of the gas from the sample to give a completely portable, selfcontained analysis system. Figure 3 shows the system and illustrates the operation of the main elements in the design.

Figure 3. Transport X Portable DGA system, Principle of Operation. The oil sample is drawn from the transformer in the conventional manner. It is then introduced into the measurement container directly from the sampling syringe. The oil is stirred while the air in the headspace is re-circulated though

the sampling loop and oil to extract the dissolved gases. Once a stable equilibrium has been established the headspace gases are analysed using the PAS spectrometer, and the results presented on the integrated display.

Initial Testing of Transport X

Recently Kelman described how the Transport X was extensively tested worldwide and also beta tested by two major US utilities2. This included laboratory and field testing to assess accuracy and repeatability of the device and also to compare directly against the performance of the traditional GC technique. This was an important matter to address since prospective users would have to be satisfied that the results would tally with their current DGA program and the often significant amount of historical data accrued. These tests showed that, despite the wide ranging conditions and practices and the large variance in results that can exist between different laboratories3, the overall correlation between the two techniques is very strong. The very strong repeatability of results from the Transport X was also illustrated This is an extremely important issue for a reliable DGA program, for without good repeatability results cannot be depended upon.

Adding Moisture to the Transport X

On initial request from Randy Cox of TXU Electric Delivery (then Oncor), and subsequently reiterated by other US utility personnel, Kelman began to look at the possibility of adding moisture measurement to the Transport X. The option of having a moisture sensor in the oil sample to measure the water content, in a similar way to an on-line water monitor, was not feasible for a portable device that could be seeing many different oil samples over a short time period. Therefore Kelman had to look at this problem from another direction. H2O has a strong IR absorption characteristic; hence the ambient humidity is measured by the Transport X in order to compensate for variation. This was then further developed to monitor the moisture content of the headspace throughout the measurement cycle, detecting any change in humidity. This allowed Kelman to detect the relative transfer of moisture between the headspace and the oil sample. Since the initial humidity of the headspace prior to sample injection is known, looking at the relative transfer of moisture between the headspace and the oil sample can give the original moisture content of the oil in ppm. Tests have shown the results to be very repeatable and correlate well with the results from the traditional Karl Fisher technique. However, it should be

noted that this is not designed as a replacement for lab based moisture measurement. It is planned to further develop this to allow calculation of the percentage Relative Saturation (%RS) of the oil, provided a temperature reading was taken of the oil at the time of sampling.

Software Developments
Many users requested that the Transport X provide some assistance in the interpretation of DGA results. As a result the embedded software has been further developed to include features such as user settable Caution and Warning thresholds for gas levels, Rogers Ratios, Duvals Triangle and IEEE Key Gas diagnostic tools. These analysis algorithms do not give the definitive answer to the condition of the transformer in question and do have to be used with caution, (as stated in the existing standards); however they do offer a valuable tool to the user for the interpretation of DGA results if applied correctly.

Figures 4 7. Screen shots showing DGA interpretation tools. Further development will include algorithms to assist in the interpretation of DGA results from Load Tap Changers (LTCs). Traditionally LTC DGA interpretation has proved difficult, because the active operation of a tap changer is so different to a transformer main tank, and the interpretation is very type-specific to the tap changer in question. This area of DGA interpretation is not as fully matured as that for transformers, however a lot of work has been done in the industry,

including Randy Cox of TXU Electric Delivery4, and this is becoming much more understood. The Transport X will have a number of user selectable ratios and levels, based on industry experience. It will also allow the user to set their own thresholds and ratios, to provide the necessary flexibility for the area of tap changers. Kelman have also developed an initial version of TransportPro, an accompanying PC software package that allows records to be easily downloaded and stored. TransportPro allows easy searching and exporting of records, and it is planned to incorporate all the interpretation algorithms into this package.

Figure 8. TransportPro software and exporting to TOA

Danny Bates of Alabama Power, along with many others inn the industry indicated that it would be advantageous to US utilities if they could import their Transport X results into the software program TOA from DeltaX Research. As a result records from Transport X can now be easily imported into TOA and examined using that software.

Utility Experience of Transport X TXU Electric Delivery Initial TXU Electric Delivery Program
The pilot program for TXU Electric Delivery began in late 2003. The overall concept was to gather data from the Transport X, and compare that data against the in-house laboratory DGA values. TXU Electric Deliverys in-house laboratory

uses ASTM, method #D3612 (headspace extraction). The results are corrected to standard temperature and pressure (0 degrees Celsius, and 760 mm mercury). Referencing Table 1 you will see a total of 4 samples taken from the same unit at a substation located near downtown Dallas. This particular Load Tap Changer had maintenance performed recently, and the samples were taken as a follow up to that maintenance. There are a few things that we wanted to know about the new portable device from Kelman. The first of these is how well it compares to our laboratory, and the second is how well it compares to itself, i.e. the repeatability of the unit. Shown in Table 1, we elected to take one sample for our in-house laboratory and three samples with the Kelman Transport X. As you can see from the chart below, the Transport X not only compares well with the in-house laboratory, it also compares favorably with itself from a gas standpoint. You will notice a 13ppm difference between the in-house laboratory and that of the Kelman regarding the water content of samples one and three. We are not sure why this is the case, but again the Transport X shows good repeatability. Table 1 shows the in-house laboratory and the Kelman Transport X tracking very closely. As you will read later in this paper, following procedures is extremely important when testing samples of high gas values such as LTCs, and it could be that the cleaning process had some impact on the results of the water content in Table 1. We are continuing to work at finding our optimum procedures for sampling and testing in the field. We believe that the data below supports the fact that we are close. Table 1. Carbon Carbon Water Hydrogen Methane Ethane Ethylene Acetylene Monoxide Dioxide Sample# CH4 C 2H 6 C 2H 4 C 2H 2 PPM H2 CO CO2 Transfer 1 Transfer 2 Transfer 3 Transfer 4 16 10 10 10 15 16 15 15 13 14 15 14 84 79 82 77 18 17 18 17 30 22 23 20 639 650 605 567 LAB

26 In-House 38 Transport X 39 Transport X 38 Transport X

Procedures for TXU Electric Delivery

While the Transport X is easy to operate, it still requires some expertise to operate. In an independent laboratory, technicians perform this testing all day,

every day. As a result of that experience, the laboratory technician understands the importance of a clean piece of test equipment, as well as a clean sample for test. The field technician may well recognize the importance of a clean sample for test, but when it comes to the test device itself, they may have a learning curve when it comes to the value of a clean piece of test apparatus. The equipment is only as reliable as the technician running the sample, provided it is properly calibrated. In the earlier portion of the pilot program, technicians were only purging the unit one time before performing the next test. As many of the samples being tested were LTCs with very high gas values some of the gases from the previous test did affect the next sample test. After some discussion with Kelman personnel, TXU Electric Delivery elected to adopt their own cleaning procedures. These entail cleaning the sample jar twice with a dry rag. Each time we would use a new clean rag, or paper towel, and then run two air samples (atmosphere) through the unit, reaching less than zero before continuing to the next test (this does not include CO and CO2 due to the amount of these gasses present in the atmosphere). There are times when running the air test once is sufficient. Prior to running the samples we flush the injection tube with air five to six times to ensure there is no gas residue or oil left in the tube. This procedure allows for more favorable comparisons between the Transport X, and the in-house laboratory when sampling high gassed samples from LTCs.

Figure 17. Randy Cox and Tracy Nolan of TXU Electric Delivery Practical Use for TXU Electric Delivery TXU Electric Delivery sees two possible advantages associated with the Transport X. The first of these is the ability to measure fault gasses in transformers that have been removed from service during emergency situations

via relaying schemes. The industry at large uses Transformer Combustible Gas Analyzers for such emergency situations. While this test continues to be a very reliable test, in many cases a Dissolved Gas Analysis follows it up before returning the unit to service. Using the Transport X, the technician is able to actually see what gases exist in the oil, thereby enabling them to make a more educated decision regarding the service reliability of the transformer in question. This can save time and money. Without a way to determine these gases at the location, the samples must be sent to a laboratory to determine the results. This can take anywhere from a few hours to a few days, depending upon where the laboratory is located. When determining whether or not a fault exists in the transformer, the Transport X can be used to determine what gasses are present in not only the main tank, but also the Load Tap Changer, which can reduce outage times to the customer. It has only been in the last few years that utilities have begun to understand gassing patterns of LTCs. In the past the only way to know if a LTC had a problem was to open it up for inspection. In todays environment we are equipped to understand these gassing patterns, and also realize the significance of being able to interpret these results; thereby eliminating in some cases the invested labor expense of an internal inspection should one not be needed. One of the leading causes of transformer failures can be traced back to the LTC. By using the Transport X the technician can capture both samples, review the data and determine if a problem exists within the hour.

Further Testing
Extensive testing has continued with the Transport X around the world, in both laboratory and field conditions in countries such as South Africa, UK, France, Sweden, Mexico, Malaysia, Singapore, China, Ireland, Finland, Germany, Switzerland, Norway and more. While these tests are to voluminous to fully report here, they have shown overall that the repeatability of the Transport X is at least as good as any of the labs concerned, and often better. However, as the initial testing showed, the overall correlation between the laboratories and the Transport X is strong. One typical example which shows both the repeatability and the correlation with the GC is from a field test from Finland conducted 30th November 2004, where three transformers were tested from the national transmission company. Duplicate samples taken, with one sent to the local laboratory and the other tested on-site by using the portable unit. The lab results were returned in 3 days,

whereas the Transport X results were ready in 25 minutes. The portable device was tested for repeatability on one transformer, but the lab was not tested for repeatability. First Test (duplicate Transport X samples compared to GC result) Measurement Transport X (1st) Transport X (2nd) GC H2 52 52 66 CO 397 396 418 CO2 2071 2069 2337 CH4 17 17 14 C2H6 3 3 4 C2H4 31 31 34 C2H2 32 31 42 Second Test Measurement H2 CO CO2 CH4 C2H6 C2H4 C2H2 Third Test Measurement H2 CO CO2 CH4 C2H6 C2H4 C2H2

Transport X 7 254 1520 6 2 3 <1

GC 7 267 1784 4 2 3 Not detected

Transport X 3 171 1239 6 2 5 <1

GC 4 194 1471 4 2 5 Not detected

These tests illustrate the Transport X being tested in different countries and climates, demonstrating excellent repeatability and accuracy for a portable DGA unit.

Development of On-Line DGA

Kelman have now further developed the PAS module for DGA for the application of on-line monitoring. The Transfix is a self-contained DGA system, providing measurements of all the fault gases plus oxygen and moisture. There are no consumables required, such as tanks of carrier gases or calibration gases. Figures 9 and 10 show the system and illustrate the connection to the transformer.

Figure 9. Transfix Unit

Figure 10. Connection to the Transformer

This new on-line device has a programmable sampling rate and can test the transformer up to every hour. This allows the electrical company to have an in depth view into the condition of their transformer, viewing important behaviour such as load and temperature dependence. The Transfix does not require a membrane for gas extraction, nor does it use vacuum. The target gases are reliably extracted from the oil sample by controlled excitation, with all oil being safely returned to the transformer after sampling. The extracted gases are analysed using the Kelman PGA module, with the internal memory able to store up to 10,000 records. An important advantage of this technique is that the results are real time DGA snapshots of the transformer. This on-line device does not use averaging over time to get information on the gas content of the oil, but rather replicates true oil samples being taken up to every hour.

Wide-ranging local and remote communications options mean that the Transfix is easily adapted into any system. These include modem, GSM, Bluetooth and LAN, with the additional capability of a MODBUS option. The system also has extensive alarm capabilities, allowing flexibility in configuration. There are six independent alarm screens available, each settable by the operator. These are based on gas levels, rates-of-change, total gas levels or gas ratios; therefore the user is able to have up to six alarm screens configured at the same time. For example, one screen could monitor Caution and Warning for individual gas levels, another could monitor rates of change of particular gases and another could monitor ratios of various gases, thus allowing Transfix to analyze many different potential fault scenarios. Each screen can activate the front panel LEDs (see Figure 3), one of three alarm relays or send warning messages, even via SMS messages (only available with GSM option). There will also be detailed history kept of all alarm settings. An important part of the package is the TransCom PC software. This allows the user to configure all alarms and sampling rates, offering password protection for all settings if required. The operator can interrogate the Transfix (remotely or locally, depending on the comms options selected) and download all DGA data. TransCom is also used to graph and trend results in order to aid the diagnosis of transformer condition. The new Transfix has been installed from September 2004 for extensive testing in the US and Europe. As previously with the Transport X trials, the Beta Test sites in the US are TXU Electric Delivery and Alabama Power, although many other US utilities have adopted the system.

Figure 11 & 12. Danny Bates of Alabama Power at the Transfix Installation

Figures 13 14. Texas Transfix Installation. In order to see some significant values in a short period of time it was decided by Danny Bates of Alabama Power to install their Transfix onto a LTC. A newly installed resistive-type tap changer unit was chosen, as this would produce small amounts of gas for every tap position change, thereby simulating a developing fault on a power transformer. The data gathered from this unit is shown in Figure 15, using the software.

Figure 15. LTC test site for Transfix. (Results shown on TransCom)

For the installation on a healthy transformer main tank the Transfix does not see the dramatic rise in gases shown in Figure 15. Instead Figure 16 illustrates the typical TransCom display from a healthy transformer site.

Figure 16. Transfix data from a healthy transformer main tank.

A Utilities Perspective on Transfix TXU Electric Delivery

The Transfix is the online version of the Transport X. TXU Electric Delivery installed the unit in the Fall of 2004. The transformer was selected due to its gassing history. In Table 2 you will find the results of this unit as compared to the in-house laboratory, and the portable Transport X.

Table 2. Sample# Carbon Carbon Water Hydrogen Methane Ethane Ethylene Acetylene Monoxide Dioxide LAB CH4 C 2H 6 C 2H 4 C 2H 2 PPM H2 CO CO2 Main 1 687.4 100.5 15.1 0.3 3.2 6.4 939.4 0.5 Transfix Main 2 734.7 100.4 16.8 0.7 3.2 6.2 958 0.5 Transfix Main 3 725.4 100.6 16.6 0.8 3 6 949.1 0.3 Transfix Transport Main 4 602 108 33 1 <1 10 905 5 X Main 5 958 105 27 0 0 4 869 3 In-House

The Transfix unit compares favorably with the Transport X and our in-house laboratory with a few exceptions, which we are currently working together with Kelman to correct. The portable unit and the on-line unit compare within reason to H2 while the in-house laboratory is a few hundred ppm higher. With regards to C2H6, the Transport X and the in-house laboratory compare favorably, while the Transfix is half the value. There was an hour difference between sampling for each of the Transfix tests mentioned above. You will also notice from Table 2 that the Transfix C2H2 values are at 3-ppm, while the Transport X and the inhouse laboratory are at zero. This Transfix unit is a beta test system, and Kelman personnel are currently working with us to resolve these issues.

Conclusion
Extensive laboratory and field testing has shown that the technique of Photoacoustic Spectroscopy can be applied successfully to dissolved gas analysis for the electrical utility industry. With extensive input from US utilities the portable device has been further developed to add moisture measurement and software support. The technology has also been applied to the area of on-line DGA monitoring, with a new product, with beta tests showing promise of dependable results with a flexible comms and software platform for the utility user.

References 1. McIlroy, Colin. Photo-Acoustic Spectroscopy, A New Technique for Dissolved Gas Analysis in Oil. EPRI Substation Equipment Diagnostics Conference, New Orleans, LA, USA. February 2326, 2003

2. McIlroy, Colin. A Comparison of Photo-Acoustic Spectrometer and Gas Chromatograph Techniques for Dissolved Gas Analysis of Transformer Oil. EPRI Substation Equipment Diagnostics Conference, New Orleans, LA, USA. February 15 18, 2004 3. M. Duval; CIGRE T-07; 2001 4. Randy Cox. FinePoint, Pittsburg. October 2002