Analysis of faults detected by

DGA method
in
GETCO

Mr.R.D.Naik

Ms. A S Shah

Chief Engineer (TR)

Deputy Engineer (TR)

Dissolve Gas Analysis (DGA)

Most
acceptable predictive maintenance tool for oil filled
transformer.
The gases are formed due to breakdown of insulating
under fault condition and dissolve in oil.

material

The distribution of gases has been related to type of fault.

The rate of gas generation has been related to severity of
fault.

Advantages of DGA

Non intrusive means of condition monitoring

Advance warning of developing faults
Prevent unexpected outage
Status checks on new and repaired units
Convenient scheduling of repairs
Reduce risk

Dissolve Gas Analysis (DGA)

The principal cause of gas generation in transformer are

1.Thermal Energy Dissipation
Decomposition of insulation due to copper loss
Chemical Reaction

2.Electrical Disturbance
Discharge of energy in oil
Arcing
The distribution of gases has been related to type of fault.
The rate of gas generation has been related to severity of
fault.

Gases analyzed by DGA

Methane
Ethane
Ethylene
Acetylene
Hydrogen
Carbon Monoxide
Carbon Dioxide
Nitrogen
Oxygen

CH4
C2H6
C2H4
C2H2
H2
CO
CO2
N2 -Non fault gas
O2 Non fault gas

some of these gases will be formed in larger or smaller

quantities depending on the energy content of the fault.
5

Methods for interpretation of DGA

Key Gas Method

Rogers Ratio Method
Duval triangle

DGA Diagnostic Tools

[1] Dissolved Gases acceptable limits as per IEEE C57.104
Conditi
on

H2

CH4

C2H2

Lower

Upper

Lower

100

120

101

700

121

400

701

1800

401

1800

inf

1000

Upper Lower Upper

C2H4

C2H6

C0

Co2

TDCG

Lower

Upper

Lower

Upper

Lower

Upper

Lower

Upper

Lower

Upper

25

50

65

350

2500

720

36

50

51

100

66

100

351

570

2500

4000

721

1920

1000

51

80

1010

200

101

150

571

1400

4001 10000 1921

4630

inf

81

inf

201

inf

151

inf

1401

inf

Normal
Above normal value. Additional investigation needed to establish
trend. Fault(s) may be present.

High level of decomposition. Additional invetigation needed to stablish

trend. Fault(s) are probably present.

Excessive decomposition. Continued operation could result

to failure of the transformer.

>10% increase per month above typical levels = active fault

>50% per week or evolving faults of higher energy = serious

10000

inf

4631

inf

DGA Diagnostic Tools

[2] Key Gases Method
Individual value of gases are taken in to consideration for evaluation.

DGA Diagnostic Tools

[3] Rogers Ratio-based method
Ratio method has to be employed in the incipient fault diagnosis. It has to be employed also
in conjunction with key gas method to check the severity of the fault.
Code for examining analysis of gas dissolved in Mineral oil
C2H2
C2H4

CH4
H2

C2H4
C2H6

<0.1
0.1-1
1--3
>3

0
1
1
2

1
0
2
2

0
0
1
2

Analyses

0
1
2
1--2
1
0
0
0
0

0
1
1
0
0
0
2
2
2

0
0
0
1--2
2
1
0
1
2

Code

NO FAULT
LOW ENERGY PD
HIGH ENERGY PD
LOW ENERGY SPARKING ARCING
HIGH ENERGY SPARKING ARCING
THIRMAL FAULT <150C
THIRMAL FAULT 150C-300C
THIRMAL FAULT 300C-700C
THIRMAL FAULT >700C

DGA Diagnostic Tools

[4] Duval Triangle
The method is based on 3
gases (i.e.CH4, C2H4,
C2H2)
The triangle plots the
relatively percentage of
three gases on each side.
The figure depicts 6 main
zone of faults .

Each DGA test report gives

one point in triangle , which
indicate the fault in the
respectively zone.

Type of Faults
IEC 60599 has defined 6 basic types of faults detectable by DGA.
1. Partial discharges of the corona-type (PD).
-Typical examples: Discharges in gas bubbles or voids trapped in paper, as a
result of poor drying or poor oil-impregnation.
2. Discharges of low energy (D1)
-Typical examples: Partial discharges of the sparking-type, inducing carbonized
punctures in paper.
-or low-energy arcing, inducing surface tracking of paper and
carbon particles in oil.
3. Discharges of high energy (D2)
-Typical examples: High energy arcing, flashovers and short circuits with power
follow through, resulting in extensive damage to paper, large
formation of carbon particles in oil, metal fusion.

Type of Faults
4. Thermal faults of temperatures < 300 C (T1).
Typical examples: Overloading, blocked oil ducts paper turning brown.
5. Thermal faults of temperatures between 300 and 700 C (T2)
Typical examples: Defective contacts, defective welds, circulating
currents.
Carbonization of paper or formation of carbon
particles in oil.
6. Thermal faults of temperatures > 700 C (T3).
Typical examples: Large circulating currents in tank and core, short
circuits in laminations. Sparking/burning of joints
formation of carbon particles in oil

Population of Power Transformers in GETCO

> 30 Yrs
16%

0 - 10 Yrs
32%

21 - 30 Yrs
17%
11 - 20 Yrs
35%

Sr. No.

Voltage
Class

Aging of Power Xmers in Years

Total
Nos.

0 - 10

11 - 20

21 - 30

> 30

400 KV

20

08

08

04

00

220 KV

195

60

85

31

19

132 KV

162

14

68

27

53

66 KV

1885

641

635

329

280

Total

2262

723

796

391

352

Practices Adopted by GETCO

DGA for 132KV & above class transformers once in a year.
However, frequency depends on rate of rise of individual
gas.
Table top assessment for normal & abnormal unit.
For abnormal unit, analysis of DGA done by Key gas,
Rogers ratio & Duval triangle through our own software
For abnormal unit, further low voltage testing & rectification
has been planned.

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 400/220 KV

Sr.
No

S/S

Asoj

Chorania

Vadavi

Fault observed

T3

Magnetic shunt on inner

tank body found shorted
with multiple earthing

MVA

167

Thermal
Fault
>500C

167

Thermal
Fault
>500C

Not defined

T3

Tertiary winding connections

loose. Other loose points
observed at HV

Thermal
Fault
>500C

Core and Tank

circulating
current,
Overloaded
Joints

T3

No abnormality observed
during internal inspection

315

Ratio Method
Analyses

Duval
Triangl
e

Key Gas
Method

Not defined

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 220/66 KV

Sr.
No.

S/S

Shivlakha

Kim1

Khanpur

MVA

100

100

100

Key Gas
Method

Thermal
Fault >500C

Ratio Method
Analyses

Core and tank

circulating
current,over
loaded joints

Thermal
Fault >500C

Not defined

Thermal
Fault >500C

Core and Tank

circulating
current,
Overloaded
Joints

Duval
Triangle

T3

Fault observed

In Y phase switch many

contacts found eroded. In
R phase and B phase
also contacts of preselector found eroded.

T3

OLTC lead connection to

winding loose, sparked
and bolt thread damaged

T3

Nut found at the bottom

touching the core and
also water found at
bottom.Multiple earthing
of core

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 220/66 KV

Sr.N
o.

S/S

Viramgam

Sachin

Kim2

MVA

Key Gas
Method

Ratio Method
Analyses

Duval
Triangl
e

Fault observed

50

High arcing

Not defined

T3

OLTC selector and

diverter damaged

100

Thermal
Fault
>500C

Circulating
currents in
winding

T3

OLTC Tap contacts

and terminals found
overheated

T2

OLTC Y phase lead

connection to winding
loose with missing cap
nut found at bottom.
Copper
wire
also
found at bottom

100

Thermal
Fault<>500
C

Not defined

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 220/66 KV

Sr.N
o.

S/S

Ranavav

Ichchhapur

Key Gas
Method

Ratio Method
Analyses

50

All within
limit

Partial
Discharge corona with
tracking

100

High
energy
discharge

Arc-- with
power flow
through

MVA

Duval
Triangl
e

Fault observed

PD

OLTC diverter switch B

phase main lead bolt
at the common ring
loose, sparked with
insulation damaged

D1

66 KV Y ph.lead found
opened.2
bolts
of
lower portion of jumper
found melted.

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 132/66 KV

Sr.N
o.

S/S

Jambuva

Idar

Bhestan1

Bhestan2

Fault observed

MVA

50

Thermal
Fault
>500C

Not defined

T3

Yoke and Core near

HV R phase found
overheated
and
damaged

50

Thermal
Fault
>500C

Not defined

T3

OLTC polarity switch

damaged

Thermal
Fault
>500C

Core and Tank

circulating
current,
Overloaded
Joints

T3

OLTC diverter switch

lead to drum loose at
drum end

T2

Oil leakage from OLTC

to main tank due to O
ring damaged and
loose contact.

50

50

Overheatin
g ,oil

Ratio Method
Analyses

Duval
Triangl
e

Key Gas
Method

Not defined

Summary of results of typical cases of DGA

(found in GETCO)

Voltage Ratio 132/11 KV

Sr.
No.

S/S

Gotri

MVA

12.5

Key Gas
Method

Ratio Method
Analyses

Partial
Discharge

Partial
Discharge corona with
tracking

Duval
Triangl
e

Fault observed

PD

LV B phase winding
insulation
at
lead
insulation failed at
joint

Analysis & classification of faults based on

inspection
Key gas method

Identify the general faults

Ratio & Triangle

method

Further qualitatively analyzed the fault which

enabled us taking decision regarding continuation
in service or immediate repair

4 main type faults are found (i.e. T2,T3, PD, D1)

T3

Hot spots in oil with overheated joint in oil or circulating

current in core & winding

T1 & T2

Thermal faults in oil & paper with heating and browning of

paper.

D1 & D2

Electrical discharge with power follow through with lesser

or higher degree & may lead to failure of paper insulation
& winding

Case Study-1 : 220/66KV, 100 MVA (220 KV Sardargadh)

[1] Year of Mfg.

:- 1997

(2) Year of Comm.

:- 1997

[2] Problem observed :- In April 2009, during annual routine monitoring of DGA,
the higher concentration of key gases were detected.
DGA Test Results
Date

H2

CH4

C2H4

C2H6

C2H2

CO2

CO

17.04.08

10

2505

431

17.04.09

28

19

23

39

3625

330

25.06.09

32

21

23

37

3983

477

21.07.09

35

20

21

24

3629

410

28.08.09

19

16

20

19

3386

333

30.09.09

38

22

23

11

3937

446

16.11.09

79

13

17.03.10

430

40

03.08.10

1328

121

Case Study-1 : 220/66KV, 100 MVA (220 KV Sardargadh)

DGA Analyses
1.By Key Gas

:-High energy fault

2.By Ratio method

:-Arc with power follow through

3.By Duval Triangle :-D2- Discharge of high energy. High energy arcing, flashovers
and short circuits with power follow through, metal fusion are
some of the example of D2.

23

Case Study-1 : 220/66KV, 100 MVA (220 KV Sardargadh)

The Trend of gas concentration and further testing: The test was repeated after one month, there was no increase in
concentration of dissolved gasses.
The low voltage test including winding resistance indicates no fault.
The trend as per triangle indicates there was either one time arc
between joint, which has subsequently stopped or there may be mixing
of Tap changer oil.
In September 2009 --- increasing trend of Hydrogen.
The internal inspection of transformer through inspection windows was
arranged.

 80 % of Lead wire of B phase bushing found burnt at the top joint

The rectification done at site and transformer put in service
Catastrophic failure averted

Case Study-2 : 220/66KV, 100 MVA (220 KV Chhatral)

[1] Year of Mfg.
:- 1996
(2) Year of Comm.
:-1996
[2] Problem observed :- In August-2009, during annual routine monitoring of
DGA, the higher concentration of key gases were
detected.
Date

H2

CH4

C2H4

C2H6

C2H2

CO2

CO

06.08.06

922

123

20.06.07

814

91

14.07.08

2556

266

12.08.09

44

207

186

50

1399

99

24.09.09

85

732

642

211

6619

586

16.10.09

123

24

17.11.09

13

442

36

10.03.10

13

1175

78

25.06.10

13

13

1507

92

Case Study-2 : 220/66KV, 100 MVA (220 KV Chhatral)

1. By Key Gas Method
2. By Ratio
3. By Triangle Method

:-Thermal fault -Oil

: Not defined
: Thermal faults of temperatures between 300 and 700 C
(T2).
Carbonization of paper, formation of carbon particles in oil.
Typical examples: lead / paper involvement problem.

27

Case Study-2 : 220/66KV, 100 MVA (220 KV Chhatral)

The Trend of gas concentration and further testing: Periodical test results indicates rise in concentration of H2, CH4,C2H4 , C2H6 and
CO gases.
Low voltage test including winding resistance indicates no fault.
SFRA testing was carried out, no abnormality observed.
The increasing trend of key gases became faster over a period of time and DGA
trend indicates persistence thermal fault.
Due to increasing trend of key gases, it was planned to carry out internal
inspection at site.

Internal Inspection

Internal inspection of transformer was done on dtd.26.09.09.

During internal inspection, equipotential link between two top frames were found burnt.
Also frame earthing link found burnt.

The rectification done at site and transformer put in service.

Catastrophic failure averted

Case Study-3 : 220/66KV, 100 MVA (220 KV Kim)

[1] Year of Mfg.
:- 2001
(2) Year of Comm. :- 2001
[2] Problem observed :- In July 2008, the high concentration of key gases were
observed during annual testing.

DGA Test Results

Date

H2

CH4

C2H4

C2H6

C2H2

CO2

CO

18.07.08

10

92

125

15

2888

201

25.11.08

18

107

146

20

2928

143

09.01.09

19

115

151

23

3226

153

19.02.09

14

131

181

25

3452

153

12.03.09

22

144

190

28

3826

172

18.03.09

10

21

452

14

15.06.09

20

476

15

06.10.09

16

1023

28

07.11.09

19

1290

57

Case Study-3 : 220/66KV, 100 MVA (220 KV Kim)

1. By Key Gas Method
2. By Ratio
3. By Triangle Method

:-Thermal fault -Oil

: Thermal Fault >700 C
: Thermal faults of temperatures > 700 C (T3).

T3 Typical examples: large circulating currents in tank and core, short

laminations. Sparking/burning of joints

circuits in

DUVAL TRIANGLE
0

100

T1

T2

CH4

C2H4
1
D1
DT
D2

100

T3

100
0

C2H2

32

Case Study-3 : 220/66KV, 100 MVA (220 KV Kim)

The Trend of gas concentration and further testing: Periodical

test results indicates rise in concentration of CH4,C2H4 and

C2H6 gases.
Routine test of above transformer (Magnetic balance test, magnetic
current test, voltage ratio test, Short ckt. test, measurement of winding
resistance) was carried out on 20.1.09.
All test results were found in order except winding resistance test.
Winding resistance of LV Y ph for tap no.14 was found high compared to R
&B phase.
OLTC inspection by draining oil was carried out in presence of OEM on
dtd.24.2.09, No abnormality has been observed. Again winding resistance
measured on all tap, but on tap no.14 winding resistance found higher.
For investigation of fault, transformer detailed inspection after draining of
oil and opening of all inspection covers was carried out from dtd . 12.3.09
to 15.3.09.

Case Study-3 : 220/66KV, 100 MVA (220 KV Kim)

During detailed inspection, BV6 connection
on OLTC switch ( i.e. BV6 No. connection
used for Y-Ph tap no 14 connection 2-6 ) is
sparked and melted due to loose
connection.
The bolt thread found damaged up to 3
threads. Same was replaced by new one
with two washers.
Minor pitting was also noticed on
connection bush and Lug. Same was
cleaned and smoothen by the emery paper.
Also all other connection checked for
tightness. No other abnormally was found
inside the transformer.
After refilling of oil and necessary testing
transformer was put in service.

Case Study-4 : 132/66KV, 50 MVA (220 KV Jambuva)

[1] Year of Mfg.
(2) Year of Comm.

:- 2008
:- 2008

[2] Problem observed :- In Nov10, during annual routine monitoring of DGA,

the higher concentration of key gases were detected.
DGA Test Results
Date

H2

CH4

C2H4

C2H6

C2H2

CO2

CO

02.06.08

187

28

23.06.08

168

21

25.06.09

13

1714

110

23.11.10

29

63

151

17

1918

115

Case Study-4 : 132/66KV, 50 MVA (220 KV Jambuva)

DGA Analyses
1.By Key Gas
:-High energy fault
2.By Ratio method :-Core & tank circulating current, over loaded joints
3.By Duval Triangle :-Thermal faults of temperatures > 700 C (T3).
T3 Typical examples: large circulating currents in tank and
core, short circuits in laminations. Sparking/burning of joints

36

Case Study-4 : 132/66KV, 50 MVA (220 KV Jambuva)

The Trend of gas concentration and further testing: The low voltage test including winding resistance carried out, under
which
In turn ratio test,%Deviation not available at Tap Nos 1,5,13 for B
Ph.
Winding resistance not available for Tap No.1,3,5,7 & 13 for LV b
Ph.
For further investigation, the internal inspection of transformer through
inspection window was arranged.

 Fixed & moving contacts of B phase OLTC was found damaged.

The contacts replaced at site and transformer put in service
Catastrophic failure averted

Benefits realized
Total 28 nos of transformers are observed problematic in
DGA in last three years and all are attended at site
before catastrophic failure.
By attending the transformer at site, huge amount of
procurement cost or its repairing cost saved.

Reduction in failure

4.5

3.5

2.5

1.5

0.5

2006-07

2007-08

2008-09

2009-10

400 KV

220 KV

132 KV

% failure

3.93

2.51

1.63

1.33

Popul
ation

354

358

369

377

400 KV

220 KV

132 KV

% failure

Failure in %

failures in Nos

Transformer failure

Conclusion
From DGA test , according to key gases value , Critical
transformers are identified & further rectification actions taken.

Four main types of faults namely T2,T3,PD and D1 were

identified .By co relating three methods of DGA ,we were able to
take corrective actions before the faults become severe i.e. D2.
While the Key Gas method helped to identify general fault, Ratio
and Triangle methods further qualitatively analyzed the fault
which enabled us taking decision regarding continuation in
service or immediate repair.
We have diagnosed the fault at site and attended it timely
before permanent failure.
By SFRA , Accoustic Emission, tan delta & capacitance
measurement also provide information to locate fault once the
gassing in transformer starts.