CONDITION MONITORING OF TRANSFORMERS

ON
INDIAN RAILWAYS
PUNKAJ GUPTA
PROFESSOR
INDIAN RAILWAYS INSTITUTE OF ELECTRICAL ENGINEERING
POST BOX –233 NASIK ROAD 422101 MAHARASHTRA

ABSTRACT

Transformers are a critical component of any electrical distribution network. In Indian Railways they are widely used in
the distribution of power for traction purposes. Transformers are considered to be reliable component of the electric
traction distribution system however any unforeseen failures can cause disruption of electrical power with serious
repercussion to traffic. Traction transformers are generally subjected to highly fluctuating load patterns with short time
overloading of 50 % for 15 minutes and 100% for 5 minutes as a part of its duty cycle. Thus traction transformers are
subjected to very high electrical and thermal stresses. Reliable distribution of electrical power therefore requires
replacement of aged transformers or repair of faulty ones before they fail in service. In this context, condition
monitoring of transformers assumes prime importance. The main objective of monitoring is to assess deterioration and
accordingly determine the maintenance requirements.

Though the philosophy of condition monitoring transformers is well established the benefits can only be derived by
putting it in practice. This involves periodic recording of the identified parameters and evaluating the trend to establish
the problem and maintenance requirements.

This paper is an attempt to share the experience gained in this area during the last few years at Indian Railways Institute
of Electrical Engineering, Nasik Road.

INTRODUCTION

Transformers find wide spread application on Railways. They are one of the major equipments on an electric
locomotive, traction feeding posts and power supply distribution system for Railway offices, Station buildings, and
Railway colonies. Traditional form of maintenance is periodic in nature wherein Oil BDV, condition of silica gel
and oil temperature are recorded. Generally transformers require attention in the form of

1. Oil filtration / Reconditioning

2. Oil reclamation / replacement
3. Core lifting, cleaning and tightening of spacer blocks etc. during periodic overhauling and oil replacement.
4. Opening up for emergency maintenance or fault repair as per requirement.

The need for particular type of maintenance activity as mentioned above has to be decided based upon the condition
of oil and transformer insulation or any other alarm given by sensing and protection system. Traditionally on the
railways BDV and acidity have been used to monitor the condition of the transformer oil. This formed the basis to
decide the need for reconditioning / replacement of oil . Further fault condition developed/ developing inside the
Transformer were not monitored which now is possible with Dissolved Gas Analysis. Periodic overhauling of
transformers is carried out after 7 – 10 years of service. The down time involved could be from few days to months
depending upon the size and location of the transformer. In traction distribution system supply outages are out of
question thus the system design provides for a standby at each feeding post. The need for improved reliability and
availability has gained importance as increase in traffic has to be catered by improving the asset utilisation.

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CURRENT STATUS

Availability of electric locomotives on Indian Railways is about 85 % with reliability of about the same order. The
general maintenance philosophy has been periodicity based. Induction of state of art technology on Indian Railways
and need for improved utilisation of existing assets have forced the concept of condition based maintenance.

The different ratings of transformers finding application on Indian Railways is as follows :-

1. Traction Distribution - 12.5 – 25 MVA

2. Traction Rolling Stock - 4 - 5 MVA

3. Stationary application - 0.250 – 6.0 MVA

Power distribution

The availability and reliability is very critical for the first two application in comparison to the third one. Periodic
overhauling for transformer’s is required after 7 – 10 years as per current maintenance schedule. Being a time
consuming activity there is a strong felt need to carry out maintenance on need basis rather than on a fixed time
based schedule. In fact, abroad transformers are generally not opened during their complete life cycle. Core lifting
etc. is resorted to when there is a suspected faults based upon the monitoring data.

FUNCTION OF OIL IN TRANSFORMER

In transformers the main function of the oil is to act as a coolant and insulant media, to absorb the heat from the
core and conductors where it is generated and to conduct it to the cooling surfaces where it is dissipated and to
efficiently insulate parts of the transformer which are at different electric potentials. The oil therefore must be free
from dirt, fibers, moisture, solid matter and also be stable against oxidation. The oil must have the right viscosity
and thermal conductivity to be an efficient coolant.

DETERIORATION FACTORS AND FAILURE MECHANISMS

Deterioration of the paper oil insulation in service is caused by thermal stresses and is accelerated by the presence
of moisture.

DETERIORATION OF OILS

If the physical, chemical and electrical properties of a new insulating oil could be retained throughout its service, it
would provide an ideal liquid insulation. This however is not possible and oil begins to lose its initial properties
from the very on set of its service.

The deterioration may be due to :

(1) Physical contamination.

(2) Chemical decomposition.

(3) Contamination by gases.

The deterioration is evidenced by changes affecting certain constituents of the oil.

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Table below summarises these aspects.

Physical contamination Chemical deterioration Contamination by gases

a) Dust, Fiber, metallic particles
other solids impurities
b) Dissolution of varnish
c) Free and dissolved water
a) Oxidation resulting in
acids, sludges and other
polar impurities
a) Dissolved air from atmosphere,
nitrogen, carbon dioxide
b) Generated in the oil e.g. methane,
ethane, acetylene and ethylene
etc.

FAILURE MECHANISM

The transformers usually fail as a consequence of :

(a) Short circuit faults.

(b) Local overheating due to circulating currents, unequal current sharing or the effects of leakage flux.

(c) As a result of insulation failure under electric stress perhaps as a final stage of a Scenario involving (a) &
(b) above.

Faults in transformers can be classified as developing in one of three time - scales.

(a) An immediate fault where electrical breakdown occurs within seconds of a short circuit or
lightning impulse surge.

(b) A local fault developing over days, weeks or months.

(c) Deterioration of high voltage insulation over a period of months or years

Diagnostic techniques have been introduced mainly to detect the presence of small local faults and their
development over a period of weeks or months.

DIAGNOSTIC PARAMETERS

Perhaps a parallel can be drawn between the health diagnostic for the human body and that of a transformer.
Visualize the tank and core as the skeleton, insulation as the flesh and oil as the blood in the human form. The oil
acts as a messenger and witness to the happening of every event which takes place in every nook and corner of the
transformer. Just as presence of bile in the blood is an indication of liver malfunction in a similar fashion the
condition of oil with respect to certain test parameters e.g. Breakdown Voltage, Interfacial Tension and Tan δ reflect
on the health and condition of the transformer.

Thus there is a growing appreciation of the relationship between transformer life and oil condition. Insulating oil is
the life blood of power transformers. Oil condition is a measure of transformer condition and can be used to predict
future transformer problems and transformer service life.

The total health monitoring of transformer implies knowing condition of oil and its internal health i.e. assessment of
its internal condition in terms of development of faulty conditions i.e. loose connection, sparking, over heating etc.

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Although no single test can judge health of oil. Each test is significant as it provides information about a particular
aspect of deterioration e.g. Inter Facial Tension co-relates with sludge formation BDV with moisture and
conducting impurities etc. The oil tests carried out as per IS 1866 provide assessment of oil condition. The fault
condition / development of fault etc. can be detected at an early state using Dissolved Gas Analysis technique.

The above two techniques are well established and need no clarification. However, while using these techniques
correct interpretation of results is very important. It has been our experience that until unless these techniques are
used over a period of time one can not expect the benefits to accrue. The co-relation of test results with respect to
the significance of each parameter is essential for assessing the condition of transformer. In the case of Dissolved
Gas Analysis, it is often seen that ratios obtained may not fall in the fault table provided in the IS 10593 – 1992.
Here one needs to see the total gas volume per unit volume of oil as also trend of key gases over a period of time to
establish the fault condition. At times the fault could be a combination of sparking and overheating as in real life
scenario both do not take place in isolation. Accordingly one may end up with ratios which are combination of two
fault conditions shown in IS – 10593.

CONDITION MONITORING OF TRANSFORMERS BY ANALYSIS OF

TRANSFORMER OIL
CASE STUDY

Traction Transformer of South Central Railway

Transformer oil of twenty seven traction transformers on the South Central Railway, Secunderabad and six of
Vijaywada division were tested for Tan Delta, Resistivity and Inter Facial Tension (IFT). As can be seen from the
data given in Annexure – 1 oil of transformers at Sr.No. 1 to 10 is still in good condition even after service of 8 –
10 years, while those Sr.No 11 to 14 need to be replaced / reclaimed . The oils at Sr.No. 25 – 27 are showing higher
rate of deterioration compared to those at Sr.No. 1 to 10. The oil of transformer for Vijaywada division at Sr.No. 1
needs to be reclaimed as it is having very low IFT.

Further Dissolved Gas Analysis for few transformers has been carried and the results for four typical case studies are
given Annexure – 2. Two case studies are for traction transformer of Central Railway while other two are for
locomotive transformer of Western Railway .

In the case of Pimperkhed, there had been tripping through BUCHOLZ relay for which the oil had been sent to us
for carrying out DGA. Since nothing abnormal was detected by DGA, further investigations revealed that a gasket of
BUCHOLZ relay had been left in the relay during commissioning which was causing tripping. Removal of gaskets
rectified the problem of false tripping.

As can be seen for the Kalyan transformer the fault could be diagnosed to overheating and sparking and
subsequently when transformer was opened Y phase jumper was found connected with the bushings with one bolt
instead of four.

Two cases of locomotive transformers given in Annexure 2 further reinforce the utility of DGA in detecting faults at
an incipient stage, thus providing advance warning for imminent failures.

CONCLUSION
The life of transformer oil for a typical application in traction has been studied on the basis of data collected over a
period of 3 years. It is seen that in some of the transformers, oil is giving service of more than 10 years whereas in
others it is in the range of 7 – 10 years. Also there are few cases of accelerated aging which need to be monitored
further. In all these cases we have not been able to co-relate the deterioration with the loading pattern of each
individual transformer as this data was not easily available.

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There is growing awareness among the utilities for carrying out tests on transformer oil for condition monitoring the
transformers. However, it needs to be appreciated that apart from periodic testing it is essential that history, loading
patterns and temperature profiles of the transformers are also recorded so that the synergy of the complete data is
available for precise knowledge of the health of the equipment and its residual life.

Further it would be appropriate to use inhibited oil as is being done abroad. This will considerably increased the life
of the oil. Care must be exercised while purchasing inhibited oil as reclaimed oils also contain artificial inhibitors
and the tests for differentiating new oil with artificial inhibitor from reclaimed oil with artificial inhibitor are
expensive and available only with sophisticated test laboratories. In view of this IS 335 prohibits addition of
artificial inhibitors in new insulating oil.

Accordingly the best course of action would be to purchase new oil as per IS 335 and add the artificial inhibitors in-
house after ensuring that the new oil confirms to IS 335. Although this is highlighted in IS 12463 of 1988 however
there seems to be lack of awareness on this issue.

The use of inhibited oil alongwith period monitoring coupled with recording of loading patterns and temperature
profile for the transformers will obviate the need for periodic overhauling of transformer. Maintenance activities on
the transformer would be an exception rather than the rule, thus realising is a long cherished goal of maintenance
engineers.

REFERENCES
1. IS 10593 – 1992 “Method of evaluating the analysis of gases in oil filled electrical equipment in service.
2. IS 9434 – 1992 “Guide for sampling and analysis of free and dissolved gases oil from oil filled electrical
equipment.
3. IS 1866 – 1983 “Code of practice for maintenance and supervision of mineral insulating oil in equipment.
4. M.C.Ratra, K.R.Krishanaswamy, K.Kumar & Ramakrishna : “CPRI’s experience on detection of incipient faults in
transformers in operation
5. K.Kumar and Ramakrishna : “Prediction of faults and prevention of transformer failures by Gas-in-Oil analysis.
6. Lecture notes of the course “Condition Monitoring of Electrical Equipments and Insulation Testing Techniques” at
IRIEEN by Shri M.C.Ratra, Retd. Director CPRI

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 Annexure - 1

VIJAYWADA DIVISION

SN TRANSFORMER COMMISSION TEST TAN δ RESISTIVITY ρ IFT

NO DATE DATE AT AT 90 0 C (N / m)
90 0 C (Ω - Cm)
01 TR-06 12.10.90 12.05.98 0.0770 0.421 X 10 12 0.0148
02 TR-07 01.01.94 12.05.98 0.0150 0.230 X 10 12 0.0238
03 TR-08 01.05.92 12.05.98 0.0250 0.210 X 10 12 0.0238
04 TR-11 23.05.92 13.05.98 0.0200 0.912 X 10 12 0.0250
05 TR-13 03.12.94 13.05.98 0.0090 0.867 X 10 12 0.0286
06 TR-14 03.12.94 13.05.98 0.0080 0.402 X 10 12 0.0286

SECUNDERABAD DIVISION

SN TRANSFORMER COMMISSION TEST TAN δ RESISTIVITY ρ IFT

NO DATE DATE AT AT 90 0 C (N / m)
90 0 C (Ω - Cm)
01 TR-01 20.02.91 10.03.98 0.025 3.02813 X 10 12 0.0298
16.12.96 0.0154 2.86794 X 10 12 0.0286
20.10.95 0.008 2.54928 X 10 12
02 TR-02 11.11.89 10.03.98 0.0200 2.23125 X 10 12 0.0298
16.12.96 0.0147 3.05913 X 10 12 0.0227
20.10.95 0.010 2.35808 X 10 12
03 TR-03 17.06.89 16.12.96 0.0140 6.05454 X 10 12 0.0298
20.10.95 0.003 8.285 X 10 12
04 TR-04 17.06.89 16.12.96 0.0150 5.09856 X 10 12 0.0286
20.10.95 0.006 7.010 X 10 12
05 TR-05 14.02.89 16.12.96 0.0075 24.2181 X 10 12 0.0347
20.10.95 0.002 16.5703 X 10 12
06 TR-06 14.02.89 16.12.96 0.0070 25.4928 X 10 12 0.0347
20.10.95 0.002 12. 1090 X 10 12
07 TR-07 28.11.88 16.12.96 0.0190 3.1866 X 10 12 0.0286
20.10.95 0.011 2.1031 X 10 12
08 TR-08 28.11.88 16.12.96 0.0184 3.1866 X 10 12 0.0286
20.10.95 0.017 2.3580 X 10 12
09 TR-09 02.05.88 18.03.98 0.0400 0.0892 X 10 12 0.0274
16.12.96 0.0300 1.0834 X 10 12 0.0227
20.10.95 0.0180 1.3383 X 10 12
10 TR-10 02.05.88 18.03.98 0.0300 1.4658 X 10 12 0.0262
16.12.96 0.0303 1.4021 X 10 12 0.0262
20.10.95 0.0110 2.549 X 10 12

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 Annexure - 1

SECUNDERABAD DIVISION

SN TRANSFORMER COMMISSION TEST TAN δ RESISTIVITY ρ IFT

NO DATE DATE AT AT 90 0 C (N / m)
90 0 C (Ω - Cm)
11 TR-11 04.03.88 18.03.98 0.11 0.18482 X 10 12 0.0126
16.12.96 0.0887 0.29435 X 10 12 0.0126
20.10.95 0.064 0.24218 X 10 12
12 TR-12 04.03.88 18.03.98 0.094 0.20394 X 10 12 0.0116
16.12.96 0.0905 0.02230 X 10 12 0.0115
20.10.95 0.045 0.31866 X 10 12
13 TR-13 15.07.87 10.03.98 0.268 0.07012 X 10 12 0.0095
16.12.96 0.1760 0.10197 X 10 12 0.0095
20.10.95 0.138 0.08603 X 10 12
14 TR-14 15.07.87 10.03.98 0.184 0.11475 X 10 12 0.0085
16.12.96 0.1330 0.14021 X 10 12 0.0105
20.10.95 0.089 0.17207 X 10 12
15 TR-15 11.11.89 16.12.96 0.0125 4.14258 X 10 12 0.0262
20.10.95 0.012 4.46124 X 10 12
16 TR-16 11.11.89 16.12.96 0.0142 3.50526 X 10 12 0.0286
20.10.95 0.012 4.52497 X 10 12
17 TR-17 20.03.92 16.12.96 0.012 10.1971 X 10 12 0.0335
20.10.95 0.001 13.3887 X 10 12
18 TR-18 20.03.92 10.03.98 0.012 5.1 X 10 12 0.0373
16.12.96 0.012 10.19712 X 10 12 0.0298
20.10.95 0.001 13.3887 X 10 12
19 TR-19 21.06.93 10.03.98 0.0300 0.08287 X 10 12 0.0323
16.12.96 0.0090 5.0985 X 10 12 0.0286
20.10.95 0.008 4.4612 X 10 12
20 TR-20 12.03.93 16.12.96 0.0275 1.4717 X 10 12 0.0250
20.10.95 0.030 1.1153 X 10 12
21 TR-21 17.06.93 16.12.96 0.0156 2.8679 X 10 12 0.0286
20.10.95 0.006 5.0985 X 10 12
22 TR-22 28.03.95 16.12.96 0.0215 2.5492 X 10 12 0.0323
20.10.95 0.012 1.7844 X 10 12
23 TR-23 20.06.95 16.12.96 0.0110 3.1866 X 10 12 0.0274
20.10.95 0.009 3.8239 X 10 12
24 TR-24 15.11.94 16.12.96 0.0185 2.4218 X 10 12 0.0298
20.10.95 0.01 31.866 X 10 12
25 TR-25 15.11.94 16.12.96 0.0157 2.2306 X 10 12 0.0262
20.10.95 0.016 1.7207 X 10 12
26 TR-26 18.08.95 16.12.96 0.0275 0.9555 X 10 12 0.0262
27 TR-27 18.08.95 16.12.96 0.0243 1.3383 X 10 12 0.0274

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 Annexure - 2

PIMPERKHED (TSS) C.RLY BHUSAWAL

DISSOLVED GAS ANALYSIS

Transformer :- 132 / 27 KV 20 MVA

Crompton make :-Sr.No. 8355-9

Date of commissioning :- 22.09.94

Date of testing :- 23.06.98

The gas concentration detected are given below :-

Sr.No. Gas BUCHOLZ MAIN TANK

1 Propane 10.15 ppm 13.78 ppm
2 Hydrogen 3.40 ppm 3.61 ppm
3 Methane 8.62 ppm 7.27 ppm
4 Ethylene 5.18 ppm 2.67 ppm
5 Ethane 14.72 ppm 14.71 ppm
6 Acetylene 13.89 ppm 6.00 ppm
7 Carbon Dioxide 182.30 ppm 212.00 ppm
8 Carbon monoxide 53.60 ppm 41.25 ppm

Ratio analysis

C2 H2 CH 4 C2 H 4

C2 H 4 H2 C2 H 6

1 2 0

Ratio analysis gives the ratio code 120 for both BUCHOLZ and MAIN TANK which does not find place in IS
10593 of 1992. The total gas contents in both cases is less than 500 ppm. Apparently nothing appears to be wrong in
the transformer. However, it would be appropriate to monitor periodically at regular intervals to be sure of the
absence of faults. (DGA could be carried out every month initially and if nothing abnormal is indicated by the trend
every 3 months thereafter.

FAULT OBSERVED

Gasket has been left in the BUCHOLZ relay while commissioning, which was causing false tripping.

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 Annexure - 2

KALYAN (TSS) C.RLY MUMBAI

DISSOLVED GAS ANALYSIS

Transformer :- 22 KV / 1160 V 3.3 MVA

Crompton make :- Sr.No. V-7842/2

Date of commissioning : - 10.05.95

Date of testing :- 20.06.98

The gas concentrations detected are given below.

Sr.No. Gas
1 Propane 139..52 ppm
2 Hydrogen 3.27 ppm
3 Methane 130.58 ppm
4 Ethylene 268.26 ppm
5 Ethane 103.49 ppm
6 Acetylene 75.85 ppm
7 Carbon Dioxide 311.6 ppm
8 Carbon monoxide 225.96 ppm

Ratio analysis

C2 H2 CH 4 C2 H 4

C2 H 4 H2 C2 H 6

1 2 1

This does not find place in the IS 10593 fault table. However, high value of Acetylene is an indication of sparking
and the ratios appeared to be combination of code no. 3 & 6 i.e. sparking is evidentally leading to overheating also.

FAULT DIAGNOSED

Overheating and sparking suspected.

FAULT OBSERVED

On opening the transformer found Y phase jumper between winding to bushing contact fitted with one nut and bolt
instead of four resulting in overheating and sparking in the contact.

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 Annexure - 2

TRANSFORMER DETAILS

• TRANSFORMER RATING : 3.22 MVA

• TRANSFORMER VOLTAGE RATIO : 22.5/1.73 KV
• LOAD ON DUTY (MAX) : VARIABLE
• DATE OF COMMISSIONING : 28.05.1982
• QUANTITY OF OIL IN SYSTEM : 1700 KG.
• DATE OF LAST MAINTENANCE : AUGUST 1993

RESULTS OBTAINED

NAME OF GAS CONCENTRATION (ppm)

HYDROGEN (H2) : 45
METHANE (CH4) : 296
ACETYLENE (C2H2) : 4
ETHYLENE (C2H4) : 2228
ETHANE (C2H6) : 1292
CARBON MONOXIDE (CO) : 60
CARBON DIOXIDE (CO2) : 1450

RATIO OF CONCENTRATION OF GAS

C2H2 CH4 C2H4 CO2

------- ------ ------- ------
C2H4 H2 C2H6 CO

0 2 1 2

FAULT DIAGNOSED

THERMAL FAULT OF MEDIUM TEMPERATURE RANGE (300 – 700oC)

FAULT OBSERVED

ONE OF THE METALLIC BOLTS ON THE STAMPING OF TRANSFORMER WINDING GOT MELTED.

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 Annexure - 2

TRANSFORMER DETAILS

• TRANSFORMER RATING : 3.64 MVA

• TRANSFORMER VOLTAGE RATIO : 22.5/1.73 KV
• LOAD ON DUTY (MAX) : 3.46 MVA
• DATE OF COMMISSIONING : 05.02.1988
• QUANTITY OF OIL IN SYSTEM : 1700 KG.
• DATE OF LAST MAINTENANCE : 17.12.91

RESULTS OBTAINED

NAME OF GAS CONCENTRATION (ppm)

HYDROGEN (H2) : 1049

METHANE (CH4) : 6086
ACETYLENE (C2H2) : 1476
ETHYLENE (C2H4) : 39998
ETHANE (C2H6) : 6462
CARBON MONOXIDE (CO) : 40773
CARBON DIOXIDE (CO2) : 94996

RATIO OF CONCENTRATION OF GAS

C2H2 CH4 C2H4 CO2

------- ------ ------- ------
C2H4 H2 C2H6 CO

0 2 2 1

FAULT DIAGNOSED

LOCAL OVERHEATING UPTO 700oC

FAULT OBSERVED

HOT SPOT IN ONE OF THE CONNECTING LEADS HAVING JOINT.

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