1

Dissolved Gas Analysis (DGA) of Current Transformer (CT) oil

– A reliable tool to identify manufacturing defects

A.K. Datta, S.C. Singh, S.K. Mishra and S. Suresh

Power Grid Corporation of India Limited

ABSTRACT:

Current Transformer (CT) and Capacitive Voltage Transformer (CVT) are

important equipment in any electrical installation. The protection, metering
and operation of the sub-stations are decided based on their inputs. In our
past experience, it was found that many CTs and CVTs have failed during
service and some time in a few months after the initial commissioning.

Present paper discusses about prevention of failure of CTs by carrying out

DGA of CT oil as a standard practice, after commissioning and also in case
of violation of CT parameter such as C & Tan-Delta with respect to
commissioning value during service life of CT. It also covers two case
studies--- first case is related to generation of gases within 2 – 3 months after
commissioning in some of CTs supplied in batch of 48 Nos. and the second
is about CT with three years of service life found with increase in Tan-Delta
value. Paper covers various measurements carried out at sites and
subsequent shifting of CTs to respective manufacturer’s works, for detailed
testing including high voltage insulation tests. In this paper, it is established
that the DGA of CT oil indicates a clear sign of incipient fault in CTs, if not
taken care of same, premature failure of CT is unavoidable.

Keywords:

DGA - Dissolved Gas Analysis

CT - Current Transformer
CVT - Capacitive Voltage Transformer
PD - Partial Discharge
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Nomenclature:

Name Symbol
Nitrogen N2
Oxygen 02
Hydrogen H2
Carbon monoxide CO
Carbon dioxide CO2
Methane CH4
Ethane C2H6
Ethylene C2H4
Acetylene C2H2

INTRODUCTION:

Power Grid Corporation of India (POWERGRID) is one of the largest 400

kV / 220 kV / 132 kV transmission utility in the world operating about
55000 circuit kms and 95 sub-stations having transformation capacity of
49500 MVA, with average availability of system on yearly basis more than
99%.

POWERGRID is having stringent system for maintenance of high voltage

switchyard equipment. All equipments are tested as per the standard pre-
decided frequency and test results are analysed in detail, for identification of
defects in the equipments.

The population of 400 / 220 / 132 kV Current Transformers in

POWERGRID network is approx. 3200, these include both Dead and Live
tank design and majority of CTs are oil immersed.

The paper discuss about the introduction of DGA test for CT oil as standard
test apart from routine tests at site. Normally Tan delta & Capacitance,
Thermography of CT are being carried out on yearly basis apart from other
tests. Inspite of doing all the best possible maintenance, failure of CTs are
observed at all voltage levels (400 / 220 / 132 kV). Failure status of CT is
indicated at table- 1.
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S.No Make Population No.of failure No.of failure

Newly
(3-15 yrs) commissioned
1 Manufacturer-1 695 74 5
2 Manufacture -2 1046 5 17
3 Manufacture -3 168 0 4
4 Manufacture -4 174 0 3
5 Manufacture -5 872 4 3
6 Manufacture -6 42 3 0
7 Manufacture -7 132 0 0
TOTAL 3129 86 32
Table-1

The cases of failure of CTs can be divided into two categories viz. failure of
CT within a year of commissioning and failure of CTs after three years and
more in service.

Power Grid have established two nos. oil Lab for conducting various test as
per IEEE-C57.104 and DGA of oil is being used as one of important tool,
for identifying the fault of transformer and reactors since last 15 years.
With successful interpretation of DGA results, failure of number of
transformers and reactors were avoided in the past.

As CT is also oil filled equipment, DGA of CT was also started since last
4 – 5 years on case to case basis. Initially, DGA of CT was opposed by the
manufacturer with the pretext that CT has limited oil capacity and
functioning of CT may deteriorate due to breakage of hermetically sealing of
the CT. But with our experience, it was found that DGA is a very important
tool, for identifying the manufacturing process defects or aging affect of CT
at the very initial stage. The maximum admissible values for sealed
instrument transformer without any action to be taken on the transformer are
as below (as per IEC 60599)

H2 CO CO2 CH4 C2H6 C2H4 C2H2

300 300 900 30 50 10 2

The paper discusses about two Case Studies, which correlates evolution of
gases with inconsistency in manufacturing in CTs.
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CASE STUDY – I:

In one of the newly commissioned projects, 48 Nos. of 400 / 220 kV CTs

were supplied in one manufacturing lot in the year 2004 – 05. The CTs were
commissioned in July – Aug. 2005. One no. CT of 400 kV has failed after
51 days of charging of the CT. As all the test results both at factory and site
were perfectly in order for all the CTs including that of failed CT, the
manufacturer contended that it may be an isolated case and CT has failed
due to lightening affect as the CT failed in rainy season under thunder storm.
But it was decided that DGA of oil of all the CTs shall be carried out and
accordingly DGA was carried out and results are tabulated as under:
Sl.
No. Sample TGC N2 O2 Total
Date (%) (%) (%) H2 CH4 C2H4 C2H6 C2H2 CO CO2 Furans
1 30-Oct-05 3.35 2.24 0.84 83 1 0 0 0 63 184 0
2 30-Oct-05 3.37 2.2 0.71 156 2 0 0 0 54 216 0
3 30-Oct-05 3.65 2.37 0.8 223 1 0 0 0 53 243 0
4 30-Oct-05 2.91 1.98 0.7 65 1 0 0 0 53 153 0
5 30-Oct-05 4.37 2.91 1.04 88 1 0 0 0 86 197 0
6 30-Oct-05 2.91 2.02 0.66 69 1 0 0 0 84 169 0
7 30-Oct-05 2.77 1.84 0.74 216 2 0 0 0 26 198 0
8 30-Oct-05 3.35 2.29 0.85 79 1 0 0 0 53 181 0
9 9-Dec-05 7.48 5.35 1.69 741 35 6 2 46.8 49 1380 0
10 9-Dec-05 9.06 6.67 1.97 128 2 0 0 0 95 276 0
11 9-Dec-05 4.1 2.85 1.03 199 3 0 0 0 87 585 0
12 9-Dec-05 5.43 3.65 1.55 138 1 0 0 0 35 475 0
13 9-Dec-05 5.42 3.75 1.43 210 1 0 0 0 45 221 0
14 9-Dec-05 3.66 2.46 0.98 134 2 0 0 0 59 195 0
15 9-Dec-05 3.81 2.52 1.09 162 2 0 0 0 78 324 0
16 9-Dec-05 2.2 1.46 0.6 123 2 0 0 0 40 292 0
17 9-Dec-05 3.37 2.31 0.9 96 2 1 0 1.3 104 434 0
18 9-Dec-05 4.83 3.49 1.19 94 2 0 0 0 104 281 0
19 9-Dec-05 4.39 3.01 1.21 118 2 0 0 0 84 226 0
20 9-Dec-05 3.67 2.54 1.01 158 2 0 0 0 65 208 0
21 8-Dec-05 5.84 4.23 1.45 133 2 0 0 0 89 183 0
22 8-Dec-05 6.88 5.02 1.61 128 2 0 0 0 58 253 0
23 8-Dec-05 4.88 3.68 1.06 123 2 0 0 0 74 487 0
24 8-Dec-05 3.37 2.36 0.89 182 3 1 0 2.8 72 245 0
25 8-Dec-05 9.11 6.65 2.94 94 2 0 0 0 60 420 0
26 8-Dec-05 3.08 2.12 0.8 127 3 0 1 0.3 59 229 0
27 8-Dec-05 2.64 1.77 0.76 207 2 0 0 0 33 232 0
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28 8-Dec-05 2.94 2.07 0.75 421 1 0 0 0 52 254 0

29 8-Dec-05 2.5 1.72 0.67 262 2 0 0 0 29 178 0
30 17-Dec-05 9.37 7.51 1.36 922 2 0 0 0 118 787 0
31
17-Dec-05 8.54 6.73 1.4 361 5 0 2 0 102 234 0
32
17-Dec-05 8.51 6.45 1.51 308 2 0 0 0 70 1113 0
33 17-Dec-05 8.89 6.62 1.74 343 1 0 0 0 105 1049 0
34
17-Dec-05 8.07 6.41 1.16 606 2 0 0 0 101 266 0
35
17-Dec-05 8.02 6.5 1.06 749 3 0 0 0 61 242 0
36 3-Jan-06 7.72 6.43 1.06 562 2 0 0 0 91 268 0
37 3-Jan-06 8.8 6.87 1.61 649 1 0 0 0 139 512 0
38 3-Jan-06 9.16 7.47 1.32 1143 2 0 0 0 149 785 0
39 3-Jan-06 7.55 6.25 0.98 749 2 0 0 0 110 174 0
40 3-Jan-06 8.68 7.34 1.15 533 2 0 0 0 132 601 0
41 3-Jan-06 10.5 8.26 1.96 187 2 0 0 0 96 381 0
42 3-Jan-06 9.95 8.43 1.16 518 2 0 0 0 125 534 0
43 3-Jan-06 9.62 8.12 1.14 482 2 0 0 0 121 545 0
44 3-Jan-06 9.37 7.97 1.17 466 1 0 0 0 113 241 0
45 3-Jan-06 9.06 6.98 1.58 427 2 0 0 0 100 1170 0
46 3-Jan-06 9.83 7.9 1.22 3053 80 0 8 0 224 642 0
47 3-Jan-06 9.08 7.12 1.63 578 2 0 0 0 151 357 0
48 3-Jan-06 9.62 7.83 1.23 3077 70 0 7 0 216 346 0

As can be seen from the results, in majority of the CTs, content of

Hydrogen is comparatively high, even after only few days of charging of CT.
To investigate the matter of high generation of dissolved gas in majority of
CTs, it was decided to select some CTs for detailed high voltage testing at
manufacturing works. Total 4 Nos CTs at Sr.No.9, 30, 46 & 48 were
selected. These CTs were sent to the manufacturer works for detailed testing.

a) 400 KV CT at Sr.No. 9

Following tests were carried out in CT

1. Capacitance and Tan Delta test up to 1.1 Um/Square root3.
2. HV one minute power frequency test at 630 KV
3. PD at 291 KV and 420 KV
4. Long duration Power Frequency test (6 hour) with simultaneous
monitoring of PD.
5. Capacitance and Tan Delta test upto 1.1 Um / Square root 3
6. Lightning Impulse test as per IEC – 60044-1
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7. Switching Impulse test as per IEC – 60044-1

8. PD Test up to 170 KV
9. Capacitance and Tan Delta test up to 170 KV.

The test results were normal up to Sr.No.7 i,e switching Impulse test,
while carrying out PD test after completion of switching Impulse test,
PD was found very high i.e. exceeding meter range at 170 kV. The CT
was again tested for C & Tan Delta value at different voltage, but bridge
did not balance at 1.1 Um/ square root 3 and test could not be completed.

As can be seen that CT has passed majority of the tests except PD test
after the impulse testing. All the wave form during impulse test were
matching, but it is very clear that CT has failed during the impulse test as
PD was very high immediately after impulse test. Subsequently, CT was
taken for internal inspection and the observation were as follows.

1. Tan delta test connection was normal.

2. Secondary windings were normal.
3. The physical distance between two foils was found varying between
15 mm to 40 mm, where as internal standard of manufacture says 30
mm +-5.
4. Puncture marks were observed on the straight limb between first main
grading and fifth partial foil at the distance of 920 mm and 1300 mm
from top.
5. At 1300 mm, the flashover marks were dominant. (Figure-1)
6. The first grading foil in the puncture / flashover zone was not intact
whereas the same was perfectly alright in balance portion.
7. Sharp edged were found in primary conductor at about 1300mm from
top.(Figure-2).

(Fig – 1) (Fig-2)
Puncture Mark Sharp edges
Photographs with puncture mark and sharp edges are shown in Fig. 1 & 2.
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b) 220 KV CT at Sl. No. 46:

As per past experience of 400 KV CT, since CT has passed majority of the
high voltage power frequency tests except the impulse test. It was decided
to carry out the Lightening Impulse Test as per IEC-60044-1, immediately
after Capacitance & Tan delta test of CT. Accordingly following Tests were
carried out.

1. Capacitance and Tan Delta up to 1.1 Um / Square root 3

2. Lighting Impulse test as per IEC -60044-1 in which CT failed during
positive impulse test.

It was observed that Capacitance & Tan Delta was normal, it had also
passed negative impulse test, however, it failed on first positive Impulse
shot. (Graph-1)

(Test waveform) (First full voltage waveform)

(Second full voltage waveform)

(Graph-1)
(Positive Impulse waveform)
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Subsequently, CT was taken for internal inspection and the observation

were as follows.

1. Tan delta connection was normal.

2. Secondary windings were normal.
3. Puncture mark was observed on the straight limb just below the
secondary core. (figure -3)
4. Placement of insulating grading foil was checked and found OK.
5. In insulation, wrinkles and deep depression near the failed point was
observed. The wrinkles were observed in both paper and semi
conductor layer and aluminums layer.(figure-4)
6. The puncture mark was on the outward side in the final 8 grading
layer and then on the opposite side for balance 5 grading
layers.(figure-5)
7. The built of insulation on the curved portion at the bottom was largely
uneven and was abnormal.(figure-6)

It is very clear that CT was failed due to poor workmanship during

manufacturing of CT core.

(Fig-3) (Fig-4)
Puncture mark Wrinkles on paper
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(Fig.5 Puncture mark) (Fig -6 Insulation on curved portion uneven)

Photographs with puncture mark & inconsistency in manufacturing is given

in Fig. 3, 4, 5 & 6.

c) 220 kV CT at Sl. No. 48:

CT was put to 1 minute Power frequency test and at 368 KV ( 80 % of 1

minute power frequency test).

CT failed in the above test and build up of volatage was tried again at 20
KV, PD level was found to be beyond range of meter. Further test was
discontinued.

d) 220 KV CT at Sl. No. 30:

1. Partial discharge test at Um was carried out and same was found to
be 7 pC as against pre-dispatch value of 1-2 pC. The CT was pre-
stressed at 368 KV ( 80 % of 1 min HV) CT withstood the voltage.
2. Lightning Impulse test at 1050 KV was conducted and CT failed
during 2nd positive shot.

CTs of this lot were supplied after detailed type testing to prove its design
capability. Generation of gases immediately after commissioning indicates
the discrepancy in manufacturing quality.
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CASE STUDY – II:

In one of the projects, 16 Nos. 400 kV CTs were supplied. The CTs were
commissioned in the year 2002 after carrying out all the pre-commissioning
tests. In August 2005, one of 400 kV CT had failed. As we had never
witnessed the failure of this design CT in our network, it was decided to
investigate in details about the healthiness of other CTs. Detailed testing of
all the balance CTs were carried out and results are tabulated as Table-2.

Measured on 04.09.05

N2 Measured value at 10 Pre-commissioning

Sr.No Phase Pressure N2 pressure KV value at 10 KV
found filled Capa. Tandelta Capa Tandelta

1 R 0.8 1.05 1.124 0.0029 1.117 0.0028

2 Y 0.2 1.05 1.133 0.0047 1.124 0.0029
3 B 0.4 1.05 1.143 0.0026 1.133 0.003

4 R 0.8 1.05 1.133 0.0011 1.133 0.002

5 Y 0.6 1.05 1.119 0.0021 1.118 0.0018
6 B 0 1.05 1.145 0.0019 1.144 0.0025

7 R 0.7 1.05 1.129 0.0021 1.117 0.0026

8 Y 0.6 1.05 1.119 0.0022 1.117 0.0022
9 B 0.4 1.05 1.125 0.0023 1.129 0.0023

10 R 0.6 1.05 1.142 0.0029 1.121 0.0028

11 Y 0.6 1.05 1.123 0.0021 1.107 0.0019
12 B 0.4 1.05 1.123 0.0029 1.107 0.0029

13 R 0.4 1.05 1.135 0.003 1.122 0.0034

14 Y 0.3 1.05 1.124 0.0028 1.105 0.0031
15 B 0.2 1.05 1.146 0.0028 1.177 0.0036

(Table-2)
Tan Delta values of CTs.

In one number CT Nitrogen pressure was found ‘zero’, oil sample of the CT
was tested for BDV and PPM and no abnormality was found while in one no.
CT (at Sl. No.2) the appreciable rise in tan delta value with respect to
previous values was observed, although, absolute value of tan delta was well
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within the limit, as per IEC 60044-1. To further investigate the reason of
increase in Tan delta value, oil sample of the CT along with some other CTs
(at Sr.No.2,6,7 & 15) were taken for DGA and the results for the same are
tabulated as Table-3.

CT
Sl Sample TGC N2 O2 Total
No Date (%) (%) (%) H2 CH4 C2H4 C2H6 C2H2 CO CO2 Furan
15 6-Sep-05 8.08 6.65 1.31 69 2 0 1 0 93 1115 0
11
6 5-Sep-05 8.73 7.06 1.55 87 2 0 0 0 2 1210 0
7 5-Sep-05 8.72 6.64 0.95 78 1 0 0 0 82 791 0
2 5-Sep-05 7.79 5.51 0.55 10633 1174 1 182 1.3 99 998 0

Table – 3
( DGA of CTs )

The CT with appreciable increase in tan delta value was found also with
high content of Dissolved Gas in the oil. CT was withdrawn from service
and sent to the manufacturing works, for detailed high voltage testing. The
modalities of the test were pre-decided and carried out as per the following
details:

1. Capacitance and Tan delta at different voltages and up to 267 KV -

Results were same as per site values.
2. HV test at 80% of 1 minute Power Frequency Voltage (504 kV) - It
withstood.
3. Voltage was reduced to PD measuring voltage i.e 1.2Um/square root 3
(291kV) and kept for 6.5hrs and PD was measured continuously - PD
was found less than 5 PC.
4. Voltage was again raised to 420 KV and kept for one hour. PD was
measured and found that less than 5 PC.
5. Again Capacitance and Tan Delta was measured and there was no
appreciable changes.
6. CT was heated in a oven up to 95 Deg.C, Capacitance and Tan Delta
was measured and found with marginal increase in Tan Delta value.
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7. CT was again tested for PD at 291 KV for one hour and found that PD
was less than 5 PC, where as while measuring PD at 420 KV kept for
30 minutes, PD was 7-8 PC.
8. Tan Delta was measured at surface temperature of 57 Deg and no
appreciable change was observed.

Inspite of extensive high voltage / thermal stress testing, we did not find any
appreciable change in Partial Discharge and Tan delta values at the factory.
To rule out the possibilities of deterioration of oil, it was decided to change
the oil of the CT and reprocess the CT. DGA of CT oil was done after
reprocessing . Subsequently CT was again tested for partial discharge for six
hours at 291 KV, although PD was less than 5pC but DGA of oil after test
indicates generation of gases again. DGA results are indicated in Table -4.

Sl Sample TGC N2 O2 Total

No Date (%) (%) (%) H2 CH4 C2H4 C2H6 C2H2 CO CO2 Furans
1 29-Jan-06 8.81 5.8 2.7 21 48 1 14 0 12 382 0
2 29-Jan-06 8.76 5.66 2.69 0 1 1 1 0 8 1038 0

Table – 4
(DGA of CTs)

From the table, it is very clear that inspite of change of oil, generation of
gas from the CT has not stopped. It is also clear from the detailed testing
that none of the high voltage tests mentioned above were able to identify the
reason of the generation of gas. As per our experience in Case Study-1, CT
shall be tested for impulse test as per IEC 60044-1. CT shall be subsequently
internally inspected for identifying the reason for generation of gases.
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OUTCOME OF INVESTIGATION:

From the case studies, following can be concluded:

i) DGA of CT oil is reliable tool for ascertaining the healthiness of

CT.

ii) DGA test is very sensitive test for ascertaining healthiness of CT,
which cannot be diagnosed in high voltage test other than
Lightening Impulse Test. As can be seen in Case Study – 2, the
CT has passed all tests despite the generation of high content of
Gas and also in Case Study – I (a), CT had passed all the tests
except the Impulse Test.

iii) DGA of CT oil after commissioning is an essential tool to ascertain

the manufacturing quality of lot.

iv) In the service span of CT, if any appreciable changes are observed
in the routine test , oil sample of CT shall be taken for DGA, for
ascertaining the healthiness of CT, as indicated in Case Study – 2.

CONCLUSION:

It can be concluded that correlation of DGA findings with the factory testing
can be established and DGA of CT oil can be used as an effective tool, for
ascertaining the healthiness of CT in service and accordingly, the service
utilities can introduce DGA test as commissioning test for CTs.
POWERGRID had already made DGA test of CT oil as mandatory after
commissioning and included the same in technical specification for
ensuring manufacturing quality of CT.

Reference:

1. IEC – 60044-1
2. IEC – 60599
3. IS-9434:1992
4. POWERGRID norms.