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Procedia Engineering 150 (2016) 18 – 25

International Conference on Industrial Engineering, ICIE 2016

Stationary system for monitoring technical state of power

transformer
S.A. Evdokimov, Yu.N. Kondrashova, O.I. Karandaeva*, M.S. Gallyamova
Nosov Magnitogorsk State Technical University, Lenina Av. 38, Magnitogorsk, 455000, Russia

Abstract

Implementation of stationary systems of continuous monitoring technical state of power transformers is considered to be an
important and relevant task. The paper provides a summery on the systems implemented at transformers of OJSC Magnitogorsk
Iron and Steel Works. It characterizes the transformer of the power generating set of the thermal power plant equipped with the
system for monitoring technical state. It lists diagnostic methods and offers an integrated system structure. The monitoring
system is based on TDM package developed by OAO Dimrus. As a device for oil condition control, the Hydran Ɇ2 analyzer
identifying gases dissolved in oil was used. Functions of separate modules, their version and arrangements are under
consideration. The system interface is characterized, too. The main screen of controlled parameter of the transformer is
provided in Inva-format. There is a challenge to develop methods for fault localization and identification based on the total
of diagnostic features. The paper highlights a practical need for investigation of discharge activity with portable devices
for control of partial discharges.
© 2016
© 2016TheTheAuthors.
Authors. Published
Published by Elsevier
by Elsevier Ltd. Ltd.
This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the organizing committee of ICIE 2016.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of ICIE 2016
Keywords: power transformer; technical state; monitoring; control methods; stationary system; structure; functional composition; equipment;
interface; implementation; recommendations.

The systems of continuous control (monitoring) are designed to prevent failures of power transformers
accidents; they use a sensor set for recording various parameters change of which indicates developing defects.
Due to the introduction of modern methods and means of effective diagnostics, operational personnel is
provided with the following data:

* Corresponding author. Tel.: +7-351-943-1256.

E-mail address: AED174@mail.ru

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of ICIE 2016
doi:10.1016/j.proeng.2016.07.270
 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25 19

x current technical condition of the transformer, sources and defects which have stipulated its deterioration;
x remaining (currently) service life, that is, the possible time period at which their failure-free operation is possible
despite the revealed and developing defects;
x optimal terms of the maintenance of this equipment needed to provide its failure-free operation.
These purposes are inseparably associated with each other; the most difficult of them is the issue of
effective detection of a current technical state.
It is practically to analyze the state of power transformers in on-line mode without shutdown for
maintenance (continuous diagnostic method). Currently, innovative computer-based methods for control of
transformers' condition are being intensively developed and implemented; they ensure automatic data
collection, processing and analysis. Engineering support of these methods consists of various detectors or
sensors directly installed on the equipment.

1. Problem statement

The list of priority areas of OJSC Magnitogorsk Iron and Steel Works includes provision of main facilities
with means for technical diagnostics because its transformer stock is largely overaged. Correspondingly, the
methods of diagnostics in the real time mode play an increasingly prominent role. Within the framework of the
implementation of the adopted strategy, the systems for continuous control of technical state of transformers
installed at the arch steel-making and ladle furnaces of the electric steel-making steel works shops have been
developed and commissioned [37]. A similar system has been mounted and commissioned at NDMS
63000/100000/110U1 transformer at sub-station No. 96 of the network and sub-station shop [8]. These systems
are based on the diagnostics equipment of OAO Dimrus (Perm) which is operated at many domestic and
foreign power facilities. The main purpose of works performed is reduction of accidents and outages of the
essential equipment.
At present, the stationary system for continuous control of technical state of 80 MVA transformer at power
generating unit No. 4 of the combined heat and power plant at OJSC Magnitogorsk Iron and Steel Works has
been successfully implemented. A number of issues has been solved at its development including the
following:
x validation of system functions and diagnostic methods;
x structure development, selection of diagnostic equipment;
x mounting, testing and pilot commissioning.
Therefore, company's proprietary developments were adapted according to specific conditions and
requirements of the customer.

2. Main part

TD-80000 power step-down three-phase oil transformers are manufactured at Tolyatti's Transformer plant (OOO
Tolyattinsky Transformator). TDN-80000/110-U1 110 kV type two-winding transformer is equipped with high
voltage controller operating within the range of 16% with the ONAN, ONAF or OFAF cooling system. These
transformers are designed for operation at power plants completed with the generator. See specifications in Table 1.
The following diagnostic methods are validated for the system of monitoring transformer condition:
1. Transformer oil assessment:
x control of oil humidity;
x monitoring content of gases resolved in oil.
2. Thermal analysis:
x monitoring temperatures of the higher and lower oil layers;
x control of environment temperature.
x 3. Electrical analysis:
x measuring operating currents and voltages of the transformer;
x measurement of the dielectric loss angle tgį, capacity of basic insulation and current imbalance of galvanic
currents of inputs.
20 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25

Table 1. Specifications of TD 80000/110-U1 transformer

Rated
Short
Rated voltage, Winding wiring Losses, W Weight, kg
circuit Idle run Length, Width, Height,
Type power, kV scheme and
voltage, current, % mm mm mm
kVA group idle short
HV LV % of oil full
run circuit
TD-
6.3
80000/110- 80000 121 Y /'-11 40.0 310.0 10.5 0.23 6,200 4,650 6,150 12,400 87,500
10.5 0
U1

4. Detection of discharge events:

x detection of insulation areas with presence of partial discharges (PDs);
x revealing arching assemblies;
x detection of PDs at high-voltage inputs and in the tank.
The vibroacoustic method may not practically applied for transformer of this class due to a relative event
load.
Based on the analysis of measuring results, parameters reflecting transformer condition are calculated.
Estimation of their temporary changes enables definition of condition change trends, planning necessary repair
and maintenance operations.
Data collection and processing are provided by stationary TDM P034 system developed by ɈȺɈ Dimrus
(Fig. 1) [9].
The main diagnostic devices are the Hydran Ɇ2 analyzer of gases dissolved in oil [10], PD detectors
installed at the high-voltage inputs, PD acoustic sensors and gauges measuring temperature in the upper and
lower oil layers. There are over 20 sensors. All they are certified.
The system is implemented as a technically and algorithmically integrated structure. Its construction
consists of five modules processing signals from primary detectors and immediately of the main device of the
TDM monitoring system installed in the control cabinet at the controlled transformer. Functions of the
modules see in Fig. 1.
Monitoring modules (Ɇ0) is a central system module. Three main tasks are solved with it:
x collecting and processing data from other modules, complex statement on the transformer technical state, storage
of the data obtained in the memory of the central module;
x system connection and data exchange with automated process control systems of higher level; for this purpose,
data channels of all general types (industrial interfaces, local area network) may be connected;
x collection of data from primary detectors and diagnostic systems apart from the system of condition control.
Module of transformer temperature monitoring and automated control of the cooling system (Ɇ1) is used to
enhance transformer thermal modes and monitor the state of motors of the cooling system. Initial data for
monitoring thermal modes are the values of temperature at the input and output of the chilling units supplied by
Pt100 detectors connected to the module. The monitoring module provides additional information on temperature of
oil in the tank.
The emergency operation recorder (EOR No. 2) monitors phase primary and secondary voltages. Recorded
values are used in the built-in calculation units that determine remaining lifetime of the winding insulation. The
same information is used for generating output signals of the system for automated RUL position control as a
function of maintaining the set output voltage.
The module for monitoring the state of input insulation and winding geometry violations (Ɇ3) is designed to
realize one of the most essential function of the monitoring system that is reflected in its name. DB-2 detector is
installed at PIN-output of each input; its output signal contains data on the conduction current and pulses of partial
discharges. Conduction current are recorded in this module; PD information is transferred into special module 4.
Module M3 provides capability of simultaneous measuring parameters of three inputs of the same voltage.
 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25 21

Fig. 1. Structure of system monitoring transformer's technical state

Additionally, measuring parameters of inputs of the same phase but different voltages are provided; here, load
current of the same phase is synchronously recorded. The information obtained may be used at plotting a vector
diagram of the reduced transformer and analytical calculation of Zk short circuit impendence of its phases. Thus,
changes of winding form due to fault through currents in the transformer may be controlled.
Module for recording and analyzing ɢ partial discharges in the transformer, system No. 4. Up to 12 PD detectors
installed at the transformers may be connected to this module. The maximum configuration includes the following
detectors:
x DB-2 PD detectors at high voltage inputs – 6 units;
x KS-60 korona sensors 3 units;
x RFCT-4 PD detectors at the transformer neutral conductor– 3 units.
22 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25

Recording partial discharges in the transformers is a complex challenge because of significant influence of
corona discharges which parameters are similar to DP pulses. That is why, the module implements technical and
algorithm capabilities of interference tuning out at the maximum extent.
A full range of modules of the TDM system and their detail description are given in [8]. The module
structure used in the monitoring system helps to implement a structure required for each specific application
easily.
3. System implementation
Main view of TDM cabinet with all the above modules is shown in photo, Fig. 2.a. The cabinet is wall-
mounted in close proximity to the transformer. Fig. 2, b shows attachment of the gas analyzer. The system
developed ensures convenient representation of outcome of complex parameter assessment on the screen: from
their trend graphs to the summary in the table form. Data on transformer condition are output within Inva
system developed by ɈȺɈ Dimrus [11]. Inva is a software and hardware complex providing collecting,
analyzing and modeling parameter changes during operation of the electric equipment. The system is designed
for effective diagnostics of technical state, detection of dangerous and developing defects.

Fig. 2. Main view of TDM system of the combined heat and power plant transformer ɚ; connection of Hydran Ɇ2 gas analyzer b

The main screen with general controlled parameters is shown in Fig.3. It provides average data reflecting
condition of inputs, windings and data on partial discharges at the high voltage side of the transformer.
Environmental variables, phase currents according to the inputs and other coordinates are shown, too.
Visual representations that are convenient for operational personnel are „traffic light“ signals characterizing
the correlation between parameters and their limit values. Along with the current data, it provides an effective
response to the over-range. Table 2 shows the threshold values exceeding of which actuates "traffic light"
signaling [12].
4. Results discussing
The disadvantage of the solution is that effective operation of the systems for control of technical state is
obstructed because of the lack of available engineering methods for fault localization and identification based on the
total of diagnostic features. Recording and storing data supplied by channels 6–8 are of low efficiency and do not
enable actual estimation of technical state. So, the systems implemented are generally used as fault signal
indications only.
It is also practical to investigate discharge activity with portable devices for control of partial discharges. The
author team has an experience of investigations of this type at transformers of the central power station of OJSC
 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25 23

Magnitogorsk Iron and Steel Works [13]. The method of subtractive (mounting) clustering seems to be appropriate
for processing measuring results, thus, the corresponding methodology has been elaborated [14].

Table 2. Threshold values of parameters of 80 MVA transformer at the combined heat and power plant at OJSC Magnitogorsk Iron and Steel
Works
Threshold of impaired condition Threshold of pre-emergency
Parameter Device
condition
Coefficient of temperature dependence 0.08%/qɋ Not specified
Imbalance of conduction currents 5% 10%
TDM
Input tangent, A-phase
Module 3
Input tangent, B-phase 0.6% 0.7%
[Bushing]
Input tangent, C-phase
Imbalance level trend 5% in a year Not specified
PDI-trend (PD power) TDM
Module 4 5 times in a year 5 times in a year
Q02 trend (the largest recurrent PD value)
[PD]
TDM
'Zk_b1 Module 10 162% 163%
[Zk]

Fig. 3. Main screen of transformer controlled parameters

24 S.A. Evdokimov et al. / Procedia Engineering 150 (2016) 18 – 25

There is a challenge to develop the improved model for thermal characteristic calculation designed for the system
of on-line monitoring. For this purpose, the algorithm has been developed that enables analysis of thermal state in
the real time mode [15]. It is integrated into software of the monitoring systems being introduced at the
transformers. Thus, efficiency of diagnostic control is improved.
The software of the monitoring system should contain the thermal model of the transformer. This is a prerequisite
for provision of the most accurate account of its state enabling early fault detection. It is reasonable to develop
systems that identify faults by means of comparing measuring results with the values "predicted" with models [16-
23]. This is a way to specify transformer load bearing in mind environmental conditions and to reduce electric
power losses due to the load optimization.
Results of multi-parameter diagnostics are:
x prevention of transformer failures due to continuous control and analysis of the technical parameter complex;
x increasing lifetime of transformers owing to fault detection at the stage of appearance and early development;
x effective generation of integral estimation of a current technical state of the power equipment;
x maintenance and repair cost reduction.

Acknowledgements

This research was performed with financial support in the form of a grant from the President of the Russian
Federation (Grant No. MD-3395.2015.8)

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