Application Research Based on Modern-Technology
for Transformer Health Index Estimation
Hasmat Malik#1, Abdul Azeem#2, and R.K. Jarial#3
#
Electrical Engineering Department, NIT Hamirpur (HP)-177005, India
1
hasmat.malik@gmail.com
2
aaaazeem@gmail.com
3
jarial0@gmail.com
Abstract— Diagnosis of power transformers becomes important
due to the age of the transformer in service. Diagnosis methods
can be separated in integral or differential methods. This paper
describes a realistic Health Index formulation method for power
transformers using readily available data. The method considers
practical limitations on obtaining data, and the possible
constraints on the parameters.
This Health Index estimation considers not only typical test
results such as dissolved gas analysis (DGA), oil quality, furan,
and power factor, but also other parameters such as frequency
response analysis (FRA), turn ratio, tap changer and bushing
condition, physical observations, load history, maintenance work
orders, and In-Service age of transformer. The calculation
includes condition ratings, weighting factors, and assigned scores
for specific condition parameters. By using a multi-criteria
analysis approach, the method combines the various factors into
a condition-based Health Index.
Keywords— Transformer, Health Index, Dissolved Gas Analysis,
Frequency Response Analysis, Aging, Modern Technology.
I. INTRODUCTION
Power transformers are the key elements in any electric
power station networks. It has been noticed that most electric
power utilities are highly motivated to assess the actual
condition of their transformers because there is an increasing
demand for improved financial and technical performance. To
achieve the optimal balance among capital investments, asset
maintenance costs, and operating performance, there is a need
to provide economic and technical justifications for
engineering decisions and capital replacement plans.
Health Indices (HI) represent a practical method to
quantify the results of operating observations, field
inspections, and site and laboratory testing into an objective
and quantitative index, providing the overall health of the
assets. Asset HI is a powerful tool for managing assets and
identifying investment needs and prioritizing investments into
capital and maintenance programs [16, 17]. Several studies
discuss different condition assessment and life management
techniques for power transformers by measurement or
monitoring of parameters such as partial discharge, dissolved
gas analysis, moisture, oil quality (dielectric strength, acidity,
color, and interfacial tension), frequency response analysis,
recovery voltage method, tap changer tests, bushing condition,
online partial discharge measurement, and other methods [7-
10, 18-21]. Utilities may conduct some of these tests
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periodically to evaluate the condition of the power
transformers, but there is no recommended method available
by standards or individuals to quantify the condition of the
asset considering all available data. This paper describes a
practical HI calculation method by using resent Modern
techniques [1] using available data by considering standard
recommendations from [8-10], [18-21].
II. POWER TRANSFORMER CONDITION ASSESSMENT
METHODOLOGY
Power transformers (>500 Kilovoltampere [KVA]) are key
components in the power train at electrical systems and are
appropriate for analysis under a risk assessment program.
Determining the existing condition of power transformers is
an essential step in analyzing the risk of failure.
According to the latest CIGRE WG 12 report, the main
subsystems of a transformer that are exposed to degradation
are [8]:
Dielectric (major / minor insulation, leads, windings)
Magnetic circuit (core, clamping)
Tap changers (LTC)
Mechanical parts (bushing, tank, cooling, etc.)
The most applicable methods currently used as a routine test,
diagnostic method, or monitoring technique are: group one
(Tier-1) tests and group two (Tier-2) tests.
¾ In group one (Tiers-1) tests include:
A. Insulating Oil Analysis (DGA & Furan)
B. Power Factor and Excitation Current tests
C. Operation & Maintenance History
D. Age
¾ In group two (Tier-2) tests are include:
E. Turn Ratio
F. SFRA
Condition assessment of the power transformer depends upon
the test result of both groups (Tier-1 and Tier-2).
A. Condition Indicator-1 (Insulating Oil Analysis)
1. Dissolved Gas Analysis:
IEC 60599 provides a coded list of faults detectable by
dissolved gas analysis and IEEE Std C57.104 introduces a
four-level criterion to classify risks to transformers, for
continued operation at various combustible gas levels [6, 10].
The production of organic gases such as methane (CH4),
ethane (CH6), ethylene (C2H4), propane, acetylene (C2H2), and
 propylene as well inorganic gases such as hydrogen (H2), projects the expected life of the equipment. As this
carbon dioxide (C02) and carbon monoxide (CO), in the degradation is not observable by any other means, it is one of
insulating system of the operating transformers in alarming the essential tests to diagnose the equipment. Other furanic
proportions in indicative of fault occurrence. These faults may derivatives are 5-hydroxymethyl-2-furaldehyde, 2-acetyl furan,
lead to the breakdown of the equipment. Some of the faults 5-methly-2-furaldehyde, furfural alcohol, 2-furoic acids,
that can be indicated by the production of particular gas are which are produced in much smaller quantities when
given bellow: transformer paper degrades thermally. The concentration of 2-
1. Acetylene in major concentration indicates arcing furaldehyde (furfural) was found to be highest of all the
2. Ethylene indicates over heating products and it increased exponentially with time to the
3. Hydrogen with considerable proportion indicates maximum value. Furan concentration is sensitive to operating
partial discharge. temperature, transformer loading, transformer design and
4. Methane with considerable proportion indicates concentration of moisture and oxygen in contact with the
partial discharge. cellulose.
5. Carbon dioxide and carbon monoxide indicates the
involvement of solid insulation in the fault. Table 1 Correlation between Furan concentration and DP
Now it has been found that the quantitative analysis of the Total furan level Range of DP Recommended
(ppb) retest period
above mentioned gases is more reliable & far more sensitive (Months)
that hazards fault detection devices, Such as bucholtz relay & 100 444-1200 12
differential relay. For quantitative gas analysis gas 101-250 333-443 6
chromatography is one of the most sensitive commonly used 251-1000 237-332 3
techniques. Gas chromatography should be done online bases 1001-2500 217-236 1
>2500 <217 Failure likely
regularly while the transformer energized. The result of gas
analysis provides an inside about incipient fault. Corrective
Correlation of 2-furaldehyde with DP has been expressed by
action may be taken for preventive maintenance. This
the following set of equations:
technology is however more useful in the case of power
transformer but can be equally effective in the distribution
transformer. DP =

2. Furfural Analysis DP =
The Cellulose insulation has a structure of long chain o
molecules. The cellulosic paper contains about 90% cellulose, DP =
6-7% of hemicelluloses and 3-4% of lignin processed by the
Kraft chemical process (Kraft in German is used for strong). DP =
Cellulose is a polymer of alpha-D-glucose units linked to one
another in a special manner. It may be represented simply as Where F is 2-furaldehyde concentration in the equation [1] is
best used to estimate an average DP in transformer having
[C5H10O5], where n is the degree of polymerization (DP). The
DP of paper can be determined using ASTM method D-4243. Kraft paper insulation with free breathing conservator. For
Generally, DP lie in the range of 1100-1600 for new paper but other insulation and preservation systems the equation can be
its value can drop by 10% after drying and oil impregnation used to estimate paper degradation from thermal events.
[11]. The DP range of Kraft pulps varies from 110 to 1200, for Tested results are analyzed and applied as per Table no. 2 for
mixed pulp fibbers it varies from 1400 to 1600 [12]. Middle arrive at a condition indicator score for transformer health
index [5].
aged and old aged paper have DP around 500 and <250
respectively. If the cellulose has DP around 200 or below [4], Table 2 Insulating Oil Analysis Scoring
it is basically a power without significant mechanical strength Result Condition
and considered to be the end of useful life. Indicator
Cellulose degrades slowly as the polymer chain breakdown Score
during its service, releasing degradation products into the oil. TDCG Generation Rate less Than 30 parts million per 3
month(ppm/month) and:
The paper eventually degrades to such an extent that it loses All Individual combustible gas generation less than 10
all its mechanical strength which puts the electrical integrity ppm/month
of the equipment at risk. The damaged paper cannot provide Exceptions: carbon monoxide (CO) generation less than 70
adequate physical support for the windings and this may lead ppm/month and acetylene (C2H2) generation rate 0 ppm.
And Furans 150 parts per billion(ppb) or less
to premature failure. The rate of change of furan concentration TDCG generation rate between 30 and 60 ppm/month and: 2
can indicate the rate of aging of paper. The degraded paper All individual combustible gas generation rate less than 15
insulation can be analyzed by the content of furanic ppm/month.
derivatives present in the oil. Like DGA, 2-furaldehyde (FAL) Exceptions: CO generation rate 0 ppm.
OR Furans between 150 ppb and 200 ppb.
is also an important diagnostic test. The 2-furaldehyde (FAL)
reveals the rate of insulating paper degradation and it directly

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 TDCG generation rate between 50 and 80 ppm/month and: 1 percentage. For decimal values up to 0.05, or
All individual combustible gas generation rate less than 25
ppm/month. values are equal to each other.
Exception: CO generation rate less than 350 ppm/month and The exact relationship between and is given by
C2H2 generation rate 5 ppm/month.
OR Furans between 150 ppb and 200 ppb.
following equations:
TDCG generation rate greater than 80 ppm/month and: 0 = or = (5)
Any individual combustible gas generation rate more than 50
ppm/month. As per IS 335, tan delta at 90 centigrade is 0.002 (max) for
Exception: CO generation more than 350 ppm/month and C2H2
generation rate no more than 10 ppm/month.
fresh oil and according to IS-1866, it varies from 0.010 to
OR Furans above 250 ppb 0.015 (max) at 90 centigrade depending upon the rating of
power transformer.
The main drawback of furan analysis is that when According to various range of power factor and excitation
transformer oil is replaced or refurbished, the analysis of current, the condition indication score for health condition is
furans in the refused oil may not show any trace of summed up in Table no. 3.
degradation, although the cellulose may have degraded
significantly. Table 3 Power Factor and Excitation Current Test Scoring [5]
Test Results Condition Indicator
B. Condition Indicator-2 (Power Factor and Excitation Score
Current Tests) Power Factor result normal(Good-G) 3
And
This test has been effective in detecting and confirming Normal excitation current values and patterns
compared to other phases and prior tests.
winding and core fault. The purpose of this test is to detect Power factor result show minor 2
short-circuited turns, poor electrical connections, core de- degradation(Deteriorated-d)
laminations, core lamination shorts, tap changer problems, and OR
other possible core and winding problems. On Single-phase Minor deviation in excitation current values and
patterns compared to other phases and prior tests.
transformers, results are also compared with sister units. This
Power factor result show significant deterioration. 1
test measures current needed to magnetize the core and (Investigation-I)
generate the magnetic field in the windings. Doble DTA OR
software only gives two indications on this test; one is “G” for Significant deviation in current values and
good and “Q” for questionable . Power factor (Tan delta) is an patterns compared to other phases and prior tests.
Power factor results show severe degradation. May indicate serious
important property determining the insulating condition of (Bad-B) problem requiring
power transformer. It can detect the insulation integrity in OR immediate evaluation,
winding, bushing, arrester, tank and oil. When an AC voltage Severe deviation in current values and patterns additional testing,
is applied to the insulation, the leakage current flows, which compared to other phases and prior tests. consultation with
expert, and
have two components, resistive and capacitive, as shown in remediation prior to
Fig.1. The power factor ( ) is dimensionless ratio of re-energization.
resistive current (Ir) to total current (It) flowing through the Power factor and excitation current test are conducted in the
insulation. The dissipation factor or is a dimensionless field on de-energized, isolated, and properly grounded
ration of the resistive current (Ir) to capacitive current (Ic) transformer [5].
flowing through the insulation. Del (δ) is represented as loss
angle. C. Condition Indicator-3 (Operation and Maintenance
History)
Operation &Maintenance history (O & M) are used in the
application as given below.
Sustained overloading.
Unusual operating temperatures indicated by gauges
and continuous monitoring.
Abnormal temperatures indicated by infrared
Fig.1 : Tan delta Representation
scanning.
Nearby lightning strikes or through faults.
As per ASTM D 924 [16], tan delta ( ) or power factor Abnormally high corona detected.
( ) is a measure of the dielectric loss in an electric Abnormally high external temperatures detected.
insulating liquid when used in an alternating field. Tan delta Problems with auxiliary systems (fans, radiators,
may be useful as an indication of change in insulating quality cooling water piping, pumps, motors, controls,
resulting from contamination and deterioration. A low value nitrogen replenishment system, and indicating and
of indicates low AC dielectric loss. The loss protection devices).
characteristics may be expressed in terms of decimal or in

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 Deteriorated control and protection wiring and
devices.
Increase in corrective maintenance or difficulty in
acquiring spare parts.
Anomalies determined by physical inspection
(external inspection or internal inspection not
requiring untanking) (e.g., incorrectly positioned
valves, plugged radiators, stuck temperature
indicators and level gauges, noisy oil pumps or fans,
oil leaks, connections to bushings).
Previous failures on this equipment.
Failures or problems on equipment of similar design,
construction, or age operating in a similar
environment.
Table 4 Operation and Maintenance History Scoring [5]
History Results Condition
Indicator
Score
Operation and maintenance are normal.
Some abnormal operating conditions experienced and /
or additional maintenance above normal occurring.
Significant operation outside normal and/or significant
additional maintenance is required; or forced outage
occurs; or outages are regularly extended due to
maintenance problems; or similar units are problematic.
Repeated forced outage; maintenance not cost effective;
or major oil leaks and/or severe mechanical problems; or
similar units have failed.
Qualified personnel should make a subjective
determination of scoring that encompasses as many O&M
factors as possible under this Indicator [5]. Results are
analyzed and applied to Table 4 to arrive at a Condition
Indicator Score.
D. Condition Indicator-4 (Transformer In-Service Age)
Transformer age is an important factor to consider when
identifying candidates for transformer replacement. Age is one
indicator of remaining life and upgrade potential to current
state-of-the-art materials. During the life of the transformer,
the structural and insulating properties of materials used for
structural support and electrical insulation, especially wood
and paper, deteriorate. Although actual service life varies
widely depending on the manufacturer’s design, quality of
assembly, materials used, operating history, current operating
conditions, and maintenance history, the average expected life
for an individual transformer in a large population of
transformer is statistically about 40 years[5]. The transformer
age is applied to table 5 to arrive at the Condition Indicator
Score.
Table 5
Age scoring [5]
Age Condition Indicator Score
Under 30 year 3
30-45 years 2 winding moment which changes its winding inductance and
Over 45 years 1 capacitance. Other mechanical faults occur is in the form of
E. Condition Indicator-5 (Turn Ratio Test)
The transformer turns ratio (TTR) test detects shorts
between turns of the same coil, which indicates insulation
failure between the turns. These tests are performed with the
transformer de-energized and may show the necessity for an
internal inspection or removal from service [5].
Turns ratio tests are traditionally made at a very low
voltage of 100 volts which will confirm the status of the
winding in all but a few cases. An example of such a case
would be a spot on a turn where the insulation has been almost
entirely lost due to some kind of unwanted activity, but where
there is still enough to withstand the low voltage applied by
the typical TTR test set. Take that same spot and energize it at
10 KV, and the little remaining insulation would break down
and slow the shorted turn. It is an extra tool that is especially
useful on a suspect transformer where other test may not yield
useful information. In addition, by having test result entered
automatically into electronic forms in case of M4000 with the
3 DTA program, the expected ratio and permissible limits for
each test are automatically calculated for the user, saving time
2 and helping prevent human error.
Transformer turns ratio tests at 10 KV are performed with
1
the M4000, provided the optional Doble Turn Ratio Capacitor
is available. The capacitance of the turn ratio capacitor is
measured, and is used as the “True” capacitance value. The
0 capacitor is then measured again by energizing the high
voltage winding of the transformer with the capacitor
connected to the corresponding winding of the low voltage or
opposite winding. That is referred to as the “apparent”
capacitance. The turn ratio is then calculated by using the ratio
of the “true” to the “apparent” capacitance.
Results are analyzed and applied to Table 6 to arrive at a
Transformer Condition Index score adjustment.
Table 6 Turns Ratio Test Scoring [5]
Test Result Adjustment to transformer
Condition Index
Less than 0.20% difference No change
from nameplate V1/V2 and
compared to previous reading.
0.20% to 0.50% difference Subtract 1.0
compared to nameplate V1/V2
Greater than 0.5% difference May indicate serious problem requiring
compared to nameplate V1/V2. immediate evaluation, additional
testing, consultation with expert, and
remediation prior to re-energization.
F. Condition Indicator-6 (SFRA)
Frequency Response Analysis (FRA) testing makes a
qualitative assessment of the mechanical condition of the
transformer core and winding. The loss of mechanical
integrity that may occurs due to large mechanical forces, fault
current, winding shrinkage result in release of clamping
pressure, transportation and relocation etc. A power
transformer would experience large number of short circuits
during its service life. Due to short circuits, there could be
displace winding, hoop buckling, winding moment,

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 deformation and damaged winding. Winding movement may KW. Test results for oil analysis using Kalman Transport-X
also result from stresses induced by electrical faults such as DGA analyzer is given in Table no. 8.
inter turns ,short circuits etc as a result of lightning strikes. It
may also results in insulation damage. Another important Table 8 Dissolved Gas Analysis Results
factor is winding shrinkage which occurs due to aging, leading Gases

H2

CO2

CO

C2H4

C2H6
CH4

C2H2

TDCG
to a reduction in clamping pressure and short circuits
withstand strength. The deformation can also be due to aging
of paper. Winding deformation in transformers are difficult to Test Result (in <5 727 74 2 1 2 <0.5 80
ppm)
establish by conventional methods of diagnostics test like ratio,
impedance/inductance, magnetizing current etc. Winding
Test results for frequency response analysis using M5100
deformation results in relative changes to the internal
Sweep Frequency Response Analyzer are given in Fig. 2.
inductance and capacitance of the winding .These changes can
be detected externally by low voltage impulse method or FRA
method. It is therefore desirable to be able to check the
mechanical condition of transformer periodically during their
service life.
In the FRA technique, a low amplifier swept frequency
signal is applied at the end of one winding and response is
measured at the other end of the winding with one phase at a
time. The method is based on the fact that every transformer
winding has a unique signature of its transfer function which (a) (b)
is sensitive to change in resistance, inductance and
capacitance. It consists of measuring the impedance of
transformer over a wide range of frequency and comparing the
results of this measurement with a reference set taken either
during insulation or at any other point of time. Difference in
signature of the responses may indicate damage to the
transformer which can be investigated further using other
techniques or by an internal examination. Several utilities
have considered this test as benchmark for newly installed
locations of Power transformer to ascertain mechanical (c) (d)
integrity of the entire structure intactness before energizing at
new location & prevent catastrophic failure [3].

Table 7 Sweep Frequency response Analysis Scoring [5]

Test Result Adjustment to Transformer Condition Index
Good Result. No change
Minor deviation. Subtract 2.0
Moderate deviation. Subtract 3.0
Significant deviation. Subtract 4.0 (e) (f)
Severe deviation. May indicate serious problems requiring immediate Fig 2 Frequency response of the considered transformer when (a) test was
evaluation, additional testing, consultation with taken between high voltage winding and low voltage winding, (b) neutral and
experts, and remediation prior to re-energization. low voltage winding with neutral short circuited, (c) high voltage winding and
neutral with tertiary short circuited, (d) low voltage winding and neutral with
tertiary short circuited, (e) Test on tertiary winding (Y1-Y2) and with all other
Condition of the transformer is calculated by subtracting terminals open, (f) between low voltage winding and neutral.
the result value of Tier-2 from the result value of Tier-1. The
value of subtraction shows the condition of the transformer i.e. Test results for insulation power factor and excitation
Good condition, Fair condition, and Bad condition. These current analysis using Insulation Analyzer M-4000 (DOBLE)
indicators are based on “Tier 1" inspections, tests, and are given in Table no. 9 and Table no. 10.
measurements conducted by utility staff or contractors over
the course of time. Table 9 Power Factor Result
Meas. Test mA Watts %PF Corr Cap(pF)
IRauto

Kv Corr Fctr
III. CASE-STUDY
The test methods discussed in the section II have been
performed on single-phase step-up Autotransformer 26.67/33 CH+CHT 10.002 14.034 0.3100 0.22 1.00 4473.6
MVA of Himachal Pradesh State Electricity Board (HPSEB), CH 10.002 7.609 0.1660 0.22 1.00 2425.4 G
India, having current in HV winding 262.4A and current in CHT(UST) 10.002 6.419 0.1450 0.23 1.00 2046.2 G
LV winding 437.39A, frequency 50 HZ and The Guaranteed CHT 6.425 0.144 0.22 1.00 2048.200 G
Load Losses 67 KW and Guaranteed No Load Losses 13.5 CT+CHT 10.002 16.632 0.4280 0.26 1.00 5301.7
CT 10.002 10.208 0.2840 0.28 1.00 3254.1 G

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 CHT(UST) 10.002 6.418 0.1450 0,23 1.00 2045.9 G 0-3(Poor) Immediate evaluation including
CHT 6.424 0.144 0.22 1.00 2047.600 G additional Tier 2 testing.
Consultation with expert. Adjust
Table 10 Exciting Current Tests Results O&M as prudent. Begin replacement
S.No.. Test kV mA Process.
1 10.002 17.702
2 10.002 17.969
Test results for transformer turn ratio analysis using M-4000 As calculated transformer net Condition Index 7.713 is lie in
(DOBLE) analyzer are given in Table no. 11. between 8 and 10, therefore the transformer is operating at
Himachal Pradesh State Electricity Board (HPSEB), Mattan
Table 11 Turn ratio Tests Results Sidth (India), under fair health condition.
Test Np Np Volt(2nd ) Cal Turn Ratio
serial No. Volt(1st ) V. CONCLUSIONS
1 127000 76000 1.671 1.6651
2 127000 76000 1.671 1.6643 The health indexing quantifies equipment condition based
on numerous condition criteria that are related to the long-
Evaluation of the Health Index (HI) term degradation factors that cumulatively lead to an assets
As discussed in above cases, the test results can be summed end- of-life. This paper described a realistic Health Index
up in Table no. 12 for Tier-1 and in Table no. 13 for Tier-2 as method for power transformers using available data with
follows: considering the IEEE and IEC standard's recommendations for
condition assessment parameters.
Table 12 Tier 1-Transformer condition assessment Summary The HI calculation is based on weighting factors,
Indicator No. Indicator Score * Weighting Factor=Total Score condition ratings, and assigned scores for any specific
1 Oil Analysis 1 1.143 1.143
parameter. By using a multi-criteria analysis approach, the
2 Power factor and 3 0.952 2.856
Excitation Current various factors are combined into a condition-based Health
Test Index. DGA, oil quality tests, furan, power factor, O&M
3 Operation and 3 0.762 2.286 history, transformer In-Service Age, turn ratio and FRA are
Maintenance the parameters that have been used as quantitative data. The
History
4 Age 3 0.476 1.428 physical health condition of transformers was included using a
Transformer Condition Index 7.713 count of corrective maintenance work orders. Some of the
important factors include bushing condition, oil leak, tank
Table 13 Tier 2 Transformer Condition Summary corrosion, cooling system, infra-red Thermography,
1 Turn Ratio No change grounding, and foundation.
2 Sweep Frequency Response No change
Analysis
Tier 2 Adjustments to Transformer Condition Index 0.00
ACKNOWLEDGMENT
The authors would like to thank Himachal Pradesh
To calculate the net transformer condition index, subtract the Electricity Board (HPSEB), Shimla (India) for providing the
Tier 2 Adjustment from the Tier 1 Condition Index. transformer's oil samples for experimental testing results in
Tier 1 Transformer condition Index= 7.713 this study.
Minus Tier 2 Adjustment = 0.00 The authors are also thankful to Technology
So, Net Transformer Condition Index= 7.713 Information Forecasting and Assessment Council and Centers
of Relevance & Excellence (TIFAC-CORE) on Power
IV. RESULT AND DISCUSSIONS Transformer Diagnostics at NIT Hamirpur for providing
Net calculated transformer condition index in section III is necessary infrastructural facilities for carrying out the research
directly applied in given Table 14 for concluding the heath work.
condition of a service transformer.
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IN USA, 19-22 September 2004, pp. 163 -168.
[18] "ABB Service Handbook for Transformers", 2nd edition, ABB
Management Service Ltd, Switzerland, 2007.
[19] IEC 60422, "Mineral insulating oils in electrical equipment -
Supervision and maintenance guidance", Third edition, 2005.
[20] IEC 60505, "Evaluation and qualification of electrical insulation
systems," Third Edition, 2004.
[21] IEEE Std C57.106-2006, "IEEE Guide for Acceptance and
Maintenance of Insulating Oil in Equipment", IEEE Transformers
Committee, 2006.