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New Horizon Electric

Gary B. Elliott
This is a presentation on DGA analysis
using a ratio method of hot metal gases
Will show results from four examples
Three DGA ratios and one fluid quality
This method is a proven tool in NHEC
Predictive Maintenance

New Horizon Electric

A Different Approach To
Regulator Analysis

A New Way To Find Regulator Problems


Through Gas Ratios?
Objectives:
Establish a Pattern
Recognize Potential Problems
Establish Solid Gas Ratio Formulas
Keep It Simple As Possible

Why We Elected To Use Gas Ratios


Have a two year old database
Regulators were serviced in the field
Regulator oil was not replaced with new oil or
degassed
Couldnt find a good ppm value on any hot metal
gases due to extremely high gas values due to
excessive arcing
Ratios are Independent of number of operations

Which Gases Should Be Evaluated?


Methane

H
Ethane

H C H
Ethylene

H
H

C C

H C

H
Heating

Heating

H HH H Heating
C
C
C
C
C
H H HH H H
Arcing

Corona

H C C H

H H

Acetylene

Hydrogen

H
C H
H

Key Hot Metal Gases


Methane
Ethane
Ethylene
Acetylene

NHEC Gas Ratio Standards

1-Ethane .5 to 1.0 of Methane


2-Ethylene .5 to .75 of Acetylene
3-Ethylene .75 to 1.0 of Acetylene
4-Ethane 1 to 1 or Greater of Methane
5-Ethylene 1 to 1 or Greater of Acetylene

Example #1

Regulator was last serviced 4-99


Regulator was in service
Regulator seen normal duty
Regulator load was about 75% normally
Had no previous DGA or Fluid Quality
data

333 kva Regulator at Fairplay Sub


TOA Software

Targeted
Regulator

DGA Report 5-25-2001


TOA Software

Ethylene 19224ppm
Acetylene 7246ppm
Ratio 2.65

DGA Report 10-29-2001


TOA Software

Ethylene 14143ppm
Acetylene 5601ppm
Ratio 2.52

DGA Report 12-11-2001


TOA Software

Ethylene 12792ppm
Acetylene 5098ppm
Ratio 2.50

Fluid Quality Report


TOA Software

Color on 5-25-2001

Fluid Quality Report


TOA Software

Color on 10-29-2001

Ratio Results Ethylene > Acetylene

Reversing Switch Assembly


(Load Carrying)

Reversing Switch Stationary Contact

Stationary Contact

Reversing Switch Moveable Contact

Conclusion
Regulator failure was inevitable
Regulator was last serviced 4-99
Contacts were damaged due to not
exercising the selector (reversing) switch

Example #2 114.3kva Regulator


Regulator was in service
Had no record of last service
Had no previous DGA or Fluid Quality
data

Regulator at McCormick Sub

Targeted
Regulator

DGA Report 4-23-2001


TOA Software

No indication of a
problem

DGA Report 4-22-2002


TOA Software

No indication of a
problem

Fluid Quality Report 2001

Moisture 28ppm
IFT 16

Fluid Quality Report 2002

Moisture 45ppm
IFT 13

Untanking The Regulator

Evidence of Moisture

Moisture

Rust Present

Moisture

Conclusion
State of regulator was deteriorating rapidly
Regulator had a significant increase in
moisture, IFT, and acidity
Regulator had a deteriorating gasket on
the bushing which allowing moisture to
enter equipment
This problem would haven't been found
through DGA

Example #3
333kva regulator currently in service
Not scheduled for maintenance

Regulator at Newry Sub

Targeted
Regulator

DGA Report 10-15-2001

Ethylene 8713ppm
Acetylene 3176ppm
Ratio 2.74

DGA Report 5-09-2002

Ethylene 10911ppm
Acetylene 3432ppm
Ratio 3.18

DGA Report 6-13-2002

Ethylene 11059ppm
Acetylene 3746ppm
Ratio 2.95

Fluid Quality Report 5-09-2002

No indication of a
problem

Ratio Results Ethylene > Acetylene

Contact Lead Termination Point

Contact Lead Termination Point


Close-Up

Reversing Switch

Conclusion
Found contact wire lead missing fastening
nuts
Failure was inevitable
Only reason hadnt failed is lack of
frequency on that step

Example #4
333kva regulator currently in service
Not scheduled for maintenance
Regulator had been serviced in the field
previously
Regulator load was around 75% normally
Had no previous DGA or Fluid Quality
data

Regulator at Westminster Sub

Targeted
Regulator

DGA Report

Ethylene 203063ppm
Acetylene 4390ppm
Ratio 46.26

Fluid Quality Report

No indication of a
problem

Ratio Results Ethylene > Acetylene

Reversing Switch Assembly


(Load Carrying)

Reversing Switch Assembly


(Continued)

Reversing Switch Assembly


Moveable Contact

Reversing Switch Assembly


Stationary Contacts

Normal Set of Reversing Switch


Stationary and Moveable Contacts

Conclusion
Failure was inevitable
Contacts were burned due to constant
coaking from lack of exercising the
reversing switch

Questions ?