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OIL ANALYSIS

Online DGA Monitoring

Autonomous monitoring system for dissolved gas analysis of power transformers – around the clock with true lab accuracy, directly on site.

The OnlineDGA version 2 analyses the insulating liquid of your power transformer around the clock – with true lab accuracy, directly on site. Highly efficient vacuum extraction combined with a sensitive gas chromatograph separates and quantifies the gases formed during transformer failures. You receive the results via network connection or visually via signal columns.

ASTM D3612IEC 60567Version 2 – autonomous, 24/7
Online DGA version 2 – open monitoring cabinet with gas chromatograph and oil circulation panelonline
11 gases
+ total gas content (TGC)
0.1 ppm
detection limit for hydrocarbons
up to 3
transformers with one device
24/7
monitoring with alarm
Features

All benefits at a glance

Highly efficient vacuum extraction

Vacuum extraction to ASTM D3612, Method A – the basis for true lab accuracy directly at the transformer.

11 gases by gas chromatography

A sensitive gas chromatograph separates and quantifies all 11 fault gases – including the memory gases propane and propylene.

Up to 3 transformers

One device monitors up to three transformers. Isolated oil circulation panels prevent cross contamination and ensure oil return to the conservator.

Self-calibration

A built-in calibration gas mixture (10 L) calibrates the system automatically – for reliable readings in the long run.

Alarm, relays & signal columns

Customisable signal columns and physical relay outputs indicate transformer or DGA faults immediately and trigger individual fault responses.

Touch monitor & industrial PC

15" touch monitor for on-site adjustment, result check, chromatogram review and trend visualisation of each gas.

Modules

System layout

All components sit in an AC-controlled outdoor cabinet (IP55). Tap or point at a number.

Open Online DGA cabinet with monitoring unit, gas chromatograph, vacuum extraction module, oil circulation panel and touch monitor
  1. 1OnlineDGA cabinet
  2. 2Monitoring unit (control unit)
  3. 3Gas chromatograph
  4. 4Signal column
  5. 5Vacuum extraction module
  6. 6Calibration gas mixture (10 L)
  7. 7Hygrometer
  8. 8Oil circulation panel
  9. 9Lamp
  10. 1015" touch monitor
  11. 11Industrial PC
Process

How the system works

From the transformer to the alarm – the OnlineDGA version 2 works fully automatically according to a customisable measurement routine.

01

Oil sampling

Oil is drawn directly from the transformer via the oil circulation panel and then returned to the conservator.

02

Vacuum extraction

The dissolved gases are extracted by highly efficient vacuum extraction; a pressure sensor determines the total gas content.

03

GC analysis

The gas chromatograph separates and quantifies all 11 gases with lab accuracy to ASTM / IEC.

04

Evaluation & alarm

The integrated software interprets the results based on international standards. If gases increase, the transformer is prioritised and an alarm is raised.

Detection limits

Accuracy · ppm
H₂
1 ppm
CO
0,2 ppm
CO₂
0,2 ppm
CH₄
0,1 ppm
C₂H₂
0,1 ppm
C₂H₄
0,1 ppm
C₂H₆
0,1 ppm
C₃H₆
0,5 ppm
C₃H₈
0,5 ppm
O₂
30 ppm
N₂
30 ppm
Σ
Total gas

11 gases standardised – lab accuracy as per ASTM / IEC. Many other online systems cannot detect propane and propylene, the important “memory gases”.

Technical details

Housing
AC-controlled outdoor cabinet, IP55
Dimensions (W × H × D)
1700 × 1600 × 700 mm
Power supply
230 V, 50–60 Hz
Power consumption
1400 W
Degassing
Highly efficient vacuum extraction (ASTM D3612, Method A)
Analysis
Gas chromatograph, 11 gases + total gas content
Transformers
Up to 3 with one device, isolated oil circulation panels
Calibration
Built-in calibration gas mixture (10 L) for self-calibration
Operation
15" touch monitor with industrial PC, trend view per gas
Signalling
Customisable signal columns, relay outputs, network
Measurement routine
Customisable, automatic prioritising in case of faults
Option
Measurement of relative moisture of the insulating liquid
Standards
ASTM D3612, IEC 60567
Background

Why Online DGA Monitoring?

Why online monitoring matters

DGA is known as the “blood test” of the transformer. Both the test and the instrument used must therefore be very accurate and cover all required parameters.

An online DGA system monitors important transformers 24/7: it automatically analyses the gases dissolved in the oil, sends data and reports and raises an alarm as soon as it detects an unusual increase.

This protects critical transformers through precise diagnosis and proactive failure prevention – provided the instrument is 100 % in line with ASTM D3612 / IEC 60567 and achieves true lab accuracy.

Why 11 gases and not just 9?

Any gas evolved in the oil relates to the energy released by a thermal, electrical or mechanical fault – including small, unnoticed ones.

Other instruments cannot detect propane and propylene: they occur in very low quantities and require a highly accurate instrument following ASTM D3612. As “memory gases”, even traces of them indicate that

  • a fault did occur, but was so minor that the oil quenched it instantly, or
  • a very small fault exists that is currently still covered by the insulating property of the oil.

The transformer should then be monitored carefully for some time.

Proactive maintenance & total gas content

Ignoring the memory gases and waiting for a fault to evolve defeats the purpose of DGA. The volume of gas from a fault cannot be controlled – but even the slightest increase can be detected.

All gases dissolve in oil, but to different degrees; only after saturation do they collect in the Buchholz relay. A special pressure sensor therefore determines the total gas content of the oil sample online – a key criterion for the transformer's health.

Gallery

In operation

The OnlineDGA version 2 stands right next to the transformer – weatherproof and climate-controlled.

Service

Service & support

Warranty

All equipment supplied is covered by a one-year warranty as per manufacturer specification.

Lead time

The standard lead time is 16–20 weeks after receipt of order.

Service & maintenance

Almost maintenance-free (depending on the measurement routine). Online access allows remote diagnosis in case of failure; service is performed by the manufacturer or a trained representative.

Training

We offer on-site user training after installation – alternatively, training at our factory in Germany before shipment.

Important note

Operating our system is very easy – but more importantly, the DGA result must be interpreted correctly, the actual cause of the fault in the transformer identified and the right steps taken to eliminate it.

Technical consultancy

Energy Support has been working in transformer maintenance and diagnosis for more than 25 years and also provides consultancy and training in this field – tailored to your needs.

Our expert from Germany can come to you and provide the required knowledge on site. This is a separate paid programme that is arranged individually.

Reference projects in recent years

  • Power plant, Germany
  • Iran Maintenance Intl. for Iran Power Plant
  • Infracor Industrial Park, Germany
  • ABB Service for transformer factory, Germany
  • Vattenfall, Germany
  • TNB, Malaysia
  • KOEPCO, Korea
  • KESCO, Korea

Interested in the Online DGA Monitoring?

Download the datasheet or talk to us about using it on your transformer.