ISSUE 27

March 2023 transformer-technology.com ISSN 2642-2689

POWER SYSTEMS TECHNOLOGY

MONITORING &
DIAGNOSTICS

Mitigating Transformer Supply Chain Risks with Online Monitoring

Adoption of Asset Health Monitoring Solutions for Power Grid Equipment
Saving the Day: On-line DGA Monitoring Case Studies
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COMPANY
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transformer-technology.com
4 TABLE OF
CONTENTS

Contents

Table of
Index
Table of Contents_04 12
Editors & Impressum_08
Mitigating
Editor’s Letter_10
Transformer
Mitigating Transformer Supply Chain
Supply Chain
Risks with Online Monitoring_12 Risks with Online
Interview with Bidesh Kar, Director Monitoring
of Product Management at
Sentient Energy_18
Unlocking Grid Performance_26
Automated real time ML-based
Trip Coil Analysis_30
Cargill introduces FR3r™ natural
ester, a new rapeseed dielectric
fluid_38
Adoption of Asset Health
Monitoring Solutions for Power
Grid Equipment_42

18
Interview with
Bidesh Kar
Director of Product
Management at
Sentient Energy

Underground
Grid for Better
resiliency and
Reliability
Transformer Technology March 2023 5

Issue 27

38
Cargill introduces
FR3r™ natural ester,
a new rapeseed
dielectric fluid

26
Unlocking Grid
Performance

42
30 Adoption of Asset
Automated real Health Monitoring
time ML-based Solutions for Power
Trip Coil Analysis Grid Equipment
6 TABLE OF
CONTENTS

Contents

Table of
Index
New technologies can help
compensate for the loss of
personnel knowledge and the
increased demands on operating
equipment_48
Leveraging Operator-Driven Safety
and Reliability Programs to Boost
IIoT Program Success_56
How to effectively address lightning
performance and continuously
48
monitor system failures?_62 New technologies can help
compensate for the loss of personnel
Women of Note: Julie Rotchell,
knowledge and the increased demands
Hitachi Energy_69 on operating equipment

56
Electromagnetic Properties of
0.18 mm Thin-gauge Grain-
oriented Silicon Steel and Its Leveraging Operator-
Application in Transformer Driven Safety and
Cores_70 Reliability Programs
Saving the Day: On-line to Boost IIoT Program
DGA Monitoring Success
Case Studies _76
Online Transformer Data
Comes at a Price_82
Coming in May_88
Transformer Technology March 2023 7

Issue 27

62 76
How to effectively address Saving the Day:
lightning performance On-line DGA
and continuously monitor Monitoring Case
system failures? Studies

69 82
Women of Note Expert opinion
Julie Rotchell Online Transformer
Hitachi Energy
Data Comes at a Price

70
Expert opinion
Electromagnetic Properties of
0.18 mm Thin-gauge Grain-oriented
Silicon Steel and Its Application in
Transformer Cores
8 EDITORS &
IMPRESSUM

Impressum TAB Executive Advisor,

The Chair and Managing Editor
Alan M. Ross, CRL, CMRP
Transformer maintenance and
reliability

Technical Advisory Board (TAB)

Executive Advisors TAB Executive Advisor
Alan M. Ross, CRL, CMRP Corné Dames
The Chair and Managing Editor Independent transformer
Corné Dames consultant Transformer oils
Independent transformer consultant
Transfomer oils
Ben Lanz, IEEE PES Senior Member
Power system reliability, asset management
and diagnostics TAB Executive Advisor
Technical Advisory Board Members Ben Lanz, IEEE PES Senior Member
Diego Robalino, PhD, PMP Power system reliability,
IEEE Senior Member asset management
Tony McGrail and diagnostics
Asset management & Condition monitoring
Edward Casserly, PhD
Senior Scientist, Transformer oils TAB Member
Maria Lamorey
Diego Robalino PhD, PMP
Industrial OEM manufacturing
IEEE Senior Member
Alan Sbravati, ME, MBA
Transformer insulating materials Transformer condition
Marco Tozzi, PhD assessment and
Diagnostics and asset monitoring diagnostics
Curtus Duff
Power transformer design
Traci Hopkins, IEEE Member
Transformer Condition Assessment
Jon Trout, PE
TAB Member
Electric utility
Michael Riccio, CRL, IRT CAT-1
Tony McGrail, PhD
Reliability, Electrical safety Asset management &
Alexander Doutrelepont Condition monitoring
High voltage bushings & insulators
Ed Khan
Power Systems, Relay protection, Training
Graphic design
BE Koncept Communication Boutique TAB Member
Photo Cover Edward Casserly, PhD
Shutterstock Senior Scientist,
Transformer oils
Sales & Marketing
Rachel Linke
[email protected]
Kevan Sears
[email protected]
Sales & Marketing Americas TAB Member
Jose Mora Maria Lamorey
[email protected] Industrial OEM
Sales & Marketing Mexico manufacturing
Fernando Campos
[email protected]

Sales & Marketing Brazil

Marcelo Braga
[email protected] TAB Member
Marketing Global Alan Sbravati, ME, MBA
Marin Dugandzic Transformer insulating
[email protected] materials
Transformer Technology March 2023 9

Issue 27

Editors
TAB Member
Marco Tozzi, PhD
Diagnostics and asset
monitoring

ISSN 2642-2689 (Print)

ISSN 2642-2697 (Online)
TAB Member
DIGITAL Membership Curtus Duff
Free Power transformer design
Transformer Technology magazine is a quarterly
magazine published by APC MEDIA LLC, 2152
Caper Dr., Marietta, GA 30064, USA. Published
content does not represent official position of APC
MEDIA LLC. Responsibility for the content rests TAB Member
upon the authors of the articles and advertisers, Traci Hopkins
and not on APC MEDIA LLC. APC MEDIA LLC Transformer Condition
maintains the right to keep the textual and Assessment
graphical documents submitted for publication.
Copyright and reprint permission
Abstracting is permitted with credit to the source.
Libraries are permitted to photocopy isolated
pages for private use of their patrons. TAB Member
For other copying, reprint or republication Jon Trout, PE
permission requests should be addressed to Electric utility
[email protected]
Publisher:
APC MEDIA LLC
2152 Caper Dr.
Marietta, GA 30064, USA
TAB Member
transformer-technology.com
Michael Riccio, CRL, IRT CAT-1
Reliability, Electrical safety

TAB Member
Alexander Doutrelepont
High voltage bushings
& insulators

TAB Member
Ed Khan
Power Systems,
Relay protection, Training
10 LETTER FROM
THE EDITOR

Dear Readers,

I have had the great fortune of interviewing some While supply chain issues are still around, the big-
special subject matter experts (SME’s) at the re- gest supply chain issue that cannot be resolved in
cent DistribuTECH International conference and the short term is the supply of the most important
three things stood out as important. First is the resource we all have, the human resource. The pool
amount of change taking place in the power in- of engineers, data scientists, and more importantly
dustry globally. Distributed Energy Resources tradespeople is not keeping up with the demand,
(DER) is creating a changing landscape and new both demand from growth and from a generational
problems for grid operators, as they try to make shift with more and more people opting for retire-
adding the generation from wind and solar. While ment. We are not the only industry suffering this
that is nothing new, the pace and scope of that problem, but it compounds our ability to decar-
change has increased dramatically. bonize, decentralize and digitalize.

While supply chain issues are still

around, the big­gest supply chain
issue that cannot be resolved in
the short term is the supply of
the most important resource we
all have, the human resource.

Some solar and wind projects have gone from Martin Robinson of IRISS presents a unique per-
2 years to get approval to over 4 years in some spective on the issue in his article based on how
markets. Getting permits has been complicated by monitoring can help alleviate some of the problem
the difficulty of studies from grid operations on through Operator Driven Safety and Reliability
the impact and feasibility of new connections. In (ODSR). By giving operators the ability to see
the US, the government has made a major com- problems through condition-based maintenance
mitment to green energy, but all that money won’t systems rather than time-based, we use the mon-
solve the problems of an aging grid and the diffi- itored condition of the asset to guide our mainte-
culty of making long term plans when so much has nance teams making them more responsive and
changed in the short term. less bogged down doing time-based actions that
likely only make things worse and waste a tremen-
The second thing we heard was about the rapid dous number of resources.
increases in technology that will help create a re-
liable and resilient grid. Solid state, digital tech- The overall sense that we walked away with from
nology is being used throughout the grid in ways the event is that the amount of change we are go-
we could only dream about. It was at the vendor ing through as an industry has rapidly increased.
showcase that this became more pronounced with Changes around us force us to change internally
companies both large and small displaying new for the best way to respond. The rapid increase
advanced technologies, several being represented of monitored assets and more importantly moni-
in this issue with technical articles, many focused tored systems will change the way we rebuild the
on monitoring most of the assets within the grid. grid in every country and in every neighborhood.

Monitoring will once again help

us to focus reduced human inter-
action on a mostly remote asset.
Transformer Technology March 2023 11

Issue 27

Alan M Ross
For instance, the electrification of transportation
alone will require significant changes to how we
respond and how we monitor remote assets de-
signed to support recharging both at home and for
public consumption. DER, while not new, is cre-
ating its own issues, where monitoring will once
again help us to focus reduced human interaction
on a mostly remote asset.

As always, we thank the experts who were will-

ing to take the time to unselfishly share their
knowledge, understanding and wisdom with our
community and, as always, we thank their com-
panies for supporting them in these efforts.
Managing Editor
Alan M Ross

Technical Director
CRL, CMRP

APC Media
12 ONLINE
MONITORING

Mitigating Transformer
Supply Chain Risks
with Online Monitoring
by Dan Roth

Photo: iStock
Transformer Technology March 2023 13

Issue 27

There are many challenges that grid. The average age of a large power
utilities face today in the never-ending transformer is 40 years old, which is
goal of continuing to provide safe at the end of its designed service life
and reliable power. These challenges [2]. This increasing demand for units is Dan Roth is currently the Sales and Market-
include trying to improve the resiliency being met with a volatile supply chain ing Director for Dynamic Ratings based in
of the grid to natural disasters, struggling to keep up. Sussex, Wi. He received his Bachelor of Sci-
replacing aging infrastructure and ence degree in electrical engineering from
making power delivery more efficient, Power transformer lead times the University of Illinois at Urbana-Cham-
all while integrating renewable energy have gone up across all kVA sizes paign. He possesses more than 20 years of
sources. including large substation units to industry experience having previously been
small distribution pole tops. In many employed at Eaton (Cooper Power Systems)
One key element of these initiatives cases, these lead times are reported and Schweitzer Engineering Labs. His ca-
is the large power transformer, which to be 2-3 years [3]. Coupled with reer has allowed for a wide range of experi-
is a critical building block to the these increasing lead times is the ences from relay system protection, feeder
grid [1]. New transmission lines will significant cost of replacement, as the automation, communicating smart sensors
require substation upgrades, including natural economic forces of supply and to distribution line installation and protective
power transformers. New renewable demand have driven up the price far equipment. Mr. Roth has contributed several
energy plants will require power greater than inflation or commodity papers and patents to the industry in that
transformers to interconnect to the increases would predict. time.
14 ONLINE
MONITORING

There are some very real compromises accounts for roughly 25% of the unit’s balance caused by the 25% tariff
that utilities have been forced to cost. Most of this material is imported was magnified by the labor impacts
make to meet this demand. These into the United States with only one because of the global pandemic. The
often include using new suppliers, domestic supplier [1]. With a significant net result of these two major market
non-standard designs or refurbishing decline in domestic manufacturing of impacts is that the average large
units. All three will have an impact large power transformers and cores power transformer lead time has
on the performance of that power and concerns over the national security doubled and the cost has increased
transformer, increasing the risk of of bulk power systems, the presidential substantially [3].
unexpected failures and potentially administration implemented Section
leading to a shorter service life. 232 Tariffs on Steel. While this did Procurement departments at large
improve the financial stability of utilities, renewable energy producers,
Large Power Transformers are largely domestic suppliers, it was disruptive to and other large industrial customers
dependent on the availability of grain- the large power transformer industry are faced with approving alternative
oriented electrical steel (GOES),) which supply chain. This flux in competitive suppliers. Many of these alternative
 Transformer Technology March 2023 15

Issue 27

suppliers are not commonly used in Demand for new transformers and equates to more than 150 large power
the supply of large power transformers replacement of existing transformers transformers that will need to be
for the US bulk power system is going to increase soon. Large managed for end of life each year [2].
because of design limitations and power transformer consumption in
reduced quality controls. When the the United States is expected to grow The bulk power industry must
legacy supplier lead times were not 20% between 2019 and 2027 [1]. maximize the service life of large
acceptable, these customers were This is being driven by the upgrading power transformers as demand
forced to take on the additional risk of of existing infrastructure to better continues to outpace supply over the
transformer failure to maintain power serve the increasing demand and next decade. The answer to extending
delivery. The same risks exist when a penetration of renewable energy. Over asset life cannot simply be more
nonstandard design is sourced that 70% of the United States large power maintenance. The increased energy
may have a reduced capacity, or when transformers are over 25 years old [2]. costs (up 8% in 2022) are challenging
a unit is refurbished with an unknown If the average service life of a large utilities to find savings through
history. power transformer is 40 years, this Operations and Maintenance (O&M)

With a significant decline in domestic

manufacturing of large power transformers and
cores and concerns over the national security of
bulk power systems, the presidential administration
implemented Section 232 Tariffs on Steel. While
this did improve the financial stability of domestic
suppliers, it was disruptive to the large power
transformer industry supply chain.
Photo: iStock, Shutterstock
16 ONLINE
MONITORING

The bulk power industry must

maximize the service life of large
power transformers as demand
continues to outpace supply over
the next decade.

budget cuts, so the funding can be If large power transformers are being References
repurposed into new investments [4]. procured through new sources, [1] Department of Energy “Electric Grid
Therefore, more and more utilities, online monitoring can also be used to Supply Chain Review: Large Power
renewable energy producers and mitigate the risk of infancy failures. Transformers and High Voltage
large industrials are turning to online Often infancy failures are fast- Direct Current Systems,” February
transformer monitoring to extend the developing failure modes that occur 24, 2022
life of large power transformers and before first scheduled maintenance [2] Department of Energy “Large Power
reduce the risk of unexpected failures. and online monitoring is the ideal Transformers and the U.S. Electric
The real-time measure of operational solution to catch these before the Grid,” April 2014
parameters provides visibility into interruption of power. [3] J. Postelwait, “Transformative
the condition of an asset. This allows Times: Update on the U.S.
for better confidence in loading Utilities are leveraging digital Transformer Supply Chain,” T&D
transformers, planning maintenance, technologies to continually improve World, July 2022
and proactively detecting changes in the efficiency of the grid. It is [4] U.S. Energy Information
performance. important to realize that online Administration “Short Term Energy
transformer monitoring is a critical Outlook,” December 2022 [Online].
Most transformer failures occur component to ensure successful Available: https://www.eia.gov/
shortly upon energization or after management of these critical assets. outlooks/steo/report/electricity.
meeting design service life. Monitoring The return on this investment has
Photo: Shutterstock

php#:~:text=We%20forecast%20
aging transformers will help extend never been easier to justify with the%20U.S.%20residential,by%20
the life of an asset which approaches the current impacts on large power higher%20natural%20gas%20prices.
that designed service life. transformer supply chains.
Transformer Technology March 2023 17

Issue 27

Leverage Digital
Technology to
Improve Efficiency

Transformer Monitoring
Online transformer monitoring is a critical
component to ensure successful manage-
ment of critical assets. With current large
power transformer supply chain issues,
monitoring provides a great return on in-
vestment making it easy to justify.
Learn more about transformer monitoring.

RESPONSIVE
Scan to Learn More!
 18

Director of Product Management

Interview with Bidesh Kar at Sentient Energy
FEATURE
INTERVIEW

Bidesh Kar
 Transformer Technology March 2023 19

Issue 27

If you are replacing

your aged infrastructure
overhead with
underground, you
are fixing the aging
infrastructure problem
at the same time you are
also building resilience.
Photo: Sentient Energy
20 FEATURE
INTERVIEW

Alan Ross: My guest is Bidesh Kar. Bidesh is the The macroeconomics of it, the geopolitical
Product Manager for Sentient Energy. situation of it, it's beyond any company's
control. So, leaving that aside from the utility
We're going to get into product management, perspective, I think the aging infrastructure
because that's right now kind of exciting, there's paired with the extreme weather conditions
a lot going on. But first off, tell me a little bit has a very detrimental effect. Now, from our
about your background in the power industry. perspective, there's good news too it if you
How long you been in it? How did you get in it? look at it.

Bidesh Kar: Absolutely. First of all, thank you, Companies like Florida Power & Light have
Alan, for having me here. I have been in the proven that undergrounding improves
power industry since 2003, so just over 20 years reliability and resilience. So, in the back-to-
now. back storms last year, when the areas with
overhead were down with power for several
And back in time, right out of college, I had no days, the areas with underground barely
idea about the power industry. I was just pushed had any outages. What this means is other
into it in my first company and never looked companies can look at this example and build
back since then. I've worked in companies that a strategy towards undergrounding. And how
provide products and services from substation this helps is if you are replacing your aged
to metering. infrastructure overhead with underground,
you are fixing the aging infrastructure problem
I've worked with companies like Itron, which at the same time you are also building
does smart metering and grid edge stuff. I've resilience.
worked with companies like S&C Electric, which
does switching/protection equipment in the Sentient has a vast portfolio of underground
distribution grid. And my last four years been line sensors which covers your whole
a fantastic journey at Sentient Energy. I'm distribution grid, from the feeder to the last
responsible for the whole underground product mile on the lateral residential. So, that brings
portfolio as well as the software platform. in visibility that otherwise it wouldn't have for
your underground networks.

AR I love that we got a lot to talk about

with the Underground portfolio.
But first of all, when we were here last year AR Underground makes sense, especially
in fire prone areas, because then you
and when we were at IEEE doing interviews, don’t risk fire ignition when you run the lines
and when we did them at RE+, the number underground.
one problem last year was supply chain issues.
Everybody had them. They're not gone, but There's a cost to undergrounding. What is
we are working on them. But the problem that the cost differential between overhead and
we have today is the dynamics of change. For undergrounding? I used to hear that it was
instance, Bloomberg have just announced that about four times. Is that still the case or not?
their prediction for the adoption of EV charging
was way off. It's going to be 2.4 to 2.6 times what
they said it was. That's a lot of change. So, there's
a lot of new demand on utilities. They're going
BK Well, there's a difference. You cannot
look at the cost of just undergrounding
at once. You need to look at the total lifecycle
to maintain the old grid, which is aging. With cost. So, Sentient Energy is a partner member
supply chain issues, it takes sometimes two and at PDi2 (Power Delivery Intelligence Initiative).
a half to three years to get transformers. And It's a nonprofit organization. We have done
that's not the only problem. The demands on a lot of research and models where utilities
the utility are greater than they've ever been can look at it and say, “What's my total cost
— maintain the grid, be reliable, be resilient, of ownership of underground?” It's not just
get ready for DER, make sure you're green, the $200,000 or a million dollars per mile of
decarbonization. underground conversion, but imagine once you
have undergrounded and there is a storm or a
From your perspective, talk about all of those tornado, it's not getting those lines down three
demand changes and a little bit about how that times in ten years. So, you add that up, you add
equates to your job in product management at up the safety aspect of it, then it makes sense
Sentient. in most of the cases. Otherwise, PG&E wouldn't
have gone for 10,000 miles of commitment.
Photo: Sentient Energy

BK You highlighted two key things that

stood out as you were explaining
this. Number one, as you said, the supply chain AR Most utilities are state regulated, right?
They have to go to the Public Utilities
issue is not gone for us. It's going to stay here. Commission, and a lot of rate-based things are
Transformer Technology March 2023 21

Issue 27

Sentient has a vast portfolio of

underground line sensors which
covers your whole distribution grid,
from the feeder to the last mile on the
lateral residential.
22 FEATURE
INTERVIEW

based on capital spending. Is most of the cost of for that. How do you address that? I mean,
undergrounding covered by capital? you're going to compete with people saying let's
just get as much power to as many people as we

BK Yes, because you're improving your

reliability of service. So as a customer
myself for PG&E…well, the area I’m in is already
possibly can. Forget about underground. How
do you answer those people to say, no, we are a
solution that is going to be a better solution long
undergrounded, but imagine not losing power term than short-term reactionary solutions.
anymore when there is a high fire threat and
there are critical patients and those who need
life support. I think it makes sense ratepayers
wouldn't mind that increase over time as long
BK I think the change in demand profile
has immense impact on how you
do your asset management strategy. What it
as of course it has to be kind of vetted out with means is your typical duck curve doesn't exist
different parties. anymore, and here is why: we are pushing for
more EV. That means that when you come back

AR So that is a great connection between

what you do and the focus on
reliability. At the same time, utilities are dealing
home from work, at five, six in the evening, you
are plugging in the EV, so your load profile just
increased dramatically. Let's say you don't plug
with the hockey stick of the demand curve in at 6:00 p.m. You have it programmed to run
which they have not had to deal with in the last late at night. The power consumption of an EV
15 years. There's going to be competing priorities to fully charge is equivalent to a fully running
 Transformer Technology March 2023 23

Issue 27

The change in demand profile has

immense impact on how you do your
asset management strategy.

home, which means your load didn't drop after recently flagged as having the transformer
midnight. It actually stayed at the same level, overloaded 150 times over eight months. And
because now, even though the lights are off, your the peak loading was 212%. Average was 126%.
EV is charging, so it's still pulling the load. How do That's something you don't want. Now with this
you balance that? The typical grid, the traditional data they can upgrade it to a 75 kVA transformer
grid, was planned for single directional power before it fails. This is what we call data-driven
flow. If I pick a transformer, a 50 kVA transformer asset management strategy – don't just wait for
typically would have seven customers. Now all of the transformer to fail.
a sudden, all the seven homes plug in EVs at the
same time. That wasn't what it was planned for.

While a transformer can operate at beyond

AR So given the fact that you're in product
management, you have to be looking
ahead at what's coming. What are the issues that
its nameplate rating, you do not want to do it the industry is facing that you're solving?
day over day, week after week, year after year.
So that's where we come in as an end-to-end
BK There are a couple of things that
Photo: Shutterstock

solution. We have one of our newest products come to mind. Number one, utility
UM1 – it monitors for fault in our underground companies. I feel for them because they are
system, but also monitors for your loading of under a resource constraint. They have a ton
the transformer. One of our customers was of projects to work on and they can only focus
24 FEATURE
INTERVIEW

Just having gigabytes and petabytes of data means nothing

unless it's actionable. So, one of the challenges I think needs
to be solved over the years is what are the actionable insights.
Don't just show me the data. Tell me in a nutshell, what action
do I need to take today, three weeks from now, a month out.
 Transformer Technology March 2023 25

Issue 27

on so many things. A solution to that is as they of them talk to each other? I think what we're
are dealing with all these different software looking forward to is that different vendors like
platforms and data points from all different Sentient and other companies would need to
kinds of devices, they need to look at more at partner together and have those devices talk to
what cloud capabilities they can leverage, so each other locally and make grid edge decisions
that the in-house team doesn't need to focus — and what that means is open protocols
on managing, doing the cookie-cutter task of and open communication, standardized
system management, but they can focus on how communication mechanism and data exchange
to optimize their business processes and have across devices.
other vendors kind of take care of cloud-based
solutions and deal with the data. And the second
thing, very linked to that, is an immense amount
of data. Just having gigabytes and petabytes of
AR Does that not increase the risk for
cybersecurity?

data means nothing unless it's actionable. So,

one of the challenges I think needs to be solved
over the years is what are the actionable insights.
BK Of course, it does. But we do have the
technology to make it cybersecure.
You can have them all communicate within
Don't just show me the data. Tell me in a nutshell, the utilities. Private LTE is the utilities network.
what action do I need to take today, three weeks They can manage it as long as all these devices
from now, a month out — so that something that's talk within their network, that's absolutely fine.
likely to get impacted further along the line I can
delay, and then I can prioritize my workforce.
AR EVs and EV charging – most of that is
underground. You don't see overhead

AR Since you just talked about that big

data – I know a utility that I spoke
with recently mentioned that they hired more
lines going to you. So, they've already adopted
the charging technology, but they haven't
adopted a standardized approach to plugins.
utility and data scientists that year than they I mean, I rented an EV, and I could not charge
hired electrical engineers. And they said that was it at the Tesla charging station because my
a first for them, which is kind of an indication connector didn't work with the Tesla. So how
of what you're saying. There's just going to be a does Sentient work within the industry to do
huge need for people that help us, because data open architecture, open protocols? Everybody
scientists don't make a decision. They just create has a part of the solution. Where do you come
data that allows us to make the decision. The together to create standardization of those
demand for electricity is doing this, the amount kinds of things?
of data with all of these wired systems and
wireless systems is doing that too.

Okay, so we're on an airplane, we're at 35,000ft.

BK There are areas where things are very
well defined. DNP3 protocol is a very
common protocol used for communicating
Let's assume that we mitigate the supply chain across all these devices. That's just at the
issues, that we begin to really integrate DER into device level, however, how different systems
the whole network. We are decarbonizing, we are interact. For example, our analytics platform
putting more utility work underground so that can ingest data from a completely unknown
we can create a much more resilient grid. What device. I think that's the kind of standardized
do you think are the storms on the horizon that interaction or integration that must be in place.
we ought to be looking at now that are going to We are thinking ahead in terms of building
be coming in ten years, if we could predict them? open application programming interfaces,
which is called APIs, so that anybody can

BK Well, that's a hard one. We are thinking

that, you know, just bringing in solar PV
and EVs is going to decarbonize, but you still need
consume the data. We are thinking along those
lines where we publish a message, anybody
within the secured network can actually
to look at the variations those bring in. You know, subscribe to it. I think we'll see more of those
the sun is not shining 365 days a year at the same changes coming in down the road. And to your
level, so you still need your traditional means of point about EVs, yes, absolutely. We want
generation in place. How do you balance all of it to be like a gas station. You know exactly
that without impacting your service levels? how it works. So, on the EV side of things, all
these manufacturers have to go towards the
The second thing is that a lot of these product standard.
solutions work on their own. So, what the
utilities would need to think of is how do I
minimize or optimize the information that AR Excellent. Bidesh, thank you for
joining us. It's been a delight and I
Photo: Hitachi Energy

I'm getting from all these systems? How do wish you good success at Sentient.
they work in an integrated fashion? I don't
want to jam my communication network with
millions of devices out in the field. Can some BK Thank you, Alan. Nice speaking to
you.
26 UNLOCKING GRID
PERFORMANCE

Unlocking Grid Performance

OUR VIEW OF
THE FUTURE INCLUDES
CONTINUED INNOVATIONS AND NEW
SOLUTIONS, ESPECIALLY IN ON-LINE
MONITORING.

It’s nothing new that the electrical industry is changing, We never stop evolving and it is essential that we under-
with new challenges and trends appearing all the time. stand the changing needs of our customers so that we can
It’s therefore essential that those in the industry keep up continue offering modern, comprehensive, and relevant
with the changes and meet these challenges head on. To solutions. As such, we work closely with our customers,
that end, Megger has made it its mission to offer you a listening to their feedback and ideas and, in response, con-
wide range of solutions to meet your needs, as well as stantly develop and invest in new technologies, all so that
the trends and demands of the market. Megger has a wide we can provide them with the solutions they need.
range of supplemental technologies for condition moni-
toring and predictive maintenance to improve reliability Our view of the future includes continued innovations and
and optimise your grid performance. Indeed, the grid is new solutions, especially in on-line monitoring. We also
under more strain today than ever before, with stressors want to give you a closer look into our monitoring business
coming from renewable resources, varying power gener- and show you how you can benefit from Megger’s Grid
ation and consumption, and extreme weather conditions, Performance Solutions, such as with our Grid Analytics
to name a few. As such, increasing the visibility of your Solutions.
grid has never been more important.
Unlocking visibility by monitoring your grid
Megger’s evolution in testing, diagnostics, and with Megger
condition monitoring
Off-line testing devices are essential for asset condition
Megger has been a leader in the electrical industry for test analysis; they allow flexibility and manipulation of testing
and measurement equipment for over a century. Megger’s voltage, ensuring that assets will perform well under stress
instruments are used globally by power utilities, repair and giving you a comprehensive picture of their present
shops, and industrial production plants. Thanks to mod- performance, as well as predicting their future performance
ern trends, such as electrification and decarbonisation, and identifying any risks. Additionally, trending off-line test
Photo: Megger

they are also used in a range of other industries including results provide you with even more insight and analytics,
transportation and renewable energy. allowing you to be more confident in your decision making.
Transformer Technology March 2023 27

Issue 27

constantly for increased

evolving solutions grid visibility

MODERN FEATURES
GIVE YOU REMOTE ACCESS
AND CAN NOTIFY YOU WHEN ISSUES
ARISE NO MATTER WHERE YOU ARE.

However, in between testing phases, unexpected events The industry has recognised PD as an important indicator in
can occur that may be missed, or their detection delayed. insulation that needs to be detected. We understand that
This is where Megger’s monitoring solutions can help. predictive maintenance requires you to know about upcom-
Through continuous data collection, they provide real-time ing problems as early as possible, and there is no method
fault detection, and can even identify weak spots, allow- that can detect potential insulation problems earlier than
ing you to prevent faults and failures before they occur. partial discharge measurement.

By combining data from various sources, including off-line Additionally, PD results can be tailored to identify the spe-
and on-line measurements, we can help you to increase cific type and location of faults. When making decisions for
your grid’s visibility and improve your overall grid perfor- asset management, such as whether to replace, repair, or
mance, giving you the detailed information necessary for extend the life of a particular asset, PD monitoring results
good decision making and successful asset management. are an important factor in the decision-making process.

PD monitoring – What else? Permanent PD monitoring allows for live condition mon-
itoring and predictive maintenance. When you constantly
Not only are we well established in the electrical testing in- measure PD, you are made aware of insulation concerns
dustry, but we also have decades of experience in asset mon- immediately instead of needing to wait months or years
itoring, particularly the monitoring of partial discharge (PD). between maintenance schedules, and you don’t need to
28 UNLOCKING GRID
PERFORMANCE

risk interrupting operations to gain a view of insulation The role of Distribution System Operators (DSO) is be-
condition. coming more critical as power-flows are becoming more
complex and energy is constantly imported and exported
When a fault triggers the alarms, you can plan an outage by prosumers.
safely so that PD can be measured off-line enabling you
to perform further investigations that are only possible To tackle the challenges that arise from the modern
with off-line PD testing. This means PD monitoring can power system, Megger offers Grid Analytics Solutions,
enable you to avoid asset failures. which is composed of Smart IoT sensors - the MS5000
- that constantly monitor the electrical grid to find faults
Our monitoring solutions, such as the ICMmonitor and quicker and reduce the number of outages. After easy
GISmonitor, provide a continuous view of your insulation’s installation, the sensors start to immediately communi-
condition. Modern features give you remote access and cate with each other and share information. Electrical
can notify you when issues arise no matter where you faults are detected in real time, immediately notifying
are. Integration with digital systems, for example, via operations and maintenance crews when a fault has been
IEC61850 protocol, give you ultimate visibility via the located, thereby decreasing the time needed for fault
Smart Grid and give you remote access for service and location, identification, and service restoration (FLISR).
support. This enables you to decrease your System Average Inter-
ruption Duration Index (SAIDI), an important metric for
We also offer hybrid solutions, which cover both portabil- measuring grid performance, thereby ensuring the best
ity and on-line monitoring. The portability and ruggedness uninterrupted service to your customers in the face of the
of the instruments allow for on-line measurements to be energy transition.
recorded over a period of time ranging from days to
months, before moving to another electrical asset for an- Not only does Megger offer help to minimise the duration
other period. This allows users to prioritise their needs and of faults, but they also help you prevent faults, improving
decide which asset is most critical for PD measurement your System Average Interruption Frequency Index (SAIFI).
at a given time. By identifying weak spots in the grid based on anomalies,
predictive maintenance can occur, preventing permanent
As technology continues to evolve, we must keep our eyes faults in advance. Thanks to modern innovations in sen-
open for opportunities to improve grid visibility. As such, sor and communication technology, grid sensors can
we know that partial discharge is not the only important serve multiple roles in addition to fault location. These
parameter to be monitored to improve grid visibility, and features can assist with power quality analysis, informed
this why it is our mission to provide on-line monitoring data-based decision making, and can even reduce the
for multiple additional sources. risk of wildfires.

Our next chapter: Grid Analytics Solutions From the arctic circle in Northern Europe to the rural
areas of South America, our customers around the world
Due to recent trends, the Smart Grid requires constant mon- face similar challenges and share the need for improved
itoring and analysis of valuable information required for op- grid visibility to unlock their grid performance. We have
erations and maintenance. Distributed Energy Resources proven, together with our customers, that locating faults
(DER) require maximum grid flexibility, as operational and in difficult to access regions, in extreme weather condi-
loading requirements change constantly depending on tions, and on-line and in real-time, can be made easier
many external factors, such as wind and sunlight. Climate and more efficient. This requires flexible communication
change and associated extreme weather events, as well as options, including direct cellular communication, mesh-
an aging grid infrastructure, add to these growing concerns, radio, and/or integration with SCADA/DMS, and cyberse-
while the digitalisation of the Smart Grid contributes to solu- curity provisions to protect your data with the highest
tions for improved reliability. security standards.
Photo: Megger
Transformer Technology March 2023 29

Issue 27

Enterprise Asset Management (EAM) This allows us to translate our insightful measurement
and Asset Performance Management (APM) results, such as partial discharge measurements (off-line
or on-line), tan delta (power factor), dissolved gas analysis
Planning for the future is a core part of Megger’s strategy (DGA), grid analytics, and much more, to an asset health
and is essential for us to reach our goal “to provide electri- index and risk profile.
cal utilities with innovative solutions to meet the challenges
of enabling and improving electrical grid performance”. Our IPS Energy is our answer to the question “What do I do with
recent strategic partnership with IPS (Intelligent Process the data?”. Together, Megger and IPS provide an unrivalled
Solutions), a company based in Munich, Germany, brings to- and compelling solution for public and private sector
gether a strong combination of intellectual capabilities, open- utilities.
ing doors to new solutions that enable increased efficiency
and effectiveness for electrical utilities in maintaining the As the energy industry is rapidly changing and facing
grid network, reducing costs, and minimising downtime. many simultaneous challenges, condition-monitoring and
predictive maintenance have increasing urgency. Optimal
IPS and Megger Group announced their strategic part- grid performance is achieved with the support of power-
nership in September 2021. IPS Energy is a leading provider ful measurement hardware and software tools. Off-line
of enterprise asset management, asset performance testing instruments, on-line monitoring solutions, and
management, and workforce management for the global AI-driven software and analytics provide valuable insights
energy supply industry. As partners, we're working to- and efficiencies to meet the challenges of the ever-
gether to improve the operational efficiency of power evolving grid.
and combined utilities by leveraging our collective intel-
ligence to help the power industry reliably measure its own
performance and act to minimise unplanned downtime is here to support you on your journey
and system outages. By combining our knowledge, the IPS to unlock your grid performance
Intelligent Data Lake was born; a unique solution enabling
each party to contribute their expertise towards creating
a final product. For more
information,
Combining IPS’s sophisticated software solutions, AI ex- visit our
pertise, and easy integration with Megger’s test and mea- websites.
surement expertise produces a greater and more powerful
predictive dimension to electrical utilities’ testing methods,
enabling true condition-based maintenance practices. Grid Analytics solutions IPS energy

Your assets are speaking!

Are you ready to listen?

IPS®SYSTEMS – Everything you need

to take control of your assets.

ips-energy.com
30 ADVANCES
TOPIC
ON CIRCUIT
MISSING
BREAKERS

Automated real time

ML-based Circuit Breaker
Trip Coil Analysis Marco Tozzi received the M. S. degree in
Electrical Engineering from the University of
Trieste in 2005 and the Ph. D. degree in elec-
trical engineering in 2010 from the University
by Marco Tozzi
of Bologna. From 2007 to 2011 was Project
and Michael Skelton
Manager and Technical Advisor in Techimp,
Italy, being involved in research activity on
diagnostic of insulating systems by Partial
A key requirement from must quickly disconnect Discharges analysis. From 2012 to 2022 was
electricity networks is the fault to protect the Product Designer and then Senior Product
to provide safe, efficient, network upstream and Manager for Camlin Energy, involved in de-
and reliable power to maintain supply to the signing solutions for holistic transformer
monitoring. Since 2022 he is Sr. Technical
customers. When faults majority of customers.
Advisor for Camlin Energy, involved in asset
occur due to weather, Therefore, the Circuit
Photo: Shutterstock

diagnostics, consultancy services and op-

equipment failure, Breaker can be considered timisation of monitoring and maintenance
or accidental damage, the guardian of the programs. He is author or co-author of more
then the Circuit Breaker power network. than 40 technical and scientific papers.
Transformer Technology March 2023 31

Issue 27

Circuit Breakers can be slow to the first trip and, very likely, normal feedback to the asset manager
operate, or fail to trip due to defects timing during the second trip. from the field, and open a workorder
in the trip coil and operating immediately. This removes delays
mechanisms caused by friction, To prevent the breaker from failing to caused by waiting for data analysis
often due to lack or wrong type of trip, it is recommended to periodically and reduces the time-to-action to
lubrication. International statistics test the operating mechanism seconds.
indicate that 80% of the observed through a planned trip operation
failures are linked to operating with the breaker online and without The basics and the importance of the
mechanism and auxiliary control affecting customer supplies. This First Trip Analysis
circuits [1]–[4], possibly causing can be done with a hand-held device
catastrophic failures [5-6]. by recording the first trip current The method enabling the assessment
profile, the DC battery voltage, and of the operating mechanism health
The traditional offline test and the three AC interrupted currents. by monitoring the current flowing
inspection can be difficult to plan This procedure has been carried through the trip coil was developed
due to the operational constraints out successfully for years, as back in the 90s [9], extensively
and require a significant amount of documented in [8]: “circuit breaker described in literature, and widely
time and resources, while leaving signature analysis can be used adopted in the utility industry [9-14].
the problems that arise in-between as an excellent tool to assess the
regular inspections unnoticed. condition of our breaker operators, The trip coil circuit is an electro-
Moreover, the standard test could prioritize maintenance and minimize magnetic circuit with reluctance in
not detect the causes of a slow trip. equipment outages”. the magnetic part, and inductance
Before an off-line test is performed, and resistance in the electric part.
the breaker is first tripped, and then The interpretation of the data requires The mechanism consists of a
isolated from the system. Then the an expert operator to compare the solenoid around a movable plunger,
offline test kit is connected, and the recorded curves with “reference” a latch, a spring and a mechanical
breaker is tripped again. However, ones to identify the malfunction of connection to the main contacts;
the first trip, which was not recorded, the breaker: this can be challenging once the control circuit receives a
could show a longer opening time considering the test devices command signal, the coil is energised
due to a mechanical defect. The could be used by any operator in (typically from station DC batteries)
issue could be cleared after the first the substation, even without the causing the plunger to move and hit
operation and show no criticality necessary experience. the latch mechanism as shown in
during off-line testing. For example, Figure 1. This activates the movement
faulty lubricants and/or questionable The following article proposes a new of the operating mechanism and
lubrication practices [7] often create
a sticky compound causing slower ++++++++++++++++++++++
movement of the mechanism during
Circuit breaker signature analysis can
be used as an excellent tool to assess
the condition of breaker operators,
prioritize maintenance and minimize
equipment outages.
++++++++++++++++++++++
Machine-Learning-based method discharges the compressed spring
able to provide a diagnosis and mechanically connected to the main
Michael Skelton has been working for North- suggested action automatically contacts, which open. After a short
ern Ireland Electricity (NIE) for over 33 years by comparing the last recorded delay the auxiliary contacts open
and has extensive experience in the planning, trip operation with a reference and disconnect the coil from the
Efra F. Usmani
design and operation
is a Team
of distribution
Lead and Project
and trans-
Ma- profile generated with advanced substation voltage, causing the coil
mission
nager ofnetworks.
the E-Mobility
He joined
Department
the Camlinat Power
Group AI techniques using a statistical current to go to decay to zero. As the
in
Technology
2009 as Product
ResearchManager
(PTR). for
As athe
nature
High lover
Volt- population of curves relevant to plunger moves, the reluctance of the
age
and Monitoring
a traveler, she
andlikes
Testing
to see
products,
the rolesuch
she breakers having the same trip coil magnetic part reduces, increasing the
us
plays
DGAas monitoring,
part of the energy
Bushing
transition
monitoring
that helps
and mechanism. inductance of the electric circuit.
Circuit
preserve Breaker
the planet.
testing equipment. He is now As the rate of inductance increases,
consultant for Camlin Energy, working in the The diagnosis is done in less than the rate of change of current
Technical Advisory Group and his current ac- 5 seconds, and the field operator, decreases.
tivity involves diagnostics on Circuit Breakers even if inexpert, can understand
(CB) and the application of ML/AI analytics on if a major or minor maintenance Therefore, if a DC Hall Effect probe
the CB First Trip data. is needed. They can then provide is clamped around the coil current
32 ADVANCES
ON CIRCUIT
BREAKERS

Coil energized, Plunger Plunger strikes the Latch unlocked, plunger Main contacts starts to Main contacts open (F) Trip coil de-energised (H)
begins to move (A) latch (C,D) strikes buffer (E) open (E-F) Auxiliary contacts
open (G)

Figure 1. Step by Step process of a trip mechanism

circuit, a current profile can be

recorded during the trip and close
process which increases and
decreases over the time depending
on the changes in the reluctance and
inductance: the recorded profile of
the current will have a shape similar
to that shown in Figure 2, with an
increasing current reaching a peak, a
plateau, and then a rapid decrease.
Photo: Kelvatek (Camlin group)

By comparing the actual trip/close

profile with a reference one (depicting
normal operation), we can understand
if there are delays causing a slow trip
and, most importantly, the cause of
Figure 2. Trip current profile the slow trip.
Transformer Technology March 2023 33

Issue 27

Figure 3: overall architecture

Some of the failures that are usually There are however challenges in the coming from families of breakers
detected result from: data interpretation: having the same trip coil mechanism,
using Machine Learning and
+ Supply Voltage (too high, too low, 1. The reference curve can change advanced analytics combined with the
inconsistent, battery issues, poor over the time due to degradation of experience of the SME labelling the
connections) components data and providing feedback after the
+ Trip/Close Coils (increase or 2. The analysis is very subjective maintenance.
decrease of resistance, degraded and requires skills and knowledge
contacts, CB fitted with incorrect of data interpretation and circuit The overall architecture (Figure 3)
trip coil, misalignment of coil, breaker operation consists of a centralised cyber-
insufficient lubricant) 3. If the analysis is deferred to the secure data center where the data are
+ Auxiliary Contact Performance Subject Matter Expert (SME), collected and processed combining an
(auxiliary bounces, faulty delays can occur between the test ML engine with human expertise. The
operation) and the suggested action, after the role of the human SME should not be
+ Latch mechanism (friction or (often over-burdened) SME has underestimated, being crucial in the
insufficient lubricant) received and analyzed all the data training and assistance to the AI-based
4. Inexperienced operators could fail automated system. The cloud-based
Application of Machine Learning to to connect the sensors properly, database ingests data from various
Current Profile Data and realize this days later upon sources, including online monitors, and
data analysis provides actionable outputs, including
The challenges: do the right thing prescriptive actions, that can be sent to
at the right time The solution: an augmented Work Field Management systems via a
The assessment of the breaker intelligence tool standard API mechanism.
capability of tripping within the right These challenges can be overcome
time is done by comparing the latest by using an intelligent digital solution In terms of implementing the solution
recorded curves with a reference one, that ingests the recorded data (Figure 4), it is necessary to select
which represents “normal” behavior. while the operator is still in the field, a family of breakers with the same
processes it in real time, and provide operating mechanism and gather the
The reference template can come immediate feedback on: historical current profile, even from
from: different users, to generate a template.
+ quality of data Then features are automatically
+ Factory test, OEM provides the trip + possible defect extracted whenever a new record is
curves + suggested maintenance action processed, the data are compared to
+ Commissioning test the template and processed to identify
+ Historical data The solution is created by analyzing a defects and classify severity according
+ First vs second trip significant amount of historical data to a Health Score.

Figure 4: Step by step deployment of an automated digital solution

34 ADVANCES
ON CIRCUIT
BREAKERS

Figure 5 shows the overlap of tens

of current trip profiles of two specific
types of breakers labelled by the SME
as “normal” in terms of health. The
red trace is the template generated
by the algorithm used from now on
to compare with any new data. The
template could still change and improve
over time, learning from the new data
and feedback. This is a key advantage
of the proposed solution: the ability
to generate and dynamically improve
a template that is the best fit within a
number of different “normal” profiles
of the same breaker type, based on a
Figure 5: Template extraction from a number of profiles coming from the same type of breaker statistical population of curves; this
is more effective than using just one
In the final stage maintenance curve, since it takes into account a
Defect List
instructions for Asset Management certain variability of the key-points due
No defect are created automatically. to standard operation and ageing.

CASE#1
Defect in trip coil operation

Defect in auxiliary contacts operation

Defect in the battery

Defect in the battery circuit

Defect in main contacts opening

Table 1: Example of possible defects

CASE #1: Buffer, Acon (auxiliary contact) and
Action List Healthy HV breaker End (trip coil de-energized) timings
are automatically extracted, and the
No action
The grey trace represents the keypoints are visualised overlapped
Repeat Test template generated by the automated to the trace
Lubricate the trip coil
algorithm, while the colored trace is
the most recent trip current profile. The profile shape analysis indicates
Lubricate the operating mechanism that the breaker is opening with a
Identify the cause of battery voltage The color of the last trip depends small delay within 4 ms, which is
drop and rectify on the status of the breaker and is acceptable, and results from the
determined by the algorithm; here it is natural inertia when a circuit break
Check battery charger operation and
replace it if necessary green, showing there are no issues. has been inoperative for a long time.

Check alignment of the auxiliary

contacts and clean them

Replace the Trip Coil

Clean and lubricate the operating

mechanism

Table 2: Example of possible actions

Condition
Urgency
Group

1. Good No action

2. Suspect Test again within 6 months

Inspect in the next

3. Defective
planned maintenance

Plan an emergency
4. Critical
maintenance

Table 3: Example of urgency Figure 7: Normal healthy trip

Transformer Technology March 2023 35

Issue 27

Automated prescriptive actions

The algorithm is able to evaluate the
possible defect, suggest an action, and
assign a health score to the breaker to
provide a priority list to the end user.
Tables 1 and 2 showcase some of
the defects and actions automatically
generated by the algorithm. Table 3
shows the health categories with the
relevant urgency.

Real Cases

The following cases were collected

by processing hundreds of trip coil
profiles captured with a hand-held
tester, collecting the AC currents, the
DC current of the trip/close coil, and
the DC Battery Voltage. The results
were generated in real time upon
loading the data to the web-portal.

The condition of the breakers is

summarised in the following table: Figure 6: Circuit Breaker fleet view sorted by health condition, automatically generated

CASE #2: The delay on the auxiliary contact is actions to be planned and automatically
Defective HV breaker only 4ms. The voltage seems to be provided by the system:
slightly unstable, while the AC currents
The last trip recorded is yellow, since are not recorded due to poor connection + Check the voltage stability of
there is an anomaly. of the sensors, or missing load during the battery charger. This can
the test. be deferred to the next planned
The profile shape analysis indicates maintenance
that the breaker is slightly slower than The breaker can still be operated + Repeat the test in 6 months to verify
expected (16ms). as normal, however there are a few if the delay has increased. In that
case a maintenance of the trip coil
is required
+ While repeating the test, make sure
there is sufficient load to capture
CASE
the AC current waveforms (check
the sensors or try to trip the breaker
while on-load)
#2

Figure 8: Slower than normal breaker, still good to operate but with possible issue
in the battery and trip coil
36 ADVANCES
ON CIRCUIT
BREAKERS

CASE #3: that the breaker is about 10ms slower

Suspicious LV breaker (<33 kV) than expected.

In this case the last record is in two According to the SME and the expert CASE#3
colors: orange and green, indicating algorithm, the breaker can still be
that the trip coil mechanism is operated as normal, however there
operating correctly and the delay is are signs of possible issues with the
due to the main mechanism. main mechanism.It is suggested to
re-test within 6 months, since this
The profile shape analysis indicates could point to degradation over time.

Figure 9: Slower than normal breaker, still good to operate, but with possible
issues in the main mechanism
Transformer Technology March 2023 37

Issue 27

CONCLUSIONS overlap the measured records with The overall solution improves the
“normal” templates generated using pace of decision-making minimising
The analysis of the first trip current an AI engine and human experience. the time-to-action and optimising the
profile, the battery voltage, and The solution can indicate the health maintenance schedule. In particular,
the AC currents is an established of the breaker, identify the defects, the proposed approach leads to
technique to assess the braker’s suggest an action and relevant major benefits:
capabilities to trip within the urgency.
expected time, and thus protect the + Improving circuit breaker
upstream equipment on the power This solution allows inexperienced performance
grid. operators to perform the test in the + Minimizing damage to plant and
field and have immediate expert risk of injury to personnel
Challenges in the interpretation feedback with clear suggested + Enabling a condition-based
and the time needed to prescribe a actions. Work orders can be maintenance strategy
suggested action can be overcome generated on the field and minor + Reducing operational costs
utilising a digital solution that can maintenance can be carried out + Reducing the time between the test
ingest data and automatically immediately. and the action.

++++++++++++++++++++++
The overall solution improves the
pace of decision-making minimising
the time-to-action and optimising the
maintenance schedule.
++++++++++++++++++++++

References
[1] CIGRE Working Group 13.06, ranasan and limdi substations [11] R. Peilei, H. Jian, H. Xiaoguang,
“Final report of the second of gujrat electric transmission and X. Jin, “Testing of circuit
international enquiry on high company (Getco),” Central breakers using coil current
voltage circuit breaker failures Electricity Authority Ministry characteristics analysis,” in
and defects in service,” Of Power Government Of India, Proc. IEEE Control Autom.
Paris, France, Rep. no. 83, New Delhi, 2006 [Online]. Conf., Dec. 2009, pp. 185–189
Aug./Sep. 1994. [7] Doble Circuit Breaker [12] A. A. Razi-Kazemi, M. Vakilian,
[2] G. Balzer, D. Drescher, F. Heil, Committee, Lubrication K. Niayesh and M. Lehtonen,
P. Kirchesch, R. Meister, and Subcommittee: “Lubrication “Circuit-Breaker Automated
C. Neumann, “Evaluation of Guide of the Doble Circuit Failure Tracking Based on
failure data of HV circuit- Breaker Committee”, 1995. Coil Current Signature”,
breakers for condition based [8] W.R Speed “Circuit Breaker IEEE Transactions on Power
maintenance,” in Proc. CIGRE Operating Signature Analysis”, Delivery, vol. 29, no. 1,
Sessions, 2004. available online https:// pp. 283-290, February 2014
[3] M. Knezev, Z. Djekic, and M. studylib.net/doc/18135816/ [13] M. Kezunovic, Z. Ren, G.
Kezunovic, “Automated circuit circuit-breaker-operator- Latisko, D. R. Sevcik, J. Lucey,
breaker monitoring,” in Proc. signature W. Cook, E. Koch, “Automated
IEEE Power Eng. Soc. Gen. [9] G. K. Nelson, C. A. Monitoring and Analysis of
Meeting, Jun. 2007, pp. 1–6. Zimmerman, “Circuit Circuit Breaker Operation,”
[4] M.H.B. de Grijp, R. A. Hopkins, Breaker Response Time IEEE Transactions on Power
J. S. Bedet and J. E. Greyling, Testing, An Evaluation”, 1991 Delivery, Vol. 20, No. 3, pp
“Condition monitoring of HV Transmission & Substation 1910-1918, July 2005.
circuit breakers”, 1996 IEEE Design & Operation [14] H. Ahmad, T. S. Kiong, “Trip Coil
[5] “Root cause analysis for Symposium,September 1991. Signature Measurement and
center substation 138 kV [10] H. Johal and M. J. Mousavi, Analysis Techniques for Circuit
circuit breaker event on Jan. “Coil current analysis method Breaker”, 7th International
16, 2012”, Indiana government for predictive maintenance Conference on Intelligent
RCA report” , 2012 [Online]. of circuit breakers,” in Proc. Systems, Modelling and
[6] “Report on failure of circuit Transm. Distrib. Conf. Expo. Simulation, 2016, pp. 261-267
breaker and transformer at Conf., Apr. 2008, pp. 1–7.
38 TECHNOLOGY
SPOTLIGHT

Cargill a new
introduces rapeseed
FR3r™ dielectric
natural ester fluid

Cargill, the global ag and bioindustrial firm, has launched

FR3r™ natural ester, a new transformer insulating fluid de-
rived from more than 95% rapeseed oil.

AS THE ORIGINAL Utilities, transformer manufacturers and commercial

NATURAL ESTER building owners around the globe seeking a higher perform-
ing, more reliable and more sustainable insulating fluid than
MANUFACTURER, mineral oil now have a 100% biodegradable natural ester
CARGILL CONTINUES option made from the renewable rapeseed plant.
TO EXPAND OUR
“As the original natural ester manufacturer, Cargill contin-
PORTFOLIO OF HIGHLY ues to expand our portfolio of highly renewable plant-based
RENEWABLE PLANT- solutions for industrial needs around the globe and the launch
BASED SOLUTIONS of FR3r fluid is another example of how we’re meeting the
needs of our customers to achieve their sustainability goals,”
FOR INDUSTRIAL said Javi McGuiggan, global category leader in Cargill’s
NEEDS AROUND THE Bioindustrial group. “Developing more natural ester options
GLOBE AND THE for the power generation and distribution industry provides
better alternatives for customers around the globe who
LAUNCH OF FR3R continue to expand their sustainability efforts while also
FLUID IS ANOTHER looking for higher performing products.”
EXAMPLE OF HOW
Compared to traditional mineral oil, FR3r fluid contin-
WE’RE MEETING uously dries paper insulation without creating any harmful
THE NEEDS OF by-products or sludge, which makes transformers more
OUR CUSTOMERS reliable to help meet the challenging and growing demands
placed on the power grid, and contains no petroleum, hal-
TO ACHIEVE THEIR ogens, silicones or sulfurs. FR3r fluid’s superior moisture
SUSTAINABILITY management extends insulation life up to eight times lon-
GOALS. ger compared to mineral oil, increasing the life of the
Photo: Cargill

transformer, and requires no maintenance under normal

Javi McGuiggan operating conditions.
Transformer Technology March 2023 39

Issue 27

DEVELOPING MORE
NATURAL ESTER
OPTIONS FOR THE
POWER GENERATION
AND DISTRIBUTION
INDUSTRY
PROVIDES BETTER
ALTERNATIVES
FOR CUSTOMERS
AROUND THE GLOBE
WHO CONTINUE
TO EXPAND THEIR
SUSTAINABILITY
EFFORTS WHILE
ALSO LOOKING FOR
HIGHER PERFORMING
PRODUCTS.
Javi McGuiggan
40 TECHNOLOGY
SPOTLIGHT

Plant-based natural ester continues to replace tradition-

al mineral oil in transformers around the world as users
seek more sustainable and more reliable solutions. Along
with being 100% biodegradable, FR3r fluid is also non-toxic
in soil, water, and to humans and wildlife.

FR3r fluid is K-class certified, helping mitigate the risk

of fire because of its exceptionally high flash point of 360°C
compared to only 160°C with mineral oil. Because of its
excellent high heat capabilities and up to 140°C top fluid
operating temperature, FR3r fluid filled transformerscan
achieve up to 20% more loading capacity compared to
mineral oil, meaning transformers can be designed to be
more power dense and be smaller with the same loading
capacity, the same size with up to 20% more loading ca-
pacity, or anywhere in between.

Photo: Cargill
Transformer Technology March 2023 41

Issue 27

Backed by Cargill’s extensive technical and manufactur-

ing expertise from over 25 years of successful applications
of the original natural ester (FR3™ fluid), FR3r natural ester
meets or exceeds all IEC 62770 and IEE C57.147 standards.

FR3r joins a diverse portfolio of Cargill Bioindustrial

plant-based solutions for a variety of manufacturing
needs including asphalt rejuvenation, immersion cooling,
adhesives and binders, wax and lubricants.
42 ASSET HEALTH
TOPIC
MONITORING
MISSING
SOLUTIONS

Adoption of Asset Health

Monitoring Solutions for
Power Grid Equipment
by Saifa Khalid
 Transformer Technology March 2023 43

Issue 27

Power transformers and HV AHM solutions help save money by

switchgear are usually the most optimizing performance/maintenance,
valuable assets in a substation, extending the life of the equipment,
requiring proper monitoring and and predicting failure. Associated
maintenance. Therefore, optimizing costs with AHM solutions include
the life of an aging transformer and consultancy fees, the cost of software,
HV switchgear equipment is a major and sensors.
cause of concern for utilities and
• Power transformers and HV industries that have a significant There are usually five maintenance
switchgear are usually the most installed base of transformers and strategies that are adopted for an
valuable assets in a substation, HV switchgear. In some cases, electric grid asset in the maintenance
requiring proper monitoring and this equipment dates back to the industry, namely: run to failure, time-
maintenance. 1950s, and, ergo, needs to be based, usage-based, condition-based,
consistently monitored through asset and predictive maintenance. Power
• Cost-benefit analysis is a vital health monitoring (AHM) solutions Technology Research believes that,
tool that helps electric utility that ensure optimum network as the maintenance strategies for HV
companies, regulators, and grid performance and longevity. switchgear and power transformers
operators in making informed shift towards condition-based and
investment decisions. Cost-benefit analysis is a vital tool predictive maintenance, savings
that helps electric utility companies, can be increased significantly
• In the coming years, asset health regulators, and grid operators (through life extension and optimized
monitoring is expected to become in making informed investment performance).
a key focus of utilities on a global decisions. When it comes to the
scale. cost-benefit analysis of installing
AHM solutions for costly electricity
grid equipment, such as power
transformers and HV switchgear,
savings outweigh the associated
costs. That is precisely why electricity
grids in advanced economies, that
can afford the upfront investment
cost, are opting for AHM solutions
and are reaping the benefits in
terms of improved network reliability
standards.

Saifa Khalid is a senior analyst at PTR Inc.

Her main area of focus is power systems.
Currently, she leads the power grid research
team in developing PTR’s syndicated power
grid services and manages custom research
projects for Fortune 500 clients globally. The
topics under her mandate include HV switch-
gear, MV switchgear, power transformers,
distribution transformers, etc. Saifa comes
from a technical background and has a BSc.
degree in Electrical Engineering.
Photo: Shutterstock

Figure 1: Maintenance strategies for an electrical grid asset.

Source: PTR Inc.
44 ASSET HEALTH
MONITORING
SOLUTIONS

Efficiency

1) Improves the performance and

increased utilization of the asset
by converting information into
actionable intelligence.

2) Reduces the total cost of

ownership of the grid asset.

3) Provides dynamic fleet

management and benchmarking.

4) Active network management

capabilities for deeper renewable
penetration in the energy mix.

5) Caters to the fluctuations in the

Figure 2: Cost benefit analysis of AHM solutions. grid in an intelligent manner, with a
Source: PTR Inc. short response time.

Reliability Future-proof investment

1) Carries out the monitoring and 1) New industry-standard: digitally

diagnosis of the asset in real- integrated and ready to connect.
time, focused on preventing forced
outages and failure of equipment 2) Modular and scalable platform
with timely warnings. with the full ecosystem of smart
devices, software, and service
2) Enhances the integrity of solutions.
equipment through condition-
based and predictive maintenance. 3) Building block for digital
substations and state-of-the-art
3) With remote access and online cyber security.
asset management facilities, the
exposure of human resources
to substation environment may
be reduced, therefore improving
safety.

Features of Asset Health Monitoring

General
ABB Siemens
Electric
The major features of an asset
health monitoring solution for HV
Circuit Breaker Sentinel
switchgear and power transformers • CBS
include reliability, efficiency, and Assetguard
• CBS Lite CB Watch 3
PDM
future-proof investment. These are • CBS Lite CSA
discussed below in detail. • CBS-F6

Generator Circuit Breaker Monitoring System GMS600

• GMS600-G
Assetguard
• GMS600-GT DWatch
GDM
• GMS600-GA
• GMS600-GTA

Modular Switchgear Monitoring (MSM) B Watch

Switchsync PWC600 PD Watch

Asset Health for Switchgear (AHS) BA300

Figure 3: Product portfolio of asset health monitoring solutions for HV switchgear.

Source: PTR Inc.
 Transformer Technology March 2023

Issue 27

With remote access and online asset management

facilities, the exposure of human resources to substation
environment may be reduced, therefore improving safety.
Photo: Shutterstock
46 ASSET HEALTH
MONITORING
SOLUTIONS

A digital transformer is not a product in itself, but a solution that

requires the integration of existing transformers with physical
sensors and a digital platform.

Photo: Shutterstock
Transformer Technology March 2023 47

Issue 27

Product Portfolio and Case Studies

As far as the product portfolio of

digital transformers is concerned,
it is significant to note that a digital
transformer is not a product in itself,
but a solution that requires the
integration of existing transformers
with physical sensors and a digital
platform. For instance, when Region Company Case Study
the existing power transformer
(from Hitachi ABB or any other Problem: A customer required a reliability-
manufacturer) is integrated with centered program built around condition
TXpertTM Ready Sensors (from Hitachi monitoring, data analysis, and spare parts
ABB or any other manufacturer) and inventory management in South America for
a fleet of 550 kV 30-year-old BBC GIS.
with TXpert Hub (Hitachi ABB),
it becomes TXpert enabled. Solution: The local service center collaborated
to develop a solution for the legacy equipment
South ABB
The product portfolio of AHM solutions which would keep it reliable well into the
America (ASEA Brown Boveri)
future at a cost that was far lower than
for HV switchgear is given in the figure alternative options. Data from condition
below. This suggests that the product monitoring devices allow for strategic as well
range offered by ABB and General as proactive decision-making for prioritizing
Electric is greater than Siemens, which maintenance to the assets that need it, while
leaving alone the assets that are healthy.
only offers two products (Assetguard It also assists in the replacement planning
PDM and Assetguard GDM). of failing assets.

Several case studies, illustrated in

Problem: The challenge was to lower
Figure 4, explain how the deployment greenhouse gas/SF6 emissions, as a part of
of asset health management solutions an aggressive “Green” initiative within a strict
for HV switchgear and power deadline. Field retrofitting monitoring devices
transformers in various parts of the on installed breakers was not possible within
that time frame.
world has improved electricity network The U.S. ABB
reliability. Solution: ABB’s well-trained field service staff
met the project deadline by enabling early SF6
Looking Ahead gas leak detection using remote monitoring
by CBS-F6, eliminating costly and unplanned
outages. CBS-F6 – works with any brand OEM
In the coming years, asset health HV circuit breaker.
monitoring is expected to become a
key focus of utilities on a global scale.
Problem: The aim was to boost the energy
This is especially true for advanced reliability and efficiency of the Nile Delta’s
economies that can afford to make a 500/220-kilovolt Kafr El Sheikh and New
significant initial investment in AHM Zagazig governorates (highly loaded link of
solutions. Power Technology Research transmission grid of Northern Egypt).
Egypt Siemens
carried out a Europe-wide study of Solution: Sensformers were provided to the
35 transmission system operators Egyptian Electricity Transmission Company
in order to establish a relationship (EETC) by Siemens which dealt with the
between network reliability indicators network reliability and efficiency of the delta
area.
and the adoption of AHM solutions.
It was observed that countries
that have better network reliability Problem: The challenge was to achieve a more
indicators, such as lower SAIDI sustainable grid and improve power quality in
the well-known mountain resort of Cortina in
(System Average Interruption Duration Northern Italy.
Index) or SAIFI (System Average
Interruption Frequency Index) values, Italy Hitachi ABB Solution: In Enel’s substation of Cortina
were actually more inclined towards D’Ampezzo, TXpertTM Ecosystem for the
digitalization of transformers was deployed to
the adoption of digital solutions increase the reliability of the electricity grid and
for AHM. reduce the risk associated with the consequent
life extension of power transformers.
Contact:
Hassan Zaheer
Chief Commercial Officer
+49-89-12250950 Figure 4: Case studies of AHM solutions for HV switchgear and Power Transformers.
[email protected] Source: PTR Inc.
48 NEW MONITORING
SOLUTIONS

PART 1

NEW TECHNOLOGIES CAN HELP

COMPENSATE FOR THE LOSS
OF PERSONNEL KNOWLEDGE
AND THE INCREASED DEMANDS
ON OPERATING EQUIPMENT

New technologies in monitoring and diagnostics help compensate for the loss
of personnel knowledge and the increased demands on operating equipment.
Also, energy transition is posing enormous challenges for the power supply:
Infrastructure conceived decades ago suddenly must transport electricity in a
different way. Power grids are aging, and with maintenance strategies that have
been the norm up to now, there is an increasing need for renewal, entailing further
expense. One solution lies in intelligent, data-driven utilization concepts that
enables the use existing infrastructure more efficiently and extend the lifetime.

To achieve this, a balanced portfolio for the different automation levels is

necessary (see Figure 1).

Sensors continuously record the signals at the process level. All measured
data is then communicated to a central communication node in the field level for
further processing and enrichment. Thus, fail-safe and centralized information on
maintenance and health status is resiliently available on site. On the control level
a global classification can be carried out and risk-based maintenance strategies
are enabled. For a holistic system for the diagnosis of power transformers, mo-
dular and manufacturer-independent solutions must be found to ensure the best
possible application.

Figure 1:
MR’s System solution for maximum operational reliability
 Transformer Technology March 2023 49

Issue 27

How these solutions can look in practice is demonstrated by the following

applications.

Simplifying and enriching sensors in their use on transformers

To make the best possible conclusions about the health of transformers,

it is useful to work on accuracy and reliability of data sources (sensors). The
following examples show how this has been done for monitoring the various
components on the transformer.

DGA – Dissolved Gas Analysis

The analysis of dissolved gases in the insulating oil in the gas phase is carried
out using various analysis approaches: semiconductor sensors, electrochem-
ical sensors, infrared spectroscopy, or gas chromatography. An extraction of
the gases from the insulating oil takes place prior to the actual analysis for all
methods. These two essential processes are influenced by external factors
such as oil and ambient temperature, humidity, air pressure, and other chemical
components, which often lead to very high measurement uncertainties and
incorrect analysis results. One method for counteracting this is to keep the
conditions of gas extraction and detection constant. Detection can also be
improved by separating interfering components from the actual target gases.
All of these measures require additional components in a DGA analysis system,
which significantly increases both its cost and complexity.

Another approach includes mathematical-statistical methods from the tool-

box of machine learning or artificial intelligence. The correlation between the
actual target variable (in the case of a DGA – the gas concentrations in the
insulating oil), the sensor signal, and the disturbing influences is determined
using a training data set. The training data set should represent the entire data
space of the application to the greatest extent possible. For a DGA, this means
recording the temperature range of the insulating oil and the environment, the
humidity range, the ambient pressure, and all relevant chemical disturbance
components, and thus taking their influences into account as completely as
possible in the mathematical model. Other methods such as support vector
regression (SVR) are also conceivable. The advantage of this approach, as
implemented in the MSENSE® DGA 2/3, is a much simpler and less expensive
design of the measurement system. While more effort is needed in the devel-
opment phase, the customer receives a robust, easy-to-operate, and more
cost-effective analysis system.
Photo: MR
50 NEW MONITORING
SOLUTIONS

Another advantage of this approach is the possibility of self-adjustment of the

analysis system during operation. With the aid of a reference point, the analysis
system can auto-calibrate using machine learning methods and existing
measurement (measured-data memory of the analysis system) in order to
adapt to the individual conditions on site. In this way, effects such as sensor drift,
aging of the insulating oil and the like can be compensated for and consistent
measurement repeatability can be ensured.
OLTC DGA

In the CIGRÉ publications CIGRÉ Technical Brochure 443 and CIGRÉ Technical
Brochure 771, the gas patterns of on-load tap-changers are interpreted using
the gas ratios of methane, ethylene and acetylene according to Duval (Duval
triangles) and classified into fault classes or normal operation.

The interpretation of gas patterns of tap changers remains difficult compared

to transformers and requires expert knowledge about the functionality of the
respective tap changer type and its mode of operation. Nevertheless, the condition
assessment of a tap changer by means of DGA is a powerful tool and helps to
optimize maintenance measures within the framework of condition-based main-
tenance and to indicate deviations from normal operation in good time.

For continuous online monitoring, as with transformers, the use of multi-gas online
DGA sensors for fault diagnosis is usually not necessary. Often, trend analysis
of a few key gases such as hydrogen, carbon monoxide or acetylene/methane is
sufficient to detect deviations from normal operation at an early stage. Our in-
vestigations showed that with vacuum tap changers of the built-on more than
80% of the deviations from normal operation could already be detected with the
monitoring of hydrogen.
The interpretation of DGA data from on-load tap-changers remains difficult,
since further information on the operation and function of the on-load tap-
changer is required. Therefore, deviating from the previously known approaches,
an interpretation approach is proposed, which uses statistical-mathematical
algorithms. In addition to the gas concentrations, information on the tap changer
is used as input variables, such as tap changer type, number of switch operations,
and more. As a result, a diagnosis with an indication of the probability is obtained
(see Figure 2).

In the example shown (Fig. 2), normal operation is assumed with a high degree
of probability (the greater the proportion of the gray area, the greater the uncertainty
of the statement made). Here, it was possible to provide a lot of supplementary
information on the tap changer, so that the reliability of the statement is high.

Figure 2: Figure 3:
Example of a DGA interpretation of a vacuum tap changer based Second Example of a DGA interpretation of a vacuum tap changer
on a statistical approach. based on a statistical approach.
Transformer Technology March 2023 51

Issue 27

The example shown in Fig. 3 illustrates how, at the same gas concentrations as
in Fig. 2, the reliability of the statement decreases when only very little information
is available on the tap changer. The proportions of the gray areas (uncertainty
ranges) are very large. This also indicates that a diagnosis based on too little data
is not meaningful.

As part of the condition monitoring of on-load tap-changers, the online DGA

is a valuable tool for detecting deviations from normal operation at an early stage
and thus avoiding damage or failures. It contributes to a cost-optimized condition-
based maintenance strategy. For continuous trend monitoring, the analysis of a
few key gases using cost-effective and robust online DGA systems is sufficient.
Caution should be exercised when interpreting DGA data for fault diagnosis, as
the most accurate knowledge of the operation and function of the on-load tap-
changer under consideration is additionally required and should be taken into
account in the interpretation.
Oil moisture and breakdown voltage

In insulating systems for electrical equipment moisture is undesirable. Excessive

moisture in insulating oil or insulating paper impairs their insulating strength.
Water promotes degradation reactions of the insulating oil and the insulating
paper and reduces the service life of a transformer or on-load tap-changer.

Figure 4:
Deterioration of insulating materials because of water

Figure 5:
Loss of lifetime because of increase water content
52 NEW MONITORING
SOLUTIONS

This results in two aspects regarding to moisture: a) The penetration of moisture

into the transformer or tap changer should be avoided. This is done by appropriate
handling of the insulating materials and by using dehumidifiers to dry the air
breathed in by the transformer or tap changer. b) The moisture content of the
insulating oil should be continuously monitored. Since it is not possible to monitor
the moisture content of the insulating paper directly while a transformer is in
operation, this is also done indirectly via the moisture content of the insulating oil.
The insulating strength of the liquid insulating medium is determined by means of
the breakdown voltage in accordance with appropriate test standards such as IEC
60156 or ASTM D 1816. For this purpose, a defined quantity of the insulating oil is
filled into a test chamber, where there are two electrodes at a defined distance - in
the case of IEC 60156 this is 2.5 mm. The test voltage between the two electrodes
is continuously increased until breakdown occurs. Several test runs are carried
out from which individual values of the breakdown voltage are determined by
averaging in kV. According to the requirements for a fresh insulating oil in IEC
60296, the breakdown voltage must be at least 30 kV. Fresh insulating oils usually
have breakdown voltages between 60 and 80 kV. A major influencing factor on the
breakdown voltage, as a characteristic parameter for the insulating strength, is
the moisture content of the insulating oil. The breakdown voltage of an insulating
oil is thus another important parameter for assessing the condition of the liquid
insulating medium and thus of the transformer or tap changer. Continuous moni-
toring of the breakdown voltage is therefore recommended.
The methods described in the relevant test standards for determining the
breakdown voltage are not suitable for online monitoring. The construction of a
device that can be used in the field is complex and expensive, and breakdowns
in the oil would be provoked, which would damage the insulating oil with time.
A relatively simple way of implementing online monitoring of the breakdown
voltage makes use of the influence of the moisture in the insulating oil on the
breakdown voltage. The relationship between relative oil moisture, oil temperature,
and breakdown voltage can be described using statistical methods from the
machine learning toolbox. Here, the data for the breakdown voltage at different
oil temperatures and humidities are determined experimentally using a reference
method, IEC 60156. A mathematical model is trained with these data. The model is
validated and optimized using test data that are independent of the training data.
Figure 6:
Resulting BDV models for Since the test standard used to determine a breakdown voltage in the labo-
different oil types ratory already has a large measurement uncertainty, it is advisable to divide the
results of the BDV calculation into classes based on the IEC 60422 standard, and
display the information in the form of a traffic light. This is considered sufficient
for long-term trend monitoring. Integrated into a higher-level monitoring system, a
condition assessment of the equipment is thus obtained, taking into account other
characteristics of the equipment.

Bushing monitoring

Based on the CIGRE study working group A2.37 and A2.43, “Transformer
Reliability Survey” and “Transformer bushing reliability”, almost 18% of all failures
documented for substation transformers can be tracked down to malfunctions
related to transformer bushings. Those numbers show how critical and important
monitoring of transformer bushings can be.

The most efficient way to estimate bushing condition based on on-line mo-
nitoring is to control the change of the main capacitance C1 and the associated
dielectric dissipation factor tanδ. It is proven that humidity and aging are impacting
capacitance only at higher temperatures. A short circuit between elementary
condensers will increase the capacitance independent of temperature. Change of
the tanδ and PF is temperature dependent. Increase of tanδ indicates a higher loss
in the bushing’s insulation system and is often caused by introduction of moisture
or ageing.
Transformer Technology March 2023 53

Issue 27

Limits for the change of C1 and tanδ depend on the system voltage and
technology used for bushings construction.

The tanδ measurement is much more sensitive to external factors (temper-

ature, weather condition) than capacitance due to the very small value of angle δ.
Bushing condition evaluation based on tanδ measurement depends on the bushing
insulation type and construction. Two evaluation methods can be applied: based
on the specified tanδ value or a relative tanδ change.

Sum of current method: The amplitude and phase angle of the current at all
of three bushing taps are measured and compared to each other. Simple current
amplitude changes with change of the capacitance and the phase shift with
the dielectric loss factor of the bushing assuming that the summation of the
currents of the three bushing of the different phases under consideration of its
phase angles is zero. In that method the measurement is very strongly affected
by the fluctuation of the system voltages and phase. Monitoring system utilizing
that method can be easily installed on the transformer. Less technical effort and
simplicity are the main advantages; however, the results are impacted by the
imbalance and external factors.
Comparison method: to avoid problems recognized in the sum of currents
method, the comparison method was introduced. This method uses a signal
from voltage transformers installed on the same phase as a reference. The volt-
age transformer is not affected by the defects and aging that typically affects
bushings. Monitoring systems utilizing this method need additional technical
effort to connect the reference signal. In most cases the VT are placed far away
from the transformer, however the results are not affected by network imbalance
and external factors.

Measured voltage signal can be additionally compared with other phases of

the same transformer, improving immunity to external factors like temperature or
weather condition.
The double-reference method improves the voltage comparison method
and capacitance measurement if the reference voltage is not accessible (volt-
age change during tap changer switching).

Bushing monitoring system in most cases can utilize the same decoupling
devices for electrical Partial Discharge (PD) measurement. Signals in different
frequency ranges can be used for PD activity recognition and early warning. The
electrical measurement on bushing is strongly affected by external noise, which
can be compensated by combining it with the UHF method (antennas installed
on the transformer tank) for better PD recognition.

Figure 7:
Voltage comparison method can be easy and cost effective
integrated with ETOS® or work as a stand-alone (MSENSE®BM)
providing best solution for bushing monitoring. Figure 8
54 NEW MONITORING
SOLUTIONS

Vibro acoustic monitoring of OLTCs

Since on-load tap-changers are among the most important components of

power transformers, it is crucial for network operators to know their conditions
at all times. Thanks to more than 20 years of experience in on-load tap-
changer monitoring, Reinhausen has developed a unique online diagnostic tool:
MSENSE® VAM. “VAM” stands for vibroacoustic measurement and can be used
universally for all types and brands of OLTCs. The basis of MSENSE® VAM is
a high-resolution vibroacoustic measurement system for detecting vibrations
that occur during the switching sequence of an OLTC. Envelope curves are
generated from the time-frequency spectra emitted during the switching
sequence. The evaluation of these envelope curves is performed with the aid
of a dynamic limit value curve which increasingly approximates the envelope
curve during each switching sequence by means of a self-learning algorithm.

Assuming a Gaussian probability distribution, the significant peaks of the

recorded curve are then expanded. As a result, a limit curve is generated over
the sound signal peaks characterizing the tap changer switching process.

Figure 9:
Self- learning limit value curve for an easy installation

An upper limit value curve is generated from the statistics, which represents an absolute limit value for
the acoustic signal. The limit value curves are determined independently by the system using statistical
methods on the basis of the stored historical data.

The resulting limit value curve serves as an alarm limit value and is at the same time used for flexible
adjustment of the amplitude range that is still permissible. The limit values are thus updated. Through
this tracking procedure, the system iteratively learns during the switching operations what the acoustic
signature of a correctly operating on-load tap-changer looks like, in order to check the correct course of all
subsequent on-load tap-changer switching operations on the basis of the self-generated envelope curve.
Whereas in the past it was necessary to determine individual limit value curves via the temperature curve
in a test pro-cedure that took months, the system now learns the correct limit value curves for the specific
on-load tap-changer.

Tobias Gruber is Automation Portfolio Mana- Jürgen Schübel completed a PhD in physical
ger at Maschinenfabrik Reinhausen GmbH, chemistry in 1991 and worked for 20 years
where he has worked for 10 years. He helped in a major European mineral oil company. He
develop the current automation systems, i.e., is senior expert for insulating materials and
ETOS® for power transformers. He holds MSc. analytics at MR, Product Owner of DGA-, Fiber
in electrical engineering and is an expert for Optic- and Moisture sensors and is an active
Photo: MR

automation applications responsible for the member of CIGRÉ D1.

automation portfolio at MR.
Transformer Technology March 2023 55

Issue 27

To be continued in our MAY Issue.

In the next article, we will describe
the use and integration of typical
sensors with more analysis and
inside-view and will expand the
collection and further analysis by
edge devices and central solutions.
56 SAFETY AND
TOPIC
RELIABILITY
MISSING
PROGRAMS

Leveraging Operator-Driven
Safety and Reliability Programs
to Boost IIoT Program Success
by Martin Robinson
 Transformer Technology March 2023 57

Issue 27

Industry 3.5 is a term used to had succeeded in their IIoT initiatives,

describe the transitional phase with most companies struggling to
between Industry 3.0 and Industry scale their programs beyond pilot
4.0. It refers to integrating digital projects. In addition, the study found
technologies into traditional that the most significant challenges
manufacturing and industrial associated with IIoT implementation
processes to a lesser extent than were data integration, security, and a
Industry 4.0. Industry 3.5 involves lack of internal expertise.
the use of technologies such as
Martin Robinson is the founder, owner, and computer-aided design (CAD), Another study by Bain & Company
CEO of IRISS Inc., a leading manufacturer of computer-aided manufacturing found that the majority of IIoT
infrared inspection windows. Robinson fo- (CAM), and enterprise resource programs fail to deliver their intended
cuses on innovation and is a pioneer of Elec- planning (ERP) systems, which results, with only 5% of companies
trical Maintenance Safety Devices (EMSDs) enable companies to automate reporting significant financial
that help protect technicians from harm while and optimize their manufacturing benefits from their IIoT programs.
protecting their companies’ bottom line. He processes, reduce costs, and The study identified several factors
holds several patents for condition-based improve productivity. Industry 3.5 is that can contribute to the failure of
maintenance devices and has designed mul- considered a stepping stone towards IIoT programs, including a lack of
tiple maintenance programs that include Industry 4.0, as it allows companies executive support, internal expertise,
infrared, ultrasound, partial discharge test- to gradually introduce digital and a failure to focus on solving
ing, non-destructive testing (NDT) and energy technologies into their operations specific business problems.
management strategies. He holds a NEBOSH and establish a foundation for more
certificate in Occupational Safety and Health, advanced systems. While there is no specific data on
an IAM Certificate in Asset Management, is a the exact number of IIoT programs
certified Level III Thermographer, a Certified The Industrial Internet of Things (IIoT) that have failed to deliver their
Maintenance and Reliability Professional has become increasingly popular, with design intent, several studies have
(CMRP) and a Certified Reliability Leader companies investing heavily in IIoT highlighted the challenges associated
(CRL). He is a member of IEEE, NFPA and is programs to improve their operations. with implementing IIoT programs
a standing member on the technical commit- However, not all IIoT programs have and the factors that can contribute
tee CSA Z463 guidelines on maintenance of successfully delivered their intended to failure. These studies suggest
electrical systems. results. While there is no specific that companies must be mindful
data on the number of IIoT programs of these challenges and take steps
that have failed to deliver their design to mitigate them to increase the
intent, several studies have highlighted likelihood of success. One possible
the challenges associated with initiative to increase the success of
implementing IIoT programs and the IIoT programs is to use operators to
factors that can contribute to failure. implement solutions into Operator
For example, one study by Cisco Driven Safety and Reliability
found that only 26% of companies Programs.

One possible
initiative to
increase the
success of IIoT
programs is to
use operators
Photo: AdobeStock, American Public Power Association

to implement
solutions
into Operator
Driven Safety
and Reliability
Programs.
58 SAFETY AND
RELIABILITY
PROGRAMS

Operator-Driven Safety and reliability issues. In addition, by

Reliability (ODSR): involving operators in identifying
and addressing safety and reliability
Operator-driven safety and reliability concerns, ODSR programs can
(ODSR) is a program that empowers help build a safety culture and
operators to take ownership of their improve overall performance in
equipment and processes. ODSR manufacturing and industrial
programs enable operators to environments.
identify and address potential safety
hazards and reliability issues before How ODSR Programs Can Improve
they become problems, leading to the Success of IIoT Programs:
increased safety, reduced downtime
and improved productivity. ODSR ODSR programs can help improve
programs involve training and the success of IIoT programs by
support, performance metrics, and addressing some of the challenges
integrating equipment inspection associated with IIoT implementation.
system designs and IIOT monitoring For example, a lack of internal
systems. ODSR programs can expertise is a familiar challenge
help build a safety culture and company face when implementing
improve overall performance in IIoT programs. ODSR programs
manufacturing and industrial can help address this challenge
environments by involving operators by empowering operators with the
in identifying and addressing safety knowledge and skills to identify and
and reliability concerns. address potential safety hazards
and reliability issues. In addition,
ODSR programs can help enhance by involving operators in the
Industry 3.5 by providing real-time implementation and maintenance
feedback to operators, allowing them of IIoT systems, companies
to make informed decisions and can leverage their expertise and
take corrective actions in response experience to ensure the success of
to potential safety hazards and their IIoT programs.
 Transformer Technology March 2023 59

Issue 27

ODSR programs
can help
improve safety
and efficiency,
reduce downtime,
and improve
productivity,
leading to
financial benefits
and improved
operator job
satisfaction.

Another common challenge Additionally, ODSR programs can

associated with IIoT implementation help to address the challenge of
is data integration. ODSR programs scaling IIoT programs beyond pilot
can help address this challenge by projects. By involving operators
providing real-time feedback on the in the implementation and
performance of equipment, enabling maintenance of IIoT systems.
operators to quickly identify and
address potential issues before In conclusion, the success of
they become significant problems. IIoT programs depends on several
This can help prevent data silos and factors, including data integration,
ensure that IIoT systems are fully security, internal expertise, and
integrated into existing processes. executive support. ODSR programs
can help address these challenges
Security is another significant by empowering operators to take
challenge associated with IIoT ownership of their equipment and
implementation. ODSR programs processes and providing them
can help address this challenge by with real-time feedback on
involving operators in identifying and equipment performance. As a
addressing potential security issues. result, ODSR programs can help
Companies can reduce the risk of improve safety and efficiency,
cyberattacks and other security reduce downtime, and improve
Photo: AdobeStock

breaches by providing operators with productivity, leading to financial

the tools and knowledge to identify benefits and improved operator
and address security issues. job satisfaction.
60 SAFETY AND
RELIABILITY
PROGRAMS
 Transformer Technology March 2023 61

Issue 27

By leveraging By involving operators in

implementing and maintaining IIoT
companies can optimize their existing
processes, leading to a gradual shift
ODSR programs systems, companies can leverage towards Industry 4.0.
their expertise and experience to
to enhance ensure the success of their IIoT In summary, ODSR programs
IIoT programs, programs. Companies can also can help improve the success of
enhance ODSR programs by adding IIoT programs by addressing the
companies can equipment IIoT monitoring systems challenges associated with data
optimize their and designing or modifying equipment
to allow safe access for inspection.
integration, security, internal expertise,
and scaling beyond pilot projects.
operations, ODSR programs can also enhance
Industry 3.5 is a stepping stone Industry 3.5 by empowering operators
leading to towards Industry 4.0, and ODSR and providing real-time feedback
financial benefits programs are a powerful tool on the performance of equipment.
for enhancing Industry 3.5 and By leveraging ODSR programs to
and improved transitioning towards a fully digitalized enhance IIoT programs, companies
Photo: AdobeStock

operator job and connected manufacturing

environment. By improving the
can optimize their operations, leading
to financial benefits and improved
satisfaction. safety and efficiency of operations, operator job satisfaction.
62 MONITORING OF
SYSTEM FAILURES

How to effectively address

lightning performance
and continuously monitor
system failures?
by Florent Giraudet

One possible
initiative to
increase the
success of
IIoT programs
is to use
operators to
implement
solutions
into Operator
Driven Safety
and Reliability
Programs.
Photo: Shutterstock
Transformer Technology March 2023 63

Issue 27

500kV Tower in South East Asia

For non-specialists, this double

circuit lattice tower might seem
conventional, but on closer inspection
it is rather unique. Each phase conductor
is protected by Line Surge Arresters (LSA).

LSA are used to prevent lightning induced

flashovers. In this case, the system operator
has adopted an EGLA technology (Externally Florent Giraudet received a Dipl. Ing. Degree
Gapped Line Arrester). Although the choice of in Industrial and Electrical Engineering from
EGLAs is rather appropriate, especially on 500kV CESI in Lyon, France in 2010. He later joined
lines, some essential questions arise on such Siemens, Germany as Area Sales Manager
installations: for surge arresters application. He then took
on additional responsibilities in the business
• Is it optimal to protect every phase development of overhead line solutions that
conductor? Couldn’t we find a better include applications of transmission line ar-
optimization? resters as well as polymeric insulators. He
• How can I assess the condition of my LSA subsequently took over Sales & Marketing
over time? How do I get the confidence they responsibilities at Tridelta Meidensha. Cur-
are still effective to protect my line? rently, he offers consulting for lightning per-
• Even better, can I get a confirmation they formance and surge arrester technologies.
have done their duty of protection? And how You can contact the author via his e-mail ad-
many times? dress: [email protected].
64 MONITORING OF
SYSTEM FAILURES

Screenshot I3CM LLS – Lightning parameters

Due Diligence as
prerequisite

Many utilities and system operators

are often confronted with difficulties
in analyzing the lightning performance
of their lines but especially in selecting Many biases come into play in the Sigma SLP allows the modeling of
effective and affordable methods to process because data are missing, your transmission line to analyze
reduce outages. information is wrong, or because long- the effect of lightning strokes on
held beliefs persist. its performance. Simulation can be
Very often, the choice of LSAs comes made on systems without and with
as a last resort because they are Working with real-world data LSA. Sigma SLP includes a special
considered (wrongly) as too expensive feature to run those simulations on
and not reliable enough. Lightning detection techniques have a complete line (various TFR and
been developing and improving in line spans) including an automatic
But let us start from the beginning: performance in recent years. Modern LSA placement. It helps the users
utilities and system operators hardware/software solutions like I3CM minimize their budget for a maximum
normally invest in LSA to reduce the LLS can help users record and analyze improvement.
lightning outages which are causing all lightning activities in the area of
severe financial consequences: interest. The customized stroke distribution
model can be used based on
• Financial Damages In the screenshot above, a typical 1km real-world data instead of using
• Penalties from clients buffer has been chosen along the line conservative (and often excessive)
• Costs of Momentary Outages of interest. Primary information is then CIGRE models which vary depending
• Grid instability / Continuity of extracted for further study: on the countries.
Service
• Intensive use of circuit breaker • Ground Flash Density or Keraunic Sigma SLP has been first commer-
Level cialized in the early 2000’s. It results
The first challenge is to identify the • Cumulative Stroke Distribution from different research works by Prof.
critical line sections and start a due o Median of the stroke amplitude Dr. Salih Sadovic in collaboration with
diligence process: o Logarithmic standard deviation international experts.

• Identification of lightning induced Having taken care to carry out

outages vs. others outages appropriate field inspections and
Utilities
• Investigation on Ground Flash measurements, it is appropriate to and system
Density (GFD) and Keraunic level report the grounding conditions that are
• Verification of insulation essential for effective system studies: operators
coordination study
• On-site measurement of tower • Soil resistivity
normally invest
footing resistance • Towers Footing Resistances (TFR) in LSA to reduce
• Inspection of shield wires/OHGW
Simulate and define your the lightning
A decision matrix should help them target outages which
evaluate the situation and prioritize
a list of options to mitigate lightning A simulation software like Sigma SLP are causing
Photo: Shutterstock

outages with cost-effective solutions. can help the users to optimize their
investment by running a computation
severe financial
This process is NOT easy! of lightning performance. consequences.
Transformer Technology March 2023 65

Issue 27

Screenshot Sigma SLP – Composite Performance

and automatic LSA placement

Nevertheless, monitoring solutions

might be required to be effective in
maintenance to be able to detect
failure and plan the replacement.

Today there are proven technologies

The software continues to be • 80.1% improvement (outages
which can tackle the challenging
supported by Sadovic Consultant. reduction) by protection only
process of line monitoring and failure
The latest update of Sigma SLP is 3 phases and results in 100%
detection:
version 3.1 (2022) that includes the improvement for double circuit
possibility to define the failure rate outages.
• Lightning Location System (LLS)
probability based on specific stroke
• Double Ended Traveling Wave (TW)
distribution models. True Digitalization of the • Synchronization GNSS timestamp
Monitoring • Weather data analysis
Users can then easily define their
• Online-based software application
budget (number of LSA) to reach Monitoring is a “question” that often
with dedicated functions
a specific target (performance – comes up, but it is also a concern that is
outages / 100km / year). Experience often expressed by utilities and system
I3CM LLS includes all those
often shows that a study of this type operators. LSA is often seen as an asset
technologies. It is a comfortable real-
can achieve very significant levels that can fail and must be monitored.
time online monitoring tool intended
of improvement without the need to When properly designed, dimensioned,
to facilitate the identification, the
completely equip a line with LSA. This manufactured and installed, LSAs
categorization and the location of line
is a thorough and scientific approach. should not fail and their reported
faults. It goes much further than LSA
failures should remain low. When a
failure detection. Here are some key
The example below shows the failure occurs on one LSA, it does not
features:
following results for a 170kV shielded jeopardize the system because other
double circuit line: LSAs play their role along the line.
• It helps utilities and system
Therefore, a preventive maintenance
operators categorize faults and
• 89.2% improvement (outages known as condition assessment, which
provide real-time notifications.
reduction) by protecting only could be costly and complex, should
It supports decisions and helps
4 phases not be justified on LSA.
with prioritization.

Sigma SLP composite performance study on

170kV system in Turkey – INMR 2022, ADM A simulation
software like
Sigma SLP can
help the users
to optimize
their investment
by running a
computation
of lightning
performance.
66 MONITORING OF
SYSTEM FAILURES

Screenshot I3CM LLS – Fault detection

with corresponding LLS data.

• Lightning outages can be detected

and localized with high accuracy
(~60 meters) and their types can
be differentiated (Backflashover/
Shielding failure). Weather data
providers are queried if LLS data
do not match.
• Suspicious faults can be localized
precisely and crews can be sent
to the exact location for line Overview of EGLA failures in Japan over 20 years operation
inspection.
• Digital twin of the line in I3CM Type (a) Type (b) Type (c)
LLS can be customized to provide EGLA 1st generation EGLA 2st generation Current Limiting Gaps (CLG)
specific features such as LSA Approx. Quantity 90,000 160,000 115,900
failure detection.
Overload/Failure 10 36 9
Japan — an example to Bird deterioration 0 19 0
follow in terms of reliability

As per CRIEPI report from 2009, Failure rate EGLA Compact The performance remains stable over
almost 365,900 units are installed = 0.0225 failure / 1000 units / year time, as opposed to other methods,
in Japan. About 120,000 units are such as improving grounding
Current Limiting Gaps (CLG), which In view of the statistical information on conditions. Individual LSA monitoring
is a non-metal oxide technology. failures, there are countermeasures to is not justified economically and
Therefore, we can estimate about easily reach low failures rates close to remains complex today.
250,000 EGLA units in operation in zero by adapting the charge transfer
Japan since the 1980’s. capability of SVU and improve the Dedicated real-time monitoring
tightening system of the EGLA sets solutions, such as I3CM LLS, have
Dedicated monitoring of EGLA units (better design/ extensive vibration tests). been developed to offer comfortable
does not apply in Japan. Regular LSA failure detection among others
inspections are performed on Conclusion features, such as fault localization and
transmission towers, insulators and categorization.
therefore on EGLA in the meantime. LSA is still an underrated method for
Japanese utilities and system operators
are able to localize a fault when a
effective lightning performance
improvement.
Over 20 years,
lightning induced outage is detected. the total
Biases and misconceptions prevent
Over 20 years, the total number of putting LSA in the spotlight. number of
overload/failures reported on a total overload/failures
of 365,900 units is 55 units! This is an EGLA experience feedback shows
extraordinary figure that should make extremely high reliability. reported in
you think about the EGLA technology
and its reliability in improving the Modern monitoring solutions can help
Japan on a total
lightning performance on transmission system operators to simulate lightning of 365,900 units
lines compared to biases and performance with real word data.
misconception. is 55 units!
Simulations tools, such as Sigma This is an extraordinary figure
If we look at the modern EGLA type SLP, can be very effective to optimize that should make you think
(compact) made of light-weight investments. about the EGLA technology
polymer housings and optimized ZnO and its reliability in improving
Photo: Shutterstock

blocks sizes, only 36 failures have been The behavior of lightning is predictable. the lightning performance on
found for 160,000 units installed across And so must be the expected perfor- transmission lines compared to
the country for a period of 10 years. mance improvement. biases and misconception.
 ADVERTISING
Transformer Technology March 2023 67

Issue 27

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Transformer Technology WOMEN March 2023 69

Issue 27 OF NOTE

Julie Rotchell
Julie Rotchell is leading to securing power systems Engineering, and Mathematics
Transformer Service operations around the world, particularly (STEM) exhibition, held at the
for Hitachi Energy in the on improving the reliability and Science Museum in London.
UK, with nearly 4 decades sustainability of the UK power
of experience in Power grid. She supports and mentors She is proud to be part of a
Engineering. She has held others in the industry, providing team that creates an excellent
various roles in the areas insight into the opportunities work environment. They
of Engineering, Tendering, available in engineering, emphasize the positive impact
Project Management, as well applicable to both women and their work has on the industry
as the role of an operations men. Julie has been recognized and environment, by improving
manager. As the Transformer for her achievements and was the electricity system across
Service Manager, she leads a even invited to be a part of the the UK, and the rest of the
team that supports the asset female Science, Technology, world.
management and maintenance
of the transformers they’ve
designed, manufactured,
and installed for various
applications, including those
from other manufacturers.

She targets the development

of her team to support the
growth in new and expanding
areas, one of which is on
offshore renewables. She
provides lifecycle management,
monitoring, service, and
maintenance support to extend
the life expectancy of the
equipment.

Throughout her working

life, Julie has contributed
70 EXPERT OPINION:
SILICON STEEL IN
TRANSFORMER CORES

Electromagnetic Properties
The electromagnetic properties
of grain-oriented silicon steel
significantly affect the service

of 0.18 mm Thin-gauge
performance of transformer cores.
The product (18PTD075) of 0.18
mm thin-gauge grain-oriented
silicon steel shows a remarkable

Grain-oriented Silicon Steel

thickness uniformity and an
excellent electromagnetic property.
The iron loss (P1.7/50 ) can be reduced
to 0.73 W/kg, achieving a high grade.

and Its Application Thus, the low iron loss can improve
the comprehensive performance
and energy efficiency level of

in Transformer Cores
transformers, save energy, and
reduce carbon emissions.

Key words:
Grain-oriented silicon steel;
Thin-gauge; Transformer core;
Iron loss.

by Qingsong Zhang R&D engineer

at Wuxi Putian Iron Core Co., Ltd.
PTTX
 Transformer Technology March 2023 71

Issue 27

Grain-oriented silicon steel is a kind Thickness Uniformity

of functional soft magnetic material
that is used as the raw material for Precise full-process production
transformer cores manufacturing. control technology can ensure the
The service performance of thickness uniformity of the product of
transformer cores mainly depends 0.18 mm thin-gauge grain-oriented
on the electromagnetic properties silicon steel. The results of in-line
of grain-oriented silicon steel. thickness tests of the product are
Therefore, it is crucial to improve the shown in Figure 2, with an average
electromagnetic properties. Thinning thickness of 0.175 ± 0.003 mm.
the thickness can significantly The thickness fluctuations are small
reduce the iron loss [1]. Therefore, throughout the length, ensuring
the research and development (R&D) a superior surface quality of the
of thin-gauge grain-oriented silicon product.
steel is the trend of the industry [2].
Figure 1. Product of 0.18 mm thin-gauge
At present, thin-gauge and ultra- grain-oriented silicon steel (18PTD075).
thin-gauge product is mainly applied
in the transformer under a medium
or a high frequency. However, there
is less research on the application
of thin-gauge product in the large-
power transformer under a low
frequency. Therefore, this report
focuses on demonstrating the
electromagnetic properties of the
0.18 mm thin-gauge grain-oriented
silicon steel (18PTD075, Figure 1)
and its application in the large-power
transformer core under a frequency
of 50 Hz.
Figure 2. Results of in-line thickness tests.

Figure 3. Results of in-line specific total

Qingsong Zhang obtained his Ph.D. degree loss tests.
in Materials Science and Engineering from
China Southwest Jiaotong University in 2020.
He visited the Spain National Centre for Metal-
lurgical Research during 2019 as a joint train-
ing student. He previously worked at China
Huazhong University of Science and Technol-
ogy as a postdoctoral researcher, focusing on
service performance and surface strengthen-
ing of metallic materials. Then, he joined Wuxi
Putian Iron Core Co., Ltd. (PTTX) as a R&D en-
gineer, working on thin-gauge and high-grade
grain-oriented silicon steel. PTTX is a world-
class power transformer core full process
Photo: Shutterstock, PTTX

solution provider, with products including

global high-end low-carbon electrical steel and
materials, large ultra-high voltage electrical
Figure 4. Magnetization characteristic
transmission and distribution equipment, and curve of 0.18 mm thin-gauge grain-oriented
smart international logistics services. silicon steel.
72 EXPERT OPINION:
SILICON STEEL IN
TRANSFORMER CORES

Figure 5. Excitation power curve of 0.18 mm

thin-gauge grain-oriented silicon steel.

The
Thecomplex
complex
mechanism
mechanism
of
ofcore
coreloss
loss
isisrelated
relatedto
to
the
thespecific
specific
total
totalloss,
loss,core
core
structure,
structure,and
and
manufacturing
manufacturing
process.
process.

Figure 6. Magnetic domain morphology of 0.18 mm

Specific Total Loss
thin-gauge grain-oriented silicon steel.
Specific total loss is one of the most
important electromagnetic properties
of grain-oriented silicon steel and
a major indicator of product
performance. The specific total loss
can be significantly reduced by laser
scribing tech-nology [3]. As shown
in Figure 3, the specific total loss
(P1.7/50 ) of the 0.18 mm thin-gauge
grain-oriented silicon steel after laser
scribing is less than 0.75 W/kg under
a magnetic flux density of 1.7 T and a
frequency of 50 Hz. The value achieves
a high grade. The low specific total
Figure 7. Core loss tests of 50MVA type core at 50 Hz.
loss means that the 0.18 mm thin-
gauge product will have a large market
potential and advantage.

Magnetization Characteristic Curve

The magnetization characteristic curve

reflects the magnetic flux density
(B) as a function of magnetic field
intensity (H), which corresponds to
the magnetizability of grain-oriented
silicon steel. Figure 4 shows the
magnetization characteristic curve of
Photo: Shutterstock, PTTX

the 0.18 mm thin-gauge grain-oriented

silicon steel under direct-current
conditions. When the magnetic flux
Figure 8. Iron loss curve of 0.18 mm thin-gauge density is 1.7 T, the required magnetic
grain-oriented silicon steel. field intensity is 139 A/m.
Transformer Technology March 2023 73

Issue 27

Excitation Power Curve

The excitation power (Ss) vs. the

magnetic flux density (B) can
reflect the magnetizing current of
the transformer core under various
excitation conditions. It is worth noting
that the excitation power should be
considered during transformer design.
Figure 5 shows the excitation power
curve of the 0.18 mm thin-gauge
grain-oriented silicon steel under
a frequency of 50 Hz. The required
excitation power is 2.48 VA/kg under
the magnetic flux density of 1.7 T.

Magnetic Domain Morphology

The magnetic domain morphology

of grain-oriented silicon steel is
closely related to the specific total
loss and the magnetostriction [4].
A clear and regular domain was
observed in the 0.18 mm thin-gauge
grain-oriented silicon steel after
laser scribing, as shown in Figure 6.
Besides, the direction of the magnetic
domain is almost parallel to the
rolling direction and the spacing of
the domains is also small. Therefore,
there is good agreement between the
regular magnetic domain morphology
and the low specific total loss
(P1.7/50 <0.75 W/kg).
74 EXPERT OPINION:
SILICON STEEL IN
TRANSFORMER CORES

Transformer Core Loss

The transformer core acts as

the application product of grain-
oriented silicon steel, and its
service performance can reflect the
electromagnetic properties of grain-
oriented silicon steel. The core loss
is the ineffective electrical energy
consumed by the core when it is
magnetized under an alternating
magnetic field of ≥50 Hz. The larger
the core loss, the greater the electrical
energy lost by the transformer. In
addition, the energy efficiency level of
the transformer is mainly determined
by the core loss.

Figure 7 shows a 50MVA type core

manufactured by the 0.18 mm thin-
gauge grain-oriented silicon steel
and its core loss was tested at a
frequency of 50 Hz. Then, the iron
loss was calculated by equation:
PT
P0 = ––––
(k.m)
where P0 is the iron loss with a unit of
W/kg, PT is the core loss with a unit of
W, k is the technological coefficient of
core, m is the core weight with a unit
of kg. The relationship curve of the
iron loss vs. the magnetic flux density
was obtained, as shown in Figure 8.
Specifically, when the magnetic flux
density is 1.7 T, the iron loss is 0.73
W/kg, reaching a high grade.

Generally, the core loss (PT ) consists

of hysteresis loss (Ph ), eddy current
loss (Pe ), and anomalous loss (Pa )
three parts. It is worth noting that the
complex mechanism of core loss is
related to the specific total loss, core
structure, and manufacturing process
[5]. Especially for the thin-gauge and
high-grade grain-oriented silicon steel,
the process of manufacture and the
mechanism of core loss are more
complex. Therefore, the electromagnetic
properties of grain-oriented silicon
steel should be further optimized to
effectively reduce the core loss.

According to the above analysis, the

iron loss (P1.7/50 ) of the 0.18 mm thin-
gauge grain-oriented silicon steel
reaches a high-grade level with the
value less than 0.75 W/kg. Therefore,
Photo: Shutterstock

the thickness thinning for the reduction

of iron loss has a positive effect and an
important significance.
Transformer Technology March 2023 75

Issue 27

Prospect of Transformer
Energy-saving

With the rapid development of

global technology, low carbon
environmental protection and
sustainable development have
become the social focus. Therefore,
it is crucial to save energy and
reduce emission. The development
of thin-gauge and high-grade grain-
oriented silicon steel products through
thickness thinning can reduce the
iron loss and improve the energy
efficiency level of transformer, thus
saving energy [2]. It has been proved [3] M.R. Jahangiri, H. Bayani, M.
that the high-efficient transformer Ardestani, M. Mehdizadeh.
made of high-grade grain-oriented Core loss reduction in grain
silicon steel can reduce the carbon oriented silicon steel sheets
emissions by 13~18% under 50% by two-sided laser scribing in
load [6]. The product of 0.18 mm the presence of a magnetic
thin-gauge grain-oriented silicon field [J]. Journal of Alloys
steel shows a remarkable thickness References and Compounds, 2022, 891:
uniformity, ensuring the safety of [1] Guang Ma, Ling Cheng, Licheng 162080.
the core laminations. The low iron Lu, Fuyao Yang, Xin Chen, [4] R. Schäfer, I. Soldatov, S. Arai.
loss decreases the temperature rise Chengzhi Zhu. Effects of DC Power frequency domain
of the transformer during service, bias on magnetic performance imaging on Goss-textured
thus significantly improving the of high grades grain-oriented electrical steel [J]. Journal
operation stability. In addition, the silicon steels [J]. Journal of of Magnetism and Magnetic
thin-gauge product also reduces Magnetism and Magnetic Materials, 2019, 474: 221.
magnetostriction and transformer Materials, 2017, 426: 575-579. [5] Hao Tang, Yuzhou Qiu, Shuqi
noise. Therefore, the application of [2] Ling Cheng, Fuyao Yang, Zhang, Jinzhong Li, Yu Tian, Yu
0.18 mm thin-gauge product in cores Guang Ma, Xin Chen, Wenkang Chen. Exciting characteristics
can improve the comprehensive Zhang, Zhiguang Cheng. of high magnetic induction
performance and energy efficiency Development and application of grain-oriented silicon steel
level of transformers, thus achieving high magnetic induction grain- for UHV transformer [J]. High
energy saving and emission reduction. oriented silicon steel for power Voltage Engineering, 2018,
transformer [J]. Materials 44(03): 959-967.
Conclusion Reports, 2014, 28(11): 115-118. [6] Hai-zhen Liu, Jun Chen, San-lin
Gu, Xiao-wei Zhao, Jun-ping
The mentioned 0.18 mm thin-gauge Liu, Yi Xia, Ji-cheng Yang.
grain-oriented silicon steel shows Procurement strategy of energy
a remarkable thickness uniformity, efficiency transformer under
ensuring the surface quality of the "carbon perspective" [J]. Value
product. After laser scribing, the Engineering, 2022, 41(27):
product shows a homogeneous 30-32.
magnetic domain morphology,
inducing an excellent electromagnetic
property. Such excellent properties
can promote the structural
optimization of transformer cores,
thus reducing core loss. In addition,
the iron loss (P1.7/50) of the 0.18 mm
thin-gauge grain-oriented silicon steel
applied to a large-power transformer
core is 0.73 W/kg, reaching a high
grade. The application of this product
in cores can effectively improve
the comprehensive performance
and energy efficiency level of
transformers, thus saving energy and
reducing carbon emissions.
76 DGA MONITORING
CASE STUDIES

Saving the Day:

On-line DGA Monitoring
Case Studies
by Emilio Morales

When I first met Emilio Morales, it was Now more than ever we need people
at a Comet Conference workshop and like Emilio to share their decades
he was presenting on Transformer of experience as we deal with so
Maintenance and Reliability. much change in the power industry
Comet, sponsored by Qualitrol, was Dealing with the addition of so many
always one of my favorite industry new “green generation” projects
conferences. I was very impressed being added to an aging grid, making
with his understanding and the depth interoperability and interconnection
of his wisdom on the topic. It was that much more important and
also the beginning of a friendship that challenging. Thank you Emilio, for
reminds me why I love this industry your willingness to share with our
so much; professionals like Emilio community as we deal with these
are graciously willing to share their challenges. Enjoy everyone!
knowledge, understanding and insight
on things that advance the cause of Alan Ross, Technical Director
transformer safety and reliability. and Managing Editor, APC Media
 Transformer Technology March 2023 77

Issue 27

On-line DGA have the unique ability

to continuously trend transformer
fault gases and correlate them
with other key parameters such as
transformer load, oil and ambient
Emilio Morales attended Nuevo Leon State temperatures, as well as customer
University in Mexico, receiving his bachelor’s specified sensor inputs. This
degree in Electromechanical Engineering capability enables users to relate
in 1980. He has over 30 years of experience gassing to external events, a key to
determine the existence or type of
Figure 1. in power transformer
Product of 0.18 mm design which includes
thin-gauge
transformers
grain-oriented siliconupsteel
to 500(18PTD075).
MVA and 500 kV, fur- a fault. A study has also shown that
nace and rectifier transformers and reactors. some on-line DGA tools offer better
He is member of the IEEE/PES Transformer accuracy and repeatability than
Committee, IEC and CIGRE. He previously laboratory DGA. Specifically, those
worked with GE-Prolec, Ohio Transformer, with on-board automated calibration
Sunbelt Transformer and Efacec. He joined verification that ensures performance
Qualitrol in June 2012 as a Technical Appli- to specification throughout the entire
cation Specialist in transformer applications. operating life of the monitor. This
His focus is to support solutions in compre- can improve the transformer asset
hensive monitoring for transformer applica- manager’s decision timeliness and
tions. confidence when incipient faults
are detected.

The ability to automatically populate

traditional DGA diagnostic tools with
on-line DGA data offers users of
on-line DGA monitors unprecedented
insight into the nature and
identification of developing faults.
The tools are typically ratio-based,
and the on-line data set enables
trending of fault gas ratios over time
rather than the traditional static
snapshots. Diagnostic outcomes can
now be determined quickly and with
more certainty than in the past. The
use of on-line DGA monitoring has
allowed the detection of developing
faults in transformers in a timely
manner. On-line DGA monitoring
has produced multiple case studies
that document the development of
critical faults, which could cause
catastrophic transformer failure if
left undetected, in timeframes from
a few days to a few weeks, where
there was a low probability of
capturing these rapidly developing
fault conditions with a laboratory or
portable-based transformer DGA
testing program. This article presents
some of those cases.

I
Photo: Shutterstock

The use of on-line DGA monitoring has allowed the detection

of developing faults in transformers in a timely manner.
78 DGA MONITORING

Case 1:
CASE STUDIES

It’s important to measure Oxygen in DGA

BACKGROUND
An 8 gas monitor is monitoring O2 can facilitate oxidation in the N2 pressure does not prevent
an old (30+ years) 3-phase 230kV transformer and thus shorten the entrance of water — only a good
shell-form nitrogen (N2 ) blanketed life of the paper. However, the big gasket seal does.
GSU. At midday on Nov 16th, the concern with a transformer sucking
monitor alarmed for increasing atmospheric air in is that inevitably, NOTE
concentration of Oxygen (O2 ), which it also brings moisture into the While this incident occurred on a N2
had been stable at 130ppm for an transformer. blanketed transformer the same vacuum
conditions can occur within an operational
extended period. Over the course of
constant oil preservation system (COPS)
the following 3 days O2 concentration While none of the modern diagnosis transformer. This can occur during cool-down if
continued to increase, peaking at methods explained this sudden breather piping to the atmospheric is too narrow
2,150ppm before gradually declining increase in O2 it was possible to or is restricted and air cannot enter fast enough
back to a stable 200ppm. detect this incident with online DGA, to avoid a vacuum in the main tank. A vacuum
deduce the cause and implement can then suck air past a gasket that does not
Reviewing the data around the corrective action. If O2 was not show an oil leak. Another obscure fact is that
degassed oil is effectively a vacuum to the
time of the sudden increase in O2 monitored this process could have atmosphere and in a sealed system can create a
concentrations using proprietary occurred many times over without vacuum in the gas phase. It’s important
data management system, no fault being detected, drawing a lot of to give the oil time to reach equilibrium with the
is detected using any of the moisture into the transformer. N2 blanket to avoid this situation.
established diagnostic methods.

OUTCOME
The sudden O2 increase, with no
associated change in any other gas
indicated that the O2 originated from
the atmosphere. The supporting
vendor experts suggested that Nov 16th, 2017
the transformer may have had @ 12:00pmA
sudden and
an atmospheric air injection and dramatic increase
requested the operator to investigate. in O2 begins.
No other gases
Upon a physical examination of the show any
transformer, it was noticed that there meaningful
was a leaky manhole cover gasket change. O2 peaks
at 2150ppm a
and that the pressure of the nitrogen few days later
blanket was close to atmosphere. before gradually
declining.
It was determined that a partial
vacuum occurred in the transformer
during a cool down that resulted in
atmospheric air being sucked into
the transformer.

I N2 pressure does not prevent entrance of water — only a good

gasket seal does.

Case 2:
BACKGROUND
Hour by hour changes catch a developing fault

Once again an 8-gas monitor is

used on a single-phase 336 MVA,
elevated but stable for several
months. Over the next 5 days the
transformer had been heavily loaded
at the time and that increasing load
500/230 kV autotransformer. The operator kept the transformer correlated well with increasing gas
transformer was placed into service under load for operational purposes production. Reviewing the DGA
in 1979. This transformer is known and carefully monitored all gases. data, Duval Triangle 1 indicated
to have gassed in the past and base When Acetylene (C2H2) climbed to High temperature overheating while
levels of hydrocarbons are as high as an actionable level (10ppm) the Triangle 5 indicated Medium
100ppm. At 1:00am on June 23rd, the transformer was taken off load. to High temperature hot spots.
monitor alarmed for Rate of Change
increases in concentration Reviewing the load data around the However, this diagnosis would have
of Ethylene(C2H6) and Methane time of the increasing gas generation been the same before the exponential
(CH4) both of which had been rate it was observed that the increase in gases occurred as can also
Transformer Technology March 2023 79

Issue 27

be seen from the Duval diagnosis. but was needed for operational hour-by-hour basis. This transformer
The key to managing this situation purposes. Despite its known issues will continue to be available as a
was that the user could see the gas it was used safely because its spare together with online DGA until
levels increasing dramatically over gassing could be monitored on an it can be replaced.
a very short period of time and knew
when to take the transformer offline
before runaway conditions developed.
This is something that periodic
offline testing would not provide for.

OUTCOME
The transformer was taken to a repair June 23rd, @
shop where maintenance personnel 9:00pm. Ethylene
& Methane start
found carbon deposits in damaged to increase
insulation that is used to isolate exponentially.
Carbon Dioxide
the core and coil assembly form and Hydrogen
the tank. Repairs were undertaken concentrations
and the transformer was put back climb. Acetylene
increases slowly
into service. Despite the repairs but surely from
the transformer continues to gas 0ppm up to
12ppm.
at a slow rate and is scheduled for
replacement over the next few years.

In this case the transformer was

known to have gassing issues

Figure 1: TRIANGLE 1. Thermal Fault >700°C Figure 2: TRIANGLE 5 Hot Spots T2/T3 in oil

Case 3:
BACKGROUND
An 8-gas DGA monitor was
being used to monitor a 3-phase,
Runaway fault detected by 8-gas monitor
resulting in action to prevent a catastrophic failure

the fault was not manageable by

managing load.
before this gas generation event
occurred would have indicated the
1100 MVA, 345 kV GSU transformer. same diagnosis it was the rapid
While gas concentration for all gases Reviewing the DGA data resulted in change in gas concentration, as
were relatively high and stable there the following indications at the point alarmed by the Rate of Change
was a sudden exponential increase in time when the transformer load alarming function in the monitor
on Aug 28th, 2016, at midday. was reduced to Zero. that drove the reduction in load and
While not recorded in the chart the eventual full shedding of load.
transformer load was reduced by All diagnosis systems point to a
50% after 48 hours of gassing and thermal fault >300°C with some OUTCOME
was reduced to zero load 8 hours suggestion that there was paper Upon physical inspection it was
later when it became obvious that involved. While the ratios of gases revealed that localized burning of
80 DGA MONITORING
CASE STUDIES

Diagnostic System Result

Duval Tringle 1 Thermal Faults [300°C < T < 700°C]

Duval Triangle 5 Border of Hot Spots in Paper and Hot Spots in oil

Duval Pentagon 1 Thermal Faults [300°C < T < 700°C]

Duval Pentagon 2 Thermal Fault with carbonisation

TOAN Overheated Oil: Immediate attention required, consider removal from service. (See Figure 2)

IEC 60599 Condition 2: Thermal Faults [300°C < T < 700°C]

Doernenburg Ratios Thermal Faults [300°C < T < 700°C]

IEEE C57.104-2008 Condition 4. Immediate action required

paper had occurred. With paper notified to the user by a “rate of this detailed insight that allowed
stripped back from the crimped ends change” alarm on the monitor. Only the transformer operator to take
of the LV connection there was Online DGA would provide this level the transformer offline before a
evidence of hot metal damage. of resolution in data, and it was catastrophic even occurred.
Thus, it was concluded this was the
site of the gas production.

The conclusion in this case was that

the root cause was a combination
of high eddy losses in the crimps,
overheating because of over-
insulation of the LV crimped Aug 28th there
was a sudden
connections and poor oil circulation in and exponential
the crimped bundle areas. Remedial increase in all the
work was undertaken, and the hydrocarbon gases
and Hydrogen.
transformer was subsequently put Also, an increase
back into service. in the CO2 and CO
was observed.

In this case the transformer was

known to have had historic gassing
issues but was stable. After a period
under full load the transformer
suddenly started to produce large
increase in gases which was

Figure 3: TRIANGLE 1. Thermal Fault 300°C – 700°C Figure 4: Rodgers Ratio indicating condition
T3: Thermal Fault 300°C – 700°C

I On-line DGA undoubtedly saves another transformer from

Photo: Qualitrol

catastrophic failure.
Transformer Technology March 2023 81

Case 4:
Issue 27

Gradual increase
in gases detect a transformer design flaw
BACKGROUND
An 8-gas monitor was monitoring a Monoxide. Unsure as to the nature Table below represents Results of
three-phase 700 MVA, 400kV GSU of where and when these gases reviewing the DGA data on a range
transformer at a power plant in North were being generated, a monitor was of common diagnostic systems.
America. This online DGA monitor was employed to provide hour by hour This is all performed automatically.
installed when the operator noticed tracking of gas generation (Figure 5). All diagnosis systems pointed to
year-over-year DGA lab data indicating Reviewing the DGA data with vendor a thermal fault >300°C with some
increased levels of hot metal gases software resulted in the following fault suggestion that there was paper
and a sustained growth in Carbon indications. involved in the fault.

Diagnostic System Result

Duval Tringle 1 Thermal Faults [300°C < T < 700°C]

Duval Triangle 5 Hot Spots in Paper >300oC

Duval Pentagon 1 Thermal Faults [300°C < T < 700°C]

Duval Pentagon 2 Thermal Fault with carbonisation

TOAN Overheated Oil: Immediate attention required, consider removal from service. (See Figure 2)

IEC 60599 Condition 2: Thermal Faults [300°C < T < 700°C]

Doernenburg Ratios Thermal Faults [300°C < T < 700°C]

IEEE C57.104-2008 Condition 4. Immediate action required

OUTCOME
I DGA lab data indicating increased levels of hot metal gases
and a sustained growth in Carbon Monoxide.
Physical inspection revealed evidence (C2H6)) there was also charred / The four cases above show that
of significant overheating at the site burned paper which would have On-line DGA provides the capabilities
of a brazed connection at the bottom created CO and CO2. to track gradual increases in gases,
end of the LV winding lead (Figure 6). facilitating predictive maintenance
This transformer was repaired, of an expensive and critical assets,
In addition to the discoloration of together with appropriate design and identify incremental changes in
the metal associated with changes, the leads were retaped where important gases in the presence of high
overheating (the source of the ethane the paper was significantly damaged accumulated PPMs of gases, which
(C2H6), methane (CH4) and ethylene and put back into service. it is not possible with periodic lab DGA.

Figure 5. A gradual climb in 6 key gases was noted. There was Figure 6: Overheated brazed connections
no acetylene (C2H2), meaning this fault had not yet advanced at the bottom end of the LV winding lead.
to include any arching. The continuously increasing gas levels
were a significant concern.

Dates, times, and other details may have been changed to maintain the anonymity of the owner / operator in these case studies.
All DGA data, timelines and technical specification are factually accurate.
82 EXPERT OPINION:
THE COST OF ONLINE
MONITORING

Although multi-gas DGA monitors

have become more reliable than they
were 10 or 15 years ago, they are still
complex machines that are installed
outdoors in electric substations where
they are subjected to all the elements
weather forecasters have to offer.

Online
Transformer Data
Comes at a Price
 Transformer Technology March 2023 83

Issue 27

In a data-driven world where

transformer owners want to have
as much data as possible from their
transformers, they start by monitoring
the top oil temperature, winding
temperature, pressure relief device,
liquid level, tank pressure, sudden
pressure, and various load
tap changer (LTC) data.

When transformers fail without Leon White is Vice President of Transformer

warning, they realize that more data Sales and Business Development at H2scan.
is necessary. They then investigate A 15-year industry veteran, White joined
single and multi-gas online dissolved H2scan from Qualitrol and previously worked
gas analysis (DGA), partial discharge, at General Electric. White began his career as
bushing monitoring, acoustic a substation design engineer at Ameren, an
vibration, etc. Then they build asset electric utility. White has electrical engineer-
health centers and hire data scientists ing and MBA degrees from Southern Illinois
to manage the vast amount of data University at Edwardsville and is a registered
they didn’t realize would be such a professional engineer (P.E).
monumental task to manage.

There must be a better way.

Large utilities on the bleeding edge of Although multi-gas DGA

technology have found that all of this monitors have become more
data comes at a price. While many reliable than they were 10 or 15
monitors do not interface directly with years ago, they are still complex
transformer fluids, the online DGA machines that are installed
monitor must measure gases either outdoors in electric substations
directly in the fluid, or extract gases where they are subjected
from the fluid for measurement after to all the elements weather
extraction. forecasters have to offer.

by Leon White Vice President

Photo: Shutterstock

Transformer Sales and Business Development

H2scan
84 EXPERT
TOPIC OPINION:
THE COST OF ONLINE
MISSING
MONITORING

Utilities need affordable solutions

that can be installed fleet-wide that
can alert them to internal transformer
faults prior to failure so potential
failures can be managed during
the regular workday rather than on
overtime.

In addition, they must survive ground warranty expires? Due to limited What Have Utilities Learned from
faults, corona, electro-magnetic flux, maintenance budgets, most utilities Their Online Data?
vibration, corrosive compounds in are unable to keep their multi-gas
the oil, etc. Data scientists love data monitors running after the warranty Many utilities are frustrated because
from multi-gas monitors because expires. Therefore, after 10-20% of they spend more time installing,
they get a better idea of the real-time the transformer’s life, the utility is commissioning, and maintaining their
health of the asset. Unfortunately, back to relying on annual data from multi-gas monitors than they spend
the reality is that most multi-gas manual samples. Some utilities are actually fixing problems on their
monitors of any type are prone to now getting 10 year warranties on transformers. This means that they are
some type of failure within 2-5 years their monitors. While this extends the starting to understand that using low-
after installation. life of their monitors, does the cost of cost, reliable single-gas sensors that
the monitor and warranty outweigh last 10+ years makes more sense than
While a 5 year warranty sounds like other options that could alert utilities trying to equip every large transformer
a good plan, what happens after the to more transformer failures? with a high-end monitoring solution.
 Transformer Technology March 2023 85

Issue 27

Large monitoring systems may

be justified for critical or sick
transformers, but, today, most
utilities spend too much time and
effort getting their large monitoring
systems installed, commissioned
and maintained, when 90% of their
fleet has no online monitoring. With
an average transformer failure rate
of roughly 1% annually, utilities need
affordable solutions that can be
installed fleet-wide that can alert
them to internal transformer faults
prior to failure so potential failures
can be managed during the regular
workday rather than on overtime.

In a world where people have less

resources and more to get done
every day, utilities need valuable,
reliable and maintenance-free
devices to alert them to problems
with their transformers. It’s time for
utilities to take a step back and look
at which data is most useful. They
need to look at how they will get
the most bang for their buck in the
future.
Photo: Shutterstock
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transformer-technology.com
 COMING
IN MAY

ADVANCED
TRANSFORMER
TESTING AND
TECHNOLOGIES
From green steel in transformers to new ways of manu-
facturing transformers, and to the liquids we use for insu-
lation, we are excited to bring you a combined April and
May issue. With so much change taking place, it is exciting
to see how even little changes will make a big difference
in the long run.

We have had our issues, and still have, with supply chains
for transformer components, but most manufacturers are
addressing this issue in unique ways, not so much with
revolutionary changes, but with evolutionary changes.
While there are a good number of articles and interviews
already committed, there is still time for you to add your
voice. Contact me at [email protected] to add your
article or interview.
Alan Ross
Technical Director and Managing Editor, APC Media

COMING IN MAY ISSUE

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