TXpert™ ecosystem

Transformer asset management solutions overview

2022-03-01
2021-10-22 © Hitachi Energy 2021. All rights reserved.
 TXpert™ ecosystem topics
Transformer asset management
Monitoring and diagnostics with TXpert™ Hub
TXpert™ ready sensors
TXpert™ solutions for DGA - CoreSense
TXpert™ BM solutions for bushing monitoring
TXpert™ asset management software – APM EDGE
TXpert™ services

2 © Hitachi Energy 2021. All rights reserved.

Grid of the future – an evolutionary vision

Today Tomorrow

Increasing complexity of the grid will impact transformers in new ways, for example:

Integration of renewables leads to reverse Increasingly overloaded based on Dynamic load profiles and increasing risk
and dynamic power flows generation mix of outages

Amplified need for data-driven decisions to meet new challenges

3 © Hitachi Energy 2021. All rights reserved.

Enhancing efficiency

​USD 80 billion per year or 5% of annual power generation costs

​Power systems overall savings from digitalization, enabled by:
- Reducing operations and maintenance costs
- Improving power plant and network efficiency
- Reducing unplanned outages and downtime
- Extending the operational lifetime of assets

4 © Hitachi Energy 2021. All rights reserved.

From IEA Digitalisation and Energy
External stresses may affect transformer life expectances

Transformer lifecycle
Stress

Ideal transformer resiliency curve

Extreme Real transformer resiliency curve
weather event Electrical stress
System fault
Emergency
overloading
Increased
harmonics

Switching event

Unplanned
Operational outage Planned
stress end of life

Time

Unplanned outages are costly and result in significant downtime. With proper monitoring, they can be avoided.

5 © Hitachi Energy 2021. All rights reserved.

Transformer failure mode analysis

Failure location analysis – manufactured after 1980 Failure mode analysis – based on 964 failures

Core and magnetic circuit Cooling unit

2.63% 1.46% Unknown ; 12.66%

Bushings
18.13% Tap Changer
Tank 30.70%
Flux Shints 1.17%
0.88%
Mechanical ; 20.02% Dielectric; 36.62%

Insulation
2.34%

Lead Exit CT
5.56% 0.29%
Physical Chemistry;
3.32%

Winding Thermal; 10.89% Electrical; 16.49%

36.84%

Monitoring the windings, bushings and tap changer covers 80% of transformer failures

6 © Hitachi Energy 2021. All rights reserved. Source: Cigré SCA2.37 Report Technical Brochure 642/2015 Transformer Reliability Survey
Reliability-centered maintenance – evolutionary approach to maintenance

Time based maintenance Condition based maintenance Reliability centered maintenance

​Maintenance actions are planned according to ​Maintenance actions are planned according ​Maintenance actions are planned according to
time intervals recommended by the OEM, to the actual measured condition/health of the risk profile of critical components.
even if they are not really needed critical components ​Risk profile depends on component health
​Component criticality and impact of failure are and its impact on substation availability.
not considered during planning. ​Failure Mode and Analysis Method is used to
assess the impact on substation availability.

7 © Hitachi Energy 2021. All rights reserved.

TXpert applications

​01.
Sensor readings
​Monitor discrete parameters, alarm on unusual value value proposition: avoid unplanned outage due to
​Monitoring of pressure, ​Example application: Monitor oil level to detect oil leaks low oil, avoid environmental cost of oil spill
level, temperature

​02.
Thermal ​Monitor oil temperature, air temperature and load Value proposition: Allow for real time evaluation of
​Application: calculate and track hot spot, use hot spot to load/overload potential
​Monitor top oil, ​determine allowable load in real time, use hot spot to evaluate Allow asset life extension based on aging data
ambient, load ​paper aging (humidity can improve accuracy), use humidity Detect abnormal behavior before fault occurrence
​to determine bubbling temperature
​Optional: humidity

​03.
Cooling ​Monitor correct operation of cooling banks Value proposition: Reduced temperature
​Control cooling banks on/off or variable speed fluctuation reduces stress and extends life
​Use thermal data for ​Exercise coolers to avoid underuse damage Optimize lifetime of cooling system
cooling control Detect abnormal behavior before fault occurrence

​04.
Gas in oil ​Monitor dissolved gases and moisture in oil in real time Value proposition: Fault avoidance, asset life
​Application: Determine if thermal fault, partial discharge, high extension, real time nursing and optimal operation
​Monitor dissolved gases ​energy discharge, accelerated insulation aging or tank leakage
and humidity in oil ​are occurring

​05.
Bushing condition ​Monitor bushing tap leakage current and phase Value proposition: Fault avoidance, asset life
​Application: Determine if bushing insulator is extension
​Monitor bushing tap ​degrading, detect partial discharge activity
leakage current

8
​06. Tap charger condition ​Monitor tap position, temperature
​Monitor tap changer
© Hitachi Energy 2021. All rights reserved.
​Application: Determine contact wear,
​Correct operation of diverter
Value proposition: Fault avoidance, asset life
extension, Preventive maintenance optimization
Introducing the TXpert™ Ecosystem

TXpert™ Hub
Integrated Transformer Monitor Lumada APM
Asset Performance Management
CoreTec™ 4 Edge | On-premise | Cloud
Data aggregator

CoreTec™ 5
Data aggregator

Optimize
Automate Simulate
Control Predict
Secure Automate

TXpert Ready TXpert Services

Sensors
Transformer Care
CoreSense Assess Service Agreements
DGA – Single Gas Connect Advice
Store Transform
Re-think TXpert OnDemand
CoreSense M10 Inform
Device hire
DGA – Multi-Gas
And more…
TXpert BM
Bushing monitoring
The Digital
And more… TXpert™ Ecosystem

© Hitachi Energy 2021. All rights reserved.

Evolving the technology, retaining our expertise

2001
TEC 2009
Transformer Electronic TEC 2.2 2018
Control (TEC) introduced to Improved version of the 2022
enable condition monitoring. original TEC. CoreTec 4 TXpert Hub
It build on early pioneering Customizable and digitally
experience from the field. improved, it was launched together CoreTec 5
with the first digitally native TXpert
Enabled Power Transformer
TX Building on the CoreTec 4
best-in-class software and
new hardware to
accommodate cyber
security and retrofitability
requirements for distribution

2019
TXpert DRY
World’s first dry-type digital
transformer offered for
greenfield only

2017
TXpert Distribution
World’s first digital
distribution transformer
offered for greenfield only

© Hitachi Energy 2021. All rights reserved.

TXpert™ Ecosystem and its components

Power or TXpert™ TXpert™ TXpert™

TXpert™ Transforming
Distribution Ready Enabled Services & APM
Hub performance
Transformer Sensors Transformer

Open, Scalable, Manufacturer agnostic

− TXpert™ Enabled Transformer is any transformer from

any manufacturer equipped with the TXpert Hub and
TXpert Ready devices.

− Transformers can come with built in capabilities from

the factory or existing installed transformers can be
upgraded with the technology.

− Available for power, liquid-filled distribution and dry-type

transformers

11 © Hitachi Energy 2021. All rights reserved.

TXpert Hub : Tailored to transformer type - application specific algorithms

Power Distribution Oil Distribution Dry

TXpert Hub TXpert Hub TXpert Hub

Touchscreen Sensors Power Quality Sensors Power Quality Sensors

Bushing Module Relays Self Power Relays Self Power Relays
OLTC Module Fan control
Fans Fans
FO Module
IO Module
Power Qaulity
© Hitachi Energy 2021. All rights reserved. Proprietary and confidential
TXpert™: transforming performance

TXpert BM

​The top three locations of faults bushing tap

adapters

in transformers are its windings,

tap-changers and bushings1)
TXpert BM
bushing tap adapter

​The TXpert Ecosystem provides

options to mitigate all of these.
For example:
− Failure of bushings can lead
to transformer tank rupture
and explosions
− This can result in millions of
dollars in repairs and
CoreTec 4
Transformer
monitoring system TXpert BM TXpert BM TXpert BM

settlement costs
CoreTec 5 Sensor Sensor Sensor
Transformer monitoring
TXpert BM
system
Bushing monitoring

−
APM Edge system
The cost of replacing a high-
CoreSense M10
Asset performance monitoring Multigas sensor

voltage bushing is a few

percentage points of this
Tap Changer
With monitoring
connection

Powering informed decisions

13 © Hitachi Energy 2021. All rights reserved. 1)Transformer reliability survey, CIGRE Working Group A2.37, 2015
CoreTec™ 4 – Transformer Monitoring Platform

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CoreTec™ 5 – New more flexible platform

Analog 1 4x RTD or Thermocouple,

Inputs 2 4x 4-20mA

Digital 3 4x Digital Inputs

Inputs
Relays 4 5x Relay (10A) 6
5
Status LEDs,
5 LCD Display,
HMI Touch Screen through
6 8 3
HDMI 2 1
7
IN: Modbus RTU
8 2x RS485
OUT: DNP3
IN: Modbus TCP,
9 2x Ethernet
Comms. 1x Fiber ST (optional)
OPCUA
10 OUT: Modbus TCP,
11 Wi-Fi
DNP3, IEC61850,
Cellular
12 IEC60870-104, MQTT
Time sync GPS
13
2GB RAM / 8GB Storage
SD Removable Storage
Memory 14
(Optional Memory
Expansion) 9 18 7 14 17 12
110-240V AC and/or
15 24VDC, 16 4
Power 16 Self-powered up to 500V 10 11
(optional module)
13
Reset ● 15
17
Update 2x USB
18 IP21 (IP67 requires
Rating cabinet)

15 © Hitachi Energy 2021. All rights reserved.

TXpert™ Enabled Transformer

New transformers
The TXpert Hub and its
accessories are mounted
inside the control cabinets
of new transformers.

Existing transformers
The TXpert Hub and its

+
accessories are mounted
inside a standard retrofit
cabinet.

© Hitachi Energy 2021. All rights reserved. Proprietary and confidential

TXpert™ Hub : CoreTec™ 5 transformer monitoring platform

– Data aggregation and expansion

– Alarm watch and safety devices monitoring
– Transformer accessories
– Thermal and electrical data
– Aging calculations with thermal and load analysis
– Power quality, analysis, harmonic distortion
– Cooling control (Oil filled and dry type)
– DGA integration and analysis
– Bushing monitoring
– Tap changer monitoring
– Uplink connectivity using IEC61850
– Cybersecurity

17 © Hitachi Energy 2021. All rights reserved.

Thermal analysis – Winding hot spot

. .

Transformer heat dissipation Thermal diagram

EC 60076-7:2005, Power transformers – Part 7: Loading guide for oil-immersed transformers

18 © Hitachi Energy 2021. All rights reserved.
Insulation aging and degree of polymerization

. .

Accelerated aging in mineral oil DP degradation

Degree of Polymerization (DP)

​Δ Thermally upgraded paper Time in hours (t)

​• Non thermally upgrade paper
​Accelerate aging in sealed tube of mineral oil at 150 ̊C for normal and
thermally upgraded paper.
​Paper starts around DP=1000 and end of life is around DP=200
Source: IEEE Std C57.91™-2011, IEEE Guide for Loading Mineral Oil-Immersed Transformers
19 © Hitachi Energy 2021. All rights reserved.
 Aging analysis

. .

Aging vs temperature and moisture Aging vs oxygen

30 years dry

10 years dry

1 year 4%, 90C

1 year 2%, 105C

The main variable that impact the life expectancy of the transformer ​Additionally, the amount of dissolved oxygen in the oil can also impact
insulations are temperature and moisture the life expectancy of the transformer to a lesser degree.
Monitoring and controlling these parameters can help significantly ​All things being equivalent, an increase in oxygen will have roughly 3
extend the life of transformer assets times less impact than temperature or moisture.
​Low oxygen is <6000ppm; medium is about 10000 and high 30000
Source: Ageing Rate of Paper Insulation used in Power Transformers; IEEE Transactions on Dielectrics and Electrical Insulation Vol. 19, No. 6; December 2012
20 © Hitachi Energy 2021. All rights reserved.
 Overload analysis

. . .

Nominal rating 500MVA Operator selected maximum 590MVA Smart loading – variable MVA
1.2 1.2

Loading (pu)
Loading (pu)
1.2
Loading (pu)

1.1 1.1
1.1
1 1
1
0.9 0.9
0.9
0.8 0.8
0.8 1000 2000 3000 4000 5000 6000 7000 8000
1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000

Ambient temperature (°C)

Ambient temperature (°C)
Ambient temperature (°C)

40 40
40
30 30
30
20 20
20
10 10
10
0 0
0
-10 -10 -10
1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000

Hot-spot temperature (°C)

Hot-spot temperature (°C)
Hot-spot temperature (°C)

140 140 140

120 120 120

100 100 100

80 80 80

60 60 60

40 40 40
1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000

15 15 15

Aging acceleration
Aging acceleration

Aging acceleration
10 10 10

5 5 5

0 0 0
1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000

​This transformer is loaded at 100% nominal ​Transformer now loaded at 120% of nominal ​Transformer load based on hot spot margin from
​Ambient temperature varies over time ​Ambient temperature is unchanged 110% to 140%

​Hot spot roughly tracks ambient temperature ​Hot spot continues to track ambient ​Ambient temperature is unchanged
under constant conditions, max design temperature, however due to the increased ​Load is modelled to keep hot spot temperature
temperature is never exceeded load the hot spot temperature will exceed max flat bellow the design limit.
​Aging is occurring at an acceptable under design limit during the hottest part of the day ​By monitoring the hot spot we can change the
these circumstances without significant ​For the same reason accelerated aging of up loading dynamically, keep aging in check and get
acceleration from nominal to 5 times is observed during the hottest part more actual energy through the transformer
of the day – this will significantly reduce the without reducing its life expectancy
useful life of the asset
21 © Hitachi Energy 2021. All rights reserved.
Latent fault detection

Industrial customer detects a latent fault

​Industrial plant installed online monitoring: DGA, temperature and load
monitors on its transformer.

​Operator detected an increase of dissolved gasses due to an increase

of oil temperature while constant load.

​The monitoring system allowed ABB experts to detect the blocking of a

OFWF heat exchanger due to a mineral buildup.

​The problem was corrected before any equipment was damaged thus
avoiding future outages and expensive repairs

© Hitachi Energy 2021. All rights reserved.

CoreTec™ 5 class leading user interface

The web interface provides a visually intuitive integrated dashboard for the vital signs of a transformer

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CoreTec™ 5 class leading user interface

Advanced trending and plotting capabilities for data analysis

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CoreTec™ 5 automated DGA analysis

Rogers ratios Duval triangles

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TXpert™ ready smart sensors - eDevices

​Benefits

Continuous online monitoring

Easy installation – no maintenance –

suitable for retrofitting conventional
non digital equivalents

Connectivity to TXpert Hub via

MODBUS RTU or 4-20mA

Cost effective transformer condition

monitoring

TXpert hub
monitoring
platform

26 © Hitachi Energy 2021. All rights reserved.

Self-dehydrating breather, eSDB

Moisture effect: ageing of the cellulose/oil insulation

Reference
IEC60076-22-8 (Draft)
Standard
Key features Benefits for the customer
- No silica gel visual inspection, replacement, disposal
Maintenance
- Full control of drying agent saturation status
Total cost of ownership reduction (no necessary to change
Cost
the silica gel for all transformer life)
Environment No environmental impact for silica-gel disposal
Dry air gets inside the conservator in any time (two tanks
Trafo reliability
that work alternatively)

27 © Hitachi Energy 2021. All rights reserved.

Basics of gas formation

Insulation in a transformer
​Dielectric Oil
​Cellulose (Paper)

​Purpose of the insulation:

– Dielectric Insulator
– Thermal Transfer Oil
(Mineral, ester, silicone)

​When the insulation system is stressed, gases are produced

and they will dissolve in the oil
Cellulose
​Gas-in-Oil is a very good incipient fault indicator (Paper, pressboard,
laminated wood)

28 © Hitachi Energy 2021. All rights reserved.

Chemical and physical processes for dissolved gas

The degradation of the oil molecule

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Chemical and physical processes for dissolved gas

The degradation of the cellulose chain

 One component of the transformer has a “NON-reversible life
characteristic”: the solid insulation (cellulose) that degrades
over time.

 Insulation system is designed to be compatible with life expectation for

loading during the life

 Several factors affect the life of the cellulose:

– Heat
– Paper moisture
– Oxygen content in oil

 All of this requires monitoring.

30 © Hitachi Energy 2021. All rights reserved.

CoreSense™ – hydrogen & moisture sensor

Engineered simplicity & robustness

Flag incipient faults

Hydrogen and moisture in oil are important indicators that can alert you to a
developing condition. These indicators will not give you a precise diagnostic of
the underlying condition, rather indication that something is happening in the
transformer.

No moving parts, no consumables

Robustness was a key design parameter during the product development
process. We eliminated weak points such as the membrane that separates
dissolved gas from oil and removed consumables. To ensure oil circulation we
implemented a forced convection thermal pump with no moving parts.

Universal oil support

DGA for mineral oils, ester fluids and silicon fluids supported with correct alarm
settings for each type of oil

31 © Hitachi Energy 2021. All rights reserved.

CoreSense™ – hydrogen & moisture sensor

Reliable design

Solid state in situ hydrogen sensor

- No gas separation membrane
- Capable of withstanding vacuum and overpressure
- Never requires maintenance or calibration
- Reading are insensitive to other gases or temperature variations

Solid state in situ moisture sensor

- Direct reading of moisture in oil
- Capable of withstanding vacuum and overpressure
- Never requires maintenance or calibration
- Readings are insensitive to temperature variations

Forced Convection
- Avoid stagnant oil and allow more representative sampling
- No need for a mechanical pump and associated maintenance
- Enables an extension from the tank up to 40 cm

32 © Hitachi Energy 2021. All rights reserved.

CoreSense™ M10 – Multigas Dissolved Gas Analyzer

ABB third generation multigas DGA technology - advantages

​Easy installation right out of the box
​Without any external oil circulation loop, installation is as easy as mounting the
measurement head on a valve and hanging the analytical unit on a wall, no need for
welding or piping at site. This approach also greatly limits the likelihood of any oil leaks
related to the DGA system installation

Fast response with continuous sampling

Oil is being sampled continuously with readouts every 10 minutes allowing for fast
response times. A gas increase in a transformer can be detected in as little as 10 minutes
and accurately quantified in under 2 hours.

​Lowest cost of ownership with no maintenance for 10 years

​Without any need for carrier gases or calibration, CoreSense™ M10 has double and
triple redundancies built in to allow the user to use the device for at least 10 years
without maintenance.

Space proven ABB FTIR technology

ABB used a technology sold for over 25 years in different industries (including for NASA,
the Canadian Space Agency, the European space agency and the Chinese Space
Agency) and re-adapted it for transformer monitoring. Allowing CoreSense™ M10 to
offer excellent measurement repeatability, no cross-interference between the gases and
no calibration ever in the field.

Universal oil support

DGA for mineral oils, ester fluids and silicon fluids supported with correct alarm
settings for each type of oil

33 © Hitachi Energy 2021. All rights reserved.

CoreSense™ M10 – Multigas Dissolved Gas Analyzer

Mobile Skid Advantages

- CoreSense™ M10 is easy to move between transformers.

- This enables selective nursing of sick transformers

- CoreSense™ M10 fast installation can be performed under an hour

with the mobile skid

- The mobile skid can be equipped with wireless connectivity

Mobile CoreSense™ M10 possible because of simple installation technology

34 © Hitachi Energy 2021. All rights reserved.

CoreSense™ M10 – Patented gas extraction system

Thermal convection ensures fresh oil is

continuously flowing into sensor head
Hydrogen and moisture measured in situ using
solid state sensors
Triple redundant gas pumping module for 10
years maintenance free operation
Dual redundant infrared source
Permanent calibration with semiconductor laser
based frequency reference

35 © Hitachi Energy 2021. All rights reserved.

Detecting bushing failures – the sum of currents

The sum of currents in a three-phase power system What happens in a bushing

​The principle of three phase power is that we have 3 conductors that ​In a bushing we can measure the leakage current at the diagnostics
are carrying voltage, current and power offset by 120̊ tap with a very simple circuit
HV

C1
Tap adaptor

Bushing
R1
C2
Voltage measurement
GND2

GND1

​We measure the voltage across R1 and determine current as I=V/R1

​If the 3 bushings have identical capacitance and tan δ the sum of the
currents ∑I = I(phase 1)+I(phase 2)+I(phase 3) will be 0
If for any given bushing tan δ varies it will cause a phase shift

If you add three phases together the sum is always 0 If for any given bushing C varies it will cause a change in amplitude

To monitor the bushings in a transformer we note the initial amplitude

of the sum of currents and look for any variations Δ∑I

36 © Hitachi Energy 2021. All rights reserved.

TXpert™ BM bushing monitoring solution

Sum of currents Voltage reference

TXpert BM acquisition IED

​- Includes CoreTec 4 and TX BM

​- Supports 3 or 6 bushings
​- Vector sum of current for three phases should be zero, non-zero sum ​- Includes CoreTec 4 and VR bushing sensor
indicates variation in tan δ : Δtan δ and capacitance: ΔC ​- Supports 1, 2 or 3 bushings
​- Applicable to one three phase or three single phase transformers ​- Voltage reference allows direct measurement of tan δ and C

37 © Hitachi Energy 2021. All rights reserved.

TXpert™ BM Electrical PD monitoring

Electrical PD ABB solution

​High frequency partial discharge pulses ​On the same electrical feed as the bushing monitoring system high
speed data acquisition is performed to identify partial discharge events
​FFT analysis allows to catalog the partial events and group them

38 © Hitachi Energy 2021. All rights reserved.

TXpert™ installations

TX BM tap adaptor
TX BM custom tap adaptor and TX BM sensor

TX BM Ambient temperature and humidity sensor

39 © Hitachi Energy 2021. All rights reserved.

Tap Changer monitoring

Oil temperature  Monitor relative temperature of main tank and tap

tap changer tank changer tank oil. Under normal operation tap changer
will not generate much heat and its oil will be heated
by contact with the main tank.
 Certain tap changer malfunctions could start injecting
significant energy into the tap changer compartment
and cause the tap changer oil to get really hot.

 This is a sure indication that the tap changer requires

a maintenance overhaul
Top oil
temperature main
tank
Transformer

40 © Hitachi Energy 2021. All rights reserved.

Tap Changer monitoring

Signal What it means

Time in same tap
position Time in position Too long in the same position and
Number of times the contacts may weld
a tap position
was used
Number of Allows evaluation of contact wear
Contact wear operations
estimation for based on design rules
ABB tap changer

41 © Hitachi Energy 2021. All rights reserved.

Lumada™ APM: Flexible communication options and structure

DE APM Cloud
Sensor to Cloud

Seamless
Upgrade

On-Premise to Cloud
Sensor to On-Premise

APM Edge
(DE Connect provisioned)
CoreTec 4
Wired
WIFI
Cellular

42 © Hitachi Energy 2021. All rights reserved.

Clean and crisp user interface to make understanding data easy

Fleet analytics DGA analysis (online, offline) Thermal model

Parameter, SOT, bushing POF and risk factors Expert recommendations

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The patented models digests data from online and offline sources

Data Digestion

342 unique transformer parameters available

Mandatory data
– Nameplate data
– Outline drawing data
– Factory test report data
Online sensors data
– CoreSense DGA sensors
– CoreTec transformer monitor (load, top oil, etc.)
Inspection data
– DGA lab results
– Insulation test results
– LTC DGA lab results
– Standard oil test results
– Visual inspection results
– Bushing test results

44 © Hitachi Energy 2021. All rights reserved.

TXplore™ system overview

No bubbles would be generated in gas saturated oil during an

internal inspection.

4x Camera Pods Handlebar Thruster/ Magnetic Coupler

Main Hull Seal

Depth Sensor & Pressure Gauge
Status LED Indicators

45 © Hitachi Energy 2021. All rights reserved.

Global footprint

Canada

USA Spain Hefei

China
India
Singapore

Brazil

Regiona digital support centers

Service centers

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