ISSUE 22

October 2022 transformer-technology.com ISSN 2642-2689

ADVANCES
IN BUSHINGS
TECHNOLOGY
SPECIAL SUPPLEMENT

When Bushings Go Bad: Check Your Data

Building Transformers. Building Quality. Interview with Prabhat Jain, CEO-CTO of Virginia Transformer Corp
Integrating Condition Monitoring into the Product: Economical, Accurate and Hassle-free
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4 TABLE OF
CONTENTS

Index Contents

Table of
Table of Contents_04
Editors & Impressum_10
Editor’s Letter_12
When Bushings Go Bad: Check
Your Data_16
Should You Consider Online
Bushing Monitoring?_24
Building Transformers. Building
Quality. Interview with Prabhat Jain,
CEO-CTO of Virginia Transformer
Corp_28

16
Are you focusing on the RIGHT
box?_36
Perspectives: How Remanufactured When Bushings Go
Transformers Are Helping Bad: Check Your Data
Companies Navigate Supply Chain
Disruptions_42
Tranco core. Still the best solution
24
Should You Consider
after almost 50 years!_44
Online Bushing Monitoring?
Transformer Technology October 2022 5

Issue 22

42
Perspectives:
How Remanufactured
Transformers Are Helping
Companies Navigate
28 Supply Chain Disruptions
Interview with Prabhat Jain
CEO-CTO of Virginia
Transformer Corp 44
Building Transformers. Tranco core. Still the best
Building Quality. solution after almost 50 years!

36
Are you focusing on
the RIGHT box?
6 TABLE OF
CONTENTS

Index Contents

Table of
PST Special Supplement_48
How Canada and JFE are pushing
beyond 2050_50
Predictive Maintenance and
Remaining Useful Life for
Underground Cable Systems_54
Coming in November_59
Integrating Condition Monitoring into
the Product: Economical, Accurate
and Hassle-free_60
How can the modern monitoring
methods upgrade laboratory testing 50
practice?_64
How Canada and
Women of Note: Nurul Noor, Special JFE are pushing
Project Leader for Cybersecurity at beyond 2050
Siemens Energy Malaysia_69
Monitoring Technology of Dissolved
Hydrogen in Transformer Oil_70
Yash Highvoltage Ltd. – A True
Solution Provider for Capacitive
SPECIAL SUPPLEMENT
54
Transformer Bushings_76
Predictive
Maintenance
Transformer Bushing Monitoring:
and Remaining
The Reference Signal
Useful Life for
Method_82 Underground
Cable Systems
Transformer Technology October 2022 7

Issue 22

60
Integrating

70
Condition
Monitoring
into the Product:
Economical, Monitoring Technology
Accurate of Dissolved Hydrogen in
and Hassle-free Transformer Oil

76
Yash Highvoltage Ltd. –
A True Solution Provider
for Capacitive
Transformer
Bushings

64
How can the modern
monitoring methods
upgrade laboratory
testing practice?

69
82
Women of Note:
Nurul Noor
Special Project Leader for
Cybersecurity at Siemens Transformer Bushing Monitoring:
Energy Malaysia The Reference Signal Method
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Transformer Technology October 2022 9

Issue 22
10 EDITORS &
IMPRESSUM

Impressum TAB Executive Advisor,

The Chair and Editor in Chief
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 Editor in Chief 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
Maria Salamanca 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 October 2022 11

Issue 22

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
12 LETTER FROM
THE EDITOR

Dear Readers,

The two most downloaded and read issues of our

digital magazine are Bushings and Oils & Fluids,
both areas that are changing more dramatically
than many other areas of transformer technology.
Given the very name of the magazine it is no won-
der. In November, you will see a departure from
our Transformer Technology focus with more of
a focus on Power System Technology, but first…
Bushings!
Some of the change taking
I have had the opportunity to interview some place in bushings technology
thought leaders in the transformer market at the
IEEE PES T&D Conference, and more recently via
has been driven by supply
Zoom, and one of the major things I came away chain issues, forcing
with is how change is taking place in bushings
technology. Some of that change has been driv-
manufacturers to rethink
en by supply chain issues, forcing manufacturers bushing material design.
to rethink bushing material design. Another is the
desire to decarbonize, digitalize and decentralize
Another is the desire to
power. While those larger objectives will be part decarbonize, digitalize and
of our PST reporting, they also impact transform-
er manufacturing.
decentralize power.

We will keep some of our thoughts on natural and In another interview with the CEO of Virginia
synthetic esters for the December issue on Oils & Transformer and Georgia Transformer, Prabhat
Fluids, but the move to esters is also important in Jain, you will read about how their R&D and de-
bushings manufacturing. One President of a ma- sign teams are working with their own suppliers,
jor bushings manufacturer shared in an inter- internally and externally, to address issue of re-
view (that you will be able to access in the com- liability, resilience, and reduced lead times. Bush-
ing weeks) that their effort to decarbonize has led ings are part of those changes. With articles from
them to make a determined decision to replace our Technical Advisory Board members, Tony
mineral oil filled bushings with esters and move McGrail and Marco Tozzi, authors Emilio Morales
away from SF6 insulation to RIF where possible, or and Robert Middleton, and a Perspective piece
to gases with less harmful impacts on the planet. from Camden Spiller, we believe we have done
another great job of representing the industry.

Now we turn our attention to November and De-

cember with Power System Technology front and
center in November. What a tremendous lineup
we have with interviews with several CEOs articles
on battery safety and e-mobility, and a market re-
view from Power Technology Research. While
transformers are the heart of the power system,
the power system is the heart of the economy, life
as we know it, and part of the most dramatic shift
in our lifetimes as we decarbonize, move to elec-
tric vehicles and deal with climate change.

From recorded interviews with over 30 people

during the recent RE+ Conference in Anaheim,
Netherlands, where 27,000 attendees gathered, it
was clear that our global power system is under-
going dramatic and much needed change; change
that will affect every one of us in ways we can only
begin to imagine.
Transformer Technology October 2022 13

Issue 22

While transformers are the

heart of the power system,
the power system is the heart

Alan M Ross
of the economy, life as we
know it, and part of the most
dramatic shift in our lifetimes
as we decarbonize, move to
electric vehicles and deal
with climate change.

Our mission at APC Media as the Voice of the

Power Industry is to bring you the best and most
important news, information and thought leader-
ship on Power System Technology. I hope you en-
joy our current issue and look forward to end the
year with two more great additions to the APC
Technologies body of knowledge.
Alan M Ross
Editor in Chief
Technical Director
CRL, CMRP

APC Media
14 SUBSCRIPTION

TRANSFORMER
TECHNOLOGY
IS NOT (JUST) A MAGAZINE
IT'S A COMMUNITY
OF OVER 10,300 MEMBERS

JOIN THE LARGEST DIGITAL COMMUNITY

IN THE TRANSFORMER INDUSTRY
SUBSCRIBE FOR FREE
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Transformer Technology October 2022 15

Issue 22
16 BUSHING
MONITORING

When
Bushings
Go Bad:
Check
Your
Data
by Tony McGrail
and Kenneth R. Elkinson

Photo: Shutterstock
 Transformer Technology October 2022 17

Issue 22

In bushing monitoring it is very important to be aware of all available data – the raw phase
angles and rms leakage currents for each individual bushing are often as useful as the
derived power factors and capacitances in terms of deterioration detection, investigation
and diagnosis.

Tony McGrail is Doble Engineering Compa-

ny’s Solutions Director for Asset Management
& Monitoring Technology, providing condition,
criticality and risk analysis for utility compa-
nies. Previously Tony has spent over 10 years
with National Grid in the UK and the US; he
has been both a substation equipment spe-
cialist and subsequently substation asset
manager, identifying risks and opportunities
for investment in an aged infrastructure. Tony
is a Fellow of the IET, a member of the IEEE,
CIGRE, ASTM, ISO and the IAM, and is cur-
rently active on the Doble Client Committee
on Asset and Maintenance Management and
a contributor to SFRA, Condition Monitoring
and Asset Management standards. His initial
degree was in Physics, supplemented by an
MS and a PhD in EE followed by an MBA.

Kenneth Elkinson, P.E., received his Bachelor

of Science in Electrical Engineering degree
from the University of Massachusetts at
Lowell. Kenneth has held a number of posi-
tions at Doble Engineering, as Field Engineer,
Client Service Engineer, and now Apparatus
Analytics Engineer. Previously, Kenneth worked
with National Grid in the US as a Substation
Photo: AdobeStock

Engineer. Mr. Elkinson is a licensed Profes-

sional Engineer in the state of Massachusetts,
and is an active member of IEEE, CIGRE, and
the NSPE.
18 BUSHING
MONITORING

Figure 1. Showing the variation in leakage current magnitude for three GSU bushings over 7 days in 2022

Figure 2. Exaggerated phase angle change for Phase 3 bushing showing Phase 1-to-2 staying unchanged

Bushings are usually reliable assets – of ‘noise’ in the measurements, as provides far greater capability and will
a failure rate, per year, of no more than shown in Figure 1. be discussed in a separate article. For
about 0.5% is usual [CIGRE]. Power now, we have three bushings, with
factor and capacitance are good As a result of the ‘natural’ variation in three leakage currents and an interest
indicators of deterioration in offline leakage current, it is usual to put some in diagnostics.
bushing tests and are commonly averaging into the resulting power
used [Doble]. In addition, it is generally factors to avoid false positives from In Figure 2, we show the three phasors
found that: sudden system variations: phase angle associated with the three leakage
variation due to bushing deterioration currents from a set of bushings which,
• it is not common for two bushings start at ~0.1°, but system variation in an ideal balanced system would
in a set of three to ‘go bad’ may be above 1° to 1.5° and vary all be 120°. We have added a very
simultaneously; minute by minute, making it difficult large change in the Phase 3 bushing
• a rising power factor is a to detect the bushing deterioration. – a change 100 times greater than
significant indicator of insulation At Doble we calculate daily, weekly and expected from bushing deterioration –
deterioration. monthly trends for power factor and so we can easily see the effect on the
capacitance, but also instantly respond relative phase angles:
These two findings are also useful to sudden changes if they exceed a
in online measurements where raw user set threshold. • Phase 3-to-1 increases
current waveforms are recorded, • Phase 3-to-2 decreases by the
from which we can calculate relative Power factor and capacitance have same amount that 3-to-1 increased
phase and rms magnitudes for the been used to detect and prevent failure • Phase 1-to-2 stays the same
leakage current of each bushing; from in many bushings, of many different
these values we can calculate the types, from Westinghouse, ABB, Consequently, if we were to plot the
individual bushing power factors and Trench, GE and others (Doble) using data over time, Phase 1-to-2 should
Photo: AdobeStock

capacitances (TT). Leakage current only the individual bushing leakage stay constant if just bushing 3 is
varies with both bushing condition currents for diagnostic purposes. deteriorating. Also note that the sum of
and system voltage providing a lot The addition of a voltage reference the three phase angles is always 360°.
Transformer Technology October 2022 19

Issue 22

Three Relative Phase Angles

122

121.5

121

120.5

120

119.5

119

118.5

118
7/6/20 0:00

7/7/20 0:00

7/8/20 0:00

7/9/20 0:00

7/10/20 12:00

7/11/20 12:00
7/6/20 12:00

7/7/20 12:00

7/8/20 12:00

7/9/20 12:00

7/10/20 0:00

7/11/20 0:00
Phase 1-2 Phase 2-3 Phase 3-1

Figure 3. Step change in phase angle for Phase 2 bushing

Three Bushing Leakage Currents

12.4

12.3

12.2

12.1

12

11.9

11.8

11.7

11.6

11.5

11.4
7/10/20 12:00

7/11/20 12:00
7/6/20 0:00

7/7/20 0:00

7/8/20 0:00

7/9/20 0:00

7/10/20 0:00

7/11/20 0:00
7/6/20 12:00

7/7/20 12:00

7/9/20 12:00
7/8/20 12:00

Tap1 mA Tap2 mA Tap3 mA

Figure 4. Leakage current magnitude for the three bushings

In Figure 3 we can see example show reflections of the variation, as shows no particular disturbance at the
results where both traces involving expected: the increase in one is the date/time of the anomaly in Figure 3.
the phase 2 bushing show a same as the decrease in the other.
sudden change in angle. Note that In Figure 5 we can see the relative
the remaining trace is relatively At the same time as recording the phase angles for three low voltage
constant, indicating that it is just one phase angles, we can also look at bushings recorded over several
bushing deteriorating. As expected leakage current magnitude for the months. The changes recorded in
in Figure 3, the sum of phase angles three bushings, shown in Figure 4. Figure 3 were small, as expected, but
at any point is 360°, and the traces The natural variation in current in Figure 4 we are seeing changes of
involving the deteriorating bushings magnitude, following a daily cycle several degrees.
20 BUSHING
MONITORING

Power factor and capacitance have been used to detect and prevent failure in many
bushings, of many different types, using only the individual bushing leakage currents for
diagnostic purposes.

Photo: Shutterstock
Transformer Technology October 2022 21

Issue 22

The addition of a voltage reference provides far greater capability and will be discussed in
a separate article.
22 BUSHING
MONITORING

X Bushings phase deltas

125

124

123

122

121

120

119

118

117

116
18/07/2021

26/10/2021
29/05/2021

06/09/2021

15/12/2021
X1 -> X2 X3-> X1 X2-> X3

Figure 5. Relative phase for 3 bushings

X Bushings rms current

12.5

12

11.5

11

10.5

10
29/05/2021

18/07/2021

06/09/2021

26/10/2021

15/12/2021

X1 mA X2 mA X3 mA

Figure 6. Leakage current magnitude for three bushings

In Figure 5, none of the traces show a contamination or moisture ingress It is very important in bushing
constant value, indicating that more and can eventually lead to a negative monitoring to be aware of all
than one bushing is deteriorating. power factor being recorded. available data – the raw phase
The two traces with large changes The effect of tracking can also be angles and rms leakage currents for
in phase angle both include the X1 seen in the leakage current magnitude each individual bushing are often
bushing, which is thus the suspect over the same time period, as shown as useful as the derived power
bushing. In addition, the fact that in Figure 6. factors and capacitances in terms of
for the X1 bushing the phase angle deterioration detection, investigation
heads in one direction then reverses A rising current is typical of and diagnosis. A voltage reference
implies that the power factor has deteriorating bushing, but here the is recommended when possible,
increased then decreased again. current rises, and then subsequently as this helps to remove the effects
This is an uncommon effect where a falls – again, an uncommon event, and of system variation and can focus
bushing shows the effect of internal one which relates to internal tracking investigation on to an individual
tracking within the bushing due to within the bushing. bushing.
Transformer Technology October 2022 23

Issue 22

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24 ADVERTORIAL

Should
You
Online Bushing
Consider Monitoring?

Online monitoring enhances the safe, reliable operation of

substation power equipment, measured performance, reduced
failure rates, and provides more consistent and frequent
information of the existing fleet. Online monitoring can be a key
tool to help understand the condition of your bushings.
Photo: GE
Transformer Technology October 2022 25

Issue 22

As utilities move from traditional off-line, routine testing of power

transformer towards on-line continuous monitoring, many benefits
are realized. On-line monitoring enhances the safe, reliable operation
of substation power equipment, measured performance, reduced
failure rates, and provides more consistent and frequent information
of the existing fleet. In addition to these benefits the end user real-
izes improved integration of relevant information so that Operations
Managers are better positioned to make more informed decisions.

In this perspective we want to show you the benefits of on-line

bushing monitoring, establish what properties you can see and
demonstrate why on-line monitoring can be a key tool to help un-
derstand the condition of your bushings.
Cigre WG A2.37[1] established, via a survey of 964 major failures between
1996-2010, that approximately 14.4% of the failures were caused by bushings
over all voltage ranges and 47% of those led to fire, explosion and leakages.
While we understand off-line monitoring is the most widely applied program, we
can demonstrate the benefits of an on-line monitoring system especially when
the time taken for incipient faults to develop can be less than the measurement
time between off-line inspections. Although we do not see online monitoring
replacing off-line monitoring but complementing it – it is another tool in your
diagnostic toolbox for early detection of faults that otherwise may go unnoticed
until it is too late to correct.
When monitoring bushings there are two main measurements collected –
Capacitance change of C1, and Power Factor enabling a customer to understand
the mechanical integrity of the bushing core (C1) and assessing the condition
of the bushing insulation (PF) respectively. Off-line monitoring can measure
these directly. However, these measurements are not systematic and can be
affected by change in operator and the presence of contaminants. Also, off-line
measurements are not taken under operational conditions. Conversely on-line
measurements are continuous, systematic and are taken under operational
conditions enabling better trending of developing faults to mitigate surprise fail-
ures of these critical transformer components.
26 ADVERTORIAL

On-line bushing monitoring capturing a Conductive Layer failure

Figure 1 shows a relative change of C1 Trend Chart (left) of a set of three bush-
ings where all three are in very close proximity of each other, as they should be in
normal conditions; when C1% of bushing B suddenly increases by a significant
step and then it maintains this deviation against the other two phases. The Polar
Plot (right) offers a different view to the same data where the step change can be
more easily observed, alerting the end user of an issue.

Figure 1. Relative change of capacitance C1: Trend Chart (left); Polar Plot (right)

Figure 2. Inter-phase shift increase for LV phase B (indicative of a PF increase): Trend Chart (left); Polar Plot (right)

Through online monitoring, terminal bushing failures can

become incipient bushing failures.

On-line bushing monitoring capturing an accelerated ageing of the

insulation layers
Figure 2 shows an increasing inter-phase angle (as measured at the bushings’
test tap) for the LV phase B (same data shown in Trend Chart -left-, and Polar Plot
-right-). This behaviour alerted the user of a rapidly degrading insulation for this
bushing.
Photo: GE
Transformer Technology October 2022 27

Issue 22

Benefits of on-line monitoring

The two events (Figure 1 and Figure 2) occurred irrespectively of the monitor-
ing of the bushings. Neither of the respective utilities had planned off-line testing
for more than a year when the bushing monitors triggered their respective alarms.
However, because of the on-line monitor warnings these faults were detected at
an early stage. Although there is no certainty that this would be the case, it is
highly likely that either bushing would have failed before the next planned off-line
test. Thus, the respective utilities had the time to plan the de-energisation of each
transformer, and the bushings were replaced before a developing failure could
affect the surrounding assets.

By on-line monitoring, terminal bushing failures became incipient bushing

failures [2].

Figure 3. DGA 900 Plus

GE’s BMT family continuously monitors the condition of bushings in real-

time and provides end users with the information they are used to receiving
from off-line tests, namely changes in capacitance and power factor (tan
delta), to assess the bushing dielectric efficiency and insulation integrity.

GE’s BMT family continuously monitors the condition of bushings in real-

time and provides end users with the information they are used to receiving
from off-line tests, namely changes in capacitance and power factor (tan delta),
to assess the bushing dielectric efficiency and insulation integrity. This is avail-
able as a stand-alone product or available as an integrated solution with our
DGA Plus monitor.

References
[1] CIGRE brochure 642,
Transformer Reliability Survey,
WG A2-37, 2015, ISBN: 978-2-
85873-346-0
[2] CIGRE brochure 755,
Transformer Bushing
Reliability, WG A2-43, 2019,
ISBN: 978-2-85873-457-3
 28 FEATURE
INTERVIEW

Prabhat Jain
CEO-CTO of Virginia
Transformer Corp

The great thing about

Virginia Transformer is that
we only make transformers.
This is our business.
And we drive it so that
Interview with Prabhat Jain

people understand what

we are doing. And we have
done it for so long that
we understand where to go.
Photo: Virginia Transformer Corp
Transformer Technology October 2022 29

Issue 22

Building Transformers. Building Quality.

30 FEATURE
INTERVIEW

Transformer Technology talked to Prabhat Jain, CEO-CTO of Virginia Trans-

former Corp, a leader with a fascinating biography, a mechanical engineer
with an MBA who originally worked in the company and had nothing to
do with transformers but then turned into a transformer guru as Virginia
Photo: Virginia Transformer Corp

Transformer and Georgia Transformer, formerly Efacec, became arguably

one of the very largest power transformer manufacturers in the world and
the largest US-owned manufacturer in North America.
Transformer Technology October 2022 31

Issue 22

AR Normally, when we do the interviews,

we try to keep them purely editorial.
However, it is impossible to do that with you
because you are a forward-thinking leader and
you've done some amazing things within Virginia
Transformer and Georgia Transformer, which
used to be Efacec.

There are a couple of things I want to talk about.

The first is, you have a very unique approach to
quality and quality assurance. And since we are
still in an industry where transformers are pretty
much built by hand, uniquely, there is no mass
production, can you talk a little bit about when
you started to think about quality and quality
assurance? How do you go about controlling
quality and how do you make a difference doing
quality?

The transformer is a handmade product.

So, we have to get people to produce
quality, think quality and build quality all
the way across in every step.

PJ I would start by saying it’s all about

people. As you said, a transformer is a
handmade product. So, we have to get the people
to produce quality, think quality and build
quality all the way across in every step. Another
factor is that the transformer is a technological
product, and technology is not obvious. You can't
see the electrons and the field running around
when you're building a transformer. So, I will
start from the fact that it's down to the people.

That being said, over the last 50 years the work

ethic of the people has changed. In fact, the
norm has changed. People used to work in a
plant for ten, 20 or 30 years. But not anymore.
Now it's like five years. That produces a huge
challenge in terms of how we maintain the
skill level that it takes to produce a custom
manufactured product and custom designed
product. We don't have as much of an issue with
the designers. They see the opportunities of
Alan Ross: In this interview I am hosting a the technology and the development we do in
frequent guest, or at least he's been a guest the company. So, they attach value to that and
more than some other people. Prabhat Jain, stay with us longer. However, our hourly worker
the CEO and President of Virginia Trans- typically does not have what you call a broader
former and Georgia Transformer, as well as a view of the industry. They just look at it from
new plant coming online in Chihuahua, Mexico, their own perspective, basically speaking, and
and then another new plant that will come they realize the challenge of manufacturing.
online near their existing plant in Virginia. So, this is how I have approached it over the last
Prabhat, it's so good to have you here. seven to nine years, when we became a major
force in the transformer production scene in
Prabhat Jain: You're quite welcome, Alan. our country, and we took steps to overcome the
I am very excited about the interview and short tenure of trained, skilled employees.
the opportunity to tell your readership and
the industry community gathered around There are several avenues we have pursued. One
Transformer Technology and Power Systems is training. That has given us some edge, but not
Technology about Virginia Transformer and really as much as it takes to maintain the high
what we are doing. level of quality.
32 FEATURE
INTERVIEW

The second thing we did was installing mechanically in terms of forces, friction and
technicians who are actually subject matter handling; how to lift a 20,000 pound coil and
experts – 20-year-knowledge people, and we bring it down straight onto the court so it doesn't
have taken them offline, so to speak, to monitor scrape the sides and damage the insulation,
what is being done on the floor. Therefore we how to make sure the coating coil assembly is
assured the processes are being followed because vertical if it leans one degree, et cetera – these
there is someone who understands them. things are very easily understood by mechanical
engineers and mechanical inspectors. I also sent
The technicians must be trained. They are our mechanical inspectors to American Quality
as good as our designers in understanding Association courses to get them certified for
insulation, dielectric spacing clearance and the mechanical inspection. So, these are examples
tying down of the cable so the cable won't fly of very simple ground changing initiatives.
away when the short circuit hits it, etc. All these Just by realizing that the transformer making is
things are known to them. Some five years ago, mechanical, I started building up to the higher
we made an addition to that as I realized that level of leadership, also mechanical.
everything we do in transformer manufacturing
is mechanical. The diameter of the coil is To ensure quality, you need people. There
mechanical. The strength and the tension on are 250 engineers in the company today,
the wire is mechanical. The clearance between and we are going to add more. They are
the coil and the inner diameter ID and the core the ones who are our assurance that we
outer diameter iOD is mechanical. The 2-mm gap will continue to deliver and build a quality
that we have to maintain on the core corners is product. This takes a lot of drive from the
mechanical. No waviness in the three-meter long CEO because it takes a lot of money. But
core legs is mechanical. Everything is mechanical. if I am going to add 100 people, I know
Photo: Virginia Transformer Corp

So, for years and years we had electrical that's the right thing to do.
inspectors on the floor because a transformer
is an electrical product. Another important area when we speak about
quality is, of course, that we need more quality
But when it comes to mechanical issues, what assurance people. Quality control is inspection.
tools to use, how to calibrate, and then think Quality assurance means that already at the
Transformer Technology October 2022 33

Issue 22

design and then the production stage we ensure

the product is made so that it doesn’t need
much inspection in the first place. So, we are
AR It's very interesting what you just
explained. Yes, the transformer
is part of the electrical system, but it’s
continuously adding more people. mechanically built, and some mechanical
engineers think differently than electrical
If you want to have a better product consistency engineers. So, the idea that we can get
and a reliable product, as we are continuing to mechanical engineers into production is an
grow, we need a lot more people in the layers interesting approach.
of technical and engineering knowledge. So, we
have 250 engineers in the company today, and The second thing I want to talk about is the
we're going to continue to add more engineers. history of transformers that is going back to
My direction to all my leaders is hire any pre-Westinghouse days, but the technology has
engineer that you can find to come and work in not really changed that much. One of the things
our company, because we have so much going on, that has changed is that we used to design them
and they are the ones who are our, what you call, using slide rules. We did it with our eyes. Today,
assurance that we will continue to deliver and we have better ways of doing design and we are
build a quality product. It's very simple. However, much more exact. We build to specification. We
it takes a lot of drive from the CEO because it don't overbuild anymore.
takes a lot of money. If I'm going to add
100 people, I know that's the right thing to do. You talked about some changes that are
happening in the technology of building
I don’t need to go to Sweden and get permission transformers. What do you see are the current
to add 100 engineers. I don't have to go to GE and future technology changes in transformer
Prolec headquarters saying I need to add 100 design and manufacturing?
people. I just add them. And that's the great
part about Virginia Transformer – we only make
transformers. This is our business. And we
drive it so that people understand what we are
PJ Design is a very vast field, and in
designing, electrical engineers are kings.
They are the ones who see, who understand
doing. And we have done it for so long that we the forces and the maximal equation, the
understand where to go. electromagnetic, etc.
34 FEATURE
INTERVIEW

In any system, there are many safety factors, or are going to come closer and that's not good.
margins, as we call them. So, there is a margin in So, we want to design accordingly, and this is
force, there is a margin on field strength, there about materials, the dialectic design, and the
is a margin on thickness of insulation, there is a temperature design.
margin on the tolerances of the conductor, there
are margins everywhere. And sometimes the Sound reduction is another very important
margin in the system can vary from 1.5 safety area where we have made progress, which,
factor to something like ten safety factors, just believe it or not, gives you longer life because
by nature and by practices that have occurred. sound comes from vibrations. Vibration means
So, what we have done at Virginia Transformer that there is something that is rubbing against
over the last seven or eight years is having a something else and the rubbing is going to
development department that consists of very eventually lead to abrasion and failure.
analytically oriented, highly skilled engineers, So, these are the areas that we have improved
who try to bring that safety factor to more in terms of technology.
nominal numbers, raise the one and a half, and
lower the ten. The system is only as strong as Looking down the road, there is much coming
the weakest link. at us and we have to evolve beyond just the
mechanical and electrical spheres. There is EV
So we try to optimize and we have done a lot charging and data centers, which are becoming
of work in that area in terms of the hot spot, important very exponentially, rising faster and
the directive margin, the stresses, insulation, faster. And, of course, solar and wind that has
top oil rise, the velocity of the oil, the number given rise to battery storage.
of oil driving washers, how many we need to
place to optimize them so we don't impede the Battery storage uses a lot of computers,
flow, etc. Every time you have the oil making and harmonics. So, all of these together are
180-degree turn, you lose some head and pushing us in an area of what I would call
thus you lose velocity. We have done a lot of solid-state electronics. Certainly, the solid-
fundamental analysis using CFD, and using, of state transformer is the next step, if you will,
course, just very simple temperature gradient from just normal inversion and conversion.
calculations with finite element analysis. So, Essentially, EV charging is about taking AC and
we have improved that and this is one area taking DC out of that. We are going to need
of technological development that we have a lot of that. And then the electrical vehicle
furthered in the last seven to ten years. And we is another area where we're going to use a
are continuing to work on that. lot of solid-state electronics in order to drive
the motors in the wheels, to drive the wheel
The other technology area is materials. directly, and eliminate a lot of mechanical
Materials are becoming more and more systems from there.
expensive. Millstone used to cost thirty cents a
pound, now it costs sixty cents a pound. This shift towards solid state electronics will
So, there were times when it was okay to use apply to transformers in various aspects of its
half an inch wall thickness, but now we are application. The transformer will exist as an
saying, instead of using 36,000 PSI, we would electromagnetic device like we have today.
Photo: Virginia Transformer Corp

like to use 80,000 PSI steel which is available for However, it will be combined with a lot of
a small premium. However, it saves a lot of cost. solid-state electronics in order to make the
But then other issues emerge, and we have to transformer continue to serve the application.
manage those. The deflection goes up. We can Our knowledge of harmonics is very deep.
manage deflection by putting it where it doesn't Virginia Transformer’s foundation is in
hurt. For instance, if bushings deflect, then they variable speed drive isolation transformers.
Transformer Technology October 2022 35

Issue 22

So that is growing nicely. There are so many

other areas that we are working on as an
engineering company to reduce the weight of
AR Prabhat, you always leave me with
so many questions to ask that we
have to do another one of these interviews.
the transformer, and then by using different And I have to comment on this. Most of the
materials and smoothening the fields. Very far- people that I have talked to who are leading
reaching developments are underway right now. transformer companies, don't know much about
transformers. They know a lot about business.
Here I would like to mention ester fluids You happen to know a lot about business but,
and vegetable oil, which has been around boy, do you know a lot about transformers, too!
for a long time. Now we are able to take the I really appreciate that, because you can tell
technology to 200 MVA, so we can supply that transformer is in your blood, and that's
transformers for data centers, particularly very good to see, because I think that's what brings
large transformers for data centers, which are things forward.
mostly located in urban areas. We want to keep
them safe and ester is very powerful for that. So thank you from the industry, because I
And we're going to take this technology to 230 appreciate it very much.
KV now. We are planning to do that. We have
many PhDs on our staff who are chemistry and
electrical engineering specialists in order to
combine the knowledge and then see how we
PJ Thank you, Alan. And I always like to
finish by saying one has to have passion.
And passion brings excellence, and excellence
can take that technology forward. will serve the industry better. Absolutely.

Another area is the dry type transformer, which

is again a safe device in terms that it has no oil
and of course, no leaks. We can make dry type
AR That's what we're going to end with.
Passion. Thank you so much, Prabhat,
and we will talk again.
transformers up to 35 kV, 150 bil, 15 MVA, which
is a fairly good size transformer to serve most of
the industries. PJ Thank you.
36 TECHNICAL
ADVISORS’ COLUMN:
MARCO TOZZI

Accuracy and sensitivity are detect?” or “What is the analysis, which is: what is the Searching for the
a MUST for online monitors. minimum pF change you condition of my transformer; pico-Coulomb
However, balance is needed can detect in a bushing?” or and what potentially needs
while seeking for perfection “Can your monitor match my to be done? Sometimes the A 345 kV bushing was
without compromising the laboratory readings?”. link to these core questions monitored online and, after
bigger picture. The focus can be lost in the details. about one year, a Partial
ultimately needs to be your Although it is indisputable Discharge (PD) event of 8
transformer. that we need reliable and Can a single absolute value pulses per seconds was
accurate monitors, too from just one reading tell detected [1]. It occurred only
I’ve been asked so many many times we are focused you what you are going to do at that time, never before and
times “How many pico- on small details and we next? Sometimes yes, more never after. At the same time
Coulomb can your monitor miss the larger scope of the often not. the monitor detected a small

Are you focusing on

the RIGHT box?

Marco Tozzi received the M.Sc. degree in
electrical engineering from the University of
Trieste, Italy in 2005 and the Ph.D. degree in
electrical engineering from the University of
Bologna, Italy in 2010. From 2007 to 2011
While the ‘little box’ – your Marco was the Project Manager and Techni-
cal Advisor at Techimp, Italy, where he was
monitor – is important, involved in research on diagnostic of insu-
lating systems through Partial Discharges
it is vital to remember that analysis. From 2012 to 2022 Marco was a

its sole purpose is to give Product Designer and then Senior Product
Manager at Camlin Energy, involved in de-

an insight into the signing solutions for holistic transformer

monitoring. In 2022 he took the role of Sr.

‘big box’ – your Technical Advisor at Camlin Energy, involved

Photo: Shutterstock

in asset diagnostics, consultancy services

transformer. and optimisation of monitoring and mainte-

nance programs. He is author or co-author of
more than 40 technical and scientific papers.
Transformer Technology October 2022 37

Issue 22

increase of capacitance in likely due to a short circuit in which winding, bushing, from an online DGA
the same bushings, less than between two layers. or phase, and whether they monitor by two labs. One
2%. No one would take an are stable over time or oil sample was analysed
action based on just one of Would have this action been not, provides much more in lab #1, and two samples
the two pieces of data, but different if the PD was 1, 100 information than knowing were analysed in lab #2.
the simultaneous occurrence or 1000 pC? My contention how many pico-Coulombs. The lab data are apparently
of the two events suggested is that it wouldn’t. The inconsistent showing
a correlation. A DGA test correlation of data led to the Inaccuracies in variations in both inter-
of the oil was done, which right test and right actions, DGA accuracy laboratory reproducibility
confirmed that the bushing not the value of the specifics (lab 1 vs. lab 2) and intra-
had experienced an internal of the data itself. Confidently Table 1 shows the laboratory repeatability
arcing (76 ppm C2H2), knowing if there are PDs, comparison of readings (in lab 2).

Although we need reliable and

accurate monitors, too many times
we are focused on small details and we
miss the larger scope of the
analysis, which is: what is the condi-
tion of my transformer; and what
potentially needs to
be done? Sometimes the
link to these core quest-
ions can be lost in the
details. Figure 1. Simultaneous variation
of bushing capacitance an PD occurrence

Online Lab 1 Lab 2 Lab 2

Gas
Monitor Sample #1 Sample #2

H2 116 96 140 117

CH4 37.6 46.3 47 39

C2H6 57.8 76.1 70 56

C2H4 1 1.9 1 2

C2H2 0 0 <1 <1

CO 268.3 322.2 330 231

CO2 2872 3165.1 1802 2067

Table 1. Gas concentrations in ppm. Comparison Figure 2. DGA diagnostics using DGA Matrix
of DGA monitor readings by two labs
38 TECHNICAL
ADVISORS’ COLUMN:
MARCO TOZZI

Where is the truth? Which laboratory can be done, but is that the different data is inaccurate? It might
lab and which sample shall it must be done in a sapient sets provide the same happen, but most likely, it
I use to validate my manner, as described in diagnostic information. is because the increase of
monitor? The interesting IEC60567 [3] and CIGRE bushing losses is a complex
thing is that if you process TB783 [4], which can be Online data could not match dynamic process; it can be
the data of each column expensive in terms of time offline, but it might be slow and can be fast, can
through all the standard and money. The alternative correct be permanent or can be
diagnostic methods way of comparing just one intermittent, can be small
(Figure 2) you will see that single value with a single How many times have you and can be big. The online
all the readings provide the sample in a single lab will switched off the transformer, monitoring system gives
same, identical diagnostic often provide inaccurate taken an offline bushing you a real picture of what is
results [2]. results, due to the test and realised that the happening at real operating
inaccuracy of the method results are different from conditions. The offline
Comparing online DGA rather than the data. those in the online monitor? test is an instantaneous
results with those of a In the end, what matters Is that because the monitor snapshot at fixed and

Inaccurate results will usually

occur due to the inaccuracy of
the method rather than
the data. What matters is
that the different data
sets provide the
same diagnostic
information.
Figure 3. Bushing Power Factor
seasonal variation
 Transformer Technology October 2022 39

Issue 22

controlled conditions, and here, which is that there values, there is no doubt but the information given
crucially, those may not be is a faulty process in the that the bushing must be by the correlation of the
the same conditions that insulation which increases replaced. data, enabling a proactive
are causing the bushing to the dielectric losses with maintenance program.
lose its properties. Figure temperature. In this case, While some can still get
3 shows the relative power as expected, the offline test attracted by the debate on
factor monitored online done at ambient temperature the 1-to-1 comparison of So, the ‘little box’ is
that is apparently ok in cold showed a value twice the online to offline data, online important, but it is vital
season, while it is higher in nameplate (0.6%), while vs. laboratory data, millivolt
the hot season. If you test the monitor at operating versus pico-Coulomb etc., to remember that its sole
the bushing offline without temperature was about four it is key to focus on the
taking into consideration the times the nameplate (1.3%). right information and not purpose is insight into
oil temperature, you might Which one is right? Both get “lost in the weeds”. Very the ‘big box’ – your
not see any deviation. But are right. And, despite the often the most important
the monitor tells the truth difference in the absolute thing is not the data itself, transformer.

References
[1] M. Tozzi, “Risk Management
Requires Actionable Insight:
Adding Value with Truly Integrated
While some can still get attracted by the Transformer Monitoring,”
Transformer Technology, Issue 3,
debate on the 1-to-1 comparison of online
Sept 2019, pp 88-96
to offline data, online vs. laboratory data, [2] https://camlingroup.com/en-
millivolt versus pico-Coulomb etc., it is key us/dissolved-gas-analysis-
to focus on the right information and not dga-matrix
[3] IEC 60567:2011, Oil-filled
get “lost in the weeds”. Very often the
electrical equipment –
most important thing is not the Sampling of gases and
data itself, but the information analysis of free and dissolved
given by the correlation of gases – Guidance
Photo: Shutterstock

[4] CIGRE TB783, Technical

the data, enabling a proactive
Brochures – DGA monitoring
maintenance program. systems
 40
ADVERTORIAL

Photo: Shutterstock
Transformer Technology October 2022 41

Issue 22
42 PERSPECTIVES

How Remanufactured Transformers

Are Helping Companies Navigate
Supply Chain Disruptions
by Camden Spiller

PERSPECTIVES
In the transformer industry, new factory-built units are
encountering unprecedented lead times due to material
shortages with electrical grade steel and various other
components.

Camden Spiller began his career as a soft-

ware engineer, attended Missouri State Uni-
versity and completed the Owner/ President
Photo: Maddox Industrial Transformer

Management Program at Harvard Business

School. Away from work, Camden has served
on the boards of various civic and business
organizations and is very engaged with his lo-
cal church and community. Camden and his
wife Sarah reside with their kids near their
family's farm in the Pacific Northwest.
Transformer Technology October 2022 43

Issue 22

PERSPECTIVES
As supply chain disruptions continue the innovative utilization of existing remanufactured transformers is often
to eat away at the global economy, equipment is opening a wider berth for longer than new factory-built units.
companies are left searching for ways remanufactured transformers.
to navigate this crisis. The COVID-19 From a fourth and broader perspective,
Pandemic of 2020 with its concurrent Transformer remanufacturing has purchasing remanufactured
leash of restrictions and the growing existed as a niche industry since transformers helps alleviate an
labor shortage in the US have left the the early days of the technology’s already bogged down supply chain.
market in a bad way [1]. Near the end invention. The process has been While recycling an electrically healthy
of 2021, The Economist concluded performed by many groups over the transformer increases the availability of
that a return to the “pre-covid years” years from small localized repair shops recycled materials for new products, it
was unlikely anytime soon as the to large OEMs. Though the availability also increases the demand for the same
world settled into an “era of predictable of remanufactured transformers is product taken out of service, which
unpredictability” [2]. As this prevailing nothing new to the market, it provides now must be replaced. This cyclical
climate of uncertainty continues to four distinct advantages to help manufacturing method cannot make
shape and change the way companies companies steer through the current room for the current industry demand.
operate, the desire for certainty and supply chain dilemma. Utilizing remanufactured transformers
reliability in the procurement of goods reduces the overall product demand,
and services remains as steady as it The most obvious advantages to which in turn brings relief to factories
ever has, perhaps even more so in the remanufactured transformers are their for the manufacture of new units.
face of such challenges. faster delivery times and lower upfront Remanufactured transformers also
costs. With new factory transformer lower the high energy consumption and
In the transformer industry, new lead times out eighty plus weeks, in- greenhouse gas emissions associated
factory-built units are encountering stock, remanufactured transformers with new material manufacturing.
unprecedented lead times due to can be made available in as little
material shortages with electrical as one to three weeks. Against the For many would-be purchasers of new
grade steel and various other inflated cost of new factory-built units, transformers, the remanufactured
components. The relative scarcity remanufactured transformers offer a option represents a new way of
of electrical grade steel is a problem cost reduction between 10% and 40%. thinking. Remanufactured transformers
further exacerbated by the new are providing a reliable product, while
subsidies and incentives in the Another benefit, equally worth noting outmaneuvering and reducing the
Inflation Reduction Act which will is the reliability of remanufactured disruptions within the supply chain.

For many would-be purchasers of new transformers, the

remanufactured option represents a new way of thinking.
Remanufactured transformers are providing a reliable
product, while outmaneuvering and reducing the disrup-
tions within the supply chain.

result in increasing amounts of the transformers. According to a study References

steel formerly available for transformer done by The Hartford Steam Boiler [1] Ron Hetrick et al., “The Demographic
manufacturing now being allocated to Inspection & Insurance Co. [3] the Drought,” accessed at https://
electrical vehicle charging applications. second leading cause of transformer fs.hubspotusercontent00.net/
These factors have put considerable failure stems from design & hubfs/4906807/Demographic%20
pressure on the new transformer manufacturing issues. Such failures Drought%20V18.pdf
market. Utilities, electrical distributors, can be detrimental to project deadlines [2] “The new normal is already here.
contractors, and project managers and incur a significant loss in revenue. Get used to it,” The Economist,
who have ordinarily been able to Many such failures occur at initial accessed at https://www.economist.
operate with a build-to-order mentality energization. Purchasing a unit with a com/leaders/2021/12/18/the-new-
are having to rethink their sourcing proven track record in the field provides normal-is-already-here-get-used-
strategy. Now, the procurement plumb an additional level of assurance for to-it
line is shifting to an emphasis on the future reliability. In the same vein, the [3] William H. Bartley P.E, “Analysis of
ability to adapt and think resourcefully, remanufacturing process includes Transformer Failures,” IMIA 2003,
leading to a greater focus on readily identifying any previous design flaws accessed at https://www.imia.com/
available equipment that can be and correcting and improving any wp-content/uploads/2013/05/
quickly fitted into a project’s particular defects for a longer service life. For this wgp3303.pdf
needs. This growing focus toward same reason, the warranty period for
44 ADVERTORIAL

TRANCO STILL THE BEST

SOLUTION AFTER
ALMOST
CORE 50 YEARS!

TRANCO BUILDS FAST, RELIABLE CORE

WINDING PRODUCTION MACHINES

Wound magnetic cores are commonly used in the manufacturing process of distribution
and instrument transformers around the world. Thanks to automation and continuous feed-
ing, the wound core process offers greater production capacity and efficiency than the cut
& stack option. The core winding process needs to be very accurate and consistent for the
end product to be performing as expected. The machines used in the winding process need
to be highly reliable and flexible so that a variety of gap patterns (Distributed, Flare, Zig-ZAG,
Concentric) are available with ease of set up.
 Transformer Technology October 2022 45

Issue 22

Key to profitability is also the possibility to operate the core winding machines without the
need of a lot of manpower and space. High degree of automation and small footprint design are
therefore important factors to consider during the selection and procurement process of a core
winding machine. Of course, the up time and speed of process execution are also key in order to
maximize the production rate and meet the highest possible output required to keep production
costs down. Safety considerations which apply to equipment with moving parts and sharp tools
also need to be included in the design and operation procedures in order to protect the physical
integrity of the operators and maintenance crew.

CUSTOMERS TELL US THAT THEY HAVE BEEN

USING EXCLUSIVELY TRANCO CORE WINDING
MACHINES IN DISTRIBUTED GAP (DG) CORE
PRODUCTION FOR MANY YEARS AND WOULD
NOT CONSIDER ANY OTHER MANUFACTURING
METHOD FOR HIGH VOLUME DG CORE
PRODUCTION. - Grattan Schutte – Tranco President
THE TRANCO CORE TECHNOLOGY
Transformer core manufacturing is normally done either in-house by the transformer man-
ufacturer or is outsourced to specialized manufacturers which have in-depth expertise and
dedicated processes. This second type of arrangement is widely popular for smaller, mostly
distribution type, transformers as it allows economies of scale. Historically, transformer core
production has been a manual and labor-intensive operation but things changed in the mid
1970’s when the Original Automatic Core Winding machine was invented by Alfred S. Cooper
who went on to establish TRANCO Production Machines Ltd, a company based in Canada and
from where they have been designing, producing and supplying their high quality core winding
machines to the transformer industry around the world for almost 50 years. TRANCO Machines
have been sold in over 20 countries and the count keeps growing. Tranco has grown to be so
recognized in the industry that Tranco core has became synonymous for the wound core tech-
nology in general.
The TRANCO Production Machines work from a continuous feed of magnetic steel that
Photo: TRANCO

enables the most efficient process. Thanks to their adjustable settings, Tranco machines
allow for the production of a wide variety of core diameters with consistent gap patterns
featuring exact specifications.
46 ADVERTORIAL

TECHNOLOGICAL ADVANCEMENTS
In order to meet the high expectations of our customers, TRANCO has been, since inception,
developing and implementing innovations on a continuous basis. We also support our cus-
tomers with the training and after sales service that they expect. Over the years, continuous
improvement has been integrated to the TRANCO machines, including electronically-controlled
patterns, improved set-up speed and broader versatility, all of which allows the customers to
address a wide range of transformer types while lowering total core production cost.
Automation has been a significant part of the innovations integrated in the TRANCO machine
in recent years. The machines are now controlled by their integrated PLC (Programmable
Logic Controller) and have a very user-friendly HMI (Human Machine Interface) digital display
with which the operator can easily control all operations. They can also easily be integrated
with the user’s in-house SCADA (Supervisory Control and Data Acquisition) system for
remote input of production specification and adjustments as well as production performance
monitoring. Utilizing the newest versions of PLC and proprietary computer programming,
TRANCO can configure the equipment to operate under many different computer languages.
TRANCO Machines are able to have scan times in the sub second range which is imperative
for cut accuracy at high speeds.

TRANCO MACHINES ARE RELATIVELY

SIMPLE AND EASY TO MAINTAIN, AND
THEY OFFER PLENTY OF FLEXIBILITY
IN THE RANGE OF CORE SIZES, FROM
THE SMALLEST OF CORES ONLY A FEW
INCHES IN DIAMETER TO VERY LARGE
CORES OF A FEW FEET IN DIAMETER.
TRANCO also has integrated numerous additional improvements. The newest and most crit-
ical innovation is the Tranco servo driven shear which now enables run speed of 400 ft/min
(122 m/min) with improved cut gap accuracy and much quicker cut engagement (50% faster).
The revised design of the linear rails of the Tranco Machine improves the square of the
mandrel relative to the machine to maintain alignment, improves gap cut consistency, extends
the life span of the bearings and therefore reduce maintenance time and cost. Upgraded
electronic pneumatics controlled by the PLC have allowed improvements in the pressure
accuracy and consistency. They have also been relocated, as did the PLC console, to reduce
any interference which may be associated with vibration. Other recent improvements deserving
a mention include the adjustable winding cheeks and horizontal guide. The new design reduces
Photo: TRANCO

the down time for change overs and eliminates the need to replace or carry the spacers. This
improvement facilitates the work when the operator wants to align the steel into the machine.
This system always keeps the steel centered and can be adjusted in 0,000 increments.
Transformer Technology October 2022 47

Issue 22

TRANCO DOES NOT GET OUT OF STYLE

Some older TRANCO machines which have been in service for many years can benefit from
the latest technology improvements that have been introduced. In such cases, TRANCO offers
its retrofitting process of which the extend can vary depending on the age of the existing ma-
chine, and how heavily it has been used. But the end result is always a machine that looks and
operates like a brand new one. This means that companies whose budget might not accom-
modate a new machine purchase can still enjoy the recognized high quality of a TRANCO core
winding machine and all its associated benefits. Typical turn around time for refurbishing can
be as quick as three months compared to completely new models which take around 5 months
to produce.
TRANCO machines are customized to meet each customer’s specific requirements. They
come in right or left handed design, require only a small footprint installation, and do not re-
quire any special services to operate. TRANCO production experts collaborate with each end
user to clearly establish their unique production parameters and ensure that their TRANCO
core winding machine is equipped and programmed to meet the specific targeted production
requirements and objectives.TRANCO Machines are able to have scan times in the sub sec-
ond range which is imperative for cut accuracy at high speeds.

TRANCO MACHINES ALLOW MANUFAC-

TURING STRIP WOUND DISTRIBUTED GAP
CORES AND THEY READILY ACCEPT ALL
COMMON THICKNESS RANGES FOR THIN
GAUGE, GRAIN ORIENTED AND NON-
ORIENTED STEELS WITHOUT HAVING TO
CHANGE ANYTHING.

For more information on TRANCO core winding machines,

visit our web site at www.tranco.ca and contact us at [email protected]
or by phone at +1 905 669-4840.
48 SPECIAL
TOPIC
MISSING
SUPPLEMENT

Photo: Shutterstock
Transformer Technology October 2022 49

Issue 22

SPECIAL SUPPLEMENT
50 ADVERTORIAL

How Canada and At JFE Shoji Power Canada

(JFE), we’re committed to
JFE are pushing helping Canada and the world
reach this goal. However,
beyond 2050 our commitment to the
environment goes well beyond
that. Our mission is to support
In June of 2021, the government our clients and society as a
of Canada adopted the whole in building a stronger,
Canadian Net-Zero Emissions more efficient and expansive
Accountability Act to achieve electrical grid to lessen the
net-zero emissions by 2050. burdens on our environment.

Achieving net-zero emissions means

our economy will emit no greenhouse
gases OR we will offset emissions
through actions such as tree planting
or implementing technologies that can
capture carbon before it is released.
Photo: JFE
Transformer Technology October 2022 51

Issue 22

Every day, now and into the future, we’re

working to develop a stronger, renewable energy
source. For over a century, we have relied on
burning fossil fuels to create energy and gas-
powered vehicles to take us from A to B.
There must be a shift to clean electrical,
renewable energy sources to make a positive
environmental impact. How do we do this?
By providing customers with the services,
products and expertise that will help us through
this transformation.

We’ve been inspired to work with our clients As a start, here are some tangible steps that a
and suppliers to find more sustainable energy business can take:
solutions. Still, for many companies, taking a
first step toward the climate goals for 2050 1. Create a carbon reduction budget. This is a
can feel somewhat daunting. To begin, let’s clear first step for all companies, but
discuss how companies can get started in a specifically those in the energy sector.
positive, productive way. Though Canada as a country uses emission
targets rather than a carbon budget, budgets
can be scalable, and are great tools to help
Making “environmental protection” you measure progress to see where you
a true priority at a company level stand.

Easing the strain on Mother Earth is a 2. Prioritize early adoption. The time for waiting
discussion that’s coming up more and more at is far gone. For companies, now is the time
the corporate level. As Canada is one nation on to seize opportunities for cleaner, more
the growing list of countries that have pledged renewable energy sources while looking at
to achieve net zero in carbon emissions, many new technology, new products and services
companies are asking what they can do to take and, frankly, new ways of thinking.
up the cause. Still, throwing the phrases “net
zero” or “renewable energy” around at a board 3. Stay on top of policy makers. Business
meeting or a town hall is the easy part. leaders have the leverage to inform and
The reality is that Canada cannot achieve its positively impact climate change strategy.
environmental goals without a collaboration We need to ensure that the economic
between businesses, government groups and changes made to reach 2050 goals result in
non-governmental organizations. good-paying jobs and strong business
communities. We cannot wait for mandates
Overall, businesses need to have an or policy initiatives to regulate these
understanding of how they’re currently improvements – now’s the time to act and
impacting the environment and how they can lead. Business leaders must provide the
actively create climate-minded initiatives to vision and the resources to deliver creative
share with their partners and clients. solutions to make these changes.
52 ADVERTORIAL

A global leader in a number of pledges to help reach our goals for

sustainability energy conservation. These include:

Originally known as Cogent Power, JFE Shoji - To develop and maintain a variety of eco-
Power Canada came into existence when it friendly products and technologies to aid in
was acquired by JFE Shoji Trade Corporation renewable energy power generation;
(JFE Group) in September 2019. Based in Tokyo,
the JFE Group is one of the world’s largest steel - To seek business opportunities that allow
producers, but places climate change as a JFE to enhance its contributions to
critical business concern. As a whole, the steel decarbonization throughout society; and
business emits 99.9% of JFE Group’s total CO2
emissions, so developing new technologies for - To prioritize JFE’s offshore wind-power
renewable energy is more imperative than ever. business by uniting the strengths of each.
When looking ahead, the JFE Group has made individual group within the organization.

“Our team is very excited about the

work we’re doing to improve our
electrical efficiency, the sustainability
of our grid and providing lower-carbon
solutions for many of our clients.”
Ron Harper, CEO, JFE Shoji Power Canada
Photo: JFE
Transformer Technology October 2022 53

Issue 22

3. Electrification of the transportation grid.

It is of critical importance that we reduce the
number of gas-powered vehicles currently on
the road and replace them with cleaner
alternatives. Most transportation OEMs have
announced bold strategies in this direction,
and we seek to support and strengthen the
capacity for this transformation. Again, this
task is driven not by economic reasons, but
by environmental ones. Though there
continues to be a strong growth in the
number of Plug-in Electric Vehicles (PEVs) on
the road, as of 2021, PEVs accounted for only
5.2% of new vehicle registrations in Canada.
JFE’s three-part strategy for Our work is ongoing to ensure Canadians feel
sustainability in Canada compelled to see them as a viable option.
This includes working with our utility clients
So, what are we doing here at home? It’s easy to to ensure consumers have a full
make claims that we’re working toward understanding of the positive impacts electric
lessening the impact on our environment, but mobility will have (i.e., where will charge
where’s the evidence? Our CEO Ron Harper has outputs be available, and what will the cost
outlined three critical initiatives that our be?). As Ron outlined, “We’re working very
Canadian business is working on to show its hard with automotive OEMs (Original
dedication to the cause. Equipment Manufacturers) to make sure
we’re providing energy-efficient solutions for
1. Increasing the capacity and efficiency of the growth and demand of electrically
our electrical grid. We have worked for efficient vehicles.” In 2021, we announced our
decades to provide cost-effective, higher- strategic collaboration with Enedym Inc.,
efficiency materials and parts to the a Canadian-based inventor and designer of
transformer industry that supports our paradigm-shifting motor technologies.
electrical grid. As society increases its Along with our sister companies within the
demand for electrical energy, we are JFE Shoji Group, including JFE Steel, we
strengthening and renewing that intend to be a major force in enabling this
commitment. We are expanding our North transition to allow Canada to be a leader in
American electrical grid’s capacity by clean energy technologies. It is our
replacing aged equipment and finding more commitment to work with these OEMs and
renewable generation sources. Sustainability industry partners within our supply chain
of our electrical energy sources is of along with governments and government
paramount importance to our modern partners to achieve these objectives.
society. Our path to get there must be an
efficient one. With eyes toward the future, there’s a lot less
road ahead than expected. Nevertheless, JFE
2. Carbon reduction. JFE is currently working has a number of additional strategies in the
very closely with all its suppliers, particularly works for 2023 and beyond. We are working with
raw material suppliers, on carbon awareness governments, industry partners, clients and
and reduction. In fact, we are in an advanced advocacy groups to advise and create the
partnership with one of our European needed policies to protect future generations.
suppliers and a North American OEM client As Ron puts it, “We’re fortunate that we’re
to start using a carbon-reduced electrical working with some very progressive companies
steel product for a Canadian Utility to build strategies, and we will have a positive
Transformer. As Ron elaborated, “This impact in the future.”
initiative, working through our supply chain
with our business partners and clients, is an
important part of our carbon-reduction
strategy and our support of the 2050 net-
zero initiative.” We seek to expand and
strengthen our carbon reduction strategy
through our supply chain, and our internal Company contact details:
processes. We will be formalizing our JFE Shoji Power Canada Inc.
strategy through the balance of 2022, along 845 Laurentian Drive, Burlington, ON L7N 3W7
with efforts to deepen awareness and Local: (905) 637-3033
understanding of our initiatives. Toll-Free: 1 (800) 296-1103
54 ADVERTORIAL

The first of three articles by IMCORP

presenting a new technology that will
redefine underground cable life-cycle
management.

PREDICTIVE MAINTENANCE UNDERGROUND

FOR
AND REMAINING USEFUL LIFE CABLE SYSTEMS

When it comes to electric power distribution, the fundamental goals of

today’s electric utilities have not changed much in fifty years. They comprise
a safer distribution system that poses minimal risks to the public and to utility
workers, the reliable and stable delivery of power to critical, commercial, and
residential customers, and economically sound business operations that meet
both shareholder and ratepayer expectations.
The challenges to these goals, however, have grown significantly over the
past decade. Increasingly intense and frequent weather events raise the threat
of outages and environmental risks; the process of shifting from a centralized
to decentralized grid to meet decarbonization mandates creates complexities;
and the integration of renewable energy sources and the proliferation of electric
vehicles are escalating the demands on an aging distribution grid. The resulting
economic impacts to utilities range from high O&M costs to loss of revenue,
the need for new investments in infrastructure, and, sometimes, class action
lawsuits.
The replacement of overhead lines with underground power cable inherently
mitigates some of these challenges by increasing the reliability, stability, safety,
and, ultimately, resiliency of the grid. Underground power cable systems are
less susceptible to windstorms, lightning, wildfires, ice and snowstorms, vehicle
collisions, and other environmental hazards. This results in lower life cycle
costs compared to overhead lines, where costly O&M restorations and preventive
maintenance programs, such as pole inspections and vegetation management,
drive long-term costs. Overall, an investment in underground systems pays off
in improved safety, reliability, and economic return.
Although underground cable systems are much more reliable, they do occa-
sionally fail. When they do, they can be more expensive than overhead lines to
repair, as the failures can be more difficult to pinpoint and to remediate. Replacing
failed underground cables can cost even more, as it can be time consuming. The
replacement of direct buried cables, for example, can involve directional boring,
a slow process that comes with costly risks of hitting other underground infra-
structure. Underground cable replacement can take months or even years,
depending on circuit mileage, design, and construction work. Hence, the potential
for cable defects can certainly not be ignored. Left undetected, they will lead to
power outages, and to health and safety risks to the public.
Photo: IMCORP
Transformer Technology October 2022 55

Issue 22

Predictive tools combine innovative

data analytics and IoT technologies to
significantly improve maintenance
efficiency, asset availability, reliability
and lifetime value.

Cross-section of a typical solid dielectric cable

56 ADVERTORIAL

The Problem
The essential problem is that there is no visual inspection of underground
cables. Although manufacturers’ quality control standards for cable and
accessory performance assume a life expectancy of approximately 40 years,
that presumed reliability diminishes from factory to installation through ship-
ping and handling and installation workmanship. Of the new cable systems
IMCORP has commissioned, only around 60 percent met the manufacturers’
quality standards. Approximately 23 percent had deficiencies primarily due to
workmanship-related issues that were easy to remediate before the cables
were put into service, while 17 percent had deficiencies involving underground
issues, such as damaged cable or splices, that required additional rework
to meet standards. As we look further down the life cycle at the aged cable Underground cable
systems (30+ years old) that IMCORP has tested, 43 percent on average met
system components
the factory-grade quality standards. Again, approximately 23 percent had
deficiencies that were easily remediated, leaving 34 percent involving cable are highly engineered
or splice rework. The testing and subsequent repair effectively reset the “life and adhere to
cycle clock,” demonstrating that cables can last well beyond the 40-year life significant quality
expectancy. control standards
In sum, these results mean that a large percentage of cables—new and old— during manufacturing.
are perfectly fine. An additional percentage do not meet standards, but they After shipping
may not all be at risk of failure anytime soon. In the millions of miles of cable and installation,
already present in an evolving power grid, how do we know which cables meet approximately only 60%
manufacturers’ specifications—or come close to meeting them—and can be
safely left alone? How do we identify the cables not meeting the standards of cable systems meet
that can be locally repaired or, in some cases, require replacement? How do we those quality control
ascertain what defects they have developed or how much longer they may last? standards.
Although underground The replacement of underground cable just because it is old is an expensive
power cable systems undertaking, costing as much as hundreds of dollars per foot and taking perhaps
a day or more for a single cable to be replaced. Testing a foot of cable to find
are less susceptible out whether it really needs to be replaced, on the other hand, carries a small
to windstorms, fraction of that cost and can reach five to seven times the amount of cable that
lightning, wildfires, wholesale replacement does in the same amount of time. But repeating cable
ice and snowstorms, diagnostics or resetting the “life cycle clock” every so many years is not always
vehicle collisions, and economically or operationally efficient.
other environmental So, with only these options available to them—wholesale replacement or
hazards, the ongoing recurrent testing—how can utilities prioritize risks, establish budgets and financial
health assessment is forecasts, and maintain the safety and reliability of their underground systems?
The answer is a technology that makes it possible to locate defects, diagnose
completely different them, and predict the remaining useful life in the relatively small percentage of
than overhead lines. cable that does not meet the manufacturers’ quality control requirements.
To that end, IMCORP’s objective has been to develop a proactive and predictive
maintenance model for underground cable systems that provides visibility for
future reliability and, ultimately, lower life cycle costs—a technology that costs
less, takes less time, and is more accurate than training and using human ana-
lysts to analyze and interpret results from measurements taken in the field.

The Problem of Partial Discharge

According to the Institute of Electrical and Electronics Engineers (IEEE), over
90 percent of failures in underground cable systems are associated with partial
discharge (PD), a phenomenon in which an electrical discharge does not completely
bridge the gap between two electrodes. Underground cable and accessory
manufacturers go to great lengths, from design to manufacturing and quality
control, to eliminate any potential for PD in their products. Once these products
get installed, however, PD inevitably is introduced into these cable systems. In
these cases, PD slowly erodes the insulating material at the point of the defect
Photo: IMCORP

until the cable eventually fails. The challenge to the utility is to find the instances
in which PD is occurring and to determine the severity of the PD and the potential
time to failure.
Transformer Technology October 2022 57

Issue 22

When activated, PD produces high-frequency signals that are symptomatic

of dielectric deterioration and, eventually, fault. At the factory, manufacturers
are able to test cables and accessories for PD to high standards because they
typically perform their measurements in multimillion-dollar electrically shielded
rooms with metallic walls that block all electromagnetic interference from radio
waves and other high-frequency signals that can obscure PD defect signals.
These tests are performed on all new components at the manufacturing plant
prior to shipping and installation, with results that must meet Insulated Cable
Engineers Association (ICEA) standards for power cable and IEEE standards for
separable connectors, joints, and terminations.
Detecting PD becomes more complicated once the cable is installed and
then assembled with other cable system components. The only way to achieve
a factory-comparable result in the field is to use a factory-grade technology,
using 50/60Hz excitation voltage, high-efficiency sensors, and advanced digital
signal processing capable of achieving a measuring sensitivity of at least 5 pico
Coulomb. This allows identification of potential PD signals by human analysts,
IMCORP’s objective who “characterize” the signals—that is, they assign labels to the PD signals,
has been to develop a including location, magnitude, and PD type, and determine how far they deviate
proactive and predictive from the manufacturers’ standards and, therefore, how likely they are to lead to
cable failure and how soon.
maintenance model
for underground The interpretation of PD signals by human analysts is subjective and can
cable systems that vary from person to person, which makes the process time consuming, expen-
provides visibility for sive, and difficult to scale. With the tremendous expansion of underground
transmission and distribution cable systems in recent years, automation of
future reliability and, this task has become of paramount necessity. To accomplish it, IMCORP has
ultimately, lower life set out to develop a technology that uses deep learning to do what the human
cycle costs. analysts do, faster, more reliably, and on a much larger scale.

Typical PD-producing defects in underground power cables.

Top row: nonradial cut (left), electrical tree (center), and insulation void (right).
Bottom: cable failure (Photo courtesy of General Cable)
58 ADVERTORIAL

Deep Learning and PD Diagnosis

Machine learning is a branch of artificial intelligence (AI). It involves developing
algorithms that allow computers to identify and learn from patterns in sample
(training) data, based on which they can make predictions whose accuracy
increases as they learn. The larger the base of training data, the greater the
potential for the computer to find patterns and successfully learn from them.
Two general types of machine learning exist: supervised and unsupervised
learning. Supervised learning means the training data fed into the machine
learning algorithms are supplemented by the correct outputs—called “labels”—
from the analysis of those data. In IMCORP’s case, the inputted data are the
PD signals, and the labels are those that have been generated by the human
experts analyzing them. With deep learning—a subset of machine learning—
neural networks are created by IMCORP that simulate the behavior of the human
brain doing PD characterization.

The end goal is to be Over the past 25 years, IMCORP has tested over 250,000 cable systems and
more than 300 million miles of underground cable, amassing a database com-
able to predict faults prising tens of millions of instances of PD labelled by human analysts. Using
before they occur, rank this database as sample data, the deep learning networks we are developing are
all defects by severity learning to identify and characterize signals by “partial discharge” or “nonpartial
and the risk they discharge,” PD location of origin, and PD defect type with ever greater precision
present, and determine and accuracy. Already, they are providing results that rival the accuracy of
the human analysts in finding and diagnosing defects in underground cable
what this means in systems—to date, an accuracy rate of 97 percent. They also provide a more
terms of the remaining consistent level of quality and a time savings of up to 500 percent in the analysis
useful life of the cable. and interpretation of complex data sets.

Signal waveform of a positively identified PD

A Proactive, Predictive Maintenance Model

Locating and characterizing PD signals through automation is helpful for
preventing cable failure, but it is only a first step toward developing a predictive
maintenance system for underground asset management. Already, the neural
network has learned so much about finding and assessing defects that we can
rank them according to how severe they are and how likely they are to lead to
cable failure. Eventually, it will be able to indicate how soon failure will happen—
that is, it will predict the cable’s remaining useful life. With this information,
utilities will be able to prioritize preventive maintenance, cable repair, and
cable replacement and will know exactly where, along the millions of miles of
cables in their systems, to make available the materials, equipment, and human
Part 2 of the series will
resources needed to carry out the work.
describe the underlying
Ultimately, we want our deep learning networks to perform classifications data IMCORP is using
in near-real-time so that technicians in the field can see the results soon after and how deep learning
data are captured, with the benefit that cables already very close to failing may
not get switched back into service. The end goal is to be able to predict faults is being applied to
before they occur, rank all defects by severity and the risk they present, and develop its predictive
determine what this means in terms of the remaining useful life of the cable. models.
COMING
IN NOVEMBER

Power System
Technology:
The Solid-State
Revolution
Protection systems, relays, switchgear, batteries, and
solid-state technology, oh my!

We are tremendously excited to announce our special

November Issue! We will get to report on the ground-
breaking changes from an electromechanical approach to
a truly digital approach, discussing the topics of protec-
tion systems, relays, switchgear, batteries, and solid-state
technology.

In fact, we will feature articles that we believe will show-

case the next great leap in solid-state technology for the
battery market. It will be electrifying!

While a large part of our content is already assigned, there

is always room for a few new pieces of content.

Would you like to present your company’s expert knowledge

and technological solutions in our November issue?

Reach out to Dorotea Filipan

Coming in November Issue

60 INTEGRATED
MONITORING
SYSTEMS

A recent generation of dry type Condition monitoring of electrical

insulation technologies has changed power equipment has evolved into a
the economics for real-time significant growth industry offering
insulation condition monitoring. a wide variety of very sophisticated,
This article discusses integrated multi-parameter solutions. However,
condition monitoring solutions with these solutions come the
that can be built into the primary significant costs of managing the
condenser cores of transformer large volume of data that is generated
bushings, current transformers and from these systems and the ongoing
cable accessories (terminations maintenance of the monitoring
and joints). These solutions include devices. Robert L. Middleton received his degree in
monitoring of capacitive current electrical engineering from the University of
in the primary condenser core to This article will describe integrated Manitoba, Canada in 1971. He is a registered
detect changes in the condenser monitoring systems that can be professional engineer in the Province of British
core C1 capacitance, a new approach built in during the manufacture of Columbia. He has an extensive background in
for capturing and processing high the equipment and/or components. generation and transmission engineering in-
frequency PD pulse signals in power With this type of system accurate cluding quality assurance. He has served on
transformers [1] and HV cable monitoring is ensured due to a several CSA, CIGRE and IEC working groups
circuits and monitoring accuracy high interference shielding design and co-authored numerous technical papers.
“drift” in revenue-metering current and insensitivity to changes in He is presently the Chief of Technology and
transformers. These factory- temperature or frequency. These Engineering for RHM International, a manu-
installed sensing solutions provide integrated monitoring systems require facturer of high voltage dry type current trans-
the customer with low-cost real-time no external power source as they formers, transformer bushings and cable
condition monitoring options in place are powered directly from the grid terminations. Prior to joining RHM International
of expensive maintenance and field connection. Integrated monitoring he worked over 40 years at two western Cana-
testing programs [1]. systems have been developed for dian provincial electrical utilities.

Integrating Condition
Monitoring into the Product:
Economical, Accurate
and Hassle-free
by Robert L. Middleton
 Transformer Technology October 2022 61

Issue 22

the real-time monitoring of the The Smart RIF® Bushing voltage divider for accurately mea-
condition of the primary insulation suring these changes (see Figure 1).
for transformer bushings, current The smart RIF® bushing provides The two ends of Cs are brought out
transformers and HV cable terminals, a simple and economic alternative to a smart measurement terminal
the detection of partial discharge for insulation condition monitoring installed on the bushing mounting
activity in transformers and HV of the bushing. Condenser-graded flange where a factory calibrated LED
cable circuits and the monitoring of insulation can be modelled as a sensor can be plugged in to collect
accuracy “drift” in revenue-metering series of capacitors separating the and process the signal (see Figure 2).
current transformers over their conductor and ground. During the The LED lights “Green” for normal
service life. process of insulation breakdown condition and turns “Red” should a
screens fail sequentially change of capacitance be detected
eventually leading to total in the condenser core. The LED
breakdown of the insulation. “Red” indication is only a pre-alarm
Integrated monitoring As subsequent screens of a deteriorating condition and
systems that can be built breakdown the capacitance and allows the utility time to schedule
capacitance current gradually future options for the affected
in during the manufacture increases [2]. The smart RIF® equipment. There is no risk of an
bushing is manufactured with a imminent failure as lab testing has
of the equipment and/or large Cs capacitance (Cs>>C1) shown that subsequent failures of
capacitive screens will be very slow
components ensure accurate integrated into the condenser progressing.
core to create a capacitive
monitoring due to a high
Figure 1.
interference shielding design Smart RIF® Bushing Schematic
Representation
and insensitivity to changes
in temperature or frequency.

HV – HV terminal connected to grid, E – earth terminal, EP – equipotential plate,

C1 – main core insulation capacitance, Cs – signaling capacitance (Cs˃˃C1),
C2 – test tap to bushing flange insulation capacitance

Figure 2.
Smart RIF® Bushing LED Sensor
Integrated monitoring
schemes provide economical
but accurate real-time
monitoring of key condition
parameters without having
to manage the large volume
of data generated by
Photo: RHM International

conventional monitoring
systems.
62 INTEGRATED
MONITORING
SYSTEMS

Scheme for Detecting PD Figure 3a.

3-Ph View Showing RIF® Bushing PD
Activity in a Transformer Sensors and Tank Mounted PD Monitor
Using the Smart RIF®
Bushing as the Sensor

Field testing for partial discharge

in transformers is costly requiring
specialized equipment and highly
skilled technicians to perform the
testing and interpret the data. A more
economical solution for detecting PD
activity can now be realized by using
RIF® bushings equipped with a smart
measurement terminal and plug-in
PD sensor to couple the discharge
pulse current signals coming from the
transformer (see Figures 3a and 3b).
Depending on the number of RIF®
bushings installed on the transformer
the scheme can be configured to
simultaneously monitor transformer
Figure 3b.
PD signals from up to 9 locations [1] 1-Ph View Showing RIF® Bushing PD Sensor
thereby ensuring a very accurate Details
locating of the PD source. The coupled
signals from each RIF® bushing are
transmitted by a signal cable to a PD
monitor installed on the transformer
tank wall for data acquisition and
processing (see Figure 4). Data
for the PD analysis system can be
downloaded from the PD monitor,
transmitted with optical fibers to a
computer in a central control room or
transmitted wirelessly.

With this scheme the transformer’s

entire insulation condition is
monitored; it simultaneously monitors
the transformer PD condition and the
bushings insulation condition.

Monitoring PD Activity in HV plug-in PD sensors for detecting sensitivity. With the smart RIF® cable
Cable Circuits Using Smart PD activity in the terminations and accessories the insulation condition
RIF® Cable Accessories cable circuit (see Figure 5). Partial of the terminations and cable circuit
discharge detection uses the pulse can be monitored 24/7. The working
RIF® cable accessories (terminals, current method and direct coupling principle is consistent with IEC 60270
joints) can also be provided with provides positive anti-interference and requires no additional sensor
smart measurement terminals and performance and high detection installation [3].

Figure 4.
RIF® Bushing Signal Coupling Schematic
 Transformer Technology October 2022 63

Issue 22

Dry Type CT with Real-Time equipped with this monitoring

Insulation Condition and allows the utility to regularly
Error Monitoring Integrated monitoring check the accuracies without

The current transformer comes

systems come factory having to do expensive off-line
testing.
equipped with a built-in monitoring calibrated and provide a
device that provides real-time Conclusion
monitoring of the CT's primary lower cost plug and play
insulation condition and the ratio The integrated monitoring
and angle errors for each of the CT's installation. schemes discussed in this
secondary coils (see Figure 6). This article provide economical
is achieved by built-in information but highly accurate real-
collector technology and benchmark and inter-turn short circuits. It is well time monitoring of key condition
coils that are guaranteed not to known that revenue-metering current parameters without having to
drift over the CT's service life. This transformers once installed usually manage the large volume of data
built-in monitoring device needs no do not get checked for accuracy “drift” generated by conventional monitoring
external power as its power source over their service life. This can result systems. These systems come
comes from the CT itself and is in a significant loss of revenue for the factory calibrated and provide a lower
isolated from the HV primary so as utility. Using a current transformer cost plug and play installation.
not to affect the CT's performance.
Finally, standardized data Figure 5.
interfaces according to IEC 61850 Scheme for Detecting in HV Cable Circuits
communication protocol are provided. RIF® Cable Terminators using Smart RIF® Cable Accessories
fitted with smart
This monitoring will help to prevent measurement terminals
outages due to failing insulation and RIF® Cable Joints fitted
Window type
discover accuracy errors in real-time Current
with smart measurement
terminals
caused by secondary remanence Transformer
Power cable
circuit

RealPD
Optical
Communication
Cable

Figure 6. References
Dry Type CT Equipped with Real-Time [1] E. Euvrard, R. Middleton, H. Wang,
Accuracy Display Monitor
X. Song, Innovative Condition
Monitoring Solutions Using
Integrated Sensing Enabled by
a New Generation of Dry Type
Insulation Technologies, IEEE PES
T&D New Orleans USA, April 2022
[2] Tianshui Zhou, XiaoDong Zuo,
HaiLiang Wang, Ruzhang Wang,
Robert Middleton, Eric Euvrard,
The Development and Operation of
Novel Built-in Insulation Monitoring
Functions in the Management of HV
Bushings, INMR World Congress
Munich Germany, October 2015
[3] R. Middleton, E. Euvrard, H. Wang,
D. Song, Y. Zhao, Development of a
New High Voltage Dry Type Cable
Photo: RHM International

Terminator with Optional Integrated

Partial Discharge Monitoring, CIGRE
Session 48 (Virtual), Paper B1-102,
August/September 2020
64 ADVERTORIAL

How can upgrade

modern laboratory
monitoring testing
methods practice

Transformer monitoring is the measurement, collection and careful analysis of

all relevant data. If we measure the right data in real time and learn to interpret
that data, we can get a good insight into the operating condition of a transformer.
Constant monitoring then provides information about possible and necessary
immediate maintenance or can result in a guarantee for maintenance-free and
carefree availability.

Miroslaw Ch. Wrobel received the M.Sc. degree

in applied physics from Silesian University of
Technology, Gliwice, Poland, in 1993. He re-
ceived his Ph.D. degree from the Institute of
Fundamental Technological Research, Polish
Academy of Sciences Warsaw, Poland. He pur-
sued his Ph.D. research in the area of medical
physics focusing on molecular acoustics. He
worked on non-invasive medical diagnostic and
imaging techniques as a visiting fellow at the
Defence R&D Canada, Toronto (previously known
as DCIEM) of the Canadian National Defence.
Since 2005, parallel to his medical research, he
has been working on the application of acous-
tic and optical sensing method in high-voltage
technology. He holds several patents in the field
of medical diagnostics and monitoring of in-
Photo: Passerro

dustrial plants.
Transformer Technology October 2022 65

Issue 22

The digital revolution has changed everything Other oil properties such as the neutralization number
(IEC 62021-1 [4]) are used to make a prognosis about the
in our lives these days. Every day we face new further operation of the transformer. The neutralization
opportunities and challenges. Internet search number or Total Acid Number (TAN) indicates the
oxidation state of the insulating oil. If the neutralization
engines allow us to answer almost any question number is too high the formation of organic acids is very
advanced and there is a risk of sludge precipitation, which
that comes to our mind. So-called social media can result in serious consequential damage. An increased
give us the opportunity to connect with like- neutralization number is often reflected in a reduced
surface tension of the oil (ISO 6295 [5]). The oxidized oil
minded people all over the world, just like components act as surfactants and therefore influence
e-commerce gives us the opportunity to buy the surface tension. This is measured as the interfacial
tension (IFT) in the oil/water system and is a very sensitive
or sell products in a global marketplace. measure for the expected further aging behavior of the
insulating oil.
Information is freely accessible; people are
instantly connected, and markets are available As a preventive measure against accelerated oxidation,
the oil is usually treated with approx. 0.3% of the oxidation
worldwide. The mankind has integrated digital inhibitor DBPC (IEC 60666 [6]). Determining the
technology into the "soul of its being". It is hard decomposition gases dissolved (DGA) in the oil (IEC 60567
[7] and 60599 [8]) allow conclusions about impending
to imagine a day without a smartphone, WiFi faults in the transformer. Local thermal overloads of the
insulation system or partial discharges within the solid
or social networks, but then the question arises, insulation can be detected. The determination of the
why are our all-important but vulnerable high- furans in the insulating oil (IEC 61198 [9]) has been used
for some time as an additional information-source about
voltage systems still being monitored with the the condition of the solid insulation. With abnormal
“steam gauges” systems known from the last thermal aging of solid insulation (cellulose), various furan
derivatives are formed, which greatly accelerate the aging
few centuries? of the solid insulation.

Electrical systems make a significant contribution to the Passerro has found the solution to integrate
stability of the global energy supply, but their aging and
all the necessary sensors and mathematical
stress lead to irrevocable changes in the insulation
material. These changes can inform the operator about processes into an online oil sensor.
the electrical insulation and cooling ability of the oil during
the operation of the transformer and about its safety Unfortunately, these types of measurements and analysis
status. Therefore, monitoring these parameters is crucial. for the purpose of monitoring the correct operation of any
given transformer are only being carried out by selective
Extensive repertoire of laboratory test procedures and sporadic laboratory analyzes of the oil far away from
actual operation and with sometimes great delay. This
Theoretically, this task is solved by regular sampling and means that no real-time and immediate action can be
testing according to the IEC regulations. Basic monitoring taken and a response to measured parameters is taking
consists of recording the easily ascertainable main place, long after the circumstances have changed. Only
parameters of the system, e.g. of the transformer. These a proactive approach based on real-time and online oil
consist of mainly two methods – a dielectric-chemical condition monitoring can extend the transformers life.
analysis, which gives an insight into the oil quality; and The "gold standard" is the best study and laboratory test
the chromatographic methods, which allow a statement we could do right now – but the downsides are cost and
to be made about the "inner life" of the oil-insulated high- delay. However, this is still necessary, e.g. because of
voltage system. The dielectric-chemical parameters are insurance cover. The many standards and guidelines cover
the breakdown voltage (IEC 60156 [1]) and the dielectric almost all aspects of good laboratory practice but cannot
loss factor tgδ (IEC60247 [2]). Determining the breakdown keep up with the changing times. Laboratory tests are
voltage (BDV) and the dielectric loss factor tgδ (tan DELTA) extremely accurate when done well but are only performed
offers the possibility of assessing the current insulation sporadically.
condition of the oil. An increased (Wc) water content (IEC
60814 [3]) drastically worsens the insulating properties How can we change it and what procedure can give a
of the oil. more power grid security and cheaper overall cost?
 ADVERTORIAL

insulated high-voltage system? The measurement

practice that has been common up to now “only” provides
us with a snapshot under laboratory conditions, the
measurement done of the oil parameters under IEC
guidelines – usually at 20°C – cannot provide any
Figure 1. Typical connection and sampling field of a 40 MVA, information on the behavior of the oil at operating
110 kV/15 kV transformer temperatures which are greatly deviating from 20°C; also
keeping in mind that an error due to falsifying oil samples
Standard procedures are not enough to keep the grid by incorrect human handling is omnipresent.
safe and future-proof

Authorities agree that despite the current IEC 60567

regulation [7], incorrect and careless sampling and testing
techniques are at the root of 99 percent of "poor" dielectric
and DGA readings; showing once again that the human
factor is the weakest "link in the chain".

According to IEC 60567 “Oil-filled electrical equipment –

Sampling of gases and oil for analysis of free and
dissolved gases” [7] and IEC 60475 “Method for sampling
liquid dielectrics” [10], the sample should be taken from
that part of the container where the insulating liquid is
likely to be most contaminated. Two samples can usually Figure 2. A bypass cabinet with oil pump and sensors
be taken to assess the quality of a delivery (point 4.1.1).
Furthermore, in the same standard, in point 4.1.2, the Just image a cabinet created by Passerro containing a
quantity of the sample to be taken is explained. It depends sensor connected to the transformer oil filler necks or to
on the tests to be carried out and the methods used. the top/bottom oil check valves as a bypass to a trans-
former to feed the oil, in a closed circuit with an average
Typically, a 2-liter sample is taken. In addition, there is the capacity of about approx. 1.4 m³/h, see (Figure 2) or other
clarification in point 4.1.4.1 Sampling from transformer online systems such as online DGA (Figure 3).
tank: “the valve is opened and at least 10 liters of insulating
liquid are allowed to flow slowly into a waste oil container;
the sample bottles are rinsed with the insulating liquid;
The sample bottles are filled”. What does 10 liters mean
for a medium-sized 110 kV/15 kV, 75 MVA transformer
with approx. 30 m³ oil volume (Figure 1)?

When developing and testing the sensors, we

paid special attention to the use of modern
materials and energy-efficient components
and assemblies.
Figure 3. Direct installation on the transformer oil connections –
with DGA, moisture and break-down-voltage sensors
When using the drain valve AA023 "Bottom" for oil
sampling, we have approx. 0.5 liters of oil in the line (this Such sensor, with full digital and true Internet of Things
is negligible). If we use the drain valve AA022 "Middle" for capability is able to make several measurements a second
oil sampling, we will already have approx. 1.5 liters in the and depicture the fast changes in an inhomogeneous
line (no longer negligible). liquid insulation system. Some “gas flares” coming from
PD or spontaneous environmental gas intrusions as it is
What is then the volume we can take for our sampling by O2 can be detected and traced. This can be made only
running, say, 12 liters of oil through – then grabbing 2-liter with direct-in-oil immersed gas sensors without using
sample of new oil for the lab test? Assuming that the new membranes to separate the liquid and gas sections.
oil is tapped in a sphere around the connection, this results
in a sphere with an effective radius of 13 to 15 cm around
the tapping point. Let us compare this with the transformer The innovation includes the research,
LxWxH dimensions, which are 7,350 x 2,970 x 4,755 cm.
development and integration of a
We know that every oil-insulated high-voltage system is
unique due to its aging, its design and its load history. measurement method that also enables
Photo: Passerro

The oil reflects this history. So, the question arises: Is it

inspection and targeted monitoring of ester-
a representative sample of our oil? Does the single
sample give an insight view into the "inner life" of this oil- based transformer fluids.
Transformer Technology
Issue 22

Passerro was able to build an online sensor that can

measure the following oil properties:

✖ Temperature [°C]
✖ Relative humidity (RS) [%]
✖ Water content [ppm] Figure 4. Installation in OLTP top hatch
✖ Dielectric strength (BDV) [kV]
✖ Color [N] efficient components and assemblies. At the same time,
the innovation includes the research, development and
✖ Dissolved gas:
integration of a measurement method that should also
✕ Hydrogen – H2 [ppm]
enable the inspection and targeted monitoring of ester-
✕ Carbon Monoxide – CO [ppm] based transformer fluids. Ester-based transformer fluids
will, not only in our opinion, replace the current and long-
Other parameters will follow shortly: used standard mineral oil in the future. From an ecological
✖ Neutralization number (TAN) [mg/kg] point of view, transformer oil based on mineral oil is not
✖ Interfacial tension (IFT) [mN/m] the optimal dielectric. Mineral oil spills can have
✖ Dissipation factor (tan_Delta) [deg] devastating effects on the natural environment – including
✕ Ethylene – C2H2 [ppm] animals, plants, water, and humans – due to the poly-
chlorinated biphenyls (PCB) and polychlorinated
✕ Methane – CH4 [ppm]
terphenyls (PCT) found in mineral oil. Unlike mineral oils,
✕ Carbon Dioxide – CO2 [ppm]
natural ester dielectrics (ester oil) are non-toxic in water
and soil, non-hazardous, and quickly and thoroughly
and as the parameters acquired with Passerro’s system
biodegradable. Recent installations of ester oil filled power
are completely in line with already established, well-known
and distribution transformers around the world, due to
and implemented IEC procedures, this then becomes a
their natural dielectric properties, have shown the industry
real online “laboratory” allowing a constant and real time
that this can be a path towards a cheaper, more resilient,
monitoring (Figure 4). Some very important readings
better performing, and safer industry. However, the
nowadays are coming from laboratory methods knowns
corresponding measuring and monitoring sensors must
as titration (KF for water and KOH for TAN). Applying a
also work for this type of oil.
stringent chemical titration in an online procedure is
currently not possible without contaminating the oil with
So, the constant monitoring of oil parameters provides
the titrant. In this case, some substitutes must be used
accurate and up-to-date values as well as trends over
for this procedure. The engineers at Passerro GmbH have
time and with this knowledge the electrical systems can
solved already the KF-Water measurement Wc using the
be operated and loaded in a more targeted manner, so
acoustical resonator and working very intensively on some
that the economic efficiency of the systems is optimized.
online solutions to the TAN challenge.
Look out for more of our articles in the following editions
The constant monitoring of oil parameters of the magazine, where we will talk more about alterna-
tives that use modern digital monitoring systems.
provides accurate and up-to-date values as
References
well as trends over time and with this [1] IEC 60156 – Insulating liquids – Determination of the breakdown
knowledge the electrical systems can be voltage at power frequency – Test method
[2] IEC 60247 – Insulating liquids – Measurement of relative
operated and loaded in a more targeted permittivity, dielectric dissipation factor (tan d) and d.c. resistivity
manner, so that the economic efficiency of [3] IEC 60814 – Insulating liquids – Oil-impregnated paper and
pressboard – Determination of water by automatic coulometric Karl
the systems is optimized. Fischer titration
[4] IEC 62021-1 – Insulating liquids – Determination of acidity – Part 1:
Passerro has found the solution to integrate all the Automatic potentiometric titration
necessary sensors and mathematical processes into an [5] ISO 6295 – Petroleum products — Mineral oils — Determination of
online oil sensor. One of the main challenges, besides interfacial tension of oil against water — Ring method
estimating the Wc and BDV, is estimating the neutralization [6] IEC 60666 – Detection and determination of specified additives in
number (TAN). Other challenge is to find a high- mineral insulating oils
performance gas sensor that could withstand the everyday [7] IEC 60567 – Oil-filled electrical equipment – Sampling of gases and
environments of multi-megavolt-ampere power trans- analysis of free and dissolved gases – Guidance
former for long periods of time. We build new platinum- [8] IEC 60599 – Mineral oil-filled electrical equipment in service –
palladium-doped MOX selective gas sensors specially Guidance on the interpretation of dissolved and free gases analysis
designed for such missions. [9] IEC 61198 – Mineral insulating oils – Methods for the determination
of 2-furfural and related compounds
When developing and testing the sensors, special attention [10] IEC 60475 – Method of sampling insulating liquids
was paid to the use of modern materials and energy-
A BETTER ENERGY FUTURE IS
A FUTURE OF COLLABORATION
68

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 Transformer Technology WOMEN October 2022 69

Issue 22 OF NOTE

Nurul Noor

Nurul Noor
l
is the Specia for
a d e r
Projec t le in
cu ri ty
cyberse y
e n s E n e rg
Siem e ntly
rr
Malaysia. cu
e M id
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M a na g e m e n
C on tr o l &
n team.
Digitalizatio ting
e
She is a rk ndm a
p m e n t a
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stra n
th a
with more
20 years o f
experience.

raduating
Right after g e in Business
with a d eg re
ion from
Administrat a University
N or th um b ri aster’s
e pursued ed with a M
in the UK , sher studies and graduat ational) from
to further h Administration (Intern k record of success
in Business University UK . Her trac e Phillip Morris, Dell,
Nottingham tinational companies lik driving force for
with top mul s distinguished her as adled multiple events
and Shell ha nal changes. She han al contexts where
transformatios within local and glob cts across multiple
and project diverse matrix projevirtual stakeholders
she delivered al locations,
involving and maintaining
s
geographic eing operational task she was one of the
while oversee brand name. Recentlyunch of a prestigious
the corporatittee members for the la ersecurity Hub in Asia
main comm r a ground-breaking Cyba dedicated mom
ceremony fo emens Energy. Nurul is ves the beaches,
Pacific for Si aveler at heart, and lo her weekends going
of three, a trand rivers. She spends ily, reading books and
mountains, ding time with her fam nce her knowledge of
out and spen topics that could enha technology.
new excitingies, empowerment, and
human stud
Photo: Nurul Noor, rawpixel.com

Source:
Nurul Noor
70 TOPIC
MISSING

Monitoring Technology
of Dissolved Hydrogen
in Transformer Oil
by Julie Feng

Photo: Shutterstock

Figure 1.
Asia Pacific Dissolved Gas Analyzer Market
by extraction type, 2013 - 2024 (USD Million)
(Source: Grand View Research [1])
Transformer Technology October 2022 71

Issue 22

Introduction Background

The Asia Pacific dissolved gas China's electric power industry has
analyzers (DGA) market is expected rapidly developed with the accelerated
to reach USD 1.11 billion by 2024, development of China's economy and
expanding at a CAGR (Compound associated science & technology. This
Annual Growth Rate) exceeding 12.0% economic development has improved
over the forecast period, according to the quality of life by propelling forward
Grand View Research [1]. This growth increased requirements for the
is based on mitigating faults in high- operation, reliability, and life of their
voltage transformers combined with the power system equipment. To this
high cost of transformer replacement. end, analyzing dissolved gases in
Incorporating real time DGA analytics transformer oil is the most effective
aids companies in detecting faults method of evaluating the operation
in power transformers at the onset of oil-filled transformers. Online
instead of weeks or months later. Early monitoring devices that measure
diagnosis allows clients to develop dissolved gas in transformer oil are
proactive maintenance programs to vital tools for the power industry's
avert faults and extend the life of power operation and maintenance
transformers. This is expected to propel management of critical equipment.
global demand for online DGA systems Hydrogen is one of the key gases
significantly over the next few years. reflecting the internal insulation
Figure 1 illustrates this trend specific to defects of fluid-filled equipment.

D
Asia Pacific. Monitoring hydrogen in transformer
fluid has several advantages including
small size, convenient installation, and
GA hydrogen rapid response to sudden failures. In
monitoring in recent years China’s DGA programs
have been standardized and applied in
transformer monitoring both in-service and newly
oil has the installed large power transformers to
mitigate the risk associated with loss
advantages of small size,

H
of these important assets.
convenient installation,
and rapid response to ydrogen is
sudden failures. one of the
critical and
characteristic
gases reflecting internal
insulation defects of
oil-filled equipment.

Hydrogen Sensor Application

A Hydrogen sensor is a device that

Julie Feng obtained her degree in mechani-
detects hydrogen and generates an
cal engineering from China Shanxi Technology
electrical signal proportional to the
University in 2008. Over the past ten years
Hydrogen concentration. Compared
Julie has been engaged in industrial sales,
with traditional gas chromatograph
working with the largest DGA OEMs in China,
or mass spectrometer detection, solid
supporting the State Grid and other private
state Hydrogen sensors provide the
entities. Julie is currently Business Develop-
advantages of low cost, small size,
ment Director at H2Scan, China.
fast response, no maintenance, no
cross-sensitivity, long life and online
real-time monitoring.
72 DGA HYDROGEN
MONITORING

Technical Principles of Transformer Measurement accuracy performance

Oil Decomposition: is rated in Classes A, B, C: Table 2
for 750 kV and above sub-station
Transformer oil is a mixture of various device requirements; Table 3 for 500 kV
hydrocarbon molecules of different Substation device requirements;
molecular weights. Electrical or Table 4 for Lower voltage device
thermal failure can break certain C- H requirements.
bonds and C- C bonds, accompanied
by the generation of a small number of
active Hydrogen atoms and unstable The testing Measurement range
Measurement limits
hydrocarbon radicals (China State Grid parameter (pL/L)
Research Center). These Hydrogen
atoms or radicals rapidly recombine 2~20a ±2 µL/L or ±30%
through complex chemical reactions Hydrogen

A
to form hydrogen. 20~1000 ±30%

0.2~5a ±0.2 µL/L or ±30%

hydrogen sensor Acetylene 5~10 ±30%
is a device 10~50 ±20%
that detects 0.5~10a ±0.5 µL/L or ±30%
Methane, Ethane,
hydrogen and Ethylene 10~150 ±30%
generates an electrical 25~100a ±25 µL/L or ±30%
signal proportional to the Carbon Monoxide
100~1500 ±30%
hydrogen concentration. 25~100a ±25 µL/L or ±30%
Carbon Dioxide
100~7500 ±30%
Technical Core Performance
Indicators Include: 2~10a ±2 µL/L or ±30%
Total Hydrocarbons
1. Detection range and measurement 10~150 ±30%
C1+C2
accuracy 150~500 ±20%
2. Minimum detection concentration
3. Minimum sampling interval time
a
whichever is greater
4. Measurement repeatability
5. Response Time (T90) Table 2. Measurement requirements for multi gas monitors in substations of 750 KV and above.
6. Cross sensitivity Standard Q/GDW 10536-2021 (Source: China State Grid Research Center [3])

Hydrogen requirements/ Transformers and Voltage/Current

Bushing
Attention values reactors Transformer

330 kV 220 kV 330 kV 220 kV 330 kV 220 kV

Voltage level
and above and below and above and below and above and below

Before Operation ISO 2512 <30 PPM <50 PPM <100 PPM <50 PPM <150 PPM

In operation 150 PPM 150 PPM 150 PPM 150/300 PPM 500 PPM 500 PPM

Table 1. Technical Standards and the Application of Hydrogen Diagnosis in Oil (PPM Level) (Source: China State Grid Research Center [2])

Per China State Grid Corporation

Standard Q/GDW 10536-2021,
the measurement range for monitors
should meet the requirements
outlined in Tables 2, 3 and 4.
Transformer Technology October 2022 73

Issue 22

The testing Measurement range Measurement limits Measurement limits Measurement limits
parameter (pL/L) Level A Level B Level C

2~20a ±2 µL/L or ±30% ±3 µL/L or ±30% ±4 µL/L or ±30%

Hydrogen
20~2000 ±30% ±35% ±40%

0.2~5a ±0.5 µL/L or ±30% ±1 µL /L or ±30% ±1.5 µL /L or ±30%

Acetylene 5~10 ±30% ±35% ±40%

10~200 ±20% ±30% ±40%

Methane, Ethane, 0.5~10a ±0.5 µL/L or ±30% ±1 µL/L or ±30% ±2 µL/L or ±30%
Ethylene 10~600 ±30% ±35% ±40%

25~100a ±25 µL/L or ±30% ±30 µL/L ±40 µL/L

Carbon Monoxide
100~3000 ±30% ±30% ±40%

25~100a ±25 µL/L or ±30% ±30 µL/L ±40 µL/L

Carbon Dioxide
100~15000 ±30% ±35% ±40%

2~10a ±2 µL/L or ±30% ±3 µL/L ±4 µL/L

Total Hydrocarbons
10~150 ±30% ±35% ±40%
C1+C2
150~2000 ±20% ±30% ±40%
a
whichever is greater

Table 3. Measurement requirements for multi gas monitors in substations of 500 KV and below. Standard Q/GDW 10536-2021
(Source: China State Grid Research Center [3])

The testing Measurement range Measurement limits Measurement limits Measurement limits
parameter (pL/L) Level A Level B Level C

2~20a ±5 µL/L or ±30% ±10 µL/L or ±30% ±15 µL/L or ±30%

Hydrogen
20~2000 ±30% ±35% ±40%

0.2~5a ±0.5 µL/L or ±30% ±1µL/L or ±30% ±1.5µL/L or ±30%

Acetylene 5~10 ±30% ±35% ±40%

10~200 ±20% ±30% ±40%

25~100a ±25 µL/L or ±30% ±30 µL/L ±40 µL/L

Carbon Monoxide
1100~15000 ±30% ±35% ±40%

Composite gas 2~20a ±5 µL/L or ±30% ±10 µL/L or ±30% ±15 µL/L or ±30%
(H2,CO,C2H4,C2H2) 20~2000 ±30% ±35% ±40%
a
whichever is greater

Table 4. Measurement Requirements for few gas monitors Table 3. Standard Q/GDW 10536-2021
(Source: China State Grid Research Center [3])
74 DGA HYDROGEN
MONITORING
 Transformer Technology October 2022 75

Issue 22

Commonly Used Devices Conclusion

Monitoring devices for dissolved In summary, the application of online

hydrogen in transformer oil include monitoring ensures the stability of
a dissolved hydrogen sensor, control the transformer, saves high labor
and data acquisition equipment, costs, reduces the frequency of
communication and auxiliary modules, sampling and improves efficiency.

C
and an installation interface. Ongoing improvement in the industry
requires suppliers, operators and
technicians to conduct in-depth
ompared with research and continuous improvement
traditional based on problems arising in the
industry. The sector strives to provide
hydrogen gas the most reliable data for transformer
chromatograph monitoring to allow for the power
grid's optimized function
or mass spectrometer for everyone's benefit.
detection, hydrogen References
gas sensor provides [1] “Dissolved Gas Analyzer

advantages of low cost, Market Size, Share & Trends

Analysis Report By Extraction
small size, fast response, Type (Vacuum Extraction,

no maintenance, no Headspace Extraction,

Striper Column Method),
cross-sensitivity, By Power Rating (100-500

and online real-time MVA, 501-800 MVA, 801-

1200 MVA), By Analysis Type
monitoring. and Segment Forecasts To
2024,” Grand View Research,
Installation Simulation Tests accessed at https://www.
and Setup Examples include: grandviewresearch.com/
industry-analysis/dissolved-
1. Gas relay gas collection alarm gas-analyzer-dga-market
testing [2] “Monitoring Technology
2. 100°C oil temperature continuous for Dissolved Hydrogen
power-on assessment in Transformer Oil,” China
3. Simulation test for retrofitting a State Grid Research Center,
single hydrogen monitoring device accessed at https://edirc.
4. Joint pipe installation monitoring repec.org/
device vibration; vibration stress [3] “Standard Q/GDW 10536-
2021,” China State Grid
In-plant Installation and Corporation
Verification

Chinese Academy of Electrical

Sciences has installed a hydrogen
monitoring device on a large power
Photo: H2scan , Shutterstock

transformer and ran feasibility

analysis. Physical testing takes place
once the performance verification and
simulation operation tests have been
carried out.
76 ADVERTORIAL

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progress and sustainable development, substation equipment around it, the failures of
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Bushings solutions has been playing a pivotal business maturation time along with dedicated
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helping power utilities and transformer OEMs know-how, infrastructure, human resources
alike to help realize the goal of uninterrupted and, above all, a slow gestation period for brand
and sufficient power supply by ensuring recognition and establishment of trust with
minimal downtime of transformers due to customers, which is the primary reason that
unavailability of a highly critical component globally there are only a handful of recognized
of transformers – Capacitive Bushings. manufacturers for transformer bushings – with
YASH being a part of this distinguished list.
It is well known that capacitive transformer
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bushings are mission-critical devices for a There are several surveys and technical papers
power transformer/reactor/GIS and power internationally on power transformer failures
Transformer Technology October 2022 77

Issue 22

(transformers catching fire and explosive failure guided by seasoned technical experts hailing
leading to disruption of power availability), from transformer bushing industry from Europe
clearly indicating that transformer bushings and India as well as utility stalwarts in field of
contribute to an average >18 to 20% of power HV/EHV power substation and engineering
transformer failures, several of which are at design – all of them having a combined
times catastrophic in nature causing damage experience of 120+ years between them.
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transformers are repairable, the time to repair Possessing the ability to offer a combination
runs in several months thereby disrupting of all bushing technologies under one roof and
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or change in technologies and capabilities. are to be retrofitted.

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-PALM TERMINATIONS, CUSTOM ENGINEERED- -AS A RETROFIT-SOLUTION TO US,-
-FOR A GENERATION STATION- -TURKEY & OTHER MARKETS-

Replacing them requires a lot of value YASH being an independent manufacturer

engineering, involving considerable time, effort solely focused on transformer bushings with
and risk purchasing. Being an independent global supply experience of 27,000+ bushings
manufacturer solely focused on transformer across 50+ countries, has developed a unique
bushings, YASH possesses the ability to adapt identity of being more than an established
and deliver made-to-order solutions whether the bushing manufacturer, and as a one-stop
requirement is for a few bushings or for many, solution provider to power industry (generation
through a lean and responsive team which has and transmission) for all combination of
a separate and dedicated focus for custom transformer bushings which has been
engineering, while maintaining industry best appreciated alike by the end users and global
development times even for non-standard parts. MNCs such as Siemens, GE, Hitachi-ABB,
The solutions are developed by an experienced Toshiba, CG, Schneider, Hyundai, BTW, and many
and passionate in-house engineering team more. In addition to a well-established
78 ADVERTORIAL

and standardized product range, YASH

possesses the ability to offer flexible and highly
customizable retrofit bushings solutions to all
customers alike for the comprehensive product
basket of transformer bushings not only to
transformer OEMs as well as transformer
overhauling/repairing and servicing companies,
but also directly to the end user sites with supply
of interchangeable transformer
bushings retrofitted to any reputed global
bushing make hence justifying itself as a
solution provider rather than merely a bushing
supplier.

-ONE STOP SHOP FOR HIGH CURRENT,-

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There have been plenty of situations wherein

transformers have been under breakdown due
to problems with the existing bushings and
identical spares being non-available. This not
only results in heavy losses to the end user but
also forces them to replace the complete -145 KV OIL TO OIL-
transformer driving the cost of maintenance in -BUSHING SUPPLIED-
millions at times. A very similar situation was -AS RETROFIT SOLUTION-
witnessed by a huge thermal power generating
station in Turkey (2x660 MW) where power
generation was hindered due to issues faced in
LV high current bushings for seven generator
step up transformers thereby crippling the
entire plant’s generation. The LV high current
bushings of 36 kV 16,000 A had to be custom
engineered and retrofitted. YASH successfully
managed to develop this solution in record lead
 Transformer Technology October 2022 79

Issue 22

time overcoming the issues posed by the then

ongoing COVID-19 pandemic. These special
efforts by YASH were highly appreciated by the
end user and helped restore power to a million
households as well as industry and hospitals
especially during COVID. Similar executions
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transmission substations across the world
including some noteworthy executions of 36 kV
16,000 A HC bushings and 34.5 kV 8,000A IEEE
design high current bushings for multiple power
generating stations of USA, 170 kV 1,250 A 860
CT OIP and 36 kV 10,000 A 0 CT high current
bushings for Ecuador, to name a few.

Not limiting its capabilities of providing

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transmission application or generation

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Globally there are several solution providers for

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YASH remains unrivaled in providing retrofit/
repair solutions specific to transformer
bushings, and this capability is well appreciated
and welcomed by global utilities/power
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substations/EPCs and transformer repairing/

overhauling enterprises.
80 ADVERTORIAL

-600 KV EHV TEST LAB AT YASH-

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transformer bushings also warrants an utmost product which departs from the factory.
attention to detail towards quality and testing.
YASH factory consists of world class The infrastructure is further strengthened by
manufacturing and testing equipment sourced integrated ERP systems and world class 2D-3D
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winding machines, SCADA controlled autoclave market and be the preferred transformer
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systems, industry best handling and storage bushing solution provider to our discerning
systems, state of the art testing and evaluation customers.
Transformer Technology October 2022 81

Issue 22

-YASH CONSOLIDATED PRODUCT RANGE-

About Yash Highvoltage Ltd.

Established in 2002, YASH Highvoltage Ltd,

is an ISO 9001 certified independent and
indigenous manufacturer of niche condenser
graded transformer bushings. From a humble
beginning as manufacturer of high current
bushings, today YASH has grown steadily and
has craved a niche for itself not only in terms of
product range and business volumes of 27,000
products supplied globally but also in terms of
the customers and 50+ markets served, as a
true “one-stop solution provider” with a wide
product basket comprising of OIP (Oil Impreg-
nated Paper) Capacitive Bushings up to 245kV
for Oil – Air, Oil – Oil and Air - Air application in
power transmission, High Current Capacitive
Bushings up to 25kA for generator step up
transformers, Resin Impregnated Paper (RIP)
Capacitive bushings up to 245 kV under
technology and equity partnership with Moser
Glaser – Switzerland, IEEE range of OIP
condenser bushings and many more.

Yash Highvoltage Ltd.

[email protected]
www.yashhv.com
82 ONLINE
MONITORING

Transformer Bushing Monitoring:

The Reference Signal Method
by Emilio Morales

Photo: Shutterstock
Transformer Technology October 2022 83

Issue 22

Emilio Morales attended Nuevo Leon State

University in Mexico, receiving his bachelor’s
degree in Electromechanical Engineering
Transformer bushings are one of the most critical components in 1980. He has over 30 years of experience
in power transformer design which includes
of a transformer. Up to 20% of major failures on high voltage transformers up to 500 MVA and 500 kV, fur-
transformers today can be related to bushings. Almost half nace and rectifier transformers and reactors.
of these failures result in catastrophic failures like explosions, He is member of the IEEE/PES Transformer
Committee, IEC and CIGRE. He previously
fire or oil spillage. The cost of these damages and the lost worked with GE-Prolec, Ohio Transformer,
opportunity to deliver energy could be several hundred times Sunbelt Transformer and Efacec. He joined
higher than the price of a bushing. Even a failing bushing which Qualitrol in June 2012 as a Technical Appli-
cation Specialist in transformer applications.
does not lead to a transformer catastrophic failure can harm
His focus is to support solutions in compre-
people due to burst porcelain insulators, catapulted through hensive monitoring for transformer applica-
the air by the force of the arc of the breakdown. tions.
84 ONLINE
MONITORING

Experience has shown that there are aging rates are not considered in the Continuous monitoring solutions were
two main periods when bushings fail. methods where the sister bushings not used extensively in the past, due to
The first period of bushing failures are used as a reference source to n-1 availability of the main equipment.
has to do with production/quality assess the condition of a bushing Furthermore, monitoring solutions
related failures which occur once (like the balanced current method). were less reliable or not available
the bushings reach an age of 10 to Methods using voltage sources as 10 to 20 years ago. Nevertheless, the
13 years. The second period occurs reference signals from the same phase condition assessment in the utilities
between 20 and 30 years of age, which of the monitored bushing provide the of the old economies was carried
is considered its normal lifetime. required accuracy. The phase shift out under comprehensive periodic
However, it is also true that bushings between the leakage current signal measurements and maintenance
can fail before they reach 10 years of from the bushing and the voltage from programs. Nowadays these utilities are
age, while at the same time there are the voltage transformer is measured seeking more solutions to operate their
bushings installed in transformers that and corrected by the phase shift offset costly components till their real
are more than 50 years old. so the loss factor can be calculated end of life. Furthermore, asset
directly. By using a voltage transformer exchange programs will be based
(VT) as reference source, accuracies on the condition of the equipment.
up to 0.1mrad in terms of measuring Condition monitoring and condition-
the phase shift can be achieved and based maintenance are seen as an
In order to have a reliable small but relevant changes can be important factor to achieve these goals.
monitoring system, the detected.
accuracy of the acquisition In 2012, the CIGRE WG A2.37 released
an interim report [1] which shows the
of the monitored statistic on transformer failures
parameters needs to be (Table 1).
The two main health
very high, so that the
indicators for a bushing The results show that over all voltage
system can detect the
are the loss factor (tan δ/ classes, the failure rate is 0.44%, which
slight changes of the lost means, out of approximately 230
Power Factor) and
angle that occur due to transformers, one will fail per year.
capacitance. While the Besides the preventions of faults or
moisture contamination
loss factor is sensitive to early detection of upcoming faults,
in the bushing core. almost all bushing faults,
the assessment of the remaining life
and the health of the equipment is of
capacitance is an important immense interest, especially for aged
The two main health indicators for factor to detect partial equipment. In order to assess the asset
a bushing are the loss factor (tan δ/ health, a combined set of data from
Power Factor) and the capacitance. breakdowns between the main transformer and its main
While the loss factor is sensitive capacitive layers, and in components needs to be measured/
to almost all bushing faults, the combination with the loss monitored. Besides other components/
capacitance is an important factor to parts, bushings are one of the main
detect partial breakdowns between factor, to detect contact causes of transformer failures,
capacitive layers and to detect, in problems inside contributing around 20% to the overall
combination with the loss factor, the bushing. transformer major failures, depending
contact problems inside the bushing. on the type of transformer. Bushing
failures can lead to catastrophic
Bushing monitoring is aiming to Failure Statistic failures and can be accompanied
detect incipient faults and give by environmental disasters or fatal
an early warning as well as using Transformers are one of the most accidents to people. According to a
the bushings till its real end of critical components within the transformer reliability study published
life. In order to have a reliable electrical network and cannot, once in [2], 70% of all transformer fires are
monitoring system, the accuracy one fails, be exchanged easily by a new caused by bushing failures.
of the acquisition of the monitored one. Often transformer failures cause
parameters needs to be very high, the inability to deliver energy, have The causes of bushing failures vary
so it can detect the slight changes high potential to harm people and can from normal aging, moisture, quality
of the lost angle due to moisture cause environmental disasters. Due issues during manufacturing, repeated
contamination in the bushing core. to all of these, a high financial impact thermal and mechanical cycling,
often is connected to transformer transients, and external influences like
There are bushing monitoring systems failures. external flashovers. As a result, a high
today that are not able to capture these number of bushing failures develop
slight, but important changes. Voltage The old economies like Europe, North from partial breakdowns, thermal
and angle differences between phases America and Japan are especially instabilities or degradations of
as well as different temperatures facing aged key network components. longitudinal isolation interfaces.
Transformer Technology October 2022 85

Issue 22

HIGHEST SYSTEM VOLTAGE (kV)

FAILURES & POPULATION

69 kV < 100 100 kV < 200 200 kV < 300 300 kV < 500 700 kV All
INFORMATION

Failures 145 212 163 154 11 685

Transformer-Years 15220 48994 47473 41569 959 156186

FAILURE RATE/YEAR 0.95% 0.43% 0.34% 0.37% 1.15% 0.44%

Table 1. Transformer failure statistics [1]

Others Others
1% Tap Changers 5%
11%

Tap Changers
26% Core and magnetic circuit
7%

Bushings
Winding 9%
45%

Core and magnetic circuit

3%
Winding
49%

Lead exit
Bushings 19%
17%

Insulation Lead exit

Substation Transformers 1% 7% Generator Step-Up Transformers

Figure 1. Failed component statistic [1]

To improve transformer reliability can detect different failures in an early of increasing moisture content in the
the demand of reliable bushing stage of its development. insulation system, which is difficult to
monitoring is increasing throughout achieve under online condition. External
the industry. Power Factor influences like low frequency magnetic
fields, external noise and harmonics
The Power Factor reflects the condition as well as the lack of stable reference
and the health of the insulation itself. It signal sources are the factors which
represents the ratio between capacitive influence these measurements.
By using a voltage and resistive current, which in their
transformer (VT) as summation give the leakage current.
reference source,
The capacitive current is the result
accuracies up to 0.1mrad of the capacitive layer design and The advantage of online
in terms of measuring therewith provide a given value. The monitoring is that the
the phase shift can be resistive current is defined by the Power Factor of a bushing
resistivity of the insulation material
achieved and small but and is a direct parameter of the quality can be seen at different
relevant changes can be of the insulation system. Each healthy temperatures. Offline
detected solid and liquid insulation material has measurements without
a typical resistive current component.
An increasing resistive current will additional active heating
Bushing Monitoring indicate a degradation of the insulation of the bushing and
Parameters system and will increase the angle δ online monitoring that
and decrease the angle θ resulting in an
The main bushing parameters that increase in Power Factor (see Figure 2). use the sister bushings
are used today for bushing online as a reference source to
monitoring are the Power Factor in the The Power Factor measurement assess the condition of
IEEE world (or Dissipation Factor in under online conditions requires high
the IEC world) and the bushing main accuracy in order to detect small a bushing are not able to
capacitance. These two parameters changes and to guaranty the detection detect this kind of defects.
86 ONLINE
MONITORING

Figure 3 shows the behavior of the Capacitance leakage current of a bushing and its
insulation system with increased stable reference signal.
moisture content. The accuracy of the As described above for the capacitive
measured power factor needs to be current, the capacitance is a para-
very high, considering the power factor meter which represents the design of
difference at 20°C for a wet and dry the capacitive layers. It will increase,
insulation. if two or more layers of the electrical One of the newest
field control foils are short circuit methods used today for
The advantage of online monitoring (see Figure 4). If only two layers are
is that the power factor of a bushing shorted, the capacitance will increase bushing monitoring is the
can be seen at different temperatures. by a percentage equivalent to the total reference signal method,
Depending on the load of the number of layers. For example, which measures the
transformer, the temperature of the if two out of total 50 layers will be
bushing will increase or decrease. It short circuit, the capacitance will phase shift of the leakage
can be seen in Figure 3 that the power increase by 2% current of a bushing and
factor gradient of wet bushings is its stable reference signal.
much higher at higher temperatures Overview of the Reference
than for dry bushings. Offline Signal Bushing Monitoring
measurements without additional Method Today, the biggest drawback when
active heating of the bushing and it comes to increasing the accuracy
online monitoring that use the sister One of the newest methods used in Power Factor and Capacitance
bushings as a reference source to today for bushing monitoring is monitoring is that the bushings will
assess the condition of a bushing are the reference signal method, which be compared to each other across the
not able to detect this kind of defects. measures the phase shift of the phases and the balances between
Silicon screen

Flange
Leakage
A It
current
Measuring tap
Ic tan δ = Dissipation factor (DF)
Ground δ cos ϕ = Power factor (PF)
Ir IC
ϕ
High voltage
Ir
Conductor

Condenser core

Ic - Capacitive current
Tan δ / temperature curve
C1
0.8 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14
Ir - Resistive current
0.7
Figure 2. Leakage current and Power Factor C1 – Main Capacitance C2 – Tap Capacitance
0.6
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
= + + + + + + + + + + + + + +
𝐶𝐶1 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
0.5 𝐶𝐶1 𝐶𝐶2 𝐶𝐶3 𝐶𝐶3 𝐶𝐶4 𝐶𝐶5 𝐶𝐶6 𝐶𝐶7 𝐶𝐶8 𝐶𝐶9 𝐶𝐶10 𝐶𝐶11 𝐶𝐶12 𝐶𝐶13 𝐶𝐶14
Tan δ

0.4
Figure 4. Bushing series capacitances
Tan δ / temperature curve 0.3
0.8

0.7 0.2
D20tan

D40tan

D60tan

0.6 0.1

0.5 0
1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Tan δ

0.4
Temperature
0.3
Dry bushing Normal aged bushing Bushing with moisture

0.2
D20tan D40tan D60tan
D20tan

D40tan

D60tan

0.1 Valid for wet bushings only!

0
1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

Temperature
Dry bushing Normal aged bushing Bushing with moisture

D20tan D40tan D60tan

Figure 3. Power factor behavior over temperature due to increased moisture
Valid for wet bushings only!
Transformer Technology October 2022 87

Issue 22

the phases are not stable and are far The major challenges using this Conclusion
from neglectable. method are noise reduction or noise
elimination and the availability of a Lab measurements done by bushing
The only approach to overcome this stable reference source. The latter manufacturers with real bushings
drawback is to find a load independent is especially not always given. and results from onsite installations
reference signal source within the show that the accuracy of the power
same phase as the monitored bushing. Sometimes there are only VTs/CVTs factor values measured/monitored
A voltage transformer (VT) always has on the high voltage side or far away using this method is far better
a stable load on its secondary winding. in a separate switchyard (especially compared to the methods which
Furthermore, the VTs do not change in power plants) or VTs/CVTs existing compare bushings from different
their transfer behavior according only for one phase (mostly the middle phases. The results achieved in the
to the load of the network. As pure phase). A comparative monitoring in lab showed even better results in
measurement principle, the phase shift these cases can be applied, which stability and accuracy (less than
measurement between leakage current then increases the inaccuracy of 0.0057 degree).
and reference signal reduces the needed the system due to the comparison
hardware to a minimum because after of different phases as described Extensive tests and first applications
digitizing the signal, all signal processing above. Alternative methods are under of this method for bushing
will be done by software algorithms. development. monitoring showed that using the
Figure 5 shows the principles of the reference method with a reference
reference signal method using VTs from Noise elimination or limitation of is source from the same phase has
the same phase. one of the major requirements to the ability to detect small changes
achieve the necessary accuracy in the in power factor and capacitance
Due to the circumstance that the phase shift measurement of 0.0057 changes due to partial breakdowns
reference signal from the same phase degree (or 0.1 mrad). between two capacitive layers
is used, the achievable accuracy does even for voltage levels up to 1 MV
not depend on phase asymmetries Figure 6 shows a noisy signal before installations. Furthermore, this
anymore. Existing phase constant and after signal processing which is method can also be used for single
shifts from VT, cables etc. are illustrating the efficiency of the noise phase transformers/reactors without
compensated for. elimination algorithm. limitations.

L1 References
L2 [1] 1. CIGRE WG A2.37.
L3
Transformer Reliability Survey:
VT VT VT
Interim Report. s.l., No. 261,
ELECTRA, 2012
C1 C1 C1
Tap Tap Tap
[2] Berg, H.-P. and Fritze, N.
Reliability of Main
C2 R C2 R C2 R Transformers, Salzgitter,
Germany, Bundesamt für
Strahlenschutz, 2011

Phase Shift Phase Shift Phase Shift

Bushing Monitor

Figure 5. Principle of Reference signal method

Raw Signal

Signal processing
Amplitude

• Noise and harmonics need to be eliminated by 0 30 60 90 120 150 180 210 240 270 300 330 360
Ref. Voltage
Leakge Current
advanced software algorithms
• The accuracy of the phase measurement is better than
0.1 mrad (0.0057 degree) Phase
• The accuracy enables detecting changes in tan δ form, Software algorithm
e.g. 0.325% to 0.340%
• It enables early detection of moisture increase,
insulation system aging and degradation
Amplitude

• Temperature compensation will be necessary to 0 30 60 90 120 150 180 210 240 270 300 330 360
Ref. Voltage
Leakge Current

achieve this accuracy

90° - δ Phase
Phase shift measurement

Figure 6. Example of effective noise elimination

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