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Saving Transformers Worldwide
Fault Diagnostic Devices FDD-EPTTM or
FAN-EPTTM
Presented to: IEEE-TC,
WG C.57.127 revision
April 13, 2015
Hyatt Regency Riverwalk
San Antonio, TX
By:
Hemchandra M. Shertukde, Ph.D.
Professor, ECE, UHART
And;
President/CTO, Diagnostic Devices, Inc.
DDI, 2015
8
Saving Transformers Worldwide
Saving Transformers Worldwide
Saving Transformers Worldwide
Fault Diagnostic Products
– Transformers
– Submarine structures
– Aircraft fuselages
– Bridges
– Petroleum Tanks
Services
– Engineering
– Design
– Field service
and monitoring
DDI was established in 1992 as a defense contractor
Dr. H. Shertukde developed this product in 1996 and now Exclusive License for product is with DDI
Saving Transformers Worldwide
KINDS OF SYSTEMS
ON-LINE, ON-SITE - FDD-EPT
– Transformer is in-service, test equipment and
personnel are also on site
Saving Transformers Worldwide
Kinds of Systems contd.
ON-LINE, OFF-SITE – FAN-EPT
– Transformer and test equipment are in-service
at site and test personnel off-site in remote
control room
SITE REMOTE
OFFICE
Saving Transformers Worldwide
Data Acquisition System
System can be configured for six to sixteen
channels or higher per requirement
Gen 1: 2 CHANNELS (SENSORS) – ISA
Gen 2: 4 CHANNELS (SENSORS) – PCI
Gen 3: 2 CHANNELS/SENSOR – PC 104
FORM FACTOR
> or = 1 MHz sampling rate per channel
BW: 50kHz – 350kHz BW for each sensor
Saving Transformers Worldwide
Standard ‘X’mer tank model
with sensors
Need to detect and locate PD co-ordinates
(x,y,z)
Saving Transformers Worldwide
FDD-EPTTM /FAN-EPTTM
Innovative Approach
Utilizes advanced Wavelet Transform digital signal processing techniques
Passive externally located Acoustic Sensors
Compact lunch-box device
DDI is developing a “Gold Standard” for on-line transformer diagnostics
Saving Transformers Worldwide
Intellectual Property Existing patent on signal processing Patent #
6,178,386
Patents pending on other systems
Future additional patents on hardware and
software
Copyright protection on software already with
DDI
Exclusive License for FDD-EPT now with DDI
Saving Transformers Worldwide
Case I – 5 MVA, 33 kV three phase
distribution transformer - NU PD fault location estimates were provided
to the customer at the average location of
[18.2”, 136.35”, 18.56”] inside the tank.
Actual evaluation and verification of the
location by customer indicated the
coordinates of the failure to be at [23”,
106”-132”, 18”] inside the tank.
Saving Transformers Worldwide
Case II - 30 MVA, 245/13.8 kV,
Delta/Wye, Three Phase, Mobile
Transformer
Testimonials
"...Your test pinpointed the problem very
accurately in this case. We might have
saved $20,000 and 5-6 weeks in shipping
time..."
-Mr. George Reitter, Corporate Technical
Director of Delta Star, Inc. in CA, USA
(1998)
Saving Transformers Worldwide
Aluminum Crepe paper failure
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Locations of failure pinpointed
Saving Transformers Worldwide
Testing with shelf-top FDD-
EPT
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Pinpointed locations
Saving Transformers Worldwide
HVDC CONVERTER TRANSFORMER
315 MVA, SINGLE PHASE, 400Y/213Y/213D
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Failure at LV Delta connection
of GSU –Case III Bad flexible link surface – front and back
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FDD-EPT at the back of a
Utility truck or SUV
Operator at a distance of 30’ from ‘X’mer
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Case IV - 180 MVA, 3-phase,
525/18 kV, Wye/Delta, GSU
Test conducted using FAN-EPT
2-180 MVA, 525 kV GSU transformers
monitored simultaneously
One healthy
Other faulty
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Signals on several sensors
monitored 24/7 by FAN-EPT
Saving Transformers Worldwide
FAN-EPT
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Briefcase
This is our portable “lunchbox”-style
Briefcase technology.
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More Briefcase Pictures
Saving Transformers Worldwide
EASY PLACEMENT OF
SENSORS ON TANK
No need to cross voltage barrier
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LV Turret view
Failure at the ZNOX connections
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Failure at the cleats of OLTC
lead outs
Saving Transformers Worldwide
180 MVA, 345 kV GSU
Saving Transformers Worldwide
Large 345 kV Transformer
Saving Transformers Worldwide
500 kV, GSU, Single Phase, CANDU
CANADA Failure detected in HV HISERCAP winding
Westinghouse Design of the eighties.
Saving Transformers Worldwide
Saving Transformers Worldwide
Saving Transformers Worldwide
Saving Transformers Worldwide
Saving Transformers Worldwide
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Advantages of Acoustic System for PD
Detection and Location
Can be used when Transformer is on-line & in the
field
Can be used when Transformer is being tested
during Applied Voltage or Induced Voltage test
Non-invasive and considerably safe and personnel
kept far from ‘harms way’
System robust enough to differentiate between
actual PD and other noise
Saving Transformers Worldwide
• Transformer failure rate in the USA by 2008 – 6%*
• 100,000 units
•Transformer failure rate worldwide by 2008 – 6%*
• 400,000 units
• Recent studies by Mr. Bill Bartley, IEEE Fellow, ‘14 of
erstwhile HSB have shown that the average failure age is
14.9 yrs vs. 25 years as traditionally envisaged** * Transformer Asset Management – A New Paradigm, Energy
Central, Energy Plus, 2004
•** An Analysis of Transformer Failures, Part 1
& An Analysis of Transformer Failures, Part 2 — 1988 through 1997, By
William H. Bartley, P.E.
Transformer
Failure Facts
Saving Transformers Worldwide
Wavelet Transforms (WT)
Methodology Benefits A powerful preventative maintenance tool
Early detection of incipient faults avoids costly repairs and downtime
Extends the life of costly transformers and minimizes premature failure
Maximizes uninterrupted power generation and distribution
Minimizes customer-outage minutes
Saving Transformers Worldwide
WT Method contd.
Can diagnose type and level of problem
from remote or local stations
Used for quality acceptance test on new
transformers and generates base-line data
Minimizes health & safety problems
Reduces insurance costs for equipment and
personnel
Saving Transformers Worldwide
“Briefcase”
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800 MVA, 161 kV, GSU, high
LV currents
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Saving Transformers Worldwide
Saving Transformers Worldwide
Recent tests in Cabanatuan S.Luzon, Philippines –100 MVA
Saving Transformers Worldwide
Das Marinas Sub-Station, Philippines, 300 MVA
Auto
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90 MVA shell
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25 MVA , 34.5 kV
Rectifier Transformers
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PD due to Bubbles
1) Temperature onset-150 deg C
2) Signal characteristics - similar to being an arrow-head with a
considerable amount of signal pile-up. BW : 100 k Hz to 200 kHz
3) Sensors are typically mounted on the cover of the transformer with
care to see if the electrical clearances for specific voltage levels are
met and with the permission of the use/client in shop testing and
linemen in the field operations. Sensor relocation to be done only by
qualified individuals not by the PD testers by acoustic methods.
4) DGA gases to be simultaneously checked: are large quantities of
Hydrogen. Carbon monoxide and Carbon dioxide ratio of least
concern. Roger's test to be watched carefully.
Saving Transformers Worldwide
26 MVA, 34.5 kV
Rectifier Transformer
PD Test during Heat Run
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450 MVA Core type
Saving Transformers Worldwide
www.hartford.edu
UHART –Go Hawks!
UCONN-Go Huskies!
Tel: (860) 768-4847
Fax: (860) 768-5073
www.diagnostic-devices.com
DDI
Tel: (860) 651-6583
Fax: (860) 735-6384
USA