Fault Diagnostic Devices -...

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


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


KINDS OF SYSTEMS

ON-LINE, ON-SITE - FDD-EPT

– Transformer is in-service, test equipment and

personnel are also on site


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


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


Standard ‘X’mer tank model

with sensors

Need to detect and locate PD co-ordinates

(x,y,z)


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


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


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.


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)


Aluminum Crepe paper failure


Locations of failure pinpointed


Testing with shelf-top FDD-

EPT


Pinpointed locations


HVDC CONVERTER TRANSFORMER

315 MVA, SINGLE PHASE, 400Y/213Y/213D


Failure at LV Delta connection

of GSU –Case III Bad flexible link surface – front and back


FDD-EPT at the back of a

Utility truck or SUV

Operator at a distance of 30’ from ‘X’mer


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


Signals on several sensors

monitored 24/7 by FAN-EPT


FAN-EPT


Briefcase

This is our portable “lunchbox”-style

Briefcase technology.


More Briefcase Pictures


EASY PLACEMENT OF

SENSORS ON TANK

No need to cross voltage barrier


LV Turret view

Failure at the ZNOX connections


Failure at the cleats of OLTC

lead outs


180 MVA, 345 kV GSU


Large 345 kV Transformer


500 kV, GSU, Single Phase, CANDU

CANADA Failure detected in HV HISERCAP winding

Westinghouse Design of the eighties.


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


• 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


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


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


“Briefcase”


800 MVA, 161 kV, GSU, high

LV currents


Recent tests in Cabanatuan S.Luzon, Philippines –100 MVA


Das Marinas Sub-Station, Philippines, 300 MVA

Auto


90 MVA shell


25 MVA , 34.5 kV

Rectifier Transformers


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.


26 MVA, 34.5 kV

Rectifier Transformer

PD Test during Heat Run


450 MVA Core type


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

http://www.hartford.edu/



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