Unlocking Enhanced Reliability: A Deep Dive into Continuous Monitoring and Optimising Transformer Testing
Overview: Monitoring critical transformer assets
In the dynamic setting of a customer’s manufacturing facility, the uninterrupted operation of medium voltage dry type transformers is critical for their sustained production. This case study explores the journey of updating and modernising critical testing procedures, highlighting the challenges faced, strategic decisions made, and the positive outcomes achieved.
The Challenge: Managing testing against production led to errors and unreliability
Initially, machinemonitor® adhered to the test instructions and recommendations of the transformer's OEM, conducting yearly offline testing. However, this routine presented challenges for both the operation and engineering departments. The pressure to balance testing schedules with ongoing production led to increased risks of errors, potential unreliability of test results, and the utilisation of diverse resources.
The ‘A-HA Moment’: Integrating offline testing, historical data and ongoing monitoring is key
The limitations of the offline testing regime led to the realisation that valuable information was lacking. Results were incomparable between tests, and visibility into asset conditions during operation remained uncertain. Moreover, there was a potential decrease in asset reliability due to operator mistakes or oversights.
Strategic Shift: Online Condition Monitoring
In response to these challenges, a strategic shift was made from offline to online testing to enhance visibility into asset conditions during service and mitigate the risk of introducing issues. Permanent sensors were strategically installed, enabling safe access to testing points without interrupting ongoing operations.
The implementation of the Optmonitor solution played a pivotal role in consolidating historical information, previous tests, and new tests. This comprehensive approach enabled our experts to provide a thorough risk assessment.
Outcomes – Unplanned shutdown avoided, costs managed and maintenance savings
The benefits of this new online testing approach manifested quickly as this new approach detected partial discharge (PD) phenomena on several transformers. Subsequent investigations identified the PD fault was likely link to contamination. An outage was strategically planned, allowing for thorough cleaning, complete offline testing, and a reassessment post re-energisation. Results conclusively demonstrated that the partial discharge issues were the result of surface contamination, and the cleaning process effectively resolved the issue.
This facility is now installing continuous online monitoring throughout, facilitating real-time visibility into asset conditions through the Optmonitor platform.
Case Study Summary
The new testing procedure not only provided an early warning system for transformer conditions but also allowed for monitoring problem behaviour and planning outages only where necessary, without compromising full diagnostic information.
This article is part of a series of videos, article and case studies that looks at the latest developments in continuous monitoring including our cutting-edge continuous monitoring solution, OptMonitor.
This ground-breaking solution was designed to together with our customers and can now help you navigate the complexities of asset management with confidence.
A short video explaining how you can ensure asset management confidence through continuous monitoring with expert oversight.