Acoustic/Vibration-Based Condition Monitoring System for Tapchangers 21 March 2018 Paul Marshall Innovation Delivery Manager 1
Agenda Introduction Background Previous research Results so far Weaponisation Next steps 2
Transformer and tapchanger fleet 33 kV Tapchangers 132 kV Tapchangers 720 units 180 units 45 predicted end of life by 2023 345 predicted end of life by 2023 3
Transformer strategy – our focus today 25% 5% Bushings and Tank and connections radiator Objective £40 – 50 million savings Use CBRM to reliably manage the fleet ~15% ~55% 85% reduction in unit cost v replacement Tap changer Insulation Improve unit reliability 4
Acoustic monitoring of TC with Liverpool University Fibre mounted under flashing tape 5
11 sites trialled across Electricity North West Three types of acoustic signals arise from the tap changer unit Continuous and variable background transformer humming Acoustic events produced by the operation of the tap changer unit (TC signals ) ‘Other’ events, which are produced either by the transformer itself 6
Primary chromatic processing of TC events Demonstrates chromatic processing of the acoustic signals Chromatic algorithms are then used to translate the three R, G, B event parameters into a parameter space known as the Hue (H), Lightness (L) and Saturation (S) system The H and S parameters for the TC event are then plotted on an intermediate H-S polar plot representation 7
Modelling of results 8
Opportunities Proved their Data not easy Requires Used on the Needs further was an to interpret additional CLASS project innovation to opportunity to inputs to be to show wear be able to eg PD collect data in more usable on TC weaponise TPs Now BAU 9
Our strategy Engaged with Camlin Developed requirements TC Generate monitoring value for Needs to be ENW ‘Weaponisation’ easily now interpreted Collect more richer timely data 10
Background Record Goal: to process information recorded data NIA funded during each tap with tools project to test Acoustic/ change switching looking for trends Will lead to feasibility of vibration event for a referable to improved asset detecting acquisition period of two ageing of management of problems system years tapchanger tap changers 11
Prototype installations Wide bandwidth Proved that motor Three units sensors initially current is related to developed and used to collect data the torque it applies installed to learn to fine tune from friction, what we can or bandwidth of stiction etc need to collect sensors 12
Alpha prototype installations Introduction of Complete specific lossless Each system waveform from Three alpha compression should generate Accelerometer prototypes reduced data size about 2/3 GB per and CTs @ 192kHz installed and by 50% month Preliminary ‘hand- Temperatures commissioned in Installed system Down sampling of crafted’ data July 2017 Tap position for generate on CT’s waveform analysis has each switching Winifred Road average 3/4 should be identified issues event Primary events per day implemented to on two of three Altrincham Grid All data sent to each around reduce data of monitored tap Baguley Primary remote server 15/25MB about 30% changers 13
Latest system overview Transformer control kiosk Tap changer Tap changer monitoring system 2G/3G link SFTP server collects vibration and current waveform Ambient generated by each Temperature switchover probe 2x temperature probes 4x accelerometers (1x tap changer tank temp, or AE sensor 1x transformer tank temp.) Tap position 4x CTs (1x transformer current, 3x tap changer motor current) Mains power input 14
Acquisition module High and not scalable cost Relatively low sampling frequency (50kHz) Proprietary and high cost development tools (LabView) Limited amount of data means high failure risk of statistical analysis approach 15
Acquisition model Complete custom USB acquisition module GSM designed antenna Flexible 8 channel 24bit 192kHz differential input Usb Auxiliary isolated analogue input Auxiliary isolated digital I/O All sensors 4 input for RTD temperature sensor USB interface compatible with any Linux PC using standard drivers Acquisition module designed and tested in Tap changer Buzby2 about 6 months acquisition module Cost effective and quantity scalable solution 16
Vibration and acoustic sensors Analysis of mechanical vibration produced by gear and switch Require sensor capable of vibration detection with phase coherence across spectrum up to 10kHz 15kHz ICP Industrial accelerometer used (0.5 to 10-15kHz) 17
Vibration and acoustic sensors Detection of noise produced by arcing and PD during switching Require sensor capable of detect high frequency acoustic energy (> 50kHz, where mechanical noise 150kHz roll off) Acoustic emission resonating sensor used (15 to 150kHz) 18
Vibration and acoustic sensors Acquisition module can sample up to 192kHz so can be used with all kind of sensor (AE requires specific preamp) Hi quality industrial accelerometer 20kHz is similar cost to AE sensor and seems capable to detect energy up to 100kHz. 19
Electro-mechanical system Acquisition Module GSM Antenna Buzby2 EPC Power Supply Customized enclosures Cooling and suitable for indoor/outdoor Heating system 20
Project status Acquisition Three alpha Electromechanical Linux software module fully prototypes fully designed designed and designed and installed and (Lisburn) tested (Glasgow) tested (Parma) commissioned Statistical analysis of incoming data Basic statistic Site inspections 40 systems and algorithm implemented on carried out to plan installation development to server (Parma) installation scheduled determinate ‘system condition’ 21
Alpha prototype installation: Winifred Rd Site: Winifred Road Primary Tap changer type: Ferranti DC3 During the selector movement phase of last step of switching sequence 5->4->3 or 3->4- >5 arcing noise presence can be clearly heard. Any other 4->3 or 4-5 switchover switchover 22
Alpha prototype installation: Winifred Rd The arcing noise indicates that tap 4 contact of one of the three selectors is excessively worn Observing tap usage statistics shows that tap 4 is the most used tap position Currently the tap changer is on fixed tap awaiting inspection 23
Alpha prototype installation: Altrincham Site: Altrincham Grid Tap changer type: Fuller HS319 Recorded anomalous events 2/3 time per week always involving tap 8 Currently under investigation 24
Next steps \\\ 40 sites are being Data collection ongoing Examine the key installed now for next two years questions on TC Use machine learning and Move from time based to Develop a TC signature data mining to create a condition based for various TC models signature envelope interventions 25
For more information www.enwl.co.uk/innovation e innovation@enwl.co.uk 0800 195 4141 @ElecNW_News linkedin.com/company/electricity-north-west facebook.com/ElectricityNorthWest youtube.com/ElectricityNorthWest Please contact us if you have any questions or would like to arrange a one-to-one briefing about our innovation projects 26
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