Dispelling the Old Myths of Winding Hot Spot Measurement Using Fiber Optics

Today Fiber Optic Temperature Measurement is Critical to the Health of Transformers

Brett Sargent, Sr. Director of Energy Solutions, LumaSense Technologies, Inc.
LumaSense (formerly Luxtron) has been measuring winding hot spot temperatures
accurately and in real time for more than 20 years. Since LumaSense was one of the
pioneers in using fiber optic technology to measure hot spots, we have been on the
leading edge of development and have had the opportunity to listen to our customers
concerns for two decades. As with any new technology, there were growing pains, but
we have been in a unique position of working with your customers to successfully
develop a sound, robust system that is now being used in more than 1,000 transformers
globally.
However, due to these early growing pains and the traditional nature of our industry,
some of these Myths still exist today, which is unfortunate, given the fact that recent
industry polls show winding hot spot temperature monitoring is the most critical
parameter to monitor within transformers. These Myths have prevented customers
from trying fiber optics in transformer temperature measurements, or prevented
customers from continuing to use fiber optics after initial trials. The purpose of this
article is to try and dispel some of these Myths that still exist today.
Myth #1: Fiber Optics Are Too Fragile For Transformers
During the initial usage of fiber optics in transformers, there was
a high percentage of failures due to breakage. Fiber optic
breakage mainly comes during three points in the life of a
transformer:
1. Transformer manufacturing and initial installation
2. Transport of the transformer
3. Internal inspections of the transformer after it's put in
service

Figure 1: Patented Fluoroptic

Rugged Probe by
LumaSense Technologies

Fortunately for the industry, LumaSense has had the opportunity to redesign the fiber
optic probes with over a 95% success rate in fiber optic installation and transport without
breakage. In 2003, LumaSense introduced the Rugged Probe, which is our fourth
generation design to allow for minimal breakage. We have had tremendous success with
this probe over the past four years. Additionally, transformer manufacturers have gained
invaluable experience handling and installing fiber optics over the years. LumaSense
works with over 50 manufacturing sites globally, and through on-site training and
feedback from the transformer manufacturing partners, we have developed a design and
installation methodology that works very well in the transformer industry. This is also
the result of 20 years experience in fiber optic temperature measurement.

Double and triple installation of fiber optics at select monitoring points is no longer
required with the LumaSense Rugged Probe. This eliminates additional material costs
as well as transformer manufacturers efforts, which leads to more cost savings.
Myth #2: Fiber Optics Are Too Expensive
Any new technology that is introduced into the
market has higher initial costs. This can be seen
from our experience with DVD players, cell phones
and flat screen televisions. The same has held true
with fiber optic temperature measurement systems.
LumaSense has reduced the costs of our systems by
75% over the past 15 years, while at the same time
adding enhanced features and functionality to the
systems. This year we have introduced our
ThermAsset2 Winding Hot Spot Monitoring and
Temperature Control unit that is 75% less expensive
than our original WTS-11 system launched 15 years Figure 2: The danger of not knowing
ago. Our new system has the capability to monitor 8 your transformer condition and the
expense of replacing it
channels, has memory storage of up to 1 year,
cooling fan and oil pump controls, self diagnostics, alarms, protective trips and requires
no calibration. Given the fact that many
transformers can run in excess of $2
Million USD, a fiber optic temperature
monitoring system is a fraction of a
percent of the costs associated with large
power transformers.
Myth #3: Fiber Optic Temperature
Measurements Are Not Reliable
The winding hot spot is one of the most
critical parameters to monitor within a
transformer. The life of a transformer is
dependent upon the life of the insulating
material located within a transformer. The
life of the insulating material is directly
related to the temperature to which it is
exposed. The winding hot spot is the
hottest region within the transformer, and
it is typically where the maximum flux
leakage occurs - usually located within the
upper region of the winding on the Low
Voltage (LV) side of core type transformers. Figure 3: Data collected from a polling question
taken during two recent web seminars hosted by
For years, WTI instruments (gages) have
LumaSense Technologies
been used on transformers for top oil

indication and winding hot spot indication. This measurement for the winding hot spot is
only a simulation based on heating an oil bath via a current transformer that is connected
to one of the phases of the transformer. No simulation is as good as the real thing.
LumaSense has several documented instances where the actual temperature measured
using fiber optics located directly at the winding hot spot region provides results that are
accurate, and up to 20C different than what a WTI indication provides. Additionally, a
WTI instrument can include up to four hours of delay in indications from what is actually
occurring within the transformer. Direct fiber optic temperature measurement provides
immediate indication of any temperature changes. Another consideration is the affect of
cooling on the winding hot spot. Many older WTI instruments have no correlation with
what is happening to the cooling fans and oil circulation pumps, since they are based
solely on the load of the transformer. Therefore, if the fans were to become inoperable, a
WTI instrument would show no change from normal since it is only a simulation. Direct
fiber optic temperature measurement would immediately give indications of cooling
changes by measuring the real affect this has on the winding hot spot.
The fact is that WTI instruments are not reliable.
Myth #4: Fiber Optic Temperature Monitoring Systems Require More
Maintenance
Compared to WTI systems, maintenance on some
fiber optic monitoring systems is nonexistent.
LumaSense uses a long life LED as a light source
within our fiber optics systems. This LED has the
ability to last more than 50 years without
replacement, and our experience in more than 25
years we have never had a light source burn out and
require replacement. This is important because when
a light source has to be replaced, recalibration of the
system has to be performed. Some fiber optic
Figure 4: New ThermAsset2
temperature monitoring systems that exist in the market Transformer Winding Hot Spot and
Control System from LumaSense
do not use long life LEDs (they use halogen lamps or
Technologies
gas filled bulbs), and these will burn out in a few years
of operation. LumaSense has designed systems that never require calibration or
maintenanceever. In fact, our systems are designed so they can be moved from
transformer to transformer without any calibration or maintenance. WTI instruments
have to be calibrated continuously (usually annually), which means another trip to the
field and potential replacement if the calibrations fail.

Myth #5: I Want To Measure More Than the Winding

Hot Spot, and Fiber Optics Cannot Do That
LumaSense has used fiber optics to measure winding hot
spots, top oil temperature, core temperature, bottom oil
temperature, tank wall temperature, etc. Fiber optics offer a
level of diversity that has not been available in years past.
We have seen fiber optics used as a direct replacement for
WTI and Top Oil Temperatures successfully. Since fiber
optics are EMI, RF and Microwave resistant, and designed
for high voltage applications using high voltage rated fiber,
they can be placed practically anywhere in the transformer.

Figure 5 Fiber optic routing in a

power transformer

Myth #6: Fiber Optics Cannot Last for the Lifetime of a Transformer
The material used in fiber optics is long lasting in an oil submersed (or SF6 filled / dry)
environment. From LumaSenses perspective, we have transformers that have been
successfully using our fiber optics for more than 25 years. With two and a half decades
of experience, I believe we have crossed the longevity threshold with fiber optics.
Myth #7: I Do Not Overload My Transformer, So I Dont Need Fiber Optics
While initial new transformers put into service are rarely used at 100% capacity, there is
no guarantee that you would be able to keep your transformer at low load through its
entire life. Transformers do fail, which means other transformers have to pick up the
load. Service areas and loading will grow, which means transformers will see an increase
in load throughout their life.
There are several reasons to use fiber optics for direct temperature measurement:
1. Design Verification
2. Dynamic Loading
3. Transformer Life Calculations
4. Transformer Cooling Performance
5. Condition Based Maintenance
Transformers are one of the most critical
assets to own and manage. Any additional
piece of information that you can obtain is
vital. Direct winding hot spot measurement
with fiber optics can provide one of the most
useful pieces of information to help manage
your transformer through both good and bad times. While this technology may be new to
some users, it is not new to the industry. LumaSense has experienced the learning curve
with fiber optic temperature measurements, and through our experience have been able
to address those lurking Myths within the industry.