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POWER TRANSFORMER CONSULTING

The AI Advanced Electrical Systems USA (AI AES USA) Power Transformers Group provides a wide range of engineering and technical subject matter experts for all owners and operators of large power transformers at electrical utilities, industrial, commercial, and institutional facilities. ​


Due to ever changing global conditions, power transformer owners are highly concerned with the reliability and health of their transformers and their ability to ensure continuous operation in these difficult times. Avoidance of transformer failures is critical as lead times for new power transformers can be upwards of 36 months or more depending on the ratings. The used transformer market is significantly depleted and global inventories are in short supply or non-existent. In addition, we are experiencing and ever-shrinking experienced work force, and companies no longer have the in-house expertise to rise to these challenging times. We have the expertise that you need and seek. ​

AI Advanced Electrical Systems USA (AI AES USA) has the expertise you require for all of your engineering and monitoring needs regarding power transformers.

 

Our experts can resolve your concerns regarding any of the following:
 

  • Consultation

  • Condition Assessment

  • Specifications Writing & Review

  • Proposal Evaluation

  • Design Review

  • Owners Engineer

  • Electrical Test Data & Oil Analysis Review

  • Factory Inspections and Test Witnessing

  • Factory Audits

  • Standard and Advanced Electrical Testing including EMSA

  • Deep Blue RF Monitoring System™

Power Transformer
Electrical Transformer

CONDITION ASSESSMENT
Condition Analysis involves the following:

  • A comprehensive review of electrical and oil test data results.

  • Maintenance & Operational information to assess the transformer's major components (core, windings, oil, bushings, surge arrestors, cooling systems, and controls.

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Engineering Analysis involves the following:

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  • Review of transformer design.

  • Review of reported problems and failures of similar transformers.

  • Assess the design for deficiencies, failure modes, and other reliability concerns.

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Upon completion and findings of the initial equipment assessment, repairs, maintenance, and inspections may be recommended.

SPECIFICATION WRITING
AND REVIEW

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We work with the client to identify the specific details of the transformer application in question. This includes the following:

 

• Loading requirements

• Voltage variations
• Short Circuit Stresses
• Environmental conditions and other considerations

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The engineer reviews this data and applies his knowledge and experience to write a purchase specification. The specification incorporates state-of-the-art design features and manufacturing requirements tailored to meet the client's specific design specifications and in accordance with established ANSI/IEEE and IEC guides and standards.

Analyzing Data
Discussing Data in meetings

PROPOSAL EVALUATIONS

 

The AI AES USA Subject Matter Experts (SME) utilize their knowledge of various designs and capabilities of the various transformer manufacturers and perform a comprehensive evaluation of the bids for new, rebuilt, and used transformer orders. The evaluation will include:

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  • Specification considerations

  • Past performance

  • Applications needs

  • Factory capabilities and condition

  • Craftsmanship and reliability

  • Schedules

  • Other factors may also be required for a comprehensive and complete evaluation.

DESIGN REVIEW

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Our SME arranges a meeting with the transformer manufacturer after the award is executed. The manufacturer provides detailed information on the following:

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  • Thermal and Dielectric requirements

  • Material aspects of the design

  • Electrical Clearances

  • Oil Flow

  • Conductor size

  • FEA/FEM validation/verification

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Other design factors will also be thoroughly reviewed and discussed with the manufacturer to ensure all the technical requirements set forth by the client’s specifications are understood and will be agreed and adhered to.

Writing of Reports
Analyzing Samples

ELECTRICAL TEST
DATA AND OIL ANALYSIS
REVIEWS

 

Our Subject Matter Experts can perform a review of electrical test data and oil analysis results to ensure findings are accurate and correct. Based on this review, maintenance plans may be revised. repairs, maintenance, and inspections may be recommended.

FACTORY AUDITS

 

Factory audits are performed for many reasons including:

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• Determining inclusion on a bidders list
• Part of the bid evaluation
• Part of an assessment or root cause evaluation

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The audit includes a comprehensive review of the factory processes for:

  • Designing

  • Manufacturing

  • Management

  • Supply chain

  • Problem resolution/mitigation

  • Financial strength and analysis

  • Overall financial status

  • Productivity

  • Delivery performance

  • Process control metrics

  • Safety practices and performance

  • Technology level

  • Quality records

  • Service History

  • Training programs

  • Management Philosophy

  • Plant layout

  • Housekeeping

  • Modernization

  • Throughput

Implementing factory audits photo
Tesla Coil Testing

FACTORY INSPECTIONS
AND TEST WITNESSING

 

Upon receipt of manufacture’s design approval from the design review, the manufacture of the transformer can begin. The SME begins monitoring the various stages of the construction process at selected hold points to ensure that the product is of high quality and free from defects and is adhering to the design.

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Inspection points may include the following:

  • Core Inspection

  • Core/coil assembly inspection

  • Acceptance testing

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All aspects of the manufacturing process performed are scrutinized including the following:

  • Quality of materials

  • Component selection

  • Suitability of construction

  • Test witnessing and approval of test results

  • Complete evaluation.

Deep Blue RF Monitoring System™

 

This AI-based advanced monitoring system is designed to identify and trend anomalies, incipient faults, or previously developed faults before they become catastrophic. Deep Blue RF Monitoring System™ performs a comparative data analysis against our library of findings utilizing complex ElectroMagnetic Signature Analysis techniques. The Deep Blue RF Monitoring System™ monitoring system goes far beyond any other online or offline electrical testing technology available on the market today.​

Deep Blue RF Monitoring TM Logo

The advantages include:

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  • 24/7 Online assessment of your asset’s health being monitored in real-time, under real conditions.

  • Data is sent to our Command Center via the cloud for our qualified engineers to review at a moment's notice from anywhere around the globe.

  • The client is notified immediately if the alarm condition requires attention.

  • Detects defects in generators, motors, bus systems, transformers, switchgear, and switchyards.

  • Quarterly health reports are provided on all assets being monitored.

  • State-of-the-art high-speed proprietary hardware, software, and analytic technologies.

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