Electrical Substation Monitoring with Radiometric Infrared Camera

Ensuring Power Stability, Preventing Equipment Failures, Reducing Costs and Downtime in Substations

Keeping distribution grids running is critical to sustaining our current way of life. Electrical transmission and distribution lines are crucial for linking power stations to consumers, and substations create extensive interconnections. Growing electricity demand and the rapidly changing load cases due to renewable energy put more strain on these electrical substations. This expansion increases the risk of equipment failures, compromising power reliability. Aging infrastructure and increased demand for low-cost energy have stressed substations and grids, increasing the risk of costly brownouts and blackouts so much that energy supply companies face increasing pressure. Reliable solutions are needed to increase capacity, maintain reliability, and control costs. Understanding the thermal distribution of substation components is critical, as electrical resistance causes degradation and energy dissipation as heat.

Traditional spot-check monitoring with handheld thermal imaging cameras is ineffective due to time and workforce limitations, not to mention safety risks. In addition, manual thermal camera inspections are infrequent, conducted only monthly at best, which risks undetected faults because field-based technicians with handheld infrared cameras can only perform periodic checks, which may miss transient problems or those that develop between inspections. This manual inspection of substation equipment is labor-intensive and prone to errors due to missed inspection spots, wrong settings, image blurring, or subject to the technician’s subjective interpretation of thermal images. A modern and innovative approach involves installing low-powered thermal cameras around substation equipment for continuous monitoring. These solutions allow remote monitoring, reducing downtime and costs associated with equipment failures. Despite higher initial costs, this approach improves reliability and reduces long-term expenses due to fewer power outages, equipment failures, and labor and maintenance costs.

Detecting Loose Connections and Malfunctioning Fans with Xi410 Infrared Cameras

At a large Midwest power generation facility, the need for early detection of reliability issues with transformers and switchgear assets was paramount. The implementation of Optris Xi410 infrared cameras significantly improved this process. These robust thermal cameras provided a rugged, edge-based solution for continuous infrared image acquisition, coupled with backend software for trending, alarming, and image review.

For instance, when monitoring a transformer, the tank temperature and the temperature of each bushing were continuously tracked and alarmed, with temperature values trending over time. Monitoring maximum and delta temperatures between the three phases identified a loose connection on the high line drop to the transformer. The plant also discovered loose busbar connections and loose connections on drops from HV lines to GSU bushings, which could lead to corona, heat buildup, and eventual arcing, potentially resulting in catastrophic failures.

The thermal surveillance solution further revealed that a third of the radiator fans were not functioning, risking transformer overheating, reduced performance and unit derate. Cleaning the radiators was necessary to enhance performance.

The Xi 410 infrared cameras were instrumental in identifying these issues, allowing for timely intervention and performance improvements. With their high accuracy and affordable price point, these industrial cameras significantly lower the initial cost of a comprehensive monitoring system.