CONSULTING SERVICES

SPECIFICATION DEVELOPMENT

The client specification defines the requirements by which the vendor is to design, manufacture, test, ship, and installs the transformer.  This document may be relatively simple to very complex.  JBTC has written specifications for many types of power transformers including distribution substation transformers, generator step up transformers, autotransformers, phase shifting transformers, gas insulated power transformers, power transformers for wind and solar power generation, shunt reactors, mobile transformers and mobile substations, and transformers for SVC or STATCOM application.

The specification defines all aspects of the power transformer taken as a system.  Performance characteristics, dielectric capability, short circuit capability, mechanical design internally and externally, thermal performance, magnetic field heating analysis, and dielectric fluid requirements are some of the more important elements of the transformer that must be addressed in the specification.  In addition, the accessories that are comprised of bushings, heat transfer equipment, surge arresters, current transformers, oil preservation, controls and instrumentation, wiring, and monitoring systems must be specified.  Any special operating conditions have to be identified for the vendor and these may include the ambient temperature range, seismic activity, ice load, wind load, and geomagnetic disturbance capability, to name a few.

JBTC follows the philosophy that the specification is not intended to tell the vendor how to design the power transformer.  The specification is written to define minimum requirements so all vendors quoting are on a level playing field for the development of their proposal to the client.        

FACTORY AND VENDOR EVALUATIONS

Not all vendors and not all factories have the same capabilities.  In the procurement process the evaluation of vendors and their associated factories is a perfectly legitimate process.  The key in this process is to use objectivity in the evaluation process to obtain a reliable assessment of vendor capabilities.

JBTC has performed the evaluation process for clients for approximately 19 years.  The process utilizes a structured questionnaire that probes the vendor organization in eight categories.  The vendor’s answers are scored and compared with a minimum scoring value.  This is how the objectivity is maintained.

EVALUATION OF VENDOR PROPOSALS

The evaluation of vendor proposals to a given client procurement need is also a service provided by JBTC.  The vendor proposals are typically comprised of a technical proposal as well as a commercial proposal.  JBTC has the expertise to assist the client with the technical proposal and to evaluate the proposals in regard to compliance with the client specification and industry standards.

DESIGN REVIEWS

The design review activity is the predominant service provided by JBTC.  The design review is a detailed meeting between the client, the vendor, and JBTC to review all of the technical aspects of the transformer design.  A major initiative of the design review is to ensure compliance with the client specification, industry standards, and compliance with the vendor proposal.

The design review dives into the details of the vendor’s design process and the analytic capabilities and methods used in the design process.  This is important to understand the state of the vendor’s technology development.  A part of this design review is also to quantify the experience level of the vendor with the type of transformer being reviewed as well as the extent to which the vendor has experience with the U.S. market, i.e. an experience list of customers.

The design review meeting has typically been conducted at the vendor’s facility or the client’s office.  However, as a result of the covid-19 pandemic, it has been necessary to accommodate design reviews by remote meetings.  Remote design review meetings have actually been very effective.  It may be that this process may be a “new normal” as meetings in this way can save time and money.  The vendors have been able to bring multiple resources from their organization into the meeting to provide valuable technical input whereas this may not have been possible in all cases with past practice.

JBTC has found the design review to be very helpful for the client.  Problems have been highlighted during the design review that would have otherwise been unknown until a n anomaly occurred in service.  Many vendors have also expressed the advantages of having a design review as it puts more sets of eyes on the design.  Catching design problems in the paper study portion of the transformer manufacturing cycle is much more cost and time effective.   

IN-PROCESS MANUFACTURING SURVEILLANCE

JBTC has performed many manufacturing surveillance activities.  These activities typically occur at specific points in the manufacturing cycle.  Clients define with the vendor the points at which they prefer to have a surveillance performed.  Examples of surveillance points are end of coil winding, end of core building, and the end of active part assembly and pre-tanking process.

JBTC has the expertise to conduct these surveillance activities since Mr. Templeton has not only engineering experience, but also manufacturing experience.  Over the years numerous issues have been identified during these surveillance activities that could have led to failures during FAT or in service.  As mentioned previously, these activities can be performed for both shell form and core form transformers.

WITNESS FACTORY ACCEPTANCE TESTING (FAT)

The FAT is a well-defined set of performance tests that are to be performed for each transformer.  The industry standards, IEEE Standards, and the client specification are normally used as the body of information that defines the required tests and the acceptance criteria.  The witness of the FAT is a routine activity for JBTC.

The FAT may be witnessed in its entirety or for a portion of the tests.  It is very common for the client to request witness of the thermal performance test and dielectric tests only.  If this is the case, the JBTC practice is to review all other test data to ensure compliance to guaranteed values as well as adherence to all acceptance criteria.  Mr. Templeton has observed and witnessed hundreds of transformer tests for both shell form and core form transformers.  Mr. Templeton also has an extensive background in the analysis of test anomalies and test failures.

ANALYSIS OF OPERATING DATA

Various tests are performed on power transformers during operation.  These tests are routine and performed on a periodic basis for preventive maintenance.  The interpretation of the measured data is frequently required and JBTC has the expertise to perform these tasks.  The data that are most often reviewed are dissolved gas in oil measurements and the normal oil characteristics test results.  Power factor tests, particles in oil, metals in oil, insulation resistance, and Megger tests are some of the other tests routinely investigated.  There are other specialized tests that may be indicated by the results of routine tests and JBTC can assist in this effort.

FORENSIC ANALYSIS

Approximately 2% of operating transformers fail in service each year.  For many of these failures it is a simple issue of reaching the normal end of life.  However, when a transformer fails prematurely, it is routine to initiate a forensic analysis to determine the root cause of the failure.  The process of the forensic analysis follows a relatively routine outline; however, each failure is unique and requires the ability to assess data and let the data lead the investigator to the determination of the root cause.  Mr. Templeton has performed many forensic analyses for both field failures and factory failures during his 45 year career.

EXPERT WITNESS

JBTC has been involved as an expert witness as a member of a team affiliated with a law firm or an insurance adjusters.  Mr. Templeton has experience with writing technical briefs for cases involving litigation, has testified in court, has testified to public utility commissions, and has provided technical information to insurance adjusters for property loss cases.  Each cases is very specialized and requires the ability to understand the technical aspects of the case as well as the legal aspects or insurability aspects of the case.  Mr. Templeton has the experience and background to provide this service.

TRAINING SEMINARS

JBTC has written and presented training seminars to electric utility clients as well as other organizations that support the electric utility business.  JBTC has presented transformer training to organizations in South Africa, South Korea, Brazil, and the United States.  Each of the training seminars is developed specifically for each presentation as the needs of the organization differs from one to the other.  These seminars have been very comprehensive (up to 4 days duration) to limited scope (single day) depending of the client requests.