On-line resistance measurement of substation connectors focused on predictive maintenance

To detect faults in their early stage in a substation, it is necessary to monitor, measure and analyze periodically the health condition of the electrical connectors, which are among the most critical devices in such installations. To do so, the electrical connector has to be combined with low-cost intelligent electronic devices (IED), including different sensor types and microcontrollers with wireless capabilities. Such an electrical connector is referred as SmartConnector. Using the data collected by the IED, it is possible to estimate accurately the current condition of the electrical connector in real-time, which in turn will determine the expected faults in the substation before a major failure occurrence. The electrical resistance plays a key role to determine the current health condition, and therefore to estimate the remaining lifetime of the electrical connector. The electrical resistance of a high-voltage substation connector is calculated in real-time using different methods proposed in this work, by using an analog-bipolar Hall effect sensor and an instrumentation amplifier. Experimental results, when compared with the standard 4-wire Kelvin method, show an error of less than 10%. Although the proposed methods have been validated for substation connectors, they can be applied to many other types of hardware with electrical contacts.Peer ReviewedPostprint (published version

Low-cost online contact resistance measurement of power connectors to ease predictive maintenance

© 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting /republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksWith the increasing use of sensors and wireless communication systems, predictive maintenance is acquiring more and more importance to assess the condition of in-service equipment. Predictive maintenance presents promising cost savings, as it allows minimizing unscheduled power systems faults, which can have very costly and catastrophic consequences. Early stage detection of power system failure requires acquiring, monitoring, and periodically analyzing the condition of the elements involved, such as high-voltage power connectors, since they are critical devices which are often located in key points of power systems. This paper proposes a low-cost online system to determine the contact resistance of high-voltage direct current (dc) and alternating current (ac) power connectors, to determine their health condition in order to apply a predictive maintenance plan. The contact resistance is considered as a reliable indicator of the connector's health condition. However, it cannot be directly measured, and the applied strategy differs between dc and ac power systems. The experimental results show a maximum uncertainty of 4.5%, thus proving the accuracy and feasibility of the approach presented in this paper, since the proposed limit of acceptable resistance increase is 20%. This approach can also be applied to many other power systems' elements.Postprint (author's final draft

Development of the future generation of smart high voltage connectors and related components for substations, with energy autonomy and wireless data transmission capability

The increased dependency on electricity of modern society, makes reliability of power transmission systems a key point. This goal can be achieved by continuously monitoring power grid parameters, so possible failure modes can be predicted beforehand. It can be done using existing Information and Communication Technologies (ICT) and Internet of Things (10T) technologies that include instrumentation and wireless communication systems, thus forming a wireless sensor network (WSN). Electrical connectors are among the most critical parts of any electrical system and hence, they can act as nodes of such WSN. Therefore, the fundamental objective of this thesis is the design, development and experimental validation of a self-powered IOT solution for real-time monitoring of the health status of a high-voltage substation connector and related components of the electrical substation. This new family of power connectors is called SmartConnector and incorporates a thermal energy harvesting system powering a microcontroller that controls a transmitter and several electronic sensors to measure the temperature, current and the electrical contact resistance (ECR) of the connector. These measurements are sent remotely via a Bluetooth 5 wireless communication module to a local gateway, which further transfers the measured data to a database server for storage as well as further analysis and visualization. By this way, after suitable data processing, the health status of the connector can be available in real-time, allowing different appealing functions, such as assessing the correct installation of the connector, the current health status or its remaining useful life (RUL) in real-time. The same principal can also be used for other components of substation like spacers, insulators, conductors, etc. Hence, to prove universality of this novel approach, a similar strategy is applied to a spacer which is capable of measuring uneven current distribution in three closely placed conductors. This novel IOT device is called as SmartSpacer. Care has to be taken that this technical and scientific development has to be compatible with existing substation bus bars and conductors, and especially to be compatible with the high operating voltages, i.e., from tens to hundreds of kilo-Volts (kV), and with currents in the order of some kilo-pm peres (kA). Although some electrical utilities and manufacturers have progressed in the development of such technologies, including smart meters and smart sensors, electrical device manufacturers such as of substation connectors manufacturers have not yet undertaken the technological advancement required for the development of such a new family of smart components involved in power transmission, which are designed to meet the future needs.La mayor dependencia de la electricidad de la sociedad moderna hace que la fiabilidad de los sistemas de transmisión de energía sea un punto clave. Este objetivo se puede lograr mediante la supervisión continua de los parámetros de la red eléctrica, por lo que los posibles modos de fallo se pueden predecir de antemano. Se puede hacer utilizando las tecnologías existentes de Tecnologías de la Información y la Comunicación (1CT) e Internet de las cosas (lo T) que incluyen sistemas de instrumentación y comunicación inalámbrica, formando así una red de sensores inalámbricos (WSN). Los conectores eléctricos se encuentran entre las partes más críticas de cualquier sistema eléctrico y, por lo tanto, pueden actuar como nodos de dicho VVSN. Por lo tanto, el objetivo fundamental de esta tesis es el diseño, desarrollo y validación experimental de una solución IOT autoalimentada para la supervisión en tiempo real del estado de salud de un conector de subestación de alta tensión y componentes relacionados de la subestación eléctrica. Esta nueva familia de conectores de alimentación se llama SmartConnector e incorpora un sistema de recolección de energía térmica que alimenta un microcontrolador que controla un transmisor y varios sensores electrónicos para medir la temperatura, la corriente y la resistencia del contacto eléctrico (ECR) del conector. Esta nueva familia de conectores de alimentación se llama SmartConnector e incorpora un sistema de recolección de energía térmica que alimenta un microcontrolador que controla un transmisor y varios sensores electrónicos para medir la temperatura, la corriente y la resistencia al contacto eléctrico (ECR) del conector. De esta manera, después del procesamiento de datos adecuado, el estado de salud del conector puede estar disponible en tiempo real, permitiendo diferentes funciones atractivas, como evaluar la correcta instalación del conector, el estado de salud actual o su vida útil restante (RUL) en tiempo real. El mismo principio también se puede utilizar para otros componentes de la subestación como espaciadores, aislantes, conductores, etc. Por lo tanto, para demostrar la universalidad de este enfoque novedoso, se aplica una estrategia similar a un espaciador, que es capaz de medir la distribución de corriente desigual en tres conductores estrechamente situados. Hay que tener cuidado de que este desarrollo técnico y científico tenga que sea compatible con las barras y "busbars" de subestación existentes, y sobre todo para ser compatible con las altas tensiones de funcionamiento, es decir, de decenas a cientos de kilovoltios (kV), y con corrientes en el orden de algunos kilo-Amperes (kA). Aunque algunas empresas eléctricas y fabricantes han progresado en el desarrollo de este tipo de tecnologías, incluidos medidores inteligentes y sensores inteligentes, los fabricantes de dispositivos eléctricos, como los fabricantes de conectores de subestación, aún no han emprendido el avance tecnológico necesario para el desarrollo de una nueva familia de componentes intel