Optimizing Transformer Health: How KAMO Electric Cut Costs and Improved Monitoring with Mobile Online DGA

This case study explores how KAMO Electric successfully tackled rising acetylene levels in a 2012 Waukesha 84 MVA transformer by adopting advanced online monitoring technology. Previously, the cooperative relied on costly and labor-intensive manual Dissolved Gas Analysis (DGA) sampling, which failed to provide timely insights into the transformer's condition despite extensive testing.

To enhance fault detection and reduce operational and maintenance (O&M) costs, the team implemented a Vaisala OPT100M mobile online multi-gas DGA monitor, enabling real-time data collection. This shift to continuous monitoring delivered clear, actionable insights, leading to a significant reduction in acetylene levels and cutting testing costs by 50%. Additionally, the Vaisala MHT410 hydrogen gas and moisture monitor was integrated as an early warning system, further improving transformer health management.

Key benefits achieved through this transition include:

• Reduced Manual Sampling – Lowered the frequency of costly and time-consuming lab tests while improving monitoring accuracy.
• Enhanced Fault Detection – Provided real-time visibility into transformer condition, allowing for proactive maintenance decisions.
• Significant Cost Savings – Saved tens of thousands of dollars in O&M expenses through a more efficient, data-driven approach.
• Improved Asset Management – Increased confidence in transformer health and longevity, reducing the risk of unexpected failures.

This presentation highlights how combining mobile multi-gas monitoring with a single-fault gas monitor can enhance operational efficiency, optimize maintenance strategies, and drive substantial cost savings. By embracing smart monitoring technology, utilities can achieve greater reliability, lower costs, and improved asset performance.