The New Dimenson of Reli­a­bility

How well do you know your trans­former? Intel­li­gent MSENSE® sensors in combi­na­tion with ETOS® , the first open oper­ating system for power trans­formers, contin­u­ously provide you with all rele­vant infor­ma­tion as well as recom­men­da­tions for action in regard to all ques­tions crucial to reli­able oper­a­tion.

How can I detect high-voltage bushing errors in good time?

How can I detect mechan­ical tap-changer irreg­u­lar­i­ties before they become a serious problem?

How can I measure the temper­a­ture of the wind­ings directly in order to prevent damage?

Who will send me a timely warning in the event of elec­trical and thermal prob­lems?

How can I contin­u­ously monitor the gas content in the oil?

How can I actively keep mois­ture out of my equip­ment?


What damages the trans­former

The service life of a trans­former is crucially depen­dent on the transformer’s oper­ating condi­tions and its envi­ron­ment. Loads are signif­i­cantly higher in an indus­trial appli­ca­tion than they are in normal grid oper­a­tion. One way or another, it is impor­tant to be aware of the weak spots of the trans­former in order to prevent damage and disrup­tions at an early stage.

3 % points in the mois­ture in the insu­la­tion make a big differ­ence. When the mois­ture level in the insu­la­tion increases from 1 % to 4 %, the service life expec­ta­tion drops from around 35 years to fewer than 5 years.

17 % of trans­former fail­ures can be traced back to defec­tive bush­ings.

45 % of all trans­former fail­ures are the result of prob­lems with the wind­ings.

INVISIBLE and unde­tectable from the outside: this is the nature of mechan­ical irreg­u­lar­i­ties, time differ­ences in switching oper­a­tions and anom­alies in the tap changer.

12 °C An increase of just 12° C in the winding temper­a­ture reduces the service life of the trans­former by 75 %.

30 ppm This corre­sponds to a share of 0.000003 % and is a crit­ical value of mois­ture in the oil.

26 % of trans­former fail­ures can be traced back to anom­alies in the on-load tap-changer.


Sensors with System

Rein­hausen offers the MSENSE® sensor family and the main­te­nance-free MTRAB® dehy­drating breather in combi­na­tion with ETOS® as a perfectly customized soft­ware and hard­ware system.


Learn more at:


What should be done with the trea­sure trove of data?

The MSENSE® real­izes its full poten­tial when combined with ETOS®, the first open oper­ating system for power trans­formers. This intel­li­gent system helps to opti­mize and protect the entire service life of the trans­former, which bene­fits all parties: manu­fac­turers, EPCs and grid oper­a­tors.


The life of a trans­former begins with its design and produc­tion. ETOS ® provides manu­fac­turers with a precon­fig­ured and tested system that is ready for connec­tion and will cut costs by 65 % when compared with conven­tional automa­tion. New digital busi­ness models, such as live support, are also possible. In addi­tion, the data collected and expe­ri­ence gained in the field can be used to opti­mize future trans­former designs.


After the trans­former has been produced, it is sent to its desti­na­tion. EPCs (Engi­neering-Procure­ment-Construc­tion compa­nies) perform the instal­la­tion, during which up to 70 % on costs can be saved with the ETOS ® solu­tion. This is because, instead of each sensor having many copper cables, just a single fiber-glass cable is used for connec­tion to the moni­toring system. The intel­li­gence is located directly in the control cabinet on the trans­former. In addi­tion, data inte­gra­tion into a SCADA system is much simpler thanks to a stan­dard­ized commu­ni­ca­tion protocol (e.g. IEC 61850).


After a trans­former has been installed, it can be oper­ated for decades. Networking makes it substan­tially easier to utilize the capacity and service life of the trans­former. In this way, load and weather fore­casts are trans­mitted via the control room directly to the trans­former. This enables the trans­former to auto­mat­i­cally make deci­sions, such as when the cooling should be acti­vated.


During oper­a­tion, asset-manage­ment and service personnel are respon­sible for performing main­te­nance, over­haul and modern­iza­tion tasks on the trans­former. They can use the data collected from the trans­former to contin­u­ously monitor its condi­tion and mini­mize fail­ures. Calcu­la­tions have demon­strated that online moni­toring reduces the failure rate by 42 %.


When should I invest in new equip­ment? Where should this equip­ment be used, and how should it be config­ured? Grid plan­ners can use the data gained from the trans­former for future load fore­casts, and reduce the service-life costs of the trans­former as a result. In addi­tion, more precise require­ment spec­i­fi­ca­tions can be sent to manu­fac­turers for future invest­ments.



Do you have ques­tions about the MSENSE® sensor family and ETOS®?
Frank Micksch would be glad to answer your ques­tions: