Safer Monitoring, Safer Assets, Fewer Failures.
When failure isn’t an option, companies turn to Qualitrol. Our products are known for their precision, reliability, and impact—helping customers reduce downtime, avoid costly repairs, and improve safety across the board. With decades of proven performance and a global reputation for trust, Qualitrol delivers peace of mind in every monitor, sensor, and service we provide.
or over 80 years, Qualitrol has been a trusted name in protecting the world’s power infrastructure. Our advanced monitoring solutions—used in over 125 countries—help power producers detect issues in generation transformers before they become disasters. From cutting-edge sensors to intelligent analytics, we empower teams to make smarter, faster decisions that protect generation assets and maintain uptime. Backed by deep industry expertise and a commitment to customer success, Qualitrol solutions are built to safeguard critical equipment and ensure reliable power for generations to come.
The tank maintains dielectric liquid, pressure margins, and mechanical integrity around active parts. Risks include oil overfill (pressure/PRD operation/leaks) and oil level drops (leaks/exposed insulation), both of which undermine cooling and dielectric strength.
Qualitrol pressure and smart level sensors with temperature/load compensation, plus DGA for O₂/N₂ and moisture trends, detect abnormal breathing, leakage, and unsafe pressure behavior early.
The insulating liquid provides cooling and dielectric strength but deteriorates with thermal stress, moisture/oxygen ingress, and particulate contamination—producing acids/sludge and elevating PD risk.
Qualitrol online DGA (thermal/electrical fault gases, oxygen trend), moisture-in-oil monitoring, and optional particle counting pinpoint root causes and support oil-life management.
The LTC regulates voltage under load by adding or subtracting turns through switching taps via contacts and transition elements in a dedicated oil system. Failures commonly arise from contact wear/cooking, oxidation/contamination of LTC oil, misalignment or inadequate contact pressure (high resistance/heat), motor drive issues (motor, gears, brake), or control/power anomalies.
Qualitrol online DGA (Serveron™ TM series), temperature/ΔT models (main tank top-oil vs. LTC oil), motor current/torque and operation analytics, tap position & raise/lower status, and control-power monitoring reveal early thermal, arcing, mechanical, and control problems for condition-based maintenance.
The DETC fixes the turn ratio offline and relies on sound contact integrity and correct pre-energization position. High-resistance joints from corrosion, oxidation, contamination, or mis-torque—as well as motorized-DETC control faults—can impair voltage suitability at re-energization.
Qualitrol main-tank DGA trends hot-metal/thermal gases (and CO/CO₂ when paper is involved), while tap position/raise-lower/contact inputs and supply/logic checks confirm correct settings before energizing.
Windings and cellulose insulation transfer energy between voltage levels and dictate thermal and dielectric life. Failures stem from general and localized overheating (load/cooling deficits, eddy/circulating currents, short strands), moisture/oxygen ingress, bad joints, partial discharges, mechanical looseness/distortion, static electrification, and overload events.
Qualitrol online DGA (Serveron™ TM series), Neoptix® fiber-optic hot-spot sensing with thermal life models, UHF PD monitoring, and integrated cooling/pressure/level analytics expose incipient thermal, electrical, and mechanical stresses to prevent escalation.
Bushings conduct current through the tank wall; some use graded capacitance, normally ≥ 69 kV. Failures include partial breakdowns of capacitor layers, internal contact problems, core insulation aging/moisture, liquid deterioration, terminal connection heating, and porcelain surface contamination—raising tan-δ/power factor, PD, and flashover risk.
Qualitrol bushing monitors (capacitance & tan-δ with temperature compensation), PD monitoring for surface/internal activity, terminal temperature/IR-survey guidance, and DGA correlation (for bottom-terminal issues) surface emerging defects for timely intervention.
The core confines and guides the alternating magnetic flux in a closed loop so flux links the windings efficiently instead of leaking into the tank/structure. The core must be made of insulated coated laminations to reduce losses. The core can pick up charge through capacitances if left floating; therefore, it should be grounded at a single point. Shields made of the same core material, mounted in the transformer tank walls, are used to control stray leakage flux.
Typical issues include steel-joint opening, over-excitation (V/Hz, harmonics), unintended or lost core/shield grounds, GIC exposure, lamination insulation breakdown, unbalanced/stray flux heating, core-bolt insulation shorts, and loose laminations—raising losses, temperature, vibration, and PD risk.
Qualitrol online DGA, core hot-spot/top-oil temperature and vibration trending, core/shield ground-current inputs, excitation/V-Hz/harmonic analytics, and PD monitoring identify flux/grounding defects before they propagate.
The cooling system removes heat via oil circulation and air/water exchange; performance is sensitive to configuration, sensor fidelity, and mechanical health. Failures arise from mis-settings, fan/pump faults or reverse rotation, blocked radiators/coolers, and bad temperature sensors—driving hot-spot elevation and life loss.
Qualitrol monitors motor current baselines, run status, relay timing and control voltage, oil-flow indicators, and winding/top-oil/ambient temperatures with thermal-model residuals to detect underperformance and verify corrective actions.
Oil preservation systems maintain oil quality by isolating it from the atmosphere. Failures include bladder rupture, seal degradation, incorrect valve positions, or inadequate gas space—leading to moisture/oxygen ingress, abnormal pressure cycling, and accelerated aging.
Qualitrol headspace/tank pressure and level trending, bladder-rupture and PRD inputs, moisture-in-oil, and DGA (O₂/N₂ ratio) confirm ingress and configuration issues so operators can restore proper isolation.
Qualitrol provides a wide range of both basic and advanced sensor solutions, each designed to be scalable with enhanced levels of functionality. These packages are tailored to meet the diverse needs of our customers across the power industry, supporting condition-based monitoring strategies with trusted, reliable technology that evolves with your operational requirements
Get started with essential transformer protection. Our Core package combines trusted hardware and smart software to catch early signs of trouble—simple, effective, and budget-friendly.
Go beyond the basics with deeper insights. The Pro package uses advanced gas analysis to spot issues faster and help you make smarter decisions for long-term asset health.
Maximum protection for your most critical assets. The Elite package delivers real-time alerts with cutting-edge tech like partial discharge and fiber optics—so you’re always one step ahead.
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