AI empowers transformer operation and maintenance: a technological leap from fault repair to predictive maintenance

Why is’ seeing data ‘not enough?

With the popularization of IoT technology, more and more transformers have become “talking” – a large amount of operational data is collected, uploaded, and stored. But new problems arise:

Data can be seen, but cannot be understood; Before the problem occurs, there is still no way to determine.

This is the fundamental reason why artificial intelligence (AI) has entered the field of transformer operation and maintenance.

1.The core role of AI in transformer maintenance

AI is not replacing engineers, but undertaking the following three key tasks:

• Discovering patterns from massive amounts of data
• Identify abnormal patterns that are difficult for the human eye to detect
• Probabilistic prediction of future operational status

In complex, multivariate, and strongly nonlinear transformer systems, AI algorithms have natural advantages over traditional threshold judgment.

2.Typical applications of AI in transformer monitoring

2.1 Exception detection: no longer relying on fixed thresholds

Traditional monitoring systems typically use:

Temperature>95 ℃ → Alarm

But AI models can learn:

• Multi parameter correlation relationship under normal operation
• Normal range under different loads, seasons, and environments
• Once the operating characteristics deviate from the ‘healthy mode’, an alarm can be triggered in advance even if it does not exceed the limit.

2.2 Fault prediction: from “post analysis” to “pre intervention”

Based on historical fault data, AI can construct:

• Overload aging model
• Insulation life prediction model
• Partial Release Development Trend Model

So as to answer the most concerned question of operation and maintenance personnel:

How long can this transformer operate safely?

2.3 Operations Decision Assistance: Making Maintenance More “Accurate”

The AI system can perform health scoring and risk ranking on multiple transformers, helping owners:

• Prioritize maintenance of high-risk equipment
• Delay the maintenance of health equipment
• Reasonably allocate spare parts and components

This is of great significance for large power grids, industrial parks, and new energy clusters.

3.AI+IoT: Building a ‘digital twin’ of transformers

When real-time data is combined with AI models, a digital twin system of transformers can be formed:

• Real time mapping of virtual models to real devices
• Simulate different loads, environments, and fault scenarios
• Verify the security of the running strategy in advance

Digital twins are becoming an important development direction for high-end transformers and intelligent substations.

4.The Long term Impact of AI Operations on Cost and Reliability

Practice has shown that after adopting AI predictive maintenance:

• The unplanned power outage rate has significantly decreased
• Extended lifespan of equipment
• Reduce operation and maintenance costs by 10% -30%

This is particularly critical for high reliability scenarios such as new energy power stations, data centers, and electric vehicle charging infrastructure.

5.Challenge and Reality Boundary: AI is not a “panacea”

What requires rational understanding is:

• AI effectiveness highly depends on data quality
• Sufficient sample accumulation is required in the initial stage
• Still needs to be combined with engineering experience

A truly mature AI operation and maintenance system is a fusion product of algorithms, electrical engineering, and operation and maintenance experience.

The future transformer will definitely be a ‘thinking device’

When AI begins to understand the operating language of transformers, operations will shift from “experience driven” to “data-driven” and then to “intelligent driven”.
This is not only a technological upgrade, but also a reconstruction of the operation and maintenance logic of the entire power industry.

Luoyang Datang Energy Technology Co., Ltd. is a high-tech enterprise integrating R&D, manufacturing and supply of power equipment such as transformers, new energy components, distribution cabinets and inverters. With technological innovation as the core, we focus on creating high-reliability and high-performance power solutions to serve global customers. With a strict quality control system and international standard certification, we continue to output excellent products and enable customers to build safe and stable power systems.