Case Studies — Real-World DGA Fault Detection
Detailed accounts of how PAS DGA monitors detected developing transformer faults, enabled planned maintenance, and prevented catastrophic failures. Each case includes gas trend data, diagnostic analysis, and quantified cost savings.
Thermal Fault Detected at Steel Mill — $2.3M Saved
DGA-500 detected H₂ spike from 8 to 85 ppm in 48 hours on a 120 MVA arc furnace transformer. Duval Triangle T2 diagnosis. Tracking damage found on bushing during planned outage. 270:1 ROI.
- Product: DGA-500
- Fault: Thermal T2 (300-700°C)
- Result: $2.3M Avoided
Remote DGA for Offshore Wind — LoRa Eliminates Cable Costs
DGA-200 + LoRa deployed on 22 offshore platform transformers, 12 km from shore. 3+ years zero maintenance. 60% cost reduction vs. cable-based monitoring. Fleet-wide hydrogen trending from onshore control center.
- Product: DGA-200 + LoRa
- Application: Offshore Wind
- Result: 60% Cost Reduction
Nuclear Compliance DGA — DGA-300 4+ Years Zero Drift
DGA-300 dual-mode OEM sensor replaced electrochemical sensors at a nuclear plant. 4+ years continuous operation with zero calibration drift. 85% compliance cost reduction. MODBUS integration with plant DCS.
- Product: DGA-300
- Application: Nuclear Compliance
- Result: 85% Cost Reduction
9-Gas DGA at ±800kV HVDC — DGA-900 Detects Arcing Fault
DGA-900 LPAS detected C₂H₂ at 2.3 ppm — early arcing signature on a converter transformer. 72-hour early warning enabled planned outage. Loose shield connection found and repaired. Catastrophic failure avoided.
- Product: DGA-900 LPAS
- Fault: Low-Energy Discharge D1
- Result: Planned Outage vs. Emergency
High-Speed Rail Transformer — DGA-500 Survives Vibration & Overload
DGA-500 IP66 deployed on traction transformers. Detected overheating during peak load period. Post-overload H₂ persistence confirmed permanent insulation degradation. Repaired during overnight maintenance window.
- Product: DGA-500
- Fault: Thermal T2 (Overload)
- Result: In-Service Failure Prevented
Have a DGA monitoring success story?
We are always looking for new case studies. If PAS DGA monitors have helped you detect a transformer fault or optimize your maintenance program, we would love to feature your experience.