Your main transformer is the most expensive piece of equipment at your plant. A new one costs $3 to $8 million. Replacement takes 12 to 18 months to manufacture and ship. And when it fails — really fails, the kind that makes the local news — it can take down the whole unit, catch fire, and damage everything around it. The brutal truth: most transformer failures send out warning signs months in advance through three different signals at the same time. Tiny gases dissolving in the oil. Small electrical sparks inside the windings. Hot spots that creep up over weeks. Each signal alone is ambiguous. Together, they tell the whole story. The Transformer Health Agent watches all three signals continuously, fuses them with your load history, and predicts faults 6 to 18 months ahead — long enough to plan a replacement, schedule an outage, and avoid a fire. Register for the event to see the agent flag a real transformer fault on live plant data.
The On-Prem Server Stack — Watching Your Transformers Without Leaving Your Substation
Transformer data is sensitive. Gas chromatograph readings, partial discharge waveforms, thermal patterns — the kind of data utility regulators and insurance companies want kept inside your perimeter. Three pieces of hardware sit inside your control room and never connect to the internet. Together they fuse all three failure signals into a single confident answer. Register for the event to see the full setup running live.
AT THE TRANSFORMER
NVIDIA Jetson AGX Orin The Listener
JobReads gas analyzer, PD sensors, oil temp, load
SpeedContinuous monitoring, 24/7
WhereMounts in the substation control cabinet
FormSmall ruggedized box, weatherproof
What it does: Streams data from your existing online gas analyzer, partial discharge sensors, RTDs, and load CTs to the brain. Buffers data so nothing is lost when the network blinks.
CONTROL ROOM · THE BRAIN
RTX PRO 6000 Blackwell The Brain
JobRuns the Transformer Health Agent fusion model
SpeedFault classification in seconds
WhereSits in your control room behind your firewall
FormTower computer, fits under a desk
What it does: Combines DGA gas patterns, partial discharge signatures, top-oil temperature trends, and load history. Matches against thousands of historical transformer failures to predict fault type, severity, and remaining useful life.
ENTERPRISE · TRANSFORMER FLEET
NVIDIA DGX Station GB300 Ultra · Fleet Brain
JobWatches transformer fleet across all substations
SpeedCross-fleet pattern matching in hours
WhereSits at corporate HQ in a server rack
FormRack-mounted, 24/7 enterprise grade
What it does: Tracks aging across 100+ transformers. Spots when the same fault signature appears at multiple sites. Builds the fleet-wide replacement priority list your CFO needs.
100%
Stays inside your building · never goes online
$0/mo
No subscription · buy once, own forever
Offline
Works fully air-gapped if your team requires it
Yours
Source code included · modify it freely
The Three Signals That Tell the Whole Story — Fused Together
Each signal alone is confusing. A small rise in any one of them could mean a dozen different things. Together, they paint a clear picture of exactly what is wrong. The Transformer Health Agent watches all three at the same time and tells you what your transformer is trying to say. Register for the event to see live signal fusion in action.
SIGNAL 01
Dissolved Gas Analysis
DGA
Tiny gases dissolve in the transformer oil whenever something is wrong. Different gases mean different problems.
Hydrogen (H₂)
Sparking inside windings
Acetylene (C₂H₂)
Arcing — most dangerous
Ethylene (C₂H₄)
Hot spots over 700°C
CO + CO₂
Paper insulation aging
Catches faults 3-12 months early
SIGNAL 02
Partial Discharge
PD
Tiny electrical sparks fire off whenever there is a weak spot in the insulation. Each spark has a unique pattern.
Internal voids
Air pockets in solid insulation
Surface tracking
Insulation breakdown on surfaces
Corona
Sharp edges discharging
Floating particles
Debris in oil
Catches faults 6-18 months early
SIGNAL 03
Top-Oil Temperature
+ LOAD
Oil temperature relative to load. Should follow a predictable curve. When it drifts, something is restricting cooling.
Cooler fouling
Radiators clogged or fans failing
Oil flow drop
Pump issues or sludge
Hotspot growth
Internal blockage
Overload aging
Insulation life consumption
Catches faults 2-8 weeks early
Three Real Transformer Problems — How the Hardware Solves Each One
Three real transformer scenarios from real plants — each one walked through in plain language. Same pattern every time: substation listener → control room brain → maintenance ticket. Register for the event to see these scenarios replayed live.
CASE 01
"Acetylene just appeared in the gas analyzer. Should we pull the transformer offline tonight?"
THE PROBLEM
The online gas analyzer detected acetylene — the gas that means arcing inside the transformer. Just 3 ppm. Could be a real arc developing toward catastrophic failure, or a one-off blip from a load swing. Pull the transformer offline now and you lose $400K in generation while you investigate. Wait too long and the transformer could fail catastrophically — fire, environmental damage, $5M+ replacement. The maintenance director needs an answer in the next hour.
HOW THE HARDWARE SOLVES IT
The Listener (Jetson)
Captures the acetylene reading along with hydrogen, ethylene, partial discharge data, oil temp, and load — all in real time.
The Brain (RTX)
Cross-checks: partial discharge is normal, oil temp is stable, no hydrogen rise. Pattern matches "transient gas event," not active arcing. Confidence 94%. No emergency action needed — but increase sampling frequency for 30 days.
Maintenance Ticket
Auto-creates: "Transient acetylene event — no active arc detected. Continue operation. Increase DGA sampling to weekly for 30 days. Re-evaluate."
THE RESULT
Transformer kept running. Sampling stayed clean for 30 days. Acetylene confirmed as a false alarm from a load transient. $400K unnecessary outage avoided. Zero risk taken.
CASE 02
"Top-oil temp is running 6°C hotter than last summer. Is the transformer in trouble?"
THE PROBLEM
Top-oil temperature is running 6°C hotter than last summer at the same load. Could be an internal hot spot from blocked oil flow (very serious — paper insulation degrading), or just dirty radiators (annoying but cheap to fix). Without knowing which, you either schedule an expensive internal inspection that may not be needed, or wait and risk the insulation aging out years before its time.
HOW THE HARDWARE SOLVES IT
The Listener (Jetson)
Tracks top-oil temp, bottom-oil temp, ambient, fan status, and load — gives the brain the full thermal picture.
The Brain (RTX)
Compares against the thermal model: top-bottom oil temp difference is normal, but cooling fan amps are 12% lower than baseline. Cross-checks DGA — no thermal fault gases. Diagnosis: radiator fouling, not internal hot spot. Confidence 91%.
Maintenance Ticket
Auto-creates: "External cooling system fouling — not internal fault. Schedule radiator cleaning within 60 days. Skip internal inspection."
THE RESULT
Radiators cleaned during scheduled maintenance window. Top-oil temp back to baseline. Insulation life preserved. $180K internal inspection avoided. $40K/year fan energy saved.
CASE 03
"Hydrogen is creeping up over 6 months. Can we keep running until next planned outage?"
THE PROBLEM
Hydrogen has crept from 50 to 180 ppm over 6 months on the generator step-up transformer. Slow rise — definitely a real fault developing — but is it weeks away from failing or months? Replacing this transformer now is a $5M, 12-month project. Running it to failure could mean a fire and a year of unit downtime. The reliability director needs to know exactly how long they have.
HOW THE HARDWARE SOLVES IT
The Listener (Jetson)
Pulls 6 months of DGA history, partial discharge waveforms, oil temp trends, and load profile.
The Brain (RTX)
Pattern matches against 47 historical hydrogen rises. PD activity is increasing in lock-step — confirms low-energy partial discharge in oil. Predicts severe degradation in 8-14 months. Confidence 89%.
Maintenance Ticket
Auto-creates: "Low-energy PD developing. Order replacement transformer immediately (12-month lead time). Plan swap during next outage in 10-12 months. Continue operation with weekly DGA."
THE RESULT
Replacement ordered 11 months before failure. Swapped during planned outage. No fire. No emergency. $8M+ catastrophic failure avoided. Insurance premiums dropped.
$8M+
Worst-case failure avoided on a single main transformer save — fire damage, environmental cleanup, replacement cost, and 12+ months of lost generation. The hardware pays for itself many times over on the very first transformer save.
Why This Matters — The Industry Numbers Your Director Needs to See
Transformer failures are not rare events at the fleet level. The numbers below are what the utility industry has been measuring for the last 30 years — and what AI fusion changes.
11%
Of large power transformers experience a major failure during their service life — your fleet has the same odds
$3-8M
Replacement cost of a single main power transformer — and 12-18 months to manufacture and ship
6-18mo
Typical early warning when DGA + PD + thermal signals are fused together
95%+
Confidence on fault calls when all three signals point the same way — operators trust it, they act on it
6-12 wk
From hardware delivery to live agent watching every transformer in your substation
$0/mo
No subscription, ever. Buy the system once. Own it forever. Source code included.
May 12 · 5:30 PM EST · Orlando · Hands-On
Bring Your Last DGA Report. Watch the Agent Find What Your Lab Missed.
Walk in with your most recent DGA results. Watch the Transformer Health Agent fuse them with partial discharge and thermal patterns to surface findings your lab analysis would not have caught alone. Get a real fault call with confidence score in front of you. Walk out with a quote and an order date. Pilot to fully running in 6 to 12 weeks.
What You Get — Everything In One Box, Yours Forever
A pre-configured server arrives at your control room. The Transformer Health Agent is already loaded — trained on thousands of historical transformer failure events. Plug it in, point it at your existing gas analyzers and PD sensors, watch it baseline your fleet within weeks.
Buy Once, Own Forever
No monthly fees. No per-transformer charges. No annual price increases. Pay one price up front.
Your Data Stays Home
Gas analyzer readings, PD waveforms, thermal data — all stays inside your perimeter. Insurance and regulators approve fast.
Source Code Included
You can change it, add new fault types, or build your own checks. Not locked in to us forever.
Ready Out of the Box
DGA + PD + thermal fusion model — all pre-loaded. No 6-month integration project. Just plug in and run.
Frequently Asked Questions
How fast can the Transformer Health Agent be running on our fleet?
From the day you sign the order to the day your team is using it daily is usually 14 to 22 weeks. The hardware arrives in 4 to 6 weeks already pre-set-up. Once on-site, our team connects it to your existing online gas analyzers, partial discharge sensors, and DCS thermal data. The agent then trains on your historical DGA records and load profile. Your team is getting fault calls in 6 to 12 weeks. Pre-trained on thousands of historical transformer failures — only fleet-specific tuning is needed.
What if we don't have online DGA — just quarterly oil samples?
Still works, just with less lead time. The agent ingests offline DGA results too — through a manual upload or lab integration. With quarterly samples plus continuous PD and thermal monitoring, you still get 3 to 6 months of early warning, instead of the 6 to 18 months you would get with online DGA. Many customers start with quarterly DGA and add online analyzers over time. The agent works either way.
Can it identify the specific fault type, or just flag a problem?
Yes — specific fault classification is the whole point. The agent classifies faults into the standard categories: partial discharge, low-energy discharge, arcing, thermal fault in oil, thermal fault in cellulose, plus combined faults. Each comes with a confidence score and severity rating. This is a major step forward from traditional ratio methods (Doernenburg, Rogers, IEC) which often produce conflicting diagnoses for the same gas profile. Our agent uses ensemble machine learning trained on thousands of validated cases.
Will it work with our existing gas analyzer brand?
Yes. The agent reads from any major online DGA monitor — Hydran, Calisto, Kelman, GE Kelman, ABB CoreSense, Morgan Schaffer, Vaisala, and others. It also accepts manual lab DGA upload from any IEEE/IEC-compliant lab. Same goes for partial discharge sensors — Megger, Doble, Qualitrol, and others all integrate. The Jetson edge gateway handles the protocol conversion regardless of brand.
What does "you own it" really mean? Are there hidden costs?
It means exactly that. You pay one price up front for the hardware, software, and source code. No monthly fees. No per-user charges. No annual increases. The only optional future costs are entirely your choice: support contracts if you want our help, custom feature work if you want something specific built, or hardware refresh whenever you decide. You can run the system forever without paying us anything more.
May 12 · 5:30 PM EST · Hands-On Hardware
Lock Your Spot. See How Three Signals Together Beat One.
Walk in. Bring your last DGA report. Watch the Transformer Health Agent fuse it with PD and thermal patterns to find what single-signal analysis would have missed. Ask the engineers anything. Leave with a quote and an order date. Pilot to fully running in 6 to 12 weeks. Buy it once, own it forever — no monthly fees, ever.
