🔧 Drying Without Downtime: A Case Study from PGCIL Jamshedpur (2004–2005)
As part of our commitment to advancing transformer reliability without compromising uptime, PTss successfully executed online reactor drying at Power Grid Corporation of India Ltd (PGCIL), Jamshedpur in 2004–2005.
This milestone marked a turning point in transformer maintenance, eliminating the need for shutdowns while restoring insulation performance and ensuring continuous system availability.
- PGCIL’s Eastern Region had a 50 MVAR bus reactor that underwent drying three times using conventional vacuum and heat methods, but each attempt resulted in rapid moisture reoccurrence.
- When PTss offered one of its first online Transformer Dryout Systems for trial, PGCIL evaluated its performance over an extended period, installing the system without taking the reactor offline and maintaining 24×7 power availability.
📈 Results at a Glance (Dec 2004 – Mar 2005)
The graph captures real-time data during the drying period
📉 Moisture (PPM) and Water Activity (AW) showed a sharp initial drop
🔁 Periodic upticks aligned with cartridge saturation
✅ Stabilization at 8-10 PPM moisture, sustained over months
Simultaneously, winding, oil, and machine temperatures remained stable, validating thermal equilibrium and process safety.
📌 Key Impact:
Long-term drying of the reactor, unlike any previous method tried
Validation by PGCIL, encouraging further product improvement at PTss
Recommendation by CEA to state utilities across India for similar applications
Adoption by PGCIL and OEMs into standard transformer specifications
This landmark case laid the foundation for PTss systems being deployed across regional substations by PGCIL to dry hundreds of transformers and reactors-before being embedded into OEM designs.