Transformer Monitoring & Bushing Monitoring

Real-time insights to protect transformer performance and extend asset life.

QTMS is a robust, scalable transformer monitoring system which can be tailored to a specific transformer or standardized across a fleet of transformers. Designed to support up to 14 modules QTMS can support digital and analog inputs as well as fiber temperature monitoring and monitoring for up to 6 bushing. QTMS supports 1 to 14 modules with a mix of digital and analog inputs suited to the specific asset and sensors needed to monitor it.
QTMS also supports fiber temperature monitoring and bushing monitoring.

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Qualitrol QTMS Transformer Monitoring System, front-1

Application Overview

Monitoring insulation condition of transformer bushings
Detecting partial discharge activity in bushings
Identifying deterioration before failure occurs
Supporting predictive maintenance strategies
Enhancing transformer reliability and lifespan
Providing early warning for internal bushing faults
Reducing unplanned outages and maintenance costs
Integrating with transformer condition monitoring systems
Complying with asset management and reliability standards

Qualitrol Bushing Monitor

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Qualitrol Bushing Monitor System is an on-line Tanδ (PF) and Capacitance monitoring system for substation bushings. It measures the phase difference induced by capacitive layers of bushings and calculates the rate of change to predict defects in bushing insulation. It can predict defects related to partial breakdowns, moisture, contact problems and aging of insulation material.

Accurate and early incipient fault detection ensures reliable operation and reduces supply outages
Creates highly accurate data on asset condition, hence reducing maintenance costs
Monitors single bushings without the need for a secondary bushing.
Robust design and excellent interference immunity for measurements under difficult environmental conditions
User-friendly UI, trending, data logging, dashboard.
Advanced HMI provisions(intelligent data handling, display, and interpretation)
Flexible installation and configuration options to meet customer expectations
Smart and quick real-time alarming / alerting mechanism
Remote monitoring and configuration
Web-based, no need for dedicated software.
Expandable and field upgradable without reconfiguration
Supports 1 to 6 bushings independently.
1 Spare/available module to grow with you and your needs (analog signal, digital)
Can integrate third-party devices and other Qualitrol Transformer monitors (DGA, UHF Partial Discharges Systems, Breather, etc)

What We Solve For

Transformers experience gradual deterioration driven by moisture, overheating, insulation breakdown, mechanical stress, contact wear, cooling inefficiencies, and electrical faults. Many failure modes develop long before a major event occurs. Our monitoring solutions identify these issues early, enabling proactive intervention, reducing the risk of catastrophic loss, lowering maintenance costs, supporting condition‑based maintenance strategies, and extending the life of aging transformer fleets.

TECHNICAL

Features & Functionality

Functionality & Options

Thermal modelling including hotspot calculation, bubbling temperature, and thermal comparisons.
Oil diagnostics integration, including DGA, moisture‑in‑oil, oil quality, and particle count.
LTC/DETC monitoring including tap position, motor current, switch timing, control voltage, and dynamic resistance measurement.
Cooling system verification, tracking pump currents, fan currents, flows, radiator condition, and cooling control logic.
Core condition monitoring including excitation current, core ground current, shield ground condition, and overheating indicators.
Partial discharge monitoring (optional) using UHF sensors for early detection of dielectric faults.
Vibration and tank condition sensing (optional) for mechanical integrity assessment.
Integration with SmartSUB / APM software for analytics, visualization dashboards, alarms, and asset health indexing.

Key Technical Specifications

Power Supply: 120–240 VAC or 125–250 VDC, <50 W
Communications: Ethernet, RS‑485, USB; IEC 61850, DNP3, Modbus, IEC 60870‑5‑104
Analog Inputs: 8 per module, up to 112 per system
Digital Inputs: 14 per module, up to 196 per system
Relay Outputs: 8 per module, up to 112 per system
Fiber Optic Inputs: Up to 8 probes, ±1 °C accuracy
Bushing Monitoring: Up to 6 bushings; high‑accuracy tan delta, capacitance & leakage current
Data Logging: Configurable intervals, 4 GB internal memory
Environmental: –40 °C to +72 °C operation, IP20 (higher on request)

EXPERIENCE

Projects featuring Qualitrol Condition Monitoring

Explore project highlights to see where Qualitrol Condition Monitoring is making an impact.

For tailored advice on whether this solution suits your network, please connect with our team here.

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Vales Point Power Station

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Alcoa Portland Aluminium Smelter

ADVANTAGES

Why Choose Qualitrol QTMS

Choosing the right Transformer Monitoring solution means ensuring it can reliably detect issues early and support condition‑based maintenance. Insulect’s systems—built on proven Qualitrol technology—monitor the critical components and failure modes that most affect transformer health, providing clear insights that help prevent outages and extend asset life.

Industry‑Leading
Hardware & Reliability

Built on Qualitrol’s globally trusted monitoring technology—used worldwide since 1945—our systems offer long‑term reliability and comprehensive monitoring coverage. Proven across thousands of transformers, they help organizations shift from scheduled to condition‑based maintenance.

Full Asset Visibility &
Diagnostic Confidence

Our multi‑sensor approach monitors electrical, thermal, mechanical, and chemical health indicators, providing accurate diagnostics for all major transformer components. Advanced analytics, including Duval and ratio methods, ensure confident decision‑making and early detection of developing faults.

Customisable & Scalable
to Any Transformer

Whether monitoring a single transformer or an entire fleet, our modular packages (Core, Pro, Elite) and flexible hardware options scale to asset criticality and budget. Systems can be upgraded over time—adding DGA, PD, or fiber optics as needs evolve.

IMPLEMENTATION

Services & Support

Insulect offers comprehensive services and support for the products we specialise in, enhancing value for local utilities, major energy users, equipment manufacturers, and service operators.

LOCAL TECHNICAL TEAM

Our local technical team provides exceptional support and expertise, ensuring quick response times and personalised service to tackle any challenges that may arise during project execution.

ENGINEERING EXPERTISE

Through Qualitrol, our team utilises advanced technology and industry knowledge to assist customers.

PROCUREMENT & LOGISTICS

We facilitate smooth procurement and logistics processes by sourcing from trusted, proven partners and coordinating timely deliveries, ensuring projects remain on schedule and within budget.

TESTING & COMMISSIONING

Professional testing and commissioning support ensures that every transformer monitoring system functions safely and reliably, adhering to all regulatory standards and client expectations.

TURNKEY PROJECT DELIVERY

We are able to oversee every phase from concept to completion, providing comprehensive solutions that simplify complex projects and ensure successful outcomes.