Automated inert gas management system

Abstract

An automated inert gas management system (100) includes an inert gas container (102), control valves (110, 138), electronic pressure transmitters (106, 114, 136), and a controller (128) The inert gas container (102) stores and releases an inert gas into a tank (122) via a container valve (104). The control valves (110, 138) selectively inject and release the inert gas into / from the tank (122). The electronic pressure transmitters (106, 114, 136) continuously measure and transmit pressure values of the inert gas in the inert gas container (102) and the tank (122). The controller (128) determines a condition associated with the inert gas in the tank, for example, leakage, oil expansion, etc., based on the pressure values and one or more configurable parameters, and selectively actuates the control valves (110, 138) to maintain a pressure of the inert gas in the tank based on the determined condition.

Description

AUTOMATED INERT GAS MANAGEMENT SYSTEMFIELD

[0001] The present disclosure, in general, relates to a gas control system. More particularly, the present disclosure relates to an automated inert gas management system that automatically determines various conditions associated with an inert gas in a tank, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank.BACKGROUND

[0002] Transformers are electrical devices utilized in electrical power distribution systems for changing voltage levels and facilitating efficient transmission and distribution of electrical power over long distances. These transformers require specific care and protection to maintain their functionality and longevity, as they are exposed to varying environmental and operational stresses. Transformers include multiple components, for example, a core coil assembly, bushings, transformer oil for insulation and cooling purposes, and other solid insulation materials. In addition to these components, transformers are typically provided with a conservator to accommodate expansion of the transformer oil and contraction of the transformer oil that may result due to fluctuations in temperature of the transformer oil. In some applications and continents, instead of providing a dedicated conservator, the volume of a main tank of a transformer is increased and utilized as a conservator. While the core coil assembly of the transformer is filled with the transformer oil, the increased volume of the tank that is free of the transformer oil is filled with an inert gas to maintain a positive pressure (compared with atmospheric pressure), to preclude the entry of contaminants such as atmospheric air, dust, moisture, etc., inside the transformer, which may mix with the transformer oil and impact the life and operational safety of the transformer.

[0003] The inert gas, for example, nitrogen gas, is often utilized to preclude the entry of oxygen and other contaminants into the tank because nitrogen gas is chemically inert. A blanketing process, for example, nitrogen blanketing, may beutilized in transformers and other systems such as pipelines, storage tanks, reactors, boilers, etc., to protect the transformer oil from being contaminated and to protect their equipment from corrosion caused by exposure to oxygen and / or moisture. Oxygen and / or moisture are harmful to an insulating system of the transformer and can cause chemical degradation, leading to breakdowns or failures. For example, oxygen and / or moisture that enter the transformer can react with the transformer oil stored in the tank of the transformer, leading to a formation of acids and sludge that degrade insulating properties of the transformer oil. Oxygen and / or moisture can also cause corrosion of equipment such as metal components including windings and an internal structure of the transformer. Nitrogen blanketing refers to a process of maintaining a gas space above the core coil assembly in the tank with a nitrogen gas to preclude the core coil assembly from being exposed to oxygen, moisture, and other contaminants, which may lead to corrosion, insulation breakdown, and contamination of the transformer oil. The nitrogen gas, being dry and inert, prevents any chemical reaction, rust, or corrosion from forming, thereby extending a lifespan of the equipment of the transformer.

[0004] During operation or service of a transformer or another system such as a storage tank, a reactor, a boiler, etc., the inert gas is required to be maintained at a safe operating pressure limit. However, due to environmental conditions and due to a fluctuation of a level of the transformer oil, the pressure of the inert gas fluctuates. This fluctuation of the pressure of the inert gas either increases or decreases the available inert gas in the transformer, which must be maintained at the safe operating pressure limit either by venting out the excess pressure or by pumping in the inert gas into the transformer.

[0005] Further, a loss of the inert gas in the tank of the transformer typically occurs, for example, due to leakages, internal pressure fluctuations, or system malfunctions. For example, over time, seals and gaskets in the tank can degrade due to aging, wear and tear, or mechanical stress, which can lead to small leakages, allowing the inert gas to escape and compromising the positive pressure or the required operating pressure in the tank. In some cases, the loss of the inert gas in the tank may occur due to improper maintenance or a failure to monitor the pressureof the inert gas within the tank. Further, if the supply of the inert gas is not regularly checked and replenished, a slow loss of the inert gas may be overlooked. The loss of the inert gas can lead to a decrease in the pressure within the tank, allowing air and oxygen to enter the tank, which can cause oxidation of the transformer oil, cause degradation of the insulation system, and potentially increase a risk of electrical faults or fires.

[0006] Further, while the loss of the inert gas may be compensated by the inert gas stored, for example, in an inert gas cylinder, when the inert gas cylinder is empty, atmospheric air may come in contact with the transformer oil in the tank or a metal surface of the tank through a leakage in the tank. Atmospheric air contains moisture that may reduce an insulation property of the transformer oil, react with the tank, and cause the tank to rust. Therefore, there is a need for continuously monitoring filling of the inert gas in the tank, while distinguishing the inert gas demand due to a leakage versus a fluctuation in the temperature or the level of the transformer oil in the tank. Further, for enhanced reliability and safety, there is a need for continuously monitoring the pressure of the inert gas in the tank and alerting users about a potential loss of the inert gas in the tank due to a leakage or an oil expansion in the tank.

[0007] Hence, there is a need for an automated inert gas management system and a method for automatically determining various conditions associated with the inert gas in the tank, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank. Furthermore, there is a need for an automated inert gas management system and a method for facilitating online and remote monitoring of the inert gas in the tank and alerting users about the various conditions associated with the inert gas in the tank to allow proactive inert gas management.SUMMARY

[0008] The automated inert gas management system and the method disclosed herein address the above-recited need for automatically determining various conditions associated with an inert gas in a tank of a system, for example, a transformer, a boiler, a storage tank, etc., while continuously monitoring andmaintaining the inert gas at a required operating pressure in the tank. The automated inert gas management system continuously measures, monitors, controls, and maintains a pressure within the tank automatically. Moreover, the automated inert gas management system continuously monitors filling of the inert gas in the tank, while distinguishing the inert gas demand due to a leakage versus a fluctuation in a temperature or a level of a storage material, for example, oil, in the tank. Further, the automated inert gas management system and the method disclosed herein address the above-recited need for facilitating online and remote monitoring of the inert gas in the tank and alerting users about the various conditions associated with the inert gas in the tank to allow proactive inert gas management.

[0009] The automated inert gas management system disclosed herein includes an inert gas container, a container valve, multiple control valves, multiple electronic pressure transmitters, and a controller. The inert gas container is configured to store and release an inert gas, for example, a nitrogen gas, into a tank via the container valve. The control valves are selectively configured to inject the inert gas into the tank when pressure of the available inert gas decreases below a predefined minimum acceptable pressure threshold, and release at least a part of the inert gas, that is, excess inert gas, from the tank when the pressure increases to more than the predefined minimum acceptable pressure threshold. The electronic pressure transmitters are configured to continuously measure and transmit pressure values of the inert gas in the inert gas container and the tank.

[0010] The controller is operably coupled to the electronic pressure transmitters and the control valves. The controller is configured to receive the transmitted pressure values of the inert gas from the electronic pressure transmitters; determine a condition associated with the inert gas in the tank based on the transmitted pressure values of the inert gas and at least one configurable parameter of multiple configurable parameters; and selectively actuate the control valves to maintain a pressure of the inert gas in the tank based on the determined condition. The condition includes, for example, a leakage of the inert gas from the tank, an expansion of the inert gas due to an expansion of the storage material in the tank, a contraction of the inert gas due to a contraction of the storage material in the tank,etc. The configurable parameters include, for example, a geographical location of the tank, a loading schedule, a rate of change of pressure in the tank, a temperature cycle of the storage material stored in the tank, frequency of actuation of the control valves, duration of activation of the control valves, frequency of replacement of the inert gas container, environmental conditions such as atmospheric pressure, atmospheric temperature, or the like, and historical data.

[0011] In an embodiment, when the condition is determined as a leakage of the inert gas from the tank, the controller is configured to trigger an alarm when a loss of the inert gas in the inert gas container exceeds a configurable threshold.

[0012] In another embodiment, the automated inert gas management system includes one or more electronic devices, for example, sensors, transmitters, or the like, operably coupled to the tank. The controller, in communication with the electronic device(s), is configured to determine an amount of the inert gas dissolved in the storage material stored in the tank. In an embodiment, the controller is configured to transmit an alert to a monitoring system when the determined amount of the dissolved inert gas exceeds a configurable threshold.

[0013] In various embodiments, the controller is configured to identify a loss of the inert gas in the tank and determine a demand for the inert gas in the tank based on the determined condition. In an embodiment, the controller is configured to monitor filling of the inert gas in the tank.

[0014] In several embodiments, the controller is configured to monitor a depletion of the inert gas in the inert gas container based on a pressure value of the inert gas in the inert gas container.

[0015] In an embodiment, the automated inert gas management system includes a monitoring system in communication with the controller. This monitoring system includes a user interface configured to facilitate at least one of setting thresholds for the pressure of the inert gas within the tank; controlling actuation of the control valves; and monitoring real-time pressure values at the inert gas container and an inlet and an outlet of the tank.

[0016] These and other features and advantages of the present disclosure may be appreciated from a review of the following detailed description of the presentdisclosure, along with the accompanying figures in which like reference numerals refer to like parts throughout.BRIEF DESCRIPTION OF DRAWINGS

[0017] The accompanying drawings illustrate various embodiments of systems, methods, and other aspects of the disclosure. As such, the embodiments herein are not limited to the specific components, structures, and methods disclosed herein. Further, the description of a component, or a structure, or a method step referenced by a numeral in a drawing is applicable to the description of that component, or structure, or method step shown by that same numeral in any subsequent drawing herein.

[0018] Various embodiments of the present disclosure are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which:

[0019] FIG. 1 is a diagram that illustrates an automated inert gas management system, in accordance with an embodiment of the present disclosure;

[0020] FIG. 2 is a diagram that illustrates the automated inert gas management system, in accordance with another embodiment of the present disclosure;

[0021] FIG. 3 is a flowchart that illustrates a method for automatically determining various conditions associated with an inert gas in a tank, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank, in accordance with an embodiment of the present disclosure;

[0022] FIG. 4 is a flowchart that illustrates a method for determining a condition associated with an inert gas in a tank, in accordance with an embodiment of the present disclosure;

[0023] FIG. 5 is a front view of the automated inert gas management system, in accordance with an embodiment of the present disclosure;

[0024] FIG. 6 is a front view of the automated inert gas management system housed in an enclosure with a panel door in an open condition, in accordance with an embodiment of the present disclosure;

[0025] FIG. 7 is a front view of a controller assembly of the automated inert gas management system, in accordance with an embodiment of the present disclosure;

[0026] FIG. 8 is a screenshot that illustrates a user interface of a monitoring system configured to communicate with a controller of the automated inert gas management system, in accordance with an embodiment of the present disclosure; and

[0027] FIGS. 9 - 10 are screenshots that illustrate user interfaces including control settings of the monitoring system, in accordance with an embodiment of the present disclosure.

[0028] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. The detailed description of exemplary embodiments is intended for illustration purposes only and is, therefore, not intended to necessarily limit the scope of the disclosure.DETAILED DESCRIPTION

[0029] The present disclosure is best understood with reference to the detailed drawings and the description set forth herein. Various embodiments are disclosed below with reference to the drawings. However, those skilled in the art will readily appreciate that the detailed descriptions disclosed herein with respect to the drawings are merely for explanatory purposes as the systems and methods may extend beyond the disclosed embodiments. In one example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the implementation choices in the following embodiments that are described and shown.

[0030] References to “an embodiment”, “another embodiment”, “yet another embodiment”, “one example”, “another example”, “yet another example”, “for example”, and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the sameembodiment. Further, the terms “first”, “second”, and “third” are used herein for descriptive purposes only and are not to be construed to indicate or imply relative importance.

[0031] Various embodiments of the present disclosure may be found in the disclosed systems, devices, and methods for automatically determining various conditions associated with an inert gas in a tank of a system, for example, a transformer, a boiler, a storage tank, etc., while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank. Further, various embodiments of the present disclosure provide an automated inert gas management system and a method for facilitating online and remote monitoring of the inert gas in the tank and alerting users about the various conditions associated with the inert gas in the tank to allow proactive inert gas management. For purposes of illustration, the detailed description refers to automatically determining various conditions associated with an inert gas in a tank of a transformer; however, the scope of the present disclosure is not limited to automatically determining various conditions associated with an inert gas in a tank of a transformer, but may extend to include automatic determination of various conditions associated with an inert gas in tanks of other systems, for example, storage tanks, pipelines, reactors, mixing vessels, boilers, etc. Boilers, under maintenance, may be filled with the inert gas to maintain positive pressure compared to atmospheric pressure, to preclude moisture ingress.

[0032] FIG. 1 is a diagram that illustrates an automated inert gas management system 100, in accordance with an embodiment of the present disclosure. In an embodiment, the automated inert gas management system 100 is configured as a substantially electronic system including multiple electronic components for automatically performing the functions disclosed herein. In various embodiments, the automated inert gas management system 100 is configured for utilization in electrical substations, particularly, in unmanned substations. In an exemplary implementation as illustrated in FIG. 1, the automated inert gas management system 100 includes an inert gas container 102, a container valve 104, multiple control valves 110 and 138, multiple electronic pressure transmitters 106, 114, and 136,and a controller 128. In an embodiment, the inert gas container 102 is, for example, a cylindrically-shaped container, and is hereinafter exemplarily referred to as an “inert gas cylinder”. The container valve 104 that is fitted on the inert gas cylinder 102 is hereinafter exemplarily referred to as a “cylinder valve”. The inert gas cylinder 102 is filled with an inert gas. The inert gas cylinder 102 is configured to store and release the inert gas into a tank 122 of a transformer 118 via the cylinder valve 104. The transformer 118 is utilized in power transmission and distribution systems. The inert gas cylinder 102 stores the inert gas under pressure. In another embodiment, the inert gas cylinder 102 is configured in a different shape in accordance with system requirements, to store the inert gas. The inert gas is, for example, a nitrogen gas or any other inert gas that may be utilized for blanketing a storage material stored in the tank 122 of the transformer 118. Blanketing, for example, nitrogen blanketing, protects the storage material from being contaminated and protects the transformer 118 from corrosion caused by exposure to contaminants such as oxygen, moisture, dust, etc. The storage material is, for example, an oil 202 such as a mineral oil or a dielectric fluid illustrated in FIG. 2, configured for use as a coolant and an insulator. The storage material stored in the tank 122 of the transformer 118 is hereinafter exemplarily referred to as the “transformer oil 202”. For performing blanketing, the inert gas is released from the inert gas cylinder 102, passed through an inlet gas pipeline 152, and injected into the tank 122 of the transformer 118 via an inlet 120 of the tank 122. The tank 122 includes the inlet 120 through which the inert gas from the inert gas cylinder 102 is injected and an outlet 124 through which the inert gas is released. The injected inert gas fills a gas space 122a above the transformer oil 202 stored in the tank 122 illustrated in FIG. 2, and forms a blanket to protect the transformer oil 202 from exposure to the contaminants.

[0033] As illustrated in FIG. 1, the inert gas cylinder 102 is fitted with the cylinder valve 104. The cylinder valve 104 is configured to control flow of the inert gas from the inert gas cylinder 102 and into the inlet gas pipeline 152 that connects the inert gas cylinder 102 to the tank 122 of the transformer 118. The cylinder valve 104, in an open condition, releases and controls the flow of the inert gas from theinert gas cylinder 102, allowing for precise flow adjustment. The cylinder valve 104, in a closed condition, terminates the flow of the inert gas from the inert gas cylinder 102.

[0034] In the exemplary implementation illustrated in FIG. 1, the electronic pressure transmitters include a first electronic pressure transmitter 106, a second electronic pressure transmitter 114, and a third electronic pressure transmitter 136.In an embodiment, the first electronic pressure transmitter 106 is fitted on the inlet gas pipeline 152, proximal to the cylinder valve 104 as illustrated in FIG. 1. The first electronic pressure transmitter 106 monitors and measures pressure of the inert gas stored in the inert gas cylinder 102 and generates an electrical output, for example, a voltage output or a current output, corresponding to the measured pressure of the inert gas available in the inert gas cylinder 102. In an embodiment, the second electronic pressure transmitter 114 is fitted on the inlet gas pipeline 152, proximal to an inlet control valve 110 as illustrated in FIG. 1. In an embodiment, the third electronic pressure transmitter 136 is fitted proximal to an outlet gas pipeline 154 as illustrated in FIG. 1. The second electronic pressure transmitter 114 and the third electronic pressure transmitter 136 monitor and measure pressure of the inert gas in the tank 122 and generate an electrical output, for example, a voltage output or a current output, corresponding to the measured pressure of the inert gas available in the tank 122.

[0035] The first electronic pressure transmitter 106 is configured to continuously measure and transmit a pressure value of the inert gas in the inert gas cylinder 102 to the controller 128. The first electronic pressure transmitter 106 continuously monitors pressure of the inert gas stored in the inert gas cylinder 102 and communicates the pressure values as an input 140 to the controller 128. When the pressure value of the inert gas in the inert gas cylinder 102 drops below an acceptable minimum pressure threshold, the controller 128 generates potential free and remote communication outputs to alert users.

[0036] In an embodiment, the automated inert gas management system 100 further includes a pressure regulator 108 operably coupled to the inlet gas pipeline 152, proximal to the first electronic pressure transmitter 106. The pressure regulator108 is, for example, a double-stage regulator. The pressure regulator 108 is configured to regulate the pressure of the inert gas released from the inert gas cylinder 102 through the inlet gas pipeline 152. The pressure regulator 108 maintains the pressure of the released inert gas within a safe and optimal pressure range to prevent excess pressure from damaging the automated inert gas management system 100 and / or the transformer 118. As the inert gas is stored in the inert gas cylinder 102 under high pressure, for example, 150 Bar, the inert gas may be at a high pressure before injection into the tank 122 via the inlet 120. To reduce and maintain the pressure of the inert gas within a safe operating pressure threshold, for example, about 10 Pounds per Square Inch (PSI), before injection of the inert gas into the tank 122, the pressure regulator 108 regulates the high pressure of the inert gas, at the inlet 120, to the safe operating pressure threshold at the outlet 124 of the transformer 118. In an embodiment, the pressure regulator 108 includes a safety relief valve 108a configured to release excess pressure to the atmosphere if the pressure at the outlet 124 exceeds the set safe operating pressure threshold of, for example, 10 PSI. In an embodiment, the automated inert gas management system 100 allows a user to set the safe operating pressure thresholds of the inert gas via a user interface 800 rendered by a monitoring system 206 illustrated in FIG.2 and FIG. 8. In an embodiment, the pressure regulator 108 ensures that the inert gas is injected into the tank 122 at a stable and safe operating pressure, preventing both under-pressure and over-pressure, as under-pressure may lead to inadequate blanketing and over-pressure may damage the automated inert gas management system 100 and / or the transformer 118 or cause leaks.

[0037] In an embodiment, the control valves 110 and 138 are electrically-controlled valves, for example, solenoid valves, that allow or prevent the flow of the inert gas through the inlet gas pipeline 152 and the outlet gas pipeline 154, respectively. For purposes of illustration, the present disclosure refers to solenoid valves being utilized for controlling the flow of the inert gas within the automated inert gas management system 100; however, the scope of the automated inert gas management system 100 is not limited to including solenoid valves, but may be extended to include valves of other types, for example, motorized ball valves, otherelectrically-operated valves, or any combination thereof. The control valves 110 and 138 are selectively configured to inject the inert gas into the tank 122 and release at least a part of the inert gas, that is, excess inert gas, from the tank 122, respectively. In the exemplary implementation illustrated in FIG. 1, the control valves 110 and 138 include the inlet control valve 110 and an outlet control valve 138 operably coupled to the inlet gas pipeline 152 and the outlet gas pipeline 154, respectively. The inlet control valve 110 is disposed proximal to the inlet 120, and the outlet control valve 138 is disposed proximal to the outlet 124 of the tank 122, to control the flow of the inert gas within the automated inert gas management system 100. The inlet control valve 110 is configured to inject the inert gas into the tank 122 via the inlet 120. The inlet control valve 110 injects the inert gas into the tank 122 when the pressure of the available inert gas decreases below a predefined minimum acceptable pressure threshold. The outlet control valve 138 is configured to release at least a part of the inert gas, that is, the excess inert gas, from the tank 122 via the outlet 124. The outlet control valve 138 releases the excess inert gas from the tank 122 when the pressure increases to more than the predefined minimum acceptable pressure threshold.

[0038] The second electronic pressure transmitter 114 is operably coupled to the inlet gas pipeline 152, proximal to the inlet control valve 110. The second electronic pressure transmitter 114 is configured to continuously measure and transmit a pressure value of the inert gas injected into the tank 122 via the inlet 120, to the controller 128. For example, when the transformer oil 202 stored in the tank 122 expands, the pressure value of the injected inert gas in the tank 122 may change. The second electronic pressure transmitter 114 continuously monitors the pressure of the inert gas stored in the tank 122, for example, during an expansion of the transformer oil 202 in the tank 122, and communicates the pressure values as an input 142 to the controller 128.

[0039] In an embodiment, a valve member, for example, a ball valve 116, is operably coupled to the inlet gas pipeline 152, between the second electronic pressure transmitter 114 and the inlet 120 of the tank 122. The ball valve 116 is configured to control the flow of the inert gas through the inlet gas pipeline 152 andinto the tank 122 via the inlet 120. In an embodiment, the ball valve 116 is configured to isolate sections of the inlet gas pipeline 152 to prevent the inert gas from flowing into the sections being operated on during maintenance, allowing for safe maintenance without the need to shut down the entire inlet gas pipeline 152.Similarly, in an embodiment, another valve member, for example, a ball valve 130, is operably coupled to the outlet gas pipeline 154. The outlet 124 of the tank 122 is operably coupled to the ball valve 130. The ball valve 130 is configured to control the flow of the inert gas from the outlet 124 through the outlet gas pipeline 154. In an embodiment, the ball valve 130 is configured to isolate sections of the outlet gas pipeline 154 to prevent the inert gas from flowing into the sections being operated on during maintenance, allowing for safe maintenance without the need to shut down the entire outlet gas pipeline 154.

[0040] In an embodiment, the automated inert gas management system 100 further includes a pressure relief valve 132 operably coupled to the outlet gas pipeline 154 between the ball valve 130 and the outlet control valve 138. The pressure relief valve 132 refers to a mechanical safety device configured to automatically release pressure from the automated inert gas management system 100 when the pressure exceeds a preset safe operating pressure threshold. For example, when the transformer 118 is disposed in a storage area after installing the automated inert gas management system 100, due to the absence of electricity and due to climatic conditions, if the transformer oil 202 in the tank 122 expands and the pressure in the tank 122 exceeds the safe operating pressure threshold, for example, about 8 PSI, the pressure relief valve 132 vents out the excess inert gas to maintain the pressure of the inert gas in the tank 122 at the safe operating pressure threshold. In an embodiment, the pressure relief valve 132 is configured as a backup to the outlet control valve 138 to safeguard the transformer 118 from over-pressure in the absence of electricity. Although the embodiments in FIG. 1 illustrate a valve arrangement including the control valves 110 and 138, the pressure relief valve 132, and the ball valves 116 and 130, the automated inert gas management system 100 is not limited to the particular valve arrangement illustrated in FIG. 1, but may be extended to include different types of mechanical, electronic, and / or electro-mechanical valve arrangements for executing the automated control, maintenance, and management of the pressure of the inert gas in the automated inert gas management system 100.

[0041] In an embodiment, the third electronic pressure transmitter 136 is operably coupled to the pressure relief valve 132. The third electronic pressure transmitter 136 is configured to continuously measure and transmit a pressure value of the inert gas released from the tank 122 via the outlet 124, to the controller 128. The third electronic pressure transmitter 136 continuously monitors the pressure of the inert gas released from the tank 122 and communicates the pressure values as an input 144 to the controller 128. The third electronic pressure transmitter 136 is coupled to the outlet gas pipeline 154 while the second electronic pressure transmitter 114 is coupled to the inlet gas pipeline 152. The second electronic pressure transmitter 114 and the third electronic pressure transmitter 136 sense and measure the pressure of the tank 122, however, due to a volume of the tank 122, there may be a minimal pressure difference in their pressure readings. The second electronic pressure transmitter 114 and the third electronic pressure transmitter 136 are connected to the controller 128, and communicate the measured pressure values to the controller 128, based on which the controller 128 executes control actions.

[0042] In an embodiment, the automated inert gas management system 100 further includes oil collection chambers 112 and 134 disposed proximal to the second electronic pressure transmitter 114 and the third electronic pressure transmitter 136, respectively. These oil collection chambers 112 and 134 are connected to the inlet gas pipeline 152 and the outlet gas pipeline 154, respectively. The oil collection chambers 112 and 134 are configured to collect the transformer oil 202 that may contact the inlet gas pipeline 152 and the outlet gas pipeline 154, respectively, due to filling of excess transformer oil 202 in the tank 122. In an embodiment, the oil collection chambers 112 and 134 are each provided with a drain plug by which users can drain the excess transformer oil collected. In an embodiment, the oil collection chambers 112 and 134 are configured to collect the inert gas and may be utilized for performing gas sampling of the inert gas to analyseits chemical composition, contaminants, concentration levels, etc., or to detect any hazardous conditions.

[0043] The controller 128 is operably coupled to the electronic pressure transmitters 106, 114, and 136 and the control valves 110 and 138. In an embodiment, the controller 128 is a Programmable Logic Controller (PLC) configured to automate control and management of the flow of the inert gas within the automated inert gas management system 100 for maintaining a desired inert atmosphere in the tank 122. In an embodiment, the controller 128 operates as a central processing unit. The controller 128 monitors and controls the electrical outputs from the electronic pressure transmitters 106, 114, and 136, based on which the controller 128 executes a selective actuation of the control valves 110 and 138.The controller 128, in operable communication with the first electronic pressure transmitter 106, continuously monitors the pressure value in the inert gas cylinder 102. The controller 128, in operable communication with the second electronic pressure transmitter 114, continuously monitors the pressure value at the inlet 120 of the tank 122. The controller 128, in operable communication with the third electronic pressure transmitter 136, continuously monitors the pressure value at the outlet 124 of the tank 122. In an embodiment, the electrical outputs from the electronic pressure transmitters 106, 114, and 136 are current outputs, for example, in the range of about 4 milliamperes (mA) to about 20 mA.

[0044] The controller 128 is configured to receive the transmitted pressure values of the inert gas from the electronic pressure transmitters 106, 114, and 136; determine a condition associated with the inert gas in the tank 122 based on the transmitted pressure values of the inert gas; and selectively actuate the control valves 110 and 138 to maintain a pressure of the inert gas in the tank 122 based on the determined condition. The condition includes, for example, at least one of a leakage of the inert gas from the tank 122, an expansion of the inert gas due to an expansion of the transformer oil 202 in the tank 122, and a contraction of the inert gas due to a contraction of the transformer oil 202 in the tank 122. The expansion of the transformer oil 202 in the tank 122 is herein referred to as an “oil expansion”. In an embodiment, the controller 128 determines the condition as an oil expansionbased on an increased pressure value of the inert gas in the tank 122. In an embodiment, the controller 128 determines the condition as a contraction of the transformer oil 202 based on a decreased pressure value of the inert gas in the tank 122

[0045] In an example, when the tank 122 is filled with the inert gas, due to loading, temperature differences, atmospheric and other related conditions, the transformer oil 202 stored in the tank 122 expands or contracts, resulting in fluctuations in the pressure of the inert gas from a required operating pressure. When the pressure in the tank 122 reduces to a particular level, for example, during a contraction of the transformer oil 202 in the tank 122, the controller 128, in operable communication with the second electronic pressure transmitter 114, receives the pressure value of the inert gas in the tank 122 as an input 142 and transmits a command 148 to the inlet control valve 110 to open and allow flow of the inert gas through the inlet gas pipeline 152 for injection into the tank 122 via the inlet 120. This injection of the inert gas into the tank 122 increases the pressure of the inert gas in the tank 122 to the required operating pressure.

[0046] When the pressure in the tank 122 increases to more than a permissible operating pressure threshold, for example, during the oil expansion in the tank 122, the controller 128, in operable communication with the second electronic pressure transmitter 114 and the third electronic pressure transmitter 136, receives the pressure values of the inert gas in the tank 122 as inputs 142 and 144 and transmits a command 150 to the outlet control valve 138 to open and allow release of excess inert gas from the tank 122 via the outlet 124 and through the outlet gas pipeline 154 into the ambient atmosphere. The selective actuation of the control valves 110 and 138 based on the commands 148 and 150 from the controller 128, respectively, maintain the pressure of the inert gas at a required operating pressure within the transformer 118 to prevent the entry of external contaminants such as oxygen, moisture, dust, etc., ensuring the internal environment in the transformer 118 remains stable for optimal quality or reaction conditions and for preserving performance and longevity of the transformer 118.

[0047] In another embodiment, the controller 128 is configured to determine a condition associated with the inert gas in the tank 122 based on the transmitted pressure values of the inert gas and at least one configurable parameter of multiple configurable parameters. The configurable parameters include, for example, a geographical location of the tank 122, a loading schedule, a rate of change of the pressure in the tank 122, a temperature cycle of the transformer oil 202 stored in the tank 122, frequency of actuation of the control valves 110 and 138, duration of activation of the control valves 110 and 138, frequency of replacement of the inert gas cylinder 102, environmental conditions such as atmospheric pressure, atmospheric temperature, or the like, historical data, etc. In an embodiment, a user may input the configurable parameters to the controller 128 manually via the user interface, for example, 604, 800, 900, or 1000, of the monitoring system 206 as illustrated in FIG. 6 and FIGS. 8 - 10. In another embodiment, the controller 128 retrieves one or more of the configurable parameters including, for example, the historical data, from a database in the monitoring system 206.

[0048] In an example, if the transformer 118 is loaded to about 100% of its capacity and / or is overloaded, the temperature of the transformer oil 202 may increase, resulting in an oil expansion. In this example, the inert gas which occupies about 15% volume of the gas space 122a above the transformer oil 202 in the tank 122 may be compressed by the oil expansion, thereby increasing the pressure of the inert gas. Over-pressurization can lead to the activation of the pressure relief valve 132, leakage from the tank 122, or activation of the outlet control valve 138 to release excess inert gas, resulting in a loss of the inert gas. In an embodiment, the automated inert gas management system 100 determines whether the loss of the inert gas is due to the leakage or the oil expansion by utilizing the transmitted pressure values of the inert gas and one or more of the configurable parameters. For example, loading of the transformer 118 and an overall rate of increase of the temperature of the transformer oil 202 may be influenced by atmospheric temperature in a particular geographical location where the transformer 118 is installed. A user may input the geographical location to the controller 128 via a user interface of the monitoring system 206, based on which the controller 128determines the atmospheric temperature and accordingly determines the overall rate of increase of the temperature of the transformer oil 202. In this example, if the user inputs the geographical location as the United States of America or Canada, the controller 128 determines that the average temperature of the transformer oil 202 in the tank 122 installed at those geographical locations cannot exceed more than 20 degrees Celsius (°C) even if the transformer 118 is loaded for 100% of its capacity, and as such the incremental percentage of the temperature increase is significant. Since the temperature increase is negligible, the controller 128 determines that any loss of inert gas is due to a possible leakage in the tank 122 and not due to an oil expansion.

[0049] In another example, if there is a leakage in the tank 122, there would be a continuous loss of the inert gas, requiring the inlet control valve 110 to be opened multiple times to inject the inert gas into the tank 122 and replenish the inert gas in the tank 122. Therefore, if a user inputs the frequency of actuation of the inlet control valve 110 to the controller 128 via the user interface of the monitoring system 206, the controller 128 determines that the loss of the inert gas is due to a leakage in the tank 122 and not an oil expansion. Similarly, the controller 128 processes one or more of the configurable parameters along with the pressure values transmitted by the electronic pressure transmitters 106, 114, and 136 to determine various conditions associated with the inert gas in the tank 122, based on which the cause of the loss of the inert gas may be identified and the user may be alerted.

[0050] Consider another example where the automated inert gas management system 100 is implemented in a boiler instead of the transformer 118. In this example, the boiler is not expected to undergo any thermal expansion or contraction as a full volume of the boiler is filled with the inert gas. When there is a frequent loss of the inert gas in the boiler, the controller 128 actuates an inlet control valve operably coupled to an inlet of the boiler to inject the inert gas into the boiler multiple times in order to maintain the pressure of the inert gas in the boiler. However, in an example, despite the frequent injection of the inert gas into the boiler, the controller 128 determines that the pressure value of the inert gas in the boiler still drops below the acceptable minimum pressure threshold, therebydetermining a leakage of the inert gas from the boiler. Accordingly, based on the frequency of opening of the inlet control valve, the controller 128 identifies the loss of the inert gas due to the leakage in the boiler, as unless there is a leakage in joints or cracks of the boiler, the loss of the inert gas would not be possible. If a user inputs the frequency of actuation of the inlet control valve to the controller 128 via the user interface of the monitoring system 206, the controller 128 utilizes the inputted frequency of the actuation of the inlet control valve to determine that the loss of the inert gas is due to a leakage in the boiler.

[0051] In an embodiment, the controller 128 determines the condition as a leakage of the inert gas from the tank 122, when the controller 128 determines that a pressure drop is not restored despite injection of the inert gas into the tank 122 under a normal operation of the inlet control valve 110 over a particular operational time period. In an embodiment, when the condition is determined as a leakage of the inert gas from the tank 122, the controller 128 is configured to determine a rate of the leakage of the inert gas from the tank 122 and trigger an alarm when the rate of the leakage of the inert gas exceeds a configurable threshold. To determine the rate of leakage, in an embodiment, the controller 128 compares a rate of the pressure drop with historical data during the normal operation of the inlet control valve 110 over the same operational time period. In another embodiment, when the condition is determined as a leakage of the inert gas from the tank 122, the controller 128 is configured to trigger an alarm when a loss of the inert gas in the inert gas cylinder 102 exceeds a configurable threshold.

[0052] In another embodiment, the automated inert gas management system 100 further includes one or more electronic devices 126, for example, an inert gas sensor, transmitter, an oil temperature sensor, etc., operably coupled to the tank 122. In an embodiment, the inert gas sensor or the transmitter measures the level of the inert gas in the transformer oil 202 and allows monitoring of an inert gas solubility level. The oil temperature sensor measures a temperature of the transformer oil 202 stored in the tank 122. In various embodiments, the electronic device(s) 126 is disposed at different locations in and / or around the tank 122. For example, the electronic device(s) 126 is disposed proximal to the outlet 124 of thetank 122 as illustrated in FIG. 1. The electronic device(s) 126 is connected to the controller 128 via a wired connection or a wireless connection. The controller 128, in communication with the electronic device(s) 126, is configured to determine an amount of the inert gas dissolved in the transformer oil 202 stored in the tank 122.In an example, when the temperature of the transformer oil 202 in the tank 122 increases, some volume of the inert gas dissolves in the transformer oil 202.Therefore, the solubility of the inert gas in the transformer oil 202 increases as the temperature of the transformer oil 202 in the tank 122 increases. In an embodiment, the electronic device(s) 126 detects and quantifies the presence of the inert gas in both gas and liquid phases within the tank 122, indicating the extent to which the inert gas dissolves in the transformer oil 202. The electronic device(s) 126 measures and transmits the temperature and pressure values of the transformer oil 202 as an electronic device output 146 that is input to the controller 128. On receiving the electronic device output 146, the controller 128 processes the electronic device output 146 in combination with the inputs 142 and / or 144 from the second electronic pressure transmitter 114 and / or the third electronic pressure transmitter 136, respectively, and determines the rate of increase of the inert gas in the transformer oil 202. In an embodiment, the controller 128 executes a built-in algorithm to determine whether the dissolved inert gas is due to the increased temperature of the transformer oil 202.

[0053] In an embodiment, the controller 128 determines the amount of the inert gas dissolved in the transformer oil 202 by measuring the decrease in the amount of the inert gas concentration in the gas space 122a in the tank 122. In an embodiment, if the determined amount of the dissolved inert gas exceeds a safe threshold, that is, if the level of the inert gas in the transformer oil 202 exceeds the safe threshold, the controller 128 automatically transmits an alert to the monitoring system 206. In an embodiment, the user may set the safe threshold via the user interface of the monitoring system 206. The monitoring system 206, in turn, generates an alarm for alerting a user. In an embodiment, the electronic device(s) 126 and / or the controller 128 communicate the electronic device output 146 to themonitoring system 206 for allowing tracking of electronic device readings and inert gas concentration increase in the transformer oil 202 over time.

[0054] In an embodiment, the controller 128 is configured to transmit an alert to the monitoring system 206 when the determined amount of the dissolved inert gas exceeds a configurable threshold, to alert users about a potential loss of the inert gas and inert gas solubility in the transformer oil 202. In an embodiment, the controller 128 alerts the users about the potential loss of the inert gas and the inert gas solubility in the transformer oil 202, for example, through an audio alarm, a visual alarm, or a digital remote notification displayed on the user interface of the monitoring system 206. The automated inert gas management system 100, therefore, allows online and remote monitoring of the solubility of the inert gas in the transformer oil 202 and alerts the users if a solubility limit exceeds a permitted level for safe operation of the transformer 118. Simultaneously, the controller 128 transmits the command 148 to the inlet control valve 110 to open and allow flow of the inert gas through the inlet gas pipeline 152 for injection into the tank 122 via the inlet 120 to compensate for the loss of the inert gas in the tank 122. By compensating for the loss of the inert gas in the tank 122 of the transformer 118, for example, a high voltage, extra high voltage, or ultra-high voltage transformer, the automated inert gas management system 100 precludes the production of bubbles in the transformer oil 202, thereby maintaining an insulation property of the transformer oil 202 in the tank 122.

[0055] In various embodiments, the controller 128 is configured to identify a loss of the inert gas in the tank 122 and determine a demand for the inert gas in the tank 122 based on the determined condition. For example, if the controller 128 determines a leakage of the inert gas from the tank 122, the controller 128 identifies a loss of the inert gas in the tank 122 and determines a demand for the inert gas in the tank 122 based on the determined leakage.

[0056] In an embodiment, the controller 128 is configured to monitor filling of the inert gas in the tank 122. If there is a leakage in the tank 122, the loss of the inert gas in the tank 122 due to the leakage is compensated by the available inert gas in the inert gas cylinder 102. However, when the inert gas cylinder 102 is empty,atmospheric air may enter the tank 122 through a leakage point of the tank 122 and contact the transformer oil 202 and metal surfaces of the tank 122. The atmospheric air contains moisture that reduces the insulation property of the transformer oil 202.Further, reaction of the moisture with the tank 122 may cause the tank 122 to rust. The controller 128, therefore, is configured to continuously monitor filling of the inert gas is filled in the tank 122, while distinguishing the inert gas demand due to a leakage in the tank 122 versus an oil expansion. In an embodiment, the controller 128 continuously monitors the frequency of filling the inert gas in the tank 122, that is, the number of times the inert gas is filled in the tank 122, while distinguishing the inert gas demand due to a leakage in the tank 122 versus an oil expansion. In several embodiments, the controller 128 is configured to monitor a depletion of the inert gas in the inert gas cylinder 102 based on a pressure value of the inert gas in the inert gas cylinder 102. The embodiments disclosed herein are not limited to the particular arrangement of components in the exemplary implementation of the automated inert gas management system 100 illustrated in FIG. 1, but may be extended to include different arrangements with more or less number of components to execute the same functions and achieve the same results discussed herein.

[0057] FIG. 2 is a diagram that illustrates the automated inert gas management system 100, in accordance with another embodiment of the present disclosure. FIG.2 shows some of the components required to execute the functions of the automated inert gas management system 100. The embodiments illustrated in FIG. 2 are described in association with a transformer 118 including an inlet 120, an outlet 124, and a tank 122. The tank 122 of the transformer 118 is configured to store a storage material 202, for example, oil, herein referred to as “transformer oil 202”.The automated inert gas management system 100 performs blanketing, for example, nitrogen blanketing, to protect the transformer oil 202 in the tank 122 from being contaminated by exposure to contaminants such as oxygen, moisture, dust, etc. The automated inert gas management system 100 fills a gas space 122a above the transformer oil 202 stored in the tank 122 with an inert gas, for example, a nitrogen gas, to preclude the transformer oil 202 from being exposed to oxygen, moisture,and other contaminants, which lead to corrosion, insulation breakdown, and contamination of the transformer oil 202.

[0058] The automated inert gas management system 100 includes an inert gas cylinder 102 that stores and releases the inert gas into the tank 122 via a cylinder valve 104. The automated inert gas management system 100 continuously monitors and controls a pressure of the tank 122 by utilizing the electronic pressure transmitters 114 and 136 and the controller 128 as disclosed in the description of FIG. 1. In an embodiment, the electronic pressure transmitters 114 and 136 are configured to monitor the pressure of the tank 122 continuously without interruption. The electronic pressure transmitters 106, 114, and 136 transmit their inputs 140, 142, and 144, respectively, for example, 4 mA to 20 mA current inputs, to the controller 128, based on which the controller 128 determines a condition associated with the inert gas in the tank 122 and selectively actuates the control valves 110 and 138, for example, solenoid valves, to maintain the pressure of the inert gas in the tank 122 at a required operating pressure as disclosed in the description of FIG. 1.

[0059] The automated inert gas management system 100 further includes a monitoring system 206 in communication with the controller 128 via a communication network 204. The monitoring system 206 is, for example, a local monitoring system or a remote monitoring system. In an embodiment, the monitoring system 206 is configured as a Supervisory Control And Data Acquisition (SCAD A) system to control, monitor, and analyse various components of the automated inert gas management system 100 at a site of the tank 122. The monitoring system 206 includes hardware and software components that facilitate remote and onsite gathering of data from the automated inert gas management system 100. The monitoring system 206 allows online and real-time monitoring of the transformer 118 and the conditions associated with the inert gas in the tank 122 of the transformer 118, for example, from a remote substation. For enhanced reliability and safety, the monitoring system 206 allows real-time monitoring of the pressure of the inert gas in the inert gas cylinder 102 and the tank 122 and alertingusers about a potential loss of the inert gas in the tank 122 due to a leakage or an oil expansion in the tank 122.

[0060] In an embodiment, the monitoring system 206 includes a user interface, for example, 604, 800, 900, or 1000 as illustrated in FIG. 6 and FIGS. 8 - 10, configured to facilitate at least one of: setting thresholds for the pressure of the inert gas within the tank 122; controlling the actuation of the control valves 110 and 138; and monitoring real-time pressure values at the inert gas cylinder 102 and the inlet 120 and the outlet 124 of the tank 122. A user, for example, an onsite operator or a remote operator of the automated inert gas management system 100, may utilize the user interface, for example, 604, 800, 900, or 1000, to set thresholds for the pressure of the inert gas within the tank 122; control the actuation of the control valves 110 and 138; and / or monitor real-time pressure values at the inert gas cylinder 102 and the inlet 120 and the outlet 124 of the tank 122. The communication network 204 that allows communication between the controller 128 and the monitoring system 206 is, for example, a short-range network or a long-range network. The communication network 204 is, for example, one of the internet, an intranet, a wired network, a wireless network, a communication network that implements Bluetooth® of Bluetooth Sig, Inc., a network that implements Wi-Fi® of Wi-Fi Alliance Corporation, an ultra-wideband (UWB) communication network, a wireless universal serial bus (USB) communication network, a communication network that implements ZigBee® of ZigBee Alliance Corporation, a general packet radio service (GPRS) network, a mobile telecommunication network such as a global system for mobile (GSM) communications network, a code division multiple access (CDMA) network, an Nth generation mobile communication network where N is, 3, 4, 5, 6, etc., a longterm evolution (LTE) mobile communication network, a public telephone network, etc., a local area network, a wide area network, an internet connection network, an infrared communication network, etc., or a network formed from any combination of these networks. In an embodiment, the communication network 204 implements communication protocols, for example, the Generic Object Oriented Substation Event (GOOSE) protocol and other advanced communication protocols such asInternational Electrotechnical Commission (EEC) 61850, Recommended Standard (RS) 232, RS 485, etc. The monitoring system 206 allows the user to monitor the pressure of the tank 122 by communicating with the controller 128 via the communication network 204.

[0061] By way of a non-limiting example, the tank 122 of the transformer 118 may be filled with the transformer oil 202 up to about 85% of the volume of the tank 122, with about 15% of the remaining volume herein referred to as the gas space 122a, filled with the inert gas. In this example, the user may set a configurable threshold of about 3 Pounds per Square Inch (PSI) as a desired operating pressure for the inert gas in the tank 122, via the user interface 800 rendered by the monitoring system 206 as illustrated in FIG. 8. Under normal operating conditions, the inert gas is made available from the inert gas cylinder 102 till the inlet control valve 110. The user may set maximum and minimum pressure values for the inert gas in the inert gas cylinder 102 and the tank 122 via the user interface 800 rendered by the monitoring system 206. The cylinder valve 104, in an open condition, releases the inert gas from the inert gas cylinder 102 at a pressure of, for example, about 150 bar. While the pressure regulator 108 may be configured, for example, to regulate the 150-bar pressure to 1-bar pressure, the pressure regulator 108 regulates the 150-bar pressure of the inert gas released from the inert gas cylinder 102 to a pressure value of 10 PSI. When the pressure of the inert gas in the tank 122 falls to less than or equal to 3 PSI, the controller 128 transmits a command 148 to the inlet control valve 110 to open and automatically inject the inert gas into the tank 122 to maintain the pressure value at a safe positive inert gas pressure threshold of, for example, about 5 PSI. The controller 128 receives the pressure values of the inert gas at the inlet 120 and the outlet 124 of the tank 122 from the electronic pressure transmitters 114 and 136, respectively. When the pressure of the inert gas in the tank 122 increases beyond 7 PSI, the controller 128 transmits a command 150 to the outlet control valve 138 to open and automatically release the excess inert gas from the tank 122. The controller 128 automatically closes the outlet control valve 138 when the pressure of the inert gas reaches 5 PSI.

[0062] FIG. 3 is a flowchart 300 that illustrates a method for automatically determining various conditions associated with an inert gas in a tank 122 shown in FIGS. 1 - 2, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank 122, in accordance with an embodiment of the present disclosure. The method disclosed herein employs the automated inert gas management system 100 including the inert gas cylinder 102, the control valves 110 and 138, the electronic pressure transmitters 106, 114, and 136, the controller 128, and the monitoring system 206 illustrated in FIGS. 1 - 2, for automatically determining various conditions associated with the inert gas in the tank 122, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank 122. The inert gas cylinder 102 stores and releases the inert gas into the tank 122 via the cylinder valve 104 shown in FIGS. 1 - 2. The control valves 110 and 138 inject the inert gas into the tank 122 and release at least a part of the inert gas from the tank 122, respectively. The electronic pressure transmitters 106, 114, and 136 continuously measure and transmit pressure values of the inert gas in the inert gas cylinder 102 and the tank 122.

[0063] In the method disclosed herein, at step 302, the controller 128 receives the transmitted pressure values of the inert gas from the electronic pressure transmitters 114 and 136. At step 304, the controller 128 determines a condition associated with the inert gas in the tank 122 based on the transmitted pressure values of the inert gas and at least one configurable parameter of multiple configurable parameters as disclosed in the description of FIG. 1. The condition includes, for example, at least one of a leakage of the inert gas from the tank 122, an expansion of the inert gas due to an expansion of a storage material, for example, transformer oil 202 shown in FIG. 2, stored in the tank 122, and a contraction of the inert gas due to a contraction of the transformer oil 202 in the tank 122. The configurable parameters include, for example, a geographical location of the tank 122, a loading schedule, a rate of change of pressure in the tank 122, a temperature cycle of the transformer oil 202 stored in the tank 122, frequency of actuation of the control valves 110 and 138, duration of activation of the control valves 110 and 138, frequency of replacement of the inert gas cylinder 102, environmental conditions, and historicaldata. In an embodiment, the controller 128 determines the condition based on realtime pressure values received from the electronic pressure transmitters 114 and 136 and historical records stored in the monitoring system 206. Further, at step 306, the controller 128 selectively actuates the control valves 110 and 138 to maintain a pressure of the inert gas in the tank 122 based on the determined condition. In an embodiment, the controller 128 identifies a loss of the inert gas in the tank 122 and determines a demand for the inert gas in the tank 122 based on the determined condition. In another embodiment, the controller 128 monitors filling of the inert gas in the tank 122. In another embodiment, the controller 128 monitors a depletion of the inert gas in the inert gas cylinder 102 based on a pressure value of the inert gas in the inert gas cylinder 102.

[0064] In an embodiment, the controller 128, in communication with one or more electronic devices 126 operably coupled to the tank 122, determines an amount of the inert gas dissolved in the transformer oil 202 stored in the tank 122. When the determined amount of the dissolved inert gas exceeds a configurable threshold, the controller 128 transmits an alert to the monitoring system 206.

[0065] FIG. 4 is a flowchart 400 that illustrates a method for determining a condition associated with an inert gas in a tank 122 shown in FIGS. 1 - 2, in accordance with an embodiment of the present disclosure. The condition associated with the inert gas in the tank 122 of a transformer 118 shown in FIGS. 1 - 2 is, for example, a leakage of the inert gas and an associated loss of the inert gas. The method disclosed herein employs the automated inert gas management system 100 including the inert gas cylinder 102, the control valves 110 and 138, the electronic pressure transmitters 106, 114, and 136, the controller 128, and the monitoring system 206 illustrated in FIGS. 1 - 2, for automatically identifying the loss of the inert gas in the tank 122 based on the leakage of the inert gas, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank 122. The loss of the inert gas may occur due to a leakage in the tank 122 or an expansion of a storage material, for example, transformer oil 202 shown in FIG. 2, stored in the tank 122. A user, for example, an operator, of the automated inert gas management system 100 may configure an operating pressure threshold for the inertgas in the tank 122 via a user interface 800 rendered by the monitoring system 206 illustrated in FIG. 8. In the method disclosed herein, to maintain the inert gas at the operating pressure threshold in the tank 122, at step 402, the controller 128, in communication with the electronic pressure transmitters 114 and 136, checks pressure of the inert gas in the tank 122. At step 404, the controller 128 determines whether the pressure of the inert gas is greater than the operating pressure threshold. If the controller 128 determines that the pressure of the inert gas is not greater than the operating pressure threshold, the controller 128 proceeds to re-check the pressure of the inert gas in the tank 122. If the controller 128 determines that the pressure of the inert gas is greater than the operating pressure threshold, at step 406, the controller 128 actuates the outlet control valve 138 to release excess inert gas from the tank 122 to the atmosphere. The controller 128 then proceeds to re-check the pressure of the inert gas in the tank 122. In an example, when the pressure of the inert gas such as a nitrogen gas in the tank 122 of the transformer 118 exceeds the set safe operating pressure threshold due to an oil expansion, the electronic pressure transmitters 114 and 136 illustrated in FIGS. 1 - 2, communicate the pressure values of the nitrogen gas at the inlet 120 and the outlet 124 of the tank 122, respectively, to the controller 128. Accordingly, the controller 128 activates the outlet control valve 138 illustrated in FIGS. 1 - 2, to vent out the excess nitrogen gas into the atmosphere automatically. When the pressure of the nitrogen gas inside the tank 122 reaches the set safe operating pressure threshold, the controller 128 deactivates the outlet control valve 138 automatically and therefore, terminates further loss of the nitrogen gas from the tank 122.

[0066] Further, at step 408, the controller 128 determines whether the pressure of the inert gas is less than the operating pressure threshold. If the controller 128 determines that the pressure of the inert gas is not less than the operating pressure threshold, the controller 128 proceeds to re-check the pressure of the inert gas in the tank 122. If the controller 128 determines that the pressure of the inert gas is less than the operating pressure threshold, at step 410, the controller 128 actuates the inlet control valve 110 to inject the inert gas into the tank 122. The controller 128 then proceeds to re-check the pressure of the inert gas in the tank 122.

[0067] In an example, when the pressure of the nitrogen gas in the tank 122 drops below the set safe operating pressure threshold due to a contraction of the transformer oil 202, the electronic pressure transmitters 114 and 136 communicate the pressure values of the nitrogen gas at the inlet 120 and the outlet 124 of the tank 122, respectively, to the controller 128. Accordingly, the controller 128 activates the inlet control valve 110 to inject the nitrogen gas into the tank 122 automatically. When the pressure of the nitrogen gas inside the tank 122 reaches the set safe operating pressure threshold, the controller 128 deactivates the inlet control valve 110 automatically and therefore, terminates further injection of the nitrogen gas into the tank 122.

[0068] In an embodiment, the controller 128 executes a built-in algorithm to determine whether the loss of the inert gas is due to a leakage or an oil expansion. For example, the controller 128 identifies the loss of the inert gas in the tank 122 based on the leakage of the inert gas. At step 412, the controller 128 checks a rate of the leakage of the inert gas. At step 414, the controller 128 determines whether the rate of inert gas loss is greater than a learnt average value. If the controller 128 determines that the rate of the inert gas loss is not greater than the learnt average value, the controller 128 proceeds to re-check the rate of the leakage of the inert gas. If the controller 128 determines that the rate of the inert gas loss is greater than the learnt average value, at step 416, the controller 128 triggers an alarm and in an embodiment, communicates the inert gas loss to the user via the monitoring system 206. The alarm is, for example, an audio alarm, a visual alarm, an audiovisual alarm, a digital alert transmitted to the monitoring system 206, etc.

[0069] If the tank 122 is manufactured with a leak or a leakage is developed over a period of time, then since the tank 122 is always maintained at a positive pressure, which is more than the atmospheric pressure, the inert gas from the tank 122 leaks continuously, which requires the inlet control valve 110 to be activated continuously to inject the inert gas into the tank 122 to compensate for the loss of the inert gas. In an embodiment, one of the configurable parameters utilized for determining the leakage in the tank 122 is, for example, a duration of activation or opening of the inlet control valve 110, which may be input to the controller 128 toallow the controller 128 to learn about a potential leakage in the tank 122 and alert the user to execute an action.

[0070] If there is a loss of the inert gas due to a load variation and temperature of the transformer oil 202, the rate of oil expansion and inert gas loss may be slow. In an embodiment, one of the configurable parameters utilized for determining the leakage in the tank 122 is, for example, frequency of replacement of the inert gas cylinder 102. In this embodiment, the monitoring system 206 renders a user interface, for example, a Human Machine Interface (HMI), to allow the user to enter the frequency of replacement of the inert gas cylinder 102, based on the user’s past experience and with respect to a geographical location where the transformer 118 is installed. If the frequency of replacement of the inert gas cylinder 102 exceeds a configured threshold for a period of time, the controller 128 determines the leakage in the tank 122. In another embodiment, the controller 128 is programmed to execute a self-learning algorithm configured to monitor the frequency of activation or opening of the control valves 110 and 138. By executing this self-learning algorithm, the controller 128 intelligently determines whether, over the period of time, the activation of the control valves 110 and 138 is too frequent to alert the user about any potential leakage in the transformer 118.

[0071] FIG. 5 is a front view of the automated inert gas management system 100, in accordance with an embodiment of the present disclosure. As illustrated in FIG.5, the automated inert gas management system 100 includes the cylinder valve 104, the electronic pressure transmitters 106, 114, and 136, the pressure regulator 108, the inlet control valve 110, the outlet control valve 138, the oil collection chambers 112 and 134, and the ball valves 116 and 130. The cylinder valve 104 is configured to open and close the inert gas cylinder 102 of the automated inert gas management system 100 shown in FIGS. 1 - 2. In an exemplary implementation illustrated in FIG. 5, the first electronic pressure transmitter 106 that is disposed proximal to the cylinder valve 104 is configured to continuously measure and transmit pressure values of the inert gas in the inert gas cylinder 102. The pressure regulator 108 is operably coupled to the inlet gas pipeline 152, proximal to the first electronic pressure transmitter 106, and is configured to regulate the pressure of the inert gasreleased from the inert gas cylinder 102 through the inlet gas pipeline 152. The inlet control valve 110 is configured to inject the inert gas into the tank 122 of the transformer 118 via the inlet 120 as illustrated in FIGS. 1 - 2. The outlet control valve 138 is configured to release at least a part of the inert gas, that is, the excess inert gas, from the tank 122 via the outlet 124 as illustrated in FIGS. 1 - 2. The second electronic pressure transmitter 114 is operably coupled to the inlet gas pipeline 152, proximal to the inlet control valve 110. The second electronic pressure transmitter 114 is configured to continuously measure and transmit a pressure value of the inert gas injected into the tank 122 via the inlet 120, to the controller 128. The third electronic pressure transmitter 136 is configured to continuously measure and transmit a pressure value of the inert gas released from the tank 122 via the outlet 124, to the controller 128. The ball valves 116 and 130 are operably coupled to the inlet gas pipeline 152 and the outlet gas pipeline 154, respectively. The ball valves 116 and 130 isolate sections of their respective gas pipelines 152 and 154 to prevent the inert gas from flowing into the sections being operated on during maintenance, allowing for safe maintenance without the need to shut down the entire gas pipelines 152 and 154.

[0072] FIGS. 6 is a front view of the automated inert gas management system 100 housed in an enclosure 600 with a panel door 602 in an open condition, in accordance with an embodiment of the present disclosure. FIG. 6 illustrates the positioning of various components including the inert gas cylinder 102, the cylinder valve 104, the electronic pressure transmitters 106, 114, and 136, the pressure regulator 108, the inlet control valve 110, the outlet control valve 138, the oil collection chambers 112 and 134, the ball valves 116 and 130, and the controller 128 of the automated inert gas management system 100 in the enclosure 600 in a simulated environment. In an embodiment, the controller 128 is disposed inside the enclosure 600. The automated inert gas management system 100 may be installed on the transformer 118 illustrated in FIGS. 1 - 2, and the communication with the gas space 122a of the transformer 118 is established by utilizing, for example, flanges, connectors, etc., extending from the enclosure 600 and fasteners. In an embodiment, due to the absence of electricity during storage of the transformer 118with the automated inert gas management system 100 installed, to maintain a positive pressure of the inert gas inside the transformer 118, a manual override valve of the inlet control valve 110 is maintained in an open condition. During commissioning, due to the availability of electricity, for the correct functioning of the automated inert gas management system 100, the manual override valve should be maintained in a closed or OFF condition before energizing the automated inert gas management system 100. To ensure that the manual override valve of the inlet control valve 110 is maintained in the closed condition during commissioning to allow the automated inert gas management system 100 to function electrically, an interlock mechanism is provided through a microswitch by which the controller 128 can alert users about the status of the inlet control valve 110. During storage, the microswitch is in a normally closed condition and the same has to be set in the normally open condition during commissioning.

[0073] In an embodiment, a control panel 606 including a user interface 604, for example, a Human Machine Interface (HMI), is disposed proximal to the controller 128 in the enclosure 600 as illustrated in FIG. 6. In an embodiment, the control panel 606 is operably coupled to the controller 128, for example, via an Ethernet cable or by any other suitable communication mechanisms. The user interface 604 is configured to operate as a communication medium between the users and the controller 128. In an embodiment, the user interface 604 allows a user to set safe operating pressure thresholds for a pressure of the inert gas within the tank 122 of the transformer 118, and a pressure range for activation of the control valves 110 and 138. Based on these settings, the controller 128 can tune its operation logic to maintain a safe operating pressure inside the tank 122 based on requirements. In another embodiment, the user interface 604 allows the user to set an over-pressure threshold. The user interface 604 also displays alerts, visual alarms, and other information such as the pressure range for the activation of the control valves 110 and 138, for viewing by the user. In an embodiment, the control panel 606 is configured to communicate with a remote monitoring system of the automated inert gas management system 100 via the communication network 204 illustrated in FIG.2.

[0074] FIG. 7 is a front view of a controller assembly 700 of the automated inert gas management system 100 shown in FIG. 6, in accordance with an embodiment of the present disclosure. In an embodiment, the controller assembly 700 is installed in the enclosure 600 of the automated inert gas management system 100 illustrated in FIG. 6. In an exemplary implementation illustrated in FIG. 7, the controller assembly 700 includes the controller 128, a Switched-Mode Power Supply (SMPS) 702, fuses 704, and relay modules 706. The SMPS 702 converts an input voltage, for example, from an Alternating Current (AC) power source, into a stable, regulated Direct Current (DC) voltage required by the controller 128 and associated components. The SMPS 702 provides a regulated output voltage to the controller 128 and the associated components, ensuring the controller 128 receives a stable and consistent power supply, even if the input voltage fluctuates. The fuses 704 are safety devices that protect the controller assembly 700 from overcurrent. The fuses 704 protect the controller 128 and other associated components from excessive current or potential electrical faults. The relay modules 706 control the flow of electrical power to various parts of the controller assembly 700, allowing the controller 128 to automatically switch power on or off in response to specific conditions or inputs. The relay modules 706 also provide electrical isolation between different sections of the controller assembly 700.

[0075] FIG. 8 is a screenshot that illustrates a user interface 800 of the monitoring system 206 configured to communicate with the controller 128 of the automated inert gas management system 100 shown in FIGS. 1 - 2, in accordance with an embodiment of the present disclosure. The user interface 800 displays real-time pressure values transmitted by the electronic pressure transmitters 106, 114, and 136 of the automated inert gas management system 100 shown in FIGS. 1 - 2. For example, the first electronic pressure transmitter 106 continuously measures pressure values of the inert gas stored in the inert gas cylinder 102 shown in FIGS.1 - 2, in real time or near real time, and transmits the measured pressure values of the stored inert gas to the controller 128. Similarly, the second electronic pressure transmitter 114 and the third electronic pressure transmitter 136 continuously measure pressure values of the inert gas in the tank 122 at the inlet 120 and theoutlet 124 of the tank 122, respectively, in real time or near real time, and transmit the measured pressure values of the inert gas in the tank 122 to the controller 128.The controller 128 renders the transmitted pressure values of the stored inert gas and the inert gas in the tank 122 on the user interface 800 in real time or near real time for viewing by a user onsite or at a remote site via the communication network 204

[0076] In an example, the user interface 800 displays the pressure value of the stored inert gas as a cylinder pressure of about 232.66 Pounds per Square Inch (PSI), and the pressure values of the inert gas at the inlet 120 and at the outlet 124 of the tank 122 as 0.00 PSI and 2.66 PSI, respectively, as illustrated in FIG. 8. The user interface 800, therefore, provides a real-time status of the pressure of the inert gas to the user to allow the user to monitor the inert gas stored in the inert gas cylinder 102 and the inert gas flowing through the gas pipelines 152 and 154 shown in FIGS.1 - 2. The user interface 800 displays the real-time pressure values at the inert gas cylinder 102 and at the inlet 120 and the outlet 124 of the tank 122 to execute timely actions in cases of substantial increases or decreases in the pressure of the inert gas with respect to the set operating pressure thresholds.

[0077] FIGS. 9 - 10 are screenshots that illustrate user interfaces 900 and 1000 including control settings of the monitoring system 206 shown in FIG. 2, respectively, in accordance with an embodiment of the present disclosure. The user interface 900, illustrated in FIG. 9, displays the control settings that allow a user to set minimum and maximum threshold values for pressure of an inert gas at the inlet 120 and the outlet 124 of the tank 122 and in the inert gas cylinder 102 to ensure safe operation of the transformer 118 illustrated in FIGS. 1 - 2. In an example, the user interface 900 displays the minimum and maximum threshold values set for the pressure of the inert gas at the inlet 120 and the outlet 124 of the tank 122 as 0 PSI and 145 PSI, respectively, as illustrated in FIG. 9. Similarly, the user interface 900 displays the minimum and maximum pressure values set for the inert gas cylinder 102 as 0 PSI and 3626 PSI, respectively, as illustrated in FIG. 9. Further, in an embodiment, if the pressure value of the inert gas stored in the inert gas cylinder 102 drops below the threshold value, the controller 128 generates an alert for theuser, informing the user about an urgency to replace the inert gas cylinder 102 with another inert gas cylinder filled with the inert gas or refill the inert gas cylinder 102. In another embodiment, the user interface 900 displays a real-time pressure value of the inert gas at the inert gas cylinder 102 to allow the operator to execute timely actions without an alarm or an alert. In an embodiment, the user interface 900 also displays the number of inlet and outlet control valve open events. In another embodiment, the user interface 900 also renders a reset button to allow the user to clear all the set values and a next button to allow the user to move to the next page for viewing additional control settings.

[0078] The user interface 1000, illustrated in FIG. 10, displays the control settings that allow the user to set a cylinder pressure low alarm value and set point pressure values for actuating the control valves 110 and 138 shown in FIGS. 1 -2.The control valves 110 and 138 are denoted by Solenoid Valve 1 (SV1) and SV2, respectively. The cylinder pressure low alarm value on the user interface 1000 denotes the value of the pressure of the inert gas cylinder 102, for example, 200 PSI, below which the controller 128 must generate an alarm. The set point pressure values denote the pressure values at which the controller 128 must turn SV1 and SV2 on and off. For example, the user may enter the set point pressure values for turning SV1 on and off as 1 PSI and 8 PSI, respectively, and for turning SV2 on and off as 8 PSI and 1 PSI, respectively, on the user interface 1000 as illustrated in FIG. 10. When SV1 is turned on or is activated, SV1 injects the inert gas into the tank 122 via the inlet 120, and when SV1 is turned off or is deactivated, SV1 terminates the injection of the inert gas into the tank 122. When SV2 is turned on or is activated, SV2 releases the excess inert gas from the tank 122 via the outlet 124 and into the atmosphere, and when SV2 is turned off or is deactivated, SV2 terminates the release of the inert gas from the tank 122. The set point pressure values for SV1 and SV2 can be selected based on customer requirements. Accordingly, the controller 128 self-configures its functional logic to actuate SV1 and SV2.

[0079] The automated inert gas management system 100 includes electromechanical components and electronics required for automated maintenance andmonitoring of the inert gas in the tank 122 of the transformer 118. Pressurised inert gas availability inside the transformer 118 eliminates the possibility of atmospheric moisture entering the transformer 118, thereby enhancing a lifespan of the transformer 118.

[0080] Techniques consistent with the disclosure provide, among other features, the automated inert gas management system 100 for automatically determining various conditions associated with an inert gas in a tank 122, while continuously monitoring and maintaining the inert gas at a required operating pressure in the tank 122. While various exemplary embodiments of the disclosed systems, devices, and methods have been described above, it should be understood that they have been presented for purposes of example only, not limitations. The foregoing examples and illustrative implementations of various embodiments have been provided merely for explanation and are in no way to be construed as limiting of the disclosure to the precise form disclosed. Further, although the embodiments are described herein with reference to particular means, materials, techniques, and implementations, the embodiments herein are not intended to be limited to the particulars disclosed herein; rather, the embodiments extend to all functionally equivalent structures, methods, and uses, such as are within the scope of the appended claims.

[0081] While the present disclosure is described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departure from the scope of the present disclosure. In addition, many modifications and variations may be made to adapt a particular situation or material to the teachings of the present disclosure or may be acquired from practicing the disclosure, without departing from its scope. Therefore, it is intended that the present disclosure is not limited to the embodiments disclosed, but that the present disclosure will include all embodiments that fall within the scope of the appended claims.

Claims

CLAIMSWe Claim:

1. An automated inert gas management system (100), comprising:an inert gas container (102) configured to store and release an inert gas into a tank (122) via a container valve (104);a plurality of control valves (110, 138) selectively configured to inject the inert gas into the tank (122) and release at least a part of the inert gas from the tank (122);a plurality of electronic pressure transmitters (106, 114, 136) configured to continuously measure and transmit pressure values of the inert gas in the inert gas container (102) and the tank (122); anda controller (128) operably coupled to the plurality of electronic pressure transmitters (106, 114, 136) and the plurality of control valves (110, 138), wherein the controller (128) is configured to:receive the transmitted pressure values of the inert gas from the plurality of electronic pressure transmitters (106, 114, 136);determine a condition associated with the inert gas in the tank (122) based on the transmitted pressure values of the inert gas and at least one configurable parameter of a plurality of configurable parameters; andselectively actuate the plurality of control valves (110, 138) to maintain a pressure of the inert gas in the tank (122) based on the determined condition.

2. The automated inert gas management system (100) as claimed in claim 1, wherein the condition comprises at least one of a leakage of the inert gas from the tank (122), an expansion of the inert gas, and a contraction of the inert gas.

3. The automated inert gas management system (100) as claimed in claim 2, wherein when the condition is determined as a leakage of the inert gas from the tank (122), the controller (128) is configured to trigger an alarm when a loss of the inert gas in the inert gas container (102) exceeds a configurable threshold.

4. The automated inert gas management system (100) as claimed in claim 1, wherein the plurality of configurable parameters comprises a geographical location of the tank (122), a loading schedule, a rate of change of pressure in the tank (122), a temperature cycle of a storage material stored in the tank (122), frequency of actuation of the plurality of control valves (110, 138), duration of activation of the plurality of control valves (110, 138), frequency of replacement of the inert gas container (102), environmental conditions, and historical data.

5. The automated inert gas management system (100) as claimed in claim 1, comprising one or more electronic devices (126) operably coupled to the tank (122), wherein the controller (128), in communication with the one or more electronic devices (126), is configured to determine an amount of the inert gas dissolved in a storage material stored in the tank (122).

6. The automated inert gas management system (100) as claimed in claim 5, wherein the controller (128) is configured to transmit an alert to a monitoring system (206) when the determined amount of the dissolved inert gas exceeds a configurable threshold.

7. The automated inert gas management system (100) as claimed in claim 1, wherein the controller (128) is configured to identify a loss of the inert gas in the tank (122) and determine a demand for the inert gas in the tank (122) based on the determined condition.

8. The automated inert gas management system (100) as claimed in claim 7, wherein the controller (128) is configured to monitor filling of the inert gas in the tank (122).

9. The automated inert gas management system (100) as claimed in claim 1, wherein the controller (128) is configured to monitor a depletion of the inert gas in the inert gas container (102) based on a pressure value of the inert gas in the inert gas container (102).

10. The automated inert gas management system (100) as claimed in claim 1, comprising a monitoring system (206) in communication with the controller (128), wherein the monitoring system (206) includes a user interface (604, 800, 900, 1000) configured to facilitate at least one ofsetting thresholds for the pressure of the inert gas within the tank (122); controlling actuation of the plurality of control valves (110, 138); and monitoring real-time pressure values at the inert gas container (102) and an inlet (120) and an outlet (124) of the tank (122).

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