Hydrogen Sensor Assembly for Transformer Oil Monitoring

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Solution Overview

Problem

Conventional methods for monitoring hydrogen gas in transformer oils are costly, require equipment downtime, and lack real-time and spatially resolved data, making it difficult to detect incipient faults in electrical equipment effectively, especially for smaller transformers.

Innovation Solution

A low-cost, real-time hydrogen sensor assembly that utilizes existing fittings or ports on transformers, specifically attaching to the pressure sensor port without needing new openings, employing a semiconductor palladium-based sensor for accurate hydrogen detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional offline DGA methods are used to monitor hydrogen in transformer oil, then cost is reduced by using simple lab analysis, but real-time monitoring capability is lost and equipment downtime is required

Engineering Contradiction:

Improvereal-time fault detection capabilityVSAvoidequipment downtime for fluid removal

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical offline sampling and lab analysis system with an online electrochemical hydrogen sensor that continuously monitors hydrogen concentration in transformer oil without requiring fluid removal or equipment downtime

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a hydrogen sensor as an intermediary device that interfaces with the transformer oil system through a port, enabling continuous hydrogen monitoring without directly removing or disturbing the oil

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If offline DGA analysis is performed in a lab, then measurement equipment complexity is reduced, but localized position information and spatial variations of gases are lost

Engineering Contradiction:

Improvespatially resolved hydrogen concentration dataVSAvoidlocalized fault position information

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent adds the dimension of spatial localization by equipping the hydrogen sensor with position identification capabilities, transforming the monitoring from bulk oil analysis to location-specific fault detection within the transformer

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If hydrogen sensors are installed on smaller transformers, then monitoring coverage is expanded, but device cost becomes prohibitive with conventional expensive sensors

Engineering Contradiction:

Improveapplicability to various transformer sizesVSAvoidsensor assembly cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective electrochemical hydrogen sensor design that is economically viable for installation on smaller transformers, replacing expensive conventional sensors while maintaining functional reliability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent creates a universal sensor assembly that can be installed on transformers of various sizes by utilizing existing pressure sensor ports, eliminating the need for transformer-specific custom installations

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of operation

If new openings are made in transformer housings for sensor installation, then sensor access to oil is improved, but equipment integrity and sealing are compromised

Engineering Contradiction:

Improvesensor installation simplicityVSAvoidtransformer housing integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent leverages the existing pressure sensor port infrastructure already present on transformers, allowing the hydrogen sensor to utilize this pre-existing access point without requiring additional modifications to the transformer housing

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables cost-effective, real-time monitoring of hydrogen levels in transformer oils with minimal maintenance, providing accurate and localized fault detection without requiring fluid removal, suitable for both new and existing transformers.

Implementation Method 1

employing a semiconductor palladium-based sensor for accurate hydrogen detection

Methodology Applied

Scientific EffectSemiconductor palladium-based hydrogen detection:

Data Source

PatentEP2691746B1Combined hydrogen and pressure sensor assembly

Publication Date: 2018.02.14 QUALITROL CORP

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AI summary

A housing sensor having a semiconductor element for measuring hydrogen concentration in an insulating fluid in equipment having a mounting flange having a plurality of bolt receiving openings in a first pattern. The sensor includes a first flange having one or more openings and an outer periphery. The sensor also includes a tubular housing support member having one end received in one of the openings and a plurality of bolt receiving apertures arranged in a pattern corresponding to the first pattern within the outer periphery of the first flange. The sensor further includes at least one wire receiving opening extending through the housing body, a cover closing an end of the housing body distal from the one end, a first seal disposed between the first flange and the tubular housing support member and a second seal disposed on the first flange for engaging the mounting flange.