Transformer Active Part Drying With Real-Time Moisture Equilibrium Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing drying processes for electric transformer active parts rely on empirical 'recipes' that lack real-time moisture content control, leading to inefficiencies and potential moisture content deviations above safe limits, causing production bottlenecks and risking transformer failure.
Innovation Solution
A method and system for drying the active part of electric transformers that uses continuous sensing of temperature, pressure, and humidity to determine and maintain equilibrium moisture content through vapor phase drying, retightening, and vacuum drying phases, employing sensors and a control unit to adjust the drying process in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If empirical drying recipes are used without real-time moisture control, then the drying process is simpler to operate, but the moisture content cannot be precisely controlled and may exceed safe limits
Solution Approach 1:
The patent implements continuous moisture content measurement during the drying process using sensing devices. The measured moisture content is fed back to a control unit that adjusts drying parameters (temperature, pressure, time) in real-time to maintain moisture content within specified limits, thereby achieving precise control while managing system complexity through automated feedback loops
Solution Approach 2:
The patent replaces empirical, experience-based drying control with an automated control system that uses sensors and control algorithms. This substitution of mechanical/manual control with automated sensing and control enables precise moisture content management without requiring complex manual monitoring and adjustment procedures
2Reliability
If the drying process is extended to ensure low moisture levels, then the moisture content reaches required levels, but production time increases causing bottlenecks
Solution Approach 1:
The continuous moisture monitoring system provides real-time feedback on drying progress, allowing the process to be terminated as soon as the target moisture content is achieved. This prevents unnecessary extension of the drying process while ensuring reliability requirements are met, thereby optimizing production time without compromising transformer quality
Solution Approach 2:
The drying system uses automated sensing and control to self-regulate the drying process, eliminating the need for manual intervention and extended processing times. The system automatically adjusts parameters to achieve optimal drying efficiency, balancing reliability requirements with production speed
3Productivity
If high temperature vapor phase drying is applied, then moisture removal efficiency increases, but the insulation material may be damaged by excessive heat exposure
Solution Approach 1:
The continuous moisture content measurement allows the system to monitor drying progress in real-time and adjust temperature parameters accordingly. When the target moisture level is approached, the control system reduces temperature or extends time gently, preventing thermal damage while maintaining efficient moisture removal throughout the process
Solution Approach 2:
The patent employs dynamic adjustment of drying parameters (temperature, pressure, humidity) based on real-time moisture content measurements. The system transitions between different drying phases with varying parameter combinations, using higher temperatures initially for rapid moisture removal and then reducing temperature as the target moisture content is approached, thereby preventing insulation damage
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
This approach ensures precise control over moisture content, reducing exposure to high temperatures, preventing premature termination of the drying process, and ensuring the active part reaches the required low moisture levels for optimal transformer operation, thus enhancing efficiency and reliability.
Implementation Method 1
Vapor phase drying is the preferred technology for removing moisture from the solid insulation in the factory; kerosene vapor is used to add heat to the active part
Implementation Method 2
kerosene vapor is used to add heat to the active part
Implementation Method 3
followed by vacuum drying once a required temperature is reached
Implementation Method 4
applying vacuum pressure inside the tank, allowing vacuum drying of the active part
Implementation Method 5
the solid insulation, being hygroscopic, will absorb moisture of approximately 5 to 10% of its own weight when exposed to the open air
Implementation Method 6
at least one first temperature sensor for continuously sensing temperature inside a drying oven
Implementation Method 7
at least one first pressure sensor for continuously sensing pressure inside the drying oven
Implementation Method 8
at least one relative humidity sensor for continuously sensing relative humidity outside the drying oven
Data Source
AI summary
A method and system for drying an active part of an electric transformer, by continuously determining a moisture content in the solid insulations during vapor phase drying in a drying oven and stopping this drying when an equilibrium moisture content is reached. Then, continuously determining a moisture content in the solid insulations during the retightening and geometric adjustment phase of the active part outside the drying oven and continuing with the determination of moisture content during vacuum drying once the active part is inside the hermetically sealed tank, and stopping vacuum drying when an equilibrium moisture content is reached in the solid insulations. The determination of moisture content and equilibrium moisture content is carried out by applying the diffusion equation.