transformersOnline monitoring systems — Transformer Condition Monitoring and Fault Early Warning Solution

The product line covers temperature and environmental monitoring (PHM 300U, three-in-one oil temperature, oil level, and oil pressure device), electrical and structural safety monitoring (core clamps, current-limiting devices, DC bias, on-load tap changers), insulation partial discharge monitoring (bushings monitoring, partial discharge monitoring), oil gas analysis (oil chromatography, low-component analysis, oil spectroscopy, hydrogen monitoring), and comprehensive diagnostic platforms, totaling more than 14 product models.

The PHM 300U can simultaneously monitor the temperatures of a transformer’s three-phase windings and core, electrical parameters on the low-voltage side, ambient temperature and humidity, and vibration levels. Using life prediction algorithms, it comprehensively calculates the equipment’s expected service life and load utilization rate.

The device has a temperature accuracy of ±2°C, an oil level accuracy of ±2 mm, and a pressure accuracy of ±2 kPa. Data is updated every ≤0.2 seconds, it has an IP68 protection rating, and it can operate stably in environments ranging from -40°C to +70°C.

The IN-205B series includes three models: the Online Insulation Monitoring System for Transformer Bushings (IN-205B), the Online Partial Discharge Monitoring System for Bushings (IN-205B2), and the Integrated Online Insulation and Partial Discharge Monitoring System for Bushings (IN-205B3), which can be selected based on monitoring requirements.

The IN-203 monitors ground currents in cores and clamps, with a measurement range of 1 mA to 10 A. Its measurement accuracy is ±5% + 1 mA of the standard reading, and its resolution is 1 mA. It supports wall-mounted or rack-mounted installation.

The IN-203X model integrates an automatic switching device for current-limiting resistors based on ground current monitoring. It features automatic switching of four-stage current-limiting resistors and can serve as an emergency response measure to reduce ground current and rapidly suppress circulating currents.

The IN-204 model comes standard with DC bias monitoring; vibration monitoring and load monitoring are optional features that can be flexibly combined according to on-site requirements. The DC current measurement range is -100 A to 100 A, with a measurement accuracy of ±2 A.

The IN-309F model can monitor switch current (0–50 A), temperature (–40°C–120°C), vibration (0–50 g), and position (0–19) in real time, with a response delay of just 0.5 seconds, enabling the timely detection of potential faults.

The system employs multi-sensor fusion technology that combines ultrasonic partial discharge sensors, high-frequency current partial discharge sensors, and ultra-high-frequency partial discharge sensors for oil valves, and uses 3D PRPD and PRPS spectra to visually display key data such as discharge amplitude and phase.

The online partial discharge monitoring device offers a choice of 4 or 6 channels, with a sampling rate of up to 200 MS/s, channel consistency of ≤0.5 dBm, and a dynamic range of -80 to -20 dBm, making it suitable for simultaneous monitoring at multiple locations.

This system can detect seven key gases online that indicate transformer faults: hydrogen (H₂), carbon monoxide (CO), carbon dioxide (CO₂), methane (CH₄), ethane (C₂H₆), ethylene (C₂H₄), and acetylene (C₂H₂), and can be expanded to include trace moisture content monitoring as needed.

The system has a data storage capacity of ≥10 years and supports trend analysis of historical data. The minimum sampling interval for analysis is ≤2 hours per sample, and the monitoring interval can be flexibly configured according to operational requirements.

The IN-201C model is suitable for oil-immersed transformers rated at 110 kV and below, such as those found in power plants, substations, traction substations, and special-purpose substations. It can also be used with on-board transformers in trains. With its compact design, it can be mounted directly on the transformer’s oil valve as a wall-mounted, all-in-one unit.

The device utilizes nano-ceramic degassing technology, eliminating the need for additional separation and carrier gas operations. The sample injection process is automatic and quantitative, and the device features automatic temperature control, audible and visual alarms, and remote alarm capabilities. It is maintenance-free throughout its entire lifecycle.

The IN-201G model operates on the principle of photoacoustic spectroscopy: an oil sample is drawn through the sampling port into a vacuum degassing unit to separate the gases; laser light is then directed at the gas molecules to generate a photoacoustic signal, which is detected, processed, and transmitted to the backend system for analysis.

The system primarily monitors seven gases: hydrogen, methane, ethane, ethylene, acetylene, carbon monoxide, and carbon dioxide. It can also be optionally configured to monitor parameters such as iron-core ground current, moisture, oxygen, and nitrogen. Each gas has a precise detection range and accuracy.

The IN-201D model uses a palladium-nickel alloy measurement principle, with a response time of ≤30 minutes, a measurement range of 5–5,000 μL/L, and a measurement accuracy of ±20% or ±5 μL/L. It achieves a fast response without the need for a degassing module.

The device features a highly integrated, all-in-one design and can be mounted directly on the transformer body without the need to shut down power during installation; the sensor automatically corrects for zero drift before each measurement, eliminating the need for periodic calibration and ensuring maintenance-free operation throughout its entire lifecycle.

The IN-200 model can simultaneously monitor high-frequency partial discharges, radio-frequency partial discharges, and ultrasonic partial discharges in transformers and reactors, as well as core and clamp grounding currents, vibration data, load data, and oil temperature data. It can also integrate data from oil gas analysis, infrared imaging, and fiber-optic temperature measurement.

The IN-6000+ platform is based on a fully domestically developed, secure, and controllable SCADA system. It supports edge computing and integrated diagnostics across multiple devices and parameters, and features partial discharge spectrum analysis (PDA) and a transformer intensive care system (DICS), enabling health assessment and lifespan prediction.