Hydrocal 1009

Hydrocal 1009

The HYDROCAL 1009 is a permanently installed multi-gas-in-oil analysis system with transformer monitoring functions.

It individually measures the key gases dissolved in transformer oil, such as:

• Hydrogen (H₂)
• Carbon Monoxide (CO)
• Carbon Dioxide (CO₂)
• Methane (CH₄)
• Acetylene (C₂H₂)
• Ethylene (C₂H₄) 
• Ethane (C₂H₄)
• Oxygen (O₂)

It additionally measures Moisture in Oil (H₂O).

As Hydrogen (H₂) is involved in nearly every fault of the insulation system of power transformers and Carbon Monoxide (CO) is a sign of involvement of the cellulosic / paper insulation, the presence and increase of Acetylene (C₂H₂) and Ethylene (C₂H₄) further classifies the nature of a fault as overheating, partial discharge or high energy arcing. Oxygen (O₂) can be a sign of excessive ageing or leakages within the sealing of hermetic transformers.

The device can serve as a compact transformer monitoring system by the integration/connection of other sensors present on a transformer via its optional analog inputs:

• 4 Analog inputs 0/4 ... 20mADC
• 6 Analog inputs 0/4 ... 20mAAC +20% or 0 ... 80 VAC +20% (configurable by jumpers)

It also has digital outputs for transmitting alerts or performing control functions (e.g. controlling a transformer cooling system):

• 10 digital relay outputs
• 6 digital optocoupler outputs (Option)

Key Advantages

• Individual measurement of Hydrogen (H₂), Carbon Monoxide (CO), Carbon Dioxide (CO₂), Methane (CH₄), Acetylene (C₂H₂), Ethylene (C₂H₄), Ethane (C₂H₆) and Oxygen (O₂)
• Moisture in Oil (H₂O) measurement
• Easy to mount on a transformer valve
  (G 1½" DIN ISO 228-1 or 1½" NPT ANSI B 1.20.1)
• Installation on the operational transformer without any operational interruption
• Advanced software (on the unit and via PC)
• Maintenance-free system
• Communication interfaces ETHERNET 10/100 Mbit/s (copper-wired / RJ 45 or fibre-optical / SC Duplex) and RS 485 to support MODBUS^®RTU/ASCII, MODBUS^ÒTCP, DNP3 proprietary communication and IEC 61850 protocols
• Optional 2G/3G modem with external adhesive antenna
• Optional DNP3 serial modem for SCADA connection
• Optional IEC 61850 modem for SCADA connection
• Optional HV and LV bushing sensors for HV and LV bushing monitoring applications via communication interface

Transformer monitoring functions

The Hydrocal 1009 can be used as a complete monitoring system for the condition of the transformer. The main monitoring options are listed below:

Voltages and Currents

• via voltage and current transformers/transducer

Temperature Monitoring

• Bottom and top oil temperature, ambient temperature (via additional temperature sensors)

Cooling Stage / Tap Changer Position

• e.g. via a current transducer

Free configuration

• Analog inputs can be free allocated to any additional sensor

Further Calculations

• Hot-Spot (acc. IEC 60076)
• Loss-of-Life
• Ageing Rate

HV and LV Bushing monitoring functions (option)

The Bushing Monitoring System simultaneously monitor’s the bushing leakage current of 2, three-phase groups of bushings. The Bushing Monitoring system incorporates three different measurement modes on each tested component to provide accurate Power Factor and Capacitance values to evaluate the condition of bushing insulation. The measurement modes are:

Phase comparison: Compares the power factor of the tested component with another tested component energised with the same phase voltage

Sum of three current tests: Measures the imbalance current from the summation of A, B and C phase currents from three tested components such as the three HV or LV bushings on the transformer

Adjacent phase reference test: Compares the power factor of the tested components with other phase components on the same equipment

The bushing sensors/adapters are connected to the capacitor taps designed for all types of bushings to allow measurement of the leakage current up to 140 mA. The adapters are designed for bushings with grounded and undergrounded capacitor taps. The adapter is designed to prevent voltage from developing on the equipment should the sensor become disconnected from Bushing Monitoring System.

Monitoring of high- and low voltage side

Different bushing sensor configurations are possible:

• Monitoring of high voltage side
• Monitoring of high- and low voltage side
• Reference HV bushing from other transformers
• Reference CCVT / CCPT

Configuration with 3, 6, 9 or 12  bushing sensors possible.

HydroSoft PC-Software

Program key features

• Configuration and administration of each HYDROCAL unit
• Data and configuration readout of HYDROCAL units
• Processing and presentation of data readout (trend or table)
• Online functions (online sensors, extraction status and process flow)
• Diagnostic functions (Duval triangle and Rogers 3D graphic)
• Further processing of the processed data (Excel, CSV, clipboard and printing)
• Storage of the processed data and unit configuration
• Automatic data readout and alerting by e-mail

Key Features

• 230V AC or 110V DC supply
• Connection to valve: NPT 1” ½ or DIN-ISO 1” ½
• Degree of protection: IP55
• 10 Relay outputs
• 10 analog outputs 4-20 mA
• Communication: RJ45 interface or multimodal fibre optic with SC-Duplex interface with ETHERNET or MODBUS®TCP protocol

Operation principle

• Miniaturised gas-sample production based on headspace principle (no membrane, negative pressure proofed)
• Patent-pending oil sampling system (EP 1 950 560 A1)
• Near-infrared gas sensor unit for CO, C₂H₂ and C₂H₄
• Near-infrared gas sensor unit for CO₂, CH₄ and C₂H₆
• Micro-electronic gas sensor for H₂ and O₂
• Thin-film capacitive moisture sensor H₂O
• Temperature sensors (for oil and gas temperature)