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Transformer Oil Regeneration (Reclamation)

Case Studies Of Oil Reclamation, , , ,

Transformer Oil Reclamation

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During the different stages of its operation, transformer insulating oil is exposed to many different hazards including water, moisture, acids, and particulate matter.  Periodic monitoring therefore, is an important part of a comprehensive transformer preventive maintenance program.  Important characteristics of transformer oil, including purity and other useful properties, are very important in determining the performance and service life of transformers.  The service life of a power transformer, whether short or long, has a very high impact on the financial health of electric power utilities and their ability to provide consistent and reliable service to their customers.  The decision to replace, refurbish, repair, or service an aged power transformer requires the consideration of several factors.  Of special consideration for power companies is the time and cost involved in performing maintenance and the possibility of extended service interruptions for their customers.

The service life of a power transformer is directly related to the condition of the oil and paper insulation system and how that system is maintained.  The best and most cost efficient method of transformer preventive maintenance is the industry leading GlobeCore Process.  The heart of the GlobeCore Process is the innovative use of a “Fuller’s Earth” filtration system that automatically reactivates the Fuller’s Earth sorbert materials precluding the need to dispose of and replace sorbent materials after each reclamation cycle.  The GlobeCore Process allows for the complete re-use of the transformer insulating oil because the oil is completely reclaimed and restored to original new like condition.  The economic benefits are quite obvious because of the ever increasing costs of replacing both mineral and synthetic transformer oils and the costs of disposing of contaminated oils.   These costs are eliminated when the GlobeCore Process is implemented as part of your company’s preventive maintenance program.  In addition to eliminating oil replacement and disposal costs, the GlobeCore Process preserves resources and is the most environmentally friendly maintenance system in the world today.

Oil Sampling and Oil Analysis Before Transformer Oil Reclamation

During the service life of the power transformer, the Insulating Oil becomes contaminated with water, moisture, and other impurities causing oxidation.   As the presence of these contaminates in the oil increases with age, the oil loses important electrical and chemical properties important to the proper operation of the transformer.  The key to long transformer service life is a good and well planned preventive maintenance program.  The best way to monitor transformer oil is through oil sampling and oil analysis.  By periodic sampling and laboratory analysis, it is possible to monitor and verify the level of contamination found in the oil.  Once the oil’s acid number reaches 0.08, a GlobeCore Oil Reclamation Process can be performed preventing aggressive contaminated oil from damaging the insulating paper.  The GlobeCore Service Life Extension Program allows for “Right On Time” preventive maintenance which keeps the insulating paper and transformer core free from water, moisture and other contaminates before they can damage and degrade the paper.  The GlobeCore Process therefore, can effectively extend the service life of your transformers between 5 and 10 years.

Cleaning and Drying of Insulating Oil as Part of Oil Reclamation.

The GlobeCore Process includes oil purification and additionally includes a process for Cleaning and Drying of the insulating oil and the transformer core and insulating paper.  This two for one process is know as the GlobeCore “Two for one Engineering Miracle.”  The GlobeCore Process is capable of removing the contaminates and water from the core, the windings and the insulating paper.  When the GlobeCore Process is compete, there is no contaminated oil left anywhere in the transformer and the all important insulating paper is also left free of contaminates thereby completely stopping any degradation process from the aggressive effects of water, acids and other contaminates.
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Oil Reclamation Systems

Case Studies Of Oil Reclamation, , , , , , ,
oil reclamation

The main purpose and benefit of transformer oil reclamation is to completely restore the insulating oil back to new like condition without having to buy new oil or dispose of old oil.

The GlobeCore Process of oil reclamation is performed by extracting water/moisture, acids, particulate matter and other undesirable contaminates such as unsaturated hydrocarbons, asphalt-resinous substances, sulfur and nitrogen compounds from the oil.  The process of regenerating transformer oil uses various technologies based on (1) physical, (2) physico-chemical and (3) chemical processes.

There are several chemical methods of deep oil reclamation.  The most common one consists of  an acid-alkaline-earth method.  This method of oil purification is based on treating the oil with sulfuric acid.  The sulfuric acid acts to compact and bind all the unstable compounds into an acid sludge oil.  Tar is then removed by “settling” and the remains of the sulfuric acid and organic acids are neutralized by the use of an alkali treating oil.  Following that, the oil is washed with distilled water, dried and treated for complete neutralization with bleaching earth.  After final filtration, the oil becomes completely regenerated.

Transformer Oil Recloil reclamation unit CMM 6R with degassingamation Methods

  • Mechanical – To remove from the oil moisture/water and solid contaminants (filtration, centrifugal action, sludge removal);
  • Thermo-physical – evaporation, vacuum distillation;
  • Physico-chemical – coagulation, adsorption;
  • Chemical – if three methods are not enough, this method involves the usage of much more difficult and costly equipment.

Physical Methods of Reclamation of Transformer Oil

The physical method of transformer oil reclamation is usually referred to as purification by removing mechanical impurities and water, i.e. drying.

All Transformer oils, (whether new, old, or operational), that are contaminated by mechanical impurities and water, can be corrected in most cases by one of the following reclamation methods as long as there have been no changes in its chemical properties or other the significant changes that have altered the basic qualities of the oil.  Undesirable contaminates that deteriorate the initial properties of the oil, can be dissolved in the oil or found in the oil in an undissolved state.  Thanks to mechanical cleaning, these undesirable  contaminates can be removed from the oil.

Oil Drying

The most advanced and cost effective method of oil drying is by spraying the oil under vacuum at a low temperature.  The solution of the oil and water is sprayed through a nozzle that is placed in a tank of water in which “under-pressure” is created.  Thus the free and dissolved moisture and the dissolved air are removed from oil.  When the oil is “thin dispersed” it quickly gives up its moisture. Dry oil, as droplets, then fall to the bottom of the vacuum tank.

The efficiency and speed of drying rate is further increased by heating the oil.  This increases the evaporation process of the water.  Oil loss from evaporation is insignificant.  The rate of water evaporation from oil will also depend on the difference between the pressure of saturated steam at a given temperature and the residual pressure in the vacuum tank.

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GlobeCore’s engineer with a collegue from Saudi Arabia after successful start of equipment

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The choice of the plant was far from random. The CMM-10 is a versatile unit, allowing heat and vacuum treatment not only of transformer oil, but also turbine, industrial and other oils. The oil is restored by removing water, gas and various solid particles.

The CMM-10 plant has a wide range of application. If can be used for installation, repairs and operation of oil filled high voltage equipment, sealed or breathing. up to 1150 kV.

Besides, the CMM-10 can successfully heat equipment with hot oil, introduce nitrogen into the oil and add oil into high voltage systems.

The unit is protected from overloads, overheating and short circuit of controls, pumps, drives, lights and heaters.

The CMM-10 stops in case of phase skipping, incorrect phase connection, as well as overheating of oil from or the oil heater. Light and sound alarms are available.

The plant is simple in operation and can be used both indoors and outdoors.

GlobeCore representatives particiapted in a seminar in Jordan

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The company’s professionals attended a seminar in Amman, Jordan, on 15 April. The meeting was focused on equipment to improve efficiency of transformer operation.

GlobeCore’s Daria Shaddad and Yevheniy Svirid presented the main types of equipment which the company can offer for Jordan’s power plants.

Yet one automated system for Oil Reclamation Shipped

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In 2014, GlobeCore supplied and commissioned an automated mobile plant CMM-0.6A for purification and drying of transformer oil.

The unit uses classic vacuum drying process, as well as purification by multiple passes through a series of filters. The input oil’s viscosity must be below 70 cSt at 50 °С.

The unit is fully automated. It features a GSM module for remote control of the unit by cell phone. Error messages and process parameters are transmitted to the cell phone as text messages.

The CMM-0.6A unit will be most beneficial to facilities involved in installation, repairs and operation of transformers, oil-filled switches etc.

Regeneration of Oil

Case Studies Of Oil Reclamation, , , , , , , , ,

Oil Regeneration today has become a very interesting and important subject.  Oils can be regenerated in a number of ways by different equipment and to varying degrees of purification.

GlobeCore has developed and built oil regeneration equipment for many different applications that involve regeneration and purification.  The equipment varies widely in terms of number of applications and the degree of regeneration desired by the operator and include the following:

  • oil regeneration
  • heat and vacuum purification of oil,
  • purification of oil by adsorbents
  • drying of transformer windings,
  • dehydration of oil,
  • degassing of oil,
  • reactivation and preparation of sorbents, including full regeneration of MINERAL oils with color lightening.

The following is a brief list of GlobeCore’s equipment for oil regeneration, putificaton and other industrial applications.

  • Themovacuum oil purification units, mobile oil plants: СММ-0.6; СММ-0.7(Р); СММ-0.6; СММ-1.0; СММ-1.7; СММ-2.2; СММ-4.0; СММ-4.3 and some other models;
  • Comprehensive oil restoration units, including heating, nitrogenation, drying and filtration of insulation oils: CMM-3, CMM-4, CMM-5, CMM-5М, CMM-6, CMM 10-10, CMM 10-10В, CMM 10-10Л, CMM 10-10М, CMM-12B, CMM-12B1, CMM-12B2, CMM-12B3, CMM-14B У1, CMM-14B1, CMM-14B2, CMM-10-3, CMM-10-3Е, UDV-2М, PDV-Е and other range.
  • units for purification, drying and removal of solids from transformer and turbine oils – MCU-2-U1, MCU-4-U1, MCU-4С-U1,  MCU-4А,  MCU-4СА,  MCU-4C, MCU-4CF, MCU-4CS,  MCU-4CSA, MCU-А, MCU-С, MCU 4Р-N, MCU 4Р-NС, MCU 4Р-NA, MCU 4Р-NСА,  BC-N, MCU-7, FSM-2, FSMB-110М etc;
  • Sorbent regeneration systems– BR, PS-1, PS-1А,  PS-1Е, BRPS, MCU-4Р-BR, zeolite drying cabinet
  • Systems and vacuum sections for drying of solid insulation of power transformers – “Iney-4″, ” Iney-4М”, ” Iney-5″, ” Iney 5М”, ” Iney-6″, ” Iney-4.1″, ” Iney-4.1М”, ” Iney-4.2″, ” Iney-4.2М”, vacuum units BV-1 and BPR;
  • Units for drying of air to dew point below -50°С – “Sukhovey”, ” Sukhovey-4″, ” Sukhovey-5″, ” Sukhovey-4Е” with two independent heaters
  • transformer and transformer oil heating units: NTML, NTML-160М, NTML-80М, NTML-120М, NTML-200М, NTML-240М, NTML-150Е, for parameters of processed oil: solid content no more than 5 (10) ppm, filtration from 5 to 20 micron
  • oil filtration systems – FUM-P, FUM-А, customized drying and solid removal systems for mineral oils up to 50 m3/hour capacity, purity class from 7 toо 11, filtration ratios from 20 to 2000, filtration fineness 1, 3, 5, 10, 20 and 40 micron;

The full range of GlobeCore products is presented in the attached file, and can also be seen on the company’s website at www.globecore.com

The company has a global dealership network, and the products are supplied to more than 80 countries world wide.  Certified explosion protection option is available. Production certified in accordance with ISO 9001 – 2000.

Transformer Oil Drying– An Integrated Approach

Case Studies Of Oil Reclamation, , , ,

Various international and local regulations contain instructions and specifications on oil quality.  Additional regulations instruct where, when, and how oils can be used and how used oil can be disposed of legally.  In order to comply with the myriad of regulations and to keep the environment protected from harmful emissions, and/or hazardous spills, a business may be required spend large sums of money.  The timely replacement of transformer oil, environmental controls, preventive maintenance and corrective can impose even more costs.

One way to avoid, and possibly eliminate, some of these costs is to maintain your transformers in top working condition.  This can be accomplished by paying close attention to the purity levels of your transformer insulating oil with an oil analysis program.  The only way to maintain (or recover) the high dielectric strength of the transformer’s insulting oil is through the process of deep drying and degassing using modern purification and “Regeneration” technology.

Efficient oil drying and removal of solved gases requires vacuum treatment.  Water and air are removed faster when the atmospheric pressure is lower and the temperature is higher (to a limit). The optimal vacuum process parameters are 80C/176F temperature and 133 Pa/0.01929 psi atmospheric pressure.

The best modern designs for oil drying and regeneration are more economical due to unification of many processes and a more versatile purification system all contained in one piece of equipment.  Oil purification, drying, degassing and regeneration used to require several different types of processing equipment.  GlobeCore engineers have developed the industry leading GlobeCore Process that has combined the purification and drying process in one machine that now fully regenerates all the oil in the transformer.

The CMM-R and CMM oil regeneration units manufactured by GlobeCore are designed for drying, degassing, removal of solids, nitrogenation and heating of transformer oil from power transformers and other electric equipment.  In other words, they perform the complete oil regeneration process that combines purification of oil and the drying and cleaning of solid core insulation with one machine and one operator.  It is a two for one process known as the GlobeCore “Two for One Engineering Miracle.”

The CMM-R units are equipped with electric heaters, oil and vacuum pumps, fine filters and adsorption sections. They are used for regeneration of oxidized transformer oil and can be connected directly to energized transformers.

A unique distinction of the modern regeneration units is that there is no atomization of oil or thin-film insets in the vacuum chamber, instead, “activator filters” are used, which allows the spreading of the oil for processing.  The design allows for the elimination of bulky nozzles and sprayers and prevents ingress of oil into the vacuum line, greatly increasing the process consistency.

The UVR regeneration and oil reclamation system ensures a very high degree of efficiency of oil reclamation. The regenerated oils are consistent, resistant to oxidation and do not darken or accumulate odors.  The complete purification, drying, degassing and regeneration units offer the full range of services for transformer oil maintenance and oil regeneration.

Its time to get with the Process, the GlobeCore Process!

Typical Time and Energy Consumption for treatment of a 25000 Liter Transformer with the GlobeCore CMM-R12

Case Studies Of Oil Reclamation

This evaluation is based on the GlobeCore CMM 12R/CMM 4 Transformer Oil Regeneration unit  with Regeneration Unit production capacity of 4000 l/h and 1600 kg of Fuller’s Earth in 12 columns.  The GlobeCore CMM-R12 is able to regenerate 6400 liters of oil during one regeneration cycle.

Globe Core Transformer Oil Regeneration Plant on a trailer.

The GlobeCore CMM-12R production capacity calculation is based on initial oil acidity of 0.2mg KOH/g and is equal to 4 liters of regenerated oil per 1 kg of Fuller’s Earth. The amount of Fuller’s Earth required to treat oils with higher or lower acidity level will increase or decrease proportionally. At this average rate, it will require four (4) sorbent reactivation cycles to regenerate 25000 liters of transformer oil.

In practice, the oil acidity level of an average transformer (acid number) may increase to values higher than 0.2mg KOH/g, thus, requiring more regeneration cycles.  This is due to delayed maintenance that allows the transformer oil to become more contaminated which increases acid levels considerably.  Ideally, oil regeneration should be initiated when the oil’s acid number reaches 0.08 and before higher levels of oxidation and contamination can damage the insulating paper.

One of the main advantages of the GlobeCore Transformer Oil Regeneration units is that they use the GlobeCore Process which is capable of removing sludge deposits from transformer windings and insulation.  This is achieved by increasing circulating oil temperature to the aniline point, which is usually around 80ºC/176ºF.  Dissolved deposits of sludge are removed by the sorbent before oil is returned to the transformer.  On-line (energized) oil regeneration therefore, does not only restore oil quality to “like new” conditions, but also clears the transformers of contaminants that could not be removed by simple oil replacement or purification processes.

The De-sludging process will actually be more efficient and faster on energized transformers as winding vibrations and generated heat will also help to remove sludge.  With average oil parameters, it typically takes 10-20 passes to de-sludge an energized transformer and up to 50 passes on a de-energized transformer.

The number of operational cycles needed to regenerate 25000 liters of oil and de-sludge transformer windings will depend on the level of transformer contamination and can vary from 4 to 50 cycles.

The example below shows average energy consumption and time required to treat a 25,000 L transformer.

Estimation is based on 10 operational cycles.

Oil-Regeneration-Plant-Connection-Diagram

 Oil regeneration plant connection diagram.

The GlobeCore CMM-12R operational cycle consists of two stages:

1.       Oil Regeneration. Takes 6-10 hours depending on transformer oil conditions.

2.       Fuller’s Earth Reactivation. Takes 14-16 hours and depends on ambient temperature.

Approximate duration of one operational cycle is 24 hours.

Average energy consumption for one operational cycle on GlobeCore CMM 12R is 90 kW.

In the “oil regeneration mode,” the GlobeCore CMM 12R consumes insignificant amounts of electricity (0.1-0.2 kW/h) as oil is being drawn through the Fuller’s Earth columns by Oil Purification Unit – CMM -4 .

In “Fuller’s Earth reactivation mode” 12 Thermo- electric heaters (3kW/h each) are turned on for 40minutes (0.66 hour) to initiate sorbent regeneration: 12 x 3 kW/h x0,66 = 23,76 kW. Remaining 66.24 kW are used by Vacuum Pump and automation and actuating systems.  Ten (10) operational cycles consumption will be: 90 kW x 10 cycles = 900kW.

Oil Purification Unit – GlobeCore CMM-4 is used in conjunction with GlobeCore CMM 12R to remove dissolved gasses and moisture from the transformer oil before regeneration.  CMM 6000 power consumption is 60 kW/h.  The unit operates during both Oil Regeneration and Fuller’s Earth Reactivation modes.

GlobeCore CMM-4 energy consumption during one cycle (24 hours) will be: 60kW/h x 24h = 1440 kW.

Ten (10) operational cycles power consumption will be 1440 kW x 10 cycles = 14400 kW.

GlobeCore CMM 12R/CMM-4will consume 900 kW + 14400 kW = 15300 kW for complete treatment of 25000 L of transformer oil.

The transformer tank shall be topped up with transformer oil after treatment. 0. 3% to 1% (75L to 250 L) of initial oil volume will usually be required.

One additional day is required to connect and disconnect the GlobeCore CMM 12 R/CMM-4 from the transformer.

25000 L Transformer:

Oil treatment duration (including connection and disconnection) – 12 days.

Electricity consumption – 15300 kW.

Oil consumption – up to 250 liters.

Note: this calculation is based on average oil conditions and assumption that CMM-12R/CMM-4 is operating on its full production capacity.  While caring out regeneration on energized transformer it might be necessary to reduce the flow to prevent  turbulence.

Transformer Oil Parameters Before and After Regeneration.

Parameter

Test Methods

Before regeneration

After regeneration
Appearance

Visual

Cloudy brown

Clear and transparent
Acid number, mg КОН/g

IEC 296; ASTM D-664

0.63

0.01
Corrosive sulfur

ISO 5662; ASTM D-1275

Present

None
Moisture content, ppm

IEC 733; ASTM D-1533

170

5
Breakdown voltage, kV

IEC 156; ASTM D-1816

11

73
Dielectric loss tangent at 90ºС

IEC 247; ASTM D-924

4.0

0.001
Gas content, %

IEC 60599; ASTM D-3612

12

0.1
Surface tension, mН/m, at 25ºС 

ISO 6295; ASTM D-2285

22

45
Mechanical contaminants size,micron

50

5
Oxidation stability:mg КОН/g

IEC 1125А; IEC 1125B; IP-307

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Our participation in MEE – 2013 at Dubai Convention & Exhibition Centre, Dubai, UAE

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Our company is well known around the globe. We’ve supplied our products to the countries of Europe, Asia Pacific, Africa, Middle East, Latin America, etc. We are always conscious of our customers’ needs to provide them with the best solutions and service. This is why GlobeCore`s managers and engineers often make presentations in terms of various different exhibition.

We particularly attended Middle East Electricity Exhibition – 2013 in Dubai to report a technology of oil regeneration implemented into Globecore machine CMM-R.

Darina Shadad, GlobeCore`s sales manager, to attend the exhibition, reported difference between transformer oil regeneration (reclamation) and oil purification as well as main operating principles of CMM-R.
Transformer-oil-regeneration-PC-GlobeCore

GlobeCore Sales Manager Darina Shadad at Middle East Electricity Exhibition in Dubai, UAE.

Darina also noted that insulation was the most important part of a transformer to maintain as it was the weakest link of any of it. Life of insulation is the life of a transformer itself. Insulation requires early and swift attention.

In oil purification (degassing) the following specifications are most important: dielectric strength; color; flash point; interfacial tension; pour point; specific gravity; viscosity; neutralization number or acid number. But for regeneration such factors as: water content; tan delta also known as power factor or electrical dissipation factor; oxidation stability also matter.

Regeneration is the complete treatment of oil to “like new” condition. When oil purification or degassing is no longer effective, oil must be either changed what they mostly do today or regenerated, getting a perfect alternative. Another advantage of oil regeneration is the oil price. In the days of economical crisis it reached 150 US $ per barrel. But now customers don’t need to worry because now they don’t need to buy new oil as they can just regenerate it.

Besides, our equipment is environmentally friendly. This factor is very important today, because to have investors motivated, manufacturers have got to demonstrate “green” and environmentally friendly approaches. CMM-R unit reactivates sorbent except of oil regeneration.

Here you get a summary of CMM-R’s advantages:

– You don`t need to disconnect a transformer because the machine treats energized transformer, as result there’s no money loss and no unsatisfied customers.

– Low labor cost – to manage these equipments one requires the only operator.

– No transportation of transformer oil.

– No need to buy new oil – you need just to regenerate old oil to get “like new”condition of it.

– No environmental polllutions – our equipment isenvironmentally friendly because it excludes sorbent utilization.

– No atmospheric discharge.

So, you’ve got to make a right decision.
Middle-East-Electricity-2013