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Transformer oil regeneration
t is no secret that the existing transformer fleet is worn. Transformers have not been replaced for a long time. n recent years
they have become so expensive that it is very unlikely that in the near future old transformers will be massively replaces with new
ones. n this context prolongation of transformer lifetime takes on special significance.
Transformer lifetime is determined by condition of the core and cellulose insulation whose defects beyond repair lead to its
reduction. While the core has an almost unlimited lifetime, cellulose insulation is ageing continuously. This is why it is cellulose
insulation condition that determines transformer lifetime.
Natural ageing of cellulose insulation is rather a lengthy process. However, it is exposed to a number of factors inside the
transformer that make it age faster: heat, moisture, oxygen and, what's more important, to oil ageing products concentrated in the
cellulose insulation.
Cellulose, being basically an oil filter, captures and concentrates oil ageing products inside and on the surface. t wouldn't be an
overstatement to say that concentration of oil ageing products is higher in cellulose than in the oil itself.
Thus, the key objective of transformer lifetime prolongation and this task in particular is to clean the cellulose.
t should be noted that given the rapidly growing prices of oil products, including transformer oil, the fact that upon cleaning
characteristics of transformer oil that has been in use for a long period of time match characteristics of fresh oil adds high value
to the cleaning process.
Our company owns unique equipment which cleans transformer insulation without power supply disruption E575R mobile unit.
Transformer cellulose insulation is cleaned by circulating pure oil. The cleaning process can be carried out without disconnecting
consumers from transformer supplied power or arranging temporary oil facilities.
Oil regeneration does not require disposal of spent adsorbent. Adsorbent properties are restored in the unit using a unique
technology developed by Fluidex company. This treatment method is environmentally friendly.
Automated unit management and in-process control over oil condition delivers high performance and reliability of insulation
cleaning.
The unit is designed to regenerate transformer oils in high-voltage oil-filled equipment with reduced ecological impact.
Recommended insulation cleaning intervals
The need for insulation cleaning is defined by transformer condition indicators and preventive maintenance
frequency.
Definition of transformer condition indicators which signal that transformer needs cleaning
Condition indications are defined by the type of transformer oil used and the processes that accelerate insulation
ageing. Ageing and accumulation mechanisms as well as characteristics of oil ageing products vary depending on
the type of transformer oil. This is why physicochemical analyses needed to assess the actual oil condition and
initial criteria for cellulose insulation cleaning can be different for different types of oil.
Mostly TKp and TSp oils were used for 35, 110 and 150 kV transformers. T750 and T1500 were further used to
fill up transformers. High content of aromatic hydrocarbons is a distinctive feature of these oil types This feature
makes them similar in terms of ageing processes, products and catalysts. Even if initial acid index is high in
these oils (as-supplied condition of TKp and TSp oils allows 0.02 mg of normal concentration/g) it increases
slowly. Moreover, initially only soluble sediments are formed as a result of ageing. Thus, there were incidents
when TKp oil with acid index 0.03-0.04 contained excessive amount of soluble sediments. The key risk with the
soluble sediments is that they concentrate in the cellulose insulation where their acid index can be ten times
higher than the acid index of the oil itself.
Thus, transformer oil kind of discharges acid products that concentrate in the cellulose insulation. All the while
the oil acid index changes rather slowly increasing up to approximately 0.06-0.07. However, it starts growing
faster afterwards and the following processes are triggered: insoluble sediments and water-soluble acids start to
form. Ionol antioxidant does not work in this case but rather backfires accelerating the oxidation process. It is
obvious that when acid index reaches a mark of 0.03-0.04 processes are triggered that make cellulose insulation
age faster and the acid index limit set by regulations is unacceptable in terms of lifetime prolongation.
Therefore, 0.07 mg of normal concentration/g can be considered an acid index which requires immediate
cleaning of transformer insulation.
Preventive insulation cleaning interval is defined by transformer lifetime. As transformer insulation ages exposed
to ageing acceleration factors the borderline beyond which ageing processes should be more carefully attended
to is a 20-year period. This is the time after which insulation starts to age much faster as compared to the
natural process (see the chart below). The chart contains averaged numbers and curves because ageing
specifics vary by transformer, however, it does reflect the process dynamics. The impact that regular preventive
insulation cleaning produces on ageing speed and potential transformer lifetime are shown on the chart:
Thus, transformers over 20 years old with oil acid index 0.03-0.07 require regular preventive insulation cleaning
with recommended frequency of once every six years. In this case functionality of the continuous oil
regeneration system installed in transformers should also be used. It is also recommended to change silica gel
once every three years in thermosyphon filters in transformers over 20 years old with oil acid index 0.03-0.07.
Definition of recommended preventive insulation cleaning interval
Preventive insulation cleaning interval is
defined by transformer lifetime. As
transformer insulation ages exposed to
ageing acceleration factors the borderline
beyond which ageing processes should be
more carefully attended to is a 20-year
period. This is the time after which
insulation starts to age much faster as
compared to the natural process (see the
chart below). The chart contains averaged
numbers and curves because ageing
Pycckn English
105082, Russia, Moscow,
13 bld., 18 Perevedenovskiy side St.
Tel./fax: 8(495)730 21 48
mailto:mail@energoprom.msk.ru
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specifics vary by transformer, however, it
does reflect the process dynamics. The
impact that regular preventive insulation
cleaning produces on ageing speed and
potential transformer lifetime are shown
on the chart:
Thus, transformers over 20 years old with
oil acid index 0.03-0.07 require regular
preventive insulation cleaning with
recommended frequency of once every six
years. In this case functionality of the continuous oil regeneration system installed in transformers should also
be used. It is also recommended to change silica gel once every three years in thermosyphon filters in
transformers over 20 years old with oil acid index 0.03-0.07.
Results of oil regeneration performed by Energoprom CJSC using E575R regeneration unit
Operating capacity
- Expected regeneration capacity is 2,500,000 liters of finished product per year
- Maximum cleaning or drying capacity is 4,000 l/h
- Level of vacuum created by the vacuum unit is under 8 x 10-2 mbar
- Vacuum block capacity is 918 m3/h
- The system will allow to raise oil temperature to 65C per cycle of maximum capacity
Power
380/220 V, 3 phases, 50 Hz
Dimensions and weight
- The system (regeneration columns, tanks, degasser) is mounted in a 12-meter full trailer. Working
weight is 20 500 kg
Process description
Treatment
phase:
Treatment phase includes cleaning and regeneration and takes 8 hours. Oil flow rate can be
adjusted between 20 and 100% of rated capacity depending on application requirements.
Cleaning:
Cleaning operation is limited to removing moisture and gasses, filtering particles by using high
vacuum, heat and high-quality cleaning (0.5 micron) with oil temperature maintained at 65-
70C.
Regeneration:
During Permasorb process the oil is regenerated using forced percolation (filtration) through a
column with "activated Fuller's earth" at ~70C. Upon regeneration the oil is degassed and
passed through 1.0 micron filter.
Reactivation
phase:
After a certain amount of oil passes through filtration columns, Fuller's earth becomes
saturated and its performance sharply declines which signals that it should be reactivated.
Then the Fuller's earth is reactivated in the columns and a small amount (0.2% of treated oil)
of "residual" contaminants are extracted as an oil skim and collected into a special tank. Pure
oil captured by the clay is separated. Upon reactivation which takes about 16 hours the
treatment phase is resumed by pressing a functional button on the keypad.
Instruments and
meters:
The unit is operated and controlled through a PLC (programmable logic controller) and
interfaces with data control system based on 32-bit Windows operating system. It allows for
automatic operation of the unit and, when necessary, for operator control through a standard
computer. Unit condition including emergency signals, flow rate, pressure, liters of treated oil
etc. are continuously displayed and stores on hard drive. The control system above can offer
the following optional functions that improve regeneration safety:
(a) Precise monitoring of oil level in transformer
(b) Precise monitoring of oil level in storage tank
(c) Storage of oil testing data (dielectric strength, water content, acidity etc.)
All associated meters and pneumatic controls are of the highest quality and reliability
Operator:
Operator enters global instructions such as start/stop treatment, etc. only through a keyboard
or computer mouse. In reality treatment will start and then stop automatically whereas
operation reliability will be maintained by a PLC program. Operator can get access to the unit
only by typing a current operator password.
Unit capacity:
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High and stable capacity of the unit delivers complete treatment of the oil (both in
transformers and in case of single treatment cycles) bringing it into compliance with IEC
standard (296) for new oils.
Unit output:
Output depends on initial oil acidity. Acid index 0.2 mg of normal concentration/g is assumed
in the design output. At different initial acidity, output will be inversely proportional to initial
acidity.
Note:
Regeneration units have 2 design capacities - flow rate in liters per hour or regeneration
output in liters passed through Fuller's earth.
Heating,
degassing and
treatment:
In this procedure output is measured in liters/hour according to the unit model. Maximum flow
rate of our unit is 4,000 liters per hour.
Regeneration:
For this operation we define capacity as the volume of treated oil in liters. Treated oil volume
directly depends on the amount of Fuller's earth placed in the unit and not on the unit flow
rate. In average the unit treats approximately 4 liters of oil per 1 kg of Fuller's earth with acid
index 0.2 mg of normal concentration/g.
Experience of using a similar unit
Transformer TDTN-40000/110 No. 113511 made by Zaparozhye Transformer Plant in 1981, in operation for 22
years.
Oil acid index in transformer tank - 0.23 mg of normal concentration/g.
Dielectric loss tangent of oil in transformer tank - 56.5% @ 90C
Moisture content of oil in transformer tank - 58 ppm.
The transformer had low insulation resistance and dielectric loss tangent over 1%.
Amount of oil in transformer tank - ~25 t.
Upon completion 83,823 liters of oil have been treated which is almost three times the initial volume of oil in
the transformer. The table below compares results delivered by the laboratory of ZTZ-Service Scientific and
Engineering Center with initial data.
Parameter Before treatment After treatment
Color 4,5 2,5
Acid index 0,23 0,011
tg @ 90C 56,5 1,276
Moisture content 58 14
The obtained resuIts meet fresh transformer oiI requirements
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