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Sales Manager
Globecore GmbH
Edewechter Landstraße 173,
Oldenburg-Eversten,
Deutschland, 26131
Tel: +49 4484 202 35 91
Email: [email protected]
Skype: mg2globecore_de
www.oilregeneration.globecore.com
GlobeCore Transformer Oil Regeneration Plant with Fuller Earth reactivation system
CMM 12R/4000
- increases breakdown voltage
- reconstitutes oil chemical composition - refines oil color
- increases oxidation stability - decreases gas dissolving capacity
- reactivates Fuller earth up to 300 times free of replacement - easy to operate and service
- operates simultaneously with drying and degassing plants - treats transformer on-line - treats any transformer oil.
Scope of application.
Many of industrial electric systems contain dielectric oils. Extending the lifetime of the equipment and the oil it contains requires the dielectrics to be prepared and periodically treated. Thermal vacuum drying and degassing of dielectrics is a method of such treatment. In combination with filtration this technique allows to extend the life time of oil filled equipment significantly. Long term use of oils causes the oils to degrade thermally and chemically. The products of such degradation are chemical elements adversely affecting the oil’s dielectric properties as well as operation of electric equipment. This problem is solved by periodic oil regeneration. The plant is used during installation, maintenance and operation of oil-filled high voltage equipment (power transformers, high-voltage switchgear, etc.). The plant is designed for processing of electric insulation oils and servicing of transformers. The process of dielectric oil treatment includes the following: Removal of gases solved in the oil. Removal of free and dissolved water. Removal of solid particles. Removal of oil decomposition products. Transformer servicing includes: Transformer evacuation. Heating of the transformer and the active part of the windings with hot oil. Removal of sediment from the windings.
Specifications.
Parameter Unit Value
Max throughput m3/hour 4
Max oil temperature оС 90
Output pressure bar 2,5
Oil heater power kW 75
Vacuum system nominal suction rate m3/hour 280
Fuller’s earth load kg 1600
Max power consumption kW 95
Power supply
Phases 3p+1N+PE
Voltage V
AC frequency Hz
Connections
Oil input DN 40/Camlock C150
Oil output DN 40/Camlock C150
Transformer evacuation inlet DN Flange DN80
Vacuum pump exhaust DN 50
Reactivation exhaust DN 50
Filter elements specifications
Coarse filter (mesh strainer) m 100
Pre-filter with filtering element m 25
Regeneration section filter with filtering element m 0,3х2
Fine filter with filtering element m
1
Dimensions/no trailer
Length mm 11500
Width mm 2090
Height mm 2110
Weight kg 20000
New oil specifications after processing
Parameter Unit Value
One heat and vacuum degassing cycle
Moisture content by weigth ppm 5
Gas content by volume Vol % 0.1
Three heat and vacuum degassing cycles
Moisture content by weigth ppm 3
Gas content by volume Vol % 0.05
Used oil specifications after regeneration
Parameter Unit Value
One heat anc vacuum degassing cycle
Moisture content by weight ppm 5
Gas content by volume Vol % 0.1
Acidity, as per IEC 296; ASTM D-664 mgКОН/g 0.01
Corrosive sulfur as per ISO 5662; ASTM D-1275 ----
Dielectric strength, as per IEC 156; ASTM D-1816 kV 70
Interfacial tension, at 25ºС as per ISO 6295; ASTM D-2285 N/m 45
Dissipation factor at 90ºС as per IEC 247; ASTM D-924 0,001
Attention! Oil specification may vary depending on initial oil condition.
Description of the plant
The unit is built on a frame, including the following sections: Oil regeneration section Oil degassing section Operator room
Degassing section – the part of equipment responsible for filtration, heating and vacuum drying of oil. The degassing section is equipped with a pipelines to supply oil to the regeneration and to receive oil from regeneration. Regeneration section – the part of the plant responsible for chemical restoration of the oil. The oil is regenerated by sorbent. It can absorb products of oil decomposition, making it lighter and improving its dielectric properties. Operator room – the compartment containing control panel, desk etc. Electric control cabinet – a metal case with power and control equipment. The cabinet is connected to every electric component and each component is protected from short circuit or overheating.
Component diagrams and descriptions.
The control diagram is shown in the pneumatic and hydraulic chart, which contains all primary hydraulic, pneumatic and vacuum devices and possible flows of liquids and gases. The flow diagram is provisionally divided into the following sections:
Degassing section
Regeneration section
Pneumatic control section
Transformer Security System – TSS
Degassing section
The degassing section filters the oil and removes solved water and gas. Heated oil is processed in high vacuum.
Regeneration section
The regeneration section restores the oil with the help of the sorbent. The regeneration section is equipped
with devices for sorbent reactivation.
Pneumatic distribution section
The pneumatic distribution section is designed for supply of air to the pneumatic drives of pump equipment.
Application or removal of compressed air is signaled by PLC.
Transformer Security System – TSS
Component locations.
All components are marked according to the flow diagram.
Figure. Component locations. Right view
C1
C2
C3
C4
C5
C6 BT
BT
Connection ports area
are
H Operator`s
area
Figure. Component locations. Front view
Figure. Component locations. Left view
Figure. Component locations. Back view
IM
Oil color compare
sight glasses VC
F1
MF1
P2
P1
F2
7
8
9
10 12
11
P3
F3 AC VP3
SR
CF
P4
VP4 VP5 VP2
VP6 VP1
MT
IC
Description of the primary components of the unit
Degassing section component
MF1 – Mesh filter.
The filter is installed in the inlet line. The filter contains a 100 micron mesh. The filter can be disassembled
and washed. The filter features a flow switch at the inlet and a drain valve.
Figure. MF– Mesh filter.
F1 – Preliminary filter and F2 – Fine filter
The preliminary filter removes solid particles from the oil.
The filtering element can be removed; the design also allows draining of oil and sampling of oil after
filtration.
The filter features an automatic air release valve and filter contamination sensors.
Figure. F1 – Preliminary filter and F2 – Fine filter
Sampling valve Output flange
Pressure after filter
sensor
Pressure before filter
sensor
Inlet flange
Cover
Oil heater
Oil drain switch
Filter mesh
Oil flow switch
Cover
Inlet flange
Outlet flange
Filtering element with
magnets
Air release valve
Oil drain valve
Н1– Oil Heater
The oil heater consists of two 35 kW sections.
The heater is of unique design. It is inertia-free and low mean surface power (up to 1.1 W/cm2).
Figure. Н- oil heater.
OT – Oil Trap
The oil trap is a cylindrical vessel accumulating oil which may enter the vacuum system and drains into the
vacuum chamber.
The trap features an oil level sensor, vacuum sensor, foam level control sensor, vacuum break, oil drain
and cutoff valves.
Figure. OT- oil trap
Oil drain valve
Oil heater Cover
Outlet flange
Input flange
Thermostat
Heater terminals
protection cover
Vacuum break and oil
drain valve
Outlet flange
Inlet flange
Vacuum column cutoff
valve Level sensor
Foam level sensor
Vacuum sensor
VC – Vacuum chamber.
The vacuum chamber is a metal vessel with coalescers; the oil emits moisture and gas on the surface of the
coalescers under the influence of temperature and vacuum.
The chamber contains level sensors, foam sensor, a sight glass with lighting and a drain valve.
Figure. Н- Vacuum column. Left view
Figure. Н- Vacuum column. Right view
Oil drain valve
Vacuum chamber
Oil level sensor
Outlet flange
Coalescers
Foam sensor
Air/moisture outlet
Oil inlet
Light
Sight glass with light
IM – Inhibitor mixer
Inhibitor mixing assembly blends an antioxidant additive with oil.
The mixer is equipped with a bin for loading of the additive with a cover.
The mixer features level sensors and a vane agitator with drive.
The mixer features level sensors and a vane agitator with drive.
Figure. IM- Inhibitor mixer
С1…С12 sorbent columns.
The columns contain sorbent. The sorbent is able to accumulate oil degradation products. The columns are equipped
with a sorbent ignition device and thermal sensors. The sorbent layer is supported by a screen in the bottom of the
column. A hatch is installed in the lower portion of the column for cleaning and servicing.
When the sorbent in the column is burning, the conflagration is moving from top to bottom. This removes oil decay
products. The process is monitored with the help of thermal sensors. The sensors are located along the column in
column 1, and at the top and bottom of the remaining columns. The burning process occurs at 500-700oC and takes
approximately 16 hours. After the lower part of the column cools to 100oC, the process is complete.
Bin
Cover
Drain valve
Level sensor
Level sensor
Mixer drive
Inlet/outlet flange
Figure. Sorbent column.
IC – Intermediary tank
This tank accepts oil after regeneration, captures and releases air. During sorbent reactivation, the vessel
accumulates waste oil pumped into the buffer tank.
An automatic air release valve is installed in the tank.
Level sensors and a visual level tube facilitate level monitoring.
An oil drain valve facilitates draining of oil from the tank.
Figure. IC – Intermediary tank
Temperature sensor
Sorbent ignition device
Sorbent
Service hatch
Retaining screen
Inlet flange
Outlet flange
Visual level tube
Oil drain valve
Level sensor
Outlet flange
Outlet flange
Outlet flange
MT- Demister
This tank is designed for separation of heavy fraction and moisture from burning products. The vessel is equipped
with a sight glass and an emergency condensate level sensor. The vessel reduces the influence of exhaust on the
vacuum pump.
Figure. MT- Demister
SR- Noise suppressor.
During sorbent reactivation the vacuum system generates a lot of noise. The noise suppressor reduces that noise.
Condensate may accumulate in the suppressor during operation. A valve for draining is installed in the device.
Figure. СF Charcoal filter.
Visual level tube
Oil drain valve
Level sensor
Outlet flange
Inlet flange
Drain valve
Service hatch
Inlet
Outlet
F3 – Filter During regeneration, the oil can carry out sorbent particles. A filter is installed to capture these particles. The filter is a metal vessel containing replaceable filter element. The filter element must be changed from time to time. Frequency of change depends on quality of processed oil. Filter element is pressed down by a spring loaded lid. The filter is equipped with an automatic valve for air release and a drain valve for oil.
Figure. F1 Filter
BT- Buffer tank
The buffer tank contains oil reserve. The reserve is necessary to compensate for oil loss during sorbent reactivation. In the process of reactivation, some of the oil burns out, and some is pumped into the buffer tank. The buffer tank is divided into two compartments: “Clean Oil Area” and “Dirty Oil Area”. “Clean Oil Area” is designed for storage of clean oil, which enters the unit in the filling stage, as well as for draining columns before reactivation. “Dirty Oil Area” is designed for storage of dirty oil during sorbent reactivation. It is recommended to drain at least 60 liters of settling oil before each reactivation. The unit is serviced through a hatch, drain valves are installed for the oil, oil level is monitored visually in level tubes.
Side view Cut away view
Figure. BT- Buffer tank
Air release valve
Filter element
Spring loaded lid
Oil drain valve
Inlet flange
Output flange
Visual level tube “Dirty Oil Area ”
Visual level tube “Clean Oil Area ”
Drain valve
“Clean Oil Area ”
“Dirty Oil Area ”
Level sensor Service hatch
Level sensor
Principles of operation
The plant may be operated automatically or manually. The plant operates in the following stages: Plant filling. Degassing section filling Regeneration section filling Connection to transformer or other equipment. Warm up and air release from hoses. Regeneration of oil in transformer. Degassing and regeneration of oil Sorbent reactivation Resuming oil regeneration and degassing Normal stop
Plant filling.
This stage is necessary when working with a transformer. Over 3000 liters of oil is required to fill all vessels of the plant. When the plant is connected to a transformer, the oil level may drop below critical. Fill the unit with oil to the transformer. The plant may be filled manually or automatically.
Electric power connection Electric power is connected to a separate terminal box. The box contains three terminals and 1 grounding lug. Each terminal corresponds to a certain phase. The terminals are marked A B C.
Figure. Electric power connection terminal box
Power is connected by a 3 wire cable with wire cross section of no less than 240mm2. Connection of two wires of 120 mm2 each to one terminal is also possible if necessary.
Grounding cable in
Phase A in
Phase B in
Phase C in
Cable connection buses
One 120mm2 wire is used for grounding. To connect ground, secure the wire to the grounding lug and connect the other end of the cable to the transformer grounding circuit. For regenerating oil NOT from a transformer, connect unit grounding to any other grounding circuit.
Connection panel and connection of the plant to oil-filled systems
Connection of the plant to oil-filled systems is facilitated by the connection panel. This panel contains all valves and connection point requiring constant access and servicing.
Transformer evacuation valve
Oil in
let valves
Oil o
utlet valves
Air to
bo
ttom
TSS valve
Air to
top
TSS valve
Transfo
rme
r vacuu
m b
reak valve
Oil w
aste drain
valve
Figure. Connection valve panel
Control panel and electric control description
All electric components are connected to the electric components. The control cabinet is separated into two parts: power and control. The power compartment contains all protection circuit elements, automatic switches, breakers and pump contactors. The control compartment contains the controller, frequency variators and several automatic switches.
The plant is controlled from a laptop computer with pre-installed Windows 7® and SCADA Movicon® system. A USB key is supplied for operation with the SCADA system. This key contains unique licensing information for control system start.
Before operation, connect the key to a USB port of the PC.
SCADA system description The SCADA (Supervisory Control And Data Acquisition) system offers the operator access to all elements of the plant. The operator may control the plant operation, select various operation modes, monitor sensor indications and view event log. The system consists of several screens. Each control mode uses its own screen. Mode selection is made in the main screen. The following modes are selectable:
Manual control (MANUAL)
Plant filling (CHARGING)
Degassing and regeneration mode (DEGASING/REGENERATION)
Abnormal event mode (ALARM)
Control elements are shown in the mimic diagram on the screen. The diagram shows all pumps, valves, sensors etc. The mimic diagram is a simplified flow representation of the plant. All controlled valves are shown according to their position in the process diagram.
The top part of the diagram shows the regeneration section, with transformer oil level and TSS status in the lower left part, and degassing section in the lower right part.
Regeneration unit
TTS oil level monitor
Oil degasing unit
Figure. Control system mimic diagram
The diagram is displayed in MANUAL, CHARGING and REGENERATION/DDEGASING modes. Faults are displayed in a sceen showing fault title, date, time and fault status.
Figure. Fault screen
BT C1…C12 IC MT CGC
IM VC F2 F1 H1 OT
BV1000
