Q. How much important is the maintenance of oil purifiers?

Periodic and Right Maintenance of Oil Purifiers is critical and essential. With timely service, oil purifier machine operates without any glitches. It also provide several benefits, like extended life span, and reduction in repairing and replacement costs.

Q. What is BDV Test in transformer?

BDV is break-down voltage, which is also called Dielectric Strength Valve. BDV Test is an imperative testing procedure for the insulation oils in transformer. As the transformer continues to operate, the insulation oils with time will catch dirt or degrade, resulting in loosing function of the oil in transformer. In this case the transformer can face some serious issues. Timely BDV Testing is the major procedure for monitoring and checking the quality of oil. The low value in the testing result means the oil needs to be purified or replaced.

Q How to perform Dielectric Strength Test for transformer oil?

The transformer oil when tested undergoes an AC electric field with continually enhancing voltage till it breaks down. The test cell can be of either plastic or glass. It must be non-absorbent and transparent with effective volume between 300 ml to 500 ml.

The electrodes must be of material like SS, Bronze, Copper or Brass, and well polished having spherical shape with dip 12.5 mm to 13 mm as well a spherical front. Horizontally mounted in the cell, the electrodes' axis must be immersed at a depth of 40 mm approx. and the electrode must be 2.5 0.1 mm.

To start with the test, one must take the clean cell rinsed with the test oil. Tester must gently agitate the sampling vessel containing the test oil to have uniform distribution of impurities and air bubbles to escape. The oil temperature during the testing must be between 15C to 35C.

A continuously increasing AC voltage of rated frequency is applied to the electrodes, at the rate of 2 kV/Sec, starting from zero upto the value generating breakdown. There is a provision in the test kit for automatic switching off of the supply voltage within 0.02 second.

The test must be conducted six times on repeat, on the same cell filling and the arithmetic mean. All six results are noted as the electric strength or BDV (Break Down Voltage) of the oil under test. It is important to carry out this test in a dry place, which is free from dust. And, the voltage must be applied only after disappearance of any air bubbles. In case one can not observe the disappearance of air bubble, the time intervals between the test must be five minutes.

Q. Why oil is needed in transformer?

Oil, especially transformer oil serves many purposes in a transformer, like the ones mentioned below:

A. Electrical Insulation

The oil in transformer provides electrical insulation between the tank and winding as well as between the windings.

B. Cooling of transformer

It has an effect of mobilizing the heat from the core and winding to cooling surfaces of the tank.

To make sure that the oil effectively and efficiently serves aforesaid purposes, it must have basic qualities needed and that are:

1. The oil must be clean, free from any dust, moisture, metal ions fibres, etc.
2. It should display its stability against oxidation when subjected to different temperatures
3. It should be non-corrosive in nature
4. It should be insoluble with respect to transformer material of construction

Q. Why operator must note when maintaining and operating an Oil Filtration Machines?

The operation must follow a correct procedure when operating an oil filtration machines. So, that he can run the machine without any troubles for longer time and save repairing, replacing and maintenance costs.

Notes When Operation
(1). Keep an eye on the vacuum pump oil of vacuum pump which is shower by the oil scale. The level of the oil must be up to the middle of observe hole on the vacuum pump. If there is too much water in the vacuum pump oil, please change immediately.
(2). If one notices too much water in cooler condenser when running, then discharge the water immediately.
(3). One must observe the change of pressure gauge value. If the pressure is more than 0.3Mpa, then either change the filter parts or clean them.
(4). Both primary and secondary filter elements must be timely subjected to cleaning for avoiding jamming which can cause the quantity of inlet oil to be insufficient or high pressure. These elements must be checked once every six months.
(5). One must keep an open eye and ear when operating or maintaining an oil filtration machine. The person must observe whether the sound of pumps and related motors is normal or not. If it is different from what they hear usually, please resolve the issue immediately.
(6). When unused, all oil from the machine must be exhausted and let the machine standby for next time use.

Timely and continuous Maintenance can solve many potential serious issues with the machine when it is operated for more than one year.
1. After a certain time span of operations, the machine must be scrutinized to know whether:
a) The electrical control system is reliable and safe;
b) The temperature controller is reliable, sensitive and accurate;
c) The oil seals of the pump shaft are broken with leakage or still intact;
d) There is any blockage with the running system.
e) There the pumps and related motors are making any abnormal noise;
f) There is any leakage of air or oil with the oil running system as well as at sealing joints.
g) The Oil level control is reliable.

2. After each 3000 hours operations, grease must be renew or refilled for preventing motors from being burnt.
3. Special vacuum pump oil or lubricating oil N46 must be added in the vacuum pump and oil replaced or refilled if necessary at any time.
4. If the machine will not be used over one month, it should be placed in a dry environment, while closing all its panel door and valves. The machine must be properly protected by a covering.

Especially in Summer and hot days, careful maintenance is required and the operator or maintenance person must pay attentions to all the important notices.

Q. What is an oil treatment plant? (OTP)

Transformer oil is generally dilluted with water, gases and contaminants. As the time passes, the content of the contaminants increases. To separate the water, gases and contaminants from the oil, the oil treatment plants (OTP) are used. In transformer applications, it is because of the electrical field that the oil does not contain too much of the contaminants, water and gases. The oil treatment plant treats the oil and give a stabilized oil which can be again used in power transformers.

Following operations are performed by the plant:

--Transformer oil dewatering, degassing and filtering
The oil treatment plant effectively degasses, dewaters and filter the crude oil. The ZYD-O Model OTP treats the unqualified oil, especially the contaminants present in the oil.

--Dry out the electrical apparatuses while simultaneously carrying out the oil treatment processes on-site and filling the electrical apparatuses with oil.
The use of ZYD-O Model OTP is to install and  overhaul the transformer on-site.

--The use of ZYD-O Model OTP is to regenerate the transformer oil. This OTP improves the quality indexes of used and old oil. The capacity of this plant is 600 Liters/ hour ~ 18000 Liters/ hour, or more.

Q. What is the need of transformer oil and importance of transformer oil purification?

Transformer Oil Filtration
Transformer oil, also called insulating oil is a highly refined mineral oil which remains stable at high temperatures. With superior electrical insulating properties, this oil is essential for the secure and efficient operation of various electrical equipment like high voltage bushing, instrument transformer, power transformer and circuit breaker.

The need of using transformer oil
Transformer oil is widely used as liquid insulation and vanishes the transformer heat by dispersion. This oil is used as a coolant in transformers and in circuit breaker as a means of arc suppression. In transformers, core and windings remain fully immersed in the oil for the purpose of preservation. This oil is also helpful in preventing direct contact of atmospheric oxygen which lead to oxidation of the cellulose made, paper insulation around the windings.

Transformer Oil degrades the desired properties in an environment. It degrades by passing time even with a proactive maintenance program. During the service, this oil gets contaminated by water, particles, gases and chemical products.

Why purify transformer oil?

The purity of the insulating oil is one factor upon which the operation of the electrical equipment depends. It is important to know whether electrical equipment can be continuously operated with contaminated fluid or not, whether its efficiency will be impaired or not. It is important to know because it can result eventually in the risk of total failure.

All high capacity transformers have to cope with excessive voltages of 400kV. The insulating material and fluid are subjected to greater electrical stress as in the manufacturing of transformers and electrical apparatus, the rating requirements and drive to tighter tolerances are focused. The transformer oil gets contaminated over a period of time and loses ita cooling/ insulating properties.

Q. What happens to aging hydraulic press oils?

Contamination is the only cause of oil breakdown and failure of hydraulic press. Moisture and particulate contamination creates an environment wherein the hydraulic ream seal and o-ring degrades. This leads to leaks and unscheduled downtime. O-rings, valve seals, actuator and pump can be contaminated by dirt and moisture, which can upset a preventive maintenance effort. To avoid malfunctioning, it is important to prevent it with FUOOTECH Hydraulic Oil Filtration Systems.

Problems one can experience

High new oil cost
High disposal cost
Seals leakage
"New" oil contamination
Moisture in oil
Diminished performance

Solution to above mentioned problems: FUOOTECH Hydraulic Oil Filtration Systems

FUOOTECH is capable of providing both standard and custom-designed equipment for hydraulic press operations, ranging from single filter housings to larger, vacuum oil filtration system, on-site, bypass recycling systems to multi-stage filtration system. The goal of FUOOTECH is for cleaner-than-new oil without removing oil additives.

Q. What is the Technical Feasibility of Turbine Oil Purification System and Turbine Oil Purifier?

The FTY Series Turbine Oil Purification Systems can be found in a number of industries, like gulf fertilizers, mills, hydropower, turbine, etc. The Turbine Oil Purification Systems are utilized for increasing the life span of turbine filter by removing particles, varnish, and sludge formed in the oil. Apart from removing, it stops the formation of aforementioned waste by eliminating emulsified water and discharging the gas from the oil.

This type of Oil Purification System is capable of cleaning the oil down to NAS 5,  emulsifying water down to less than 100 ppm, removing contaminants down to 5 microns. It also ensures there is no valve sticking problem in the governing system. Using just centrifuge, customers can not achieve these results.

Many people may ask: What is actually the Technical Feasibility of High Vacuum Turbine Oil Purification System and Turbine Oil Purifier ??

At the moment, some customer are making use of centrifuges for cleaning the Turbine Oils by removing free water and contamination.

But it is true that a centrifuge is unable to remove free water content thoroughly. It can not even eliminate emulsified water from turbine oils, which increases oxidation process and causes foaming in oils and reduction in component life. The continuous presence of water in oil forms a thin, insoluble film deposit called varnish that is usually found on bearings and servo-valves. This high molecular weight substance that is insoluble in oil. There are more than 75% soft contaminants that are less than 1 micron in size are in insoluble varnish. These contaminants can not measured by traditional particle counts. Due to the polar affinities in insoluble compounds, they begin to migrate from the base oil's body to machine surfaces over time. At initial stages, a golden / dark brown color can be seen on the surface, which turns to darker gum layers that hardens into lacquer. Centrifuge is unable to remove the varnish. It can create serious issues, like blocking turbine oil filters, servo pencil filters, reducing the life of bearing, cause sticking and failure of servo and directional valve and causing shut-down of turbine. The propensity of varnish to attract contaminants promotes wearing of component. The insulation effect of varnish leads to heat transfer loss in heat exchangers.

It is because of the above explained factors and inability of centrifuge, a high vacuum turbine oil purification system is required for solving the problems, as well as prolonging the oil life and protecting the related systems working.

Q. How to clean old/ degraded/ unqualified transformer oil?

Old transformer oil solutions:

Old transformer oil, used insulating oil and aging insulation oil is generally a blended form containing water, gases, particles, and other contaminants. With time, the quantity of contaminant increases. Using the oil purification plants, all the aforesaid unwanted substances can be separated and removed from the oil. Before using the oil in transformers, it is essential that the transformer oil is free from aforesaid substances. The oil filtration equipment offered by us is the right solution to eradicate this problem from the root. It can be used for cleaning the oil for reusing purpose. The treated oil can used into these electrical devices again.

How to treat Transformer oil?

The series ZYD double-stage vacuum Transformer oil regeneration plant effectively and efficiently deal with various oils, like transformer oil, mutual oil, and switch oil, which are used in several industries.

1, Get rid of free water and trace water from transformer oil by the double stage vacuum system. This oil filter can completely remove water content from the oil.
2, Vacuum degassing system can easily eliminate air, gas content from the old transformer oil.
3. Three filters (Primary, secondary and fine) are employed for removing acidity, free carbon, dirt, contaminants, sludge and discoloration substances.
4. Independent vacuum oiling system  is a oil purifier which can vacuum dry transformer and perform on-line operation with transformer.
5. The oils which can be purified can be categorized into dielectric, insulating, transformer, mutual, switch and many more.

The main purpose of the standard ZYD oil filtration system is to process oils in storage tanks, workshops as well as energized or de-energized transformers.

Q. What is the role of Double-stage vacuum Transformer Oil Filtration Machine?

The role of Double-stage vacuum transformer oil filtration machine is to prepare new and in-service insulating oil to be used in electrical high-voltage equipment. As it removes the dissolved gas, water and particulate contaminants, the insulating oil breakdown voltage values automatically increases. It also improves the insulation oil properties. The dielectric breakdown voltage can be up to 75kV after treatment.

Some common used names

Transformer Oil Purifier
Transformer Oil Purification Machine
Insulating Oil Degasifier
Transformer Oil Conditioning System
Insulating Oil Dehydration Rigs
Oil Purification Plant
Insulating Oil Purification Plant

Q. What Advantages One Can Get from Our Oil Filtration Plants?

It gives Super-Clean oil every time
As it protects the components, such as pumps, hydrostatic bearings, proportional valves / servo valves; the life of machine automatically increases
One can experience better machine operation
The production will improve as well as the product quality
The oil life will also increase
Pollution will be reduced
Reasonable to operate and quick ROI

Q. How Long Will The Filters Last?

This is a commonly asked question. The reasons why the filters are changed are many and some of them are quality and cleanliness of oil, method of user, differential pressure or frequency.  Dirt and oil viscosity are two points that lead to differential pressure are dirt and oil viscosity. The filter can be sized to a clean element pressure drop of less than 0.3 MPa and adjust for oil viscosity. If the filter shows differential pressure at a constant flow, then it should be based only on particulate levels. The one who uses it must know how dirty the oil is which has to be filtered. If one can not judge how dirty the fluid is, then he won't be able to answer the question.

Meanwhile, if one continues to use the machine and filter for purifying the dirty oils every hour or every day,  then the filter is more possible to be broken or blocked. The life span of the filter is also affected when the user  runs the machine by mistake or ignorance.

Q. How Fast Can One Remove Water From Oil?

The oil quality degrades in presence of water. The rate of water to be removed from oil can be different and vary widely. The reason behind the difference is that they all have different viscosities and water removal methods. As a general rule of thumb, the higher viscosity fluids hold water better in suspension. For every machine, the size of vacuum oil purifier machine will differ as well as the water removal speed. The more water can be removed if both, heating temperature and vacuum degree are higher. It must be noted that other problems can also arise, if the heating temperature and vacuum degree are too high.

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