Transformer Oil Regeneration Plant CMM-6R

Transformer Oil Regeneration Plant CMM-6R

Technical specifications

Parameter Units Value
Capacity m3/hour 1
Maximum allowable oil temperature оС 90
Outlet pressure bar 1,5
Oil heater power kW 50
Vacuum system nominal suction rate m3/hour 280
Fuller’s earth load kg 900
Maximum power consumption kW 95
Electric parameters
Phases 3p+1N+PE
Voltage V 415
Frequency of AC Hz 50
Connections
Oil inlet DN 25/Camlock C100
Oil outlet DN 25/Camlock C100
Transformer evacuation inlet DN Flange DN100
Vacuum pump exhaust DN 32/G1 1/4
Reactivation exhaust DN 50/G 2”
Filter element specifications
Strainer (mesh filter) hm 100
Pre-filter with filter element hm 25
Regeneration section filter with filter element hm 0,2х2
Fine filter with filter element hm 5
Dimensions (without trailer)
Length mm 10680
Width mm 2090
Height mm 2110
Weight kg 8000

Parameters of processed oil

Parameter Unit Value
In 1 thermal vacuum degassing cycle
Moisture content ppm 5
Volumetric gas content Vol % 0,1
In 3 thermal vacuum degassing cycles
Moisture content ppm 3
Volumetric gas content Vol % 0,05

Parameters of used oil after regeneration

Parameter Unit Value
In 1 thermal vacuum degassing cycle
Moisture content ppm 5
Volumetric gas content Vol % 0,1
Acid number, as per IEC 296; ASTM D-664 mg КОН/g 0,01
Corrosive sulfur as per ISO 5662; ASTM D-1275 None
Breakthrough voltage, 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

UNIT DESCRIPTION

Composition of the unit:

  • The unit is a frame with the following components:
  • Oil degassing section (also referred to as degasser in this manual)
  • Oil regeneration section
  • Operator room

CMM-6r(1)

  • The unit is used during installation, maintenance and operation of oil-filled high voltage equipment (power transformers, high-voltage switchgear, etc.).
  • The unit is designed for processing of electric insulation oils and servicing of transformers.

The process of dielectric oil treatment includes the following:

  • Removal of dissolved gases.
  • Removal of free and dissolved water.
  • Removal of particulate matter.
  • Removal of oil degradation products.

Servicing of transformer includes:

  • Evacuation of the transformer.
  • Heating of the transformer and its core with hot oil.
  • Removal of sediment from the coils of the transformer.

Operation process

  • The principle of processing the dielectric oil is heating the oil and passing it through a vacuum vessel. The heat and low pressure reduce partial pressure of water and gases in the oil. This facilitates evaporation of water and emission of gases and their removal.
  • Degradation products are removed by sorbent (Fuller’s earth. The oil is directed to vessels, containing the sorbent. When the oil contacts the sorbent, the oil is filtered on molecular level. The oil’s chemical and physical properties are thus restored.
  • Sorbent is reactivated in the Sorbent reactivation mode. This method allows reusing the sorbent without the need to replace it.

Methods of operation

The oil may be treated as follows:

  • Connection of the unit’s inlet and outlet to an oil vessel and circulating the oil in the vessel.
  • Connection of the unit’s inlet and outlet to a transformer and circulating the oil in the transformer.
  • Connection of the unit’s inlet to an oil vessel, and connection of the outlet to a transformer.
  • Connection of the unit’s inlet to one oil vessel and the unit’s outlet to another oil vessel.
  • For evacuation of transformer or other equipment, the unit is equipped with a vacuum evacuation port.

UNIT DESIGN

The unit consists of two primary operating sections: the degasser and the regeneration section. These sections are interconnected by pipelines.

The unit is optionally equipped with a system to control oil level in the transformer, the TSS (Transformer Security System).

The unit is controlled by an industrial PLC controller, which is programmed for operation and control of the unit’s components.

Location of the unit’s main components

Location of the unit’s main components

Electric control system

  • Automation and electric control system consists of two power cabinets and a control cabinet.
  • Power cabinet is installed directly on the unit’s frame. The cabinet contains communication equipment: magnetic starters, motor protection automation, heating power control section and automatic switches (circuit breakers), while the control cabinet contains the controller with a number of digital and analogue inputs and outputs.
  • Automatic protection of motor drives (Q1 – Q6) are installed for protection of the motor from current overloads and short circuits. The magnetic starters (КМ2 – КМ7) move the drives in accordance with the logic programmed in the controller.
  • The power of electric heater is controlled by a solid state relay and depends on the current throughput and temperature set by the operator. The heaters are protected from short circuit by a triplepole switch.
  • The control cabinet is located in the operator room and contains power supply, reducing transformers, power supply filter and automatic protection. The front panel contains power supply and phase control lights, emergency stop button and the control touch panel.

The control panel in the operator room

control system

Components of the control system

Pos Item Description
1. Touch panel The panel is used to control the unit’s components
2. Manual circuit breaker lever Disconnects power supply
3. “Phase control” light The light is on if power is connected correctly
4. “Power” light The light is on when the unit is powered
5. “Stop” button Emergency stop button

Using the operator touch panel

  • The control system is based on a controller and a touch panel. The controller contains a set of instructions to control the logic of actuator operation.
  • The touch panel is a device for display and control. The panel allows the operator to view main parameters, such as the temperature, pressure, vacuum and throughput, as well as the status of actuators. The panel is also a means to control the processes in the controller’s memory.
  • The control system is designed for the following modes of operation:
Mode Specifics
«СHARGING» mode – filling the unit. In this mode, the vessels of the unit are filled to the maximum level, and air is released from pipelines.

Oil regeneration/degassing mode:

«DEGASING/REGENERATION»

 

 

Oil degassing Moisture, gases and solids are removed from transformer oil in this mode.
Oil regeneration Oil is regenerated and degassed in this mode.
Sorbent reactivation

Sorbent properties are restored in this mode. All contaminants within the sorbent are burned out, those that cannot be burned out are collected in waste trap.

While this mode is active, the unit continues to degas the oil in the transformer.

Equipment testing and adjustment mode: «MANUAL». All components of the unit may be turned on or off in this mode.
  • Mode of operation is selected from the start screen

node

  1. – Start screen; 2. – Charge mode selection button; 3. – Degassing mode selection button; 4 – Transformer Safety System selection button; 5 – Manual mode selection button

Degassing section flow diagram

flowDegassing section components

Pos Item Description
MV 1 ; MV 1.1 Ball valves Stops oil flow into the unit
V1 Automatic oil inlet valve Stops oil flow into the unit.
P1 Centrifugal pump Pumps oil into the unit.
MF1 Coarse filter Stops particles larger than 100 micron
LS1 Oil level sensor Stops the unit when no oil is present at inlet
MV2 Ball valve Drains oil from coarse filter
FCV Regulation valve Adjusts the flow rate of oil input
G1 Pressure sensor Indicates pressure at coarse filter inlet
SV1 Ball valve Sampling valve for incoming oil
F1 Fine filter Stops particles larger than 25 micron
AV1 Air release valve Discharges air from filter
MV3 Ball valve Drains oil from fine filter
G2 Pressure sensor Indicates pressure at coarse filter outlet
Н Oil heater Heats the oil to operating temperature
MV4 Ball valve Drains oil from the heater
T1 Thermistor Controls oil heating
T2 Thermostat Prevents oil overheating
FS1 Flow switch Controls oil heating and prevent oil heater from engagement with no oil flow
LC1 Flow counter Used for flow control and counting of total treated oil
VC Vacuum column Boiling and emission of water and gases from the oil
V3 Automatic ball valve Supplies the oil to regeneration section
V2 Automatic ball valve Stop oil line to the column
V4 Automatic ball valve Sends oil to the unit after regeneration
V5 Angle valve Prevents oil from being sucked into the column by vacuum
VC Vacuum column Water and gases boil out of the oil in the column
MV5 Disk gate Vacuum system stop valve
OT Oil trap Foam or oil mist trap
MV6 Disk gate Vacuum to transformer valve
MV7 Ball valve Vacuum system stop valve
MV8 Ball valve Drain oil from oil trap
V7 Electromagnetic valve Air inlet into vacuum system in emergencies and to reduce foaming
VG1 Vacuum sensor Indicates vacuum pressure, locks booster pump operation if vacuum not sufficient
LS4 Oil level sensor Shows oil level in trap. Stop the unit if the level of oil in the trap exceeds acceptable level.
VP1 Backing pump Creates vacuum to 30 mbar
VP2 Roots pump Creates vacuum to 1 mbar
FL Foaming sensor When foam appears in the vacuum column, this sensor commands air inlet valve open
SL2 Liquid level sensor Stops oil input pump if the oil level exceeds limit
SL3 Liquid level sensor Stop oil output pump if the oil level falls below limit
MV9 Ball valve Drains oil from vacuum column
P2 Centrifugal pump Drains oil from the vacuum column and supplies it to the unit’s outlet
MV10 Ball valve Vacuum column oil level control system adjustment valve
MV11 Ball valve Vacuum column oil level control system adjustment valve
MF2 Mesh filter Protects oil level control system from contamination.
G4 Pressure and vacuum sensor Indicates pressure in oil level control system
V8 Angle valve Prevents oil from being sucked into the vacuum column by vacuum. Controls oil level in the vacuum column
V9 Automatic ball valve Bypass line valve. Lets the oil bypass the vacuum column in heating and filtration mode
G5 Pressure sensor Indicates pressure at coarse filter inlet
F2 Fine filter Stops particles larger than 25 micron
AV2 Air release valve Removes air from filter
MV12 Ball valve Drains oil from fine filter
G6 Pressure sensor Indicates pressure at coarse filter outlet
SV2 Ball valve Incoming oil sampling valve
V10 Automatic ball valve Stops oil output from the unit.
V11 Automatic ball valve Oil circulation valve
MV 13 ; MV 13.1 Ball valves Stop oil input to the unit.
LP1 Leak collector Leak collector/tray to contain spills in emergency situations
LS5 Oil level sensor Stop the unit if an oil spill is detected
BV1 Return valve Prevents air from being sucked into the F1 filter by vacuum
BV2 Return valve Prevents air from being sucked into the F2 filter by vacuum
MV14 Ball valve Tray oil drain valve
MV15 Ball valve Buffer tank filling line stopping valve
V12 Electromagnetic automatic valve Send oil to buffer tank

Regeneration section flow diagram

regdiagramRegeneration section components

Position Item Description
V13 Automatic ball valve Stops oil flow in sorbent reactivation mode
AV3 Air release valve Removes air from pipeline
G7 Pressure sensor Adjust vacuum system capacity during sorbent reactivation
V14 Automatic ball valve Opens air flow to the column during reactivation
AF Air filter Purifies air entering the columns during reactivation
С1-С6 Sorbent column Transformer oil regeneration column
ТС1-ТС15 Thermistor Indicates temperatures during sorbent reactivation
DP Intermediary tank In this vessel air bubbles are separated during oil regeneration, and condensate formed during reactivation is collected and discharged
MV15 Ball valve Oil drain from drain tank
LS6 Level sensor Indicates oil presence in the bottom of intermediate tank.
LS7 Level sensor Indicates oil presence at the top of the intermediate tank
G8 Pressure sensor Indicates pressure in the intermediate tank
F3 Intermediary filter Stops particulate matter after oil regeneration
AV4 Air discharge vavle Removes air from fine filter
MV26 Ball valve Drains oil from spill tray
G10 Pressure sensor Indicates filter contamination
V15 Automatic ball valve Stops vacuum line during oil regeneration
MT Condenser Condenses moisture and heavy fractions during sorbent reactivation
MV16 Ball valve Drains condensate from the condenser
LS8 Level sensor Indicates level limit in the condenser
V16 Automatic ball valve Stops vacuum line during oil regeneration
G9 Pressure sensor Adjust vacuum system operation during sorbent reactivation
MV17 Ball valve Lets air into the vacuum system
VP3 Vacuum pump Creates air flow required for sorbent reactivation
SR Noise suppressor Reduces noise at the outlet of the vacuum system
MV18 Ball valve Drains moisture from the noise suppressor SR
MV19 Ball valve Vacuum system exhaust valve. Used for direct exhaust bypassing charcoal filter CF.
MV21 Ball valve Disconnects charcoal filter CF from exhaust line
MV22 Ball valve Drains condensate from charcoal filter СF
CF Charcoal filter Purifies exhaust during sorbent reactivation
P3 Screw pump Pumps condensate from the exhaust line
SF1 Safety valve Prevents the body of pump P3 from overpressure
BV3 Return valve Prevents oil from being sucked into the intermediary tank DP
V17 Automatic ball valve Pumps reactivation waste and corrosive sulfur into buffer tank BT
BT Buffer tank Oil tank. Used for adding oil to the unit and collection of condensate.
LS9 Level sensor Limits oil level in the buffer tank.
V18 Automatic ball valve Pumps oil into buffer tank BT
V19 Automatic ball valve Supplies oil from the buffer tank BT
MV23 Ball valve Drains condensate from settling tank
MV24 Ball valve Drain from buffer tank
MV25 Ball valve Drain from buffer tank
P4 Centrifugal pump Lets oil out of buffer tank BT and refills the unit with oil
FS2 Flow relay Registers oil flow during refilling of the unit with oil.
LP2 Spill collector Tray to collect oil spills in emergencies
LS10 Oil level sensor Stop the unit of an oil spill is detected
BV4 Return valve Stops air from being sucked into the line by vacuum
BV5 Return valve Stops air from being sucked into filter F3 by vacuum
MV27 Ball valve Spill tray drain valve

Flow diagram of transformer oil level control system TSS (Transformer Security System)

diagr

Oil level control system components

Position Item Description
V21 Electromagnetic valve The valve prevents oil spills from the transformer in emergencies
MV27 Ball valve Redirects oil flow during operation
MV28 Ball valve Redirects oil flow during operation
MV29 Ball valve Redirects oil flow during operation
MV30 Ball valve Redirects oil flow during operation
MV31 Ball valve Redirects oil flow during operation
V22 Electromagnetic valve The valve prevents oil spills from the transformer in emergencies
V4 Air discharge valve Removes air from pipelines
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