Transformer oil regeneration system (Purchasing, Inastallation, Services)

Invex’s Transformer & Turbin Regeneration System has been designed for onsite use to completely regenerate insulating oil in energized or de-energized transformers. This system can be mounted on a leakproof base and can be installed and operated on a truck or sea freight container. It provides regular oil purification such as degassing, drying, and particulate removal but its main application is in the removal of acidity, sludge, other oil soluble oil decay products, and discoloration. This is accomplished using high vacuum de-gasification technology and particulate filters combined with our special catalyst filtration leading technology.

The unique feature that distinguishes our system from other mobile processing plants is the ability to reactivate the used catalyst. The Invex reactivation process is fully automated and enables the system to process oil again and again using the same catalyst. This clay need not be removed from the system for a period of up to two years or 300 reactivations. Bleaching earth is used in the other methods which retains about 3 to 5 % of oil. The used oil contains acidic compounds and is very dangerous for the environment.

Transformer Oil Regeneration System Advantages

Environmentally friendly
Recover the oil quality
Prevent the currency outflow
Cost-effective
Made of the best
Made of the best European equipment
2-years guarantee and 15 years after-sale services

Transformer Oil Regeneration System Components

Heaters	Vacuum Pump
Inlet Strainer	Vacuum Booster
Treatment Columns	Processing Vacuum Chamber
Inlet/Outlet Gear Pump	Liquid Sensitive Sensor Inside Water Trap
Foam Sensor on vacuum Chamber	Vacuum Valve (for evacuation and dry out)
Condenser or Water Trap	Trailer (Optional)
Temperature/Pressure Controller	Moisture Meter (Optional)
Inlet/Outlet Filter	Control Room (Optional)
Oil Level Controller	Lab Instruments (Optional)

1. Heaters

Heater elements are encapsulated in seamless steel tubes thus completely insulated from oil to prevent a fire hazard. The heater is controlled by heavy-duty contactors and an electronic temperature controller. The oil temperature is thermostatically controlled from 20 to 120ºC.

2. Inlet Strainer

A 40-mesh cleanable basket strainer is provided to remove large particles from the oil before entering the inlet pump. The strainer vessel is constructed of cast iron steel while the strainer basket is constructed of stainless steel. The strainer vessel comes complete with a quick disconnect cover that allows for quick and easy cleaning of the strainer basket.

3. Treatment Columns

A set of mild steel columns are filled with a special blend of activated catalyst packing. The number of columns is dependent on the flow rate of the system.

4. Inlet/Outlet Pump

pump Positive displacement gear-type pumps, complete with mechanical seal, are utilized to draw oil into and pump out of the system. Each pump is equipped with a pressure switch which trips in the case of clogging or high pressure….

5. Vacuum Chamber

Shell and all internal parts are made of carbon steel. The oil is degassed and dehydrated in this chamber. A series of level switches, an optical probe, and a float-actuated level controller are in this vacuum chamber too.

6. Vacuum Pump

A direct drive, high-efficiency rotary vane vacuum pump (0.5) is supplied to degasify the oil.

7. Vacuum Booster Pump

Direct drive roots type vacuum booster is applied for flow rates over 3000 l/h to achieve an ultimate vacuum of 0.1 mbar. For transformer evacuation and dry-out, a vacuum booster is recommended because the vacuum booster and pump combination is less sensitive in pumping large amounts of water.

8. Oil Trap

A secondary chamber located between the vacuum chamber and the vacuum pump is provided to ensure that no oil is pulled into the vacuum pump. It is equipped with a high-level switch to immediately shut down the system upon the sensing of oil accumulation at the bottom of the oil trap.

9. Oil Filters Pre & Magnetic Filter

Avoids big metal particles entering the system. Fine filter: Filter vessels that are made of aluminum come complete with a 1-micron absolute-rated filter cartridge. The differential pressure of the filter cartridge is continuously monitored, and the operator is notified when the filter is to be changed out.

10. Flow Meter

This digital flow sensor totalizes the amount of oil delivered on the outlet side of the system. It can provide the operator with instantaneous monitoring of the system’s flow rate.

11. Sampling Ports

One inlet and one outlet sampling port allow easy oil sampling.

12. Sight Glass

There are double window sight glasses on the inlet and outlet side of the catalyst’s columns. They provide the operator with the ability to gauge the efficiency of the catalyst’s regeneration process by allowing the operator to compare the oil color before and after the catalyst’s regeneration process.

13. Inlet/Outlet Hoses

These flexible oil hoses are suitable to be used under vacuum conditions too. Their material and length depend on the customer’s specific requirements. They can be provided for both inlet and outlet connections.

14. Skid with Spill Containment

This system is equipped with a unique oil spill containment base for maximum environmental protection. This consists of a full system skid with a 2-lip and oil level switch to shut the system upon detection of an oil spill.

15. Control Panel Instrumentation, Alarms & Interlocks

All the equipment on the control panel is of known European brands such as Tele-mechanic and Siemens. The control panel can be equipped with a fan for special climates like tropical climates. A series of instruments, alarms, and interlocks are available to provide fully automatic operation.

Transformer Oil Regeneration System Process Description

Regeneration of transformer oils is needed when the transformer oil has deteriorated to a level whereby regular oil purification) degasification & filtration are no longer adequate. The regeneration or reclamation process requires passing the deteriorated transformer oil through an adsorbent. Before undertaking the regeneration of transformer oil, sample oil will have to be taken and tested. The results of the test sample will provide an estimate of the duration of the regeneration and its parameters, but the gas analysis will determine whether the transformer can be tested in the energized (Inviv) or de-energized state.

Invivo – Energized:

In order not to create turbulence, the least flow rate is used with an energized transformer which is variable depending on transformer size. The number of cycles is dependent on the degree of contamination (acidity, sludge, color), etc…

De-energized Turbulence:

Is such an important factor with de-energized transformers and consequently, the oil flow rate through the system can be increased to a maximum rate. The number of cycles is dependent on the level of oil contamination.

An operator has the choice of two separate operating conditions in which he may treat the oil, purification, or regeneration. This decision is based on oil analysis done before the processing of the oil. Operating temperatures and flow rates must also be determined, and these decisions are determined by the type of application and the degree of contamination as determined by earlier oil analysis.

Regardless of which process is chosen, the oil is pumped from the bottom of the transformer through the system and returned to the top of the unit after being treated The Invex system is connected by hoses to the transformer in a loose arrangement and the entire system including hoses, is filled with oil before processing is initiated. Once the system is filled, the oil is automatically re-circulated for a minimum of 10 minutes through the inlet and outlet hoses to ensure that all air is eliminated from the system.

A set of manual air eliminators and several automatic valves are located near the transformer to provide safe and reliable re-circulation, the oil in the transformer is ready to be processed.

Purification:

Is an operation that is limited to moisture extraction, degassing, and particulate filtration. The oil enters the system whereby it is heated by a set of electric heaters to bring and maintain oil at 65-70ºC before pumping through a pre-filter rated at 5 microns. From the filters, it enters the vacuum chamber. In the vacuum chamber, the oil passes through fiberglass coalescing elements where it is exposed to a high vacuum of (0.01) to be degassed and dehydrated. Finally, it passes through a fine filter rated 1 micron and then pumped out as processed oil.

Regeneration:

Regeneration operating condition consists of two phases:

1- Processing phase:

In this process, the oil is regenerated by forced percolation through columns at about 65ºC. After regeneration, the oil is pumped through a 1-micron-rated filter before it is degassed. Degasification and dehydration of oil occur within the vacuum chamber. The processing duration depends on the quality of the oil being treated.

2- Reactivation phase:

After having circulated a nominal quantity of oil, the catalyst beds are quite saturated with contaminates absorbed from the oil and their efficiency drops off sufficiently to justify reactivation. The catalyst is reactivated in the reactors and a small quantity (0.1 % of oil processed) of oily scum is collected in a holding tank before being drummed for resale and reprocessing or waste disposal.

Transformer Oil Regeneration System Treatment Parameters

Transformer Oil Regeneration System is used to treat the following parameters:

Reduce acidity
Improve oil color
Improve oil interfacial tension
Remove corrosive sulfur from oil
Improve the power factor
Optional corrosive sulfur treatment

Transformer Oil Regeneration System Specification

Model	Capacity (lit/h)	Oil Heater kw	Vacuum Pump M3h-1 (cfm)	Roots Booster M3h-1 (cfm)	Oil Pumps Kw (HP)	Supply Required Amps 380v (480v)	No. of Columns	Pipe Size (inch)	L/W/ Hmm (mm)	Weight (kg)
NN-TOR 2	200	8	6	____	3(4)	25	2*1	½”	350018002450	3000
NN-TOR 5	500	12	25	____	3(4)	30	2*2	¾”	450022002450	4800
NN-TOR 10	1000	24	40	____	4.5(6)	45	2*3	¾”	450022002450	6500
NN-TOR 20	2000	30	60	150 (optional)	4.5(6)	55	2*6	1″	600022002450	8500
NN-TOR 30	3000	48	80	150 (optional)	4.5(6)	85	2*9	1¼”	750022002450	9000
NN-TOR 40	4000	54	100	250	7.5(10)	100	2*12	1½”	900024002450	10500
NN-TOR 60	6000	63	160	500	7.5(10)	125	2*18	1½”	920024002450	13000
NN-TOR 80	8000	96	190	500	13(17.5)	170	2*26	1½”	1000024002450	14500
NN-TOR 100	10000	120	270	1000	15(20)	220	2*30	2″	1220024002450	17000

Role of Oil in Transformer

Increase electric resistance
Control the temperature
Lubricant/anti-abrasion and corrosion
Increase the transformer life
Sealant
Prevent electric arc

Factors Cause Oil Dark Color

Oil contaminants like suspended particles and free water and oil aging and oxidation may be the reason for oil’s dark color.

Factors Cause Oil Electric Breakdown (according to IEC 60156)

Suspended particles
Gases and air pockets
Moisture
To determine a trace amount of water

In a sample, the Karl Fischer titration method is applied. When the moisture level in oil increases, its effectiveness as an insulating material is reduced.

Factors Cause Oil Acidity

The aging process and degradation of oil are dependent on its acidity.

Oil Interfacial Tension According to ISO6295- ASTMD971

Surface tension is the cohesive forces between oil and water molecules. The surface tension of the new oil should be 40 Mn/m. Low surface tension may be the result of some impurities such as chemical contaminants or some polar compounds.

Oxidation

The oxidation occurs when the oil is exposed to a combination of heat and oxygen. Acid and polar compounds are formed because of oxidation and in turn, become sludge.

Stability Against Oxidation According to IEC61125-IEC60296

This test is done to determine the level of sludge, acidity, and tan delta of oil. About 25 gr of oil is exposed to a copper ring at 120 ◦C. The test duration is different depending on the oil type. (without antioxidant: 120 h, with antioxidant: 500 h). The oil viscosity is measured according to ISO- 3104 ASTMD 445.

Oil Pour Point According to ISO 3016

The oil pour point is the temperature at which it becomes semi-solid and loses its flow characteristics.

Factors Cause Particles in the Oil

Paper insulation fibers, sludge from oxidation, and metal filings from wear and corrosion.

Gas Generation Sources of Transformer Oil

Aged transformer
Transformer switching on
Oil oxidation
Tab changer
Transformer failure

Dissolved gasses in Oil

Nitrogen, oxygen, hydrogen, carbon monoxide, carbon dioxide, methane, ethane, ethylene, acetylene

Transformer Oil Regeneration System Desludging Methods

Desludging takes place at a higher temperature than oil regeneration. The two most important criteria for desludging to take place are:

– The temperature of the oil in circulation through the transformer must be over its aniline point of about 78◦C, to dissolve sludge

– Oil supplied to the transformer during circulation must be regenerated to dissolve and absorb sludge

Invivo Energized

This process is very efficient and is aided by the slight mechanical vibration and heat generated by the energized transformer. Between 2- 20 passes may be necessary to complete the task depending on the level of oil contamination.

De-energized

Less efficient than the Invivo method and desludging takes longer, depending on the size of the transformer.

Tank to Tank Regeneration

To utilize the catalyst to the best efficiency, flow should be reduced to 20-25 % of the nominal (full) flow.

Transformer Oil Regeneration System Standard Instrumentation & Controls

1. Temperature Controller

These electronic temperature controllers provide safe operation. They stop the heater in the case of high temperature and involve them in the case of low temperature.

2. Indicator Gauges

Pressure gauges are used to monitor the status of pre-filter and fine-filter cartridges. A vacuum indicator is provided to determine the level of vacuum within the chamber.

3. Foam Control

Occasional foams can be formed under certain circumstances. If the photo eye sensor, located in the vacuum chamber, detects high foam, a solenoid valve will be actuated to break the vacuum and thus, the foaming will be reduced to acceptable levels. Plant operation is not affected unless severe foaming conditions persist. If they persist, the system will safely shut down.

4. Alarms & Interlocks

All potential scenarios that the system may be encountered have been accounted for. In the case of any alarm situation, the plant will shut down automatically.

5. Tan Delta

According to the IEC60247 standard, the Tan delta depends on polar and ionized molecules in oil. Tan delta is sensitive to the contamination generated during the purification process. Even only a small amount of contamination (suspended particles, sludge, deposits) can be multiplied rapidly. Excessive increase in tan delta can result in thermal instability.

6. Controls & Instrumentation

The operator can monitor and control all aspects of the operating system. All pertinent operational data and events are displayed and logged in real-time. The application offers an alarm system to alert the operator to critical events.

Extra Information about Invex Transformer Oil Regeneration System

Here are some extra information you may need to know:

1. The Main Location for Providing Service & Selling Transformer Oil Regeneration System

The company’s headquarters is in Germany, but we have representatives in the UAE, Türkiye and Canada to follow up on services and products.

Address: Praunheimer Landstrasse 32, 60488 Frankfurt am Main, Germany

2. Guarantee for the Services

There is a 6 month to 1 year warranty for the performance of the equipment and the work process.

3. Regions of the World We Can Provide the Services

Germany, Türkiye, Canada, Iran.

4. Periodic Services

This is the list of jobs in periodic services by Invex after selling Transformer Oil Regeneration System:

Cleaning the pumps, connections and changing the vacuum oil after 500 working hours of the device.
Temperature, pressure and flow test of all connections and equipment after 500 working hours of the device.
Checking the leakage of all connections and pipes after 1000 working hours of the device.
Checking and screwing the connecting screws every 30 days.
Inspection of cables in terms of annual obsolescence.
Cleaning the internal and external parts of the device after every 3-month period of operation.
Inspection of the device in terms of annual corrosion.

5. Price Range of Extra Services

Starts from 3,000 dollars to 40,000 dollars, which varies according to the location and the type of service.

6. Steps to Receive Services

After the customer’s request, the service request form is completed according to the customer’s needs and referred to the after-sales service unit and then checked by the technical and engineering unit of this company. Technical and executive are sent to the desired location to provide approved services.

7. Production Location(s)

Structure equipment and tanks produce in Iran. Control systems and vacuum pumps produce in Germany.

8. Shipping Worldwide

There is no limit to send products, it is possible to send all products to all over the world.

9. Price Range of Each Product

Model	Price (Rial)	Price (Dollar)
NN-TOR 2	3,374,400,000	84,360
NN-TOR 5	3,844,800,000	96,120
NN-TOR 10	4,315,600,000	107,890
NN-TOR 20	5,374,400,000	134,360
NN-TOR 30	9,962,400,000	249,060
NN-TOR 40	11,374,400,000	284,360
NN-TOR 60	15,962,400,000	399,060
NN-TOR 80	19,492,000,000	487,300
NN-TOR 100	23,021,200,000	575,530

10. How Much Is the Shipping Cost of Transformer Oil Regeneration System?

The shipping cost of Industrial Oil Purification Machine starts from $8,000 to $15,000.

11. Ordering & Preparation for Shipping

Transformer Oil Regeneration System production is based on the customer’s order and it takes 10 to 14 weekss to be ready for shipping.

12. Packaging for Shipping

All products are packed in containers according to Incoterms 2024 international standard by land or sea.

13. Transformer Oil Regeneration System’s Standards & Codes

A- Mechanical

– Tanks:

All pressure vessels shall be designed and constructed in accordance with ASME Sec VIII Div 1. Welding shall be as per ASME Sec IX standard.

– Heat exchangers:

Shell and tube heat exchangers will be designed and manufactured based on TEMA and ASME Sec VIII Div 1 standards. Welding shall be as per ASME Sec IX standard.

– Pumps:

All centrifugal pumps will be designed and manufactured based on ANSI, ISO or DIN standards.

– Safety valves:

Safety valves will be designed and manufactured in accordance with ASME/API/ISO standards.

– Plumbing:

Design and construction of pipes will be in accordance with ANSI B.31.3 standard.

– Flanges:

All flanges shall be designed and manufactured in accordance with ANSI B.16.5.

– Structure:

Niro Nomad Khorasan company, having a technical and expert team in various departments, will build skid structures based on good engineering rules.

B- Electric

All electrical equipment shall, under certain circumstances, operate on a 400V, 3-phase, 50Hz or 240V, single-phase, 50Hz supply.

14. Transformer Oil Regeneration System Certifications

Property	Test Method	IEC 60422	Unit	After Reclamation	Before Reclamation
Acid Number	IEC 62021	Max: 0.03	mg KOH/g	> 0.3	≤ 0.01
Oil Color & Oil	ISO 2049	Max:2	…	>4	≥ 1
Breakdown Voltage	IEC 60156	> 55	kV	≤40	> 70
Moisture Content	IEC 60814	< 20	ppm	>30	5
DDF (90 C°)	IEC 60247	Max: 0.015	…	>0.3	≤ 0/003
Surface Tension	ASTM D971	Min: 35	mN/m	<15	≥ 40

15. Purchasing Process

Contacting the sales unit, sending the customer’s requests, designing and sending the design to the customer, approving the design by the customer, issuing a proforma invoice, approving the proforma invoice and paying the deposit by the customer, final settlement, sending the order to the customer.

Invex’s Transformer Regeneration System offers a comprehensive onsite oil regeneration solution in energized and de-energized transformers. This system, mounted on a truck or sea freight container, excels in degassing, drying, and particulate removal and eliminates acidity, sludge, and other oil decay products. Our unique catalyst reactivation process allows for repeated use of the same catalyst, significantly reducing waste and environmental impact. Explore our advanced high vacuum de-gasification technology, particulate filters, and automated reactivation process to enhance your transformer and turbine maintenance. For more details on our oil regeneration process, system components, and environmental benefits, please Contact our team.