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Transformer oil regeneration is the process of restoring aged or degraded transformer oil to its original quality by removing contaminants, oxidation by-products, and other impurities. This is a more comprehensive process than standard purification. Here’s a detailed breakdown of the regeneration process:
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1. Testing and Assessment
Before regeneration, the oil is tested to assess its condition, including:
- Dielectric Strength: Indicates the oil’s insulating capability.
- Acidity (Neutralization Number): Measures the level of oxidation by-products.
- Moisture Content: Determines the presence of water.
- Gas Content: Identifies dissolved gases that may indicate faults.
- Sludge Formation: Evaluates sediment or oxidation residues.
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2. Heating
- The transformer oil is heated to reduce its viscosity and facilitate the removal of impurities.
- Temperature is carefully controlled to avoid oil degradation, typically around 60°C to 80°C.
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3. Vacuum Dehydration and Degassing
- The oil is passed through a vacuum dehydration system, which removes free, dissolved water, and gases like oxygen, hydrogen, or nitrogen.
- This step improves the oil’s dielectric strength and insulation properties.
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4. Filtration
- The oil is filtered to remove particulate contaminants using micro- or nano-filtration techniques.
- Filters with pore sizes of 1-3 microns are commonly used for effective removal.
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5. Removal of Oxidation By-products
- The oil is passed through Fuller’s Earth or activated clay columns.
- These materials adsorb acidic compounds, sludge, and other oxidation by-products that reduce the oil's quality.
- The adsorption process neutralizes acidity and restores the oil’s chemical properties.
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6. Vacuum Treatment (Advanced Step)
- The regenerated oil undergoes an advanced vacuum treatment to remove any remaining volatile contaminants.
- This ensures thorough purification and improves oil stability.
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7. Cooling and Reconditioning
- After treatment, the oil is cooled to a safe handling temperature.
- Additives may be introduced to improve the oil’s performance, such as oxidation inhibitors or anti-foaming agents.
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8. Testing and Certification
- Post-regeneration, the oil is tested again to ensure it meets industry standards such as IEC 60296 or ASTM D3487.
- Parameters like dielectric strength, moisture content, and acidity are verified.
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9. Reintroduction into the Transformer
- The regenerated oil is pumped back into the transformer, sometimes while the transformer remains in service (online regeneration).
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Advantages of Transformer Oil Regeneration
- Cost-effective: Extends the life of transformer oil, reducing the need for replacement.
- Environmentally Friendly: Minimizes waste by reusing oil instead of disposing of it.
- Prolongs Transformer Life: Prevents the adverse effects of aged oil on the transformer’s insulation and components.
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Equipment for Regeneration
- Transformer oil regeneration plants include features such as:
- Vacuum dehydration systems.
- Fuller’s Earth columns (regenerable or disposable).
- Filtration units with multi-stage filters.
- Inline monitoring systems for real-time quality checks.
Proper oil regeneration ensures transformers operate efficiently and reliably, reducing the risk of breakdowns and extending their operational lifespan.
