Double Stages Vacuum Transformer Oil Filtration

• Customization: Available
• After-sales Service: on-Line Support
• Warranty: Except for Fragile and Consumable Parts, 12 Months
• Model NO.: ZJA-100T
• Keyword: Oil Purification
• Type: Close, Movable, Fixable
• Flow Rate: 6000h/L
• Working Vacuum Degree: -0.08~-0.099MPa
• Working Pressure: Less Than 0.5MPa
• Temperature Range: 20-80
• Power Supply: 460V/60Hz, Three-Phase Four-Lines
• Working Noise: No More Than 75 dB(a)
• Total Power: 72kw
• Inlet/out Diameter: 40 mm
• Net Weight: 1800kg
• Breakdown Voltage(Kv): More Than 85kv
• Transport Package: Standard Export Package
• Specification: 20GP
• Trademark: Trihope
• Origin: Shanghai, China
• HS Code: 8421299090
• Production Capacity: 20 Sets / Month

Product Description

I. Application
ZJA Series Two Stage Vacuum Transformer Oil Purifier is widely used for industries of power plant, power station, electricity company, transformer factory, metallurgy, petrochemical, mechanical engineering, transportation, railway and transformers manufacturing etc. Especially, it applies to maintenance of transformers above 500KV and deep purification of high grade new transformer oil, imported transformer oil, mutual inductor oil and ultra high voltage transformer oil. It can be also used for oil vacuum filling and vacuum drying as well as transformer vacuum evacuation operation. Moreover, the machine can be working online without stop of transformers.
II. Performance
ZJA machine offers performance in a single pass through the purifier at full flow rate including:
1. Dielectric Strength: Improvement in dielectric strength up to 70kv with new oil
2. Water Removal: From 50ppm down to less than 5 ppm in a single pass and down to 3ppm after two passes as measured by the GB/T7600 for new oil (subject to operating and environmental conditions)
3. Particulate removal: 98% of particles over 0.5 micrometer, or over 1 or 5 micrometer as your preference.
4. Gas Removal: From fully saturated with air (10 to 12% by volume) down to less than 0.1% by volume as measured by the GB/T423
III. Features
1. Advanced double-stage large capacity dehydration and degassing system which adopts large area three-dimensional flash evaporation technique to remove harmful composition in the oil such as water, air, gas and hydrocarbon etc.
2. It can be widely used for transformers on-site installation or maintenance to fill oil into transformers and circuit breakers under vacuum condition or conduct transformers evacuation operation.
3. Precise filtration system, high-quality filtering elements and multi-stage filtration with gradual precision can help to remove mechanical impurities from the oil effectively. While the filters are with self-inspection function for the pollutant-containing conditions.
4. Equipped with automatic temperature control system, liquid-level control system, defoaming control system, pressure protection system and high quality main components to ensure operation of the equipment with high reliability and perfect performance.
5. The machine supports on-line operation without supervision with indicators to show operation status.
6. The machine adopts humanization design with low noise, easy operation, long free-maintenance time and energy saving to lower the operation cost.
7. With electrical control inter-lock design. Vacuum system, oil pump system and heating system are interlocked in control.
8. Equipped with indication for changing filters and automatic stop device for overloaded filters.
9. Equipped with emergency stop for electric leakage and power overload to protect the motor.
10. With phase-sequence, phase lose protection function and safety control for sudden shut-down.
11. Equipped with vacuuming interface for transformer evacuation operation.
12. The outlet and inlet can be interchanged.
IV. Flow chart

V. Workinig Principle
Oil to be purified passes through the first filter and the secondary filter into the heater to proceed heating. The hot oil shall be changed into coarse granule mist by a distributor and transferred into the vacuum separator, then its water content shall be evaporated. The oil mist drops on the surface of the reactor, then a three-dimensional and multi-layered evaporating structure shall be formed in the reaction tank, which can be purified by a short cycle.
After dehydration and degassing, the oil is filtered through the secondary filter to complete a work cycle. The water vapor which is separated by the vacuum separator shall be vacuum pumped into the condenser, then most of it condenses into liquid water which shall be stored in the water collector and then drained out, while part of it and other gas content shall be discharged by the vacuum pump.
The purifier is a single unit without any auxiliary machinery. It adopts saturation temperature curve of water and vacuum drying principle to carry out the technology of rapid and efficient oil and water separation. Multi-stage large flow capacity and deep precision filtration can reliably remove water content, impurities, gas and other harmful substances from the inferior oil thus to recover its using performance fast and efficiently and make the purified oil to meet its using standard.
VI. Technical parameters List

Model	ZJA-100T
Flow Rate	6000 L/H
Working Vacuum Degree	-0.08~-0.099MPa
Working Pressure	≤ 0.5MPa
Constant Temperature Control Range	20~80ºC
Power Supply	460V/60HZ, Three-Phase Four-Lines (Can be customized.)
Working Noise	≤75dB
Heating Power (KW)	65 KW
Total Power (KW)	72KW,
Inlet/Out Diameter	Φ 40 mm
Net Weight	1800Kg
Overall Dimension	2700×1600×2300mm
Continuous Running Period	≥ 200h
Mean Time Between Failure	≥ 8000h

Remark: Above-mentioned size and weight of this equipment are for reference only, the specific data shall be subject to its physical object.

Oil Index After Treatment

Oil Performance  AFTER thress circulations
Breakdown Voltage (KV)	≥85KV
Water Content (ppm)	≤3PPm
Gas Content (%)	≤0.05%
Filtration Precision (μm)	≤0.5μm
Acetylene Content (%)	0

VII. Technical Faetures and Advantages
1. Heating System
Sufficient heating power, rapid electric heating to rise temperature as required.
It is equipped with an automatic temperature controller, oil temperature can be adjusted between 20~80ºC automatically. The heaters can stop to operate automatically after the temperature reaches to setting point. Two operation modes can be choose, auto heating and manual heating.
It is equipped with a Heating Protection System. The heating system, vacuum system and oil pump system are interlocked to avoid dry heating when there is no oil in heaters. It can ensure the heating operation safety and reliable by adopting our own patent.
The heaters can be operated in group and can start automatically at low temperature while stop at high temperature.
The heater adopts German technology, internal/external dual-bar heating system. It can warm up the air in the heaters firstly and the warmed air heat oil evenly. The heating load at surface is less than 1.1W/cm² with rapid and evenly heating, stable temperature, no blockage oil which can ensure no hydrogen and no ethyne induced from the heating process.
The appearance of heater is flanged. Heating tube is U shape with advantages of good appearance, easy for repairing and long service life. Its cost is about 10 times of common heaters. The heating bar is installed in cylinder to heat up the oil without oil blockage to increase the oil temperature to 30ºC in one circle quickly. The gap between heater and its chamber is 10cm which will not destroy paint surface during heating operation.
Temperature Controller: intelligent digital temperature controller from Korea, PID fuzzy control, precision automatic adjustment of temperature between 20~80ºC, high temperature alarm and pull down protection. Temperature is interval control without frequent flip of solenoid to extend its life span.
2. Oil Pumping System
Adopts high quality oil pump imported from Italy. The oil pump can bear high pressure of high viscosity oil to adapt to high vacuum environment with excellent self sucking ability, stable flow, no peak, low noise and long life span.
The high precision machining process in manufacturing guarantees no leakage in oil pump. It can pump oil normally at ultimate vacuum condition. It solves the problems of abnormal oil outlet or no oil outlet at high vacuum status unless we release the vacuum which will affect purification efficiency a lot (Under same temperature, the vacuum degree determines purification effects).
Oil Back-flow Prevention Device: It adopts our own technology, by this technique, oil will not flow back at machine's halt, to guarantee oil in normal level.
Automatic Oil Level Controller: It adopts our own technology , automatically adjust inlet / outlet oil, without intervention of operators.
3. Vacuum Separation System
The vacuum separation chamber adopts vertical tank dual evaporation structure with double vacuum tank, which is composed of atomizer, evaporator, separation chamber, oil collection tank, buffer tank and observation window.
The atomizer atomizes the oil and sprays it into the evaporator.
Evaporator: adopts dual evaporator stereo evaporation structure (US HY-PRO vacuum) with entire stainless steel degassing and dehydration separation tower with large separation area, which makes oil in the best thin-film and realizes the best effect of evaporation. The technique can greatly increase the exposure time of oil in a vacuum chamber to ensure the best effect in just one circle of treatment.
The separation chamber: located between the evaporator and the oil collection tank. In the chamber, water and gas will be separated again from oil.
The oil collection tank: for gather the oil after the separation of water and gas. Then the oil will be pumped out by oil outlet pump.
Buffer tank: an individual tank for separated gas and vapor to avoid these materials dissolve with oil again.
The observation window: adopts glass to replace organic glass to avoid deformation defects in high temperature and high vacuum condition.
De-foaming And Anti-injection Device, adopts advanced automatic level control technology to control the volume of inlet oil by setting normal oil level range. Meanwhile, manual defoamer is adopted to control the oil foam level and timely eliminate it to avoid oil blowout phenomenon.
Vacuum tank adopts flange connection which is convenient for daily maintenance of vacuum tank (we need to clean the inner surface of vacuum tank as it will be rusted after operating for some time) so as to extend life span of the oil purifier machine and avoid secondary pollution to the oil during the process.
4. Condensation System:
Adopts heat exchange condensation Technology.
Based on the optimized design of the condenser to increase the heat dissipation area in maximum and efficiently condense the water from vacuum separation system into water tank and then discharge the water. This operation can prevent large quantity of steam directly into the vacuum pump and make vacuum pump oil emulsified so as to reduce the replacement frequency of vacuum pump oil, thereby prolong the service life of vacuum pump.
Through the condensation system, we can judge qualitatively whether the water has been removed from oil completely.
5. Filtration System
Equipped with overpressure protection device. Through the automatic alarm and overflow overpressure protection device, the machine can automatically shut down on the condition that the pressure of the fine filters reaches to 0.5Mpa or more. It can effectively protect the machine and filter automatically and achieve unattended operation.
The machine can alarm and stop working automatically once filters over-pressured and filter element over-loaded with pollutants happens and accordingly indicate to replace filters.
Prevent filters from damage for over-pressured which may increase operation to keep safety of filtration system.
Configuration of filtration system: Adopts multi-stage filtration system. Oil can be firstly filtrated by magnetic filters to remove metallic materials then pass through primary filters to remove large particles to protect oil pump from damage by the large particles. The magnetic filters and primary filters are made of stainless steel and can be cleaned and reused for long time. The fine filters adopt imported high precision filtering elements with progressive fine-meshed structure to block the impurities step by step. The filtration area of fine filters is 20 times of oil flow rate with strong pollutant-contain ability and long life span. It can effectively prolong the replacement period and lower the operation cost. The precision of fine filters can be 10µm.
The structure of filtration system adopts quick-change style for convenience of filers dispatch and replacement. The threaded coupling of primary filters is equipped with special O-ring seal to ensure the precision of that.
In the oil outlet, sampling port is provided, convenient for oil sampling and test.
Alarm Controller: adopts stainless steel pressure controller to ensure the control performance. Meanwhile it is equipped with shockproof pressure meter.
6. Control System
Control system adopts Schneider Electric products with reliable quality and stable performance to ensure continuous operation of the machine.
Equipped with sequential relay and phase sequence indicator to realize fault shutdown protection with light and sound alarm.
With perfect protection and alarm functions, such as motor overload, over-current, lack-phase and fault-phase protection. While electrical cabinet is equipped with damping device.
Trinitarian electrical control inter-lock design. Vacuum pump, oil pump and heaters are interlocked in control. Any problems happen from the three components will cause emergency stop to avoid dry heating, oil leak and electric leakage as well as machine damage for incorrect operation.
Vacuum pump is interlocked with heaters. The heaters start to work only when vacuum pump start and oil comes into the heaters. Oil pump is also interlocked with heaters. When the oil pump stop, the heaters will stop working automatically.
Electrical control system is manufactured based on standard IEC60204-1: 2000/GB5226.1-2002.
There are intelligent digital temperature controller, oil pump operation status indicators, vacuum pump operation status indicators, heaters operation status indicators, power supply indicators, sound and light alarm and other components on the control panel.
7. Vacuum Pumping System
Vacuum Pump adopts high quality imported Leybold vacuum pump, which is the primary stage pump of vacuum system, mainly used to remove a large number of gas in the system. Naturally air-cooled, pump body has the function of self-purification and drying of impurities, its noise is low, the pumping speed is fast, and the sealing property is good. The rotor has high machining precision and overload protection function. It is easy to use and ensures the equipment running for a long time without fault..
Roots Pump adopts high quality Shanghai roots blower pump with CUIMAN motor, which is a post stage vacuum pump of vacuum system. It is mainly used to remove trace gases in the system, increase the vacuum level of the primary stage pump, make the system achieve the vacuum as needed, and it is natural air-cooled.
Equipped with vacuum pump oil anti-backflow device to prevent vacuum pump oil flow back into vacuum tank to contaminate the treated oil and lower vacuum pump oil consumption so as to avoid vacuum pump damage because of lack of vacuum pump oil and reduce replacement frequency of vacuum pump oil.
Vacuum gauge adopts shockproof model to ensure stable performance.
There is no oil injection phenomenon for the vacuum pump and the vacuum pump can be running without clamping stagnation for long time.
8. Other Description
Reliability of the machine: structure as simple as possible; intuitive and clear in operation; No matter in theory or in practice, the less connection interface and adopted components with the machine, the higher reliability and the less malfunction happening as well as the easier maintenance. BZL absorbs advantages in structure and appearance design of different brand such as HY-PRO, ABB, KATO and Mitsumi etc.
Appearance of the machine: All the components such as vacuum separation tank, electric heaters, condenser and their brackets etc should be intact without connection loose, weld flaw, burr and rust. All the structure parts are treated with sand blast and shot blast treatment while the inner surface painted with 1032 antirust paint. The surface of the whole machine adopts plastic spray process to enhance surface strength and hardness. Meanwhile, the machine is equipped with lifting eyes for easy loading and unloading operation.
The quick change coupler: Inlet and outlet connections adopt quick change couplers for reliable sealing and convenient operation.
Sealing: all the connection parts, adopt imported special non leakage sealing materials with strict inspection process to ensure excellent performance and no leakage.
Materials: The machine base adopts rectangular steel tube well welded to make it more reliable; Pipe line adopts seamless steel tube; Valves are stainless steel ball valve. Oil hoses adopt acid-proof, pressure-resistant and high temperature resistance PVC stainless steel enhanced flexible hoses.
The machine supports on-line operation without supervision. No easily damaged parts, so no additional expenses.
Customized designs and optional functions are available according to clients requirements.
VIII. Optional Accessories                                                                                                                  
- PLC intelligent control with touch screen operation and operation status dynamic display.
- Online water content tester.
- Additionally equipped with press filter for dusty working conditions.
- The whole structure of the machine can be mobiles style with four wheels, fixed style, mobile style with trailer(double axles or single axle),
- fully enclosed style, conceal eaves type and open style of canvas etc.
Lifting hook
4 way motion and breaks
Double  axle tralier design/wheelbase

Indirectly heating
Carbon steel weather canopy