Transformer Oil Regeneration System (TORS) is a specialized industrial unit that restores aged, contaminated transformer oil to a like-new condition by removing moisture, dissolved gases, acids, sludge, and solid particles. It enables on-site, online treatment (while the transformer remains energized), reducing downtime, new oil purchases, and environmental waste.
Purpose & Why It Matters
Transformer oil insulates, cools, and suppresses arcs in high-voltage transformers. Over time it degrades:
Moisture → lowers dielectric strength (risk of breakdown)
Acids → corrode metal and degrade paper insulation
Sludge/solids → clog cooling paths, overheat windings
Dissolved gases → indicate faults and reduce insulation performance
Regeneration reverses this, extending oil life by 5–10 years and transformer life by 15–20 years.
Core Working Principle
It combines vacuum dehydration, degassing, adsorption ( Fuller's earth / bentonite), and multi-stage filtration in a closed-loop process:
Coarse Filtration: Removes large debris (≥5 μm).
Heating: 40–60°C to reduce viscosity and boost moisture/gas removal.
Vacuum Chamber (0.1–0.5 mbar): Boils off water (to <5 ppm) and dissolved gases (to <0.01% vol).
Adsorption Columns: Oil passes through Fuller's earth (or activated alumina/silica gel) to adsorb acids, oxidation products, and sludge.
Fine Filtration: Removes submicron particles (≤1 μm).
Inhibitor Restoration: Adds anti-oxidants (e.g., DBPC) to stabilize the oil.
Online Reactivation: Sorbent is regenerated in-situ (no frequent replacement).
Key Components
Vacuum Pump System: High-vacuum (0.1–1 mbar) for dehydration/degassing.
Heater: Electric or hot-water jacket (temp controlled ≤60°C).
Regeneration Columns: 2–4 vessels with Fuller's earth (reusable via thermal reactivation).
Filters: Coarse (5–20 μm) → fine (1–5 μm) → polishing (0.1–1 μm).
PLC Control: Automated flow, temp, vacuum, and quality monitoring.
Oil Pumps: Positive-displacement or centrifugal (explosion-proof).
Sensors: Dielectric strength, moisture, acidity, interfacial tension, gas content.
Main Advantages
Online Operation: Treat oil while transformer is energized (no shutdown).
Cost Savings: 70–90% cheaper than oil replacement.
Environmental: Closed-loop, no waste oil disposal; sorbent reused.
Quality: Restores oil to new or better specs.
Extended Life: Oil + transformer life significantly prolonged.
Applications
Power Transformers: 10 kV – 1100 kV (grid, generation, industrial).
Distribution Transformers: 10–35 kV (utilities, factories).
Instrument Transformers: CTs, PTs.
Oil-Filled Switchgear: Circuit breakers, tap changers.
Transformer Oil Regeneration System is a critical asset for maintaining transformer reliability, reducing operational costs, and minimizing environmental impact.
More information about the machine, welcome to contact us!
