NIRMAL. Generating Efficiency. Transforming Businesses

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1 NIRMAL Generating Efficiency. Transforming Businesses

2 Innovation meets inspiration at Nirmal. With oil filtration and regeneration system that are designed to enhance performance and generate efficiency. Experience the cuttingedge of technology with the industry leaders to power your business ahead. 02

3 A Legacy of Excellence Nirmal is part of Fowler Westrup, established in 2000 as a joint venture between John Fowler (India) Pvt. Limited and Westrup A/s, Denmark. We are the leading providers of oil filtration and regeneration systems for clients worldwide. Our agricultural and postharvest division creates solutions state of the art equipment such as silos, rice millers and colour sorters. Our solutions are earmarked with characteristic efficiency, quality and reliability that have become the cornerstone of our products. Our people skills and capabilities are continuously upgraded to meet worldclass benchmarks. Processes such as Six Sigma and Total Quality Management have contributed immensely to the enable productivity, reliability and punctuality. Expertise meets experience Fowler Westrup carries out a thorough study of the client's requirement recommends solutions, creates customized designs, implements the solution and even trains personnel to operate and maintain the systems. Most importantly, we support them fully incorporating our system seamlessly into customer's existing infrastructure.all of the above features are backed up by excellent aftersales service provided by Fowler Westrup's widely spread dealer network and ready availability of spares. Equipped to Perform Our modern manufacturing facility is located at Bangalore, India. Spread across a sprawling 20acre area, it is equipped with state of the art equipment and advanced design setups. Housed in the facility are six bays with massive material handling capability as well as machinery. There s also a dedicated bay exclusively for filtration equipment. It also incorporates a wellequipped R&D centre, quality control lab as well as the final assembly and testing facilities. Every single touch point designed to ensure quality and performance that adheres to international standards. 03

4 Nirmal Oil Filtration & Regeneration Systems Transformer Oil All high capacity transformers in use today have to cope with voltages in excess of 400kv. Therefore it becomes imperative to maintain optimal insulation properties of the transformer oils by rigid control over moisture, dissolved gases and particulate contamination.transformer oil is in an environment that lead to degradation in its desired properties and even in a proactive maintenance program, transformer oil will lose its insulation & cooling properties over a period of time. The rating requirements and drive to tighter tolerances of modern transformers and electrical apparatus results in greater electrical stress in insulating material and fluids. To handle these stresses, oils are required to have better dielectric strength, and also lower residual water content must be maintained to reduce the speed of oil ageing. The periodic and proper treatment of these insulating fluids will result in the improvement of properties of the entire insulating system of power transformers and will extend the effective lifetime of the asset. 04

5 Function of Oil in Electrical Equipment Used as cooling media Used as dielectric media To isolate winding from atmosphere To quench the arc Contaminants of Oil Solid particles like rust, scale, dust and fibers. Generation of carbon particles due to ageing in switchgears Oil absorbs moisture resulting in free and dissolved water. Absorption of air. Absorption of gases. Sludge formation. Increase in acidity level. Effects of Contaminants of Oil Physical Colour not clear, turbid, hazy Low interfacial tension Decrease in flash point Change in density Chemical Increase in acidity Neutralization value Electrical Low di Electric strength Low resistivity Increase in tan delta value. 05

6 Transformer Oil Filtration Machine Standard Machine These machines are known as JTM Series. these machines are used for small capacity transformers mainly for Distribution Tranformers these machines are offfered in capacity range of 50 GPH 500 GPH. JTM Machine Features Improves dielectric strength of the Transformer oil from 20 Kv to 50 Kv & above Imported filter cartridge for better performance. Mounting options like mobile, semimobile (with castor wheel) and skid Major pipe connections are made of wire braided hoses Ball valves with SS balls and Teflon seatings Centralized control panel (Fuse less panel using MCCBs, MCBs, MPCBs) Pair of good quality wire braided 1OO R1 hoses, 10 metres long with end fittings Powder coated outer panels and internal parts spray painted withpu paint Temperature gauge, vacuum gauge, compound gauge Safety relief valves NOTE: The parameters shown confirm to IS & IEC standards 06

7 High Vacuum Machines High Vacuum machines are used for large capacity transformers known as Power Transformers. This series has three models namely Medium Vacuum (JMHV) High Vacuum (JHV) Ultra high vacuum (JHVR) THe techinical para meters indicated in the below table which differenciates between the models. The capacity range is from 500 LPH 15,000 LPH Description Models JMHV JHV JHVR Vacuum Level at Final Oil Run Through (in torr) <3 <1 <0.5 A. Unprocessed Oil Quality 1. Water content (Max) ppm 2. Gas content (Max) % vol Breakdown voltage Kv (min) B. Oil Quality After Single Circulation 1. Water content (Max) ppm 2. Gas content (Max) % vol Breakdown voltage Kv (min) C. Oil Quality After Three To Five Circulations 1. Water content (Max) ppm Gas content (Max) % vol Breakdown voltage Kv (min) * The above values indicated are under factory test conditions. And may vary according to site conditions. * Stationary truck mounted and Mobile configurations available. * The parameters shown confirm to IS & IEC standards 07

8 Machine Sel Description standard Machine Application Oil Filtration for Distribution Transformer Model JTM JMHV Range 50 GPH 500 GPH Oil parameters Used Oil 3 5 Pass 2 3 Pass Water Content ( ppm) Gas content (%) 10 2 Breakdown Voltage (Kv) kv 50 Appearance Cloudy Brown Colour 5 Interfacial Degree C (N/m) 0.02 Neutralisation value (mg KOH/g oil) 0.5 Degree C (ohmcm) 1.0 X 1012 Degree C (ohmcm) 0.1 X 1012 Tan Degree C 1 Mounting Options Stationary (Skid) Sem 08

9 ection Chart Higher Vacuum Machine Regeneration Machine Oil Filtration for Power Transformer To Reclaim Used Oil JHV JHVR JTORS 500 LPH 15,000 LPH 400 LPH 5000 LPH PROCESSED OIL QUALITY 3 5 Pass 2 3 Pass 3 5 Pass 2 3 Pass 3 5 Pass 5 Pass Sparkling clear and transparent X X i Mobile / Mobile / Truck Mounted Stationary (skid) / Mobile type 09

10 Accessories Transformer Evacuation System Transformer Evacuation System are required for evacuation of transformers before filling the new filtered oil. Transformer evacuation systems are classified based on the type of mounting of the system like Transformer evacuation systems are further classified based on the capacity of the system ranging from 10 cub.mtr/hr to 2500 cub.mtr/hr. Skid (stationary) Mounted SemiMobile type (Castor Wheel mounted) Oil Storage Tank Transformer oil storage tanks are required to store contaminated / clean oil so that the same can be used as and when it is required. Transformer Oil storage tanks are further classified based on the capacity (Volume) of the tank ranging from 1000 Liters to Liters. Transformer oil storage tanks are classified based on the type of mounting of the tank as mentioned bellow Skid (stationary) Mounted Trailer Mounted Truck Mounted Vertical Mounted Oil Transfer System A trolley mounted transfer pump is provided for transfer of transformer oil from one transformer or storage tank or oil drum to another transformer/tank. It consists of positive displacement gear pump, magnetic strainer, control cabinet, inlet and outlets isolation valves and oil hoses. flow meter will be available as optional item. Oil transfer systems are further classified based on the flow rate / capacity of the system ranging from 100 LPH to LPH. Oil transfer systems are classified based on the type of mounting of the system. Following are the types of mounting. Skid (stationary) Mounted SemiMobile type (Castor Wheel mounted) 10

11 Lube Oil Filtration Machine The Lube oil filtration machine is used for purifying the various types of turbine and hydraulic oil used in the machines of the power plant viz turbine, generators etc. This machine conditions lube oil of grade ISO VG 32, ISO VG 46 & ISO VG 68 and enhance the parameters of oil by reducing the water content from 2000 ppm to 5 ppm apart from separating (removes) the free water, sludge and carbon from lube oil. This Lube oil filtration machine is also used for purifying the hydraulic oil grade ISOVG46 used to clean the hydraulic cylinders. For testing power packs, fresh hydraulic oil is required in every cycle with good particle cleanliness and water content less than 50 ppm. This machine consists of 3 stage filtration with heating and degassing vacuum system. This machine mainly consists of two parts. Centrifuge Filtration and vacuum system 11

12 Regeneration Systems Regeneration is the restoration of used oil to virgin oil specifications, or even higher. Fowler Westrup regeneration systems have a reactivation feature which enables special environmental friendly media to be reused several hundred times before recharging the system with new media. Our optimized regeneration system uses dual banks of regeneration columns which provide for continuous operation of the system by regenerating oil in one bank while reactivating the media in the other bank. Regeneration is the greenest technology offered today and It is a revolution in the oil filtration industry where the resultant savings for the user in terms of investment and oil is enormous. Fowler Westrup carries out a through study of the client's requirement, recommends solutions, creates customized designs, implements the solution and even trains personnel to operate and maintain the systems. Most importantly, we support them fully incorporating our system seamlessly into customer's existing infrastructure. Transformer Oil Regeneration System All high capacity transformers in use today have to cope with voltages in excess of 400 Kv. Therefore it becomes imperative to maintain optimal insulation properties of the transformer oils by rigid control over moisture, dissolved gases, particulative contamination and acidity. Transformer oil deteriorates with time and the decay begins the moment the transformer oil is shipped from manufacturer's factory. High temperatures, the presence of oxygen and water, the catalytic action of the materials within the transformer, all combine to result in oxidation and cracking of the transformer oil. The byproducts of this oxidative process are acidic in nature which results in an ever increasing rate of deterioration of the transformer and its oil. This type of contaminated oil can be reused if the oxidized products are completely eliminated. It cannot be filtered through normal thermovacuum filtration process and hence has to be discarded or can be reused using the regeneration technique developed by us. Transformer oil when properly maintained can give practically unlimited extension of life. Only a limited percentage of the crude available is used for conversion to transformer oil. Hence it is our responsibility to preserve the life of the most precious asset in today's world "Oil". All high capacity transformers in use today have to cope with voltages in excess of 400 Kv. Therefore it becomes imperative to maintain optimal insulation properties of the transformer oils by rigid control over moisture, dissolved gases, particulative contamination and acidity. Transformer oil deteriorates with time and the decay begins the moment the transformer oil is shipped from manufacturer's factory. High temperatures, the presence of oxygen and water, the catalytic action of the materials within the transformer, all combine to result in oxidation and cracking of the transformer oil. The byproducts of this oxidative process are acidic in nature which results in an ever increasing rate of deterioration of the transformer and its oil. This type of contaminated oil can be reused if the oxidized products are completely eliminated. It cannot be filtered through normal thermo vacuum filtration process and hence has to be discarded or can be reused using the regeneration technique developed by us. Transformer oil when properly maintained can give practically unlimited extension of life. Only a limited percentage of the crude available is used for conversion to transformer oil. Hence it is our responsibility to preserve the life of the most precious asset in today's world "Oil". 12

13 Parameter Unit Used Oil After Regeneration Appearance Cloudy Brown Sparkling, Clear and Transparent Colour Breakdown Voltage Gas Content Interfacial 270c Neutralisation Value kv % N/m mg KOH/g oil c ohm cm 1.0 X X c ohm cm 0.1 X X Tan 900c Water Content ppm Lubricating Oil Regeneration system It is a well known fact that different types and grades of oils like engine oil, lube oil, hydraulic oil, turbine oil etc. used by various sectors gets contaminated during the course of time due to different factors. As a standard practice in many organizations, these oils are discarded and replaced with new oil during regular / periodic maintenance. If the carbon content present in these oils are removed by distillation process, then it is called as distilled lube oil (base oil). However such oils have a stinking odour and are brown in colour. Fowler Westrup has designed an advanced machine that removes the odour from the distilled lube oil, apart from a drastic improvement in colour. This machine serves as an economical alternative to hydrogen treatment/clay processing plants and is extremely cost effective. Processing the distilled lube oil through our regeneration system results in oil that is stable against oxidation over any measured timescale. This increase in shelf life is an added benefit compared to the existing clay polishing system. Furthermore the viscosity index is not degraded due to passing of oil in our regeneration system. 13

14 Regeneration Cycle Transformer or Oil tank Heat and Prefilter Adsorbent media in columns Fine filtration Vacuum degasification and dehydration Applications Transformer Oil Lubricating Oil Hydraulic Oil Engine Oil Cable Oil After filter Features Advanced design with superior quality Stationary & mobile configurations Reusable Media Rejuvenates the life of oil and makes it an asset Manual /fully automatic with SCADA system Fully customizable with flow rate ranging from 500 LPH to 6000 LPH & above Benefits Life extension of a limited resource Economically advantageous Extended life of expensive capital equipment Minimal running cost Huge savings due to media reactivation Fully customizable Futuristic technology for online / offline applications Tests carried out at CPRI Bangalore, India. The parameters confirm to Indian & International standards. Results under test conditions. Parameter Unit Before Regen (Distilled Use Oil) After Regen Appearance Cloudy Brown Sparkling, Clear Colour Odour Smell Stinking Odourless 14

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16 FOWLER WESTRUP (INDIA) PVT. LTD. (A joint venture of John Fowler, India & Westrup, Denmark) Plot No , KIADB Industrial Area, IV Phase, Malur Kolar Dist. Karnataka. INDIA. web: Fowler Westrup Creating a Greener & Cleaner World Store Clean Recycle Contact : Malur Tel : Delhi Tel : / 42 Mumbai Tel : / 59 Kolkata Tel : Overseas Mobile : ACE Services01/01/2016