Transformer evacuation process

The transformer evacuation process is an essential procedure in the manufacture and maintenance of high-voltage power transformers, especially those rated from 150 kV to 750 kV. This process is carried out before the transformer is filled with oil to remove the air, moisture, and gases dissolved in the oil, as well as the moisture absorbed by the insulation. Proper evacuation ensures the reliable operation of transformers with improved insulation performance and extended service life.

Purpose and importance of the transformer evacuation process

The main objective of the transformer evacuation process is to remove the air present inside the transformer tank and dissolved in the oil, as well as to eliminate the moisture that has been absorbed by insulating materials. Preliminary evacuation serves a number of purposes. First, it allows for checking the integrity of vacuum seals, ensuring that no leaks compromise the process. Second, it helps in removing the surface moisture from the transformer's active parts, which directly improves the dielectric strength of the insulation.

During preliminary vacuuming, the quality of welds and seals in the transformer tank is also assessed. Early detection of defects allows for timely corrective actions, which may involve partial disassembly if any significant leaks are identified. While addressing the air ingress issues may take a considerable amount of time, completing this step is crucial for achieving the reliability and longevity of transformers.

Evolution of transformer evacuation methods

Historically, steam-jet ejector systems were used for transformer evacuation. These systems required large amounts of steam produced by boilers, resulting in high consumption of oil, water, fuel, and electricity. They also demanded complex and frequent maintenance, making the process time-consuming and energy-intensive.

Modern transformer evacuation systems employ dry mechanical pumps, which are now widely adopted worldwide. Compared to steam-jet ejectors, these systems reduce electricity consumption by approximately 80% and decrease exhaust emissions by up to 90%. As a result, the evacuation process becomes more cost-effective and environmentally friendly, with potential annual savings in exhaust gas treatment reaching hundreds of thousands of dollars.

FLD V transformer evacuation system

The FLD V transformer evacuation system is designed to efficiently and reliably develop the required vacuum for evacuation of transformer tanks. It is suitable for transformers and high-voltage circuit breakers with voltages up to 1,150 kV and supports both transformer evacuation and drying processes. This makes it ideal for companies engaged in installation, repair, and maintenance of transformers, as well as in treatment of transformer oil.

The FLD V systems ensure rapid and effective removal of air, vapor, non-aggressive gases, and vapor-gas mixtures owing to an integrated booster technology. They achieve high-level vacuum conditions, which are essential for safe assembly and servicing of tranformers. With robust pumping capacity, the FLD V system can handle even large transformers, ensuring complete evacuation of the transformer tank and proper insulation without compromising the processing rate or efficiency.

Applications of the transformer evacuation process

The transformer evacuation process is applicable to a wide range of transformers and equipment, including distribution transformers in electricity networks, power transformers at electric power plants, traction transformers used in electric rail systems, mining transformers, marine transformers, electric furnace transformers, and step-up transformers installed at wind power facilities.

Through meticulous removal of air, moisture, and dissolved gases, the evacuation process ensures that transformers meet stringent quality and reliability standards. Proper evacuation promotes optimal performance, minimizes the risk of insulation failure, and extends the operational lifespan of transformers across all applications.

Advantages of transformer evacuation in FLD V 

The use of modern mechanical vacuum systems for the transformer evacuation process provides numerous advantages, which include:

• Reduced power consumption and operational costs
• Lower environmental impact due to decreased exhaust emissions
• Faster evacuation and drying cycles
• Enhanced insulation performance and extended transformer lifespan
• Reliable leak detection and improved quality control

The FLD V system exemplifies these advantages, offering a reliable and versatile solution for transformer manufacturers, service providers, and maintenance teams worldwide.