Case Study | Optimizing Transformer Oil Processing with High-Capacity Heating Systems

Topic:        OEM Factory upgrade

Location:     California, Virginia, Montreal.

Problem: Transformer manufacturers are rapidly ramping up capacity in response to a perfect storm of rising demand, supply chain constraints, and aging infrastructure. Many transformers in use today are over 35–40 years old, prompting large-scale replacement

programs, especially in the United States.

A major Transformer manufacturer recently started expanding production, and their oil processing systems were limited to just basic integrated heaters, which slowed down production. They needed a stand-alone heater system to supplement and increase the effectiveness of the oil heating process of their existing Enervac degasification units to reduce production process times.

Solution: Enervac supplied a model E873A heater skid engineered with several custom features to meet the manufacturer’s specific production requirements.

Results: Enervac provided a standalone oil heating system, which included 288 KW of low-density electric heating at 11KW/in2. Individually controlled banks of heaters with several split control zones allow for precise process control with widely varying flow rates from 10 to 60 gpm. PLC control with integration into the facility network, as well as local instrumentation, provides a high level of control and monitoring. Performance of 39⁰C (70⁰F) rate of rise per pass ensures production is always ready to work without process downtime.

Uniform heating of transformer oil is crucial for several reasons, especially during maintenance procedures like oil filtration or dehydration.

• Efficient Moisture Removal: Transformer oil often contains moisture that can degrade insulation. Increased oil temperature ensures more effective degasification when paired with an Enervac E865A degas system.

• Improved Filtration: When used with an Enervac E865A Degasifier, this additional heating reduces oil viscosity, making it easier to filter out impurities.

• Maintenance of Oil Quality: Keeping oil at stable temperatures when in storage helps to reduce impurities and reduce production cycle times.

Conclusion: The Enervac system added safe, reliable heating capability to the plant with minimal disruption to existing infrastructure and operations. It easily integrates into the existing process flow with the capability for full remote automated control.

Ready to take the next step? Our team can quickly assess your current system and recommend a customized heating solution designed to boost performance and eliminate bottlenecks. Connect with us today to get started.