Fundamentals of Preventive Maintenance

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.
Xi n q i a o In d u st r i a l Zo n e | Sh a p i n g b a Di s tr i c t | Ch o n g q i n g Ch i n a
Tel: 0086 23 65226029 | Fax: 0086 23 65226013 | Email: sale3@lushuntec.com | Website: www.cnlushuntec.com
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ZJA-100 Series Double Stage High Efficiency Vacuum Transformer Oil Purifier
(Capacity flow:6000L/H)

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Application
ZJA series are 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 110KV and purification of high grade new transformer oil, imported transformer oil, mutual
inductor oil and ultra high voltage transformer oil. The main functions of the machine are to remove trace water, gas and particles
from insulating oil to improve properties of that. It can be also used for oil vacuum filling and vacuum drying as well as transformer
vacuum evacuation operation.
Working Flow Chart

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NO. Description NO. Description NO. Description
0 Oil Tank for Untreated Oil 5.7 Blowdown Valve 16 Roots vacuum pump
1 Oil Inlet Valve 6 Outlet Oil Pump 17 Buffer Tank
Double-Clip Type Check

2 Magnetic Filters 7 18 Water Collection Tank
Valve
3 Primary Filter 5.7 Blow off Valve 15 Ponding Tank
4 Heaters 6 Oil Drain Pump 15.1 Air inlet valve
Double-clip type one way

4.1 Temperature Probe 7 15.2 Blowdown Valve
valve
4.2 Temperature Controller 8 Internal circulation valve 16 Roots Pump
Vacuum Separation
5 9 Fine filter 17 Accumulator Tank
Chamber
5.1 Air Inlet Solenoid Valve 10 Pressure Meter 18 Water Connecting Tank
5.2 Infrared Defoamer 11 Pressure Control 18.1 Air inlet valve
5.3 Inspection Window 12 Sampling Valve 18.2 Blowdown Valve
5.4 Liquid Level Controller 13 Outlet oil valve 19 Vacuum Pump
5.5 Vacuum Meter 14 Condenser 20 Vacuum gauge
5.6 Manual Air Release Valve 14.1 Draw off Valve 21 Bleeding Point
Working Principle
The untreated oil passes through primary filters to remove large particles and enters into the heaters for heating. The hot oil is
evaporated into fog through distributor and enters into vacuum separation chamber. Then water in the oil starts to evaporate, oil fog
falls down to the reactor, forms into three-dimensional multi-layered structure and be separated. After dehydration and degas
process, the oil goes through fine filter to finish one treatment recycle. The vapor and gas is separated and sucked into condenser
and most of that is condensed in the water collection tank and discharged. Other vapor and gas is condensed into water collection
tank by condenser of vacuum pump and then discharged. The rest of that is blow off from vacuum pump. Moreover, the machine can
vacuum the other equipment directly through vacuum evacuation port.
This is individual machine without other affiliated equipment. It adopts multi-dimensional quick evaporation and high efficiency oil
water separation technique taking advantage of saturation curve of water and vacuum dehydration mechanism, together with

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treatment by multi-stage deep filtration to remove water, impurities, and gas from oil and restore oil quality to meet its application
requirements.
Technical Parameter
1. Flow 6000 L/H
Operating Vacuum
2. -0.08～ -0.0999MPa
Degree
3. Limit vacuity ≤ 5Pa
4. Working vacuity ≤ 80Pa
5. Working Pressure ≤ 0.35MPa
6. Temperature Range 20～ 80℃
Operational oil
7. 50℃
temperature
8. Supply Power 3 Phase,220V., 60 Hz

9. Working Noise ≤78dB
10. Heating Power 60KW
11. Total Power（KW） 66 KW
12. Pipeline Diameter Φ 40mm
13. Net Weight 1000Kg
14. Overall Dimensions 154*185*200(cm)
Continuous Working
15. ≥ 200h
Time
16. Mean Time to Failures ≥ 8000h

Above information only for reference, Actual data will be depend on real products
Oil Quality after Treatment
Breakdown Voltage(KV) ≥70KV
Water Content(PPm) ≤3PPm
Gas Content(%) ≤0.01%
Filter Precision(μm) ≤1 μm (according user’s requirement)
Ethyne(%) 0

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Features and Advantages
 Heating System
(1) Sufficient heating power, rapid electric heating to rise temperature as required.
(2) Auto temperature control, oil temperature can be adjusted between 20 ～ 80℃ freely. 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.
(3) 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 (No.
ZL200620111197.7)
(4) The heaters can be operated in group and can operate automatically at low temperature, stop at high temperature.
(5) Heater is 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.
(6) The appearance of heater is flange type. Heating bar 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 30℃ in one circle quickly；The gap between heater and its chamber is 10 ㎝
which will not destroy paint surface during heating operation.
(7) Temperature Controller: intelligent digital temperature controller from Korea, PID fuzzy control, precision automatic adjustment
of temperature between 20 ～ 80℃, high temperature alarm and pull down protection. Temperature is interval control without
frequent flip of solenoid to extend its life span.
 Oil Pump System

(1) Adopted screw oil pump for oil outlet with diversified selections of good quality Italy brands. 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, long life span.
(2) 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).
(3) Oil back-flow prevention device, (Patent No.: ZL200820100418.X), by this technique, oil will not flow back at machine’s halt, to
guarantee oil in normal level.
(4) Automatic oil level controller, (Patent No.: ZL200820100420.7), automatically adjust inlet / outlet oil, without intervention of
operators.
 Vacuum Separation System

(1) The vacuum separation chamber adopts vertical tank dual evaporation structure with double vacuum tank (Patent No.:

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ZL200820100419.4), which is composed of atomizer, evaporator, separation chamber, oil collection tank, buffer tank and
observation window.
(2) The atomizer atomizes the oil and sprays it into the evaporator.
(3) Evaporator: adopts dual evaporator stereo evaporation structure (USA 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.
(4) The separation chamber: located between the evaporator and the oil collection tank. In the chamber, water and gas will be
separated again from oil.
(5) 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.
(6) Buffer tank: an individual tank for separated gas and vapor to avoid these materials dissolve with oil again.
(7) The observation window: adopts glass to replace organic glass to avoid deformation defects in high temperature and high
vacuum condition.
(8) 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.
(9) Defoaming and anti injection device (Patent No.: ZL200620111199.6), 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.
 Condensation System
(1) Adopts heat exchange condensation Technology (Patent No.: ZL200620111198.1).
(2) 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.
(3) Through the condensation system, we can judge qualitatively whether the water has been removed from oil completely.
 Filtration System
(1) Equipped with overpressure protection device (Patent No.: ZL200620111200.5). 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.
(2) 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.
(3) Prevent filters from damage for over-pressured which may increase operation to keep safety of filtration system.
(4) Configuration of filtration system: Adopts multi-stage filtration system. Oil can be firstly filtrated by magnetic filters to remove

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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.
(5) 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.
(6) In the oil outlet, sampling port is provided, convenient for oil sampling and test.
(7) Alarm Controller: adopts stainless steel pressure controller to ensure the control performance. Meanwhile it is equipped with
shockproof pressure meter.
 Control System
(1) Control system adopts Schneider Electric products with reliable quality and stable performance to ensure continuous operation
of the machine.
(2) Equipped with sequential relay and phase sequence indicator to realize fault shutdown protection with light and sound alarm.
(3) 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.
(4) 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.
(5) 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.
(6) Electrical control system is manufactured based on standard IEC60204-1: 2000/GB5226.1-2002.
(7) 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.
 Vacuum Evacuation System

(1) Vacuum pump: With diversified selections of Germany brands high quality vacuum pump. The vacuum pump acts as backing
pump of the vacuum system to suck out the large quantity of gas. The body of the vacuum pump can be natural air-cooled,
self-cleaning and self-drying. The machine is low noise, high evacuation capacity, good sealing, precised rotor manufacturing
and over-loaded protection which is convenient to user and ensures the machine keep working for long time without failure.
(2) Roots vacuum pump: With diversified selections of Edwards brands high quality Roots vacuum pump as blower pump of the
vacuum system, it can suck out the left air based on evacuation of backing pump to increase the vacuum degree by one order of
magnitude so as to achieve the required vacuum degree. It is also natural air-cooled.
(3) Equipped with vacuum pump oil anti-backflow device to prevent vacuum pump oil flow back into vacuum tank to contaminate the

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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 (Patent No.: 200920294061.8).
(4) Equipped with evacuation port for vacuuming of transformer as vacuum pump system when the machine is not working for oil
purification.
(5) Vacuum gauge adopts shockproof model(brand Brighty) to ensure stable performance.
(6) There is no oil injection phenomenon for the vacuum pump and the vacuum pump can be running without clamping stagnation
for long time.
 Other Description
(1) 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.
(2) 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.
(3) The quick change coupler: Inlet and outlet connections adopt quick change couplers for reliable sealing and convenient
operation.
(4) Sealing: all the connection parts, adopt imported special non leakage sealing materials with strict inspection process to ensure
excellent performance and no leakage.
(5) 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.
(6) The machine supports on-line operation without supervision. No easily damaged parts, so no additional expenses.
(7) Equipped with oil outlet circulation route to adjust the flow rate of oil outlet. During vacuum oil filling operation, it can adjust the
flow rate of oil outlet and control the oil filling capacity.
(8) Customized designs and optional functions are available according to clients requirements.
Optional Accessories:
- PLC intelligent control with touch screen operation and operation status dynamic display.
- Online moisture tester, online particle counter and online flow meter with adding-up function.
- Frequency converter for free adjustment of flow rate
Customized Design:
- The whole structure of the machine: mobiles tyle with four wheels, fixed style, mobile style with trailer(double axles or single axle),

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fully enclosed style, conceal eaves type and open style of canvas etc.
- functional interchangeability of oil inlet pipe and oil outlet pipe: During the vacuum oil filling and hot oil circulation operation, to
controller the relative valves can change the direction of oil flow and change without change oil hoses so as to avoid oil leakage.
 Main Parts of Machine :
No. Name Parameter & model No Brand & origin QTY
1. Oil Pump YPXF055 Italy brand 1 SET

Inlet Oil System
2. Oil Pump Electrical Motor Y132S/6/3KW/B35 Shanghai Zhongtian 1 SET
3. Multiple Evaporation Double Unite States HY-PRO
ZKQ-100 1 SET
Vacuum Tank Technology
4. Full Stainless Steel Dewater& Unite States HY-PRO
FSQ-100 1 SET
Degassing Separation Tank Technology
5. Unite States HY-PRO
Fog machine BMQ-100 1 SET
Technology
6. Vacuum Pump& Electrical SV-100/2.2KW
Vacuum System
Motor （100m³/h） Leybold 1 SET
7 ZJY.150A/RTO.150S/2. Yangguang,Shanghai/C
Roots pump
2KW（500m³/h） uima company 1 SET
8 Lushun(patent
Condenser LLQZ-100 no.ZL200620111198.1 1 SET
）
9 Lushun(patent
Anti back flow ZFLZ-100
no.200920294061.8）
10 Filter Tank GLT-100 Chongqing Lushun 1 SET
10 Imported high
Primary Filter precision stainless 1 SET
Filter System
LS001-500-050M steel mat net
11 Imported high
Fine Filter
LS002-500-003T precision mat net 1 SET
12 Heating Tank JRT-100 Chongqing Lushun 1 SET
13 AI Jie Technology,
Heating System Electric Heater LHTO-60 1 SET
Germany
14 Temperature Gauge / Korea（autonix） 1 SET
15 Trinity Electrical Protector - Schneider 1 SET
Electric Control
16 Pressure Conttroller P6-5bar JIASHAN JIADE, China. 1 SET
System
17 Infrared Defoam Device HHWX-10 Korea（autonix） 1 SET

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18 Main Electronic Control
- Schneider some
Components
19 Lushun(patent
Safely Device for Preventing
FYDZ-100 no.ZL200820100418.X 1 SET
Liquid Level Control Backflow of Oil flow
）
20 System Lushun(patent
Automatic Liquid Controller
ZDYZ-100 no.ZL200820100420.7
Device 1 SET
）
22 Vacuum Gauge Z-60（抗震） Brady 1 SET
Instruments
23
Pressure Gauge YN-60（抗震） Brady 1 SET
24 Mount and Pipe for Whole

JRQZ-100 Chongqing Lushun 1 SET
Machine
25 Valve for Whole DN32、DN15/1.6MPa Joint Venture Some
26 Others Jiangsu （ tempered
Observation φ100×10 1 SET
glass）
28 PVC WIRE Reinforced
DN38
tube Shanghai Zhongtian 20 M

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Real Viewing for our oil purifier series

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Our Factory Show:

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China Chongqing Lushun Scientific and Technological Development Co.,Ltd was built in 2003..We specialize in
design and manufacturing high quality Oil Purifier such as Transformer Oil Purifier,Turbine Oil Purifier,
Engine Oil Purifier, Lube Oil Purifier,Filling oil Machine and so on. Our products are widely used in Electric
Power, Petroleum, Chemical, Metallurgy ,etc.
Our registered capital is 10 million RMB(1.7 million US Dollar) . We have more than 120 employees.We have
manufactured more than 1000 sets of oil purification equipments each year.
We have a prove record of more than 10 years of satisfied customers and good after sale services within and
outside of China.
Our company rule: WE ONLY MAKE GOOD PRODUCTS FOR OUR CLIENTS

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Production line for Oil Purifier Equipment

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Oil Purifier Used on Customer’s Site：

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Main Parts choice
Leybold Vacuum Pump Imported Oil Pump
Circuits Filter

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Screw Pump from Italy Vacuum Pump
Heater Flow Meter

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Package for Machine

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Contact Information :
Email: Sale3@lushuntec.com
Tel : +86 23-65227191
MP : +86 15826183872
Fax : +86 23-65226013
Whatsapp ID : +86 15826183872
Skype ID : Isabelwan02
Web : www.cnlushuntec.com
Add : Xinqiao Industrial Zone,Shapingba District, Chongqing,China.

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Fundamentals of Preventive Maintenance

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vacuum evacuation operation.

Working Flow Chart

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

1 Oil Inlet Valve 6 Outlet Oil Pump 17 Buffer Tank

Double-Clip Type Check

3 Primary Filter 5.7 Blow off Valve 15 Ponding Tank

4 Heaters 6 Oil Drain Pump 15.1 Air inlet valve

Double-clip type one way

4.2 Temperature Controller 8 Internal circulation valve 16 Roots Pump

5.2 Infrared Defoamer 11 Pressure Control 18.1 Air inlet valve

5.3 Inspection Window 12 Sampling Valve 18.2 Blowdown Valve

5.4 Liquid Level Controller 13 Outlet oil valve 19 Vacuum Pump

5.5 Vacuum Meter 14 Condenser 20 Vacuum gauge

vacuum the other equipment directly through vacuum evacuation port.

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

3. Limit vacuity ≤ 5Pa

4. Working vacuity ≤ 80Pa

5. Working Pressure ≤ 0.35MPa

6. Temperature Range 20～ 80℃

8. Supply Power 3 Phase,220V., 60 Hz

10. Heating Power 60KW

11. Total Power（KW） 66 KW

12. Pipeline Diameter Φ 40mm

13. Net Weight 1000Kg

14. Overall Dimensions 154*185*200(cm)

16. Mean Time to Failures ≥ 8000h

Oil Quality after Treatment

Breakdown Voltage(KV) ≥70KV

Water Content(PPm) ≤3PPm

Gas Content(%) ≤0.01%

Filter Precision(μm) ≤1 μm (according user’s requirement)

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

which will not destroy paint surface during heating operation.

frequent flip of solenoid to extend its life span.

 Oil Pump System

noise, long life span.

guarantee oil in normal level.

 Vacuum Separation System

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

one circle of treatment.

avoid secondary pollution to the oil during the process.

level and timely eliminate it to avoid oil blowout phenomenon.

pollutants happens and accordingly indicate to replace filters.

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

shockproof pressure meter.

electrical cabinet is equipped with damping device.

machine damage for incorrect operation.

(6) Electrical control system is manufactured based on standard IEC60204-1: 2000/GB5226.1-2002.

 Vacuum Evacuation System

magnitude so as to achieve the required vacuum degree. It is also natural air-cooled.

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

for long time.

HY-PRO, ABB, KATO and Mitsumi etc.

loading and unloading operation.

excellent performance and no leakage.

PVC stainless steel enhanced flexible hoses.

- Frequency converter for free adjustment of flow rate

CHONGQING LUSHUN SCIENTIFIC & TECHNOLOGICAL DEVELOPMENT CO., LTD.

 Main Parts of Machine :

No. Name Parameter & model No Brand & origin QTY

1. Oil Pump YPXF055 Italy brand 1 SET

14. Overall Dimensions 154185200(cm)