A vacuum oil purifier looks like a few large tanks and a few lengths of pipe, but taking it apart into functional sections makes it clear: the oil comes in at the inlet, passes through a number of sections in turn, and leaves at the outlet. The routing of the pipework is not exactly the same on every model, but the functions carried out are one and the same. For the people on site, a structure diagram like this gives a steady reference when they read the figures, trace a fault or change an element.
The sections, divided by function
The inlet section. It brings the oil to be treated into the machine in a controlled way and at the same time holds back some of the larger particles, so that the sections after it carry less. As far as the element sizes go, the coarse filter elements come as 150-250-50 and 110-250-50.
The filtration section. It carries out the main filtration, with 110-400-20 as the usual secondary filter element and 110-600-5 and 150-500-5 as the fine filter elements. The standard configuration of the ZYD-100 is five 150-500-5 fine filter elements in parallel, and the purpose of the parallel arrangement is to share the total flow across several paths and extend the life of the elements.
The heating and atomisation section. Far-infrared carbon fibre heating brings the oil up to the temperature the process needs, and the oil is then atomised and sent into the vacuum chamber. The temperature control range of the TYA series is 45–80 °C, with the upper limit pulled back to 70 °C where the water content is high.
The vacuum degassing section. It is made up of the two stages, the X-100 vacuum pump and the JRP-500 roots blower, which treat the atomised oil at low pressure and draw the gas out of it. The working vacuum of the ZYD-100 is -0.08 ~ -0.0999 MPa and the ultimate vacuum is ≤5 Pa.
The outlet section. It returns the treated oil to the tank or sends it on to the next operation.
The components behind each section
| Section | Main components | Key figure |
|---|---|---|
| Inlet and transfer | ZH screw oil pump | Sets the rate at which the oil is fed in |
| Filtration | Coarse, secondary and fine filter elements | 150-250-50 / 110-400-20 / 150-500-5 |
| Heating and atomisation | Far-infrared carbon fibre heating | Temperature control 45–80 °C |
| Vacuum degassing | X-100 vacuum pump, JRP-500 roots blower | Working vacuum -0.08 ~ -0.0999 MPa |
| Monitoring and protection | Infrared level and foam detection, automatic defoaming | The foam is dealt with before it reaches the vacuum stage |
| Protection | Overpressure audible and visual alarm with shutdown, phase failure and phase sequence protection | Pressure drop alarm value on the fine element 0.35 MPa |
The common figures and the part that can be adjusted
The common figures of the ZYD-100 are: flow rate 6000 L/h, filtration accuracy ≤1 μm, water content in oil ≤3 ppm (GB/T 7600), gas content in oil ≤0.01% (GB/T 423), breakdown voltage ≥65 kV (GB/T 507), cleanliness NAS 1638 class 5, total power 72 + 5 kW, supply three-phase 380V / 50Hz, dimensions 1200×1400×1800 mm, weight approx. 720 kg. The flow rates of the ZYD-200 and the ZYD-300 are 12000 L/h and 18000 L/h, and the rest follow the same series figures.
Within this fixed structure, the parts that can genuinely be adjusted to suit the conditions on site are the element sizes and the configuration of the filtration section. Different accuracy requirements call for a different fine filter element; a large difference in the incoming state of the oil changes the way the coarse and secondary elements are combined. The basis for the adjustment is always the incoming state of the oil and the target result, never the model of the machine.
What the models have in common and where they differ
Within one series, the functional sections are the same across the models and the differences lie in the sizes and the configuration. The flow rates of the ZYD-100, the ZYD-200 and the ZYD-300 are 6000 L/h, 12000 L/h and 18000 L/h; the filtration accuracy, cleanliness, water content, gas content and breakdown voltage follow the same series figures; and the vacuum degassing stage is carried out by an X-100 vacuum pump and a JRP-500 roots blower of the same configuration.
Once the flow rate grows, three things have to grow with it. First, the filtration section has to carry a larger total flow, so the number of elements and the filtering area increase, otherwise the pressure drop will rise noticeably faster. Second, the degassing section has to keep the volume of oil matched to the vacuum, or the tank cannot keep up with the treatment. Third, the heating section has to supply the corresponding amount of heat, or the rate of feed rises while the oil temperature lags behind and the degassing performance suffers for want of temperature.
So when a new machine arrives, checking the configuration of each section against this structure diagram is a quicker way to judge whether it suits the site than reading the datasheet alone. The figures on the datasheet are the result; the structure diagram shows where those figures come from.
What the structure diagram is worth on site
With this structure diagram to hand, the direction of the search when something goes wrong is much clearer. If the vacuum level will not come up, the question is the vacuum degassing section; if the pressure drop rises, it is the filtration section; if the oil temperature will not rise, it is the heating section; if an alarm acts, it is the monitoring and protection section; if the oil leaving the machine is too hot or too cold, it is the way the outlet section and the inlet section work together. Judging section by section is far quicker than probing around the whole machine.
Changing an element is the same. Knowing where the filtration section sits in the structure tells you the order for draining, releasing the pressure and venting; knowing that the fine elements are five in parallel tells you that the reading on the pressure gauge reflects only the most open of the five, and why the first element to block cannot be identified from the total pressure drop alone.
Each section the oil passes through does one thing only; when something goes wrong, work out which section it is before going further.
