Smart Dehydrating Breathers

Protecting Transformer Health Through Intelligent Moisture Management

Moisture is one of the most destructive elements affecting transformer longevity and performance. Even the smallest amounts can accelerate insulation ageing, reduce output and, in extreme cases, lead to catastrophic failure. At Insulect, we offer dehydrating breathers from reputable brands like Qualitrol and Comem, providing a universal, maintenance-free solution designed to keep transformers dry, protected, and operating reliably.

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What Is a Dehydrating Breather?

A Dehydrating Breather prevents moisture from entering oil‑filled equipment during thermal breathing cycles. Unlike traditional silica gel breathers, smart breathers:

Actively monitor humidity and operating conditions
Automatically regenerate desiccant using internal heaters
Provide alarms, data, and remote communication
Eliminate routine site visits for silica gel replacement

These systems work continuously to ensure only dry air enters the transformer, even in highly variable or harsh environments.

Application Overview

Dehydrating breathers supplied by Insulect are suitable for:

Power and distribution transformers
Generator step‑up transformers
Shunt reactors
Phase‑shifting transformers
Tap changers
Petersen coils and arc suppression coils
Offshore, coastal, and high‑humidity installations
Tropical, desert, and cold climate environments

COMEM eSDB breathers support applications from ≤40 tonnes oil up to >200 tonnes, while Qualitrol STB breathers are designed for both main tank and conservator systems, including LTC applications.

What We Solve For

Moisture Risk

Prevents atmospheric moisture ingress during breathing cycles
Protects cellulose insulation and oil quality

Maintenance Burden

Eliminates routine silica gel replacement
Reduces site visits and labour costs

Asset Ageing

Reduces oxidation and insulation degradation
Helps extend transformer service life

Visibility & Control

Enables condition‑based maintenance
Provides alarms, status indication, and communication interfaces

Fleet Standardisation

Multiple models and sizes available
Supports both retrofit and new installations

TECHNICAL

Core Functions

Moisture absorption using colourless, non‑toxic silica gel
Continuous monitoring via humidity, pressure, or load‑based sensing
Automatic regeneration using internal heaters to dry silica gel
Ventilation control to avoid condensation formation
System feedback and alarms to indicate operational or fault conditions

Regeneration occurs only when required, ensuring efficient operation and preventing moisture being drawn into the transformer during heating cycles.

Key Features

Maintenance‑free desiccant regeneration
Indoor and outdoor installation suitability
Wide ambient temperature operation (down to –40°C)
IP‑rated enclosures for harsh environments
Local visual status indication
Condition‑based operation logic
Communications options:
- Dry contacts
- 4–20 mA
- Modbus RTU / TCP
Data logging for long‑term trending
Retrofit and new‑build compatibility

These features support modern asset management programs and align with IEC transformer standards.

PRODUCT RANGE OVERVIEW

Qualitrol – STB Smart Transformer Breathers

Best suited for:
Universal applications, retrofits, and mixed transformer fleets

Highlights:

Universal design for conservator and main tank systems
1 kg and 2 kg desiccant options
Pressure‑based regeneration logic
Five‑year warranty
Side‑mounted LED status indication
Data logging and communications available
Harsh‑environment variants:
- Offshore Xtreme™
- Polar Xtreme™

Qualitrol STB breathers are ideal for fleet standardisation and locations with demanding environmental conditions.

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COMEM – eSDB Self‑Dehydrating Breathers

Best suited for:
Large power transformers, reactors, and high‑oil‑volume installations

Highlights:

Sizes: eSDB XS, S, M, L
Oil volume coverage up to >200 tonnes
Dual‑sensor redundancy (M & L models)
4–20 mA, Modbus RTU/TCP, USB data logging
Stainless steel and aluminium construction
IP55 enclosure, IP65 terminal box
Designed for ISO and IEC compliance

COMEM’s eSDB series offers scalable solutions where detailed monitoring and integration into substation systems is required.

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IMPLEMENTATION

Services & Support

Insulect offers comprehensive services and support for the products we specialise in, enhancing value for local utilities, major energy users, equipment manufacturers, and service operators.

LOCAL TECHNICAL TEAM

Our local technical team provides exceptional support and expertise, ensuring quick response times and personalised service to tackle any challenges that may arise during project execution.

ENGINEERING EXPERTISE

Through Qualitrol, our team utilises advanced technology and industry knowledge to assist customers.

PROCUREMENT & LOGISTICS

We facilitate smooth procurement and logistics processes by sourcing from trusted, proven partners and coordinating timely deliveries, ensuring projects remain on schedule and within budget.