Insulation Oil Treatment and its Necessity in Power

Transformers
Gerards Gavrilovs, Olegs Borscevskis
Riga Technical University
gerards.gavrilovs@latvenergo.lv, olegs.borscevskis@latvenergo.lv

Abstract-The insulation oil has one of the main ensigns in useful

life of electrical equipment. Each quality parameter of insulation
oil is significant, therefore there are should be controlled during
electrical equipment maintenance. Deterioration and aging
process of oil has place to be in equipment lifetime. The
insulation oil, like a insulation material, is comparatively
expensive and it is the reason not to buy, but thinking about oil
regeneration. The insulation oil quality parameters will be
regenerated in this wise.

I.

used for regenerating of oil. This is naturally occurring clay

with huge adsorbent properties as a result of high surface
activity. Regeneration is the complete treatment of oil to like
new condition. Regeneration of oil in transformer is far more
efficient than simple oil changing. The total volume of oil is
recirculated a number of times thorough the regeneration
plant and flushing effect of transformer is achieved. It is
obvious that regeneration as complete oil treatment method is
the best technical solution to aged transformer oil. Apart from
this it is also highly cost effective in comparison to an old
procedure of oil replacing.

INTRODUCTION

Insulating liquids used in power transformers, instrument

transformers, circuit breakers and high voltage bushings
require proper testing and maintenance to keep them in good
condition. Liquid insulation oil that is not in good
conditions may cause damage to equipment and become a
hazard to personnel and environment.
The majority of electrical equipment in operation today is
filled with insulating (mineral) oil. The primary function of
the oil is to provide a high dielectric insulating material and
an efficient coolant. The effectiveness of the oil as insulating
material is reduced as the moisture level increases, while
cooling is reduced as the oil oxidizes. Paper insulation will
also absorb moisture from oil, thus increasing power factor
readings.
The oxidation of insulation oil begins as soon as the
equipment is energized. A chemical reaction occurs when the
oil is exposed to a combination of heat, oxygen, core and coil
components. As the process of oxidation progresses, acids
and polar compounds are formed and in turn become sludge.
This sludge will then coat heat transfer surfaces on the
core/coil and the tank/radiators, in case of transformer,
reducing the heat transfer capacity of the system. The
operational temperatures are increased, thus accelerating the
degradation of the oil. When the properties of oil have
changed the oil can no longer perform. Under such
circumstances oil has to be changed or treated. Treatment
methods are: oil filtering, purification and oil regeneration. In
the process of purification water, dirt, and gasses are removed
from power transformer oil. Regular purification will increase
breakdown voltage to required level. Oil purification is an
effective preventive maintenance method. When oil in
transformer, due to deterioration, reaches a stage where
purification is no longer efficient, oil has to be changed or
regenerated. Adsorption clay is the material most frequently

II.

OIL QUALITY PARAMETERS AND TESTS

Basic quality parameters of insulating oil are: dielectric

strength (tg ), voltage breakdown, moisture content, color
visual inspection, flash point, acidity, interfacial tension,
particles contamination. Other tests for determination of other
parameters may be required due to the operating environment
and the transformer age [1].
A. Dielectric Strength
This quality parameter determined by test which measures
the voltage at which the oil electrically breaks down. The test
gives an indication of the amount of contaminants (water and
oxidation) in the oil. The minimum breakdown voltage level
is defined in valid standard. If a dielectric strength test falls
below this number, the oil should be reclaimed. Do not base
any decision on one test result, or on one type of test; look at
all the information from several tests and review tendency
before making any decision.
The dielectric strength test is not extremely valuable.
Moisture in combination with oxygen and heat will destroy
cellulose insulation long before the dielectric strength of the
oil has indicated anything is going wrong.
B. Dielectric Losses
It indicates the dielectric losses of the oil. High dielectric
losses indicate deterioration and/or contamination from
byproducts such as water, carbon or other conducting
particles, including metal soaps caused by acids attacking
transformer metals and products of oxidation. If the dielectric
losses value is greater than in standard acceptable limit, that
the oil may cause failure of the transformer. Replacement or
purification of the oil is required immediately. Too bed oil
quality with huge dielectric losses cant be reclaimed without
special oil regeneration equipment (plant).

23

C. Moisture Content
Moisture, especially in presence of oxygen is extremely
hazardous to transformer insulation. Each time the moisture is
doubled in a transformer, the live of the insulation is cut by
one-half. The technical staff must keep in mind that the life of
the transformer is the life of the paper and the life of the
paper is extended by keeping out moisture and oxygen.
Oil should be dried when moisture in oil overachieve
values given in standard. Segregated technical decision is
possible too.

undergoes oxidative degradation there are formed carboxylic

acids, which are acidic in nature. The presence of these acidic
materials can be quantitatively determined by a procedure
called titration.
Since the insulating fluid in new equipment would have
little or no acidic materials initially present, as the acidic
materials start to form the small amounts present would be
soluble. However, as more of the acidic material forms it
would reach a saturation point and further formation would
result in the separation of solid material. This material would
settle to the bottom of the equipment as sludge. Another
source of sludge would be from the reaction of the acidic
materials in the insulating fluid with various metals present in
the equipment to give salts, which would also tend to be
insoluble in the insulating fluid.

D. Color Visual Inspection

The color of an oil sample is related to the deterioration of
the sample. Virgin mineral oil fresh from the refinery is
essentially colorless, however, as the sample ages over time
or is subjected to severe conditions such as local hot sports or
arcing the sample will become darker in color. The clarity of
a fresh virgin sample of oil should be sparkling with no
indication of cloudiness, sludge, or particulate matter. The
clarity of an oil sample is determined by observation of the
sample when illuminated by a narrow focused beam of light.
The color of a sample is determined by direct comparison to a
set of color standards.
The color of an oil sample is used mainly as a guide to the
degree of refinement of the oil when it is new. If the sample is
from a transformer that has been in service then the color can
be followed over a period of time to indicate the possible
condition of the oil. It should be pointed out that the color of
the oil by itself should never be used to indicate the dielectric
quality of the oil [2]. However it can be used to determine
whether more definitive tests should be done to determine
specific characteristics of the sample that are more related to
the performance of the oil.
The clarity of the sample can also give possible suggestions
for further tests. Cloudiness of the sample can indicate the
presence of water, which in turn will decrease the dielectric
strength of the sample.

G. Interfacial Tension
As oil ages, it is contaminated by tiny particles (oxidation
products) of the oil and paper insulation. Particles on top of
the water extend across the water/oil interface line which
weakens the surface tension between the two liquids.
Particles in oil weaken interfacial tension and lower the
interfacial tension number. Interfacial tension and acid
number, Fig. 1, together are an excellent indication of when
oil needs to be reclaimed. It is recommended the oil be
reclaimed-filtered when the interfacial tension number falls to
25 dynes per centimeter.

E. Flash Point
The flash point and fire point refer to the flammability
characteristics of the fluid being tested. The flash point is
defined as the lowest temperature at which the vapor formed
above a pool of the liquid ignites in air at a pressure of one
atmosphere.
The flash point is used to assess the hazardous nature of a
material and the risk of the materials ability to support
combustion. A low flash point can be indicative of the
presence of highly volatile materials in the fluid. For mineral
oils the minimum accepted value for the flash point oil used
in outdoor transformers is 145oC, although this could vary
according to local standards. In general the fire points are
about 10oC higher than the flash point [3].

Fig. 1. Insulating oil service limits.

The attraction between the water molecules at the interface

is influenced by the presence of polar molecules in the oil in
such a way that the presence of more polar compounds causes
lower interfacial tension.
If oil is not reclaimed, sludge will settle on windings,
insulation cooling surfaces, etc., and cause loading and
cooling problems. This will greatly shorten transformer
lifetime.

F. Acidity
The acidity of an oil sample is related to the deterioration
of the sample. The mineral oil insulating fluid is essential a
non-polar saturated hydrocarbon, however, when the sample

24

H. Particles Contamination
Particles of sludge materials can indicate the products of
oxidation such as acids that will raise the acidity and lower
the interfacial tension. Particles of carbon and metal can
indicate severe local overheating and or arcing. All of these
can suggest further testing to determine the source of these
materials and decide about necessity of oil treatment.
Particles may be drawn into or expelled from high stress
regions. Fine particles may agglomerate or be dispersed.
Particle chains may develop. These complex physical factors
have not been related directly to voltage breakdown in the oil.
Particles may cause partial discharges to develop in oil but
these discharges also have not been related directly to short
time breakdown of the oil. Insulating oil which is deteriorated
with particles has to get purification process.
III.

Regeneration is required when purification on its own is

unable to upgrade the insulating properties of the oil due to
high acidity, sludge and chemical contamination from other
oil decay products. During regeneration, degassing and
drying also takes place, but the main function is to extract, by
absorption in the special columns of regeneration plant, acid
contaminants and other soluble and colloidal oil decay
products, as in Table I.
TABLE I
DIAGNOSTIC RESULTS OF INSULATION CONDITION

Oil parameters
Breakdown
voltage, kV
Dielectric losses,
%
Flash point, oC
Moisture content
in oil, ppm
Acidity,
mgKOH/g of oil
Particles,
according
ISO4406:2004

OIL TREATMENT AND EFFECTIVENESS

The oil regeneration process is the complex oil treatment of

the oil with the aim of improves all technical characteristics
and parameters of transformers oil to the quality of new oil.
First of all, the insulation oil treatment or replacement is
needed for power transformers lifetime extension. The
insulation oil replacement has economical disadvantages. It
has come to be generally recognized as the most efficient and
cost effective method for restoring transformer oil available
today[4].
The level of oil quality is going down during the
maintenance and the specialists must to check oil condition
[5]. The final result of oil degradation can be reducing of
transformers lifetime and transformers failure. The time
based maintenance strategy is very applicable in this situation
to minimize risk of abnormal systems schedules.
The most important oil quality parameters described in
chapter above.
There are three possibilities of oil treatment in
maintenance:
filtering;
purification with drying process;
regeneration (reclamation) with degassing.
It could be done in substation on-site or remove the oil from
transformer and to treat by special regeneration plant. It helps
to get out the moisture from power transformers solid
insulation [6]. The filtering process realized at 40oC and it
involve oil filtering from rude and fine particles
contamination with fine filter help.
The purification with drying process starts by heating the
oil to a maximum of 90oC. Processing begins when the oil
reaches a minimum 65oC. The special filter removes acid and
polar compounds from the oil. Next the oil is under vacuum
and occurs degassing process. The moisture will be getting
out from paper.
Regeneration with degassing it is combined the second
method with additional oxidant additives option.
Purification and regeneration constitute the processing
phase. Duration of this phase is dependent on initial oil
condition.

Color (visual)

Before oil
regeneration

After oil
regeneration

14

75

7.55

0.06

143

145

60.68

6.0

0.051

0.01

21/19/15

14/13/9

Brown (dark)

Clear, light
yellow

Absorption efficiency is maximized at the processing

temperature of about 60-70oC, Fig. 2.

Fig. 2. Oil visual difference before and after oil regeneration.

25

above those of new oil. Subsequent oil changes may be

required to remove these redissolved products of oxidation.
Each time this is done, the transformer must be de-energized.
Another method is to filter press the oil. The only thing
accomplished by filter pressing is the removal of solid
particles that have been in suspension and free water. This
process does not significantly change the acid or polar
compound levels or remove dissolved water. Oxidation and
sludge formation will continue as soon as filtering is stopped.
Very little is gained from this method.
A third method is to un-tank a unit, flush the tank,
radiators, core and coil with solvents, then refill the unit with
new oil. This method can result in a successful stabilization
of the oil, but there are several major drawbacks. The units
must be de-energized and sent to a service factory. This
means days, weeks or months without the use of the power
transformer, plus expensive handling, transportation and
service charge.
The next one method is ageing products removal by
absorbent treatment of insulating oil. The selection of
absorbent for rehabilitation of paper-oil insulation has been
made after detailed laboratory tests. It should be noted, that
the oil color was slightly changed while highly volatile
aromatic agents and natural inhibitors mainly remained in oil.
This conclusion was done after interfacial tension analysis.
The relatively new one method is low frequency heating
[7]. During the transformer revision, service or reconstruction
on site or in the assembly halls the moisture gets into the
paper insulation and wooden barriers. After the works and
assembling of the transformer on site is advisable/necessary
to get the moisture out priori to putting the transformer into
the operation. Low frequency heating is modern technology
for heating of solid insulation of the transformers by external
low frequency source of power. Technology based on the
principle of reduction the inductive reactance with low
frequency. Low frequency heating technology operates in the
interaction with filtration or regeneration process. It is a
mobile technology and it is used on customers site. The
insulation system beneath the oil, which is its natural
environment. The balanced state of water depends on the
temperature of the system and the solid insulation is a
significant water reservoir. The principle of eliminating the
water from the solid insulation is to disrupt the balanced state
by drying the oil with the connected regeneration plant.
Creates the imbalance consisting of different temperatures
between the solid insulation and the transformer oil
(temperature wave), because it is necessary to supply the
solid insulation with heat by using a special power source.
The heat is transported from the transformer windings to the
insulation and barriers. There is interaction of low frequency
heating and regeneration of oil by plant. The water is pushed
from solid insulation into the oil, where it is removed by
regeneration plant, otherwise without regeneration/filtration
plant would stay the water in the oil and then goes back in
solid insulations [8].

Before mentioned oil treatment methods, as said before, we

can use like drying process of power transformers solid
insulation. It can be realized in substation on-site in online
state.
The regeneration process ensures:
valuation of aged oil and its reusing;
saving the costs for the purchasing of the new oil;
reduction of oil disposal => environmental
friendly;
reduction of oil handling, reduction of transport
costs;
providing of complex services on the customer
site (also under the voltage and during
operation);
cleaning up the inner parts of transformer (core,
winding), removal of products of ageing;
improvement of oil qualitative characteristics,
extension of transformer life time.
It means, that oil regeneration, as function, is a good help
tool to renovate oil quality with perfected parameters and
extend lifetime of power transformer. The oil quality should
be controlled further in maintenance, after treatment, with
reinforced attention. Some oil quality parameters after
treatment and refilling in transformer during years are given
in Table II.
TABLE II
OIL PARAMETERS AFTER TREATMENT DURING YEARS

Oil
parameters
Breakdown
voltage, kV
Dielectric
losses, %
Flash point,
o
C
Moisture
content in oil,
ppm
Acidity,
mgKOH/g of
oil
Particles,
according
ISO4406:2004
IV.

2007

2008

2009

2010

73

73

71

67

1.0

1.72

1.64

1.8

143

143

143

139

8.75

12.05

12.5

9.32

0.01

0.01

0.01

0.013

15/12/9

15/13/9

15/13/10

15/13/10

OIL TREATMENT AND DRYING PROCESS

ALTERNATIVES

Correcting the problems of oil oxidation can be

accomplished in several ways with varying degrees of
success. Changing the oil will result in clean oil, but will do
little to remove sludge adhering to the radiators, tank walls,
and core and coil. Within a year of changing the oil, oxidation
products not removed will be redissolved into the new oil
resulting in acidity and polar compound levels appreciably

26

REFERENCES

CONCLUSIONS
[1]

The oil treatment is needed for keeping the power

transformer on good technical condition. The oil treatment
process helps to make better the solid and liquid insulation
parameters. In the paper are mentioned few methods how to
get back insulation properties in maintenance with energized
and de-energized power transformer. Each of them is useful
and has a positive result. But most effective method of
transformer oil regeneration and power transformer drying is
on-site with additional using low frequency heating method.
Insulation oil can be regenerated in energized or de-energized
transformers depending on process cycle. The concept of this
method is highly cost effective, but owner must to think about
necessary and safety efforts regarding to environment.

[2]
[3]
[4]
[5]
[6]
[7]
[8]

27

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