CAGRE 2015

Algiers, Mars 24 -26, 2015

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http : //www.cigre.org

Needs for New Values in the Technical Specifications of

Insulating Power Transformer Oils
Benlahneche Saâd-eddine
Transmission chief engineer – DTE / ST
GRTE - SONELGAZ - ALGERIA
E-Mail: benlahneche.saadeddine@grte.dz

SUMMARY

During the last decade, most of the specifications concerning the insulating
transformer oil have known a remarkable number of changes. Indeed these changes are often
due to the result coming from specific using issues or other requirements such the presence of
corrosive sulphur, the level of oil quality needed for units of a wide power rating range,
safety and extension of service life desired in operating conditions. Several maintenance
manuals consider generally that the oil is a separate component and it can be treated alone, but
in the reality, it is viewed as an integrated part of transformer playing a very dynamic role in
the condition assessment of all the dielectric system. These new requirements are therefore a
good argument to redefine and to forecast again the importance of the insulating oil on the
reliability of power transformers with a great consideration to the aspects of thermal and
dielectric stresses evolution in new designed units. The present article describes first the
specifications in current use, those that have changed and finally the future trends for the next
years.

KEYWORDS

Insulating oils – Alternative oils – Oil degradation – Oil properties comparison – Power
transformers aging

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1. INTRODUCTION

The insulating oil is an inseparable component of power transformers. It should not only
ensure the insulation of the various active parts but also the cooling and evacuation of the
produced heat. These functions must be guaranteed for all the lifetime of these devices with a
high degree of reliability and this, despite the aging of the oil that can be more or less
pronounced during the operating conditions (Presence of humidity, temperature, oxidation
products ...).
For several years ago, insulating oils have met some requirements such protecting the
environment, people and security in fire situations. Obviously, the technical and the economic
aspect is the main objective in all this evaluation and that’s why, they must be submitted to
several maintenance actions during their operation like different treatments to extend
sufficiently their lifetime. These new pressures push positively many progresses towards
finding alternative oils or combination by blending different ones to replace traditional
mineral oils, unable to provide suitable security measures especially against fire and the
environment despite their cheap price, availability and their technical properties correctly
accepted. . This growth has generated then a great challenge among experts, laboratories,
maintenance personnel, oil and transformer manufacturers to model the right oil whose
characteristics are able to meet these pressures of the current requirements. The choice
comparisons and testing appeared so, and were conducted at various levels between oils
such : Naphthenic and paraffinic mineral ones, inhibited and uninhibited oils, vegetal based
esters versus synthetic esters, with additives and without additives, mixed and not mixed,
creating thus a wide range of research and competitiveness. Standardization in a large scale,
particularly in Europe and USA, has followed this trend by formulating different standards
like the: IEC 60296 ; 60836 ; 60099 , 60422 , ASTM D 3487 , 4652 D ; D 6871
and IEEE C57. 106 ; C57.147 supported by some particular laboratories specifications
such TOPS 2008 of doble, CSA C50-08, AS.1767 .1 1999 and JIS C2320-1993. In this
article, we will see these comparisons between different oils, with the necessary illustrations
including their fundamental features inside this broad context imposed by the evocated
constraints and requirements.

2. HISTORY AND TECHNICAL EVOLUTION OF TRANSFORMERS:

Since the first patent registered in 1882 of the first transformer, technology has continued
to progress. This progress was, and continues to cover several facets of improvement and
incorporates within these changes, especially two things which are the materials and design.
Among the most significant changes, affecting these two facets, we find in [1] :
- 1907 : The use of 2 to 4% of silicon steel
- 1908 : The introduction of the condenser bushing
- 1921 : De-energized tap changer
- 1926 : Subdivided conductors to reduce eddy current
- 1955 : Computer used in design
- 1957 : Load tap changer
- 1960 : Thermally upgraded kraft paper
- 1970 : Copper improvements

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 - 1980 : Amorphous core material; Nomex paper (Aramid)
- 1990 : High temperature super conductors (HTS), wide use of alternative
fluids, alternative power sources (phase shifting transformers, DC transformers,) and on
line monitoring.
It is clear for transformer manufacturers, which means for them that they have to adapt
these design changes and reductions in the size for their production system while
manufacturing reliable units in operation. This challenge does not mean only that the
transformer is taking more reduced tolerances with even lower weight, but also, it will be
exploited at higher rating. This wonderful change going in both directions, impacted by the
development of analytical tools for optimization, reveals the following comparison between
the changes caused in the year of 1970 and the year of 1980 where apparent differences
were found [1] :
- 12% decrease in the total weight of the transformer
- 11% decrease in case weight
- 10% decrease in oil weight
- 13% decrease in core and coil weight
- 9% decrease in no-load losses
- 3.5% decrease in load losses
- 25% increase in number of pumps

All these changes achieved primarily in the design of power transformer, have pushed it
finally to support more and more hard operating conditions and involving at same time all its
materials (copper, electrical steel, oil and solid insulation) to operate in the most extreme
conditions, unlike what has been practiced before, with older units. This trend is due also to
the fact that the transformer industry is not static and must at all times adapt itself to new
market demands. These new changes in the market have been felt in recent years, particularly
in the case of the insulating oil of power transformers. For example, they are very serious
problems caused by corrosive sulphur in oil and each actor activating in this area was obliged
to undertake the necessary work for mitigating its effect on power transformer failures.

3. INSULATING OILS : PROPERTIES AND SPECIFICATIONS:

A- Mineral Oil :

It is the kind of oil which nowadays, is widely used and most familiar with operators and
maintenance crews. Their origins date back to the year of l889 and since then, it has continued
to undergo changes in its properties following the evolution of those of power transformers.
All mineral oils contain naphthenic and paraffinic proportions. Depending on the
concentration of the dominant proportion, each base will be declared naphthenic or paraffinic
oil. Paraffinic oils that were widely used before the year 1925, provide a major weakness
known by their poor flow point at low temperatures (- 25 ° C) due to the crystallization of
their molecules, which limit then the use of transformers in colder areas [2]. This handicap is
often overcome by adding an additive where the pour point can reach values from - 45 ° C to
-60 ° C, and there by inducing an additional operating cost. During the last thirty years, with
the growing techniques known in petroleum refining [3], the industry of insulating oils has
launched in the market more efficient oils able in absorbing gases generated in service and

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having a better behavior against lightning impulse, which gives properly the required
specifications desired by some utilities. It is well known by all worldwide experts that
transformer life is closely linked to the life of its solid insulation, and as long as it is
impregnated and immersed in oil, the problem of aging becomes one and inseparable from the
unique context for the both materials. Improvements in required ratings for modern
transformer service is not the only factor that pushed oil manufacturers to develop further
better products, but also because the volume of oil used in transformers begins to decline
significantly in active parts putting thus, the oil at highly thermal and dielectric stresses in
operating conditions as shown clearly in the table below. [4]

Manufacturing year Liters of oil per kVA rating

1915 7.6
1945 1.9
1960 1.3
1977 0.5
In recent years 0.4

Table N° 1: Decrease of oil volume per Kva rating [4]

It will be therefore required from modern oils to meet these following specific properties
such good heat dissipation and a good stability against degradation to ensure a long life for
power transformers. Mineral oils are now standardized according to IEC 60296 document-
edition 2012 which had replaced the one of 2003. Chemical and physical properties in this
standard, which has been modified, take into account some of the more recent problems such
as [5] :
- New interpretation of inhibited and uninhibited oil
- Metals passivators / deactivators (IEC 60666). [6]
- Presence of dibenzyl disulfide (IEC 60535). [7]
- Other additives
- Test of corrosive sulphur (IEC 60535) [7].
It is clear that this standard is applied to new oil before filling power transformers ; and
to understand the necessary properties while in service, one must refer to IEC 60422. It is
noted that the edition 2013 has replaced the one of the year 2008, where profound changes
were conducted mainly in the manufacture of mineral oil free from the risk factors
contributing to the components failure due to corrosive sulphur. [8] The aging of the mineral
oil in use is often accompanied by an increase in the acid number value which is the synonym
of the existence of polar products that can simultaneously reduce its dielectric strength and
weaken the cellulose by producing sediments and sludge deposits. In order to get of a higher
withstand against oxidation and degradation and thus against aging, the use of an antioxidant
or inhibitor is usually performed ; it concerns the DBPC (2,6-tert-butyl-para-cresol) in
amount ranging from 0.3 % to 0.4 %. This aging inhibitor is consumed in use and requires
frequent monitoring along the life of the transformer according to the analytical procedure
described in the document of IEC 60 666. This assessment should cover the entire period of
induction where the antioxidant can act effectively versus degradation precursors ; it can be

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also added later during the drying out of oil or regeneration treatments when we want to
suppress the polar decomposition products like acids, peroxides, aldehydes and ketones. To
choose the right oil, we must always refer to aging tests brought on the data sheets of the oil
suppliers or via conflicting tests, which must guarantee the conditions listed in IEC standard
[Table 2]. Sometimes it is strongly recommended to confirm the presence of this inhibitor
even in the case of uninhibited oils to avoid unpleasant experiences related to compliance
with the required specifications. Experience has also shown that the service life of inhibited
oil can be easily multiplied by three. IEC standard 61125 edition 2004 provides test during
500 hours, but this test phase is only 164 hours for the case of uninhibited oils [9], [10].

Oil Type Acid number in m Tan delta at 90 °C

Sludge in %
g KOH / g in%
IEC limit for
1.2 0.8 0.5
uninhibited oil
IEC limit for
0.3 0.05 0.05
inhibited oil

Table N° 2: IEC: Limits recommended for inhibited and uninhibited oils against degradation [9] .

As the integrity and the withstand of the power transformer dielectric system will be
determined for the most part by the properties of mineral oil, this system mainly done of an
immersed solid insulation in the bulk oil, often undergoes during operation of the
transformer, highly dielectric stresses. Indeed, channels and oil ducts inside the coil level are
their ultimate concentration point where the action of these stresses is generally destructive.
The correlation between the electric field in the oil (Eo in kV / mm) and in the insulation
paper ( Ep) is expressed by the following ratio :
Eo //EP = εp / εo ……….Equation (1)
The dielectric permittivity (εp ) of paper is however equal to 4.0 and of the oil (εo is
between 2 and 2.2) ; This means in other words, that the dielectric stress in the oil is 1.8 to
1.9 higher than the one in the insulating paper. In addition, the dielectric strength of the
pressboard is about 3 to 4 times higher than that of oil, all this proves generally that the
mineral oil in this impregnated system is the most sensitive point of partial discharge
occurrence, particularly in those channels, and especially those located below the windings
where the deformation of the electric field is important [11] (Figure 1). This problem can
increase drastically by the existence of high concentration of moisture or decomposition
products and conductive particles, as there can, for example, be overcome by using an
alternative oil, mixed with mineral oil, having a dielectric permittivity close to that of the
paper and capable of dissolving the maximum of humidity under the operating conditions
without affecting its dielectric strength [12], [13]. The conditions of this mixture are
imperative to meet the criteria of miscibility and material compatibility, and should interfere
positively with the internal design of the transformer.

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 Turns

Horizontal oil duct

Vertical
oil duct
Turns

Horizontal oil duct

Figure (s) N° 1: Simulation and Real oil flow ducts

B - Vegetal Based Ester Oil:

This type of oil was developed in the early nineties of the last century (1990) in the USA
from natural esters. Major research is still being conducted by the guidelines of
manufacturers. Its chemical structure is often made of a blend of natural esters, with a
simpler composition but which may vary within wide proportions depending on the origin of
used plants or seeds. It is an oil which proved to be an interesting response to the
environmental problems posed by mineral insulating oils.
Their key features include fire resistance, high water solubility, toxicity and excellent
biodegradability, but on the other hand, certain properties are completely adverse such
viscosity and high flow point, the dissipation factor and its oxidation stability related to
unsaturated character of its molecular bonds an structure [14]. However, this last specific
characteristic, initially, allowed it to be used in current and tension transformers, cables and
reactors because of its high capacity for absorbing generated gases. Its main success was
probably with distribution transformers, especially those located in coastal areas where the
moisture is a serious problem affecting the condition of the transformer [15].
Several kinds of vegetable oils currently available on the market contain chemical
additives that reduce the pour point and improve the oxidation stability. At - 10 ° C, the oil is
so viscous for a normal use like in the case when we are moving the tap changer or energizing
the transformer at cold temperatures. However, we can lower the pour point with 10 ° C by
adding the dimethyl - acrylate at a concentration of about 1% with practically no effect
registered on its electrical conductivity. In some formulated packaging, we can find even
other corrosive sulfur deactivators and anti-bacterial additives. [16] Recent progresses made
on a new insulating oils based from palm fatty acid ester plant type have simultaneously
improved the dynamic viscosity, by lowering it of about 60% and the dielectric permittivity,
by increasing it of about 30% [17]. These conditions are both favorable respectively in the
use of pumps in cold regions and the dielectric strength of the transformer, especially at the
level of flow channels inside the windings.
The comparison of the dielectric strength between mineral oil and vegetable based ester oil
as a function of relative humidity, shows that the water saturation is 40 to 60 ppm for the
mineral oil and 800 to 1100 ppm for ester-type one. It can be therefore used to retain high
amounts of moisture diffused from cellulose parts due to its hydrophilic character in order to
be removed after by a physical drying out process. The dielectric strength values maintain
thus acceptable limits even these high concentrations of water compared to those of mineral
oils. According to recent studies, it has been verified that the dissolved water reacts with

6
ester-type oil to form long chains fatty acids. Hydrolysis increases then the acid value, but
paradoxically to what is always happening with mineral oil, these fatty acids are less
aggressive.
In mineral oil, high acid number is undesirable and is generally considered as an
indication that sludge may be depositing; but in natural ester fluid, higher acid number is
inconsequential and most often indicates that the cellulose and fluid are getting drier by this
hydrolysis reaction [18].
The cellulose insulation impregnated with vegetal based oil displays a much reduced rate
of aging compared to that impregnated with mineral oil; this corresponds to an overload
capacity for a temperature increase of nearly 20 ° C. Both equations below compare the
relative aging rate of cellulose impregnated with ester fluid to that with a Mineral one:

…………….Equation (2 )

…………….Equation (3 )

Where: Vmo = Relative aging rate in mineral oil

Vne = Relative aging rate in vegetal ester oil
Θh h = Temperature of the hot spot point of the winding
In other words, for a hot spot point of 98 ° C for example, the relative value of aging
rate of cellulose with the mineral oil is equal to 1 while that of the ester oil is 0.16 , with the
order of 6.3 times lower. This feature combined with its good thermal conductivity; greatly
outweigh the effect of viscosity and the high value of the hot spot point which is higher than
that with mineral oil (5 to 20 ° C). This issue is similar either with normal cellulose paper or
Nomex (aramid) paper type or even with a thermally upgraded paper [19] (Figure 2).

Figure 2: Hot spot point simulation [20]:

A– Mineral oil (68 °C) and B - Vegetal based ester oil (80°C)

To overcome this deficiency, the development of an efficient thermal model will lead to
appropriate design calculations, especially for the windings, taking into account the type of
flow resulting from the thermo physical properties of this oil. However, we must to be careful

7
when using this oil for transformers with a rating tension higher than 150 kV because simply,
the dielectric withstand for long distance gap of ester oil is significantly different from that of
mineral one [21].

C - Synthetic Based Ester Oil:

Since 1976, a great development took place in the field of synthetic ester base oils. This
type of oil was the source of the setting of the IEC 60 099 standard developed in 1992 and
revised in 2010 [22]. It is synthesized from alcohols and organic acids. During operation, it
generates no dioxin or toxic products in the presence of fire as the case of PCBs and has at
the same time a good biodegradability behavior. These esters have been developed primarily
to resist against oxidation and to absorb considerably higher quantities of humidity without
any deterioration of the dielectric system. A value, greater than 3% of this oil blended with
mineral one does not weaken electrical properties of the resulting system. Among these oils,
we find the tetra esters and phosphoric esters. The first category is often used for traction
transformers and mobile stations. A maintenance guide for this type of oil is available in the
document of the standard IEC 61203 [23]. In the case of hermetic transformers, this oil can
absorb the moisture produced by the thermal degradation of the cellulose, present inside the
windings, but for others with an ordinary preservation system, it can absorb more consistent
amounts of water through the carbonyl groups of the chemical structure. Its high solubility is
certainly the highlight of this type of oil where the water saturation is reached at about 2600
PPM. The using of the second oil is however very limited. The table below compares the
physical properties of various listed oils [24].

Properties Mineral uninhibited oil Synthetic ester Midel 7131 Natural ester Biotemp
2
Viscosity at 40 ° C /
9 30 42
mm / s
Viscosity at 100 ° C /
2 2.5 5.25 9
mm / s
Density at 25 ° C / kg
0.88 0.97 0.91
/m3
Pour Point ° C -25 / - 50 - 50 - 20
Specific heat at 20 °
1860 1880 1963
C / J / kgK
Thermal conductivity
0126 0144 0.17
at 25 ° C / W / mK
Coefficient of
thermal expansion / 1 0.00075 0.00075 0.00068
/°C
Dielectric strength
> 70 > 75 > 75
IEC 60156 / kv
Relative permittivity
according to IEC 2.2 3.2 3.2
60247
Tan delta at 90 ° C
according to IEC <0.001 <0006 <0.02
60247
Acidity / mg KOH / g 0.01 0.03 0022
Aging RBOT / min
300 420 197
(ASTM 2112)
Biodegradation after
25 89 95
28 d /%

Table N° 3: Comparison of physical properties of the several oils [24]

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4 – INSULATING OIL : AS A TOOL OF ASSET MANAGEMENT AND
IMPROVEMENT OF TRANSFORMER SPECIFICATIONS

The different group works of CIGRE related to transformers, including the mainly one
CIGRE WG12.18 consider that the oil can hold about 70% of information required for
diagnosis of power transformers, which can be performed by on-line and off line methods.
The evaluation of different electrical, thermal, dielectric and magnetic withstands is often
done by these informations, acquired via the insulating oil where all statutes expressing the
health of the transformer are well illustrated. Among these statutes, there are the aging, the
degradation and finally the dielectric status. This correlation, provided by the oil as a vector
of information between these withstands and deterioration processes, linked to defect and
failure states of the transformer, are the main source of feeding of the asset manager and
manufacturers with analytical tools, focused on the management of transformer life and the
improvement of specifications and standards, especially the ones directly connected with the
use, maintenance and redesign of transformers (Design Review) This feedback guaranteed by
this ongoing dynamic, will continue in the future to make the necessary changes to
requirements because, simply, the transformer will remain for a long time, a key equipment in
the main electricity transmission systems of any energy source used.

5 – FUTUR AND PER SPECTIVES

The intrinsic properties of the mineral oil have been already in use well over a century of
existence and will continue to do so for future decades. Moreover, there have two reasons for
the choice of the vegetal ester oil compared to mineral oil, which concern first its resistance to
biodegradation and fire, and second, because of the inevitable depletion of oil resources from
the second half of 21 century. Environmental pressures, continuously in growing issues ,
allow to the alternative oils mixed with suitable additives to be well positioned in the future.
In the USA, the application of vegetal fluids was initiated by the retro filling of transformers
in service of some power rating categories. This movement will not remain isolated and it will
further expand in the short and medium terms. The arrival of insulating oils, loaded with
nanoparticles can significantly improve the properties of heat transfer and dielectric strength,
which will be favorable for compact designs of modern units [25]. Future research will
certainly clarify the underlying mechanisms of the interaction between the nanoparticles with
the used oil.

6 – CONCLUSIONS

The insulating oil is a vital component in the insulation system of high voltage devices
such as transformers, circuit breakers, bushings, cables and capacitors and reactors. Each
application requires an insulating fluid with specific properties of chemical, electric and
physical appropriate orders. In the case of power transformers, IEC 62535 standard – edition
2008 imposed significant changes in the production of mineral oils. The inhibited oils,
containing the anti-oxidant additive, were little affected by this standard ; unlike in the case
of uninhibited ones where important changes have been seen because of their market share,
providing thus satisfactory performances for transformers with high rating power under very
stressed loads. The retrofilling of power transformers with natural ester fluid drew already its
future, especially when is blended with appropriate additives. Its success with distribution

9
transformers was wonderful and the experience with power transformers will certainly be
positive, especially since it will be supported by appropriate designs made on the active parts
of power transformers. Intensive normalization that followed this type of oil will further
accelerate its implementation in the coming years. At the end, each insulating fluid has its
own specifications, Including at the same time, the advantages and disadvantages that must
be used optimally under the operating conditions associated with desired outcomes and
assessed risk.

7 – REFERENCES

[1]: SD Meyers: An Introduction to the Half Century Transformer –Seminar Notes. Transformer
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[4]: SD Meyers et al: A guide to transformers maintenance, 2nd Edition, Transformer Maintenance
Institute, Akron, OH, 1988.
[5]: Fluids for electrotechnical applications: Unused mineral insulating oils for transformers and
switchgear. IEC 60296, (Ed 4), 2012.
[6]: Detection and determination of specified additives in mineral insulating oils. IEC 60666, (Ed 2),
2010.
[7]: Insulating liquids: Test method for detection of potentially corrosive sulphur in used and unused
insulating oil. IEC 60535, (Ed 1), 2008.
[8]: Mineral insulating oils in electrical equipment: Supervision and maintenance guidance. IEC
60422, (Ed 4), 2013.
[9]: Unused hydrocarbon- based insulating liquids: Test methods for evaluating the oxidation
stability. IEC 60125, (Ed 1), 1992.
[10]: Working group D1. 30: Oxidation stability of insulating fluids. Report 526, 2013.
[11]: HP Moser et al: Transformerboard 2, 2nd Edition, H WEIDMANN, 1999.
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[16]: P.Mcshane: Relative properties of new combustion – resistant vegetal oil based dielectric
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Jul-Aug, 2001.
[17]: T. Kano, H. Iwabuchi, Y. Hoshida, J. Yamada, T. Hikosaka, A. Hatta, and H. Koide: Analyses
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with natural ester fluid. IEEE – PES Transmission and Distribution conference, Orlondo, FL, 2012.
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using high temperature insulation. IEC 60076, (Ed 2), 2009.
[20]: K. Kaineder: Transformers - Increased heat tolerance/ alternative insulating fluid. Siemens AG,
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[21]: Q.Liu, and Z.Wang: Streamer characteristic and breakdown in synthetic and natural ester
transformer liquids under lightning impulse voltage. IEEE, Trans. Dielect. Elect, Insu, Vol 18, N°1, pp
285 - 294, 2011.

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[22]: Insulating liquids: Specifications for unused synthetic organic esters for electrical purposes.
IEC 61099, 2010.
[23]: Synthetic organic esters for electrical purposes – Guide for maintenance transformer esters in
equipment. IEC 61203, 1992.
[24]: C. Perrier et al : Retour d’expérience sur les nouveaux liquides isolants. Broch. Cigré N° 436,
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