TRANSFORMER OIL Analysis

M.G.Morshad / ACM ( Elect)

Transformer Maintenance Division / TPS II
 Transformer Insulating system
Oil Paper

1. Acts as a Coolant 1. Mechanical Strength

2. Act as an insulation 2. Dielectric Strength
3. Protects the Paper from chemical 3. Dielectric Spacing
attack
4. Prevention of sludge buildup
5. Used as Diagnostic Tool
 Transformer oil classifications
NAPTHANIC OIL
Naphtha oil is more easily oxidized than Paraffin oil.
But oxidation product i.e. sludge in the naphtha oil is
more soluble than Paraffin oil.
Thus sludge of naphtha based oil is not precipitated in
bottom of the transformer.
Hence it does not obstruct convection circulation of the
oil, means it does not disturb the transformer cooling
system
Mineral Oil
(petroleum product )
PARAFFINIC OIL
Oxidation rate of Paraffin oil is lower than that of
Naphtha oil
But the oxidation product or sludge is insoluble and
precipitated at bottom of the tank and obstruct
the transformer cooling system.
Transformer Oil It has high pour point due to the wax content
In India it is generally used because of its cheaper and
easy availability.

SILICON OIL
Synthetic Oil Fire retardant, hence it is used only for fire prone area.
Lower heat dissipation capacity and high moisture
(Chemical Product)
absorbing capacity
Costlier than mineral oil
 Oxidation Inhibitor in mineral oil

Mineral insulating oil undergo oxidative degradation process in the presence of oxygen to
form acid & sludge. To prevent these process , oxidation inhibitor is used for interrupting
process of oxidation and thereby minimize oil deterioration and extend the operating life of
the transformer the oil.

Depending on the presence of oxidation inhibitor, mineral insulating is categorized as

1. Uninhibited oil 2. Inhibited oil

1. Uninhibited oil
New insulating oil as normally refined contains small amounts of certain chemical
compounds that act as oxidation inhibitors. These naturally occurring materials retard oil
oxidation until such time as they are expended. The rate at which the inhibitors in the oil
are used up is dependent upon the amount of oxygen available, soluble contaminants in
the oil, catalytic agents in the oil, and the temperature of the oil

2. Inhibited oil,
To increase the oxygen inhibitor beyond its natural limit, oxygen inhibitor is added in the oil
for reducing the rate of oxidation process in a view to increase the life expectancy of the
transformer . Phenolic materials are quite good for this purpose and the two most
commonly used inhibitors are 2,6-ditertiary- butylphenol (DBP) and 2,6-di-tertiary-butyl-4-
methylphenol or 2,6-di-tertiary-butyl-paracresol (DBPC).
5
Heat transferring capacity of Approximate Oil
transformer oil requirement for transformer
Capacity Oil Requirement
Up to 1.5 MVA 0.85 KL / MVA
1.6 to 16 MVA 0.50 KL / MVA

> 16 to 250 MVA 0.28 KL / MVA

Approximate solid insulation

requirement for transformer

Solid insulation Requirement

Thick Press board
5% of total oil weight
( Barrier )
Thin press board
3% of total oil weight
(Barrier)
Paper insulation
2% of total oil weight
( Winding insulation )

6
TRANSFORMER OIL SPECIFICATIONS
IEC -60296 General Specification

Functional Properties:
Viscosity, Pour point, Water content, BDV, Density, Tan.

Stability Properties:
Appearance, Acidity, IFT, corrosive Sulfur, Antioxidant additive

Performance Properties:
Oxidation Stability, Sludge

HSE Properties:
Flash Point, PCB content, PCA content

7
 TRANSFORMER OIL SPECIFICATIONS

NEW OIL:
An unused mineral insulating oils intended to use in transformers for
insulation and cooling purpose.
IS-335/1993 Specification for uninhibited new insulating oils.
IS-12463/1988 Specification for inhibited mineral insulating oils.
IEC -60296/2003 Specification for unused mineral insulating oils
for transformers and switchgear. This standard cover both uninhibited
and inhibited oils.
ASTM D3487/2000- Standard Specification for Mineral
Insulating Oil used in Electrical apparatus. This standard also covers
both uninhibited and inhibited oils.

8
 TRANSFORMER OIL SPECIFICATIONS
Unused Mineral Insulating oils filled in New
transformers
IS 1866/2000 Code of Practice for Electrical Maintenance and
supervision of Mineral Insulating oil in Equipment.
(Refer Table.1 for limiting values of various parameters)
IEC 60422/1998 Supervision and maintenance guide for
mineral insulating oils in electrical equipment.

In service Mineral Insulating oils

IS 1866/2000 Code of Practice for Electrical Maintenance and
supervision of Mineral Insulating oil in Equipment.

9
 TRANSFORMER OIL SPECIFICATIONS
IS-335/1993 ( New Oil)
Appearance ------------ Clear and transparent
Density at 29.5C (Max) 0.89 g/cm2
Kinematic Viscosity (Max)
1) at 27C ------------------ 27 cSt
2) at 40C ------------------ Under consideration
IFT at 27C (Min) --------- 0.04 N/m
Flash Point (Min) --------- 140C
Pour Point (Max) --------- -6C
Neutralization Value
1) total Acidity (Max) ---- 0.03 mg KOH/gm
2) Inorganic acidity ------ Nil
Corrosive Sulphur ------- Non-corrosive

Electric Strength (BDV)

1) New unfiltered Oil(Min) 30 KV (rms)
2) After filtration (Min) If the above value is not attained, the oil shall be
filtered to 60 KV (rms)
Dielectric dissipation factor (tan )at 90C(max) 0.002
Specific resistance (Resistivity)
1) at 90C (Min)
2) at 27C (Min) 35 x 1012 ohm-cm
Oxidation Stability 1500 x 1012 ohm-cm
1) Acidity (max)
2) total sludge (max) 0.4 mg KOH/gm
0.1 % by weight
10
 TRANSFORMER OIL SPECIFICATIONS
IS-335/1993 (Ageing characteristics)

Ageing characteristics
a) Resistivity (Min)
1) at 27C 2.5 x 1012 ohm-cm
2) at 90C 0.2 x 1012 ohm-cm
b) Tan at 90C (Max) 0.20
c) Total acidity (Max) 0.05 mg KOH/gm
d) Total sludge (Max) 0.05 % by weight
Presence of Oxidation inhibitor The oil shall contain natural
anti oxidant additives.
Water content 50 ppm
SK value Under consideration

11
 TRANSFORMER OIL SPECIFICATIONS
IS-1866/2000-Recommended Limits of Unused Mineral Oil filled in New Transformer

Property Highest voltage of Equipment (KV)

<72.5 72.5-170 >170

Appearance Clear, Free from sediment and suspended matter

Density at 29.5C (g/cm2),Max 0.89 0.89 0.89

Viscosity at 27C (cSt),Max 27 27 27

Flash Point (C),Min 140 140 140

Pour Point (C),Max -6 -6 -6
Total acidity(mgKOH/gm),Max 0.03 0.03 0.03
Water content (ppm), Max 20 15 10
IFT at 27C (mN/m),Min 35 35 35
Tan at 90C, Max 0.015 0.015 0.010
Resistivity at 90C(x10e12ohm-cm),Min 6 6 6

BDV (KV),Min 40 50 60
 TRANSFORMER OIL SPECIFICATIONS
IS-1866/2000-Violation Limits for in service oils

Property Highest voltage of Equipment (KV)

<72.5 72.5-170 >170
Appearance Clear and without visual contaminations
Water content (ppm), Max No Free water 40 20
BDV (KV),Min 30 40 50
Total acidity(mgKOH/gm),Max 0. 3 0. 3 0. 3
IFT at 27C (mN/m),Min 15 15 15
Resistivity at 27C(x10e12ohm-cm),Min 1 1 1
Resistivity at 90C(x10e12ohm-cm),Min 0.1 0.1 0.1
Tan at 90C, Max 1.0 1.0 0.2
Flash Point (C),Min Maximum decrease of 15C from initial value
Sediment and sludge No sediment or perceptible sludge should be
detected. Results below 0.02% by mass may be
neglected.
 TRANSFORMER OIL SPECIFICATIONS
IS-1866/2000-Frequency of testing

Property Frequency of testing

Appearance In conjunction with other Quantitative tests

Water content After filling or refilling prior to energizing, then after

three and 12 months, subsequently along with DGA

BDV After filling or refilling prior to energizing, then yearly

Total acidity Yearly

IFT After filling or refilling prior to energizing, then yearly

Resistivity After filling or refilling prior to energizing, then yearly

Tan After filling or refilling prior to energizing, then yearly

Flash Point Yearly

Sediment and sludge Yearly

 TRANSFORMER OIL SPECIFICATIONS
IS-1866/2000-Recommended Actions

Property Recommended Actions

Appearance As dictated by other tests

Water content Check Source of water and consider reconditioning

BDV Recondition the oil or alternatively, if more

economical or other tests dictate replace oil

Total acidity Replace or reclaim oil

IFT Replace or reclaim oil
Resistivity Replace or reclaim oil

Tan Replace or reclaim oil

Flash Point Replace the oil, equipment may require inspection

Sediment and sludge Where sediment is detected recondition the oil

15
 TRANSFORMER OIL SPECIFICATIONS
IS-1866/2000-Classification of oils in service.

Group 1: This group contains oils that are in satisfactory condition

for continued use. The frequency can be followed as described
earlier.
Group 2: This group contains oils that requires reconditioning for
further service. (Low BDV and High water content). The frequency
can be followed as described earlier after reconditioning.
Group 3: This group contains oils in poor condition that it can
restore satisfactory properties only after reclaiming. Insulating oils this
group should be reclaimed or replaced depending on economic
considerations.
Group 4: This group contains oils, in such poor state that it is
technically advisable to dispose of them.

16
 Categories of equipment
In order to take account of different user of mineral oil requirements, equipment
has been placed in various categories as O, A, B, C, D, E, F, G

O : 400 KV and above

A : 170 to 400 KV

B : 72.5 to 170 KV

C : transformers <72.5 KV. OCB, switchgear

D : Instrument transformers >170 KV

E : Instrument transformers <170 KV

F : Diverter tanks of on-load tap-changers

G : Circuit breakers <72.5 KKV

17
 PHYSICAL PROPERTIES OF OIL
Physical
Definition Purpose Effects
Properties

To determine the presence of moisture,

Appearanc The oils should be clear, Decreases the Electrical
sediments, carbon, fibers, dirt in the oil
e transparent, and free from strength, IFT value etc.,
which changes the appearance of the oil,
suspended matter.

It measures the weight of oil To ensure that the free water always Since density is inversely
with respect to the mass of remains at the bottom and oil can proportional to temperature ,
Density an equal volume of pure circulate easily due to lighter weight. heat dissipation capacity of
water at the same (Lower the density better the heat the oil decreases with the
temperature transferring capacity ) decrease of temperature

To ensure the mobility of oil at low

Heat removal capacity from
It measures the resistance of temperature since presence of
windings increases with Low
Kinematic the oil to continuous flow sediments, moisture and aging of the oil
viscosity at low temperature
Viscosity without the effect of external increases the viscosity value. (Lower the
and prevent localized
force viscosity better the oil quality & heat
overheating.
transferring capacity)

To determine the presence of polar

It measures the molecular
Interfacial
attractive force between
Tension
water and oil molecule.
Oil with lower IFT reduces
contaminates such as of sludge and
the cooling effect due to
other degrading products as a result of
presence of sludge & oil
oxidation (Higher the IFT better the oil
decay product
quality heat transferring capacity )
 PHYSICAL PROPERTIES OF OIL

Physical
Properti Definition Purpose Effects
es

To determine the self ignition

It is the lowest temperature at temperature of oil for safe operation Low value to the specified
Flash
which oil vapour gets and storing . (Higher the flush point value Risk of fire in
point
ignited. safer the operation & storing transformer
hazards)

To determine the lowest temperature

It is the lowest temperature at at which oil stop flowing due to Low value to the specified
Pour
which oil stops to flow due to solidification. (Lower the flush point value transformer oil stop
point
solidification. safer the operation & storing flowing.
hazards)

Oxidation or degradation products

of insulating materials, fibers of
Solid matter comprises
Sludge & various origins, carbon, and metallic
insoluble in solvent. It can be Reduces the electric strength
Sedimen oxides etc., arise from the conditions
determined by Centrifuge and hinder heat transfer.
ts of service of the equipment. (Good
method
oil must be free form sludge &
sediments )

19
 CHEMICAL PROPERTIES OF OIL
Chemical
Definition Causes Effects
Properties

It is the number of
Neutralizati milligram of Potassium
Oxidation of Corrosion of various parts of transformer,
on Number hydroxide required to
insulating oil due to Lower the electric strength and causes
neutralize completely the
aging Insulation degradation
or Acidity acids present in 1 gm of the
transformer oil.

It the evolution of acid and

Oxidation sludge formation tendency Metal corrosion which minimizes the life of the
Stability of new mineral oil due to Moisture transformer
oxidation

It measures in ppm the By breathing Decreases electric strength (BDV)

Moisture presence of moisture in action, Electric dissipation factor (Tan Delta)
the oil Chemical reaction Resistivity

H2 = Partial discharge
It measures of dissolved Thermal H2,CH4 = Low energy discharge
Dissolved
Gases produced in the oil degradation Arcing, CH4 = Low temp hot spot
Gases
due to decomposition of oil Partial discharge H2, C2H2 = Arcing
C2H4 = High temp
 ELECTRICAL PROPERTIES OF OIL
Electrical
Definition Causes Effects
Properties

Solid impurities
Dielectric It is the minimum voltage that oil can Higher the value, Higher
Water content , Fiber
Strength withstand due to its dielectric strength the purity
Conductive particles

The resistivity of a liquid is a measure of its

electrical insulating properties under
prescribed conditions. High resistively Moisture , Acidity Higher the value , better
Resisti
reflects low content of free ions and ion- Solid contamination the condition of the oil
vity
forming particles and normally indicates a
low count ratio of conductive contaminants.

C Capacitive current
B Actual current

Dielectric
= (90-) Increased value causes in
Dissipation Soluble varnishes, resins ,
increase in temperature,
Factor / O (Applied voltage V) A Moisture
increase in corrosion
Tan Delta
PF = Cos = Cos ((90-) = Sin = Tan
Heat dissipation in the insulator due to leakage
Current = OA x OB Tan (Watt)
Since heat dissipation in the insulator increases
With increase of PF / Cos / Tan - this factor is
known as dielectric dissipation factor and should be
as low as possible
TRANSFORMER OIL TEST PACKAGE
(As per IS: 1866)

22
 Inference of the oil test result
1. Determination of moisture in the solid insulation
( on the basis of Ooman graph)

2. Decision of hot oil circulation / drying out for improving dielectric

properties by removing moisture from oil & solid insulation
( On the basis of Water PPM,, BDV)

3. Decision of providing air bellow at conservator, Silica jel breather

leak arrester for preventing air ingression
( On the basis of presence of oxygen )

4. Decision of discarding oil for loosing its dielectric or cooling

properties
( On the basis of Resistivity, Tan delta ,BDV, IFT , Acidity , Colour)
5. Tracing of internal fault due to thermal and electrical stress
(On the basis of DGA)
6. Aging status of the solid insulation
( On the basis of Furna Analysis ,CO2 / CO ratio)
24
 OIL QUALITY WITH COLOUR

Good Proposition Marginal Bad Very bad Extremely Discarded

oil A oil oil oil oil bad oil oil

Oils in disastrous condition

Pale Yellow Bright Amber Brown Dark Black

yellow yellow brown
 ACIDITY OR NEUTRALISATION NUMBER(NN)
Acids in the oil originate from decomposition/oxidation of oil.
These organic acids are detrimental to the insulation system and can induce corrosion
inside the transformer when water is present.
An increase in the acidity is an indication of the rate of deterioration of the oil with SLUDGE
.
The acidity of oil in a transformer should never be allowed to exceed 0.25mg KOH/g oil.

INTERFACIAL TENSION(IFT)
The Interfacial Tension (IFT) measures the tension at the interface between two liquid (oil
and water) which do not mix and is expressed in dyne/cm.
The test is sensitive to the presence of oil decay products and soluble polar contaminants
from solid insulating materials.
Good oil will have an interfacial tension of between 40 and 50 dynes/cm.
Oil oxidation products lower the interfacial tension and have an affinity for both water
(hydrophilic) and oil.
This affinity for both substances lowers the IFT. The greater the concentration of
contaminants, the lower the IFT, with a badly deteriorated oil having an IFT of 18 dynes/cm or
less.
 Determination of oil quality based on IFT &
NN
IFT NN MIN = IFT/NN Colour Oil Quality & Observations
Pale Very Good
30 - 45 0.00 0.10 300 - 1500
Yellow (provides all the required function)
Good(provides all the required function , a
27.1 29.9 0.05 0.10 271 - 600 Yellow drop in IFT to 27.0 may signal the beginning of
sludge & sediment)
Acceptable
Bright (not providing proper cooling and winding
24 27 0.11 0.15 160 - 318 protection. Organic acids are beginning to coat
Yellow winding insulation; sludge in insulation voids is
highly probable.)
Bad
(sludge has already been deposited in and on
transformer parts in almost 100 percent of
18.0 - 23.9 0.16 - 0.40 45 - 159 Amber these units. Insulation damage and reduced
cooling efficiency with higher operating
temperatures characterize the Very Bad and
Extremely Bad categories.

14.0 - 17.9 0.41 - 0.65 22 - 44 Brown Very Bad

Dark
9.0 - 13.9 0.66 - 1.50 6 - 21 Extremely Bad oil
Brown

300 1500
Very Good
271 600
Good
6 22 45 160 318
Acceptable / Bad / Very Bad / Extremely bad
Interfacial Tension, Acid Number, Years in
Service
Condition of paper with increase of acid content in oil
 Moisture in transformer oil
1.Moisture may be present in four possible forms
1.Free water That is water that has settled out of the oil in a separate layer. It is this
water which is indicated by a lower IR value of the transformer.
2.Emulsified water Water that is suspended in the oil and has not yet settled out into
free water . It is indicated by caramel colour oil. A high Tan Delta value indicates the
possible presence of this suspended water trapped in oil decay products.
3.Water in solution It remain dissolved in the oil.
4.Chemically bound water It remains chemically attached to the insulating paper
and it is released when oxidized.

2. Movement of Moisture between oil and paper insulation

Water solubility With the increase of temperature ,water saturation level of oil
Temp
level in TR oil
increases and transformer oil absorbs moisture from the paper
0 Deg C 22 ppm insulation till its gets saturated .
10 Deg C 36 ppm
Water dissolved in Water
20 Deg C 55 ppm Moisture movement
oil (High Temp) available
30 Deg C 83 ppm
in the
40 Deg C 121 ppm
paper
50 Deg C 173 ppm Water dissolved in Moisture movement insulation
60 Deg C 242 ppm oil (Low temp)
70 Deg C 331 ppm
With the decrease of temperature ,water saturation level of oil
80 Deg C 446 ppm
decreases and transformer oil exudes moisture which is absorbed by
90 Deg C 592 ppm paper and subsequently deposited as free water at the insulation layers
100 Deg C 772 ppm and bottom of the transformer .
 Moisture in transformer oil Relative saturation
Water content in oil sample taken at 60 Deg C 45 ppm
(as per lab analysis)
Water solubility level in oil at 60 Deg C 242 ppm
(as per graph)
Relative saturation (RS) at 60 Dec C (45/242)x100 = 18.36%
Relative saturation (RS) indicates migration of moisture quantity between solid insulation and oil
during operation

Condition of solid insulation based on relative saturation (RS) of oil as per IEEE
62:1995 (B6)
Percent saturation water Condition of cellulosic insulation
in oil adjusted to 20C

05% Dry insulation

Moderate wet, low numbers indicate fairly dry to moderate levels of
6 20 % water in the insulation. Values toward the upper limit indicate
moderately wet insulation
21 30 % Wet insulation

> 30 % Extremely wet insulation

 Moisture in transformer oil
3. Moisture Distribution
The internal moisture distributed not
uniformly.
When the transformer is energized water is
attracted to areas of strong electric fields,
since water is a polar liquid having a high
permittivity or dielectric constant.
It also begins to migrate to the coolest part
of the transformer . This location is normally
the insulation in the lower one-third of the
winding
Paper insulation has a much greater affinity
for water than does oil. Thus, insulation acts
just like blotting paper or paper towels; it
soaks up water superbly. The water will
distribute itself unequally, with much more
water being in the paper than in the oil.

33
 Moisture in transformer oil
4. Damages caused by moisture
Moisture in oil reduces the insulating ability (BDV) of the oil .
This may occur from the following events:
During periods of high load and high ambient temperatures, oil absorbs the moisture from
the paper that may decrease BDV of the oil and causes dielectric breakdowns.
With sudden high loads, water can boil off conductor surfaces and the vapour bubbles can
cause dielectric failures as they rise to the top.
During the cool-down period after high load, the relative saturation of oil will increase. At its
extreme at 100% relative saturation, water will precipitate out and greatly reduce the dielectric
strength of the oil.
Moisture in paper causes the following destructive effects :
Moisture and oxygen cause paper insulation to decay much faster and to form acids, metal
soaps, sludge, and more moisture.
Sludge settles on windings and inside the structure, causing transformer cooling to be less
efficient. Acids cause an increase in the rate of decay, which forms more acid, sludge, and
moisture at a faster rate
Expansion of the paper insulation, altering the mechanical pressure of the transformer
clamping system.
Loss of insulating ability (Dielectric Breakdown Voltage)
Increased corrosion of the core and tank
Progressive consumption of oil additives
34
Determination of moisture accumulation in solid
insulation through water ppm in oil

35
 Calculation of moisture accumulation in solid
insulation through water ppm in oil

Parameters Formula Value

Oil capacity of Transformer V 80,000 Liters
Density of oil D 0.86 Kg / Liters
Mass of the oil M=VxD 68800 Kg
Mass of the solid insulation SM = M x 0.1 6880 Kg
Water ppm in oil at 60 Deg C
( Lab test ) WCO 20 ppm

Corresponding water content

in solid insulation WCP 2.2%
( as per the graph)

Approximate weight of water

in solid insulation SM X WCP /100 150 Kg

36
Effects of moisture accumulation in the
solid insulation
 Limit value : Water ppm in transformer oil

No free (< 72 Transformer)

water
New oil

(72 170 KV Transformer)

(>170 KV Transformer)

Dry Oil

1. The presence of water molecule in the oil is measured by Karl Fisher Titration
methods.
2. The limit value of water ppm ( part per million) need to be maintained as per
the guideline of IS 335 shown in the above graph 38
 Effect on presence of polar particles in Transformer oil

High AC Voltage

+ - + + -
+ -
-
+ + - -
+ + + -
- -
+ +
+ + -
+ -
+ - -
+ + +
+ +
Charging Charging
current current
Leakage current

The insulating properties of transformer oil decreases with the increase of soluble
polar particles such as water molecule, sludge & sediments, varnish, resin etc, in
the oil.
The polar particle present in the oil gets ionized under the influence of high AC
voltage. These ionized particles gets attracted by the opposite polarity causing
the flow of leakage current through the oil (insulator). The intensity of the leakage
current increase with increase of concentration of polar particulates in the oil.
Because of this reasons BDV, Resistivity & Tan delta value of the transformer oil
gets affected due to presence of polar particles such as water molecule, sludge &
sediments, varnish, resin etc in the oil.
 Limit value : Break Down Voltage in KV

> 170KV Transformer

72.5 -170 KV Transformer

< 72.5 KV Transformer

BDV of oil is determined by applying AC
voltage across a gap of 2.5mm ,filled with
transformer oil to be tested .
The voltage at which the spark is observed
between the gap , is the BDV of the oil.
Average of six such BDV value is taken as
the actual BDV of the oil.

BDV value of transformer oil mainly depends on water ppm in the oil and it decreases with
the increase of water ppm in oil .In such case BDV of oil is improved by reducing water ppm
in oil through filtration .
BDV of oil may also decrease due to low resistivity of oil caused by degradation of oil or
contamination of oil with soluble polar particles. In such case oil needs to be replaced after
confirming low resistivity & IFT value and high tan delta & acidity value with colour of oil.
 Resistivity
As transformer oil is act as pure insulator, its resistance ( R ) should be is
always as high possible.
Resistance R = x L/A where L = length & A = Area of the oil of the oil
column and = Resistivity i.e. Resistance of per unit length of oil.
Hence to maintain high resistance ,resistivity of the oil should be as high as
possible or conductivity should be as low as possible.
With the increased concentration of polar particle in the oil, the conductivity
gets increased proportionally due to flow of leakage current.
Hence low Resistivity indicates :
1.Contamination of oil with polar particles produced by oxidation of oil due to
overheating , moisture & oxygen or aging of oil.
2.In such case oil replacement is required after confirming low IFT value, high
tan delta & acidity value with colour of oil.
3.Some time excess moisture contamination also can reduce resistivity. It is
confirmed with low BDV. In such case oil filtration can improve the oil resistivity .
4.Because of covalent, oil also shows low resistivity at increased temperature.
Limit value (at 90 Deg C) : Resistivity

(Very Good)

Resistivity is measured by
(Good) applying 500 V DC voltage
across the oil sample after
heating up the sample at
(Min) 90 Deg C which is the
maximum allowable
operating temperature of
transformer
 DDF / Tan Delta
OA = Applied voltage,
B OC = Charging current,
C OB = Total current ( Charging current + Leakage
current)
charging current

Charging current = OB Sin ,

Capacitor

Leakage current = OB Cos ,

PF = Cos = Cos ((90-) = Sin = Tan ( since
= (90-) is very small)
Dielectric leakage current = OB Cos = OB
Applied Voltage
O A Tan
Heat dissipation in the oil due to leakage current
Being a pure insulator, transformer oil = V x I x like
behaves PF dielectric of a capacitor under high AC
= OAatx90
voltage and it absorb charging current OBleading
0
Cos with
= OA x OB Tan
respect applied
to the (Watt) voltage
and maintain the PF angle of the insulator at 90 Deg.
With the increase of concentration of soluble polar particle in the oil, PF angle ()
decrease and angle increases due to flow of leakage current. As result of this Tan delta
value of the Transformer oil gets increased .
Since oil is a covalent compound, its resistivity decrease at increased temperature and
conductivity increases. As a result of this Tan Delta value is also increased with
temperature.
Since heat dissipation in the insulator increases with increase of PF / Cos / Tan - this
factor is known as dielectric dissipation factor DDF and should be as low as possible.
Inferences :
1.Increase in Tan delta value indicates the contamination of oil with soluble ionized particles
such as water
molecule, sludge & sediments, varnish, resin etc or due to loosing of insulating
 Limit value ( At 90 Deg C) : Tan Delta
Angle value % Value Max < 72.5 KV
Transformer
TAN 0.000 AB/OB 0.000
Ideal Max > 72.5 KV
0 0.0 Deg OC 0.% of OB Transformer
TAN 1 0.002 AB/OB 0.002
Normal
1 0.1 Deg OC 0.2 % OB
Maximum TAN 2 0.200 AB/OB 0.200
( > 72.5 KV
Transformer) 2 11.3 Deg OC 20 % OB
Normal
Maximum TAN 3 1.000 AB/OB 1.000
(< 72.5 KV
Transformer) 3 45 Deg OC 100 % OB

Charging current

Total current
Tan delta value is measured
A B by applying 1000 V AC
1 voltage across the oil
sample after heating up the
sample at 90 Deg C which
2 is the maximum allowable
3 operating temperature of
transformer
O C Leakage current
 Effect of temperature on oil parameters

Res
istiv
ity
Resistivity & tan delta cm
(indicates deteriorating status of the %
D elta
dielectric due to oxidation & Tan
contaminations of oil)

200 C 900 C
Presence of the Polar
particles / Increase in
temperature

BDV
Water ppm & bdv in K
V
(indicates present status of the
dielectric due to contaminations of
oil with water )
200 C 900 C
Presence of dissolved & free water /
Increase in temperature
46
 Transformer oil processing

RECONDITIONING
( Mechanical process)
for oil having higher water ppm
OFF Line
Removal of
process Circulating hot oil through
Free & dissolved water,
filter & vacuum chamber
Dissolved combustible gas
in FILTER MACHINE
Solid particulate matter

ON Line
process Circulating oil
Removal of
continuously through
Free & dissolved water,
cartridge banks filled with
molecular sieve

RECLAIMING
( Chemical process)
for oil having higher acid number
and lower IFT

Removal of - OFF Line

Sludge & sediments process Circulating oil
(Polar, Acidic & Colloidal continuously through fuller
materials) earth column
 Off line reconditioning through filter machine

Vacuum
Pump

Vacuum Transformer
Chamber
Fine Tank filled
Gear
Filter Pump
with oil

Automatic Magnetic
Heater Filter

Transformer oil is sucked from the bottom of the tank and passes through the magnetic
filter where metallic particles are removed and then it is heated up to 60 Deg C with the
help of automatic heaters. Heated oil is then pushed into a vacuum chamber where it is
made to fall in droplets forms for increasing surface area and timing so that dissolved water
in the oil gets evaporated ( under 760mm of vacuum, water gets evaporated at 40 Deg C)
and extracted by vacuum pump along with other dissolved gases. Then the degassed oil is
passed through fine filter where particles of size 3 to 5 micron is removed and pushed into
the top of the tank through gear pump. This process is going on continuously till the oil
parameters - water ppm, BDV, Resistivity & Tan Delta are achieved.
 On line reconditioning through molecular sieve

Molecular sieve material

When transformer is in service, moisture available in the paper insulation is absorbed by oil
due to increase in water saturation level as result of oil temperature.
In such condition if the oil is circulated through the water absorbing cartridge filled with
molecular sieve material, moisture present in the oil gets absorbed by the sieve.
As a result of this process, moisture available in the paper is extracted by sieve through the
media of transformer oil.
This process is applicable only when the transformer is in service .
49
Oil Reclaiming / Regeneration process as per IEC 60422

Oil reclamation remove oxidation inhibitors. Additives

shall be replaced in the reclaimed oil after the reclaiming
process and before the equipment is re-energized The
most widely used additives are 2,6-di-tert-butyl-
paracresol (DBPC) and 2,6-di-tert-butyl-phenol (DBP).
51
 Dissolved Gas Analysis (DGA)
Due to normal aging or internal faults different types of gases
are generated which subsequently dissolve in oil.

Hence dissolved gas analysis of the transformer oil gives indication of

the nature of fault inside the transformer.

A sudden increase in key gases and the rate of gas production is more
important in evaluating a transformer than the accumulated amount of gas

The advantages of dissolved gas analysis are -

52
 Generation of gases
At elevated temperature between 500K and 200K, following reaction
takes place and gases are produced which remains dissolved in the oil.
C (Solid) +2H2 (Gas) CH4 (Gas)
2CH4 (Gas) + 2H2 (Gas) C2H4 (Gas) + 2H2 (Gas)
C2H4 (Gas) C2H2 (Gas) + H2 (Gas)
C2H4 (Gas) + H2 (Gas) C2H6 (Gas)
C2H2 (Gas) + 2H2 (Gas) C2H6 (Gas)

Types of gases
1. Hydrocarbons 2. Carbon oxides 3. Non fault gases
& Hydrogen Carbon CO Nitrogen N2
Methane CH4 monoxide
Oxygen O2
Ethane C2H6 Carbon CO2
dioxide
Ethylene C2H4
Acetylene C2H2
Hydrogen H2

53
 Types of Faults & generation of gases

TYPES OF FAULTS

THERMAL FAULTS ELECTRICAL FAULTS

1. Low temperature heating 1. Corona

OIL CELLULOSE OIL CELLULOSE
CH4,C2H6 CO2,(CO) H2 H2,CO,CO2

2. High temperature heating 2. Arcing

OIL CELLULOSE H2,C2H2,(CH4,C2H6,C2H4)
C2H4,H2,(CH4,C2H6) CO,(CO2)

54
 Normal Operation & aging
Over loading
Over heatingof oil and paper

Failure of Pumps, Fans

Improper cooling

Misdirection flow of cooling oil

Types of Faults & generation of gases

due to looseness of oil directing

Thermal Fault

bafe
Blocking of oil duct by sludge
present in the oil
Humming due to looseness of
windings that causes winding
heating as result of friction
Formation of Key
gases in the oil as
Bad leads connection / Poor
contact in the tap changer
result of
decomposition of
Hot spot - causing overheating of oil & paper
oil and burning of
paper insulation.
Discharging of static electrical
charges that build up on shields
or core and structures which
are not properly grounded
Electrical arcing between
Deteriorated /damaged insulation
Electrical Fault

windings and ground, between

windings of different potential,
or in areas of different
potential on the same winding,
Arcing in the transformer due
to short circuit / ground fault
Arcing in the transformer due
to voltage surge such as a
lightning strike or switching
surge
Conditions
External Accumulation of
Exposure of oil to the environment due to oil
environmental
leak and not providing air bellows & silica jel
gases - O2, CO2,
breather in the conservator
N2, H2O in the oil
 Acceptance limits (1)
CIGRE ELECTRA ALSTHOM
Dissolved Gases ERDA
(1976) (1978) (1980)
H2 ( Hydrogen) 235 28.6 200 100
CH4 ( Methane) 100 42.2 200 200
C2H2 ( Acetylene) 330 - 200 30
C2H4 (Ethylene) 145 74.6 200 300
C2H6 (Ethane) 270 85.6 200 200
CO (Carbon Monoxide) 670 289 1000 -
CO2 (Carbon Dioxide) 4250 3771 10000 -
 Acceptance limits (2)
CIGRE CPRI CBIP

Gases
0-5 6 - 10 11-15 0-4 4 10 > 10 <4 4-10 > 10
Yrs Yrs Yrs Yrs Yrs Yrs Yrs Yrs Yrs

H2 100 200 300 150 300 500 100/150 200/300 300/400

CH4 60 200 200 30 80 130 50/70 100/150 200/300

C2H2 40 200 300 15 30 40 20/30 30/50 100/150

C2H4 80 300 300 30 50 150 100/150 150/200 200/400

C2H6 40 100 200 30 50 110 30/50 100/150 800/1000

CO 700 700 700 300 500 700 200/300 400/500 600/700

CO2 8000 9000 9000 4000 - 10000 3000/5000 4000/5000 9000/12000

58
 Acceptance limits (3)

as per IS: 9434 / 1992 , IS: 10593 / 1983 & IEC 599 1978

LESS THAN FOUR MORE THAN 10

4-10 YEARS IN
GAS YEARS IN SERVICE YEARS IN SERVICE
SERVICE (PPM)
(PPM) (PPM)

HYDROGEN 100-150 200-300 200-300

METHANE 50-70 100-150 200-300

ACETYLENE 20-30 30-50 100-150

ETHYLENE 100-150 150-200 200-300

ETHANE 30-50 100-150 800-1000

CARBON
200-300 400-500 600-700
MONOXIDE

CARBON DIOXIDE 3000-3500 4000-5000 9000-12000

59
 Fault identification (1) - by Key gas methods
Type of faults Dissolved Gasses

Over heating of solid insulating materials Key Gas - Carbon mono oxide
(Insulating papers, Cloths, Parma Wood , Press Board ) (CO & CO2)

Key Gas Ethylene

Overheating of oil
(CH4 ,C2H4 & H2)

Key Gas Acetylene

Arcing in oil
(H2 ,C2H2)

Key Gas - Carbon mono oxide

Overheating of Paper and Oil
(CO, CO2, CH4, C2H4 & H2)

Key Gas Acetylene

Arcing of Oil and Paper
(C2H2, H2, CO, CO2)

Key gas Hydrogen

Corona Discharge
(H2)

Key gas Hydrogen

Partial Discharge
(H2)

60
Fault identification (2) - by gas ratio methods

61
 Significance of acetylene (C2H2) in oil

Generation of acetylene (C2H2) of any amount above a few ppm

indicates high-energy arcing.
Trace amounts (a few ppm) can be generated by a very hot thermal fault
(500 Deg C or higher).
One time arc, caused by a nearby lightning strike or a high voltage
surge, can also generate a small amount of C2H2.
If C2H2 is found in the DGA, oil samples should be taken weekly or even
daily to determine if additional C2H2 is being generated.
If no additional acetylene is found and the level is below the acceptable
limits, the transformer may continue in service.
However, if acetylene continues to increase, the transformer has an
active high-energy internal arc and should be taken out of service
immediately.
Further operation is extremely hazardous and may result in explosive
catastrophic failure of the tank, spreading flaming oil over a large area.
62
 Significance of CO/CO2 ratio in oil
If there is a sudden increase in H2 with only carbon monoxide (CO)
and carbon dioxide (CO2) and little or none of the hydrocarbon gases,
CO2/CO ratio indicates the degradation of cellulose insulation due to
overheating.
With normal loading and temperatures, the CO2 / CO ratio is found to
be between 7 to 20 .
If H2, CH4, and C2H6 increase significantly with CO2/CO ratio less
than 5 , it indicates the probability of problem.
If the ratio is 3 or under, severe and rapid deterioration of cellulose is
certainly occurring
The ratio should be based on the gas generation of both CO2 and CO
between successive DGAs and not on accumulated total CO2 and CO gas
levels
Extreme overheating from loss of cooling or plugged oil passages will
produce a CO2/CO ratio around 2 or 3 along with increasing Furans

63
Significance of atmospheric gases (O2 & N2) in
oil
Oxygen may be present inside the transformer due to ingression of air
through breather, leaks and air packets tapped in the winding.
The oxygen reacts on the cellulose of the insulating paper and leads to the
formation of organic acids, which dissolved in oil and consequently form sludge.
This sludge blocks the free circulation of the oil and thus increases the
operating temperature.
The presence of sludge in transformer oil reduces the resistively and
increases the tan delta of the oil.
Many experts and organizations, including EPRI, believe that presence of
oxygen above 2,000 ppm, in the oil greatly accelerates paper deterioration with
moisture above safe levels.
It is recommended that if oxygen reaches 10,000 ppm in the DGA, the oil
should be de-gassed and new oxygen inhibitor needs to be installed.

Nitrogen may be present inside the transformer due to leaking of N2 filled

bellow provided in the conservator tank air and exposure of oil to atmosphere
through leaks , breathers etc.
Presence of nitrogen in the air indicates the leaking of conservator bellow or
exposure of oil to the atmosphere. 64
 Fault Analysis ( 1) - by Roger methods
CH4 C2H6 C2H4 C2H2
H2 CH4 C2H6 C2H4 Faults

0.1 0 0 0 Partial discharge

0 0 0 0 Normal deterioration
1 0 0 0 Over heating >150 Deg C
1 1 0 0 Over heating 150 200 Deg C
0 1 0 0 Over heating 200 300 Deg C
0 1 1 0 General condition of overheating
1 0 1 0 Circulating current / Overheating of joints
0 0 0 1 Flash over without power flow
0 1 0 1 Current breaking through tap changer
0 0 1 1 Arc with power flow

Ratio less than 0.1 is designated as 0

Ratio greater 1 is designated as 1

65
 Fault Analysis (2) - by IEC 599 and CBIP
methods
C2H2 CH4 C2H4
Ratio of the dissolved gases
C2H4 H2 C2H6
0 1 0 Ratio less than 0.1
1 0 0 Ratio from 0.1 to 1.0
1 2 1 Ratio from 1.0 to 3.0
2 2 2 Ratio greater than 3
Fault detection chart
C2H2 CH4 C2H4
Faults & Causes
C2H4 H2 C2H6
0 0 0 No fault Normal aging
Partial discharge of low intensity . Discharge in gas filled cavities,
0 1 0 resulting from incomplete impregnation / super saturation / cavitations of high
humidity
Partial discharge of high intensity As above but leading to tracking /
1 1 0
perforation of solid insulation
Discharge of low energy Continuous sparking in oil, between bad
1 to 2 0 1 to 2 connection of different potential or to floating potential. Break down of oil
between solid material
Discharge of high energy Discharges with power follow through. Arcing /
1 0 2 breakdown of oil between windings or coils or between coils & earth , tap
changer breaking current
Thermal fault of low temp (150 Deg C) General overheating of insulated
0 0 1
conductor
Thermal fault of low temp (150 to 300 Deg C) Local over heating of the
0 2 0 core due to concentrations o f flux , increasing hot spot temperature, varying
from small hot spots in core, shorting links in core
Thermal fault of medium temp (300 to 700 Deg C) Over heating of
0 2 1 copper due to eddy current, bad contracts / joints, circulating current between
core and tank
Thermal fault of high temp (more than 700 Deg C) Over heating of
0 2 2 copper due to eddy current, bad contracts / joints, circulating current between
core and tank 66
 fault analysis (3) by IEEE (Std). C57-104

Condition 1: Transformer is operating satisfactorily.

Condition 2: A fault may be present. Take DGA samples at least often
enough to calculate the amount of gas generation per day for each gas.
Condition 3: A fault or faults are probably present. Take DGA samples at
least often enough to calculate the amount of gas generation per day for
each gas.
Condition 4: TDCG within this range indicates excessive decomposition of
67
cellulose insulation and/or oil. Continued operation could result in failure
of the transformer.
Recommendations IEEE (Std). C57-104

68
 Fault analysis (4) - by DUVAL triangle
In order to display a DGA result in the Triangle, one must start with the
concentrations of the three gases, (CH4) = A, (C2H4) = B and (C2H2) = C, in ppm.
Calculate the sum of these three values: (CH4 + C2H4 + C2H2) = S, in ppm,
Calculate the relative proportion of the three gases, in %:
X = % CH4 = 100 (A/S),
Y = % C2H4 = 100 (B/S),
Z = % C2H2 = 100 (C/S).
Plot X, Y and Z in the DUVAL Triangle
Point of intersection will be laying in a particular zone indicated in the triangle
Interpret the reason from the DUVAL table

This special graph for Duval triangle can be

obtained by sending email to duvalm@ireq.ca.

69
Duval Triangle

70
 Classification of faults- Duval method

Faults

Thermal Type Electrical Type

T1 PD
Thermal Fault Partial Discharge
t<300 Deg C

T2
T2 Thermal Fault
Thermal Fault 300<t<700 Deg C
300<t<700 Deg C

T3 T3
Thermal Fault Thermal Fault
t>700 Deg C t>700 Deg C

71
Duval Table for interpretation

72
73
74
 solid insulation
Paper and cloth used in transformer is known as solid insulation.

The main constituent of paper and cloth is fibrous material known as Cellulose
Cellulose is an organic compound whose molecule is made up of a long chain of
glucose monomers (rings), typically numbering between 1000 and 1400

Glucos Glucos Glucos

e e e

With breaking down of cellulose chain, the number of glucose ring decreases in
the cellulose molecule
Degree of polymerization (DP) is the average number of glucose rings in the
cellulose molecule and DP values state the aging status of the insulating paper
DP value > 900 indicates good paper whereas DP value < 200 indicates bad
papers.

75
 Reasons for degradation of solid insulation

1. Thermal degradation ( Heat) :

Heat produced during the operation of transformer breakdowns the glucose
monomers in the cellulose molecule. Because of this, the chain length of
cellulose gets reduced and free glucose molecules, moisture, CO, CO2 gases
and organic acids are produced. Because of this reason overheating of
transformer leads to reduction of its life

HEAT
Cellulose Glucose molecule +H2O+CO+CO2

2. Hydrolytic degradation (Moisture):

Water and acid separate the bonds between the glucose units in cellulose chain
and produce free glucose. Because of this reason only after careful drying of
insulating paper, transformers are put into service

76
Aging process of transformers solid insulation

Moisture Oxygen Heat

Oil impregnated solid insulation

Chemical degradation of solid insulation (Paper)

And production of Acids, Peroxides, O2, H2O, Furan contents

Dielectric degradation Mechanical degradation

Conduction & Ionization (Partial Discharge)

Glow discharge (Corona)

Short Lighting /Switching

circuit Insulation Failure impulse
77
78
 DP values and aging of transformer
Age (Yrs) DP Values
DP Values
0 >1000

1 975

12 700

22 450

25 390
Years
35 125

79
Interpretation of DP values

80
 Furan analysis
The mechanical properties of insulating paper can be established by direct
measurement of its tensile strength or degree of polymerization (DP).
Direct measurement of these properties is not practical for in-service transformers since
it requires removal of a few strips of paper from suspect sites.
This procedure can conveniently be carried out during transformer repairs. The results of
these tests will be a deciding factor in rebuilding or scrapping a transformer.
Since it is usually not practical (and often dangerous to the transformer) to obtain a
paper sample from a de-energised, in-service transformer an alternative method has been
found.
When a cellulose molecule de-polymerises (breaks into smaller lengths or ring
structures), a chemical compound known as a furan is formed.
By measuring the quantity and types of furans present in a transformer oil sample, the
paper insulation overall DP can be inferred with a high degree of confidence.
The types and concentration of furans in an oil sample can also indicate abnormal stress
in a transformer, whether intense, short duration overheating or prolonged, general
overheating.
Furan analysis can be used to confirm Dissolved Gas Analysis where carbon monoxide
present indicates problems with solid insulation
81
Inference of the chemical compounds obtained during
furan analysis of transformer oil

82
 Aging & Furfural in oil BHEL study
Age Furfural
(Years) (mg/Ltr)
2 0.01
5 0.02
6 0.03
7 0.04
8 0.05
9 0.06
10 0.08
11 0.10
12 0.12
13 0.15
14 0.18
15 0.21
16 0.24
17 0.30
18 0.37
19 0.48
20 0.60
21 0.75
22 0.90
23 1.05
24 1.20
25 1.35
26 1.80
27 2.25
28 2.70
29 3.15
30 3.65 83
Relation between furan content in oil and DP values
of solid insulation

84
Limiting values for furan analysis

85
 conversion table I
1% = 10,000ppm 1ppm = 0.0001%
Percent (%) ppm ppm Percent (%) 60 ppm 0.0060%
0.0000% 0 ppm 0 ppm 0.0000% 70 ppm 0.0070%
0.0001% 1 ppm 1 ppm 0.0001% 80 ppm 0.0080%
0.0010% 10 ppm 2 ppm 0.0002% 90 ppm 0.0090%
0.0100% 100 ppm 3 ppm 0.0003% 100 ppm 0.0100%
0.1000% 1000 ppm 4 ppm 0.0004% 200 ppm 0.0200%
1.0000% 10000 ppm 5 ppm 0.0005% 300 ppm 0.0300%
2.0000% 20000 ppm 400 ppm 0.0400%
6 ppm 0.0006%
3.0000% 30000 ppm
7 ppm 0.0007% 500 ppm 0.0500%
4.0000% 40000 ppm
8 ppm 0.0008% 600 ppm 0.0600%
5.0000% 50000 ppm
9 ppm 0.0009% 700 ppm 0.0700%
6.0000% 60000 ppm
10 ppm 0.0010% 800 ppm 0.0800%
7.0000% 70000 ppm
20 ppm 0.0020% 900 ppm 0.0900%
8.0000% 80000 ppm
30 ppm 0.0030% 1000 ppm 0.1000%
9.0000% 90000 ppm
40 ppm 0.0040% 2000 ppm 0.2000%
10.0000% 100000 ppm
20.0000% 200000 ppm 50 ppm 0.0050% 3000 ppm 0.3000%
30.0000% 300000 ppm 4000 ppm 0.4000%
40.0000% 400000 ppm 5000 ppm 0.5000%
50.0000% 500000 ppm 6000 ppm 0.6000%
60.0000% 600000 ppm 7000 ppm 0.7000%
70.0000% 700000 ppm 8000 ppm 0.8000%
80.0000% 800000 ppm 9000 ppm 0.9000%
90.0000% 900000 ppm 10000 ppm 1.0000%
100.0000% 1000000 ppm 100000 ppm 10.0000%86
1000000 ppm 100.0000%
 conversion table II
Torr mm Hg Atm. PSI kg/sq.cm kPa mBar
760 760 1.00 14.69 1.03 101.31 1013.3
600 600 0.79 11.66 0.82 79.98 800.0
500 500 0.66 9.67 0.68 66.65 666.7
400 400 0.53 7.68 0.54 53.32 533.3
300 300 0.39 5.83 0.41 39.99 400.0
200 200 0.26 3.84 0.27 26.66 266.7
100 100 0.13 1.99 0.14 13.33 133.3
80 80 0.11 1.56 0.11 10.66 106.7
60 60 0.08 1.13 0.08 8.00 80.0
40 40 0.05 0.711 0.05 5.33 53.3
20 20 0.03 0.426 0.03 2.67 26.7
10 10 0.01 0.142 0.01 1.33 13.3
5 5 0.01 0.142 0.01 0.67 6.7
2.5 2.5 0.00 0.00 0.00 0.33 3.3
1 1 0.00 0.00 0.00 0.13 1.3
87
 conversion table III

Water Vacuum
Boiling Gauge
point (Deg Reading
C) (mmHg)
0 755.42
10 750.79
20 742.47
30 728.18
40 704.68
50 667.50
60 610.62
70 526.30
80 404.24
90 234.24
92 193.01
94 149.10
96 102.38
98 52.73
100 0.00
88
 conversion table III

TR Oil Water solubility

Temp level in TR oil

0 Deg C 22 ppm
10 Deg C 36 ppm
20 Deg C 55 ppm
30 Deg C 83 ppm
40 Deg C 121 ppm
50 Deg C 173 ppm
60 Deg C 242 ppm
70 Deg C 331 ppm
80 Deg C 446 ppm
90 Deg C 592 ppm
100 Deg C 772 ppm