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Transformer Oils
J. Sabau
INSOIL Canada, Ltd.
Abstract
The reclamation of aged transformer oils by Fullers Earth has long been practised by the electrical power industry. Although the major analytical properties of processed oil such as the dissipation factor at lOOOC, the interfacial tension (IFT) and the total acid number (TAN) improve to the level of new oils, the quality of reclaimed oil is considered to be doubtful. Consequently, conditionbased maintenance planners believe that purified liquid insulation can never regain the performance of new oil. This mistrust is fuelled by the fact that the existing testing procedures are not capable of establishing a quantitative relationship between oxidation stability and gassing tendency under electrical stress determined in laboratory conditions and the performance of oil in real life. Over the past years, the co-operation between certain state of the art instrument manufacturers and enhanced testing procedure developers has provided the electrical power industry with the means of eliminating this deficiency. This paper intends to show that the quality of properly reclaimed aged oils can successfully compete with that of new oils. Thus, in addition to extending the life cycle of a non-renewable resource, the on-line reclamation of liquid insulation might also prevent the premature ageing of paper insulation. Key Words. Aged transformer oil, Reclamation technology, Dissolved decay products, Particle counting, Oxidation test, Gassing tendency.
inhibitors has proven to be only a partial solution because, rather than preventing the decay of oil, the process is only retarded. The endeavours of service providers to control the damage by reclaiming the aged oils are currently hampered by missing testing procedures capable of reliably determining its effectiveness. One example is ASTM Standard Test Method for Oxidation Stability of Mineral Insulating Oil, Designation D 2440-99 [2], which in Section 1, Scope, states, This method is applicable to new oil, both uninhibited and inhibited, but is not well defined for used or reclaimed oils. New achievements that improve the chemistry of mineral insulating oils can provide the electrical power industry with an excellent opportunity to maximize the service reliability of high, and most importantly, of very high voltage ageing power transformers.
2 Theoretical Background
There is no doubt that the service reliability of power transformers largely depends upon the condition of the oil. The gradual deterioration of purity due to its ageing process has an important impact upon the paper insulation. The extent of the damage to the windings becomes obvious when its dielectrical properties are measured and compared to the values of the same transformer when it was commissioned. Since the relationship between the ageing of oil and the deterioration of the internal insulation is very seldom monitored, the growing amount of decay products reflected in the slowly changing analytical properties of aged oils is not currently considered to be a threat to the operational safety of power transformers. As a result, there is no consensus regarding the level at which these characteristics should be categorized as being too bad. As a result, the selective removal of decay products by 1 Introduction reclamation cannot be economically justified. In contrast, According to a paper published ten years ago by a what maintenance planners believe to be alarming is the team of Australian researchers [l], a major problem dissolved gas content in oil [3]. A closer examination of encountered world-wide by both producers and large the mechanism responsible for the genesis of all decay industrial consumers ,of electrical energy is the ageing of products, as well as certain new findings offered by an transmission and distribution power transformers. Nearly applied research project should stimulate a fresh half of them are now over 25 years old and it is an consideration of this relationship between the purity of oil accepted view that replacement is not an economically and the service reliability of power transformers. viable option. Since the large majority of these expensive machines are free breathing, with the exception of many sealed units in the US, the primary cause of ageing is considered to be the oxidation of oil. The use of oxidation
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R : H ~ > R . + .H
The fact that the molecular weight of these two fractions diflers by one or two orders of magnitude is very unilaterally interpreted. A major importance is attributed to the small fraction that, based upon Henrys Law, has the tendency to diffuse into the gas space above the surface of the oil, very little attention is given, on the other hand, to the large fraction which remains in the oil. The random chemical reactions between these short-lived intermediaries are the source of a large variety of decay products that have far-reaching effects on the development of incipient electrical failures [7]. The experimental section will provide data in support of this statement.
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transformers is retarded by the use of oxidation inhibitors, ignoring the fact that the oxygen molecule is also paramagnetic. It is possible, therefore, that the oxygen concentration inside the windings may be higher than the amount determined by DGA in average oil samples taken from the bottom of the tank. DGA of certain aged insulating oils display dissolved oxygen contents far above the saturation level. A more realistic explanation of the large dissolved oxygen contents, exceeding the saturation level of approximately 20,000 PPM, interpreted as random variations, could be the paramagnetic nature of these gas molecules. In addition all primary decay products having an unpaired electron can catch a free electron
R. 3 Rthus becoming charge carriers and causing an increase in the dissipation factor of oil.
Soluble Compounds in O i l Collisions between the small free radicals generated by the decomposition of certain hydrocarbon chains produce gases that dissolve in the oil. Based upon their composition as determined by chemical analysis, debatable information are obtained regarding the nature of electrical incipient failure (heat, partial discharge, etc.) that caused the decomposition reaction. The oxidation reactions of large free radicals also lead to soluble compounds. These change the chemical properties of aged oils (TAN, IFT) as well as their absorbance in the visible and ultraviolet range of the spectrum.
Insoluble Compounds in Oil When the large free radicals couple their unpaired electrons with another of similar size, a compound
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with a molecular weight between 500-600 arises. This size of hydrocarbon chains is no longer soluble in the blend. By coalescence, sludge is generated when oxygen is present; x-waxes are produced when it is absent. None of these insoluble suspensions of colloidal size can be detected by traditional testing procedures, but both can potentially clog the pores of paper insulation and to promote the formation of hot spots.
Symposium held in Calgary, Canada three years ago [14]. If the oil is degassed and saturated with nitrogen, the dissolved oxygen can be removed in a few days.
3. Experimental
In order to avoid the oxidation decay of oil-paper insulation and to reduce the gassing of oil, several new techniques have been developed during recent years. Some of them consist of industrial procedures, aimed at eliminating the cause of these deficiencies. Others are state of the art testing procedures, capable of determining the effectiveness of the above-mentioned preventive maintenance technologies.
constructed by the Southern Alberta Institute of Technology (SAIT) provided the opportunity to verify the effectiveness of this technology under quasi-industrial conditions.
3.2
As long as existing testing procedures cannot establish a quantitative relationship between the purity of oil on the one hand, and the service reliability of power transformers on the other, the reclamation of aged oils is economically difficult to justify. Therefore more relevant analytical methods have been developed.
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oxidation compounds are responsible for this shift has been confirmed by the analysis of two oil samples during the oxidation stability test. As illustrated by Fig. 1, the absorbance curve of a high stability oil submitted to the seven-day Oxidation Test D 2440 shows little change. By contrast, the low-stability oil in Fig. 2 shifts significantly during the first three days. Although no specific peak at a certain wavelength is available to characterize the ageing extent of oil in service conditions, quantification is possible by integration of the surface below the absorbance curves. Thus, the deterioration of oil purity in power transformers can be monitored on a step-by-step basis, even during the early stages of the oxidation process. An example is given in Fig. 3
Absorbance in the Visible Range of Spectrum
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10
08
New
0.32 0.83
0.94
A O6
04
3.36
TABLE 1 Dissipation Factor Increase of Oils Subjected to an Electrical Discharge. The benefits of this new stability test are described in the Special Technical Publication STP 1376, published by ASTM last year in March [171. According to our findings, the gassing of liquid insulation is dependent not only upon the chemical composition of the hydrocarbon blend, but also on its degree of purity. In other words, the gas evolvement of an aged oil decreases after its purification by reclamation. Thus, other new testing procedures proved to be necessary to reliably assess the degree of trace impurities in aged insulating oils.
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Fig. 1: Absorbance Curves over 7-day Oxidation Test of Good Stability New Oil
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Fig. 2: Absorbance Curves over 7-day Oxidation Test of Poor StabilityNew Oil
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14 12
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DF=Dissipation Factor, T=Turbidity. ABS=Absorbance Fig. 3: Absorbance Curves of New, Slightly Oxidized and Heavily Oxidized Oils
Another advantage of this fast, inexpensive and relevant analysis lies in the fact that during the reclamation of aged oils the absorbance curve shifts in the opposite direction towards shorter wavelengths. Consequently, the effectiveness of reclamation can be objectively determined. Moreover, a cross examination of the purity of oil and its gassing pattern can be carried out. This new testing procedure is currently under ASTM Technical Committee D 27 consideration, with good chances of approval in the foreseeable future [181.
(ESZ) principle and permitted a direct measurement by counting and sizing particles smaller than 50 nm from less than 50,00O/ml in new products to tens of millions in aged transformer oil. Unlike the turbidity assessment, which is more appropriate for field routine determinations, particle counting and sizing is recommended for laboratory analysis and cross examination with DGA results. When the gas content of oil is alarming, the number of insoluble particles should also be high. In such situations it must be determined whether a low electro-chemical stability of oil, or an incipient electrical failure is the source of the particle content and gas of concern forming these decay products. Without knowing the gassing pattern of the liquid insulation under electrical stress, the DGA results alone can be very misleading. By recording the distribution curves of a new oil before and after the Stability Test D 6180 as shown in Fig. 4, the direct relationship between the gas evolvement of oil under electrical discharge and the formation of insoluble suspensions is irrefutably demonstrated and accurately determined.
lW*ld
DiffermtialNumber (Average) -New OilBefore UeclncalStaWyD 6180 (188 arO/mL) New O d ARmElect~icalShb~y D 6180(1 066 COO/$
6 7 8
IO
Pmiicls D~mekm(p)
Fig. 4: Particle Distribution Curve of New Oil Before and After Stability D 6180
Comparing the distribution curve of particles in a new oil and an aged oil as shown in Fig. 5, the contrast is even more striking.
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-AgedO~l(163mOMllmL)
410*103
-NewOd(l8
7S7Ida
5 m*103
loa*ld 0
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.
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.
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5 i j 6 i 1 i 8 o 10 i Patticle Eameter(pxn)
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Following the development of this laboratory technique for counting and sizing insoluble decay products in mineral insulating oils, a standard test method has been drafter and forwarded to ASTh4 [20]. The benefits of this new method are currently under scrutiny by the members of Technical Committee D 27. Modernisation of the analytical procedures related to the properties of liquid insulation is expected to better establish the relation between its purity and the service reliability of power transformers. With the availability of the methods necessary to establish a quantitative relationship between the results of laboratory endurance tests on one hand, and the performance of oil in real life conditions on the other, the preventive maintenance of liquid insulation will become cost effective. Moreover, environmentally friendly on-line reclamation will extend the life expectancy of the oil (a non-renewable resource), while enhancing the service reliability of power transformers.
4. Conclusions
4.1 Modernisation of the analytical techniques used in examining liquid insulation has highlighted the reality of the irreversibly damaging efSect of the deterioration of its purity on the solid insulation, and implicitly, on the service reliability of power transformers. 4.2 Taking into account all the properties of dissolved Of which is so Oxygen, the to the Purity Of Oil, it is obvious that
oxidation inhibitors cannot properly protect solid insulation against its destructive effect. 4.3 Since both the ever-present high voltage field, and dissolved oxygen can transform the small amount of precursors in decay products, the stability of oil can be maximised by minimising the content of vulnerable hydrocarbons. 4.4 Prior to becoming decay products, all components of the hydrocarbon blend in power transformers are very similar. The elimination of those that are vulnerable at the manufacturing stage is very difficult. Only the end-users have the privilege of using reclamation to selectively remove what is by then identified by a different chemical composition. 4.5 By using means now available to measure and compare the stability of insulating oils under electrical discharge, the impact of reclamation on the quality of recycled aged oil can be reliably determined. 4.6 Without measuring the gassing pattern of aged oils, the transformer fault diagnosis is based solely upon DGA, which can be very misleading. 4.7 The currently available method for determination of oil stability under laboratory conditions can generate all the decay products which arise under electrical discharge in standard conditions, namely, gases, free and x-waxes. radicals, charge
Acknowledgement
The applied research project enabling the of this paper is the result of international co-operation bemeen the private sector and educational institutions.
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Without the provision of the laboratory instruments provided by the HACH Company, Perkin-Elmer (Canada) inc. and Beckman Coulter, Inc. the results cited and conclusions reached would not have been possible. Consideration of our joint endeavours by the American Society for Testing and Materials (ASTM) and ATCO Electric Shearness Generating Station, is also gratefully acknowledged. Special thanks are due for the support received from Hilary Inyang, Ph.D., Duke Energy Distinguished Professor of Environmental Engineering at the University of North Carolina, Charlotte, NC and Director of the Global Institute for Energy and Environmental Systems (GIEES).
References
1 Darwenzia, M., Hill, D., Tri Le and Saha, T.K., Studies o f the Condition o f Insulation in Aged Power Transformers, Part 2, Fundamental Electrical and Chemical Considerations, Proceedings of the 3rd International Conference of Properties and Applications of Dielectric Materials, July 18-20, 1989, Tokyo, Japan.
2 Designation D 2440-99, Standard Test Method for Oxidation Stability of Mineral Insulating Oil, Vol. 10.03. IEEE Guide for the Interpretation o f Gases 3 Generated in Oil Immersed Transformers, IEEE Std. C57.104- 1991. 4 Sabau, J. and Stokhuyzen, R., Aging and Gassing of Mineral Insulating Oils, Proceedings of TechCon 2000, Dave Hanson, Editor, TJ/J2b, Sacramento, CA. Forster, E.O. Electrical Breakdown of Dielectric 5 Fluids, ASTM Monograph 2, Engineering Dielectrics, Vol. 111, chapter 3, January 1994.
6 Mousseron-Canet, M. and Mani, J.C., Photochemistry and Molecular Reactions, Dunod, Paris, 1969.
7 Sabau, J., Gassing and Aging of Oil in Power
Transformers, Proceedings of SAIT/CEA Technology
9 ASTM Designation D 2300-00, Standard Test Method for Gassing of Insulation Oils Under Electrical Stress and Ionization (Modified Pirelli Method), Vol. 10.03. 10 Christian Mayoux, On the Degradation of Insulating Materials Withstanding Electrical Stress, IEEE Transactions on Dielectrics and Electrical Insulation, Vol. 7, pp. 59-60, October, 2000.
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11 Tanaka, J., Free Radicals in Electrical Insulation, Proceedings of the Nineteenth Symposium on Electrical Insulating Materials, Osaka, Japan, 1986. 12 Pryor, W.W., Free Radicals, Inc., New York, 1966. McGraw-Hill,
13 ASTM Designation D 3612, Standard Test Method for Analysis of Gases Dissolved in Electrical Insulating Oil by Gas Chromatography, Vol. 10.03. 14 Sabau, J., A New Type of Nitrogen Blanketing System for Freely Breathing Power Transformers. Report prepared by INSOIL Canada Ltd. for the Southern Alberta Institute of Technology (SAIT), June 1998, Calgary, AB., Canada. 15 Sabau, J., Purification of Aged Insulating Oils by Regenerable Resin, Part B, Report 334 T 768A, prepared by INSOIL Canada Ltd., for the Canadian Electrical Association, April, 1994, Pontreal PQ, Canada. 16 ASTM Designation D 6180-97, Standard Test Method for Stability of Insulating Oils of Petroleum Origin Under Electrical Discharge, Vol. 10.3. 17 Sabau, J. and Stokhuyzen, R., Electrochemical Stability of Mineral Insulating Oils, ASTM, STP 1376, Electrical Insulating Materials, International, Issues, Marcel M. Hirscheler, Ed., March 2000.
18 Standard Test Method for Determination of the Relative Content of Dissolved Decay Products in Mineral Insulating Oils by Spectrophotometry, (Under consideration by ASTM).
19 ASTM Designation D 6181-97, Standard Test Method for Measurement of Turbidity in Mineral Insulating Oil of Petroleum Origin, Vol. 10.3. 20 Standard Test Method for Determining the Size and Number of Particles in Mineral Insulating Oills of Petroleum Origin Using the Electric Sensing Zone (ESZ) Principle. (Under consideration by ASTM).
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