TRANSFORMER OIL Analysis

M.G.Morshad / ACM ( Elect)

Transformer Maintenance Division / TPS II

Transformer Insulating system

Oil
1. Acts as a Coolant
2. Act as an insulation
3. Protects the Paper from chemical
attack
4. Prevention of sludge buildup
5. Used as Diagnostic Tool

Paper
1. Mechanical Strength
2. Dielectric Strength
3. Dielectric Spacing

Transformer oil classifications

NAPTHANIC OIL

Mineral Oil

(petroleum product )

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

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.
It has high pour point due to the wax content
In India it is generally used because of its cheaper and
easy availability.

Transformer Oil

Synthetic Oil
(Chemical Product)

SILICON OIL
Fire retardant, hence it is used only for fire prone area.
Lower heat dissipation capacity and high moisture
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-4methylphenol or 2,6-di-tertiary-butyl-paracresol (DBPC).

Heat transferring capacity of

transformer oil

Approximate 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
Thick Press board
( Barrier )
Thin press board
(Barrier)
Paper insulation
( Winding insulation )

Requirement
5% of total oil weight
3% of total oil weight
2% of total oil weight

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

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.

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.

TRANSFORMER OIL SPECIFICATIONS

IS-335/1993 ( New Oil)

Appearance -----------Density at 29.5C (Max)

Kinematic Viscosity (Max)
1) at 27C -----------------2) at 40C -----------------IFT at 27C (Min) --------Flash Point (Min) --------Pour Point (Max) --------Neutralization Value
1) total Acidity (Max) ---2) Inorganic acidity -----Corrosive Sulphur ------Electric Strength (BDV)
1) New unfiltered Oil(Min)
2) After filtration (Min)

Dielectric dissipation factor (tan )at 90C(max)

Specific resistance (Resistivity)
1) at 90C (Min)
2) at 27C (Min)

Oxidation Stability
1) Acidity (max)
2) total sludge (max)

Clear and transparent

0.89 g/cm2

27 cSt
Under consideration
0.04 N/m
140C
-6C

0.03 mg KOH/gm
Nil
Non-corrosive

30 KV (rms)
If the above value is not attained, the oil shall be
filtered to 60 KV (rms)
0.002

35 x 1012 ohm-cm
1500 x 1012 ohm-cm

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) at 90C
b) Tan at 90C (Max)
c) Total acidity (Max)
d) Total sludge (Max)
Presence of Oxidation inhibitor

Water content
SK value

2.5 x 1012 ohm-cm

0.2 x 1012 ohm-cm
0.20
0.05 mg KOH/gm
0.05 % by weight
The oil shall contain natural
anti oxidant additives.
50 ppm
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

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

72.5-170

>170

Clear, Free from sediment and suspended matter

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

0.03

0.03

0.03

Water content (ppm), Max

20

15

10

IFT at 27C (mN/m),Min

35

35

35

0.015

0.015

0.010

Resistivity at 90C(x10e12ohm-cm),Min

BDV (KV),Min

40

50

60

Total acidity(mgKOH/gm),Max

Tan at 90C, Max

TRANSFORMER OIL SPECIFICATIONS

IS-1866/2000-Violation Limits for in service oils
Property

Highest voltage of Equipment (KV)

<72.5

Appearance
Water content (ppm), Max

72.5-170

>170

Clear and without visual contaminations

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

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

Appearance

Frequency of testing
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

Appearance
Water content
BDV

Recommended Actions
As dictated by other tests
Check Source of water and consider reconditioning
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
Sediment and sludge

Replace the oil, equipment may require inspection

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
Properties

Definition

Purpose

Effects

To determine the presence of moisture,

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

Density

Kinematic
Viscosity

It measures the weight of oil

with respect to the mass of
an equal volume of pure
water
at
the
same
temperature

To ensure that the free water always

remains at the bottom and oil can
circulate easily due to lighter weight.
(Lower the density better the heat
transferring capacity )

To ensure the mobility of oil at low

It measures the resistance of temperature since presence of
the oil to continuous flow
sediments, moisture and aging of the oil
without the effect of external increases the viscosity value. (Lower the
force
viscosity better the oil quality & heat
transferring capacity)

It measures the molecular

Interfacial
attractive force between
Tension
water and oil molecule.

To determine the presence of polar

contaminates such as of sludge and
other degrading products as a result of
oxidation (Higher the IFT better the oil
quality heat transferring capacity )

Since density is inversely

proportional to temperature ,
heat dissipation capacity of
the oil decreases with the
decrease of temperature

Heat removal capacity from

windings increases with Low
viscosity at low temperature
and prevent localized
overheating.

Oil with lower IFT reduces

the cooling effect due to
presence of sludge & oil
decay product

PHYSICAL PROPERTIES OF OIL

Physical
Properti
es

Definition

Purpose

Effects

Flash
point

To determine the self ignition

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

Pour
point

To determine the lowest temperature

It is the lowest temperature at at which oil stop flowing due to Low value to the specified
which oil stops to flow due to solidification. (Lower the flush point value transformer oil stop
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
oxides etc., arise from the conditions
Sedimen
determined by Centrifuge
and hinder heat transfer.
of service of the equipment. (Good
ts
method
oil must be free form sludge &
sediments )
19

CHEMICAL PROPERTIES OF OIL

Chemical
Properties

Neutralizati
on Number
or Acidity

Definition

Causes

Effects

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

Oxidation
Stability

It the evolution of acid and

sludge formation tendency
of new mineral oil due to
oxidation

Moisture

It measures in ppm the

presence of moisture in
the oil

Dissolved
Gases

H2 = Partial discharge
H2,CH4 = Low energy discharge
It measures of dissolved
Thermal
Gases produced in the oil
degradation Arcing, CH4 = Low temp hot spot
due to decomposition of oil Partial discharge
H2, C2H2 = Arcing
C2H4 = High temp

Moisture

Metal corrosion which minimizes the life of the

transformer

By breathing
action,
Chemical reaction

Decreases electric strength (BDV)

Electric dissipation factor (Tan Delta)
Resistivity

ELECTRICAL PROPERTIES OF OIL

Electrical
Properties
Dielectric
Strength

Definition

Causes

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

The resistivity of a liquid is a measure of its

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

Effects
Higher the value, Higher
the purity

Higher the value , better

the condition of the oil

current
C Capacitive
B Actual current

Dielectric
Dissipation
Factor /
Tan Delta

= (90-)

O (Applied voltage V) A
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

Increased value causes in

Soluble varnishes, resins ,
increase in temperature,
Moisture
increase in corrosion

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
oil

Proposition
A oil

Marginal
oil

Bad
oil

Very bad
oil

Extremely
bad oil

Discarded
oil

Oils in disastrous condition

Pale
yellow

Yellow

Bright
yellow

Amber

Brown

Dark
brown

Black

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

30 - 45

0.00 0.10

300 - 1500

Pale
Yellow

27.1 29.9

0.05 0.10

271 - 600

Yellow

Oil Quality & Observations

Very Good
(provides all the required function)

Good(provides all the required function , a

drop in IFT to 27.0 may signal the beginning of
sludge & sediment)
Acceptable

24 27

0.11 0.15

160 - 318

Bright
Yellow

(not providing proper cooling and winding

protection. Organic acids are beginning to coat
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
these units. Insulation damage and reduced
cooling efficiency with higher operating
temperatures characterize the Very Bad and
Extremely Bad categories.

18.0 - 23.9

0.16 - 0.40

45 - 159

Amber

14.0 - 17.9

0.41 - 0.65

22 - 44

Brown

Very Bad

9.0 - 13.9

0.66 - 1.50

6 - 21

Dark
Brown

Extremely Bad oil

300

1500
Very Good

271
6

22

45

160

600
318

Good

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

Temp

Water solubility
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

With the increase of temperature ,water saturation level of oil

increases and transformer oil absorbs moisture from the paper
insulation till its gets saturated .

Water dissolved in
oil (High Temp)
Water dissolved in
oil (Low temp)

Moisture movement

Moisture movement

Water
available
in the
paper
insulation

With the decrease of temperature ,water saturation level of oil

decreases and transformer oil exudes moisture which is absorbed by
paper and subsequently deposited as free water at the insulation layers
and bottom of the transformer .

Moisture in transformer oil Relative saturation

Water content in oil sample taken at 60 Deg C
(as per lab analysis)

45 ppm

Water solubility level in oil at 60 Deg C

(as per graph)

242 ppm

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
in oil adjusted to 20C

Condition of cellulosic insulation

05%

Dry insulation

6 20 %

Moderate wet, low numbers indicate fairly dry to moderate levels of

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

80,000 Liters

Density of oil

0.86 Kg / Liters

Mass of the oil

Mass of the solid insulation

M=VxD

68800 Kg

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
( as per the graph)

WCP

2.2%

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
current

+
+

+
+

+
+
Leakage current

+
+

Charging
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)

(Good)
(Min)

Resistivity is measured by
applying 500 V DC voltage
across the oil sample after
heating up the sample at
90 Deg C which is the
maximum
allowable
operating temperature of
transformer

DDF / Tan Delta

B
Capacitor
charging current

= (90-)

OA = Applied voltage,
OC = Charging current,
OB = Total current ( Charging current + Leakage
current)
Charging current = OB Sin ,
Leakage current = OB Cos ,
PF = Cos = Cos ((90-) = Sin = Tan ( since
is very small)

Dielectric leakage current = OB Cos = OB

Tan
O
A
Heat dissipation in the oil due to leakage current
Being a pure insulator, transformer oil =
V x I x like
PF dielectric of a capacitor under high AC
behaves
0
voltage and it absorb charging current
respect
to the
= OAatx90
OBleading
Cos with
= OA
x OB Tan
applied
(Watt) voltage
Applied 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)

Angle value
Ideal

Normal
Maximum
( > 72.5 KV
Transformer)

Maximum
(< 72.5 KV
Transformer)

: Tan Delta

% Value

TAN

0.000

AB/OB

0.000

0.0 Deg

OC

0.% of OB

TAN 1

0.002

AB/OB

0.002

0.1 Deg

OC

0.2 % OB

TAN 2

0.200

AB/OB

0.200

11.3 Deg

OC

20 % OB

TAN 3

1.000

AB/OB

1.000

45 Deg

OC

100 % OB

Max < 72.5 KV

Transformer
Max > 72.5 KV
Transformer

Normal

Charging current
Total current

1
2
3
O

Leakage current

Tan delta value is measured

by applying 1000 V AC
voltage across the oil
sample after heating up the
sample at 90 Deg C which
is the maximum allowable
operating temperature of
transformer

Effect of temperature on oil parameters

Res

Resistivity & tan delta

(indicates deteriorating status of the
dielectric due to oxidation &
contaminations of oil)

istiv
ity

cm

%
elta
D
Tan

200 C

900 C

Presence of the Polar

particles / Increase in
temperature
BDV

Water ppm & bdv

(indicates present status of the
dielectric due to contaminations of
oil with water )
200 C

in K
V

900 C

Presence of dissolved & free water /

Increase in temperature

46

Transformer oil processing

RECONDITIONING
( Mechanical process)
for oil having higher water ppm
Removal of
Free & dissolved water,
Dissolved combustible gas
Solid particulate matter

Removal of
Free & dissolved water,

OFF Line
process

ON Line
process

Circulating hot oil through

filter & vacuum chamber
in FILTER MACHINE

Circulating oil
continuously through
cartridge banks filled with
molecular sieve

RECLAIMING
( Chemical process)
for oil having higher acid number
and lower IFT
Removal of Sludge & sediments
(Polar, Acidic & Colloidal
materials)

OFF Line
process

Circulating oil
continuously through fuller
earth column

Off line reconditioning through filter machine

Vacuum
Pump

Vacuum
Chamber

Fine
Filter

Automatic
Heater

Gear
Pump

Transformer
Tank filled
with oil

Magnetic
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-butylparacresol (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
& Hydrogen
Methane

CH4

Ethane

C2H6

Ethylene

C2H4

Acetylene

C2H2

Hydrogen

H2

2. Carbon oxides
Carbon
monoxide

CO

Carbon
dioxide

CO2

3. Non fault gases

Nitrogen

N2

Oxygen

O2

53

Types of Faults & generation of gases

TYPES OF FAULTS

THERMAL FAULTS

1. Low temperature heating

ELECTRICAL FAULTS

1. Corona

OIL

CELLULOSE

OIL

CELLULOSE

CH4,C2H6

CO2,(CO)

H2

H2,CO,CO2

2. High temperature heating

OIL

CELLULOSE

C2H4,H2,(CH4,C2H6)

CO,(CO2)

2. Arcing
H2,C2H2,(CH4,C2H6,C2H4)

54

Types of Faults & generation of gases

Thermal Fault
Electrical Fault
External
Conditions

Normal Operation & aging

Failure of Pumps, Fans

Misdirection flow of cooling oil
due to looseness of oil directing
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
Bad leads connection / Poor
contact in the tap changer

Discharging of static electrical

charges that build up on shields
or core and structures which
are not properly grounded
Electrical arcing between
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

Exposure of oil to the environment due to oil

leak and not providing air bellows & silica jel
breather in the conservator

Arcing in the transformer due

to voltage surge such as a
lightning strike or switching
surge

Over heatingof oil and paper

Hot spot - causing overheating of oil & paper

Over loading

Improper cooling
Deteriorated /damaged insulation

Formation of Key
gases in the oil as
result of
decomposition of
oil and burning of
paper insulation.

Accumulation of
environmental
gases - O2, CO2,
N2, H2O in the oil

Acceptance limits (1)

CIGRE

ELECTRA

ALSTHOM

(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

Dissolved Gases

ERDA

Acceptance
CIGRE
Gases

limits (2)

CPRI

CBIP

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
GAS

YEARS IN SERVICE
(PPM)

4-10 YEARS IN
SERVICE (PPM)

MORE THAN 10
YEARS IN SERVICE
(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

200-300

400-500

600-700

3000-3500

4000-5000

9000-12000

CARBON
MONOXIDE
CARBON DIOXIDE

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)

Overheating of oil

Arcing in oil

Overheating of Paper and Oil

Arcing of Oil and Paper

Corona Discharge

Partial Discharge

Key Gas Ethylene

(CH4 ,C2H4 & H2)
Key Gas Acetylene
(H2 ,C2H2)
Key Gas - Carbon mono oxide
(CO, CO2, CH4, C2H4 & H2)
Key Gas Acetylene
(C2H2, H2, CO, CO2)
Key gas Hydrogen
(H2)
Key gas Hydrogen
(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

0.1

Partial discharge

Normal deterioration

Over heating >150 Deg C

Over heating 150 200 Deg C

Over heating 200 300 Deg C

General condition of overheating

Circulating current / Overheating of joints

Flash over without power flow

Current breaking through tap changer

Arc with power flow

Faults

Ratio less than 0.1 is designated as 0

Ratio greater 1 is designated as 1

65

C2H2
C2H4
0
1
1
2

Fault Analysis (2) - by IEC 599 and CBIP

methods
CH4
H2
1
0
2
2

C2H4
C2H6
0
0
1
2

C2H2
C2H4
0

CH4
H2
0

C2H4
C2H6
0

1 to 2

1 to 2

Ratio of the dissolved gases

Ratio less than 0.1
Ratio from 0.1 to 1.0
Ratio from 1.0 to 3.0
Ratio greater than 3
Fault detection chart
Faults & Causes
No fault Normal aging
Partial discharge of low intensity . Discharge in gas filled cavities,
resulting from incomplete impregnation / super saturation / cavitations of high
humidity
Partial discharge of high intensity As above but leading to tracking /
perforation of solid insulation
Discharge of low energy Continuous sparking in oil, between bad
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 /
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
conductor
Thermal fault of low temp (150 to 300 Deg C) Local over heating of the
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
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
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
T1
Thermal Fault
t<300 Deg C
T2
Thermal Fault
300<t<700 Deg C
T3
Thermal Fault
t>700 Deg C

Electrical Type
PD
Partial Discharge
T2
Thermal Fault
300<t<700 Deg C
T3
Thermal Fault
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
e

Glucos
e

Glucos
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

Cellulose

HEAT

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
circuit

Insulation Failure

Lighting /Switching
impulse
77

78

DP values and aging of transformer

Age (Yrs)

DP Values

>1000

975

12

700

22

450

25

390

35

125

DP Values

Years

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
(Years)
2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Furfural
(mg/Ltr)
0.01
0.02
0.03
0.04
0.05
0.06
0.08
0.10
0.12
0.15
0.18
0.21
0.24
0.30
0.37
0.48
0.60
0.75
0.90
1.05
1.20
1.35
1.80
2.25
2.70
3.15
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
1ppm = 0.0001%

1% = 10,000ppm
Percent (%)
0.0000%
0.0001%
0.0010%
0.0100%
0.1000%
1.0000%
2.0000%
3.0000%
4.0000%
5.0000%
6.0000%
7.0000%
8.0000%
9.0000%
10.0000%
20.0000%
30.0000%
40.0000%
50.0000%
60.0000%
70.0000%
80.0000%
90.0000%
100.0000%

ppm

ppm

Percent (%)

60 ppm

0.0060%

0 ppm
1 ppm
10 ppm
100 ppm
1000 ppm
10000 ppm
20000 ppm
30000 ppm
40000 ppm
50000 ppm
60000 ppm
70000 ppm
80000 ppm
90000 ppm
100000 ppm
200000 ppm
300000 ppm
400000 ppm
500000 ppm
600000 ppm
700000 ppm
800000 ppm
900000 ppm
1000000 ppm

0 ppm

0.0000%

70 ppm

0.0070%

1 ppm

0.0001%

80 ppm

0.0080%

2 ppm

0.0002%

90 ppm

0.0090%

3 ppm

0.0003%

100 ppm

0.0100%

4 ppm

0.0004%

200 ppm

0.0200%

5 ppm

0.0005%

300 ppm

0.0300%

6 ppm

0.0006%

400 ppm

0.0400%

7 ppm

0.0007%

500 ppm

0.0500%

8 ppm

0.0008%

600 ppm

0.0600%

9 ppm

0.0009%

700 ppm

0.0700%

10 ppm

0.0010%

800 ppm

0.0800%

20 ppm

0.0020%

900 ppm

0.0900%

30 ppm

0.0030%

1000 ppm

0.1000%

40 ppm

0.0040%

2000 ppm

0.2000%

50 ppm

0.0050%

3000 ppm

0.3000%

4000 ppm

0.4000%

5000 ppm

0.5000%

6000 ppm

0.6000%

7000 ppm

0.7000%

8000 ppm

0.8000%

9000 ppm

0.9000%

10000 ppm

1.0000%

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

0.01

0.142

0.01

0.67

6.7

2.5

2.5

0.00

0.00

0.00

0.33

3.3

0.00

0.00

0.00

0.13

1.3
87

conversion table III

Water
Boiling
point (Deg
C)
0
10
20
30
40
50
60
70
80
90
92
94
96
98
100

Vacuum
Gauge
Reading
(mmHg)
755.42
750.79
742.47
728.18
704.68
667.50
610.62
526.30
404.24
234.24
193.01
149.10
102.38
52.73
0.00

88

conversion table III

TR Oil
Temp

Water solubility
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