Transformer Oil Condition Monitoring

Dr B Pahlavanpour and I A Roberts

National Grid Company plc, Engineering and Technology, Kelvin Avenue, Leatherhead,
Surrey KT22 7ST

1- Introduction
Mineral insulating oil has been used in the electrical industry .formore than a century: its use in
transformers dates back to 1887. Early oils were paraffin-based crudes, the oxidation of which
produces an insoluble sludge, which increases the viscosity. T h s results in reduced heat transfer
capabilities, overheating and reduced service life. As a result of this paraffin crudes were
(successfully)replaced with naphthenic oils. Although naphthenic oils are more readily oxidized
than paraffinic, the oxidation products are soluble in the oil and thus less of a problem.
Experienceshows that liquid insulating oil is aproduct that requires proper care and maintenance
to ensure satisfactory service.

Crude oil selection is the most important step in the manufacturing of insulating oil. The degree
of refining of the crude and kind of process and treatment m;aygreatly change the constituents
in the final product. In the refining process the most desirable characteristicsof the crude oil are
selected and the less desirable constituents removed. The end product is a structure with the
desired proportions of aromaticrings, naphthenics and paraffins. The process may include hydro
treatingihydrogenation,solvent extraction, dewaxing, acid and clay treatment. However, there
is no singlebest method for the manufactureof good insulating liquid. Regardlessof the refining
method used the insulating oil produced should have high e1ec:trical performance, gas absorbing
properties, chemical stability and resistance to oxidation. Additionally, optimum aromatic
hydrocarbon concentration and sulphur and nitrogen content are important factors.

2- Performance Requirements for Insulating (Oil

Numerous tests are employed to determinethe condition of uniused and used insulatingoils. Such
tests can be used to establish the properties of unused oils and to demonstrate that the insulating
liquid meets the specification. BS 148 and IEC 296 are usually considered as the minimum
specificationwith users also introducing their own supplementaryrequirements which include
tests to ensure the longest possible service life. In service oils can be monitored to provide
assurancethat their essentialproperties are maintained and that equipment is operatingproperly.
IEC 422, BS 5730 and IEEE Std 637 can be used as guide to the frequency of testing,
recommended action limits on the test and action that should be taken based on the results. Once
the oil condition reaches an unacceptable level, it should be replaced with either unused or
reclaimed oil. Alternatively the oil in the transformer can be reclaimed in situ.

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3- Insulating Oil in Service
Insulating oils used in air breathing transformers absorb oxygen to the point of saturation.In the
presence of metallic compounds and high temperatures,the oils oxidize and eventually lose their
dielectric stability. This is directly related to the formation of polar compounds and sludge in the
oil. At the initial oxidation stage, non-acidic polar compounds such as alcohols, aldehydes,
ketones, etc, are produced. As oxidation proceeds, acids and eventually sludge are formed as
well. The oil becomes corrosive and solid particles forming the sludge are deposited at different
places in the transformer,building up sediment that reduces the oil’s heat-dissipation capability
and electrical properties. Moreover, the increase in soluble acidity and sludge can lead to
accelerated degradation. Sludge and acids attack the insulating material, in particular paper,
resulting in a weakening of the insulating system. Clearly, damaged paper cannot provide
adequate physical support for the windings and this may lead to premature failure.

il Condition Monitoring
Since transformer oils are a vital part of the insulation system, they require regular checking.
Yearly intervals are the most common test period. Based on the results corrective actions can,
if necessary,be applied to avoid further oil and insulation paper deterioration. Guidelines for the
maintenance of transformer oil in service are published in IEC 422. Whilst some of the oil
testing equipment seems expensive, the cost is small in comparison with that associated with
insulation failure. Regardless of what test is specified, it is imperative that it be run on a
representative liquid sample since accurate sampling is the prerequisite to any standard test. Oil
may change appreciablyin storage so samples should be tested as soon as possible after removal
and dates of sampling and testing recorded. Oil tests performed on site can be the most
representative and informative providing cleanliness and quality control are maintained.

4.1 Acidity
This test is also called acid number or neutralisation number. The acids in the oil are one result
of oil oxidation in service. These fatty organic acids are detrimental to the insulation system and
can induce rusting of iron when moisture is also present. An increase in acid number is an index
of the rate of deterioration of the oil. Sludge will be the inevitable end product of an acid
situation that is neglected. Acid content is expressed as the number of milligrams of potassium
hydroxide (KOH), a base, that it take to neutralise the acid in a one gram of the oil sample.

A semi-quantitativespot test kit has in the past been used by some utilities for acid measurement.
This was based on ASTM D 1902 and usually applied in the field. The test involves applying
drops of an acidity buffer solution to a piece of filter paper and allowing it to soak in. Two drops
of oil were then added in the same place followed by a single drop of an indicator. This caused
a colour change which was compared to a standard colour chart. However, due to the difficulty
of achieving consistent results the method has been discontinued.

An alternative field method for acidity measurement is ASTM D 1534. This test is run by
placing a 20 millilitre oil sample in a graduated cylinder and adding an indicator solution.
Potassium hydroxide is added to the oil and the solution is shaken. After allowing it to settle the
colour change is noted. Being semi-quantitative the method cannot produce accurate results.

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The recommended standard method for acidity measurement of insulating oil is outlined in IEC
296. This is a laboratory acid test method and based on a colour-indicator titration. The test
consists of mixing a known amount of sample with a suitable: solvent, adding an indicator and
titrating with KOH to a coloured end point. It can be applied to used and unused oil. However,
reproducibility can be a problem with dark oils as it is difficult for the operator to detect the end
point. Additionally the specification requirement for acidity of unused oil is C0.03 mgKOWg.
This is very close to the detection limit of the method and awurate results are also difficult to
achieve at these levels. Furthermore,the scope for human error in this method can be high as the
colour change is largely subjective. In acknowledgement of this the IEC has recently set up a
working group to renew this method with the aim of revisinglreplacing it.

The total acidity of used and unused transformer oil can be measured quantitativelyby using an
electro chemical technique. The technique consists of the measurement of pH or mv of the
solution at room temperature against the volume of alcoholic potassium hydroxide used for
neutralisationof the acids. The method is rapid and accurate and the colour of the oil sample has
no effect on the titration end point. By automatingthe process, operator error can be significantly
reduced. This method has been proposed to IEC as an alternative to the acidity measurement
technique currently in IEC 296.

4.2 Moisture

During the service life of a transformer, the moisture content may increase by breathing damp
air, natural ageing of the cellulose insulation, oil oxidation, condensationor by accidentalmeans
and the water content of the paper may rise to five or even six percent. The presence of moisture
increases the ageing rate of both the oil and the paper. Insulating paper with a one percent
moisture content ages ten times faster than one with only 0.1 %. Water is a polar liquid and is
attracted to areas of strong electrical field. Water-solubleacids produced by oxidation of the oil
act as a catalyst for almost all reactions and will combine with water or oil to assist or promote
corrosion to exposed metal parts in the transformer. The cellul.osehas a greater affinity for water
than oil and so water will replace the oil in oil-impregnated cellulose. Presence of water in the
oil will reduce the electrical strength of the oil and may shorten life of the insulation system and
lead to earlytransformerfailure. The maximum allowablewater content of oil in servicedepends
on the transformervoltage: recommendedvalues are given in IEC 422. Like other oil properties,
the moisture content should be monitored regularly (at least once a year).

A number of techniques have been investigated over the years to measure the quantity of
moisture in a dielectric fluid, but the only method which has stood the test of time is that
developed by Karl Fischer in the early 1930's. The test is normally conducted in a laboratory.
New equipment, which performs the titration automaticallyand is capable of measuringmoisture
contents down to 1ppm in the oil, can perform field analysis of moisture in transformer oil. The
most obvious direct benefit of a portable moisture meter is the elimination of the possibility of
further contamination that might occur while a sample is being transferred to a laboratory for
analysis.

Estimates of moisture content of the cellulose can be made by relating water content of the oil
in ppm to the % concentration of water in the cellulosic insulation. However, this requires a
knowledge of the moisture equilibrium data for the oil in question together with its normal
temperature and moisture content.

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To preserve transformer life it is essential to know the degree of moisture in the solid insulation
so that the need for dehydration or for evaluating the end-point of the drying process can be
determined. Internationally gathered experience has shown that the insulation life is inversely
proportion to the residual water content at a given temperature. The lower the water content, the
greater the possibility of prolonging the life of the transformer. It has also been demonstrated
that the insulation resistance measurement is not sensitive enough to give a reliable means of
judging the moisture condition of the solid insulation of a transformer in service.

4.3 Other Tests

Other tests for monitoring the condition of the insulating oil are outlined in IEC 422. The test
duration and its significance is also outlined in the standard. For a true picture of a service-aged
oil’s condition and an insight into conditions inside the transformer the results of a full set of
tests need to be considered in combination. These include interfacial tension, dielectric
dissipation factor, dielectric strength and resistivity. However the presence of moisture and acids
in the oil significantly affects the above tests, hence they are the primary indicators of early oil
deterioration.

5- Remedial Actions
The following remedial actions can be implemented in the cases of oil oxidation and or BCB
contamination.

5.1 Oil Reclamation

Clearly it is important to protect and if possible prolong the life of existing equipment in service.
Reclamation of usedoxidized oil is an attractive technique for oil preservation and can also be
financially viable. The standard technique for aged insulating oil consists of filtering through a
polar adsorbent material known as “Fuller’s Earth“. This procedure is normally applied as soon
as the acidity of the oil approaches 0.15 mg KOWg or the interfacial tension of the oil reaches
20 d l m . Reclamation using Fuller’s earth removes the acidic molecules and sludge but a large
proportion of non acidic polar compounds ,such as alcohols, aldehydes, ketones, etc., remain in
solution. These products act as catalysts of oil oxidation and, if they remain in the oil when it
goes back into service, can accelerate its oxidation rate.

The principal disadvantage of “Fuller’s Earth”, apart flom not producing the highest quality
reclaimed oil, is that it can only be used once. After it is saturated, it must be disposed of as a
chemical waste, with the associated oil and oxidation products. Usually for every 5 to 15 litre
of oil 0.5 kg of “Fuller’s Earth” is used. Thus this technique produces significant volumes of
contaminated waste which increases cost of the reclamation and reduces its attractiveness.

A synthetic clay can be used as an alternative to “Fuller’s Earth” and this is capable of being
regenerated and used for several years. Use of this product produces reclaimed oil of a quality
comparable to unused oil. With appropriate process control equipment reactivation of the clay
can be carried out automatically within percolating clay columns and to comply with pollution

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control regulations, exhaust gases fi-om the reactivation cycle can be cleaned in a scrubber.
Considerablyless waste is generated since all the contaminantsremoved from the clay during the
reactivation cycle are concentrated within a small quantity of oil (typically <0.1% of the
processed oil volume).

Such a system can be used on oil in a tanker or within a transformer tank, in some cases when
the equipment is on load. This can offer several advantagesas the need for outages, transport and
disposal of old oil is eliminated. The technique involves circulation of the oil &om the
transformer to the reclamation unit and back again. The process is repeated for a period of time
(typically 10 days) until the oil quality in the transformer improves to an acceptablelevel. Using
this technique may increase the ultimate life of a power transformer.

A similar technique can be used for desludging transformers. (The most serious effect of sludge
occurs when it is absorbed into cellulose. This can lead to shrinkage, and reduced thermal and
mechanical performance and in such a case the transformer loses its ability to absorb shock
loadings.) Naphthenic insulating oil dissolves the deposited sludge on the interior of the
transformer providing its temperature is in excess of 80°C (the aniline point) and this can be
achieved by introducinghot clean oil into the top of the transformer. The oil circulateswithin the
transformer and is then removed from the bottom of the tank. This process works most
efficiently on a loaded transformer. It should be noted that oil replacement is not a good option
in such a cases as the trapped oxidized oil in the cellulosewill leach out and contaminatethe new
oil in a short period. Even a small quantity of heavily oxidized oil can contaminate large
quantities of new oil. In addition, simply changing the oil will not, on its own, remove the
depository sludge from the core and coils.

5.2 Dehydration of transformer

The continued reliability of an insulation system requires the highest measure of dryness. For
high voltage transformers it is particularly important to minimise moisture contamination in-
service and, if contamination does occur, to remove it as completely as possible. Moisture
removal can be accomplished by several routine methods. The general categories of drylng
practice involves use of heat andor vacuum, performed at a manufacturers works or on site
methods.

6- Oil Disposal Practice

Once transformer oil has deteriorated to the point that can no 'longerbe economicallyreclaimed,
or used as a fuel (or for any other permitted use) then it must be disposed of in accordance with
governmental regulations.
7- Conclusion

Oil condition monitoring plays a vital role in assessing plant status and integrity and also in
estimating remanant life of the units. It needs to be canied out on a regular basis so that oil
deterioration can be detected at an early stage. Trends can then be monitored and corrective
actions taken at the optimum time.

8- Acknowledgement
The work was carried out at the National Grid Engineering and TechnologyLaboratories and the
paper is published with the permission of The National Grid Company plc.

0 1998 The Institution of Electrical Engineers.

Printed and published by the IEE, Savoy Place, London WCPR OBL, UK.

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