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INSULATING OIL

Mineral insulating oil is a product of crude petroleum. Insulating oil is usually

obtained from naphtenic type crude. The advantage of this type of crude is that
low-pour point oils can be produced without expensive de-waxing treatment. The
crude oil is distilled in order to separate it into a number of different fractions or
distillate stocks. The selection of distillate stocks governs such properties as flash
point, viscosity and volatility.

Insulating oil distillate can be thought of as being similar to domestic fuel but
with the high volatile ends removed. It thus has a much higher flash point and
much narrower boiling range than fuel oil.

The distillate stock contains many unstable components, which tends to oxidize
quite readily. These are removed by one of several solvent extraction refining
prosses to produce clear, bright and stable oil. The purpose of refining is to
remove as much of the unstable materials as possible and thereby increase the
oxidation stability of the oil, which is necessary for long service life.

Insulating liquids such as mineral insulating oil is commonly used in electrical

apparatus such as transformers and oil circuit breakers.

In large and small oil-filled transformers, the oil functions as:

 An electrical insulating medium

 As a coolant to conduct heat away from the windings

In switching apparatus, the oil functions as:

 An electrical insulating medium

 An arc quenching medium formed during breaking of the circuit

In order to fulfill these functions, mineral insulating oil must meet these
requirements:

 A high flash point – to minimize fire hazards

 Non-volatile at operating temperatures – to avoid evaporation
 Low pour point – it should remain fluid at the lowest ambient temperature
 Water should separate from the oil readily
 Flow freely on order to transfer heat efficiently from the windings of the
transformer to the radiating and cooling surfaces
 Stable and inert even under conditions of operation because of many years
of uninterrupted service without replacement of the oil
 Resist oxidation which results in development of acid and sludge
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1. ELECTRIC STRENGTH OF INSULATING OIL

Electric strength is not a criterion of insulating oil manufacturing quality but a

conventional test intended to reveal the extent of physical pollution by water and
other suspended matter, and the advisability of carrying out drying and filtration
treatment before the oils are introduced into the apparatus for which they are
intended.

The measured value of the electric strength depends essentially on the apparatus
and procedure used.

Although in principle the technical problem concerning the assessment of electric

strength is the same for new oils, treated oils and used oils, it would seem that this
test should be standardized solely for the purpose of international transactions in
new oils intended for electrotechnical users, transactions in which a common
denominator is desired. Each national committee can standardize, in its own
country, a special different method for the control of used oils.

The test described below consists in subjecting the oil, contained in a specified
apparatus, to an a.c electric field with a continuously increasing rate of voltage
rise, till the oil breaks down.

2. GENERAL

The test is, in principle, the same for all classes of oil (for transformers, for oil-
filled cables, for circuit breakers, for capacitors), whether new or used. It is
mainly intended for the acceptance of new oils at the time of their delivery: its
application is restricted to oils having a viscosity of not more than 50 centistokes
at 20 deg. C.

3. SAMPLING

As the electric strength is exceptionally sensitive to the slightest contamination of

the sample, the importance of careful sampling, with special reference to possible
absorption of humidity, cannot be too strongly emphasized. Samples of insulating
oil for electric strength tests are only drawn by or under the immediate
supervision of persons of judgement, skill and experience in the handling of
insulating oils.

The oil is sampled at the place where it is considered to be the most polluted for
example, at the lowest point of the receptacle holding it.

4. CONDITION OF THE OIL

The test is carried out on the oil as received, without drying or degreasing.
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5. TEST CELL

The cell, made of glass or plastic, is transparent, with an effective volume

between 300 and 500 ml. It is preferably closed

6. ELECTRODES

The copper, brays, bronze or stainless steel polished electrode arc either spherical
(12.5mm to 13.0mm diameter) as given in fig. 1 or spherical surfaced of the shape
and dimensions given in fig. 2. The electrodes are mounted on a horizontal axis
and are 2.5mm apart.

The gap between them is set to an accuracy of plus minus 1mm by means of
thickness gauges. The axis of the electrodes is immersed to a depth of
approximately 40mm.

Electrodes tire replaced as soon as pitting caused by discharges is observed.

7. PREPARATION OF THE CELL

When it is not in use, it is recommended to store the apparatus full of dry oil in a
clean dry place, protected from dust.

If it has not been used for some time, it is thoroughly cleaned: the electrodes are
removed, cleaned and finally rinsed with dry clean new oil. Replacement of the
electrodes is carried out with the greatest care, avoiding all direct contact with the
fingers.

Immediately before use, the cell is cleaned by rinsing with the test oil (several
times, if possible) before proceeding to the final filling under the conditions laid
down in clause 7.

8. PREPARATION OF THE SAMPLE

The vessel containing the test oil is gently agitated and turned over several times
in such a way as to ensure as far as possible a homogeneous distribution of the
impurities contained in the oil without causing the formation of air bubbles.

Immediately after this, the sample is poured down into the test cell, slowly in
order to avoid air bubbles forming e.g by means of a clean, dry glass rod. The
operation is carried out in a dry place free from dust.

The oil temperature at the time the test shall be the same as that ambient air,
preferably in the neighborhood of 20 deg. C (15 to 25 deg. C) and noted.
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9. TEST METHOD

The test consist of applying to the electrodes an increasing a.c voltage of

frequency 40 to 62 Hz, the rate of increase of the voltage being regular and equal
to 2 kV/s, starting from zero up to the value producing breakdown.

The circuit is opened manually if a transient spark (audible or visible) occurs

between the electrodes or automatically if an established arc occurs.

In the latter case the automatic switch shall break the voltage within 0.02 second.

The breakdown voltage is the voltage reached during the test at the time the first
spark occurs between electrodes, whether it is transient or established.

The test shall be carried out six times on the same cell filling.

The first application of the voltage is made as quickly as possible after the cell has
been filled, provided there are no longer any air bubble in the oil, and at the latest
ten minutes after filling. After each breakdown, the oil is gently stirred between
the electrodes by means of a clean, dry glass rod, avoiding as far as possible the
production of air bubble. For the five subsequent tests, the voltage is re-applied
one minute after the disappearance of any air bubble that may have been formed.
If the observation of the disappearance of air bubbles is not possible, it is
necessary to wait five minutes before a new breakdown test is started.

The dielectric strength is the arithmetic mean of the six results which have been
obtained.

10. ELECTRICAL APPARATUS

The characteristic of the electrical apparatus shall comply with the following
requirements:

10.1 TRANSFORMER

The test voltage may be obtained by using a step-up transformer supplied from an
a.c (40 to 62 Hz) low voltage source. The primary voltage is gradually increased,
either manually or by an automatic control device.

The voltage applied to the electrodes of the oil-filled has an approximately

sinusoidal wave-form, such that the peak factor is within the following limits:
1.34 (i.e square root two – 5%) and 1.48 (i.e square root two + 5%).
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The transformer and associated equipment are designed to produce a minimum

short-circuit current of 20mA for voltages higher than 15 kV.

10.2 PROTECTIVE GEAR

The test is carried out so as to prevent high-frequency oscillations as far as

possible.

To protect the equipment and to avoid decomposition of the oil at the instant of
breakdown, a resistance limiting the breakdown current may be inserted it series
with the test cell.

The primary circuit of the high voltage transformer is fitted with a circuit breaker
operated by the current flowing. Following the breakdown of the sample, and with
a delay not more than 0.02 second. The circuit breaker is fitted with a no-voltage
release coil to protect the equipment.

10.3 VOLTAGE REGULATION

Voltage regulation may be ensured by one of the following methods:

a. Variable ratio auto transformer

b. Resistance type voltage divider
c. Generator field regulation
d. Induction regulator

Preference is given to an automatic system for increasing the voltage, because it is

difficult to obtain manually a reasonably uniform rate of voltage rise as a function
of time.

10.4 MEASUREMENT OF TEST VOLTAGE

For the purpose of this document, the magnitude of the test voltage is defined as
its peak value divided by square root two.

This voltage may be measured by means of a peak voltmeter or by means of

another types of voltmeter connected to the input or output side of the testing
transformer, or to a special winding provided thereon the instrument then used
must be calibrated against a sphere gap to the full voltage which it is desired to
measure.

The ratio of the voltage derived from the sphere gap to the voltage indicated on
the auxiliary instrument may be dependent upon the presence of the test cell or of
the sphere gap and it is importance that the test cell (or an equivalent load) should
be it’s the circuit during the calibration.
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The sphere gap may be disconnected during the actual test if its presence is
known to have a negligible influence on the voltage ratio.

11.0 RESULTS

The report shows, expressed in kilovolts, the breakdown voltages obtained during
all the tests which have been carried out, and the average of the results. The report
shall mention the type of electrodes used, the frequency of the test voltage and the
oil temperature.

12.0 SAMPLING AND TESTING OIL FOR DIELECTRIC STRENGTH

The following notes, on the care necessary in making a reliable test for the
breakdown voltage of a sample of oil, are mainly intended for the guidance of
those whose experience in the subject may be limited. They should be read in
conjunction with the relevant specification.

13.0 CAUSE OF BAD OIL

Transformer and switchgear oil may be rendered unsuitable for further use by four
main causes:

a. Low dielectric strength

b. High acidity
c. High sludge content
d. Excessive free water content

Low dielectric strength may result from many causes, the most common of which
is foreign particles or fibers and water in combination. Individually their effect
may be relatively small, but together, a contamination of only a few parts in a
million can cause considerable lowering of the breakdown voltage of the oil. High
acidity, sludge and free water should not be tolerated, but they will not necessarily
reduce the dielectric strength below acceptable or specified levels.

14.0 APPEARANCE OF THE SAMPLE

Only an experienced worker can judge the condition of an insulating oil from its
appearance, but a general guide may be obtained from the following observations.

a. A cloudy appearance may indicate that sludge has been formed

b. A dark yellow colour could be a sign of overheating
c. A blackish colour often results from an arc having taken place with either
carbonization of the oil or of the insulation within the equipment
d. A green colour may be due to copper salts dissolving in the oil
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15.0 CLEANLINESS OF APPARATUS

The necessity for scrupulous cleanliness in the apparatus and during the process
of sampling, cannot be over emphasized. The measurement of the dielectric
strength of the sample is as dependent on the cleanliness of the test cell and
sampling apparatus as the condition of the oil itself.

After cleansing the apparatus, it should under no circumstances be wiped, dried or

even handled with a dusty fibrous cloth as loose dust or fibers are liable to cause
immediate contamination

16.0 THE SAMPLING VESSEL

Glass sampling vessels should be cleaned with chromic acid cleaning solution.
The glass sampling should then be washed with distilled water, drained, dried in a
warm oven and cooled (if necessary by blowing with clean dry air to prevent
condensation of moisture). In the absence of chromic acid, hot soapy water may
be used followed by a thorough rinsing with hot water and dried in a warm oven.
Trichlorethylene, n-heptane or a light petroleum spirit is also suitable. Chromic
acid or water should not be used for the cleansing of steel sampling vessels and
thiefs.

Corks, leather washers or other absorbent materials must be kept clear of contact
with water.

17.0 THE TEST CELL

Water should not be used for the cleaning of test cells since the intricate electrode
assemblies are liable to trap moisture, cleansing glass or moulded resin vessels
should be with n-heptane, trichlorethylene or a light petroleum spirit followed by
drying in a warm oven and cooling where necessary with clean dry air. Care
should be taken that the sealing washers do not become permanently
contaminated with the cleaning solution. Prospect vessels should be thoroughly
washed out with clean oil only.

Once a clean test cell has been obtained, it should preferably be kept filled with a
high dielectric strength clean sample of oil. The previously tested sample can
frequently be used for this purpose. A lid is provided for the cell and this should
always be kept in place to prevent atmospheric pollution.

Should an inferior sample of oil be tested, the cell and sampling bottles must be
cleaned, as suggested above, before taking further samples.
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18.0 PRECAUTIONS NECESSARY DURING SAMPLING

Always run off a small quantity of oil into a bottle or test tube for a check on the
appearance of the oil. Attention to this point may prevent contamination of a clean
test cell or samplings bottle.

When a sample is required from a tank or drum, the oil should be set to flow at a
steady rate into the sampling bottle and after being swilled around the sides and
neck, it should be discarded. Without altering the rate of flow of the oil the
quantity required for the test should then be run off while taking extreme care to
prevent the ingress of atmospheric dust, cloth fibers or moisture.

Since the oil taken from a drain cock will inevitably contain an excess of settled
out solid impurities and will not necessarily be representative of the bulk of the
oil, it should either be run until clear or an intermediate sample should be drawn
by means of a thief.

Under some conditions of excessive turbulence of the stipulated minimum

standing period of ten minutes may need to be considerably increased in order to
achieve the true electric strength. Times up to one hour may become necessary in
extreme cases.

Particular care to prevent contamination is necessary when a test is to be made on

a bulk delivery tanker and on all occasions when a high value of electric strength
is anticipated. The procedure suggested above should be rigorously applied and
preferably some 3 to 4 gallons should be run off to thoroughly clean the outlet
before the test sample is taken.
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19. MENGUJI MINYAK PENEBAT

Ujian minyak dilakukan pada perkakas elektrik terutamanya alatubah dan

perkakasuis yang bertebatkan minyak. Pelbagai jenis ujian boleh dijalankan untuk
menentukan keadaan minyak dan meneliti status minyak penebatan tersebut.

Apabila ujian ini dijalankan dengan sempurna, keadaan status alatubah atau
perkakasuis boleh diketahui dan perancangan senggaraan atau membaikpulih
boleh dijadualkan. Dengan cara ini kita dapat menjimatkan kos membaiki
kerosakan.

Diantara ujian-ujian yang dijalankan untuk menentukan minyak penebatan

menepati tahap yang diperlukan ialah:

 Ujian Dielectric Strength

 Ujian Asid (Acidity)
 Ujian Fisikal (Warna dan Air)

19.1 UJIAN DIELECTRIC STRENGTH

Ujian ini dijalankan mengikut spesifikasi IEC 156/63 atau BS 5874/80. Ujian ini
dijalankan untuk menentukan ketahanan minyak penebatan apabila voltan tinggi
AC dikenakan (inject) sebelum berlaku pecah-tebat (breakdown).

Pengujian cara ini adalah yang paling biasa digunakan ditempat kerja.

Ujian ini dapat menentukan kandungan lembapan, habok atau lain-lain objek luar
seperti benda-benda ‘fibrous’.

Ujian ini dijalankan dengan mengambil contoh minyak didalam bekas yang
mengandungi dua elektrod dan dijarakkan mengikut spesifikasi tertentu. Voltan
tinggi dialirkan kepada kedua-dua elektrod dan dilaraskan sehingga kedua-dua
elektrod itu flash-over. Flash-over yang terjadi menandakan tahap voltan tinggi
berkenaan yang dapat dikenakan kepada contoh minyak tersebut.

Ujian minyak penebatan mengikut spesifikasi 156/63 atau BS 5874/80.

19.2 UJIAN ASID

Ujian asid ialah ukuran kandungan asid didalam minyak penebatan. Ujian ini
biasanya dijalankan didalam makamal, berfungsi untuk mengesan tindakbalas
kimia apabila minyak bercampur dengan kekotoran seperti enapan (sludge).

Minyak yang mengandungi melebehi 1.0mg KOH/gm (potassium hydroxide)

mesti ditukar dengan segera dan minyak yang mengandungi 0.5mg KOH/gm dan
keatas perlu diuji sekali lagi dalam tempoh 4 bulan.
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19.3 UJIAN FIZIKAL (WARNA DAN AIR)

i). Secara fizikal warna minyak dapat menggambarkan minyak itu sendiri tetapi
ini bukan petunjuk yang tepat dan tidak dapat digunakan sebagai ukuran yang
tertentu.

a. Warna kuning tua (dark brown) menunjukkan minyak terlalu panas

b. Warna kelabu (cloudy) menunjukkan minyak mengandungi enapan
(sludge)
c. Warna merah tua atau hitam menunjukkan minyak mengandungi serpihan
karbon
d. Warna hijau menunjukkan minyak mengandungi ‘copper salt’

ii) Secara fizikal kita boleh melihat kandungan air (droplets) didalam minyak

20. ATURCARA PENGUJIAN

i. Laraskan jarak elektrod didalam bekas pengujian mengikut spesifikasi

(IEC 156/63 atau BS 587/80 ialah 2.5mm)
ii. Bersihkan bekas pengujian dua atau tiga kali dengan minyak yang hendak
diuji misalnya minyak yang baru dari tong, perkakasuis atau alatubah
iii. Penuhkan contoh minyak sehingga keparas yang ditandakan dibekas
pengujian
iv. Letakkan bekas pengujian yang mengandungi contoh minyak kedalam alat
penguji dan rehatkan selama 10 minit
v. Selepas 10 minit, ujian pertama boleh dilakukan dan catatkan bacaan
voltan pecah-tebat (breakdown voltage) minyak tersebut
vi. Kacau (stir) contoh minyak dan rehatkan selama 5 minit sebelum ujian
kedua dijalankan
vii. Mengikut spesifikasi IEC 156/63 atau BS 5874/80, sejumlah 6 ujian perlu
dijalankan dan diantara setiap ujian ikut prosidur (vi)
viii. Setelah selesai 6 ujian, dapatkan purata bacaan ke enam-enam ujian tadi
ix. Bacaan purata tersebut ialah nilai voltan pecah-tebat contoh minyak
tersebut dan sebagai garispanduan, 30kV dianggap nilai minima.
x.

SEMASA MENJALANKAN UJIAN PENGENDALI MESTILAH BERDIRI

DIATAS TIKAR GETAH DAN KAWASAN PENGUJIAN MESTILAH
DIKEPONG DAN DIGANTUNG TANDA ‘AWAS’
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21. ATURCARA MENGAMBIL CONTOH MINYAK

i. Alirkan sedikit minyak yang hendak diuji kedalam bekas berkaca untuk
mempastikan warna minyak berkenaan. Ini dapat mengelakkan bekas
penguji tidak tercemar
ii. Apabila contoh minyak diambil dari tong atau tangki, minyak tersebut
mesti dialirkan tanpa henti kedalam bekas contoh untuk tujuan
pembersihan. Tanpa menghentikan aliran minyak tersebut, ambil minyak
yang diperlukan untuk pengujian
iii. Contoh minyak yang diambil dari injap keluar (drain cock) lazimnya akan
mengandungi kekotoran yang berlebihan, minyak yang mula-mula
mengalir dibuang, selepas itu barulah contoh minyak diambil untuk
pengujian
iv. Jangan gunakan bahan bergetah atau gasket sebagai penutup kepada bekas
contoh minyak tersebut
v. Jangan biarkan contoh minyak terdedah kepada cahaya matahari

22. FAKTOR KEGAGALAN MINYAK PENEBATAN

a. Daya ketahanan elektrik yang rendah

b. Kandungan asid yang tinggi
c. Kandungan enapan yang tinggi
d. Mengandungi kelembapan