21, rue dArtois, F-75008 PARIS

A2-215

CIGRE 2008

http : //www.cigre.org

The effect of passivator additive used in transformers and reactors mineral oil
to neutralize the sulphur corrosion, and its influence on low thermal defects.
Andr Vita Furnas Brasil (*)
Paulo R. T. Patrocinio Furnas Brasil (*)
Srgio A. Godinho Furnas Brasil
Edilson G. Peres Furnas Brasil
Joo Baudalf Areva - Brasil
(*) Principal Authors.

1. SUMMARY
1.1. In mid 1998, Brazilian manufacturers of transformers and reactors began to use
napthenic insulating mineral oils, made of Venezuelan crude, Type Nitro 10 GBA or 10 GBN.
All of the reactors that failed since 2004, from a number of different manufacturers, used this
type of oil which was used also in the 550 kV Furnas reactors connected in the Ibina/Bateias
transmission line and that till this moment have not failed.
1.2. The failures that occurred in the equipment filled with Nitro 10 GB oil were associated
with the corrosive sulphur present in these oils.
1.3. The transmission utilities in Brazil, including Furnas due to the importance of the
transmission line Ibina/Bateias to the Brazilian system, decided to investigate what was
happening to the reactors - on one hand concerned with the integrity of the equipments, on the
other hand concerned about the high costs involved in losing commercial operation. Due to
the long transmission line lengths involved, the Brazilian transmission utilities cannot operate
without reactors and their failure could result in both loss of revenue and penalties imposed
by the National Regulating Agency of Brazilian System.
1.4. In all the equipment where the presence of corrosive sulphur was confirmed, Furnas
passivated the insulating oil, together with the reactor manufacturers, using a passivator
derived from benzotriazol recommended by the oil supplier.
2. KEYWORDS
Passivator - Sulphur Corrosion - Thermal Defect - Mineral Oil Reactors - Combustible
Gases - Hydrogen

1
avita@furnas.com.br

3. History:
3.1. Characteristics and installation site:
- Installation site: Ibina Substation ( Ibina/Bateias transmission line )
- Equipment: Single Phase Shunt Reactor
- Line Voltage: 550 kV
- Frequency: 60 Hz
- Power: 35 MVAr
- Serial number: 111281-5, 111-281-7, 111281-1
- Manufacturing year: 2002
- Energization year: 2003
3.2. Due to the fact that all the reactors in the Ibina/Bateias transmission line were filled
with Nitro 10 GBN, they were passivated ( adding one liter of passivator for each 1000 liters
of oil) between 02/09/2005 and 17/09/2005. In the table below are indicated the ppm of H2,
using the DGA test some days after the passivation, and the ppm of passivator found in the oil
of the Ibina reactors almost one year later:
Reactor
111281-1
111281-2
111281-3
111281-4
111281-5
111281-6
111281-7

Sample
28/09/2005
28/09/2005
28/09/2005
28/09/2005
28/09/2005
28/09/2005
28/09/2005

H2 (ppm)
55
6
6
10
368
2
6

Passivator (ppm) in 08/2006

58
28
23
23
>150
27
28

3.3. Two years after initial energization, reactor serial number 111281-5 of the Ibina
Substation began to display an abnormal evolution of combustible gases in the insulation oil.
The main gas was hydrogen and the gas increase in this reactor was much higher than in the
other identical units installed in the same substation. The gas evolution before the equipment
was removed from service was:
Test date
H2
24/02/2003 3
25/03/2003 4
27/03/2003 5
12/06/2003 21
19/11/2003 20
22/01/2004 17
22/11/2004 17
22/11/2005 714
07/12/2005 545

O2
11560
20384
11024
15046
10580
8171
2744
3279
5505

N2
24666
44059
25532
47875
59153
54124
59665
57467
57231

CH4
1
1
1
4
37
37
49
43
36

CO
32
55
46
214
381
402
120
393
345

CO2 C2H4 C2H6 C2H2

78
0
0
0
202
0
0
0
141
0
0
0
587
2
10
0
1524
6
46
0
2127
6
55
0
1858
4
87
0
1505
3
101
0
1224
2
85
0

3.4. Analyzing the evolution of the key gases CH4, C2H6 (which existed prior to passivation)
and H2 in the table above, the diagnostics using the IEC and LABORELEC methods they
indicate a thermal problem and partial discharges in oil.
After an internal investigation in the field, made in January 2006, where nothing was found,
before return to commercial operation the oil was degassing and the reactor was energized

2
avita@furnas.com.br

again and after a few days in operation the gases increased again with a predominance of the
hydrogen as can be seen in the follow table:
Test date
H2
16/01/2006 9
26/01/2006 220
03/02/2006 220
23/02/2006 315
03/03/2006 349
23/03/2006 399

O2
N2
CH4 CO CO2 C2H4 C2H6 C2H2
1785 5354
1
13
61
0
1
0
12052 42643
9 162 672
0
10
0
1529 12948
8 144
391
0
8
0
1620 20405
14 216 655
0
14
0
4387 31729
22 426 888
0
19
0
1396 23464
23 169 799
0
18
0

The gas analysis were still indicating a thermal defect in the reactor and the unit was returned
to the factory for a thorough inspection and investigation.
4. Inspections
4.1. In the field:
4.1.1. Two internal inspections were made at the substation: one as previously mentioned and
another prior to returning to the manufacturer. No non conformity was found in the equipment
that could explain the gas evolution.
Also an acoustic detection was made and it did not indicate any partial discharge activity that
could be associated with the internal anomaly.
4.2. In the factory:
4.2.1. After a factory partial discharge test that did not show any problem, the reactor was
opened and the winding removed with the presence of Furnas. See the pictures below:

3
avita@furnas.com.br

4.3. During the inspection it was verified:

4.3.1. Darkening of the paint in the middle of the core pressing structure ( under the winding )
in the bottom of H1 side , caused by a strong heating due to a modification of the
nonmagnetic characteristics of the stainless steel plate as a consequence of the welding
process. The fenolic insulation material used between the pressing structure and the core
showed also heating signs as it can be seen in the picture:

4.3.2. Darkening with less intensity in the same zone of the side H0 and the upper pressing
structures.
5. Solution:
5.1. The core clamping structure used in the reactor are all made of nonmagnetic stainless
steel to avoid excessive heating due to the winding stray flux. The reason why one of the
lower plates become warmer than the other three ( including the upper structure where the oil
is warmer) can probably be attributed to the welding process that was used because high
temperatures can alter the characteristics of the nonmagnetic stainless steel making it become
magnetic.
5.2. As a solution to the problem, to avoid heating of the core clamping structure, aluminum
shields were introduced to reject the leakage flux. To avoid double earthing the shield was
insulated with aramid.

4
avita@furnas.com.br

5.3. Besides the removal of the paint in the affected zone and the introduction of the shield, all
the insulation material with heating signs or damaged during disassembling was substituted.
6. Conclusion:
6.1. Analyzing the DGA results of the reactors it can be seen the higher the quantity of
passivator, the higher the quantity of hydrogen (H2). This verifies studies presented in some
papers that link the passivator quantity to the hydrogen, which tends to increase even under
normal operating conditions.
6.2. Some minor thermal faults do not require the user of transformers and reactors to
deenergize the equipment to make repairs. These faults may be tolerated with regular
monitoring of the evolution of the gas in oil.
6.3. The presence of a metallic part with high temperature, even without any risk of failure,
after the addition of passivator in the oil caused a significant increase in the quantity of
hydrogen in a very short time obliging Furnas and the manufacturer to return the reactor to the
factory and make a repair.
6.4. The heated metallic parts were the cause of the increase of CO, CO2, CH4 and C2H6.
6.4.1. Normally an increase of hydrogen is due to:
-Partial discharges
-Paint not well cured
-Galvanized metal
-Unpainted stainless steel
-Thermal faults
6.5. The experience described above, showed in this specific case, that metal passivator used
in the Ibuna-Bateias 550 kV reactors made sudden increase the hydrogen (H2) gas in the oil
where there was a thermal defect.
6.6. Metal passivator did not have any influence on thermal defect, but was the reason of
hydrogen increase and anticipated necessity of repair the Furnas 550 kV reactors.
6.7. After the described repair the reactor is operating normally and displaying acceptable
DGA results without increase in the hydrogen level as indicated in the next table:

5
avita@furnas.com.br

Test date
06/11/2006
18/11/2006
20/11/2006
24/11/2006
19/12/2006
11/01/2007
13/02/2007
13/03/2007
13/04/2007
16/05/2007

H2
0
0
0
1
1
0
0
0
3
5

O2
11676
2377
2448
1854
7772
12486
12421
19141
12839
17352

N2
32919
6388
7308
6727
25297
36358
44554
68950
60493
60991

CH4
1
1
1
1
2
3
3
6
6
6

CO
3
10
12
19
95
156
276
451
579
546

CO2
40
41
40
51
264
467
660
1496
1580
1770

C2H4 C2H6 C2H2

0
0
0
1
0
0
0
0
0
0
0
0
2
1
0
2
1
0
2
0
0
2
1
0
5
2
0
2
1
0

6.8. As a precaution Furnas decided to ask to the manufacturer to change the oil of all the
reactors installed in Ibina and Bateias Substations. This preventive action has the objective
of avoiding the increase of hydrogen in the oil that could lead to errors in the DGA
interpretation and to ensure the avoidance of any problem due to the corrosive sulfur present
in the original oil that could impact upon the commercial operation of the Ibina Bateias
transmission line.
7. BIBLIOGRAPHY
[1] The Copper Corrosion Phenomenon Nynas ( May/2005 )
Mr. Kjell Sundkvist, Mr. Bruce Pahlavanpour
[2] Corrosive Sulphur Its Origin Detection and Prevention Siemens ( June/2005 )
Mrs. Martinato, Mr. Miethke, Mr. Asano, Mr. Alaor, Dr. Knorr, Mrs. Hhlein
[3] Copper Strip Corrosion Standards ASTM Method D130/IP 154
[4] ASTM D1275 Standad Test Method for Corrosive sulfur in Mineral Oils
[5] NBR 10505 leo Mineral Isolante Determinao de Enxofre Corrosivo
[6] IEC 60296 Fluids for Electrotechnical Applications Unused Mineral Insulation Oils for
Transformers
[7] IEC 60422 Mineral Isulating Oils in Electrical Equipment Supervision and
Maintenance

6
avita@furnas.com.br