IEEE Transactions on Dielectrics and Electrical Insulation Vol. 23, No.

2; April 2016 873

A Review on Critical Evaluation of Natural Ester vis-a-vis

Mineral Oil Insulating Liquid for Use in Transformers:
Part 1
Dhruvesh M. Mehta
Dept. Electrical Eng., SVNIT, Surat, Gujarat, India
Transformers and Rectifiers (I) Ltd, Gujarat, India

P. Kundu, A. Chowdhury
Dept. Electrical Eng., SVNIT
Surat, Gujarat, India

V.K. Lakhiani and A.S. Jhala

Transformers and Rectifiers (I) Ltd
Gujarat, India

ABSTRACT
In a long 130 years of its journey in service to mankind, the power transformer has
grown in many aspects; ratings, performance, technology, aesthetics and eco-
friendliness. Today, the transformer industry is witnessing the era of shifting from
petroleum based mineral oils that are depleting, environmentally unfavorable, and
proven dangerous to natural esters (vegetable oil based) that are renewable,
environmentally friendly, and non-hazardous. The market and regulatory pressures to
reduce liability risk exposure of mineral-oil-filled distribution and power transformers
are increasing. In addition, there are demands to improve equipment efficiency and
adopt more "earth-friendly" options in our power systems. In the last two decades
there has been a resurgence of usage of natural ester insulating liquids for their
“GREEN” and Safety credentials. These renewable resources have good dielectric
properties and are compatible for use in power transformers. This paper evaluates and
relates the new natural ester oil with existing mineral oil technology in terms of
environmental concern, fire safety, physio-chemical properties, thermal performance,
and dielectric performance. It also covers key modifications in design, manufacturing
and operation to help assure excellent functionality and long life. In brief, this paper
provides transformer designers and users about the advantages and challenges of
“Green Insulating Liquid". Due to the voluminous properties that are compared and
discussed, this paper is presented in two parts: Part 1 discusses on key properties and
standards for the two liquids. Part 2 emphasizes on additional key properties and
material compatibility related to electrical design. Based on evidence discussed in both
parts, it is concluded that natural esters are acceptable for both new transformers and
for retro filling existing units.
Index Terms - Transformer, insulating liquids, transformer solid insulation, natural
Ester liquid, mineral oil, vegetable oil.

1 INTRODUCTION transmission applications. Today, the reliability of this

TRANSFORMERS are the most critical equipment in the
transmission and distribution system effectively catering to
diverse needs, indoor and outdoor distribution, medium
voltage, high voltage, extra high voltage and ultra-high voltage
Manuscript received on 1 April 2015, in final form 26 August 2015, accepted 3
November 2015.
apparatus is governed by its complex three dimensional
insulation structure of paper and pressboard surrounding
the conductors immersed in a volume of insulating liquid
[1].
The liquid-cellulose forms the main component of
insulation having the triple role of dielectric barrier,
mechanical support and heat escape route. Insulating liquid

DOI: 10.1109/TDEI.2015.005370
874 D. M. Mehta et al: A Review on Critical Evaluation of Natural Ester vis-a-vis Mineral Oil Insulating Liquid for Use in Transformers
is the backbone of the insulation systems in the transformers.
Billions of kiloliters of insulating liquids are in use in power
equipment all over the world. [2]. Insulating liquid has three
important functions, i.e. electrically insulate the active parts;
effectively transfer the heat from conductors to the radiators
and providing diagnostic support to assess the health of the
equipment through regular monitoring. Additionally, it works
as quenching media of arc discharges and acoustic dampening
media in power equipment. This is important from the point of
view of longer life of the equipment.
In 1892, Thompson patented chemically stable mineral oil
for use in transformers from petroleum. A decade later,
General Electrical first applied mineral oil in a transformer [1].
After hundreds of years of material development, today’s
transformers are continued to be constructed essentially with
the same material. Over the years, there have been changes
with mineral oils; crude petroleum types (trending paraffinic to
naphthenic), and their manufacturing processes. The early
refining method of distillation used acid cleaning. Today’s
highly refined oils are made by severe hydro-cracking process
and by gas to liquid technology. Also, to improve the
performance of the transformer oil, additives were developed.
The basic mineral insulating oil has a very long history of
reliable performance from lowest kV class right up to 1200 kV
class AC, including the ± 800 kV HVDC transformers.
In Transformers, mainly two types of mineral oils are used.
One is paraffinic based and other is naphthenic based. The
oxidation of paraffin-based crude produces an insoluble sludge,
which increases the viscosity as well as high pour point. It results
in reduced heat transfer capabilities, overheating and reduced
service life under normal operating condition and at very low
temperatures. To overcome the limitations of paraffinic based
transformer oil, naphthenic oils were developed. Though
naphthenic oil is more readily oxidized compared to paraffinic oil,
its oxidation by-products are more soluble in the oil thereby
reducing the severity of the problem. Naphthenic oils contain
aromatic compounds which remain fluid at comparatively low
temperature such as -40 °C [3]. But now isoparaffins have been
developed which give equivalent or better performance compared
to naphthenic.
One of the concerns with mineral oil was its flammability [4,
5]. Today’s escalation in power demand pushes often aging
networks to their limits, causing unprecedentedly high failure
rate in medium and large power transformers. In these
situations, mineral-oil based insulating liquids have shown
costly limitations. Mineral-oil-immersed transformer
explosions and consequent fires causing heavy collateral
damage have raised major safety concerns. Government
regulatory agents are imposing stiff penalties for spills of
mineral oils in environments. There is a major environmental
concern over the toxic effects of uncontained mineral oil spills
[6]. Transformer oil is poorly biodegradable. It can
contaminate our soil and waterways if serious spills occur.
Thousands of transformers are located in populated areas,
shopping centers, and near waterways. Petroleum products are
depleting, and there could be shortage even by the mid-twenty-
first century. Conserving the petroleum reserves and
recycling are vital for petroleum-based products [7, 8].
From 1929 to 1972, polychlorinated biphenyl, PCB’s filled
transformers were commonly used, promoting fire safety in
addition to the common liquid-filled transformer benefits
[1], until mid-1970s, when it was discovered that they were
not environment friendly [5]. The governments put a ban
on further production and commercialization of PCB
liquids due to environmental concerns.
The National Electric CodeTM (NECTM), published by the
National Fire Protection Association, formally incorporated
less-flammable transformer fluids in 1978, termed as “K”
class liquids. Qualifying fluids must meet a minimum
criterion of 300 °C open-cup fire point [1]. Silicone and
synthetic ester based insulating liquids have been
successfully used for almost 40 years as PCB replacements.
Due to this series of environmental regulations and liability
risks involving non-edible oils such as mineral oil and other
PCB replacement, an extensive research and development
program began in the early 1990s [5, 9]. Natural esters
have been used as insulating liquids since their invention in
the late 1880s.
In the last 14 years there has been a surge of usage in the
use of natural ester insulating liquids because of their
obvious “Green” credentials. Two main commercially
available natural ester based liquids are “BIOTEMP”® and
“Envirotemp FR3”®. These liquids are from standard-
grade oleic base oils [5, 10].
Transformer industry has begun use of natural ester
liquids as alternative to mineral oil due to its eco-
friendliness. The world is facing challenge in the use and
dumping of environmental fate of petroleum products.
Many countries do not have their own mineral oil deposits.
These countries include, among others, Paraguay, India and
Pakistan. But these countries are involved in growing
crops, which can be used for the production of vegetable
oils.
However, in order to have widespread application, they
must demonstrate that they are safe, economical, and offer a
high standard of electrical performance over a long
working life of transformer. Hence, it is important to study
their performance under various test conditions as well
continuous operation so that optimized design can be
worked out. Increasing global competition is responsible
for continuous efforts to reduce insulation content in
transformers to reduce the cost. Due to this, margin
between withstand levels and operating stress levels is
reducing. This requires researchers and designers to make
accurate calculation of stress levels at various critical
electrode configurations under different test voltage levels
and different test connections for this new class K liquid.
In short, aggressive competition in transformer industry
and environmental concerns pushes transformer industry to
use environment friendly, class K liquid. In the backdrop of
all this, paper presents comparison on mineral oil and
natural ester liquids. It covers important aspects to provide
IEEE Transactions on Dielectrics and Electrical Insulation Vol. 23, No. 2; April 2016 875

Table 1. Basic properties of insulating liquids (mineral oil and natural Ester liquid). petroleum. Natural esters liquids can be extracted from
Natural Ester Ref crops like, canola, sun-flower, flax, soyabean, olive, poppy,
Properties Standard Mineral Oil
Liquid No. rapeseed and others.
Crops, To offer perceptibility for examination of an assembled
Material Petroleum crude Sunflower
Used
-
oil beans, Soya
11 device in a tank, a low color number of mineral insulating
beans, etc. oil is desirable. Oil deterioration increases the color number
Principal Complex mixture Plant based during service which indicates presence of contaminants in
- 11
components of hydrocarbons natural ester oil. New natural ester liquids may originally be somewhat
darker in color, than highly refined new mineral oil.

3 INTERNATIONAL STANDARDS
Chemical 11,
composition
-
12 Use of natural ester in transformer is evolving. Presently,
these liquids are being used primarily in distribution and
medium power transformers in new as well as for
retrofilling existing transformers. Research is still on in
Visual ASTM D 13, application of natural ester in EHV class transformers.
Clear and bright Clear and bright Siemens has already developed 400 kV class power
examination 1524 14
ASTM D
Pale Yellow Light Green
13, transformer using natural ester liquid. To provide assistance
Color 1500 14, to transformer designer and operator, a guide is required.
IEEE 0.5 ≤1 15
Therefore, for natural ester liquid different standards are
well established just like mineral oil. Table II gives the list
of different standards commercially available for mineral
Appearance
of liquid oil and natural ester liquid.

Table 2. List of available international standards on different insulating liquids.

Ref.
Mineral Oil Natural Ester Liquid
No.
a comprehensive guide to the designer to understand the key IEC 60296 - Edition 4.0 - IEC 62770 - Edition 1.0 -
merits and demerits of this new insulating liquid for acceptable 2012-02 - Fluids for 2013-11 - Fluids for
electrotechnical applications - electrotechnical applications 16,
performance of the transformer. The paper provides thorough Unused mineral insulating oils - Unused natural esters for 17
assessment of the natural ester in terms of chemical for transformers and transformers and similar
composition, referable standards, environment friendliness, fire switchgear electrical equipment
confidence, oxidation stability, dissipation factor, permittivity, ASTM D 6871-03 - 2008 -
ASTM D 3487-09 - Standard
Standard specification for
density, pour point, kinematic viscosity, DC resistivity, specification for Mineral
Natural (Vegetable Oil)
18,
electrostatic charging tendency, breakdown voltage Insulating Oil Used in 19
Ester Fluids Used in
Electrical Apparatus
performance, effect of concentrated heat flux, dissolved gas Electrical apparatus
generation and analysis methods, impregnated pressboard IEEE STD C57.106 - 2006 - IEEE STD C57.147 - 2008 -
IEEE Guide for Acceptance IEEE Guide for Acceptance 13,
behavior, performance and behavior under application of and Maintenance of Insulating and Maintenance of Natural 14
lightning impulse, partial discharge behavior, design changes oil in equipment Ester Fluids in Transformers
and challenges and overall impact on it, OLTC performance
and material compatibility with this natural ester liquid, etc.
4 PHYSIOCHEMICAL PROPERTIES
In view of numerous properties to be compared and COMPARISON
analyzed, the paper is split in to two parts. Part 1 deals with
basic properties, environmental concerns, fire and flash point, Table III compares the physio-chemical properties of
physio-chemical properties, water saturation, oxidation different liquids. Acidity of transformer mineral oil is
stability and design challenges. Part 2 covers miscibility of hazardous property for insulation in transformer. It
natural ester with mineral oil for retro filling of the transformer deteriorates the insulation property of solid insulation.
as well as material compatibility. It also covers the properties Acidic mineral oil, allows more water content to dissolve
governing dielectric design requirements in detail including into oil. Acidity accelerates the oxidation process in the oil.
lightning impulse, PD behavior and OLTC performance. Acid also impacts rusting of iron in presence of moisture. A
higher relative acid value is inherent in natural esters;
however, they are benign due to their long molecular chain.
2 CHEMISTRY AND APPEARANCE OF
Short chain acids from deterioration of mineral oil are more
TRANSFORMER INSULATING LIQUIDS aggressive. Acidity of insulating liquid is expressed in mg
Table I, gives the comparison of basic properties, atomic of KOH required to neutralize the acid present in a gram of
structure and appearance of mineral oil and natural ester insulating liquid. This is, also known as “Neutralization
insulating liquids. Transformer mineral oil is extracted from Number”. Inter facial tension (IFT) between the water and
876 D. M. Mehta et al: A Review on Critical Evaluation of Natural Ester vis-a-vis Mineral Oil Insulating Liquid for Use in Transformers

oil interface is the way to measure molecular attractive force supervisory representatives are now looking into this issue
between water and oil. It is measured in Dyne/cm or mN/m. and are imposing rigid punishments on petroleum based
Inter-facial tension is exactly useful for determining the leaks. Thousands of transformers filled with mineral oil are
presence of polar contaminants and mineral oil decay products. located in populated areas, shopping centers, and near
New mineral oil generally exhibits relatively higher inter-facial waterways which are potentially dangerous from points of
tension than new natural ester liquid. Insulating liquid view of fire safety, and environment issues.
oxidation contaminants lower the IFT.
Table 4. Fire and flash point details of insulating liquids [13, 14, 16-25].
Table 3. Physiochemical properties of transformer insulating liquids [13, 14,
Mineral Natural
16, 17-23]. Properties Standard
Oil Ester Liquid
Natural Ester Fire Safety Class IEC O1 K2
Properties Standard Mineral Oil
Liquid
Total acidity ASTM Limit 145 Limit 275
IEC 1.2 Max. 0.6
(mg KOH/g) Flash Point (°C) IEEE - Min. 275
Neutralization ASTM 0.03 0.06
IEC ≥ 135 Min. 250
number IEEE 0.015 0.015
Between ASTM Limit 170 Limit 300
ASTM 40 Fire Point (°C)
Interfacial 26 to 30 IEEE - Min. 300
Tension Between IEC - Min. 300
IEEE 38
[dyne/cm] 25 to 30 Calorific Value MJ/kg Ref. [23] 46 37.5
mN/m No general
IEC - Transformer separation
requirement
Uninhibited oil: Not distance requirement FM GLOBAL 1/10th The distance
Detectable from other transformer STANDARD required for mineral oil
(< 0.01 %) or building or other 3990 immersed transformers
Trace Inhibited oil: Total substation equipment
Inhibitors and <0.08% additives - Not required
Requirement of Fire
Total IEC Inhibited oils: 0.08% Max. weight needed even for indoor
extinguishing system
Additives – 0.40% fraction application
Note: Supplier shall 5%
declare types and Table 5. Environmental impacts of transformer insulating liquids.
concentration of all Natural Ester Ref.
additives Properties Standard Mineral Oil
Liquid no.
Method
Biodegradability 20,
5 FIRE ASSURANCE at 28 days
OECD <10% >94%
26
301 F
The fire and flash points are measures of the liquids OECD Toxic/forms
Non-Toxic
27,
resistivity to catch fire. The flash point of a flammable liquid is Soil Eco-toxicity fresh as well
Methods toxic products 28
as aged oil
the lowest temperature at which the vapor pressure is sufficient Acute aquatic
to form an ignitable mixture with air near the surface of the OECD 203 Toxic Non-Toxic 20
toxicity
liquid. The fire point is the lowest temperature at which a Acute Oral
OECD 420 Toxic Non-Toxic 20
liquid in an open container will attain a vapor pressure toxicity
sufficient to continue to burn when once ignited. Table 4 To avoid Due to Fast
contamination biological
compares the fire resistive property of mineral oil and natural Contamination with ground degradation, on
ester liquids. Mineral oil has a much lower flash and fire point with ground water oil major leakage 29
in comparison with natural ester liquid. NECTM requires a fire water compartment in no need of oil
point of at least 300 °C to classify as “less flammable liquids”. the foundation compartment in
is needed the foundation
Natural esters have significantly higher flash and fire points
than that of conventional mineral oil. Calorific value of the Dept. of
Natural Ester has less than 2 %
insulating liquid is a measure of the amount of energy Total life cycle Commerce
of the carbon foot print than 20
carbon footprint NIST BEES
produced by the complete combustion of the material tested. V 4.0
mineral oil.
There have been no reported cases of transformer fires
Dept. Of
involving natural ester liquid. Overall
Commerce
environmental 1/4th Impact Of Mineral Oil 20
NIST
impact
6 ENVIRONMENTAL IMPACTS BEES V4.0
Greenhouse
Table V gives the significant advantage of natural ester over gases attributed
TONS per
mineral oil in terms of environmental concerns. Two major to transformer
1000 4.18 0.075 20
environmental impacts lead towards use of alternate natural liquid for its
Gallons
complete life
resources in transformers: cycle
1. Petroleum products are sooner or later going to run out, and Carbon Neutral
Not Carbon Carbon
30
there could be severe shortage by the mid twenty-first century. Neutral Neutral
ASTM
2. Transformer oil is poorly biodegradable. It could pollute our Corrosive
D1275-06 Non Corrosive Not Detected 20
sulphur
soil and waterways if severe leaks happen. Government Method B
IEEE Transactions on Dielectrics and Electrical Insulation Vol. 23, No. 2; April 2016 877

7 WATER SATURATION sub-zero (0 °C) temperatures and may float on liquids that
may have densities higher than 0.917. Table 8 provides the
Water presence in transformer insulation is dangerous to
relative density limits given in different standards for
overall life of transformers. It may be present in insulating
mineral oil and natural ester liquids.
liquids in several forms. Presence of water in the form of
distinct droplets or as a cloud detached throughout liquid can Table 7. Oxidation stability limits of different insulating liquids.
be noticed by visual examination. This type of water presence Mineral Natural Ref
results into decreased dielectric strength of the liquid. Oil Ester Liquid No.
As per IEC, Test method C is
It is important to note that water saturation limit for mineral 164 hours 48 hours at
same for both liquid, accept 17
oil is not directly applicable to natural ester liquid as it is at 120 °C 120 °C
duration for accelerated aging
hygroscopic in nature and can handle more water and still can Mineral Oil >>> Natural
Oxidation Stability
maintain the dielectric strength to permissible value. However, Ester
11
Oxidation Stability values 300
the effect of water content on dielectric strength as a function of < 40 Minutes
obtained using RBOT Test Minutes
percent of saturation is the same for both natural ester and
mineral oil [31, 32]. Table 6 gives the water content limits for Table 8. Relative density of different insulating liquids.
mineral and natural ester liquid specified in different standards Natural Ref.
Property Standard Mineral Oil
in as received condition from suppliers. Ester Liquid No.
Relative Density
ASTM ≤ 0.91 ≤ 0.92
Table 6. Water content limits specified in different Standards on Insulating [g/ml][15 °C/15 °C] 13,
Liquids [13, 14, 20, 23, 33]. ≤ 0.91 at 15 ≤ 0.96 at 14
IEEE
Natural Ester °C/15 °C 25°C
Standard Mineral Oil Density at 20 °C 16,
Liquid IEC Max. 0.895 Max. 1.0
ASTM ≤ 35 ≤ 200 [g/ml] 17
Allowable
≤ 30 For Bulk supply
water content IEC ≤ 200
≤ 40 For Drum supply
in liquid as
≤ 200 For bulk
10 POUR POINT
received from
suppliers IEEE Max. 25
supply at 20 °C Pour point is defined as 3 °C above the temperature of
[mg/kg] ≤ 100 For drum fluid in a tube tilted at 90 °C where the fluid does not flow
supply at 20 °C
within five seconds of time [34]. Pour point of an insulating
liquid is a vital property mostly where ambient temperature
8 OXIDATION STABILITY can be below freezing point. If the oil temperature drops
The presence of Carbon - Carbon double bond makes below pour point of the insulating liquid, flow may stop.
insulating liquids prone to oxidation. In a natural ester more Also, the movement of tap changer could be impacted.
carbon – carbon double bonds are present in comparison with Table 9 compares pour point limits given in different
mineral oil and it is more susceptible to oxidation. The standards and also compares the behavior of mineral oil and
oxidation process is irreversible and in reaction process, natural ester liquids under cold condition.
oxygen is consumed. In case of natural ester liquids,
continuous exposure to oxygen will produce complex Table 9. Pour point of different insulating liquids.
molecules that can slightly increase the viscosity of natural Natural Ref.
Properties Standard Mineral Oil
Ester Liquid no
ester in the tank and/or produces oxygen containing Pour Point (°C) ASTM ≤ -40 (°C) ≤ -10 (°C) 13,
byproducts such as alcohols, aldehyde, acids, and ketones. IEEE ≤ -10 (°C) 14
With continuous exposer to oxygen, thin film of gel is formed 16,
IEC ≤ -40 (°C) ≤ -10 (°C)
in natural ester. To avoid the oxidation of the natural ester 17
liquid during manufacturing process as well as during Natural ester has reduced
Tendency to tendency to develop voids when
operation, it is necessary to limit exposure of the insulating develop voids cooled beyond its Pour Point
35
liquid to the atmosphere. Due to this reason ester liquid Temperature.
immersed transformers are constructed with sealed type No special care required to be
transformer [17]. Large transformers design often uses taken during cold start of 34,
Cold Start
natural ester immersed 35
nitrogen in the headspace or those with an insulating liquid transformer.
conservator require a diaphragm barrier between the insulating Recommended to run
Ambient falls
liquid and external venting. Table VII provides the oxidation below 0°C
transformer under No Load 29
Condition
stability details mentioned in different references for mineral
oil and natural ester liquid.
11 DISSOLVED GAS ANALYSIS (DGA)
9 DENSITY AND STRAY GASSING
The relative density of an insulating liquid is the ratio of the Stray gassing is defined as “The formation of gases when
weights of equal volumes of liquid and water at 15 °C. In insulating oils is heated at relatively low temperatures (90-
certain cold climates, ice may form in equipment exposed to 200 °C)” [36]. Table 10 gives the changes in DGA methods
878 D. M. Mehta et al: A Review on Critical Evaluation of Natural Ester vis-a-vis Mineral Oil Insulating Liquid for Use in Transformers

and Duval Triangle for their applicability to analyze natural Table 11. Effect of concentrated heat flux on transformer insulating oil.
ester liquid and mineral oil under different fault conditions. In Mineral Oil Natural Ester Liquid Ref No.
natural ester at relatively low temperatures in the range of 80 Effect of
Due to local overheating, The disintegration
and decomposition of molecular bonds and
°C to 250 °C a substantial development of stray gases like overheating
polar particles appearance may take place.
ethane and hydrogen is observed for a period of time (weeks to Effect of adhesion of liquid layer to the surface
42
Experiment
months) after transformer is energized [29]. It is also observed of the heater is clearly observed while in
result
that susceptibility towards stray gas generation varies from mineral oil no such phenomenon is observed.
batch to batch of FR3 [38]. Natural esters have higher gas
generation on account of PD (hydrogen with traces of Table 12. Transformer overall design challenges.
acetylene) compared to mineral oil at the same voltage level Natural Ester Ref
Mineral Oil
Liquid No.
[40].
Transformer Tank Design
Table 10. DGA analysis of transformer insulating liquids. Breathing
Recommended Not Recommended
transformer
Ref 11
Mineral Oil Natural Ester Liquid Hermetical sealed
No Recommended Recommended
transformer
Same diagnosis methods are applicable for natural 29, OLTC
ester; however amongst all Duval triangle is the 36, Recommended Hermetical sealed 29
DGA method compartment
most reliable method to be applied for natural 38, Breathing Rubber bag, Nitrogen
esters. 40 Alternate to sealed
transformer / blanket or Expanding 29
Duval Electrical faults in natural ester liquid (electrical transformer
sealed corrugation
triangle for discharges, breakdowns and partial discharge) can
electrical be detected using existing mineral oil dual triangle
29, Table 13. Transformer MVA rating and dimensional challenges.
fault without any modification.
40 Natural Ester Ref
Duval Thermal fault can be detected for natural ester by Mineral Oil
Liquid No.
triangle for modifying zone boundaries for thermal faults T1,
thermal fault Using natural ester liquid, continuous MVA
T2, and T3 of existing mineral oil Duval triangle.
Continuous capacity of existing mineral oil immersed 20,
Applicable MVA transformer can be increased up to around 12 % 43,
Duval capacity (Ref 27 suggest up to 20%) keeping same losses 44
Triangle for and impedance at base MVA.
Duval Triangle 4 Duval Triangle 6 29
low thermal Using natural ester liquid, despite increase in
faults and Footprint Of MVA rating of mineral oil transformer, 20%
stray gassing 43
Transformers reduction in overall size of the transformer
footprint and 18% in volume.
For natural ester liquid immersed transformer,
Energy
12 EFFECT OF CONCENTRATED HEAT FLUX Efficient
though increase in rating and reduced in size, 43,
losses can be maintained same as mineral oil 45
To remove the moisture and to increase the impregnation rate, Transformer
immersed transformer.
transformer insulating liquid is heated before filling in the heat Sludge
Natural esters generate less sludge as compared to
20,
exchanger which is a part of filtration unit. Excessive heat flux mineral oil. Only 1/20 the sludge is formed in
Formation 43
natural esters in comparison with mineral oil.
has adverse impact on dielectric dissipation factor (DDF) of the Life Cycle
insulating liquids [42]. Natural ester liquid has a lower thermal Natural esters immersed transformer can result
Cost and
into much lower life cycle costs and deferred 43
limit than mineral oil to initiate a phase change. During Capital
capital expenditure.
processing, due to their higher viscosity, natural ester liquid expenditure
To take advantage of reduction of cellulose
remains in contact with heating element for more time in
degradation, higher temperature rises are possible
comparison with mineral oil. Together, these factors mean that High if high temperature materials in line with IEC
the allowable maximum watt density for exposure is lower for Temperature 60076: Part 14 can be used. In such cases the foot 45
natural esters. Probable solutions could be limiting the Insulation print of transformer can be reduced. Also, Natural
ester high fire point increases the fire safety of
maximum watt density or heat flux density or avoiding
high temperature transformers.
immersion heaters and using plate-to-plate heat exchangers in
lieu thereof (to increase heating surface and reduce concentrated
heat flux). Table 11 shows the effect of exceeding the critical 14 MOISTURE DIFFUSION COEFFICIENT
heat flux temperature for natural esters compared to mineral oil. OF LIQUID IMPREGNATED PRESSBOARD
INSULATION
13 TRANSFORMER OVERALL DESIGN
Presence of moisture in cellulose insulation influences
CHANGES / CHALLENGES
the performance of pressboard-insulating liquid systems in
Table 12 explains the recommended changes that are to be transformers by accelerating the aging processes and also
incorporated during designing the natural ester liquid decreases its dielectric strength [46]. During the normal
immersed transformer compared to mineral oil immersed operation of the transformer, on account of ageing of
transformers. Table 13 provides overall design changes needed insulation or some local instances of moisture ingress from
to be incorporated for natural ester liquid immersed atmosphere, the moisture migrates to surrounding liquids.
transformers. This quantum of migration depends upon the diffusion
IEEE Transactions on Dielectrics and Electrical Insulation Vol. 23, No. 2; April 2016
coefficient of the fluid and pressboard. Natural ester liquid due
to its hydrophilicity has much higher moisture diffusion
coefficient compared to mineral oil [46], this means, natural
ester liquid can extract more moisture from the pressboard.
This further explains faster drying of solid insulation in natural
ester liquid than in mineral oil. Table 14 compares the drying
time of pressboard with different thicknesses impregnated with
mineral oil and natural ester oil at 70 ºC and variable moisture
concentration between 1 to 8%.
Table 14. Drying times of different thickness pressboard samples at 70 ºC and
moisture concentration between 1-8%.
Pressboard Sample Drying time in hours at 70 ºC Ref
Thickness [mm] Mineral Oil Natural Ester Liquid No.
1 379 192
2 427 344 46
3 499 438
15 CONCLUSIONS
Considering environmental risks, fire safety, health hazard,
demand of footprint reduction, insulating liquid based on
natural ester is the next-generation transformer liquid that is
going to substitute the mineral oil. Natural ester score over
mineral oil on environment concerns with fully
biodegradability, non-toxicity, and is a sustainable source with
carbon neutral characteristics. As well as environmentally
favorable, natural ester is the insulating liquid which has
properties desired for transformer. Natural ester proves as fire
safe with high fire point (“K” class liquid). Water saturation
limits of natural ester being very high it can hold more water.
Also, due to hygroscopic nature water remains in liquid instead
of migrating to solid insulation which extends the life of the
solid insulation. Poor oxidation stability of natural ester
requires a special care and sealed construction of the tank.
Natural Ester also shows stray gassing tendency and generates
hydrogen and ethane leading to misinterpretation in DGA
analysis. Considering, Natural ester liquid’s higher temperature
withstand capability, overall space requirement of transformer
can be reduced by usage of high temperature insulating
materials. Part 2 of the paper discusses dielectric design
challenges and concludes the suitability of natural esters both
for retro- filling and new designs of distribution and power
transformers.
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Electr. Insul. Mag., Vol. 29, No. 5, pp. 13-25, 2013.
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Dhruvesh M. Mehta received the Bachelor’s degree
in electrical engineering from the Gujarat University,
Gujarat, India in 2009, and the Master’s degree with
specialization in Power Systems from the Gujarat
Technological University, Gujarat, India in 2011. He is
currently pursuing the Ph.D. degree in electrical
engineering from the SVNIT, Surat, Gujarat, India.
He is working as Sr. Engineer in Technology Dept. of Transformers and
Rectifiers (I) Ltd., Ahmedabad, Gujarat, India since 2011. He is engaged in
research development activities in the field of electrostatic, electromagnetic
and value engineering of transformers. His area of research is environment
friendly energy resources; design of transformer, FEM based electrostatic and
electromagnetic analysis of transformers, dielectric insulating liquids and
thermal analysis of transformers.
Prasanta Kundu received the B.E. degree in electrical
engineering in 1992 and the M.E. degree in electrical
engineering with specialization in high voltage
engineering from the Indian Institute of Science (IISc),
Bangalore in 1994 and the Ph.D. degree in electrical
engineering from the Indian Institute of Technology
(IIT), Kharagpur, India in 2009.
He is working as Assistant Professor with SV National Institute of
Technology, Surat. He is the recipient of 2007 IEEE DEIS graduate student
fellowship. His area of research is condition monitoring, application of DSP
techniques, electromagnetic field computation. He is associate member of the
Institution of Engineers (India).
Anandita Chowdhury received her B.E. and M.E.
degree from the University of Calcutta, and the Ph.D.
degree from the Indian Institute of Technology,
Kharagpur. Presently she is working as an Associate
Professor in the Department of Electrical
Engineering of S. V. National Institute of
Technology, Surat, India. She is having more than
twenty two years of teaching experience. Her area of
research interest includes Electrical Machines, Drives
and Power system Stability.
V. K. Lakhiani has BE (Hons.) in electrical
engineering) from the University of Jabalpur (1968).
He is presently Director Technical with
Transformers and Rectifiers, Ahmedabad and is
involved in establishment of state-of-the-art
Technology of 765 kV class transformers and Shunt
reactors in T&R.
He has more than 4 decades of experience in design and research
development activities in the field of Power Transformers upto 1200 kV. He
has been associated with various technical committees constituted by
IEEMA, CEA, BIS, CIGRE and CBIP. He was actively involved recently in
revamping CBIP Manual on Transformers. He is convener of panel P2/ET16
on Distribution Transformers and an active member of Transformers
Sectional Committee, ET16 of BIS and represents T&R. He has contributed
more than 30 technical papers in National / International Conferences on
Transformers.
A.S. Jhala received the Bachelor’s degree in
electrical engineering from the Gujarat University,
Gujarat, India in 2004 with Gold Medal. He has
started his professional career with T and R India
Ltd in 2005. From 2005 onwards to till date. He has
been associated with various functions e.g. Testing,
Designs and Technology Development in T&R
India Ltd.
Currently he is working with Technology Division and involved in
various activities of design reliability, design optimization, value
engineering, process improvement, standardization and development of
Technology for UHV transformers. He has contributed around 19 papers
and case studies in various National / International conferences.