MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,

MUMBAI

A MICRO PROJECT REPORT

ON

“Prepare report on diagnosis of transformer sample oil

by conducting various tests on it”
Submitted In Partial Fulfillment of the Requirement for the
Course
Of

Six Semesters

DIPLOMA COURSE
IN
ELECTRICAL ENGINEERING
Submitted by

MAHAJAN VISHAL SUPADU

ENROLLMENT NO - 1715440023

Under the guidance of

PROF. V. R. PATIL

DEPARTMENT OF ELECTRICAL ENGINEERING

SSPM’S VASANTRAO MORE POLYTECHNIC, TEHU
2019-20
 SSPM’S
VASANTRAO MORE POLYTECHNIC TEHU
DEPARTMENT OF ELECTRICAL ENGINEERING

CERTIFICATE
This is to be certified that MAHAJAN VISHAL SUPADU students of
third year v semester of Electrical Engineering Department, Vasantrao
More Polytechnic Tehu, completed Micro Project entitled

“Prepare report on diagnosis of transformer sample oil

by conducting various tests on it”

Submitted Project Report for the partial fulfillment of the

curriculum of the course MAINTENANCES OF ELECTRICAL
EQUIPMENT (MEE) (22625) of Six Semester Diploma course
in Electrical Engineering from Maharashtra State Board of Technical
Education, Mumbai.

Guide HOD Principal

Prof. V. R. Patil Prof. N. A. Patil Prof. D.G. Patil
 Proposal
Of
Micro Project
“Prepare report on diagnosis of transformer sample oil by
conducting various tests on it”

1.0 Rationale

The objective of this micro-project study the transformer oil

various test on it. Transformer oil is used for insulation and
cooling purpose in transformers and other electrical equipment,
needs to be tested periodically check its dielectric strength. This
is because it tends to deteriorate over time because of the
environmental condition.

2.0 Literature Review

Transformer oil (also known as insulating oil) is a special type of

oil which has excellent electrical insulating properties and is stable
at high temperatures. Transformer oil is used in oil-filled electrical
power transformers to insulate, stop arcing and corona discharge,
and to dissipate the heat of the transformer (i.e. act as a coolant).
Transformer oil is also used to preserve the transformer’s core and
windings – as these are fully immersed inside the oil. Another
important property of the insulating oil is its ability to prevent
oxidation of the cellulose-made paper insulation. The transformer
oil acts as a barrier between the atmospheric oxygen and the
cellulose – avoiding direct contact and hence minimizing oxidation.
The level of transformer oil is typically measured using a MOG
(Magnetic Oil level Gauge).

Transformer Oil Types

There are two main types of transformer oil used in transformers:

1. Paraffin based transformer oil

2. Naphtha based transformer oil
 Naphtha oil is more easily oxidized than paraffin oil. But the
product of oxidation – i.e. sludge – in the naphtha oil is more
soluble than the sludge from the paraffin oil. Thus sludge of
naphtha-based oil is not precipitated in the bottom of the
transformer. Hence it does not obstruct convection circulation of
the oil, means it does not disturb the transformer cooling
system.

Although Paraffin oil has a lower oxidation rate than Naphtha

oil, the oxidation product (sludge) is insoluble and precipitated
at the bottom of the tank. This sludge acts as an obstruction to
the transformer cooling system.

 Electrical Properties of Transformer Oil

Dielectric Strength of Transformer Oil

The dielectric strength of transformer oil is also known as the

breakdown voltage (BDV) of transformer oil. Breakdown voltage
is measured by observing at what voltage, sparking strands
between two electrodes immersed in the oil, separated by a
specific gap. A low value of BDV indicates presence of moisture
content and conducting substances in the oil.
Or measuring BDV of transformer oil, portable BDV measuring
kit is generally available at site. In this kit, oil is kept in a pot in
which one pair of electrodes are fixed with a gap of 2.5 mm (in
some kit it 4mm) between them. Now slowly rising voltage is
applied between the electrodes. The rate of rising voltage is
controlled at 2 KV/s and observes the voltage at which sparking
starts between the electrodes. That means at which voltage
dielectric strength of transformer oil between the electrodes has
been broken down.

This measurement is taken 3 to 6 times in the same sample of oil,

and we take the average value of these readings. BDV is an
important and popular test of transformer oil, as it is the primary
indicator of the health of oil and it can be easily carried out at the
site.

Dry and clean oil gives BDV results, better than the oil with
moisture content and other conducting impurities. Minimum
breakdown voltage of transformer oil or dielectric strength of
transformer oil at which this oil can safely be used in transformer,
is considered as 30 KV.
 Transformer Oil Testing

Transformer oil needs to be tested to ensure that it works for

today’s standards. Testing standards and procedures are defined
by various international standards, and most of them are set by
the ASTM.

Oil testing consists of measuring the breakdown voltage, and other

chemical and physical properties of the oil, either through portable
test equipment or in a laboratory. Through proper testing, the
transformer’s lifespan is increased, reducing the need to pay for
replacement.

 What Factors Are Tested

Here are the most common things to look for when performing a
transformer oil test:

 Standard Specification for Mineral Insulating Oil Used in

Electrical Apparatus (ASTM D3487)
 Acid number (ASTM D664)
 Dielectric breakdown voltage (ASTM D877)
 Liquid power factor (ASTM D924-08)
 Interfacial tension (ASTM D971)
 Specific resistance (ASTM D1169)
 Corrosive sulfur (ASTM D1275)
 Visual examination (ASTM D1524)

These tests will help determine if the oils are clean and will create a
baseline of properties that need to be tested periodically. Although
there are a large number of tests that are available, they are
expensive. So it’s best to use them as diagnostics if an issue occurs
during primary testing.

The recommended frequency is dependent on the power and the

voltage. If the results from the test are showing some red flags, the
frequency will have to increase. Even if the cost of testing is high,
the expense should be compared to the cost of replacing a
transformer and the downtime associated with losing the
transformer. It’s important to understand the difference between
excessive and normal gassing rates. The amount of dissolved gas in
transformer oil can be found using a dissolved gas analysis (DGA)
test. The gassing rate will vary based on the loading, insulation
material, and transformer design.
 Common Problems When Testing

The table below shows the most common issues that can occur
when testing transformer oil:

Fault Key Gas Results

Corona Hydrogen Low energy discharges create methane
discharge and hydrogen and smaller quantities of
ethylene and ethane.
Arcing Acetylene Large amounts of hydrogen or acetylene
or minor quantities of ethylene and
methane can be produced.
Overheated Carbon If cellulose is overheated, then it will
Cellulose Monoxide produce carbon monoxide
Overheated Methane Overheating oil will produce methane
Oil and and ethylene (300 degrees F) or
Ethylene methane and hydrogen (1,112 degrees
F). Traces of acetylene might be created
if the unit has electrical contacts or if
the problem is severe.

1.0 Proposed Methodology

Procedure to do the micro-project:

1. We collect all the information on internet, books and
references’ books.
2. Divide the total work in group members.
3. We are seen the different test of transformers.
4. We put the all information in Microsoft word
2.0 Action Plan

Name of
Sir Planned Planned
Details of Activity Responsible
No Start Date Finish Date
team member
1 Collect the 16/01/2019 19/01/2019
information in Vishal
textbook
2 Also search the 20/01/2019 22/01/2019
information internet,
Laxmi
and references
books.
3 We are seen the 23/01/2019 23/01/2019
Vishal
different test of
transformer.
4 Put the all 24/01/2019 25/01/2019
Laxmi
information on
Microsoft word

3.0 Resource Required

Sr. Resources Name Quantity Remark

No
1 Internet Google 1 Available
2 Book Electrical Machine 1 Available
3 References Electrical 1 Available
book Technology
4 Microsoft Word 1 Available
office
Micro Project
Report
1.0 Brief Description

In this micro project we conduct the test of transformer oil.

Transformer oil testing is a key part of any maintenance program.
An annual DGA is the most important test for liquid insulation.
Analysis of gases in the oil can indicate insulation
overheating/overloading, liquid overheating, partial discharge
(corona), or arcing in the transformer. The screen test is a
collection of additional physical, electrical and chemical tests,
including: dielectric breakdown, power factor, interfacial tension,
acidity and color. No single test alone will indicate the true
condition of the liquid, so all the screen tests should be performed.
Additional useful tests performed by transformer oil laboratories
include those for water content, PCBs furanic compounds and
metals-in-oil.

2.0 Aim of Micro-project

Conduct the test different test on transformer oil.

3.0 Course Outcome Integrated

 Maintain single phase and three phase transformers

 Maintain insulation system of electrical equipment
4.0 Actual Procedure Followed.

Procedure to do the micro-project:

1. We collect all the information on internet, books and
references’ books.
2. Divide the total work in group members.
3. We are seen the different test of transformers.
4. We put the all information in Microsoft word

5.0 Actual Resources Used.

Sr. Resources Name Quantity Remark

No
1 Internet Google 1 Available
2 Book Electrical Machine 1 Available
3 References Electrical 1 Available
book Technology
4 Microsoft Word 1 Available
office
6.0 Outputs of Micro-Project.

(Drawings of prototype, drawing of survey, presentation of collected data, finding )

What is oil dielectric breakdown voltage testing? Put simply, a

dielectric breakdown voltage test is a measure of the electrical
stress that an insulating oil can withstand without breakdown. The
test is performed using a test vessel that has two electrodes
mounted in it, with a gap between them. A sample of the oil to be
tested is put into the vessel and an ac voltage is applied to the
electrodes. This voltage is increased until the oil breaks down –
that is, until a spark passes between the electrodes. The test
voltage is then immediately turned off. The voltage at which
breakdown occurred is the test result, and is typically evaluated by
comparing it with guidelines set out in various standards, or in the
oil manufacturer’s specifications. The exact method of performing
the test is determined by the standard that is being used, as will be
explained later. The standard typically defines parameters such as
the size and shape of the electrodes, the gap between them, the
rate at which the test voltage is increased, how many times the test
is repeated and whether or not the oil is stirred during the test

Recently time-consuming testing procedures in test labs have been

replaced by on-site oil testing procedures. There are various
manufacturers of portable oil testers. With low weight devices in
the range of 20 to 40 kg, tests up to 100 kV rms can be performed
and reported on-site automatically. Some of them are even battery-
powered and come with accessories.

Breakdown voltage testing procedure

To assess the insulating property of dielectric transformer oil, a
sample of the transformer oil is taken and its breakdown voltage is
measured. Lower the resulting breakdown voltage, the poor quality
of the transformer oil.

1. The transformer oil is filled in the vessel of the testing device.

Two standard-compliant test electrodes with a typical
clearance of 2.5 mm are surrounded by the dielectric oil.
2. A test voltage is applied to the electrodes and is continuously
increased up to the breakdown voltage with a constant,
standard-compliant slew rate of e.g. 2 kV/s.
3. At a certain voltage level breakdown occurs in an electric arc,
leading to a collapse of the test voltage.
4. An instant after ignition of the arc, the test voltage is switched
off automatically by the testing device. Ultra-fast switch off is
highly desirable, as the carbonization due to the electric arc
must be limited to keep the additional pollution as low as
possible.
5. The transformer oil testing device measures and reports the
root mean square value of the breakdown voltage.
6. After the transformer oil test is completed, the insulation oil is
stirred automatically and the test sequence is performed
repeatedly: typically 5 repetitions, depending on the standard.
7. As a result the breakdown voltage is calculated as mean value
of the individual measurements.
  Types of test
 Color; e.g., ASTM D1500.
 Dielectric breakdown voltage; e.g., D 877, ASTM D1816
 Dissolved gas analysis; e.g., ASTM D3612
 Dissolved metals; e.g., ASTM D7151
 Flash point, fire point; e.g., ASTM D92
 Interfacial tension; e.g. D 971
 Furanic compounds; e.g., ASTM D5837
 Karl Fischer moisture; e.g., ASTM D1533
 Liquid power factor; e.g., ASTM D924
 Neutralization number; e.g., ASTM D974
 Oxidation inhibitor content; e.g., ASTM D2668
 Polychlorinated biphenyls content; e.g., ASTM D4059
 Relative density (specific gravity); e.g., D 1298, ASTM D1524
 Resistivity; e.g., ASTM D1169
 Visual examination; e.g., D1524

 International transformer oil testing standards

 VDE370-5/96
 OVE EN60156
 IEC 60156/97,
 ASTM1816-04-1
 ASTM1816-04-2
 ASTM877-02A
 ASTM877-02B
 AS1767.2.1
 Table of testing type

Test ASTM Significance of Test Units

Type Method
Color D1500 Used to observe darkening of the 0-5
oil by comparing it to previous
samples of oil from the same
transformer. Oil color is
determined by means of
transmitted light and given a
numerical value (0-5) based on
comparison with a series of color
standards. Noticeable darkening
oil indicates either contamination
or that arcing is taking place.
Dissolved D3612 Identifies various gas ppm levels ppm
gas analysis that are present in transformer
(DGA) insulating oil. Different gasses will
dissolve in the oil that indicates
various types of thermal and
electrical stress occurring within
the transformer. An oil sample
tube and syringe is used to draw,
retain and transport the oil
sample in the same condition as it
is inside a transformer with all
fault gases dissolved in it. An
internal fault in a transformer can
be discovered earliest using this
test method.
Dissolved D7151 Identifies any dissolved metals µm
metals that could originate from
overheating or arcing and a
portion of the particulate metals
that may originate from
mechanical wear. Measured by
inductively coupled plasma
ammonic emission spectrometry
(ICP-AES) and expressed in
micrometers.
Flash point, D92 Indicates the volatility of °C
fire point insulating oil by measuring the
minimum temperature at which
the heated oil gives of sufficient
vapor to form a flammable
mixture with air.
 Test Type ASTM Significance of Test Units
Method

Furanic D5837 Determines the presence of

compounds degradation in cellulosic
materials such as paper,
pressboard, and cotton, which Ppb
generate furanic compounds in
the insulating oil. Measurements
are made using high-performance
liquid chromatography (HPLC).
Moisture (Water) D1533 Measured in parts per million ppm
Content (ppm) using the weight of
moisture divided by the weight of
oil. Moisture content in oil lowers
the insulating system dielectric
strength and allows flashover
that can damage a transformer.
For mineral oil, generally
accepted maximum moisture
content is 35 ppm. This test does
not measure the water content in
the transformer paper insulation.
Neutralization D974 New transformer oils contain mg
(Acid) number practically no acids. The acidity KOH/g
test measures the content of
acids formed by oxidation and
contaminates. Measurements are
made by the amount of
potassium hydroxide (KOH in mg)
required to neutralize the acid in
one gram of oil. Typically, results
of 0.10 mg KOH/gram of oil or
less are considered good. Higher
values are indicative of a
problem.
Oxidation D2668 Measures the amount of 2, 6- %
inhibitor ditertiary-butyl paracresol and 2,
content 6-ditertiary-butyl phenol that has
been added to new insulating oil
as protection against oxidation.
In used oil it measures the
amount remaining after oxidation
has reduced its concentration.
 Test Type ASTM Significance of Test Units
Method
Polychlorinated D4059 Detects the concentration level of ppm
biphenyls (PCB) polychlorinated biphenyls in
content transformer oil by gas
chromatography. Measured in ppm, it
also applies to the determination of
PCB present in mixtures known as
askarels.
Pour point D97 Indicates the lowest temperature at °C
which the insulating oil will flow. This
test is particularly useful in cold
climates to ensure that the oil will
circulate and serve its purpose as an
insulating and cooling medium.
Resistivity D1169 Measures the electrical insulating ohms
properties of transformer oil under
conditions comparable to those of the
test. A low resistivity reflects a high
content of free ions and ion-forming
particles in the insulating oil, and
normally indicates a high
concentration of conductive
contaminates.
Visual D1524 Oil is visually examined by passing a Bright,
examination beam of light through it to determine dark,
transparency and identify foreign clear of
matters. Contamination of the oil is particles
exhibited by poor transparency, etc.
cloudiness, or the observation of
foreign particles.

Transformer oil testing is important to:

 Determine essential electrical properties of transformer oil

 Identify if a certain oil is suitable for future use
 Detect whether regeneration or filtration is needed
 Reduce oil costs and enhance component life
 Prevent untimely failures and maximize safety
7.0 Skill developed / Learning outcomes of this micro-
projects.

This project is expected to develop the following skills for the

industry identified the competency: Maintain different electrical
equipment following safe practices.
1) Select the various meters
2) Measure electrical quantities
3) Follow safe practices