

HOME PRODUCTS VIDEO NEWS TESTIMONIALS CAREER SUPPORT CONTACT 

Globecore / Fuller Earth / Quality Assurance: Methods of Transformer Oil Testing

QUALITY ASSURANCE: METHODS OF TRANSFORMER

OIL TESTING

LEAVE YOUR
REQUEST
Name

E-mail

Phone
039 123 456

Message

Transformer Oil Testing Methods Value. Transformer Oil Testing is a proven loss
prevention technique which should be a part of any condition based predictive
maintenance program. This early warning system can allow maintenance
management to identify maintenance priorities, plan work assignment schedules,
LEAVE A MESSAGE
arrange for outside service, and order necessary parts and materials. GlobeCore uses
test results to diagnose transformer problems. The transformer’s fluid not only serves as
a heat transfer medium, it also is part of the transformer’s insulation system. It is
therefore prudent to periodically perform tests on the oil to determine whether it is
capable of fulfilling its role as an insulant. Some of the most common tests for
transformer oil are: Dissolved Gas In Oil Analysis, screen tests, water content, metals-in-
oil, and polychlorinated biphenyl (PCB) content. In this article, we will examine the value
and benefits of each test.
transformer oil
ASTM Significance of Transformer Oil Testing
testing Units
Method Method
methods

Color D1500 Used to observe darkening of the oil by 0-5

comparing it to previous samples of oil from the

same transformer. Transformer oil colour is
determined by means of transmitted light and
given a numerical value (0-5) based on
 comparison with a series of color standards.
HOME PRODUCTS
Noticeable darkening oilVIDEO 
NEWS TESTIMONIALS CAREER SUPPORT CONTACT
indicates either
contamination or that arcing is taking place.

D877 Measures the voltage at which the oil fails kV

electrically, which is indicative of the amount of
contaminant (usually moisture) in the oil. The
Dielectric
dielectric breakdown voltage is measured by
breakdown
applying a voltage between two electrodes
voltage
under the oil. New oil should have a minimum
dielectric strength of 35 kV by ASTM
Transformer Oil Testing Methods.

D3612 Identifies various gas ppm levels that are ppm

present in transformer insulating oil. Different
gasses will dissolve in the oil that indicate
various types of thermal and electrical stress
Dissolved gas
occurring within the transformer. An oil sample
analysis (DGA)
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.

D7151 Identifies any dissolved metals that could µm

originate from overheating or arcing and a
portion of the particulate metals that may
Dissolved
originate from mechanical wear. Measured by
metals
inductively coupled plasma atmonic emission
spectrometry (ICP-AES) and expressed in
micrometers.

D92 Indicates the volatility of insulating oil by °C

Flash point, fire measuring the minimum temperature at which
point the heated oil gives of sufficient vapor to form a
flammable mixture with air.

Interfacial D971 Measures the presence of soluble contaminants mN/m

tension and oxidation products in transformer oil.
Expressed in mN/m, it is a test of interfacial
tension of water against oil, which is different
from surface tension in that the surface of the

water is in contact with oil instead of air. A
decreasing value indicates an increase in
 contaminants and/or oxidation products within
HOME 
the oil.PRODUCTS VIDEO NEWS TESTIMONIALS CAREER SUPPORT CONTACT 
D5837 Determines the presence of degradation in ppb
cellulosic materials such as paper, pressboard,
Furanic and cotton, which generate furanic compounds
compounds in the insulating oil. Measurements are made
using high-performance liquid chromatography
(HPLC).

D1533 Measured in parts per million (ppm) using the ppm

weight of moisture divided by the weight of oil.
Moisture content in oil lowers the insulating
system dielectric strength and allows flashover
Moisture
that can damage a transformer. For mineral oil,
(Water) Content
a generally accepted maximum moisture
content is 35 ppm. This test does not measure
the water content in the transformer paper
insulation.

D974 New transformer oils contain practically no mg

acids. The acidity test measures the content of KOH/g
acids formed by oxidation and contaminates.
Measurements are made by the amount of
Neutralization
potassium hydroxide (KOH in mg) required to
(Acid) number
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.

D2668 Measures the amount of 2,6-ditertiary-butyl %

paracresol and 2,6-ditertiary-butyl phenol that
Oxidation
has been added to new insulating oil as
inhibitor
protection against oxidation. In a used oil it
content
measures the amount remaining after oxidation
has reduced its concentration.

D4059 Detects the concentration level of ppm

Polychlorinated polychlorinated biphenyls in transformer oil by
biphenyls gas chromatography. Measured in ppm, it also
(PCB) content applies to the determination of PCB present in

mixtures known as askarels.

Pour point D97 Indicates the lowest temperature at which the °C

 insulating oil will flow. This test is particularly
HOME
usefulPRODUCTS
in cold climates toVIDEO NEWS
ensure that 
TESTIMONIALS CAREER SUPPORT CONTACT
the oil will
circulate and serve its purpose as an insulating
and cooling medium.

D924 Indicates the dielectric losses of the oil, or %

energy that is dissipated as heat. Useful for
measuring changes within the insulating oil
resulting from contamination or deterioration.
Power Factor The power factor of insulating oil equals the
cosine of the phase angle between an ac
voltage applied and the resulting current. For
mineral oil, the power factor of new oil should
not exceed 0.05 percent at 25 degrees C.

D1298 Determines the density, relative density (specific number

gravity), or API gravity of transformer oil by use
Relative
of hydrometer at a reference temperature. A
density
high specific gravity indicates the oil’s ability to
(specific
suspend water. In extremely cold climates,
gravity)
specific gravity can be used to determine
whether ice will float on the oil.

D1169 Measures the electrical insulating properties of ohms

transformer oil under conditions comparable to
those of the test. A low resistivity reflects a high
Resistivity
content of free ions and ion-forming particles in
the insulating oil, and normally indicates a high
concentration of conductive contaminates.

D1524 Oil is visually examined by passing a beam of Bright,

light through it to determine transparency and dark,
Visual
identify foreign matters. Contamination of the oil clear of
examination
is exhibited by poor transparency, cloudiness, or particles
the observation of foreign particles. etc.

See bigger list of transformer oil testing methods in the end of the article.

The performance characteristics of transformer insulating oil are

monitored and tested at several stages during its service life. Regular
monitoring of the oil’s quality and condition is a part of the process of
servicing electric power equipment. The condition of the oil, its purity and

contamination level will greatly help in indicating the condition of the
transformer’s solid insulation. It is therefore, essential to the life of the
transformer to periodically monitor the condition of the insulating oil. The
HOMEis the
heart of the transformer PRODUCTS VIDEO
solid insulation, NEWS
but the TESTIMONIALS
insulating oil is the  
CAREER SUPPORT CONTACT

life blood of the transformer. Without the life blood, the heart will die.

The ability of insulating oil to maintain its original performance characteristics during long
term operation of electric equipment is referred to as “oil stability.” If the electric power
equipment has no defects and operates in accordance with design and expectations, the
performance characteristics of new oil will change and degrade slower. When new,
transformer oil has a very light color and complies with performance standards that
include dielectric strength and other important characteristics. During the course of the
oil’s service life, the stability of the oil decreases and visible changes occur and oil’s color
slowly becomes darker and darker.

Contaminated oil usually has a high ash content, increased acidity and presence of low
molecular acids. Acidic sludge forms in contaminated oil and aggressively attacks the
cellulose insulation and reacts with the metals of the transformer’s other internal
components.

Timely oil monitoring and oil analysis programs can identify when the oil needs to be
changed or serviced through an oil purification and/or oil regeneration process.
Servicing the oil before it becomes aggressive against the solid insulation is the key to
extending the service life of your transformers.

The main physical and chemical properties tested in Transformer Oil Testing Methods
are the oil’s dielectric strength, dissipation factor, flashpoint, color, amount of solid
particulate matter, water content, gas content and the oil’s acid number.


 
HOME PRODUCTS VIDEO NEWS TESTIMONIALS CAREER SUPPORT CONTACT 

Dielectric strength is one of the most important indications of oil stability and this is often
the first test performed. The “dielectric breakdown test” is calculated as an average of
five breakthroughs achieved in a standard discharger with two electrodes submersed in
the oil at 2.5 mm distance from each other. Six breakthroughs are achieved in the test
and the last five are averaged. If the oil is fresh, the lowest allowable breakthrough
voltage is 30 kV. In some transformers, that meets the minimum operating standard.

Decreasing dielectric strength is caused by contamination of the oil by gas, moisture,

cellulose fibers or other particulate matter.

A similar process is used to calculate the oil’s “dissipation factor.” It is the the oil’s ability
to neutralize energy, prevent breakthroughs and cool the transformer. It is a
characteristic of the oil’s quality and purity and acidity. In general, an increased
dissipation factor means degradation of the oil’s dielectric capabilities.


 Transformer
HOMEoilPRODUCTS
degassing. Connecting
VIDEO NEWS the deg…
deg…
TESTIMONIALS 
CAREER SUPPORT CONTACT 

See more video about transformer oil purification

The color of transformer oil changes from light yellow to cloudy brown under the
influence of temperature, contaminants and electric current. The color is not in itself an
indication of any specific problem, but a dark color is usually an indication of aged and/or
contaminated oil.

TRANSFORMER OIL TESTING METHODS

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., ASTM D1524
The presence of solid particles in the oil and the acid number of the oil are two related oil
purity characteristics. HOME
Unsolved materials
PRODUCTS accumulated
VIDEOin the oil
NEWSin the form of sludge or
TESTIMONIALS
suspended particles (fibers, dust, solved paint, metal particles, ash etc) degrade the oil’s
 
CAREER SUPPORT CONTACT

dielectric properties and promote oil oxidation. The more particles that are present in the
oil, the faster the oil ages. The acid number is expressed as milligrams of KOH required
to neutralize all acids in a gram of oil and indicates the degree of oil aging. A normal and
acceptable acid number is 0.25 mg KOH/g, while the limit of contaminant content is 515
parts per million (ppm).

Moisture and gas content in transformer oil must be tested for thoroughly. Water and
gases are very damaging to your transformer insulation system and are two main cause
of the oxidation process and oil aging process.

Moisture and water content is measured as amount of hydrogen when reacting the oil
with calcium hydride in a certain period of time. Gas content is measured by an
absorptiometric analyzer or a chromatographer.

The oil’s flashpoint and the oil’s setting point are two indications of the general fire safety
of the oil and the oil’s ability to operate in adverse temperature conditions both hot and
cold.

The are distinct advantages of testing and analyzing transformer oil before starting your
electric power equipment and during scheduled maintenance events. Oil testing allows
the
operator to determine the equipment’s operating efficiency, conditions and the
possibility of future malfunctions. If the purity and quality standards are followed, the
equipment will be less likely to experience failures and downtime and unscheduled
maintenance and repair costs.
INSULATION OVERHEATING
HOME PRODUCTS VIDEO NEWS  
TESTIMONIALS CAREER SUPPORT CONTACT

The paper insulation which is normally used to insulate the windings of a transformer is a
cellulose product. If a transformer becomes overloaded for any reason, the windings will
generate more heat and deteriorate the cellulose insulation. So, insulation overheating
measurement is also transformer oil testing methods. A DGA test can identify an
overloaded transformer by a test result showing high carbon monoxide, high carbon
dioxide, and in extreme cases, even elevated methane and ethylene. If a transformer is
overloaded for a long period of time, the deteriorating condition of the cellulose
will shorten the life of the transformer. When the cellulose insulation breaks down to the
point where arcing starts to occur, the transformer must be taken out of service.

INSULATION LIQUID OVERHEATING

Overheating of the liquid insulation is a slightly different problem in transformers and can
be on of transformer oil testing methods. A DGA test will indicate high thermal gases
(methane, ethane and ethylene) as a result of overheating of the liquid. These gases are
formed from a breakdown of the liquid caused by heat. Heating may be caused by
poor contacts on a tap changer, or loose connections on a bushing or a grounding strap,
or circulating currents in the core due to an unintended core ground. Actions that can be
taken once a thermal gas problem is detected would depend on the severity of
the problem. If conditions are not severe, the transformer should be monitored closely. If
conditions gets worse, and thermal combustibles elevate, the transformer will need to be
taken out of service. If the combustibles are stable and remain present, the transformer
should be inspected at the next outage or downtime scheduled.

CORONA

Corona is considered to be partial discharge and occurs at areas of high electrical stress,
such as at sharp points along an electrical path. Partial discharge is commonly explained
as being intermittent

ARCING

Arcing is the most severe condition in a transformer because it indicates a breakdown of

the insulation. The presence of acetylene is an indicator of arcing and so it’s one of the
most important transformer oil testing methods; and even low levels of this gas should
cause concern. Normally, arcing occurs only after other problems surface which show up
through DGA testing. However, the high energy required to produce an arc will cause all
combustibles to be elevated. If the arc occurs in the area of cellulose insulation, carbon
dioxide and carbon monoxide also will be elevated. Arcing can be generated in many
areas of a transformer. Insulation breakdown in the windings, from coil to coil or coil to

ground, will result in arcing. A portion of the insulation may deteriorate until it can
no longer contain the stress of the electrical conductor. If a winding shorts from turn to
turn, or phase to phase, or phase to ground, arcing will occur and the transformer will fail.
When arcing occurs in the area of the windings, the usual result is de-tanking of the
transformer, and a rewind
HOMEconducted. A loose connection
PRODUCTS VIDEO also NEWS
may causeTESTIMONIALS
greater significance would be arcing due to insulation breakdown.
arcing, but of  
CAREER SUPPORT CONTACT

SCREEN TESTING

The “screen test” is a collection of physical, electrical and chemical transformer oil testing
methods. These tests include dielectric breakdown, power factor, inter-facial tension,
acidity, and color. A larger quantity of oil is needed for these tests. To gather the sample,
a clean, moisture free container must be used — typically a 1 liter glass bottle. Each test
is an indication of how suitable the insulation liquid is for service. No single test alone will
represent or indicate the true condition of the liquid. Therefore, it is suggested that they
all be performed.

SUMMARY

Transformer Oil Testing Methods are 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.

LIKE THIS? TELL YOUR FRIENDS: