2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022
The Impact of the Use of Dry Lubricating
Compound on the Dielectric Properties of Solid
and Liquid Insulation of a Power Transformer
Gopalan Ramesh Senior Member, IEEE, Ashutosh Sharma, MCIGRE and Hemang Thakkar
Abstract -- This paper discusses the impact of the use of dry
lubricating compound during the manufacturing of a power
transformer on the dielectric properties of the solid and liquid
insulation. Change in dielectric properties noticed in specific
cases are discussed. An experimental set up was used for the
research work. The experimental set up and basis for simulating
the operating conditions and the impact of the use of dry
lubricating compound on the solid and liquid insulation of the
transformer are discussed. The test results of the experiment
indicate that the dielectric properties namely surface
conductivity and DC resistivity of the solid insulation can be
affected. This can be measured using the capacitance and power
factor test. Manufacturers often study the compatibility of the
compound with liquid insulation (mineral oil) only and seldom
on the solid insulation. The results suggest that the
manufacturers should study the impact of the compounds on the
solid insulation as well and not only on liquid insulation.
Index Terms—Power Transformers, Solid insulation, Dry
Lubricating Compound, Insulation Power factor, Surface
Conductivity, Tangent Delta
I. INTRODUCTION
T HIS paper discusses an important research work on the
impact of the use of dry lubricating compound containing
Molybdenum di-sulfide and graphite. One such commercially
available product in the market is the MOLYKOTE® G Rapid
Plus [1], which was used in the research experiment.
Manufacturers often study the compatibility of a material [2]
during the manufacture of the power transformers with the
liquid insulation using the ASTM standard D3455 [3].
Published work is available for compatibility with mineral oil
and ester oil only [4]. However, the compatibility of the
construction material with that of the solid insulation is not
available and most manufacturers seldom perform it. Field
failures may have occurred, but such data is not available in
the public domain. The increase in insulation power factor
(tangent delta) after some failures in the network is discussed
in [5] but the root cause for the increase in insulation power
factor (tangent delta) after the noted failures and events of the
power transformer during service is not discussed. The aim
of this research and experiments conducted is to study the
impact of the use of the dry lubricating compound on the solid
and liquid insulation. The research work discussed in this
paper suggests manufacturers to perform such investigations
in light of some specific factory failures and known field pre-
G. Ramesh is with Grid Assets Management and Studies Group of DNV
Energy Systems, PO Box 11539 Dubai, United Arab Emirates (e-mail:
gopalan.ramesh@dnv.com).
978-84-XX-XXXXX-X /22 © 2022 Red iNtransf
mature non-compliances of insulation properties of the power
transformer. The premature increase in insulation power
factor and changes in solid insulation properties of power
transformers measured in the field and after factory dielectric
test failures may be attributed to the contamination of solid
insulation with compounds used during manufacture of the
power transformer.
II. IMPACT OF MATERIALS USED IN THE MANUFACTURE OF
POWER TRANSFORMERS
Dielectric properties of the solid and liquid insulation may
be affected by the use of construction materials in the
transformer. Usually, factory tests are conducted such as the
capacitance and tan delta test or the modern dielectric
frequency response analysis test to test the insulation
condition of the transformer at the factory and in the field.
However, some construction materials used in the
manufacture may result in non-conformities and may affect
the dielectric properties at a later date during the service life
of the transformer. Such non-conformities may not be
immediately manifested during the factory acceptance tests or
during site acceptance tests. This depends upon the material
used and the actual place of use within the transformer. DNV
have noted that some of the transformer manufacturers use
Molybdenum disulfide and graphite or solely Molybdenum
disulfide based dry lubricants. In order to study the impact of
the use this compound on the dielectric properties of the solid
and liquid insulation, DNV and Emirates Global aluminium
(EGA) collaborated to conduct an investigative exercise, as a
research experiment on this subject. The experimental setup
was established at the EGA workshop with an objective to
assess the impact of the use of the dry lubricating compound
on the solid and liquid insulation of the transformer.
A. Use of Dry Lubricating Compound
Dry lubricating compound is used in power transformers
for the larger fasteners used inside the transformer namely
core-yoke clamps at the top and bottom and also sometimes
on the tank cover bolts. While the use of dry lubricating
compound on the tank cover bolts do not affect the internal
insulation structure of the transformer, the use of the dry
lubricating compound in the top and bottom yokes do affect
the internal insulation structure as the compound does mix
with oil and may also fall on the surface of the solid insulation,
A. Sharma is with Grid Assets Management and Studies Group of DNV
Energy Systems, PO Box 11539 Dubai, United Arab Emirates (e-mail:
ashutosh.sharma@dnv.com).
H. Thakkar is with the Energy Group of Emirates Global Aluminium,
Dubai, United Arab Emirates (e-mail: hthakkar@ega.ae).
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2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022
and depending upon the time of service, this may be absorbed
in the insulation as well. The compatibility of the transformer
construction materials with transformer oil is studied prior to
the use in a transformer. However, no research data or
manufacturer experience is available in the public domain for
the compatibility of the dry lubricating compound with solid
insulation namely, pressboard and insulation paper which is
of cellulosic origin. DNV has conducted investigations on
some 200 – 500MVA, 132kV-400 kV class, generator, and
transmission class transformers in the past where the tan delta
(insulation power factor) of the transformers found increased
within a short span (a few months to about 4 years) of service
life. In some transformers, increase in capacitance was also
seen. Investigation revealed use of Molybdenum disulfide and
graphite or solely Molybdenum disulfide on those
transformers. The effect of these compounds present in the
MOLYKOTE G-Rapid Plus are discussed in the next sections.
B. Molykote® G Rapid Plus
The Molykote G-Rapid Plus is a dry lubricant (Fig. 1) used
in a spray form on fasteners. MoS2 is used as a dry lubricant
in the industry from a very long period of time. It is also used
as an additive in lubricating grease and oils as well. Solid
lubricants gained a lot of interest for space applications as
space missions involve a wide range of operating conditions
and longer durations where drive mechanisms need a robust
and reliable operation without maintenance. Authors are of
the view that the use of the compound in transformer
application depends upon the skill of the operator and the
amount of spray is only controlled by the operator. In general,
manufacturers do not have a limit on the amount of spray on
the fastener and no standard operating procedure exists for the
spraying of the compound on the fasteners.
Fig. 1. Molykote ® G Rapid Plus Compound.
It is noted from the datasheet [1] that this compound has
about 7-8% Molybdenum Disulfide (MoS2) and about 2.7%
graphite. The lubrication properties are achieved out of
Molybdenum disulfide and Graphite; both are well known
solid lubricants. Table I provides the physical properties of
Molybdenum Disulfide (MoS2) . It is heavier than oil with a
2
specific gravity of 5.06. It is insoluble in water and
transformer oil. It is usually seen as a grey deposit in the
bottom of the frames. Existing literature indicates that MoS2
is an inorganic semiconductor [6] and at appropriate
frequencies can affect the electric field distribution of the
transformer. This can be seen in the change in tan delta values
of the transformer and may be associated with an increase in
capacitance as well.
TABLE I
PHYSICAL PROPERTIES OF MOLYBDENUM DISULFIDE
Description Value for Molybdenum Disulfide
Molecular Weight 160.07
Appearance Black powder or solid in various
forms
Melting Point 1185 ° C (2165 ° F)
Density 5.06 g/cm3
Solubility in Water Insoluble
Graphite, another component of the compound, is one of
the allotropes of carbon. Graphite is not an element or a
compound, it's an allotrope of carbon. It doesn’t have any
chemical formula of its own. Graphite is a well-known good
conductor of electricity due to its free delocalized electrons. It
is insoluble in organic solvents and has density of about 2.2
g/cm3.
C. Dissipation Factor (Tan Delta) or Insulation Power
Factor
One of the tests that is used when testing the transformer
insulation is the dissipation factor (tan delta) or the power
factor test. Both tests are the same and they are based on the
trigonometric relations between the current and the applied
voltage and which angle is measured and used for calculation.
The difference is marginal when the insulation power factor
is less than 10% and both tests can be used interchangeably.
Hence all these terms are used interchangeably in this research
work and mean one and the same factor. The insulation power
factor of the winding is a measure of the losses in the
insulation under the influence of an electric field. Increasing
power factor makes the insulation system more conductive
and hence increase the losses dissipated in the insulation. The
insulation power factor can increase primarily due to:
1. Increase in moisture content of the insulation- Increase
in moisture content increases the conductivity of the
insulation surface by polarizing the surface. However, it
should be noted that low levels of moisture in solid insulation
up to 1% moisture content by weight of solid insulation, the
change or increase in conductivity with insulation moisture
content is not significant for the electric field levels
maintained in the transformer.
2. Contamination of the insulation system (composite oil
and solid insulation)- The insulation power factor or tan delta
has a direct relationship with the conductivity of the
insulation. Increase in conductivity causes a higher power
factor. Hence if the insulation is contaminated with chemicals,
then we can infer that the cause of power factor increase is
present. A high voltage power transformer insulation has to
be clean, smooth, and dry for it to provide adequate insulation
at the operating and test voltages. Contamination also
increases permittivity and hence if the capacitance has
2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022

increased with the power factor, we can conclude that the Two set ups were used. In set up-1 Fig. 3 and Fig. 4 as
contamination has affected the insulation. shown below, two pieces of insulation were separated by bolts
3. Aging of the insulation- Aging of the insulation in an oil bath. The bolts were used for separation only. One
increases the tangent delta of the transformer as polar side of the bolt had insulation sprayed with the
molecules are present in the oil and on the surface of the MOLYKOTE® compound and the other side had plain
insulation as a result of the insulation aging process which insulation without any spraying of the compound.
results in the decomposition and breakdown of the cellulose
molecules into esters, carbonates, water, and other organic
compounds.
4. Partial discharges or surface tracking path on the surface
of the solid insulation- The insulation power factor or tan delta
can increase if there are tracking paths available on the surface
of the insulation. A detailed inspection of the insulation
surface is necessary to determine whether or not these paths
are available on the surface.

III. EXPERIMENTAL SET UP

Most research literature available have studied the effect

of moisture on conductivity of the insulation but published
data is not available on the relationship of contamination with
conductivity of the insulation. Therefore, DNV in
collaboration and assistance with EGA set up an experimental
basis to study the impact of the MOLYKOTE® compound
applied on the fasteners of the transformer. The basis of the
investigation is to spray some MoS2 on the insulation and
bolts inside an oil bath and leave them at 90°C for 10 days and Fig. 3. Preparation of Samples
study the insulation electrical properties of the insulation and
oil along with reference insulation. This will provide an In the above Fig. 3, only one side of the insulation board is
indication of the change in properties of the insulation. sprayed -. The insulation board on the other side is not sprayed
with any compound and they are placed in the oil bath as
A. Preparation of Samples shown in the set up in Fig. 4.
All insulation samples were 150mm x 150mm x 0.5mm
thick press board (PSP). The same insulation being used in
the transformers. The following pictures highlight the
experimental set up and process of the experiments. The oil
was set at 90°C in the oil bath for 10 days and was monitored
regularly. Fig. 2 shows below the dried insulation samples
being cut and prepared for the experimental set up. The choice
of 90°C is to simulate the maximum oil temperature that can
be expected for the operating conditions of the transformers
based on ambient conditions.

Fig. 4. Set up-1 seen without oil in the bath

In the second set up, Fig. 5, a bolt was sprayed and hung
from the top of the insulation bath with a wire. This is to
simulate the dripping of the Molybdenum disulfide compound
from the top yoke frames onto the insulation structure in the
winding of the transformer.

Fig. 2. Preparation of Samples

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2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022
Fig. 5. Set up-2 seen without oil in the bath
During the experiment for 10 days, the oil bath was set at
90°C. Figures. 6-8 show the set up as seen below.
Fig. 6. Set up-1 seen in oil in the bath
Fig. 7. Set up-2 seen in the oil in the bath
4
Fig. 8. Oil in the bath being set at 90°C
B. Collection of Samples for testing after 10 days
After 10 days in the oil bath at 90°C, samples were
collected for all the 4-press board (PSP) samples. They were
removed from the oil bath and placed on a piece of white
paper. In the set-up 1, we can clearly see the sediments of
molybdenum disulfide at the bottom of the oil bath.
Fig. 9. Sediments of Molybdenum Disulfide seen at the base of the oil bath
The four insulation samples two each per oil bath
numbered from the left of Fig. 10 as 1-A, 1-B, 2-A, and 2-B
were collected, sealed, and sent to a laboratory in Europe for
electrical testing. A reference sample which was originally
received from the factory was also sent to be used for
comparison of the test results.
.
Fig. 10. Insulation Samples for testing. From the left, 1-A, 1-B, 2-A, and 2-
B
2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022

IV. TEST RESULTS We can infer that dissipation factor has increased
significantly due to the presence of Molybdenum disulfide.
The samples 1-A, 1-B and 2-A, 2-B along with reference The dissipation factor has increased by nearly 50 times and is
samples were sent to a laboratory for analysis. The tests out of the acceptance limit for transformers operating in the
requested were tan delta and surface conductivity or field at 0.01 or 1%. The capacitance and the relative
resistivity. These are the two parameters that can affect permittivity have also increased for the insulation sample
insulation performance. Any increase in tan delta or surface sprayed with the compound.
conductivity will lead to detrimental electrical performance of
C. Oil Test Results
the insulation. The results are summarized below in the
figures. The front and back side of each sample is The transformer oil samples from the oil bath were
distinguished as the sprayed side is taken as the front side for subjected to tests as per IEC 60296 [7] and IEC 60422 [8].
the surface conductivity test. The oil from the new oil drum was used as a reference. The
test results indicate that the oil test results for the oil in the oil
A. Surface Conductivity and Resistivity
Bath 1 and Bath 2 with dry lubricant present are similar to that
The results of the surface conductivity and resistivity of the of the new oil drum. This indicates that liquid insulation i.e.,
insulation samples is shown below in the Table II below. mineral oil is not affected by the presence of dry lubricant as
it is heavier and settles down at the bottom of the container
TABLE II
SURFACE CONDUCTIVITY AND SURFACE RESISTIVITY TEST RESULTS
V. DISCUSSION ON INSULATION TEST RESULTS
Sample Nr after 1 min Surface Surface A. Impact of dry lubricant on the Surface Conductivity of
Resistivity Conductivity Insulation
V A σin Ω κ in S As seen in the test results above, the surface conductivity
and tan delta of the sample spayed directly with dry lubricant
A 1000 1.25E-08 2.75E+12 3.63E-13 (main component MoS2) has increased significantly by many
Ref
B 1000 2.39E-08 1.44E+12 6.94E-13 times. However, in practice, the compound is sprayed on the
A 1000 6.70E-09 5.14E+12 1.95E-13 bolts and if excess quantity of the lubricant flows down and
Front side 1 reaches the solid insulation, it settles down and during the
B 1000 6.94E-05 4.96E+08 2.02E-09 drying process can get absorbed on the insulation surface. If
A 1000 1.29E-08 2.67E+12 3.75E-13 the surface of the insulation where the contaminant lubricant
2 settles down is in a high electrical stress area, then it can affect
B 1000 1.14E-08 3.02E+12 3.31E-13 the electrical properties due to increased surface conductivity
A 1000 2.09E-08 1.65E+12 6.07E-13 which leads to reduced creepage distance. This may lead to
Ref flash overs during testing. This is because the test voltages are
B 1000 9.30E-09 3.70E+12 2.70E-13
much higher than the operating voltages.
A 1000 3.63E-08 9.48E+11 1.05E-12 The test results indicate that there is an increase in the
Back side 1
B 1000 1.45E-08 2.37E+12 4.21E-13 conductivity of the samples sprayed with dry lubricant.
Clearly the insulation sprayed with dry lubricant has increased
A 1000 1.17E-08 2.94E+12 3.40E-13 conductivity nearly 10,000 times on the sprayed side, and
2
B 1000 1.92E-08 1.79E+12 5.58E-13 nearly 10 times on the back side of the non-sprayed sample
(back side) in the same oil bath. Therefore, while MoS2 is
We can clearly see the surface conductivity of the sprayed being used a lubricant, it has to be used with care and any
sample has increased by an order of 104 times the reference excess will flow down the insulation and may lead to increase
and other non-sprayed sample. in tan delta and conductivity of the insulation. Increase in
conductivity decreases electrical creepage, which is not
recommended as this may affect design calculations for
B. Insulation Power Factor or Dissipation Factor voltage stress and clearance. Fig. 11 below shows graphically
The results of the dissipation factor, capacitance, and relative the increase in surface conductivity of the insulation board of
permittivity of the insulation samples is shown below in the the various samples.
Table III.
TABLE III Sample Reference
DISSIPATION FACTOR, CAPACITANCE AND RELATIVE PERMITTIVITY TEST
RESULTS 1.00E-05
Front Side Conductivity- K

Ref-ARef-B 1-A 1-B 2-A 2-B

1.00E-07
Siemens

1.00E-09

1.00E-11

1.00E-13
Fig. 11. Increase in surface conductivity of solid insulation.

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2022 7th International Advanced Research Workshop on Transformers (ARWtr) – Baiona - Spain, (23)24-26 October 2022
B. Impact of dry lubricant on the Dissipation Factor of
Insulation
As seen in the test results above, the dissipation factor of
the insulation can be affected by contamination of the
insulation and not only by moisture. The level of
contamination has an impact on the quantum of increase in tan
delta of the insulation. As we infer from the test results, the
contaminated sample has an increase of tan delta nearly five
times the values of the other samples. Hence, the level of
contamination decides the magnitude of increase in
dissipation factor of the transformer. Fig. 12 shows the
increase in tan delta of the insulation samples.
4.00E-02
Dissipation Factor or Tan
3.00E-02
2.00E-02
1.00E-02
Delta
0.00E+00
1 2 3 4
Ref-ARef-B 1-A 1-B
Reference Samples
Tan Delta at 23°C Tan Delta at 90°C
Fig. 12. Increase in dissipation factor of solid insulation.
VI. CONCLUSION
The results of the tests conducted indicate that dielectric
properties namely surface conductivity and DC resistivity of
the solid insulation are affected by construction materials used
in the transformer industry. Increase in electrical conductivity
of the solid insulation decreases the creepage path and this
may affect the clearances. If Molybdenum disulfide, which is
used in the manufacture of power transformers as a solid
lubricant is sprayed in sufficient quantities and it spreads into
the solid insulation either during manufacture or later when
the transformer is in service, then this may affect the electrical
performance of the transformer.
VII. RECOMMENDATION
The results and discussions suggest that the manufacturers
who use the dry lubricating compound to use the same with
caution. Manufacturer of power transformers should conduct
material compatibility tests to study the impact of
construction materials on the solid insulation to determine
whether there will be any issue with the performance of the
transformers during tests or later in service.
VIII. ACKNOWLEDGMENT
The authors gratefully acknowledge the support provided
by EGA for collaborating on this experiment and for the
contributions of Electrical Maintenance Department Staff of
EGA, who helped in the experimental set up and collection of
samples for the tests.
IX. REFERENCES
[1] Form No. 71-0084F-01 (11/20) AGP16261, MOLYKOTE® G Rapid
Plus, Dupont Corporation, 1997-2020
[2] H. M. Wilhelm, V. Franch, L. Tulio, A. F. Franch “Compatibility of
Transformer Construction Materials with Natural Ester-based
Insulating Fluids”, IEEE Transactions on Dielectrics and Electrical
Insulation Vol. 22, No. 5; October 2015.
[3] ASTM D3455, “Standard test methods for compatibility of construction
material with electrical insulating oil of petroleum origin”, ASTM
International, West Conshohocken, PA, 2011, http://www.astm.org.
[4] Technical Brochure 436, Experiences in Service with New Insulation
Liquids, CIGRE, Paris, 2010, page 39-40
[5] Fajli Mustafa, Shaga Shaulagara, Muhammad Ihsan, “The Through
Fault Current effect of 150/20 kV Transformer to Its Insulation
Resistance and Tan Delta test in PT. PLN (Persero) TJBB APP
Durikosambi”, International Conference on High Voltage Engineering
and Power System, October 2-5, 2017, Bali, Indonesia
[6] El Beqqali, I. Zorkani, F. Rogemond, H. Chermette, R. Ben
Chaabane,M. Gamoudi , G. Guillaude, “Electrical properties of
Molybdenum disulphide MoS2. Experimental study and density
functional calculation results;” Synthetic Metals, November 1997
[7] IEC 60296, Fluids for Electrotechnical Applications- Mineral
Insulating Oils for Electrical Applications, International
Electrotechnical Commission, 2021.
5 6 [8] IEC 60422, Mineral Insulating Oils for Electrical Applications-
Supervision and Maintenance Guidance, International Electrotechnical
2-A 2-B Commission, 2013
I. BIOGRAPHIES
Gopalan Ramesh was born in Chennai, India and graduated with a degree in
Electrical Engineering from the Annamalai University in 1989 and obtained
a Post Graduate Diploma in Engineering by Research from Auckland
University of Technology, in 2000.
He is currently with DNV as a Senior Consultant with Grid Assets
Management and Studies Group of DNV, based in Dubai in the United Arab
Emirates. His employment experience includes working in the General
Electric Company of India, ETEL Transformers in New Zealand, ALSTOM
and later AREVA Transformers in New Zealand, and in the UAE. Ramesh
has several years extensive experience in power and distribution transformers
and shunt reactors- Design, manufacturing, testing, field diagnostics,
dissolved gas analysis, factory repair, onsite repair, on-site high voltage
testing, refurbishment, condition assessment and life extension up to
800MVA, 400kV. Ramesh has gained extensive experience in the power,
distribution transformers and shunt reactors up to 800MVA, 400kV across
several countries in India, New Zealand, Australia, North Africa, Middle
East, Turkey, Mexico and in Europe.
Ramesh is a Senior Member of IEEE and a member of Dielectrics and
Insulation Society (DEIS) and the Power and Energy Society of IEEE.
Ashutosh Sharma is presently working as Senior Principal Consultant in
Grids Asset Management and Studies team of DNV based in United Arab
Emirates. His expertise is in the field of power failure investigations on
capital electrical assets and network blackouts. He has performed numerous
failure investigations on assets up to 400kV. He has extensive experience in
the field of installation, testing, commissioning, and maintenance of capital
electrical equipment. In 2007 Ashutosh Sharma joined KEMA as Senior
Consultant with his enriched experience in the field of asset management and
delivered projects covering skills related to asset condition assessment
starting from development of the asset health assessment data templates,
formulation of the health assessment knowledge rules to derive the health
index, calculation of health index.
He is an active member of CIGRE in the Gulf Region. He is a
professionally certified project manager from 2009 and gained his
qualification from Project management Institute, USA. http://www.pmi.org.
Hemang Thakkar is currently working with Emirates Global
Aluminium (EGA) as a Senior Manager - Energy and Electrical Projects.
He has extensive experience in the field of Electrical Power Systems
involving various high voltage, medium voltage and low voltage electrical
equipment and systems.
His experience covers design, engineering, studies, electrical protection
systems, maintenance aspects, failure assessments, electrical safety audits
and many other aspects in power stations, transmission, and distribution
systems, in Oil & Gas and many other industries.