MINERAL

INSULATING OIL
INTRODUCTION
 For the fifty to sixty years prior to the
beginning of the 1990’s, Paraffinic base oil quality was very slow
to change. With a few exceptions, most Paraffinic stocks,
regardless of location, were made through solvent extraction of
selected crude oil streams. Over the last decade, however,
significant changes have occurred within this industry.

In the early 1990s, the changes began when

European engine oil volatility specifications drove European
suppliers to offer higher VI/lower volatility base oils. Those cost-
effective alternatives to the only preexisting solution – using
expensive synthetic blend stocks such as polyalphaolefins (PAO) –
typically involved solvent dewaxing of a fuels hydrocracker (HC)
bottoms stream to achieve a high-VI, low volatility product.
 Although effective as low volatility base
stocks, these generally are limited product offerings intended only to
complement existing Group I base oil slates. These first-generation
Group III base oils were low-capital-cost solutions to the volatility
challenge that allowed maximum use of existing Group I base oils to
be retained. As a result, European base oil capacity still is almost
entirely solvent refined (Group I) today, and shows few signs of
making any major shift in the near future.

In contrast, starting in the mid-1990s the

North American base oil industry changed direction, and started to
build new base oil plants or substantially modify existing plants to
manufacture hydroprocessed (Group II/II+/III) base oils,
recognizing their benefits in product quality, low operating costs and
flexibility. The result is that in less than a decade, Group II capacity,
currently at 40% of the paraffinic market, will have grown to be the
dominant paraffinicbase oil type in North America.
 While quality and base oil performance were
important drivers of base oil changes in Europe and North America,
in Asia supply shortfalls precipitated the building of new base oil
plants, often by new players in the industry, and mostly utilizing the
newer hydro processing technology. The result has been the creation
of significant availability of higher performance base oils in a
market which, ironically, generally does not yet need them.

Why did Europe and North America, two

interrelated base oil markets with many very similar driving forces
at play, diverge in their approach to improving base oil quality and
performance? Will this disparity in base oil supply capability widen
or narrow in the future? Will the availability of higher-performing
Group II/III base oils in Asia drive existing Group I producers to
upgrade to Group II/III, as it did in North America? What further
changes are in store for the base oil industry, in each of these
regions, in the future?
 This paper will attempt to answer these
questions by examining the underlying drivers for change in each
of these three major regions. Because of similarities in their
technical requirements, North American and European lubricant
and base oil markets will be discussed first. These two markets
will then be compared and contrasted in terms of how base oil
suppliers have responded to these forces. Next, the Asian base oil
market, where drivers are mostly commercial rather than technical,
will be discussed briefly. By examining these many varied driving
factors, both technical and commercial, in each of the three
markets, the authors hope to shed light on why the base oil
industry is where it is today, and where it may be going in the
future.
 LATEST TRENDS
IN MANUFACTURING
TRANSFORMER OIL
 NATURE AND CHARACTERISTICS OF
TRANSFORMER OIL

DEPENDS ON CRUDE NATURE (ORIGIN OF CRUDE )

DEPENDS ON REFINING PROCESS.

 Hydrocracking
 Hydrogenation
 Acid treatment
 Clay treatment.
MANUFACTURING PROCESS
Crude
Distillation
TOBS
Refining/Treatment
(acid, hydrotreatment, solvent extrn)
Clay treatment
Filtration
Transformer oil
TRANSFORMER OIL TYPES

 PARAFFINIC TYPE

 NAPTHENIC TYPE

 MIXED TYPE
NATURE AND COMPOSITION
OF OIL
CHAIN OF HYDRO CARBONS (CH)
84% carbons,14% hydrogen ,1-3 % sulphur,1% N2,
O2 metals &salts

MAIN CONSTITUENT TYPES

 Napthenic
 Paraffinic
 Aromatic
 PARAFFINIC TYPE

Derived From Crudes Having Substantial Contents of

Naturally Occurring N Paraffinic (Wax ) – require
Dewaxing

Chain Structure

Most Commonly Used in India

High Viscosity, Low Resistivity

 NAPTHENIC TYPE

Derived From Crudes Having very Low Naturally

Occurring N Paraffinic(wax)contents

Has Low Natural Pour Points,no Dewaxing

Requirement
Cyclic Structure and Hence Stronger Bonding

Used Abroad &Now Also in India

Low Viscosity, High Quality, Costlier

 IDEAL TRANSFORMER OIL
 Low Density & Low Viscosity - Better Heat Transfer

 Low Pour Point- Avoid Solidification

 High Flash Point - Fire Resistance

 Low Dissipation Factor - Less power loss

 High BDV -High Voltage Application

 High Resistivity - Better Insulation Resistance

 STANDARDS

Important Indian Standards for Acceptance, Limit

Values and Interpretation

 IS 335/1993 for New Oil

 IS 1866/2000 for Oil in Service
 IS 10593 for DGA

There Are Other Standards for Testing Methods.

 QUALITY
OF
TRANSFORMER
OIL
 OIL TESTS

PHYSICAL TESTS

 Appearance
 Density
 Viscosity
 Pour point
 Flash point
 Inter Facial Tension
CHEMICAL TESTS

 Acidity
 Oxidation stability
 Water content
 SK value
 Inhibitor content
 Corrosive sulphur
 Sludge
ELECTRICAL TESTS

 Electric Strength(BDV)

 Resistivity

 DDF
 SIGNIFICANCE AND MEANING OF
TESTS

APPEARANCE

Clear, Transparent : No suspended

matters and sediments

COLOUR OF OIL:

Clear pale yellow : Good

Bright yellow : O.K.
Amber,Brown: Start of deterioration/Sludge

Green :Dissolved Cu or metallic contaminants;

Investigate and Repalce oil

Bad smell oil : Investigate and replace oil

Applicable Standards: IS 335, 1866

DENSITY
 Mass per unit volume;

 Higher Density Means Higher Viscosity Which Will

Reduce Oil Flow and Hence Affects Heat
Dissipation.
 Transformer Oil Density Max =0.89g/cm3

 Applicable Standards : IS 1448 ,335, 1866/2000

 VISCOSITY

 Resistance to Flow;
 High Viscosity Means Higher
Resistance to Flow.
 Hence Low Viscosity Oils to Be Preferred.
 More heat transfer;
 Value-27 cst
 Applicable Standards : IS 335, 1866
 POUR POINT

 Temperature at Which Oil Begins to

Solidify
Lowest temperature at which oil flows
Cold weather application
Value : -6°c
Applicable Standards : IS 1448 , 1866
 FLASH POINT
The minimum temperature at which oil when heated gives off enough
vapour to form a flammable mixture with air.

This test assumes significance after an arcing fault inside a

transformer.

If FP is low -- Fire risk

Flash point can reveal presence of volatile and flammable materials
in oil
APPARATUS :
Fully Automatic Flash Point Test Kit has Been Procured
Recently for the Chennai R&D Lab.

LIMITS:
New oil: 140 C (Min)
 Transformer New Before commissioning 140 C
(Min)
 In service 125C (Min) and should not to decrease by

more than 15 C from previous value.

Applicable Standards : IS 1448 ,335, 1866
 Prepare the brass cup of the FP kit for
filling the oil ; 75 ml of oil is taken;
 Prepare the kit with appropriate settings
 The flame is automatically dipped for
every 3 deg(settable value), starting
from 105 deg till the flash point occurs.
The flash point is displayed
automatically.
IFT
Interfacial tension between oil and water surface.
It is the force necessary to detach a planar ring.
IFT is a good indicator of oil quality and it should be
high.
Very low IFT oil indicates sludge and deterioration.
IFT helps in the detection of polar contaminants .
Apparatus: KRUSS / German make
Limits:
New oil :0.040 N/m
Transformer New before commissioning : 0.035 N/m
For in service Transformer : min 0.015 N/m
Applicable Standards : IS 6104,335,1866
 CORROSIVE SULPHUR

 To detects corrosive and free sulphur compounds in oil.

 If present they are hazardous and deteriorates metal parts

of transformer .

 Requirement – Non corrosive

 Applicable Standards : IS 335

Acidity
The acid content in the oil and plays a major part in
oil contamination.
High Acidity: Metal parts corrosion, Insulation
deterioration,Sludge formation.

Limits:
New oil:0.03 mg KOH / gm(Max)
Transformer New before
commissioning : 0.03 mg KOH / gm (Max)
For in service Transformer : 0.3 mg KOH /
gm(Max)
Applicable Standards: IS 1448, 335, 1866
 OXIDATION STABILITY

 Stability of oil under oxidation .

 Acidity & Sludge are tested after subjecting oil to ageing .

 Acidity max: 0.4 mg KOH/g

 Total Sludge : Max 0.1%

 Applicable Standard : IS 335

WATER CONTENT
Amount of dissolved water in oil.

The test is carried out using automatic coulomatric

titration and expressed in PPM.

If high, affects BDV,IR value/winding PF.

Apparatus

 Automatic water content test kit swiss make

 TEST PROCEDURE

 Take 2ml of the oil in a Syringe;

 Weigh it in an accurate digital balance;

 Inject the oil in the syringe into the
Automatic Titrator kept ready; Titration
is started and goes on until end point is
detected;
 Weigh the empty syringe to find the
weight of oil alone; The weight of oil is
automatically transferred to the
titrator for calculation;
 The software does the necessary
calculations and the water content is
displayed automatically in ppm.
Limits : New oil 50 (max)
New Tr. In service Tr.
Before commg
For V >170KV 10ppm 20 ppm
For V between 72.5 to
170 KV 15 ppm 40 ppm
For V < 72.5 KV 20 ppm 50 ppm

Applicable Standards : IS 13567, 335, 1866

 SK VALUE
 Degree of refining of oil .
 Optimum H2SO4 dosage during refining results in
good quality oil.
 No limits prescribed in standards
 Preferable value 2 to 4%
 Very low over refining, natural anti oxidation are
killed.
 Very high under refined.
 Applicable Standards: IS 335
 BDV
Why oil should have high BDV?
 Transformer insulation composite insulation --Paper and
oil
 Electrical stress = 1/Dielectric constant
 Dielectric constant of cellulose = 4.5
 Dielectric constant of Transformer oil : 2.1 – 2.2
 Electrical stress on Transformer oil is double for the
same thickness. Hence oil should have high BDV .
 The Breakdown Voltage value of oil in KV
measured across 2.5mm gap electrodes.
It is the min. voltage at which the oil breaks down
when subjected to an electric field with a continuously
increasing voltage, contained in a specified apparatus.
Low BDV indicate presence of contaminants such
as water , dirt, cellulose fiber or conducting particles
Limit value :
New oil 30 KV , min (un filtered)
60 KV min (filtered)

 Minimum requirement New Tr. Before commg Inservice Tr.

For V >170KV 60 KV 50 KV
 For V between 72.5 to 170 KV 50 KV 40 KV
 For V < 72.5 KV 40 KV 30KV

 Applicable Standards: IS 6792, 335, 1866

 DDF
 Quality of oil

 Measure of dielectric loss in oil and hence the amount of

energy dissipated as heat.

 Low DDF – Good oil, as it indicates low dielectric losses

and and low level of soluble polar ionic or colloidal
contaminants.
 The dielectric dissipation factor and is a
measure of the quality of oil. It is the tangent of the
angle (delta) by which the phase difference between
applied voltage and resulting current deviate from 90°
when the dielectric of the capacitor consists exclusively
of the insulating oil. Will be high if oil has conducting
impurities, moisture, ageing products like acid and
sludge.
LIMITS:

 New oil 0.002 (max) at 90°C (filtered oil)

 Transformer new before commissioning
 Max : 0.010, for v > 170 KV
 Max: 0.015, for v <170 KV
 In service Transformer (max) : 0.2, v > 170 KV
(Max): 1, for v < 170 KV
 Applicable Standards: IS 6262, 335, 1866
 RESISTIVITY

RESISTANCE PER UNIT VOLUME

RESISTANCE BETWEEN OPPOSITE FACES OF A
CENTIMETRE CUBE OF OIL - - CM.
MEASURE OF ELECTRICAL INSULATING PROPERTY ,
HIGH
RESISTIVITY – LOW FREE ION AND CONDUCTING
CONTAMINANTS.
WILL BE LOW IF OIL HAS CONDUCTING IMPURITIES,
MOISTURE AND FREE IONS. AFFECTS IR VALUE.
LIMITS:
For new oil : 35x1012 Ohm--cm (min) at 90 °C
1500x1012 Ohm-cm (min) at 27 °C
For Transformers New before commissioning : 6x1012
Ohm-cm
For In service Transformers : 0.1x1012
Ohm-cm
Applicable Standards: IS 6103, 335, 1866
SLUDGE
For all voltages should be Nil
 TEST PROCEDURE

 About 40ml of oil is taken in the oil cell and

the entire test is carried out as per the IS
with the help of built in software ;
 BUCHHOLZ GAS COLLECTION TEST
 Test with Silver Nitrate –solution1(AgNo3)
 COLOR: No color – Air – investigate air collection
 WHITE BLACK : Presence of CO – Deterioration of
solid insulation – DGA , Furan tests .
 WHITE : Presence of Acetylene – Arcing – Hi temp
oil degradation – DGA – Internal Inspection.
 TEST WITH AMMONIACAL SILVER
NITRATE SOLUTION
 Color : No color – air
 Red brown to black with Silver gray intermediate – CO
 Green Yellow – Acetylene
 Combustibility Test:
 Collect portion of Gas in a test tube and apply a lighted
match stick to check combustibility of the gas.
 If not combustible -- Air
 BDV TEST
Most commonly carried out test on oil
Test Equipment
 Modern Fully Automatic Kit
STEP BY STEP PROCEDURE
1. Gap between electrode of 2.5mm +/- 0.01
2. Take sample oil, Rinse twice the electrode and
container
3. Take oil in the container sufficiently to immerse the
electrodes
4. Switch on the BDV equipment, keeping in place the
oil container.
5. Allow 10 minutes initial time (as per IS)

6. Raise voltage at 2KV/sec rate and the oil breaks at

a voltage.

7. After the first break (it may be a low value but still
has to be taken), stir oil using magnetic stirrer for 2
minutes and allow stand time of two minutes. Then
raise voltage to get second trip (breakdown) value.
 8. Repeat the above for 6 readings. Take the average
of 6 readings for the BDV value of the oil

Note:

1. Oil for BDV test from the transformer should be

taken from the bottom sampling valve with due
precautions.
2. Care should be taken to avoid air bubbles
3. BDV test should always be done at ambient
temperature.
4. Humidity should not be more than 50%

5. Spheres must be cleaned of deposits preferably by

steel wool. Never use cotton, fibrous materials.

6. Sampling vessel to be dry, clean; Hands also to be

dry and clean; atm. to be dry;

7. Sample to be protected from light, air and moisture

8. Sample to be drawn very quickly and tested within a

few hours
 TEST PROCEDURE

 Observing proper precautions, take about 400ml of

sample oil in the test vessel;

 The gap set is 2.5mm

• The oil is kept in the test kit and the preset test
procedure as per Indian Standard is activated;

• The BDV value is displayed automatically at the end of

the test;
 OIL QUALITY TEST (all the
above tests determine oil quality)
OIL TEST
DGA TEST (determines
transformer healthiness)
 Mixing of Transformer oils

During recent years, the question of mixing of

different types of transformer oils has gained considerable
importance and doubts are often expressed as to whether the mixed
oil would be able to give satisfactory performance during its service
life. The state electricity boards and various electricity supply
undertakings who form the main consumers of transformer oils
have normally to fulfill their requirements by purchasing oil from
different sources, and therefore mixing of different oils is a problem
for a maintenance engineer, who has to top up a transformer with
oil of a different brand when the brand of oil he uses is in short
supply. This very often faced by O & M engineers as the bulk of
insulating oil is imported from various sources.
O & M engineers of utilities confront the
following prior to mixing of oils: -

• Type of oil in the transformers,

uninhibited/inhibited
• Type of inhibitor, if any, and compatibility
thereof
• Brand type of oil to be mixed
• Percentage of oil to be mixed
 The IS: 335 (1963) (Specification for
insulating oil for Transformers and Switchgear) ¹ lays
down in its clause 3.3: “Unused oils complying with
the requirements of this standard are considered to be
compatible with one another and can be mixed in any
proportion. This provision does not, however apply to
inhibited oil”. The trend, these days is to add
antioxidants or inhibitors to the oil for prolonging its
service life. Every oil supplier usually develops his
own inhibitors and the formulation of these is a
carefully-guarded secret. The question then arises
whether oils containing various inhibitors of unknown
composition can be mixed without any serious
damage. This paper reports the results of the
experimental work conducted on this subject.
Experimental work
The main objects of the experimental work are as
follows:
1.  To determine the composition of oils and their
mixtures.
2. To compare various physical, chemical and electrical
properties of the oils and their mixtures.
3. To study the ageing characteristics of inhibited and
uninhibited oils and ascertain their compatibility.
4. To determine the rate of deterioration of oils and their
mixtures.
5 To study the effect of transformer constructional
materials, viz. metals and insulating materials, on the
deterioration of oils and their mixtures.
 The selected oil samples termed
A, B, C, D & E were mixed in equal
proportions with each other resulting in the
formation of ten sample mixtures, viz. AB, AC,
AD, AE, BC, BD, BE, CD, CE & DE. The
composition of the oils and their mixtures was
determined by using the analysis described by
Cornelissen and Waterman. ¾ The results of
this analysis are given in table 1.
 Table – 1
Properties of oils and oil-mixtures
Property Oil A Oil B Oil C Oil D Oil E

         
Density gm. Per cm³. 0.8823 0.8772 0.8738 0.8968 0.8954
At 20° C          
Viscosity, Centistokes
at 35° C
29.58 28.91 33.43 35.22 32.84
Refractive index 1.4806 1.4808 1.4777 1.4958 1.4913
Pour point, ° C -51 -48 -51 -51 -40
Flash point, ° C 147 144 153 147 162
         
Interfacial tensions, 35.2 25 38.5 33 45
dyne per cm          
Neutralisation number,
mg. of KOH per gm.
0 0.004 0.008 0.013 0
         
Saponification value, 0.06 0.05 0.03 0.12 0.05
mg. of KOH per gm.
Copper strip corrosion passes passes passes passes passes
test electric strength withstands withstands withstands withstands withstands
(40KV min.)
 Table – 2
Properties of oils and oil mixtures
Oil A + Oil B Oil A + Oil C Oil A + Oil D Oil A + Oil E

       
0.8807 0.8782 0.8896 0.8887
       
29.36 33.15 33.85 32.11
1.4807 1.4796 1.4885 1.4862
-51 -48 -48 -45
147 147 144 156
       
30 30 28 37
       
0.004 0.004 0.008 0
       
0.1 0.1 0.12 0.08
Passes Passes Passes Passes
Withstands Withstands Withstands withstands
• New oils can be mixed with each other irrespective of the source and
degree of refinement provided they conform to the same Std Specification
& do not contain any additives. The composition properties & the ageing
characteristics of the oil mixtures are between those of the component oils.
• New oils containing additives may be mixed in a similar manner
provided they contain the same additive even though in a different
concentration.

• Also oils with additives can be mixed with those without additives in
any proportion.

• The rates of deterioration of the prescribed mixtures are in between

those of component oils.

• Mixing oils which contain different additives may lead to formation of

more acids or sludge earlier than in normal time, if the additives are not
compatible
• If no data is available regarding two oils the properties of
the mixture should be studied including oxidation stability
before allowing them to be mixed. The presence or absence
of additives must also be confirmed.

• During topping of the equipment, the oil in use should

not have Neutralization number of more than 0.3 mg of
KOH/g.

• Field trials: Studies conducted using 400KV generator

Transformer in a utility system over a period of 2 years have
confirmed the compatibility of quality oils mixed with
paraffinic as well as naphthenic oils.
 EFFECTS OF
TRANSFORMER OIL
 AGEING AND DETERIORATION OF
TRANSFORMER OIL
CAUSES OF DETERIORATION

 Thermal stress
 Electrical stress
 Chemical contamination
 Gaseous contamination

ARRESTING DETERIORATION

 Procuring good quality oil

 Proper maintenance
 Prevention of moisture/air entry through leak points, sealing
and breather etc.
How to know oil condition and level of deterioration?
 by periodical testing and comparing the characteristic with
prescribed limit values
Why take action if oil is deteriorated?
Deteriorated oil
 can transfer moisture to paper and lower IR value
(resistivity, water content)
 can reduce heat dissipation (IFT, sludge)
 can affect other components of the transformer (water
content, acidity)
 can contribute to transformer failure
What action to be taken if oil is deteriorated?
--- depends on degree of deterioration Corrective actions
available
---- Reconditioning, Reclamation and Replacement.
Reconditioning
---- When the following characteristic becomes bad on a
sustained basis:
BDV, water content, IFT and sludge. Also for degassing oil.

Reconditioning normally cannot improve acidity, resistivity

and tan delta significantly.
 Reclamation
 Promising area

 Currently carried out only in Distribution Transformers

Re refining

 Some apply refining and filtering to used oil as is done

in the same way transformer oil is manufactured from
crude oil. This involves no addition of inhibitors.
Replacement

Resorted to when
 Acidity, Resistivity, Tan delta and IFT are very poor
 Served more than 10 years
 After confirming deteriorating trend
 Resistivity less than 0.03*1012 with very low IR/PI value
or high winding tan delta value

On line Filtration techniques

Moisture absorbing cartridges
 EFFECT OF MOISTURE
• Power transformers critical equipment
• Capital intensive
• Generally oil filled
• Solid insulation kraft paper, wood and
porcelain
• Average life of transformers is 25-30 yrs
• Most of failures is due to insulation failure
• Hence keep insulation in good condition for
long life
Reasons for insulation degradation are

• Voltage transients, heat, dirt. Oil

degradation, moisture and oxygen
• Of all the above the worst enemy of
insulation is moisture
• Moisture is absorbed in solid as well as
liquid insulation
 Moisture in paper present in four forms

i) Absorbed to surfaces
ii) In vapor form
iii) Free water in capillaries
iv) As embedded free water
 Moisture in oil is found in three states
a) Dissolved state
b) Tightly bound to oil molecules in
deteriorated oil
c) Free water suspended in the oil as water
droplets (when moisture in oil exceeds
saturation value)
• Moisture in transformers is distributed between
paper and oil
• Paper has much higher moisture content than oil
• When transformer is energized moisture
migrates from paper to oil, till saturation of such
oil
• Solubility of moisture in oil changes with
temperature
 MOISTURE DISTRIBUTION IN OIL AND PAPER

Temp Degree Moisture in Oil Moisture in Paper

Centigrade
20 1 3000 times of what is
in oil

40 1 1000 of what is in the

oil

60 1 300 times of what is in

the oil
• Moisture in oil highly undesirable as it
adversely affects the dielectric properties
and accelerates deterioration due to
oxidation
• Paper being highly hygroscopic absorbs
moisture from the oil
• Affects insulation properties and reduces
life
• Oxidation of oil due to moisture and
oxygen in the presence of heat produces
acids
• These acids attack paper reducing the life
• The process is cumulative as acid coupled
moisture further decompose the oil giving
raise to more acids and moisture
• Thus the rate of deterioration of oil
increases
• Rate of thermal deterioration of paper is
proportional to moisture content
• Mechanical life insulation reduces by half for each
doubling of moisture content
• At high temp moisture migrates from paper to oil
• Moisture in oil is measured by Karl Fischer
Titration
• No direct method available for measure of
moisture in paper
• Moisture in paper determined from equilibrium
curves for Oil – Paper system developed by
scientists
THANK YOU