Maintenance of in-service mineral insulating oil

Dr B Pahlavanpour, Nynas UK

Functional Requirements for Oil

An insulant A heat transfer and cooling medium An arc quenching medium for tapchanger diverter switches and oil filled switchgear Must be compatible with the materials used in electrical equipment

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Oil Condition monitoring

Monitoring and maintaining oil quality is essential to ensure the reliable operation of oil-filled electrical equipment. Codes of practice for this purpose have been established by electrical power authorities, power companies and industries in many countries.

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Transformer Failure
Before 1930 Lack of transformer oil maintenance many kinds of oil in use Lack of specification for manufacture of oil Lack of standard for determining oil quality Lack of understanding of what transpires inside a transformer as it ages

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In Privatized Electricity Industry

5 hours forced outage = 30 days loss of revenue availability is more important than reliability

Nynas- 2012

2012-11-03

Why Oil Maintenance?

Insulating oil in-service is subjected to heat and air Oil oxidation deterioration If a certain amount of oil deterioration is exceeded, there is inevitably some erosion of safety margins and the question of the risk of premature failure has to be considered. While the quantification of the risk can be very difficult, a first step involves the identification of potential effects of increased deterioration. Unused mineral oils are limited resources and should be handled with this in mind.

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Maintenance standard
IEC60422 Mineral insulating oils in electrical equipment Supervision and maintenance guidance.
IEEE C57, 106 IEEE Guide for acceptance and maintenance of insulating oil in equipment.

Utility, organisation standards TGN158

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Current situation of IEC6042

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Aim
Prevent forced outage Eliminate unnecessary maintenance Provide the appropriate amount of maintenance at right time Prevent premature ageing

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Basic oil characteristics required for reliable performance

High dielectric strength to withstand the electric stresses imposed in service Sufficiently low viscosity so that its ability to circulate and transfer heat is not impaired Adequate low-temperature properties down to the lowest temperature expected at the installation site Resistance to oxidation to maximise service life

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IEC60422 recommendation
Three group of tests are recommended:
Routine tests (Group 1) Complementary tests (Group 2) Special Investigative tests (Group 3)

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Routine tests (Group 1)

Minimum tests required to monitor the oil and to ensure that it is suitable for continued service. If the results obtained from these tests do not exceed recommended action limits usually no further tests are considered necessary until the next regular period for inspection but, under certain perceived conditions, complementary tests may be deemed prudent.

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Complementary tests (Group 2)

These are additional tests, which may be used to obtain further specific information about the quality of the oil, and may be used to assist in the evaluation of the oil for continued use in service.

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Special Investigative tests (Group 3)

These tests are used mainly to determine the suitability of the oil for the type of equipment in use and to ensure compliance with environmental and operational considerations.

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Group one tests

Property Colour and appearance Breakdown voltage Water content Acidity (neutralization value) Dielectric dissipation factor (DDF) and resistivity Inhibitor content Group 1 1 1 1 1 1 Method ISO 2049 IEC 60156 IEC 60814 IEC 62021-1 or IEC 62021-2 IEC 60247 IEC 60666

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Group 2 tests

Sediment Sludge Interfacial tension (IFT)

Annex C of IEC 60422 ASTM D971 EN 14210 IEC 60970

Particles (counting and sizing)

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Group 3 tests
Oxidation stability Flash point Compatibility Pour point Density Viscosity Polychlorinated biphenyls (PCBs) Corrosive sulphur 3 3 3 3 3 3 3 3 IEC 61125 ISO 2719 IEC 61125 ISO 3016 ISO3675 ISO 3104 IEC 61619
IEC 62535 ASTM D1275B DIN 51353

Dibenzyl disulfide (DBDS) content Passivator content

3 3

IEC 62697-1 Annex B of IEC 60666

2012-11-03

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Oil sampling
It is essential that every effort be made to ensure that samples are representative of the insulating oil in equipment Sampling should be performed by an experienced person, who has received adequate training, in accordance with IEC 60475. Where available, manufacturers instructions should be followed.

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Important required information

Temperature of the oil sample WTI reading(s) Proper labelling of sample Equipment type and number Tests requested Reason for sampling Ambient air condition .. Name of person taking the sample.

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Handling and analysis of oil sample

The sample begins to deteriorate as soon as it has been taken Sunlight Air Heat Analysing the sample in the laboratory as quickly as is reasonably practical

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Categories of equipment
In order to take account of different user requirements, equipment has been placed in various categories as O, A, B, C, D, E, F, G O, 400 KV and above A, 170 to 400 KV B, 72.5 to 170 KV C, transformers <72.5 KV. OCB, switchgear D, Instrument transformers >170 KV E, Instrument transformers <170 KV F, Diverter tanks of on-load tap-changers G, Circuit breakers <72.5 KKV

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Evaluation of mineral insulating oil in new equipment

Property
Appearance Colour (on scale given in ISO 2049) Breakdown voltage (kV) Water content (mg/kg) Acidity (mg KOH/g) Dielectric dissipation factor at 90 C and 40 Hz to 60 Hz Resistivity at 90 C (G.m) Corrosive sulphur DBDS content (mg/kg) Interfacial tension (mN/m) Total PCB content (mg/kg) Particles Min. 35

Highest voltage for equipment (kV)

<72,5 Max. 2,0 >55 20 Max. 0,03 Max. 0,015 Min. 60 72,5 to 170 Max 2,0 >60 <10 Max. 0,03 Max. 0,015 Min. 60 Non-corrosive <5 Min. 35 Min. 35 See Table 9 Not detectable (< 2 mg/kg total) >170 Max. 2,0 >60 <10 Max. 0,03 Max. 0,010 Min. 60 Clear, free from sediment and suspended matter

Recommended limits for mineral insulating oils after filling in new electrical equipment prior to energization
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Evaluation of oil in service

Insulating oil in service is subjected to heat, oxygen, water and other catalysts, All of which are detrimental to the properties of the oil. In order to maintain the quality of the oil in service, regular sampling and analysis should be performed.

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interpretation of results
should be performed by experienced personnel Characteristic values for the type and family of oil and equipment, developed by statistical methods Evaluation of trends and the rate of variation of the values for a given oil property Normal, or typical values, for fair or poor for the appropriate type and family of equipment

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Frequency of examination of oils in service

It is impossible to lay down a general rule for the frequency of examination of oils in service which will be applicable to all possible situations that might be encountered. Property O Group 1 (Routine Tests) years
1 to 2

Equipment category A
1 to 3

B
1 to 4

C
2 to 6

D
1 to 2

E
2 to 6

F
2 to 6

G
2 to 6

Group 3 (passivator content)

6 month or less, depending on the rate of decrease and the absolute value.

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Condition monitoring interval, CMI

CMI = (P - F)/2 P= Time of detecting an upcoming failure F= Moment of failure

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Maintenance of in-service insulating oil

Oil tests
Field tests Only limited number of tests can be performed Obtain a prompt estimation of oil condition Establish the classification of service-aged oils Eliminate any changes to the oil samples properties due to transportation to a laboratory and/or storage of oil samples Laboratory tests More accurate A complete examination scheme of recommended tests can be performed

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Classification of the condition of oils in service

oils in service may be classified as: Good Fair Poor based on the evaluation of significant properties

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Good
Oil in normal condition; continue normal sampling No corrective action is require

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Fair
Oil deterioration detectable; more frequent sampling recommended

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10

Poor
Oil deterioration abnormal schedule effective actions

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Corrective action
Two types of contamination / deterioration of the oil can be considered physical chemical Each one requires a different remedial action

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Important point:
Where a test result is outside the limits recommended value should be compared with previous results and fresh sample obtained for confirmation before any other action is taken. If rapid deterioration or acceleration in the rate of deterioration is observed more frequent tests should be instituted promptly and/or appropriate remedial action should be taken. It may be desirable to consult the manufacturer of the equipment

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Colour and appearance

All equipment

Dark and/or As dictated by Clear and turbid other tests. without visible contamination

Dark colour is a symptom of chemical contamination or ageing. Turbidity is a symptom of high water content.

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Breakdown voltage (kV)

O, A, D B, E C F

>60 >50 >40

50 to 60 40 to 50 30 to 40

<50 <40 <30

<30 kV for OLTC in star-point application <40 kV for OLTC in delta or line-end application <30 Good: Continue normal sampling. Fair: More frequent sampling.. Poor: Recondition the oil

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Water content (mg/kg at transformer operating temperature)

O, A B, D C, E F <15 <20 <30 Action necessity >40 Not a routine test. Good: Continue normal sampling Fair: More frequent sampling Poor: Check source of water 15 to 20 20 to 30 30 to 40 >20 >30 >40

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variation in saturation water content with oil temperature and acidity

250

saturation water content in unused oil (log Ws = 7.0895 - 1567/T) typical saturation water content in oxidised oil with acidity of 0.3 mg KOH/g

200 satu ratio n w ater co n ten t o f o il (m g /kg )

150

100

50

0 0 10 20 30 40 50 60 oil temperature during operation (C)

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Sampling oil temperature above 20 C

f 2,24e0,04 t s
2,00 Correction factor

1,00

0,00 20 30 40 50 60 ts (C) 70 80 90 100

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Maintenance of in-service insulating oil

Moisture correction factor

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2009

Maintenance of in-service insulating oil

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Sampling oil temperature below 20 C

LogWs 7,0895 1567

Percent saturation water in oil 05% 6 20 %

% Saturation = (mg/kg of water / Ws) x 100 Condition of cellulosic insulation Dry insulation Moderately wet, low numbers indicate fairly dry to moderate levels of water in the insulation. Values toward the upper limit indicate moderately wet insulation Wet insulation Extremely wet insulation Source : IEEE C57.106:2002 (B6)

21 30 % > 30 %

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2009

Maintenance of in-service insulating oil

Effect of temperature

water ppm
35
Loaded

water ppm 20

oil temp
60

Loaded Loaded Loaded

Water content (ppm)

30 25 20 15 10 5 0 1 2 3 4 5 6
Time

50 40 30 20 10 0

10

11

12

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Maintenance of in-service insulating oil

Acidity (mgKOH/goil)
O, A, D B, E C F, G <0,10 <0,10 <0,15 0,10 to 0,15 0,10 to 0,20 0,15 to 0,30 Not a routine test. >0,15 >0,20 >0,30

Good: Continue normal sampling Fair: More frequent sampling. Check the presence of sediment and sludge. An inhibited oil that reached fair values has possibly lost its oxidation protection. Poor: Starting from a value of 0,15, Reclaim the oil or change the oil
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Temperature (C)

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Dielectric dissipation factor at 40 Hz to 60 Hz at 90 C

O, A B, C D E F, G <0,10 <0,10 <0,01 <0,10 0,10 to 0,20 0,10 to 0,50 0,01 to 0,03 0,10 to 0,30 Not a routine test. >0,20 >0,50 >0,03 >0,30

Good: Continue normal sampling. Fair: More frequent sampling. Check other parameters. Poor: Reclaim oil, change the oil

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Resistivity (Gm)
At 20 C O, A B, C D E O, A B, C D E >200 >60 >800 >60 >10 >3 >50 >3 20 to 200 4 to 60 250 to 800 7 to 60 At 90 C 3 to 10 0,2 to 3 10 to 50 0,4 to 3 <3 <0,2 <10 <0,4 <20 <4 <250 <7

Good: Continue normal sampling Fair: More frequent sampling. Check other parameters. Poor: Reclaim the oil or change the oil
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Example of variation of resistivity with oil temperature

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Inhibitor content
Good >60 % of original value Fair 40 % to 60 % of original value Poor <40 % of original value

Good: No action require if not indicated by other properties Fair: (where acidity <0,08 mgKOH/g and IFT >28 mN/m). Consider re-inhibition to original base line level based on local experience Poor: Continue to use and monitor as uninhibited oil, reclaim or change the oil

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Passivator content (mg/kg)

O, A, B, C, D, E, F >70 and stable, (rate of decrease <10mg/kg/year ) 50-70 mg/kg or <50 and <70 mg/kg, decreasing at with a >10mg/kg/year significant rate of decrease of >10mg/kg/year

Good: less frequent monitoring acceptable Fair: maintain regular monitoring Poor: remove the source of corrosivity by changing the oil or by removing corrosive compounds by mean of suitable oil treatments or passivat the oil

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Sediment and sludge (%)

All No sediment or precipitable Where sediment is detected sludge. Results below 0,02 % recondition the oil by mass may be neglected. Where precipitable sludge is detected reclaim oil Alternatively if more economical, or other tests dictate, replace the oil

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Interfacial tension (mN/m)

O, A, B, C, D Inhibit ed Uninhi bited E F, G

>28 >25

22 to 28 20 to 25

<22 <20

Good: Continue normal sampling. Fair: More frequent sampling. Poor: Check the presence of sediment and sludge.

Not a routine test. Not applicable. Refer to Manufacturer's best practice.

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Corrosive sulphur
Category

Recommended Action Limits Good Fair Poor Non corrosive

Recommended Action

O, A, B, C, D, E, F

Corrosiv For corrosive oil: e - conduct risk assessment - reduce the corrosivity of the oil by adding a copper passivator (e.g. triazole derivates) or - remove the source of corrosivity by changing the oil or by removing corrosive compounds by mean of suitable oil treatments.

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Particles (counting and sizing)

O, A, B, C, D, E, F

Informative test

If the breakdown voltage and water content are near or outside the limit for the appropriate equipment category and the particle number is higher than the limits for any of the size ranges, filter the oil.

Not require for category G

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Flash point

All Categories

Maximum decrease 10 Equipment may require inspection. Investigate.

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Options for equipment owner

Do nothing Risk of failure Establish rate of deterioration Establish type of contamination Physical Chemical Take corrective action

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Maintenance of in-service insulating oil

Summary of typical actions

Key factors Physical Symptoms
- High water content - Low breakdown voltage value - High particles content - Turbid (not clear)

Corrective actions - Reconditioning

Chemical

- High colour value

- Low IFT - High acidity value - High dissipation factor value - Presence of sediments or sludge, or both - Low inhibitor content, for inhibited oil - Low passivator content for passivator containing oil

-Reclaiming -- or change the oil Restore original additive concentration according to recommendations

PCB Corrosive Sulphur

PCB contamination detectable - Oil corrosiveness

- Refer to local regulations

Perform risk assessment and correct as necessary - Passivation - Oil change - Reclaiming

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Reconditioning
Reconditioning is a process that eliminates or reduces physical contamination by means of physical processes (filtration, drying, degassing etc.) Reconditioning reduces the particle and water content of the oil The process may also remove some dissolved gases and other components such as Furanic compounds it is recommended that the oil should not be vacuum treated at temperatures over 85 C. If it is desirable to reduce particles or free water, cold treatment at atmospheric pressure may be appropriate.

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Conditions for processing inhibited and/or passivator containing mineral insulating oils Temperature (C) 40 50 60 70 80 85 Minimum Pressure (Pa) 8 15 30 80 200 280

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Vacuum Treatment of Insulating Oil

Pressure [Pa]

100000 10000 1000 100 10 1 0

Water

40

50

65

100

150

200

250

300

350

Working Temperature [C] Insulating Oil Working Point

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Removing water from liquid and solid insulation

On-line methods
Advantages: Possible for transform ers that cannot withstand vacuum Transformer remains in service
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Off-line methods
Advantages: Efficiency Speed Disadvantages: Transformer has to be taken out of service for the duration of the process Cost
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Disadvantages:

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Reconditioning equipment
Filter Filtering equipment usually forces oil under pressure through absorbing material such as paper or other filter media. Centrifuge use for rough bulk cleaning where large amounts of contaminated oil are to be handled. Vacuum dehydrator It is an efficient means of reducing the gas and water content of a mineral insulating oil to very low values

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Oil reconditioning application to electrical equipment

Direct reconditioning The oil is passed through a purifier and then stored in suitable clean containers Reconditioning by circulation The oil is circulated through the purifier, being taken from the bottom of the tank of the electrical equipment and re-delivered to the top It is useful for removing suspended contaminants

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Oil Reclamation
This is a process that eliminates or reduces soluble and insoluble polar contaminants from the oil by chemical and physical processing. The resulting product should be evaluated on critical parameters Reclamation of oils of moderate to high acidity will usually result in oils with a lower oxidation resistance than the original new oil IEC developed new standards for reclaimed oil IEC62701

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Replacement of oil in electrical equipment

Lower than 72.5 KV A small extra quantity of oil is needed to rinse the interior of the tank and the immersed parts It is essential that the tank and the surfaces of conductors and insulators be cleaned effectively and subsequently be kept free from fibres Possibly up to 10% of the original oil might remain adsorbed in the solid insulation and its contaminants may take some time to migrate into the new oil

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Replacement of oil in transformers rated 72,5 kV and above

Use manufacturers recommendation Removed used oil from main tank as much as possible Rinse the winding with clean hot unused oil (hot flashing) Apply vacuum with care (manufacturers recommendation)

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Passivation
Metal passivator is added as a stock solution, dissolved in insulating oil The stock solution can be added via an oil processing unit or other suitable equipment. This treatment is recommended for unused and in-service insulating oil

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Renewal of additives
Oil reclamation remove oxidation inhibitors Additives shall be replaced in the reclaimed oil after the reclaiming process and before the equipment is re-energized The most widely used additives are 2,6-di-tert-butyl-paracresol (DBPC) and 2,6-di-tert-butyl-phenol (DBP). Metal passivators will also be reduced or removed due to their polar nature.

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Decontamination of oils containing PCBs

Contaminated oil may change and replaced by unused oil There are several processes and techniques available for either onsite and off-site decontamination of PCB contaminated oils All PCB decontamination methods, either off-site or on-site, have to be applied by skilled companies complying fully with local regulations.

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Dehalogenation process
Several process are available
Dehalogenation processes using sodium and lithium derivatives Dehalogenation processes using polyethylene glycol and potassium hydroxide (KPEG) Dehalogenation in continuous mode by closed circuit process

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