ISSUE 24

December 2022 transformer-technology.com ISSN 2642-2689

DIELECTRIC
OILS & FLUIDS

Interview with Rainer Frotscher, Maschinenfabrik Reinhausen

Interview with Marta Reinas & Margarida Figueiredo, Amorim Cork Composites
Interview with Johan Fournel, GMT International & Akhelec
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4 TABLE OF
CONTENTS

Contents

Table of
Index
Table of Contents_04
Editors & Impressum_10
Editor’s Letter_14
Interview with Rainer Frotscher:
Green Oils - The Power behind the
Power_18
Getting the Most out of Key Gas
Monitoring_26
From Plants to Processors_34
Interview with Marta Reinas
& Margarida Figueiredo: Behind
the Cork_40
Diagnostics basics and
laboratory data sets_48

18
Interview with
Rainer Frotscher,
Senior Expert for Insulating
Liquids, Gases and Tap Changers
at Maschinenfabrik Reinhausen

Green Oils -
The Power behind
the Power
Transformer Technology December 2022 5

Issue 24

26
Getting the Most out
of Key Gas Monitoring
40
Interview with
Marta Reinas & Margarida Figueiredo
Global Technical Manager &
Global Product Manager at Amorim

Behind the Cork

34 48
From Plants Diagnostics basics and
to Processors laboratory data sets
6 TABLE OF
CONTENTS

Contents

Table of
Index
Best practice innovative
transformer oils based on Shell
GTL technology_56
Interview with Johan Fournel_62
56
Best practice innovative
Women of Note Profile: Merve transformer oils based on
Maden Avci_71 Shell GTL technology
Interview with Senja Leivo_72
6 Things Every Transformer Owner
Should Know About Dielectric
Breakdown Voltage_78

62
Coming in January_86

Interview with
Johan Fournel,
CEO of GMT
International
and Akhelec
Transformer Technology December 2022 7

Issue 24

72
Interview with
Senja Leivo,
CEO and Senior
Industry Expert,
Vaisala Oyj

78
71 6 Things Every Transformer
Women of Note: Owner Should Know About
Merve Maden Avci Dielectric Breakdown Voltage
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Transformer Technology December 2022 9

Issue 24

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10 EDITORS &
IMPRESSUM

Impressum TAB Executive Advisor,

The Chair and Managing Editor
Alan M. Ross, CRL, CMRP
Transformer maintenance and
reliability

Technical Advisory Board (TAB)

Executive Advisors TAB Executive Advisor
Alan M. Ross, CRL, CMRP Corné Dames
The Chair and Managing Editor Independent transformer
Corné Dames consultant Transformer oils
Independent transformer consultant
Transfomer oils
Ben Lanz, IEEE PES Senior Member
Power system reliability, asset management
and diagnostics TAB Executive Advisor
Technical Advisory Board Members Ben Lanz, IEEE PES Senior Member
Diego Robalino, PhD, PMP Power system reliability,
IEEE Senior Member asset management
Tony McGrail and diagnostics
Asset management & Condition monitoring
Edward Casserly, PhD
Senior Scientist, Transformer oils TAB Member
Maria Lamorey
Diego Robalino PhD, PMP
Industrial OEM manufacturing
IEEE Senior Member
Alan Sbravati, ME, MBA
Transformer insulating materials Transformer condition
Marco Tozzi, PhD assessment and
Diagnostics and asset monitoring diagnostics
Curtus Duff
Power transformer design
Traci Hopkins, IEEE Member
Transformer Condition Assessment
Jon Trout, PE
TAB Member
Electric utility
Michael Riccio, CRL, IRT CAT-1
Tony McGrail, PhD
Reliability, Electrical safety Asset management &
Alexander Doutrelepont Condition monitoring
High voltage bushings & insulators
Ed Khan
Power Systems, Relay protection, Training
Graphic design
BE Koncept Communication Boutique TAB Member
Photo Cover Edward Casserly, PhD
Shutterstock Senior Scientist,
Transformer oils
Sales & Marketing
Rachel Linke
[email protected]
Kevan Sears
[email protected]
Sales & Marketing Americas TAB Member
Jose Mora Maria Lamorey
[email protected] Industrial OEM
Sales & Marketing Mexico manufacturing
Fernando Campos
[email protected]

Sales & Marketing Brazil

Marcelo Braga
[email protected] TAB Member
Marketing Global Alan Sbravati, ME, MBA
Marin Dugandzic Transformer insulating
[email protected] materials
Transformer Technology December 2022 11

Issue 24

Editors
TAB Member
Marco Tozzi, PhD
Diagnostics and asset
monitoring

ISSN 2642-2689 (Print)

ISSN 2642-2697 (Online)
TAB Member
DIGITAL Membership Curtus Duff
Free Power transformer design
Transformer Technology magazine is a quarterly
magazine published by APC MEDIA LLC, 2152
Caper Dr., Marietta, GA 30064, USA. Published
content does not represent official position of APC
MEDIA LLC. Responsibility for the content rests TAB Member
upon the authors of the articles and advertisers, Traci Hopkins
and not on APC MEDIA LLC. APC MEDIA LLC Transformer Condition
maintains the right to keep the textual and Assessment
graphical documents submitted for publication.
Copyright and reprint permission
Abstracting is permitted with credit to the source.
Libraries are permitted to photocopy isolated
pages for private use of their patrons. TAB Member
For other copying, reprint or republication Jon Trout, PE
permission requests should be addressed to Electric utility
[email protected]
Publisher:
APC MEDIA LLC
2152 Caper Dr.
Marietta, GA 30064, USA
TAB Member
transformer-technology.com
Michael Riccio, CRL, IRT CAT-1
Reliability, Electrical safety

TAB Member
Alexander Doutrelepont
High voltage bushings
& insulators

TAB Member
Ed Khan
Power Systems,
Relay protection, Training
12 TRANSFORMER
COMPANY
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transformer-technology.com
U
14 LETTER FROM
THE EDITOR

Dear Readers,

“Well Magoo, you’ve done it again.” This frequent Fortunately, we can adjust for our mistakes but
quote, offered up by Mr. Magoo of the old cartoon due to the nature of digital publishing, the mistakes
franchise is one of my favorites whenever I inad- can live on forever.
vertently take what could be chaos and turn it
into gold, much like the annual focus on Oils & I want to move past the two oils & fluids issues
Fluids. It was, and is, a tremendous team effort. and onto something dramatically different for
When we invite subject matter experts (SME’s) February 2023 when our theme is the Green
to share their thoughts and ideas about the Energy Revolution. I am as excited about this
topic of insulating systems and fluids, little did pivot as I have been for anything we previously
I realize how much has changed in the space provided for our Transformer Technology (TT)
and how many qualified experts would jump at Community and for our commitment to Women
the chance to write or be interviewed. So much in Power Systems (WPS). These past four years
good content was available that we decided the have been a labor of love for all of us at APC
annual issue would be delivered, once again, as a Technologies, a Division of APC Media.
two-part issue, once in December and another in
January 2023. When we made the decision to expand our focus
into Power System Technology (PST), it came with
Two topics seem to take center stage: Things in a great deal of hesitation and pushback from
oil, like moisture, gases, inhibitor, and green oils some of our staff, all to preserve our great work
and fluids; a subject that grows with interest as focusing on transformers. Since I love metaphors
natural and synthetic esters grow in popularity. as a means to develop a better understanding of
I have enjoyed conducting most of the interviews a complex topic, I decided I needed a better way
with our SME’s and while we must cut down on to explain the changes.
the back and forth between me and my guest
once the transcription is edited, if you have the Transformers are like engines in vehicles. Power
chance to watch the archived video version, please systems are the vehicle, but they make up a whole
do so since it will bring the interview to life and system of transportation. We can report on sport
give you a greater appreciation for the expert cars with their very unique engines and capabili-
credibility of our guests. ties, and we can focus on 18-wheelers, or pick-up
trucks, or SUV’s. All are part of the system we call
As for technical articles, once again our Technical transportation, and all have engines and compo-
Advisory Board members have come through. nents that drive the system. (Pardon the pun please.)
Their unique ability to bring technical knowledge
to life in such a compelling way is a delight to
all of us at APC Technologies and for that we are
tremendously grateful. Writing an 1800-word tech-
nical article with supporting graphs, charts or
pictures is not an easy task. Publishing them is
even harder given the adage, “Doctors bury their
mistakes and publishers print them.”

Well Magoo, you’ve

done it again.
Transformer Technology December 2022 15

Issue 24

As we expand our offering to the community, we

Alan M Ross
will never abandon reporting on the heart of the
power system, the transformer. We will add to it,
great interviews and articles on the overall system
that transformers support. Since there are so many
changes taking place in power system technology,
with the advent of Distributed Energy Resources
(DER), Smart Grids, solid state technology and
green energy to name just a few, our growth in this
area is only natural.

Which brings me back to the impetus for the

February theme, the Green Energy Revolution.
At the Renewable Energy, RE+ Conference and
Expo in Anaheim, California, we were able to
interview 29 SME’s and thought leaders and I am
tremendously excited about all the innovation
and development taking place in this space, so
much so that I want to feature some of these
interviews, and articles from those I was not able
to interview. While much of the issue content has
been planned, there is still room for long form
Technical Articles and short form Perspectives.
If you have an idea for a topic, please contact me
directly at [email protected] and give me a brief
description of a topic you would like to present.

As I write this, we are celebrating a uniquely

American holiday called Thanksgiving. It allows
me time to reflect on those things, people, and
events I am most thankful for and one of those is
you, our APC Community. It is because we publish
to our audience of so many, I never lose site of
the fact it is a privilege and honor to do so, and
we will faithfully continue to bring quality news,
technical information, and great interviews. I am
also thankful for a wonderful staff at APC Media,
without whom we could do none of this.

Be blessed and thank you.

Managing Editor
Alan M Ross

Technical Director
CRL, CMRP

APC Media
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Transformer Technology 17

Issue 24

JOE DONOVAN NAMED

EXECUTIVE DIRECTOR OF TMAA
Pierce Atwood LLP is pleased to announce that energy partner Joe Donovan
has been named executive director of the Transformer Manufacturing
Association of America.
TMAA is a national trade organization serving as the voice of the domestic
transformer manufacturing sector on a wide range of policy and regulatory
issues, and is an important informational resource to its members. TMAA’s
members include domestic power transformer manufacturers, related service
suppliers, vendors, contractors, and utility customers.
As executive director, Joe will lead TMAA’s
administrative function and support the
industry’s leadership in pressing federal policy
initiatives such as supply chain concerns, the
application of the Defense Production Act, and
providing a unified position before Congress,
the White House, and the U.S. Departments of
Energy and Commerce.
If you’re interested in learning more about
TMAA and its membership opportunities, please
contact Joe at [email protected].

1875 K STREET NW | SUITE 700 | WASHINGTON, DC 20006 | 202.530.6420 | PIERCEATWOOD.COM

 18

Senior Expert for Insulating Liquids, Gases and

Interview with Rainer Frotscher Tap Changers at Maschinenfabrik Reinhausen
FEATURE
INTERVIEW

Rainer Frotscher

Photo: MR
Transformer Technology December 2022 19

Issue 24

Green Oils - The Power behind the Power

Don't get me
wrong, it is
absolutely
desirable
to intensify
the use of
green oils,
biodegradable
oils, less
flammable oils
with a good
CO2 footprint,
and so on.
20 FEATURE
INTERVIEW

Alan Ross: I am delighted to have as a guest and they are also very local. Every country is
today, Rainer Frotscher, who is the Senior trying to develop its own liquids for reasons
Expert for Insulating Liquids, Gases, and Tap I don't know. But it creates a challenge for us
Changers at Maschinenfabrik Reinhausen (MR). because we have to approve them all. Don't get
It is so good to have you. me wrong, it is absolutely desirable to intensify
the use of green oils, biodegradable oils, less
Rainer Frotscher: It’s my pleasure, thank you for flammable oils with a good CO2 footprint, and so
inviting me. on. But all transformer, bushing, and accessories
manufacturers have to invest a lot of time and

AR How long have you been with MR? effort to qualify all these new liquids. And this
leads to the situation that each equipment
manufacturer designs its own test procedure

RF Oh, about 36 years. because the current standards do not provide

them. These standards do not cover all liquid
properties which determine the performance

AR That is a long time to be a technical

expert. Tell me a little bit about your
background. Did you have a degree in chemistry
of the equipment. They only determine some
properties of the liquid itself, but not how it
interacts with the equipment.
or chemical engineering?

Unlike in the rest of the world, in the

US, most of the transformers are sealed
but when you want to use natural
esters, then you must rethink how to
seal the tap changer as well.

RF No, I'm an electrical engineer, and

I studied high-voltage engineering
in Munich. After my studies, I came here
to Reinhausen and I found a very good
environment to develop tap changers and to
do calculations and really did deep dives into
numerical field calculations, project studies, and
on how tap changers interact with insulating
liquids. And then over the years, this developed
into my favorite subject, and I just sort of picked
up the chemical knowledge on the go, as it were.

AR There's a gentleman named Dan Martin

whom you worked with and he said to
me Rainer knows absolutely everything to know
about tap changers. So, you're going to be our
tap changer expert. I'm going to add even more
to your title. I would like to hear your insights on
the changes happening in the industry with the
addition of a lot of synthetic esters, natural esters,
and even changes in mineral oils and the fact that
tap changers need to be looked at specifically
when it comes to fluids. Could you please talk
about what the current situation is as it relates to
oils and fluids and these new products?

RF Yes, that is true. The current situation

is that many new liquids are entering
the markets. There are new synthetic esters
and a bunch of new natural esters, plus the
further developed so-called mineral oils which
are GTL oils and oils made from renewable
Photo: MR

hydrocarbons. They are all entering the market

simultaneously, and all are a little bit different,
Transformer Technology December 2022 21

Issue 24

AR I remember reading something you said

about this. I believe you said that part
of the problem is the standards for the alternative
significantly different. And in combination with
the complex insulating arrangements which
you find in a transformer or a tap changer, this
liquids were created based on transformer leads to a different dielectric strength. Other
mineral oil standards. So, it's not like they were very important factors for tap changers are the
specifically created. The standards were created viscosity range, lubrication, oxidation stability,
for something that's been used in transformers and so on which are all different. We must take
for years. What then is the difference when you're all that into account. Another example is the
using alternative fluids and you're developing new sealing of transformers. Unlike in the rest of
standards for them? the world, in the US, most of the transformers
are sealed but when you want to use natural

RF As I said, there is much research

going on, both in the industry and in
academia. And these researches have revealed
esters, then you must rethink how to seal the tap
changer as well.

that alternative liquids, particularly esters, show

significantly different properties. For example,
when it comes to the dielectric properties, like
AR I would like to go back to lubrication
for a moment. Because we don't think
of that in transformers. I don't think it needs
the streamer breakdown properties. They are lubrication, but it's an important part of what the
22 FEATURE
INTERVIEW

liquid does. It has to have lubrication qualities.

Could you elaborate a little bit on the lubrication
requirements for these alternatives?
AR But there are also other complex
situations that you've got to think
about, the sludge and soot and arc quenching
and all of the other things. Talk a little bit about

RF All types of tap changers were

originally designed for mineral oil. This
is what all mechanisms have been optimized to.
the different application requirements of the
alternative fluids. How do we prevent the buildup
of sludge at the bottom of the tap changers?
But now we have these biobased hydrocarbons
or GTL oils which can be very low-viscosity
liquids. And viscosity is connected to the
lubricating behavior. Not directly, but it has
RF It actually gets even worse if you run
these old arc-breaking tap changers
with ester liquids. The viscosity is somewhat
a certain influence. And when the viscosity is higher, which means that the arc is not cooled
too low, then the lubricating properties can be as directly and efficiently as it is in mineral
insufficient which leads to functional problems, oil. So, the arcing time is somewhat longer,
Photo: MR

as it affects the switching sequence of the tap which produces more sludge and also may
changer. produce some unwanted gasses. If you do
Transformer Technology December 2022 23

Issue 24

politics, okay? Each country has its own thing.

Somebody tells the politicians, who then tell the
regulators, who tell the manufacturers, that's how
it goes. But what can liquid manufacturers, the
people that make these alternative fluids, do?

Viscosity is connected to the

lubricating behavior, and when the
viscosity is too low, then the lubricating
properties can be insufficient which
leads to functional problems, as it
affects the switching sequence of the
tap changer.

RF They should take into account the

elaborated requirements. It is not
only about electrical insulation and cooling.
There are also additional properties of the tap
changers like an adequate viscosity range and
compatibility with all existing materials and
designs.

AR An alternative fluid manufacturer who

was out trying to sell his product to,
either the specifiers at the utility or whoever is
buying the transformer needs to ask questions
about applications. How is this going to be used?
What kind of tap changers are going to be used?
And then that way they can become consultants
if you will. That way they could learn how to make
the fluid that fits the customer’s needs best. But
they're not going to do that. What they're going to
do is make a problem.

RF Yes, they simply don’t seem to be aware

of all these issues in detail.

AR Exactly. And that's why we're doing this,

to make them aware. Reinhausen makes
load tap changers, and you are the global leader
of load tap changers in the marketplace and have
been for a long time. So, you're the equipment
manufacturer. Could you talk a little bit about
what the equipment manufacturers ought to do to
some maintenance on these tap changers, you address this problem?
should provide a good ventilation system so
that some possibly toxic gases can come out. So,
this is what happens when you have a pyrolytic
degradation of ester liquids and this is the reason
RF From our meetings with transformer
manufacturers, we have learned that
they all have their own test setups for their
why Reinhausen doesn’t approve ester liquids insulating arrangements like paper-wrapped
in combination with arc-breaking tap changers, windings, for example. They have established test
only with vacuum-type tap changers. There, setups and they test with AC or with a lightning
esters work just fine, without sludge or toxic gas impulse which is quite similar to that what we do.
byproducts. So it would be a good idea to bring us all together
to come up with simple and practical setups and

AR I would like to talk about different

segments because I honestly don't
believe most of the market understands the issues.
methods and to develop model arrangements that
are applicable in practice and that represent real
insulating arrangements. The standards we have
You said you're not quite sure why each country now for dielectric strength, and for breakdown
is producing its own, different fluids. It's called voltage, are not sufficient because they only allow
24 FEATURE
INTERVIEW

an estimate of the dielectric strength of the liquid, windows and he's told to develop the specs and
but not of the complete insulating arrangement. he's disconnected from things going on on-site.
What can you tell him or her about what they
need to do?
The standards we have now for
dielectric strength, and for breakdown
voltage, are not sufficient because they
only allow an estimate of the dielectric
RF It's not so easy but perhaps he could
encourage the liquid manufacturer to
develop environmentally friendly liquids with
strength of the liquid, but not of the properties that are not too far away from what
complete insulating arrangement. we know from classic mineral oils.

AR At the end of the day, the end user,

the customer, says, Hey, we need a
AR And that will force the liquid
manufacturers to really look into what
changes in viscosity they need to make. Because
transformer or a series of transformers and we I think, as you have stated, they can do that, but
have to specify them. What do you say to the they just have to have a standard to go by. And
end users in their specification projects? There without well-developed industry standards,
is an electrical engineer sitting in a room with no they're going to have to go by the specification

Photo: MR
Transformer Technology December 2022 25

Issue 24

standard that the end user uses. Talk about what that CIGRE could also set up a working group,
you are talking to the industry now. Your fellows for example, where manufacturers, be it for
in the IEEE transformer committee and your transformers or other equipment, come together
fellows at CIGRE and IEC talk about what they to propose and agree on test methods that allow
can do in order to address this problem. Because an estimate of the performance of liquids.
it's going to create greater problems down the
road sooner rather than later and people are
going to go It's because of the fluid. AR Well, this has been a delight. Rainer,
thank you for joining us, this has been
very informative. We will do some follow-up

RF The industry should do, what I'm

currently doing. I'm working on the
IEEE C57.166 which is the combined liquid guide
interviews on this because I'd like to find out
more, and I'd like to use this to help the industry
come together. Thank you for sharing with us
that combines all the previous liquid guides the problem and the solution for equipment
for mineral oil, for synthetic and natural esters, manufacturers, liquid manufacturers, for end
and for high molecular weight hydrocarbons. users, and for the industry.
I had an annex inserted into this guide which
puts the finger on these special issues, special
requirements, that tap changes have. I think RF Thank you, Alan, for the
opportunity.
26 KEY GAS
MONITORING

Getting the Most out

of Key Gas Monitoring
by Chris Rutledge

As maintenance practices for utilities transformer. This can result in solid monitoring is considered, it requires
are quickly shifting from cyclic to a insulation degradation, causing a good understanding of several
more condition-based approach, it the unit’s premature failure. While factors to establish a successful
has become a customary practice there are several approaches to monitoring program. This would
to install online monitoring for most applying this type of monitoring, include the types of conditions
high-value assets. Much of this ranging from complex multi-gas associated with various levels of
monitoring has focused on dissolved systems to key gas monitoring, hydrogen generation, where alarm
gas analysis for power transformers. there must be a good understanding points need to be set to best detect
The formation of hydrogen and hot of the data being collected and these conditions, and how to utilize
Photo: Shutterstock

metal gases is typically the leading how that data can be used to best offline tests in conjunction with key
indicator of excessive thermal determine the overall health of a gas monitoring to provide the best
conditions developing within the particular transformer. When key gas assessment of transformer health.
Transformer Technology December 2022 27

Issue 24

Chris Rutledge is currently an Applications

Engineer at Dynamic Ratings, Inc. He joined
the Dynamic Ratings team in July 2019. Prior
to his present position, he served as Substa-
tion Asset Manager and chairman of the
Substation Safety Committee at Memphis,
Light, Gas and Water. He has 27 years of
experience in the utility industry, primarily
focused on the installation, service and main-
tenance of both substation and distribution
equipment. He has done extensive research
and published multiple papers concerning the
interpretation of dissolved gas analysis test-
ing. Chris is dedicated to assisting cus-
tomers in finding creative cost-effective
solutions for improving safety and reliability
across their entire electrical system.
28 KEY GAS
MONITORING

Introduction change in transformer condition since

the last oil sample was collected.
While some form of dissolved gas Therefore, this article will examine
monitoring has become a standard the use of key gas monitoring in
practice for most utilities, there is conjunction with trending data from
still a strong reliance on the data manual samples as a means of
collected from manual samples. maintaining optimal transformer
This continuance of manual testing reliability.
procedures, even in cases where
there are multi-gas monitors in place, Hydrogen Generation
should raise the question of what
purpose in the overall maintenance Hydrogen monitoring represents one
plan these monitors serve. To best of the earliest and most frequently
answer this question, there are used types of online transformer
several factors to be considered, monitoring. This is due to its relatively
such as the type of monitoring low cost, ease of installation and the
being installed, as there is a much association of hydrogen as being an
higher level of analytics that can be indicator of many of the common
performed using the data collected faults which occur in transformers.
from a multi-gas monitor compared To better understand this association,
to that of key gas monitoring. How is an examination of the conditions
the transformer being operated? This under which hydrogen is produced
question is critical when determining and empirical data from case studies
the type of monitoring being installed will be displayed.
as transformers, which are heavily
loaded, tend to operate at thermal Hydrogen in transformers is
conditions which can cause a produced due to a breakdown of
considerable amount of hydrogen the hydrocarbon chains which form
generation and make it difficult to mineral oil. This process starts
assess the health of the transformer when the thermal, condition within
on hydrogen values alone. Finally, the transformer exceeds 150°C. At
how frequently is the offline DGA this point, we would begin to see
testing being performed? Typically, hydrogen and methane molecules
if samples are being collected on an as a byproduct of the degradation
annual basis, this can provide enough of the temperatures increase, these
data to detect many of the common methane molecules will be replaced
root cause failures, as transformers by ethane at around 250°C, ethylene
tend to show deterioration over at around 350°C and finally acetylene
a period of several years before at 1000°C. However, despite these
failure occurs. Monitoring is then changes in the production of other
responsible for detecting conditions hydrocarbon gasses, hydrogen
that can occur suddenly between production remains constant through
sample periods. These would include all these thermal ranges. It is this
things such as partial discharge, consistent formation despite the
in-tank arcing or exposure to high thermal condition that makes
through-fault values. Since hydrogen hydrogen an ideal key marker for
is typically the leading indicator of single gas monitoring. Taking that
these conditions having occurred, into consideration, there are several
key gas monitoring should provide a adverse conditions that can occur
reasonably high level of confidence within a transformer of which
that there has not been a sudden hydrogen is a leading indicator.
Photo: Shutterstock
Transformer Technology December 2022 29

Issue 23

ARCING EVENT Event 1

is from a transformer that
60% experienced an internal arc while in
service.

The DGA results from this event

40%
exhibit a signature example of arcing
occurring within the transformer.
The key indicator of this arc being
20% the levels of hydrogen present are
roughly two times greater than that of
acetylene. While the key gas monitor
alone would not allow this analysis to
0% be performed, the levels of hydrogen
H2 CH4 C2H4 C2H6 C2H2 produced would be sufficient to raise
an alarm that the event had occurred.
Typically, these types of events
tend to occur suddenly and result
in relaying tripping the unit out of
Hydrogen in transformers is produced service at which time a DGA sample
due to a breakdown of the hydrocarbon could be collected, and a full analysis
performed. Another factor that needs
chains which form mineral oil. to be considered is that saturation
of the gasses into the oil does not
occur instantaneously, and in some
cases may take as much as 24 hours
before an accurate assessment of the
event can be made. So, when these
types of events occur, there would be
little advantage in having a multi-gas
monitor in place, other than the ability
to perform an analysis of the event
remotely once equilibrium of the
gasses had occurred.

In instances of partial discharge

occurring within the transformer,
hydrogen is the key indicator.
Because partial discharge typically
starts as a low-energy event, thermal
conditions are lower than those
associated with other types of
incipient faults.
30 KEY GAS
MONITORING

Event 2 transformer’s historical DGA data,

DGA Test Results alarm points can be established in
a manner that provides notification
In Event 2, hydrogen is the key when gas levels have deviated
indicator of PD occurrence followed outside of that transformer’s normal
by the production of methane and operating levels. This approach will
low levels of ethane. However, it help eliminate instances of false
should be noted that as this condition alarms occurring. Another approach
evolves in severity, we start to see to consider is alarming based on a
increased production of ethane and rate of change. This can be done in
ethylene, which is indicative of higher unison with the total ppm values but
thermal conditions developing at the provides much earlier notification
site of the defect. Again, this level that something has changed in the
of analytics is not possible with key way the transformer is performing.
gas monitoring alone, however key These rate of change alarms can be
gas monitoring would have raised based on daily, weekly, or monthly
an alarm to provide notification that rates of change. The reason these
the PD event is present and allow for alarms are preferred is that the
preventative action to be taken. sudden generation of hydrogen
can always be associated with an
Setting Alarm Points active event occurring within the
transformer and will provide an
Many of the conditions associated alarm even if the levels of hydrogen
with sudden failure, which may generated do not exceed a total ppm
develop rapidly between manual value. This is important because
sampling intervals, can successfully of the volatile nature of hydrogen
be detected in their initial stages when in a dissolved state. Hydrogen
using key gas monitoring. However, is the least soluble of all the hot
another critical point to consider is metal gasses and tends to diffuse
at what level alarm points should quickly across the oil gas partition.
be set at for the earliest notification This in conjunction with hydrogen’s
of these critical conditions. While nonhomogeneous distribution in
setting alarm points based on a total the oil can lead to a cumulative
ppm value can prove to be useful in ppm value representative of actual
detecting abnormal conditions, there hydrogen generation difficult to
are several factors to be considered achieve at the monitor’s static
when establishing these limits. The measuring point. These physical
first thing to be established when attributes of hydrogen, combined
setting alarm points is the historical with any possible leaks which may
data for the transformer on which be present in the transformer’s
the monitor is installed. While tank, can greatly affect the levels of
IEEE guidelines provide a useful hydrogen saturated in oil, causing
starting point, the user must review total ppm values to appear much
historical data for the transformer lower due to the loss of hydrogen to
to determine what is considered the atmosphere. In these instances,
normal operational levels. For the rate of change alarm may be
many transformers, this will be well triggered based on a 25-ppm daily
within the guidelines recommended rate of change, whereas the total ppm
tables, but in other cases normal value may never be exceeded due to
operation may range in the 100 or conditions not allowing for complete
200 ppm range. By examining the saturation of hydrogen in oil.
Photo: Shutterstock
Transformer Technology December 2022 31

Issue 23

DGA Laboratory Test Results (ppm) Developing a

maintenance plan
1400
1200 While key gas monitoring can prove
effective in detecting changes in
1000
transformer condition in the incipient
800 stages it is not comprehensive
600 enough to forego the manual DGA
testing required to optimally maintain
400 a transformer fleet. This requires a
200 combination of routine sampling and
electrical testing or monitoring in
0
conjunction with key gas monitoring
H2 CH4 C2H4 C2H6 C2H2 CO CO2
to provide the most reliable level
4/15/2014 11/29/2014 1/7/2015 2/14/2015 of service. With manual sampling,
many conditions which could lead to
transformer failure can be detected,
many of which would not be associated
While key gas monitoring can prove with rapid hydrogen generation. A good
example of this would be moisture
effective in detecting changes in ingress into the transformer’s tank.
While this could easily be detected
transformer condition in the incipient through manual sampling of the
transformer oil, it would likely not lead
stages it is not comprehensive enough to significant hydrogen production

to forego the manual DGA testing until a great deal of damage to the
transformer’s solid insulation system
required to optimally maintain a had already occurred. Also, slow-
developing hot spots within the
transformer fleet. transformer may progress over time
due to poor insulation or electrical
connections. While this would result in
some low-level hydrogen production,
values may not rise quickly enough to
trigger any of the alarms associated
with the monitor. However, when
trending values over time from manual
samples, the condition is likely to
become apparent through increases
in ethane or ethylene values. The
total ppm values of these gasses
would likely be a better indicator of
the condition than that of hydrogen
values due to their higher solubility in
oil. The maintenance plan would also
need to take into consideration some
of the other components which are
primary causes of transformer failure.
This would require online monitoring
of bushings as well as OLTC
compartments.
32 KEY GAS
MONITORING

This requires a combination of values due to their higher solubility

routine sampling and electrical in oil. The maintenance plan would
testing or monitoring in conjunction also need to take into consideration
with key gas monitoring to provide some of the other components which
the most reliable level of service. are primary causes of transformer
With manual sampling, many failure. This would require online
conditions which could lead to monitoring of bushings as well as
transformer failure can be detected, OLTC compartments.
many of which would not be
associated with rapid hydrogen Conclusion
generation. A good example of this
would be moisture ingress into the Key gas monitoring can be highly
transformer’s tank. While this could effective at increasing the overall
easily be detected through manual reliability of the electrical grid. This
sampling of the transformer oil, it is due to its ability to rapidly provide
would likely not lead to significant an early warning when a transformer
hydrogen production until a great deviates from its normal operating
deal of damage to the transformer’s conditions. Also, because of the
solid insulation system had already relatively low cost of implementing
occurred. Also, slow-developing key gas monitoring, it can be more
hot spots within the transformer widely dispersed across the entire
may progress over time due to poor grid than more complex monitoring
insulation or electrical connections. systems, increasing the chances
While this would result in some low- of detecting problems before they
level hydrogen production, values result in failure. Key gas monitoring
may not rise quickly enough to trigger also requires less maintenance than
any of the alarms associated with many multi-gas systems, allowing
the monitor. However, when trending operating costs to be better directed.
values over time from manual While these devices alone cannot
samples, the condition is likely to provide the level of data needed for a
become apparent through increases comprehensive analysis of equipment
in ethane or ethylene values. The condition, when used as part of an
total ppm values of these gasses overall maintenance plan, they can
would likely be a better indicator of be a welcome addition in the effort to
the condition than that of hydrogen improve transformer reliability.

Photo: Shutterstock
 Transformer Technology December 2022 33

Issue 24

Online monitoring is highly reliable as an early

indicator of various internal transformer conditions.
Dynamic Ratings’ B100 Electronic Temperature
Monitor + Hydrogen is an all-in-one, low-cost solution
that provides remote notification of any problems
detected. The B100 replaces up to five mechanical
gauges and has a robust design for durability in any
environment. The B100 is easy to install, configure
and maintain, making your job easy. Request a quote
at www.dynamicratings.com.

RESPONSIVE
Scan To Learn More!
Or visit: www.dynamicratings.com
34 ADVERTORIAL

From Plants
to Processors:
Cooling the Data
Mining Landscape
NatureCool TM 2000
with Immersion
Immersion Cooling Fluid Cooling

Immersion cooling technology has existed for decades, And while 35-percent of the total energy bill in an air-
but within the last several years it has started to see cooled data center is used just for cooling, the industry is
wider adoption in commercial applications. As chip den- seeking a more efficient solution as tighter renewable
sity continues to rise and the amount of data generated energy and greenhouse gas emission goals are
continues to grow, computing and data center needs will established.
also continue to increase globally.
Companies that operate large data centers, such as
As a result of increasing computing power and the amount Google, Microsoft, Amazon and Facebook are examples
of data generated, data center power use has gone from of likely adopters of immersion cooling, but anyone who
several hundred kilowatts just 10 years ago to several operates a data center, accesses data in the cloud or at
hundred megawatts today, an over 1,000 times increase. an on-site data center and cryptocurrency miners are also
This means more servers and more heat generated. key end users.
 Transformer Technology December 2022 35

Issue 24

AS CHIP DENSITY
CONTINUES TO RISE AND
THE AMOUNT OF DATA
GENERATED CONTINUES
Kristin Anderson is the business development TO GROW, COMPUTING
IMMERSION COOLING IS manager for Cargill’s global bioindustrial cool-
ing solutions sector. She is responsible for AND DATA CENTER NEEDS
THE LATEST APPLICATION new product development including market WILL ALSO CONTINUE TO
FOR PLANT-BASED and industry research, channel management
and marketing. Prior to Cargill, Anderson held INCREASE GLOBALLY.
TECHNOLOGY FOR similar roles at Honeywell, AMEC and Colder
CUSTOMERS LOOKING Products Company. She holds a mechani-
cal engineering degree from the University of
TO IMPROVE THEIR Minnesota.
OPERATIONAL PROCESSES
AND REDUCE THEIR
ENVIRONMENTAL IMPACT.

As the generation and use of data continues to grow

exponentially, more data centers and cryptocurrency
mining centers that use massive amounts of power are
needed. Data centers account for nearly 3 percent of the
global electricity used and over 2 percent of total
greenhouse gas emissions, as much as the carbon
footprint generated by the entire airline industry.

As these businesses look for ways to reduce their energy

use and support corporate social responsibility goals, they
are turning to immersion cooling methods to replace
conventional air-cooling systems. In addition to data
centers, this technology can be applied to electric vehicle Large data centers are turning to immersion
charging stations and other complex electronics. cooling to offset massive energy demands

Even beyond data centers, immersion cooling applications

Photo: Shutterstock

can be found in other areas, such as electric vehicles and

other computing sectors as manufactures seek a more
sustainable and efficient solution.
36 ADVERTORIAL

AS A RESULT OF INCREASING
COMPUTING POWER AND THE AMOUNT
OF DATA GENERATED,
DATA CENTER POWER USE HAS GONE
FROM SEVERAL HUNDRED KILOWATTS
JUST 10 YEARS AGO TO SEVERAL
HUNDRED MEGAWATTS TODAY, AN
Understanding Immersion Cooling
OVER 1,000 TIMES INCREASE.
Electronic components within computing hardware are
submerged in the dielectric fluid that transfers the heat
from the electronics to the coolant, which then circulates
to a heat exchange chamber. The cooled fluid is cycled
back to the electronics in a continuous process that great-
ly reduces energy consumption.

This does not damage the electronics because the

dielectric fluid and electronics components are designed
to work together. In fact, using immersion cooling instead
of air cooling typically prolongs the life of the electronic
components by keeping them cooler and free from air-
borne contaminants like dust.

This cooling method has more than 1,000 times more

cooling capacity than conventional air cooling and uses
significantly less power by removing fans and large air
conditioning systems, requiring up to 60-percent less
energy.

Computer processing equipment Compared to conventional air cooling with HVAC systems,
submerged with immersion cooling fluid immersion cooling submerges servers in a bath of non-
conductive liquid, allowing thermal heat generated by the
computer components to be transmitted into the fluid
and cooled. This method greatly reduces energy use,
extends the life of the equipment, supports higher chip
densities and lowers the overall operating cost.
 Transformer Technology December 2022 37

Issue 24

COMPARED TO CONVENTIONAL AIR

COOLING WITH HVAC SYSTEMS,
IMMERSION COOLING SUBMERGES
SERVERS IN A BATH OF NON-
CONDUCTIVE LIQUID, WHICH REDUCES
ENERGY USE, EXTENDS THE LIFE OF
THE EQUIPMENT, SUPPORTS HIGHER
CHIP DENSITIES AND LOWERS THE
Plant-based innovations offer a renewable
OVERALL OPERATING COST. solution for common industrial applications

A Renewable Alternative

Cargill has been innovating in the bioindustrial space for

many years. Given its deep agriculture and technology
resources, it’s working with customers around the globe
to bring plant-based solutions to meet a variety of manu-
facturing and construction needs – from dielectric fluids
to renewable asphalt, adhesives, coatings and plasti-
cizers.

Immersion cooling is the latest application for its plant-

based technology for customers looking to improve their
operational processes and reduce their environmental
impact.

The Minnesota-based company’s newest bioindustrial

product, NatureCool TM 2000, is the first plant-based
dielectric immersion cooling fluid on the market for use
in data centers, cryptocurrency mining and other ad-
vanced applications that allows for a more sustainable
and efficient way to cool electronic systems.

The fluid, made from more than 90-percent vegetable oil, Cargill’s NatureCoolTM 2000 is the first plant-
a renewable resource, along with performance-enhanc- based immersion cooling fluid available
Photo: Cargill, Shutterstock

ing additives, allows for over 1,000 times more cooling

capacity and up to 60-percent less energy usage com-
pared to conventional air cooling. Plant-based solutions
like this take the benefits of immersion cooling to another
level by creating an even more sustainable method.
38 ADVERTORIAL

AS A RESULT OF INCREASING
COMPUTING POWER AND THE AMOUNT
OF DATA GENERATED,
DATA CENTER POWER USE HAS GONE
FROM SEVERAL HUNDRED KILOWATTS
JUST 10 YEARS AGO TO SEVERAL
HUNDRED MEGAWATTS TODAY, AN
OVER 1,000 TIMES INCREASE. The fluid is CO2 neutral with a Global Warming Potential of
zero, helping make applications adopting the fluid more
sustainable. It has a 10-percent higher heat capacity
than leading synthetic immersion cooling fluids, making
it higher performing. It also provides a superior level of
fire safety with a very high flash point of 325°C and unlike
synthetic fluids, it doesn’t self-ignite and flames out after
the heat source is removed.

“Immersion cooling is the new frontier of technologies

that allows for more efficient, higher performing systems
that also help make the IT industry more sustainable,”
said Kurtis Miller, managing director of Cargill’s Bioin-
dustrial business. “In just the last 10 years, data center
power usage has increased from several hundred kilo-
watts to several hundred megawatts, an over 1,000 times
increase. As chip density continues to rise and the amount
of data generated seems endless, we need to find more
efficient and sustainable ways to operate these complex
systems.”

Temps inside immersion cooling tanks are A Self-Contained Cooling and Heating Solution
lower than conventional fan colling methods
Immersion cooling, while still a relatively new technology,
is quickly becoming the preferred method for cooling
power-hungry electronic equipment as data generation
and online activity continues to skyrocket. What’s more,
immersion cooling is serving as a source for heating
 Transformer Technology December 2022 39

Issue 24

Data mining immersion cooling tanks positioned at a

large ag operation in Manitoba provides an affordable,
renewable heating source for their operations

buildings in colder climates without needing conventional

electric or gas heat sources.

Mindful Energy Solutions, Inc., based in Manitoba,

Canada, is using NatureCool™ 2000 fluid in modular data
mining tanks positioned at large farming, greenhouse
and industrial facilities near Winnipeg. The fluid provides
a source to cool the data processing equipment and the
thermal energy stored in the fluid is then upcycled as an
effective and affordable heat source for warming those
facilities nine months out of the year.

Mindful Energy is conducting its own crypto currency

mining in these locations and is currently working with An employee with Mindful Energy Solutions, Inc.
large Canadian corporations on decentralizing data mining monitors tailored immersion cooling systems at
in the same manner to reduce energy costs and power an agricultural customer site
outage risks for a more efficient and renewable solution.

“We were seeing businesses with huge losses on both

ends of the energy use spectrum – from inefficient co-
oling of processors upfront – to not having the ability to
capture and reuse generated heat on the back end,” said
Stephane Gauthier, partner and CEO of Mindful Energy
Photo: Cargill, Shutterstock

Solutions, Inc. “Now, by utilizing the heat held in the

immersion cooling fluid, we’re seeing some customers
cover 100 percent of their annual heating cost in facilities For more information about Cargill’s NatureCoolTM 2000,
that are over 10,000 square feet, representing huge email Kristin Anderson at [email protected]
savings while being more sustainable.” or visit naturecool.com
 Global Technical Manager &
40

Interview with Marta Reinas & Margarida Figueiredo Global Product Manager at Amorim
FEATURE
INTERVIEW
 Transformer Technology December 2022 41

Issue 24

Marta Reinas
& Margarida
Figueiredo

We don't
damage
the tree,
we only
use the
bark.
Photo: Amorim
42 FEATURE
INTERVIEW

Cork has
very good
compressibility
and recovery
characteristics,
and when we
mix it with
rubber, we don't
lose this factor.
Photo: Amorim
Transformer Technology December 2022 43

Issue 24

Alan Ross: Hello, I'm Alan Ross, and I am the We then started to evolve as a company and
managing editor of APC Media. Today we are began to develop different areas. We have
interviewing two members of Amorim Cork 5 business units that belong to Corticeira
Composites. Amorim is a very unique company, Amorim which includes our raw materials
in fact when I first heard about them, I thought, division (Amorim Florestal), Amorim Cork
why are we interviewing a cork company? that it´s responsible for the cork stoppers
However, there's so much more than cork. production, Amorim Cork Composite which
We're going to find out today what exactly cork produces composites, Amorim Cork Flooring,
has to do with the power industry. and Amorm Cork Insulation. Amorim Cork
Composites has a presence in ten different
My first guest is Marta Reinas and she is an sectors, three joint ventures, and we have a
engineer and the Global Technical Manager worldwide presence. When we talk about the
with Amorim Cork Composites. Marta, it’s vision of the group, specifically for the power
lovely to have you. Could you tell us a little bit industry, it's really important to understand
about what you do at Amorim? that our wish is to add value to cork. As a
company, we play a major role in terms of
Marta Reinas: Hello, Alan, it’s wonderful innovation and developing new products.
to be here. I am a part of the Innovation
Department, and I provide all the technical
support to our customers and even to our
commercial team. Apart from that, I'm also
AR I really want to focus on what
Margarida just said about adding
value to cork and innovation. Marta, talk to me
responsible for making all the adjustments to a little bit about how you do that in regard to
the formulations and also for developing new the power industry. How do you add value to
products for this area. cork?

AR I love the innovation adjustments

to the product. It's cork. How do
you make adjustments to cork? We're going
MR Yes, in this case, specifically, we
are mixing cork with different
raw materials and specifically rubbers in
to talk about that. And then my other guest is order to enlarge the value proposition of our
Margarida Figueiredo. Margarida, thank you for materials. In mixing these two raw materials,
being here. Could you tell us what do you do we are able to have what we call the best of
with Amorim? two worlds because with the introduction of
rubber, we are able to have the compatibilities
Margarida Figueiredo: I work with Marta at needed. For example, for the sealing sector,
the Innovation and Product Management when it comes to insulating the transformers,
Department. I'm not a Technical Manager, the addition of cork allows us to have other
however, I am a Product Manager. I make the benefits that rubber alone doesn't allow. What
bridge between technical management and I mean is that, is with the introduction of cork,
the markets. Therefore, I'm responsible for the we are able to have a better compressibility
portfolio management of our industry sectors inside of the material, meaning it has less
and basically making the bridge between the extrusion than the rubber.
market needs and to the possible applications
of cork.
AR I want you to talk about that
specific technology. Speak to our

AR Every company is going through

great changes right now specifically
decarbonization. In the power industry, we
audience about why the products that you
make for sealing the transformer at the top
are so important and what the difference is.
have to make twice as much power and we Because that's important to the transformer
have to reduce dependence on oil and gas. manufacturers to avoid getting moisture and
Amorim is the world’s largest cork processing air in that area.
group, but you've gotten into other products
that support that. Talk to me about the vision
of the company. Where are you going as an
organization?
MR Cork has very good compressibility
and recovery characteristics, and
when we mix it with rubber, we don't lose this
factor. We add it to our materials. So compared

MF I think we should start with the

background and the origin of the
company. Amorim Cork Composites belongs
to the traditional rubber present in the market,
our cork-and-rubber materials allow us to have
better compressibility and recovering solutions
to the Corticeira Amorim. It's a family-owned or properties. When we are dealing with these
company, and our origin starts back in the 70s types of transformers, which are very large
with four generations. We started with cork, in size, sometimes they have deformations
mainly with cork stoppers. and cork, when it is compressed, absorb the
44 FEATURE
INTERVIEW

movements of the rubber, and conform to the

flange's surface. Which is great for minimizing
the contact or improving the contact areas and
AR Explain to me how your product
helps with vibration. It does help
with noise too, but to me, the biggest thing that
minimizing the defects that we have. you do is help create a stable product when it
arrives. Talk about that, please.

AR
brilliant.
The cork actually acts like a sealant
when you press that down, which is
MR When we are talking about the
transportation of transformers,
some of our customers have a solution that

MR Yes, exactly Alan, the cork will we provide together with them, with our
conform and adjust perfectly to all material, for example, we may cut the cork like
the imperfections that you may have. It can be a donut shape to put on the pins to prevent
used with oils or as you were saying, to prevent any impact, to prevent the deformation of the
moisture, or other substances to enter the transformer. This is one solution we provide to
transformer. our customers. Other customers also work with
some PADs to decouple the metallic parts to

AR Margarida, you are talking to prevent, any damage during transportation. We

customers, right? Now customers also have solutions for transportation from the
are probably not used to hearing about a cork- factories to the commissioning sites.
rubber combination. It’s not a normal gasketing
material. How do you present that to the
people who specify transformers? For instance, AR Ok so the application for your
products is flat and you can add
thickness, correct? Different thicknesses.
does your product happen at the specification
level or does it happen after the transformer These blocks can go anywhere. You can pretty
much create anything out of the cork/rubber
manufacturer gets the spec and then is just
combination. Is that right?
buying the material?

MF In terms of sealing, we have a long

track record not from the power
MR Correct. Because the blocks can be
cut by different means, for instance
by a CNC or by water jet if needed, the
industry, but in the automotive industry. For
thickness can be adjusted to as fine as needed
more than 50 years we have been using this
so, there is no problem. And the customer can
technique for automotive engines. Therefore,
cut it according to their designs or the place
we have a lot of knowledge and background
of application with the traditional equipment
in this area. What we then decided to do is,
present in this type of industry.
transfer part of that knowledge into the power
industry. We work with the main OEMs of the
power industry, and we work with them to
prescribe our materials together. So basically,
AR Do most people buy material and
then do the cutting? Or do you sell
precut, ready-to-deliver parts?
we have the capability internally to help them
with technical drawings for example, and we
have proven throughout the composition
of our materials and our reverse engineer
MR We work in two ways. First, our main
business is to supply the materials
to our customers, and then they have the
the performance of our materials in the technology to customize our product according
equipment. to their transformer. Second, we supply it
directly to the customer if needed.

AR I think that's fascinating. I'm going

AR
to come back to you, Marta, because One of the commitments of the
I know you can put rubber and you can put company is sustainability, and I love
cork. Right. But when you say it's infused, it's a the fact that you're using cork. It's one of the
different technical process of how you create most sustainable products that we can do. But
it. How do you do that? I think you will be where do you get the cork from?
showing us a picture of that. Explain that to me

MF
because I don't understand how that happens. The majority of cork is from the
south of Portugal. And then we

MR Yes, so in our factory, we have

different mixers that are able and
specifically designed to mix different rubbers
have some cork that we also get from the
Mediterranean area. Mainly Spain, Italy, and
Greece.
with cork and all the additives needed for the

AR
Photo: Amorim

final product. We then mix it, and after that, Wow you have European cork, but
we produce all blocks or cylinders that we then does it come from the cork tree? You
cut to a thickness that our customer needs. only take the bark from the tree, right?
Transformer Technology December 2022 45

Issue 24

We work with the main OEMs of the

power industry, and we work with
them to prescribe our materials
together. So basically, we have the
capability internally to help them
with technical drawings for example,
and we have proven throughout the
composition of our materials and
our reverse engineer the performance
of our materials in the equipment.
46 FEATURE
INTERVIEW

Cork is actually a great vibration

insulator. In addition to that, when
we remove the vibration of the
equipment coming from the active
part or even from other parts of the
transformer, we are able to bring
the DB level of the transformer to
a minimum.
 Transformer Technology December 2022 47

Issue 24

MF Yes, that is correct, we only use the

bark and we don't damage the tree,
therefore we only take the outer bark of the
AR I have a final question for you,
Margarida. The problem is that
transformers have been around for a long, long
tree and we harvest it. The cork tree can be time and they've been made the same way
harvested every nine years by peeling the for a long, long time. Now they're beginning to
outer bark and that is how we do it. evolve. Talk to me as I was a customer and tell
me why I should work with your company.

AR Marta what's next? If you can put

cork with rubber and you can create
this composite type material that does what it MF As a customer, you would want to
work with Amorim because we are
does, what do you think is next either for that the world cork leader. Therefore, if you want
material application or innovation? What are to use cork and any of our products for this
you working on? application, you won't get any other player
with the presence that we have in the market.

MR We are trying to develop

new materials with different
characteristics in order to get to different
The second thing is that our brand is already
consolidated in the market. Our mission and
our vision for our brand is to be considered as
applications or even markets that we are not a quality partner. In terms of quality material,
present in due to high demand. We are also you won't find any other player in the market
trying to see if we can enter into new solutions that can deliver the quality material that
and also in new places and new types of we have. And in terms of distribution, we
transformers. are present all over the world. Additionally,
we have been in this business for more than

AR I love the fact that the company

has made a commitment to
sustainability and the very product is
20 years, with the biggest OEMs. Therefore,
we have a lot of knowledge and several
engineering teams that are only dedicated to
sustainable in using rubber products. Do you this sector which in turn helps our customers
make your own rubber products, or are you to provide the best solution for the power
purchasing from another supplier? industry.

MR Yes, we supply the raw material,

meaning the rubber and other
additives needed for the formulation, and we
AR Well said. I've learned from working
with Marta before. You've been in
the industry a long, long time. You've made
mix it internally. In our factory, we have all the a commitment to the industry. Pedigree
equipment needed to produce the materials matters. You have a proven technology, you
from the mixing part to the vulcanization and are innovating all the time. Marta, you just
afterward split it to the thickness according inspired me with the fact that cork and rubber,
to the customer’s needs or even finish the and innovation work together to make the
piece for them according to their designs and transformer industry better. So, thank you for
specifications. the innovation. And that's important because
that's what's happening. The best companies

AR Excellent. You're a totally controlled

source. You make your own rubber.
It's wonderful. Is there anything else that you
evolve. They create products that matter!

Thank you for joining us. I enjoyed this

think the customer ought to know? Anything interview with you. You're both wonderful.
else that you think they should know about the Thank you again.
advantages of using core rubber?

MR Yes, we also have another solution,

which is our vibration control
MR &MF Thank you so much
Alan.

solution. We have four of them that can be

internal or external PADs material to be put
inside of the tank wall, on the tank wall, and
also material to decouple metallic parts. What
they have in common is the minimization
of the vibration of the equipment. Cork is
actually a great vibration insulator. In addition
to that, when we remove the vibration of
the equipment coming from the active part
Photo: Amorim

or even from other parts of the transformer,

we are able to bring the DB level of the
transformer to a minimum.
48 DIAGNOSTICS
BASICS

Diagnostics basics
and laboratory
data sets
by Miroslaw Wrobel
and Andrzej Dabrowski

Diagnostics to determine the status of a device have gained considerable importance in recent
years for many reasons. Both technical and economic aspects play a major role. In the case
of electrical energy supply devices, the focus is, among other things, on the diagnosis of the
insulation system, as this largely determines its service life.

Knowledge of the operating conditions, the parameters, and their effects on the insulation system
Photo: Shutterstock

are necessary to meet the diagnostic requirements. The parameters can be obtained offline
or online. This article will discuss data from offline measurements and associated diagnostic
procedures and their importance.
Transformer Technology December 2022 49

Issue 24

Miroslaw Ch. Wrobel received the M.Sc. degree

in applied physics from Silesian University of
Technology, Gliwice, Poland, in 1993. He re-
ceived his Ph.D. degree from the Institute of
Fundamental Technological Research, Polish
Academy of Sciences Warsaw, Poland. He pur-
sued his Ph.D. research in the area of medical
physics focusing on molecular acoustics. He
worked on non-invasive medical diagnostic and
imaging techniques as a visiting fellow at the
Defence R&D Canada, Toronto (previously known
as DCIEM) of the Canadian National Defence.
Since 2005, parallel to his medical research, he
has been working on the application of acous-
tic and optical sensing method in high-voltage
technology. He holds several patents in the field
of medical diagnostics and monitoring of in-
dustrial plants.

Andrzej Ludwik Dabrowski received the M.Sc.

degree in mathematics from Wroclaw University,
Wroclaw, Poland, in 1970. He received his Ph.D.
degree from Wroclaw University, Wroclaw,
Poland, in 1983 for the dissertation Statistics
of periodic time series and its applications in

KNOWLEDGE OF THE hydrology. He worked as lecturer in Wrocław

University and University of Life Sciences where

OPERATING CONDITIONS, THE he taught the theory and practice of statistical

methods and probability theory. He has been

PARAMETERS, AND THEIR also working in Institute of Meteorology and

Water Management, Wrocław, as head of the

EFFECTS ON THE INSULATION Laboratory of Mathematical Models. As a sta-

tistical consultant, he participated in interna-

SYSTEM ARE NECESSARY tional projects building biomedical, environ-

mental and econometric models. He is the

TO MEET THE DIAGNOSTIC author of the book On theory of information

and academic manual on statistical quality

REQUIREMENTS. control as well as the author of all the entries

from statistics in the 25-volume encyclopedia.
50 DIAGNOSTICS
BASICS

Introduction The technical possibilities and the costs All these economic boundary
for the collection of measurement conditions and increasing load have
Diagnostics, as originally defined, data and their storage as well as led to significant research growth in
means the ability and teaching transmission to the corresponding the field of diagnostics, sensors,
of recognizing diseases - strictly control centers have changed and processing methods, and from a
speaking, it is the process of significantly in recent years so that the large number of good ideas, the best
determining which disease or condition collection and storage of measurement ones are proving themselves
explains a person's symptoms and values do not represent a significant in practice now.
signs. In the technical field, diagnosis is economic factor, but rather the task of
associated with the term examination what the data tells us and how the issue In the laboratory dielectric-chemical
and the monitoring procedure with should be solved intelligently. analysis according to IEC 60422
which the condition of a device or its The improvement of mathematical (Mineral insulating oils in electrical
components is determined. Sometimes tools and the development of new equipment - Supervision and
including additional suggestions for evaluation and prediction methods have maintenance guidance), the aging
measures that may be necessary. In also led to an increase in diagnostic condition of the oil-paper insulation
the field of electrical power engineering, options, the use, and efficiency of system is determined from key figures
diagnosis has a much higher priority which still must be tested in operational of the insulating oil. The breakdown
today. The desired change from practice. The economic boundary voltage enables a statement to be
previous time-based maintenance conditions of the electrical energy made about the current insulating
of the system to condition-based supply will lead to an increasing load capacity of the Isolation liquid. The
maintenance of the equipment requires on the existing systems in the next neutralization number (TAN – total
better knowledge of the most important few years, the lifespan of which is acid number) and the interfacial
parameters of the system to be able to increasingly approaching the "mature" tension are very sensitive indicators
take appropriate and timely measures. age, as shown in Figure 1 representative of the oxidation state of the insulating
The replacement of electrical energy of the transformers of a Central oil and the aging of the entire oil-
supply facilities, which in the past was European energy supplier company. paper insulating system. They are
often caused by changes in the voltage
or power level because of an increased
energy requirement, is now often DIAGNOSTICS OFFERS A
delayed if possible due to the increased
demands on the economic efficiency of VERY VALUABLE TOOL TO
energy supply companies. Diagnostics
offers a very valuable tool to evaluate EVALUATE THE PERFORMANCE
the performance of existing systems
and to assess the risk in terms of OF EXISTING SYSTEMS AND
reliability and probability of failure. The
partial redundancy of the devices is TO ASSESS THE RISK IN
no longer maintained in the same way,
so if a component fails, consequential TERMS OF RELIABILITY AND
damage occurs that can cost far more
than a new one. PROBABILITY OF FAILURE.
early indicators of sludge precipitation.
An increased water content (Wc)
drastically worsens the insulating
properties of the oil and accelerates
the aging of paper and pressboard.

For example, the functional diagram

can show a graph of the relationship
between many of the oil variables that
are examined according to IEC 60422
– Figure 2. This is derived from the fact
that in datasets with many variables,
groups of variables often move
together. One reason is that there can
be more than one variable measuring
the same “driving principle” that
determines the behavior of the mineral
oil/electric system. A multiplicity
Figure 1. Average age of the transformers in the grid supply company - as an example for any of laboratory equipment makes it
middle European region possible to measure and display
 Transformer Technology December 2022 51

Issue 24

dozens of system variables

simultaneously. In this case, we can
use this informational redundancy
very well to determine the oil
parameters and their “driving forces”
behavior – Figure 2.

Objective of the diagnosis

The aim of the diagnosis is to offer

support and expertise to meet the
requirements for an economical,
stable, and trouble-free electrical
energy supply. Strictly speaking, it
is about achieving the best possible
electrical energy supply with minimal
effort. What does that mean in
everyday operation? This means that
a prognosis for the future in terms
of reliability, failure probability, and is a strong correlation between Wc, The moisture in the solid insulating
expected service life should be made TAN, and BDV for mineral oil-based material can be determined from
from the data recorded by laboratory insulating liquids as shown in Figure the moisture measurements of the
measurements in the past and the 2, acid and moisture are the "driving liquid under known conditions, so that
detailed knowledge of the properties forces" of BDV. It is known that the information about the development
of the devices. Such a statement must water content influences the properties of the moisture in the solid insulating
be made for a single device or for a of solid insulation materials, but material can be obtained due to the
group of devices or even an entire Wc cannot normally be measured established model by continuously
substation, depending on the cost of directly during operation, since Wc determining the moisture in the liquid,
the device in question, as well as its measurement needs e.g., KF-Titration. see Figure 3 [1, 2].
maintenance and service. For example,
because of their large number,
medium-voltage equipment needs Figure 3.
Moisture
to be treated differently than high- distribution in
voltage equipment, and the impact a paper/liquid
of a failure on this equipment can be insulation as
very different, sometimes even very a function
of the oil
dramatic and grievous. Let’s take the temperature
data from a high-voltage transformer
presented in Figure 2, as an example
of the task and goal of the diagnosis.
Based on several thousand laboratory
data sets, we were able to show that
it is sufficient to measure only two of
the parameters described in order to
assess the BDV value - since there

Figure 2. function
chart graph of THE AIM OF THE DIAGNOSIS
the relationship
between many
of the oil’s
IS TO OFFER SUPPORT
variables. The
color bar shows AND EXPERTISE TO MEET
the correlation
coefficient
between all the
THE REQUIREMENTS
variables
FOR AN ECONOMICAL,
STABLE, AND TROUBLE-
Photo: Shutterstock

FREE ELECTRICAL ENERGY

SUPPLY.
52 DIAGNOSTICS
BASICS

Basics & Operating Conditions

Today, paper gets its structural

stability from the use of cellulose
fibers made from the primary cell wall
of green plants. To keep the paper
stable during and after production, for
example, it is treated with potassium
aluminum sulfate, one of the
substances commonly used in the
production process here. This makes
the paper weakly alkaline since the
potassium aluminum sulfate lowers
the paper’s pH, making it acidic. This
is desirable in papermaking since
this additive primarily improves fiber
bonding. However, if the paper is
stored for a longer period of time,
a lower pH value and ubiquitous Figure 4. Water distribution in an aging transformer population
moisture will lead to the destruction
of the cellulose chains, as these
are linked by acid-sensitive acetal
bridges. This process breaks down
the fiber structure of the paper. As
the cellulose macromolecules break
down into smaller molecular units, the
paper in question loses its flexibility
and tear strength. This is accelerated
by the presence of water and
temperature changes. This is called
paper decay or “paper corrosion”. It
refers to the aging-related dissolution
of paper, which is often triggered by
the effects of acids present in the
material (acid corrosion) but can also
be accelerated by external influences.

From this point of view, the parameter

changes recorded in the laboratory Figure 5. Acid (total acid TAN) distribution in an aging transformer population
test can depend very much on the
mode of operation of the device, temperatures, meaning over 90°C processes experience a very strong
so that evaluating the measured (190°F), the aging factor doubles with acceleration there and lead to local
variables alone without taking the each additional 6°C (10°F). For the destruction of the insulation and can
operational boundary conditions aging diagnostics of the paper, lead to the device’s failure. Due to
into account can lead to incorrect this statement also means that it a high electrical field strength, the
statements. Determining the moisture is important to precisely know the occurrence of partial discharges is
in the liquid and drawing conclusions temperature in the insulating material, usually a very early warning sign for
about the moisture in the solid especially at the points of highest local defects and leads to an increased
insulation material is only permissible temperature (core), since the aging formation of decomposition gases
if the entire insulation system is in
equilibrium. With knowledge of the
relationship between Wc & TAN (see THE MEASUREMENT OF THE DIS-
Figure 2) as well as information on
water migration between oil and SIPATION FACTOR TAN ᵟ IS PRIMARILY
paper insulation (see Figure 3), the
processes observed in the older AN ASSESSMENT OF THE LOSSES IN
transformer population now become
perfectly clear and understandable. THE INSULATION SYSTEM AND IS
Unfortunately, the aging factor accele- THEREFORE NOT PREDOMINANTLY
rates significantly with increasing
temperature. At very high core A DIAGNOSTIC PROCEDURE.
Transformer Technology December 2022 53

Issue 24

hydrocarbons during thermal or

electrical faults are complex.
The basic steps in gas production
are the breaking of carbon-hydrogen
and carbon-carbon bonds. Active
hydrogen atoms and hydrocarbon
fragments are formed. These free
radicals can combine into gases,
molecular hydrogen, methane,
ethane, etc., or recombine into new,
condensable molecules.

The acronyms and abbreviations

used in Figure 7 mean:
• R – catalytic reactions,
• PD – partial discharges,
• S – Stray gas formation,
• T1, T2, T3 – thermal
Figure 6. Breakdown Voltage distribution in an aging transformer population • O – superheating of paper or
mineral oil,
• C – possible carbonization of
paper,
• D2 – high energy discharges,
• D1 – low energy discharges

The amount of hydrogen produced

can be relatively high and
temperature-insensitive for some
failure types such as stray gas
formation, partial discharge (PD),
and catalytic failure. The formation
of acetylene only becomes noticeable
at temperatures close to 1000 °C.
Also, the formation of methane,
ethane, and ethylene each has a
unique dependence on temperature.
In addition to the number of gases
produced by the processes, the
Figure 8 Change in dissipation factor tan δ in an aging transformer population ratio between the gas types is also
important. The IEEE Guide for the
such as Hydrogen H2. To establish a diagnosis of the processes that have Interpretation of Gases Generated in
diagnosis, all of the following factors occurred in the insulation system, for Mineral Oil-Immersed Transformers
must be considered: in which insulating example, partial discharges, thermal provides a very comprehensive
material these partial discharges occur, overload, or low-energy or high- overview of this topic [3].
under which boundary conditions, and energy breakdowns. Figure 7 shows
at which point. As mentioned above, that mineral oils for transformers The measurement of the dissipation
the presence of free gases in the oil are mixtures of many different factor tan δ is primarily an
is another important factor. The DGA hydrocarbon molecules and the assessment of the losses in the
(Dissolved Gas Analysis) enables a decomposition processes for these insulation system and is therefore
not predominantly a diagnostic
Figure 7 Relative procedure. However, the change
percentage of in the loss factor over time is an
dissolved gas
concentrations
indication of aging and thus of the
in mineral oil change in the insulation system, so
as a function of some diagnostic parameters can be
temperature and derived from this. It is amazing how
fault type
the tan δ correlates with the changed
Wc and TAN profile. Please compare
Figures 4, 5, and 8. The X-axes in all
of these images use the logarithmic
scale to highlight and emphasize the
changes over time.
54 DIAGNOSTICS
BASICS

Photo: Shutterstock
Transformer Technology December 2022 55

Issue 24

Conclusions times, and for strategically important

devices, the costs for diagnosis can
Modern measurement technology be higher than for devices with a
and data processing as well as data lower purchase price and importance.
storage enable the recording of However, the importance of a device
many parameters that contribute is not only determined by its price but
to the monitoring of an electrical also very much by its place of use and
system. The mathematical methods the consequences associated with
for evaluating measurement results its failure, whereby the assessment
range from simple comparisons of the importance can change very
to various statistical models and quickly here, e.g., due to changed
methods of artificial intelligence. legal framework conditions, insurance
From the wealth of information requirements or simply the possible
available, it is now a matter of delivery times.
selecting the most important ones
and recording them systematically, Diagnostics is a decision-making
as well as understanding the factor in maintenance and asset
consequences that the data contain. management and can provide
It should be noted that these significantly better information
consequences depend very much on about the condition of oil-insulated
the respective insulation system. Is electrical systems with the online
it just a single and isolated device or and real-time monitoring devices and
a group of devices or even a whole methods available today. A sensor for
substation as recently announced? oil temperature, water content Wc,
The results of this statistically breakdown voltage BDV as well as
supported evaluation, the importance hydrogen H2 and carbon monoxide
of which is constantly increasing due CO content can be regarded as the
to the increased use of diagnostic best and most sufficient "first line of
systems and field sensors as well as diagnostic defense".
the increasing knowledge of basic
research, must then be transferred to This applies to all systems that work
a risk and cost analysis. However, the with a liquid insulating agent based
risk analysis should also consider the on mineral oil (and/or GTL based).
following factors and the spendings: Further studies must show whether
Costs for a complete replacement of this also applies to ester oils.
the device, costs for condition-based
maintenance, costs for unforeseen References
events and longer downtimes, and [1] Y.Du et. all, “Moisture
costs for consequential damage. Equilibrium in Transformer
These factors then define the costs of Paper-Oil System”, IEEE
a diagnostic system and the possible electrical Insolation Magazine
sensors and their use. Given these Vol. 15, No. 1
conditions, a simple conclusion [2] E.T. Norris, “High Voltage
can be drawn. The diagnostic Insulation”, Proceedings IEEE
results to be expected regarding the Vol. 110, No.2
assessment of the insulation systems [3] IEEE Std C57.104TM-2019,
must bring a recognizable economic “IEEE Guide for the
benefit for the operator of these Interpretation of Gases
diagnostic systems. For devices Generated in Mineral Oil-
with a high purchase price, which is Immersed Transformers”
often associated with long delivery
56 ADVERTORIAL

Best practice
innovative
transformer oils
based on Shell
GTL technology
 Transformer Technology December 2022 57

Issue 24

Introduction
Shell introduced in 2013, the Diala S4 range, the first and only
transformer oils using unique gas-to-liquid (GTL) technology.
Designed to revolutionize the reliability and lifespan of transformers,
this technology has been tested and approved by OEMs and utility
companies alike, and is successfully being used in thousands of
power and distributions transformers globally.
The challenge
The project-team for the development next generation of transformer
oil had interviewed experts at leading OEMs, Technical Institutes,
and grid companies to define the requirements and criteria; good
electrical behavior and thermal properties, consistent quality, long
life (high grade), recyclability, miscible with traditional oils, and not
to forget; maintenance tools applicable based on industry standard
Oil Condition Monitoring (OCM) techniques. This article focusses
on sharing best practice OCM and field experiences.
Utility companies operate large populations of 100s or 1000s of
transformers, of different types, varying ages, with different operating
conditions and stresses, and which can contain different transformer
oils or even mixtures. OCM and database tracking, and statistical
evaluation, is an integral part of a utilities maintenance activities to
ensure maximum power generation and transmission performance
and reliability from its assets[1], while seeking to control and reduce
their total cost of ownership[2]. Electrical insulating oils have a
specific and often unique list of OCM and other tests, when compared
to conventional lubricants, such as DGA), DDF, inhibitor content,
surface tension, etc [3], and need confirmation that new oils are
miscible and compatible with other similar fluids, and can use the
same suite of OCM tests and alert levels.
Insulating materials in service will age due to degradation processes
such as oxidation, thermal breakdown, and hydrolysis, under
moderate to high electrical stresses (depending on the transformer
and conditions). OCM enables the ageing process to be tracked and
interventions made before it leads to transformer electrical faults
and transformer failure.
The solution
Before the Shell Diala S4 range was introduced in 2013, extensive
laboratory testing was undertaken, this included miscibility and
compatibility, and the resulting performance testing of mixed
inhibition and unmixed, iso-paraffinic (GTL) and naphthenic
hydrocarbons insulating oils, both aged and unaged, uninhibited
and inhibited, and in different ratios and combinations. The data
confirmed that all the tested hydrocarbon oils were fully miscible
and compatible, and that mixed hydrocarbon oil systems display
resultant performance properties that are an average of the type
and quantity and performance of its constituent parts. The larger
the proportion of GTL oil in a mixed hydrocarbon oil system, generally
the greater the oxidative stability of the mixture[4],[5].
DGA testing was also run at the University of Manchester, and the
Schering Institute, University of Hannover. This involved testing Shell
Diala S4 ZX-I and a conventional inhibited naphthenic fluid,
transformer faults were simulated covering partial discharge (high
and lower energy), and thermal hot spot faults (low and higher
temperature). DGA analysis of the resultant gasses was then
interpreted in terms of the Duval triangle/pentagon. It was confirmed
that the DGA behavior and fault diagnosis was very similar for both
fluids, and that routine DGA and interpretation could be used for
Photo: Shell

Shell Diala S4 ZX-I as for conventional mineral oils as expected

since they are both hydrocarbon based[6],[7].
58 ADVERTORIAL

Customer experience
A field trial to compare the DGA performance of the Shell Diala S4
ZX-I GTL based oil back-to-back with the conventional inhibited
naphthenic oil, was run with a local grid company in Switzerland.
BKW operates two Siemens 132 MVA transformers, which run under
• Case study:
the same load and similar conditions, and so were ideal for this
Switzerland
comparison testing. Samples were taken in May and June 2016,
June 2017 and April 2018, and DGA performed. DGA results for Shell
Diala S4 ZX-I and the inhibited naphthenic oil were very similar in
trends and concentrations, confirming that DGA is suitable and
reliable for both these hydrocarbon oils (see table 1).

Transformer T1 sample Date CO2 CO H2 CH4 C2H6 C2H4 C2H2

May 2016 70 22 0.3 0.3 0.5 0.5 0.2

T1 June 2016 170 50 5 2 0.5 0.5 0.5

Oil:
Diala S3 ZX-I
(naphthenic) June 2017 280 132 2.5 1 4 5 0.5

April 2018 280 178 2.5 2 4 2 0.5

Transformer T2 sample Date CO2 CO H2 CH4 C2H6 C2H4 C2H2

May 2016 70 25 0.3 0.2 0.5 0.5 0.05

T2 June 2016 100 60 7 1 0.5 0.5 0.5

Oil:
Diala S4 ZX-I
(GTL) June 2017 260 150 2.5 2 2 6 0.25

April 2018 275 200 2.5 2 2 0.5 0.25

Surveillance guidelines normal < 350 < 100 < 120 < 65 < 50 <2

IEEE PC57.104 D11d warning 350-570 100-700 120-400 65-100 50-100 2-5

alarm > 570 >700 > 400 > 100 > 100 >5

Table 1.
DGA for transformer 1 filled with conventional naphthenic oil and transformer 2 filled with GTL based oil
Photo: Shutterstock
Transformer Technology December 2022 59

Issue 24

Station Transformer T8 (132 kV, 90 MVA Hawker Siddeley)

Oil Surface Tension. Oil Acidity. DDF (Power factor). Dissolved

Oil type in service Decreasing values indicate Increasing values indicate Increasing values indicate gas analysis
oil degradation. oil degradation oil degradation (DGA)

Original uninhibited
transformer oil,
6 times 20 times Normal
Performance change Halved
increase increase (low)
after two years in
service

Diala S4 ZX-I
No significant change No significant change No significant change Normal
performance change
(≈ 52) (≈ 0.01 mg KOH/gr) (< 0.001) (low)
after being in service

Table 2.
Station transformer T8, OCM data (previous uninhibited vs Shell Diala S4 ZX-I)

EDF (UK) had observed oil degradation issues in its 132 kV, 90 MVA
Hawker Siddeley Station transformer T8, built around 1980. The
operational temperatures of this transformer were trending higher,
indicating future reducing of cooling performance. The transformer
had last been filled with an uninhibited oil two years previously and
was already showing signs of accelerated ageing. Following detailed • Case study:
technical discussions with Shell, the decision was made to replace EDF Heysham 2
the transformer’s oil with Diala S4 ZX-I. Power Station, UK[8]

Shell Diala S4 ZX-I has now been in successful continual service in

this transformer, stabile and reliable performance, and as well as
the reduction in transformer operating temperature, the rate of oil
ageing has also declined as shown in table 2.
Based on the good experiences with the Hawker Siddeley Station
transformer, EDF (UK) decided to select Shell Diala S4 ZX-I for their
new generator transformers, scheduled to supply in 2014 - 2016.
Per block, 3x GE-Alstom, single phase 400 kV (800 MVA) Generator
Transformers. (Video: Shell Diala case study with EDF - YouTube)
EDF Energy Heysham has an extended condition monitoring program
in place; critical transformers are equipped with on-line DGA
monitoring (Kelmann), and oils samples are taken on a regular basis.
“The obvious improvements in reliability and performance Shell
Diala S4 ZX-I has produced, have prompted Heysham 2 to specify
the high-performance oil for all future tap changer maintenance
and in transformers above 23 kV”
Douglas Barker, Electrical Engineer, Heysham 2

Based on the good experiences, the EDF Nuclear department approved

the filling of 3 single phase generator transformers at Chinon Nuclear
Power plant (900 MW) with Shell Diala S4 ZX-I in 2020.
60 ADVERTORIAL

OEM experiences and acceptance

During the pre-launch phase, Shell technical experts have been in
contact with leading OEMs, and get input on their nowadays and
future requirements, and confirmation on market trends. Multi test
programs have been agreed upon with OEMs (Siemens, HE (ABB),
GE, etc.) and Universities [1],[7] to confirm the typical performance
test data sets. These collaborations supported a smooth market
acceptance of the GTL based Shell Diala S4 ZX-I.

Country Transformer type notes/comments

Nigeria Power Transformers 340 KV

Vietnam Power Transformers 220 KV

India Power Transformers 1200 KV

Ethiopia Power Transformers 500 KV

Kenya Power Transformers 220 KV

Germany Power /Distributions 220 KV and below

China Reactors 500 KV

Malaysia Power/Distributions 275 KV / 340 MVA

Heilongjiang province,
HVAC, reactor 500 KV / 50000 kvar
China

Netherlands Power Transformers 380 KV

UAE Power transformers 500 KV / 882 MVA

Germany Power transformers 400 KV

Saudi-Arabia GSU (Generator Set-up) 400 KV / 864 MVA

Germany / Belgium HVDC link project 380 KV

Netherlands /
HVDC link project 320 KV
Denmark

Belgium Power transformers 380 KV

UK / France HVDC link project 320 KV

UK HVDC link project 400 KV

Germany Power transformers 380 / 110 KV

France Power transformers 235 KV / 660 MVA

Italy / France HVDC link project 400 KV

Photo: Shutterstock

Finland Power transformers 400 kV / 400 MVA

Table 3.
compact overview with reference projects
Transformer Technology December 2022 61

Issue 24

Figure 1.
Global coverage, with local production facilities has been realised within a decade.

Summary References
Shell is already active in the Power generation and distribution [1] 1 ‘Condition monitoring and
market for over 80 years, historically the product portfolio was based diagnostic assessment of
on traditional mineral oils (Diala AX, Diala B, Diala DX, etc.). With the transformers’ Z. D. Wang, Q.
introduction Shell Diala S4 ZX-I, based on GTL technology, the Liu, P. Jarman, G. Wilson, R.
performance scope was pushed to the next level; higher flash point Hooton, D. Walker, P. Dyer, CH.
(safety), Sulphur free formulation (eliminate corrosive Sulphur risk), Krause, P. W. R. Smith, A. Gyore,
lower density (weight saving), superb oxidation resistant (long oil R. Martin, P. Mavrommatis,
life/cost reduction) and easy recyclability (sustainability). J. Noakes. Paper given at the
Cigre, Paris, 2016 conference,
Obviously, for smooth the market introduction and acceptance, easy as part of A2-109
handling and continuity in oil condition monitoring best practices [2] Shell lubricants white paper
are important key points. Leading OEMs and customers have ‘Unlocking, efficient, reliable
collaborated to closely monitor the important oil condition power’ 2016
parameters (physical, chemical and DGA) and share the positive [3] IEC 60422:2013 Mineral
findings. Standard oil condition best practice remains valid with insulating oils in electrical
Diala S4 ZX-I. equipment – Supervision and
maintenance guidance
[4] ‘Fact or fiction benefits of
inhibited versus uninhibited
hydrocarbon oils for
transformers’, P. Smith, B.
Lohmeyer, A. Hilker, Cigre
A2 & D1 colloqium, 2011, Kyoto
[5] ‘The benefits of inhibited
transformer oils using GTL
technology’, Dr J. Friedel,
Transformer Life Symposium
(TLM) 2014, Neuss
[6] ‘Benefits and experiences of
GTL transformer oil’, Euro
TechCon, Nov 2016, Bristol,
Dr J. Friedel, Dr P Smith
[7] ‘DGA of a GTL hydrocarbon
transformer oil under thermal
faults’, X. F. Wang, Z. D.
Wang, Q. Liu, Ch. Krause, P.
W. R. Smith, D. Walker, 19th
International Symposium
on high voltage engineering,
Pilzen, Czech republic,
Aug 2015
[8] ‘Application experience with
GTL based transformer oils’,
Euro TechCon, Dec 2018,
Cardiff, Dr V Null
 62 FEATURE
INTERVIEW

Johan Fournel
CEO of GMT International
and Akhelec

To translate my
vision for the future,
I would like to take
the opportunity to
talk about this new
filter that we have
Interview with Johan Fournel

recently put on
the market, these
15-liters-per-minute
ones.
 Transformer Technology December 2022 63

Issue 24
Photo: GMT International, Akhelec
64 FEATURE
INTERVIEW
 Transformer Technology December 2022 65

Issue 24

Alan Ross: My guest today is Johan Fournel. Switzerland, and then started doing overseas
He is the CEO of GMT International and business. As you said, we are not doing
Akhelec. And we're going to talk about both anything in the US yet, but we have exported.
companies. Johan, thank you for joining us. We have been exporting materials to Latin
America, to Asia, Australia, and New Zealand.
Johan Fournel: My pleasure Alan.

AR You've been the CEO of GMT

International for three or four years
AR Are you selling mostly to the OEMs?
For instance, are they taking care of
that part of the installation process or are you
now, correct? selling to the final end customer?

JF Well, I've been working for GMT

International for the past twelve years.
CEO, now for three and a half years. GMT
JF I would say half and half. I mean, half
of our business is done directly with
the utilities, the end user, and about 50% is
international and its subsidiary AKHELEC are done through OEMs or Integrators or EPC, even
specialized in environmental protection of EPC contractors.
oil immersed electrical transformers such as
metallic spill containment berms/retention
bunds. Natural dielectric fire extinction
devices, and oil rainwater filtration systems.
AR I've been in the power industry for
the last 15 years and honestly, I had
never heard of a bund before. I've heard of
different containment systems, but not a bund.

AR Tell me a little bit about your

background and what got you into
the transformer industry. How did you get JF Maybe you don't call it the same way
I assume you call it spill containment
involved in it, and what is your educational and berms in the US.
work background?

JF My education is in chemical
engineering. I started my career
AR Yes, that is exactly what we call
them. However, when I figured out
what a bund was, I thought, oh, it's a very high
working for an oil company called British quality, and very unique. Tell me then what
Petroleum, and then I switched to a service makes the bunds that you provide different
company, which is still in the oil business. than what we normally use which is a berm?
I worked for ABB, but not in the electrical
divisions, only in the petroleum division.
I then had a good opportunity to move to
automotive. In the beginning, I was optimizing
JF Traditionally most of the end users use
concrete berms . This is what has been
done for the past 50 years. Now we have come
fuel production at BP and ABB, and then I up with a different solution which is metal. It
moved to the automotive industry to use the is a hot-galvanized steel berm with different
fuel, and somehow, I ended up in the electrical advantages or disadvantages compared to
business. concrete berms. Thanks to the metal berms, we
minimize the onsite work, we deliver the bund

AR Let's now talk about GMT

International. GMT International is
primarily in France and Akhelec is in the rest
and we can install a very large bund, around
70 m² or even larger within one or two-days
max. If you build it in concrete, it will take
of Europe and the rest of the world. We don't weeks. It takes three or four weeks just for it to
have anything happening in the United States. dry. So, it's quite a lot of time that can be saved
We need to encourage you to come to North thanks to the steel bund.
America and Canada but we'll talk about that
at the end of the interview. Tell me about the
two companies. AR There is another issue with that.
Concrete that is not allowed to cure
creates all kinds of problems. Like when you

JF In the beginning, we only had GMT and

that was in France. We started this
company back in 1995, and a few years later
put the weight of a transformer, an oil-filled
transformer on top of concrete, if the ground
hasn't been prepared, if the concrete hasn't
the previous CEO decided to send someone been allowed to dry and cure properly, guess
to Spain to study the potential opportunities what happens? You put the weight on it, and
Photo: GMT International, Akhelec

there. They then decided to launch a new the concrete cracks. So now that I know that
company based in Spain in 2005 and this there's a solution, well done!
company was called Akhelec. After this, we
started to develop the export business outside
of France and outside of Spain. We first started
working with Great Britain, Belgium, Italy,
JF It's a rapid solution on-site. I think the
quicker you go on-site, the less risk of
accidents or personal injuries you have.
66 FEATURE
INTERVIEW
 Transformer Technology December 2022 67

Issue 24

AR You have a filtering system that

you're introducing. Tell me a little bit
about that.

JF Yes, so as you know, berms are installed

underneath transformers. Whenever
transformers are installed outdoors, the
rainwater picks up traces of oil present on the

100% of our transformer itself and collects in the berm. In

order for the berm not to flood and overflow,

business is in
you need to purify the water before draining it.
If you use a safety syphon, your berm will remain
full of water. That's something maintenance
and around the operators don't really like. When you work
on a power transformer with cubic meters of

transformer water underneath it, it's not really safe. Also,

the electrical standout across Europe and the
US as a matter of fact requires you to have the
business. berm as empty as possible in order to have space
in case there is a huge sudden oil leak. And if

So those filters such a massive oil leak does occur, you need
to recover 100% of the oil inside the berm. For

have been
that to happen there needs to be as little water
as possible in the berm. This is why few years
back we developed a filtration system based on
specially designed absorbing polymers.

to treat the water These are oleophilic polymers that don't like
water at all. So, molecules of hydrocarbon are
trapped in the polymer, whereas water can flow
around electrical through it freely. This is basically how it works.

transformers. AR Your chemical engineering background

just showed itself here, Johan. So, there
is a problem with water but there's also a
problem with contamination. I think all
governments are getting very restrictive
New because any kind of leak, any kind of oil spill is a
contaminant. You said the filtration system helps

FILTRELEC® F15 with that. Explain that a little bit more for me.

filter is more JF Yes, what you just mentioned, Alan,

is called the Clean Water Act in most
countries. Each time you release rainwater or

economical, processed water into nature, you must first make

sure that you're not going to pollute anything.

more robust and

Therefore, you need to make sure that the water
does not contain hydrocarbons. It is as follows,
in certain areas, the maximum hydrocarbon
environmentally content in the released water has to be lower
than ten milligrams of hydrocarbon per liter of

friendly. water. And in other areas or specific countries,

the hydrocarbon content has to be less than five
milligrams per liter. This is a standard. Those five
milligrams per liter is the standard we follow.
Now, we have developed this filtration unit
Photo: GMT International, Akhelec

based on this standard. So, we usually release

the water directly into the substation gravels, or
we have lots of projects with hydraulic plants,
and we drain the filtered water directly to the
river, making sure that it contains less than five
milligrams of hydrocarbon per liter of water.
68 FEATURE
INTERVIEW
 Transformer Technology December 2022 69

Issue 24

AR Today society is very concerned about

pollutants getting into the water. So,
when you talk about a five milligram per liter of
JF To translate my vision for the future, I
would like to take the opportunity to
talk about this new filter that we have recently
release, I can't fathom what scale that is, because put on the market, these 15-liters-per-minute
if you tell some people, hey, there is any number ones. They are called F15, and the reason they
of hydrocarbons floating into the river, they're are my vision for the future is that we developed
going to get upset. Now you are following a this filter to be more environmentally friendly.
stricter standard than what is required in North The housing of this filter has been totally
America. redesigned and, in the end, it offers about 70%
mass reduction compared to the main products

JF I think California has five milligrams per

liter.
available on the market. We end up with a
reduction of fuel consumption to transport the
product and we end up with a reduction in the

AR
way.
California leads the way in prevention
and assumes everybody will move that
weight of waste generated when the product is
being saturated by oil. Therefore, this is part of
my vision for the future. We all have a role to
minimize the footprint of our activities on the

JF But to answer your earlier question

about what that means: Five milligrams
per liter is maybe a 10th of a drop of oil in a liter
environment. And that is my vision; to minimize
our footprint on the environment and try to
use our minds better to end up with a more
of water. environmentally friendly product.

AR All right. That's a scale that I can

understand. Johan when we were
prepping for this interview there was a word
AR Product development then has to
be one of the benchmarks of what
you're doing. You got to keep making what you're
that came up. It's hydrophobic. Explain what making, but at the same time, you have to do the
hydrophobic means, please. product development in order to come up with
improvements. How did you do that?

JF Hydrophobic means that the product

doesn't like water at all and does not
react with water at all. So, there is no reaction JF In the beginning, we had PVC casings,
and we have already equipped very
at all between the absorbing media and the large solar farms in Australia, Mexico, in other
rainwater. countries. And after a few years, when we get
photos or when we go on-site, after two or three

AR Talk about the range of the rainwater

filtration systems you've got.
years and we see our product being seriously
damaged by UVs, to the point where there's no
color anymore. But sometimes it can even break

JF We have different filters. The smallest

one is five liters per minute water flow
rate. Then we have a brand-new filter that we
the plastic. If you expose your product to UVs,
after one or two years, the weight of the product
itself breaks. And this was the starting point of
are now putting on the market, which is 15 per this new development.
minute. Then we have 1,500 liters per minute and
all of these work on gravity. We also have a pump We understood that PVC is not the solution.
system for maintenance activity that is about 50 I mean, if you want to have a product that stays
liters per minute. outside, that is exposed to UV rays, you cannot
use such PVC, even though it's pressure PVC or

AR And those applications are

transformer-related?
reinforced PVC, you just delay the problem. We
then decided to think about and study other
plastic casings that can handle UVs much better.

JF Yes, they are, Alan. 100% of our business

is in and around the transformer
business. So those filters have been specially AR That’s a great vision. Well done. Again,
I would like to thank Johan Fournel for
designed to treat the water around electrical joining us today.
transformers. New FILTRELEC® F15 filter is more
economical, more robust and environmentally
friendly. JF Thank you very much Alan.
Photo: GMT International, Akhelec

AR My final question for you is a vision for

the future. You're the CEO, you must
cast the vision and leadership for the future of
the company. What's your vision for the future of
GMT and Akhelec?
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 Transformer Technology WOMEN 71

Issue 24 OF NOTE

Merve Maden Avci

Championing ambition for women

Merve Made
n
is Produc t L Avci
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Manager for
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Systems and lec trical
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and pricing. lo w vo ltage solutio w as Ea ton's lead fo ng
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Photo: Merve Maden Avci, rawpixel.com

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 72 FEATURE
INTERVIEW

Senja Leivo
Senior Industry Expert
at Vaisala Oyj

As temperature
varies, we see
variations in water
content in insulation
liquid. It's never in
thermodynamic
Interview with Senja Leivo

equilibrium
unfortunately when it
comes to operational
transformers.
Photo: Vaisala

Issue 24
Transformer Technology
December 2022

Moisture in solid insulation,

the bane of dielectric strength
73
74 FEATURE
INTERVIEW

Alan Ross: My name is Alan Ross, I am the majority of the moisture comes from the
Managing editor of APC Technologies, and my surroundings, either from ambient air humidity
guest today is Senja Leivo from Vaisala. or some rare cases rainwater.

Senja Leivo: Thank you, Alan.

AR Okay. Most of the insulation products
are cellulose based in transformers.

AR I'm going to ask you a true or false

question as a scientist. Every 1%
increase of moisture inside of a transformer
And as I understand it, there's more moisture
potentially trapped in the cellulose than there is
in the oil. The oil may be dry, but if the cellulose
degrades the paper by half. True or False? has got moisture in it, as you said, that's going
to migrate out. Talk about moisture in general

SL Yes, I would agree, this is like a rule of

thumb.
as it relates to transformers and operating
transformers. Just give me a primer on that.

AR This was an IEEE statement 20 years

ago, and most people don't realize it.
Whether it's by half or 20%, what it really says is
SL It’s exactly like you said Alan, cellulose
materials especially insulation paper
are very hygroscopic. The water will go there,
moisture in a transformer is not good, correct? regardless of the insulation liquid, whether
it's mineral oil or esters. And only a small

SL Yes, exactly. portion of the water is in liquid. It’s said that

99% of the water is in solid insulation, and
when the transformer is operated and when

AR Where does the moisture come

from?
the temperature varies, some of the water is
released from the insulation paper surface to
the insulation liquid,. Therefore, if we follow

SL After factory drying, there is always

residual moisture, which is very small.
However, it is very difficult and noneconomical
the water content in liquid in real-time, we
can see fluctuation. As temperature varies, we
see variations in water content in insulation
to dry it completely. Transformers are really liquid. It's never in thermodynamic equilibrium
dry when they arrive on-site, and during the unfortunately when it comes to operational
lifetime of the transformer, I would say the transformers.

There are also short-term risks

because moisture is the major factor
Photo: Vaisala

that affects the dielectric strength

of the oil.
Transformer Technology December 2022 75

Issue 24

It really is a risk that the water

saturation in the oil becomes far too
high considering the loading, and
may cause flash over.

AR Here's the problem. I don't think the

industry understands how bad this
is because I talk to people and ask them if they
temperature information, and in order to be
able to evaluate the meaning of the water
content in the oil, you really have to know the
test for moisture in their transformers. They oil temperature, when the sample was taken
respond with “Why would I do that?” I think because like I said, it varies a lot.
there's a real ignorance about the damage that
moisture in transformers does.
AR Talk to me like I'm a risk manager at a
company and explain to me what the

SL There are basically two major issues.

One is the paper degradation in long
term, as you mentioned. The other issue is
risk to my company would be and to my asset
which is the transformer if I don't manage the
moisture.
more related to the operational conditions
of the transformer. There are also short-term
risks because moisture is the major factor
that affects the dielectric strength of the oil.
SL If it’s an older transformer, and if the
solid insulation has a high level of
water, or if that transformer needs to be loaded
Especially if we have a wet transformer that heavily for some reason - Let's say there is a
has a lot of water in its solid insulation.. sister transformer that needs to be put out of
Then in some conditions you may be at risk service, and all the load is put to the other one
of having a breakdown because of moisture which is wet. In this case, with such a quick
in the oil. high loading, the water is pushed from the solid
insulation into the oil. It really is a risk that the

AR What's the problem with the annual

or quarterly or semi-annual lab
testing as it relates to moisture?
water saturation in the oil becomes far too high
considering the loading, and may cause flash
over. Another similar issue may occur. If we
have a wet transformer that was out of service

SL It's often that the sample is just once

a year or once in two years. As I
mentioned, the moisture is exchanged between
for a while and when it's put back online and
loaded quickly, the oil is still cold it cannot hold
that water that is pushed from the winding
oil and paper. It's continuous, and you may not insulation. And you can really have a so-called
see those extremes with periodical samples. “raining” in a transformer. That for sure will
Also, quite often the samples are missing the cause a breakdown.
76 FEATURE
INTERVIEW

AR I want to switch gears a little bit.

We're trying to decentralize energy,
right? We're trying to go wind and solar. Those
We started doing real-time
monitoring 20+ years ago. If I look
transformers become more like inverters than
back at that time, it was more
transformers because they must take power in. challenging to convince the asset
Is there a greater risk to an inverter-based owners that online monitoring of
system because of moisture, or is it just the moisture could be useful.
same? What do you think?

SL If we only think about the basics, like

thermodynamics it's the same, it doesn't
matter which direction it goes. If it's a question
of moisture, it's a question of temperature, it's a
moisture sensors, which basically measure
question of the materials involved. But all in all,
the relative moisture saturation of oil and the
I would say it's the same.
temperature and if needed it calculates the
absolute water content as ppm.
AR My next question then is, how do
I mitigate the risks of moisture in
transformers?
We started doing real-time monitoring 20+
years ago. If I look back at that time, it was
more challenging to convince the asset
SL The first thing I would say is to get a
good picture of the moisture levels, and
the overall moisture dynamics in a transformer
owners that online monitoring of moisture
could be useful.
by having online monitoring to really see what is
the moisture level during the normal operating
conditions of the transformer, and if there are
AR We both agree that moisture in
transformers is often overlooked,
and misunderstood and it's a real problem
risks like the relative saturation of moisture
that transformer owners, and transformer
going too high. One option would be to apply an
operators really need to know about. There
online dryer to that transformer.
is no way to deliver a transformer that is

AR IEEE has now made passive drying one

of the primary functions of eliminating
moisture in a transformer. And there's a lot of
them, a lot of them being made by different
companies. It’s a cost-effective way as it really
works. Moisture tends to escalate and it tends to
move with temperature, load, and everything.
Therefore, it’s the trend lines of moisture
monitoring.

SL Yes, that's true. But even following trend

is challenging because the desorption
of moisture from paper to oil is faster than completely moisture-free unless you want to
the absorption of water back to paper. So just pay a lot more money than you already do
comparing temperature and moisture levels is for the transformer. Therefore, the idea of
not so straightforward as you would think. But monitoring moisture is an important one. It is
obviously, when you have real-time monitoring one that can be coupled with DGA monitoring
and you have the loading data and you have the so that it becomes simpler, but it gives you
temperatures, you can get a clear picture of the the data and the information that you need
overall moisture household in the transformer in order to make a decision. Is that a fair
and if there are risks involved short term or statement?
long term.

AR Vaisala is arguably one of the world

leaders in monitoring technology.
SL Yes, I would agree. But even more, I
would say that for new transformers,
I really encourage the asset owners to pay
Tell me about what has happened in the whole attention to the early life of the transformers
monitoring as it relates to moisture. What because like I said, the moisture comes
technology should I be looking for? from the surroundings. And by taking care
of the breathing systems, taking care of the

SL I think nowadays basically all online

moisture sensors are using the same
technology principle, which is the capacitive
dehydrators of the breathing systems are in
good condition, you can really extend the life.
But once the transformer is already wet and
 Transformer Technology December 2022 77

Issue 24

has high water content in its solid insulation, then

I would say the online monitoring becomes more
and more important because that's where the
AR Okay, great thank you very much for
that answer. This has been a great
interview. Thank you for the work that you do
operational risks may come up. and thank you for willing to share that with us at
APC Technologies.

AR Last question, moisture in oil,

moisture in esters. Is there a
difference between oil and esters in terms of SL Thank you, Alan, it was a pleasure to
be here.
what happens with the moisture? Is it better?
Is ester a better solution to treating moisture
and transformers at the beginning? Or is that
a myth that esters are better?

Once the transformer is already wet

and has high water content in its
solid insulation, then I would say the
online monitoring becomes more
and more important because that's
where the operational risks may
SL That's a question I've been asked
a lot, and I don't want to take any
specific opinion. However, looking at this from
come up.

a scientific point of view, it's true that esters,

synthetic or natural, have much higher water
solubility than mineral oils. But after all it
is water content in paper and transformer
Photo: vaisala

temperature that determines what will be the

relative moisture saturation in insulation liquid
whether it is mineral oil or ester.
 6
78 BREAKDOWN
VOLTAGE

Things Every Transformer

Owner Should Know About:
Dielectric Breakdown
Voltage
by Andy Shkolnik
Jason C. Dennison
and Ryan Tate
Technical Authors
from SDMyers

1
When it comes to the ability of your What is dielectric
breakdown voltage
transformer’s insulating liquid to
testing?

A dielectric breakdown
withstand electrical stress, there are voltage test measures
the electrical stress
Photo: Shutterstock

some things you should know about an insulating liquid

can withstand without
dielectric breakdown voltage. “breakdown”—when
Transformer Technology December 2022 79

Issue 24

Here are six things every transformer

owner should know about dielectric
breakdown voltage.

electrical potential is high enough to A sample of the liquid being tested fills test standard is used (D877, D1816, or
cause discharge through the dielectric the test cell, and the two electrodes IEC 60156, more on these later). The
liquid. This test is used to evaluate a are subjected to a steadily increasing standard defines the test method and
liquid’s ability to withstand electrical electrical potential until there is a parameters required to conduct each
stress and can be performed for discharge through the liquid from one test. These parameters are the rate at
accepting new insulating liquids or electrode to the other. The voltage which the test voltage is increased, the
evaluating in-service insulating liquids. level at which the breakdown occurs size and shape of the electrodes, the gap
The test is performed using a test cell is recorded as the test result and size between the electrodes, how many
with two electrodes spaced with a compared to acceptable levels. There times the test is repeated, and whether
predetermined gap between them. are different methods based on which or not the liquid is stirred during the test.
2
80 BREAKDOWN
VOLTAGE

Why should you detect contamination in the liquid transformer's overall reliability and
perform dielectric before it leads to a catastrophic lifespan.
breakdown voltage failure. Contamination of the liquid
testing? due to such things as fibers from the The test can also be performed on
solid insulation, conductive particles, new, reprocessed, or reconditioned
For in-service contamination by foreign matter, dirt, insulating liquids before being used to
transformers, and water can affect the dielectric fill equipment. Acceptable test results
the dielectric breakdown voltage. When done in are necessary (but not sufficient by
breakdown voltage conjunction with other tests, the themselves) to ensure that the liquid
test is one way to test results can help you assess a was stored and transported properly.

3
Which types of insulating liquid. Regardless of which • Natural Ester (vegetable oil) Liquids
insulating liquids type your transformer contains, • Synthetic Ester Fluids
can be tested? each is subject to contamination, • High Molecular Weight
the presence of conductive particles, Hydrocarbon (HMWH) Liquids
For a long time, aging, and moisture. There are five
our industry has common insulating liquid types
* Note: This list represents broad categories
used the generic found in transformers.*
of the most common liquid types. Additional
Photo: SDMyers

terms “oil” or “fluid” They include: types can be tested but are relatively rare.
when referring to • Mineral Oil Consult a transformer specialist if you have
a transformer’s • Silicone Fluids questions.
 4
Transformer Technology December 2022 81

Issue 24

How often should transformer maintenance and

I test for dielectric reliability program. It is recommended
breakdown that your insulating liquid is tested at
voltage? least once a year, with the test results
being recorded to track trending
Dielectric results. Understanding the trend
breakdown voltage of your data will help you identify
testing should sudden or unexpected changes and
be essential to plan accordingly with preventative
your regular maintenance actions.

5
What are the (approximately 2.54 mm) apart. The levels. It does not do a good job of
different test rate of voltage increase is 3,000 volts detecting oxidation decay products.
standards? per second. D877 has limited use in
measuring water contamination in ASTM D1816 – The D1816 method
ASTM D877 – insulating liquids because it is not has been used by many standards
The D877 method sensitive to moisture at saturation organizations to replace the D877
uses two flat levels below about 60%. It is sensitive method as both a new liquid test and
disk electrodes to contamination by some other as an in-service liquid test because
with sharp edges materials and to the presence of the VDE electrodes more closely
spaced 0.10 inches particles in addition to high moisture resemble the geometry of conductors
82 BREAKDOWN
VOLTAGE

inside operating electrical equipment Further investigation would be The presence of magnetic particles
and because the test is much more required. would affect dielectric breakdown in
sensitive to moisture and cellulose the transformer, so removing those
particles. There are two possible gap IEC 60156 - Standard 60156 uses particles by the stirrer during the
settings for the electrodes: 1 mm electrodes that are similar geometri- analysis would yield unrepresentative
(approximately 0.04 inches) and cally to the VDE electrodes used values.
2 mm (approximately 0.08 inches). in ASTM D1816. The spherical
The rate of voltage increase is electrodes are spaced 2.5 mm apart, For several years, the ASTM D877
500 volts per second. A difficulty with and the rate of voltage increase is test was regarded as the standard
this method is that it is also sensitive 2,000 volts per second. The method way to perform the dielectric
to dissolved gases, which may not in Standard 60156 allows the optional breakdown voltage test on insulating
present any operational problem at use of an impeller, operating similarly liquids for electric power equipment.
levels that affect the test. So, while to the one used in the D1816 method, In recent years, organizations such
an acceptable D1816 value can be except that it operates at 250 to 300 as IEEE and ASTM have compared it
interpreted as an indication of normal rpm. The IEC method also allows the to ASTM D1816 and found that the
operation, a questionable or unac- use of a magnetic stirrer operating at D1816 test provides more accurate
ceptable value may not automatically a similar rate if there is no significant results for determining the dielectric
be interpreted as a definite sign that chance that magnetic particles characteristics of liquid inside power
something is wrong. will be removed from the liquid. equipment.

6
What does a “bad” breakdown voltage results. In such they need to know about the health
test result mean? cases, the cause of the results of their equipment. Because the
would generally be either excessive dielectric breakdown voltage test is
When we evaluate gas content or an abnormally high all about identifying the presence of
results outside number of suspended particles in contaminants in insulating liquids,
the acceptable the insulating liquid. If gas content it is, however, a critical piece of
range, the first is not excessive, the appropriate the puzzle regarding your electric
consideration is to response is to repeat the dielectric power system's overall reliability and
cross reference the breakdown voltage determination performance.
results to moisture, on another sample. If this second
liquid power factor, and liquid screen sample also has an unacceptable When gathered over time alongside
tests to identify possible causes for result, a particle count distribution other essential tests and mainte-
the depressed dielectric breakdown test should be performed using the nance activities, transformer owners
voltage values. The dissolved gas standard method ASTM D6786. can use the dielectric breakdown
analysis is also consulted to This is generally sufficient to estab- voltage test data to track trends and
determine whether the gas content lish the cause of the abnormal act when needed. The information
could have depressed the levels dielectric breakdown voltage results. you gather helps you predict your
outside the acceptable range. equipment's lifespan, reduces the
Invest in Reliability risk of failures, increases safety,
Frequently, we can eliminate and is an investment in your
Photo: SDMyers

moisture, liquid aging, and most No single test is sufficient to define overall reliability. That means less
types of contamination as all known conditions and provide downtime and saving time and
probable causes for poor dielectric transformers owners with everything money for your organization.
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86 COMING
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Oils & Fluids
PART 2

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tent than space to place in the Digital Magazine for
December so we have split the Insulation and Oils &
Fluids issue into two editions, December and January.

Once again we would like to thank our digital commu-

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Best Wishes to you all and see you in the New Year.

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COMING IN JANUARY ISSUE

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