193
4
Insulating Oils, Fluids, and Gases
4.1 Introduction
Insulating oils, fl uids, and gases are used as dielectrics in the electrical equipment
and apparatus. The liquids used in the transformers are mineral oil
and synthetic fl uids, such as askarel, silicone, RTemp, Wecosal, Alpha 1, and
GE R113. (The synthetic fl uids such as askarel, silicone, RTemp, etc. have a
fi re point of not less than 300°C and are classifi ed as less fl ammable insulating
fl uids by the National Electric Code, NEC.) Mineral oil is also used as a
dielectric in circuit breakers, reclosers, interrupters, and the like. The most
common insulating gas used in circuit breakers and completely enclosed
substations is sulfur hexafl uoride (SF6). This chapter covers electrical, chemical,
and visual tests which are normally conducted for the maintenance of
transformer oils and fl uids. Also, this chapter includes a discussion on the
inspection, handling, and reconditioning of insulating oil, fl uids, and gases
used in electrical equipment.
The ability of insulating oils, fl uids, and gases to serve as effective dielectric
and coolant is adversely affected by their deterioration. The deterioration
of insulating oil, fl uids, and gases is due to contamination, overheating, electrical
stress, and oxidation. Moisture is the most common contaminant which
adversely affects the insulating properties of these liquids and gases. High
temperatures from increased load and/or environmental conditions accelerate
the deterioration process. To assure continuity of service, safety, and
maintenance, a condition monitoring program, consisting of electrical and
chemical testing, is necessary for these dielectrics.
4.2 Insulating Oil
Hydrocarbon (mineral oil #10) oil is used as an insulating fl uid in transformers
and circuit breakers because of its high dielectric strength and chemical
stability. To properly maintain the transformer oil free of contaminants,
regular inspection of the transformer and purifi cation of the oil is needed.
A brief discussion on the deterioration of the insulating oil is undertaken for
maintenance purposes.
194 Electrical Power Equipment Maintenance and Testing
4.2.1 Deterioration of Insulating Oil
4.2.1.1 Effect of Oxygen on Oil
Moisture contamination is the most common cause of deterioration in the
insulating quality of oil. This contamination can be readily corrected by
purifi cation. A slow but more serious deterioration, the formation of acids
and sludge, is caused by oxidation. Thus, the exclusion of oxygen is of
prime importance. In open-breather transformers, the oxygen supply is
virtually unlimited and oxidative deterioration is faster than sealed transformers.
Atmospheric oxygen and oxygen contained in water are the
sources available for the oxidation of insulating oils. When water is present
in insulating oils, oxidation of the oil will take place. Therefore, leaking
gaskets and seals constitute a very real hazard since a water leak is, in
effect, an oxygen leak. The rate of oxidation also depends on the temperature
of the oil; the higher the temperature is, the faster the oxidative breakdown.
An increase in temperature of 10°C (50°F) generally doubles the rate of
oxidation. The fact points to the importance of avoiding overloading of
transformers, especially in the summertime. Oxidation results in the formation
of acids in the insulating oil and the formation of sludge at a more
advance state of oxidation.
4.2.1.2 Moisture in Oil
Water can be present in oil in a dissolved form, as tiny droplets mixed with the
oil (emulsion), or in a free state at the bottom of the container holding the oil.
Demulsifi cation occurs when the tiny droplets unite to form larger drops,
which sink to the bottom and form a pool of free water. Emulsifi ed water
typically requires vacuum dehydration, as the emulsifi cation cannot typically
be broken by fi ltration or by excellerated gravity (centrifuge). Water in
the free state may be readily removed by fi ltering or centrifugal treatment.
However, dissolved water is not removed by centrifugal treatment; the fi ltration
process can partially remove dissolved water if the fi lter papers are thoroughly
dried before fi ltration, but the effi ciency of the fi ltration process
depends upon oil temperature and fi ltration media.
The effect of moisture on the insulating properties of oil depends upon
the form in which the moisture exists. A very small amount of emulsifi ed
water has a marked infl uence in reducing dielectric strength of oil. Free
moisture in oil usually shows up above 50 to 60 ppm depending upon
temperature. Accepted levels of water in oil are shown in Table 4.1. The
amount of moisture that can be dissolved in oil increases rapidly as the oil
temperature increases, as shown in Figure 4.1. Therefore, an insulating oil
purifi ed at too high a temperature may lose a large percentage of its
dielectric strength on cooling, because the dissolved moisture is then
changed to an emulsion, unless vacuum dehydration is used as the purifi
cation process.
Insulating Oils, Fluids, and Gases 195
4.2.1.3 Oil Deterioration in Transformers
In transformers, sludge sticks to the surface through which heat should be
dissipated; the sludge forms a blanket barrier to the fl ow of heat from the oil
to the coolant and from the core and coils to the cool oil. If allowed to continue
long enough, the sludge may even block off the fl ow of oil through the
cooling ducts. As a result, the transformer insulation gets too hot and is damaged,
particularly between turns of the windings. Deterioration of the turn
insulation may eventually lead to short circuits between turns and the breakdown
of the transformer. When oxidation progresses to the point where
sludge is being precipitated, the fi rst step should be to remove the sludge
from the transformer by a high-pressure stream of oil or hot oil circulation to
dissolve the sludge, or to either replace the sludged oil or treat it with activated
clay to remove the acid. Under favorable conditions, complete treatment
of the oil is less costly than replacing it with new oil.
TABLE 4.1
Maximum Allowable Moisture in Oil
Voltage Level (kV) Maximum Moisture (ppm)
5 30
15 30
35 25
69 20
138 and up 15
240
200
160
120
80
40
0 10 20
Temperature (C)
Parts per million (ppm) by volume 30 40 50
FIGURE 4.1
Maximum amount of water dissolved in mineral oil as affected by temperature.
196 Electrical Power Equipment Maintenance and Testing
4.2.1.4 Absorption of Moisture by Insulating Materials
Solid insulation (paper insulation) in transformers is very porous and thirstily
absorbs water. Some of the water that is dissolved in the oil is absorbed from
the oil by the cellouse (paper) winding insulation. As more water is dissolved
in the oil, more water is absorbed by the insulation of the transformer windings.
Once absorbed, it is diffi cult to remove. The most effective method for
drying out the insulation in transformers is with heat and vacuum. Sometimes
a vacuum cannot be applied in the fi eld; then the transformer insulation must
be dried by circulation of hot, dry oil. This oil should then be cooled and dried.
Since the dielectric strength of insulation is reduced by absorption of moisture,
it is important that the insulation not be allowed to absorb it in the fi rst place.
4.2.1.5 Absorption of Nitrogen by Oil
Special precaution should be taken in operating transformers with nitrogen
over the oil to avoid bubbling of the oil due to release of dissolved nitrogen
when the pressure drops. Experience has shown that the automatic gaspressure
regulating system should be adjusted to limit the nitrogen pressure
range from 1/2 to 3 psi (lb/in.2) gauge to avoid formation of these bubbles
and subsequent troubles due to corona deterioration.
4.2.2 Insulating Oil Testing
Transformer oil reacts with oxygen to form organic acids, esters, and phenolic
compounds which ultimately leads to sludging of the transformer. The rate of
this phenomena increases with an increased exposure to air and temperature.
Also it should be noted that oxygen is more soluble in oil than found in air. Not
only will the sludge adversely affect the dielectric properties of the oil, but it
will also interfere with dissipation of heat within the transformer. The purpose
of these tests are to chart the gradual deterioration and take preventative
measures before insulating oil reaches a point where failure of the transformer
is inevitable. The routine tests and sampling procedures that are conducted on
insulating oil are shown in Table 4.2, and are discussed in text of this chapter.
TABLE 4.2
ASTM Method of Test for Insulating Liquids
Test ASTM Test Method
Color D1500
Dielectric breakdown voltage D877, D1816
Visual examination D1524
IFT (oil only) D971, D2285
Neutralization number (acidity) D974, D664, D1534
Power factor/dissipation factor D924
Moisture (Karl Fischer method) D1533
Specifi c gravity D1298
Viscosity D445, D2161
Sedimentation D-1698
Insulating Oils, Fluids, and Gases 197
4.2.2.1 Dielectric Breakdown Voltage Test (Cup Tests)
This is an AC overvoltage test applied to the insulating liquids to detect their
breakdown strength. A typical test set is shown in Figure 4.2. The American
Society for Testing and Materials (ASTM) has established test standards for
these liquids, which are listed in Table 4.2. The dielectric test simply consists
of placing a liquid sample from the transformer or (circuit breaker) in a cup
containing two electrodes of specifi ed gap. High voltage is then applied to
the sample. The test is repeated for a least fi ve different samples to determine
the average dielectric strength. The minimum accepted values for the various
liquids are listed in Table 4.3.
Two different electrodes are used in these tests, one for mineral-based oils
and the other for mineral-based oils and synthetic liquids. The Verband
Dentschev Elektrotechniker (VDE) cup is used for mineral-based oils; it has
FIGURE 4.2
Oil dielectr