Niche Market Testing

Transformer Oil Sampling

by Lynn Hamrick
ESCO Energy Services

I
n dealing with the various firms that perform laboratory testing of trans- for transformers with a high-voltage
former oil samples, I have noticed different recommended tests and different rating of 230 kV and above and 27 kV
for transformers with a high-voltage
threshold levels associated with the results. Therefore, I thought it might rating below 230 kV. New oil should
be useful to discuss what is considered to be the more useful tests that need to have a minimum dielectric strength of
35 kV by ASTM methods of testing.
be performed and the acceptable results associated with those tests. It is highly
Oil is not necessarily in good condi-
recommended that transformer oil sample tests be performed at least on an an- tion even when the dielectric strength
nual basis with results compared from year to year. In this article, I will discuss is adequate, because this tells nothing
about the presence of acids and sludge.
transformer oil sample tests other than dissolved gas analysis (DGA). We will Lower values are indicative of damp
leave the DGA discussion for another day. or dirty oil.
Transformer oil sample tests can be separated into two general categories, Moisture Content – Moisture in oil
those that assess the immediate acceptability of the insulation system and those is measured in parts per million (ppm)
that assess the degree of aging or degradation of the insulation system. using the weight of moisture divided
by the weight of oil. Water can be
Insulation System Acceptability present in oil in a dissolved form, as
To evaluate the immediate acceptability of the insulating system, three im- tiny droplets mixed with the oil (emul-
portant oil sample tests should be carried out: sion), or in a free state at the bottom
of the tank holding the oil. Demulsi-
1. dielectric breakdown voltage fication occurs when the tiny droplets
2. moisture content unite to form larger drops which sink
to the bottom and form free water.
3. power factor When the moisture in oil exceeds
These test measurements should be reviewed to verify that there are no sudden the saturation value, there will also be
changes that would indicate the possibility of the entrance of moisture or other free water precipitated from the oil in
contaminants. If there is a sudden change, the transformer should be carefully suspension or drops. In general, the
inspected for leaks, and the oil processed if the dielectric is below an acceptable moisture content in the oil lowers the
level or water content is above acceptable levels. A description of these tests is insulating system dielectric strength
provided below: and allows flashover that can damage
a transformer. Moisture can also ac-
Dielectric Breakdown Voltage – The dielectric breakdown voltage is a measure- celerate paper-insulation aging rates
ment of electrical stress that an insulating oil can withstand without failure. It is that will reduce the expected useful
measured by applying a voltage between two electrodes under prescribed condi- life of equipment. For mineral oil, a
tions under the oil. The dielectric test measures the voltage at which the oil breaks generally accepted maximum moisture
down, which is indicative of the amount of contaminant (usually moisture) in the content is 35 ppm.
oil. For mineral oil, a generally accepted minimum dielectric strength is 30 kV

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 Power Factor - The power factor of
insulating oil equals the cosine of
the phase angle between an ac volt-
age applied and the resulting current.
Power factor indicates the dielectric
loss of the insulating oil and, thus, its
dielectric heating. The power-factor
test is widely used as an acceptance
and preventive maintenance test for
insulating oil. A high power factor in
service-aged oil indicates deteriora-
tion, contamination, or both with
moisture, carbon, or deterioration
products. For mineral oil, the power
factor of new oil should not exceed
0.05 percent at 25oC. Service-aged
oil with a power factor in excess of 0.5
percent should be further analyzed in
a laboratory to determine the cause of
the high power factor. Oil with a power
factor in excess of 2.0 percent may be
an operational hazard. It should be
investigated and either reconditioned
or replaced.
in such a way that the presence of more polar compounds causes lower IFT. The
Insulation System Aging/ test measures the concentration of polar molecules in suspension and in solution
Degradation in the oil and thus gives an accurate measurement of dissolved sludge precursors
The principal indicators to assess in the oil long before any sludge is precipitated. Typically for mineral oil, new
the degree of aging or degradation of oil has a minimum reading of 36 dynes/cm and an in-service oil is generally
the insulation system (lead conductor considered good until a reading of less than 25 dynes/cm is reached. It has been
insulation, winding insulation, core in- established that an IFT of less the .015 N/m (15 dyne/cm) almost invariably
sulation, and the fluid insulation) are: shows sludging. An IFT of 0.015 to 0.022 N/m (15 to 22 dyne/cm) shows an
uncertain condition, and an IFT value of more than 0.022 N/m (22 dyne/cm)
1. interfacial tension is generally indicative of no sludging. If there is an interfacial tension decrease
2. acid neutralization of 20 percent or more (with a change in the color between annual readings), the
oil should be resampled and tested for confirmation of the results. A significant
3. color change denotes an accelerated aging of the insulation system, which would be
These indicators should be reviewed indicative of overheating of the insulation. The transformer should be scheduled
for any abrupt changes as they would for winding insulation tests as soon as possible if these results are verified.
normally change very little from year Acid Neutralization Number – The acid neutralization number, or acid num-
to year. A significant change in these ber, is the amount of potassium hydroxide (KOH in mg) required to neutralize
values may indicate overheating of all the acid in one gram of oil. It is indicative of the acid content in the oil. With
or part of the insulation system. The service-aged oils, it is also indicative of the presence of contaminants, like sludge.
transformer should be scheduled for It should be recognized that the acidity test alone determines conditions under
acceptance tests as soon as possible if which sludge may form but does not necessarily indicated that actual sludging
these results are verified. conditions exit. New transformer oils contain practically no acids. The acidity
Interfacial Tension –The interfacial test measures the content of acids formed by oxidation. The oxidation products
tension (IFT) test is employed as an polymerize to form sludge which then precipitates out. Acids react with metals
indication of the sludging character- on the surfaces inside the tank and form metallic soaps, another form of sludge.
istics of power transformer insulating For mineral oil, sludging has been found to begin when the acid number reaches
oil. It is a test of IFT of water against or exceeds 0.4 mg KOH/gram. New oil has an acid number of less than 0.05 mg
oil, which is different from surface ten- KOH/gram. Oil showing an acid number of 0.15 or larger can be expected to
sion in that the surface of the water is show accelerated acid formation. Typically, results of 0.10 mg KOH/gram of oil
in contact with oil instead of air. The or less are considered good. Higher values are indicative of a problem. If there
attraction between the water molecules is an acidity increase of 25 percent or more (with a change in the color between
at the interface is influenced by the annual readings), the oil should be resampled and tested for confirmation of the
presence of polar molecules in the oil results. A significant change denotes an accelerated aging of the insulation system,

2 NETA WORLD Summer 2009 www.netaworld.org

which would be indicative of overheating of the insulation.
The transformer should be scheduled for acceptance tests
as soon as possible if these results are verified.
Color – The color of an insulating oil is determined by
means of transmitted light and is expressed by a numerical
value based on comparison with a series of color standards.
It is recognized that color by itself could be misleading in
evaluating oils for service quality. The primary significance
of color is to observe a change or darkening of the oil from
previous samples of oil from the same transformer. Notice-
able darkening in short periods of time indicates either
contamination or that arcing is taking place. A darkening
color, with no significant change in neutralization value or
viscosity, usually indicates contamination.
The acceptable levels provided for the above parameters
are for cases when mineral oil is used as the insulating oil.
Below is a table which includes a compilation of suggested
acceptable levels for other insulating oils:
The above levels are consistent with NETA/ANSI MTS-
2007, Standard for Maintenance Testing Specifications for
Electrical Power Distribution Equipment and Systems and
the IEEE C57 series of specifications on transformer fluid
testing. Additionally, I am sure that tests other than those
shown above could be recommended based on conditions
and results. My suggestion is that the above recommended
tests and results should provide the minimum requirements
for a condition-based, transformer oil analysis program.
As suggested above, transformer fluid sample tests should
be performed at least annually, with more frequent testing
performed if issues arise.

As Operations Manager of ESCO Energy Services Company, Lynn

brings over 25 years of working knowledge in design, permitting, con-
struction, and startup of mechanical, electrical, and instrumentation and
controls projects as well as experience in the operation and maintenance
of facilities.
Lynn is a Professional Engineer, Certified Energy Manager and has
a BS in Nuclear Engineering from the University of Tennessee.

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