A Guide To Transformer Oil Analysis
A Guide To Transformer Oil Analysis
BY
I.A.R. GRAY Transformer Chemistry Services
INTRODUCTION
The fault free operation of power transformers is a factor of major economic importance
and safety in power supply utilities and
industrial consumers of electricity.
In the current economic climate, Industries/Supply Utilites tighten their control on capital
spending and make cutbacks in maintenance, an
increased awareness is placed on the reliability of the existing electric power supply.
Down time is at a premium. Often, the loading is
increase on present units , as this will defer purchasing additional plant capacity. Thus
the stress on the transformer increases. The net total
effect of the thermal , electrical and mechanical stress brought on by increased service
needs to be monitored to ensure reliability.
Regular sampling and testing of insulation oil taken from transformers is a valuable
technique in a preventative maintenance program. If a
proactive approach is adopted based on the condition of the transformer oil, the life of
the transformer can be extended.
This paper reviews some of the transformer oil tests and there significance.
WATER CONTENT
Test Method IEC 814
The dielectric strength of an insulating oil is a measure of the oils ability to withstand
electrical stress without failure.
The test involves applying a ac voltage at a controlled rate to two electrodes immersed in
the insulating fluid. The gap is a specified
distance. When the current arcs across this gap the voltage recorded at that instant is
the dielectric strength breakdown strength of the
insulating liquid.
Contaminants such as water, sediment and conducting particles reduce the dielectric
strength of an insulating oil. Combination of these
tend to reduce the dielectric strength to a greater degree.
Clean dry oil has an inherently high dielectric strength but this does not necessarily
indicates the absence of all contaminates, it may
merely indicate that the amount of contaminants present between the electrodes is not
large enough to affect the average breakdown
voltage of the liquid.
Authorities now agree that careless sampling and testing technique has been the source of 99 percent of bad
dielectric readings
ACIDITY OR NEUTRALISATION NUMBER(NN)
Test Method: ASTM D974
Acids in the oil originate from oil decomposition/oxidation products. Acids can also come
from external sources such as
atmospheric contamination.
These organic acids are detrimental to the insulation system and can induce corrosion
inside the transformer when water is present.
An increase in the acidity is an indication of the rate of deterioration of the oil with
SLUDGE as the inevitable by-product of an
acid situation which is neglected.
The acidity of oil in a transformer should never be allowed to exceed 0.25mg KOH/g oil.
This is the CRITICAL ACID NUMBER and
deterioration increases rapidly once this level is exceed.
INTERFACIAL TENSION(IFT)
Test Method : ASTM D971
The Interfacial Tension (IFT) measures the tension at the interface between two liquid (oil
and water) which do not mix and is expressed
in dyne/cm.
The test is sensitive to the presence of oil decay products and soluble polar contaminants
from solid insulating materials.
Good oil will have an interfacial tension of between 40 and 50 dynes/cm. Oil oxidation
products lower the interfacial tension and have an
affinity for both water (hydrophilic) and oil. This affinity for both substances lowers the
IFT. The greater the concentration of
contaminants, the lower the IFT, with a badly deteriorated oil having an IFT of 18
dynes/cm or less.
IFT-NN Relationship
Studies have shown that a definite relationship exists between acid number(NN) and
Interfacial Tension(IFT). An increase in NN should
normally be followed by a drop in IFT. The IFT test is a powerful tool for determining how
an insulating oil has performed and how much
life is left in the oil before maintenance is required to prevent sludge.
The IFT provided an excellent back up test for the NN.
IFT not accompanied by a corresponding increase in NN indicates polar contamination
which have not come from normal oxidation.
Although a low IFT with a low NN is an unusual situation , it does occur because of contamination such as solid
insulation materials,
compounds from leaky pot heads or bushings, or from a source outside the transformer.
HISTORICAL DATA BASE ESTABLISHING CORRELATION
BETWEEN NEUTRALIZATION NUMBER-INTERFACIAL
TENSION AND SLUDGE FORMATION IN OIL
FILLED TRANSFORMERS
Neutralization Number vs Sludge
(A)
NN Percent Units Sludged
mg/KOH/g of 5001
0.00-0.102 0 0
0.11-0.20 38 190
0.21-0.60 72 360
0.60 and up 100 500
Interfacial Tension vs Sludge
(B)
IFT Percent Units Sludged
Dynes/cm of 5001
1) Below 14 100 500
2) 14-16 85 425
3) 16-18 69 345
4) 18-20 35 175
5) 20-22 33 165
6) 22-24 30 150
7) Above 24 0 0
1 ASTM - 11 year test on 500 transformers(1946-57).
2 Realistic value of 0.03-0.10.
problem.
DISSIPATION FACTOR
Test Method: IEC 247
The Dissipation test measures the leakage current through an oil, which is the measure
of the contamination or deterioration i.e. Reveals
the presence of moisture resin, varnishes or other products of oxidation oil or of foreign
contaminants such as motor oil or fuel oil. The
test is not specific in what it detects i.e. is more a screening test.
POLYCHLORINATED BIPHENYL
Polychlorinated biphenyls (PCB) is a synthetic transformer insulating fluid, that has found
its way into mineral insulating oil via cross
contamination .
POLYCHLORINATED BIPHENYL: Non-specific methods that determines Chlorine in oil, as all
PCBs contain some amount of
Chlorine.
This test is susceptible to false positive results, i.e. the test indicates the presence of PCB
when actually there is none present.
POLYCHLORINATED BIPHENYL: Specific method (ASTM D4059-Gas
chromatography/Electron Capture) that differentiates between
PCBs and a related compound e.g. trichlorobenzene.
All commercially produced PCB are complex mixtures of many different congeners (A
congener is a PCB molecule containing a specific
number of chlorine molecules at specific sites)
Analysing for PCB, therefore, is not a case of simply finding an easily quantifiable
compound, but of quantifying a complex mixture of
compounds.
The main reasons for stopping further use are the environmental risks. PCB is very stable
and its degradation process is slow, it is also
Biological accumulative in the food chain.
PCB liquid is not more toxic than many other common fluids. The lower the figure, the
higher the toxicity
Chemical LD50 g/Kg
PCB 8.7
Trichloroethylene 5.2
Acetone 9.8
Methyl alcohol 12.9
Polychlorinated dibenzofuranes <0.001
Far more serious are the risks of a fire or an explosion. At temperatures around 500
degrees C extremely toxic compounds Polychlorinated
dibenzfuranes are formed. Small amounts of these compounds have been found at
accidents where transformers and capacitors have been
exposed to fire or have exploded. Even if the amounts have been extremely small and
have caused no personal injuries, it has been
necessary to perform very extensive and costly decontamination work.
Furaldehyde Analysis
INTERPRETATION
Transformers are vital components in both the transmission and distribution of electrical
power. The early detection of incipient faults
in transformers is extremely cost effective by reducing unplanned outages. The most
sensitive and reliable technique used for evaluating
the health of oil filled electrical equipment is dissolved gas analysis (DGA). .
Insulating oils under abnormal electrical or thermal stresses break down to liberate small
quantities of gases.The qualitative
composition of the breakdown gases is dependent upon the type of fault. By means of
dissolved gas analysis (DGA), it is possible to
distinguish faults such as partial discharge (corona), overheating (pyrolysis) and arcing in
a great variety of oil-filled equipment.
Information from the analysis of gasses dissolved in insulating oils is valuable in a
preventative maintenance program. A number of
samples must be taken over a period of time for developing trends. Data from DGA can
provide
Advance warning of developing faults.
A means for conveniently scheduling repairs.
Monitor the rate of fault development
NOTE : A sudden large release of gas will not dissolve in the oil and this will cause the
Buchholtz relay to activate.
GAS CHROMATOGRAPHY
By separating and quantifying (measuring) the gasses found dissolved in the oil, the
specialist can identify the presence of an incipient
fault (early warning).
The amounts and types of gases found in the oil are indicative of the severity and type of
fault occurring in the transformer.
The separation, identification and quantification of these gases requires the use of
sophisticated laboratory equipment
and technical skills and therefore can only be conducted by a suitably equipped and
competent laboratory.
Other higher hydrocarbon gases are produced, but these are not generally considered
when interpreting the gas analysis data.
ORIGIN OF GASES IN TRANSFORMER OIL
Fault gases are caused by corona (partial discharge), thermal heating (pyrolysis) and
arcing.
PARTIAL DISCHARGE is a fault of low level energy which usually occurs in gas-filled voids
surrounded by oil impregnated material.
The main cause of decomposition in partial discharges is ionic bombardment of the oil
molecules.
The major gas produced is Hydrogen. The minor gas produced is Methane.
THERMAL FAULTS
A small amount of decomposition occurs at normal operating temperatures. As the fault
temperature rises, the formation of the
degradation gases change from Methane (CH4) to Ethane (C2H6) to Ethylene (C2H4).
A thermal fault at low temperature (<300deg/C) produces mainly Methane and Ethane
and some Ethylene.
A thermal fault at higher temperatures (>300deg/C) produces Ethylene. The higher the
temperature becomes the
greater the production of Ethylene.
ARCING is a fault caused by high energy discharge.
The major gas produced during arcing is acetylene. Power arcing can cause temperatures
of over 3000deg/C to
be developed.
NOTE : If the cellulose material (insulating paper etc.) is involved , carbon monoxide and
carbon dioxide are
generated.
A normally aging conservator type transformer having a CO2/CO ratio above 11 or below
3 should be regarded as perhaps indicating a
fault involving cellulose, provided the other gas analysis results also indicate excessive
oil degradation.
Results
All reports this included Graphs can be e-mailed to the customer ie full integration with Microsoft Office
2000.
The interpretation of transformer oil gas analysis is still an art and not an exact science.
The interpretation should be left to a specialist and
his advice and recommendations should be followed. Samples should be taken regularly
and records kept.
TABLE 2
TABLE 3
WESTINGHOUSE
GUIDELINES ON
TOTAL COMBUSTIBLE GASES(TCG)
>30
10-30
<10
Monthly
Monthly
Quarterly
Exercise extreme caution
Plan outage
Analyse for individual gases
Advise manufacturer
Condition 1
720
>30
10-30
<10
Monthly
Quarterly
Annually
Exercise extreme Caution.
Analyse for individual gases
Determine load dependence
Exercise extreme Caution.
Analyse for individual gases
Determine load dependence
Continue a normal operation
TABLE 4
CEGB/ANSI/1EEE GUIDE FOR
GAS CONCENTRATION LIMITS IN PPM V/V
GAS GENERATOR
TRANSFORMERS
TRANSMISSION
H2 240y 100
C0 580 350
CH4 160 120
C2H6 115 65
C2H4 190 30
C2H2 11 35
TABLE 5
OTHER INTERNATIONAL
GAS CONCENTRATION LIMITS
IN PPM V/V
GAS HYDRO QUEBEC
CANADA
BBC
SWITZERLAND
OY STROMBERG
FINLAND
H2 250 200 100
CO 850 1000 500
CH4 33 50 100
C2H6 15 15 150
C2H4 40 60 100
C2H2 25 15 30
TABLE 6
SECR - JAPAN
LIMITING VALUES
IN PPM V/V
GAS TRANSFORMERS
>275kV & >10MVA
TRANSFORMERS
TABLE 7
EDF - FRANCE
TRANSMISSION TRANSFORMERS
WITHOUT ON-LOAD TAP CHANGERS
GAS GENERATOR
TRANSFORMERS
TRANSMISSION
TRANSFORMERS
H2 33 130
C0 770 1000
CH4 44 130
C2H6 33 150
C2H4 11 44
C2H2 0.4 0.4
TABLE 1
Code for examining analysis of gas dissolved in mineral oil
Code of range of ratios
IEC 599
C2H2
C2H4
CH4
H2
C2H4
C2H6
Ratios of characteristic gases
< 0.1 0 1 0
0.1-1 1 0 0
1-3 1 2 1
>3222
Case No.
Characteristic fault
Typical examples
0
No fault
0
0
0
Normal ageing
1
Partial discharges of Low energy
density
0
but not
significant
1
0
Discharges in gas-filled cavities resulting
from incomplete impregnation, or supersaturation
or cavitation or high humidity.
2 Partial Discharges of Low energy
density
1 1 0 As above, but leading to tracking or perforation
of solid insulation.
3 Discharges of low energy(see Note 1) 1-2 0 1-2 Continuous sparking in oil between bad
connections of different potential or to
floating potential. Breakdown of oil
between solid materials.
4
Discharges of High Energy 1 0 2 Discharges with power follow-through.
Arcing-breakdown of oil between windings
or coils, or between coils to earth.
Selector breaking current.
5 Thermal fault of Low Temperature
<150C(see Note 2)
0 0 1 General insulated conductor overheating
6 Thermal Fault of Low Temperature
range 150C-300C(see Note 3)
0 2 0 Local overheating of the core due to concentrations
of flux. Increasing hot spot tempretures;
varying from small hot spots in core,
overheating of copper due to eddy currents, bad
contacts/joints(pyrolitic carbon formation)
up to core and tank circulating currents.
7 Thermal fault of Medium temperature
range 300C-700C
021
8 Thermal fault of high temperature
>700C(see Note 4)
022
Notes 1. - For the purpose of this table there will be a tendency for the ratio
between 0.1 and 3 to above 3 and
C2H2
C2H4
C2H4
C2H6
2. - In this case the gases come mainly from the decomposition of the solid insulation, this explains
the value of the ratio C2H4
C2H6
CH4
is normally
H2
<1.0
<1.0 3.0 3.0 Continuous discharge
>1.0
<1.0
<1.0 1.0 or 3.0
<3.0
0.5 or 3.0
<3.0
Arc - with power follow
through
>1.0
<1.0
<1.0 <1.0 0.5
<3.0
Arc - no power follow
through
1.0 or 3.0
<3.0
<1.0 <1.0 <0.5 Slight Overheatingto
150c
1.0 or 3.0
<3.0
1.0 <1.0 <0.5 Overheating
150-200C
>0.1
<1.0
1.0 <1.0 <0.5 Overheating
200-300C
>0.1
<1.0
>1.0 1.0
<3.0
<0.5 General conductor
overheating
1.0
<3.0
<1.0 1.0
<3.0
<0.5 Circulating currents
in windings
1.0
<3.0
<1.0 3.0 <0.5 Circulating currents
core and tank;
overloaded joints
Fault gas generation rates for
transformer with 50 m3 of oil
Normal Serious
H2 Less than 0.1 ppm/day more than 2ppm/day
CH4 0.05 6
C2H2 0.05 6
C2H4 0.05 6
C2H6 0.05 1
CO 2 10
CO2 6 20