IS 1866:2000

Indian Standard
CODE OF PRACTICE FOR ELECTRICAL
MAINTENANCE AND SUPERVISION OF MINERAL
INSULATING OIL IN EQUIPMENT
(Third Revision,)

ICS 29.040.10; 29.130

0 BIS 2000

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December 2000 Price Group 8

f
Fluids for Electrotechnical Applications Sectional Committee, ET 03

FOREWORD

This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by Fluids for Electrotechnical Applications Sectional Committee had been approved by Electrotechnical Division
Council.

This standard was first published in 1961 to cover the maintenance of insulating oil complying with
-—
IS 335:1953 ‘Insulating oils for transformers and switchgem’. The first revision was undertaken in 1978 to
bring in line with the new oil requirements given in IS 335: 1972 ‘Specification for new transformers and
switchgear’. The second revision was carried out to align with the corresponding IEC 60422 (1973).

This third revision has been aligned with IEC 60422 (1989) ‘Supervision and maintenance guide for mineral
insulating oils in electrical equipment’ issued by International Electrotechnical Commission. Values of permissible
limits, relating to resistivity, dielectric dissipation factor (Tan delta) and neutralization value of oil have been
aligned with those in IEC 60422”( 1989). The following changes have been made in this revision:

a) Equipment has been categorized in order to take into account different user requirements. The application
and interpretation of tests are tabulated categorywise.
b) Classification of oils in service has been made based on the evaluation of significant properties andfor
their ability to be restored to the characteristics desired.

The requirements of new insulating oils at the time of delivery is covered by IS 335:1993 ‘New insulating oils’.
After receipt and storage, but prior to actual use there maybe a change in the properties of the oil particularly
in the electrical characteristics due to ingress of moisture or extraneous contamination. It is normal practice to
filter/dehydrate this oil before filling in the equipment. Moreover, monitoring and maintaining oil quality are
essential in ensuring the reliable operation of oil filled electrical equipment. No specific guidelines exists, as it
is possible that some characteristics may be lower than those specified in IS 335. However, the quality level is
expected to be better to the limiting values applicable for the case specified in the code. This code helps to
compare the value and significance of standardized oil tests and recommends uniform criteria for evaluation of
test data. This standard also indicates the type of treatment to which oil should be subjected if considered
necessary.

If oil deterioration exceeds a certain limit, there is some erosion on safety margins and therefore, the question
of the risk of premature failure of the equipment must be considered. While the quantification of the risk may
be very difficult, a first step involves the identification of potential effects from the increased deterioration. The
objective of this code of practice is to furnish the users with as broad a base for understanding the oil quality
deterioration as available so that they can make informed decisions on maintenance practices.

The values of the various properties given in this standard should be considered only as indication of the
characteristics. In fact, for the proper interpretation of results, account has to be taken of various factors, such as
conditions of use, type of equipment and the general progression of the oil characteristics, Sound engineering
judgment will have to be exerted in ,seeking the best compromise between the technical requirements and
economic factors. In deciding the standardized values of the oil properties, it is important to seek the advice of
the equipment manufacturer also.

In preparing this code, assistance has been derived from the following publications:

IEC 60422 (1989) ‘Supervision Maintenance and Guide for Mineral Insulating Oils in Electrical Equipment
issued by the International Electrotechnical Commission.

Technical Report No. 0037-INS-Ott. 1967: A New Test for Quickly Determining the Acid Content of Transformer
Oils. Central Power Research Institute, Bangalore.

Technical Report No. 0050-TD (Chem)-March 1970: The Interracial Tension Test as Guide to the Quality of
Insulating Oils. Central Power Research Institute, Bangalore.
(Continued on third cover)
 IS 1866:2000

Indian Standard
CODE OF PRACTICE FOR ELECTRICAL
MAINTENANCE AND SUPERVISION OF MINERAL
INSULATING OIL IN EQUIPMENT
(Third Revision)
1 SCOPE mixture of equal parts of toluene, acetone and alcohol .—
under prescribed conditions.
1.1 This standard deals with maintenance and
supervision of mineral insulating oils complying 3.5 Neutralization Value (Total Acidity)
with the requirements of IS 335 and IS 12463 in
transformers, switchgears, and similar electrical It is the measure of free organic and inorganic acids
apparatus where oil sampling is practicable and where present together in the oil. It is expressed in terms of
the normal operating conditions specified for the the number of milligrams of potassium hydroxide
equipment are observed. required to neutralize the total free acids in one gram
of the oil.
NOTE— Recommendations for oil used in hermetically seated
and low volume equipment are excluded from thk code because
3.6 Specitlc Resistance (Reaistivity)
such equipment is not designed for the process of routine oil
sampling. It is the ratio of the dc potential gradient in volts
per centimeter paralleling the current flow within
2 REFERENCES
the specimens to the current density in amperes per
2.1 The Indian Standards given in Annex D are square centimeters at a given instant of time and
necessary adjuncts to this standard. under prescribed conditions. This is numerically
equal to the resistance between opposite faces of
3 TERMINOLOGY
a centimeter cube of the liquid. It is expressed in
For the purpose of this standard, the following ohm-centimeter.
definitions shall apply.
3.7 Dielectric Dissipation Factor (Tangent Delta)
3.1 Electric Strength (Break Down Voltage)
It is the tangent of the angle (delta) by which the phase
The voltage at which the oil breaks down when difference between applied voltage and resulting
subjected to an ac electric field with a continuously current deviates from 7c/2 radian when the dielectric
increasing voltage contained in specified apparatus. of the capacitor consists exclusively of the insulating
The voltage is expressed in kV. oil.
3.2 Flash Point
3.8 Interracial Tension
The temperature at which the oil gives off so much of
It is a force necessary to detach a planar ring of
vapour that this vapour, when mixed with air, forms a
platinum wire from the surface of the liquid of higher
ignitable mixture and gives a momentary flash on
surface tension that is upward from the water-oil
application of pilot flame under the prescribed condhions.
surface. It is expressed in N/m.
3.3 Precipitable Sludge
3.9 Reconditioning
Oil deterioration products or contaminants or both,
which are insoluble after dilution of the oil with This is a process to eliminate, by physical means only,
rz-heptane but are soluble in the solvent mixture of solid particles from the oil and to decrease the water
equal parts of toluene, acetone and alcohol under content to acceptable level.
prescribed conditions.
3.10 Reclaiming ●

3.4 Sediment This is a process to eliminate from the used oil, all
Any substance which is insoluble after dilution of the contaminants, insoluble and dissolved, to obtain an oil
oil with rr-heptane and also insoluble in the solvent with characteristics similar to those of a new oil.

1
Is 1866:2000

4 OIL DETERIORATION AND 5 SAMPLING OF OIL FROM EQUIPMENT

RECOMMENDED TESTS
5.1 Every effort should be made to ensure that samples
4.1 In service, insulating oils are subjected to normal are representative of the insulating oil in equipment.
deterioration due to the conditions of use. For example, Experience indicates that oil is sometimes rejected
in many applications the oil is in contact with air. It is, unjustifiably because inadequate care has been taken
therefore, subjected to oxidation reactions accelerated during sampling.
by temperature and presence of catalysts (solid iron
5.2 It is strongly recommended that the procedures
and copper, dissolved metallic compounds). As a result,
and precautions outlined in IS 6855 are closely
the oil darkens in colour and its acidity begins to
followed. Sampling for the determination of low
increase. There will be a simultaneous change in the
moisture content and analysis of dissolved gases,
electrical characteristics, such as, fall in resistivity .—
sampling as per IS 9434 shall be followed. The oil
values and/or an increase in the dielectric dissipation
sampled should be stored safely in a dark place.
factor. In the advanced stages of oxidation, sludge
formation may also occur. 5.3 Sampling from equipment should preferably be
carried out while the equipment is operating normally
4.2 In certain special cases, other changes in the
or very shortly after de-energization. This requirement
characteristics of the oil may be a sign of abnormal
is particularly necessary when water content, or charac-
deterioration of certain other materials used in
teristics dependent on it, are to be checked and in these
construction of the equipment. All these changes may
cases the temperature of the oil at the time of sampling
have effect on both solid and liquid insulating materials
should be recorded.
and interfere with the proper functioning of the
equipment, shorten its working life and in some cases 5.4 Where available, manufacturer’s instructions
increase in no load losses. should be followed. This is especially required with
certain type of equipment, such as instrument transfor-
4.3 The development of an odour and a change in
mers, in view of the limited oil volume as well as
cokn.w, although not being of a decisive nature, may
specific design.
on comparison, give useful indication about the trend
of changes in the oil. 5.5 Oil samples (1 or 2 litres depending on the number
and type of tests needed) are normally drawn from the
The following contaminants may be found in insulating
sampling valve or bottom valve at least, observing the
oils in service:
following general rules :
a) Water Its presence is determined
by Karl Fischer method Ensure that sampling is done by an experienced
person.
b) Sediment and : These are determined by
precipitable sludge method given in Annex ‘A’ Sampling outdoors in rain, fog, snowfall or strong
wind should be avoided. However if sampling is
c) Polar substances : Their presence is deter-
inevitable in such conditions special precautions
mined by fall in values
shall be taken to ensure that ambient conditions
of dielectric dissipation
do not influence the characteristics of the sample.
factor, specific resistance
Sampling under high humidity is to be avoided.
and interracial tension
Preferably sampling should be carried out when
properties
the humidity is less than 50 percent.
d) Acids Their presence is deter-
mined by neutralization Use, only dry and clean containers, such as amber
value coloured glass bottles or seamless metal containers
of stainless steel. Plastic containers can be used
e) Dissolved gases : These can be determined
provided their suitability has been proved. Clear
by gas chromatography
glass bottles should be provided with opaque
f) Light hydrocarbons : These can be determined covers.
by flash point test
Run off sufficient quantity of oil to remove any
The presence of these contaminants or any kind of contaminants that may have accumulated at the
deterioration of an oil is made evident by changes in sampling orifice.
any one or more of the properties covered by these
Rinse the containers with the oil being sampled.
tests. The details of test methods (a) to (f) as above
are covered in 7.0. Fill the containers, if possible allowing the liquid

2
 1s 1866:2000

being sampled to flow against the side of the laboratory tests are contemplated for the sample,
containers, thus avoiding tmppecl air. crackle test or any other testis not warranted.
– Ensure that each container is filled to about 95 NOTE — S D Myer et al have proposed determination of
percent of its capacity. quality index calculated as ratio of Interracial tension in dynes
to Neutralization value in mg KOH/g of oil. This index cm
– After sampling, carefully close the sampling valve. also be employed in field by determining both the properties
at fieId.
– Label the samples, including at least the following
details : 7 SIGNIFICANCE OF TESTS AND TEST
a) Equipment identification, METHODS

b) Sampling point, There are a large number of tests that can be applied to
oil delivered in equipment or oil from equipment in
c) Temperature of oil, and
service but the following tests are believed to be
d) Date of sampling. sufficient to determine whether the oil condition is
– A minimum of 1 Iitre and maximum of 2.5 litres adequate for continued operation and suggest the type
oil depending on number of tests needed shall be of corrective action required:
sampled and stored in a dark place if clear glass Property Method
bottles have been used.
Appearance Is 335
6 INSPECTION OF SAMPLE Electric strength IS 6792
Water content IS 13567
6.1 Visual inspection and odour give useful infor-
Neutralization value IS 1448 [P: 2]
mation, for example :
Sediment and sludge Annex ‘A’
a) Cloudiness in oil may be due to suspended Dielectric dissipation IS 6262
moisture or sediments such as iron-oxide or factor
sludge. Undissolved water present in oil may
Resistivity IS 6103
he determined by crackle test (7.3).
Interracial tension 1) IS 6104
However total moisture content can be deter- Oxidation stability 1) Annex C of IS 335
mined from water content test (TabIe I). IS 12422 as
b) Acid smell indicates the presence of volatile applicable
acids which can cause corrosion. This may Total gas content IS 9434
render oil unsuitable for treatment at site. Pour point 2) IS 1448 [P : 10]
c) Colour can indicate different stages oil quality Density 2) IS 1448 [P : 16]
under ageing: Flash point IS 1448 [P : 21]
Pale yellow : Good oils Viscosity 2) IS 1448 [P : 25]
Yellow : Proposition ‘A’ oils Inhibitor content ~) IS 13631
Bright yellow : Marginal oils Remark : See Note under 1.
Amber : Bad oils 7.1 Appearance
Brown : Very bad oils
The appearance of oil may show cloudiness or sedi-
Dark brown : Extremely bad oils ments which may indicate the presence of free water,
Black : Oils in disastrous condition insoluble sludge, carbon, fibres, dirt, etc.
( Dark brown colour indicates dissolved asphal- 7.2 Breakdown Voltage
tenes and green coIour indicates presence of copper The breakdown voltage is of importance as a measure
compounds.) of the suitability of an oil to withstand electric stress.
Inferences drawn from the above mentioned visual Dry and clean oil exhibits an inherently high
inspection can be used as screening tests at site and breakdown voltage. Free water and solid particles, the
also at the laboratory after receipt of .wmples for
evaluation. The information shaIl be noted for record !)Only under special cireumstzmces.

purposes, as it is valuable to decide the periodicity of ‘) Not essentiaf, but can be used to establish type of oil.
laboratory tests given in Table 2. However, when the ~)Restricted to inhibited oi]s.

3
IS 1866:2000

latter particularly in combination with high levels Its value, negligible in an unused oil, increases as a
of dissolved water, tend to migrate to regions of result of oxidative ageing and is used as a general guide
high electric stress and reduce breakdown voltage for determining when an oil should be replaced or
dramatically. The measurement of breakdown voltage, reclaimed, provided suitable rejection limits have been
therefore serves primarily to indicate the presence of established and confirmation is received from other
contaminants such as water or conducting particles, tests.
one or more of which can be present when low break-
For quickly determining the total acidity of insulating
down voltage values are found by test. However, a high
oils in service, a portable acidity testing kit has also
breakdown voltage does not indicate the absence of
been devised with which test for acidity of oils can be
contaminants.
determined at site with ease. The details of the portable
7.3 Water Content kit is given in Annex C.

Water may originate from the atmosphere or be 7.5 Sediment and Sludge
produced by the deterioration insulating materials. At
This test distinguishes between sediment and total
comparatively low water content, the water rem~ns
sludge that is oil insoluble sludge plus sludge which is
in solution and does not alter the appearance of the
precipitated by adding heptane).
oil. Dissolved water shall therefore be detected by
chemical or physical methods. Solid matter comprises insoluble oxidation or degra-
dation products of insulating materials, fibres of
Dissolved water may or may not affect the elec-
various origins, carbon, metallic oxides, etc. arising
trical properties of the oil. The volubility of water in
from the conditions of service of the equipment. The
transforiner oil increases with increasing temperature
presence of solid particles may reduce the electric
and neutralization value (see Fig. 1). Above a certain
strength of the oil and, in addhion, deposits may hinder
water content (The saturation Water content), all the
heat transfer, thus promoting further deterioration of
water cannot remain in solution and free water maybe
insulation.
seen in the form of cloudiness or water droplets; free
water invariably results in decreased dielectric strength Sludge consists of products formed at an advanced
and resistivity and increased dielectric dissipation stage of oxidation and is forewarning of sludge deposits
factor. in the equipment.

In a transformer, the total water content is distri- 7.6 Dielectric Dissipation Factor (DDF) and
buted between the paper and the oil in a ratio that is Resistivity
predominantly in favour of the paper. Small changes These characteristics are very sensitive to the presence
in temperature significantly modify the water content in the oil of soluble polar contaminants, ageing products
of the oil but only slightly that of paper. or colloids. Changes may be motivated even when
Using graphs which may be found in the literature, it contamination is so slight as to be undetectable by
is possible to obtain at a given temperature the water chemical tnethods.
content of the paper from the measured water content Acceptable limits for these characteristics depend
of the oil assuming equilibrium conditions. The limi- largely upon the type of apparatus and application.
ting values for water content which are recommended However, high values of dissipation factor may
in Table 2 are intended to control the water content in influence the power factor andlor the insulation
cellulosic insulation within acceptable values and resistance of transformer windings.
are related to normal operating oil temperatures over
40 to 601’C. There is generally a relationship between DDF and
resistivity at elevated temperature with resistivity
High water content accelerates the chemical deteri- decreasing as DDF increases. It is normally not
oration of insulating paper and is indicative of required to conduct both tests on the same oil.
undesirable operating conditions or maintenance
requiring correction. Crackle test may be used as a field Useful additional information can be obtained by
test for detecting free moisture. measuring resistivity or DDF at both ambient and at
higher temperature such as 90”C. A satisfactory result
7.4 Neutralization Value at 9@C coupled with an unsatisfactory value at lower
The neutralization value of an oil is a measure of the temperature is an indication of the presence of water
acidic constituents or contaminants in the oil. or degradation products precipitable in the cold but

4
 IS 1866:2000
generally at a tolerable level. Unsatisfactory results at deterioration levels considered in this guide. Vkcosity
both temperatures indicate a greater extent of conta- measurements may be useful for oil type identification.
mination and that it may not be possible to restore the
7.13 Inhibitor Content and Oxidation Stability
oil to a satisfactory level by reconditioning.
Inhibited oils deteriorate more slowly than uninhibited
7.7 Interracial Tension
oils so long as active inhibitor is present and the oil
The interracial tension between oil and water provides still has inhibitor response. For a given oil/inhibitor
a means of detecting soluble polar contaminants and pair, the induction period is generally proportional to
products of deterioration. This characteristics changes the active inhibitor content and dependent on the
fairly rapidly during the initial stages of ageing but presence of oxidation promoter.
levels off when deterioration is still moderate. For this
reason, results are rather dlfilcult to interpret in terms The degree of protection provided by the oxidation
of oil maintenance. However, oils with interracial inhibitor is a function of base oil chemistry and
inhibitor concentration. The determination of residual
values at or near the minimum limit value specified in
Table 2 should be further investigated (see Fig. 2). inhibitor in service-aged inhibited oil assesses the rate
of inhibitor depletion.
7.8 Total Gas Content
The oxidation test for unused inhibited oil (see IS 12463)
For most applications of mineral insulating oil, the enables the induction period of an oil to be easily
determination of total dissolved gas content normally measured by means of the determination of volatile
has little significance for assessing the quality and acids developed. This test, applied to a used oil previously
serviceability y of the oil. However, for certain types of tested will indicate to what extent the induction period
EHV equipment, a maximum gas content is some times has been reduced.
specified when filling apparatus or in service. Gas-in-
7.14 Polar Substances
oil analysis for the detection of incipient faults is dealt
within IS 9434 and IS 10593. These are oil-soluble compounds resulting from
7.9 Flash Point oxidation of the oil itself, or from the solution in the
oil of external contaminants or materials used in the
A low flash point is an indication of the presence of construction of the equipment.
volatile combustible products in the oil.
Measurements of dissipation factor and to a least
Prolonged exposure of the oil to very high temperature extent, resistivity and interracial tension of the oil
nnder fault conditions may produce sufficient quan- enable such contaminants to be detected and periodi-
tities of low molecular weight hydrocarbons to cause cally assessed.
a lowering of the flash point of the oil.
A comparison of the rate of change of neutralization
7.10 Pour Point value with that of one of these three characteristics
Pour point is a measure of the ability of the oil to flow namely, dissipation factor, resistivity, and interracial
at low temperature. There is no evidence to suggest tension gives, to some extent, an indication of the
that the property is affected by oil deterioration. deterioration of the oil. For example, a high value of
Changes in pour point may normally be interpreted as dissipation factor associated with a low neutralization
the result of topping-up with a different type of oil. value may some time be considered as an indication
of oil contamination other than that of oil origin.
7.11 Density
8 CATEGORIES OF EQUIPMENT
Density is not significant in determining the quality of
an oil but may be useful for type identification or to “In order to take account of different user requirements,
suggest marked compositional changes, In cold clima- equipment has been placed in various categories as
tes density may be pertinent in determining the follows :
suitability for use, for examples ice crystals formed
Category O :
from separated water, may float on oii of high density
and lead to flash over on subsequent melting. Power transfonuers with a system highest voltage
above 420 kV.
7.12 Viscosity
Vkcosity is a controlling factor in the dissipation of Category A:
heat. Ageing and oxidation of the oil tend to increase Power transformers with a system voltage above 170
viscosity but the effect is not discernible at the kV and up to 420 kV. Also power transformers of any

5
 m I
1

10 I , 1 I
Is 1 I I I I I
0-10 20 30 40 50 60
OIL TEMPERATURE DURING OPERATION (oC)

Curve ‘A’: Saturation Content of Water in Unused Oil

Curve ‘B’: Saturation Content of Water in Used Oil

FIG. 1 EFFRCTOFTEMFERATTXW
ONVOLUBILITY
OFWATERCONTENT
ININSULATING
OJLS

SLUOGE
FORMATION ZONE

o 5 10 15 20 2s 30 3s

INTERFACIAL TENSION x 1i? NEWION/MEIRE ~

FIG. 2 PRESENCE OF SLUOGEINOrLs RELATED TOINTERFACIAL

TENSIONVALUES
AT AN hBIENT TEr@Erum OF 27°C

6
 Is 1866:2000

rated voltage where continuity of supply is vital and In addition, other oil properties, such as breakdown
similar equipment for special applications operating voltage and water content should be adequate to the
under onerous conditions. category and functions of the equipment.

Category B: The characteristics of oil in new equipment are integral

parts of the equipment design for which the manufac-
Power transformers with a system highest voltage
turer has final responsibility. However, user may
above 72.5 kV and up to 170 kV (other than those in
require these characteristics to be definitely better
category A).
than minimum standards for reliable service. The
Category C: characteristics listed in Table 1 are representative of
goad operating practice and are recommended as basis
Power transformers with a system highest voltage up to
for agreement.
72.5 kV (other than those in category A), oil filled ___
switches, a.c. metal enclosed switch gear and control gear. 10 EVALUATION OF USED OIL

Category D: 10.1 Frequency of Examination of Oils in Service

Instrument transformers with a system highest voltage It is impossible to lay down general rule for the fre-
above 170 kV. quency of examination of oils in service which will be
applicable to all possible situations that might be
Category E:
encountered.
Instrument transformers with highest voltage up to
The optimum interval will depend on the type,
170 kv.
function, power, construction and service conditions
Category F: of the equipment. A compromise shall often be
found between economic factors and reliability
Diverter tanks of on-load tap changers.
requirements.
Category G:
By way of a guide, a suggested frequency of tests
Oil filled circuit breakers. suitable for different types of equipment is given in
NOTES
Table 2. However, oil preservation systems designed
to control exposure of oil to atmosphere may permit
1 Separated selector tanks of cm-load tap changers belong to
the same category as the associated transformer. less frequent testing.
2011 impregnated paper bushings nnd other hermeticrdly seated
Generally, check measurements can be carried out on
equipment may be placed in category D if a routine monitoring
progmrnme is desired. Any tests considered necessary would
the basis of the following criteria, which apply
be specialized in nature and require separate considemtion. particularly to transformer oils :
Refer to mnnufactureris instmctions.
- Check characteristics periodically, at intervals as
3 Small trnosformers up to 1 MVAand 36 kV are not included
in this classification. Routine monitoring progrnmme is consi- suggested in Table 2, unless otherwise defined by
dered uneconomical for this type of equipment. Where a the manufacturer.
monitoring programme is required for these transformers, the
guidelines given for Category C should be adequate. - If possible, check at more frequent intervals
characteristics that are determinable at site.
9 EVALUATION OF NEW INSULATING OIL IN
NEW EQUIPMENT – Heavily loaded transformers may require more
frequent testing.
A substantial proportion of mineral oil is supplied to
– Increase frequency of examination where any of
the final user already filled into electrical apparatus
the significant properties approaches the limit
and it is commonly recognized that certain properties
recommended for contiitued service.
which reflect the presence of dissolved contaminants
may differ from those accepted for unused oil, that is 10.2 Tk.sting Procedures
oil which has not been in contact with insulation and m. r.. . . , ., . .
,.s?
1ne venue or tesung ana me numDer ana types til LC3LS
4-., ”

construction materials. The extent of changes may vary

that can be carried out on a given sample of oil may
with type of equipment due to the different types
vary depending on local circumstances and economic
material and ratios of liquid-to-solid insulation, and
consideration.
should be kept within acceptable limits through proper
oil processing techniques and careful selection of Oil in service will vary widely in the extent of degra-
materials. dation and the degree of contamination.
IS 1866:2000

In general no one test can be used as the sole criterion 10.3 Classification of 011s in Service
of the condition of the oil sample.
It is virtually impossible to set hard and fast rules for
Evaluation of condition should be preferably based on the evaluation of oil in service or even to recommend
the composite evaluation of significant characteristics test limits for all possible applications of insulating
determined in properly equipped laboratories. However, oil in service.
some users find it advantageous to make field screening
According to current industrial experience, oils in
test.
service can be placed in the following classification
10.2.1 Field Screening Test based on the evaluation of significant properties and/
Field tests are usually limited to visual inspection or their ability to be restored to the characteristics
(colour and appearance), breakdown voltage and, with desired. ——
some approximation, neutralization value. These tests Group 1:
can sometimes be used classification of service-aged
oils in accordance with 10.3, though, more often, field This group contains oils that are in satisfactory condi-
tion for continued use. Oils with property values laid
tests are made to identify oil samples requiring laboratory
evaluation. in Table 2, for the appropriate category of equipment,
are considered to belong this group. It should be
Experience has shown that breakdown voltage tests understood that these limits are indicative only. With
made on site often produce results that are more reliable the exception of breakdown voltage, one or more
than those obtained in the laboratory following long- properties outside the limits indicated do not require
distance transportation and prolonged storage of oil immediate action although, in the long run, the
samples. Portable dielectric test sets have been available condition can result in accelerated deterioration and
for a long time and have proved quite satisfactory. shortened equipment life. In interpreting the data,
10.2.2 Laboratory Tests account has to be taken of various factors such as :
conditions of use, age of equipment and general
The complete examination scheme includes all the tests progression of oil characteristics.
listed in 7. Along with the evaluation of the general
condition of the oil, consideration of all results together Graup 2:
often enables the cause of degradation or the source of This group contains oils that require reconditioning
a contaminant to be recognized, so that the appropriate for further service. This condition will be usually
action can be taken to ensure the reliable operation of indicated by bigher water content and lower breakdown
the equipment. voltage while all other criteria are still satisfactory.
Quite often, laboratory testing merely seeks to establish (Sometimes dielectric dissipation factor and specific
resistance may not be satisfactory under this condition).
the continued serviceability of the oil. The folIowing
tests are believed to suffice to meet this objective: The oil may have a cloudy or dirty appearance. The
appropriate treatment consists of removal of moisture
– Interracial tension
and insoluble matter by mechanical means. Treatment
– Breakdown voltage must be adequate to result in values of water content
– Flash point and breakdown voltage to those given in Table 1 where
– Dielectric dissipation factor applicable. However, it should be appreciated that
excessive water in oil be indicative of an undesirable
– Specific resistance
condition of the solid insulation which also requires
– Neutralization value correction.
– Water content
Graup 3:
– Sediments and sludge m- . –.. —.. .. . . . . .—. .,, .,–.,– —., ..-
1 rus group comams 01]s m poor conamon mat N can
NOTES
restore satisfactory properties only after reclaiming.
1 In order to assess the continued serviceab]fity of the oil, This condition will usually be indicated by evidence
water content tests, while desirable in all cases, becomes
particuhrly necessary when the brenkdown voltage appro-
of soluble or precipitable sludge and values of neu-
aches the rejection level. tralization value and/or dielectric dissipation factor in
2 Regarding oil in switchgear, it may be suftlcient to check excess of those indicated in Table 2. Insulating oils in
breakdown voltage either periodically or after a given number this group should either be reclaimed or replaced
of operations. depending on economic considerations.

8
 IS 1866:2000

Group 4: are determined on a mixture of the component oils.

The ratio of this mixture should be the same as that
This group contains oils, in such poor state that it is
effectively chosen in practice or, if this is not known,
technically advisable to dispose of them. Usually many
a 50-50 ratio is used.
properties will be unsatisfactory.
The results obtained on the composite should not be
10.4 Corrective Action
less favorable than those of the worst individual oil.
The action to be taken is detailed in Table 2. The
Reference to the oil supplier or the equipment supplier
following recommendations should also be noted :
is recommended if any doubts concerning compa-
a) Where a test result is outside the recommended tibility arise.
limits, compare it with previous results and, if
appropriate, obtain a fresh sample for confir- 12 HANDLING AND STORAGE
mation before any other action is suggested. To ensure satisfactory service, the utmost care in
b) As a general rule, several characteristics will have handling oil is essential. Drums used transport and
to be unfavorable in order to justify its use storage should be kept under cover. In practice owing
However, if the breakdown voltage is below the to contamination in the containers, difficulty may be
limits given, irrespective of the values of the experienced in maintaining the purity of the oil when
other characteristics, action as detailed in Table it is transferred from one vessel to another, and once a
2 is essential. vessel or drum has been filled with moist oil it is
c) If rapid deterioration or acceleration in the extremely difficult to clean. Drums should be clearly
process of deterioration is observed, institute marked to indicate whether they are for clean or for
more frequent tests and inform the manufacturer dirty oil and should be reserved for the type indicated.
of the equipment. When oil is stored in drums, these should be placed in
11 MUTUAL COMPATIBILITY OF MINERAL such a position that there is a head of oil on the stopper
INSULATING OILS or plug to prevent the entry of water during storage.
However, it is recognized that storage of oil in drums
Topping-up should preferably be with unused
is not always satisfactory, particularly when oil is stored
insulating oil conforming to IS 335 or IS 12463. Under
in drums which have been bent or otherwise damaged
no circumstances should the properties of the oil added
in transit or storage, and the transfer of oil from such
be worse than those of the in-tank oil.
containers to electrical equipment should normally be
Unused oils complying with IS 335, of the same class through a suitable treatment plant.
and containing no additives, are onsidered compatible
In substations with fixed oil-handling equipment the
with each other and can be mixed, in any proportion. pipe work from the clean oil tanks to the electrical
Field experience indicates that no problems are apparatus should be kept clean and free from moisture.
normally encountered when fresh oil is added in small Where portable oil handling equipment is used, flexible
percentage, say less than 5 percent, to Group 1 used
pipe work and hand pumps should be carefully ins-
oils, though larger additions to heavily aged oil may
pected to ensure that they are free from dirt and water,
cause sludge to precipitate. and should be flushed with clean oil before use. If the
Experience is very limited regarding the use of oil clean oil is from drums, it should have been recently
containing pour point depressants as makeup fluid for tested, and the filling orifices of the drums should be
naturally low pour point oils. Hc>wever, extensive clean. Hoses used for clean oil and dkty oil should be
laboratory investigations suggest that no significant clearly marked and provided with plugs for sealing
deterioration of low temperature behaviour is likely to the ends when not in use.
occur. For any specific problems, reference may be made to
However, when substantial quantities of servic,e-aged equipment manufacturer’s instructions.
oils or of fresh and used oils are to be mixed, it is
13 TREATMENT
good practice to perform laboratory tests to determine
if the properties of the blended oil are still satisfactory. 13.1 Reconditioning
Compatibility tests are particularly required in the case 13.1.1 General Considerations
of oils containing additives. This is a process which eliminates, by physical means
The main characteristics, including oxidation stability only, solid particles from the oil and decreases water
and measurement of dissipation factor after ageing, content to acceptable level.

9
IS 1866:2000

The physical means that are used for removing water 13.1.2 Reconditioning Equipment
and solids from oilinclude several types of filtration,
13.1.2.1 Fiiters
centrifuging and vacuum dehydration techniques.
These are generally based on the principle of forcing
If vacuum treatment is not employed it is advisable to oil under pressure through absorbing material such as
limit the temperature to 60’C. Vacuum is employed a paper or other filter media. Filters of this type are
higher temperature may be advantageous. If vacuum preferentially used in removing contaminants in
is employed, the initial boiling-point of that oil should suspension (The filter medium should be capable of
not be exceeded, to avoid undue loss of lighter ffac- removing particles larger than a nominal 10 ~m). These
tions. If this information is not available, it is reco- devices do not de-gas the oil.
mmended that the oil should not be vacuum treated at
temperature over 70”C (see Note). The water-removing ability of a filter is dependent
upon the dryness and quantity of the filter medium.
If it is desired to reduce sludge or free water, cold When filtering oil containing water, the water content
treatment may be appropriate. of the filter medium rapidly comes into equilibrium
Filters deal efficiently with solid impurities, but are with water content of the oil. A continuous indication
generally capable of removing small quantities of water of the water content of the out going oil is useful to
such as may be found in oil from equipment housed in monitor the eftlciency of the process.
buildings. Where relatively large quantities of water Care should be taken that paper filters are of the correct
are present, most of it can, and shall, be drained away grade to ensure that no fibres are shed by them.
before filtration of the oil.
13.1.2.2 Centrifitges
Centrifugal separators are, in general, satisfactory for
removing free water from oil and can in any case deal In general, a centrifuge can handle a much greater
also with any finely divided solid impurities. concentration of contaminants than can a conventional
filter but cannot remove some of the solid contaminants
If oil is purified hot, its viscosity is reduced and the as completely as a filter.
throughput with certain types of purifiers is greater.
On the other hand, sludge and free water are more Consequently, the centrifuge is generally found in use
soluble in hot oil than in cold, therefore, more for rough bulk cleaning where large amounts of
effectively removed by cold treatment. Dissolved and contaminated oil are to be handled.
suspended water is effectively removed by hot vacuum Frequently the output of the centrifuge is put through
treatment. a filter for the final clean-up.
If the oil contains solid matter, it is advisable to pass 13.L2.3 Vacuum dehydrators
through some kind of filter processing under vacuum.
The vacuum dehydrator is an efficient means of
NOTE — Processing inhibited oil under vacuum and at reducing the gas and water content of mineral
elevated temperatures may crmse partial loss of oxidation
insulating oil to very low levels.
inhibitors; the common inhibitors, 2,6-di-tertiary - butyl-
paracresol and 2,6-di-teritiary-butyl-phenol, are more volatile There are two types vacuum dehydrators; both function
thun rninernt insrdntrng oil. The selectivity for rvmovat of writer
and air in preference to loss of inhlbkor and oil is improved
at elevated temperature. In one method the treatment
by use of is low processing temperature. is accomplished by spraying the oil into a vacuum
chamber; in the other the oil flows in thin layers over
Conditions that have been found satisfactory for most
a series of baffles inside a vacuum chamber. In both
inhibited /uninhibited mineral oil processing are :
types the objective is to expose maximum surface and
Temperature Pressure minimum thickness of oil to the vacuum.
In addition to removing water, vacuum dehydration
“c Pa
will degas the oil and remove the more volatile acids.
40 5
13.L3 Application to Electrical Equipment
50 10
13.1.3.1 Direct purification
60 20
The oil is passed through a purifier and then stored in
70 40
suitable clean containers. When the electrical equip-
80 100 ment is to be refilled the oil is passed through the

10
 Is 1866:2000

purifier again, and then directly into the equipment. 13.3 Re-refining
This method should be used for switchgear. It is
This is treatment that makes use of primary refining
suitable, too, for small transformers but care is needed processes that may include distillation and acid, caustic,
to ensure that the core, the windings, the interior of solvent, clay or hydrogen treatment and other physical
the tank and other oil-containing compartments are and chemical means to produce an oil with oil charac-
thoroughly cleaned. The oil-containing compartments teristics complying with IS 335.
of all equipmgnt should also be well cleaned, by means
of oil from the purifier. Re-refining should be performed by an oil refiner and
such a process is outside the scope of this guide.
13.1.3.2 Purification by circulation
14 REPLACEMENT OF OIL
The oil is circulated through the purifier, being taken
from the bottom of the tank of the electrical equipment 14.1 Replacement of Oil in’lbmformers Rated Below
and re-delivered to the top. The return delivery should 72.5 kV and in SWitchgearandksociited Equipment
be made smoothly and horizontally at or near the top A small extra quantity of oil is needed to rinse the intenor
oil level to avoid, as far as possible, mixing cleaned of the tank and the immersed parts. It is essential that
oil with oil which has not yet passed through the the tank and the surfaces of conductors and insulators
purifier. The circulation method is particularly useful be kept free from tibres. Such ilbres aereadily introduced
for removing suspended contaminants, but all adhering by the use of unsatisfactory cleaning materirds during
contaminants will not necessarily be removed. plant maintenancrz in practice the only el%cient and
Experience has shown that it is generally necessary to permissible materials are plastic wipers and chamois
pass the total volume of oil through the purifier not leathers. It is also essential that the tank and other surfaces
less than three times, and equipment of appropriate be kept free from moisture.
capacity should be chosen with this in mind. The final There should be as little aeration as possible during
number of cycles will depend on the degree of contami- the filling of tanks and, as far as possible, the end of
nation, and it is essential that the process be continued the delivery pipe should be held below the surface of
until a sample taken from the bottom of the electrical the oil in order to avoid splashing: alternatively, the
equipment, after the oil has been allowed to settle for tanks should be filled from the bottom. There should
a few hours, passes the breakdown voltage test. be a standing period of not less than 12 h to allow
The circulation should be performed with the electrical de-aeration before commissioning transformers ( one
equipment disconnected from the power source, and hour may be adequate for switchgear).
this is essential when using a purifier which aerates 14.2 Replacement of AU in llansformers Rated 72.5
the oil. In al} cases, and especially when aeration has kV and Above
occurred, the oil should be allowed to stand for some
time in accordance with the manufacturer’s instructions Reference should be made to the equipment manufacturer.
before the equipment is re-energized. 15 HYGIENE AND ENVIRONMENTAL
Another technique is sometimes used for transformers, PRECAUTIONS
in which oil is continuously circulated during normal The oils with which this code of practice is concerned
service through an adsorbent, such as molecular sieve, are mineral hydrocarbon (petroleum) oils.
thus keeping both oil and windings dry and removing
Although no special risks are involved in the handling
many oil oxidation products: this is a specialized
and use of mineral insulating oils, attention is drawn
method not further considered in this guide.
to the need for personal hygiene (washing of skin and
13.2 Reclaiming clotling which has come into contact with oil) by those
This is a prccess which eliminates soluble and insoluble working with these products.
contaminants from the oil by chemical and adsorption When mineral oil has to be disposed off, certain pre-
means in addition to mechanical means, in order to cautions are necessary to avoid risk of environmental
restore properties as close as possible to the original pollution, and legal requirements may apply. Normally,
values. if the precautions and regulations applicable to the
handling and d@osal of industrial and other lubricants
Reclaiming is a process often performed by an oil
refiner but, since in some countries reclaiming is (for example automobile crank-case drainings) are
performed by the user on site, some guidance is given applied to mineral insulating oils, no problems should
in Annex B. arise.

11
IS 1866:2000

Table 1 Recommended Limits of Unused Mineral Oil FJled in New Power Transformer
(Clauses 6.1 and 10.3)

Pruperty IUghest Voltageof Equipment (kV)

1
‘ <72.s 72.5 to 170 >170
Appemtnce Clear, free form sediment and suspended matter
Density at 29.5C Q/cm’), Max 0.89 0.89 0.89
Vkcosity at 2?’C (cSt), Max 27 27 27

Flash point, (W), Min 140 140 140

Pour point, (“C), Mar -6 -6 -6
Neutralization value (mg KOH/g), Max 0.03 0.03 0.03
.-. —.—
Water content ( ppm), (.ree Note 1), Max 20 15 10
Imerfacial tension (mN/m), Miri 35 35 35
Dielectric dissipation factor at 90’C
and 40 Hz to 60 Hz (see Note 2), Merx 0.015 0.015 0.010
Resistivity (9WC) x 10’Z(ohm-cm), Afin 6 6 6
Breakdown voltage (kV), Mirr 40 50 60
Oxidation stability of uninhibited oil
i) Neutralization value (mg KOH/g), Max 0.4 0.4 0.4
ii) Sludge (percent by mass), Max 0.1 0.1 0.1
Oxidation stability for inhibitedoil
induction period (hours) SImilnr values as before filling

NOTES
1 For use in transformers under 72.5 kV class; the maximum water content should be agreed between supplier and user depending upon
local circumstance.
2 Higher dielectric dissipation factor values may indicate excessive contamination or the misapplication of solid materiafs used in
manufacture and should be investigated.

Table 2 Application and Interpretation of Tests

(Clauses 7.3,7.7, 10.1, 10.3 am’ 10.4)

Property Test Venue ~ategory of Frequency of Recommended Action Notes

(Unit) F = field :quipmertt Tests Action Limits
.= laboratory
(1) (2) (3) (4) (5) (6) (7)

Appearance Lor F ),A,B,C,D,E In conjunction with Clear, without visible As dictated by other
other quantitative contamination tests
tests

Breakdown Lor F ),A,B,C,D, O,A,B-After tilling or O,A,D: >50 kV Recondition oil or Refer to
vol~~ge i,F,G refilling prior to B, E :MOkV dtematively, if 10.3
energizing-then c :>30 kV more economical and 10.4
yearly G :>20 kV or other tests dictate
C. D. E- After filling F replace oil
or refdfing prior to a) Tap changer of
energizing– neutral end tap
then yearly changer O, A,B,C,
F–After transformer 25 kV
u.%lling
filling or b) Single phase or
priorto energizing– connected tap
then every c) Changer O,A,B,
four yearsor tmnsformemAO kl
70000 operations d) C transformers
whichever the lower e)> 30 kV
or manufacturer’s
instructions.
G–Refer to
manufacturer’s
specifications
(see 9.2.2, Note 2)

12
 Table 2 (Concluded)

Proper~ Test Venue ~ategory of Frequency of Recommended Action Notes

(Unit) F = field T
.quipment Tests Action Limits
,= laboratory
(1) (2) (3) (4) (5) (6) (7)
Water LA,B,C,D,E 2,A- Atlcr filfing or 3,A,D: <20 PPM Check source of 1. The given
content retilIing prior to B: <40 ppM water and consider values are
mergizing-then E: 530 PPM reconditioning applicable onfy
lfter three and 12 -.
-. <No f~ where acidhy
months, subsequently moisture does not exceed
m conjunction with at room 0.1 mg KOHg
tissolved gas anrdysis temperature L For
B,D,E–After variation of
filling or water content
refilling prior to of (Is 335)
energizing-then transformer
after 12 months, oil with oil
suhsequetttly every temperature
one year or in and acid
conjunction with vafue.
dissolved gas annfysi.% See Fig. 1
Not a routine test onfy
when break down
voltage approaches
the rejection level

Neutrali- L ),A,B,C,D, Yearly O,A,B,C,D,E, Mux Replace or Ferformtestsrmw’e

zation I,F,G 0.3 mg KOH/g reclaim oil kequentfy when
value neutralization
vattte exceeds
0.2 mg KOH/g

Sediment L ),A,B,C,D,E Routine test–yearly No sediment or Where sediment is

and sludgt precipitable sludge detected, tccondhion
should he detected, oil. Alternatively if
results below 0.02 more eeonomic, or
percent by mass other tests dictate,
may be neglected replace oil. Where
preeipitable sludge
is detected consider
replacing or reclai-
ming existing oil

Resistivit! L ), A, B,C,D,E Atter tilling or At 201’C,A4in Investigate

U,E-Routine refilling prior to 1 x 10’2 ohm-cm
est–yearly energizing–then 0.1 x 101~ohm-cm
yearly At 90’C, Min I
Gohm- m

Dielectric L ), A,B,C,D,E After tilling or O,A,D, Mm 0.2 Investigate Comply with

dissipation ;,E–Routine refilling pnior to B.C. Mu-x 1.0 manufacturers
factor at est–yearl y energizing–then E, Mm 0.3 instructions if
9(YC and yearly other frequency
40 to 60 and limit are
Hz recommended

Interracial L ), A,B,C,D,E O;A.B.C.D.E- O,A,B,C,D,E Investigate

tension After &ing or Min.: 15 mN/m
refilling prior
to enc@zing-
then yearly

Gas conte] L ), A, B, C,D,E Comply with

manufacturer
instructions
Flash poil L 3, A,B,C,D,E Yearly O,A,B,C,D,E,Mux Replace oil,
decrease 15“C equipment may
require inspection

13
IS 1866:2000

ANNEX A
(Clause 4.3)
DETERMINATION OF SEDIMENT AND SLUDGE

This method covers the determination of sediment and with fresh n-heptane to ensure complete transfer of
of precipitable sludge in used insulating oils. the precipitate to the crucible. Wash the crucible and
precipitate with n-heptane until free from oil.
NOTES — For the purpose of this guide, sediment is any
substance which is insnluble after dilution of the oil with
Allow any n-heptane to evaporate and then dry the
n-heptarre and which is insoluble insolvent mixture mentioned
in A-1. crucibIe in an oven at 100 to 11O“C for 1 h. Cool the
crucible in a desiccator and then weigh it. Calculate
For the purpose of this guide, perceptible sludge is the increase in mass of the crucible as a percentage of
oil deterioration products or contaminants, or both, the mass of oil taken. Denote this value, representing
which are insoluble after dilution of the oil with the total of insoluble material such as sediment and
n-heptane under prescribed conditions but which are perceptible sludge, as A.
soluble in the solvent mixture mentioned in A-1.
Dissolve the sludge in the crucible by treatment with
A-1 PROCEDURE the minimum quantity of a mixture of equal parts
Thoroughly agitate the sample of used oil in the original of toluene, acetone and alcohol (either ethanol or
container until any sediment is homogeneously sus- iso-propanol maybe used, 95 percent being satisfactory
pended in the oil. in either case), at approximately 50”C, until no more
will dissolve, and collect the washings in an accurately
Weigh approximately 10 g of oil to the nearest 0.1 g tared flask. Distill off the solvent; visual examination
into a stoppered conical flask and introduce a volume of the flask content at this stage will show whether
of n-heptane corresponding to 10 ml for each gram of any precipitable sludge was present in the oil.
oil taken.
If a quantitative value is required dry the flask in an
Thoroughly mix the sample and solvent and allow the oven at 100 to 110C for 1 h. Cool the flask in a
mixture to stand in the glass flask, in the dark, for 18 desiccator and then weigh it. Calculate the mass of
to24h. residue in the flask as a percentage of the mass of oil
If a solid deposit is observable filter the solution taken. Denote this value as B.
through a tared sintered glass crucible of Grade P1O The difference A-B, if any, will represent sediment in
porosity with the assistance of vacuum; rinse the flask the oil.

ANNEX B
(Clause 13.2)
GENERAL GUIDANCE FOR OIL RECLAIMING

B-1 GENERAL CONSIDERATIONS washed, steam-treated, or acid-treated. The processed

cIays are more active but also more expensive. Acti-
This is a process which eliminates, by chemical and
vated alumina is an adsorbent for impurities found in
adsorbent means, the acidic and colloidal contaminants
oil. It is mechanically more stable, and may be
and products of oil deterioration from the oil to obtain
reactivated.
an oil with many characteristics similar to those of a
new product. In general, reclaiming is done in accordance with one
of two methods:
B-2 ADSORBENT PROCESS
a) Percolation through coarse clay using either
Fuller’s earth, a naturally occurring clay with a fairly
gravity or pressure to force the oil through the
high surface activity, is the material most frequently
clay, or
used for reclaiming oils and is the least expensive. It
may be used in its original state, except for drying, b) Contact at an elevated temperature with finely
crushing, and sizing, or it may be calcined, water- divided clay.

14
 IS 1866:2000
B-2.1 Percolation by Pressure necessary in the third tank in the series. Some
convenient mechanical means of agitating the oil in
Pressure percolation is similar to gravity percolation
this tank is essential.
in general principle except that the oil is forced through
the clay by a pump. Pressure percolators are commer- It has been proved that the undesirable characteristics
cially available and vary in mechanical detail, but all of the over treated oil that first comes through the earth
have a chamber to hold a container such as a bag or are offset in the blending process.
cartridge filled with clay. The chamber is so designed
By this method, the oil can be treated to any desired
that oil is admitted around the outside of the clay pack
degree. The flow rate of such a method is slow, being
and must pass through a certain amount of clay before
about 400 litres per hour per square meter of filter bed
leaving the chamber.
area for an installation such as the one described above.
These machines are capable of processing large This slow flow rate results in a relatively long contact
volumes of oil in a relatively short time. They accom- time which makes for efficient use of the clay.
plish this by forcing the oil through a comparatively
B-2.3 Contact Process
shallow depth of clay at a pressure of about 400 kN/
m2 resulting in a short contact time. Since the amount The contact process for reclaiming oil makes use of
of clay is relatively small with respect to the amount 77 mesl-dcm to 96 mesh/cm Fuller’s earth and relatively
of oil, frequent changes of clay are required. high operating temperatures usually 60 to 70”C.
Specially treated clays are sometimes used for inc- This process makes the most efficient use of the earth
reased efficiency. The output is a graded one for the and produces a uniform product. The degree of
same reasons that apply to the gravity percolation reclaiming depends on the amount of earth used which
output (see B-2.2), and the same control tests are used is determined by an analysis of the deteriorated oil.
periodically.
In typical commercial apparatus, oil is introduced into
An advantage of such machines is that they may be a heated mixing chamber as a measured amount of
brought to the job and used directly on the apparatus earth is fed in through a hopper. The mixture is stirred
whose oil is to be reclaimed. They have been used on as heat is applied and the process continues until the
energized equipment to a limited extent, and such use desired temperature is reached. This operation requires
will increase when proper safety procedures have been about half an hour. The oil is then dropped into a tank
developed. before it is pumped through a filter especially built to
accommodate the earth. Much of the oil ordinarily
B-2.2 Percolation by Gravity
retained in the earth is extracted by the application of
Gravity percolation makes use of gravity or the hydro- compressed air to the filter. A semi-automatic type of
static head of a column of oil to force the oil through a apparatus is on the market which recharges itself and
column of clay. Atypical gravity-percolation system, operates until the filter becomes filled with clay.
shown schematically in Fig. B 1, consists of three tanks
This type of apparatus does not lend itself to the
on different levels. The upper tank is used as a dirty-
treatment of oil in transformers under load as operating
oil reservoir, the middle tank as the filter contaifiing
on the batch principle, it withdraws oil from the
Fuller’s earth (24 mesh/cm to 32 mesldcm), and the
apparatus and does not return the oil for 45 min. Also
lower tank as a blending chamber for the filtered oil.
it should not be used to process oil containing 2,6-
The middle tank is equipped with a strainer type bottom ditertiary-butyl-paracresol if it is desired to retain the
covered by canvas or filter cloth supporting a 2 m bed inhibitor in the oil, as this additive when catalyzed by
of clay. Afloat valve controls the flow of oil from the clay, begins to decompose at 100W.
dirty-oil storage tank above so that a consta4t head of
B-2.4 Choice of Methods
about 5 m to the filter plate is provided. Once the
process is started it continues in operation with very The choice of reclamation methods that will prove the
little attention other than periodic sampling. Tests for most practical and economical for a given system
interracial tension or acidity are used regularly to depends upon the geographical characteristics of the
control the process. power system, the existing facilities available for
application of such work, and the facts concerning the
The output of gravity percolation is a graded one
various types of reclaiming equipment and methods
starting with water-white over treated oil and ending
previously described.
with oil in approximately the same condition as before
treatment. To obtain a uniform product, blending is For example, on a compact system with large quantities

15
Is 1866:2000

of damaged oil or on a system where oil recomhtioriing B-3.2 Reclaiming by Activated Carbon Sodium
has been done in the past at a central location, the Silicate
gravity-percolation method of reclaiming has many
advantages in requiring a minimum amount of new This method is capable of variation to meet the
equipment, attention and labour. requirements of different grades of service-aged oil
under favorable conditions, this process is a conti-
On a system where the oils requiring attention me widely nuous one. The method consists of the following basic
scattered in location, service outages are difficult to treatments:
obtain, and spare equipment is at a premium, some type
– An activated carbon treatment in which 2 percent
of portable pressure percolator may be preferred for
reclaiming in the field by recirculating the oil in the by mass of activated carbon is used.
equipment. The possibility of recirculation with the – A treatment involving 30 percent by volume of a 2
equipment alive may be considered in such cases, with percent by mass sodium silicate solution. ----
due regard to safety measures. – A clay treatment in which 2 percent by mass of
Irrespective of the type of clay used, two adjuncts activated Fuller’s earth is used.
should also be incorporated with the treater: The oil is heated to 85(’C and is maintained at this
a) The oil should be put through some device for temperature until the final filtering operation is reached.
removing free water before it contacts clay in
The first step consists of a treatment by agitation with
order to prevent water f’rom wetting the clay.
activated carbon in cases where the acid rating of the
b) Water will cause at least partial and possibly oil is 0.5 mg KOH/g or over. This step is necessary to
complete blocking of the clay, thus making it prevent subsequent emulsification of acid oil with the
necessary to discard that batch of clay. ‘I’he oil sodium silicate solution where the acid value is low,
coming out of the clay treater should be put this process may be omitted.
through some kind of foolproof completely
automatic dehydrator equipped with positive The oil is next decanted through a filter to a second
tank where it is paddle-stirred with the sodium silicate
means and safeguards for preventing any water
from being present in the finished product. This solution. It is then run through a centrifuge and the
silicate solution discarded.
is particularly true when recirculating the oil in
a transformer and absolutely essential if the The oil is now run into a reaction tank with clay added
reclai-ming is done when the transformer is through a hopper. The resulting mixture is agitated,
energized. allowed to settle and then cleaned by passing through
B-3 OTHER a second centrifuge. The oil is then run into a receiving
RECLAIMING METHODS
tank and allowed to cool. Finally it is filtered and run
B-3.1 Reclaiming by Trisodium Phosphate
into storage tanks.
The trisodium phosphate/activated Fuller’s earth
method (see Fig. B2) consists in agitating a mixture of When used without activated carbon, the process is
oil and trisodium phosphate solution maintained at continuous with an output of 570 Iitres per hour. When
80”C for 1 h and then allowing the mixture to separate. the activated-carbon treatment is necessary the process
Most of the spent phosphate solution is drained from becomes a batch process with an output of 1900 litres
the tank, the balance is washed from the oil with a per day. As both clay and activated-carbon retain about
water spray, and the oil is then decanted through a 60 percent of their weight of oil, the process should be
centrifuge and a heater to another tank, where 77 mesh/ run with a minimum of these materials. Oil in fair
cm activated Fuller’s earth is added and the mixture condition shows satisfactory characteristics when
agitated. This agitation with clay is allowed to settle treated with activated carbon and clay; 1 percent of
out overnight. The oil is again washed with hot water, the oil volume of either material is normally sufficient.
decanted through a centrifuge, and then dehydrated B-3.3 Percolation by Thermo-Siphon Bypass on
by passage through a dehydrator or filter. In-Service Transformer
The process is described as economical and capable Good oil which is deteriorating slowly maybe held in
ot’ yielding a uniform product by varying the amounts safe operating condition by applying a special bypass
of reclaiming agents as determined by the analysis of earth filter to the individual transformer. The oil is
the deteriorated oil. The method may be more economical forced through the filter by the action of the heat
than reclaiming with clay alone for large quantities of generated by the apparatus and the heat dissipated by
badly deteriorated oil. the filter. As the actuating force is small, the filters
 IS 1866:2000
must be loosely packed coarse activated alumina or inoperative as the heat necessary to its operation is
0.66 mesh/cm Fuller’s earth is employed, and the not constantly available. The operation of bypass
appmatus operates without attention during the active filters might also be termed very ‘gentle’ as little
life of the adsorbent. force is available to drive the oil through even a
The bypass method of maintaining oil in usable coarse filter bed. There is also the possibility that
condition has certain definite limitations. On fine particles of the earth may leak through the
standby transformers or on circuit breakers it is system into the processed oil.

-. _

T(!)
o10
A-Y
7 I o11

1 J

1. Used oil storage tank 7. Clay bed

2. Oil 8. Filter cloth
3. Manhole 9. Support grid
4. Stirrer 10. Valve
5, Clean oil mixing and storage tank 11. Fuller’s earth filter
6. Float valve

FIG. B 1 SCHEMATIC
DIAGRAMOFGRAVITY-PERCOLATION
RECLAIMING
APPARATUS

17
IS 1866:2000

@\

I ‘a) Q
(4 Q-Q!
1. Used oil storage tank 5. Filterpress
2. Pump 6. Clean oil storage tank
3. Heater 7, Process oil tank No. 1
4. Centrifuge 8. Process oil tank No. 2

FIG. B2 SCHEMATIC
DIAGRAMOFTRISOL)IUM
PHOSWATBWLLER’S&CLMMING&PARATUS

ANNEX C
(Clause 7.4)
PORTABLE KIT TEST METHOD

C-O This is a simple, mpid and yet sensitive method If the same amount of alkali is added to an oil of total
tor determining the total acidity of insulating oils. acidity greater than 0.5 the resulting solution would
be acidic or have apH value between Oand 6 depending
C-1 PRINCIPLE on the amount of acid left un-neutralized.
C-1.l The total acidity of oil is expressed as neutra- Similarly, if the total acidity is less than 0.5 the resulting
lization number which is defined in as the number of solution would be alkaline or have apH value between
milligrams of potassium hydroxide required to neutralize 8 and 14, depending on the amount of alkali left behind.
completely acids present in one gram of the oil.
C-1.4 This change in pH values may be sensitively
C-1.2 It is well known that all acids produced by determined by use of standard indicators.
oxidation of mineral oils are soluble in alcohol and
Thus, if the quantity of alkali is so adjusted that it
can be extracted from the oil by it.
neutralizes 0,5 total acidity exactly oils having a total
C-1.3 It’ these extracted acids are treated with a fixed acidity of less than 0.5 would be in the alkaline range
quantity of suitable olkali, the resulting mixture would and those with total acidity above 0.5 in the acid range.
be acidic, neutral or alkaline depending upon the
C-1.5 It has been found experimentally that sodium
amounl of acids present.
carbonate (anhydrous) is the most suitable alkali, as its
For example, if the total acidity of an oil is 0.5 and to solutions do not change concentration rapidly in contact
the extracted acids some alkali is added which just with atmosphere, and universal indicator is a good
neutralizes the acids, the resulting solution would be indicator, as this gives different colours at different pH
neutral or have pH value of 7. values which may be easily determined visually.

18
 IS 1866:2000
C-1.6 Thus, with use of appropriate reagents the C-4 PREPARATION OF SODIUM CARBONATE
total acidity can be determined calorimetrically. SOLUTION
C-2 PROCEDURE This solution is prepared by dissolving 0.1183 g of
A I.lmlofportion of theinsulating oil(approximately anhydrous sodium carbonate in 250 ml of distilled water.
1 g) to be tested is accurately pipetted into a clean dry 1.0 ml of this solution has just enough alkali to neutralize
test tube. To this added 1 ml of rectified spirit (ethyl the acids extracted from an oil with an acid number
alcohol) and mixture is gently shaken. ofo.5.

One millilitre of solution of 0.085 N sodium carbonate Sodium carbonate solution should be prepared carefully
is then added. taking the necessary precautions as used in such
procedures. This solution has a life of three to four
After shaking the test tube again, five drops of universal
months after which it must be discarded and fresh one
indicator are added.
shall be made.
The resulting mixture develops a colour depending
on the pH value of the mixture. C-5 PRECAUTIONS

Oils having total acidity of 0.5 total acidity of Oto 0.5 C-5.1 The test tubes and pipettes used for the test
shall show transition colours from prussian blue to should be absolutely clean and dry. It is best to wash
yellow, whereas those having total acidity 0.5 and them with soap and hot water followed by a final
above shall show a change from yellow to vermilion. rinse with distilled water. The use of chromic acid for
cleaning is also recommended where possible, but
Plate 1 gives the colours obtained by using this test on
traces of the acid must be completely washed off before
oils having neutralization value (total acidity) ranging
drying the glassware.
from O to 10.
C-5.2 Rectified spirit used shall be of good quality
C-3 PORTABLE TEST KIT
conforming to IS 323. Commercial spirit (methylated )
C-3.1 Thk kit consists of a box containing the following: should not be used. Where possible, the use of ethyl
a) Two polyethene bottles containing 100 ml each alcohol A R grade is recommended.
alcohol and sodium carbonate solution of 0.008 C-5.3 While conducting the tests, the test tube should
5 N concentration; be gently shaken to mix the solutions and not closed
b) An indicator bottle containing univemal indicatoq with the thumb and vigorously agitated. This may lead
c) Four clean glass test tubes; to contamination of the solution.
d) Three graduated droppers, with neutralization C-5.4 The same pipette can be used for a number of
number values; an:l oils provided it is thoroughly rinsed with oil to be
e) Instructions bookie:. tested before pipetting it.

ANNEX D
(Clause 2.1 )
LIST OF REFFRED INDIAN STANDARDS

IS No. Title IS No. Title

323:1959 Rectified spirits [P: 21] :1990 Flash point (closed) by Pensky-
335:1993 New insulating oils (fiourthrevision) Martens apparatus (third revision)
[P: 25] :1976 Determination of kinematic and
1448 Methods of test for petroleum and
dynamic viscosity (first revision)
its products:
6103:1971 Methods of test for specific resis-
[P: 2] :1967 Acidity tance (resistivity) of electrical
[P: 10] :1970 Cloud point and pour point insulating liquids
[P: 16] :1990 Density of crude petroleum and 6104:1971 Methods of test for interracial
liquid petroleum products by hy- tension of oil against water by the
drometer method (third revision) ring method

19
lS 1866:2000

IS No. Title IS No. We

6262:1972 Methods of test for power factor 12422:1988 Test method for oxidation stability
and dielectrical constant of electrical of inhibited mineral insulating oils
insulating liquids Inhibited mineral insulating oils
12463:1988
6792:1992 Method for determination of elec-
13567:1992 Determination of water in insulating
tric strength of insulating oils
liquids and in oil-impregnated
(jlrst revision)
paper and press board by automatic
9434:1992 Guide for sampling and analysis coulometric Karl Fkher titration–
of free and dissolved gases and oil Method of test
from oil-filled electric equipment
13631:1993 Method of test for detection and
(first revision)
determination of antioxidant addi-
10593:1992 Method of evaluating the @ysis tives in insulating oils
of gases in oil-filled electric equip-
ment in service (first revision)

20
(Continued from second cover)

Transformer Maintenance Guide – S D Myer et al (Myer’s Index),

For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2:1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.

—
 -1

Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

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Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
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needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘BIS Catalogue’ and ‘Standards: Monthly Additions’.

This Indian Standard has been developed from Doc : No. ETD 3 (3655).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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