Transformer oil

Transformer oil or insulating oil is an oil that is stable at high temperatures and has excellent
electrical insulating properties. It is used in oil-filled transformers (wet transformers),[1] some
types of high-voltage capacitors, fluorescent lamp ballasts, and some types of high-voltage
switches and circuit breakers. Its functions are to insulate, suppress corona discharge and
arcing, and to serve as a coolant.

Transformer oil is most often based on mineral oil, but alternative formulations with different
engineering or environmental properties are growing in popularity.

Function and properties

Oil transformer with air convection cooled heat exchangers in the front and at the side

Transformer oil's primary functions are to insulate and cool a transformer. It must therefore
have high dielectric strength, thermal conductivity, and chemical stability, and must keep
these properties when held at high temperatures for extended periods.[2] Typical
specifications are: flash point 140 °C or greater, pour point −40 °C or lower, dielectric
breakdown voltage 28 kV (RMS) or greater.[3]

To improve cooling of large power transformers, the oil-filled tank may have external
radiators through which the oil circulates by natural convection. Power transformers with
capacities of thousands of kVA may also have cooling fans, oil pumps, and even oil-to-water
heat exchangers.[4]

Power transformers undergo prolonged drying processes, using electrical self-heating, the
application of a vacuum, or both to ensure that the transformer is completely free of water
vapor before the insulating oil is introduced. This helps prevent corona formation and
subsequent electrical breakdown under load.

Oil filled transformers with a conservator (oil reservoir) may have a gas detector relay
(Buchholz relay). These safety devices detect the buildup of gas inside the transformer due
to corona discharge, overheating, or an internal electric arc. On a slow accumulation of gas,
or rapid pressure rise, these devices can trip a protective circuit breaker to remove power
from the transformer. Transformers without conservators are usually equipped with sudden
pressure relays, which perform a similar function as the Buchholz relay.
Mineral oil alternatives

Mineral oils are still widely used in the industry. Mineral oil is generally effective as a
transformer oil, but it has some disadvantages, one of which is its relatively low flashpoint
versus some alternatives. If a transformer leaks mineral oil, it can potentially start a fire. Fire
codes often require that transformers inside buildings use a less flammable liquid, or the use
of dry-type transformers with no liquid at all. Mineral oil is also an environmental
contaminant, and its insulating properties are rapidly degraded by even small amounts of
water. Transformers are well equipped to keep water outside the oil for this reason.

Pentaerythritol tetra fatty acid natural and synthetic esters have emerged as an increasingly
common mineral oil alternative, especially in high-fire-risk applications such as indoors due
to their high fire point, which can be over 300 °C.[5] They are readily biodegradable.
Pentaerythritol tetra fatty acid natural and synthetic esters are more expensive than mineral
oil. Transformers require special design change to operate with Pentaerythritol tetra fatty
acid natural and synthetic esters. Natural esters have very poor oxidation stability (typically
only 48 hours in the same test vs 500h for Mineral oils and they produce acids) as a
consequence, natural esters are only really a viable solution in hermetically sealed
transformers in a distribution context. As transformers get larger than around 1 MVA and
above 33kV it becomes more challenging to achieve a hermetically sealed design (due to
thermal expansion and contraction). Mid-size and large power transformers will typically
have a conservator and even if a rubber bag is employed the use of natural ester should be
carefully considered because if there is oxygen ingress the natural ester will experience much
faster oxidation than utilities are accustomed to with mineral oils. Silicone or fluorocarbon-
based oils, which are even less flammable, are also used, but they are more expensive than
esters, and less biodegradable.

A 380 kV transformer with vegetable oil [6]

Researchers are experimenting with vegetable-based formulations, using coconut oil for
instance. As yet these are unsuitable for use in cold climates or for voltages over 230 kV.[7]
Researchers are also investigating nanofluids for transformer use; these would be used as
additives to improve the stability and thermal and electrical properties of the oil.[8]

Polychlorinated biphenyls (PCBs)

Polychlorinated biphenyls are synthetic dielectrics first made over a century ago and found to
have desirable properties that led to their widespread use.[9] Polychlorinated biphenyls
(PCBs) were formerly used as transformer oil, since they have high dielectric strength and are
not flammable. Unfortunately, they are also toxic, bioaccumulative, not at all biodegradable,
and difficult to dispose of safely. When burned, they form even more toxic products, such as
chlorinated dioxins and chlorinated dibenzofurans.

Beginning in the 1970s, production and new uses of PCBs were banned in many countries,
due to concerns about the accumulation of PCBs and toxicity of their byproducts. For
instance, in the USA, production of PCBs was banned in 1979 under the Toxic Substances
Control Act.[10] In many countries significant programs are in place to reclaim and safely
destroy PCB contaminated equipment. One method that can be used to reclaim PCB
contaminated transformer oil is the application of a PCB removal system, also called a PCB
dechlorination system.

PCB removal systems use an alkali dispersion to strip the chlorine atoms from the other
molecules in a chemical reaction. This forms PCB-free transformer oil and a PCB-free sludge.
The two can then be separated via a centrifuge. The sludge can be disposed as regular non-
PCB industrial waste. The treated transformer oil is fully restored, meeting the required
standards, without any detectable PCB content. It can, thus, be used as the insulating fluid in
transformers again.[11]

PCBs and mineral oil are miscible in all proportions, and sometimes the same equipment
(drums, pumps, hoses, and so on) was used for either type of liquid, so PCB contamination of
transformer oil continues to be a concern. For instance, under present regulations,
concentrations of PCBs exceeding 5 parts per million can cause an oil to be classified as
hazardous waste in California.[12]

Testing and oil quality

Transformer oils are subject to electrical and mechanical stresses while a transformer is in
operation. In addition there is contamination caused by chemical interactions with windings
and other solid insulation, catalyzed by high operating temperature. The original chemical
properties of transformer oil change gradually, rendering it ineffective for its intended
purpose after many years.[13] Oil in large transformers and electrical apparatus is periodically
tested for its electrical and chemical properties, to make sure it is suitable for further use.
Sometimes oil condition can be improved by filtration and treatment. Tests can be divided
into:

1. Dissolved gas analysis

2. Furan analysis

3. PCB analysis

4. General electrical & physical tests:

Color & Appearance

Breakdown Voltage

Water Content

Acidity (Neutralization Value)

Dielectric Dissipation Factor

Resistivity

Sediments & Sludge

Flash Point

Pour Point

Density

Kinematic Viscosity

The details of conducting these tests are available in standards released by IEC, ASTM, IS,
BS, and testing can be done by any of the methods. The Furan and DGA tests are specifically
not for determining the quality of transformer oil, but for determining any abnormalities in the
internal windings of the transformer or the paper insulation of the transformer, which cannot
be otherwise detected without a complete overhaul of the transformer. Suggested intervals
for these test are:

General and physical tests - bi-yearly

Dissolved gas analysis - yearly

Furan testing - once every 2 years, subject to the transformer being in operation for min 5
years.
On-site testing

Some transformer oil tests can be carried out in the field, using portable test apparatus.
Other tests, such as dissolved gas, normally require a sample to be sent to a laboratory.
Electronic on-line dissolved gas detectors can be connected to important or distressed
transformers to continually monitor gas generation trends.

To determine the insulating property of the dielectric oil, an oil sample is taken from the
device under test, and its breakdown voltage is measured on-site according to the following
test sequence:

In the vessel, two standard-compliant test electrodes with a typical clearance of 2.5 mm
are surrounded by the insulating oil.

During the test, a test voltage is applied to the electrodes. The test voltage is continuously
increased up to the breakdown voltage with a constant slew rate of e.g. 2 kV/s.

Breakdown occurs in an electric arc, leading to a collapse of the test voltage.

Immediately after ignition of the arc, the test voltage is switched off automatically.

Ultra fast switch off is crucial, as the energy that is brought into the oil and is burning it
during the breakdown, must be limited to keep the additional pollution by carbonisation as
low as possible.

The root mean square value of the test voltage is measured at the very instant of the
breakdown and is reported as the breakdown voltage.

After the test is completed, the insulating oil is stirred automatically and the test sequence
is performed repeatedly.

The resulting breakdown voltage is calculated as mean value of the individual

measurements.

See also

Heat-transfer oil

References

1. Frank D. Petruzella, Industrial Electronics, p. 51, Glencoe/McGraw-Hill, 1996 ISBN 0028019962.

2. Gill, Paul (2009). Electrical power equipment maintenance and testing (2nd ed.). Boca Raton: CRC
Press. p. 193. ISBN 978-1-57444-656-2.
 3. Hirschler, Marcelo M. (2000). Electrical insulating materials : international issues (Online ed.). West
Conshohocken, Pa.: ASTM. pp. 82–95. ISBN 978-0-8031-2613-8.

4. Kenneth R. Edwards, Transformers, American Technical Publishers Ltd., 1996 ISBN 0-8269-1603-1
pp.138-14

5. "Fluids Comparison" (http://www.midel.com/productsmidel/fluids-comparison) . Midel.

6. "Siemens has produced the world's first large-scale transformer that uses vegetable oil" (https://www.
siemens.com/about/sustainability/en/core-topics/innovation/references/vegetable-oil-transformer.
htm) .

7. "Coconut Oil As An Alternative To Transformer Oil" (http://www.elect.mrt.ac.lk/Coconut_oil_eru_200

1.pdf) (PDF). ERU Symposium. November 2001.

8. n'Cho, J. S.; Loiselle, L.; Fofana, I.; Beroual, A.; Aka-Ngnui, T. (2010). "Parameters affecting the
electrical and thermal properties of transformer oils" (https://www.researchgate.net/publication/2242
23202) . Parameters affecting the electrical and thermal properties of transformer_oils. Conference
on Electrical Insulation and Dielectric Phenomena. pp. 1–4. doi:10.1109/CEIDP.2010.5723967 (http
s://doi.org/10.1109%2FCEIDP.2010.5723967) . ISBN 978-1-4244-9468-2. S2CID 22800355 (https://a
pi.semanticscholar.org/CorpusID:22800355) . Retrieved 6 February 2022.

9. "PCB-RS Series – PCB Removal System | HERING VPT: The standard in oil purification and
transformer drying technology" (http://www.hering-vpt.com/products/pcb-removal-system/) .
Retrieved 2020-05-20.

10. Blackmore, Carolyn. "Classification and Handling of PCB Waste" (http://www2.lbl.gov/ehs/waste/do

c/WMG02rev0.pdf) (PDF). Lawrence Berkeley National Laboratory. Retrieved 20 October 2017.

11. "PCB Dechlorination System" (http://www.hering-vpt.com/products/pcb-removal-system/) . Hering-

VPT GmbH. Retrieved 20 October 2017.

12. California Code of Regulations, Title 22, section 66261

13. "Transformer Oil Detoriation - Why is transformer oil purification essential?" (http://www.hering-vpt.co
m/products/transformer-oil-purification/transformer-oil-deterioration/) .

Less and nonflammable liquid-insulated transformers, approval standard class Number 3990, Factory
Mutual Research Corporation, 1997.

McShane C.P. (2001) Relative properties of the new combustion-resistant vegetable oil-based
dielectric coolants for distribution and power transformers. IEEE Trans. on Industry Applications,
Vol.37, No.4, July/August 2001, pp. 1132–1139, No. 0093-9994/01, 2001 IEEE.

"The Environmental technology verification program", U.S. Environmental Protection Agency,

Washington, DC, VS-R-02-02, June 2002. [1] (http://www.epa.gov/etv/pdfs/vrvs/06_vs_cooper.pdf)

IEEE Guide for loading mineral-oil-immersed transformers, IEEE Standard C57.91-1995, 1996.

External links
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Last edited 13 days ago by Comfr