1LFI1149-en rev.

H
TRANSFORMER OIL
Quality and treatment

1LFI1149-en rev. H 2 / 14

Table of contents
1 General Safety Information ....................................................................................... 3
2 Overview..................................................................................................................... 4
3 Quality ........................................................................................................................ 4
3.1 New oil................................................................................................................. 4
3.2 Impurities............................................................................................................. 5
3.3 Deterioration........................................................................................................ 5
3.4 Assessment of the properties of used oil (IEC 60422) ......................................... 6
4 Supervi sion ................................................................................................................ 7
5 Sampling of oil from transformers ........................................................................... 7
5.1 Equipment ........................................................................................................... 7
5.1.1 Sample vessel ............................................................................................. 7
5.1.2 Sampling tube ............................................................................................. 8
5.1.3 Waste oil vessel........................................................................................... 8
5.2 Sampling ............................................................................................................. 8
5.3 Markings.............................................................................................................. 9
6 Treatment ................................................................................................................. 10
6.1 General.............................................................................................................. 10
6.2 Filtering.............................................................................................................. 10
6.3 Drying................................................................................................................ 11
6.3.1 Centrifugal treatment ................................................................................. 11
6.3.2 Vacuum treatment ..................................................................................... 11
6.3.3 Molecular sieve dehydrator........................................................................ 12
6.3.4 Diatomaceous earth treatment .................................................................. 13
7 Mixing ....................................................................................................................... 13
8 Gas analysis............................................................................................................. 13


1LFI1149-en rev. H 3 / 14


1 General Safety Information

Only skilled personnel are to be involved in the procedures relating to the handling of
power transformer oils. Ensure that the transformer handbooks, these instructions and
other related documentation are available to the personnel carrying out the required
assignment. Check before commencing work that the personnel involved have studied
the above-mentioned documents and understood their content.
Be very careful when handling oil because waste oil, oily earth and oily cloths are
problem waste, which require special measures for disposal.
Check the type of the transformer oil used from the transformers name plate. Make note
that, in addition to mineral oil, silicon oil or synthetic and natural esters can be used as
insulation liquid for the transformer. These instructions only deal with mineral oils.
Regional and local regulations are also to be followed.
Use tested and safe working methods, and pay special attention to thorough
consideration and caution. Use only sound, purposeful and safe machines and tools, as
well as personal protective equipment when required.
Make sure that the rescue personnel are aware of all of the risks and dangers related to
the work to be carried out.
The most common hazards in tasks related to transformers are:
Highly dangerous voltages
Moving machinery
Heavy and sharp components
Slipping, tripping or falling accidents
High pressures
Oil leaks
Disregard of these instructions may result in personal injuries or damage to property or
the environment.
Dangerous situations are defined using the following three categories in the instructions
depending on the seriousness of the consequences resulting from damage or careless
action.
ORDER
An order forbids a certain action or defines that the procedure is to be carried out in a
specific manner. Non-compliance will result in personal injury or death, or severe
damage to property or the environment.

WARNING
A warning is intended against possible damage or wrong procedure which may result in
personal injury or death, or damage to property or the environment.

1LFI1149-en rev. H 4 / 14



NOTE: A remark provides instructions for the most appropriate method or warns against
damage or careless action which may result in minor personal injury or slight damage to
property or the environment.
2 Overview

Transformer oil is made of mineral oil. Its boiling point is between 250C and 300C. After
refining, the oil is very pure and comprises only liquid hydrocarbons. The main purpose of
the oil is to act as an electrical insulator and conduct heat from the active parts of the
transformer to the radiators. The solidification point of the oil must be less than -40C and
the flashpoint more than 140C.
3 Quality
3.1 New oil

Table 1. Chemical and physical requirements for transformer oils to be used in new
transformers (IEC 60422)
Transformers nominal voltage [kV] Property Testing
method < 72.5 72.5 - 170 > 170
Appearance Clear, free from sediment and
suspended matter
Dielectric strength (kV) IEC 60156 > 55 > 60 > 60
Water content (mg/kg) IEC 60814 < 20 < 10 < 10
Acidity (mg KOH/g) IEC 62021-1 Max. 0.03 Max. 0.03 Max. 0.03
Dielectric dissipation
factor (tan ) at +90C, 40
60 Hz
IEC 60247 Max. 0.015 Max. 0.015 Max. 0.010
Interfacial tension (mN/m) ISO 6295 Min. 35 Min. 35 Min. 35
PCB content (mg/kg) IEC 61619 Not detectable (< 2)
Corrosive sulfur ASTM D-1275 B
extended (ABBs
requirement)
No corrosive sulfur

Oil delivered directly from the oil manufacturer cannot be used as such in a transformer.
The oil is first to be filtered and vacuum-treated. This improves the oil's dielectric strength,
and its water and impurity content is reduced.
In field conditions the oil must be treated before pouring it into the transformer if its
dielectric strength is less than 55 kV / 2.5 mm. If the transformer is delivered without any
oil, the oil to be added must always be vacuum-treated and poured into the transformer
under vacuum.
The values of a sample taken from the transformer must be in accordance with the values
presented in Table 1.

1LFI1149-en rev. H 5 / 14



NOTE: If barrels have been used for the transport of the transformer oil, the oil
should always be filtered before being poured into the transformer, if U
m
> 36 kV.
Otherwise filtering is recommended.

3.2 Impurities

Three types of impurities can be found in oil, i.e. moisture, solid particles and dissolved
polar compounds. The first two elements have an effect on the oils dielectric strength,
and the third element affects the oils dissipation factor (tan ).
The requirements for the dielectric strength of oil depend on the nominal voltage of the
transformer. IEC requirements for the dielectric strength of oil in new transformers are
presented in Table 1.
If the oils dielectric strength does not fulfill the above-mentioned standards, the oil may
contain solid particles, or it may be contaminated with moisture. The moisture content of
the transformer oil used increases as a consequence of insulation deterioration resulting
from use.
3.3 Deterioration

Transformer oil is an organic substance which oxidizes with time. As a result its
properties decay slowly. As the oil ages it becomes more acidic and its interfacial tension
decreases. The acidity of the oil must not rise too high because this causes the paper
and pressboard insulating materials to deteriorate faster. The oil must not be allowed to
decay so much that precipitation is formed. The neutralization value is an indicator for
oxidization. Table 2 presents the actions to be taken on the basis of the neutralization
value.
The interfacial tension of the oil could also be too low. If the oils interfacial tension is
reduced excessively, it is possible that aging products are precipitated in the oil. As a
result, more efficient condition monitoring for the oil is required. Whenever precipitation is
found in the oil it should be regenerated or changed.









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3.4 Assessment of the properties of used oil (IEC 60422)

Recommended limits for
procedures
Recommended procedures Property Nominal
voltage
(kV) Good Fair Poor
Appearance All Bright,
no
visible
deterior
ation
Dark
and/or
turbid
According to the results from other
tests. The dark color is a sign of
chemical deterioration or aging.
Turbidity is a sign of high water
content.
72.5 > 40 30 - 40 < 30
72.5 - 170 > 50 40 - 50 < 40
Dielectric strength
(kV)
> 170 > 60 50 - 60 < 50
Fair: Take samples more frequently
and study other properties, such as
water content and the number of
particles. Poor: Filter and/or dry or
change the oil.
72.5 < 10 10 - 25 > 25
72.5 - 170 < 5 5 - 15 > 15
Water content
(mg/kg, at +20C)
> 170 < 5 5 - 10 > 10
Fair: Take samples more frequently
and study other properties, such as
dielectric strength and the number
of particles. Poor: Identify the origin
of the water. Filter and/or dry or
change the oil.
72.5 < 0.15 0.15 0.30 > 0.30
72.5 - 170 < 0.10 0.10 0.20 > 0.20
Acidity (mg
KOH/g)
> 170 < 0.10 0.10 0.15 > 0.15
Fair: Take samples more frequently
and study the precipitate and
sludge content in the oil. Poor:
Regenerate or change the oil.
72.5 < 0.10 0.10 0.50 > 0.50
72.5 - 170 < 0.10 0.10 0.50 > 0.50
Dielectric
dissipation factor
(tan ) at +90C,
40 60 Hz
> 170 < 0.10 0.10 0.20 > 0.20
Fair: Take samples more frequently
and study other properties. Poor:
Regenerate or change the oil.
Interfacial tension
(mN/m)
All > 28 22 28 < 22 Fair: Take samples more
frequently. Poor: Study the
precipitate and sludge content in
the oil.
Inhibitor content All a ) Inhibitor content is 40-60% of
the original, acidity 0.06 mg
KOH/g and interfacial tension
30 mN/m

b ) Inhibitor content < 40% of the
original or acidity > 0.06 mg
KOH/g and interfacial tension <
30 mN/m

Add inhibitor to the original content.



Regenerate the oil and add inhibitor
to the original content.
PCB content All The limit values and procedures are
determined according to the local
regulations.






1LFI1149-en rev. H 7 / 14


4 Supervision

For suitable corrective actions to be taken in time, oil condition monitoring is required. Oil
samples are taken and the dielectric strength, moisture content and deterioration level
are studied.
Frequency of sampling
It is not possible to give exact guidelines for the oil sampling frequency because it
depends on the transformer type, operating conditions and the importance of operational
reliability.
The following is a recommendation for the frequency according to which samples are to
be taken for studying the oil condition.
12 months after start-up for all transformers (does not apply to standard
distribution transformers).
Only one oil sample is allowed regarding hermetically sealed transformers
without adding any oil. The addition of oil requires special measures.
Approximately every two years for 72.5 kV transformers.
Approximately every six years for < 72.5 kV transformers, but every two years if
the transformer is used in straining conditions or its operational reliability is very
important.
If the oil properties approach the limit values given above, possible further
measures, such as increased supervision, should be agreed upon with the
manufacturer.
During the period of increased supervision it is advisable to take samples more
frequently, e.g. once a year.
If the transformer is to be stored for a long period, sampling before and after the
storage is recommended.
5 Sampling of oil from transformers
5.1 Equipment
5.1.1 Sample vessel

A suitable sampling vessel for conservator-type transformers is a one liter glass bottle
with a plastic screw cap or a tin-coated steel can. A similar half liter bottle is to be used
with hermetically sealed transformers. Copper, plastic or brass vessels must not to be
used, nor a rubber cap to seal the sample vessel.
The sample vessels are to be dry and clean because even very small impurities, such as
moisture and dirt, reduce the electrical properties of the transformer oil significantly. This
will provide a false picture of the condition of the transformer oil.

1LFI1149-en rev. H 8 / 14


The bottles can be washed and dried as follows:
Dirty bottles are first to be rinsed with water. Wash the bottles with Solvent 1 washing
liquid using a brush and rinse the bottles well with hot water. Finally rinse the bottles with
deionized water. Dry the bottles in a drying oven placing the bottles upside down at a
temperature of 100C for at least 4 hours. The screw caps are to be washed and dried
similarly to the bottles. If the caps have plastic seals, dry them in an oven for about 5
minutes. When the bottles are taken from the drying oven they must be sealed
immediately and allowed to cool down.
If the oil samples are to be investigated in the Materials Laboratory of ABB Oy, we
recommend that the sample bottles are also ordered from there. At the same time, the
tests to be performed are to be reported. An oil sample bottle for gas analysis has a small
valve in the cap through which the laboratory takes a sample of the gas contained by the
bottle. A separate one liter oil sample is taken for the gas analysis and a second one liter
sample is taken for other tests. For hermetically sealed transformers, only a half-liter
sample is taken.
5.1.2 Sampling tube

Use a new and clean plastic tube, which has the required plug or flange for connecting it
to the transformers valve. Transformers manufactured by ABB Oy usually have a
separate valve for sampling purposes, or a hat is fitted to the transformers closing flange
for the main valve. The hat has a connection for sample taking. The sampling valve
connection normally has an R 1/2" external thread while the thread of the hat is an R 1/2"
internal thread. If the sampling bottles are ordered from the Materials Laboratory of ABB
Oy, the sampling tube and connector are delivered with the bottles. Hermetically sealed
transformers are equipped with a drainage device containing a sampling connection.
5.1.3 Waste oil vessel

Use a plastic bucket or similar.
5.2 Sampling

WARNING
Be very careful when handling oil because waste oil, oily earth and oily cloths are
problem waste, which require special measures for disposal.

Great care is to be exercised while taking an oil sample in order to ensure that the
sample does not become contaminated with dirt or moisture. When the sample is taken
from a transformer that is located outdoors, make sure that suitable protection against
rain, fog and dust (wind) is provided. Generally, the sample is only taken from the bottom
valve. In irregular situations, e.g. when investigating a failure, a sample is also taken from
the top of the tank, if a suitable valve is provided.

1LFI1149-en rev. H 9 / 14



Hermetically sealed transformers are equipped with a drainage device containing a
sampling connection. Only one oil sample is allowed regarding hermetically sealed
transformers without adding any oil. The addition of oil requires special measures.
Execution:
All impurities, moisture, dirt, etc. is to be removed from the valve.
The plastic sampling tube is to be connected in an appropriate manner to the
transformers sampling valve, and the exterior of the tube is to be cleaned with a
lint-free cloth.
The other end of the tube is to be put in a waste oil container, and the valve is
opened sufficiently. The valve must not be adjusted while taking the sample
because this may dislodge dirt into the oil.
Allow about 2 to 5 liters of oil flow into the waste oil container (approximately 2 dl
for hermetically sealed transformers).
Put the end of the tube into the sampling bottle and fill the bottle so that about 2
liters runs into the waste container (approximately 2 dl for hermetically sealed
transformers). This is especially important when taking an oil sample for gas
analysis in order to ensure that no air is mixed with the oil.
Take the tube from the bottle and place it in the waste oil container.
Pour some of the oil from the bottle so that there is about 2 cm free space in the
neck of the bottle. As a result, the bottle will not break if the oil expands due to
heat.
Seal the bottle immediately, thoroughly and tightly, and protect it from light.
Close the valve.
5.3 Markings

Attach a label to the bottle including the following information:
Customers name, name of person who took the sample and contact information
Date
Transformer type, serial number and location
Position of sampling valve (upper or lower)
Temperature of the transformer
Loading when the sample was taken and immediately before the sampling


1LFI1149-en rev. H 10 / 14


6 Treatment
6.1 General

Special care and cleanliness are to be followed when handling transformer oil so that its
properties do not degrade during the different stages of handling. Clean and dry barrels
or tanks are to be used for the storage and transport of oil. It is recommended that barrels
and tanks designed for the transport of transformer oil are used. New oil must not be
stored or transported in vessels that have been used for the transport or storage of damp
or old dirty oil because cleaned containers may contain some moisture or dirt. If oil is
stored in barrels, they are to be protected from rain or laid on their side so that the oil acts
as a seal and prevents water from entering.
Naturally, the same requirements for cleanliness and dryness apply to the tubes, pumps
and drying and cleaning equipment used in the handling of new oil. If required, these
should be rinsed with clean and dry oil. The ends of tubes and connection fittings should
be plugged or protected with other suitable methods during storage.
WARNING
During the handling of oil the risks of damaging the environment should always be kept in
mind. The containers for the transport of oil should be mechanically robust and approved
for the transport and storage of oil. Tubes should also be oil resistant and strong, and
their joints tight and secure.

WARNING
Separate handling vessels and devices must be used for different types of insulation
liquids. Ensure the type of the insulation liquid before handling.

WARNING
A static electrical charge is generated, when the oil is flowing. The transformer coils and
tank, and the equipment used during oil treatment are to be earthed. The risk of fire is to
be always kept in mind.

6.2 Filtering

Mechanical impurities are removed from oil by filtering. A paper, cloth or an edge filter
can be used. With paper and cloth filters, the oil flows directly against the filter surface.
These filters allow quite a high flow rate, and particles of more than 10 m can be
removed. The edge filter is more dense and removes particles down to 1 m in size.

1LFI1149-en rev. H 11 / 14


6.3 Drying
6.3.1 Centrifugal treatment

Centrifugal treatment is the most effective method of removing free water from oil. At the
same time it removes particles heavier than oil. Water droplets and impurities fly outward
in a centrifuge. Clean oil gathers in the center and is taken from the centrifuge through
the top of the chamber. After the centrifugal treatment oil usually needs to be filtered and
vacuum treated.
6.3.2 Vacuum treatment

Vacuum treatment is the most common method for drying oil. This also removes any
gases (air) contained by the oil. Normally about 10 per cent of oil volume is air. Oil does
not impregnate well unless the oil is vacuum-treated in advance. The impregnation is
necessary for the transformers insulation parts in order to achieve good withstanding
voltage. During the vacuum treatment the oil temperature should be between 50C and
60C. The oil is first run through a heat exchanger and then into the vacuum chamber
where it is spread as a thin layer over a large area. Often, a second vacuum chamber
connected in series with the first chamber is used. If the pressure in the first chamber is
about 100 Pa, and 10 Pa in the second chamber, final moisture of about 1 mg / 1 dm
3
can
be achieved. Normally, a filter is fitted in series with the heat exchanger and vacuum
chamber (Image 1).


Image 1. Vacuum treatment for oil


1LFI1149-en rev. H 12 / 14


6.3.3 Molecular sieve dehydrator
If the oil in a transformer contains moisture, it is normal that the windings also contain a
degree of moisture. Moisture is divided between the oil and paper according to the
diagram in Image 2 when the oil circulates in the transformer due to the effect of
temperature differences. When the relation between the paper and oil content in the
transformer is approximately 1:7 the result is that more than 95% of the transformers
moisture is contained by the paper. As a result, fixed insulation must also be dried. This
may be performed by drying the oil continuously over a long period of time.
20C
30C
40C
50C
60C
80C
100C
W
a
t
e
r

c
o
n
t
e
n
t

o
f

p
a
p
e
r

%
Water content of oil g/t
5
0
10
0 20 40 60
80

Image 2. Moisture balance between oil and paper in the transformer used at different
operating temperatures

A molecular sieve dehydrator may be used for long-term oil drying. The drying process
takes months and can be performed while the transformer is in use. All molecular sieve
materials are synthetic zeolites, which have a high capacity for absorbing moisture. In
addition, their pores are so small that they do not become clogged due to the effect of the
oil. Normal salts used in regular air driers are not suitable for this purpose. Molecular
sieves can absorb water from oil to a rate of about 10 mg / dm
3
. In order to improve the
drying efficiency, the oil is circulated by pumping it through the molecular sieve. A filter is
used to prevent fixed particles from entering the oil through the sieve material. A diagram
concerning the drying process is shown in Image 3.

Image 3. Drying with a molecular sieve

1LFI1149-en rev. H 13 / 14


6.3.4 Diatomaceous earth treatment

Activated diatomaceous earth is used to remove chemical impurities (aging products and
other polar substances). The treatment can basically be performed similarly to the drying
process using a molecular sieve - by using oven-dried diatomaceous earth instead of
molecular sieve substances. In cases where the oil contains many chemical impurities or
has become too old, treatment with diatomaceous earth is not economical. It is more
reasonable to change the oil altogether.
7 Mixing

ABB does not recommend that different types of oils are to be mixed. When mixing oils,
the properties of the compound often lie between the properties of the two component
oils. The mixture may, however, have poor aging resistance, or sludge or water droplets
may form in the oil due to aging products or reduced solubility of water.
Transformer oils must not be mixed under any circumstances if any of the following
conditions is not fulfilled:
a) The oils meet the requirements of the same standard (e.g. IEC 60296)
b) The neutralization value of the oils is less than 0.1 mg KOH / g
c) Moisture content of the oils is less than 10 g / t
d) The oils contain the same inhibitor or compatible inhibitors
e) The oils do not contain corrosive sulfur according to the latest testing requirements.
ABB Oy uses naphthenic oil in transformers. Paraffin-based oil must not be mixed with
the oil.
If a small quantity of oil is added to a transformer, the properties of the oil added must
not, under any circumstances, be worse than those of the in-tank oil. In cases of
uncertainty, the mixing compatibility must be checked by performing mixing and aging
tests if the amount of the oil to be added is more than 5%. The most important properties,
such as aging resistance, must not be worse in the mixture than those of the worst
component used. The test is to be performed with the mixture ratio intended to be used. If
the mixture ratio is not known, the oils are mixed at the ratio of 1:1. In cases of
uncertainty, contact the transformer or oil manufacturer.
8 Gas analysis

If discharges or overheating appears in the transformer, the oil and paper molecules will
degrade. This generates gases, such as hydrogen, methane, ethane, ethylene, acetylene
and other hydrocarbons, as well as carbon monoxide and dioxide, which dissolve in the
oil partially or totally. They can be separated from the oil and analyzed using a gas
chromatograph (IEC 60567).




Copyright 2007 ABB, All rights reserved

Document Title
TRANSFORMER OIL
Document No. Date & Rev. Ind. No. of Pages Page
1LFI1149-en H 14 14

It has been observed that large quantities of methane (CH
4
) and ethylene (C
2
H
4
) are
produced when the oil decomposes due to overheating. Low-energy partial discharges
produce hydrogen (H
2
) in particular. Hydrogen may also be produced by paints and other
oxidizing reactions. As the energy in the electrical discharges increases (e.g. an arc
flame) acetylene (C
2
H
2
) is produced. When paper and pressboard insulation degrades,
carbon monoxide (CO) and carbon dioxide (CO
2
) are produced.
Absolute limit values for the gas content cannot be given because even a transformer in
normal condition produces gases. In addition, the formation of gases depends on the
operating conditions. On the basis of practical experience gained, it has been noted that
the following indicative limit values stated in IEC 60599 can be used for transformers
manufactured by ABB Oy. However, the hydrogen content in hermetically sealed
transformers may be significantly greater when there is no transfer of gas to the outside
air. The gas content is defined as the ratio of the volume of gas removed from the oil to
the volume of oil (cm3 / m
3
= ppm).
Hydrogen
H
2

Methane
CH
4

Ethylene
C
2
H
4

Ethane
C
2
H
6

Acetylene
C
2
H
2

Carbon
monoxide
CO
Carbon
dioxide
CO
2

150 ppm 110 ppm 280 ppm 90 ppm 50 ppm 900 ppm
13000
ppm

When one of the gas levels exceeds the values above it is reasonable to increase the
amount of supervision concerning the transformer by taking oil samples more frequently
and monitoring the change speed in the gas content. In order to diagnose the type of
failure, different gas level ratios are generally used. Typical gas ratios to be used include:
C
2
H
2
/ C
2
H
4
, CH
4
/ H
2
, C
2
H
4
/ C
2
H
6
, and C
2
H
6
/ CH
4
. IEC 60599 covers the interpretation
of gas analysis in more detail.
If the failure is sudden, e.g. a strong arc flame, the formation of gas is so sudden that all
of the gas cannot be dissolved in the oil, and some of the gas is formed in the gas relay,
from which a sample can be taken and analyzed. The composition of the gas formed in
the relay is not in the same as that of the gas mixture formed by the failure. This is due to
the fact that as the gas flows through the oil, the different gases are absorbed into the oil
at different rates, and air is separated from the oil. As a result, it is much more difficult to
diagnose the nature of the failure from a gas sample taken from the relay.