INSULATING OILS, FLUIDS, AND

GASSES
Insulating oils, fluids, and gases are used as dielectrics in the electrical
equipment and apparatus. The liquids used in the transformers are mineral oil
and synthetic fluids, such as askarel, silicone, RTemp, Wecosal, Alpha 1, and
GE R113.

Transformer oil or insulating oil is usually a highly-refined mineral oil that is

stable at high temperatures and has excellent electrical insulating properties.

The oil helps cool the transformer. Because it also provides part of the
electrical insulation between internal live parts, transformer oil must remain
stable at high temperatures for an extended period.
 Insulating Oil
Hydrocarbon oil is used as an insulating fluid in transformers and circuit breakers
because of its high dielectric strength and chemical stability.

Deterioration of Insulating Oil

Effect of Oxygen on Oil
Moisture contamination is the most common cause of deterioration in the insulating quality of oil.
This contamination can be readily corrected by purification.

Moisture in Oil
Water can be present in oil in a dissolved form, as tiny droplets mixed with the oil (emulsion), or in a
free state at the bottom of the container holding the oil.

Oil Deterioration in Transformers

In transformers, sludge sticks to the surface through which heat should be dissipated; the sludge
forms a blanket barrier to the flow of heat from the oil to the coolant and from the core and coils to
the cool oil. If allowed to continue long enough, the sludge may even block off the flow of oil
through the cooling ducts. As a result, the transformer insulation gets too hot and is damaged,
particularly between turns of the windings.
 Insulating Oil Testing
Dielectric Breakdown Voltage Test (Cup Tests)
This is an AC overvoltage test applied to the insulating liquids to detect their breakdown strength.

Acidity Test
The acidity test measures the content of acids formed by oxidation.

Interfacial Tension (IFT)

The IFT test is employed as an indication of the sludging characteristics of power transformer insulating
liquid.

Color Test
This test consists of transmitting light through oil samples and comparing the color observed with a standard
color chart.

Power Factor Test

The power factor indicates the dielectric loss of the liquid and thus its dielectric heating. The power factor
test is widely used as an acceptance and preventive maintenance test for insulating liquid.

Specific Gravity
Specific gravity of oil is defined as the ratio of the mass of a given volume of oil to the mass of an equal
volume of oil of water at a specified temperature. This test is conducted by floating a hydrometer in oil and
taking the reading at the meniscus.

Water Content Test (Karl Fisher Method)

This test is based on the reduction of iodine according to the traditional Karl Fisher reaction.
Combustible Gas Analysis of Insulating Oil
An oil-filled transformer insulation system consists of insulating oil and cellulose (paper) materials. Under
normal use, transformer insulation deteriorates and generates certain combustible and noncombustible
gases.

TCG(Total Combustible Gas)

TCG can be determined in the field or analyzed in the laboratory from a sample of gas drawn from the gas
space above the oil. The method is applicable to power transformers with a nitrogen blanket or conservator
system.
DGA(Dissolved Gas Analysis)
The DGA is basically a laboratory test using an oil sample taken from a transformer. The oil sample is
subjected to a vacuum to remove the combustible gases. These gases are then passed through a gas
chromatograph and each gas is then extracted and analyzed for type and quantity.

The rate of gas generation in gas space above the oil can be calculated by taking the sum of the gas
concentrations of all combustible gases in the first and second samples and using the equation* given
below:

where:
R is the rate of gas generation (ft 3/day)
So is the concentration of first sample (ppm)
ST is the concentration of second sample (ppm)
V is the volume of the oil in tank (gal)
T is the time (days)
Assessing the Transformer Condition Using the TCGA in the Gas Space
A new transformer should be tested within a week after energization. If it is not gassing and does
not start gassing, subsequent tests should be made progressively increasing intervals until the 12-
month normal interval is reached.

Assessing the Transformer Condition Using the DGA Method

a new transformer should be tested for combustible gases within a week after energization, and
continued with testing until the 12-month normal interval is reached. However, if there is no
previous DGA history on the transformer, then it can be difficult to determine whether a
transformer is operating normally or not.

Less Flammable Insulating Fluids

There has been a great increase in the use of less flammable liquids as an insulating and cooling
medium in transformers.

Insulating Liquid Sampling Procedures

The validity of the test results is dependent upon the sampler being certain that the oil sample is
truly representative of the oil in the equipment.
Sampling Oil from Transformers

Sampling Oil from Drums or Shipping Containers

Taking Oil Samples for Gas-in-Oil Analysis

This procedure has been developed to maintain uniformity of all oil samples taken in the field for
a laboratory gas-in-oil analysis.

Maintenance and Reconditioning of Insulating Oil and Fluids

As discussed earlier, moisture and oxygen are the most prevalent contaminants present in
transformer oil and fluids. As a result of these contaminants and other catalysts and accelerators,
oxidation of these liquids takes place. Overtime oxidation results in deterioration of the
transformer insulating system.

Reconditioning Used Insulating Oils

Modern vacuum oil purification systems with integral Fuller’s earth or activated alumina can
correct all contamination conditions of deteriorated oils. First the contaminated oil condition has
to be identified and then an appropriate method or combinations of the methods are used for a
complete purification of the oil.
Cartridge Filters
These units are available in various sizes with oil-processing capacities ranging from 10 to 75
gal/min and utilize disposable cartridges with filter densities ranging from 1 to 25 micrometers
(μm).

Centrifuges
Another means of separating free and suspended contaminants, such as carbon, water, and
sludge, from oil is the continuous centrifuge.

Coalescers
This method is quite similar to centrifuging with respect to performance and limitations;
however, coalescing filters have no moving parts and, therefore, are simpler in operation and
maintenance and suitable for unattended and automatic operation.

Vacuum Dehydrators
The vacuum dehydrator (Figure 4.5) is effi cient in reducing the water content of insulating oil to a
very low value. In this apparatus, the oil is exposed to a vacuum and heat for a short interval of
time.
 Maintenance of Less Flammable Fluids
Maintenance of RTemp
The maintenance of RTemp fluid can be carried out similarly to that for oil and askarel. Special
maintenance instructions for RTemp are the following:
Filtering: If it is necessary to filter RTemp fluid to remove excess moisture, sludge, and the like,
it can be filtered through conventional filtration systems.
Cold start: RTemp fluid has a pour point of −30°C. At this point, the dielectric strength is still
sufficient to allow safe energization of the transformer.
Precautions: RTemp transformers are high-fire point liquid-insulated transformers.

Maintenance of Silicone
Silicone insulating fluid is used in transformers to provide heat transfer. Transformers
containing silicone should be installed, operated, and serviced by competent and trained
maintenance personnel who are familiar with good safety practices. The following are special
maintenance instructions relating to silicone-filled transformers:
Receiving and handling: Immediately upon receipt of shipping drums or a transformer filled
with silicone fluid, an examination should be made for leaks.
Storage: Shipping drums should be stored indoors in an area specially selected for this
purpose.
Filtering: If test results indicate that moisture or other contaminants are present, they can
usually be removed by passing the insulating liquid through a filter press.
Precautions: Static charges can be developed when silicone fluid flows in pipes, hoses, and
tanks.
Maintenance of Wecosol
Wecosol fluid is a transformer grade of tetrachloroethylene (sometimes called
perchloroethylene). Wecosol fluid will slowly evaporate to produce Wecosol vapors.
The following are special maintenance instructions for Wecosol:
Receiving and handling: Immediately upon receipt of drums or a transformer
filled with Wecosol fluid, examine for leaks.
Sampling: Samples should be taken to prevent air from entering the tank.
Inspection and maintenance: Periodic inspection and maintenance test should
be conducted to determine whether a transformer fluid should continue to
be used, dried, or reprocessed.
Storage and handling: The same basic procedures for storing and handling
conventional transformer oil should be followed with FR3 fluid.
Fluid maintenance tests: Physical, chemical, and electrical properties are used to
evaluate new and in-service electrical insulating fluids.
 Performance tests
Insulating fluids provide both electrical insulation and cooling for the electrical apparatus. The
dielectric breakdown voltage and viscosity are two key properties that affect the function and
performance of an electrical insulating fluid.

Dielectric breakdown voltage tests: The dielectric breakdown voltage tests measures the integrity
of the insulation.
Viscosity: The viscosity influences the cooling performance.

Quality tests
These tests are conducted to give indicators of changes in the electrical insulating fluid over time
due the operation of the equipment.

Dielectric strength per ASTM D1816 and D877: The acceptable limit for continued use of service-
aged FR3 fluid is 30 kV minimum for equipment rated 69 kV and below.
Water content
Dissipation factor
Color: A low color number of FR3 insulating fl uid is desirable to permit
inspection of assembled apparatus in a tank. An increase in color number
during service is an indicator of oil deterioration or contamination.
 Diagnostic tests
Flash point and fire point: serves both for quality verification of new FR3 fluid and diagnostics and
safety evaluation of in-service fluid.

Dissolved gas analysis: This test is recommended particularly for high value equipment or
equipment servicing critical loads

Safety and care procedures

Users should obtain a material safety data sheet (MSDS) for each natural ester fluid in use. Follow
the manufacturer’s instructions at all times:
Personnel should avoid eye/fluid contact and inhalation of spray mists, and take appropriate steps
if such incidents occur.
MSDSs should provide appropriate
guidelines with respect to handling these fluids. Although not listed as a hazardous substance or
waste by any federal agency, disposal of natural ester fluids may require certain precautions
Maintenance of Askarels
Askarel is a generic name for PCBs which were used extensively in electrical transformers,
capacitors, and other equipment since the 1940s. Askarel was used by many electrical equipment
manufacturers under their own trade name such as Pyranol (GE), Inerteen (Westinghouse), and
so on.

Inspection: Visual inspection and dielectric strength tests should be made on askarel when
installing equipment and on a regular schedule at 1-year intervals thereafter.
Sampling: Samples of askarel should be taken in a clean, dry glass quart bottle.
Testing: The testing procedure for askarel is the same as for mineral oil, but care should be taken
to see that there is no mineral oil in the test cup.
Contamination: Water contamination is the primary cause of deterioration of askarel dielectric
strength.
Reconditioning askarel: The fact that the transformer tanks are generally sealed and that any
condensation will fl oat on top of askarel makes filtering by a blotter press rarely necessary.
Handling and disposal of askarel: While askarel is generally considered to be noncombustible,
under arcing conditions gases are produced that consist predominately of noncombustible
hydrogen chloride and varying amounts of combustible gases depending on the askarel
composition.
Safety precautions: Based on about 40 years of industrial usage, askarels are considered harmful
materials to humans.
 Insulating Gases
Insulating gases, such as SF6, N2, fl uorocarbons (freons), H2, and CO2 are used in varying
degrees as insulating medium in electrical equipment and apparatus.

Maintenance of SF6
One maintenance item of concern is to monitor the leakage of SF6 gas from the electrical
apparatus. This can be easily accomplished by using a refrigerator-type freon detector.

Conducting Particles
Particles of metallic or carbonaceous matter may be found in the gas, especially in the
gas-insulated bus. At normal operating voltages these particles may cause local ionization
of the gas. Under normal circumstances no internal flashover results from this ionization
because the SF6 gas will absorb the free electrons as rapidly as they are generated.

Moisture
The SF6 gas shipped from the factory has very low moisture content, less than 40 ppm by
volume. Moisture is usually introduced into the gas during installation by inadequate
evacuation of the equipment before filling. Water molecules adhering to the solid
surfaces inside the equipment will diffuse into the gas after filling.
Oil Contamination
Oil and oil vapor containing free carbon molecules can cause flashover of the SF6 gas. Operating
experience has shown that clean oil and oil vapor free of carbon does not degrade the
performance of the gas-insulated equipment in any way.

Gaseous Contamination
The gaseous contamination in the SF6 gas may result from three different sources. The first
source of contamination is from the factory where it may have been introduced into the gas. The
second source of contamination is in filling or operation of the gas-insulated equipment due to
improper handling and procedures. The third source is due to arc decomposition products.

Arc Products
The SF6 gas is referred to as a self-healing gas. This is because the gas absorbs the free electrons
generated by the arc which causes the gas to ionize. These ions recombine to reform the SF6 gas.