2-2015 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 43

Anna GOS, Jarosław SKOWROŃSKI, Paweł MROCZKOWSKI

Institute for Sustainable Technologies – National Research Institute, Radom
[email protected], [email protected],
[email protected]

INSULATING OIL REGENERATION

AND ITS INFLUENCE ON THE TECHNICAL SAFETY
OF TRANSFORMERS

Key words
Paper-oil insulation, insulating oil, diagnostics of transformers, oil regeneration.

Abstract
Insulating oils are the coolants of the transformer winding. During the
operation, they are subjected to numerous and diverse extortion; they
accumulate destruction of a variety of products of structural elements of the
transformer in themselves and, as a result they change their own properties. The
systematic analysis of composition and characteristics of the insulating oil
provides information about the condition of the whole transformer. The article
presents the results of an investigation of insulating oil condition during
operation of a transformer, and it proposes actions to monitor the insulation oil
and prolong its service life. Regular tests allow the regeneration of oil (e.g. by
vacuum treatment, drying) at the right time, which eliminates the need for costly
oil exchange in many cases. Monitoring of the insulating oil also has a large
impact on the technical safety, which is related to risk mitigation of major
accidents, such as electric shocking or even transformer explosions. The
obtained results confirm the validity of the insulating oil regeneration process as
44 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 2-2015

a method for decreasing operating costs, which is simultaneously efficient and

environmentally friendly.

Introduction
The proper functioning of the transformer is determined by the condition of
the oil-paper insulation. Transformer oil serves as a coolant, restricts the access
of air, protects against corrosion, and serves electrical insulating functions. The
main factors that affect the intensity of the transformer oil aging process during
operation are high temperature, the impact of oxygen, the presence of water, the
catalytic effect of the copper and the depolymerization of cellulose in paper
insulation. The cellulose insulation is intended to protect windings made of
electrolytic copper [1, 2]. The stability of the transformer insulation determines
the transformer operating time and depends on many factors, such as
temperature, humidity, impurities, winding displacement at points of expansions
and contractions, and vibration [3, 4]. The more wetted cellulose is, the faster
the process of depolymerization goes. Under the influence of load and time, the
transformer occurs the aging process. The nominal life of a transformer is
estimated at approx. 30 years; however, economic considerations have shaped
the trend of maximizing the functional life transformers, which entails the need
to carry out the regular inspections, modernization, and repairs. These actions
are intended to ensure the faultless operation of transformers [5].
Extending the functional life of a transformer requires the fulfilment of the
following basic conditions affecting its operation [1]:
• Protection against external factors;
• Maintaining the temperature and the load;
• Controlling the insulating oil parameters;
• The implementation of maintenance and renovation; and,
• Conducting a comprehensive diagnosis of the unit’s technical condition.
One of the primary transformer operation management tools is their
comprehensive diagnostics [6]. Proper control of the technical condition of the
transformer is based, inter alia, on the determination of moisture and aging of
paper insulation, insulating oil moisture measurement, measurement and
localization of partial discharge, dielectric loss factor measurement at high
voltage and winding resistance, transformer winding deformation detection, and
the investigation of gases dissolved in the oil (DGA – Dissolved Gas Analysis)
[3, 7]. The diagnostic tests selected depend on the type and power of the
transformer. It is necessary to appropriately select suitable research techniques,
because transformer failures have very serious consequences, both technical and
economic. For example, these are power failure costs and the costs of repair and
replacement of damaged equipment and facilities, including the contamination
of the area. An improperly supervised and maintained transformer can cause
2-2015 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 45

environmental problems associated with the possibility of still commonly used

mineral transformer oils entering into the environment. Preferably, it would be
the best to avoid it leaks into the ground and, consequently, contamination of
water reservoir and watercourses [1, 8].
Transformer oil exploitation involves the gradual deterioration of its
operating parameters, often as a result of contamination, which may be
impurities such as sand, corrosion products, microfiber cellulose, or chemicals
such as water, furan derivatives, organic acids, and gaseous products [9].
If irregularities of the technical condition of the transformer or transformer
oil, they can be removed depending on their degree of complexity.
One of the major solutions is the regeneration of the oil. This procedure
allows improving the operating characteristics, and thus extending the faultless
operation of the transformer.

1. Insulating oil regeneration methods

For transformer oil regeneration, physical, chemical, and physico-chemical
methods are applied. The selection of the appropriate method depends on the
degree and the type of oil contamination. Moisture can be removed by draining
oil, solid contaminants are removed by appropriate purification, and gaseous
products are removed by degassing the transformer oil. For transformer oil
purification, the following methods are applied [1]:
• Filtration,
• Centrifugal separation,
• Sorption, and
• Electrostatic separation.
Filtering methods are based on the use of porous materials and allow
removal of solid contaminants such as metal particles, carbon black,
microfibers, etc. Filtration methods include gravity filtration, in which the oil
flows through the filter by gravity forces, pressure filtration, wherein the oil
passes through the filter due to the pressure difference before and behind the
barrier filter, filtration through extrusion, wherein the solid particles are
separated from the oil as a result of extrusion through a filter using a press. The
advantage of filtration methods is their high process effectiveness.
The centrifugal methods use the phenomenon of the movement of the
impurities contained the oil to separate them. The rates of deposition of the
particulate impurities contained in the oil depend on the size and the density
difference between them and the oil. In practice, two methods for producing
centrifugal force field are used: driving the oil in centrifugal rotation in
a stationary apparatus called a hydrocyclone or putting the oil into a centrifuge,
which is the more popular technique. The advantage of using these techniques is
the ability to quickly remove water and solid contaminants.
46 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 2-2015

Sorption methods are based on the selective retention of the contaminants

using absorbents, including aluminosilicates. Selectively removing polar
impurities improves the colour of the oil, the thermo-oxidative stability, and
dielectric properties. The methods of sorption also reduce acidity and the
content of the resins and asphaltenes. A common sorption method is the
percolation method, which involves passing oil through an adsorbent layer
usually placed in a column. This method may use both stationary and portable
devices. The advantages of sorption methods are the low cost of the purchase
and maintenance of the apparatus, and the fact that they do not require high
pressures and temperatures. The disadvantage is the problem of the waste
management of sorbents.
Electrostatic methods rely on the release of polar impurities (endowed with
a partial electrical charge) that are deposited on the respective electrodes
constituting the cover of the capacitor. Electrostatic methods allow for the
removal of moisture as well as solids from transformer oils, which translates
into an improvement in the dielectric parameters and physicochemical.

2. Research methodology
As the object of investigation, insulating oil working in a 49-year-old
transformer with a power 3.6 MVA was chosen. This oil had not been subjected
to physical and chemical analysis for over 10 years, which makes it a suitable
subject for study. Special analysis for insulating oils collected from such power
transformers were performed, including the following: visual evaluation of the
sample oil (clarity, separated water content, the content of foreign bodies), acid
number, flash point, and the content of dissolved water. Analysis of the
insulating qualities of the oil was also performed: breakdown voltage,
resistivity, and dielectric loss factor. The used methods have a technical
meaning and allow the correct diagnosis of the technical condition of
transformers. Appearance evaluation of the transformer oil is based on visual
observation of a sample having a thickness of about 10 cm in transmitted light at
ambient temperature. This method allows determining the clarity of oil, the
presence of visible contamination, and separated water. Water content
determination was performed by coulometric titration using a Metrohm
apparatus proposed by Karl Fischer. The acid number was determined by acid-
base titration with a glass burette and titrated chemicals. Determination of flash
point was performed with a Pensky Martens closed cup semi-automatic
apparatus by Herzog. To determine the value of breakdown voltage, automatic
apparatus by MEGGER was used. For each sample, 6 determinations were
performed and the relative standard deviation was found. Measurements of the
resistivity and dielectric loss factor were made using an automatic oil tester by
BAUR DTL C. The oil resistivity measurements were performed at a constant
2-2015 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 47

voltage at a field strength of 0.25 kV/mm after 60 seconds from the time
of application of voltage. The oil tgδ measurement was performed under
alternating voltage of 50 Hz frequency and an intensity of the electric field
of 1 kV/mm.
To examine the degree of cellulose insulation aging, the measurement of
the concentration and changes in the content of furan compounds in particular 2-
furfural (2 FAL) was performed. The content of furan derivatives in the oil was
determined using the authors’ methodology developed under the guidelines of
the standard PN-EN 61198:2002. Analyses were performed using a high
performance liquid chromatograph Perkin Elmer equipped with a UV-VIS
detector for separation using a C18 reverse phase column.

3. Test results
An exemplary analysis chromatogram of an insulating oil collected from a
49-year-old transformer with a power of 3.6 MVA is shown in Fig. 1.

2 FAL

Fig. 1. The chromatogram of the transformer oil

In the chromatogram shown in Fig. 1, the peak of 2-furfural is marked.

Based on a calibration curve prepared earlier, the content of 2-furfural in the test
oil is 0.09 mg/kg. Such a low content of this compound in the oil provides
minimal cellulose insulation aging, which has the non-negative effect on the
mechanical strength of the cellulose. [10].
The results of physico-chemical properties of insulating oil are shown in
Table 1. The tested oil successfully passed a visual assessment. It was limpid,
and there was no separated water content or the presence of particulate matter.
Resistivity, the dielectric loss factor, acid number, and flashpoint meet the
requirements of the relevant standards. However, it was found that the value of
the breakdown voltage is lower than required, which is undoubtedly a result of
excessive water content in the oil, which was much higher than the permissible
values. As a result, it was found that the test oil does not meet the requirements
of the posed insulating oils in transformers group II in terms of breakdown
48 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 2-2015

voltage and water content. Allowing such oil to continue to work in the
transformer without regeneration is therefore impossible. The oil was
regenerated through the filtration under reduced pressure, after its previous
heating to a temperature that allows the simultaneous dehydration. This
procedure prevents the overheating of the oil during dewatering and its
degradation and enables a reduction of the amount of heat energy needed to heat
the oil. The properties of the regenerated oil are shown in Table 1.

Table 1. Transformer oil test results

The The oil sampled

Type of the Assessment The oil after
Unit required from the
test criteria regeneration
value transformer
The clarity – PN-EN Limpid Limpid Limpid
60296:2012
The separated – PN-EN Does not Does not contain Does not
water content 60296:2012 contain contain
The suspended – PN-EN Does not Does not contain Does not
solids content 60296:2012 contain contain
The kV PN-EN ≥ 40 28.7*) 68.8*)
breakdown 60156:2008
voltage
The relative % PN-EN ≤ 20 19 10
standard 60156:2008
deviation
The resistivity Ωm PN-EN ≥ 5 x 109 5.8 x 1010 7.4 × 1010
at 50°C 60247:2008
The dielectric – PN-EN ≤ 0.07 0.003608 0.003225
loss factor Tgδ 60247:2008
(50ºC)
The water ppm PN-EN ≤ 25 31.1 13.1
content by 60814:2002
Karl Fischer
method
The acid value PN-ISO ≤ 0.25 0.09 0.09
[mg KOH/g] 6618:2011
The flash-point °C PN-EN-ISO ≥ 130 154 154
2719:2007
2 FAL content mg/kg PN-EN - 0.09 0.09
61198:2002
*) The arithmetic mean of 6 measurements

As the presented data show in Table 1, after oil filtration under reduced
pressure, the water content was reduced by 70%, which resulted in an increase
in the value of breakdown voltage to the required level. Other parameters such
as resistivity and dielectric loss tgδ were also improved. These data allow
concluding that, as a result of insulating oil recovery by filtration under reduced
2-2015 PROBLEMY EKSPLOATACJI – MAINTENANCE PROBLEMS 49

pressure, it is possible to restore the oil properties required for the insulating
oils used in transformers Group II.

Summary
In order to assess the technical condition and suitability for further
transformer operation, a series of diagnostic tests were performed. Physical and
chemical properties of the dielectric oil were investigated. Visual inspection of
the sample, the acid number, water content, breakdown voltage, and dielectric
loss factor were determined. Based on the test results, it was found that the
tested transformer oil does not meet the requirements for insulating oils in
transformers group II in operation. The oil contained too much water and had
breakdown voltage below the required limit. The content of furan derivatives
indicated a good state of transformer cellulose insulation. Taking into account
the results of the analyses, it was decided to regenerate the oil such way that
removing the excess water does not degrade the oil. The oil was filtered under
reduced pressure. As a result of such a treatment, the water was removed from
the oil, which raised value of the breakdown voltage to the required level. An
additional benefit resulting from the purification of oil and reduction of its water
content is to slow or inhibited degradation of cellulose insulation, which is
hydrolytic and quickly occurs in the presence of water. Oil with such properties
can be further exploited in a transformer in accordance with its intended
purpose and technical parameters. However, due to the age of the transformer
(49 years), there must be systematic control of the stat of the transformer oil and
its regeneration, when necessary. This will enable the safe and reliable operation
well beyond its originally estimated service life.

Scientific work executed within the Strategic Programme “Innovative

Systems of Technical Support for Sustainable Development of Economy” within
Innovative Economy Operational Programme.

References
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Diagnostyka – Regeneracja, Wydawnictwo Naukowe Instytutu Technologii
Eksploatacji – Państwowego Instytutu Badawczego, Radom 2010.
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furfural formation, Electrical Insulation Conference and Electrical
Manufacturing & Coil Winding Technology Conference (2003) 283–288.
3. Klistala T., Przegląd metod diagnostycznych układów izolacyjnych
transformatorów dużej mocy w eksploatacji. PAK (2008), 11, 754–759.
4. Van Bolhuis J.P., Gulski E., Smit J.J., Monitoring and diagnostic of
transformer solid insulation, Power Delivery (2002) 17, 2, 528–536.
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5. Malewski R., Subocz J., Szrot M., Płowucha J., Zaleski R., Podstawy oceny
opłacalności modernizacji transformatorów, Energetyka (2006)12, 884–891.
6. Matulewicz W., Diagnostyka transformatorów energetycznych (1998) WPG.
7. Krüger M., Koch M., Kraetge A., Rethmeier K., Diagnostic measurements
on power transformers, Energetyka (2009), 5, 299–305.
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elektroizolacyjnych. Mat.konf. Transformatory w eksploatacji, Sieniawa
(2002) 103–111.
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Regeneracja olejów elektroizolacyjnych i jej wpływ na bezpieczeństwo

techniczne transformatorów

Słowa kluczowe
Izolacja papierowo-olejowa, olej elektroizolacyjny, diagnostyka transforma-
torów, regeneracja olejów.

Streszczenie
Oleje elektroizolacyjne są czynnikiem chłodzącym uzwojenie transformatora.
Podczas pracy urządzenia poddawane są one licznym i różnorodnym wymuszeniom,
gromadzą w sobie różnorodne produkty destrukcji elementów konstrukcyjnych
transformatora i, w efekcie, zmieniają swoje właściwości. Systematyczne badanie
składu i właściwości oleju elektroizolacyjnego dostarcza więc informacji o stanie
technicznym całego transformatora. W artykule przedstawiono wyniki badań stanu
oleju elektroizolacyjnego w trakcie eksploatacji transformatora oraz zaproponowano
działania mające na celu kontrolę stanu izolacji olejowej i wydłużenia czasu jej
eksploatacji. Regularne badania pozwalają na regenerację oleju (np. poprzez
wirowanie, osuszanie) we właściwym czasie, co w wielu przypadkach eliminuje
konieczność kosztownej wymiany oleju. Monitoring właściwości oleju
elektroizolacyjnego ma również duży wpływ na bezpieczeństwo techniczne
związane z ograniczeniem ryzyka wystąpienia poważnych awarii, takich jak
przebicia elektryczne, a nawet wybuch transformatora. Uzyskane rezultaty
potwierdzają zasadność procesu regeneracji oleju elektroizolacyjnego jako metody
obniżającej koszty eksploatacji, a przy tym efektywnej i przyjaznej środowisku.