Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
By
D.V.Jagannathan
Contents
EIGHTIES
MEDIUM HYDROFINISHED OIL
• SOLVENT EXTRACTION
• DEWAXING
• HYDRO TREATING
• HYDRO CRACKING
2. High Oxidation Stability - For longer life and trouble free operation.
3. Low Viscosity - For good circulation and cooling – better heat transfer.
4. Low Gassing Tendency - For better Gas absorption and effective diagnostics
by DGA & Safe operation
REFINING & - INFLUENCED BY QUALITY, TYPE AND DEGREE OF REFINING & ADDITIVES
STABILITY Appearance , Interfacial Tension ( IFT) , Acidity , Aromatic Content ,
Carbon Type Composition ( PNA ) , Corrosive Sulphur, , Total Sulphur Content ,
Mercaptan Sulphur Content , Oxidation Inhibitor Content
Hydrocracked Hydrotreated
Parrafinic Oil Naphthenic Oil
( Higher VI ) ( Lower VI )
• Lower the Water Content higher the electric strength & lower the dissipation losses
• Water solubility in oil depends on temperature & amount of polar / aromatic molecules
Higher aromatic content gives higher water saturation
• Water ingress takes place due to breathing of drums when stored in areas of high
humidity and temperature.
• G - 4 filtration reduces water content to achieve higher breakdown voltage but care to be
taken to avoid over heating while filtration as water solubility increases with temperature
--------------------------------------------------------------------------------------------------------------------------
• DDF is measure of dielectric losses caused by the oil , depends on ionisable and
polar molecules in the oil
• Very sensitive to contaminants like Engine Oils, Lubricants , Used Oils that can enter
from the filter machines due to their earlier use if proper care is not taken while filling
Transformers
Carbon Type Composition
PARAFFINIC - SATURATED NORMAL (Straight Chain ) & ISOPARAFFINS ( Branched Chain)
Higher Pour Points, Higher Viscosities, Low Solubility for water and
oxidation products forming precipitated sludge, Lower Thermal stability
• Mono aromatics & lower ring Poly Cyclic Aromatics up to certain levels act as
good natural radical destroying oxidation inhibitors - hence selectively retained
in the oil for better Oxidation Stability and better Gas Absorption with optimum
Electrical Properties. Preferred Aromatic Content for optimum performance – 4 to12 %
• PCA content increases with increase in boiling range and aromatic content.
• Higher molecular size Poly Cyclic Aromatics are not preferred in the oil as they
have negative effect on the electrical properties like impulse breakdown voltage
and streaming charges.
• Over refining causes depletion of preferable natural inhibitors like mono aromatics
and lower size poly cyclic aromatics
• IS 335 - 1993 Specifies Oxidation Stability at less severe conditions of 100 o C for 164 Hrs.
• Inhibition of oil with DBPC helps to increase oxidation stability but requires careful monitoring
of inhibitor content and proper replenishment when it drops below the minimum required level
( half of original level ), otherwise the inhibited oil deterioration will be much faster than
uninhibited oil - More faster in Paraffinic Inhibited Oil than Naphthenic Inhibited Oil.
New Standards for Oxidation Stability
120
IEC 60296 – 2003 (U) (T) (I)
/ BS 148 – 1998 Air Air Air
IEC 61125 C / BS EN 61125 C
110 Only in Both in
ASTM D 3487 – 00 ( 2006 ) - Type I & II IEC 60296 IEC 60296: 2003
: 2003 &
Doble TOPS – 2006 Uninhibited ,Type I BS 148: 1998
Temp 0 C. & Type II - Inhibited and not in but with
ASTM D 2440 Oxygen BS148- 1998 different limits
100
IEC 296 –1982 / IS 335 – 1993
( for uninhibited ( with 0.05 % max
& for lnhibited - Inhibitor considered
Measure only as Uninhibited Oil &
Induction Period ) for Inhibited - RBOT)
IEC 74 , IEC 474 / IS 335 Annexure C
Oxygen
NTS
0 72 Hours 164 332 500
Other Tests: PFVO & SFL in Doble TOPS – 2006 for all Types of Oils ( U , T (Type I) & I ( Type II)
ASTM D 2112 – RBOT in ASTM D 3487 – 00 ( 2006 ) for Type II Inhibited Oil &
in Doble TOPS – 2006 for Type I & Type II Inhibited oils
Also stringent Oxidation Stability limits for Special Applications in IEC 60296 – 2003
Failures due to Copper Sulphide Corrosion
The Issues:
• Large Power Transformer and Reactor failures starting in 2000.
• Doble has recorded about 25 + units that have failed worldwide.
• Many of these are units only 5 to 7 years old.
• Sudden failures with no / hardly any advance warnings.
DBDS & Selective Refining
Selective Refining
• Total Sulphur alone is not a sure indicator of whether an Oil is Corrosive.
• Corrosive character of Oil is the result of Sulphur type.
• Can be controlled by increasing Severity of treating Process to selectively
remove the unwanted Sulphurs.
Mitigation Methods
• Low levels of Corrosive content can be achieved by starting with low sulphur crude and refining by deep
Hydo de sulfurization method and severe hydrotreatment.
• Most of the standards specify only qualitative Corrosive Sulphur tests and not quantitative Corrosive &
Mercaptan Sulphur content tests. Type test provided in IS 335 and other standards are not adequate
enough to assess the exact levels of detrimental sulphur in oils as they are qualitative tests and at less
severe test conditions – ( Temp - 140 0c, Heating Time19Hrs ).
• Only IEC 60296 specifies Total Sulphur Content limit as 0.05 %, max , by ISO 14596 ( WDXRF- Wave
length X - Ray Fluorescence Spectrometry ) / IP 373 ( Microcoulometry Oxidative) Methods & Corrosive
Sulphur by DIN 51353 ( Silver Strip , Temp 100 o C , Heating Time 18 Hrs ).
• Similar test methods like ASTM D 2622 ( WDXRF ) & ISO 20847 ( EDXRF ) can also be followed for
Total Sulphur Content.
• Need to specify more stringent tests like :
A ) Modified ASTM D 1275 Method B for Corrosive Sulphur ( Temp 150 0c, Heating Time 48 hrs ,
N2 bubbling for15 mints. pre and 30 mints post start of test and keeping oxygen free subsequently )
B ) CIGRE TF. A2. 32. 01- CCD – Covered Conductor Deposition ( OIL + KRAFT PAPER, Temp 150 0 c,
Heating Time 72 hrs ) & IEC 62535 – CCD + SEM – EDX for detection of Copper Sulphide on Paper.
New Standards for Corrosive Sulphur
Other sensitive Test : DIN 51353 – IEC 60296 ( 2003 ) – Silver Strip, 100 0 C, 18 hrs. NTS
* CIGRE TF. A2 . 32 . 01 ( CCD ) / Doble – CCD / IEC 62535 – CCD with SEM – EDX
Tests Produce results close to real case operation.
Oils that previously passed the less severe Tests are NOT able
to handle the higher Temperature & Duration of the new Tests
Sulphur Vs Oxidation – Balancing Act for Refiner
Requirement
Oxidation Sulphur
Oxidation
Sulphur
Non Corrosive
High Stablility
• Increased Oxidation Stability and Non Corrosive requirements in oils are
contradictory challenges for refiner.
• Sulphur removal also causes depletion of aromatics and lowering oxidation stability.
• Thiophenes & Mono aromatics / lower size PCAs are natural inhibitors – preferred in oil for control of
oxidation stability and sulphur corrosion.
• Very low aromatic oils ( < 2 % ) have very low corrosive sulphur but also lower oxidation stability.
• Breakdown behavior with DC impulse and heterogeneous gap is very different from
the AC breakdown strength. It is sensitive to both polarity and electrode geometry.
• It is the capacity of the oil for reducing short electric shocks such as arcing of wires
or the load on transformer while being connected and disconnected during switchovers.
• Impulse Breakdown Voltage decreases with increase in PCA content and vice versa.
Possible to achieve > 200 kV value in optimum refined oils with up to maximum 3 % PCA.
2- FAL , FURANS & PCB / PCT CONTENT
2- FAL - Caused from improper distillation in solvent extracted oils during refining
leaving residual furfural or from contamination with used oil.
- Preferable to have low level of 2 - FAL and related compounds in oils.
- IEC 60296 standard specifies maximum acceptable limit of 2- FAL in
new oil as 0.05 mg / kg as measured by IEC 61198 Method.
PCB / PCT - Polychlorinated Biphenyls / Terphenyls - Not present in new insulation oils
produced from crude oils. Present only in synthetic / re-refined / used oils.
- To be measured in any mixture of old and new oils.
- Have negative environmental impact and hence banned by many countries.
- Classified as hazardous waste and require special method of disposal.
- Unused mineral insulating oil should be free from PCB / PCT ( < 2 ppm )
as tested by IEC 61619 / BS EN 61619 / ASTM D 4059 Method.
Oil Properties - Significance / Preference
Sr.No PROPERTY SIGNIFICANCE PREFERENCE
1. Density at 20 o C / Mass Volume Calculations < 0.895
Specific Gravity Values Indicate Type of Oil Paraffinic Oils – 0.81 to 0.83
Naphthenic Oils – 0.85 to 0.895
2. Kinematic Viscosity In Heat transfer / Cooling Lower Value < 12 cSt at 40o C
3. Flash Point Safety & Fire Hazard Higher Value > 135 o C (140 min )
6. Acidity / Neutralization No Corrosion / Sludge build up / affects Lower Value < 0.01 mg KOH / g
electrical properties
7. Water Content Affects electrical properties Lower Value < 30 ppm
Sludge / Paper deterioration
8. Sulphur Content Decides corrosion chances Lower Value < 0.05 %
9. Corrosive Sulphur Copper conductor corrosion To pass more severe tests -
copper sulphide formation ASTM D1275 B , DIN 51353,
Cigre TF A2.32.01 , IEC 62535
10. Oxidation Stabilitry Service life / Deterioration of To pass more severe / stringent
electrical properties / Sludge tests IEC 61125 C
Oil Properties - Significance / Preference
Sr.No PROPERTY SIGNIFICANCE PREFERENCE
11. Ageing Characteristics Service life / Deterioration of electrical To pass specified test limits to
properties / Sludge ensure ageing stability
12. Breakdown Voltage Electrical Strength – Lower values indicate Higher Values > 30 delivered
impurities like moisture / dirt / particles & > 70 after filtration treatment
13. Specific Resistance / Resistivity, Lower values indicate Higher Values > 2000 x 1012 at
ohm - cm conducting impurities 27 o C & > 100 x 1012 at 90 o C
14. Dielectric Dissipation Factor , Higher values - presence of polar compounds - Lower Values < 0.005
Tan Decides refining quality & dissolved ( Preferred - < 0.002 )
contamination
15. Power Factor , % Percentage power loss - DDF x 100 Lower Values < 0.5
( Preferred - < 0.2 )
16. Gassing Tendency Decides extent of Hydrogen Gas evolution / Lower Values in PTs < + 1 5
absorption, Important for better diagnosis by In HVDC / C T - V T s < + 5
DGA & Safe operation or < 0 ( Negative )
17. Impulse Breakdown Voltage Decides Insulation Life Higher Values > 145
18. PCA - Poly Cyclic Aromatics Decides Gassing Tendency / Health hazards Lower Values < 3 % but not
while handling < 0.75 % due to higher gassing
19. PCB / PCT Highly Hazardous / Banned Must be non detectable
< 2 ppm
20. 2 FAL / Furans Quality of refining / Higher values due to Must be Very low level
In new oil < 0. 05 ppm
Group - I ( SN ) Oils / Used / Re refined oils
Transformer Oil Standards - National Versus International
Sr. CHARACTERISTICS IS 335 / ASTM D 3487 DIN 57370 AS 1767.1 IEC BS 148 Doble TOPS
No IS12463 TYPE I / II VDE 0370 CL I / II 60296 CL I / II Uninhibited /
U/T/I Type I / Type II
1. Aniline point , o C -- 63 Min -- -- -- -- 63 Min
7. Kinematic Viscosity,
cSt ( SUS )
@100 o C Max -- 3 (36) -- -- -- -- 3
@40 o C , Max -- 12 (66) -- 16.5 / 11 12 16.5 / 11 11
@ 27 o C , Max 27 -- 25(20O c) -- -- -- --
@ 0 o C , Max -- 76 (350) -- -- -- -- 76
@ -15 o C , Max -- -- 1800 800 / -- -- 800 / -- --
@ -30 o C , Max -- -- - -- / 1800 1800 -- / 1800 --
8. Visual examination Clear,Tpt, Clear & bright Clear & Clear & Clear Clear & --
free of bright bright bright bright
suspend
matter &
Sediment
Transformer Oil Standards - National Versus International
S.No CHARACTERISTICS IS 335 / ASTM D DIN 57370 AS 1767.1 IEC BS 148 Doble TOPS
IS12463 3487 VDE 0370 CL I / II 60296 CL I / II Uninhibited /
TYPE I / II U/T/I Type I / Type II
9. Dielectric breakdown 30 / 60 30 / 50 30 / 50 30 / 50 30 / 70 30 30
voltage, KV Min.
Delivered /
After treatment
10. Dielectric breakdown -- 145 -- -- -- -- 145
voltage Impulse
conditions, 25o C, KV Min.
Needle negative to
sphere grounded 1-in
( 25.4 mm ) gap , Min.
11. Dissipation Factor
@ 60Hz, % , Max
@ 25 o C 0.05 -- -- -- -- 0.05
@ 90 o C 0.002 @ 100oC 0.005 0.005 0.005 0.005 0.3 @ 100 o C
0.30
14. Oxidation stability 100 o C 110 o C 100 o C 120 o C 120 o C 120 oC 110 o C
(Acid Sludge Test),Max . O2 O2 O2 Air Air Air, O2
72 hrs. Sludge % mass -- 0.15 -- -- -- 0.15 / 0.15 /
TAN mg KOH/mg -- 0.50 -- -- -- -- 0.1
0.5 / 0.5 / 0.3
Genl. Special
164 hrs. Sludge % mass 0.1 0.30 0.06 0.80 0.80 0.05 0.80
0.3 / 0.3 / 0.2
TAN mg KOH/gm] 0.4 0.60 0.30 1.20 1. 20 0.30 1. 20 0.6 / 0.6 / 0.4
DDF at 90 o C -- -- -- 0.50 0.50 0.05 -- --
15. Ageing Resistance
according to Baader
(140 hrs / 110 o C)
Saponification No.,
-- -- 0.60 -- -- -- --
mg KOH/gm
Sludge content, wt%, max -- -- 0.05 -- -- -- --
Dielectric Dissipation -- -- 0.18 -- -- -- --
Factor @90 o C, Max
16. Oxidation Stability - RBOT
minutes, Min -- / 195 195 -- -- -- -- NA / 195 / 220
17. Oxidation inhibitor
content % mass , Max-
Uninhibited 0.05 --- ND ND ND ( < 0.01 ) ND ND
Trace inhibited ( Type I ) -- 0.08 -- -- 0.08 -- 0.08
Inhibited oil (Type II ) 0.3 0.3 -- 0.15 - 0.4 0.08 - 0.4 0.3 0.3
Transformer Oil Standards - National Versus International
Sr. CHARACTERISTICS IS 335 / ASTM D DIN 57370 AS 1767.1 IEC 60296 BS 148 Doble TOPS
No IS12463 3487 VDE 0370 CL I / II U/T/I CL I / II Uninhibited /
Type I / II Type I / Type II
18. Corrosive Sulphur Non Non Non Non Non Non Non corrosive
corrosive corrosive corrosive corrosive corrosive corrosive
Test Method IS 335 ASTM D DIN 51353 ASTM D DIN BS 5680 ASTM D 1275 B
Annex - B 1275 A / B 1275 A 51353
Cu , 140 , 19 Cu , 140 , 19 / Ag, 100 ,18 Cu , 140 , 19 Ag, 100 ,18 Cu,100 ,19 Cu , 150 , 48
(Strip , Temp o C , Hrs )
Cu , 150 , 48
i. Pour Point -- Higher Limits ( In IS 335 & IEC 296 Class I & I A )
Changes in new IEC 60296 : 2003 from the earlier IEC 296 : 1982 Standard
Three Classes are replaced by only two namely Transformer Oil and Low Temperature
Switchgear oil.
New concept of Lowest Cold Start Energizing Temperature ( LCSET ) for different ambient
temperature conditions have been included and new property like Electrostatic Charging
Tendency ( ECT ) has been added and values for the other properties have been revised.
Class I , Class II , Class III for Uninhibited Oils & Class I A , Class II A & Class IIIA for
Inhibited Oils of IEC 296 are replaced with only three Types - (U) Uninhibited ,
(T) Trace Inhibited & (I) Inhibited in IEC 60296.
Merging differences in the physical properties between the Classes and making it as one
general specification with lower Viscosity (< 12 cSt at 40 o C) & Pour point ( - 40 o C max)
Increasing severity of Oxidation Stability Test conditions in IEC 61125 C (to 120 o C ) and
with Air instead of Oxygen to make it represent the real life Transformer operating condition.
Differentiating the duration of Oxidation Stability test to 164 Hrs for ( U ), 332 Hrs for (T)
and 500 Hrs for ( I ) grades instead of only 164 Hrs as common for all types of grades.
Including Special Application Requirements of higher oxidation stability for High Grade Oils
with more stringent limits for Total Acidity , Sludge, DDF @ 90 o C.and Sulphur Content.
Changes in IEC 60296 : 2012 – Edition 4 against IEC 60296 : 2003 – Edition 3
Sr.No PROPERTY IEC 60296 : 2003 Ed. 3 IEC 60296 : 2012 Ed. 4
1. Inhibitor Content for Not Detectable Not Detectable ( < 0.01 % )
Uninhibited ( U )
2. Other Additives - PPD , Not mandatory to report To report generic name of all additives
Gas Absorbers etc present and only in case of Inhibitor
also to report concentration
3. Passivator Content Not Specified Non Detectable ( < 5 ppm ) or
To be decided between oil supplier
and buyer
4. DBDS Content Not Specified Non Detectable ( < 5 ppm )
• IS 335 : 1993 & IEC 296 : 1982 Standards are not adequate enough to
address to the various new demands of oil performance requirements.
• Major Utilities & OEMs world over have upgraded their specifications in line
with IEC 60296 : 2003 / 2012 Standard and also taking additional special
properties from ASTM D 3487, BS148 & Doble TOPS for EHV Transformers.
• These special requirements are achieved with very low Sulphur and
low Aromatic Oils that have excellent BHT( Anti oxidant ) response.
• For still higher special application oxidation stability and non corrosive
requirements new options of Inhibited Naphthenic & Inhibited Iso paraffinIc
oils are available out of which the naphthenic oils are preferred for their
advantages of optimized higher performance levels.
Conclusions
For EHV Power Transformers > 132 it is imperative to select the right quality
High Grade naphthenic oils of upgraded specification for longer trouble free
performance.
Conclusions
Characterization of a good Transformer Oil is based on its :
POWEROIL Transformer oils meet the latest CCD - Cigre TF A2.32.01 / IEC 62535
& Modified ASTM D 1275 B Corrosive Sulphur Test Requirements.
POWEROIL Transformer Oils
Extensive range meeting all International Standards:
Special Grades are also available for meeting specific customer requirements.
Development Work Done by APAR
Long term tie ups and working closely with our international source for developing
Oils to meet latest severe requirements of Corrosive Sulphur & Oxidation Stability.
Round Robin Tests conducted for Corrosive Sulphur & Oxidation Stability
at Doble - USA, Laborelec - Belgium , Sea Marconi - Italy Laboratories.
Sulphur Speciation Tests conducted at Doble – USA & Tests for DBDS Content.
Global Approvals from major international OEMs – Siemens, ABB & AREVA T& D
Special Grades Developed
APAR GRADES MEETING STANDARD / SPECIFICATION
POWEROIL TO 1020 60 U IEC 60296 : 2003 Standard General
( Naphthenic Uninhibited ) Specification
& ESKOM 32 - 406 : 2008 Specification
POWEROIL TO 1020 60 UX IEC 60296 : 2012 & 2003 (I) General Specification
POWEROIL TO 1020 60 HX IEC 60296 : 2012 & 2003 (I) Specific Requirements
POWEROIL TO 1020 60 SNX for Special Applications - Ultra Low Sulphur
STANDARD GRADES
Sr. No PRODUCT TYPE STANDARD RECOMMENDED FOR
3. POWEROIL TO1020 - 60 UX Inhibited IEC 60296 – 2012 Ed.4 > 132 k V All types Power
General Specification & Transformers, Higher O S
BS EN 60296
4. POWEROIL TO 1020 - 60 H Uninhibited IEC 60296 – 2012 Ed. 4 > 132 k V All Types Power
General Specification Transformers
5. POWEROIL TO 1020 - 60 HT High Grade IEC 60296 – 2012 > 170 k V All types Power &
Trace Specific Requirements for Instrument Transformers
Inhibited Special Application Higher O S , Ultra Low Sulphur
6. POWEROIL TO1020 - 60 S NX High Grade IEC 60296 – 2012 > 170 k V All types Power &
& Inhibited Specific Requirements for HVDC Transformers
7. POWEROIL TO1020 - 60 HX Special Application Higher O S , Ultra Low Sulphur
8. POWEROIL TO 1020 AUT Trace ASTM D 3487 - 2009 Type I < 170 k V All types Power
Inhibited Transformers
9. POWEROIL TO 1020 AUX Inhibited ASTM D 3487 – 2009 Type II > 170 k V All types Power
Transformers, Higher O S
Types of Transformers and Application
TWO GENERAL TYPES - FREE BREATHING TYPE - WITH A DEHUMIDIFIER
APPLICATIONS :
• Special Low Sulphur and Low Gassing Oils for HVDC Systems
POWEROIL FOR 765 kV AC TRANSFORMERS
One of the many 765 kV Transformers operating with APAR’s High
Grade Naphthenic Transformer Oil POWEROIL TO 1020 60 SNX
POWEROIL Applications : Transformers & Switch Gears
• Furnace Transformers
• Shunt Reactors
• Rectifier Transformers
• Distribution Transformers
• Traction Transformers
• Instrument Transformers
• Switch Gears
Approvals
OEMs :
Global : ABB - Sweden, Areva T& D - France , Brush Electric -.UK, Daihen Electric –
Japan, Fortune -Taiwan , Hyundai , Pauwels, Siemens - Germany, Wilson
Transformer - Australia, WEG Transformers - Brazil.
India : ABB, ALSTOM, BHEL / Bharat Bijilee /Crompton Greaves / EMCO / SIEMENS /
TELK / TOSHIBA/ Transformers & Rectifiers / Voltamp
Utilities :
Global : ESKOM -South Africa ,Energy Australia /Country Energy / Powerlink - Australia,
MEW - Oman / Kuwait , SEC - Saudi Arabia, TEIAS -Turkey, TNB - Malaysia.
India : NHPC / NPCIL / NTPC / POWERGRID / State Electricity Companies
Reliance / Sterlite / Adani / Lanco
Test Labs :
TURKEY
• Supply points at
Bulk Storage
& Distribution
strategic locations
INDIA
Manufacturing
• Easy availability Rabale -Thane
Silvassa- DNH
AUSTRALIA
Bulk Storage
& Distribution
and logistics
SOUTH
AFRICA MIDDLE
Bulk Storage EAST SINGAPORE
& Upcoming Marketing
Distribution Manufac- office
-turing
• Long term business tie - ups for continuous quality raw material supply.
• ISO 9001 - 2008 & ISO 14001 – 2004 certified manufacturing facilities.