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GE’s Liquid Insulation Laboratory

“The Denver LIL”
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“The Denver LIL”

Dielectric Fluids “Liquid Insulation” Laboratory

•Fluid Quality Testing

•Internal Fault Detection

•Cellulose Insulation Aging

•Inhibitor (Type II Oil) analysis

•Expert Diagnostic Interpretation

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Dielectric Fluid Testing

• Fluid Type Identification
• Critical Tests
• Aging / Oxidation
• Refining Parameters
• Dissolved Gases (Faults)
• Inhibitors, dissolved metals, Furans
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Fluid Types
• Askarels (Pyranol, Inerteen, etc.)
– PCB based fluids
– 500,000 ppm (50%) to Pure (100%) PCB
– Tri & Tetrachlorobenzene solvent
• WECOSOL (Westinghouse Trade Name)
– Perchloroethylene / Tetrachlorethylene
• Silicone
• RTemp (Less Flammable Hydrocarbon Fluid)
• EnviroTemp, Others (Ester-based)
• Mineral Oils
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Critical Tests
• Dielectric Strength
• Water Content
• Viscosity (Askerals)
• Visual
– particles
– carbon
– fibers
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Aging, Oxidation
• Color
• Acidity (Neutralization)
• IFT (Interfacial Tension)
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Refining Parameters
(specification)
• Pour point
• Flash point
• Coefficient of Expansion
• Specific Gravity
• Viscosity
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Viscosity of Dielectric Fluids

Secondary purpose of Fluids is to DISSIPATE HEAT.
Viscosity of the fluid affects the ability of the fluid to flow around and
through the windings. The design of the cooling ducts must be
matched to the fluid based on its viscosity.

Viscosity & Pour Point of common Dielectric Fluids

Mineral Oil: 8 - 12 @ 40C - 40C ( - 40F)
R-Temp * (HFHC): 120-140 @ 40C - 15C ( 5F)
Silicone: 35 - 40 @ 40 C - 50C ( - 58F)
EnviroTemp FR3 * 35 Max @ 40C - 18C ( - 0.4F)

* R-Temp & EnviroTemp are trademarks of Cooper Industries

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FURANS
• Cellulose Breakdown (paper insulation)

• Five (5) different Furanic breakdown compounds; 2-

furaldehyde diagnostic

• DP = Degree of Polymerization (amount of cross

linking of cellulose molecules

• Level of 2-furaldehyde used to calculate DP and thus

APPARENT age of paper

• Compare Apparent Age to Actual on-Line Age to

determine damage. (+- 10 %)
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INHIBITORS in Mineral Oil

• TYPE I verse TYPE II Mineral Oil
– Type I: Un- inhibitor ( < 0.08% a.k.a. < 800 ppm)
– Type II: Inhibited. ( 0.1% to 0.3% a.k.a. 1000 to 3000 ppm)

• Inhibitor Compound:
– DBCP 2,6-Ditertiary-Butyl Para Cresol (used in oils)

• Inhibitors of value in Free Breathing Transformers

• Inhibitors not required in Transformers with Oil Preservation Systems:

– N2 blanket
– Conservator Tanks
– Sealed Tanks
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METALS; Dissolved in Oil

• Recommended only for a limited number of circumstances.

• Directed Flow (FOA) units: wearing of oil immersed components

• Suspect Dirt Contamination (Silica)

• Tribology:
– study of wear, frictional
– Engine Oil Analysis: thousands of RPMs in a few gallons
– Particle size must be small to either dissolved or remain suspended
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Dissolved Gas-in-Oil Analysis

(DGA)
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Dissolved Gas-in-Oil Analysis:

(DGA, Fault Gas Detection)

• INTERNAL faults
Secondary Effects

• External Faults
Secondary Effects

• Operator /
Operational Error
detection
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Dissolved Gases & Fault gases in Oil

• Atmospheric gases
(N2, O2, CO2)

• Cellulose material
breakdown (CO, CO2)

• Oil (Hydrocarbon)
break down (H2,
C2H6, C2H4, C2H2)
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Atmospheric Gases
• Nitrogen Blanket Transformer

– Normal O2:N2 > 2:30 (15)

– Minimum Ratio > 2:15 (7)
• Open Breather, Vented or
Compromised Head space:

– Ratio of O2:N2 =
Atmospheric ratio = 2:8 (4)
• Bad sample affects this ratio
significantly
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Cellulose Breakdown Gases (CO & CO2)

• CO suggested ????? limits

– Oil: <500 ppm

– Silicone (NON-Degassed ) 900 - 1200 ppm

– Silicone (Degassed) < 100 ppm

• Confirm with Hydrocarbon gases

• Compare rate of change (History)

• CO2 is of Little Diagnostic value

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Hydrocarbon (fault) Gases

• CH4 -> Low temp. heating (normal)

unless high level = poor cooling

• C2H6 -> Moderate temp. (200C) hot spot

• C2H4 -> High temp. (400C) Hot Spot

• C2H2 -> ARCING!!!!!!!

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Hydrogen (H2)
• Hydrolysis of Water ( H2O -> H2 + O2)

• Rusting (Fe + H2O -> FeO2 + H2)

• Coronal Discharge (Hydrocarbons -> H2)

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Methane CH4
• Low rate of formation is Normal in operating Transformers

• High Rate: OPERATIONAL ERROR / MAINTENACE ERROR

– Over loading
– Low Fluid Level
– Blocked radiators
– No or insufficient number of cooling fans
– Fan themo-switch not set correctly
– Transformer enclosed by 3 walls thus reducing air flow
– Xfmr located on roof or against South (sunny) side of bldg..
– Blocked cooling ducts in winding or insufficient size
– Wrong fluid type for winding cooling ducts (viscosity)
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Ethane C2H6
• Low to moderate temperature Hot Spot: (200 - 300 C)
– Undersized Conductor
– Conductor made of 5 to 8 units creating flux
between separated strands.
– By-product of higher temp hot spots
– Hot metal at surface of oil (bushing connection)
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Ethylene C2H4
• High Temperature Hot Spot (approx.. 400 C)
– Circulating Currents between Core & Tank
• second ground
– Circulating current in windings
• shorted turns. CO usually produced
– Bad Joint or Connection
• Tap connection, bolted connections, etc
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Acetylene C2H2
• ARCING !!!!!!!
• Always taken seriously!
• ANY STATISTICALLY SIGNIFICANT
INCREASE REQUIRES ATTENTION!
–External power surge
–Sparking / sputtering
–Arc with Power Follow Through
–Catastrophic winding failure
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Acetylene ( C2H2 ) = Arcing

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Fault Identification & Significance

• Concentration of gases (ppm)

• Ratios of individual gases

• “Rate of Formation” of TCG’s

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Ratios
• Hydrocarbon Gas Ratios

– CH4 / H2; C2H6 / CH4; C2H4 / C2H6

– C2H2 / C2H4; C2H6 / C2H2

• Indicates Temperature of Fault & Energy

• Faults have Specific Ratio Patterns

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Ratio Patterns
(beginners tools)
• Roger’s
• Roger’s Binary 3
• Roger’s Binary 4
• Dorenberg’s
• Duvall's Triangle
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Rate of Formation (of TCG’s)

• TCG’s = Total Combustable Gases =

(H2 + CO + CH4 + C2H6 + C2H4 + C2H2)

• Rate = [( TCG2 - TCG1 ) x V x 10E-6 ]

– __________________________________________
– (7.5 x # days)

–(Units = cubic Ft. of TCG’s /day)

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Rate of Formation Guides

• R = > 0.1 ------------------ Active fault

• 0.1 > R > 0.01 ------- High

monitor closely, perform electrical tests

• 0.01 > R > 0.0001 ------- Moderate to Low,

Overloading, Poor Cooling

• R < 0.00005 ----------------- Normal

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ppm verse Volume of Fluid

• Critical in determining the significance of gas levels

– 100 ppm in a 1,000 gallon unit is less significant than

100 ppm in a 10,000 gallon unit

– identical faults produce the same amount of gases but

dissolved in different volumes of oil = different ppm’s

• Rate of Formation formula corrects for fluid volume

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ppm verse under load Age of Oil

• Critical in determining the significance of gas

• levels100 ppm in a unit 1 month old IS significant

–100 ppm in a unit 5 years old MAY NOT be

significant

• Rate of Formation formula corrects for time (days)

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Actual Case History

Discussion
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Job #33253-96 S/N 508931 C2H2 = 20 ppm

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Job #31859-94 S/N XHS70841

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EXPERIENCE OF CHEMIST

• Knowledge of fluid breakdown characteristics

• Accuracy & Reproducibility of Laboratory

• Data base for determining trends

• Subjective & Objective ability to use data

• Laboratory is part of repair & testing facility

• Chemist - Engineer - Technician Team

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Thank You

Questions?

Example Lab Reports?

Mel Wright
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Hand outs / DGA reports & Photos

• #1) XHS70841 (previous) (PSC); Tap connection C2H2

• #2) 508931 (previous) (Yellowstone); Turn to Turn C2H2

• #3) SHV005502 (Cordero); Corona & Connectors H2 & C2H6

• #4) 018226527701 (PSC); Non Transposed conductor C2H6

• #5) M122448 (Simpson Paper); Washer with Wire left in unit C2H2 & C2H6

• #6) F962650 (NASS); Core Ground “Kidney plates” C2H4