CONDITION MONITORING OF

TRANSFORMER OIL 
Parameters for condition monitoring of oil service 
Two ways are available to an operating engineer
1. To make periodic oil tests to establish trends and classify
them.
2. To conduct dissolved gas analysis to assess the internal
condition of transformers
PARAMETERS TO BE CHECKED ARE:
1. FLASH POINT
2. DIELECTRIC DISSIPATION FACTOR
3. SPECIFIC RESISTANCE
4. NEUTRALISATION.
5. MOISTURE CONTENT
6. SLUDGE %
7. BREAK DOWN VOLTAGE
8. D.G.A.
 PHYSICAL CONTAMINATION
1. Dust, fibre, metallic, particles, other solid impurities.
2. Dissolution of varnish.
3. Free and dissolved water.

CHEMICAL DETERIORATION
Oxidation resulting in acids sludges and polar
impurities.
CONTAMINATION OF GASES
a) Dissolved air from atm. Nitrogen, co2
b) Generated in oil, methane, ethane, acetylene,
ethylene etc.Before the oil is put in the
transformer, its properties should be fully
ensured.
 CHEMICAL DECOMPOSITION OF
HYDROCARBONS
 
Catalyst
RH R* + H
(Hydrocarbon) (Free radical)
  R* + O RO2*

(Peroxy radical)
 RO2* + RH RO2*H+ R*

(Hydro per oxide)

 2 RO2* Oxidation products
(Higher Temperature metal
R* + RO2*
Ions as catalyst favours
the reaction)
2 R*

Hydrocarbon RH first produces a free radical R. The radical R

now combines with the available oxygen giving peroxide RO2.
First product of oxidation peroxides reacts with any
hydrocarbon (RH) giving hydro peroxide RO2H and another free
radical R. this type of chain propagation continues till the chains
are broken adding suitable inhibitor.
 SERVICE OIL TESTS
The service oil tests to be conducted are furnished below:
Service oil tests as per IS: 1866 – 2000
INFORMATION PROVIDED BY
Sl. No. TESTS
TESTS
1
Interfacial Tension Sludge present in the oil.
2
Neutralisation Number Acid present in the oil

3 Moisture content Reveals total water content or

(ppm) cellulosic deterioration.

Sudden drop in flash point indicates of

4
Flash point unsatisfactory working condition of
transformer.

5 Sludge Indicated deterioration

 Reveals presence of moisture, resins,
Dielectric Dissipation
6 varnishes or their products of oxidation
Factor
in oil

Conductive contaminants and moisture

7 Dielectric strength
present in the oil.

8 Resistivity Indicative of conducting impurities.

Reveals ppm of combustible gases

9 Dissolved Gas Analysis dissolved in the oil to assess the internal
condition of the transformer.
A Typical Method to Maintain Test Record for Transformer Oil
 TRANSFORMER DATA OIL DATA
Location……………………… Oil supplier……………………
Manufacture’s Name………… Code Designation of Oil………
Manufacture’s Number………. Inhibited or
Un-inhibited…………………….
 User’s
reference………………
Number of phases……………. Type of Inhibitor
If present……………………………..
 Voltage Ratio…………………
Outdoor or Indoor…………….
Type of cooling………………. Quantity of oil in
The system………………………….
 Withor without Conservator……
Type of Breather…………
 INSTALLATION DATA

Filled on………………………………….
Commissioned on………………………..
Maximum load…………………………...
Maximum oil temperature………………..
Normal load………………………………
Normal Oil Temperature…………………
 MAINTENANCE OF DATA
1. Date of sampling……………………..
2. Topping up done up………………….
Type and quantity of oil added………
3. Note on abnormal operations………...
4. Oil filtered on………………………...
5. Breather reconditioned on……………
6. Physical observation…………………
7. Tests conducted:
a. Interfacial Tension.
b. Neutralisation Number
c. Moisture content (ppm)
d. Flash point
e. Sludge
f. Dielectric Dissipation Factor
g. Dielectric Strength
h. Resistivity
 TABLE 1: APPLICATION AND INTERPRETATION OF
TESTS ON OIL IN TRANSFORMERS
 AS PER IS: 1866 – 1983
Permissible
Sl.
Equipment limit, Action if outside
N Characteristic voltage satisfactory for permissible limit
o.
use
Recondition it the
Specific
value of dielectric
1 resistance at All
0.1 * e12 dissipation factor
90° c ohm- voltages
permits, reclaim if
cm, min
not.
Dielectric
2 dissipation > 145 kv 0.2
Reclaim
factor at 90° c, < 145 kv 1.0
max
Sl. Equipment Permissible limit, Action if outside
Characteristic
No voltage satisfactory for use permissible limit

Neutralization
All
3 value, 0.5 Reclaim
voltages
mg / KOH / g

Precipitate All No perceptible

4 Reclaim
sludge voltages sludge

Decrease in flash
point 15°c (max) of
All Reclaim after
5 Flash point the initial value,
voltages checking causes.
minimum value
125° c
 Permissible Action if
Sl.
Characteristi Equipment limit, outside
N
c voltage satisfactory for permissible
o
use limit
Interfacial
tension at All
6 0.015 Reclaim.
27°c, n/m, voltages
min
145 kv +
50kv min Recondition
above
Electric 40 kv min Recondition
7 < 145 kv
strength 40 kv min Recondition
> 72.5 kv
30 kv min Recondition
< 72.5 kv

Water > 145 kv 25 ppm Recondition

8
content ppm < 145 kv 35 ppm Recondition
 LIMITING VALUES IS: 1866 – 1983
Test Equ. Voltage Method Limit

> 145 kv 50
 
Electric strength < 145 > 72.5 40
Is: 6792
kv< 72.5 kv 30

Water content > 145 kv   25

ppm, max < 145 kv Is: 335 35

Specific
resistance @ 90, All voltage Is: 61 0.1
10 E12 ohm, cm

Tan delta @90, > 145 kv 0.2

Is: 6262
max < 145 kv 1.0
ACIDITY mg ALL
IS: 144 0.5
KOH / g, Max VOLTAGE

ALL
IFT, N/m. Min IS: 6104 0.015
VOLTAGE

FLASH POINT ALL IS: 1448

125
Deg C, Min VOLTAGE Max Dec 15

SEDIMENT
AND / OR ALL
IS: 1666 NIL
PRECIPITABLE VOLTAGE
SLUDGE

FOR TRANSFORMERS IN SERVICE

GENERAL
Properties Condition Remedies

Breakdown
Low
voltage Filtration under vacuum
+ temperature
Moisture High

Dielectric
dissipation High
factor Filtration as above if the
cause is moisture or other
Volume
Low
resistivity

IFT Low Reclamation

NV HIGH  

INVESTIGATE THE
FP LOW
CAUSE

SLUDGE % HIGH DE-SLUDGING

SUGGESTED LIMITS FOR IN SERVICE OILS GROUP I BY VOLTAGE CLASS,
BASED ON IS: 1866-1983
LIMITS
___________________________________________________

VOLTAGE CLASS
PROPERTIES
145 KV & 72.5 KV BELOW
ABOVE & < 145KV 72.5 KV
ELECTRIC STRENGTH ≥ 50 ≥ 40 ≥ 30
(MIN) (MIN) (MIN)
NEUTRALISATION VALUE ≤ 0.1 ≤ 0.1 ≤ 0.1
(mgKOH/g) (MAX) (MAX) (MAX)
INTERFACIAL TENSION N/m ≥ 0.015 ≥ 0.015 ≥ 0.015
(MIN) (MIN) (MIN)
DIELECTRIC DISSIPATION ≤ 0.2 ≤ 1.0 ≤ 1.0
FACTOR AT 90° C (MAX) (MAX) (MAX)
WATER CONTENT, ppm ≤ 25 ≤ 35 ≤ 35
(MAX) (MAX) (MAX)
SPECIFIC RESISTANCE
Ohm-cm 0.1x1012 ≥ 0.1x1012 ≥ 0.1x1012
 Suggested limits for in service oils group ii by voltage class
(reconditioning) based on
IS: 1866-1983
LIMITS
VOLTAGE CLASS
PROPERTIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --------------
145 KV & 72.5 KV BELOW
ABOVE & < 145KV 72.5 KV
Electric strength < 50 < 40 < 30
Neutralisation 0.1 0.1 0.1
Value (mg.KOH/g) UPTO 0.5 UPTO 0.5 UPTO 0.5
Interfacial < 0.015 < 0.015 < 0.015
Tension N/m (MIN) (MIN) (MIN)
Dielectric dissipation > 0.2 > 1.0 > 1.0
Factor At 90° C
Water Content, ppm > 25 > 35 > 35
Specific resistance < 0.1 x1012 < 0.1 x1012 < 0.1x1012
Ohm-cm
 TABLE IV
Suggested values for in-service oils group II by voltage class
(reconditioning) based on IS: 1866 (1983)

LIMITS
Voltage Class
Properties
145 Kv & 72.5 Kv Below
Above & < 145kv 72.5 Kv

Electric Strength < 50 < 40 < 30

Neutralisation Value 0.1 0.1 0.1
(mg KOH/g) Upto 0.5 Upto 0.5 Upto 0.5
Interfacial Tension < 0.015 < 0.015 < 0.015
N/m
Dielectric Dissipation > 0.2 > 1.0 > 1.0
Factor at 90° C
Water Content, ppm > 25 > 35 > 35
Specific Resistance < 0.1 < 0.1 < 0.1
Ohm-Cm
 GROUP III OILS:
To categorize under group III, the parameters should be
well beyond the limits proposed in table IV. Such oils
should be initially filtered under vacuum and temperature
to verify whether the properties improve or not. If
properties like Dielectric Dissipation Factor, Interfacial
Tension do not improve on filtration, then there is a case
for oil to be replaced.
Properties of oils evaluated in transformers of a utility

Sl. Voltage
BDV Tan Delta Resistivity IFT Acidity
No class

1 33 / 11 18 0.0321 0.914E12 30 0.1

2 66 / 11 38 0.0392 0.046E12 30 0.3

3 66 / 11 47 0.29 0.666E12 10 0.5

4 220 / 11 27 0.0108 2.75E12 30 0.1

5 220 / 11 35 0.263 0.912E12 30 0.1

Properties of oils evaluated in transformers of a utility
Sl. Voltage Tan
BDV Resistivity IFT Acidity
No class Delta

16 220 / 66 45 0.0032 6E12 30 0.1

17 66 / 11 47 0.0063 5.86E12 30 0.2

18 66 / 11 11 0.014 2.68E12 30 0.1

19 66 / 11 8 0.039 2.18E12 30 0.1

20 66 / 11 24 0.023 1.76E12 25 0.2

21 66 / 11 13 0.011 6.68E12 30 0.5

 Properties of oils evaluated in transformers of a
utility oil to be replaced/reclaimed
Capacity Voltage in Tan
BDV Resistivity Acidity IFT
in MVA KV Delta

5 10
33 / 11 29 1.000 0.0177 0.6
5 - 10
33 / 11 1.050 0.0151 0.6

5 110 / 33 / - 15
0.820 0.0194 0.6
11
5 10
33 / 11 24 0.270 0.0643 0.8
5 15
33 / 11 29 1.050 0.0168 0.8
5 15
33 / 11 37 0.720 2.3700 0.8
5 10
33 / 11 44 1.170 0.0150 0.8
 Properties of oils evaluated in transformers of a
utility – oil to be replaced/reclaimed
Capacity Voltage in Tan
BDV Resistivity Acidity IFT
in MVA KV Delta

5 33 / 11 44 0.990 0.0175 0.5 10

5 33 / 11 30 0.370 0.0452 0.8 15

5 33 / 11 39 0.290 0.0589 0.8 15

5 33 / 11 33 0.190 0.0905 0.8 10

5 33 / 11 29 0.680 0.0227 0.8 15

Contd…
5 33 / 11 63 0.880 0.0187 0.6 15

5 33 / 11 27 0.775 0.0222 0.6 10

5 33 / 11 22 1.100 0.0157 0.6 10

5 33 / 11 18 0.620 0.0283 0.8 10

5 33 / 11 15 0.700 0.0243 0.6 10

 CONCLUSIONS
a. In view of the importance of service oil tests, all tests have to
be carried out as per IS: 1866 systematically and periodically,
as a part of maintenance schedule, as no single test is a reliable
indicator.
b. The periodic testing will help O & M personnel to build up
databank and case histories of power Transformers.
c. Periodic testing will help to know the oil condition as well to
know growing of any incipient faults by Dissolved Gas
Analysis.
d. The preventive maintenance followed by all utilities will result
not only savings in O & M costs but also prevent any
premature breakdown / Failures besides improving the overall
system reliability.
 Test required to assess the level of oil
degradation 
Screening tests: - Laboratory evaluation can be minimised by
performing screening tests at site.

The tests are:

1. Appearance
i. Colour
ii. Visible particles
iii. Haziness or cloudiness
2. Acidity by colour
CPRI acidity testing kit
3. Interfacial tension test
By field method
4. Quality index
By Myers method
 PORTABLE ACIDITY TESTING KIT

 A portable acidity testing kit was developed by cpri to quickly

check the acidity of transformer oil at site
 Procedure:

A)  1.1 ml of oil in a test tube.

B)  Add 1ml of rectified spirit.
C)  Shake well
D)  Add 1 ml. of alkaline solution
E)  Add few drops of universal indicator
F)   Match the colour with the colour chart to arrive at the acidity
value.
Advantages: Test can be performed by semi skilled personnel at
the site of transformer / remote areas.
 SHAPES OF SPOTS
 
OIL ALONE INDICATOR ALONE

NEW OIL + INDICATOR SERVICE OIL + INDICATOR

SHAPES OF INDICATOR SPOT ARE DEPENDENT ON IFT OF OIL

 Recommended limits of unused mineral oil filled in new
power transformer
Property Highest voltage equipment (kV)

  <72.5 72.5 to 170 > 170

Clear, free from sediment and suspended

Appearance
matter

Density @ 29.5° C (g / cc),

0.89 0.89 0.89
max

Flash point, (° C), max 140 140 140

Neutralisation value, mg /
0.03 0.03 0.03
KOH /g
Water content, ppm, min 20 15 10

Interfacial tension, N/m, min 35 35 35

Dielectric Dissipation Factor

0.015 0.015 0.010
@ 90° C, 40-60 Hz², max

Resistivity, ohm-cm, min 6 6 6

Breakdown voltage, kV, min 40 50 60

Oxidation stability of
 
uninhibited oil
 
 
 
Neutralisation value,
0.4 0.4 0.4
Mg.KOH/g, min
0.1 0.1 0.1
Sludge (% by Mass), max
 
 
 
oxidation stability of inhibited
Similar values before filling
oil - induction period
 POSSIBLE CASES OF FAILURES
1. Failure in appearance:
i. Colour.
ii. Rusty particles.
Prolonged storage in the case of drums contamination from
the tankers and deliberate adulteration
• Failure in physical properties
i. Low flash point
ii. High pour point
iii. High / low viscosity.
Prolonged storage combined effect of thermal and oxidative
degradations and chemical reactions
3. Failure in electrical properties
i. Low dielectric strength
ii. Low resistivity
iii. High dissipation factor
Prolonged storage ingress of moisture and bad sampling
4. Non attainment of IR values
i. Improper design / construction
ii. Poor quality of construction and solid
iii. Insulating materials