Reclamation of Transformer Oil

Results of Case studies (Table 1)

No Perameters Case 1 Case 2 Case 3 Case 4 Case 5
1 Voltage class (KV) 132/66 132/66/11 66/11 66/11 132/11
2 Rating (MVA) 50 20 20 18.4 20
3 Date of Commission Sep-78 Jan-76 Mar-75 Oct-76 Apr-80
105 (near to
Degree of fault site),322
4 237 108 298 345
Polymerization(DP) (away from fault
site)
5 2-fufural content(ppm) 9.2 9 12 7.5 6.6
Dissolved oxides of
6 2258 4573 5490 5822 1541
carbon(ppm)
Tthemal fault in winding failure Paper and
Electrical Winding got
7 Fault observed Y-phase on due to thermal winding
discharge melted
H.T.side fault insulation burnt
Repair Repair
Replace Replace Replace damaged damaged
8 Suggestion
winding winding winding portion but portion but
monitor closely monitor closely
 Results of Case studies (Table 2)
No Perameters Case 6 Case 7 Case 8 Case 9 Case 10
1 Voltage class (KV) 220/132 66/11 66/11 132/66 132/66
2 Rating (MVA) 150 5 10 40 50
Failed with in
six months in
3 Date of Commission Mar-76 Jan-79 Aug-75 Feb-86
gaurantee
period
Degree of
4 780 480 403 960 810
Polymerization(DP)
5 2-fufural content(ppm) 1 3.9 6 Nil Nil
Dissolved oxides of
6 417 1242 1490 236 397
carbon(ppm)
winding
Bucholtz winding failure Failed due to
distorted due to
7 Fault observed operated in due to thermal internal short Electrical fault
improper
June 96 fault circuit
pressing
Replace Replace Repair
Repair Repair
damaged damaged damaged
8 Suggestion damaged damaged
portion and portion and portion but
portion portion
recommission recommission monitor closely
 International scenario

• World oil crisis – conservation – reclamation

• Simple process – fullers’ earth – antioxidant
• Modern reclamation plant – settling tank,
Transformer pump, filter / Water separator, clay
towers, Vacuum dehydrators, Final filter,
Inhibitor injection system etc.,
 Process of reclamation
1. Centralised reclamation site for pooled oil.
2. Mobile reclamation of pooled oil.
3. On-site reclamation.
• Most of the advances countries adopt the process
of reclamation & re-use the oil in their supply
systems. In U.S.A. the oils are reclaimed and
used in high voltage Transformers also – table.
•  Recently ABB, Norway & Sweden have
brought out a technical paper in which they have
described the experiences from oil reclaiming on
more then 170 energised Power Transformers.
Table: Suggested test limits for reclaimed oil in transformers and
reactors by voltage classification (after filling but before energizing)

Property / Test Limit

ASTM Test
Above 69KV Method
Voltage class 69KV and Below 345 and above
thru 288KV

Dielectric breakdown
30 35 35 D-877
voltage 60 Hz minimum,
KV

Dielectric breakdown
26 26 26 D-1816
voltage, 60 Hz, 040 gap,
minimum, KV

30 30 30 D-1816
Desirable, KV

Neutralisation number 0.05 0.05 0.05 D-974

maximum, mg, KOH/g
Interfacial
tension
minimum, dyes /
30 30 35 D-971
cm (mN/m)
15
Water 20
maximum, ppm
35 D-1533
(10Desira
ble)
Gas content D-1817
when specified, 2
maximum
2 2 or
percent² D-2945
Color,
maximum
1.5 1.5 1.5 D-1500

Condition –
visual
Clear Clear Clear D-1524
 IEEE Insulating fluids subcommittee
(proposed April, 1980) project 637

Some transformers are equipped with

diaphragms to prevent the introduction of air.
The dissolved gas content in these
transformers should be maintained in
accordance with the manufacture’s
recommended limits.
Reclamation of discarded & unserviceable
Transformer oil Indian scenario
 
Preamble
•Mineral oils
•Oxidation
•Acids / Sludges
•Discarded / Reclaimed
Need for reclamation:
 
•Power generation – huge quantity of oil
• World oil crisis – depletion of petroleum
crudes – increase demand
• Conservation / reclamation
• Substantial savings / bring down of the
petroleum crudes for processing new
Transformer oil.
Field Trials:

Simple indigenous process developed

SEB’s / Reclamation plants
Reclaimed oil successfully used in
distribution Transformers
Contemplating use in power
Transformers – lower ratings
 RECONDITIONING

PROCESS OF FILTERING & VACUUM DRYING

REMOVES: -

• PARTICLES
• MOISTURE
• DISSOLVED GASES
 RECLAMATION
Process of treating service oil with adsorbent
materials and reclamation Removes:

• ACIDS
• SLUDGE
• DECOMPOSITION PRODUCTS
• PARTICLES
• MOISTURE
• DISSOLVED GASES
 FULLERS EARTH

Hydrated magnesium aluminum silicate

ANTIOXIDANT

2, 6 Ditertiary butyl para-cresol

 RECLAMATION PROCESS
Types of reclamation

1. Batch process
2. Percolation process
Batch process
Pooled oil from different transformer
are treated with fine earth materials
for 2 hrs, allowed to settle, decant &
filtered.
• Slow process
• Large working space
• On-line reclamation impossible
Percolation process

Aged oil is percolated through coarse

grained earth materials under
pressure, followed by filtration &
addition of antioxidant

• Suitable for mobile reclamation

 COMPARATIVE PERFORMANCE OF USED TRANSFORMER OIL RECLAMATION PROCESSES
ORDER OF CHANGE PROCESS
PERFORMANCE CRITERIA
Vacuum Adsorptoin Distillation
Acid--Clay Extraction Hydrogenation
Evaporation Microfiltration Microfiltration
1 Yeild of Reclaimed oil %of used oil 96-98 94-96 92-95 88-90 90-95 98-99
2 Adaptability small scale Mobile small scale Mobile All capacities Medium scale Large scale V large scale
3 Application as Maintenance tool Yes Yes No No No No
A little
4 Aromatics content No change A little change Reduces No change A little
change
5 Environmental problem None None None Severe Sevvre Reduces
6 PRODUCT QUALITY
1. Neutralization Number Increases(0.005) Upto specs Upto specs Upto specs Upto specs Upto specs
Improves to Improves to Improves to Improves to Improves to
2.breakdown voltage Imprvoes(5-10 KV)
original original original original original
Imprvoes(0.0005- Improves to Improves to Improves to Improves to Improves to
3.power factor
0.001) original original original original original
Imprvoes(5-
4.Resistivity
15X10E12)
5.Pour point No change No change No change Increses 2-4c Increses 2-4c Increses 2-8c
6.Oxidation test Poorer Poorer Poorer Poorer Upto specs Upto specs
7.Ageing test Poorer Poorer Poorer Poorer Poorer Upto specs
 Reclamation of transformer oil

• CPRI contributions
• Stationary units
• Mobile on-line units
• To be deployed by SEB’S and
private utilities
 FLOWCHART OF RECLAMATION
 
FULLERS EARTH
 
HEAT @ 150° C FOR 2 Hrs
 
MIX WITH DISCARDED OIL @ 60° C FOR 2 Hrs
 
ALLOW TO STAND FOR 16 Hrs AT AMBIENT
 
DECANT & FILTER UNDER VACUUM
 
RECLAIMED OIL
 
ADD 0.3% BY WEIGHT DBPC
 Results
Test Unserviceable
Oil
Reclaimed Oil
Clear, Transparent, light
Dark brown, opaque
wine red in color and
Appearance containing dust and
free from suspended
suspended matter
matter or sediments
Density @ 27°C, g/cm³ 0.886 0.884

Kinematic viscosity @
19.9 20.2
27°C, cst
Interfacial tension @
0.0165 0.0405
27°C, N/m

Flash point °C 132 145

Pour point °C -15 -15

Neutralization value (Total

0.4 0.02
acidity), mg KOH/gm
Corrosive Sulphur Corrosive Non-Corrosive

Electric strength, BDV KV

(un-treated oil)
15 50

Dielectric dissipation factor

(Tan Delta) @ 0°C
0.015 0.003

Specification resistance
0.1 x 10¹² 130 x 10¹²
@ 1.     90° C (Resistivity)
ohm-cm 2. 27°C 1.03 x 10¹² 1300 x 10¹²

* 0.3% DBPC is added

Presence of oxidation
inhibitor *
Nil to lend stability to the
oil

Water content, PPM 80 15

Oxidation stability:    
a) Neutralisation value after -  0.098 
oxidation, mg/KOH/gm
b) b) Total sludge after - 0.013
oxidation by weight
 Tests conducted Reclaimed oil Treated with
 
0.2 % DBPC 0.3 % DBPC 0.4 % DBPC
Clear, Clear, Clear,
Transparent, Transparent, Transparent,
yellow in color yellow in color yellow in color
Appearance and free from
and free from and free from
suspended suspended suspended
matter & matter & matter &
sediments sediments sediments
Density @ 27°C, g/cm³ 0.88 0.88 0.88

Kinematic viscosity @
21 21 21
27°C, cst

Interfacial Tension @ 27°C,

0.043 0.043 0.043
N/m

Flash point °C 165 165 165

Pour point °C -23 -23 -23

Neutralisation value (Total

0.006 0.006 0.006
acidity), mg KOH/gm

Corrosive Sulphur Non-corrosive Non-corrosive Non-corrosive

Electric strength, (Break

50 50 5
down voltage)-KV

Dielectric dissipation factor

0.002 0.002 0.002
(Tan Delta) @ 0°C

Specific resistance @ 1)
90°C 130 x 10¹² 160 x 10¹² 150 x 10¹²
(Resistivity) ohm-cm 2) 4000 x 10¹² 3700 x 10¹² 3000 x 10¹²
27°C
Presence of oxidation
Present Present Present
inhibitor *

Water content, PPM 15 15 15

Oxidation stability:
a) Neutralization value, 0.05 0.04  0.045
mg/KOH/gm      
b) Total sludge 0.01 0.005 0.007
% by weight
 Field Trials
Based on the know-how of our process many state
Electricity Boards / Public Sectors have set up their own
Reclamation Units. The reclaimed oil processed in these
units, are being used in their 11KV Transformers and are
giving satisfactory performance so far. In this context, we
understand that one of the state Electricity Boards used the
reclaimed oil utilised with an antioxidant initially in 11KV
Transformers, which constitute bulk of the Transformers in
our systems. The oil is giving satisfactory performance for
the past 3 to 4 years. From the feedback data available nonce
of equipment failure was reported so far due to oil. This has
given a strong impetus for them to use the reclaimed oil in
their Transformers of higher ratings also.
 Economics of mobile reclamation
 

The cost of batch process is considerably

high compared to mobile reclamation system
designed & developed by CPRI. The increased
cost of the batch process is due to the requirement
of high volume reaction vessel and settling tanks.
The space and the process cycle time is also high.
 The cost of the 1000 liters capacity plant works out to 8.0
lakhs. The cost of reclamation per liter of oil is worked out in
full details.
 I. Fixed charges per day
1. Reclamation plant of 1000 liters capacity consisting 8.00 lakhs.
Oil filtration unit, reaction columns, Pumps, Heater unit and
trolley etc., (excluding the cost of LMV)
2. Portable Electric strength equipment………………………0.75
3. Oil quality index kit………………………………………..0.10
4. Baking oven earth
heating………………………………….0.40
Total : 9.25 Lakhs
 Interest on fixed charge at 18% 1.665 Lakhs
Depreciation at 10 % 0.925
Total : 2.59 lakhs
  Taking an average of 8 Hrs / day for 300 days in a
year
  Fixed charge per day = 225000 / 300
= Rs. 860 /-
 Running cost of the plant for 1000 liters
1. Cost of 250 Kg. earth @ 3 per Kg…………………… 750 /-
2.    Power consumption……………………………………... 300
/-
3.    Labour Charges.................................................................
300 /-
4.    Cost of DBPC (2.6 Kg. @ 750 /- per Kg……………
1,950 /-
5.    WASTAGE OF OIL @ 5% (50 LITS X Rs. 7)…………
350 /-
  Total cost of reclaiming 1000 liters oil (Fixed + Running cost)

= Rs. 863 + 3,650 = 4,153/-

Cost of reclamation per litre of oil = Rs. 4513 / 1000 = 4.51

The cost of fresh Transformer oil is Rs. 28 /- litre, where as

Advantages of mobile on-line reclamation system
• Simple, compact & can be easily attached to a light
vehicle
• Reclamation under energised condition
• Reduced down time
• Minimum wastage of oil
• Low cycle time & less space required
• System can be used for oil filtration
• Elimination of prior cleaning (sludge & other deposits)
• Large quantity of oil can be processed
 FUTURE PLAN OF WORK

• Power Transformer Oil reclamation is not carried

out in our country as on now
• Filter al (UK) Ltd, are manufacturing plant that can
be used for power Transformer
• Development of reclamation plant for power
Transformer
• Finding suitable adsorbent which can be
reactivated
 CONCLUSIONS

• CPRI has developed a simple & economical process

for on-line mobile reclamation of Transformer Oil
• System is novel & first of its kind in the country
• Reclaimed oil can be used in distribution
Transformers.
 PROCEDURE FOR ADDING DBPC
ANTIOXIDANT TO TRANSFORMER OILS
It is essential to know how to add the DBPC antioxidant
to the Transformer oils – either reclaimed or in service. After
the used Transformer oils have been reclaimed, 0.3 % by
weight of the DBPC has to be added to improve the oxidation
stability characteristics of the reclaimed Transformer oil. The
density of Transformer oil is around 0.9 gm/cc, and the
amount of DBPC to be added, therefore works out to 2.7 gm.
For every litre of the oil or 270 gm per 100 litres. Depending
on the quantity of reclaimed Transformer oil for treating with
DBPC antioxidant, the required quantity of DBPC (at the rate
of 2.7 gm. for every litre of the oil is weighed. This weighed
quantity is then added to a small quantity of Transformer oil
to prepare a concentrated solution.
This small quantity is heated to 50°C to facilitate quick
dissipation of the DBPC crystals. Thereafter the concentrated
solution can be mixed with the bulk of the oil and stored in
tanks or drums.
For Transformer already in service with reclaimed inhibited
Transformer oils, addition of DBPC is called for every 2½ to
3 years depending on the severity of service of the
Transformer. For this purpose, DBPC in concentrated solution
of oil or in crystal form can be added. If a solution is used,
then the Transformer must be taken out of service and the
solution is added with the Transformer remaining
unenergised.
After adding the concentrated solution, it is better to
wait for at least six hours before energizing the
Transformer again. This is because a high
concentration of say 10 % to 20 % DBPC solution
has an appreciably low dielectric strength which
might endanger the Transformer. Hence the need to
wait for some hours so that the DBPC gets
completely dispersed in the oil in the Transformer. It
is also convenient to add DBPC crystals to the
Transformer in service. Here the crystals should be
added slowly at intervals and sufficient time be
allowed for the crystals to get completely dissolved
in oil before the next lot is added.
 Study of use of reclaimed Transformer oil in power
Transformers
Objective:
Insulating oil used in power Transformers deteriorated over
the years of service due to: -
1.Thermal and electrical stresses
2.Presence of Oxygen
3.Presence of moisture and gradually loosed its original
characteristics and beyond a certain limits it is not capable of
performing the functions for which it is used. In such cases,
the oil has to be replaced by new oil.
As per the present practice released oil is reclaimed
which is generally no used in power transformers,
due to the fact that, the natural inhibitors present in
the oil are lost during the reclaiming process and
hence the oil looses its stability thereby the oil
deteriorates at a very fat rate. It is possible to
overcome this problem by adding synthetic
inhibitors in a few selected power Transformers to
study the performance by periodically monitoring
the various oil characteristics and the quality of
inhibitors used in the oil, in order to find out the
viability of use of reclaimed oil
Justification:
In the KPTCL, power system there are more than 1300 power
Transformers in service. Many of these have been in service for
more than 15 to 20 years and some of these require replacement
of oil and the quality of oil involved is quite huge of the order of
hundreds of kilometers. The cost of replacement by new oil is of
the order of several crores of rupees. By reclaiming and utilising
the released oil for use in power Transformer considerable
savings can be effected, as the cost of reclamation is about of
Rs. 5 per litre as against the cost of new oil of Rs. 25 litre. In
addition this results in not only savings in foreign exchange but
also helps in conservation of limited non-renewable source of
energy. Further the results of this study can be adopted by other
state electricity boards which will result in large savings would
running to several crores of Rupees.
In view of the above it is strongly felt that this study should be
immediately taken up by KPTCL.
Technical Programme:
The technical programme of the project envisages the
following:-
1.    Identification of suitable power Transformers for the
project.
2.    Processing of quality reclaimed Transformer oil.
3.    Addition of synthetic inhibitors in reclaimed oil.
4.   Filling up of reclaimed oil doped with synthetic inhibitors in
power Transformers identified for the study.
5.    Periodic evaluation of reclaimed oil characteristics in order
to find out the extent of deterioration as well as the inhibitor
content.
6.  Doping of used up inhibitors with required quantity of
synthetic inhibitor whenever needed.
7.  Preparation of a comprehensive technical report after
completing the investigation for a period of three years.
 Duration : Three years
  Facilities required : The infrastructure
facilities for complete oil evaluation in respect of all oil
parameters are available in the R & D centre in KPTCL and
hence no new facilities are to be created at present, expect for
determination of inhibitant content which can be got done at
CPRI, Bangalore by paying the necessary test field. However
technical guidance of a specialist in the field of Transformer
oil is necessary as the project mainly envisages chemistry
aspects of the Transformer oil.
 
Staff requirement : The R & D staff in position at
KPTCL will take up this project and no new staff is
required for this technical programme.