Maintaining your
transformer for
optimal performance
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As the world’s population continues to grow and societies seek sustainable solutions,
energy networks are expanding and changing. Higher voltages are improving
transmission efficiencies and renewable power generation can mean fluctuating loads
and harsh climatic conditions. At the same time, people expect greater reliability.
For the transmission and distribution of electricity, proper care and maintenance of
transformers and their oils is more important than ever as suppliers strive to provide
reliable power and avoid disruptive, costly downtime.
Avoiding unplanned downtime
Although oil quality is critical to successful operation,
proper transformer maintenance is equally important to
avoid this disruptive and costly scenario. Improper system
maintenance will lead to
•oil leakages
•performance challenges and low system efficiency
•unplanned outages
•component and system damage
•incorrect system readings.
Following the four steps in this guide can help to keep your
transformers continuously operating at maximum efficiency.
1. Choose a suitable transformer oil
The main functions of transformer oil are to provide By considering these factors, you should choose a product
electrical insulation, protect critical components and that will provide the best performance in these areas,
transfer the heat generated by the transformer core to the as this will help to lower your total cost of ownership.
external heat exchangers to keep the equipment cool. Make sure that the transformer oil meets, and preferably
exceeds, the proper requirements, as set down by the
To insulate, cool and protect, a transformer oil must
equipment manufacturer.
possess good electrical insulation properties. In addition,
because efficient heat transfer depends on good To make smart choices for your system’s operation, it is
circulation, the oil should have good fluidity so that it can helpful to understand what properties transformer oils
flow through the transformer, even at low temperatures. should have to provide adequate protection for your
equipment.
Equipment manufacturers also have expectations; for
example, the oil should be compatible with the materials
used in construction, have long-term ageing stability and
provide information through oil condition monitoring tests
and dissolved gas analysis.
Cooling Electrical insulation Life time Material Health, safety Other
compatibility and the
environment
•Viscosity •Breakdown voltage •Oxidation •Chemical •Flash point •Density
•Pour point •Dielectric dissipation factor stability composition •Health, safety •Interfacial
•Impulse breakdown •Inhibitor content and environment tension
•Resistivity •Sulphur content classification •Gassing
•Water content tendancy
2. Filling your transformer
When filling a transformer, always check any specific •checking the condition of elastomeric and other types of
guidance from the manufacturer. Some examples of good sealants and gaskets when topping up or doing a full oil
practice include change
•keeping all dedicated tools such as pumps and hoses •replacing seals and gasket materials when doing a full
clean by flushing them through under vacuum with clean oil change. The previous oil fill may have caused them
insulating oil before each use to soften and swell significantly and/or they may have
•preventing bubbles forming when filling with a hose by a compression set that could be disturbed, which could
making sure that the hose reaches the bottom of the lead to incomplete sealing and leaks after refilling the
tank and remains submerged during filling transformer with new oil.
•allowing the transformer to stand for at least 24 h to •Procedures for checking and fitting these components
enable air bubbles to rise to the surface after filling with correctly are available from the manufacturers. Incorrect
traditional oils (this “resting” time can be significantly fitting can lead to many issues, one of which is leakages.
reduced if using gas-to-liquids (GTL) oils, as they do not •If seals and gaskets are replaced but leaks still occur,
foam in the same way as traditional oils do) please seek advice from the manufacturer to ensure that
•running the transformer on a short circuit at a low the correct installation procedures have been followed.
voltage for some hours after filling to minimise moisture
and trapped air
•fully degassing the system by correctly using the air
vents and taking care not to introduce fresh air or
moisture, and regularly checking the oil level
3. Monitoring and maintaining transformer oils in service
Oil condition monitoring Oil level monitoring
Monitoring the oil’s condition by oil sampling and The oil level should be measured and monitored on an
monitoring the oil level is critical to ongoing efficient ongoing basis:
transformer operation. a. Measuring level – density/floaters
b. Minimising leaks – seals, gaskets
Monitoring has two purposes:
a. to assess the condition of the oil Detecting the oil level in the transformer conservator/
b. to identify if the transformer has experienced any faults Buchholz relay can sometimes be challenging, especially
through dissolved gas analysis. as various materials are used for floats.
The design of each type of test and the frequency with Many transformers use a magnetic oil gauge that
which tests are carried out may differ. indicates the change in oil level inside the conservator
The oil’s condition and the health of the transformer by going up and down according to the expansion and
are interdependent, so a well-structured oil condition contraction of the oil through temperature changes in the
monitoring programme enables you to assess the oil’s transformer. The float moves up and down in response
condition over an extended period. This offers peace of to the oil level similarly to the water level float in a toilet
mind and enables the operator to determine when an oil cistern. See Figure 1 for a schematic of the magnetic oil
change or reconditioning is necessary. gauge.
Fixing screw
Oil level
indicator Float arm
Float
MAX.
+20°C Conservator
MIN.
Terminal box
with cover
Figure 1: The magnetic oil gauge.
A red float and yellow float arm rest above a conservator (thick black line) on the right of the figure. The float and its arm’s movement when the oil level changes is
indicated with two dashed lines. A fixing screw, terminal box with cover and oil level indicator are identified on the main body. A third dashed line dissects the main body
and connects the float arm to a temperature gauge on the bottom left marked with “min”, “plus 20 degrees Celsius” and “max”.
The float, or swimmer, can be made from many different •coated cork balls – used swimmers are soaked full of oil
materials and its composition is important to the response and can sometimes sink over time resulting in a rating out
of the float to the oil level. of the scale
Typical materials for the float (swimmer) include •hollow plastic swimmers.
•closed-cell polymethacrylimide foam, which is resistant
to mineral oil and other common transformer insulating
fluids
Whatever the gauge type, it needs maintenance to ensure Maintenance and inspection of gaskets
there are no inaccurate readings due to leakage of oil into
the flotation device or vibrations, and especially when it Installation
has been in use for a long time.
When using a gasket follow the instructions supplied by
Floats or swimmers should be checked for saturation the manufacturer, but in case they are not supplied, the
levels during regular maintenance of oil, top-up or following instructions can be followed for general cases.
when replacing the oil completely to ensure there is For the gaskets on the curved surface of the common
not oversaturation and they are still delivering accurate transformer, cork or nitrile is used, although cork is no
ratings. longer employed. For some unions, special lead or
It is suggested that cork floats be replaced with floats asbestos gaskets or O-rings are used; if the type of gasket
made from polymethacrylimide foam. You should seek is indicated, it must be used following the instructions.
guidance from the manufacturer on the best float material
for extended use. Methods of joining or connecting gaskets
If readings are inaccurate, it is recommended that It is better to use the gasket without a joint, but this cannot
you refer to the manufacturer’s user manual for be avoided when the gasket is too large. There are round
troubleshooting; in many instances, replacement of old gaskets, square, rectangular and oval-shaped, but in any
floats is recommended. case, try to join the gaskets by using a flat portion of the
gasket. The part that overlaps must measure more than 50
Minimising leaks mm and adhesive must be applied to the union.
Understanding seal types and their behaviour in contact When using an element or a component to seal, make
with transformer oil is critical to maintaining performance sure the selection restrictly follows the guideline from
and minimising leaks. gasket producer. An improper selection may drastically
reduce the friction between gasket and flange, reducing
Seal materials behave differently in different fluid types.
the sealing pressure and leading to premature leakage
Materials can swell, harden, shrink or crack to different
and failure.
degrees depending on their composition and that of
the fluid. Therefore, it is important when filling new
Work instructions
transformers that you select the right transformer oil.
To remove corrosion, nitrile, oil or grease, use a wire brush,
With time, swelling, hardening, shrinking or cracking
thinner and alcohol. Apply the adhesive only to the side of
of seals can occur during the normal operation of a
the gasket and use only the necessary amount to attach it
transformer. This results in the seal not performing to its
to its place.
original engineering specification.
If the gas or oil leak is not stopped after correct
Oil leaks can be caused by gasket deterioration or
adjustment, the gasket will have to be replaced with a
incorrect positioning. It is important that the condition of
new one. A gasket with low elasticity such as lead type
seals and gaskets is checked regularly or when changing
must always be replaced with a new one. Do not use the
or topping up the oil in the transformer.
old one again.
Testing of transformer oils
All transformer oils are tested to strict standards for
compatibility with all components used in a transformer to
ensure that they do not contribute to leakages in the field.
4. Proper oil storage and handling
The performance of a transformer oil can be severely on their sides or, if this is not possible, upside down so that
compromised by contamination with particles, chemicals the bungs are at the bottom and raising the drums off the
and moisture. Small amounts of contaminants can lower ground on, for example, wooden pallets.
the oil’s electrical strength. Larger amounts can affect its If indoor storage is unavailable, an open-sided shed or
insulating ability and lead to damage in the transformer. shelter should be used. The drums should be regularly
It is, therefore, important during transit, storage and inspected for leaks and the obliteration of identification
service to keep the oil clean at all times. and hazard marks. Local regulations and standards should
Dedicated tankers, tanks and equipment should be used always be adhered to.
to avoid contamination. Nitrogen-blanketed tankers
Before use, it is advisable to move the drums from storage
and tanks are preferable for keeping the oil dry. Drums
and allow them to stand upright (bung up) under suitable
containing transformer oil are best stored under cover so
cover for about 12 h before they are opened. This will
that they are not exposed to the weather and temperature
ensure that the drums are at ambient temperature and
variations.
thus prevent air, which may contain dust or moisture, being
Changes in temperature may cause the drums to drawn in when they are opened. Before a drum is opened,
“breathe” and draw dirt and moisture into the oil. This is remove any loose dirt and dust from around the bung with
particularly likely for upright drums with bungs at the top a rag or brush. When the bung is removed, it should be
when the top of the drum is exposed to water. The risk of placed with the inner part upwards in a clean, dry place.
this contamination can be avoided by storing the drums
The Shell Diala portfolio
The Shell Diala range of transformer oils offers lifelong protection against corrosion and sludge, and
extended oil life through higher oxidation stability and enhanced heat transfer performance. Their greater
efficiency over a wide range of operating temperatures is helping to enable the next generation of smaller
transformers with higher loads and voltages.
Compared with conventional products, Shell Diala S4 •make potential issues easier to identify4 thanks
oils to their low gassing tendency for more accurate
•offer long oil life1 and excellent resistance to dissolved-gas analysis
degradation •are simple, safe and easy to use, providing
•contain effectively zero sulphur, thus protecting the benefits of GTL technology while being fully
your transformer against unplanned shutdowns compatible and miscible with conventional oils; they
and component failures due to oil-related copper can be used and recycled in the same way, and
corrosion retrofitted
•improve transformer performance2 by reducing •are globally available with consistent
operating temperatures performance.
•meet and exceed IEC 60296: 2020 Type A •For units in environmentally sensitive locations,
transformer oil specifications readily biodegradable Shell Diala S5 BD retains
the high performance of the Shell Diala brand
•help to improve transport and installation
without compromising on performance. It is readily
efficiency3 by reducing transformer weight, as they
biodegradable5 and offers excellent low-
have an 8.5% lower density
temperature performance6.
1
Data source: Doble TOPS survey (no. 108), GTL-based products (Shell Diala S4 series) perform over 700 minutes in oxidation stability rotating pressure vessel tests
(ASTM D2272), than the average of 500 minutes of other market products.
2
Shell Diala S4 tier products have an average of 9% higher specific heat capacity than conventional naphthenic products.
3
The typical density of Shell Diala S4 (0.805 g/ml) is 8.5% lower than that of conventional products (0.880 g/ml).
4
Shell Diala S4 ZX-I has 10 x lower gassing levels than the maximum specification of IEC 60296 Edition 5.
5
Shell Diala S5 BD meets and passes OECD 301B.
6
Shell Diala S5 BD has a very low pour point (typically -51ºC) and shows better fluidity at low temperatures (<1,000 mm2/s at -40ºC typical) than conventional
products (>1,500 mm2/s at -40ºC typical).
Product Category Benefits Technology Specifications and approvals
descriptor The Shell Diala range meets the requirements
of or is approved by most leading equipment
manufacturers and utility companies.
Shell Premium, readily • Readily Inhibited IEC 60296: 2020 Type A transformer oils
Diala S5 BD biodegradable, biodegradable OECD 301 B readily biodegradable
inhibited • Improved low- Meets technical requirement of CAN/
transformer oil temperature CSA-C50-14 (R2018) Class A (Canadian
performance standard)
• Extended oil life
Shell Premium, inhibited • Extended oil life Inhibited Meets and exceeds IEC 60296: 2020
Diala S4 ZX-I transformer oil • Extra performance Type A transformer oil specification
• Enhanced protection
Shell Inhibited • Reliable performance Inhibited Meets the requirements of ASTM D3487 Type II
Diala S2 ZX-A transformer oil
Speciality grades
Shell Premium, inhibited, • Extended oil life Inhibited IEC 60296: 2020 Type A transformer oil
Diala S4 ZX-IG gas-absorbing • Gas absorbing specification
transformer oil Meets the performance requirements of ASTM
D3487 Type II
Shell Naturelle Advanced, • Lower flammability Synthetic ester IEC 61099 T1
Transformer synthetic • Readily IEC 61039 K-class fire point class 3 low
Oil S4 I transformer oil biodegradable heat value
OECD 301 B readily biodegradable
Full details of approvals for all products can be obtained from your Shell representative; approvals
and claims will vary by viscosity grade.
Sources:
ABB transformer and oil user’s manual – 1ZCL000002EG-EN– rev. 1, 2007
Shell Diala Handbook
Siemens presentation – Test methods for characterising GTL based insulating fluids – Shell Technology Forum, Nov 2014
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