SHELL DIALA

TRANSFORMER OIL
HANDBOOK
SHELL DIALA MAKES IT POSSIBLE
[Link]/lubricants

SHELL LUBRICANTS
TOGETHER ANYTHING IS POSSIBLE
CONTENTS /

1. ABOUT THIS HANDBOOK 3 4. FILLING TRANSFORMERS WITH OIL 10

(i) Filling a transformer for the first time
2. SELECTING AN INSULATING OIL 4 (ii) Refills and top-ups
(i) Transformer oil types
(ii) Transformer oil standards and specifications, 5. MONITORING AND MAINTAINING OILS IN SERVICE 12
and what to look for (i) Taking samples from drums, tanks and transformers
(ii) Maintenance tests: Testing of inhibited and
3. OIL STORAGE AND HANDLING 8 uninhibited transformer oils
(i) Storage
(ii) Oil handling: Health, safety and 6. THE SHELL DIALA PORTFOLIO 16
the environment

THIS HANDBOOK IS BASED ON SHELL’S EXPERIENCE

AND RELATIONSHIPS WITH MAJOR EQUIPMENT
MANUFACTURERS AND POWER COMPANIES, AS
WELL AS ENGAGEMENT WITH INDUSTRY BODIES,
INDEPENDENT LABORATORIES AND EXPERTS.

2 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 1 / ABOUT THIS HANDBOOK

This Shell handbook provides information

and guidance for works and utility company
Shell Lubricants engineers responsible for the maintenance,
SHELL DIALA operation and performance of transformers.
TRANSFORMER OIL
HANDBOOK It does not replace instructions issued by equipment
EVERYTHING YOU NEED TO KNOW FOR
PERFORMANCE AND PEACE OF MIND
manufacturers, rather it adds to them by providing further
information about the transformer oil. This handbook is
based on Shell’s experience and relationships with major
equipment manufacturers and power companies, as well as
engagement with industry bodies, independent laboratories
and experts.

WORKS HERE.

SHELL DIALA HANDBOOK VERSION 1.0/2016 3

SECTION 2 / SELECTING AN INSULATING OIL

The functions of transformer oil are to provide

electrical insulation, protect critical components
and transfer heat generated by the transformer
core to the external heat exchangers to keep the
equipment cool.
In addition, equipment manufacturers have other expectations
for transformer oil, for example, it should be compatible with
the materials used in construction, have long-term ageing
stability and be capable of providing information through oil
condition monitoring tests and dissolved gas analysis.

(i) TRANSFORMER OIL TYPES Mineral-based oils

Transformer oils are classified according to their base materials. Mineral-based oils are often then further differentiated as
This handbook covers mineral-oil-based transformer oils, which naphthenic or paraffinic oils. This distinction is based on the
are produced from hydrocarbons. Other oil types, for instance, proportions of the different types of hydrocarbon molecule in the
those made from ester-based, silicone and synthetic aromatic oil (Table 1).
components, are not within the scope of this guide.
Most conventional mineral base oils contain all molecule types and
Transformer oil consists of base oil plus, in some cases, additives are thus mixtures or blends.
(Figure 1). Typical additives include antioxidants (inhibitors),
As a guide, transformer oils can be classified as shown in Table 2.
metal passivators and pour point depressants.

LETTER TYPE OF OIL

P Paraffinic
N Naphthenic
A Aromatic

Base fluid TABLE 1: Mineral oil designation

Additives

CLASSIFICATION PARAFFINIC CONTENT

Naphthenic More paraffinic Paraffinic content

below 50%
Paraffinic Paraffinic content
56% and above

FIGURE 1: The composition of transformer oil TABLE 2: Mineral oil classification

4 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 2 / SELECTING AN INSULATING OIL

Normally, the composition of transformer base oils is measured using Inhibitors work in a sacrificial manner; they sacrifice themselves
a technique called Fourier transform infrared spectroscopy (FTIR), by reacting with oxygen in the oil to form inactive molecules. This
as described in ASTM D2140. It gives an approximate percentage reduces the rate at which oxidation of the base oil occurs, which,
breakdown of the component parts of paraffinic and naphthenic oils. consequently, prevents the formation of corrosive acids and high-
molecular-weight sludge.
A typical example of an oil classed as paraffinic using FTIR contains
CP = 67%; CN = 32%; CA = 1%. The first transformer oils were uninhibited and contained natural
sulphur compounds with some natural antioxidant properties.
A typical example of an oil classed as naphthenic using FTIR Today, there are both uninhibited, trace-inhibited and inhibited
contains oils. Some regions such as North America and China only use
CP = 47%; CN = 49%; CA = 4%. inhibited oils whereas other regions in Asia and in Europe may use
a mixture.
Mineral-based oils are mainly produced by traditional refining of
crude oil. This process relies on the quality and composition of the The most common inhibitor in transformer oils is di-tert-butyl-p-
crude oil; different crude oils from different parts of the world have cresol (DBPC), also known as butylated hydroxytoluene (BHT),
different compositions and contain different levels of impurities which may be used at up to 0.08% for trace inhibition or at
such as sulphur, oxygen or nitrogen. These variations can affect 0.08–0.40% for inhibited oils. Uninhibited oils do not contain any
the quality and consistency of the transformer oils produced from artificial antioxidants.
them. However, there are now new methods capable of producing
Table 3 shows that the oxidation test for uninhibited oils (U) lasts
hydrocarbon mineral-oil-type products such as-gas-to-liquids (GTL)
only 164 h compared with 500 h for inhibited oils (I). This clearly
technology in which mineral oils are produced from natural gas
demonstrates the longer resistance of inhibited oils to oxidation. For
using methane as the first building block. GTL-based transformer
high-voltage applications, oil according to IEC 60296 Section 7.1
oils are classed as isoparaffinic; the carbon molecules are similar to
should be chosen.
those found in traditional paraffinic oils but have more branching,
which results in improved low-temperature properties. Some manufacturers may produce oils containing additives such
as passivators in addition to inhibitors to improve performance,
Inhibited or uninhibited transformer oils especially if corrosive sulphur is suspected. These additives need to
Inhibited oils contain inhibitors known as antioxidants that prevent be declared.
or slow down oxidation and thus improve the oxidation stability
of the oil. They prolong oil life and consequently reduce paper
degradation in the transformer.

OXIDATION PERFORMANCE RANKING LIMIT IEC 60296 (U) LIMIT IEC 60296 (I) LIMIT IEC 60296, SECTION 7.1

Uninhibited Inhibited (standard) Mainly inhibited (higher oxidation

stability and low sulphur)
Oxidation test according to IEC 61125C
Test duration, h 164 500 500
Total acidity, mg KOH/g
a
≤1.2 ≤1.2 ≤0.3
Sludge level, wt% a
≤0.8 ≤0.8 ≤0.05
Dielectric dissipation factor at 90°C a
≤0.5 ≤0.5 ≤0.05
Sulphur content, % No general requirement Maximum 0.05
a
In some countries, more stringent limits and/or additional requirements may be requested.

TABLE 3: The IEC 60296 specification limits clearly show that uninhibited oils are expected to degrade more quickly than inhibited oils

SHELL DIALA HANDBOOK VERSION 1.0/2016 5

SECTION 2 / SELECTING AN INSULATING OIL

(ii) TRANSFORMER OIL STANDARDS AND

PROPERTY ASTM D3487 IEC 60296
SPECIFICATIONS
Transformer oils are normally produced in accordance with Viscosity at 100°C, mm²/s ≤3 –
international standards. These standards may be supplemented or Viscosity at 40°C, mm²/s ≤12 ≤12
replaced by standards published by the transformer manufacturer Viscosity at 0°C, mm²/s ≤76 –
or the utility company.
Viscosity at –30°C, mm²/s – ≤1,800
International standards are set by the IEC (International
Electrotechnical Commission) and ASTM, which is a US-based TABLE 5: Specified standards for viscosity at set temperatures
international technical standards organisation for the construction,
manufacturing and transportation industries. Cooling
One of the main functions of the oil in a transformer is to transfer
The major international standards for unused mineral transformer
heat from the core to the external radiators. The oil’s viscosity plays
oils are IEC 60296 and ASTM D3487. They cover the properties of
an important role in the effectiveness of this heat transfer. The lower
the oil and their significance, specifications, sampling and testing
the viscosity, the easier the oil can be pumped or can circulate
methods for inhibited and uninhibited oils.
freely throughout the transformer for improved heat transfer and
In order to insulate, cool and protect, a transformer oil must possess better cooling.
good electrical insulation properties. In addition, because efficient
At low temperatures, oils are more viscous. This is a critical factor
heat transfer depends on good circulation, the oil should have a
at low operating temperatures when poor or no circulation of the
low viscosity so that it can flow through the transformer, even at
oil can cause overheating at the hot spots in the transformer. The
low temperatures. The significance of some of the key properties
oil’s pour point indicates the temperature at which it ceases to flow.
are summarised in Table 4.
This is a maximum of –40°C for most specifications (Table 5).

COOLING ELECTRICAL LIFE TIME MATERIAL HEALTH, SAFETY OTHER

INSULATION COMPATIBILITY AND THE
ENVIRONMENT

n Viscosity n Breakdown voltage n Oxidation stability n Chemical n Flash point n Density

n Pour point n Dielectric dissipation n Inhibitor content composition n Health, safety n Interfacial tension
factor n Sulphur content and environment n Gassing tendency
n Impulse breakdown classification
n Resistivity

n Water content

TABLE 4: Summary of property requirements

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SECTION 2 / SELECTING AN INSULATING OIL

Electrical insulation Material compatibility

For a transformer to function, the main electrical windings need to Transformers are complex in design and contain many different
be electrically isolated from one another. This insulation is achieved materials, including paper, board, seals and coatings such as
using cellulose paper that is wrapped around the windings and paint, so it is important that the oil does not adversely react with
impregnated with the transformer oil. The insulating performance of any of these.
the oil is affected by its inherent physical characteristics, water content
In most transformers, it is the degradation of the insulating paper
and cleanliness in terms of particulate contamination. The insulation
that determines when a transformer needs replacing. Experience
effectiveness of the oil is assessed using parameters such as
has shown that doubling of the water content in the oil halves the
n breakdown voltage
working life of the insulation paper. Similarly, an increase in the
n dielectric dissipation factor
average operating temperature of just 8°C has the same effect. So,
n impulse breakdown the cooling and protecting properties of the insulating oil are vital
n resistivity. to extending a transformer’s working lifetime.
During the life of a transformer, the oil will degrade through
Health, safety and the environment
normal oxidation processes, which can lead to an increase in
water content and the formation of sludge (or deposits) and acids. From the safety perspective, it is important to look for oil with a high
These can reduce the insulating properties of the oil and increase flash point. The flash point is the lowest temperature at which the oil
the rate of degradation of the insulating material. Consequently, vaporises and can be ignited with a flame.
a structured oil condition monitoring programme is always For safety reasons, IEC 60296 specifies a minimum flash point of
recommended for transformer oils. 135°C to prevent the risk of fire and accidental ignition.

Lifetime Transformer oils should also be free of environmental toxins

such as polychlorinated biphenyls and carcinogens such as
The lifetime of a transformer is governed by the life of the oil and
polychlorinated alkanes.
of the insulating paper. Water, oxygen and oil ageing by-products,
including acids and sludge, can reduce the life of the paper, the oil
Other
and, ultimately, the transformer.
Interfacial tension is a measure of the tension at the interface
Acids may attack some of the materials used in transformer between oil and water. Transformer oil should have a certain
construction, including metal components and the insulating paper. interfacial tension to prove that it is high quality, clean and free
Sludge coats the windings and interferes with heat transfer by of impurities. A high interfacial tension shows that the level of
restricting oil and heat flow. contamination of the oil is low, but the interfacial tension will
Keeping the production of acid and sludge as low as possible decrease with time, so it is a useful indication of oil condition
is critical to the performance of the oil and the protection of the (Table 6).
transformer. Therefore, it is vital to use refined oils that provide high Decreases in interfacial tension may also indicate compatibility
oxidation stability. problems between the oil and one of the transformer materials, for
example, the varnish or the gasket material, or of contamination
when filling with oil.
INTERFACIAL TENSION

Fresh oil typical value, nM/m >40 The density of the transformer oil is determined by its type. In
general, isoparaffinic oils have a lower density than naphthenic
First warning, mN/m <25
grades and can lead to lower overall transformer weights.
TABLE 6: Interfacial tension of transformer oils
Technical data sheets
The technical data sheets showing the performance specifications
for all Shell oils can be accessed online at [Link].

SHELL DIALA HANDBOOK VERSION 1.0/2016 7

SECTION 3 / OIL STORAGE AND HANDLING

(i) STORAGE
Dedicated tankers, tanks and equipment should be used to
avoid contamination. Nitrogen-blanketed tankers and tanks are
preferable for keeping the oil dry.
Drums containing transformer oil are best stored under cover
so that they are not exposed to the weather and temperature
variations. Changes in temperature may cause the drums to
“breathe” and draw dirt and moisture into the oil (Figure 2). This is
particularly likely for upright drums with bungs at the top when the
top of the drum is exposed to water.
The risk of this contamination can be avoided by
n storing the drums on their sides or, if this is not possible, upside
down so that the bungs are at the bottom (Figure 3)
n raising the drums off the ground on, for example, wooden pallets.
RAIN SUNLIGHT

x x
The performance of a transformer oil can be
severely compromised by contamination with
particles, chemicals and moisture.
Small amounts of contaminants can lower the oil’s electrical
strength and larger amounts can affect its insulating ability
and lead to damage to the transformer. It is, therefore,
important at all times during transit, storage and service to
keep the oil clean.
FIGURE 3: Storage position: unexposed to weather, drums on side and raised
off the ground

RAIN SUNLIGHT NIGHT

Air penetration

Breathing caused Vacuum created

by pressure by night-time cooling
differences

Free water

FIGURE 2: How oil becomes contaminated when stored outside

8 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 3 / OIL STORAGE AND HANDLING

If indoor storage is unavailable, an open-sided shed or shelter Environmental management

should be used and the drums should be regularly inspected for Unused mineral transformer oil received from a refiner will
leaks and the obliteration of identification and hazard marks. Local not be classified as an environmental hazard. Modern oils do
regulations and standards should always be adhered to. contain major constituents that are expected to be inherently
Before use, it is advisable to move the drums from storage and biodegradable, but they also still contain components that may
allow them to stand upright (bung up) under suitable cover for persist in the environment.
about 12 h before they are opened. This will ensure that the drums All oil purchased and disposed of must be logged using an
are at ambient temperature and thus prevent air, which may on‑site oil management book. The book must be kept up to date
contain dust or moisture, being drawn in when they are opened. to meet international standards. Any spillages or leaks also need
Before a drum is opened, remove any loose dirt and dust from measuring and recording.
around the bung with a rag or brush. When the bung is removed, it In the case of an accidental leak or spillage, it is necessary to use
should be placed with the inner part upwards in a clean dry place. appropriate containment to avoid environmental contamination
and to prevent accidents. Prevent spillages from spreading or
(ii) OIL HANDLING: HEALTH, SAFETY AND entering drains, ditches or rivers by using sand, earth or other
THE ENVIRONMENT appropriate barriers.
Health and safety
Reclaim the liquid oil by scooping it into a container and soak up
Manufacturers produce material safety data sheets (MSDS) for their any residue using clay, sand or other suitable materials.
oils that provide detailed information on physical and chemical
properties, toxicology, disposal, health and safety. Dispose of both the contaminated oil and the absorbent, including soil
or sand, properly and in accordance with local and national laws.
Always refer to the product’s MSDS to determine the potential risks
and hazards associated with the handling and use of transformer oils. Local authorities should be advised if significant spillages cannot
be contained.
Personal protective equipment used when handling oil should
meet recommended national standards: check with your suppliers. When transformer maintenance or breakdown occurs:
Protective eyewear is recommended. n drain the oil before starting work where necessary
n retain the drained oil in sealed containers ready for disposal
Gloves approved to relevant standards (for example, in Europe: EN
or recycling
374; in the USA: F739) and made from PVC, neoprene or nitrile
n classify and dispose of the waste oil safely, as this is the
rubber may provide suitable chemical protection when handling
oil. Always seek advice from glove suppliers. After using gloves, responsibility of the end-user
hands should be washed and dried thoroughly. The application of n check with local authorities if the oil needs sending for

an unperfumed moisturiser is recommended. incineration or to refining or treatment plants for recycling

n comply with local area and regional laws and regulations.
Transformer oils typically have a normal petrochemical odour and
do not require the use of specific breathing equipment. Used oil may contain harmful impurities that have accumulated
during use and older transformers may contain oil that contains
It is important to observe good personal hygiene measures
polychlorinated biphenyls, the concentration of which will depend
such as washing hands after handling the material and before
on use. They may present risks to health and the environment on
eating, drinking and/or smoking. Routinely wash work clothing
disposal. All used oil is generally classified as special or hazardous
and protective equipment to remove contaminants. Discard
waste, depending on the state of the oil and its polychlorinated
contaminated clothing and footwear that cannot be cleaned.
biphenyl content.
For more information or the answer any enquiries about Shell
MSDS, please email lubricantsds@[Link].

SHELL DIALA HANDBOOK VERSION 1.0/2016 9

SECTION 4 / FILLING TRANSFORMERS WITH OIL

(i) FILLING A TRANSFORMER FOR THE FIRST TIME Filling

Smaller transformers normally arrive from the manufacturer When filling a transformer, always check any specific guidance
already filled, but larger transformers are delivered without oil from the manufacturer. Remember to
and therefore require filling on-site. If this is the case, always n keep all dedicated tools such as pumps and hoses clean by
follow the procedures outlined by the transformer manufacturer. flushing them through under vacuum with clean insulating oil
The following guidelines are designed for use in conjunction with before each use with the transformer
the manufacturer’s instructions. n prevent bubbles forming when filling with a hose by making
sure the hose reaches the bottom of the tank and remains
Oil preparation submerged during filling
n take care when inserting the hose into the tank to avoid any
Drums of oil should be allowed to stand before use for about
12 h until they are at ambient temperature. Their contents should damage to the windings
then be tested for electric strength by measuring the breakdown n fill larger units fitted with conservators from the bottom and

voltage using an on-site portable oil tester, if available. then top up from the conservator until the oil reaches a depth
of about 8 cm
Contaminants and water content affect the dielectric properties
n make sure the oil covers the windings and cooling tubes in
and strength of the oil. Therefore, if the oil’s electric strength
units with no conservator
is below the specified minimum, it should be dried using
n allow the transformer to stand for at least 24 h to allow air
purification methods such as vacuum dehydration or gas
bubbles to rise after filling with traditional oils (this “resting”
sparging. It should also then be filtered.
time can be significantly reduced if using GTL oils, as they do
Shell offers two levels of water content in its transformer oils: a not foam in the same way as traditional oils)
standard product and a more highly dehydrated one that goes n open the air release vents on tank covers, cable boxes and
through an extended drying period before shipment. For more inspection covers when doing the final top-up
information, please contact your local Shell technical advisor. n run the transformer on short circuit at low voltage for some

During transportation, care needs to be taken to maintain the hours after filling to minimise moisture and trapped air
oil’s condition: it can and will absorb moisture, especially under n open the air vents again to fully degas the system, taking care

hot and humid conditions. not to introduce fresh air or moisture, and check the oil level;
alternatively, fill the transformer under a half vacuum
To ensure the oil is dry before filling a transformer, a further
n check the electric strength of the oil before applying the full
processing step is recommended immediately before filling (see
filling section). working voltage or at least perform a crackle test on a sample
from the bottom valves on the transformer and conservator
Note that all batches of Shell transformer oils are rigorously (flush at least 5 L before taking the sample)
tested after manufacture and each batch has its own specific n check the insulation resistance of the windings.
certificate of analysis.
For more information on Shell quality assurance or to recall
a certificate of analysis, please contact your Shell sales
representative.

10 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 4 / FILLING TRANSFORMERS WITH OIL

(ii) REFILLS AND TOP-UPS Generally, new transformer oils conforming to the same
Refilling an old transformer specification are miscible with each other. If in doubt, contact
your transformer service company to discuss testing the oils
The procedure and guidelines for refilling are the same as those
for compatibility. No properties should get worse after the
on the previous page for a new transformer, although care
transformer is topped up as the oils are mixed. Typical mixing
should be taken to remove as much of the old oil as possible:
tests will assess foaming, oxidation, corrosive sulphur and the
85–90% is feasible.
presence of copper passivator for different mixtures.
Before starting work on any transformer, ensure that the
As with filling a new transformer, any top-up oil should be clean
equipment is isolated and safe to work on.
and dry. If this is not possible, the breakdown voltage of the
A suggested process for draining and refilling a transformer is as oil should be checked to ensure that the resultant mixture is still
follows: suitable for service.
1. Drain the oil.
Most new mineral transformer oils are miscible and compatible
2. Leave the transformer for at least 12 h to allow the oil to drain with aged oils; however, large top-up volumes should be avoided
off the windings, core and components. with heavily aged oils. This is because of the risk of sludge
3. Drain the remainder of the oil using a plastic hose to get as precipitation and the resultant impact on oxidation stability. Your
much oil out as possible. transformer service company can help with options such as extra
4. Flush with 20% hot oil by pouring it in through the conservator filtration, but if a top-up is more than 60% of the volume, a full
and removing it from the bottom drain valve while heating to drain and refilling are recommended.
about 80°C and filtering with a processing unit.
The new GTL inhibited oils, such as those in the Shell Diala
5. Complete at least three passes.
range, can be topped up or be used to top up either uninhibited
6. Drain and dispose of the flushing oil. or inhibited oils in accordance with IEC 60422.
7. Fill as normal but under a maximum of half vacuum to avoid
damaging any bushing seals and gaskets that have not been If topping up uninhibited oil with inhibited oil or vice versa, the
replaced. oil should still be monitored as the original oil. It is very unlikely
that a transformer will need to be topped up to such an extent
8. Process for at least three passes.
that this changes.
If planning to refill transformers containing old uninhibited oils
with an inhibited oil meeting IEC 60296, check the compatibility.
The oil manufacturer usually provides such details.
If an old transformer is being refilled, elastomeric and other
types of sealants and gaskets should be checked to assess their
condition (they should preferably be replaced). The old oil may
have caused them to soften and swell significantly and/or they
may have a compression set that could be disturbed, which
could lead to incomplete sealing and leaks after refilling the
transformer with new oil.
Take care during the refilling process to dispose of the old waste
oil and any oil used for flushing properly. Check the correct
disposal methods with the local authority and dispose of oil in
accordance with local and national laws.

Topping up transformer oil

Transformer oil top-up is not generally required during
maintenance. However, it may be necessary in some cases. As a
general guide, top-up volumes should be <5% of the total volume
of the transformer.

SHELL DIALA HANDBOOK VERSION 1.0/2016 11

SECTION 5 / MONITORING AND MAINTAINING OILS IN SERVICE

(i) TAKING SAMPLES FROM DRUMS, TANKS Transformers

AND TRANSFORMERS To take a contamination-free sample from a transfer, use an oil
It is important to have a robust sampling procedure that ensures sampling kit. If the instructions in the sampler kit are followed,
that neither the bulk oil nor the sample becomes contaminated they should ensure that no contamination by ambient air or any
during sample taking. The equipment used must, therefore, be introduction of dirt occurs.
clean and treated with great care. It is important to use new or
Oil sampling kits usually contain
uncontaminated hoses, pumps and sample vessels. Failure to
n tubing
follow this guidance may lead to inaccurate data collection that
n couplings
means no reliable conclusions can be made.
n connectors
Sampling frequency is largely dependent on the size of the
n multifunctional grippers
transformer and its importance in the network. Annually is
n syringes and bottles.
typical, but this frequency can be increased if necessary owing
to specific concerns over a particular transformer. The sampling procedure is normally as follows:
1. Take samples when the oil is warm and record its temperature.
Drums 2. Flush the sampling point with oil from the transformer first.
When taking a sample from a drum: 3. Collect the flushed oil in a clean container if using sample
n take the sample indoors when the oil is at or above ambient bottles or into a first syringe if using sample syringes.
temperature to avoid condensation 4. Label all the bottles and syringes.
n make sure the drums have been allowed to rest, bungs up and 5. Follow the relevant documentation and protocols if sending
undisturbed for 12 h before sampling to allow moisture to settle the sample to a laboratory for testing. It is important to create
n take an initial sample from the middle of the drum and discard a good historical record of results, as this will help to identify
it to flush the sampling tube trends and deviations from them. If possible, use the same
n always use new sampling equipment or equipment that is laboratory to achieve this, as variations between laboratories
dedicated to transformer oils can have impacts.
n take the final sample from the bottom. 6. It is important to test the sample as soon as possible, as
characteristics, especially for dissolved gas analysis, can
Storage tanks change over time.
When taking a sample from a storage tank: There are also many on-site portable testing units that can be used.
n take the sample from the bottom when impurities have been
allowed to settle For additional guidelines relating to sampling, please consult
IEC 60475.
n flush the test tap with oil from the tank before taking the sample

n take the sample slowly to avoid air bubbles.

12 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 5 / MONITORING AND MAINTAINING OILS IN SERVICE

(ii) MAINTENANCE TESTS: TESTING OF INHIBITED Many tests can be applied to mineral insulating oils in electrical
AND UNINHIBITED TRANSFORMER OILS equipment. The tests in Table 7 are considered sufficient to determine
Oil sampling has two purposes: whether the condition of the oil is adequate for continuing operation
a. oil condition monitoring to assess the condition of the oil and to suggest the type of corrective action required, where
applicable. In general, the frequency of oil condition monitoring
b. dissolved gas analysis to identify if the transformer has
testing should be determined according to IEC 60422. For critical
experienced any faults.
transformers, this should be at least every 12 months.
The design of each type of test and the frequency with which the
Always monitor transformer oil in accordance with the specific
tests are carried out may differ.
guidance offered by the transformer manufacturer.
Oil condition monitoring The oxidation (ageing) of uninhibited oils is normally monitored
The oil’s condition and the health of the transformer itself are by measuring the formation of acidic compounds and oil soluble
interdependent, so a well-structured oil condition monitoring and insoluble sludge. An oil acidity test is generally used. Regular
programme enables the operator to assess the oil’s condition over an acidity measurements are taken and tracked to calculate the
extended period. This offers peace of mind and enables the operator to oxidation rate and therefore the safe operation of the oil in the
determine if and when an oil change or reconditioning is necessary. transformer.

PROPERTY GROUPa SUB-CLAUSE METHOD

Colour and appearance 1 5.2 ISO 2049

Breakdown voltage 1 5.3 IEC 60156
Water content 1 5.4 IEC 60814
Acidity (neutralisation value) 1 5.5 IEC 62021-1 or IEC 62021-2
Dielectric dissipation factor and resistivity 1 5.6 IEC 60247
Inhibitor contentb 1 5.7.3 IEC 60666
Sediment sludge 2 5.8 IEC 60422, Annex C
Interfacial tension c
2 5.9 ASTM D971
EN 14210
Particles (count and size)c 2 5.10 IEC 60970
Oxidation stabilityc 3 5.7 IEC 61125
Flash pointd 3 5.11 ISO 2719
Compatibilityd 3 5.12 IEC 61125
Pour point d
3 5.13 ISO 3016
Density d
3 5.14 ISO 3675
Viscosity d
3 5.15 ISO 3104
Polychlorinated biphenyls 3 5.16 IEC 61619
Corrosive sulphur c
3 5.17 IEC 62535
ASTM D1275, Method B
DIN 51353
Dibenzyl disulphide content 3 5.18 IEC 62697-1
Passivator contentb 3 5.19 Annex B of IEC 60666:2010
a
Group 1 tests are routine; Group 2 tests are complementary; Group 3 tests are special investigations
b Restricted to inhibited and/or passivated oils.
c Only necessary under special circumstances: see applicable sub-clause.
d Not essential, but can be used to establish identity

TABLE 7: Tests for in-service mineral insulating oils from IEC 60422

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SECTION 5 / MONITORING AND MAINTAINING OILS IN SERVICE

Base oil
Typical behaviour
uninhibited oil

High-quality
inhibited oil

Safe operation

Time (x years)

FIGURE 4: Oxidation rates of oils

Inhibited oils are also monitored using an oil acidity test but they expensive. It simply measures the quantity of antioxidant left in the
have a different oxidation pattern compared with uninhibited oils oil to enable prediction of the remaining oxidation protection, i.e.,
(Figure 4). At the beginning of an oil’s service life, its inhibitor the oil life.
(antioxidant) is consumed with little formation of oxidation
The normal method of monitoring antioxidant consumption is to
products. This is referred to as the induction period.
measure its concentration as a percentage drop of its starting point
After the antioxidant is consumed, the oxidation rate is determined according to IEC 60666. Once the antioxidant reaches the warning
mainly by the base oil’s oxidation stability, so the patterns and levels (see Table 8), the recommended actions must be taken.
rates of oxidation are very different, which means that the total
The antioxidant content should be monitored at regular intervals,
acidity test is not as useful.
the frequency of which will depend on operational temperature
As acidity levels increase more slowly with inhibited oils, an and load levels. For calibrating the method, the same base oil type
additional measurement is useful that directly measures the amount as the oil to be measured should be used.
of antioxidant in the oil. This periodic testing is not difficult or

PROPERTY CATEGORY RECOMMENDED ACTION LIMITS RECOMMENDED ACTION

GOOD FAIR POOR

Antioxidant All >60% of 40–60% of <40% of GOOD: No action required if not indicated by
content original value original value original value other property tests
FAIR: where acidity <0.08 mg KOH/g and
interfacial tension >28 mN/m. Consider re-inhibition
to the original base line level
POOR: Continue to use and monitor as uninhibited
oil. Reclaim or change the oil

Note: If an inhibited oil has an initial level of 0.2% antioxidant, the poor alert level will be 0.08% (<40%) of its original level.

TABLE 8: Antioxidant content levels and required actions

14 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 5 / MONITORING AND MAINTAINING OILS IN SERVICE

Dissolved gas analysis The equipment available includes gas chromatographs that
A fault in a transformer, for instance, a partial electrical discharge, are very accurate but too heavy and bulky for on-site use and
will result in the decomposition of the electrical insulation materials portable units that are less accurate. Those units that comply with
such as the oil or the paper. This can create specific gases that IEC 60567 and ASTM 3612 are often used for on-site analysis and
dissolve in the oil and leave a unique chemical signature. The in laboratories, and are cost-efficient, precise and easy to use.
analysis of these gases (dissolved gas analysis) is used to determine Note that, in all cases, the sample should be analysed as soon as
the health and functionality of the transformer, and can help the possible to prevent the loss of volatile gases.
operator decide whether additional action is necessary.
The first step in evaluating dissolved gas analysis results is to
Dissolved gas analysis on transformer oil is usually carried out consider the concentration levels of each key gas. These values are
periodically to observe trends or changes, as these are often more recorded at intervals so that the rate of change of the various gas
significant than the individual results. Interpreting the results for a concentrations can be evaluated. Any sharp increase in key gas
particular transformer depends on the age of the unit, the loading concentration indicates a potential problem with the transformer.
cycle and the date of any major maintenance such as filtering (and
degassing) of the oil. The IEC standard 60599 gives guidelines for The faults that the dissolved gas analysis results determine are
the assessment of equipment condition based on the amounts of shown in Table 9.
different gases present.

FAULT EXAMPLES

Partial discharge Discharges of cold plasma (corona) type in gas bubbles or voids with the possible formation of x-wax in the paper
Low-energy discharges Partial discharges of the sparking type inducing pinholes or carbonising punctures in the paper
Low-energy arcing inducing carbonised perforation or surface tracking of the paper or the formation of carbon
particles in the oil

High-energy discharges Discharges in paper or oil with power follow through that result in extensive damage to the paper or the formation of
numerous carbon particles in the oil, metal fusion, tripping of the equipment and gas alarms
Thermal fault <300°C Evidenced by the paper turning brownish (>200°C) or carbonised (>300°C)
Thermal fault Carbonisation of paper, formation of carbon particles in oil
300 < T <700°C
Thermal fault >700°C Extensive formation of carbon particles in oil, metal colouration (800°C) or metal fusion (>1,000°C)

TABLE 9: Transformer faults determined by dissolved gas analysis

The dissolved gases in transformer oils can be measured and the

UNRESOLVED WRONG TOTAL, %
faults diagnosed using the following methods: DIAGNOSES, % DIAGNOSES, %
n IEEE methods (Rogers, Dornenburg and key gases methods)
Key gases 0 58 58
n IEC ratio codes
Rogers 33 5 38
n the Duval triangle.
Dornenburg 26 3 29
The relative performance of these methods is summarised in Table 10.
IEC 15 8 23
One drawback of the gas ratio methods (Rogers, Dornenburg and
Duval triangle 0 4 4
IEC) is that some results may fall outside the ratio codes and no
diagnosis can be given (unresolved diagnoses). This does not occur TABLE 10: Relative performance of the different dissolved gas analysis
with the Duval triangle method. diagnostic methods

Note that dissolved gas analysis can be used on inhibited and

uninhibited oils. For critical transformers, online monitoring
equipment can be installed.

SHELL DIALA HANDBOOK VERSION 1.0/2016 15

SECTION 6 / THE SHELL DIALA PORTFOLIO

Shell has been at the forefront of technology developments

in transformer oils for over 50 years and during that time has
constantly updated and improved its oils to meet the performance
needs of its customers.
Table 11 summarises the Shell portfolio of transformer oils and how
it has evolved over recent years.

PORTFOLIO STANDARDS PORTFOLIO STANDARDS PORTFOLIO STANDARDS PORTFOLIO STANDARDS

BEFORE 2005 2005–2010 2010–2016 2016–

Shell Diala B IEC 60296 – Shell Diala B IEC 60296 – Shell Diala S2 ZU-I IEC 60296
uninhibited uninhibited uninhibited

Shell Diala D IEC 60296 + Shell Diala D IEC 60296 +

VDE 0370 PI/ VDE 0370 PI/
DIN 57370-1 DIN 57370-1 –
– uninhibited uninhibited

Shell Diala M IEC 60296 – Shell Diala M IEC 60296 –

uninhibited uninhibited

Shell Diala S IEC 60296 –

uninhibited

Shell Diala BX IEC 60296 – Shell Diala BX IEC 60296 – Shell Diala S3 ZX-I IEC 60296 Shell Diala S4 IEC 60296
inhibited inhibited higher oxidation ZX-I higher oxidation
stability and low stabilitya and low
Shell Diala DX IEC 60296 Shell Diala DX IEC 60296 sulphur content – sulphur content –
– higher – higher inhibited inhibited
oxidation oxidation
stability and stability and
low sulphur low sulphur
content – content –
inhibited inhibited

Shell Diala MX IEC 60296 –

inhibited

Shell Diala GX IEC 60296 Shell Diala GX IEC 60296 Shell Diala S3 IEC 60296 Shell Diala S4 IEC 60296 –
inhibited + gas inhibited + gas ZX-IG inhibited + gas ZX-IG higher oxidation
absorbing absorbing absorbing stabilitya and low
sulphur content
– inhibited + gas
absorbing
ASTM D3487
Type II inhibited
Shell Diala A ASTM D3487 Shell Diala A ASTM D3487
I – Type I – I – Type I –
uninhibited uninhibited
Shell Diala AX ASTM D3487 Shell Diala AX ASTM D3487 Shell Diala S2 ZX-A ASTM D3487 Shell Diala S2 ASTM D3487
II – Type II – II – Type II – II – Type II – ZX-A II – Type II –
inhibited inhibited inhibited inhibited
Shell Diala S4 ZX-I’s performance has been compared with conventional mineral oils following testing by Shell and third-party laboratories. Details are available from your local Shell representative.
a

TABLE 11: The Shell Diala portfolio history

16 SHELL DIALA HANDBOOK VERSION 1.0/2016

SECTION 6 / THE SHELL DIALA PORTFOLIO

Summary of the benefits of the

Shell Diala S4 range
n Offers long oil life and excellent resistance to degradation
n Contains effectively zero sulphur, thereby protecting
your transformer against unplanned shutdown and
component failure due to oil-related copper corrosion
n Improves transformer performance compared with
conventional mineral oils by reducing operating
temperatures
n Meets and exceeds IEC 60296 and ASTM D3487 Type II

n Easy to use, fully miscible and compatible with other

transformer oils and all materials typically used in
transformer construction
n Testing and monitoring via dissolved gas analysis and oil
condition monitoring can be performed
n Globally available with consistent performance

Shell Diala S4 ZX-I is the latest inhibited transformer oil from Shell
and a very important one, as Shell’s GTL technology offers a long
life, high-performance oil with effectively zero sulphur. A summary
of usage guidelines for Shell transformer oils based on GTL
technology is shown in Table 12.

OPERATION GUIDELINES FOR SHELL DIALA S4 OILS

Vacuum treatment and filtration No change compared with Shell Diala S2/S3
Oil reclamation No change compared with Shell Diala S2/S3
Topping up with conventional oils Up to 10% if no maintenance change proves possible without significant performance impacta
Filling old transformers 15% if remaining oil proves to be acceptablea
Oil monitoring As described in IEC 60422
Interpretation of dissolved gas analysis As described in IEC 60599
Concentration measurement of antioxidant As described in IEC 60666
Assuming oil is not heavily aged
a

TABLE 12: Usage guidelines for Shell transformer oils based on GTL technology

SHELL DIALA HANDBOOK VERSION 1.0/2016 17

NOTES

18 SHELL DIALA HANDBOOK VERSION 1.0/2016

NOTES

SHELL DIALA HANDBOOK VERSION 1.0/2016 19

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