Natural Ester Fluid Diagnostics

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1 Natural Ester Fluid Diagnostics Weidmann 7 th Annual Technical Conference September 17, 2008 BY: C. Patrick McShane and John Luksich

2 Market Demand Accelerating More than 130,000 transformers in service More than 120 power transformers in service 200 MVA generator step-up retrofill 242 kv reactor new Recent US Utility announced conversions: Alliant Energy: 1P and 3P distribution, Iowa GSU substation retrofills Energy East: 1P and 3P distribution Xcel Energy: 1P distribution ComEd: 1P pole distribution & networks American Electric Power: network SMUD: distribution and network

3 Natural Ester Market Drivers More desirable environmental profile Improved insulation system life Increasing demand for sustainable supply Smaller carbon footprint Potential for reduced maintenance, dry-outs Greatly improves fire safety Eliminates key eco/health issues Reduces or eliminates m.o. required safeguards

4 Natural Ester Environmentally Preferred Rapid and complete biodegradation Equal to EPA ultimately biodegradable class. >80% in 10 day. >99% 45 days. Does not contain hazardous additives Passes OCED Acute Aquatic Toxicity No mortality (trout fry) Renewable Source contributing to Sustainability

5 Insulation System Life Extension Envirotemp FR3 Mineral Oil Envirotemp FR3 Mineral Oil Envirotemp FR3 Mineral Oil Sealed Tube Test - ML Sealed Tube Test - ML Sealed Tube Test - ML Upgraded Paper C Upgraded Paper C Upgraded Paper C 500 hours 2000 hours 4000 hours

6 Fire Safety FM Global Separation Requirements can be less than 1/10 distance required for mineral oil. Table 2a. Separation Distance Between Outdoor Liquid Insulated Transformers and Buildings Horizontal Distance 1 Two Hour Fire Noncombustible Combustible Vertical Approved Transformer Liquid Volume Resistant Construction Construction Construction ft Distance ft Liquid or Equivalent gal (m 3 ) ft (m) ft (m) (m) (m) Yes N/A 3 (0.9) 5 (1.5) Less Flammable 10,000 (38) 5 (1.5) 25 (7.6) 25 (7.6) (Approved Fluid) No > 10,000 (38) 15 (4.6) 50 (15.2) 50 (15.2) Mineral Oil (or unapproved fluid) N/A 1) All transformer components must be accessible for inspection and maintenance. < 500 (1.9) 5 (1.5) 15 (4.6) 25 (7.6) 25 (7.6) 500-5,000 (1.9-19) 15 (4.6) 25 (7.6) 50 (15.2) 50 (15.2) > 5,000 (19) 25 (7.6) 50 (15.2) 100 (30.5) 100 (30.5) distance from transformer distance from containment edge Table 2b. Outdoor Fluid Insulated Transformers Equipment Separation Distance 1 Liquid Approved Transformer or Equivalent Liquid Volume gal (m 3 ) Distance ft (m) Yes N/A 3 (0.9) Less Flammable 10,000 (38) 5 (1.5) (Approved Fluid) No > 10,000 (38) 25 (4.6) < 500 (1.9) 5 (1.5) Mineral Oil (or N/A 500-5,000 (1.9-19) 25 (4.6) unapproved fluid) > 5,000 (19) 50 (7.6) 1) All transformer components must be accessible for inspection and maintenance. distance from transformer distance from containment edge

7 Our History research begins full-scale accelerated life tests started formulation selected first distribution transformers retrofilled transformers available commercially available to OEMs first new power transformer first new mobile substation 161 kv, 200 MVA GSU retrofill ASTM natural ester standard first new GSU Major US utilities convert 100% for distribution first new 242 kv reactor first distribution transformers installed utility field trials begin first GSU retrofill 69 kv, 50 MVA US EPA grants Environmential Technology Verification first utility 100% conversion for distribution 230 kv retrofills 100th power transformer installed

8 How to Diagnose Basic chemistry is different between NE and MO, so. Depending on the property, there can be significant differences in the initial and typical service aged values What s important is to differentiate between performance vs. diagnostic values

9 Key properties comparisons Similar Dielectric strength* Dielectric impulse* Color (ASTD1500) Visual Examination (ASTM D 1524) Material Compatibility

10 Key properties comparisons Higher Acid Number Dissipation Factor Dielectric Constant Kinematic Viscosity Flash & Fire Points Relative Density Water Content (ppm) Absolute and Relative Saturation Pour Point

11 Key properties comparisons Lower Volume Resistivity Interfacial Tension Gassing under Electrical Stress D2300 Corrosive Sulfur

12 Oxidation Oxidation stability Both mineral oil and natural esters oxidize The fluids oxidize differently Products of mineral oil oxidation form sludge precipitates Products of natural ester oxidation form oligomers (larger molecules) that stay in solution The long term effect on the transformer is the same: less efficient heat transfer

13 Oxidation 12 Kinematic Viscosity, 100 o C (mm 2 /s) Envirotemp FR3 fluid 130 o C 150 o C 170 o C mineral oil 130 o C 150 o C 170 o C Equivalent "Normal" Lifetimes

14 Mineral oil 2000 hrs at 170 o C Oxidation

15 NE fluid 2000 hrs at 170 o C Oxidation

16 Cold Temperature Cold temperature performance Water saturation Viscosity Cold start

17 Water Saturation 5000 Water Saturation Point (mg/kg) Envirotemp FR3 fluid from Doble Engineering mineral oil from IEEE C Temperature ( o C)

18 80 D1816 Dielectric Breakdown Strength (kv) Envirotemp FR3 fluid mineral oil Water Content (mg/kg)

19 80 D1816 Dielectric Breakdown Strength (kv) Envirotemp FR3 fluid mineral oil Water Content (% of 20 o C saturation)

20 Water Saturation 1000 Water Content (mg/kg) IEEE C max water content in new equipment 69 kv and less mineral oil saturation (IEEE C57.106) Envirotemp FR3 fluid saturation (Doble Eng.) Temperature ( o C)

21 DGA Dissolved Gas Analysis IEEE C DGA Guide: Key Gases Method with rate of rise OK, but not Ratio Methods IEC Duval method recommended Gas generation & solubility similar to mineral oil Expect higher proportion of ethane compared to mineral oil due to basic fluid chemistry Fine tuning of all limits will come with additional field data and lab investigations

22 Field Case History Alliant Energy - 50 MVA, 69 kv, built 1957, retrofilled 2001

23 Dielectric Strength

24 Dielectric Strength (1mm converted to 2mm)

25 Absolute Water Content

26 Relative Water Content

27 Dissipation Factor

28 Acid Number

29 Interfacial Tension

30 Dissolved Gases

31 Dissolved CO & CO2

32 Ethane - The Mischief Maker!

33 Key Standards ASTM D Standard Specification for Natural (Vegetable Oil) Ester Used in Electrical Apparatus New IEEE C IEEE Guide for Acceptance and Maintenance of Natural Esters in Transformers

34 New IEEE Standard Guide for NE Sec 8 - Maintenance of Natural Esters in Transf. Field Screening Test Limits for service aged fluid Currently only properties listed: Dielectric Strength Fire Point Reconditioning Reclaiming Mixtures of different fluids discussion Most are miscible and compatible Should be avoided Silicone definitely should be avoided, even traces

35 IEEE Standard Guide for NE Informative Annex B Alternative Oxidation Stability Test Relative Moisture Saturation DGA Information Provisional Guidelines for Trigger Value Limits Key Properties Mixtures Natural Ester with Mineral Oil Relative Cooling

36 IEEE Standard Guide for NE Table B.5: Provisional Guidelines for Trigger Value Limits Alternative Oxidation Stability Test Dissipation Factor Water Content Flash Point Color Viscosity Increase Inhibitor Content

37 Eletronorte (Brazil) 242 kv Reactor

38 Alliant Energy retrofill March 2004, 200 MVA, 161 kv, built 1966, Burlington Iowa

39 Missoula Electric retrofill December MVA, 230 kv, built 1980, Montana

40 Keyspan Energy retrofill April 2004, 25 MVA, 19 kv, New York City

41 Summary Typically the same properties are tested Some properties are significantly different Typically same ASTM test methods apply DGA: Similar faults produce similar gases Exception: Ethane is produced naturally Much more field data required to fine tune interpretation from field samples

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