Dr Joerg Friedel Product Application Specialist Shell Technology Centre Hamburg, Germany

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1 Dr Joerg Friedel Product Application Specialist Shell Technology Centre Hamburg, Germany

2 An inhibited transformer oil based on Shell gas-to-liquids (GTL) technology

3 The evolution of hydrocarbon transformer oils 2013 Transformer oils based on GTL technology 1970 Hydrorefining Use of synthetic inhibitors 1980 Use of ester fluids 1960 Use of polychlorinated biphenyls for transformer oils c Sulphuric acid refining

4 Shell GTL transformer oil An inhibited transformer oil based on Shell GTL technology Exceeds the requirements of IEC (high grade)

5 The Shell GTL process Methane + Oxygen Hydrogen Carbon monoxide Fischer Tropsch distillates Water Catalyst Raw natural gas Gas processing CH 4 O 2 Synthesis gas manufacturing Syngas Fischer Tropsch synthesis CO + 2H 2 CH 2 Products Ethane LPG Condensate 120,000 bbl/d Conversion of natural gas to clean, high-quality liquid products using proven technology GTL naphtha GTL kerosene GTL gas oil GTL NP GTL base oils 140,000 bbl/d

6 Current uses of GTL products Diesel fuel Low emissions, biodegradable GTL products: Light GTL fractions Kerosene/naphtha Aviation, heating Turbine oils Thermally stable, excellent surface properties GTL products: GTL base oils Passenger car engine oils Shell PurePlus technology Transformer oils

7 Typical data showing the properties that differentiate Shell transformer oil Standard IEC Table 2 + Section 7.1 Density at 20 C, kg/m³ ISO 3675 max Kinetic viscosity at 40 C, mm²/s ISO 3104 max. 12 9,6 Kinetic viscosity at 30 C, mm²/s ISO 3104 max. 1, Flashpoint PM, C ISO 2719 min Pour point, C ISO 3016 max Total sulphur content, mg/kg ASTM D 5185 max. 500 <1 DBPC content, % Volatility 107 C, 22 h, wt% ASTM D Dielectric dissipation factor (DDF) at 90 C IEC max <0.001 Oxidation stability (500 h/120 C) IEC 61125C Total acidity, mg KOH/g max Sludge, wt% max <0.01 DDF at 90 C max

8 Transformer oil requirements Dissipate heat High heat conductivity (9% higher)* Low viscosity in the cold (200 mm²/s lower at 30 C)* Electrical insulation High impulse breakdown voltage (approximately 50 kv higher)* Low conductivity Protection Prevention of copper corrosion (<1 ppm sulphur) Maintaining low acidity to protect paper insulation Diagnostic information Detect impurities via measurement of interfacial tension Detect heat or electrical issues using dissolved gas analysis (DGA) Ageing resistance must be maintained over the oil s lifetime. Therefore, oxidation stability is key (GTL based oil has five times higher oxidation stability)* *Shell GTL transformer oil compared with inhibited naphthenic oil

9 Base fluids Changes and challenges High-performance base fluid, consistent in supply, composition and performance Inhibited insulating oils Very low sulphur content Demanding design of transformers Compactness, load, voltage, efficiency Higher stress on insulating oil and paper Increased severity in operation and higher reliability of transformers Ambient and high oil temperatures, service life, protection

10 Resistance to degradation Inhibited GTL versus conventional uninhibited oil IEC 61125C The induction period is reached when the volatile acidity significantly exceeds 0.1 mg KOH/g Inhibited GTL Uninhibited conventional oil Inhibited oils show predictable and best resistance to degradation Monitoring antioxidant concentration gives an indication of the oil condition before significant quantities of acids develop and potentially attack the insulating paper

11 Shell GTL transformer oil s cooling properties Customer transformer trials* showed comparable or better cooling properties for GTL-based oils compared with conventional oils GTL-based oils have a higher heat transfer coefficient than naphthenic-based oils for laminar and turbulent flow, although the differences are small Modelling showed the advantages of GTL-based oil, especially under high-stress conditions The parameters influencing cooling properties are Specific heat capacity Thermal conductivity Viscosity Density *Customer trials run by equipment manufacturers and utilities

12 Superior oxidation stability Oxidation stability test IEC 61125C Induction period IEC (0.1 mg KOH/g volatile acid) GTL inhibited Naphthenic, inhibited Naphthenic, uninhibited ,000 Typical RPVOT results (min.) ASTM D 2112: Naphthenic inhibited transformer oil 405 min GTL inhibited transformer oil 750 min

13 Resistance to degradation GTL inhibited oil versus conventional inhibited oil UIEC C extended oxidation stability test Test run for standard 500 h. When the inhibitor content fell to approx 50% of initial value, the antioxidant was topped up to initial level (refer to IEC 60422); later regular inhibitor topping up. Test run for approx 2,180 h (more than four times the usual duration) Extended resistance to degradation in normal service and when reinhibited.

14 Resistance to degradation GTL inhibited oil versus conventional inhibited oil GTL inhibited oil Acidity 0.18 mg KOH/g Sludge <0.01 wt% Oil loss 0 wt% Naphthenic inhibited oil Acidity 0.96 mg KOH/g Sludge <0.01 wt% Oil loss 24 wt% Results from Shell data

15 Electrical properties Lightning impulse breakdown Lightning impulse breakdown voltage testing Needle-plane and needle-sphere electrode configurations (gap typically 25 mm, using positive and negative impulses 4 kj; 50 µs) Testing at the University of Manchester, UK GTL inhibited oil and naphthenic inhibited oil (water content <10 ppm)

16 Electrical properties Lightning impulse breakdown Needle sphere (IEC method A) 300 ml oil Steel needle tip radius 7 2 μm ellipse Brass sphere electrode 12.5 mm diameter Needle plane 12.5 L oil Tungsten needle tip radius 50 ±5 μm Brass plane electrode 200 mm diameter

17 Shell GTL transformer oil offers highvoltage impulse stability GTL transformer oil offers higher resistance than naphthenic oils against high-voltage impulses caused by lightning or switching because of its low aromatic content mm gap Naphthenic GTL Needle - sphere +ve Needle - sphere -ve Needle - plane +ve Needle - plane -ve Source: University of Manchester Average breakdown voltage in kilovolts (gap 25 mm unless specified; 4 kj; 50 µs)

18 Foaming and air release improved 10 seconds shaking to incorporate air Classic naphthenic oil New GTL-based oil Classic naphthenic oil New GTL-based oil

19 Comparison flash point COC and evaporation loss Significantly higher flash point and reduced volatility provides additional safety GTL Diala S4 ZX-I Paraffinic Oil Naphthenic Diala S2 ZX-U C Evaporation loss ASTM D h at 107 C ASTM D h at 250 C Naphthenic oil 26% 100% GTL 0.75% 40%

20 Water saturation versus temperature No significant difference in water solubility compared with conventional transformer oils (Measurement Schering Institute, Vaisala Humicap MM 70)

21 Comparison with mineral-based transformer oils Dissolved gas analysis (DGA) Failure detection Material compatibility Water solubility Compatibility with naphthenic oils GTL-based transformer oil DGA interpretations can use same tools as for traditional hydrocarbon oils (e.g., with a Duval diagram) In the case of a transformer failure (e.g., through partial discharge), hydrogen will be generated and a Buchholz relay can release an alarm Compatibility given for materials that are compatible with mineral oils same substance class as mineral oils (hydrocarbons) Comparable with naphthenic transformer oils No issues observed in many tests with used and unused oils

22 DGA evaluation Duval diagrams Partial discharge Partial discharge low energy PD: Partial discharge D1: Discharge low energy D2: Discharge high energy T1: thermal failure <300 C T2 Thermal failure C Shell GTL oil Shell naphthenic oil Hot spot C Hot spot >700 C Absolute gas concentration is lower for the GTL oil compared with the naphthenic oil Source: Schering Institute

23 Ease of use: Compatible and miscible No miscibility, compatibility or solvency issues found GTL-based transformer oils can be used alongside traditional oils Top-up performance even better than for naphthenic oil Topped up with GTL oil Oven test, 35 days at 100 C Topped up with naphthenic oil Oil + Cu Oil only Oil + Cu + air

24 Comparison with inhibited naphthenic oil B Shell GTL oil, % Naphthenic oil B, % Density, kg/m³ ISO Flash point PM, C DIN EN Kinetic viscosity at 40 C, mm²/s ISO Breakdown voltage, kv IEC DDF 90 C IEC Oxidation stability IEC 61125C 500 h Acidity, mg KOH/g Sludge, wt% <0.01 < <0.01 DDF 90 C Oxidation stability IEC 61125C (500 h, 120 C)

25 Comparison with uninhibited naphthenic oil A Shell GTL oil, % Naphthenic oil A, % 100* Density, kg/m³ ISO Flash point PM, C DIN EN Kinetic viscosity at 40 C, mm²/s ISO Breakdown voltage, kv IEC DDF 90 C IEC Oxidation stability IEC 61125C 500 h Acidity, mg KOH/g Sludge, wt% <0.01 <0.01 DDF 90 C Oxidation stability IEC 61125C (500 h, 120 C)

26 Shell GTL transformer oil Performance in the field

27 Positive experiences with Shell GTL transformer oil Since 2013, Shell GTL transformer oil has been used to fill thousands of transformers across three continents For applications in Distribution transformers Power transformers Reactors Instrument transformers Traction transformers Good performance no issues observed; functions as expected for a high-grade oil No design or maintenance changes required (possible optimisation and maintenance reduction being explored!) Proven to be able to detect failures in transformers by initiating Buchholz relay alarm

28 Properties of Shell GTL transformer oil in use in a transformer GTL oil still bright with no signs of sludge after 18 months Date CO 2 CO H 2 CH 4 C 2 H 2 C 2 H 4 C 2 H 6 TAN BDV DDF IFT 10 Jul 12 1, Oct 12 1, Jan 13 1, May 13 1, Jul Aug Dec Jan Mar Jul Nov Source: EDF UK Power plant station unit transformer (10 years old) Hawker Siddeley (1986), 132 kv, 90 MVA, free breathing. Changed to Shell GTL oil June/July Vacuum applied January No issues

29 Shell GTL transformer oil performance after one year in service New transformers filled with Shell GTL transformer oil; first oil analysis after one year in service Type N 2 O 2 CO 2 CO H 2 CH 4 C 2 H 2 C 2 H 4 C 2 H 6 C 3 H 6 C 3 H 8 TAN BDV DDF BHT IFT 380-kV grid transformer (350 MVA) 380-kV grid transformer (350 MVA) 380-kV grid transformer (350 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 30-kV reactor (50 MVA) 53,423 24, ,849 4, ,006 1, ,753 31, ,678 15, ,935 31, ,350 28, ,358 34, ,609 24, ,788 3, Source: Amprion/Siemens

30 Shell recommendation for use of Shell GTL transformer oil In the case of a change from a conventional transformer oil to Shell GTL oil Vacuum treatment and filtration Oil reclamation Top up with Shell GTL or naphthenic oil Fill old transformers No change to Shell naphthenic oil No change to Shell naphthenic oil Up to 10% no objection* 15% remaining oil acceptable* Oil monitoring As described in IEC Interpretation of DGA As described in IEC Concentration measurement of antioxidant As described in IEC 60666

31 Summary benefits of Shell GTL transformer oil High flash point: Additional safety Oxidation stability less acid formation: 1 Longer transformer lifetime expected (with lifetime filling) 2 Transformer lifetime Oxidation stability less sludge formation: 1 No blockage of cooling drains, maintains low temperature Virtually no sulphur: Risk of corrosion caused by oil sulphur eliminated Higher impulse breakdown voltage: Lower probability of arc formation, reduced oil ageing 1 1 Compared with conventional inhibited transformer oils 2 In ambient conditions

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