Natural Ester
Dielectric Fluids
Overview
FMEA
Fall Conference
November 6th, 2015
www.cargill.com
CONFIDENTIAL. This document contains trade secret information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those employees who do not have a need to know is prohibited except as authorized by Cargill in writing.
Agenda
• Public Power DEED story
• History
• Fluid comparison
• Natural Ester Fluid
– Fire Safety
– Environmental Impact
– Longer life
– Industry Validation / Testing
• Key takeaways
2
APPA's American Public Power Association
DEED programConceives Natural Ester Revolution
……………and Envirot™ FR3™
• Natural Ester transformer
placed into service in 1997 by
Waverly Power & Light- Iowa.
• Waverly P&L• Piloted field testing.
A transformer containing the Envirotemp FR3 transformer fluid is
pictured in the foreground. Photo courtesy of Waverly Light & Power
3
• Now nearly 1 million
transformers use Natural
Esters as part of their
insulation system.
Transformer history
(1890-present)
Diagnostics put into practice
Free Breathing
Designs
1880
1900
Common failure mode: mineral oil
(sludge, a bi-product of oxidation)
impacted heat transfer/dissipation
Thermally
Upgraded
Kraft
Sealed
Designs
1930
Common failure mode: shifted
to solid insulation; constrained
by operating temperature
1960
1990
High temperature
materials standards
Natural
Esters
2010
2020
Common failure mode:
solid insulation; operating
temperature increased
Common failure mode:
solid insulation; operating
temperature increased
55oC AWR, 95oC HST
4
65oC AWR, 110oC HST
85oC AWR, 130oC HST
Fluid characteristics impact performance
capabilities in transformer application
5
Mineral Oil
Natural Ester
(FR3 fluid)
Synthetic Ester
Silicone Oil
Base Fluid
Petroleum Oil
Vegetable Oil
Hydrocarbons
Polydimethylsiloxanes
Diagnostic
Capability
Yes
Yes
Yes
Less
Fire point
160°C
360°C
310°C
340°C
Biodegradability
Low
Ultimately
Readily
No
Biobased
No
Yes
No
No
Oxidation
Good
Acceptable
Very good
Very good
Aging
Average
Best
Better
Average
Initial Cost
$
$$
$$$
$$$
(non-free breathing)
Fluid differences impact performance
Fluid
Characteristics
Transformer
performance
Mineral Oil
Natural Ester
65 AWR
85 AWR
110ºC hottest spot
130ºC hottest spot
Allows for overload or life extension
Reliability-dielectric
strength
Moisture saturation
(@20°C) – Keep
Dielectric strength declines
as heat increases due to
water saturation
Retains dielectric strength in presence of
water
Self Drying - Hydrolysis “consumes” the
water
55 ppm
1,100 ppm
Moisture out of the Paper!
Fire safety
Environmental
footprint
Flash point 155ºC
Flash point 330ºC
Fire point 160ºC
Fire point 360ºC
Non-biodegradable
Non toxic, non-hazardous in soil and water
Carbon neutral
Biodegradable in 28 days
6
Insulation system is the primary failure
mode of a transformer
Transformer solid insulation is limiting factor in
transformer life
•
Degrades over time, based upon temperature,
loading degree/cycle, and contaminants (water,
oxygen, and acids)
Design limits defined by insulation system hot
spot temperature (HST)
•
Natural Esters (IEEE c57.154) demonstrates
20°C additional thermal capability (compared to
mineral oil)
Economic value and opportunity
•
7
Natural Ester filled transformers thermal capability
enables lower cost per kVA, longer life, reduced
transformer price, and positive NPV
Hottest Spot Temperature (Ԩ)
Average Winding Rise (K)
(Top Temp ‐ Bottom Temp)/2
Over 20+ years of experience with Natural Esters
DGA Standard Published
2015
High Temp Insulation System
Standards Published
IEC Standard Published
2010
Envirotemp Dielectric Fluids
Business Purchased by Cargill
19Jun12
IEEE Standard Published
2005
Cargill begins FR3 fluid production
ASTM Standard Published
2000
1995
1990
8
FR3 fluid Commercially Available
FR3 fluid Applied to 1st Transformer
FR3 fluid Formulation Developed
Natural Esters:
Three important benefits to
remember
 Increased Safety - Reduces Fire Risk
 Improved Environmental Footprint
Optimized Transformer Performance
 Lower total cost
 Greater Reliability
9
Natural Esters
Key Advantages
 Increased Safety - Reduces Fire Risk
10
Fire Safety(K class fluid) - UL and FM
11
No reported fire related failures!
Fire Safety
Flash and Fire Point of Ester K-Class
Fluids
» Fluids classified as “Fire Resistant” (K Class) must
have Fire Point above 300°C
Temperature (°C)
400
Flash Point
Fire Point
350
308
300
360
343
330
300
270
250
200
155
150
165
Mineral
Oil
Envirotemp
200 Synthetic
Silicone
Envirotemp FR3 Natural Ester
Safety& Fire Benefits of K Class
 High Firepoint
• No fires/self extinguishing
•
Employees and Stakeholders are safer.
•
Discounted insurance
 No firewalls needed
•
Reduced construction $$$$
•
No costly sprinkler systems
 Smaller footprint
•
Reduced separation distances
•
Better use of land and retail space
CONFIDENTIAL. This document contains trade secret information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those employees who do not have a need to know is prohibited except as authorized by Cargill in writing.
Natural Esters
Key Advantages
 Increased Safety - Reduces Fire Risk
 Improved Environmental Footprint
14
Natural ester fluid is a better choice
for the communities you serve
• Made from a renewable resource
-
>98% vegetable oil
-
Carbon neutral*
-
Contains no petroleum, halogens, silicones or sulfurs
• Non-toxic, non-hazardous in water and soil
- OECD oral and aquatic toxicity test
• Biodegrades in less than 28 days
- Ultimately biodegradable according Environmental Protection Agency (EPA)
• Recyclable
* According to BEES 4.0 lifecycle analysis
15
Natural Esters c57.154
Key Advantages
 Increased Safety - Reduces Fire Risk
 Improved Environmental Footprint
Optimized Transformer Performance
 Lower total cost
 Greater Reliability
16
Optimize performance: Increase
capacity with reduced transformer size
INCREASE LOADABILITY BY UP TO 20% WITHOUT
DEGRADING ASSET LIFE
• IEEE C57.154 (IEC 60076-14)
High temperature insulation
system standard
17
−
Current standard 110oC hot spot with
65 AWR limits transformer capability
−
Envirotemp™ FR3™ fluid-based
insulation systems can be run 20oC
warmer without degrading life
−
Design new transformers smaller with
same or more load capability
−
Existing transformers can be upgraded
to provide overload capability
Improve reliability: Extend insulation and
asset life 5-8x longer than mineral oil
Protecting life of insulation paper is the
number one factor that determines asset
life
18
Tested, validated
and proven
19
SPCAA Presentation – May 13, 2014
Validated by industry
Meets IEEE and IEC
standards
- More than 250 series of tests
conducted on FR3 fluid
- IEEE C57.154 (IEC 60076-14)
High temperature insulation
system standard enables 75
rise new transformer designs
Classified as a less
flammable fluid (K-class)
- Underwriters Laboratory
- FM Global
20
Environmental testing
- Carbon neutral according to BEES 4.0
lifecycle analysis
- Ultimately biodegradable by EPA
- Non-toxic and non-hazardous in soil and
water by OECD
Industry recognition
- 2013 Presidential Green Chemistry
Award
- 2013 EPA Design for the Environment
(DfE) designation
- USDA BioPrefered Program
- EPA Environmental Technology
Verification California Environmental
Technology Certification
- FERC ruling – retrofills with FR3 fluid
may be capitalized
ASTM, IEEE and IEC natural ester standards
New Oil
Natural Esters
ASTM D6871
IEC 62770
Mineral Oil
ASTM D3487
IEC 60296
Use and Maintenance
IEEE C57.147
IEEE C57.106
IEC 60422
Transformers
IEEE C57.12.00
IEC 60076 series
IEEE C57.154
IEC 60076-14
IEEE C57.12.00
IEC 60076 series
IEEE C57.154
IEC 60076-14
Loading Guide
IEC 60076-7
IEC 60076-7
IEEE C57.155
IEEE C57.104
IEC 60599
Dissolved Gases
Fire
11
FM Global Property Loss Prevention Data Sheets, 5-4 Transformers
IEC 61936-1 Power installations exceeding 1 kV a.c. – Part 1: Common rules
Proven, global installations
Nearly 1 million FR3 fluid filled
transformers in service globally
− 500 medium & large power
−
−
−
−
transformers
20,000 indoor units
5,000 substations
10,000 retrofills
Industrial, utility and network
transformer
Over 100 US utilities, including
100% new distribution adopters
-
22
Network design systems in major
cities like SF, NY, Chicago, Atlanta
FR3 fluid approved for
transformers above
420kV/300MVA
− HV testing validates usage
through 500kV
− 500kV transmission line for
Electronorte, Brazil
− 345KV transmission line for
Bureau of reclamation
Over 100 global OEMs
applying and promoting
technology
Key Takeaways
•
Fire safety
•
•
•
•
•
No fires, cleanup, downtime, or replacement costs
Protects nearby equipment and buildings
Reduced fire mitigation requirements (sprinklers, etc.)
Greatly reduced risk to personnel working at site
Environmental
•
•
•
•
•
Environmental safety (no hazardous fumes, fires,
reduced spill mitigation)
Petroleum independent
Reduced carbon emissions
Biodegradable/non-toxic/recyclable
Extended transformer life
•
•
•
•
23
Insulation system up to 8X* extended lifespan
Transformer asset extended lifespan
Better handle’s overload conditions
Enables smaller, lighter (75-85C rise) designs
Ty Severson- Utility Sales Manager
ty_severson@cargill.com
952.984.4052
THANK YOU
How was natural ester dielectric fluid
developed and tested?
• Cargill and Cooper Power Systems (CPS) developed a partnership
in early 2000’s where Cargill would be the manufacturer and supply
chain channel and CPS would be the sales channel and technical
support team
• For distribution class equipment, CPS systems knowledge used
to develop an extensive validation program through testing
• For power class equipment, industry expert Harold Moore was
consulted:
– Special equipment required, industry labs were not capable of producing
results without significant increases to impulse generation capability
– Extensive test matrix developed to test all capabilities of FR3
– Comparison results with Mineral Oil
– 10 year testing program costing millions of dollars by independent labs
– Reference ICHVE Papers
In 2012 Cargill completed a full acquisition of CPS Dielectric Fluids operations
25
SPCAA Presentation – May 13, 2014
Appendix
26
Improve reliability: Extend insulation and
asset life 5-8x longer than mineral oil
Unique chemistry of
FR3™ fluid protects
insulating paper by:
• oil
• FR3
fluid of
can
absorb
Hydrolysis
natural
ester
“consumes”
waterwater
and
significantlythe
more
Protecting
produces
fatty acids.
than mineral
oil This life of insulation paper is the number
one
factor that determines asset life
process
removes
• FR3
fluid
has 10dissolved
times the
water
water saturation (PPM)
than mineral
• FR3™ Fluid is in essence
‘self drying.’ Water
concentrations in the fluid will
be reduced due to hydrolysis
over time.
27
FR3
Key Advantages
 Increased Safety - Reduces Fire Risk
 Improved Environmental Footprint
Optimized Transformer Performance
 Lower total cost
 Greater Reliability
28
Fluid differences impact performance
Fire point
Readily and ultimately biodegradable
Breakdown voltage
Moisture saturation (20°C)
Cellulose ageing = transformer life
Oxidation stability
Compact transformer design
29
Mineral Oil
Envirotemp FR3
160° C
350° C
✗
✓
70 kV
> 75 kV
55 ppm
1,100 ppm
poor
5-8 times slower proven
sealed or breathing
transformers
shut or breathing
transformers
✗
✓
Installation Benefits
Minimal separation distances
Firewall
Sump
Relevant
Edification
Fluid
Mineral
Oil
>0,5m
FR3
>0,5m
From equipment to edification
X1
Non
combustible
X2
< 1.900
1,5 m
4,6 m
1,5 m
> 1.900
< 19.000
4,6 m
7,6 m
7,6 m
> 19.000
7,6 m
15,2 m
15,2 m
< 38.000
1,5 m
1,5 m
> 38.000
4,6 m
7,6 m
Sump
Relevant
Edification
Relevant
Edification
Sump
X1
X2
MINERAL Oil
Between
equip
Fire resistant
for 2h
Building wall
Building
wall
30
Fluid
Volume
(liters)
X1
X2
ENVIROTEMP FR3 Fluid
2013
recipient of
Presidential
Green
Chemistry
Award
2013
recipient of
EPA DfE
certification
USDA
BioPreferred
Program
US EPA
Environmental
Technology
Verification
31
California
Environmental
Technology
Verification
Cargill Background
History:
• Founded in 1865 as a single grain elevator in the American frontier
(Iowa)
•
Over 150 years as an international provider of food, agricultural and
risk management products and services
•
•
Cargill Today:
A privately held, family and employee-owned company with
corporate headquarters in Minneapolis, MN, USA
•
An international marketer, processor, and distributor serving food,
agricultural, financial and industrial customers
•
Business activities span 67 countries and include 143,000
employees
•
FR3 fluid produced from U.S. Soybeans
• U.S. Farmers & U.S. JOBS !
CONFIDENTIAL. This document contains trade secret information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those employees who do not have a need to know is prohibited except as authorized by Cargill in writing.
143,000
Employees
150 years
of
experience
Installation Benefits
Typical Containment system for Mineral Oil
Designed to 110% of larger equipment oil volume + rain
water + fire fighting system water, automatic or manual
Rocks for flame
suppresion
Oil / Water separation tank
Sump
Oil + Rocks volume
Simplified sump proposed for
Envirotemp FR3 (if required)
Fluid volume +
rain water
Designed for larger equipment oil volume
+ rain water
Manual or Automatic
draining system
33
Simpler, less costly spill remediation
Mineral Oil
–
–
–
–
–
Soil
Tap Water
34
FR3 fluid
Low viscosity
Fast seepage (infiltration)
May reach water reservoir
Biodegradation very slow
Very high remediation cost
Water
– Non toxic
– Seepage very slow
– Ready and complete
biodegradation
– Very low remediation cost
Soil
Tap Water
Water
Validation
OVER TIME, THE NUMBER OF VALIDATION TESTS HAS SURPASSED 270. THE
NUMBER OF 3RD PARTIES THAT HAVE CONTRIBUTED TO THE GLOBAL KNOWLEDGE
BASE NOW EXCEEDS 30 (SAMPLING BELOW).
University of Manchester - England
University of Hannover - Germany
University of New South Wales - Australia
Monash University - Australia
Doble
Weidmann
EHV
Weidmann Labs
Quality Switch
University of Cincinnati
35
University of Graz - Austria
TJH2B Labs
Reinhausen
Cooper Power Systems - Franksville
FM Global
UL
Powertech Labs
SPX Transformers
SD Myers
EPRI
US Dept of Commerce - NIST
Fluid Comparative Summary
36

FR3™ FLUID
 MINERAL OIL






Good Fire Safety & Overall Reliability
Biodegradable
Sustainable, Renewable Supply
Extends solid insulation lifespan
Carbon neutral footprint
Higher cost







Excellent Reliability
Low Temperatures & Low Losses
Lowest Cost
Diagnostic Testing Capability
Fire Hazard in Sensitive Areas
Increasing Environmental Regulation
Instability of Supply & Price
CAST RESIN DRY TYPE
SILICONE
 Good for Clean, Indoor Locations
 No Liquid Spill Risk
 Good Fire Safety & Overall Reliability
 Low Temperature & Low Losses
 Higher Temperatures & Losses
 Sensitive to Overload & Harmonics
 Regular Cleaning Required
 Minimal Diagnostic Testing
 Service Life Concerns
 High Initial & Operating Cost
 Higher Cost
 Less Diagnostic Testing Capability
 Inferior Coolant & Dielectric
 Not Suitable as Switching Medium
 Environmental Concerns – Not Biodegradable
 FR3™ fluid is superior to other dielectric
fluids in many ways.
Comparison of Dielectric Fluids
Electrical Properties
Test Method
M.O.
FR3™ Fluid
Biotemp
DC 561
2mm gap,
lab
ambient
D-1816
62
48-75
65
43
1mm gap,
lab
ambient
D-1816
31
28
32
25C
D-924
0.010
0.023-0.103
0.015
0.007
0.050
0.67-3.86
0.2
0.0015
D-1169
200
20
10
1000
CPS
0.01
Dielectric
Breakdown
(kV)
Dissipation
Factor
100C
Volume
Resistivity
(1012-cm)
DC Leakage
(µA)
Dielectric
Constant
37
0.04
2.2
3.2
3.2
2.26
223
Impulse
Strength (kV)
D-3300
269
226
100
Gassing
Tendency
(µL/min)
D-2300
+6
-79
+5
Comparison of Dielectric Fluids
Physical Properties
Test Method
M.O.
FR3 Fluid
Biotemo
DC 561
Appearance
D-1524
Clear &
bright
Clear & lt
green
Clear &
bright
Clear &
bright
Color
D-1500
L-0.5
L-0.5
L-0.5
L-0.5
Flash Point
(ºC)
D-92
150
330
330
300
Fire Point (ºC)
D-92
165
360
360
343
Auto ignition
Temp (ºC)
E-659
225-228
401-404
40 ºC
D-445
9.2
33.5
45
37
100 ºC
D-445
2.3
8.0
10
15
D-97
-50
-21
-15
-55
E-1269
1.92
2.11
D-2300
.000795
.00074
399-402
Viscosity (cSt)
Pour Point
(ºC)
Heat Capacity
(J/gºC
Thermal
Expansion
(ºC-1)
38
50 ºC
.000104
Comparison of Dielectric Fluids
Chemical Properties
Test Method
M.O.
FR3 Fluid
Biotemp
D-1533B
12
50
150
Acid Number
(mgKOH/g)
D-974
0.01
0.02-0.06
0.075
Interfacial
Tension
(dynes/cm)
D-971
47
20-25
Water Content
(mg/kg)
5-day
SM5210B
6
250
Chemical
Oxygen
Demand
(ppm)
SM5220D
82
560
7
45
30-35
> 99
BOD/COD
ratio (%)
Aquatic
Biodegradabili
ty (%)
39
OECD 301B
0.002
44.6
Environmental Properties
Biochemical
Oxygen
Demand
(ppm)
DC 561
97
Ultimate
Biodegradable
EPA OPPTS 835.3100
Readly
Biodegradable
EPA OPPTS 835.3110 (m)
40
Success = FR3 Fluid
PLUS
DOE Opportunity
41
1 Phase
Pole/Pad Mount
IN US, ALL 1P POLE MOUNT TRANSFORMERS OPERATE WELL BELOW DESIGN
TEMPERATURES. NO LOAD LOSSES DOMINATE TOC CALCULATIONS. SO HOW CAN
FR3 FLUID DELIVER VALUE?
Most 1P Pole mount transformers are loaded to
25% of nameplate rating.
25kva and/or 50kva dominate utility purchases
Resultant demands:
25kva – 6.5kva
50kva – 12.5kva
New Concept solution Employ a ‘slash’ rating to right size the transformer for
load while achieving reliability;
65C AWR/top thermal rating of insulation system as
determined by your transformer OEM
Conceptual solutions: transformers nameplated 10/15KVA
or 15/25KVA or 25/32KVA or 37.5/50KVA
Benefits: First Cost benefit. No Load Losses significantly
less; Life similar to mineral oil today; operation behavior
unchanged
42
Small 3 Phase
Pad Mount
IN SMALL 3P PAD MOUNT TRANSFORMERS, FRONT FACEPLATE IS LIMITING FACTOR.
SO HOW CAN FR3 FLUID DELIVER VALUE?
Most smaller 3P pad mount transformers
(1000kva or less) are mechanically limited by the
size of the face plate
Proposed solution – Specify ‘slash’ ratings
65C AWR/top thermal rating of the insulation
system as determined by your transformer OEM
Most 3P pad mount transformers are not loaded
to nameplate rating
Top thermal rating equal to standard
Benefits: First Cost benefit. No Load Losses
significantly less; Life similar to mineral oil today;
operation behavior unchanged
43
To Specify the most
reliable insulation
system
Base ratings for transformers shall be DOE
compliant, and designed to operate at 110C
hottest spot temperature, with a 65C average
winding rise. Overload capacity shall equal
the thermal limits of the insulation system, as
verified by the manufacturers of the insulating
materials, in conjunction with IEEE C57.154,
annex B.
Transformer Insulation System:
Transformer insulation system shall be
comprised of solid and liquid insulating
material. Solid insulation shall be
Weidmann TUK solid insulating materials.
Liquid insulation system shall Envirotemp
FR3 fluid.
Other ‘systems’ may be approved with the
submission of life cycle data establishing
aging rates similar to those outlined in IEEE
C57.154, Annex B.
44
Large 3 Phase Pad
Mount through
substations
IN LARGER 3P PAD MOUNT, AND CONTINUING THROUGH SUBSTATION
TRANSFORMERS, OPERATING LIMITS ARE TEMPERATURE BASED. SO HOW CAN FR3
FLUID DELIVER VALUE?
Most larger 3P pad mount transformers (1500kva
or more) are thermally limited
The limitations of those temperature bands
outlined by IEEE are for mineral oil insulating
systems (the intent is to establish insulation aging
rate., and therefore predict transformer life)
Changing the insulation system allows changing
the temperature limits, goal is to achieve similar
aging rates, predictable transformer life.
45
Suggested solution – Specify thermal class 140
insulation system, with optimal temperature rise and
hot spot ratings
75C AWR, 120C HST up to 85C AWR, 130C HST
Benefits: reduction of external cooling (may
eliminate failure mode), smaller footprint; less
materials. Life similar to mineral oil today; operation
behavior unchanged
How Others have taken
advantage of FR3 fluid
Situation
•
•
•
•
•
Large utility
600k gal/yr. distribution volume
$1,500/transformer
20,000 transformers replaced/year
Reduced quality of transformers
decreased asset life
Goals
•
•
•
46
Reduced failure due to dielectric
Prolong asset life minimum
20 percent
Increased fire safety added benefit
Results
• 17%/year reduction in number of
transformers replaced
• Savings/year
- 3,400 transformers
- $5.1 Million net/yr