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.
FMEAFall Conference
November 6th, 2015
www.cargill.com
Natural Ester Dielectric Fluids
Overview
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 program-Conceives Natural Ester Revolution
……………and Envirot™ FR3™
3
• Natural Ester transformer placed into service in 1997 by Waverly Power & Light- Iowa.
• Waverly P&L-• Piloted field testing.
• Now nearly 1 million transformers use Natural Esters as part of their insulation system.
A transformer containing the Envirotemp FR3 transformer fluid is pictured in the foreground. Photo courtesy of Waverly Light & Power
Free Breathing Designs
Sealed Designs
Thermally Upgraded
KraftNatural Esters
1880 1900 1930 1960 1990 2010Common failure mode: mineral oil (sludge, a bi-product of oxidation) impacted heat transfer/dissipation
Diagnostics put into practice
2020
High temperature materials standards
Common failure mode: shifted to solid insulation; constrained by operating temperature
Common failure mode: solid insulation; operating temperature increased
85oC AWR, 130oC HST55oC AWR, 95oC HST 65oC AWR, 110oC HST
Common failure mode: solid insulation; operating temperature increased
Transformer history (1890-present)
4
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°CBiodegradability Low Ultimately Readily No
Biobased No Yes No No
Oxidation Good Acceptable(non-free breathing)
Very good Very good
Aging Average Best Better AverageInitial Cost $ $$ $$$ $$$
Fluid characteristics impact performance capabilities in transformer application
5
Fluid differences impact performance
6
FluidCharacteristics
Mineral Oil Natural Ester
Transformer performance
65 AWR110ºC hottest spot
85 AWR130ºC hottest spotAllows for overload or life extension
Reliability-dielectric strength
Dielectric strength declines as heat increases due towater saturation
Retains dielectric strength in presence of waterSelf Drying - Hydrolysis “consumes” the water
Moisture saturation (@20°C) – Keep Moisture out of the Paper!
55 ppm 1,100 ppm
Fire safety Flash point 155ºCFire point 160ºC
Flash point 330ºCFire point 360ºC
Environmental footprint
Non-biodegradable Non toxic, non-hazardous in soil and waterCarbon neutral Biodegradable in 28 days
Hottest Spot Temperature
( )
Average Winding Rise (K)(Top Temp ‐ Bottom
Temp)/2
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• Natural Ester filled transformers thermal capability
enables lower cost per kVA, longer life, reduced transformer price, and positive NPV
Insulation system is the primary failure mode of a transformer
7
FR3 fluid Formulation Developed
ASTM Standard Published
Envirotemp Dielectric Fluids Business Purchased by Cargill
19Jun12
FR3 fluid Applied to 1st Transformer
FR3 fluid Commercially Available
IEC Standard Published
IEEE Standard Published
High Temp Insulation System Standards Published
1990
1995
2000
2005
2010
2015DGA Standard Published
Over 20+ years of experience with Natural Esters
Cargill begins FR3 fluid production
8
Increased Safety - Reduces Fire Risk
Improved Environmental Footprint
Optimized Transformer Performance Lower total cost Greater Reliability
Natural Esters:Three important benefits to remember
9
Increased Safety - Reduces Fire Risk
Natural EstersKey Advantages
10
Fire Safety(K class fluid) - UL and FM
No reported fire related failures!11
Fire SafetyFlash and Fire Point of Ester K-Class Fluids » Fluids classified as “Fire Resistant” (K Class) must
have Fire Point above 300°C
150
200
250
300
350
400
Tempe
rature (°C)
MineralOil
Envirotemp200 Synthetic
Silicone Envirotemp FR3 Natural Ester
Flash PointFire Point
308
343360
165155
270300
330
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.
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
Increased Safety - Reduces Fire Risk
Improved Environmental Footprint
Natural EstersKey Advantages
14
Natural ester fluid is a better choice for the communities you serve
15
• 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
Increased Safety - Reduces Fire Risk
Improved Environmental Footprint
Optimized Transformer Performance Lower total costGreater Reliability
Natural Esters c57.154Key Advantages
16
Optimize performance: Increase capacity with reduced transformer sizeINCREASE LOADABILITY BY UP TO 20% WITHOUT DEGRADING ASSET LIFE
17
• IEEE C57.154 (IEC 60076-14) High temperature insulation system standard− 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
18
Protecting life of insulation paper is thenumber one factor that determines asset
life
Tested, validated and proven
19 SPCAA Presentation – May 13, 2014
Validated by industryMeets 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
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
20
Natural Esters Mineral OilNew Oil ASTM D6871 ASTM D3487
IEC 62770 IEC 60296
Use and Maintenance IEEE C57.147 IEEE C57.106IEC 60422
Transformers IEEE C57.12.00 IEEE C57.12.00IEC 60076 series IEC 60076 series
IEEE C57.154 IEEE C57.154IEC 60076-14 IEC 60076-14
Loading Guide IEC 60076-7 IEC 60076-7
Dissolved Gases IEEE C57.155 IEEE C57.104IEC 60599
ASTM, IEEE and IEC natural ester standards
Fire FM Global Property Loss Prevention Data Sheets, 5-4 TransformersIEC 61936-1 Power installations exceeding 1 kV a.c. – Part 1: Common rules
11
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
- 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
22
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
• Extended transformer life• Insulation system up to 8X* extended lifespan• Transformer asset extended lifespan• Better handle’s overload conditions• Enables smaller, lighter (75-85C rise) designs
• Environmental • Environmental safety (no hazardous fumes, fires,
reduced spill mitigation)• Petroleum independent• Reduced carbon emissions• Biodegradable/non-toxic/recyclable
23
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
SPCAA Presentation – May 13, 201425
Appendix
26
Improve reliability: Extend insulation and asset life 5-8x longer than mineral oilUnique chemistry of FR3™ fluid protects insulating paper by:
• oil
27
• Hydrolysis of natural ester “consumes” the water and produces fatty acids. This process removes dissolved water
• FR3™ Fluid is in essence ‘self drying.’ Water concentrations in the fluid will be reduced due to hydrolysis over time.
• FR3 fluid can absorb significantly more water than mineral oil
• FR3 fluid has 10 times the water saturation (PPM) than mineral
Protecting life of insulation paper is the number one factor that determines asset life
Increased Safety - Reduces Fire Risk
Improved Environmental Footprint
Optimized Transformer Performance Lower total cost Greater Reliability
FR3Key Advantages
28
Fluid differences impact performance
29
Mineral Oil Envirotemp FR3
Fire point 160° C 350° C
Readily and ultimately biodegradable ✗ ✓
Breakdown voltage 70 kV > 75 kV
Moisture saturation (20°C) 55 ppm 1,100 ppm
Cellulose ageing = transformer life poor 5-8 times slower -proven
Oxidation stability sealed or breathing transformers
shut or breathing transformers
Compact transformer design ✗ ✓
Rel
evan
t E
dific
atio
n
Building wall
X1
Sump
ENVIROTEMP FR3 Fluid
X2
Installation Benefits
FluidFluid
Volume (liters)
Minimal separation distancesFrom equipment to edification
X1 Between equip
X2Fire resistant for 2h
Non combustible
Mineral Oil
< 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
FR3< 38.000 1,5 m 1,5 m> 38.000 4,6 m 7,6 m
Rel
evan
t E
dific
atio
n
MINERAL Oil
Sump
>0,5m >0,5m
Firewall
X1 X2
Sump
Building wall
Rel
evan
t E
dific
atio
n
3030
CaliforniaEnvironmental
Technology Verification
2013 recipient of Presidential
Green Chemistry
Award USDA BioPreferred
Program
US EPAEnvironmental
Technology Verification
31
2013 recipient of
EPA DfE certification
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.
Cargill BackgroundHistory:• 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 !
143,000 Employees
150 years of
experience
Installation BenefitsTypical Containment system for Mineral Oil
Designed to 110% of larger equipment oil volume + rain water + fire fighting system water, automatic or manual
Simplified sump proposed forEnvirotemp FR3 (if required)
Designed for larger equipment oil volume + rain water
Manual or Automatic draining system
Fluid volume + rain water
Rocks for flame suppresion
SumpOil + Rocks volume
Oil / Water separation tank
3333
Simpler, less costly spill remediation
34
Mineral Oil– Low viscosity– Fast seepage (infiltration)– May reach water reservoir – Biodegradation very slow– Very high remediation cost
WaterSoil
Tap Water
FR3 fluid– Non toxic– Seepage very slow– Ready and complete
biodegradation– Very low remediation cost
WaterSoil
Tap 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).
35
University of Manchester - EnglandUniversity of Hannover - GermanyUniversity of New South Wales - AustraliaMonash University - AustraliaDobleWeidmann
EHVWeidmann Labs
Quality SwitchUniversity of Cincinnati
University of Graz - AustriaTJH2B LabsReinhausenCooper Power Systems - FranksvilleFM GlobalULPowertech LabsSPX TransformersSD MyersEPRIUS Dept of Commerce - NIST
Fluid Comparative Summary
36
MINERAL OIL 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 Good for Clean, Indoor Locations No Liquid Spill Risk
Higher Temperatures & Losses Sensitive to Overload & Harmonics Regular Cleaning RequiredMinimal Diagnostic Testing Service Life Concerns High Initial & Operating Cost
SILICONE Good Fire Safety & Overall Reliability Low Temperature & Low Losses
Higher Cost Less Diagnostic Testing Capability Inferior Coolant & Dielectric Not Suitable as Switching Medium Environmental Concerns – Not Biodegradable
FR3™ FLUID Good Fire Safety & Overall Reliability Biodegradable Sustainable, Renewable Supply Extends solid insulation lifespan Carbon neutral footprint Higher cost
FR3™ fluid is superior to other dielectric fluids in many ways.
Comparison of Dielectric Fluids
37
Electrical PropertiesTest Method M.O. FR3™ Fluid Biotemp DC 561
Dielectric Breakdown (kV)
2mm gap, lab
ambient
D-1816 62 48-75 65 43
1mm gap, lab
ambient
D-1816 31 28 32
Dissipation Factor
25C D-924 0.010 0.023-0.103 0.015 0.007
100C 0.050 0.67-3.86 0.2 0.0015
Volume Resistivity (1012-cm)
D-1169 200 20 10 1000
DC Leakage (µA)
CPS 0.01 0.04
Dielectric Constant
2.2 3.2 3.2 2.26
Impulse Strength (kV)
D-3300 269 226 100 223
Gassing Tendency (µL/min)
D-2300 +6 -79 +5
Comparison of Dielectric Fluids
38
Physical PropertiesTest 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-659 225-228 401-404 399-402
Viscosity (cSt)
40 ºC D-445 9.2 33.5 45 37
100 ºC D-445 2.3 8.0 10 15
Pour Point (ºC)
D-97 -50 -21 -15 -55
Heat Capacity (J/gºC
50 ºC E-1269 1.92 2.11
Thermal Expansion (ºC-1)
D-2300 .000795 .00074 .000104
Comparison of Dielectric Fluids
39
Chemical PropertiesTest Method M.O. FR3 Fluid Biotemp DC 561
Water Content (mg/kg)
D-1533B 12 50 150
Acid Number (mgKOH/g)
D-974 0.01 0.02-0.06 0.075 0.002
Interfacial Tension (dynes/cm)
D-971 47 20-25 44.6
Environmental PropertiesBiochemical Oxygen Demand (ppm)
5-day SM5210B
6 250
Chemical Oxygen Demand (ppm)
SM5220D 82 560
BOD/COD ratio (%)
7 45
Aquatic Biodegradability (%)
OECD 301B 30-35 > 99 97
Readly Biodegradable
Ultimate Biodegradable
EPA OPPTS 835.3100
EPA OPPTS 835.3110 (m)
4040
PLUS
DOE Opportunity
Success = FR3 Fluid
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?
42
Most 1P Pole mount transformers are loaded to 25% of nameplate rating.
25kva and/or 50kva dominate utility purchases
Resultant demands:25kva – 6.5kva50kva – 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
Small 3 Phase Pad Mount
IN SMALL 3P PAD MOUNT TRANSFORMERS, FRONT FACEPLATE IS LIMITING FACTOR. SO HOW CAN FR3 FLUID DELIVER VALUE?
43
Most smaller 3P pad mount transformers (1000kva or less) are mechanically limited by the size of the face plate
Most 3P pad mount transformers are not loaded to nameplate rating
Proposed solution – Specify ‘slash’ ratings65C AWR/top thermal rating of the insulation system as determined by your transformer OEM
Top thermal rating equal to standard
Benefits: First Cost benefit. No Load Losses significantly less; Life similar to mineral oil today; operation behavior unchanged
To Specify the most reliable insulation system
44
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.
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.
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?
45
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.
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
46
Goals• Reduced failure due to dielectric • Prolong asset life minimum
20 percent• Increased fire safety added benefit
Situation• Large utility • 600k gal/yr. distribution volume• $1,500/transformer• 20,000 transformers replaced/year• Reduced quality of transformers
decreased asset life
Results• 17%/year reduction in number of
transformers replaced
• Savings/year - 3,400 transformers- $5.1 Million net/yr
