Global

Development of
Natural Ester
Technology

CBIP February 2017

CONFIDENTIAL. This document contains trade secret information. Disclosure, use or reproduction outside Cargill or inside
www.cargill.com Cargill, to or by those employees who do not have a need to know is prohibited except as authorized by Cargill in writing.
 Where Do Esters Come
From and What do they
do?

2
Development History: from Mineral Oil via Synthetic
Ester to Natural Ester

1970s: Banning of ASKARELS (PCB)

 Cooper Power (USA Transformer OEM) Inititates search for fire safe, non-toxic alternatives transformer fluids

1975: High Molecular Weight Hydrocarbons

– Manufactured from High Molecular Weight Hydrocarbons
– High Flash and Fire Point, but Not Readily Biodegradeable
– Not in mainstream use, not sustainable

1984: Synthetic Ester

– Manufactured from several fatty acids and alcohol derived from crude oil, manufactured ingredients
– High Flash and Fire Point, Biodegradeable
– High Cost ingredients, not sustainable
1993: Natural Ester
 Refined from vegetable oils (over 40 formulations developed and tested), renewable, sustainable, low or zero CO2 footprint
 Highest Flash and Fire Point, Highest Biodegradeability
 Comparatively low cost and scaleable to replace mineral oils long term
 Development Of Natural Ester
Transformer Technology
High temperature
materials standards

Thermally
Free Breathing Sealed Natural
Upgraded
Designs Designs Esters
Kraft

1880 1900 1930 1960 1990 2010 2020

Common failure mode: mineral oil

(sludge, a bi-product of oxidation)
impacted heat transfer/dissipation Oxidation one of the factors
most damaging for insulation.
Operating temperature could
be Improved by sealing
55oC AWR, 95oC HST
The temperature limitation
by cellulose degradation
could be improved with
Further improvement of
thermally upgraded paper
transformer design with
upgraded insulation system
when using natural esters
65oC AWR, 110oC HST 85oC AWR, 130oC HST
 Research to ensure natural ester
performs in Distribution and Power
Transformers

5
 Testing and Validation by 3rd Parties
Number of validation tests has surpassed 270

UNIVERSITY OF MANCHESTER - ENGLAND UNIVERSITY OF GRAZ - AUSTRIA

UNIVERSITY OF HANNOVER - GERMANY TJH2B LABS; USA/GERMANY
UNIVERSITY OF NEW SOUTH WALES - MASCHINENFABRIK REINHAUSEN (MR);
AUSTRALIA GERMANY
MONASH UNIVERSITY - AUSTRALIA COOPER POWER SYSTEMS - USA
DOBLE, GLOBAL FM GLOBAL, GLOBAL
WEIDMANN EHV, GLOBAL UL – UNDERWRITTEN LABORATORIES, GLOBAL
WEIDMANN LABS, SWITZERLAND LABORELEC, BELGIUM
ABB VAASA, FINLAND SIEMENS TRANSFORMATOREN, GERMANY
UNIVERSITY OF CINCINNATI USA UNIVERSITY OF STUTTGART, GERMANY
US DEPT OF COMMERCE – NIST USA EPRI, USA
ERDA, INDIA CPRI INDIA
EASUN MR, INDIA CTR, INDIA
SEA MARCONI, ITALY

6
 Validation Parameters
• Insulation – Testing for Distribution and Power
• Heat transfer
• Diagnostics= Operation and Maintenance
• Aging of liquid (oil parameters) and transformer equipment (insulation system
parameters)
• Fault condition (DGA)
• Fire Safety
• Sustainability as a long term solution across all transformer sizes: cost long term, wide
availability and scaleability

7
 5 Standards Related To Natural Ester
Fluid

8
IEC 62770
Vegetable Insulating Oil – Acceptance Values for New Fluid

Property Method Value

Appearance Clear
Kinematic Viscosity (cSt) ISO 3104
100°C ≤15
40°C ≤50
Pour Point (°C) ISO 3016 ≥-10
Water Content (mg/kg) IEC 60814 ≤200
Density at 20°C (g/ml) ISO 3675 or 12185 ≤1
Breakdown Voltage (kV) 2.5mm gap IEC 60156 ≤ 35
Dissipation Factor (tan d) 90°C IEC 60247 ≤ 5%
Soluble Acidity (mg KOH/goil) IEC 62021-3 ≤0,06
IEC 62535 or ASTM D Non corrosive
Corrosive Sulfur (DBDS)
1275B IEC 62697-1 below detection
Total Additives (% weight fraction) IEC 60666 or other ≤5
Fire Point (°C) - open cup ISO 2592 ≥300
Flash Point (°C) - closed cup ISO 2719 ≥250
OECD 301B, C or F Readily
Biodegradation
OPPTS 835.311 (US EPA) biodegradable
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IEEE C57.147 - Table 3 – Power
transformers
New equipment, AFTER contact and BEFORE energization

>69kV ≥230kV
Property Method ≤69kV ≥345kV
<230kV <345kV
Dielectric Strength (kV) ASTM D1816
1mm gap ≥25 ≥30 ≥32 ≥35
2mm gap ≥45 ≥52 ≥55 ≥60
Dissipation Factor (25°C) (%) ASTM D 924 ≤0,5
Color ASTM D 1500 ≤L1,0
Visual Examination ASTM D 1524 Bright and clear
Neutr. number (mg KOH/g) ASTM D 974 ≤0,06
Water Content (mg/kg) ASTM D 1533 ≤300 ≤150 ≤100 ≤100
Fire Point (°C) ASTM D 92 ≥300
Kinematic Viscosity 40°C (cSt) ASTM D 445 ≤50
Total dissolved gas (%) ASTM D 2945 ≤0,5% ≤0,5%

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IEEE C57.147 Power Transformers
Limits for starting investigation for in service equipment

>69kV
PROPERTY ASTM ≤69kV >230kV
<230kV

Dielectric Strength (kV) D 1816

1mm gap >23 >28 >30
2mm gap >40 >47 >50
Dissipation Factor (25°C) (%) D 924 ≥3,0
Water Content (mg/kg) D 1533 ≥400 ≥200 ≥150

Viscosity increase from initial at

D 445 ≥10
energization at 40°C

Neutr. Index (mg KOH/g) D 974 ≥0,3

Flash Point (°C) D 92 ≤275
Color D 1500 ≥1,5

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 High Temperature Insulation System
IEC 60076-14 and IEEE C57.154
• IEC presents in its Annex C the suggested classifications of thermal class for
paper immersed in mineral oil and immersed in natural ester, making the difference
very clear.
• IEEE c57.154 presents same table on Annex B Additional
Capacity

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DGA Guide IEEE Std C57.155-2014

Hydrogen Methane Ethane Ethylene Acetylene Carbon

monoxide

Insert meeting and date

In Service Profile: Number of Tx with Natural
Ester

• Distribution transformers >1,000,000

• Total power transformers in use ~ 26,000

 Natural Ester Across All Continents
Region Projects
USA • US Glen Canyon National Hydro Power
India • Getco
• Torrent
• Tata Power
Brazil • Eletronorte

Europe • 5 TSO committed to HV with Natural Ester

• 5 Transformer OEM offer HV with Natural Ester

South Africa • Eskom Press Release

China • Wind Turbine and Solar Transformers

Japan • Solar plants

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