RETROFILLING AGING TRANSFORMERS WITH NATURAL ESTER BASED

DIELECTRIC COOLANT FOR SAFETY AND LIFE EXTENSION

C. Patrick McShane John Luksich Kevin J. Rapp
Cooper Power Systems Cooper Power Systems Cooper Power Systems
1900 E. North Street 1900 E. North Street 11131 Adams Road
Waukesha, WI 53188 Waukesha, WI 53188 Franksville,WI 53126
pmcshane@~cooDerPower.com jlu ksich@cooDerpower.com kraDp@cooDerpower.com
Member IEEE

Abstract: The number of mineral oil filled distribution and substation transformers at cement and
mineral extraction plants that are approaching the end of their normal life expectancy is
increasing. A proposed method of extending their remaining life is possible by retrofilling with a
natural ester dielectric coolant. Additional benefits include reduced fire and environmental risks if
the unit fails or when it is decommissioned. This paper reports on tests of miscibility and
compatibility of mixtures of the two types of dielectric coolants. The paper also discusses field
experience with retrofilling mineral oil-filled distribution and power transformers with a natural
ester. Finally, results of an accelerated paper aging retrofill study are presented. The data
collected to date suggests that the aging rate of the paper is significantly improved. Other
benefits indicated by data include an increase in the fire point by approximately 2OO0C, a
significant reduction in the moisture content of the insulation paper, the probable elimination of
bubble formation due to sudden overload, and the elimination of oil sludge formation. The
increase in the dielectric coolant fire point to over 3OOOC essentially eliminates the risk of oil pool
fires by arcing in the event of internal fault arcing.

INTRODUCTION

The cement industry is a relatively mature industry in North America. While some new plants have been
constructed in recent years, many plants are many decades old, often utilizing their original substation
transformers. One cement plant reported ten units with a medium age of 30 years, which is 9 years
beyond the ANSMEEE target life requirement. Extending the useful life or increasing the output of
existing plant assets is a topic of considerable interest, particularly in this era of tighter operational
budgets. The related issue of increasing age of the substation infrastructures and the corresponding
increased risk of equipment failure is a growing concern. Studies by Factory Mutual [3] and Hartford
Steam Boiler [4] indicate that a certain percentage of substation transformer failures will be “eventful”.
Another growing concern is minimizing the impact of transformer operations on the environment.

The Industry has been developing and using high fire point dielectric coolants since the mid 1970s. The
primary motivation was to develop environmentally preferred alternatives to askarel dielectric coolants.
The initial substitute fluids introduced included a fire resistant high molecular weight hydrocarbon and a
dimethyl-siloxaneoil, both with fire points of >300° C.

Synthetic polyol esters were introduced in 1984 to replace askarels used in compact heavy-duty
locomotive applications. Synthetic ester dielectric coolants have better cold temperature flow and
improved lubricity. End-users observed that the annual failure rate was reduced dramatically after
retrofilling with synthetic esters. However, synthetic ester dielectric coolants are expensive to produce.
Because of many chemical similarities between the synthetic polyol esters and certain natural esters
(vegetable seed oils), our attention turned to developing a more economical ester dielectric coolant in
1992 using food grade vegetable oils.

In 1999, a salad oil based dielectric coolant, Envirotemp@FR3TM,was commercialized by the introduction
of the EnviroTranTMtransformer. This introduction followed extensive accelerated aging studies and field
trials. Insulation paper is used for insulating the windings in the transformer. Our accelerated aging

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 studies indicated that insulating paper degrades much faster in mineral oil than in the natural ester fluid.
Previously published results on accelerated life testing of new distribution transformers [ I ] and small
scale insulation systems using virgin insulating paper [2] describe the degree of paper aging
improvement.

This paper reports on testing that determined the degree partially aged insulating paper in mineral oil
improves the aging rate if retrofilled with the natural ester. The results complement the studies on new
virgin paper referenced in the preceding paragraph. The paper also reviews data on field history of some
of the nearly 100 field mineral-to-vegetableoil retrofills.

There is no doubt that certain natural esters manufactured from food grade materials improves
environmental and fire safety profiles [5]. Now, with evidence that the fluid significantly reduces the aging
rate of both new and used insulating paper, there are multiple reasons to consider retrofilling existing
transformers. The investment offers a significant return by extending the life or capacity of the
transformer, and by reducing risk of direct and consequential damages due to fire and environmental
incidents.

LABORATORY TEST ON COMPATIBILITY OF ESTERS WITH MINERAL OIL

A retrofill fluid must be compatible with the transformer materials and its key performance properties
remain unaffected by contamination with the original fluid. Some of the original mineral oil will remain in
the unit regardless of the amount of flushing done. Therefore, contamination of the retrofill fluid by the
residual mineral oil will occur. Typically the expected residual oil after a proper drain, flush, and fill
operation should be less than 4%, most of which is found in the impregnated insulating paper. Even
without flushing, the residual oil should rarely, if ever, exceed 7%. It is important to know what effect one
fluid may have on the other at various ratios. Figures 1-6 show the properties of mixtures in various
proportions of conventional mineral oil mixed in the natural ester fluid.

"Om
300
I
A
0
Fire Pant
FlaShPant

-oool -00 0 10 20 30 40 50 60 70 80 90 100

Mineral Oil Content in Envirotemp FR3 (wt 36) Mineral Oil Content in Envimtemp FR3 (36)

Flash and fire points Viscosity

FIGURE 1 FIGURE 2

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 401 " " " " " " " " " ' J 20
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100

Mineral Oil Content in Envirotemp FR3 (36) Mineral Oil Content in Envimtemp FR3 (%)

Pour point Interfacial tension

FIGURE 3 FIGURE 4

100 ,, . , . , . , , , . , ,

0 001 r

0 10 20 30 40 50 80 70 80 90 100 0 20 40 80 80 100

Mineral Oil Content in Envirotemp EFR3 (%) MineralOil Content (%)

Dissipation factor at 25 "C. Dielectric breakdown strength

FIGURE 5 FIGURE 6

Discussion: Flash and fire point results are shown in Figure 1. While the flash point reduction is
consistent with expectations as the ratio of oil to natural ester is increased, the fire point reduction does
not reduce significantly until a threshold value of between seven and eight percent mineral oil content is
reached. Various tests have shown consistent results, and this is fortuitous indeed. This permits the
retrofilling of mineral oil with the natural ester that all but guarantees the fire point will remain well above
the less-flammable requirement of 300°C,even after extended time. Prototype retrofill data show the high
fire point remains well above 300°C,even for units retrofilled without drip time, flushing, nor vacuuming.
Details of this will be covered in the next section.

All other key fluid property results are as were anticipated and do not indicate any incompatibilities of
mixing the two fluids. Dielectric strength had the most scattered data points at 10% mixture level.

PROTOTYPE FIELD RETROFILL RESULTS

Two 225 kVA transformers serving transformer core annealing ovens were ideal candidates for the first
field retrofills of mineral oil transformers with natural ester fluid. The pad-mounted units, installed in the
early 1970s, are loaded continuously at approximately 80% of nameplate rating. Two different retrofilling
procedures were used. The "minimal effort" method was simply to drain out the mineral oil and
immediately refill the transformer with the natural ester fluid. The "best effort" method involved draining,
an extended drip time, flushing with hot natural ester fluid, a second drip period, vacuuming the residual
oil dregs, and finally adding the natural ester. The changes in key properties with time are shown in
Figures 7-14.

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 (Note 1: The reference limit values are from IEC 1203 for synthetic esters for transformer application.
ASTM is developing a guide specifically for natural esters, which may differ from the IEC standard. Note
2: Unknown at the time of the retrofilling, the unit selected for the minimal effort retrofill had a heavily
coked sectionaliting switch. The coking was discovered when the first DGA was taken after retrofilling.
The switch was replaced during a scheduled shutdown several months after the retrofill.)

) , o o , ;,
-----11-1--1---1-1-1-

iE' 1 3 3 00-t

Time in Service
I,
.Ut6 a<P,,"e ,""Y,m"'-

(years)

Fluid dissipation since retrofilling.

O j
0
0 1 2

Time in Service
Dielectric breakdown strength since retrofilling.
3

(years)
4 5

FIGURE 7 FIGURE 8

3 7 5 [ . , . , . , . , .

. i
I
30Q @ 0

40°C: A
0

minimumeffort
0 besteffort
3
e
2
$
3 4 .

325
L

-
:
.
300-----------------------
r,

- "
A,

4
- __ ___
A

_ _ ^ -

1 0 0 ~A
~ : minimum effort
LC I'? nt. I
L ? ;
..............
8 besteffort E
.
2 275 1

0-92 Fire Point A minimum effort

i"
0
A A

1 2
4

3 4
c
i
5
250

225
D-92 Flash Point A minimum effort
0 besteffort
1

Time in Service (years)

Kinematic viscosity since retrofilling.
FIGURE 9

8 0 0 . I . , . , . , .

70
0 besteffort

40-
W .
h .
s -
c .
0
- 400

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 Interfacialtension since retrofilling. Water content since retrofilling.
FIGURE 11 FIGURE 12

le+15 . , . , . , . , ,

0 besteffort

0
0

001' " " " " ' J le+ll

0 1 2 3 4 5 0 1 2 3 4

Time in Service (years) Time in Service (years)

Acid number since retrofilling. DC resistivity since retrofilling.
FIGURE 13 FIGURE 14

As predicted by the laboratory tests discussed in the previous section, the fire points of both units remain
high. It can also be seen that the best effort retrofill procedure provides superior values of the key
properties. Part of the reason is due to the extra contamination of the mineral oil in the unit with the
coking switch that was replaced soon after the first retrofill was taken, and part of the reason is due to the
different residual oil content. In 2002 it was also discovered that the minimum effort unit was allowing
external moisture ingress through a small tank leak.

Some properties are more affected than others from the switch coking and moisture ingress. For
example, dissipation factor and IFT results are very sensitive to contamination, whereas fire point is not.
The only property that does not appear to have any significant difference is kinematic viscosity. The
prototype retrofilled units are still functioning, with samples scheduled to be drawn and tested each July.

FIRST MEDIUM POWER TRANSFORMER RETROFILL RESULTS

In October 2001, Alliant Energy retrofilled a substation transformer (Manufacturer: Pennsylvania;

Nameplate data: 3Phase, 50 MVA, 69 kV, 350 kV BIL, 7000 gallons, built in 1957) with the natural ester
dielectric fluid. Immediately prior to retrofilling, the mineral oil had a water content of about 11% RH (7
mglkg). Six weeks after the retrofill, the natural ester had a water content of about 3%RH (36 mg/kg).
One year after the retrofill, the fire point of the natural ester at 350"C, while the flash point dropped below
250°C indicating about 7% residual mineral oil (the unit was not flushed nor vacuumed during the
retrofill). Furan content level dropped to non-detectable. Dielectric strength tested at 57 kV and the water
content at 30 ppm.

ACCELERATED AGING TEST WITH PARTIALLY AGED PAPER IN OIL AT TIME OF RETROFILL

Previous papers report on the improvement of insulation life in accelerated aging test between the natural
ester and mineral oil [1,2]. The current test series was undertaken to determine how insulating paper
partially aged in mineral oil would age after replacing the mineral oil with natural ester fluid. The sealed
tube systems initially contained insulating paper in mineral oil. Earlier testing indicated that 250 hours at
170°C resulted in about a 50% reduction in degree of polymerization for mineral oil impregnated paper. At
the 250 hour point, half of the mineral oil systems were retrofilled with the natural ester and replaced in
the ovens for continued aging. The results to date are shown in Figures 15-17.

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 1000 2000 3000
0 '
0
8'.
1000
.._..__
MOO
-
3000

Aging Time (hours) Time (hours)

Degree of polymerization - sealed tube Tensile strength - sealed tube
systems at 170°C. systems at 170°C.
(Retrofills at 250 hours). (Retrofills at 250 hours)
FIGURE 15 FIGURE 16

I-" -

t ri
1

0
0 1WO 2000 3W0

Aging Time (hours)

Water content of paper - sealed tube systems Retrofilling a 50 MVA transformer installed in 1957.
at 170°C (retrofills at 250 hours). FIGURE 18
FIGURE 17

The results shown in Figures 15 & 16 clearly show that paper partially aged in mineral oil degrades at a
much slower rate after retrofilling with the natural ester fluid. In fact, the retrofilled aged paper aging rate
matches the rate for the new paper. Figure 17 provides a clue to the reason for the significant difference
in aging rates.

The paper samples tested at the 500 hour point, two hundred and fifty hours after the retrofill point, show
a major difference in the moisture content. The moisture in the samples aged in oil increased to a 1.0%
level, while the paper aged in the natural ester decreased to under 0.4%. Water is known to be the major
factor for accelerating the aging process in paper, and as paper ages it produces more water. By 1,000
hours the water content in the insulating paper aged in oil reaches approximately 6%, where it begins to
disintegrate.

These results indicate retrofilling older transformers with the natural ester may be a very effective way to
extend the useful life of the insulation system or allow increased loading. Not only does the aging rate
decrease dramatically, the natural ester also dries out paper that contains water resulting from aging.
With the paper at a very low water content, not only is the aging rate improved, the dielectric strength of
the insulation is increased and the potential for vapor bubble formation due to sudden overload is
eliminated. In addition to performance improvements, the fire and environmental risks are decreased,

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Field Experience: To date, approximately I 0 0 distribution and substation transformers have been
retrofilled with the natural ester dielectric coolant. There have been no reported field problems. All were
mineral oil filled units with one exception, an askarel (PCB) unit. Due to the favorable retrofill history and
their maintaining a very high fire point even with the residual mineral oil migrating out of the impregnated
insulating paper,

Reduced Required Safeguards: One property risk research company has recently revised is
transformer safeguards requirements. It has increased the threshold for Approved, less-flammable
dielectric coolants that qualify for significant reductions in fire safeguarding. For example, for a minimum
required distance between a transformer and other substation equipment of 5 feet, the maximum mineral
oil volume allowed is 500 gallons. That compares with an allowance of 10,000 gallons for Approved
fluids.

In the same revised loss prevention document, the transformer safeguards requirements also consider
relative environmental properties. For example, the threshold volume for transformer fluid containment is
500 gallons for mineral oil. These compare to natural esters with certified high biodegradation rates
having a threshold of 2,640 gallons before requiring containment (unless there is exposure to a navigable
water way, which has a threshold of 1320 gallons).

SUMMARY

Based on the results of both laboratory and field testing, it is clearly technically viable to retrofill mineral
oil transformers. Immediate improvement in the aging rate of the insulating paper suggests that the
procedure can lead to extending the useful life of transformers or allowing an increase in energy capacity.
Other benefits show that the fire safety margin is increased, a reduction of insurance and Code
requirements may be available, and the environmental profile of the installation can be improved.

ACKNOWLEDGMENTS

A special thank you to IEEE members Mark Huber, Lafarge North America, Inc. for sharing field data and
Jack Stroker of Penta for coordinating this technical paper and presentation for the 2003 IEEE
conference. We gratefully acknowledge Rob Weber and Bill Mitchell of Alliant Energy for making the
making the 50 MVA prototype power transformer prototype retrofill possible. Also a special thanks to
Warren Zaren & Kevin Rapp and the folks at the Thomas A. Edison Laboratory, Franksville, WI for their
excellent analytical work.

REFERENCES

1. McShane, C.P., Gauger, G.A., Luksich, J.; “Fire Resistant Natural Ester Dielectric Fluid and
Novel Insulation System for its Use”, IEEEIPES T & D Conf., Apr. 12 -16, 1999.
2. McShane et. al., “Aging of Paper Insulation in Natural Ester Dielectric Fluid”, IEEEIPES T&D
Conf., Oct. 2001, No. 0-7803-7287-5/01 0 2001 IEEE
3. Factory Mutual Global, Loss Prevention Data Sheet 5-4, pp.28-30. Rev. 2003
4. Bartley, William; An Analysis of Transformer Failures, The Locomotive, Hartford Steam Boiler I. &
I. CO,1997.
5. McShane, C.P.; “Relative Properties of the New Combustion-Resistant Vegetable Oil-Based
Dielectric Coolants for Distribution and Power Transformers”, IEEE Transactions on lndustrv
Amlications, Vol. 37, No. 4, JulyIAugust 2001, pp. 1132-1139, NO. 0093-9994/01 0 2001 IEEE.
6. McShane, C.P., “Vegetable-Oil-BasedDielectric Coolants”, IEEE Industry ADDlications Maaazine,
Vol. 8, No. 3, May/June 2002, pps.34-41, No.1077-2618/02,0 2002 IEEE.
7. Moylan, W.J., McShane,C.P., Corkran, J.L, Pierce, A., “Power Engineering Effective Solution: A
Case History on Meeting Energy Let-Through Requirements for a Distribution Transformer”,
Transactions on lndustrv Awlications, Vo1.38, No.6, NovembedDecember 2002, pps. 1714-1721,
N00093-9994/02.0 2002 IEEE.

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