Document B8R2o26028EL17oONgeOYd08k

1\ Monsanto ,"OB'>w,LO"r|Q"1 J. G. Bryant - St. Louis_____________ D`Tl December 14, 1970 cc New Dielectric for Liquid Pilled Cables, Transformers and Circuit Breakers September 30, 1970 memo TO DISTRIBUTION LIST P. Baber - MBABE H. S. Bergen - HBERG P. G. Benignus - PBENI D. E. Roush - DROUS R. Davis - RDAVI J. R. Fallon - JPALL T. L. Gossage - TGOSS R. H. Munch - Oueeny J. S. Pullman - New York . R. Richard - WRICH J. C. Wygant - JWYGA J. J. Roder - Chicago W. C. Crawford - WCRAW DSW 201787 STLCOPCB4059854 The purpose of this report is to follow up the actions out lined in the September 30 memo which have either been com pleted or reevaluated. The information to date is summarized in this report together with an outline of needed action and target dates. Since there have been several reports issued on various phases of the work, the input to this report is a summary of these actions. In respect to these inputs a special acknowledgement is made to M. P. Baber, D. E. Roush, J. J. Roder, J. S. Pullman, and R. Weiss for each of their important con tributions. SUMMARY The primary emphasis on the application of the new dielectric fluid has been liquid filled-force cooled cables. Prom an electrical standpoint, the cable fluid application is somewhat unique in that you need adequate heat transfer characteristics, high dielectric strength, low dissipation factor, low dielectric constant, a fluid completely void of gas or gaseous forming materials and complete electrical compatibility of the fluid with the system. The alkalate benzene high boiler is the only can didate to meet these requirements and it meets them only after vigorous refinement. Alkalate benzenes have been used for some time in liquid filled cable applications both as an additive and for cable filling. We have quoted and worked with Rio Light and Power in Brazil and Pirelli of Italy. Also, in the U.S. the cables have been looked at by Westinghouse and General Electric. Small amounts of alkalate benzenes are presently added to the cable system to improve the electrical properties. The prime problem has been the high price (80 cents plus per gallon) for alkalate benzenes. As with other dielectric fluids, the pricing must be competitive. The high boiler can be priced competitively with fluids presently being used for the application. However, we can ruin our chances of entering this market by ex cessive pricing of the product. The market potential of two million gallons in the U.S. for this fluid is presently being met with polybutenes priced at an average of fifty cents per gallon. The total market based on fifty cents per gallon is expected to grow from the $1 million to $1.5-$2.0 million by 1975. Although preliminary tests in our laboratories have indicated the alkalate benzene high boiler would be an acceptable candi date, complete electrical compatibility must be demonstrated. Compatibility tests are now being run. We must still gain cus tomer acceptance. We are proceeding with samples for testing by the customers. DSW 201788 STLCOPCB4059855 2- - As previously mentioned, the alkalate benzene hi-boiler in its present state will not meet the need. However, by closing up the storage tank vents and by installing adsorbers which should hQ the material can be' brought within the desired" specifications. The cost of these changes combined with the material costs would amount to about 15 cents per gallon. With a selling price ceiling of 50 cents per gallon, a reasonably good gross profit could be realized. Again the product will have to be priced below 50 cents to develop a market. Also, at a reasonably low price the alkalate benzene high boiler probably has other applications in specialty transformers and switch gear where the needs are presently being filled with mineral oils or synthetics. FUTURE ACTIONS 1. Submit samples for customer evaluation. 2. Establish the electrical compatibility of the high boiler with the cable system. 3. Write product specifications. 4. Determine plant needs to produce specification material. 5. Determine sales price for material. 6. Write a market plan. APPLICATION In recent years there has been an active interest in the U.S. on underground power distribution around cities because of the excessively high cost for "right of way" and public opinion against overhead cables. As underground installation is expen sive, too, the load on the underground cables is increased. The increased load causes increased heat which then necessitates liquid filled cables to dissipate the heat. Once the conductor reaches 85C, then forced circulation cooling must be used to remove the heat. The cooling fluid for this system is where our candidate fluid has application. To better understand the re quirements, the cable system must be understood. CABLE SYSTEM The system must handle primarily 138KV to 345 KV. The typical cable consists of stranded wire (normal power transmission is along the surface rather than the core) wrapped with paper in sulation. The cables are wrapped in a bundle with paper insu lation and a spacer to create voids for circulation and placed in an 8-inch schedule 20 pipe. Since the cables must be DSW 201789 STLCOPCB4059856 -3- up in advance to field installation, the insulation is thoroughly impregnated with a high viscosity polybutene1"l!:> completely dis place any air in the insulation which may lead to corona when the system is installed and energized. High viscosity polybutene is used to Impregnate the cables because an immobile fluid is needed to avoid storage leakage and "messy" installation. a Once the cable is installed, low viscosity polybutene is used as the circulating fluid. Obviously there is no compatibility problem with the polybutenes. However, when other cheaper fluids are used as the circulated coolant they leech out the high vis cosity polybutene. The fluids must be compatible physically but more importantly must be compatible electrically. When cheaper circulation fluids such as mineral oils are used there can be lowering of electrical properties because of incompatibility. FLUID REQUIREMENTS The electrical properties tend to combine both the capacitor and transformer requirements. First, the dielectric strength must be high to provide the desired insulation. The dielectric constant must be low to avoid a high capacitance buildup and the need for power factor correction. The dissipation or power fac tor must be low to avoid power factor corrections. The gaseous content or gas forming components must be low to avoid corona which would cause cable failure. The material must have a low pour point of -45C or lower. The heat transfer properties must be adequate and the viscosity fairly low. Also, physiologically the fluid must have a low or light color similar to polybutene. SCREENING OF VARIOUS CANDIDATES Several process streams were evaluated from Alvin, Texas and several from Texas City. All these streams fall short of meet ing the need with the exception of the alkalate high boiler streams. There are two alkalate high boiler streams which re sult from the two alkalate feed streams. These streams are known as the alkalate high boiler light (MCS 1071) and alkalate high boiler heavy (MCS 1072). The other candidates were eliminated for the following reasons: the aromatic oils were too low in flash point; the resin oils were too high in unsaturates and felt to be too reactive in considering the system; also, the resin oil is from a dwindling process and the source of supply was not believed dependable. Also, the stream requires hydrogenation to improve the stability. Of the ethyl benzene only the bottoms 5D4 were considered because of the low flash point. Even with 5D4 the flash point is marginal, the power factor on 5D4 cannot be lowered sufficient to meet the specs, and the low resistivity confirms the poor power factor reflecting undesirable electrical DSW 201790 STLCOPCB4059857 -4- properties. The color is extremely dark and would physiolo gically kill any chances the material may have even if it were acceptable on other properties. The attached table lists the properties of the various candidates. PROPERTIES OP THE ALKALATE HIGH BOILER STREAM Once the material is dried and adsorptive refined, it closely meets the desired specifications of the polybutene. See the comparison in the attached table. The high water content (80 ppm) was the cause for the poor dielectric strength ob tained in the first alkalate high boiler samples. The water may be moisture pick up in the storage system, in which case the problem may be resolved by closing up the system. However, if the moisture is attributed to the actual process the removal can still be accomplished but would be more expensive. Like other dielectric fluids, the alkalate high boiler must be ad sorptive refined to improve the electrical performance. The color is slightly darker than polybutene but probably suf ficiently close to be acceptable. It must be understood that as the material presently comes off the process it cannot be used. Since the alkalate streams are divided into high and low streams, the high boiler also varies accordingly. The high boiler "highs" MCS 1072 are more viscous which is less desirable, but is only slightly out of the desired range. However, when the lows are blended the material meets the requirements. Although it would be desirable to store the two products separately and blend according to need, this would not be economical and probably is not necessary. We believe a suitable solution can be worked out in the requirements to take the material as it leaves the process. Although additional research work must be conducted on compati bility of the high boiler with the cable system, no problem is anticipated. The electrical compatibility of especially the high boiler and the polybutene will be checked in Monsanto labo ratories. Customers will test compatibility of the cable system. This is slightly different from our original plan to have an independent laboratory evaluate the product but probably more desirable. ACTIONS TAKEN TO DEVELOP THE MARKET Research Samples of various candidates have been screened. Most likely candidates have been selected. Manufacturing process has been DSVV 201791 STLCOPCB4059858 -5- reviewed to simplify handling of product. Compatibility tests for screening the candidates against polybutene have been run. Samples have been prepared for customer testing. Production Availability of product and approximate inter-division price have been established. Market Contacts have been made with utility (customer) and cable manu facturers.. Test arrangements have been made for evaluating the product. ACTIONS NEEDED Research 1. Evaluate the compatibility of 1071 with polybutene, parti cularly the effect of concentrations on power factor. 2. Evaluate the system compatibility - customer testing 3. Write a complete product specification 4. Evaluate plant process and determine needs for meeting specification Production 1. Review present system and establish additional equipment necessary for producing the desired product 2. Establish with production any change in the collect system necessary to produce the desired product Market 1. Establish pricing 2. Obtain orders 3. Expand application to other areas such as switch gear and transformers 4. Expand other heat transfer applications which may be de veloped out of the system DSW 201792 STLCOPCB4059859 6- - SPECIPIC PLANS AND TARGET DATES FOR ACTION ACCOMPLISHMENT (REFER TO ACTIONS NEEDED)' : Target Action Specific Plan Responsibility Date la. Evaluate electrical properties of polybutene - power factor 1. heavy J. C. Wygant 2. light R. H. Munch 1/30/71 lb. Evaluate various concentrations of polybutenes with high boiler as a function of the effect on J. C. Wygant power factor R. H. Munch 2/15/71 2. Evaluate customer compatibility J. C. Wygant data. R. H. Munch J. G. Bryant J. J. Roder D. E. Roush 2/15/71 3. Write a product specification J. C. Wygant J. G. Bryant D. E. Roush 1/30/71 4. Evaluate plant process and de termine needs for meeting spec!' fication J. G. Bryant 2/15/71 Production .1 Review the present system and establish additional equipment necessary for producing the de sired product 2. Establish with production any change in the collect system necessary to produce the de sired product. J. G. Bryant J. G. Bryant 12/30/70 2/15/71 Market .1 Establish pricing J. G. Bryant D. E. Roush 2. Obtain orders J. G. Bryant J. S. Pullman J. J. Roder 3. Expand application to other areas G. R. Graham such as switch gear and trans- J. G. Bryant formers M. F. Baber 2/28/71 3/15/71 DSW 201793 STLCOPCB4059860 -7- Specific Plan Responsibility Target Date 4. Expand other heat transfer ap D. E. Roush plications which may be de J. S. Pullman veloped out of the system J. J. Roder Time Table for Completion of Specific Plans Action Research Dec.'70 15 30 Jan. 15 30 Feb. 15 28 >1 March 15 30 4 Production 1 ---------------------- >| 2----------------------------------------------------------- Market 1 2 3 4 *1 Continuing ----------- > Continuing DSW 201794 STLCOPCB4059861 *4 SS c >* ^ N 4J C 4) in <j> hv o cs 05 -l-a5 Q on (14 3 V O 41 3u 0m ffl X e U3 O' 0 C TJ >1 4J r-l 0M r-l OJ W HU x -* r O O (N X *-3 HP 0 Io 4J <H 0U r-l 0) CO HO X -H E r-l 0 <m P xo ou n >1 > v* 0o oo vO in vO p VE EH *w *0* 3S' S3 jo 22 2S32 2 u o.'o pw a. oc v o w x u c a 4) *J "4 E > 0 H i) U m 0. 0 V> U X <a u X o) O UH 4J U 1-1 ff> 0 A *cDe>CO Xan 0 Q -H ao X -4 -. Li i 5-1 05 4J I tu a m *t j -- Vl PS 4J CO OQ 00 4 (ft O O 01 a 4 o< \o < ?3>1 E- 41 V C *a > 0 ~i Eh > o (4 4J C T3 T3 V P UV a. + mr4 co ac a-h gE a U 0Q ti n vo x a 0 P- EH O o 0 <i Vi vrt IS S3 0-- Vj O O^ p Vl 0 O -TV o < Vl STLCOPCB4059862