Document JxKdrKOgdm9zDRNL3G0nGXyv

ENERGY RESEARCH & DEVELOPMENT ADMINISTRATION Room 5619 Main Interior Bldg. 18th ft C Streets, N. W. Washington, D. C. 20240 Proposal No. FIRE RESISTANT TRANSeOP.HER DJSULATION SYSTEM Submitted by H. A. Pearce. Project Manager WEST INCHOUSE FIECTRIC CORPORATION Materials Manufacturing Technology Department Sharon, IVnnsy1vania December 11, 1975 NPC00026376 753713 Proposal to: ENERCY RESEARCH & DEVELOPMENT ADMINISTRATION Room 5619 Main Interior Bldg. 18th & C Streets, N. W. Washington, D. C. 20240 FIRE RESISTANT TRANSFORMER INSULATION SYSTEM December 11, 1975 NPC00026377 753714 TAREE OF CONTENTS Page 1. Introduction..................................... .. 2. Objectives.............................................. 3. Work Statement .......................................... Phase I - Development of New Materials and Evaluation of present materials ....................... * ........ 3.1.1 Dow C o r n i n g ............................... 3.1.1.1 Materials to be Evaluated .......... 3.1.1.2 Conventional Tests ................. 3.1.1.3 Specialized Tests ................... 3.1.2 Westinghouse ............................... 3.1.2.1 Transformer Life Tests ............ 3.1.2.2 Evaluation of Fire Resistance . . . . Phase II - Evaluation of New Fire Resistant Liquids . . 3.2.1 Electrical Properties ..................... 3.2.2 Chemical Properties ....................... 3.2.3 Physical Properties ....................... 3.2.4 Application Tests ......................... 3.2.5 Transformer Life Tests . .. ............... 3.2.6 Evaluation of Fire R e s i s t a n c e ............ Phase III - High Power Model T e s t i n g .................. rhasc IV - Full Size Transformer T e s t i n g .............. 4. Project T i m e t a b l e ..................................... 5. Project Organization ................................... 6. Capabilities and Facilities ........................... 6.1 Dow Corning Corporation........................... 6.2 Westinghouse Electric Corporation ........ . . . . 7. Program Management and Per s o n n e l....................... 1 3 5 5 5 6 7 8 9 13 13 14 15 16 19 21 22 23 24 25 25 25 25 26 xxm NPC00026378 753715 FIRE RESISTANT TRANSFORMER INSULATION SYSTEM I. INTRODUCTION Present day dielectric liquids must possess a unique combination of electrical and physical properties in order to provide optimum performance in transformers, capacitors and circuit breakers. In certain types of transformers and capacitors, a specialized fluid termed askarel has been used to achieve desirable product performance. The composition of the askarel provides a high flash point, fire resistant liquid which under arcing conditions produces predominately hydrogen chloride and varying amounts of combustible gases depending upon the insulation system. Recent studies have shown that env Lronmental pollut ion problems are associated with the use of askarels. Insulation system integrity is probably the most important factor in sat Lsfact.ory and safe transformer performance. While this proposal is concerned with the develop ment of a new safety transformer insulation system, not having environmental problems associated with askarels (PCP'Sl, it must be stressed that transformer design principle:' must be adhered to whan developing a new insulation system. The transformer end user in industry and utilities have four different commercial types of transformer insulation systems to choose from: 1. Liquid cooled systems 2. Dry typo air cooled systems 3. Cas cooled sealed systems 4. Air cooled encapsulated systems Preliminary analysis of these four systems shows that the liquid cooled system permits operation at the highest voltage stresses and under the best heat transfer conditions. Liquid cooled systems also have the greatest short time, overload cnpabllLt i NPC00026379 753716 2- presenL liquid cooled systems uso primarily mineral insulating oil as a dielectric fluid, however, certain applications require the use of a non-flammable Fluid to reduce fire and explosion risk. Historically askarels (polychlorinated biphenyl, PCB) have been used for these applications. When considering different alternatives to transformer liquids derived from poly chlorinated biphenyls or blends of polychlorinated biphenyls with chlorinated benzene a complex dilemma was encountered. While such liquids are essentially nonflaranable, they are very resistant to oxidation even at elevated temperatures. Un fortunately, resistance to oxidation is often accompanied by a comparable resistance to chemical and biological degradation. Persistence in the environment may cause long-term toxicological and ecological effects. In addition to the dichotomy presented by the undesired persistence in the environment and the desired non-flanmability of the transformer liquid, the situation was further complicated by the nature of the decomposition products formed when the liquid was subjected to arcLng. Historically chlorinated liquids were selected be cause when they vere subjected lo arcing conditions they produced primarily a non-com bustlble mixture of products, mainly HCl. The need for obtaining the non-conbustible gas mixture was to minimize the explosion hazard in transformers located around buildings and people. In this context, askarel liquids arc defined as fire resistant synthetic liquids, which, when decomposed in an electric arc, evolve primarily non flammable gases. This definition lias been used in safety standards and codes, especially the National Electric Code and for products listed by Underwriter's Laboratories. Cas evolution is only one factor in a complex process that takes place under failure conditions. The hazard associated with different insulation systems can best be determined by a systematic evaluation of the materials, transformer components I NPC00026380 753717 -3- and total design. Tank rupture and fire spread tests are necessary when evaluating any new insulation system. Limited testing of insulation systems in the U.S. and Japan has indicated that certain silicone liquids can provide a degree of safety. An evaluation program for silicone liquids to be used in railroad transformers has been carried out in Japan with this liquid having been put into service there. Silicone liquid is the generic name for a series of inert and thermally stable insulating liquids with electrical properties similar to mineral oil. in addition, silicone liquids are generally con sidered to be of low toxicity and of low flammability depending upon the viscosity. For technical and economic reasons, the development, emphasis for transformer applica tion has been placed on rhe po lyd ima 1hy 1siloxane liquid of 50 cs. viscosity. Tht system presently in operation in Japan use* ihis particular type of silicone liquid. While this system has a degree of reliability and safet.-. It mav not bp equivalent, in safety to the presently used ashare Is. Tn the presence of an electric discharge, silicone liquLds evolve predominately hydrogen gas, however, the nature of any re sultant hazard needs further Investigation. ThLs proposaL suggests a systematic analysis of the capabilities of silicones for use as new safety liquids. It deals with the testing of existing liquids and also the development and testing of new liquid, using the full system evaluation of these materials in models and transformers. Such testing includes complete fire and explosion testing. Sene synthetic materials which have the desired electrical and heat transfer properties may also have flammability, toxicity, and stability characteristics which are of inLorest for this application. Materials such as high temperature oils, silicate esters and others will be considered Blends of materials such as blends with tricholorbcnzcne will be screened. 2. OBJECTIVES The objectives of this project are as follows; NPC00026381 753718 Develop an Insulation system with good electrical, mechanical and heat transfer properties to provide adequate reliability and efficiency under normal and overload transformer operating conditions. Develop an insulation system that will enable the construction of transformers that are adequately safe from fire and explosion hazard under internal overload, arc or failure conditions as described In Section 3.1.2.2. Develop a transformer insulation system that contains materials that do not present toxic hazard or environmental pollutant danger as measured by movement into the environment, bioconcentration, degradation, and toxicity to animals and fish. Develop a system that is economically acceptable. NPC000263B2 753719 3. WORK STATEMENT 3.1.1 PHASE X - DOW CORNING The following portion of this proposal will cover the work to be performed by Dow Corning. 3.1.1.0 The primary purpose of this effort will be to evaluate silicone liquids for use as transformer coolants. Initially existing liquids will be evaluated. In addition new structures may be proposed and subsequently evaluated. The following are examples of materials which will be con sidered. 3.1.1.I* Type of materials to be evaluated. 3.1.11.1 Polydimethylslloxane. 3.1.1.1.2 Polyphcnyimethylsiloxanes or copolymers with polydimethylslloxane, 3.1.1.1.3 PolymethyIhydrogens iloxane or copolymers with polydimethylslloxane. 3.1.1.1.4 Polyalkylmcthvlsiloxanes or copolymers based on them. 3.1.1.2 Conventional Evaluation Tests The following screening tests will be run to verify the acceptability of the materials under study. Materials showing favorable results will b e `given to Westlnghousc for further detailed study. 3.1.1.2.1 Physical Properties. Such properties as flash point, fire point, pour point, viscosity, OTC00026383 753720 viscosity temperature relationship will be evaluated. 3.1.1.2.2 Dielectric Properties. These would include volume resistivity, dielectric constant, dissipation factor and dielectric strength. 3.1.1.2.3 Environmental Effects. Toxicity and potential ecological impact of large volume usage will be evaluated, 3.1.1.2.4 Explosion Characteristics. This study will be relevant to the impact to potential transformer in stallations. 3.1.1.2.3 Compatibility. This will cover common materials of transformer construction. 3.1.1.2.6 Arclny and Corona. This will include the amounts and types of gases and solids formed during these disturbances. 3.1.1.2./ Thermal Stability. Systems will be subjected to thermal and ulcctrLcai stresses over extended periods of time. 3.1.1.2.6 Availability. This will include considerations of quantities, time span and sizes of expansions that are anticipated. 3.1.1.2.9 Cost. Consideration of the cost/volumc relationship will be made. 3.1.1.3 Specialized Tests. 3.1.1.3.0 In addition to a thorough evaluation of candidate liquids by the above conventional methods, ft UPC00026384 753721 -7 other test methods will be developed to more com pletely define the fluid capabilities and safety properties. These new tests will include: 3.1.1.3.1 Dielectric Breakdown. A test method to determine dielectric breakdown of silicone liquids and combinations of liquids and solids such as kraft paper. 3.1.1.3.2 Arcing Behavior, A test method to study arc behavior and arc quenching in silicone liquids. 3.1.1.3.3 Fire and Explosion Hazards. These tests will assess fire and explosion hazards of silicone liquLds under internal arc conditions. 3.1.1.3.A Maintenance of Silicone Liquids. This work will cover methods used in manufacturing and maintenance of silicone liquids in transformers. 3.1.1.3.3 Manufacturing Tests. These will cover tests used in manufacturing of silicone liquids, 3.1.1.4 It will be necessary, as a final portion of Dow C o m i n g work, to develop the technology necessary to process the liquids in order to make it consistently acceptable for dielectric applications. This includes identification of impurities and techniques for removing and/or controlling these impurities. 3.1.2 PHASE I - WESTIWP1WWSE. The following discussion will cover the Phase I portion of the proposal which will be conducted by tfestinghouae. NPC00026385 753722 -8- 3.1.2.1 Life Tests. 3.1.2.1.0 Life Lest units will be built with a dielectric cooling liquid known as Dow Corning Q2-1090. The transformers will have a rating of 25 kVA, type S f 7200 to 120/240 volt, single phase, 60 hertz. Four units will comprise the test set. Three transformers will be standard units, the fourth will contain a thermocouple to control the coil temperatures of the other three units. A load current will be applied to maintain the hot spot temperature at 220*C and normal potentials will be impressed on the windings during aging. 3.1.2.1.1 Cellulose Based Insulation System. Previous life tests run hy Westinghouse have illustrated Che excellent stability of a silicone/ i non-cellulose transformer. These units applied XOMEX, glass polyester and glass silicone in areas where cellulose is normally used. Since cellulose is considerably less expensive than this system, the behavior of a cellulose/ i silicone unit is of interest. i Ii 3.1.2.1.2 lYoeess and Test Transformers. The test units will* be fitted with special covurs to permit sampling, processing, pressure and temperature monitoring dried and filled with the experi mental liquids. The test set will consist of 3-unlps filled with the-Q2-1090 liquid, and one unit also with 1 i NPC00026386 753723 -9- Q2-1090 and used as a monitor. All transformers except the monitor unit will be given periodic end point test. 3.1.2.1.3 Life Aging and End Point Testing. End point tests consisting of (1) BS% full wave impulse; (2) 65% applied potential; (3) short cir cuit i 25 time normal for 2 seconds and (6) over potential, 130% at 400 Hz for 18 seconds at specific time intervals. Transformers that do^not fail during the program outlined above will he Lested to failure after completion of the final cycle. Using 100% values of the above end point tests and increasing the 65% applied potential in 5% steps until failure. 3.1.2.1.4 Analysis of Gas Samples Extracted from Liquid. Samples ot the Q2-109G will be taken at the start and periodically during the 10,000 hour life test* Gases will be extracted from the fluid and analyzed. Replacement fluid will be added to each unit atcer samp line, to maintain normal levels in the transformer. 3.1.2.1.5 Analysis of Gas Samples. At the stare and periodically during the test, gas samples from the gas space will be taken and analyzed. 3.1.2.1.6 Inspection of Units. At the end of the life tests, each of the units will be dismantclcd and inspected, The failure area will be located if possible and photographs made of the.aged units. 3.1.2.2 Evaluation of Eire Resistance. NPC00026387 753724 -10- 3.1.2.2.0 For an electric insulating material to be suitable from a fire resistant standpoint, two re quirements must be met: (1) the material must not burn; (2) the decomposition products produced in the presence of an arc must not be flammable. Considering actual applications, the latter requirement may be altered to state that a material is acceptable as being non-flammable if the arc formed gases, while flammable themselves, are produced in such quantities that no explosive danger exists. The data collected in this section will actually serve a two-fold purpose; (1) it will pro vide a comprehensive comparison of askarel, silicone fluid (Q2-1090), and synthetic materials relative to flammability, and; (2) it will provide baseline data from which to evaluate any new candidate materials which Dow Corning will submit. In view of the flananabllity definitions noted earlier, the following investigations will be conducted: 1. Flash point - Cleveland open cup 2. Flash point - Handslcorn test 3. Fire point - Cleveland open cup 4. Flammability of nrced formed gases 5. Low pressure spray 6. Relationship between 'Arcing, Flash Point and Burning of a Liquid 7. Simulated transformer model 3.1.2.2.1 Flash Point - Cleveland Open Cup. This `test Is conducted per ASTM D-92. A test cup is filled to a specified level with the sample,- The NPC00026388 753725 T i m n i n -- iv ~ . # -11- temperature of the sample is increased rapidly at first and then at a slow constant rate as the flash point is approached. Ac specified intervals a small test flame is passed across the cup. The lowest temperature at which application of the Lest flame causes the vapors above the surface of Che liquid to Ignite is taken as the flash point. 3.1.2.2.2 Flash Point - Handelcorn. This test is similar to the Cleveland Open Cup flash point. The difference exists in that the cup has attached to it a thermocouple; after the flame has appeared, the temperature of the liquid under study is lowered until the flame is extinguished. The temperature at this point is noted and compared with other materials. 3.1.2.2.3 Fire Point - Cleveland Open Cup. This test is also conducted per ASTM D-92. The procedure is the same as the flash point wLch the additional step of continuing the application of the flame until the material under study is ignited and burns for at least five seconds. 3.1.2.2.4 Flannablllty of Arced Formed Cases. This portion of the study will evaluate both the composit Ion of the arc formed gases and their degree of flammability. The gases can be generated many ways. ^ One method involves using two carbon electrodes. The f electrodes arc mounted such that a gap of varyine length can be obtained. Power can be suppLled using conventional-- equipment. As the gas is generated, It can be collected NPC00026389 753726 -12- by displacing liquid in a glass tube on top of an Inverted glass funnel. The gases will be analyzed with a chromatograpb to determine the composition. In addition, the degree of flammability will be evaluated by passing a flame over the exit gas port during the arcing. 3.1.2.2.5 Low Pressure Spray,, This test has the designation AMS 3150C. The fluid'is sprayed from a Binks Thor No. T paint spray gun (.070 in diameter orifice, 40 Psl air) in bursts over the source of ignition, which may be a gas flame. Any increase or decrease in the flame caused by the fluid mist is ob served. This test would simulate ignition caused by con tact with a flame of fluid ejected from a transformer under pressure. 3.1.2.2.6 Study of Relationship Between Arcing. Flash Point and Burning of j Liquid, In this test an arc is generated in the liquid under study. The gases formed during this arcing reach the liquid surface and burn with the help of the arc itself and oxygeo supplied from the, air. This burning then provides heat to warm the oil. The oil itself then burns when U s temperature exceeds its flash point. Therefore, for any one arrangement of electrodes oml applied power, different liquids will burn aftedifferent periods of arcing governed by their respective * -flash points. NPC00026390 753727 -13- 3.1.2.2.7 Simulated Transformer Model In this portion of the flansnabllity and safety study a pressure vessel will be constructed to contain the samples and simulate the operation parameters of a transformer relative to arcing and the subsequent generation of gases in the insulating liquid. The arc power and length will be controlled. Partial coils will be constructed using cellulose and non-cellulose con ductor insulations with faults introduced to simulate turn to turn or layer to layer type failures. The coils w -y / wLll be processed in the liquids under study. y The set-up will include* provisions for jjQ y \ measuring parameters to determine, rate of gas generation, ! pressure rise, rate of pressure rise, arc power, currents and voltages, secondary explosive capabilities and the failure mechanism, PHASE II - EVALUATION OF KEW CANDIDATE FIRE PKSISTAWT LtorTT>fi 'ihrV^ i'L In this phase new fire resistant materials developed by Dow Corning will be evaluated for their suitability for use as dielectric liquids. Initially the 'jc following basic tests will be run. 3.2.1 Electrical Properties. 3.2.1.0 The following electrical tests will he run to determine that the candidates pass the basic requirements of insulating liquids, which arc Standard ASTM procedures, 3.2.1.1 Dielectric Strength. 3.2.1.1.1 60 Hertz Disk Electrodes (ASTM D-877) This test is useful In assessing the quality of the liquid as received. It Is not sensitive enough for a. NPC00026391 753728 processed dielectric liquid used in electrical apparatus. This properly is determined with VDE electrodes. 3,2.1.1.2 60 Hertz VDE Electrodes. (ASTM D-1816) Because of its sensitivity the VDE method is used to assess the intrinsic breakdown strength of dielectric liquids. Prior to testing the liquid must be filtered and degassed so that the moisture content will be 15 parts per million or less and the dissolved gas content will be 0.5 percnt or less by volume 3.2.1.1.J Impulse. (ASTM D-3300) The impulse strength of dielectric liquids is critical in electrical apparatus. The breakdown strength indicates the liquids ability to resist electrical breakdown under transient voltage stresses (lightening and switching surge). The break* down is measured using a 1/2 -r AO micro sec. full wave impulse between two electrodes one a steel phonograph needle and the other a 1/2" diameter round brass hemisphere 3.2.1.2 Power Factor. (ASTM D-924) This test evaluates the power dissipated in an innulating material (watts) relative to the product of the effective voltage and current when tested under prescribed condition.s. 3.2.1.3 Dielectric Constant. (ASTM D-924) This is the ratio of the capacitance of a material measured with a given electrode con figuration and spacing with the material as the dielectric to the capacitance with vacuum as the dielectric. The value of the dielectric constant of Insulation components In an electrical system determine the potential stresses on the components^ 3.2.2 Chemical Properties. HPC00026392 753729 15- 3.2.2.1 Moisture Content. (ASTM D-1533) This ASTM method will be altered slightly relative to the solvent system to avoid the interference caused by the silanols present in silicone materials. A low moisture content is necessary to achieve adequate electrical strength and low dielectric loss characteristics, to maximize the insulation system life, and to minimize metal corrosion. 3.2.2.2 Neutralization Number. (ASTM D-972) A low acid con tent (neutralization number) of liquid is necessary to minimize' electrical conduction and metal corrosion and to maximize die life of the insulation system. 3.2.2.3 Oxidation Stability. (ASTM D-2440, 1^943, D-2112) The development of a sludge or acidity resulting from oxidation during storage, processing, and long service life should he held to a minimum. This minimizes electrical conduction and metal corrosion, maximizes insulation system life and electrical break down strength, and insures satisfactory heat transfer. 3.2.3 Physical Properties. 3.2.3/1 Viscosttv. (ASTM D-88) Viscosity influences the heat transfer and consequently, the temperature rise of apparatus. At low temperatures the resulting higher viscosities influence the. speed of moving parts, such as those In power cltcult breakers, switchgear load-tap-changec mechanism, pumps, and regulators. Viscosity controls a fluids processing conditions, such as de ii hydration, degassification and filtration and impregnation rates., i ! High viscosity may adversely affect the starting up of apparatus, that is, spare transformers and replacements in cold climates. Viscosity measurements will be made throughout the expected i ?#S9I NPC00026393 753730 -16- operating range of a transformer. 3.2.3.2 Pour Point. (ASTM D-97) The pour point ts che temperature at which complete lack of fluidity exists. This property becomes very important where very low ambient temp eratures exist such as North Slope applications. Should the pour point be too high relative to the ambient such mechanisms as tap changers will not operate properly if at all, 3.2.3.3 Color. (ASTM D-1500) A low color number permits visual inspection of assembled apparatus in the tank.. An increase in the color with time indicates deterioration of the fluid. 3.2.3.4 Interfacial Tension. (ASTM D-971) A high value in dicates the absence of undesirable soluble polar contaminants. This test is frequently applied also to in service liquids as an indicator of the degree of deterioration. 4$ 3.2,3.3 Specific Gravity. (ASTM D-129S) The specific gravity of a liquid influences the heat transfer rates and may be pertinent, in determining suitability for use in specific applications. 3.2,4 Application Tests, 3.2.4.0 Candidate Materials having acceptable test values from the above evaluations will now be subjected to a second set of tests. These are more involved and complex than those of the initial evaluation and will fully confirm or reject the can didates relative to suitability as a dielectric fluid. 3.2.4.1 Compatibility Studies. These tests are made to determine the effect materials of construction of electrical equipment have on the candidate liquids and also the effect of the liquids on the "I NPC00026394 753731 -17- materials. 3.2.A. 1.1 Short Tern. The first series of tests are run at 105C for one week which can be extended to one month for borderline materials. The condition of the liquid and solid insulation will be compared with their initial condition. 3.2.4.1.2 tong Term. A second type of test is made on enamel conductors for one month at 150*C. Samples of Kraft paperf NOMEX, and electrical steel will be included in the test tanks to represent the general insulation system used in units. Tests on the insulated conductor include dLclectric breakdown voltage, scrape, and visual inspection for cracking or erasing of the enamel. Bursting strength tests will be made on the flexible in sulation for comparison to similar samples tested In askarels and hydrocarbon oils. 3.2.4.2 Heat Transfer. Since one of the major functions of an in sulating liquid Is cooling, it is necessary to determine if there is a difference between the candidate liquid and oil or askarula. Tests will be made under carefully controlled conditions to deter mine the effectiveness of the different insulating liquids as coolants. 3.2.4.3 Thermal Conductivity. (ASTM D-2717) This property is closely associated with heat transfer. Measurements will be made to obtain comparative values with presently used dielectric liquids. 3.2.4.4 Specific Heat. (ASTM D-2766) This physical value*as that of thermal conductivity arc required fnr itwSdUCMnaafnr cal- 1 NPC00026395 753732 \-jVaagrr 18- culations and markedly effect the cooling capacity of the liquid. 3.2.4.5 Gas Absorption Characteristics. (ASTM D-2298, D-2300) The subject pi the solubility of gases in a dielectric liquid is of importance in liquid immersed gas covered electrical equipment that operates under sealed conditions. The liquid may become saturated with gas at one pressure and temperature and then tend to evolve dissolved gas as the environmental pressure or temp erature is changed. Such gas evolution could impair the operation of the equipment. This study will provide comparative data be tween candidate liquids and askarel and hydrocarbon oils. 3.2.4.3.1 The gas absorption study will also evaluate the influence of dissolved gas on the dielectric strength of the lLquid. 3.2.4.6 Lubricity. Present dLelectric liquids while not out standing as lubricants are effective enough to permit the operation of tap changers, power circuit breakers, pumps and various gear mechanisms. Tests such as the Falex, 4-ball and sliding*block tests will he made to show the .comparative lubricity of the can didate liquid with those currently In service. 3.2.4.7 Race of Insulation Impregnation. A vital concern in processing of units is the complete impregnation of the coil assembly and the race of impregnation. -The candidate materials will be evaluated for impregnation rate relative to the accepted liquids of oil and askarel. Assemblies of fLexlble insulation and conductor will be combined in a test fixture. Varying tiroes of imprgnation relative to the standard materials will be run. .Jlielectric tests NPC00026396 753733 -19- vlll then be conducted to study the degree of impregnation. 3,2.4.8 Moisture Absorption Characteristics. While-drying of units is part of the regular processing, moisture may enter the unit inadvertently due to a gasket leak or other such occurancc. The moisture may also be produced during the normal aging of other insulation components. The behavior of a dielectric fluid In the presence of moisture is, therefore, of considerable im portance. The candidate materials will be exposed to varying degrees of moisture corresponding to the levels that are possible in a unit. These values will be compared to the present standard materials of oil and askarel. 3.2..9 Coefficient of Expansion. In order to effectively deter mine the level of the dielectric liquid under operating conditions, the coefficient of expansion is required. This property will be determined per ASTM D-1903. 3.2.4.10 Thermal Agine. The candidate liquid study will be ex panded to include temperatures representative ot operational temperatures and somewhat higher. These data will be used to determine the effect of temperature on breakdown voltage, power factor, and volume resistivity. 3.2.4.11 Effect of High Temperature on Stability. A study of the behavior of the candidate liquids exposed to 200C and higher temperatures Is required to determine the viscosities of the liquid as a function of time and tumperature. 3.2,5 Life Tests. NPC00026397 753734 -20- 3.2.5.1 Life test units will be built and filled with the can didate liquids which, by their properties as measured in the tests noted above, appear to be the most promising. The transformers will be 25 kVA, type S, 7200 to 120/2&0 volt, single phase, 60 hertz distribution units. Four units will comprise a set evaluating each candidate liquid. Three transformers will be standard units, the fourth will contain a thermocouple to. control the coil temp eratures of the set. The load will be constantly adjusted to maintain a hot spot temperature of 220C with normal potentials applied to the windings. If necessary, a method of limiting the temperature of the cop liquid will be employed. 3.2.5.2 Two insulation systems will be evaluated. 3.2.5.2.2 Cellulose based systems, . 3.2.5.2.2 NOHEX based system. These units will have no cellulose in them; polyester silicone glass, NOMEX will be used wherever cellulose would apply on conventional designs. 3.2.5.3 Process and Test- Transformers. The test units will be fitted with special covers to permit sampling and monitoring, dried and filled with the experimental liquids. Each group of four will consist of 3 units with the experimental liquid under study, and one unit also with the experimental liquid to be used as a monitor. AIL transformers except the monitor unit will he given periodic end point tests. 3,2.5.6 Life Aging and End Point Testing. End point tests consist of subjecting the test units to the following at specific time KKSQ H s&R&m H ew aim ossa NPC00026398 753735 21- intervals: (1) 837. full wave impulse; (2) 65% applied potential, (3) short circuit, 25 times normal for 2 seconds, and (4) over potential, 130% at 400 flz for 18 seconds. Transformers that do not fail during the above program will be tested to failure after completion of the final cycle. Using to 100% values of the above end point tests and increasing the 65% applied potential in 5% steps until failure. 3.2.5.5 Analysis of Gas Samples Extracted from Liquid, Samples of the dielectric liquid will be taken at the start and periodically during the 10,000 hour life test. Gases will be extracted from the liquid and analyzed. Replacement liquid will be added to each unit after sampling to maintain norm-1 levels in the transformer. 3.2.5.6 Analysis of Gas Samples. At the start and periodically during the test, gas samples from the gas space will be taken and analyzed, 3.2.5.7 Inspection of Units, At the end of the life tests, each of the units will he dismantled and inspected. The failure area will be located if possible and photographs made of the aged units. 3.2,6 Evaluation of Fire Resistance. In the following sections, the areas of study and test to evaluate the candidate liquids will be identical to those outlined in section 3.1.2-2 of Phase I. 3.2.6.1 Flash Point (Cleveland Open Cup) 3.2.6.2 Flash Point (Mandelcorn Test) 3.2.6.3 Fire Point (Cleveland Open Cup) 3.2.6.4 FlammabLlity of arc formed gases 3.2.6.5 Low Pressure Spray , NPC00026399 753736 23 evaluation tests satisfactorily will be submitted to Underwriter Labora tories for approval as a non flammable liquid for electrical applications, 4.4.1 PHASE XV - FULL SIZE TRANSFORMER TESTING. After Phase ITT of the program has been completed, it is proposed to build two full size transformers having a rating of 1000 kVA, 13200 volts, 3 phase, 60 hertz with a built in fault, and test by applying high power. The Westinghouse South Boston Plant will manufacture the transformers and Che testing will be performed at the Westinghouse High Power Laboratory. The test conditions such as temperature, power, type of tank and other features will be agreed between Westinghouse and ERDA and then specified by analyzing previous work. OTC00026400 753737 -24 4 PROJECT TIMETABLE Time Per Job Step (Mao Months) Est. Elapsed Time (Months) PHASE I Dow Corning Westinghouse 36 34 12 PHASE II Dow Corning Westinghouse 12 34 12 PHASE III Dow Corning Westinghouse 12 24 6 PHASE IV Westinghouse 6 FINAL REPORT Westinghouse 2 160 36 NPC00026401 753738 -25- i 5. PROJECT ORGANIZATION The project will involve a Joint effort by Dow Corning and Westinghouse Electric. Engineering and technical specialists from both companies will par ticipate in the program. The Electrical-Electronic Industry division is the specific Dow Corning group to be involved in the work. For Westinghouse, Materials Engineering and Small Power Design Engineering will be the groups involved, with the Westinghouse Research Laboratories available for consultation on mechanical, electrical or material problems, should such assistance be required. 6. CAPABILITIES AND FACILITIES 6.1 Dow Corning Corporation. Dow Corning has been the leader in the silicone field since the company was formed in 1943. The company.has invested more man-years in silicone technology than all the rest of the world's silicone manufacturers. Laboratories and facilities are available for synthesizing silicone materials and theLr complete evaluation. The laboratories are fully equipped to per form tests to evaluate chemical, physical and ecological properties of materials. The Dow Corning group involved in the specific area covered by this proposal has the responsibility for silicone applications in the Electrical-Electronic Industry. 6.2 Westinghouse Electric Corporation, 6.2.1 Materials and Manufacturing Technology. The Materials end Manufacturing Technology Department of the Transformer Divisions is the central location for materials and pro cessing development, supplier approvals, and quality control studies for Westinghouse18 five transformer manufacturing locations. The Insulating Materials Section of this department manages the various V.VKW-. ( NPC00026402 753739 -26- insuldting liquids for the transformer divisions. The laboratories are fully equipped to perform all types of tests relative to the evaluation of liquid and solid insulating materials and other trans former materials of construction. These facilities include physical, electrical and chemical test equipment, equipment for evaluating oil gassing and oxidation properties and system compatibility studies; and insulation systems evaluation of test transformers under full electrical stress at elevated temperatures to provide accelerated aging, 6.2.2 Small Power Transformer Design Engineering. The Small Power Transformer Design Engineering Department performs the design and development work involved in the manufacture of small power transformers at the South Boston, Virginia' Plant, The majority of the transformers having non flammability requirements are made at this plant. The small power personnel have many years experience in the problems associated with the operation of power transformers. Their personnel will be responsible for providing consultation during the design of the model units In the flammability study of Phase III, and clic design of the comnercial units for the test in the final Phase IV of this proposal, 6.2.3 Research and Development Laboratories, As the central research and development activity of Westinghonse, the Research Laboratories maintain a broad capability in engineering and science. One of its main functions Is to provide an effective consulting service to all divisions. 7, PROGRAM MANAGEMENT AND PERSONNEL The proposed program as performed by Dow Corning and Westinghouse will have the following approximate percent participation: "rmrrTTTrTi ~Trr T~ wnii i i b i m i i kii.pij i,u m m 111111 .... TnriiilinriiM 1 NPC00026403 753740 -27- Dov Corning ................... 35 Westinghouse ......... . 65% Westinghouse will be considered the prime contractor with the proposed program under the general guidance of the Materials end Manufacturing Technology Departnen, Mr. H. R, Sheppard, Manager. For Dow Corning the prime representative will be Mr. Tor Orbeek. The project manager will be Mr. H. A. Pearce, Manager of Insulating Materials Section of Materials and Manufacturing Technology Department. This section provides biographical information on the professional personnel who are expected to actively contribute to the proposed study. NPC00026404 753741 NPC00026405 1 Tine Schedule 1 _________________________________________ _ J _______________________,_________________________ -- --- ---------- -------- - Iz3 6 9 13 16 21 24 fy 27 30 33 36 > Phase I i Oow Corning New Liquid Dev. Westinghouse 'Life Tests Fia;im;ibillcy TusLs Phase II Westinghouse Electrical & Physical FLarctnaliillty Life Tests Phase III Westinghouse Model Tests 1! 1 i f It t Phase TV Westinghouse Progress Reports I Final Report Transformer Tests AA t> _____ K3 A7 A - NPC00026406 R. R. Sheppard Manager, Materials &Kfg. Technology Transformer Divisions Sharon, Pennsylvania B S , Chemical Engineering Carnegie Institute of Technology Senior Member - IEEE -Senior Member * AICHE Vice President - IEEE Administrative Committee on Electrical Insulation Member - American Chemical Society, American Society for Testing Materials Member - IEEE Coordinating Committee No. 4 and 4.1 Chairman Pro Tern * NEMA Ad Roc Conmlttee on Electrical Insulating Oil Crisis Professional Engineer - Pennsylvania A Chemical Engineering graduate of Carnegie Institute of Technology, Mr. Sheppard undertook engineering graduate studies at Brooklyn Polytechnic Institute and the University of Pittsburgh. His early research and development work was done at Mellon Institute of Industrial Research. Since joining the Heatinghouse Electric Corporation in 1951, he has devoted his efforts principally to the management of materials engineering and manufacturing engineering organizations. Although devoting considerable effort to the electrical Insulation field, he has also had management responsibility for lubricating, organic finishing, electro* chemical, metallurgical and magnetic materials. In addition, he has organized multimillion dollar annual facilities programs for Improving transformer manu facturing efficiency and capacity. Mr. Sheppard's publications have been largely directed toward Insulation evalua tion and standardization for motors, generators and transformers. He holds patents on Insulating materials and systems for switchgear and transformers. Mr. Sheppard has served ab chairman for the National SPI Conference on reinforced plastic materials. He has served as National NEMA-IEEE Electrical Insulation Conference director and division chairman. He Is the 1975 Technical Chairman of the Electrical Insulation Conference. The Materials & Manufacturing Technology Department, which he now manages, pro vides service to five domestic transformer divisions.of Westinghouse as well as fourteen world-wide affiliates and licensees. NPC00026407 753744 H. A. Pearce, Jr. Manager, Insulating Materials Section Materials & Manufacturing Development Dept. Transformer Divisions BS Chemical Engineering Grove Ci.ty College, Grove City, Pa. Member - American Chemical Society Member - IEEE Chairman - Program Committee Local Chapter of IEEE Mr. Pearce graduated from Grove City College in 1953 with a BS degree in Chemical Engineering. After two years at Goodyear Atomic Corporation, he Joined Mestinghouse in 1953 as a Materials Engineer. He spent about ten years in the areas of aolid insulating materials and then for the past ten years has been involved in development programs and application studies with electrical insulating fluids. He has been active in the area of the analysis of gases in transformers and in the extracting of gases from transformer oil. Mr. Pearce has a patent issued on transformer cooling and has two patents pending on the separation of gases from transformer oil. He collaborated with Dr. Sloat on the preparation of a booklet entitled ^Protective Maintenance of Transformers by Gas-Oil Analysis". The Insulating Materials Section, which he now manages, provides service for the five transformer divisions of Westlnghouse in the areas of solid and fluid insulating materials. ir NPC00026408 753745 T. K- Sloat, Consulting Engineer Materials & Manufacturing Technology Dept. Transformer Divisions, Sharon, Pennsylvania BS - Pennsylvania State University MS - Pennsylvania State University PhD -Pennsylvania State University Member - American Chenical Society Senior Member - ZEEE Member - Insulating Fluids Subcommittee of IEEE Transformer Committee Chairman - ASTM D-27 Committee on Elec trical Insulating Oil and Gases Chairman - Subcommittee on Fluids of ZEEE Committee G-32 Member - ANSI C.-107 on Use and Disposal of Askarels Professional Engineer - Pennsylvania Dr. Sloat, who was born In 1914. received his education at Pennsylvania State University, earning the BS degree in Chemistry in 1936 and the MS and PhD degrees In organic chemistry in 1937 and 1940 respectively. He joined Vestinghouse in 1940 and spent his first year at the Research Labor atories working on the development of improved insulating fluids. Re moved to Che Transformer Divisions at Sharon in 1941, continuing work on the same subject. In 1945 he moved up to supervision of various laboratory functions. Since 1955, Dr. Sloat has been a section manager, responsible for the development and test ing of insulating fluids. In 1974, he was made a Consulting Engineer. lie has authored ten technical papers or articles and has been extremely active in the establishment of Industry-wide standards on insulating oils through his chairmanship of the ASTM D-27 Committee and through his work in IEEE and ANSI committees. i NFC00026409 753746 R. H. Hollister, Section Manager Development Engineering Srall Power Transformer Division South Boston, Virginia BEE - Electrical Engineering University of Louisville Member - ZEEE, Tran Transformer Subcommittee Insulation, IEEE Working Group Short Circuit, IEEE Working Group Users Guide, ANSI Alternate C57.12.1 Mr. Hollister began his professional career with Vfestinghouse in 1953 on the ffestingtouse Graduate Student Program. He joined the Transformer Division at Sharon, Fa. in 1954. As a design engineer he warked in comercial order design of rectangular and circular core form liquid filled transformers of various types up thru 15 000 KVA, 69 K.V. He also worked on dry type transformers thru 3750 KVA. In addition, he worked one year in the Cost Control Department. In 1965 he joined the rectangular core form development group. In 1966 he was appointed Section Manager of the Small and Medium Gore Form Development. In JL967 he was appointed in his present capacity. Development Section Manager, of the Snail Power Transformer Division. He has authored several technical papers and holds two patents. A5C00026410 753747 C. R. Murray Customs Order Engineer Westinghouse Electrical Corporation South Boaton, Virginia B.E. Electrical Engineering Banderbilt University Additional Graduate studies - Electrical Engineering - Wniversity of Pittsburgh. Senior Member - IEEE Chairman ANSI Subcommittee on Underground and Secondary Network Transformers (C57.12.4) Member Joint Section Unit Substation Member IEEF. Transformer Committee Registered - Professional Engineer - State of Virginia and State of Pennsylvania Mr. Murray worked in commercial design development application in small and medium power transformers for twenty-five years. Transformers range through 5000 kVA and 69 kV class applied to utility and industrial systems. Application consists of substations, networks, pad mount and primary and secondary substations. Mr. Murray presently is responsible for commercial design of transformers huilt at Westtnghouse Small Power Transformer Division located ac South Boston. Virginia. Patents Transformer having series multiple linings (3,717,631) Technical Publications Application of Power Center and Unit Substations - West inchouse Electric Utility Conference - Sharon, Pennsylvania. 1955 Pad Mount Transformer - Design Cons{duration, Complexity and Standardization Westinghouse Electric Utility Conference - Pittsburgh, Pennsylvania, 1973 IEEE - P.E.S Underground Transmission and Distribution.Conference - 1974 Transformer for Mining Duty - Open Pit MlnLng Association - Kansas City, Missouri, 1975. NPC00026411 753748 M. W. Rose Manager Evaluation Laboratory Materials & Manufacturing Technology Dept. Transformer Divisions Crove City College, Grove City, Pa. Member - IEEE Registered Professional Engineer (Pa.) Mr. Rose attended Grove City College and completed all of the technical courses leading to a B.S. Degree in Applied Science. Major subjects Included Mathematics, Physics, Electrical Engineering and Mechanical Engineering. He participated in several University of Pittsburgh Extension Courses covering such subjects as Heat Transfer, Industrial Electronics and Statistical Analysis, Penn State Extension Courses, Engineering in Training Review and Professional Engineering Review were also taken. Many local Westinghouse and IEEE courses were taken. These in cluded Public Speaking, Transformer Insulation, Computer Programming, Solid State Devices, Transformer Design and Design of Experiments. Westinghouse Headquarters courses taken Included Creativity Tn Manufacturing, Management Techniques, Principles of Management and Management Functions. Work experience ranged from machinist to engineer for the Grove City Heat Exchanger Company where the majority of experience consisted of building and running tests on experimental heat exchangers. Westinghouse work experience Included thirteen years of designing, building and testing equipment for quality control, testing of transformer components, torpedoes, reactors and transformers ranging In sise from radar to large power transformers. Sixteen years were spent in the Materials end Manufacturing Engineering Department developing and building test methods, transformer auxiliary apparatus and machine design. The past seven years has been spent as Section Manager of Evaluation Laboratory Section of the Materials and Manufacturing Technology Department. Two patents have been obtained covering transformer apparatus and test equipment. One magazine article, two technical papers and one Doble Conference Paper have been prepared. Technical activities Included Chairman of Sharon Section of IEEE, member of IEEE Power Group and member of the IEEE Working Group on Thermal Evaluation of Povar and Distribution Transformers. NPC00026412 753749 J. A. Robinson, Sr* Materials Engineer Materials &Mfg. Technology Department Transformer Divisions, Sharon, Penna. Mr. Robinson joined Westinghouse in 1941 in the Sharon Transformer Division and, except for a time serving in the U.S. Navy In Radar Electronics, has held various positions concerned with electrical measuring, design, application, safety, repair and construction cover ing transformers, components and test equipment. The most-recent major responsibility has been to conduct functional life test of transformers and models representing, a range of insulation systems. He has completed (1) a Radio Engineering Course through DeForests Training Institute, (2) the Navy Radar Course at Naval Research Laboratories, Washington, D.C., (3) the Professional Engineering Course through ICS, (4) several Pennsylvania State University exten sion courses covering industrial, electrical and electronic engineering, and business management. Mr. Robinson has taken many local Westinghouse and lEEF. courses covering transformer design, differential and integral calculus, design of exper iments, public speaking, computer programming, MATS program and presupervlsory training, and a (W) Headquarters course in problem solving. His work experience covers electrical testing of instrument transformers, distribution and special apparatus for 13 years, and electrical evaluation of materials, components, complete transformers, and design of control equipment for 20 years. itn i 13PC00026413 753750 R. A. Kurz Materials Engineer Transformer Division, Sharon, Pa. BS - Washington University, St. Louis, Mo. Mr. Kurz was born in 1937. He attended Washington University in St. Louis, graduating in 1959 with a BS degree in Chemical Engineering. He came to Westlnghouse that same year and after completion of the graduate student program, joined the Transformer Division at Sharon, Pa. as a materials engineer. For three years, he worked with dry type transformers. In this area, he evaluated and applied new varnishes, layer and turn insulations. For the next 11 years, he was involved in epoxy casting projects. During this time, he had the responsibility, from a materials stand point, of initiating three casting lines. The items cast were an epoxy distribution transformer, outdoor bushings for pole type transformers and a line of bushings for pad mount units. Along with design engi neering, he also developed and put into production a line of cast condenser bushings for 25 - 69 KV service. . For the last year he has been involved in the evaluation and development of Insulating fluids. He is also responsible for the engi neering involved in chromatographic analyses of transformer gases, PCB concent in plant effluents and analysis of plant environments for solvent contaminants. Mr. Kurz holds four patents on various insulation materials and methods and has authored six technical papers or articles on this subject. NPC00026414 753751 T. Orbeck Dow Corning Corporation (A159) received dcgrccB in electrical engineering from Gothenburg Technical Institute, Gothenburg, Sweden, in 1955, and Carnegie Institute of Technology, Pittsburgh, Pennsylvania, in 1962 Chairman - IEEE G-32 Subcommittee on Electrical Insulating Aging Pchnomcna and the ASTM D-9 Subcoimittee on Thermal Aging Associate Editor for the IEEE transactions in electrical insulation In 1955 Hr. Orbeck joined ASEA as a Junior Lab F.nglncer in the Insulating Haterials Lab in Vnesteras, Sweden. After a study visit in France in 1958, he joined the Large Rotating Apparatus Division of (testinghouse as an Insulation Development Engineer. In 1962 he returned to Scandinavia to become Section Supervisor for HV Insulation Development in ASEA Central Research. During 1965*1967, he served as Manager of the Insulating Materials Lab in Central ASEA Research. At the end of 1967 he joined the Dow Corning International Market Department in Brussels, Belgium, as a Stall''Special 1st. In 1970 he transferred to Dow CornLng's Technical Service and Development Department in Midland, Michigan, where he has served as a Specialist and Coordinator of Insulating Materials Development and Test lug. ( NPC00026415 753752 G. A. Vincent Dow Corning Corporation Born April 26, 1939 in Saginaw, Michigan Married, no children and resident of Midland, Michigan B. S. in Chemistry from University of Michigan (1961) M. S. in Organic Chemistry from Michigan State University (1966) Nominated member Sigma Xi/RESA Member - IEEE Member - ASTM (D-27) Member of organizing committee and session chairman for 1976 IEEE International Symposium on Electrical Insulation Work Experience July 1961 - August 1963 - Research Chemist at Dow Corning. Principle activity was the synthesis of novel pcncacoordinated silicone compounds. February 1966 - January 1971 - Research Chemist at Dow Corning . Principle Interest was the synthesis of fluorosilicne monomers and polymers. January 1971 - Present - Research Chemist at Dow Corning. Principle interest has been the synthesis and testing oT silicone fluids for use as dielectric liquids, and the development of test methods for evaluating silicone dielectrics. Publications and Papers One publication related to M.S. thesis work Two publications related to pentacoordinated silicone Three publications resulting from presentations at Conferences on Electrical Insulation and Dielectric Phenomena Three papers resulting from presentations at IEEE Power Engineering Society meetings. Four papers presented at American Chemical Society Meetings but not published. Patents Holder of two patents on silicone fluids for use as capacitor dielectrics. HPC00026416 753753 W. T, Brooks Dow Corning Corporation BSHE - University of Southern California in 1959 Graduate of the Test Pilot Training School, NATC Patucent River, Md., and the School of Aviation Safety, University of Southern California Hr. Brooks enlisted in the United States Navy in 1946. He was designated as a Naval Aviator in 1949 and commissioned as an Ensign, USN in 1950. lie served in various anti**submar Inc and fighter squadrons and staffs and as an experimental test pilot in the Carrier Suitability Branch, Flight Test Division, NATC Patusent River, Md. After retirement from the United States Navey in 1968, he joined the Dow Corning Corporation. Work assignments have been primarily in electrical materials development and biocide evaluation and development. Recent experience has been primarily in the field of "development of silicone based capacitor fluids. NPC00026417 753754 Edward J. Hobbs Born: Juno 14, 1934 In Chicago, U. S. Citi2 cn Married - Throe children Illinois Education 1958 - B.S. in Pharmacy at Ferris State College, Big Rapids, Michigan Experience Head - Health and Environmental 1973 to present - Dow Corning Toxicologist - 1963-1973 - Dow Corning Pharmacist - 1960-1963 - Dengler Drugs Pharmacist - 1958-1960 - Russell Drugs Membership Society of Toxicology American Industrial Hygiene Association Toxicology Committee AIHA Registration Registered Pharmacist, State of Michigan Publications Hobbs, E.J., Sancher, O.E., and Calandra, J.C. - "Effect of Selected Orgnnopolvsiloxanes on Male Rat and Rabbit Reproductive Organs" - Toxicology and Applied Pharmacology, Volume 21, No. I, January, 1972, Pages 45-54. Pallazzalo, R.J., Mcllard, J.A., Hobbs, E.J., Sancher, O.E., Cal.mdra, J.C. "Investigation of the Toxicologic Properties of Phenylmethylcyclosilop.ane" Toxicology and Applied Pharmacology Volume 21, 1972, Pates 15-28 Hobbs, E.J., Kcplingcr, M.L., Calandra, J.C. -"Toxicity of Pclydimcchylsiloxancs in Certain Environmental Systems" - Environmental Research, Accepted Cor Publication 1975. NPC00026418 753755