Document wpomYJLwaYODkdDzgxKKNV5V

FLU-050 P(a7r/t6 8I) ORGANIC CHEMICALS DIVISION RESEARCH DEPARTMENT Project Analysis - Functional Fluids Project: Electrical Fluids - Part I - Measurements Objectives: 1. Develop standard methods for measuring power factor and resistivity. 2. Put these methods into use throughout our company. 5. Publish our methods and promote their use by others. Justification: Due to the improved quality of present Aroclor production, available methods for measuring electrical properties of these materials, are no longer adequate. Measurements of power factor and resistivity are not reproducible in a given laboratory and even larger variations are found from laboratory to laboratory. It is therefore necessary to improve the methods, adopt them in all Monsanto labora tories fcnd promote their use by others in order to secure adequate control of plant processes, avoid disputes with customers and permit advanced research on dielectric fluids. Status; 1. Equipment and methods which make possible greatly im proved reliability and precision of measurement of power factor and resistivity have been developed. The experimental work is essentially complete. 2. These methods have been discussed with personnel from our Krummrich and Anniston laboratories. They must now secure the necessary equipment and begin to use the new methods. The Krummrich laboratory has started to acquire the new equipment needed. A supply of cells to be distributed to Krummrich, Anniston and Monsanto Mitsubishi was ordered and is now on hand. 3. A paper describing the method's can now be started. It should be finished about October 15. ( Nev 02S013 741267 \ FLU-030 Part I (7/68) -2- Plana: Responsibility RHM/RC d a /o v m CRC Job Finish method development; put into use in our oompany laboratories, and write paper Target Date 10^ 15/68 11/ 1/68 Manpower AsBlgnmente: R. H. M u n c h R. C. Cox Estimated 1968 Costs: * 5,000 Job Mos. Applicable? 1650128 References: Job Ho. *987 Job No. 6658 ManYears For 1968 T~. .25 .1 Sponsor: R. H. Munch Date: July 18, 1968 NV 028014 741268 ) FLU-030 Part II (7/68) -3 Project: Electrical Fluids - Part II - Transformer Fluids Objectives: 1. Develop capability for measuring high voltage dielectric strength, impulse strength and impulse ratio. 2. Measure these properties for Inerteen, Aroclor 1242 and mineral oil as well as for pressboard impregnated with these. 3. Find sheet Insulation which when impregnated with askarel will have better impulse ratio than oil impreg nated pressboard. Targets: (a) Promote use of askarel fluids in transformers for higher working voltages; and (b) High temperature transformers, 150C operating temperature. 4. Follow-up the Acme Electric inquiry about FR insula tion for transformers and see if it offers an oppor tunity for Monsanto. 5. Investigate the usefulness of instruments for deter mining transformer askarel condition. 6. Assess "all Aroclor" fluid vs. Aroclor blends in transformers. Review with G.E., Westinghouse and Allis Chalmers. Justification: Purpose of this work is to expand the use of Inerteen and Pyranol filled transformers. Our present market for these transformer fluids Is about 6,000,000. Successful achievement of our research objectives in this field might expand this market by 25#. Status: 1. Equipment for measuring A.C. dielectric strength up to 200 KV and impulse strength up to 300 KV is on order and delivery is expected within 2 weeks. Power lines, ground wire and a safety screen have been in stalled. A dielectric strength test cell for fluids and impregnated pressboard samples has been constructed NV 026015 741269 ! PLU-030 Part il (7/68) Status: (Continued) and tested. A vacuum chamber for impregnating of pressboard and other sheet insulation has been built and is nearly ready to use. Quantities of the fluids and pressboard to be tested are on hand. 2. Measurements will be started as soon as the installa tion and testing of the equipment is complete, about August 15, 1968. 5. Westinghouse at Sharon, Pa. is working on high temper ature transformers uBing oil and air. They have said that Inerteen (Aroclor blend) filled transformers are at a disadvantage at high voltages >46 KV and at high temperatures, because of low impulse strength and be cause of incompatible solid insulating materials. We agreed to undertake research work to find a solution to the impulse and high temperature insulating prob lems with Aroclor. Westinghouse is to explore the possibility of removing Insulating restrictions on 27 and 34 KV Inerteen transformers. Westinghouse wants cheaper 15 KV insulation compatible with Inerteen. We have not worked out an approach to the 15 KV prob lem. 4. Liquid filled transformers are in competition with dry type and more recently with solid encapsulated units. Acme Electric at Cuba, New York, reports a desire to meet overload transformer tests without emission of flame or molten metal. "Normal resins will not pass this test and PR self extinguishing ad ditives must have the flame to release the extinguish ing materials". They ask could Monsanto polymerize or solidify Aroclors to use this as basic insulation system? We should examine the possibility of supplying flame retardant solid or semi-solid insulation to the trans former industry. We have Aroclor and tetrachlorophthalic as raw materials. 6. Isomerizing Aroclor 1238 to 124o with AICI3 and distil ling will result in fluid with a pour point of -32C to -27C. This fluid may extend the operating range of Aroclor 1242 in transformers to include a wider geographic area without resorting to TCB/Aroclor blends. NEV 026016 741270 FLU-0?0 Part II (7/68) Status: (Continued) The problem Is to determine whether the "all Aroclor" Is fire resistant enough to be called an "Askarel" and whether it can extend the range of Aroclor 1242 sufficiently to compete with blends. This isomerized Aroclor can compete economically with straight Aroclor 1242 only if we make it by direct chlorina tion. O.E. will be assessing Aroclor 1242 vs. TCB/Aroclor blends. We will submit properties of the isomerized Aroclor plus samples if they so desire. If these properties are desired, then work in direct chlori nation will be attempted to avoid the costs of an isomerization step. Plans: Responsibility Job Target Date RHM/AB Install and test equipment. 9/1/68 r h m /rc Measure dielectric strength, impulse strength, calculate impulse ratio for fluids and impregnated pressboard. 12/31/68 r h m /p g b Present results to WeBtinghouse. 2/1/69 r h m /p g b Jim Ford Select new types of sheet Insulation for test. 11/1/68 LF/RHM Test new instruments for determining condition of transformer askarel. JDS/RHM/PB Provide inputs of new fluids and possible pricing to G.E.'s assessment of Aroclor 1242 as a transformer fluid. 1/15/69 JDS/TSD Assess problems of chlorinating with A IC I3 at isomerizlng temperatures. 12/30/69 Manpower Assignment: R. H. Munch R. C. Cox Man-Years 1968 T 7 -------- NTT .25 .4 NV 028017 741271 -6- Manpower Assignment: (Continued) J. D. Sullivan L. Fowler J. Ford (Consultant) Estimated 1968 Costs; 2(30,000 Job No. Applicable: 1630228 References: Job No. 4668 Job No. 6607 Sponsor: R. H. Munch I FLU-030 Part II (7/68) Man-Years 1968 r r - ------- h t . .20 .10 July 18, 1968 NEV 026018 741272 FLU-050 Part i n (7/68) -7- Project: Electrical Fluids - Part III - Capacitor Fluid Objectives: 1. Maximize compatibility of Aroclor 1242 with polypropyl ene film in capacitors. 2. Develop methods for purifying epoxy scavengers and used Askarel Supply sample concentrates to capacitor makers. 5. Discover agents which will promote wetting of poly propylene film, aluminum foil and capacitor paper by Aroclor. 4. Follow developments in metallized paper and metallized plastic capacitors and assess their Impact on Aroclor sales, particularly ex U.S.A. 5. See if oxidative degradation of Aroclor might affect its performance in capacitors; develop methods for avoiding such effects. 6 . Develop lower viscosity Aroclor capacitor fluid. Meet competitive threat of new fluids - Prodelec 1500 and Clophen LK 8014 for example. 7. Develop a better understanding of factors causing cor ona discharge in capacitors and seek ways of suppress ing it. Justification: Our present sales for capacitor fluid is about 6,000,000. Capacitor manufacturing technology is currently in a state of rapid change due to the advent of epoxy scavengers, polypropylene film and, ex U.S.A., of metallized film. All these developments tend to decrease the amount of fluid required per KVAR. Therefore, we must understand the fluid properties required for capacitors Involving these new developments. We must know the fundamental properties of our present fluids and develop means for im proving them where possible. Where this is impossible, we must be prepared to supply alternate fluids which do satis fy present needB. NfcV 028019 741273 FLU-030 P(7ar/6t8)h i Status: 1. A method for testing the effect of polypropylene film on the electrical properties of Aroclor 1242 has been developed. It shows that there are striking differ ences among film samples. Some samples of film de grade the Aroclor so seriously that they should not be used in capacitors. Others degrade it much less and would probably be satisfactory for use up to 100C. This indicates that the problem can be solved if a suitable grade of film can be secured. 2. Unox 206 has been fractionated on a 5 -gallon scale in the laboratory. The purified material yields a 6# concentrate in Aroclor 1242 which has a lower power factor than Prodelec Superad 6# concentrate. This will be used to formulate a quantity of 50# con centrate which will be supplied to customers in Europe to see how well it fills their needs. Discuss use of Unox 206 with Q.E. to determine if we should acquire their know-how in this area. Decide whether or not we should do work on upgrading of used Pyranol II. 5. Samples of materials to be tested as surface active agents to promote wetting of polypropylene aluminum film, foil and paper are being collected. These will be tested by measuring contact angle for Aroclor with and without the additive when placed on the above surfaces. 4. C. R. Coleman has written an excellent report on metal lized paper and plastic (Job No. 76001, 70250, June 17, 1968 APL8423 MCL). 5. Laboratory experiments of two kinds have demonstrated that some samples of Aroclor 1242 degrade when ex posed to oxygen at temperatures in the vicinity of 100C. Anti-oxidants to minimize this degradation are being tested. Tests will be made to see if any are effective against oxidative degradation will also improve capacitor life. 6. Samples of Aroclor 1258, 124o and 124l have been pre pared and isomerized to produce fluidB with lower vis cosity, pour point and cracking temperatures than reg ular Aroclor 1242 or Prodelec 1500. Larger quantities of these will be prepared for market tests. NEV 028020 741274 FLU-020 Part III (7/68) -9- 7. Procure corona measuring equipment. Develop suitable test cell and investigate effect of additives fluid properties, solid insulation and impregnation process on corona levels. Plans: Responsibilities Job RHM/RC 1 . Test polypropylene film for effect on Aroclor electri cal properties. RHM/RC/VS/ NM/CRC 2 . Fractionate Unox 206, pre pare 50# concentrate and market test. Target Date 10/1/68 8/1/68 and 1/1/69 VS CRC/PB/RHM/ WRR 3. Develop wetting agents to facilitate impregnation of polypropylene film capaci tors. 4. Follow metallized paper capacitor development. Plan countermeasures. 5/1/69 10/15/68 RHM/RC VS/JDS CRC JDS 5. Determine if antioxidants improve performance of Aroclor 1242. 6 . Define a lower viscosity, pour point cracking tem perature fluid and pro duce 1000 lbs. of electri cal quality. 7. Seek ways of suppressing corona discharge in capaci tors. 8. Write Tentative Procedure for the isomerization of Aroclor 1258. 6/1/69 9/68 9/68 7/50/68 JDS 9. Determine the required 7/50/68 conditions for earth treat ing isomerized Aroclor to insure an electrical grade capacitor fluid. JDS 10. Obtain 2-55 gallon drums of 7/50/68 undegasBed Aroclor 1158 from W.G.K. NEV 0200*1 741275 -10- ) . FLU-050 Part III (7/68) Plans; (Continued) Responsibilities Job CRC 11. Maintain liaison with ERA on fundamental research on dielectrics. Target Date Continuing JDS 12. Determine critical physical 7/50/68 properties of laboratory isomerized Aroclor 1258 to check out the starting material. JDS 15. Prepare 100 gallons of 9/1/68 isomerized Aroclor 1258 in the Pilot Plant. JDS 14. Submit samples of isomer 9/1/68 ized Aroclor 1258 to the sales department for cus tomer evaluation. Manpower Assignments: R. H. Munch R. C. Cox V. Saeger C. R. Coleman N. Mueller J. D. Sullivan W. Knapp - Pilot Plant Estimated 1968 Costs: Man-Years 1968 T 7 --------- .25 .4 .5 .5 .5 .5 45,000 Job No. Applicable: 1650028 References: Job No. 6668 Sponsor: R. H. Munch July 18, 1968 NV 01802c 741276 FLU-030 Part IV (7/68) -11- Project: Electrical Fluids - Part IV - Gable Fluids Objectives: 1. Assess the usefulness of purified alkyl benzene by product streams as cable fluids. 2. Explore the desirability of using Aroclors as cable fluids for short industrial voltage A.C. fire resistant power cables. 3. Explore factors affecting the use of Aroclors in D.C. applications. Justification: Askarels are presently not used in cables because they are not compatible with present solid cable insulating materials, they are too viscous and too expensive. However, there are some applications both A.C. and D.C. where fire resis tant cables would be desirable. We have been told that new techniques have been developed which might overcome the deficiencies of askarels in cables. We must investigate this information and use it to expand the market for our askarel fluids if possible. Alkyl benzenes are known to be more oxidatively stable than mineral oil and to have good di electric strength. (Monsanto has available certain by product streams from our alkyl-benzene manufacturing oper ation. ) Therefore, we should assess the value of these as cable fluids. Status: 1. Use of purified alkyl benzene byproduct material has been explored in a preliminary way. Results were not promising enough to Justify pushing this idea at pres ent. The competition is cable oil, a cheap high qual ity product. Our material probably has better oxida tive stability and perhaps slightly better dielectric strength but its price/performance is not enough better than competition to produce real interest. 2. We have received an inquiry from an organization which claims to have patented technology which would permit the manufacture of askarel filled industrial voltage A.C. power cables. We will investigate their claims and cooperate with them in construction of cables for a trial Installation if this is warranted. NEV 741277 FLU-030 P(7ar/6t8)IV -12- Status: (Continued) 3. It Is known that askarel type fluids degrade when ex posed to D.C. fields. They can be used In D.C. capaci tors by adding stabilizers. The mechanism of the de gradation Is not known. There Is Interest In high voltage D.C. installations which require cables filled with non-flammable fluid. We should therefore try to determine the mechanism of the degradation by D.C. and seek a remedy for it. Plans: Responsibility Job Target Date PGB 1. Follow developments in this Continuing area and alert Research to reactivate this project when ever it seems necessary. PQB/RHM WRR CRC/RHM 2. Evaluate usefulness of patented technology and decide if it warrants construction of trial cables. 3. Study degradation of Aroclor by D.C. electrical fields to determine cause and develop a cure. 2/1/69 8/1/69 Manpower Assignments: C. R. Coleman R. H. Munch R. W. Weiss Man-Years 1968 T 7 --------- HT. .2 .05 .1 Estimated 1968 Costs: #10,000 Job No. Applicable: 1630328 Sponsor: R. H. Munch July 18, 1968 NV 02802* 741278 I FLU-030 Part V (7/68) -13- Project: Electrical Fluids - Part V - New Dielectric Fluids Objectives; 1. Test and synthesize fluorine compounds related to Aroclors. 2. Determine if nitriles related to the Aroclors are useful dielectrics. Desired properties: a) Less active as solvents for polyolefins b) New less soluble polyolefin capacitor film c) Lower viscosity, pour point and crack point for capacitors. d) Superior resistance to corona. e) Lower DK for transformer fluids. f ) Higher IK for specialty capacitors. Justification; In the event that our efforts to improve the properties of our present fluids so that they meet the needs of the polypropylene film capacitor makers fail, we must have alternate fluids to fill their needs. Capacitor makers would like to design capacitors for 120C hot spot temper atures. New capacitor grade plastic film with the ability to withstand such temperatures in the presence of Aroclor would be needed to achieve this goal. Materials such as poly 4-fliethyl pentene-1 or crystalline polystyrene if they can be produced in the form of thin, defect free film might be a step in the right direction. In addition, there is a need for fluids for use In low temperature applications, both transformers and capacitors. NV 028025 741279 -14- ) FLU-030 P(7a/r6t 8v) Statue and Plans: Examine fluoro compounds which Monsanto has synthesized, for example at Dayton (MRC) and at Imperial Smelting (Air Force Contract) to see if any have suitable fluid properties. Procure enough samples to teBt the electri cal properties including corona breakdown voltages. Test compatibility of fluids vs. isotactlc polyolefin solid dielectric materials. Prepare the fluorochlorobiphenyl derivatives and examine as dielectric fluids. Manpower Assignments: 0.. E. Thompson "R. W. Weiss R . H . Munch V. W. Saeger R. C. Cox Man-Years 1968 T 7 --------- HT7 .1 .2 .1 .1 .2 Estimated 1968 Costs: #20,000 Job No. Applicable: 1630028 Sponsor: R. H. Munch/Q.E. Thompson July 18, 1968 NfcV 028026 74280 FLU-030 Part VI (7/68) -15- Project: Electrical FluldB - Part VI - Air and Water Pollution Control Objectives: 1. Follow developments in analytical chemistry leading to more sensitive and specific methods for identi fying Aroclors in our environment. 2. Keep in touch with laboratories doing research on environmental contamination by Aroclors including Universities, FDA, USDA, Fish and Wildlife Service. 3. Study present methods for disposal of Aroclors and if necessary develop safer ones. 4. Assess possible toxic effects on humans. Justification: During studies of the fate of chlorinated organic in secticides, biochemists have isolated unknown chlorinated hydrocarbons which they have tentatively identified as chlorinated biphenyls. These have been shown to be present in some fish, birds, and wild animals from certain areas at concentrations in the parts per million range. Public health authorities have therefore felt that it was necessary to determine whether or not environmental contamination by chlorinated biphenyls is a hazard to human life or health. It is vital that we cooperate in these studies so that we can be sure that the results are valid and so that we can assess the Impact of the findings on the Aroclor business. We may need to cooperate in developing disposal procedures which will not result in harmful contamination in order to avoid restrictive legis lation. Status: At present, we are collecting all available information on this problem. The Medical Department is following the toxicology and will start a test program at Calandra Labs to determine biological effects of trace Aroclor. Res earch will evaluate the validity of the published analyti cal ldentyication. Samples of Aroclors, and in some NEV 02*027 741281 / ) -16- PLU-030 Part VI (7/68) Status; (Continued) cases of pure chlorinated biphenyl isomers are being made available to government and university laboratories working on this problem for use as calibration standards. Plans: Responsibilities Job Target Date REK/ST Assess validity of analytical methods used by workers in this field. 3/69 WRR/EW/ST Collect information on all work being done by others in this field. Continuing PB/JB/PH Determine present disposal methods for Aroclors. REK/ST Elmer Wheeler Toxicology - Review with gov ernment agencies, Research Institutes. Start outside test program. 3/69 8/15/68 Manpower Assignments: R. E. Keller/Scott Tucker W. R. Richard Elmer Wheeler/P. Hodges P. Benignus/J. Bryant Total Man-Years 1968 T^ w z ~ 1.1 .1 .3 Estimated 1968 Costs? 25,000 (Calandra Labs for *68) 25,000 (Metabolic Study) Job No, Applicable 1630328 Sponsors: E. Wheeler/Scott Tucker P. Benignus/R. H. Munch July 18, 1968 fcgv 028026 74A282