Technical Perspectives

Potential benefits of Cargilr FR3. fluid-filled

transformers increasing load capability in
distribution transformers.
Knowing or estimating customer demand for distribution This expanded thermal capability can:
transformers, especially in residential areas, can be quite
• Reach a capability as high as +50% without additional life
challenging. Renewable power sources are growing in the
reduction (continuously loaded).
market, making power flow even harder to predict. Since the
cost to replace a transformer is many times higher than the • As much as 2x more capacity, with limited additional paper
actual transformer cost, an engineer often times needs to use degradation, but not damaging the insulation.
a larger rated capacity to plan for future growth. Excluding cases where the required rated capacity is defined by
Using a larger transformer increases the initial cost and may lead voltage drop, this can lead to economic savings.
to higher operational costs due to increase of no-load losses
associated with the larger transformer size.
Conversely, the increased capability enabled by the lower Loading Guides
degradation rate of the paper immersed in FR3" fluid may The loading guides IEEE C57.91 and IEC 60076-7 have
allow a relevant value of extra effective capacity without incorporated (from even their very early versions) additional limits
reducing the expected lifespan. for loading distribution transformers above nameplate rating;
allowing up to 300% loading (for less than ½h), with top-oil as
high as 120°c and a hotspot up to 200°c.
Rated Capacity versus Capability When using FR3 fluid-filled units, the only modification is an
The nameplate rated capacity does not indicate the actual increase of the temperature limit for the top-oil, (or "top-liquid").
capability of a transformer. Standardization, efficiency mandates, All other limits remain the same.
safety margins, etc., may lead to a "reserve of capacity" often Increasing the top-liquid value to 140°C using FR3 fluid instead
higher than 10%. FR3 fluid chemistry "wicks" water away from of 120°c with mineral oil is a great benefit, as it allows higher
insulating paper thus protecting the paper from further aging/ loading along with lower loss of paper life (paper degradation)
thermal degradation. by being immersed in FR3 fluid.

Table 1
1 – Time
Time durations
Table fordurations for operating
operating above above temperature
rate hottest-spot rate hottest-spot temperature
for different for different
loss of life venues loss
assuming of life class
a thermal valuesof assuming a thermal
140 for thermally
class
upgraded kraft of 140
paper for thermally
immersed upgraded
in FR3 fluid kraft
not crossing notpaper immersed
crossing in FR3
the indicated fluid
loss of life. not crossing the indicated loss of life.

Percent loss of life for operating at the hotspot temperature during the indicated hoursa
Hot Spot FAA
temp (aging acceleration factor)
0.0133b 0.02 0.05 0.1 0.2 0.3 0.4
130˚C 0.94 x 25.4 h - - - - - -
140˚C 2.32 x 10.3 h 15.5 h - - - - -
150˚C 5.48 x 4.4 h 6.6 h 16.4 h - - - -
160˚C 12.4 x 1.9 h 2.9 h 7.2 h 14.5 h - - -
170˚C 27.2 x 53 min 1.3 h 3.3 h 6.6 h 13.2 h 19.9 h -
180˚C 57.4 x 25 min 38 min 1.6 h 3.1 h 6.3 h 9.4 h 12.5 h
190˚C 117.4 x 12.3 min 18.4 min 46 min 1.5 h 3.1 h 4.6 h 6.1 h
200˚C 232.9 x 6.2 min 9.3 min 23.2 min 46.4 min 1.6 h 2.3 h 3.1 h
a
Based on a normal life of 180,000 h. Time durations not shown are in excess of 24 h.
b
This column of time durations for 0.0133% loss of life gives the hours of continuous operation above the basis-of-rating hottest-spot
temperature (130.6˚C) for one equivalent day of operation at 130.6˚C. (verify that 0.0133% = 24th/180,000h = nominal life consumption rate)
 Technical Perspectives

Paper life
The available Arrhenius curve for thermally upgraded kraft The moisture content of the insulating paper in FR3 starts at a
(TUK) paper immersed in FR3 fluid (informative Annex B of typical value of 0.5% in a new transformer and remains fairly
IEEE C57.154:2012 and Annex C of IEC 60076-14) allows stable throughout the transformer life.
the development of the "loss of life" tables and "percent loss
of life" chart widely used from IEEE C57.91 (for TUK paper Additional benefits of this include:
in mineral oil). Both the table and the chart are presented in • Dielectric withstand capacity of the insulation system is
this document. preserved throughout life.
The most relevant result is the ability of handling larger values • Risk of failure by "Bubbling," which is driven by the moisture
of overloading for longer periods of time. It means the limits content in paper, is mitigated.
for planned loading above nameplate or even the emergency
overloading will lead to a much smaller sacrifice of transformer • Increasing the average assets utilization level may improve
life expectation as seen in Table 1 and Figure 1. the overall system efficiency.

1
0.9
0.8
Utilities benefits
0.7
0.6 • New transformers purchase savings. Although price per
0.5
rated kVA is higher, the price for effective kVA will be
0.4
lower. The total initial investment will be reduced, as
Loss of Life (%)

0.3
"nameplate kVA rating" of some units will step-down .
0.2
• Peace of mind for handling large load fluctuations due to
s the amplified capacity for overloading
ur
ho 1/
2
24 16 12 8 6 4 3 2 1 1
0.1
0.09
• Resilient grid, due to the expanded capability
0.08
0.07 • Higher reliability, as paper is continuously dried
0.06
0.05
1/
2 • Increase asset utilization, as the average loading factor
0.04
140 150 160 170 180 190 200 will be increased
Hottest Spot Temperature (˚C) • Fire safety, ZERO fires reported in FR3 fluid filled units
Figure 1Figure 1 - Percent loss of life expectancy for time at temperature
Percent loss of life(based on a normal
expectancy life at
for time of temperature
180,000 h) for (based
TUK paper
on aimmersed
normal life • Environmentally friendly, bringing benefits in
in FR3™
fluid, having thermal
in FR3class
fluid,140.
of 180,000 h) for TUK paper immersed having thermal class 140. sustainability, carbon footprint, renewability, and safety
in the case of spills

Continuous drying of insulated paper Cargil/'s technical team is ready to help your company
In a mineral oil filled unit, the moisture content in paper estimate the Capability Factor of your transformers.
gradually increases with years of operation, even in perfectly
sealed units. This process occurs because moisture is both
a byproduct and a catalyst of paper degradation. This "self-
induced" reaction does not occur with the paper in FR3 fluid .
The moisture generated by paper degradation migrates to the
FR3 fluid and then gets consumed by a hydrolysis reaction.

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