Renewable Energy 49 (2013) 33e38

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Renewable Energy
journal homepage: www.elsevier.com/locate/renene

Synthetic ester transformer uid: A total solution to windpark transformer

technologyq
H. Al-Amin*, J. OBrien, M. Lashbrook
M&I Materials (MIDEL 7131), Hibernia Way, Manchester M32 0ZD, United Kingdom

a r t i c l e i n f o

a b s t r a c t

Article history:
Available online 17 March 2012

Synthetic ester transformer uid has the ability to substantially reduce the risk associated with operational on/off-shore transformers. In comparison to alternative dielectrics such as cast resin, silicone uid
and natural ester, synthetic ester has proven to be the most suitable transformer dielectric. This paper
presents evidence to support these claims.
2012 Published by Elsevier Ltd.

Keywords:
Ester
Transformer
Alternative uids
Synthetic ester
MIDEL 7131
Natural ester

1. Introduction

2. Offshore windpark transformers

With many governments committing to the generation of

renewable energy around the globe, a huge amount of investment
is about to be placed into on/off-shore windparks.
Reliability of equipment is key to the success of any operational
windpark and this is particularly true of the electrical transformer,
without which none of the generated electricity would reach the
end user. Due to the criticality of its role it is becoming increasingly
important to ensure that the correct transformer is chosen for both
the turbines and on/off-shore substation. This can reduce a variety
of risks that a transformer can be exposed to in challenging on/offshore conditions.
Owners, operators and engineers should not observe a transformer as a grey box that performs a mundane duty. Instead, every
effort should be made to understand that specifying the correct
dielectric inside can have a huge impact on the reliability and safety
the windpark.
This paper aims to give the reader an overview of transformer
dielectric technology and hopefully provide sufcient evidence that
specifying the correct technology will ultimately lower the risk of
transformer failure.

Fig. 1 and Ref. [1] shows a basic schematic diagram of an offshore

wind farm. Electricity is generated at a low voltage within the turbine
which is then stepped up via a turbine specic transformer. Dependant on how far offshore the windpark is, this may be further stepped
up via power transformers located on the offshore electrical substation. Future offshore substations may house as many as 3 power
transformers. Due to the remote location and harsh environment
increasing demands will be made upon the transformer dielectric.

q World Renewable Energy Congress XI and Exhibition 2010, Abu Dhabi, 25e30
Sep10.
* Corresponding author.
E-mail address: HussamAl-Amin@mimaterials.com (H. Al-Amin).
0960-1481/$ e see front matter 2012 Published by Elsevier Ltd.
doi:10.1016/j.renene.2012.01.071

3. Brief explanation of transformer dielectrics

Transformer types are largely dictated by the use of dielectric
insulation inside and as such it is important that end users have
a clear understanding of all the available technologies. Two typical
types of transformer are
1. Cast resin transformers: Use a solid epoxy resin to encapsulate
the windings. An obvious restriction is the inability to dissipate
heat as effectively as uid.
2. Fluid lled transformer: Can be lled with mineral oil or alternative uids such as synthetic ester, natural ester or silicone uid.
A dielectric as the name suggests is used to provide electrical
insulation. Fluid dielectrics also offer an efcient cooling medium
conducting away the heat generated by the transformer losses.
Types of transformer dielectric specic to their application are
shown below (Table 1):

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H. Al-Amin et al. / Renewable Energy 49 (2013) 33e38

Fig. 1. Offshore transformer locations.

Fluid lled transformers can include mineral oil, silicone liquid,

synthetic and natural esters. The suitability of each uid will be
compared later in the paper.
4. Offshore wind turbine transformers

Fig. 2. Typical offshore turbine transformer locations.

Offshore turbine transformers are located within the turbine

nacelle, turbine tower or inside a specially constructed housing unit
below the nacelle. Each design is dependant on the respective
manufacturer and will have repercussions as to the demands
placed upon the transformer and ultimately the transformer
dielectric. Typical designs are shown below (Fig. 2):
5. Fire risk assessment of transformer dielectrics
As can be seen from the transformer locations there is a significant need to address re safety to reduce the risk to the associated
multi million dollar turbines. Traditionally mineral oil is used in
standard transformers however it is known to carry a high re risk
and therefore alternatives are regularly being considered.
According to IEC 61039 [2], uid dielectrics can be classied
according to re point. Table 1 shows the re point and resulting
classication (Table 2).
K Class classication is obviously a very desirable attribute and
will dramatically reduce the risk of a transformer re occurring, as
the following text from IEC TS 60695-1-40 shows
More than 150,000 transformer containing Class K insulating
liquids are in service, with an excellent re safety record
Mineral oil does not satisfy the criteria of Class K less ammable
uid and should be deemed as high risk.
6. Environmental risk assessment of transformer uid
dielectrics
As the transformers will be in offshore locations it is advisable to
perform an environmental risk assessment of the potential impact
of the uid should it detank from the transformer.
Table 1
Transformer dielectric suitability.
Dielectric

Cast resin

Fluid lled

Turbine
transformer

High voltage offshore

substation transformer

Both natural and synthetic esters are ofcially classied as readily

biodegradable. This means they pass strictly controlled degradation
tests carried out according to OECD methods [3]. These test methods
are internationally established and recognised. Their behaviour
contrasts markedly with mineral oil and silicone liquid (Table 3).
The new standard, IEC 61039 (2008) classies the biodegradability of dielectric uids, tested to OECD 301 C or F, using the % of
Theoretical Oxygen Demand (ThOD) removed [4]. The results of
which are shown in Table 4.
To further support the environmental credentials of ester uids
they are also ofcially classed as non-water hazardous according
to Umweltbundesamt (UBA), Germany.
Following these ndings silicone liquid and mineral oil can be
deemed as high risk to the environment, should the uid leech or
be dispelled from the transformer.
7. Performance risk assessment of transformer dielectrics in
offshore locations
7.1. Cooling performance
All devices that use electricity give off waste heat as a byproduct of their operation. Transformers are no exception. The
heat generated in a transformer operation causes temperature rise
in the internal structures of the transformer. This generated heat is
dissipated via an air exchange within a cast resin transformer and
via a uid exchange within a uid lled transformer. It must be
considered that air is a poor cooling medium with a very low
specic heat, poor thermal conductivity and requires large ow rate
to remove heat effectively. Conversely, uid is a good cooling
medium with a high specic heat, good thermal conductivity and
much lower ow rate to remove the same amount of heat. It is
therefore expected that forced cooling of a cast resin transformer is
required with the addition of specic fans within the turbine.
Table 2
Classication according to IEC 61039.
Type of uid

Fire point

Classication

Mineral oil
Synthetic ester (MIDEL)
Natural ester
Silicone uid

w170
C
>300
C
>300
C
>300
C

O
K
K
K

H. Al-Amin et al. / Renewable Energy 49 (2013) 33e38

35

7.3. Mechanical stress withstand

Table 3
OECD 301 biodegradation classications.
Type of uid

OECD 301 classication

Mineral oil
Synthetic ester (MIDEL)
Natural ester
Silicone uid

Not biodegradable
Readily biodegradable
Readily biodegradable
Not biodegradable

Table 4
IEC 61039 biodegradation classications.
Type of uid

IEC 61039 classication

Mineral oil
Synthetic ester (MIDEL)
Natural ester
Silicone uid

Not biodegradable
Fully biodegradable
Fully biodegradable
Not biodegradable

However, this method of cooling can push potential corrosive sea

air across the exposed windings of the cast resin transformer.
According to Declercq et al. [5] the only way to protect a dry type
transformer is to house it in a hermetic envelope equipped with an
heat exchanger, an air treatment unit (drying/ltering) and forced
ventilation. A total concept which is costly, large in dimensions,
consumes energy and needs maintenance. In case the fans would
refuse to work the transformer and turbine have to be shut down.
7.2. Transformer overload, harmonic and transient withstands
Power electronics within the turbine and variable wind patterns
can subject the transformer windings to rapid increases of heat. It is
known that aluminium is often used as the conductor within a cast
resin transformer as the expansion coefcient is closer to that of
epoxy resin than copper. However, the expansion of aluminium is
still different to that of epoxy and as such thermal cracks can appear
in the insulation. These cracks represent the weak point within the
insulation structure. According to Dr Volker Wasserberg [6].
within cast resin insulation this has the potential to lead to partial
discharge in a concentrated area, which cannot be dissipated or
diluted. This has the potential to increase the likelihood of failure.
Fluid lled transformers are much more capable of coping with
partial discharge as they have the ability to self heal, i.e. will
automatically send new liquid to the fault area to replace the
damaged one (Picture 1).

Picture 1. Faults within a cast resin transformer taken from an offshore wind turbine [7].

As the wind load hits the offshore turbine it can cause dramatic
vibrations in the transformer especially when situated in, or under
the nacelle. To reduce the vibrations and resonance a liquid lled
transformer can incorporate a corrugated tank with vertical and
horizontal reinforcements. The active part of the transformer is also
highly clamped to the tank restricting movement in any of the
dimensions. The uid lled transformer has a much greater withstand to any generated movement than a cast resin transformer,
which is much more vulnerable at these low frequency stresses.
8. Risk assessment of transformer uid stability
8.1. High temperature operation
As space within a nacelle or tower is at a premium it is desirable
to have the turbine transformer build as small as possible. In this
instance the transformer will run hotter than a conventional
transformer. To allow for high temperature operations designers
opt for uid/aramid paper insulation. Top oil temperatures can
regularly reach 135
C and hot spot winding temperatures 180
C.
At these temperatures mineral oil would be very close to its ash
point and would be expected to experience uid degradation in the
form of sludging.
Silicone, natural and synthetic esters have the ability to operate
at these elevated temperatures and remain stable providing that
the transformer remains in a sealed form. However, as these
transformers are in an offshore location and with large mechanical
force exerted on them there is a small possibility that the seals of
the transformers could be compromised. Therefore, it is prudent to
consider the risk to each of these uids should air or moisture
ingress into the operating transformer.
8.2. Oxygen stability of each of the transformer uids
The rotating bomb test, according to ASTM D2112, subjects the
test uid to pressurised oxygen at elevated temperature in the
presence of common catalysts. Measuring the time for the oxygen
pressure to drop, to a predetermined level, gives understanding of
how oxygen stable the uids are.
The results presented in Graph 1 clearly show that synthetic ester
is a far more oxygen stable dielectric than mineral oil or natural ester.
As natural ester performed very poorly in this test further studies

Picture 2. Oxidation of a natural ester [9].

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H. Al-Amin et al. / Renewable Energy 49 (2013) 33e38

Graph 1. RBOT results of transformer uid [8].

Graph 2. Moisture saturation curves [10].

Graph 3. Absolute moisture v breakdown strength [11].

H. Al-Amin et al. / Renewable Energy 49 (2013) 33e38

where made with the uid to understand the chemical reactions that
occur during the oxidation process. Research performed at M&I
Materials internal laboratory shows that excessive oxidation of
a natural ester can result in gels forming as shown in Picture 2.
Natural ester represents a high risk should any of the seals
around the transformer be compromised. In contrast the risk of
oxidation when using a synthetic ester is low.
8.3. Moisture tolerance of each of the dielectric uids
Should a transformer seal be compromised as explained above it
is important to consider the effect of moisture on each of the
dielectrics.
Below are the moisture saturation curves for each of the uids.
Synthetic ester has the highest saturation limit of all the
transformer uids. As the uid is used primarily as a dielectric it is
important to understand how moisture affects the dielectric
rigidity. Results are shown in Graph 3.
When considering Graphs 2 and 3 it can be concluded that
synthetic ester is the most moisture tolerant of all the uids and
still remains dielectrically strong even in the presence of high
absolute values of moisture.
9. Offshore transformer substations
For offshore substation transformers, at voltages of greater than
100 kV and with ratings in excess of 100 MVA, the only commercially available option is a uid lled transformer. Cast resin
transformers are limited in rating to around 40 MVA at the time of
writing and this is unlikely to increase signicantly in the foreseeable future. Silicone liquid is not suitable for these high voltage
transformers as it more prone to electrical instability at voltages
above 36 kV [6].
Natural and synthetic esters offer a viable alternative to mineral
oil in this power range. Indeed synthetic ester has been used as the
dielectric medium inside a 238 kV power transformer since 2004
with exemplarily performance. However, as discussed earlier in the
paper natural ester will have to operate in a sealed transformer and
with the possibility of the seal being compromised and maintenance very difcult it would be advisable to insure against this with
the use of a synthetic ester.
10. Conclusion
With the evidence presented it is possible to use the following
scoring system to assess which dielectric uid will present the least
risk to the offshore windpark

37

It can be seen that cast resin dielectrics offer a greater operational risk in comparison to uid dielectrics. As such the following
graphs make risk comparisons of the uid only.

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H. Al-Amin et al. / Renewable Energy 49 (2013) 33e38

a portfolio of successful brands including APIEZON, METROSIL,

MIDEL and WOLFMET.
Midel is a re safe and environmentally friendly transformer
uid that provides excellent service in thousands of sealed and
free-breathing systems around the globe.

References

Using the scoring system it can be seen that synthetic ester

scores the lowest points and hence presents the lowest risk of
dielectric failure within an offshore windpark.
11. About M&I Materials
M&I Materials Limited is dedicated to manufacturing Specialist
Materials for Industry and Science and is the driving force behind

[1] www.wind-energy-the-facts.org.
[2] IEC 61039. Classication of insulating liquids.
[3] Ready biodegradation of MIDEL transformer uids. Cantest 2007 M&I archive
document.
[4] IEC 61039. Classication of insulating liquids; 2008.
[5] Transformers for offshore multi-megawatt turbines: discussions on specications, safety and environment e European Offshore Wind 2007.
[6] Volker Wasserberg. Step-up transformers for wind energy plants.
[7] Cracks in Siemens Geafol transformers used in Middelgrunden Windturbine
Park e Karsten Borch Gylding.
[8] M&I materials internal technical report TD3203.
[9] M&I materials internal technical report TD3255.
[10] Dumke et al. Fundamental investigations on the inuence of temperature and
water content on the electrical behavior of uid impregnated insulating
paper.
[11] Russell Martin. Ester transformer uids for environmental protection,
improved re safety, and operational reliability.