by Thermo 11. December 2012 14:49

Third Party

Dear Alert Amphibian-

Can you provide third party data demonstrating that cable injection will extend the life cycle of underground cables? My colleagues and I are preparing for a rate filing with the OEB and we are looking for some firepower, facts and figures to bolster our case for additional cable injection monies for 2014 and beyond.

Seeking help,

Organizing in Ontario

Dear Organized-

I can think of four “flavors” of third-party data.

Flavor 1

Flavor 1 includes data gathered by third parties at the behest of a firm engaged in rejuvenation. The third party is independent, and is generally working for the technology supplier. There is an ample supply of this type of data, spanning over two-and-a-half decades. As an example of this type of data, consider Figure 3 of the paper published by my colleagues at the IEEE International Symposium on Electrical Insulation in September 2004…

New Developments in Solid Dielectric Life Extension Technology 

Figure 3 shows the substantial improvement in AC break-down performance seven days after injection at Cable Technology Laboratories. There is an abundance similar Flavor 1 third-party data. A compilation of that data can be found in the bibliography presented at the NETA Powertest Electrical Conference on March 17, 2008.

History and Status of Silicone Injection Technology with Bibliography

This paper provides 50 references including flavors 1, 2, and 3 of third-party data.

Flavor 2

The second flavor of third-party data are results reported by end-users. There have been several North American utilities that have reported their post-rejuvenation reliability over multiyear periods. The IEEE’s Insulated Conductor’s Committee (ICC) Discussion Group C30 is compiling several of these case studies as part of its efforts to craft a Guide entitled, “Extending the Life of Power Cables in the Field.” One exemplary data set was published by Northeast Utilities at the spring 2008 ICC. I have attached an excerpt of the ICC meeting minutes below. Over a nine year period from 1999 to 2007, the failure rate of the post-rejuvenated cable was 0.7% and the failure rate of the non-rejuvenated cable was 12%. Novinium’s failure rate is about half of the failure rate enjoyed with this older technology – see flavor 3.

R.Vencus. Cable Injection Program CL-P 2008.pdf (8.13 kb)

Flavor 3

The third flavor of third-party data is the overall failure rate of rejuvenated cables. Circuit owners have an incentive to report their post-injection reliability issues as they get cash for doing so! Novinium transparently publishes these statistics at …

http://www.novinium.com/Lessons.aspx

Novinium’s post rejuvenation failure rate is less than that of new cable! Check out my March 23, 2012 post, “Better Than New” to learn more.

Flavor 4

The fourth flavor of third-party data would be a Coke vs. Pepsi, side-by-side “taste test” of different rejuvenation technologies funded by electrical circuit owners and conducted by a third-party laboratory. There is good news, there is bad news, and some new that falls between good and bad. The good news is such a test was arranged by NEETRAC (National Electric Energy Testing, Research & Applications Center) sponsoring firms including: AEP, BG&E, ConEd, Oncor, FPL, Exelon, Southern Company, PEPCO, Southwire, and Snohomish Public Utility District. The bad news is that only Coke showed up for the taste test! The other technology supplier participated in the experimental design, but withdrew just as the testing was to commence citing, “Business and commercial reasons.” I will leave it for your contemplation why the other guys would not want to participate in a side-by-side test. The test proceeded with Novinium only. The news that is not bad, but not ideal is that even though the test was completed about two years ago, NEETRAC has not yet published the results in anything other than draft form. An excerpt of the draft NEETRAC report provides the bottom line of the testing:

“ … the stress at which the rejuvenated cables fail is higher than for the non rejuvenated cables: 26 kV/mm and 16 kV/mm, respectively. These stresses are taken at the 50th percentile (median). Moreover, it would appear that the [Novinium] rejuvenated cables have a threshold for failure at 4.5 kV/mm whereas there is no threshold for the Non Rejuvenated cables."

The reported performance advantage was measured after about 18 months of accelerated aging – well beyond the originally planned twelve-month experimental plan. The electrical stress of a typical 175 mil insulated URD cable energized at about 8kV to ground is 1.8kV/mm. The treated failure threshold is 2.5-times typical operating voltages even after extended thermal and electrical accelerated aging.

Ready for any party,

Thermonuclear Frog

Tags: , , , ,

Rejuvenation Science

by Thermo 28. June 2012 14:58

Honesty – Best Policy

Dear ample amphibian-

A gentleman from UTILX says that while he worked for Dow Corning Corporation in the early 1990’s he and his colleagues tested the materials that Novinium uses today and that Dow Corning rejected their use because these materials were second-rate, that is they did not work as well as the PMDMS (or phenylmethyldimethoxysilane), the main ingredient of CableCURE®/XL fluid.

What say you?

California Dreamer

Dear Dreamer-

There are three assertions being made by an Individual From Competition (IFC) who knows better:

Assertion 1: Dow Corning tested the materials that Novinium uses today,

Assertion 2: The performance of those materials was second-rate in comparison to the main component of CableCURE/XL, namely PMDMS, and

Assertion 3: Even with all the other process and catalyst improvements Novinium has made, Novinium’s fluid remains second-rate.


pieces of eight

by t. b. frog

 

you are not the first person, to whom this dream has been spun,

i was not even a glimmer in my father’s eye when this work was done;

somebody is indeed dreaming, but it is easy to set the record straight,

consider these pieces, there are eight.

 

Piece One: Assertion without proof

Let’s say that you had data which demonstrated your competitor’s product was inferior to your own. Wouldn’t you publish it? IFC, come clean … show us the data you purport to possess!

Piece Two: Testimony

To get the straight scoop I went to my colleague, Glen Bertini. Mr. Bertini directed the early work at Dow Corning (circa 1992). He is the guy who conceived of CableCURE/XL fluid, and he is a co-inventor of the materials that Novinium uses today. Mr. Bertini knows that all three of IFC’s assertions are not entirely forthright. The silane materials that Novinium uses today are listed unambiguously on the Ultrinium™ 732 and Ultrinium™ 733 material safety data sheets (MSDS). These materials are …

• tolylethylmethyldimethoxysilane (+ isomer of same & 8-carbon alkoxy analog)

• cyanobutylmethyldimethoxysilane (and 8-carbon alkoxy analog)

Mr. Bertini provides a sworn and notarized declaration (link is nearby) asserting that neither of these materials were tested by Dow Corning or UTILX during the 22-year period from July 1980 to December 2001.

80-20120627_GJB_Declaration.pdf (281.40 kb)

Piece Three: Challenge

Mr. Bertini hereby challenges IFC to a public debate exploring the merits of these assertions. The debate will be recorded in its entirety and provided, unedited on YouTube for the entire world to see and hear. Novinium will bear all of the production costs and will travel to meet IFC at a venue of his choice – any time, anywhere.

Piece Four: Side-by-side taste test – Round I

IFC's employer had an opportunity to demonstrate the superiority of its technology when NEETRAC, NEETRAC’s sponsoring circuit owners, and other NEETRAC-affiliated industry leaders invited UtilX to participate in a side-by-side laboratory experiment together with Novinium. UtilX helped craft an experimental protocol, but withdrew its participation when the experiment was to actually begin. That experiment is complete and included the only rejuvenation firm willing to share their post-injection results in a truly independent experiment – that would be Novinium. UtilX demurred, citing “business and commercial reasons.”

Piece Five: Side-by-side taste test – Round II

If UTILX now regrets that it did not participate in the NEETRAC side-by-side test, Novinium will grant it a Mulligan. Novinium will eagerly participate in a new experiment, which directly compares the post-injection performance of UTILX’s products against Novinium products. It’s not too late to end the debate, but you have to promise not to withdraw at the eleventh hour this time! Novinium will fund the experiment, which will be executed by an independent laboratory with a substantially similar protocol as was previously agreed by UTILX.

Piece Six:  Analogous materials are not second-rate

It should be clear to the critical reader that Novinium’s modern fluids were never tested by Dow Corning or UTILX, but what about the second claim – the claim that the untested materials were second rate? If the materials were never tested, the assertion seems a little silly, but there is another less-than-honest dimension to this second assertion. IFC is suggesting that phenylmethyldimethoxysilane (PMDMS) utilized in CableCURE/XL fluid and Novinium’s own Perficio™ 011 fluid is first-rate or has no peers. Let’s test that assertion against the following statement proffered by UTILX in its paper, “Failures in Silicone-treated German Cables Due to an Unusual Aluminum-Methanol Reaction,” published at the IEEE, PES, ICC in October 2001. To wit …

“In those experiments there was not a statistically significant difference between the performance of methoxy silanes and their ethoxy equivalents. For example, the screening experiments included phenylmethyldimethoxysilane, tolylmethyldimethoxysilane, dimethyldimethoxysilane, and vinylmethyldiethoxysilane, which all had very similar performance profiles. The ultimate choice of the alkoxy group was not driven by performance, but was rather driven by commercial availability.”

PMDMS was chosen because it was cheap and easy to come by! UTILX names several materials for which “there was not a statistically significant difference between the [dielectric] performance” from the PMDMS that IFC now suggest is the one-and-only first-rate performer. The careful reader with some background in chemistry will note a similarity between the named tolylmethyldimethoxysilane and Novinium patented (U.S. 7,658,808 & 8,101,034) tolylethylmethyldimethoxysilane – different only in the two extra methylene units encompassed in the “ethyl.” The two materials are not identical, but they are analogous. The reported data contradict IFC’s second assertion. Novinium has done many experiments with its actual materials and these materials consistently outperform PMDMS. Check out my post of March 15, 2011 to learn how those two methylene units boost post-injection reliability of tolylethylmethyldimethoxysilane using “Chain Entanglement.” But there is more, not only are there unidentified materials in the data published by Dow Corning and reproduced in the illustration nearby, but there are materials which are not disclosed at all. Some unidentified materials performed better than PMDMS. IFC should publish all of the results – even if those results do not support his contentions.

Data Sources: U.S. Patent 5,372,841 to Dow Corning & UTILX, Tables 1-3, Dec. 13, 1994. Kleyer & Chatterton (both of Dow Corning), “The Importance of Diffusion and Water Scavenging in Dielectric Enhancement of Aged Medium Voltage Underground Cables,” Proceedings of the IEEE/PES Conference, April 1994.

Piece Seven:  Devil in the Details

In the illustration nearby I provide a compilation of data from the two cited sources – both are Dow Corning/UTILX documents. These data are a subset of the data to which IFC is undoubtedly referring when he makes his assertions. As you can see from Mr. Bertini’s Declaration there is even more data, which if it were made public would cast an even darker shadow on the assertions of IFC. It’s interesting data for sure, but it does not support the notion that PMDMS is particularly special. There are a variety of other materials, which show statistically similar performance. But what is the ACBD of the y-axis? It’s the AC breakdown strength (50% probability) after 6 months of immersion in ambient temperature water and 2.5X rated voltage (20 kV). Is that test protocol a good predictor of performance after 20 years? After 40? Of course, not. To suggest so would be like declaring that the horse in first place at the first turn will win the derby. The testing to which IFC refers is a short-term screening experiment and cannot discriminate long-term performance.

Piece Eight:  Overlooking the catalyst

Not only was the experiment woefully short and not thermally accelerated, all of the silanes tested were catalyzed with 0.2%w titanium(IV) isopropoxide (TIP). Novinium does not use TIP because it suffers from an unacceptably low catalytic efficiency. It’s about 39% inefficient. Novinium’s patented catalyst technology is 98% efficient. See my previous posts on the subject of catalytic efficiency at …

Catalytic Considerations – Component I (January 3, 2011)

Catalytic Considerations – Component II (January 5, 2011)

Novinium’s master scientists have not tested every water reactive material shown in the illustration with our patented catalyst technology, but we have tested all the commercially important ones. Without exception, long-term performance, what I like to call persistence, is substantially improved by the application of Novinium’s U.S. Patent 7,700,871.

There is an old Madison Avenue adage, “If you don’t have anything to say – sing it!” Which of the following do you like the best for the IFC Corollary? (check all that apply)

ü  If you don’t have any facts – wing it!

ü  If the facts don’t support your position – obfuscate!

ü  If you won’t spend money on R&D, cite 20-year-old data out of context!

Finally, I have a selfish appeal directly to IFC, who is one of my most loyal readers. Don’t change your story one iota! The reason that so many circuit owners tell us of your tale, is that it isn’t credible. Send me your comments and I will publish them here unedited.

Credibility is transparency,

T. B. Frog

80-20120627_GJB_Declaration.pdf (281.40 kb)

by Thermo 9. January 2012 13:59
The Other Real World 
In my last post of 2011 one of my local fans, Wondering in Western Washington, questioned the veracity of the claims made by UTILX® in a document titled, “Life Extension Estimate for UtilX® CableCURE® Rejuvenation Fluid.”  Because that document is 17 pages long and includes so many interesting thoughts it will take me several posts to explore the entirety of that inquiry.  The author of the 17 page missive, used the phrase “real world” 26 times. As my future posts unfold it will become clear that the author is almost certainly an alien, because his “real world” is not the same planet on which you and I live.  Some of my critics are no doubt screaming that a talking frog is not of this Earth, but I would refer them to the literature, which is replete with references to talking frogs. If anybody wishes to meet me in the flesh, come to Novinium’s headquarters and ask to speak with the real brains behind the Novinium Masters of Reliability™.  Links to the future posts, which provide analysis of specific “real world” claims will appear below as they become available.
          Real World I – High K
 
Before we delve into the specifics outlined above, I want to go on the record as stating unequivocally that the phenylmethyldimethoxysilane (PMDMS) fluid used by UTILX works well in non-demanding cable rehabilitation applications in the real, real world. Novinium founders invented that fluid about two decades ago. Heck the spouse of one of the Novinium founders coined the “CableCure” trademark! Novinium provides Perficio™ 011 fluid, which uses the same PMDMS monomer for non-demanding applications. The Novinium Masters have made significant improvements – Perficio 011 is the perfection of PMDMS technology. To learn about those perfections, check out my post of one year ago entitled, ”Catalytic Considerations – Component II.”
I suspect that the author’s propensity to repeat the notion of “real world” is to imply that Novinium’s technology has not been tested against real world conditions.  I would reply to that implication in two ways …
1.    Novinium offers an improved version of what UTILX offers – same monomer, better catalyst.  We also offer an even more advanced product (Ultrinium™ 73X fluid) that builds upon the prior two-decades of experience. Whether or not the data and analysis proffered by the author is representative of the real world remains to be discussed in future posts. Whether or not it is representative, the data provides the same experiential foundation to Novinium’s improved technology as it does to the two-decade-old approach. If people were not willing to try something new and improved, the earth would still be flat.
2.    Novinium has injected millions of feet of cable on this real world – the planet Earth.  We have aspirations to get to other planets some day, but for now the entirety of our experience is admittedly terrestrial.  In the figure nearby I illustrate Novinium’s actual failure experience in the form of a Crow-AMSAA analysis.  To learn more about Crow, check out my August 11, 2011 post of the same name.  We publish this graph regularly and we transparently discuss our faults. Check out: “Lessons Learned” UTILX has a data analysis system similar to that of Novinium. We know this to be the case, because Novinium employees designed and programmed UTILX’s original CTS database. UTILX could end any debate about which set of technologies provides more reliable post-injection service by publishing its total failure history. If they don’t know how to do the required analysis, I will volunteer to provide the requisite lesson in statistics.  Two dozen large crickets is all I will charge for an afternoon lesson in Crow.

There is undoubtedly a reason why Novinium’s post-injection performance is transparent and others choose opacity.  As we shall see, the anecdotes selectively plucked from data and provided in “Life Extension Estimate for UtilX® CableCURE® Rejuvenation Fluid” are the opposite of the “irrefutable proof” claimed.

Signing off from the planet Earth,

Thermo

Tags: , , ,

Crazy Competitor Claims

by Thermo 2. June 2011 20:16
Evolution of a Revolution

Dearest Green One,

I have a need to rehabilitate some aging URD circuits.  How long have Novinium fluids and injection technologies been in use?  I prefer to use proven technology.

Signed,

Risk Adverse
 
Dear Risky-
Are you still using an Intel® 8086 processor?  The processor was introduced in mid-1978. If you are still using an 8086 you’ll probably want to use continuous air drying or perpetual injection of acetophenone to extend the life of your cable.  On the other hand, if you have a modern microprocessor in your computer, you’ll probably want the suped-up version of those older rejuvenation technologies, which were introduced in the early 1980’s.
I suspect that what you really want to consider is not the number of years a specific fluid has been used, but the evolution and lineage of the products and processes available to you.  Just like Intel upgrades the capabilities of its processors every 18 to 24 months, the two global rejuvenation vendors do the same thing – each at a different pace.  There are no commercially significant rejuvenation fluids used today, which have been in use without formulation changes for more than six years – that’s a fact. The more relevant answer to your question requires a discussion of the “evolution of a revolution” in small diameter (cable conductors 4/0 and smaller) cable rehabilitation.  Check out the chart nearby, which is a kind of rejuvenation genealogy.  This chart can be downloaded by clicking the link below. You may wish to print this illustration to follow along with the discussion which follows.
There are two main dimensions to rejuvenation technology, fluid and process.  The evolutions of both of these dimensions are presented alongside the innovation timeline down the middle of the illustration.  The innovation timeline provides inventor names, patent application dates, and the U.S. Patent number of all commercially significant innovations in the rejuvenation of small diameter cables.  The timeline stretches 30 years from 1981 to 2011.  The very first inventors, Fryszczyn and Bahder were both with Cable Technology Laboratories (CTL).  They invented two methods of perpetual continuous feed, one that involved a flow of desiccant (typically dry air or nitrogen) and the other involved non-water reactive (NWR) hydrocarbons such as fatty-alcohols and acetophenone. Neither of these two ideas enjoyed substantial commercial success, because the notion of perpetually maintaining flow in a cable was not attractive. The air-drying approach survives today in some small volume specialty applications.
After the groundbreaking work at CTL, all innovation since 1986 was led by Novinium founders, Bertini and Vincent.  That’s right, every significant improvement in the fluids and the process involved these two men.  Today, Novinium’s competitor, UTILX® Corporation, utilizes technology invented by Bertini and Vincent.  In the diagram the portion of that technology, which remains under patent protection for about two-more years, is delineated with a rose-colored background. This technology is over 18-years old. In 2005, UTILX changed the formulation of its CableCURE®/XL product by reducing the level of the very volatile and flammable monoalkoxysilane (MAS) additive by a factor of six, hence the CableCURE/XL fluid in use today has been in use for about six years. This happens to be about the same length of time as Novinium’s fluid offerings, but what is really important is the lineage.
As you can see from the illustration, there is an unbroken lineage of fluid and process improvements that trace back over three decades.  The majority components of all rejuvenation fluids since 1986 have been water reactive dialkoxysilanes (DAS).  Patented improvements made by Novinium and represented in the figure with a light blue background include:
iDAS – improved-dialkoxysilanes provide longer life.
iNWR – improved-non-water-reactive components do not suffer the fire hazard of the MAS component in CableCURE/XL, but provide a variety of short and long-term performance benefits.
Improved catalyst –all but eliminates the need for uneconomical and dangerous soak periods.
SPR – sustained pressure rejuvenation, together with the chemistry changes above, doubles life-extension.
Improved UPR – improved unsustained pressure rejuvenation eliminates the soak period, saving time and improving safety.
More historical perspective is available in a paper titled, “History and Status of Silicone Injection Technology” presented on October 4, 2007 at the Energy Council of the Northeast’s (ECNE) Engineering and Operations Conference.  Click here to see that paper.
If you are still using Intel’s 8086 microprocessor, you do not want to do business with Novinium, because we are never satisfied. We will continue to make incremental and, occasionally, revolutionary improvements in our fluids and our processes. Only at Novinium can you interact with the development team that made rejuvenation possible. For your project the lowest risk is achieved by selecting the world’s leading experts.
I for one embrace the state-of-the art and the reduction of risk by the judicious application of technology,
Thermo

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