報告_OCP2026_ExxonMobil_浸沒液氧化與電子可靠度_20261015

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圖片清單（已驗證 2026-10-15）

原始內容

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Bobby Glidwell VP of Technology, fluidiQ by Magnalytix Vanja Boyd Application Development Engineer, ExxonMobil Fluid Oxidation and Electronic Reliability: A Multi-Fluid EID Measurement Study Cooling Environments Immersion Project

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Oxidation 101 A free-radical chain reaction influenced by fluid chemistry, operating conditions, and contamination WHAT DRIVES IT OPERATING CONDITIONS Heat Oxygen Time CONTAMINATION Moisture Metals Particulates FLUID CHEMISTRY Base chemistry HOW IT PROCEEDS ●free radical ○stable molecule 1 INITIATION It starts Heat, dissolved metals, or contamination breaks a carbon-hydrogen bond of the base fluid and a free radical forms › 2 PROPAGATION It feeds itself That radical reacts with oxygen and surrounding molecules, producing additional radicals. › 3 CHAIN BRANCHING It accelerates Peroxides and other intermediates break down into multiple free radicals, increasing the rate of degradation. › 4 TERMINATION It winds down Free radicals combine to form stable products, slowing and eventually stopping the oxidation process. THE TAKEAWAY Inherent fluid stability drives long-term oxidation resistance. Some fluids maintain oxidation resistance even after antioxidants are largely depleted. Color alone is not a reliable indicator of oxidation.

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The Gap WHAT WE PERIODICALLY MEASURE TODAY WHAT WE NEED TO KNOW IN REAL TIME CHEMICAL TAN Total acid number · ASTM D664 Acidic oxidation byproducts FT-IR Fourier transform infrared spectroscopy Oxidation byproducts and molecular changes GC-MS Gas chromatography–mass spectrometry Oxidation products and composition changes PDSC Pressure differential scanning calorimetry Induction time, onset temperature, and resistance to oxidative degradation PHYSICAL Kinematic viscosity Molecular changes from oxidation and chain scission ELECTRICAL DDF Dielectric dissipation factor Polar products, ionic species, and contaminants Breakdown voltage Ability to withstand electrical stress before failure ? Surface resistance at the board Volume resistivity Signal integrity BER and eye diagram These all test the fluid. These monitor hardware reliability. No published thresholds link these measurements to board-level failure. That is the gap, and it is the reason this multi-phase study exists. Conductivity through the bulk fluid Leakage current between conductors

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OCP Participants and Samples Eight fluid manufacturers contributed fresh and in-service chemistry to an independent, blinded test. STUDY SPONSORS PARTICIPATING FLUID MANUFACTURERS

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Study Looked at Three Main Conditions FRESH FLUID BASELINE Unused fluid, straight from the manufacturer containers. Sets the electrical reference every later comparison is made against. TEMPERATURE AGED (ACCELERATED) Fresh fluids are aged under controlled laboratory conditions to evaluate how thermal exposure affects fluid chemistry and electrical performance. IN-SERVICE AGED Fluids returned from a real deployment, measured against their own fresh baseline. HOW THE THREE CONDITIONS CONNECT IN THE LAB IN THE FIELD Fresh fluid baseline (0 h) Temperature Aged Real deployment: time and conditions set in the field In-Service Aged IMPORTANT • This test is intended to be a controlled comparison. Not a service-life prediction, or a pass or fail rating on any product. • Measurement and lab testing all run at Magnalytix, and every fluid is reported by study code only.

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Measuring Electrical Effects Directly TEST CARD PRODUCTION-LIKE SURFACES CH1 Quad QFN 48-1 0.5 mm pitch CH2 FBGA 244 1.0 mm pitch CH3 QFP160-1 0.65 mm pitch CH4 3 × 3 Power Choke array HOW THE MEASUREMENT WORKS Each channel on the removable, immersed test card operates under continuous bias. Leakage current between conductors is converted to surface resistance and tracked against the fluid’s fresh baseline. Includes 2-channel embedded heaters for localized thermal control INTENDED PRODUCTION USE Continuous monitoring of fluid health in a tank Intended to remain in the tank during normal operation, tracking real-time fluid-health trends to guide sampling, inspection, and further testing.

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The Test Protocol EXPOSURE TIMELINE 0 h Cards in fluid First Sample Taken 168 h Sample Taken 500 h Test end Sample Taken PARAMETERS Bath Temperature 80 °C, accelerated aging Duration 500 hours per condition Test Card four geometries, continuous 5V bias Electrical Measurements Surface resistance (logged continuously) Fluid Measurements TAN (total acid number) RI (refractive index °Brix) FTIR (Fourier transform infrared) Karl Fischer water test (end of study) 336 h Sample Taken

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The Study in Practice Photographs from the exposure in progress.

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• Covered Test Vessels — minimized airborne contamination and foreign material ingress • Dedicated Thermometers — individual monitoring for each test vessel to avoid cross contamination • Ambient Temperature & Humidity Monitoring — laboratory room temperature continuously recorded • Controlled Fluid Volume — consistent starting volume across test vessels • Consistent Test Geometry — standardized beakers, card position, and immersion depth • Controlled Test Temperature — common target temperature and exposure conditions • Dedicated Test Card & Instrument — minimized cross-contamination between fluid samples • Standardized Sample Handling — consistent handling, sampling, and measurement procedures • Continuous Data Logging — electrical and environmental conditions recorded throughout exposure • Validated Test Equipment — each test device was validated with known resistor values prior to test Experimental Controls

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Results: Lab Data (All)

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Surface Resistance Results: Lab Accelerated Aging

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Surface Resistance Results: By Chemistry

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Surface Resistance Results: Individual

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The Field-Aged Sample Hydrocarbon B-1 Aged Fresh In service, this fluid's TAN rose slightly past the 500-hour lab value. Its board runs 13.8GΩ below the temperature-aged fluid. SURFACE RESISTANCE SERVICE AGED 19.3% lower than Temperature Aged 57.7 GΩ vs 71.5 GΩ (Fresh) WHAT IT MEANS The fluid came back from service slightly more acidic than 500 hours at 80 °C made it, yet once settled its board ran lower than the temperature- aged fluid. Acidity alone did not predict an electrical result. TAN flags this fluid as aged. The board says it is close to normal hydrocarbon data. ~2 years in service

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The Field-Aged Sample Aged Ester E-1 Fresh In service, this fluid's TAN is only slightly above the 500-hour lab value. Its board runs 20.6GΩ lower on nearly every channel. WHAT IT MEANS The drop is persistent and shows on every package, so the cause travels with the bulk fluid. Though absolute isolation is still high, this is worth investigating. Not evidence of hardware failure. A TAN story much like the hydrocarbon but dropped into a warning band in-service. SURFACE RESISTANCE SERVICE AGED 85.1% lower than Temperature Aged 3.6 GΩ vs 24.2 GΩ (Fresh) ~6 months in service

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Similar TAN, Lower Resistance in Service Temperature Aged fluids rose in TAN without a drop in surface resistance. At a similar TAN, the In-Service Aged fluids ran lower: E-1 20.6GΩ lower, B-1 13.8GΩ lower Lines: each fluid from fresh (open dot) through 500 h at 80 °C Diamonds: In-Service Aged, 192–500 h average What else can affect the electrical performance of a fluid? Ionic contamination Flux residues, organic acids and salts from the hardware Water Dissolved or free water; in esters, hydrolysis to acids Metals and particles Corrosion and wear products carried in the fluid Leached material From elastomers, cable jackets, plastics and coatings Acid type, not amount TAN counts all acid, not which acids or how ionic Temperature and history Service temperature, duty cycle, top-ups and handling THE CHEMISTRY TAN, FTIR and refractometer readings of both In-Service Aged fluids sat close to their 500 h Temperature Aged values. Whatever lowered resistance, those tests did not see it.

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OCP Test Methods: Is Clarification Needed? OCP Base Specification for Immersion Fluids, Rev 1.0 (1 Dec 2022), §5.10 and §6.4 “Oxidation Potential”. OCP Immersion Requirements Rev 2.10 SR 4.2-1. IEC 62021-2:2007 §10 · JIS K 2501:2003 §5.7 · ASTM D664-18e2, D664-24 · AOCS Cd 3d-63 FTIR oxidation Base Spec §6.4 Total acid number Base Spec §5.10 OCP SPECIFIES FTIR analysis, with ASTM D4310 ≤0.01 mg KOH/g new hydrocarbon fluid ≤0.02 mg KOH/g over its life Study Method Results from different setups: ATR vs. Liquid Transmission Cell, varying cell types and optical path lengths Results from four methods: IEC 62021-2, JIS K 2501 / ASTM D974, ASTM D664, AOCS Cd 3d-63 WHY IT MATTERS Whole-spectrum ATR match barely moved (17 of 17 at 0.9996– 0.9998); early oxidation needs a band-specific, longer-path setup Most fluids we tested were well above 0.02 mg KOH/g, yet showed no apparent operational issues OPEN QUESTION Should we recommend a band-specific method (e.g. carbonyl area) and a defined cell path length? Is 0.01/0.02 the right limit, and which method and protocol should verify it? SUPPLIERS SENT ATR-FITR Colorimetric TAN measurements

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• Fresh fluids retained broadly stable surface resistance through 500 hours of laboratory aging. • Data collected confirms some of the original published work showing peak oxidation is typically beyond several years of operation. • Longer-duration testing is needed to characterize later-stage oxidation and its relationship to electrical performance. • The electrical test method distinguished in-service samples from their matched laboratory-aged counterparts, revealing lower surface resistance in the in-service fluids. • TAN increased without a consistent decline in surface resistance. TAN, FT-IR, RI, and color alone did not establish electrical degradation under the conditions tested. • TAN tracks bulk acidity. Understanding what fluid aging means for electronic reliability requires chemical characterization alongside direct electrical measurements. Conclusions

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Call to Action CONTRIBUTE FIELD-AGED SAMPLES • In-service fluids with their matched fresh fluid, acid number, and a real service history. • We especially would like to test any fluids that have been in extreme conditions or perhaps were removed from service due to failing lab testing. DOE PHASE 2: LONGER DURATIONS (RUN UNTIL FAILURE) • Multiple participants have agreed to test their fluids until failure, which will help us classify the failure modes for various fluid chemistries. • Testing is planned to begin in November 2026, with initial results targeted for OCP EMEA. DOE PHASE 3: “BEYOND THE TAN” MATERIAL EFFECT ON ELECTRICAL DEGRADATION • Controlled adding of bulk materials to test interactions with oxidized fluids. DOE PHASE 4: FLUID AGING EFFECT ON SIGNAL INTEGRITY • Record signal integrity metrics like BER, Df, Eye Diagram alongside volume resistivity and surface changes. OPEN WHITEPAPER PUBLICATIONS • All results will be published in a whitepaper (currently in draft) through the fluid oxidation workstream, blinded, with the method documented well enough to easily replicate it. CONTACT US FLUID OXIDATION WORKSTREAM

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