2015abr14&15 dr. josé carlos mendes abb brasil

ABB Brazil JCM A-1Power Products Division

Power Transformers© ABB Group14 de abril de 2015 | Slide 1

ABB BrasilPower Products Division

Dr. José Carlos MendesGte Tecnologia Transmissão e Produtos de PotênciaGte Desenvolvimento & EngenhariaEngenheiro Corporativo Executivo Global

ABB Asea Brown BoveriDivisão de Produtos de PotênciaTransformadores de PotênciaSão Paulo, SP - Brasil

email: [email protected]: + 55 11 2464 8410cel: + 55 11 9 8354 5358

+ 55 11 9 8112 7575

SANTIAGO CLJornadas Técnicas 2015

2015Abr14&15

Power Transformers:Life Cycle and Operational Cost Optimization –

From Purchase to Minimum Maintenance



ContentContent

Content

q introduction§ buying by performance to a long life§ useful life and maintenance

q transformers and useful life aspects§ life cycle§ end of life

q from purchse to minimum maintenance§ transport§ installation§ knowledge based§ condition based§ event based§ minimum periodic inspection

q advanced asset managment

ContextRenewables Energy



Power TransformersLife Cycle Optimization

Transformer Life CycleTransformer Life Cycle



Power TransformersUseful Life and Reliability

Specification, Design, Manufacturing, Tests, Transportation, Receiving,Storage, Installation, Operation, Monitoring, Maintenance, End of Life




USD$kVA x Useful Life x Overloading Factor

Capital Cost:n purchasen transportn installation

Operation Cost:n losses (noLoad,

Load, Auxiliar)n maintenancen insurance premiumn repairsn performance

End of Life Cost:n replacementn transfern refurbishment

NPV, Total Cost / Life Cycle $ = $1+$2+$3

$1

$2

$3

Warranty of Useful Life Garantida, year

Life Cycle, years

Power TransformersLife Cycle and Global Evaluation of Alternatives




cellulosemoleculecellulosemolecule

O2 chemical bond


Transformer End of LifeTransformer End of Life



Insulation PaperPolymerization Degree DP

Insulation PaperPolymerization Degree DP

n New Paper - DP 1050 ... 1300tensile strength of a new paper

n Half Life Paper - DP 380 ... 450residual tensile strength of a half-life paperis about 50% of the one of a new paper

n End of Life Paper - DP 150 ... 200residual tensile strength of a end-of-life paperis about 25% of the one of a new paper

n New Paper - DP 1050 ... 1300tensile strength of a new paper

n Half Life Paper - DP 380 ... 450residual tensile strength of a half-life paperis about 50% of the one of a new paper

n End of Life Paper - DP 150 ... 200residual tensile strength of a end-of-life paperis about 25% of the one of a new paper

Dielectric Strength at end-of-life is reduced justabout ~ 10% of its original new paper value

Dielectric Strength at end-of-life is reduced justabout ~ 10% of its original new paper value


Transformer End of LifeTransformer End of Life



Power Transformers Applications and Operation OptmizationFrom Purchase to Minimum Maintenance - Conclusions

Power TransformersLife Cycle and Operation Optimization



Transport Factory-to-SiteTransport Factory-to-Site

Transportation Process

At Site1. Retrieve, collect and review impact recorder registers:

• at arrival at final destination installation site• after truck unloading• verify for abnormal transport accelerations• together ABB define actions as needed

Long Time Storage – critical process1. In case of long time storage – follows specific procedures

depending on storage time period:• up to 6 months• up to 12 months• above 12 months – assembly oil conservator and oil filled

2. To learn more please see:• IEEE Std C57.93-2007 Guide for Installation and Maintenance• ABB Installation, Operation and Maintenance Manual




InstallationInstallation

Installation Process

Key Aspects1. Substation pad conditions:

• high importance to minimum external stresses• properly levelled and plan

2. ABB Installation, Operation and Maintenance Manual

3. Right and Qualified Equipment – per ABB requirements:• lifting equipment• dry-air machine or dry-air bottles• vacuum pumps• thermo vacuum oil processing system

4. Right and Qualified Personal:• following and safety CUSTOMER and ABB requirements• experience with references in similar power equipment• full ABB supervision





Main Steps1. Overall external inspection:

• main tank• accessories

2. Open main tank

3. Internal overall inspection

4. Assembly:• radiators• conservator• bushings (C1 and tanδ tests before assembly)• all accessories• electrical connections• replace by new gaskets in all opened man-holes etc






Final Processing1. URSI Insulation Surface Moisture:

• pull vacuum and check for tightness• pressurize with super dry-air and check for tightness• dew-point readings (12h, 18h, 24h after pressurization)

2. Oil Filling and Processing:• pull final vacuum• complete (main tank, radiators, conservator) oil filling under

vacuum• oil circulation• oil sampling (2 syringes for DGA and 1000ml bottle for Oil

Properties tests)

3. Commissioning Tests:• routine tests• FRA tests





Operation StrategyExtended Useful Life andMinimum Maintenance

1. Knowledge• update and develop technical knowledge about the equipment

• electrical, thermal, mechanical technical limits• according to purchase technical specification• system operation monitoring to limit over-stressing on

equipment's

• advanced monitoring of few and key operating parameters• advanced trend analysis• diagnostic of on-line and off-line monitored results

• condition assessment• risk of failure• reliability indicators

OperationOperation




Minimum MaintenanceCondition BasedMinimum Invasive

Operation and Performance Data

• chronology• data, time, number of maneuvers (in and off)• data, time, lightning strikes

• date, time, current, voltage, power, reactive power• date, time, temperatures – ambient, oil, winding• date, time, oil – key dissolved gas and moisture• date, time, OIP bushing – C1 and tanδ variations

• periodic external inspection – oil level, leaking, vibration, rubber bag, silica gel, etc• periodic infrared scanning – radiators, tank and bushings• periodic in lab oil tests – Properties, DGA, 2Fal

MaintenanceMaintenance

Advanced MonitoringCondition Based Maintenance

on-line

on-line

periodic

monitoring and data analysis




Minimum MaintenanceCondition BasedMinimum Invasive

4. Maintenance Electrical Tests• HV OIP condensive bushings C1 & tand testü on-line monitoring of HV OIP condensive bushings C1 & tandü consider to install PCORE® TEST TERMINAL to C1& tand testsü eliminate periodic condensive bushings C1 & tand tests

• FRA Frequency Response Doble M5400 testü base line before energizationü perform just after a major system event or a major earthquake

• Core and Winding testsü commissioning tests at siteü eliminate periodic core and winding tests

MaintenanceMaintenance

Advanced MonitoringCondition Based Maintenance

1. before2. after a major

system event3. after a relevant

change in themonitored pattern

event & condition based


system event


system event3. after a relevant

change in themonitored pattern

PCORE® Test Terminal HUBBEL Power Systems




q Overall1.Available Technology allows utilization of a Minimum Invasive

Condition Based Maintenance Strategy2.Combined efforts from High Quality Shunt Reactors, Knowledge

Based Operation, Monitoring Data Analysis and Asset Managment!

q power transformers purchasing process§ to evaluate overall performance§ global economic evaluation aligned with Transmission Project ROI§ regulation requires minimum invasive condition based maintenance

q steps to minimum maintenance§ high quality power transformers from a well known technology§ knowledge on the power transformers design limits to reliable operation§ detailed care of all process steps: from purchasing to energization

q condition based maintenance§ time based periodic inspections§ on-line monitoring of minimum key parameters§ off-line tests/maintenance supported by on-line monitoring data analysis

q advanced asset managment

ConclusionsConclusions




Monitoring

On-Line Monitoring and Sensors:

n load – current & voltagen ambient temperaturen top-oil temperaturen winding hotspot temperaturen moisture in oil/solid insulationn gas in oil H2, CO, C2H4, C2H2 (Hydran)n HV OIP cond bushings C1 & tand

ABB TECüs

üs

üs

üs

üs

? s? s

ISAreactors




Advanced Asset Management

ActionAnalysisData1 2 3

EAM Mobile ERP

Sensors SCADA Historiador

§ Strategic Decisions§ Maintenance Plan§ Later Maintenance§ Replacement

§ Centralized Information§ Data Storage§ Data Management§ Data Protection

ALGORITHMS

§ ABB Methods§ Data Mining§ Condition Assessment ModelsØ failure riskØ asset condition




Advanced Operational BI

Data Processing andAnalytics

Subject Matter Workbench

Enterprise Asset and WorkManagement

Engineering Workbench

Complete InformationFleet to Equipment HealthActionable NotificationsBusiness Process WorkflowOptimization &Planning

Enterprise DataSources

Advanced Asset Management




Advanced Asset Management - Potential Benefits




Advanced Asset Management - Monitor




Advanced Asset Management – Maintenance Planning


2015abr14&15 dr. josé carlos mendes abb brasil

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