Transforming know-how into solutions. Siemens Transformer Service TLM

Transcription

1 Transforming know-how into solutions. Siemens Transformer Service TLM

2 TLM Agenda Introduction Instalation and Comissioning Condition Assessment Monitoring Repairs and Retrofit Spare Parts - Solutions After Sales and Training Page 2

3 TRANSFORMERS STRUCTURE Page 3

4 TLM WORLD STRUCTURE Page 4

5 Vision / Mission Page 5

6 Why TLM is strategic? Legacy transformers Landscape Number of Explosions Average age of US transformers: 39 years Exponential growth of explosion occurrences Sergi Transformer Explosions in the United States along with the end of life Year William H. Bartley P.E., Hartford Steam Boiler Inspection & Insurance Co., "Life Cycle Management of Utility Transformer Assets," Page 6

7 Brazilian Legacy transformers Landscape Average age of Brazilian transformers: ~29 years Legacy Transformers Age - Brazil 25,00% 20,00% ~65% of legacy transformers 20,80% 16,20% 15,00% 11,90% 10,00% 9,50% 9,20% 10% 5,00% 5,50% 5,70% 6,30% 5% 0,00% years years years years years years years years years >46 years Page 7

8 Transformer Rate Failure Fonte: William H. Bartley - International Association of Engineering Insurers 36th Annual Conference Stockholm, Page 8

9 solutions for power transformers of any brand and any age - Portfolio Transport Installation & Commissioning Disassembly, Preparation for Transport, Shipping & Transport Management, Installation & Commissioning Condition Analysis & On-Site Diagnostics Oil Laboratory Services, Condition Assessment, Fleet Screening, Lifecycle Assessment, Advanced Electrical Measurement, H-V Tests On-Site Lifecycle Maintenance Preventive, curative corrective Maintenance, Long-Term Maintenance, Online Drying & Degassing, Active Part Drying, Oil Regeneration, End of Life Management, Scrapping On-line Monitoring Measuring Sensors, Gasguard, Tapguard, Single Transformer Comprehensive Monitor, Integrated Substation & Central Server Monitoring Troubleshooting Repair & Retrofit Failure Diagnostics, Repair on-site, Repair & Modifications in-house, Refurbishment, Retrofit, Modernization, Up-grading Spare Parts Accessories Bushings, Tap-Changer Motor Drives & Contacts, Coolers, Fans & Pum ps, Protection Devices & Relays, Consulting Expertise Training Engineering Service, Advice & Recommendations for preventive, corrective and curative actions, Educational Seminars and Workshops Page 9

10 TLM Organization Chart - Brazil TLM BRASIL - ORGANIZATION CHART TLM BERNARDO SALUM SALES AND COORDINATION - TLM MONITORING CONSULTANT MONITORING AFTER SALES - PT AFTER SALES - DT FIELD SERVICE Ademir Santana José Geraldo David Scaquetti Mauro Mathiazi Andre Rosendo MAURICIO IRAHA REPAIR ENGINEERING WILTON A. FA RIAS FIL HO REPAIR WORKSHOP IVAN GAZZI Page 10

11 TLM Agenda Introduction Instalation and Comissioning Condition Assessment Monitoring Repair and Retrofit Spare Parts - Solutions After Sales and Training Page 11

12 TLM Instalation Two types: Assembly supervision Full Assembly including labour and devices/tools Estimated time between 2 and 6 weeks. (depending on the site conditions) Page 12

13 TLM Comissioning Comissioning is transformer functional check and its system integration. It holds of: Functionals checking of auxiliary systems Tests and Electrical measurements Performed in accordance with customers/siemens rules/standards Estimated time of 3 days to 1 week depending on the specific conditions. Page 13

14 TLM Instalation - Facilities Page 14

15 TLM Agenda introduction Instalation and Comissioning Condition Assessment monitoring Repair and Retrofit Spare Parts - Solutions After Sales andtraining Page 15

16 TLM situations that every single customer is exposed to: Transformer life* decreases naturally with time as a consequence of natural ageing processes. operating temperatures (load, ambient) moisture content and increase (i.e. as a result of ageing) oxygen level and inrush (through conservator, ) mechanical & electrical stress (short circuit events, harmonics, system overvoltages, ) * The design life of a transformer is defined as the life of the cellulosic insulation according to L.Pettersson, 1990 Page 16

17 TLM - condition assessment diagnostics SITRAM DIAG SITRAM DIAG assessment-levels High-Voltage tests on-site PD at applied voltage any HV according to IEC ANSI IEEE On-site tests & diagnostics recommended to be performed in regular intervals during outages, or if level 1 gives indication Non-electrical on-site assessments Complete oil analysis, DGA, furans, external visual inspection First level of classification and recommendations modular adjustable for all power transformers complete transformer populations Page 17

18 Condition Assessment Technical Report Level 1 The report consists in: Data bank structure Dissolved gas analysis (DGA) Insulating oil Physical and chemestry properties 2FAL Parameter Comissioning tests Maintenance and operational review Global Analysis Ranking of the equipments Overload impact in the life expectation Conclusions / Recommended actions Page 18

19 Analysis tools s Transformer Life Management Toolbox Artificial Neural Net and Fuzzy Interference 2 C H C H ,0 T1 0,01 PD 0,1 0,1 T2 0,01 T1 0,2 1,0 4,0 CH 4 H D1 2,5 D1 D2 1,0 1,0 D2 0,6 CH H 4 2 C H C H C 2 H 4 C2H ,2 T ,1 1,0 0/1 3/4 5 0,3 PD T1 2 0,1 T2 IEC Rogers Ratio Duval Triangle C H C H CH C H D1 D2 DT T3 1,0 3,0 C H 2 2 Human Expert normal high very high Gas Level NIF SIF FL T VFT NONE SOME IMP CRITICAL ANN Indication of Fault IEC normal high very high Gas Generation Rate Page 19

20 Condition Assessment Technical Report TRT14 TRT12 TRT13 TRT11 TR0 T0 TR2 T1 T2 TRT23 TRT26 TRT24 TRT22 TR1 TRT25 TRT21 TR3 T3 TRT15 TRT Transformers Fuzzy classification, priority at the equipments that have simultaneous problems (gas, 2FAL, oil quality, etc). Page 20

21 TLM - condition assessment diagnostics SITRAM HVT SITRAM HVT High Voltage Testing Level 3 Diagnostics Routine tests acc to IEC IEEE standards Additional high voltage tests: - Applied voltage tests - Induced voltage tests - Partial Discharge measurement Helps arrive at critical decisions such as: keeping the unit in service carrying out a repair removing from service (scrap) Page 21

22 TLM Agenda Introduction Instalation and comissioning Condition Assessment Monitoring Repairs and Retrofit Spare Parts - Solutions After sales and Training Page 22

23 Monitoring Sensors Individual Transformers Multiple transformers TLMC Page 23

24 Main monitoring parameters bushings Oil level Top oil temp. Environment temp. OLTC lower oil temp. Load humidity Gas in oil Cooling control Page 24 Oil flux

25 Simotemp relay of thermal protection Page 25

26 TLM - online monitoring SITRAM GAS-Guard. SITRAM GAS-Guard The DGA laboratory at the transformer gas chromatography optimized for use in the field Diagnosis of individual gases (acc. to IEC/ IEEE) Indication of load-dependent gas development Page 26

27 Monitoring Sensors Individual Transformers Multiple Transformers TLMC Page 27

28 Smart Monitor Descentralized solution Page 28

29 Smart Monitor Monitor stand-alone, instaled and locally accessed. Every monitor is responsable for diagnostic of one transformer. It can accessed by Web interface and addicionaly local access. External status indication by LEDs in the panel. Page 29

30 Monitoring Sensors Individual Transformers Multiple Transformers TLMC Page 30

31 TMDS Centralized solution Page 31

32 Substation Arquitecture Local Central Panel Panel WebServer Local Panel Engineering Server LAN WAN Local Panel Anel Optic fiber Page 32

33 TMDS Multiple substations Arquitecture Substation 1 Substation 2. Substation n WAN Page 33 Control Center

34 Local Panel Page 34

35 Central Panel Page 35 Frontal view Back View

36 Monitoramento Sensors Individual Transformers Multiple Transformers TLMC Page 36

37 TLMC Transformer Life Management Central Monitoring Center Page 37

38 TLMC Data Transmission by mobile Data collect Firewall Engineering server Data collect GPRS MONITORING CENTER Data collect Page 38

39 TLMC Monitoring Center Customer Data Process and Analysis Data Bank Action Follow-up with Customer Page 39 TLMC Assets managing Diagnostics / Sample Service and field support Monitoring / on-line support Managing of transformers data / reactors

40 TLM Agenda Introduction Instalation and Comissioning Condition Assessment Monitoring Repairs and Retrofit Spare Parts - Solutions After Sales and Training Page 40

41 REPAIR OR BUY A NEW TRANSFORMER COMPARATIVE ADVANTAGE AND DISADVANTAGES TO REPAIR ADVANTAGE Maximum cost of 70% of new equipment. (Considering scrap and the work performed in workshop) Small installation costs DISADVANTAGES Unavailability of equipment during the repair period. Usually No load losses is little bit higher. Short delivery time Small assets Possibility to increase the capacity up to 30% (using a conventional raw materials). Same warranty period. Page 41

42 Repair in Workshop Reactor repair Opening 800 kv transformer tank Page 42

43 Repair in Workshop Main Brazilian Facilities Dedicated area to repair up to 150 MVA 230 kv (1300 m2), distributed in two areas Two cranes (80 ton and 50 ton) Segregated areas dirt and clean areas Place to parking tanks, conservators Hot oil spray devices Core table Page 43

44 REPAIR ON SITE OR ON WORKSHOP MR$ 2.200, , , , , , ,00 800,00 600,00 400,00 200,00 - Structure costs x Transportation costs Sheltered place installation with lifting devices 250 KM 700 KM 1300 KM 2300 KM Structure 30 ton 50 ton 72 ton 112 ton 150 ton 262 ton Page 44

45 TLM - emergency support solutions on-site SITRAM REP SITRAM REP Repair On Site fast intervention solutions emergency support avoiding costly shipping to workshops Accurately adapted mobile workshop solutions shipped on site, providing optimum dry and clean working environment Well experienced and perfectly equipped supervising crews guaranteeing an efficient working process on-site Efficient project management along the whole repair process with direct access to TLM engineering and spare parts Page 45

46 Transformers Repairs and Retrofit Page 46

47 Repair on site Feasibility to repair in field: Large distances and long transportation period. Road in bad condition. High transportation cost. Large amount of transformers in same place, in order to dilute the costs of structure in field. Resulting: More competitive price Small repair period Possibility to follow all repair process by customer. Same warranty period of transformer repaired in workshop. Page 47

48 Repair on site Page 48

49 Necessary facilities to Repair on site Pressurized cabinet and retracted cabinet roof Page 49

50 Necessary facilities to Repair on site Core table assembling Page 50

51 Necessary facilities to Repair on site Tank and special devices to winding dispatch. Test winding device Page 51

52 Necessary facilities to Repair on site Mobile Transformers Test Unit Electrical resistance Voltage Ratio Insulating resi stance Angle displacement and phase sequence No load loss / excitation current Impedance and Load losse s Induced voltage of short period Induced voltge with partial discharge measurement Acce ssories Functional SFRA (special) Page 52

53 TLM Agenda Introduction Instalation and Comissioning Condition Assessment Monitoring Reparos e Retrofit Spare Parts - Solutions After Sales and Training Page 53

54 Spare Parts - Solutions Bushings On load tap changers (OLTC) Bombs, fans Protection relays (Buchholz relay) Indicators (temperature, oil, level, Oil flux) Gaskets Rubber bags Valves Dehydrant air Bushing Buchholz relays Page 54

55 Spare Parts Estimated life period Item Estimated life period Seriousness Probability (years) Solid porcelain bushing High Low Condensive bushing Very high Medium Off load Tap changer Very high Medium Bucholz Relay Medium Medium Pressure relief Valve High Medium Winding/oil temperature indicator Medium Medium Oil level indicator 5-15 Low Medium Oil/water flux indicator 5-10 Low Medium Fans Medium Medium Bombs High Medium Gaskets 5-10 Low High Rubber bag Low Medium Valves Low High Dehydrant air 5-10 Low Medium Page 55

56 TLM - thermal improvement SITRAM COOL (Transviso) SITRAM COOL (Transviso) A sophisticated cooling upgrade as retrofit self-learning and self-optimizing optimizing the thermal efficiency minimising noise & losses Higher airflow with lower power consumption Reduced noise levels, more efficient fans Adjusting the cooling according to power consumption, temperatures, limits on noise radiation, ) Smooth temperature profile avoiding peaks and downs Page 56

57 TLM - moisture reduction SITRAM DRY SITRAM DRY reliable and proven drying methods, specifically accustomed to the needs Page 57

58 TLM - oxygen reduction SITRAM SEAL Air Oil SITRAM SEAL Hermetic sealing retrofitting rubber bags in conservators to avoid unwanted intrusion from outside of: Air and oxygen Moisture Individual designs possible according to the transformer size and local conditions Page 58

59 TLM Agenda Introduction Instalation and Comissioning Condition Assessment Monitoring Repairs and Retrofit Spare Parts After Sales and training Page 59

60 After Sales and Training After Sales After sales of power and distribution transformers are including in TLM group in order to improve the sinergy. Training: - Transformers basic concepts - Assembling and inspection - Comissionig Tests - Preventive and corrective Maintenance - Operation - Oil sampling and results analisys Page 60

62 TLM - where to contact, how to get information TLM@siemens.com 7 segments - for customers 5 segments - for simplified reporting info material in PDF - for easy print Page 62 SITRAM DIAG SITRAM DRY SITRAM HVT SITRAM MONITORING MONITORING LEAFLET in preparation SITRAM COOL SITRAM SEAL SITRAM REPAIR

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65 TLM - repair & refurbishment SITRAM REP SITRAM REP Repair In Workshop repair, refurbishment, reconstruction, modification, improvement - any brand A dedicated repair facility is being made available at the traditional Trafo Union workshop in Nürnberg. Centrally located in Europe, allowing cost effective access by rail and barge Modern and accurate design, materials and manufacturing standards is essential for quality and reliability in the industry. The integrative support and expertise from our global experts is made available to repair facilities throughout the world Page 65

66 Organisational changes MCS reorganised to TLM P OI = 5,4 MIO Page 66 OI = 12 MIO

67 TLM SITRAM matching set of solutions Condition assessment SITRAM DIAG diagnostics in 3 levels SITRAM HVT high-voltage testing Condition monitoring SITRAM MONITORING on-line condition monitoring Temperature SITRAM COOL (Transviso) intelligent cooling system Moisture SITRAM DRYING on-line DRY; off-line LFH, HOS Oil quality SITRAM REG on-line oil-regeneration Oxygen inrush SITRAM SEAL ageing prevention air sealing Repair & refurbishment SITRAM REP repair on-site, or in workshops Page 67