ASSET MANAGEMENT. Services and replacement solutions from MR 2013

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1 ASSET MANAGEMENT Services and replacement solutions from MR 2013 Page 1

2 THE AVERAGE AGE OF INSTALLED TRANSFORMERS IS INCREASING AROUND THE GLOBE Avg. age of 35 years Avg. age of 41 years Avg. age of 31 years Avg. age of 22 years Avg. age of 26 years Avg. age of 33 years Avg. age of 36 years Croatia: Transformer built in 1954 Average age of installed transformers in network operations (source: various) Examples: Canada, Brazil, Great Britain, Qatar, India, Japan, New Zealand Page 2

3 WE HAVE FIELDS OF ACTION FOR THIS Diagnosis e.g. measurements on a tap changer and transformer Maintenance & Repairs Around the world by trained and certified service technicians Spare parts & Accessories e.g. innovative transformer accessories from Messko Instruments Training Fully equipped training centers on all continents Consultancy & Engineering Technical support throughout the entire life cycle Retrofit & Modernization e.g. replacement solutions and actions for extending service life Installation & Commissioning Installation, function tests and transformer component retrofitting Monitoring Condition-oriented equipment monitoring Page 3

4 DIAGNOSIS WHAT WE CAN DO I Increased reliability through preventive condition assessment I Oil diagnostics and dynamic resistance measurement (TAPSCAN DRM) I Electric and dielectric measurements (DIN/IEC) Transformers measuring devices at Reinhausen South Africa PrimeLab at Messko Instruments Page 4

5 DIAGNOSIS DYNAMIC RESISTANCE MEASUREMENT (TAPSCAN DRM) Measuring the direct current resistance of a complete transformer winding I Assessment of the diverter switch operation for an on-load tap-changer by recording the entire switching sequence I Comparison with recorded motor current I Interpretation of the curve Quick diagnostics using diverter switch criteria and the mechanical behavior of the OLTC (3-phase measurement possible) Comparison with fingerprint/earlier measurement/ measurements in the MR database Combination with gas-in-oil analysis Useful method for classifying an on-load tap-changer population (aged tap changers) Our measuring instrument partner: Ibeko AB (DV Power) Page 5

6 DIAGNOSIS OIL ANALYSIS Oil analysis for transformers and on-load tap-changers I The Duval Triangle exists for on-load tap-changers, but oil analysis is only informative for VACUTAP OLTCs (arcing in vacuum interrupters) I We are familiar with typical gas patterns for VACUTAP on-load tap-changers (resistor and reactor) and the influencing factors (load, number of switching operations, oil temperature) I Carbon monoxide is an indicator for thermal overload and, together with hydrogen, an indicator for oil degradation A Messko DGA sensor for this purpose is being launched on the market in 2013 I All analyses by Messko PrimeLab oil laboratory. An oil collection kit is also available. Duval Triangle for on-load tap-changers not measurable Typical gas pattern for "VM" vacuum onload tap-changers without acetylene Page 6

7 MAINTENANCE AND REPAIRS WHAT WE CAN DO I Global service center network I Highly trained and certified service technicians I 24/7 availability I CST department I I Page 7

8 MAINTENANCE AND REPAIRS ON-SITE OR IN OUR WORKSHOPS Premium Service Provider (PSP) I Maintenance and repair by our specially trained service technicians Training and testing for each tap changer type Regular retesting Global "PSP support points" I 24 month warranty on all the work we do Page 8

9 MAINTENANCE AND REPAIRS FOR OILTAP I TYPE ON-LOAD TAP-CHANGERS Why is maintenance necessary? I Wear on mechanical components such as energy accumulator springs (depending on type and number of switching operations) I Contact wear or wear difference between switching contacts and resistor contacts(depending on material, load current and the number of switching operations) I Carbon build-up in insulating oil caused by arcing I Electric strength of the insulating oil in the on-load tap-changer (both dependent on the load current and number of switching operations) OILTAP M: energy accumulator spring (top) worn contact (bottom left) good-asnew contact (bottom right) The criteria for when an on-load tap-changer requires maintenance are the number of tap-change operations and a time interval, whichever comes first Page 9

10 MAINTENANCE AND REPAIRS FOR OILTAP II TYPE ON-LOAD TAP-CHANGERS Scope of maintenance I Removal and installation of the diverter switch insert I Cleaning and inspection of mechanical equipment I Visual inspection of insulation distance of the diverter switch insert and oil compartment I Part replacement (such as springs or sets of contacts) including a diverter switch insert update I Replacement of switching oil (new oil with electric strength of > 50 kv/2.5 mm, in accordance with IEC 60156) I Determining contact wear I Measuring transition resistors I Checking the motor-drive unit, drive shaft and protective relay I Function test "D" tap changer maintenance in Brazil Transition resistors/contact wear measurement Page 10

11 MAINTENANCE AND REPAIRS WORK ON NON-MR TAP CHANGERS Maintenance or replacement? I We have databases and technical documentation on all of our own on-load tapchangers in addition to the following types: -Trafo-Union, AEG and Siemens -Westinghouse UVT, UTT and UTS -ABB, Elprom and additional manufacturers -MR-licensed tap changers I Maintenance/replacement evaluation specifically for older models in regard to costs, spare part availability, maintenance intervals, etc. I Quick condition assessment possible using measurements (TAPSCAN DRM) I We can replace any motor drive unit brand! "ABB" (top) and "Elprom" (bottom) on-load tapchangers from Germany Page 11

12 SPARE PARTS AND ACCESSORIES WHAT WE CAN DO I Worldwide availability of spare parts for entire product life I Own workshop for repairs and special components I Innovative transformer accessories Page 12

13 SPARE PARTS AND ACCESSORIES FOR EXTENDING THE SERVICE LIFE OF YOUR TRANSFORMERS We provide repairs on site or in our workshop and deliver to anywhere in the world I Spare parts for all of the on-load tap-changers produced by MR I Repair or even replacement of on-load tap-changer sets from individual 'third-party tap changers', such as Elprom and General Electric I Special designs for replacing on-load tap-changers and motor-drive units as well as transformer accessories. The images below show the replacement of an old dial thermometer with a new 'Messko' type in a MRiB protective housing in South Africa Before During After Page 13

14 ASSET MANAGEMENT SOLUTIONS: SERVICE PORTFOLIO FOR BUSHINGS Service Portfolio I Measurements of bushings (tan, PD, capacity, ), on- or offline I Diagnostics and recommendations I Procurement of standard- and special bushings I Exchange of bushings on-site, e.g. aged bushings to silicon bushings I All services can be ordered separately or in connection with diagnostics / service / exchange of on-load tap-changer and transformer components I Complete project management Service und Exchange of transformer components, also as project business Page 14

15 TRAINING WHAT WE CAN DO I Fully equipped training centers on all continents I Tailored training programs I On-site training Page 15

16 TRAINING ON-SITE OR AT OUR TRAINING CENTERS Training centers on all continents I Three training levels: Basic, Specialists, PSP Regensburg, Germany Sao Paulo, Brazil Suzhou, China Kuala Lumpur, Malaysia Page 16

17 CONSULTANCY AND ENGINEERING WHAT WE CAN DO I Project planning and implementation of complete solutions I Technical support in product life cycle I Development of tailored service concepts City of Pra+ McGraw Tie Transformer 115/12.47 Tie Sub West Day Task list Mobilize/set up Tanker stage Acquire manlims Crane Prelim TTR/oil sample/meggar/pf Drain oil from main Drain oil from LTC Remove and regasket bushings Remove and regasket radiators Set blankets / fire cloth Internal inspecvons DETC inspecvon and cleaning Tag and disconnect LTC leads Set crane/remove LTC Set and place new LTC Cut, set, tape new leads Check BIL clearances 12 hr vac; fill dry air; set 12 hrs Dewpoint Vacuum Vac fill and top off Test/funcVonal check Wiring Page 17

18 RETROFIT AND MODERNIZATION WHAT WE CAN DO I Modernization and retrofit solutions for transformers I Extension of service life and assurance of availability I Complete project handling Retrofit of 'M' into 'VM', Indonesia Retrofit of Westinghouse UVT into RMV-II Page 18

19 RETROFIT AND MODERNIZATION TURNKEY REPLACEMENT PROJECTS Complete project handling by MR I Project planning and organization I Technical clarification I Preparation of all components Example 1: Great Britain Replacement of English Electric type OLTC including design of a special attached tank for Scottish & Energy (90MVA, 132kV power grid transformer) Retrofit in Great Britain Example 2: Lithuania Replacement of RS-4 type OLTC (Elprom). Complete project management by MR. Customer: ELGA (6.3MVA, 115kV transformer from Togliatti) Retrofit in Lithuania Page 19

20 RETROFIT AND MODERNIZATION TURNKEY REPLACEMENT PROJECTS Example 3: Brazil Replacement of FKT-MI1000 type OLTC (Toshiba) with VACUTAP VM-II-650Y for the Copel power company in Brazil (150MVA, 220kV transformer from Fuji) Example 4: USA Turnkey replacement of LRT200 type OLTC (General Electric, bolt-on tap-changer) with VACUTAP RMV-II for the Delmarva Power power company on the US East Coast (22.4MVA, 69kV transformer) Retrofit in Brazil Turnkey replacement includes project management, measurements on the transformer (before/after), oil treatment and associated work. In addition, old transformer accessories are replaced with maintenance-free 'Messko' versions Retrofit in the USA Page 20

21 RETROFIT AND MODERNIZATION "SMART" REPLACEMENT SOLUTIONS VM LUE (VACUTAP VM diverter switch insert) Replacement of the "M" type diverter switch insert (oil) with a "VM" type (vacuum) Also for licensed tap changers (such as Alstom) More than 100 diverter switch inserts already replaced OILTAP MSE and VME A 340 A on-load tap-changer with a special adapter head for replacing a Bulgarian on-load tap-changer of RS3, RS4 or RS9 type. SeAh Besteel, South Korea RMT slide-in retrofit Replacement solution for the UTT type from Westinghouse slidein solution with 1,320A, V maintenance-free to 500,000 switching operations OILTAP MSE RMT-I slide-in Page 21

22 INSTALLATION AND COMMISSIONING WHAT WE CAN DO I Retrofitting transformer components I Performance of correct function I Documentation and approval TRAFOGUARD commissioning in India ConEd phase shifter commissioning (New York) in 2013 I CST department I I Page 22

23 INSTALLATION AND COMMISSIONING RETROFITTING TRANSFORMER COMPONENTS Attaching and commissioning Example 1: Control device upgrade in Australia Modernization with TAPCON 240 with DNP 3.0 communications protocol in order to enable remote communication using centralized network operation. Customer: BHP Billiton (15MVA, 66kV transformers) Example 2: Replacement of motor-drive units in Germany Replacement and commissioning of two motor-drive units including monitoring systems at the Gundremmingen nuclear power plant. Customer: e.on/rwe, 1,000MVA machine transformer, 27/420kV) Page 23

24 MONITORING WHAT WE CAN DO I Monitoring of key system components I Automatic error detection and trend analysis I Condition-oriented operational management Page 24

25 MONITORING INTEGRATED SMART MODULE Monitoring modules integrated into motor-drive unit I collection of information from different sensors I conversion of signals and data transmission I tailored to customer requests perfect as retrofit solution Page 25

26 ASSET MANAGEMENT SERVICE FROM REINHAUSEN Used around the globe I Complete project handling from analysis to the final report I Solutions from experts from a single source I CST department I I Page 26

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