ABB Brasil. Power Transformers: Life Cycle and Operational Cost Optimization From Purchase to Minimum Maintenance
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1 SANTIAGO CL Jornadas Técnicas Abr14&15 Dr. José Carlos Mendes Gte Tecnologia Transmissão e Produtos de Potência Gte Desenvolvimento & Engenharia Engenheiro Corporativo Executivo Global ABB Asea Brown Boveri Divisão de Produtos de Potência Transformadores de Potência São Paulo, SP - Brasil [email protected] tel: cel: ABB Brasil Power Products Division : Life Cycle and Operational Cost Optimization From Purchase to Minimum Maintenance ABB Brazil JCM A-1 14 Power de abril de Products 2015 Slide Division 1
2 Context Renewables Energy Content Content q q q q introduction buying by performance to a long life useful life and maintenance transformers and useful life aspects life cycle end of life from purchse to minimum maintenance transport installation knowledge based condition based event based minimum periodic inspection advanced asset managment ABB Brazil JCM A-2 14 Power de abril de Products 2015 Slide Division 2
3 Life Cycle Optimization Transformer Life Cycle ABB Brazil JCM A-3 14 Power de abril de Products 2015 Slide Division 3
4 Useful Life and Reliability Transformer Life Cycle Specification, Design, Manufacturing, Tests, Transportation, Receiving, Storage, Installation, Operation, Monitoring, Maintenance, End of Life ABB Brazil JCM A-4 14 Power de abril de Products 2015 Slide Division 4
5 Life Cycle and Global Evaluation of Alternatives Transformer Life Cycle Warranty of Useful Life Garantida, year Life Cycle, years Capital Cost: purchase transport installation $1 Operation Cost: $2 losses (noload, Load, Auxiliar) maintenance insurance premium repairs performance End of Life Cost: replacement transfer refurbishment $3 NPV, Total Cost / Life Cycle $ = $1+$2+$3 USD$ kva x Useful Life x Overloading Factor ABB Brazil JCM A-5 14 Power de abril de Products 2015 Slide Division 5
6 Life Cycle and Global Evaluation of Alternatives Transformer End of Life cellulose molecule O2 chemical bond ABB Brazil JCM A-6 14 Power de abril de Products 2015 Slide Division 6
7 Life Cycle and Global Evaluation of Alternatives Transformer End of Life Insulation Paper Polymerization Degree DP New Paper - DP tensile strength of a new paper Half Life Paper - DP residual tensile strength of a half-life paper is about 50% of the one of a new paper End of Life Paper - DP residual tensile strength of a end-of-life paper is about 25% of the one of a new paper Dielectric Strength at end-of-life is reduced just about ~ 10% of its original new paper value ABB Brazil JCM A-7 14 Power de abril de Products 2015 Slide Division 7
8 Applications and Operation Optmization From Purchase to Minimum Maintenance - Conclusions ABB Brazil JCM A-8 14 Power de abril de Products 2015 Slide Division 8
9 Transport Factory-to-Site Transportation Process At Site 1. 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 process 1. 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 C Guide for Installation and Maintenance ABB Installation, Operation and Maintenance Manual ABB Brazil JCM A-9 14 Power de abril de Products 2015 Slide Division 9
10 Installation Installation Process Key Aspects 1. 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 10
11 Installation Installation Process Main Steps 1. 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 11
12 Installation Installation Process Final Processing 1. 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 12
13 Operation Operation Strategy Extended Useful Life and Minimum 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 13
14 Maintenance Minimum Maintenance Condition Based Minimum Invasive Operation and Performance Data monitoring and data analysis Advanced Monitoring Condition Based Maintenance chronology data, time, number of maneuvers (in and off) data, time, lightning strikes on-line 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 on-line 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 periodic ABB Brazil JCM A Power de abril de Products 2015 Slide Division 14
15 Maintenance Minimum Maintenance Condition Based Minimum Invasive Advanced Monitoring Condition Based Maintenance 4. Maintenance Electrical Tests event & condition based HV OIP condensive bushings C1 & tand test ü on-line monitoring of HV OIP condensive bushings C1 & tand ü consider to install PCORE TEST TERMINAL to C1& tand tests ü eliminate periodic condensive bushings C1 & tand tests FRA Frequency Response Doble M5400 test ü base line before energization ü perform just after a major system event or a major earthquake Core and Winding tests ü commissioning tests at site ü eliminate periodic core and winding tests PCORE Test Terminal HUBBEL Power Systems 1. before 2. after a major system event 3. after a relevant change in the monitored pattern 1. before 2. after a major system event 1. before 2. after a major system event 3. after a relevant change in the monitored pattern ABB Brazil JCM A Power de abril de Products 2015 Slide Division 15
16 Conclusions q Overall 1.Available Technology allows utilization of a Minimum Invasive Condition Based Maintenance Strategy 2.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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 16
17 Monitoring On-Line Monitoring and Sensors: load current & voltage ambient temperature top-oil temperature winding hotspot temperature moisture in oil/solid insulation gas in oil H2, CO, C2H4, C2H2 (Hydran) HV OIP cond bushings C1 & tand ISA reactors üs üs üs üs? s? s üs ABB TEC ABB Brazil JCM A Power de abril de Products 2015 Slide Division 17
18 Advanced Asset Management Data Analysis Action EAM Mobile ERP ALGORITHMS Sensors SCADA Historiador Centralized Information Data Storage Data Management Data Protection ABB Methods Data Mining Condition Assessment Models failure risk asset condition Strategic Decisions Maintenance Plan Later Maintenance Replacement ABB Brazil JCM A Power de abril de Products 2015 Slide Division 18
19 Advanced Asset Management Advanced Operational BI Data Processing and Analytics Engineering Workbench Complete Information Fleet to Equipment Health Actionable Notifications Business Process Workflow Optimization &Planning Subject Matter Workbench Enterprise Data Sources Enterprise Asset and Work Management ABB Brazil JCM A Power de abril de Products 2015 Slide Division 19
20 Advanced Asset Management - Potential Benefits ABB Brazil JCM A Power de abril de Products 2015 Slide Division 20
21 Advanced Asset Management - Monitor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 21
22 Advanced Asset Management - Monitor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 22
23 Advanced Asset Management Maintenance Planning ABB Brazil JCM A Power de abril de Products 2015 Slide Division 23
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