Pomona, CA May 24 25, 2016 Transformer Technology Seminar Modular approach on economic condition assessment for power transformer; data management, Fleet screening and risk ranking Siemens AG 2014 All rights reserved. siemens.com/answers
Content Current situation and tasks Modular approach Level 1: Basic Level 2: Advanced Level 3: HV testing Data handling and data management Outcome Page 2
Current situation Page 3
Current situation Moisture Oxygen Temperature Oil / Cellulose - Insulation Chemical decomposition Acids, Peroxides, add. water, oxygen Accelerated Aging Mechanical Degradation Dielectric Degradation Lightning- and Switching Impulses Insulation Failure Short Circuits The ageing of oil and cellulose are strongly related
Current situation Unplanned failure of a large GSU Forced outage, i.e. NPP loosing ~$1.5 million per 24h Replacement with a spare unit if available: downtime minimum 2 weeks Risk of personal injury, environmental damage Image-, company value-, stockmarket quotation- depreciation Page 5
Current situation Market Condition Average age of transformers >30 years Lead time of new transformers >1 year Increasing utilization Demand for modernization Demand for relocation Page 6
Current situation Economic demands Why? Identify condition of installed transformer fleet Prioritize based on Risk ranking of transformer fleet Maintenance recommendations Reduction of unplanned outages Intelligent spending of limited financial resources Avoidance of damaging company s image Support strategic procurement of new units Page 7
The Three Level Approach Level 3: Level 2: Level 1: On-Line and Off-Line condition assessment Page 8
The Three Level Approach Off-line advanced, HV - Testing ( Level 2, Level 3) On-line essential (Level 1) winding resistance ratio & vector group Insulation resistance Impedance / Uk Po / Io at 230 / 380 V C tan delta windings C tan delta bushings FRA Measurement FDS/PDC - Measurement oil-parameter Furane, DP - temperature profile - noise - vibration - PD - measurement -... DGA Mobile HV - Testing: - applied overvoltage - induced overvoltage - PD - measurement - DC - tests - loss measurements - Oil ageing Paper ageing Insulation condition Faults Page 9
Level 1: Essential Level 1: Basic All modules in the diagnosis Level 1 essential are to be applied on energized transformers. The most powerful toolbox for this application is the diagnosis of the insulating liquid. Standard oil tests, dissolved gas analysis and furanic components analysis are well developed and reliable to detect ageing and severe faults. Moisture measurement applied during the sample taking will provide reliable detection of the moisture content inside the transformer insulation. Additional stand alone modules are available to be applied when the oil tests and/or the operating personnel gave indication for deficiencies or changes. Page 10
Level 1: Essential Content of Level 1 (essential): DGA Furanic components Moisture (by capacitive sensor) Visual Inspection: Leaks, Corrosion, Oil levels, Bushings, cooling, surge arrester counter... Optional: corrosive sulphur,... Additional stand alone modules: PD (UHF-, acoustic sensors) Noise measurement Vibration measurement Thermograph scans Page 11
Level 1: Essential Parameter of the Level 1 Module: Page 12
Level 1: Essential Level 1 (essential): Operational Data Operation and maintenance (O & M) history provide an indication of overall transformer condition. O & M history factors that may apply are: Sustained overloading Unusual operating temperatures indicated by gauges and continuous monitoring Abnormal temperatures indicated by infrared scanning Nearby lightning strikes or through faults Abnormally high external temperatures detected Problems with auxiliary systems (fans, radiators, cooling water piping, pumps, motors, controls, nitrogen replenishment system, and indicating and protection devices) Increase in corrective maintenance or difficulty in acquiring spare parts Page 13
Level 2: Advanced Level 2: Advanced The advanced modules are applied on de-energized and disconnected transformers. Most measurements repeat the measurements as shown in the manufacturers test report and by comparing the results any differences will be highlighted. Modern methods such as Frequency Response Analysis (FRA) are part of a Level 2 assessment and provide information about the insulation (dielectric) condition as well as the mechanical condition (displacements) of the active part of a transformer. All modules of Level 1 apply. Page 14
Level 2: Advanced Content of Level 2 Diagnostics: Transformer Turns Ratio Winding resistance Power factor (windings and bushings) Insulation resistance No load current and losses at low voltage Partial Discharges FRA Additional stand alone modules: All modules of Level 1 apply Page 15
Level 2: Advanced Typical measurements for Level 2 Diagnostics: Ratio, Winding Resistance, Impedance, No-Load, Insulation Resistance Page 16
Level 2: Advanced Advanced measurements for Level 2 diagnostics: FRA Magnitude 0-10 -20-30 -40-50 -60-70 1U1V 1V 1W 1W 1U High Voltage Tap10 1 10 100 1000 10000 100000 1000000 10000000 Frequency Page 17
Level 2: Advanced Advanced measurements for Level 2 diagnostics: PD - Measurement Page 18
Level 2: Advanced C-tan-delta Advanced measurements for Level 2 diagnostics: C-tan-delta Measurement 7,0 6,0 tan δ [ ] 5,0 4,0 3,0 2,0 1,0 0,0 1976 1992 1997 2001 2006 2011 0,7 0,6 tan δ [ ] 0,5 0,4 0,3 2011 0,2 0,1 0,0 0 50 100 150 200 250 300 Prüffrequenz [Hz] 350 400 Page 19
Level 3: Mobile HV testing Level 3: Mobile HV testing High Voltage Testing on-site is usually required following on-site repairs, factory repairs, refurbishment, or relocation and also performed based on the results from the level 1 and level 2 assessments. The SITRAM DIAG mobile test fields provides solutions for all kind of HV testing and loss (no load and/or short circuit losses) measurement. Special test cycles or long duration tests are also possible. Level 3 assessment can be combined with all modules out of level 1 and level 2. Page 20 Pressurized cabinet with retractable roof for onsite repairs
Level 3: Mobile HV testing Measurements available with the mobile test field: No load current and losses Load losses and impedance Applied voltage test (76kV) Induced voltage test PD-measurement DC tests Page 21
Level 3: mobile HV testing Measurements available with the mobile test field: Application of mobile test field Page 22
Levels 1-2 -3 Page 23
Levels 1-2 -3 Page 24
Processing, assessing and managing data TLM Condition Assessment Manager Built on the experience of transformer experts for design, testing and maintenance Standardizing assessment approaches and providing families for comparison Considering historical data, events and maintenance actions Ensured findings and recommendations starting from basic level 1 up to high end level 3 evaluations Providing measures to select and rank single transformers from a complete fleet. Page 25
Processing, assessing and managing data Input data can be imported directly from the measurement instrument, manually or by an import functionality from an external data base. Page 26
Processing, assessing and managing data Input of measured data and static data Setting thresholds and assumptions for precession and repeatability Building physical groups Consolidation for final grade and significance Checking for correlation between groups and parameters, spec. models Findings, route cause and recommendations Page 27
Outcome Page 28
Outcome -Transformer Fleet Management System - Transformers ranking based on score to facilitate targeted maintenance and budget management -Strategic planning of spares -Fleet Reliability
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Service is not everything Juan Acosta Manager Transformer Lifecycle Management USA Siemens EM CS TR Wendell, NC Mobile: (919) 376 6572 juan_c.acosta@siemens.com Thank you very much for your attention! Your reliable Service Partner. Ihr verlässlicher Servicepartner. Siemens AG 2014 All rights reserved.