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Stiegemeier, ABB TRES North America Technology & Marketing Director, February 2009
NRECA TechAdvantage 2009 Substation Transformer Maintenance Best Practices / Condition Based Actions
ABB Group February 12, 2009 | Slide 1
China Chongquing
Peru Lima
Brazil Guarulhos South Africa Pretoria South Africa Booysens Australia Perth
Australia Darra
Brazil Blumenau
56 Factories in 28 Countries 56 Factories in 28 Countries Sales to 130 Countries Sales to 130 Countries
ABB Group February 12, 2009 | Slide 4
Transformer Remanufacturing & Engineering Services TRES Localized Services, Global Support
Edmonton (SPT Repair, Field Service) Varennes (LPT Repair, Field Service) Brampton (Field Service, Engineering) St. Louis (MPT Repair, Field Service, Engineering) Crystal Springs (Field Service) South Boston (SPT Repair, Field Service) Nashville (Field Service)
Substation Transformer Maintenance Best Practices Execute The Plan Understanding Transformer Stresses, Failure Modes and Aging
ABB Group February 12, 2009 | Slide 7
How many failures are caused by: poor maintenance? short circuits? overloading?
Stresses Acting on Power Transformers Understanding These Allows Development of an Effective Maintenance Plan for Your Transformer
Mechanical Stresses Forces between conductors, leads and windings due to overcurrents or fault currents caused by short circuits and inrush currents
Thermal Stresses Due to local overheating, overload currents and leakage fluxes when loading above nameplate ratings; malfunction of cooling equipment
Dielectric Stresses Due to system overvoltages, transient impulse conditions or internal resonance of windings
Mechanical Stresses in Power Transformers Due to: Short Circuits / Through Faults, Motor Starting
A short circuit gives rise to: Mechanical forces Temperature rise The transformer must be designed so that permanent damage does not take place Electromagnetic forces tend to increase the volume of high magnetic flux, causing mechanical forces that force: Inner winding to reduced radius Outer winding towards increased radius Winding height reduction
Risk: Short Circuit Forces & Stress Failures Through faults often Initiate Transformer Failures
Many older designs have insufficient margin for todays fault currents Loose coils due to aging can cause failures Normal aging results in brittle insulation and increased failures Even brief overloading may cause significant aging Oxygen in the oil can double the aging rate Moisture in the insulation increases aging rate 2-5 times depending on the amount of moisture
Mechanical Stresses in Power Transformers Mechanical Risk: Short Circuit Forces & Stresses
Little Risk of Failure
Design Margin
HV Radial HV Axial LV Radial LV Axial (Hoop) (tipping or (Buckling) (tipping or crushing) crushing)
oi l
o il
ing
Tan k
nd
Wi
Winding
ABB Group February 12, 2009 | Slide 19
Ambient
Bottom oil
Temperature
Wi
nd
ing
Thermal Stresses in Power Transformers Loss distribution in the tank wall caused by LV current
Intelligence Based Maintenance Practices The best designed and manufactured transformer . . .
Must withstand severe mechanical strain Is subjected to extended high temperatures or load conditions and limited by the current condition of its cooling system May experience unusually high or frequent overvoltages
A condition based periodic maintenance plan and diagnostic tools are available from ABB to identify when the transformer is at an unusually high failure risk if operation is continued
Transformer Condition Must Determine Maintenance Practices Curves are Determined by Maintenance Actions or Inactions
Actual Withstand
Design Withstand
Incidents Failure
Actual Stress
X X
Normal Life Expectancy
ABB Group February 12, 2009 | Slide 30
Extended Life
Age
Diagnostic Techniques for Power Transformers Highly Effective On-line Actions are Best
PROBLEMS DIAGNOSTIC TECHNIQUES SERVICE CONDITIONS PROVEN EFFECTIVENESS M L H M/H H H M M/H M/H L H M L M/H M/H H H
[2]
MECHANICAL
1. Excitation Current 2. Low-voltage impulse 3. Frequency response analysis 4. Leakage inductance measurement 5. Capacitance GAS-IN-OIL ANALYSIS 6. Gas chromatography 7. Equivalent Hydrogen method
THERMAL
OIL-PAPER DETERIORATION 8. Liquid chromatography-DP method 9. Furan Analysis HOTSPOT DETECTION 10. Invasive sensors 11. Infrared thermography OIL ANALYSIS 12. Moisture, electric strength, resistivity, etc. 13. Turns ratio
DIELECTRIC
PD MEASUREMENT 14. Ultrasonic method 15. Electrical method 16. Power Factor and Capacitance 17. Dielectric Frequency Response
[1] OFF-S = equipment out of service at site, OFF-L = equipment out of service in laboratory, ON = equipment in service [2] H=High, M=Medium, L=Low
Effective Analysis Depends on Design Understanding Oil Expansion / Oil Preservation Systems
Bladder
Air
Gas Space
Oil
Oil
Oil
Buchholz Relay
Oil
Buchholz Relay
Why Test at Every Outage? Every Test Establishes a Baseline for Comparison
Establishment of a trend is a key to prevent this kind of result
When Routine Checks Identify a Problem . . . On-Site Services Can Improve Reliability
Engineering Assessments (MTMP) Advanced Diagnostic Testing Bushing Replacement Tap Changer Services or Retrofit Unit Uprates / Cooling Systems Upgrades COPS tank modifications Control system upgrade Internal Inspections Insulation system maintenance Reblocking / rewedging Biodegradable fluid retrofills Partial or full winding replacement
A Thorough Condition Evaluation Should Include Possible Risk Mitigation for Urgent Ranked Transformers
ID #
Location
Serial Number
Manufacturer
Possible Risk Mitigation Actions [L1] = ASAP, [L2] = 1 Yr. [L3] = 2 - 3 Yrs., [L4] = 3 5 Yrs
AR 2
702282
Federal Pacific
Investigate for possible PD including installing Hydran [L1] Perform Acoustic PD measurements [L1] Increase DGA sampling to trend H2 production [L1] Perform complete oil screening test from samples taken when transformer is hot [L1] Condition Assessment [L2] SFRA test [L2] Review PF and capacitance history [L2] Implement measures to reduce number of through faults such as tree trimming [L2] Limit auto-reclosing to 1 reclose [L3]
BA 5
MLL939216
ABB
Resample oil in tap changer for DGA. If Acetylene is confirmed, then remove from service and perform internal inspection on LTC compartment [L1].
Upgrade Task
1. Replacing the oil in the transformers with new oil with lower charging tendency. This will reduce the risk of streaming electrification failure.
Reduced ROF,%
Estimated Cost
30
2. Replacing the cooling system with a new, more efficient system. This will reduce the risk of a forced outage due to component failure and lower the oil temperatures in the transformer. Lower oil temperatures will reduce the future aging rate and also reduce the hot spot temperatures, thus reducing the risk of catestrophic failure caused by the overheating condition. The new cooling system will have to take into account the risk of streaming electrification caused by excessive oil velocity in the windings. 3. Removing the sound enclosure This will improve the cooling efficiency somewhat and allow better diagnostic measurement of the tank wall temperatures using infrared thermography.
18
$$$
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4. Converting the oil preservation system from inertaire to Constant Oil Preservation System (COPS). This will eliminate the need to have a nitrogen line going to each transformer and will keep the the oil in a degassed state. Oil with a lower gas content will not have the possibility of nitrogen bubble formation, which can lead to failure in the
33
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Metal in Oil Testing CCD Testing for Sulfur contamination Particle count Oxidation Inhibitor Testing Furanic Analysis Degree of Polymerization Testing
Advanced Diagnostics
Advanced DGA Acoustics FRA Measurements Dielectric Spectroscopy Field Induced Testing Recurrent Surge Testing
The DFR test is a series of power factor measurements at multiple frequencies. It provides more information about the dielectric behavior of the insulation system than a 60Hz test. The method can be used to diagnose the following conditions:
Moisture in the cellulose insulation High oil conductivity due to aging or overheating of the oil Chemical contamination of cellulose insulation Carbon tracking in cellulose High resistance in the magnetic core steel circuit
Lo
Ground
Hi Lo
Dielectric Frequency Response Testing Distinguishing Between Aged Oil and Moisture
1.000
Tan D
0.010 0.001
.001
ABB Group February 12, 2009 | Slide 53
.01
.1
10
60 100
1000
Frequency, Hz
0.100
Aged Oil, 0.5% Moisture Good Oil 1.3% Moisture PF =. 00324 Measured DR 0.7% Moisture
Tan D
0.010 0.001
.001
ABB Group February 12, 2009 | Slide 54
.01
.1
10
60 100
1000
Frequency, Hz
.01
.10
10
100
1000
.01
.10
10
100
1000
Frequency, Hz Surface Moisture in Paper - Moisture in Oil vs. Volume Moisture From DFR
Xfrmr # 1 2 3 4 5 6 7 Temp (o C) 23 28 23 23 13 27 27 Type GSU GSU GSU GSU 3-wdg Auto Auto Constr. Core Core Core Core Shell Core Shell Oil Cond (pS/m) 0.381 0.492 0.412 1.34 1.5 3 0.3 Moist by Oil Moist. by DR Sat (%wt) (%wt) 2.5 1.8 1.4 2.8 * 3.5 3.3 0.9 0.9 0.9 0.7 1.2 2 1
Frequency, Hz
Overload Type
Normal Loading Planned O/L Beyond N/P Long Time Emergency (1-3 mo.) Short-Time Emergency ( -2hr)
Dielectric Frequency Response Signature Example Another Use: High Core Ground Resistance
XV to Ground
.01
.10
Frequency, Hz 10
100
1000
Dielectric Response Fingerprint Function caused by a High Core to Ground Resistance in Auxiliary Transformer
ABB Group February 12, 2009 | Slide 56
10.0
1.0
It is assumed that the DP of transformer insulation is approx. 1,000 at the start of life and approx. 200 at the end of life. This graph shows the expected life of thermally upgraded insulation (Insuldur) under various conditions.
Conc. (ppm)
Many old LTCs are Still Supported OEM-Grade (or better) Parts and Services are still available for many old tap changers, including the following models:
Westinghouse
UVT UTT-A,A70,B URT URT-ATS URT-DTG URT-46,69 URT-HC URS UTH UNR UTN UT UT-ATS UTR UR UB UC UVW (-A) URL-4,8,16 URF URH LR URV VR SDR PDR
General Electric
LR9 LR10 LR15 LR17 LR19 LR21 LR27 LR29 LR31 LR38 LR40 LR41 LR45 LR47 LR48 LR59 LR63 LR65 LR67 LR68 LR69 LR72 LR79 LR81 LR83 LR85 LR89 LR91 LR92 LR95 LR96 LR200 LR300 LR400 LR500 LR700
Reinhausen
RMS-I RMT-I RMV-I,II TYPE M TYPE T TYPE G TYPE R TYPE F TYPE MS
ABB
BUE UZE UZF UCG UCC UCD UBB UCL UZD
Moloney
MA, -1,-2 MB, -1, -2 MC MH MJ
Federal Pacific
TC-15 TC-25 TC-515 TC-525 TC-546
Ferranti Packard
138RT32 25RT32 34RT32 69RT32
Allis Chalmers
TLB TLH TLS
McGraw Edison
220 397 500 550 996 V2A
Accelerometer
Tap-4 device
Current sensor