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Enhanced availability of transformers via transformer remote monitoring - TEC ABB Power Products Service

Raben Naidoo, Technology days, May 21-22th, 2014, Cape Town, South Africa,

Source: Black & Veatch’s 2011 Strategic Directions Survey Results

Why a session on availability? Top utility concerns

© ABB BU Transformers May 27, 2014 | Slide 2

Our every day necessities

Ever growing population

Energy consumption to double within 30 years

Sustaining a power-hungry world

Ensure the reliability & availability of an ageing grid infrastructure

Concern about climate change

Green solutions - providing energy efficient products and service

Economic environment


Areas of power consumption reflected on the earth’s surface

More than ever, the need of energy efficient products and reliable grids. ABB’s transformers support the systems that keep our world running.

Utility and Industry challenges Asset management with new challenges

Ensure high reliability of aged assets

Avoid unplanned power outage

Optimize assets performance

Increase production output


Move towards Condition Based Maintenance / Reliability Centered

Need for tools to decide based on technical & economical criteria

Optimize capital expenditure and increase return on assets

Reduce Life Cycle Costs – Lowest operation and maintenance costs

Extend lifetime of existing assets while looking for sustainability

Delay investments while considering green solutions

Failure probabilities (Network Transfor.)

0

0.02

0.04

0.06

0.08

0.1

1 6 11 16 21 26 31 36 41 46 51 56Age (years)

Pro

bab

ilit

y

How to enhance availability?

Avoid unexpected failures

Plan maintenance and repair during low load periods

Efficient maintenance actions reducing downtime

Solutions to shorter repair time

Retrofit solution to increase personal and asset safety

Green footprint

Financial benefits


Condition based maintenance Assess the condition / withstand capability


Thermal ageing Temperature Moisture Oxygen

Mechanical ageing Delta temperature Over current Vibration / Number of operation

Electrical ageing Over voltage Over current Harmonics - VFT

Source: CIGRE

Assessing the condition Needs for a structured analysis process

Input Data Risk Categories


Risk of Failure (RoF)

Condition Assessment Three steps: Optimize ratio Accuracy / Costs, Time


Electrical tests and DGA Diagnostic matrix

Overall condition

Oil, DGA, Furans

Mechanical condition

Frequency Response Analysis (FRA)

Thermal condition

Dielectric Frequency Response (DFR)

Electrical condition

Partial Discharge Analysis (PDA)

Accessories

Bushing Power Factor

OTC Vibration


Mechanical Electrical Thermal Accessories Overall Risk Mitigation - Actions

TFO 2 Winding Arcing Heating 95 Visual Inspection and repair in factory / rewinding

TFO 5 Tank OLTC heating 80 Repair on site and OLTC overhaul

TFO 1 Aged oil Bushing 70 Oil regeneration / filtration and advanced diagnosis / change HV bushing

TFO 6 Arcing Thermometer 50 Exchange TopOil - thermometer / on line monitoring of DGA

TFO 3 Silicagel 40 Exchange Silicagel

TFO 7 25 Standard maintenance actions and controls

TFO 8 15 Standard maintenance actions and controls / 10 % overload capabilities

TFO 4 10 Standard maintenance actions and controls / 15 % overload capabilities

Plant 1 - Results of condition assessement and action plan

Transformer condition assessment Typical output and recommendations


Utility, ZA – Belhar and Dinaledi Substation

Pilot Installation Utility, South Africa, Western Cape & North West Year: 2012

Customers need Lower shutdown periods

Reduce OLTC maintenance scheduling

Trouble-free operation

ABB’s response Vacuum On-load tap changer

Immediate prognosis allowing to take appropriate actions before a problem occurs

Customers benefits Lower life cycle costs, less maintenance needs, and increased

time in operation because of a radical reduction in contact wear.

Routine inspection takes place in a cleaner environment which reduces downtime.

Only the diverter switch mechanism differs which means that the unit is completely interchangeable, thus no redesign of the transformer is necessary.

Operation of the transformers has become more efficient allowing overloading and aging forecasting on-line. Online Monitoring has increased the availability of the transformers

Transformer Service Success Story


Monitoring Infrastructure from sensor to repair or upgrade


Upgrades

Optimum Grid Control and

Dynamic Overload Control Integration - Load Forecast -

Temperature algorithms

Transformers Substations

Consulting

Asset Health Management

Data Aggregation Monitoring – data storage, local service and

control – remote control

Sensor Technologies Basic and advanced sensors. Local display and preparation for

remote connection

Grid integration – Asset Health Center Fleet Screening / Assessment

Service Transformers

Enable smart transformer management

Monitoring enables smart grids for:

Fleet assessment Optimum control

TEC

Voltage, Current,

Gases and Bushing, etc,

On load Tap Changer, Oil and Ambient Temperature,

Communication system

Online Transformer Monitoring

“ABB” monitoring system (converts raw data into useful informations)


Online Transformer Monitoring

Control Room


TEC platform – key benefits

User friendly web interface – no additional software needed on users computer

Based on a microprocessor and Modular design, possible to add the sensors that the customer requests with additional hardware

Very strong mechanical stability and temperature endurance => Long lifespan

Reliable and proven technology (longest serving unit has >10 years in the field)

Compact and easy to install

Support for standard communication protocols, including IEC 61850 (certified by SGCC)


No special computer is

needed

Dual language support

User friendly interface


Display interface

Important information available at the transformer in real-time

• Press to see next value

• Press and hold (> 3 sec) to see active events

ALARM

WARNING NORMAL


RI2 losses high voltage winding kW 89.5 32.2RI2 losses low voltage winding kW 131.0 47.2RI2 losses tertiary winding kW N/A N/AEddy losses in high voltage winding kW 8.3 3.0Eddy losses in low voltage winding kW 9.55 3.4Eddy losses in tertiary winding kW N/A N/ACalculated values for type test AF AN (When applicable)

Top oil temperature rise °C 56.5 58Average oil temperature rise °C 41.5 49No load loss at test kW 124 124Load losses at test - 764 275Tap-changer position - -2X2.5%(2) -2X2.5%(2)Current high voltage winding A 510.5 306.3Current low voltage winding A 1600 960Current tertiary voltage winding A N/A N/AHot-spot temperature high volt. wind. °C 74.3 67.5Hot-spot temperature low volt. wind. °C 75.3 67.5Hot-spot temperature tertiary volt. wind. °C N/A N/ATemperature gradient high volt. wind. °C 17.8 (3) 9.5(3)Temperature gradient low volt. wind. °C 18.8(3) 9.5(3)Temperature gradient tertiary volt. wind. °C N/A N/AMass parametersCu-Mass of high voltage winding kgCu-Mass of low voltage winding kgCu-Mass of tertiary winding kgFree oil kgOil in insulation kgCore steel mass kgOther steel mass (tank, yoke plate, etc.) kgPaper mass kgType test values AF AN (When applicable)

Ambient temperature °CTop oil temperature rise °C

438

3337 kg/limbN/A999154000

67000

4461 kg/limb

89049

Design data – fingerprint concept


Web interface – graphs with data


Intelligent cooling control

Signal from

CT

TEC Cabinet

T Top Oil

T Bottom Oil Thermometer pocket

Hot-spot temp

ON CABINET

ALARM

WARNING

NORMAL

Display

Algorithms

Group 1 Group 3

Up to 6 Cooler Groups can be controlled

Group 2 Group 4

Group 5

Group 6

Enhancements from traditional cooling

• Control up to 6 cooler groups

• Starts on top oil, hot-spot and forecast

• Remote start of coolers possible

• All cooler groups equally used

• Logic to exercise motors each week

• Time in service shown in station interface

• Time delay between cooler group start

• Reduced noise level

• More stable temperature, reduced breathing

Traditional top oil thermometer used as back-up start of coolers and for emergency trip


Wear on: • Right side of Fixed Contact 4 • Main Contact W = C . In

7

6

5

4

3

2

1

I

7

6

5

4

3

2

1

I

IcIc

Wear on: • Right side on Fixed Contact 4 • Left Transition Contact W = C. (I/2-Ic)n

Contact wear calculation according to theory and experience

On load tap changer

Position statistics

Temperature

Contact Wear


No traditional hot-spot thermometer needed

Hot-spot temperature calculation • HV winding

• LV winding • Tertiary winding

Hot-spot Temperature Calculation – IEC & IEEE

yroh KHg+Θ=Θ

IEC-354 Θo = Top oil temperature Hgr = Hot-spot to top-oil gradient K = Load factor (load current/rated current) y = Winding exponent


Thermal Ageing at the Hot-Spot Ageing calculation gives a possibility to compare the thermal ageing of different transformers, for overload or replacement planning

0.001 ~0%

0.01 1%

0.1 10%

1 100%

10 1000%

50 100

Hot-Spot Temperature [ °C]

Aging Speed

IEC, used for normal paper

IEEE, used for thermally upgraded paper

−

= 6 98 T

IEC

HS

2 F ( )

+

− = 273 T

15000 383

15000

IEEE HS e F

Calculated age of the transformer

Aging Speed at this time


Overload Capability

Overload capacity: Displays the loading capability at present conditions


Cooling from Radiators or Coolers

Losses

T Top Oil

T Bottom Oil

T Air

Cooling from the Tank

TEC keeps track of the transformer temperatures and compares them with a theoretical model to indicate changes, in the cooling conditions or heat generation, that could place restrictions on the overloading capacity.

Transformer Temperature Balance


Gas and moisture measurement

To be able to analyze gas readings it have to be correlated with load, temperatures and cooling status in the transformer

TEC keeps track of the transformer and helps you analyze gas readings together with all relevant transformer data.

To know when an oil sample is needed.

Combination of load, temperatures, cooling status and DGA is required to give the complete picture

Early warnings for fast developing gas related faults


TEC few sensors high functionality

On-load tap-changer (OLTC) Position Contact wear Temperature Temperature balance Moisture OLTC

Gases and moisture Trends Bubbling temperature

Current transducers Hot-spot temperature Load Ageing Cooling control Contact wear Temperature balance

Bottom oil temperature Temperature balance

Ambient temperature Sun Shadow

Top oil temperature Hot-spot temperature Load Ageing Temperature balance Cooling control

Cabling One cable to/from transformer Bus communication available

on transformer


TEC system

TCP/IP

Fiber optic

Gas sensor

Connection with customer´s network

Minimum scope of supply


TMU 100 Bushing monitoring Capacitance Tan delta

DGA device Individual 8 gases Moisture TEC system

Thermal Currents Coolers OLTC

TCP/IP

Fiber optic





New Transformers

Old Transformers

Non-ABB Transformers

TEC – transformer installation


TEC cabinet installation

1) Mount TEC on transformer.

2) Connect sensors and power supply according to drawings and connection tables.

3) Start system.

Note: The display indicates present status and events.


Placing TEC in one existing Transformer

Retrofit of the transformer


Sensors. Can any existing sensors or sensor pockets be used? New sensors, what type should be used? New sensors, where are they best placed?

Historical data. To be able to display correct ageing of transformer and contact wear on the tap-changer, it is necessary to program the TEC with historical data.

Feedback from coolers. To monitor the coolers, TEC need feedback signal from each cooler when it is active. Are there any free contacts on existing cooler starting contactors? If not, how can the feedback be provided?

Retrofit of the transformer RI2 losses high voltage winding kW 89.5 32.2RI2 losses low voltage winding kW 131.0 47.2RI2 losses tertiary winding kW N/A N/AEddy losses in high voltage winding kW 8.3 3.0Eddy losses in low voltage winding kW 9.55 3.4Eddy losses in tertiary winding kW N/A N/ACalculated values for type test AF AN (When applicable)

Top oil temperature rise °C 56.5 58Average oil temperature rise °C 41.5 49No load loss at test kW 124 124Load losses at test - 764 275Tap-changer position - -2X2.5%(2) -2X2.5%(2)Current high voltage winding A 510.5 306.3Current low voltage winding A 1600 960Current tertiary voltage winding A N/A N/AHot-spot temperature high volt. wind. °C 74.3 67.5Hot-spot temperature low volt. wind. °C 75.3 67.5Hot-spot temperature tertiary volt. wind. °C N/A N/ATemperature gradient high volt. wind. °C 17.8 (3) 9.5(3)Temperature gradient low volt. wind. °C 18.8(3) 9.5(3)Temperature gradient tertiary volt. wind. °C N/A N/AMass parametersCu-Mass of high voltage winding kgCu-Mass of low voltage winding kgCu-Mass of tertiary winding kgFree oil kgOil in insulation kgCore steel mass kgOther steel mass (tank, yoke plate, etc.) kgPaper mass kgType test values AF AN (When applicable)

Ambient temperature °CTop oil temperature rise °C

438

3337 kg/limbN/A999154000

67000

4461 kg/limb

89049


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