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Design ReviewRisk Management in TransformerProcurement and Design /Manufacture
Derick van der Zwan, Joint Electrical Enginnering Institutions‘ Lecture Program, 2014
Introduction
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CIGRE Pub. 529, April 2013 – “Guidance for conducting DesignReviews for Power Transformers.
“A design review is a planned exercise to ensure both parties to thecontract understand the application and the requirements of the
applicable standards and specification.”
qInappropriate products can be eliminated.
qEverybody can benefit.
The Changes
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Over the past 15 or more years the Australian transformer industryexperienced significant changes:
q“In-house” technical expertise.
qYoung engineers have very few or no opportunity to gain expertknowledge and product training.
qLess external consultants with the right expertise.
qLess local technical capability.
qProject management.
qE-mails is the preferred method of communication.
qTechnical personnel only meet when something goes wrong.
qPurchaser’s specifications (except for the utilities) do not alwaysrequest design reviews.
“It is the responsibility of the Purchaser to ensure those participating in thereview on the Purchaser behalf must have necessary expertise tounderstand and evaluate the design and production considerations toevaluate what is proposed.”
èDoes this discourage Purchasers from calling for Design Review if theydo not have transformer design experts available?
It should not.
Purchasers should be in the position to draw on the expertise of theManufacture and still get the most out of the review process.
Participating in the Reviews
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Managing the technical Risk
qClear and mutual understanding of the technical requirements.
qUnderstanding the application and verify the system and projectrequirements.
qVerify that the design complies with the technical requirements.
qBetterments in the design and, or improvements and change in thespecification.
qUnderstand the technical capabilities of the Manufacturer.
qTo strengthen the technical relationship.
Time Schedule of Reviews
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qPre-award Review
§ Prior to award of contract.
§ Clarify, review and confirm the specifications and standardsrequirements of the contract.
qPost-award Review
§ Immediately after the award of contract.
§ Review and confirm requirements and specifications of thecontract.
qDesign Review
§ Last hold point prior to material purchasing.
§ In-depth technical review of the transformer.
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Design Review ArchitectureqTwo stages to consider
§ Electrical Design and Mechanical Design.
qElectrical Design
§ Electrical and Magnetic Performance.
§ Active Part Design Construction.
§ The “Internals” components.
qMechanical Design
§ Dimensions and external Mechanical strength.
§ Site Demands and safety Requirements.
§ Points of major Purchaser interaction with the product.
§ Customer Drawing Review.
§ Control System interaction.
§ The “Externals” components.
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Electrical Design Review
qPreparation for design review
qDetails on the geometry of the design. (CIGRE Pub. 529)
qDesign summary document should show:
§ Calculated performance vs guarantee.
§ e.g. Losses, Impedances, winding temperatures,Insulation levels
§ Calculated performance of non measurablevalues (AS standard estimates).
§ e.g. hot spot gradient, non winding temperatures, short circuitwithstand.
§ Performance beyond nameplate and capabilities.
§ e.g. overload, sound level.
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Mechanical Design Review
q Best to be combined with Electrical design reviewCustomer Drawings will almost be Complete
§ Purchaser expectations in specification
§ Site safety/work practices need to be considered
qDimensions, masses and interface.
§ Positioned on a existing or new foundation ?
§ Flexibility to interchange if moved to other location?
qAssess the placement of fittings.
§ Cost effectiveness and convenience
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Examples of improvements during Design Reviews
q Winding arrangement
q Winding design
q Cable box interphase
q Contract performance management
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Design Review – In a first time Relationship
q It is good to see and learn about Manufacturer technology
§ Understand capability and limitations
qLocation of the review meeting is potentially relevant
§ Viewing the Construction/Technology in context is easier at theproduction facility.
qBenchmarking.
§ The technology, quality system, design and production are a marriagethat cannot be split or translated in isolation
§ Better to benchmark against Manufacturer’s prior experience andknowledge than others’ transformers.
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Design Review – In a first time Relationship
qUnderstanding the capability of the Manufacturers design tools.
§ Different Manufacturers have different strengths and experiences.
§ It is great to have accurate design tools but at the end it is all abouthow risk is managed with the tools you have.
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Concluding Remarks
qThe design review is important for both Purchaser and Manufacturer
§ It opens opportunities to learn from each other ( transformer designerare unlikely to be power system experts and other way around).
§ Increased confidence that tested performance indicate there is nounderlying, unrevealed quality issues.
§ Knowledge of the suitability of the transformer beyond that proven inthe factory testing.
§ Opportunity for enhanced transformer performance at no additionalcost or opportunity to save cost to the Purchasers external equipment.
§ Opportunity for refinement of the specification application for futurerequirements.
§ Confirmation of suitability of a Manufacturer for future projects.
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Summary
“It is important to the success of the design review that both thePurchaser and the Manufacturer have the same profound interest in asound and safe design and to assure the design is understood and in
agreement“
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