LIMA PE

Jornadas Técnicas 2015

2015Abr23

Dr. José Carlos Mendes

Gte Tecnologia Transmissão e Produtos de Potência
Gte Desenvolvimento & Engenharia
ABB Brasil
Engenheiro Corporativo Executivo Global Power Products Division
ABB Asea Brown Boveri
Divisão de Produtos de Potência Power Transformers:
Transformadores de Potência
São Paulo, SP - Brasil
Life Cycle and Operational Cost Optimization –
email: [email protected]
Conventional, Wind and Solar Applications
tel: + 55 11 2464 8410
cel: + 55 11 9 8354 5358
+ 55 11 9 8112 7575

© ABB Brasil – PP Division

Power Transformers
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 ABB Brasil Power Products Division
Power and Distribution Transformers

ABB Brazil
Power Products Division
Power Transformers

PPTR Distribution Transformers

Guarulhos, São Paulo - BR

n PPTR Power Transformers

l power transformers up to 765kV
l shunt reactors up to 765kV
l heavy current industrial transformers
l service (Eng Solution, Factory and Site Repairs,
Monitoring Systems, TrServices)
l insulation components
l transformer components (Bushings, Tap
Changers, etc)
n PPMV Medium Voltage, PPHV High Voltage Blumenau, SC - BR
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 Context
Renewables Energy and Transformers Optimization

Content

Content

q introduction
q renewables energy
§ solar and wind power generation
§ transformers applications and needs
§ useful life and maintenance
q life cycle optimization
§ from specification to end of life
§ design optimization
§ selection of alternatives
§ loss evaluation to efficient transformers
§ advanced technologies
q performance, reliability and failure modes
q advanced minimum maintenance
§ optimized monitoring
§ knowledge, condition and event based
§ minimum periodic inspection
q advanced asset management
q conclusions
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 Renewables Energy and Transformers Applications
Solar and Wind Power Generation – Trends and Transformers Needs

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 Solar and Wind Power Plants PE MINEM
Power Transformers Applications Plan Energético Nacional 2014-2025

PERU and PBI evolution

Maximum Demand
2013-2025

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 Solar and Wind Power Plants PE MINEM
Power Transformers Applications Plan Energético Nacional 2014-2025

PERU and PBI evolution

Ingress of Renewables
Energy 2014-2017

Investments 2015-2025 Mio USD

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 Solar and Wind Power Plants PE MINEM
Power Transformers Applications Plan Energético Nacional 2014-2025

Ingress of Renewables
Energy 2014-2017

Wind Power Solar Power

- total 77 000 MW - total 77 000 MW
- usable 22 500MW - usable 22 500MW

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 Solar and Wind Power Plants
Power Transformers Applications

Solar PV Wind Farms

Connection Connection
Transformer Transformer

Collector Collector Collector Collector

Transformer Transformer Transformer Transformer

Inverter Inverter Inverter Inverter

WTG WTG WTG WTG
Transformer Transformer Transformer Transformer
Transformer Transformer Transformer Transformer

PV DC PV DC PV DC PV DC
Generator Generator Generator Generator

Solar CSP

WTG Technologies
Connection, GSU
Transformer

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 Power Transformers
Solar and Wind Power Applications

Wind Farm – Daily Variation of Load Current, Voltage, Power Factor

Wind Farm Collector Substation - Load Current, Voltage and Power Factor
Current, Arms Voltage, pu power factor, pu

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 Power Transformers
Solar and Wind Power Applications

Wind Farm – Steady State Voltage Load Flow

Us LF IL UHVc ULVc Ulim

Connection SS Connection Connection SS pu % pu pu pu pu

BUS 230 kV Transformer BUS 69 kV
IL , LF = load factor 1.00 54 0.28 1.035 1.044 1.091
1.05 54 0,28 1.086 1.095 1.091
1.00 100 0.52 1.038 1.052 1.070
TL230 - 1 Wind Farm 2
1.05 100 0.52 1.089 1.100 1.070
TL230 - 2 Wind Farm 3

Wind Farm 4 Collector SS

TL230 - 3
BUS 69 kV
UChv

TL230 - 4 Wind Farm 5 Collector

Transformer
Ulim

TL230 - 5 TL69-1 Collector SS UClv

BUS 34.5 kV
TL230 - 6 TL69-2

WTG
BUS 690 V
Capacitor Capacitor
Bank Bank WTG
Transformer

US WTG
BUS 690 V

G Wind Farm 1

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 Power Transformers
Solar and Wind Power Applications

Wind Farm - Voltage Control and Transformers Taps Adjustments

Power System WIND FARM 300MW – Electrical System

1 – 70.725 kV 34.500kV 1 – 36.225 kV 0.690kV
2 – 69.000 kV 2 – 35.363 kV
3 – 67.275 kV 3 – 34.500 kV
P ± jQ 4 – 65.550 kV
5 – 63.825 kV
4 – 33.638 kV
5 – 32.775 kV

Us Us UL UL Uc Uc Ug
Ug

50.2GVA 9.8GVA 1.5GVA

NhvL NlvL Nhvc Nlvc Nhvg Nlvg
SIN BR 230kV SIN – CEAS1 69kV COLLECTOR 34.5kV WTG DFIG 0.690kV

NhvL Nhvc Nhvg

US = × UL UL = × Uc Uc = × Ug
NlvL Nlvc Nlvg
operation
inductive PF
NhvL Nhvc Nhvg × Ug Nhvc Nhvg
US = × × UL = × × Ug
NlvL Nlvc Nlvg Nlvc Nlvg

back-feeding NlvL × Us
no-load UL =
NhvL

complete analysis requires Load Flow and Harmonic Load Flow for loading conditions

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 Renewables Energy and Transformers Applications
Life Cycle – From Specification to End of Life

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 Power Transformers
Life Cycle Optimization

Transformer Life Cycle

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 Power Transformers
Life Cycle Optimization

Transformer Life Cycle

Specification, Design, Manufacturing, Tests, Transportation, Receiving,

Storage, Installation, Operation, Monitoring, Maintenance, End of Life

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 Renewables Energy and Transformers Applications
Life Cycle – Design Optimization

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Power Transformer

Transformer
§ core
§ windings
§ connections
§ tank
§ expansion tank
§ accessories
Ø bushings
Ø tap-changers
Ø radiators
Ø motor-fans
Ø thermometers, level indicators, Buchholz
relay, pressure relief valve, pressure relay,
air breathers, etc
Ø bushing current transformers BCTs
Ø surge arresters
Ø command, control and protections
Ø sensors and monitoring system

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Power Transformer – Design Optimization

Transformer Design
§ core induction
§ no load losses - core Transformer Design Optimization
§ load losses – windings, connections, metal
structures § cost optimization
§ short-circuit impedances § no load losses optimization
§ leakage flux § load losses optimization
§ inrush-current § characteristics optimization
§ short-circuit current § performance (thermal, loading, short-
§ short-circuit forces circuit, etc) optimization
§ core over-excitation § transportation limits
§ DC excitation component § interchanged ability
§ voltage and current harmonics
§ overloading
§ insulation (windings and main) § transformer optimization strategies:
§ cooling and temperature rise Ø Total Initial Cost
§ noise level Ø Losses Cost
§ new technologies (Nomex, Vegetable Oil, Ø Total Operational Cost
Vacuum OLTC, CTCs, Bushings RIP & RIS, etc) Ø Life Cycle Total Cost
§ on-line monitoring and diagnostic
§ on-line asset management
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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Transformer Life Cycle

Steps:

1. Technical Specification
2. Procumeremt process
3. Manufacturer and Factory qualification
4. Quotations, Technical&Economic Analysis, Purchase, Contracts
5. Electrical Design
6. Design Review
7. Mechanical Design
8. Manufacturing
9. Factory Final Acceptance Tests
10. Final Tests Results and Analysis
11. FRA at Factory before transport
12. Monitored Transportation
13. FRA at Site after transportation
14. Erection at Site
15. Commissioning at Site
16. Energization
17. Operation
18. Monitoring
19. Maintenance
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 Renewables Energy and Transformers Applications
Life Cycle – Optimized Selection of Alternatives

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Transformer Life Cycle

Warranty of Useful Life Garantida, year

Life Cycle, years

Operation Cost: $2
n losses (noLoad,
Capital Cost: $1 End of Life Cost: $3
Load, Auxiliar)
n purchase n maintenance
n replacement
n transport n insurance premium n transfer
n installation n repairs n refurbishment
n performance

NPV, Total Cost / Life Cycle $ = $1+$2+$3

USD$
kVA x Useful Life x Overloading Factor

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Transformer Life Cycle

Usual Evaluation Method: Usual Method does not Evaluate:

§ Quality
§ Design and Manufacturing
n initial total cost:
§ Withstand (electrical mechanical, thermal)
q equipment initial cost § Risk of Failure
q spare components cost § Useful Life Expectancy
q transport cost § Overloading Capability
q installation cost (erection, supervision, etc)
q comissioning cost
q extended guarantee cost

n losses cost (capitalisation) Global Value Index:

q no-load, load, auxiliar losses § total initial price, USD$
§ rated power, kVA
n technical data table
§ guaranteed useful life, years
q technical performance data
§ guaranteed overload, pu
q technical guaranteed data § return on investment, % year

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Power Equipment Performance Equalization

Guaranteed Technical Data Technical Performance Evaluation

To meet declared guaranteed § quantitative evaluation method

technical data it is not a guarantee: § powerful technical performance comparison of
different suppliers
q for a specified minimum performance § technical & economical equalization of several
q for a specified useful life technical quotations
q for a short-circuit withstand with § main performance data:
reliability Ø thermal performance (core, windings, connections)
q for a economic optimized solution Ø useful life (as per IEEE)
Ø total losses
q for a minimum LC total cost
Ø short-circuit (IEC)
q for a reliable operation life with no
Ø certified/qualified seismic performance
failure Ø transient voltages and internal insulation withstand
(switching of reactors!)
USD$ Ø reliability analysis
kVA x UsefulLife x OverLoadingFactor Ø global economic evaluation

Increasing Asset Quality: Minimum Maintenance

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 Power Transformers
Life Cycle Optimization and Global Evaluation of Alternatives

Power Equipment Performance Equalization

Alternatives A B
Cellulose ThUpgraded Hybrid, Nomex Paper,
Characteristic Unit
Paper, 65Cdeg 95Cdeg
Initial Cost USD 1 000 000 1 200 000
Rated Power kVA 50 000 60 000
Useful Life years 42 80
Overloading Factor pu 1.15 1.40
Overloadind Time h 4 4
Global Value Index USD/kVA . year 0.46 0.23
Ratio % 100 50.4

USD$
kVA x UsefulLife x OverLoadingFactor

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 Renewables Energy and Transformers Applications
Life Cycle – Losses Evaluations to Efficient Transformers

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Power Equipment Performance Equalization

value, $

value, $
manufac- manufacturing
turing cost cost + losses cost

manufac-
turing cost

losses Manufacturing Cost: losses

cost § material cost
§ labor
§ over-heads
transformer mass, kg transformer mass, kg

$$ Total Cost = Manufacturing Cost + Losses Cost = f (design variables)

q core induction, diameter, mass

q winding current density Loss Capitalisation Cost, $/kW
optimization q distance between windings maximum cost to pay to reduce
q winding diameters, width, height, mass transformer losse by 1 kW
q tank mass

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Power Equipment Performance Equalization

1 kW losses in 30 years 8600 hours/year

Interest rate 0.02 $/kWh 0.03 $/kWh 0.04 $/kWh

No Load
Losses
Evaluations 4% 3100 4650 6200
Values
8% 2100 3150 4200

12% 1550 2300 3100

Load Loss evaluations depend on load profile per day, months etc and are
therefore a varying % of the full year value

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Power Equipment Performance Equalization

Net present value of future losses

§ assumed value of energy losses during lifetime
§ interest rate to calculate present value

Loss
Specifications Values translated into evaluations in
for low loss specifcations
power § value of NoLoad loss $/kW have been
transformers relatively stable
§ value of Load losses $/kW in recent years

Loss evaluations are key part of specifications

§ actual values reflect future energy price expectations
§ interest value chosen determines time horizon

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 Renewables Energy and Transformers Applications
Life Cycle – Specification for High Performance and Reliability

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Harmonic Voltage and Current DC Current

Effect on Transformer and Design Consideration Effect on Transformer and Design Consideration

Harmonics: Voltage & Presence of DC current

Current § small % of DC current leading to saturation
§ core & windings losses § harmonics significantly higher for
§ faster degradation of insulation system unbalanced DC
§ possible partial discharge
§ arcing

Required data from user Required data from user

§ K factor § % of DC present
§ harmonic spectrum

Design Considerations Design Consideration

§ alteration of induction § core appropriate induction
§ additional cooling capacity

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Continuous OverVoltage - OverExcitation StepUp and StepDown Operation and OverLoading

Effect on Transformer and Design Consideration Effect on Transformer and Design Consideration

Exceeding V/F ratio & Back feeding a step up

component’s rating transformer
§ additional losses- core and coil
§ insulation system weakening under full load with § transformer designed as step up
overvoltage
§ partial discharge PDs generation § inrush current, voltage compensation
§ failure of component
Required data from user
Required data from user § step up /down operation possibility
§ possible voltage limits
§ short time overload duration & frequency
§ frequency & duration of voltages going over the
continuous overvoltage

Design consideration
Design considerations
§ core appropriate induction
§ core appropriate induction
§ possible increase in BIL § cooling
§ strengthen insulation system & processing § additional kVA
§ possible use of power transformer components

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers: DGA Dissolved Gas Analysis

Dissolved gas analysis Reference to IEEE Standard C57.104,

(DGA) use as guiding Table 1
principles
§ Standard refers to power Guideline for TDCG - Total Dissolved
transformers Combustible Gases
§ IEEE reviewing large Two key points:
data but pertaining to
power transformers § Table 1 assumes that no previous tests on
§ it is still an art not a
the transformer for DGA have been made
science and that no recent history exists.
§ volume of paper § the numbers shown in Table 1 are in parts of
insulation/absorption of gas per million parts of oil (ppm)
gases volumetrically and are based on a large
power transformer with several thousand
gallons of oil.

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers: DGA Dissolved Gas Analysis

Dissolved gas analysis DGA can be used as a guide to

(DGA) use as guiding
principles detect:
§ Standard refers to power
transformers § partial discharge PD
§ IEEE reviewing large § high energy electrical arcing
data but pertaining to
power transformers
§ thermal faults
§ it is still an art not a
science
§ cellulose insulation breakdown
§ volume of paper
insulation/absorption of
gases § overload(s)
§ overexcitations

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers: DGA Dissolved Gas Analysis

Dissolved gas analysis The principal or key gasses associated with each
(DGA) use as guiding type of issue:
principles § Hydrogen (H2): generated by partial discharge/arcing
§ Standard refers to power § Methane (CH4): generated by relatively low elevated
transformers temperatures (150° C).
§ IEEE reviewing large § Acetylene (C2H2): generated by arcing.
data but pertaining to § Ethane (C2H6): generated by high temperatures
power transformers (<300° C).
§ it is still an art not a § Ethylene (C2H4): generated by high temperatures
science (>300° C).
§ volume of paper § Carbon Monoxide (CO): generated by oxidation of
insulation/absorption of cellulose insulation.
gases § Carbon Dioxide (CO2): generated by oxidation of
cellulose insulation.

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers: DGA Dissolved Gas Analysis

Dissolved gas analysis Points to be considered in data

(DGA) use as guiding analysis
principles
§ generation of gases in normal operation of
§ Standard refers to power transformer
transformers
§ IEEE reviewing large § rate of change of gases over a period of time
data but pertaining to § necessity of more than one sample over a
power transformers period of time
§ it is still an art not a
science § significance of change with reference to any
event
§ volume of paper
insulation/absorption of § normal operation of components
gases
§ manufacturing process
§ comparison with a baseline DGA

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers: DGA Dissolved Gas Analysis

Dissolved gas analysis

(DGA) use as guiding
Recommendation
principles § IEEE C57.104 Table-1: use as a guide
§ Standard refers to power
transformers § analyze the data based on more than
§ IEEE reviewing large data one sample
but pertaining to power
transformers § compare the analysis with the baseline
§ it is still an art not a § further testing based on significant
science
rate of change
§ volume of paper
insulation/absorption of § consult manufacturer for further
gases testing/recommendations

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Wind Farm Collector Transformers: DGA and Gasssing

120 ppm

TRc01 TRc02 TRc03 TRc04 TRc05 TRc06 TRc07 TRc08 TRc09 TRc10

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Wind Farm Collector Transformers: DGA and Gasssing

2500 ppm

TRc01 TRc02 TRc03 TRc04 TRc05 TRc06 TRc07 TRc08 TRc09 TRc10

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 Renewables Energy and Transformers Applications
Life Cycle – Performance, Reliability and Failure Modes

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 Power Transformers
Life Cycle and Failure Mode

Collector
Transf TR03
load, MVA

l
Power Factor, pu
Load Factor, ONAF2, pu

daily load variation

WFarm Coll Tr01

WFarm Coll Tr02
WFarm Coll Tr03

oil and insulation oil gas voltage oil, core, winding

moisture saturation over-excitation temperature reduction
actions drying insulation degassing oil WTG voltage control Replace Motor Fans D800
Transf TAPS adjustments Temperature Controlled
oil & insulation condition monitoring
by a Hydran M2
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 Power Transformers
Life Cycle and Failure Mode

Dielectric Inter-Turn Insulation Failure of LV Winding

reduced inter-turn insulation strength (withstand)

oil gas saturation • dissolved gas in oil

• free gas bubbles at load changes
• reduced PD inception voltage
• reduced Insulation Breakdown Voltage

oil and insulation moisture • free-water formation at reduced temperatures

• free water vapor bubbles at load changes
low-energy PD
• oil and insulation oxidation
• increased oil conductivity
• water droplets in the oil
• reduced PD inception voltage
• reduced Insulation Breakdown Voltage • free water
Dielectric Inter-Turn
winding temperature fast reduction • bubbles
daily load variation • Insulation Failure
• oil temperature slow reduction • water droplets
• water exchange from oil to insulation
• free-water and bubbles at oil-insulation interfaces
• bubbles formation at reduced temperatures
• free water vapor bubbles at load changes
• reduced PD inception voltage reduced breakdown voltage
• reduced Insulation Breakdown Voltage

voltage over-excitation • magnetic core saturation

• high harmonics saturated flux outside the core
• overheating and metal hot-spots
• oil gassing
• water formation
• oxidation oil/insulation
• moisture increasing
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 Power Transformers
Life Cycle and Failure Mode

water in oil environment

• insulation residual moisture at factory • long time storage under N2 Nitrogen:
• entry during factory preparation for shipment Ø long time under N2 with in-tank gas variable
• entry during transportation Environment and Conditions pressure (not automatic gas injection system)
• moisture condensation over long time storage
• moisture condensation in accessories • site assembly:
(conservator – shipped/storage not pressurized) Ø standard final processing
• entry during site assembly Ø standard vacuum time even after a long time
• short-vacuum time at site after long time storage storage
• core/winding/insulation heating in operation
• long time storage:
water in insulation Ø oil filled

• insulation residual moisture at factory • insulation conditioning:

• entry during factory preparation for shipment Ø oil samples and tests only 2 months before
• entry during transportation Ø oil/insulation not conditioned to energization
• moisture condensation over long time storage
• entry during site assembly • energization:
• short-vacuum time at site after long time storage Ø voltage control during a Wind Farm start-up
• core/winding/insulation heating in operation Ø connection to a strong HV power system
Ø WTG GSU and collector transf tap settings
oil gas saturation Ø over-excitation
• long time storage
• high N2 content trapped in insulation
• oil gassing from heated core/winding/metal parts
transformer
• water and/or moisture vapor • designed according to the specification
• oil/insulation oxidation (ñCO2) • no-load excitation very low margin
• short-vacuum time at site after long time storage • full-load excitation very low margin
• motor-fans OFF due to control with high
oil and core high temperatures temperature settings keeping
• fans may be OFF due controls high settings • long time storage under N2 with in-tank gas
• high core and windings hot-spots temperatures variable pressure (no-automatic injection system)

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 Renewables Energy and Transformers Applications
Life Cycle - Operation Monitoring Optimization

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 Power Transformers
Life Cycle and Operation Optmization

Monitoring

Minimum
On-Line Monitoring and Sensors: Sensors
ABB TEC
n load – current & voltage üs
n ambient temperature üs
n top-oil temperature üs
n winding hotspot temperature üs
n moisture in oil/solid insulation üs
n gas in oil H2, CO, C2H4, C2H2 (Hydran) üs
n HV OIP cond bushings C1 & tand ! !

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Power Transformers
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 Renewables Energy and Transformers Applications
Life Cycle – Advanced Asset Managment

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 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management

1 Data 2 Analysis 3 Action

EAM Mobile ERP

ALGORITHMS

Sensors SCADA Historiador

§ Centralized Information § ABB Methods § Strategic Decisions

§ Data Storage § Data Mining § Maintenance Plan
§ Data Management § Condition Assessment Models § Later Maintenance
§ Data Protection Ø failure risk § Replacement
Ø asset condition

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 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management

Advanced Operational BI

Data Processing and Engineering Workbench

Analytics Complete Information
Fleet to Equipment Health
Actionable Notifications
Business Process Workflow
Optimization &Planning

Subject Matter Workbench

Enterprise Asset and Work

Management
Enterprise Data
Sources

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 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management - Potential Benefits

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Power Transformers
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 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management - Monitor

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Power Transformers
2015Apr23, JCM - | Page 48
 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management - Monitor

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Power Transformers
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 Power Transformers
Life Cycle and Operation Optmization

Advanced Asset Management – Maintenance Planning

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 Renewables Energy and Transformers Applications
Conclusions

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 Power Transformers
Life Cycle Optimization and Performance Equalization

Renewables Energy Transformers

Conclusions
§ technology is now available for economic Wind and Solar power production
§ renewables energy power generation are fast moving up in Peru and SAM
§ up to 2016 renewables energy to be 5% of power source in Peru
§ Wind and Solar together Hydro and Natural gas forming Hybrid Power Plants
§ renewables energy bring demand for power transformers
§ specific requirements are established for such transformers applications
§ transformers key aspects:
Ø environmental friendly
Ø advanced technology application
Ø long useful life minimum 30 years
Ø high reliability and availability at minimum maintenance
Ø intelligent monitoring and advanced asset management
Ø optimum overall life cycle
§ demand for a partner with a solid and experienced technology

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