Victor Khuboni, Power Products Service, November 2014 … Hope/19-3 ABB PPTR Ser… · Overview of ABB Transformer Service Capabilities ... • Power Transformer Testing, ... Monitoring

Overview of ABB Transformer Service Capabilities

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PG Transformer Remanufacturing and Engineering Services (TRES)

December 24, 2014 | Slide 1

Victor Khuboni, Power Products Service, November 2014 – AMEU

Transformer Service Transformer Total Health Care (TTHC)

The activities that make up the TTHC concept are namely:

Taking of oil samples.

Laboratory analysis of oil samples.

Interpretation of the report and recommendations.

Technical evaluation of the report.

Rectification activities.

Oil rejuvenation (Oil purification, supply regen oil, e.t.c).

In depth diagnostics and condition assessment (Tan-Delta,

SFRA, OLTC Continuity test, etc….)

Scheduled Service Activities.

Condition monitoring.

Specialized services including supply of spare parts.

Dry Ice cleaning of the transformer and the control room.

Cleaning of the sub-station yard.

Transport, Installation and Cold Commissioning.

First Line Maintenance Training.

Our vision: To create a “One Stop Shop” solution for customers

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IS35 CLEANS TAR.MPG

Let‘s look to an exemplary transformer park TrafoAssetManagementTM

Analysis of History of Transformers

Condition & Risk-Assessment / Maintenance Planning

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Analysis of Transformer History ABB has a 360° view of transformers



Design data

Information in the installed

base system

Results of the condition

assessment

Maintenance history

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Condition and Risk-Assessment Step 1: Transformer Fleet Screening

Urgent

Action Needed Preventive

Action Needed

Normal

Maintenance

Action Needed



Fleet Screening: Basic Diagnostic (Oil testing) & Analysis of history

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Maintenance Planning Asset management scenarios


End of Life or

Remanufacturing 30-70 years


Urgent

Action Needed

Preventive

Action Needed

Normal

Maintenance

Action Needed

NewTransformer

Old Transformer

Life Cycle of a Transformer

Mid Life

Refurbishment 7-25 years

Regular

Asset Services Yearly

Early Life

Inspection 3-7 years

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Condition Assessment Several steps: Optimize the ratio Accuracy / Costs, Time Step 1

Transformer Fleet

Screening Number of unit: 20 - 100+

Objective: Maintenance Strategy & Budget

Transformer

fleet

Refurbishment Cooling Upgrade Replacement

Engineered solutions

→ Basic Diagnostics

→ History

→ Advanced

Diagnostics

→ Design Review

Step 2

Transformer Design &

Condition Assessment Number of unit: 10 - 20

Objective: Maintenance Plan & Actions per

unit

Step 3

Life Assessment / Profiling Number of unit: 1 - 10

Objective: Troubleshooting / Upgrade

proposal

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Transformer Condition Assessment

Typical output results of a Transformer Condition Assessment:

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

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Transformer Service Transformer Electronic Control (TEC)

ABB Transformer Electronic Control

TEC

Benefits:

On-line monitoring of key condition indicators

Data acquisition:

Gas, moisture, temperature, load, OLTC,

Features:

General status – Yearly report

Hot spot

Moisture in solid insulation

Ageing rate - overload ability

Bubbling temperature

Cooling

OLTC contact wear & torque

Communication using modem, TCP/IP

Remote supervision contract

More than 1770 units installed to date globally

Engineering

Solutions

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Transformer Service Tap-changers types - Four main product families

On-tank and in-tank

BIL level up to 1050 kV

Through current up to 1600 A in star connected applications

for resistive and up to 2500 A for reactance type.

Unsurpassed reference list in challenging applications, e.g.

HVDC and Ultra High Voltage systems (800 kV AC and DC)

Type UZ Type (V)UC Type (V)UB Type VRLTC

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Transformer Service Transformer bushing concepts (1/2)

Conformance: IEC, IEEE and regional standard variants

Resin impregnated with

composite or porcelain

insulators up to 550 kV

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Conformance: IEC, IEEE and regional standard variants

Oil impregnated with

porcelain insulators

36 - 1200 kV

Transformer Service Transformer bushing concepts (2/2)

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Transformer Service ABB University – Sessions Held In Johannesburg

• Transformer Operation & Maintenance Course

• Tap-changer Operation & Maintenance Course

• Oil Management Course – Level 1 & 2

• Insulating Oil Management Course

• Power Transformer Testing, Monitoring & Troubleshooting

• Power Transformer Fault Finding & Failure Analysis

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Utility, ZA – Belhar and Dinaledi Substation

Local Installation

Utility, South Africa, Western

Cape & North West Province

Year: Current

Customer need

Lower shutdown periods

Reduce OLTC maintenance scheduling

Trouble-free operation

ABB response

Vacuum On-load tap changer

Immediate prognosis allowing to take appropriate actions before a problem occurs

Customer 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

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Transformer Service Success Story

1ZSC000717-AAT_en_576p_10000.mpg

1ZSC000717-ABE_en_576p_10000.mpg

eThekwini Municipality, KZN

Before

Customers need

Repair of a Transformer (315 MVA 275/132/22 kV)

Time challenge to secure the power load in network.

On-site repair

ABB’s response

TrafoSite RepairTM

Replacement of Spare parts

Dry bushings (RIP)

Replacement of tap changer

New wiring to marshalling kiosk

Dry Ice Blast Cleaning and repainting of transformer

Drying out of windings

Testing

Commissioning

Customer benefits

Transformer repaired on-site

Saving of huge transportation costs

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Transformer Service Success Story

After

Transformer Service Service Level Agreements ( SLA )

ABB can provide a Service Level Agreement / Contract to the need of the customer and

equipment. A service agreement always guarantees that the resources you need are available

in the form of well-trained specialists with an in-depth knowledge about the customers'

equipment

Customer Service Plan Options

• Condition Assessments

• Service Work/Workshop repairs

• Spare parts

• Training

• Service Exchange Units

• Emergency call Outs

• Condition Monitoring

• Preventative Maintenance

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Transformer Service Conclusion - Spend money on the right assets at the right time

ABB’s Service solutions developed and

implemented world-wide by ABB in

recent years keep your transformers

humming and we can support you to…:

Ensure a high reliability of installed

assets

Enable move towards Condition

Based Maintenance

Reduce down-time of equipment

Delay heavy investments

Plan efficient maintenance

Upgrade existing transformers

Adopt environmental friendly solutions

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Transformer South Africa Contacts

PPTR allocation and contact information Allocated Service Unit: ZATAD – Johannesburg, South Africa Service Unit contact: Victor Khuboni , PP Service KAM Tel: +27 10 202 5168 Cell: +27 60 524 2817 New Trfrs contact: Antonio de Sa, Snr Sales Engineer Tel: +27 10 202 5135 Cell: +27 83 227 1335

Johannesburg Service Unit Market allocation list:

South Africa and Southern Africa

mailto:Julio Ferreira/BRABB/ABB@BRABB

mailto:Raben Naidoo/ZAABB/ABB@ABB_ZA01

Questions ?

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Documents

Victor Khuboni, Power Products Service, November 2014 … Hope/19-3 ABB PPTR Ser… · Overview of ABB Transformer Service Capabilities ... • Power Transformer Testing, ... Monitoring