Dubai, Middle East Electricity 18th February 2013
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Diagnostic Coverage and Integrated Treatments (2013) based on IEC Standards, “State of the Art”,
Best Available Techniques (BAT) and Best Environmental Practice (BEP)
Vander Tumiatti- President and Founder of Sea Marconi (1968) - Turin (Italy);- Ass. Secretary IEC TC 10 (International Electrotechnical Commission) Geneve-CH;- IEC AWARD 1906 – 2009- ACS Member (American Chemical Society)- IEEE Member (International Electronical Electrical Engineering)- Expert PEN - UNEP (POPs-PCBs Elimination Network - United Nations Environment Programme) Geneve - CH.
Smart LCM-O&ESmart Life Cycle Management (LCM)of Oils & Equipment
Part 1
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Contents
1. Sea Marconi Introduction2. Transformers, Insulating Oils & Fluids3. Loss prevention4. Focus on LCM & Key Steps5. Fluid Carrier Approach6. Regulations, Standards & Guidelines7. Hot Topics - Criticalities8. New Sustainable Solutions 20139. Knowledge Value & Case Histories10. Conclusions
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Main locations
Headquarter:
Collegno (Turin, Italy)
Homécourt (region of Lorena, France)
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Collegno (Turin) – Italy1968
Seclì (Lecce) – Italy1992
Homécourt – France2002
Barakaldo – Spain2002Buenos Aires – Argentina
2004
Karlsruhe – Germany2007
Where we are
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• Foundation: 1968, by Vander Tumiatti in Turin Italy• Mission: Protection of company assets and environmental resources• Activities: Research, Technologies, Services and Products for Energy & Environment• Clients: > 3,000 users in the energy, industry and service sectors in Europe, South America and others countries• Human resources: 100 employees, engineer, doctors (chemistry, mechanics, economics, ICT, etc.) and qualified technicians• Diagnostics: lab Accreditation, EN ISO 17025, Databases, hi-tech instruments• Decontamination: on site Mobile Units (DMU) different sizes • Quality: ISO 9001, Globe (Sea Marconi Technologies) • Patents: EEC, USA, others countries patented processes• R & D: Qualified by Italian Ministry of University and Scientific Research • European Project: HALOCLEAN APPLICATION; contract number - G1RD-CT-2002-03014 (Principal Main Contractor)• Experts: members in WGs (IEC, CEN, CIGRE)
Key informations
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Strength Points Pioneer & Expertise since 1968 Independence from Oils & Equipment
manufacturers Full technological capability (from idea to
operation) Innovation (new solutions from R&D); 40 patents According IEC Standards, State of the Art, BAT &
BEP International Accreditation Lab (Accredia, IAF, EA,
ILAC) Integrated & Effective approach for Life Cycle
Management
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We are Pioneer since 1968
… 1976 particles, 1978 DGA, 1979 PCBs HRGC-ECD, 1982 PCBs Dehalogenation, 1984 ICP - metals dissolved, 1989 2Fal and CO2 investigation…
2005 “DBDS & Corrosive Sulfur” discover and solution with Selective Depolarisation
2006 fingerprinting - AED profile
2008 “NO DBDS & Corrosive Sulfur”. Discover of quantitative determination of Total Corrosive Sulfur - TCS
2010 “SDBP & Corrosive Sulfur”. Sulfur Degradation ByProducts - DBTP, H2S, Mercaptans, etc.
2012 consumed “Thermal Life” for deep investigation relation to 2Fal, CO2 and Methanol and oxidation byproducts with multidetection approach…
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Power transformers treated per year (2012) 596
PCBs Dehalogenation (CDP Process) 135
Depolarisation and Reclaim (Chedcos) 120
Reconditioning (Chedcos) 341
Oil mass treated per year (2012) 5.177 ton
PCBs Dehalogenation (CDP Process) 1.270 ton
Depolarisation and Reclaim (Chedcos) 2.048 ton
Reconditioning (Chedcos) 1.859 ton
Number of Decontaminat. Mobile Units (DMU) 25
Oil samples analysed per Year (2012) 12.600
Transformers analysed per Year (2012) 7.750
Oil Test performed per Year (2012) 66.000
Transformers and equipment database > 50.000
Diagnostics database > 150.000
Technical Capabilities
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My Transfo: International Meetings2002
(R. Maina) Corrosive Sulfur (V. Sokolov) Transformer LCM
2004
(R. Maina) Oil Fingerprint and forecast (V. Sokolov) Transformer LCM
2006
(F. Scatiggio) Corrosive sulfur (R. Maina) Diagnostics for LCM (V. Sokolov) Post mortem inspection (D. Schubert) Insurance reliability and best practices
2008
(V. Tumiatti) Fingerprinting, Ageing, Diagnosis, Decontamination, Depolarisation and Detoxification of Oils (M. Pompili) Risk assessment (R. Maina) A.I. for Advanced Diagnostics
2010
(M. Duval) Dissolved Gas Analysis – DGA (F. Scatiggio) Corrosive Sulfur Removal (M. Pompili) PD Measurement in Insulating Liquids (S. Kapila) Advanced analytical techniques (R. Maina) Post Mortem diagnosis
Hot Topics Pioneers: exchange of global knowledge, experience, sustainable solutions in Oil & Transformer Life Cycle Management (LCM)
2012…
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Energy & Environment
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FLEET- Type - Power (MVA)- Voltage (KV max)- Age (year)- Fluid (type)- Manufacturer - Serial number- Asset Value (€/$)- Consumed thermal life- OLTC (type, fluid)- Bushing (Oil, SF6, etc.)
TRANSFORMERS = STRATEGIC ASSETSKey role in the networks: Generation, Transmission, Distribution and Use of Energy
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PCAs/PAHs
Priority: Insulating Mineral Oils
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• > 10,000 million litres of insulating oils • Typical replace value is more than ~ 1,5-2 € / litre• Insulating Oil represents ~ 5-6% value of transformer• Insulating Oil represents ~ 25% weight of transformer
€OECD - Total Asset Value:
Generation Power Transformer
> 150,000 million€ - Euro
Oils & Asset Management
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…other Insulating Fluids (ref. IEC Standards)
• Natural esters• Synthetic esters• Silicon liquids• Askarels - PCBs based• SF6• Others…
and Dry Transformers…
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Black-Out
Failure
InfancyOccasional
Old age
Explosion Fire
Damages
• Direct: Assets & Personal• Indirect: Loss Production• Environment: Soil, Water, Air
Protection of the Assets & Environment
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http://news.bbc.co.uk/2/hi/europe/8209663.stm
http://news.bbc.co.uk/2/hi/europe/8209663.stm
Typical Site
GSU Transformer explosion
Knowledge Value for Loss Prevention
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Russia 17th August 2009 - Accident Sayano-Sushenskaya RusHydro power plant – 6500 MW
* Vladimir Markin, spokesman of the investigation commission by the federal prosecution office
The impact of this accident, based upon the information available, indicates a severe profile of damages: 1- damages to persons (17 killed and 58 missing); 2- damages to assets and infrastructures (estimated over 1 billion dollars for a complete rebuild); 3- damages for the loss of production of energy, aluminium and other steel products (several billion dollars); 4- environmental damages for the contamination by insulating oils, turbine hydraulic fluids and lubricants that could endanger the delicate eco-system of this sub arctic area (estimated over 80 sq km with contaminated surface waters).
Knowledge Value from:Catastrophic Accident “Explosion of GSU Transformer in Insulating Mineral Oils”*
Dubai, Middle East Electricity 18th February 2013
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Life Cycle Management (LCM) of insulating Oils & Equipment has been developed, in 10 key steps, in accordance with the following objectives:A. Prevention and/or mitigation of losses (direct and indirect) and
risks for workers, assets, public health and environment, arising from human error, malfunction, or failures of the equipment that cause fires or spillage of hazardous compounds (Oils, PCA, etc.) and Persistent Organic Pollutants (POPs; PCBs, etc.);
B. Implementation of IEC Standards, “State of the Art”, “Best Available Techniques” (BAT), “Best Environmental Practices” (BEP) and methodologies available for safety, whilst taking into account the surroundings and the criteria of self-sufficiency and functional recovery;
C. Technical feasibility of the activities within the prescribed time schedules, according local regulations, based on cost/benefit analysis and economical feasibility. (CENELEC CLC/TR 50503 – February 2010, etc.)
Win-Win Strategies & Opportunities
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I. Start - Inventory, Requirements and General Specifications (unused insulating oils & fluids: AED fingerprint; additives, viscosity, flash point, etc.)
II. Acceptance (Tests of unused insulating oils & fluids)III. Factory TestIV. Prior EnergizationV. Post EnergizationVI. Supervision - Control and Diagnosis for Insulating Oils &
Equipment (anamnesis; signs; markers; symptoms; trends; typical value, alert value, alarm value; critical factors, type/priorities; corrective actions & countermeasures, type/priorities, etc.)
VII. Oils & Fluids Maintenance with Integrated Treatments & Processes
On-Load/Off-Load (physical decontamination/reconditioning; selective depolarisation-DBDS, metal dissolved, acid and polar compound/reclaim; dehalogenation/detoxification of PCBs & POPs; transformer drying; transformer desludging; additives; etc.)
VIII.Equipment Maintenance & ReparationIX. Post Failure (Tests, Diagnosis and Treatments)X. End of Life - Post Mortem (Tests, Diagnosis and Treatments)
a. Material recoveryb. Decontamination and/or disposal Waste (PCBs, etc.)
Key Steps for Oils & Power Transformer LCMAccording with IEC Standards and CIGRE Guidelines and specific Requirements
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Added Value for Customers, Holders, & Partners
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Integrated methods based on “Fluid Carriers” equivalent to “human blood”.
The «Fluid Carrier» Approach
PARADIGM: diagnostic Tests and dialysis therapies applied to the body and internal organs
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Representative Sampling for Diagnostic Testsin Accredited laboratory
Transformer fluids Human bood
The «Fluid Carrier» Approach
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BAT/BEP – IEC methods & ISO 17025 lab accreditation for independent analysis and diagnostic coverage to support insurance coverage
Example Sea Marconi lab Typical Hospital lab
The «Fluid Carrier» Approach
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Advanced analysis and diagnostic methods Quality certification: ISO 9001; ISO
17025-2000 Uncertainty determination for each Test
Independent Expertise (since 1968) for:
• High skilled human resources; • Multidisciplinary approach;• Large number of Tests performed;• Advanced instrumentation;• R&D for the future methods;• Robust data base for decision support
of global customers
The «Fluid Carrier» Approach
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Trend analysis
Test results with Method, Uncertainty ISO 17025
Diagnosis for Identification of Functional and Environmental Criticalities According to IEC 61619, EN 12766 and IEC Standards
Diagnosis with Health Index, Critical Factors, Actions And Countermeasures (type and priorities)PCBs Test
Report
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Example of Sea Marconi DMU for ON-LOAD treatments
500 KV Brazil (2009)
Human blood dialysis
DMU (Decontamination Mobile Unit) for integrated treatments & processes (decontamination, selective depolarisation, dehalogenations and detoxifications) in continuous mode, off-load/on-load conditions
The «Fluid Carrier» Approach
BAT/BEP Technology
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Main functionPhysical
decontamination
CHEDCOS depolarisati
on
CDP PROCESS®
dehalogenation
Recovery of dielectric properties
Recovery of the chemical properties of the oil (acidity, delta tg, colour)
Elimination of sulfur corrosive contaminants, DBDS
Elimination of dissolved organo-metallic contaminants
Dehalogenation/Detoxification of PCBs/PCTs/PCBTs, POPs compounds etc.
DMU (Decontamination Mobile Unit) for Multifunctional Integrated Treatments & Process
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Typical DMU configuration
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Regulation, Standards & Guidelines
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IEC 60296 ed. 4 - 2012“Unused mineral insulating oils for Transformers and Switchgears”
1-Function
2-Refining /Stability
3-Performance
4-Health, Safety, andEnvironment (HSE)
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PART 1 DBDS quantification and oils fingerprint (AED profile: C, S, etc.) PART 2Total Corrosive Sulfur - TCS QuantificationPART 3Total mercaptans and disulfides
IEC 62697-1: 2012Test method for quantitative determination of corrosive sulfur compounds in unused insulating liquids
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IEC 60422 Ed. 4 – 2013Mineral insulating oils in electrical equipment – Supervision and maintenance guidance
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CENELEC CLC/TR 50503 - 2010Guidelines for Inventory, Control, Management, Decontamination and/or Disposal of Electrical Equipment and Insulating Liquids containing PCBs
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The recommendations for concentration limit for Corrosive Sulfur compounds in oils (CIGRE A2.32 figure 9, pag. 31):• “<10 mg/kg for DBDS (after 90 days);• < 5 mg(S)/Kg total difulphides + mercaptans content in oil.” Total Corrosive Sulfur compounds (after 90 days)
CIGRE – Brochure 378 - 2009 Guidelines - Copper Sulphides in transformer insulation
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CIGRE - Brochure n. 413 – 2010 Guidelines Insulating Oil Regeneration and Dehalogenation – PCBs
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Priority: Hot Topics
DBDS & Corrosive Sulfur
Copper Sulfide formation CuS,
Cu2S
C1Markers
DBDS (IEC 62697-1)
TCS (IEC 62697-2 preliminary draft)
Additives: Passivators (BTA, Irgamet 39, Irgament 30)
Additives: Bio Copper Corrosion Inhibitors (adenine, purine, etc.)
CCD Test, DIN Test, ASTM Test
Metals
Particles (Pioneer 1976)
Others…
Criticality: Corrosion Phenomena
NO DBDS & Corrosive Sulfur
C2
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SDBP & Corrosive SulfurSulfur Degradation
ByProducts:H2S, Mercaptans, etc.
Silver Sulfide formation Ag2S
“The oil regeneration process plant involves the high temperature reactivation of sorbent and fuller earth column by uncontrolled combustion. The Sulfur Compounds naturally present (DiBenzoThioPhene – DBTP, etc.) in the Oil and additives (DBDS, etc.) are decomposed in Sulfur Degradation ByProducts (SDBP such as corrosive H2S, Mercaptans, etc.) forming Sulphides CuS, Cu2S, Ag2S, etc.”.
«At relatively high temperature, sulphur-containing oil molucules may decompose and react with metal surface to form metal sulphides» (IEC 60422 Ed. 4 – 2013 art. 5.17)
Priority: Hot Topics
Markers
TCS – Total Corrosive Sulfur (IEC 62697-2 preliminary draft)
Total Sulfur
DiBenzoThioPhene – DBTP, etc.
Metals
Particles
Others…
Criticality: Corrosion Phenomena
C3
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Service Period (Years)
Copper
in o
il m
g/k
g
43
NO Sulfur Corrosion & Copper/Metal dissolution
Priority: Hot Topics
Markers
Metals
TAN
DF
IFT
Particles
Others…
Criticality: Corrosion Phenomena
C4
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Markers
Consumed Thermal Life & Solid/Paper Insulation
2Fal, CO2, H2O, Methanol, etc.
Oil & Fluid Degradation TAN, DF, IFT, Particles, Oxidation byproducts, etc.
Sludge Formation TAN, Sediments, Aspect, Particles, etc.
Priority: Hot Topics
Criticality: Thermal Life & Degradation
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Hot Spot> 700 °C
Electrical
Arching
PD Partial discharges
D1 Discharges of low
energy
D2 Discharges of high
energy
T1 Thermal fault, t < 300 °C
T2 Thermal fault, 300 °C < t <
700 °C
T3 Thermal fault, t > 700 °C
Priority: Hot Topics
Criticality: Faults
Markers
DGA
Particles
Metals
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According to IEC 61619, EN 12766, IEC 60296, IEC 60422, CENELEC 50503
Priority: Hot Topics
Criticality: PCBs/POPs - Environment
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New Sustainable Solutions: 2013
Smart Field Test Kits (Patents Pending by Sea Marconi)
Kit forTotal Acid Number
Kit forTotal Corrosive Sulfur
Kit forTotal Chlorine/PCB
SM-TAN SM-TCS SM-TCPs
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New Sustainable Solutions: 2013
Smart Field Multi Detection (online/offline)
Kit forSampling and
Detectionof selective DGA, SF6, Particles and Moisture
& Black Box
(Patents
Pending by Sea
Marconi)
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Smart Detection for Dry Transformers
Thermal profile
Vibro-acustic profile
SMELL PROFILE: nanosponges cartridge for selective adsorption of chemical byproducts correlated with thermal degradation of polymers (equiv. to DGA)
New Sustainable Solutions: 2013
(Patents Pending
by Sea Marconi)
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New Sustainable Solutions: 2013
Smart DMU (Decontamination Mobile Unit)
DMU (Decontamination Mobile Unit) -
Multifunctional and Integrated Treatments &
Processes for Decontamination, Depolarisation and
Detoxification of insulating liquids
(Patents Pending
by Sea Marconi)
Dubai, Middle East Electricity 18th February 2013
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Smart LCM – O&E
GSU Power TransformerYear: 1997, ABBPower: 192 MVAVoltage: 400 KVOil Mass: 58.000 Kg
DBDS[mg/Kg]
IFT[mN/m]
TAN[mg
KOH/g]DF
Before treatment 110 17 0,133 0,0448
After treatment < 5 40 < 0,01 0,0118
DBDS: ON-LOAD TREATMENTS
Italy 2006
Knowledge Value, for Twin & Family Units, from:Case history of Integrated Treatments with DMU
Dubai, Middle East Electricity 18th February 2013
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Smart LCM – O&E
ALUMINIUM FactoryRectifier TransformerYear: 1930, Brown BoveriPower: 19 MVAVoltage: 13 KVOil Mass: 15000 Kg
PCB[mg/Kg]
IFT[mN/m]
TAN[mg
KOH/g]DF
Before treatment 27 22,1 0,034 0,01483
After treatment 0,35 43,3 0,01 0,0013
PCBs: ON-LOAD TREATMENTS
Sweden
2012
Knowledge Value, for Twin & Family Units, from:Case history of Integrated Treatments with DMU
Dubai, Middle East Electricity 18th February 2013
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DBDS[mg/Kg]
H2O[mg/Kg]
TAN[mg
KOH/g]DF
Before treatment 125 7 0.095 0,0190
After treatment < 5 3 < 0,01 0,0033
Chemical Factory GSU TransformerYear: 2000, GetraPower: 47 MVAVoltage: 34 KVOil Mass: 12000 Kg
DBDS: ON-LOAD TREATMENTS
Qatar 2012
Knowledge Value, for Twin & Family Units, from:Case history of Integrated Treatments with DMU
Dubai, Middle East Electricity 18th February 2013
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DBDS[mg/Kg]
H2O[mg/Kg]
TAN[mg
KOH/g]DF
Before treatment 144 16 < 0,01 0,0026
After treatment < 10 5 < 0,01 0,0015
Electrical substationPower TransformerYear: 1998, Zaporozhtransformator
Power: 250 MVAVoltage: 345 KVOil Mass: 118000 Kg
Chile
2012
DBDS: ON-LOAD TREATMENTS
Knowledge Value, for Twin & Family Units, from:Case history of Integrated Treatments with DMU
Dubai, Middle East Electricity 18th February 2013
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Smart LCM – O&E
Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
TSN
Lines 1181 km
Substations 6
Total reactors 40
Reactors with corrosive sulfur 37 (92,5%)
Total failed reactors 15 (37,5%)
Novatrans
Lines 1278 km
Substations 6
Total reactors 36
Reactors with corrosive sulfur 13 (36,11%)
Total failed reactors -
Brazil
2005
Shunt reactors 500 KV line,
Nynas Naphtenic Oil
Dubai, Middle East Electricity 18th February 2013
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Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Extraction of core and windings on 19th of April 2006 for VISUAL INSPECTION
Total estimated losses (direct and undirect): more than 20 mln €
Italy
2006
GSU Transformer 400 KV, 192 MVA, Nynas
Naphtenic Oil
Dubai, Middle East Electricity 18th February 2013
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Sinusoidal deformations of the windings, sector opposite to the
failure
Internal view of the HV winding, failure zone
Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Inspection and Analysis on internal HV windings
Italy 2006
GSU Transformer 400 KV, 192 MVA, Nynas
Naphtenic Oil
Dubai, Middle East Electricity 18th February 2013
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VISUAL MAPPING OF THE COPPER SULFIDE DEPOSITS
Italy 2006
GSU Transformer 400 KV, 192 MVA, Nynas Naphtenic Oil
Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Dubai, Middle East Electricity 18th February 2013
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MAPPING OF THE THERMAL DEGRADATION Italy 2006
GSU Transformer 400 KV, 192 MVA, Nynas Naphtenic Oil
Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Dubai, Middle East Electricity 18th February 2013
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COLLECTION OF PAPERS FROM THE WINDING- Internal conductors of the winding heavily contaminated by copper sulfide.The strong corrosiveness of the oil (corrosiveness code: 4c, by repeated analyses according to ASTM D 1275 A ext. 48h) caused the deposition of elevated amounts of copper sulfide on the paper components.
Italy 2006
GSU Transformer 400 KV, 192 MVA, Nynas Naphtenic Oil
Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Dubai, Middle East Electricity 18th February 2013
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Israel 2009
GSU Transformer 400 kV, 175 MVA, SHELL Napftenic Oil Diala AX
Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «NO DBDS & Corrosive Sulfur»
Dubai, Middle East Electricity 18th February 2013
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Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «SDBP* & Corrosive Sulfur»*Sulfur decomposition byproducts related to high temperature and
Uncontrolled combustion for reactivation of sorbent and fuller earth
Uruguay 2010
Grid Transformer 500 kV, 425/3 MVA - OLTC, YPF65 Paraffinic Oil not inhibited
Dubai, Middle East Electricity 18th February 2013
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Pacific Area
2012
Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»
Rectifier Transformer ODAF with membrane, year: 1998, 66/0,4 KV, 93,4 MVA, Nynas Napftenic Oil Nitro 10 GBN, winding CTC (enameled conductors)
Copper sulfide formation on paper and on enameled conductors
Dubai, Middle East Electricity 18th February 2013
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a. Technical Standards (IEC, CENELEC, etc.) and Guidelines (CIGRE, etc.)
b. State of the Art (2012)c. Best Available Techniques (BAT)d. Best Environmental Practices (BEP)e. Accredited Laboratories (ISO IEC 17025)
with uncertainty determination for each Test
f. Qualified Expertise based on a Robust database and Case Histories
Conclusion 1
Smart LCM O&E - Key Factors
Dubai, Middle East Electricity 18th February 2013
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Smart LCM – O&E
The Smart LCM O&E is able to prevent and/or mitigate the potential losses and unreasonable risks for the
asset, workers, public health and environment.
This sustainable solutions is targeted for protection of specific fleet of strategic electrical equipment filled
with insulating fluids.
This approach guarantees knowledge added value for Customers, Holders & Partners in terms of best
innovative technologies, reliability, quality control, traceability, economics, environmental protection,
social and stakeholders relationship.
Conclusion 2
Dubai, Middle East Electricity 18th February 2013
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Thank you for your kind attention
Q & A
Dubai, Middle East Electricity 18th February 2013
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Smart LCM – O&E
Since 1968
www.seamarconi.com
ContactsVander Tumiatti
Founder and General Partner
Sea Marconi TechnologiesVia Ungheria 20
10093 Collegno (Turin - Italy)Tel. +39 011 2343434Fax +39 011 2343435
e-mail: [email protected]
Ideas and Innovation for Energy and Environment
Alessandro CapoInternational Sales Manager
Sea Marconi TechnologiesVia Ungheria 20
10093 Collegno (Turin - Italy)Tel. +39 011 2343434Fax +39 011 2343435
e-mail: [email protected]