ABB Brasil. Power Transformers: Life Cycle and Operational Cost Optimization Conventional, Wind and Solar Applications

Transcription

1 SANTIAGO CL Jornadas Técnicas Abr14&15 Dr. José Carlos Mendes Gte Tecnologia Transmissão e Produtos de Potência Gte Desenvolvimento & Engenharia Engenheiro Corporativo Executivo Global ABB Asea Brown Boveri Divisão de Produtos de Potência Transformadores de Potência São Paulo, SP - Brasil jose-carlos.mendes@br.abb.com tel: cel: ABB Brasil Power Products Division : Life Cycle and Operational Cost Optimization Conventional, Wind and Solar Applications ABB Brazil JCM A-1 14 Power de abril de Products 2015 Slide Division 1

2 ABB Brasil Power Products Division Power and Distribution Transformers ABB Brazil Power Products Division PPTR Distribution Transformers Guarulhos, São Paulo - BR PPTR power transformers up to 765kV shunt reactors up to 765kV heavy current industrial transformers service (Eng Solution, Factory and Site Repairs, Monitoring Systems, TrServices) insulation components transformer components (Bushings, Tap Changers, etc) PPMV Medium Voltage, PPHV High Voltage Blumenau, SC - BR ABB Brazil JCM A-2 14 Power de abril de Products 2015 Slide Division 2

3 Context Renewables Energy and Transformers Optimization Content Content q q q q q q q introduction renewables energy solar and wind power generation transformers applications and needs useful life and maintenance life cycle optimization from specification to end of life design optimization selection of alternatives loss evaluation to efficient transformers advanced technologies performance, reliability and failure modes advanced minimum maintenance optimized monitoring knowledge, condition and event based minimum periodic inspection advanced asset management conclusions ABB Brazil JCM A-3 14 Power de abril de Products 2015 Slide Division 3

4 Renewables Energy and Transformers Applications Solar and Wind Power Generation Trends and Transformers Needs ABB Brazil JCM A-4 14 Power de abril de Products 2015 Slide Division 4

5 Context Renewables Energy Solar Power Chile Renewables Central Strategy reduce electricity price solar and wind up to 20% in tenders for regulated clients 400MW solar PV generation under contruction Atacama Desert PV Solar Power Plant Cerro Dominador 110MW CSP Concentrated Solar Power Plant Vision by Solar Energy Supply from Chile ABB Brazil JCM A-5 14 Power de abril de Products 2015 Slide Division 5

6 Context Renewables Energy Wind Power Chile Renewables Central Strategy reduce electricity price solar and wind up to 20% in tenders for regulated clients 836MW wind installed capacity (~500MW in 2014) El Arrayán 115MW Wind Park 50x2.3MW, 0.69/35kV-220kV ABB Brazil JCM A-6 14 Power de abril de Products 2015 Slide Division 6

7 Solar and Wind Power Plants Applications Solar PV Wind Farms Connection Transformer Connection Transformer Collector Transformer Collector Transformer Collector Transformer Collector Transformer Inverter Transformer Inverter Transformer Inverter Transformer Inverter Transformer WTG Transformer WTG Transformer WTG Transformer WTG Transformer PV DC Generator PV DC Generator PV DC Generator PV DC Generator Solar CSP Connection, GSU Transformer WTG Technologies ABB Brazil JCM A-7 14 Power de abril de Products 2015 Slide Division 7

8 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 ABB Brazil JCM A-8 14 Power de abril de Products 2015 Slide Division 8

9 Solar and Wind Power Applications Wind Farm Steady State Voltage Load Flow Us LF IL UHVc ULVc Ulim Connection SS BUS 230 kv Connection Transformer Connection SS BUS 69 kv IL, LF = load factor pu % pu pu pu pu , TL230-1 Wind Farm TL230-2 Wind Farm 3 TL230-3 Wind Farm 4 Collector SS BUS 69 kv UChv TL230-4 Wind Farm 5 Collector Transformer Ulim TL230-5 TL69-1 Collector SS BUS 34.5 kv UClv TL230-6 TL69-2 Capacitor Bank Capacitor Bank WTG BUS 690 V WTG Transformer US WTG BUS 690 V G Wind Farm 1 ABB Brazil JCM A-9 14 Power de abril de Products 2015 Slide Division 9

10 Solar and Wind Power Applications Wind Farm - Voltage Control and Transformers Taps Adjustments Power System WIND FARM 300MW Electrical System P ± jq kv kv kv kv kv kV kv kv kv kv kv 0.690kV 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 US = US = NhvL NlvL UL NhvL NlvL Nhvc Nlvc UL = Nhvg Nlvg Ug Nhvc Nlvc Uc UL = Nhvc Nlvc Uc = Nhvg Nlvg Ug Nhvg Nlvg Ug operation inductive PF back-feeding no-load UL = NlvL NhvL Us complete analysis requires Load Flow and Harmonic Load Flow for loading conditions ABB Brazil JCM A Power de abril de Products 2015 Slide Division 10

11 Renewables Energy and Transformers Applications Life Cycle From Specification to End of Life ABB Brazil JCM A Power de abril de Products 2015 Slide Division 11

12 Life Cycle Optimization Transformer Life Cycle ABB Brazil JCM A Power de abril de Products 2015 Slide Division 12

13 Life Cycle Optimization Transformer Life Cycle Specification, Design, Manufacturing, Tests, Transportation, Receiving, Storage, Installation, Operation, Monitoring, Maintenance, End of Life ABB Brazil JCM A Power de abril de Products 2015 Slide Division 13

14 Renewables Energy and Transformers Applications Life Cycle Design Optimization ABB Brazil JCM A Power de abril de Products 2015 Slide Division 14

15 Life Cycle Optimization and Global Evaluation of Alternatives Power Transformer Transformer core windings insulation connection tank expansion tank accessories bushings tap-changers radiators motor-fans thermometers, level indicators, Buchholz relay, pressure relief valve, pressure relay, air breathers, etc bushing current transformers BCTs surge arresters command, control and protections sensors and monitoring system ABB Brazil JCM A Power de abril de Products 2015 Slide Division 15

16 Life Cycle Optimization and Global Evaluation of Alternatives Power Transformer Design Optimization Transformer Design core induction no load losses - core load losses windings, connections, metal structures short-circuit impedances leakage flux inrush-current short-circuit current short-circuit forces core over-excitation DC excitation component voltage and current harmonics overloading insulation (windings and main) cooling and temperature rise noise level new technologies (Nomex, Vegetable Oil, Vacuum OLTC, CTCs, Bushings RIP & RIS, etc) on-line monitoring and diagnostic on-line asset management Transformer Design Optimization cost optimization no load losses optimization load losses optimization characteristics optimization performance (thermal, loading, shortcircuit, etc) optimization transportation limits interchanged ability transformer optimization strategies: Total Initial Cost Losses Cost Total Operational Cost Life Cycle Total Cost ABB Brazil JCM A Power de abril de Products 2015 Slide Division 16

17 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 17

18 Renewables Energy and Transformers Applications Life Cycle Optimized Selection of Alternatives ABB Brazil JCM A Power de abril de Products 2015 Slide Division 18

19 Life Cycle Optimization and Global Evaluation of Alternatives Transformer Life Cycle Warranty of Useful Life Garantida, year Life Cycle, years Capital Cost: purchase transport installation $1 Operation Cost: $2 losses (noload, Load, Auxiliar) maintenance insurance premium repairs performance End of Life Cost: replacement transfer refurbishment $3 NPV, Total Cost / Life Cycle $ = $1+$2+$3 USD$ kva x Useful Life x Overloading Factor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 19

20 Life Cycle Optimization and Global Evaluation of Alternatives Transformer Life Cycle Usual Evaluation Method: initial total cost: q equipment initial cost q spare components cost q transport cost q installation cost (erection, supervision, etc) q comissioning cost q extended guarantee cost losses cost (capitalisation) q no-load, load, auxiliar losses technical data table q technical performance data q technical guaranteed data Usual Method does not Evaluate: Quality Design and Manufacturing Withstand (electrical mechanical, thermal) Risk of Failure Useful Life Expectancy Overloading Capability Global Value Index: total initial price, USD$ rated power, kva guaranteed useful life, years guaranteed overload, pu return on investment, % year ABB Brazil JCM A Power de abril de Products 2015 Slide Division 20

21 Life Cycle Optimization and Global Evaluation of Alternatives Power Equipment Performance Equalization Guaranteed Technical Data To meet declared guaranteed technical data it is not a guarantee: q q q q q q for a specified minimum performance for a specified useful life for a short-circuit withstand with reliability for a economic optimized solution for a minimum LC total cost for a reliable operation life with no failure USD$ kva x UsefulLife x OverLoadingFactor Technical Performance Evaluation quantitative evaluation method powerful technical performance comparison of different suppliers technical & economical equalization of several technical quotations main performance data: thermal performance (core, windings, connections) useful life (as per IEEE) total losses short-circuit (IEC) certified/qualified seismic performance transient voltages and internal insulation withstand (switching of reactors!) reliability analysis global economic evaluation Increasing Asset Quality: Minimum Maintenance ABB Brazil JCM A Power de abril de Products 2015 Slide Division 21

22 Life Cycle Optimization and Global Evaluation of Alternatives Power Equipment Performance Equalization Alternatives A B Characteristic Unit Cellulose ThUpgraded Paper, 65Cdeg Hybrid, Nomex Paper, 95Cdeg Initial Cost USD Rated Power kva Useful Life years Overloading Factor pu Overloadind Time h 4 4 Global Value Index USD/kVA. year Ratio % USD$ kva x UsefulLife x OverLoadingFactor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 22

23 Renewables Energy and Transformers Applications Life Cycle Losses Evaluations to Efficient Transformers ABB Brazil JCM A Power de abril de Products 2015 Slide Division 23

24 Life Cycle Optimization and Performance Equalization Power Equipment Performance Equalization value, $ manufacturing cost value, $ manufacturing cost + losses cost manufacturing cost losses cost transformer mass, kg Manufacturing Cost: material labor over-heads losses cost transformer mass, kg $$ Total Cost = Manufacturing Cost + Losses Cost = f (design variables) optimization q core induction, diameter, mass q winding current density q distance between windings q winding diameters, width, height, mass q tank mass Loss Capitalisation Cost, $/kw maximum cost to pay to reduce transformer losse by 1 kw ABB Brazil JCM A Power de abril de Products 2015 Slide Division 24

25 Life Cycle Optimization and Performance Equalization Power Equipment Performance Equalization 1 kw losses in 30 years 8600 hours/year No Load Losses Evaluations Values Interest rate 0.02 $/kwh 0.03 $/kwh 0.04 $/kwh 4% % % Load Loss evaluations depend on load profile per day, months etc and are therefore a varying % of the full year value ABB Brazil JCM A Power de abril de Products 2015 Slide Division 25

26 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 Specifications for low loss power transformers Values translated into value of NoLoad loss $/kw value of Load losses $/kw Loss evaluations in specifcations have been relatively stable in recent years Loss evaluations are key part of specifications actual values reflect future energy price expectations interest value chosen determines time horizon ABB Brazil JCM A Power de abril de Products 2015 Slide Division 26

27 Renewables Energy and Transformers Applications Life Cycle Specification for High Performance and Reliability ABB Brazil JCM A Power de abril de Products 2015 Slide Division 27

28 Life Cycle Optimization and Performance Equalization Harmonic Voltage and Current Effect on Transformer and Design Consideration DC Current Effect on Transformer and Design Consideration Harmonics: Voltage & Current core & windings losses faster degradation of insulation system possible partial discharge arcing Required data from user K factor harmonic spectrum Design Considerations alteration of induction additional cooling capacity Presence of DC current small % of DC current leading to saturation harmonics significantly higher for unbalanced DC Required data from user % of DC present Design Consideration core appropriate induction ABB Brazil JCM A Power de abril de Products 2015 Slide Division 28

29 Life Cycle Optimization and Performance Equalization Continuous OverVoltage - OverExcitation Effect on Transformer and Design Consideration Exceeding V/F (Volts/Hz) ratio & component s rating additional losses- core and coil insulation system weakening under full load with overvoltage partial discharge PDs generation failure of component Required data from user possible voltage limits frequency & duration of voltages going over the continuous overvoltage Design consideration core appropriate induction possible increase in BIL strengthen insulation system & processing possible use of power transformer components StepUp and StepDown Operation and OverLoading Effect on Transformer and Design Consideration Back feeding a step up transformer transformer designed as step up inrush current, voltage compensation Required data from user step up /down operation possibility short time overload duration & frequency Design considerations core appropriate induction cooling additional kva ABB Brazil JCM A Power de abril de Products 2015 Slide Division 29

30 Life Cycle Optimization and Performance Equalization Renewables Energy Transformers: DGA Dissolved Gas Analysis Dissolved gas analysis (DGA) use as guiding principles Standard refers to power transformers IEEE reviewing large data but pertaining to power transformers it is still an art not a science volume of paper insulation/absorption of gases Reference to IEEE Standard C57.104, Table 1 Guideline for TDCG - Total Dissolved Combustible Gases Two key points: Table 1 assumes that no previous tests on the transformer for DGA have been made and that no recent history exists. the numbers shown in Table 1 are in parts of gas per million parts of oil (ppm) volumetrically and are based on a large power transformer with several thousand gallons of oil. ABB Brazil JCM A Power de abril de Products 2015 Slide Division 30

31 Life Cycle Optimization and Performance Equalization Renewables Energy Transformers: DGA Dissolved Gas Analysis Dissolved gas analysis (DGA) use as guiding principles Standard refers to power transformers IEEE reviewing large data but pertaining to power transformers it is still an art not a science volume of paper insulation/absorption of gases DGA can be used as a guide to detect: partial discharge PD high energy electrical arcing thermal faults cellulose insulation breakdown overload(s) overexcitations ABB Brazil JCM A Power de abril de Products 2015 Slide Division 31

32 Life Cycle Optimization and Performance Equalization Renewables Energy Transformers: DGA Dissolved Gas Analysis Dissolved gas analysis (DGA) use as guiding principles Standard refers to power transformers IEEE reviewing large data but pertaining to power transformers it is still an art not a science volume of paper insulation/absorption of gases The principal or key gasses associated with each type of issue: Hydrogen (H2): generated by partial discharge/arcing Methane (CH4): generated by relatively low elevated temperatures (150 C). Acetylene (C2H2): generated by arcing. Ethane (C2H6): generated by high temperatures (<300 C). Ethylene (C2H4): generated by high temperatures (>300 C). Carbon Monoxide (CO): generated by oxidation of cellulose insulation. Carbon Dioxide (CO2): generated by oxidation of cellulose insulation. ABB Brazil JCM A Power de abril de Products 2015 Slide Division 32

33 Life Cycle Optimization and Performance Equalization Renewables Energy Transformers: DGA Dissolved Gas Analysis Dissolved gas analysis (DGA) use as guiding principles Standard refers to power transformers IEEE reviewing large data but pertaining to power transformers it is still an art not a science volume of paper insulation/absorption of gases Points to be considered in data analysis generation of gases in normal operation of transformer rate of change of gases over a period of time necessity of more than one sample over a period of time significance of change with reference to any event normal operation of components manufacturing process comparison with a baseline DGA ABB Brazil JCM A Power de abril de Products 2015 Slide Division 33

34 Life Cycle Optimization and Performance Equalization Renewables Energy Transformers: DGA Dissolved Gas Analysis Dissolved gas analysis (DGA) use as guiding principles Standard refers to power transformers IEEE reviewing large data but pertaining to power transformers it is still an art not a science volume of paper insulation/absorption of gases Recommendation IEEE C Table-1: use as a guide analyze the data based on more than one sample compare the analysis with the baseline further testing based on significant rate of change consult manufacturer for further testing/recommendations ABB Brazil JCM A Power de abril de Products 2015 Slide Division 34

35 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 35

36 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 ABB Brazil JCM A Power de abril de Products 2015 Slide Division 36

37 Renewables Energy and Transformers Applications Life Cycle Performance, Reliability and Failure Modes ABB Brazil JCM A Power de abril de Products 2015 Slide Division 37

38 Life Cycle and Failure Mode load, MVA Collector Transf TR03 l Load Factor, ONAF2, pu Power Factor, pu daily load variation WFarm Coll Tr01 WFarm Coll Tr02 WFarm Coll Tr03 oil and insulation moisture oil gas saturation voltage over-excitation oil, core, winding temperature reduction actions drying insulation degassing oil WTG voltage control Transf TAPS adjustments oil & insulation condition monitoring by a Hydran M2 Replace Motor Fans D800 Temperature Controlled ABB Brazil JCM A Power de abril de Products 2015 Slide Division 38

39 Life Cycle and Failure Mode Dielectric Inter-Turn Insulation Failure of LV Winding reduced inter-turn insulation strength (withstand) oil gas saturation oil and insulation moisture daily load variation voltage over-excitation ABB Brazil JCM A Power de abril de Products 2015 Slide Division 39 dissolved gas in oil free gas bubbles at load changes reduced PD inception voltage reduced Insulation Breakdown Voltage free-water formation at reduced temperatures free water vapor bubbles at load changes oil and insulation oxidation increased oil conductivity water droplets in the oil reduced PD inception voltage reduced Insulation Breakdown Voltage winding temperature fast reduction oil temperature slow reduction 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 Insulation Breakdown Voltage magnetic core saturation high harmonics saturated flux outside the core overheating and metal hot-spots oil gassing water formation oxidation oil/insulation moisture increasing low-energy PD free water bubbles water droplets reduced breakdown voltage Dielectric Inter-Turn Insulation Failure

40 Life Cycle and Failure Mode water in oil insulation residual moisture at factory entry during factory preparation for shipment entry during transportation moisture condensation over long time storage moisture condensation in accessories (conservator shipped/storage not pressurized) entry during site assembly short-vacuum time at site after long time storage core/winding/insulation heating in operation water in insulation insulation residual moisture at factory entry during factory preparation for shipment entry during transportation moisture condensation over long time storage entry during site assembly short-vacuum time at site after long time storage core/winding/insulation heating in operation oil gas saturation long time storage high N2 content trapped in insulation oil gassing from heated core/winding/metal parts water and/or moisture vapor oil/insulation oxidation (ñco2) short-vacuum time at site after long time storage oil and core high temperatures fans may be OFF due controls high settings high core and windings hot-spots temperatures ABB Brazil JCM A Power de abril de Products 2015 Slide Division 40 Environment and Conditions environment long time storage under N2 Nitrogen: long time under N2 with in-tank gas variable pressure (not automatic gas injection system) site assembly: standard final processing standard vacuum time even after a long time storage long time storage: oil filled insulation conditioning: oil samples and tests only 2 months before oil/insulation not conditioned to energization energization: voltage control during a Wind Farm start-up connection to a strong HV power system WTG GSU and collector transf tap settings over-excitation transformer designed according to the specification no-load excitation very low margin full-load excitation very low margin motor-fans OFF due to control with high temperature settings keeping long time storage under N2 with in-tank gas variable pressure (no-automatic injection system)

41 Renewables Energy and Transformers Applications Life Cycle - Operation Monitoring Optimization ABB Brazil JCM A Power de abril de Products 2015 Slide Division 41

42 Life Cycle and Operation Optmization Monitoring On-Line Monitoring and Sensors: load current & voltage ambient temperature top-oil temperature winding hotspot temperature moisture in oil/solid insulation gas in oil H2, CO, C2H4, C2H2 (Hydran) HV OIP cond bushings C1 & tand Minimum Sensors üs üs üs üs üs üs!! ABB TEC ABB Brazil JCM A Power de abril de Products 2015 Slide Division 42

43 Renewables Energy and Transformers Applications Life Cycle Advanced Asset Managment ABB Brazil JCM A Power de abril de Products 2015 Slide Division 43

44 Life Cycle and Operation Optmization Advanced Asset Management Data Analysis Action EAM Mobile ERP ALGORITHMS Sensors SCADA Historiador Centralized Information Data Storage Data Management Data Protection ABB Methods Data Mining Condition Assessment Models failure risk asset condition Strategic Decisions Maintenance Plan Later Maintenance Replacement ABB Brazil JCM A Power de abril de Products 2015 Slide Division 44

45 Life Cycle and Operation Optmization Advanced Asset Management Advanced Operational BI Data Processing and Analytics Engineering Workbench Complete Information Fleet to Equipment Health Actionable Notifications Business Process Workflow Optimization &Planning Subject Matter Workbench Enterprise Data Sources Enterprise Asset and Work Management ABB Brazil JCM A Power de abril de Products 2015 Slide Division 45

46 Life Cycle and Operation Optmization Advanced Asset Management - Potential Benefits ABB Brazil JCM A Power de abril de Products 2015 Slide Division 46

47 Life Cycle and Operation Optmization Advanced Asset Management - Monitor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 47

48 Life Cycle and Operation Optmization Advanced Asset Management - Monitor ABB Brazil JCM A Power de abril de Products 2015 Slide Division 48

49 Life Cycle and Operation Optmization Advanced Asset Management Maintenance Planning ABB Brazil JCM A Power de abril de Products 2015 Slide Division 49

50 Renewables Energy and Transformers Applications Conclusions ABB Brazil JCM A Power de abril de Products 2015 Slide Division 50

51 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 Chile and SAM up to 2018 will be 20% and in will be 30% of power source in Chile 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: environmental friendly advanced technology application long useful life minimum 30 years high reliability and availability at minimum maintenance intelligent monitoring and advanced asset management optimum overall life cycle demand for a partner with a solid and experienced technology ABB Brazil JCM A Power de abril de Products 2015 Slide Division 51

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