SANTIAGO CL Jornadas Técnicas 2015 2015Abr14&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 email: jose-carlos.mendes@br.abb.com tel: + 55 11 2464 8410 cel: + 55 11 9 8354 5358 + 55 11 9 8112 7575 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
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
Context Renewables Energy Content Content q q q q introduction buying by performance to a long life useful life and maintenance globsl rvslustion index transfomer design optimization overview aspects to consider multi-parameter optimization losses evaluation overview losses components losses capitalisation principle impact on materials examples evaluation conclusions ABB Brazil JCM A-3 14 Power de abril de Products 2015 Slide Division 3
Life Cycle Optimization ABB Brazil JCM A-4 14 Power de abril de Products 2015 Slide Division 4
Life Cycle and Global Evaluation of Alternatives 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-5 14 Power de abril de Products 2015 Slide Division 5
Life Cycle and Global Evaluation of Alternatives Power Transformer Transformer core windings connections 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-6 14 Power de abril de Products 2015 Slide Division 6
Life Cycle and Global Evaluation of Alternatives 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 optimization no load losses optimization load losses optimization characteristics optimization performance (thermal, loading, shortcircuit, etc) optimization transportation limits interchandability transformer optimization strategies: Total Initial Cost Losses Cost Total Operational Cost Life Cycle Total Cost ABB Brazil JCM A-7 14 Power de abril de Products 2015 Slide Division 7 Power Transformer Design Optimization Tecnologia
Life Cycle and Global Evaluation of Alternatives Power Equipment Performance Equalization value, $ manufacturing value, $ manufacturing + losses manufacturing losses transformer mass, kg Manufacturing Cost: material labor over-heads losses 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 Losses Capitalisation Cost, $/kw maximum to pay to reduce transformer losses by 1 kw ABB Brazil JCM A-8 14 Power de abril de Products 2015 Slide Division 8
Life Cycle and Global Evaluation of Alternatives 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% 3100 4650 6200 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 ABB Brazil JCM A-9 14 Power de abril de Products 2015 Slide Division 9
Life Cycle and Global Evaluation of Alternatives 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-10 14 Power de abril de Products 2015 Slide Division 10
Specifications of energy efficient transformers Losses in transformers have always been considered as important For efficiency For safe and reliable operation Transformers are purchased with future losses taken into account By including losses in comparison value Net present value of NoLoad losses Net present value of Load losses By requiring maximum loss values (< kw) Comparison value is sum of unit + future losses NoLoad loss $/kw Load losses $/KW ABB Brazil JCM A-11 14 Power de abril de Products 2015 Slide Division 11
Net present value of future losses 200 180 160 140 120 100 80 60 40 20 0 NPV of loss per year, Loss per year, 5 10 15 20 25 30 Energy value 0,02 /kwh, 8600 h/yr, Assume 12% investment interest rate è 1550 /kw ABB Brazil JCM A-12 14 Power de abril de Products 2015 Slide Division 12
Net present value of future losses 200 180 160 140 120 100 80 60 40 20 0 NPV of loss per year, Loss per year, 5 10 15 20 25 30 Energy value 0,02 /kwh, 8600 h/yr, Assume 8% investment interest rate è 2100 /kw ABB Brazil JCM A-13 14 Power de abril de Products 2015 Slide Division 13
Net present value of future losses 450 400 350 300 250 200 150 100 50 0 NPV of loss per year, Loss per year, 5 10 15 20 25 30 Energy value 0,02 /kwh, 8600 h/yr, Assume 3% energy value increase/yr Assume 11% investment interest è 2100 /kw ABB Brazil JCM A-14 14 Power de abril de Products 2015 Slide Division 14
Loss Evaluations values Example: 1 kw losses in 30 years 8600 hours per year Interest rate 0.02 /kwh 0.03 /kwh 0.04 /kwh 4% 3100 4650 6200 8% 2100 3150 4200 12% 1550 2300 3100 Examples above are for No Load losses (=8600 h/yr) Load Loss evaluations depend on load profile per day, months etc and are therefore a varying % of the full year value Stable values in customer specifications recently ABB Brazil JCM A-15 14 Power de abril de Products 2015 Slide Division 15
Specifications for low loss power transformers Net present value of future losses Assumed value of energy losses during lifetime Interest rate to calculate present value Values translated into Value of NoLoad loss $/KW Value of Load losses $/KW Loss evaluations are key part of specifications Actual values reflect future energy price expectations Interest value chosen determines time horizon Loss evaluations in specifcations have been relatively stable in recent years ABB Brazil JCM A-16 14 Power de abril de Products 2015 Slide Division 16
How are losses affected by materials s? LME COPPER PRICES 2002-2007 8,400 7,400 USD/MT 6,400 5,400 4,400 3,400 2,400 1,400 May-07 Mar-07 Jan-07 Nov-06 Sep-06 Jul-06 May-06 Mar-06 Jan-06 Nov-05 Sep-05 Jul-05 May-05 Mar-05 Jan-05 Nov-04 Sep-04 Jul-04 May-04 Mar-04 Jan-04 Nov-03 Sep-03 Jul-03 May-03 Mar-03 Jan-03 Nov-02 Sep-02 Jul-02 May-02 Mar-02 Jan-02 Material s have increased 3-5 times recently! How does this affect losses? Where is industry going? ABB Brazil JCM A-17 14 Power de abril de Products 2015 Slide Division 17
Losses versus material content in transformers Load Loss Total load losses decrease with increasing conductor mass NoLoad Loss Conductor mass Total NoLoad losses decrease with increasing core material mass Core mass ABB Brazil JCM A-18 14 Power de abril de Products 2015 Slide Division 18 Basic laws of physics, cannot be disregarded
Transformer versus material content Load loss & Material Conductor mass Conductor s increase with increasing conductor mass NoLoad loss & Material Core s increase with increasing core material mass Core mass ABB Brazil JCM A-19 14 Power de abril de Products 2015 Slide Division 19 Total material increases with more material
Evaluated versus material content Costs Total evaluated Transformer Evaluated loss Core + conductor mass ABB Brazil JCM A-20 14 Power de abril de Products 2015 Slide Division 20 Evaluated has a flat minimum Trafo loss depends critically on loss evaluation values
Evaluated versus material content Costs Total evaluated Transformer Evaluated loss Core + conductor mass Higher loss evaluation è Lower loss transformer ABB Brazil JCM A-21 14 Power de abril de Products 2015 Slide Division 21
Evaluated versus material content Costs Total evaluated Transformer Evaluated loss Core + conductor mass ABB Brazil JCM A-22 14 Power de abril de Products 2015 Slide Division 22 Evaluated has a flat minimum Trafo loss depends critically on loss evaluation values
Evaluated versus material content Costs Total evaluated Transformer Evaluated loss minimum Higher materials prices è Higher loss transformer ABB Brazil JCM A-23 14 Power de abril de Products 2015 Slide Division 23
Conclusions: Losses vs Costs of power transformers Losses are primarily defined by the relation between materials s and loss evaluations In recent years key materials s have increased by a factor of 3 to 5 times Loss evaluations have changed very little è è Increased s of transformers Risk for increased losses in transformers Loss evaluations determined by Interest rate chosen for investment Expected future energy prices What are future expectations? Energy efficiency specifications needed ABB Brazil JCM A-24 14 Power de abril de Products 2015 Slide Division 24
Qualitative discussion of materials utilization Optimum material utilization with normal loss evaluation and high material prices Material utilization 100% Optimum material utilization with normal loss evaluation and material prices Technical limit of Flux density Current density Acoustic emissions Mechanical stresses low normal Loss evaluation high ABB Brazil JCM A-25 14 Power de abril de Products 2015 Slide Division 25