POWER TRANSFORMER SOLUTION

By y Didik Susilo Widianto / UTR Technical General Manager g ENGINEERING DESIGN WORKSHOP ALSTOM GRID INDONESIA AND PLN SUAR 9th 10th November 2011 Samosir Resort, Samosir North Sumatra

GRID

ALSTOM Technology Center

ALSTOM Global Power Transformer Manufacturers

TST UK MMC C d Canada AGM Germany ATT Turkey

Technical Int.Center France

AST China UTR I d Indonesia i

TCT Brazil

TFR Australia PTI India

Group Highlight experience : Power transformer Reactors

Presentation title - 01/01/2010 - P 3

: 2250 MVA, 1200 kVAC, 800 kVDC : 125 MVAR , 765 kV

Furnace transformer : 200 MVA, 260 kAmp

1100 MVA 525 kV in Germany

Presentation title - 01/01/2010 - P 4

Shunt Reactor 100 MVAR 765 kV

Presentation title - 01/01/2010 - P 5

ALSTOM GRID - HVDC global reference (up to 800 kVDC)

Presentation title - 01/01/2010 - P 6

Mechanical Standardization

Organization - Standardization
PTR R&D
Standardization Director
Design, Quality & Cost Product Center N
M Manager Electrical Design Mechanical Design Industrial Rules

PTR Industrial

H
M Manager Electrical Design Mechanical Design Industrial Rules

S
M Manager Electrical Design Mechanical Design Industrial Rules

R
M Manager Electrical Design Mechanical Design Industrial Rules

Roll out of rules & tools (range specific)

Unit 1

...

Unit N

Mechanical Standardization covering best practices

1200 1200

kV

220 300

H-Range N Range N-Range

150

E-Range
25 75 2500

MVA

Presentation title - 01/01/2010 - P 9

H Design = ROBUST up to 5G
CORE STEEL BANDAGES

TOP PIN & CUP ANCHORING

BOTTOM ACTIVE PARTS PIN & CUP ANCHORING

10

H Range Concept (experienced up to 1100 MVA)

ALSTO ALST OM - UK practice 11

SEISMIC ANALYSIS UP TO 5G
Cooperation with ITB, oldest technical institute in Indonesia. Contact person ; Prof. Dr. Komang Bagiasna Analysis ; Static & Dynamic Experiences; 2008 ; CHILEAN LNG (50 MVA) 2009 ; QAFCO Middle East (50 MVA 82 MVA ONAN = 13 units)

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SEISMIC PROOF transformer

13

Reactor Clamping system

Core clamping

Design with inner tie rods

3phaseshuntreactors 060411.ppt, 04/04/2011 - P 14

Design with outer tie rods

Furnace Transformers
Electrolysis Industry
Zinc, Copper, Chlorine)

=> Rectifier Transformers (Aluminium,

Chemical, Oil&Gas Industry => Converter Transformers

Steel Industry

=> Electrical Arc Furnace (EAF)Transformers

Presentation title - 01/01/2010 - P 15

EHV analysis & winding

16

Intershield Disc Winding Technology Research

In 2007 : To Tests Models ISDW With Few Turns/Disc With Results To Be Used As Input For The Design Of A Full Size 800 kV UHVDC ISDW Prototype

To Design With EDT&PD Team; To Build And To Test A Full Size 800 kV UHVDC ISDW Prototype
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FEM Analysis for Structure Validation Oil stress determination

Path B

Path C

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Typical Partial Discharge less than 50 pC at 150% Um (IEC 60076 < 500pC)

Presentation title - 01/01/2010 - P 19

Short Circuit Analysis

20

Mean Hoop Stress

dl

p
Leakage/ flux
e

S
Rav
e

S
X

2B B Rav

F Y

Buckling Stress

Tilting Stress

Clamping Structure
Clamping structure reactions
Rt= -F2,n Rt= 0 Rt= -(F1,n+ F2,n ) if F2,n > F1,n Rt= 0 if F1,n> F2,n Rt= -(F1,n -F2,n )

F2,n F2,n F2,n

F2,n

F2,n

F1,n

F1,n F1,n F1,n F1,n

Rb = -F1,n Rb = -(F1,n + F2,n)

Rb = 0

Rb= -(F2,n -F1,n )

Rb = 0

Clamping forces of reactions on each layer

Axial Clamping System

Applied Clamping Forces on the winding assembly must be more than

the axial force per phase & active part weight/3

Transformer with built in reactor

Limiting reactor

26

Short Circuit Forces Analysis

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Oil Directed Cooling

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Pumped Oil Directed Cooling

The winding is starved of oil il

Coil support block

Oil seal (diaphragm)

Base Trough

END VIEW

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ODAF Computer programs

L L A A Y Y D D D E E U U U R R C C C T T T 1 2 1 Outsid e stops Inside stops 2 3

The results screen will display the following parameters : 1. Individual winding labels 2. Horizontal oil speed for each winding in mm/ sec 3. The vertical duct oil speed at the inside and outside diameters of each winding in mm/ sec 4. The division of oil flow in Litres/ second for each individual winding 5. The oil speed in any restriction holes (if applicable) y displayed p y of the input p data to enable comparissons p when any y There is also a summary modifications are made and the calculation is re-run.
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ODAF Technology

Oil Viscosity Factors:

It can be seen from manufacturers data that the viscosity of the oil differs between oil types. This will have an impact upon the performance of the coolants performance and should be borne in mind when evaluating the calculations. Typical values are given below:
VISCOSITE DES HUILES MINERALES EN FONCTION DE LA TEMPERATURE
1600 ShelL DIALA F 1400 Esso UNIVOLT 52 Shell DIALA S Nynas 10 GBN Viscosit (cSt 1000

1200

800

600

400

200

0 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40

Temprature (C)

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INFRA RED to monitor the surface hot spot

Maximum < 125oC

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ODAF COOLING

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ODAF with AIR COOLER

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Moisture Evacuation and Stabilization

35

Transformer Parts
Oil Preservation

Winding

Cooler

Transformer Liquid

36

Moisture in Cellulose Material

The active part as heart of transformer is containing approximate i 25% cellulose ll l i insulation l i material. i l This cellulose Thi ll l material t i l will ill d drive i th the i insulation l ti structure of the transformer to strengthen the voltage g withstand up p to 100 times the air insulation voltage strength. Moisture in cellulose of winding conductor insulation is detected thru the water content in oil.
37

Equilibrium water content of paper vs oil

T2 air temperature (C)

T1 oil temperature (C)

20 30

rel. humidity (%)

T1
40

10 wate er content of f paper [%]

T2

10 50

20 50

10 100

30 50

20 100

30 100

50

60 70 80 90 100

20

40 water content of oil [ppm]

60

38

80

Oil Moisture Content vs. Dielectric Strength

Power Fre eq. Withsta and Voltag ge [%]

Moisture Content In Oil [pap]

Paper Moisture Content vs Dielectric Strength

Automatic Vacuum Vapor Phase Oven 9.5 x 5.5 x 5 m (L ( x W x H) )

300 kW heating, 125 oC, 0.025 mBar Automatic process under programmable computer Dew p point control ( (final ; less than -45oC) ) Water extraction (final ; less than 0.01 g/ton.h g/ton.h) )
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Vacuum Vapour Phase Schematic

42

ISO-Static pressure while the winding in the oven

Presentation title - 01/01/2010 - P 43

Manufacturing and Industrial

44

45

Bended Core type NO Core Bolts (In order to avoid hot spot due to magnetic discontinuity)

CHERRY PICKER Safety high installation Movable Equipment

47

AIR Cushion Movable Platform (SAFETY compliance)

48

TESTING LABORATORY 1600 kVp Full Wave Impulse, 1300 kV Switching Zero Flux Losses measurement S d proof f wall ll & Faraday d cage Magnetic i Shi ld Sound Shield

49

Materials & Sourcing

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Main Materials Sourcing

Core Magnetic (Frame agreement); M5X POSCO, Korea M0H POSCO - Korea Domain Refined Core AK Steel - UK, UK NIPPON Steel/JFE - Japan Rectangular Copper, CTC, TWIN (Frame agreement); ASTA, SHENYANG, SAMDONG. METROD Malaysia. Transformer oil (Frame agreement); NYNAS Insulation material; Pressboard = WEIDMANN Switzerland. Switzerland Crepe papers = WEIDMANN (22HCC). Bushings; Condenser type = PASSONI VILA Italy (Frame agreement). Solid Porcelain = WARCO USA, USA COMEM Italy. Italy Tank subcontractor (Frame agreement); HITACHI . SKAS SINISA. SINISA On Load Tap Changer (Frame agreement); MR Germany. ABB Sweden.
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SMS System & Supplier Assessments

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Supplier Feedback & Corrective Actions

Example p

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Tank Supplier Guidance Continuous Improvement Provide the SOP (Standard Operating Procedure) for supplier. supplier FAT (Final Acceptance Test) for oil leakage test & fittings

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Hydro pressure leakage test by tank supplier

Picture 2

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PAINTING typical Design Heavy Marine Corrosive Class

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Technology VISION & TRENDS

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Technology VISION & TREND

ECO design (CO2 reduction); Low noise & Low partial discharge Environmental Friendly SAFETY Precaution SMART grid ; EWS (Early Warning System) CBM (Conditioned Based Maintenance) Aging A i &F Failure il prevention ti Intranet Information Technology
On Line Partial Discharge (UHF or Ultra Ultra-sonic method) On Line Gas Monitoring. On Line Hot Spot Temperature Monitoring. Tap Changer Behaviour Monitoring
58

Safety Harness Attachment Points

59

ERGONOMIC Design

Elevated Oil level Indicator

60

CO2 reduction Programs WATER Based Paints (Under Research - year 2012 target)

61

EcoEco -Design/vegetable g g oil transformer

Description
Environmentally friendly transformers and reactors filled with vegetable oil
Vegetable oil totally biodegradable , with higher fire point than mineral oil (envirotempFR3 oil from COOPER) Existing experiences : transformers and reactors up to 300kV.

62

Future Environmental Friendly Liquid

Environmental liquid Inhibited I hibit d oil il Property typical values Antioxidant, phenols Oxidation stability by 120oC Biodegradable in 21 days Saturated moisture at 25oC Temp. rise for unity life time *) Fl h point Flash i t Pour point = Enviro-Temp FR3 by COOPER = Gemini-X G i i X by b NYNAS Inhibited oil 0.08% per Wt 500 hours 25% 80 ppm 60/65/78 K 145oC -57oC FR3 n.a. continuous 100% 1200 ppm 80/110/130 K 330oC -18oC

Liquid Water Absorption versus Time Exposure

Water Absorption of Dielectric Fluids Exposed to Ambient Air (2 of 2)
100

R e la tiv e W a te r C o n te n t ( % s a tu ra tio n )

80

Envirotemp FR3 fluid conventional transformer oil

60

Water Absorption of Dielectric Fluids Exposed to Ambient Air (1 of 2)

600

40

20

Absolut te Water Content (p ppm)

500

400

0 0 500 1000 1500 2000 2500 3000 3500

300 Envirotemp FR3 fluid conventional transformer oil

Exposure Time (hrs)

200

100

100% Saturation S t ti = FR3, 1200 ppm Mineral Oil, 80 ppm

500

1000

1500

2000

2500

3000

3500

Exposure Time (hrs)

Liquid Dielectric Strength vs. Water Content

Dielectric Strength versus Water Content
80 70 60 50 40 30 20 10 0 0 100 200 300 400 500 600 Envirotemp FR3 fluid conventional ti lt transformer f oil il

D 18 816 Dielectric c Breakdown (kV)

Water Content (ppm)

GREEN Transformer
(Environmental Friendly Oil Filed Transformer)

Presentation title - 01/01/2010 - P 66

Hermetical Power Transformer

Description
N or H range power transformers hermetically sealed No oil conservator radiators with expansion capacity Special p p p y Rated power from 10 to above 100MVA Voltage level up to 245kV transfomers with Low maintenance & longer service life

Key Countries / Customers GERMANY and EUROPE/ NME, SEA, PACIFIC /customer /customer with life cycle cost concerns concerns, , who values low maintenance (utilities, railways) railways) Key Competitors Competitors Product No competition known with same product Conventional transformers of all manufacturer
Milestones 2000:Technology gy developed p in Germany y together g with radiator supplier pp 2006:Design tools and rules made available to all PTR units 2006:New Product brochure +3D model for promotion in fair 67

Noise Reduction Research

Active part interface

Careenage for double wall effect

Tank pads

Solution needed for demonstrator

Stiffeners

Double walled tank bottom

68

On Line Monitoring System

Module Main Operating Voltage (1 phase) Load Current (1 phase) pp Power and Load Factor Apparent Oil Temperature Hot-Spot Temperature Gas-in-Oil Content Moisture-in-Oil Content Ageing g g Rate On-load Tap Changer Position Number of Switching Operations Sum of Switched Load Current Operating Condition of Pumps and Fans Operating Time of Pumps and Fans Cooling Efficiency (Rth) Ambient Temperature Auxilary digital inputs Module Insulation Gas-in-oil Gradient Moisture of Paper Bubbling Temperature and Safety Margin Lifetime Consumption Predicted top oil temperature Predicted hot spot temperature breakdown voltage  Module Bushings Operating voltages (3 phases) Overvoltages, number of overvoltages Change of capacitance, online capacitance

 Module Tap Changer Power consumption of the motor drive OLTC oil temperature Assessment of mechanical quality Contact wear model Oil temperature difference OLTC / tank

 Module Overload Load currents (3 phases) Overcurrents and short circuit currents Number of overcurrents Overload capacity Emergency overloading time Thermal model Actual losses

Real-Time On Line Monitoring System

MS 3000
Office PC FAX
ALARM

Intranet / Internet

TCP/IP (Ethernet) Protocols, e. g. IEC 60870-5101, -104, DNP3.0, IEC61850, Modbus Point to Point, e. g. 0/4 .. 20 mA, Dig.

Telephone Transformer Antenna: GSM Modem Laptop TCP/IP or RS232

Protection & Control

Monitoring Module incl. Server Module

Industrial PC without fans, moving parts (flashmemory)

Real Hot Spot Fiber Optic Measurement

Interbus Transformer Solution

72

Three covering supplies Interbus Transformer

275 kV
A t transformer Auto t f 275 kV WYE 150 kV WYE

150 kV

20 kV DELTA Grounding transformer

275/150 kV Interbus Transformer with loadable tertiary (20 kV)

20 kV

Conventional vs Autotransformer

I1, I2

= Current primary (1) & secondary (2)

V1, V2 = Voltage primary (1) & secondary (2) Common Winding = N1 x (I1 I2)
Presentation title - 01/01/2010 - P 74

Seri Winding = (N2 N1) x I2

Comparison between Autotransformer vs Conventional

Presentation title - 01/01/2010 - P 75

Vacuum Interrupter - OLTC

Free maintenance for 300000 operation

Conclusion
1. For primary voltage : secondary voltage in ratio of 2 : 1 such as this inter bus 275/150 kV, , the autotransformer is the best solution. 2. At new a days, OLTC with vacuum interrupter technology is available. il bl This Thi will ill b be b best t choice h i t to reduce d th the maintenance i t f for especially oil treatment in the tap changer compartment. 3 For in case tertiary winding will be loaded, 3. loaded the impedance between tertiary and other winding shall not be small (e.g minimum 5% at tertiary rated capacity) to consider worst three phases short circuit withstand. withstand 4. For in case tertiary winding will be loaded, a grounding q to p provide artificial g grounding g on the transformer is required DELTA connection of tertiary winding.
Presentation title - 01/01/2010 - P 77

UTR High Lighted project experiences

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CANADA : ARCTIC remote area transformer

Special tank & support steel suitable for -50oC temperature

Presentation title - 01/01/2010 - P 79

CANADA : Stainless steel radiator for arctic + high corrosive

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POSO ENERGY 80 MVA & 90 MVA 275 kV

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Export to Phillipines 100 MVA 230kV

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PHILIPINES : 2 x Interbus Transformer 100 MVA 230/115kV

Equipped with on line monitoring EARLY WARNING system MS3000

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MYANMAR : 3 x 33.3 MVA 1 PH 230kV

Equipped with built in short circuit limiting reactor

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THANKS

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www.alstom.com