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Tutorial
TomBreckenridge
WGA236
WhyProcurement?
Scope:Design,construction,manufactureandoperation
forallkindsofpowertransformers,includingindustrial,DC
convertersandphaseshifttransformersandforalltypesof
reactorsandtransformercomponents(bushing,tap
changer)
Today,thetwoStrategicDirectionsforA2 futureactivitiesare:
ServicestoCustomers(Reliability,Lifemanagement,
Economics,Tutorials,...)
TechnologyIssues(Safety,NewtechnologiesandNew
concepts,Electricalenvironment,Prestandardisationwork,...)
Scope
Design,construction,manufacture thesearekeypartsof
theprocurementprocess
Gooddecisionsmadehereimpactonfuturelife
experiences
Baddecisionsmadehereleadtoserviceproblemsorearly
failure
ServicestoCustomers
LifeManagementbeginsatconceptionthroughdesignand
manufacturer itdoesntstartwhenthetransformeris
commissioned
Futurereliabilityisdeterminedatthepurchasestage
Economicsoftransformeroperationisheavilyinfluenced
bypurchasecostandtheunderlyingdesign
Notsimplytheactofpurchasingatransformer
Decisionsmadeintheprocurementprocessaffect
Thefutureoperatingcostsofthetransformer
Thefuturereliabilityofthetransformer
Thelifeexpectancyofthetransformer
Caninfluenceoverallsystemperformance
Howcanprocurementbeorganisedtomaximisethe
assetvalueatminimalcosts?
Howcanthepurchaserensureafitforuseproductis
theendresult?
Lossofexperienceinpurchaserscouldleadto
inferiorproductsbeingsourcedthroughignorance
Pressureonassetcostsfrompurchasingmanagers
Pressureonassetperformancefromoperations
managers
Balanceofincreasingcostswithdesiretoreduce
purchaseprice
Purchasersneedtorelymoreheavilyonexternal
agencies
ThreenewCigr TechnicalBrochuresprovidesupport
andguidanceinthiscriticalarea.
TB528 GuideforthePreparationofSpecificationsfor
PowerTransformers
TB529 GuidelinesforConductingDesignReviewsfor
PowerTransformers
TB530 GuideforConductingFactoryCapability
AssessmentforPowerTransformer
Warning! Theseguidesdonotcoverallaspectsof
transformerprocurement
Whathasbeenprepared?
Arevisedversionofthepreviousspecificationguide
TB156
Thenewguidebuildsonthepreviousguideand
enhancesitinmanyareaswhereexperienceshows
additionalinformationisnecessary
Thepreviousguidewasconsideredtobestillavalid
andgooddocumentpriortotheupdate
Thenewguideremovesthevoltageandratedpower
limitsasitisapplicableonamorewidespreadbasis
Whatisthemainpurposeofaspecification?
ShouldbeusedtoprovideinformationtoTenderers
on;
Whatisrequiredintermsofthekeyparametersofthe
transformer,e.g.Ratedvoltage,currentandpower;
impedance,tappingrange,losses,noiseetc.
Howthepurchaserwouldlikethistolookintermsof
constructionstyle,generalarrangement
Anylimitationsinthedesignandmanufacturingapproach
whichthepurchaserthinksisnecessary
Anyotheraspectsofthemanufacture,deliveryand
installationthatmayneedtobeadvised
Whatisthemainpurposeofaspecification?
Shouldalsobeusedtoobtaininformationon;
Thetechnicalparametersofthetransformerbeingoffered
bythesupplier
Thetypeofancillaryequipmenttobefittedbythe
supplier,e.g.Tapchanger,bushings,oil,coolersetc.
Anyareaswherethesuppliercannotmeetthespecified
requirements,i.e.wherethesupplierdeemshisoffertobe
noncompliantforanyreason
Butthereareoftenissuesofmisunderstandingor
evenmajorerrorsinmanyspecifications
Whyisthis?
Whatisaspecification?
ASpecificationdetailswhatistobedoneandhow.
Itspecifiesapplicablestandards.
Orisit:
Anaccumulationofbadexperiencederivedfrom
manufactureandserviceperformance.........
TooPrescriptive
Constraintson
Innovation
Constraintson
Manufacturing
LessCompetitive
FunctionalSpecifications
Keepitsimple
Minimisesinputatspecificationtime
Shiftsrisktothesupplier
PutstheCustomerinthedrivingseat
Ordoesit?
Istheexperienceavailable?
Procurement&PurchasingChallenges
GlobalMarketPlace
LowestCost>Bestvalueformoney?
Whatisthelowestcost?>Lowestcapitalcostor
lowestlifetimecost
Whatisthepurposeofthespecification?Isit:
Toprescribetothemanufacturerexactlywhattomake&
howtosetaboutmakingit?
Toconfusethetransformersuppliersuchthattheyhaveto
takeabestguessonwhatisrequired?
Totrickthetransformersupplierintomissingsomething
thattheclientcanthenclaimtheyshouldhavebeenaware
ofbecauseitwasinthespecification?
Toprovideafunctionalframeworktoenablepotential
supplierstobidforatransformerwhichfulfilsthesystem
requirementsandinterfacerequirements?
Somespecificationsrecentlyreceived:
Theoneliner
Themultidocumentrefertothis,refertothat,refertothe
other
Thenevermissasinglenationalorinternationalstandard
and/orspecificationthatwayyoullneverhave
overlookedanything!
Thedusteddownblastfromthepast
Theperfectspecification?
Thespecificationisthekeystoneinthetechnical
understandingofanypotentialcontract,thereforeit
should:
Beclearandunambiguous
Usesimplelanguagewhichisdifficulttomisinterpret
Definelimitationsintermsofthedesigncriteria
Identifyinterfacepointsandrequirements
Recognisesitespecificrequirementswhen
possible
Thespecificationisthepurchasersopportunitytoget
therightequipmentwiththeminimumofproblems:
Enlistsupport
Technicalexperts
Manufacturers
Bepreparedtotearupexistingspecifications
Avoidmultitudesofpretenderquestionsbyarrivingata
clearspecification
CheckTenderers understandingandofferswithpost
tendermeetings dontassume
Bepreparedtorobustlydefendaspecification
Theguideisstructuredinamannerthatcouldbeusedasthe
formatforapurchasespecification
Theguideprovideslistsofitemsthatneedtobeconsideredin
eachsectionanddiscusseskeypoints
Theguideincludesasuggested/recommendedsetof
schedulesforinclusioninaspecificationfortheTenderer to
complete
Thecomplexityofthespecificationneedstotakeintoaccount
thecriticalityoftheapplicationandanyunusualaspects
Thereisaneedforadegreeofexpertinputtoany
specificationproducedbytheguideinordertofullyensure
theunitprocuredissuitablefortheintendedpurpose.
Followtheguideandyouwillendupwithagood
specification,but
Needtoensurethatthelevelofdetailincludedinyour
specificationisconsistentwithyourrequirements
Needtounderstandthetechnicalissuesinsomeareasto
beabletocorrectlyspecifyforit whattheguidedoesis
drawsattentiontothearea
Theguidecannotcovereveryeventualityandifthereis
anyuncertaintyaboutanyaspectthenseekadditional
assistance
Whathasbeenprepared?
Amuchmoredetaileddesignreviewguidebasedon
theworkdoneinproducingTB407 HVDCconverter
transformers guidelinesfordesignreview
Thenewguidewillhelpimprovethequalityofdesign
reviewscarriedoutinthefuture
Thisinturnshouldmeanbettermorereliable
transformersarecommissioned
Ajointreviewoftheproposeddesignoftransformer
betweenthemanufacturerandthepurchaserto:
Assesscompliancewithspecificationsandstandards
Understandqualityissues
Ensurebothsidesagreeonwhatisbeingsupplied
Guidesuggeststhatitshouldbeconvenedandchairedby
thePurchaser,buttheremaybetimeswhenthismayneed
tobemanufacturerled
Shouldbeheldatthemanufacturersfactory
Seenbysomeutilitymanagersasawasteoftime
Commentsarisesuchas:
Doyoureallyneedtodothis?
Canttheycometoouroffice?
Youdonthavethetimetodothis,Ineedxxxdoneinstead
Somesupplierstrytorequestdesignreviewsbut
nevermanagetosucceed.
Manufacturersometimeshastoguesswhatthecustomer
reallymeansinthespecification
Designreviewhelpsbothmanufacturerand
purchaser
1. Toensurethatthereisaclearandmutualunderstandingofthe
technicalrequirements
2. Toverifythesystemandprojectrequirementsasperspecification
andtoindicateareaswherespecialattentionmayberequired
3. Toverifythatthedesigncomplieswithtechnicalrequirements
4. Toidentifyanyprototypefeaturesandevaluatetheirreliabilityand
risks
5. Toidentifyrelevantdesignmarginsvs thetestrequirementsand
thedesignmarginspossiblesignificanceforthelifetime
performanceofthetransformer.Toidentifypossiblebetterments.
Toverifythatthedesigncomplieswiththetechnical
requirements
Toidentifyanyprototypefeaturesandevaluatetheir
reliabilityandrisks
Tointerchangeexperiencesthatcanbeusedtoidentify
eventualbettermentsinthedesignand,orimprovementsand
changesinthespecification
Forpurchasertobetterunderstandthetechnicalcapabilities
ofthemanufacturer
Toensuresupplierhasfullyandcorrectlyunderstoodthe
customerrequirements
Toensurethecustomerfullyunderstandswhatthe
manufacturerintendstodobeforemanufacturing
commences
Todevelopunderstandingandenhancethecustomer/
supplierrelationship
Toagreehowthefinalacceptancetestswillbecarriedout
Thedesignreviewisthe mostimportantstepinensuringthe
finaltransformermeetstheoriginallydefinedrequirements.
Variousreviewscantakeplaceduringthecontractual
discussionperiod,bothbeforeoraftercontractaward
Afulldesignreviewisbestleftuntil:
Themanufacturerhascompletedthefulldesign,includingelectrical,
thermalandmechanicaldesigns
Themanufacturerhascompletedthedimensionaldrawingsandthe
ratingplatediagram
Butitshouldbedonebefore anykeymaterialandcomponentsare
ordered
Itmaybeusefultosplitthereviewintotwopartswhichmay
takeplacewithsometimebetween
Electricalreview toreviewthebasicdesignoftheactivepart
oftheunitintermsofdielectric,thermalandmechanical
designrules typeofbushings,OLTCpositioninthewindings
etc.Thisstagewillallowthepurchasertoorderthelonglead
timeitemsbeforethemechanicalreviewtakesplace.
Mechanicalreview toreviewthegeneralarrangementof
thetransformer,thetankandallancillarycomponentssuchas
coolers,fans,pumps,controlcabinets,pipeworketc.
Thereareanumberofissuesthatneedtobeclarifiedinorder
tofacilitateagooddesignreview
Protectionofintellectualpropertyandknowhow
Informationmadeavailableonaneedtoknowbasis
Confidentialityagreementsneeded?
Theguideliststhebasicissuesforallaspectsofthe
designthatneedtobeconsideredinareview
Guideincludesindicativescheduleswhichshouldform
thebasisofadesignreview
Eachpurchasershoulddevelophisowndesignreview
schedulesbasedontheexamplegiven
Complexityofthedesignreviewdependsonthe
criticalityandcostofthetransformerbeingprocured,
andonhowunusualthedesignis
Guideprovideslistsofitemsthatshouldbeconsideredin
anindepthdesignreview
Manufacturingplantassessments
Whathasbeenprepared?
Acomprehensivedocumenttoguideinexperienced
engineersthroughthecomplexprocessofassessing
thecapabilityofaspecificfactory
Tohelpfocustheengineeronthekeyissuesdependingon
hisspecificneedsandthefactorymethodsadopted
Toassistmanufacturersunderstandtheassessmentwhich
customersmaybeundertakingoftheirfactory
Whathasnot beenproduced?
Amethodologyofassessingandrankingfactoriesfor
publicationtosupport/enhanceexistingISOaccreditation
Theguidecouldbeusedasthebasisforsomeformof
independentthirdpartyassessmentsystem,butthiswill
requirealotmorework whoshoulddothis?
Itisalsomuchmorecontroversial!
ItisconsideredthatthisissomethingthatCigr willnot
wanttoundertakeasitisoutsidescopeofCigr
AgendaofCapabilitySection
Introduction whyisitsodifficulttofindasupplier?
WhentoInspect?
HowtoInspect?
Whattolookfor? outlineofCigr TB530
Conclusions
ThreeoutoffourlargetransformerfactoriesinUKclose200203.
InvitedTenders/FrameWorkAgreements
Besttimeforinspectionisprobablyaspartoftheprequalification
process,beforetheinvitationtender/finalnegotiationsconcerning
theframeworkagreement.
ReQualification
Thesituationwillchangeintimeandtheusermayneedtore
evaluatemanufacturerstoseethattheyarestillabletomeettheir
needs.
ItisimportantthatthisManageris:
Suitablyqualifiedandexperienced(engineeringgraduateor
equivalent,registeredprofessionalengineer)
Dedicated(theroleistooimportanttocombinewiththatof
engineeringorproductionmanager)
Permanent(theroleistooimportantforasixmonth
secondment)
Respected(sitsonmainmanagementboard)
Doesthemanufacturingplantenjoyharmonious,
longtermrelationshipswiththeirmainsuppliers?
Ordotheysimplyprocuretheirmaterialsona
spotmarketbasis?
Ingeneral,thesecanbegroupedintothreeareas:
Cleanliness
Organisation
BuildQuality
Everythingelsefollowsfromthesethree........
Iftheycanttestit,..theycantmanufactureit!
Ifthefactorydoesnotcareaboutitsemployees,doesitcare
aboutthequalityofyourtransformer?
TransformerProcurementProcess TutorialSession11th September2013Zurich
Whattolookfor transport
Oncethetransformerhaspassedtest,itneedstobemoved
fromthefactorytotheuserssite.Needtoenquirewhich
transportmethodsareavailableandwhetheranyparticular
limitsonmassordimensionsapply.
Oncethetransformerhasreachedsite,
itneedstobeinstalled.Needto
enquirehowthemanufacturewould
dothis.
Ifthemanufacturerisunfamiliarwith
workinginthecountrywherethe
transformeristobeinstalledthenit
mightbebetteriftheyusedareliable
localpartnerforsomeorallofthe
work.
AspartoftheirISO9000complianceprocess,most
manufacturerscompileoverallperformancestatistics.
Transformerusersmaybeparticularlyinterestedinthe
following:
Testfailurerate
Servicefailurerate(orpossiblerateofwarrantyclaims)
Ontimedeliveryrate
Notes:
Differentmanufacturersmaynotcompilethesestatistics
onthesamebasis.
Thereisnoclearconsensusonwhatconstitutesafailure
ThenewCIGRTB530shouldbeabigstepforwardforthe
industry,improvingthequalityofmanufacturersandallowing
userstogetbestvaluefortheirmoney.