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Fleet Strategy
Table of Contents
EXECUTIVE SUMMARY ...................................................................................................................... 4
SUMMARY OF STRATEGIES .............................................................................................................. 7
1 INTRODUCTION ....................................................................................................................... 8
1.1 Purpose ................................................................................................................................. 8
1.2 Scope .................................................................................................................................... 8
1.3 Stakeholders ......................................................................................................................... 8
1.4 Strategic Alignment ............................................................................................................... 8
1.5 Document Structure .............................................................................................................. 9
2 ASSET FLEET ........................................................................................................................ 10
2.1 Asset Statistics .................................................................................................................... 10
2.2 Asset Characteristics .......................................................................................................... 14
2.3 Asset Performance .............................................................................................................. 26
3 OBJECTIVES .......................................................................................................................... 39
3.1 Safety .................................................................................................................................. 39
3.2 Service Performance ........................................................................................................... 39
3.3 Cost Performance ............................................................................................................... 40
3.4 New Zealand Communities ................................................................................................. 40
3.5 Asset Management Capability ............................................................................................ 41
4 STRATEGIES.......................................................................................................................... 43
4.1 Planning .............................................................................................................................. 43
4.2 Delivery ............................................................................................................................... 51
4.3 Operation............................................................................................................................. 57
4.4 Maintenance ........................................................................................................................ 60
4.5 Preventive Maintenance ...................................................................................................... 60
4.6 Disposal and Divestment .................................................................................................... 67
4.7 Asset Management Capability ............................................................................................ 68
4.8 Summary of RCP2 Fleet Strategies .................................................................................... 72
APPENDICES ..................................................................................................................................... 74
A POWER TRANSFORMER IMAGES ....................................................................................... 75
B ADDITIONAL COSTING INFORMATION ............................................................................... 76
C ADDITIONAL BENCHMARKING RESULTS .......................................................................... 77
D TRANSFORMER ASSET STRATEGY ECONOMIC ANALYSIS, 2010 ................................. 80
E POWER TRANSFORMER WINDING FAILURE HISTORY ................................................... 93
F HISTORIC TRANSFORMER ‘MID-LIFE’ OVERHAULS ......................................................... 96
EXECUTIVE SUMMARY
Introduction
Power transformers play an essential role within the transmission network by enabling the
transfer of energy between different voltage levels of the Grid. The performance of power
transformers is critical to maintaining reliability of supply to customers.
Our asset management approach for power transformers seeks to achieve a high level of
reliability for this essential equipment, to mitigate safety hazards and to achieve least whole-
of-life cost.
1
For the purposes of this population count, we classify a three-phase set of single-phase transformers as one
transformer bank.
SUMMARY OF STRATEGIES
The following summary lists the main strategy and its respective costs during the RCP2
period (2015–2020).
Our strategy is to replace 30 unreliable transformers with modern equivalents over the
RCP2 period. This includes the replacement of five transformers at Kinleith Substation as
part of a large-scale project at that site. The replacement programme for the
30 transformers has been prioritised taking into account asset health, criticality, the
coverage provided by national spares and the mobile substation, and integrated works
planning considerations.
The cost estimates for these transformer replacements have been developed using a
customised estimating process. The total forecast cost of the replacement programme
during RCP2 is $106.2m.
Chapter 4 has further detail on this strategy and a discussion of the remaining strategies.
1 INTRODUCTION
Chapter 1 introduces the purpose, scope, stakeholders, and strategic alignment of the power
transformer asset fleet strategy.
1.1 Purpose
The purpose of this strategy is to describe our approach to lifecycle management of our
power transformer asset fleet. This includes a description of the asset fleet, objectives for
future performance and strategies being adopted to achieve these objectives.
The strategy sets the high-level direction for fleet asset management activities across the
lifecycle of the asset fleet. These activities include Planning, Delivery, Operations, and
Maintenance.
This document has been developed based on good practice guidance from internationally
recognised sources, including BSI PAS 55:2008.
1.2 Scope
The scope of this asset strategy encompasses the fleet of supply and interconnector
transformers including single-phase and three-phase types. It excludes transformers in the
HVDC system, as their management is described in the HVDC Fleet Strategy.
1.3 Stakeholders
Power transformer assets are important components of the transmission system. Correct
operation and maintenance of these assets enables the reliable operation of the power
system. Key stakeholders for these assets include:
relevant Transpower Groups: Grid Development, Performance and Projects
regulatory bodies: Commerce Commission, Electricity Authority, and the
Environmental Protection Authority
customers, including distribution network businesses and industrial plants and
generators that are directly connected
local residents.
Lifecycle Strategies
Figure 1: The Power Transformer Asset Strategy within the Asset Management Hierarchy
2 ASSET FLEET
Chapter 2 provides a high-level description of the power transformer asset fleet, including:
Asset statistics: including population, diversity, age profile, and spares
Asset characteristics: including safety and environmental considerations, asset
criticality, asset condition, asset health, maintenance requirements and interaction
with other assets
Asset performance: including reliability, safety and environmental and risks and
issues.
The two main classes of power transformers considered in this fleet strategy are supply
transformers and interconnecting transformers.
Supply transformers: These transformers connect between the main
transmission/distribution network (220 kV or 110 kV or 66 kV) and supply networks
(33 kV, 22 kV or 11 kV).
Interconnecting transformers: These transformers interconnect between the main
transmission network (220 kV) and the regional transmission and sub-transmission
network (110 kV or 66 kV).
Our fleet of power transformers also includes small transformers that provide local service
and earthing functions. These small transformers are not given significant coverage in this
fleet strategy because they typically have only minor impact on overall service, and we have
spares that can be deployed promptly in the event of failure.2
Traction transformers (dedicated to supply KiwiRail) are not specifically covered in strategies
in this document, but are dealt with on a case-by-case basis. There are spares to cover the
traction transformer units in service.
2
The replacement of two aged local service transformers of unusual rating at Islington is planned during RCP2 as part of
a major upgrade of the local service supply system, as described in the Fleet Strategy – ACS Other.
As at June 2013, we have 355 ‘other’ transformers in service, including local service,
earthing, and regulators, as shown in Table 2.
66 kV &
Type 220 kV 110 kV Total
below
Local Service 2 0 213 215
Earthing 0 0 137 137
Regulators 0 0 3 3
Total 2 0 353 355
Table 2: Other power transformer fleet population
Power transformers
Our main system voltages are 220 kV, 110 kV, 66 kV, 50 kV, 33 kV, 22 kV and 11 kV. In
addition to these, there are a few other supply and local service voltages to suit particular
applications such as HVDC, SVCs, railway traction, distribution companies and industry
requirements. Figure 2 shows the diversity of our power transformers.
The transformer fleet originates from 57 different manufacturers and is highly diverse. Our
transformers are generally ‘bespoke’. Each unit was specified, designed and built to meet
site specific operational, seismic, and customer requirements. Only a very small number of
3
The voltages shown on the tables are the highest transformer voltage. We note that this may not necessarily mean that
it is the primary voltage of the transformer.
Tap changers
As mentioned above, our transformer fleet consists of a diverse range of makes and models.
Our fleet has about 200 different models and types of tap changers. Although many tap
changers are from broadly similar families, the diversity in the fleet presents significant
challenges for maintenance, as discussed further in subsection 2.3.4.
25
20
15
10
0
0 5 10 15 20 25 30 35 40 45 50 55 60+
AGE (YEARS)
The average age for the 132 banks of single-phase transformers is 51 years and 20 years for
the 211 three-phase transformers.
Table 3 illustrates the effect on the age profile of the transition from purchasing mainly
single-phase to purchasing mainly three-phase transformers during the 1970s. The table
shows the average age of different transformer types in the fleet and compares the number
Supply – three-phase 20 0 0%
2.1.4 Spares
Our contingency planning aims to respond promptly in the event of a transformer failure, to
minimise the risk that a further failure of a parallel transformer will lead to significant
interruptions of service for customers. Our objective is to restore full security within one
calendar month of a transformer failure occurring, as outlined in subsection 4.3.2. Achieving
this objective depends on the availability of spare transformers. The transformer spares
holdings are dominated by single-phase units, as set out in Table 4.
66 kV
Type 220 kV 110 kV Total
& below
Interconnecting: three-phase units 3 1 0 4
Interconnecting: single-phase units 13 1 0 14
Supply: three-phase units 4 5 3 12
Supply: single-phase units 11 52 9 72
Total 31 59 12 102
Table 4: Transformer spares by type and voltage
4
Fifty years in itself has no special significance, but it is close to the nominal life expectancy for power transformers
adopted in some jurisdictions.
Spares – bushings
A number of spare standard bushings have been purchased and are in store at Otahuhu,
Bunnythorpe and Addington. Yet many of these spares are not interchangeable between
different transformer makes and models. We are currently assessing the condition of all
spare bushings and the extent of coverage that they provide.
Safety considerations
The most significant safety considerations for the power transformer fleet are set out below.
Bushing explosion
Bushing failures are a serious safety risk because many of the old transformer bushings are
made of porcelain. An explosive failure may result in sharp shards of porcelain being
propelled into the surrounding environment.
Working at heights
Work at heights is a safety issue for transformers, because maintenance and repair works
are often carried out at the top of the transformer, a substantial height above ground.
Environmental considerations
We are committed to managing environmental impacts associated with the transmission
network and will proactively protect, enhance and respect the environment. In this respect
there are a number of issues with the power transformer fleet.
Insulating oil
All power transformers are filled with insulating oil which is classed as an environmental
hazard. Some of our larger transformers contain more than 50,000 litres of oil. It is
important to prevent and contain spillage when filling, treating or emptying the transformer
oil. Power transformers are installed within a bunded area that will catch all oil spillage and
oil contaminated storm-water and direct this to an oil interceptor which will separate the oil
and water. The captured oil is pumped into a storage container and the water discharged
into a storm-water drain.
We occasionally undertake oil treatment on site for some of our transformers. The oil
treatment process involves using ‘fuller’s earth’ to filter oil of moisture and other
contaminants. The contaminated ‘fuller’s earth’ must be disposed of appropriately to ensure
that the waste does not have a harmful effect on the environment.
Noise emissions
Acoustic noise emissions can be a significant concern depending on the neighbouring
environment. A few sites have been fitted with sound walls to block the transformer noise
reaching residential areas. Modern three-phase transformers feature improved
environmental characteristics, including lower acoustic noise emissions than single-phase
units. Our strategy to replace older units with three-phase units will therefore improve the
environmental impact of the transformer fleet. This aspect is discussed in more detail in
chapter 4.
LOW (87%)
MEDIUM (12%)
HIGH (2%)
Single-phase transformers
The ageing fleet of single-phase transformers poses some maintenance concerns.
Approximately 85% to 90% of the older single-phase transformers have been overhauled
over the last 25 years to address generic problems such as:
broken winding support blocks
loose, damaged, wet and deteriorated windings, leads and barrier insulation
wet and damaged bushings
misaligned and worn on-load and off-load tap changers
badly corroded radiators.
The mid-life overhaul of these transformers has helped to ensure reliable operation. There
have been few significant failures of transformers that have previously undergone major
overhaul.
The remaining 10% to 15% of single-phase transformers have not been overhauled. These
units are considered to be uneconomic for overhaul, but may require more frequent
maintenance than overhauled units, and are at greater risk of major failure. The majority of
the additional maintenance requirement is associated with high moisture levels and
replacement of aged ancillary components.
Three-phase transformers
As discussed in subsection 2.1.3, our three-phase transformer fleet is generally much
younger than the single-phase units and is in good condition overall. This is reflected in the
much lower forced and fault outage rates of three-phase transformers compared with
single-phase units (see subsection 2.3.1).
Three-phase transformers purchased up to the early 1990s were built to the older
standards, and are vulnerable to failure as a result of original design and manufacturing
defects. We do not intend to undertake mid-life major overhauls on these transformers, and
these factors combined means that the older three-phase units have an increased risk of
major failure when compared with their modern equivalents.
Tap changers
Mechanically ganged tap changers
Many of the older single-phase transformers use mechanically ganged tap changers which
suffer from deterioration in the drive shafts and internal diverter componentry. Typically,
these types of tap changers require extensive maintenance to the drive shafts, bushings and
gears as these wear very easily compared to other types of tap changers. We have 40
transformers with this type of tap changer still in service.
Bushings
Modern condenser type transformer bushings have test taps that enable straightforward
measurement of bushing condition. However, most of the old transformer bushings do not
have test taps hence it is difficult to assess the condition of the bushings without removing
the entire bushing from the transformer. Also, in the past, some bushings have suffered
from deteriorating seals and caused oil leaks.
Resin bonded paper bushings were also widely used in transformer design in the early 1950s
through to the 1980s. These types of bushings have a high failure rate and are no longer
used in modern designs. Unfortunately our original records do not allow us to determine
which of our transformers have resin bonded paper bushings. The only way to determine
this is to take suspect transformers out of service to remove the bushings for inspection.
Our single-phase and three-phase transformers generally require significant bushing repair
or replacement at 30 years of age. The components that may fail after 30 years are:
bushing oil seals, leading to risk of electrical insulation failure
oil sight glasses (which become blocked and impossible to read, preventing the
identification of low oil levels that can lead to failure).
In some severe cases, it is more cost-effective to replace the entire bushing rather than
repair oil seals that have failed – especially if the bushing internal components have
deteriorated due to moisture ingress as a result of the failed oil seals.
5
Based on Energy Networks Association’s ‘National Equipment Defect Reports, June 2013’ and on recommendations
from Brush (as the successor of ATL).
Control systems
Deterioration of control system components is commonly observed in transformers after
about 30 years in service, and can lead to forced and fault outages. The components that are
typically most at risk of age-related failure include:
cooling control relays
oil and winding temperature monitors and probes6
fans, fan motors and pump relays
tap changer motor drive control relays
cubicle weather seals.
Our single-phase and three-phase transformers generally require significant control system
repair or replacement at around 30 years of age to ensure reliable performance.
Cooling systems
Cooling systems comprise radiators, fans and circulating oil pumps.
The older single-phase units are cooled by radiators alone (comprised of tubes or plates).
The plates are formed of thin sheets of mild steel and are prone to rusting around the welds,
internally and externally, necessitating major repairs or replacement.
Modern plate radiators are made from thicker sheet steel and shaped to eliminate internal
deposits and then thoroughly washed and coated to prevent corrosion. The outer surface is
galvanised and then painted to provide a rust resistant coating.
In some recent projects we have introduced stainless steel radiators, to mitigate site-specific
pollution factors such as the presence of hydrogen sulphide (H2S) in geothermal areas. We
have limited operating experience with stainless steel radiators to date and are not yet able
to draw firm conclusions about their long-term performance.
Our operating experience with transformer cooling fans has shown that they typically have
to be replaced two or three times during the lifetime of the transformer. Fitting of improved
temperature controls has reduced the number of fan start/stop operations and the length of
fan running times.
6
We note that modern electronic temperature monitors provide improved features and performance, but are likely to
require lifecycle replacement within a 20-year period rather than the typical 30-year life of the older electromechanical
monitoring devices.
Adjustment to
Factors Commentary
remaining life
As outlined in subsection 2.2.3, we have improved our transformer
Manufactured <1992 – Base design specification since 1992. Only one of the transformers
life of 60 years manufactured after 1992 has had a winding failure. We expect this
Base life type of transformer to have a longer base life than those
Manufactured >1992 – Base manufactured before 1992. The base life of transformers
life of 70 years manufactured before 1992 is established from the economic
analysis for optimal age for replacement, as detailed in Appendix D.
Adjustment to
Factors Commentary
remaining life
Single-phase units that have We have completed a programme of major overhaul on most single-
undergone major overhaul – phase transformers in our fleet. As these overhauled transformers
Major overhaul
remaining life is adjusted by have not yet had a major failure or intervention, we expect them to
an increase of 10 years be fit to remain in service for at least another 10 years.
We allocate power transformers into AHI bands of ‘now due’, 0–2 years, 2–7 years, 7–12
years, and 12+ years. The distribution of asset health for the power transformer fleet as at
2013 is set out in the chart in Figure 5.
POWER TRANSFORMERS -
ASSET HEALTH (12/13)
12+ YRS (76%)
7-12 YRS (8%)
2-7 YRS (4%)
0-2 YRS (1%)
NOW DUE (11%)
The AHI shows that a significant number of transformers are ‘now due’ or have a remaining
life between 0 and 2 years. Our strategy for improving asset health is set out in
subsection 4.1.2.
Preventive
Condition assessments
The internal condition of power transformers cannot be directly observed and this presents
a challenge in quantifying their failure risk. There are many transformer tests used for
condition assessments such as Dissolved Gas Analysis (DGA), furans and Degree of
Polymerisation (DP) tests (these are described in detail below).
These tests can help us understand how the transformer ages and indicate if there are any
systemic issues. However, these condition assessment techniques only provide inferences
about actual transformer condition, and standard techniques are unable to identify many
factors that contribute to transformer failure.
In some cases, testing may indicate the need for more intensive monitoring using on-line
DGA monitors. Our experience is that these online monitors are helpful, but are often more
useful in identifying the cause of failure after the fact, than in preventing failures.
Our condition monitoring tests and inspections are as shown in Table 6.
Frequency Activities
Monthly: An in-service visual and audible noise level 1 inspection during routine station inspection
Yearly: An in-service level 2 inspection is carried out, which is more comprehensive than the level 1
inspection and includes operational checks.
A thermo-graphic survey is carried out during a survey of the station.
Oil screen tests.
Dissolved gas analysis of oil samples.
Two yearly: Tests of inhibitor levels in oil samples.
Four yearly: An out-of-service diagnostic inspection of the transformer and all of its components.
Out-of-service diagnostic tests, including winding insulation resistance and polarisation index, and
tests of bushing insulation.
Tests of levels of furans in oil samples.
A high-level condition assessment on which to base major work such as refurbishment, repair or
replacement.
Frequency Activities
Two, four or Major service of on-load tap changer (interval depends on make, type and operating duty).
six yearly:
Table 6: Condition-monitoring tests and inspections
Servicing
Transformer tap changers
On-load tap changers operate in response to voltage regulation requirements. The
frequency of operation can vary from several operations each day to more than 20 each day.
As with all mechanical equipment, the bearings and gears wear, locking pins loosen, limit
switches move, grease and lubricants harden and thicken hampering operation of tap
changers. Modern tap changer manufacturers have improved the designs of their tap
changers, reducing maintenance requirements (and improving reliability). Some
maintenance is still required, but is non-invasive.
On-load tap changer contacts wear out due to arcing during normal on-load tap changer
operation. The drive mechanisms of on-load tap changers ultimately wear out as a result of
normal operation. The oil qualities of on-load tap changers deteriorate due to oil breakdown
products generated during normal arcing operation. Off-load tap changers can fail due to oil
carbonisation around tap changer contact surfaces.
Tap changers can fail if they are improperly repaired or re-assembled. Recent on-load tap
changer problems are attributable to limited experience and knowledge of the tap changer
maintainers.
Our single-phase and three-phase transformers generally require routine servicing every 4
years and significant tap changer servicing at 10–30 years of age. The actual time period
depends on the number of tap operations and the loadings at which tap changing occurs.
The components that require repair or replacement during servicing are:
on-load tap changer motors, springs, bearings and gear mechanisms
on-load tap changer contacts
off-load tap changer contacts.
Corrective
Fault response
The main causes of power transformer events requiring a call out fault response are:
older tap changer-drive mechanisms (that are badly worn causing alignment
problems with subsequent jamming)
bushing failure due to moisture ingress and overheated terminations
cooling system and instrumentation faults.
Repairs
The most common repairs required for power transformers are:
oil leak repairs
Maintenance projects
Maintenance projects typically consist of relatively high-value planned repairs or
replacements of components of larger assets. Maintenance projects would not be expected
to increase the original design life of the larger assets. Maintenance jobs are typically run as
a project where there are operational and financial efficiencies from doing so.
Maintenance projects are usually planned at least 12 months in advance, and are usually
part of a long-term strategy for a particular fleet of assets. Maintenance projects are
included in the Integrated Works Planning (IWP) process and are supported by individual
business cases.
Historically, we have spent approximately $6m a year over the last 5 years, and the
predominant work was a programme of major overhauls on our single-phase transformer
fleet. See Appendix F for more information.
Major failures
Australia/NZ CIGRE surveys show a probability for total major and minor failure of power
transformers of approximately 1.0% a year for each transformer. This increases to 1.5% each
year for transformers greater than 30 years of age. The probability of a major (winding)
failure is approximately 1/3 of the total failure rate. Our annual rate of major 220 kV
transformer failures is comparatively poor, with a winding failure rate of around 0.83% each
year (for banks, rather than units). The average major failure rate for the entire population is
7
Most transformers are able to carry the maximum substation load on a cyclic basis until the security is restored by the
return to service of the original transformer following the outage, or the mobilisation and commissioning of a strategic
spare. This may take up to a month.
Winding failures
The distribution of winding failures (from 2007 to 2012) by primary voltage is illustrated in
Table 7. A detailed list of winding failures can be found in Appendix E.
Fault type 220 kV 110 kV 66 kV 50 kV 33 kV 11 kV Total
Winding Failure 4 2 0 0 0 0 6
Table 7: Power Transformers – Winding Failures
Table 7 shows there are more winding failures for the 220 kV transformer fleet. High-voltage
stresses are likely to contribute to winding failures.
Analysis of the root cause of major failures indicates that in almost every case the failure is
attributable to design and/or manufacturing errors. They would not have been predicted
through routine CA techniques.8
Improvements in the design, procurement, and commissioning of transformers since the
1990s has improved their performance. Yet 56 220 kV transformers dating from the 1970s to
the 1980s are still in service. These units present a higher risk of winding failure (resulting
from design and manufacturing defects) than their modern equivalents.
8
The majority of the failure modes were dielectric failures under impulse, or mechanical and electrical failure on
through-fault. These failures occurred with little or no prior warning. Routine power transformer condition assessment
techniques would not have predicted most of these failures.
0.12
0.10
0.08
0.06
0.04
0.02
0.00
06/07 07/08 08/09 09/10 10/11 11/12
9
Figure 6: Power Transformers – Forced/Fault Outages
The causes of the forced and fault outages are set out in Figure 7.
35
30
25
20
15
10
0
06/07 07/08 08/09 09/10 10/11 11/12
10
Figure 7: Power Transformers – Fault Causes
The forced and fault outage rate of single-phase transformers is significantly higher than that
for the three-phase transformers. The leading causes of outages differ significantly. Faults
and failures of tap changers are the most significant cause of the poor performance of
single-phase transformer banks. The root causes of tap changer related failures are age
related deterioration and inadequate design. The majority of the ‘other’ outage causes in
2010/11 and 2011/12 were caused by Bucholz trips due to the Christchurch earthquakes and
aftershocks.
9
Historic population data (used to normalise outage numbers) derived from current fleet data and population figures
published in 2009.
10
This data includes outages affecting all ‘power’ and ‘other’ transformers. Note this data is not normalised.
Outage performance
Figure 8 and 9 (taken from the ITOMS 2011 benchmarking round) show transformer forced
and fault outages (per unadjusted transformer) for 100 kV–199 kV and 200+ kV
transformers. Our total forced and fault outage rate for 110 kV and 220 kV transformers is
significantly above the average rate of the ITOMS 2011 benchmark group. We are
represented by the ‘K’ marker in each figure.
The average forced and fault outage rates reported in the ITOMS 2011 results are
approximately 3.5% each year for 100 kV–199 kV and 5% for 200+ kV transformers. We
would need to reduce the present forced and fault outage rates for transformers
substantially, just to be an average performer in this study.
The main cause of our poor performance was equipment failure due mainly to minor
equipment malfunctions (for example, a pressure relief device junction box was severely
corroded and caused a trip). Equipment faults were responsible for 48% of transformer
forced and fault outages in the study. The remaining forced and fault outages include
Buchholz relay trips during the Christchurch February 2011 earthquakes and aftershocks.
Table 8 compares the forced and fault outage rate performance reported by participants in
the ITOMS 2011 study against our performance (in events per 100 each year).
ITOMS Best
Voltage ITOMS Average Transpower Average
Performer
100 kV–199 kV 0 3.4 6.6
200+ kV 0.37 5 12
Table 8: Forced and Fault Outage Rate against Benchmark Average
Cost performance
The following Figures from the ITOMS 2011 benchmarking round show composite service
level and cost for 100 kV–199 kV and 200 + kV transformers. We are represented by the ‘K’
marker. The vertical axis represents the spectrum of forced and fault outage performance,
from 0 (worst performer), to 2 (best performer).
We are observed to be in the ‘higher-cost, lower-performer’ quadrant for all voltage classes.
Benchmarking results between 2005 and 2011, show that the maintenance spend for 110 kV
and 220 kV transformers has remained about the same since 2005. Over the same period,
our unplanned outage rates for 220 kV transformers is generally trending upwards, but the
110 kV transformers outage rates has decreased since 2005. While the increasing outage
rates for 220 kV transformers can be partly attributed to anomalies such as the Christchurch
earthquakes, there is a clear need to improve reliability. We would need to reduce our
outage rates by more than 50% just to be an average performer.
Approximately 60% of all the forced/fault outages (disregarding anomalies11) over the last
20 years are attributed to minor equipment malfunction/failure which does not cause
damage or prolonged outages. While we are working to reduce these minor failure rates, we
are also concerned with the risk of major failures that could cause significant damage and
prolonged outages, with significant risk of interruptions to customers. The main cause for
major failures are the bushings, windings and tap changers.
Safety
We are committed to providing employees and service providers with a safe and positive
working environment, and minimising risks to the public. An explosive failure of an oil filled
11
These anomalies include incidents involving animals, droppings, lightning strikes and earthquakes.
Environmental
In the last few years, the following environmental incidents were recorded:
in 2012, Benmore T2 lost approximately 360 litres of transformer oil into the
Benmore tailrace (the cause was a leaking heat exchanger and both heat exchangers
were repaired)
as reported above in safety incidents, there was a small oil leak from a transformer at
Southdown (the leak was quickly contained).
Minor oil leaks that are fully contained by our bunding and interception systems are not
specifically reported.
Deteriorating condition
Power transformers deteriorate with age; particularly their cellulose insulation and
insulating oil which are affected by heat, moisture, acids and the compounds generated by
the deterioration of the cellulose, oil and internal coatings (such as varnishes, sealants and
Fleet diversity
As mentioned in subsection 2.1.2, our transformers are diverse in design and manufacture.
This creates issues for maintenance, especially with the transformer tap changers where
unique and specialist knowledge may be required for each different make and model.
Historically, we have held training sessions for our maintenance service providers and we
will continue doing this to retain the knowledge and skills in the industry.
Failure modes
Significant power transformer failures fall into five general categories:
winding failures
tap changer failures
failures due to excessive moisture levels in oil
bushing failures
control and instrumentation system failures.
Winding failures
The windings of heavily loaded power transformers deteriorate due to thermal ageing which
breaks down the internal cellulose insulation, releasing moisture into the transformer oil.
This reduces the internal dielectric strength and increases the risk of electrical failure. The
thermal ageing of the internal cellulose insulation also causes shrinkage which weakens the
mechanical strength of windings and increases the risk of failure under short-circuit through-
fault conditions.
While the consequences of thermal ageing apply to some extent to transformers on our
network, our transmission transformers are not usually heavily loaded. As a result, their
windings are not usually at significant risk of failure from load-related thermal ageing.
Asset knowledge
Asset knowledge is a critical input into asset management decisions. While our basic
transformer asset knowledge, such as the transformer age, make/model and external
condition is currently sufficient, there are some areas where we can improve. The following
are some asset knowledge issues we have identified.
A portion of our asset management database is currently decentralised. In particular,
transformer test results, condition assessment reports and detailed maintenance
records are stored electronically in a variety of locations and are not always readily
accessible.
Some transformer test results, such as DGA, are well maintained in the asset
management database, but there is a need to further capture SFRA, winding,
bushing, tap changer, control system and furans test results.
We do not currently have a formal record of the volumes of oil used in topping up oil
levels in transformers.
Asset information is currently deficient for auxiliary equipment. This includes the
makes and models, condition and age of pressure relief devices, cubicles and so on.
Transformers are also bespoke items and many parts and auxiliary equipment are not
common/standardised.
Our data-gathering requirements need improvement to ensure that our various
service providers take a consistent approach to the coding and recording of asset
data.
Photographic evidence of the external condition of the transformer is currently
lacking, so the condition is difficult to assess without specifically engaging the
maintenance service provider on site.
Our strategy for improving asset knowledge is set out in subsection 4.7.1.
3 OBJECTIVES
Chapter 3 sets out asset management related objectives for the power transformer asset
fleet. As described in section 1.4, these objectives have been aligned with our corporate and
asset management policies, and higher-level asset management objectives and targets.
The overarching vision for our power transformer assets is to improve the overall
performance of transformers taking into account network criticality. Further objectives have
been defined in the five following areas:
Safety
Service performance
Cost performance
New Zealand communities
Asset management capability.
These objectives are set out below, while the strategies to achieve them are discussed in
chapter 4.
3.1 Safety
We are committed to becoming a leader in safety by achieving injury-free workplaces for our
employees and to mitigating risks to the general public. Safety is a fundamental
organisational value and we consider that all incidents are preventable.
Recognising the reduced level of control we have in relation to public safety, we will take all
practicable steps to ensure Grid assets do not present a risk of serious harm to any member
of the public or significant damage to property.
- The 10-year rolling average major failure rate to be less than 0.3% each year.
- The forced and fault outage rate to be less than 7% each year.13
- Restore security of supply within one calendar month of a major failure occurring.
13
The average forced and fault outage rate is about 7.5% over the last 5 years (removing the Christchurch earthquake
events). Given the replacement rate of single-phase transformers over RCP2, a 7% rate is considered appropriate.
- Engage overseas specialists to resolve issues with specific tap changer makes and
models.
- Improve existing procedures and practices via the use of new materials, diagnostic
devices or techniques.
- Maintain awareness of good international procedures and practices in transformer
management, and evaluate new initiatives for possible adoption.
4 STRATEGIES
Chapter 4 sets out the fleet specific strategies for the management of the power
transformer asset fleet. These strategies are designed to support the achievement of the
objectives in chapter 3. They reflect the characteristics, issues and risks identified in
chapter 2 and provide medium-term to long-term guidance and direction for asset
management decisions. The strategies are aligned with our lifecycle strategies below and the
chapter has been drafted to be read in conjunction with them:
Planning Lifecycle Strategy
Delivery Lifecycle Strategy
Operations Lifecycle Strategy
Maintenance Lifecycle Strategy
Disposal Lifecycle Strategy
This chapter also discusses personnel and service provider capability related strategies which
cover asset knowledge, training and competence.
Scope of strategies
The strategies focus on expenditure that is planned to occur over the RCP2 period (2015–
2020), but also include expenditure from 1 July 2013 to the start of the RCP2 period and
some expenditure after the RCP2 period (where relevant). Capex planned for the RCP2
period is covered by the strategies in sections 4.1 and 4.2, while opex is covered by the
strategies in sections 4.3 to 4.6. The majority of capex relates to asset replacement, as
described in subsection 4.1.3.
4.1 Planning
This section describes the strategies for the Planning Lifecycle for the power transformer
asset fleet. It identifies where and how these strategies support the higher-level lifecycle
strategies and objectives for the overall fleet.
Planning activities
The planning lifecycle is primarily concerned with identifying the need to make capital
investments in the asset fleet. The main types of investment considered for this fleet are:
enhancement and development
replacement and refurbishment
customer-driven projects
spares acquisition.
We support these activities through a number of processes, including:
Integrated Works Planning (IWP)
cost estimation.
System growth
Ensure that the transformer fleet is managed to ensure compliance with grid
reliability standards in support of our objectives and procure and install new
transformers to enable system growth.
Our Annual Planning Report (APR) considers the latest generation and demand forecasts for
the upcoming 10-year period. During the planning process, we assess the capability of the
transmission network against these forecasts to identify the Grid investments needed to
meet the grid reliability standards, or which provide a net electricity market benefit. The APR
summarises planned and possible upgrades of interconnection and connection assets,
including power transformers.
For new or upgraded interconnection transformer assets with an expected cost greater than
$20m, a Major Capex proposal will be prepared and submitted for approval. For new or
upgraded interconnection transformer assets with an expected cost less than $20m, an
enhancement or development project is established under Base Capex. The process includes
consulting customers and applying investment tests.
14
See the Power Transformers Asset Management Plan for additional details.
15
This includes replacement, enhancement, development and divestment projects in the period 2013/14 to 2019/20.
Customer consultation
Customer-driven projects are subject to differing drivers that are not as predictable as other
transformer works. To accommodate customer requirements while balancing workload for
other transformer replacement projects, we will seek to align condition-based replacement
works with customer-driven transformer replacements to the extent practicable.
Scope and estimate project works to a P50 confidence level (that is, the
estimate is based on a 50% probability that the cost will not be exceeded).
Transformer installations (whether greenfield or replacement works) will have elements that
are unique to each particular project. This reduces the extent to which historic project costs
can be relied on to forecast future projects. Transformer projects also involve relatively large
investments which if inaccurately estimated can lead to large cost overruns and delays.
Therefore the cost for each transformer replacement or new transformer has been
estimated individually, taking into account the specific context, risks, and requirements of
the transformer and the installation site using the customised cost estimation process.19
A key requirement for an accurate customised cost estimate is to establish a site-specific
scope of work. To determine the scope, a design layout drawing is developed for each
project. The likely location of the replacement transformer will be determined from a
desktop review of aerial photographs, site layout drawings, underground services drawings,
and available cable corridors for the new low-voltage cables. This assessment provides
reasonably accurate estimates for the numerous variable quantities of materials and work
(such as switchyard extension area, new fencing, new bay(s), power and control cabling,
outdoor junction boxes, oil containment, lighting, lightning poles, fire walls, and so on).
18
P50 means that there is a 50% probability of the actual cost being below the estimate.
19
This assessment is later refined via a Solution Study Report investigation that informs the BC3.
One key determinant of accurate cost estimates for capital projects is managing scope risk.
As part of its customised cost estimation process for transformers, we have developed a
specific risk estimation approach. We use this approach to determine the need for and
magnitude of any risk adjustments to be applied to individual cost items.
The cost items to be considered will vary by project given the specific site conditions and
equipment scope. In general, the main cost items that we risk adjust for include:
cable lengths based on transformer position
geotechnical/ground condition potential need for ground improvements, piling, and
so on
excavation requirements and the potential for contaminated soil.
We have developed three typical scope ranges for each individual line item. Each range has
three estimates for the ‘Minimum’, ‘Most Likely’ and ‘Maximum’ value. Using these ranges,
we have derived a P50 estimate using a PERT20 distribution. The adjustment is based on
likely quantities, as scope has tended to be the most significant variance on this type of work
and we are reasonably comfortable with potential unit rate variances.
Further information on our approach to risk estimation is included in the Planning Lifecycle
Strategy.
4.2 Delivery
Once planning activities are completed, capex projects move into the Delivery Lifecycle.
Delivery activities are described in detail in the Delivery Lifecycle Strategy. The following
discussion focuses on delivery issues that are specific to the transformer fleet.
4.2.1 Design
Detailed design is undertaken during the delivery phase21 of the investment process by
design consultants from a pool of preferred specialist consultants. The consultants will take
the following six points into consideration.
Transformers are very heavy pieces of equipment (can weigh up to 300 tons). The
foundation design must therefore take into account site specific ground conditions to
ensure ground settlement is not an issue. The foundation will also need to fully
comply with earthquake standards appropriate to the New Zealand environment,
which are higher than many other countries.
It is critical that every effort is made to ensure that designs respond fully to the
environmental conditions, to avoid problems (such as corrosion) that can lead to oil
leaks, increased maintenance costs and premature end of life (or even failure).
20
Programme Evaluation and Review Technique – see the Planning Lifecycle Strategy for a discussion on how this has
been used.
21
While design activities are undertaken during the Planning Lifecycle, the majority of detailed design takes place as part
of the Delivery Lifecycle.
Transformer specification
Major power transformers are bespoke items, and there are typically only a few units
manufactured for each design. The wide diversity in the existing fleet is a significant driver of
increased maintenance cost and risk.
New transformers will be specified based on standard designs and footprints wherever
practical, and use standard components such as tap changers and bushings. Although
competition for the supply of transformers is required to maintain commercial tension, all
reasonable efforts must be made to limit diversity during the design process. Table 9 lists
the standard design ratings that we have adopted.
Function Voltage Ratio MVA Rating
Interconnecting 220/110/11 kV 250 150 100
220/66/11 kV 250 180
Supply 220/33 kV 120
(see note below) 220/11 kV *
110/33 kV 120 75/85 60 40
110/11 kV 20 10
66/11 kV 40
*Mainly for special industrial customers, rated as required
Table 9: Design Ratings – Power Transformers
Standard ratings were considered for all supply transformers, but because of customer
requirements and the low number of likely purchases we deemed it impractical to set
standard ratings for all future power transformers.
No standard 110/11 kV supply transformers over 20 MVA have been detailed because
transformers rated above this rating are customer specific due to such factors as fault-level
limitations within the customers networks.
22
See Service Advisory TP.DS 61.06 SA1 – Firewalls for outdoor power transformers, dated 2 September 2011.
We will future proof transformer site designs and layouts by proactively considering likely
future requirements and current requirements. This may involve:
ensuring the transformer bunded area has sufficient space to account for:
o future strategic spares and future larger transformers
o future firewalls that may be required
site oil interception and containment systems are sufficient to contain oil for future
transformers.
Provide online dissolved gas analysis monitoring equipment for all new
transformers with a criticality rating of ‘high’.
Experience in New Zealand and elsewhere has shown two main benefits of providing online
dissolved gas analysis.
Online dissolved gas monitors can trigger a removal of a transformer in distress from
service before major failure occurs. There are clear operational and safety benefits in
being able to plan for urgent removal, rather than have a sudden forced outage
occur.
In some cases, destructive power faults within the transformers may be avoided.
There are a number of points to consider before installing online dissolved gas monitoring
on the fleet. An online monitor can provide advanced warning of serious internal
deterioration. However, this warning may not necessarily provide a significant reduction in
the ultimate costs of the fault. Following the indication of serious internal defects emerging,
costly contingency measures, such as installing strategic spares, may still be required to
restore security.
Overall, there is limited value from widespread installation of online monitors to existing
transformers. Therefore, the installation of online monitors will be limited to all high-
criticality transformers and problematic transformers as required.
Procurement risk
The analysis of major power transformer failures over the past 30 years clearly indicates that
the root cause of failure is latent design and/or manufacturing errors. Theses failures have
generally occurred during the mid-life of the transformer. So it is essential that we take all
practical steps to mitigate risks at the procurement stage.
Power transformers cannot be considered as ‘ex-catalogue’ items. They are bespoke and
therefore considerable risk can arise with each design. The materials and manufacturing
methods used to build the transformer are also continuously evolving so that the
manufacturer can reduce or minimise costs – this builds in additional manufacturing risk
with every new power transformer purchased.
The present risk management practice for power transformers includes:
purchase only from three pre-qualified power transformer suppliers with a proven
track record
perform a design review at the manufacturer’s premises after award of a contract
(see specific strategy below)
perform qualified inspection during key manufacturing stages and final factory
acceptance testing of the power transformer
continually review and periodically audit the performance of the pre-qualified
suppliers
continuously review the performance of the consultants and inspectors hired to
assist with the design review, manufacturing inspections and witnessing of final
factory acceptance testing.
All these risk mitigation activities should continue. The benefits of these activities include:
reduced risk of factory test failures and delays prior to delivery to the site
reduced risk of premature failures on site
reduced maintenance requirements as the transformer ages
better performance during emergency overload conditions and system faults
higher asset utilisation potential over the life of the transformer.
Based on our historic failures and experience, there is a need to further specify the design
for individual components in a transformer. Transformer bushings and tap changers are the
main cause of transformer forced and fault outages. These two main components are
standardised for new transformer specifications and the rationale is described below:
Bushings
As identified in subsection 2.2.3, resin bonded paper bushings are not reliable and have a
high failure rate. This type of bushing is no longer used in modern transformer design. Resin
impregnated (RIP) bushings with silicone sheds were introduced in the early 2000s.
A RIP bushing uses resin impregnated paper as solid insulation and contains no oil. It
therefore presents a greatly reduced fire risk compared with previous oil filled technology.
The reliability of RIP bushings is good, based on international experience and our own short
experience, and they have recently been adopted as our standard requirement.
As described in subsection 2.2.1, bushings made of porcelain have a risk of ejecting sharp
pieces of porcelain in the event of a bushing failure. Our standard specification now requires
bushings using RIP and with silicone sheds.
Tap changers
As described in subsection 2.3.4, tap changer diversity is an issue in terms of requiring a vast
knowledge base for tap changer maintenance. The strategy to address this risk on all new
power transformers we have purchased is to accept a small number of standard type tap
changers from only the two best manufacturers in the world. These two manufacturers also
have a worldwide ability to service and repair their tap changers with their own skilled
personnel in the event of a failure at site.
Other components
Other transformer componentry we are standardising on are online DGA monitoring
equipment and using a particular manufacturer of high-quality oil pumps. The supporting
rationale is noted below.
We have standardised online DGA monitoring equipment (including SCADA and
communications hardware) to reduce complications associated with different makes
and types.
We have standardised on a particular manufacturer of high-quality oil pumps for all
our modern power transformers, because of the need for high reliability. Although oil
pumps are generally very reliable, standardisation will improve interchangeability in
the event of a fault.
Ensure that design reviews are undertaken during design and manufacturing
processes.
4.2.3 Construction
The construction phase of an asset’s lifecycle is a significant determinant of quality and is
characterised by particular safety risks. So our project management of construction projects
is very important, and given substantial support and focus. To support the reduction of
construction risks, we maintain a ‘lessons learned’ register for all construction projects that
is fed back into how we manage future projects.
During the construction phase, it is standard practice for our project team to hold regular
meetings with the service provider (together with the design team as appropriate) to
address any construction issues and risks. Some of these issues and risks may need to be
considered before actual construction begins and are addressed as part of the initial
workshops. These workshops identify issues and risks associated with constructability,
environmental, Safety by Design, operation and any required outages.
These construction issues and risks will need to be covered off on a site-specific, basis but in
general may consider the following:
transformer delivery to site – for example, temporarily widening roads for the
transformer trailer when you need to ensure roads and bridges can handle axle load
of transformer and truck, and checking clearances to transmission lines and road
access from port to substation
construction access
construction security – for example, temporary construction fences may need to be
erected to prevent theft of materials and equipment
excavation – confirming that existing foundation capacities are not compromised by
the new excavation, and taking extra care when excavating around areas where
underground services are suspected to be not shown on maps or drawings
proximity to live equipment during construction
contingency planning is done throughout the whole construction process
extreme weather conditions
outage planning.
4.2.4 Commissioning
Commissioning is the process of bringing new or reinstalled equipment under the system
controller’s normal real-time operational control of the power system. A commissioning plan
Pre-commissioning testing
Completion of all pre-operational tests of the transformer, accessories, and in particular the
cooling system, is essential as these items are critical components that allow the
transformer to operate correctly and safely while in service. The main items to be checked
prior to livening include:
main transformer diagnostic tests: ratio tests, bushing power factor tests etc.
completed as per the manufacturers requirements and the service specification
SS.04.60
transformer accessories checked and functional tests completed: checking of
Bucholz relay, pressure relief device, and so on
cooling system operation: fans/pumps operate in ‘manual’ and ‘auto’
electronic Winding Temperature Indicator (WTI): settings applied and WTI tested to
confirm correct winding temperature calculations and correctly starting/stopping the
fans/pumps.
visual checks: sight checks of equipment (such as ensuring radiator valves are open,
and there are no oil leaks).
4.3 Operation
The Operation Lifecycle phase for asset management relates to planning and real-time
functions. Operational activities undertaken are described in detail in the Operations
Lifecycle Strategy. The following discussion focuses on operational issues that are specific to
transformer assets.
Plan and manage outages in a way that creates a safe environment for
employees while minimising the disruption for customers.
We coordinate with key stakeholders to ensure that any unavoidable system disruption and
outages are notified well in advance so affected parties can prepare. This aligns with our
service performance objectives.
The majority of sites are designed with N-1 security, and this allows outages to be arranged
for maintenance with reasonable flexibility. However, we also have a number of small
capacity N security sites.
Outage planning at the N security sites is often highly constrained, because an outage leads
to an interruption of supply to customers. To minimise impact on customers, maintenance
must be completed in a very short timeframe. This often results in only priority maintenance
being completed, and carries the risk of jobs being rushed.
Most N security sites have a primary operating voltage of 110 kV, but some sites operate at
N security at 220 kV, 66 kV and 33 kV.
To mitigate the difficulties of maintenance and replacement works at N security sites, we
have designed and built a 110/33-22-11 kV, 15 MVA mobile substation. This provides an
alternative means of supply that will allow for extended outages at the 110 kV primary
voltage N security sites.
Efficient placement and connection of the mobile substation requires enabling works at
some sites.
Subject to case-by-case agreement with the customer, we will undertake enabling works at
110 kV N security sites to allow prompt deployment of the mobile substation.
Our objective for contingency planning is to be able to restore full security of supply within
one calendar month of the major failure of a power transformer.
We have a number of new three-phase spare transformers, dedicated spare transformers
for single-phase banks, and other used transformers that are potentially available as spares.
However, transporting and installing a spare transformer at sites not designed for the spare
transformer may present challenges because of the bespoke nature of most transformer
installations. The 1-month restoration target may be difficult to achieve at sites that require
a new foundation, controls, or bus work.
To ensure that the contingency planning target can be achieved, deployment plans are
required that set out the process and resources required to mobilise and install a spare
transformer. The highest priority requirements are for deployment plans for the dedicated
three-phase strategic spare transformers.
We will complete the preparation of deployment plans on a site-by-site basis, prioritised by
criticality.
When a strategic spare transformer is deployed, there is a significant increase in the risk
profile associated with all remaining transformers that were previously covered by the
deployed spare. The risk cover for the remaining power transformers should be restored as
soon as is reasonably practicable. Strategic spares will either be recovered within 2 years (via
repair or replacement of the original failed transformer), or, alternatively, we will procure a
replacement strategic spare.
4.4 Maintenance
We and our service providers carry out ongoing works to maintain assets in an appropriate
condition and to ensure that they operate as required. The maintenance undertaken seeks
to proactively manage failure risk as well as responding to actual failures as these occur. Our
approach to maintenance and the activities we undertake are described in detail in the
Maintenance Lifecycle Strategy.
We classify maintenance tasks into the following categories:
preventive maintenance
- condition assessments
- servicing
corrective maintenance
- fault response
- repairs
maintenance projects.
The following discussion focuses on maintenance activities and associated strategies specific
to the power transformer fleet.
Our maintenance documentation is based on overseas standards and our own experience.
An outline of our standard service requirements is set out below:
Bushings
Oil-filled bushings aged 35 years or more are to be inspected yearly to see that the oil level is
within the operating range. The service provider shall also check the following, which shall
be repaired if required:
oil quality
oil seals
oil sight glasses on oil filled bushings
internal dielectric strength on all types of bushings
condition of the exterior sheds on all types of bushings.
Bushing oil levels have been found to be below the operating range and not noticed because
of oil staining on the white background of the oil level sight glass. A more thorough
inspection will discern the difference between the oil level and the oil stain.
Bushing maintenance is required because the oil quality in oil filled bushings deteriorates
due to weather-related ageing of oil seals resulting in moisture ingress. The internal
dielectric strength of all types of bushings deteriorates due to moisture ingress, thermal
stress, electrical stress and age-related weakening of internal insulation materials. Tests of
the dielectric properties of bushings are undertaken every 4 years, to identify internal
deterioration. The dielectric condition of older bushings is a particular area of focus.
On-load tap changers
The on-load tap changers are to be serviced in line with our specified requirements that
supersede the manufacturer’s original recommended intervals and operations.
Our maintenance intervals have been selected to suit our own operational conditions. Our
strategy is to ensure that all internal maintenance and servicing of tap changers is carried
out by certified and fully trained personnel. The following aspects will be checked, and
repaired if necessary:
tap changer contacts
Consider safety risks and mitigations when planning and carrying out
maintenance.
Maintaining power transformers involves a number of risks. The main risks and risk
mitigations to consider when planning and carrying out maintenance are:
Corrosion assessment
Detect corrosion before it deteriorates to the point where oil leaks may occur
and corrosion is too deep to repair.
Corrosion is a significant problem with many power transformers. Painted metal surfaces
deteriorate due to weather conditions, and as a result of salt deposits and industrial
pollution. Gaskets providing oil seals between bolted joints wear out due to thermal ageing
and weather conditions.
Corrosion is an ongoing problem that varies with paint systems, climatic and regional
conditions.
We plan to improve the maintenance process by taking photographs of corrosion at the
yearly inspections and providing these together with a condition report for recording in our
maintenance management system. This will allow the corrosion to be assessed and repaired
at an appropriate time.
The photographs will show the extent and depth of corrosion, and together with our service
provider we will use these photographs to help determine when and how the transformer is
to be repaired.
Repairs
Transformer repairs include the correction of defects identified during preventive
maintenance or fault response and additional predictive works driven by failure mode and
effect analysis and investigations. High-quality repairs reduce the risk of future failure for in-
service assets; for out-of-service assets they improve redundancy and remove system
constraints by allowing the assets back into service.
We will make repairs to power transformers where a defect has been identified that could
potentially result in a failure, or when a failure has occurred. In both cases, the repairs are
carried out to support our service performance objectives. The general strategies for repairs
on power transformers are outlined in the rest of this subsection.
Corrosion control
The paint and galvanising systems applied to power transformers are specified to be suitable
for severe environmental conditions, but cannot fully prevent deterioration or corrosion
developing over time. General deterioration of the protective coatings typically necessitates
repainting of a transformer two or three times in its lifetime.
The radiators in modern transformers are made of 1.6mm-thick galvanised mild steel and
corrosion of these will rapidly cause oil leaks. The corrosion also weakens the steel and in
the event of a rapid oil pressure rise, due to a through fault or oil pump starting, may burst
causing a major oil leak.
The original protective coatings of small ancillary equipment such as monitors are often not
in line with our current requirements. Significant corrosion can lead to risks of fault and
forced outages. Deterioration of ancillary equipment is usually addressed by replacement
rather than by painting.
We have identified a number of transformers as having corrosion problems requiring repair.
It is expected that at least five transformers a year will require corrosion control work.
During the life of the transformer the ancillary equipment degrades more quickly than the
main parts of the transformer. In most cases it is better to replace the ancillary equipment
rather than to repair it. The ancillary components to be repaired or replaced include:
control systems and instrumentation
porcelain bushings.
Control systems and Instrumentation
Control and instrumentation systems on a transformer typically require replacement within
the lifecycle of the main transformer. The scope of this equipment includes:
Oil treatment
We will maintain oil condition of the fleet by refurbishing or replacing oil as required. Oil in
poor condition may be treated in-situ or replaced with new oil or regenerated oil.
Regenerated oil is used oil that has been treated with a catalyst to restore it to a condition
that meets the IEC standard for unused oil.
The forecast expenditure is approximately $300,000 each year. This work will be funded
from the routine maintenance allowance.
Replace the oil in three critical transformers already identified with high
levels of corrosive sulphur, and assess the extent of the problem in other
potentially at-risk transformers.
The risk associated with corrosive sulphur in oil is outlined in subsection 2.3.4. The risk
cannot be completely eliminated without totally replacing the transformers or their
windings.
Options for partially mitigating the risk include replacing the oil, or processing the oil and
adding ‘metal passivators’. Early indications from international experience with the
passivation technique suggest that it is not effective. So we consider that, for now, replacing
the oil is the only appropriate solution.
Our strategy is that the oil in three transformers already identified with high levels of
corrosive sulphur will be replaced with regenerated oil between 2015 and 2017. These
transformers are at relatively high risk because they either have been highly loaded or have
the ability to be highly loaded (one of the pre-conditions of failure resulting from corrosive
sulphur). The transformers are:
Penrose T11 (220/33 kV, 200 MVA, manufactured in 1999)
Otahuhu T3 (220/110/11 kV, 250 MVA, manufactured in 2003)
Otahuhu T5 (220/110/11 kV, 250 MVA, manufactured in 2000).
We will replace approximately 190,000 litres of oil. We will also carry out further tests to
establish the levels of corrosive sulphur in oil of all three-phase transformers purchased
between 1995 and 2008. These tests will be carried out on 60 transformers, and we
estimate that approximately 30 transformers will require a second test.
Transformers are DGA tested yearly and more frequently if excessive gassing is occurring.
Fitting online dissolved gas analysis monitors can help us understand how gassing
transformers are performing, and assist in any decision to remove the transformer from
service before it fails.
We have identified a total of 34 three-phase transformers that have excessive gassing: 28
are from the population manufactured before 1992. Two of the more recent units have been
fitted with online gas monitors, leaving potentially 32 transformers that may warrant the
installation of online dissolved gas monitors.
We plan to install online DGA monitors on the following four transformers over the RCP2
period:
TAK T5
TAK T8
TKU T21
TKU T22.
4.6.1 Disposal
The implementation of asset disposal also has many similarities with capital projects,
including consideration of cost, safety, environmental impacts, and project management.
Aspects that are specific to successful disposal projects are site restoration and termination
of all support activities and planning.
Requirements for recovery and recycling/disposal work include safe work and site
management processes and appropriate probity and environmental responsibility of scrap
disposal processes.
Some decommissioned transformers are retained as spares for specific sites where there are
concerns about the condition of the existing units and they are not adequately covered by
general spares.
Yet most older transformers are scrapped and the oil sold for regeneration. The components
are mostly obsolete and have deteriorated to the point where they cannot be re-used.
The metal such as steel and copper is recovered, smelted and re-used.
Because of environmental risk issues, the oil is sold to a licensed oil dealer for regeneration
and re-use, as it is a valuable and diminishing product. The re-generated oil meets the
International Electrotechnical Commission’s requirements for unused insulating oil and is
considerably cheaper than unused oil.
Asset transfers
We are proceeding to transfer a number of assets at the fringes of the existing Grid to our
distribution business customers. This process is described fully in the Disposal and
Divestment Lifecycle Strategy.
The current plan for asset transfers will result in the power transformer assets noted in
Table 10 being transferred to customers in the RCP1 and RCP2 period.
Voltage 33 kV 66 kV 110 kV
Number 1 16 13
Table 10: Number of transformers being divested across RCP1 and RCP2 periods
Over RCP2 we will work to improve the power transformers asset health model to provide
better forecasts of future replacement requirements and to inform replacement
prioritisation. This may include:
Applying a robust and systematic scoring system to the entire fleet based on
condition testing such as SFRA, DGA, Furans and/or oil moisture content testing
being aware or notified of significant new risk issues, and incorporating these into the
asset health model (that is, utility peer alerts to specific design defects with certain
transformer makes/models)
tap changer operation counts – forecast expected tap changer end of life based on
manufacturer recommended operation count limit and historic records of operations
external condition modelling – model steel degradation based on corrosion zones and
frequency of maintenance/painting
developing hazard functions for particular characteristics that affect asset health
reviewing our model against international guidelines for asset health (CIGRE study
group is currently preparing a guideline for use).
Knowledge of transformers
Transformer asset knowledge is paramount in determining asset health, fault analysis, end
of life predictions and replacement decisions. As mentioned in subsection 2.3.4, transformer
asset knowledge is currently decentralised and while the information we currently have is
generally sufficient, there are efficiencies and improvements to be found.
The recent implementation of our new asset management information system (MAXIMO)
enables a number of business improvements in data gathering, storage and retrieval
processes. As part of these business improvement processes, we have prepared standard
maintenance procedures that will allow for more accurate recording and frequent
maintenance of asset information.
Ensure a continued capability within New Zealand for major repairs of power
transformers.
One of the benefits of the historic programme of transformer overhauls was that it provided
three workshops and trained staff to undertake investigation of transformer faults and carry
out major repairs. The overhaul programme has now come to an end, and some of the
skilled personnel involved in this work are no longer available. This has affected our ability to
undertake major invasive repairs of power transformers in New Zealand.
The history of transformer faults and failures shows that some serious internal defects in
transformers are economic to repair. Recent examples of economic repair of serious internal
defects include the Clyde 3-phase 220/33 kV transformer, and a Waitaki single-phase
220/110 kV interconnecting transformer.
We need to preserve a credible capability in New Zealand to undertake major internal
repairs of power transformers, where this is economic. This capability is required based on:
the expected future failure rate from internal causes
the likelihood that a proportion of internal faults will be economically viable to repair
the potential for some invasive repairs to be conducted on site, providing that
appropriately skilled personnel are available
the likelihood that some invasive repairs will require the transformer to be relocated
from site to a controlled workshop environment
the high cost of replacement transformers
the lead time for replacing major power transformers.
A number of three-phase units with elevated gassing may require invasive inspection and
repair in future. We also expect that some future transformer winding failures may be
economic to repair locally, compared with replacing the transformer or sending it overseas
for repair.
Maintaining some form of transformer major repair capability in New Zealand will, under
appropriate circumstances:
enable timely and cost-effective repairs on site (where feasible)
reduce the need to deploy strategic spares to restore security
reduce the period of time that strategic spares are deployed at sites
reduce the need for faulty transformers to be replaced, or to be sent overseas for
repair.
We will review our ongoing requirements, and define the minimum baseline capability that
we require in future for undertaking invasive repairs.
Establish specific targeted training for tap changer maintenance and repair.
We will run tap changer training for those service providers who work on tap changers.
Planning
Enhancement and Ensure that the transformer fleet is managed to ensure compliance with Grid reliability standards in
Development support of our objectives and procure and install new transformers to enable system growth.
Replace single-phase and three-phase transformers with more reliable new three-phase units based on
failure risk.
Replacement and
Refurbishment Do not undertake mid-life transformer overhauls and during the RCP2 period.
Communicate our transformer strategies with relevant customers to manage life-time risk.
Integrated Works
Align customer driven transformer replacements with condition-based policy replacements as appropriate.
Planning
Scope and estimate project works to a P50 confidence level (that is, the estimate is based on a 50%
Cost Estimation probability that the cost will not be exceeded).
Reflect identified risks in expected cost for projects.
Delivery
Standardise transformer specification to limit the diversity in the fleet.
Where practicable, retrofit fire walls between closely spaced power transformers rated 20 MVA or more
with a criticality rating of ‘high’.
Design
Future proof transformer site designs and layouts.
Provide online dissolved gas analysis monitoring equipment for all new transformers with a criticality
rating of ‘high’.
Mitigate risk in procurement through the detailed technical and economic analysis of the tender and
contract documentation.
Procurement
Standardise component specification to limit diversity in the fleet.
Ensure that design reviews are undertaken during design and manufacturing processes.
Test transformers prior to commissioning to ensure outage durations and system implications are
Commissioning
minimised.
Operation
Plan and manage outages in a way that creates a safe environment for employees while minimising the
Outage Planning disruption for customers.
Ensure mobile substation at N security sites can be deployed in a timely manner.
Restore security of supply within one calendar month of a major failure occurring.
Contingency
Maintain a fleet of strategic spare transformers to provide coverage for the three-phase transformer fleet.
Planning
Recover or initiate replacement of strategic spare within 2 years of deployment.
Capability
Risk Management Refine the power transformers asset health model.
Improve the knowledge of existing transformers through accurate recording and frequent maintenance of
Asset knowledge
asset information.
Training and Ensure a continued capability within New Zealand for major repairs of power transformers.
Competence Establish specific targeted training for tap changer maintenance and repair.
Appendices
Figure 15: International Comparison < 100 MVA Transformer Age (ITOMS 2011)
Figure 16: International Comparison - 100-350 MVA Transformer Age (ITOMS 2011)
Figure 17: International Comparison – 100 kV–199 kV Transformer Maintenance Costs (ITOMS 2011)
Figure 18: International Comparison – 200+ kV Transformer Maintenance Costs (ITOMS 2011)
Executive summary
This document outlines a high-level cost-benefit analysis that we have conducted to
estimate the optimal retirement age of a typical 220 kV transformer and compare with a
‘run to failure’ strategy.
One important assumption in the analysis is that the range of measures described in the
Asset Strategy will reduce the failure rates for new transformers. This document discusses
the economic case for further reducing the overall failure rate by retiring transformers,
eliminating the older units with the higher failure rates.
The costs and benefits taken into account include capital costs; maintenance costs and
transmission losses, both of which are reduced for modern three-phase transformers; direct
costs of major failures; and unserved energy from parallel major failures or repairable
failures on the parallel branch.
Other effects are more difficult to quantify and have not been taken into account. They
include reputational and environmental risks; the impact of diminished industry, business
and community confidence on the national economy; the (very low) risk of fire; short
outages and risks involved with off-load tap changers; and problems associated with spares
for older transformers.
The analysis shows that it is better to replace a transformer at a certain age than to allow it
to run to failure, even before the less easily quantified effects are considered. The predicted
optimum age for replacement depends on the analysis assumptions but is around 60 years
old. The NPV of costs of the replacement policy are approximately 5% lower than those of
‘run to failure’. Both these figures should be taken as conservative because the less easily
quantified effects all favour replacement.
The greatest increased benefit of a replacement strategy comes from the lower probability
of parallel major failures and the consequent lower probability of extensive loss of supply.
Because parallel major failures would be a high impact low probability (HILP) event, both the
probability and the duration of the outage are difficult to estimate, but it is reassuring to see
that the predicted optimum replacement age is similar to, or slightly higher than, the
regulatory life used in other jurisdictions.
D1 Introduction
The analysis is a statistical Net Present Value calculation on a typical 220 kV transformer
position, with the probabilities of the transformer failure at various times taken into
account.
The sections that follow are:
typical transformer assumptions – the size, loading and losses of the typical
transformer
failures – a detailed discussion of the assumptions behind the major and minor failure
rates
economic assumptions – the economic parameters required for the calculation
lifecycle costs – capital and maintenance costs of a typical transformer as well as
salvage value
results.
50 17
60 2
100 4
120 8
160 2
200 10
210 2
Total 45
Table 11: Distribution of sizes of 220 kV single-phase bank transformers
D2.2 Loading
Most 220 kV transformers are in N-1 configurations, either multiple supply transformers at
the same substation (for example, Penrose), or providing multiple entry points to a lower
voltage network (for example, Halfway Bush and Roxburgh). As most of these are in N-1
pairs, rather than larger groups, the peak loading is often less than 50%. We have chosen
30% as an estimate of the peak loading.
D2.3 Losses
Transformers dissipate energy via heating of the iron core, which is approximately
independent of the load (so-called ‘iron’ or ‘no load’ losses) and via heating of the copper
windings, which is approximately proportional to the current squared (‘copper’ or ‘load’
losses).
Copper losses have not changed with advances in transformer technology and remain
approximately 4 kW/MVA at full loading Iron losses have decreased significantly, as Figure
21 shows. From approximately 1.25 kW/MVA for single-phase transformers manufactured in
the 1960s, iron losses have reduced to 0.4 kW/MVA for modern three-phase replacements.
5.00
4.50
4.00
No load losses kW/MVA
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
1940 1950 1960 1970 1980 1990 2000 2010 2020
Year of Manufacture
1.4 Target
1.2
0.8
0.6
0.4
0.2
0
0 10 20 30 40 50 60
years
The failure rate for 220 kV transformers only is plotted as the red line in the same figure. As
the red line is outside the error bounds of the black line in the first and fourth decades, we
can conclude that 220 kV transformers aged 0 to 10 years and 30 to 40 years have more
major failures than transformers of the same age but lower voltage. For ages 10 to 30 the
position is less clear – 220 kV units perform worse than average but not significantly in a
statistical sense. For ages greater than 40, there are too few data points for any inferences
to be made.
In contrast to the clear distinction between 220 kV and < 220 kV transformers, there is no
evidence that single-phase banks have different failure rates from three-phase transformers.
Nor is there any evidence that more recently manufactured transformers perform better. So
the primary motivation for replacing single-phase banks with three-phase transformers is to
reduce the failure rate through operating newer transformers.
The overall average failure rate is the average of the black line, weighted by the number of
transformer-years of each age in the data. It is approximately 0.4% each year.
Many of the early failures are from only a small number of types. Many may stem from the
historic ‘least cost’ procurement policy in the 1960s–1980s. We expect that major failures
will be rarer as a consequence of our improved specification and procurement process. The
Fleet Strategy presents strategies that will be used to bring the failure rate down as much as
possible.
The blue line in Figure 22 represents a failure rate per age that these strategies should
produce. It asks for a considerable reduction in failures in the second and third decades.
The target for the fleet is 0.3% a year for major failures – a significant but not unachievable
reduction.
The values on the blue line will be assumed for new transformers in the remainder of this
study. Existing transformers will be assumed to follow the black line
It is more difficult to estimate failure rates for later dates, but we assume the values
included in Table 12.
Tabulated in Table 12 are the corresponding values of the reliability function representing
the fraction surviving to the end of each decade.
(the failure of the two Whakatu 220/33 kV transformers 22 days apart at age 4 years in
1984), occurred within 30 days. There have also been several near misses.
From this admittedly very sparse history, we conservatively estimate the probability of the
second major failure, before a spare is in place to cover for the first, at 1-in-50 major
failures.
For this analysis we assume that the time with both transformers out is half the replacement
time, or 15 days, and that the load lost averages 60 MW, twice the assumed single
transformer load.
Parallel major failures are clearly High Impact Low Probability (HILP) events. The
probabilities and costs of such events are very difficult to estimate, and a risk-neutral cost-
benefit approach may not be the best method of including them. It can be argued that such
an approach tends to under-value the severity of the potential events. With this caveat, we
consider the values here reasonable in these circumstances
D3.4 Parallel minor failure
If a transformer is out due to a major failure, then the supply is vulnerable to the failure of
any asset on the parallel branch. Based on analysis of transformer branches, we estimate the
probability of branch failure at 70% each year and the average outage duration at 23 hours.
The duration is from the mean of all minor outages, capped at 15 days for the average time
of replacing the first transformer.
D3.5 Failures at a transformer device position
There is an important distinction between the failure rate for an individual transformer and
that for a transformer device position. If the transformer installed in a position has a major
failure then it must be replaced. So, through time, more than one transformer may occupy
the same position. It is the costs associated with a device position that must be compared
between strategies. The mathematical relationship between the individual transformer
failure rate and position failure rate is discussed in Appendix D9.
D4 Economic assumptions
Valuing the cost of outages requires a value of lost load (VOLL). We use the Grid investment
test24 (GIT) value of $20,000 first used in 2004 which gives $23,000 inflating to 2009 at 3%.
The discount rate for NPV calculations is 7% (real), also from the GIT. A ‘public good
infrastructure’ rate of 4% is included as a sensitivity.
Valuing of losses requires a cost of the extra energy that is lost. The quantity to use is the
long run marginal cost of generation, which is in the region of $80/MWh.
D5 Lifecycle costs
The cost of a new ‘typical’ transformer is estimated at $4m. Failed transformers can be sold
for scrap for approximately $50,000 for each single-phase unit or $100,000 for each three-
phase unit.
Maintenance costs are approximately $13,000 for each single-phase unit and $16,000 for
each three-phase unit.
24
Electricity Governance Rules, Schedule F4, Grid Investment Test at
http://www.electricitycommission.govt.nz/pdfs/rulesandregs/rules/rulespdf/PartFSectionIIIScheduleF4-
gridinvestmenttest-17Jan08.pdf
When a major failure does occur there is the direct cost of moving equipment, draining and
filling transformers, connections, and so on. A conservative estimate of the cost is $500,000.
D6 Results
The numbers below represent the average costs for the next 60 years on a per transformer
position basis under the strategies of ‘run to failure’ and ‘replace at age 60’, for a
transformer currently 40 years old.
The analysis shows that it is better to replace a transformer at a certain age than to allow it
to run to failure, even before the less easily quantified effects are considered. The predicted
optimum age for replacement depends on the analysis assumptions but is around 60 years
old. The NPV of costs of the replacement policy are approximately 6% lower than those of
‘run to failure’.
The table shows that an expected reduction in the number of major failures, and the
consequent direct costs, replacement cost and parallel failure risk, is the greatest benefit of
replacement.
The failure costs in the table depend on assumed probabilities of major failure, which are
greater for older transformers.
Figure 23 shows the NPV of the replacement policy as a function of the replacement age.
The asymptote is the limit as the replacement age tends to infinity (that is, the NPV of ‘run
to failure’).
$5,000,000
$4,400,000
$4,200,000
$4,000,000
$3,800,000
$3,600,000
$3,400,000
$3,200,000
$3,000,000
0
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
10
Age of Replacement of Transformers
Replacing all transformers too early brings forward capital costs which outweigh any savings.
Not replacing them at all results in more major failure events. The best compromise for this
set of assumptions is replacement at 60 years of age.
D6.1 Sensitivities
We vary various parameters that could influence the result.
The sign of the NPV result is robust against these sensitivities, but the magnitude does vary.
The ideal retirement age is relatively stable.
Reliability function
The reliability or survivor function, R(t),
R t 1 f u du
t
(2)
0
25
Electricity Transmission Regulatory Reset 2008/9-2013/14, Appendix E, Asset Management Strategy, SP AusNet,
Melbourne, 2007, page 66.
26
M Rausand and A Høyland, System Reliability Theory: Models, Statistical Methods and Applications, Wiley, 2004,
page 15.
Failure rate
The failure rate, z(t) measures the probability of failure at time t per transformer in service
at time t. It is the quantity usually measured
failure probability
z t
number surviving
f (t )
(3)
R t
f (t )
t
1 f u du
0
failure probability
z t
number surviving
f (t )
R t
f (t )
t
1 f u du
0 ( 3 ) inverts to
t
f t z t exp z u du (4)
0
The rate is calculated using the Kaplan-Meier estimate27 of the reliability function and then
R t 1 f u du
t
27
E L Kaplan and P Meier, Nonparametric estimation from incomplete observations, J Amer. Statist. Assoc., 53, 457–81.
28
J Kalbfleisch and R Prentice, The Statistical Analysis of Failure Time Data, Wiley, 2002, page 17.
only exception is for three-phase transformers over 40 years old of which there are very
few.
There is no evidence to suggest that three-phase transformers as a group have a different
major failure rate from single-phase transformers.
0.95
0.9
0.85
0.8
0.75 All
Bounds
Bounds
0.7 3 Phase
Single Phase
0.65
0.6
0.55
0 10 20 30 40 50 60
No evidence of different failure rates, Single Phase vs. 3 Phase
0.95
0.9
0.85
0.8
0.75 All
Bounds
Bounds
0.7
Pre 1975
Post 1975
0.65
0 10 20 30 40 50 60
No evidence of different failure rates, Pre- vs. Post-1975
t t t'
p(t ) f1 (t )
t ' 0
f3 (t t ') f1 (t ')dt '
t '0 t ''0
f 3 (t t ') f 3 (t ' t '') f1 (t '')dt '' dt ' (5)
29
Strictly, p(t) is not a pdf as its time integral is greater than 1, but that is not important in this context.
an infinite sum of self-convolutions, where f1 t is the pdf for the existing single-phase
bank failures and f3 t is the pdf for new three-phase transformer failures.
For times less than the average life of a transformer, the series in ( 5 ) converges rapidly as
many failures at the same position are unlikely. We have calculated the integrals by
discretising at a resolution of one year and truncated at the second term.
If there are closed forms available for f1 t and f3 t , then p(t ) may be calculable via
Laplace transforms as ( 5 ) and properties of the Laplace transform imply that
L f1 t , s
L p t , s (6)
1 L f3 t , s
where L f t , s f t e
st
dt is the Laplace transform operator. The most likely
t 0
forms for f1 t and f3 t fitted to data points are piecewise linear or a polynomial
restricted to [0, the maximum life]. In these cases L p t , s is a complicated expression
involving exponentials and rational functions and does not obviously lead to a useful form
for p(t ) .
Major failures are winding failures that require the transformer to be out of service for many months or up to two years while the transformer windings are
repaired or the entire transformer is replaced.
Age when
Manufacturing Failure
Device Voltage Phase Type Manufacturer failure Failure Cause Notes
year Year
occurred
Design/manufacturing
HEN T2 220/33 kV Single Supply IEL 1966 1980 14
error
Design/manufacturing
HEN T3 220/33 kV Single Supply IEL 1966 1998 32
error
Design/manufacturing
BPE T9 220/33 kV Single Supply English Electric 1954 1988 34
error
Design/manufacturing
STK T9 220/33 kV Single Supply CGE 1964 2003 39
error
Design/manufacturing
HAM T5 220/33 kV Single Supply Mitsubishi 1972 2006 34
error
On-load tap changer
PEN T8 220/33 kV Single Supply Tyree Aus 1976 2008 32 Design/manufacturing
error
Design/manufacturing
WHU T3 220/33 kV Three Supply Hawker Siddeley 1976 1984 8
error
Design/manufacturing
WHU T4 220/33 kV Three Supply Hawker Siddeley 1976 1984 8
error
WIL T3 220/33 kV Three Supply Mitsubishi 1980 2004 24 Manufacturing error
CYD T8 220/33 kV Three Supply Tyree Power 1987 2006 19 Water ingress
33 kV winding
LTN T2 220/33 kV Three Supply Hawker Siddeley 1976 2010 34 design/manufacturing
error
KAW T11 220/110 kV Three Interconnector Italtrafo 1979 1988 9 Design error
KAW T12 220/110 kV Three Interconnector Italtrafo 1979 1988 9 Design error
Age when
Manufacturing Failure
Device Voltage Phase Type Manufacturer failure Failure Cause Notes
year Year
occurred
MDN T2 220/110 kV Three Interconnector Savigliano 1966 2007 41 Design error
220/110/11
PEN T10 Single Interconnector Savigliano 1973 1981 8 Design error
kV
220/110/11 Design/manufacturing
OTA T1 Single Interconnector Ferranti 1962 1996 34
kV error
220/110/11
HWB T4R Single Interconnector Savigliano 1966 2001 35 Design error
kV
220/110/11
HWB T4B Single Interconnector Savigliano 1966 2002 36 Design error
kV
The original unit was scrapped
220/110/11
HWB T4R Single Interconnector Savigliano 1966 2012 46 Design error and spare moved into position
kV
however this unit failed too.
220/66/11 Design/manufacturing
ISL T4 Single Interconnector Brown Boveri 1959 1981 22
kV error
220/66/11 Design/manufacturing
BRY T5 Single Interconnector CGE Canada 1959 1984 25
kV error
220/33/16 Incorrect tap changer
BEN T2R Single Interconnector CGE Canada 1965 1992 27
kV operation
220/33/16 Incorrect tap changer
BEN T2Y Single Interconnector CGE Canada 1965 1995 30
kV operation
TMN T5 220/55 kV Three* Traction OEL 1987 1990 3 Design error
Was repaired and failed a
TMN T5 220/55 kV Three* Traction OEL 1987 1993 6 Design error
second time.
BPE T15 220/55 kV Three* Traction OEL 1987 1993 6 Design error
TNG T3 220/55 kV Three* Traction OEL 1987 1995 8 Design error
Design/manufacturing
ARI T9 110/50 kV Single Interconnector ASEA 1952 1994 42
error
Earth Sticks left on 50 kV bus
EDG T2 110/50 kV Single Interconnector Ferranti 1953 1998 45 Operator error
accidentally
HEP T2R 110/33 kV Single Supply Parsons 1969 1981 12 Design error
Age when
Manufacturing Failure
Device Voltage Phase Type Manufacturer failure Failure Cause Notes
year Year
occurred
Was repaired and failed a
HEP T2R 110/33 kV Single Supply Parsons 1969 1985 16 Design error
second time.
HEP T2Y 110/33 kV Single Supply Parsons 1969 2003 34 Design error
Design/manufacturing
MPE T2 110/33 KV Single Supply Mitsubishi 1972 1990 18
error
Design/manufacturing
KAW T1 110/11 kV Single Supply ASEA 1954 1990 36
error
Design/manufacturing
MTM T3 110/11 kV Single Supply Brush 1954 1997 43
error
KWA T2 110/11 kV Three Supply Siemens 1996 2008 12 Manufacturing error
KWA T3 110/11 kV Three Supply Siemens 2010 2010 0 Air ingress Air ingress during oil filling
Crompton Design/manufacturing
WPT T1 66/11 kV Three Supply 1954 1978 24
Greaves error
Metropolitan Design/manufacturing
UTK T1 66/11 kV Three Supply 1952 1994 42
Vickers error
Design/manufacturing
ADD T3 66/11 kV Single Supply ASEA 1948 1976 28
error
Metropolitan Design/manufacturing
ARI T10 50/11 kV Single Supply 1951 1978 27
Vickers error
Design/manufacturing
TUI T9 50/11 kV Single Supply English Electric 1952 1996 44
error
Design/manufacturing
WPW T2 11/11 kV Three Regulator English Electric 1950 1985 35
error