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Inc. Fifth
Technical
Conference,
Albuquerque,
13-15 Nov 2006; Christoph
Krause:
Weidmann-ACTI
Inc. Annual
Fifth Annual
Technical
Conference,
Albuquerque,
13-15
Nov 2006
Design
by diagnostics
of transformers
still in operation and of apparatuses taken out of service
"New improvement
Diagnostic Concepts
for Better
Asset Management"
Group
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Contents
1. Power rating enhancement by elimination of the limitation set by induced tank
heating through a complex, three-dimensional electromagnetic-thermal study of
a transformer still in operation, and subsequent design adaptation.
2. In-depth diagnostics of aged transformers by forensic investigations after
having been taken out of service before being scrapped
provides accurate information about the cooling efficiency of the apparatus.
enables better assessment of the status of similar transformers in the grid
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Contents
1. Power rating enhancement by elimination of the limitation set by induced tank
heating through a complex, three-dimensional electromagnetic-thermal study of
a transformer still in operation, and subsequent design adaptation.
2. In-depth diagnostics of aged transformers by forensic investigations after
having been taken out of service before being scrapped
provides accurate information about the cooling efficiency of the apparatus.
enables better assessment of the status of similar transformers in the grid
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
No Mag
Steel Cover
Bushing
Inspection on site
6
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Plane of symmetry
Technical challenges:
Aluminum shields inside the tank
Mild steel tank wall
Non-magnetic steel cover parts
3-dimensional modeling
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Infrared scan
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Acting together with the manufacturer of the current bus enclosures, a different
design was developed with significantly lower losses in the critical area of the tank
Original Design
Improved Design
11
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Creating the
FEM mesh
659000
(number of tetraedra)
Detail view
12
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Loss distribution
n
nts
g
i
e
s
De rovem
Imp
Original Model
Modified Model
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Re-Design
14
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
17
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Reference list
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Contents
1. Power rating enhancement by elimination of the limitation set by induced tank
heating through a complex, three-dimensional electromagnetic-thermal study of
a transformer still in operation, and subsequent design adaptation.
2. In-depth diagnostics of aged transformers by forensic investigations after
having been taken out of service before being scrapped
provides accurate information about the cooling efficiency of the apparatus.
enables better assessment of the status of similar transformers in the grid
19
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
21
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
22
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
23
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
24
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
25
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
26
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
DP
1000
DP (t)
500
time (years)
27
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer A
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
Transformer B
110 / 63 kV
31.5 MVA
3
ONAF
Siemens Schuckert, Berlin, Germany
E.ON, Germany
1955 - 2003
Transformer C
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
220 / 110 kV
140 MVA
3
OFAF
TRO, Berlin, Germany
Vattenfall, Germany
1974 - 2004
one phase
380 / 220 kV
600 MVA / 3
1
OFAF
MFO, Zurich, Switzerland
NOK, Switzerland
1962 - 2005
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer A
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
110 / 63 kV
31.5 MVA
3
ONAF
Siemens Schuckert, Berlin,
Germany
Operating utility: E.ON, Germany
In service:
1955 - 2003
29
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
30
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer A
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
110 / 63 kV
31.5 MVA
3
ONAF
Siemens Schuckert, Berlin,
Germany
Operating utility: E.ON, Germany
In service:
1955 - 2003
Core
LV
Degree of Polymerization
1200
HV
Tap
> 900
801-900
701-800
601-700
501-600
401-500
301-400
201-300
< 200
Windings
1000
800
bottom
600
middle
top
400
LV
HV
Tap
200
0
31
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer B
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
220 / 110 kV
140 MVA
3
OFAF
TRO, Berlin, Germany
Vattenfall, Germany
1974 - 2004
32
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
33
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer B
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
220 / 110 kV
140 MVA
3
OFAF
TRO, Berlin, Germany
Vattenfall, Germany
1974 - 2004
Tert LV
> 900
801-900
701-800
601-700
501-600
401-500
Degree of Polymerization
Core
1000
800
bottom
middle
top
200
HV
301-400
201-300
< 200
Windings
400
LV
Tap
DP
1200
600
HV
Tap
34
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Transformer C
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
380 / 220 kV
600 MVA / 3
1
OFAF
MFO, Zurich, Switzerland
NOK, Switzerland
1962 - 2005
35
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
36
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
cylinders
Transformer C
380 / 220 kV
600 MVA / 3
1
OFAF
MFO, Zurich, Switzerland
NOK, Switzerland
1962 - 2005
LV
HV
DP
laminated strips
Core
Voltage:
Rating:
Phases:
Cooling:
Manufacturer:
Operating utility:
In service:
Tertiary
1200
> 900
801-900
701-800
601-700
501-600
401-500
301-400
201-300
< 200
Degree of Polymerization
1000
800
bottom
middle
top
600
400
Tertiary
LV
HV
200
0
37
Windings
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
16
14
Frequency
12
10
6
4
2
0
0
250
500
750
Degree of Polymerization
38
1000
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
1200
2% water content
40C
1000
50C
800
600
60C
400
70C
200
90C
80C
0
0
10
20
30
40
1200
60C
1000
70C
800
80C
600
90C
400
100C
200
110C
0
0
50
10
20
30
40
= A e
t
is not precise.
DP( t ) DP
39
50
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Summary
The DP profiles matched the expectation: lower DP-values at the winding top and
around the conductors, higher values at the bottom and of the inter-winding
insulation.
The insulation of transformers A (50 years) and C (40 years) was still in relatively
good condition.
The youngest transformer B (30 years) had reached its end of life - continuing
operation would have been associated with catastrophic failure hazard.
The moisture content was high, perhaps right from the beginning?
The DP of paper at the beginning of life time was lower, due to overheating
during drying?
The cooling design was insufficient?
The transformer was operated beyond name plate?
40
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Remarks
It takes relatively little effort to collect solid insulation samples, when power
transformers are scrapped. The findings may be of high value.
For a comprehensive aging replica, it is necessary to take samples
systematically throughout the transformer.
With the water content information of the samples, it is possible to assess
the operating insulation temperatures with better precision. Yet, measuring
the moisture of the samples requires quick handling on-site, due to
inevitable water absorption when exposed to the (humid) air.
41
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
42
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
43
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
44
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
45
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
46
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
49
Weidmann-ACTI Inc. Fifth Annual Technical Conference, Albuquerque, 13-15 Nov 2006; Christoph Krause:
Design improvement by diagnostics of transformers still in operation and of apparatuses taken out of service
50