POWER TRANSFORMER SOLUTIONPOWER TRANSFORMER SOLUTIONBy By DidikDidik SusiloSusilo WidiantoWidianto / UTR Technical General Manager/ UTR Technical General Manager

ENGINEERING DESIGN WORKSHOPALSTOM GRID INDONESIA AND PLN SUAR

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ALSTOM GRID INDONESIA AND PLN SUAR9th 10th November 2011

Samosir Resort, Samosir North Sumatra

GRID

ALSTOM Technology CenterALSTOM Technology CenterALSTOM Technology CenterALSTOM Technology Center

2

ALSTOM Global Power Transformer Manufacturers

ATTTurkey

TSTUK

AGMGermany

MMCC dCanada

Technical Int.CenterFrance

ASTChina

UTRI d i

TCTBrazil

TFRAustralia

Indonesia

PTIIndia

Group Highlight experience : :

Power transformer Power transformer : : 2250 MVA, 1200 kVAC, 800 2250 MVA, 1200 kVAC, 800 kVDCkVDC

Presentation title - 01/01/2010 - P 3

ReactorsReactors : 125 MVAR , 765 kV: 125 MVAR , 765 kVFurnace transformer : 200 MVA, 260 Furnace transformer : 200 MVA, 260 kAmpkAmp

1100 MVA 525 kV in Germany

Presentation title - 01/01/2010 - P 4

Shunt Reactor 100 MVAR 765 kV

Presentation title - 01/01/2010 - P 5

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

Presentation title - 01/01/2010 - P 6

Mechanical StandardizationMechanical StandardizationMechanical StandardizationMechanical Standardization

7

Organization - StandardizationPTR R&D PTR Industrial

Standardization DirectorDesign, Quality & Cost

RSHN

Product Center

M M M M

Mechanical Design

Electrical Design

Mechanical Design

Electrical Design

Mechanical Design

Electrical Design

Mechanical Design

Electrical Design

Manager Manager Manager Manager

Industrial Rules

Industrial Rules

Industrial Rules

Industrial Rules

Roll out of rules & tools(range specific)

8Unit 1 Unit N...

Mechanical Standardization covering best practices

kVkV

1200

220

1200

H-Range

N Range

220

300

150N-Range

E-Range

MVA25 75 2500

Presentation title - 01/01/2010 - P 9

H H Design = Design = ROBUST up to 5GROBUST up to 5G

CORE STEEL BANDAGESCORE STEEL BANDAGES

TOP PIN TOP PIN & CUP & CUP ANCHORINGANCHORINGTOP PIN TOP PIN & CUP & CUP ANCHORINGANCHORING

BOTTOM ACTIVE PARTS PIN CUP BOTTOM ACTIVE PARTS PIN CUP ANCHORING ANCHORING BOTTOM ACTIVE PARTS PIN & CUP BOTTOM ACTIVE PARTS PIN & CUP ANCHORING ANCHORING

10

H Range Concept (experienced up to 11001100 MVA)

ALSTALSTOOM M -- UK UK practicepractice

11

ALSTALSTOOM M UK UK practicepractice

SEISMIC SEISMIC ANALYSIS UP TO 5GANALYSIS UP TO 5G

Cooperation with ITB, oldest technical institute in Indonesia.

Contact person ; Prof. Dr. Komang Bagiasna

Analysis ; Static & Dynamic

Experiences; 2008 ; CHILEAN LNG (50 MVA) 2009 ; QAFCO Middle East (50 MVA 82 MVA ONAN = 13 units)

12

SEISMIC PROOF transformerSEISMIC PROOF transformer

13

Reactor Clamping system

Core clamping

Design with Design with outer

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

inner tie rods tie rods

Furnace Transformers

Electrolysis Industry => Rectifier Transformers (Aluminium, Zinc, Copper, Chlorine)

Chemical, Oil&Gas Industry => Converter Transformers

Steel Industry => Electrical Arc Furnace (EAF)Transformers

Presentation title - 01/01/2010 - P 15

EHV analysis & windingEHV analysis & windingEHV analysis & windingEHV analysis & winding

16

Intershield Disc Winding Technology ResearchIntershield Disc Winding Technology Research

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

To Design With EDT&PD Team; To Build And To Test A Full Size 800 kV UHVDC

17

ISDW Prototype

FEM Analysis for Structure ValidationFEM Analysis for Structure ValidationOil stress determination

Path BPath C

Path B

18

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

Presentation title - 01/01/2010 - P 19

Short Circuit AnalysisShort Circuit AnalysisShort Circuit AnalysisShort Circuit Analysis

20

Mean Hoop Stress Mean Hoop Stress

p

Leakage/ flux

dl

XRav

S Se

I2B

B

Leakage/ flux

F

e

Rav

RavY

Buckling StressBuckling Stress

Tilting StressTilting Stress

Clamping StructureClamping Structure

Clamping structure reactions

Rt= -F2,n Rt= 0 Rt= -(F1,n+ F2,n)if F2,n> F1,n

Rt= -(F1,n-F2,n)if F1,n> F2,n

Rt= 0

F2,n

F2,n

F2,n

F2,n F2,n

F1,n F1,n

F1,n F1,n F1,n

Rb= -F1,n Rb= -(F1,n+ F2,n) Rb= 0 Rb= -(F2,n-F1,n) Rb= 0

Clamping forces of reactions on each layer

Axial Clamping SystemAxial Clamping System

Applied Clamping Forces on the Applied Clamping Forces on the winding assembly winding assembly must be more than must be more than

the axial force per phase & active part weight/3the axial force per phase & active part weight/3the axial force per phase & active part weight/3the axial force per phase & active part weight/3

Transformer with built in reactorTransformer with built in reactor

Limiting reactor

26

Short Circuit Forces AnalysisShort Circuit Forces Analysis

27

Oil Directed CoolingOil Directed CoolingOil Directed CoolingOil Directed Cooling

28

Pumped Oil Directed CoolingPumped Oil Directed Cooling

The winding is starved of

iloil

Coil support block

Base Trough

Oil seal (diaphragm)

29END VIEW

ODAF ODAF Computer programsComputer programs

LAYER

LAYER

DUC

DUC

DUC

Inside

Outside stops

R

1

R

2

CT

2

CT

1

CT

3

Inside stops

The results screen will display the following parameters :

1. Individual winding labels2. Horizontal oil speed for each winding in mm/sec3. The vertical duct oil speed at the inside and outside diameters of each winding in

mm/secmm/sec4. The division of oil flow in Litres/ second for each individual winding5. The oil speed in any restriction holes (if applicable)

There is also a summary displayed of the input data to enable comparissons when any

30

y p y p p ymodifications are made and the calculation is re-run.

ODAF TechnologyODAF Technology

Oil Viscosity Factors:It can be seen from manufacturers data that the viscosity of the oil differs between oil types. This will have an impact upon the performance of the coolants performance and should be borne in mind will have an impact upon the performance of the coolants performance and should be borne in mind when evaluating the calculations.Typical values are given below:

VISCOSITE DES HUILES MINERALES EN FONCTION DE LA TEMPERATURE

1200

1400

1600

ShelL DIALA F

Esso UNIVOLT 52

Shell DIALA S

800

1000

V

i

s

c

o

s

i

t

(

c

S

t

Nynas 10 GBN

200

400

600

31

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

Temprature (C)

INFRA RED to monitor the surface hot spotINFRA RED to monitor the surface hot spot

Maximum < 125oC

32

ODAF COOLINGODAF COOLING

33

ODAF with AIR COOLERODAF with AIR COOLER

34

Moisture Evacuation and StabilizationMoisture Evacuation and Stabilization

35

Transformer PartsTransformer PartsOil PreservationOil Preservation

Winding

36Cooler Transformer Liquid

Moisture in Cellulose MaterialMoisture in Cellulose Material

The active part as heart of transformer is containing i ll l i l i i lapproximate 25% cellulose insulation material.

Thi ll l t i l ill d i th i l ti This cellulose material will drive the insulation structure of the transformer to strengthen the voltage withstand up to 100 times the air insulation g pvoltage strength.

Moisture in cellulose of winding conductor insulation is detected thru the water content in oil.

37

Equilibrium water content of paper vs oil

40

20 30 T1T1 oil temperature (C)T2 air temperature (C)

rel. humidity (%)

10 T2 205030100

3050

20100

10100

1050

40

f

p

a

p

e

r

[

%

]

50

5

e

r

c

o

n

t

e

n

t

o

f

60

7080

w

a

t

e 8090

100

38

00 20 40 60 80

water content of oil [ppm]

Oil Moisture Content Oil Moisture Content vs. vs. Dielectric StrengthDielectric Strengthg

e

[

%

]

a

n

d

V

o

l

t

a

g

e

q

.

W

i

t

h

s

t

a

P

o

w

e

r

F

r

e

Moisture Content In Oil [pap]

Paper Moisture Content vs Dielectric StrengthPaper Moisture Content vs Dielectric Strength

Automatic Vacuum Vapor Phase OvenAutomatic Vacuum Vapor Phase Oven9.5 x 5.5 x 5 m (L x W x H)9.5 x 5.5 x 5 m (L x W x H)( )( )

300 kW heating, 300 kW heating, 125 125 ooCC, 0.025 , 0.025 mBarmBar

Automatic process under programmable computerAutomatic process under programmable computer

Dew point control (final ; less than Dew point control (final ; less than --4545ooC)C)

41

p ( ;p ( ; ))

Water extraction (final ; less than 0.01 g/Water extraction (final ; less than 0.01 g/ton.hton.h))

Vacuum Vacuum VapourVapour Phase SchematicPhase Schematic

42

ISO-Static pressure while the winding in the oven

Presentation title - 01/01/2010 - P 43

Manufacturing and IndustrialManufacturing and IndustrialManufacturing and IndustrialManufacturing and Industrial

44

45

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

CHERRY PICKERCHERRY PICKERCHERRY PICKERCHERRY PICKERSafety high installationSafety high installationMovable EquipmentMovable Equipment

47

AIR Cushion Movable Platform AIR Cushion Movable Platform (SAFETY compliance)(SAFETY compliance)

48

TESTING TESTING LABORATORYLABORATORY1600 1600 kVpkVp Full Wave Impulse, 1300 kV SwitchingFull Wave Impulse, 1300 kV SwitchingZero Flux Losses measurementZero Flux Losses measurementS d f ll dS d f ll d i Shi ldi Shi ldSound proof wall & Faraday cage Sound proof wall & Faraday cage Magnetic ShieldMagnetic Shield

49

Materials & SourcingMaterials & SourcingMaterials & SourcingMaterials & Sourcing

50

Main Materials SourcingMain Materials Sourcing

Core Magnetic (Frame agreement); M5X POSCO, Korea M0H POSCO - Korea Domain Refined Core AK Steel - UK NIPPON Steel/JFE - JapanDomain Refined Core AK Steel UK, NIPPON Steel/JFE Japan

Rectangular Copper, CTC, TWIN (Frame agreement); ASTA, SHENYANG, SAMDONG. METROD Malaysia.

Transformer oil (Frame agreement); NYNAS

Insulation material; Pressboard = WEIDMANN Switzerland Pressboard = WEIDMANN Switzerland. Crepe papers = WEIDMANN (22HCC).

Bushings; Condenser type = PASSONI VILA Italy (Frame agreement).

Solid Porcelain = WARCO USA COMEM Italy Solid Porcelain = WARCO USA, COMEM Italy.

Tank subcontractor (Frame agreement); HITACHI . SKAS

SINISA

51

SINISA.

On Load Tap Changer (Frame agreement); MR Germany. ABB Sweden.

SMS System & Supplier AssessmentsSMS System & Supplier Assessments

52

Supplier Feedback & Corrective ActionsSupplier Feedback & Corrective ActionsExamplep

53

Tank Supplier Guidance Tank Supplier Guidance Continuous ImprovementContinuous Improvement

Provide the SOP (Standard Operating Procedure) for supplierProvide the SOP (Standard Operating Procedure) for supplier.

FAT (Final Acceptance Test) for oil leakage test & fittings

54

Hydro pressure Hydro pressure leakage test by tank supplierleakage test by tank supplier

Picture 2

55

PAINTING typical DesignPAINTING typical DesignHeavy Marine Corrosive ClassHeavy Marine Corrosive Class

56

Technology VISION & TRENDSTechnology VISION & TRENDSTechnology VISION & TRENDSTechnology VISION & TRENDS

57

Technology VISION & TRENDTechnology VISION & TREND

ECO design (CO2 reduction); Low noise & Low partial discharge Environmental Friendly SAFETY Precaution

SMART grid ;SMART grid ; EWS (Early Warning System) CBM (Conditioned Based Maintenance)

A i & F il ti Aging & Failure prevention Intranet Information Technology

On Line Partial Discharge (UHF or UltraOn Line Partial Discharge (UHF or Ultra--sonic method)sonic method) On Line Gas Monitoring.On Line Gas Monitoring. On Line Hot Spot Temperature Monitoring.On Line Hot Spot Temperature Monitoring. Tap Changer Tap Changer BehaviourBehaviour MonitoringMonitoring

58

Safety Harness Attachment PointsSafety Harness Attachment Points

59

ERGONOMIC DesignERGONOMIC Design

Elevated Oil level IndicatorElevated Oil level Indicator

60

COCO22 reduction Programs reduction Programs WATER Based PaintsWATER Based Paints(Under Research (Under Research -- year year 2012 2012 target)target)

61

EcoEco--Design/vegetable oil transformerDesign/vegetable oil transformerg gg gDescriptionEnvironmentally friendly transformers and reactors filled Environmentally friendly transformers and reactors filled

with vegetable oil Vegetable oil totally biodegradable , with higher fire

point than mineral oil (envirotempFR3 oil from COOPER)COOPER)

Existing experiences : transformers and reactors up to 300kV.

62

Future Environmental Friendly Liquid

Environmental liquid = Enviro-Temp FR3 by COOPERI hibit d il G i i X b NYNAS Inhibited oil = Gemini-X by NYNAS

PropertyProperty typical valuestypical values Inhibited oilInhibited oil FR3FR3Property Property typical valuestypical values Inhibited oilInhibited oil FR3FR3Antioxidant, phenols 0.08% per Wt n.a.

Oxidation stability by 120oC 500 hours continuousOxidation stability by 120oC 500 hours continuous

Biodegradable in 21 days 25% 100%

Saturated moisture at 25oC 80 ppm 1200 ppmSaturated moisture at 25oC 80 ppm 1200 ppm

Temp. rise for unity life time *) 60/65/78 K 80/110/130 K

Fl h i t 145oC 330oCFlash point 145oC 330oC

Pour point -57oC -18oC

Liquid Water Absorption versus Time Exposure

100

Water Absorption of Dielectric FluidsExposed to Ambient Air (2 of 2)

Water Absorption of Dielectric Fluids

n

t

(

%

s

a

t

u

r

a

t

i

o

n

)

60

80 conventional transformer oilEnvirotemp FR3 fluid

Exposed to Ambient Air (1 of 2)

p

p

m

)

500

600

a

t

i

v

e

W

a

t

e

r

C

o

n

t

e

20

40

t

e

W

a

t

e

r

C

o

n

t

e

n

t

(

p

200

300

400

Envirotemp FR3 fluidExposure Time (hrs)

0 500 1000 1500 2000 2500 3000 3500

R

e

l

0

0 500 1000 1500 2000 2500 3000 3500

A

b

s

o

l

u

t

0

100

200 conventional transformer oil

100% S t ti100% S t tiExposure Time (hrs)

100% Saturation = 100% Saturation = FR3, 1200 FR3, 1200 ppmppmMineral Oil, 80 Mineral Oil, 80 ppmppm

Liquid Dielectric Strength vs. Water Content

Dielectric Strength versus Water Content

(

k

V

)

60

70

80c

B

r

e

a

k

d

o

w

n

40

50

60

8

1

6

D

i

e

l

e

c

t

r

i

c

20

30

40

Envirotemp FR3 fluidti l t f il

0 100 200 300 400 500 600

D

1

8

0

10

conventional transformer oil

Water Content (ppm)

0 100 200 300 400 500 600

GREEN Transformer (Environmental Friendly Oil Filed Transformer)

Presentation title - 01/01/2010 - P 66

HermeticalHermetical Power TransformerPower Transformer

DescriptionDescriptionN or N or H H range power transformers hermetically sealed range power transformers hermetically sealed

No oil conservator No oil conservator Special radiators with expansion capacitySpecial radiators with expansion capacityp p p yp p p y Rated power from 10 to above 100MVARated power from 10 to above 100MVA Voltage level up to Voltage level up to 245kV 245kV transfomerstransfomers with Low maintenance & longer with Low maintenance & longer

service lifeservice lifeKey Countries / Key Countries / CustomersCustomersKey Countries / Key Countries / CustomersCustomersGERMANY and EUROPE/ GERMANY and EUROPE/ NME, SEA, PACIFIC /NME, SEA, PACIFIC /customercustomer withwith life cycle life cycle costcost concernsconcerns, , whowho values values lowlow

maintenance (utilities, maintenance (utilities, railwaysrailways) )

Key Key CompetitorsCompetitors Product Product No No competitioncompetition knownknown withwith samesame productproductConventionalConventional transformerstransformers of all manufacturerof all manufacturer

MilestonesMilestones

2000:Technology developed in Germany together with radiator supplier2000:Technology developed in Germany together with radiator supplier

67

gy p y g ppgy p y g pp 2006:Design tools and rules made available to all PTR units 2006:Design tools and rules made available to all PTR units 2006:New Product brochure +3D model for promotion in fair2006:New Product brochure +3D model for promotion in fair

Noise Reduction ResearchNoise Reduction Research

Active part interface

Careenage for double wall effect

Tank pads

68Solution needed for demonstrator

Stiffeners Double walled tank bottom

On Line Monitoring System

Module Main Operating Voltage (1 phase) Load Current (1 phase) Apparent Power and Load Factor

Module Bushings Operating voltages (3 phases)

Overvoltages, number of overvoltagespp Oil Temperature Hot-Spot Temperature Gas-in-Oil Content Moisture-in-Oil Content Ageing Rate

Change of capacitance, online capacitance

Module Tap Changer Power consumption of the motor drive

OLTC oil temperatureg g On-load Tap Changer Position Number of Switching Operations Sum of Switched Load Current Operating Condition of

Pumps and Fans

OLTC oil temperature

Assessment of mechanical quality

Contact wear model

Oil temperature difference OLTC / tank

Operating Time of Pumps and Fans

Cooling Efficiency (Rth) Ambient Temperature Auxilary digital inputs

Module Overload Load currents (3 phases)

Overcurrents and short circuit currents

Module Insulation Gas-in-oil Gradient Moisture of Paper Bubbling Temperature and Safety Margin Lifetime Consumption

Number of overcurrents

Overload capacity

Emergency overloading time

Thermal model Lifetime Consumption Predicted top oil temperature Predicted hot spot temperature breakdown voltage

Thermal model

Actual losses

Real-Time On Line Monitoring System

Office

MS MS 30003000

PC FAXIntranet / Internet

TCP/IP (Ethernet)

PC FAXALARM

TelephoneProtocols, e. g. IEC 60870-5-

101, -104, DNP3.0, IEC61850, Modbus

Protection & Control

Transformer

Antenna:GSM Modem

Point to Point, e. g.0/4 .. 20 mA, Dig.

Laptop

TCP/IP orRS232

Monitoring ModuleIndustrial PC without fans, moving parts (flashmemory)

Monitoring Moduleincl. Server Module

Real Hot Spot Fiber Optic MeasurementReal Hot Spot Fiber Optic Measurement

Interbus Transformer SolutionInterbus Transformer SolutionInterbus Transformer SolutionInterbus Transformer Solution

72

Three covering supplies Three covering supplies Interbus TransformerInterbus Transformer

275 kV275 kV150 kV150 kVA t A t t ft f

275 kV WYE275 kV WYE 150 kV WYE150 kV WYE

150 kV150 kVAuto Auto transformertransformer

20 kV DELTA20 kV DELTA

Grounding Grounding transformertransformer

275/150 275/150 kV kV Interbus TransformerInterbus Transformer

with with loadable tertiary (20 kV)loadable tertiary (20 kV)

20 kV20 kV

Conventional Conventional vsvs AutotransformerAutotransformer

I1, I1, I2I2 = Current primary (1) & = Current primary (1) & secondary (2)secondary (2)

V1, V1, V2V2 = Voltage primary (1) & = Voltage primary (1) & secondary (2)secondary (2)

Presentation title - 01/01/2010 - P 74

Common Winding = NCommon Winding = N11 x (Ix (I11 II22))

Seri Winding = (NSeri Winding = (N22 NN11) x I) x I22

Comparison between Autotransformer Comparison between Autotransformer vsvs ConventionalConventional

Presentation title - 01/01/2010 - P 75

Vacuum Interrupter Vacuum Interrupter -- OLTCOLTC

Free Free maintenance for 300000 operationmaintenance for 300000 operation

ConclusionConclusion

1. For primary voltage : secondary voltageprimary voltage : secondary voltage in ratio of 2 : 1 2 : 1 such as this inter bus 275/150 kV, the autotransformer is the best ,solution.

2. At new a days, OLTC with vacuum interrupter technology is il bl Thi ill b b t h i t d th i t f available. This will be best choice to reduce the maintenance for

especially oil treatment in the tap changer compartment.

3 For in case tertiary winding will be loaded the impedance 3. For in case tertiary winding will be loaded, the impedance between tertiary and other winding shall not be small (e.gminimum 5% at tertiary rated capacity) to consider worst three phases short circuit withstand phases short circuit withstand.

4. For in case tertiary winding will be loaded, a grounding transformer is required to provide artificial grounding on the q p g gDELTA connection of tertiary winding.

Presentation title - 01/01/2010 - P 77

UTR UTR High Lighted project experiencesHigh Lighted project experiencesUTR UTR High Lighted project experiencesHigh Lighted project experiences

78

CANADA : ARCTIC remote area transformerCANADA : ARCTIC remote area transformer

Presentation title - 01/01/2010 - P 79

Special tank & support steel suitable for Special tank & support steel suitable for --5050ooC temperatureC temperature

CANADA : Stainless CANADA : Stainless steel radiator for arctic + high corrosivesteel radiator for arctic + high corrosive

80

POSO ENERGY 80 MVA & 90 MVA 275 kVPOSO ENERGY 80 MVA & 90 MVA 275 kV

81

Export to Export to PhillipinesPhillipines 100 MVA 230kV100 MVA 230kV

82

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

83Equipped with on line monitoring Equipped with on line monitoring EARLY WARNING system MS3000EARLY WARNING system MS3000

MYANMAR : 3 x 33.3 MVA 1 PH 230kVMYANMAR : 3 x 33.3 MVA 1 PH 230kV

84Equipped with built in short circuit limiting reactor Equipped with built in short circuit limiting reactor

THANKSTHANKS

85

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