Trafo Rehab vs New
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Transcript of Trafo Rehab vs New
Power
Tran
sfor
mers
Econ
omicsof
Refur
bish
men
tvsRep
lace
men
t
Pres
enter:
Moh
ammad
RSidd
iqui
Nationa
lGrid,
Saud
iArabia
CoAutho
rs:A
bdullahOBa
mou
saNationa
lGrid,
Saud
iArabia
Introd
uction
•Th
ispa
perisb
ased
on–
•Dataob
tained
from
theGrid
•Interaction
with
some
Tran
sformer
man
ufacturers.
•Te
chnicalPa
pers
publishe
don
the
diffe
rent
compo
nents
ofPo
wer
Tran
sformers
•Ong
oing
Projects
intheGrid
TheNee
dto
Refur
bish
/Ren
ovate
•In
theearlyseventies,
Utilities
wen
tfora
HV
Tran
smission
Level
of110
kV/132
kV.
•In
theWestern
Region
Grid,2
38of
atotal
of730
Tran
sformers
were
commission
edbe
tween
1975
to1985
.Th
eywou
ldbe
30to
40yearsby
the
year
2015
Tran
sfor
mer
sC
omm
issi
onin
gD
etai
lsfr
om19
75to
1985
inW
OA
Nat
iona
lG
rid
Are
a
Year
ofC
omm
issi
onin
g
Tota
lFr
omTo
From
To
1975
To19
8019
81To
1985
JED
DA
H79
5213
1
MA
KK
AH
1927
46
TAIF
1014
24
MA
DIN
AH
Nil
2525
TAB
OU
KN
il12
12 238
Spec
ific
Prec
eden
ce
In1971
thefir
stfour
110/13.8kV
Tran
sformers
were
put
inservice
.Tw
oeach
inCity
Substation
andDSP
Substation
inJedd
ah
Thetw
oTran
sformersin
CitySu
bstation
were
servingon
fullload
andha
dto
bereplaced
2yearsba
ckne
ar
The2Tran
sformersin
DSP
Substation
were
notfully
load
edan
darestill
inservice.
This
raises
thefollow
ingissu
es
•To
determ
inetheag
ingeffect
ontheun
its
•Step
stobe
take
nto
mak
eade
cision–whe
ther
replaceor
refurbishtheUnits.
Aging
depe
ndson
•Th
eload
ing
cycles
that
the
tran
sformersha
vebe
ensu
bjected
toov
ertheyearsa
nd
•Th
eNum
berof
Throug
hfaults
that
theTran
sformer
hass
uffered
Agingis
best
establishe
dby
•Ex
ternal
inspection
oftheTran
sformer
anditsA
uxiliary
equipm
ent.
•Insulating
Streng
thof
theTran
sformer
Oil.
•DGAAna
lysiso
fthe
Tran
sformer
Oil
•Freq
uenc
yRe
spon
seTe
st(Previou
sRe
ferenc
eRe
sults
necessary)
•Bipo
larT
est
Plan
ned
stud
yan
dtim
ely
replacem
ent/refurbishm
ent
will
preven
tsu
dden
deaths
ofTran
sformers
that
resu
ltin
unplan
ned
outages
and
possible
extend
edda
mages.
APo
wer
Tran
sformer
isa
stationa
ryde
vice
anddo
esno
tcon
tain
compo
nents
that
requ
ire
precision
Engine
ering.
Disman
tling
aTran
sformer
and
replacingtheco
mpo
nentsisrelativ
elyan
easy
proc
edure.
Thepictures
inthefollo
wingslides
show
diffe
rent
stages
ofassembly
and
dism
antling
ofthe
Tran
sformer
indiffe
rent
location
s
InWorksho
p
Gen
erally
theco
mpo
nent
sth
atremainintact
over
theye
arsare:
•Th
eMain
Tank
•Th
eCo
rean
dFram
e•
TheEx
ternal
Metallic
fittin
gs–Con
servator,
Piping
,Rad
iator
•Th
eMecha
nicalP
rotectionDevices
and
ControlC
ubicles
Theco
mpo
nent
sth
atne
edinsp
ection
before
deciding
replac
emen
t/reus
e:
•Ta
pCha
nger
/DiverterS
witc
h.•
CoolingFa
ns.
•Protectio
nDevices.
•Bu
shings.
•Cu
rren
tTrans
form
ers.
Major
Com
pone
ntsto
bereplac
ed:
•Th
eCo
ilsform
ingtheH
V/LVW
inding
sha
veto
bereplaced
•New
Gaske
tsfors
ealin
gan
dco
nsum
ables
•Pressb
oard
materialu
sedforins
ulation
andspacing.
Com
pariso
n:
•Th
eco
stof
ane
w40
MVA
110/13.8kV
Tran
sformer,
includ
ingDesignMan
ufacturing
,Trans
portation,
Installatio
nTe
sting&Co
mmission
ing
in20
12is2.8to
3.2mSR
anda67
MVA
trafoco
sts3
.5to
4.0mSR
•Re
furbishm
entof
anexistin
g40
MVA
Tran
sformer
will
costab
out1.5
mSR
.Th
eco
stof
refurbishm
ento
faTran
sformer
isab
out5
0%
asco
mpa
redto
theco
stof
replacem
ent.
•Be
lowisaco
stco
mpa
risonTa
bleba
sedon
inform
ationexch
angedwithsomeman
ufacturers.
Item
Des
crip
tion
as%
ofto
talc
ost
ForN
ewTr
afo.
ToR
efur
bish
1D
esig
n5
0
2P
roje
ctM
onito
ring,
Inst
alla
tion
Test
ing
&C
omm
issi
onin
g15
53
Tran
spor
tatio
n+
Dut
y15
5
4Tr
ansf
orm
erC
ompo
nent
s4.
1C
oil
2012
4.2
Cor
e7
0
4.3
Tank
,Con
serv
ator
,Rad
iato
rs,
Pip
ing,
Gas
kets
,Con
sum
able
s,fa
nsan
dC
ontro
lCub
icle
s12
2
Item
Des
crip
tion
as%
ForN
ewTr
.To
Ref
urbi
sh
4.4
Coo
lant
-Tra
foO
il8
5
4.5
Mec
hP
rote
ctio
ns,C
Ts5
2
4.6
Tap
Cha
nger
105
5Fa
ctor
yTe
sts
33
6D
ism
antli
ngan
dA
ssem
bly
010
Tota
l10
0%49
%
In20
06a
100M
VA13.8kV
/132kV
Tran
sformer
had
allitsW
inding–
HV
and
LV,replaced
for1.3
mSR
.Th
eco
stof
such
Tran
sformer
then
was
abou
t5mSR
.
•238Tran
sformersin
theWestern
Region
will
be30
40yearso
ldby
2015.If10%
ofthese238Tran
sformersare
iden
tifie
dforrefurbishm
enteach
year
over
thene
xtten
years
,it
will
berequ
ired
torefurbish
one
Tran
sformer
every2weeks.
•If
extend
edto
the
entire
Cou
ntry
that
has4
such
Region
sin
all,
the
refurbishm
ent
rate
can
beestimated
as4
Tran
sformers
in2
weeks
that
is2
Tran
sformersp
erweek.
•MoreTran
sformerswill
fallin
this
catego
rywith
each
passing
year.
•An
Assem
blyplan
tspon
sored
bythe
Utility
wou
ldbe
idealtotake
upthis
workas
theorde
rbo
okwill
befullforthe
next
soman
yyears.Itwill
beafir
ststep
towards
indigeno
usHeavy
Indu
stry
for
prod
uctio
nof
Tran
sformers
and
gene
rate
employ
men
tforskilled
andsemiskilled
worke
rsin
theco
untry.
ANew
Team
will
have
tobe
setu
p.
•Alte
rnativelyit
can
beou
tsou
rced
toon
eof
the
compa
nies
working
with
the
requ
ired
facilities
with
intheKingd
om
ADVA
NTA
GES
OFREF
URBISHMEN
T:
•CostS
aving.
•Node
sign
cost.
•En
vironm
entfrien
dly.
•NoCivilWorkrequ
ired
.•
Con
trol
andIndication
srem
ainun
chan
ged.
•Sh
ortc
ycleop
eration–Can
beaimed
for16
weeks.
DISADVA
NTA
GES
:
TheRa
ting
oftheTran
sformer
hastobe
retained
,itc
anno
tbe
increased.
Facilities
need
ed
1.Aworksho
pwithsu
itab
leun
Tank
ingfacilitieso
fthe
Live
Partan
dreplacem
ento
fcoilsby
newon
es.
2.Arran
gemen
tofW
ashing
andClean
ingof
MainTa
nkan
dCorean
dretigh
tening
ofCore.
3.Ovenfacilityford
ryingtheassemblybe
fore
sealingfor
tran
sportation
.4.
Testingfacilitiesfor
theTran
sformer
andits
compo
nents.
5.Su
fficient
Storagean
dha
ndlin
gfacility.
6.Oilregene
ration
unit(atsite
)withOilTa
nksfor
treatm
enta
ndstorage.
TheTran
sformer
oilw
illha
veto
beregene
rated.
Theco
stof
regene
ratio
nisab
out6
0%
asco
mpa
redto
theco
stof
newoil.Th
isisan
environm
entally
friend
lyproc
edurean
dthesuccessr
ate
asexpe
rien
cedin
theexistin
gsubstatio
nsis100%
.
Pastepicture
Con
clus
ion
•Th
erefurbishe
dTran
sformer
will
have
alife
nearlyas
good
asthat
ofane
wTran
sformer,as
stud
ieso
fthe
silic
onsh
eets
used
toform
the
core
oftheTran
sformersh
averevealed
noag
ing
effect.
•Th
epu
rposeof
thispa
peristoinitiateahe
althy
discus
sion
onthissubjecttotake
timelystep
sto
tack
lethesituationthat
wou
ldarisein
coming
years.