Life Cycle Management (LCM) of fleet of transformers with insulating fluids

Dubai, Middle East Electricity 18th February 2013

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Diagnostic Coverage and Integrated Treatments (2013) based on IEC Standards, “State of the Art”,

Best Available Techniques (BAT) and Best Environmental Practice (BEP)

Vander Tumiatti- President and Founder of Sea Marconi (1968) - Turin (Italy);- Ass. Secretary IEC TC 10 (International Electrotechnical Commission) Geneve-CH;- IEC AWARD 1906 – 2009- ACS Member (American Chemical Society)- IEEE Member (International Electronical Electrical Engineering)- Expert PEN - UNEP (POPs-PCBs Elimination Network - United Nations Environment Programme) Geneve - CH.

Smart LCM-O&ESmart Life Cycle Management (LCM)of Oils & Equipment

Part 1


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Contents

1. Sea Marconi Introduction2. Transformers, Insulating Oils & Fluids3. Loss prevention4. Focus on LCM & Key Steps5. Fluid Carrier Approach6. Regulations, Standards & Guidelines7. Hot Topics - Criticalities8. New Sustainable Solutions 20139. Knowledge Value & Case Histories10. Conclusions


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Main locations

Headquarter:

Collegno (Turin, Italy)

Homécourt (region of Lorena, France)


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Collegno (Turin) – Italy1968

Seclì (Lecce) – Italy1992

Homécourt – France2002

Barakaldo – Spain2002Buenos Aires – Argentina

2004

Karlsruhe – Germany2007

Where we are


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• Foundation: 1968, by Vander Tumiatti in Turin Italy• Mission: Protection of company assets and environmental resources• Activities: Research, Technologies, Services and Products for Energy & Environment• Clients: > 3,000 users in the energy, industry and service sectors in Europe, South America and others countries• Human resources: 100 employees, engineer, doctors (chemistry, mechanics, economics, ICT, etc.) and qualified technicians• Diagnostics: lab Accreditation, EN ISO 17025, Databases, hi-tech instruments• Decontamination: on site Mobile Units (DMU) different sizes • Quality: ISO 9001, Globe (Sea Marconi Technologies) • Patents: EEC, USA, others countries patented processes• R & D: Qualified by Italian Ministry of University and Scientific Research • European Project: HALOCLEAN APPLICATION; contract number - G1RD-CT-2002-03014 (Principal Main Contractor)• Experts: members in WGs (IEC, CEN, CIGRE)

Key informations


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Smart LCM – O&E

Strength Points Pioneer & Expertise since 1968 Independence from Oils & Equipment

manufacturers Full technological capability (from idea to

operation) Innovation (new solutions from R&D); 40 patents According IEC Standards, State of the Art, BAT &

BEP International Accreditation Lab (Accredia, IAF, EA,

ILAC) Integrated & Effective approach for Life Cycle

Management


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We are Pioneer since 1968

… 1976 particles, 1978 DGA, 1979 PCBs HRGC-ECD, 1982 PCBs Dehalogenation, 1984 ICP - metals dissolved, 1989 2Fal and CO2 investigation…

2005 “DBDS & Corrosive Sulfur” discover and solution with Selective Depolarisation

2006 fingerprinting - AED profile

2008 “NO DBDS & Corrosive Sulfur”. Discover of quantitative determination of Total Corrosive Sulfur - TCS

2010 “SDBP & Corrosive Sulfur”. Sulfur Degradation ByProducts - DBTP, H2S, Mercaptans, etc.

2012 consumed “Thermal Life” for deep investigation relation to 2Fal, CO2 and Methanol and oxidation byproducts with multidetection approach…


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Power transformers treated per year (2012) 596

PCBs Dehalogenation (CDP Process) 135

Depolarisation and Reclaim (Chedcos) 120

Reconditioning (Chedcos) 341

Oil mass treated per year (2012) 5.177 ton

PCBs Dehalogenation (CDP Process) 1.270 ton

Depolarisation and Reclaim (Chedcos) 2.048 ton

Reconditioning (Chedcos) 1.859 ton

Number of Decontaminat. Mobile Units (DMU) 25

Oil samples analysed per Year (2012) 12.600

Transformers analysed per Year (2012) 7.750

Oil Test performed per Year (2012) 66.000

Transformers and equipment database > 50.000

Diagnostics database > 150.000

Technical Capabilities


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My Transfo: International Meetings2002

(R. Maina) Corrosive Sulfur (V. Sokolov) Transformer LCM

2004

(R. Maina) Oil Fingerprint and forecast (V. Sokolov) Transformer LCM

2006

(F. Scatiggio) Corrosive sulfur (R. Maina) Diagnostics for LCM (V. Sokolov) Post mortem inspection (D. Schubert) Insurance reliability and best practices

2008

(V. Tumiatti) Fingerprinting, Ageing, Diagnosis, Decontamination, Depolarisation and Detoxification of Oils (M. Pompili) Risk assessment (R. Maina) A.I. for Advanced Diagnostics

2010

(M. Duval) Dissolved Gas Analysis – DGA (F. Scatiggio) Corrosive Sulfur Removal (M. Pompili) PD Measurement in Insulating Liquids (S. Kapila) Advanced analytical techniques (R. Maina) Post Mortem diagnosis

Hot Topics Pioneers: exchange of global knowledge, experience, sustainable solutions in Oil & Transformer Life Cycle Management (LCM)

2012…


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Energy & Environment


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FLEET- Type - Power (MVA)- Voltage (KV max)- Age (year)- Fluid (type)- Manufacturer - Serial number- Asset Value (€/$)- Consumed thermal life- OLTC (type, fluid)- Bushing (Oil, SF6, etc.)

TRANSFORMERS = STRATEGIC ASSETSKey role in the networks: Generation, Transmission, Distribution and Use of Energy


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PCAs/PAHs

Priority: Insulating Mineral Oils


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• > 10,000 million litres of insulating oils • Typical replace value is more than ~ 1,5-2 € / litre• Insulating Oil represents ~ 5-6% value of transformer• Insulating Oil represents ~ 25% weight of transformer

€OECD - Total Asset Value:

Generation Power Transformer

> 150,000 million€ - Euro

Oils & Asset Management


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…other Insulating Fluids (ref. IEC Standards)

• Natural esters• Synthetic esters• Silicon liquids• Askarels - PCBs based• SF6• Others…

and Dry Transformers…


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Black-Out

Failure

InfancyOccasional

Old age

Explosion Fire

Damages

• Direct: Assets & Personal• Indirect: Loss Production• Environment: Soil, Water, Air

Protection of the Assets & Environment


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http://news.bbc.co.uk/2/hi/europe/8209663.stm

http://news.bbc.co.uk/2/hi/europe/8209663.stm

Typical Site

GSU Transformer explosion

Knowledge Value for Loss Prevention


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Russia 17th August 2009 - Accident Sayano-Sushenskaya RusHydro power plant – 6500 MW

* Vladimir Markin, spokesman of the investigation commission by the federal prosecution office

The impact of this accident, based upon the information available, indicates a severe profile of damages: 1- damages to persons (17 killed and 58 missing); 2- damages to assets and infrastructures (estimated over 1 billion dollars for a complete rebuild); 3- damages for the loss of production of energy, aluminium and other steel products (several billion dollars); 4- environmental damages for the contamination by insulating oils, turbine hydraulic fluids and lubricants that could endanger the delicate eco-system of this sub arctic area (estimated over 80 sq km with contaminated surface waters).

Knowledge Value from:Catastrophic Accident “Explosion of GSU Transformer in Insulating Mineral Oils”*


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Smart LCM – O&E

Life Cycle Management (LCM) of insulating Oils & Equipment has been developed, in 10 key steps, in accordance with the following objectives:A. Prevention and/or mitigation of losses (direct and indirect) and

risks for workers, assets, public health and environment, arising from human error, malfunction, or failures of the equipment that cause fires or spillage of hazardous compounds (Oils, PCA, etc.) and Persistent Organic Pollutants (POPs; PCBs, etc.);

B. Implementation of IEC Standards, “State of the Art”, “Best Available Techniques” (BAT), “Best Environmental Practices” (BEP) and methodologies available for safety, whilst taking into account the surroundings and the criteria of self-sufficiency and functional recovery;

C. Technical feasibility of the activities within the prescribed time schedules, according local regulations, based on cost/benefit analysis and economical feasibility. (CENELEC CLC/TR 50503 – February 2010, etc.)

Win-Win Strategies & Opportunities


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I. Start - Inventory, Requirements and General Specifications (unused insulating oils & fluids: AED fingerprint; additives, viscosity, flash point, etc.)

II. Acceptance (Tests of unused insulating oils & fluids)III. Factory TestIV. Prior EnergizationV. Post EnergizationVI. Supervision - Control and Diagnosis for Insulating Oils &

Equipment (anamnesis; signs; markers; symptoms; trends; typical value, alert value, alarm value; critical factors, type/priorities; corrective actions & countermeasures, type/priorities, etc.)

VII. Oils & Fluids Maintenance with Integrated Treatments & Processes

On-Load/Off-Load (physical decontamination/reconditioning; selective depolarisation-DBDS, metal dissolved, acid and polar compound/reclaim; dehalogenation/detoxification of PCBs & POPs; transformer drying; transformer desludging; additives; etc.)

VIII.Equipment Maintenance & ReparationIX. Post Failure (Tests, Diagnosis and Treatments)X. End of Life - Post Mortem (Tests, Diagnosis and Treatments)

a. Material recoveryb. Decontamination and/or disposal Waste (PCBs, etc.)

Key Steps for Oils & Power Transformer LCMAccording with IEC Standards and CIGRE Guidelines and specific Requirements


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Added Value for Customers, Holders, & Partners


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Integrated methods based on “Fluid Carriers” equivalent to “human blood”.

The «Fluid Carrier» Approach

PARADIGM: diagnostic Tests and dialysis therapies applied to the body and internal organs


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Representative Sampling for Diagnostic Testsin Accredited laboratory

Transformer fluids Human bood



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BAT/BEP – IEC methods & ISO 17025 lab accreditation for independent analysis and diagnostic coverage to support insurance coverage

Example Sea Marconi lab Typical Hospital lab



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Advanced analysis and diagnostic methods Quality certification: ISO 9001; ISO

17025-2000 Uncertainty determination for each Test

Independent Expertise (since 1968) for:

• High skilled human resources; • Multidisciplinary approach;• Large number of Tests performed;• Advanced instrumentation;• R&D for the future methods;• Robust data base for decision support

of global customers



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Trend analysis

Test results with Method, Uncertainty ISO 17025

Diagnosis for Identification of Functional and Environmental Criticalities According to IEC 61619, EN 12766 and IEC Standards

Diagnosis with Health Index, Critical Factors, Actions And Countermeasures (type and priorities)PCBs Test

Report


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Example of Sea Marconi DMU for ON-LOAD treatments

500 KV Brazil (2009)

Human blood dialysis

DMU (Decontamination Mobile Unit) for integrated treatments & processes (decontamination, selective depolarisation, dehalogenations and detoxifications) in continuous mode, off-load/on-load conditions


BAT/BEP Technology


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Main functionPhysical

decontamination

CHEDCOS depolarisati

on

CDP PROCESS®

dehalogenation

Recovery of dielectric properties

Recovery of the chemical properties of the oil (acidity, delta tg, colour)

Elimination of sulfur corrosive contaminants, DBDS

Elimination of dissolved organo-metallic contaminants

Dehalogenation/Detoxification of PCBs/PCTs/PCBTs, POPs compounds etc.

DMU (Decontamination Mobile Unit) for Multifunctional Integrated Treatments & Process


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Typical DMU configuration


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Regulation, Standards & Guidelines


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IEC 60296 ed. 4 - 2012“Unused mineral insulating oils for Transformers and Switchgears”

1-Function

2-Refining /Stability

3-Performance

4-Health, Safety, andEnvironment (HSE)


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PART 1 DBDS quantification and oils fingerprint (AED profile: C, S, etc.) PART 2Total Corrosive Sulfur - TCS QuantificationPART 3Total mercaptans and disulfides

IEC 62697-1: 2012Test method for quantitative determination of corrosive sulfur compounds in unused insulating liquids


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IEC 60422 Ed. 4 – 2013Mineral insulating oils in electrical equipment – Supervision and maintenance guidance


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CENELEC CLC/TR 50503 - 2010Guidelines for Inventory, Control, Management, Decontamination and/or Disposal of Electrical Equipment and Insulating Liquids containing PCBs


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The recommendations for concentration limit for Corrosive Sulfur compounds in oils (CIGRE A2.32 figure 9, pag. 31):• “<10 mg/kg for DBDS (after 90 days);• < 5 mg(S)/Kg total difulphides + mercaptans content in oil.” Total Corrosive Sulfur compounds (after 90 days)

CIGRE – Brochure 378 - 2009 Guidelines - Copper Sulphides in transformer insulation


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CIGRE - Brochure n. 413 – 2010 Guidelines Insulating Oil Regeneration and Dehalogenation – PCBs


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Priority: Hot Topics

DBDS & Corrosive Sulfur

Copper Sulfide formation CuS,

Cu2S

C1Markers

DBDS (IEC 62697-1)

TCS (IEC 62697-2 preliminary draft)

Additives: Passivators (BTA, Irgamet 39, Irgament 30)

Additives: Bio Copper Corrosion Inhibitors (adenine, purine, etc.)

CCD Test, DIN Test, ASTM Test

Metals

Particles (Pioneer 1976)

Others…

Criticality: Corrosion Phenomena

NO DBDS & Corrosive Sulfur

C2


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SDBP & Corrosive SulfurSulfur Degradation

ByProducts:H2S, Mercaptans, etc.

Silver Sulfide formation Ag2S

“The oil regeneration process plant involves the high temperature reactivation of sorbent and fuller earth column by uncontrolled combustion. The Sulfur Compounds naturally present (DiBenzoThioPhene – DBTP, etc.) in the Oil and additives (DBDS, etc.) are decomposed in Sulfur Degradation ByProducts (SDBP such as corrosive H2S, Mercaptans, etc.) forming Sulphides CuS, Cu2S, Ag2S, etc.”.

«At relatively high temperature, sulphur-containing oil molucules may decompose and react with metal surface to form metal sulphides» (IEC 60422 Ed. 4 – 2013 art. 5.17)


Markers

TCS – Total Corrosive Sulfur (IEC 62697-2 preliminary draft)

Total Sulfur

DiBenzoThioPhene – DBTP, etc.

Metals

Particles

Others…


C3


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Service Period (Years)

Copper

in o

il m

g/k

g

43

NO Sulfur Corrosion & Copper/Metal dissolution


Markers

Metals

TAN

DF

IFT

Particles

Others…


C4


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Markers

Consumed Thermal Life & Solid/Paper Insulation

2Fal, CO2, H2O, Methanol, etc.

Oil & Fluid Degradation TAN, DF, IFT, Particles, Oxidation byproducts, etc.

Sludge Formation TAN, Sediments, Aspect, Particles, etc.


Criticality: Thermal Life & Degradation


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Hot Spot> 700 °C

Electrical

Arching

PD Partial discharges

D1 Discharges of low

energy

D2 Discharges of high

energy

T1 Thermal fault, t < 300 °C

T2 Thermal fault, 300 °C < t <

700 °C

T3 Thermal fault, t > 700 °C


Criticality: Faults

Markers

DGA

Particles

Metals


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According to IEC 61619, EN 12766, IEC 60296, IEC 60422, CENELEC 50503


Criticality: PCBs/POPs - Environment


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New Sustainable Solutions: 2013

Smart Field Test Kits (Patents Pending by Sea Marconi)

Kit forTotal Acid Number

Kit forTotal Corrosive Sulfur

Kit forTotal Chlorine/PCB

SM-TAN SM-TCS SM-TCPs


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Smart Field Multi Detection (online/offline)

Kit forSampling and

Detectionof selective DGA, SF6, Particles and Moisture

& Black Box

(Patents

Pending by Sea

Marconi)


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Smart Detection for Dry Transformers

Thermal profile

Vibro-acustic profile

SMELL PROFILE: nanosponges cartridge for selective adsorption of chemical byproducts correlated with thermal degradation of polymers (equiv. to DGA)


(Patents Pending

by Sea Marconi)


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Smart DMU (Decontamination Mobile Unit)

DMU (Decontamination Mobile Unit) -

Multifunctional and Integrated Treatments &

Processes for Decontamination, Depolarisation and

Detoxification of insulating liquids

(Patents Pending

by Sea Marconi)


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GSU Power TransformerYear: 1997, ABBPower: 192 MVAVoltage: 400 KVOil Mass: 58.000 Kg

DBDS[mg/Kg]

IFT[mN/m]

TAN[mg

KOH/g]DF

Before treatment 110 17 0,133 0,0448

After treatment < 5 40 < 0,01 0,0118

DBDS: ON-LOAD TREATMENTS

Italy 2006

Knowledge Value, for Twin & Family Units, from:Case history of Integrated Treatments with DMU


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ALUMINIUM FactoryRectifier TransformerYear: 1930, Brown BoveriPower: 19 MVAVoltage: 13 KVOil Mass: 15000 Kg

PCB[mg/Kg]

IFT[mN/m]

TAN[mg

KOH/g]DF

Before treatment 27 22,1 0,034 0,01483

After treatment 0,35 43,3 0,01 0,0013

PCBs: ON-LOAD TREATMENTS

Sweden

2012



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DBDS[mg/Kg]

H2O[mg/Kg]

TAN[mg

KOH/g]DF

Before treatment 125 7 0.095 0,0190

After treatment < 5 3 < 0,01 0,0033

Chemical Factory GSU TransformerYear: 2000, GetraPower: 47 MVAVoltage: 34 KVOil Mass: 12000 Kg


Qatar 2012



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DBDS[mg/Kg]

H2O[mg/Kg]

TAN[mg

KOH/g]DF

Before treatment 144 16 < 0,01 0,0026

After treatment < 10 5 < 0,01 0,0015

Electrical substationPower TransformerYear: 1998, Zaporozhtransformator

Power: 250 MVAVoltage: 345 KVOil Mass: 118000 Kg

Chile

2012




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Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»

TSN

Lines 1181 km

Substations 6

Total reactors 40

Reactors with corrosive sulfur 37 (92,5%)

Total failed reactors 15 (37,5%)

Novatrans

Lines 1278 km

Substations 6

Total reactors 36

Reactors with corrosive sulfur 13 (36,11%)

Total failed reactors -

Brazil

2005

Shunt reactors 500 KV line,

Nynas Naphtenic Oil


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Knowledge Value, for Twin & Family Units, from: case history of Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»

Extraction of core and windings on 19th of April 2006 for VISUAL INSPECTION

Total estimated losses (direct and undirect): more than 20 mln €

Italy

2006

GSU Transformer 400 KV, 192 MVA, Nynas

Naphtenic Oil


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Sinusoidal deformations of the windings, sector opposite to the

failure

Internal view of the HV winding, failure zone


Inspection and Analysis on internal HV windings

Italy 2006

GSU Transformer 400 KV, 192 MVA, Nynas

Naphtenic Oil


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VISUAL MAPPING OF THE COPPER SULFIDE DEPOSITS

Italy 2006

GSU Transformer 400 KV, 192 MVA, Nynas Naphtenic Oil



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MAPPING OF THE THERMAL DEGRADATION Italy 2006




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COLLECTION OF PAPERS FROM THE WINDING- Internal conductors of the winding heavily contaminated by copper sulfide.The strong corrosiveness of the oil (corrosiveness code: 4c, by repeated analyses according to ASTM D 1275 A ext. 48h) caused the deposition of elevated amounts of copper sulfide on the paper components.

Italy 2006




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Israel 2009

GSU Transformer 400 kV, 175 MVA, SHELL Napftenic Oil Diala AX

Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «NO DBDS & Corrosive Sulfur»


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Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «SDBP* & Corrosive Sulfur»*Sulfur decomposition byproducts related to high temperature and

Uncontrolled combustion for reactivation of sorbent and fuller earth

Uruguay 2010

Grid Transformer 500 kV, 425/3 MVA - OLTC, YPF65 Paraffinic Oil not inhibited


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Pacific Area

2012

Knowledge Value, for Twin & Family Units, from:Post-Failure Diagnosis related to «DBDS & Corrosive Sulfur»

Rectifier Transformer ODAF with membrane, year: 1998, 66/0,4 KV, 93,4 MVA, Nynas Napftenic Oil Nitro 10 GBN, winding CTC (enameled conductors)

Copper sulfide formation on paper and on enameled conductors


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a. Technical Standards (IEC, CENELEC, etc.) and Guidelines (CIGRE, etc.)

b. State of the Art (2012)c. Best Available Techniques (BAT)d. Best Environmental Practices (BEP)e. Accredited Laboratories (ISO IEC 17025)

with uncertainty determination for each Test

f. Qualified Expertise based on a Robust database and Case Histories

Conclusion 1

Smart LCM O&E - Key Factors


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Smart LCM – O&E

The Smart LCM O&E is able to prevent and/or mitigate the potential losses and unreasonable risks for the

asset, workers, public health and environment.

This sustainable solutions is targeted for protection of specific fleet of strategic electrical equipment filled

with insulating fluids.

This approach guarantees knowledge added value for Customers, Holders & Partners in terms of best

innovative technologies, reliability, quality control, traceability, economics, environmental protection,

social and stakeholders relationship.

Conclusion 2


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Thank you for your kind attention

Q & A


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Smart LCM – O&E

Since 1968

www.seamarconi.com

ContactsVander Tumiatti

Founder and General Partner

Sea Marconi TechnologiesVia Ungheria 20

10093 Collegno (Turin - Italy)Tel. +39 011 2343434Fax +39 011 2343435

e-mail: [email protected]

Ideas and Innovation for Energy and Environment

Alessandro CapoInternational Sales Manager

Sea Marconi TechnologiesVia Ungheria 20

10093 Collegno (Turin - Italy)Tel. +39 011 2343434Fax +39 011 2343435

e-mail: [email protected]

Life Cycle Management (LCM) of fleet of transformers with insulating fluids

Technology

Transcript of Life Cycle Management (LCM) of fleet of transformers with insulating fluids