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Regeneration and Strengthening of Oil- immersed Transformers Horst Penack Berlin, 25 October 2010 Presentation 02.03.2010, Page 1 MultiMetall the MetalExistenceCompany Agenda Regeneration and Strengthening of Oil- immersed Type

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Presentation 02.03.2010, Page 1 MultiMetall the MetalExistenceCompany

Regeneration and Strengthening of Oil- immersed Transformers

Horst Penack

Berlin, 25 October 2010

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Presentation 02.03.2010, Page 2 MultiMetall the MetalExistenceCompany

Agenda

1. Introduction 2. Overhauling and strengthening 3. Use of PolymerMetal & elastomer 4. Use of Moisture-in-Oil Measurement 5. Concluding discussion

Regeneration and Strengthening of Oil- immersed Type Transformers

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Introduction.

1

Corrosion = main cause of wear and tear OH- ions etc. acting as free radicals Ingress via seals and oil leaks still invisible to the eye Visible oil leaks indicate that OH- ions have already infiltrated and reacted with the H+ ions to become H2O Hermetically sealed transformers and SF6 plants are equally affected

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Chapter 2.

2

Chapter overview:

  • 1. Introduction
  • 2. Overhauling and

strengthening

  • 3. PolymerMetal &

elastomer

  • 4. Moisture-in-oil

measurement

  • 5. Transformer

assessment

  • 6. TPM
  • 7. Servicing the active

parts of oil-filled transformers

  • 8. Discussion

Overhauling and strengthening.

  • Third-party services to be kept between 30–50%
  • Repair and maintenance costs to be kept between 3-

12% of the plant value

  • Plant reliability must be the primary goal of all efforts
  • Crash management to be ruled out
  • Preventive overhauling and strengthening must be the

chief objective

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Overhauling and strengthening.

2

Classification in categories

Maintenance

Strengthening

Servicing

Inspection Regeneration (Repair) Renewal Replacement Partial replacement

Overhauling

Inspection DIN 31051

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Overhauling and strengthening.

Servicing

The sum total of all measures used to preserve and restore the TARGET state and to determine and assess the ACTUAL state of a system's technical facilities

Measures to assess and determine

the ACTUAL state of a system's technical facilities

Measures to be taken:

Inspection visits including readings Measurements Checks

Inspection

Measures to preserve the

TARGET state of a system's technical facilities

Measures to be taken:

Cleaning Flushing Conservation Lubrication

Maintenance

Measures to restore the

TARGET state of a system‘s technical facilities

Measures to be taken:

Repair Replacement Setting

Overhauling

2

Scheduled maintenance: at regular intervals Condition-based maintenance, as needed Preventive

  • verhauling, scheduled

Reactive maintenance, unexpected

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Overhauling and strengthening.

2

Operation of electrical power installations

Operation of electrical power installations

Operation Work Monitoring Setting Modification Commissioning

Maintenance

e.g.

  • cleaning
  • troubleshooting
  • ..

e.g.

  • switching
  • adjusting
  • controlling

* Source: DIN 57105 Part1 / VDE 0105 Part1

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Overhauling and strengthening.

2

Servicing

* Source: DIN 57105 Part1 / VDE 0105 Part1

Servicing comprises works designed to prevent interruptions and/or eliminate defects, to include:

Maintenance, e.g. lubrication or painting Monitoring, e.g. occasional or regular inspections, measurements, checks Repair Replacement of parts Tests and test runs

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Overhauling and strengthening.

2

In-house and third-party services

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Overhauling and strengthening.

2

Decision-making support for in-house or third-party award

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Overhauling and strengthening.

2

Overhauling an oil-immersed type transformer

Sealing the transformer Checking and replenishing the insulating oil Checking the diverter switch / repairing the on-load tap changer Repairing motor-drive mechanism Replacing the signage Checking the oil conservator vessels Checking the fan control and bearings Overhauling the oil pump Checking the protection and monitoring equipment Visual checking for corrosion damage Cleaning Replacing the standard parts

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Overhauling and strengthening Maintenance strategies

Condition-based servicing

  • Definitions for reaching the limit values
  • Determining the condition based on diagnostics
  • Use of cost reduction potential

Reliability-based servicing

  • A combination of different strategies
  • Taking into account all monitoring parameters
  • Assessment of condition and importance
  • Determination of failure risk, i.e. preparation of a model for technical and economic evaluation

2

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Overhauling and strengthening

Parameters for determining a transformer‘s condition

  • Age
  • Number of switching operations
  • Operating load, notably power transfer
  • Noise level
  • Annual utilization
  • Revisions and repairs
  • Measured and visual diagnostic findings
  • Service and spare part procurement
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Chapter 3.

Use of PolymerMetal & elastomer

  • Leaks in transformers and converters
  • Video of applications

3

Chapter overview:

  • 1. Introduction
  • 2. Overhauling and

strengthening

  • 3. PolymerMetal &

elastomer

  • 4. Moisture-in-oil

measurement

  • 5. Transformer

assessment

  • 6. TPM
  • 7. Servicing the active

parts of oil-filled transformers

  • 8. Discussion
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Chemistry Metallurgy Resin Hardener Fillers

  • Metal powder
  • Ceramic powder

Basic material + Hardener = PolymerMetal Resin + Filler

Use of PolymerMetal & elastomer.

3

Manufacture of PolymerMetal

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Use of PolymerMetal & elastomer.

3

Properties of PolymerMetal

Cold processing, produced on site Pot life between 2 minutes….60 minutes No fire – no explosion risk Thixotropic, i.e. “no expiry“ Very low shrinkage Mechanical processing possible after approx. 3 hours Full functional strength achieved after approx. 24 hours Supports any type of mechanical processing Hardens even in sub-zero temperatures ..

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Use of PolymerMetal & elastomer.

3

Properties of PolymerMetal (cont‘d.)

No rust formation underneath the coating, high resistance to chemicals Outstanding corrosion protection No stress cracking from heat Repairs possible without need of disassembling components Shelf life approx. 5-10 years at approx. 20° C Significant reduction of repair times Significant reduction of repair costs Available all over the world

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Use of PolymerMetal & elastomer.

3

Surface preparation

Surface preparation is of vital importance for ensuring optimum success of the repair measures

A: For normal PolymerMetals

  • 1. Create a metallically clean and sound surface
  • 2. Roughen the surface mechanically through particle-blasting, machining, grinding, etc.
  • 3. Reclean the surface by brushing, air-blasting, or vacuum extraction
  • 4. Thoroughly degrease the surface with special solutions

…

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Use of PolymerMetal & elastomer.

3

Surface preparation (cont'd.)

Surface preparation is of vital importance for ensuring optimum success of the repair measures

B: For MM-metal oL-steelceramic

  • 1. Create a sound surface
  • 2. Always remove any paint, surface should be roughened where possible
  • 3. Grinding residue is not a problem
  • 4. Reduce the oil flow for economical reasons

C: For MM-metal UW

Moist or water-immersed repair surfaces should be degreased and roughened, where possible.

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Use of PolymerMetal & elastomer.

3

MM-metal oL-steelceramic

Processing instructions

Mixing ratio

For the use of red hardener by volume

MM-metal oL-steelceramic: 2 Red hardener: 1 Auxiliary tool: measuring spoon, red Pot life: 4 minutes at 20° C, congealing time 20 min utes, hardening time 45 minutes

For the use of yellow hardener by volume

MM-metal oL-steelceramic: 8 Yellow hardener: 1 Auxiliary tool: measuring spoon, yellow Pot life: 30 minutes at 20° C, congealing time 2.5 h, hardening time 24 h

Application procedure

It is important to adhere precisely to the mixing ratio specified for MM-metal oL to red or yellow

  • hardener. Mixing must be very intense and thorough. Compact volumes should be avoided to ensure

compliance with the specified pot times. For good adhesion the PolymerMetal must permeate all oil, grease or gasoline contamination.

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Use of PolymerMetal & elastomer.

3

MM-Basic Set Rs

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Use of PolymerMetal & elastomer.

3

Sealing with oL

Insert video

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Chemistry Metallurgy Urethane Hardener Fillers

Oligomeric diamines Polyisocyanate Ceramic powder

Basic material + Hardener = elastomer MM 95 Urethane + Filler

Use of PolymerMetal & elastomer.

3

Manufacture of elastomer MM 95

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Use of PolymerMetal & elastomer.

3

Properties of elastomer MM 95 Cold processing, prepared on site Pot life approx. 11 minutes at 20° C High elongation at break: 330% High shore hardness A = 95 Full functional strength achieved after approx. 24 h Electric strength approx. 10-13 KV/mm Heat resistant in oil up to 120° C Available all over the world

Explain kit with elastomer

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Use of PolymerMetal & elastomer.

3

Surface preparation and processing of MM95

Surface preparation

Create a metallically sound surface through roughening

  • Clean the surface by brushing, air-blasting, or vacuum extraction
  • Thoroughly degrease the surface with MM solutions as alcohol, gasoline or varnish thinner

are unsuitable for this purpose

  • If elastomer is applied to a rubber surface it is enough to mechanically roughen and clean the

surface

  • Thinly coat all surfaces not intended to bond with elastomer with a separating agent and

repolish these surfaces after a brief drying period

Processing

Mixing ratio by volume

MM elastomer MM95 : 4 Hardener EL95: 1 Auxiliary tool: Measuring cup It is important to adhere precisely to the mixing ratio specified. Mixing must be very intense and thorough. The material should not be processed at temperatures under +5° C. Videofilm einblenden

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Use of PolymerMetal & elastomer.

3

Coating with MM95

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Use of PolymerMetal & elastomer.

3

Converter heads for 110kV and 220kV

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Use of PolymerMetal & elastomer.

3

Summary description of how to use oL and MM 95

1. Clean the transformer with a high-pressure washer (e.g. make Kärcher) 2. Locate suspected leaks using e.g. Paris white 3. Removal all paint in the area(s) to be sealed 4. Apply PolymerMetal oL with red hardener to the leak 5. Apply another coating of PolymerMetal oL and yellow hardener 6. After approx. 24 h perform leak checks using e.g. Paris white 7. When treating very big oil leaks be sure to apply vacuum to the transformer during the repair works 8. Repair sites exposed to vibrations or switching operations should be recoated with elastomer after sealing with PolymerMetal

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Use of PolymerMetal & elastomer.

3

MM SET oL

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Chapter 4.

Use of Moisture-in-Oil Measurement

  • Online moisture in transformer oil measurement

with HMT330

  • MM70 moisture meters for random

measurements on site

  • Measuring kit for load-dependent

moisture-in-oil analysis over an extended period of time.

4

Chapter overview:

  • 1. Introduction
  • 2. Overhauling and

strengthening

  • 3. PolymerMetal &

elastomer

  • 4. Moisture-in- oil

measurement

  • 5. Transformer

assessment

  • 6. TPM
  • 7. Servicing the active

parts of oil-filled transformers

  • 8. Discussion
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Use of Moisture-in-Oil Measurement.

4

Moisture-in-oil meter HMT330

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Use of Moisture-in-Oil Measurement on Site.

4

MM70 Handheld moisture meter

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Use of Moisture-in-Oil Measurement.

4

Breakdown voltage

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Continuation of Chapters 5 -7 Continuation of the seminar by

  • Mr. Georg Daemisch (Chapters 5–8)

Ageing behaviour, determination of remaining substance (remaining lifetime) and preservation of power transformers during

  • ngoing operation
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Chapter 8.

Concluding discussion

Q&A and discussion …

8

Chapter overview:

  • 1. Introduction
  • 2. Overhauling and

strengthening

  • 3. PolymerMetal &

elastomer

  • 4. Moisture-in-oil

measurement on site

  • 5. Discussion
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Thank you for your kind attention!

Dipl.-Ing.oec.Ing. Horst Penack

  • Sewanstr. 161

10319 Berlin

  • Tel. & Fax 030 / 535 62 58

Mobile 0172 / 21 10 492