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Transformers
5.1 Introduction Transformers 5.1.1 Overview 5.2 5.3 5.4 Reliability and Project Performance Transformer Loss Evaluation Power Transformers
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5.4.1 Large Power Transformers 5.4.2 Medium Power Transformers 5.4.3 Small Power Transformers 5.5 5.6 5.7 5.8 5.9 Reactors Special Transformers for Industrial Applications Phase-Shifting Transformers HVDC Transformers Distribution Transformers
5.9.1 Liquid-immersed Distribution Transformers for European/US/Canadian Standard 5.9.2 Voltage Regulators 5.9.3 GEAFOL Cast-Resin Transformers 5.9.4 GEAFOL Special Transformers 5.10 5.11 Traction Transformers Transformer Lifecycle Management
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5 Transformers
5.1 Introduction
5.1.1 Overview
Whether in infrastructure systems, industry or households, transformers always play a key role in the reliable transmission and distribution of power. The construction, rated power, voltage level and scope of the application are all key factors that determine the transformers design. Siemens provides the right transformer for every need from compact distribution transformers to large power transformers with ratings far above 1,000 MVA. The Siemens product range covers all mainstream requirements like UHV DC applications, low noise emission and environmentally friendly products with alternative insulation liquids, also embedded in a complete power system from generation via transmission to distribution networks. The long-term reliability of a transformer begins with its initial high quality. Then transformer lifecycle management measures maintain that quality throughout the transformers entire life. Fig. 5.1-1 and table 5.1-1 are an overview of how various transformers can be used in a network. Global Footprint Emerging countries are not just extended workbenches for producing goods. First and foremost, they are important future markets. Through its own local production and sales locations, Siemens provides service to customers in the most important global markets. The local presence of Siemens in many countries also ensures that customers have better access to Siemens services and that they benet from an efcient and effective distribution of Siemens resources as part of a global network. As Siemens factories around the world develop and produce their products, Siemens also encourages them to share their expertise. Siemens meets the growing global demand for transformers in a variety of ways: by further optimization of value-added steps in the worldwide network, by use of approaches such as vertical integration and by the pursuit of programs for boosting productivity.
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Transformers
5.1 Introduction
Fig. 5.1-1: Product range of Siemens transformers Generator and System Transformers Above 2.5 MVA up to more than 1,000 MVA, above 30 kV up to 1,500 kV (system and system interconnecting transformers, with separate windings or auto-connected), with on-load tap changers or off-circuit tap changers, of 3-phase or 1-phase design To control the amount of active power by changing the effective phase displacement
Phase Shifters
Reactors
Liquid-immersed shunt and current-limiting reactors up to the highest rated powers Reactors for HVDC transmission systems
HVDC Transformers
Transformers and smoothing reactors for bulk power transmission systems up to 800 kV DC Transformers for DC coupling of different AC networks
100 kVA to more than 40 MVA, highest voltage for equipment up to 36 kV, of 3-phase or 1-phase design, GEAFOL-SL substations
50 to 2,500 kVA, highest voltage for equipment up to 36 kV, with copper or aluminum windings, hermetically sealed or with conservator of 3- or 1-phase design pole mounted transformers and distribution transformers acc. to IEC with amorphous cores Electric arc furnace transformers Electric arc furnace series reactors DC electric arc furnace transformers Rectier transformers Converter transformers for large drives Traction transformers mounted on rolling stock
Traction Transformers
Condition assessment & diagnostics Online monitoring Consulting & expertise Maintenance & lifecycle extension Spare parts & accessories Repair & retrot Transport, installation & comissioning
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Product/Service quality
Greatest possible customer satisfaction
Process quality
Quality strategy
... combined with efcient processes results in the best cost position
Personnel quality
... and best trained and motivated employees
Nine mandatory elements are dened: Customer integration Embedded quality in processes and projects Consequent supplier management Business-driven quality planning Focused quality reporting Qualication of employees on quality issues Continuous improvement Management commitment Control and support role of quality manager Elements of quality (mandatory elements) Customer integration Customer integration depends on the consistent use of: Analysis tools for customer requirements and market studies Analysis of customer satisfaction Professional management of feedback from and to the customer Complaint management Customer requirements need to be precisely dened in a specication. And the specication must be continuously updated throughout the denition phase of a transformer project. The actual requirements must also be available to all responsible employees. Rapid feedback loops in both directions are essential in order to increase customer trust and satisfaction. Siemens resolves customer complaints to the customers satisfaction in a timely manner through its complaint management system. Embedded quality in processes and projects The quality of the processes used to produce a product has a signicant impact on the quality of the product that is actually produced. Process discipline and process stability can be
achieved by a high degree of process standardization. All processes should be standardized for all employees based on simple procedures. If this condition is met, it is possible to implement clearly dened work instructions (g. 5.2-2). Quality gates are placed at points in the process at which quality-relevant decisions are necessary. The following quality gates are mandatory for the power transformer business. Bid approval Entry order claried Release of design Release of fully assembled transformer Evaluation of project For each quality gate, there is a clear denition of participants, preconditions, results (trafc light) and the escalation process, if necessary. If the result is not acceptable, the process must be stopped until all requirements are fullled. Supplier management The quality of the product depends not only on the quality of the own processes but also on that of the suppliers. Problems and costs caused by inadequate supplier quality can only be reduced by a systematic supplier management process that includes: Selection Assessment Classication Development Phasing out of suppliers as well as the support process Supplier Qualication
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Transformers
5.2 Reliability and Project Perfomance
A further condition for a high level of supplier quality is close cooperation with the suppliers. Joint development of requirements for suppliers and processes leads to continuous improvements in quality. In this context, supplier know-how can also be used to create innovations. This aspect of the relationship with suppliers is becoming more and more important, especially in the transformer business. Business-driven quality planning Planning quality means analyzing possible future scenarios and anticipated problems and taking preventive steps to solve those problems. It is crucial that both current and future critical business factors are considered in planning. That means that quality is based on business-driven planning and specic objectives, activities and quantitative indicators. Focused quality reporting Reporting is based on: Focused key performance indicators such as non-conformance costs, external failure rate, internal failure rate and on-time delivery Concrete quality incidents Root cause analysis of quality problems including denition of corrective and preventive measures For customers, the reliability of transformers is of special importance. ANSI C57.117 has made an attempt to dene failures. Based on this denition, statistics on in-service failures and reliability values can be derived. An example for power transformers appears in table 5.2-1. Qualication of employees on quality issues People are the decisive factor inuencing quality. Therefore, all employees involved in the processes must have the skills and abilities appropriate to the quality aspects of the process steps they perform. Any qualication measures that may be necessary must be determined on the basis of a careful analysis of existing decits.
SIEMENS
PEQ
TPD 2.01.02
Page 1/6
SIEMENS
PEQ
TPD 2.01.02
Page 1/6
1. Purpose/objective
Process description for the manufacture of transformer core within the tolerances which are laid down
4. Process sequence
Subprocess 1: Setting up the construction devices and limit stops
2. Scope/application
applies to all the core forms of the power transformers does not apply to the cores of compensating reactors Adjusting the construction supports
3. Process overview/description
Stack of core laminations dimensions checked by the supplier to ensure that they agree with the drawing Frame parts dimensions checked by the supplier to ensure that they agree with the drawing Insulating parts dimensions checked by the supplier (internal ore external )to ensure that they agree with the drawing washers, small accessories Job related core drawings Process report TPD 2.01.01
INPUT INPUT
Tools Assembly area with special support beams for xing the core laminations which have been put on into position Integrated slewing mechanism for mounting the nished core
Measure-Measure ment
> Setting the middle distance of the support beams to one another in accordance with the drawing guideline > Tolerance +/5 mm to the desired size
> Setting the clearance of the support trestles (on the support beams) for the core-limb laminations Adjusting the support trestles > The position of support trestles are to be placed in the middle between the single bandages > The position and clearance of the bandages are dened in the core drawing
Completed core with clamping frame also completely mounted OUTPUT Process report TPD 2.01.02
Clearance support trestles The following clearances apply to cores without single bandages (e.g. wound bandage cylinders):
< 650 650 to 800 800 to 1,000 1,000 to 1,200 1,200 to 1,500
References/guidelines, recommendations Stack height tolerances as in drawing N00 08 792 Arrangement of the cooling duct shims as in drawing N10 11 100 Locking the screwed connections in accordance with TPD 3.036.01 Measurement of insulation resistance with TUQ 1634
Checked/approved:
Dr. Knorr
As of date:
2004-02
Drawn up by:
Matthes
Checked/approved:
Dr. Knorr
As of date:
2004-02
The passing on as well as the duplication of this document. use and communication of its contents is not permitted. nor may the contents be expressed. Offenders are liable to pay damages. All rights reserved. in particular for the case of patent granting or GM-entry
The passing on as well as the duplication of this document. use and communication of its contents is not permitted. nor may the contents be expressed. Offenders are liable to pay damages. All rights reserved. in particular for the case of patent granting or GM-entry
Continuous improvement Because there is nothing that cannot be improved, continuous improvement must be an integral part in all processes. The objective is to continue optimizing each process step. This is also the purpose of improvement teams. Appropriate coaching of these teams should make it possible to reach almost all employees.
Plant 7*
Plant 13*
* Plant 7 & 13: new plants; ** Plant 14: 9 years 2001 2009 N = No. of units in service SY = No. of service years nF = No. of units failed FRe (%) = Failure rate = nF 100/SY MTBF (yrs) = Mean time between failures = 100/FRe FRe 0.5 % < 1.0 % < 1.5 % < FRe > 0.5 % FRe 1.0 % FRe 1.5 % FRe 2.0 % 2.0 % excellent good satisfactory acceptable not acceptable
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Transformers
5.2 Reliability and Project Perfomance
Methods like, Kaizen, 5S and methods and tools from Six Sigma e.g. DMAIC circle, FMEA, IPO are helpful in supporting this continuous improvement process (g. 5.2-3). Management commitment Every manager in a company also bears responsibility for quality. Thus, each managers actions must be characterized by a high level of quality awareness. The level of commitment shown by all levels of management in the event of quality problems, the establishment of quality demands and the creation of targeted quality controls in day-today work together produce a culture in which there is a high level of quality. Control and support role of the quality manager The role of the quality manager is of fundamental importance for well-running processes. The quality manager combines a supporting role with that of a neutral controller. Quality management must be directly involved in processes and projects. The independence of the quality department and individual quality managers in the processes and projects must be guaranteed and agreed by top management. Conclusion The quality of a transformer is based on the quality of all processes that are necessary from project acquisition to project closing. The quality of the processes depends essentially on people. Only well-trained and motivated employees are able to guarantee that a process will be performed with a high degree of quality.
Dene Check
DpMO 7000 6000 5000 4000 3000 2000 1000 0 PONC x 1000 RMB
DpMO NCC
Measure
Are we improving?
DMAIC circle
Improve
Analyze
ANSI Standard C57.117, 1986, Guide for Reporting Failure Data for Power Transformers and Shunt Reactors on Electric Utility Power Systems.
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Transformers
5.3 Transformer Loss Evaluation
Capital cost
taking into account the purchase price Cp, the interest rate p, and the depreciation period n
Depreciation period Interest rate Energy charge Demand charge Equivalent annual load factor A. Low-cost transformer
P0 = 19 kW no-load loss Pk = 167 kW load loss Cp = 521,000 purchase price . Cc = 521,000 13.39 100 = 69, 762 / year CP0 = 0.2 . 8,760 . 19
P0 = 16 kW no-load loss Pk = 124 kW load loss C p = 585,000 purchase price . C c = 585,000 13.39 100 = 78,332 / year C P0 = 0.2 8,760 16 = 28,032 / year CPk = 0.2 8,760 0.64 124 = 139,039 / year CD = 350 (16 + 124) = 49,000 / year Total cost of owning and operating this transformer is thus: 294,403 / year
= 33,288 / year CPk = 0.2 . 8,760 . 0.64 . 167 = 187,254 / year CD = 350 (19 + 167) = 65,100 / year Total cost of owning and operating this transformer is thus: 355,404 / year
C Pk = Ce 8,760 h / year
a2
Pk
CD = Cd (P0 + Pk)
Cd
The energy saving of the optimized distribution transformer of 61, 001 per year pays for the increased purchase price in less than one year.
Fig. 5.3-1: Calculation of the individual operation cost of a transformer in one year
Fig. 5.3-2: Example for cost saving with optimized distribution transformer
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In order to make an inquiry regarding a GSU power transformer, the technical data for the items in this section are required. Step-down transformers Step-down transformers transform the voltage down from the transmission voltage level to an appropriate distribution voltage level. The power rating of step-down transformers may range up to the power rating of the transmission line.
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Transformers
5.4 Power Transformers
Fig. 5.4-2: Medium power transformer with natural oil based insulation uid
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Specic items EAF transformers are rigidly designed to withstand repeated short-circuit conditions and high thermal stress, and to be protected against operational overvoltages resulting from the arc processes. The Siemens EAF reactors are built as 3-phase type with an iron core, with or without magnetic return circuits. Design options Direct or indirect regulation On-load or no-load tap changer (OLTC/NLTC) Built-in reactor for long arc stability Secondary bushing arrangements and designs Air or water-cooled Internal secondary phase closure (internal delta) Main specication data Rated power, frequency and rated voltage Regulation range and maximum secondary current Impedance and vector group Type of cooling and temperature of the cooling medium Series reactor and regulation range and type (OLTC/NLTC) DC electric arc furnace transformers Direct-current electric arc furnace (DC EAF) transformers are required for many different furnace processes and applications. They are built for steel furnaces with a Thyristor rectier. DC EAF transformers operate under very severe conditions, like rectier transformers in general but using rectier transformers for furnace operation. The loading is cyclic.
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Transformers
5.6 Special Transformers for Industrial Applications
Rectier transformers Rectier transformers are combined with a diode or Thyristor rectier. The applications range from very large aluminum electrolysis to various medium-size operations. The transformers may have a built-in or a separate voltage regulation unit. Due to a large variety of applications, they can have various designs up to a combination of voltage regulation, rectier transformers in double-stack conguration, phase-shifting, interphase reactors, transductors and lter-winding (g. 5.6-2). Specic items Thyristor rectiers require voltage regulation with a no-load tap changer, if any. A diode rectier will, in comparison, have a longer range and a higher number of small voltage steps than an on-load tap changer. Additionally, an auto-connected regulating transformer can be built in the same tank (depending on transport and site limitations). Design options Thyristor or diode rectier On-load or no-load tap changer (OLTC/NLTC)/lter winding Numerous different vector groups and phase shifts possible Interphase reactor, transductors Secondary bushing arrangements and designs Air or water-cooled Main specication data Rated power, frequency and rated voltage Regulation range and number of steps Impedance and vector group, shift angle Type of cooling and temperature of the cooling medium Bridge or interphase connection Number of pulses of the transformer and system Harmonics spectrum or control angle of the rectier Secondary bushing arrangement Converter transformers Converter transformers are used for large drive application, static voltage compensation (SVC) and static frequency change (SFC). Specic items Converter transformers are mostly built as double-tier, with two secondary windings, allowing a 12-pulse rectier operation. Such transformers normally have an additional winding as a lter to take out harmonics. Different vector groups and phase shifts are possible. Main specication data Rated power, frequency and rated voltage Impedance and vector group, shift angle Type of cooling and temperature of the cooling medium Number of pulses of the transformer and system Harmonics spectrum or control angle of the rectier
Line Feeder This kind of transformer realizes the connection between the power network and the power supply for the train. Transformer is operating in specic critical short circuit condition and overload condition in very high frequencies per year, higher reliability is required to secure the train running in safety. Main specication data Rated power, frequency and rated voltage Impedance and vector group Overload conditions Type of cooling and temperature of the cooling medium Harmonics spectrum or control angle of the rectier Design options Direct connection between transmission network and railway overheadcontactline Frequence change via DC transformation (e.g. 50 Hz 16,67 Hz) Thyristor or diode rectier On-load or no-load tap changer (OLTC/NLTC)/lter winding Secondary bushing arrangements and designs Air or water-cooled
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