Maintenance 2012

99

Click here to load reader

description

Maintenance

Transcript of Maintenance 2012

Page 1: Maintenance 2012

On-Load Tap-Changer

Theoretical foundations

Maintenance of On-Load Tap-Changers

Page 2: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

On-Load Tap Changer: OILTAP®

OLTC

-Tap selector

Diverter switch

insert

Type MS

OLTC

-Tap selector

OLTC Diverter switch

-insert

Type R

Page 3: Maintenance 2012

TAP CHANGER OPERATING

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 3

Motor Drive Unit

Tap Selector

Diverter Switch

Page 4: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 4

Maschinenfabrik Reinhausen GmbHSwitching sequence

Load current IL

Circulating

current IK

Ik

Page 5: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 5

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 6: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 6

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

0 5010 20

Page 7: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 7

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 8: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 8

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

0 5010 20

Page 9: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 9

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Ic

Diverter switch mid-position:

circulating curent Ic determined by step voltage and transition resistor

load current split up in ‚old‘ and „new“ tap

Page 10: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 10

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 11: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 11

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 12: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 12

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 13: Maintenance 2012

Switching sequence Type M

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 13

MCa MSCa TCa TCb MSCb MCb

MCa

MSCa

TCa

TCb

MSCb

MCb

Page 14: Maintenance 2012

On-Load Tap Changer OILTAP® V III 200 D

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 14

Page 15: Maintenance 2012

TAP SELECTOR OPERATING

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 15

Motor drive unit

Time in second

Switching element

On-load tap changer

Page 16: Maintenance 2012

Switching Principle

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 16

Switching sequenc V

Page 17: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 17

Ib

a1

0 10 20 30 40 50

b1a/b

1

b

a

transition contact a1

transition contact b1

main switching contact a/b

Switching sequence Type V

Page 18: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 18

a1

0 10 20 30 40 50

b1a/b

Ib

2

Switching sequence Type V

Page 19: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 19

a1

0 10 20 30 40 50

b1a/b

Ib

2

Switching sequence Type V

Page 20: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 20

a1

0 10 20 30 40 50

b1a/b

Ib

3

Switching sequence Type V

Page 21: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 21

a1

0 10 20 30 40 50

b1a/b

Ib

3

Switching sequence Type V

Page 22: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 22

a1

0 10 20 30 40 50

b1a/b

Ib

3

Switching sequence Type V

Page 23: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 23

a1

0 10 20 30 40 50

b1a/b

Ib

Ib/2

Ib/2

Ic

4

Switching sequence Type V

Page 24: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 24

a1

0 10 20 30 40 50

b1a/b

Ib

5

Switching sequence Type V

Page 25: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 25

a1

0 10 20 30 40 50

b1a/b

Ib

5

Switching sequence Type V

Page 26: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 26

a1

0 10 20 30 40 50

b1a/b

Ib

5

Switching sequence Type V

Page 27: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 27

a1

0 10 20 30 40 50

b1a/b

Ib

6

Switching sequence Type V

Page 28: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 28

a1

0 10 20 30 40 50

b1a/b

Ib

6

Switching sequence Type V

Page 29: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 29

a1

0 10 20 30 40 50

b1a/b

Ib

7

Switching sequence Type V

Page 30: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 30Page 30

Arcs produced during a switching operation

Contact wear

Carbonization of the switching oil

Why Maintenance ?Why Maintenance ?

Switching operation under load in 40 – 50 msSwitching operation under load in 40 – 50 msSwitching operation under load in 40 – 50 msSwitching operation under load in 40 – 50 ms

R

Mechanical stress

Page 31: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 31

Springs

Braided contact leads

Screw connections

Energy accumulator etc.

Mechanical stressMechanical stressMechanical stressMechanical stress

Why Maintenance ?Why Maintenance ?

Page 32: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 32Page 32

Tap changer head

Drive shafts

Motor drive unit

Protective relay

Why Maintenance ?Why Maintenance ?

Subject to weatherSubject to weatherSubject to weatherSubject to weather

Page 33: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 33

The degree of carbonization of the diverter switch oil and the amount of carbon deposits inside the OLTC oil

compartment depend on:

Arcing energy (switched current, etc.)

Number of tap change operations

During maintenance the carbon deposits can easily be removed. Diverter switch type R

with carbon deposits.

Major aspects of Major aspects of maintenancemaintenance criterion: criterion:

Oil carbonisationOil carbonisation

Oil carbonisationOil carbonisation

Page 34: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 342007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 34

Studies show that moisture content in the sludge ( mixture of oil, carbon and water) deposited on the insulating material surface may be much higher than moisture content of the tap-changer oil.

This effect cannot be determined by taking and analysing oil samples.

Reduction of dielectric properties of OLTC which can only be avoided by regular maintenance..

Diverter switch type R with carbon deposits.

Major aspects of Major aspects of maintenancemaintenance criterion: criterion:

Oil carbonisationOil carbonisation

Oil carbonisationOil carbonisation

Page 35: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 35Page 35

Number of operationsNumber of operationsNumber of operationsNumber of operations

or

whichever comes first!whichever comes first!

Usually applying for OLTCs in network

application

Usually applying for OLTCs in industrial

application

Maintenance criteriaMaintenance criteria ::

Time in serviceTime in serviceTime in serviceTime in service

Page 36: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 36Page 36

Survey of number of OLTC operations in various transformer Survey of number of OLTC operations in various transformer applications:applications:

min. mean max

Power range MVA

Voltage range

kV

Current range

A

Number of on-load tap-changer operations.

Power Transformer

Generator

Distribution

Arc furnace

20000

100 - 1300 110 - 765 100 - 2000 500

60 - 525 50 - 1600 2000 7000

50000 200000

Transfomer data

2,5 - 150 20 - 230 50 - 1000 20000

3000 10000

15 - 400

Maintenance criteriaMaintenance criteria ::

Page 37: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 37Page 37

6 to 7 years

For OLTCs of today‘s manufacturing program used in starpoint application:

i. e. OLTC type M III 600 Y

5 to 6 years

For OLTCs manufactured up until the 70s used in starpoint application:

i. e. OLTC type D III 400 Y

2 years for first,4 years for further

maintenance

For OLTCs in line-end application with Um 245 kV(delta connected windings, autotransformers):

i. e. OLTC types V III delta

3 x M I 1200 – 245 kV

MaintenanceMaintenance intervals are stated in the OLTC’s intervals are stated in the OLTC’s operating instructionsoperating instructions

Maintenance criteriaMaintenance criteria ::

Time in ServiceTime in ServiceTime in ServiceTime in Service

Page 38: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 38Page 38

Tap changers of same type have been produced for periods of approx. 25 years.

During such a long period each product is subject to an innovation process (new materials, field experience, etc.)

MR’s service policy:

Adaption of easily accessible parts to the latest state of production during OLTC routine maintenance

Applying for measures which increase the operational reliability

Since diverter switch is removed and partially disassembled during maintenance anyway, the updating

measures are comparatively inexpensive

UpdatingUpdating

Maintenance criteriaMaintenance criteria ::

Time in ServiceTime in ServiceTime in ServiceTime in Service

Page 39: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 39Page 39

Water content*) Dielectric strength**)Neutral-end tap changers 40 ppm 30 kV / 2.5 mmSingle-pole tap changers 30 ppm 40 kV / 2.5 mm

(delta application and autotransformers)

*) measured according to Karl Fischer-Method**) measured according to DIN 57 370 Teil 1 / VDE 0370 Teil 1 / 12.78.

Guideline values for supervision of diverter switch oil were published in CIGRE report 12-13 (1982). These values are value for tap changer oil heated during operation and are stated in

the OLTC operating instructions:

Limit values while OLTC and transformer are in service

Oil valuesOil values

Maintenance criteriaMaintenance criteria ::

Time in ServiceTime in ServiceTime in ServiceTime in Service

Page 40: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 40Page 40

Difference of contact wear between main switching contacts and transition contacts due to varying transformer load

Maximum permissible difference of contact wear:

Cannot be determined without maintenance

Must not be exceeded during the service of

the OLTC

Contact wearContact wear

Maintenance criteriaMaintenance criteria ::

Number of operationsNumber of operationsNumber of operationsNumber of operations

Page 41: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 412012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 41Page 41

Contact wear depends onContact wear depends on

Maintenance criteriaMaintenance criteria ::

Number of operationsNumber of operationsNumber of operationsNumber of operations

- wear characteristics of the contact material

- numer of operations

- operating current of the transformer

Evaluation CriteriaEvaluation Criteria

- individual wear

- wear differences

- contact surface

Page 42: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 42Page 42

Parts replacementParts replacement

Mechanical stress for OLTC components during tap change operation (especially for diverter switch parts).

Precautionary replacement of mechanically stressed components in the course of maintenance

E. g. braided contact leadfor type M: 150,000 operations performed

E. g. energy accumulator springfor type M: 400,000 - 500,000 operations

Maintenance criteriaMaintenance criteria ::

Number of operationsNumber of operationsNumber of operationsNumber of operations

Page 43: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 43Page 43

Supervision of tap changer oil quality

Taking oil samples from tap changer suction pipeand determination of breakdown voltage

Check of the anti-condensation heater of the motor drive unitPreventing corrosion inside motor drive housing

Check of effectiveness of dehydrating breather of OLTC conservatorAvoiding penetration of water into OLTC conservator and OLTC oil

compartment

This is also valid for transformers which have been shut down or are out

of service

Checks between Inspetctions

Page 44: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 44Page 44

Precautionary spare parts: cover gaskets (tap changer head cover, protective relay)

Spare parts which depend on the number of operations: Energy accumulator springs, flexible

leads, contact carrier etc.

Spare parts which are subject to wear: arcing

contacts, drive shaft coupling bolts etc.

Spare parts to up-date the tap-changer to the lates state of manufacture

Spare parts requirement during routine Spare parts requirement during routine maintenancemaintenance

Spare part replacementSpare part replacement

Page 45: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 45Page 45

The MR service also applies to tap-changers like:

On-load tap changer manufactured by Siemens,

AEG & Trafo Union

On-load tap changers manufactured under the MR licence (e.g. Toshiba, Mitsubishi etc.)

MR TECHNICAL SERVICEMR TECHNICAL SERVICE

Page 46: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 46

Summary

High operating safety

A routine inspection of the tap changer can be completed by qualified and experienced personnel within few hours

The life time of the arcing contact used in network application exceed the life of the transformer in the majority of cases

Transition resistance values shows no change even at the highest switching requency

Page 47: Maintenance 2012

2009 CS5O© Maschinenfabrik Reinhausen GmbH

Page 47Page 472012 CS5O Boris Wende

Maintenance performance

Page 48: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 48Page 48

General Notes on the Preparation of an On-Load Tap-Changer Maintenance by MR

OLTC-type ** A B C250 C350 D (D Δ) E F G H KM / MS(MΔ)

T / R V VV

Oil quantity (l)* 30 100 150 250200

(300)220 320 900 355 650

190(280)

210 220 325

Weight of the diverter sw itch insert (kg)

20 60 100 150100

(120) 150 250 500 80 35080

(90) 120 60 50

Max. lif ting height (mm) 1900 2250 2500 2400

1500(2150) 1850 1750 2300 2150 1900

1400(1870) 1650 1950 2200

Table: Oil quantities, weights, lifting height

* Transformer oil in accordance with IEC 60296 und IEC 60422 with a dielectric strenght of at least 50 kV/2,5mm (measured as per IEC 60156)

** Information on on-load tap-changers made by Siemens, AEG and Trafo-Uniion is available on request

Page 49: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 49

• Switching OLTC into adjustment position

• Draining off tap changer oil

• Removal of horizontal drive shaft

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 49 of 24

Page 50: Maintenance 2012

2009 CS5O© Maschinenfabrik Reinhausen GmbH

Page 50Page 502012 CS5O Boris Wende

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 50 of 24

• Removal of OLTC cover

• Withdrawal of diverter switch insert

Page 51: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 512012 CS5O Boris Wende

Cleaning of OLTC oil conservator and oil compartment

Visual check of insulating material (oil compartment, suction pipe and indicating rod) and of sliding contacts

Check of pressure tightness of diverter switch oil compartment

WARNING: To clean only use pure transformer oil.

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 52: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 52

Removal of diverter switch supporting cylinderCleaning and visual inspection of supporting cylinder and insulating drive shaft

View inside diverter switch supporting cylinder before cleaning

Diverter switch insulating drive shaft

before cleaning

2012 CS5O Boris Wende

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 53: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 53

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Pawl in locked position Pawl in unlocked position

• Unlocking the pawl of the diverter switch and bringing the diverter switch in mid-position for reduction of contact pressure (see above)

• Removal of diverter switch contact shells in diverter switch mid-position

Page 53 of 24

Page 54: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 54

Removal of contact shells Undo the fixing screws of the contact shells

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 55: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 55

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Diverter switch contact shell

• Removal of diverter switch contact shells

• Cleaning and visual inspection of contact shells

• Measurement of contact wear on fixed contacts

• Check of spark gaps

• Measurement of transition resistors

• If necessary, replacement of:Resistor connection leadsFixed contactsCurrent strips

Page 55 of 24

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 56: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 562012 CS5O Boris Wende

Measurement of transition resistors Measurement of contact wear

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 57: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 572012 CS5O Boris Wende

Removal of diverter switch contact shells in diverter switch

mid-position

Cleaning and visual inspection of diverter switch (overall

condition)

Measurement of contact wear on movable contacts

If necessary, replacement of: - Braided contact leads, - Contact carriers, - Contacts, - Arcing chambers - Energy accumulatorMovable contact system of diverter switch after

removal of contact shells

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 58: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 58

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 59: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 59

Removal of stationary and movable contacts

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 60: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 60

Removal of braided leads

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 61: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 612012 CS5O Boris Wende

Re-installation of arcing chambers

Re-installation of contact shells

Re-installation of insulating drive shaft and supporting cylinder

Measurement of transition resistors as a countercheck (corresponding contacts must be open)

Manual test operations (pawl must be locked in!)

Final flushing with clean oil

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 62: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 62

Fill new oil into the diverter switch oil compartmentVent the tap changer head through the bleeder screwVent the suction pipe

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 63: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 63

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Opening and cleaning OLTC protective relay

Visual check

Installation of new gasket and closing cover again

Test of protective relay

Page 63 of 24

Page 64: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 64

• Installation of horizontal drive shaft

• Check symmetry of coupling between motor drive and OLTC

• Trial operations across the regulating range by means of hand crank operation (comparison of position indicated on OLTC and motor drive)

Page 64 of 24

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Page 65: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 65

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

Check of overall condition and function of motor drive:

• safety switch

• limit switches

• step-by-step function

• anti-condensation heater etc.

Page 65 of 24

Page 66: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 66

OILTAP® MMaintenance of On-load Tap-changer OILTAP® M

• Writing maintenance report with all relevant data

• Keeping file or a databank with maintenance results (documentation)

Page 66 of 24

Page 67: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 67

Reaching adjustment position by turning hand crank clockwise

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

• Switching OLTC into adjustment position

Page 68: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 68

• Draining off tap changer oil

• Removal of horizontal drive shaft

• Remove OLTC head cover

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 69: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 69

Removal of OLTC gear and suction pipe

Check of marks for re-installation of OLTC insert

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 70: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 702012 CS5O Boris Wende

Careful withdrawal of OLTC insert by means of MR lifting device or crane and chain hoist

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 71: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 71

Cleaning of oil compartment

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 72: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 722012 CS5O Boris Wende

Placing OLTC insert on a working table in horizontal position

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 73: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 73

Removal of the switching elements

Removal of the inner screening rings

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 74: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 74

Cleaning switching tube of OLTC insert inside and outside by means of transformer oil and brush

Cleaning of switching elements

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 75: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 75

Measurement of the transition resistors

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 76: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 76

Determination of the contact wear

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 77: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 77

Checking the spring movement of the contact rollers

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 78: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 782012 CS5O Boris Wende

Preparation of OLTC insert for re-installation

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 79: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 79

Re-installation of suction pipe

Re-installation of the cleaned gear unit

Trial operations and check of limit position blocking

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 80: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 802012 CS5O Boris Wende

Opening and cleaning OLTC protective relayVisual checkInstallation of new gasket and closing cover again Test of Protective relay

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 81: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 812012 CS5O Boris Wende

Check of overall condition and

function of motor drive:

safety switch limit switches step-by-step function anti condensation heater etc.

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 82: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 822012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 82

• Installation of horizontal drive shaft

• Check symmetry of coupling between motor drive and OLTC

• Trial operations across the regulating range by means of hand crank operation (comparison of position indicated on OLTC and motor drive)

Page 82 of 24

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 83: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 832012 CS5O Boris Wende

Writing inspection report with all relevant data

Keeping file or a databank with inspection results (documentation)

OILTAP® VMaintenance of On-load Tap-changer OILTAP® V

Page 84: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 842012 CS5O Boris Wende Page 84

Practical example for the preservation and evaluation of the condition of the equipment

Online oil filtration with Oil Filter unit

Effects:

- Removal of carbon particles from the tap-changer oil

- Keeping the water content to a minimum

Active measure for improving oil quality

Benefits:

- Improving operational reliability of OLTC and transformer

- Extension of maintenance intervals

- Reduction of maintenance cost

- No need for cleaning during maintenance

Page 85: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 85

Use of maintenance-free dehydrating breather for OLTC and transformer conservator

Effects:

- No changing of Silica-gel

- Always the same dry condition of the air into the transformer

Active measure for good working condition of the breather

6. Measures for Equipment Preservation

Page 86: Maintenance 2012

Date: 26.03.20072007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 862012 CS5O Boris Wende Page 86

Practical example for the preservation and evaluation of the condition of the equipment

Use of maintenance-free equipment

Use of VACUTAP® OLTCs for new transformers

Preferable strategy for OLTCs and transformers

replaced by

Page 87: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 872012 CS5O Boris Wende

Advantages of the vacuum technology

Vacuum technologycontact wear reduced to a minimumNo arcing in the oilNo oil carbonization

Conventional technologyWear of single contactsContact wear differenceOil carbonization

VACUTAP®: Extension of the maintenance interval up to 300.000 operations and no time based maintenance

Vacuum interrupter

Transition contactMain switching contact

Transition contact

Switching elementVACUTAP®VV

Switching element OILTAP®V

Page 88: Maintenance 2012

2007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 882012 CS5O Boris Wende

Innovation VACUTAP® Life-Cycle-Cost Consideration

OILTAP ®

Significant savings in maintenance costs

Benefits

longer availability of the transformer

simplified maintenance logistics

protection of environment and natural resources due to reduction of oil changes

only familiar checks required

Considerably reduced operating costs

Maintenance-free up to 300.000 operations with VACUTAP® V V and VR

No time-based maintenance

Page 89: Maintenance 2012

Are you still using conventional on-load tap-changer technology?

Maintenance Intervals

Page 90: Maintenance 2012

2012 CS5O Boris Wende© Maschinenfabrik Reinhausen GmbH

Page 90

Retrofit - Solution

OILTAP®M VACUTAP®VM

Page 91: Maintenance 2012

91

Perfect Retrofit-Solution

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Compatible with OILTAP® M / MS and other on-load tap-changers based on OILTAP® M

No modification work on the oil compartment required

Page 92: Maintenance 2012

92

Retrofittable VACUTAP® VM Diverter Switch Insert

100% connection-compatible with OILTAP® M

• Licensed tap-changers can also be upgraded

• Also suitable for non-authorized models similar to OILTAP-M

Benefits of VACUTAP®

• Lifetime of diverter switch insert: 1.2 million tap-change operations

• 300,000 tap-change operations without any maintenance

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Page 93: Maintenance 2012

93© Copyright MR Maschinenfabrik Reinhausen GmbH

No Interaction between Arc and Oil

Conventional technology

Switching arc under oil

Oil: insulating, cooling, lubricating and arc quenching

VACUTAP® technology

Switching arc in vacuum

Oil: just insulating, cooling and lubricating

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Page 94: Maintenance 2012

94

Extended Oil Service Life

Conventional technology

Oil ageing due to carbon particles resulting from arc quenching

Oil filter to be exchanged regularly

VACUTAP® technology

No break-down arc in tap-changer oil

No oil filter unit necessary

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Page 95: Maintenance 2012

95

Marginal Contact Wear

Conventional technology

Contact wear

Contact life: 200,000 to 500,000 switching operations

VACUTAP® technology

Rate of contact wear is more than one decade lower compared with copper-tungsten contacts

Contact life: 600,000 switching operations

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Page 96: Maintenance 2012

96

Less Maintenance

Conventional technology

Maintenance each 40,000 to 100,000 switching operations, depending on the operation mode

Additional time-based criteria

VACUTAP® technology

Maintenance each 300,000 switching operations, therefore maintenance-free in most network applications

Enhanced transformer availability

No time- or current-based criteria

Less spare parts, simplified logistics

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Maintenance intervals Maintenance intervalst t

Page 97: Maintenance 2012

97

OILTAP® VACUTAP®

55 %

100 %

Electric Arc Furnace (EAF) Application

High system availability and reliability

- Maintenance interval: 300,000 switching operations without time- or current-based criteria

- Significantly longer oil service life and contact life

- Reduced downtime of the transformer due to faster maintenance

Protection class IP 66 for TAPMOTION® ED suited for aggressive environment

Significant reduction of maintenance costs

- Example: 200,000 switching operations per year, 20 years transformer service life, operation in central Europe

- 45 % cost reduction for on-load tap-changer maintenance, spare parts and oil filters over the transformer service life

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH

Maintenance costs

Page 98: Maintenance 2012

VACUTAP® VM © Copyright MR Maschinenfabrik Reinhausen GmbH 98

The VACUTAP® VM diverter switch insert is

retrofittable, which means longer maintenance

intervals and maximum cost-effectiveness

The new VACUTAP®

Arc-Control System™

extinguishes the commutating arc with

absolute reliability

The new VACUTAP® Step Protection System™

effectively protects the diverter switch against tap short circuits in the event of overvoltage on the grid

The Interrupter Exchange Module

shortens production downtimes for maintenance

41

2 3

Unique. Better For 4 Reasons.

Page 99: Maintenance 2012

Date: 26.03.20072007 Gerhard Peißer© Maschinenfabrik Reinhausen GmbH

Page 99