Asset Management of Power Transformer Optimization of Operation and Maintenance Costs

Asst.Prof.Dr.-Ing. Thanapong Suwanasri

25 October 2013
The Sirindhorn International Thai-German Graduate School of Engineering (TGGS) King Mongkuts University of Technology, North Bangkok (KMUTNB)

Asset Management of Power Transformer

Contents
Introduction Working Procedure Failure Statistics, Database Management Condition Assessment Risk Assessment Spare Part Management Conclusion
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Asset Management of Power Transformer

Introduction
Demands on high reliability, good power quality and acquiring more benefits

from electrical asset asset management approach cost reduction

Risk assessment of power transformer should be focused due to high

acquisition, maintenance cost and its catastrophic failure consequences.

Power transformer has been maintained by preventive maintenance. Condition-based maintenance is performed according to its known condition. Risk-based maintenance considers the condition and importance of equipment.

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Asset Management of Power Transformer

Introduction
Objective
Risk based maintenance Condition + Importance To optimize spare parts and minimize inventory cost.

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Asset Management of Power Transformer

Power Transformer Asset Management Process

Asset Management Strategies Asset Information Network Data

Condition Assessment

Importance Assessment

Financial Information

Risk Management

Economic Risk Management Optimized maintenance strategies Decisions

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Asset Management of Power Transformer

Power Transformer Asset Management Process

Database Setup systematic record of periodic test and visual inspection Condition-based Maintenance Importance Index Risk-based Maintenance

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Asset Management of Power Transformer

Failure Statistics
To determine critical components and failure causes
(1)

The well-known Weibull distribution method is applied.

Probability Distribution Function (PDF) Failure Rate; (t)
f (t ) t (t ) = = R(t )
1

t f (t )

,t

Cumulative Distribution Function (CDF)

Mean Time between Failures (MTBF)

F (t ) = 1 e
Reliability; R(t)

,t

MTBF = + .[1 +

R (t ) = 1 F (t ) = e

,t

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Asset Management of Power Transformer

Transformer 230/115 kV, 200 MVA has 117 units with 30 failure records Transformer 115/22 kV, 50 MVA has 186 units with 59 failure records

Defective components of 230/115 kV, 200 MVA

Defective components of 115/22 kV, 50 MVA

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Asset Management of Power Transformer

Database Management
For a convenient and systematic data record in the central database server. Integrated web application for using as decision support tool.

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Asset Management of Power Transformer

Condition Assessment
Components are classified into 7 groups.
Active Part Insulating Oil Bushing Arrester OLTC Tank Protective Devices

Diagnostic tests are used to access the component condition.

Electrical Test Insulating Oil Test Visual Inspection

Scoring and weighting technique is applied Component HI

%Index =

(Si Wi ) (S
n i =1 i =1 max i

Si

=Score of each test =Weightng factor =Number of diagnostic tests

Wi

100

Smax,i=Max. score of each test Wi n

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Asset Management of Power Transformer

Condition Assessment
The component condition and weighting are used to evaluate the overall

condition or overall HI.

Active Part Bushing

Arrester OLTC

Insulating Oil

Protection

Main Tank

% HI = (W j HI j ) 100
j =1

j =m

Overall Condtion

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Asset Management of Power Transformer

Risk Assessment
Evaluation Criteria of Transformer Importance
Load criticality Impact on system stability Possibility of failure Failure consequence Damage of property Social impact Environmental concern

The criteria are scored into low, moderate and high importance. The criteria with more impacts to supply interruption and system availability will

be assigned with higher weighting factor.

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Asset Management of Power Transformer

Risk-based Maintenance
Combining the condition and importance index to create risk matrix. Maintenance strategies of each zone can be setup appropriately.
Maintenance Strategies: 1=Repair/Replace when fail (without blackout) 2=Replace/Repair/Refurbish by economic condition 3=Replace/Repair/Refurbish immediately 4=Corrective Maintenance (CM) with normal maintenance 5=Time-based maintenance (TBM) and normal maintenance 6=Condition-based maintenance (CBM) and online monitoring 7=CM with routine inspection 8=TBM 9=TBM and CBM

The risk is measured by distance d with respect to 45O reference line. Thanapong Suwanasri 13

Asset Management of Power Transformer

Spare Part Management

method to optimize number of spare parts for effective inventory control. Using Pareto analysis, components of power transformer in the stock are

classified as ABC classes.

Class A means a few most expensive ones that need special care. Class B means ordinary ones that need standard care. Class C means large number of cheap items that need little care.

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Asset Management of Power Transformer

Spare Part Classification

Class A: Items are account for 80% of the total inventory cost but about 20% of total inventory items. High capital investment and requires a close control. Due to high cost of these items, a minimum safety stock is maintained. Class A are busing, arrester and on-load tap changer. Class B: Items are account for 20% to 30% of the total cost but about 20% to 30% of total items. The class B item of power transformer is insulating oil. Economic order quantity should be applied. Class C: Items are account for 20% of the total cost but about 80% of total items. This item has the cheapest price and needs a minimal control. E.g. seal, gasket, bolt and nut.

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Asset Management of Power Transformer

Work Procedure and Calculation

High voltage equipment Determination of major or critical components and auxiliary components Component classification by Pareto diagram

Class A

Class B

Class C

Statistical distribution techniques

Economic order quantity

Two bin policy

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Asset Management of Power Transformer

A. Statistical Distribution Techniques for Class A Management

Normal distribution technique Highly accurate technique, when number of recorded failures is sufficient. Information needed for the analysis First energized date must be known. Calculation Firstly, the number of service year (sum of operating time that every piece of component is in service). Then, the failure rate is calculated. Systematic failure record Finally, calculate the optimum stock for smooth operation within the equipment lifetime (N)
M = number of items

= N M T + T Z

T = lifetime of considered item. Z can be obtained from the precalculated standardized normal tables, e.g. if availability in stock is required as 99%, then Z is equal to 2.33. 17

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Asset Management of Power Transformer

B. Poisson distribution technique

The percentage of stock reliability (RI ) and availability of items (I) in the stock within the time interval T.
I -A A e P 100 A = M 'T = I!

MxTi MTTR ( ) = Nf

=
'

% RI = Pi
i =0

MTTR M Ti Nf A T I

is mean time to repair. is number of the items used in the system. is interval of observation is number of failure. is expected number of demand. is lead time of stock ordering. is the replacement rate. is number of the items kept in the stock.
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Asset Management of Power Transformer

Transformer Bushing as Class A Item

115 kV transformer bushings are investigated. The data of 120 bushings from 40 transformers rating 115/22 kV, 25 MVA 1,890 unityears. The design lifetime 25 years. 5 failure records within 10 years time interval. If the need for availability of items in stock is 99% of service level, the number of 115 kV bushing in stock should be:

Normal distribution technique: The number of bushing in the stock is 2.2 or 3. Poisson distribution technique The 115 kV bushing should be kept in stock 3 units per year for 99% stock reliability.

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Asset Management of Power Transformer

Surge Arrester as Class A Item

115 kV surge arrester are investigated. The data from 120 arresters rating 115 kV (for transformer 25 MVA) 2,350 unit-years. 2 failure records occurring within 10 years. The design lifetime 25 years. If the need for availability of items in stock is 99% of service level, the number of 115 kV arresters kept in stock should be:

Normal distribution technique: The number of arrester in the stock is 1.2 or 2. Poisson distribution technique The 115 kV arrester should be kept in stock 2 units per year for 99% stock reliability.

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Asset Management of Power Transformer

Number of bushing per year for various transformer ratings.

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Asset Management of Power Transformer

Conclusion
Risk-based maintenance has been developed by combining condition and importance. The spare part management was applied by classifying transformer component into

ABC classes.
The statistical analysis was performed to find the optimum number of class A item. It is

clearly seen that only a few numbers of bushings and arresters should be kept in stock each year
The computerized web-application program is developed to facilitate the maintenance

tasks.
The effective maintenance tasks can be setup, resulting in high availability, low failure

risk, lower overall maintenance costs and ability to extend the useful lifetime.

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Asset Management of Power Transformer

Thank you for your attention

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