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

Part 1

Smart LCM-O&E
Smart Life Cycle Management (LCM)
of Oils & Equipment
Diagnostic Coverage and Integrated Treatments (2013)
based on IEC Standards, “State of the Art”, Best Available
Sea Marconi Technologies sas - All Right Reserved

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.
©20013

Dubai, Middle East Electricity 18th February 2013

Smart LCM – O&E

Contents
1. Sea Marconi Introduction
2. Transformers, Insulating Oils & Fluids
3. Loss prevention
4. Focus on LCM & Key Steps
5. Fluid Carrier Approach

6. Regulations, Standards & Guidelines
7. Hot Topics - Criticalities
8. New Sustainable Solutions 2013
9. Knowledge Value & Case Histories
10. Conclusions
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Smart LCM – O&E

Main locations
Headquarter:
Collegno
(Turin, Italy)

Homécourt (region of Lorena, France)
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Smart LCM – O&E

Where we are
Karlsruhe – Germany
Homécourt – France
2007
2002
Collegno (Turin) – Italy
1968

Seclì (Lecce) – Italy
1992

Barakaldo – Spain
Buenos Aires – Argentina 2002
2004
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Smart LCM – O&E

Key informations
• 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)
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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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Smart LCM – O&E

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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Smart LCM – O&E

Technical Capabilities
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
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Smart LCM – O&E

My Transfo: International Meetings
2002 (R. Maina) Corrosive Sulfur
(V. Sokolov) Transformer LCM
Hot Topics
2004 (R. Maina) Oil Fingerprint and forecast
(V. Sokolov) Transformer LCM Pioneers:
exchange of global
2006 (F. Scatiggio) Corrosive sulfur
(R. Maina) Diagnostics for LCM knowledge, experien
(V. Sokolov) Post mortem inspection ce, sustainable
(D. Schubert) Insurance reliability and best practices solutions in Oil &
Transformer Life

2008 (V. Tumiatti) Fingerprinting, Ageing, Diagnosis,
Decontamination, Depolarisation and
Cycle Management
(LCM)
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
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2012…

Smart LCM – O&E

Energy & Environment
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Smart LCM – O&E

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

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.)
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Smart LCM – O&E

Priority: Insulating Mineral Oils

PCAs/PAHs
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Smart LCM – O&E

Oils & Asset Management
• > 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
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Smart LCM – O&E

…other Insulating Fluids (ref. IEC Standards)
• Natural esters
• Synthetic esters
• Silicon liquids
• Askarels - PCBs based
• SF6

• Others…

and Dry Transformers…
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Smart LCM – O&E

Protection of the Assets & Environment
Failure Explosion Fire
Old age
Occasional
Infancy

Damages

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

Black-Out
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Smart LCM – O&E

Knowledge Value for Loss Prevention

GSU Transformer
explosion

Typical Site

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


Smart LCM – O&E

Knowledge Value from:
Catastrophic Accident “Explosion of GSU Transformer in
Insulating Mineral Oils”*
Russia 17th August 2009 - Accident Sayano-Sushenskaya
RusHydro power plant – 6500 MW
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).
©20013

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


Smart LCM – O&E

Win-Win Strategies & Opportunities
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.)
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Smart LCM – O&E

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

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 Test
IV. Prior Energization
V. Post Energization

VI. 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 & Reparation
IX. Post Failure (Tests, Diagnosis and Treatments)
X. End of Life - Post Mortem (Tests, Diagnosis and Treatments)
a. Material recovery
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b. Decontamination and/or disposal Waste (PCBs, etc.)


Smart LCM – O&E

Added Value
for Customers, Holders, & Partners
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Smart LCM – O&E

The «Fluid Carrier» Approach
Integrated methods based on “Fluid Carriers” equivalent to “human blood”.

PARADIGM: diagnostic Tests and dialysis therapies
applied to the body and internal organs
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Smart LCM – O&E

Representative Sampling for Diagnostic Tests
in Accredited laboratory

Transformer fluids Human bood
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Smart LCM – O&E

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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Smart LCM – O&E

 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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Smart LCM – O&E

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

Test results with Diagnosis with Health Index,
Method, Uncertainty Critical Factors, Actions And
ISO 17025 Countermeasures (type and
Trend analysis priorities)
PCBs Test

Report
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Smart LCM – O&E

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

Example of Sea Marconi DMU for Human blood dialysis
ON-LOAD treatments
©20013

500 KV Brazil (2009)


Smart LCM – O&E

DMU (Decontamination Mobile Unit)
for Multifunctional Integrated Treatments & Process
Physical CHEDCOS CDP PROCESS®
Main function
decontamination depolarisation 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.
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Smart LCM – O&E

Typical DMU configuration
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Smart LCM – O&E

Regulation, Standards & Guidelines
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Smart LCM – O&E

IEC 60296 ed. 4 - 2012
“Unused mineral insulating oils for Transformers and
Switchgears”
4-Health, Safety, and
1-Function Environment (HSE)

2-Refining
/Stability

3-Performance
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Smart LCM – O&E

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

PART 1
DBDS quantification and oils
fingerprint (AED profile: C, S, etc.)
PART 2
Total Corrosive Sulfur - TCS
Quantification
PART 3
Total mercaptans and disulfides
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Smart LCM – O&E

IEC 60422 Ed. 4 – 2013
Mineral insulating oils in electrical equipment – Supervision and
maintenance guidance
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Smart LCM – O&E

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

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

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)
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Smart LCM – O&E

CIGRE - Brochure n. 413 – 2010
Guidelines Insulating Oil Regeneration and Dehalogenation –
PCBs
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Smart LCM – O&E

Priority: Hot Topics
Criticality: Corrosion Phenomena

C1
DBDS & Corrosive Markers
Sulfur DBDS (IEC 62697-1)
NO DBDS & TCS (IEC 62697-2 preliminary draft)

Corrosive Sulfur Additives: Passivators (BTA,
C2 Irgamet 39, Irgament 30)
Additives: Bio Copper Corrosion
Inhibitors (adenine, purine, etc.)
CCD Test, DIN Test, ASTM Test
Metals
Particles (Pioneer 1976)
Copper Sulfide Others…
formation CuS, Cu2S
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Smart LCM – O&E


C3 SDBP & Corrosive Sulfur
Sulfur Degradation ByProducts: Markers
H2S, Mercaptans, etc.
TCS – Total Corrosive
«At relatively high Sulfur (IEC 62697-2
preliminary draft)
temperature, sulphur-

containing oil molucules Total Sulfur
may decompose and DiBenzoThioPhene –
react with metal surface DBTP, etc.
to form metal sulphides» Metals
(IEC 60422 Ed. 4 – 2013 art. 5.17)
Particles
Silver Sulfide Others…
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 –
©20013

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.”.

Smart LCM – O&E


C4
NO Sulfur Corrosion &
Copper/Metal dissolution

Markers

Metals
Copper in oil mg/kg

TAN
43 DF

IFT

Particles

Others…
©20013

Service Period (Years)


Smart LCM – O&E

Criticality: Thermal Life & Degradation

Markers
Consumed Thermal Life & Solid/Paper 2Fal, CO2, H2O, Methanol, etc.
Insulation
Oil & Fluid Degradation TAN, DF, IFT, Particles, Oxidation
byproducts, etc.
Sludge Formation TAN, Sediments, Aspect, Particles,
etc.
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Smart LCM – O&E

Criticality: Faults

Hot Spot Electrical
> 700 °C Arching
Markers

DGA

Particles
Metals

T1 Thermal fault, t < 300 °C PD Partial discharges
T2 Thermal fault, 300 °C < t < 700 °C D1 Discharges of low energy
T3 Thermal fault, t > 700 °C D2 Discharges of high energy
©20013


Smart LCM – O&E

Criticality: PCBs/POPs - Environment
According to IEC 61619, EN 12766, IEC 60296, IEC 60422, CENELEC 50503
©20013


Smart LCM – O&E

New Sustainable Solutions: 2013
Smart Field Test Kits (Patents Pending by Sea Marconi)

Kit for Kit for Kit for
Total Acid Number Total Corrosive Sulfur Total Chlorine/PCB

SM-TAN SM-TCS SM-TCPs
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Smart LCM – O&E

Smart Field Multi Detection (online/offline)

Kit for

Sampling and Detection
of selective DGA, SF6,
Particles and Moisture
&
Black Box
©20013


Smart LCM – O&E

Smart Detection for Dry Transformers

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

Vibro-acustic profile
Thermal profile
©20013


Smart LCM – O&E

Smart DMU (Decontamination Mobile Unit)

DMU (Decontamination Mobile

Unit) -
Multifunctional and Integrated
Treatments & Processes for
Decontamination,
Depolarisation and
Detoxification of insulating
liquids
©20013


Smart LCM – O&E

Knowledge Value, for Twin & Family Units, from:
Case history of Integrated Treatments with DMU
DBDS: ON-LOAD TREATMENTS

GSU Power Transformer
Year: 1997, ABB
Power: 192 MVA
Voltage: 400 KV

Oil Mass: 58.000 Kg

DBDS TAN
IFT
[mg DF
[mg/Kg] [mN/m]
KOH/g]
Before treatment 110 17 0,133 0,0448

After treatment <5 40 < 0,01 0,0118
©20013


Smart LCM – O&E

PCBs: ON-LOAD TREATMENTS

ALUMINIUM Factory
Rectifier Transformer
Year: 1930, Brown Boveri
Power: 19 MVA

Voltage: 13 KV
Oil Mass: 15000 Kg

PCB TAN
IFT
[mg DF
[mg/Kg] [mN/m]
KOH/g]
Before treatment 27 22,1 0,034 0,01483

After treatment 0,35 43,3 0,01 0,0013
©20013


Smart LCM – O&E


Chemical Factory
GSU Transformer
Year: 2000, Getra
Power: 47 MVA

Voltage: 34 KV
Oil Mass: 12000 Kg

DBDS TAN
H2O
[mg DF
[mg/Kg] [mg/Kg]
KOH/g]
Before treatment 125 7 0.095 0,0190

After treatment <5 3 < 0,01 0,0033
©20013


Smart LCM – O&E


Electrical substation
Power Transformer
Year: 1998, Zaporozhtransformator
Power: 250 MVA

Voltage: 345 KV
Oil Mass: 118000 Kg

DBDS TAN
H2O
[mg DF
[mg/Kg] [mg/Kg]
KOH/g]
Before treatment 144 16 < 0,01 0,0026

After treatment < 10 5 < 0,01 0,0015
©20013


Smart LCM – O&E

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
Shunt reactors 500
36
KV line, Nynas
Reactors with corrosive sulfur 13 (36,11%) Naphtenic Oil
Total failed reactors -
©20013


Smart LCM – O&E

case history of Post-Failure Diagnosis related to
«DBDS & Corrosive Sulfur»
Total estimated losses (direct and undirect):
more than 20 mln €

GSU Transformer 400
KV, 192 MVA, Nynas
Naphtenic Oil

Extraction of core and windings on 19th of April 2006 for VISUAL
INSPECTION
©20013


Smart LCM – O&E

Inspection and Analysis on internal HV windings

GSU Transformer 400
KV, 192 MVA, Nynas
Naphtenic Oil

Sinusoidal deformations of the
Internal view of the HV winding,
windings, sector opposite to the
failure zone
©20013

failure


Smart LCM – O&E

VISUAL MAPPING OF THE COPPER SULFIDE DEPOSITS

GSU Transformer 400
KV, 192 MVA, Nynas
Naphtenic Oil
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Smart LCM – O&E

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 GSU Transformer 400
repeated analyses according to KV, 192 MVA, Nynas
ASTM D 1275 A ext. 48h) caused Naphtenic Oil
the deposition of elevated
amounts of copper sulfide on the
paper components.
©20013


Smart LCM – O&E

Post-Failure Diagnosis related to
«NO DBDS & Corrosive Sulfur»

GSU Transformer 400 kV,
175 MVA, SHELL
Napftenic Oil Diala AX
©20013


Smart LCM – O&E

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

Grid Transformer
500 kV, 425/3
MVA - OLTC,
YPF65 Paraffinic
Oil not inhibited
©20013


Smart LCM – O&E

Post-Failure Diagnosis related to
Copper sulfide formation on paper and on enameled conductors

Rectifier Transformer
ODAF with membrane,
year: 1998, 66/0,4 KV,
93,4 MVA,
Nynas Napftenic Oil Nitro
10 GBN, winding CTC
(enameled conductors)
©20013


Smart LCM – O&E

Conclusion 1

Smart LCM O&E - Key Factors

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
©20013


Smart LCM – O&E

Conclusion 2
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.
©20013


Smart LCM – O&E

Since 1968

www.seamarconi.com
Ideas and Innovation for Energy and Environment

Contacts
Vander Tumiatti Alessandro Capo
Founder and General Partner International Sales Manager

Sea Marconi Technologies Sea Marconi Technologies
Via Ungheria 20 Via Ungheria 20
10093 Collegno (Turin - Italy) 10093 Collegno (Turin - Italy)
Tel. +39 011 2343434 Tel. +39 011 2343434
Fax +39 011 2343435 Fax +39 011 2343435
e-mail: tumiatti@seamarconi.it e-mail: capo@seamarconi.it
©20013


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

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