2008 International Conference on Condition Monitoring and Diagnosis, Beijing, China, April 21-24, 2008

Preparation of Power Transformers CBM Implementation In PLN P3B Jawa Bali

N. Ukhita A.W1*, A. Pharmatrisanti1
1 PT. PLN (Persero) P3B JB Region Jawa Barat-Indonesia 2 PT. PLN (Persero) P3B JB Region Jakarta dan Banten-Indonesia *E-mail : ni2el@yahoo.com

Abstract--Since year of 2004 PLN P3B Jawa Bali has decided to apply a new strategy of maintenance, i.e.: condition based maintenance (CBM) to its high voltage assets. Transformer, which is the most crucial and expensive asset in electrical power network, becomes the first priority to be applied on. Performing FMECA (Failure mode Effect and Criticality Analysis) in order to find failure path of each transformer subsystem and developing model became the first step should be done by PLN P3B Jawa Bali. There are two kinds of model developed by PLN P3B Jawa Bali; they are statistic model and physical model. This paper focuses on preparation of statistic model development. There are five kinds of data that PLN has been collected for 5 last years related to critical component found by FMECA process , they are : DGA (dissolved gas analysis), Load and Temperature (manual reading by operator),Polarization Index, Tan delta, Oil characteristic test. Through data trending analysis, PLN has found that the data collected was not sufficient enough for model development. Therefore PLN has analyzed the problems and defined the new step to handle them, i.e.: Maintenance procedure standardization, DGA oil sampling standardization, Regular calibration of testing equipment.

Fig. 1. CBM step: FMECA and Modeling

Index Terms--Condition Based Maintenance, Failure Effect and criticality analysis, modeling, transformer.

There are two approaches defined by PLN. They are : qualitative approach by performing FMECA (Failure Mode Effect and criticality Analysis) and quantitative approach by modeling the transformer (physical model and statistical model). II.FAULT HISTORY OF TRANSFORMER 150/20 KV A Causes of Failure

I. INTRODUCTION N order to maintain consumers availability and reliability demand of power energy supply and to achieve the maintenance cost effectiveness, PLN P3B Jawa Bali (Transmission and Load Dispatch Centre of Java Bali System) has decided to change the existing maintenance strategy, from.: time-based maintenance to condition-based maintenance (CBM). Amongst transformers operated in Jawa Bali transmission system, 150/20 kV 60 MVA class is the most population (24.23 %). This class is also the most crucial transformer that supplying energy directly to the distribution level, which is the consumer of PLN P3B Jawa Bali. Based on that reasons, PLN P3B Jawa Bali has selected transformer class of 150/20 kV 60 MVA as the pilot project of condition-based maintenance implementation To start CBM implementation define step as below:
Fig. 2. Cause of Failure on transformer installed in P3B JB

978-1-4244-1622-6/08/$25.00 2007 IEEE

As the picture depicted above, TFC (trough fault current) is the major ( 61. 6%) cause of transformer failure. Therefore, the major part of transformer failed caused by TFC is winding. B Damage parts on Transformer

Fig. 3. Kind of Damage parts

Since the major failure cause is through fault current during short circuit fault on transformer feeder, the most damage part of transformer is winding. This occurs because the through fault current has mechanical impact to the winding. Since 2000 until 2005, the most damage part of PLN P3B JB transformer is winding (41.38%).

III. FMECA, CRITICAL COMPENENTS AND MONITORING Failure Mode Effect Analysis (FMEA) is a method that examines potential failure in product or process; it may be used to evaluate risk management priorities for mitigating known threat vulnerabilities (1) By using CIGRE WG A2.18 reference, PLN P3B Jawa Bali divided its transformers into 10 subsystems. After defining the functional subsystems, functional failures, possible failure modes, and failure effects, determining the recommended actions to overcome the possible failure modes of each subsystem is the next step. The step which takes important place in FMECA is weighting process. By performing weighting process, the consequences of each failure possibility are obtained. There are six criteria that are used by PLN in weighting process i.e.: frequency, escalation factor, corrective cost, safety impact, system impact and environment impact. The criteria used by PLN to define the consequences in order to find out the critical component of PLN transformer are listed in the following table.

Fig. 4. Winding damage caused by TFC

The picture above describes how bad the impact of TFC to the winding is. TFC can cause winding deformation. TFC VS TRANSFORMER AGEING: According to CIGRE reference, TFC may lead the transformer to ageing (categorized in operational stresses and environment influencing ageing). Mechanical force of TFC has impact to the winding displacement. Significant winding displacements lead to step reduction in withstand strength leading to accelerated local ageing.(7)

Fig. 5. Influences affecting ageing

As a result of FMECA process which is based on the analysis and recorded failure history data and weighting process using PLN criteria above, PLN has found out the critical components of 150/20 kV 60 MVA transformer. The critical components are: z Current carrying unit z Electromagnetic circuit z Dielectric Subsequently the failure paths of each critical subsystem and the action that should be taken to mitigate the possible failure effects can be obtained. Then the symptoms to breakdown, the parameters that should be monitored; the recommended monitoring and diagnostic methods, and the actions that should be done are listed in table 7.

Consideration in defining score: a) Frequency criteria Based on the statistic data of 150/20 kV transformer fault as depicted on the figure 2, we can see that not all kind of causes take place on transformer failure. There is an extreme difference intensity between TFC (61.6%) and any others causes (e.g. insulation system: 11%, and lightning : 0%). Therefore, The score of frequency is not linier amongst score 1, 2, 3, 4 ad 5. b) Escalation factor Escalation factor is used for defining whether the failure has low impact or high impact. Therefore there are only 2 score 1 for low impact and 2 for high impact. c) Corrective cause The score of corrective cost is defined based on the PLN experience in handling any kinds of transformer failure. The most expensive cost according to PLN experience is more than 3000 million rupiah, and the lowest is less than 1 million rupiah. Based on this two points, then PLN divided the score become 5 points. d) Safety impact Safety impact is defined based on the management policy about safety. e) Environment impact. Safety impact is defined based on the management policy about environment. f) System impact System impact is defined based on the system operation strategy and PLN experience in handling the failure. The biggest score is 5 if the transformer should be out of operation and the lowest score is 0 if the failure has no system impact.

III. PREPARATION OF STATISTIC MODEL DEVELOPMENT Statistic Model is a model that is developed based on the historical data of the transformer including operational data and maintenance data as well. The data related to the critical components (as listed on the table above) that already have to be measured and monitored by PLN are:

responsibility of different utility, improving protection setting coordination has been done between P3B as transmission utility and distribution utility. Impact of TFC to transformer winding is related to the duration, magnitude and frequency. Since the duration of fault is limited by relay protection, recording the magnitude and the frequency of TFC occur are needed to be done by PLN. IV. CONCLUSIONS 1. PLN operational and environment condition is unique. Since the frequency of feeder fault (Through Fault Current) is extremely high, PLN need the special manufacturer design on current carrying unit and electromagnetic circuit of transformer. 2. FMECA (Failure Mode Effect and Criticality Analysis) is important step in CBM (Condition Based Maintenance) implementation to find the critical components and the appropriate monitoring tools. 3. Validity of data is the most important thing in developing model. The more accurate data, the better model. The better model, the more accurate condition prediction of equipment. Validity data of maintenance result only can be achieved by performing a good quality of maintenance process. 4. Maintenance standard procedure and Human Resource are absolutely needed in order to increase the quality of maintenance. 5. Data storage tool may help us to store the huge data to be analyzed. Therefore, data storage is CBM need.

Before starting to develop statistic model based on the data collected (as listed on table 2), relating to figure 5 (influence affecting ageing), then PLN analyze many probability causes ageing on PLN transformer: a. Quality of original equipment specification, design, manufacturing and associated system : As the unique operational condition in PLN that TFC is often occurs on transformer feeders, PLN needs a special design of current unit and electromagnetic circuit construction that originally have more withstand strength. b. Quality of Maintenance programs Since the data didnt show a trend, its difficult to analyze them and develop the model. Therefore, after doing maintenance audit, PLN decided that PLN need to standardize maintenance procedure in order to increase the quality of maintenance programs. Some steps have been done by PLN for increasing the quality of maintenance, they are: - DGA oil sampling standardization - Regular calibration of testing equipment. - Standardization of maintenance procedure, such as tan delta measurement, index polarization measurement, oil characteristic and DGA, and FRA measurements. c. Operational stresses and environment TFC as the major causes of transformer failure in PLN, can be categorized as operational stresses and environment. Besides increasing the manufacturer original design quality, PLN also tried to decrease the frequency of feeder faults of transformer. As, transformer and feeder become the

V.REFERENCES
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