Maintenance 2012

On-Load Tap-Changer
Theoretical foundations Maintenance of On-Load Tap-Changers
On-Load Tap Changer: OILTAP
OLTC
OLTC Diverter switch
-Tap selector
-insert
Diverter switch
insert
OLTC
-Tap selector
Type MS
Type R
2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH
TAP CHANGER OPERATING
Motor Drive Unit
Tap Selector
Diverter Switch
Page 3
Maschinenfabrik Reinhausen GmbH Switching sequence
Load current IL
Circulating current IK
Ik
Page 4
Switching sequence Type M
MCa
MSCa
TCa
TCb
MSCb
MCb
MCa MSCa TCa TCb MSCb MCb
Page 5
MCa
MSCa
TCa
TCb
MSCb
MCb
MCa MSCa TCa TCb MSCb MCb 0 10 20 50
Page 6
MCa
MSCa
TCa
TCb
MSCb
MCb
Page 7
MCa
MSCa
TCa
TCb
MSCb
MCb
MCa MSCa TCa TCb MSCb MCb 0 10 20 50
Page 8
Ic
MCa
MSCa
TCa
TCb
MSCb
MCb
Diverter switch mid-position:
MCa MSCa
circulating curent Ic determined by step voltage and transition resistor
TCa TCb MSCb
load current split up in old and new tap
MCb
Page 9
MCa
MSCa
TCa
TCb
MSCb
MCb
Page 10
MCa
MSCa
TCa
TCb
MSCb
MCb
Page 11
MCa
MSCa
TCa
TCb
MSCb
MCb
Page 12
MCa
MSCa
TCa
TCb
MSCb
MCb
Page 13
On-Load Tap Changer OILTAP V III 200 D
Page 14
TAP SELECTOR OPERATING
Motor drive unit
On-load tap changer
Switching element
Time in second
Page 15
Switching Principle
Switching sequenc V
Page 16
Switching sequence Type V
Ib
a
transition contact a1
b
transition contact b1
main switching contact a/b
a1 b1 a/b 1
10
20
30
40
50
Page 17
Ib
a1 b1 a/b 2
10
20
30
40
50
Page 18
Ib
a1 b1 a/b 2
10
20
30
40
50
Page 19
Ib
a1 b1 a/b 3
10
20
30
40
50
Page 20
Ib
a1 b1 a/b 3
10
20
30
40
50
Page 21
Ib
a1 b1 a/b 3
10
20
30
40
50
Page 22
Ib Ib/2
Ic
Ib/2 a1 b1 a/b 4
10
20
30
40
50
Page 23
Ib
a1 b1 a/b 5
10
20
30
40
50
Page 24
Ib
a1 b1 a/b 5
10
20
30
40
50
Page 25
Ib
a1 b1 a/b 5
10
20
30
40
50
Page 26
Ib
a1 b1 a/b 6
10
20
30
40
50
Page 27
Ib
a1 b1 a/b 6
10
20
30
40
50
Page 28
Ib
a1 b1 a/b 7
10
20
30
40
50
Page 29
Why Maintenance ?
Switching operation under load in 40 50 ms Mechanical stress Arcs produced during a switching operation Contact wear Carbonization of the switching oil
R
Page 30
Why Maintenance ?
Mechanical stress
Springs
Braided contact leads Screw connections Energy accumulator etc.
Page 31
Why Maintenance ?
Subject to weather Tap changer head Protective relay Drive shafts Motor drive unit
Page 32
Oil carbonisation
Major aspects of maintenance criterion: Oil carbonisation
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.

2012 CS5O 2007 Gerhard Boris Peier Wende Maschinenfabrik Reinhausen GmbH
Diverter switch type R with carbon deposits.
Page 33
Oil carbonisation
Major aspects of maintenance criterion: Oil carbonisation
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.
Page 34
Maintenance criteria :
Time in service
Number of operations
or
whichever comes first!
Usually applying for OLTCs in network application
Usually applying for OLTCs in industrial application
Page 35
Survey of number of OLTC operations in various transformer applications:

Transfomer data
Power Transformer
Generator Distribution Arc furnace
Power range MVA 100 - 1300 15 - 400 2,5 - 150
Voltage range kV 110 - 765 60 - 525 20 - 230
Current range A 100 - 2000 50 - 1600 50 - 1000
Number of on-load tap-changer operations. min. 500 2000 20000 mean 3000 7000 50000 max 10000 20000 200000
Page 36
Maintenance criteria : Time in Service

For OLTCs manufactured up until the 70s used in starpoint application: 5 to 6 years i. e. OLTC type D III 400 Y
For OLTCs of todays manufacturing program used in starpoint application: 6 to 7 years i. e. OLTC type M III 600 Y
For OLTCs in line-end application with Um 245 kV (delta connected windings, autotransformers): 2 years for first, 4 years for further maintenance i. e. OLTC types V III delta 3 x M I 1200 245 kV
Maintenance intervals are stated in the OLTCs operating instructions

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH Page 37

Updating 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.)
MRs 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

Oil values
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: Water content*) Neutral-end tap changers 40 ppm Single-pole tap changers 30 ppm (delta application and autotransformers) Dielectric strength**) 30 kV / 2.5 mm 40 kV / 2.5 mm
Limit values while OLTC and transformer are in service

*) measured according to Karl Fischer-Method **) measured according to DIN 57 370 Teil 1 / VDE 0370 Teil 1 / 12.78.
Maintenance criteria : Number of operations

Contact wear
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
Maintenance criteria : Number of operations

Contact wear depends on
- wear characteristics of the contact material - numer of operations - operating current of the transformer
Evaluation Criteria
- individual wear - wear differences - contact surface
Page 41
Number of operations
Parts 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 lead for type M: 150,000 operations performed
E. g. energy accumulator spring for type M: 400,000 - 500,000 operations

Page 42
Checks between Inspetctions

Taking oil samples from tap changer suction pipe and determination of breakdown voltage Supervision of tap changer oil quality Check of the anti-condensation heater of the motor drive unit Preventing corrosion inside motor drive housing Check of effectiveness of dehydrating breather of OLTC conservator Avoiding 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
Spare part replacement

Spare parts requirement during routine maintenance
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
MR TECHNICAL SERVICE
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.)
Page 45
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 46
Maintenance performance
2012 CS5O Boris Wende 2009 Maschinenfabrik Reinhausen GmbH
Page 47
General Notes on the Preparation of an On-Load Tap-Changer Maintenance by MR

Table: Oil quantities, weights, lifting height
OLTC-type ** Oil quantity (l)* Weight of the diverter sw itch insert (kg) Max. lifting height (mm)
A 30
B 100
C250 150
C350 D (D ) 250 200 (300) 100 (120) 1500 (2150)
E 220
F 320
G 900
H 355
K 650
M / MS (M) 190 (280) 80 (90) 1400 (1870)
T/ R 210
V 220
VV 325
20
60
100
150
150
250
500
80
350
120
60
50
1900 2250
2500
2400
1850 1750 2300 2150 1900
1650
1950 2200
* 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 48
OILTAP M Maintenance of On-load Tap-changer OILTAP M
Switching OLTC into adjustment position Draining off tap changer oil Removal of horizontal drive shaft
Page 49 Page 49 of 2
Removal of OLTC cover Withdrawal of diverter switch insert
2012 CS5O Boris Wende 2009 Maschinenfabrik Reinhausen GmbH

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.

2012 CS5O 2007 Gerhard Boris Peier Wende Maschinenfabrik Reinhausen GmbH Page 51
View inside diverter switch supporting cylinder before cleaning
Removal of diverter switch supporting cylinder Cleaning and visual inspection of supporting cylinder and insulating drive shaft
2012 Gerhard CS5O Boris Wende 2007 Peier Maschinenfabrik Reinhausen GmbH
Diverter switch insulating drive shaft before cleaning
Page 52
Pawl in locked position
Pawl in unlocked position
Unlocking the pawl of the diverter switch and bringing the diverter switch in midposition for reduction of contact pressure (see above) Removal of diverter switch contact shells in diverter switch mid-position
OILTAP M Maintenance of On-load Tap-changer OILTAP M Removal of contact shells Undo the fixing screws of the contact shells
Page 54
Removal of diverter switch contact shells Cleaning and visual inspection of contact shells Measurement of contact wear on fixed contacts Check of spark gaps
OILTAP M If necessary, replacement of: Maintenance of On-load Tap-changer OILTAP M

Resistor connection leads Fixed contacts Current strips
Measurement of transition resistors
Diverter switch contact shell
Measurement of transition resistors

Measurement of contact wear

Page 56
OILTAP M Maintenance of On-load Tap-changer OILTAP M 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 accumulator
Movable contact system of diverter switch after removal of contact shells

Page 57
Page 58
OILTAP M Maintenance of On-load Tap-changer OILTAP M Removal of stationary and movable contacts
Page 59
OILTAP M Maintenance of On-load Tap-changer OILTAP M Removal of braided leads
Page 60
OILTAP M Maintenance of On-load Tap-changer OILTAP M 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 M Maintenance of On-load Tap-changer OILTAP M Fill new oil into the diverter switch oil compartment Vent the tap changer head through the bleeder screw Vent the suction pipe
Page 62
Opening and cleaning OLTC protective relay Visual check Installation of new gasket and closing cover again
Test of protective relay
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)
Check of overall condition and function of motor drive:
safety switch limit switches step-by-step function anti-condensation heater etc.
Writing maintenance report with all relevant data
Keeping file or a databank with maintenance results (documentation)
OILTAP V Maintenance of On-load Tap-changer OILTAP V
Switching OLTC into adjustment position
Reaching adjustment position by turning hand crank clockwise
Page 67
Draining off tap changer oil Removal of horizontal drive shaft Remove OLTC head cover
Page 68

Removal of OLTC gear and suction pipe
Check of marks for reinstallation of OLTC insert
Page 69
Careful withdrawal of OLTC insert by means of MR lifting device or crane and chain hoist
Page 70
Cleaning of oil compartment
Page 71
Placing OLTC insert on a working table in horizontal position
Page 72
Removal of the switching elements Removal of the inner screening rings
Page 73
Cleaning switching tube of OLTC insert inside and outside by means of transformer oil and brush
Cleaning of switching elements
Page 74
Measurement of the transition resistors
Page 75
Determination of the contact wear
Page 76
Checking the spring movement of the contact rollers
Page 77
Preparation of OLTC insert for re-installation
Page 78
Re-installation of suction pipe Re-installation of the cleaned gear unit
Trial operations and check of limit position blocking
Page 79
OILTAP V Maintenance of On-load Tap-changer OILTAP V Opening and cleaning OLTC protective relay Visual check Installation of new gasket and closing cover again Test of Protective relay
Page 80
Check of overall condition and function of motor drive: safety switch limit switches step-by-step function anti condensation heater etc.
Page 81
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)
Writing inspection report with all relevant data Keeping file or a databank with inspection results (documentation)
Page 83
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 84
6. Measures for Equipment Preservation
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
Page 85
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
replaced by
Preferable strategy for OLTCs and transformers
Date: 26.03.2007
Page 86
Advantages of the vacuum technology
Switching element VACUTAPVV

Vacuum interrupter
Switching element OILTAPV

Transition contact Main switching contact Transition contact
Vacuum technology contact wear reduced to a minimum No arcing in the oil No oil carbonization
Conventional technology Wear of single contacts Contact wear difference Oil carbonization
VACUTAP: Extension of the maintenance interval up to 300.000 operations and no time based maintenance
Innovation VACUTAP Life-Cycle-Cost Consideration

Maintenance-free up to 300.000 operations with VACUTAP V V and VR
OILTAP
lifespan 40 years < 300,000 operations
Benefits
Significant savings in maintenance costs Considerably reduced operating costs
10 x maint. delta application 5 x maint. star point application VACUTAP maintenancefree OILTAP
No time-based maintenance
longer availability of the transformer simplified maintenance logistics
Performance of maintenance during lifespan for typical network application
protection of environment and natural resources due to reduction of oil changes only familiar checks required
Page 88
Are you still using conventional on-load tap-changer technology?

Maintenance Intervals
Retrofit - Solution
OILTAPM
VACUTAPVM
Page 90
Perfect Retrofit-Solution
Compatible with OILTAP M / MS and other on-load tap-changers based on OILTAP M No modification work on the oil compartment required
VACUTAP VM Copyright MR Maschinenfabrik Reinhausen GmbH
91
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
92
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
Copyright MR Maschinenfabrik Reinhausen GmbH
93
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
94
Marginal Contact Wear
Conventional technology
VACUTAP technology Rate of contact wear is more than one decade lower compared with coppertungsten contacts
Contact wear
Contact life: 200,000 to 500,000 switching operations
Contact life: 600,000 switching operations
95
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
Maintenance intervals
Maintenance intervals
96
Electric Arc Furnace (EAF) Application

High system availability and reliability - Maintenance interval: 300,000 switching operations without time- or current-based criteria
Maintenance costs
- 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
100 % 55 %
OILTAP
VACUTAP
97
Unique. Better For 4 Reasons.
1
The new VACUTAP Arc-Control System extinguishes the commutating arc with absolute reliability
4
The VACUTAP VM diverter switch insert is retrofittable, which means longer maintenance intervals and maximum cost-effectiveness
2
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
98
2007 Gerhard Peier Maschinenfabrik Reinhausen GmbH
Date: 26.03.2007
Page 99

Maintenance 2012

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On-Load Tap-Changer

Theoretical foundations Maintenance of On-Load Tap-Changers

On-Load Tap Changer: OILTAP

OLTC Diverter switch

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

TAP CHANGER OPERATING

Motor Drive Unit

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Maschinenfabrik Reinhausen GmbH Switching sequence

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb 0 10 20 50

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb 0 10 20 50

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

Diverter switch mid-position:

circulating curent Ic determined by step voltage and transition resistor

TCa TCb MSCb

load current split up in old and new tap

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type M

MCa MSCa TCa TCb MSCb MCb

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

On-Load Tap Changer OILTAP V III 200 D

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

TAP SELECTOR OPERATING

Motor drive unit

On-load tap changer

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

2012 CS5O Boris Wende Maschinenfabrik Reinhausen GmbH

Switching sequence Type V

main switching contact a/b

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V

Switching sequence Type V