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Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Rajaram Shinde
Cargill Industrial specialities
Paper Number: 7.04
Session Number: 7
16 November 2017
Sustainable Alternate material in
Power Sector (Transformer) for
developing countries
Company
Logo (this
slide only)
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Outline
� Topic 1
• Introduction to Ester Fluids for transformer application
• Experience
• Fluids développement
• Standards
� Topic 2
• Reason for Utility (GETCO) to adopt sustainable alternatematerial Natural Ester for the Transformers
• Snap-shot of case studies
• Way forward (Monitoring parameters)
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Introduction
What is an Ester Dielectric Fluid?
• Dielectric-fluid is fluid used in dieletric application & an ester word comes from chemical linkage of reaction from an alcohols & an acids
• Mainly two types
– Natural Ester-Derived from refined plant seed oils.(Soya, Sunflower)
– Synthetic Ester-Manufactured from acids & alcohols
• All Edible oil may not be used for Dielectric application
• Find balance between properties & sustainable solution
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Natural Ester for Transformer Application
Balance between best in class properties & sustainability
• Made from a renewable resource
- >98% vegetable oil
- Carbon neutral*
- Contains no petroleum, halogens, silicones or sulfurs
• Non-toxic, non-hazardous in water and soil
¯ OECD oral and aquatic toxicity test
•Biodegrades in less than 28 days
¯ Ultimately biodegradable - Environmental Protection Agency
(EPA)
• Recyclable
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Fluid development & Validation
Laboratory testing
• Measurement of all physical and chemical properties (complete temp. range)
• Material compatibility
• Oxidation stability using numerous methods
• Dielectric tests up to 200mm (1800kV)
Accelerated life testing
• Insulation system life (Real Xmer)
• Lockie Method test (IEEE C57.100)
Transformer (application) testing
• Cold Start tests in cooling chamber
• Internal arcing testing for fire safety
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Standards
Natural Esters Mineral Oil
• New Oil ASTM D6871 ASTM D3487
IEC 62770 IEC 60296
• Use and Maintenance IEEE C57.147 IEEE C57.106
IEC 60422
• Transformers IEEE C57.12.00 IEEE C57.12.00
IEC 60076… IEC 60076…IEEE C57.154 IEEE C57.154IEC 60076-14 IEC 60076-14
• Loading Guide IEC 60076-7 IEC 60076-7
• Dissolved Gases IEEE C57.155 IEEE C57.104
IEC 60599
Fire: FM Global Property Loss Prevention Data Sheets, IEC 61936-1 Power installations exceeding 1 kV a.c. IEC 60695-1-40
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Fire Point a most critical factor in transformer fire hazard
�Zero fire history in natural ester fluid filled transformers*
�Natural ester dielectric fluid fire point = 360oC
�UL Classified and FM Approved*
�Eliminate deluge systems and fire walls
�Reduced clearances
Underwriters Laboratories Classified
Less Flammable Fluid
Factory Mutual Research Corporation Approved
Less Flammable Fluid
FM
Fire wall
Natural ester
simplified
border
Mineral oil
containment and
suppression rocks
Mineral oil transformerNatural ester fluid transformer
Automatic fire
suppression system
Building
Reduced
clearance
8
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Pre-requisites of GETCO
Utility has standard questions before adopting any new technology…..
1. What is Natural esters proven experience & up to whichvoltage class? (Global)
2. Local experience of natural ester & highest voltage class? (India)
3. Any local utility adopted this technology?
4. What will happen if any leak or puncture of aircell in conservator? (Lot heard about oxydation)
5. Can On Load Tap changer be with Natural ester?
6. What about Long term supply reliability?
7. What is the Utility Value Proposition?
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Experience in Highest voltage class
Characteristic Value
Rated Voltage 420 kV
Rated Power 300 MVA
Performance 180 / 300 / 400 MVA
Ratio 405 ± 11% / 115 / 22 kV
Cooling KNAN / KDAF1 / KDAF2
Liquid Soy-Based Natural Ester
AC Insulation Level 630 kV
Lightning Impulse Insulation Level 1425 kV
Switching Impulse Insulation Level 1050 kV
Operating Weight 400 ton
Liquid Capacity 97 ton
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Experience in Local Market (India)
Tata
25-30MVA 33/11kV Commissioned in
June’15
(Total 50plus)
Torrent
20MVA 33/11kV Commissioned in
June’16
(Total 40plus)
T&R
75MVA 145kV manufactured in
Sept’ 2015
(Total mfd200plus)
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Free Breathing Reactor case
A 145kV / 11.4 MVAr reactor in service for 7+ years at rated load and free-breathing.
• Installation deviation resulted in free breathing condition• Acidity & Tgδ were trigger for case study• Location: Brazil/Peru/Bolivia• High temperature & moisture
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Indian Utilities adopting Natural Ester
• Natural ester usage in India started since 2000 with few distribution transformers
• Few retrofill pilot projects were implemented by privateUtility
• Accelarated adoption started since 2012 with Utilities like� Tata
� NDPL
� Torrent
� KPTCL
� BESCOM
� CESC
� BEST
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Tap Changer with Natural Ester
Tap changer is only moving part in transformer & needs to beevaluated from all perspective.
• Impulse behavior in Uniform & Non-uniform
• Compatibility with Material
• Reaction with Contact
• Lubrication property
• Gassing tendancy
• Switching Time
• Viscosity
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Supply Reliability
• Local manufacturing
• Raw material supply sustainability
• Cost stability
• After sales support
• Technical assistance
• Quality Consistency
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Value proposition (Increase life, load-ability or Both)
High temperature insulation system standard (IEEE C57.154 or IEC 60076-14)
� Current Kraft (cellulose) standard 95oC hot spot with 55 AWR limits transformer capability & (TUK)standard 110oC hot spot with 65 AWR limits transformer capability
� Natural ester fluid-based insulation systems can be run 15oC (Kraft) & 20oC (TUK) warmer without degrading life
� Design new transformers smaller with same or more load capability
� Existing transformers can be upgraded to provide overload capability
High temperature curve based on standard Kraft (cellulose) paper
High temperature curve based on thermally upgraded Kraft (TUK) paper
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
GETCO case study high lights (20MVA, 66KV)
• Details evaluation of technology
• Development of specifications
• Standard tendering process
• Monitoring manufacturing
• FAT-Including heat run test as per high temp
standard IEC 60076 part 14.
• Evaluate increase rating (sustainable peak almost
30MVA at KNAN class 130)
• Parameters to be monitored
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
GETCO (Installation close to building)
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Specifications
Sr.No. Technical Specification Rating
1 Rated Power 15 MVA, Three Phase
2 Voltage Ratio 66/11.55 kV
3 Rated Frequency 50 Hz
4 Vector Group Dyn11
5 % Impedance at rated tap 9.5 %
6 Voltage Regulation + 15 % to – 5.0 % in steps of 1.25% on HV for LV variation VFVV mode
7 Cooling Type KNAN
8 Temperature Rise ºC 35 Oil, 45 Winding
9BIL LI (kVp) One minute PF voltage (kVrms)
HV - 350, LV - 90 HV - 140, LV - 30
10 Guaranteed losses No Load loss : 9.50 kW Maximum Load loss : 51.0 kW Maximum
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
• Service guideline (Stainless steel instruction plate riveted)
• Insulation Resistance & PI
• Breakdown Voltage
• Thermography
• Tan delta
• Viscosity
• Acidity
• DGA
Parameter monitored
Electricity Supply to Africa and Developing Economies: Challenges and Opportunities
Thank You
Rajaram Shinde
+919765410104
Rajaram_Shinde@Cargill.com
Global Technology Adviser
Dielectric fluids-Cargill Industrial specialities
Member IEEE, Cigre WG D1.68,
Represent NC India in IEC TC10, TC14 & TC96
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