Transformers

5.2 Reliability and Project Perfomance

A further condition for a high level of supplier quality is close cooperation with the suppliers. Joint development of requirements for suppliers and processes leads to continuous improvements in quality. In this context, supplier know-how can also be used to create innovations. This aspect of the relationship with suppliers is becoming more and more important, especially in the transformer business. Business-driven quality planning Planning quality means analyzing possible future scenarios and anticipated problems and taking preventive steps to solve those problems. It is crucial that both current and future critical business factors are considered in planning. That means that quality is based on business-driven planning and specic objectives, activities and quantitative indicators. Focused quality reporting Reporting is based on: Focused key performance indicators such as non-conformance costs, external failure rate, internal failure rate and on-time delivery Concrete quality incidents Root cause analysis of quality problems including denition of corrective and preventive measures For customers, the reliability of transformers is of special importance. ANSI C57.117 has made an attempt to dene failures. Based on this denition, statistics on in-service failures and reliability values can be derived. An example for power transformers appears in table 5.2-1. Qualication of employees on quality issues People are the decisive factor inuencing quality. Therefore, all employees involved in the processes must have the skills and abilities appropriate to the quality aspects of the process steps they perform. Any qualication measures that may be necessary must be determined on the basis of a careful analysis of existing decits. Continuous improvement Because there is nothing that cannot be improved, continuous improvement must be an integral part in all processes. The objective is to continue optimizing each process step. This is also the purpose of improvement teams. Appropriate coaching of these teams should make it possible to reach almost all employees.

SIEMENS
PEQ

Core assembly stacking core laminates

TPD 2.01.02
Page 1/6

SIEMENS
PEQ

Core assemblystacking core laminates

TPD 2.01.02
Page 1/6

1. Purpose/objective
Process description for the manufacture of transformer core within the tolerances which are laid down

4. Process sequence
Subprocess 1: Setting up the construction devices and limit stops

2. Scope/application
applies to all the core forms of the power transformers does not apply to the cores of compensating reactors Adjusting the construction supports

3. Process overview/description
Stack of core laminations dimensions checked by the supplier to ensure that they agree with the drawing Frame parts dimensions checked by the supplier to ensure that they agree with the drawing Insulating parts dimensions checked by the supplier (internal ore external )to ensure that they agree with the drawing washers, small accessories Job related core drawings Process report TPD 2.01.01

INPUT INPUT

Stacking core laminates

Tools Assembly area with special support beams for xing the core laminations which have been put on into position Integrated slewing mechanism for mounting the nished core

MeasureMeasure ment

> Setting the middle distance of the support beams to one another in accordance with the drawing guideline > Tolerance +/5 mm to the desired size

Process owner Staff trained in core assembly

> Setting the clearance of the support trestles (on the support beams) for the core-limb laminations Adjusting the support trestles > The position of support trestles are to be placed in the middle between the single bandages > The position and clearance of the bandages are dened in the core drawing

Completed core with clamping frame also completely mounted OUTPUT Process report TPD 2.01.02

Max. sheet width BS MeasureMeasure ment

Middle distance support trestles

Clearance support trestles The following clearances apply to cores without single bandages (e.g. wound bandage cylinders):

< 650 650 to 800 800 to 1,000 1,000 to 1,200 1,200 to 1,500

550 450 350 300 250

References/guidelines, recommendations Stack height tolerances as in drawing N00 08 792 Arrangement of the cooling duct shims as in drawing N10 11 100 Locking the screwed connections in accordance with TPD 3.036.01 Measurement of insulation resistance with TUQ 1634

Drawn up by: Matthes

Checked/approved:

Dr. Knorr

As of date:

2004-02

Drawn up by:

Matthes

Checked/approved:

Dr. Knorr

As of date:

2004-02

The passing on as well as the duplication of this document. use and communication of its contents is not permitted. nor may the contents be expressed. Offenders are liable to pay damages. All rights reserved. in particular for the case of patent granting or GM-entry

The passing on as well as the duplication of this document. use and communication of its contents is not permitted. nor may the contents be expressed. Offenders are liable to pay damages. All rights reserved. in particular for the case of patent granting or GM-entry

Fig. 5.2-2: Example of standardized working instruction

E T TR In-Service Failure Statistic 2000 2009 for Power Transformers

based on ANSI C 57.117

E T TR N SY nF FRe (%) MTBF (yrs) 11,278 51,429 91 0.18 565

Plant 1 572 2,358 9 0.38 262

Plant 2 1,704 7,479 7 0.09 1068

Plant 3 755 3,858 10 0.26 386

Plant 4 793 3 11 0.37 273

Plant 5 774 4,326 1 0.02 4,326

Plant 6 534 1,996 11 0.55 181

Plant 7*

Plant 8 735 3,341 3 0.09 1,114

Plant 9 1,076 4,561 6 0.13 760

Plant 10 705 4,17 2 0.05 2,085

Plant 11 649 2,889 7 0.24 413

Plant 12 994 4,899 8 0.16 612

Plant 13*

Plant 14** 1007 3,781 3 0.08 1,26

Plant 15 980 4,771 13 0.27 367

* Plant 7 & 13: new plants; ** Plant 14: 9 years 2001 2009 N = No. of units in service SY = No. of service years nF = No. of units failed FRe (%) = Failure rate = nF 100/SY MTBF (yrs) = Mean time between failures = 100/FRe FRe 0.5 % < 1.0 % < 1.5 % < FRe > 0.5 % FRe 1.0 % FRe 1.5 % FRe 2.0 % 2.0 % excellent good satisfactory acceptable not acceptable

Table 5.2-1: In-service failure statistic

Siemens Energy Sector Power Engineering Guide Edition 7.0

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