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NORTH AMERICAN
SUBSTATION SERVICES
TRANSFORMER LIFE
EXTENSION METHODOLOGY
THRU LTC REPLACEMENT
LTC Operation
TRANSFORMER FAILURE CAUSE 1955 - 1988
60%
DATA FROM ANSI/IEEE C37.91, TABLE 1
50%
50%
40%
% OF TOTAL
30%
21%
20%
11%
10%
10%
6%
2%
0%
Winding
Tap Changer
Bushings
Terminal Board
Core
Other
FAILURE CAUSE
V/T = 12,470/1.732/160 = 45
LV has 160 turns therefore the LTC tap winding has
16 turns and 1247 volts.
16 turns divided by 8 taps yield 2 turns per step or
90 Volts per step.
There are two Types of LTCs:
Reactive in the past the arcing in oil LTCs were used like the
FPE TC25, McGraw 550 A&B, Allis Chamers TLH 20&21,
Westinghouse UTTA&B etc Todays designers have very
few choices but the Reinhausen RMV has over 90% of the
Reactive LTC market.
Resistive the choices are UZD, UZE or UZF.
Transformer Regulation
Configurations
Delta Winding
WYE Winding
Auto-Transformer Configurations
Transformer Regulation
Delta Winding
Transformer Regulation
WYE winding
LTC Comparison
LTC TYPICAL GAS LEVELS
LTC Type
Acetylene
Methane
Ethane
Ethylene
Vacuum
150
50
250
Reactive Selector
Compartment
25
250
100
500
Reactive Diverter
Compartment
7000
650
500
1400
Resistive
5000
300
250
500
LTC Replacement
is the answer
Prevent the problems from re-occurring.
Fix the problem at its root. Replace the arcing in oil LTC.
Extend the life of the transformer.
LTC Replacement
Process Steps
Base line testing - TTR, Resistance, Doble PF, Megger and
oil sample (Day 1)
Drain LTC compartment Dispose of oil (Day 2)
Drain Main tank oil into storage tank (Day 2)
Internally disconnect all LTC leads and Blank LTC off with
Fire Blankets (Day 2)
Remove old tap changer off transformer main tank (Day 3)
Weld LTC tank transition piece (Day 4)
Weld new RMV LTC on transition piece (Day 4)
Pressure Leak Test (Overnight day 4)
Independent Experienced Safety Quality Customer Focused, Not Numbers Focused
LTC Replacement
Process Steps
Crimp lead extensions on all LTC leads (Day 5)
Rework/Replace reactor if applicable (Day 5)
Crimp extension leads to reactor leads as required (Day
6)
Make all internal connections to the LTC back board (Day
7 & Day 8)
Test (TTR, Resistance & Make before break) to verify
new connections (Day 9)
Pressurize tank with dry air (Day 9)
Independent Experienced Safety Quality Customer Focused, Not Numbers Focused
LTC Replacement
Process Steps
Take a Dew Point to determine dryness of transformer (Day
10)
Rewire Controls New Control Cabinet if necessary (Days 6
thru 12)
Perform field dry-out if necessary (Day 10 & 11)
Apply vacuum and hot oil fill transformer (Day 12)
Perform final testing (Day 13 & 14)
Provide as built control, outline and nameplate drawings
Economic Evaluation
for 50 MVA
(Based on a 10 year cycle)
New Transformer
Replacement
Repair of LTC
failure at repair
facility
LTC
Replacement in
field
LTC
maintenance Contact
Replacement
etc
Material
82%
34%
10%
15%
Installation labor
(Contractor and/or
Customer)
10%
14%
10%
12%
Transportation
8%
12%
0%
0%
Total
100%
59%
20%
27%
Outage Length
3 weeks
12 weeks
3 weeks
1 week x 3
Conclusion
Q&A
QUESTIONS