Electricity and Control March 2020

TRANSFORMERS, SUBSTATIONS + CABLES : PRODUCTS + SERVICES

Submersible robots join transformer inspection services Simcoa Operations is an Australian-based company committed to producing high quality silicon which is used in many of the products that make our modern lives easier. The company sources its power from the Australian grid and the manufacturing facility is supplied through two power transformers (rated at 132/22/11 kV).

service, TXplore™. Simcoa Operations welcomed the chance to use this new inspection technology and once it was agreed, ABB was on site within two days. Through the ‘eyes’ of the robot Despite poor visibility due to the dark oil, the TXplore was able to capture all internal areas and faults of the transformer using its on-board camera and LED lighting system. It can also ‘swim’ through tight areas to investigate and document all the internal workings of the transformer. The photos and videos taken during the inspection are streamed live and, in this instance, were viewed together by ABB’s transformer engineers and the team at Simcoa Operations. The transmission provided the data and evidence needed to make decisions for the next steps. The tap-changer was found to be operating in good order and was therefore not the issue. On the same day that the unit was disconnected from the network, ABB concluded that the transformer could be energised and put back into service. Reducing downtime and inspection costs With the TXplore inspection service, there was no need to drain the oil, add breathable air or assemble a confined space rescue team. This saved about 50% on the costs of the traditional inspection process. It was found that the trace amounts of gas in the oil would not stop the transformer from working properly and the recommendation was that this issue be addressed during the next planned maintenance outage.

When traces of gas were observed in the oil of one of the transformers, which handles 50% of the facility’s production capacity, Simcoa Operations sought the expertise of the local ABB Transformer Service team in Australia to conduct an internal inspection of the unit. According to oil test results, the transformer had experienced high energy discharges and electrical arcing. The initial hypothesis was that the issue was related to the tap-changer, a critical component in a transformer, and that it might need immediate maintenance. Simcoa had planned to allow for the inspection using the traditional method – where personnel enter the confined space of the transformer, a process that first requires the lengthy draining out of the oil and then adding breathable air. Taking the faulty transformer out of service for inspection would also place significant strain on the other transformer which would have to handle the additional power load. Furthermore, this approach could take up to five days working around the clock, and carries with it safety concerns and some limitations on the visibility, to the human eye, of some areas in the internal works of the transformer. ABB offered Simcoa a new way of inspecting the transformer – using its submersible inspection robot

For Simcoa Operations, ABB’s inspection of the transformer ensured minimal downtime of the transformer – just one day rather than a possible five or more – and enabled the issues to be identified quickly and safely.

For more information email: Namita Asnani, namita.asnani@in.abb.com or visit: https://new.abb.com

Using the TXplore transformer inspection service, Simcoa Operations could minimise downtime and saved on traditional inspection costs.

ABB’s TXplore submersible robot.

A TXplore high- definition

camera view through the transformer’s dark oil.

26 Electricity + Control

MARCH 2020