SteelAsia Manufacturing Corp

Meycauayan Bulacan

FEASIBILITY STUDY
FOR
REWINDING OF 4MVA TRANSFORMER

SteelAsia Manufacturing Corporation

TIBAY NG PILIPINO

2F B2 Bonifacio High Street Bonifacio Global City,

22nd floor
Taguig City, National Ore Central
Capital Region,Building
Philippines 1634
31st Street corner 9th Avenue Bonifacio Global City, Taguig City, 1634

EPC - Design and Engineering

Electrical Design Team

Approved by: R.M.T. FS No.: FS22-M1-02-S305

Civil & Struc : R. B.P. 11-04-2021 Date of Prep.: October 28, 2021

Mechanical: W.E.B. Date of Issue.

Electrical J.B.C.G Doc. No.:

Prepared by: G.J.P.D.

 Certificate of Acceptance

It is hereby certified that the FS Report has been thoroughly and carefully read and recommended to the
Budget Committee for the acceptance of Final Project for the year 2022

Michael T. Marcial
Plant Manager

Jeffry T. Leodones
Department Head

Ramil C. Sulat
Requestor

SteelAsia Head Office: 25 th floor Ore Central Building, 9 th Avenue corner 31st street, Bonifacio Global City, Taguig, Philippines
Tel: (02) 8856-6888 | Fax: (02) 8856-5555
Meycauayan Works: #090 Ciudad Industria, Bahay-Pare Meycauayan City, Bulacan 3020
Tel: (02) 8856-6888 | Fax: (02) 8856-6888
 Table of Contents
I. General Information………………………………………………………….1
A. Background of the Study……………………………………………………...1
B. Objectives of the Study...……………………………………………………...1
C. Significance of the Study……………………………………………….……..1
D. Scope & Limitation………………………………………….………………...1
II. Technical Analysis………………….………………………………………...1
A. Specification of the existing 4MVA Transformer for Rewinding……………1
B. Transformer Standard Test Results…………………………………………..3
C. Condition of Existing Operational Transformers……………………........….4
D. Cost Comparison……………………………………………………....….….4
III. Conclusions and Recommendations …………………………………….........5
IV. References ………………………………………………………………........5

APPENDIX A – PROJECT FEASIBILITY REQUEST FORM INCLUDING 2017 TEST

RESULT OF TRANSFORMER FOR REWINDING

APPENDIX B – 2021 TEST RESULT OF THE 5 OPERATIONAL TRANSFORMERS

APPENDIX C – 2020 TEST RESULT OF THE 5 OPERATIONAL TRANSFORMERS

APPENDIX D – COST REFERENCE FOR THE TOTAL RECONDITIONING OF

TRANSFORMER & SUPPLY OF BRAND NEW TRANSFORMER
 I. General Information

A. Background of the Study

A transformer is an electrical device designed and manufactured to step voltage up or step

down. It transforms the voltage on the input side to the voltage required by the device or
equipment connected to the output. In our case, we need to transform the voltage from
34.5kV to 480V.

Meycauayan Works has an existing transformer with a capacity of 4MVA that is not
currently operational which they are planning to utilize as a spare. This transformer has
been operational from 1995 to 2012 (17 years) and it was replaced last 2012 due to failed
Dissolved Gas Analysis (DGA) and low resistance as per test result. During that time, the
contractor opened the transformer and found out that the insulation had deteriorated. The
recommendation is to subject the transformer for rewinding.

B. Objectives of the Study

1. To justify the need of having a spare transformer as a back-up in case the existing
transformer experience failure.
2. To validate if the existing transformer needs to have rewinding or if there are other
tests necessary to make it operational
3. To be able to provide a cost-effective solution by comparing if it is more feasible
to rewind the existing transformer or purchase a new one.

C. Significance of the Study

This study will benefit the Plant/Company by the following aspects:
1. Help save money by showing the cheaper option of having a spare
transformer
2. The usual delivery lead time for a transformer is 6 months. By having a
spare transformer, long down time will be avoided since there will be a
back-up transformer ready for installation in case one of the operational
transformers fails.

D. Scope & Limitation

This study focuses on evaluating the existing 4MVA transformer recommended for
rewinding. However, this study is limited to the data gathered provided by Meycauayan
works such as results of previous test conducted on the transformer, condition of the
existing transformer and other necessary information they witnessed relative to this project.

II. Technical Analysis

A. Specification of the existing 4MVA Transformer for Rewinding

The table below shows the specification of the transformer for rewinding.
Brand EFACEC
Capacity 4000kVA
Primary Voltage 36kV
Secondary Voltage 480V
Temperature Class Insulation A
Cooling Type ONAN
Impedance 5.6%

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 Total Weight 7,400kg
Total Volume of Oil 4,540L
Dimension (L x W x H) 2.5m x 3.5m x 2.8m

This transformer has been operational for 17 years (1995 to 2012). There were no problems
encountered during that time aside from the overloading that happened in 2009 when the
loads of Transformer 3 were transferred to it. During overloading conditions, excess heat
will cause the insulation system to break down, resulting in decreased life expectancy of
the transformer. More information about the average life of a transformer to be discussed
in Section II.C.

It was only in 2012 when it was replaced due to failed Dissolved Gas Analysis Test Result
that falls under Condition 4. Under this condition, continued operation could result in
failure and faults are probably present inside the transformer.

B. Transformer Standard Test Results

In 2017, the following test were conducted to the Transformer:

• Oil Quality Test
• Dissolved Gas Analysis – used to monitor the dissolved gases in the
transformer medium
• Corrosive Sulfur Test - If corrosive sulfur compounds are present in the oil,
they may react with system components and compromise performance.

The Test Result for this transformer are as follows:

• Oil Quality Tests are within the allowable limit.

• Dissolved Gas Analysis result showed that the Total Dissolved Gas Content
(TDCG) is within the allowable limit (<720) and falls under Condition 1 but
the Carbon Dioxide (CO2) content exceeded the allowable limit. Under

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 Condition 1, it is stated that the transformer is operating satisfactorily but
individual gases exceeding specified level should prompt additional
investigation.

The total CO2 is developed from normal aging, thermal fault involving cellulose
and accumulation from oxidation. A fault in paper (cellulose) is generally
considered as more serious than a fault in oil because paper is placed in HV area
(windings, barriers). A popular ratio to detect fault in a paper is CO2/CO ratio. If
the CO2/CO ratio is <3, this is a strong indicator of a fault in a paper, either a
hotspot or electrical arcing. If the CO2/CO ratio is >11, this indicates cellulose
aging from thermal heating. However, this is only valid when the individual gases
are above 5000/500ppm.

In this case, the CO2/CO is lower than 5000/500ppm. This means that there is no
indication of fault in paper.

• Corrosive Test Result showed that it was Corrosive 4A.

Under ASTM D 130, Classification 4A means corrosive sulfur is already present

in the oil. Dibenzyl Disulfide (DBDS) is a sulfur compound often found in
transformer oil that is known to react with the copper (such as windings), creating
by products that attack the insulation. Eventually, the transformer may fail. Based
on the result, the copper windings, thermal cellulose and transformer oil needs total
reconditioning.

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 C. Condition of Existing Operational Transformers

The reason for Meycauayan Works’ request for a spare transformer is due to the
existing condition of the other operational transformers. If ever a problem occurs in one of
the transformers, they would have a back up ready for installation that will avoid long down
time. The usual delivery lead time for a transformer is 6 months.

The table below shows the summary of the ages of the five operational distribution
transformers. Same with the transformer for rewinding, four (4) out of five (5) are already
24 years old. They have been operational since the plant was started in 1995.

The average life expectancy of the transformers operating under ANSI/IEEE (ANSI
C57.96) basic loading condition is between 20-30 years. The ANSI / IEEE basic loading
conditions for Transformer are:

1. The transformer is continuously loaded at rated kVA (kilo Volt Ampere) and rated
voltages (transformer must be operated at the rated voltage and kVA)
2. The average temperature of the ambient air during any 24-hour period is equal to
30°C (86 °F) and at no time exceeds 40°C (104 °F).
3. The height where the transformer is installed is not above 3300 feet or 1000 meters.

This means that the 4 transformers are also near the life expectancy.

Description Age Brand

Transformer #1 27 years EFACEC
Transformer #2 27 years ABB
Transformer #3 27 years EFACEC
Transformer #4 27 years EFACEC
Transformer #5 4 years TATUNG

The annual test results of these operational transformers for this year showed the
following results:
• For Transformer 1, leak at the top cover was observed. This can be corrected by
retightening.
• All other transformers are within the allowable limits. However, Transformers 1,
2, and 3 already underwent Oil filtering aside from the annual preventive
maintenance to address the failed DGA Test Result on the previous year’s
preventive maintenance tests.

D. Cost Comparison

Part of this study is to also consider the most cost-effective solution to provide a back up
or spare transformer at the plant. The team asked for assistance from the Costing
Department to consider the two options:

Option 1 is to continue the proposed rewinding of the transformer plus the change
oil and replacement of thermal cellulose
Option 2 is to check the cost of a brand new transformer.

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 The table below shows the summary of cost comparison for the two options:

Option 1 Option 2
Reconditioning of the transformer which
Supply of brand new 4MVA
includes: Transformer including hauling,
-Rewinding positioning, testing & commissioning at
-Checking or Replacement of thermal site
Paper insulation
-Changing of oil
Total Cost: P4,450,000.00 Total Cost: P5,500,000.00

The cost difference of the reconditioning should be within the allowable limit. If it is less
than 50%, it is best to purchase new transformer instead of reconditioning. Based on the
table above, the cost difference between supply of brand new transformer is only 21.11%.
This means that the best option for having a spare transformer is by purchasing a brand
new one.

III. Conclusions and Recommendations

1. Meycauayan Works’ plan to have a spare transformer was somehow considerable.

Although the latest test results showed that one (1) out of five (5) transformers has
a minor problem, it is significant to take note that four (4) of them are already more
than 20 years operational which means that they are already near the average life
expectancy. Having a spare transformer will incur less down time for replacement
in case one of the operational transformers failure occurs.
2. The initial proposal is only to do rewinding of the existing transformer intended as
a spare considering the recommendation of the contractor who conducted the tests
last 2012. However, upon further study using the test results in 2017, it was found
out that the transformer also needs to change the transformer oil and replace
thermal cellulose. Thus, instead of rewinding, the project should be Total
Reconditioning of the Transformer.
3. If total reconditioning will proceed, it is also best to conduct complete tests on the
transformer to check for other possible damage since it was already 24 years (15
years operational, 9 years not operational).
4. Another possible option for having spare is to purchase a brand new transformer if
the cost difference between the two is within the allowable range. If it is less than
50%, it is best to purchase new transformer instead of reconditioning. Based on the
table above, the cost difference between supply of brand new transformer is only
21.11%.
5. Based on the cost comparison provided between the two options, it is therefore
recommended that the purchase of a brand new transformer as a spare is more
feasible considering the cost difference.
6. Factors to consider when purchasing a new transformer is the limitation of the
existing room dimension and the total weight. The transformer should not exceed
2.5m length x 3.5m width x 2.8m height and 7400kg total weight.

IV. References

https://www.cigre.cl/wp-content/uploads/2017/03/presentacion_12ago.pdf

https://iiee.org.ph:89/uploads/files/917.pdf

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 https://boilerproperty.com/corrosive-sulfur-in-transformer-oil/

http://focuslab.co.th/pdf/coppercorrosion.pdf

https://www.cigre.cl/wp-content/uploads/2017/03/presentacion_12ago.pdf

https://www.electricaltechnology.org/2019/12/average-life-expectancy-
transformer.html

APPENDIX A – PROJECT FEASIBILITY REQUEST FORM INCLUDING 2017 TEST

RESULT OF TRANSFORMER FOR REWINDING

APPENDIX B – 2021 TEST RESULT OF THE 5 OPERATIONAL TRANSFORMERS

APPENDIX C – 2020 TEST RESULT OF THE 5 OPERATIONAL TRANSFORMERS

APPENDIX D – COST REFERENCE FOR THE TOTAL RECONDITIONING OF

TRANSFORMER & SUPPLY OF BRAND NEW TRANSFORMER