Circular Economy in Transformer Service.pptx

HITACHI ABB POWER GRIDS
© Hitachi ABB Power Grids 2021. All rights reserved
Circular Economy in Transformer Service
How can we get there together?
2021-05-03 - Document ID:2413EUM0013 - Rev: A
POWERING GOOD FOR SUSTAINABLE ENERGY

Collaborative Effort to reduce carbon and greenhouse emissions
2

3
Overview:
• Analysis by the Netherlands Environmental Assessment Agency (PBL) in 2019 indicates that the Netherlands is not on track to meet the 2030
emissions reduction target. The target was to reduce by 49% the CO2 emissions compared to 1990.
• In 2018, heating and electricity generation was the largest source of energy-related CO2 emissions (35%), followed by industries (24%), transport
(20%), residential (11%) and services/other (10%).
Outcome:
• Large power plants and energy intensive industries in Netherlands will have to reduce CO2 emissions by 43% by 2030. (EU Target)
• The mathematics:
• 35% CO2 emissions from the energy sector = 55 Mts
• Reduction by 43% means approx. 24 Mts CO2 emissions in the next 9 years
Netherlands Energy Policy
Collectively we need to work together to achieve our common goals

Source: picture sourced from www.iea.org 4
What can we expect as results from working together and applying CE concepts?
• Reduction of CO2, material extraction footprint and logistics
• Reduced waste ► reduced landfill space + incineration
• Customer savings and increased asset efficiency + lifetime
• Enhanced collaboration amongst ourselves (customers + service + suppliers)
• Ability to apply to various European CE programs and standards
Circular Economy Expectations

5
Our ambition is to collaborate and enhance sustainability of our products and reduce their environmental impact
Our vision of Transformers in a Circular Economy
›
›
›
›
Evaluation criteria and design considering TOC and LCAs
• Reduced Losses
• Design for manufacturing and design for recycling
• Reduced carbon footprint material
• Dry technologies and biodegradable liquids
• Safety by design
Manufacturing with reduced environmental impact
• Optimized operations, reducing carbon footprint
• Renewable energy, fossil free electricity sourcing
Transportation
• Optimization of transport and logistics
• Selection of sourcing closer to utilization
Responsible sourcing (Procurement)
• Production with a more sustainable energy mix carbon
footprint reduction, energy efficiency programs
• Mix of secondary and primary raw materials, use of
recycled materials
• Cellulose sourcing considering sustainable foresting and
biodiversity
• Location to minimize logistics
• Transformers are ~90% recyclable
• Disposal processes and regulations
• Industry agreements
• Life asset management programs
• Energy efficiency programs
• Preventive maintenance
• Digitalization

6
High level Liquid filled power transformer recyclability (ISO 14001)
• Reduce carbon footprint
• Reduce waste
• Reduce water
• Reduce and control chemicals
• Increase biodiversity
Bottom line:
• Keep assets in service for longer periods of time
• Reduce waste
• Rehabilitate
Circular Economy viewed from Hitachi ABB Service
Part % average mass % that can be recycled
Magnetic steel (core) 46 99
Iron/Steel (tank, cover,
conservator)
31 99
Copper (windings,
cables)
16 99
Cellulose (insulation) 3 75
Other 4 97
TOTAL without oil 100 90
Keeping fit and staying young even after 30-40 years in service 
The material content (average percentage of the mass) which have been used in
the manufacturing the electrical equipment is the following.
Oil can be refined (recycled) and used in a lower grade for
new products.

7
Dutch liquid filled transformer HAPG install base Serviceability – maximizing asset lifetime & performance
Call to Action - where and how?
Currently doing:
• Time based condition monitoring
• Maintenance:
 Condition based
 Time based
What can we do better to extend the transformer lifetime via:
• Digitalization
• Proactive consultancy
• Mid-life refurbishments
• Reengineering by maximizing MVA per transformer tank
• On-site services by extending asset life and reducing risks
 Site transformer rehabilitation
 Oil reclamation
 Low Frequency Heating (Drying)
 High Voltage Testing

8
Who are we? Our offering
Hitachi ABB
Transformer
Service
Spare Parts
Training,
Engineering &
Consulting
Condition
Monitoring &
Asset
Management
Solutions
Life Cycle
Assessment
Service
Agreements
Basic &
Advanced
Maintenance
On-Site and
Factory
Repairs
Replacement
Units
Installation and
commissioning
• European footprint: 11 Units
• 6 Centers of Excellence in Europe
 Sweden for HVDC, bushings and tap changer replacements
 Germany for high voltage testing and workshop repairs
 Norway for low frequency heating and oil & gas analysis
 Switzerland for traction transformer repairs
 Poland for off-shore service
 Spain for TrafoSiteRepair
• Globally interconnected service & product teams across Power Grids
~ 115 factories globally
~2,000 engineers & scientists in R&D
European Transformer Service organization

* Assumption = 1500km travelled where 1000km are travelled by rail and 500km by road = 3,208kg CO2e + 4,520kg CO2e = 7,728kg CO2e ; Right hand picture source: CIGRE 227 9
Background Customer benefit – economics compared to a new unit
Transformer:
Rating: 33MVA, 120/12kV (Manufacturing Date: 1961)
Location: Densely populated area with customer contingency to keep operations running
Repairs and complexity:
Required: Major Work on OLTC, bushings and accessories
Complexity: Transportation issue due to load restrictions and surrounding buildings
Circularity outcome:
• Transportation completely eliminated (diesel + railway)
• Repaired transformer with minimum component change + recycling
• Transformer: 144t in CO2 emissions reduction
• Transportation: 7.2t in CO2 emissions reduction
TOTAL CO2 reduction (compared with purchasing a new unit):
151t in CO2 emissions
Case #1 On-Site repair due to problematic transportation

Transformer:
Rating: 250MVA, 13.8/315kV (GSU type)
Location: Customer site with client contingency to keep operations running
Repairs and complexity:
Required: Complete unit investigation, repair and tests
Complexity: Remote area hence problematic transportation
• Transportation partly eliminated (on-site mobilization)
• Only winding replacement while repairing the core & keeping the tank & so on
• Transportation*: 6.4t in CO2 emissions reduction
Case #2 On-Site core repair & winding replacement

Transformer:
Rating: 100MVA, 140/10kV GSU type (Life in service: 15 years)
Location: Customer site with no spare unit in place 
Repairs and Complexity:
Required: Complete unit investigation, repair and tests
Complexity: Outage time resulted in production loss = loss in earnings
• Transportation reduced by 1/3
• Repaired transformer with minimum component change + recycling
• Transportation*: 5.5t in CO2 emissions reduction
Case #3 On-Site repair due to unplanned outage

12
Background Rehabilitated Transformer
Site info:
 2 sites with a total of 12 transformers (ABB and 3rd Party)
 Units in service since 1986
Customer need:
 Complete rehabilitation of the outdoor transformers
 Extend safe operation for another 20-30 years
 Integrate digital features
 Circular solution
• Reused 90% of the material saving 100t of steel
• Saved 25t of oil
TOTAL CO2 reduction:
Case #4 – Rehabilitation of 30+ year transformers
AFTER
BEFORE

13
Rehabilitation – Reuse all major components What can we do more?
• Upgrade performance
• Major repairs after catastrophic incidents – ie: after a fire
Rehabilitation overview
Part Scope
Core Cleaning
Windings Cleaning, Drying, Reimpregnation
Oil Regeneration
Tank, cover, conservator Clean, sandblast, surface treatment
Feedthroughs ≥ 60kV Replacement
Instrumentation Replacement with Digital Options
Cooling Equipment Refurbishment where possible
Switches (load, step ctrl) Refurbishment where possible
EVENT OUTCOME REPAIR
Circularity Outcome:
Refurbished major componets & reducing material extraction

14
Bushing Fleet Assessment Winding Upgrades
Can we do more?
Failure Fun Fact: 1/4 comes from Bushings with possible fire/explosion; 1/3 from Tap Changers and 1/3 from Windings
Why?
• To improve transformer reliability
• Reduce failure and explosion/fire risks
How?
• Fleet scanning & study o determine bushing condition
• Collaborate with our factories to:
 Find best retrofit options with latest bushing technology
 Reduce the spare parts inventory by using interchangeable parts
 Optional opt-in for Air-RIP bushings to enable a modularity
 Optional TXpert BM for online bushing monitoring
 Parts availability = Reliability
 Optimized logistics and spare parts management strategies
Why?
To maximize the MVA per tank size
Reduce losses
How?
Re-engineer for maximum efficiency
On-site installation
On-site testing
Did you know?
A fully rehabilitated with today‘s technology could have 30-40%
lower load losses than a transformer built in the 1980s!
(case by case)

1. Regulations are under review, new revisions expected in 2021 in Europe 15
In the past few decades, manufacturers and consumers have recognized the impacts of their processes, products and actions. Therefore, they are
focusing on sustainability based on applicable safety and environmental standards.
Framework to start - Sustainability standards & regulations
ISO 14001
Environmental management –
For companies and organizations
of any type that require practical
tools to manage their
environmental responsibilities.
.
ISO 50001
Energy management systems –
For organizations committed to
addressing their impact,
conserving resources and
improving the bottom line through
efficient energy management.
.
ISO 14040
Life cycle assessment – Describes
the principles and framework for
life cycle assessment including
definition of the goal and scope
of the LCA.
.
EU Directive 2009/125/EC
Evaluates the environmental
impact throughout a product’s
conceptualization, manufacture,
use and eventual disposal.
.
Europe1
F-gas regulation EU 517/2014
Voluntary agreement of electrical
power industry
. .

16
What do we have in stock? Can we do better? Yes, but together!
Product Name Benefits
CoreSense
Very low maintenance due to no moving
parts. Detects Hydrogen & Moisture and
IEC61850 compliant
CoreSense M10
Low maintenance and IEC61850
compliant. Detects hydrogen, moisture
and 9 other gases
CoreTec 4
Modular monitoring platform to ensure
continuous asset optimal performance
with actionable intelligence
APM Edge
Scalable software solution to provide
actionable insights, reliability and
minimize risks
TXpertBM
Plug and Play sensor to monitor your
bushings and integrate with Lumada and
CoreTec 4 as well as reduce risks and
unplanned outages
Txplore
Submersible robot for quick and safe
internal inspections (multiple inspections
per day)
Various eDevices
eOLI, eWTI, etc for better overview and
improved site proactiveness.
Digital
Digital
Solutions
Hitachi ABB
Expertise
Proactive
customer
engagement
Peace of mind

17
Transformers are a resource!
Let’s work together and ensure we reach our CE goals by:
• Proper maintenance to reduce risks and other errors
• Extend the asset of fleet lifetime by 20+ years
• Reuse material to its max. potential
• Reengineer to make older transformers more efficient
• Digital technology will help us to prevent costly breakdowns and a safer operation
Conclusion
ZERO IS HERO

18
Mircea Gingu Mark Maerevoet Petter Nilsson
Tel: +32 478 293 774
E-Mail: mark.maerevoet@hitachi-powergrids.com
Business Profile: LinkedIn Profile
Tel: +46 702 308 040
E-Mail: petter.nilsson@hitachi-powergrids.com
Tel: +49 160 9546 9894 (call, text)
E-Mail: mircea.gingu@hitachi-powergrids.com
Contact Information
Regional Product Marketing
BeNeLux Marketing Manager
Technical Marketing Manager

POWERING GOOD FOR SUSTAINABLE ENERGY
19

20
Acronym Meaning
CE Circular Economy
TOC Total Ownership Cost
LCA Life Cycle Assessment
Mts Megatons
GHG Green House Gasses
SDE Stimulation of Sustainable Energy Production
GSU Generator Step-up
ENG Engineering
CSR Corporate Social Responsibility
ECI Environmental Cost Impact (In The Netherlands, the Environmental Cost Indicator (ECI) is known as Milieu Kosten Indicator (MKI))
Acronyms

21
1. IEA (2020), IEA – International Energy Agency, www.iea.org
2. Ecochain LCA, www.ecochain.com
3. Ecochain ECI, https://ecochain.com/knowledge/environmental-cost-indicator-eci/
4. Ellen Macarthur Foundation, www.ellenmacarthurfoundation.org
5. Vehicle Energy Consuption, https://ec.europa.eu/clima/policies/transport/vehicles/vecto_en
6. CIGRE, https://www.cigre.org/GB/publications/papers-and-proceedings
7. CIGRE 227, Life Management Techniques for Power Transformers
8. CIGRE 248, Economics of Transformer
9. CIGRE 342, Mechanical conditioning assessment of transformer windings
10. CIGRE Paper No. FP0648, Bushing Live Management Procedures Used to Improve Transformer Reliability
11. IEC60422-2005, Mineral Insulating Oil in electrical equipment
12. IEEE C57.93-2007, Guide for Installation of Liquid-Immersed Power Transformers
13. IEEE C57.140-2006, Guide for Evaluation and Reconditioning of Liquid Immersed Power Transformers
14. IEEE C57.637-2007, Guide for Reclamation of Insulating Oil and Criteria for its use
References/Sources

22
Social benefits Environmental benefits Economic benefits
– Less flammable
– Reduced risk of explosion
– Longer life expectancy
– Overloadability
– Renewable sources
– Biodegradability
– Non-toxic waste
– Low carbon-footprint
– Reduced or delayed investments
– Reduced maintenance costs
– Higher revenues (overloadability)
– Reduced risk of environmental fines
Ester fluid usage in transformers
Mineral Oil Ester fluid

23
What is important to know?
• Natural esters are made on bases of renewable seed oils.
• Synthetic esters are synthesized in chemical laboratory.
• Both esters have high fire safety, high environmental protection, high moisture tolerance, overload potential (extended transformer insulation life)
and no corrosive Sulphur.
• Both esters are non-toxic & non-water hazardous.
Ester fluids: synthetic vs natural esters
Synthetic Natural
• Suitable for breathing & sealed transformers • Used in sealed transformers (poor oxidation
stability)
• Suitable for cold climate • Not recommended to be used where the ambient
temperature goes below – 10°C.
• Low maintenance • Require more cooling equipment
• Radially biodegradable • Fully biodegradable

Sources: CIGRE 227 and IEA.ORG 24
CO2 emission Netherlands by Sector Energy sector CO2 emission Netherlands Conditions grouped in different risk
categories to find the total risk of failure
OLTC DUTY Drying Time with Various Technologies Life Cycle Impact Assessment (I/O)
Additional visual helpers

Source: CIGRE 227 25
Transformer Oils OLTC Maintenance Lack of Maintenance poss. impacts
Additional visual helpers

26
Material Quantity Unit
Magnetic steel (syn: electrical steel) 2,764556 kg CO2e / kg
Market for copper, Global 4,738 kg CO2e / kg
Copper production, primary, Asia 5,826 kg CO2e / kg
Copper production, primary, rest of the world 4,691 kg CO2e / kg
Copper production, primary, Europe 1,666 kg CO2e / kg
Market for copper, Global 4,738 kg CO2e / kg
Mineral oil, material recovery (closed-loop) 0,021354 kg CO2e / kg
Mineral oil, incineration 0,021354 kg CO2e / kg
Paper and board, incineration 0,021354 kg CO2e / kg
Paper and board, material recovery 0,021354 kg CO2e / kg
Paper and board, landfill 1,041888 kg CO2e / kg
Material CO2 emissions
Assumptions:
• Mineral oil in closed loop
• Global copper CO2e average
• Cradle to grave material footprint
• ONLY material and no use phase impact
• Insulating paper is treated as Paper and board to incineration, since usually it is quite contaminated with oil after EOL

27
Transportation CO2 emissions
Transportation Mode Quantity Unit
Road 0.062 kg CO2e / tonne-km
Rail 0.022 kg CO2e / tonne-km
Airfreight 0.602 kg CO2e / tonne-km
Water – Barge 0.031 kg CO2e / tonne-km
Water – Deep Sea Container 0.008 kg CO2e / tonne-km
Water – Deep Sear Tanker 0.005 kg CO2e / tonne-km

28
33MVA, 120/12kV (ONAN/ONAF type) 100MVA, 140/10kV (GSU type) 250MVA, 13.8/315kV (GSU type)
Material Weight (kg) CO2e (kg)
Electrical steel 30,500 84,319
Copper 12,560 59,509
Insulating 1,100 23
Oil (tank+conservator) 16,200 346
Total 60,360 144,198
Approx. transformer CO2 cradle to grave material footprint
Copper 25,000 118,450
Insulating 1,100 23
Oil (tank+conservator) 26,000 555
Total 90,600 225,463
Copper 16,413 77,765
Insulating 2,771 59
Oil (tank+conservator) 49,500 1,057
Total 145,747 291,926

29
33MVA, 120/12kV (60,360 kg = 60.4t) 100MVA, 140/10kV (90,600kg = 90.6t) 250MVA, 13.8/315kV (145,747 kg = 145.8t)
Transportation Mode CO2e (kg/t-km)
Road 3.7448
Rail 1.3288
Airfreight 36.3608
Water – Barge 1.8724
Approx. transformer CO2 transportation footprint
Road 5.6172
Rail 1.9932
Airfreight 54.5412
Road 9.0396
Rail 3.2076
Airfreight 87.7716

30
EconiQ in action – Eco-efficient High Voltage Products
Game changing
technology for SF6
alternatives to reduce
environmental impact
Pioneered the world’s
first high-voltage
eco-efficient GIS as
an alternative to SF6
1Lifecycle Assessment Lifetime of equipment: 30 years. Assumed gas leakage rate: 0.1 percent p.a. accumulated over a period of 30
years, 1 percent loss during handling, 1 percent loss during decommissioning.
>50% reduction of CO2-equivalent emissions throughout the
total lifecycle
Over a decade of innovation in eco-efficient technologies
Based on reliable technology for gas circuit-breaker
Longest field experience worldwide
Scalable to ultra-high voltage for both interruption and insulation
Standard solution for the industry
Future proof compliant to future environmental regulations
Life cycle assessment (50% less CO2e)
Gas-insulated
switchgear (GIS)
ELK-04, 145 kV
Eco-passive
elements for GIS
420 kV
Live Tank
Breaker LTA
72.5 kV
Live Tank
Breaker LTA 145
kV
Disconnecting Circuit
Breaker (DCB) LTA,
72.5 kV

Power Consulting - life cycle assessment overview
- A method to quantify the environmental impact
e.g. in tonnes CO2 equivalents (Global Warming Potential)
of a service, a product or a system
- Includes the whole life cycle – from extraction of materials,
manufacturing, use or operation to end of life
- Shows what phase and materials that have the highest
environmental impact
- Is the base for improvements, comparisons etc.
kg CO2
kg PO2
kg SO2
kg R11
kg DCB
kg DCB
kg DCB
Environmental Impact Categories

Power Consulting - life cycle assessments offering
32
Value for the customer
Identify key environmental impact contributors
and act accordingly
Optimize of supply chain
Compare alternatives that result in informed
strategic decisions
Enhance commitment towards sustainability
Comparative LCA studies: Comparison of the different system solutions, services and products - Sustainable
solutions since the design/ definition
Environmental performance: Identification and quantification of the system improvements over the time –
Optimization
LCA studies for CO2 footprint evaluation: Strategic identification and prioritization of processes that can be
improved - Decarbonization of Operations
Study types
Product, system or service LCA studies: Understand the environmental footprint of a specific product, system or
service - Awareness and informed decisions

33
Definition Standards Methodology
Life Cycle Assessment (LCA) is a holistic and
science-based process that quantifies the
environmental impact i.e., in tonnes CO2
equivalents of a product or a system -
throughout its life cycle from raw material
acquisition through production, use and
disposal.
In the past few decades, manufacturers and
consumers have recognized the impacts of
their processes, products and actions.
Therefore, relevant safety and environmental
standards have been developed.
Based on those standards, an LCA identifies,
quantifies and assesses sources of
environmental impact throughout a product's
life cycle. An LCA helps prioritize how to make
improvements on our environmental footprint.
Power Consulting - life cycle assessment methodology
System definition
Data collection
Modelling & interpretation
Discussion & report
ISO 14001 - Environmental
management
ISO 50001 - Energy
management systems
ISO 14040/14044 - Life cycle
assessment
Environmental Product
Declaration
Cradle
to
Grave
Cradle
to
Cradle
Product
Lifecycle
Product Use
Distribution
Product
Manufacturing
Material
Processing
Raw Material
Extraction
End of Life
R
Cradle
to
Gate

34
Power Consulting - sustainability services
Power Consulting Sustainability Services support our customers addressing their unique environmental performance needs. That means reducing risks and
optimizing their environmental footprints along the entire value chain.
We perform a complete technological, regulatory, environmental and economic analysis of different scenarios or alternatives providing the deep insights that our
customers need to guide their sustainability-related initiatives and improve their overall efficiency.
New technologies Operation
Life cycle Multi-Energy carriers
Emerging technologies will have a significant impact on GHG. This impact
has to be considered when comparing new technologies with existing ones.
Performing a Life Cycle Analysis (LCA) of the emission throughout the
complete life of a product or service is necessary to understand the
complete cycle of its environmental impact.
Aspects such as: fuel, electricity consumption, optimal operation and
losses are relevant to stablish a clear decarbonisation strategy for the
operation.
Understanding which energy carrier to use is key to exploit their potential
and achieve a more efficient and sustainable operation with lower
environmental impact.

1 - Through the lifetime of the substation, assumption 35 years
2 - Based on assumption a tree absorbs an average of 12 kg CO2 in one year
3 - Based on assumption a car emits 19 kg CO2 equivalent per 100 km 35
Pioneering technology leaders
Our eco-efficient solutions:
By comparing a typical standard and an eco-efficient substation
Reduce GHG emissions Improve efficiency and
reliability of the system
Enable a stronger, smarter
and greener grid
GHG emission
reduction1
2,900t CO2 eq
Capacity
80MVA = 1,520
Taken off the road 3
Running one year (10,000
km each)
145/72.5 kV 80MVA system
145 kV 72.5 kV
= 240,000
Planted in one year 2

Power Consulting - LCA– substation study case
* Calculations valid for utilities application and an average EU-28 electricity grid mix
* End of life; Maintenance activities; Other phases of transportations (raw materials to components manufacturing)
36
The study case quantifies the environmental impact of a 40 MW distribution substation by the application of the LCA methodology (ISO 14040 and ISO 14044). The
assessment provides insights about the environmental impact of the processes, products and materials through their lifetime.
Results System and parameters
Material production and Equipment manufacturing -
over 1 013 tons of CO2 equivalent emitted
Civil works accounting for 75%
Parameters Unit Quantity
Operational
lifetime
years 20
Nominal power MW 40
System location -
EU-28
Electricity mix -
0.00
2,000.00
4,000.00
6,000.00
8,000.00
10,000.00
12,000.00
tonnes
CO2e/20
years
lifetime
40 MW Substation – environmental performance
over time
SF6 LEAKAGE FILTER HV-SWITCHGEAR
MV CELLS MAIN TRANSFORMER CIVIL WORKS
LOSSES
75%
1%
3%
15%
6%
40 MW Substation – environmental impact of manufacturing
CIVIL WORKS
FILTER
HV-SWITCHGEAR
MAIN TRANSFORMER
MV CELLS
Environmental performance over time -
9 804 tons of CO2 equivalent* emitted through 20
years lifetime
Power losses accounting for 90% - scenario that
could be improved with more efficient
equipment/operation
Notes:
• Mineral oil transformer
• SF6 MV and HV cell
75%
1%
3%
15%
6%
40 MW Substation – environmental impact of manufacturing
CIVIL WORKS
FILTER
HV-SWITCHGEAR
MAIN TRANSFORMER
MV CELLS

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