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Miljenko Hrack SPT Global Technology Manager customer day Guatemala october 16th/2012
SPT T f
Miljenko Hrack, SPT Global Technology Manager , customer day, Guatemala october 16 /2012
Transformers
© ABBMonth DD, YYYY | Slide 1
ABB Small Power TransformersCustomer Value Proposition
Introduction
Customer Value Proposition
Introduction
ABB Small Power Transfomer
Who we are
SPT Global Product Platform
ABB’s Customer value propositionABB s Customer value proposition
Natural Esters filled Transformer
© ABBMonth DD, YYYY | Slide 2
ABB Small Power TransformersWhere We AreWhere We Are
Finland – Vaasa
USA – South Boston
Ireland - Waterford
Turkey – Istanbul China – Zhongshan &
Switzerland – Geneva
Colombia - Pereira
Turkey Istanbul
Spain - BilbaoItaly – Monselice
Vietnam - Hanoi
China – Zhongshan & Datong
USA – Crystal Springs
Colombia PereiraVadodara– India
Thailand - Bangkok
© ABBMonth DD, YYYY | Slide 3
ABB Small Power TransformersTechnologyRated voltage
Power Transformers
Technology
Power Transformers
2 kV
171 kV Small Power Transformers
72.5 kV
CORE TYPE
Dry Type
Liquid filled
36 kV
Liquid filleddistribution
Four common technology platforms guaranteeing highest quality
SHELL TYPE
40 MVA 63 MVA Rated power10 MVA
© ABBMonth DD, YYYY | Slide 4
Four common technology platforms guaranteeing highest quality
ABB Small Power Transformers Who we areWho we are
O r positionOur positionLargest global manufacturer of Small Power Transformers
Twice as big as number 2Twice as big as number 2
Market leader for traction transformers
A self standing business dedicated to this range of productsA self standing business dedicated to this range of products
World wide production in 14 Factories including 10 units with dedicated lines
Production capacity 55,000 MVA
© ABBMonth DD, YYYY | Slide 5
ABB Small Power Transformers Who we areWho we are
The largest investor in the industryThe largest investor in the industrySwitzerland: new TT line inaugurated in 2010
India: TT new plant inaugurated in 2010India: TT new plant inaugurated in 2010
Italy: new plant inaugurated in autumn 2009
USA: new plant inaugurated in summer 2008 p g
USA: Kuhlmann acquisition in 2008
China : TT new plant inaugurated in summer 2008p g
India: new plant inaugurated in spring 2008
Colombia: new plant inaugurated in summer 2008
Vietnam: last expansion inaugurated in fall 2006
China: new plant inaugurated in summer 2006
© ABBMonth DD, YYYY | Slide 6
Finland: new hall inaugurated in summer 2006
ABB Small Power TransformersConceptsConcepts
PRODUCT EXCELLENCE PROCESS EXCELLENCEPRODUCT EXCELLENCEmeans:
ReliabilityProven technology
PROCESS EXCELLENCEmeans:
Modular designStandardized design toolsProven technology
Demonstrated short Circuit strength and full scale tests
Standardized design toolsHigh throughput production linesLatest production technologiestests Latest production technologies
UNIQUENESS ON THE MARKET means:Dedicated technology & production lines, as compared to competitors, that often scale power transformers down to distribution (→ heavy concept & design) or scale distribution transformers to power (→ reliability & testing problems)transformers to power (→ reliability & testing problems)
ABB uses a common design and manufacturing system,
© ABBMonth DD, YYYY | Slide 7
called Global Product Platform, to cover this range
SPT Global Product PlatformDesign and optimizationDesign and optimization
T f d i d i i i l fTransformers design and optimization result from:
Customer specifications
Electric Design $
TOC
Electro-mechanical Design
Electro-thermal Design
Losses Eval.Trafo cost
kW
minimumTOC
Costs
kW
Optimizing the transformers is a complex task
© ABBMonth DD, YYYY | Slide 9
SPT Global Product PlatformStructured approach to knowledgeStructured approach to knowledge
Global Design ToolsGlobal Design ToolsDesign rules are based on ABB criteria, which areproven on thousands of transformers ranging from thesmall distribution to the large powersmall distribution to the large power
Using Global Tools allows synchronizing the bestdesign practices in all our factories
Global Design DatabaseA repository of designs from different factories
ABB ibABB LibraryContaining all Technical, Material and ProductionStandards from various transformer technologies
Knowledge Communication CenterAn ongoing initiative to spread the technical knowledge
© ABB Group October 12, 2012 | Slide 10
SPT Global Product PlatformT h l D i & P E h tTechnology, Design & Process Enhancement
Simulations make possible an accurateknowledge of the final overall transformerperformances about electromagnetic mechanical and thermal phenomena
Skilled specialists, through computer aidedengineering and simulation-optimizationtechniques, support engineeringproduct developmentp p
ABB has proprietary and commercial2D/3D simulation tools for particulardesigns and optimized custom solutions
ABBSimulation
Toolbox
© ABBMonth DD, YYYY | Slide 11
SPT Global Product PlatformT h l D i & P E h tTechnology, Design & Process Enhancement
DIELECTRICS MECHANICSDIELECTRICS MECHANICS
MAGNETICS THERMALMAGNETICS
THERMO-FLUIDODYNAMICS
© ABBMonth DD, YYYY | Slide 12
Technology, Design & Process Enhancement3D Modeling3D Modeling
Additional losses outside the windings are important as well and shall be controlled in order to avoid localized hot spots in
the core clamping structure or in the tank walls
© ABB Group October 12, 2012 | Slide 13
p g
Technology, Design & Process EnhancementInsulation designInsulation design
During transformer operation, internal or external over-voltagescan cause abnormal stresses inside the transformer
Switching operations
Faults
Lightning strokes
...
It is of utmost importance to make a proper design of the insulationsystem to prevent a catastrophic breakdown
Advance computational tools have been developed in ABB tocalculate the impulse voltage distribution
An optimal winding design shall take into account the dielectricAn optimal winding design shall take into account the dielectricstresses during impulse test
© ABB Group October 12, 2012 | Slide 14
Technology, Design & Process Enhancement Insulation designInsulation design
2D and 3D field mapping techniques are used to calculatethe dielectric stresses once that the voltage distribution isknown
ABB has developed dielectric withstand criteria againstp gdifferent possible failure modes of transformer insulation
These criteria are well proven by our records ofsuccessfully tested transformers
© ABB Group October 12, 2012 | Slide 15
successfully tested transformers
Technology, design and process improvements CFD Simulation TechnologyCFD Simulation Technology
CFD (Computational Fluid Dynamics) is a method to obtainCFD (Computational Fluid Dynamics) is a method to obtaindetailed information of flow velocities and temperatures bynumerical solution of a set of equations for mass,momentum and energymomentum and energy
It can be applied to transformer technology in order toanalyze the temperature rise (Hot spots) of differentwindings and cooling types (ONAN, ONAF, ODAF, …)
The most important cooling performances can be retrieved:
Oil t t i ( t th t d t th b tt fOil temperature rises (at the top and at the bottom ofthe windings)
Average winding temperature riseg g p
Hot spot temperature rise and location
Technology, Design & Process EnhancementCFD Si l i T h lCFD Simulation Technology
A detailed knowledge of the temperature distribution in thewindings is essential to improve the technology andoptimize designs and production processes
Technology, Design & Process EnhancementCFD Simulation TechnologyCFD Simulation Technology
Our thermal models have been validated through many tests using fiberoptic sensors
© ABB Group October 12, 2012 | Slide 18
using fiberoptic sensors
Technology, Design & Process Enhancement Transformer noiseTransformer noise
Nowadays noise requirements are becoming more andNowadays noise requirements are becoming more andmore challenging
The design of the core, of the windings and of the coolingequipment can greatly be affected by the constraints on theadmissible sound level.
ABB developed analytical models for the calculation andlow noise solutions are also availablelow noise solutions are also available.
In collaboration with Corporate Research Centers,multiphysical analyses are carried out usingelectromagnetical, mechanical and acoustic simulationtools in order to improve the product performance
© ABB Group October 12, 2012 | Slide 19
Technology, Design & Process EnhancementSound Generation and ABB R & D activitiesSound Generation and ABB R & D activities
Sound powerAcousticsMeasurements& t ti ti
Radiation
& statistics
Structurald i
Tank
Tank resonance dynamics
Vibrationtransmission
Oiltransmission
TransformerspecificStructural & Fluid
Core resonanceWinding
resonance
Dynamics
ElectromagneticForces
Core
Magnetostriction
Windings Magnetic pullTransformerPhysicsEl t tiForces Electromagnetism
Technology, Design & Process Enhancement Laser Doppler Vibrometr & sim lation toolDoppler Vibrometry & simulation tool
Acoustic camera
Technology, Design & Process EnhancementSIMULATIONS & SEISMICSIMULATIONS & SEISMIC
It is important to proof the solid and safe design and manufacture of ABB d t i f i i li it ti
World Seismic Hazard Map
ABB products in case of seismic solicitation. Seismic qualifications for substation’s equipment can be done by shake tables testing. For heavy products like transformers, the use ofh k t bl i t ti lshake tables is not practical.
Simulations give relevant information about equipment
© ABBMonth DD, YYYY | Slide 22
structure behavior, when used in crucial areas
Technology, Design & Process EnhancementProcess ExcellenceProcess Excellence
Production of SPT transformerst k l i ABB FOCUStakes places in ABB FOCUS FACTORIES:
F ifi dFocus on specific productranges
Dedicated production lineFocus on speed and
efficiencyProduction covers:- Core cutting and stacking- Winding- Drying - Test facilities- Factory lay–out- Quality
Technology, Design & Process Enhancement Product Quality: HighlightsProduct Quality: Highlights
STATE OF THE ART MANUFACTURINGSTATE OF THE ART MANUFACTURINGFACILITIES AND PROCEDURES
INSULATION COMPONENTS FROMABB GROUP COMPANIES
TEST WITH DIGITAL CONTROL AND& DATA ACQUISTION& DATA ACQUISTION
GLOBAL QUALITY STANDARD CERTIFICATION(worldwide ISO 9001, ISO 14001 , 18001)
© ABBMonth DD, YYYY | Slide 24
ABB Small Power Transformers Product CertificationProduct Certification
Short circuit tested transformersShort circuit tested transformers 28 SPT transformers successfully passed short circuittests in first attempt (Pereira, Monselice, Vadodara,V C t l S i )Vaasa, Crystal Springs)
First passed yield : 96 % against industry averageFirst passed yield : 96 % against industry averageof aprox 60 % (CIGRE 2006)
Five SPT Factories have made successfully s.c.tests
First time in ABB successfully short-circuit tested 40MVA transformer with CTC netting disc type windingtechnologygy
ABB Small Power Transformers Beyond Standard ProductBeyond Standard Product
SPT OD ConceptSPT OD Concept
ABB Small Power Transformers Beyond Standard ProductBeyond Standard Product
Transformers for Mobil SubstationTransformers for Mobil Substation
ABB Small Power TransformersBeyond Standard Product Railways ApplicationBeyond Standard Product – Railways Application
ABB Small Power Transformers Be ond Standard Prod ctBeyond Standard Product
Current limiting reactor VSD Transformer
R tifi T fRectifier Transformer Arc Furnance transformer
ABB Small Power Transformers Be ond Standard Prod ctBeyond Standard Product
Step up Transformer Adjustable Neutral reactor
Subsea Transformer
ABB Small Power Transformers Beyond Standard ProductBeyond Standard Product
Traction transformerTraction transformer
Milj k H k SPT Gl b l T h l M t d G t l t b 16th/2012Miljenko Hrack, SPT Global Technology Manager , custonmer day, Guatemala october 16th/2012
Natural Esters Filled Transformer
© ABBOctober 12, 2012 | Slide 33
Summary
Natural ester dielectric insulating fluid
Advantages of natural esters filled transformers in the modern substation
Market trend
© ABBOctober 7, 2011 | Slide 34
Alternative fluids overviewHistoryHistory
S l lt ti h b dTransformers Several alternatives have been proposed without successfully addressing both issues at the same time:
A k l il (PCB ) Fi i t t
Transformers with natural ester based fluid have been introduced in 90’s
Askarel oils (PCBs) – Fire resistant but toxic
Silicone oils – Fire resistant but low bi d d bilitbiodegradability
Starting in the 1980’s, ester-based fluids came as a new alternative g ,combining excellent fire safety properties with high biodegradability.
Synthetic esters - compounds chemically synthesized from organic precursors.p
Natural esters: available from agricultural products.
© ABB22/07/2009 | Slide 35
Vegetable Oil Sources: Seeds
Although natural ester fluids can be produced from a wide variety of crop oils, natural esters for electrical applications are most commonly produced from soya, rapeseed and sunflower oil.
Natural Esters filled Transformer in the Modern SubstationExecutive summaryExecutive summary
Natural ester dielectric insulating fluidNatural ester dielectric insulating fluid
A natural ester made from renewable resources (vegetable-based oil)
Combines biodegradability and non toxicity (green),superior explosion and fire resistance (safe), and longer lifetime and long-term stability (reliable)longer lifetime and long term stability (reliable)
ABB green transformers portfolio
Consists of (but is not limited to) units filled with natural ( )esters dielectric insulating fluid from distribution to power size transformers incl. service solutions and components
© ABB22/07/2009 | Slide 37
Natural Esters filled Transformer in the Modern SubstationToday’s Transformer liquid trendToday s Transformer liquid trend
Natural esters are now recognized asNatural esters are now recognized as environmentally friendly and “less flammable” dielectric insulating fluids by the industry
Meet the US National Electrical C dCodeListed by Factory Mutual (FM Global) and Underwriters Laboratories (UL)Verified by the US Environmental Protection Agency (EPA)
Classified K2 fire hazard class (IEC 61100)
Specified by Industry Standards
ASTM D6871 and IEEE C57.147 published since 2003 and 2008, respectivelyp y
ABNT NBR 15422 published since 2005 (Brazil)
Cigré technical brochure 436 on new insulating liquids published in 2010 and IEC standard publication anticipated
© ABB22/07/2009 | Slide 38
published in 2010 and IEC standard publication anticipated in end of 2012
Natural Esters filled Transformer in the Modern SubstationCurrent product scopeCurrent product scope
Up to 230 kV class (1050 kV BIL)Up to 230 kV class (1050 kV BIL) 200 MVA max rated powerKNAN/KNAF cooling modesConstant oil pressure sealed with membrane or pnitrogen blanket system required(free breathing applications to be avoided)
© ABBOctober 7, 2011 | Slide 39
Natural esters filled atu a este s edTransformers in the modern substationAdvantages
© ABB22/07/2009 | Slide 40
Summary of the Advantages
Natural ester is proposed to be used in powerNatural ester is proposed to be used in power transformers to eliminate the side effects of the mineral oils. The main advantages are:
Fire safety
Slower rate of aging cellulose
Overloading possibility
Environmental compatibility
Savings in many aspects
© ABBOctober 7, 2011 | Slide 41
Natural esters filled atu a este s edTransformers in the modern substationFire Safety
© ABB22/07/2009 | Slide 42
Anatomy of a fire
All three elements of fire triangleAll three elements of fire triangle MUST be present to start and sustain a fire
For a transformer fire
Fuel = vaporized oil
Ignition = hot metal, arcing
Oxygen = inrush of air
Ai i t h t l t
IGNITION
Aim is to see how natural ester compares to mineral oil in “feeding” these three elements
| Slide 43© ABB GroupOctober 12, 2012
Initiation and Evolution of Transformer Fire
There is no free oxygen in a sealed transformer to start orThere is no free oxygen in a sealed transformer to start or sustain a fireA low impedance fault creates an arc that heat the oil to several thousand degrees Celsius If high current protection operates, only small volume of oil vaporizes and not much pressure is built upIf protection fails, large quantity of oil is vaporized and g yproduces large quantity of combustible gasesRapid increase in gases can increase tank pressure to point of ruptureHot oil and combustible gases will be released and oxygen will rush inIf volume of vaporized oil is within flammability limits there is high probability of firehigh probability of fireIn case of fire, propagation or extinction depends on behavior of heat release rate
Month DD, Year | Slide 44© ABB Group
Fire Risk Properties
Flash point is the lowest temperature at which a liquid can vaporize to form an ignitable mixture in air without necessarily maintaining a firean ignitable mixture in air, without necessarily maintaining a fire
Fire point is the lowest temperature beyond the flash point at which the mixture of vapors and oxygen will burn continuously if ignited
Auto ignition temperature is the lowest temperature at which a materialAuto-ignition temperature is the lowest temperature at which a material will self-ignite and sustain a fire even in the absence of a flame or spark
Net caloric value is a measure of the amount of thermal energy released from a fire per unit of time
Month DD, Year | Slide 45© ABB Group
Pressure Build-up TestHigh Energy Arcing ResultsHigh Energy Arcing - Results
25-50% as much gas dissolved in natural ester as in mineral oil however25 50% as much gas dissolved in natural ester as in mineral oil, however
Similar amounts of gases in gas space
Peak of measured pressure wave very similar for natural ester and for mineral oilPeak of measured pressure wave very similar for natural ester and for mineral oil
Similar results obtained for a synthetic ester fluid
Conclusion – the risk of tank rupture is independent of the type of insulating fluidConclusion the risk of tank rupture is independent of the type of insulating fluid
Month DD, Year | Slide 46© ABB Group
Flammability Limits (LFL and UFL) – ASTM E918ResultsResults
.
Explosive environment exists with 0.6% mineral oil in air mixture at 200°C200°C
Explosive environment exists with >9.0% of natural ester in air mixture at 350-400°C
Conclusion – 15 times more volume of vaporized natural ester required at 200°C higher temperature to form the same explosive mixture as mineral oil
Month DD, Year | Slide 47© ABB Group
Heat Release RateResults
If heat source is
Results
If heat source is maintained heat release is similar for natural ester and mineral oil
If heat source is turned off, natural ester heat release declines with time and fire extinguishes
Heat release rate of mineral oil is the same whether heat source is maintained or removed
Month DD, Year | Slide 48© ABB Group
Summary
Similar pressures are generated by high energy arcs inSimilar pressures are generated by high energy arcs in natural esters as in mineral oil
Natural ester has much reduced risk of fire initiation and propagation
In case a fire ignites, natural ester fire self-extinguishes if heat source is removedheat source is removed
Natural ester demonstrates much reduced fire risk as compared to mineral oil
Month DD, Year | Slide 49© ABB Group
Putting it All Together Transformer Arcing Tests
Similar arcing energy
Transformer Arcing TestsHigh Energy Arcing Tests
Similar arcing energy was simulated in distribution transformer tanks filled with natural ester and mineral oil
In both cases the tank lid In both cases the tank lid released from the overpressure in the tank
Oxygen was admitted into the tank and mixed with the vaporized oil
In the case of mineral oil an explosive mix was formed which ignited and produced a sustained fire
I th f t l
Mineral oil Natural ester
In the case of natural ester the mix was not explosive – carbonized oil was released from the tank but there was no fire. Tank lid resealed
The videos show the results of the fault in both fluids
Month DD, Year | Slide 50© ABB Group
Natural esters filled atu a este s edTransformers in the modern substationLow Ageing
© ABB22/07/2009 | Slide 51
Low Ageing Natural Ester and Cellulose PaperNatural Ester and Cellulose Paper
20 °C
Natural ester impregnated paper experiences lower aging rate compared to mineral oil impregnated paper leading torate compared to mineral oil impregnated paper, leading to an increase in the insulation system life, hence in the transformer life
© ABBOctober 7, 2011 | Slide 52
Natural esters filled atu a este s edTransformers in the modern substationEnvironmental C tibilitCompatibility
© ABB22/07/2009 | Slide 53
Natural Esters filled Transformer in the Modern SubstationSubstationEnvironmental Compatibility
Readily biodegradable: 99 % in 21 days
di t CEC Laccording to CEC L-33-A-93 , non toxic¹
Natural ester is not treated as toxic wasteThe negative carbon footprint of producing vegetable-based oils gives natural ester a near neutral carbon footprint of 0.07 kg CO2 equivalent/kg produced (about ten times less than mineral oil)oil)
© ABBOctober 7, 2011 | Slide 54
Natural Ester – ABB sensible solutionSavings
Potential CAPITAL & MAINTENANCE COST AVOIDANCE: natural ester is
Savings
El NationalPotential CAPITAL & MAINTENANCE COST AVOIDANCE: natural ester is defined as “less-flammable”, therefore certain installations do not require fire-suppression systems or fire barriers. This provides savings in installation and maintenance of such systemsPotential INSURANCE COST SAVINGS from less-flammable, non-toxic,
d d l i i k f t l t fill d t f
El National Electrical Code (NEC), o NFPA 70, es un estandard estadounidense
reduced explosion risk of natural esters filled transformersPotential AVOIDANCE OF FIRE LOSS because of less-flammable characteristicPotential AVOIDANCE OR REDUCTION OF OIL SPILL CLEAN-UP
para la instalación segura de alambrado y equipos eléctricos. Es
COSTS: applicable laws and regulations will determine how fines are imposed. However, with 99% biodegradability and non-toxicity, natural ester spills can often be disposed through normal means (at a much lower cost)Potential for INCREASED REVENUES associated with short-term increased load pass thru: ability to overload natural ester filled power
eléctricos. Es parte de la serie de normas de prevención de incendios publicada por laincreased load pass-thru: ability to overload natural ester-filled power
transformers could mean higher revenues during peak demand periods without sacrificing transformer lifePotential to DELAY CAPITAL EXPENDITURES due to increased asset replacement intervals
publicada por la National Fire Protection Association(NFPA). "National replacement intervals
Increased life of natural ester impregnated insulation can translate to longer replacement intervals. Investments in additional equipment could also be delayed because of overloadability advantage of natural esters filled transformers
Electrical Code" y "NEC" son marcas registradas NFPA
overloadability advantage of natural esters filled transformers
Natural Esters filled Transformer in the Modern SubstationSubstation Market trend: Modern Substation Features
In recent market trend customers that clearly request O 4000In recent market trend, customers that clearly request natural ester filled products are increasing every day, especially from Oil & Gas market, for fire safety and environmental compatibility aspects:
Over 4000 transformers (up to 56 MVA and 145 kV) ldenvironmental compatibility aspects:
Kuwait National Petroleum CompanyENI/Agip PETROAMAZONAS
kV) sold or retrofitted with natural ester since 1999CEMIG
DUPONTGLNG
APLNGPETROBRASSANTOS
1999
More then 220 PGLNG
SHELLCODELCO
SANTOSLION Oil Company
220 Power transformers above 10 MVA installedinstalled
Natural Esters filled Transformer in the Modern SubstationSubstation
More then 5000 BIOTEMP distribution transformers delivered More than 220 Power transformers filled with BIOTEMP220 Power transformers filled with BIOTEMP above
Most of insallations are in USA and
10 MVA successfully delivered.
starting application in South America, Australia , Europe and Africa
Main customers are Petrochemical, Industry, Data centers and Buildings
With OLTC and DETC and with KNAN and KNAF CoolingCooling
Many customer moving to natural ester filled transformers: Petroamazonas, Agip, LNG, Schlumberger; CodelcoSchlumberger; Codelco
Natural Esters filled Transformer in the Modern SubstationSubstation Market trend: Modern Substation Features
UpgradedUpgraded from 15 to 25 MVA with overload capacity of up to 37.5 MVA for 6 hours (150%) or up to 42 MVA for 420 MVA AGIP REFINERY 18 75 MVA REFINERY
25 MVA URBAN SUBSTATION IN BELO HORIZONTE (Brazil)
MVA for 4 hours (170%)
20 MVA AGIP REFINERY SUBSTATION (Congo)
18.75 MVA REFINERY SUBSTATION (Ecuador)
20 MVA LNG SUBSTATION (Australia)
50 MVA CEMENT FACTORY EGYPT
40 MVA , 115/12.7 kV Codelco –
© ABBOctober 7, 2011 | Slide 58
(Australia) EGYPT Chile , order under execution
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