MH - ABB SPT Transformers Guatemala October16 2012.ppt · ASTM D6871 and IEEE C57.147 published since 2003 and 2008, resppyectively

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


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


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


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


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


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,


called Global Product Platform, to cover this range

Technology Design &Technology Design & Process Enhancement


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


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


SPT Global Product PlatformT h l D i & P E h tTechnology, Design & Process Enhancement

DIELECTRICS MECHANICSDIELECTRICS MECHANICS

MAGNETICS THERMALMAGNETICS

THERMO-FLUIDODYNAMICS


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


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


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


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


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


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


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)


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



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


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


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)


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


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


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


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


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


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


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


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


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)


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 –


(Australia) EGYPT Chile , order under execution

MH - ABB SPT Transformers Guatemala October16 2012.ppt · ASTM D6871 and IEEE C57.147 published since 2003 and 2008, resppyectively

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