SPT T f Transformers
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Miljenko Hrack Hrack, SPT Global Technology Manager , customer day day, Guatemala october 16th/2012 SPT T Transformers f © ABB Month DD, YYYY | Slide 1 ABB Small Power Transformers Customer Value Proposition © ABB Month DD, YYYY | Slide 2 Introduction ABB Small Power Transfomer Who we are SPT Global Product Platform ABB’s ABB s Customer value proposition Natural Esters filled Transformer ABB Small Power Transformers Where We Are Finland – Vaasa Ireland - Waterford USA – South Boston USA – Crystal Springs Switzerland – Geneva Turkey – Istanbul Spain - Bilbao China – Zhongshan & Datong Italy – Monselice Vietnam - Hanoi Colombia - Pereira Vadodara– India Thailand - Bangkok © ABB Month DD, YYYY | Slide 3 ABB Small Power Transformers Technology Rated voltage Power Transformers 171 kV Small Power Transformers 72.5 2 kV Dry Type CORE TYPE Liquid filled distribution 36 kV SHELL TYPE 10 MVA 40 MVA 63 MVA Four common technology platforms guaranteeing highest quality © ABB Month DD, YYYY | Slide 4 Rated power ABB Small Power Transformers Who we are O r position Our © ABB Month DD, YYYY | Slide 5 Largest global manufacturer of Small Power Transformers Twice as big as number 2 Market leader for traction transformers A 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 are The largest investor in the industry © ABB Month DD, YYYY | Slide 6 Switzerland: new TT line inaugurated in 2010 India: TT new plant inaugurated in 2010 Italy: new plant inaugurated in autumn 2009 USA: new p plant inaugurated g in summer 2008 USA: Kuhlmann acquisition in 2008 China : TT new p plant inaugurated g in summer 2008 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 Transformers Concepts PRODUCT EXCELLENCE means: Reliability Proven technology Demonstrated short Circuit strength and full scale tests PROCESS EXCELLENCE means: Modular design Standardized design tools High throughput production lines 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) ABB uses a common design and manufacturing system, called Global Product Platform, to cover this range © ABB Month DD, YYYY | Slide 7 Technology Design & Process Enhancement © ABB Month DD, YYYY | Slide 8 SPT Global Product Platform Design and optimization T Transformers f design d i and d optimization i i i result l ffrom: Customer specifications Electric Design $ TOC Electro-mechanical Design minimum TOC Trafo cost Losses Eval. Electro-thermal Design kW Costs Optimizing the transformers is a complex task © ABB Month DD, YYYY | Slide 9 SPT Global Product Platform Structured approach to knowledge Global Design Tools Design rules are based on ABB criteria, which are proven on thousands of transformers ranging from the small distribution to the large power Using Global Tools allows synchronizing the best design practices in all our factories Global Design Database ABB Library ib Containing all Technical, Material and Production Standards from various transformer technologies Knowledge Communication Center © ABB Group October 12, 2012 | Slide 10 A repository of designs from different factories An ongoing initiative to spread the technical knowledge SPT Global Product Platform T h l Technology, D Design i & Process P Enhancement E h t Simulations make possible an accurate knowledge of the final overall transformer performances about electromagnetic mechanical and thermal phenomena Skilled specialists, through computer aided engineering and simulation-optimization techniques, support engineering product development p p ABB has proprietary and commercial 2D/3D simulation tools for particular designs and optimized custom solutions © ABB Month DD, YYYY | Slide 11 ABB Simulation Toolbox SPT Global Product Platform T h l Technology, D Design i & Process P Enhancement E h t MECHANICS DIELECTRICS THERMAL MAGNETICS THERMOFLUIDODYNAMICS © ABB Month DD, YYYY | Slide 12 Technology, Design & Process Enhancement 3D Modeling Additional losses outside the windings are important as well and shall be controlled in order to avoid localized hot spots in p g structure or in the tank walls the core clamping © ABB Group October 12, 2012 | Slide 13 Technology, Design & Process Enhancement Insulation design © ABB Group October 12, 2012 | Slide 14 During transformer operation, internal or external over-voltages can cause abnormal stresses inside the transformer Switching operations Faults Lightning strokes ... It is of utmost importance to make a proper design of the insulation system to prevent a catastrophic breakdown Advance computational tools have been developed in ABB to calculate the impulse voltage distribution An optimal winding design shall take into account the dielectric stresses during impulse test Technology, Design & Process Enhancement Insulation design © ABB Group October 12, 2012 | Slide 15 2D and 3D field mapping techniques are used to calculate the dielectric stresses once that the voltage distribution is known ABB has developed p dielectric withstand criteria against g different possible failure modes of transformer insulation These criteria are well proven by our records of successfully tested transformers Technology, design and process improvements CFD Simulation Technology CFD (Computational Fluid Dynamics) is a method to obtain detailed information of flow velocities and temperatures by numerical solution of a set of equations for mass, momentum and energy It can be applied to transformer technology in order to analyze the temperature rise (Hot spots) of different windings and cooling types (ONAN, ONAF, ODAF, …) The most important cooling performances can be retrieved: Oil temperature t t rises i ( t the (at th top t and d att the th bottom b tt off the windings) Average g winding g temperature p rise Hot spot temperature rise and location Technology, Design & Process Enhancement CFD Si Simulation l i T Technology h l A detailed knowledge of the temperature distribution in the windings is essential to improve the technology and optimize designs and production processes Technology, Design & Process Enhancement CFD Simulation Technology Our thermal models have been validated through many tests using fiberoptic sensors © ABB Group October 12, 2012 | Slide 18 Technology, Design & Process Enhancement Transformer noise © ABB Group October 12, 2012 | Slide 19 Nowadays noise requirements are becoming more and more challenging The design of the core, of the windings and of the cooling equipment can greatly be affected by the constraints on the admissible sound level. ABB developed analytical models for the calculation and low noise solutions are also available. available In collaboration with Corporate Research Centers, multiphysical analyses are carried out using electromagnetical, mechanical and acoustic simulation tools in order to improve the product performance Technology, Design & Process Enhancement Sound Generation and ABB R & D activities Acoustics Sound power Measurements & statistics t ti ti Radiation Structural d dynamics i Tank resonance Tank Vibration transmission Oil transmission Core resonance Winding resonance Core Windings Magnetostriction Transformer specific Structural & Fluid Dynamics Magnetic pull Electromagnetic Forces Transformer Physics El t Electromagnetism ti Technology, Design & Process Enhancement Laser Doppler Vibrometr Vibrometry & sim simulation lation tool Acoustic camera Technology, Design & Process Enhancement SIMULATIONS & SEISMIC World Seismic Hazard Map 9 9 It is important to proof the solid and safe design and manufacture of ABB products d t in i case off seismic i i solicitation. li it ti Seismic qualifications for substation’s equipment can be done by shake tables testing. For heavy products like transformers, the use of shake h k ttables bl i nott practical. is ti l Simulations give relevant information about equipment structure behavior, when used in crucial areas © ABB Month DD, YYYY | Slide 22 Technology, Design & Process Enhancement Process Excellence Production of SPT transformers t k places takes l in i ABB FOCUS FACTORIES: Focus on specific F ifi product d ranges Dedicated production line Focus on speed and efficiency Production covers: - Core cutting and stacking - Winding - Drying - Test facilities - Factory lay–out - Quality Technology, Design & Process Enhancement Product Quality: Highlights STATE OF THE ART MANUFACTURING FACILITIES AND PROCEDURES INSULATION COMPONENTS FROM ABB GROUP COMPANIES TEST WITH DIGITAL CONTROL AND & DATA ACQUISTION GLOBAL QUALITY STANDARD CERTIFICATION (worldwide ISO 9001, ISO 14001 , 18001) © ABB Month DD, YYYY | Slide 24 ABB Small Power Transformers Product Certification Short circuit tested transformers 28 SPT transformers successfully passed short circuit tests in first attempt (Pereira, Monselice, Vadodara, V Vaasa, C t l Springs) Crystal S i ) First passed yield : 96 % against industry average of aprox 60 % (CIGRE 2006) Five SPT Factories have made successfully s.c. tests First time in ABB successfully short-circuit tested 40 MVA transformer with CTC netting disc type winding technology gy ABB Small Power Transformers Beyond Standard Product SPT OD Concept ABB Small Power Transformers Beyond Standard Product ABB Small Power Transformers Beyond Standard Product Transformers for Mobil Substation ABB Small Power Transformers Beyond Standard Product – Railways Application ABB Small Power Transformers Be ond Standard Prod Beyond Product ct Current limiting reactor VSD Transformer R tifi T Rectifier Transformer f Arc Furnance transformer ABB Small Power Transformers Be ond Standard Prod Beyond Product ct Step up Transformer Subsea Transformer Adjustable Neutral reactor ABB Small Power Transformers Beyond Standard Product Traction transformer Milj k Hrack, Miljenko H k SPT Gl Global b lT Technology h l M Manager , custonmer t day, d Guatemala G t l october t b 16th/2012 Natural Esters Filled Transformer © ABB October 12, 2012 | Slide 33 Summary © ABB October 7, 2011 | Slide 34 Natural ester dielectric insulating fluid Advantages of natural esters filled transformers in the modern substation Market trend Alternative fluids overview History Transformers with natural ester based fluid have been introduced in 90’s Severall alternatives S lt ti h have b been proposed d without successfully addressing both issues at the same time: Askarel A k l oils il (PCBs) (PCB ) – Fire Fi resistant i t t but toxic Silicone oils – Fire resistant but low bi d biodegradability d bilit © ABB 22/07/2009 | Slide 35 Starting g in the 1980’s,, ester-based fluids came as a new alternative combining excellent fire safety properties with high biodegradability. Synthetic esters - compounds chemically synthesized from organic p precursors. Natural esters: available from agricultural products. 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 Substation Executive summary Natural 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 long term stability (reliable) ABB green transformers portfolio © ABB 22/07/2009 | Slide 37 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 Natural Esters filled Transformer in the Modern Substation Today’s Today s Transformer liquid trend © ABB 22/07/2009 | Slide 38 Natural esters are now recognized as environmentally friendly and “less flammable” dielectric insulating fluids by the industry Meet the US National Electrical C d Code Listed 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 p y 2008, respectively ABNT NBR 15422 published since 2005 (Brazil) Cigré technical brochure 436 on new insulating liquids published in 2010 and IEC standard publication anticipated in end of 2012 Natural Esters filled Transformer in the Modern Substation Current product scope © ABB October 7, 2011 | Slide 39 Up to 230 kV class (1050 kV BIL) 200 MVA max rated power KNAN/KNAF cooling modes Constant oil p pressure sealed with membrane or nitrogen blanket system required (free breathing applications to be avoided) Natural atu a este esters s filled ed Transformers in the modern substation Advantages © ABB 22/07/2009 | Slide 40 Summary of the Advantages Natural ester is proposed to be used in power transformers to eliminate the side effects of the mineral oils. The main advantages are: © ABB October 7, 2011 | Slide 41 Fire safety Slower rate of aging cellulose Overloading possibility Environmental compatibility Savings in many aspects Natural atu a este esters s filled ed Transformers in the modern substation Fire Safety © ABB 22/07/2009 | Slide 42 Anatomy of a fire All three elements of fire triangle MUST be present to start and sustain a fire For a transformer fire IGNITION © ABB Group October 12, 2012 | Slide 43 Fuel = vaporized oil Ignition = hot metal, arcing Oxygen = inrush of air Aim iis tto see h Ai how natural t l ester t compares to mineral oil in “feeding” these three elements Initiation and Evolution of Transformer Fire © ABB Group Month DD, Year | Slide 44 There is no free oxygen in a sealed transformer to start or sustain a fire A 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 up If protection fails, large g quantity y of oil is vaporized and produces large quantity of combustible gases Rapid increase in gases can increase tank pressure to point of rupture Hot oil and combustible gases will be released and oxygen will rush in If volume of vaporized oil is within flammability limits there is high probability of fire In case of fire, propagation or extinction depends on behavior of heat release rate Fire Risk Properties © ABB Group Month DD, Year | Slide 45 Flash point is the lowest temperature at which a liquid can vaporize to form an ignitable mixture in air 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 Auto 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 Test High Energy Arcing - Results © ABB Group Month DD, Year | Slide 46 25-50% 25 50% as much gas dissolved in natural ester as in mineral oil oil, however Similar amounts of gases in gas space Peak 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 fluid Flammability Limits (LFL and UFL) – ASTM E918 Results . © ABB Group Month DD, Year | Slide 47 Explosive environment exists with 0.6% mineral oil in air mixture at 200°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 Rate 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 © ABB Group Month DD, Year | Slide 48 Summary © ABB Group Month DD, Year | Slide 49 Similar 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 removed Natural ester demonstrates much reduced fire risk as compared to mineral oil Putting it All Together Transformer Arcing Tests High Energy Arcing Tests Mineral oil © ABB Group Month DD, Year | Slide 50 Natural ester Similar arcing energy was simulated in distribution transformer tanks filled with natural ester and mineral oil 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 the In th case off natural t l 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 atu a este esters s filled ed Transformers in the modern substation Low Ageing © ABB 22/07/2009 | Slide 51 Low Ageing Natural Ester and Cellulose Paper 20 °C Natural ester impregnated paper experiences lower aging rate compared to mineral oil impregnated paper paper, leading to an increase in the insulation system life, hence in the transformer life © ABB October 7, 2011 | Slide 52 Natural atu a este esters s filled ed Transformers in the modern substation Environmental C Compatibility tibilit © ABB 22/07/2009 | Slide 53 Natural Esters filled Transformer in the Modern Substation Environmental Compatibility Readily biodegradable: 99 % in 21 days according di tto CEC L L33-A-93 , non toxic¹ © ABB October 7, 2011 | Slide 54 Natural ester is not treated as toxic waste The 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) Natural Ester – ABB sensible solution Savings Potential 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 systems Potential INSURANCE COST SAVINGS from less-flammable, non-toxic, reduced d d explosion l i risk i k off natural t l esters t filled fill d transformers t f Potential AVOIDANCE OF FIRE LOSS because of less-flammable characteristic Potential AVOIDANCE OR REDUCTION OF OIL SPILL CLEAN-UP 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: pass thru: ability to overload natural ester ester-filled filled power transformers could mean higher revenues during peak demand periods without sacrificing transformer life Potential to DELAY CAPITAL EXPENDITURES due to increased asset 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 El National Electrical Code (NEC), o NFPA 70, es un estandard estadounidense para la instalación segura de alambrado y equipos eléctricos. Es parte de la serie de normas de prevención de incendios publicada por la National Fire Protection Association (NFPA). "National Electrical Code" y "NEC" son marcas registradas NFPA Natural Esters filled Transformer in the Modern Substation Market trend: Modern Substation Features In recent market trend 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: Kuwait National Petroleum Company ENI/Agip PETROAMAZONAS CEMIG APLNG DUPONT PETROBRAS GLNG SANTOS SHELL LION Oil Company CODELCO Over 4000 O transformers (up to 56 MVA and 145 kV) sold ld or retrofitted with natural ester since 1999 More then 220 P Power transformers above 10 MVA installed Natural Esters filled Transformer in the Modern Substation More then 5000 BIOTEMP distribution transformers delivered More than 220 Power transformers filled with BIOTEMP above 10 MVA successfully delivered. Most of insallations are in USA and 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 Cooling Many customer moving to natural ester filled transformers: Petroamazonas, Agip, LNG, Schlumberger; Codelco Natural Esters filled Transformer in the Modern Substation Market trend: Modern Substation Features Upgraded 25 MVA URBAN SUBSTATION IN BELO HORIZONTE (Brazil) 20 MVA LNG SUBSTATION (Australia) © ABB October 7, 2011 | Slide 58 20 MVA AGIP REFINERY SUBSTATION (Congo) 50 MVA CEMENT FACTORY EGYPT 18.75 18 75 MVA REFINERY SUBSTATION (Ecuador) 40 MVA , 115/12.7 kV Codelco – Chile , order under execution from 15 to 25 MVA with overload capacity of up to 37.5 MVA for 6 hours (150%) or up to 42 MVA for 4 hours (170%)
