Professional Documents
Culture Documents
ABB Group
February 19, 2013 | Slide 1
ABB Special Transformers (PG SPT)
Agenda
ABB Group
February 19, 2013 | Slide 2
ABB Special Transformers (PG SPT)
Allocation Map Oil Type transformers
Lead Center
Vaasa
South Boston
Zhongshan
Shanghai
Pereira
ABB Group
February 19, 2013 | Slide 3
ABB Special Transformers (PG SPT)
Factories for VSD transformers
ABB Group
February 19, 2013 | Slide 5
Transformers for Variable Speed
Drive Applications
ABB Group
February 19, 2013 | Slide 6
What is a drive system?
A drive system is used to control speed, torque and power of an electric motor in the
most efficient way in an application
It consists of transformer, variable speed drive and motor
ABB Group
February 19, 2013 | Slide 7
Transformers for Variable Speed Drives (AC) for ...
Special applications,
Power Pulp & Paper Water e.g. wind tunnels
ABB Group
February 19, 2013 | Slide 8
Typical Applications
ABB Group
February 19, 2013 | Slide 9
Standards
IEC 61378-1 Converter
transformers, Part 1 Transformers
for Industrial Applications
IEEE C57.18.10 IEEE standard
Practices for Semiconductor
Power Rectifier Transformers
IEC makes no requirements for
BIL levels unlike IEEE
We design always to cover
Increased electrical stress drive
side
Common mode voltages
High DU/dt 2000
iu
1500
500
0
EMC reduction -500
0 5 10 15 20 25 30 35 40 45 50
-1000
-2000
MEA and ASIA markets, CE
labelled
Transformer ratings in IEC 61378-1
Rated power = Fundamental kVA
kVA calculated with rated voltage and fundamental current component
of the load current
RMS kVA
kVA calculated with rated voltage and total RMS load current
Equivalent kVA
kVA calculated with rated voltage and defined equivalent sinusoidal
current which will give the same losses in the transformer than the
actual load current when all its harmonic components are considered in
relation they cause losses in the transformer
IEEE C57.18.10 is technically close to IEC 61378-1, differencies mainly in
terminology
IEEE gives defined requirements for insulation levels (BIL-levels)
Transformer ratings in IEC 60076
Fundamentals
Harmonic currents arise extra stray losses in
windings, bars, core clamps and tank / enclosure
Degree of severity depends on drive type, load type
and transformer design
Dimensioning
Calculation of equivalent current or derating factor is
enough in standard VSD applications (limited power
& current)
More detailled study is necessary as power / current /
harmonic content gets higher.
Converter duty for transformers
U Pmotor _ shaftpower
Sn
Un motor output _ trafo converter cos
St Sn K
8 6 pulse rectifier
12 pulse rectifier
7
P ercent o f IL
0
5 7 11 13 17 19 23 25 29 31 35 37 41 43 47 49 TDD
Harmonic Order
ABB Group
February 19, 2013 | Slide 15
Converter Transformers / Definition & Why
Why converter transformers are
needed (main issues)
Adapts the network supply voltage to
the converter input voltage
Isolates the converter from feeding
network and restricts short-circuit
currents to the converter
Relieves the motor and/or network
from common mode voltages
Reduces radio interference (EMC)
from drive to the network (special
screen)
Protects the drive from voltage
transients from the feeding network
Reduces harmonics (transformer
impedance and special connections
for multipulse operation)
ABB Group
February 19, 2013 | Slide 16
Converter duty for transformers / Harmonics
Reducing line harmonics with transformer connections
As the power increases the network harmonics come more critical
Harmonics on the line side: n x p 1 (n=1,2,3...), p=pulse number
The order of characteristic harmonics (h) in relation to the rectifier pulse number (n):
h= k n 1
k is any integer,
a 6 pulse rectifier produces 6-1=5th, 6+1=7th, 12-1=11th and 12+1=13th
harmonic currents (in ideal case)
a 12 pulse rectifier produces 12-1=11th, 12+1=13th, 24-1=23rd and 24+1=25th
harmonic currents (in ideal case)
Pulse number can be increased by applying multiple 6 pulse groups with phase
shifted supply voltages
30 degrees phase shift can be obtained by using basic connection
groups on the transformer (Y and D)
Phase shifts other than 0, 30(or multiple) require a special phase
shift winding. Most common are Z and extended delta connection
ABB Group
February 19, 2013 | Slide 17
Converter duty for transformers / Connections
ABB Group
February 19, 2013 | Slide 18
Harmonics - Visualisation
1.5
0.5
fundamental
3th harmonic
pu
0 5th harmonic
0 0.005 0.01 0.015 7th harmonic
total
-0.5
-1
-1.5
time
ABB Group
February 19, 2013 | Slide 19
Effect of Harmonics / Fundamentals
ABB Group
February 19, 2013 | Slide 20
Effect of Harmonics / Fundamentals
HV (Primary) LV (Secondary)
Eddy Loss multiplier 8.300 Eddy Loss multiplier 8.300
Stray loss multiplier 1.573 Stray loss multiplier 1.573
0.077754887
TDD 27.9%
791.175 1019.634
Rectifier 22605 6567 0 30898 8463 7519 76052
DISEO BASE OK
ABB Group
February 19, 2013 | Slide 21
Effect of Harmonics / Thermal Modeling
ABB Group
February 19, 2013 | Slide 22
EMC screen
3
EU has set limits for radio frequency (RF) pollution
of power supply system at point of power drive
system connection (including transformer) EN 2 1
61800 4
transformer window
Metal foil
Same requlation is applied increasingly also
Insulating cylinder
Middle of
outside europe
Drive systems generally do not fullfil requirement
without filtering or screening
Industry require system to be EMC compliant (CE
labelling) anywhere although EU requirement is
5 5
valid only at point of connection to public network
or at 10 m distance from the boarder fence
Correctly designed electrostatic screen is a cost
efficient way of fullfilling the requirement for drive-
transformer package Hint: This is the general description
of screen in transformer specification,
Electrostatic screen is also protecting the drive but making functional screen is not
against common mode voltage stress from supply so simple
system (lightning and switching)
ABB Group
February 19, 2013 | Slide 23
Static screen issues
ABB Group
February 19, 2013 | Slide 24
Liquid insulated transformers IEC 60076
Insulation liquids O,K, L
Mineral oil O is standard for industrial installations, but out of question (low fire
point and high combustion energy) on ships and offshore
Less flammable liquids class K, fire point >300 C, are applied when low fire risk is
required
synthetic esters (bio-degradeable non-toxic) IEC 61099, (Midel 7131)
silicone oils (non-toxic, stable) IEC 60836, (DC 561, TR50)
Non flammable liquids class L not existing today
Liquid transformers are quite new application area for ships and FPSO
Increasing power of propulsion drives created need for compact solutions-liquid
transformers up to 20 -30 MVA feasible as one unit
Water cooling easy to apply
Low height , can be fitted on one deck height
Cost benefits
Liquid transformers dominant for drive applications on off-shore platforms and
rigs with harsh environmental conditions, so not new technology
Installation of liquid transformers possible at explosion hazard Zone 1 and
Zone 2 with simple measures.
Summary & Conclusions
Modern AC converter drives need transformers of special desing
normal distribution transformers are not feasible
The above fact has been a reason why separate standards have been
published by IEC and IEEE
Without appropriate desing and manufacturing the performance, reliability of
the system and adequate lifetime of the transformer can not be ensured
The special desing needs to consider especially;
increased dielectric stress
thermal issues (related to harmonics etc.)
increased mechanical stresses
many cases complex internal connections with phase shifts & multiwinding
desings for ensuring
The special considerations need to be done especially for medium voltage
drives and in general for drives above 1 MW
The drive transformer manufacturer should have some general and specific
knowledge about drives
ABB has a unique position since it can offer the full scope of a drive system
with its products. ABB Transformers is having a unique position since it has
global common product desing platforms that are making broadening of the
manufacturing footprint possible (technical support and technical transfers)
ABB Group
February 19, 2013 | Slide 26
ACS 1000 Input Transformer
Medium Voltage Medium Voltage Medium Voltage
Supply Bus Supply Bus Supply Bus
Main Feeder Main Feeder Main Feeder
I>> Prot I>> Prot Breaker I>> Prot Breaker
Breaker
& Protection & Protection & Protection
12-pulse 24-pulse
Converter Input Converter Input
Transformer 24-pulse
Transformer
Converter Input
Transformer
Rectifier
Rectifier
Rectifier
ABB Group
February 19, 2013 | Slide 27
ACS 1000 common mode voltage
I_Cfuvw_G
A
35
30
20
10
-5
-15
-20
-30
0 5 10 15 20 25 30
ms
ABB Group
February 19, 2013 | Slide 28
ACS 1000 24-pulse input transformer
One 5-winding transformer Two separate 3-winding transformer
U L U L
I PN I PN
Screen
P
D A
P2 P1
C B Screen Screen
D C B A
Id/2 Id/2
Id/2 Id/2
Id
Id
Udi0
Udi0
ABB Group
February 19, 2013 | Slide 29
Large 12 pulse rectifier transformer active part
ABB Group
February 19, 2013 | Slide 30
ACS 5000 Converter topology
Transformer
2 x 4-winding or 1 x 7-winding Output voltage up to 6.9 kV
Optional integrated dry type solution EMC-filter (dv/dt limitation at output) as
36-pulse diode rectifier standard
3 x 12-pulse bridges Motor type
Input voltage: 1920 V / 10% Asynchronous
DC link (in triplicate)
Synchronous
Three 5-level inverter unit
Permanent magnet
H-bridge configuration
ABB Group
February 19, 2013 | Slide 31
ACS5000 - 36-pulse transformers
One 7-winding transformer Two separate 4-winding transformer
Inverter Inverter
-25 -20
-15 0
-5 20
MCB MCB
Inverter Inverter
5 -20
15 0
25 20
Transformer 2:
SR/2
Inverter Inverter
Technically a compromise, only for small powers Technically ideal and save solution
(non-characteristic harmonics)
More compact nut not always lowest costs Larger in size; compromise is to have two active parts in one oil
tank
Primary currents must be measured separately
Oil transformers, two separate transformers are lowest costs
2 sets of CTs on primary side is required for overcurrent
detection (each primary side measured separately)
ABB Group
February 19, 2013 | Slide 32
ACS 5000 Network friendliness
ABB Group
February 19, 2013 | Slide 33
Aluminum and natural ester in ESP
Transformers
ABB Group
February 19, 2013 | Slide 34
NATURAL ESTER TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
Preserving life and property
According to FM NATURAL ESTER has a flash and
Global property loss
prevention fire point of 340C and 360C,
datasheet for respectively (vs. 160C and 180C
transformers
typically for mineral oil)
Listed as a less flammable
dielectric fluid by FM Global and
Underwriters Laboratories
Tested in strict accordance with IEC
standard 61100 and meet the K2
classification
Active fire suppression and barrier walls can essentially be eliminated when
minimal spacing is maintained (for transformers with ratings 10 MVA and
lower)
Savings apply to initial installation, rehabilitation and maintenance
costs
Meet fire safety requirements for indoor applications and outdoor areas of
heightened safety sensitivity without additional safety equipment
Reduce risk of transformer explosion and fire, hence mitigating collateral
damage and potentially lowering insurance premiums
ABB
22/07/2009 | Slide 35
NATURAL ESTER TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
Miscibility Between Electric Insulating Liquids
ABB
October 7, 2011 | Slide 36
NATURAL ESTER TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
Current product scope
20
C
ABB
October 7, 2011 | Slide 38
NATURAL ESTER TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
High Overloadability
Overloadability:
Cellulose-based insulation parts have a longer life
expectancy in NATURAL ESTER than in mineral oil
ABB
October 7, 2011 | Slide 39
NATURAL ESTER TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
Savings Summary
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 explosion risk of NATURAL ESTER filled transformers
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: ability to overload NATURAL ESTER -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 ESTER filled transformers
ABB
October 7, 2011 | Slide 40
ALUMINIUM TRANSFORMERS IN THE MODERN
OFF AND ON SHORE SUBSTATION
Summary
Transformers with Aluminum windings having the same losses as that of Copper
windings are technically feasible and economically advantageous.
Copper is extensively used in power transformer windings.
The price of copper fluctuates heavily during the last years and the price level is
expected to be at high levels, due to limited copper reserves.
As the price of Cu has recently moved ahead much faster than the price Al, usage of
Al in winding conductors has become more viable option.
Aluminum wound transformers have better mechanical and thermal performance
during S.C w.r.t copper wound one, for the same load losses
ABB Group
February 19, 2013 | Slide 42
Harmonics, Transformers and K-Factors
Eddy loss due to high harmonics: Al vs Cu
Cu Al
Conductivity 100% 62%
Penetration Depth 100% 127%
Eddy losses 100% 62%
ABB Group
February 19, 2013 | Slide 43
Harmonics, Transformers and K-Factors
Eddy loss due to high harmonics: Al vs Cu
ABB Group
February 19, 2013 | Slide 45
Aluminum Conductor in Transformers
Environmental Considerations
ABB Group
February 19, 2013 | Slide 46
Aluminum Conductor in Transformers
Reliability Considerations
ABB Group
February 19, 2013 | Slide 47
ABB Aluminum Wound Transformers
Experience
ABB Group
February 19, 2013 | Slide 48
ABB Aluminum Wound - Natural ester Transformers
COMBO 3
VSD TRANSFORMER +
ALUMINUM + NATURAL
ESTER
ABB Group
February 19, 2013 | Slide 49
New responsables ESP TRX in COABB
CHILE,
COLOMBIA
C&CA AND BOLIVIA & ARGENTINA
ROLL BRAZIL PERU &
MEXICO ECUATOR URUGUAY
VENEZUELA
PARAGUAY
Luis Tatiana
PRODUCT Ana Mara Jakeline Andrs Ana Mara
MANAGER
Fernando Paola
Daz Franco Salazar Restrepo
Osorio Padilla
Juan Juan
SALES Karen Anyela Felipe Natalia
SUPPORT
Felipe Alejandro
Restrepo Vasquez Echeverri Loaiza
Castao Bedoya
ABB Group
February 19, 2013 | Slide 50