Edoardo Siano and Victor Khuboni , May 2013 …FILE/Overview+of+Transformer+technology.pdf · transformer manufacturing Asea Brown Boveri Ansaldo/Ital Trafo GE, USA National Industri

Overview of ABB Transformers technology

Edoardo Siano and Victor Khuboni , May 2013

© ABB Group

Transformers

ABB serves utility, industrial, commercial customers with a comprehensive portfolio of transformers and components supported by an extensive service offering

Designed for reliability, efficiency and minimum environmental impact, ABB Transformers help maximize return on investment by optimizing total ownership cost

© ABB Group May 20, 2013 | Slide 2

www.abb.com /transformers

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Transformers A long pioneering history

The combined experience of 700 years of transformer manufacturing Asea Brown Boveri Ansaldo/Ital Trafo GE, USA National Industri Strömberg Westinghouse Kuhlman Trasfor (in 2011) …


Transformers Global manufacturing capability

73 production units in 25 countries

36 service centers in 28 countries

Around 17000 employees

Revenues in more than 100 countries

Voltage range up to 1000 kV AC and +-800 kV DC


Production unit(s): Americas • Brazil • Canada • Colombia • Mexico • USA Europe • Finland • Germany • Italy • Poland • Russia • Slovakia • Spain • Sweden • Switzerland • Turkey India, Middle East and Africa • Egypt • India • Saudi Arabia Australasia • Australia • China • Korea • New Zealand • Singapore • Thailand • Vietnam

Transformers Present in 34 countries worldwide

73 production units in 25 countries, and 36 service centers in 28 countries

Production unit(s) and Service center(s) Service center(s)


Power Distribution

The most complete range of transformers, components and services

Month DD, Year | Slide 6 © ABB Group

IEC, ANSI, IEEE standards and other local

standards (e.g. JB, CSA, GOST)

Insulation and components

Service

Industrial & special Traction

Transformers ABB is your “one-stop shop” supplier

Dry-type



Transformers One common global design standard

Liquid-filled distribution transformers (CDS)

Dry-type distribution transformers (CDS)

Power transformers (TrafoStarTM)

Special transformers for HVDC, Phase shifting, industry and traction


Transformers Power transformers (TrafoStarTM)

Power transformers (TrafoStarTM)


• Technology developed by

merging experiences and

best-practices

• Best selectively combined

into an improved, common

technology

• TrafoStar technology is used by all ABB

power transformer factories around the

world

• TrafoStar is a common platform for both

design and manufacturing

The combined experience of 700 years of transformer manufacturing Asea Brown Boveri Ansaldo/Ital Trafo GE, USA National Industri Strömberg Westinghouse Kuhlman ….



TrafoStar main elements Global design and process rules Robust design Common technical standards Common Quality System (6 Sigma) Key Components in house (Bushings, Tap-changers, insulation etc.) Global Feedback System …

Customer benefits from ABB TrafoStar Design Short Circuit Strengths and Transport Strength Dielectric Robust Design Low Losses and other magnetic values as currents and core

temperatures Low Acoustic sound at No Load and Load Continuous design improvement by Global Feedback … and more…


TrafoStar Other

As of today ABB has delivered more than 15,000 power transformers (ca. 20,000,000 MVA) based on TrafoStar


Factory testing, short-circuit testing, and years of in-service history have demonstrated the high quality of ABB’s power transformer products. Product quality is what allows ABB to remain as the largest power transformer manufacturer in the world. Through continuously improved design and manufacturing procedures, ABB has reduced test failures by 50 percent between 2000 and 2010. As a result, ABB’s short-circuit withstand is now more than twice as high as the market average.

Proven technology: failure frequency reduced by 50% in 10 years



Proven technology: reliability more then twice market average


Transformers Distribution: Common Design System (CDS)

Liquid-filled distribution transformers (CDS)

Dry-type distribution transformers (CDS)


• CDS technology is used by all ABB distribution transformer

factories around the world

• Common platform for designing ABB transformers up to 36kV

• For both Electrical Design (CDSe) and Mechanical Design

(CDSm)


Electrical Design based on documented

Design Rules

Material Standards

Production Manual

R&D Project Reports

Transformers Common Design System (CDSe)


User Interface

CDS Database

Mechanical Design and 3D CAD

ABB Designs Specification database

Transformers Common Design System (CDSm)

Mechanical Design

3D CAD

Rules for local market needs possible

Bill of Materials

Production unit(s): Americas • Brazil • Canada • Colombia • Mexico • USA Europe • Finland • Germany • Italy • Poland • Russia • Slovakia • Spain • Sweden • Switzerland • Turkey India, Middle East and Africa • Egypt • India • Saudi Arabia Australasia • Australia • China • Korea • New Zealand • Singapore • Thailand • Vietnam

Transformers Present in 34 countries worldwide

Local presence for Servicing our customers in South Africa

Production unit(s) and Service center(s) Service center(s)



Transformers In South Africa

Local presence for Servicing our customers:

Transformer Total Health Care (TTHC)

Spare Parts Management

ABB University

Transformer in South Africa Transformer Total Health Care (TTHC)


The activities that make up the TTHC concept are namely:

Taking of oil samples.

Laboratory analysis of oil samples.

Interpretation of the report and recommendations.

Technical evaluation of the report.

Rectification activities.

Oil rejuvenation (Oil purification, supply regen oil, e.t.c).

In depth diagnostics and condition assessment (DFR, SFRA, OLTC Continuity test, etc….)

Scheduled Service Activities.

Condition monitoring.

Specialized services including supply of spare parts.

Dry Ice cleaning of the transformer and the control room.

Cleaning of the sub-station yard.

Transport, Installation and Cold Commissioning.

First Line Maintenance Training.

Our vision: To create a “One Stop Shop” solution for customers

Transformer in South Africa Spare parts management

Having critical spare parts on hand can significantly reduce the down-time associated with: Transformer maintenance Forced outages Electrical failures Mechanical failures

As a minimum for operational reliability, it is essential to have critical parts and components readily available, such as: Bushings (oil or dry) Tap changer contacts (conventional or vacuum) Relays Gaskets Fan motors and pumps The above parts should be in stock in the customer warehouse for immediate use in order to avoid long outages. Some of these parts can take considerable time to obtain from the manufacturer.


Transformer in South Africa ABB University


Transformers and Tap-changer training sessions held in ABB Johannesburg


TrafoStarTM – Units produced

< 72,5 < 170 < 245 < 330 < 550 < 800 > 800

< 63 1313 3896 787 34 451 22 2 < 100 128 838 525 26 258 32 1 < 200 108 447 1586 96 466 95 1 < 300 1 56 577 55 699 19 2 < 500 1 36 193 32 852 59 2 < 750 15 36 5 168 46 > 750 1 3 75 10 1 Σ 1551 5289 3707 248 2969 283 9

kV

MVA


TrafoStarTM – Short Circuit references

160 short circuit tested ABB power transformer units 58 short circuit tested ABB TrafoStarTM units

< 72,5 < 170 < 245 < 330 < 550 > 800 < 63 3 10 8 3 1 < 100 2 4 1 2 < 200 4 5 < 300 4 3 < 500 7 Σ 5 14 17 20 1

kV

MVA

Documents

Edoardo Siano and Victor Khuboni , May 2013 …FILE/Overview+of+Transformer+technology.pdf · transformer manufacturing Asea Brown Boveri Ansaldo/Ital Trafo GE, USA National Industri