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ABB green transformer - reducingenvironmental impact withoutcompromising reliability

Yangliu, Sales&marketingt, Nov-2014

December 9, 2014

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§ Distribution Transformer

§ 30kVA~10000kVA up to 35kV Oil Immersed DistributionTransformers

§ Padmounted Transformers

§ Insulation & Components

§ Oil treatment plants On load tap changers RIP condenserbushings

ABB Hefei Transformer Co., Ltd

December 9, 2014

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ABB Hefei Transformer Co., Ltd

§ Established July 14th, 2000

§ Employees 210*

§ Power range 30kVA to10000kVA

§ Primary voltage Up to 35kV

§ Conduct material Cu, Al

§ Available fluids Mineral oil, refer to IEC 296 ( Silicon oil, Midel oil, Biotemp )

§ Available standards China Standard GB1094,6451; IEC 60076

§ Certificates ISO9001, ISO14001, OHS18001China Energy Conservation Product Certificate,SSE-L2 (Safety Standardization Level 2)

§ Standard version 3 Phase Hermetically sealed oil immersed

§ Option Galvanized Type, Gas Gap Type,Equipped with on-load tap changers, cable box, oilconservator, Eco-transformer with silicone oil &protection devices

Distribution Transformer

*Till to March 2011

December 9, 2014

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Liquid filled distribution transformers

§ Two major technologies

§ Stacked core with one global design platform (CDS)

§ Wound core with another global design platform (LWCT)

§ Global technology lead centers

§ Stacked core Lodz, Poland

§ Wound core Jefferson City, USA

§ 2,5-10 MVA, LMDT Istanbul, Turkey

§ ABB common technology concept based on global tools andstandards

§ Common design systems (CDS and LWCT)

§ Common technical, material and production standards

Production and technologies

l

December 9, 2014

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§ High efficiency and energy saving

§ Operation cost is low

§ Safety for persons and property

§ Good anti-short circuit ability

§ Excellent load capacity

§ Resistance to lightning

§ Low noise

§ Easy installation

§ Free maintenance

Liquid filled distribution transformersThe main features

December 9, 2014

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Hefei Transformer Co., Ltd

Our focus is to define optimized, customized solutions based on today‘srequirements and evaluation criteria's, and participate in defining customersolutions addressing the green agenda and setting new standards for the future§ Modularization choices support high speed customization§ Windings Copper or Aluminum

Paper or enamel insulated conductors

§ Cores Step lap stacked cores or wound core technologyAll available GO steel, ranging from M5 to DR (Laser) indifferent thicknesses or the ultimate in low losses usingamorphous metal.

§ Tank solution Hermetically sealed or conservator typeCorrugated fin walls or radiators

§ Liquids BIOTEMP® fluid and FR3Silicon oil, Midel, or other biodegrable fluidsMineral oil

§ Surface treatmentsWater based or powder painting in different RALHot dip galvanized for aggressive environmental conditions

The green DTR program

December 9, 2014

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Voltage： 35kV

Capacity Range： 30 - 10,000kVA

The advantage of stacking core：

§ Tradition structure

§ Mature Technology

§ Higher ability for short circuit

§ Lower losses

§ Better for any running condition

§ Small outline

§ Lower noises

§ S11 less than GB standard about 12 dB

§ S13/S14* less than GB standard about 17 dB

§ Lower no load current

Hefei Transformer Co., LtdLower losses products

Base on S11GB20052 Or

JB/T3837

Reduce percentage for No load losses

0% 15% 30% 45% 70% 75%

Red

uce

perc

enta

gefo

rlo

adlo

sses

0% S11 S12 S13 S14 SH15 SH16

15% S12 S13 S14* S15

30% S13 S14 S15*

Case for 400kVAyearly losses（10000 kWh）

December 9, 2014

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Voltage ： 35 kV

Capacity Range ： 50 - 630kVAThe advantage of amorphous：§ Energy savings and increased efficiency

§ No-load losses 40 - 70% less than with e-steel

§ Efficiency increase by 0,5% to 1%, depending on rating

§ Lower Total Ownership Cost (TOC)§ Continuous, guaranteed energy savings from the

moment of installation

§ Mitigation of generation needs to meet growingdemand§ Environmental benefit accrue from less greenhouse gas

emissions

§ Less heat generation due to lower losses, leading toa favorable reduction of cooling capacity and fluid

§ Savings do not require end user behaviormodification nor a sacrifice of comfort

§ Amorphous material can be reusedand recycled

Hefei Transformer Co., LtdAMDT product

December 9, 2014

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§ Voltage ： 6 - 10kV

§ Capacity Range ：30 - 500kVA

§ Adjustable capacity： Load or no load

§ Scope of application： Adjusting power transformeris mainly used to seasonal consumption biggerdifferences and the place of the average load rate islow

§ The advantage of product：

§ Replace the simple

§ Economic and security

§ Energy-saving and total loss of small capacityless than total loss of the same standarddistribution transformer capacity

§ Easy to operate, only adjust the switch

Hefei Transformer Co., LtdAdjusting power transformer

December 9, 2014

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§ Voltage ： 35 kV

§ Capacity Range ： 30 - 3,300kVA

§ PMT structure is compact and easy to installation inthe ground, facilitate and underground cableconnection, safe and reliable and is widely used tocity power supply and wind power

§ The advantage of PMT：

§ Compact structure and low cost

§ Safe environmental protection, reliable powersupply

§ ABB CDS technologies

§ Strong ability of corrosion resistance

§ Good ventilation and heat dissipationperformance

§ Inside prevention measures for condensation

§ A variety of low-voltage alternative

Hefei Transformer Co., LtdPad-mount transformer

December 9, 2014

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§ Voltage： 35kV

§ Capacity Range ： 1,000 - 8,000kVA

§ ABB have developed the Slender transformer forapplications where dimensional access is limited

§ It is a liquid filled transformer defined by the verynarrow width dimension.

§ Location:

§ Tower

§ Nacelle

§ On-shore or off-shore installations=> humid and salty environment

§ High and low temperature performance

§ Strong vibrations – 100 m high towers

§ Liquid - biodegradablefluids (natural or synthetic esters)

Hefei Transformer Co., LtdABB wind turbine ( Slender ) transformer

December 9, 2014

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§ With BIOTEMP® and FR3, ABB aims at offering acomplete and sustainable solution for both distribution andpower transformer applications associating environmentalfriendliness (high biodegradability), safety (superior fireresistance), reliability and efficiency (high overload capacity)

Hefei Transformer Co., LtdPower transformer immersed in fire resistance fluid

BIOTEMP® and FR3 is a superiordielectric insulating fluid combining…

§ 99% biodegradability with nonhazardous and non toxic waste

§ High fire point, i.e., 360°C vs. 180°Cfor mineral oil

§ Much greater ability to hold moisture,i.e., 10 times more than mineral oil

December 9, 2014

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§ Voltage： 35kV

§ Capacity Range ： 400kVA – 2500kVA

§ The secondary voltage： 500V~3000V

§ Scope of application： Electrolysis, traction,transmission, dc transmission, magnetic,electroplating, electrostatic dust removal, etc.

§ Product application: 6 pulse, 12 pulse

§ product features:

§ Highly reliable

§ Strong resistance to short circuit and overloadability

§ Low noise

§ Free maintenance

§ 40 year design life

§ Environmental and safety

Hefei Transformer Co., LtdABB converter transformer

December 9, 2014

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§ Voltage： 35kV

§ Capacity Range ： 30 - 10000kVA

§ The advantage of ABB Al product：

§ ABB aluminum wire transformer has a long historyand mature production technology, ABB transformerproduction of aluminum wire and copper wiredistribution transformer has the same technicalparameters and use of performance, concretemanifestation in:

§ The same no load loss/load loss

§ Basically the same size

§ The same 40 years design life

§ Has a good cost performance

油浸式配电变压器ABB经济型变压器

December 9, 2014

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Customer Segment

China Export

Utilities Industries OEM Distributors

ElectricalPower

Company

SubsidiaryPowerSupply

Bureaus

Minerals & Mining,Chemical, Consumer,Metals and Foundry,Petrochemicals, Oiland Gas, Pulp and

Paper, RailTransportation, Water

Supplying

CompactSubstation

(CSS),active parts

ChannelPartners

Sales by local FES or

back up factory

December 9, 2014

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ABB Hefei Transformer Co., LtdCustomer values

CustomerValues

HighEfficiency

EnergySaving

Lower Noise

SafeLongerLifetime

Environmentally Friendly

Lower TOC

December 9, 2014

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Transformer Main manufacture process

December 9, 2014

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Manufacture processTank manufactory

High qualitymaterial

• Cold rolling• Free breath

Fin foldingmachine

• 1 meter line and1.6 meter line

• Higher quality• High strength

Automaticwelding

• Gas protectwelding process

• High quality

Tank welding

• Gas protectwelding process

• High quality

Leakage testing

• Reduce oilleakageopportunity

December 9, 2014

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Manufacture processCore manufactory

Silicon steel

• High quality• Laser

DEORG Cuttingmachine

• Lowertolerance

• No burr

with pre-stacked legs

• Highefficiency

• Stackingneat

6 Steps

• Low NoLoadCurrent

• Low NoiseLevel

Glue

• Tighten

Core assemblytable

• Positioningaccuracy

• Assemblyprecision ishigh

December 9, 2014

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Manufacture processLV winding manufactory

Foil

• No loadlosses

WindingMachine

• AutomaticLV windingmachines

Foil & Strip

• High shortcircuitwithstandability

Thermosettingepoxy resin

• Mechanicalstrength

Winding onleg

•No core andcoil assemblyprocess

•High shortcircuitwithstandability

Cold presswelding

• Clean• Mechanical

strength

December 9, 2014

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Manufacture processHV winding manufactory

High quality wire

• No load losses

TUBOLY

• High efficiency• Tension Control• Consistent

Performancecontrolledcopper losses

Wire FlatteningMachines

• ≤ 630kVA• Tension Control• Improved Space

Factor• Large conductor

area in contactwith glue giveshigh Shortcircuit strength

Winding on LV

• ≥ 800kVA• Coil tightness• Improved Space

Factor

High Frequencywelding

• Better quality• Clean

December 9, 2014

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Manufacture processActive part manufactory

Stacking table

• No load losses• Noise

Core tighten

• ≥ 800kVA• Metal strip

Active partassembly

• Protect loose

Active parttighten

• Self-locking nuttight

Cold presswelding

• Clean

December 9, 2014

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Manufacture processFinal assembly

Automatic Oven

• Less 630kVA• Constant

temperature

Vacuum oil filling

• Less 630kVA• ≤0.1mm Bar• 55 ℃ oil• remove air and

moisture fromthe transformer

Vacuum oil filling

• ≥ 800kVA• ≤0.1mm Bar• 55 ℃ oil• remove air and

moisture fromthe transformer

Tank seal

• Higher qualityseal

• Be heated to200℃

• Longer lifetime

Leakage test

• 24 Hours• To prevent

leakge

December 9, 2014

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