Abb+power+transformers+for+grid +reliability PDF

High Quality Power
Transformers for Grid

Thomas Fogelberg Reliability
Head of Quality
ABB Power Transformers Singapore Sept 22-23, 2008
© ABB BU Transformers - 1 -
9/26/2008
Transformers enable efficient energy transfer in society
The
Theworkhorses
workhorses
Generator of
ofthe
theelectrical
electrical
Step-Up system
system
transformers
Reliability
Reliabilityand
and
availability
availabilityin
in
focus
focus
System
transformers
The
Thecorrect
correctuse
useof
ofvoltage
voltage&&current
currentisisthe
thekey
keyto
toefficiency
efficiency
Energy efficiency: Optimum use of voltages & currents
Process Plant Grid Process Drive & Building

Transport
automation automation operation automation motor Installa-
systems
systems systems systems systems systems tions
net energy
transport Total
Totalelectrical
electricalsystem
system
from
from transmissionto
transmission to
distribution very efficient
distribution very efficient
conversion
efficiency line losses
production
process motor efficiency
buildings
Trans-
Primary Electrical Industrial Motors &

mission & Buildings
energy energy Plant Drives
Distribution
The Purpose of the Power Transformer = Gear Box
It is the long term available “Gear Box” for production and transport
of electric power which counts !! It shall always work !!
The “Gear box” shall be as efficient as today, 99.6 – 99.7 % !!!
The efficiency of the transformer is not the major purpose, it is to

work as a gearbox over 40 years to make the electric infrastructure
system efficient
You get the infrastructure efficiency from “94 % to 97 %” to go from
66 to 110 kV
110 to 145 kV or 220 V
220 to 400 kV
315 to 765 kV
500 kV DC to 800 kV DC
And soon on…
And the “Gear Box” helps you

Reliability of Power Transformers
300 MVA
220/115/37 kV
transformer
800 kV
transformer
1200
MVA
400 kV
Phase
Shifter
Engineering To Order business Concept
From Unique Specification

To One unique Power Transformer
This Tutorial will describe some very important aspects in the

process from making a proposal (tender) to manufacture and test
the final Transformer
The whole power industry needs more to discuss how we can
mitigate the risks from designing grids/Substations, making
Transformer Specs to manufacturing/installing and maintain power
transformers for over 40 years of service.
T&D Products Complexity charter
Units per
design < 2
Volume
Power Many unique
products:
Many
products:
Many products:
medium
Several
products:
One product:
very high
Transformers one each low volume volume high volume volume
Large Power Transformers

Functional layout, Job GIS Substations
flow extremely
varied Shop
Small Power Transformers
Complexity and Size
Layout and Flow
Cellular layout, Batch HV Switchgear

flow varied with
patterns
Flow
Distribution Transformers
Large Motors
Small Motors
Line flow, operator Operator Paced
paced, flow mostly
regular MV & HV Breakers Line Flow
MV Apparatus
Line flow, Machine Paced
equipment paced, Line Flow
flow regular Machining & Components
LV Breakers
Continuous flow: Continuous
flow rigid
Insulation Materials Flow
HV & LV Cables
ETO ATO STD
Types
Typesof
ofmanufacturing
manufacturingprocesses
processes
High Quality Power Transformers for Grid Reliability
Agenda
Market Background: The biggest Change since ever

Loss Evaluations and impact on today's design
Procurement processes
ABB TrafoStar Technology and Design Consideration to
build reliable transformers
Manufacturing aspects
Short Circuit Safe Design & Manufacturing&Testing
Quality Management
Summary remarks
World Energy Investment
1 , -
% 72% $
" # $ 13% (1 %
! 15% ( . /0
% ((
++ $
&' ! +
% )*
$ ! 22 $
2
Transformers
for reliable
Power Quality Power Transformer World Market
1994 – 2004: About 500.000 – 600.000 MVA/ year
2004 – 2007: From 750.000 to double numbers
2008 – 2015: with base demand form Asia (China,India),

further demand increase to be expected ?
Huge Capacity Demand issue
Material Prices increased 3 -5 times 2005 – 2007 !!!!

Low or Stable Loss evaluations

Transformers
for reliable
Power Quality Expected World Market ?
GNP development in old and growing countries

GNP index
6
16000
5 USD/Capita
4 US
CH
SE
DE
3
China
2 India
1
0 5000 10000 15000 20000 25000 30000 35000 40000 45000

GNP/Capita
50000
GNP/Capita
Many conflicting requirements on transformers
Optimization of
Electric fields
Magnetic fields
Losses
Temperatures
Forces
Ageing
Noise
Transport
…...
Requires
Requiresadvanced
advanced
design
design andengineering
and engineering
capabilities
capabilities
Net present value of future losses
450
400 NPV of loss per year,
350 Loss per year,
300
250
200
150
100
50
0
5 10 15 20 25 30
Energy value 1 kW at 0,02 /kWh, 8600 h/Yr,

Assume 3% energy value increase/Yr

Assume 11% investment interest
2100 /kW
Loss Evaluations values
Example: 1 kW losses in 30 years 8600 hours per year
Interest 0.02 0.03 0.04

rate /kWh /kWh /kWh
4% 3100 4650 6200
8% 2100 3150 4200
12% 1550 2300 3100
Examples above are for No Load losses (=8600 h/Yr)

Load Loss evaluations depend on load profile per day, months etc
and are therefore a varying % of the full year value
Stable values in customer specifications recently

Evaluated cost versus material content
Costs
Total evaluated
cost
Transformer
cost
Evaluated
loss cost
Core and Conductor mass

Higher materials prices

Higher loss transformer
Conclusions: Losses vs Costs of power transformers
Losses are primarily defined by the relation between materials costs

and loss evaluations
In recent years key materials costs have increased by a factor of 3 to
5 times
Loss evaluations have changed very little
Increased costs of transformers

Risk for increased losses in transformers
Loss evaluations determined by

Interest rate chosen for investment
Expected future energy prices
What are future expectations?
Energy
Energyefficiency
efficiencyspecifications
specificationsneeded
needed
Qualitative discussion of materials utilization
"
!
Deregulation in the Western World ?
The Electrical System Industry was working rather well up to the

mid 80ies. But
All actors wanted a change
Rational: Interconnections through countries/states in EU and US
Political: Competition in all public sectors was a motto, also in old infra-
structure areas
Results:
From governmental bodies to profit making companies
Unbundling of Power – Transmission – Distribution
Difficulties to get a collected responsibility
A gradually change from long term commitments to short sighted
horizons
Fluctuations in electrical prices for all consumers
What can be expected in the Future ?
What could happen?

Purchaser drives standards lower to reduce costs –
Why?
Key people have personal targets based on financial
performance, project budgets, see case examples:
ENRON ?,Subprime loans…?
Engineering staff has been reduced to the extent that
relevant experience has almost disappeared
Inexperienced engineers may feel pressurised into
supporting or making bad decisions

Decisions made in the procurement process determine the future

reliability of the transformer. Skills, Knowledge ?
What is the risk?
Transformers are supplied that are not fit for purpose!
Long term reliability of whole family groups will be compromised
Background
Transformer prices/costs have risen sharply
Lead times are pushing out to three years or more
But, procurement is being driven by cash conscious asset
managers, or even worse, non or less technical procurement
people
This might lead to a pressure to cut corners to reduce costs
through ignorance or lack of competence
How has this developed?

Reduction in technical expertise due to privatisation
and regulatory driven cost pressures
Senior utility managers are focused on cost and not
the technical aspects
Short sight horizons
What do we need to do?????

Stop the problem at source
How do we do that?
Educate senior management of the importance of the
key decision points in the procurement process
Raise the profile of these key steps
Specification
Design review of overall technology used in the
order, consistency, experience, track records

The importance of correct and accurate testing
That’s why I am here now !!!!!!!!
Power Transformers are known as very Reliable

Products
We are going through the biggest Market change since
ever
Will the Reliability numbers stay the same ?

Agenda

Quality Management
Summary remarks
Power Transformer ETO Process
The ETO Business Process of Power Transformers

consists of
Tender
Order design
Manufacturing
Testing
Shipping
Site erection and commissioning
Lead by Quality Management
Continous Improvement and R&D

ABB’s Global Transformer Plants in ETO business
SETFO PLABB
Ludvika, Sweden Lodz, Poland
DETFO
Bad Honnef, Germany
CNTPH
CATRM Hefei, China
Varennes, Canada ESABB
Bilbao, Spain CNCTC
USTSL Chongqing, China
St.Louis, USA ESABB
Cordoba, Spain CNZTC
Zhongshan, China
TRABB
Istanbul, Turkey THABB
Bangkok, Thailand
INABB
Vadodara, India
BRABB
Guarulhous, Brazil
Footprint 14 Plants
Capacity 200.000 MVA
Capacity 1.500 Units
Headcount 5000 Employees
Engineering To Order business Concept

From Unique Specification
To One unique Power Transformer
Requires on the Manufacturing side
Rigid well proven Technology

Orderliness and Clarity in all procedures and
documentation
ABB TrafoStar Technology
TM
Common Technical Standards

Common Standard drawings
Common Material Specifications
Common Method Provisions
Common Quality System
Common Tooling and Equipment
Common Design rules
Common Design process
Common IT design tools/software

ABB TrafoStar Technology Modularization
TM
TM
A global Business Concept

Basic Product Design Rules, Transformer Physics
Product order design process & IT tools, Design Modules, Global
Release system
Methods and tools for product manufacturing
Method Provisions/Instructions and Common Tooling
Material/Component specifications
Planning, Capacity reservation
Supply Chain Management, contracts/audits, delivery times
Quality Management
Testing
Training, global HR interactions, Knowledge Communication Center
Global Feedback System
TM
Key parts of Power Transformer technology:

Product design rules physical design and dimensioning rules
Order design methods and tools engineering of specific unit

Manufacturing methods and tools produce actual unit
Product order design Methods and tools for

process & tools product manufacturing
Trans-
Basic product design rules , Transformer Physics former
• Basic Dielectric
• Acoustics
• Transients and 3D Electro-Magnetic Simulations
• Load Losses and Thermal Performance
• Core Performance
• Short Circuit Strength
ABB TrafoStar – Basic Dielectrics
TM
What is the definition of margin?

A margin must be defined towards a probability to a failure
Transformers could be designed for a probability for 1 failure of
1000 units
Probability for an electric breakdown
0,7%
10% over stress means that
0,6% the risk for an electric
breakdown is approximately
Probability for a breakdown
0,5% 3/1000
0,4%
0,3%
0,2%
0,1%
0,0%
0,85 0,90 0,95 1,00 1,05 1,10 1,15
Relative design criterion

TM
Electric breakdown strength is depending on: E [kV/mm]

Material properties
Permeability
Conductivity
Direction of the stress
Stress perpendicular to a surface
Duration
Stress along a surface (creep stress)
The amplitude of the electric stress
The duration of the stress
Service stress
Transients
It takes some time to flash over
Short duration is permitting higher stress than long

AC or DC
In AC fields the stress is governed by the capacitances
In DC fields the stress is governed by the resistivity
TM
Mixing materials Material 1 Material 2
Materials with higher permeability ε1 ε2

are pushing the electric field in to
material with lower permeability E1 * ε1 = E2 * ε2
Oil has lower permeability than
cellulose
Cellulose is stronger than oil
Conductor Conductor
Stress in oil wedge

TM
Reversible Reversible
Irreversible
TM
3-D 2-D, cylindrical

TM
Standardized winding end stacks

which are automatically optimized by
electrical design system
ABB+CEMIG 145kV Transformer
Brazil
Brazil -- ABB+CEMIG
ABB+CEMIG 145kV
145kV Transformer
Transformer
ABB TrafoStar – Core Performance
TM
Generate Accurate Calculations of:

Core loss
Magnitude & harmonic content of exciting
current
Number of cooling ducts in the core
Core hot-spot and core surface hot- spot
temperatures
Using unique Anisotropic 2 D model of
stacked cores
10%
8%
Meas/Calc Stdev [%]

PAST
6%
4%
2%
0%
ABB Plant
10%
8%
Meas/Calc Stdev [%]

6%
PRESENT 4%
2%
0%
ABB Plant
ABB TrafoStar – Acoustics
TM
Accurate calculation of No-load Noise -

level considering:
Core steel magnetostriction characteristics
Core type, core geometry, type of core joints, flux density,
and frequency
Sound radiation properties of the transformer
Accurate calculation of Load Noise

level considering:
Physical properties of windings and insulation
Accurate calculation of core & tank

Resonance Frequencies
Allows accurate prediction of noise-level at design stage
Avoids serious noise-level problems
Accurate Calculation of Frequency

Spectrum
Considering No-load, Load, Current harmonics and DC
magnetization
Identified and developed a number of noise

reduction techniques
Core steel / Tank design / Tank damping / Vibration
isolation
Novel technique for sound reduction in oil
ABB TrafoStar – Acoustics
TM
93 MVA Transformer
Size equivalent to a 250 MVA Transformer
No – Load Noise: 44.7 dBA
Load Noise: 53.4 dBA
Total Noise: 53.9 dBA
[Typical Total Noise: 75 dBA]
65 MVA Transformer
Size equivalent to a 200 MVA Transformer

No – Load Noise at 100% V: 49.6 dBA
Load Noise at 100 % I: 51.6 dBA
Total Noise: 53.7 dBA
[Typical Total Noise: 72 dBA]

ABB TrafoStar Load Losses and Thermal Performance
TM
Load Losses
- Both the total load losses according
to the Contract, and the detailed loss
distribution are thoroughly calculated
- The figure shows an example of the

three loss types in a winding
a) DC-loss (grey)
b) Axial eddy loss (blue)
c) Radial eddy loss (red)
- Well-known loss distribution in windings

and structural parts in active part and tank
dangerous hot-spots are avoided
improved serviceability of the transformer
ABB TrafoStarTM Load Losses and Thermal Performance
Minimize the risk of hot spots in tank and constructional parts

training of electrical engineers
3D Simulation user support network
best practice guidelines
simulation for different transformer designs
ABB TrafoStar - Short Circuit strength
TM
Setting the criteria for permissible mechanical forces at

fault currents
Producing Mechanical Calculation Programs
Follow up on Short Circuit tests
ABB TrafoStar - Short Circuit strength
TM
Mechanical model for

spiraling in 3 D
Simulation
ABB TrafoStar - Simulations
TM
Power Transformer manufacturing

is an ETO business: Design
Elaborated simulation tools are

essential and provide:
Simulation support & design rules
Simulation Know-How
Simulations Development of design tools
Design Tool
Simulation Guide Training

Result
Design Rules
TM
3D Design Verification
• Once the transformer is modelled in 3-D,
the models are used for analysis and
verification.
• Electrical stresses can be mapped and

evaluated
• Electrical clearances are checked.
• Mechanical interferences can be verified.
• Magnetic losses and temperatures in
structural parts can be calculated
TM
Example of Design Tools:

• For Engineering and Development work
Transient
Insulation projects Dielectric
Simulations
Simulations
(WINTRAN) …
(ACE, Simulation toolbox)
SpecTra 5.4
Spiraling forces
Shielded Windings
…
…
Electro-mechanical
Simulations
Electro-thermal (Infolytica/Toolbox/ABACUS…)
Simulations Core design
(Infolytica) …
ABB TrafoStar Standard Documentation
TM
Technical Standards
TM
Method Provisions
TM
Material Specifications
TM
Sigma Cards & Instructions

TM
Test Standards - A set of common Test Standards is used by all plants to

secure that the tests are made in the same way in all ABB test rooms
TM
Newsletters
All new tools or methods are communicated via electronic Newsletters, distributed to
Production and Operations Managers in particular plants. Copies of Newsletters are also
located in commonly available LN database
TM
Uniform Tooling
All standard tools and equipment are described in commonly available in Uniform
Tooling database, including: specification, sourcing information and price of every tool.
We constantly make sure our equipment is up to date and up to recent available
technology.
TM
The follow-up of Metrics is an important

tool to judge performance and to make

benchmarking between transformer
plants
TrafoStar – Design Process
TM
Total Design Process

Design Quality Assurance/ Design
Review
Basic Design
Performance calculation
Design verification
Creation of design elements
Integration of modules
Verification using 3D CAD models

Design for Short Circuit Strength
Design for Transport Forces
TrafoStar – Total Design Process
TM
Order Design Design

Customer clearing review approval Inspections Witness
Quotation Elec Design Mech Design Manufacture Test
Forecast Material supply

TrafoStar – Design Quality Assurance / Design Review
TM
Quotation review
Order clearing (Int and Cust)
Pre-Design
Peer
Test
Approval (Int and Cust)
Pre-Design
Peer
Cross-check
Approval (Int and Cust)
Pre-start intro
Logistics
Inspections
Audit
Test Report
Quotation Elec Design Mech Design Manufacture Test

TrafoStar – Basic Design
TM
Basic Design parameters such as current density, flux

density, winding turns, winding configuration and core
dimensions are all optimized using the TrafoStar computer
design tool Spectra, to achieve minimum Total Operating Cost
TrafoStar - Performance calculation
TM
No Load Losses
Load Losses
Noise Levels
Temperatures
TrafoStar - Design verification
TM
Transients
Voltage distribution
Stress calculation
Magnetic flux
Losses
Temperatures
Forces
AC Test
Electrical stresses
TrafoStar - Creation of design elements
TM
Computer calculated geometry.

Automatic creation of
manufacturing documentation
for Windings, Core and
Clamping structure.
Automatic Winding Exit design
Templates for Tank,
Conservator using pre-defined
modules.
TrafoStar – Integration of modules
TM
Proven design modules are

maintained in a global library.
These are re-configured or
used directly.
#
TrafoStar - Verification using 3D CAD models
TM
2D and 3D electric and

magnetic field analysis
After a 3D model of the transformer
has been created it can be used for
analysis and verification.
Electrical stresses can be mapped
and evaluated
Magnetic flux losses and hot spot
temperatures can be calculated in
structural parts
Mechanical clearances can be
verified.
Implementation Management in huge corporations
Implement Design Technologies from global Design
Development Team
All instructions and revisions available on the corporate network. Notifications are
sent out to keep everyone op to date.
The IT design tools receive yearly releases
Huge staff of design and IT engineers in global centersl
ABB drives a Knowledge Communication Center in Germany where employees are
educated and certified
Secure and spread know-how
Same engineering and production process
Improved contacts between factories
Agenda

Quality Management
Summary remarks
TrafoStar Manufacturing Process
TM
Winding
Winding
Assembly
Core Active Part Final

Core Cutting VP Drying Test Shipping
Building Assembly Assembly
Cleats & Tank

Leads Manufact.
Materials Receiving
Internal Transport
Planning & Scheduling

© ABB BU Transformers - 71 - Core
© ABB BU Transformers - 72 - Core
© ABB BU Transformers - 73 - Winding
© ABB BU Transformers - 74 - Assembly
© ABB BU Transformers - 75 - Assembly
© ABB BU Transformers - 76 - Test
© ABB BU Transformers - 77 - Test
© ABB BU Transformers - 78 - Shipping
Testing of Power Transformers
Dielectric Tests
Seems OK today but “all” people talk about it
Thermal Tests
Accuracy in Cold Resistance ?
Are we measuring ambient correct ?
Is Top Oil well defined ?
Heat Run stability ?
Is winding temperature average enough?
Mechanical Tests
This is the issue Today !!
Are we making Short Circuit tests ?
Agenda

ABB TrafoStrar Technology and Design Consideration
to build reliable transformers
Quality Management
Summary remarks
Short - Circuit Withstand Capability
Why talking about Fault Currents in network today ?
Are Fault Currents affecting Transformers more today ?
Who cares about Mechanical Forces in transformers ?

History – Why SC tests ?
SC tests have been used in different countries
Reasons: Customers didn’t get SC safe
transformers
SC tests introduced 1950 -1960
SC tests have been debated during the years
Many opinions in different countries about the
needs and what one test shows
IEC has edited new revised Standards
SC tests seem very relevant to discuss today !?

Expanding cross-border electricity trade brings network

operations close to their physical limits
Development of wind generation integrates regions
without taking into account available network capacities
Load flows are changing
Network components are ageing
The network operation conditions have changed
New and old transformers will see more severe SC duty

than before
Loss Evaluations are the same or lower since interest

rates have been set higher after the privatization
Material prices (Copper, Core Steel, Oil, Electrical
Board) have increased by a factor of 3 – 5
Qualitative discussion of materials utilization
"
!
How will all those changes affect today's transformer

designs ?
There are now more strong temptations to save active material
and/or go closer to mechanical limits !!??
Are tenders from SC point of view comparable ?
Does the Industry have efficient measures/test

Standards to check the mechanical integrity of such
infrastructure products like Power Transformers ?
New IEC SC standard proposes

SC Tests or
Design review evaluation/verification
IEC proposes typical allowable, critical stresses
Short Circuit Integrity
Electromagnetic forces tend to

increase the volume of high flux
or minimize the magnetic energy
density in the volume
• Inner winding towards

reduced radius
• Radial Forces
• Outer winding towards
increased radius
• Radial Forces
• Winding height reduction
• Axial Forces
Radial forces failure modes:
- Buckling of inner winding
- Diameter increase of outer winding
- Spiralling of end turns in helical winding
Axial forces failure modes:
- Mechanical withstand of yoke insulation,

core clamps and spacers
- Conductor tilting
- Axial bending between spacers

- Telescoping
Unit removed after 15 years of
service due to increased
impedance.
Buckling of inner windings Note: No electrical damages
250 MVA, 400 kV auto

B B Fax Fax
- Gaps in a winding
will create large
variations in the
radial component of
B B Fax Fax the leakage flux
- Consequently, large
axial forces will be
developed
Excessive axial
forces towards
yoke
Damages from
a SC test
Inner winding Outer winding
Spiralling
A tangential shift of
end turns in helical
type windings
Spiralling on the winding of a 370 MVA

GSU transformer during the short-circuit
withstand test.
a) entire outer layer of the LV winding
b) detail of the upper lead exit on the

same layer heavily bent and distorted
TrafoStar Design for Short-Circuit Strength
TM
Design with respect to radial forces:

All windings are radially self supporting
Inner windings are subject to “free buckling”

No radial support
A dynamic phenomenon
Strength is determined by Cu hardness (yield point) and
conductor geometry
Outside windings are subject to tension

Strength is determined by Cu hardness
TrafoStar Design for Short-Circuit Strength
TM
Design with respect to axial forces:

Axial forces are calculated by FEM
Considering axial displacement due to workshop tolerance
Considering axial displacement due to winding pitch when
applicable
Windings are dimensioned for maximum compression forces

Dynamic effects are considered by dynamic factors on the
forces
Winding ends are dimensioned for

maximum unbalance forces and

a part of the maximum compression force (“Bounce Back”)
TrafoStar Manufacturing aspects and accuracy
TM
Strict Manufacturing
Procedures and Tolerances
Short Circuit Strength Verification
IEC gives two options to verify the ability to withstand the

dynamic effects of a Short Circuit, IEC 60076 – 5: (2006-2)
By full SC test at a certified lab, or

By theoretical evaluation of the ability to
withstand a SC event by manufacturer’s
experiences supported by IEC guidelines.
TrafoStar Short Circuit Strength – Verification by testing
TM
300
• 35 TrafoStar
short-circuit
tested 250
1997 – 2008
Sept
200
• 7 with voltage
400 kV or Rated Power MVA
above 150
• 10 rail track
feeder 100
transformers
50
• 3 test failures
32 / 35 = 91 %
first pass rate
0
1997 1998 2000 2001 2002 2005 2005 2007 2008
Short Circuit Tests at KEMA
KEMA numbers published at CIGRE 2006
25 -30% of large transformers (> 25 MVA) fail to pass

initially short-circuit tests.
No common root-cause
16
20 initially not OK
n u m b e r o f tra n s fo rm e rs
n u m b e r o f tra n sfo rm e rs
initially not OK
16 initially OK 12
initially OK
12
8
8
4
4
0 0
25-50 50-100 100-200 >200 20-100 100-200 200-300 300-400 >400
MVA (rated) kV (rated)
From the statistics it seems that there are large

differences in the number of SC test failures among
manufacturers
ABB has done the most number of tests during the
years and have got a large amount of feedback and
experience
ABB is using simple physical rules to calculate forces
and applies modest critical stresses
ABB has stringent manufacturing control on winding
related dimensions and processes.

Short Circuit Recommendation
All transformers are Dielectrically and Thermal tested

Some very few are SC tested
Customers shall consider in tender documentations to

include new 60076-5@IEC:2006
Always to require manufacturers’ stresses compared with their
allowed or critical values, deviations to IEC guidelines to be
commented. Design reviews to be required
AND/OR
Mention in the specs that customer considers the rights to ask for
SC tests one month after the order signature.
ABB Short Circuit Recommendation
What units to be SC tested ?
Important Generator Step Up transformers and Auxiliary units in Power

Plants
Key feeding transformers at Power plant Sub Stations or huge load
centers
Strategic Intertie Transformers
3 winding system transformers (Tertiary), Autos
Transformers with helical windings and axial split winding connections
Series of transformers, one to be taken out
Always Track feeding transformers
Transformers connected to networks known for many faults and high
fault currents
All Power Transformers designs/contracts to be checked by design

reviews acc to IEC 76 Part 5 (2006-02)
TrafoStar Strategic Transformer Components
TM
ABB uses it own manufactured Components

On and Off Load Tap changers
Bushings
Insulation material and Insulation Components
TrafoStar Electrical Components
TM
Bushings
Off-Circuit
Tap Changers
On-Load
Tap Changers
TrafoStar Insulation
TM
Outlets & Moulded

Parts
Active part
Insulation Kits
Winding
Kits
TrafoStar – Kit Insulation Systems
TM
Delivers ready for use

on the winding mandrel
improving…
Productivity
Space utilization
Material flow
Inventories
Capacity
Quality
..and
Complete Active Part kits
Agenda

Short Circuit Safe Design & Manufacturing
Quality Management
Summary remarks
TrafoStar Quality Management System
TM
Quality Assurance in Sales, Project Management,

Technology & Design, SCM, Production and Testing
Continuous Improvement Process
Quality Assurance in Packing, Transport & Site
Assembly
Training and Education
Test Failure Management
Benchmarking
TrafoStar Quality Management System
TM
Quality Assurance in all Business Processes
Project Management
Front End
Supply
Technology Packing & Installation &
Chain Production Testing
& Design Transport Commissioning
Mgmt.
TrafoStar Quality Assurance in Front End
TM
Customer requirement review

Design review process
Concept/pre-design review
Process for Novelties
Novelty Risk Assessment
Process for introduction to manufacturing
Hand-over process
Sales to Electrical Design
Electrical to Mechanical Design and Test

Mechanical Design to Supply Management and
Manufacturing
TrafoStar Quality Assurance in Technology & Design
TM
Designer Qualification
Education
Experience
Design Capacity
Number of designers
Access to expert support
Know-how development
Formal and informal training
Job rotation
TrafoStar Quality Assurance in Supply Chain Management
TM
The level of vertical integration is very different for

different manufacturers
Supplier Qualification Process
Supplier Quality Inspections
Supplier Audits
Supplier Performance Monitoring
Continuous Improvement Process
TM
Example: Radiators
Quality Inspection Cards

TM
AUDIT PROGRAM FOR GLOBAL & REGIONAL SUPPLIERS 2007
1
Supplier
Kawasho
Country
Singapore
Commodity
Slitting of electrical steel H. W. Kropp
Auditors Date Number of Incoming Inspection Claim
2 Cogent UK Electrical Steel H. W. Kropp Audited 2005
3 AK Steel USA Electrical Steel Troy Mullen/US
4 Posco Korea Electrical Steel H. W. Kropp
5 Vicente Torns Spain Copper conductors 40
6
7
MKM
KME
Germany
Germany
Copper Foil
Copper Foil 35 Q1
8 Dahrentrad Sweden Enamel copper wire
30
9
10
Invex
Sam Dong
Italy
Korea
CTC
CTC & Enamelled copper wire
Hakan Wikberg/DE
Audited 2005
Okt
25 Q2
11 De Angeli Italy CTC
12 Metrod Malaysia Copper conductors 20 Q3
13 Metrod Thailand Copper conductors
14 Hydro Aluminum Norway Aluminum Foil 15 Q4
15 Comem Italy Accessories Hakan Wikberg/DE Nov
16 Elmek Turkey Accessories 10
17 Messko Germany Thermometers Hakan Wikberg/DE June
5 Akk
18 MR Germany Tap-changers Troy Mullen/US
19
20
Nynas
Nynas
Belgium
Houston
Antwerp
USA
Hakan Wikberg/DE
Hakan Wikberg/DE
April
Sept
0
21 Albert Maier GmbH Germany Radiator valves Bernt-Ove Hellström/SE Kari Miettinen/SE March
22 TTP India Radiators Audited 2005
G
ta
TA
EM ltec
n
k
ui
t
a.
id
en
se
M
23 Sinjungwoo S. Korea Radiators
R&
El
its
A B C D E F G H I
hw
hm
AS
i
24 ZPREP Poland Radiators Audited 2006
ys
Co
M
Sc
Sc
25 GE SYPROTEC INC Canada Sensors and Monitoring systems
Th
26 Zapel Poland Porcelain Richard Yngvesson/SE
27 Munksjo Sweden Insulation paper Leif Hakman/SE
28 Roechling Germany Pre-compressed wood Leif Hakman/SE
29 Hexion (Bakelite) Germany Epoxy resin mix Rudolf Schutzeichel/DE
Supplier Audit Plan 2007 Supplier Performance Statistics-Example
Supplier Error Statistics 2007 Number of Incoming Inspection Claim per Quarter
80
14.0%
Q1 70
12.0%
10.0% Q2 60
8.0% 50
Q3
6.0% 40
Q4
4.0% 30
2.0% Akk
20
0.0%
10
0
Sc R
G
c
TA
ta
n
k
a.
ui
t
id
lte
en
se
M
R&
El
its
hw
A B C D E F G H I J
hm
AS
i
-06 Average Q1 Q2 Q3 Q4 -07 Average

ys
M
Co
M
Sc
Th
EM
Supplier Performance Statistics-Example Supplier Performance Statistics-Example

TrafoStar Manufacturing Process
TM
Winding
Winding
Assembly
Core Active Part Final

Core Cutting VP Drying Test Shipping
Building Assembly Assembly
Cleats & Tank

Leads Manufact.
Materials Receiving
Internal Transport
Planning & Scheduling

TrafoStar Quality Assurance in Production
TM
3 5 6
2
7
TM
1) Winding Process Control

IC1: Winding
IC2: Conductor Material

IC5: Brazing Control Sheet

IC4: Preparation/Winding Assembly
Inspection of coils prior to fitting outer
wraps
Skills
IC3: Winding Insulation Material Cp1 Elec. Des, Mech.Des, QC, Manuf.
TM
Winding Process Control

Windings Control Point 1 in
•Shielding ring dimensions Inspection Card 4
6 sigma measurements
in the manufacturing of
windings!
•Former cylinder
•Inner oil ducts dimensions
•Winding radial height
•Winding height
•Winding exit protrusion
•Winding exit lead stability
Reduction of process variation

© ABB BU Transformers - 120 - Inspection and Test Plan controlling right performance of final tests
TrafoStar Continuous Improvement Process
TM
Cost of poor Quality (COPQ)

Every Power Transformer Factory is committed to integrate the
COPQ process into its Continuous Improvement Process.
Installation Support
Sales Proj.Mgt Engg. Supply Manufact. Transport Commissioning
Warranty
Processes
TrafoStar Training & Education
TM
Training and Education is key in the approach for operational Excellence. Highly skilled and motivated
employees are a precondition. Employees must be given continous education and training.
Operational Excellence Program (OEP)

The OEP Program helps to develop Resources,
increase competences and break down barriers.
Quality School
Every Power Transformer Factory has a Quality School with
an education program and a dedicated Classroom. The
contents of the Training should be adapted to the maturity
and existing knowledge and specific needs. Objectives of the
Quality School are:
Reinforce training and education in all key areas
Secure good knowledge management and secure technical
competence
Estabish a formalized communication channel to all employees
Knowledge Communication Center (KCC)

The KCC is a channel between the factories for
Benchmarking and the exchange of Best Practices
The KCC increases the competence throughout the

corporation and within the Factories, encourages Teamwork
and motivates employees. Knowledge Communication Center - KCC
TrafoStar Test Failure Management
TM
The worldwide analysis of test failure is very critical !!

The data provides the opportunity to learn,
analyze and prevent recurrence. This helps us to continuously
reduce our test failures and to reduce costs associated
with poor quality. It also helps us to identify gaps in our
guidelines, method provisions or work instructions.
Rules for Reporting and Management of Test Failures are

described in an instruction. At least 3 times per year, a team
of experts analysis all Test Failures on a global base and
defines corrective actions.
TrafoStar Benchmarking
TM
Having global manufacturing footprint with 14 factories worldwide.

Benchmarking and best practice implementation is driver for continuous
improvement
Process OK or
improvement
completed
On-going
improvements
Gap to be
closed
Common Improvement
TrafoStar Platform – Global Feedback System
TM
Measured Core Losses

All those performance data
Measured Load Losses
goes back to the Product
Measured Sound levels Platform for maintenance,
Measured Temperatures improvements
and further developments !!
Measured Impedances
Measured Pd An organization of 50 global
engineers in 5 plants and
Short Circuit Tests
CRC labs
Test Failures
Field Failures
Non conformances reports of key processes

A number of Key Performance Factors for key processes in an
advanced global Operational Excellence structure
Agenda

Short Circuit Safe Design & Manufacturing
Quality Management
Summary remarks
Risk mitigation in the Power transformer procurement chain
Recommendation for Customers

1. Most important specification parameters
Specification must be well structured and clearly written
Specify all requested functions rather than solutions
Avoid hidden requirements easily overlooked by engineers on
the manufacturer’s side
Eliminate all requirements which complicate the transformer
Specify the dielectric test levels with sufficient margin
Short Circuit Tests ?, prolonged Heat Run Tests ?
Do not exclude design solutions because this may force a
manufacturer out of his standards

Recommendation for Customers & Suppliers

2. Basic important issues in a Design Review
Check the design of the transformer for compliance with the
service requirements
Identify novelties and deviations from proven solutions
Ensure that all vital functions are verified by testing
Verify that all important stresses vital for the long term service
reliability have been calculated and are within proven and
experienced limits by the manufacturer.
Verify that the design is a result out from a well documented
engineering system and accurate, consistent engineering
TM
tools/systems (ABB TrafoStar )
Recommendation for Suppliers

3. Material and Component Suppliers
Ensure high quality material suppliers by Supplier Qualification
Clear Material and Component Specifications ref to IEC and
ANSI Standards
Continuous Improvements
Recommendation for Suppliers

4. Consistent Delivery Process and Quality System
Well defined total process flow
All manufacturing processes, equipments, tools are documented
in Method Instructions
Quality assurance in
Technology & Design
Supply Chain Management (SCM)
Production
Testing
Packing & Transport

Installation & Commissioning
Continuous Improvement Process guided by a structured
feedback system from test measurements, field experience
TM
A global Business Concept……

Basic Product Design Rules, Transformer Physics
Product order design process & IT tools, Design Modules, Global
Release system
Methods and tools for product manufacturing
Method Provisions/Instructions and Common Tooling
Material/Component specifications
Planning, Capacity reservation
Supply Chain Management, contracts/audits, delivery times
Quality Management
Testing
Training, global HR interactions, Knowledge Communication Center

Global Feedback System
For long term reliability

TM
….for long term Reliability
Thank you for your attention !!


Abb+power+transformers+for+grid +reliability PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Abb+power+transformers+for+grid +reliability PDF

Hochgeladen von

Copyright:

Verfügbare Formate

High Quality Power

Transformers for Grid

Process Plant Grid Process Drive & Building

Primary Electrical Industrial Motors &

The efficiency of the transformer is not the major purpose, it is to

And the “Gear Box” helps you

Engineering To Order business Concept

From Unique Specification

This Tutorial will describe some very important aspects in the

Large Power Transformers

Cellular layout, Batch HV Switchgear

ETO ATO STD

Market Background: The biggest Change since ever

1994 – 2004: About 500.000 – 600.000 MVA/ year

2004 – 2007: From 750.000 to double numbers

2008 – 2015: with base demand form Asia (China,India),

Huge Capacity Demand issue

Material Prices increased 3 -5 times 2005 – 2007 !!!!

Low or Stable Loss evaluations

GNP development in old and growing countries

0 5000 10000 15000 20000 25000 30000 35000 40000 45000

350 Loss per year,

Energy value 1 kW at 0,02 /kWh, 8600 h/Yr,

Assume 3% energy value increase/Yr

Example: 1 kW losses in 30 years 8600 hours per year

Interest 0.02 0.03 0.04

8% 2100 3150 4200

12% 1550 2300 3100

Examples above are for No Load losses (=8600 h/Yr)

and are therefore a varying % of the full year value

Stable values in customer specifications recently

Core and Conductor mass

Higher materials prices

Losses are primarily defined by the relation between materials costs

Increased costs of transformers

Loss evaluations determined by

The Electrical System Industry was working rather well up to the

What could happen?

supporting or making bad decisions

Decisions made in the procurement process determine the future

How has this developed?

What do we need to do?????

order, consistency, experience, track records

Power Transformers are known as very Reliable

Will the Reliability numbers stay the same ?

Market Background: The biggest Change since ever

The ETO Business Process of Power Transformers

Continous Improvement and R&D

Engineering To Order business Concept

Requires on the Manufacturing side

Rigid well proven Technology

Common Technical Standards

Common IT design tools/software

A global Business Concept

Key parts of Power Transformer technology:

Order design methods and tools engineering of specific unit

Product order design Methods and tools for

What is the definition of margin?

Relative design criterion

Electric breakdown strength is depending on: E [kV/mm]

Short duration is permitting higher stress than long

Mixing materials Material 1 Material 2

Materials with higher permeability ε1 ε2