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Transforming the future of energy

ABB Transformer Days
Vadodara

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11-12 APRIL, 2019

Technology trends in Transformers and Reactors

Jan Hajek
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Agenda

Green Transformers
Digitalization
Shunt reactors
TXpand™ – A rupture resistant transformer solution
Maintenance free transformers
HVDC – taking new steps in technology
Phase Shifting Transformers
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Green Transformers
Ester Filled Power Transformers
Synthetic Ester Natural Ester
• Suitable for breathing & sealed transformers • Used in sealed transformers (poor oxidation stability)
• Suitable for cold climate • Not recommended to be used where the ambient
• Low maintenance temperature goes below – 10°C
• Readily biodegradable • Require more cooling equipment (higher viscosity)
Application

• More costly than natural ester • Fully biodegradable

• Fire class >300 C • Fire class >300 C
Dense populated urban areas Offshore installations Wind and solar power installations Mobile emergency units

April 22, 2019 Slide 3

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Green Transformers
Ester Filled Power Transformers

ABB References
o For more than 20 years ester fluids are used in ABB transformers
o Over 10 000 distribution transformers globally sold or retrofitted with
ester liquids since 1999
o More than 300 power transformers produced and in operation
o Up to 400 kV voltage class produced and ready for higher levels

World largest single-phase 420 kV ester transformer

April 22, 2019 Slide 4

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Green Transformers
Low loss transformers - Magnetic Stray Flux Management
Plain magnetic steel Cu shielding of walls and Optimized location,
tank bottom thickness and coverage
Optimization of magnetic stray Other Eddy Loss 98 kW 74 kW by magnetic tank shunts
flux management using 3D FEM. 56 kW

Less complex solutions like tank

shunts vs copper lining may
perform even better.
A load loss reduction of 18 kW at a
capitalization of e.g. 1000 $/kW
represents a value of 18 k$.

April 22, 2019 Slide 5

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Digitalization for online monitoring
Transformer Intelligence eco system

4 - Together
Collaborate, advice, transform, re-think
Expert
Services Service Oil Engineering HV Training Consultancy
Agreements Analysis Studies Testing

3 - Do better
Asset
Management Optimize, simulate, predict, automate
Solutions
ABB Ability™ Ellipse® APM
Asset Performance Management

2 - Do more
Monitoring and Automate, monitor, control, secure, manage
Diagnostics
CoreSense Hub CoreTec 4
software Transformer Monitoring
Platform

1 - Know more
Sensor Technologies Assess, connect, store, inform, measure

CoreSense CoreSense M10 eOTI eWTI eOLI eBR ePRD eSDB

DGA DGA Liquid Winding Liquid Level Buchholz Relay Pressure Relief Self Dehydrating
Single Gas Multi-GAs Temperature Temperature Device Breather

© Copyright 2019 ABB AG ABB CUSTOMER CONFIDENTIAL.

April 22, 2019 Slide 6 The data and information discussed and identified in this document are considered ABB Customer Confidential and are not to be reproduced,
used or disclosed to third parties without written permission.
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Shunt Reactors
Variable Shunt Reactors: Application Windparks

§ Unpredictable and fluctuating active power exchange

§ Grid codes specify the amount
of reactive power exchanged with the main grid
§ The variations in reactive power consumption with varying
wind-power production require control:
- SVC
- Regulated shunt reactor
- Switched shunt reactors
§ VSR the most cost effective way to provide this
controllability
§ The possibility to make VSR with high ratings (300 Mvar,
3ph) enables to make cost effective high voltage AC cable
transmission instead of HVDC

April 22, 2019 Slide 7

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Shunt Reactors
Variable Shunt Reactors: Design and Technology

§ Maximum feasible regulation ratio, R, varies with rated voltage

- Grey: “Traditional”, one OLTC (40% at 400kV 0.6

- Black: “Extended”, one OLTC (60% at 400kV)

- 80% regulation range at 400 kV can be achieved by using
0.5
3 OLTCs per reactor and complex winding configurations (very
costly designs compared to 40%-60% regulation range)
§ Available ratings 0.4

- Up to around 525 kV
- Up to around 300 Mvar 0.3
110
§ A new and advanced application based on proven technology 525
- Same OLTC as in transformers, same number of steps
- Main- and regulation windings similar to transformers 0 100 200 300 400 500
- Requires high design competence

April 22, 2019 Slide 8

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TXpand™ – A rupture resistant transformer solution
Probability & consequences

India transformer blast headline news1

– 2 injured in transformer explosion receive 40% burns, India,
Ghaziabad, May 2017
– Transformer explosion shuts down power plant in Tuticorin,
India, Chennai, January 2017
– Two transformers catch fire and leave Bhadrak in darkness,
India, Odisha, June 2017
– Three Maharashtra utility officials suspended over fatal
transformer blast, India, Maharashtra, December 2016
– Transformer blast at Bawana PP affects power supply in
Delhi, India, New Delhi, March 2015
– Transformer blast forces shutdown of Kinnaur power station,
India, Himachal Pradesh, January 2015
V.N. Nguyen, P. Zhao and M. Foata, Transformer Rupture R&D [Online]. Available: M. Foata and G. Khouzam, “Power Transformer Tank
http://transformerscommitee.org/subcommittees/power/TankRupture/F06- Rupture”, Canadian Electrical Association, Toronto,
TankRuptureHQPerspectives-1.ppt March 1994

1 Transformersmagazine
© Copyright 2019 ABB. All right reserved.
April 22, 2019 Slide 9
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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TXpand™ – A rupture resistant transformer solution
Video

© Copyright 2019 ABB. All right reserved.

April 22, 2019 Slide 10
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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TXpand™ – A rupture resistant transformer solution
Expertise available and offered for risk reduction

North America Europe Asia

Over 70 units delivered to Canada (Hydro 1Ph, 570 MVA 400/24 kV for EDF during 3-ph 150 MVAr/400 kV Shunt Rector for
Quebec main customer and development testing at ABB Transformer factory in Singapore Power during testing at ABB
partner, Hydro One, BC Hydro and to the Cordoba, Spain Transformer factory in Chongqing, China
States (Dow Chemical, PSE&G)

Proven design and production experience with ~ 50 designs and 90 units delivered

© Copyright 2018 ABB. All right reserved.

April 22, 2019 Slide 11
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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Maintenance free transformers
Self dehydrating breather - SDB series

• Regeneration by heating up the silica gel à water

evaporates and silica gel is renewed
• Two tanks working alternatively
• Complete isolation between the tank under
regeneration and the transformer conservator
• Regeneration can be condition-based or time- SDB 10/15/30/40 SDB 10C/12C/14C
based
• Condition-based: humidity is assessed by a load
cell, which triggers regeneration (typically above
60MVA or 40t of oil
• Time-based: regeneration is started at pre-set
time interval, based on environmental data (for
on-load tap changers or transformers below
60MVA or 40t of oil)

April 22, 2019 Slide 12

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Maintenance free transformers
Self dehydrating breather values

It is a unique solution to guarantee that any moisture can get into the transformer conservator with two tanks that work alternatively:
complete isolation between the tank under regeneration and the transformer conservator
It increases reliability and reduces total cost of ownership

Continuous online monitoring Flexible connectivity towards SCADA systems via

Modbus RTU and Analogue output 4-20 mA
Easy installation – no maintenance – possible
to retrofit
Operational Cost Saving
6 months data storage Cost effective to monitor the transformer’s condition
No silica gel visual inspection, replacement, disposal
Complete isolation between tank in
regeneration and conservator

Status at-a-glance with colored LED interface No environmental impact for silica-gel disposal

April 22, 2019 Slide 13

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HVDC – taking new steps in technology
ABB HVDC transformers is pioneering the future and has solutions for all applications

1954

Gotland HVDC transmission link,

first commercial HVDC project,
20MW and 100kV DC

2018
Changji – Guquan +/- 1100kV DC
UHVDC transmission link,
12.000MW and 1100kV DC

April 22, 2019 Slide 14

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HVDC Transformers - North East – Agra
Multiterminal at 800 kV DC - will supply electricity to serve 90 million people

Customer Powergrid Corporation in India Ltd

Customer needs • Transmission of 6,000 MW

hydropower from the north-eastern
parts of India to the region of Agra –
over 1,700 km
ABB’s response • Turnkey 9000 MW converter
capacity, including a 2,000 MW
redundancy, MW ±800 kV UHVDC
system
• Multiterminal – three converter
stations
Customer benefits • Low losses – 6 %
• 6,000 MW converter capacity,
providing redundancy for loss of one
converter with retained transfer
capacity
• Effective use of right-of-way
Commissioning year • 2017
Number of • 60
transformers

April 22, 2019 Slide 15

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Enabling power transmission with inteconections in India since 1989
A long term partner for greener, smart and stronger grid
Vindhyachal , a 500 MW Vindhyachal back-to-back HVDC station in the central
Indian state of Madhya Pradesh interconnects the 400 kV AC networks of the
Northern and Western regions Commissioning year: 1989
Rihand – Delhi Power from Uttar Pradesh is transmitted to Delhi meeting the
urgent need for power in India's northern region., with a rated capacity of 1,500
MW at ±500 kV Commissioning year: 1990
Chandrapur – Padghe a 500 kV HVDC Bipole link feeding Mumbai with 1,500 MW
from a Chandrapur in the eastern part of Maharashtra State 752 km away
Commissioning year: 1999
Vizag II a 500 MW back-to-back HVDC link in southern India to enable increased
power interchanges between eastern and southern parts of the country
Commissioning year: 2005
Raigarh – Pugalur 800 kV, 6,000 MW Raigarh - Pugalur UHVDC link, which will
transmit power from central India to around 80 million pepole in the south, over a
distance of 1,830 km. Commissioning year: 2019

April 22, 2019 Slide 16

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Phase Shifting Transformers
Load flow control with Phase Shifting Transformers

• The transmission grid is a very complex machine.

• Different lines are picking up the load based on physics
• Some lines are heavy loaded others still have capacity
• Better utilization requires control of power flow

• ABB Phase shifting transformers are a economical way control

your power flow

April 22, 2019 Slide 17

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Phase Shifting Transformers
Power flow control - Optimization of load sharing and transmission capacity

Two synchronous systems.

V S , fS V L , fL
Transmission lines with different impedances e.g. overhead /
cable or 400 kV / 110 kV.

G P L
Transmission angle difference fS - fL drives power flow with
unbalanced load sharing of lines. G
A heavy loaded line may limit the total transmission capacity of
G L
the corridor.

PST impose an additional circulating current, thus improving L

the balance of power flows.
L L
The total transmission capacity increases

P G

April 22, 2019 Slide 18

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Summary
Transformers for a sustainable world

• Green transformers
• Esters, lower losses
• Fire safety
• Digitalization
• TXpand™ – A rupture resistant transformer solution
• Reduced maintenance
• Self dehydrating breather
• Vacuum tap changers
• RIP bushing
• UHVDC
• Up to 1100 kVdc
• Up to 12 GW
• Phase shifting Transformers
• Power flow control

April 22, 2019 Slide 19