review

Transformers
special report

55

—
06 – 27
28 – 45
Smarter
Greener
23
46 – 63 Stronger

18
2 ABB REVI EW

37
Transformer energy efficiency

Transformers to meet special needs

22
Transformer asset
management

51
Ecological oil-free transformers

28
 SP ECI AL R EP OR T | T R AN S FOR ME RS 3

—
05 Editorial

—
Smarter
06 TXplore robot inspects transformers

46
13 ABB Ability Power Transformer
18 ABB Ability TXpert
22 Transformer asset management
Quality power with shunt
reactors —
Greener
28 Ecological oil-free transformers
33 Eco-efficient ester liquid transformers
37 Transformer energy efficiency
42 Transformers in renewable applications

55 —
Stronger
UHVDC and UHVAC 46 Quality power with shunt reactors
transformers 51 Transformers to meet special needs
55 UHVDC and UHVAC transformers
60 Transformers for Indian Railways

—
63 Imprint

06
TXplore robot
inspects transformers
—
In an increasingly digitalized world,
ABB is at the forefront of driving
the energy revolution. Technologies
like transformers are shaping a
stronger, smarter and greener grid.

ABB Ability™ - based power and

distribution transformers are
allowing power grids, industries,
infrastructure and transport
sectors to be managed with
higher reliability, safety,
efficiency and intelligence.
 SP ECI AL R EP OR T | T R AN S FOR ME RS 5

—
E DI TO R I AL

Transformers
Dear Reader,
For over 100 years, ABB has pioneered the transformer
technology that continues - now even more than ever - to play a
pivotal role in the running of the power grids that work day and
Markus Heimbach
night to keep society going.
ABB Transformers
Managing Director
Transformers business unit
Transformers can be found wherever electricity is generated,
transmitted, distributed and consumed. Their primary function
is to “transform,” or, adapt, voltage levels - stepping up for
long-distance high-voltage transmission - and stepping down
for distribution to consumers.

The grid continues to increase in complexity, integrating more

Stephane Schaal
ABB Transformers
clean and renewable energy than ever before, while balancing
Technology Manager
Transformers business unit new loads, like electric vehicle charging and data centers,
inspiring innovative transformer technology from ABB engineers.

Quantum leaps in transformer technology have been taken by

ABB in the areas of digitalization, asset life-cycle management,
energy and eco-efficiency, ultra-high-voltage DC and AC
applications, and transformer resiliency providing protection
from extreme weather events and physical security.

Please enjoy this report on the latest transformer innovations to

see why ABB is a partner of choice for enabling a smarter,
greener and stronger grid.

Let’s write the future together.

Markus Heimbach Stephane Schaal

Managing Director Technology Manager
Transformers business unit Transformers business unit
6 ABB REVI EW SMARTE R

—
S M AR TER

ABB’s TXplore robot

redefines transformer
inspection
ABB’s new validated robot inspection system, TXplore, is tailored to the
complex oil-filled transformer environment. Rigorous testing provides
overwhelming support of robotic over human internal inspection in terms
of cost, safety and digital leverage.

Gregory Cole
Harshang Shah
ABB USCRC Mechatronics
and Sensors Bloomfield,
CT, United States

gregory.a.cole@
us.abb.com
harshang.shah@
us.abb.com

Craig Stiegemeier
ABB Transformer
Remanufacturing and
Engineering Services
St. Louis, MO,
United States

craig.stiegemeier@
us.abb.com

Jamie Stapleton
ABB Transformers
Business Unit
Worthing, United
Kingdom

jamie.stapleton@
gb.abb.com

01
 SP ECI AL R EP OR T | T R AN S FOR ME RS T XPLORE ROBOT INSPE C TS TR ANSFORME R S 7

—
01 TXplore remotely
driven robot uses
propellers and buoyancy
control to navigate freely;
light sources and cameras
secure quality images.

—
02 Oil-immersed power
transformer can be
taken out of service and
inspected without the
need to drain the oil.

—
03 An in-situ internal
inspection of a
transformer showing the
robot pilot, equipment
manager and the robot.

02

Despite the use of non-invasive condition With over 200,000 projects completed, ABB is a
monitoring techniques to determine possible global leader in the production, monitoring and
faults and avoid adverse failures in oil-immersed maintenance of transformers. Much thought
transformers [1], there are routine and emergency has been devoted to internal inspections of
situations that require costly internal inspections these devices with the aim of lowering capital
with major risk to both transformer structure and costs, improving the effectiveness of inspection
human inspectors. Nowadays, utilities perform data, lowering the safety risk to humans and
internal visual inspections following lightning transformer assets and reducing downtime.
strikes and when there is the need to isolate
the exact location or severity of a fault, multiple In late 2012, ABB proposed a concept to develop a
faults or complete a planned repair [2]. remotely driven robotic system to operate reliably
and effectively within the toxic and fragile
In cases such as these, the mineral oil must environment of a transformer unit and eliminate
be removed and stored so that a highly skilled the need for human inspection. To be a viable
transformer inspector can enter the hazardous option for utilities, the remotely driven robotic
enclosed space of the transformer tank, risking system must inspect the transformer, navigate
damage to both the inspector and transformer. The effectively and maintain the integrity of both the
inspection process also requires medical teams and transformer and its oil. High quality visual images
other expert personnel to be present. Commonly, and data must be collected and transmitted
during inspections, transformer downtime is three to external systems for evaluation. A multi-
days – seen overall, internal human inspection has disciplinary team of scientists and engineers
high human and capital costs. from ABB was formed to design such a system.
8 ABB REVI EW SMARTE R

Equipment manager Device inspection

Robot pilot

03

The result of their efforts is the submersible TXplore is designed to navigate and collect
transformer inspection robot now known as high quality inspection data safely and easily.
TXplore →1. The photos and videos can be produced without
becoming stuck or damaging the transformer
Technical development and validation of TXplore or its components →4. The tetherless robot is
Power transformers are expensive yet critical shaped and sized to balance ease of navigation
machines that are designed and manufactured with robustness, which allows the submersible
using complex engineering and construction robot to inspect all areas of interest such as
methods to deal with stressors encountered bushings, leads, tap changer, core top, core
during their lifetime - eg, overvoltage, short- support and insulation and more. Additionally,
circuit currents, high temperature of windings redundant safety systems and extensive thermal
and contaminants. The circulation of insulating and environmental safety testing verify the
oil allows heat to be removed from the windings TXplore system is ready to inspect transformers
and is crucial to the health of the transformer. under a variety of demanding conditions.
Any object, including a robot, which enters the
transformer must preserve the integrity of the With the preservation of mineral oil quality of
oil. For this reason, ABB designed the entirely primary importance, the robot construction is
new TXplore system →2. optimized to leave no detectable footprint –
either chemical or physical – as it operates within
TXplore system design the transformer. The robot’s outer shell is made
The newly designed inspection system for of a high performance plastic that minimizes the
de-energized transformers only requires two risk of electric coupling and structural damage
personnel once the unit is prepared: a top-side to the transformer while allowing the craft to
equipment technician to setup and manage the operate safely in demanding environments at
robot and a robot pilot to navigate, gather data high temperatures.
and communicate with experts and customers →3.
The equipment operator is responsible for the
installation tasks and placement of the robot into
or out of the system →3.
 SP ECI AL R EP OR T | T R AN S FOR ME RS T XPLORE ROBOT INSPE C TS TR ANSFORME R S 9

—
03 An in-situ internal
inspection of a
transformer showing the,
robot pilot, equipment
manager and the robot.

—
04 Examples of the
results given by
numerical simulations.

04a Temperature
distribution.

04b Velocity streamlines.

04c Temperature
isosurfaces.

—
05 Temperature
distribution along
conductor. Comparison
of 3-D numerical model
and heat run test results.

04

High quality inspection images can be made on- Human versus robot
site and transmitted worldwide. Redundant radio The safety of the people responsible for
systems ensure that navigation can continue even inspection and the integrity of the transformer
when communications are impaired. The unique are paramount and the system design ensures
system architecture allows future technologies optimal navigation and communication ability.
to be added as advances are made and end user A comparison of the proposed workflow to
demand grows →5. conduct a robot inspection with that of a
traditional human invasive inspection indicates
In this way the TXplore system provides digital this →6. TXplore navigates in the oil, thereby
leverage. eliminating the need for processing equipment
eg, tanker trucks, processing and vacuum filling
rigs or personnel to remove and store the oil – a
common practice during human inspections.

Radio interface box

Submersible
Primary
radio

Processing

Actuators

Backup Operator station

radio • Piloting
Safety lift
• Image and video storage
• External communications

Sensors Vision

05
10 ABB REVI EW SMARTE R

25 100000

20 80000

15 60000
Disconnect

10 40000
Drain
Cost, time and personnel

5 20000

0 0
Human D1816 1 mm Total gas
inspection
2500 1200

2000 1000
Vacuum
800
Disconnect 1500
Fill 600
Inspect 1000
400
Reconnect Reconnect 500 200

0 0
Traditional internal Proposed ROV Total particles 10 mL Total particles 1 mL
inspection inspection

06 07

And, because the robot enters the unit instead The impact of the robot prototype on the mineral
of a human, no medical or environmental safety oil was evaluated in an elegant way: Two tanks
team is required during inspection. Remarkably, of oil were prepared, one with a volume of highly
only two employees, a robot pilot and a top-side contaminated oil (taken from a field transformer)
equipment operator, are needed on-site during and one with 100 gallons of clean oil. A baseline set
a TXplore inspection, once the transformer has of measurements were made for volumes of oil.
been prepared →3. Overall, robotic inspection can The robot was then placed in the tank of highly
be completed in less than one day with only two contaminated oil for 6 hours. The robot was
employees – a dramatic reduction in personnel, removed and re-processed using ABB’s validated
time and cost compared to a standard human cleaning and site preparation techniques.
inspection, which requires a large team and lasts
three or more days. Afterward, the remotely driven robot was placed
in the clean oil tank for an extended period. At this
Validation point samples were retrieved from this oil tank
Whole system and subsystem investigations and analyzed to ascertain whether or not the robot
were undertaken in the laboratory and at testing contaminated the second oil tank. The results were
facilities before pilot studies were conducted in then compared to the baseline results.
near-real-world installations. Tests were performed
for leakage, navigation capability, temperature and
chemical stability and possible oil contamination.
Prototypes were tested for leakage at various
temperatures for more than 96 hours under
pressure conditions that reached up to more
than twice the expected field pressures. Spatial
and depth navigation abilities were assessed in
seven different oil-filled tanks to determine robot
stability and to ensure that visual system could be
stabilized to support high quality images.
 SP ECI AL R EP OR T | T R AN S FOR ME RS T XPLORE ROBOT INSPE C TS TR ANSFORME RS 11

—
The contamination level of the oil (from clean and Case study
06 Current human
workflow versus new to practically black and highly contaminated Robotic inspection test results have been
proposed robot
with particles present) →7, temperature (from -5 °C reaffirmed by transformer inspections conducted
workflow for a
transformer inspection. to 27 °C) and the impact of the robot on the oil in 2016 at the St. Louis power transformer factory
were examined. The findings show that the oil on production transformers and on a critical
—
07 An example of maintains its integrity throughout the inspection substation that provides power to the high-
oil contamination
process if procedures are followed. voltage test facility →9.
test results showing
no particulate
contamination following
introduction of the robot
It is known that remotely operated vehicle (ROV) Additionally, American Electric Power (AEP),
in the oil-immersed propulsion systems often generate bubbles a large utility in the United States, viewed a
transformer.
through cavitation. Design elements were demonstration of a remotely driven robot
— carefully included to prevent this. For example, inspection of a tank at ABB Customer World in
08 Images taken by
TXplore during an
the propulsion system of the robot can be a March, 2017. AEP approached ABB about the
inspection of a 20 year source of cavitation. A stroboscopic investigation possibility of performing an inspection of one
old transformer that
had tripped off line.
of the propeller was performed at all possible of their large power transformers that would be
08a The customer rotational frequencies to evaluate this process. taken out of service.
thought the source of
failure could be the tap
There were no gas bubbles detected, even in
changer but TXplore areas likely to act as cavitation nucleation sites During the summer of 2017, ABB’s development
image shows this is
not the case.
such as the leading edge of the propeller or the team brought the robot and control and recording
08b TXplore image shows gap between the propeller and shroud. equipment to the AEP station and successfully
clearly that a disk to disk
failure was the source of
performed an internal inspection of a transformer
the problem. Pilot system inspections were conducted under that was more than 50 years old without the
various conditions and temperatures; the result need for any oil handling. TXplore successfully
was a dramatic reduction in inspection time inspected the transformer and ABB could verify
to less than two-hours. Clear and accurate the benefits of effective mobility of the robot,
images were taken →8, recorded and provided visualization ability and collaboration potential,
to the customer in the form of a detailed both remote and local, as well as the efficient
report that documents the inspection. All overall operation.
relevant information could be shared with
experts worldwide in near-real-time. This
capability ensures customer will have the right
diagnosticians to deal with any transformer
issues encountered. TXplore inspection allows a
return to service with confidence that the future
plan of operation or repair of the transformer
asset can be maintained.

08a 08b
12 ABB REVI EW SMARTE R

—
09 The Txplore
Product Launch Nevertheless, the most significant advantage
transformer inspection Prototype data and performance information of using a remotely driven robot to navigate
process is shown.
09a A demonstration of were reviewed following these pilot inspections. the oil is the ability to visually map the entire
a remotely driven robotic As a result, design modifications were made to interior of the transformer unit and remotely view
inspection within an
oil-filled tank. improve reliability, longevity and to enhance the the inspection results safely without requiring
09b The inspection ability of TXplore to perform inspections in hot oil. humans to enter the enclosed space of the
utilizes a top-side
equipment technician to The first production robots were initially tested transformer. ABB takes this advantage one step
set-up and manage the and completed trial inspections in February 2018. further and will integrate the robot and system
inspection and a robot
pilot to navigate. The robot was introduced to the market at the into the ABB Ability Platform. The forthcoming
09c TXplore is safely Hanover Trade Fair and initial orders for pilot digital solutions and services will be built around
placed into the oil-filled
transformer by a top-side trials of the final design were received March 1. the inspection data.
equipment technician. Production service inspections are scheduled to
09d TXplore navigates
freely and safely within begin in May 2018. From this time forward robot By revolutionizing oil-immersed transformer
the oil- immersed production will allow global ABB to perform inspection, not only has ABB anticipated the
transformer without
risk to employees. inspections on any oil-filled transformer large customers’ desire to improve safety and lower
enough to accommodate the patented robot. costs, they have transformed inspection data
Production will continue to enable a fleet of robots gathering and management to provide digital
— to support ABB service operations. leverage to customers and that all important
References
[1] L. Carlzon, competitive edge. l
A. Fazlagic, P. Lorin, The future is safe and digital
Service Handbook for
Transformers, P. Boss, Robotic inspection eliminates the need to bring
G. Frimpong, and in heavy equipment and reduces the size of
M. Turner, eds. ABB, 2007.
[2] H.C Sun, Y.C. Huang, the supervisory team, dramatically shortens
C.M. Huang, “A review of downtime, usually to under a day, and is cost-
dissolved gas analysis
in power transformers” effective. Moreover, the ability of the system to
Energy Procedia, volume provide a comprehensive inspection data set
14, pp. 1220-1225, 2012.
make robotic inspection beneficial.

09a 09b

09c 09d
 SP ECI AL R EP OR T | T R AN S FOR ME RS ABB ABILIT Y POWE R TR ANSFORME R 13

—
S M AR TER

The ABB Ability Power

Transformer sets new
industry standards
With its standard digital capabilities, the ABB Ability Power
Transformer provides a future-proof platform that delivers
health data and actionable intelligence. Users gain access
to ABB’s digital ecosystem and can thus optimize reliability,
availability and productivity while improving capital efficiency.

Helmut Bockshammer The power landscape is predicted to change more their efficiency and productivity in order to remain
ABB Transformers
Ratingen, Germany in the next 10 years than it has in the last 100 [1] →1. competitive in their respective fields.
This is mostly due to the change in generation mix,
helmut.bockshammer@
de.abb.com where the integration of renewables and distributed Power transformers are critical elements in the
energy resources is having the double impact of electrical grid infrastructure that are impacted by
Andrew Collier ABB
Transformers adding volatile supply sources while causing a these changes in the grid. While nobody can predict
Bad Honnef, Germany decline in traditional high-inertia generation such the exact effects on the typical power transformer
andrew.collier@ as coal. This volatility will increase further, on the over its lifetime of 30 to 50 years, it is certain that
de.abb.com demand side, as e-mobility plays a greater role in changing demand patterns will result in a more
Miguel Cuesto the near future. At the same time, many utilities and dynamic loading of the transformer, which can be
ABB Transformers industrial companies are under pressure to increase detrimental to its remaining life →2.
Cordoba, Spain

miguel.cuesto@ 01
es.abb.com

—
01 The ABB Ability
Power Transformer
delivers health data and
actionable intelligence
so users can optimize
reliability, availability
and productivity while
improving capital
efficiency.
14 ABB REVI EW SMARTE R

Temperature (arbitrary units)

Digital power transformer platform
and ecosystem
The technical development of the AAPT was based
on a future-proof modular solution. The platform
Hotspot temperature
Oil temperature
concept covers everything from the standard
package with electronic temperature monitoring
Time (arbitrary units) and indicators, up to a full monitoring package
K5 with plug-and-play connectivity including the
Loading (arbitrary units)

whole family of ABB eDevices (digitally enabled

K3
instrumentation and protection devices), ABB’s
K1 dissolved gas analyzers (DGA) CoreSense and
K2 CoreSense M10, and the option to integrate third-
K4 party sensors and instrumentation. →4-5.

Upstream connectivity options range from local

Time (arbitrary units)
02 devices such as laptops or tablets, control or SCADA
(supervisory control and data acquisition) systems,
To address this situation, users need actionable to ABB’s own ABB Ability Ellipse asset performance
information and insights to enable better decision management (APM) software.
making and asset management as well as a future-
proof technology concept. Therefore, the time has Even just the standard AAPT configuration brings
come for transformers to become digital by design. the benefit that multiple data points can be trended
This is why ABB has developed the ABB Ability and stored for future reference or used to compare
Power Transformer (AAPT) as a new standard for the relative performance of parallel units and aid in
power transformers. The AAPT is an integrated future planning. The AAPT also includes a self-check
solution with electronic temperature monitoring or watchdog function.
and on-board intelligence on load and aging
conditions. →3. Additionally, the AAPT offers a wide The AAPT platform has been conceived to
range of options, leveraging ABB’s broad portfolio be independent of the type and size of the
of devices, software and services. transformer, as the accessories defined for the
standard package are typically used in every oil-
immersed power transformer.

03

Winding
temperature
(via current transformer)

Top-oil temperature
(via resistance
temperature detector)

Sensors

Electronic
temperature
monitoring (CoreTec 4)
 SP ECI AL R EP OR T | T R AN S FOR ME RS ABB ABILIT Y POWE R TR ANSFORME R 15

eDevices

Product type Description

Winding temperature
The beating heart of a power transformer is its
eSDB Self-dehydrating breather
windings, but traditional methods for controlling
eOTI Liquid temperature indicator transformer cooling are based on monitoring
the oil temperature rather than what is actually
eWTI Winding temperature indicator
happening at the transformer’s hotspot. The aging
eOLI Liquid level indicator
of the insulation at the hottest point in the winding
typically determines the life span of a power
eVIEWER Remote viewer for eOLI transformer; an oil temperature just 8°C above
nominal could reduce the insulation life by up to 50
eBR Buchholz relay
percent [3] →6.
ePRD Pressure relief device
The AAPT’s modern Electronic Temperature
Monitoring solution can accurately calculate the
Dissolved gas analyzers transformer’s hotspot based on design data and
factory type-test results, together with dynamic
Product type Description
variables such as the loading and oil temperature.
CoreSense Hydrogen and moisture monitor
This can then be used to regulate the transformer’s
hotspot temperature.
CoreSense M10 Monitor for nine different gases and moisture

CoreTecTM 4
04 The brain of the AAPT is the CoreTec 4 module.
CoreTec 4 is a digital hub, responsible for collecting
— The design models, drawings, installation and and analyzing readings from the different sensors,
02 Transformer loading
behavior: As the operating instructions, plus functional and and processing them to provide an assessment
transformer loading installation tests are compatible with any power of transformer operation (including cooling
increases, there is an
offset in the oil’s ability transformer and have been defined with this global equipment governance, if needed) and life
to transfer the additional requirement in mind. Last, but not least, the AAPT is expectancy.
heat, which leads to
increased hotspot fully compliant with industry standards applicable
temperature. to both power transformers and low-voltage For the development of CoreTec 4, ABB was able
02a Oil temperature level controls for any region of the world. to leverage existing expertise and experience in
and hotspot temperature. transformer monitoring systems, building on
02b Transformer loading. Connectivity developments that go back to the 1980s with first
Many customers now demand actionable fiber-optic temperature monitoring systems, the
—
03 The standard information, intelligent asset optimization and 2000s with Transformer Electronic Control (TEC)
ABB Ability Power the ability to use real-time data to mitigate “nasty and the previous CoreTec generations.
Transformer offering.
surprises.” The potential to network the AAPT
— is, therefore, a driver for many customers. The Apart from functionality, additional design
04 DGA and eDevices.
transformer can easily be connected to the station requirements such as compactness, expandability
control via a built-in Ethernet cable and fiber-optic (by plug-ins), ease of installation and durability
interfaces or via wireless. All connectivity solutions were considered in the development process.
are supported by state-of-the art cyber security and
options include connection to ABB Ability cloud- To ensure system robustness, demanding
based services. mechanical, thermal and dielectric laboratory trials
were carried out. Mechanical testing covered not
Today, not everybody wants their most critical only vibration but also thorough seismic and shock
assets connected to the outside world. So, tests (over 10 G). Thermal validation was achieved
independent of the onboard cyber security, in steady-state conditions and in contingency
transformer monitoring can operate in on-premise situations, such as when cabinet cooling is lost.
or in standalone mode. Customers may send ABB All these validation tests had positive results – the
raw data for interpretation and translation into readings were consistent during the tests with
useable information. Alternatively, customers can no interruption, no visual damage and successful
utilize ABB’s expertise on site. operation after the tests.
 16 ABB REVI EW SMARTE R

ePRD
eBR Pressure relief
eOLI
Buchholz device
Liquid level
relay
indicator

eOTI
Liquid
temperature
indicator

SDB
Self-dehydrating eWTI
breather Winding
temperature
indicator

CoreSense
CoreTec Gas sensor

05

The AAPT has been validated as an integrated Field experience

solution in several new and retrofit applications of Various use cases were identified and proven in the
different types. The validation included thousands field. In a transmission network, the information
of hours of real on-site conditions, at different provided on temperature and load enabled the
locations and applications around the world. Data operator to optimize the cooling control in such
gathered during validation demonstrated reliable way that the top oil temperature fluctuation was
performance, with all functional parameters within reduced from over 15 °C to less than 5 °C, under
expected ranges, confirming the benefits of the varying ambient and load conditions. This results in
measurement analysis. Indeed, the owners of these stable conditions for the insulation and extends the
pilot units have started to see the benefits of the transformer’s lifetime.
AAPT technology by making use of the advanced
analytics to translate the collected data into In an industrial installation, the operator noticed an
actionable information. increase of temperature and dissolved gases while
the load was constant. An investigation found a that
a mineral buildup had resulted in a faulty fan at a
heat exchanger – a situation that could have proven
1000
costly in the long run.

In a smelter application, the customer wanted to

100
increase their production capacity by 15 percent.
Thanks to the digital capability it was possible
Aging acceleration factor

10
to calculate the trade-off in terms of remaining
transformer life, and to ensure the asset integrity
1
while running the transformer in overload condition.

0.1

0.01

0.001
50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Hottest spot temperature (°C)

06
 SP ECI AL R EP OR T | T R AN S FOR ME RS ABB ABILIT Y POWE R TR ANSFORME R 17

—
In the future, with more data becoming available ABB is enabling asset owners to meet all these
05 Transformer with
eDevices. from an expanded base of installations, and challenges by digitalizing new transformers
with the advancement of analytics technologies, as a standard feature. The ABB Ability Power
—
06 Even moderate additional use cases will emerge that further Transformer monitors health data and delivers
overtemperatures have
leverage the digital capabilities and the ecosystem actionable information to enhance grid reliability
a significant detrimental
effect on transformer that ABB can provide. and the efficiency of load distribution, and increase
lifetime. [2]
service and maintenance productivity by enabling
— The future of power transformers is digital condition-based maintenance.
07 Summary of the concept
In the past, transformers were an asset that kept
and benefits of the ABB
Ability Power Transformer. running under stable conditions in a centralized During the lifetime of the transformer, upgrades
grid. The exact condition of the transformer, are easily possible thanks to a modular and scalable
— especially that of its insulation and aging, were architecture. Therefore, the ABB Ability Power
References
not known but due to stable load conditions many Transformer is a future-proof investment designed
[1] World Economic Forum,
with analytical support transformers had a long lifetime. Today, however, to open the world of digital possibilities to asset
from McKinsey & Company,
grid conditions have become more stressful due owners and enable them to gain a competitive edge
“Fostering Effective Energy
Transition A Fact-Based to the integration of volatile renewables and in a changing environment →7.
Framework to Support
distributed energy resources, and, for example,
Decision-Making.“
Available: the rise in the number of electric-vehicle charging The AAPT was introduced to the public at the
http://www3.weforum.
stations. Hannover Messe 2018 and garnered positive
org/docs/WEF_Fostering_
Effective_Energy_ Additionally, asset owners feel pressure to ensure reactions and feedback. The market launch of this
Transition_report_2018.pdf
competitiveness and effective allocation of capital new product underlined how ABB has, throughout
[2] ABB Data Manifesto. and operational expenditures. Therefore, better its long history, been able to solve important
Available:https://www.
insights are needed in order to ensure sound customer problems, deliver real benefits and
forbes.com/sites/
abb/2017/04/13/a-call-to- decisions on transformer maintenance, repair or spearhead innovation. l
action-for-the-internet-
new investment.
of-things-industry-
lets-write-a-data-bill-
of-rights-for-cloud-
Further, those armed with the right data
customers/#7d4731829a21
interpretation can benefit from dynamic
[3] Institute of Electrical
optimization of the transformer loading and reduce
and Electronics Engineers,
“IEEE Std. C57.91: Guide the need for site visits. They can make informed
for Loading Mineral-Oil-
decisions and trade-offs between overloading the
Immersed Transformers
and Step-Voltage transformer for immediate financial gains versus
Regulators,” 2011.
shortening transformer life.

07

Digital transformer
monitoring platform
Cloud computing
and analytics
Monitors vital signals from
different sensors
Models and stores data from
running algorithms in real time
Controls cooling fans to
All part of a wider
maintain winding temperature
Digital ecosystem
ABB Ability
edge device

Hardware Software Services

Station control Customer benefits
room
Reliable – prevent failures
and critical events
Efficient – reduce total
cost of ownership
Enabled by
Futureproof – scalable
ABB Ability
design provides flexibility

Plug-and-play capabilities Download

Digital mechanical sensors from device
Dissolved gas analyzers locally
Digital safety devices
18 ABB REVI EW SMARTE R

—
S M AR TER

Dawn of the
digital distribution
transformer
ABB’s ABB Ability TXpert is the world’s first truly
intelligent distribution transformer. TXpert combines
ABB’s world-class transformer expertise with digital
technologies and advanced analytics to give customers
actionable insights into transformer and grid health.

Distribution utilities are dealing with far more

complicated power grids than ever before.
Unprecedented challenges are posed by a
bewildering array of factors: rapid expansion of
cities and urban areas; incremental grid upgrades;
the addition to the grid of renewable generation
sources such as solar and wind; and the inclusion of
Deidre Cusack unique loads such as electric vehicle (EV) charging
ABB Transformers
Business Unit stations. These changes stress distribution
Raleigh, NC, United States transformers – the vital link between the electrical
deidre.e.cusack@ grid and homes, industries and infrastructure – and
us.abb.com can result in premature failures, unplanned outages
and less-than-optimal grid operation.

Uptime, safety and the environment are major

concerns for operators of, for example, data
centers, oil and gas installations, and industrial
plants. To handle these concerns, such enterprises
maintain their equipment through condition-based
asset management systems. Now, to further
Deia Bayoumi
ABB Transformers improve reliability and to protect themselves from
Business Unit the stresses described above, these operators are
Raleigh, NC, United States
interested in integrating their electrical equipment,
[email protected] such as transformers, into these systems.

This interest – and the need for faster decisions,

real-time action, and improved reliability of
distribution transformers – led ABB to explore
how to exploit digital technologies to produce a
new distribution transformer that would enable
customers to address not just today’s challenges
but also those of tomorrow.
 ABB ABILIT Y T XPE RT 19

01 ABB Ability TXpert development

Starting from a blank sheet of paper, an open
innovation process was begun in ABB that
eventually generated a development roadmap
based on market segment needs and trends. This
roadmap led ultimately to the launch of the new
digital distribution transformer, the TXpert →1-2.

At every step of the TXpert development, design

and manufacturing decisions were made with
the customer’s perspective and expectations
regarding engineering, operation, maintenance,
etc. firmly in mind.

Which measurements provide vital information?

Customers expect distribution transformers to last
for 25 to 30 years; any new additions to the product
line should do so too. The question then arises as to
which parameters, if they were measured directly,
would provide vital information about the asset and
electrical supply quality – and which sensors best
measure these parameters. Given the conservative
nature of the industry, only sensors designed for, and
used in, harsh environments and with excellent field
reliability were considered. The sensors finally picked
are from mature industries and are expected to last
longer than the transformer itself. The sensors chosen
are for top oil temperature, ambient temperature,
pressure, moisture, hydrogen, voltage and current,
plus two measurements for the oil levels.

Data capture and analysis

Every 10 seconds, 14 sensor values of TXpert key
operating parameters are recorded and time-
stamped. This data is stored fully encrypted for
20 years in appropriately dimensioned memory.
Customers reported that data quantities can be
overwhelming over time, so advanced analytics
integrated directly into the distribution transformer
process much of the raw data to produce insights
that allow the customers to take suitable action →3.

The current TXpert release conducts two analytics:

• Consumed life of the distribution transformer,
which informs the customer how old the
transformer is, based on its specific operating
conditions.
• Total harmonic distortion (THD), which indicates
the quality of the grid around the distribution
transformer.

02
20 ABB REVI EW SMARTE R

03

These two analytics were released first to address installation anywhere in their electrical grid.
the basic needs of most customers. ABB is TXpert has a Web service user interface that does
developing further analytics to address asset health not require a software installation on customer
and grid health. Future advanced and predictive computers, thus eliminating any burden on the
analytics aimed at specific customer segments will customer’s IT organization.
be released over time via software upgrades.
This is the first time in the industry that so many TXpert outputs can be integrated into several
key distribution transformer parameters are software packages, allowing the customer full
recorded simultaneously. ABB is capitalizing on this flexibility to display or integrate data and analytics
opportunity by developing artificial intelligence outputs in a way with which their personnel are
models that analyze the available data and predict familiar.
failures and operational events →3.
Cyber security is a key concern for customers. In
Connectivity addition to the stringent ABB guidelines followed
Almost 80 percent of distribution transformers during development, testing and validation, three
are not connected to or are even near a layers of defense were added to support customers:
communications infrastructure. ABB has included • The TXpert built-in WiFi is turned off by default
WiFi in TXpert for customers to retrieve data and needs to be enabled by an RFID access card.
and analytics outputs →4-6. For installations in It turns back off after 10 minutes of inactivity.
substations, solar farms, wind farms or wherever • Customer computers need to have a
communication access points exist, there is a valid security certificate to authenticate
wired Ethernet option to allow customers to use communication sessions.
their existing infrastructure. Future expansion • Stored data is encrypted and customers need a
of connectivity options such as LTE wireless will decryption key to be able to read the data.
appear in future releases. TXpert is not locked to
a specific protocol or communication medium,
which allows the customer maximum flexibility of

04 05
 SP ECI AL R EP OR T | T R AN S FOR ME RS ABB ABILIT Y T XPE RT 21

—
01 A transformer
Ease of installation For industry and data centers:
fitted with TXpert, The TXpert hardware is self-powered from the • TXpert reports actual, real-time operating
IEC model, ready to be
installed. On top is the
transformer, so there is no additional effort needed conditions, thus increasing the visibility of uptime
communications pod for during installation and energization. TXpert is and reliability.
accessing transformer
data and analytics.
like a traditional distribution transformer from • TXpert presents a real asset management and
the installation and energization perspectives proactive maintenance opportunity based on
—
02 TXpert is available
so requires no special treatment from customer actual operating conditions where customers
as ANSI and IEC models organizations such as operation, maintenance, can integrate TXpert outputs in their asset
based on regional
standards.
health and safety, communications and IT. management and maintenance programs.

—
03 TXpert collects and
Customer values For oil and gas:
analyzes a comprehensive The main focus of TXpert is to support ABB’s • Knowing key operating parameters in real time
set of transformer data.
Where appropriate, front-
customer needs by providing vital insights for and taking appropriate and timely action is of
end analysis processes informed decisions that increase reliability and great value for oil and gas customers and the
large amounts of raw
data to present the
reduce operating costs. operational safety of the transformer.
operator with actionable • Oil level indication and leak detection help protect
intelligence.
Each market segment has its own needs, challenges the environment.
— and opportunities. Each customer has their own
04 Engaging TXpert’s
secure Wi-Fi to access
unique needs. Product launch
transformer and grid ABB launched ABB Ability TXpert in March 2017
information.
For utilities: and it has been commercially available worldwide
— • TXpert reduces maintenance costs by scheduling since September 2017. The current release covers
05 An operator views
data and analytics from
inspections more intelligently – ie, customers transformers from 300 kVA to 10 MVA in the 36 kV
TXpert ANSI model to focus on inspection based on data trends class. Coming product releases will expand the range
understand how the
transformer and grid are
rather than measurements with absolute value of transformer sizes.
operating. at specific moments in time. With remote
—
communications enabled, key operational data Positive customer experiences are already being
06 Typical TXpert display. and analytics output is available in real time. reported. For example, one customer reported
• Knowledge of transformer age allows more that TXpert showed their transformers were only
accurate replacement planning and reduces 30 percent loaded. The assumption had been that
inventory cost by reducing the need to buy stock the load would be 80 percent, while in actual fact
units. some transformers in the network were overloaded.
• Balancing the load based on transformer and With the right data and some simple changes, the
grid conditions allows customers to utilize customer was able to optimize the grid better and
assets better. make cost savings by right-sizing the transformers.
• With remote communications, immediate outage
notification is possible, thus reducing downtime ABB’s deep domain knowledge and expertise are
and possible financial penalties. being further enhanced through edge technologies
• Revenue protection or energy theft is a concern based on ABB Ability, such as TXpert. As TXpert
for some utilities. Energy thieves will connect matures, it will be a catalyst for further refining
to the grid at the transformer point. Not only distribution transformer performance, improving
does the utility lose revenue but the transformer predictability and increasing reliability. l
can become overloaded and possibly fail.
With TXpert, revenues running through the
transformer can be calculated and compared
against billing meters to make sure they match.

For renewables:
• With the THD value, customers get an indication
of the network quality. Further analytics for
overall system efficiency, which is crucial in
renewable generation, are planned.
• A voltage-profile analytic is planned where
customers would get a specific voltage profile
for a particular part of the grid during different
seasons and at different times, allowing them to
take informed decisions rather than the current
practice of assumption and simulation. This can
eliminate the need for a voltage regulator and
allow better grid optimization.

06
22 ABB REVI EW SMARTE R

—
S M AR TER

Transformer asset
management –
do more with less
Market pressures lead companies to reduce budgets for
transformer maintenance and replacement – and ask
more from existing assets. The ABB Ability Transformer
Intelligence portfolio helps reduce transformer
maintenance costs by optimizing transformer asset
management and supporting units in service.

Lony Tehini With an average age in industrial plants of 30 years

ABB Transformer
Remanufacturing and and in utilities of 40 years, the world’s transformer
Engineering Services fleet is aging – and is incurring associated
Montreal, Canada
increasing replacement and repair costs, and risk
[email protected] of failure. The economic pressures of deregulated
Pierre Lorin and competitive markets, and the tendency to
ABB Transformer overload transformers, only exacerbates matters.
Remanufacturing and
Engineering Services Many transformers are now also operated beyond
Geneva, Switzerland their recommended life span in order to smooth
[email protected] investment peaks.

Tucker Reed
ABB Transformer These conditions make it imperative to adopt life-
Remanufacturing and prolonging measures and to optimize transformer
Engineering Services
St Louis, MO, United States maintenance.

[email protected]
One significant maintenance optimization strategy
is to replace simple time-based maintenance that
mitigates risk by doing everything, every year,
for all transformers, with a more sophisticated
condition-based maintenance strategy – ie,
focusing maintenance on high-risk transformers.
It is estimated that a life extension of 5 to 15
years can be achieved with properly focused
preventive maintenance programs. The ABB Ability
Transformer Intelligence portfolio supports this
strategy shift by focusing on three elements:
monitoring hardware, interpretation software and
expert service →1.
 SP ECI AL R EP OR T | T R AN S FORME RS ARTIC LE TITLE 23

01

— The benefits of condition assessment In the medium term, a condition assessment gives
01 ABB offers
transformer monitoring On a long-term and strategic level, a condition asset managers the input necessary to make the
systems that help reduce assessment study gives top management a clear best use of maintenance or replacement budgets.
repair, maintenance and
running costs. picture of the maintenance and renewal investments Funds can be allocated to units that show the best
that are required over the next 20 to 30 years to return on investment while reducing technical and
—
02 Key parameter provide asset reliability and availability. This type environmental operation risks.
monitoring gives of insight provides solid information to compare
early warning of faults
developing in the main different asset management strategies and choose
tank or accessories, the approach that best supports the overall technical
allowing an operator to
evaluate the severity of and financial strategy of the company.
the situation.
Early Warnings
Short Circuit Mon
Mechanical
Early Warnings
Faults
ShortWarnings
Early Circuit Winding Displacement Monitored Parameters:
warnings Monitored parameters:
Mechanical
Faults Winding
Short DisplacementWinding
Circuit Looseness
circuit l l l l Monitored Parameters:
Mechanical
Mechanical WindingDisplacement
Looseness Temperature
Temperature
faults
Faults Winding
Winding displacement l l l

Winding Looseness
Partial Discharge
Winding looseness
Partial Discharge Temperature
Electrical
Electrical Electrical l l l Electrical
Main Main Faults
Main Tank
Tank Tank Over Voltage/Through
Partial discharge
Faults Discharge Over
FaultsVoltage/Through
l Faults l Electrical
Electrical
Electrical Mechanical
Mechanical
Main Tank Arcing
Over Voltage/Through
Overvoltage Faults
through faults
Faults l l
faults Arcing Mechanical
Arcing
Arching
Cooling Issues l l Chemical
Chemical
Thermal Cooling
Cooling issues
Insulation Ageing
Issues Cooling Issues l l
Chemical
Faults Overloading
Insulation
Insulation aging
Ageing l
Thermal
Thermal
Faults
faults Thermal Insulation Ageing
Overheating (eg. Improper Connection)
Overloading l l l

Faults
Cooling System
Overheating (eg, Overloading
improper
(eg. Improper connection)
Connection) l l

Bushings
Cooling system
System l l l l
Accessories
Tap Changers
Overheating (eg. Improper Connection)
bushings
Bushings l l l l
Accessories
Accessories Oil Preservation
Tap Changers
changers Cooling
System System
l l l

Oil Preservation System

preservation system
02 Bushings l l

Accessories
Tap Changers
Oil Preservation System
24 ABB REVI EW SE RV IC E

03

And in the short term, the assessment can tell the Transformer monitoring relies on temperature,
maintenance manager how to apply the maintenance electrical, mechanical and chemical sensors →2.
actions that secure the asset reliability required. ABB offers multiple sensors for these parameters,
including the CoreSense™ family for dissolved gas
Plug and play devices to unlock analysis (DGA). CoreSense provides a nonintrusive,
even more value from the transformer maintenance-free and easy-to-install solution that
A CIGRE study has shown that transformer flags a potential fault with hydrogen measurement.
monitoring can reduce the risk of catastrophic Deeper analysis can be performed with the multigas
failures by 50 percent [1] and that early problem version, the CoreSense M10 →3.
detection can reduce repair costs by 75 percent
and loss of revenue by 60 percent. Furthermore,
annual cost savings can amount to 2 percent of
the price of a new transformer – ie, approximately
$40,000 to $80,000 [2].

Transformer monitoring, then, makes good

financial sense.
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME R ASSE T MANAGE ME NT 25

— CoreSense M10 multigas analyzer Applying proven and robust FTIR technology
03 CoreSense M10 is the
ultimate transformer The CoreSense M10 utilizes Fourier-transform to transformers assures that the DGA sensor is
DGA diagnostic tool. It infrared (FTIR) technology combined with solid- accurate, reliable and calibration-free.
monitors the transformer
condition by observing state hydrogen and moisture sensors to measure
moisture levels and nine moisture and nine gases: hydrogen (H2), methane ABB Ability Ellipse Asset Performance Management
different gases. It can
be provided with a local (CH4), acetylene (C2H2), ethylene (C2H4), ethane In the context of transformer health management,
(ie, non-cloud) version (C2H6), propene (C3H6), propane (C3H8), carbon a major challenge for many industrial and utility
of ABB Ability Ellipse,
ABB’s asset management monoxide (CO) and carbon dioxide (CO2). The customers is to analyze and keep track of the
solution. CoreSense M10 is also provided with a local version data generated by both online and offline
— of Ellipse, ABB’s asset management solution. Ellipse measurements. Often, data exists in isolation and
04 Historical data along employs a number of algorithms sequentially to its interpretation relies heavily on transformer
with real-time data
analytics provide an asset establish if there is any abnormality and, if there is, experts, many of whom are soon to retire.
probability of failure to make recommendations for action →4.
along with maintenance
recommendations. ABB’s solution to these issues is ABB Ability Ellipse
Tough and accurate enough for space Asset Performance Management (APM). APM
The gas-measuring FTIR module in the CoreSense combines decades of subject-matter expertise
M10 is based on the same ABB technology that is in transformer manufacturing and maintenance
deployed in satellites to analyze greenhouse gases with historical and real-time data analysis from
and meteorology in the Earth’s atmosphere. The transformer sensors. This continuous health and
first unit was launched more than 15 years ago and performance insight prevents critical asset failures
is still in service today. This technology is sought while optimizing asset life cycle costs [3]. Each asset
after for its outstanding reliability, accuracy is also categorized according to its current health
and stability in harsh environments. In addition, condition and expected life.
the calibration-free nature of the technology
provides significant savings in maintenance and With all this actionable intelligence, utilities
replacement costs. can optimize the operational and maintenance
spend to maximize the capabilities of their
On earth, ABB’s FTIR is also used in other assets and budgets and build business cases
applications such as refineries, semiconductor for repair/replace decisions.
factories and chemical plants to measure chemical
compounds in liquids because it can meet up to 99
percent reliability and provide stable measurements
over extended periods of time, allowing
identification of long-term trends.

04
26 ABB REVI EW SMARTE R

— ABB specialists interpret data from the Historical review

05 TXplore and images
captured during transformer and provide services ABB has a plethora of data on the transformer
inspections. Once APM triggers an alarm or recommends an installed base. This data is continuously updated,
05a The TXplore action, for specific and complex cases, ABB experts eg, current owner details and history. The system
inspection “submarine” is can help make good use of the data collected by provides an important basis for the proactive
lowered into a tank.
online monitoring sensors, as well as the output detection of problems. For example, one analysis
05b The robot inspecting of asset management software, to analyze the revealed a potential cooler problem in about 700
tap changer contacts.
condition of certain transformers or transformer transformers in the installed base. The search
05c A still from the robot’s fleets. The combination of this data with the focused on 10 to 600 MVA transformers that were
inspection video showing
a flashover on a winding. design data, the information in ABB’s installed over 20 years old and had oil- and water-type
base system, the results of oil analysis, condition coolers. Some had failed due to leakages in these
—
06 On-site repair and assessments and the maintenance history provides cooling systems and one such failure resulted in
testing – retrofit of a ABB with a 360-degree view of a transformer fleet. significant revenue loss for the operator. Using
substation transformer
with ester oil. This insight plays a pivotal role for ABB in the installed base data, operators were contacted
condition assessment process [4]. proactively and advised to carry out regular checks.

ABB has access to design knowledge worldwide Training and consultancy

and original designs for more than 30 legacy ABB experts also provide on-site or off-site training
brands. Also, all new ABB transformers are built in transformer technical specifications, design,
using the same design concept, which incorporates manufacturing, quality and factory acceptance
standardized, service-proven components, thus tests, testing, diagnosis, online monitoring and
ensuring an efficient service out in the field. Expert asset management systems as well as spare parts,
assessment is not only important for minimizing maintenance, repair, upgrade and replacement –
the risk of failure and extending lifetime but also including safety, environmental aspects
for providing valuable information for initiating and economics.
maintenance or repair work should a problem occur,
resulting in shorter downtimes. Inspection robot
Troubleshooting sometimes involves draining the
transformer oil so a specialist can gain access. This
procedure involves a significant outage, risks and
expense. However, ABB has now developed TXplore –
a remotely controlled inspection “submarine” –
to do this job →5. This automated inspection tool
eliminates the need to put a human at risk and
expose the transformer’s internal structure to
external contaminants.

05a 05b 05c

 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME R ASSE T MANAGE ME NT 27

06

—
References On-site repair Eco-friendly retrofit
[1] “Economics of
ABB’s on-site repair service [5] speeds up The environmental impact of new plant or
transformer management,”
CIGRE Technical Brochure transformer repair and has, over the years, saved retrofits can be reduced by employing ABB eco-
248, June 2004.
users millions of dollars by reducing downtime by friendly solutions that combine component reuse,
[2] Cheim L. et al.,
“Transformer Reliability four or more weeks. The on-site repair is achieved innovative materials (natural and synthetic ester
Taking Predictive
by bringing the transformer factory setup to the oils, aramid fibers, amorphous steel) and modern
Maintenance Program
to the Next Level,” CIGRE work site, which allows for any scope of work to technologies (dry bushings, vacuum tap changers,
Study Committee A2
be carried out, from refurbishment to full winding active noise control) [6].
COLLOQUIUM, October
2017 replacement – all performed to the same quality
[3] Boss P. et al.,
standards as in the ABB workshop →6. Such These solutions reduce the risk of fire and
“Economical aspects and
practical experiences of repairs have been carried out worldwide on over pollution, minimize losses and noise, allow
power transformer online
500 transformers, including ultrahigh-voltage material recycling and reduce maintenance. They
monitoring,” Report 12-
202, CIGRE 2000. transformers, converter transformers, industrial also allow capital investments to be deferred while
[4] Lorin P. “Forever
units and shunt reactors. providing extra overload capacity to cope with
young (long-lasting
transformers),” IET Power growing power demands.
Engineer, 19(2), pp. 18–21,
April/May 2005.
Due to significant progress in power electronics,
[5] L. Eklund et al., ABB’s compact test systems can now perform most The ABB Ability Transformer Intelligence portfolio
“On-site transformation:
TrafoSiteRepairTM
high-voltage tests on site, including applied and is helping transformer operators around the world
combines the old with the induced voltage, heat run and impulse tests. cope with ever-increasing commercial and regulatory
new to improve power
constraints by allowing them to closely monitor
transformer availability,”
ABB Review 4/2007, pp. equipment condition, analyze and interpret results to
45–48.
produce actionable intelligence and benefit from the
[6] P. Lorin et al.,
“Sustainable and long experience ABB has built up since it launched its
available: Enhancing
first transformer over a century ago. l
performance and reducing
environmental impact
of existing transformer
fleets,” ABB Review Special
Report: Transformers, pp.
64-68 April 2012.
28 ABB REVI EW GRE E NE R

—
G R EE N ER

Environment comes
first with ABB’s oil-
free transformers
Oil-filled transformers are the predominate transformer
technology in use today. Nonetheless, hazardous risks to
humans and the environment still exist such as fire and
spills. ABB continues to develop oil-free transformers to
eliminate these potentially catastrophic events.

Increasing environmental awareness and

demand for electric energy coupled with modern
urbanization trends have led ABB to develop
innovative products for the supply, generation
and transmission of power. Transformers are
critical components in energy grid systems and are
increasingly required to operate at reduced risk to
Joel Kern humans and eco-sensitive environments.
ABB Transformers
Raleigh, NC, United States
Transformers, which traditionally use mineral
[email protected]
oil for insulation and cooling, allow energy to be
transported from the production source to the
location where power is needed. Increasingly
located in metropolitan areas →1 and near
environmentally sensitive areas like harbors,
Though the dielectric capabilities of solid
transformers that use oil can pose safety and
insulations are comparable to that of oil [2],
environmental challenges and generate additional
transformer oils are orders of magnitude better
long term costs. Since the late 1980’s ABB has
at cooling than ambient air. This allows oil-filled
sought alternative liquids and materials to reduce
transformers to be smaller, lighter, and produce
these risks. Oil-free transformers have continued to
lower noise levels than dry-type transformers of
be a viable alternative in a growing number of niche
equivalent power ratings. These advantages have
markets, where ecology and safety drive choice.
made oil-filled transformers the primary technology
for today’s globally installed transformer market.
Advantages of oil-filled transformers
Currently, oil-filled and oil-free (dry-type)
transformers are available; the obvious difference is
the presence or absence of oil. Oil has ideal dielectric
and cooling properties for use in transformers.
Oil-free transformers rely solely on solid insulation
ie, polyester films, aramid fibers and epoxies as the
dielectric material and ambient air for cooling.
 SP ECI AL R EP OR T | T R AN S FOR ME RS E COLOGIC AL OIL-FRE E TR ANSFORME RS 29

01

—
01 Crowded urban areas,
Mineral oil for transformer use was successfully rises (up to a maximum 75°C rise) and greatly
like Dubai, are ideal introduced in the 1970’s to replace the increases their fire safety ratings. Further, ester oils
locations for dry-type
transformers.
polychlorinated biphenyls (PCB) that were are renewable, non-bio-accumulating and non-toxic
progressively banned due to their hazardous and are potentially biodegradable.
impact on human and environmental health.
Despite the extensive safety history of oil-filled Transformer oil risks
transformers, mineral oil has a relatively low Despite the risk mitigation achieved by using ester
flash point (170°C); a property that can result in oil instead of mineral oil, measurable risks still exist:
catastrophic fires and explosive failures under rare all oils have flashpoints, and therefore pose
conditions – causing concerns. a fire or explosion risk; and all oils can leak and
present a risk to humans and the environment.
During the late 1980’s ester oils, or seed oils, were As previously stated, mineral-oil and esters, both
investigated as an alternative fluid for transformers synthetic and natural oils, are characterized by flash
to diminish these risks. Natural esters have a higher points of 170°C and 330-360°C, respectively [1].
flash point (330-360°C) than mineral oils; this allows
the transformer to operate at higher temperature
30 ABB REVI EW GRE E NE R

02 03

Design features are implemented to control environmentally hazardous; any leakage must be
transformer rise temperatures to ensure that oil treated comprehensively and quickly. Ester oils are
flash points are never exceeded under normal fully biodegradable when unused [5].
operating conditions. Nonetheless, some electrical
events eg, short circuits or internal arcing faults, Small spills (< few liters) can be consumed by natural
can push internal temperatures to values above organisms over a period of 28 days [6]. Larger spills
the oil flashpoint →2. Though rare, a potential however, can cause oversaturation and greatly
catastrophic failure of the transformer is by no prolong the natural biodegradability of the oil.
means a negligible risk.
A two MVA transformer requires more than 2000
Furthermore, if a surrounding forest or building liters of oil to operate properly. A spill of this size,
catches fire and reaches an oil-filled transformer, typically the result of rupture to corroded tanks,
the temperatures within will surpass the flash accidental structural damage, or theft due to
point of any oil, thereby exacerbating conditions copper harvesting, could be devastating to the
and possibly augmenting the fire to the point surrounding environment. Oil that enters waterways
of uncontrollability. Despite extreme measures poses an immediate threat to nature and wildlife
taken to extinguish transformer fires they can and to water meant for human consumption.
burn for hours, or even days, emitting smoke and Huge financial costs can ensue for cleanup and
toxic or corrosive gases into the air, and dumping re-establishment of operations. This burden is
hazardous debris from the combustion or fire often magnified by a risk to corporate reputation.
extinguishing process into the surroundings [3]. Obviously, the oil must be removed immediately to
avoid all further negative outcomes [7].
In the event of a low impedance fault, an internal
arcing can cause temperatures to reach a few All transformer oils become contaminated during
thousand °C. The potential energy released by such operation, thus reducing biodegradability.
an event, for large transformers, can reach 147 Major environmental agency regulations do not
MJ. Such high temperatures will vaporize the oil, differentiate between ester or mineral oil in their
thereby producing combustible gas, which in small regulations concerning the handling, spillage
amounts is harmless. If, however, the structures treatment, or disposal of these oils in regard to
are left unattended and pressure builds up, the environmental or human health impact. Either
tank may pose an explosion risk. Mechanical and at the end of life or following carbon saturation,
electrification methods are typically executed ester oils are replaced and, like mineral oil, must be
to mitigate this risk eg, oil-breathers, pressure treated as a bio-sensitive material.
relief valves, and the addition of equipment to
regularly monitor the dissolved gas are installed. Dry-type transformers
[4] Consequently, transformer explosions are In addition to mechanical and electrical design
uncommon as evidenced by long-term studies in features, surrounding protective devices such
which the probability of failure for a fleet of 765 kV as fast-acting fire suppression systems and
transformers was 1.21 percent; and of these failures oil containment structures →3 reduce hazard
only 0.14 percent resulted in fires [4]. potential. And yet the most economical solution
would be to place an oil-filled transformer, with
Despite precautions to prevent internal arcing, a minimum protection, in a location where it would
residual risk remains. Approximately 54 percent not pose a threat. However, power needs often
of transformer fires are due to the rupture of require transformers to be situated near densely
tanks or bushing turrets, which can result in populated areas, or in the vicinity of waterways or
oil spills. Mineral oil is non-biodegradable and other sensitive eco-systems. For this reason,
 SP ECI AL R EP OR T | T R AN S FOR ME RS E COLOGIC AL OIL-FRE E TR ANSFORME RS 31

— dry-type transformers that use alternative The predominant disadvantage of using dry-type
02 ABB’s ester oil
power transformer with dielectric and coolant materials are primarily transformers is the reduced cooling capacity
surrounding containment installed in these areas. that limits the achievable power and voltage
is shown.
ratings for oil-free technologies. Also, they are
— All dry-type transformer components are in solid typically larger and heavier than oil-filled units.
03 72 kV dry-type
transformer with dry- form; they do not have flash points, nor do they Consequently, dry-type power transformers have
type on-load tap-changer. require bushings. Thus, major causes of fire and been traditionally used for power transmission
— spillage are eliminated. The ability to operate and distribution with a rated power below 15 MVA
04 Wind farms located at high temperatures gives these transformers and voltage less than 36 kV.
in eco-sensitive coastal
regions benefit from dry- increased durability and overload capacity.
type transformers. Furthermore, by minimizing the impact on the The decision of whether or not to use dry-type
environment and eliminating the risk of fire, total transformers depends on the environmental
costs can also be reduced. Consequently, dry-type and safety considerations and power needs.
transformers are increasingly used in metropolitan Nevertheless, cost is always a factor and dry-type
areas to step down three-phase medium-voltage to transformers are cost-effective. The total cost
low-voltage for power distribution. of ownership, which includes the total cost of
installation and the additional costs of providing
There are a few limited applications in which water protection against fire and leakage, translate to
may be used to cool the air or the conductor itself lower civil works and building code requirements
inside a dry-type transformer. These applications (no containment, fire suppression or fire rated
include installations where cold-water loops are building structures etc. are required).
used to cool other equipment, eg, hydro generation,
marine vessels and offshore wind parks. All other Overall, dry-type technologies are the best
applications that use dry-type transformers employ transformer choice for specific markets where
only solid components and are self-extinguishing; ecology and safety are paramount concerns. ABB’s
in other words, in case of an arcing failure, no fire oil-free transformers provide the best solution for
will be sustained once the arc has dissipated. In customers who operate in sensitive areas eg, urban
addition, the majority of insulating components can centers, public buildings, waterways, harbors, off-
be recycled; these materials can be placed in inert shore wind farms and railways among others →4.
landfills making waste management effortless and Nevertheless, for large power and transmission
cost-effective. voltage classes, oil-filed transformers are still
today’s only possible choice.

04
32 ABB REVI EW GRE E NE R

— The future is bright for dry-type transformers ABB is also investigating new ways to increase the
05 ABB’s dry type power
transformer HiDry for The need to improve environmental and personal monitoring capacity of dry-type transformers to
sub-transmission up to safety, motivates ABB to continually expand the be more like that of existing oil-filled units.
145 kV/63 MVA.
limits of dry-type technologies. In 2010, ABB
increased the power and voltage limit of dry- In 2018, ABB is scheduled to release the ABB Ability
— type transformers to sub-transmission up to TXpert™ digital dry-type transformer. Using the
References
[1] B. Zimmerman, 72 kV / 63 MVA →5. Today, there are dozens of ABB Ability TM platform technology, this transformer
“Consideration of installations around the world that benefit from will have increased capabilities to monitor the
Ester-Based Oils as
Replacements of these increased ratings in utility for urban power power quality at the unit, provide advanced
Transformer Mineral Oil,” transmission and rail traction infrastructure. warning of any abnormal system occurrences,
PGE, Nov. 1 2014.
[2] L.I. Berger, “Dielectric Global trends in urbanization and environmental monitor fan function and control, and provide flood
Strength of Insulating awareness have incited ABB to aim for superior water damage alerts. These features will allow
Materials,” 2018
www.chemistry.mdama.ch results in dry transformer technology. In 2016, users to obtain a more accurate understanding
[3] E. Csanyi, “What ABB successfully tested a prototype of a dry-type of the transformer life cycle status and prevent
happens when a
transformer fire occurs in transformer for sub-transmission up to 145 kV / unnecessary outages.
a substation,” EEP, 62 MVA, thereby meeting safety standards and
Aug. 12th, 2016.
www.electrical- ensuring environmental integrity. Such power Overall, there are millions of dry-type transformers
engineering-portal.com systems feed higher voltage directly to the main in operation worldwide. Currently, ABB produces
[4] G. Frimpong,
“Cause of Hydrogen Gas load centers; higher power is achieved at reduced more than 40,000 units each year and offers
in Transformers,” distribution loss. The current challenge is to develop its customers, oil-free transformer solutions
T&D World, Mar. 10, 2014.
www.tdworld.com an accompanying dry-type on-load tap-changer –  with primary voltages through 72.5 kV built in
[5] Midel “Fluids a necessity for higher voltage classes [8]. accordance with major standards such as IEC and
Comparison,” 2018.
www.midel.com ANSI. The expansion of ABB’s transformer portfolio
[6] “Envirotemp™ FR3™ to include a variety of dry-type transformers
Fluid,” Cargill, 2018.
www.cargill.com provides customers with innovative solutions
[7] “Vegetable Oils to meet their unique power needs without
and Animal Fats,” US
Environmental Protection relinquishing environmental or human safety. l
Agency, 2018.
www.epa.gov
[8] M. R. Ayuso,
“Safe and Ecological:
HiDry type Transformers
for Subtransmission,”
ABB, 2017.

05
 SP ECI AL R EP OR T | T R AN S FOR ME RS E CO-E FFIC IE NT E STE R LIQU ID TR ANSFORME RS 33

—
G R EE N ER

Eco-friendly ester liquid

transformer designs
Ester liquids have been used in transformers for insulation and
cooling purposes for over 20 years. These liquids greatly reduce
environmental impact and significantly mitigate spillage and fire
risks. Recent experience underlines the benefits of using ester
liquids instead of traditional mineral oils.

George Frimpong Since the 1990s, ester liquids have been gaining almost obvious, solution, and they have related
ABB Power Grids,
Transformers acceptance for transformer insulation and cooling benefits such as smaller substation footprint and
Raleigh, NC, United States →1, with application voltages now reaching simplified oil containment design [1-2]. The 10 to
george.k.frimpong@ 420 k. This shift from traditional mineral oils can 15 percent extra cost of ester-filled transformers
us.abb.com be attributed to growing environmental awareness is more than compensated for by the benefits it
Jan Hajek and the need to address the risks of tank rupture brings.
ABB Power Technologies and fire, especially in crucial locations. Ester
AB, Power Transformers
Ludvika, Sweden liquids lend themselves as a natural and safe, and

[email protected] 01

Krzysztof Kulasek
ABB Power Grids
Montreal, Canada

krzysztof.h.kulasek@
ca.abb.com
 34 ABB REVI EW GRE E NE R

Parameter Unit Envirotemp FR3 MIDEL 7131 Mineral oil

Density at 20 °C g/ml 0.92 0.97 0.87

Kinematic viscosity at 100 °C mm2 /s 8 5.25 3

Kinematic viscosity at 40 °C mm2 /s 33 29 12

Kinematic viscosity at 0 °C mm2 /s 190 280 76

Thermal conductivity at 20 °C W/m K 0.167 0.144 0.120

Pour point °C -21 -60 -60

Flash point °C 315 275 160

Fire point °C 355 317 ± 5 170

Relative permittivity - 3.2 3.2 2.2

Classification of flammability - K K O

Breakdown voltage IEC 60159 2.5 mm kV 73 > 75 > 70

Dielectric dissipation factor, Tan σ at 90 °C 50 Hz - 0.005 < 0.008 < 0.002

Moisture saturation at ambient temperature ppm 1,000 2,700 55

02

— In recent years, much progress has been made in This seemingly low incidence rate conceals a
01 As transformer
insulation and coolants, ester-filled transformer applications, especially in significant risk as, on top of danger to workers and
ester liquids have the realms of: reputational loss, the average cost of replacement,
many advantages over
traditional oils. • Eco-efficiency and safety clean-up and lost revenue is about $3 million, and
• Life extension – slower aging of insulation and individual cases have been known to incur costs of
—
02 Comparison longer lifetime up to $86 million [4].
of different liquid • Overloadability – flexibility in handling the load
characteristics.
or minimizing footprint for mobility In any of the abovementioned situations, cooling
— and insulation fluid biodegradability, and high
03 Moisture evolution in
cellulose impregnated Eco-efficiency and safety flash and fire point, improve operator safety, while
with natural ester and The major safety and environmental concerns of reducing the impact and cost of cleanup.
mineral oil at 130 °C.
transformers are catastrophic failure and oil spill.
Small leaks can occur due to handling errors (eg, Natural ester liquids are classified (see, eg,
overfilling) but more serious leakages happen when standard EC 61039) as non-toxic and readily
a unit ruptures. Leakages can also lead to fires: of biodegradable substances. Therefore, spills are
the around 1 percent of failures that necessitate characterized as nonhazardous.
major repair or scrapping [3], one-tenth result in a
transformer fire. If a transformer protection system is slow to react
to a low-impedance fault, the high-energy internal
arc generated can produce gases that lead to
overpressure and tank rupture, thus allowing the
ingress of oxygen to create a fire-prone environment
600 50 [2]. For such failures, the most important parameters
Mineral oil – upgraded insulation
45 of the liquid used are its flash and fire point values.
Natural ester – upgraded insulation
500 Compared with mineral oil, ester liquids have
40
much higher flash and fire point temperatures →2.
Moisture in mineral ester (ppm)

Moisture in mineral oil (ppm)

35
400 They meet the US National Electric Code (NEC)
30 definition of less flammable dielectric liquids and
300 25
are recognized as such by both FM Global and
Underwriters Laboratories (UL), both independent
20
product safety certification organizations. The
200
15 byproducts of the combustion of natural esters are
10 much less toxic than those of mineral oils, further
100
reducing their overall impact on the environment.
5

0 0 Hydro plants that are located close to sensitive

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000
waters, for example, can benefit from the
Aging time (Hrs) reduced environmental threat provided by
03
ester-filled transformers.
 SP ECI AL R EP OR T | T R AN S FOR ME RS E CO-E FFIC IE NT E STE R LIQU ID TR ANSFORME RS 35

IEEE C57.154-2012 IEC60076-14

Mineral oil Ester fluid Mineral oil† Ester fluid

Maximum continuous temperature rise limits for transformers with high-temperature insulation systems

Minimum required high-temperature solid insulation thermal class 120 140 120 140

Top liquid temperature rise, (°C) 65 90 60 90

Average winding temperature rise, (°C) 65 85 75 95

Hottest spot temperature rise, (°C) 80 100 90 110

Suggested maximum overload limits for transformers with high-temperature insulation systems

Maximum top liquid temperature with normal life expectancy (°C) 105 130 105 130

Maximum top liquid temperature with loading above nameplate rating (°C) 110 140 115 140

Maximum solid insulation hottest spot temperature with normal life expectancy (°C) 120 140 115 140

Maximum solid insulation hottest spot temperature with planned loading beyond nameplate rating (°C) 130 150 130 150

Maximum solid insulation hottest spot temperature with long-term emergency loading (°C) 140 160 140 160

04 †For semi-hybrid insulation winding

— Between 2002 and 2016, ABB delivered 14 Insulation systems composed of ester liquids and
04 Maximum continuous
temperature rise limits transformers with powers ranging from 16 to 40 cellulose materials have been shown to operate
and suggested overload MVA to the Warmian-Masurian region of Poland, with lower moisture content in the insulation
temperature limits
for 120- and 140-class well-known for its many nature reserves and lakes, system and endure higher temperatures than those
insulated transformers. and for being part of the EU Natura 2000 project. composed of mineral oil and cellulose materials,
— The choice of synthetic ester liquid Midel 7131 making them an ideal choice [5].
05 138 kV compact contributed to the protection of the landscape
mobile substation filled
with a natural ester by obviating the need for oil containment and fire There are three factors that contribute to the
insulating liquid, in suppression systems. lower aging rate and longer lifetime of ester-filled
transit.
transformers:
Life extension – slower aging • The moisture content in the mineral-oil-filled
of insulation and longer lifetime system increases with time, while that of the
The lifetime of a power transformer is defined by ester-filled system declines. An ester-filled
the decay rate of its cellulose insulation. This decay cellulose insulation system operates with lower
increases with increasing oxygen and water content cellulose insulation moisture content than one
in the paper and the surrounding insulating medium. filled with mineral oil →3.
• The solubility of water in ester liquids is several
times higher than in mineral oil at typical
transformer operating temperatures. This
means more water is drawn out of the paper
into the ester liquid.
• Cellulose polymers change when aged in natural
ester liquids. The chemical reaction of water
generated during the cellulose aging process
with natural esters produces free fatty acids
that attach to the cellulose structure through
a reaction called trans-esterification, thus
forming a barrier to water ingress, leading to
a decline in the rate of deterioration of the
cellulose insulation [5].

The practical result of the combined effect of all

these phenomena is that cellulose insulation has a
20 °C thermal advantage when aged in ester liquids
[5-6]. Specifically, for the same life expectancy,
cellulose impregnated with ester liquids can
be designed with a 20 °C higher hottest spot
temperature than one with mineral oil.
05
36 ABB REVI EW GRE E NE R

—
Overloadability – flexibility in load handling or Consequently, low- and medium-power
06 200 MVA/420 kV
liquid-ester unit. minimizing footprint for mobility. transformers with ester liquids can be
In a typical transformer design, the insulation overloaded continuously by an average of 25
system limits the highest temperature at which percent without negative impact on their lifetime.
—
References the conductors and metallic parts can operate. In combination with Aramid insulation – a high-
[1] J. C. Mendes et al.,
For a conventional system with mineral oil and temperature insulation paper material that can
“Oiled and ready to go:
Advanced application of thermally upgraded cellulose insulation, the highest be used up to 200 °C – the overloadability of
ABB BIOTEMP® vegetable
temperature allowed is 105 °C for the oil and 120 °C such transformers can be even higher without
oil in a HV power
transformer,” ABB Review for the conductor →4. Higher MVA supplied for the appreciable loss of life. This combination leads
3/2007, pp. 53-57.
same footprint would mean higher temperatures to the ultimate value proposition for end users:
[2] G. Frimpong et
al., “Transformers in the transformer, which shortens its lifetime. To transformers with the same performance but
transformed: Using
achieve higher MVA in the same or smaller footprint, with a much smaller footprint.
vegetable oil as an
insulating fluid reduces the transformer would need to be designed
transformer fire risk,”
using high-temperature insulation materials. For example, instead of using two 30 MVA
ABB Review 2/2012.
[3] “Guide for Such materials, like ester liquids and ester-liquid conventional transformers to meet a station
Transformer Fire Safety
Practices,” Cigre Report
impregnated cellulose, allow operation at higher capacity of 60 MVA, two 20 MVA ester liquid
537, temperatures without appreciable deterioration insulated transformers (with their additional
June 2013.
[4] William H. Bartley,
of the insulation system. Also, there should be overload capability) could be applied to meet the
“Analysis of Transformer no additional risk of failure from operating the load and contingency requirements for the station.
Failures,” The Hartford
Steam Boiler Inspection
transformer at higher temperatures. Also, these lower-rated transformers use less core
& Insurance Co. steel and therefore will have lower no-load losses.
International Association
of Engineering Insurers
For transformers insulated with thermally The higher thermal performance of ester-liquid-
36th Annual Conference – upgraded cellulose and ester liquid, the limit for insulated transformers can be used to advantage
Stockholm, 2003.
[5] G. K. Frimpong, et
the top oil temperature is 130 °C and the hotspot in mobile transformer applications →5, offshore
al., “A Survey of Aging temperature under normal cyclical loading can be applications and industrial production applications.
Characteristic of
Cellulose Insulation in
as high as 140 °C. The only limiting factors will be
Natural Ester and Mineral transformer components such as tap changers A global trend
Oil,” IEEE Electrical
Insulation Magazine, Vol.
or bushings, which will also have to sustain much In comparison to mineral oil, ester liquids
27, No. 5, pp. 36-48, 2011. higher temperatures. have cost, operation and safety advantages in
[6] IEEE C57.154-2012,
“Standard for the Design,
specific applications. They require careful design,
Testing, and Application production process considerations and compatible
of Liquid-Immersed
Distribution, Power, and
material and accessories selection [7]. When such
Regulating Transformers considerations are made, ester liquids can be
Using High-Temperature
Insulation Systems and
used in high- voltage power transformers →6.
Operating at Elevated ABB has delivered more than 200 ester-filled
Temperatures.”
[7] J. Hajek et al.,
power transformers.
“Considerations for the
Design, Manufacture, and
Retro – filling of Power
Globally, environmental requirements are
Transformers with High increasingly part of the business decision process.
Fire Point, Biodegradable
Ester Fluids,” CIGRE
One major goal is to retain as much value as
Paris 2012. possible from resources, products, parts and
materials to create a system that allows for long
life, optimal reuse, refurbishment, remanufacturing
and recycling. ABB’s eco-efficient power
transformers can help do this. l

06
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME R E NE RGY E FFIC IE NC Y 37

—
G R EE N ER

Driving down energy

losses in transformers
With some 5 percent of global electrical energy being consumed by
transformer losses, energy efficiency has become one of the main
drivers of transformer technology evolution and regulation.

01

Miguel Cuesto
Miguel Oliva
ABB Transformers
Cordoba, Spain

[email protected]
[email protected]

Kai Pollari
ABB Transformers
Vaasa, Finland

[email protected]
38 ABB REVI EW GRE E NE R

Energy demand and availability are intertwined Advantages of energy-efficient transformers

with a nation’s economic growth and welfare. Efficiency improvements in transformers can lead
This symbiosis is reflected in many countries by to significant energy and emissions savings, while
the relentless escalation in energy requirements bringing net economic benefits because the marginal
driven by thriving economic activity and increasing cost is spread over the lifetime of the equipment.
population. At present, electric power satisfies a Energy-efficient transformers also provide extra
large proportion of this demand and new factors, capacity, potentially lower electricity bills, reduce peak
such as electric vehicles and renewable energy loading and related pollution at power plants, and
sources, are expected to increase this share. enhance energy security and reliability.

In this context, electrical equipment efficiency plays ABB pursues many technical solutions for enhancing
a vital role, especially in transformers, where losses transformer energy efficiency. These range from
account for some 5 percent of global consumption – better core construction techniques to lower-loss
more than the electricity demand of the continent core and conductor materials. Winding design and
of Africa. utilization of magnetic shields and other solutions
to decrease load losses can also have a considerable
ABB is at the forefront of the energy efficiency impact. Efficiency also comes from how the system
revolution and provides technologies right along is configured and how products, technology and
the electrical energy value chain that typically pay knowledge can be combined to deliver a stronger
for themselves within a few years through lower and smarter grid – for example, by transmitting
energy costs. Transformers are key links in this energy more efficiently by using higher voltages,
energy value chain. both AC and DC, or by using products that make
more efficient use of the network, such as:
In fact, energy efficiency has become one of the • Better interconnections.
main drivers of transformer technology evolution • FACTS (Flexible Alternating Current
and regulation. For example, a major initiative Transmission Systems).
being implemented by major economies in support • Reactors or phase-shifting transformers.
of a more efficient use of energy is the so-called • Transformers specifically designed to simplify
minimum energy performance standard (MEPS) for renewable energy generation and integration:
transformers →2-3. Transformer MEPSs differ by solar and wind transformers; collector
country and region and have to be normalized to transformers, and AC and HVDC units for local
provide a comparison →3. In 2017, The first global connection to the grid.
reference document for transformer efficiency and
related metrics was published (IEC 60076-20 TS). New transformer technology and materials, and
physical modeling and simulations can also deliver
designs that lower losses or give the same losses
but with less material or improved transportability.

EU: TIER 1 (2015)

TIER2 (2021)
Japan
China
US: MEPS Top
MEPS
2010 & 2016 runner
grade 3

Australia
MEPS 2004

02
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME R E NE RGY E FFIC IE NC Y 39

99.50

—
01 With rising concern 99.00

Percent efficiency (IEC: 50% of rated capacity)

over climate change, it is
more important than ever
to use energy efficiently. 98.50
As 5 percent of global
energy is consumed by Australia MEPS 2004
losses in transformers, 98.00 Canada MEPS
any measures that reduce China MEPS (grade 3)
these losses will have a Europe TIER 1 (2015)
major positive impact 97.50 Europe TIER 2 (2021)
on the world’s energy
Israel MEPS
consumption.
Japan top-runner
97.00
— Republic of Korea MEPS
02 Examples of current US MEPS (2010)
initiatives for energy 96.50 US MEPS (2016)
efficiency.

— 96.00
03 Example of MEPS 10 100 10,000
1,000
(normalized) for
three-phase liquid- kVA Rating
filled transformers [1].
03
Efficiency at 50 percent
load, using the IEC
definition of rating and
efficiency.
Other techniques improve overall cost-effectiveness No-load losses
and performance: No-load losses are the losses created in the
—
• Transformer intelligence via digitalization – ie, transformer magnetic circuit due to the magnetic
04 Example of the use of
3-D tools for optimized the collection of monitoring and service data to flux circulation through it. These losses are incurred
use of magnetic shunts
better use the existing assets and increase their from the very first moment that the transformer is
to reduce tank wall
losses. Green areas show availability and life expectancy. energized and do not depend on the transformer
where leakage flux is
successfully collected;
• Transformer life cycle management. load level. The use of new and more efficient
blue shows where it is • Reusing or recycling materials at the end of life. electrical steels reduces these losses. The electrical
not.
steel specific losses, defined as losses per unit mass
04a Large blue areas Battling the losses by design at certain conditions, range roughly from 1.22 to
indicate this design is
poor at leakage flux
Transformer losses have three main components: 0.70 W/kg, meaning that depending on the type of
collection, so there will be load losses, no-load losses and auxiliary losses. material selected, the no-load losses can be reduced
high loss in the tank.
by up to 57 percent from one case to another.
04b The prevalence of Load losses Furthermore, there are ongoing developments in the
green indicates high
collection of leakage flux
Load losses are created by current circulation along field of amorphous electrical steels to further reduce
and lower losses in the the windings and will vary with the transformer losses. The use of these amorphous materials is,
tank.
load. Regardless of the type of transformer, 2-D and however, currently limited to small transformers.
3-D software tools, together with ABB expertise,
allow the designer to minimize these losses, Auxiliary losses
especially those that cannot be calculated easily – Auxiliary losses are the losses from the transformer
ie, the losses due to leakage flux (also called stray control cabinet and accessories – ie, mainly cooling
losses). These losses can be reduced with magnetic equipment such as fans and pumps. Even for a
shunts, which are basically collectors or shields that certain level of load plus no-load losses, there can
avoid leakage flux going to areas like the tank walls, be significant differences in terms of transformer
where the flux would create even higher losses →4. internal temperatures that will determine the
dimensions of the cooling equipment and therefore
its energy consumption.

04a 04b
40 ABB REVI EW GRE E NE R

— Tools such as computational fluid dynamics The benefits for the user are related to:
05 ABB’s Effilight traction
transformer. (CFD) modelling are used to calculate these • Reliability and proven lifetime
temperatures, for liquid-filled or air cooled (dry- • Optimization of weight, losses and energy
—
06 Examples of efficiency type) transformers, and thus allow the correct consumption (energy costs represent around 10
comparison between the specification of the cooling equipment. percent of all rail operator expenses)
classic solution and ABB’s
Effilight. • Design flexibility (the possibility to have the
Transportation industry case study: same part for different mounting positions)
06a Comparison of
transformer efficiency as Effilight® traction transformer • Life cycle cost reduction, in terms of investment
a function of the output One case that exemplifies ABB efforts toward and maintenance.
power. Roof-mounted
1.1 MVA, 15 kV, 16.7 Hz energy efficiency in transformers is the Effilight®
to 25 kV 50 Hz traction traction transformer →5. The first commercial order for Effilight is for 42
transformer. Effilight
offers a significant units on 21 trains, the initial step of a long-term
improvement in terms of Over half the world’s trains are powered by ABB relationship intended to deliver and install up to
efficiency compared to
the classical technology traction transformers. Traditionally made of iron 600 traction units for 300 trains by the end of 2024.
in the case of bi-system and copper, traction transformers are among the
traction transformers too.
heavier components on a train. These transformers United for efficiency
06b Typical efficiency use oil for insulation and cooling, as oil has excellent In 2016, in line with its commitment to support
vs. weight curve for a
roof-mounted 1.1 MVA, electrical insulating properties and high reliability. transformer energy efficiency, ABB became
15 kV, 16.7 Hz traction a founding partner of the so-called United
transformer. Increasing
efficiency always requires ABB’s Effilight traction transformer opens up new for Efficiency (U4E) group. U4E is a public-
increasing weight. opportunities in rail vehicle design by reducing private partnership led by the United Nations
Since Effilight offers a
significant reduction of the weight of onboard components and ensuring Environment Program (UN Environment) and other
weight at equal efficiency, more energy-efficient rail networks, two of the rail major agencies, including the United Nations
it is possible to get
drastically improved industry’s priority objective →6. Development Program (UNDP). The program
efficiency compared to
the classical technology at
the same weight.

—
07 The ABB transformer
efficiency portal – an
ABB Web site that
provides a transformer
cost and energy
efficiency calculator
and information on all
aspects of transformer
efficiency.

—
Reference
[1] The Clean Energy
Ministerial (CEM)
and the International
Partnership for Energy
Efficiency Cooperation
(IPEEC), “SEAD Standards
& Labelling Working
05
Group Distribution
Transformers
Collaboration. Part
1: Comparison of
Efficiency Programmes
for Distribution
Transformers,” 2013.

Based on an innovative approach to mechanical essentially aims to help countries and economies
integration, this major advancement of a proven become energy-efficient through collaboration with
technology offers unprecedented energy-efficient and international companies. This collaboration includes
lightweight transformers with a smart combination of helping governments develop and implement
lower losses and less use of materials. national and regional strategies to improve their
energy efficiency – an important element in the
Effilight uses a unique and patented cell design goals of the Paris Climate Agreement, agreed in
that reduces the quantity of oil needed by up to 2016, to limit the pace of climate change.
70 percent, without compromising functionality.
The technology enables unprecedented weight The partnership focuses on five product categories,
reduction (up to 20 percent) and energy savings including distribution transformers and electric
(up to 50 percent) for train manufacturers and motors (both with ABB representation), with the
rail operators thanks to a unique approach that aim of accelerating and encouraging the uptake of
keeps the oil exactly where it is needed around energy-efficient electrical products.
the windings.
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME R E NE RGY E FFIC IE NC Y 41

99.00 4500
Efficiency to weight curve
98.00 4300 relationship for classic transformer
Efficiency to weight curve
97.00 4100
relationship for Effilight
96.00 3900

Total weight (kg)

Efficiency (%)

95.00 3700
TT standard 2
94.00 3500
Efflight
93.00 3300 version
1 efficient
92.00 3100
Classical 15kV
91.00 Classical 25kV 2900
Effilight 15kV Efflight version light
90.00 2700
Effilight 25kV
89.00 2500
100 200 400 600 800 1000 1200 1400 1600 1800 92.5 93.0 93.5 94.0 94.5 95.0 95.5 96 96.5 97.0
89.2 83.0 76.9 70.8 64.7 58.5 52.4 46.3 40.1 34.0
Transformer output power (kW)
Efficiency (%) – Total losses (kW)

06a 06b

There are two main phases of ABB contribution ABB transformer efficiency portal
from the transformers side: the first phase ABB has a dedicated Web page for transformer
(now concluded) consisted of supporting UN efficiency that contains a blog and links to relevant
Environment in creating a model that assesses articles and Web pages →7. The Web page also
the impact and benefits for relevant countries includes a useful online tool for calculation of
of moving toward energy-efficient transformers. transformer total cost of ownership (TCO). The tool
Here, ABB also provided technical expertise and also compares transformers with different initial
knowledge about appropriate energy efficiency costs and loss values from the following aspects:
levels and metrics. • TCO with payback time on marginal cost.
• Energy consumption.
The second phase (global outreach, now starting) • CO2 emission impact (in kg of CO2) with
will focus on distribution transformers. ABB will the equivalent number of trees needed to
develop training packages and tools to support compensate the extra emissions caused by the
countries and regions in their transition to energy- transformer with lower efficiency.
efficient products and will provide the training.
ABB will also foster interregional collaboration to As energy demands rise, ever more attention will be
promote energy-efficient products. paid to the efficiency of equipment throughout the
power network. By innovating on all fronts and by
ABB is the first transformer manufacturer to join adopting an open, proactive stance to the ongoing
this initiative. evolution of the energy world, ABB will contribute
significantly to the evolution of a highly energy-
efficient power infrastructure. l

07
42 ABB REVI EW GRE E NE R

—
G R EE N ER

ABB transformers
for renewable
applications
As wind and solar power penetration reaches new
dimensions, ABB’s global transformer experience,
grid solutions portfolio and digital technologies
position it perfectly to supply transformers for
renewable electricity grids.

01

Pawel Prylinski Wind and solar are the fastest-growing sources of Dry-type transformers for solar
ABB Transformers
Lodz, Poland electric power today for a few simple reasons: They ABB dry-type transformers are a dependable asset
are renewable energy sources that do not produce in any solar project, ensuring the highest product
[email protected]
greenhouse gases or other emissions; the “fuel” reliability with the broadest service and production
Alberto Rivas is free and essentially infinite in supply; and as footprint in the market. These transformers can
ABB Transformers
Zaragoza, Spain technology matures, equipment costs continue to help harness the power of the sun in any location
drop [1] →1-2. and under virtually any conditions - from central
[email protected]
inverters at 1,000 V DC for high efficiency in Japan
Peter Rehnstrom As one of the largest independent suppliers to multi-winding solutions for 1,500 V DC up to
ABB Transformers
Ludvika, Sweden of electrical components, as well as a power 4.6 MVA inside a conventional high cube container
technology leader, ABB helps renewable energy for installation and logistics savings. The design
Peter.rehnstrom@
se.abb.com customers along the complete value chain to adaptability of ABB dry transformers allows owners
generate, connect, monitor and control power as to integrate the transformer inside the inverter, thus
Juan Pedro Gracia
ABB Transformers well as to maintain and optimize their systems. taking the containerized concept to the next level.
Zaragoza, Spain

juan-pedro.gracia@ Solar applications – Higher-temperature products, like ABB’s hi-T

es.abb.com the latest transformer technology Plus concept with upgraded insulation, can allow
Marie-Azeline Faedy ABB transformers provide customized products further cost efficiency in a solar project. Owners
ABB Sécheron Ltd. for solar inverter manufacturers and solar farm can optimize the rated power for multiple ambient
Geneva, Switzerland
developers for both indoor containerized inverter temperatures without footprint or weight changes,
marie-azeline.faedy@ stations and outdoor inverter solutions. As the granting inverter standardization and economy of
ch.abb.com
global technology leader for transformers, ABB scale. An upcoming proliferation of utility string
Ilario Scian offers a deep knowledge of inverter configurations, inverters will entail a further expansion of compact,
ABB Transformers
Monselice, Italy real operating conditions and specific customer safe and virtually maintenance-free dry-type
requirements. This knowledge helps ABB customers transformers, as MV applications will be integrated
[email protected]
understand the implications of equipment load into compact substations of up to 5 MW each →3.
cycles and thus optimize their balance of systems. String solutions from ABB involve a simplification of
This deeper understanding increases their transformer design requirements and further cost
competitiveness in a market that is extremely savings while increasing the available power inside
dynamic and price-driven. conventional, easy-to-ship containers.
 SP ECI AL R EP OR T | T R AN S FOR ME RS TRANSFORMERS IN RENEWABLE APPLICATIONS 43

ABB has also developed MultiSOLAR, a transformer

that can connect up to six inverters in solar plants
with a central inverter. This is an efficient and
compact solution that can be containerized up to
6 MVA and allows owners to minimize logistic and
operational costs.

Energy-efficient designs based on different inverter

sizes, and power and voltage ratings, meet all
current regulations and standards worldwide.
Liquid-filled transformers can be manufactured and
tested with mineral oil, synthetic-ester or natural-
ester fluids, based on customer requirements.

ABB works closely with equipment owners to

optimize designs, not only for the transformer
but also for the total cost of ownership of the
entire site. This includes ease of installation and
full integration. ABB has a global network of
factories and expertise, so transformer design and
production can take place close to most customers.

The ABB fit-for-purpose approach perfectly

matches the modern solar industry’s challenges,
such as longer times for funding approvals and
shorter times for project execution, and pressure to
reduce system and project costs.

Wind applications -
The latest transformer technology
Wind applications can take advantage of a variety
— Liquid-filled transformers for solar
01 As costs tumble of ABB transformers, both liquid-filled and dry:
and climate change With market constraints in mind, ABB has developed
awareness increases, liquid-filled distribution transformers for the solar
growth in solar Dry-type transformers for wind
generation and wind industry that pair with various solar inverter sizes.
ABB dry-type transformers provide customized
power is far outstripping These “fit-for-purpose” transformers are designed
other forms of energy solutions for turbine manufacturers and wind farm
generation. to optimize the performance, reliability and return
developers that can be used in power generation
on investment of any solar installation. From
— or distribution. As the global technology leader,
02 Indexed electricity residential rooftops to commercial and industrial
ABB offers the broadest experience, with a
generation by fuel applications and utility-grade power plants, ABB’s
(2001-21). The share of deep knowledge of drivetrain interfaces and
renewables in global fit-for-purpose solar distribution transformers are
real operating conditions that lead to compact
electricity generation specifically matched to different solar inverter sizes
is expected to increase and optimized options for up to 8 MVA and E3
from over 23 percent in and their applications. Streamlined quotation and
certification for such applications. With more than
2015 to 28 percent in manufacturing processes shorten lead times so
2021 as renewable power 32 GW worldwide capacity added by transformers
output is anticipated to aggressive customer timelines can be met →4.
grow much faster than
delivered since 1998 to more than 55 countries, ABB
global power from coal, is truly enabling the power of wind.
natural gas and overall
electricity generation [1].

02 280

280 Renewable
Coal
240
Natural gas
220 Global power generation
2001 = 100

200

180

160

140

120

100
2001 2003 2005 2007 2009 2011 2013 2015 2017 2019 2021

Year
44 ABB REVI EW GRE E NE R

03 04

Dry transformers are suitable for installation inside By 2020, 65 percent of the new installations in
the wind turbine, either on the ground floor, at a northern Europe will operate at 66 kV. This boost in
first level or in the most demanding location, the voltage level will significantly reduce losses, make
nacelle →5. In all cases, the design implements generation systems more efficient, deliver life cycle
a vibration-proof configuration according to benefits and enable major efficiency gains.
IEC 60068-2-6/59 and EN 600. The design also
includes a class H insulation system to minimize the In mid-2017, ABB announced its latest innovation
footprint and prevent continuous overloads from in transformer technology with the introduction
aging the transformers. of the 66 kV WindSTAR transformer. WindSTAR’s
modular design can adapt to specific customer
Liquid-filled transformers for wind requirements and makes installation and
ABB has a portfolio of liquid-filled distribution commissioning easier than ever before →6-7.
transformers for the wind energy sector. These
transformers cover all applications from onshore Space is valuable and restricted inside wind
pad-mount or ground-mount to offshore tower- or turbines and WindSTAR’s design is lightweight with
nacelle-mounted versions. a minimal footprint. Forced oil and forced water
cooling methods are used to remove heat from
Within the portfolio, ABB can supply different liquids the transformer while making the transformer
like mineral oil and ester liquids (both synthetic and assembly more compact.
natural). Should the requirement be for an onshore
padmount, or a very complex offshore in-tower The WindSTAR design is as safe, robust and reliable
solution, ABB provides a tried and tested cooling as possible to minimize the costs of repair and
design to meet any specific requirements. maintenance that are generally high in offshore
locations. The transformer uses high-temperature
With over 5,000 liquid-filled transformers in service insulation paper and an environmentally friendly
in the wind energy industry, ABB has class-leading and high-flashpoint ester. Ester fluids demonstrate
experience in the field. Designs give appropriate a much-reduced risk of fire initiation and
consideration to all the industry-specific propagation, not to mention outstanding self-
characteristics such as harmonics, vibration, extinguishing and biodegradability properties.
voltage spikes, load cycle, short-circuit strengths,
etc., giving the purchaser assurance that the design 05

will perform the tasks required while in service.

WindSTAR – the world’s largest offshore

wind turbine transformer
Increasing competitiveness in offshore and onshore
wind projects is mainly driven by the increasing
power output of the wind turbines. Today, the
current maximum power output of an individual
unit of around 9 MW is expected to rise to 12-14 MW
by the year 2020. To accommodate higher offshore
power densities and to reduce the levelized cost
of energy (LCoE), wind farm collection grids are
moving from 33 kV up to 66 kV.
 SP ECI AL R EP OR T | T R AN S FOR ME RS TRANSFORMERS IN RENEWABLE APPLICATIONS 45

—
03 Dry-type transformers
can be used to remove
the risk of fires or spills.

—
04 Liquid-filled
distribution transformers
are a proven solution with
quicker lead times.

—
05 Dry-type transformer
placed in nacelle for wind
application.

—
06 ABB’s WindSTAR – The
world’s largest offshore
wind turbine transformer.

—
07 WindSTAR
characteristics.

—
Reference
[1] International Energy
Agency, “Energy
Snapshot:Indexed
electricity generation
by fuel (2001-21).”
Available: https://www. 06
iea.org/newsroom/
energysnapshots/
indexed-electricity-
generation-by-
fuel-2001--2021.html WindSTAR can cope with the rough and exceedingly Building a sustainable future
variable conditions out at sea. The design has been ABB also offers transformer solutions for collection
extensively tested against vibration and short circuits, stations (offshore platform and onshore) and
and for further robustness, the transformer’s tank has integration of remote renewable energy sources
been hermetically sealed by a welded-on cover. into the grid with powerful ultrahigh-voltage DC
and AC transformers.
WindSTAR offers a best-in-class solution to
withstand sudden variable loading and is available ABB’s global transformer experience, grid solutions
for both 36 and 72.5 kV class applications. Both portfolio and digital technologies uniquely position
products are compliant with international standards the company to support the complete transformer
and regulations for wind turbine transformers. Low life cycle. With 40 dedicated transformer service
overall system losses and improved LCoE ensure a centers, nine service workshops and thousands of
low total cost of ownership. team members, ABB helps its customers provide a
stronger, smarter and greener grid. l
When it entered service in 2014, the Vestas V164 had
the largest installed capacity of any wind turbine.
In 2017, the 9 MW version of the V164 set a one-day
production record of 216 MWh. It is for power levels High voltage 33 kV 66 kV
such as these that the WindSTAR has been conceived
and 128 units of the 33 kV version and 16 units of KV class 36 kV 72.5 kV

the 66 kV version have already been delivered to five

Rated power > 10 MVA > 10 MVA
offshore wind farms in the UK and Germany. Now,
more than 70 66 kV units are in the pipeline, with Cooling KFWF KFWF
powers ranging from 11 MVA to 14 MVA.
Insulation liquid Ester Ester

Insulation material High-temperature class High-temperature class

Tapping range +/- 2 x 2.5% +/- 2 x 2.5%

Low voltage > 400 V > 400 V

Frequency 50 or 60 Hz 50 or 60 Hz

07
46 ABB REVI EW STRONGE R

—
ST R O NG E R

Shunt reactors improve

voltage stability
and power quality
ABB’s leading position in high and ultrahigh-voltage shunt
reactors stems from an uncompromising commitment
to quality, innovation and technical excellence. ABB shunt
reactors provide innovative technology to meet the needs
for voltage stability, power quality and integration of
renewable energy.

The networks for transmitting and distributing

electrical energy face new demands due to changes
in power generation and load structure. Both
commercial and environmental drivers contribute
to this demand, as does power quality. Dynamic
and time varying effects associated with renewable
energy also influence networks. The active power
Claes T. Bengtsson flow in the network and the balance of reactive
ABB Transformers
Ludvika, Sweden power must both be regulated to maintain voltage
stability – a key to power quality in HV transmission.
claes.t.bengtsson@
se.abb.com The voltage level in the grid must also be kept
within specified limits regardless of the loading,
which varies with time (hourly, daily or seasonally).

Shunt reactors are cost-effective and reliable

Shunt reactors (SR) are commonly used to
compensate reactive power and to maintain voltage
stability →1. Traditionally, SRs have fixed ratings
with no means of voltage regulation. If regulation
Joel A. Kern is needed, fixed reactors are switched in and out
ABB Transformers
Raleigh, NC, United States along with load variations. However, the resulting
large steps in reactance lead to step changes in the
[email protected]
system voltage level, especially if the grid is weak.
This creates power quality issues and places stress
on the breakers.

Wherever power quality is essential, variable shunt

reactors (VSR) are an attractive alternative to fixed
reactors →2. VSRs have regulation capability and
can interact with other regulating devices such as
Static Var Compensators (SVC) [1], [2].
 SP ECI AL R EP OR T | T R AN S FOR ME RS QUALIT Y POWE R WITH SHU NT RE AC TORS 47

— VSRs based on transformer tap changers have a the electromagnetic forces. Flexible structures will
01 One of ABB’s shunt
reactor is shown; it is regulation speed on the order of minutes between adjust to the forces more than will a rigid structure.
an absorber of reactive the extreme positions. As load variations occur The core column must therefore be very stiff to
power, thereby increasing
the energy efficiency of slowly, i.e. mostly on the order of hours or longer, minimize vibrations [3], [4]. For three-phase reactors,
the system. VSRs based on tap changer technology prove to be the three wound limbs must also be properly
the most cost-effective and reliable technology for aligned during stacking and accurately levelled at
controllable shunt reactors. the top yoke. These assembly operations require
high precision and skilled workshop operators to
Iron core shunt reactor technology achieve low vibration and noise levels.
ABB’s high-voltage shunt reactors are built according
to the gapped core concept; this is the dominant High-voltage shunt reactors can be built either
core-type reactor on the market today. as single- or three-phase units; the three-phase
unit is more economical. Apart from a lower direct
For the largest reactors (300 MVAr), pulsating investment, the three-phase alternative has lower
forces across air gaps caused by the magnetic field losses and requires less space in a substation.
can be as high as 50 tons [3] and appear 100 times Reactors are selected for reliability in some regions,
per second in 50 Hz systems. Vibrations that result where the cost of keeping a spare unit is lower than
from the electromagnetic forces will generate the cost of a three-phase unit. Shunt reactors at or
sound. The degree of vibration depends on the above 765kV are predominantly single-phase, yet
rigidity of the mechanical structure exposed to can currently be constructed as three-phase units.

01
48 ABB REVI EW STRONGE R

High-voltage shunt reactors are designed and Power quality

optimized according to customers’ specifications. Switching in and out of fixed reactors produces
Besides the basic design parameters, such as steps in the system voltage. This can be avoided by
voltage, rated power, linearity etc. limits to losses using VSRs, in particular if the grid is weak.
and sound disturbances also affect design.
Generally, the lower the loss, the more material is Integration of renewables and wind parks
added to windings and core to keep the current Large installations that are connected to the
density and flux density low, thereby reducing transmission or sub-transmission grid can
losses. Similarly, the maximum acceptable sound experience unpredictable fluctuating active-
level of the reactor – often a dimensioning factor power exchanges and reactive-power fluctuations
in the design process – is important from an – serious concern for the operational security
environmental and energy saving perspective. of the grid →3. VSRs provide a way to control
reactive power fluctuations and allow the wind
A VSR is based on the same concept as an SR, park operator to comply with the connection
yet has one or more regulating windings in requirements of the grid code →2 [5].
combination with a tap changer, like a transformer.
A VSR is, however, distinctly different from a Emerging grids
transformer, because it has a substantially larger VSRs are useful when reactors are installed at HV
regulation range, normally up to between 50 and lines that initially carry a low load that will increase
60 percent. Larger regulation ranges up to 80 with time – a common scenario in developing
percent at 400 kV can also be achieved, at higher economies. One VSR is a more cost-effective
complexity and cost. solution than two fixed reactors: less expensive,
smaller footprint, lower losses and only one breaker.
Depending on the tap changer position, the
magnetic flux will vary within the reactor; the Zero crossing
maximum value is achieved at the maximum rating This phenomenon occurs more often because of the
with a minimum number of connected electrical increasing use of HV AC cables at transmission levels.
turns. As flux varies, the sound level and losses of The absence of current zero-crossing can delay the
the reactor vary depending on tap changer position. opening of the circuit breaker, thus leaving the system
If the same number of turns per regulating step unprotected and vulnerable to failures [6], [7]. One VSR
are installed, each step, albeit small, will not have is therefore the most cost-effective solution.
exactly the same Mvar rating.
Tuning of Static Var Compensators (SVC)
Field applications of shunt reactors The system operator can adapt the reactive power
Shunt reactors are essential equipment in high- compensation to the actual load, thus running the
voltage networks operating over long distances grid optimally. If SVCs are installed in the grid, the
and in cable networks to provide voltage stability use of VSRs can provide optimum headroom; the
and increase the transmission efficiency. VSRs are SVC can operate in a minimum loss position.
applicable for the compensation of varying load
conditions in many circumstances described below. Flexible and universal spare
A VSR can be used in several positions in the grid
provided that the voltage levels are similar and can
be used as a universal spare if required [1].

166.5

166.0
Voltage at busbar (kV)

165.5

165.0

164.5

Switchable shunt reactor: reactor connected.

164.0 Regulated shunt reactor: reactive-power-control-mode.
Regulated shunt reactor: voltage control mode.
Switchable shunt reactor: reactor not connected.
163.5
0 20 40 60 80 100 120

Power produced (MW)

02
 SP ECI AL R EP OR T | T R AN S FOR ME RS QUALIT Y POWE R WITH SHU NT RE AC TORS 49

—
02 Voltage at a 165 kV
substation is shown as
a function of the active
power produced by a
wind park; four different
cases are illustrated.

—
03 Different operators
have different
requirements for
the reactive power
exchange at the point of
connection on large wind
farms.

03

Air core reactor technology Field applications of air core reactors

Air core reactors are available in oil-free and oil- Air core reactors are used for a variety of industrial
filled solutions. For moderate voltages and power and utility field applications: harmonic filters, shunt
ratings, the most economical type of current reactors, short-circuit current limiting, thyristor
limiting reactor is usually a dry-type transformer controlled reactors, inrush damping, neutral
without an enclosure or active cooling →4. grounding, smoothing and electrical arc furnaces.
Numerous reactors of this type are in operation
around the world, mostly in medium to high- Harmonic filters are typically installed with capacitors
voltage industrial power systems. and resistors, close to the source of harmonics to
provide a low impedance path for harmonic currents;
Air core reactors have larger footprints than iron-core they are tuned to a specific frequency to cancel or
options. As a result, the magnetic field that spreads mitigate the relevant harmonic.
freely in the surroundings may cause excessive
heating of iron reinforcements in objects like Shunt reactors are employed when the
concrete walls. For this reason these objects should compensation of the capacity reactive power is
be located at sufficient distances so that magnetic required; where lightly loaded long transmission
field strength values are below 80 A/m at the floor lines or cables are used. They are also installed on
and ceiling and below 30 A/m at adjacent walls. the tertiary winding of a power transformer or on
the substation busbar system.
ABB’s outdoor air core reactors utilize a proprietary
construction that gives the coils the industry’s Short-circuit current limiters reduce the short-
highest levels of mechanical strength for short circuit current to values accepted by the installed
circuit and environmental protection. This advanced circuit breakers when faults occur. Consequently,
construction has been validated during decades standard equipment can be installed in the network
of robust use by traction rolling stock and in for high short-circuit currents.
offshore oil and gas production facilities. The
construction features a vacuum impregnation Thyristor controlled reactors (TCR) are employed in
process that uses an unique Class H epoxy resin, SVC systems for dynamic load balance in industrial
a dedicated oven-curing cycle to give the reactor plants where large variable loads are installed. TCR
additional mechanical strength and a final coating reactors, unlike shunt reactors, use thyristor valves
of protective varnish to shield against UV and to continuously regulate current.
corrosive elements.
Inrush damping is commonly installed in series with
a shunt capacitor bank, which functions to limit the
inrush currents due to switching and the outrush
current of the capacitor bank.
50 ABB REVI EW STRONGE R

— Neutral grounding is installed between the network

04 Three-phase, stacked 1969 The world’s first 400 kV shunt reactor
outdoor air core reactors. neutral point and earth to limit the line-to-earth
fault current. In balanced networks the through 2004 Introduction of Variable Shunt Reactors
—
05 History of shunt current is nil even though the networks are
reactor development. designed with a continuous current in mind; this is 2008 Testing of world’s largest 3 phase reactor, 300 MVAr/400 kV
at full power
due to the unbalance of the network.
— 2009 The world’s largest Variable Shunt Reactor, 200 MVAr/420 kV
References Smoothing reduces the harmonic voltage and
[1] K. Ryen et al., 2011 VSRs with 60 % regulation range at 400 kV
currents in DC lines and the ripple in the DC
“Application of Variable
Shunt Reactors in High currents. This is mainly used where large rectifiers
2016 VSRs with 80 % regulation range at 400 kV
Voltage Networks,” Cigré
are installed, in traction substations or in
A2/C4 Colloquium Zurich,
2013. HVDC substations. 05
[2] C. Bengtsson et al.,
“Variable Shunt Reactors:
Applications and System Electrical Arc Furnaces (EAF) are typically installed construction is be made to manage the high forces
Aspects,” Cigré, paper
in series with the primary power transformer in in the winding induced by the switching operations.
A2-211, 2014.
[3] C. Bengtsson et al., smelter plants. Particular care to the mechanical Furthermore, these reactors are often equipped
“Design and Testing of
300 Mvar Shunt Reactors,”
with taps to increase operational efficiency.
Cigré, paper A2-305, 2008.
[4] C. Bengtsson et al.,
“Field Performance and
New and future technologies
Sound of Shunt Reactors Since the introduction of the gapped-core shunt
in Service,” Cigré, paper
A2-306, 2008.
reactor in the late 1960’s, ABB has delivered more
[5] M. Bollen et al., than 2,950 shunt reactors to around 60 different
“Application of Regulated
Shunt Reactor for Off-
countries. Today, ABB has the capacity to deliver
Shore Wind Farms,” Cigré and test both fixed SRs and variable SRs with
Colloquium Bruge, paper
42, 2007.
extremely high ratings →5.
[6] F. Faria da Silva
et al.,”Methods to
Minimize Zero Miss
Customer demands and competition in the
Phenomenon,” IEEE energy market have increased over the last
Trans. on Power Delivery,
TPWRD-00683-2009.
decade. Environmental concerns drive growth
[7] S. Wijesinghe et al., in renewable energy, extending the use of cable
“Transients Following
the Energizing of High
networks and generating an interest in producing
Voltage AC Cables with lower noise levels. Recognizing these trends,
Shunt Compensation,”
International Conference
ABB offers shunt reactors tailored to these
on Power Systems specific applications eg, ultralow noise reactors
Transients (IPST2013),
Vancouver, July 2013.
without the need for external sound damping;
three-phase SRs that operate at 765 kV, and the
ability to custom design and build VSRs at 765
kV. Relying on experience and know-how, ABB
continues to set new limits for reactors and to
provide new sophisticated products to meet the
often complex needs of customers. l

04
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME RS TO ME E T SPE C IAL NE E DS 51

—
ST R O NG E R

ABB’s transformers for

special applications meet
special needs
Designed to be flexible, compact, and adaptable, ABB’s
specialized transformers are available in a broad range of
voltage levels and power ratings; units for subsea or mobile
substations and data centers operate with reduced losses.

Esa Virtanen For complex applications or harsh conditions Data centers

ABB GPG OY Transformers
Vaasa, Finland
standard transformer products might not be feasible. Data center technology is dynamic and continually
Drawing on 100 years of experience and a global expanding – ABB ensures safe, reliable, and
[email protected]
footprint, ABB has developed special application efficient operation of these invaluable information
Joel Kern transformers with this in mind. High quality materials fortresses →1. Building on its background in
ABB GPG Dry Transformers
Raleigh, NC, United States
for core and winding, improved components and supplying mission critical power and automation
perfected connection technologies allow ABB to technologies, ABB has developed a transformer
[email protected]
develop transformers to suit the end user; the result is that can operate safely with fast-acting breakers
Pablo Pacheco reduced power losses and extended product lifetime. to provide reliable commissioning and load-bank
GPG Power Transformers
Córdoba, Spain
In this way, ABB meets customers’ technological switching operations.
demands while reducing investment time.
pablo.pacheco@
es.abb.com
01
Ruggero Bordon
ABB GPG Power
Transformers
Monselice, Italy

ruggero.bordon@
it.abb.com
52 ABB REVI EW STRONGE R

02 03

Switching of fast-acting breakers, such as vacuum industry that is located on the seabed: boosters,
and SF6 breakers, can produce fast transient pumps, compressors, pipeline heating systems
overvoltages inside transformer windings; some of and frequency converters →3. In the near future,
which lead to failures, with subsequent downtime subsea transformers and reactors will be used for
and irreparable equipment; both of which are grid connections of wave power, tidal turbines and
incredibly costly to network managers. ABB’s offshore wind parks.
Transient Voltage ResistantTM Transformer (TVRTTM)
provides complete peace of mind during network Traditional production facilities, without subsea
switching operations →2. The TVRT functions in any electric machinery, must cope with the constant
electrical network because it is the only solution that decrease of the pressure of the reservoir and a
controls transient voltages. All its components are shortened economic lifetime of the field. Typically,
oil-free, which greatly reduces installation costs and subsea booster pumps increase the pressure of oil
removes the risk of fires or spills; this is the safest flow and water pumps raise the oil by injecting water
solution for people, property and the environment. into the reservoir, thereby increasing the lifetime
and productivity of the wells. Compressors raise
The development of the TVRT by ABB engineers the pressure of the gas and increase the flow from
led to the knowledge that switching transients are the seabed to shore along the gas pipeline. Subsea
generated inside of the windings, unlike lightening high-voltage (HV) transformers allow pumps and
voltage transients. Furthermore, overvoltages compressors to be placed farther away from the
caused by high frequency re-ignitions are the source existing power generation and supply point.
of the major voltage stress, not amplification of
voltage due to resonance inside the transformer, Electric motors located on production facilities,
as was previously thought. With that insight, ABB’s controlled by topside drive these pumps and
engineers addressed the problem and provided a compressors. Long HV cables supply power from
simple solution: varistors are placed strategically the topside drives to the subsea machinery situated
along the windings in proprietary arrangements apart from the topside installation. Step- down
to limit transient overvoltages for re-ignitions subsea transformers are then installed at the
that may occur inside of the breaker as well as for seabed nearby to adapt the supplied high voltage
any amplified voltages from harmonic resonance to the operation voltage of the machinery. Higher
inside of the transformer. Combined with advanced transmission voltage reduces the load current and
winding design, this engineered technology controls therefore the size and weight of the cables and the
peak voltages that might occur without the need to voltage drop in the cable.
know the characteristics of the connected system.
Dedicated subsea power distribution grids can be
The TVRT technology also eliminates the risk and constructed with constant voltage and frequency
maintenance associated with oil-filled capacitors. (50/60/16.7 Hz) with a main subsea transformer
This is particularly important for data centers that and a subsea power distribution grid on its
rely on dry-type transformers to lower the need for low voltage side. Recently, ABB has successfully
maintenance and reduce the risk of fire. conducted underwater tests of a drive unit that
includes an integrated subsea transformer; this
Subsea applications demonstrates that power transformers up to 100
ABB delivered the world’s first commercial subsea MVA can be manufactured and operated.
transformers in 1998 – a pioneering achievement.
Robust, maintenance-free and exceptionally ABB’s subsea transformers are designed
reliable, transformers are routinely used nowadays to operate at great depth and extreme
to power the field equipment of the oil and gas atmospheric pressure. The devices are liquid-filled
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME RS TO ME E T SPE C IAL NE E DS 53

— and pressure-compensated to keep the internal operation in just a few days. It would take weeks or
01 Data centers count
on reliable power, which pressure near that of the external water. even months to mobilize a large, spare, standard
ABB’s TVRT makes three-phase transformer.
possible.
ABB uses high-quality insulating oil with a low
— expansion coefficient and high compatibility with Ten years ago, ABB manufactured the world’s
02 TVRT is designed
specifically to resist other components in the transformer. Because the first HV mobile transformer using the robust
load-bank switching transformer is housed in a solid corrosion-proof shell technology to give utilities a flexible and fast
operations.
tank that cannot expand, even when hot, the oil recovery solution. Thanks to research on materials
— is degassed before installation and the tank is and winding configurations, this solution has
03 ABB’s rugged subsea
power transformers provided with a patented pressure compensating been recently improved: it is more compact, with
deliver the power system, thereby ensuring safe operations. a higher-rated power and a higher number of
that makes subsea
exploration by the oil and voltage ratios; polyvalent transformers can be
gas industry feasible. Once installed on the seabed, the scope for repairs easily transported to any desired substation rapidly,
— is limited. ABB has invested in resources to ensure thereby optimizing grid operation.
04 Polytransformers that its transformers are maintenance-free and all
rely on a multi-voltage
approach and are components are of the highest quality. Rigorous Multi-voltage configurations must allow rapid
compact; they can be testing enables these transformers to enjoy a long, adaptation to different grid voltage levels, to
shipped and installed in
any substation. maintenance-free operating life. allow full working capabilities. The latest Shell HV
mobile units solves these challenges. Successfully
ABB’s shells HV mobile transformers for planning tested in its Córdoba, Spain facility in early 2018,
Nowadays, utilities are asked to prepare detailed ABB could then design and manufacture a 550 MVA
contingency plans, to efficiently manage partial three-phase bank composed of modular hybrid
grid unavailability in case of a power transformer single-phase units, with multi-voltage capacity for
failure. If failure occurs at a critical substation, different voltage ratio configurations by means of
with approximately 500 MVA rated power, revenue 400-220/220-138-66/33-20 kV rated voltages →5.
losses can reach up to $0.3 million per day, before These are the world’s first mobile single-phase
consideration of financial losses caused by damage transformer units operating at 420 kV with full
to reputation. Two main strategies exist to meet voltage range and capacity OLTC in HV. Now,
these challenges: replace the failed unit with a emergency conditions will not impact the operation
local spare unit within the same substation (ie, the of these mobile units.
traditional N+1 spare approach), or use adaptable
transformers that are compact, rapidly deployable Conceived to provide emergency support for up to
multi-voltage solutions. The latter approach is fourteen substations spread over an approximate
dominant today: a single design with outstanding 1000 km2 area, end users can now count on an
flexibility that leads to lower investment costs. optimized spare fleet instead of turning to the
typical N+1 approach. This single adaptable
The use of HV Mobile transformers →4, can modular design solution therefore results in a
significantly reduce reaction time – ie, a compact significant reduction in investment.
single phase unit can be transported and put in to

04
54 ABB REVI EW STRONGE R

Available for various voltages and power ratings,

—
220 kV the transformers are reliable – supplying high-
05 Simplified diagram 400 kV
shows the possible HV 220 kV
138 kV quality energy to many different substation
66 kV
levels, LV levels and configurations and applications:
tertiary voltage levels
that can be adjusted. • Dispersed and unpredictable generation sites
• Generation from renewable sources
—
06 Power transformers • Fast-recovery plan due to aging of the
for mobile substations existing plant
can be easily arranged
in many configurations, 33 kV • Skid mounted arrangement to limit civil works
20 kV
mounted for air, rail and • Fully relocatable modularized switchyard
road transportation
and installed almost • Power supply to facilitate projects by providing
anywhere. 05 an alternative temporary supply in substations
06a Power transformers • Emergency installations in adverse
at 27MVA 150/8.4kV for Additionally, the newest HV mobile unit’s limit environmental conditions
MFM “Lean-type”, used
in the ACEA Substation, weight is below 100 tons, and shipping height
Salisano, Italy. The MFM’s is less than 3.5 meters to ensure short and easy Most recently, ABB moved the first generator step-up
are skid-mounted and
were installed on existing transit. Nevertheless, the transformer must still (GSU) 60 MVA and 220 kV power transformer on a
foundations. operate properly once it reaches the substation. single trailer in combination with the high-voltage
06b Generator step-up By adapting to the existing system voltage levels at hybrid switchgear PASS module (Plug and Switch
power transformers each new location, ABB’s mobile solution achieves System) – forming a fully assembled MFM – to the
at 30/40/60 MVA
11.5/220 kV for MFM, the greatest voltage ratios available for a HV energy grid in Algeria →6b. In cooperation with
to be coupled with gas mobile unit in the industry today. The HV level can Energy Services Inc. (ESI), a Pratt & Whitney affiliated
turbine-generating units.
The MFMs are installed be adapted either to 400 kV or 220 kV, LV level can engineering group, this concept has been developed
on trailers for road be adjusted to 220 kV, 138 kV or 66 kV, and tertiary for the power supply through their MOBILEPAC® self-
transportation in Algeria.
voltage can be selected from 33 kV to 20 kV →5. contained gas turbine-powered electric generating
The main voltage can be altered after arrival, and units, which feed the GSU power transformers rated
additional minor voltage levels on-load adaptations at 30/40/60 MVA, 11.5/220 kV, BIL 1050 kV.
can be provided by the permanently installed OLTC
HV side during operation. This special power transformer is designed with
three cooling stages and is integrated to the
Overall, ABB’s shell HV mobile transformers help PASS through oil-SF6 bushings. The MFM’s are
utilities to deal with emergency contingency plans, then equipped with synchronizing relays for the
thanks to mechanical robustness, compactness generator gas turbine and digital relays for control,
and ease of transit, straightforward voltage tap protection and metering. The compact design of
adaptations, and reliability. these GSU power transformers for MFM and the
MOBILEPAC® power supply system allow energy to
Mobile substations and multi-functional modules be supplied less than one day after arrival. Currently,
During contingent events (eg, interim grid in operation in four different locations in Algeria,
connections) utilities still need to provide for power, these units guarantee flexibility and adaptability to
but how? Enter ABB’s Power Transformers for customers, who count on ABB to meet the unique
Mobile Substations (MoSS) →6a and Multi-Functional demands in the transformer market.
Modules (MFM) →6. These devices enable: power to
be supplied during emergency or planned outages, “ESI chose ABB’s MFM solution on account of its
loads to be moved and the integration of distributed compact design, speed of delivery as well as ABB’s
or renewable power and generation. commitment to supply products as per stringent
technical specifications, thereby paving the way for
Completely assembled, these units are mobile and this important collaboration.” stated Larry Pitts. l
ready-to-connect. Designed to comply with any grid
codes, these power transformers are invaluable for
the demands of special substations.

06a 06b
 SP ECI AL R EP OR T | T R AN S FOR ME RS U HV DC AND U HVAC TR ANSFORME RS 55

—
ST R O NG E R

Power fulfillment with

ABB’s UHVDC and UHVAC
transformers
By enabling high transmission voltages, large amounts
of electric power can be transmitted over great distances
at high efficiency. ABB has made groundbreaking
developments in UHVDC and UHVAC transmission; today
1,100 kV DC and 1,200 kV AC is possible.

Mattias Viksten Energy demands are growing and a 70 percent technology for the essential link between the AC
Markus Pettersson
HVDC transformers
increase in electricity consumption anticipated by network and DC systems.
Ludvika, Sweden 2040, with over half of that growth expected in India
mattias.viksten@
and China [1]. As renewables increasingly become ABB has pioneered this enabling technology,
se.abb.com part of power generation in these countries, the working to increase voltage levels and developing
markus.pettersson@
se.abb.com
need to transmit energy greater distances with groundbreaking components to meet the
reduced losses becomes ever more desirable. stringent requirements to transmit unprecedented
Ryan Ladd
Power Transformers
However, the renewable energy sources can be power capacity ever farther under the harshest
Ludvika, Sweden located thousands of kilometers away from the load field conditions. ABB’s 100 years of experience
[email protected]
centers where electricity is needed. In these extreme and expertise in the design and manufacture of
cases, ultrahigh-voltage (UHV) is often the most transformers, along with a pioneering role in the
economical way to transmit the growing amount development of HVDC transformer technology in
of power, and converter transformers are the key the 1950s, provides the basis for their scientists and

01

AC side DC side

DC Transmission

AC Bus

HVDC
Transformer
56 ABB R EVI EW C HAPTE R 01

02

engineers to reach milestones in the development Converter transformers are typically large in terms
of power transmission, thereby establishing world of physical size due in part to the high power
records time and time again. ratings, and because both windings necessitate a
high degree of insulation; the AC winding is often
The high-voltage power transformers developed by connected to high-voltage AC grids while the DC
ABB for 1,100 kV DC and 1,200 kV AC utilize the most winding has heightened insulation requirements.
advanced technology available. The most notable For this reason, dielectric performance is vital
advancements have been made in improving to the design of HVDC converter transformers.
dielectric performance but developments have Converter transformers must not only withstand
also been achieved in all associated fields, such as AC-stress, but also DC-stress generated during
thermal and mechanical performance. tests and service of the DC transmission system.
Designing converter transformers to withstand
The HVDC converter transformer DC-stress has proven to be one of the most
The HVDC converter transformer is unique in terms complex and formidable challenges undertaken by
of the challenges it must overcome to function engineers who design this enabling technology.
reliably and efficiently. Acting as the electrical and Thus, HVDC converter transformers are the most
mechanical interface between the AC system and rigorously tested transformers in the entire
the DC converter, such transformers are exposed to transformer industry.
the demands of both systems simultaneously →1.
Comprehensive testing must also be applied to
The main function of the HVDC converter the bushings and tap-changers. ABB’s unique
transformer is to insulate the DC-voltage of the position to design and manufacture these devices
converter valve from the AC-network to which in-house – relying on unprecedented expertise and
the HVDC system is connected. All the power experience allows ABB to develop sophisticated
that flows through the HVDC system passes the designs and deliver the most reliable and optimized
converter transformers, thereby delivering current transformers possible on schedule.
at a suitable voltage level to the converter valve,
transformed from the AC network voltage level.
 SP ECI AL R EP OR T | T R AN S FOR ME RS U HV DC AND U HVAC TR ANSFORME RS 57

— Development of UHVDC converter transformers a large power infeed and the enormous distances
01 Simplified diagram
showing the HVDC The Itaipu HVDC power link in Brazil, developed and to the load led to the investigation of a new
converter transformer installed by ABB in the early 1980’s, was a complex voltage level of 800 kV DC– ultrahigh-voltage DC
function at the interface
between the AC and DC megaproject that pushed the limits of voltage levels (UHVDC). Thus, an even higher power transmission
sides. and power capacity beyond the then established rating was feasible; a rating that is required by the
— norms. The system reached an outstanding power Chinese electric energy market. The Xiangjiaba-
02 Power transformer transmission level of 3,150 MW and a voltage level Shanghai HVDC project was thus the first 800 kV
for 800 kV UHVDC
transmission is shown. of 600 kV DC– a world record voltage level that UHVDC transmission system to go into commercial
remained unsurpassed for 25 years. Nearly all operation with a power rating of 6,400 MW and a
—
03 The world’s first 1,100 devices and components used for this HVDC project transmission voltage of 800 kV DC; it has operated
kV DC UHVDC could were designed and developed by ABB. Viewed in successfully since 2010 [1] →2.
transmit 12 GW electricity
over 3,000 km. retrospect this project ushered in the modern era of
HVDC technology within ABB. The ability to transmit huge amounts of power over
thousands of kilometers led, in 2011, to the next
The first Chinese HVDC transmission systems major HVDC transmission development – 1,100
were rated 3,000 MW and 500 kV DC, delivering kV UHVDC. In 2016, ABB was awarded a contract
an Itaipu-type transmission power and voltage to supply the world’s first 1,100 kV DC converter
level. An important outcome of these early HVDC transformers, for the 3,000 km, 12,000 MW Changji-
projects was the realization that it is possible to Guquan UHVDC link, inaugurating the commercial
have single infeed points in networks that can development of 1,100 kV DC →3.
handle substantially more than 3,000 MW. China
has access to energy resources, increasingly from
renewables, with transmission distances far from
load centers – ie, 2,000 km. The possibility of such

03
 58 ABB REVI EW STRONGE R

kV MW

1.200 14.000

12.000
1000

10.000
Rated voltage (kVDC)

800

Rated power (MV)

8.000
600
6.000

400 Rated voltage kVDC

4.000
Rated power MW

200
2.000

0
1953 1960 1962 1970 1979 1985 2010 2012 2013 2017 2018
nd

nd

tie

pu

gh -

Su ng-

xi -

gz i-

iz -

uq ji-
ne

an ba

ao ou

Ta eng
ai

ng

Xi u

Ch ou

n
ss

en am

G ng
na

ho

ua
r
la

la

l
an

Ita

Sh jia
Ba

Sh zh
pi
te

h
ot

Zh H

a
m
ng
Ch

In
Ze

ng
G

ra

an
fic

Ji

Li
ew
s

ho

Xi
os

ci
N

Ca
Pa
Cr

04

The rapid development of HVDC technology over UHVAC transformers

the past five years, from 800 kV DC to 1,100 kV DC, Lately, ABB has been able to raise the voltage
is both noteworthy and remarkable considering level of AC networks and significantly improve
that the step from 600 kV DC to 800 kV DC took transformer capabilities. The same motivation was
25 years →4. used to drive gains in AC voltages to facilitate the
efficient long distance transmission of electricity.
Recently, two further groundbreaking developments
have been achieved in the HVDC transformer domain Although ABB has been producing UHVAC
that continue to demonstrate ABB’s leadership transformers for many years, a major
role in transformer innovation and customer breakthrough was achieved in 2016 when ABB
commitment. One such advancement concerns the delivered the world’s first commercial 1,200 kV
power rating for 800 kV DC transmission links, which AC transformer to a substation in India. Fully
was increased from 8,000 MW to 10,000 MW. To assembled, this single-phase 333 MVA, 1,200 kV
raise the power rating by 25 percent, ABB redesigned autotransformer weighs 270 tons and is over
the thermal system to cope with the increased 9 meters in length, more than 8 meters wide
current for the converter transformer. The technical and more than 18 meters in height. ABB’s HV
challenge of increased physical size and scale due to bushing extends 11.5 meters from the top of the
the power increase was also successfully addressed. transformer tank, which weighs up to 6 tons →5.
Consequently, ABB supplied converter transformers
for the world’s first 10,000 MW, 800 kV UHVDC Case study – the 1,100 kV DC project
transmission project and other similar projects. Major load centers are located in the eastern region
of China, while a significant amount of its energy
Another breakthrough concerns the AC-voltage resources, such as hydropower, are located in the
level of HVDC converter transformers. ABB has west and northwest [1]. The expansive geography
developed the ability to interconnect all existing and increased energy demand experienced over the
DC-transmission voltage levels to all existing last decade have prompted the buildup of ultrahigh-
AC network voltage levels. The LingShao project voltage capacity to transmit larger amounts of
was the first commercial application of this power over greater distances with minimum losses.
new technology. ABB’s converter transformers One example of this is the 1,100 kV Changji-Guquan
facilitated the interconnection of 750 kV AC UHVDC project that will transmit 12 GW from the
network with an 8,000 MW, 800 kV HVDC- Xinjiang region in the Northwest to Anhui province
transmission. The successful type testing of this in eastern China and will set a new world record in
technology resulted in a contract award – the terms of distance, voltage level, and transmission
JiuQuan-Hunan project. The supply of leading capacity – a 50 percent increase in transmission
edge converter transformers and components capacity compared to the existing 800 kV 8 GW
facilitates long distance transmission of electricity UHVDC currently in operation [1].
with reduced losses and showcases the ability of
HVDC to reinforce the AC grid.

In the first commercial application of 1,100

kV UHVDC-transmission, ABB’s converter
transformers are also connected to a 750 kV AC
network; this demonstrates the trend of UHVAC
to UHVDC interconnection.
 SP ECI AL R EP OR T | T R AN S FOR ME RS U HV DC AND U HVAC TR ANSFORME RS 59

— The giant converter transformers developed for ABB AbilityTM

04 The advancement
of HVDC converter this project are essential because the transmission The ability to monitor and control the performance
transformer technology distance will be extended from around 2,000 km of transformers that operate at such high powers
has led to flexibility in
HVDC transmissions — to over 3,000 km, thereby playing a key role in and voltages is critical. To ensure that operators
almost any conceivable integrating remote renewables on a large scale. are alerted in case of any problems, devices that
rating combination is
possible. Power can then be transmitted over greater monitor temperatures and transformer oil status
distances; this will facilitate a more interconnected are essential and therefore installed.
—
05 ABB’s 1,200 kV grid. When fully operational , this UHVDC link
AC transformer was will deliver enough power to meet the needs of a In the near future, ABB will extend this monitoring
developed, manufactured
and tested at ABB’s megacity larger than Shanghai. capability with the development of the ABB AbilityTM
Vadodora facility in Power Transformer. This package of integrated
India and currently
supports India’s central The single-phase HVDC transformers developed devices will enable sophisticated aggregation,
transmission utility, at by ABB have a power rating of 607 MVA and an analysis and management of transformer health
Bina India.
installed weight of more than 800 tons. The DC- data – ensuring customers have access to the most
—
References side bushings of this transformer are 40 percent reliable and efficient product possible and
[1] Game Changers
longer, three times heavier and have a 30 percent providing the means to incorporate all advances in
in the Energy System
Emerging Themes larger diameter than the 800 kV DC bushing. The the emerging digital revolution to come [2].
Reshaping the Energy
Landscape, McKinsey
technical innovation required to design and build
& Company, World components of this size and scale challenge even Domain expertise and experience coupled with
Economic Forum 2017,
the world’s most advanced production and testing the most modern test facilities and innovative
“www3.weforum.org/
docs/WEF_Game_ facilities to the limit. simulation tools make ABB the world leader in the
Changers_in_the_Energy_
development of high-voltage power transformers –
System.pdf”
[2] M. Berglund, M. a market position that allows it to develop the most
Peterssen, T. Freyhult, R.
Montano, “Developments
powerful transformer solutions for its customers. l
in UHVDC and UHVAC
Transmission Power
transformers,” ABB white
paper, 2016.

05
60 ABB REVI EW STRONGE R

—
ST R O NG E R

Transformers to
power Indian Railways
Indian Railways has ambitious electrification targets and has found
that ABB’s comprehensive range of transformers provides an ideal
and eco-efficient means not only to power trains, trackside and
stations but also to boost rolling stock speed and performance.

Sanjay Saxena With approximately 200,000 employees and a

ABB India Ltd.
Vadodara, India rail network that encompasses over 64,000 km
of routes, Indian Railways is one of the biggest
[email protected]
public-sector enterprises in the world. Of this
Ilario Scian 64,000 km, around 60 percent is not yet electrified.
ABB Spa
Monselice, Italy Indian Railways have a goal to electrify the entire
network, at an average rate of around 10 km per
[email protected]
day (5,000 km is the 2018-19 target), in order to
Valter Porcellato improve passenger experience and freight handling,
ABB Sécheron Ltd.
Geneva, Switzerland reduce carbon emissions from diesel locomotives
and save on fuel costs →1-2. The company also looks
valter.porcellato@
ch.abb.com to employ equipment that reduces overall carbon
footprint and improves energy efficiency.
Puneet Arora
ABB India Ltd.
Dry Transformers To meet electrification goals, Indian Railways will
Vadodara, India
have to acquire more rolling stock and more of
[email protected] the trackside transformers that supply the 25 kV
overhead lines. ABB already supplies locomotive
transformers to Indian Railways’ original
equipment manufacturers (OEMs), like Chittaranjan
Locomotive Works (CLW) and Diesel Locomotive
works (DLW). In fact, 40 percent of Indian
Railways’ high-speed trains, like the “Rajdhani”
and “Shatabdi” passenger trains, are powered
by ABB traction transformers. ABB’s 30.24 MVA,
trackside transformers, with a low-loss design, are
also helping Indian Railways and their engineering,
procurement, and construction (EPC) partners in
their mission →3-4.
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME RS FOR INDIAN R AILWAYS 61

— The traction transformer market is also driven ABB traction transformers for Indian rolling stock
01 Indian Railways
have an ambitious by measures being taken to combat the rapid Traction transformers have two main purposes
electrification program urbanization taking place in India, where metro in trains. Firstly, they convert single-phase, high-
both in the national and
metro networks. Shown cities and other B-class cities are facing serious voltage (normally ranging from 15 to 25 kV) from
here is a Lucknow Metro traffic jams and vehicle pollution. The Indian the overhead catenary lines to levels (400 V – 1.8
train.
Ministry of Housing and Urban Affairs has approved kV) that are usable by the power converters in
a policy to commission environmentally friendly the train’s traction chain. Secondly, traction
metro railways in cities having a population of transformers provide galvanic insulation for safety
more than one million. This will help to decongest, and protection purposes.
and reduce pollution levels in, cities and make
commuting easier. In support of the Ministry’s The key specific technical product challenges in
vision, ABB electric multiple unit (EMU) technology India are:
for traction transformers are helping to develop the • Harsh environmental conditions: ambient
Metro network in cities like Delhi, Lucknow, Kochi temperature, shock, vibration, flooding,
and Mumbai. ABB traction transformers produced humidity and aridity.
in India are suitable for local conditions and are well • India Railways’ maximum temperature limits
accepted by Delhi Metro Rail Corporation (DMRC), a (which are 20 °C lower than international
central agency for approval of metro equipment. standards) for transformer components
combined with the high ambient temperatures
India’s metro networks also have many stations makes it difficult to cool a contained traction
that require distribution auxiliary and rectifier transformer effectively and still maintain a
transformers. Here, ABB’s latest vacuum-cast-type reasonable weight and size.
technology on dry-type distribution transformers
is helping metro EPCs to supply auxiliary loads and One of the vital factors for success in India is the
third-rail systems. ability to manufacture locally – a fact understood
by ABB at the end the 1990s when local production
of traction transformers for WAP passenger and
WAG freight locomotives was started up. ABB has
developed its portfolio to cover almost all local
01 rolling stock and propulsion system makers – for
example, CLW, DLW, Bombardier, Siemens, Alstom
and Medha.

Recently, ABB had its Indian premiere of

compact, lightweight transformers that use
an ester as cooling fluid. These provide a safer
and biodegradable alternative to traditional
transformers. The metro in Lucknow was an
early recipient of one such (1 MVA, 25 kV/50 Hz)
transformer, equipped with one auxiliary and two
traction windings. With an inductor included in the
tank plus a cooling system, the total transformer
weight is just 3,100 kg. This project was the first
one awarded by Alstom India to ABB India and
all manufacturing is local. The ABB global team
delivered to Alstom’s satisfaction, which paved the
way for the Madhepura Century Project – a very
large order – being awarded in 2016 to ABB India
by Alstom for 1,600 traction transformers to be
delivered over a period of 11 years.

The 5.8 MVA, 25 kV/50 Hz Madhepura transformers

have one filter and four traction windings, one
three-phase transformer included in the tank and
two heat exchangers. The total weight is 7,500
kg. This new transformer allows freight trains to
increase their speed from 60 to 90 km/h.
62 ABB REVI EW STRONGE R

The compact and lightweight design guarantees

efficiencies that go well beyond the customer’s
minimum efficiency requirements to ensure a low
total cost of ownership and a greater reduction
of carbon footprint during operation. ABB
transformers have excellent global references
and more than 250 of these units have been
manufactured locally – with an excellent history of
on-time delivery and short lead time – and installed
in the Indian Railways power network.

Dry-type transformers
for mass rapid transit systems in India
The self-extinguishing nature of dry-type
transformers makes them the ideal choice for
installations in busy metro stations →5. These
transformers are mostly installed indoors, for
example in underground or aboveground metro
02
stations. Because of the tight dimensions in these
—
ABB liquid-filled trackside transformers support locations, most of the transformers are supplied
02 Indian Railways has
a route length of over the greener goals of Indian Railways with fully removable enclosures that allow for
64,000 km, with running
Since 2002, ABB has supported Indian train line them to be reassembled at the installation site.
track length of 87,000
km. The total trackage electrification by providing a variety of single-phase, These enclosures are modular, so their assembly
including yards, sidings,
liquid-filled 21.6/30.24 MVA trackside transformers is simple. The light weight and easy handling of
etc., exceeds 113,000 km.
to connect power systems at 66, 110, 132 and even aluminum-wound, dry-type transformers has
—
220 kV to the 27 kV catenaries that supply power encouraged most metros networks to migrate to
03 ABB trackside
transformer. to the electric locomotives. Reliability of the units them from copper-wound, dry-type transformers.
has been proven by extensive short-circuit tests Dry-type transformers in metro stations are
performed at the Central Power Research Laboratory used primarily in 24 kV AC systems, third-rail DC
(CPRI), the accredited testing laboratory with bases systems and monorails.
in Bangalore and Bhopal.
Auxiliary dry-type transformers in the Metro
ABB is currently the largest single supplier of railway Auxiliary dry-type transformers, usually three-
trackside transformers to Indian Railways. The phase, are widely used to power heating, ventilation
transformers are designed to withstand frequent and air-conditioning systems at metro stations – as
and severe overloads – of up to 200 percent of well as the lighting loads of various associated
the nominal load – to support heavy freight and shops and malls. Normally, transformers with
passenger traffic even during the hottest days, when ratings from 1,600 kVA to 3,150 kVA are used in
ambient temperatures can exceed 50 °C. The units underground metro stations, while lower ratings
are equipped with fiber-optic sensors to monitor are used aboveground. ABB has supplied auxiliary
working conditions and thus optimize their lifetime. dry-type transformers to various metros in India,
Conventional oil filtration units and no-load or on- eg, Delhi Metro Rail Corporation, Ghaziabad Metro,
load tap-changers are used to reduce maintenance Noida – Greater Noida Metro, Lucknow Metro, Navi-
intervals and substation personnel levels. Mumbai Metro, Chennai Metro and, most recently,
Ahmedabad Metro.

Predominantly, oil-immersed transformers are

used for supplying overhead railway lines of
24 kV AC systems. Recently, ABB successfully
commissioned a dry-type, single-phase
transformer having a voltage ratio of 33/24 kV
(Noida – Greater Noida metro) for this task.

ABB has supplied 12-pulse rectifier, dry-type

transformers along with two six-pulse rectifiers for
a third-rail DC system. Third-rail DC systems are
used as they provide a smoother operation than
24 kV AC systems, though the latter system has
a lower initial investment. Reference locations for
this application are Kochi Metro Rail Corporation,
Kolkata Metro Rail Corporation and, outside of

03
 SP ECI AL R EP OR T | T R AN S FOR ME RS TR ANSFORME RS FOR INDIAN R AILWAYS 63

04 05

—
India, Bangkok Metro. ABB has also supplied On the fast track
04 An array of four ABB
trackside transformers 12-pulse rectifier, dry-type transformers along ABB, as a technology leader in infrastructure
installed by Indian
with two six-pulse rectifiers for a monorail and transportation and with its portfolio of
Railways.
system. These transformers were additionally transformers for locomotives and trackside,
—
equipped with a surge arrester protection is helping Indian Railways in their mission to
05 Dry-type transformers
are ideal for underground system to help the transformer withstand fast electrify their network. ABB technologies are also
or enclosed applications.
transients generated by vacuum circuit breakers helping Indian Railways to provide more powerful
during the switching operations. This solution freight locomotives, increasing their average
is known as ABB’s Transient Voltage Resistant™ speed to 90 km/hr. This increased performance
Transformer (TVRT) and is specifically designed is enabling Indian Railways to haul more freight,
to withstand voltage transients generated increase revenue, shift freight from road to rail,
from switching. The reference location for this decongest roads and reduce air pollution. And
application is Mumbai Monorail. with the introduction of more eco-efficient, ester-
filled transformers, fire safety is promoted and
environmental impact reduced. l

—
Imprint

— — For a ­sub­scription, please Vorarlberger The information The companies of the ABB
Editorial Council Publisher contact your nearest Verlagsanstalt GmbH contained herein Group do not make any
ABB Review is published ABB representative or 6850 Dornbirn/Austria reflects the views of warranty or guarantee,
Gerhard Salge by ABB Group R&D and subscribe online at the authors and is for or promise, expressed or
Head of Technology, Technology. www.abb.com/abbreview — informational purposes implied, concerning the
Power Grids Division Layout only. Readers should not content or accuracy of the
ABB Switzerland Ltd. Partial reprints or DAVILLA AG act upon the information views expressed herein.
Harmeet Bawa ABB Review reproductions are Zurich/Switzerland contained herein without
Head of Communications, Segelhofstrasse 1K per­mitted subject to seeking professional ISSN: 1013-3119
Power Grids Division CH-5405 Baden-Daettwil full acknowledgement. — advice. We make
Switzerland ­Complete reprints require Artwork publications available http://www.abb.com/
Stephane Schaal [email protected] the publisher’s written Konica Minolta with the understanding abbreview
Technology Manager, consent. Marketing Services that the authors are not
Business Unit ABB Review is published WC1V 7PB London, rendering technical or
Transformers four times a year. Publisher and copyright United Kingdom other professional advice
ABB Review is free of ©2018 or opinions on specific
charge to those with ABB Switzerland Ltd. facts or matters and
Giuseppe Petrelli
an interest in ABB’s Baden/Switzerland assume no ­liability
Marketing & Sales
tech­nology and whatsoever in
Manager, Business Unit
objectives. connection with
Transformers
their use.
Namita Asnani
Communications
Manager, Business Unit
Transformers — —
Printer Disclaimer

Tablet edition Stay informed . . .

ABB Review is Have you ever missed a copy of ABB Review?
also available Sign up for the email alert at
for your tablet. abb.com/abbreview
and never miss another edition.

Please visit Please note that when you register for this alert, you will
abb.com/ receive an email with a confirmation link. Please ensure that
abbreview you have confirmed your registration.
—
Control your future,
transform theirs
Digitally integrated transformers

Digital natives like Kenny are growing up fast. So is the utilities sector.
With changing energy sources and usage, reliable power is more important
than ever – and this is exactly what the new ABB Ability™ power and
distribution transformers deliver. Digitally enabled right out of the box,
optimising asset performance is simple. Early warning prevents failures and
the modular, scalable design provides a future-proof solution. So take control
of your future, and transform it for the next generation.
new.abb.com/products/transformers/smart-transformers