—

Accelerating sustainable growth

in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Rail & Transport
Tapas K. Sarkar
—
ABB in the rail industry
Global partner for sustainable transportation

What On-board power &

Asset Management Wayside power
(Offering) propulsion

For whom Rail OEMs & EPCs

Urban Mass Transport
Infrastructure owners
(Customers) & Rail Operators

Where Globally
(Geographies)

Sustainable mobility for a better world

January 2, 2025 Slide 2

—
ABB in the rail industry
Today rail business in simple terms

2002 > 130 > 3000

Repositioning of Traction Power Traction packages
ABB in the railway System projects delivered to rail OEMs
business. ABB delivered since 1980 since 2003
becomes a growing
independent electrical
subsystem supplier

Center of $1.4 billion Local presence and

excellence in service support with
Geneva, Switzerland In orders (2016)
engineering,
manufacturing and
services centers

January 2, 2025 Slide 3

—
ABB in the rail industry
Global footprint: engineering manufacturing and service sites

Infrastructure: 1. Canada 2. Germany 3. Norway 4. Finland 5. Sweden 6. Poland

Power (Montreal): (Ratingen, Heidelberg, (Oslo, Skien): (Vaasa): (Västerås, (Lodz):
LV Products, LV Brilon, Minden): MV Transformers, Ludvika): Rectifiers
Transformers,
Systems Switchgears, Switchgears MV FACTS, SCADA, and
Rectifier Energy Storage, MV Breakers, Switchgears Power consulting Inverters
Transformers, Energy Resibloc Transformers, Traction Motors, Traction
Rectifiers and 7. USA
Dissipation Systems Power consulting LV Products converters
(South Boston, Bland, 18. Korea
Inverters, Traction Vacuum Interrupters,
Deer Park, Boulder, (Chonan):
Sub-stations, MV LV Products, Traction
Richmond): Dry
Switchgears, MV converters
Transformers Transformers
Breakers, FACTS , Enterprise Software,
LV Products, Power consulting
Traction Transformers 17. China
Communication, 4
Traction motors, 3 5 (Datong, Xiamen,
SCADA, Braking Shanghai,…):
Traction converters
Energy 1 MV Switchgears,
Management
Turbochargers 2 6
9 13 18 Transformers,
Systems, 8. Mexico 7 11 LV Products
(Mexico): 10 12 Traction Transformers,
Enterprise 17
MV Traction motors
Software, UPS
Switchgears LV Products
Power consulting 9. Switzerland 8 16
(Geneva, Turgi, Lenzburg 14
8
Rolling Stock: Baden, Wettingen,
Traction Quartino):
Transformers, Static Frequency 16. Thailand
Traction Converters, (SamutPrakan
Traction Substations, ):
Converters,
MV breakers & modules Transformers
Traction Motors, Communication Systems, 15
Auxiliary Surge Arresters, UPS 12. Italy 14. India
Converters, Traction Transformers, 10. Spain (Vittuone, 13. Czech (Vadodara, Nashik, 15. Australia
Battery Chargers, Traction Converters, (Zaragoza, Dalmine, Republic Bangalore): (Brisbane, Melbourne):
Semiconductors, Aux. Converters, Bilbao, Cordoba, Monselice, (Brno): Traction Sub-stations, MV Enterprise Software,
Semiconductors, Madrid), Genova): MV Switchgears, Power EAM development
Surge Arresters, LV
Surge Arresters, Transformers, 11. MV Switchgears, Switchgears, consulting Service hub for Aux.
Products, Power France Transformers Instrument Traction Transformers, Converters,
Turbochargers,
Turbochargers Reactors, aux. consulting (Chassieu): Traction Transformers Traction & Aux. Traction Motors Services
transformers, Traction Motors LV Products Generators, Converters,
Traction motor and Services Auxiliary conv. Traction Motors
transformer services LV Products

January 2, 2025 Slide 4

—
ABB in the rail industry
Local footprint: engineering manufacturing and service sites

Regional Office
Delhi Kolkata
Zonal office - • Lucknow
Zonal office - East
North • Chandigarh
• Nagpur
• Ahmedabad
Vadodara Bangalore • Bhopal
Traction Transformers, Head Quarter –
Traction Motors • Chennai
India
Zonal office - • Coimbatore
South • TATA Nagar
Traction Converter
• Vishakhapatna
Aux. Converters,
Battery Charger m
Mumbai Vehicle Control Unit • Kochi
Zonal office – West
• Pune
PCB • Hyderabad
Manufacturing • Jaipur
plant
• Raipur
Nashik
Traction Sub-
stations, MV
Switchgears

January 2, 2025 Slide 5

—
ABB in the rail industry
Global portfolio for railway applications

1. Traction Substation and SFC

2. High Voltage Products
3. Power Transformers and Surge Arresters 18
1
4. Power Quality
5. Indoor Medium Voltage Switchgears
6. Distribution & Special Transformers &
Rectifiers 2 3
7. Low Voltage Switchgear 9
8. Braking Energy Management Systems 8
7
9. Outdoor Medium Voltage Modules 6
5
10. Communication 4 17

11. Motors - Generators Turbo chargers 10

12. Traction Fuses 16
12 15
13. Converters - Semiconductors 13
14
14. Traction Transformers 11
15. Low Voltage Components
16. DC circuit breaker
17. Outdoor Medium Voltage Products
18. Enterprise Asset Management & SCADA

January 2, 2025 Slide 6

—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Energy-efficient and reliable power solutions
Tanvi Srivastava / Puneet Arora
—
Trackside transformers
—
ABB Power Transformers
Power transformers Global Capabilities – Transformer Locations

Finland
Vaasa
Poland
USA Switzerland Lodz
USA Geneva Turkey
South Boston
Crystal Spring Italy Istanbul
China
Monselic Zhongshan and Datong
India Vietnam
 Ratings – 10MVA – 100 MVA, 66 KV to 220 e
VadodaraThailan Hanoi
Colombia
KV Pereira d
Bangko
 Commencement of Production – 2008 k
South Africa
Johannesbourg
 No. of Transformers Supplied - >800
(>250)
 No. of Transformers SC Tested – 11 nos.
INABB Railway Trackside Journey
Design Design Design Continued
First 30.24 1st Transformer Collaboration
Upgradation Upgradation Supplied 50 upgradation
MVA Trafo SPT Plant First 132 KV, for Metro
for 132 KV, for 110 KV, Units in a for 220 KV, - Digital
(132, 110 & established 42 MVA Trafo Project
(CMRCL) 30.24 MVA 30.24 MVA Year 30.24 MVA - High Speed (V
220 KV)
Trafo Trafo Trafo Connected)

2002 2008 2011 2012 2014 2017 2017 2018 Future

The combined experience of 700 years of transformer manufacturing

(Ansaldo / Ital Trafo / IEL / OEL / OTE,BBC, GE, USA, National Industries, Strömberg, Westinghouse & more .. .)

January 2, 2025 Slide 9

—
ABB Trackside Transformers
Design Philosophy & Capability

Design Philosophy
• High reliability
• Less maintenance demands
• Standardized active part design on global platforms
• Same look, same quality around the world

Design Capability
• Designers with rich experience
• Common CAD software's (CDS) for design, calculation
and modelling
• Continuous learning & training at global knowledge
Centers
• Common design rules, global database for reference
• Global support/guidance in trouble shooting, design
review and latest design practices

January 2, 2025 Slide 10

—
ABB Trackside Transformers
Salient Features - Manufacturing
ABB Salient Feature What it means for Customer Visual
- Dust Free Winding
Dust Free Pressurized Shp Floor - Better Performance
- Longer Life

- Delivers Compact & tight windings with least

Semi Automatic Vertical Winding Machine dimensional Variations
- Offers windings with better short circuit strength

- Lesser joints means better reliability

HV windings made, with built in shields - Lesser chances of hot spots
- Better Short Circuit withstand strength

- Higher short circuit buckling withstand strength.

Low voltage windings are made with epoxy coated, CTC
- Transposition eliminates the need for manual
transpositions (weak link in any windings)

All joints from windings to lead and in the leads hydraulically crimped - Solder less terminals results in clean, low resistance and
joints reliable joints.
Proven, imported, Elpress make hydraulic machine and terminals for
crimping
- High dielectric strength & reliability
Insulation components from dedicated manufacturers - Longer insulation life
- Partial discharge free insulation
- Longer transformer life

January 2, 2025 Slide 11

—
ABB Trackside Transformers
Salient Features - Manufacturing
ABB Salient Feature What it means for Customer Visual
- Minimized Losses
Boltless Core Design, Step Lap Mitred Core
- Lesser Noise & vibration
High Quality CRGO – M4, MOH, ZDKH Type
- Low magnetizing current
Procured from Japanese Manufacturers Nippon, Kawasaki Steel.
- Better quality control as CRGO purchased from best
mills and slitted at dedicated lines

- Stress free handling of core laminations resulting in

Hydraulic Core Table – 40 Ton Capacity
lower losses and noise

Tightened using hydraulic machine - Optimum tightening ensures less vibration & lower
Symmetrical tightening of the core- for uniform clamping pressure sound level

Make – Micafil - Uniform drying of active part in comparison to

Utilizes Kerosene vapour to wash and clean the active part assembly conventional ovens
during drying process - Longer insulation life: thanks to complete drying
Washing ensures dust free active part
- Proper pressing of active part ensures mechanically
Symmetrical Pressing of AP using hydraulic jacks and pullers stable active part and improved short circuit withstand
Ensures precise winding height strength

- No dripping of oil
Drip proof , high quality, cast steel taper plug valves for drain and filter.
- Lesser Maintenance

Poly Urethane finish coat with epoxy zinc rich primer with intermediate
- Longer rust free paint life
epoxy paint coating (20% costlier in comparison to conventional
- Gloss retention and scratch resistance due to
synthetic enamel paint) on tank and radiators for better corrosion
polyurethane coating
protection

January 2, 2025 Slide 12

—
ABB Trackside Transformers
Quality Certifications

• Quality Process same

throughout all the ABB
Transformer factories
worldwide

• ISO 9001, ISO 14001

Certification

• 4-Q approach for problem

solving

• In process check/sigma
cards to ward away the
errors

• Check Points at various

stages to ensure
everything as per
standards

January 2, 2025 Slide 13

—
ABB Trackside Transformers
Quality Control Points

CP Control Piont

January 2, 2025 Slide 14

—
ABB Small Power Transformers
Short Circuit Tested Units
ABB India : List of Short Circuit Tested Jobs
Sr. No. Customer Description of Transformer Year Test lab
132 kV Class
1 Indian Railways 21.6MVA, 110/27kV 1-Phase, Track side Transformer 2002 CPRI, Bangalore
2 Indian Railways 21.6MVA, 132/27kV 1-Phase, Track side Transformer 2002 CPRI, Bangalore
3 PSEB 20MVA, 132/33kV 3-Phase Power Transformers 2006 CPRI, Bhopal
4 PSEB 50MVA, 132/66-33kV 3-Phase Power Transformers 2006 CPRI, Bangalore
5 RRVPNL 50MVA, 132/33kV Power Transformer 2009 CPRI, Bangalore
6 NTPC 7.5MVA, 132/11.5kV 3-ph Power Transformer for Mauda Power Project 2010 CPRI, Bhopal
80MVA, 132/11.5/11.5kV 3-ph Power Transformers for Mauda Power
7 NTPC 2010 CPRI, Bangalore
Project
8 NTPC 16MVA, 132/11.5kV 3-ph MST for Mauda Project 2011 CPRI, Bhopal
9 BRBCL 70MVA, 132/6.9/6.9kV 3-ph ST for Nabinagar Project 2011 CPRI, Bangalore
10 Indian Railways 42MVA, 132/37 kV 1-ph Trackside transformer 2011 CPRI, Bangalore
11 Indian Railways 30.24MVA, 110/27 KV 1-ph Trackside transformer 2017 CPRI, Bangalore

66 kV Class
12 DMRC 40MVA, 66/27kV 1-Phase Transformers 2004 CPRI, Bangalore
13 DMRC 30 MVA, 66/33 kV, 3 Phase, Power Transformer 2009 CPRI, Bhopal
14 DMRC 30MVA, 66/33kV 3-Phase Transformer 2009 CPRI, Bangalore
15 DMRC 50 MVA, 66/27 kV 1-ph Trackside transformer 2013 CPRI, Bangalore

33 kV Class & below

16 MMOPL 20MVA. 33/27.5kV 1-Phase Transformer for Mumbai Metro 2009 CPRI, Bhopal
17 NTPC 45MVA, 21kV 3-ph for Mauda project 2010 CPRI, Bangalore
18 BRBCL 35MVA, 16.5/6.9 kV UT for Nabinagar 2011 CPRI, Bhopal
19 ERDA 2 MVA, 11/1.5 kV Transformer 2012 CPRI, Bhopal

January 2, 2025 Slide 15

—
ABB Transformers India – Power Transformers
Best Short Circuit Withstand ability

 32 No. Power Transformers Short circuit tested at CPRI

and KEMA till date. ( Highest in India). Short Circuit Tested
Transformers
 First to test largest ratings in the world for all kV classes. 12
11

10

 Till date Largest Rating of the world Tested among all kV 8

8
classes.
• 400kV - 260 MVA, 1 Ph. GSU for NTPC Barh in year 2008 6

• 765 kV - 315 MVA, 1 Ph. GT. for NTPC Gadarwara in year 2016. 4 4
4
3
• 765 kV -85 MVA, 1 Ph. Auto for NTPC Gadarwara in year 2017. 2
2

 Other Major Ratings :- 0

>= 33 >= 66 >= 132 >= 220 >= 400 >= 765
• Auto Transformer of 315 MVA in year 2009 kV kV kV kV kV kV
• Generator Transformer of 315 MVA in year 2012.

SC test proves the transformer’s robustness to withstand Video

rigors Link:-
in the field, http://search.abb.com/library/Download.asp
x?DocumentID=9AKK107045A8929&Langu
validating design excellence and flawless production. ageCode=en&DocumentPartId=&Action=L
aunch

January 2, 2025 Slide 16

—
ABB Trackside Transformers - Reference
30MVA, 66/33kV for Delhi Metro Rail Corporation

January 2, 2025 Slide 17

—
ABB Trackside Transformers - Reference
20MVA, 33/27kV, Single phase traction supply transformer for Mumbai
Metro One Pvt. Ltd

First single phase transformer short circuit tested globally on SPT platform

January 2, 2025 Slide 18

—
ABB Trackside Transformers - Reference
30/42MVA, 132/27kV, Single phase trackside traction transformer
for Indian Railways

January 2, 2025 Slide 19

—
ABB Trackside Transformers - Reference
21.6/30.24 MVA, 110/27kV, Single phase trackside traction
transformer for Indian Railways

January 2, 2025 Slide 20

—
ABB Ability™ Power Transformer
Transformers for a digital world

1. Many unknowns, this applies equally to the demand & supply.

2. Changing Energy Sources & usage; reliable power is more important than ever.
3. Further, demands for safety, & profitability will only increase.
4. Exactly what the ABB Ability™ Power Transformer delivers
5. A modular platform provides the foundation to support the digitalisation needs.
6. Options for both connectivity and on premise solutions are required to meet diverse policies
and possible future positions.
7. Monitoring of key Transformer parameters compliments existing or future “external”
solutions.
8. Domain knowledge is fundamental to converting bits / bytes into actionable information.

January 2, 2025 Slide 21

—
ABB Ability™ Power Transformer
The Power Transformer eco system

4 - Together
Collaborate, advice, transform, re-think

Service Oil Engineering HV Training Consultancy

Expert Agreements Analysis Studies Testing
Service
s
3 - Do better
Asset Optimize, simulate, predict, automate
Manag
ement
Solutio ABB Ability™ Ellipse® APM
ns Asset Performance Management

2 - Do more
Monitorin Automate, monitor, control, secure,
g and manage
Diagnosti
cs CoreSense
Hub
CoreTec 4
Transformer Monitoring
software Platform

1 - Know more
Sensor Assess, connect, store, inform,
measure
Technologies
CoreSens CoreSense eOTI eWTI eOLI eBR ePRD eSDB
e M10 Liquid Winding Liquid Level Buchholz Relay Pressure Relief Self Dehydrating
DGA DGA Temperature Temperature Device Breather
Single Gas Multi-GAs

http://new.abb.com/products/transformers/power/abbabilitypowertransformer

January 2, 2025 Slide 22

 —
Traction Transformers
Compact, lightweight and reliable product for Rolling Stock
ABB Traction Transformers
Footprint: 5 operative manufacturing sites

Lipesk, Russia,
Approved – on hold

Geneva,
Switzerland
South-Boston, Dudullu, Turkey Datong, China
VA USA On study Vadodara,
India

Johannesburg,
South-Africa

Geneva Center Of Excellence

Traction Transformers

January 2, 2025 Slide 24

ABB Transformers
Traction Transformers factory capability

 Factory Location – Maneja, Vadodara .

 Dedicated Assembly lines for Locomotive and EMU
Traction Transformers.
 Area - 8,300 sq. meters , Capacity ~ 300 Units per year.
 Manufacturing since 1999. Supplied More Than 1500 Units.
 Total Employees 150 +

January 2, 2025 Slide 25

ABB Traction Transformers
Insight into the New Traction Transformer Plant

January 2, 2025 Slide 26

ABB Traction Transformers
Traction Transformers

 EMU’s (Electric Multiple Units)

- 0.6 MVA to 4 MVA
- Insulating fluid: Silicon/ester and mineral
- Mounting positions: roof, underframe and ,
machine room.
- Insulation class: A, Hybrid, F and H
- Cooling Type – Oil or Air

 Locomotive Traction Transformers :

- 4 MVA to 10 MVA
- Insulating fluid: Ester or mineral
- Mounting positions: under frame/ machine room.
- Insulation class: A, Hybrid, F and H
- Cooling Type – Oil or Air

January 2, 2025 Slide 27

ABB Traction Transformers
References

MRVC LOT7500 –WAP

5/7

DMRC Lucknow Metro

WAG 9 – LOT 6500

WAP – 5 –LOT7775

January 2, 2025 Slide 28

ABB Traction Transformers
Summary

 Manufacturing Traction Transformer since 1999

 Supplied > 500 nos. Loco transformers
 Capacity: 120 nos. Loco transformers per year
 Supplied > 1300 nos. EMUs
 Capacity: 350 nos. EMUs per year
 More than 600 nos. Traction Transformers per year can be produced at New Traction shop
with addition of winding machines.
 EMU transformer produced for Indian Railways has passed short circuit test at NABL
accredited laboratory, CPRI-Bangalore.
 Locomotive transformer produced for E-Loco Madhepura project for ALSOTM (DFCL project)
successfully passed the stringent short circuit test at CPRI -Banglore & Shock & Vibration
Test in CESI Italy Laboratory.

January 2, 2025 Slide 29

—
Dry type transformers for Metro
applications
 Dry-type Transformers
Footprints in India – 3rd Rail DC system, Monorail system and AC system

Rectifier Duty Dry Auxiliary Duty Dry

Our Metro footprints Transformers Transformers

Delhi Metro Noida

Jaipur Metro Metro
Lucknow
Ghaziabad Metro
Metro Dhaka
Ahmedabad Metro Metro
Kolkata
Nagpur Metro
Mumbai Metro
Monorail
Navi Mumbai Bangkok
Metro Metro
Bangalore Chennai
Metro Metro
Kochi
Metro
Kochi – 2600 kVA, Kolkata – Delhi, Kochi, Chennai, Noida,
Mauritius 3300 kVA, Mumbai Monorail – Navi - Mumbai and Ghaziabad
Metro
2230 kVA Metro

January 2, 2025 Slide 31

Dry-type transformers
Value opposed to oil-filled solutions

Oil- Feature Dry-

filled type
Size & Weight
Initial Cost
Losses/Efficiency
Fire Safety
Environmental
Safety
Short Circuit
Strength
Total Installation
Cost
Maintenance Cost

Total Ownership
Cost

January 2, 2025 Slide 32

Dry-type Transformers
Product Range & Application areas

Widest product portfolio

 Power up to 10 MVA
 Voltages up to 33 kV Class (IEC, IEEE, IS)
 Unique class “H” vacuum cast coil transformers
 Ingress Protection from IP00 to IP44 enclosures
 Any type of cooling AN, ANAF (up to +30%)
 Frequency of 50 / 60 Hz
 Winding Material of Aluminum / Copper
 Tapping : OCTL / OLTC

Public works Special industries

 Hospitals  Ships
 Airports  Oil and gas
 Shopping centers  Mining industry
 Public buildings  Wind and solar power
 Office buildings  Applications with
 Stadiums Variable Speed Drive
 Metro systems/ trains (VSD)
 Applications with
rectifiers

January 2, 2025 Slide 33

Advancements in traction substation power
transformers
Taking dry-type technologies to new limits

New power and voltage levels for dry-types

– Voltages up to 145 kV/550 kV BIL and 63 MVA, highest for

dry-type transformer technologies

– Introduced in 2010 and now have nearly 100 installations

– Completely dry solutions including optional on-load tap-

changer (OLTC)

– Ideal for new indoor installations or outdoor installations

near high populated or environmentally sensitive areas

January 2, 2025 Slide 34

Advancements in traction substation power
transformers
First HV dry-type transformer for traction infrastructure

Project details Atocha Station, Madrid, ES

Unit scope: (1) 10 MVA, 27.5/-27.5 (250 kV

BIL, 120 Ua)
Application: Autotransformer, voltage drop
compensator for high-speed
train line
Owner: ADIF

Details: This installation is in the most

used train station in the
country. Customer has had
problems with oil-transformer
explosions in the past and
wanted to eliminate risk in this
high traffic area.
End user made the choice for dry to increase passenger safety in highly populated area

January 2, 2025 Slide 35

—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Energy-efficient and reliable power solutions : FACTS for Railways
Sethuraman Ganesan
The grid is changing
Shift in the electrical value chain

The rising share of renewable energies is influencing the robustness of our

grids.
Complex, sensitive and Weaker Systems -Lower fault levels

January 2, 2025 Slide 37

Challenges in Railway Grid and Solutions

Major Challenges
– RE is intermittent, seasonal
– Load dynamics, peaks
– Railway sub station connection with 2 phases(normally), Solar
integration possible with 3 phases
– Phase current un-balance (Power is fed through 2 phases
alternatively)
– Network voltage and Short circuit levels
– Un balance and negative sequence currents, harmonics
– protection coordination for various operating points
– Local grid code compliance, for MV/HV grid connection
– Complex study requirements

Technology Solutions
– 3 phase Load Balancer – balances 2 phase currents and grid
code compliance
– Intelligent sub stations – Fed through SFC and operating in
parallel with existing sub stations
– Battery storage and load balancing, Microgrids
– Digital sub stations

Power electronics based technologies to enable Greener railway Grid

January 2, 2025 Slide 38

FACTS
Managing the Reactive Power – Power Transfer
V1 /1 V2 /2
Power flow P

V1 V2 (d1 - d2)
P= sin
X12

SVC or SC or TCSC
STATCOM

Managing the Reactive Power – Voltage support

Simple equation but several considerations are needed!

January 2, 2025 Slide 39

FACTS solutions
Solution benefit
Cost effective solution to increase power transfer capability in
transmission lines instead of building new transmission corridors
Series Compensation

Fixed Series
Compensation
‒ Improved voltage and transient stability
‒ Improved voltage profile along the line

‒ Provides damping torque on inter-area electromechanical

Thyristor oscillations (POD)
Controlled Series ‒ Inherent immunity against sub synchronous resonance (SSR)
Compensation ‒ Enhances capabilities for dynamic power flow control
(TCSC) ‒ Often the TCSC is combined with fixed series compensation to
increase transient stability in the most cost effective way
Active power in-feeding 3 phases-1 phase to 16,7/25Hz, 50/60 Hz
Rail Static ‒ Full decoupling of grids
SFC

Frequency ‒ Independent, fast control of frequency,

Converters (SFC ‒ voltage, active and reactive power on both sides
‒ Connection to weak grids
Shunt Compensation

‒ Improved voltage stability, facilitated integration of renewables

‒ Load balancing
SVC Classic
‒ Flicker mitigation and power quality enhancement
‒ Increased productivity by power factor improvement
‒ Similar benefits as for SVC Classic
‒ More robust integration in weak grids
STATCOM (Hybrids)
‒ High performance flicker mitigation
‒ Reduced footprint thanks to fewer passive elements

January 2, 2025 Slide 40

Effect of the railway load on the supply network
Conventional Power Supply (50 Hz AC Railways)

 Unbalanced power grid

 Only two phases connected
FACTS
 Voltage fluctuations SVC
Load
 Train is accelerating, braking and Balancer
passing zero sections
 Harmonics
 Due to train power electronics
 Power factor
 Due to train power electronics

January 2, 2025 Slide 41

Rail Load Balancers
50 Hz AC Railways

– Active load balancing between 2 phase

consumption in 3 phase grid
– Benefits QH
Load
V
• Possible connection to medium-voltage grids with balancin
limited short circuit power g
converte
• Balanced phases on HV grid r

• Mitigates voltage fluctuations

• Harmonics mitigation
• Fulfillment of grid code requirement at PCC PG PG

– FACTS solutions
• SVC (Static Var Compensator)
• STATCOM (Static Synchronous Compensator)

January 2, 2025 Slide 42

FACTS Rail Load Balancers
Sizing aspects

 Power Quality Limits (by Grid Code):

 Voltage unbalance
 Loads from the traction system  Power factor
 Load in MVA and cosphi.  Statistical evaluation window
 Definition of worst case scenarios  Harmonics
Size of Load
 Train harmonics Balancing
Equipment

 Grid paramaters

 HV Grid Short Circuit Power

 Background harmonics

January 2, 2025 Slide 43

 Rail Load Balancers
Scenario definitions

HV Grid HV Grid

HV bus, PCC HV bus, PCC

Traction Traction Traction Traction

transformer transformer transformer transformer

A B BC A B BC

STATCOM STATCOM
Traction load Traction load Traction load Traction load
MVA and pf MVA and pf MVA and pf MVA and pf

Unbalanced load of: on phases A and B, on phases B and C Unbalanced load of both loads on phases A and B

January 2, 2025 Slide 44

Evron SVC Light Rail Load Balancer, France
Rail Load Balancers

January 2, 2025 Slide 45

Rail Load Balancers
PCS 6000 STATCOM – Compact Solution for Urban Rail Systems

Unit rating:
12MVAr – 40 MVAr

Higher ratings:
By paralleling units

POC:
10-230 kV (higher on request)

January 2, 2025 Slide 46

50Hz Railway Power Supply
Static Frequency Converter Power Supply

Technical benefits of SFC based supply

– 3 phase supply from HV or MV grid
– Independent active and reactive power control
• Optimized use of regenerative energy QHV
• Dynamic catenary voltage control
• Reactive power control AC

DC

– Coupled through catenary system SFC

DC Pconv
AC
• Reduced number of separation sections .

• Lower rated peak for substations QOH

• Partial redundant supply L

– Low harmonics content Prege

– Limited catenary short circuit current n

– Reference: 50 Hz railway supply in Wulkuraka

Australia

January 2, 2025 Slide 47

Static Frequency Converter (SFC)
SFC Feeding Concept

Introduction to frequency converter

U1 U2 U1 U2
Q1
~ ~ Q2 Q1 V1 P V2 Q2
f1 = = f2 f1 f2
P

– Static Frequency Converter Decouples Electrically the two grids

– Active Power cannot be stored, but can be controlled
– Frequency , Voltage & Reactive Power can be controlled on both converter sides

January 2, 2025 Slide 48

Static Frequency Converters (SFC)
P/Q Diagrams – Three phase grid

SFCs can act like a STATCOM on the 3ph grid

as well as on 1ph rail side. They can run at a
desired power factor and voltage. They can
correct the power factor and support the
voltage.
An example of the reactive power capability
for a 30 MW unit is shown.

Negative real power:

Power is drawn from the grid and transferred
to the railway grid

Positive reactive power:

The utility grid voltage is supported, the
converter acts
like an over-excited machine.

January 2, 2025 Slide 49

Wulkuraka rail grid intertie
Australia

Customer needs
– Increased energy demand for the Brisbane
Rosewood Line and for a new rolling stock
maintenance depot nearby
– Conversion of country’s 3-phase 50 Hz grid to 1-
phase 50 Hz railway grid without unbalance effects
to the supplying grid

ABB response
– Turnkey solution incorporating a 20 MVA static
frequency converter
– Transformers, switchgear, control and cooling
systems
– Design, engineering, installation, commissioning
and civil works

Customer benefits
– Stronger railway corridor performance
– Higher power supply without fault current rating
increase

Customer: Queensland Rail, Australia

January 2, 2025 Slide 50 Start of commercial operation: 2015
Limburg traction power supply
Germany

Customer needs
Secure energy supply of the 280 km/h DB ICE high-
speed line from Frankfurt to Cologne in Germany

ABB response
– Converter station of 8x 15 MW
– Frequency converters, transformers, switchgear and

control system
– Design, engineering, installation, commissioning
and civil works

Customer benefits
– Reliable rail power supply
– Remote control of the converter station from the
power control center in Frankfurt
– De-icing function of rail catenary

Customer: Deutsche Bahn (DB) Energie, Germany

January 2, 2025 Slide 51 Start of commercial operation: 6 units in 2002 / 2 units in 2005
PCS 6000 SFC Rail
ABB References

PCS 6000 Rail SFC References

– Largest installed base
• more than 45 SFC units in operation,
• more than 1.5 GW SFC installed power
– More than 20 years of experience in applications for rail
power supply
– Proven control and protection algorithms for 17 Hz and
50 Hz
– Satisfies high reliability and availability demands
Preferred supplier for 50Hz railway supply:
– Wulkuraka, Queensland Rail (Australia)
1x 20MVA, in operation since 2016
– IEP DDP (Potteric Carr), Network Rail (UK) 1x 20 MVA
1x 20 MVA

1x 42 MVA, awarded May 2017

– Northgate and Moolabin, Queensland Rail (Australia)
2x 20 MVA, awarded September 2017

January 2, 2025 Slide 52

—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Power Quality Solutions for Railways
Hari R
Introduction : what is meant by Power Quality

• Power Quality is defined as the electrical

network’s or the Grid’s ability to supply
a clean & stable power supply.
• In other words, Power quality ideally
creates a perfect power supply that is
always available, has a pure noise- free
sinusoidal wave shape, & is always
within voltage & frequency tolerances.
• Any significant deviation in the
waveform magnitude, frequency, or
purity is a potential power quality
problem.

January 2, 2025 Slide 54

Railway Power Supply in India
Overview of Electric Traction Feeding Concepts

HV Network 110/132/220 kV 50 Hz

 AC Traction Substation Static Frequency

DC Traction Substation
Converter Station
25kV / 2x25kV TSS
600…3000V  25kV / 2x25kV

AT AT

January 2, 2025 Slide 55

Rail Power Supply @ TSS and power quality

• TSS (Traction sub station feeding rail

loads) draw power from 3 phase utility
power supply converted to single phase
or two phase system
• Railway traction load is a 1-phase load.
Always gives possibility for unbalance
• Maximum harmonics recorded is 3rd
Harmonic. Affects sine wave distortion
levels
• Railway supply voltage is 25KV AC can
have as much as +/- 20 % voltage
variation
• Loads are purely dynamic in nature
means susceptible to voltage
disturbances

The Cost of electrical power has a major say in the operating costs for railways and Power
quality has a major impact on this operating cost and economics of railways

January 2, 2025 Slide 56

Power Quality Problems in TSS … Root cause ??
And impact

The major power quality problems in 25 kV AC railway systems could be as listed

below.
• Unbalanced load due to single phase catenary connection and its dynamic nature due
moving trains
• Harmonic currents are generated by train rectifiers (power convertors), other loads on
the train and station loads
• Reactive power consumed by traction loads and all other inductive loads on train
(lighting, fans, AC, Pantry ,, etc) . The stations TSS have huge transformers ,maintenance
sheds, passenger / material loading stations all have huge inductive loads
• Voltage flicker due to moving load from one section to another

Poor power quality in rail power system affects

• Power reliability and continuity, power losses, power factor penalties, THD (Total
harmonic distortion), equipment failures & its life expectancy, malfunction of electronic
&/or digital systems and more…

January 2, 2025 Slide 57

Power Quality Problems in Railway TSS and
Mitigation techniques
Mitigation of Power quality problems at
Problems TSS level
– Recorded huge amount of 3rd & 5th – Reactive power compensators in the form
Harmonics currents and excessive THDV of
and THDI !!!
– (FC) Fixed capacitors with detuned
– Recorded very high and fast changing
reactors
(dynamic) reactive power demand and
load unbalances – (DRPC) Dynamic reactive power
– Various problem associated in TSSs compensators
caused due to above two factors, – In the form of cap based solutions or active
– Frequent nuisance feeder tripping – Compensators. Both are called DRPC.
– Transformer and switchgear failures – Hybrid DRPCs combining both 1 & 2
– High power losses caused by combined
– DRPCs having active compensators
reactive power & harmonics
use
– Sensitive equipment malfunctions due
to Harmonic amplification / resonance, – Power electronic based VSC to generate
THD. – Variable reactive power and harmonic
– Higher cost of operations due to all of – mitigation currents
above and higher power bills and
penalties.

January 2, 2025 Slide 58

How to improve PQ in Railways- RPC
21.6 MVA TSS - Reactive Power Compensation

21.6 MVA Transformer:

Kvar = Kw(tanφ1 – tanφ2)
Total requirement of 6700 KVAR in each TSS
Each 6700 KVAR splitted as follows
Fixed compensation: 25 kV 3350 kvar Fixed
Detuned Filter Bank
Variable compensation: +/-3350 kvar PQCR
Overall compensation : 0- 21.6 MVA TSS requirement
6700 KVAR Reactive Power Compensation
Initial power factor (p.f) 0.8
Reactive power compensation can be done in
the form of (FC) Fixed capacitors with Final Power factor (p.f) 0.95
detuned reactors (DRPC) Dynamic reactive
Load on the system (kW) 16000
power compensators
Compensation Required (kVAr) 6741.10

January 2, 2025 Slide 59

How to improve PQ in Railways
DRPC Product Range

LV PQCR
• IGBT based smooth, step less, Ultra fast dynamic reactive power
compensator. Inductive/capacitive reactive power operation.
• PQCR module rating starts with (1ph & 3ph) 200V to 440V/690V.
It can be used also for high voltage applications with suitable
Step-Up Transformer.
• PQCR module rating starts with 50kVAr, 100kVAr, 150kVAr
250kVAr and 375 Kvar. Any other higher ranges can be provided
by paralleling the above unit ratings.
• Reactive power compensation, Unbalance compensation,
harmonic mitigation (5th,7th,11th & 13th).
MV PQCR
• PQCR module rating starts with 3ph,6.6/11/33KV and 1ph 27.5
KV. It can be used for extra high voltage applications through
Step–Up Transformer.
• PQCR module rating starts 0 -12 Mvar or any higher ratings.
• Reactive power compensation, Voltage control mode, harmonic
mitigation(3rd,5th,7th,11th & 13th)

January 2, 2025 Slide 60

Power Quality in Railway
Case Study – DFCC Project

 The offered scope was reactive power

compensation for 23 Traction Sub
Station,
 starting from Rewari to Vadodara(Phase
I) and Vadodara to JNPT ( Phase II)
 Total reactive power requirement of
10,000 KVAR per TSS. it shall be
distributed between 2 sets of 5000 KVAR
Compensation per TSS
 Each 5000 KVAR has splitted as follows
• Fixed compensation: 2500 kVAR Fixed
Detuned Filter Bank
• Variable compensation: +/-25000 kVAR
STATCON
• Overall compensation: 0 kVAR to 5000
KVAR

January 2, 2025 Slide 61

PQ Problems in Metro
Observations

• It was observed that The active power is

varying from 1190 Kw to 4250 Kw.
• The reactive power requirement is varying
from -2280 kvar leading to -3470 Kvar
leading, which is purely Inductive reactive
power requirement due to cable
capacitance. The average power factor is
observed as 0.560
• The voltage harmonic distortion is 0.75 %,
which is within the limits as specified by
the IEEE 519-2014 standard, i.e. 5 %
• The current harmonic distortion is 14.05
%, which exceed the limits as specified by
the IEEE 519-2014 standard, i.e.8 %

January 2, 2025 Slide 62

PQ Problems in Metro
Recommendations

Option1: (considering 25KV,33KV & 132 KV Bus

couplers are in open condition)
• 1 phase, 25kV, +/- 1.5 Mvar PQCR for traction
load for each Incomer side.
• 3 phase, 33 Kv, - 3.5 Mvar Fixed shunt reactor
for each Incomer AMS & 415V, +/- 500 kvar
PQCR at the ASS nearest to AMS to fine tune
the dynamic kvar over base Kvar
(or)

Option2: (considering 25KV,33KV & 132 KV Bus

couplers are in closed condition)
• 1 phase, 25kV, +/- 1.5 Mvar PQCR for traction
load connected to any one incomer side.
• 3 phase, 33 Kv, - 3.5 Mvar Fixed shunt reactor
connected any one Incomer AMS & 415V, +/-
500 kvar PQCR at the ASS nearest to AMS to
fine tune the dynamic kvar over base Kvar.

January 2, 2025 Slide 63

Case study of improving Power quality in
Railways
ABB improves Power Quality in Bulgarian railways

January 2, 2025 Slide 64

—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Technological trends in rolling stock
N S Nawaz / Prassana V Deshpande
—
Traction Converters
Solution Overview
ABB traction systems covering all power systems and
power ranges
Based on a modular platform

Selected mainline references

Solutions for 15kV - 25 kV AC
− 9.6 MW ICE 1 retrofit for Deutsche Bahn
− more than 100 6 MW double-deck KISS EMUs
− 4.5 MW locomotive retrofit for India
− hundreds of 3 MW FLIRT EMUs
Solutions for 1.5 kV and 3 kV DC
− 5 MW rack rail locomotives for MRS, Brazil
− more than 75 3 MW FLIRT EMUs
− metro trains for China
Solutions for multi-system trains
− 4-system 8.8 MW high-speed train for Talgo
− DC/AC 3MW FLIRT EMUs (FR/CH, IT/CH, AT/IT)
− DC/AC 3MW mountain trains
Solutions for Diesel-electric propulsion
− 3.6 MW power heads for Saudi-Arabia trains
− 2.7 MW Eurolight locomotive
− hundreds of GTW EMUs
Solutions for dual-mode or hybrid trains
− 4.6 MW hybrid locomotive DE/3 kV DC

January 2, 2025 Slide 67

Compact and reliable traction converters
For all types of rail vehicles

BORDLINE® CC series
– Modular technology platform for fast project delivery,
economies of scale, maintainability, and optimum life-cycle
cost
– Very compact, reliable, and energy-efficient

CC400 CC750
for Light Rail Vehicles, metros, for mass transit EMUs,
people movers DMUs, mountain trains, metros

CC1500
for locomotives, high-speed trains
and high-power EMUs

January 2, 2025 Slide 68

BORDLINE® CC – Compact Converter
Versatility and customization based on standard power modules

CC400 CC400 CC400 CC400 CC400 CC750 DC CC750 DC CC750 DC CC750

LRV LRV LRV LRV Monorail EMU Locomotive EMU DC
Metro

CC750 MS CC750 MS CC750 DC CC750 AC CC750 DC CC750 DE CC750 DC CC1500 AC CC1500

EMU EMU EMU EMU EMU EMU EMU Double-deck DC
EMU EMU

CC1500 CC750 AC CC750 AC CC1500 DC CC1500 MS CC1500 DE CC1500 DE CC1500 AC CC1500 AC

AC Locomotive Power Head Locomotive Locomotive Locomotive Locomotive Locomotive High-speed
EMU train

CC1500 MS CC1500 DC CC1500 CC1500 CC1500 CC1500 MS CC1500 DE CC1500 AC CC1500 MS

High-speed train EMU DE MS DC Double-deck Locomotive Locomotive High-speed
Locomoti Locomoti Locomoti EMU train
ve ve ve

January 2, 2025 Slide 69

Modular auxiliary converters and battery
chargers
For all types of rail vehicles

BORDLINE® series
– Output power range from 10 to 1’200 kW, individually
controlled
– AC and DC and multi-system input voltages
– Galvanic separation; optional integrated battery charger
– Compact, rugged, reliable, and low noise
Battery Charger - BC M260 AC
– Large variety of cabinets and protection levels For all railway applications For Locomotives

M45 MS M5200 AC
For border-crossing sleeping For locomotives/HOG - Coach
coaches

January 2, 2025 Slide 70

BORDLINE® M – Auxiliary converter and battery
charger
Broad product and power range for all rail applications

M1 DC M2 AC M1 AC M1 DC M5 M7 AC M7 AC M7 DC M10 M8 DC
Coach Double-deck Coach LRV DC Locomotiv Locomotive Metro EMU/ LRV
coach LRV e DDEMU

M15 AC M15 DC M120 M25 AC M30 M30 DC M30 DC M30 DC M35 DDC M35 DC
High-speed LRV DC Coach / DC LRV Metro LRV LRV Metro
train Coach EMU LRV

M35 DC M40 DC M45 M25 AC M45 M50 AC M55 DC M60 DC M65 AC M70 DC
Coach Coach MS EMU AC Coach LRV Double-deck EMU Metro
Coach Coach coach

M65 DC M65 MS M80 AC M95 MS M180 AC M230 DC M210 DC M60 DC M65 AC M70 DC
Metro Coach Double-deck LRV Locomotive Metro Locomotive Locomoti Locomotive Coach
EMU ve

January 2, 2025 Slide 71

—
Traction Converters
Leading-Edge solution Offering to Indian Railway
Current offering in Indian Railway Rolling Stock

2018
2017 Composit
2017 e
Bordline
Converte
2016 BC
TC+AC r
2011 M500 +VCU
2010 M130
2008 CC1500
2006
M180
Gate
Units for
GTO
converter
s
Spare

January 2, 2025 Slide 73

New IGBT converters for electric locomotives (IR)
Exact retrofit of propulsion and auxiliary converters

Country : Customer Need

India
− Replacement of GTO converters without any modification to
Operator : mechanical locomotive design, interfaces, control, transformer and
Indian Railways
motor
Category: − Design suitable for old as well as new locomotives
Locomotive
− Resistant to high temperatures
Scope of supply:
BORDLINE CC1500
− Service-friendly solution
BORDLINE M260
Vehicle Control Unit
ABB Solution
Traction transformer − Custom built IGBT based traction converter
Key data: − Conversion from bogie control to single-axle control
4.5 MW per loco
Max. tractive effort: 510 − Configurable for six-axle and four-axle variants
kN
− Increased energy efficiency, advanced adhesion control
Deliveries:
2011 - 2018 Customer Benefits
− Superior functional replacement to existing GTO based traction
converter
− Significantly improved tractive effort under all conditions
− Better energy-efficiency and less heat generation
− Higher availability due to axle control

January 2, 2025 Slide 74

—
Traction Converters
Innovative Development Project for Indian Railway
IGBT base Hotel Load converters for passenger locomotives
WAP7
Bordline M500 for Head on Generation (HoG)

Country : Customer Need

India
− To reduce the local carbon foot print by avoiding EOG operation
Operator :
Indian Railways − Improve the Energy efficiency to reduce the operating cost

Category:
Locomotive
ABB Solution
Scope of supply: − IGBT based line converter and inverter
BORDLINE M500
− Sine filtered AC output
Key data:
2 x 500kVA Output − Liquid-cooled solution
− Modular construction with standard power modules
Deliveries:
2016 - 2018

Customer Benefits
− Service-friendly
− High energy-efficiency

PROTOTYPE UNIT COMMISSIONED IN WAP7 30510 AND RUNNING SINCE 03-

January 2, 2025 Slide 76 2016
New IGBT base Composite converters for WAP5
locomotives
Independent Traction Converter and Hotel load converter in single Cubicle

Country : Customer Need

India
− Composite converter with Electrically isolated circuit for Traction and
Operator : HOG
Indian Railways
− To be accommodate in existing available space with bare minimum
Category: change
Locomotive
− Suitable for 160/200 kmph
Scope of supply:
BORDLINE CC1500
M500
ABB Solution
Key data: − Custom built IGBT based composite converter (Traction +HOG)
4.5 MW per loco
Max. tractive effort: 260 − Common water cooling circuit
kN
2 x 500 kVA – AC − Suitable for MICAS/TCN communication
Output

Deliveries: Customer Benefits

2018
− No major modification or component rearrangement
− No side wall cutout for magnetic cooling
− Possibility to retrofit the running locomotive in shed without major
modification

UNDER IC0 COMMISSIONIN IN WAP5-30140 LOCOMOTIVE

January 2, 2025 Slide 77
New SiC base Battery Charger for Electrical Locomotives
(Alstom)®
BORDLINE BC for Rolling stock application

Country : Customer Need

India
− 14kW Stand alone Battery charger
Operator :
Indian Railway − Redundancy / Degrade mode concept

Category:
− Higher Reliability
Locomotive

Scope of supply: ABB Solution

BORDLINE BC M14
− Sic Based Battery charger with modular concept
Key data:
12000HP Loco − 14kW BC assembly with less weight.

Deliveries: − Configurable for custom needs

2017 - 2028 − Standard M10 Modules available in 24VDC,36VDC,72 VDC & 110V
DC

Customer Benefits
− Degrade mode Operation
− Compact Size & Light Weight
− Higher availability due Modular Concept

India’s First SiC base Battery Charger for Rolling stock

January 2, 2025 Slide 78
application
BORDLINE® BC for Rollingstock, Signalling,
Automobile
Overview

The BORDLINE® BC base battery charger is a compact, lightweight unit

designed to charge the batteries and supply DC loads.

Key Product Features:

 High power density (with 1kW per 1 kg)

 compact design with footprint of 400 x 220 mm– the size of a shoebox

 Built with SiC power semiconductor

 Three phase AC voltage input

 19-inch rack mount installation or integration into any other on-board

Application
equipment  Rolling Stock

 E-Vehicle
 High efficiency (>95%) and consequentially energy savings and low life
 Other Industrial or
cycle cost due to SiC and resonant switching technology Marine application
 Scalable power through parallel operation

 CAN interface for configuration and diagnosis (Train Real Time Data Protocol
optional)

January 2, 2025 Slide 79

Propulsion projects worldwide
Selected references

AeroExpress, RU
Belarusian
DRS, UK Railway, BY
SDOT, US

Changchun, CN
Go Transit, CA
RENFE, ES
Indian
Railways, IN

MRS, BR Pacific
PRASA, ZA National, AU

January 2, 2025 Slide 80

Auxiliary converter projects worldwide
Selected references

National
Go Transit, CA Railway, KZ

Trenitalia, IT
Portland
Streetcar, US Shenzhen
Indian Metro, CN
Metro Railways, IN
Maracaibo, VE

Yarra trams, AU

January 2, 2025 Slide 81

—
Traction Motors
Offerings and new technologies
Typical Products overview
Traction Motors & Generator

Locomotives, EMUs / DEMU, Metros, Monorails, LRV, Tram Trains

AMXL200 AMXL225 AMXM250 AMXL200 AMXM180 AMXM280 AMXM315

LRV LRV E-Bus LRV Monorail Tram Train DEMU
Close self Ventilated Casted Aluminum Rotor Permanent Magnets Rotor Casted Aluminum Rotor Casted Aluminum Rotor Parrtially Suspended Asynchronous Generator

AMXL225 LRV AMXM180 AMXM280 AMXM280

AMXL250 AMXM315 WGX650
BacktoBack Mounted LRV Metro Metro
EMU EMU Sychronous Generator
liquid cooled Self Ventilated Filtered inlet air
Copper rotor Force Ventilated Double Bearings

AMXM280 AMXL355 AMXL400 AMXL450 AMXL450 AMXL400 WGX650

Metro Locomotive Locomotive Locomotive Locomotive HST Sychronous Generator
Wagonwheel-fully supended Single Bearing Shaft Pinion Axle Hung Male Pinion High Speed Single Bearing

January 2, 2025 Slide 83

Critical Topics for Traction Applications

Control Passive Materials

Base line – Proven and Reliable
Technology
Quality
Active Materials
What is the best solution (performance, Efficiency
energy efficiency, reliability, weight. price
Pout/Pin (%)
etc.)
Torque
The answers: It depends… Density
Motor Nm/kg
It is not about designing the best motor – design/ Topologies
it is to optimise the application and optimization
understand the use of the same

That is ABB’s true value… Drive chain Thermal management

optimization

Efficiency and reliability is most important but for railways even overall weight and price
January 2, 2025 Slide 84 of the motor is also important.
Traction Motors
Common Technology Platform Building Blocks

VHS rotor, blast

Al cast cage Cu cast Cu welded PM PM+
Rotor IM cage IM cage IM
SynRM PMaSynRM PM embedded
surface cage
welding or solid
(sintered)
Form Random Random Form
Concentrated
winding winding F winding F Random winding F winding Composite
Stator class 200 DOL VSD VSD (1000V) class 220
winding F VSD
stator
(690V)
(3kV) (690V) (690V) (3kV)
Nodular Stainless Frameless
Casings Grey iron
iron
Cast Al Extruded Al
steel design
Composite
Indirect
Open air Direct water Micro-channel
Cooling cooling
water Oil spray Heat pipe
cooling cooling
cooling
Standard Insulated Hybrid Air foil Lorenz force
Bearings steel steel bearing
Ceramic bearing
bearings bearings
Energy
Pt-100, Vibration Bearing current Low power EMC
Sensors PTC
1000 sensor sensor
managemen
communication sensors
t sensors
Thermally
Traction LV Wireless
optimised System Failure mode
Other motor/gear Motor/gear communic
Motors/drive recognition analysis
package package ation
package

Technology platforms, for any product - supported by our designs and tools

January 2, 2025 Slide 85

Traction Motors – Technology Portfolio
Topologies

Induction SynRM PMaSynRM PM inset

January 2, 2025 Slide 86

Traction Motors- Technology Portfolio
Topologies

Induction SynRM PMaSynRM PM inset

• Familiar and well- • High energy efficiency • Very high energy • Very high energy
proven technology • efficiency efficiency
High power density
• Robust • Excellent power • Compact
• Accurate speed control
• density •
Easy to use and even without sensors Synchronous speed
maintain • Accurate speed control
• Low bearing • Low speed bearing
even without sensors
temperatures and temperatures and
longer bearing lifetime • Low bearing/winding longer bearing lifetime
• Lower efficiency at
• temperatures
lower speeds No REE – just air
• Easy to tailor design
• Slip losses in rotor • Easy to use and • High cost
performance
heats up bearings maintain • Only for VSD operation
• No REE
• Torque only in • Rare-earth magnets
asynchronous • High PF and great field
• Lower power factor
operation weakening range • Uncertain cost
and higher current
variation
• High speed accuracy demand
difficult without • Demagnetization risk
• Demagnetization risk
sensors • More difficult service
due to forces from
magnets

January 2, 2025 Slide 87

All suspension types available…
Axle hung / Nose suspended Partly suspended drive Fully suspended drive

Mostly used for freight

The most common drive Mostly used for Light Rail
locomotives. (MEMU &
solution. Vehicles.
EMU)
+ + +
Lower unsuspended mass Minimal unsuspended mass
Compact
Suspended motor Suspended motor
Relatively low cost

-High unsuspended mass

-
Low integration level
-
Suspended gearbox

High shock and vibration Forces from coupling due to

levels misalignments

High integration level High shock and vibration

levels on gearbox Relatively high cost

January 2, 2025 Slide 88

Rotor types - aluminum or copper

Casted aluminum Copper: Copper bars

and CTO rings

Used mainly for low and medium power Used mainly for higher power

+ +
Lighter weight in aluminum

Lower cost

Very few parts, high reliability Higher performance

-Lower performance
-Higher cost

Restriction of diameter Heavier rotor

January 2, 2025 Slide 89 Metro motors are mainly al die cast rotors. MEMU and EMU’s are Copper rot
or.
Traction Motors and Generators
Thermal Management and Noise

 Active novel technology fields of cooling / thermal management

 Micro-channel cooling in active parts
 Oil spray cooling
 Thermal management of interfaces and filled insulation materials
 Heat-pipe technology

 Traction
 CFD simulations and thermal networks used in thermal modeling
 Advanced tools to maximize the revolution speed minimizing noise.
 Increased fan performance
 Decreased pressure drop

 Tools support
 Thermal duty cycling, hot-spot analysis, fluid flow
Traction fan optimization
 Direct evaluation of magnetic and structural noise in system

 Last success case

 Thermal and cooling optimization of NXR range (large induction)
 Well balanced inner cooling and build away hot spots
 Better utilization of materials, effective use of active parts
 Maintained or better efficiency – but 20% more power dense!

January 2, 2025 Slide 90

SmartSensor for Traction Motors
Introduction to motor condition monitoring by SmartSensor
Process

• Commissioning
SmartSensor on the motors
• SmartSensor collects
measurements at regular
intervals
• SmartSensor transfers data
to cloud based server
• High level analysis
provided by the server
• Customer can plan
maintenance based on
analysis

January 2, 2025 Slide 91

SmartSensor for Traction Motors
Monitoring provided by the SmartSensor

Supported parameters

• Vibration Parameters(overall vibration)

• Health Parameters(Bearing health, rotor health etc)

• Operating parameters(operating time, number of starts, temperature etc)

• Maintenance advice(regreasing advice, notifications )

• Sensor unit status (battery indicator)

January 2, 2025 Slide 92

Portal allows for monitoring trends over time
Simply select the parameters and time period and it plots the data for
you

Temperature and Vibration data on overland conveyor

January 2, 2025 Slide 93

Reference list
ABB manufactured motors

X2000 Sweden C20 Sweden BM21 Rumania Govia UK

Delhi Metro Rail -

Bombardier OTU Denmark AGC France VLU UK

CRH1 China SSL UK NAT France GAT South Africa

January 2, 2025 Slide 94

—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Medium & Low voltage products for rail application
Sudipkumar Das
Electrification Products Division – TRANSPORTATION (RAIL)
Infrastructure solution

Electrification Station and building Control & Signaling Tunnel & depots

 AC traction substations  Low Voltage Switchgear  Low Voltage Switchgear  Low Voltage Switchgear
 DC traction substations  Medium Voltage Switchgear  Medium Voltage Switchgear  Medium Voltage Switchgear
 Energy storage systems  Medium & Low Voltage  Medium & Low Voltage  Medium & Low Voltage
 Products Products Products
UPS Systems
 Building Automation Systems  Safety Products  Cable Protection System
 …
 …  …  Emergency lighting
 …

Complete solution from power to building management

January 2, 2025 Slide 96

Electrification Products Division – TRANSPORTATION (RAIL)
Rolling Stock

Power & Control Connection Unit Brake Systems Control

Distribution Panel
Air Conditioning Passengers coaches
Control Panel

Control & Signaling

equipment

Cable
Protection
System

Control & Distribution panel

Battery chargers Protection

Power & Auxiliary

Converters

January 2, 2025 Slide 97

Electrification Products Division – TRANSPORTATION (RAIL)
Offering for Rolling Stock

Miniature Circuit Breakers Molded Case Circuit Breakers Contactors & Contactor Relays
Connection Devices

Timers & Monitoring Relays Safety PLC and devices Motor protection DC Break

Conduit and fitting Cable Ties, Tools & accessories

Wire termination

January 2, 2025 Slide 98

Electrification Products Division – TRANSPORTATION (RAIL)
Terminal Blocks
Rolling stock

Push-In-Spring / Pluggable

January 2, 2025 Slide 99

Overview of LV / MV Concept
Design Process

MV network

Ring Main Unit

MV/LV Transformer

LV Switchboard

LV network to customer

Electrical Design Final Assembly

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100
Major Components
Enclosure

Enclosure –
• Enclosure is made out of GI sheet steel
with 1/1.5/2mm thickness
• Nuts-Bolts free enclosure construction to
avoid rusting. Stainless Steel Rivets are
used to have high mechanical strength
• Only Transformer compartment roof is
detachable type for transformer
maintenance purpose.
• K10 Enclosure class for 1500KVA
Transformer
• Internal Arc Tested for IAC-20KA/1Sec for
AB
• Enclosure Exterior is Powder Coated with
Light and Dark Grey Color.
• Available in different color shades also

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101
Advantages of CSS over Conventional S/S

Conventional Substation CSS

Procurement of individual Factory tested Solution with
substation equipment single point contact

Expensive on total cost basis Life cycle cost is less

Unauthorized tapping & power Unauthorized activities are

theft prohibited

Exposure to Environmental Protection from Environmental

Hazards Hazards

More lead time & installation Faster delivery and ready to

time install

Extensive civil work

Minimized civil works
requirement

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January 2, 2025
102
 Common features
Relion® 615 series

January 2, 2025 Slide

103
DA Retrofit

ABB Offers
Factory Assembled & tested metering door /
box with relays, meters, switches & required
accessories

New Metering Box Benefits to Customer

Newly wired factory assembled metering box
with relays, meters etc. enhance life &
reliability of protection system

Esthetic looks of metering box/ door

Numerical Relay

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104
—
Accelerating sustainable growth
in West Bengal

ABB Technology Day

—
KOLKATA, FEBRUARY 14, 2019
Innovative and leading edge traction & infrastructure
solutions
Mission Critical Communications for Rail – Fiber Optic
Lingaraj Nayak
Platform Overview for Mission-Critical Networks
Extra long life cycle

XMC20 UNEM UMUX 1500

• Ethernet services and • NMS with support to • Cross-connect system

native PDH/SDH, TDM and MPLS-TP end and flexible PDH/SDH
modular Ethernet to end provisioning STM1/4 add/drop
switch, highest port • 1991 - present multiplexer and
density Ethernet L2/L3 – high
• 2012 - present density
• 1991 - 2016

With you for the lifetime of your network

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106
XMC20 Value & Benefits
Uniquely addressing segments’ critical communication needs

Safety, availability, & security

- Robust Protection & MCS Security
- secure availability

>99.999
- Fanless & harsh environment operation
- Meets regulatory standards -25°C -
+60°C
Operating temperature
Digital future & legacy
- Legacy & advanced packet voice
% Reliability

services
- Reliable mission-critical multi-service

packet
- True Hybrid SDH/Packet smooth
>50 Multiservice
migration

Year MTBF Analog voice, V-series,

- Real-time deterministic performance E1 | MPLS-TP & L2/3
- Optimal scalability & lowest TCO VPN

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107
XMC20 Value & Benefits
Uniquely addressing segments’ critical communication needs

Real-time deterministic performance

- Deterministic end-to-end performance
- Guaranteed QoS, (symmetric) delay &

< 150 us <10 ms

Jitter
- Built-in precision time & clock, including

packet networks & unrivalled

jitter/wander network delay
encrypted packet real-time operation

Optimal scalability & lowest TCO

- Solution scalability; 3rd party

interoperability
- Extra long life cycle & support >10 >20 10’s-100’s
years Years active life and Nodes
- Simplicity & ease of use, e2e interoperability between
management generations (1000’s
- Lowest total cost-of-ownership (TCO)
services)

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108
UNEM – XMC20 Network Management Solution
State of Art end to end network provisioning for TDM and Packet Network

FCAPS Service NBI Networking

Supervision Package
Locating forwarding Monitoring of SNMP as interface to End-to-end TDM circuit
alarms, Graphical & configured TDM/MPLS- higher level provisioning for XMC20
hierarchical network TP - Defines rules management for and UMUX networks as
presentation including (alarm correlation - alarms and basic well end-to-end MPLS-
sections, root cause analysis) inventory TP provisioning for
Synchronization map, XMC20 networks
escalation
management and
documentation.

SBI Virtualization
Managing of 3rd party Helping to enable High
equipment for fault, availability feature from
inventory and cross Virtual hypervisor
launch of local craft
terminal

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109
XMC20
Cyber security features

Cyber Security Feature XMC20 R6D

System Time SNTP, PTP

SYSLOG YES

Proprietary on top of TLS

Management protocols SNMPv3
IPsec

Management accounts RADIUS

Management VLAN yes, dedicated

Rate limiter (BC, MC, UU) YES

Flow control YES

OSPF authentication MD5

Internal firewall towards management port YES

Traffic encryption, including system
YES, AES-256-GCM QRNG
protocols
ABB Permanent Encryption key management YES

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110
ABB Customers
Sample installed base

Russia: Gazprom, TRANSNEFT

Saudi Arabia: ARAMCO
Oman: PDO
United Arab Emirates: GASCO ZADCO,
ADCO
Mexico: Gasoductos del Noreste
Switzerland: Gaznat
Peru: Gasoducto del Sur Peruano
Nigeria: Shell, Nigeria
North Sea: Shell
Algeria: Sonelgaz
Libya: Sirte Oil, Total Oil, Waha Oil,
Zwetina, Rasco.
France: Total E & P
Syria: Al Fuurat Oil Company
Egypt: BAPETCO

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111
—
Ask me for further information

Tapas K. Sarkar
+91 9007000430
[email protected]
 Slide
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