VBS Presentation, Grzegorz Syska, February 2012

ABB High Voltage Products

Combined Instrument Transformer
PVA123
© ABB Group
February 10, 2012 | Slide 1
ABB Group in Poland
B i ffacts
Basic t

 Headquarters: in Warszawa
 About2600 employees working
in Poland
 Revenues in 2010: MUSD 514,-
 77%of revenues are generated
by sales off power products and
systems
 56% of production amounting to
more than MUSD 287,- is
exported worldwide
 Recent large
g investments:
 new factory for production of
electric motors commissioned in
2009
 new factory for production of power
electronics commissioned in 2010

© ABB Group
February 10, 2012 | Slide 2
ABB Group in Poland
P
Power P
Products
d t & Power
P S
Systems
t Divisions
Di i i

Przasnysz
Lebork
 HV, MV, LV
 Power Systems Gdansk
Apparatuses including:
• HV & MV Instrument
Szczecin transformers
• MV Circuit Breakers
• Switchgear
• Switch disconnectors
Poznan
Warszawa
 Power Systems
Wroclaw
Wroclaw Lodz
 Utility Automation
K t i
Katowice Lublin
• Power transformers
• Distribution transformers
Krakow • Insulation Kit Center
Rzeszow
Krakow
 Power Systems

© ABB Group
February 10, 2012 | Slide 3
ABB Group in Poland
F t
Factory in
i Lodz
L d

POWER TRANSFORMERS
 power transformers up to 300 MVA and 500 kV;
Lodz generator step-up
g p p and p
power substations
 markets: Central and Eastern Europe, Benelux,
Germany, Switzerland, Austria, France, Ireland
 Set up in 1924 and Scandinavia
 900 employees
 back-up factory for North America
 Focus factory
for power
and oil filled
DISTRIBUTION TRANSFORMERS
distribution
transformers
 oil filled distribution transformers rated from
30 to 2300 kVA
 Production for
European  market: Europe
customers and
backup for
North America INSULATION KIT CENTRE
 delivery of insulation kits and elements to all ABB
power transformers factories in Europe
 power transformers factories decreased their
cycle times and lowered costs thanks to receiving
prefabricated insulation kits from Lodz factory

© ABB Group
February 10, 2012 | Slide 4
ABB Group in Poland
F t
Factory in
i Przasnysz
P

HIGH VOLTAGE APPARATUSSES

Przasnysz  focus factor for combined instrument transformers
123 kV,, global
g delivery
y
 current and voltage instrument transformers
123 kV for domestic market and Germany
 set up in 1970 as a
subsidiary of an
electro-technical
l t t h i l
MEDIUM
U VOLTAGE
O G APPARATUSSES
USS S
company ZWAR
operating since
 indoor switch disconnectors, global sales
1918
 voltage and special purpose current instrument
 300 employees transformers, g
global sales
 focus factory for
HV, MV and LV  circuit breakers, domestic market
electrical
apparatusses  fuses, global sales
 large
g pportion of
production is LOW VOLTAGE APPARATUSSES
exported worldwide
 LOVOS surge arresters
 low voltage instrument transformers

© ABB Group
February 10, 2012 | Slide 5
ABB Group in Poland
Al k
Aleksandrow
d Lodzki
L d ki – LV motors
t

 Production of standard industrial low

voltage motors
Aleksandrow
Lodzki  Three fully
Th f ll computerised
t i d manufacturing
f t i
lines to produce low voltage electric
 newly built factory,
investment worth motors, 80 mm to 355 mm in size, with
US$ 24 Million
 production started in
power from 0.25 to 250 kW
September 2009
 150 employees
 Used for powering fans, pumps and
turbines
 Many adapted to operation in hazardous
environment [flammable or explosive]
 Vast portion of production is exported
worldwide
 The ffactory
Th t iis iimportant
t t production
d ti
centre of „Made in ABB” electric motors

© ABB Group
February 10, 2012 | Slide 6
ABB Group in Poland
Al k
Aleksandrow
d Lodzki
L d ki – Power
P electronics
l t i

 Medium voltage drives for

optimum use of electric
Aleksandrow
energy
Lodzki
 3 kV DC traction converters
 Newly built factory,
investment worth for clean ecological railway
US$ 36.3 Million
transport
 Production started
in October 2010
 130 employees
p y  Medium voltage converters
for wind power applications
 Logistic center and main
warehouse
h ffor LV products
d t
in Poland

© ABB Group
February 10, 2012 | Slide 7
Combined PVA123
HV IT family
f il

© ABB Group
February 10, 2012 | Slide 8
Combined PVA123
C bi d solution
Combined l ti – advantages
d t

Combined solution
integrates current and
voltage
lt ttransformers
f iin one
casing; this means
significant cost reduction
 Lower initial investment by
purchasing one unit instead of two
separate transformers
 Only one supporting structure is
needed
 Lower transportation cost
 Lower installation cost
 The only solution at a substation
where
here space is at a premi
premiumm

© ABB Group
February 10, 2012 | Slide 9
Combined PVA123
T core design
Top d i – advantages
d t

 In top core design the

current module is located in
transformer’s
transformer s head and
voltage module – in its
bottom tank.
 This solution makes it
possible to achieve high
values of short circuit
currents [both thermal and
dynamic] as well as vast
range off rated
t d primary
i
currents and outputs of
secondary windings.
 Many customers prefer this
solution.

© ABB Group
February 10, 2012 | Slide 10
Combined PVA123
C
Construction
t ti

1. Bottom tank
5
9 2. Insulator
8
3 3. Head

10
4. Expansion
p bellows with cover
5. Current module
6. Voltage module
7
7. Secondary terminal box
2
8. Primary terminal P1
9. Primary terminal P2/A
10. Insulating oil.
1 11. Earthing terminal
6
7
11

© ABB Group
February 10, 2012 | Slide 11
Combined PVA123
C
Construction
t ti – advantages
d t

 Silicone rubber or porcelain

insulators [with cemented
g ]; long
flanges]; g creepage
p g
distances as standard
 Stainless steel expansion
bellows
 Housing made of high quality
aluminium alloy
 All external parts made of
corrosion resistant materials
 Hermetic housing,
g o-ring
g
gaskets used for sealing
 safe sealing, safe for
environment
 corrosion proof
 safe oil expansion system

© ABB Group
February 10, 2012 | Slide 12
Combined PVA123
C
Construction
t ti – advantages
d t

 As standard we offer flat

primary terminals made of
aluminium 100 mm or 200
aluminium,
mm width.
 Pin type primary terminals,
made of copper or
aluminium, Ø 30 mm or 40
mm are available on
mm,
request.

© ABB Group
February 10, 2012 | Slide 13
Combined PVA123
C
Construction
t ti – advantages
d t

Voltage coil screen Current coil screen Current secondary terminals

Voltage secondary
terminals

Ventilation screen

Lock
Earthing strip or oil pressure signalling system Cover for sealing [option]
terminals [option]

© ABB Group
February 10, 2012 | Slide 14
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

 fully symmetric coil

Before Now

© ABB Group
February 10, 2012 | Slide 15
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

optimized, multi screen

bushing; very low axial & radial
electric stresses

Before Now
© ABB Group
February 10, 2012 | Slide 16
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

winding wire Ø 0
0.18
18 mm in
double enamel insulation in
accordance to IEC 60317-13

Before Now

© ABB Group
February 10, 2012 | Slide 17
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

homogenous, compact main paper

– oil insulation; no local electric
stresses, long term operation is
assured
gradual inter – layer insulation that
matches actual potential
differences at layers
Before Now

© ABB Group
February 10, 2012 | Slide 18
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

the only insulation medium is

oil and paper

Before Now

© ABB Group
February 10, 2012 | Slide 19
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

0.20 in
0.32 in
0.69 in
1.45 in

0.90 in
 full external screening of voltage
coil; external edges [e.g. core]

0.09 in
influence on operational electric

0.27 in
conditions of main coil insulation 0.73 in

is eliminated

Before Now
© ABB Group
February 10, 2012 | Slide 20
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – voltage
lt coilil

optimised, Al casted HV screen;

electric field stresses around
winding are removed

Before Now

© ABB Group
February 10, 2012 | Slide 21
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – currentt coilil

 Fully symmetric coil

Before Now
© ABB Group
February 10, 2012 | Slide 22
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – currentt coilil

optimized, multi screen bushing;

very low axial & radial electric
stresses

Before Now
© ABB Group
February 10, 2012 | Slide 23
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – currentt coilil

Homogenous, compact main paper

– oil insulation; no local electric
stresses, long g term operation
p is
assured

Before Now
© ABB Group
February 10, 2012 | Slide 24
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – currentt coilil

The only insulation medium is oil and

paper

Before
Now
© ABB Group
February 10, 2012 | Slide 25
Combined IT PVA123
I t d
Introduced
d construction
t ti changes
h – currentt coilil

Oval shape of cores’ box; optimal

electric field distribution on external
surface is assured

Before Now
© ABB Group
February 10, 2012 | Slide 26
Combined PVA123
P d ti process
Production

J J J J J
U

U U U U U

 All purchases and storage according to MRP system

 Whole p
production p
process under ITSet system
y control

© ABB Group
February 10, 2012 | Slide 27
Combined PVA123
P d ti – coilil winding
Production i di and
dddrying
i

Winding and drying in own most modern

winding
g shop.
p

All purchases and storage

according to MRP system;
identification of key
materials and parts for
production fully assured.

© ABB Group
February 10, 2012 | Slide 28
Combined IT PVA123
Wh l process under
Whole d one rooff – own winding
i di shop
h

 insulation continuity control system

Commissioning of winding shop – February 2012

© ABB Group
February 10, 2012 | Slide 29
Combined IT PVA123
Wh l process under
Whole d one rooff – own winding
i di shop
h

Commissioning of winding shop – February 2012

© ABB Group
February 10, 2012 | Slide 30
Combined PVA123
P d ti – assembly
Production bl

J J

U U

Coil winding and drying Assembly

Whole p
production p
process is under ITSet System
y control

© ABB Group
February 10, 2012 | Slide 31
Combined IT PVA123
P d ti – assembly
Production bl

© ABB Group
February 10, 2012 | Slide 32
Combined PVA123
P d ti – oilil filling
Production filli and
d iimpregnation
ti

J J

U U

Coil winding
g and drying
y g Assembly
y Impregnation
p g

E
Every single
i l operation
ti registered
i t d ini ITSet
ITS t system
t

© ABB Group
February 10, 2012 | Slide 33
Combined PVA123
P d ti
Production

 Coils are dried in high

vacuum over a time
period that is set out
according to insulation
dampness and paper
d
depolymerisation
l i ti
 Precise vacuum control
inside transformer
before impregnation
 Impregnation
p g is
pressurised
 Highly efficient process

© ABB Group
February 10, 2012 | Slide 34
Combined PVA123
P d ti – leakage
Production l k test
t t and
d routine
ti ttesting
ti

J J J J J

U U U U U

Coil winding and drying Assembly Impregnation Leakage test Routine test

Results of routine testing

are automatically registered
in ITSet system

© ABB Group
February 10, 2012 | Slide 35
Combined IT PVA123
R ti ttesting
Routine ti

 50 – 150 Hz converter control desk

 High voltage & p.d. station
 Integrated production control system ITSet
 Legalization for metering – PL GUM and
soon DE PTB

© ABB Group
February 10, 2012 | Slide 36
Combined PVA123
P d ti – packing
Production ki and
d ttransportation
t ti

J

J J J J J
U

U U U U U

Coil winding and drying Assembly Impregnation Leakage test Packing and
and routine testing transportation

Combined PVA123 can be transported in either

vertical or horizontal position

© ABB Group
February 10, 2012 | Slide 37
Combined PVA123
Q lit assurance system
Quality t – ITSet
ITS t

 order tracking system

 Customer
 Supplier  Production  Assembly  Tests High Quality Product
delivered on time

 Quality system  Production planning and tracking

ITSet = Instrument
Instr ment Transformer Scheduling,
Sched ling Executing,
E ec ting Tracking

© ABB Group
February 10, 2012 | Slide 38
Combined IT PVA123
P
Parameters
t

 Basic Insulation Level 123 / 230 / 550 kV

 Applicable Standards IEC 60044-1
IEC 60044-2
IEC 60044-3
 Rated primary currents from 50 to 3000 A
 Rated 1s thermal current 10 – 20 – 40 – 63 kA
 Rated secondaryy current 1 A or 5 A
 Voltage factor 1.5 / 30 s, 1.9 / 8 h
 Rated frequency 50 Hz
Paper – oil insulated IT; mineral oil for impregnation does not
contain chlorine compounds [PCB] or any other toxic
substances – impact on environment is minimized
minimized.
The oil meets IEC 60296 Standard requirements.

© ABB Group
February 10, 2012 | Slide 39
Combined IT PVA123
P
Parameters
t – currentt module
d l

Rated primary currents at:

 non reconnectable 50 A up to 3000 A
 reconnection
ti 1:2
12 50 – 100 A up tto 1500 – 3000 A
 reconnection 1:2:4 50 – 100 – 200 A up to 600 – 1200 – 2400 A
ated secondary
Rated seco da y cu
currents:
e ts 1Ao
or 5 A
Rated continuous thermal current: 120% or 150% or 200%
Rated 1 s thermal current at:
 non reconnectable 63 kA
 reconnection 1:2 50 kA
 reconnection 1:2:4 40 kA
Total rated output: 2.5 VA up to 90 VA
Metering accuracy classes: 0.2; 0.2S; 0.5; 0.5S; 1; 3 for FS5 & FS10
Protection accuracy classes: 5P; 10P for ALF 5 – 10 – 15 – 20 – 30

© ABB Group
February 10, 2012 | Slide 40
Combined IT PVA123
P
Parameters
t – voltage
lt module
d l

Rated primary voltage: 110/3 kV

Rated secondary voltage: 100/3; 100/3; 110/3; 110:3 V
Voltage factor: 1.5/30 s or 1.9/8 h
Metering accuracy classes / total rated output: 0.1 up to 75 VA
0.2 up to 150 VA
0.5; 1; 3 up to 300 VA
Protection accuracy classes / total rated output: 0.1 and 3P up to 75 VA
0.2 and 3P up to 150 VA
0.5 and 3P up to 300 VA
1 and 3P up to 500 VA
R id l winding
Residual i di accuracy / ttotal
t l rated
t d output:
t t 3 3P and
3; d 6P up tto 120 VA

© ABB Group
February 10, 2012 | Slide 41
Combined IT PVA123
C bi d solution
Combined l ti - advantages
d t

Integrates current and voltage

transformers in one casing;
 Significant cost reduction
 Lower initial
L i iti l purchasing
h i cost;t one
order instead of two separate orders
 Only one supporting structure is
needed
 Lower transportation
p cost
 Lower installation cost
 The only solution at a substation
where space is short

© ABB Group
February 10, 2012 | Slide 42
Combined IT PVA123
T core design
Top d i - advantages
d t

 Current module is located in transfor-

mer’s head
 Voltage module is located in bottom
tank.
 Enables
E bl tto achieve
hi high
hi h values
l off short
h t
circuit currents [both thermal and
dynamic] as well as vast range of rated
primary currents and outputs of
secondary windings
P f
Preferred
d solution
l ti off mostt customers
t

© ABB Group
February 10, 2012 | Slide 43
Combined IT PVA123
C
Competition
titi – Market
M k t Players
Pl

 Pfiffner
 Siemens / Trench
 Alstom / ex Ritz

ABB strength
 Short delivery time
 Most modern design
 V
Very l
low partial
ti l discharges
di h
 Highly competitive

© ABB Group
February 10, 2012 | Slide 44
Combined IT PVA123
Summary

 Less purchasing effort

 Less transport and installation
 Only one supporting structure,
additional less space
 Top core construction – high short
circuit currents
 Oil paper insulation only
 Low partial discharges level (below 10
pC)
 Low dielectric loss factor tan 
 Routine tested in own laboratory with
GUM and German PTB
certification
tifi ti
 No maintenance
 Long life span
span, estimated > 25 years
© ABB Group
February 10, 2012 | Slide 45
Combined IT PVA123
C tifi t
Certificate

© ABB Group
February 10, 2012 | Slide 46
Combined PVA123
Q lit assurance – ISO
Quality

© ABB Group
February 10, 2012 | Slide 47
© ABB Group
February 10, 2012 | Slide 48