Power and traction transformers

Advanced technology for maximum

reliability
ABB – a global leader

ABB is a global leader in Power and Automation technologies transformers, disconnectors, capacitor banks, reactive power
that enable utility and industry customers to improve compensators, power and distribution transformers and a
performance while lowering environmental impact. The ABB range of power distribution products like compact secondary
Group of companies operates in around 100 countries. substations (CSS) and ring main units (RMU).

In India, ABB serves customers with the complete range of Advantage ABB
power and automation technologies. The company has a – 120 years of technology and innovation
vast installed base, extensive manufacturing facilities and a – Unparalleled domain competence
countrywide marketing and service presence. – Vast global experience
– Total solution provider
The Power Technologies division offers electric, gas and
– Large installed base
water utilities as well as industrial and commercial customers
– Environment-friendly technologies
a wide range of products, systems and services for power
generation, transmission and distribution. ABB turnkey Commitment to quality and sustainability
solution capabilities in the sector range from bulk power ABB manufacturing facilities conform to the highest
transmission, substations and complete electrification to utility quality and environmental standards. The facilities are ISO
automation and distribution systems. 9001 and ISO 14001 compliant and certified by leading
international authorities.
The product offering covers a wide spectrum of technologies
across the entire voltage range including indoor and outdoor
circuit breakers, air and gas insulated switchgear, instrument

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Experience and expertise makes the difference

Testing facilities for transformer from 220kV to 765kV

With over 100 years of experience in manufacturing world- ABB offers a wide range of Power transformers, Traction
class transformers, ABB has led the way setting new transformers and HVDC transformers.
benchmarks in transformer technology. ABB’s advanced
ABB also manufactures a wide range of Distribution
technology, design, processes and materials that go into
transformers.
every transformer ensure trouble-free operation, high
efficiency and reliability. Like any of its numerous facilities across the world, ABB’s
state-of-the-art transformers manufacturing and testing
Extensive R&D in the field of transformer technology, power
facility in Vadodara, Gujarat, India is equipped with the
transmission and distribution has enabled ABB to develop
latest and best-in-class processes and systems for design,
various concepts in design as well as engineering of
manufacturing and testing.
transformers.
The Vadodara facility employs the best-in-class manufacturing
ABB Transformers are designed based on the patented and
practices drawn from experience and expertise developed
proven TrafoStarTM concept, ensuring minimal losses, low
over the years across ABB’s global operations.
noise and overall reduction in life-cycle costs. ABB also
undertakes repairs, refurbishment and life-enhancement of Well-trained engineers with global experience and expertise
transformers that help optimal utilisation and lower operating ensure that every transformer that rolls out is a symbol of the
costs. highest quality and reliability.

ABB is the largest manufacturer of transformers in the world

with over 49 factories in 30 countries.

Product brochure | Power and Traction Transformers 3

Unparalleled range

ABB offers the widest range of transformers which are

synonymous with technological innovation, superior quality
and reliability.

Power Transformers - 66 kV to 765 kV, 10 MVA and above

Shunt Reactors - 50-125 MVAr 400kV class HVDC Converter Transformers

Traction Transformers - LOT 6500/7500 Traction Transformers - EMU

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TrafoStarTM – for efficient and dependable transformers

“TrafoStarTM” is the common ABB concept used for the

design and manufacture of Power Transformers across all its
manufacturing facilities. It is based on the best practices and
know-how acquired over several decades coupled with global
manufacturing experience.

The concept incorporates common electrical and mechanical

design standards, global processes and quality norms with a
6-Sigma system. Every TrafostarTM transformer is built from
standardised, service proven components and modules
ensuring flexible, dependable and tailor-made transformer
designs. The high reliability of these transformers ensures
maximum availability, lower maintenance costs and reduced
life-cycle costs.

Powerful and sophisticated software tools are used to develop

the mechanical and electrical design of all transformers.
These tools help in ensuring optimum electrical design and
determining eddy current losses and short circuit forces
accurately. A 3-dimensional modelling software (Pro-Engineer)
used in developing the mechanical design enables designers
to view the virtual prototype of a transformer (including tanking
of the corecoil assembly) on the computer screen before
production commences.

TrafoStarTM design used for core type transformers has a

circular shaped core limb, surrounded by concentrically
arranged, cylinder shaped windings. This facilitates the most
efficient use of active material and reduced production time.

The core is made of cylindrical windings that can withstand

short circuits even under extreme fault conditions.

High voltage windings are built as interleaved discs, while

the low voltage windings are of helical design. The tapped
portion of the winding is normally arranged as a separate
physical winding shell. This design allows a balanced ampere
turn distribution, avoiding excessive short circuit forces and
additional losses.

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State-of-the-art processes

Windings
Windings are designed to withstand high short circuit
capability, uniform surge voltage distribution and effective heat
dissipation which are critical to transformer reliability. The disc
type design of the high voltage windings ensures better short
circuit withstand capability, uniform surge voltage distribution
and effective heat dissipation. These windings can be used
with different designs for both small and large transformers up
to the highest voltage levels. Using the latest developments
in winding technology, ABB uses “voltage stabilised” disc
windings for the high voltage side. The individual winding
turns in each group of discs are interleaved thereby increasing
the winding series capacitance to get uniform voltage
distribution.

The low voltage windings are made of helical type windings

with turns composed of several strands in parallel. Spacers
between the strands make it easy to accommodate large oil
ducts for insulation and cooling.

The specially designed vertical winding machines make

it possible to produce windings to meet the exact design
specifications. Adjustable winding mandrels guarantee
compliance with the specified winding geometry for coils of a
transformer.

The windings of the on-load tap changers are designed in

such a way that the tapped segment of each winding is evenly
distributed over the entire length of the core limb. This design
ensures proper ampere distribution facilitating electromagnetic
balance regardless of the selected tapping position.

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World-class material and components

5 Limb Core of 315 MVA, 400 kV Auto Transformer Core lifting on core table

Core
Cold-rolled grain oriented silicon steel laminations are used
to ensure low no-load losses and suppression of vibrations
resulting in lower noise levels. Using stepped sheet widths
helps in achieving an almost circular cross section of the core.

Advanced step-lap core construction technique achieve

precise core stacking with step lap joints at the corners. This
technique also helps in stacking at precise angles thereby
preventing the formation of air gaps in the core joints,
which otherwise could lead to increased losses and noise
generation.

Core form structure is used without any through bolts in the

limb or yoke portion. The core limb is wound with conducting
resin impregnated glass tape to give rigidity to core and to get
a minimum uniform circular section for inner winding. To avoid Active part view (LV side) of 100 MVA, 220 kV Transformer
internal mechanical stresses, the core is set upright in the
stacking device itself.

Active part (Core coil assembly)

In the main assembly bay the windings are assembled
with the core on movable and fixed work stations. Special
care is given to electrical connections of cleats, leads and
tap changer. All the necessary joints are made secured
by applying high frequency brazing or specially patented
crimping technology carried out by trained personnel.

Product brochure | Power and Traction Transformers 7

Best-in-class systems

Active part drying in a VPD Tanking with precision

Insulation and drying system

An oil barrier system is used as the main insulation medium
and moulded angle rings for end insulation. Major oil gaps
between the windings and earthed parts are divided into thin
oil layers by means of press board barrier cylinders enabling
uniform drying and PD (Partial Discharge) free insulation
even at high electric stresses. Pre-compressed press board
spacers and moulded end-barriers used in the active part
provide a rigid insulation structure with low PD levels.

Moisture content in insulating materials of winding assembly

is removed by application of heat and vacuum in a separate
drying oven (Winding Autoclave) before windings are
individually pressed in a hydraulic press. As the active part
can absorb moisture during the assembly process a final
drying process is carried out in a completely automated
vapour phase drying (VPD) plant. This ensures thorough and
uniform drying resulting in a clean and dry core coil assembly
(active part) which ensures long transformer life.

A clean, dust-free environment ensures the highest standards

in quality. By using an automated oil-filling and processing
system and by virtue of leak proof joints in the transformers
Final assembly
there is no oil spillage.

Tanking Bushings
After inserting the active part into the tank, processed ABB’s factory for oil-filled transformer bushings up to 245kV
insulating oil is added. The oil passes through a special is equipped with the latest vacuum evacuation and oil
flushing process in a filter system during which any remaining filling plant. The state-of-the-art testing facility comprises a
impurities are removed. An advanced nitrile rubber gasket ‘Faraday Cage’ - which is a completely metal enclosed hall
system used in the grooves ensures the joints are secure, to ensure no external electromagnetic interferences while the
making the transformer leak proof. Processing and handling equipment is tested. The facility is equipped to test bushings
of oil is done by means of an automated oil handling system, up to 440kV.
which eliminates any chance of oils intermixing.

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Testing and quality control

Testing
The Vadodara transformer facility is equipped with state-of-
the-art testing facility to test transformers up to 765 kV.

This modern testing facility includes an impulse generator,

precision power analyser for transformer loss measurement,
PD analyser and temperature data logger to carry out routine
and type tests accurately. A special motor-generator set-up is
used to test transformers at the exact operating frequency to
obtain accurate results.

Modern data collecting systems and high-end testing

instruments allow easy access to accurate results obtained
from test measurements. ABB transformers are subjected to
all the necessary routine tests in accordance with BIS or IEC,
ensuring they withstand conditions beyond normal operating
conditions. The extremes to which the transformers are tested
are a measure of the highest standards in quality and reliability
built into every transformer.

In addition to all routine tests, special and type tests that can
be carried out in-house include:
– Temperature rise test
– Lightning & switching impulse test
– Induced over-voltage test with PD measurements
– Measurement of zero sequence impedance
– Noise levels

Quality Assurance, Health and Safety

An up-to-date quality assurance system is well in place that
covers all aspects involved in the production and testing of all
transformers.

Quality checks are carried out on all material and processes

at various manufacturing stages to ensure highest quality
standards. Following a global quality manual ensures that the
quality assurance system used is on par with similar systems
deployed in other ABB factories across the world. The facility
is ISO:9001 certified for its quality systems.
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World-class facilities and operations

In-house handling
The entire facility floor is epoxy coated with no rails. ABB
uses air castors which work on the hovercraft principle for
moving windings, sub-assemblies and complete transformers
ensuring smooth and jerk-free movement.

Transportation
Moving an object, the size and weight of a large power
transformer is no easy task and requires precise coordination
and execution. ABB has state-of-the-art infrastructure and
reliable logistics partners that ensure that the end product is
packed and transported safely to its destination. ABB installs
impact recorders for higher ratings of transformers.

Installation, service and support

ABB’s well-trained and dedicated service engineers ensure
that transformers are erected and commissioned as per ABB’s
global standard procedure. Extra care is taken to supervise
the unloading, erection on foundation pads, assembly of
components, refilling the transformer with oil and performing
the necessary on-site pre-commissioning tests to assure
proper, trouble-free service.

ABB has a wide network of marketing offices and service

centres located across the country, ensuring quick response
to customer needs.

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90 MVA, 110/34.5 kV Power Transformer 87.5 MVA, 138/34.5 kV Transformer

100 MVA 220/66 kV Power Transformer 400/74.5/74.5kV HVDC back-to-back Converter Transformers

154 MVA, 11/420 kV Generator Transformer 315 MVA, 400kV Auto Transformer

Product brochure | Power and Traction Transformers 11

Contact us

ABB Limited Sai-Rish, 5 - Gawande layout C-2/201, Vaibhav Place, Indira nagar

1ZYN200802 Rev 001 Copyright© 2011 ABB. All rights reserved

Power transformers Near Chhatrapati square, Ring road Dehradun 248 006
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