Transformers For Variable Speed Drive Applications .

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Converter transformers and reactorsTransformers for variable speed driveapplicationsTransforming electricity into value

Variable speed drive systemsReliability and qualityVariable speed drives are everywhere: you can find them on board of a dredger, controlling the motors of a dam, in power plants or in mines.Variable speed drivesConverters are used to control the speed of rotation andthe torque of electric motors in many industrial applications.Typically these are pumps, ventilators, compressors, beltconveyors, rolling mills, paper machines and an innumerableamount of different machines employed in manufacturingand other industries. Converters are also operating in powergeneration and in transportation systems, like ships or railway.Electric motors consume about 65 % of all electricity usedthroughout industry. Less than 10 % of those motors arepresently fitted with variable speed drives, which allow forsignificant energy savings. In many cases savings of 50 %or more have been demonstrated. Imagine the energy savingsif more motors were controlled by a variable speed drive.The use of variable speed drives employs more sophisticatedmethods to allow better control of industrial processes andensures higher quality and reliability.Transformers for drive systemsThe transformer is the link between the supplying electrical gridand the converter. It is a major component in the transformerconverter-motor chain.Different converters require different transformer configurations.In many cases a multitude of secondary windings, connectedwith different phase angles is required and special technicalsolutions are needed due to the presence of harmonics andvoltage transients generated by the converter.Thinking as a system, not as single componentsDrive applications are subject to high technical demand. Allcomponents in the chain have to be harmonized. It is thereforeessential to handle the application as a combined system andnot as a set of single components.Additionally, environmental and efficiency aspects are gettingmore and more important and need to be considered andintegrated.ABB recognizes these specific requirements and, thanks toits highest technical and personnel competence, is able tooffer optimized solutions, tailored for different applicationsegments. Continuous high investments in R&D enable ABBto use the full scope of technologies and ensure high reliabilityfor products and systems.2 Converter transformers and reactorsConverter transformers and reactors 3

Transformer portfolio for variablespeed drive applicationsABB s comprehensive experienceA pioneer in converter transformersABB is a pioneer in designing converter transformers and hasa long and proven track record in a broad range of state-ofthe-art technologies to ensure a constant stream of benefitsfor customers. ABB converter transformers have accumulatedmillions of operating hours worldwide.Standardized and tailor-made solutionsCharacterized by their modular design, ABB converter transformers and reactors provide a competitive edge in the keyoperating areas of size, weight and reliability for almost anyrequirement. Support is given by our best experts from ourCenters of Excellence for converter transformers. Transformers are built to match the requirements of any drive, fromany manufacturer.Converter transformer portfolioWe offer liquid-immersed and dry-type transformers for lowvoltage (LV, up to 1.1 kV), medium voltage (MV, up to 36 kV)and high voltage (HV, 36 kV) immersed(kVA)Dry-type(kVA)LVLV200 - 10’00020 - 10’000MVLV200 - 10’000100 - 10’000MVMV500 - 100’000100 - 40’000HVMV1’000 - 100’000on requestThe transformers can have natural cooling, forced air coolingor forced water cooling.Reactors for drive applicationsA broad range of dry-type and liquid-immersed, iron-coreor air-core reactors for use in power converters or in drivesystems are available. Such components are used, for example, in filters or as DC-link chokes.Global experience - local solutionsABB is the world’s leading supplier of converter transformers.Building on a worldwide presence with a dozen plants and30 transformer service centers, we are close to you and ableto supply in different regions from local factories and to complymore easily with local requirements, while still using a commonglobal design. With its global network of strong local resources,ABB supports all players in the market with the expertise theyneed for their projects.ReliabilityABB converter transformers provide highest reliability, fora safe and undisturbed operation of your drive installation.Transformers are utilized in some of the harshest indoorand outdoor environments imaginable. All transformers aremanufactured to the most stringent quality control standardsin order to guarantee the full reliability of the product.Ecology and economyIt is ABB’s policy to provide customers with sustainable solutions, optimized for both, the economical and the ecologicalaspects. Solutions with low transformer losses and minimumlife cycle costs can be provided.Manufacturing locations for converter transformers – served from your neighbourhood1Oil-type transformers– South Boston, USA– Pereira, Columbia– Guarulhos, Brazil– Bad Honnef, Germany– Vaasa, Finland– Vadodara, India– Zhongshan, China23Dry-type transformers– Bland, USA– Blumenau, Brazil– Brilon, Germany– Molinazzo di Monteggio, Switzerland– Zaragoza, Spain– Vadodara, India– Shanghai, China– Chonan, Korea4 Converter transformers and reactorsConverter transformers and reactors 5

The art of converter transformersIndividual solutions for demandingcustomersRequirements for converter transformersTransformers supplying converter applications are connectedon their secondary side to a converter. The converter inputcan be a passive rectifier or have an active front end usingcontrollable semiconductor switches. These elements createa lot of harmonic frequencies. Different drive types are quitediverse in the amount of harmonics produced.Therefore, normal transformers, designed and dimensionedfor electricity distribution duty do not work satisfactorily in aconverter system. Harmonic frequencies increase the thermal,mechanic and dielectric stresses and therefore the transformersmust be specially designed for this duty. Over-dimensioning ofa normal distribution transformer is not an adequate measure.Transformer primary voltageThe converter transformer is usually powered by a medium orlow voltage network. Powering from a high voltage network isalso possible but not common. Only small converters can bedirectly connected to a LV network without a transformer dueto harmonics and EMC requirements. Networks show differentsensitivity to harmonics and the decision whether to use anindividual supply transformer or not must be made on a caseby case basis.Transformer secondary voltageThe input voltages for LV converters are typically between 190 Vand 900 V, and for MV drives are between 1 kV and 7 kV.Multi-winding transformersThe rectifiers used in LV converters are usually 6- or 12-pulserectifiers, made of diode bridges, thyristor bridges or powertransistor solutions. The 6-pulse rectifier is supplied by a twowinding transformer; whereas the 12-pulse rectifier needsa three-winding transformer, having two separate secondarywindings with 30 phase shift.Electrostatic screenAn earthed screen can be installed between the primary andsecondary windings. It is used to capacitively decouple primaryand secondary winding and eliminate the effects of highfrequency transients on the other winding.MV converters and converters with higher ratings specificallyrequire a higher converter pulse number which is used to limitthe network harmonic distortion to an acceptable level. Pulsenumbers higher than 12 require special phase shifting, multiwinding transformers or several transformers with phase shiftsrunning in parallel. Nowadays the pulse number of a convertersystem can be up to 48. This requires in total eight phaseshifted transformer windings supplying the converter system.HarmonicsTransformers supplying converters suffer from the presenceof harmonics, whose effects differ, depending on the type ofconverter. By knowing the harmonic spectrum it is possibleto carry out a complete study which will identify hot spotsthat require special attention during the design of the transformer. The image on the next page highlights the presenceof a dispersed flux which can create hot spots at the end ofthe windings and requires special attention during design.Transformer ratingsAccording to IEC 61378-1 rating of a converter transformeris the same as the fundamental rating:– Fundamental frequency rating: calculated with rated voltageand the fundamental sinusoidal component of the loadcurrent, 50/60 Hz) – this is used for the indication of theguaranteed loss values and short-circuit impedance– RMS (Root Mean Square) rating: calculated with ratedvoltage and total RMS load current– Equivalent rating: calculated with rated voltage and anequivalent sinusoidal current which gives the same lossesin the transformer as the actual load current, including harmonics. The equivalent current is used for temperaturerise tests.According to IEEE C57.18.10 the rating of a rectifier transformer is the kVA drawn from the line. Alternative equivalentrating parameters such as K factor can also be considered.CoreThe magnetic circuit is core-type with mitered joints. Highquality grain oriented, magnetic steel is most commonlyused. Special core joints, distributed gaps and air gaps maybe used in the core construction to avoid direct current (DC)saturation when needed.Output transformersFor cases where converter output voltage and motor voltageare different an output transformer is needed. These transformers are two winding transformers, but are also exposedto some increased amount of harmonics and transients fromconverter switching.StandardsThe following main standards govern converter transformersand provide rules for correct definition of rating and specification and for the testing of the transformers.– IEC 61378-1 (ed. 2.0): 2011, converter transformers, Part 1,Transformers for industrial applications– IEC 60076 series for power transformers andIEC 60076-11 for dry-type transformers– IEEE Std, C57.18.10-1998, IEEE Standard Practicesand Requirements for Semiconductor Power RectifierTransformers– Products complying with almost any national standard(GB, GOST, CSA, etc.) or requiring specific certification(e.g. UL, FM or DNV, ABS for marine applications, etc.)can be providedTestingRoutine tests as per standards are conducted for eachtransformer unit produced. In addition, extensive type testingprograms, e.g. short circuit tests as well as temperature risetest at equivalent rating and impulse testing among others,can be performed for each design of the transformers.ABB has a long experience and lots of references fromdifferent drive applications. The high quality of our reliableproducts provides an outstanding capability to withstandshort circuits. Extensive type and special testing, includingaging tests, together with our quality control, guarantee theperformance of our products.Our compact and low-weighttransformers fully comply withthe customers’ specifications.The products are developedtogether with the convertermanufacturers, ensuring thattheir special requirements arealways met.1 Converter transformer for 36-pulse converter 2 Simulation of magnetic field in multi-winding transformer coilInverter-20 0 20 1 Diagram of variable speed drives 2 Converter transformers feeding 12-pulse r-20 0 20 16 Converter transformers and reactorsMLoadMLoadInverter212Converter transformers and reactors 7

Outstanding technical featuresHigh compatibility with different systems– Environmental classifications and surface treatmentABB oil-filled transformers can be installed in the toughestenvironmental conditions ranging from high altitudes withcold temperatures to hot and humid conditions with highcorrosivity. Ex-proof designs for hazardous areas are alsoavailable.Transformers can either be painted or hot-dip galvanizedand painted. Enviromental classes are available up toC5-M & I ISO classes. The standard color is RAL 7035,light grey. Other shades are optional.121 Liquid-immersed converter transformer 2 Dry-type transformer for converter applicationsABB’s liquid-immersed transformers– Mechanical constructionTransformers for lower power range have mostly corrugatedtanks either hermetically sealed or conservator type withflexible cooling fins. However, transformers with ratingsof approximately 7 000 kVA and above, have tanks withdetachable radiators providing adequate cooling. In orderto save space, or for some other special reason, fans canbe added to ensure more efficient cooling. Also watercooled heat exchangers can be used instead of radiators– Insulating liquidsDifferent insulating liquids can be chosen for VSD supplytransformers.– Mineral oil-based inhibited transformer oil for industrialinstallations– Silicone oils (non-toxic and stable, for reduced fire risk)– Midel , a synthetic ester-based insulating liquid (biodegradable and non-toxic, for reduced fire risk)– BIOTEMP , a renewable and biodegradable vegetableoil, for reduced fire risk)8 Converter transformers and reactors– Bushings and enclosuresThe normal bushings used are solid porcelain bushings.Outer cone bushings for plug-in type cable terminals areoptional.Most of the VSD duty transformers are installed in anindustrial environment and equipped with air insulated cabletermination boxes. These can be used for either HV or LVside, or for both. A variety of standardized cable box constructions are available permitting the cable entrance frombelow, from above, or from the side. The normal protectiondegree of a cable box is IP44. It may be higher as an option.– Protection and monitoring of transformersFor hermetically sealed transformers used in VSD duty, therecommended protection and monitoring devices are onlytwo:– DGPT2, integrated protection device, which combinesthe gas relay, over-temperature alarm, trip device andsudden pressure relay functions.– Pressure relief deviceFor the conservator transformers, the recommendedprotection and monitoring devices are:– Thermometer with alarm and trip contacts– Oil level indicator– Pressure relief device– Buchholz relay– Silicagel breatherAdditionally you may select winding temperature indicators,current transformers, surge arresters and different on-linemonitoring devices.ABB’s dry-type transformers– Coil technologies: in order to best fit your specific requirements we provide converter transformers with different coiltechnologies:– Vacuum cast coil (VCC): high quality, well-protectedwindings– Vacuum pressure impregnation (VPI): allowing efficientcooling– RESIBLOC : ultimate mechanical strength, qualified forextreme climatic conditions (- 60 C)– Simple installation: ABB dry-type transformers allow simpleinstallations, can be placed close to the load, are self-extinguishing and contain a minimum of combustible mass.– Enclosures and cooling: all our transformers can be providedwithout or with enclosures of any protection degree (IP) orof any NEMA type.The enclosures can be ventilated or be equipped with anair-to-air or an air-to-water heat exchanger for coolingpurpose. Depending on enclosures and customer requirements natural or forced convection is possible.– Direct and indirect water cooling: these are transformersand reactors where the windings are directly cooled withwater. It allows very efficient removal of the loss heat. If theconverter uses deionized water for cooling purpose, thesame water circuit can be used for the transformer wherethe windings are made with hollow conductor. If only normaltap water is available a water-cooled heat sink is installedinto the winding.– Winding temperature monitoring is achieved by Pt100probes placed in the windings and connected to digitalrelays. The relays can be equipped with remote readingfacilities.– A large variety of accessories is available to optimize thefunctionality of the transformers: cable boxes, measurementor protection current transformers, on-board earthing switch,anti-vibrators, etc.Transformers are built to match therequirements of any drive, from anymanufacturer.Transformers and reactors are also provided for ABB‘s large family of air-cooled and water-cooled umber- ACS 550General purposeup to 350 kWup to 480 V- ACS 800, ACS 880Industrialup to 5 600 kWup to 690 V6, 12, er- ACS 1000General purpose315 - 5 000 kW2.3 - 4.16 kV12, 24- ACS 2000General purpose250 - 1 600 kW4.0 - 6.9 kVAFE, 24Input transfomerseparateseparateInput transfomerseparate or integrateddirect connection,separate or integrated- ACS 5000General purpose1.7 - 32 MW6 - 6.9 kV36separate or integrated- ACS 6000Special purpose3 - 27 MW3 - 3.3 kV12, 24separate- LCILoad-commutated inverter2 - 72 MW2.1 - 10 kV6, 12, 24separateConverter transformers and reactors 9

Our referencesA broad variety of installations1 Transformer for Eskom s coal-fired power stations 2 Esperanza Gold and Copper Mine 3 Oasis of the SeasEskom, coal-fired power stations,South Africa– Total quantity of units:34 transformers– Ratings: 5.8 MVA to 11.7 MVARESIBLOC dry-type transformers– Enclosure: IP54 with air-to-air heatexchanger system– Pulse: 12-pulse– Special customer requirements:refurbishment of existing equipmentin coal-fired power stationsEsperanza gold and copper mine,Chile– Total quantity of units:12 transformers– Ratings: 19 MVA liquid-immersedtransformers for SAG and Ball millssupply duty together with 630 kVAexcitation transformers– Enclosure: IP55, ONAN– Pulse: 6- and 12-pulse– Special customer requirements:high altitude 2 300 m.a.s.l. withextreme environmental conditions.Special impedance designOasis of the SeasWorld’s largest cruise ship for 4 000passengers.– Total quantity of units:8 transformers– Ratings: 5.85 MVA to 11.7 MVARESIBLOC dry-type transformers– Enclosure: IP44, AFWF– Pulse: 24-pulse– Special customer requirements:transformer coils exchangeableon-board; limitations for dimensionsand weightESPO, East Siberia Pacific Oceanpipeline, Russia– Total quantity of units:48 transformers– Ratings: 9 352 kVA and 4 676 kVAliquid-immersed transformers– Enclosure: IP66, ONAN– Pulse: 12-pulse– Special customer requirements:Full GOST-certification, seismic design, special tank design to withstand-60 C transportation temperature,well-proven drive specific transformertechnology based on long experienceand knowledge from special projectsfailuresPumping stations in variouslocations– Total quantity of units:24 reactors– Ratings: 2 x 2 mH / 3 600 A VCCdry-type DC-link smoothing reactors– Enclosure: IP00, WF– Operating voltage: 5.4 kV DC– Special customer requirements:single phase, shell-core design.The use of forced water coolinghas allowed to reduce considerablythe dimensions of this component,which can be designed for voltagesup to 15 kV DC and more than 6 kASanmen nuclear power plant, China– Total quantity of units:2 transformers– Ratings: 19.5 MVA, 13.8 / 1.32 kVVCC dry-type transformers(3 x 6.5 MVA single phase)– Enclosure: IP21, AN– Static Excitation System Transformer– Special customer requirements:single phase transformers, assembledat site into three-phase configuration;with a total of 15 CTs on primarry andsecondary windings for protection andmeasuring; primary connection throughisolated phase ductUsina de Pelotizaçao, Vitoria (ES),Brazil– Total quantity of units:7 transformers– Ratings: from 2.5 MVA to 10.1 MVA,13.8 / 6 x 1.92 kV VPI dry-type transformers– Enclosure: IP54 with air-to-water heatexchangers– Pulse: 36-pulse, single-core– Special customer requirements:Primary windings use special conductors to cope with demanding electricaland m

cation and for the testing of the transformers. – IEC 61378-1 (ed. 2.0): 2011, converter transformers, Part 1, Transformers for industrial applications – IEC 60076 series for power transformers and IEC 60076-11 for dry-type transformers – IEEE Std, C57.18.10-1998, IEEE Standard Practices and Requirements for Semiconductor Power Rectifier

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