Reducing Fire Hazards with Dry Type Transformers

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1 ABB Dry-Type transformers Olimpia Gocan February 6, 2013 Dry-Type transformer solutions for Arctic environments Reducing Fire Hazards with Dry Type Transformers ABB Inc. February 11, 2013 Slide 1

2 Agenda! ABB dry-type transformers global product group! ABB dry-type transformers North America capabilities and support! ABB dry-type transformers for Arctic environments! Questions and answers

3 Transformers One stop shop supplier! Over $6 billion orders! employees! Global manufacturing capability: 52 plants! Global presence: revenues in more than 100 countries! Complete range of power and distribution transformers, associated products and services! Voltage range up to 1000 kv! Homepage: /transformers ABB Group February 11, 2013 Slide 3

4 Transformers History The combined experience of 700 years of transformer manufacturing! Asea! Ansaldo / Ital Trafo / IEL / OEL / OTE! BBC! GE, USA! National Industri! Strömberg! Westinghouse! Kuhlman! And more... ABB Group February 11, 2013 Slide 4

5 ABB dry-type transformers Global product group Shared technology Manufacturing Facility Development Canter Assembly Plant Trasfor! (5) Manufacturing Facilities! (5) Manufacturing Facilities! (5) Manufacturing Facilities! (5) Manufacturing Facilities! (8) Manufacturing Facilities! (4) Development Centers! (4) Development Centers! (4) Development Centers! (4) Development Centers! (3) Assembly Plants! (4) Assembly Plants! (3) Assembly Plants! Trasfor Acquisition ABB Group February 11, 2013 Slide 5

6 ABB Dry type transformers Status 2013: 8 Focus factories + 4 local assemblies Germany Russia* Spain, Zaragoza Vacuum Cast Coil USA Spain Brazil India* Egypt* Saudi Arabia* China Korea Germany, Brilon RESIBLOC *Local manufacturing with coils imported from other factories! Q USA, Bland, VA Vacuum Cast RESIBLOC Open Wound Brazil; Blumenau Vacuum Cast Coil Korea, Chonan Vacuum Cast Coil China, Shanghai Vacuum Cast RESIBLOC ABB Group February 11, 2013 Slide 6

7 ABB NAM dry-type transformers Bland, VA Lean Manufacturing Quality Assurance Program currently in effect complies with the applicable requirements of NRC Regulation 10CFR50, Appendix B, ANSI Standard N , MIL-I-45208A, CSA Z 299.3, ISO 9001 Series Standards and ISO/IEC ! Established in 1973! 30 acre site, 120,000 sq. ft. plant! 11,000Sq Ft Manufacturing,! Office 10,000! 400 Employees! Production averages 12 units/day! Over 50,000 Units Since 1973! ABB Group! February 11, 2013 Slide 7

8 System solutions Dry Type Transformers! Global presence: R&D and support.! Timely replies to quotations:! System Application knowledge:! Project Management/Customer Support! Manufacturing visits/witness testing you and your customer! Installation and field supervision technical resources! Product and process training ABB Group February 11, 2013 Slide 8

9 ABB Bland R&D lab performing a multitude of Tests American and IEC Coils Thermal Shock Energized or non energized temp tests Coils Thermal Aging Epoxy filler ratio test ABB Group February 11, 2013 Slide 9

10 Transformers Applications Distribution transformers IEC & ANSI Standards ABB Group February 11, 2013 Slide 10

11 Why are Particular Transformers Used? Design Parameters " Dielectric " Thermal " Mechanical (Short Circuit) " Efficiency / Cost ABB Group February 11, 2013 Slide 11

12 Why are Particular Transformers Used? User Parameters " Location " Application " Performance " Price/Cost ABB Group February 11, 2013 Slide 12

13 Dry Type Transformers Open Wound Vacuum Cast RESIBLOC ABB Group February 11, 2013 Slide 13

14 Open Wound Dry Type Transformers Open Wound: VPI VPE! kva! 34.5 kv Primary! Primary BIL kv! 120 V to 15 kv Secondary! 200 Deg C insulation System! Temp rise 80/115/150 Deg. C! Polyester varnish! 1 or 2-cycle process " 2-4 cycle process " Suited for harsh environments ABB Group February 11, 2013 Slide 14

15 VPI Process

16 Open Wound Advantages " Non-Flammable " No Leakage Concerns " Relatively Low Cost " Relative Light Weight and Small Size " Resistance to Contaminants " High Overload Capability " 220 C Nomex Insulation " Proven Performance in Industrial & Nuclear Applications Disadvantages " Air is a Poor Thermal Conductor " Ambient Impacts Insulation Medium " Non-Hermetically Sealed Windings " Higher Core Losses ABB Group February 11, 2013 Slide 16

17 Vacuum Cast Coil " kva " 46 kv Primary " Primary BIL kv " 120 V to 15 kv Secondary " 180 Deg C Insulation Syst. " Temp. rise: 80/100/115 Deg C ABB Group February 11, 2013 Slide 17

18 VCC Process

19 Vacuum Cast Advantages " Excellent Environmental Protection " Non-Flammable " No Leakage Concerns " Minimal Maintenance " Excellent Resistance to Contaminants " Interior Winding Insulation is Hermetically Sealed in Epoxy Disadvantages " Air is a Poor Thermal Conductor " Ambient Impacts Insulation Medium " Higher Cost than Open Wound " Lower Thermal Capability " Increased Weight over Open Wound ABB Group February 11, 2013 Slide 19

20 RESIBLOC " kva " 46 kv Primary " Primary BIL kv " 120 V to 15 kv Secondary " -60 Deg C cold start " Limited to 80 C Rise " CSA certification 06/13 " UL, CSA on-site certification available now ABB Group February 11, 2013 Slide 20

21 RESIBLOC Process ABB Group February 11, 2013 Slide 21

22 RESIBLOC Advantages " Excellent Environmental Protection " Non-Flammable " No Leakage Concerns " Relatively Light Weight & Small Size " Excellent Resistance to Contaminants " Exceptional Mechanical Strength " Most of all -60 Deg C cold start capability Disadvantages " Air is a Poor Thermal Conductor " Ambient Impacts Insulation Medium " Higher Cost than Open Wound " Lower Thermal Capability " Insulation Rated 185 C " Low Installed Experience in US " Increased Weight over Open Wound ABB Group February 11, 2013 Slide 22

23 Dry Type Transformers Comparison of Dry Type Transformer Costs! VPI: 1.0! VPE: 1.20! RESIBLOC 1.25! Cast Coil 1.35! Indoor 1.0! Outdoor 1.15 ABB Group February 11, 2013 Slide 23

24 Arctic environment for outdoor transformers ABB Inc. February 11, 2013 Slide 24

25 Standard Bland Enclosure types NEMA1 Indoor enclosure NEMA3 Outdoor enclosure IP20 Indoor Enclosure Outdoor vent boxes for NEMA3 enclosures ABB Inc. February 11, 2013 Slide 25

26 Enclosure Features Louvers ABB Inc. February 11, 2013 Slide 26

27 Enclosures for all your applications! ABB 1 Indoor! ABB 3 enclosure! ABB 3 enclosure with EZ clean filters! ABB 3 enclosure with EZ clean filters and an external barrier such as a snow fence! ABB 3 enclosure with EZ clean filters and a louver cover! ABB 3 enclosure with EZ clean filters and a louver cover and an external barrier such as a snow fence ABB Inc. February 11, 2013 Slide 27

28 EZFilters! Unique baffle design provides high dust holding capacity for longer service life and increased overall performance.! Water soluble Super Filter Coat Adhesive simplifies washing process.! Delivers high overall performance at varying velocities up to 650 fpm.! Bonded aluminum media provides strength and durability.! Meets UL Class 2 filter requirements. ABB Inc. February 11, 2013 Slide 28

29 Screens and Filters ABB Inc. February 11, 2013 Slide 29

30 TENV Enclosure Up to 1.5MVA No active cooling ABB Inc. February 11, 2013 Slide 30

31 Accessories: MV porcelain insulators ABB Inc. February 11, 2013 Slide 31

32 Accessories: MV low temperature high dielectric composite/epoxy insulators ABB Inc. February 11, 2013 Slide 32

33 Enhanced track resistant surface coating Insulator coating epoxy for corrosive environment! Hinders arc travel! Good for very low temperatures! Reduced maintenance:! Reduce regular insulator washing and cleaning! Reduce periodic reapplication of greases! Reduce replacement of components damaged by flashover! Prevents excessive leakage current, tracking and flashover ABB Inc. February 11, 2013 Slide 33

34 Feedback on the following would be appreciated:! max ambient temperature where blowing snow is an issue! does the area ever experience freezing rain or icing conditions! what is the max wind speed of the blowing snow! what is the minimum diameter of the blowing snow! how much backup power (if any) would be available to power the space heaters in the event of a de-energized transformer (maintenance or utility outage)! are overloads needed (will affect thermal design which affects the amount of air ventilation required)! level of maintenance that is acceptable (like changing filters or inspection) ABB Inc. February 11, 2013 Slide 34

35 Why Dry-Type transformers? To minimize environmental contamination and fire hazard, customers are specifying drytype transformers more frequently. These transformers meet strict parameters with respect to electrical system demands and functioning in areas with extreme climatic conditions. ABB Inc. February 11, 2013 Slide 35 ABB's dry and cast transformers are virtually maintenance free and are manufactured in accordance with industry and international standards including ISO 9001

36 Flammability std. IEC F0 and F1 F0 self extinguishing VPI, VCC and RESIBLOC all comply. F1 28 Fire behavior test (special test) 28.1 General To optimize the behavior of a transformer, it is necessary to minimize its emission of toxic substances and opaque smoke in the event of burning. The use of halogenic materials should be avoided. Checking of corrosive and harmful gas emission shall be made according to Moreover, the transformer shall not contribute significantly to the thermal energy of an external fire. The fire behavior shall be assessed by the test procedure in ABB Inc. February 11, 2013 Slide 36

37 Transformer Technology Summary Liquid Filled Benefits " Lowest Purchase Cost " Lowest Loss Per Purchase Dollar " Ability To Operate In Adverse Conditions " Excellent Dielectric Properties " Environmentally Friendly Options Available Dry Type Benefits Environmentally Safe No Leakage Non-flammable Minimal Maintenance Coordination Flexibility ABB Group February 11, 2013 Slide 37

38 ABB Group February 11, 2013 Slide 38

39 Back-up slides I ABB Inc. February 11, 2013 Slide 39

40 Arctic Environment for outdoor power transformers I am trying to show them this videoclip and then tell them that our nema3 with Al filters and gaskets and space heaters will be ok in blowing snow Arctic environments or I can use the pics in the next slide ABB Inc. February 11, 2013 Slide 40

41 Rules & Standards What does this mean for transformers?! For topside installations:! NFPA Article 500: Hazardous (Classified) Locations! Dry-Type Transformers Indoors! Class 155 or higher! Dry-Type Transformers Outdoors! Class 155 or higher! Completely enclosed except for ventilating openings! Weatherproof enclosure! Less-Flammable Liquid Transformer! (a) Indoors! Type I or Type II building! No combustible materials stored inside! Liquid confinement provided! Automatic fire extinguishing system! (b) Outdoors! Same as Indoors * If close to other buildings or equipment, those items must have additional safeguards

42 Rules & standards How does this affect you? Size and weight 12 MVA Epoxy Cast 12 MVA Mineral Oil! Dry-type are generally larger and 15% - 30% heavier than Liquid-filled units

43 Rules & standards How does this affect you? Initial Cost Cost Transformer characteristics 1.00 BASE (Mineral Oil) 1.15 VPI OW 1.30 Environmental fluid 1.40 Less flammable fluid 1.45 Wet wound glass fiber reinforced 1.50 Integrated instrumentation and alarming 1.55 Epoxy-cast

44 Rules & standards How does this affect you? Safety! Long history of being safe and dependable! Oils are combustible and increase risk of fires! Used topside Dry-type! No fire hazard / self extinguishing! No threat of oil leak! Can be installed anywhere in hull or topside Dry-type w/ internal fault protection! Same safety features of standard dry-type transformer! Additional features limit damages in rare event of an internal arc fault Increased safety ABB Group February 11, 2013 Slide 44

45 Rules & standards How does this affect you? Tilt Maximum Operation Tilt Angle 40! Liquid filled units have tilt restrictions due to the concern of leaking and exposing the active assembly! Dry-type units can operate at any degree of tilt

46 Rules & standards How does this affect you? Extreme cold! Liquid filled units require heaters and start up procedures prior to applying a load at temperatures below 0ºC! Dry-type transformers have unrestricted use at temperatures as low as -60 o C

47 Rules & standards How does this affect you? Corrosion! The enclosure or tank is most susceptible to extreme offshore environments! A dry-type transformer is not dependent on the enclosure to operate; a liquidfilled depends on the tank to retain all dielectric fluid! A dry-type core can easily rust if extra provisions are not taken to sufficiently seal the core laminations! Liquid cooling fins are particularly at risk to corrosion

48 Rules & Standards Conclusion! Historically, industrial facilities have utilized liquidimmersed transformers for medium voltage and larger low voltage systems. Liquid-immersed transformers are a well proven, reliable, long service life technology for onshore and offshore fixed facilities.! Electrical power systems for ships and floating facilities have generally been lower voltage and lower kva than many onshore or offshore fixed platform industrial facilities and utilize dry-type transformers.! However, with recent safety concerns increasing, dry-type units have been used more and more in hull and topside applications

49 Rules & Standards Conclusion! Some applications or installations may overlap hull and production facilities. These regulations may seem to be confusing and contradictory both in terms of which authority has jurisdiction and the proper transformers for specific applications! It is recommended to utilize someone with regulatory interfaces experience on projects to interface with the authorities having jurisdiction

50 ABB NAM dry-type transformers Dry-type portfolio Open Wound RESIBLOC Vacuum Cast Coil Internal Fault Protection up to 15 MVA up 32.5 kv up to 63 MVA up 72.5 kv up to 63 MVA up 72.5 kv HiDry 150 C Rise 80 C Rise 115 C Rise HydroCooler Air-Air Heat Exchanger EcoDry PoleDry TriDry Dry Network ABB Group Inc. February 11, 2013 Slide 50

51 What information we need! Type! Harmonic spectrum (k-factor),! Transform.config./#of pulses for rectifier! KVA! Primary & Secondary voltages and BIL! Conductor material! Impedance! Cooling method! Winding temperature rise! Losses! Enclosure type! Altitude! Standards! Sound & Seismic requirements! Maximum weight and dimensions! Accessories! Monitoring and metering ABB Group February 11, 2013 Slide 51

52 ABB NAM dry-type transformers O&G applications! Dry-type transformers applications! Hull installations! Topside! Auxiliary inland (Pipe freeze protection systems)! Challenges! Reduced space! Weight restrictions! Harsh environment! Safety requirements ABB Inc. February 11, 2013 Slide 52

53 Success story US - Chevron wordpress.com! Application: in hull distribution for offshore platform! Project: Jack & Snt Mailo! (10) RESIBLOC transformers! 2000kVA and 7500kVA! Power Distribution to various motors and other loads! ABS certified! Why they chose dry:! Environmental concerns! Safety concerns inside the hull! Wanted high vibration resistance! Less maintenance chevron.com ABB Inc. February 11, 2013 Slide 53

54 Success study Canada - ConocoPhillips Tycothermal.com ABB Inc. February 11, 2013 Slide 54

55 Success study Canada - ConocoPhillips! Application: Pilot for Heat Tracing/Pipe Freeze Protection System! Project details:! 49 x 500 kva VPI, 6 kv class primaries! Transformers shipping July 2012! Reason why they chose ABB dry-type transformers:! Large nationally recognized company! Supplier for a large quantity with a reliable supply chain! Less maintenance ABB Inc. February 11, 2013 Slide 55

56 Success story Mexico - Pemex! Application: platform distribution! Project: living quarters platform with distribution feeding other drill site platforms! Order details:! 4 20 MVA triplex transformers! MVA transformers! MVA transformers ABB Inc. February 11, 2013 Slide 56

57 Products for extreme environments Old and new Resibloc! Resibloc Windings! Superior mechanical strength! Ultimate environmental withstand! Non-explosive and flame retardant! Unrestricted use at -60 C Internal fault protection Sealed enclosures! Internal fault protection! Ideal for in hull applications! Channels arc blasts to safe location! Can be ABS certified! Sealed enclosures with active cooling! Air-to-Air, Air-to-water! NEMA 12, 4, 4x! Long history in marine applications ABB Inc. February 11, 2013 Slide 57

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