Douglas Getson PE, Global Product Manager, ZA … · ... Enerdata & Economist Intelligence Unit....

G R T f ™Douglas Getson PE, Global Product Manager, ZA Transformer Day, May 2013

Green-R-Trafo™Green transformer programGreen transformer program

© ABB Group May 20, 2013 | Slide 1

Agenda

Energy Policy

Transformer Losses and Efficiencyy

AMDT - Amorphous Metal Distribution Transformers

BIOTEMP® - Natural Ester Dielectric Fluid

Green-R-Trafo™ - Green Transformer Program

Summaryy


Energy Efficiency Global CO emission scenariosGlobal CO2 emission scenarios

© ABB22/07/2009 | Slide 3

Source: IEA, World Energy Outlook 2009, 450 Policy Scenario

South AfricaHistorical grid losses and emissionsHistorical grid losses and emissions

Rate of T&D losses in the South Rate of T&D losses in the South African grid was above 11% of the distribution volumes in 2009, which is higher than the worldwhich is higher than the world average (9%) increasing over time (6.5% in 1990)

Average CO2 emission factor for power generation is high because po e ge e at o s g becauseof the share of coal (90% of total generation).

Emissions of 820 gCO / kWh Emissions of 820 gCO2 / kWh in 2009 which is about 60% higher than the world average.


Source: Enerdata & Economist Intelligence Unit

South AfricaEnergy consumption and policyEnergy consumption and policy

Electricity represents 26% of final Electricity represents 26% of final energy consumption with a market share 25% as of 2009. industrial consumes about 60% of theconsumes about 60% of the electricity used in the country.

Share of energy-intensive industries consumption has decreased steadily since 1990.

Steel industry is now standing Stee dust y s o sta d garound 20%

Energy Efficiency Accord is a voluntary agreement amongstvoluntary agreement amongst major industrials to promote energy savings in the sector


Source: Enerdata & Economist Intelligence Unit

Transformer EfficiencyGlobal standardsGlobal standards

High can be meet with existingLow not common High can be meet with existing technology and levels are similar to one another Australia 2010

Low not common India 1 Star (losses) China S9 (losses) Europe DkDo (losses) Australia 2010

India 3 Star China S13 USA 2010 DOE (efficiency)

Europe DkDo (losses)

Average not common Australia 2004 (efficiency) ( y)

Europe BkBo

Very high at the limit of conventional grain oriented

Australia 2004 (efficiency) India 2 Star China S11 Europe CkCo conventional grain oriented

steel and amorphous metal Australia 2010

India 4 and 5 Star

p k o

India 4 and 5 Star China S15 Europe AkAo


Transformera s o eLosses and efficiencyy


Distribution TransformersNo load losses have greater impact at lower loadsNo-load losses have greater impact at lower loads

Graph represents typical losses for an IEEE/ANSI 1500 kVA 12,470 V primary padmount transformer

No-load losses remain constant not impacted by the transformer load Load losses increase by the square of the loading (LL x Load2)


No-load losses exceed load losses for loads less than 65% nameplate

Energy EfficiencyTransformer losses impact energy efficiencyTransformer losses impact energy efficiency

Distribution transformers are already efficient (~98%) but due to the Distribution transformers are already efficient (~98%) but due to the large installed based equates to a significant amount of losses

10)(%5PFkVALEfficiency

Efficiency reduced by N-Load (NL) and Load (LL) losses

Hysterisisbeing the reorientation of the magnetic moments taking

)()10()(% 23 LLLNLPFkVAL

Efficiency

y y ( ) ( )

NL losses are from the core when transformer is energized Hysteresis Losses - chemistry, coating, processing

place 50 or 60 times per second.

Eddy Currentsflow perpendicular to

Eddy Current Losses – laminate thickness

LL losses are from the windings when there is load on the transformer and is proportional to the load (amps)

the flux but broken up by laminating the core and adding silicon increasing resistivity

I2R Loss - material (CU vs. AL), size and length Eddy Loss - geometry, proximity to steel parts


L = per unit load, kVA = nameplate rating, PF = power factor, NL = No Load losses, LL = Load Losses

Transformer DesignOptimising for optimal lossesOptimising for optimal losses

Transformer designers can alter the design to provide a Transformer designers can alter the design to provide a solution with reduced no-load, load losses or both. Improvement in performance requires in most cases a more

e pensi e transformer ith possibl a larger footprintexpensive transformer with possibly a larger footprint

A trade off is required between high efficiency (high initial cost) and life cycle cost savings (loss evaluation) when improving transformer efficiency

Ways to Reduce NL Losses Ways to Reduce Load Losses

transformer efficiency

Use better grade of core material Use copper rather than aluminum

Use thinner core steel laminations Use a conductor with a larger area

Use more turns in the coil Use fewer turns in the coil

Use a core with larger leg area


Amorphous Metalo p ous etaLower no-load losses


Amorphous Metal Distribution Transformers (AMDT)Reducing network losses and investmentReducing network losses and investment

Distribution transformers losses consume 2 3% of USA electricity Distribution transformers losses consume 2-3% of USA electricity generation costing 25 BUSD per annum

AMDT should play a major role in reduce generation investments and emissionsand emissions

AMDT has 70% lower no-load losses as compared to conventional technology leading to increased network efficiency

Energy savings does not require the user of the electricity to change their consumption behavior or sacrifice comforts

Higher efficiency helps defer or even avoid electricity g y p ygeneration investments to keep up with increasing demand

And avoidance of new generation (fossil fuels) helps reduce CO2 emissions2


Amorphous MetalFabrication characteristics and propertiesFabrication, characteristics and properties

AM is produced by rapid solidification creating very thin material AM is produced by rapid solidification creating very thin material Material is a snapshot of the disordered liquid structure at the

moment of solidification (similar to glass)Material is absent of any crystalline structure allowing easier and Material is absent of any crystalline structure allowing easier and faster magnetization leading to much lower core losses

Fe-Si-B is the best amorphous chemistry for getting the needed magnetic and physical cooling properties in distribution transformersmagnetic and physical cooling properties in distribution transformers

Non-magnetic Boron (B) is needed to get the fast cooling but lowers the design induction of the material (1.35 Tesla)

AM material is ductile as cast but becomes brittle after required

Amorphous Structure

(Disordered; AM)

AM material is ductile as-cast but becomes brittle after required annealing under a magnetic field optimizing its magnetic properties ABB has established standard manufacturing practices for the

assembly of AM core and coilsassembly of AM core and coils Design and material selection is required to offset the higher sound of

AMDT as compared to Regular Grain Oriented (RGO) electrical steel transformers


Transformer Core LossesLoss componentsLoss components

Core losses are the power consumed in magnetizing core material Core losses are the power consumed in magnetizing core material through its excitation cycle

Core losses are the sum of the following loss componentsH t i l L B1 7 f

B (T)

Hysteresis losses Lh B1.7 x f Eddy Classical losses Lcl (B x f)2 x t2 / Eddy Excess losses Lex (B x f)1.5 x (d x t) /

H (A/M)

B-H Curve

Hysteresis is the ease of magnetization and depends linearly on excitation frequency – area within the B-H curve

Eddy currents make up the rest of the losses generated by variation in

VariablesB = flux densityf = frequencyt = thicknessresistivityd = domain width

Material is Eddy currents make up the rest of the losses generated by variation in the magnetic properties of the material

Classical are found within the uniform structure of the material dependent on material thickness and resistivity

Material is organized into domains, or regions wherein all magnetic moments are lined up in one direction dependent on material thickness and resistivity

Excess are the currents localized within the domain walls of the material dependent on material thickness, resistivity and domain spacing

direction

Domain walls are the boundaries between the domains

spacing


Transformer Core LossesAM losses are inherently lowerAM losses are inherently lower

RGO Electrical Steel (Fe Si)RGO Electrical Steel (Fe-Si)

RGO losses have been reduced over the years by improving grain orientation (Lh), reducing thickness (Lcl , Lex), and scribing to reduce domain spacing (Lex)

Lh, Lcl, Lex losses are approximately 40%, 35%, and 25%

Amorphous Metal (Fe-Si-B)

AM is inherently thin and, due to a lack of crystalline structure, has y , y ,high resistivity and an ease of magnetization

Thus, hysteresis (Lh) and eddy current losses (Lcl , Lex) are naturally lower in AM than in RGOnaturally lower in AM than in RGO

Lh and Lex are each 50% but Lcl is negligible


Transformer Loss ComparisonAMDT transformers are less costly to operateAMDT transformers are less costly to operate

Losses calculated using an average annual load of 40% on the transformer

Cost of losses were calculated using a cost of energy of 177c per kWh being Eskom’s commercial rate versus 61c for residential and 215c for industrial customers

AMDT transformers would deliver more electricity to the consumer as their losses are 37-45% lower (40% kVA loading)

Even if these transformers were loaded at 100% of nameplate, theirEven if these transformers were loaded at 100% of nameplate, their total losses would be 13% lower than CRGO transformers

ADMT would have the lowest total ownership cost even when taking into considering the higher purchase price (< 50% kVAtaking into considering the higher purchase price ( 50% kVA loading)


Green-R-Trafo AM Transformers BenefitsBenefits

AMDT lead to energy savings and AMDT lead to energy savings and lower emissions as no-load losses are up to 70% lower than RGOLower

LossesL E Lowest total ownership cost

continuously over the life of the transformer

Less Energy

Less Green House E i i

Help meet the growing electrical demand with less generation asset investment

Emissions

investment

Savings that do not require the user of the electricity to change their b h i ifi f t

2% of all electricity generated is lost due to distribution transformer behavior or sacrifice comfortdistribution transformer

inefficiency


BIOTEMP®ODielectric fluid


Ester Dielectric FluidsDevelopment of an alternative fluidDevelopment of an alternative fluid

Ester fluids came to market in the 1980’s as an alternative with Ester fluids came to market in the 1980 s as an alternative with fire safety and biodegradability properties

Esters are a class of organic compounds that can be chemically synthesized (synthetic esters) or from agricultural products (natural esters)

Natural esters have a near neutral carbon footprint as seed oilNatural esters have a near neutral carbon footprint as seed oil production nets a negative CO2 footprint (photosynthesis)

Natural ester composition from 100% renewable resource

Natural esters are recognized as environmentally friendly and “less flammable” dielectric insulating fluid by the industry

Natural esters are readily biodegradable in 21 days and non Natural esters are readily biodegradable in 21-days and non toxic


BIOTEMP Properties21 day biodegradability test (CEC L 33 A 93)21-day biodegradability test (CEC L-33-A-93)

California EPACalifornia EPA testing was per CEC-L-33-A-93 (max absorption of C-H stretch in CH2-CH3) whichCH2-CH3) which resulted in classification as 98-100% biodegradable

Organization for Economic Cooperation & Development ptested per OECD 301B (modified Sturm test) resulting in greater than g60% CO2 after 10 days considered readably biodegradable


BIOTEMP PropertiesPreserving life and propertyPreserving life and property

Less flammable Less flammable

Fire point of 360°C classifying it as a “less flammable” dielectric fluid by FM Global and UL and a “K2 fluid” according to IEC 61100

Vapors are less volatile than mineral oil

Reduced risk of explosion

Less gas and hence pressure is generated during high energy arc faults reducing risk of explosion and collateral damage

I t i i ll f Intrinsically safer

Fires have a harder time starting and are self-quenching as compared to mineral oilp

Only CO2 and H2O are produced during, minimizing air pollution


BIOTEMP PropertiesHigh energy arc testHigh energy arc test

Electrode gap (25mm) before arc Electrode gap after arcElectrode gap (25mm) before arc Electrode gap after arc

Higher Energy Arc Test Single phase pole mount transformer

Arcs simulated using pointed conically shaped rods as electrodes.

Current source used to generate 8000 amps through a short circuit Current source used to generate 8000 amps through a short circuit across the electrodes for up to 3 cycles

Dissolved gases and gas space pressure measured before and afterarc test

© ABB22/07/2009 | Slide 22

arc test

High Energy Arc TestMineral oil filled transformerMineral oil filled transformer

Pole mount single phase transformer filled with mineral oil

At the point of highest energy level, internal pressures generated by the arc ruptures the cover with an ensuing fire as the hot oil is

© ABB22/07/2009 | Slide 23

y p gexposed to the atmosphere.

High Energy Arc TestBIOTEMP with arc quenching propertiesBIOTEMP with arc quenching properties

Pole mount single phase transformer filled with BIOTEMP®

Significant reduction in internal pressures causing cover to only vent releasing small amount of carbonized fluid but no

© ABB22/07/2009 | Slide 24

ensuing fire.

BIOTEMP PropertiesEnhancing performanceEnhancing performance

Greater affinity for water Greater affinity for water

Higher water saturation limit than mineral oil 4 times that of mineral oil under normal operating conditions 4 times that of mineral oil under normal operating conditions

BIOTEMP impregnated paper becomes a barrier reducing moisture absorption in the paper

Lowers aging rate and higher hotspot temperatures

Aging rate is much lower than mineral oil impregnated paper Aging rate is much lower than mineral oil-impregnated paper

Can operate at 10°C higher hotspot temperatures at same life expectancy as mineral oil-impregnated paper


BIOTEMP PropertiesLeading to lower aging rateLeading to lower aging rate

M t i lMaterial evidence shows a 20ºC advantage for BIOTEMP

Functional life testing also shows a 20ºCshows a 20 C advantage as compared to published loading curves

ABB conservatively recommending a 10ºC higher hot spot for the same useful life


Paper AgingHow does one define end of life?How does one define end of life?

Mechanical properties are lost as paper ages Mechanical properties are lost as paper ages

Aging influenced by the amount of oxygen and water along with temperature of the insulation system

Tensile strength is one measure to assess condition End of life when reaching 50% retained tensile strength

Degree of Polymerization (DP) is another measure New oil impregnated paper between 1000-1100 DP

E d f lif ll t d t b 150 200 DP End of life generally accepted to be 150-200 DP

Arrhenius relationship – time vs. temperature

Defines aging rate as a function of temperature

50% decreased life for every 6-7°C rise in the winding hot spot at operating temperatures 80-100°Chot spot at operating temperatures 80 100 C


BIOTEMP Performance versus Mineral OilSealed tube testSealed tube test

Tensile Strength Tensile Strength

Arrhenius plot of temperature and time to reach 50% retained tensile strength (end of life)

BIOTEMP has a 10°C temperature advantage over

Extended life expectancy at same temperature

10°C

temperature advantage over mineral oil for the same life expectancy

D f P l i ti Degree of Polymerization

Arrhenius plot of temperature and time to reach a DP of 200 (end of life)

BIOTEMP has a 7°C advantage over mineral oil for same life


7°C


over mineral oil for same life expectancy

BIOTEMP Performance versus Mineral Oil Functional life testFunctional life test

ABB 4 25kVA 1Ф Transformers ABB 4-25kVA 1Ф Transformers

2 units at 180°C for 2500 hrs

2 units at 200°C for 720 hrs 2 units at 200 C for 720 hrs

IEEE C57.91 estimates 180,000 hrs of life of


20°C

expectancy for transformer under normal loading

Units reached end of life as

same temperature

U ts eac ed e d o e asinsulation DP between 185 and 260 at winding hot spot

BIOTEMP advantage of +20°C BIOTEMP advantage of +20 C over similar units specified in IEEE loading guide


Ester Dielectric FluidsIndustry standards activitiesIndustry standards activities

Industry standards have begun to incorporate the properties Industry standards have begun to incorporate the properties and benefits into their technical standards and guides

IEEE C57-154-2012High-Temperature Insulation Systems Annex B - Ester liquid and cellulose paper

IEC TS 60076-14IEC TS 60076 14High-Temperature Insulation Materials Revision incorporating ester fluids to be balloted in 2013

IEEE C57 147 2008 IEEE C57-147-2008Natural Ester Fluid Guide

IEC equivalent to be balloted in 2013q

IEEE PC57.155Dissolved Gas Analysis of natural ester fluids still in working group under development


group under development

Green-R-Trafo BIOTEMP-filled TransformersBenefitsBenefits

Operational benefits (greater affinity for Operational benefits (greater affinity for water and highest stability)

Slower aging rate of cellulose impregnated paper increasingimpregnated paper, increasing transformer life

Designs for 110% loading without shortening life of transformershortening life of transformer

Designs for a 70°C winding temperature rise at 100% load without shortening life of transformer andshortening life of transformer and smaller footprint

Start-up below fluid pour point (-12°C) exception being under fluid

ABB transformers filled with BIOTEMP® combines efficiency safety and exception being under fluid

accessories (e.g. de-energized tap changer) where top fluid temperature needs to be +5°C or greater before

efficiency, safety and environmental friendliness


operating

Green-R-Trafo™G ee a oGreen transformer programp g


Green Transformer Program Technological solutionsTechnological solutions


Green Transformer Program Green R Trafo™ models and definitionsGreen-R-Trafo™ models and definitions

i di bi iDescription

Winding Avg Rise

Ambient Temp Max

Continuous Overload

EL High Efficiency liquid filled transformer 50°C 40°C 0%

Model

BL Biodegradable high-flash point dielectric fluid 60°C 40°C 0%

EBL High Efficiency with Biodegradable high fire point fluid 60°C 40°C 0%

XBL Biotemp™ high fire point fluid - Extended Range 60/70°C 40°C 0%/10%

XEBL High Efficiency with Biotemp™ fluid – Extended Range 60/70°C 40°C 0%/10%

CBL Biotemp™ high fire point fluid Compact Design 70°C 40°C 0%CBL Biotemp™ high fire point fluid - Compact Design 70 C 40 C 0%

CEBL High Efficiency with Biotemp™ fluid – Compact Design 70°C 40°C 0%


SummarySu a y


Green Transformer ProgramSummarySummary

Many distribution transformers will on average be loaded well Many distribution transformers will on average be loaded well less than top nameplate rating (kVA)

Therefore, no-load losses are a greater proportion of total transformer lossestransformer losses

AMDT would be the technology of choice for reducing no-load losses by up to 70% increasing efficiency and deferring f t ti i t tfuture generation investments

Network reliability, safety and minimizing environmental impact are societal mandates

BIOTEMP insulation systems offer life extension, overload capability, biodegradability and increase safety with a fire point of 360°Cp

ABB’s green transformer program incorporates all the above benefits in its line of Green-R-Trafo transformers


Douglas Getson PE, Global Product Manager, ZA … · ... Enerdata & Economist Intelligence Unit....

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