OLTC - Tech. Presentation

Transformer Technology Days - 2015
ABB Transformer Components

On Load Tap Changers
Month DD, YYYY

Transformer Insulation and Components
 Overview
 Introduction to On Load Tap Changers
 New Generation of Diverter switch tap-changers
 New Generation of Selector switch tap-changers
 Summary
© ABB Group
25 March, 2015 | Slide 2
Wherever you are, our products are near by
1 6
Traction and Dry type distribution
distribution transformers
transformers 7 8
2 6 7
Distribution Subsea
transformers transformers
3 8
Power and 5 10 Dry type distribution
distribution 3 transformers
transformers
9
4 9
Power transformers Power and
4 distribution
transformers
5 10
Low sound emitting Power transformers
transformers
1 2
© ABB Group
Global manufacturing footprint
Poland Turkey Russia

Sweden Lodz Istanbul Moscow
Piteå
Sweden
Ludvika
Sweden
Figeholm China
Chongqing
Germany
Roigheim China
Hefei (2x)
USA Slovakia
Alamo Piestany India
Halol
Switzerland
Mexico
Zürich India
San Luis Potosí
Vadodara
Brazil Italy
India
Guarulhos Montebello
Mumbai
Brazil Italy
Ceggia India
Indaiatuba
Mysore
22 factories in 13 countries and ~ 2800 employees

Product Portfolio
 Cellulose insulation material

• Insulation Paper / Pressboard Kits
 Flexible / rigid laminate insulation materials
 High voltage bushings
 OIP / RIP / RIS
 On-load tap changers
 Vacuum / Conventional
 De-energized tap changers
 Distribution and power transformer
components
 Smart-Grid ready monitoring Devices
 Hollow core composite insulators
 Oil treatment plants
On-Load Tap-Changers
© ABB Group
Ludvika, Sweden The Center Of Excellence ABB On-Load Tap-Changers since 1912
73 production units in 25 countries, and 36 service centers in 28 countries
© ABB Group
Over 100 years of experience
Stockholm year
1900 1930 1960 1990
First ASEA On-Load First ASEA patent on

Tap Changer vacuum technology
Traditional technology
© ABB Group
Introduction to voltage regulation
Tap-changers are used to maintain a

uniform and load-independent voltage
from the transformer
Important function
 Malfunctions may result costly failures
 Studies agree that windings, bushings
and tap-changers are the major
sources of transformer failures
Complex requirements
 Different kinds of stress
 Different environment
Requires attention
 Regular inspection and service during
their lifetime
© ABB Group
Trends in the market

 Shorter lead times
 Less and condition based maintenance
 Greater focus on environmental and safety aspects
 Smart Grids (e.g HVDC etc.)
 Renewables (e.g. wind farms, PV systems etc.)
© ABB Group
The purpose of the tap-changer is to change the turn ratio

between windings in a transformer
 Regulation range is typically up to ± 10% of the line
voltage in 9 to 35 steps
 Operates 10 to 20 times a day in normal grid applications
© ABB Group
Other areas with emphasis of

voltage regulations
 HVDC applications
 Industrial applications
 Phase shifting
transformers
Sometimes several hundred thousand

switching operations per year
© ABB Group
Tap-changers can be located in the main transformer tank, or

on the outside
 In-tank types can be used up to the largest power ratings
and highest voltages
 On-tank types can be used for lower power ratings
(<100MVA) and voltages (<150kV)
© ABB Group
In a core type
transformer windings
are arranged as
Tap winding
shells around the
cylindrical core legs,
one for each voltage
system
Loop winding
Voltage regulation
Low voltage High voltage
Helical winding Disc winding

Few turns Many turns
High current Low current
Low voltage High voltage
© ABB Group
The Tap-changer requirements are

characterized by:
 Thermal stability of contacts
 Switching capability
 Number of operations before
contact replacement
 Breaking capacity
 Short-circuit withstand
 Mechanical stability
 Dielectric withstand
 To earth
 Within the tap-changer
© ABB Group
Switching Type
Linear switching
 Simple design of transformer and OLTC
 Lowest losses
 Max. regulating range ≈ 10%
Plus/minus switching
 Reversable (+) and (-) regulating winding
 Change-over selector required

K K
 Highest losses
 Max. regulating range ≈ ±15 %
Coarse/fine switching
 Coarse winding required
 Change-over selector required
 Higher losses
 Max. regulating range >±15 %
© ABB Group
Connection Type
Star Point Connection:
One tap-changer can serve
all three phases
© ABB Group
Connection Type
2-pole + 1-pole line-end

3-pole line-end arrangement arrangement
Delta Connection:
Regulation can be facilitated
with 1, 2 or 3 pole tap-
changers depending on type
3-pole mid-winding arrangement
© ABB Group
Connection Type: Auto Transformer
HV HV HV
LV
+ + LV
- -
LV
+
-
Neutral point regulation HV regulation LV regulation
© ABB
Month DD, YYYY | Slide 19
Four main product families
Type UZ Type (V)UB Type (V)UC Type VRLTC
 On-tank and in-tank

 BIL level up to 1175 kV
 Through current up to 1600 A in star connected applications for
resistive and up to 2000 A for reactance type.
 Unsurpassed reference list in challenging applications, e.g. HVDC
and Ultra High Voltage systems (800 kV AC and DC)
© ABB Group
Two main technologies
Traditional technology, using arc quenching in oil

 UZ, UB and UC
Vacuum technology, using arc quenching in separate interrupters
 VUC, VUB and VRLTC
© ABB Group
Portfolio overview
Conventional Portfolio
On-tank In-tank
Product name UZF UZE UBB UCG short UCG/C UCG/III UCG/F UCL/III UCL/F UCD/III UCC/IV
Max voltage [kV]
In delta connection * 145 145 72,5 245 245 245 245 300 300 245 245
Max BIL [kV] 650 650 350 1050 1050 1050 1050 1175 1175 1050 1050
Max Current [A]** 600 600 500 300 600 600 600 925 925 1000 1600
Max Positions 33 33 27 35 35 35 35 35 35 35 35
* For ∆-connection.
Y-connections is restricted by
insulation of neutral point to
Vacuum Portfolio
ground.
** Maximum current in Y-connection.
Reactance Resistive
On-tank In-tank
Product name VRLTC VUBB VUCG short VUCG/C VUCG/III VUCG/F VUCL/III VUCL/F
Max voltage [kV]
In delta connection * 34,5 72,5 245 245 245 245 300 300
Max BIL [kV] 200 380 1050 1050 1050 1050 1175 1175
Max Current [A]** 2000 600 600 600 800 800 1000 1300
Max Positions 33 19 35 35 35 35 35 35
© ABB
25-Mar-15 | Slide 22
Routine tests, IEC 60214
1. Mechanical test
2. Switching sequence test
3. Auxiliary circuit insulation test
4. Pressure and vacuum test
5. Visual inspection
Vacuum tap-changers are subject

to additional testing, these includes
1. Leakage testing of vacuum
interrupters
2. High voltage conditioning of
vacuum interrupters
3. Mechanical conditioning of the
vacuum interrupters
© ABB Group
IEC 60214
 One or more of the following

protective devices shall be fitted
and connected to TFO trip circuit:
 Overpressure relay
 Pressure relief device
 Liquid-flow controlled relay
 ABB is of the opinion overpressure

relay provides the best protection
thanks to its fastness.
 All three systems can be supplied
depending on user preferences
 Equally important as the protection
devices are factors such as built-in
redundancy, material selection,
service friendliness, and product
training.
© ABB Group
Type tests, IEC 60214 and IEEE C57.131
1. Temperature rise of contacts

2. Switching tests
 Service duty test (synthetic test
1ZSC000717-ABX circuit for vacuum types)
(Synthetic test
circuit)  Breaking capacity test
3. Short-circuit current test

4. Transition impedance test
5. Mechanical tests
6. Dielectric tests
© ABB Group
 Diverter switch tap-changers

 Selector switch tap-changers
 Summary
© ABB Group
Diverter switch tap-changers
Principle of operation
Diverter switch: Switching device used in

conjunction with a tap-selector to carry,
make or break currents in circuits which
have already been selected
Tap selector: Device designed to carry,

but not make or break, current, used in
conjunction with a diverter switch to select
tap connections
Change-over selector: Device designed to
carry, but not to make or break, current,
used in conjunction with the tap selector
switch to enable its contacts and the
connection taps to be used more than once
when moving from one extreme position to
the other
© ABB Group
Conventional type UC - Principle of operation
© ABB Group
Type VUCG – Medium transformer ratings
© ABB Group
VUCG - Principle of operation 1(2)
© ABB Group
VUCG - Principle of operation 2(2)
© ABB Group
Type UCG and VUCG
 Rated through current in

star connections up to
800 A
1ZSC000717-AAT
 BIL levels up to 1050 kV

 Up to 35 tap positions
© ABB Group
Type VUCL – Large transformer ratings
© ABB Group
VUCL - Principle of operation 1(2)
© ABB Group
VUCL - Principle of operation 2(2)
© ABB Group
Type UCL and VUCL

star connections up to
1300 A
1ZSC000717-ABV

© ABB Group
Tap-selectors
Four tap-selector types for optimal performance

 C, F, III, IV
 Long-life design based on self-cleaning, sliding contacts

 Type tested for 1,500,000 operations. Experience from the
field shows they can do double
© ABB Group
Vacuum technology
 Less maintenance and lower life

cycle costs
 300 000 operations between
maintenance
 Radical reduction in contact
wear
 Reduced downtime and cleaner
maintenance environment
 Reduced sensitivity to moisture in the
tap-changer oil
 Switching characteristics is
independent on status of the
insulating oil
 Qualified for use with bio-degradable
fluids (VUCG)
 Significantly improved breaking
capacity in demanding applications;
more efficient use in HVDC
© ABB Group
Vacuum technology - Complete reliability
 Exceptionally tested
 Redundancy in the electrical
contact system
 Rotating mechanical systems
minimize wear
 Mechanical synchronization
of the vacuum bottles
© ABB Group
Benefits
Extensive service experience

 Tens of thousands units in
service
 Unsurpassed reference list in
challenging applications (HVDC)
Quick and easy maintenance
 Unique, open design,
 No special tools needed
 Shaft outside diverter switch
housing
 Maintenance videos is several
languages
Reliable
 Few parts
 Simple and robust design
 Mechanical lifetime exceeds
1,200,000 operations
Traditional and vacuum technology
 Easy to upgrade in the field
© ABB Group
Vacuum technology- Field upgrading
1ZSC000717-ACA
 Plug and play solution for all UCG/UCL.

 Upgrade from conventional to vacuum technology in less than
one day
 As easy as a normal overhaul
© ABB Group
25 March,
Month DD,2015
YYYY| Slide
| Slide4141
 Summary
© ABB Group
Selector switch tap-changers
Principle of operation
Change-over selector: Device designed to

carry, but not to make or break, current,
used in conjunction with the selector switch
to enable its contacts and the connection
taps to be used more than once when
moving from one extreme position to the
other
Selector switch: Switching device capable

of making, carrying and breaking current,
combining the duties of a tap selector and a
diverter switch
© ABB Group
VUBB - Principle of operation 1(2)
© ABB Group
VUBB - Principle of operation 2(2)
© ABB Group
Type VUBB

star and delta connections
600 A
1ZSC000717-AAS
 Step voltage up to 1600 V

© ABB Group
Vacuum technology - Complete reliability
 Exceptionally tested
 Minimal number of parts
 Robust mechanical design
 Large electrical and thermal
margins
 Internal pre-selector eliminates
the risk of gassing in the main
tank
© ABB Group
Benefits
Compact design
 Internal pre-selector reduces
the risk of handling damages
 Single compartment in both
star and delta connections
Extensive service experience
 Thousands of units in service
 Very well proven contact

system
Quick and easy maintenance
 All contact replacements from
the inside of the cylinder
 Few tools needed
Reliable
 Few parts
 Simple and robust design with

sliding contacts
© ABB Group
Vacuum technology
Benefits
 Less maintenance and lower life

cycle costs
 No time based maintenance
 Radical reduction in contact
wear
 Reduced downtime and
cleaner maintenance
environment
 Reduced sensitivity to moisture in
the tap changer oil
 Switching characteristics is
independent from the status of the
insulating oil
 On-line oil filtration becomes
unnecessary even in demanding
applications
© ABB Group
 Summary
© ABB Group
Tap-changer types
Portfolio overview
ABB Completes your transformers
Conventional Portfolio
On-tank In-tank
Product name UZF UZE UBB UCG short UCG/C UCG/III UCG/F UCL/III UCL/F UCD/III UCC/IV
Max voltage [kV]
In delta connection * 145 145 72,5 245 245 245 245 300 300 245 245
Max BIL [kV] 650 650 350 1050 1050 1050 1050 1175 1175 1050 1050
Max Current [A]** 600 600 500 300 600 600 600 925 925 1000 1600
Max Positions 33 33 27 35 35 35 35 35 35 35 35
* For ∆-connection.
Y-connections is restricted by
insulation of neutral point to
Vacuum Portfolio
ground.
** Maximum current in Y-connection.
Reactance Resistive
On-tank In-tank
Product name VRLTC VUBB VUCG short VUCG/C VUCG/III VUCG/F VUCL/III VUCL/F
Max voltage [kV]
In delta connection * 34,5 72,5 245 245 245 245 300 300
Max BIL [kV] 200 380 1050 1050 1050 1050 1175 1175
Max Current [A]** 2000 600 600 600 800 800 1000 1300
Max Positions 33 19 35 35 35 35 35 35
© ABB
25-Mar-15 | Slide 51
Voltage regulation
Motor Drives Overview
 Types:
 BUL2: Mainly used together
with VUB and single
compartment VUCG in-tank
tap-changers
 BUE2: Most versatile. For all
in-tank tap-changers.
 Highly configurable
 Various types of multi-
position switches
 Tropical and arctic versions
 Protection class
 IP 56 / IP 66
© ABB Group
Voltage regulation
AVR Overview
The Automatic Voltage Regulation
system offers several functions
 Parallel control according to all
common modes
 Voltage regulation
 Over current blocking
 Under voltage blocking
and flexibility
 Communication by most
protocols
 Can be mounted in motor drive
cabinet
 Alternatively, Wall-, Panel or
Flush mounting in control room
© ABB Group
Our philosophy
Gives your transformers
 Maximum lifetime by using high class material

 Type tests beyond international standards
 High reliability by using few parts and low complexity in design
 Easy maintenance by use of open and accessible designs
 Easy upgrading to vacuum technology in existing installation
© ABB Group
Thank you for your attention !
© ABB Group
ABB Transformers Components
Your partner of choice for reliable Solutions
For Further information please Feel Free to contact
Suleiman Tuffaha
Regional Marketing Specialist - GCC
Phone: +971 2 493 8610

Fax : +971 2 557 0145
Mobile: +971 50 6180 820
E-mail: Suleiman.Tuffaha@ae.abb.com
Thanks for your time and attention

© ABB Group

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Transformer Technology Days - 2015

ABB Transformer Components

Month DD, YYYY

Poland Turkey Russia

22 factories in 13 countries and ~ 2800 employees

 Cellulose insulation material

73 production units in 25 countries, and 36 service centers in 28 countries

First ASEA On-Load First ASEA patent on

Tap-changers are used to maintain a

Trends in the market

The purpose of the tap-changer is to change the turn ratio

Other areas with emphasis of

Sometimes several hundred thousand

Tap-changers can be located in the main transformer tank, or

Low voltage High voltage

Helical winding Disc winding

The Tap-changer requirements are

 Simple design of transformer and OLTC

 Max. regulating range ≈ 10%

 Reversable (+) and (-) regulating winding

 Change-over selector required

 Max. regulating range ≈ ±15 %

 Coarse winding required

 Change-over selector required

 Max. regulating range >±15 %

2-pole + 1-pole line-end

3-pole mid-winding arrangement

Neutral point regulation HV regulation LV regulation

Type UZ Type (V)UB Type (V)UC Type VRLTC

 On-tank and in-tank

Traditional technology, using arc quenching in oil

** Maximum current in Y-connection.

Vacuum tap-changers are subject

 One or more of the following

 Pressure relief device

 Liquid-flow controlled relay

 ABB is of the opinion overpressure

1. Temperature rise of contacts

3. Short-circuit current test

 Diverter switch tap-changers

Diverter switch: Switching device used in

Tap selector: Device designed to carry,

 Rated through current in

 BIL levels up to 1050 kV

 Rated through current in

 BIL levels up to 1175 kV

Four tap-selector types for optimal performance

 Long-life design based on self-cleaning, sliding contacts

 Less maintenance and lower life

Extensive service experience

 Plug and play solution for all UCG/UCL.

Change-over selector: Device designed to

Selector switch: Switching device capable

 Rated through current in

 Step voltage up to 1600 V

 Very well proven contact

 Simple and robust design with

 Less maintenance and lower life

** Maximum current in Y-connection.

Gives your transformers

 Maximum lifetime by using high class material

For Further information please Feel Free to contact

Phone: +971 2 493 8610

Thanks for your time and attention