ABB Sécheron SA Maurice Iacoviello

ABB Sécheron SA Maurice Iacoviello

• Presentation of ABB Sécheron

• Use of Flux2-3D at ABB Sécheron

• Presentation of a traction transformer

• Flux3D model related to a tractiontransformer

• Electrical characteristics of a tractiontransformer

• Conclusion

• Questions

European Club Flux 99

ABB Sécheron SA Maurice Iacoviello

The company

Transformersdivision

Medium voltagedivision

ABB Sécheron SA

ABB Sécheron SA Maurice Iacoviello

Medium voltage products

ABB Sécheron SA Maurice Iacoviello

Transformers products

First

Superconducting

transformer of

the world (HTS)

FirstFirst

Superconducting

Superconducting

transformer of

transformer of

the world (HTS)

the world (HTS)

ABB Sécheron SA Maurice Iacoviello

Traction transformer market

25 %25 %25 %75 %75 %75 %

• World wide market

• 100 % of the Swiss market

Centre of excellence fortraction transformer within ABB Group

Centre of excellence forCentre of excellence fortraction transformer traction transformer within ABB Groupwithin ABB Group

ABB Sécheron SA Maurice Iacoviello

•• Short circuit impedance calculations (SCI)Short circuit impedance calculations (SCI)

•• Determination of additional losses due to EddyDetermination of additional losses due to Eddy

currents (tank, hardware material, ...)currents (tank, hardware material, ...)

•• Temperature rise calculationTemperature rise calculation

•• Electrical field calculationElectrical field calculation

Use of Flux2-3D at ABB Sécheron

ABB Sécheron SA Maurice Iacoviello

Presentation of a traction transformer

ICN transformer« INTER CITY NEIGEZUG »

• 2260 kVA• Underframe• 15 kV; 16 2/3Hz• 2 tractions windings• Aluminium tank• Mineral oil• Class A

ABB Sécheron SA Maurice Iacoviello

Why use Flux3D instead of a traditionaldesign software

• SHORT CIRCUIT IMPEDANCE

• TANK LOSSES

To optimise electrical parameters like

We have modelised the transformer in order tooptimise these parameters!

ABB Sécheron SA Maurice Iacoviello

Evolution of the transformer design

1.Increase of the cover thickness

2.Increase of the tank height

3.Use of shunts

4.Use of different aluminium alloys

5.ICN final version

ABB Sécheron SA Maurice Iacoviello

ICN model design under Flux3D

• Description of volume regions

• Description of surface regions

• Description of used material

• Description of windings

• Meshing

• Type of resolutions

• Exploitation of results

ABB Sécheron SA Maurice Iacoviello

Description of 3D regions• Magnetic circuit

– Formulation scalar total« MD3SCA »

• Fictive air gap– Used to eliminate connexity

problems

– Formulation scalar reduce« MD3RED »

• Infinity and air

– Formulation scalarreduce « MD3RED »

ABB Sécheron SA Maurice Iacoviello

Description of 3Dregions

• Magnetic shunts

– Formulation

vector potential

electrical

« MD3AV »

Description ofwindings

• Formulation scalar total– Fictive presentation– Nothing meshing• Inductors– N*Ζ Phase angle

ABB Sécheron SA Maurice Iacoviello

Description of surface regions

• Advantages of these regions

– Keep thin regions in account with a light

description

– Use of shell elements

– No volume meshing needed

– Smaller file

– Quicker resolution

ABB Sécheron SA Maurice Iacoviello

Description of surfacic regions

• Cover and tank « shellelements »

– Formulationpot.red.general double

« MD3CGR »

• Copper shunts « shellelements »

– Formulationpot.red.general double

« MD3CGR »

ABB Sécheron SA Maurice Iacoviello

Meshing• Regulate meshing « Surface regions »

– Check of number and quality of elements

ABB Sécheron SA Maurice Iacoviello

• Volume meshing– Have 2 à 3 fine elements

inside of skin thickness« Volume shunts »

Meshing In general a good meshing

should not have more than

5% bad elements

Type of resolutions

• linear magnetodynamic

– Tank without magnetic shunts

• No linear magnetodynamic

– Tank with magnetic shunts

ABB Sécheron SA Maurice Iacoviello

Exploitation of results

• Tank losses with FLUX3D

– PCOQ2 allows to determine the tank losses

• Short circuit voltage with Flux3D

– With volume and surface energy

• Visualisation of Eddy current in the tank and in shunts

• Visualisation of flux density in the magnetic shunts

• Visualisation of main flux in the magnetic circuit

• Visualisation of magnetic radial fields in the disc windings

ABB Sécheron SA Maurice Iacoviello

• Tank losses

– Average surface power

density. « complex »

– Real part of PCOQ2, give

the losses

][)2( WPCOQREALTankSurf

losses ∫=

Tank losses and magnetic shunts

• Magnetic shunt losses

][21

_ WdvJLossesV

shuntsMag ⋅⋅= ∫ σ

The factor 1/2 is due to the useof peak values

][2

1 21_ WdvJLosses

V

shuntsMag ⋅⋅= ∫ σ

ABB Sécheron SA Maurice Iacoviello

• Volume energy is calculated with FLUX3D with this relation.

• Surface energy in shell elements is given by:

• Real PCOQ2 = Eddy losses

• Im (PCOQ2) = Reactive energy

Determination of SCI

• Total energy :

• Short circuit impedance :

][)2()2(4

1JdVHMAGBMAGconjE

V

vol ∗∗⋅= ∫

}{][

4

2ImJ

f

PCOQE surf ⋅⋅

=π

][JEEE surfvol +=

][4

2H

Î

ELcc

∗=

][2 WdsPCOQLossesSurf∫ ⋅=

ABB Sécheron SA Maurice Iacoviello

• Density of surfacecurrent in the tankand the shunts– Permit to locatehot spots on thetank and currentloops

Visualisation of Eddy current

ABB Sécheron SA Maurice Iacoviello

Visualisation of the main induction magnetic circuit

Visualisation of the SCI

• Shunts saturation

– Non linear

simulation

• Core flux density

ABB Sécheron SA Maurice Iacoviello

Magnetic fields

• We can observe the radial flux hitting the tank

ABB Sécheron SA Maurice Iacoviello

Evolution of the transformer design

1. Increase of the cover thickness

2. Increase of the tank height

3. Use of shunts

4. Final version

ABB Sécheron SA Maurice Iacoviello

Increase of the cover thickness

• We have compared different coverthickness

0123456789

10

A B C

Error [%]

0.7

0.8

0.9

1

A B CThickness

Lo

ss

es

[%

]

FLUX3Dmeasured

fixed

fixed

A, B, C

ABB Sécheron SA Maurice Iacoviello

• We have compared tank height foradditional frame.

– Cover thickness constant

0.7

0.8

0.9

1

A B CTank height

Lo

sses

[%

]

Flux3D

Measured

4

4.2

4.4

4.6

4.8

5

5.2

5.4

5.6

A B C

Error [%]

Increase of the tank height

fixed A, B, C

A, B, C

ABB Sécheron SA Maurice Iacoviello

fixed

fixed

fixed

• We have add shunts under the coverand in the bottom of the tank

– Aluminium cover and tank– Magnetic shunts or copper shunts

0.5

0.6

0.7

0.8

0.9

1

Magnetic Copper Type of shunts

Los

ses

[%]

Flux3D

Measured

Use of magnetic and copper shunts

SHUNTS

MagneticCopper Type of shunts

uc

c [

%]

Flux3D

Mesured

Client

ABB Sécheron SA Maurice Iacoviello

Final

Final

Final

• Design update

– choose of low loss aluminium alloys

– Increase of cover-winding distance

– Fine tuning of the active part

FINAL VERSION

Modifications

0

0.375

0.75

1

ICN FINAL

Lo

sses

[%

]

Flux3D

Measures

ICN FINAL

uc

c [%

]

Flux3D

Measures

Client

ABB Sécheron SA Maurice Iacoviello

CONCLUSION• Comment about the results

– The infrared picture demonstrate that the hot points are following thecurrent distribution calculated with Flux3D.

Remark :With help of Flux3D the final target could be reached very fast !

ABB Sécheron SA Maurice Iacoviello

CONCLUSION

• Positive points of Flux3D

– Decrease of fabrication costs

– Results conform to reality

– Anticipation of potential problems

– Powerful tool

– Precision of calculation