KONČAR – Electrical Engineering Institute, Inc. Zagreb, Croatia

Miroslav Poljak, Ph.D

Contents

  About the Institute in general

  Business results for 2006

  R&D of Institute’s own products

  Power equipment diagnostics

  Laboratories of the Institute

  Engineering supervision

  Social responsibility

"   Institute for research, development, diagnostics, certification and monitoring in energy conversion and power management

"   Forty five years of experience in research and application of scientific achievements

"   Specialised laboratories and teams of experts for application of new technologies

ENGINEERING FOR PLANT INSTALLATION & COMMISS.

ELECTRIC VEHICLES

METAL STRUCTURES

ELECTRONICS AND INFORMATICS

INSTRUMENT TRANSFORMERS

DISTRIBUTION AND SPECIAL TRANSFORMERS

SWITCHGEAR

MEDIUM VOLTAGE APPARATUS

HIGH VOLTAGE SWITCHGEAR

GENERATORS AND MOTORS

POWER PLANT AND ELECTRIC TRACTION ENGINEERING

ENERGY AND TRANSPORT

LOW VOLTAGE SWITCHES AND CIRCUIT BREAKERS

SMALL ELECTRICAL MACHINES

ELEVATORS AND SERVICING

TOOLS

CATERING EQUIPMENT

HOUSEHOLD APPLIANCES

INDUSTRY AND TRADE

INFRASTRUCTURE AND SERVICES

ELECTRICAL ENGINEERING INSTITUTE

DEVELOPMENT AND SERVICES

SWITZERLAND

THE CZECH REPUBLIC

BULGARIA

COMPANIES ABROAD

RUSSIAN FEDERATION

BOSNIA AND HERZEGOVINA

SERBIA AND MONTENEGRO

REPRESENTATIVE OFFICES

POWER TRANSFORMERS

ASSOCIATED COMPANIES

KONČAR Electrical Industries Inc.

Organisation

R&D PROJECTS

MANAGING BOARD

CONDITION MONITORING SYSTEMS

ELECTROMOTOR TRAIN

GENERATING SET WITH FUEL CELLS

SCIENTIFIC COUNCIL

DEPARTMENTS SECTIONS

TRANSFORMERS R&D Section

SWITCHGEAR & CONTROLGEAR

ROTATING MACHINES

POWER ELECTRONICS & CONTROL

Laboratory for Rotating Machines

High Power Laboratory

Laboratory for Electronics & EMD

High Voltage Laboratory

R&D Section

R&D Section

Control, Communications & Informatics Sect. Power Electronics Section

EMC Laboratory

Calibration Laboratory

Laboratory for Safety EMC, SAFETY & CALIBRATION

MATERIALS & TECHNOLOGIES

SERVICES QM and QA Systems, LAN and INDOC

Certification and Relations with Government Institutions

Legal, Personnel and General Administrative Services

Laboratory for Physical & Chemical Tests Materials Laboratory

Purchasing & Sale

Accounting & Finance

Statement of Independence 1.  KONČAR – Electrical Engineering Institute, Inc. does

not owe shares of any company either in or outside KONČAR Group.

2.  The Management of KONČAR – Electrical Engineering Institute, Inc. is responsible to the Supervisory Board and the Shareholders’ Assembly only for business operations, to that neither the Supervisory Board nor the Assembly can influence any test or certification results by any measure.

3.  Institute has several hundreds of orders a year, and possible loss of an order for testing or certification of a product is not a decisive factor in its business or financial situation.

4.  The position of employees of the Institute who work on testing and certification of products is not dependent on any influences by the producer, supplier or seller of that particular product, and the number of tests and their results have no effect on salaries of the employees.

Certified Quality Management and Environmental Management systems

Mission

R&D of equipment and technologies for efficient and reliable energy conversion and power transmission, with minimum environmental influence.

Vision Together with other KONČAR companies, to become the leading regional company:

•  in the development of specific products and equipment, applying up-to-date technologies, and

•  in testing, diagnostics and analysis of electrical equipment and systems for electric power sector and transport.

Our future OBJECTIVE

To be a company based on application of knowledge and new technologies, appreciated by clients, employees, suppliers, owners and the social community. STRATEGY

1.  Joint R&D of new products and equipment with customers and manufacturers that are complementing KONČAR’s production programme.

2.  Activities on the markets in Croatia, South-Eastern Europe and those of other KONČAR companies.

3.  Permanent increase of added value, with intense investments in the development of new products, training of employees, and laboratory equipment.

4.  Fostering and promoting the sense of unity, ethical relations and environmental concerns.

BUSINESS RESULT FOR 2006

Business activities

ISPITIVANJA SUKLADNOSTI 11% NADZOR 6%

10%

USLUGE RAZVOJA I STUDIJE 15%

I 58%

SALES TOTAL (million EUR) 7.04 10.35

DEVELOPMENT & STUDIES 18%

DIAGNOSTICS 14% CONFORMITY TESTS 15% SUPERVISION 8%

2005 2006

APPLIED RESEARCH & DEVELOPMENT 45% OF INSTITUTE’S OWN PRODUCTS

Market segments in 2006

Sales

Market in 2006

-  Slovenia 1.3 % - Bosnia & Herzegovina 0.9% - Germany 0.8% - Italy 0.3% - Other countries 0.7%

- Production 6.5% - Transmission 4% - Distribution 2.5%

Number and structure of employees in 2006

-  142 employees -  10 scholarship students -  25 post-graduate students -  4 approved master’s theses -  1 approved doctor’s thesis

Average age and years of service of employees

Investments in education

Investments in the equipment and renovation of buildings

Operational revenue, added value and human capital per employee

RESEARCH & DEVELOPMENT OF INSTITUTE’S OWN PRODUCTS

2002 - 2006

Annual investments ∼10% of total sales

Multi-system converters for passenger coaches

Low-floor tram car: power converters and control units

Electronic equipment for commuter train (under construction)

  Main drive converter   Auxiliary power supply converter with battery charger   Central control & communication system   Intelligent controller

Electronic equipment for commuter train (under construction) (2/2)

Transformer monitoring system

Transformer monitoring system

BUSHINGS •  Voltages •  Currents •  Bushing capacity index •  Partial discharge •  Tan delta

ACTIVE PART •  Currents •  Temperatureses •  Power •  Losses •  Gasses in oil •  Moisture in oil •  Moisture in paper insulation •  Rate of insulation ageing •  Residual life

ON-LOAD TAP CHANGER (OLTC) •  Tap position •  Maximum rated through current •  Power consumption of OLTC

motor unit at tap changing •  Tap-changing time

COOLING SYSTEM & AUX. EQUIPMENT •  Temperatures •  Oil flows •  Oil level in conservator •  Service conditions of cooler,

pumps and fans •  Buchholz alarm/switch off •  Thermovision alarm/switch off •  Contact thermometer alarm/switch off •  Pressure relief actuation

Machine monitoring system

MEASURED QUANTITIES: •  Vibrations •  Relative shifts •  Air gap •  Magnetic flux •  Partial discharge •  Process variables •  ...

Machine monitoring system

Machine monitoring system

HV switchgear monitoring system

Disconnector

VT

CT

Circuit breaker

CRio

Internet

Disconnector

VT

VT

Circuit breaker

HV switchgear monitoring system (under construction)

Disconnectors and earth switches (operating times and number of switching operations, motor current, state of auxiliary circuits)

-  Voltage and current transformers (oil pressure inside)

-  Circuit-breakers

-  Switching times (Close, Open, Close-Open, arcing time, operating time)

-  Measurements of currents and time (coils, motor and heater)

-  Contact and mechanism travel and velocity

-  SF6 gas (pressure, temperature, density)

-  Hydraulics (pressures)

-  Status data (circuit breaker position, state of auxiliary circuits, lock-outs etc.)

Electromagnetic field monitoring system

Wind turbine (under construction)

Gas electric generating unit with fuel cells and cogeneration (under construction)

Heat

FUEL CELLS

REFORMER

CONTROL

DC / AC CONVERTER

GAS

HEAT EXCHANGER

HYDROGEN

CO2

DC

W A T E R

A I R

Heat

El. energy

Heat

DISTRICT HEATING SYSTEM

ELECTRICAL NETWORK

)))) ((((

DIAGNOSTICS OF POWER EQUIPMENT AND ON-SITE TESTS AND MEASUREMENTS

5 mobile test stations

Transformer diagnostics

TRANSFORMER OIL ANALYSIS: •  Physical and chemical oil analyses •  Dissolved gas analysis (DGA) •  Water content in transformer oil

MEASUREMENTS - WINDINGS AND CORE: •  No-load current (Io) •  Winding resistance in all tap

positions (UI method) •  Transformer voltage ratio •  Winding leakage inductance •  Frequency response analysis (FRA)

MEASUREMENTS – TRANSFORMER BUSHINGS AND INSULATION: •  Capacitance and tan δ of transformer insulation •  Resistance of transformer insulation, U-I method •  Moisture content in transformer insulation (RVM)

Diagnostics of HV circuit breakers

TESTS OF:   Gas quality   Quality of solid insulation   Resistance of main circuits   Operating times   Control times   Contact movements   Contact wear

Diagnostics of rotating machines

  AT REST: -  Load resistance, capacity, impedance, dielectric resistance,

discharge currents, loss angle, partial discharges -  Condition of bar, coil and winding insulation -  Stator core -  Condition of synchronous machine amortisseur and induction

squirrel cage -  Non-destructive tests of construction parts

  IN ROTATION: -  Vibrations, runout and rotational

speed -  Stray magnetic fields -  Shaft voltage or bearing currents -  Noise level -  Temperatures on key points -  Process variables

Power quality   MEASUREMENTS AND ANALYSES OF:

-  Power flows of fundamental and higher harmonics in accordance with EN 61000-x-y

-  Quality of electric power in accordance with EN 50160

Energy efficiency (start-up)

  MEASUREMENTS OF:

-  Consumption of electric

and thermal power

-  Grid and consumer loads

and losses

  CONCEPTUAL DESIGNS

AND IMPROVEMENTS:

-  As-built analyses

-  Proposals for improvements

LABORATORIES OF THE INSTITUTE

organised in accordance with IEC/EN 17025

High-Voltage Laboratory

ROUTINE AND TYPE TESTS:   Dry and wet tests with power frequency voltage up to

1000kV   Lightening impulse voltage tests (1.2/50µs)

up to 2000kV   Switching impulse voltage tests (250/2500µs) up to

1500kV (dry and wet tests)   Fast transient tests   Up to 72.5 kV in artificial pollution   Temperature rise tests of transformers and

HV apparatus and determination of thermal stability

  Partial discharge   Capacity and loss angle   Calibration of HV measurement systems for

impulse and alternative voltage.

High-Power Laboratory

  Short-circuit strength of switching devices, switchgear, instrument and power transformers, and connection accessories

  Make and break capacities and electrical endurance of LV switching devices and installation accessories

  Temperature rise and voltage drops on HV and LV switching devices, switchgear and other apparatus

Laboratory for Rotating Machines   TESTS IN ACCORDANCE WITH

STANDARDS: -  Insulating materials, conductors and

cables -  Electrical and magnetic materials -  Resistance to vibrations of

equipment up to 100 kg -  No-load, short-circuit and load

characteristics of LV and HV machines up to 400kW, 500A and 50/60Hz

-  Torque characteristics of machines and operating mechanisms with torques up to 5kN and speeds up to 3000 1/min.

-  Temperature-rise and ventilation measurements

-  Noise measurements

Electronics and EMD Laboratory (1/2)   MAKING models and prototypes of electric

devices for: -  Electric vehicles and -  Power electronic

  ROUTINE AND TYPE TESTS of electronic devices and software

  Servicing and maintenances of electronic systems and devices

  Tests of electric motor drives in accordance with applicable standards:

- powers up to 400 kW - alternating voltages up to 10000 V - direct voltages up to 4000 V - frequencies from 0 up to 600 Hz

Electronics and EMD Laboratory (2/2)

TESTING:   Equipment in climatic

chambers

  Ventilation and thermal characteristics of machines   Temperatures, pressures, flows and flow velocities of

fluids   Characteristics of fans, pumps and heat exchangers

  Protection against ingress of foreign bodies (IP 1x to IP 6x) and water (IP x1 to IP x8)

Laboratory for Electromagnetic Comaptibility

MEASUREMENTS AND ANALYSES OF:   electric devices and equipment   electromagnetic compatibility

  non-ionising electromagnetic fields

Laboratory for Safety SAFETY TESTS OF:   Gas and electrical household appliances   IT and office equipment   Electric machines, devices and

equipment   Installations in areas with and without

explosive mixtures   Working environment in and outside

premises   Assessment of hazards

ASSESSMENT OF CONFORMITY UNDER:   Low Voltage Directive 73/23/EEC   EMC Directive 89/226/EEC   Machine Directive 98/37/EC   Gas Directive 90/396/EEC

Calibration Laboratory

  Calibration of instruments and standards of direct and alternating voltages and currents, resistances, frequencies and times

  Certification of multi-purpose meters (for testing electrical installations, dielectric and earthing strength etc.)

  Testing and calibration of electronic measurement equipment

Laboratory for Physical and Chemical Tests

  Tests of properties and analysis of materials for installation in electric machines and devices

  Diagnostic and dielectric tests of transformer oil and paper insulation

  Environmental studies

Laboratory for Materials and Technologies   Destructive and non-destructive

material tests   Metalographic and fractographic

inspections of materials   Thermal treatment of metals in

various protective atmospheres and vacuum

  Corrosion protection   Helium liquefaction

  Qualification tests for welders and solders, and qualification of procedures

  Calibration of vacuum probes and tests of air tightness

ENGINEERING SUPERVISION

8 certified engineers of electrical and mechanical engineering

Supervision under the Construction Act

Motorway: ZAGREB - RIJEKA

Section: Vukova Gorica – Vrbovsko

Motorway: ZAGREB - SPLIT

Sections: Maslenica – Zadar1 – Zadar2

Pirovac – Skradin – Šibenik – Vrpolje

Dugopolje – Bisko – Šestanovac

Tunnels: Konjsko i Osmakovac

Motorway: RUPA - RIJEKA

Sections: Permani – Rupa – Border with R Slovenia

SOCIAL RESPONSIBILITY

Academic community and the Institute The Institute:  grants money awards to the best students,  sponsors the laureates of the Life Achievement Award granted by

Croatian Academy of Engineering,  sends a large number of graduates to postgraduate and doctoral

studies,  participates together with Zagreb Faculty of Electrical Engineering

and Computing in implementation of specialist studies in TRANSFORMERS,

  finances 3 junior researchers at 2 engineering faculties in Zagreb,  manages 4 scientific projects, and participates in 6 more projects

managed by Faculty of Electrical Engineering and Computing and Faculty of Mechanical Engineering and Naval Architecture.

Academic community and the Institute from 2002 to 2006

Employees (aver.) 138 Graduates 75 DSc., MSc. 18

Total revenue 35.22 mill. €

Depreciation + profit 3.5 mill. €

ACADEMIC COMMUNITY -  FER 0.38 mill.€ -  FSB, EF 0.04 mill.€ -  Donations 0.01 mill.€ TOTAL 0.43 mill.€

Investments 3.2 mill.€ New employees 61 Investments in education 0.7 mill.€ Donations 0.07 mill.€ Published 144 papers

INCOMES -  Employees 9.41 mill.€ -  Others 0.81 mil. € -  Scholarship students 0.13 mill.€ TOTAL: 10.35.7 mill.€

SUPPLIERS -  Materials 10.08 mill.€ - Services 3.74 mill.€ TOTAL: 13.82 mill.€

STATE -  Taxes, surtaxes, contributions TOTAL: 7.13 mill.€

Others in Croatia 11.71 mill.€ Export 2.29 mill.€ TOTAL: 14.0 mill.€

MINISTRY OF SCIENCE: -  Scientific projects 0.26 mill.€ -  Technolog. Projects0.22 mill.€ -  Novices 0.38 mill.€ -  Equipment 0.04 mill.€ TOTAL: 0.9 mill.€

Companies in KONČAR Group

TOTAL: 20.2 mill. €

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MINISTRY OF THE ECONOMY: −  Renavab. sources 0.31 mill.€

Recognitions 2006 – ZLATNA KUNA Award, Transformer Monitoring System, Low-Floor Tram