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