ABB Industrial Transformers

The largest technology base worldwide

L
e
a
f
le
t

n
o
.

1

L
A
B

0
0
0
0
1
9


P
r
in
t
e
d

in

G
e
r
m
a
n
y

(
0
9
.
0
4
-
x
x
x
x
-
P
P
I
)
ABB Industrial Transformers.
Unified power for your success.
Series Reactors for AC Arc Furnaces
Most AC steel furnaces will require a series reactor
in the primary.
For long-arc steel furnace operation additional reactance is
norm ally required to stabilize the arc and optim ize the operation.
A series reactor for this purpose is built into the furnace transform er
tank itself or supplied separately.
AC Arc Furnace Transformers
Furnace transformers for long-arc (steel)
and short-arc (ferroalloy) operation.
ABB produces transform ers for all furnace applications. A robust design
guarantees m echanical strength for steel furnace operation and tem perature
control for continuous high loads in ferroalloy operation.
DC Arc Furnace Transformers
DC arc furnaces are mainly for steel production.
Transform ers for D C furnace operation norm ally com e in a transform er/rectifier
package. The full package can be m anufactured/supplied by ABB.
Rectifier Transformers
For various electrolysis applications like aluminium
and other metals and chlorine.
Rectifier transform ers are com bined w ith a diode or thyristor
rectifier. The applications range from very large alum inium
electrolysis to various m edium size operations.
The transform ers m ay have a built-in or
separate voltage regulation unit.
Large Drives Converter Transformers
Drives systems for pumping stations,
wind tunnels and traction feeding.
The transform ers are com bined w ith a thyristor rectifier for
variable speed drives (VSD ) system s or frequency conversion.
ABB AG
Transformers
Lohfelder Strasse 19-21
53604 Bad Honnef
GERMANY
Phone: +49(0) 2224/14-0
E-mail: info@abb.com
Internet: www.abb.com/transformers
ABB Power Technologies S.p.A.
Unit Operativa Trasformatori di Potenza
Via Giotto, 10
20025 Legnano (MI)
ITALY
Phone: +390331479307
E-mail: info@abb.com
Internet: www.abb.com/transformers
N
o
t
e
:
W
e

r
e
s
e
r
v
e

t
h
e

r
ig
h
t

t
o

m
a
k
e

t
e
c
h
n
ic
a
l
c
h
a
n
g
e
s

o
r

m
o
d
if
y

t
h
e

c
o
n
t
e
n
t
s

o
f

t
h
is
d
o
c
u
m
e
n
t

w
it
h
o
u
t

p
r
io
r

n
o
t
ic
e
.

W
it
h

r
e
g
a
r
d

t
o

p
u
r
c
h
a
s
e

o
r
d
e
r
s
,

t
h
e

a
g
r
e
e
d
p
a
r
t
ic
u
la
r
s

s
h
a
ll
p
r
e
v
a
il.
A
B
B

d
o
e
s

n
o
t

a
c
c
e
p
t

a
n
y

r
e
s
p
o
n
s
ib
ilit
y

w
h
a
t
s
o
e
v
e
r

f
o
r

p
o
t
e
n
t
ia
l
e
r
r
o
r
s
o
r

p
o
s
s
ib
le

la
c
k

o
f

in
f
o
r
m
a
t
io
n

in

t
h
is

d
o
c
u
m
e
n
t
.
W
e

r
e
s
e
r
v
e

a
ll
r
ig
h
t
s

in

t
h
is

d
o
c
u
m
e
n
t

a
n
d

in

t
h
e

s
u
b
je
c
t

m
a
t
t
e
r

a
n
d

illu
s
t
r
a
t
io
n
s
c
o
n
t
a
in
e
d

t
h
e
r
e
in
.

A
n
y

r
e
p
r
o
d
u
c
t
io
n

in

w
h
o
le

o
r

in

p
a
r
t
s

is

f
o
r
b
id
d
e
n

w
it
h
o
u
t
A
B
B

s

p
r
io
r

w
r
it
t
e
n

c
o
n
s
e
n
t
.
C
o
p
y
r
ig
h
t

2
0
0
3

A
B
B
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.
ABB Industrial Transformers
The largest technology base worldwide
L
e
a
f
le
t

n
o
.

1

L
A
B

0
0
0
0
1
9


P
r
in
t
e
d

in

G
e
r
m
a
n
y

(
0
9
.
0
4
-
x
x
x
x
-
P
P
I
)
ABB Industrial Transformers.
Unified power for your success.
Series Reactors for AC Arc Furnaces
Most AC steel furnaces will require a series reactor
in the primary.
For long-arc steel furnace operation additional reactance is
norm ally required to stabilize the arc and optim ize the operation.
A series reactor for this purpose is built into the furnace transform er
tank itself or supplied separately.
AC Arc Furnace Transformers
Furnace transformers for long-arc (steel)
and short-arc (ferroalloy) operation.
ABB produces transform ers for all furnace applications. A robust design
guarantees m echanical strength for steel furnace operation and tem perature
control for continuous high loads in ferroalloy operation.
DC Arc Furnace Transformers
DC arc furnaces are mainly for steel production.
Transform ers for D C furnace operation norm ally com e in a transform er/rectifier
package. The full package can be m anufactured/supplied by ABB.
Rectifier Transformers
For various electrolysis applications like aluminium
and other metals and chlorine.
Rectifier transform ers are com bined w ith a diode or thyristor
rectifier. The applications range from very large alum inium
electrolysis to various m edium size operations.
The transform ers m ay have a built-in or
separate voltage regulation unit.
Large Drives Converter Transformers
Drives systems for pumping stations,
wind tunnels and traction feeding.
The transform ers are com bined w ith a thyristor rectifier for
variable speed drives (VSD ) system s or frequency conversion.
ABB AG
Transformers
Lohfelder Strasse 19-21
53604 Bad Honnef
GERMANY
Phone: +49(0) 2224/14-0
E-mail: info@abb.com
Internet: www.abb.com/transformers
ABB Power Technologies S.p.A.
Unit Operativa Trasformatori di Potenza
Via Giotto, 10
20025 Legnano (MI)
ITALY
Phone: +390331479307
E-mail: info@abb.com
Internet: www.abb.com/transformers
N
o
t
e
:
W
e

r
e
s
e
r
v
e

t
h
e

r
ig
h
t

t
o

m
a
k
e

t
e
c
h
n
ic
a
l
c
h
a
n
g
e
s

o
r

m
o
d
if
y

t
h
e

c
o
n
t
e
n
t
s

o
f

t
h
is
d
o
c
u
m
e
n
t

w
it
h
o
u
t

p
r
io
r

n
o
t
ic
e
.

W
it
h

r
e
g
a
r
d

t
o

p
u
r
c
h
a
s
e

o
r
d
e
r
s
,

t
h
e

a
g
r
e
e
d
p
a
r
t
ic
u
la
r
s

s
h
a
ll
p
r
e
v
a
il.
A
B
B

d
o
e
s

n
o
t

a
c
c
e
p
t

a
n
y

r
e
s
p
o
n
s
ib
ilit
y

w
h
a
t
s
o
e
v
e
r

f
o
r

p
o
t
e
n
t
ia
l
e
r
r
o
r
s
o
r

p
o
s
s
ib
le

la
c
k

o
f

in
f
o
r
m
a
t
io
n

in

t
h
is

d
o
c
u
m
e
n
t
.
W
e

r
e
s
e
r
v
e

a
ll
r
ig
h
t
s

in

t
h
is

d
o
c
u
m
e
n
t

a
n
d

in

t
h
e

s
u
b
je
c
t

m
a
t
t
e
r

a
n
d

illu
s
t
r
a
t
io
n
s
c
o
n
t
a
in
e
d

t
h
e
r
e
in
.

A
n
y

r
e
p
r
o
d
u
c
t
io
n

in

w
h
o
le

o
r

in

p
a
r
t
s

is

f
o
r
b
id
d
e
n

w
it
h
o
u
t
A
B
B

s

p
r
io
r

w
r
it
t
e
n

c
o
n
s
e
n
t
.
C
o
p
y
r
ig
h
t

2
0
0
3

A
B
B
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.
Customized solutions by
dedicated people in focused factories.
Experience
ABB Industrial Transform ers integrates the
experience of highly dedicated people and
techniques from serveral industrial transform er
factories in various countries. This represents the
largest technology base of its kind w orldw ide.
Quality
ABBIndustrial Transformers believes
that Quality is a vital element of the product
right from the start; it can never be achieved
by checks and controls alone.
Built-in quality procedures are im plem ented even
before the designw ork starts, ensuring correct
interpretation of custom er requirem ents. Arc furnaces
and electrolysis operations put tough stresses on
transform ers. Sophisticated 2D and 3D com puter program m es calculate
dielectric, therm al and m echanical stresses, and our quality program m e enables us
to check, verify and m easure all our processes. O nly first-class sub-suppliers are
used. The ultim ate goal is to m axim ize overall quality w hich results in high
reliability and optim um transform er Life Cycle Cost. Advanced m onitoring
system s are also available.
Know-How and Research and Development
ABBIndustrial Transformers has direct access to all the combined transformer
know-how, technical experience and expertise within the ABBGroup.
This represents its current know -how base,
achieved through dedicated em ployees,
an excellent IT structure and undisputed
leadership in Research and D evelopm ent.
ABB Industrial Transform ers is continuously
enlarging this base and finding solutions for
the future now .
Partnership & Service
ABBIndustrial Transformers designs tailor-made,
high-current solutions for all our industrial customers.
W e are com m itted to being a flexible and know ledgeable partner
for you w orldw ide. Together w e can analyze individual needs
and help to ensure that you w ill receive the optim al transform er
solution to suit your requirem ents.
ABB Industrial Transform ersglobal netw ork provides
on-dem and custom er service and support. O ur interpre-
tations of dissolved gas analysis have been recorded and
system ized.
Focused Factories
ABB Industrial Transform ers now concentrates
Research and D evelopm ent, engineering, m anu-
facturing and service for industrial transform ers
prim arily at tw o specialized and globally focused
factories w ithin the ABB group, located at
Legnano, Italy and Bad H onnef, G erm any.
Large Drives Converter Transformers
Applications
For special applications, such as large pum ping
stations, w ind tunnels and rolling stock, a transform er
com bined w ith a frequency converter w ill supply
the input for a variable speed system . For fixed
railw ay feeding stations a conversion from norm al
grid frequency to railw ay frequency takes place in
a sim ilar w ay.
Duty
The duty is m uch related to type of application.
In pum ping stations a high loading w ith lim ited
variation over tim e can be expected, w hile in
other applications there m ay be a m ore interm ittent
duty cycle w ith load peaks.
Design
D rives transform ers are m ostly built w ith tw o
secondary and tw o prim ary w indings, allow ing
for a 12-pulse rectifier reaction. Such transform ers
are norm ally built w ith a tertiary w inding system
connected to a filter bank to take out harm onics
created by the converter. D ue to the operation
cycles of the converters, there are strong require-
m ents for correct inter-w inding im pedance
relations and accuracy.
Technical Features
Ratings: U p to 137 M VA
Secondary voltages: U p to 13,4 kV
7
Customized solutions by
dedicated people in focused factories.
Experience
ABB Industrial Transform ers integrates the
experience of highly dedicated people and
techniques from serveral industrial transform er
factories in various countries. This represents the
largest technology base of its kind w orldw ide.
Quality
ABBIndustrial Transformers believes
that Quality is a vital element of the product
right from the start; it can never be achieved
by checks and controls alone.
Built-in quality procedures are im plem ented even
before the designw ork starts, ensuring correct
interpretation of custom er requirem ents. Arc furnaces
and electrolysis operations put tough stresses on
transform ers. Sophisticated 2D and 3D com puter program m es calculate
dielectric, therm al and m echanical stresses, and our quality program m e enables us
to check, verify and m easure all our processes. O nly first-class sub-suppliers are
used. The ultim ate goal is to m axim ize overall quality w hich results in high
reliability and optim um transform er Life Cycle Cost. Advanced m onitoring
system s are also available.
Know-How and Research and Development
ABBIndustrial Transformers has direct access to all the combined transformer
know-how, technical experience and expertise within the ABBGroup.
This represents its current know -how base,
achieved through dedicated em ployees,
an excellent IT structure and undisputed
leadership in Research and D evelopm ent.
ABB Industrial Transform ers is continuously
enlarging this base and finding solutions for
the future now .
Partnership & Service
ABBIndustrial Transformers designs tailor-made,
high-current solutions for all our industrial customers.
W e are com m itted to being a flexible and know ledgeable partner
for you w orldw ide. Together w e can analyze individual needs
and help to ensure that you w ill receive the optim al transform er
solution to suit your requirem ents.
ABB Industrial Transform ersglobal netw ork provides
on-dem and custom er service and support. O ur interpre-
tations of dissolved gas analysis have been recorded and
system ized.
Focused Factories
ABB Industrial Transform ers now concentrates
Research and D evelopm ent, engineering, m anu-
facturing and service for industrial transform ers
prim arily at tw o specialized and globally focused
factories w ithin the ABB group, located at
Legnano, Italy and Bad H onnef, G erm any.
Large Drives Converter Transformers
Applications
For special applications, such as large pum ping
stations, w ind tunnels and rolling stock, a transform er
com bined w ith a frequency converter w ill supply
the input for a variable speed system . For fixed
railw ay feeding stations a conversion from norm al
grid frequency to railw ay frequency takes place in
a sim ilar w ay.
Duty
The duty is m uch related to type of application.
In pum ping stations a high loading w ith lim ited
variation over tim e can be expected, w hile in
other applications there m ay be a m ore interm ittent
duty cycle w ith load peaks.
Design
D rives transform ers are m ostly built w ith tw o
secondary and tw o prim ary w indings, allow ing
for a 12-pulse rectifier reaction. Such transform ers
are norm ally built w ith a tertiary w inding system
connected to a filter bank to take out harm onics
created by the converter. D ue to the operation
cycles of the converters, there are strong require-
m ents for correct inter-w inding im pedance
relations and accuracy.
Technical Features
Ratings: U p to 137 M VA
Secondary voltages: U p to 13,4 kV
7
7 6 3 6
DC Arc Furnace Transformers
Applications
Most large DC arc furnaces are built for steel
production. The use of a thyristor rectifier for
the conversion to DC will normally reduce the
requirement for on-load voltage regulation of
the furnace transformer. The step voltages will be
larger than for an AC furnace transformer and a
no-load tap changer (NLTC) will in many applications
be adequate.
Duty
Being a rectifier transformer for furnace operation,
the DC furnace transformer will have to withstand
the characteristic stresses of furnace operation, as
well as the additional stresses related to rectifier
operation, including generated current harmonics.
Also, the HV side needs to be protected from
frequent switching overvoltages.
Design
DC furnace transformers are mostly built with
two axially displaced LV windings, normally
one connected in delta and one in wye, each
having a separate high voltage winding. In this
double-decker design the
transformer is connected to
two six-pulse rectifiers, adding
up to a 12-pulse system or
two parallel 6-pulse systems.
The regulation of the LV
transformer voltage is normally
done by using a NLTC in the
primary winding.
The location of the 6-pulse
rectifiers can be on the same
side of the transformer or on
opposite sides, as required
by plant layout.
Intermediate yoke
DC furnace transformers in double-decker design,
having two HV-LV voltage systems on the same
core may have an intermediate yoke to enable
largely independent operation of the two systems.
Technical Features
Ratings: Up to 120 MVA
Secondary voltages: Up to 1200 V
Electrode current: Up to over 100 kADC
Rectifier Transformers
Applications
Electrolysis processes are used for the production of metals, such as aluminium, magnesium,
copper and zinc, or chemicals, mainly chlorine. The largest installations are those for
aluminium electrolysis with several transformer/rectifier units in parallel operation to
achieve the required DC current. In all cases the rectifier can be with diodes or thyristors.
Duty
Electrolysis is generally considered to be continuous
and stable processes, but with a constant high loading
and current harmonics.
Design
Due to a large variety of applications there are
several influencing factors to consider:
Rectifier bridge connection: For medium to
high DC voltage level.
Rectifier single-way interphase connection: For
low DC voltage levels combined with high DC
currents.
Thyristor or diode rectifier.
Voltage range and step voltage.
Double-decker: HV and LV windings in
two levels and wye and delta connection
to achieve 12-pulse reaction.
Pulse numbers higher than 12: Requires
additional phase shifting windings.
LV winding arrangements: Adapted to minimize
winding hotspots and the influence of harmonics.
LV bushing arrangement: Adapted to rectifier
design and to limit structural heating.
Voltage regulation
Thyristor rectifiers normally require transformer
voltage regulation with a no-load-tap-changer
(NLTC), if any. For short voltage ranges the NLTC
can be situated in a HV tapped winding.
Diode rectifiers will in comparison have a longer
range and a higher number of smaller voltage
steps in the transformer. A multi-coarse-fine on-
load-tap-changer (OLTC) or an OLTC/NLTC
combination is preferred, together with LV-side
saturable reactors for the voltage fine-tuning. The
required double-wound or auto connected
regulating transformer can, depending on transport
or site limitations, be built into the same tank as
the rectifier transformer or into a separate tank.
Technical features
Unit ratings: Up to 160 MVA
Secondary voltage: Up to 1500 VAC
Unit process current: Up to over 100 kADC
5 4 5 4
Applications
In large long-arc steel furnaces with high arc voltages there will generally be required to
introduce extra reactance in order to stabilize the arc during operation. For this purpose,
a linear series reactor will be used. The reactor may be
built into the same tank as the furnace transformer,
or supplied as a separate unit.
AC Arc Furnace Transformers
Applications
Electric arc furnace (EAF) transformers
are required for many different
furnace processes and applications.
They are built for:
Steel furnaces, mainly long arc
Ladle furnaces
Ferroalloy furnaces and similar
with short or submerged arc
Duty
Steel arc furnace transformers
operate under very severe conditions
with regard to frequent overcurrents
and overvoltages generated by short-
circuits in the furnace and the
operation of the HV circuit breaker
(furnace breaker). The loading is
cyclic, while in other applications
the loading is more continuous at
high utilization.
Design
ABB EAF transformers are rigidly designed to
withstand repeated short circuit conditions and
high thermal stresses and to be protected against
operational overvoltages.
Design options:
Direct or indirect regulation
On-load or no-load tap changer (OLTC or NLTC)
Built-in reactor for long-arc stability
Secondary bushing arrangements and designs,
air or water cooled
Internal secondary phase
closure (internal
delta)
RC-SA high voltage
protection system
Series Reactors
Direct Regulation
The secondary voltage can be regulated by
tapping the primary winding. Step voltages over
the range will be unequal, due to the inherent
winding design, but adaptations can be made
to satisfy most requirements. A single core-coil
unit makes this the most cost-effective regulation
principle in a furnace transformer as long as a
suitable on-load
tap changer is
available.
A primary star-
delta reconnection
switch will expand
the range.
Indirect Regulation
When equal and/or very small
voltage steps or a very long
regulating range is required,
the alternative will be the
booster regulation with two
core-coil units directly
connected in the same tank. The main unit will supply a fixed
LV component and the series unit will supply a variable and
reversible LV component. The two LV systems are connected
in series for the desired LV voltage positions and range.
Over-voltage Protection
In order to protect the HV side of the transformer from incoming
switching over-voltages, a system of RC filters and surge arresters
(SA) should be fitted to the HV side of the transformer. On the
LV side capacitors may be added to suppress over-voltages from
the arc.
Technical Features
Ratings: Up to 200 MVA
Secondary voltages: Up to 1500 V
Electrode current (steel): Up to 100 kA
Electrode current (Fe-alloy): Up to 160 kA
Design
The reactor will have the same heavy
duty as the furnace transformer itself.
Therefore the design has to be very
rugged in order to maintain stability
and linearity of the reactance. The ABB
reactors for this kind of application are
built as coreless coils surrounded by a
shielding structure of core laminations
in a 3-phase arrangement.
Technical Features
Ratings: Up to 60 MVAr
Duty
For operational flexibility the reactor will normally
be supplied with a tap changer. Depending on the
melting process and type of steel being produced
this may be an on-load or no-load tap changer
with the required number of steps.
5 4 5 4
Applications
In large long-arc steel furnaces with high arc voltages there will generally be required to
introduce extra reactance in order to stabilize the arc during operation. For this purpose,
a linear series reactor will be used. The reactor may be
built into the same tank as the furnace transformer,
or supplied as a separate unit.
AC Arc Furnace Transformers
Applications
Electric arc furnace (EAF) transformers
are required for many different
furnace processes and applications.
They are built for:
Steel furnaces, mainly long arc
Ladle furnaces
Ferroalloy furnaces and similar
with short or submerged arc
Duty
Steel arc furnace transformers
operate under very severe conditions
with regard to frequent overcurrents
and overvoltages generated by short-
circuits in the furnace and the
operation of the HV circuit breaker
(furnace breaker). The loading is
cyclic, while in other applications
the loading is more continuous at
high utilization.
Design
ABB EAF transformers are rigidly designed to
withstand repeated short circuit conditions and
high thermal stresses and to be protected against
operational overvoltages.
Design options:
Direct or indirect regulation
On-load or no-load tap changer (OLTC or NLTC)
Built-in reactor for long-arc stability
Secondary bushing arrangements and designs,
air or water cooled
Internal secondary phase
closure (internal
delta)
RC-SA high voltage
protection system
Series Reactors
Direct Regulation
The secondary voltage can be regulated by
tapping the primary winding. Step voltages over
the range will be unequal, due to the inherent
winding design, but adaptations can be made
to satisfy most requirements. A single core-coil
unit makes this the most cost-effective regulation
principle in a furnace transformer as long as a
suitable on-load
tap changer is
available.
A primary star-
delta reconnection
switch will expand
the range.
Indirect Regulation
When equal and/or very small
voltage steps or a very long
regulating range is required,
the alternative will be the
booster regulation with two
core-coil units directly
connected in the same tank. The main unit will supply a fixed
LV component and the series unit will supply a variable and
reversible LV component. The two LV systems are connected
in series for the desired LV voltage positions and range.
Over-voltage Protection
In order to protect the HV side of the transformer from incoming
switching over-voltages, a system of RC filters and surge arresters
(SA) should be fitted to the HV side of the transformer. On the
LV side capacitors may be added to suppress over-voltages from
the arc.
Technical Features
Ratings: Up to 200 MVA
Secondary voltages: Up to 1500 V
Electrode current (steel): Up to 100 kA
Electrode current (Fe-alloy): Up to 160 kA
Design
The reactor will have the same heavy
duty as the furnace transformer itself.
Therefore the design has to be very
rugged in order to maintain stability
and linearity of the reactance. The ABB
reactors for this kind of application are
built as coreless coils surrounded by a
shielding structure of core laminations
in a 3-phase arrangement.
Technical Features
Ratings: Up to 60 MVAr
Duty
For operational flexibility the reactor will normally
be supplied with a tap changer. Depending on the
melting process and type of steel being produced
this may be an on-load or no-load tap changer
with the required number of steps.
7 6 3 6
DC Arc Furnace Transformers
Applications
Most large DC arc furnaces are built for steel
production. The use of a thyristor rectifier for
the conversion to DC will normally reduce the
requirement for on-load voltage regulation of
the furnace transformer. The step voltages will be
larger than for an AC furnace transformer and a
no-load tap changer (NLTC) will in many applications
be adequate.
Duty
Being a rectifier transformer for furnace operation,
the DC furnace transformer will have to withstand
the characteristic stresses of furnace operation, as
well as the additional stresses related to rectifier
operation, including generated current harmonics.
Also, the HV side needs to be protected from
frequent switching overvoltages.
Design
DC furnace transformers are mostly built with
two axially displaced LV windings, normally
one connected in delta and one in wye, each
having a separate high voltage winding. In this
double-decker design the
transformer is connected to
two six-pulse rectifiers, adding
up to a 12-pulse system or
two parallel 6-pulse systems.
The regulation of the LV
transformer voltage is normally
done by using a NLTC in the
primary winding.
The location of the 6-pulse
rectifiers can be on the same
side of the transformer or on
opposite sides, as required
by plant layout.
Intermediate yoke
DC furnace transformers in double-decker design,
having two HV-LV voltage systems on the same
core may have an intermediate yoke to enable
largely independent operation of the two systems.
Technical Features
Ratings: Up to 120 MVA
Secondary voltages: Up to 1200 V
Electrode current: Up to over 100 kADC
Rectifier Transformers
Applications
Electrolysis processes are used for the production of metals, such as aluminium, magnesium,
copper and zinc, or chemicals, mainly chlorine. The largest installations are those for
aluminium electrolysis with several transformer/rectifier units in parallel operation to
achieve the required DC current. In all cases the rectifier can be with diodes or thyristors.
Duty
Electrolysis is generally considered to be continuous
and stable processes, but with a constant high loading
and current harmonics.
Design
Due to a large variety of applications there are
several influencing factors to consider:
Rectifier bridge connection: For medium to
high DC voltage level.
Rectifier single-way interphase connection: For
low DC voltage levels combined with high DC
currents.
Thyristor or diode rectifier.
Voltage range and step voltage.
Double-decker: HV and LV windings in
two levels and wye and delta connection
to achieve 12-pulse reaction.
Pulse numbers higher than 12: Requires
additional phase shifting windings.
LV winding arrangements: Adapted to minimize
winding hotspots and the influence of harmonics.
LV bushing arrangement: Adapted to rectifier
design and to limit structural heating.
Voltage regulation
Thyristor rectifiers normally require transformer
voltage regulation with a no-load-tap-changer
(NLTC), if any. For short voltage ranges the NLTC
can be situated in a HV tapped winding.
Diode rectifiers will in comparison have a longer
range and a higher number of smaller voltage
steps in the transformer. A multi-coarse-fine on-
load-tap-changer (OLTC) or an OLTC/NLTC
combination is preferred, together with LV-side
saturable reactors for the voltage fine-tuning. The
required double-wound or auto connected
regulating transformer can, depending on transport
or site limitations, be built into the same tank as
the rectifier transformer or into a separate tank.
Technical features
Unit ratings: Up to 160 MVA
Secondary voltage: Up to 1500 VAC
Unit process current: Up to over 100 kADC
Customized solutions by
dedicated people in focused factories.
Experience
ABB Industrial Transform ers integrates the
experience of highly dedicated people and
techniques from serveral industrial transform er
factories in various countries. This represents the
largest technology base of its kind w orldw ide.
Quality
ABBIndustrial Transformers believes
that Quality is a vital element of the product
right from the start; it can never be achieved
by checks and controls alone.
Built-in quality procedures are im plem ented even
before the designw ork starts, ensuring correct
interpretation of custom er requirem ents. Arc furnaces
and electrolysis operations put tough stresses on
transform ers. Sophisticated 2D and 3D com puter program m es calculate
dielectric, therm al and m echanical stresses, and our quality program m e enables us
to check, verify and m easure all our processes. O nly first-class sub-suppliers are
used. The ultim ate goal is to m axim ize overall quality w hich results in high
reliability and optim um transform er Life Cycle Cost. Advanced m onitoring
system s are also available.
Know-How and Research and Development
ABBIndustrial Transformers has direct access to all the combined transformer
know-how, technical experience and expertise within the ABBGroup.
This represents its current know -how base,
achieved through dedicated em ployees,
an excellent IT structure and undisputed
leadership in Research and D evelopm ent.
ABB Industrial Transform ers is continuously
enlarging this base and finding solutions for
the future now .
Partnership & Service
ABBIndustrial Transformers designs tailor-made,
high-current solutions for all our industrial customers.
W e are com m itted to being a flexible and know ledgeable partner
for you w orldw ide. Together w e can analyze individual needs
and help to ensure that you w ill receive the optim al transform er
solution to suit your requirem ents.
ABB Industrial Transform ersglobal netw ork provides
on-dem and custom er service and support. O ur interpre-
tations of dissolved gas analysis have been recorded and
system ized.
Focused Factories
ABB Industrial Transform ers now concentrates
Research and D evelopm ent, engineering, m anu-
facturing and service for industrial transform ers
prim arily at tw o specialized and globally focused
factories w ithin the ABB group, located at
Legnano, Italy and Bad H onnef, G erm any.
Large Drives Converter Transformers
Applications
For special applications, such as large pum ping
stations, w ind tunnels and rolling stock, a transform er
com bined w ith a frequency converter w ill supply
the input for a variable speed system . For fixed
railw ay feeding stations a conversion from norm al
grid frequency to railw ay frequency takes place in
a sim ilar w ay.
Duty
The duty is m uch related to type of application.
In pum ping stations a high loading w ith lim ited
variation over tim e can be expected, w hile in
other applications there m ay be a m ore interm ittent
duty cycle w ith load peaks.
Design
D rives transform ers are m ostly built w ith tw o
secondary and tw o prim ary w indings, allow ing
for a 12-pulse rectifier reaction. Such transform ers
are norm ally built w ith a tertiary w inding system
connected to a filter bank to take out harm onics
created by the converter. D ue to the operation
cycles of the converters, there are strong require-
m ents for correct inter-w inding im pedance
relations and accuracy.
Technical Features
Ratings: U p to 137 M VA
Secondary voltages: U p to 13,4 kV
7
ABB Industrial Transformers
The largest technology base worldwide
L
e
a
f
le
t

n
o
.

1

L
A
B

0
0
0
0
1
9


P
r
in
t
e
d

in

G
e
r
m
a
n
y

(
0
9
.
0
4
-
x
x
x
x
-
P
P
I
)
ABB Industrial Transformers.
Unified power for your success.
Series Reactors for AC Arc Furnaces
Most AC steel furnaces will require a series reactor
in the primary.
For long-arc steel furnace operation additional reactance is
norm ally required to stabilize the arc and optim ize the operation.
A series reactor for this purpose is built into the furnace transform er
tank itself or supplied separately.
AC Arc Furnace Transformers
Furnace transformers for long-arc (steel)
and short-arc (ferroalloy) operation.
ABB produces transform ers for all furnace applications. A robust design
guarantees m echanical strength for steel furnace operation and tem perature
control for continuous high loads in ferroalloy operation.
DC Arc Furnace Transformers
DC arc furnaces are mainly for steel production.
Transform ers for D C furnace operation norm ally com e in a transform er/rectifier
package. The full package can be m anufactured/supplied by ABB.
Rectifier Transformers
For various electrolysis applications like aluminium
and other metals and chlorine.
Rectifier transform ers are com bined w ith a diode or thyristor
rectifier. The applications range from very large alum inium
electrolysis to various m edium size operations.
The transform ers m ay have a built-in or
separate voltage regulation unit.
Large Drives Converter Transformers
Drives systems for pumping stations,
wind tunnels and traction feeding.
The transform ers are com bined w ith a thyristor rectifier for
variable speed drives (VSD ) system s or frequency conversion.
ABB AG
Transformers
Lohfelder Strasse 19-21
53604 Bad Honnef
GERMANY
Phone: +49(0) 2224/14-0
E-mail: info@abb.com
Internet: www.abb.com/transformers
ABB Power Technologies S.p.A.
Unit Operativa Trasformatori di Potenza
Via Giotto, 10
20025 Legnano (MI)
ITALY
Phone: +390331479307
E-mail: info@abb.com
Internet: www.abb.com/transformers
N
o
t
e
:
W
e

r
e
s
e
r
v
e

t
h
e

r
ig
h
t

t
o

m
a
k
e

t
e
c
h
n
ic
a
l
c
h
a
n
g
e
s

o
r

m
o
d
if
y

t
h
e

c
o
n
t
e
n
t
s

o
f

t
h
is
d
o
c
u
m
e
n
t

w
it
h
o
u
t

p
r
io
r

n
o
t
ic
e
.

W
it
h

r
e
g
a
r
d

t
o

p
u
r
c
h
a
s
e

o
r
d
e
r
s
,

t
h
e

a
g
r
e
e
d
p
a
r
t
ic
u
la
r
s

s
h
a
ll
p
r
e
v
a
il.
A
B
B

d
o
e
s

n
o
t

a
c
c
e
p
t

a
n
y

r
e
s
p
o
n
s
ib
ilit
y

w
h
a
t
s
o
e
v
e
r

f
o
r

p
o
t
e
n
t
ia
l
e
r
r
o
r
s
o
r

p
o
s
s
ib
le

la
c
k

o
f

in
f
o
r
m
a
t
io
n

in

t
h
is

d
o
c
u
m
e
n
t
.
W
e

r
e
s
e
r
v
e

a
ll
r
ig
h
t
s

in

t
h
is

d
o
c
u
m
e
n
t

a
n
d

in

t
h
e

s
u
b
je
c
t

m
a
t
t
e
r

a
n
d

illu
s
t
r
a
t
io
n
s
c
o
n
t
a
in
e
d

t
h
e
r
e
in
.

A
n
y

r
e
p
r
o
d
u
c
t
io
n

in

w
h
o
le

o
r

in

p
a
r
t
s

is

f
o
r
b
id
d
e
n

w
it
h
o
u
t
A
B
B

s

p
r
io
r

w
r
it
t
e
n

c
o
n
s
e
n
t
.
C
o
p
y
r
ig
h
t

2
0
0
3

A
B
B
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.