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Transforming the future of energy

ABB Transformer Days
Vadodara

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11-12 APRIL, 2019

Transformers for Stronger and Greener Rail Transport

Traction Transformers for Rolling Stock
Valter Porcellato
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ABB traction transformer - Introduction
Market trends & drivers in rail transport

Steadily growth in Rail transport World rolling stock market trend up to 2023
Rail transport is a steadily growing market
through the years
Market trends:

– Global Population growth /Urbanisation

(more demand & push for public transports)

– Environment friendliness / Sustainability

(less emissions than cars/airplanes)

– Economical / Safer
(less expensive than individual transp., much lower accident rate
Source: UNIFE study 2018
than cars)

April 22, 2019 Slide 2

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ABB traction transformer - Introduction
Market trends & drivers in rail transport

Greener transport
• Reduction of energy consumption (less power losses, less weight)
• Focus on recycling and end of life disposal of the equipment

Safer transport
• Products and solutions with the safety and health of people in mind

Reduction of Total Cost of Ownership

• Reduction of operating cost (where energy cost has a substantial contribution)
• Reduction of maintenance cost ( by stronger products or towards predictive / condition-based maintenance)

Higher availability and reliability

• Customers expect enhanced reliability and availability. (by the product itself and/or by remote control, predictive maintenance)

April 22, 2019 Slide 3

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ABB traction transformer - Challenges
Specificity

Why not use a standard transformer for traction application ?

Specific network – Single phase networks with various voltages and frequencies. Often multi-system in EU,US

The largest & heaviest E component – Need to be compact & light for axles load limit and to offer more for equipment and passengers

Need to feed various train functions – Multiple secondaries to supply propulsion converters, auxiliaries, heating, Hotel Load, ….

EMC requirements – To protect people, axles counters, others near train components

Suitable for various trains & mounting – For Locomotives, High Speed, Electrical Multiple Unit for underframe, machine room & roof

Exposed to over-voltages & transients – Pantograph tripping's, neutral sections from HV side and high Du/Dt from converters side

Power load cycle – Loading profile expose transformer to fast and variable power load (accelerations, mountains)

Environmental withstand – For harsh environment conditions (e.g. deserts, - 50° C, ice, snow, flooding, etc.)

Shock & Vibrations – Subject to high shocks & vibrations associated to harsh environment conditions

Safety – Proximity with people require safety supervision, fire & smoke requirements

April 22, 2019 Slide 4

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ABB traction transformer - Challenges
Example of AC train electrical system

Main
Transformer
4 tractions
1 filter
1 auxiliary

2 x 2nd
harmonic
inductances

2 x 3ph
Aux. T

April 22, 2019 Slide 5

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ABB traction transformer - Challenges
Product mounting solutions and mechanical integration

Roof Machine room Underframe

April 22, 2019 Slide 6

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ABB traction transformer solutions and values
Global producer with focus factories: 8 sites in 7 countries

Germany
Poland
Switzerland
USA

China

India

Factories South Africa

Assembly units
Feeder factories

We are in India since end of the 90’s our 1st localization in traction transformer

April 22, 2019 Slide 7

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ABB traction transformer solutions and values
Two factories in India : 2 sites in Vadodara (Maneja and Savli)

Maneja

April 22, 2019 Slide 8

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ABB traction transformer solutions and values
Solutions references: MRVC - Bombardier

CUSTOMER NEEDS
– An integrated, under-frame AC metro transformer with
incorporated cooling system. PLEASE CHANGE THE PHOTO
– Energy efficient, reliable and safe for passenger movement.

ABB RESPONSE
– A domestic production reinforced by local suppliers
developments resulted in an increased “Make in India concept”
– Design and production transfer solution by ABB Geneva
– Tailored solution to client need.

CUSTOMER BENEFITS
– A compact, light and safe solution
– Production in India and proximity to the traction transformer
factory in Vadodara
3'000 kg

April 22, 2019 Slide 9

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ABB traction transformer solutions and values
Solutions references: Madhepura - Alstom

CUSTOMER NEEDS
– Transformer for high-power Electric locomotive. 12,000HP
(horsepower) locomotive hauling the speed of trains up to
150kmph.
– Compact transformers (2 per locomotives) for the most
demanding conditions, including extreme temperatures and
voltage fluctuations.

ABB RESPONSE
– Tailor made light and compact solution to offer a higher level of
performance for the largest ABB traction transformer order
7'800 kg
(1600 TT over 11 years).
– Deep system optimization involving the customer to maximize
product performances and costs.

CUSTOMER BENEFITS
– Optimized locomotive transformer offering reduced life
cycle cost and produced in India.

April 22, 2019 Slide 10

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ABB traction transformer solutions and values
Next generation of traction transformers

Market trends & drivers in rail transport Our solutions: Effilight and RESIBLOC Rail

April 22, 2019 Slide 11

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ABB traction transformer solutions and values
Effilight®: Next generation of oil traction transformer

Traditional Technology

Effilight Technology
“Do more with less”

April 22, 2019 Slide 12

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ABB traction transformer solutions and values
Effilight®: Next generation of oil traction transformers

Transformer active part is fully immersed in oil Traditional traction transformer

Traditional state of art solution

April 22, 2019 Slide 13

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ABB traction transformer solutions and values
Effilight®: Next generation of oil traction transformers

A patented cell enclosure Only windings are immersed in oil Traditional traction transformer

Effilight the next generation of traction transformer solution

April 22, 2019 Slide 14

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ABB traction transformer solutions and values
Effilight®: Next generation of oil traction transformers

Customer benefits Average weight benefit Average efficiency benefit

Less oil
Power 15 kV/16.7 Hz 25 kV/50 Hz Power 15 kV/16.7 Hz 25 kV/50 Hz
Flexibility in design to save weight AND/OR
improve energy efficiency at the same time 1.0 MVA Up to -20% – 1.0 MVA Up to +50% –
Reduction of cooling unit size and power 2.0 MVA -10 to -15% -20% 2.0 MVA +20 to +30% Up to +50%
Possibility to reduce the acoustic noise level 3.0 MVA Up to -10% -15% 3.0 MVA Up to +20% +20 to +40%
– Invest more weight into the core to reduce 4.0 MVA – Up to -10% 4.0 MVA – Up to +20%
induction level
– Damping of core related noise is easier in air
– More power cooler and let it run half speed all
the time
Possibility to cool the transformer with wind
generated by the speed of the train

April 22, 2019 Slide 15

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ABB traction transformer solutions and values
Effilight®: Next generation of oil traction transformers

Effilight version efficient

Traditional traction
transformer
1 MVA, 15 kV, 16,7 Hz

Effilight version light

April 22, 2019 Slide 16

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ABB traction transformer solutions and values
Conclusion: Effilight® Next generation of oil traction transformers

Unique and Maximum

patented weight saving
design

Modular design
to multiply
customer
options

Maximum
Improve CO2
energy
emissions
efficiency
savings

Reducing energy losses by up to 50%

April 22, 2019 Slide 17

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ABB traction transformer solutions and values
RESIBLOC® Rail: New generation of dry traction transformers

Introduction
- For more than 40 years, RESIBLOC® ABB technology has been
the solution for special requirements transformers.
- Thanks to the special characteristics in terms of stability,
durability and performance, RESIBLOC® transformers are
often used in applications with strigent requirements. Such as
Oil & Gas platforms, marine and mining applications, ...
- The oil-free RESIBLOC transformer enables a safe and reliable
design to meet the highest requirements and at the same
time delivers very high energy efficiency performance.
- ABB has now adapted this technology for railways use.
- This development went into the active testing phase in 2012,
and currently more than 155 RESIBLOC® Rail transformers are
successfully in operation.

April 5, 2019 Slide 18

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ABB traction transformer solutions and values
RESIBLOC® Rail: New generation of traction transformers (dry)

Increase Security and Eco-efficiency

- Dry Transformers ensure safety for people
and the environment
- Dry Transformers with fibre-glass/epoxy
insulation have a very low fire load and self-
extinguishing properties

Petroleum/Ester * 33,600 MJ 100%

Epoxy/Glass 2,000 MJ 6%

- No risk of leakage, contamination

- Simple recycling (contains no hazardous
substances)
- Substantial losses reduction
- CO2 reduction compared to traditional
transformers

800 kg Oil
April 5, 2019 Slide 19 250 kg Epoxy (The 80% glass content is non organic)
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ABB traction transformer solutions and values
RESIBLOC® Rail: New generation of traction transformers (dry)

LCC consideration transformer Savings potential

2 x 1 MVA (15kV, 16 2/3 Hz) transformers for 10%
Flirt (STADLER RAIL- Swiss regional train
"FLIRT") Trafo 97%
- Energy costs and maintenance costs in the 10%
Driving
lifecycle significantly exceed acquisition Resistance
costs. 40%
Converter
- With a typical breakdown of the energy
10%
consumption on the vehicle, about 20% is
attribued to the transformer losses.
- An Increase in efficiency of the tranformer
from 94% to 97% corresponds to about Driving Engine
10%
10% reduction in energy consumption.
- In regards to the oil transformer, the
RESIBLOC® Rail transformer can be Comfort Systems
operated almost without maintenance. 20%

April 5, 2019 Slide 20

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ABB traction transformer solutions and values
RESIBLOC® Rail: New generation of traction transformers (dry)

Maintenance-saving / lower downtime

No Oil
No oil, pumps, seals, pipes, air dyer, no pumps
- No exchange, no visual checks
- No routine work, E.g. Silica gel Change
- No oil contamination possible. May eliminate cleaning
expenses
- No spare parts stock (pumps, bearings, ...)
- No handling cooling Medium
Lower complexity

April 5, 2019 Slide 21

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ABB traction transformer solutions and values
Conclusion: RESIBLOC® Rail: New generation of traction transformers (dry)

April 22, 2019 Slide 22

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Key Takeaways

1. ABB State of art traditional traction transformer solutions are serving most of the train OEM's and systems
integrators over the world in a challenging product environment.

2. This is recognized by the market and customers in offering since years to ABB the position of market leader.

This is a privilege but also a mission for ABB to continue to push the technology boundaries and offer better
traction transformers.

Effilight and Resibloc Rail are two examples in how ABB is proposing stronger and greener solutions for a better
world.

April 22, 2019 Slide 23