Transformers & Transformer Services: Overview of Products and Services For University of Illinois ECE 431

ABB Transformers and Transformer Remanufacturing and
Engineering Services Overview for ECE 431
Transformers & Transformer Remanufacturing and Engineering Services
Transformers & Transformer Services

Overview of products and services for
University of Illinois ECE 431
© ABB Inc. 2015
A global leader in power and automation technologies

Leading market positions in main businesses
~145,000
$ 42 billion
In revenue
employees (2013)
Present Formed
in in
+100 1988
countries merger of Swiss (BBC, 1891)
and Swedish (ASEA, 1883)
engineering companies
© ABB Group
March 21, 2015 | Slide 2
Copyright © ABB Inc. 2015

All rights reserved. Any reproduction – in whole or in part – 1 March 19, 2015
is forbidden without ABB’s prior written consent.
Power and productivity for a better world

ABB’s vision
As one of the world’s leading engineering companies, we

help our customers to use electrical power efficiently, to
increase industrial productivity and to lower environmental
impact in a sustainable way.
© ABB Group
How ABB is organized

Five global divisions
© ABB Group

Power and automation are all around us

You will find ABB technology…
orbiting the earth and working

beneath it,
crossing oceans and on the sea bed,
in the fields that grow our crops and

packing the food we eat,
on the trains we ride and in the

facilities that process our water,
in the plants that generate our power

and in our homes, offices and
factories
© ABB Group
Tackling society’s challenges on path to low-carbon era

Helping customers do more using less
Rise in electricity demand by 2035 ABB power and automation

(under current policies) solutions are:
Source: IEA, World Energy Outlook 2013
In thousand Terawatt-hours (TWh)

 Meeting rising demand for electricity
40
 Increasing energy efficiency and reducing
CO2 emissions
35  Improving productivity to raise
competitiveness of businesses
30 and utilities
25 +92
20 %
15
10
0
2011 2035
Electricity demand is calculated as the total gross electricity
generated less own use in the production of electricity and
transmission, and distribution losses.
© ABB Group

Improving capacity, reliability and efficiency in the grid

A pioneer in smart technologies
Texas
Improving efficiency of Jinping-Sunan
wholesale electricity
Delivering 7,200MW
market and reducing
of hydropower over
transmission congestion
2,000 km with
minimal losses
Karnataka
Improving reliability
in grid serving state
(pop. 53 million)
© ABB Group
Renewable energy
Key growth driver for both power and automation
© ABB Group

Boosting productivity and energy efficiency

Example: Stora Enso, world’s biggest paper maker
 Skoghall mill, Sweden:

 No. 1 maker of board for drink cartons
 Two-year revamp boosted productivity and cut CO2 by 170,000
tons/year
 ABB provided key control systems:
 For boiler, collecting and analyzing data on pressure, flow,
temperature, etc. from thousands of instruments
 For total control over power supply with real-time data
© ABB Group
Leading power system’s biggest-ever transformation

Smarter, greener grid for more efficiency and reliability
 Merging power and automation technologies makes electricity

network more reliable, flexible, secure and efficient. Smart grid
benefits include:
 Lower power consumption
 Greater use of renewable energy
 ABB’s broad offering in both power and automation
technologies positions it uniquely to support this evolution
 Transformation of grid to take place over several decades
© ABB Group

Software across industries and across the Group

Enhancing operations and raising business performance
Embedded software
Office
 From protection logic in our relays to interactive

functionality in our measurement devices and
Remote robot controllers, embedded software is a key
control
center
component of many ABB products and systems
Software systems
Local
control
center  Used to control and coordinate operational
processes across industry sectors, from
Plant floor
chemical plants to power grids
Enterprise software
 Boosted by recent acquisitions, this category
Power enables ABB to bridge the divide between
grid
operational data and business intelligence,
delivering actionable information
© ABB Group
Services across the entire value chain

Creating measurable performance improvements
Value-creating partnerships
 Co-develop solutions
Advanced services  Strategic partnerships
 Process improvement  Value-based offerings
 Lifecycle management  Productivity and energy
Responsive service efficiency solutions
 Software services
 Installation &  Consulting
 Evolution programs
commissioning
 Optimization solutions
 Break & fix
 Remote solutions
 Technical support
 Spare parts
 Training
© ABB Group

Shaping the world we know today through innovation

Pioneering technology since 1883
© ABB Group
Innovation is key to ABB’s competitive advantage

Leadership built on consistent R&D investment
 More than $1.5 billion invested annually in R&D

 8,000 scientists and engineers
 Collaboration with 70 universities
© ABB Group

Developing sustainability of products and operations

Lowering environmental impact and costs
Sustainable products Sustainable operations

 Focus on resource and energy  Cuts targeted in use of energy, raw
efficiency of equipment over life cycle materials, hazardous substances
 Helping customers do more with less
© ABB Group
People make the difference

The best want to work in a first-class environment
 ABB is one of the world’s most global companies

 A culture of openness, flexibility and inclusiveness helps to
attract top performers
 ABB strives for excellence in personal development,
operational execution, health and safety, business ethics
 A Group-wide staff development program aims to bring a
culture of leadership to every level of the organization
© ABB Group

Committed to the highest standards of business ethics

Integrity as bedrock of ABB’s global culture
“At ABB performance is measured not only by

the results achieved, but also how these
results were achieved. This is why our
stakeholders can rely on the fact that our
services, operations and daily business are
based on ethical behavior.”
CEO Ulrich Spiesshofer in ABB’s Code of Conduct
 Code of Conduct defines relationships with all stakeholders
 Employees acknowledge Code of Conduct and take compulsory
training courses
 Zero tolerance toward violations
 Several reporting options in place for employees to report
suspected violations; each report thoroughly investigated
© ABB Group
A successful business and a reliable partner

Strong financial position is competitive advantage
Revenue (US$ million) by quarter

and annual operational EBITDA margin
50000 20%
18%
40000 16% 13 –19%
14% operational EBITDA
30000 12% margin corridor targeted
10% for period 2011-2015
20000 8%
6% Q4
10000 4% Q3
2% Q2
0 0% Q1
2010 2011 2012 2013
© ABB Group

More than $14 bln invested for growth since 2008

Main acquisitions and capital investment 2012/2013
New plants and expansions
Main acquisitions
and investments 2012 2013
Newave, Thomas & Betts, APS, Dynamotive, Newron
Tropos, RGM, Bob White Systems, Power One, EL-BI,
Electrix / L.E. Jarvis Alstom Ring Motors, Los
Gatos Research
© ABB Group
Well-balanced business and geographic portfolio

Capturing growth opportunities, wherever they arise
Orders by division Share of employees

% of total orders 2013 (non-consolidated) 2013 (approximate)
25% Power products

14% Power systems
23% Discrete automation and motion
19% Low voltage products
19% Process automation
Orders by region
% of total orders 2013
34% Europe
27% Asia
45% Emerging markets
29% Americas 55% Mature markets
10% Middle East and Africa
© ABB Group

Innovation, passion and diversity are hallmarks of ABB
“As a global leader in power and

automation technologies, ABB is
continuously pioneering reliable, cleaner
and more efficient energy and automation
solutions, helping its customers increase
the productivity of their industrial and
infrastructure operations.”
CEO Ulrich Spiesshofer
© ABB Group
A global leader in power and automation technologies

Leading market positions in main businesses
 145,000 employees in about 100

countries
 $42 billion in revenue (2013)
 Formed in 1988 merger of Swiss and
Swedish engineering companies
 Acquired Westinghouse (& GE large
power) transformers in 1989
 Predecessors founded in 1883 and 1891
(Westinghouse & GE in the 1880’s)
 Publicly owned company with head
office in Switzerland
 Region Headquarters in Raleigh, NC
 More than 30,000 employees working in
the United States, Canada, and Mexico
© ABB Inc. 2015 - Slide 22

ABB North America Footprint
Fort Nelson
Fort McMurray
Fort St John
Grande Prairie
Fox Creek Bonnyville
Edmonton
Edson
Rocky Mtn House Stettler
Eckville Red Deer
Calgary
Winnipeg
Vancouver
Jonquière
Saanichton Thunder Bay
Quebec City Saint Jean
Tacoma St Laurent Saint Claire
Sudbury Montreal Varennes
NAM REGION Hager City Iberville
Pointe Claire
Lachine
St Remi Saint John
Dorval Bromont
Combined Locations Scarborough
Stratford
Whitby
Brampton
New Berlin Burlington
Auburn Hills Stratford
Westland Mercer
Chicago Wickliffe Windsor
Boulder Cleveland Natrona Hts
Westerville Danbury
Pittsburgh Hackettstown
Napa Aurora Mt Pleasant/Greensburg North Brunswick
St Louis Warminster
Lewisburg Richmond
Santa Clara Mountain View Jefferson City South Boston
San Jose Sunnyvale Bland Hickory
Pinetops
Albuquerque Bartlesville Rogersville Marion • Cary
Claremore Nashville Crossville
Portland Asheville • Raleigh
Camarillo Westville Clarksville Huntersville
Carson Phoenix Athens,TN
Fort Smith Alamo Atlanta Kings Mountain
San Diego Memphis Clio
Byhalia Florence
Charleston
Greenville
Zaragoza Midland Belton
Houston Athens,GA
Sugarland
Pleasanton Ozark Gadsden Ormond Beach
Jonesboro Birmingham Lake Mary
South Haven
Gainesville
Prairieville Coral Springs
Columbus
Monterrey New Orleans Miramar
Crystal Springs
San Luis Potosí Vega Baja

Guanajuato
Jalisco Mexico City
Veracruz
© ABB Inc.
Transformers
One stop shop supplier
History
 125+ yr business
 > 20 companies
Facts
 Sales in 110 countries
 Orders & Rev: 6 BUSD
 55 locations in 23 countries
 16 500 employees
 Range: 10 kVA to 1600 MVA
 Global management team:
8 nationalities
 Homepage:
www.abb.com /transformers

World Map ABB Transformer Factories 2015

Sweden – Ludvika
Norway – Steinkjer
Sweden – Pitea
Norway – Drammen
Finland – Vaasa
Ireland – Waterford Russia – Khotkovo
Canada – Edmonton Germany – Brilon Sweden – Mjolby
Canada – Quebec City Germany – Bad Honnef Sweden – Figeholm
Germany – Roigheim Poland – Lodz
Canada – Varennes
Germany – Halle
USA – South Boston Italy– Legnano
China– Hefei
USA – Bland Switzerland – Geneve Italy– Monselice
USA - Jefferson City Spain – Bilbao South Korea – Chonan-si

Turkey– Istanbu China– Chongquing
Spain – Zaragosa
USA – St Louis Switzerland – Zurich
USA – Alamo
Spain – Cordoba
USA – Crystal Springs China– Shanghai
Egypt – 10th of Ramadan China– Zhongshan
Saudi Arabia – Riyadh

Vietnam – Hanoi
India – Baroda
Thailand – Bangkok
Singapore – Singapore
Tanzania – Arusha
Columbia – Pereira
Peru – Lima Australia – Darra

Brazil – Guarulhos
South Africa – Pretoria
South Africa – Booysens

Brazil – Blumenau
Australia – Perth
South Africa – Cape Town
• 54 Factories in 28 Countries New Zealand – New Plymouth

• Sales to 130 Countries
Transformers are all around us in different segments

You will find ABB transformers…
in buildings and in airports we use when

traveling,
crossing oceans and on the sea bed,
in substations that power our industrial

areas,
on the trains we ride and in the facilities

that process our water,
in windmills, solar fields, urban areas and

households.

Transformers are all around us in different applications

Wherever you are, transformers are near by
1 6
Traction and Dry type distribution
distribution transformers
transformers 7 8
2 6 7
Distribution Subsea
transformers transformers
3 8
Power and 5 10 Dry type distribution
distribution 3 transformers
transformers
9
4 9
Power transformers Power and
4 distribution
transformers
5 10
Low sound emitting Power transformers
transformers
1 2
ABB Transformers
Technologies
Rated voltage
Power Transformers
161 kV Small Power Transformers
72.5 kV Dry Type

CORE TYPE
Liquid filled
36 kV
distribution
SHELL TYPE
10 MVA 40 MVA 63 MVA Rated power
Four common technology platforms guaranteeing highest quality

Transformers
Complete portfolio – product offering
What ever you need
from our broad
Generator step-up, Network
portfolio ->
ABB is your “one-stop
Large Medium Coupling, Shell, Shunt Reactors,
shop” supplier Small Power Phase-Shifting & HVDC, etc.
Large Medium 1ph, 3ph, Mineral, Silicon, Midel,

Small BioTemp®, Pole, Pad, Ground,
Distribution Sub-Sea, Cooling, etc.
Cast Coil, Open Wound,

Dry Type RESIBLOC®, Vacuum Pressure
Distribution Impregnated, VP
Encapsulated, etc.
AC Furnace, DC Furnaces, DC
Industrial & Electrolysis Process (Al, Cl), AC
Special series Reactors, etc.
IEEE/ANSI & IEC standards
Transformer components
Insulation and components for transformers
 Pressboard  Protection & Preservation Systems

 Winding and Active Kits  Renewal Parts
 Transformer Bushings  Insulation Materials
 Tap Changers  Hollow Composite Insulators
 Diagnostic & Control Systems  Distribution components
In-house technology

Energy efficient and green solutions for a better world

Technology trends reflecting environmental needs
EcoDry family – dry type transformers
 Highest efficiency dry type transformer for industrial and utility
applications reducing no load loss by 2/3 and load loss by 1/3
The green liquid filled distribution transformer program

 Energy efficient products and solutions for lower CO2 emissions
 The amorphous metal distribution transformer is one concept of the
green program
Natural and Synthetic Esters
 Natural ester-based dielectric fluids
 Biodegradable insulating fluid made out of seeds
 A complete and sustainable solution for both distribution and power
transformers associating environmental friendliness (high
biodegradability), safety (superior fire resistance), and efficiency (high
overload capacity)
Ultra low sound emitting transformers
 20-25 decibles dB(A) below conventional noise specifications
 dB(A) reduction without use of sound panels or sound enclosures
Transformers for special applications

Experience well beyond standard power transformer
applications
 Generator Step up  Arc furnaces

 Excitation  Rectifiers
 Substation T&D  Boosters
Phase Shifter  Marine
 HVDC converters  Offshore distribution
 Reactors  Traction
 Step down  Variable speed drives
 Solar energy  Windmills

ABB Transformers
Factories in North America
Edmonton
St. Louis Quebec
Varennes
Bland
South
Jefferson City Boston
Alamo
(Athens)
Crystal
Springs
ABB Power Transformers - North America

Transformers Product Scope Top Rated (MVA)
System kV
LPT
275 kV
345 kV
Varennes
MPT
St. Louis
172 kV
SPT
72.5 kV South Boston
Crystal Springs
36 kV
DTR
3Ф, Top Rating

6.25 MVA 63 MVA 150 MVA 300
200MVA
MVA


Varennes, Quebec, Canada
 Built in 1971 by ASEA
 260,000 square feet
 300+ employees
 Plant's average ANNUAL production
capacity: 20,000 MVA
 Production capacity:
 Ratings from 200 to 1200 MVA
 Rated Voltage up to 800 kV
 BIL max: 2400 kV
 Shunt reactors of 5 to 300 MVAr
 Independent test lab, connected by
rail, one mile away.
 Quality/Certificates: ISO 9001, ISO
14001
 Current lead time: 15 months EXW

ABB IREQ HV
Varennes Laboratory


ABB Varennes builds the largest, most sophisticated
power transformers in North America
1200 MVA, 735 kV




St. Louis, Missouri, USA
 10 minutes from Lambert International Airport, located
in industrial area, between airport & downtown
 ABB hotel agreements near airport & downtown ($70-
100/night)
 Built in 1950’s by Moloney Electric
 Westinghouse purchased 1975 as a repair facility
 Upgraded in 1985 for new transformer production
 Recent investments: over $1M USD test floor upgrade
in 2013
 Over 300,000 square feet
 All new transformers produced to TrafoStar technology
 Waste elimination through TPS – Transformer
Production System
 Daily management GEMBA walks insures early issue
identification and resolution
 4Q quality quadrant approach
 Sigma cards document process control & quality
 Certifications:
 ISO 9001
 ISO 14001

 Capacity:
 Total output >12,000 MVA per year
 Average MVA >170 MVA per transformer
 Produces about 60-75 units per year
 230+ employees: First shift full, partial 2nd shift,
skeleton 3rd shift
 Non-union facility, very flexible workforce
 Average tenure 21 years
 Thorough interview & training process with continuous
refresher courses for all employees
 Dielectric test capability up to 345 kV, 1300 kV BIL
 Full thermal test capability through 500 MVA
 Mobile AC test system based in St. Louis allows full
PD testing for transformers through 765kV
 200 ton crane with 70’ lift, 150 ton crane with 45’ lift
 Service and Repair Center for US, Canada and
Mexico; dedicated/separate repair area


 ABB Focused Factory for Technically Challenging
Medium Power Transformers (>63 MVA, up to 500
MVA for autotransformers)
 Customer focused sales organization, covering all
transformers sold into North America
 Thorough technical and commercial specification
review
 All quotations fully designed with a production capable
design (4 designers focused on St. Louis units)
 Engineering Staff:
 5 electrical designers
 13 mechanical designers
 2 controls engineers
 Engineers participate in KCC training every 2-3 years
 Current Lead Time: 6-8 months ARO EXW

Capability
 Center of Excellence for development, design and
technical assessment of new power transformers
 Specializes in technically challenging medium
power transformers
 Repair and Assessment Center of Excellence
 TRES “owns” and maintains an archive of original
technical & manufacturing information for:
 Westinghouse (US & Canada)
 GE (Pittsfield Large Power & Canadian GE)
 Kuhlman
 Moloney Electric
 ABB; including Asea, BBC, EB National
Industri, Strömberg and others
representing 70-80% of US installed base of
power transformers

Movies should be screened in the

grey area as featured here, size
proportion 4:3. No titles should be
used.
ABB St. Louis featured on Fox Business Network

https://www.youtube.com/watch?v=HaK8vLSyphY

SPT – Crystal Springs, MS and South Boston, VA
South Boston, Virginia Crystal Springs, Mississippi (Since 1953)

2006 greenfield expansion for MPT Line Substation Transformers 1 and 3 Phase
up to 161kV and 63 MVA Oil-Filled Instrument Transformers (HV)
Network Transformers (DTR) Field Services
Unit Substation Transformers 179,000 square feet / 16 acres
3 phase Padmount Transformers 25,600 sq ft used for Oil-filled Instrument
Substation Transformers 1 and 3 Phase transformer production
Field Services ISO 9001 Registered (UL)
>100,000 sq ft IUE-CWA Local 83799 (Since 1974)
ISO 9001 Registered (UL)
Non-union


South Boston, Virginia, USA
 Factory Facts (Line 1)

 Built in 1968
 Area: >400,000 sq. ft.
 Employees: 450+
 Maximum MVA capability: 20 MVA
 Maximum voltage & BIL capability: 69
kV, 350 BIL
 2006 expansion for MPT Line – up to
161kV and 63 MVA – increased size
to >510,000 sq. ft.
 Scope of Supply
 Liquid Filled small power transformers,
including substation, secondary unit
substation, network, and padmounted.
ABB Power Transformers

Cordoba, Spain
Founded in 1930, taken over by Westinghouse in 1970
(plant enlargement, technology transfer/license)
First 525 kV unit built in 1980
Taken over by ABB and further upgraded in 1990
Plant capacity: 15,000 MVA (shell form + core form)
Capability through 525 kV, 1800 kV BIL, 1200 MVA
Employees: 300+
ABB Global Center of Excellence for Shell Form
Transformers
Certifications: ISO 9001, ISO 14001
Product range:
Core form (> 200 MVA)
Shell form (large GSU, autos, fast deployable
transformers, POLYTRANSFORMERS
Current lead time EXW:
Shell-form: 12 months ARO
Core-form: 14 months ARO

ABB Shell Transformers – Cordoba, Spain

Highlights / Main Features
 ABB Shell covers all transformer applications
especially in the large power range up to 1200MVA
and very high voltages, providing a compact and
robust alternative.
 Some important features are:
 State of the art design tools and manufacturing
processes.
 High efficiency with low losses and controlled hot
spots to increase life expectancy.
 Compact design to meet transportation limits.
 Exceptional natural mechanical robustness for
short circuit events and transport accelerations,
making them uniquely suited for high-current
industrial applications requiring excellent through-
fault performance.
 Flexibility to electrically and mechanically match
existing units to meet dimensional, connection
arrangements and impedance requirements.
 Simple retrofit and repair process.
ABB Shell Transformers

Highlights Main Applications
The main applications are:

 Generator step up transformers: Nuclear power
plants and other generating stations.
 Substation autotransformers: Interconnection
between high voltage transmission lines.
 Multi-voltage transformers: Spares,
contingency planning and asset management.
 Polytransformers: Multi-voltage
autotransformer planned to substitute within
an existing fleet a wide number of substation
transformers.
 Universal GSU’s: To replace different units
in several power plants, even with different
power outputs, generator voltages or
physical arrangements.
 Industrial Transformers: Uniquely suited for
high-power/current industrial applications
requiring excellent mechanical stability.
 Replacement of existing units: Matching
dimensions and characteristics.

ABB Shell Transformers

Large GSU’s
 1100MVA 3ph GSU 345kV at QC1 Exelon NPP (USA)

Bad Honnef, Germany
 Built in 1906 as August Lepper GmbH;
purchased by Asea in 1965; ABB since 1988
 300+ employees
 German Headquarters of Transformer
Business (Bad Honnef, Halle and Brilon)
 TrafoStar Development Group Headquarters
 Home of KCC (Transformer Knowledge
Communication Center)
 ABB Focused Factory for Phase Shifting
Transformers and Industrial Transformers
 About 75 units per year
 Up to 500 kV
 300 ton crane
 Certifications: ISO 9001, ISO 14001, KTA
 Current leadtime for PST: 15 months ARO
EXW


Ludvika, Sweden
 Built in 1900 as Elektriska AB Magnet
 Purchased by Asea in 1916, ABB from
1988
 500+ employees
 ABB Focus Factory for Large power
transformers, 800 kV, HVDC, reactors
 About 80 units per year
 Up to 800 kV, (delivered one 765 kV to
USA in 1978)
 400 ton crane
 Certifications:
 ISO 9001, ISO 14001
 Current leadtime: 15 months EXW

for Shunt Reactors

Lodz, Poland
• Production of Power Transformers since

1925, Elta purchased by ABB in 1991
• Over 350,000 square feet
• 900+ employees
• ABB Focus Factory - Medium Power
Transformers, <250MVA, up to 345kV
• About 60 units per year
• Distribution Transformers
• Insulation Kit Centre for southern Europe
• 250 ton Lifting Capacity
• Certifications:
• ISO 9001
• ISO 14001
• Lead Time: 9 months EXW

ABB Dry-type Transformers

Bland, VA
 Applications
 Secondary Unit Substation
Transformers
 Exciter transformers
 Sub-transmission
 Insulation System Technologies

 VPI, Cast Coil, Resibloc®

Transformers Product Scope Top Rated (MVA)
ABB South Boston
Westinghouse
St. Louis Varennes
Westinghouse Asea
& Crystal Springs
Kuhlman
10 63 300 1200
S. Boston Small Power
C. Springs Small Power
St. Louis Medium Power
St. Louis Repairs
Varennes Large Power
Cordoba – Shell Form
Ludvika, Sweden
(&Varennes, Canada) Shunt Reactors (5 to 300 MVAr)
ABB Off-Shore Power Production can be optimized according to workload
All core-form plants use common technology (TrafoStar)

Craig L. Stiegemeier, ABB Transformer Remanufacturing & Engineering Services
Transformer knowledge enrichment

Power transformer basics
© ABB Inc. 2015

TRES North America - Slide 55
Power Transformers – some general comments
 first transformer 1885, well developed technology today

 simple working principle - unchanged since then
 large, heavy and expensive component in the power system – optimization
 the larger a unit the less cost per unit power
 total cost is factory cost plus cost of losses over life time
 highest cleanness mandatory during production
© ABB Group

Transformer principle I
flux 
( main flux U2
 m)
~ U1
U2 ~ 
I0
U ~
1  =  = m = 
no-load condition
Current causes a magnetic field (EMF)

EMF     I  w
Time varying magnetic flux induces voltage in coil (induction law)

d d
U   w   U   
dt dt
© ABB Group
Transformer principle II
I2
U2
  ~ U1
I1
U ~ 2 U2 2 1
(stray flux  
1
load condition w1  I1  w2  I 2
I2 sc
U2=0
  ~ U1
I1 sc 2 0
U ~
1
w1  I1  w2  I 2
© ABB Group
short-circuit condition

Transformer equivalent circuit

magnetic circuit based -equivalent
i1 L i2
im1 im2
u1 u2
L1 L2
practically used T-equivalent circuit

i1 R1 L1 L2 R2 i2
im
u1 u2
uh
Lm RFe
© ABB Group
Transformer main components
 Core grain oriented silicon steel

 Winding copper
 Insulation paper, pressboard, oil
 Leads paper insulated cables / bars
 Tank steel
 Bushings component
 Tap changer component
50…60% of total factory cost is material!
© ABB Group

Transformer core - requirements
 Mechanical strength
 transportation forces
 short circuit forces
 seismic forces
 Thermal demands
 low losses
 hot spot control
 over magnetism
 Low noise
Core mass for largest units > 250 tons

© ABB Group
Transformer core - types
3-phase
cores
1-Phase
cores
© ABB Group

Transformer core - material and stacking
A A
View A-A
Conventional Step lap
 Loss and noise minimization

 Grain oriented silicon steel
0.23…0.35 mm thick
© ABB Group
Transformer core material – carries magnetic flux
The core is an unbroken path for magnetic flux

Normally reused for a repair /
A A remanufacture
View A-A
Conventional Step lap Core is cleaned and damaged

material is replaced
The core laminations are a high tech material

Iron crystals oriented to align with
flux
Insulation coating to reduce losses
from eddy currents
© ABB Group

Transformer core - mechanics
 Clamping force required to

guarantee friction force in
joints
 Step blocks to keep
clamping plate straight
 Core support beam to

withstand longitudinal forces
up to 5g during
transportation
© ABB Group
Transformer core material improvements
Core performance is set by configuration and

material
W/lb Continuous
improvement in
core steel
quality
Reduction in
specific losses
by a factor of
five
© ABB Group

Winding arrangement
Means physical location relative to core
Operating characteristics and costs are strongly affected
Optimization task for designer
Core
Core
A B C D
© ABB Group D
Winding arrangement optimization
Winding shells:
• Concentric arrangement
• Effectively equal heights
• LV often nearest core
• HV often the outer winding
• Equal current distribution
• Ensure balanced flux distribution
© ABB Group

Insulation system
 Made from organic material that

degrades over time
 Typically an aggregate of:
 Cellulose (wood fibers)
 Mineral oil
 Insulation system separates:
 HV winding
 LV winding (s)
 Regulating winding (if present)
 Ground
 Directs cooling oil to dissipate heat
from I2R and eddy losses
 Provides support in radial and axial
dimensions to withstand short
circuit forces
© ABB Group
Transformer insulation
1. winding insulation
2. winding end insulation
3. main insulation between windings
4. exit lead insulation
mainly cellulose based material

immersed in mineral oil
high dielectric, mechanical and thermal strength

© ABB Group
low shrinkage during drying

Insulation system components
 Winding & active part kits

 Winding cylinders are oil
impregnated to limit growth
 Components are manufactured
to tight tolerances
© ABB Group
Conductor material
Load losses can be reduced and short circuit performance

enhanced through the use of modern CTCs
Glue
The continuously transposed cable is an important

tool for the control of eddy current losses.
© ABB Group

Vertical winding lathes (gravity compacts the winding)
© ABB Group
© ABB Group

Winding arrangement - Examples
 Two windings
 Yoke entry HV  Four windings
 HV with body taps  Yoke entry HV
LV HV  Double layer LV Ter LV HV HVreg  Separate HV reg
 Inside Tertiary
 Four windings
 Four windings  Yoke entry HV
 Centre entry HV  Separate N reg
N LV HV  Separate N reg  Outside Tertiary
Ter N LV HV Ter
reg  Inside Tertiary
reg
© ABB Group
“Landing” of windings
© ABB Group

Nesting of windings
Proper technique can improve (tighten) radial
tolerances
© ABB Group
Transformer Cleats & leads
© ABB Group

Transformer Cleats & Leads
 mechanical withstand capability – also in short circuit case

 sufficient dielectric clearance to each other and ground (tank/core)
 temperature limits
© ABB Group
Loss components in transformers (no-load losses)
 Losses due to core flux (no-load loss)

 Losses in windings to winding current and magnetic field in winding
 Losses in structural metallic parts due to magnetic stray field entering
Load losses 100%

 Winding: ~ 85 %
 Structural parts: ~ 15%
Total losses 100%

 no-load losses: 10…15 %
 load losses: 85…90 %
© ABB Group

Winding losses – components and relative ratio

Winding losses 100%
 ohmic: ~ 85 %
 axial eddy: ~ 10%
 radial eddy: ~ 5%
Radial
eddy
loss
ohmic Axial
loss eddy
loss
© ABB Group
field plot Winding arrangement losses
Transformer tank
 Corrosion protection system – water based paint system
 Vacuum and overpressure proof
 Sealing system for live time (change gaskets only when opened)
 Controlled rupture in case of internal arcing (on tank cover)
 Low noise (avoid tank resonances)
Equipment to be mounted on tank

1. Temperature indicators
2. Oil indicators
3. Breathers
4. Gas detection relays
5. Oil conservators
6. Control cabinets
7. Tap changers
8. Bushings
9. CoreTec (Monitoring system)
10. CoreSense (Gas sensor)
© ABB Group

Transformer Remanufacturing & Engineering Services
Transformer knowledge enrichment

Transformer failure mechanisms
© ABB Inc. 2015
Stresses Acting on Power Transformers

Understanding These Allows Development of an
Effective Transformer Maintenance Plan
Mechanical Stresses
 Forces between conductors, leads and windings due to
overcurrents or fault currents caused by short circuits
and inrush currents
Thermal Stresses
 Due to local overheating, overload currents and leakage
fluxes when loading above nameplate ratings;
malfunction of cooling equipment
Dielectric Stresses
 Due to system overvoltages, transient impulse
conditions or internal resonance of windings

Transformer Failure Modes

Mechanical Stresses in Power Transformers
The fault current is
governed by:
 Open-circuit voltage
 Source impedance
 Instant of fault onset
Displacement of
current

 A short circuit gives rise to:
 Mechanical forces
 Temperature rise
 The transformer must be designed so that
permanent damage does not take place
 The first peak of a full short circuit current can
be 20 times higher than in normal operation
 The forces on the transformer windings and
leads are typically 400 times higher than in
normal operation
 Two force components on windings:
 radial
 axial
 Electromagnetic forces tend to increase the
volume of high flux
 Inner winding to reduced radius
 Outer winding towards increased radius
 Winding height reduction


Effect of the radial forces on windings
Fmean
Inner Outer
winding winding
Radial forces inwards Radial forces outwards

 compressive stress  tensile stress

Effect of the axial forces on windings
The radial
component of
the leakage
flux creates
forces in axial
direction
Axial short circuit forces accumulate towards winding mid-height



Mechanical Stresses in Power Transformers – Axial
B B Fax Fax
Axial imbalance
will create extra
axial forces
B B Fax Fax
The forces tend

to increase the
imbalance

Mechanical Stresses in Power Transformers - Radial
Failure mode Buckling: Failure mode Spiraling:
Characteristic failure Characteristic failure mode
mode for inner winding for inner and outer winding


Risk: Short Circuit Forces & Stresses
Through faults are often the cause of

transformer failures
 Many older designs have insufficient
margin for today’s fault currents
 Loose coils due to aging can cause
failures
 Normal aging can cause brittle
insulation and increased failures
 Even brief overloading may cause
significant aging
 Oxygen in the oil can double the
aging rate
 Moisture in the insulation increases
aging rate 2-5 times depending on
the amount of moisture

Two examples showing buckling of inner windings


Axial force failure modes:

 Collapse of winding end support
 Tilting of winding conductors
 Telescoping of windings
 Bending of cables between spacers
 Damage of conductor insulation

 Axial forces cause:

 Mechanical withstand of insulation material
 Risk for tilting


Failure mode
Collapse of end support
Failure mode
Bending of cables
Failure mode
Conductor tilting

Short circuit failure video example
Unit Auxiliary Test Transformer Failure

Internal High Speed Film Camera Footage
© ABB Inc.
Originally taken by The General Electric Company at
Pittsfield, Massachusetts

Winding sizing – effective axial compression
 Windings are designed for removal of pressboard

 Disc windings – can remove “minus” keyspacers
 Layer windings – adjustment done at end of windings
© ABB Group

Mechanical Risk: Short Circuit Forces & Stresses
Little Risk of Failure

Design Margin
Slight Risk of Failure
Design #1
Design #2
Design #3
High Risk of Failure
Design #4
HV Radial HV Axial LV Radial LV Axial LTC LTC

(Hoop) (tipping or (Buckling) (tipping or Winding Winding
crushing) crushing) Radial Axial
(Buckling) (tipping)
Figure 3. Results of the Short-Circuit Strength Design Analysis used in a Life Assessment Study


Thermal Stresses in Power Transformers
 Loading is primarily limited by highest permissible temperatures in

the transformer, especially within the windings
 Temperature limits are based on:
 Expected lifetime
 The risk for oil vaporization
 Permissible temperatures are generally expressed as temperature
rises above ambient
 Ambient temperature is in turn defined by current standards
 24 hour ambient temperature average 30° C
 Maximum ambient 40° C
 In accordance to Standards:
 Winding temperature rise 65° K
 Top oil temperature rise 65° K
 Hot spot temperature rise 80° K

Winding Temperature Rise and HS Calculation
Winding hot spot
Top oil rise
hot spot factor
Winding average rise
Copper over tank oil gradient
Copper over winding oil gradient
Winding Ambient Bottom oil
Temperature


Thermal Stresses in Power Transformers
Life Expectancy Based on DP and Other Factors

Thermal Risk: Intensive aging


Thermal Risk: Intensive aging

Degree of Polymerization – DP
Measures Insulating Paper Strength
Degree of polymerization is a measure of the number of
intact chains in a cellulose fiber. It provides an indication of
the ability of the transformer insulation to withstand
mechanical force (due to through-faults, etc).
Cellulose Fiber Chain


Factors affecting DP and Measurement Method
 The DP of the insulation is affected by the following

conditions:
 Moisture content
 Acidity of the oil
 Oxygen content
 Temperature
 The DP is measured by viscosity measurements according
an ASTM method after dissolving the paper samples in
cupriethylene diamine solvent.
 Paper samples must be taken from enough different
areas in a transformer in order to get a profile of
deterioration of the cellulose
 When combined with detailed design knowledge,
measurements in one area of the transformer can give
information on the condition of paper in inaccessible
areas of the windings.

Life Expectancy Based on DP and Other Factors
It is assumed that the DP of transformer insulation is approx. 1,000 at the start of life and approx.
200 at the end of life. This graph shows the expected life of thermally upgraded insulation
(Insuldur) under various conditions:
10000.0
Dry & Clean (Insuldur)
Acidic Oil (Insuldur)
1000.0 1% Water Content (Insuldur)
3-4% Water Content (Insuldur)
L ife E x p e c ta n c y (y e a rs )
100.0
10.0
1.0
0.1
50 60 70 80 90 100 110 120 130 140 150
Temperature [o C]
For long insulation life expectancy, it is important to keep the insulation dry, keep acidity
and oxygen concentration of oil low and provide good cooling for insulation

Moisture and loading capability – risk of bubble

formation
Loading limits based on moisture content
Hottest Spot Cellulose Overload Level

o Moisture Overload Type with 40°C
Temperature( C)
(% ) Ambient
120 3.5 Normal Loading 0%
130 2.4 Planned O/L Beyond N/P 6%
140 1.7 Long Time Emergency (1-3 mo.) 12%
180 0.8 Short-Time Emergency (½ -2hr) 40%
© ABB Group
March 21, 2015 | Slide 107

Dielectric Stresses in Power Transformers
Overvoltage integrity
 Overvoltages can be divided into two classes:
 Continuous
 Transitory
 Continuous overvoltage is related to the core and its

magnetization (“normal” 50Hz or 60 Hz stresses)
 Transitory overvoltage refers to intermittent stresses
placed on the insulation system, usually at much higher
levels than the power frequency stresses


Transient Voltages
 Lightning and switching impulse
surges are called “Transients”
because their duration is short.
 The frequencies are much higher
than the power frequency (60 Hz
here) operation frequency.
 Transient calculations are used to
find the time dependent distribution
of transient voltages, applied on the
line terminals, over the windings.

Winding oscillation
Voltage
Win-
ding
Winding length


Analysis of Bushing Failure
 525 kV unit – assumed bushing failure
 Simulation showed electric stress was greatest on the paper
insulation around the shield ring
 Used simulation to redesign insulation barriers
FLC evaluation
CAD-model Field distribution over the barriers and

© ABB Inc. 2015 - Slide 111 HV-LV windings

Dielectric Stresses - Main Insulation Design
2 D Field Plot
2 D field plots
can be used to
check the
design of the
main insulation

Aging Transformer Risk

 Top transformer failures (78%) from Doble:

 43% winding insulation
 19% bushings
 16% tap changers
 Other areas of concern:
 Pollution, dust & debris affecting bushings & cooling
systems
 Cooling System inefficiency
 COPS Tank elevation
 Blocking or Wedging
 In 1998, Hartford Steam Boiler projected:
 2% annual failure rate of existing installed base in 2008
 5% annual failure rate of existing installed base by 2015
ABB Transformers and Transformer Remanufacturing & Engineering Services
Transformers & Transformer Services

Transformer Research & Development
© ABB Inc. 2015

Energy efficient and green solutions for a better world

Technology trends reflecting environmental needs
EcoDry family – dry type transformers
 Highest efficiency dry type transformer for industrial and utility
applications reducing no load loss by 2/3 and load loss by 1/3
The green liquid filled distribution transformer program

 Energy efficient products and solutions for lower CO2 emissions
 The amorphous metal distribution transformer is one concept of the
green program
BIOTEMP®
 A natural ester-based dielectric, biodegradable insulating fluid made out
of sunflower seeds
 A complete and sustainable solution for both distribution and power
transformers associating environmental friendliness (high
biodegradability), safety (superior fire resistance), and efficiency (high
overload capacity)
Ultra low sound emitting transformers
 20-25 decibles dB(A) below conventional noise specifications
 dB(A) reduction without use of sound panels or sound enclosures
Rupture – Resistant Tanks;

To minimize danger and oil spills
 Calculation of arc energy

 Calculation of resulting localized high
stresses
 Using a state-of-the-art 3D tool
 Selection of tank material and

reinforcements
 To withstand localized high stresses
 Design to allow tank cover rupture

beyond a certain level of arc energy

3D Magnetic field Simulation;

To eliminate Hot Spots in GSU (s)
 Currents in the bus ducts and shorting plate

cannot be simulated during factory tests
 The Isophase bus and the “shorting plate”
have an important impact on the heating of
the transformer tank
 Developed model representing actual
service conditions
 Calculated temperatures are in agreement
with on – site measurements
Low and Ultra – Low Noise Transformers
Advantages:
 More effective than using sound walls
 Lower cost than sound walls or sound enclosures
 Enclosures require more maintenance
 Walls with sound panels are fire prone
 Enclosures & sound walls:
 Reduce cooling efficiency
 Require larger real – estate
Technology Development effort:
 In – depth understanding of the total process of
sound generation, transmission, and radiation
 Accurate calculation of No – load and load noise, and
their frequency spectrum
 Accurate calculation and avoidance of Core, tank,
and winding mechanical resonances
 Proper mounting and sound measuring techniques
 Technology available to ABB designers world - wide

Ester fluid – filled Transformers – Technology

development
 Full material parameters testing at different

temperatures & % moisture
 Extensive Thermal testing of a 50 MVA Power
Transformer
 Dielectric Testing of insulation material / structures in
Ester fluids
 Development of design rules and calculations
 Designing and testing a commercial prototype (168
MVA / 138 kV)
 Passed tests and measured very close to
calculations
 Technology available up to 230 kV class and 200 MVA
maximum rated power
Evaluation of Transformer susceptibility to effects of GIC and

GIC Capability of Power Transformers
 Step 1: Fleet Assessment
Peak Magnetizing MVAR (Fundamental Harmonic) vs GIC/Phase
16
 Identify high susceptibility transformers that would need to 14
12
Peak MVAR/Phase
10
be examined in more detail to evaluate their GIC capability 6
 Step 2: Impact of GIC and GIC Capability of transformers 0

0 5 10 15 20
GIC/Phase, Amps
25 30 35 40
Mag Current Harmonics as % of Rated Current (GIC/Phase = 40 Amps)

4.0%
3.5%
 ABB provides customers with: 3.0%

% Rated Current
2.5%
2.0%
1.5%
 VAR consumption and current Harmonics vs. GIC 1.0%
0.5%
0.0%
1 2 3 4 5 6 7 8 9 10 11
Windings and structural parts Hot Spot temperature

Harmonic Number
 Curves of GIC Capability of transformer versus load for
both short – duration and long – duration GIC pulses

Versatile recovery transformer – RecX Project

Rapid deployment transformer background information
 Began before 9/11 with EPRI’s

Infrastructure Security Initiative (ISI)
 ABB was asked to examine feasibility
of a fast-to-install transformer design
 DHS became involved after the project
created a <1 week storage to
transformer energization concept
 Prototype 500/230kV and 345/138kV
designs were developed, focused on
transportation ease & installation speed
 A utility host was identified to support a
trail deployment
 Concept demonstration exercise was
completed in March 2012, supporting a
4 day completion time
Versatile recovery transformer – RecX Project

Overcame size, weight and installation time limitations
through the use of:
Traditional • Development of Nomex/cellulose hybrid insulation
Cellulose
Insulation system
NOMEX®
Hybrid • Draw-rod bushings & key hand-holes facilitate installation
Insulation
without entering transformer
• Pre-assembled cooling system & control modules
• Transformers store oil-filled, conservator for oil expansion
Minimize disassembly, reassembly & field processing
times using factory processes & times
• All CT’s pre-installed into turrets & pre-wired into
connection boxes
• All components pre-arranged into modules on trailers,
sequenced in the order of need
• Self-contained (and protected) auxiliary power system
form 3-phase, 480 volt station service power
• Self-supporting lightning arresters provide overvoltage
protection

Movies should be screened in the

grey area as featured here, size
proportion 4:3. No titles should be
used.
www.firstresponder.gov/SitePages/ResponderNews/VideoGalleryDisplay.aspx?Video=17
ABB Transformer & IT Technology

Turning data into condition information
Assessment & data analysis toolbox . . .
• Transformer Design and Manufacturing Expertise
• ABB, Asea, GE, Kuhlman, Moloney, Westinghouse
• >70% NA Installed Base
• Condition Assessment Tools
• MTMProgram:
• >10 years experience
• >10,000 assessments globally, 3,000 in NAM
• Global experience / database
• Years of Site Inspection & Repair experience
• Leading Expertise on Special Tests (FRA, DFR, etc)
• ABB VENTYX FocalPoint Application
• IT partner
• Ability to deal with “Big Data”

Online Sensors
FRA/Transients
H2O Sensor
Gas Sensor
…
Bushing
…
LTC
PD
Future…
SCADA
Trxf. fingerprint Equations
Trxf. 1
Age
Expertise Trxf. 2
Load Utility / Computation
Enterprise
Industrial Trxf. 3
Top Oil
Headquarters
Statistics …
T. amb
Trxf. n
Tap pos.
Identify problems
Recommend actions
MTMP Risk of Failure

Maintenance actions
FRA, DFR, Z, etc
Routine tests
Off line SOT
Off line DGA
Update Risk of Failure
Static data or information

Dynamic data/information
On going development
© ABB Inc. 2015 - Slide 125 Offline Databases
Transformer Remanufacturing and Engineering Services
Transformer Services
Overview of TRES “footprint”
© ABB Inc. 2015

ABB Power Product Services

Scope of Support
 Transformers
 >70% of installed power transformers are ABB legacy
 Risk assessment and life extension
 Advanced diagnostics and testing
 Factory repair and remanufacturing
 High Voltage Breakers
 Support capability for 60-70% of installed base
 Refurbishment and retrofit
 Advanced diagnostics – radiography and SF6 leak detection
 Low- and Medium-Voltage Switchgear
 Over 1 million breakers in service in US
 Refurbishment, retrofit, roll-in replacement breakers
 Protection & Control assessment and upgrades

TRES Portfolio Overview
Engineering Solutions
 MTMProgram™ & DTMProgram™ - Tools for Effective Asset Management &
Maintenance Action Planning
 Engineering Studies – Design, Thermal, Condition & Life Assessments, Ester
Retrofill Feasibility, Geomagnetic Disturbance Impact, etc.
 Diagnostic and Assessment Services, including performing/ supporting field
or factory testing and test result analysis
 Testing Services – dielectric testing at transformer site, up to and including
full thermal heat run testing
 Training – Transformer & Service Overview or Specific Testing Training
Field Service and Retrofit
 Preventative and Corrective Maintenance
 Engineered Retrofit/Repair Solutions
 LTC & Cooling System Refurbishment, Retrofit & Uprating
 Transportation, Relocation & Logistics Services
 Installation & Commissioning Services
 TrafoOilRenewal™ Oil Upgrading/Processing (on-line capability)
 Natural and Synthetic Ester Retrofils
 Technical Assistance and Training
 Replacement and Spare Parts
Factory & Site Repair/Remanufacturing
 Repair to original performance
 Remanufacture to achieve higher ratings or to eliminate problems
 All types, all manufacturers, including Industrial/Specialty
 Focus Factories based on scope of project

ABB Transformers Worldwide

Legacy Products and Support Capabilities
 Consistently high transformer quality available from

many factories world-wide
 The combined experience of 700 years of transformer
manufacturing
Asea Ansaldo BBC
GE, USA & CA Kuhlman Moloney
National Industri Strömberg Westinghouse
And more ....
 TRES has access to all design, manufacturing and
test records from these legacy companies, and
agreements with other manufacturers
 In North America, ABB legacy brands account for
more than 70% of the installed base of power
transformers
 Backup of more than 50 Factories and service centers
in 28 countries
 Service support teams available 24 hours a day

TRES – Localized Services, Global Support
Edmonton (SPT Repair, Field Service)

Varennes (LPT Repair, Field Service)
Brampton (Field Service, Engineering)
NE Regional Service Ctr (Field Service)
St. Louis (MPT Repair, Field Service, Engineering) South Boston (SPT Repair, Field Service)
West Service Ctr (Field Services)
Nashville (Field Service)
Crystal Springs (Field Service)
SE Regional Service Ctr (Field Service)
Gulf Coast Regional Service Ctr (Field Service)
San Luis Potosi
Mexico City


TRES – Localized Services, Global Support
Remanufacturing Product Scope (Top MVA)
All Manufacturer’s Products
10 63 200 1200
S. Boston, Virginia 69kV
Edmonton, Alberta through 230kV
St. Louis, Missouri through 345kV / industrial / HVDC
Varennes, Quebec to 765kV / HVDC / reactors
TrafoSiteRepair (on-site) through 765kV / both core & shell form
Production can be optimized according to workload

All plants optimize repair technology, improving where possible –
including the use of ABB’s common technology (TrafoStar)
ABB Transformer Service Centers

Important: in addition to the service centers listed below
ABB can provide on a case by case basis repair options directly at site
Vaasa, Finland
Drammen, Norway Ludvika, Sweden
Brampton, Canada Varennes, Canada Hefei, China
Halle, Germany
Edmonton, Canada Daresbury, UK Zongshan, China
Geneva, Switzerland
St. Louis, USA Monselice, Italy
Nashville, USA South Cordoba,
Boston, Istanbul, Turkey
Bilbao,
San Luis Potosi, Mexico USA Zaragoza, Khobar, Riyad, Saudi Arabia
Spain Bangkok, Thailand
Vadodara,
India
Lima, Peru Arusha, Tanzania
Sao Paulo,
Brazil Moorebank, Australia
Pretoria,
Cape Town,
South Africa
Focus Factory – Service
Service Facility
Detailed contacts can be found at

© ABB Inc. 2015 - Slide 132 www.abb.com/transformers

ABB Red TIE Series presentations

Available at: http://www.thetransformerplace.com/
©2015 ABB Group. All Rights Reserved |
ABB Red TIE Series presentations

Available at: http://www.thetransformerplace.com
©2015 ABB Group. All Rights Reserved |

2015
Power & Automation Leaders

Program Overview
Program Basics
Definition & Overview
 Power and Automation Leaders Program is a rotational program
that supports the development of leadership talent via rotational
assignments to help young professionals find their passion within
ABB
 Recruit Electrical, Mechanical, Industrial, Chemical Engineering
disciplines, Bachelor’s degrees
 Recruit Finance, Accounting, Business degrees for Finance PAL
 Criteria
 High Academic Performance
 Relevant Internship or Co-Op Experience
 Demonstrated leadership traits in and out of the classroom
 Mobile - open to rotations
 Regional program: added 3 PAL in MX, 3 in CA in 2014
© ABB Group
March 21, 2015 | Slide 136

Program Basics
Definition & Overview
 Three 8-month rotational assignments to develop

talent
 Rotational assignment opportunities in all 5 business
divisions plus corporate functions, strategic initiatives
and front end sales
 Variety of rotational assignments available to explore
manufacturing, design, technical sales, operational
excellence, and more
 Hallmark of the program is its flexibility- tailored to the
match between the individual and ABB
 International assignments are possible but are
managed via LBU relationships
© ABB Group
March 21, 2015 | Slide 137
Program Basics
Development
 PALs attend 2 training modules together each year

 Modules last 3-4 days and focus on a geographic region or
event (Automation & Power World, site visits, trade shows)
 Build perspective of larger ABB organization
 Network with peers and business leaders
 Receive specialized training such as project management,
change management, value training, etc at least once each year
 PALs receive performance feedback
 Simple, standardized objective and evaluation forms are used to
guide rotations and provide quantitative feedback at the
midpoint and end of each assignment
© ABB Group
March 21, 2015 | Slide 138

August 2012
Power & Automation Leaders

© ABB Group
March 21, 2015 | Slide 139
Trainee Program Recruits/Retention
50
45 Left ABB
40 Retained
35
30
25
20
15
10
5
0
© ABB Group
March 21, 2015 | Slide 140

How Do I Apply?
 Check on-campus postings for interview dates and

application process
 Contact Jennifer Stoner, PAL Program Manager at
Jennifer.stoner@us.abb.com
© ABB Group
March 21, 2015 | Slide 141


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Transformers & Transformer Remanufacturing and Engineering Services

Transformers & Transformer Services

© ABB Inc. 2015

A global leader in power and automation technologies

Copyright © ABB Inc. 2015

Power and productivity for a better world

As one of the world’s leading engineering companies, we

How ABB is organized

Copyright © ABB Inc. 2015

Power and automation are all around us

orbiting the earth and working

crossing oceans and on the sea bed,

in the fields that grow our crops and

on the trains we ride and in the

in the plants that generate our power

Tackling society’s challenges on path to low-carbon era

Rise in electricity demand by 2035 ABB power and automation

In thousand Terawatt-hours (TWh)

Copyright © ABB Inc. 2015

Improving capacity, reliability and efficiency in the grid

Copyright © ABB Inc. 2015

Boosting productivity and energy efficiency

 Skoghall mill, Sweden:

Leading power system’s biggest-ever transformation

 Merging power and automation technologies makes electricity

Copyright © ABB Inc. 2015

Software across industries and across the Group

 From protection logic in our relays to interactive

Services across the entire value chain

Copyright © ABB Inc. 2015

Shaping the world we know today through innovation

Innovation is key to ABB’s competitive advantage

 More than $1.5 billion invested annually in R&D

Copyright © ABB Inc. 2015

Developing sustainability of products and operations

Sustainable products Sustainable operations

People make the difference

 ABB is one of the world’s most global companies

Copyright © ABB Inc. 2015

Committed to the highest standards of business ethics

“At ABB performance is measured not only by

A successful business and a reliable partner

Revenue (US$ million) by quarter

Copyright © ABB Inc. 2015

More than $14 bln invested for growth since 2008

New plants and expansions

Well-balanced business and geographic portfolio

Orders by division Share of employees

25% Power products

10% Middle East and Africa

Copyright © ABB Inc. 2015

Innovation, passion and diversity are hallmarks of ABB

“As a global leader in power and

CEO Ulrich Spiesshofer

A global leader in power and automation technologies

 145,000 employees in about 100