Cast Resin TransformersEngr. Saifur Rahman

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Crafted with pride First time ever in Bangladesh

Contents:

What is a dry type transformer General Application Energypac’s Competitive Edges Design, Machineries and origin Why Vacuum cast coil Benefits Environment friendly Energypac’s product competitive edges Comparison: Dry Transformers versus Oil Transformers Economical Aspects

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Product range, capacity and roadmap Standard Technical features Manufacturing process and machine visual Environmental, Climatic and fire classes Testing process and methods Quality Control Product standard accessories References

What is a dry type transformer:

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Energypac manufactures a transformer which does not use any kind of liquid for cooling, it has windings encapsulated under Vacuum, in epoxy resin reinforced with fibre glass mesh.

It is the most technologically advanced design for extreme conditions.

Energypac has flexibility to produce transformers for optimum space utilization, and special requirements.

These transformers meet strict parameters with respect to electrical system demands, are virtually maintenance free and are manufactured in accordance with industry and international standards including, IEC 60076-11, ISO 9001 and ISO 14001.

Energypac Cast Resin Transformers Production Range up to 3150 kVA and up to 22 kV

General Applications

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High Rise Buildings Hotels Hospitals Theatres and Multiplexes Radio and TV Towers Electronics Industries IT Parks Stadiums Off-Shore platforms/Oil Rigs ShipsWindmills Ports

Air ports Refineries and petrochemicals Chemical plants Cement plants Textile plants Power plants Metro railways Steel Plants Material handling equipments Power station- Hydro, Thermal, Nuclear

Energypac’s Competitive Edges

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Most advanced production technologies from Europe to guarantee the best product quality.

The most demanding quality control system to guarantee the total reliability of the product.

First time production for dry type transformers in Bangladesh.

The deepest experience in the design to guarantee the best technical solutions in all applications by European Consultant and experts.

Present all over Bangladesh and guarantee the faster delivery and best after sales service.

ISO 9001, ISO 14001 IEC 17025 certifications.

Design, Machineries and origin

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Standard designs:

o High Voltage winding material: foil conductor displaced in many disks.

o Low Voltage winding material: aluminum/copper foils.

o Insulation class: F, H.

Machineries and Origin:

o Core sharing machine, Japan

o LV Winding machine- 1no, BF Electromechanical, Italy (160kVA and above)

o HV Foil Winding machine- 1no, BF Electromechanical, Italy (250kVA and

above)

o HV Coil/wire winding machine- 1no, BF Electromechanical, Italy (100kVA-

200kVA)

o Vacuum casting machine- 1no, Hedrich, Germany

Raw materials and origin:

o Aluminum Foil and wire - Hydro, Norway;

o Resign, Hardener, Filler – Elantas Camattini, Italy;

o Insulation Material – Haotai, P. R. China;

Why Vacuum cast coil

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Partial discharge free State of the art casting technology. Stronger resistance against short-circuit stress. Superior behaviour on load changes (thermal). Better performance under dynamic loads (mechanic). Better performance under severe ambiental conditions (exceeding E2). More suitability for extreme environmental conditions.

Vacuum cast coil transformers are according to International standards.

Benefits

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Self-extinguishing material.

Maintenance free.

Compact and Space can save up to 25% compare to oil type

More flexible in use

No production loss or interruption due to maintenance.

Partial coil replacement available at site if required within short time.

Continuous same performance without loss. (Reference temperature for oil type is 750C and dry type

is 1200C)

Easy installation (need just a direct contact protection barrier).

Enclosure available if required.

High resistance to short circuits.

High capacity to support overloads.

High performance in dealing with seismic phenomenon.

Capable of withstanding the most severe of rolling and vibrating conditions.

Compared with oil cooled transformers of the same specification

Environment friendly

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Reduced environmental contamination.

Zero risk of leakage of flammable or contaminating

substances.

No pollution risks due to the absense of any cooling

fluids

Environmental safe in production.

Well suited to damp and contaminated areas.

No fire hazard.

Transformers are non flammable and self-

extinguishing.

When disposing of the transformer, the cast resin is

considered an inert material and both the secondary

windings and the core can easily be recovered

Energypac’s product competitive edges

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The lowest partial discharge value due to most advanced

casting technology.

The typical partial discharges is below 5pC (maximum

allowed 10pC).

Epoxy resin cast under vacuum avoids entry of moisture

and protects against aggressive environments.

Unique coil finishing provides smooth surface eliminating

dust accumulation.

Self-extinguishing in the event of fire or arcing and no gases

released with potential danger.

Step lap core configuration granting lower values of no load

losses, no load current and noise level. Maintaining E2, C2 and F1 classes.

Local manufacturing and competitive price

Faster delivery and response time.

Available material and automatic inventory system

European consultant and experts.

Adopted European Technology

In house testing facilities

Stringent QC and maintenance, ISO 9001-2008

Comparison: Dry Transformers versus Oil Transformers

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Suitable to operate in humid or heavily polluted environments (E2).

Suitable for operation, transport and storage at ambient temperatures down to minus 25 ºC (C2).

Restricted flammability, self fire extinction (F1). Emission of toxic substances and opacity of fumes

is minimized (F1). Partial discharges bellow 5 pc in average. Withstand the same impulse test even for exposed

situation are available source arrestors kit. Have more ability to withstand thermal and

dynamic short circuit effects. Mechanically stronger, safer against vibrations,

earthquakes, etc.. No liquid, neither leaks and no risk of polluting

spills.

The best alternative due to:

Fire hazard Safety for people and property Respect for natural life

Comparison: Dry Transformers versus Oil Transformers

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An average of 20 % less volume (more for big sizes)

15 % less weight (more for big sizes)

Wherever there are space limitations, cast resin transformers (due to their compact construction) can be installed inside of a building and consequently closer to the load

The result: savings in the cost of connection and reduced losses in the power supply

Compact Design

Compared with oil cooled transformers of the same specification

Comparison: Dry Transformers versus Oil Transformers

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Characteristics Oil Cooled XFR Cast resin XFR

Civil works for oil collection ■ ■■■■

Oil spills ■■ ■■■■

Cleanliness of installation ambient ■ ■■■■

Maintenance ■■ ■■■

Fire risk ■ ■■■

Compactness ■■ ■■■

Resistance to short circuit ■■ ■■■■

Overload capacity ■■ ■■

Further overload with fans ■■■ ■■■

Disposability ■ ■■■

Indoor installation ■ ■■■■

Local repair ■ ■■■■

Bad ■

Acceptable ■■

Good ■■■

Excellent ■■■■

Evaluating criteria:

• Less space needed.• Less civil work needed.• No special safety features required.

(fire detection)

• Maintenance free.• Longer transformer life due to low thermal

and dialectic ageing.

• Can be installed closer to the point of consumption reducing load cable losses.

• Optimal design subject to constant improvements in design as new materials become available.

• Produced in high throughput, specialised and efficient Energypac factories.

• Very low operational cost.• Easy installation of indoor or outdoor.

Economical Aspects

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Product range, capacity and roadmap

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From 100 kVA up to 3150 kVA

High voltage: up to 11 kV

Low voltage: up to 0.415 kV

Vector Group DYN11

Various ratings are available in ready stock

Per month production capacity is 10-15 Transformer, target is to reach 25-30 Transformer production per month within this facilities.

The production capacity can be doubled by introduce additional 1 no. HV machine.

• Up to 11KV

• 3150 KVA

H1 2013

• Up to 11KV

• 5000 KVA

H2 2013

• Up to 33KV

• 5000 KVA

H1 2014

• Up to 33KV

• 10 MVA

H2 2014

Standard Technical features

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Standards IEC EN 60076-11 Rated power up to 3,150 kVA Rated voltage up to 11 kV Cooling AN, ANAF (up to +40%) Protection degree IP00 up to IP23 High voltage winding Encapsulated, Aluminum/Copper foil Low voltage winding Pre-preg layer between turns, Aluminum/Copper full width Temperature rise 100K Ambient design From -25 0C up to 600C Insulation system temperature 155 ºC (Class F) Partial discharges < 10 pC Classes E2, C2, F1

Manufacturing process and machine visual

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Testing process and methods

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Routine test

1. Ratio test, Instrument Calibration from Cali-Labs, India.2. Winding resistance3. No Load losses, Vanguard Instrument, USA4. Full load losses5. Power frequency over voltage test, Phoenix

Technology, USA6. Induced over voltage test (DVDF)7. Partial Discharge (Omicron Switzerland)8. Temperature rise test

In process test

1. Magnetic balance test2. Continuity test

Testing method: IEC 60076-11, 60270-2001

Tested and certified by BUET

Quality Control

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On process HV and LV coil test

On process and finish product QC

Casting QC in the basis of failure by testing the specimen

Maintain process for casting material as per expiry date.

Visual check in all steps

Testing

ISO 9001-2008 and 14001

Product standard accessories

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Fan Mounting Kits Temperature relay and PT 100

Wheel and Anti vibration pad Heat shrink, insulation and aluminum bar

Glass fiber mesh, DMD insulation and aluminum foil

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More available accessories

Source Arrestors Electronic relay for temperature monitoring andprotection

References

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Square pharmaceuticals 5 nos. 2000kVA

Silkways Group: 1 no. 1500kVA

Gopalganj Stadium (PWD) 1 no. 2000kVA

Bando Design Limited 1 no. 200kVA

Thank you

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