Cast Resin Transformers Crafted with pride First time ever in Bangladesh Cast Resin Transformers Engr. Saifur Rahman CRT

CRT Contents: Product range, capacity and roadmap 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 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 CRT

What is a dry type transformer: 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 CRT

CRT General Applications High Rise Buildings Air ports Hotels Hospitals Theatres and Multiplexes Radio and TV Towers Electronics Industries IT Parks Stadiums Off-Shore platforms/Oil Rigs Ships Windmills 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 CRT

Energypac’s Competitive Edges 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. CRT

Design, Machineries and origin Standard designs: High Voltage winding material: foil conductor displaced in many disks. Low Voltage winding material: aluminum/copper foils. Insulation class: F, H. Machineries and Origin: Core sharing machine, Japan LV Winding machine- 1no, BF Electromechanical, Italy (160kVA and above) HV Foil Winding machine- 1no, BF Electromechanical, Italy (250kVA and above) HV Coil/wire winding machine- 1no, BF Electromechanical, Italy (100kVA-200kVA) Vacuum casting machine- 1no, Hedrich, Germany Raw materials and origin: Aluminum Foil and wire - Hydro, Norway; Resign, Hardener, Filler – Elantas Camattini, Italy; Insulation Material – Haotai, P. R. China; CRT

CRT Why Vacuum cast coil 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. CRT

Compared with oil cooled transformers of the same specification Benefits 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 CRT

CRT Environment friendly 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 CRT

Energypac’s product competitive edges 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 CRT

Comparison: Dry Transformers versus Oil Transformers The best alternative due to: 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. Fire hazard Safety for people and property Respect for natural life CRT

Comparison: Dry Transformers versus Oil Transformers 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 CRT

Comparison: Dry Transformers versus Oil Transformers 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 Evaluating criteria: Bad ■ Acceptable ■■ Good ■■■ Excellent ■■■■ CRT

CRT Economical Aspects 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. Flexibility to change the design based on material price and optimize the total price CRT

Product range, capacity and roadmap 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. H1 2013 Up to 11KV 3150 KVA H2 2013 5000 KVA H1 2014 Up to 33KV H2 2014 10 MVA CRT

Standard Technical features 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 -250C up to 600C Insulation system temperature 155 ºC (Class F) Partial discharges < 10 pC Classes E2, C2, F1 CRT

Manufacturing process and machine visual CRT

Testing process and methods In process test Magnetic balance test Continuity test Routine test Ratio test, Instrument Calibration from Cali-Labs, India. Winding resistance No Load losses, Vanguard Instrument, USA Full load losses Power frequency over voltage test, Phoenix Technology, USA Induced over voltage test (DVDF) Partial Discharge (Omicron Switzerland) Temperature rise test Testing method: IEC 60076-11, 60270-2001 Tested and certified by BUET CRT

CRT Quality Control 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 CRT

Product standard accessories Fan Mounting Kits Temperature relay and PT 100 Heat shrink, insulation and aluminum bar Glass fiber mesh, DMD insulation and aluminum foil Wheel and Anti vibration pad CRT

CRT More available accessories Electronic relay for temperature monitoring andprotection Source Arrestors CRT

CRT References Square pharmaceuticals 5 nos. 2000kVA Silkways Group: 1 no. 1500kVA Gopalganj Stadium (PWD) 1 no. 2000kVA Bando Design Limited 1 no. 200kVA CRT

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