Crafted with pride
First time ever in Bangladesh
Cast Resin Transformers
Engr. Saifur Rahman
CRT
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:

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
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General Applications
 High Rise Buildings
 Hotels
 Hospitals
 Theatres and Multiplexes
 Radio and TV Towers
 Electronics Industries
 IT Parks
 Stadiums
 Off-Shore platforms/Oil Rigs
 Ships
Windmills
 Ports
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 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

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.
The deepest experience in the design to
guarantee the best technical solutions in all
applications by European Consultant and experts.

First time production for dry type transformers
in Bangladesh.
Present all over Bangladesh and guarantee the
faster delivery and best after sales service.

ISO 9001, ISO 14001 IEC 17025 certifications.
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Design, Machineries and origin
 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;
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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.
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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
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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 selfextinguishing.
 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
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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
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Comparison: Dry Transformers versus Oil Transformers
The best alternative due to:

Fire hazard

Safety for people and property

Respect for natural life
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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.
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
Compared with oil cooled transformers
of the same specification
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Comparison: Dry Transformers versus Oil Transformers
Characteristics
Oil Cooled XFR
Cast resin XFR
Civil works for oil collection
■
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Oil spills
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Cleanliness of installation ambient
■
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Maintenance
■■
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Evaluating criteria:
Fire risk
■
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Bad
■
Compactness
■■
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Acceptable
■■
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Good
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Resistance to short circuit
Excellent
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Overload capacity
■■
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Further overload with fans
■■■
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Disposability
■
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Indoor installation
■
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Local repair
■
■■■■
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Economical Aspects
•
•
•
•
•
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•
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•
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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.
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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
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H2
2013
• Up to
11KV
• 5000
KVA
H1
2014
• Up to
33KV
• 5000
KVA
H2
2014
• Up to
33KV
• 10
MVA
Standard Technical features

Standards

Rated power

Rated voltage

Cooling

Protection degree

High voltage winding

Low voltage winding

Temperature rise

Ambient design

Insulation system temperature

Partial discharges

Classes
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IEC EN 60076-11
up to 3,150 kVA
up to 11 kV
AN, ANAF (up to +40%)
IP00 up to IP23
Encapsulated, Aluminum/Copper foil
Pre-preg layer between turns, Aluminum/Copper full width
100K
From -250C up to 600C
155 ºC (Class F)
< 10 pC
E2, C2, F1
Manufacturing process and machine visual
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Testing process and methods
 In process test
1.
2.
Magnetic balance test
Continuity test
 Routine test
1.
2.
3.
4.
5.
6.
7.
8.
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
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BUET
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
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Product standard accessories
Fan
Wheel and Anti vibration pad
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Mounting Kits
Heat shrink, insulation and
aluminum bar
Temperature relay and PT 100
Glass fiber mesh, DMD
insulation and aluminum foil
More available accessories
Electronic relay for temperature monitoring andprotection
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Source Arrestors
References
 Square pharmaceuticals
5 nos. 2000kVA
 Silkways Group:
1 no. 1500kVA
 Gopalganj Stadium (PWD)
1 no. 2000kVA
 Bando Design Limited
1 no. 200kVA
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Thank you
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