CAST RESIN DRY TRANSFORMER

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1 CAST RESIN DRY TRANSFORMER Majority owned subsidiary company of ELETTROMECCANICA COLOMBO s.a.s., Italy

2 Elettromeccanica India Elettromeccanica India Pvt Ltd (EIPL) is a joint-venture company with Elettromeccanica, Italy, a leading manufacturer of transformers based in Milan. Elettromeccanica is held in high esteem and has the confidence of an established clientele of final users, plant installators and consultants for its high quality, operational reliability and long lasting products. In India we meet the growing demand of high quality cast resin type transformers with special foil type aluminium / copper winding technology. Key highlights Majority owned subsidiary of Elettromeccanica Italy with Sharika Enterprises as equity based joint-venture partner providing plant management and looking after marketing activities across India. The company caters to the requirements of the entire Asian market. Elettromeccanica Italy, established in 1901, has been manufacturing Cast Resin Transformers since The company has supplied 30,000 MVA in 50 countries, including transformers to India with 33/0.415 kv kva ratings for the Delhi Metro Project. The Elettromeccanica India Pvt Ltd plant, located at Bari Brahmana, Jammu, was commissioned in ISO 9001:2008 certified, it is equipped with state-of-the-art testing facilities for complete type testing as per Indian Standards (IS) as well as International Standards (IEC). In the first phase of production, cast coils are being sourced from Italy. CRGO core and the transformers are assembled locally as per the designs and engineering practices of Elettromeccanica Italy. The first order executed by the company was from Delhi Metro for 15 numbers 33/0.415 kv 630/1600/2500 kva Cast Resin Transformers. Type testing of the transformers was done in the in-house facility calibrated by ERDA, Baroda. Factory at Bari Brahmana, Jammu

3 Elettromeccanica Colombo, Italy Elettromeccanica Colombo s.a.s. is a leading manufacturer of transformers, established in 1901 in Milan, Italy. The company began manufacturing cast resin transformers in the late 1980s and the range currently includes windings in copper and aluminum with natural or forced cooling up to a maximum capacity of 10 MVA at 36 kv. Elettromeccanica Colombo has customers in over fifty countries across the globe with an installed capacity of more than 50,000 MVA. In India, the company has supplied around 400 numbers of 33/0.415 kv cast resin transformers with kva capacity to the prestigious Delhi Metro Project. The worldwide presence is maintained through a network of agents and local importers while in Italy the sales network covers the entire country with agents in all regions. The high quality production at Elettromeccanica Colombo guarantees an average life time of at least 30 years under normal operating conditions. Manufacturing processes ISO-9001:2008 quality assurance system comply with leading international specifications and standards including IEC-60076, IEC-60726, VDE-0532, BS-7806, ANSI-C57-12, IS-2026, IS Type testing, including short circuit testing is done at CESI, Italy. Power transformers can be equipped with on-load tap changer. Besides the standard types, thhe production range includes, auto-transformers and transformers for starting, insulation and earthing for converters-rectifiers. Special transformers are also designed and manufactured upon customer request. Why aluminium? The thermal expansion coefficients of aluminium and the used cast resin are so similar that thermal stresses due to load changes are kept to a minimum. The Indian flag flies at the Milan factory Milan factory interior Why foil windings? Conventional Round Windings Inter-turn voltage is variable and, at times, can exceed substantially Higher chances of inter-turn insulation failure due to voltage breakdown. Foil Windings Inter-turn voltage is always constant as each layer consists of only one winding turn. Minimal failure chances of inter-turn layers.

4 Product Range EIPL manufactures all kinds of cast resin transformers for power, distribution, rectifier, etc. These transformers can be manufactured with copper or aluminum winding or both as per customer requirements. The transformer range includes: Low voltage transformers LV/LV Distribution transformers MV/LV Power transformers HV/LV HV/MV Parts/accessories of cast resin transformers Core Rating up to 2500 kva nominal voltage up to 1.1 kv Rating up to 3150 kva and nominal voltage up to 36 kv Rating up to 10 MVA and nominal voltage up to 36 kv The core is built up of cold rolled grain oriented steel sheet with low specific losses, insulated on both sides by a thin inorganic coating (Carlyte). The sheets composing the core are cut as step lap (at 45 ). Uniform pressing, stiffness and solidity of the columns assure a low noise level. Medium Voltage Winding High voltage windings are made of electrolytic aluminum conductors (wire or foil strip, depending upon power and voltage requirements). It is possible to produce copper windings as well. The windings are inglobed under vacuum in class F epoxy resin (class H is also possible on specific demand). The accuracy of execution of these processes ensure windings free from partial discharges. Low Voltage Winding Low voltage windings are made of strip or foil (copper or aluminum conductor, depending upon power and voltage requirements). Class F/H insulating material is used. Standard Accessories Skid under base or truck with bidirectional wheels, lifting lugs, earthing terminal. Temperature Monitoring Unit Temperature monitoring is essentially used for safe operation of cast resin/dry type transformers. It is suitable for control room as well as marshalling box installations and is built for long and trouble-free operation under extreme conditions of service. Force Ventilation System This is an optional accessory and is used where ventilation is either not sufficient or to increase temporarily rated power of the transformer. Enclosure The kind of enclosure is decided as per transformer size and the place where the transformer is to be installed. Frame for door thickness: 2mm/1.6mm. Side, front back panels and top sheet thickness: 1.6mm thick. Castle lock, looking glass and other accessories are provided as per client requirements.

5 Aluminium Windings for Cast Resin Transformers Parameters Copper Aluminium Additional Information/ Calculation Coefficient of linear expansion /K /K /K (Resin) The difference between the relative linear expansion of aluminium and resin is quite close while that of copper and resin is quite high. Thus, the chances of void creation or cracks in insulation are higher in copper winding as compared to aluminium winding. Conductivity (σ) S/m S/m = S/m With a higher cross-section area of Al conductor (1.6 Cu conductor) provided same conductivity and resultant load losses are easily maintained. Thermal Storage cal/g/ C cal/g/ C capacity gm/cm gm/cm Density CS Area Factor = Comparative = Capacity Aluminium can withstand greater surge and overload current than equivalent copper. By taking the reasons mentioned above into account, the weight of a cast resin transformer and resultant cost gets reduced with aluminium winding as compared to copper winding. This results in lower prices for a technically superior product.

6 Tests All transformers are singularly routine tested according to IEC and equivalent IS standards that include: Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance of voltage (principal tapping), short circuit impedance and load loss Measurement of no-load loss and current Separate-source voltage withstand test Induced over voltage withstand test. In addition EIPL also conducts special tests like: Partial Discharge Measurement Measurement of Acoustic sound level The following type and special tests can be carried out upon request: Temperature rise test (Type Test) Lightning impulse test ( Type Test) Short circuit test (Special Test) Functional Characteristics High Short Circuit Strength A coil manufactured with epoxy resin has a robust structure and can better withstand electro-mechanical force occurring during short circuit, external impacts and abnormal vibrations. High Overload Capacity Due to the high terminal time constant, a coil made with epoxy resin can endure high overloads for a short time. Fire Resistance Epoxy coils have a self-fire extinguishing performance, safe in case of fire electrical sparks. Compact Size Compact size, especially in depth, can give advantage in installation room. Environment Safe Compared to oil immersed, resin transformers are free from environmental pollution as there can be no spill or oil leakage. Maintenance-Free Coils cast with epoxy resin do not suffer from deterioration of insulating property on account of humidity and moisture; furthermore there are no joints or valves making it easy to inspect and maintain the transformer.

7 Insulation Class 12 kv, Ambient Temperature : 50 C - Temp. Rise : 90 C kva Po Pcc Pcc h4/4 h4/4 h3/4 h3/4 Zl lo lcc ln-rush Lpa windings in aluminium windings in copper e d f enclosure* (75 C) (120 C) cos f1 cos f0.9 cos f1 cos f0.9 a1 b1 h1 Weight a1 b1 h1 Weight a1 h1 b1 (W) (W) (W) (%) (%) (%) (%) (%) (%) (ka) (lr/ln) (db) (mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg) (mm) (mm) (mm) (mm) (mm) (mm) Insulation Class 36 kv, Ambient Temperature : 50 C - Temp. Rise : 90 C kva Po Pcc Pcc h4/4 h4/4 h3/4 h3/4 Zl lo lcc ln-rush Lpa windings in aluminium windings in copper e d f enclosure* (75 C) (120 C) cos f1 cos f0.9 cos f1 cos f0.9 a1 b1 h1 Weight a1 b1 h1 Weight a1 h1 b1 (W) (W) (W) (%) (%) (%) (%) (%) (%) (ka) (lr/ln) (db) (mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg) (mm) (mm) (mm) (mm) (mm) (mm) h1 e d a1 f TECHNICAL DATA Cast Resin Transformers e *Recommended minimum size b1

8 Inside the plant at Jammu Core Assembly Routine Inspection Transformer Assembly Transformer with enclosure Cut section of coil Elettromeccanica India Pvt. Ltd. Corporate Office: B-124, Sector-67, Noida , India Tel: Fax: Plant: EPIP, Kartholi, Bari Brahmana, Jammu, Jammu & Kashmir , India Tel/Fax: Head Office: 404, Chiranjiv Tower, 43, Nehru Place, New Delhi , India Tel:

COMPANY PROFILE... 1 QUALITY CERTIFICATES... 2 APPLICATIONS... 3

COMPANY PROFILE... 1 QUALITY CERTIFICATES... 2 APPLICATIONS... 3 CONTENTS COMPANY PROFILE... 1 QUALITY CERTIFICATES... 2 APPLICATIONS... 3 CONSTRUCTION... 4 ~ 5 A. CORE AND FRAME... 4 B. COIL... 5 C. TEMPERATURE INDICATOR... 5 CHARACTERISTICS... 6 MANUFACTURING FACILITIES...

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